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 Frequency Converter 7
IT Mains 8
2. Introduction 9
Type Code String 10
3. Mechanical installation 13
Before starting 13
How to install 14
4. Electrical installation 21
How to connect 21
Mains wiring overview 24
How to connect motor - foreword 28
Motor wiring overview 30
Motor connection for C1 and C2 33
How to Test Motor and Direction of Rotation. 35
5. How to operate the frequency converter 41
Three ways of operating 41
How to operate graphical LCP (GLCP) 41
How to operate numeric LCP (NLCP) 47
Tips and tricks 52
6. How to programme the frequency converter 55
How to programme 55
Initialisation to Default Settings 86
Parameter list 88
0-** Operation and Display 89
1-** Load/Motor 91
2-** Brakes 92
3-** Reference/Ramps 93
4-** Limits/Warnings 94
5-** Digital In/Out 95
6-** Analog In/Out 97
VLT
®
HVAC Drive Operating Instructions Contents
MG.11.A4.02 - 09.10.06. VLT®is a registered Danfoss trademark 1

8-** Comm. and Options 99
9-** Profibus 100
10-**CAN Fieldbus 101
11-** LonWorks 102
13-** Smart Logic 103
14-** Special Functions 104
15-** FC Information 105
16-** Data Readouts 107
18-** Data Readouts 2 109
20-** FC Closed Loop 110
21-** Ext. Closed Loop 111
22-** Application Functions 113
23-** Timed Actions 115
25-** Cascade Controller 116
26-** Analog I/O Option MCB 109 118
7. Troubleshooting 121
Warning/Alarm list 123
8. Specifications 129
General Specifications 129
Special Conditions 138
Purpose of derating 138
Automatic adaptations to ensure performance 141
Index
142
Contents VLT
®
HVAC Drive Operating Instructions
2 MG.11.A4.02 - 09.10.06. VLT®is a registered Danfoss trademark

1. Safety
1.1.1. Symbols
Symbols used in this Operating Instructions.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
* Indicates default setting
1.1.2. High Voltage Warning
The voltage of the frequency converter is dangerous whenever it is connected to
mains. Incorrect installation of the motor or frequency converter may cause damage
to the equipment, serious injury or death. Consequently, it is essential to comply
with the instructions in this manual as well as local and national rules and safety
regulations.
Installation at high altitudes:
At altitudes above 2 km, please contact Danfoss Drives regarding PELV.
1.1.3. Safety Instructions
• Make sure the frequency converter is properly connected to earth.
• Do not remove mains connections, motor connections or other power connections while
the frequency converter is connected to mains.
• Protect users against supply voltage.
• Protect the motor against overloading according to 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 earth leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switch. It does not disconnect the frequency converter from
mains.
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®
HVAC Drive Operating Instructions 1. Safety
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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 mains.
Also make sure that other voltage inputs have been disconnected, (linkage of DC
intermediate circuit), as well as the motor connection for kinetic back-up.
Before touching any potentially live parts of the VLT
®
HVAC Drive FC 100, wait at
least as follows:
200 - 240 V, 1.1 - 3.7 kW: wait at least 4 minutes.
200 - 240 V, 5.5 - 45 kW: wait at least 15 minutes.
380 - 480 V, 1.1 - 7.5 kW: wait at least 4 minutes.
380 - 480 V, 11 - 90 kW, wait at least 15 minutes.
525 - 600 V, 1.1 - 7.5 kW, wait at least 4 minutes.
Shorter time is allowed only if indicated on the nameplate for the specific unit.
Leakage Current
The earth leakage current from the VLT
®
HVAC Drive FC 100 exceeds 3.5 mA. Ac-
cording to IEC 61800-5-1 a reinforced Protective Earth connection must be ensured
by means of: a min. 10mm² Cu or 16mm² Al PE-wire or an addtional PE wire - with
the same cable cross section as the Mains wiring - must be 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.
Protective earthing of the VLT
®
HVAC Drive FC 100 and the use of RCD's must always
follow national and local regulations.
1.1.5. Before Commencing Repair Work
1. Disconnect the frequency converter from mains
2. Disconnect DC bus terminals 88 and 89
3. Wait at least the time mentioned in section 1.1.6
4. Remove motor cable
1.1.6. Special conditions
Electrical ratings:
The rating indicated on the nameplate of the frequency converter is based on a typical 3-phase
mains power supply, within the specified voltage, current and temperature range, which is ex-
pected to be used in most applications.
The frequency converters also support other special applications, which affect the electrical ratings
of the frequency converter.
Special conditions which affect the electrical ratings might be:
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.
