Danfoss VLT HVAC Basic Drive FC 101 User manual

MAKING MODERN LIVING POSSIBLE
QQuick Guide
VLT® HVAC Basic Drive FC 101
www.danfoss.com/drives
*MG18A402*
132R0078 MG18A402 Rev. 2012-03-23

Contents
1 Quick Guide 2
1.1 Safety 2
1.1.1 Warnings 2
1.1.2 Safety Instructions 2
1.2 Introduction 3
1.2.1 Available Literature 3
1.2.2 Approvals 3
1.2.3 IT Mains 3
1.2.4 Avoid Unintended Start 4
1.2.5 Disposal Instruction 4
1.3 Installation 4
1.3.1 Before Starting Repair Work 4
1.3.2 Side-by-Side Installation 4
1.3.3 Dimensions 5
1.3.4 Electrical Installation in General 6
1.3.5 Connecting to Mains and Motor 7
1.3.6 Fuses 13
1.3.7 EMC-Correct Electrical Installation 15
1.3.8 Control Terminals 17
1.3.9 Electrical Overview 18
1.4 Programming 19
1.4.1 Programming with the Local Control Panel (LCP) 19
1.4.3 The Start-up Wizard for Open Loop Applications 20
1.5.1 Main menu structure 30
1.6 Warnings and Alarms 32
1.7 General Specifications 34
1.7.1 Mains Supply 3x200-240 V AC 34
1.7.2 Mains Supply 3x380-480 V AC 35
1.7.3 Mains Supply 3x380-480 V AC 37
1.7.4 Mains Supply 3x525-600 V AC 39
1.8 Special Conditions 43
1.8.1 Derating for Ambient Temperature and Switching Frequency 43
1.8.2 Derating for Low Air Pressure 43
1.9 Options for VLT®HVAC Basic Drive FC 101 43
1.10 MCT 10 Support 43
Contents VLT®HVAC Basic Drive Quick Guide
MG18A402 - VLT®is a registered Danfoss trademark 1

1 Quick Guide
1.1 Safety
1.1.1 Warnings
WARNING
High Voltage Warning
The voltage of the frequency converter is dangerous
whenever it is connected to mains. Incorrect installation of
the motor or frequency converter may cause damage to
the equipment, serious injury or death. Consequently, it is
essential to comply with the instructions in this manual as
well as local and national rules and safety regulations.
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]
3x200 0.25–3.7 4
3x200 5.5–11 15
3x400 0.37–7.5 4
3x400 11–90 15
3x600 2.2–7.5 4
3x600 11–90 15
Table 1.1 Discharge Time
CAUTION
Leakage Current:
The earth leakage current from the frequency converter
exceeds 3.5 mA. According to IEC 61800-5-1 a reinforced
Protective Earth connection must be ensured with a min.
10 mm² Cu or an additional PE wire - with the same cable
cross section as the Mains wiring - must be terminated
separately.
Residual Current Device:
This product can cause a DC current in the protective
conductor. Where a residual current device (RCD) is used
for extra protection, only an RCD of Type B (time delayed)
shall be used on the supply side of this product. See also
Danfoss Application Note on RCD, MN90G.
Protective earthing of the frequency converter and the use
of RCDs must always follow national and local regulations.
Motor thermal protection:
Motor overload protection is possible by setting Parameter
1-90 Motor thermal protection to the value Electronic
Thermal Relay (ETR) trip.
WARNING
Installation at high altitudes
For altitudes above 2 km, contact Danfoss regarding PELV.
1.1.2 Safety Instructions
•Make sure the frequency converter is properly
connected to earth.
•Do not remove mains connections, motor
connections or other power connections while
the frequency converter is connected to power.
•Protect users against supply voltage.
•Protect the motor against overloading according
to national and local regulations.
•The earth leakage current exceeds 3.5 mA.
•The [Off/Reset] key is not a safety switch. It does
not disconnect the frequency converter from
mains.
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1.2 Introduction
1.2.1 Available Literature
This Quick Guide contains the basic information necessary
for installing and running the frequency converter. If more
information is needed, literature can be found on the
enclosed cd or downloaded from:
www.danfoss.com/BusinessAreas/DrivesSolutions/Documen-
tations/Technical+Documentation.htm
1.2.2 Approvals
Table 1.2
IP54 enclosure frequency converter
do not have UL approvals.
Table 1.3
1.2.3 IT Mains
CAUTION
IT Mains
Installation on isolated mains source, that is, IT mains.
Max. supply voltage allowed when connected to mains:
440 V (3x380-480 V units).
On IP20 200-240 V 0.25-11 kW and 380-480 V IP20 0.37-22
kW, open the RFI switch by removing the screw on the
side of the frequency converter when at IT grid.
130BB612.10
1
Illustration 1.1 IP20 200-240 V 0.25-11 kW, IP20 0.37-22 kW
380-480 V.
1 EMC screw
Table 1.4
130BC251.10
Illustration 1.2 IP54 400 V 0.75-18.5 kW
1EMC screw
Table 1.5
On all units, set to [Off] when operating in IT mains.
