Danfoss VLT HVAC Drive FC 102 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT®HVAC Drive FC 102 Low Harmonic Drive
www.DanfossDrives.com

Contents
1 Introduction 5
1.1 Purpose of the Manual 5
1.2 Additional Resources 5
1.3 Product Overview 5
1.3.1 Intended Use 5
1.3.2 Working Principle 6
1.3.3 Exploded View Drawings 7
1.4 Enclosure Sizes and Power Ratings 15
1.5 Approvals and Certications 15
1.5.1 Approvals 15
1.5.2 Compliance with ADN 15
1.6 Harmonics Overview 15
1.6.1 Harmonics 15
1.6.2 Harmonic Analysis 15
1.6.3 Eect of Harmonics in a Power Distribution System 16
1.6.4 IEC Harmonic Standards 17
1.6.5 IEEE Harmonic Standards 18
2 Safety 20
2.1 Safety Symbols 20
2.2 Qualied Personnel 20
2.3 Safety Precautions 20
3 Mechanical Installation 21
3.1 Equipment Pre-Installation Checklist 21
3.2 Unpacking 21
3.2.1 Items Supplied 21
3.3 Mounting 22
3.3.1 Cooling and Airow 22
3.3.2 Lifting 24
3.3.3 Cable Entry and Anchoring 25
3.3.4 Terminal Locations - Frame Size D13 29
3.3.5 Terminal Locations - Frame Size E9 30
3.3.6 Terminal Locations for Enclsoure Size F18 31
3.3.7 Torque 34
4 Electrical Installation 35
4.1 Safety Instructions 35
Contents Operating Instructions
MG16I322 Danfoss A/S © 04/2015 All rights reserved.

4.2 EMC Compliant Installation 35
4.3 Power Connections 35
4.4 Grounding 36
4.5 Input Options 37
4.5.1 Extra Protection (RCD) 37
4.5.2 RFI Switch 37
4.5.3 Shielded Cables 37
4.6 Motor Connection 37
4.6.1 Motor Cable 37
4.6.2 Brake Cable 38
4.6.3 Motor Insulation 38
4.6.4 Motor Bearing Currents 38
4.7 AC Mains Connection 39
4.7.1 AC line input connections 39
4.7.2 External Fan Supply 39
4.7.3 Power and Control Wiring for Non-shielded Cables 39
4.7.4 Mains Disconnects 40
4.7.5 F-Frame Circuit Breakers 40
4.7.6 F-Frame Mains Contactors 40
4.8 Control Wiring 41
4.8.1 Control Cable Routing 41
4.8.2 Access to Control Terminals 42
4.8.3 Electrical Installation, Control Terminals 42
4.8.4 Electrical Installation, Control Cables 44
4.8.5 Safe Torque O (STO) 45
4.9 Additional Connections 45
4.9.1 Serial Communication 45
4.9.2 Mechanical Brake Control 46
4.9.3 Parallel Connection of Motors 46
4.9.4 Motor Thermal Protection 47
4.9.5 Voltage/Current Input Selection (Switches) 47
4.10 Final Set-up and Test 47
4.11 F-frame Options 49
5 Commissioning 51
5.1 Safety Instructions 51
5.2 Applying Power 52
5.3 Local Control Panel Operation 52
Contents VLT®HVAC Drive FC 102 Low Harmonic Drive
Danfoss A/S © 04/2015 All rights reserved. MG16I322

5.3.1 Local Control Panel 52
5.3.2 LCP Layout 53
5.3.3 Parameter Settings 54
5.3.4 Uploading/Downloading Data to/from the LCP 54
5.3.5 Changing Parameter Settings 54
5.3.6 Restoring Default Settings 55
5.4 Basic Programming 55
5.4.1 VLT®Low Harmonic Drive Programming 55
5.4.2 Commissioning with SmartStart 55
5.4.3 Commissioning via [Main Menu] 56
5.4.4 Asynchronous Motor Set-up 56
5.4.5 Permanent Magnet Motor Set-up 57
5.4.6 Automatic Energy Optimization (AEO) 58
5.4.7 Automatic Motor Adaptation (AMA) 58
5.5 Checking Motor Rotation 59
5.6 Local-control Test 59
5.7 System Start-up 59
6 Application Examples 60
6.1 Introduction 60
6.2 Application Examples 60
7 Diagnostics and Troubleshooting 65
7.1 Status Messages 65
7.2 Warning and Alarm Types 65
7.2.1 Warnings 65
7.2.2 Alarm Trip 65
7.2.3 Alarm Trip-lock 65
7.3 Warning and Alarm Denitions for Frequency Converter 65
7.4 Warnings and Alarm Denitions - Active Filter 74
7.5 Troubleshooting 79
8 Specications 82
8.1 Power-Dependent Specications 82
8.1.1 Mains Supply 3x380–480 V AC 82
8.1.2 Derating for Temperature 86
8.2 Mechanical Dimensions 87
8.3 General Technical Data 91
8.4 Fuses 98
8.4.1 Non- UL compliance 98
Contents Operating Instructions
MG16I322 Danfoss A/S © 04/2015 All rights reserved.

