Danfoss VLT HVAC FC 100 User manual

Contents
1. How to Read these Operating Instructions
5
How to Read these Operating Instructions 5
Approvals 6
Symbols 6
Abbreviations 7
2. Safety Instructions and General Warning 9
Safety Regulations FC 100 9
Disposal Instruction 9
High Voltage 10
Safety Instructions 10
Avoid Unintended Start 11
Safe Stop 11
Safe Stop Installation 12
IT Mains 12
3. How to Install 13
How to Get Started 13
Pre-installation - High Power 14
Planning the Installation Site 14
Receiving the Frequency Converter 14
Transportation and Unpacking 14
Lifting 15
Enclosures 16
Rated Power 16
Mechanical Dimensions 17
Mechanical Installation 17
Tools Needed 17
General Considerations 18
Installation in Enclosures - IP00 / Chassis units 27
Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units 27
Floor Mounting - Pedestal Installation IP21 (NEMA1) and IP54 (NEMA12) 28
Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 30
IP21 Drip shield installation (D1 and D2 enclosure) 31
Field Installation of Options 31
Installation on pedestal 41
Electrical Installation 44
Control Wires 44
Power Connections 45
VLT
®
HVAC DRIVE High Power
Operating Instruction Contents
MG.11.F1.02 - VLT®is a registered Danfoss trademark 1

Mains connection 53
Fuses 54
Electrical Installation, Control Terminals 56
Connection Examples 58
Start/Stop 58
Pulse Start/Stop 58
Speed Up/Down 59
Potentiometer Reference 59
Electrical Installation - continued 60
Electrical Installation, Control Cables 60
Switches S201, S202, and S801 62
Final Set-up and Test 63
Additional Connections 65
Motor Thermal Protection 65
4. How to Programme 67
Graphical (GLCP) and Numerical (NLCP) Display 67
How to Programme on the Graphical LCP 67
How to Programme on the Numerical Local Control Panel 68
Quick Set-up 69
Parameter Descriptions 76
Parameter Options 78
Default settings 78
0-** Operation and Display 79
1-** Load / Motor 81
2-** Brakes 82
3-** Reference / Ramps 83
4-** Limits / Warnings 84
5-** Digital In / Out 85
6-** Analog In / Out 87
8-** Communication and Options 89
9-** Profibus 91
10-**CAN Fieldbus 92
11-** LonWorks 93
13-** Smart Logic Controller 94
14-** Special Functions 95
15-** FC Information 96
16-** Data Readouts 98
18-** Info & Readouts 100
20-** FC Closed Loop 101
Contents
VLT
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HVAC DRIVE High Power
Operating Instruction
2 MG.11.F1.02 - VLT®is a registered Danfoss trademark

21-** Ext. Closed Loop 102
22-** Application Functions 104
23-** Time Based Funtions 106
24-** Application Functions 2 107
25-** Cascade Controller 108
26-** Analog I / O Option MCB 109 110
5. General Specifications 111
6. Warnings and Alarms 119
Alarm- and Status Messages 119
7. Annexes 125
Index
131
VLT
®
HVAC DRIVE High Power
Operating Instruction Contents
MG.11.F1.02 - VLT®is a registered Danfoss trademark 3

1. How to Read these Operating Instructions
VLT
®
HVAC DRIVE High Power
Operating Instruction
4 MG.11.F1.02 - VLT®is a registered Danfoss trademark
1

1. How to Read these Operating Instructions
1.1. How to Read these Operating Instructions
1.1.1. How to Read these Operating Instructions
VLT
®
HVAC Drive FC 100 is designed to provide high shaft performance on electrical motors.
Please read this manual carefully for proper use. Incorrect handling of the frequency converter
may cause improper operation of the frequency converter or related equipment, shorten lifetime
or cause other troubles.
These Operating Instructions will help you get started, install, program, and troubleshoot your
VLT
®
HVAC Drive FC 100.
Chapter 1, How to Read these Operating
Instructions
Introduces the manual and informs you about the approvals, symbols, and abbreviations used in
this literature.
Chapter 2, Safety Instructions and Gen-
eral Warnings
Entails instructions on how to handle the FC 100 correctly.
Chapter 3, How to Install
Guides you through mechanical and technical installation.
Chapter 4, How to Programme
Shows you how to operate and programme the FC 100 via the Local Control Panel.
Chapter 5, General Specifications
Contains technical data about FC 100.