1. Safety VLT
®
HVAC Drive Operating Instructions
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Consult the relevant clauses in these instructions and in the VLT® HVAC Drive Design Guide for
information about the electrical ratings.
Installation requirements:
The overall electrical safety of the frequency converter requires special installation considerations
regarding:
Fuses and circuit breakers for over-current and short-circuit protection
Selection of power cables (mains, motor, brake, loadsharing 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.
VLT
®
HVAC Drive Operating Instructions 1. Safety
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1.1.7. Caution
Caution
The frequency converter DC link capacitors remain charged after power has been disconnec-
ted. To avoid an electrical shock hazard, disconnect the frequency converter from the mains
before carrying out maintenance. Wait at least as follows before doing service on the fre-
quency converter:
Voltage Min. Waiting Time
4 min. 15 min.
200 - 240 V
1.1 - 3.7 kW 5.5 - 45 kW
380 - 480 V 1.1 - 7.5 kW 11 - 90 kW
525 - 600 V 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)
By altitudes above 2 km, please contact Danfoss Drives regarding PELV.
1.1.9. Avoid unintended Start
While the frequency converter is connected to mains, the motor can be started/stopped using
digital commands, bus commands, references or via the Local Control Panel.
• 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.
• Unless terminal 37 is turned off, an electronic fault, temporary overload, a fault in the
mains supply, or lost motor connection may cause a stopped motor to start.
1. Safety VLT
®
HVAC Drive Operating Instructions
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1.1.10. Safe Stop of the Frequency Converter
For versions fitted with a Safe Stop terminal 37 input, 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 VLT
®
HVAC Drive Design Guide MG.11.BX.YY must
be followed! The information and instructions of the Operating Instructions are not sufficient for
a correct and safe use of the Safe Stop functionality!
130BA491
Illustration 1.1: A similar certificate will be made available for the FC 102!
VLT
®
HVAC Drive Operating Instructions 1. Safety
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1.1.11. IT Mains
IT Mains
Do not connect 400 V frequency converters with RFI-filters to mains supplies with a
voltage between phase and earth of more than 440 V.
For IT mains and delta earth (grounded leg), mains voltage may exceed 440 V be-
tween phase and earth.
Par. 14-50 RFI 1 can be used to disconnect the internal RFI capacitiors from the RFI filter to
ground. If this is done it will reduce the RFI performance to A2 level.
1.1.12. Software Version and Approvals: VLT HVAC Drive
VLT HVAC Drive
Operating Instructions
Software version: 2.0X
This Operating Instructions can be used for all VLT HVAC Drive frequency converters with
software version 2.0X.
The software version number can be seen from parameter 15-43.
1.1.13. 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.
1. Safety VLT
®
HVAC Drive Operating Instructions
8 MG.11.A4.02 - 09.10.06. VLT®is a registered Danfoss trademark
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2. Introduction
2.1. Introduction
2.1.1. Frequency Converter Identification
Below is an example of an identification label. This label is situated on the frequency converter
and shows the type and options fitted to the unit. See table 2.1 for details of how to read theType
code string (T/C).
Illustration 2.1: This example shows an identification label.
Please have T/C (type code) number and serial number ready before contacting Danfoss.
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®
HVAC Drive Operating Instructions 2. Introduction
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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 1.1 - 90 kW (1K1 - 90K)
Number of phases 11 Three phases (T)
Mains 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: IP20
E21: IP 21/NEMA Type 1
E55: IP 55/NEMA Type 12
E66: IP66
P21: IP21/NEMA Type 1 w/backplate
P55: IP55/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
Mains option 21 X: No Mains disconnect switch
1: With Mains disconnect switch (IP55 only)
Adaptation 22 Reserved
Adaptation 23 Reserved
Software release 24-27 Actual 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
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 back-up
Table 2.1: Type code description.
The various options are described further in the VLT® HVAC Drive Design Guide .
2. Introduction VLT
®
HVAC Drive Operating Instructions
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2.1.3. Symbols
Symbols used in this Operating Instructions.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
* Indicates default setting
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®
HVAC Drive Operating Instructions 2. Introduction
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2.1.4. 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
Frequency Converter 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 Metres 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 .
2. Introduction VLT
®
HVAC Drive Operating Instructions
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3. Mechanical installation
3.1. Before starting
3.1.1. Checklist
When unpacking the frequency converter, ensure that the unit is undamaged and complete. 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/IP66)
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
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
Please note that a selection of screwdrivers (phillips or cross-thread screwdriver and torx), a side-
cutter, drill and knife is also recommended to have handy for unpacking and mounting the
frequency converter. 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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®
HVAC Drive Operating Instructions 3. Mechanical installation
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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 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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®
HVAC Drive Operating Instructions
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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 back plate.
