Danfoss VLT FC 103 Guide

MAKING MODERN LIVING POSSIBLE
Design Guide
VLT®Refrigeration Drive FC 103
1.1–90 kW
vlt-drives.danfoss.com

Contents
1 Introduction 7
1.1 Purpose of the Design Guide 7
1.2 Organisation 7
1.3 Additional Resources 7
1.4 Abbreviations, Symbols and Conventions 8
1.5 Safety Symbols 9
1.6 Denitions 9
1.7 Document and Software Version 10
1.8 Approvals and Certications 10
1.8.1 CE Mark 10
1.8.1.1 Low Voltage Directive 10
1.8.1.2 EMC Directive 10
1.8.1.3 Machinery Directive 11
1.8.1.4 ErP Directive 11
1.8.2 C-tick Compliance 11
1.8.3 UL Compliance 11
1.8.4 Marine Compliance (ADN) 11
1.8.5 Export Control Regulations 12
1.9 Safety 12
1.9.1 General Safety Principles 12
2 Product Overview 14
2.1 Introduction 14
2.2 Description of Operation 17
2.3 Sequence of Operation 18
2.3.1 Rectier Section 18
2.3.2 Intermediate Section 18
2.3.3 Inverter Section 18
2.4 Control Structures 19
2.4.1 Control Structure Open Loop 19
2.4.2 Control Structure Closed Loop 19
2.4.3 Local (Hand On) and Remote (Auto On) Control 20
2.4.4 Reference Handling 21
2.4.5 Feedback Handling 23
2.5 Automated Operational Functions 24
2.5.1 Short-circuit Protection 24
2.5.2 Overvoltage Protection 24
2.5.3 Missing Motor Phase Detection 24
2.5.4 Mains Phase Imbalance Detection 25
Contents Design Guide
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2.5.5 Switching on the Output 25
2.5.6 Overload Protection 25
2.5.7 Automatic Derating 25
2.5.8 Automatic Energy Optimisation 25
2.5.9 Automatic Switching Frequency Modulation 25
2.5.10 Automatic Derating for High Switching Frequency 26
2.5.11 Automatic Derating for Overtemperature 26
2.5.12 Auto Ramping 26
2.5.13 Current Limit Circuit 26
2.5.14 Power Fluctuation Performance 26
2.5.15 Motor Soft Start 26
2.5.16 Resonance Damping 26
2.5.17 Temperature-controlled Fans 26
2.5.18 EMC Compliance 26
2.5.19 Current Measurement on All Three Motor Phases 27
2.5.20 Galvanic Isolation of Control Terminals 27
2.6 Custom Application Functions 27
2.6.1 Automatic Motor Adaptation 27
2.6.2 Motor Thermal Protection 27
2.6.3 Mains Drop-out 27
2.6.4 Built-in PID Controllers 28
2.6.5 Automatic Restart 28
2.6.6 Flying Start 28
2.6.7 Full Torque at Reduced Speed 28
2.6.8 Frequency Bypass 28
2.6.9 Motor Preheat 28
2.6.10 Four Programmable Set-ups 29
2.6.11 DC Braking 29
2.6.12 Sleep Mode 29
2.6.13 Run Permissive 29
2.6.14 Smart Logic Control (SLC) 29
2.6.15 Safe Torque O Function 30
2.7 Fault, Warning and Alarm Functions 31
2.7.1 Operation at Overtemperature 31
2.7.2 High and Low Reference Warning 31
2.7.3 High and Low Feedback Warning 31
2.7.4 Phase Imbalance or Phase Loss 31
2.7.5 High Frequency Warning 31
2.7.6 Low Frequency Warning 31
2.7.7 High Current Warning 31
Contents VLT®Refrigeration Drive FC 103
2 Danfoss A/S © 08/2015 All rights reserved. MG16G202

2.7.8 Low Current Warning 31
2.7.9 No Load/Broken Belt Warning 31
2.7.10 Lost Serial Interface 32
2.8 User Interfaces and Programming 32
2.8.1 Local Control Panel 32
2.8.2 PC Software 33
2.8.2.1 MCT 10 Set-up Software 33
2.8.2.2 VLT®Harmonics Calculation Software MCT 31 33
2.8.2.3 Harmonic Calculation Software (HCS) 33
2.9 Maintenance 34
2.9.1 Storage 34
3 System Integration 35
3.1 Ambient Operating Conditions 35
3.1.1 Humidity 35
3.1.2 Temperature 36
3.1.3 Cooling 36
3.1.4 Motor-generated Overvoltage 37
3.1.5 Acoustic Noise 37
