Danfoss VLT HVAC Drive FC 102 User manual

Operating Guide
VLT® HVAC Drive FC 102
355-800 kW, Enclosure Sizes E1h-E4h

Contents
1 Introduction 7
1.1 Purpose of this Operating Guide 7
1.2 Manual and Software Version 7
1.3 Trademarks 7
1.4 Approvals and Certifications 7
1.5 Disposal 8
2 Safety 9
2.1 Safety Symbols 9
2.2 Qualified Personnel 9
2.3 Safety Precautions 9
3 Product Overview 12
3.1 Power Ratings, Weights, and Dimensions for E1h–E4h Enclosures 12
3.2 Interior View of Enclosure E1h/E2h 13
3.3 Interior View of Enclosure E3h/E4h 15
3.4 Control Shelf 16
3.5 Local Control Panel (LCP) 17
3.6 LCP Menu 19
4 Mechanical Installation 22
4.1 Tools Needed 22
4.2 Storing the Drive 22
4.3 Operating Environment 22
4.3.1 Overview 22
4.3.2 Gases 23
4.3.3 Dust 23
4.3.4 Potentially Explosive Atmospheres 23
4.4 Installation Requirements 24
4.5 Cooling Requirements 24
4.6 E1h-E4h Airflow Rates 25
4.7 Lifting the Drive 25
4.8 E1h/E2h Mechanical Installation 26
4.8.1 Securing the Pedestal to the Floor 26
4.8.2 Attaching an E1h/E2h to the Pedestal 27
4.8.3 Creating Cable Openings for an E1h/E2h 29
4.9 E3h/E4h Mechanical Installation 29
4.9.1 Attaching the E3h/E4h to a Mounting Plate or Wall 30
4.9.2 Creating Cable Openings for an E3h/E4h 30
4.9.3 Installing Load share/Regen Terminals to an E3h/E4h 33
ContentsOperating Guide | VLT® HVAC Drive FC 102
AQ275556502253en-000101 / | 3Danfoss A/S © 2020.01

5 Electrical Installation 34
5.1 Safety Instructions 34
5.2 EMC-compliant Installation 35
5.3 Wiring Schematic 39
5.4 Connecting the Motor 40
5.5 Connecting the AC Mains 41
5.6 Connecting to Ground 44
5.7 E1h Terminal Dimensions 46
5.8 E2h Terminal Dimensions 48
5.9 E3h Terminal Dimensions 50
5.10 E4h Terminal Dimensions 53
5.11 Control Wiring 55
5.11.1 Control Cable Access 55
5.11.2 Routing Control Cables 56
5.11.3 Control Terminal Types 57
5.11.4 Relay Terminals 58
5.11.5 Connecting the Control Cable to the Control Terminals 59
5.11.6 Disconnecting the Control Cable from the Control Terminals 60
5.11.7 Enabling Motor Operation 60
5.11.8 Configuring RS485 Serial Communication 61
5.11.9 Safe Torque Off (STO) Wiring 62
5.11.10 Space Heater Wiring 62
5.11.11 Auxiliary Contact Wiring for Disconnects 62
5.11.12 Wiring the Brake Resistor Temperature Switch 63
5.11.13 Selecting the Voltage/Current Input Signal 63
6 Starting the Drive 65
6.1 Pre-start Check List 65
6.2 Applying Power to the Drive 66
6.3 Programming the Drive 67
6.3.1 Parameter Overview 67
6.3.2 Parameter Navigation 67
6.3.3 Entering System Information 67
6.3.4 Configuring Automatic Energy Optimization 68
6.3.5 Configuring Automatic Motor Adaptation 69
6.4 Testing Before System Start Up 69
6.4.1 Testing Motor Rotation 69
6.4.2 Testing Encoder Rotation 70
6.5 Starting Up the Drive for the First Time 70
6.6 Parameter Settings 71
6.6.1 Parameter Setting Overview 71
6.6.2 Uploading and Downloading Parameter Settings 71
ContentsOperating Guide | VLT® HVAC Drive FC 102
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6.6.3 Restoring Factory Default Settings Using the Recommended Initialization 72
6.6.4 Restoring Factory Default Settings Using Manual Initialization 72
7 Wiring Configuration Examples 73
7.1 Application Examples 73
7.1.1 Wiring Configuration for Automatic Motor Adaptation (AMA) 73
7.1.2 Wiring Configuration for Automatic Motor Adaptation without T27 74
7.1.3 Wiring Configuration: Speed 74
7.1.4 Wiring Configuration: Feedback 77
7.1.5 Wiring Configuration: Run/Stop 80
7.1.6 Wiring Configuration: Start/Stop 83
7.1.7 Wiring Configuration: External Alarm Reset 86
7.1.8 Wiring Configuration: RS485 87
7.1.9 Wiring Configuration: Motor Thermistor 87
7.1.10 Wiring for Regen 89
7.1.11 Wiring Configuration for a Relay Setup with Smart Logic Control 90
7.1.12 Wiring Configuration for a Cascade Controller 90
7.1.13 Wiring Configuration for a Fixed Variable Speed Pump 92
7.1.14 Wiring Configuration for Lead Pump Alternation 93
8 Maintenance, Diagnostics, and Troubleshooting 94
8.1 Maintenance and Service 94
8.2 Heat Sink Service 94
8.2.1 Heat Sink Access Panel 94
8.2.2 Removing Dust Buildup from the Heat Sink 94
8.3 Status Messages 95
8.3.1 Status Message Overview 95
8.3.2 Status Messages - Operating Mode 96
8.3.3 Status Messages - Reference Site 96
8.3.4 Status Messages - Operation Status 97
8.4 Warnings and Alarms 99
8.5 Troubleshooting 124
9 Specifications 127
9.1 Electrical Data 127
9.1.1 Electrical Data, 380–480 V AC 127
9.1.2 Electrical Data, 525–690 V AC 129
9.2 Mains Supply 132
9.3 Motor Output and Torque Characteristics 132
9.3.1 Motor Output (U, V, W) 132
9.3.2 Torque Characteristics 132
9.4 Ambient Conditions 133
9.5 Cable Specifications 133
ContentsOperating Guide | VLT® HVAC Drive FC 102
AQ275556502253en-000101 / | 5Danfoss A/S © 2020.01

