Danfoss VLT FC 103 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT®Refrigeration Drive FC 103
1.1-90 kW
www.danfoss.com/drives

Contents
1 Introduction 3
1.1 Purpose of the Manual 3
1.2 Additional Resources 3
1.3 Document and Software Version 3
1.4 Product Overview 3
1.5 Approvals and Certifications 6
1.6 Disposal Instruction 6
2 Safety 7
2.1 Safety Symbols 7
2.2 Qualified Personnel 7
2.3 Safety Precautions 7
3 Mechanical Installation 9
3.1 Unpacking 9
3.2 Installation Environments 9
3.3 Mounting 9
4 Electrical Installation 12
4.1 Safety Instructions 12
4.2 EMC-compliant Installation 12
4.3 Grounding 12
4.3.1 Grounding 12
4.4 Wiring Schematic 13
4.5 Access 15
4.6 Motor Connection 15
4.7 AC Mains Connection 16
4.8 Control Wiring 16
4.8.1 Control Terminal Types 17
4.8.2 Wiring to Control Terminals 18
4.8.3 Enabling Motor Operation (Terminal 27) 18
4.8.4 Voltage/Current Input Selection (Switches) 19
4.8.5 Safe Torque Off (STO) 19
4.8.6 RS-485 Serial Communication 19
4.9 Installation Check List 20
5 Commissioning 21
5.1 Safety Instructions 21
5.2 Applying Power 21
5.3 Local Control Panel Operation 22
Contents Operating Instructions
MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved. 1

5.3.2 LCP Layout 22
5.3.3 Parameter Settings 23
5.3.4 Uploading/Downloading Data to/from the LCP 23
5.4 Basic Programming 24
5.4.1 Commissioning with SmartStart 24
5.4.2 Commissioning via [Main Menu] 25
5.4.3 Asynchronous Motor Set-up 25
5.4.4 PM Motor Setup in VVC+25
5.4.5 Automatic Energy Optimisation (AEO) 26
5.4.6 Automatic Motor Adaptation (AMA) 26
5.5 Checking Motor Rotation 27
5.6 Local-control Test 27
5.7 System Start-up 27
6 Application Set-up Examples 28
7 Maintenance, Diagnostics and Troubleshooting 32
7.1 Maintenance and Service 32
7.2 Status Messages 32
7.3 Warning and Alarm Types 34
7.4 List of Warnings and Alarms 34
7.5 Troubleshooting 40
8 Specifications 42
8.1 Electrical Data 42
8.1.1 Mains Supply 3x200-240 V AC 42
8.1.2 Mains Supply 3x380-480 V AC 44
8.1.3 Mains Supply 3x525-600 V AC 46
8.2 Mains Supply 48
8.3 Motor Output and Motor Data 48
8.4 Ambient Conditions 49
8.5 Cable Specifications 49
8.6 Control Input/Output and Control Data 49
8.7 Connection Tightening Torques 52
8.8 Fuses and Circuit Breakers 53
8.9 Power Ratings, Weight and Dimensions 58
9 Appendix 59
9.1 Symbols, Abbreviations and Conventions 59
9.2 Parameter Menu Structure 59
Index 63
Contents Operating Instructions
2 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302

