Danfoss VLT FC 103 User Manual Download

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MAKING MODERN LIVING POSSIBLE

Instruction Manual

VLT

Refrigeration Drive FC 103, 75–400 kW

Summary of Contents for VLT FC 103

Page 1: ...MAKING MODERN LIVING POSSIBLE Instruction Manual VLT Refrigeration Drive FC 103 75 400 kW ...

Page 2: ......

Page 3: ...aution to guard against an unintended start WARNING DISCHARGE TIME Adjustable frequency drives contain DC link capacitors that can remain charged even when the adjustable frequency drive is not powered To avoid electrical hazards disconnect AC line power any permanent magnet type motors and any remote DC link power supplies including battery backups UPS and DC link connections to other adjustable ...

Page 4: ...Safety VLT Refrigeration Drive Instruction Manual MG16J122 VLT is a registered Danfoss trademark ...

Page 5: ...General Requirements 3 3 2 4 2 Grounding Requirements 3 6 2 4 2 1 Leakage Current 3 5 mA 3 6 2 4 2 2 Grounding IP20 Enclosures 3 7 2 4 2 3 Grounding IP21 54 Enclosures 3 7 2 4 3 Motor Connection 3 8 2 4 3 1 Terminal Locations D1h D4h 3 8 2 4 4 Motor Cable 3 11 2 4 5 Motor Rotation Check 3 11 2 4 6 AC Line Input Connections 3 12 2 5 Control Wiring Connection 3 12 2 5 1 Access 3 12 2 5 2 Using Shiel...

Page 6: ...ing LCP Display Values 5 2 4 1 3 Display Menu Keys 5 2 4 1 4 Navigation Keys 5 3 4 1 5 Operation Keys 5 3 4 2 Backup and Copying Parameter Settings 5 3 4 2 1 Uploading Data to the LCP 5 4 4 2 2 Downloading Data from the LCP 5 4 4 3 Restoring Default Settings 5 4 4 3 1 Recommended Initialization 5 4 4 3 2 Manual Initialization 5 4 5 Programming 6 1 5 1 Introduction 6 1 5 2 Programming Example 6 1 5...

Page 7: ...ng and Alarm Displays 9 1 8 4 Warning and Alarm Definitions 9 3 8 5 Fault Messages 9 6 9 Basic Troubleshooting 10 1 9 1 Start up and Operation 10 1 10 Specifications 11 1 10 1 Power dependent Specifications 11 1 10 2 General Technical Data 11 4 10 3 Fuse Tables 11 9 10 3 1 Protection 11 9 10 3 2 Fuse Selection 11 9 10 3 3 Short Circuit Current Rating SCCR 11 10 10 3 4 Connection Tightening Torques...

Page 8: ...Contents VLT Refrigeration Drive Instruction Manual MG16J122 VLT is a registered Danfoss trademark ...

Page 9: ...5 serial bus connector 10 Lifting ring 3 Digital I O and 24 V power supply 11 Mounting slot 4 Analog I O connector 12 Cable clamp PE 5 USB connector 13 Ground 6 Serial bus terminal switch 14 Motor output terminals 96 U 97 V 98 W 7 Analog switches A53 A54 15 Line power input terminals 91 L1 92 L2 93 L3 8 Relay 1 01 02 03 16 TB5 IP21 54 only Terminal block for anti condensation heater Table 1 1 Intr...

Page 10: ...structions supplied with those options for specific requirements Contact the local Danfoss supplier or visit the Danfoss website www danfoss com BusinessAreas DrivesSolutions Documentations VLT Technical Documen tation htm for downloads or additional information 1 4 Product Overview An adjustable frequency drive is an electronic motor controller that converts AC line power input into a variable AC...

Page 11: ...5 Capacitor bank Stores the DC power Provides 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 three 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 ...

Page 12: ...4h D4h D4h D4h 690 V D3h D3h D3h D4h D4h D4h D4h Table 1 3 kW Rated Adjustable Frequency Drives Normal Overload HP 125 150 200 250 300 350 400 450 460 V D3h D3h D3h D4h D4h D4h 575 V D3h D3h D3h D4h D4h D4h D4h Table 1 4 HP Rated Adjustable Frequency Drives Introduction VLT Refrigeration Drive Instruction Manual 1 4 MG16J122 VLT is a registered Danfoss trademark 1 1 ...