9.6 Control Input/Output and Control Data 133
9.6.1 Digital Inputs 133
9.6.2 STO Terminal 37 134
9.6.3 Analog Inputs 134
9.6.4 Pulse/encoder Inputs 135
9.6.5 Analog Output 135
9.6.6 Control Card, RS485 Serial Communication 136
9.6.7 Digital Outputs 136
9.6.8 Control Card, 24 V DC Output 136
9.6.9 Relay Outputs 136
9.6.10 Control Card, +10 V DC Output 137
9.6.11 Control Characteristics 137
9.6.12 Control Card Performance 138
9.6.13 Control Card, USB Serial Communication 138
9.7 Fuses 138
9.8 Enclosure Dimensions 140
9.8.1 E1h Exterior Dimensions 140
9.8.2 E2h Exterior Dimensions 144
9.8.3 E3h Exterior Dimensions 148
9.8.4 E4h Exterior Dimensions 152
9.9 Enclosure Airflow 156
9.10 Fastener Torque Ratings 156
10 Appendix 158
10.1 Conventions 158
10.2 Abbreviations 158
10.3 International/North American Default Parameter Settings 160
ContentsOperating Guide | VLT® HVAC Drive FC 102
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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 available with the drive.
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
Manual version Remarks Software ver‐
sion
AQ275556502253xx-xx01-01 Updated power losses in Electrical Data table. Created Starting the Drive chapter
by combining Commissioning and Pre-start Check List chapters.
5.41
MG16O2xx Previous version. 4.44
1.3 Trademarks
VLT® is a registered trademark for Danfoss A/S.
1.4 Approvals and Certifications
e30bu682.10
Illustration 1: Approvals and Certifications
More approvals and certifications are available. Contact the local Danfoss office or partner. Drives of voltage T7 (525–690 V) are UL
certified for only 525–600 V.
Thermal memory retention requirement
The drive complies with UL 61800-5-1 thermal memory retention requirements. For more information, refer to the Motor Thermal
Protection section in the product-specific design guide.
NOTICE
OUTPUT FREQUENCY LIMIT
From software version 3.92 onwards, the output frequency of the drive is limited to 590 Hz due to export control regulations.
Introduction
Operating Guide | VLT® HVAC Drive FC 102
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Danfoss A/S © 2020.01

ADN-compliance
For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to the ADN-compliant Installation section in the product-specific design guide.
1.5 Disposal
Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with
applicable local regulations.
Introduction
Operating Guide | VLT® HVAC Drive FC 102
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8 | Danfoss A/S © 2020.01