Danfoss VLT FC 103 User manual

Operating Guide
VLT® Refrigeration Drive FC 103
355-800 kW, Enclosure Sizes E1h-E4h

Contents
1 Introduction 7
1.1 Purpose of this Operating Guide 7
1.2 Manual and Software Version 7
1.3 Trademarks 7
1.4 Approvals and Certifications 7
1.5 Disposal 8
2 Safety 9
2.1 Safety Symbols 9
2.2 Qualified Personnel 9
2.3 Safety Precautions 9
3 Product Overview 12
3.1 Power Ratings, Weights, and Dimensions for E1h–E4h Enclosures 12
3.2 Interior View of Enclosure E1h/E2h 13
3.3 Interior View of Enclosure E3h/E4h 15
3.4 Control Shelf 16
3.5 Local Control Panel (LCP) 17
3.6 LCP Menu 19
4 Mechanical Installation 22
4.1 Tools Needed 22
4.2 Storing the Drive 22
4.3 Operating Environment 22
4.3.1 Overview 22
4.3.2 Gases 23
4.3.3 Dust 23
4.3.4 Potentially Explosive Atmospheres 23
4.4 Installation Requirements 24
4.5 Cooling Requirements 24
4.6 E1h-E4h Airflow Rates 25
4.7 Lifting the Drive 25
4.8 E1h/E2h Mechanical Installation 26
4.8.1 Securing the Pedestal to the Floor 26
4.8.2 Attaching an E1h/E2h to the Pedestal 27
4.8.3 Creating Cable Openings for an E1h/E2h 29
4.9 E3h/E4h Mechanical Installation 29
4.9.1 Attaching the E3h/E4h to a Mounting Plate or Wall 30
4.9.2 Creating Cable Openings for an E3h/E4h 30
4.9.3 Installing Load share/Regen Terminals to an E3h/E4h 33
ContentsOperating Guide | VLT® Refrigeration Drive FC 103
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5 Electrical Installation 34
5.1 Safety Instructions 34
5.2 EMC-compliant Installation 35
5.3 Wiring Schematic 39
5.4 Connecting the Motor 40
5.5 Connecting the AC Mains 41
5.6 Connecting to Ground 44
5.7 E1h Terminal Dimensions 46
5.8 E2h Terminal Dimensions 48
5.9 E3h Terminal Dimensions 50
5.10 E4h Terminal Dimensions 53
5.11 Control Wiring 55
5.11.1 Control Cable Access 55
5.11.2 Routing Control Cables 56
5.11.3 Control Terminal Types 57
5.11.4 Relay Terminals 58
5.11.5 Connecting the Control Cable to the Control Terminals 59
5.11.6 Disconnecting the Control Cable from the Control Terminals 60
5.11.7 Enabling Motor Operation 60
5.11.8 Configuring RS485 Serial Communication 61
5.11.9 Safe Torque Off (STO) Wiring 62
5.11.10 Space Heater Wiring 62
5.11.11 Auxiliary Contact Wiring for Disconnects 62
5.11.12 Wiring the Brake Resistor Temperature Switch 63
5.11.13 Selecting the Voltage/Current Input Signal 63
6 Starting the Drive 65
6.1 Pre-start Check List 65
6.2 Applying Power to the Drive 66
6.3 Programming the Drive 67
6.3.1 Parameter Overview 67
6.3.2 Parameter Navigation 67
6.3.3 Entering System Information 67
6.3.4 Configuring Automatic Energy Optimization 68
6.3.5 Configuring Automatic Motor Adaptation 69
6.4 Testing Before System Start Up 69
6.4.1 Testing Motor Rotation 69
6.4.2 Testing Encoder Rotation 70
6.5 Starting Up the Drive for the First Time 70
6.6 Parameter Settings 71
6.6.1 Parameter Setting Overview 71
6.6.2 Uploading and Downloading Parameter Settings 71
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6.6.3 Restoring Factory Default Settings Using the Recommended Initialization 72
6.6.4 Restoring Factory Default Settings Using Manual Initialization 72
7 Wiring Configuration Examples 73
7.1 Application Examples 73
7.1.1 Wiring Configuration for Automatic Motor Adaptation (AMA) 73
7.1.2 Wiring Configuration for Automatic Motor Adaptation without T27 74
7.1.3 Wiring Configuration: Speed 74
7.1.4 Wiring Configuration: Feedback 77
7.1.5 Wiring Configuration: Run/Stop 80
7.1.6 Wiring Configuration: Start/Stop 83
7.1.7 Wiring Configuration: External Alarm Reset 86