Cooling will be insufficient and service life can be
drastically shortened.
Illustration 3.4: If the unit must be mounted a
small distance from the wall please order the back
plate with the unit (see Ordering type code posi-
tion 14-15). A2 and A3 units have back-plate as
standard.
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®
HVAC Drive Operating Instructions 3. Mechanical installation
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Please use the following table to follow mounting instructions
Enclo-
sure: A2 (IP 20/
IP 21)
A3 (IP 20/
IP 21)
A5 (IP 55/
IP 66)
B1 (IP 21/
IP 55/
IP66)
B2 (IP 21/
IP 55/
IP66)
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
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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®
HVAC Drive Operating Instructions
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Illustration 3.7: Wrong 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 screws completely.
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®
HVAC Drive Operating Instructions 3. Mechanical installation
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Mechanical dimensions
Frame size A2
1.1-3.0 kW (200-240 V)
1.1-4.0 kW (380-480 V)
1.1-4.0 kW (525-600 V)
Frame size A3
3.7 kW (200-240 V)
5.5-7.5 kW (380-480 V)
5.5-7.5 kW (525-600 V)
IP20 IP21/Type 1 IP20 IP21/Type 1
Height
Height of back plate A268 mm 375 mm 268 mm 375 mm
Distance between mount-
ing holes a257 mm 350 mm 257 mm 350 mm
Width
Width of back plate B90 mm 90 mm 130 mm 130 mm
Distance between mount-
ing holes b70 mm 70 mm 110 mm 110 mm
Depth
Depth without option A/B C205 mm 205 mm 205 mm 205 mm
With option A/B C220 mm 220 mm 220 mm 220 mm
Without option A/B D 207 mm 207 mm
With option A/B D 222 mm 222 mm
Screw holes
c 8.0 mm 8.0 mm 8.0 mm 8.0 mm
d ø11 mm ø11 mm ø11 mm ø11 mm
e ø5.5 mm ø5.5 mm ø5.5 mm ø5.5 mm
f 9 mm 9 mm 9 mm 9 mm
Maximum weight 4.9 kg 5.3 kg 6.6 kg 7.0 kg
Table 3.3: A2 and A3 mechanical dimensions
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®
HVAC Drive Operating Instructions
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NB!
Option A/B are serial communication and I/O options, which when fitted increase
the depth on some enclosure sizes.
3.2.3. Mounting A5, B1, B2, C1 and C2.
Illustration 3.10: Drilling holes.
Step 1: Drill according to the dimensions in the
following table.
Illustration 3.11: Correct mounting of screws
Step 2A: This way it is easy to hang the unit
on the screws.
Illustration 3.12: Wrong mounting of screws
Step 2B: Do not tighten screws completely.
Illustration 3.13: Mounting of unit.
Step 3: Lift the unit onto the screws.
Illustration 3.14: Tightening of screws
Step 4: Tighten screws completely.
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®
HVAC Drive Operating Instructions 3. Mechanical installation
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Mechanical dimensions
Voltage:
200-480 V
380-480 V
Frame size A5
1.1-3.7 kW
1.1-7.5 kW
Frame size B1
5.5-11 kW
11-18,5 kW
Frame size B2
15 kW
22-30 kW
Frame size C1
18.5 - 30 kW
37 - 55 kW
Frame size C2
37 - 45 kW
75 - 90 kW
IP55/66 IP21/55/66 IP21/55/66 IP21/55/66 IP21/55/66
Height1)
Height A420 mm 480 mm 650 mm 680 mm 770 mm
Distance between mounting
holes a402 mm 454 mm 624 mm 648 mm 739 mm
Width1)
Width B242 mm 242 mm 242 mm 308 mm 370 mm
Distance between mounting
holes b215 mm 210 mm 210 mm 272 mm 334 mm
Depth
Depth C195 mm 260 mm 260 mm 310 mm 335 mm
Screw holes
c 8.25 mm 12 mm 12 mm 12.5 mm 12.5 mm
d ø12 mm ø19 mm ø19 mm ø19 mm ø19 mm
e ø6.5 mm ø6.5 mm ø6.5 mm ø9 ø9
f 9 mm 9 mm 9 mm ø9.8 ø9.8
Max. weight 13.5 / 14.2 23 kg 27 kg 45 kg 65 kg
Table 3.4: A5, B1, B2, C1 and C2 mechanical dimensions.
1) The dimensions state the maximum height, width and depth needed for mounting the frequency
converter, when the top cover is mounted.
3. Mechanical installation VLT
®
HVAC Drive Operating Instructions
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