3.1.6 Vibration and Shock 37
3.1.7 Aggressive Atmospheres 37
3.1.8 IP Rating Denitions 38
3.1.9 Radio Frequency Interference 39
3.1.10 PELV and Galvanic Isolation Compliance 39
3.2 EMC, Harmonics, and Ground Leakage Protection 40
3.2.1 General Aspects of EMC Emissions 40
3.2.2 EMC Test Results (Emission) 42
3.2.3 Emission Requirements 43
3.2.4 Immunity Requirements 43
3.2.5 Motor Insulation 44
3.2.6 Motor Bearing Currents 44
3.2.7 Harmonics 45
3.2.8 Ground Leakage Current 47
3.3 Energy Eciency 49
3.3.1 IE and IES Classes 50
3.3.2 Power Loss Data and Eciency Data 50
3.3.3 Losses and Eciency of a Motor 51
3.3.4 Losses and Eciency of a Power Drive System 51
3.4 Mains Integration 51
3.4.1 Mains Congurations and EMC Eects 51
Contents Design Guide
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3.4.2 Low-frequency Mains Interference 52
3.4.3 Analysing Mains Interference 53
3.4.4 Options for Reducing Mains Interference 53
3.4.5 Radio Frequency Interference 53
3.4.6 Classication of the Operating Site 53
3.4.7 Use with Isolated Input Source 54
3.4.8 Power Factor Correction 54
3.4.9 Input Power Delay 54
3.4.10 Mains Transients 54
3.4.11 Operation with a Standby Generator 54
3.5 Motor Integration 55
3.5.1 Motor Selection Considerations 55
3.5.2 Sine-wave and dU/dt Filters 55
3.5.3 Proper Motor Grounding 55
3.5.4 Motor Cables 55
3.5.5 Motor Cable Shielding 56
3.5.6 Connection of Multiple Motors 56
3.5.7 Motor Thermal Protection 57
3.5.8 Output Contactor 58
3.5.9 Energy Eciency 58
3.6 Additional Inputs and Outputs 59
3.6.1 Wiring Schematic 59
3.6.2 Relay Connections 60
3.6.3 EMC-compliant Electrical Connection 61
3.7 Mechanical Planning 62
3.7.1 Clearance 62
3.7.2 Wall Mounting 63
3.7.3 Access 63
3.8 Options and Accessories 63
3.8.1 Communication Options 66
3.8.2 Input/Output, Feedback, and Safety Options 66
3.8.3 Sine-wave Filters 66
3.8.4 dU/dt Filters 66
3.8.5 Harmonic Filters 66
3.8.6 IP21/NEMA Type 1 Enclosure Kit 67
3.8.7 Common-mode Filters 69
3.8.8 Remote Mounting Kit for LCP 69
3.8.9 Mounting Bracket for Enclosure Sizes A5, B1, B2, C1, and C2 70
3.9 Serial Interface RS485 71
3.9.1 Overview 71
Contents VLT®Refrigeration Drive FC 103
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3.9.2 Network Connection 72
3.9.3 RS485 Bus Termination 72
3.9.4 EMC Precautions 73
3.9.5 FC Protocol Overview 73
3.9.6 Network Conguration 73
3.9.7 FC Protocol Message Framing Structure 73
3.9.8 FC Protocol Examples 77
3.9.9 Modbus RTU Protocol 78
3.9.10 Modbus RTU Message Framing Structure 79
3.9.11 Access to Parameters 82
3.9.12 FC Drive Control Prole 83
3.10 System Design Checklist 89
4 Application Examples 91
4.1 Application Examples 91
4.2 Selected Application Features 91
4.2.1 SmartStart 91
4.2.2 Start/Stop 92
4.2.3 Pulse Start/Stop 92
4.2.4 Potentiometer Reference 93
4.3 Application Set-up Examples 93
5 Special Conditions 99
5.1 Derating 99
5.2 Manual Derating 99
5.3 Derating for Long Motor Cables or Cables with Larger Cross-section 99
5.4 Derating for Ambient Temperature 100
6 Type Code and Selection 104
6.1 Ordering 104
6.1.1 Introduction 104
6.1.2 Type Code 104
6.2 Options, Accessories, and Spare Parts 105
6.2.1 Ordering Numbers: Options and Accessories 105
6.2.2 Ordering Numbers: Harmonic Filters 107
6.2.3 Ordering Numbers: Sine-wave Filter Modules, 200–480 V AC 107