7.1.8 Wiring Configuration: RS485 87
7.1.9 Wiring Configuration: Motor Thermistor 87
7.1.10 Wiring for Regen 89
7.1.11 Wiring Configuration for a Relay Setup with Smart Logic Control 90
7.1.12 Wiring Configuration: Compressor 90
7.1.13 Wiring Configuration for Single or Multiple Refrigeration Fans/Pumps 91
7.1.14 Wiring Configuration for a Compressor Pack 93
8 Maintenance, Diagnostics, and Troubleshooting 94
8.1 Maintenance and Service 94
8.2 Heat Sink Service 94
8.2.1 Heat Sink Access Panel 94
8.2.2 Removing Dust Buildup from the Heat Sink 94
8.3 Status Messages 95
8.3.1 Status Message Overview 95
8.3.2 Status Messages - Operating Mode 96
8.3.3 Status Messages - Reference Site 96
8.3.4 Status Messages - Operation Status 97
8.4 Warnings and Alarms 99
8.5 Troubleshooting 124
9 Specifications 127
9.1 Electrical Data 127
9.1.1 Electrical Data, 380–480 V AC 127
9.1.2 Electrical Data, 525–690 V AC 129
9.2 Mains Supply 132
9.3 Motor Output and Torque Characteristics 132
9.3.1 Motor Output (U, V, W) 132
9.3.2 Torque Characteristics 132
9.4 Ambient Conditions 133
9.5 Cable Specifications 133
ContentsOperating Guide | VLT® Refrigeration Drive FC 103
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9.6 Control Input/Output and Control Data 134
9.6.1 Digital Inputs 134
9.6.2 STO Terminal 37 134
9.6.3 Analog Inputs 134
9.6.4 Pulse/encoder Inputs 135
9.6.5 Analog Output 136
9.6.6 Control Card, RS485 Serial Communication 136
9.6.7 Digital Outputs 136
9.6.8 Control Card, 24 V DC Output 136
9.6.9 Relay Outputs 137
9.6.10 Control Card, +10 V DC Output 137
9.6.11 Control Characteristics 138
9.6.12 Control Card Performance 138
9.6.13 Control Card, USB Serial Communication 138
9.7 Fuses 138
9.8 Enclosure Dimensions 140
9.8.1 E1h Exterior Dimensions 140
9.8.2 E2h Exterior Dimensions 144
9.8.3 E3h Exterior Dimensions 148
9.8.4 E4h Exterior Dimensions 152
9.9 Enclosure Airflow 156
9.10 Fastener Torque Ratings 156
10 Appendix 158
10.1 Conventions 158
10.2 Abbreviations 158
10.3 International/North American Default Parameter Settings 160
ContentsOperating Guide | VLT® Refrigeration Drive FC 103
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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 qualified
personnel. Read and follow the instructions to use the drive safely and professionally. Pay particular attention to the safety instructions
and general warnings. Always keep this operating guide available with the drive.
1.2 Manual and Software Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
Table 1: Manual and Software Version
Manual version Remarks Software ver‐
sion
AQ275652766279xx-xx01-01 Updated power losses in Electrical Data table. Created Starting the Drive chapter
by combining Commissioning and Pre-start Check List chapters.
2.42
MG16P2xx Previous version. 1.51
1.3 Trademarks
VLT® is a registered trademark for Danfoss A/S.
1.4 Approvals and Certifications
e30bu682.10
Illustration 1: Approvals and Certifications
More approvals and certifications are available. Contact the local Danfoss office or partner. Drives of voltage T7 (525–690 V) are UL
certified for only 525–600 V.
Thermal memory retention requirement
The drive complies with UL 61800-5-1 thermal memory retention requirements. For more information, refer to the Motor Thermal
Protection section in the product-specific design guide.
NOTICE
OUTPUT FREQUENCY LIMIT
From software version 1.10 onwards, the output frequency of the drive is limited to 590 Hz due to export control regulations.
