Danfoss VLT HVAC Drive FC 102 Guide

MAKING MODERN LIVING POSSIBLE
Design Guide
VLT®HVAC Drive FC 102
1.1–90 kW
www.danfoss.com/drives

Contents
1 How to Read this Design Guide 7
2 Introduction to VLT®HVAC Drive 12
2.1 Safety 12
2.2 CE Labeling 13
2.3 Air humidity 14
2.4 Aggressive Environments 14
2.5 Vibration and Shock 15
2.6 Safe Torque Off 15
2.7 Advantages 22
2.8 Control Structures 36
2.9 General Aspects of EMC 46
2.10 Galvanic Isolation (PELV) 51
2.11 Ground Leakage Current 52
2.12 Brake Function 53
2.13 Extreme Running Conditions 55
3 Selection 58
3.1 Options and Accessories 58
3.1.1 Mounting Option Modules in Slot B 58
3.1.2 General Purpose I/O Module MCB 101 59
3.1.3 Digital Inputs - Terminal X30/1-4 60
3.1.4 Analog Voltage Inputs - Terminal X30/10-12 60
3.1.5 Digital Outputs - Terminal X30/5-7 60
3.1.6 Analog Outputs - Terminal X30/5+8 60
3.1.7 Relay Option MCB 105 61
3.1.8 24 V Backup Option MCB 107 (Option D) 63
3.1.9 Analog I/O option MCB 109 64
3.1.10 PTC Thermistor Card MCB 112 66
3.1.11 Sensor Input Option MCB 114 67
3.1.11.1 Ordering Code Numbers and Parts Delivered 68
3.1.11.2 Electrical and Mechanical Specifications 68
3.1.11.3 Electrical Wiring 69
3.1.12 Remote Mounting Kit for LCP 69
3.1.13 IP21/IP41/ TYPE1 Enclosure Kit 70
3.1.14 IP21/Type 1 Enclosure Kit 70
3.1.15 Output Filters 72
Contents Design Guide
MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.

4 How to Order 73
4.1 Ordering Form 73
4.2 Ordering Numbers 75
5 Mechanical Installation 85
5.1 Mechanical Installation 85
5.1.1 Safety Requirements of Mechanical Installation 85
5.1.2 Mechanical Dimensions 86
5.1.3 Accessory Bags 89
5.1.4 Mechanical Mounting 90
5.1.5 Field Mounting 91
6 Electrical Installation 92
6.1 Connections - Enclosure Types A, B
and C 92
6.1.1 Torque 92
6.1.2 Removal of Knockouts for Extra Cables 94
6.1.3 Connection to Line and Grounding 94
6.1.4 Motor Connection 97
6.1.5 Relay Connection 104
6.2 Fuses and Circuit Breakers 105
6.2.1 Fuses 105
6.2.2 Recommendations 105
6.2.3 CE Compliance 105
6.2.4 Fuse Tables 106
6.3 Disconnectors and Contactors 114
6.4 Additional Motor Information 115
6.4.1 Motor Cable 115
6.4.2 Motor Thermal Protection 115
6.4.3 Parallel Connection of Motors 116
6.4.4 Direction of Motor Rotation 118
6.4.5 Motor Insulation 119
6.4.6 Motor Bearing Currents 119
6.5 Control Cables and Terminals 120
6.5.1 Access to Control Terminals 120
6.5.2 Control Cable Routing 120
6.5.3 Control Terminals 121
6.5.4 Switches S201, S202, and S801 122
6.5.5 Electrical Installation, Control Terminals 122
Contents Design Guide
Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22

6.5.6 Basic Wiring Example 123
6.5.7 Electrical Installation, Control Cables 124
6.5.8 Relay Output 125
6.6 Additional Connections 126
6.6.1 DC Bus Connection 126
6.6.2 Load Sharing 126
6.6.3 Installation of Brake Cable 126
6.6.4 How to Connect a PC to the Adjustable Frequency Drive 126
6.6.5 PC Software 127
6.6.6 MCT 31 127
6.7 Safety 127
6.7.1 High Voltage Test 127
6.7.2 Grounding 127
6.7.3 Safety Ground Connection 128
6.7.4 ADN-compliant Installation 128
6.8 EMC-compatible Installation 129
6.8.1 Electrical Installation - EMC Precautions 129
6.8.2 Use of EMC-Compatible Cables 131
6.8.3 Grounding of Shielded Control Cables 132
6.8.4 RFI Switch 133
6.9 Residual Current Device 133
6.10 Final Set-up and Test 133
7 Application Examples 135
7.1 Application Examples 135
7.1.1 Start/Stop 135
7.1.2 Pulse Start/Stop 135
7.1.3 Potentiometer Reference 136
7.1.4 Automatic Motor Adaptation (AMA) 136
7.1.5 Smart Logic Control 136
7.1.6 Smart Logic Control Programming 137
7.1.7 SLC Application Example 138
7.1.8 Cascade Controller 140
7.1.9 Pump Staging with Lead Pump Alternation 141
7.1.10 System Status and Operation 141
7.1.11 Fixed Variable-speed Pump Wiring Diagram 141
7.1.12 Lead Pump Alternation Wiring Diagram 142
7.1.13 Cascade Controller Wiring Diagram 143
7.1.14 Start/Stop Conditions 144
Contents Design Guide
MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.

