Danfoss VLT HVAC User manual

Contents
1. Safety
3
Safety Instructions 3
General Warning 4
Before Commencing Repair Work 4
Special conditions 4
Avoid unintended Start. 6
Safe Stop of the Adjustable Frequency Drive 7
IT Line 8
2. Introduction 11
Type Code String 12
3. Mechanical installation 15
Before starting 15
How to install 17
4. Electrical installation 27
How to connect 27
Line power wiring overview 30
How to connect the motor - foreword 35
Motor wiring overview 36
Motor connection for C1 and C2 39
How to Test Motor and Direction of Rotation. 42
5. How to operate the adjustable frequency drive 49
Three means of operation 49
How to operate the Graphical LCP (GLCP) 49
How to operate numeric LCP (NLCP) 55
Tips and tricks 60
6. How to program the adjustable frequency drive 63
How to program 63
Parameter list 99
0-** Operation and Display 100
1-** Load/Motor 102
2-** Brakes 103
3-** Reference/Ramps 104
4-** Limits/Warnings 105
VLT
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HVAC Drive Instruction Manual Contents
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5-** Digital In/Out 106
6-** Analog In/Out 108
8-** Comm. and Options 110
9-** Profibus 111
10-**CAN Ser. Com. Bus 112
11-** LonWorks 113
13-** Smart Logic 114
14-** Special Functions 115
15-** FC Information 116
16-** Data Readouts 118
18-** Data Readouts 2 120
20-** FC Closed-loop 121
21-** Ext. Closed-loop 122
22-** Application Functions 124
23-** Timed Actions 126
25-** Cascade Controller 127
26-** Analog I/O Option MCB 109 129
7. Troubleshooting 131
133
8. Specifications 139
Specifications 139
Special Conditions 149
Purpose of derating 149
Automatic adaptations to ensure performance 151
Index
152
Contents VLT
®
HVAC Drive Instruction Manual
2 MG.11.A4.22 - VLT®is a registered Danfoss trademark

1. Safety
1.1.1. Symbols
Symbols used in this Instruction Manual.
NOTE
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high voltage warning.
＊Indicates a default setting
1.1.2. High Voltage Warning
The voltage of the adjustable frequency drive is dangerous whenever it is connected
to AC line power. Incorrect installation of the motor or adjustable frequency drive
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.
1.1.3. Safety Instructions
• Make sure the adjustable frequency drive is properly grounded.
• Do not remove line power connections, motor connections or other power connections
while the adjustable frequency drive is connected to line power.
• Protect users against supply voltage.
• Protect the motor against overloading in accordance with national and local regulations.
• Motor overload protection is included in the default settings. Parameter 1-90
Motor ther-
mal protection
is set to value ETR trip. For the North American market: ETR functions
provide class 20 motor overload protection, in accordance with NEC.
• The ground leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switch. It does not disconnect the adjustable frequency
drive from the line power.
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1.1.4. General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been dis-
connected from line power.
Also make sure that other voltage inputs have been disconnected (linkage of DC
intermediate circuit), as well as the motor connection for kinetic backup.
Before touching any potentially live parts of the VLT
®
HVAC Drive FC 100, wait at
least as long as follows:
200-240 V, 1.5-5 hp [1.1 - 3.7 kW]: wait at least 4 minutes.
200-240 V, 7.5-60 hp [5.5 - 45 kW]: wait at least 15 minutes.
380-480 V, 1.5-10 hp [1.1 - 7.5 kW]: wait at least 4 minutes.
380-480 V, 15-125 hp [11 - 90 kW]: wait at least 15 minutes.
525-600 V, 1.5-10 hp [1.1 - 7.5 kW]: wait at least 4 minutes.
A shorter time is allowed only if indicated on the nameplate for the specific unit.
Leakage Current
The ground leakage current from the VLT
®
HVAC Drive FC 100 exceeds 3.5 mA.
According to IEC 61800-5-1, a reinforced protective ground connection must be en-
sured by means of: a min. 0.015 in² [10 mm²] Cu or 0.025 in² [16 mm²] Al PE wire
or an additional PE wire, with the same cable cross-section as the line power wiring,
must be terminated separately.