Chapter 6, Troubleshooting
Assists you in solving problems that may occur when using FC 100.
Available literature for VLT HVAC Drive
-Operating Instructions MG.11.Ax.yy provide the neccessary information for getting the
drive up and running.
-Design Guide MG.11.Bx.yy entails all technical information about the drive and customer
design and applications.
-Programming Guide MG.11.Cx.yy provides information on how to programme and in-
cludes complete parameter descriptions.
-Mounting Instruction, Analog I/O Option MCB109, MI.38.Bx.yy
-VLT
®
6000 HVAC Application Booklet, MN.60.Ix.yy
-Operating Instructions VLT
®
HVAC Drive BACnet, MG.11.Dx.yy
-Operating Instructions VLT
®
HVAC Drive Profibus, MG.33.Cx.yy.
-Operating Instructions VLT
®
HVAC Drive Device Net, MG.33.Dx.yy
-Operating Instructions VLT
®
HVAC Drive LonWorks, MG.11.Ex.yy
-Operating Instructions VLT
®
HVAC Drive High Power, MG.11.Fx.yy
-Operating Instructions VLT
®
HVAC Drive Metasys, MG.11.Gx.yy
x = Revision number
yy = Language code
VLT
®
HVAC DRIVE High Power
Operating Instruction 1. How to Read these Operating Instructions
MG.11.F1.02 - VLT®is a registered Danfoss trademark 5
1

Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/
DrivesSolutions/Documentations/Technical+Documentation
.
Danfoss Drives technical literature is also available online at www.danfoss.com/drives.
1.1.2. Approvals
1.1.3. Symbols
Symbols used in these Operating Instructions.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
∗Indicates default setting
1. How to Read these Operating Instructions
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HVAC DRIVE High Power
Operating Instruction
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1.1.4. Abbreviations
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
drive FC
Gram g
Hertz Hz
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
Parameter par.
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Rated Inverter Output Current IINV
Revolutions Per Minute RPM
Second s
Torque limit TLIM
Volts V
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®
HVAC DRIVE High Power
Operating Instruction 1. How to Read these Operating Instructions
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1

2. Safety Instructions and General Warning
VLT
®
HVAC DRIVE High Power
Operating Instruction
8 MG.11.F1.02 - VLT®is a registered Danfoss trademark
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2. Safety Instructions and General Warning
2.1. Safety Regulations FC 100
2.1.1. 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.
Caution
The frequency converter DC link capacitors remain charged after power has been disconnec-
ted. To avoid electrical shock hazard, disconnect the frequency converter from the mains
before carrying out maintenance. Before doing service on the frequency converter wait at
least the amount of time indicated below:
380 - 480 V 110 - 200 kW 20 minutes
250 - 450 kW 40 minutes
525 - 600 V 110 - 250 kW 20 minutes
315 - 560 kW 30 minutes
VLT HVAC Drive
Software version: 2.5x
These instructions can be used for all VLT HVAC frequency converters with software version
2.5x.
The software version number can be seen from parameter 15-43.
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®
HVAC DRIVE High Power
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2.1.2. High Voltage
The voltage of the frequency converter is dangerous whenever the frequency con-
verter is connected to mains. Incorrect installation or operation of the motor or
frequency converter may cause damage to the equipment, serious personal injury
or death. The instructions in this manual must consequently be observed, as well as
applicable local and national rules and safety regulations.
Installation in high altitudes
At altitudes above 2 km, please contact Danfoss Drives regarding PELV.
2.1.3. Safety Instructions
• Make sure the frequency converter is properly connected to earth.
• Protect users against supply voltage.
• Protect the motor against overloading according to national and local regulations.
• Motor overload protection is not included in the default settings. To add this function,
set parameter 1-90
Motor thermal protection to value ETR trip or ETR warning . For the
North American market: ETR functions provide class 20 motor overload protection, in
accordance with NEC.
• The earth leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switch. It does not disconnect the frequency converter from
mains.
2.1.4. General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been dis-
connected from mains.
Also make sure that other voltage inputs have been disconnected, such as load-
sharing (linkage of DC intermediate circuit), as well as the motor connection for
kinetic back-up.
When using the frequency converter: wait at least 40 minutes.
Shorter time is allowed only if indicated on the nameplate for the specific unit.
Leakage Current
The earth leakage current from the frequency converter exceeds 3.5 mA. To ensure
that the earth cable has a good mechanical connection to the earth connection (ter-
minal 95), the cable cross section must be at least 10 mm
2
or 2 rated earth wires
terminated separately.