8 Installation and Set-up 145
8.1 Installation and Set-up 145
8.2 Adjustable Frequency Protocol Overview 147
8.3 Network Configuration 148
8.4 FC Protocol Message Framing Structure 148
8.4.1 Content of a Character (byte) 148
8.4.2 Message Structure 148
8.4.3 Message Length (LGE) 148
8.4.4 Adjustable Frequency Drive Address (ADR) 149
8.4.5 Data Control Byte (BCC) 149
8.4.6 The Data Field 150
8.4.7 The PKE Field 151
8.4.8 Parameter Number (PNU) 151
8.4.9 Index (IND) 151
8.4.10 Parameter Value (PWE) 152
8.4.11 Data Types Supported by the Adjustable Frequency Drive 152
8.4.12 Conversion 152
8.4.13 Process Words (PCD) 153
8.5 Examples 153
8.5.1 Writing a Parameter Value 153
8.5.2 Reading a Parameter Value 153
8.6 Modbus RTU Overview 154
8.6.1 Assumptions 154
8.6.2 What the User Should Already Know 154
8.6.3 Modbus RTU Overview 154
8.6.4 Adjustable Frequency Drive with Modbus RTU 154
8.7 Network Configuration 155
8.8 Modbus RTU Message Framing Structure 155
8.8.1 Adjustable Frequency Drive with Modbus RTU 155
8.8.2 Modbus RTU Message Structure 155
8.8.3 Start/Stop Field 155
8.8.4 Address Field 156
8.8.5 Function Field 156
8.8.6 Data Field 156
8.8.7 CRC Check Field 156
8.8.8 Coil Register Addressing 156
8.8.9 How to Control the Adjustable Frequency Drive 158
Contents Design Guide
Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22

8.8.10 Function Codes Supported by Modbus RTU 158
8.8.11 Modbus Exception Codes 158
8.9 How to Access Parameters 159
8.9.1 Parameter Handling 159
8.9.2 Storage of Data 159
8.9.3 IND 159
8.9.4 Text Blocks 159
8.9.5 Conversion Factor 159
8.9.6 Parameter Values 159
8.10 Examples 159
8.10.1 Read Coil Status (01 HEX) 159
8.10.2 Force/Write Single Coil (05 HEX) 160
8.10.3 Force/Write Multiple Coils (0F HEX) 161
8.10.4 Read Holding Registers (03 HEX) 161
8.10.5 Preset Single Register (06 HEX) 162
8.10.6 Preset Multiple Registers (10 HEX) 162
8.11 Danfoss FC Control Profile 163
8.11.1 Control Word According to FC Profile (8-10 Control Profile = FC profile) 163
8.11.2 Status Word According to FC Profile (STW) (8-10 Control Profile = FC pro-
file) 164
8.11.3 Bus Speed Reference Value 165
9 General Specifications and Troubleshooting 166
9.1 Line Power Supply Tables 166
9.2 General Specifications 176
9.3 Efficiency 181
9.4 Acoustic noise 182
9.5 Peak voltage on motor 182
9.6 Special Conditions 186
9.6.1 Purpose of Derating 186
9.6.2 Derating for Ambient Temperature 186
9.6.3 Derating for Ambient Temperature, Enclosure Type A 186
9.6.4 Derating for Ambient Temperature, Enclosure Type B 187
9.6.5 Derating for Ambient Temperature, Enclosure Type C 189
9.6.6 Automatic Adaptations to Ensure Performance 190
9.6.7 Derating for Low Air Pressure 191
9.6.8 Derating for Running at Low Speed 191
9.7 Troubleshooting 192
9.7.1 Alarm Words 196
Contents Design Guide
MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.

9.7.2 Warning Words 197
9.7.3 Extended Status Words 198
Index 206
Contents Design Guide
Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22

1 How to Read this Design Guide
VLT®HVAC Drive
FC 102 Series
This guide can be used with all
VLT®HVAC Drive adjustable
frequency drives with software
version 3.9x.
The actual software version
number can be read from
15-43 Software Version.
Table 1.1 Software Version
This publication contains information proprietary to
Danfoss. By accepting and using this manual, the user
agrees that the information contained herein will be used
solely for operating equipment from Danfoss or equipment
from other vendors provided that such equipment is
intended for communication with Danfoss equipment over
a serial communication link. This publication is protected
under the copyright laws of Denmark and most other
countries.
Danfoss does not warrant that a software program
produced according to the guidelines provided in this
manual will function properly in every physical, hardware
or software environment.
Although Danfoss has tested and reviewed the documen-
tation within this manual, Danfoss makes no warranty or
representation, neither expressed nor implied, with respect
to this documentation, including its quality, performance,
or fitness for a particular purpose.
In no event shall Danfoss be liable for direct, indirect,
special, incidental, or consequential damages arising out of
the use, or the inability to use information contained in
this manual, even if advised of the possibility of such
damages. In particular, Danfoss is not responsible for any
costs, including but not limited to those incurred as a
result of lost profits or revenue, loss or damage of
equipment, loss of computer programs, loss of data, the
costs to substitute these, or any claims by third parties.
Danfoss reserves the right to revise this publication at any
time and to make changes to its contents without prior
notice or any obligation to notify former or present users
of such revisions or changes.
•Design Guide contains all the technical
information about the adjustable frequency drive
and customer design and applications.
•The Programming Guide provides information on
how to program and includes complete
parameter descriptions.
•Application Note, Temperature Derating Guide.
•MCT 10 Set-up Software Instruction Manual enables
the user to configure the adjustable frequency
drive from a Windows™-based PC environment.
•Danfoss VLT®Energy Box software at
www.danfoss.com/BusinessAreas/DrivesSolutions
then choose PC Software Download.
•VLT
®
HVAC Drive BACnet, Instruction Manual.
•VLT
®
HVAC Drive Metasys, Instruction Manual.
•VLT
®
HVAC Drive FLN, Instruction Manual.
Danfoss technical literature is available in print from local
Danfoss Sales Offices or online at:
www.danfoss.com/BusinessAreas/DrivesSolutions/Documen-
tations/Technical+Documentation.htm
How to Read this Design Gui... Design Guide
MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved. 7
11

