Danfoss VLT FC 103 User manual

MAKING MODERN LIVING POSSIBLE
Instruction Manual
VLT®Refrigeration Drive FC 103, 75–400 kW

Safety
WARNING
HIGH VOLTAGE!
Adjustable frequency drives contain high voltage when
connected to AC line power. Installation, startup, and
maintenance should be performed by qualified personnel
only. Failure to perform installation, startup, and
maintenance by qualified personnel could result in death
or serious injury.
High Voltage
Adjustable frequency drives are connected to hazardous
AC line voltage. Extreme care should be taken to protect
against shock. Only trained personnel familiar with
electronic equipment should install, start, or maintain this
equipment.
WARNING
UNINTENDED START!
When the adjustable frequency drive is connected to AC
line power, the motor may start at any time. The
adjustable frequency drive, motor, and any driven
equipment must be in operational readiness. Failure to be
in operational readiness when the adjustable frequency
drive is connected to AC line power could result in death,
serious injury, equipment, or property damage.
Unintended Start
When the adjustable frequency drive is connected to AC
line power, the motor may be started with an external
switch, a serial bus command, an input reference signal, or
a cleared fault condition. Use appropriate caution to guard
against an unintended start.
WARNING
DISCHARGE TIME!
Adjustable frequency drives contain DC link capacitors that
can remain charged even when the adjustable frequency
drive is not powered. To avoid electrical hazards,
disconnect AC line power, any permanent magnet type
motors, and any remote DC link power supplies, including
battery backups, UPS and DC link connections to other
adjustable frequency drives. Wait for the capacitors to fully
discharge before performing any service or repair work.
The wait time required is listed in the Discharge Time table.
Failure to wait for the specified period of time after power
has been removed to do service or repair could result in
death or serious injury.
Voltage [V] Power range hp [kW] Minimum waiting time
[min]
3 x 400 125–350 [90–250] 20
3 x 400 150–450 [110–315] 20
3 x 480 150–450 [110–315] 20
3 x 480 175–475 [132–355] 20
3 x 550 75–450 [55–315] 20
3 x 690 100–550 [75–400] 20
Discharge Time
Table 1.2
NOTE!
Imposed limitations on the output frequency
(due to export control regulations):
From software version 6.72, the output frequency of the
adjustable frequency drive is limited to 590 Hz. Software
versions 6x.xx also limit the maximum output frequency to
590 Hz, but these versions cannot be flashed, i.e., neither
downgraded nor upgraded.
Safety VLT®Refrigeration Drive Instruction Manual
MG16J122 - VLT®is a registered Danfoss trademark

Safety VLT®Refrigeration Drive Instruction Manual
MG16J122 - VLT®is a registered Danfoss trademark

Contents
1 Introduction 2-1
1.1 Product Overview 2-1
1.1.1 Interior Views 2-1
1.2 Purpose of the Manual 2-2
1.3 Additional Resources 2-2
1.4 Product Overview 2-2
1.5 Internal Controller Functions 2-2
1.6 Frame Sizes and Power Ratings 2-4
2 Installation 3-1
2.1 Planning the Installation Site 3-1
2.1.2 Planning the Installation Site 3-1
2.2 Pre-Installation Check List 3-2
2.3 Mechanical Installation 3-2
2.3.1 Cooling 3-2
2.3.2 Lifting 3-3
2.3.3 Wall Mounting - IP21 (NEMA 1) and IP54 (NEMA 12) Units 3-3
2.4 Electrical Installation 3-3
2.4.1 General Requirements 3-3
2.4.2 Grounding Requirements 3-6
2.4.2.1 Leakage Current (>3.5 mA) 3-6
2.4.2.2 Grounding IP20 Enclosures 3-7
2.4.2.3 Grounding IP21/54 Enclosures 3-7
2.4.3 Motor Connection 3-8
2.4.3.1 Terminal Locations: D1h-D4h 3-8
2.4.4 Motor Cable 3-11
2.4.5 Motor Rotation Check 3-11
2.4.6 AC Line Input Connections 3-12
2.5 Control Wiring Connection 3-12
2.5.1 Access 3-12
2.5.2 Using Shielded Control Cables 3-13
2.5.3 Grounding of Shielded Control Cables 3-13
2.5.4 Control Terminal Types 3-14
2.5.5 Wiring to Control Terminals 3-15
2.5.6 Control Terminal Functions 3-15
2.6 Serial Communication 3-16
2.7 Optional Equipment 3-16
Contents VLT®Refrigeration Drive Instruction Manual
MG16J122 - VLT®is a registered Danfoss trademark

