Danfoss FC 100 Series User manual

Contents
1. How to Read this Instruction Manual
5
How to Read this Instruction Manual 5
Approvals 6
Symbols 6
Abbreviations 7
2. Safety Instructions and General Warning 9
Safety Regulations FC 100 9
Disposal Instructions 9
High Voltage 10
Safety Instructions 10
Avoid Unintended Start 11
Safe Stop Installation 12
IT Line 13
3. How to Install 15
How to Get Started 15
Pre-installation - High Power 16
Planning the Installation Site 16
Receiving the Adjustable Frequency Drive 16
Transportation and Unpacking 16
Lifting 17
Enclosures 18
Rated Power 18
Mechanical Dimensions 20
Mechanical Installation 21
Tools Needed 21
General Considerations 22
Installation in Enclosures - IP 00 / Chassis units 32
Installation on the Wall - IP 21 (NEMA 1) and IP 54 (NEMA 12) Units 32
Floor Mounting - Pedestal Installation IP 21 (NEMA1) and IP 54 (NEMA12) 33
Gland/Conduit Entry - IP 21 (NEMA 1) and IP 54 (NEMA12) 35
IP 21 Drip shield installation (D1 and D2 enclosure) 36
Field Installation of Options 36
Installation on pedestal 46
Electrical Installation 49
VLT
®
HVAC DRIVE High Power
Instruction Manual Contents
MG.11.F1.22 - VLT®is a registered Danfoss trademark. 1

Control Wires 49
Power Connections 50
Line connection 59
Fuses 60
Electrical Installation, Control Terminals 63
Connection Examples 65
Start/Stop 65
Pulse Start/Stop 65
Speed Up/Slow 66
Potentiometer Reference 66
Electrical Installation - continued 67
Electrical Installation, Control Cables 67
Switches S201, S202, and S801 69
Final Set-up and Test 70
Additional Connections 72
Motor Thermal Protection 72
4. How to Program 73
Graphical (GLCP) and Numerical (NLCP) Display 73
How to Program on the Graphical LCP 73
How to Program on the Numerical Local Control Panel 74
Quick Set-up 75
Parameter Descriptions 82
Parameter Options 84
Default settings 84
0-** Operation and Display 85
1-** Load / Motor 87
2-** Brakes 88
3-** Reference / Ramps 89
4-** Limits / Warnings 90
5-** Digital In / Out 91
6-** Analog In / Out 93
8-** Communication and Options 95
9-** Profibus 97
10-**CAN Ser. Com. Bus 98
11-** LonWorks 99
13-** Smart Logic Controller 100
Contents
VLT
®
HVAC DRIVE High Power
Instruction Manual
2 MG.11.F1.22 - VLT®is a registered Danfoss trademark.

14-** Special Functions 101
15-** FC Information 102
16-** Data Readouts 104
18-** Info & Readouts 106
20-** FC Closed-loop 107
21-** Ext. Closed-loop 108
22-** Application Functions 110
23-** Time-based Funtions 112
24-** Application Functions 2 113
25-** Cascade Controller 114
26-** Analog I / O Option MCB 109 116
5. General Specifications 117
6. Warnings and Alarms 125
Alarm and Status Messages 125
Alarms and warnings 125
7. Annexes 131
Index
137
VLT
®
HVAC DRIVE High Power
Instruction Manual Contents
MG.11.F1.22 - VLT®is a registered Danfoss trademark. 3

1. How to Read this Instruction Manual
VLT
®
HVAC DRIVE High Power
Instruction Manual
4 MG.11.F1.22 - VLT®is a registered Danfoss trademark.
1

