Danfoss VLT FC 103 User manual

ENGINEERING TOMORROW
Operating Guide
VLT® Refrigeration Drive FC 103
355–800 kW, Enclosure Sizes E1h–E4h
vlt-drives.danfoss.com

Contents
1 Introduction 4
1.1 Purpose of the Manual 4
1.2 Additional Resources 4
1.3 Manual and Software Version 4
1.4 Approvals and Certications 4
1.5 Disposal 4
2 Safety 5
2.1 Safety Symbols 5
2.2 Qualied Personnel 5
2.3 Safety Precautions 5
3 Product Overview 7
3.1 Intended Use 7
3.2 Power Ratings, Weights, and Dimensions 7
3.3 Interior View of Enclosures E1h and E2h 8
3.4 Interior View of Enclosures E3h and E4h 9
3.5 Control Shelf 10
3.6 Local Control Panel (LCP) 11
4 Mechanical Installation 13
4.1 Items Supplied 13
4.2 Tools Needed 13
4.3 Storage 13
4.4 Operating Environment 13
4.5 Installation and Cooling Requirements 15
4.6 Lifting the Unit 15
4.7 E1h/E2h Mechanical Installation 16
4.8 E3h/E4h Mechanical Installation 18
5 Electrical Installation 22
5.1 Safety Instructions 22
5.2 EMC-compliant Installation 22
5.3 Wiring Schematic 25
5.4 Connecting the Motor 26
5.5 Connecting the AC Mains 28
5.6 Connecting to Ground 30
5.7 Terminal Dimensions 32
5.8 Control Wiring 42
Contents Operating Guide
MG16P222 Danfoss A/S © 04/2018 All rights reserved. 1

5.9 Pre-start Check List 47
6 Commissioning 49
6.1 Safety Instructions 49
6.2 Applying Power 49
6.3 LCP Menu 50
6.4 Programming the Drive 51
6.5 Testing Before System Start-up 54
6.6 System Start-up 55
6.7 Parameter Settings 55
7 Wiring Conguration Examples 57
7.1 Wiring for Open-loop Speed Control 57
7.2 Wiring for Start/Stop 58
7.3 Wiring for External Alarm Reset 60
7.4 Wiring for a Motor Thermistor 60
7.5 Wiring for Regeneration 61
8 Maintenance, Diagnostics, and Troubleshooting 62
8.1 Maintenance and Service 62
8.2 Heat Sink Access Panel 62
8.3 Status Messages 63
8.4 Warning and Alarm Types 66
8.5 List of Warnings and Alarms 66
8.6 Troubleshooting 76
9 Specications 79
9.1 Electrical Data 79
9.2 Mains Supply 83
9.3 Motor Output and Motor Data 83
9.4 Ambient Conditions 83
9.5 Cable Specications 84
9.6 Control Input/Output and Control Data 84
9.7 Fuses 87
9.8 Enclosure Dimensions 88
9.9 Enclosure Airow 104
9.10 Fastener Torque Ratings 105
10 Appendix 106
10.1 Abbreviations and Conventions 106
Contents VLT® Refrigeration Drive FC 103
2 Danfoss A/S © 04/2018 All rights reserved. MG16P222