CAUTION
If reinserted, only use M3x12 screw.
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1.2.4 Avoid Unintended Start
While the frequency converter is connected to mains, the
motor can be started/stopped using digital commands, bus
commands, references or via the LCP.
•Disconnect the frequency converter from mains
whenever personal safety considerations make it
necessary to avoid unintended start of any
motors.
•To avoid unintended start, always press [Off/
Reset] before changing parameters.
1.2.5 Disposal Instruction
Equipment containing electrical components
must not be disposed of together with domestic
waste.
It must be separately collected with electrical
and electronic waste according to local and
currently valid legislation.
Table 1.6
1.3 Installation
1.3.1 Before Starting Repair Work
1. Disconnect FC 101 from mains (and external DC
supply, if present).
2. Wait as stated in Table 1.1 for discharge of the
DC-link.
3. Remove motor cable.
1.3.2 Side-by-Side Installation
The frequency converter can be mounted side-by-side and
requires the clearance above and below for cooling.
Power [kW] Clearance above/below [mm/inch]
Frame IP class 3x200-240 V 3x380-480 V 3x525-600 V
H1 IP20 0.25-1.5 0.37-1.5 100/4
H2 IP20 2.2 2.2-4 100/4
H3 IP20 3.7 5.5-7.5 100/4
H4 IP20 5.5-7.5 11-15 100/4
H5 IP20 11 18.5-22 100/4
H6 IP20 15-18.5 30-45 18.5-30 200/7.9
H7 IP20 22-30 55-75 37-55 200/7.9
H8 IP20 37-45 90 75-90 225/8.9
H9 IP20 2.2-7.5 100/4
H10 IP20 11-15 200/7.9
Table 1.7
NOTE
With IP21/Nema Type1 option kit mounted, a distance of
50 mm between the units is required.
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1.3.3 Dimensions
A
a
b
B
C
D
130BB614.10
e
f
a
d
e
130BC205.10
e
f
a
e
130BC246.10
Table 1.8
Enclosure Power [kW] Height [mm] Width [mm] Depth
[mm]
Mounting hole
[mm]
Max.
Weig
ht
Frame IP Class 3x200-240 V 3x380-480 V 3x525-600 V A "A incl De-
coupling
Plate"
a B b C d e f kg
H1 IP20 0.25-1.5 0.37-1.5 195 273 183 75 56 168 9 4.5 5.3 2.1
H2 IP20 2.2 2.2-4.0 227 303 212 90 65 190 11 5.5 7.4 3.4
H3 IP20 3.7 5.5-7.5 255 329 240 100 74 206 11 5.5 8.1 4.5
H4 IP20 5.5-7.5 11-15 296 359 275 135 105 241 12.6 7 8.4 7.9
H5 IP20 11 18.5-22 334 402 314 150 120 255 12.6 7 8.5 9.5
H6 IP20 15-18.5 30-45 18.5-30 518 595/635
(45 kW)
495 239 200 242 - 8.5 15 24.5
H7 IP20 22-30 55-75 37-55 550 630/690
(75 kW)
521 313 270 335 - 8.5 17 36
H8 IP20 37-45 90 75-90 660 800 631 375 330 335 - 8.5 17 51
H9 IP20 2.2-7.5 269 374 257 130 110 205 11 5.5 9 6.6
H10 IP20 11-15 399 419 380 165 140 248 12 6.8 7.5 12
I2 IP54 0.75-4.0 332 - 318.5 115 74 225 11 5.5 9 5.3
I3 IP54 5.5-7.5 368 - 354 135 89 237 12 6.5 9.5 7.2
I4 IP54 11-18.5 476 - 460 180 133 290 12 6.5 9.5 13.8
I5 IP54 11-18.5 480 - 454 242 210 260 19 9 9 23
I6 IP54 22-37 650 - 624 242 210 260 19 9 9 27
I7 IP54 45-55 680 - 648 308 272 310 19 9 9.8 45
I8 IP54 75-90 770 - 739 370 334 335 19 9 9.8 65
Table 1.9
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The dimensions are only for the physical units, but when
installing in an application it is necessary to add space for
free air passage both above and below the units. The
amount of space for free air passage is listed in Table 1.10:
Enclosure Clearance needed for free air passage [mm]
Frame IP class Above unit Below unit
H1 20 100 100
H2 20 100 100
H3 20 100 100
H4 20 100 100
H5 20 100 100
H6 20 200 200
H7 20 200 200
H8 20 225 225
H9 20 100 100
H10 20 200 200
I2 54 100 100
I3 54 100 100
I4 54 100 100
I5 54 200 200
I6 54 200 200
I7 54 200 200
I8 54 225 225
Table 1.10 Clearance Needed for Free Air Passage [mm]
1.3.4 Electrical Installation in General
All cabling must comply with national and local
regulations on cable cross-sections and ambient
temperature. Copper conductors required, (75 °C)
recommended.
