Danfoss VLT HVAC Drive FC 102 User manual

Operating Guide
VLT HVAC Drive FC 102
1.1–90 kW
vlt-drives.danfoss.com

1
1.1
1.2
1.3
1.3.1
1.3.2
1.3.3
1.4
1.5
2
2.1
2.2
2.3
3
3.1
3.1.1
3.1.2
3.2
3.3
3.3.1
3.3.2
3.3.3
3.3.3.1
4
4.1
4.2
4.3
4.4
4.5
4.6
4.6.1
4.6.2
4.7
4.7.1
4.8
Contents
Introduction 7
Purpose of this Operating Guide 7
Manual and Software Version 7
Product Overview 7
Intended Use 7
Exploded Views 8
Block Diagram of the Drive 10
Type Approvals and Certifications 10
CE Declaration 12
Safety 14
Safety Symbols 14
Qualified Personnel 14
Safety Precautions 14
Mechanical Installation 17
Unpacking 17
Items Supplied 17
Storage 17
Installation Environment 17
Mounting 18
Cooling 18
Lifting 18
Mounting 18
Mounting with Mounting Plate and Railings 18
Electrical Installation 20
Safety Instructions 20
EMC-compliant Installation 20
Grounding 21
Wiring Schematic 22
Access 24
Connecting the Motor 25
Grounding the Cable Shield 25
Grounding with Category C1 Filter 26
Connecting AC Mains 30
Connecting the Drive to Mains 30
Control Terminals 31
AQ267037536117en-000101/130R0083 | 3Danfoss A/S © 2023.09
Contents
VLT HVAC Drive FC 102
Operating Guide

4.8.1
4.8.2
4.8.3
4.8.4
4.8.4.1
4.8.5
4.8.6
4.8.7
4.8.8
4.9
5
5.1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.5.1
5.2.6
5.2.6.1
5.2.6.2
5.3
5.3.1
5.3.2
5.3.3
5.3.3.1
5.3.3.2
5.3.4
5.3.4.1
5.3.4.2
5.3.4.3
5.3.4.4
5.3.4.5
5.3.5
5.3.6
5.3.6.1
Control Wiring 31
Control Terminal Types 31
Terminal Descriptions 32
Wiring to Control Terminals 33
Removing a Control Wire 34
Enabling Motor Operation (Terminal 27) 34
Voltage/Current Input Selection (Switches) 34
Safe Torque Off (STO) 35
RS485 Serial Communication 35
Installation Check List 35
Commissioning 37
Applying Power 37
Local Control Panel Operation 37
Local Control Panel 37
LCP Layout 37
Parameter Settings 40
Uploading/Downloading Data to/from the LCP 40
Changing Parameter Settings 40
View Changes 40
Restoring Default Settings 40
Recommended Initialization 41
Manual Initialization 41
Basic Programming 41
Commissioning with SmartStart 41
Commissioning via [Main Menu] 41
Asynchronous Motor Setup 42
Application-specific Adjustment when Running VVC+ 43
Application-specific Adjustment when Running Flux 43
Permanent Magnet Motor Set-up 43
Initial Programming 43
Programming Motor Data 44
Test Motor Operation 44
Rotor Detection 44
Parking 44
Automatic Energy Optimization (AEO) 45
Automatic Motor Adaptation (AMA) 45
Running AMA 45
AQ267037536117en-000101/130R00834 | Danfoss A/S © 2023.09
Contents
VLT HVAC Drive FC 102
Operating Guide