Table 1.2
The adjustable frequency drive complies with UL508C
thermal memory retention requirements. For more
information, refer to chapter 6.4.2 Motor Thermal Protection.
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.
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit ILIM
Degrees Celsius °C
Direct current DC
Drive Dependent D-TYPE
Electro Magnetic Compatibility EMC
Electronic Thermal Relay ETR
Adjustable frequency drive FC
Gram g
Hertz Hz
Horsepower hp
Kilohertz kHz
Local Control Panel LCP
Meter m
Millihenry Inductance mH
Milliampere mA
Millisecond ms
Minute min
Motion Control Tool MCT
Nanofarad nF
Newton Meters Nm
Nominal motor current IM,N
Nominal motor frequency fM,N
Nominal motor power PM,N
Nominal motor voltage UM,N
Permanent Magnet motor PM motor
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Rated Inverter Output Current IINV
Revolutions Per Minute RPM
Regenerative terminals Regen
Second s
Synchronous Motor Speed ns
Torque limit TLIM
Volts V
The maximum output current IVLT,MAX
The rated output current supplied by the
adjustable frequency drive
IVLT,N
Table 1.3 Abbreviations
How to Read this Design Gui... Design Guide
8 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22
1
1

1.1.1 Definitions
Adjustable Frequency Drive:
IVLT,MAX
The maximum output current.
IVLT,N
The rated output current supplied by the adjustable
frequency drive.
UVLT, MAX
The maximum output voltage.
Input:
Control command
Start and stop the
connected motor with
the LCP or the digital
inputs.
Functions are divided
into two groups.
Functions in group 1
have higher priority
than functions in
group 2.
Group 1 Reset, Coasting stop, Reset
and Coasting stop, Quick
stop, DC braking, Stop and
the "Off" key
Group 2 Start, Pulse start, Reversing,
Start reversing, Jog and
Freeze output
Table 1.4 Function Groups
Motor:
fJOG
The motor frequency when the jog function is activated
(via digital terminals).
fM
The motor frequency.
fMAX
The maximum motor frequency.
fMIN
The minimum motor frequency.
fM,N
The rated motor frequency (nameplate data).
IM
The motor current.
IM,N
The rated motor current (nameplate data).
nM,N
The rated motor speed (nameplate data).
PM,N
The rated motor power (nameplate data).
TM,N
The rated torque (motor).
UM
The instantaneous motor voltage.
UM,N
The rated motor voltage (nameplate data).
Break-away torque
175ZA078.10
Pull-out
rpm
Torque
Figure 1.1 Break-away Torque
ηVLT
The efficiency of the adjustable frequency drive is defined
as the ratio between the power output and the power
input.
Start-disable command
A stop command belonging to the group 1 control
commands - see Table 1.4.
Stop command
See Control commands.
References:
Analog Reference
A signal transmitted to the analog inputs 53 or 54, can be
voltage or current.
Bus Reference
A signal transmitted to the serial communication port (FC
port).
Preset Reference
A defined preset reference to be set from -100% to +100%
of the reference range. Selection of eight preset references
via the digital terminals.
Pulse Reference
A pulse frequency signal transmitted to the digital inputs
(terminal 29 or 33).
How to Read this Design Gui... Design Guide
MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved. 9
11

