Danfoss VLT FC 103 User manual

MAKING MODERN LIVING POSSIBLE
O
Operating Instructions
VLTpRefrigeration Drive FC 103 1.1-90 kW
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Safety
W
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains input power. Installation, start up,
and maintenance should be performed by qualified
personnel only. Failure to perform installation, start up, and
maintenance by qualified personnel could result in death
or serious injury.
High Voltage
Frequency converters are connected to hazardous mains
voltages. 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 frequency converter is connected to AC mains,
the motor may start at any time. The frequency converter,
motor, and any driven equipment must be in operational
readiness. Failure to be in operational readiness when the
frequency converter is connected to AC mains could result
in death, serious injury, equipment, or property damage.
Unintended Start
When the frequency converter is connected to the AC
mains, the motor may be started by means of an external
switch, a serial bus command, an input reference signal, or
a cleared fault condition. Use appropriate cautions to
guard against an unintended start.
WARNING
DISCHARGE TIME!
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is not
powered. To avoid electrical hazards, disconnect AC mains,
any permanent magnet type motors, and any remote DC-
link power supplies, including battery backups, UPS and
DC-link connections to other frequency converters. Wait for
the capacitors to fully discharge before performing any
service or repair work. The amount of wait time is listed in
the Discharge Time table. Failure to wait the specified time
after power has been removed before doing service or
repair could result in death or serious injury.
Voltage [V] Minimum waiting time [minutes]
4 15
200-240 1.1-3.7 kW 5.5-37 kW
380-480 1.1-7.5 kW 11-75 kW
525-600 0.75-7.5 kW 11-75 kW
High voltage may be present even when the warning LEDs are
off!
Discharge Time
Symbols
The following symbols are used in this manual.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
CAUTION
Indicates a situation that may result in equipment or
property-damage-only accidents.
NOTE
Indicates highlighted information that should be regarded
with attention to avoid mistakes or operate equipment at
less than optimal performance.
Approvals
NOTE
Imposed limitations on the output frequency
(due to export control regulations):
From software version 1.10 the output frequency of the
frequency converter is limited to 590 Hz.
Safety VLTpRefrigeration Drive FC 103 1.1-90 kW Operating Instructions
MG16E202 - VLT® is a registered Danfoss trademark
inverter.ru [phone]

S
Safety VLTpRefrigeration Drive FC 103 1.1-90 kW Operating Instructions
MG16E202 - VLT® is a registered Danfoss trademark
inverter.ru [phone]