Page 13: ...ing PELV Table 2 1 Installation in High Altitudes 2 1 2 Planning the Installation Site NOTE Before performing the installation it is important to plan the installation of the adjustable 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 the respective Desi...

Page 14: ... heat out of the back channel of the adjustable frequency drives The backchannel air can be redirected from the panel or room using one of the kits below Duct cooling A backchannel cooling kit is available to direct the heatsink cooling air out of the panel when an IP20 chassis adjustable frequency drives is installed in a Rittal enclosure Use of this kit reduces the heat in the panel and smaller ...

Page 15: ...stable frequency drive input terminals Connecting control and serial communication wiring After power has been applied checking input and motor power programming control terminals for their intended functions WARNING EQUIPMENT HAZARD Rotating shafts and electrical equipment can be hazardous All electrical work must conform to national and local electrical codes It is strongly recommended that inst...

Page 16: ...V 0V D IN OUT 0V PNP 24V NPN D IN OUT 0V 24V 29 24V NPN 0V PNP 0V PNP 24V NPN 33 D IN 32 D IN 1 2 ON A53 U I S201 ON 2 1 A54 U I S202 ON 0 20mA OFF 0 10V 95 400Vac 2A P 5 00 R 82 R 81 P RS 485 68 N RS 485 69 COM RS 485 61 0V 5V S801 RS 485 RS 485 2 1 ON S801 Bus Term OFF ON 3 Phase power input Load Share Switch Mode Power Supply Motor Analog Output Interface Relay1 Relay2 ON Terminated OFF Open Br...

Page 17: ...urrent draw the quicker the trip response The overload provides Class 20 motor protection See 8 Warnings and Alarms for details on the trip function Because the motor wiring carries high frequency current it is important that wiring for line power motor power and control is run separately Use metallic conduit or separated shielded wire See Figure 2 3 Failure to isolate power motor and control wiri...

Page 18: ...sy chain fashion Keep the ground wire connections as short as possible Using high strand wire to reduce electrical noise is recommended Follow the motor manufacturer wiring requirements 2 4 2 1 Leakage Current 3 5 mA Follow national and local codes regarding protective grounding of equipment with a leakage current 3 5 mA Adjustable frequency drive technology implies high frequency switching at hig...

Page 19: ... 2 5 Grounding Points for IP20 Chassis Enclosures 2 4 2 3 Grounding IP21 54 Enclosures The adjustable frequency drive can be grounded using conduit or shielded cable For grounding of the power connections use the dedicated grounding points as shown in Figure 2 6 130BC304 10 Figure 2 6 Grounding for IP21 54 Enclosures Installation VLT Refrigeration Drive Instruction Manual MG16J122 VLT is a registe...

Page 20: ...he motor Do not wire a starting or pole changing device between the adjustable frequency drive and the motor Connect the 3 phase motor wiring to terminals 96 U 97 V and 98 W Ground the cable in accordance with the instructions provided Torque terminals in accordance with the information provided in 10 3 4 Connection Tightening Torques Follow the motor manufacturer wiring requirements 2 4 3 1 Termi...

Page 21: ...NALS MAINS TERMINAL SECTION B B MOTOR TERMINALS AND BRAKE TERMINALS MOTOR TERMINAL BRAKE TERMINAL 130BC302 10 Figure 2 8 Terminal Locations D3h 1 2 130BC533 10 190 7 5 75 3 0 98 3 9 50 2 0 Figure 2 9 Load share or Regeneration Terminals D3h 1 Front view 2 Side view Table 2 4 Installation VLT Refrigeration Drive Instruction Manual MG16J122 VLT is a registered Danfoss trademark 2 9 2 2 ...

Page 22: ...NS TERMINAL 130BC332 10 Figure 2 10 Terminal Locations D2h A A B B 33 1 3 0 0 0 91 3 6 149 5 8 211 8 3 265 10 4 319 12 6 200 7 9 0 0 0 319 12 6 376 14 8 293 11 5 255 10 0 0 0 0 306 12 1 284 11 2 0 0 0 236 8 9 R S T U V W BRAKE TERMINALS SECTION A A MAINS TERMINALS MAINS TERMINAL SECTION B B MOTOR TERMINALS AND BRAKE TERMINALS TERMINAL BRAKE REGEN MOTOR TERMINAL 130BC333 10 Figure 2 11 Terminal Loc...