RefMAX
Determines the relationship between the reference input
at 100% full scale value (typically 10 V, 20 mA) and the
resulting reference. The maximum reference value set in
3-03 Maximum Reference.
RefMIN
Determines the relationship between the reference input
at 0% value (typically 0 V, 0 mA, 4 mA) and the resulting
reference. The minimum reference value set in
3-02 Minimum Reference
Miscellaneous:
Advanced Vector Control
Analog Inputs
The analog inputs are used for controlling various
functions of the adjustable frequency drive.
There are two types of analog inputs:
Current input, 0–20 mA and 4–20 mA
Voltage input, 0–10 V DC.
Analog Outputs
The analog outputs can supply a signal of 0–20 mA,
4–20 mA, or a digital signal.
Automatic Motor Adaptation, AMA
AMA algorithm determines the electrical parameters for
the connected motor at standstill.
Brake Resistor
The brake resistor is a module capable of absorbing the
braking energy generated in regenerative braking. This
regenerative braking energy increases the intermediate
circuit voltage and a brake chopper ensures that the
power is transmitted to the brake resistor.
CT Characteristics
Constant torque characteristics used for screw and scroll
refrigeration compressors.
Digital Inputs
The digital inputs can be used for controlling various
functions of the adjustable frequency drive.
Digital Outputs
The adjustable frequency drive features two solid state
outputs that can supply a 24 V DC (max. 40 mA) signal.
DSP
Digital Signal Processor.
Relay Outputs
The adjustable frequency drive features two programmable
relay outputs.
ETR
Electronic Thermal Relay is a thermal load calculation
based on present load and time. Its purpose is to estimate
the motor temperature.
GLCP
Graphical Local Control Panel (LCP102).
Initializing
If initialization is carried out (14-22 Operation Mode), the
programmable parameters of the adjustable frequency
drive return to their default settings.
Intermittent Duty Cycle
An intermittent duty rating refers to a sequence of duty
cycles. Each cycle consists of an on-load and an off-load
period. The operation can be either periodic duty or non-
periodic duty.
LCP
The Local Control Panel makes up a complete interface for
control and programming of the adjustable frequency
drive. The LCP is detachable and can be installed up to
10 ft [3 m] from the adjustable frequency drive, i.e., in a
front panel by means of the installation kit option.
The LCP is available in two versions:
•Numerical LCP101 (NLCP)
•Graphical LCP102 (GLCP)
lsb
Least significant bit.
MCM
Short for Mille Circular Mil, an American measuring unit for
cable cross-section. 1 MCM ≡0.00078 in2[0.5067 mm2].
msb
Most significant bit.
NLCP
Numerical Local Control Panel LCP 101.
Online/Offline Parameters
Changes to online parameters are activated immediately
after the data value is changed. Press [OK] to activate
changes to offline parameters.
PID Controller
The PID controller maintains the desired speed, pressure,
temperature, etc. by adjusting the output frequency to
match the varying load.
RCD
Residual Current Device.
Set-up
Save parameter settings in four set-ups. Change between
the two parameter set-ups and edit one set-up, while
another set-up is active.
SFAVM
Switching pattern called Stator Flux-oriented Asynchronous
Vector Modulation (14-00 Switching Pattern).
How to Read this Design Gui... Design Guide
10 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22
1
1

Slip Compensation
The adjustable frequency drive compensates for the motor
slip by giving the frequency a supplement that follows the
measured motor load, keeping the motor speed almost
constant.
Smart Logic Control (SLC)
The SLC is a sequence of user-defined actions executed
when the associated user-defined events are evaluated as
true by the SLC.
Thermistor
A temperature-dependent resistor placed where the
temperature is to be monitored (adjustable frequency drive
or motor).
Trip
A state entered in fault situations, e.g., if the adjustable
frequency drive is subject to an overtemperature or when
the adjustable frequency drive is protecting the motor,
process or mechanism. Restart is prevented until the cause
of the fault has disappeared and the trip state is canceled
by activating reset or, in some cases, by being
programmed to reset automatically. Trip may not be used
for personal safety.
Trip Locked
A state entered in fault situations when the adjustable
frequency drive is protecting itself and requiring physical
intervention, e.g., if the adjustable frequency drive is
subject to a short circuit on the output. A locked trip can
only be canceled by cutting off line power, removing the
cause of the fault, and reconnecting the adjustable
frequency drive. Restart is prevented until the trip state is
canceled by activating reset or, in some cases, by being
programmed to reset automatically. The trip-lock function
may not be used as a personal safety measure.
VT Characteristics
Variable torque characteristics used for pumps and fans.
VVCplus
If compared with standard voltage/frequency ratio control,
Voltage Vector Control (VVCplus) improves the dynamics
and the stability, both when the speed reference is
changed and in relation to the load torque.
60°AVM
Switching pattern called 60°Asynchronous Vector
Modulation (See 14-00 Switching Pattern).
1.1.2 Power Factor
The power factor is the relation between I1and IRMS.
Power factor =3 ×
U × I
1 × COS ϕ
3 × U × IRMS
The power factor for 3-phase control:
=
I
1 ×
cos ϕ1
IRMS
=
I
1
IRMS
since cos ϕ1 = 1
The power factor indicates to which extent the adjustable
frequency drive imposes a load on the line power supply.
The lower the power factor, the higher the IRMS for the
same kW performance.
IRMS = I
1
2 +
I
5
2 +
I
7
2 + . . +
In
2
In addition, a high power factor indicates that the different
harmonic currents are low.
The adjustable frequency drive's built-in DC coils produce a
high power factor, which minimizes the imposed load on
the line power supply.
How to Read this Design Gui... Design Guide
MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved. 11
11