1. How to Read this Instruction Manual
1.1. How to Read this Instruction Manual
1.1.1. How to Read this Instruction Manual
VLT
®
HVAC Drive FC 100 is designed to provide high shaft performance on electrical motors.
Please read this manual carefully for proper use. Incorrect handling of the adjustable frequency
drive may cause improper operation of the adjustable frequency drive or related equipment,
shorten lifetime or cause other problems.
This Instruction Manual will help you get started, install, program, and troubleshoot your VLT
®
HVAC Drive FC 100.
Chapter 1, How to Read this Instruction
Manual
Introduces the manual and informs you about the approvals, symbols, and abbreviations used in
therein.
Chapter 2, Safety Instructions and Gen-
eral Warnings
Contains instructions on how to handle the FC 100 correctly.
Chapter 3, How to Install
Guides you through mechanical and technical installation.
Chapter 4, How to Program
Shows you how to operate and program the FC 100 via the Local Control Panel.
Chapter 5, General Specifications
Contains technical data about the FC 100.
Chapter 6, Troubleshooting
Assists you in solving problems that may occur when using the FC 100.
Available literature for VLT HVAC Drive
-Instruction Manual MG.11.Ax.yy provides the neccessary information for getting the drive
up and running.
-Design Guide MG.11.Bx.yy provides all the technical information about the 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
-VLT
®
6000 HVAC Application Booklet, MN.60.Ix.yy
-Instruction Manual VLT
®
HVAC Drive BACnet, MG.11.Dx.yy
-Instruction Manual VLT
®
HVAC Drive Profibus, MG.33.Cx.yy.
-Instruction Manual VLT
®
HVAC Drive Device Net, MG.33.Dx.yy
-Instruction Manual VLT
®
HVAC Drive LonWorks, MG.11.Ex.yy
-Instruction Manual VLT
®
HVAC Drive High Power, MG.11.Fx.yy
VLT
®
HVAC DRIVE High Power
Instruction Manual 1. How to Read this Instruction Manual
MG.11.F1.22 - VLT®is a registered Danfoss trademark. 5
1

-Instruction Manual VLT
®
HVAC Drive Metasys, MG.11.Gx.yy
x = Revision number
yy = Language code
Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/
DrivesSolutions/Documentations/Technical+Documentation.
Danfoss Drives technical literature is also available online at www.danfoss.com/drives.
1.1.2. Approvals
1.1.3. 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. How to Read this Instruction Manual
VLT
®
HVAC DRIVE High Power
Instruction Manual
6 MG.11.F1.22 - VLT®is a registered Danfoss trademark.
1

1.1.4. Abbreviations
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit ILIM
Degrees Celsius °C
Direct current DC
Drive Dependent D-TYPE
Electro Magnetic Compatibility EMC
Electronic Thermal Relay ETR
drive FC
Gram g
Hertz Hz
Kilohertz kHz
Local Control Panel LCP
Meter m
Millihenry Inductance mH
Milliampere mA
Millisecond ms
Minute min
Motion Control Tool MCT
Nanofarad nF
Newton Meters Nm
Nominal motor current IM,N
Nominal motor frequency fM,N
Nominal motor power PM,N
Nominal motor voltage UM,N
Parameter par.
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Rated Inverter Output Current IINV
Revolutions Per Minute RPM
Second s
Torque limit TLIM
Volt V
VLT
®
HVAC DRIVE High Power
Instruction Manual 1. How to Read this Instruction Manual
MG.11.F1.22 - VLT®is a registered Danfoss trademark. 7
1

2. Safety Instructions and General Warning
VLT
®
HVAC DRIVE High Power
Instruction Manual
8 MG.11.F1.22 - VLT®is a registered Danfoss trademark.
2

2. Safety Instructions and General Warning
2.1. Safety Regulations FC 100
2.1.1. Disposal Instructions
Equipment containing electrical components may not be disposed of
together with domestic waste.
It must be collected separately as electrical and electronic waste in
accordance with local and currently valid legislation.
Caution
The adjustable frequency drive DC link capacitors remain charged after power has been dis-
connected. To avoid the electrical shock hazard, disconnect the adjustable frequency drive
from the power supply before carrying out maintenance. Before servicing the adjustable fre-
quency drive, wait the minimum amount of time indicated below:
380-480 V 150-132 hp [110-200 kW] 20 minutes
350-600 hp [250-450 kW] 40 minutes
525-600 V 150-350 hp [110-250 kW] 20 minutes
450-750 hp [315-560 kW] 30 minutes
VLT HVAC Drive
Software version: 2.5x
These instructions can be used for all VLT HVAC adjustable frequency drives with software
version 2.5x.
The software version number can be found in parameter 15-43.
VLT
®
HVAC DRIVE High Power
Instruction Manual 2. Safety Instructions and General Warning
MG.11.F1.22 - VLT®is a registered Danfoss trademark. 9
2