2.7.1 Load Share Terminals 3-16
2.7.2 Regeneration Terminals 3-16
2.7.3 Anti-condensation Heater 3-16
2.7.4 Brake Chopper 3-17
2.7.5 line Power Shield 3-17
3 Start-up and Functional Testing 4-1
3.1 Pre-start 4-1
3.1.1 Safety Inspection 4-1
3.2 Applying Power 4-3
3.3 Basic Operational Programming 4-3
3.3.1 Set-up Wizard 4-3
3.4 Automatic Motor Adaptation 4-9
3.5 Check Motor Rotation 4-10
3.6 Local Control Test 4-10
3.7 System Start-up 4-11
4 User Interface 5-1
4.1 Local Control Panel 5-1
4.1.1 LCP Layout 5-1
4.1.2 Setting LCP Display Values 5-2
4.1.3 Display Menu Keys 5-2
4.1.4 Navigation Keys 5-3
4.1.5 Operation Keys 5-3
4.2 Backup and Copying Parameter Settings 5-3
4.2.1 Uploading Data to the LCP 5-4
4.2.2 Downloading Data from the LCP 5-4
4.3 Restoring Default Settings 5-4
4.3.1 Recommended Initialization 5-4
4.3.2 Manual Initialization 5-4
5 Programming 6-1
5.1 Introduction 6-1
5.2 Programming Example 6-1
5.3 Control Terminal Programming Examples 6-3
5.4 International/North American Default Parameter Settings 6-3
5.5 Parameter Menu Structure 6-4
5.5.1 Main Menu Structure 6-5
5.6 Remote Programming with MCT 10 Set-up Software 6-8
Contents VLT®Refrigeration Drive Instruction Manual
MG16J122 - VLT®is a registered Danfoss trademark

6 Application Examples 7-1
6.1 Introduction 7-1
6.2 Application Examples 7-1
7 Status Messages 8-1
7.1 Status Messages 8-1
7.2 Status Message Definitions 8-1
8 Warnings and Alarms 9-1
8.1 System Monitoring 9-1
8.2 Warning and Alarm Types 9-1
8.2.1 Warnings 9-1
8.2.2 Alarm Trip 9-1
8.2.3 Alarm Trip Lock 9-1
8.3 Warning and Alarm Displays 9-1
8.4 Warning and Alarm Definitions 9-3
8.5 Fault Messages 9-6
9 Basic Troubleshooting 10-1
9.1 Start-up and Operation 10-1
10 Specifications 11-1
10.1 Power-dependent Specifications 11-1
10.2 General Technical Data 11-4
10.3 Fuse Tables 11-9
10.3.1 Protection 11-9
10.3.2 Fuse Selection 11-9
10.3.3 Short Circuit Current Rating (SCCR) 11-10
10.3.4 Connection Tightening Torques 11-10
12 Index 12-1
Contents VLT®Refrigeration Drive Instruction Manual
MG16J122 - VLT®is a registered Danfoss trademark

Contents VLT®Refrigeration Drive Instruction Manual
MG16J122 - VLT®is a registered Danfoss trademark

1 Introduction
1.1 Product Overview
1.1.1 Interior Views
130BC252.11
1
15 14
8
9
12
13 (IP 20/Chassis)
13
(IP 21/54
NEMA 1/12)
11
10
16
Figure 1.1 D1 Interior Components
130BC301.11
1
2
3
4
5
6
7
8
9
10
11
Figure 1.2 Close-up View: LCP and Control Functions
1LCP (Local Control Panel) 9 Relay 2 (04, 05, 06)
2 RS-485 serial bus connector 10 Lifting ring
3 Digital I/O and 24 V power supply 11 Mounting slot
4 Analog I/O connector 12 Cable clamp (PE)
5 USB connector 13 Ground
6 Serial bus terminal switch 14 Motor output terminals 96 (U), 97 (V), 98 (W)
7 Analog switches (A53), (A54) 15 Line power 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
Table 1.1
Introduction VLT®Refrigeration Drive Instruction Manual
MG16J122 - VLT®is a registered Danfoss trademark 1-1
11

1.2 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and start up of the adjustable frequency
drive. 2 Installation provides requirements for mechanical
and electrical installation, including input, motor, control
and serial communications wiring and control terminal
functions. 3 Start-up and Functional Testing provides
detailed procedures for start-up, basic operational
programming, and functional testing. The remaining
chapters provide supplementary details. These details
include user interface, detailed programming, application
examples, start-up troubleshooting, and specifications.
1.3 Additional Resources
Other resources are available to understand advanced
adjustable frequency drive functions and programming.
•The VLT
®
Programming Guide provides greater
detail on working with parameters and many
application examples.
•The VLT
®
Design Guide is intended to provide
detailed capabilities and functionality to design
motor control systems.
•Supplementary 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. Reference 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.
1.4 Product Overview
An adjustable frequency drive is an electronic motor
controller that converts AC line power input into a variable
AC waveform output. The frequency and voltage of the
output are regulated to control the motor speed or torque.
The adjustable frequency drive can vary the speed of the
motor in response to system feedback, such as position
sensors on a conveyor belt. The adjustable frequency drive
can also regulate the motor by responding to remote
commands from external controllers.
In addition, the adjustable frequency drive monitors the
system and motor status, issues warnings or alarms for
fault conditions, starts and stops the motor, optimizes
energy efficiency, and offers many more control,
monitoring, and efficiency functions. Operation and
monitoring functions are available as status indications to
an outside control system or serial communication
network.
1.5 Internal Controller Functions
Figure 1.3 is a block diagram of the adjustable frequency
drive's internal components. See Table 1.2 for their
functions.
Figure 1.3 Adjustable Frequency Drive Block Diagram
Introduction VLT®Refrigeration Drive Instruction Manual
1-2 MG16J122 - VLT®is a registered Danfoss trademark
11