Residual Current Device
This product can cause DC current in the protective conductor. If a residual current
device (RCD) is used for extra protection, only an RCD of Type B (time delayed) may
be used on the supply side of this product. See also RCD Application Note MN.90.GX.
02.
Protective grounding of the VLT
®
HVAC Drive FC 100 and the use of RCDs must
always follow national and local regulations.
1.1.5. Before Commencing Repair Work
1. Disconnect the adjustable frequency drive from the line power.
2. Disconnect DC bus terminals 88 and 89.
3. Wait at least as long as the time mentioned in section 2.1.2.
4. Remove motor cable.
1.1.6. Special conditions
Electrical ratings:
The rating indicated on the nameplate of the adjustable frequency drive is based on a typical 3-
phase line power supply within the specified voltage, current and temperature ranges, which are
expected to be used in most applications.
The adjustable frequency drives also support other special applications, which affect the electrical
ratings of the adjustable frequency drive.
Special conditions that affect the electrical ratings might be:
1. Safety VLT
®
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Single phase applications
High temperature applications which require de-rating of the electrical ratings
Marine applications with more severe environmental conditions
Other applications might also affect the electrical ratings.
Consult the relevant clauses in these instructions and in the
VLT® HVAC Drive Design Guide, MG.
11Bx.yy
for information about the electrical ratings.
Installation requirements:
The overall electrical safety of the adjustable frequency drive requires special installation consid-
erations regarding:
Fuses and circuit breakers for overcurrent and short-circuit protection
Selection of power cables (line, motor, brake, load sharing and relay)
Grid configuration (IT,TN, grounded leg, etc.)
Safety of low voltage ports (PELV conditions).
Consult the relevant clauses in these instructions and in the
VLT® HVAC Drive Design Guide for
information about the installation requirements.
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®
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1.1.7. Caution
Caution
The adjustable frequency drive DC link capacitors remain charged after power has been dis-
connected. To avoid the risk of electrical shock, disconnect the adjustable frequency drive
from line power before performing maintenance procedures. Wait at least as long as follows
before servicing the adjustable frequency drive:
Voltage Min. Waiting Time
4 min. 15 min.
200 - 240 V 1.5-5 hp [1.1-3.7 kW] 7.5-60 hp [5.5-45 kW]
380 - 480 V 1.5-10 hp [1.1-7.5 kW] 15-125 hp [11-90 kW]
525 - 600 V 1.5-10 hp [1.1-7.5 kW]
Be aware that there may be high voltage on the DC link even when the LEDs are turned off.
1.1.8. Installation at High Altitudes (PELV)
At altitudes above 6,600 feet [2 km], please contact Danfoss Drives regarding
PELV.
1.1.9. Avoid unintended Start.
While the adjustable frequency drive is connected to line power, the motor can be started/stopped
using digital commands, bus commands, references or via the Local Control Panel.
• Disconnect the adjustable frequency drive from line power whenever personal safety
considerations make it necessary to avoid unintended start.
• To avoid unintended start, always activate the [OFF] key before changing parameters.
• Unless terminal 37 is turned off, an electronic fault, temporary overload, a fault in the
line supply or lost motor connection may cause a stopped motor to start.
1. Safety VLT
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1.1.10. Safe Stop of the Adjustable Frequency Drive
For versions fitted with a safe stop terminal 37 input, the adjustable frequency drive 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 deemed suitable for the requirements of Safety Category 3 in EN 954-1. This
functionality is called Safe Stop. Prior to integrating and using safe stop in an installation, a thor-
ough risk analysis must be carried out on the installation 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 VLT HVAC Drive Design Guide MG.11.BX.YY must be
followed! The information and instructions contained in the Instruction Manual are not sufficient
for a correct and safe use of the safe stop functionality!
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®
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130BA491
Illustration 1.1: This certificate also covers FC 102 and FC 202!
1.1.11. IT Line
IT Line
Do not connect 400 V adjustable frequency drives with RFI filters to line supplies
with a voltage between phase and ground of more than 440 V.