Page 23: ...s follows Terminal no Function 96 97 98 99 Line power U T1 V T2 W T3 Ground Table 2 6 2 4 5 Motor Rotation Check The direction of rotation can be changed by switching two phases in the motor cable or by changing the setting of 4 10 Motor Speed Direction Terminal U T1 96 connected to U phase Terminal V T2 97 connected to V phase Terminal W T3 98 connected to W phase 96 97 U V 96 97 98 U V W 98 W 13...

Page 24: ...eg grounded delta set 14 50 RFI 1 to OFF When off the internal RFI filter capacitors between the chassis and the intermediate circuit are isolated to avoid damage to the intermediate circuit and to reduce ground capacity currents in accordance with IEC 61800 3 2 5 Control Wiring Connection Isolate control wiring from high power components in the adjustable frequency drive If the adjustable frequen...

Page 25: ...raided or twisted pattern a Aluminum clad with copper wire b Twisted copper wire or armored steel wire cable c Single layer braided copper wire with varying percentage shield coverage This is the typical Danfoss reference cable d Double layer braided copper wire e Twin layer of braided copper wire with a magnetic shielded armored intermediate layer f Cable that runs in copper tube or steel tube g ...

Page 26: ...ttings are summarized in 2 5 6 Control Terminal Functions 1 4 2 3 130BA012 12 61 68 69 39 42 50 53 54 55 12 13 18 19 27 29 32 33 20 37 Figure 2 19 Control Terminal Locations Connector 1 provides four programmable digital input terminals two additional digital terminals programmable as either input or output a 24 V DC terminal supply voltage and a common for optional customer supplied 24 V DC volta...

Page 27: ...tches Analog input terminals 53 and 54 can select either voltage 0 10 V or current 0 4 20 mA input signals Remove power to the adjustable frequency drive before changing switch positions Set switches A53 and A54 to select the signal type U selects voltage I selects current The switches are accessible when the LCP has been removed see Figure 2 21 NOTE Some option cards available for the unit may co...

Page 28: ... 2 7 Optional Equipment 2 7 1 Load Share Terminals Load share terminals enable the connection of the DC circuits of several adjustable frequency drives Load share terminals are available in IP20 adjustable frequency drives and extend out the top of the adjustable frequency drive A terminal cover supplied with the adjustable frequency drive must be installed to maintain the IP20 rating of the enclo...

Page 29: ...ing chopper is automatically activated when the DC bus voltage exceeds a specified level depending on the nominal voltage of the adjustable frequency drive 2 7 5 line Power Shield The line power shield is a Lexan cover installed inside the enclosure to provide protection according to VBG 4 accident prevention requirements Installation VLT Refrigeration Drive Instruction Manual MG16J122 VLT is a re...

Page 30: ...Installation VLT Refrigeration Drive Instruction Manual 2 18 MG16J122 VLT is a registered Danfoss trademark 2 2 ...

Page 31: ...rive disconnect switches for input power isolation 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 phase and phase to ground 4 Confirm continuity of the motor by measuring ohm values on U V 96 97 V W 97 98 and W U 98 96 5 Check for proper grounding of the ...

Page 32: ...sure proper airflow for cooling EMC considerations Check for proper installation 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 circuit breakers Check for proper fusing or circuit breakers Check that all fuses are inserted firmly and in operational ...

Page 33: ... been designed with industry refrigeration engineers in mind in order to ensure that the text and language used make complete sense to the installer At start up the FC 103 asks the user to run the VLT Drive Application Guide or to skip it until it has been run the FC 103 will ask every time at start up Once this has been done the application guide can be accessed through the Quick Menu screen for ...

Page 34: ...ick Menu as described below If OK is pressed the Application Guide will start with the following screen 130BC95 2 10 Figure 3 2 NOTE Numbering of steps in the wizard e g 1 12 can change depending on workflow choices This screen will automatically change to the first input screen of the Application Guide 130BC953 1 0 Figure 3 3 130BC954 10 Figure 3 4 Compressor pack set up The following example sho...

Page 35: ...h as a temperature or other sensor which is wired directly into the adjustable frequency drive and controls from the sensor signal External Open loop The FC 103 takes its control signal from another controller such as a pack controller which gives the adjustable frequency drive e g 0 10 V 4 20 mA or FC 103 Lon The adjustable frequency drive will change its speed depending upon this reference signa...

