Danfoss 102 Operating Instructions Manual Download Page 1

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MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT

HVAC Drive FC 102, 1.1-90 kW

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.ctiautomation.net - Email: [email protected]

Summary of Contents for 102

Page 1: ...MAKING MODERN LIVING POSSIBLE Operating Instructions VLT HVAC Drive FC 102 1 1 90 kW Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net...

Page 2: ...Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net...

Page 3: ...d any remote DC link power supplies including battery backups UPS and DC link connections to other frequency converters Wait for the capacitors to fully discharge before performing any service or repa...

Page 4: ...Safety VLT HVAC Drive Operating Instructions MG11AI02 VLT is a registered Danfoss trademark Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net...

Page 5: ...Shielded Cable 13 2 4 3 Motor Connection 13 2 4 3 1 Motor Connection for A2 and A3 15 2 4 3 2 Motor Connection for A4 A5 15 2 4 3 3 Motor Connection for B1 and B2 16 2 4 3 4 Motor Connection for C1 a...

Page 6: ...1 Uploading Data to the LCP 35 4 2 2 Downloading Data from the LCP 35 4 3 Restoring Default Settings 35 4 3 1 Recommended Initialisation 35 4 3 2 Manual Initialisation 35 5 About Frequency Converter P...

Page 7: ...dent Specifications 66 10 1 1 Mains Supply 3 x 525 690 V AC 74 10 2 General Technical Data 77 10 3 Fuse Tables 82 10 3 1 Branch Circuit Protection Fuses 82 10 3 2 UL and cUL Branch Circuit Protection...

Page 8: ...g switches A53 A54 14 Mains input terminals 91 L1 92 L2 93 L3 6 Cable strain relief PE ground 15 USB connector 7 Decoupling plate 16 Serial bus terminal switch 8 Grounding clamp PE 17 Digital I O and...

Page 9: ...14 Grounding clamp PE 5 Analog I O connector 15 Cable strain relief PE ground 6 Cable strain relief PE ground 16 Brake terminal 81 82 7 USB connector 17 Load sharing terminal DC bus 88 89 8 Serial bus...

Page 10: ...age of the output are regulated to control the motor speed or torque The frequency converter can vary the speed of the motor in response to system feedback such as changing temperature or pressure for...

Page 11: ...e kW V A2 A3 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4 200 240 1 1 2 2 3 0 3 7 1 1 2 2 1 1 3 7 5 5 11 15 5 5 11 15 18 5 18 5 30 37 45 22 30 37 45 380 480 1 1 4 0 5 5 7 5 1 1 4 0 1 1 7 5 11 18 5 22 30 11 18 5 22 3...

Page 12: ...frequency converter uncovered 2 2 Frequency Converter and Motor Pre installation Check List Compare the model number of unit on the nameplate to what was ordered to verify the proper equipment Ensure...

Page 13: ...nting location will support the unit weight Mount the unit to a solid flat surface or to the optional back plate to provide cooling airflow see Illustration 2 2 and Illustration 2 3 Improper mounting...

Page 14: ...OUT 39 A OUT 42 0 4 20 mA 03 0 10Vdc 10Vdc 0 10Vdc 0 4 20 mA 240Vac 2A 24Vdc 02 01 05 04 06 240Vac 2A 24V NPN 0V PNP 0V PNP 24V NPN 19 D IN 24V NPN 0V PNP 27 24V 0V D IN OUT 0V PNP 24V NPN D IN OUT 0V...

Page 15: ...utput contactor Generally not recommended 8 Mains 3 phase and reinforced PE 4 Earth grounding rail PE 9 Control wiring 5 Cable insulation stripped 10 Equalising min 16 mm2 0 025 in Table 2 2 Legend to...

Page 16: ...and over current protection Input fusing is required to provide this protection see Illustration 2 6 If not factory supplied fuses must be provided by the installer as part of instal lationinstallatio...

Page 17: ...Use RCDs with an inrush delay to prevent faults due to transient earth currents Dimension RCDs according to the system configu ration and environmental considerations 2 4 2 2 Grounding Using Shielded...

Page 18: ...s and Earth Wiring for A Frame Sizes 91 L1 92 L2 93 L3 96 U 97 V 98 W 88 DC 89 DC 81 R 8 R 130BA390 11 99 95 Illustration 2 9 Motor Mains and Earth Wiring for B C and D Frame Sizes Using Shielded Cabl...