1 Introduction
1.1 Purpose of the Manual
These operating instructions provide information for safe
installation and commissioning of the frequency converter.
The operating instructions are intended for use by
qualified personnel.
Read and follow the operating instructions to use the
frequency converter safely and professionally, and pay
particular attention to the safety instructions and general
warnings. Keep these operating instructions available with
the frequency converter at all times.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
•The VLT
®
Programming Guide provides greater
detail on working with parameters and many
application examples.
•The VLT
®
Design Guide provides detailed
information about capabilities and functionality to
design motor control systems.
•Instructions for operation with optional
equipment.
Supplementary publications and manuals are available
from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical+Documentation.htm
for listings.
1.3 Document and Software Version
This manual is regularly reviewed and updated. All
suggestions for improvement are welcome. Table 1.1 shows
the document version and the corresponding software
version.
Edition Remarks Software version
MG16E3xx Replaces MG16E2xx 1.21
Table 1.1 Document and Software Version
1.4 Product Overview
1.4.1 Intended Use
The frequency converter is an electronic motor controller
intended for
•regulation of motor speed in response to system
feedback or to remote commands from external
controllers. A power drive system consists of the
frequency converter, the motor and equipment
driven by the motor.
•system and motor status surveillance.
The frequency converter can also be used for motor
protection.
Depending on configuration, the frequency converter can
be used in standalone applications or form part of a larger
appliance or installation.
The frequency converter is allowed for use in residential,
industrial and commercial environments in accordance
with local laws and standards.
NOTICE
In a residential environment this product can cause radio
interference, in which case supplementary mitigation
measures can be required.
Foreseeable misuse
Do not use the frequency converter in applications which
are non-compliant with specified operating conditions and
environments. Ensure compliance with the conditions
specified in chapter 8 Specifications.
Introduction Operating Instructions
MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved. 3
11

1.4.2 Exploded Views
1
23
4
5
6
7
8
9
10
11
12
13
14
8
15
16
17
18
130BB492.10
1 Local control panel (LCP) 10 Motor output terminals 96 (U), 97 (V), 98 (W)
2 RS-485 serial bus connector (+68, -69) 11 Relay 2 (04, 05, 06)
3 Analog I/O connector 12 Relay 1 (01, 02, 03)
4 LCP input plug 13 -
5 Analog switches (A53), (A54) 14 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable screen connector 15 USB connector
7 Decoupling plate 16 Serial bus terminal switch
8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply
9 Screened cable grounding clamp and strain relief 18 Cover
Illustration 1.1 Exploded View Enclosure Type A, IP20
Introduction Operating Instructions
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1

1
2
3
4
5
6
7
8
9
10
11
12 13
16
17
18
19
14
15
FAN MOUNTING
QDF-30
DC- DC+
Removejumper to activate Safe Stop
Max.24 Volt !
12 13 18 19 27 29 32 33 20
61 68 39 42 50 53 54
06 05 04 03 02 01
130BB493.10
1 Local control panel (LCP) 11 Relay 2 (04, 05, 06)
2 Cover 12 Lifting ring
3 RS-485 serial bus connector 13 Mounting slot
4 Digital I/O and 24 V power supply 14 Grounding clamp (PE)
5 Analog I/O connector 15 Cable screen connector
6 Cable screen connector 16 -
7 USB connector 17 -
8 Serial bus terminal switch 18 Motor output terminals 96 (U), 97 (V), 98 (W)
9 Analog switches (A53), (A54) 19 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
Illustration 1.2 Exploded View Enclosure Types B and C, IP55 and IP66
Introduction Operating Instructions
MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved. 5
11

1.4.3 Block Diagram of the Frequency
Converter
Illustration 1.3 is a block diagram of the internal
components of the frequency converter. See Table 1.2 for
their functions.
Illustration 1.3 Frequency Converter Block Diagram
Area Title Functions
1 Mains input
•3-phase AC mains power
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
Area Title Functions
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 1.3
1.4.4 Enclosure Types and Power Ratings
For enclosure types and power ratings of the frequency
converters, refer to chapter 8.9 Power Ratings, Weight and
Dimensions.
1.5 Approvals and Certifications
Table 1.3 Approvals and Certifications
More approvals and certifications are available. Contact
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.
1.6 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.
Table 1.4 Disposal Instruction
Introduction Operating Instructions
6 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302
1
1