5.3.7
5.3.7.1
5.3.8
5.3.9
6
6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.1.8
6.1.9
6.1.10
6.1.11
6.1.12
6.1.13
6.1.14
7
7.1
7.2
7.3
7.4
7.5
7.6
7.6.34
7.6.84
7.7
8
8.1
8.2
8.3
8.4
8.5
Checking Motor Rotation 46
Changing Direction of Rotation 46
Local-control Test 46
System Start-up 46
Basic I/O Configuration 47
Application Examples 47
Wiring Configuration for Automatic Motor Adaptation (AMA) 47
Wiring Configuration for Automatic Motor Adaptation without T27 48
Wiring Configuration: Speed 48
Wiring Configuration: Feedback 50
Wiring Configuration: Run/Stop 52
Wiring Configuration: Start/Stop 54
Wiring Configuration: External Alarm Reset 56
Wiring Configuration: RS485 57
Wiring Configuration: Motor Thermistor 57
Wiring for Regen 59
Wiring Configuration for a Relay Setup with Smart Logic Control 60
Wiring Configuration for a Cascade Controller 60
Wiring Configuration for a Fixed Variable Speed Pump 61
Wiring Configuration for Lead Pump Alternation 62
Diagnostics and Troubleshooting 63
Maintenance and Service 63
Status Display 63
Status Message Definitions 63
Warning and Alarm Types 66
Warning and Alarm Displays 66
List of Warnings and Alarms 67
ALARM 38, Internal Fault 74
WARNING 200, Fire Mode 81
Troubleshooting 82
Specifications 85
Electrical Data, 200–240 V and 3x115Y/200–139Y/240 V 85
Electrical Data, 380–480 V and 3x220Y/380–277Y/480 V 87
Electrical Data, 525–600 V 90
Electrical Data, 525–690 V 93
Mains Supply 96
AQ267037536117en-000101/130R0083 | 5Danfoss A/S © 2023.09
Contents
VLT HVAC Drive FC 102
Operating Guide

8.6
8.6.1
8.6.2
8.7
8.8
8.8.1
8.8.2
8.8.3
8.9
8.9.1
8.9.2
8.9.3
8.9.4
8.9.5
8.9.6
8.9.7
8.9.8
8.9.9
8.9.10
8.9.11
8.9.12
8.9.13
8.10
8.10.1
8.10.2
8.10.3
8.10.4
8.11
8.12
9
9.1
Motor Output and Motor Data 96
Motor Output (U, V, W) 96
Torque Characteristics 96
Ambient Conditions 97
Cable Specifications 97
Motor Cable Length 97
Power Cable Cross-sections 97
Control Cable Cross-sections 98
Control Input/Output and Control Data 98
Digital Inputs 98
STO Terminal 37 (Terminal 37 is Fixed PNP Logic) 98
Analog Inputs 99
Pulse/Encoder Inputs 99
Digital Outputs 100
Analog Output 100
Control Card, 24 V DC Output 100
Control Card, +10 V DC Output 100
Control Card, RS485 Serial Communication 100
Control Card, USB Serial Communication 100
Relay Outputs 101
Control Card Performance 101
Control Characteristics 101
Fuses and Circuit Breakers 102
Fuse Recommendations 102
CE Compliance 102
UL Compliance (61800-5-1) 105
UL Compliance (508C) 106
Connection Tightening Torques 110
Power Ratings, Weight, and Dimensions 111
Appendix 116
Symbols and Abbreviations 116
AQ267037536117en-000101/130R00836 | Danfoss A/S © 2023.09
Contents
VLT HVAC Drive FC 102
Operating Guide

•
•
1 Introduction
1.1 Purpose of this Operating Guide
This operating guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified
personnel.
Read and follow the instructions to use the drive safely and professionally.
Pay particular attention to the safety instructions and general warnings. Always keep this operating guide with the drive.
VLT®is a registered trademark for Danfoss A/S.
1.2 Manual and Software Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
Table 1: Manual and Software Version
Edition
Remarks
Software version
AQ267037536117-0101
Added UL61800-5-1 updates to Electrical Data and Fuse sections.
7.3x
1.3 Product Overview
1.3.1 Intended Use
The drive is an electronic motor controller intended for:
Regulation of motor speed in response to system feedback or to remote commands from external controllers. A power drive
system consists of the AC drive, the motor, and equipment driven by the motor.
System and motor status surveillance.
The drive can also be used for motor overload protection.
Depending on the configuration, the drive can be used in standalone applications or form part of a larger appliance or installation.
The drive is allowed for use in residential, industrial, and commercial environments in accordance with local laws and standards.
NOTICE
In a residential environment, this product can cause radio interference, in which case supplementary mitigation measures can be
required.
Foreseeable misuse
Do not use the drive in applications which are non-compliant with specified operating conditions and environments. Ensure com-
pliance with the conditions specified in Ambient Conditions.
NOTICE
OUTPUT FREQUENCY LIMIT
Due to export control regulations, the output frequency of the drive is limited to 590 Hz. For demands exceeding 590 Hz, contact
Danfoss.
AQ267037536117en-000101 / 130R0083 | 7Danfoss A/S © 2023.09
Introduction
VLT HVAC Drive FC 102
Operating Guide