8.4.2 Fuse Tables 99
8.4.3 Supplementary Fuses - High Power 100
8.5 General Torque Tightening Values 101
9 Appendix A - Parameters 102
9.1 Description of Parameters 102
9.2 Frequency Converter Parameter Lists 102
9.3 Active Filter Parameter Lists 107
10 Appendix B 114
10.1 Abbreviations and Conventions 114
Index 115
Contents VLT®HVAC Drive FC 102 Low Harmonic Drive
Danfoss A/S © 04/2015 All rights reserved. MG16I322

1 Introduction
1.1 Purpose of the Manual
The purpose of this manual is to provide information for
the installation and operation of a VLT®HVAC Drive FC 102
Low Harmonic. The manual includes relevant safety
information for installation and operation.
chapter 1 Introduction, chapter 2 Safety,
chapter 3 Mechanical Installation, and Chapter 4 Electrical
Installation introduce the unit functions and cover proper
mechanical and electrical installation procedures. There are
chapters on start-up and commissioning, applications and
basic troubleshooting. Chapter 8 Specications provides a
quick reference for ratings and dimensions, as well as other
operating specications. This manual provides a basic
knowledge of the unit and explains set-up and basic
operation.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced
functions and programming.
•The VLT
®
HVAC Drive FC 102 Programming Guide
provides greater detail on working with
parameters and many application examples.
•The VLT
®
HVAC Drive FC 102 Design Guide provides
detailed capabilities and functionality to design
motor control systems.
•Supplemental publications and manuals are
available from Danfoss.
See vlt-drives.danfoss.com/Support/Technical-
Documentation/ for listings.
•Optional equipment may change some of the
procedures described. Reference the instructions
supplied with those options for specic
requirements. Contact the local Danfoss supplier
or visit the Danfoss website: vlt-
drives.danfoss.com/Support/Technical-
Documentation/ for downloads or additional
information.
•The VLT
®
Active Filter AAF00x Instruction Manual
provides additional information about the lter
portion of the low harmonic drive.
1.3 Product Overview
1.3.1 Intended Use
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 with position sensors
on a conveyor belt. The frequency converter can also
regulate the motor by responding to remote commands
from external controllers.
The frequency converter:
•Monitors the system and motor status.
•Issues warnings or alarms for fault conditions.
•Starts and stops the motor.
•Optimises energy eciency.
Operation and monitoring functions are available as status
indications to an outside control system or serial communi-
cation network.
A low harmonic drive (LHD) is a single unit that combines
the frequency converter with an advanced active lter
(AAF) for harmonic mitigation. The frequency converter
and lter are packaged together in an integrated system,
but each functions independently. In this manual, there are
separate specications for the frequency converter and the
lter. Since the frequency converter and lter are in the
same enclosure, the unit is transported, installed, and
operated as a single entity.
Introduction Operating Instructions
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1.3.2 Working Principle
The low harmonic drive is a high-power frequency converter with an integrated active lter. An active lter is a device that
actively monitors harmonic distortion levels and injects compensative harmonic current onto the line to cancel the
harmonics.