2 Safety
2.1 Safety Symbols
The following symbols are used in this document:
WARNING
Indicates a potentially hazardous situation which could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which could
result in minor or moderate injury. It may also be used
to alert against unsafe practices.
NOTICE
Indicates important information, including situations that
may result in damage to equipment or property.
2.2 Qualified Personnel
Correct and reliable transport, storage, installation,
operation and maintenance are required for the trouble-
free and safe operation of the frequency converter. Only
qualified personnel is allowed to install or operate this
equipment.
Qualified personnel is defined as trained staff, who are
authorised to install, commission, and maintain equipment,
systems and circuits in accordance with pertinent laws and
regulations. Additionally, the personnel must be familiar
with the instructions and safety measures described in this
document.
2.3 Safety Precautions
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when
connected to AC mains input power. Failure to perform
installation, start-up, and maintenance by qualified
personnel could result in death or serious injury.
•Installation, start-up, and maintenance must be
performed by qualified personnel only.
WARNING
UNINTENDED START
When the frequency converter is connected to AC mains,
the motor may start at any time, causing risk of death,
serious injury, equipment, or property damage. The
motor can start by means of an external switch, a serial
bus command, an input reference signal from the LCP, or
after a cleared fault condition.
•Disconnect the frequency converter from mains
whenever personal safety considerations make
it necessary to avoid unintended motor start.
•Press [Off] on the LCP, before programming
parameters.
•The frequency converter, motor, and any driven
equipment must be in operational readiness
when the frequency converter is connected to
AC mains.
WARNING
DISCHARGE TIME
The frequency converter contains DC-link capacitors,
which can remain charged even when the frequency
converter is not powered. Failure to wait the specified
time after power has been removed before performing
service or repair work, could result in death or serious
injury.
1. Stop motor.
2. Disconnect AC mains, permanent magnet type
motors, and remote DC-link power supplies,
including battery back-ups, UPS, and DC-link
connections to other frequency converters.
3. Wait for the capacitors to discharge fully, before
performing any service or repair work. The
duration of waiting time is specified in
Table 2.1.
Voltage [V] Minimum waiting time (minutes)
4 15
200-240 1.1-3.7 kW 5.5-45 kW
380-500 1.1-7.5 kW 11-90 kW
525-600 1.1-7.5 kW 11-90 kW
High voltage may be present even when the warning LED
indicator lights are off.
Table 2.1 Discharge Time
Safety Operating Instructions
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22

WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
frequency converter properly could result in death or
serious injury.
•Ensure correct grounding of the equipment by
a certified electrical installer.
WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment
can result in death or serious injury.
•Ensure that only trained and qualified
personnel perform installation, start up, and
maintenance.
•Ensure that electrical work conforms to national
and local electrical codes.
•Follow the procedures in this manual.
CAUTION
WINDMILLING
Unintended rotation of permanent magnet motors
causes risk of personal injury and equipment damage.
•Ensure that permanent magnet motors are
blocked to prevent unintended rotation.
CAUTION
POTENTIAL HAZARD IN THE EVENT OF INTERNAL
FAILURE
Risk of personal injury when the frequency converter is
not properly closed.
•Before applying power, ensure all safety covers
are in place and securely fastened.
Safety Operating Instructions
8 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302
22

3 Mechanical Installation
3.1 Unpacking
3.1.1 Items Supplied
Items supplied may vary according to product configu-
ration.
•Make sure the items supplied and the
information on the nameplate correspond to the
order confirmation.
•Check the packaging and the frequency converter
visually for damage caused by inappropriate
handling during shipment. File any claim for
damage with the carrier. Retain damaged parts
for clarification.
130BD796.10
CHASSIS/ IP20 Tamb. 50 C/122 F
V LT
MADE IN
DENMARK
P/N: 134F8447 S/N: 010302G162
1.1 kw / 1.5 HP
IN: 3x200-240V 50/60Hz 5.9A
OUT: 3x0-Vin 0-590Hz 6.6 A
o
CAUTION:
See manual for special condition/mains fuse
voir manual de conditions speclales/fusibles
WARNING:
Stored charge, wait 4 min.
Charge residuelle, attendez 4 min.
* 1 3 4
F
8 4 4 7 0 1 0 3 0 2 G 1 6 2 *
`
Refrigeration Drive
www.danfoss.com
T/C: FC-103P1K1T2E20H1XGXXXXSXXXXAXBXCXXXXDX
o
`
1
2
4
5
6
78
9
10
3
1 Type code
2 Order number
3 Serial number
4 Power rating
5Input voltage, frequency and current (at low/high
voltages)
6Output voltage, frequency and current (at low/high
voltages)
7 Enclosure type and IP rating
8 Maximum ambient temperature
9 Certifications
10 Discharge time (Warning)
Illustration 3.1 Product Nameplate (Example)
NOTICE
Do not remove the nameplate from the frequency
converter (loss of warranty).
3.1.2 Storage
Ensure that requirements for storage are fulfilled. Refer to
chapter 8.4 Ambient Conditions for further details.
3.2 Installation Environments
NOTICE
In environments with airborne liquids, particles, or
corrosive gases, ensure that the IP/Type rating of the
equipment matches the installation environment. Failure
to meet requirements for ambient conditions can reduce
lifetime of the frequency converter. Ensure that
requirements for air humidity, temperature and altitude
are met.
Vibration and Shock
The frequency converter complies with requirements for
units mounted on the walls and floors of production
premises, as well as in panels bolted to walls or floors.
For detailed ambient conditions specifications, refer to
chapter 8.4 Ambient Conditions.
3.3 Mounting
NOTICE
Improper mounting can result in overheating and
reduced performance.
Cooling
•Ensure that top and bottom clearance for air
cooling is provided. See Illustration 3.2 for
clearance requirements.
Mechanical Installation Operating Instructions
MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved. 9
33

