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
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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