6.2.4 Ordering Numbers: Sine-wave Filter Modules, 525-600/690 V AC 108
6.2.5 Harmonic Filters 109
6.2.6 Sine-wave Filters 111
6.2.7 dU/dt Filters 113
6.2.8 Common Mode Filters 114
Contents Design Guide
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7 Specications 115
7.1 Electrical Data 115
7.1.1 Mains Supply 3x200–240 V AC 115
7.1.2 Mains Supply 3x380–480 V AC 117
7.1.3 Mains Supply 3x525–600 V AC 119
7.2 Mains Supply 121
7.3 Motor Output and Motor Data 121
7.4 Ambient Conditions 122
7.5 Cable Specications 122
7.6 Control Input/Output and Control Data 123
7.7 Connection Tightening Torque 126
7.8 Fuses and Circuit Breakers 127
7.9 Power Ratings, Weight, and Dimensions 132
7.10 dU/dt Testing 133
7.11 Acoustic Noise Ratings 135
7.12 Selected Options 135
7.12.1 VLT®General Purpose I/O Module MCB 101 135
7.12.2 VLT®Relay Card MCB 105 136
7.12.3 VLT®Extended Relay Card MCB 113 138
8 Appendix - Selected Drawings 140
8.1 Mains Connection Drawings 140
8.2 Motor Connection Drawings 143
8.3 Relay Terminal Drawings 145
8.4 Cable Entry Holes 146
Index 151
Contents VLT®Refrigeration Drive FC 103
6 Danfoss A/S © 08/2015 All rights reserved. MG16G202

1 Introduction
1.1 Purpose of the Design Guide
This design guide for VLT®Refrigeration Drive FC 103
frequency converters is intended for:
•Project and systems engineers.
•Design consultants.
•Application and product specialists.
The design guide provides technical information to
understand the capabilities of the frequency converter for
integration into motor control and monitoring systems.
The purpose of the design guide is to provide design
considerations and planning data for integration of the
frequency converter into a system. The design guide caters
for selection of frequency converters and options for a
diversity of applications and installations.
Reviewing the detailed product information in the design
stage enables developing a well-conceived system with
optimal functionality and eciency.
VLT®is a registered trademark.
1.2 Organisation
Chapter 1 Introduction: The general purpose of the design
guide and compliance with international directives.
Chapter 2 Product Overview: The internal structure and
functionality of the frequency converter and operational
features.
Chapter 3 System Integration: Environmental conditions;
EMC, harmonics, and ground leakage; mains input; motors
and motor connections; other connections; mechanical
planning; and descriptions of options and accessories
available.
Chapter 4 Application Examples: Samples of product
applications and guidelines for use.
Chapter 5 Special Conditions: Details on unusual operational
environments.
Chapter 6 Type Code and Selection: Procedures for ordering
equipment and options to meet the intended use of the
system.
Chapter 7 Specications: A compilation of technical data in
table and graphics format.
Chapter 8 Appendix - Selected Drawings: A compilation of
graphics illustrating:
•Mains and motor connections
•Relay terminals
•Cable entries
1.3 Additional Resources
Resources available to understand advanced operation of
the frequency converter, programming, and directives
compliance:
•The VLT
®
Refrigeration Drive FC 103 Operating
Instructions (referenced as operating instructions in
this manual) provide detailed information for the
installation and start-up of the frequency
converter.