a
a
130BD528.10
Illustration 3.2 Top and Bottom Cooling Clearance
Enclosure A2-A5 B1-B4 C1, C3 C2, C4
a [mm] 100 200 200 225
Table 3.1 Minimum Airflow Clearance Requirements
Lifting
•To determine a safe lifting method, check the
weight of the unit, see chapter 8.9 Power Ratings,
Weight and Dimensions.
•Ensure that the lifting device is suitable for the
task.
•If necessary, plan for a hoist, crane, or forklift with
the appropriate rating to move the unit.
•For lifting, use hoist rings on the unit, when
provided.
Mounting
1. Ensure that the strength of the mounting location
supports the unit weight. The frequency
converter allows side-by-side installation.
2. Locate the unit as near to the motor as possible.
Keep the motor cables as short as possible.
3. Mount the unit vertically to a solid flat surface or
to the optional back plate to provide cooling
airflow.
4. Use the slotted mounting holes on the unit for
wall mounting, when provided.
Mounting with back plate and railings
130BD504.10
Illustration 3.3 Proper Mounting with Back Plate
NOTICE
Back plate is required when mounted on railings.
NOTICE
All A, B, and C enclosures allow side-by-side installation.
Exception: if an IP21 kit is used, there has to be a
clearance between the enclosures:
•For enclosures A2, A3, A4, B3, B4 and C3, the
minimum clearance is 50 mm.
•For enclosure C4, the minimum clearance is 75
mm.
C
a
b
130BA648.12
f
e
B
A
a
d
e
b
c
Illustration 3.4 Top and Bottom Mounting Holes (See
chapter 8.9 Power Ratings, Weight and Dimensions)
Mechanical Installation Operating Instructions
10 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302
33

a
e
f
130BA715.12
Illustration 3.5 Top and Bottom Mounting Holes (B4, C3, C4)
Mechanical Installation Operating Instructions
MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved. 11
33