Page 36: ...13 Info Set switch accordingly Figure 3 14 Select unit and conversion from pressure Figure 3 15 Select fixed or floating setpoint Figure 3 16 Set setpoint Figure 3 17 Start up and Functional Tes VLT Refrigeration Drive Instruction Manual 3 6 MG16J122 VLT is a registered Danfoss trademark 3 3 ...

Page 37: ...pack control set up Figure 3 20 Set number of compressors in pack Figure 3 21 Info Connect accordingly 130BC955 10 Figure 3 22 Info Set up completed Figure 3 23 Start up and Functional Tes VLT Refrigeration Drive Instruction Manual MG16J122 VLT is a registered Danfoss trademark 3 7 3 3 ...

Page 38: ... The bypass valve must be programmed to operate from one of the extra relay outputs on the MCB 105 board This is needed because the standard relay outputs in the FC 103 are used to control the compressors in the pack 3 3 2 Required Initial Adjustable Frequency Drive Programming NOTE If the wizard is run ignore the following Adjustable frequency drives require basic operational programming before r...

Page 39: ... Input at factory default Otherwise select No Operation For adjustable frequency drives with an optional Danfoss bypass no jumper wire is required 10 3 02 Minimum Reference 11 3 03 Maximum Reference 12 3 41 Ramp 1 Ramp up Time 13 3 42 Ramp 1 Ramp down Time 14 3 13 Reference Site Linked to Hand Auto Local Remote 3 4 Automatic Motor Adaptation Automatic motor adaptation AMA is a test procedure that ...

Page 40: ...tion 3 6 Local Control Test CAUTION MOTOR START Ensure that the motor system and any attached equipment are ready for start It is the responsibility of the user to ensure safe operation under any condition Failure to 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 t...

Page 41: ...o help with this task Other aids to application set up are listed in 1 3 Additional Resources The following procedure is recommended after application set up by the user is completed CAUTION MOTOR START Ensure that the motor system and any attached equipment is ready for start It is the responsibility of the user to ensure safe operation under any condition Failure to do so could result in persona...

Page 42: ...Start up and Functional Tes VLT Refrigeration Drive Instruction Manual 3 12 MG16J122 VLT is a registered Danfoss trademark 3 3 ...

Page 43: ...r to the LCP See the Programming Guide for details on use of the NLCP 4 1 1 LCP Layout The LCP is divided into four functional groups see Figure 4 1 Auto on Reset Hand on Off Status Quick Menu Main Menu Alarm Log C a n c e l Info Status 1 1 1234rpm B a c k OK 43 5Hz Run OK 43 5Hz On Alarm Warn 130BC362 10 a b c d 1 0 A Figure 4 1 LCP a Display area b Display menu keys for changing the display to s...

Page 44: ...Key Function Status Shows operational information In Auto mode press to toggle between status readout displays Press repeatedly to scroll through each status display Press Status plus or to adjust the display brightness The symbol in the upper right corner of the display shows the direction of motor rotation and which set up is active This is not programmable Quick Menu Allows access to programmin...

Page 45: ...at the bottom of the LCP 130BP046 10 Hand on Off Auto on Reset Figure 4 5 Operation Keys Key Function Hand On Starts the adjustable frequency drive in local control Use the navigation keys to control adjustable frequency drive speed An external stop signal by control input or serial communication overrides the local hand on Off Stops the motor but does not remove power to the adjustable frequency ...

Page 46: ...ization of the adjustable frequency drive Initialization can be through 14 22 Operation Mode or manually Initialization using 14 22 Operation Mode does not change adjustable frequency drive data such as operating hours serial communication selections personal menu settings fault log alarm log and other monitoring functions Using 14 22 Operation Mode is generally recommended Manual initialization e...

Page 47: ...ple for programming the adjustable frequency drive for a common application in open loop using the quick menu This procedure programs the adjustable frequency drive to receive a 0 10 V DC analog control signal on input terminal 53 The adjustable frequency drive will respond by providing 6 60 Hz output to the motor propor tional to the input signal 0 10 V DC 6 60 Hz Select the following parameters ...