•The VLT
®
Refrigeration Drive FC 103 Design Guide
provides information required for design and
planning for integration of the frequency
converter into a system.
•The VLT
®
Refrigeration Drive FC 103 Programming
Guide (referenced as programming guide in this
manual) provides greater detail about how to
work with parameters and many application
examples.
•The VLT
®
Safe Torque O Operating Instructions
describe how to use Danfoss frequency
converters in functional safety applications. This
manual is supplied with the frequency converter
when the STO option is present.
Supplemental publications and manuals are available for
download from vlt-drives.danfoss.com/Products/Detail/
Technical-Documents.
NOTICE
Optional equipment is available that may change some
of the information described in these publications. Be
sure to see the instructions supplied with the options for
specic requirements.
Contact a Danfoss supplier or visit www.danfoss.com for
more information.
Introduction Design Guide
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11

1.4 Abbreviations, Symbols and
Conventions
60°AVM 60°asynchronous vector modulation
A Ampere/AMP
AC Alternating current
AD Air discharge
AEO Automatic energy optimisation
AI Analog input
AMA Automatic motor adaptation
AWG American wire gauge
°CDegrees celsius
CD Constant discharge
CDM Complete drive module: the frequency converter,
feeding section and auxiliaries
CM Common mode
CT Constant torque
DC Direct current
DI Digital input
DM Dierential mode
D-TYPE Drive dependent
EMC Electromagnetic compatibility
EMF Electromotive force
ETR Electronic thermal relay
fJOG Motor frequency when jog function is activated.
fMMotor frequency
fMAX Maximum output frequency, the frequency
converter applies on its output.
fMIN Minimum motor frequency from the frequency
converter
fM,N Nominal motor frequency
FC Frequency converter
g Gramme
Hiperface®Hiperface®is a registered trademark by Stegmann
HO High overload
hp Horse power
HTL HTL encoder (10–30 V) pulses - High-voltage
transistor logic
Hz Hertz
IINV Rated inverter output current
ILIM Current limit
IM,N Nominal motor current
IVLT,MAX Maximum output current
IVLT,N Rated output current supplied by the frequency
converter
kHz Kilohertz
LCP Local control panel
lsb Least signicant bit
m Meter
mA Milliampere
MCM Mille circular mil
MCT Motion control tool
mH Inductance in milli Henry
mm Millimeter
ms Millisecond
msb Most signicant bit
ηVLT Eciency of the frequency converter dened as
ratio between power output and power input.
nF Capacitance in nano Farad
NLCP Numerical local control panel
Nm Newton meter
NO Normal overload
nsSynchronous motor speed
Online/
Oine
Parameters
Changes to online parameters are activated
immediately after the data value is changed.
Pbr,cont. Rated power of the brake resistor (average power
during continuous braking).
PCB Printed circuit board
PCD Process data
PDS Power drive system: a CDM and a motor
PELV Protective extra low voltage
PmFrequency converter nominal output power as
high overload (HO).
PM,N Nominal motor power
PM motor Permanent magnet motor
Process PID PID (Proportional Integrated Dierential) regulator
that maintains the speed, pressure, temperature,
and so on.
Rbr,nom Nominal resistor value that ensures a brake power
on the motor shaft of 150/160% for 1 minute
RCD Residual current device
Regen Regenerative terminals
Rmin Minimum permissible brake resistor value by
frequency converter
RMS Root mean square
RPM Revolutions per minute
Rrec Recommended brake resistor resistance of
Danfoss brake resistors
s Second
SFAVM Stator ux-oriented asynchronous vector
modulation
STW Status word
SMPS Switch mode power supply
THD Total harmonic distortion
TLIM Torque limit
TTL TTL encoder (5 V) pulses - transistor transistor
logic
UM,N Nominal motor voltage
V Volts
VT Variable torque
VVC+Voltage vector control plus
Table 1.1 Abbreviations
Introduction VLT®Refrigeration Drive FC 103
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