4 Electrical Installation
4.1 Safety Instructions
See chapter 2 Safety for general safety instructions.
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run
together can charge equipment capacitors even with the
equipment turned off and locked out. Failure to run
output motor cables separately or use screened cables
could result in death or serious injury.
•Run output motor cables separately, or
•use screened cables
CAUTION
SHOCK HAZARD
The frequency converter can cause a DC current in the
PE conductor. Failure to follow the recommendation
below means the RCD may not provide the intended
protection.
•When a residual current-operated protective
device (RCD) is used for protection against
electrical shock, only an RCD of Type B is
permitted on the supply side.
Overcurrent Protection
•Additional protective equipment such as short
circuit protection or motor thermal protection
between frequency converter and motor is
required for applications with multiple motors.
•Input fusing is required to provide short circuit
and overcurrent protection. If not factory-
supplied, fuses must be provided by the installer.
See maximum fuse ratings in chapter 8.8 Fuses
and Circuit Breakers.
Wire Type and Ratings
•All wiring must comply with local and national
regulations regarding cross-section and ambient
temperature requirements.
•Power connection wire recommendation:
Minimum 75 °C rated copper wire.
See chapter 8.1 Electrical Data and chapter 8.5 Cable Specifi-
cations for recommended wire sizes and types.
4.2 EMC-compliant Installation
To obtain an EMC-compliant installation, follow the
instructions provided in
chapter 4.3 Groundingchapter 4.4 Wiring Schematic,
chapter 4.6 Motor Connection, and chapter 4.8 Control
Wiring.
4.3 Grounding
4.3.1 Grounding
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
frequency converter properly could result in death or
serious injury.
•Ensure correct grounding of the equipment by
a certified electrical installer.
For electrical safety
•Ground the frequency converter in accordance
with applicable standards and directives.
•Use a dedicated ground wire for input power,
motor power and control wiring.
•Do not ground one frequency converter to
another in a “daisy chain” fashion.
•Keep the ground wire connections as short as
possible.
•Follow motor manufacturer wiring requirements.
•Minimum cable cross-section: 10 mm2(or 2 rated
ground wires terminated separately).
For EMC-compliant installation
•Establish electrical contact between cable screen
and frequency converter enclosure by using
metal cable glands or by using the clamps
provided on the equipment (see
chapter 4.6 Motor Connection).
•Use high-strand wire to reduce electrical
interference.
•Do not use pigtails.
NOTICE
POTENTIAL EQUALISATION
Risk of electrical interference, when the ground potential
between the frequency converter and the system is
different. Install equalising cables between the system
components. Recommended cable cross-section: 16 mm2.
Electrical Installation Operating Instructions
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44

4.4 Wiring Schematic
130BD807.10
3-phase
power
input
Switch Mode
Power Supply
Motor
Analog Output
Interface
relay1
relay2
ON=Terminated
OFF=Open
91 (L1)
92 (L2)
93 (L3)
PE
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24 V OUT)
13 (+24 V OUT)
37 (D IN)
18 (D IN)
20 (COM D IN)
10 V DC
15 mA 130/200 mA
+ - + -
(U) 96
(V) 97
(W) 98
(PE) 99
(COM A OUT) 39
(A OUT) 42
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0 V
5V
S801
0/4-20 mA
RS-485
RS-485
03
+10 V DC
0/-10 V DC -
+10 V DC
+10 V DC
0/4-20 mA
0/-10 V DC-
240 V AC, 2 A
24 V DC
02
01
05
04
06
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
19 (D IN)
24 V (NPN)
0 V (PNP)
27
24 V
0 V
(D IN/OUT)
0 V (PNP)
24 V (NPN)
(D IN/OUT)
0 V
24 V
29
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
A53
ON
21
A54
ON=0/4-20 mA
OFF=0/-10 V DC -
+10 V DC
95
P 5-00
21
ON
S801
: Chassis
: Ground
**
240 V AC, 2 A
400 V AC, 2 A
*
Illustration 4.1 Basic Wiring Schematic
A=Analog, D=Digital
*Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the VLT
®
Frequency
Converters - Safe Torque Off Operating Instructions.
**Do not connect cable screen.
Electrical Installation Operating Instructions
MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved. 13
44

130BD529.11
1
2
3
4
5
6
7
8
PE
U
V
W
9
L1
L2
L3
PE
10
11
1 PLC 6 Cable gland
2 Frequency converter 7 Motor, 3-phase and PE
3 Output contactor 8 Mains, 3-phase and reinforced PE
4 Grounding rail (PE) 9 Control wiring
5 Cable insulation (stripped) 10 Equalising min. 16 mm2(0.025 in)
Illustration 4.2 EMC-compliant Electrical Connection
NOTICE
EMC INTERFERENCE
Use screened cables for motor and control wiring, and separate cables for input power, motor wiring and control
wiring. Failure to isolate power, motor and control cables can result in unintended behaviour or reduced performance.
Minimum 200 mm (7.9 in) clearance between power, motor and control cables is required.
Electrical Installation Operating Instructions
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44