Page 19: ...ter insulation of the motor cable is removed under the clamp 130BA266 10 DC BR B M A I N S L1 L2 92 RELAY 1 Y 2 99 LC V W MOTOR Illustration 2 12 Cable Clamp Mounting 2 4 3 2 Motor Connection for A4 A...

Page 20: ...t power wiring to terminals L1 L2 and L3 see Illustration 2 16 Depending on the configuration of the equipment input power will be connected to the mains input terminals or the input disconnect L1 L2...

Page 21: ...r Covers Nm 2 4 5 2 Control Terminal Types Illustration 2 19 shows the removable frequency converter connectors Terminal functions and default settings are summarized in Table 2 4 1 4 2 3 130BA012 11...

Page 22: ...A53 and A54 select mA or V 54 6 2 Feedback Terminal Description Digital Inputs Outputs Terminal Parameter Default Setting Description 55 Common for analog input Serial Communication 61 Integrated RC...

Page 23: ...rnal RC link Use twisted pair cables to reduce interference between conductors The recommended method is in Illustration 2 24 PE FC PE FC 130BB923 11 PE PE 69 68 61 69 68 61 1 2 Illustration 2 24 Twis...

Page 24: ...53 Switch Setting Terminal 54 default is for a feedback signal in closed loop set in 16 63 Terminal 54 Switch Setting 130BT310 10 1 2 N O VLT BUS TER OFF ON A53 A54 U I U I Illustration 2 26 Location...

Page 25: ...849 1 Performance Level d MTTFd Mean Time To Dangerous Failure 14000 years DC Diagnostic Coverage 90 Category 3 Lifetime 20 years Data for EN IEC 62061 EN IEC 61508 EN IEC 61800 5 2 SIL 2 Capability S...

Page 26: ...verter or auxiliary circuits Perform work on electrical parts of the frequency converter or the motor only after isolating the mains voltage supply and waiting the length of time specified in Table 1...

Page 27: ...L d acc EN ISO 13849 1 and SIL 2 acc EN 62061 After activation of Safe Stop the display shows the text Safe Stop activated The associated help text says Safe Stop has been activated This means that th...

Page 28: ...d state and the mechanical brake if connected remains activated 1 4 Send Reset signal via Bus Digital I O or Reset key The test step is passed when the motor becomes operational again The commissionin...

Page 29: ...solation 2 Verify that there is no voltage on input terminals L1 91 L2 92 and L3 93 phase to phase and phase to ground 3 Verify that there is no voltage on output terminals 96 U 97 V and 98 W phase to...

Page 30: ...n regarding electromagnetic compatibility Environmental consider ations See equipment label for the maximum ambient operating temperature limits Humidity levels must be 5 95 non condensing Fusing and...

Page 31: ...following Frequency converters require basic operational programming before running for best performance Basic operational programming requires entering motor nameplate data for the motor being opera...

Page 32: ...n select 1 PM non salient SPM 2 Make sure to set 0 02 Motor Speed Unit to 0 RPM Programming motor data After selecting PM motor in 1 10 Motor Construction the PM motor related parameters in parameter...

Page 33: ...reduced 1 66 Min Current at Low Speed should be reduced 100 Low inertia applications 50 ILoad IMotor 5 Keep calculated values High inertia applications ILoad IMotor 50 1 14 Damping Gain 1 15 Low Spee...

Page 34: ...ensure that the motor system and any attached equipment is ready for start could result in personal injury or equipment damage NOTE The Hand On key provides a local start command to the frequency con...

Page 35: ...ury or equipment damage 1 Press Auto On 2 Ensure that external control functions are properly wired to the frequency converter and all programming is completed 3 Apply an external run command 4 Adjust...

Page 36: ...can be adjusted by pressing Status and key 4 1 1 LCP Layout The LCP is divided into four functional groups see Illustration 4 1 Auto on Reset Hand on Off Status Quick Menu Main Menu Alarm Log C a n c...

Page 37: ...l information In Auto mode press to toggle between status read out displays Press repeatedly to scroll through each status display Press Status plus or to adjust the display brightness The symbol in t...

Page 38: ...130BP046 10 Hand on Off Auto on Reset Illustration 4 5 Operation Keys Key Function Hand On Starts the frequency converter in local control Use the navigation keys to control frequency converter speed...

Page 39: ...be through 14 22 Operation Mode or manually Initialisation using 14 22 Operation Mode does not change frequency converter data such as operating hours serial communication selections personal menu set...

Page 40: ...er to receive a 0 10 V DC analog control signal on input terminal 53 The frequency converter will respond by providing 6 60 Hz output to the motor propor tional to the input signal 0 10 V DC 6 60 Hz S...

