Danfoss VLT HVACDrive User manual

Contents
1 Introduction
1-1
Copyright, Limitation of Liability and Revision Rights 1-2
2 Safety 2-1
High Voltage Warning 2-1
Before Commencing Repair Work 2-3
Special Conditions 2-3
Avoid Unintended Start 2-4
Safe Stop of the Adjustable Frequency Drive 2-5
IT Line Power 2-6
3 Mechanical Installation 3-1
Before Starting 3-1
Mechanical Dimensions 3-3
4 Electrical Installation 4-1
How to Connect 4-1
Power and Control Wiring for Unshielded Cables 4-2
Electrical Installation and Control Cables 4-3
Line Power Wiring Overview 4-9
Motor Wiring Overview 4-17
DC Bus Connection 4-21
Brake Connection Option 4-22
Relay Connection 4-24
How to Test Motor and Direction of Rotation 4-29
5 Commissioning and Application Examples 5-1
Commissioning 5-1
Quick Menu Mode 5-1
Tips and Tricks 5-6
Application Examples 5-8
Start/Stop 5-8
Pulse Start/Stop 5-8
Automatic Motor Adaptation (AMA) 5-9
6 How to Operate the Adjustable Frequency Drive 6-1
How to Operate the Graphical LCP (GLCP) 6-1
How to Operate the Numeric LCP (NLCP) 6-7
VLT
®
HVAC Drive Instruction Manual Contents
MG.11.AB.22 - VLT®is a registered Danfoss trademark

7 How to Program the Adjustable Frequency Drive 7-1
How to Program 7-1
Function Set-ups 7-1
Commonly Used Parameters - Explanations 7-7
0-** Operation and Display 7-53
1-** Load / Motor 7-54
2-** Brakes 7-54
3-** Reference / Ramps 7-55
4-** Limits / Warnings 7-55
5-** Digital In / Out 7-56
6-** Analog In / Out 7-57
8-** Communication and Options 7-58
9-** Profibus 7-59
10-** CAN Fieldbus 7-59
11-** LonWorks 7-60
13-** Smart Logic Controller 7-60
14-** Special Functions 7-61
15-** FC Information 7-62
16-** Data Readouts 7-63
18-** Info & Readouts 7-64
20-** FC Closed-loop 7-65
21-** Ext. Closed-loop 7-66
22-** Application Functions 7-67
23-** Time-based Funtions 7-68
24-** Application Functions 2 7-69
25-** Cascade Controller 7-70
26-** Analog I / O Option MCB 109 7-71
8 Troubleshooting 8-1
Alarms and Warnings 8-1
Alarms and Warnings 8-1
Fault Messages 8-5
Acoustic Noise or Vibration 8-12
9 Specifications 9-1
General Specifications 9-1
Special Conditions 9-11
Contents VLT
®
HVAC Drive Instruction Manual
MG.11.AB.22 - VLT®is a registered Danfoss trademark

10 Index 10-1
VLT
®
HVAC Drive Instruction Manual Contents
MG.11.AB.22 - VLT®is a registered Danfoss trademark

Contents VLT
®
HVAC Drive Instruction Manual
MG.11.AB.22 - VLT®is a registered Danfoss trademark

1Introduction
VLT HVAC Drive
FC 100 Series
Software version: 3.2.x
This guide can be used with all VLT HVAC Drive adjustable frequency
drives with software version 3.2.x.
The current software version number can be read from
par. 15-43
Software Version .
VLT
®
HVAC Drive Instruction Manual 1 Introduction
MG.11.AB.22 - VLT®is a registered Danfoss trademark 1-1
1

1.1.1 Copyright, Limitation of Liability and Revision Rights
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 documentation 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.
1 Introduction VLT
®
HVAC Drive Instruction Manual
1-2 MG.11.AB.22 - VLT®is a registered Danfoss trademark
1