Mains
380 to
500 VAC
Optional
RFI
Optional
Fuses
Optional
Manual
Disconnect
HI Reactor
Lm
Lm
Lm
Lac
Lac
Lac
AC
Contactor
Relay 12
Control & AUX
Feedback
Soft-Charge
Resistor
Converter Side
Filter Power Stage
AF Current
Sensors
Capacitor
Current Sensors
VLT Drive
Main’s
3
3
3
CTs
Lc
Lc
Lc
Cef Cef Cef
Ref Ref Ref
Ir
Is
It
130BB406.11
Figure 1.1 Basic Layout for the Low Harmonic Drive
Low harmonic drives are designed to draw an ideal sinusoidal current waveform from the supply grid with a power factor of
1. Where traditional non-linear load draws pulse-shaped currents, the low harmonic drive compensates that via the parallel
lter path, lowering the stress on the supply grid. The low harmonic drive meets the highest harmonic standards with a
THDi less than 5% at full load for <3% pre-distortion on a 3% unbalanced 3-phase grid.
Introduction VLT®HVAC Drive FC 102 Low Harmonic Drive
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1.3.3 Exploded View Drawings
130BX167.10
1
19 13
12
25
5
4
22
21
20
18
17
3
16
15
14
11
24
2
10
9
8
7
6
23
1 Control card 14 SCR/diode module
2 Control input terminals 15 IGBT output bus bar
3 Local control panel (LCP) 16 Output motor terminals
4 Control card C option 17 Current sensor
5 Mounting bracket 18 Fan assembly
6 Power card mounting plate 19 Fan transformer
7 Power card 20 AC input terminals
8 Capacitor bank assembly 21 AC input bus bar
9 Soft-charge fuses 22 Input terminal mounting plate assembly
10 Soft-charge card 23 Fan fuse
11 DC inductor 24 Capacitor bank cover plate
12 Soft charge module 25 IGBT gate drive card
13 IGBT module
Figure 1.2 Frame Size D13 Drive Enclosure
Introduction Operating Instructions
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130BD571.11
1
67
89
11
13
15
16
20
21
22
2
3
4
5
10
12
14
18
19
17
1 Local control panel (LCP) 13 Electrical fuses
2 Active lter card (AFC) 14 Line power disconnect
3 Metal oxide varistor (MOV) 15 Line Power Terminals
4 Soft-charge resistors 16 Heatsink fan
5 AC capacitors discharge board 17 DC capacitor bank
6 Line power contactor 18 Current transformer
7 LC inductor 19 RFI dierential mode lter
8 AC capacitors 20 RFI common mode lter
9 Line power bus bars to drive input 21 HI inductor
10 IGBT fuses 22 Power card
11 RFI
Figure 1.3 Frame Size D13 Filter Enclosure
Introduction VLT®HVAC Drive FC 102 Low Harmonic Drive
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1
3
2
7
5
4
10
9
8
25
24
6
130BX168.10
20
19 18
17
16
15
14
13
12
11
23
22
21
1 Control card 14 SCR and diode
2 Control input terminals 15 Fan inductor (not on all units)
3 Local control panel (LCP) 16 Soft-charge resistor assembly
4 Control card C option 17 IGBT output bus bar
5 Mounting bracket 18 Fan assembly
6 Power card mounting plate 19 Output motor terminals
7 Power card 20 Current sensor
8 IGBT gate drive card 21 Main AC power input terminals
9 Upper capacitor bank assembly 22 Input terminal mounting plate
10 Soft-charge fuses 23 AC input bus bar
11 DC inductor 24 Soft-charge card
12 Fan transformer 25 Lower capacitor bank assembly
13 IGBT module
Figure 1.4 Frame Size E9 Drive Enclosure
Introduction Operating Instructions
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130BD572.11
1
5
6
7
9
10
11
12
14
16
17
18
19
20
21
2
3
4
8
13
15
1 Local control panel (LCP) 12 AC capacitor current transducers
2 Active lter card (AFC) 13 Heatsink fan
3 Line power contactors 14 Line power terminals
4 Soft-charge resistors 15 Line power disconnect
5 RFI dierential mode lter 16 Electrical fuses
6 RFI common mode lter 17 LC inductor
7 Current transformer (CT) 18 HI inductor
8 Line power bus bars to drive output 19 Power card
9 AC capacitors 20 Control card
10 RFI 21 LCP cradle
11 Lower DC capacitor bank
Figure 1.5 Frame Size E9 Filter Enclosure
Introduction VLT®HVAC Drive FC 102 Low Harmonic Drive
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130BX334.11
2
3
4
5
6
1
1 Contactor 4 Circuit breaker or disconnect (if purchased)
2 RFI lter 5 AC line power/line fuses (if purchased)
3 Line power AC power input terminals
Figure 1.6 Frame Size F18 Options Cabinet
*The options cabinet is not optional for the LHD. The ancillary equipment is stored in the cabinet.
