Danfoss VLT FC 103 User manual

MAKING MODERN LIVING POSSIBLE
Instruction Manual
VLT®Refrigeration Drive FC 103
1.1–90 kW
www.danfoss.com/drives

Contents
1 Introduction 4
1.1 Purpose of the Manual 4
1.2 Additional Resources 4
1.3 Document and Software Version 4
1.4 Product Overview 4
1.5 Approvals and Certifications 7
1.6 Disposal Instruction 7
2 Safety 8
2.1 Safety Symbols 8
2.2 Qualified Personnel 8
2.3 Safety Precautions 8
3 Mechanical Installation 10
3.1 Unpacking 10
3.2 Installation Environments 10
3.3 Mounting 11
4 Electrical Installation 13
4.1 Safety Instructions 13
4.2 EMC-compliant Installation 13
4.3 Grounding 13
4.4 Wiring Schematic 15
4.5 Access 17
4.6 Motor Connection 17
4.7 AC Line Power Connection 18
4.8 Control Wiring 18
4.8.1 Control Terminal Types 19
4.8.2 Wiring to Control Terminals 20
4.8.3 Enabling Motor Operation (Terminal 27) 20
4.8.4 Voltage/Current Input Selection (Switches) 21
4.8.5 Safe Torque Off (STO) 21
4.8.6 RS-485 Serial Communication 21
4.9 Installation Check List 22
5 Commissioning 23
5.1 Safety Instructions 23
5.2 Applying Power 23
5.3 Local Control Panel Operation 24
Contents Instruction Manual
MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.

5.3.2 LCP Layout 24
5.3.3 Parameter Settings 26
5.3.4 Uploading/Downloading Data to/from the LCP 26
5.4 Basic Programming 27
5.4.1 Commissioning with SmartStart 27
5.4.2 Commissioning via [Main Menu] 27
5.4.3 Asynchronous Motor Set-up 28
5.4.4 PM Motor Set-up in VVCplus 28
5.4.5 Automatic Energy Optimization (AEO) 29
5.4.6 Automatic Motor Adaptation (AMA) 30
5.5 Checking Motor Rotation 30
5.6 Local Control Test 30
5.7 System Start-up 31
6 Application Set-up Examples 32
7 Maintenance, Diagnostics and Troubleshooting 36
7.1 Maintenance and Service 36
7.2 Status Messages 36
7.3 Warning and Alarm Types 38
7.4 List of Warnings and Alarms 39
7.5 Troubleshooting 45
8 Specifications 48
8.1 Electrical Data 48
8.1.1 Line Power Supply 3x200–240 V AC 48
8.1.2 Line Power Supply 3x380–480 V AC 50
8.1.3 Line Power Supply 3x525–600 V AC 52
8.2 Line Power Supply 54
8.3 Motor Output and Motor Data 55
8.4 Ambient Conditions 55
8.5 Cable Specifications 55
8.6 Control Input/Output and Control Data 56
8.7 Connection Tightening Torques 59
8.8 Fuses and Circuit Breakers 60
8.9 Power Ratings, Weight and Dimensions 67
9 Appendix 69
9.1 Symbols, Abbreviations and Conventions 69
9.2 Parameter Menu Structure 69
Contents Instruction Manual
Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322

Index 73
Contents Instruction Manual
MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.

1 Introduction
1.1 Purpose of the Manual
This instruction manual provides information for safe
installation and commissioning of the adjustable frequency
drive.
This instruction manual is intended for use by qualified
personnel.
Read and follow the instruction manual to use the
adjustable frequency drive safely and professionally, and
pay particular attention to the safety instructions and
general warnings. Keep this instruction manual available
with the adjustable frequency drive at all times.
VLT®is a registered trademark.
1.2 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 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 adjustable frequency drive 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
adjustable frequency drive, the motor and
equipment driven by the motor.
•system and motor status surveillance.
The adjustable frequency drive can also be used for motor
protection.
Depending on configuration, the adjustable frequency
drive can be used in standalone applications or form part
of a larger appliance or installation.
The adjustable frequency drive 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 adjustable frequency drive in applications
which are non-compliant with specified operating
conditions and environments. Ensure compliance with the
conditions specified in chapter 8 Specifications.
Introduction Instruction Manual
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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 Line power input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable shield 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 Shielded cable grounding clamp and strain relief 18 Cover
Figure 1.1 Exploded View Enclosure Type A, IP20
Introduction Instruction Manual
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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 shield connector
6 Cable shield 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 Line power input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
Figure 1.2 Exploded View Enclosure Types B and C, IP55 and IP66
Introduction Instruction Manual
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1.4.3 Block Diagram of the Adjustable
Frequency Drive
Figure 1.3 is a block diagram of the internal components of
the adjustable frequency drive. See Table 1.2 for their
functions.
Figure 1.3 Adjustable Frequency Drive Block Diagram
Area Title Functions
1 Line power input
•3-phase AC line power supply
to the adjustable frequency
drive
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 Figure 1.3
1.4.4 Enclosure Types and Power Ratings
For enclosure types and power ratings of the adjustable
frequency drives, 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 adjustable frequency drive complies with UL508C
thermal memory retention requirements. For more
information, refer to the section Motor Thermal Protection
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 Instruction Manual
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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 adjustable frequency drive.
Only qualified personnel is allowed to install or operate
this equipment.
Qualified personnel is defined as trained staff, who are
authorized 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
Adjustable frequency drives contain high voltage when
connected to AC line power. Failure to perform instal-
lation, 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 adjustable frequency drive is connected to AC
line power, 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 adjustable frequency drive from
line power whenever personal safety consider-
ations make it necessary to avoid unintended
motor start.
•Press [Off] on the LCP before programming
parameters.
•The adjustable frequency drive, motor, and any
driven equipment must be in operational
readiness when the adjustable frequency drive
is connected to AC line power.
Safety Instruction Manual
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