Danfoss VLT FC 103 User manual

MAKING MODERN LIVING POSSIBLE
O
Operating Instructions
VLTRefrigeration Drive FC 103, 75-400 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] Power range [kW] Minimum waiting time
[min]
3x400 90-250 20
3x400 110-315 20
3x480 110-315 20
3x480 132-355 20
3x550 55-315 20
3x690 75-400 20
Discharge Time
Approvals
NOTE
Imposed limitations on the output frequency
(due to export control regulations):
From software version 6.72 the output frequency of the
frequency converter is limited to 590 Hz. Software versions
6x.xx also limit the maximum output frequency to 590 Hz,
but these versions cannot be flashed, i.e. neither
downgraded nor upgraded.
Safety VLTpRefrigeration Drive Operating Instructions
MG16J102 - VLTpis a registered Danfoss trademark
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S
Safety VLTpRefrigeration Drive Operating Instructions
MG16J102 - VLTpis a registered Danfoss trademark
inverter.ru [phone]

C
Contents
1 Introduction
4
1.1 Product Overview 4
1.1.1 Interior Views 4
1.2 Purpose of the Manual 5
1.3 Additional Resources 5
1.4 Product Overview 5
1.5 Internal Controller Functions 5
1.6 Frame Sizes and Power Ratings 7
2 Installation
8
2.1 Planning the Installation Site 8
2.1.2 Planning the Installation Site 8
2.2 Pre-Installation Check List 8
2.3 Mechanical Installation 9
2.3.1 Cooling 9
2.3.2 Lifting 9
2.3.3 Wall Mounting - IP21 (NEMA 1) and IP54 (NEMA 12) Units 10
2.4 Electrical Installation 10
2.4.1 General Requirements 10
2.4.2 Earth (Grounding) Requirements 13
2.4.2.1 Leakage Current (>3.5 mA) 13
2.4.2.2 Earthing (Grounding) IP20 Enclosures 14
2.4.2.3 Earthing (Grounding) IP21/54 Enclosures 14
2.4.3 Motor Connection 15
2.4.3.1 Terminal Locations: D1h-D4h 15
2.4.4 Motor Cable 19
2.4.5 Motor Rotation Check 19
2.4.6 AC Mains Connection 19
2.5 Control Wiring Connection 20
2.5.1 Access 20
2.5.2 Using Screened Control Cables 20
2.5.3 Earthing (Grounding) of Screened Control Cables 20
2.5.4 Control Terminal Types 21
2.5.5 Wiring to Control Terminals 22
2.5.6 Control Terminal Functions 22
2.6 Serial Communication 22
2.7 Optional Equipment 23
2.7.1 Load Share Terminals 23
2.7.2 Regeneration Terminals 23
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2.7.3 Anti-condensation Heater 23
2.7.4 Brake Chopper 23
2.7.5 Mains Shield 23
3 Start Up and Functional Testing
24
3.1 Pre-start 24
3.1.1 Safety Inspection 24
3.2 Applying Power 26
3.3 Basic Operational Programming 26
3.3.1 Set-up Wizard 26
3.4 Automatic Motor Adaptation 32
3.5 Check Motor Rotation 32
3.6 Local-control Test 32
3.7 System Start Up 33
4 User Interface
34
4.1 Local Control Panel 34
4.1.1 LCP Layout 34
4.1.2 Setting LCP Display Values 35
4.1.3 Display Menu Keys 35
4.1.4 Navigation Keys 36
4.1.5 Operation Keys 36
4.2 Back Up and Copying Parameter Settings 36
4.2.1 Uploading Data to the LCP 37
4.2.2 Downloading Data from the LCP 37
4.3 Restoring Default Settings 37
4.3.1 Recommended Initialisation 37
4.3.2 Manual Initialisation 37
5 Programming
38
5.1 Introduction 38
5.2 Programming Example 38
5.3 Control Terminal Programming Examples 39
5.4 International/North American Default Parameter Settings 40
5.5 Parameter Menu Structure 41
5.5.1 Main Menu Structure 42
5.6 Remote Programming with MCT 10 Set-up Software 45
6 Application Examples
46
6.1 Introduction 46
6.2 Application Examples 46
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7
7Status Messages
50
7.1 Status Messages 50
7.2 Status Message Definitions 50
8 Warnings and Alarms
53
8.1 System Monitoring 53
8.2 Warning and Alarm Types 53
8.2.1 Warnings 53
8.2.2 Alarm Trip 53
8.2.3 Alarm Trip-lock 53
8.3 Warning and Alarm Displays 53
8.4 Warning and Alarm Definitions 55
8.5 Fault Messages 57
9 Basic Troubleshooting
63
9.1 Start Up and Operation 63
10 Specifications
66
10.1 Power-dependent Specifications 66
10.2 General Technical Data 69
10.3 Fuse Tables 74
10.3.1 Protection 74
10.3.2 Fuse Selection 74
10.3.3 Short Circuit Current Rating (SCCR) 75
10.3.4 Connection Tightening Torques 75
Index
76
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1 Introduction
1.1 Product Overview
1.1.1 Interior Views
130BC252.11
1
15 14
8
9
12
13 (IP 20/Chassis)
13
(IP 21/54
NEMA 1/12)
11
10
16
I
Illustration 1.1 D1 Interior Components
130BC301.10
1
2
3
4
5
6
7
8
9
Illustration 1.2 Close-up View: LCP and Control Functions
1 LCP (Local Control Panel) 9 Relay 2 (04, 05, 06)
2 RS-485 serial bus connector 10 Lifting ring
3 Digital I/O and 24 V power supply 11 Mounting slot
4 Analog I/O connector 12 Cable clamp (PE)
5 USB connector 13 Earth (ground)
6 Serial bus terminal switch 14 Motor output terminals 96 (U), 97 (V), 98 (W)
7 Analog switches (A53), (A54) 15 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
8 Relay 1 (01, 02, 03) 16 TB5 (IP21/54 only). Terminal block for anti-condensation heater
Table 1.1
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1.2 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 Testing 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.
1.3 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
•
•
The VLT
p
Programming Guide provides greater
detail on working with parameters and many
application examples.
•
The VLT
p
Design Guide is intended to provide
detailed capabilities and functionality to design
motor control systems.
•
Supplemental publications and manuals are
available from Danfoss.
See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical
+Documentation.htm for listings.
•
Optional equipment is available that may change
some of the procedures described. Reference the
instructions supplied with those options for
specific requirements. Contact the local Danfoss
supplier or visit the Danfoss website:
www.danfoss.com/BusinessAreas/DrivesSolutions/
Documentations/VLT+Technical+Documen-
tation.htm, for downloads or additional
information.
1.4 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 position sensors on a
conveyor belt. 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.
1.5 Internal Controller Functions
Illustration 1.3 is a block diagram of the frequency
converter's internal components. See Table 1.2 for their
functions.
Illustration 1.3 Frequency Converter Block Diagram
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A
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 1.2 Legend to Illustration 1.3
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