2Introduction to VLT®HVAC Drive
2.1 Safety
2.1.1 Safety Note
WARNING
The voltage of the adjustable frequency drive is
dangerous whenever connected to line power. Incorrect
installation of the motor, adjustable frequency drive or
serial communication bus may cause death, serious
personal injury or damage to the equipment.
Consequently, the instructions in this manual, as well as
national and local rules and safety regulations, must be
complied with.
Safety Regulations
1. Disconnect the adjustable frequency drive from
line power if repair work is to be carried out.
Make sure that the line power supply has been
disconnected and that the necessary time has
elapsed before removing motor and line power
plugs.
2. The [Stop/Reset] key on the LCP of the adjustable
frequency drive does not disconnect the
equipment from line power and is thus not to be
used as a safety switch.
3. Established correct protective grounding of the
equipment, protect the user against supply
voltage, and protect the motor against overload
in accordance with applicable national and local
regulations.
4. The ground leakage currents are higher than
3.5 mA.
5. Protection against motor overload is set by
1-90 Motor Thermal Protection. If this function is
desired, set 1-90 Motor Thermal Protection to data
value [ETR trip] (default value) or data value [ETR
warning]. Note: The function is initialized at 1.16
x rated motor current and rated motor frequency.
For the North American market: The ETR
functions provide class 20 motor overload
protection in accordance with NEC.
6. Do not remove the plugs for the motor and line
power supply while the adjustable frequency
drive is connected to line power. Make sure that
the line power supply has been disconnected and
that the necessary time has elapsed before
removing motor and line power plugs.
7. Note that the adjustable frequency drive has
more voltage inputs than L1, L2 and L3 when
load sharing (linking of DC intermediate circuit)
and external 24 V DC have been installed. Make
sure that all voltage inputs have been discon-
nected and that the necessary time has passed
before commencing repair work.
Installation at high altitudes
CAUTION
380–500 V, enclosure types A, B and C: At altitudes
above 6,600 ft [2 km], contact Danfoss regarding PELV.
525–690 V: At altitudes above 6,600 ft [2 km], contact
Danfoss regarding PELV.
WARNING
Warning against unintended start
1. The motor can be stopped with digital
commands, bus commands, references or a
local stop, while the adjustable frequency drive
is connected to line power. If personal safety
considerations make it necessary to ensure that
no unintended start occurs, these stop functions
are not sufficient.
2. While parameters are being changed, the motor
may start. Consequently, the [Reset] key must
always be activated; after which data can be
modified.
3. A motor that has been stopped may start if
faults occur in the electronics of the adjustable
frequency drive, or if a temporary overload or a
fault in the line power or the motor connection
ceases.
WARNING
Touching the electrical parts may be fatal - even after
the equipment has been disconnected from line power.
Also make sure that other voltage inputs have been
disconnected, such as external 24 V DC, load sharing
(linkage of DC intermediate circuit), as well as the motor
connection for kinetic backup. Refer to the Instruction
Manual for further safety guidelines.
Introduction to VLT® HVAC D... Design Guide
12 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22
22

2.1.2 Caution
WARNING
The DC link capacitors remain charged after power has
been disconnected. To avoid an electrical shock hazard,
disconnect the from line power before carrying out
maintenance. Wait at least as follows before doing
service on the adjustable frequency drive:
Voltage [V] Min. waiting time (minutes)
4 15
200–240 1.5–5 hp [1.1–3.7 kW] 7.5–60 hp [5.5–45 kW]
380–480 1.5–10 hp [1.1–7.5 kW] 15–125 hp [11–90 kW]
525–600 1.5–10 hp [1.1–7.5 kW] 15–125 hp [11–90 kW]
525–690 15–125 hp [11–90 kW]
Be aware that there may be high voltage on the DC link even
when the LEDs are turned off.
Table 2.1 Discharge Time
2.1.3 Disposal Instruction
Equipment containing electrical
components may 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.
2.2 CE Labeling
2.2.1 CE Conformity and Labeling
What is CE Conformity and Labeling?
The purpose of CE labeling is to avoid technical trade
obstacles within the EFTA and the EU. The EU has
introduced the CE label as a simple way of showing
whether a product complies with the relevant EU
directives. The CE label says nothing about the specifi-
cations or quality of the product. Adjustable frequency
drives are regulated by three EU directives.
The machinery directive (2006/42/EC)
Adjustable frequency drives with the integrated safety
function are now falling under the Machinery Directive.
Danfoss uses CE labels in accordance with the directive
and will issue a declaration of conformity upon request.
Adjustable frequency drives without the safety function do
not fall under the machinery directive. However, if an
adjustable frequency drive is supplied for use in a
machine, we provide information on its safety aspects.
The low-voltage directive (2006/95/EC)
Adjustable frequency drives must be CE labeled in
accordance with the Low-voltage Directive of January 1,
1997. The directive applies to all electrical equipment and
appliances used in the 50–1,000 V AC and the
75–1,500 V DC voltage ranges. Danfoss CE labels in
accordance with the directive and issues a declaration of
conformity upon request.
The EMC directive (2004/108/EC)
EMC is short for electromagnetic compatibility.
The presence of electromagnetic compatibility means that
the mutual interference between different components/
appliances does not affect the way the appliances work.
The EMC directive came into effect January 1, 1996.
Danfoss CE labels in accordance with the directive and
issues a declaration of conformity upon request. To carry
out EMC-compatible installation, see the instructions in this
Design Guide. In addition, Danfoss specifies which
standards our products comply with. Danfoss offers the
filters presented in the specifications and provide other
types of assistance to ensure the optimum EMC result.
The adjustable frequency drive is most often used by
professionals of the trade as a complex component
forming part of a larger appliance, system or installation.
It must be noted that the responsibility for the final EMC
properties of the appliance, system or installation rests
with the installer.
Introduction to VLT® HVAC D... Design Guide
MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved. 13
22