2.1.2. High Voltage
The voltage of the adjustable frequency drive is dangerous whenever the adjustable
frequency drive is connected to line power. Incorrect installation or operation of the
motor or adjustable frequency drive may cause damage to the equipment, serious
personal injury or death. The instructions in this manual must therefore be observed,
in addition to applicable local and national rules and safety regulations.
Installation at high altitudes
At altitudes higher than 6,500 ft [2 km], please contact Danfoss Drives regarding
PELV.
2.1.3. Safety Instructions
• Make sure the adjustable frequency drive is properly grounded.
• Protect users against supply voltage.
• Protect the motor against overloading in accordance with national and local regulations.
• Motor overload protection is not included in the default settings. To add this function,
set parameter 1-90
Motor thermal protection to value ETR trip or ETR warning . 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 line power.
2.1.4. 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, such as load
sharing (linkage of DC intermediate circuit), as well as the motor connection for
kinetic backup.
When using the adjustable frequency drive: wait at least 40 minutes.
A shorter time is allowed only if indicated on the nameplate for the specific unit.
2. Safety Instructions and General Warning
VLT
®
HVAC DRIVE High Power
Instruction Manual
10 MG.11.F1.22 - VLT®is a registered Danfoss trademark.
2

Leakage Current
The ground leakage current from the adjustable frequency drive exceeds 3.5 mA.
To ensure that the ground cable has a good mechanical connection to the ground
connection (terminal 95), the cable cross-section must be at least 0.016 in.
2
[10
mm
2
] or have 2 rated ground wires 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 (x=version number).
Protective grounding of the adjustable frequency drive and the use of RCDs must
always follow national and local regulations.
2.1.5. Before Commencing Repair Work
1. Disconnect the adjustable frequency drive from the line power.
2. Wait for the discharge of the DC link. See the period of time on the warning label.
3. Disconnect DC bus terminals 88 and 89.
4. Remove motor cable.
2.1.6. 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 an unintended start.
• To avoid an unintended start, always activate the [OFF] key before changing parameters.
• An electronic fault, temporary overload, a fault in the line supply, or lost motor connection
may cause a stopped motor to start. The adjustable frequency drive with safe stop pro-
vides protection against unintended start, if Safe Stop Terminal 37 is deactivated or
disconnected.
2.1.7. Safe Stop
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
function is called safe stop. Prior to integrating and using safe stop in an installation, a thorough
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 in the relevant Design Guide must be followed! The informa-
tion and instructions contained in the Instruction Manual are not sufficient for a correct and safe
use of the safe stop functionality!
VLT
®
HVAC DRIVE High Power
Instruction Manual 2. Safety Instructions and General Warning
MG.11.F1.22 - VLT®is a registered Danfoss trademark. 11
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2.1: Diagram showing all electrical terminals. (Terminal 37 present for units with safe stop function only.)
2.1.8. Safe Stop Installation
To carry out an installation of a Catego-
ry 0 Stop (EN60204) in conformity with
Safety Category 3 (EN954-1), follow
these instructions:
1. The bridge (jumper) between Termi-
nal 37 and 24 V DC must be re-
moved. Cutting or breaking the
jumper is not sufficient. Remove it
entirely to avoid short-circuiting. See
jumper on illustration.
2. Connect terminal 37 to 24 V DC by a
short circuit-protected cable. The 24
V DC voltage supply must be inter-
ruptible by an EN954-1 category 3
circuit interrupt device. If the inter-
rupt device and the adjustable fre-
quency drive are placed in the same
installation panel, you can use an un-
shielded cable instead of a shielded
one.
2.2: Bridge jumper between terminal 37 and 24
VDC
The illustration below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN
954-1). The circuit interruption is caused by an opening door contact. The illustration also shows
how to connect a non-safety-related hardware coast.
2. Safety Instructions and General Warning
VLT
®
HVAC DRIVE High Power
Instruction Manual
12 MG.11.F1.22 - VLT®is a registered Danfoss trademark.
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2.3: Illustration of the essential aspects of an installation to achieve a Stopping Category 0 (EN 60204-1)
with safety Category 3 (EN 954-1).
2.1.9. IT Line
Par. 14-50 RFI 1 can be used on the FC 102/202/302 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.
VLT
®
HVAC DRIVE High Power
Instruction Manual 2. Safety Instructions and General Warning
MG.11.F1.22 - VLT®is a registered Danfoss trademark. 13
2