For IT lines and delta ground (grounded leg), line voltage may exceed 440 V be-
tween phase and ground.
Par. 14-50 RFI 1 can 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.
1. Safety VLT
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1.1.12. Software Version and Approvals: VLT HVAC Drive
VLT HVAC Drive
Instruction Manual
Software version: 2.0X
This Instruction Manual can be used for all VLT HVAC Drive adjustable frequency drives with
software version 2.0X.
The software version number can be seen in parameter 15-43.
1.1.13. Disposal Instructions
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.
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®
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2. Introduction VLT
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2. Introduction
2.1. Introduction
2.1.1. Adjustable Frequency Drive Identification
Below is an example of an identification label. This label is situated on the adjustable frequency
drive and shows the type and the options the unit is equipped with. See table 2.1 for details of
how to read theType code string (T/C).
Illustration 2.1: This example shows an identification label.
NOTE
Please have T/C (type code) number and serial number ready before contacting
Danfoss.
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2.1.2. Type Code String
Description Pos Possible choice
Product group & VLT Series 1-6 FC 102
Power rating 8-10 1.5-125 hp [1.1-90 kW] (1K1-90K)
Number of phases 11 Three phases (T)
AC line voltage 11-12
T 2: 200-240 V AC
T 4: 380-480 V AC
T 6: 525-600 V AC
Enclosure 13-15
E20: IP 20
E21: IP 21/NEMA Type 1
E55: IP 55/NEMA Type 12
E66: IP 66
P21: IP 21/NEMA Type 1 w/backplate
P55: IP 55/NEMA Type 12 w/backplate
RFI filter 16-17
H1: RFI filter class A1/B
H2: Class A2
H3:RFI filter A1/B (reduced cable length)
Brake 18
X: No brake chopper included
B: Brake chopper included
T: Safe Stop
U: Safe + brake
Display 19
G: Graphical Local Control Panel (GLCP)
N: Numeric Local Control Panel (NLCP)
X: No Local Control Panel
Coating PCB 20 X. No coated PCB
C: Coated PCB
Line option 21 X: No line power disconnect switch
1: With line power disconnect switch (IP55 only)
Adaptation 22 Reserved
Adaptation 23 Reserved
Software release 24-27 Current software
Software language 28
A options 29-30
AX: No options
A0: MCA 101 Profibus DP V1
A4: MCA 104 DeviceNet
AG: MCA 108 LON works
AJ: MCA 109 BAC Net
B options 31-32
BX: No option
BK: MCB 101 General purpose I/O option
BP: MCB 105 Relay option
BO:MCB 109 Analog I/O option
C0 options MCO 33-34 CX: No options
C1 options 35 X: No options
C option software 36-37 XX: Standard software
D options 38-39 DX: No option
D0: DC backup
Table 2.1: Type code description.
The various options are described further in the VLT® HVAC Drive Design Guide, MG.11.Bx.yy .
2. Introduction VLT
®
HVAC Drive Instruction Manual
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2.1.3. Abbreviations and Standards
Terms: Abbreviations: SI units: I-P units:
Acceleration m/s² ft/s²
Alternating current AC A Amp
American wire gauge AWG
Area m² in², ft²
Automatic Motor Adaptation AMA
Centigrade °C
Current A Amp
Current limit I
LIM
Direct current DC AAmp
Drive Type Dependent D-TYPE
Electronic Thermal Relay ETR
Energy J = N·m ft-lb, Btu
Fahrenheit ˚F
Force N lb
Adjustable Frequency Drive FC
Frequency Hz Hz
Graphical Local Control Panel GLCP
Heat transfer coefficient W/m²·K Btu/hr·ft²·˚F
Kelvin ˚K
Kilohertz kHz
KiloVoltAmpere KVA
Length m inch, in, foot,
ft
Local Control Panel LCP
Mass kg pound, lb
Milliampere mA
Millisecond ms
Minute min
Motion Control Tool MCT
Motor Type Dependent M-TYPE
Nanofarad nF
Newton meters Nm
Nominal motor current I
M,N
Nominal motor frequency f
M,N
Nominal motor power P
M,N
Nominal motor voltage U
M,N
Numeric Local Control Panel NLCP
Parameter par.
