Danfoss VLT FC 103 User manual

Operating Guide
VLT® Refrigeration Drive FC 103
110-800 kW, D9h-D10h and E5h-E6h Enclosed Drives
drives.danfoss.com

1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
3.5
3.6
3.6.1
3.6.2
3.6.3
3.6.4
4
4.1
4.2
4.3
4.4
4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.6
Contents
Introduction 8
Purpose of this Operating Guide 8
Additional Resources 8
Manual Version 8
Approvals and Certications 8
Disposal 9
Safety 10
Safety Symbols 10
Qualied Personnel 10
Safety Precautions 10
Product Overview 13
Intended Use 13
What is an Enclosed Drive? 13
Location of Options within an Enclosed Drive 16
Drive Identication 18
Identifying the Drive and Its Options 18
Enclosure Size Identication 19
Type Code Identication 20
Power Ratings, Weight, and Dimensions 27
Control Compartment and Local Control Panel 28
Control Compartment Overview 28
Control Compartment Door 29
Local Control Panel (LCP) 30
LCP Menu 32
Mechanical Installation 34
Items Supplied 34
Split Shipment 34
Tools Needed 35
Storing the Drive 35
Operating Environment 35
Overview 35
Gases 35
Dust 35
Potentially Explosive Atmospheres 36
Installation Requirements 36
AQ357954340588en-000201/130R0881 | 3Danfoss A/S © 2020.09
Contents
VLT® Refrigeration Drive FC 103
Operating Guide

4.7
4.8
4.9
4.10
4.11
4.11.1
4.11.2
4.11.3
5
5.1
5.2
5.3
5.4
5.5
5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.7
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
5.7.6
5.8
5.8.1
5.8.2
5.8.3
5.8.4
5.8.5
5.8.6
5.9
5.9.1
5.9.2
5.9.3
Cooling Requirements 37
Airow Rates 37
Lifting the Drive 38
Combining Multiple Cabinets from a Split Shipment 39
Installing the Enclosed Drive 41
Creating an Entry for Cables 41
Installing the Drive with Back-channel Cooling Option 41
Securing the Cabinet(s) to the Floor 42
Electrical Installation 44
Safety Instructions 44
EMC-compliant Installation 44
Wiring Overview for D9h and D10h Enclosed Drives 48
Wiring Overview for E5h and E6h Enclosed Drives 49
Control Terminal Wiring Diagram Cross-reference 50
Split Shipment Wiring Harnesses 51
Connecting Wiring Harnesses 51
D10h Wiring Harness 52
E5h Wiring Harness 56
E6h Wiring Harness 62
Control Compartment Wiring 68
Safety Precautions 68
Control Compartment Interior View 69
Control Terminals 70
Relay Terminals 71
Option Card Terminals 71
Control Compartment Options 75
Connecting Motor, Mains, and Ground Cables 81
Power Cabling and Grounding Considerations 81
Connecting to the Mains 82
Connecting the Drive Module to the Motor 84
Connecting the Sine-wave Filter to the Motor 85
Connecting the dU/dt Filter to the Motor 87
Connecting to Ground 89
Installing Upstream Fuses 89
Upstream Fuse Considerations 89
Recommended Fuse Ratings for IEC Installation 90
Recommended Fuse Ratings for UL Installation 91
AQ357954340588en-000201/130R08814 | Danfoss A/S © 2020.09
Contents
VLT® Refrigeration Drive FC 103
Operating Guide