Introduction
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ADN-compliance
For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to the ADN-compliant Installation section in the product-specific 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.
Introduction
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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 Qualified Personnel
To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store,
assemble, install, program, commission, maintain, and decommission this equipment.
Persons with proven skills:
• Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably
experienced 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 specific application.
2.3 Safety Precautions
The following safety precautions must be followed when performing installation, start up, and maintenance/service of the drive.
WARNING
HIGH VOLTAGE
AC drives contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation,
start-up, and maintenance by qualified personnel can result in death or serious injury.
-Only qualified personnel must perform installation, start-up, and maintenance.
Safety
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CAUTION
HOT SURFACES
The drive contains metal components that are still hot even after the drive has been powered off. 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 off.
-Do not touch exterior areas that are marked by the high temperature symbol (yellow triangle). These areas are hot while the
drive is in use and immediately after being powered off.
WARNING
DISCHARGE TIME (40 MINUTES)
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 indicator lights are off.
Failure to wait 40 minutes after power has been removed before performing service or repair work can result in death or
serious injury.
-Stop the motor.
-Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and
DC-link connections to other drives.
-Wait 40 minutes for the capacitors to discharge fully before performing any service or repair work.
-Measure the voltage level to verify full discharge.
WARNING
UNINTENDED START
When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death,
serious injury, and equipment or property damage. The motor may start by activation of an external switch, a fieldbus
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.
-Press [Off] on the LCP before programming parameters.
-Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended
motor start.
-Check that the drive, motor, and any driven equipment are in operational readiness.
WARNING
ROTATING SHAFTS
Contact with rotating shafts and electrical equipment can result in death or serious injury.
-Ensure that only trained and qualified personnel perform installation, start-up, and maintenance.
-Ensure that electrical work conforms to national and local electrical codes.
-Follow the procedures in this guide.
Safety
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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 certified electrical installer.
CAUTION
INTERNAL FAILURE HAZARD
An internal failure in the drive can result in serious injury when the drive is not properly closed.
-Ensure that all safety covers are in place and securely fastened before applying power.
NOTICE
MAINS SHIELD SAFETY OPTION
A mains shield option is available for enclosures with a protection rating of IP21/IP 54 (Type 1/Type 12). The mains shield is a
Lexan cover installed inside the enclosure to protect against the accidental touch of the power terminals, according to BGV A2,
VBG 4.
Safety
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3 Product Overview
3.1 Power Ratings, Weights, and Dimensions for E1h–E4h Enclosures
Table 2: Power Ratings, Weights, and Dimensions for E1h–E4h Enclosures (Standard Configurations)
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)]
450–6300 (450–650) 710–800 (750–950) 450–630 (450–650) 710–800 (750–950)
Enclosure protection rating (1) 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)] – – – –
1Type 1 and Type 12 are UL designations.
Product Overview
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3.2 Interior View of Enclosure E1h/E2h
e30bf206.11
FASTENER TORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
- REGEN 83
FASTENER TORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
+ REGEN 82
2
6
4
511
12
9
1
7
10
8
3
1Control shelf (see illustration 4)
3RFI filter (optional)
5Mains terminals
7Fan power card
2Local control panel (LCP) cradle
4Mains fuses (required for UL Compliance, but otherwise
optional)
6RFI shield termination
Product Overview
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9Mains disconnect (optional)
11 Motor terminals
8Space heater (optional)
10 Brake/regeneration terminals (optional)
12 Ground terminals