1.1.2 Available Literature for VLT HVAC Drive
-Instruction ManualMG.11.Ax.yy provides the necessary information for getting the adjustable frequency drive up and running.
-Instruction Manual VLT HVAC Drive High Power, MG.11.Fx.yy
-Design Guide MG.11.Bx.yy contains all the technical information about the adjustable frequency drive and customer design and applications.
-Programming Guide MG.11.Cx.yy provides information on how to program and includes complete parameter descriptions.
-Mounting Instruction, Analog I/O Option MCB109, MI.38.Bx.yy
-Application Note, Temperature Derating Guide, MN.11.Ax.yy
-PC-based Configuration Tool MCT 10, MG.10.Ax.yy 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®VLT HVAC Drive Drive Applications, MG.11.Tx.yy
-Instruction ManualVLT HVAC Drive Profibus, MG.33.Cx.yy.
-Instruction ManualVLT HVAC Drive Device Net, MG.33.Dx.yy
-Instruction Manual VLT HVAC Drive BACnet, MG.11.Dx.yy
-Instruction ManualVLT HVAC Drive LonWorks, MG.11.Ex.yy
-Instruction ManualVLT HVAC Drive Metasys, MG.11.Gx.yy
-Instruction Manual VLT HVAC Drive FLN, MG.11.Zx.yy
-Output Filter Design Guide, MG.90.Nx.yy
-Brake Resistor Design Guide, MG.90.Ox.yy
x = Revision number
yy = Language code
Danfoss technical literature is available in print from your local Danfoss Sales Office or online at:
www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm
VLT
®
HVAC Drive Instruction Manual 1 Introduction
MG.11.AB.22 - VLT®is a registered Danfoss trademark 1-3
1

1.1.3 Abbreviations and Standards
Abbreviations: Terms: SI units: I-P units:
aAcceleration m/s2ft/s2
AWG American wire gauge
Auto Tune Automatic Motor Tuning
°CCelsius
ICurrent AAmp
ILIM Current limit
Joule Energy J = N∙mft-lb, Btu
°FFahrenheit
FC Adjustable Frequency Drive
f Frequency Hz Hz
kHz Kilohertz kHz kHz
LCP Local Control Panel
mA Milliampere
ms Millisecond
min Minute
MCT Motion Control Tool
M-TYPE Motor Type Dependent
Nm Newton meters in-lbs
IM,N Nominal motor current
fM,N Nominal motor frequency
PM,N Nominal motor power
UM,N Nominal motor voltage
par. Parameter
PELV Protective Extra Low Voltage
Watt Power WBtu/hr, hp
Pascal Pressure Pa = N/m² psi, psf, ft of water
IINV Rated Inverter Output Current
RPM Revolutions Per Minute
SR Size Related
T Temperature C F
tTime ss, hr
TLIM Torque limit
UVoltage V V
Table 1.1: Abbreviation and standards table.
1 Introduction VLT
®
HVAC Drive Instruction Manual
1-4 MG.11.AB.22 - VLT®is a registered Danfoss trademark
1

1.1.4 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 with which the
unit is equipped. See below for details of how to read the Type code string (T/C).
Figure 1.1: This example shows an identification label.
NOTE!
Please have T/C (type code) number and serial number ready before contacting Danfoss.
VLT
®
HVAC Drive Instruction Manual 1 Introduction
MG.11.AB.22 - VLT®is a registered Danfoss trademark 1-5
1

1.1.5 Type Code String Low and Medium Power
Description Pos Possible choice
Product group & Adjustable Frequency Drive
Series 1-6 FC 102
Power rating 8-10 1.5–125 hp [1.1–90 kW] (P1K1 - P90K)
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: 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: RFI filter class A2
H3: RFI filter class A1/B (reduced cable length)
Hx: No RFI filter
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 power option 21
X: No Line power disconnect switch and Load Sharing
1: With Line power disconnect switch (IP55 only)
8: Line power disconnect and Load Sharing
D: Load Sharing
See Chapter 8 for max. cable sizes.
Adaptation 22 X: Standard
0: European metric thread in cable entries.
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 Lonworks
AJ: MCA 109 BACnet gateway
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
Table 1.2: Type code description.
1 Introduction VLT
®
HVAC Drive Instruction Manual
1-6 MG.11.AB.22 - VLT®is a registered Danfoss trademark
1