Introduction Operating Instructions
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130BD573.10
1
2
5
6
7
10
11
15
17
3
4
8
9
13
14
16
18
12
1 Local control panel (LCP) 10 Line power bus bars to drive input
2 Active lter card (AFC) 11 Heatsink fans
3 Soft-charge resistors 12 Line power terminals (R/L1, S/L2, T/L3) from options cabinet
4 Metal oxide varistor (MOV) 13 RFI dierential mode lter
5 AC capacitors discharge board 14 RFI common mode lter
6 LC inductor 15 Line power contactor
7 HI inductor 16 Power card
8 Mixing fan 17 Control card
9 IGBT fuses 18 LCP cradle
Figure 1.7 Frame Size F18 Filter Cabinet
Introduction VLT®HVAC Drive FC 102 Low Harmonic Drive
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1
2
5
6
7
8
9
10
11
12
4
3
130BX331.11
13
1Rectier module 7 Module lifting eye bolts (mounted on a vertical strut)
2 DC bus bar 8 Module heatsink fan
3 SMPS fuse 9 Fan door cover
4 (Optional) back AC fuse mounting bracket 10 SMPS fuse
5 (Optional) middle AC fuse mounting bracket 11 Power card
6 (Optional) front AC fuse mounting bracket 12 Panel connectors
Figure 1.8 Frame Size F18 Rectier Cabinet
Introduction Operating Instructions
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2
1
16
15
14
13
12
11
10
8
7
6
54
9
3
130BX330.11
1 Fan transformer 9 Fan door cover
2 DC link inductor 10 Module heatsink fan
3 Top cover plate 11 Inverter module
4 MDCIC board 12 Panel connectors
5 Control card 13 DC fuse
6 SMPS fuse and fan fuse 14 Mounting bracket
7 Motor output bus bar 15 (+) DC bus bar
8 Brake output bus bar 16 (-) DC bus bar
Figure 1.9 Frame Size F18 Inverter Cabinet
Introduction VLT®HVAC Drive FC 102 Low Harmonic Drive
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1.4 Enclosure Sizes and Power Ratings
Enclosure size D1n D2n E9 F18
Enclosure protection IP 21/54 21/54 21/54 21/54
NEMA Type 1/Type 12 Type 1/Type 12 Type 1/Type 12 Type 1/Type 12
Frequency converter
dimensions
[mm/inch]
Height 1740/68.5 1740/68.5 2000.7/78.77 2278.4/89.70
Width 915/36.02 1020/40.16 1200/47.24 2792/109.92
Depth 380/14.96 380/14.96 493.5/19.43 605.8/23.85
Frequency converter
weights
[kg/lbs]
Maximum
weight 353/777 413/910 676/1490 1900/4189
Shipping weight 416/917 476/1050 840/1851 2345/5171
Table 1.1 Mechanical Dimensions, Enclosure Sizes D, E and F
1.5 Approvals and Certications
1.5.1 Approvals
Table 1.2 Compliance Marks: CE, UL, and C-Tick
1.5.2 Compliance with ADN
For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation in the
Design Guide.
1.6 Harmonics Overview
1.6.1 Harmonics
Non-linear loads such as found with 6-pulse frequency
converters do not draw current uniformly from the power
line. This non-sinusoidal current has components which are
multiples of the fundamental current frequency. These
components are referred to as harmonics. It is important to
control the total harmonic distortion on the mains supply.