Page 48: ...ue 000020 000 Figure 5 6 7 6 15 Terminal 53 High Ref Feedb Value Set maximum speed reference on Terminal 53 at 60 Hz This tells the adjustable frequency drive that the maximum voltage received on Terminal 53 10 V equals 60 Hz output 130BT774 11 Q3 21 14 7 0 00 A 1 1 Analog Reference 6 15 Terminal 53 High Ref Feedb Value 50 000 Figure 5 7 With an external device providing a 0 10 V control signal co...

Page 49: ...access function choices The default setting Start is shown 5 1 130BT770 10 5 10 Terminal 18 Digital Input 8 Start 14 7 0 00A 1 1 Digital Inputs Figure 5 11 5 4 International North American Default Parameter Settings Setting 0 03 Regional Settings to 0 International or 1 North America changes the default settings for some parameters Table 5 1 lists those parameters that are effected Parameter Inter...

Page 50: ...OK 3 Select Q5 2 Since Factory Setting to view all programming changes or Q5 1 Last 10 Changes for the most recent Q5 130BB850 10 Q5 1 Last 10 Changes Q5 2 Since Factory Setti 25 9 0 00A 1 1 Changes Made Figure 5 12 Changes Made 5 4 1 Parameter Data Check 1 Press Quick Menu 2 Scroll to Q5 Changes Made and press OK 130BP089 10 Q1 My Personal Menu Q2 Quick Setup Q3 Function Setups Q5 Changes Made 25...

Page 51: ...ps 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 3 93 Maximum Limit 3 94 Minimum Limit 3 95 Ramp Delay 4 Limits Warnings 4 1 Motor Limits 4 10 Motor Speed Direction 4 11 Motor Speed Low Limit RPM 4 12 Motor Speed Low Limit Hz 4 13 Motor Speed High Limit RPM 4 14 Motor Speed High Limit Hz 4 16 Torque Li...

Page 52: ...No 15 47 Power Card Ordering No 15 48 LCP Id No 15 49 SW ID Control Card 15 50 SW ID Power Card 15 51 Frequency Converter Serial Number 15 53 Power Card Serial Number 15 6 Option Ident 15 60 Option Mounted 15 61 Option SW Version 15 62 Option Ordering No 15 63 Option Serial No 15 8 Operating Data II 15 80 Fan Running Hours 15 9 Parameter Info 15 92 Defined Parameters 15 93 Modified Parameters 15 9...

Page 53: ... Text 23 5 Energy Log 23 50 Energy Log Resolution 23 51 Period Start 23 53 Energy Log 23 54 Reset Energy Log 23 6 Trending 23 60 Trend Variable 23 61 Continuous Bin Data 23 62 Timed Bin Data 23 63 Timed Period Start 23 64 Timed Period Stop 23 65 Minimum Bin Value 23 66 Reset Continuous Bin Data 23 67 Reset Timed Bin Data 23 8 Payback Counter 23 80 Power Reference Factor 23 81 Energy Cost 23 82 Inv...

Page 54: ...rogramming rather than using the LCP Additionally all adjustable frequency drive programming can be done off line and simply downloaded to the adjustable frequency drive Or the entire adjustable frequency drive profile can be loaded onto the PC for backup storage or analysis The USB connector or RS 485 terminal is available for connecting to the adjustable frequency drive Programming VLT Refrigera...

Page 55: ...AMA 5 12 Terminal 27 Digital Input 2 Coast inverse Default Value Notes comments Parameter group 1 2 must be set according to motor 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 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 130BB930 10 Function Setting 1 29 Automatic Motor Adaptation AMA 1 Enable complete AMA 5 12 Term...

Page 56: ... Safe Stop Alarm Default Value Notes comments If 5 12 Terminal 27 Digital Input is set to 0 No operation a jumper wire to terminal 27 is not needed Table 6 5 Start Stop Command with Safe Stop 130BB805 11 Speed Start 18 Figure 6 1 Start Stop Command with Safe Stop 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...

Page 57: ... Value Notes comments Table 6 8 External 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 5kΩ 130BB683 10 Function Setting 6 10 Terminal 53 Low Voltage 0 07 V 6 11 Terminal 53 High Voltage 10 V 6 14 Terminal 53 Low Ref Feedb Value 0 Hz 6 15 Terminal 53 High Ref Feedb Value 1500 Hz Default...

Page 58: ...e 6 11 RS 485 Network Connection CAUTION Thermistors 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 32 33 37 50 53 54 55 42 39 A53 U I 130BB686 11 Function Setting 1 90 Motor Thermal Protection 2 Thermistor trip 1 93 Thermistor Source 1 Analog input 53 Def...