1.3.2 Exploded Views
1
2
3
4
5
6
7
8
9
10
11
12
13
14
8
15
16
17
18
e30bb492.12
Illustration 1: Exploded View Enclosure Type A, IP20
1
Local control panel (LCP)
2
RS485 serial bus connector (+68, -69)
3
Analog I/O connector
4
LCP input plug
5
Analog switches (A53), (A54)
6
Cable shield connector
7
Decoupling plate
8
Grounding clamp (PE)
9
Shielded cable grounding clamp and strain relief
10
Motor output terminals 96 (U), 97 (V), 98 (W)
11
Relay 2 (01, 02, 03)
12
Relay 1 (04, 05, 06)
13
Brake (-81, +82) and load sharing (-88, +89) termi-
nals
14
Mains input terminals 91 (L1), 92 (L2), 93 (L3)
15
USB connector
16
Serial bus terminal switch
17
Digital I/O and 24 V power supply
18
Cover
AQ267037536117en-000101 / 130R00838 | Danfoss A/S © 2023.09
Introduction
VLT HVAC Drive FC 102
Operating Guide

1
2
3
4
56
7
8
9
10
11
12
13
16
17
18
19
14
15
FAN MOUNTING
QDF-30
DC-
DC+
Remove jumper to activate Safe Stop
Max. 24 Volt !
12
13
18
19
27 29
32
33
20
37
06
05 04
03 02 01
e30bb493.12
Illustration 2: Exploded View Enclosure Types B and C, IP55 and IP66
1
Local control panel (LCP)
2
Cover
3
RS485 serial bus connector
4
Digital I/O and 24 V power supply
5
Analog I/O connector
6
Cable shield connector
7
USB connector
8
Serial bus terminal switch
9
Analog switches (A53), (A54)
10
Relay 1 (01, 02, 03)
11
Relay 2 (04, 05, 06)
12
Lifting ring
13
Mounting slot
14
Grounding clamp (PE)
15
Cable shield connector
16
Brake terminal (-81, +82)
17
Load sharing terminal (DC bus) (-88, +89)
18
Motor output terminals 96 (U), 97 (V), 98 (W)
19
Mains input terminals 91 (L1), 92 (L2), (L3)
AQ267037536117en-000101 / 130R0083 | 9Danfoss A/S © 2023.09
Introduction
VLT HVAC Drive FC 102
Operating Guide

•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
1.3.3 Block Diagram of the Drive
e75za016.12
Illustration 3: Block Diagram
1
Mains input
3-phase AC mains power supply to the drive.
2
Rectifier
The rectifier bridge converts the AC input to DC
current to supply inverter power.
3
DC bus
Intermediate DC-bus circuit handles the DC cur-
rent.
4
DC reactors
Filter the intermediate DC circuit voltage.
Prove line transient protection.
Reduce RMS current.
Raise the power factor reflected back to the line.
Reduce harmonics on the AC input.
5
Capacitor bank
Stores the DC power.
Proves ride-through protection for short power
losses.
6
Inverter
Converts the DC into a controlled PWM AC
waveform for a controlled variable output to the
motor.
7
Output to motor
Regulated 3-phase output power to the motor.
8
Control circuitry
Input power, internal processing, output, and
motor current are monitored to provide efficient
operation and control.
User interface and external commands are
monitored and performed.
Status output and control can be provided.
1.4 Type Approvals and Certifications
The following list is a selection of possible type approvals and certifications for Danfoss drives:
NOTICE
Drives of enclosure size T7 (525–690 V) are not UL listed.
Table 2: Type Approvals and Certifications
089
AQ267037536117en-000101 / 130R008310 | Danfoss A/S © 2023.09
Introduction
VLT HVAC Drive FC 102
Operating Guide