3. How to Install
VLT
®
HVAC DRIVE High Power
Instruction Manual
14 MG.11.F1.22 - VLT®is a registered Danfoss trademark.
3

3. How to Install
3.1. How to Get Started
3.1.1. About How to Install
This chapter covers mechanical and electrical installations to and from power terminals and control
card terminals.
Electrical installation of
options is described in the relevant Instruction Manual and Design Guide.
3.1.2. How to Get Started
The adjustable frequency drive is designed for quick installation and is EMC-compliant. Just follow
the steps described below.
Read the safety instructions before installing the unit.
Mechanical Installation
• Mechanical mounting
Electrical Installation
• Connection to Line and Protecting
Ground
• Motor connection and cables
• Fuses and circuit breakers
• Control terminals - cables
Quick set-up
• Local Control Panel, LCP
• Automatic Motor Adaptation, AMA
• Programming
Frame size is dependent on enclosure type,
power range and line voltage.
3.1: Diagram showing basic installation including
line power, motor, start/stop key, and potentiom-
eter for speed adjustment.
VLT
®
HVAC DRIVE High Power
Instruction Manual 3. How to Install
MG.11.F1.22 - VLT®is a registered Danfoss trademark. 15
3

3.2. Pre-installation - High Power
3.2.1. Planning the Installation Site
NOTE
Before performing the installation, it is important to plan the installation of the ad-
justable frequency drive. Neglecting this may result in extra work during and after
installation.
Select the best possible operation site by considering the following (see details on
the following pages and in the respective Design Guides):
• Ambient operating temperature
• Installation method
• How to cool the unit
• Position of the adjustable frequency drive.
•Cablerouting
• Ensure the power source supplies the correct voltage and necessary current.
• Ensure that the motor current rating is within the maximum current from the adjustable
frequency drive.
• If the adjustable frequency drive is without built-in fuses, ensure that the external fuses
are rated correctly.
3.2.2. Receiving the Adjustable Frequency Drive
When receiving the adjustable frequency drive, make sure that the packaging is intact, and look
for any damage that might have occurred to the unit during transport. If damage has occurred,
immediately contact the shipping company to make a damage claim.
3.2.3. Transportation and Unpacking
Before unpacking the adjustable frequency drive, it is recommended to unload it as close as pos-
sible to the final installation site.
Remove the cardboard box and keep the adjustable frequency drive on the pallet as long as pos-
sible. Remark: The cardboard box cover contains a drilling master for the mounting holes.
3. How to Install
VLT
®
HVAC DRIVE High Power
Instruction Manual
16 MG.11.F1.22 - VLT®is a registered Danfoss trademark.
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3.2: Mounting Template
3.2.4. Lifting
Always lift the adjustable frequency drive using the dedicated lifting holes. Use a bar to avoid
bending the lifting holes of the adjustable frequency drive.
3.3: Recommended lifting method
VLT
®
HVAC DRIVE High Power
Instruction Manual 3. How to Install
MG.11.F1.22 - VLT®is a registered Danfoss trademark. 17
3