Page 59: ...rminals and or the serial communication Hand On The adjustable frequency drive can be controlled by the navigation keys on the LCP Stop commands reset reversing DC brake and other signals applied to the control terminals can override local control Table 7 1 Operation Mode Remote The speed reference is given from external signals serial communication or internal preset references Local The adjustab...

Page 60: ...1 Digital Inputs The corresponding terminal is active The adjustable frequency drive saves the actual reference Changing the reference is now only possible via terminal functions speed up and slow Jog request A jog command has been given but the motor will be stopped until a run permissive signal is received via a digital input Jogging The motor is running as programmed in 3 19 Jog Speed RPM Jog w...

Page 61: ... start command is activated and the motor will start after the start delay time expires Start fwd rev Start forward and start reverse were selected as functions for two different digital inputs parameter group 5 1 Digital Inputs The motor will start in forward or reverse depending on which corresponding terminal is activated Stop The adjustable frequency drive has received a stop command from the ...

Page 62: ...Status Messages VLT Refrigeration Drive Instruction Manual 7 4 MG16J122 VLT is a registered Danfoss trademark 7 7 ...

Page 63: ...The adjustable frequency drive logic will continue to operate and monitor the adjustable frequency drive status After the fault condition is remedied the adjustable frequency drive can be reset It will then be ready to start operation again A trip can be reset in any of four ways Press Reset Digital reset input command Serial communication reset input command Auto reset 8 2 3 Alarm Trip Lock An al...

Page 64: ...ator lights Auto on Reset Hand on Off B a c k C a n c e l Info OK On Alarm Warn 130BB467 10 Figure 8 3 Warn LED Alarm LED Warning ON OFF Alarm OFF ON Flashing Trip Lock ON ON Flashing Table 8 1 Warnings and Alarms VLT Refrigeration Drive Instruction Manual 8 2 MG16J122 VLT is a registered Danfoss trademark 8 8 ...

Page 65: ...lt X 14 53 Fan Monitor 25 Brake resistor short circuited X 26 Brake resistor power limit X X 2 13 Brake Power Monitoring 27 Brake chopper short circuited X X 28 Brake check X X 2 15 Brake Check 29 Drive overtemperature X X X 30 Motor phase U missing X X X 4 58 Missing Motor Phase Function 31 Motor phase V missing X X X 4 58 Missing Motor Phase Function 32 Motor phase W missing X X X 4 58 Missing M...

Page 66: ...X 60 External Interlock X 62 Output Frequency at Maximum Limit X 64 Voltage Limit X 65 Control board overtemperature X X X 66 Heatsink Temperature Low X 67 Option Configuration has Changed X 70 Illegal FC configuration X 71 PTC 1 Safe Stop X X1 72 Dangerous Failure X1 73 Safe Stop Auto Restart 76 Power Unit Set up X 77 Reduced Power Mode 79 Illegal PS config X X 80 Drive Initialized to Default Val...

Page 67: ...X 0 7 Clock Settings 104 Mixing Fan Fault X X 14 53 Fan Monitor 203 Missing Motor 204 Locked Rotor 243 Brake IGBT X X 244 Heatsink temp X X X 245 Heatsink sensor X X 246 Pwr card supply X X 247 Pwr card temp X X 248 Illegal PS config X X 250 New spare parts X 251 New Type Code X X Table 8 3 Alarm Warning Code List X Dependent on parameter 1 Cannot be Auto reset via 14 20 Reset Mode Warnings and Al...

Page 68: ...arning limit The limit is dependent on the adjustable frequency drive voltage rating The unit is still active WARNING 6 DC link voltage low The intermediate circuit voltage DC is lower than the low voltage warning limit The limit is dependent on the adjustable frequency drive voltage rating The unit is still active WARNING ALARM 7 DC overvoltage If the intermediate circuit voltage exceeds the limi...

Page 69: ...r Resource matches sensor wiring 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 Torque Limit can change this from a warning only condition to a warning followed by an alarm Troubleshooting If the motor torque limit is exceeded during ramp up extend the ramp up time If the generator...

Page 70: ...the brake function is disabled and the warning appears The adjustable frequency drive is still operational but without the brake function Remove power to the adjustable frequency drive and replace the brake resistor see 2 15 Brake Check WARNING ALARM 26 Brake resistor power limit The power transmitted to the brake resistor is calculated as a mean value over the last 120 s of run time The calculati...