NOTICE
The specific approvals and certification for the drive are on the nameplate of the drive. For more information, contact the local
Danfoss office or partner.
For more information on UL 508C thermal memory retention requirements, refer to the section Motor Thermal Protection in the
product-specific Design Guide.
For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by In-
land Waterways (ADN), refer to the section ADN-compliant Installation in the product-specific Design Guide.
AQ267037536117en-000101 / 130R0083 | 11Danfoss A/S © 2023.09
Introduction
VLT HVAC Drive FC 102
Operating Guide

1.5 CE Declaration
AQ267037536117en-000101 / 130R008312 | Danfoss A/S © 2023.09
Introduction
VLT HVAC Drive FC 102
Operating Guide

AQ267037536117en-000101 / 130R0083 | 13Danfoss A/S © 2023.09
Introduction
VLT HVAC Drive FC 102
Operating Guide

-
-
-
-
2 Safety
2.1 Safety Symbols
The following symbols are used in this guide:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
2.2 Qualified Personnel
Correct and reliable transport, storage, installation, operation, and maintenance are required for the trouble-free and safe operation
of the drive. Only qualified personnel are allowed to install and operate this equipment.
Qualified personnel are defined as trained staff, who are authorized to install, commission, and maintain equipment, systems, and
circuits in accordance with pertinent laws and regulations. Also, the qualified personnel must be familiar with the instructions and
safety measures described in this manual.
2.3 Safety Precautions
WARNING
HAZARDOUS VOLTAGE
AC drives contain hazardous voltage when connected to the AC mains or connected on the DC terminals. Failure to perform
installation, start-up, and maintenance by qualified personnel can result in death or serious injury.
Only qualified personnel must perform installation, start-up, and maintenance.
WARNING
UNINTENDED START
When the drive is connected to AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death,
serious injury, and equipment or property damage. The motor may start by activation of an external switch, a fieldbus command,
an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condi-
tion.
Press [Off] on the LCP before programming parameters.
Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended motor
start.
Check that the drive, motor, and any driven equipment are in operational readiness.
AQ267037536117en-000101 / 130R008314 | Danfoss A/S © 2023.09
Safety
VLT HVAC Drive FC 102
Operating Guide