Illustration 2: Interior View of Enclosure E1h (Enclosure E2h is Similar)
Product Overview
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3.3 Interior View of Enclosure E3h/E4h
FASTENER TORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
+ DC 89
FASTENER TORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
- BRAKE 83
FASTENER TORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
+ BRAKE 82
FASTENER TORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
- DC 88
e30bf211.11
1
6
2
5
9
12
13
11
7
8
3
10
4
1Load share/regeneration terminals (optional)
3Local control panel (LCP) cradle
5Mains fuses (optional)
7Ground terminals
2Control shelf (see illustration 4)
4RFI filter (optional)
6Mains terminals
Product Overview
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9Fans (used to cool the front section of enclosure)
11 Space heater (optional)
13 Motor terminals
8RFI shield termination (optional, but is standard when RFI
filter is ordered)
10 Fan power card
12 Brake terminals (optional)
Illustration 3: Interior View of Enclosure E3h (Enclosure E4h is Similar)
3.4 Control Shelf
e30bf148.11
Remove Jumper to activate Safe Stop
12 13 18 19 27 29 32 33 20 37
39 42 50 53 54 55
61 68 69
1
3
4
12
9
8
RELAY 1 RELAY 2
0102
03
040506
2
6
10
7
5
11
13
1LCP cradle (LCP not shown)
3Serial communication terminals (see table 10)
2Bus terminal switch (see 5.11.8.2 Configuring RS485 Serial
Communication)
4Digital input/output terminals (see table 11)
Product Overview
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5Cable/EMC clamps
7Control card (underneath LCP and control terminals)
9USB port
11 Analog input/output terminals (see table 12)
13 Power card (underneath the control shelf )
6Relay 1 and relay 2 (see 5.11.4 Relay Terminals)
8Control shelf
10 Analog input switches A53/A54 (see 5.11.13 Selecting the
Voltage/Current Input Signal)
12 Brake resistor terminals, 104–106 (on power card
underneath control shelf )
Illustration 4: View of Control Shelf
3.5 Local Control Panel (LCP)
e30bf155.10
Auto
On Reset
Hand
On Off
Status
Quick
Menu
Main
Menu
Alarm
Log
Back
Cancel
Info
OK
Status
1(1)
0.00 kW
Off Remote Stop
0.0 Hz
On
Alarm
Warn.
0.00 A
0 RPM
0.0 %
A1.1
A1.2
A1.3
A2
A3
B1
B2
B4
B3
C1
C2
C3
C4
C5
D1
D2
D3
E1
E2
E3
E4
Illustration 5: Graphical Local Control Panel (LCP)
The local control panel (LCP) is the combined display and keypad on the front of the drive. The LCP is used to:
• Control the drive and motor.
• Access drive parameters and program the drive.
• Display operational data, drive status, and warnings.
A numeric local control panel (NLCP) is available as an option. The NLCP operates in a manner similar to the LCP, but there are
differences. For details on how to use the NLCP, see the product-specific programming guide.
Product Overview
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A. Display area
Each display readout has a parameter associated with it. See table 3. The information shown on the LCP can be customized for specific
applications. Refer to My Personal Menu in the LCP Menu section.
Table 3: LCP Display Area
Callout Parameter Default setting
A1.1 Parameter 0-20 Display Line 1.1 Small ReferenceSpeed [%]
A1.2 Parameter 0-21 Display Line 1.2 Small Motor current [A]
A1.3 Parameter 0-22 Display Line 1.3 Small Power [kW]
A2 Parameter 0-23 Display Line 2 Large Frequency [Hz]
A3 Parameter 0-24 Display Line 3 Large kWh counter
B. Menu keys
Menu keys are used to access the menu for setting up parameters, toggling through status display modes during normal operation,
and viewing fault log data.
Table 4: LCP Menu Keys
Callout Key Function
B1 Status Shows operational information.
B2 Quick Menu Allows access to parameters for initial set-up instructions. Also provides detailed application steps. Refer
to Quick Menu mode in the LCP Menu section.
B3 Main Menu Allows access to all parameters. Refer to Main Menu mode in the LCP Menu section.
B4 Alarm Log Shows a list of current warnings and the last 10 alarms.
C. Navigation keys
Navigation keys are used for programming functions and moving the display cursor. The navigation keys also provide speed control in
local (hand) operation. The display brightness can be adjusted by pressing [Status] and [▵]/[▿] keys.
Table 5: LCP Navigation Keys
Callout Key Function
C1 Back Reverts to the previous step or list in the menu structure.
C2 Cancel Cancels the last change or command as long as the display mode has not changed.
C3 Info Shows a definition of the function being shown.
C4 OK Accesses parameter groups or enables an option.
C5 [▵][▹] [▿] [◃] Moves between items in the menu.
D. Indicator lights
Indicator lights identify the drive status and provide a visual notification of warning or fault conditions.
Product Overview
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