Power [kW] Torque [Nm]
Frame IP class 3x200-240 V 3x380-480 V Line Motor DC
connection
Control
terminals
Earth Relay
H1 IP20 0.25-1.5 0.37-1.5 1.4 0.8 0.8 0.5 0.8 0.5
H2 IP20 2.2 2.2-4 1.4 0.8 0.8 0.5 0.8 0.5
H3 IP20 3.7 5.5-7.5 1.4 0.8 0.8 0.5 0.8 0.5
H4 IP20 5.5-7.5 11-15 1.2 1.2 1.2 0.5 0.8 0.5
H5 IP20 11 18.5-22 1.2 1.2 1.2 0.5 0.8 0.5
H6 IP20 15-18 30-45 4.5 4.5 - 0.5 3 0.5
H7 IP20 22-30 55 10 10 - 0.5 3 0.5
H7 IP20 - 75 14 14 - 0.5 3 0.5
H8 IP20 37-45 90 242242- 0.5 3 0.5
Table 1.11
Power [kW] Torque [Nm]
Frame IP class 3x380-480 V Line Motor DC connection Control
terminals
Earth Relay
I2 IP54 0.75-4.0 1.4 0.8 0.8 0.5 0.8 0.5
I3 IP54 5.5-7.5 1.4 0.8 0.8 0.5 0.8 0.5
I4 IP54 11-18.5 1.4 0.8 0.8 0.5 0.8 0.5
I5 IP54 11-18.5 1.8 1.8 - 0.5 3 0.6
I6 IP54 22-37 4.5 4.5 - 0.5 3 0.6
I7 IP54 45-55 10 10 - 0.5 3 0.6
I8 IP54 75-90 14/24114/241- 0.5 3 0.6
Table 1.12
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Power [kW] Torque [Nm]
Frame IP class 3x525-600 V Line Motor DC connection Control
terminals
Earth Relay
H9 IP20 2.2-7.5 1.8 1.8 not
recommended
0.5 3 0.6
H10 IP20 11-15 1.8 1.8 not
recommended
0.5 3 0.6
H6 IP20 18.5-30 4.5 4.5 - 0.5 3 0.5
H7 IP20 37-55 10 10 - 0.5 3 0.5
H8 IP20 75-90 14/24114/241- 0.5 3 0.5
Table 1.13 Details of Tightening Torques
1Cable dimensions
≤ 95 mm2
2Cable dimensions >95 mm2
1.3.5 Connecting to Mains and Motor
The frequency converter is designed to operate all
standard three-phased asynchronous motors. For
maximum cross-section on wires see 1.6 General Specifi-
cations.
•Use a shielded/armored motor cable to comply
with EMC emission specifications, and connect
this cable to both the decoupling plate and the
motor metal.
•Keep motor cable as short as possible to reduce
the noise level and leakage currents.
•For further details on mounting of the
decoupling plate, see FC 101 De-coupling Plate
Mounting Instruction MI02Q.
•Also see EMC-Correct Installation in the VLT
®
HVAC
Basic Design Guide, MG18C.
1. Mount the earth wires to earth terminal.
2. Connect motor to terminals U, V and W.
3. Mount mains supply to terminals L1, L2 and L3
and tighten.
130BB634.10
1
2
2
3
4
Motor
UVW-DC+DC
MAINS
Illustration 1.3 H1-H5 Frame
IP20 200-240 V 0.25-11 kW and IP20 380-480 V 0.37-22 kW.
1Line
2 Earth
3 Motor
4 Relays
Table 1.14
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1
95
99
L1 91 / L2 92 / L3 93
U 96 / V 97 / W 98
03 02 01
06 05 04
234
130BB762.10
Illustration 1.4 H6 Frame
IP20 380-480 V 30-45 kW
IP20 200-240 V 15-18.5 kW
IP20 525-600 V 22-30 kW
1 Line
2 Motor
3 Earth
4 Relays
Table 1.15
12
3
4
130BB763.10
Illustration 1.5 H7 Frame
IP20 380-480 V 55-75 kW
IP20 200-240 V 22- 30 kW
IP20 525-600 V 45-55 kW
1Line
2 Relays
3 Earth
4 Motor
Table 1.16
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130BB764.10
1
2
3
4
98
97
96
99
95
93
92
91
L1 L1 L1 UVw
Illustration 1.6 H8 Frame
IP20 380-480 V 90 kW
IP20 200-240 V 37-45 kW
IP20 525-600 V 75-90 kW
1 Line
2 Relays
3 Earth
4 Motor
Table 1.17
MOTOR
MOTOR
U V W
99
130BT302.12
Illustration 1.7 H9 Frame
IP20 600 V 2.2-7.5 kW
-DC+DC
BR- BR+ U V W
99
M A I N S
95
RELAY 1 RELAY 2
- LC +
130BA261.10
Illustration 1.8
130BA262.10
M
I N S
+DC
BR- BR+ UVW
RELAY 1 RELAY 2
95
Illustration 1.9
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