Page 41: ...3 High Ref Feedb Value 50 000 Illustration 5 7 Analog Reference 6 15 Terminal 53 High Ref Feedb Value With an external device providing a 0 10 V control signal connected to frequency converter termina...

Page 42: ...igh Limit RPM See Note 3 and 5 1500 PM 1800 RPM 4 14 Motor Speed High Limit Hz See Note 4 50 Hz 60 Hz 4 19 Max Output Frequency 100 Hz 120 Hz 4 53 Warning Speed High 1500 RPM 1800 RPM 5 12 Terminal 27...

Page 43: ...tting functions in several related parameters These parameter settings provide the frequency converter with system details it needs to operate properly System details may include such things as input...

Page 44: ...15 Terminal 33 Digital Input 20 21 Setpoint 1 6 22 Terminal 54 Low Current 20 01 Feedback 1 Conversion 0 70 Date and Time Q3 21 Analog Reference 20 81 PID Normal Inverse Control 6 24 Terminal 54 Low R...

Page 45: ...cle Protection 6 23 Terminal 54 High Current 20 73 Minimum Feedback Level 2 10 Brake Function 22 46 Maximum Boost Time 22 76 Interval between Starts 6 24 Terminal 54 Low Ref Feedb Value 20 74 Maximum...

Page 46: ...Ramp Up Time 3 52 Ramp 2 Ramp Down Time 3 8 Other Ramps 3 80 Jog Ramp Time 3 81 Quick Stop Ramp Time 3 82 Starting Ramp Up Time 3 9 Digital Pot Meter 3 90 Step Size 3 91 Ramp Time 3 92 Power Restore...

Page 47: ...Ethernet Services 12 90 Cable Diagnostic 12 91 Auto Cross Over 12 92 IGMP Snooping 12 93 Cable Error Length 12 94 Broadcast Storm Protection 12 95 Broadcast Storm Filter 12 96 Port Config 12 98 Inter...

Page 48: ...18 Ext 1 Feedback Unit 21 19 Ext 1 Output 21 2 Ext CL 1 PID 21 20 Ext 1 Normal Inverse Control 21 21 Ext 1 Proportional Gain 21 22 Ext 1 Integral Time 21 23 Ext 1 Differentation Time 21 24 Ext 1 Dif...

Page 49: ...X42 9 Output 26 51 Terminal X42 9 Min Scale 26 52 Terminal X42 9 Max Scale 26 53 Terminal X42 9 Bus Control 26 54 Terminal X42 9 Timeout Preset 26 6 Analog Out X42 11 26 60 Terminal X42 11 Output 26 6...

Page 50: ...ency converter Or the entire frequency converter profile can be loaded onto the PC for back up storage or analysis The USB connector or RS 485 terminal is available for connecting to the frequency con...

Page 51: ...Parameter group 1 2 must be set according to motor D IN 37 is an option Table 6 1 AMA with T27 Connected Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12...

Page 52: ...igital Input is set to 0 No operation a jumper wire to terminal 27 is not needed D IN 37 is an option Table 6 5 Start Stop Command with Safe Stop Option 130BB805 11 Speed Start 18 Illustration 6 1 Sta...

Page 53: ...Alarm Reset Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 A53 U I 5k 130BB683 10 Function Setting 6 10 Te...

Page 54: ...rmistors must use reinforced or double insulation to meet PELV insulation requirements Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29...

Page 55: ...l the frequency converter Stop commands reset reversing DC brake and other signals applied to the control terminals can override local control Table 7 1 Status Message Operation Mode Reference Site Re...

Page 56: ...tion for a digital input parameter group 5 1 Digital Inputs The corresponding terminal is active The frequency converter saves the actual reference Changing the reference is now only possible via term...

Page 57: ...Low Standby In Auto On Auto mode the frequency converter starts the motor with a start signal from a digital input or serial communication Start delay In 1 71 Start Delay a delay starting time was se...

Page 58: ...can be reset It will then be ready to start operation again A trip can be reset in any of 4 ways Press Reset on the LCP Digital reset input command Serial communication reset input command Auto reset...

Page 59: ...atch X X 16 Short Circuit X X 17 Control word timeout X X 8 04 Control Timeout Function 18 Start Failed X 1 77 Compressor Start Max Speed RPM 1 79 Compressor Start Max Time to Trip 1 03 Torque Charact...

Page 60: ...X 60 External Interlock X 62 Output Frequency at Maximum Limit X 64 Voltage Limit X 65 Control Board Over temperature X X X 66 Heat sink Temperature Low X 67 Option Configuration has Changed X 69 Pwr...