Residual Current Device
This product can cause a D.C. current in the protective conductor. Where a residual
current device (RCD) is used for extra protection, only an RCD of Type B (time de-
layed) shall be used on the supply side of this product. See also RCD Application
Note MN.90.Gx.02 (x=version number).
Protective earthing of the frequency converter and the use of RCD's must always
follow national and local regulations.
2. Safety Instructions and General Warning
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®
HVAC DRIVE High Power
Operating Instruction
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2.1.5. Before Commencing Repair Work
1. Disconnect the frequency converter from mains
2. Wait for discharge of the DC-link. See period of time on the warning label.
3. Disconnect DC bus terminals 88 and 89
4. Remove motor cable
2.1.6. Avoid Unintended Start
While the frequency converter is connected to mains, the motor can be started/stop-
ped using digital commands, bus commands, references or via the Local Control Panel
(LCP):
• Disconnect the frequency converter from mains whenever personal safety considerations
make it necessary to avoid unintended start.
• To avoid unintended start, always activate the [OFF] key before changing parameters.
• An electronic fault, temporary overload, a fault in the mains supply, or lost motor con-
nection may cause a stopped motor to start. The frequency converter with Safe Stop
provides protection against unintended start, if the Safe Stop Terminal 37 is deactivated
or disconnected.
2.1.7. Safe Stop
The frequency converter can perform the safety function Safe Torque Off (As defined by draft CD
IEC 61800-5-2) or
Stop Category 0 (as defined in EN 60204-1).
It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This
functionality is called Safe Stop. Prior to integration and use of Safe Stop in an installation, a
thorough risk analysis on the installation must be carried out in order to determine whether the
Safe Stop functionality and safety category are appropriate and sufficient. In order to install and
use the Safe Stop function in accordance with the requirements of Safety Category 3 in EN 954-1,
the related information and instructions of the relevant Design Guide must be followed! The in-
formation and instructions of the Operating Instructions are not sufficient for a correct and safe
use of the Safe Stop functionality!
Illustration 2.1: Diagram showing all electrical terminals. (Terminal 37 present for units with Safe Stop Func-
tion only.)
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Operating Instruction 2. Safety Instructions and General Warning
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2.1.8. Safe Stop Installation
To carry out an installation of a Catego-
ry 0 Stop (EN60204) in conformity with
Safety Category 3 (EN954-1), follow
these instructions:
1. The bridge (jumper) between Termi-
nal 37 and 24 V DC must be re-
moved. Cutting or breaking the
jumper is not sufficient. Remove it
entirely to avoid short-circuiting. See
jumper on illustration.
2. Connect terminal 37 to 24 V DC by a
short-circuit protected cable. The 24
V DC voltage supply must be inter-
ruptible by an EN954-1 Category 3
circuit interrupt device. If the inter-
rupt device and the frequency con-
verter are placed in the same instal-
lation panel, you can use an
unscreened cable instead of a
screened one.
Illustration 2.2: Bridge jumper between terminal
37 and 24 VDC
The illustration below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN
954-1). The circuit interrupt is caused by an opening door contact. The illustration also shows how
to connect a non-safety related hardware coast.
Illustration 2.3: Illustration of the essential aspects of an installation to achieve a Stopping Category 0 (EN
60204-1) with safety Category 3 (EN 954-1).
2.1.9. IT Mains
Par. 14-50 RFI 1 can on FC 102/202/302 be used to disconnect the internal RFI capacitors from
the RFI filter to ground. If this is done it will reduce the RFI performance to A2 level.
2. Safety Instructions and General Warning
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HVAC DRIVE High Power
Operating Instruction
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3. How to Install
3.1. How to Get Started
3.1.1. About How to Install
This chapter covers mechanical and electrical installations to and from power terminals and control
card terminals.
Electrical installation of
options is described in the relevant Operating Instructions and Design
Guide.
3.1.2. How to Get Started
The frequency converter is designed to achieve a quick and EMC-correct installation by following
the steps described below.
Read the safety instructions before installing the unit.
Mechanical Installation
• Mechanical mounting
Electrical Installation
• Connection to Mains and Protecting
Earth
• Motor connection and cables
• Fuses and circuit breakers
• Control terminals - cables
Quick setup
• Local Control Panel, LCP
• Automatic Motor Adaptation, AMA
• Programming
Frame size is depending on enclosure type,
power range and mains voltage
Illustration 3.1: Diagram showing basic installa-
tion including mains, motor, start/stop key, and
potentiometer for speed adjustment.