Description Pos Possible choice
C option software 36-37 XX: Standard software
D options 38-39 DX: No option
D0: DC backup
Table 1.3: Type code description.
The various options and accessories are described further in the
VLT HVAC Drive Design Guide, MG.11.BX.YY .
VLT
®
HVAC Drive Instruction Manual 1 Introduction
MG.11.AB.22 - VLT®is a registered Danfoss trademark 1-7
1

1 Introduction VLT
®
HVAC Drive Instruction Manual
1-8 MG.11.AB.22 - VLT®is a registered Danfoss trademark
1

2Safety
2.1.1 Symbols
Symbols used in this manual:
NOTE!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
✮Indicates default setting
2.1.2 High Voltage Warning
The voltage of the adjustable frequency drive and the MCO 101 option card is dangerous whenever it is connected to line power.
Incorrect installation of the motor or adjustable frequency drive may causedeath, serious injury or damage to the equipment. Conse-
quently, it is essential to comply with the instructions in this manual as well as local and national rules and safety regulations.
2.1.3 Safety Note
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. Con-
sequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.
Safety Regulations
1. The adjustable frequency drive must be disconnected 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 passed 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. Correct protective grounding of the equipment must be established, the user must be protected against supply voltage, and the motor must be
protected against overload in accordance with applicable national and local regulations.
VLT
®
HVAC Drive Instruction Manual 2 Safety
MG.11.AB.22 - VLT®is a registered Danfoss trademark 2-1
2

4. The ground leakage currents are higher than 3.5 mA.
5. Protection against motor overload is set by par. 1-90
Motor Thermal Protection . If this function is desired, set par. 1-90 Motor Thermal Protec-
tion
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 passed before removing motor and line power plugs.
7. Please 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 disconnected and that the necessary time has
passed before commencing repair work.
Installation at high altitudes
Installation at high altitude:
380–500 V, enclosure A, B and C: At altitudes above 6,561 ft, please contact Danfoss regarding PELV.
380–500 V, enclosure D, E and F: At altitudes above 9,842 ft, please contact Danfoss regarding PELV.
525–690 V: At altitudes above 6,561 ft [2 km], please contact Danfoss regarding PELV.
Warning against Unintended Start
1. The motor can be brought to a stop by means of 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 stop key [STOP/RESET] must always be acti-
vated, following 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 supply line power or the motor connection ceases.
Consequently, disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures
to ensure the power cannot be inadvertently energized. Failure to follow recommendations could result in death or serious injury.
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.
The adjustable frequency drive DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock
hazard, disconnect the adjustable frequency drive from line power before carrying out maintenance. Wait at least as follows before
doing service on the adjustable frequency drive:
2 Safety VLT
®
HVAC Drive Instruction Manual
2-2 MG.11.AB.22 - VLT®is a registered Danfoss trademark
2

Voltage (V) Min. Waiting Time (Minutes)
415 20 30 40
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] 150–350 hp [110–250
kW]
450–1350 hp [315–
1000 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] 60–550 hp [45–400 kW] 600–1875 hp [450–
1400 kW]
Be aware that there may be high voltage on the DC link even when the LEDs are turned off.
2.1.4 Before Commencing Repair Work
1. Disconnect the adjustable frequency drive from line power.
2. Disconnect DC bus terminals 88 and 89
3. Wait at least the time mentioned above in the section General Warning.
4. Remove motor cable
2.1.5 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:
• Single phase applications.
• High temperature applications that require derating of the electrical ratings.
• Marine applications with more severe environmental conditions.
Other applications might also affect the electrical ratings.
Consult the relevant sections in this manual and in the VLT HVAC Drive
Design Guide, MG.11.BX.YY for information about the electrical ratings.
Installation requirements:
The overall electrical safety of the adjustable frequency drive requires special installation considerations regarding:
• Fuses and circuit breakers for overcurrent and short-circuit protection
• Selection of power cables (line power, motor, brake, load sharing and relay)
• Grid configuration (grounded delta transformer leg, IT,TN, 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 Instruction Manual 2 Safety
MG.11.AB.22 - VLT®is a registered Danfoss trademark 2-3
2