Page 61: ...rammed at 14 12 Function at Mains Imbalance Troubleshooting Check the supply voltage and supply currents to the frequency converter WARNING 5 DC link voltage high The intermediate circuit voltage DC i...

Page 62: ...rce selects terminal 18 or 19 WARNING ALARM 12 Torque limit The torque has exceeded the value in 4 16 Torque Limit Motor Mode or the value in 4 17 Torque Limit Generator Mode 14 25 Trip Delay at Torqu...

Page 63: ...peration If a short circuit occurs the brake function is disabled and the warning appears The frequency converter is still operational but without the brake function Remove power to the frequency conv...

Page 64: ...3072 5122 Parameter value is outside its limits 5123 Option in slot A Hardware incompatible with control board hardware 5124 Option in slot B Hardware incompatible with control board hardware 5376 62...

Page 65: ...dition To resume normal operation apply 24 V DC to the terminal programmed for external interlock Reset the frequency converter WARNING 62 Output frequency at maximum limit The output frequency has re...

Page 66: ...is not set or the RTC clock has failed Reset the clock in 0 70 Date and Time WARNING 200 Fire mode This warning indicates the frequency converter is operating in fire mode The warning clears when fire...

Page 67: ...connections If the display continues to cut out follow the procedure for display dark Motor not running Service switch open or missing motor connection Check if the motor is connected and the connect...

Page 68: ...group 2 0 DC Brake and 3 0 Reference Limits Open power fuses or circuit breaker trip Phase to phase short Motor or panel has a short phase to phase Check motor and panel phase for shorts Eliminate any...

Page 69: ...d or vibration have been reduced to an acceptable limit Turn off over modulation in 14 03 Overmodulation Change switching pattern and frequency in parameter group 14 0 Inverter Switching Increase Reso...

Page 70: ...6 8 9 5 11 3 15 0 Intermittent 3 x 200 240 V A 6 5 7 5 10 5 12 4 16 5 Additional specifications Estimated power loss at rated max load W 4 63 82 116 155 185 IP20 IP21 max cable cross section mains mot...

Page 71: ...0 28 0 42 0 54 0 68 0 Intermittent 3 x 200 240 V A 24 2 30 8 46 2 59 4 74 8 Additional Specifications Estimated power loss at rated max load W 4 269 310 447 602 737 IP20 max cable cross section mains...

Page 72: ...200 240 V A 80 0 104 0 130 0 154 0 Intermittent 3 x 200 240 V A 88 0 114 0 143 0 169 0 Additional Specifications Estimated power loss at rated max load W 4 845 1140 1353 1636 IP20 max cable cross sect...

Page 73: ...0 V A 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermittent 3 x 380 440 V A 3 0 4 1 5 5 7 2 9 9 12 9 15 8 Continuous 3 x 441 480 V A 2 7 3 1 4 3 5 7 7 4 9 9 13 0 Intermittent 3 x 441 480 V A 3 0 3 4 4 7 6 3 8 1...

Page 74: ...t 3 x 380 439 V A 24 2 31 9 37 4 44 60 5 Continuous 3 x 440 480 V A 19 25 31 36 47 Intermittent 3 x 440 480 V A 20 9 27 5 34 1 39 6 51 7 Additional specifications Estimated power lossat rated max load...

Page 75: ...mittent 3 x 380 439 V A 72 6 90 2 106 146 177 Continuous 3 x 440 480 V A 59 73 95 118 145 Intermittent 3 x 440 480 V A 64 9 80 3 105 130 160 Additional specifications Estimated power lossat rated max...

Page 76: ...nt Continuous 3 x 525 600 V A 2 4 2 7 4 1 5 2 5 8 8 6 10 4 17 2 Intermittent 3 x 525 600 V A 2 7 3 0 4 5 5 7 6 4 9 5 11 5 19 Additional specifications Estim power loss at rated max load W 4 50 65 92 1...

Page 77: ...61 7 82 7 99 6 130 5 Max input current Continuous 3 x 525 600 V A 20 9 25 4 32 7 39 49 59 78 9 95 3 124 3 Intermittent 3 x 525 600 V A 23 28 36 43 54 65 87 105 137 Additional specifications Estim pow...

Page 78: ...nput current Continuous 3x525 550 V A 1 9 2 4 3 5 4 4 5 5 8 10 Intermittent 3x525 550 V A 2 1 2 6 3 8 8 4 6 0 8 8 11 Continuous kVA 3x551 690 V A 1 4 2 0 2 9 4 0 4 9 6 7 9 Intermittent kVA 3x551 690 V...