5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
6
7
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.3
7.3.1
7.3.2
7.4
7.5
7.5.1
7.5.2
7.5.3
7.5.4
8
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.1.7
Enabling Motor Operation 92
Selecting the Voltage/Current Input Signal 92
Setting Up RS485 Serial Communication 93
Conguring the Passive Harmonic Filter (PHF) 94
Conguring the dU/dt Filter 94
Conguring the Sine-wave Filter 94
MCCB Conguration 94
Safe Torque O (STO) Wiring 95
Pre-start Check List 96
Commissioning 98
Applying Power to the Drive 98
Programming the Drive 98
Parameter Overview 98
Parameter Navigation 99
Programming Example for an Open-loop Application 99
Entering System Information 100
Conguring Automatic Energy Optimization 101
Conguring Automatic Motor Adaptation 101
Testing Before System Start-up 101
Testing Motor Rotation 101
Testing Encoder Rotation 101
Starting Up the Drive for the First Time 102
Parameter Settings 102
Parameter Setting Overview 102
Uploading and Downloading Parameter Settings 102
Restoring Factory Default Settings Using the Recommended Initialization 103
Restoring Factory Default Settings Using Manual Initialization 103
Wiring Conguration Examples 104
Application Examples 104
Wiring Conguration for Automatic Motor Adaptation (AMA) 104
Wiring Conguration for Automatic Motor Adaptation (AMA) without T27 104
Wiring Conguration: Speed 105
Wiring Conguration: Feedback 107
Wiring Conguration: Run/Stop 108
Wiring Conguration: Start/Stop 110
Wiring Conguration: External Alarm Reset 112
AQ357954340588en-000201/130R0881 | 5Danfoss A/S © 2020.09
Contents
VLT® Refrigeration Drive FC 103
Operating Guide

8.1.8
8.1.9
8.1.10
8.1.11
8.1.12
8.1.13
8.1.14
9
9.1
9.1.1
9.1.2
9.1.3
9.1.4
9.2
9.3
9.4
10
10.1
10.1.1
10.1.2
10.2
10.3
10.3.1
10.3.2
10.4
10.5
10.6
10.6.1
10.6.2
10.6.3
10.6.4
10.6.5
10.6.6
10.6.7
10.6.8
10.6.9
10.6.10
Wiring Conguration: RS485 112
Wiring Conguration: Motor Thermistor 112
Wiring for Regeneration 113
Wiring Conguration for a Relay Set-up with Smart Logic Control 114
Wiring Conguration: Compressor 114
Wiring Conguration for Single or Multiple Refrigeration Fans/Pumps 115
Wiring Conguration for a Compressor Pack 117
Maintenance, Diagnostics, and Troubleshooting 118
Status Messages 118
Status Message Overview 118
Status Messages - Operating Mode 118
Status Messages - Reference Site 118
Status Messages - Operation Status 119
Maintenance and Service 121
Warnings and Alarms 121
Troubleshooting 138
Specications 141
Electrical Data 141
Electrical Data, 380–480 V AC 141
Electrical Data, 525–690 V AC 144
Mains Supply 147
Motor Output and Motor Data 147
Motor Output (U, V, W) 147
Torque Characteristics 147
Ambient Conditions 148
Motor and Control Cables 148
Control Input/Output and Control Data 148
Control Card, USB Serial Communication 148
STO Terminal XD2.19 (Terminal XD2.19 is Fixed PNP Logic) 149
Control Card, 24 V DC Output 149
Control Card, 10 V DC Output 149
Digital Outputs 149
Digital Inputs 150
Pulse/Encoder Inputs 150
Control Characteristics 150
Relay Outputs 151
Analog Output 151
AQ357954340588en-000201/130R08816 | Danfoss A/S © 2020.09
Contents
VLT® Refrigeration Drive FC 103
Operating Guide

10.6.11
10.6.12
10.6.13
10.7
10.7.1
10.7.2
10.7.3
10.7.4
10.8
10.8.1
10.8.2
10.8.3
10.8.4
10.8.5
10.9
10.9.1
10.9.2
10.9.3
10.9.4
10.9.5
10.10
10.11
11
11.1
11.2
11.3
11.4
11.5
11.6
11.6.1
11.6.2
11.6.3
11.6.4
11.6.5
11.6.6
11.6.7
Analog Inputs 151
Control Card, RS485 Serial Communication 152
Control Card Performance 152
Filter Specications 152
Passive Harmonic Filter Specications 152
Line Reactor Specications 153
dU/dt Filter Specications 154
Sine-wave Filter Specications 154
Fuses, Circuit Breakers, and Switches 155
Panel Fuses 156
Contactor Switches 157
Fusible Disconnect Switches 158
Non-fusible Disconnect Switches 159
Molded-case Circuit Breakers 160
Enclosure Dimensions 161
Pedestal Dimensions 161
D9h Enclosed Drive Exterior Dimensions 161
D10h Enclosed Drive Exterior Dimensions 162
E5h Enclosed Drive Exterior Dimensions 163
E6h Enclosed Drive Exterior Dimensions 164
Enclosure Airow 165
Fastener Torque Ratings 165
Appendix 166
Conventions 166
Abbreviations 166
International/North American Default Parameter Settings 168
Required Parameter Settings for Drive Options 169
Block Diagrams 170
Input Power Option Losses 173
Contactor Losses 173
Fusible Disconnect Losses 174
Non-fusible Disconnect Losses 175
Molded-case Circuit Breaker (MCCB) Losses 176
Passive Harmonic Filter Losses 177
dU/dt Filter Losses 178
Sine-wave Filter Losses 179
AQ357954340588en-000201/130R0881 | 7Danfoss A/S © 2020.09
Contents
VLT® Refrigeration Drive FC 103
Operating Guide