4.5 Access
•Remove cover with a screw driver (See
Illustration 4.3) or by loosening attaching screws
(See Illustration 4.4).
130BT248.10
Illustration 4.3 Access to Wiring for IP20 and IP21 Enclosures
130BT334.10
Illustration 4.4 Access to Wiring for IP55 and IP66 Enclosures
See Table 4.1 before tightening the covers.
Enclosure IP55 IP66
A4/A5 2 2
B1/B2 2.2 2.2
C1/C2 2.2 2.2
No screws to tighten for A2/A3/B3/B4/C3/C4.
Table 4.1 Tightening Torques for Covers [Nm]
4.6 Motor Connection
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run
together can charge equipment capacitors even with the
equipment turned off and locked out. Failure to run
output motor cables separately or use screened cables
could result in death or serious injury.
•run output motor cables separately, or
•use screened cables
•Comply with local and national electrical codes
for cable sizes. For maximum wire sizes see
chapter 8.1 Electrical Data.
•Follow motor manufacturer wiring requirements.
•Motor wiring knockouts or access panels are
provided at the base of IP21 (NEMA1/12) and
higher units.
•Do not wire a starting or pole-changing device
(e.g. Dahlander motor or slip ring induction
motor) between the frequency converter and the
motor.
Procedure
1. Strip a section of the outer cable insulation.
2. Position the stripped wire under the cable clamp
to establish mechanical fixation and electrical
contact between cable screen and ground.
3. Connect ground wire to the nearest grounding
terminal in accordance with grounding
instructions provided in chapter 4.3 Grounding,
see Illustration 4.5.
4. Connect the 3-phase motor wiring to terminals
96 (U), 97 (V), and 98 (W), see Illustration 4.5.
5. Tighten terminals in accordance with the
information provided in chapter 8.7 Connection
Tightening Torques.
Electrical Installation Operating Instructions
MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved. 15
44

130BD531.10
U
VW
96
97
98
Illustration 4.5 Motor Connection
Illustration 4.6 represents mains input, motor, and earth
grounding for basic frequency converters. Actual configu-
rations vary with unit types and optional equipment.
95
130BB920.10
+DC
BR- B
MAINS
L1 L2 L3
91 92 93
RELAY 1 RELAY 2
99
- LC -
U V W
MOTOR
99
Illustration 4.6 Example of Motor, Mains and Ground Wiring
4.7 AC Mains Connection
•Size wiring based upon the input current of the
frequency converter. For maximum wire sizes see
chapter 8.1 Electrical Data.
•Comply with local and national electrical codes
for cable sizes.
Procedure
1. Connect 3-phase AC input power wiring to
terminals L1, L2, and L3 (see Illustration 4.6).
2. Depending on the configuration of the
equipment, input power is connected to the
mains input terminals or the input disconnect.
3. Ground the cable in accordance with grounding
instructions provided in chapter 4.3 Grounding.
4. When supplied from an isolated mains source (IT
mains or floating delta) or TT/TN-S mains with a
grounded leg (grounded delta), ensure that
14-50 RFI Filter is set to [0] Off to avoid damage to
the intermediate circuit and to reduce earth
capacity currents in accordance with IEC 61800-3.
4.8 Control Wiring
•Isolate control wiring from high power
components in the frequency converter.
•When the frequency converter is connected to a
thermistor, ensure that the thermistor control
wiring is screened and reinforced/double
insulated. A 24 V DC supply voltage is
recommended.
Electrical Installation Operating Instructions
16 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302
44