C
Contents
1 Introduction
4
1.1 Purpose of the Manual 6
1.2 Product Overview 6
1.3 Internal Frequency Converter Controller Functions 6
1.4 Frame Sizes and Power Ratings 7
2 Installation
8
2.1 Installation Site Check List 8
2.2 Pre-installation Check List 8
2.3 Mechanical Installation 8
2.3.1 Cooling 8
2.3.2 Lifting 9
2.3.3 Mounting 9
2.3.4 Tightening Torques 9
2.4 Electrical Installation 10
2.4.1 Requirements 12
2.4.2 Earth (Grounding) Requirements 12
2.4.2.1 Leakage Current (>3.5 mA) 13
2.4.2.2 Grounding Using Shielded Cable 13
2.4.3 Access 13
2.4.4 Motor Connection 14
2.4.4.1 Motor Connection for A2 and A3 15
2.4.4.2 Motor Connection for A4 and A5 16
2.4.4.3 Motor Connection for B1 and B2 16
2.4.4.4 Motor Connection for C1 and C2 16
2.4.5 AC Mains Connection 17
2.4.5.1 Mains Connection for A2 and A3 17
2.4.5.2 Mains Connection for A4 and A5 18
2.4.5.3 Mains Connection for B1 and B2 19
2.4.5.4 Mains Connection for C1 and C2 19
2.4.6 Control Wiring 20
2.4.6.1 Control Terminal Types 20
2.4.6.2 Wiring to Control Terminals 21
2.4.6.3 Using Screened Control Cables 21
2.4.6.4 Jumper Terminals 12 and 27 22
2.4.6.5 Terminal 53 and 54 Switches 22
2.4.6.6 Terminal 37 23
2.4.7 Serial Communication 25
3 Start Up and Functional Test
26
Contents VLTpRefrigeration Drive FC 103 1.1-90 kW Operating Instructions
MG16E202 - VLT® is a registered Danfoss trademark 1
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3.1 Pre-start 26
3.1.1 Safety Inspection 26
3.2 Applying Power 28
3.3 Basic Operational Programming 28
3.3.1 Set-up Wizard 28
3.4 Asynchronous Motor Setup 33
3.5 Automatic Motor Adaptation 33
3.6 PM Motor Setup in VVCplus 33
3.7 Check Motor Rotation 34
3.8 Local-control Test 35
3.9 System Start Up 35
4 User Interface
36
4.1 Local Control Panel 36
4.1.1 LCP Layout 36
4.1.2 Setting LCP Display Values 37
4.1.3 Display Menu Keys 37
4.1.4 Navigation Keys 38
4.1.5 Operation Keys 38
4.2 Back Up and Copying Parameter Settings 38
4.2.1 Uploading Data to the LCP 39
4.2.2 Downloading Data from the LCP 39
4.3 Restoring Default Settings 39
4.3.1 Recommended Initialisation 39
4.3.2 Manual Initialisation 39
4.4 How to Operate 40
4.5 Remote Programming with MCT 10 Set-up Software 40
5 Programming
41
5.1 Introduction 41
5.2 Programming Example 41
5.3 Control Terminal Programming Examples 42
5.4 International/North American Default Parameter Settings 43
5.5 Parameter Menu Structure 44
5.5.1 Quick Menu Structure 45
5.5.2 Main Menu Structure 47
6 Application Set-Up Examples
50
6.1 Introduction 50
6.2 Set-up Examples 50
6.2.1 Compressor 50
Contents VLTpRefrigeration Drive FC 103 1.1-90 kW Operating Instructions
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6.2.2 Single or Multiple Fans or Pumps 51
6.2.3 Compressor Pack 52
7 Status Messages
53
7.1 Status Display 53
7.2 Status Message Definitions 53
8 Warnings and Alarms
56
8.1 System Monitoring 56
8.2 Warning and Alarm Types 56
8.3 Warning and Alarm Displays 56
8.4 Warning and Alarm Definitions 57
9 Basic Troubleshooting
65
9.1 Start Up and Operation 65
10 Specifications
68
10.1 Power-dependent Specifications 68
10.2 General Technical Data 76
10.3 Fuse Specifications 81
10.3.1 Branch Circuit Protection Fuses 81
10.3.2 Substitute Fuses for 240 V 83
10.4 Connection Tightening Torques 83
Index
84
Contents VLTpRefrigeration Drive FC 103 1.1-90 kW Operating Instructions
MG16E202 - VLT® is a registered Danfoss trademark 3
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1 Introduction
1
23
4
5
6
7
8
9
10
11
12
13
14
8
15
16
17
18
130BB492.10
Illustration 1.1 Exploded View Frame Size A
1 LCP 10 Motor output terminals 96 (U), 97 (V), 98 (W)
2 RS-485 serial bus connector (+68, -69) 11 Relay 2 (01, 02, 03)
3 Analog I/O connector 12 Relay 1 (04, 05, 06)
4 LCP input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals
5 Analog switches (A53), (A54) 14 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable strain relief/PE ground 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 Control cable cover plate
Table 1.1 Legend to Illustration 1.1
Introduction VLTpRefrigeration Drive FC 103 1.1-90 kW Operating Instructions
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1
2
3
4
5
6
7
8
9
10
11
12 13
16
17
18
19
14
15
FANMOUNTING
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
Illustration 1.2 Exploded View Frame Sizes B and C
1 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 strain relief / PE ground
6 Cable strain relief/PE ground 16 Brake terminal (-81, +82)
7 USB connector 17 Load sharing terminal (DC bus) (-88, +89)
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)
Table 1.2 Legend to Illustration 1.2
Introduction VLTpRefrigeration Drive FC 103 1.1-90 kW Operating Instructions
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1.1 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and start up of the frequency converter.
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 Test 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.
1.2 Product Overview
A frequency converter 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
frequency converter can vary the speed of the motor in
response to system feedback, such as changing
temperature or pressure for controlling fan, compressor, or
pump motors. The frequency converter can also regulate
the motor by responding to remote commands from
external controllers.
In addition, the frequency converter 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.
1.3 Internal Frequency Converter Controller
Functions
Illustration 1.3 is a block diagram of the frequency
converter's internal components. See Table 1.3 for their
functions.
I
Illustration 1.3 Frequency Converter Block Diagram
Area Title Functions
1 Mains input
•
Three-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 three-phase output
power to the motor
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 1.3 Legend to Illustration 1.3
Introduction VLTpRefrigeration Drive FC 103 1.1-90 kW Operating Instructions
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