•
•
•
•
1 Introduction
1.1 Purpose of this Operating Guide
This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualied
personnel. Read and follow the instructions to use the drive safely and professionally. Pay particular attention to the safety instruc-
tions and general warnings. Always keep this Operating Guide with the drive.
1.2 Additional Resources
Other resources are available to understand advanced drive functions and programming.
The Programming Guide provides greater detail on working with parameters and shows many application examples.
The Design Guide provides detailed information about capabilities and functionality to design motor control systems.
The Safe Torque O Operating Guide provides detailed specications, requirements, and installation instructions for the Safe
Torque O function.
Supplementary publications and manuals are available from Danfoss.
See https://www.danfoss.com/en/search/?lter=type%3Adocumentation.
1.3 Manual Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
The original language of this manual is English.
Table 1: Manual and Software Version
Version
Remarks
Software version
AQ357954340588 - 0201
Updated enclosure illustrations and the input power option loss tables.
2.33
1.4 Approvals and Certications
The following list is a selection of possible type approvals and certications for Danfoss drives:
089
The specic approvals and certication for the enclosed drive or drive module are on the nameplate of the drive. For more informa-
tion, contact the local Danfoss oce or partner.
Thermal memory retention requirement
The enclosed drive is UL listed per UL508A and CSA 14 standards. The drive module in the enclosed drive system complies with UL
508C or UL 61800-5-1 thermal memory retention requirements. For more information on UL 508C thermal memory retention re-
quirements, refer to the Motor Thermal Protection section in the product-specic Design Guide.
AQ357954340588en-000201 / 130R08818 | Danfoss A/S © 2020.09
Introduction
VLT® Refrigeration Drive FC 103
Operating Guide

NOTICE
OUTPUT FREQUENCY LIMIT
Due to export control regulations, the output frequency of the enclosed drive (with no output lters) is limited to 590 Hz. For
demands exceeding 590 Hz, contact Danfoss. For enclosed drives with output lters, the maximum output frequency is limited to
60 Hz without derating and to 100/120 Hz with derating.
ADN-compliance
For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by In-
land Waterways (ADN), refer to section ADN-compliant Installation in the product-specic Design Guide.
1.5 Disposal
Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance
with applicable local regulations.
AQ357954340588en-000201 / 130R0881 | 9Danfoss A/S © 2020.09
Introduction
VLT® Refrigeration Drive FC 103
Operating Guide

•
•
•
•
-
2 Safety
2.1 Safety Symbols
The following symbols are used in this manual:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
2.2 Qualied Personnel
To allow trouble-free and safe operation of the unit, only qualied personnel with proven skills are allowed to transport, store, as-
semble, install, program, commission, maintain, and decommission this equipment.
Persons with proven skills:
Are qualied electrical engineers, or persons who have received training from qualied electrical engineers and are suitably ex-
perienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.
Are familiar with the basic regulations concerning health and safety/accident prevention.
Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in
the Operating Guide.
Have good knowledge of the generic and specialist standards applicable to the specic application.
2.3 Safety Precautions
WARNING
LACK OF SAFETY AWARENESS
This document gives important information on how to prevent injury and damage to the equipment or the system. Ignoring
them can lead to death, serious injury, or severe damage to the equipment.
Make sure to fully understand the dangers and safety measures incurred in the application.
AQ357954340588en-000201 / 130R088110 | Danfoss A/S © 2020.09
Safety
VLT® Refrigeration Drive FC 103
Operating Guide