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3.2. Pre-installation - High Power
3.2.1. Planning the Installation Site
NB!
Before performing the installation it is important to plan the installation of the fre-
quency converter. Neglecting this may result in extra work during and after instal-
lation.
Select the best possible operation site by considering the following (see details on
the following pages, and the respective Design Guides):
• Ambient operating temperature
• Installation method
• How to cool the unit
• Position of the frequency converter
•Cablerouting
• Ensure the power source supplies the correct voltage and necessary current
• Ensure that the motor current rating is within the maximum current from the frequency
converter
• If the frequency converter is without built-in fuses, ensure that the external fuses are
rated correctly.
3.2.2. Receiving the Frequency Converter
When receiving the frequency converter please make sure that the packaging is intact, and be
aware of any damage that might have occurred to the unit during transport. In case damage has
occurred, contact immediately the shipping company to claim the damage.
3.2.3. Transportation and Unpacking
Before unpacking the frequency converter it is recommended that it is located as close as possible
to the final installation site.
Remove the cardboard box and handle the frequency converter on the pallet, as long as possible.
Remark: The card box cover contains a drilling master for the mounting holes.
3. How to Install
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Illustration 3.2: Mounting Template
3.2.4. Lifting
Always lift the frequency converter in the dedicated lifting eyes. Use a bar to avoid bending the
lifting holes of the frequency converter.
Illustration 3.3: Recommended lifting method
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3.3. Enclosures
3.3.1. Rated Power
Enclosure type
D1 D2 D3 D4
Enclosure
protection
IP 21/54 21/54 00 00
NEMA Type 1/ Type 12 Type 1/ Type 12 Chassis Chassis
Rated
power
110 - 132 kW at 400
V
(380 - 480 V)
110 - 132 kW at 600
V
(525-600 V)
160 - 250 kW at 400
V
(380 - 480 V)
160 - 315 kW at 600
V
(525-600 V)
110 - 132 kW at 400
V
(380 - 480 V)
110 - 132 kW at 600
V
(525-600 V)
160 - 250 kW at 400
V
(380 - 480 V)
160 - 315 kW at 600
V
(525-600 V)
Enclosure type
E1 E2
Enclosure
protection
IP 21/54 00
NEMA Type 1/ Type 12 Chassis
Rated
power
315 - 450 kW at 400 V
(380 - 480 V)
355 - 560 kW at 600 V
(525-600 V)
315 - 450 kW at 400 V
(380 - 480 V)
355 - 560 kW at 600 V
(525-600 V)
3. How to Install
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HVAC DRIVE High Power
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3.3.2. Mechanical Dimensions
Mechanical dimensions , D Enclosures
Frame size D1 D2 D3 D4
110 - 132 kW
(380 - 480 V)
110 - 132 kW
(525-600 V)
160 - 250 kW
(380 - 480 V)
160 - 315 kW
(525-600 V)
110 -
132 kW
(380 -
480 V)
110 -
132 kW
(525-60
0 V)
160 -
250 kW
(380 -
480 V)
160 -
315 kW
(525-60
0 V)
IP
NEMA 21
Type 1
54
Type 12
21
Type 1
54
Type 12
00
Chassis
00
Chassis
Card board box
size
Shipping di-
mensions
Height
650 mm 650 mm 650 mm 650 mm 650 mm 650 mm
Width 1730 mm 1730 mm 1730 mm 1730 mm 1220 mm 1490 mm
Depth 570 mm 570 mm 570 mm 570 mm 570 mm 570 mm
Drive
dimensions Height 1159 mm 1159 mm 1540 mm 1540 mm 997 mm 1277 mm
Width 420 mm 420 mm 420 mm 420 mm 408 mm 408 mm
Depth 373 mm 373 mm 373 mm 373 mm 373 mm 373 mm
Max weight 104 kg 104 kg 151 kg 151 kg 91 kg 138 kg
Mechanical dimensions, E Enclosures
Frame size E1 E2
315 - 450 kW
(380 - 480 V)
355 - 560 kW
(525-600 V)
315 - 450 kW
(380 - 480 V)
355 - 560 kW
(525-600 V)
IP
NEMA 21 Type 12
54
Type 12
00
Chassis
Card board
box size
Shipping
dimensions
Height 840 mm 840 mm 831 mm
Width 2197 mm 2197 mm 1705 mm
Depth 736 mm 736 mm 736 mm
Drive
dimensions Height 2000 mm 2000 mm 1499 mm
Width 600 mm 600 mm 585 mm
Depth 494 mm 494 mm 494 mm
Max weight 313 kg 313 kg 277 kg
3.4. Mechanical Installation
Preparation of the mechanical installation of the frequency converter must be done carefully to
ensure a proper result and to avoid additional work during installation. Start taking a close look
at the mechanical drawings at the end of this instruction to become familiar with the space de-
mands.