2.2.2 What Is Covered
The EU "Guidelines on the Application of Council Directive
2004/108/EC" outline three typical situations of using an
adjustable frequency drive.
1. The adjustable frequency drive is sold directly to
the end user. For such applications, the
adjustable frequency drive must be CE labeled in
accordance with the EMC directive.
2. The adjustable frequency drive is sold as part of a
system. It is being marketed as complete system,
e.g., an air-conditioning system. The complete
system must be CE labeled in accordance with
the EMC directive. The manufacturer can ensure
CE labeling under the EMC directive by testing
the EMC of the system. The components of the
system do not need to be CE marked.
3. The adjustable frequency drive is sold for instal-
lation in a plant. It could be a production or a
heating/ventilation plant designed and installed
by professionals of the trade. The adjustable
frequency drive must be CE labeled under the
EMC directive. The finished plant should not bear
the CE mark. However, the installation must
comply with the essential requirements of the
directive. This is assumed by using appliances
and systems that are CE labeled under the EMC
directive
2.2.3 Danfoss Adjustable frequency drive
and CE Labeling
The purpose of CE labeling is to facilitate trade within the
EU and EFTA.
However, CE labeling may cover many different specifi-
cations. Thus, check what a given CE label specifically
covers.
The covered specifications can be very different and a CE
label may therefore give the installer a false feeling of
security when using an adjustable frequency drive as a
component in a system or an appliance.
Danfoss CE labels the adjustable frequency drives in
accordance with the low-voltage directive. This means that
if the adjustable frequency drive is installed correctly,
Danfoss guarantees compliance with the low-voltage
directive. Danfoss issues a declaration of conformity that
confirms our CE labeling in accordance with the low-
voltage directive.
The CE label also applies to the EMC directive provided
that the instructions for EMC-compatible installation and
filtering are followed. On this basis, a declaration of
conformity in accordance with the EMC directive is issued.
This Design Guide offers detailed instructions for installation
to ensure EMC-compatible installation. Furthermore,
Danfoss specifies with what the different products comply.
Danfoss provides other types of assistance that can help
obtain the best EMC result.
2.2.4 Compliance with EMC Directive
2004/108/EC
As mentioned, the adjustable frequency drive is mostly
used by professionals of the trade as a complex
component forming part of a larger appliance, system or
installation. Note that the responsibility for the final EMC
properties of the appliance, system or installation rests
with the installer. As an aid to the installer, Danfoss has
prepared EMC installation guidelines for the Power Drive
system. The standards and test levels stated for Power
Drive systems are complied with, provided that the EMC-
compatible instructions for installation are followed, see.
2.3 Air humidity
The adjustable frequency drive has been designed to meet
the IEC/EN 60068-2-3 standard, EN 50178 pkt. 9.4.2.2 at
122 °F [50 °C].
2.4 Aggressive Environments
An adjustable frequency drive contains a large number of
mechanical and electronic components. All are to some
extent vulnerable to environmental effects.
CAUTION
Do not install the adjustable frequency drive in
environments with airborne liquids, particles, or gases
capable of affecting and damaging the electronic
components. Failure to take the necessary protective
measures increases the risk of stoppages, thus reducing
the life of the adjustable frequency drive.
Degree of protection as per IEC 60529
The Safe Torque Off function may only be installed and
operated in a control cabinet with degree of protection
IP54 or higher (or equivalent environment). This is required
to avoid cross faults and short circuits between terminals,
connectors, tracks and safety-related circuitry caused by
foreign objects.
Introduction to VLT® HVAC D... Design Guide
14 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22
22

Liquids can be carried through the air and condense in the
adjustable frequency drive and may cause corrosion of
components and metal parts. Steam, oil, and salt water
may cause corrosion of components and metal parts. In
such environments, use equipment with enclosure rating IP
54/55. As an extra protection, coated printed circuit boards
can be ordered as an option.
Airborne particles such as dust may cause mechanical,
electrical or thermal failure in the adjustable frequency
drive. A typical indicator of excessive levels of airborne
particles is the presence of dust particles around the
adjustable frequency drive fan. In very dusty environments,
use equipment with enclosure rating IP 54/55 or a cabinet
for IP 00/IP 20/TYPE 1 equipment.
In environments with high temperatures and humidity,
corrosive gases such as sulfur, nitrogen, and chlorine
compounds cause chemical processes on the adjustable
frequency drive components.
Such chemical reactions rapidly affect and damage the
electronic components. In such environments, mount the
equipment in a cabinet with fresh air ventilation, keeping
aggressive gases away from the adjustable frequency drive.
An extra protection in such areas is a coating of the
printed circuit boards, which can be ordered as an option.
NOTICE!
Mounting adjustable frequency drives in aggressive
environments increases the risk of stoppages and consid-
erably reduces the life of the adjustable frequency drive.
Before installing the adjustable frequency drive, check the
ambient air for liquids, particles and gases. This is done by
observing existing installations in this environment. Typical
indicators of harmful airborne liquids are water or oil on
metal parts, or corrosion of metal parts.
Excessive dust particle levels are often found on instal-
lation cabinets and existing electrical installations. One
indicator of aggressive airborne gases is the blackening of
copper rails and cable ends on existing installations.
D and E enclosure types have a stainless steel backchannel
option to provide additional protection in aggressive
environments. Proper ventilation is still required for the
internal components of the adjustable frequency drive.
Contact Danfoss for additional information.
2.5 Vibration and Shock
The adjustable frequency drive has been tested according
to the procedure based on the shown standards:
•IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970
•IEC/EN 60068-2-64: Vibration, broad-band random
The adjustable frequency drive complies with requirements
that exist for units mounted on the walls and floors of
production premises, as well as in panels bolted to walls or
floors.
2.6 Safe Torque Off
The FC 102 can perform the safety function Safe Torque Off
(STO, as defined by EN IEC 61800-5-21) and Stop Category 0
(as defined in EN 60204-12).
Before integrating and using Safe Torque Off in an instal-
lation, a thorough risk analysis on the installation must be
carried out in order to determine whether the Safe Torque
Off functionality and safety levels are appropriate and
sufficient. It is designed and approved as suitable for the
requirements of:
•Category 3 in EN ISO 13849-1
•Performance Level "d" in EN ISO 13849-1:2008
•SIL 2 Capability in IEC 61508 and EN 61800-5-2
•SILCL 2 in EN 62061
1) Refer to EN IEC 61800-5-2 for details of Safe torque off
(STO) function.
2) Refer to EN IEC 60204-1 for details of stop category 0
and 1.
Activation and Termination of Safe Torque Off
The Safe Torque Off (STO) function is activated by
removing the voltage at Terminal 37 of the Safe Inverter.
By connecting the Safe Inverter to external safety devices
providing a safe delay, an installation for a Safe Torque Off
Category 1 can be obtained. The Safe Torque Off function
of FC 102 can be used for asynchronous, synchronous
motors and permanent magnet motors. See examples in
chapter 2.6.1 Terminal 37 Safe Torque Off Function.
WARNING
After installation of Safe Torque Off (STO), a commis-
sioning test as specified in section Safe Torque Off
Commissioning Test must be performed. A passed
commissioning test is mandatory after first installation
and after each change to the safety installation.
Introduction to VLT® HVAC D... Design Guide
MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved. 15
22