10.2 International/North American Default Parameter Settings 107
10.3 Parameter Menu Structure 107
Index 112
Contents Operating Guide
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1 Introduction
1.1 Purpose of the Manual
This operating guide provides information for safe instal-
lation and commissioning of the VLT®drives in an
enclosure size E (E1h, E2h, E3h, and E4h).
The operating guide is intended for use by qualied
personnel. To use the unit safely and professionally, read
and follow this operating guide. Pay particular attention to
the safety instructions and general warnings. Always keep
the operating guide with the drive.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced E1h–
E4h drive functions and programming.
•The VLT
®
Refrigeration Drive FC 103 Programming
Guide provides greater detail on working with
parameters and refrigeration application
examples.
•The VLT
®
HVAC Drive FC 102, 90–1200 kW Design
Guide provides detailed capabilities and
functionality to design motor control systems for
refrigeration applications.
•The Safe Torque O Operating Guide provides
detailed specications, requirements, and instal-
lation instructions for the Safe Torque O
function.
Supplementary publications and manuals are available
from Danfoss. See www.danfoss.com/en/search/?lter=type
%3Adocumentation for listings.
1.3 Manual and Software Version
This manual is regularly reviewed and updated. All
suggestions for improvement are welcome. Table 1.1 shows
the version of the manual and the corresponding software
version.
Manual version Remarks Software
version
MG16P2xx Added output contactor
warning and other corrections.
1.51
Table 1.1 Manual and Software Version
1.4 Approvals and Certications
Table 1.2 Approvals and Certications
More approvals and certications are available. Contact the
local Danfoss oce or partner. Drives of voltage T7 (525–
690 V) are UL certied for only 525–690 V.
The drive complies with UL 61800-5-1 thermal memory
retention requirements. For more information, refer to the
section Motor Thermal Protection in the product-specic
design guide.
NOTICE
IMPOSED LIMITATIONS ON THE OUTPUT
FREQUENCY
From software version 1.10, the output frequency of the
drive is limited to 590 Hz due to export control
regulations.
1.4.1 Compliance with ADN
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.
1.5 Disposal
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Introduction VLT® Refrigeration Drive FC 103
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2 Safety
2.1 Safety Symbols
The following symbols are used in this guide:
WARNING
Indicates a potentially hazardous situation that could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.
NOTICE
Indicates important information, including situations that
can result in damage to equipment or property.
2.2 Qualied Personnel
Correct and reliable transport, storage, installation,
operation, and maintenance are required for the trouble-
free and safe operation of the drive. Only qualied
personnel are allowed to install or operate this equipment.
Qualied personnel are dened as trained sta, who are
authorized to install, commission, and maintain equipment,
systems, and circuits in accordance with pertinent laws and
regulations. Also, the personnel must be familiar with the
instructions and safety measures described in this manual.
2.3 Safety Precautions
WARNING
HIGH VOLTAGE
Drives contain high voltage when connected to AC mains
input, DC supply, load sharing, or permanent motors.
Failure to use qualied personnel to install, start up, and
maintain the drive can result in death or serious injury.
•Only qualied personnel must install, start up,
and maintain the drive.
WARNING
UNINTENDED START
When the drive is connected to the AC mains, DC supply,
or load sharing, the motor can start at any time.
Unintended start during programming, service, or repair
work can result in death, serious injury, or property
damage. The motor can start with an external switch, a
eldbus command, an input reference signal from the
LCP or LOP, via remote operation using MCT 10 Set-up
Software, or after a cleared fault condition.
To prevent unintended motor start:
•Press [O/Reset] on the LCP before
programming parameters.
•Disconnect the drive from the mains.
•Completely wire and assemble the drive, motor,
and any driven equipment before connecting
the drive to the AC mains, DC supply, or load
sharing.
WARNING
DISCHARGE TIME
The drive contains DC-link capacitors, which can remain
charged even when the drive is not powered. High
voltage can be present even when the warning LED
indicator lights are o. Failure to wait 40 minutes after
power has been removed before performing service or
repair work can result in death or serious injury.
1. Stop the motor.
2. Disconnect AC mains and remote DC-link
supplies, including battery back-ups, UPS, and
DC-link connections to other drives.
3. Disconnect or lock motor.
4. Wait 40 minutes for the capacitors to discharge
fully.
5. Before performing any service or repair work,
use an appropriate voltage measuring device to
make sure that the capacitors are fully
discharged.
Safety Operating Guide
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22

WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
drive properly can result in death or serious injury.
•Ensure the correct grounding of the equipment
by a certied electrical installer.
WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment
can result in death or serious injury.
•Ensure that only trained and qualied personnel
install, start up, and maintain the drive.
•Ensure that electrical work conforms to national
and local electrical codes.
•Follow the procedures in this guide.
CAUTION
HOT SURFACES
The drive contains metal components that are still hot
even after the drive has been powered o. Failure to
observe the high temperature symbol (yellow triangle)
on the drive can result in serious burns.
•Be aware that internal components, such as
busbars, may be extremely hot even after the
drive has been powered o.
•Exterior areas marked by the high temperature
symbol (yellow triangle) are hot while the drive
is in use and immediately after being powered
o.
WARNING
INTERNAL FAILURE HAZARD
Under certain circumstances, an internal failure can
cause a component to explode. Failure to keep the
enclosure closed and properly secured can cause death
or serious injury.
•Do not operate the drive with the door open or
panels o.
•Ensure that the enclosure is properly closed and
secured during operation.
NOTICE
MAINS SHIELD SAFETY OPTION
A mains shield option is available for enclosures with a
protection rating of IP21/IP54 (Type 1/Type 12). The
mains shield is a cover installed inside the enclosure to
protect against the accidental touch of the power
terminals, according to BGV A2, VBG 4.
Safety VLT® Refrigeration Drive FC 103
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3 Product Overview
3.1 Intended Use
The drive is an electronic motor controller that converts AC mains input into a variable AC waveform output. The frequency
and voltage of the output are regulated to control the motor speed or torque. The drive is designed to:
•Regulate motor speed in response to system feedback or to remote commands from external controllers.
•Monitor system and motor status.
•Provide motor overload protection.
The drive is designed for industrial and commercial environments in accordance with local laws and standards. Depending
on conguration, the drive can be used in standalone applications or form part of a larger system or installation.
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 drive in applications which are non-compliant with specied operating conditions and environments. Ensure
compliance with the conditions specied in chapter 9 Specications.
3.2 Power Ratings, Weights, and Dimensions
Table 3.1 provides dimensions for standard congurations. For dimensions on optional congurations, see chapter 9 Speci-
cations.
Enclosure size E1h E2h E3h E4h
Rated power at 380–480 V [kW (hp)] 355–450
(500–600)
500–560
(650–750)
355–450
(500–600)
500–560
(650–750)
Rated power at 525–690 V [kW (hp)] 450–630
(450–650)
710–800
(750–950)
450–630
(450–650)
710–800
(750–950)
Enclosure protection rating IP21/Type 1
IP54/Type 12
IP21/Type 1
IP54/Type 12
IP20/
Chassis
IP20/
Chassis
Unit dimensions
Height [mm (in)] 2043 (80.4) 2043 (80.4) 1578 (62.1) 1578 (62.1)
Width [mm (in)] 602 (23.7) 698 (27.5) 506 (19.9) 604 (23.89)
Depth [mm (in)] 513 (20.2) 513 (20.2) 482 (19.0) 482 (19.0)
Weight [kg (lb)] 295 (650) 318 (700) 272 (600) 295 (650)
Shipping dimensions
Height [mm (in)] 2191 (86.3) 2191 (86.3) 1759 (69.3) 1759 (69.3)
Width [mm (in)] 768 (30.2) 768 (30.2) 746 (29.4) 746 (29.4)
Depth [mm (in)] 870 (34.3) 870 (34.3) 794 (31.3) 794 (31.3)
Weight [kg (lb)] – – – –
Table 3.1 Enclosure Power Ratings and Dimensions
Product Overview Operating Guide
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3.3 Interior View of Enclosures E1h and E2h
130BF206.11
FASTENERTORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
- REGEN 83
FASTENERTORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
+ REGEN 82
2
6
4
511
12
9
1
7
10
8
3
1 Control shelf (see Illustration 3.3) 7 Fan power card
2 Local control panel (LCP) cradle 8 Space heater (optional)
3 RFI lter (optional) 9 Mains disconnect (optional)
4 Mains fuses (required for UL compliance, but otherwise
optional)
10 Brake/regeneration terminals (optional)
5 Mains terminals 11 Motor terminals
6 RFI shield termination 12 Ground terminals
Illustration 3.1 Interior View of Enclosure E1h (Enclosure E2h is Similar)
Product Overview VLT® Refrigeration Drive FC 103
8 Danfoss A/S © 04/2018 All rights reserved. MG16P222
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