Protective Extra Low Voltage PELV
Power W Btu/hr, hp
Pressure Pa = N/m² psi, psf, ft of
water
Rated Inverter Output Current I
INV
Revolutions Per Minute RPM
Size Related SR
Temperature ˚C ˚F
Time s s, hr
Torque limit T
LIM
Velocity m/s fps, fpm, fph
Voltage V V
Volume m³ in³, ft³
Table 2.2: Abbreviation and Standards table
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3. Mechanical installation VLT
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3. Mechanical installation
3.1. Before starting
3.1.1. Checklist
When unpacking the adjustable frequency drive, make sure that the unit is undamaged and com-
plete. Use the following table to identify the packaging:
Enclosure
type:
A2
(IP 20/IP
21)
A3
(IP 20/IP
21)
A5
(IP 55/IP
66)
B1
(IP 21/IP
55/IP 66)
B2
(IP 21/IP
55/IP
66)
C1
(IP21/IP
55/66)
C2
(IP21/IP
55/66)
Unit size:
200-240 V 1.1-3.0
kW
3.7
kW
1.1-3.7
kW
5.5-11
kW
15
kW
18.5 - 30
kW
37 - 45
kW
380-480 V 1.1-4.0
kW
7.5-10 hp
[5.5-7.5
kW]
1.1-7.5
kW
11-18.5
kW
22-30
kW
37 - 55
kW
75 - 90
kW
525-600 V 1.1-4.0
kW
5.5-7.5
kW
Table 3.1: Unpacking table
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Please note that it is recommended to have a selection of screwdrivers (phillips or cross-thread
screwdriver and torx), a side-cutter, drill and knife handy for unpacking and mounting the ad-
justable frequency drive. The packaging for these enclosures contains, as shown: Accessories bag
(s), documentation and the unit. Depending on options fitted, there may be one or two bags and
one or more booklets.
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®
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3.2. How to install
3.2.1. Mounting
The Danfoss VLT
®
series can be mounted side by side for all IP rating units but require 3.4 in.
[100 mm] free space above and below for cooling. With regard to ambient temperature ratings,
please see the chapter
Specifications , section Special Conditions .
Illustration 3.1: Side-by-side mounting of all frame sizes.
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®
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Illustration 3.2: This is the correct way to mount
the unit.
Illustration 3.3: Other than A2 and A3 enclosures,
do not mount units as shown without backplate.
Cooling will be insufficient and service life can be
drastically shortened.
Illustration 3.4: If the unit must be mounted only
a small distance from the wall, please order the
backplate with the unit (see Ordering type code
position 14-15). A2 and A3 units are equipped with
the backplate by default.
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Please use the following table for the mounting instructions
Enclo-
sure: A2 (IP 20/
IP 21)
A3 (IP 20/
IP 21)
A5 (IP 55/
IP 66)
B1 (IP 21/
IP 55/IP
66)
B2 (IP 21/
IP 55/IP
66)
C1 (IP 21/
IP 55/66)
C2 (IP 21/
IP 55/66)
Unit size:
200-240 V 1.1-3.0
kW
3.7
kW
1.1-3.7
kW
5.5-11
kW
15
kW
18.5 - 30
kW
37 - 45
kW
380-480 V 1.1-4.0
kW
5.5-7.5
kW
1.1-7.5
kW
11-18.5
kW
22-30
kW
37 - 55
kW
75 - 90
kW
525-600 V 1.1-4.0
kW
5.5-7.5
kW
Table 3.2: Mounting table.
3.2.2. Mounting A2 and A3
Illustration 3.5: Drilling of holes
Step 1: Drill according to the dimensions in the
following table.
Illustration 3.6: Correct mounting of screws.
Step 2A: This way it is easy to hang the unit
on the screws.
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®
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Illustration 3.7: Incorrect mounting of screws.
Step 2B: Do not tighten screws completely.
Illustration 3.8: Mounting of unit
Step 3: Lift the unit onto the screws.
Illustration 3.9: Tightening of screws
Step 4: Tighten the screws completely.
3. Mechanical installation VLT
®
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