4.8.1 Control Terminal Types
Illustration 4.7 and Illustration 4.8 show the removable
frequency converter connectors. Terminal functions and
default settings are summarised in Table 4.2.
2
3
4
1
130BB921.11
Illustration 4.7 Control Terminal Locations
12 13 18 19 27 29 32 33 20 37
39 42 50 53 54 55
61 68 69
130BB931.10
1
2 3
Illustration 4.8 Terminal Numbers
•Connector 1 provides 4 programmable digital
inputs terminals, 2 additional digital terminals
programmable as either input or output, a 24 V
DC terminal supply voltage, and a common for
optional customer supplied 24 V DC voltage.
•Connector 2 terminals (+)68 and (-)69 are for an
RS-485 serial communication connection
•Connector 3 provides 2 analog inputs, 1 analog
output, 10 V DC supply voltage, and commons
for the inputs and output
•Connector 4 is a USB port available for use with
the MCT 10 Set-up Software
Digital Inputs/Outputs
Terminal Parameter Default
setting
Description
12, 13 - +24 V DC 24 V DC supply
voltage. Maximum
output current is 200
mA total for all 24 V
loads. Useable for
digital inputs and
external transducers.
18 5-10 [8] Start
Digital inputs.
19 5-11 [10] Reversing
32 5-14 [39] Day/Night
Control
33 5-15 [0] No
operation
27 5-12 [2] Coast
inverse
Selectable for either
digital input or
output. Default setting
is input.
29 5-13 [0] No
operation
20 - Common for digital
inputs and 0 V
potential for 24 V
supply.
37 - Safe Torque
Off (STO)
(Optional) Safe input.
Used for STO
Analog Inputs/Outputs
39 - Common for analog
output
42 6-50 [100] Output
frequency
Programmable analog
output. The analog
signal is 0-20 mA or
4-20 mA at a
maximum of 500 Ω
50 - +10 V DC 10 V DC analog
supply voltage. 15 mA
maximum commonly
used for potenti-
ometer or thermistor.
53 6-1* Reference Analog input.
Selectable for voltage
or current. Switches
A53 and A54 select
mA or V.
54 6-2* Feedback
55 - Common for analog
input
Serial Communication
61 - Integrated RC-Filter
for cable screen. ONLY
for connecting the
screen when experi-
encing EMC problems.
68 (+) 8-3* RS-485 Interface. A
control card switch is
provided for
termination resistance.
69 (-) 8-3*
Electrical Installation Operating Instructions
MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved. 17
44

Digital Inputs/Outputs
Terminal Parameter Default
setting
Description
Relays
01, 02, 03 5-40 [2] Drive ready Form C relay output.
Usable for AC or DC
voltage and resistive
or inductive loads.
04, 05, 06 5-40 [5] Running
Table 4.2 Terminal Description
Additional terminals:
•2 form C relay outputs. Location of the outputs
depends on frequency converter configuration.
•Terminals located on built-in optional equipment.
See the manual provided with the equipment
option.
4.8.2 Wiring to Control Terminals
Control terminal connectors can be unplugged from the
frequency converter for ease of installation, as shown in
Illustration 4.7.
NOTICE
Keep control wires as short as possible and separate
from high power cables to minimise interference.
1. Open the contact by inserting a small screw
driver into the slot above the contact and push
the screw driver slightly upwards.
130BD546.10
2
1
10 mm
29
27 32
19
18
13
12 33
Illustration 4.9 Connecting Control Wires
2. Insert the bared control wire into the contact.
3. Remove the screw driver to fasten the control
wire into the contact.
4. Ensure the contact is firmly established and not
loose. Loose control wiring can be the source of
equipment faults or less than optimal operation.
See chapter 8.5 Cable Specifications for control terminal
wiring sizes and chapter 6 Application Set-up Examples for
typical control wiring connections.
4.8.3 Enabling Motor Operation (Terminal
27)
A jumper wire may be required between terminal 12 (or
13) and terminal 27 for the frequency converter to operate
when using factory default programming values.
•Digital input terminal 27 is designed to receive an
24 V DC external interlock command. In many
applications, the user wires an external interlock
device to terminal 27.
•When no interlock device is used, wire a jumper
between control terminal 12 (recommended) or
13 to terminal 27. This provides an internal 24 V
signal on terminal 27.
•When the status line at the bottom of the LCP
reads AUTO REMOTE COAST, this indicates that
the unit is ready to operate but is missing an
input signal on terminal 27.
•When factory installed optional equipment is
wired to terminal 27, do not remove that wiring.
NOTICE
The frequency converter cannot operate without a signal
on terminal 27 unless terminal 27 is re-programmed.
Electrical Installation Operating Instructions
18 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302
44