3.4.1. Tools Needed
To perform the mechanical installation the following tools are needed:
• Drill with 10 or 12 mm drill
• Tape measure
• Wrench with relevant metric sockets (7-17 mm)
• Extensions to wrench
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• Sheet metal punch for conduits or cable glands in IP 21 and IP 54 units
• Lifting bar to lift the unit (rod or tube Ø 20 mm (0.75 inch)) able to lift minimum 400 kg
(880 lbs).
• Crane or other lifting aid to place the frequency converter in position
• A Torx T50 tool is needed to install the E1 enclosure in IP21 and IP54 enclosure types.
3.4.2. General Considerations
Space
Ensure proper space above and below the frequency converter to allow airflow and cable access.
In addition space in front of the unit must be considered to enable opening of the door of the
panel.
Illustration 3.4: Space in front of IP21/IP54 enclo-
sure type D1 and D2.
Illustration 3.5: Space in front of IP21/IP54 enclo-
sure type E1.
Illustration 3.6: Airflow direction and necessary space for cooling
Left: Enclosure IP21/54, D1 and D2.
3. How to Install
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Right: Enclosure IP00, D3, D4 and E2.
Illustration 3.7: Airflow direction and necessary space for cooling - Enclosure IP21/54, E1
Wire access
Ensure that proper cable access is present including necessary bending allowance. As the IP00
enclosure is open to the bottom cables must be fixed to the back panel of the enclosure where
the frequency converter is mounted, i.e. by using cable clamps.
Terminal locations
(D1 and D2 enclosures)
Take the following position of the terminals into consideration when you design for cables access.
Illustration 3.8: Position of power connections
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Illustration 3.9: Position of power connections - Disconnect
Be aware that the power cables are heavy and hard to bend. Consider the optimum position of
the frequency converter for ensuring easy installation of the cables.
IP 21 (NEMA 1) / IP 54 (NEMA 12) IP 00 / Chassis
Enclosure D1 Enclosure D2 Enclosure D3 Enclosure D4
A 277 (10.9) 379 (14.9) 119 (4.7) 122 (4.8)
B227 (8.9) 326 (12.8) 68 (2.7) 68 (2.7)
C 173 (6.8) 273 (10.8) 15 (0.6) 16 (0.6)
D179 (7.0) 279 (11.0) 20.7 (0.8) 22 (0.8)
E 370 (14.6) 370 (14.6) 363 (14.3) 363 (14.3)
F300 (11.8) 300 (11.8) 293 (11.5) 293 (11.5)
G 222 (8.7) 226 (8.9) 215 (8.4) 218 (8.6)
H139 (5.4) 142 (5.6) 131 (5.2) 135 (5.3)
I 55 (2.2) 59 (2.3) 48 (1.9) 51 (2.0)
J354 (13.9) 361 (14.2) 347 (13.6) 354 (13.9)
K 284 (11.2) 277 (10.9) 277 (10.9) 270 (10.6)
L334 (13.1) 334 (13.1) 326 (12.8) 326 (12.8)
M 250 (9.8) 250 (9.8) 243 (9.6) 243 (9.6)
N167 (6.6) 167 (6.6) 159 (6.3) 159 (6.3)
O 261 (10.3) 260 (10.3) 261 (10.3) 261 (10.3)
P170 (6.7) 169 (6.7) 170 (6.7) 170 (6.7)
Q 120 (4.7) 120 (4.7) 120 (4.7) 120 (4.7)
R256 (10.1) 350 (13.8) 98 (3.8) 93 (3.7)
S 308 (12.1) 332 (13.0) 301 (11.8) 324 (12.8)
T252 (9.9) 262 (10.3) 245 (9.6) 255 (10.0)
U 196 (7.7) 192 (7.6) 189 (7.4) 185 (7.3)
V260 (10.2) 273 (10.7) 260 (10.2) 273 (10.7)
Table 3.1: Cable positions as shown in drawings above. Dimensions in mm (inch).
3. How to Install
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