Although the harmonic currents do not directly aect
electrical energy consumption, they generate heat in
wiring and transformers and can impact other devices on
the same power line.
1.6.2 Harmonic Analysis
Since harmonics increase heat losses, it is important to
design systems with harmonics in mind to prevent
overloading the transformer, inductors, and wiring.
When necessary, perform an analysis of the system
harmonics to determine equipment eects.
A non-sinusoidal current is transformed with a Fourier
series analysis into sine-wave currents at dierent
frequencies, that is, dierent harmonic currents INwith 50
Hz or 60 Hz as the fundamental frequency.
Abbreviation Description
f1Fundamental frequency (50 Hz or 60 Hz)
I1Current at the fundamental frequency
U1Voltage at the fundamental frequency
InCurrent at the nth harmonic frequency
UnVoltage at the nth harmonic frequency
n Harmonic order
Table 1.3 Harmonics-related Abbreviations
Fundamental
current (I1)
Harmonic current (In)
Current I1I5I7I11
Frequency
[Hz]
50 250 350 550
Table 1.4 Fundamental and Harmonic Currents
Current Harmonic current
IRMS I1I5I7I11-49
Input current 1.0 0.9 0.5 0.2 < 0.1
Table 1.5 Harmonic Currents Compared to the RMS Input
Current
Introduction Operating Instructions
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The voltage distortion on the mains supply voltage
depends on the size of the harmonic currents multiplied
by the mains impedance for the frequency in question. The
total voltage distortion (THDi) is calculated based on the
individual voltage harmonics using this formula:
THDi =U25 + U27 + ... + U2n
U
1.6.3 Eect of Harmonics in a Power
Distribution System
In Figure 1.10, a transformer is connected on the primary
side to a point of common coupling PCC1, on the medium
voltage supply. The transformer has an impedance Zxfr and
feeds a number of loads. The point of common coupling
where all loads are connected is PCC2. Each load is
connected through cables that have an impedance Z1, Z2,
Z3.
PCC Point of common coupling
MV Medium voltage
LV Low voltage
Zxfr Transformer impedance
Z#Modeling resistance and inductance in the
wiring
Figure 1.10 Small Distribution System
Harmonic currents drawn by non-linear loads cause
distortion of the voltage because of the voltage drop on
the impedances of the distribution system. Higher
impedances result in higher levels of voltage distortion.
Current distortion relates to apparatus performance and it
relates to the individual load. Voltage distortion relates to
system performance. It is not possible to determine the
voltage distortion in the PCC knowing only the harmonic
performance of the load. To predict the distortion in the
PCC, the conguration of the distribution system and
relevant impedances must be known.
A commonly used term for describing the impedance of a
grid is the short-circuit ratio Rsce. Rsce is dened as the ratio
between the short circuit apparent power of the supply at
the PCC (Ssc) and the rated apparent power of the load
(Sequ).
Rsce =Ssc
Sequ
where Ssc =U2
Zsupply
and Sequ =U×Iequ
Negative eects of harmonics
•Harmonic currents contribute to system losses (in
cabling, transformer).
•Harmonic voltage distortion causes disturbance
to other loads and increase losses in other loads.
Introduction VLT®HVAC Drive FC 102 Low Harmonic Drive
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1.6.4 IEC Harmonic Standards
The mains voltage is rarely a uniform sinusoidal voltage with constant amplitude and frequency because loads that draw
non-sinusoidal currents from the mains have non-linear characteristics.
Harmonics and voltage uctuations are two forms of low-frequency mains interference. They have a dierent appearance at
their origin than at any other point in the mains system when a load is connected. So, a range of inuences must be
determined collectively when assessing the eects of mains interference. These inuences include the mains feed, structure,
and loads.
Mains interference can cause the following:
Undervoltage warnings
•Incorrect voltage measurements due to distortion of the sinusoidal mains voltage.
•Cause incorrect power measurements because only RMS-true measuring takes harmonic content into account.
Higher functional losses
•Harmonics reduce the active power, apparent power, and reactive power.
•Distort electrical loads resulting in audible interference in other devices, or in worst case, even destruction.