2.1.6 Installation at High Altitudes (PELV)
Hazardous Voltage!
By altitudes above 6,600 feet [2 km], please contact Danfoss regarding PELV.
Avoid unintended start
While the adjustable frequency drive is connected to line power, the motor can be started/stopped using digital commands, bus com-
mands, references or via the LCP.
• Disconnect the adjustable frequency drive from line power whenever personal safety considerations make it necessary to
avoid an 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 power supply, or lost motor
connection may cause a stopped motor to start.
Failure to follow recommendations could result in death or serious injury.
2.1.7 Avoid Unintended Start
While the adjustable frequency drive is connected to line power, the motor can be started/stopped using digital commands, bus com-
mands, references or via the Local Control Panel.
• Disconnect the adjustable frequency drive from line power whenever personal safety considerations make it necessary to
avoid an 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 power supply, or lost motor
connection may cause a stopped motor to start.
2 Safety VLT
®
HVAC Drive Instruction Manual
2-4 MG.11.AB.22 - VLT®is a registered Danfoss trademark
2

2.1.8 Safe Stop of the Adjustable Frequency Drive
For versions equipped 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 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 must be followed! The information and instructions of the
Instruction Manual are not sufficient for a correct and safe use of the safe stop functionality!
130BA491
This certificate also covers FC 102 and FC 202!
VLT
®
HVAC Drive Instruction Manual 2 Safety
MG.11.AB.22 - VLT®is a registered Danfoss trademark 2-5
2

2.1.9 IT Line Power
IT line power
Do not connect adjustable frequency drives with RFI filters to line power supplies with a voltage between phase and ground of more
than 440 V for 400 V drives and 760 V for 690 V drives.
For 400 VT IT line power and delta ground (grounded leg), AC line voltage may exceed 440 V between phase and ground.
For 690 VT IT line power and delta ground (grounded leg), AC line voltage may exceed 760 V between phase and ground.
Par. 14-50 RFI 1 can be used to disconnect the internal RFI capacitors from the RFI filter to ground.
2.1.10 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 leg-
islation.
2 Safety VLT
®
HVAC Drive Instruction Manual
2-6 MG.11.AB.22 - VLT®is a registered Danfoss trademark
2

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 complete. Use the following table to identify the packaging:
Enclosure
type:
A2
(IP 20-21)
A3
(IP 20-21)
A5
(IP 55-66)
B1/B3
(IP 20-21-55-66)
B2/B4
(IP 20-21-55-66)
C1/C3
(IP 20-21-55-66)
C2*/C4
(IP 20-21-55-66)
Unit size (kW):
200–240 V 1.1-2.2 3.0–3.7 1.1–3.7 5.5–11/
5.5–11
15/
15–18.5
18.5–30/
22–30
37-45/
37-45
380–480 V 1.1–4.0 5.5–7.5 1.1–7.5 11–18.5/
11–18.5
22-30/
22-37
37-55/
45-55
75-90/
75-90
525–600 V 1.1–7.5 1.1–7.5 11–18.5/
11–18.5
22-30/
22-37
37-55/
45-55
75-90/
75-90
Table 3.1: Unpacking table
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 adjustable frequency drive. The packaging for these enclosures contains, as shown: accessory bag(s), documentation
and the unit. Depending on options fitted, there may be one or two bags and one or more booklets.
VLT
®
HVAC Drive Instruction Manual 3 Mechanical Installation
MG.11.AB.22 - VLT®is a registered Danfoss trademark 3-1
3

A2 A3 A5 B1 B2 B3 B4 C1 C2 C3 C4
IP20/21* IP20/21* IP55/66 IP21/55/66 IP21/55/66 IP20/21* IP20/21* IP21/55/66 IP21/55/66 IP20/21* IP20/21*
Figure 3.1: Top and bottom mounting holes.
Figure 3.2: Top and bottom mounting holes. (B4+C3+C4 only)
Accessory bags containing necessary brackets, screws and connectors are included with the drives upon delivery.
All measurements in mm.
* IP21 can be established with a kit as described in the section: IP 21/ IP 4X/ TYPE 1 Enclosure Kit in the Design Guide.
3.2.1 Mechanical Front Views
3 Mechanical Installation VLT
®
HVAC Drive Instruction Manual
3-2 MG.11.AB.22 - VLT®is a registered Danfoss trademark
3