Safe Torque Off Technical Data
The following values are associated to the different types
of safety levels:
Reaction time for T37
•Maximum reaction time: 20 ms
Reaction time = delay between de-energizing the STO
input and switching off the output bridge.
Data for EN ISO 13849-1
•Performance Level "d"
•MTTFd(Mean Time To Dangerous Failure):
14,000 years
•DC (Diagnostic Coverage): 90%
•Category 3
•Lifetime 20 years
Data for EN IEC 62061, EN IEC 61508, EN IEC 61800-5-2
•SIL 2 Capability, SILCL 2
•PFH (Probability of dangerous Failure per Hour) =
1E-10/h
•SFF (Safe Failure Fraction) > 99%
•HFT (Hardware Fault Tolerance) = 0
(1001 architecture)
•Lifetime 20 years
Data for EN IEC 61508 low demand
•PFDavg for 1-year proof test: 1E-10
•PFDavg for 3-year proof test: 1E-10
•PFDavg for 5-year proof test: 1E-10
No maintenance of the STO functionality is needed.
Take security measures, e.g., only skilled personnel must be
able to access and install in closed cabinets.
SISTEMA Data
Danfoss provides functional safety data via a data library
for use with the SISTEMA calculation tool from IFA
(Institute for Occupational Safety and Health of the
German Social Accident Insurance), as well as data for
manual calculation. The library is complete and continually
extended.
Abbrev. Ref. Description
Cat. EN ISO
13849-1
Category, level “B, 1-4”
FIT Failure In Time: 1E-9 hours
HFT IEC 61508 Hardware Fault Tolerance: HFT = n
means that n+1 faults could cause a
loss of the safety function
MTTFd EN ISO
13849-1
Mean Time To Failure - dangerous. Unit:
years
PFH IEC 61508 Probability of Dangerous Failures per
Hour. This value shall be considered if
the safety device is operated in high
demand (more often than once per
year) or continuous mode of operation,
where the frequency of demands for
operation made on a safety-related
system is greater than one per year
PFD IEC 61508 Average probability of failure on
demand, value used for low demand
operation
PL EN ISO
13849-1
Discrete level used to specify the ability
of safety related parts of control
systems to perform a safety function
under foreseeable conditions. Levels a-e
SFF IEC 61508 Safe Failure Fraction [%]; Percentage
part of safe failures and dangerous
detected failures of a safety function or
a subsystem related to all failures
SIL IEC 61508 Safety Integrity Level
STO EN
61800-5-2
Safe Torque Off
SS1 EN 61800
-5-2
Safe Stop 1
Table 2.2 Abbreviations Related to Functional Safety
2.6.1 Terminal 37 Safe Torque Off Function
The FC 102 is available with Safe Torque Off functionality
via control terminal 37. Safe Torque Off disables the
control voltage of the power semiconductors of the
adjustable frequency drive output stage which in turn
prevents generating the voltage required to rotate the
motor. When the Safe Torque Off (T37) is activated, the
adjustable frequency drive issues an alarm, trips the unit,
and coasts the motor to a stop. Manual restart is required.
The Safe Torque Off function can be used for stopping the
adjustable frequency drive in emergency stop situations. In
the normal operating mode when Safe Torque Off is not
required, use the adjustable frequency drive’s regular stop
function instead. When automatic restart is used – the
requirements according to ISO 12100-2 paragraph 5.3.2.5
must be fulfilled.
Introduction to VLT® HVAC D... Design Guide
16 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22
22