Page 79: ...2 74 1 Max input current Continuous 3 x 525 690 V A 19 5 24 29 36 Intermittent 3 x 525 690 V A 21 5 26 4 31 9 39 6 Continuous 3 x 525 550 V A 52 63 Intermittent 3 x 525 550 V A 57 2 69 3 Continuous 3...

Page 80: ...98 0 98 0 98 Table 10 11 Mains Supply 3 x 525 690 V AC IP21 IP55 NEMA 1 NEMA 12 1 For type of fuse see 10 3 Fuse Tables 2 American Wire Gauge 3 Measured using 5 m screened motor cables at rated load...

Page 81: ...supply voltage Output frequency 1 1 90 kW 0 590 Hz Output frequency 110 250 kW 0 5901 Hz Switching on output Unlimited Ramp times 1 3600 s 1 Voltage and power dependent Torque characteristics Starting...

Page 82: ...4 When using a contactor with a DC coil inside in combination with Safe Stop it is important to make a return way for the current from the coil when turning it off This can be done by using a freewhee...

Page 83: ...er high voltage terminals 1 only 2 Pulse inputs are 29 and 33 Analog output Number of programmable analog outputs 1 Terminal number 42 Current range at analog output 0 4 20 mA Max load GND analog outp...

Page 84: ...terminal load AC 1 1 on 4 5 NO Resistive load 2 3 Overvoltage cat II 400 V AC 2 A Max terminal load AC 15 1 on 4 5 NO Inductive load cos 0 4 240 V AC 0 2 A Max terminal load DC 1 1 on 4 5 NO Resistiv...

Page 85: ...a standard host device USB cable The USB connection is galvanically isolated from the supply voltage PELV and other high voltage terminals The USB ground connection is not galvanically isolated from p...

Page 86: ...aR 45K 250A1 200 240 type aR 380 480 V T4 1K1 1K5 10A1 380 500 type gG 2K2 3K0 16A1 380 500 type gG 4K0 5K5 25A1 380 500 type gG 7K5 35A1 380 500 type gG 11K 15K 63A1 380 500 type gG 18K 63A1 380 500...

Page 87: ...63 gG 100 55 gG 80 gG 125 75 gG 100 gG 160 C3 37 gG 100 gG 125 45 gG 125 gG 160 D 37 gG 125 gG 125 45 gG 160 gG 160 55 75 gG 200 gG 200 90 aR 250 aR 250 110 aR 315 aR 315 132 160 aR 350 aR 350 200 aR...

Page 88: ...20 200 L25S 200 A25X 200 A25X 200 45K FWX 250 2028220 250 L25S 250 A25X 250 A25X 250 380 480 V 525 600 V kW Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1 1K1 KTS R6 JKS 6 JJS 6 5017906 006...

Page 89: ...d C Recommended max fuse SIBA Littel fuse Ferraz Shawmut Ferraz Shawmut kW Type RK1 Type RK1 Type RK1 Type J 0 37 1 1 5017906 005 KLSR005 A6K 5R HSJ6 1 5 2 2 5017906 010 KLSR010 A6K 10R HSJ10 3 501790...

Page 90: ...n KTS FWX Bussmann FWH KLNR LITTEL FUSE KLSR L50S LITTEL FUSE L50S A2KR FERRAZ SHAWMUT A6KR A25X FERRAZ SHAWMUT A50X Table 10 18 Substitute Fuses 10 4 Connection Tightening Torques Power kW Torque Nm...

Page 91: ...51 System 6 Terminals 10 18 28 34 51 37 Wire 18 Wiring 12 0 12 18 26 Cooling Cooling 8 Clearance 26 Copying Parameter Settings 34 Current Limit 30 Rating 8 58 D DC Current 7 51 Link 57 Derating 8 Dig...

Page 92: ...rent 7 29 61 33 Data 28 30 58 61 30 Frequency 33 Output 77 Power 10 0 12 61 33 Protection 12 81 Rotation 30 33 Speeds 27 Status 6 Wiring 12 0 13 26 Mounting 9 26 Multiple Frequency Converters 12 13 Mo...

Page 93: ...s Messages 51 Mode 51 Stop Command 51 Supply Voltage 17 25 60 Switching Frequency 51 Symbols iii System Feedback 6 Monitoring 54 Start Up 31 T Technical Data 77 Temperature Limits 26 Terminal 53 20 36...

Page 94: ...Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net...

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