-
-
-
-
-
-
-
-
-
-
-
-
-
WARNING
DISCHARGE TIME
The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be
present even when the warning indicator lights are off.
Failure to wait the specified time after power has been removed before performing service or repair work could result in death or
serious injury.
Stop the motor.
Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and
DC-link connections to other drives.
Wait for the capacitors to discharge fully. The minimum waiting time is specified in the table Discharge time and is also visible
on the nameplate on top of the drive.
Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors
are fully discharged.
Table 3: Discharge Time
Voltage [V]
Minimum waiting time (minutes)
4
7
15
200–240
1.1–3.7 kW (1.5–5 hp)
–
5.5–45 kW (7.5–60 hp)
380–480
1.1–7.5 kW (1.5–10 hp)
–
11–90 kW (15–125 hp)
525–600
1.1–7.5 kW (1.5–10 hp)
–
11–90 kW (15–125 hp)
525–690
–
1.1–7.5 kW (1.5–10 hp)
11–90 kW (15–125 hp)
WARNING
ELECTRICAL SHOCK HAZARD - LEAKAGE CURRENT HAZARD >3.5 MA
Leakage currents exceed 3.5 mA. Failure to connect the drive properly to protective earth (PE) can result in death or serious in-
jury.
Ensure reinforced protective earthing conductor according to IEC 60364-5-54 cl. 543.7 or according to local safety regula-
tions for high touch current equipment. The reinforced protective earthing of the drive can be done with:
a PE conductor with a cross-section of at least 10 mm2(8 AWG) Cu or 16 mm2(6 AWG) Al.
an extra PE conductor of the same cross-sectional area as the original PE conductor as specified by IEC 60364-5-54 with a
minimum cross-sectional area of 2.5 mm2(14 AWG) (mechanical protected) or 4 mm2(12 AWG) (not mechanical protected).
a PE conductor completely enclosed with an enclosure or otherwise protected throughout its length against mechanical
damage.
a PE conductor part of a multi-conductor power cable with a minimum PE conductor cross-section of 2.5 mm2(14 AWG)
(permanently connected or pluggable by an industrial connector. The multi-conductor power cable shall be installed with an
appropriate strain relief).
NOTE: In IEC/EN 60364-5-54 cl. 543.7 and some application standards (for example IEC/EN 60204-1), the limit for requiring
reinforced protective earthing conductor is 10 mA leakage current.
WARNING
ROTATING SHAFTS
Contact with rotating shafts and electrical equipment can result in death or serious injury.
Ensure that only trained and qualified personnel perform installation, start-up, and maintenance.
Ensure that electrical work conforms to national and local electrical codes.
Follow the procedures in this guide.
AQ267037536117en-000101 / 130R0083 | 15Danfoss A/S © 2023.09
Safety
VLT HVAC Drive FC 102
Operating Guide

-
-
WARNING
UNINTENDED MOTOR ROTATION WINDMILLING
Unintended rotation of permanent magnet motors creates voltage and can charge the unit, resulting in death, serious injury, or
equipment damage.
Ensure that permanent magnet motors are blocked to prevent unintended rotation.
CAUTION
INTERNAL FAILURE HAZARD
An internal failure in the drive can result in serious injury when the drive is not properly closed.
Ensure that all safety covers are in place and securely fastened before applying power.
AQ267037536117en-000101 / 130R008316 | Danfoss A/S © 2023.09
Safety
VLT HVAC Drive FC 102
Operating Guide

•
•
-
3 Mechanical Installation
3.1 Unpacking
3.1.1 Items Supplied
Items supplied may vary according to product configuration.
Make sure that the items supplied and the information on the product label correspond to the order confirmation.
Check the packaging and the drive visually for damage caused by inappropriate handling during shipment. File any claim for
damage with the carrier. Retain damaged parts for clarification.
e130bu821.11
1
2
5
4
3
6
7
8
Illustration 4: Product Label (Example)
1
Type code
2
Ordering number and serial number
3
Power rating
4
Voltage, frequency, and current (at low/high voltag-
es)
5
Enclosure type and IP rating along with maximum
ambient temperature
6
Enclosure frame size
7
QR code for additional documentation
8
Discharge time (warning)
NOTICE
LOSS OF WARRANTY
Do not remove the product label from the drive.
3.1.2 Storage
Ensure that the requirements for storage are fulfilled, see the Ambient Conditions section.
3.2 Installation Environment
NOTICE
REDUCED LIFETIME
In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/Type rating of the equipment matches the
installation environment. Failure to meet requirements for ambient conditions can reduce lifetime of the drive.
Ensure that requirements for air humidity, temperature, and altitude are met.
Vibration and shock
The drive complies with requirements for units mounted on the walls and floors of production premises, and in panels bolted to
walls or floors. For detailed ambient conditions, refer to the Ambient Conditions section.
AQ267037536117en-000101 / 130R0083 | 17Danfoss A/S © 2023.09
Mechanical Installation
VLT HVAC Drive FC 102
Operating Guide