3.3. Enclosures
3.3.1. Rated Power
Enclosure type
D1 D2 D3 D4
Enclosure
protection
IP 21/54 21/54 00 00
NEMA Type 1/ Type 12 Type 1/ Type 12 Chassis Chassis
Rated
power
150-175 hp
[110-132 kW] at 400
V
(380-480 V)
150-175 hp
[110-132 k] at 600 V
(525-600 V)
250-350 hp
[160-250 kW] at 400
V
(380-480 V)
250-450 hp
[160-315 kW] at 600
V
(525-600 V)
150-175 hp
[110-132 kW] at 400
V
(380-480 V)
150-175 hp
[110-132 k] at 600 V
(525-600 V)
250-350 hp
[160-250 kW] at 400
V
(380-480 V)
250-450 hp
[160-315 kW] at 600
V
(525-600 V)
3. How to Install
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®
HVAC DRIVE High Power
Instruction Manual
18 MG.11.F1.22 - VLT®is a registered Danfoss trademark.
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Enclosure type
E1 E2
Enclosure
protection
IP 21/54 00
NEMA Type 1/ Type 12 Chassis
Rated
power
450-600 hp [315-450 kW] at 400
V
(380-480 V)
500-750 hp [355-560 kW] at 600
V
(525-600 V)
450-600 hp [315-450 kW] at 400
V
(380-480 V)
500-750 hp [355-560 kW] at 600
V
(525-600 V)
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®
HVAC DRIVE High Power
Instruction Manual 3. How to Install
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3.3.2. Mechanical Dimensions
Mechanical dimensions, D Enclosures
Frame size D1 D2 D3 D4
150-200 hp [110-132
kW]
(380-480 V)
150-200 hp [110-132
kW]
(525-600 V)
250-350 hp [160-250
kW]
(380-480 V)
250-450 hp [160-315
kW]
(525-600 V)
150-2
00 hp
[110-
132
kW]
(380-
480 V)
150-2
00 hp
[110-
132
kW]
(525-
600 V)
250-3
50 hp
[160-
250
kW ]
(380 -
480 V)
250-4
50 hp
[160-
315
kW]
(525-
600 V)
IP
NEMA 21 Type 1
54
Type 12
21
Type 1
54
Type 12
00
Chassis
00
Chassis
Cardboard
box size
Shipping
dimensions
Height 25.6 in
[650
mm]
25.6 in [650
mm]
25.6 in
[650
mm]
25.6 in [650
mm]
25.6 in
[650
mm]
25.6 in
[650
mm]
Width
68.1 in
[1730
mm]
68.1 in [1730
mm]
68.1 in
[1730
mm]
68.1 in [1730
mm]
48 in
[1220
mm]
58.7 in
[1490
mm]
Depth
22.4 in
[570
mm]
22.4 in [570
mm]
22.4 in
[570
mm]
22.4 in [570
mm]
22.4 in
[570
mm]
22.4 in
[570
mm]
Drive
dimensions Height
45.6 in
[1159
mm]
45.6 in [1159
mm]
60.6 in
[1540
mm]
60.6 in [1540
mm]
39.3 in
[997
mm]
50.3 in
[1277
mm]
Width
16.5 in
[420
mm]
16.5 in [420
mm]
16.5 in
[420
mm]
16.5 in [420
mm]
16.1 in
[408
mm]
16.1 in
[408
mm]
Depth 14.7 in
[373
mm]
14.7 in [373
mm]
14.7 in
[373
mm]
14.7 in [373
mm]
14.7 in
[373
mm]
14.7 in
[373
mm]
Max
weight
229.3
lbs
[104
kg]
229.3 lbs [104
kg]
332.9
lbs
[151
kg]
332.9 lbs [151
kg]
200.6
lbs [91
kg]
304.2
lbs
[138
kg]
3. How to Install
VLT
®
HVAC DRIVE High Power
Instruction Manual
20 MG.11.F1.22 - VLT®is a registered Danfoss trademark.
3