•Shorten the lifetime of devices as a result of heating.
In most of Europe, the basis for the objective assessment of the quality of mains power is the Electromagnetic Compatibility
of Devices Act (EMVG). Compliance with these regulations ensures that all devices and networks connected to electrical
distribution systems full their intended purpose without generating problems.
Standard Denition
EN 61000-2-2, EN 61000-2-4, EN 50160 Dene the mains voltage limits required for public and industrial power grids
EN 61000-3-2, 61000-3-12 Regulate mains interference generated by connected devices in lower current products
EN 50178 Monitors electronic equipment for use in power installations
Table 1.6 EN Design Standards for Mains Power Quality
There are 2 European standards that address harmonics in the frequency range from 0 Hz to 9 kHz:
EN 61000–2–2 (Compatibility Levels for Low-Frequency Conducted Disturbances and Signalling in Public Low-Voltage Power
Supply Systems) states the requirements for compatibility levels for PCC (point of common coupling) of low-voltage AC
systems on a public supply network. Limits are specied only for harmonic voltage and total harmonic distortion of the
voltage. EN 61000–2–2 does not dene limits for harmonic currents. In situations where the total harmonic distortion
THD(V)=8%, PCC limits are identical to those limits specied in the EN 61000–2–4 Class 2.
EN 61000–2–4 (Compatibility Levels for Low-Frequency Conducted Disturbances and Signalling in Industrial Plants) states the
requirements for compatibility levels in industrial and private networks. The standard further denes the following 3 classes
of electromagnetic environments:
•Class 1 relates to compatibility levels that are less than the public supply network, which aects equipment
sensitive to disturbances (lab equipment, some automation equipment, and certain protection devices).
•Class 2 relates to compatibility levels that are equal to the public supply network. The class applies to PCCs on the
public supply network and to IPCs (internal points of coupling) on industrial or other private supply networks. Any
equipment designed for operation on a public supply network is allowed in this class.
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•Class 3 relates to compatibility levels greater than the public supply network. This class applies only to IPCs in
industrial environments. Use this class where the following equipment is found:
-Large converters
-Welding machines
-Large motors starting frequently
-Loads that change quickly
Typically, a class cannot be dened ahead of time without taking into account the intended equipment and processes to be
used in the environment. VLT®HVAC Drive FC 102 Low Harmonic observes the limits of Class 3 under typical supply system
conditions (RSC>10 or Vk Line<10%).
Harmonic order (h) Class 1 (Vh%) Class 2 (Vh%) Class 3 (Vh%)
5 3 6 8
7 3 5 7
11 3 3.5 5
13 3 3 4.5
17 2 2 4
17˂h≤49 2.27 x (17/h) – 0.27 2.27 x (17/h) – 0.27 4.5 x (17/h) – 0.5
Table 1.7 Compatibility Levels for Harmonics
Class 1 Class 2 Class 3
THD(V) 5% 8% 10%
Table 1.8 Compatibility Levels for the Total Harmonic Voltage Distortion THD(V)
1.6.5 IEEE Harmonic Standards
The IEEE 519 standard (Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems)
provides specic limits for harmonic voltages and currents for individual components within the supply network. The
standard also provides limits for the sum of all loads at the point of common coupling (PCC).
To determine permissible harmonic voltage levels, IEEE 519 uses a ratio between the supply short-circuit current and the
maximum current of the individual load. For permissible harmonic voltage levels for individual loads, see Table 1.9. For
permissible levels for all loads connected to the PCC, see Table 1.10.
ISC/IL(RSCE) Permissible individual harmonic voltages Typical areas
10 2.5–3% Weak grid
20 2.0–2.5% 1–2 large loads
50 1.0–1.5% A few high-output loads
100 0.5–1% 5–20 medium-output loads
1000 0.05–0.1% Strong grid
Table 1.9 Permissible Voltage THD at the PCC for Each Individual Load
Voltage at the PCC Permissible individual harmonic voltages Permissible THD(V)
VLine≤69 kV 3% 5%
Table 1.10 Permissible Voltage THD at the PCC for all Loads
Introduction VLT®HVAC Drive FC 102 Low Harmonic Drive
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