•
•
•
•
•
1.
2.
3.
4.
•
•
3.3 Mounting
3.3.1 Cooling
Ensure that top and bottom clearance for air cooling is provided. See Table 4 for clearance requirements.
a
a
e30bd528.10
Illustration 5: Top and Bottom Cooling Clearance
Table 4: Minimum Airflow Clearance Requirements
Enclosure
A2–A5
B1–B4
C1, C3
C2, C4
a [mm (in)]
100 (3.9)
200 (7.8)
200 (7.8)
225 (8.9)
3.3.2 Lifting
To determine a safe lifting method, check the weight of the unit, see 8.12 Power Ratings, Weight, and Dimensions.
Ensure that the lifting device is suitable for the task.
If necessary, plan for a hoist, crane, or forklift with the appropriate rating to move the unit.
For lifting, use hoist rings on the unit, when provided.
3.3.3 Mounting
Procedure
Ensure that the strength of the mounting location supports the unit weight.
The drive allows side-by-side installation.
Locate the unit as near to the motor as possible. Keep the motor cables as short as possible.
Mount the unit vertically to a solid flat surface or to the optional backplate to provide cooling airflow.
Use the slotted mounting holes on the unit for wall mount, when provided.
3.3.3.1 Mounting with Mounting Plate and Railings
A mounting plate is required when mounted on railings.
All A, B, and C enclosures allow side-by-side installation. Exception: If an IP21 kit is used, there has to be a clearance between the
enclosures:
For enclosures A2, A3, A4, B3, B4, and C3, the minimum clearance is 50 mm (1.97 in).
For enclosure C4, the minimum clearance is 75 mm (2.95 in).
AQ267037536117en-000101 / 130R008318 | Danfoss A/S © 2023.09
Mechanical Installation
VLT HVAC Drive FC 102
Operating Guide

e30bd504.11
Illustration 6: Proper Mounting with Mounting Plate
AQ267037536117en-000101 / 130R0083 | 19Danfoss A/S © 2023.09
Mechanical Installation
VLT HVAC Drive FC 102
Operating Guide

•
•
•
•
-
-
-
4 Electrical Installation
4.1 Safety Instructions
See 2.3 Safety Precautions for general safety instructions.
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned
off and locked out. Failure to run output motor cables separately or to use shielded cables could result in death or serious injury.
Run output motor cables separately or use shielded cables.
Simultaneously lock out all the drives.
WARNING
SHOCK HAZARD
The unit can cause a DC current in the PE conductor. Failure to use a Type B residual current-operated protective device (RCD)
may lead to the RCD not providing the intended protection and therefore may result in death or serious injury.
When an RCD is used for protection against electrical shock, only a Type B device is allowed on the supply side.
Overcurrent protection
Extra protective equipment, such as short-circuit protection or motor thermal protection between drive and motor, is required
for applications with multiple motors.
Input fusing is required to provide short circuit and overcurrent protection. If not factory-supplied, the installer must provide
fuses. See maximum fuse ratings in the Fuses and Circuit Breakers section.
Wire type and ratings
All wiring must comply with local and national regulations regarding cross-section and ambient temperature requirements.
Power connection wire recommendation: Minimum 75 °C (167 °F) rated copper wire. See 8.1 Electrical Data, 200–240 V and
3x115Y/200–139Y/240 Vto 8.4 Electrical Data, 525–690 V and 8.8.3 Control Cable Cross-sections for recommended wire sizes
and types.
4.2 EMC-compliant Installation
To obtain an EMC-compliant installation, follow the instructions provided in 4.3 Grounding, 4.4 Wiring Schematic, 4.6 Connecting
the Motor, and 4.8.1 Control Wiring.
NOTICE
POTENTIAL EQUALIZATION
Risk of burst transient when the ground potential between the drive and the control system is different. Install equalizing cables
between the system components. Recommended cable cross-section: 16 mm2(6 AWG).
AQ267037536117en-000101 / 130R008320 | Danfoss A/S © 2023.09
Electrical Installation
VLT HVAC Drive FC 102
Operating Guide