Liability Conditions
It is the user’s responsibility to ensure that personnel
installing and operating the Safe Torque Off function:
•Read and understand the safety regulations
concerning health and safety/accident prevention
•Understand the generic and safety guidelines
given in this description and the extended
description in the Design Guide
•Have a good knowledge of the generic and safety
standards applicable to the specific application
Standards
Use of Safe Torque Off on terminal 37 requires that the
user satisfies all provisions for safety including relevant
laws, regulations and guidelines. The optional Safe Torque
Off function complies with the following standards.
IEC 60204-1: 2005 category 0 – uncontrolled stop
IEC 61508: 1998 SIL2
IEC 61800-5-2: 2007 – safe torque off (STO)
function
IEC 62061: 2005 SIL CL2
ISO 13849-1: 2006 Category 3 PL d
ISO 14118: 2000 (EN 1037) – prevention of
unexpected startup
The information and instructions of the Instruction Manual
are not sufficient for a proper and safe use of the Safe
Torque Off functionality. The related information and
instructions in the relevant Design Guide must be followed.
Protective Measures
•Safety engineering systems may only be installed
and commissioned by qualified and skilled
personnel
•The unit must be installed in an IP54 cabinet or
in an equivalent environment. In special
applications, a higher IP degree may be necessary
•The cable between terminal 37 and the external
safety device must be short-circuit-protected
according to ISO 13849-2 table D.4
•If any external forces influence the motor axis
(e.g., suspended loads), additional measures
(e.g., a safety holding brake) are required to
eliminate hazards.
Safe Torque Off Installation and Set-up
WARNING
SAFE TORQUE OFF FUNCTION!
The Safe Torque Off function does NOT isolate AC line
voltage to the adjustable frequency drive or auxiliary
circuits. Perform work on electrical parts of the
adjustable frequency drive or the motor only after
isolating the AC line voltage supply and waiting the
length of time specified under Safety in this manual.
Failure to isolate the AC line voltage supply from the
unit and waiting the time specified could result in death
or serious injury.
•It is not recommended to stop the adjustable
frequency drive by using the Safe Torque Off
function. If a running adjustable frequency drive
is stopped by using the function, the unit trips
and stops by coasting. If this is not acceptable,
e.g., causes danger, the adjustable frequency
drive and machinery must be stopped using the
appropriate stopping mode before using this
function. Depending on the application, a
mechanical brake may be required.
•Concerning synchronous and permanent magnet
motor adjustable frequency drives in case of a
multiple IGBT power semiconductor failure: In
spite of the activation of the Safe Torque Off
function, the adjustable frequency drive system
can produce an alignment torque which
maximally rotates the motor shaft by 180/p
degrees. p denotes the pole pair number.
•This function is suitable for performing
mechanical work on the adjustable frequency
drive system or affected area of a machine only.
It does not provide electrical safety. This function
should not be used as a control for starting
and/or stopping the adjustable frequency drive.
Meet the following requirements to perform a safe instal-
lation of the adjustable frequency drive:
1. Remove the jumper wire between control
terminals 37 and 12 or 13. Cutting or breaking
the jumper is not sufficient to avoid short-
circuiting. (See jumper on Figure 2.1.)
2. Connect an external safety monitoring relay via a
NO safety function (the instruction for the safety
device must be followed) to terminal 37 (Safe
Torque Off) and either terminal 12 or 13 (24 V
DC). The Safety monitoring relay must comply
with Category 3/PL “d” (ISO 13849-1) or SIL 2
(EN 62061).
Introduction to VLT® HVAC D... Design Guide
MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved. 17
22

12/13
37
130BA874.10
Figure 2.1 Jumper between Terminal 12/13 (24 V) and 37
12
37
3
2
FC
4
1
130BB967.10
Figure 2.2 Installation to Achieve a Stopping Category 0
(EN 60204-1) with Safety Cat. 3/PL “d” (ISO 13849-1) or
SIL 2 (EN 62061).
1 Safety relay (cat. 3, PL d or SIL2
2 Emergency stop button
3 Reset button
4 Short-circuit protected cable (if not inside installation
IP54 cabinet)
Table 2.3 Legend to Figure 2.2
Safe Torque Off Commissioning Test
After installation and before first operation, perform a
commissioning test of the installation making use of Safe
Torque Off. Also, perform the test after each modification
of the installation.
Example with STO
A safety relay evaluates the E-Stop button signals and
triggers an STO function on the adjustable frequency drive
in the event of an activation of the E-Stop button (See
Figure 2.3). This safety function corresponds to a category 0
stop (uncontrolled stop) in accordance with IEC 60204-1. If
the function is triggered during operation, the motor runs
down in an uncontrolled manner. The power to the motor
is safely removed, so that no further movement is possible.
It is not necessary to monitor plant at a standstill. If an
external force effect is to be anticipated, provide additional
measures to safely prevent any potential movement
(e.g., mechanical brakes).
NOTICE!
For all applications with Safe Torque Off, it is important
that short circuit in the wiring to T37 can be excluded.
This can be done as described in EN ISO 13849-2 D4 by
the use of protected wiring, (shielded or segregated).
Example with SS1
SS1 correspond to a controlled stop, stop category 1
according to IEC 60204-1 (see Figure 2.4). When activating
the safety function, a normal controlled stop is performed.
This can be activated through terminal 27. After the safe
delay time has expired on the external safety module, the
STO is triggered and terminal 37 is set low. Ramp-down is
performed as configured in the adjustable frequency drive.
If the adjustable frequency drive is not stopped after the
safe delay time, the activation of STO coasts the adjustable
frequency drive.
NOTICE!
When using the SS1 function, the brake ramp of the
adjustable frequency drive is not monitored with respect
to safety.
Example with Category 4/PL e application
Where the safety control system design requires two
channels for the STO function to achieve Category 4/PL e,
one channel can be implemented by Safe Torque Off T37
(STO) and the other by a contactor which may be
connected in either the adjustable frequency drive input or
output power circuits and controlled by the safety relay
(see Figure 2.5). The contactor must be monitored through
an auxiliary guided contact and connected to the reset
input of the safety relay.
Introduction to VLT® HVAC D... Design Guide
18 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22
22