Page 71: ...n is properly installed Check for loose or missing wiring It may be necessary to contact the Danfoss supplier or service department Note the code number for further troubleshooting directions No Text 0 Serial port cannot be initialized Contact the Danfoss supplier or Danfoss Service Department 256 258 Power EEPROM data is defective or too old 512 Control board EEPROM data is defective or too old 5...

Page 72: ...rive card or the ribbon cable between the power card and gate drive card WARNING 40 Overload of digital output terminal 27 Check the load connected to terminal 27 or remove short circuit connection Check 5 00 Digital I O Mode and 5 01 Terminal 27 Mode WARNING 41 Overload of digital output terminal 29 Check the load connected to terminal 29 or remove short circuit connection Check 5 00 Digital I O ...

Page 73: ...d over temperature The control card has reached its trip temperature of 167 F 75 C WARNING 66 Heatsink temperature low The adjustable frequency drive is too cold to operate This warning is based on the temperature sensor in the IGBT module Increase the ambient temperature of the unit Also a trickle amount of current can be supplied to the adjustable frequency drive whenever the motor is stopped by...

Page 74: ...e Parameter settings are initialized to default settings after a manual reset Reset the unit to clear the alarm ALARM 81 CSIV corrupt CSIV file has syntax errors ALARM 82 CSIV parameter error CSIV failed to init a parameter ALARM 85 Dang fail PB Profibus Profisafe Error WARNING ALARM 104 Mixing fan fault The fan monitor checks that the fan is spinning at drive power up or whenever the mixing fan i...

Page 75: ...P from VLT 2800 or 5000 6000 8000 FCD or FCM Use only LCP 101 P N 130B1124 or LCP 102 P N 130B1107 Wrong contrast setting Press Status to adjust the contrast Display LCP is defective Test using a different LCP Replace the faulty LCP or connection cable Internal voltage supply fault or SMPS is defective Contact supplier Intermittent display Overloaded power supply SMPS due to improper control wirin...

Page 76: ...ection is programmed correctly Program correct settings Active reversing signal Check if a reversing command is programmed for the terminal in parameter group 5 1 Digital inputs Deactivate reversing signal Wrong motor phase connection See 2 4 5 Motor Rotation Check in this manual Motor is not reaching maximum speed Frequency limits set wrong Check output limits in 4 13 Motor Speed High Limit RPM 4...

Page 77: ... B to C C to A If imbalance leg stays on same input terminal it is a problem with the unit Contact the supplier Motor current imbalance greater than 3 Problem with motor or motor wiring Rotate output motor leads one position U to V V to W W to U If imbalanced leg follows the wire the problem is in the motor or motor wiring Check motor and motor wiring Problem with the adjustable frequency drives R...

Page 78: ...Basic Troubleshooting VLT Refrigeration Drive Instruction Manual 9 4 MG16J122 VLT is a registered Danfoss trademark 9 9 ...

Page 79: ...32 397 487 588 Continuous kVA at 400 V kVA 147 180 218 274 333 407 Continuous kVA at 460 V kVA 151 191 241 288 353 426 Max input current Continuous at 400 V A 204 251 304 381 463 567 Continuous at 460 480 V A 183 231 291 348 427 516 Max cable size line power motor brake and load share mm AWG 2x95 2x3 0 2x185 2x350 Max external electrical fuses A 315 350 400 550 630 800 Estimated power loss at 400 ...

Page 80: ...241 Continuous kVA at 690 V kVA 103 129 157 185 229 289 Max input current Continuous at 550 V A 89 110 130 158 198 245 Continuous at 575 V A 85 106 124 151 189 234 Continuous at 690 V A 87 109 128 155 197 240 Max cable size line power motor brake and load share mm AWG 2x95 2x3 0 2x185 2x350 mcm Max external electrical fuses A 160 315 315 315 350 350 Estimated power loss at 575 V W 1161 1426 1739 2...

Page 81: ...610 5150 Weight enclosure IP21 IP54 lbs kg 275 125 Weight enclosure IP20 lbs kg 275 125 Efficiency 0 98 Output frequency 0 590 Hz Heatsink overtemp trip 230 F 110 C Power card ambient trip 167 F 75 C Normal overload 110 current for 60 s Table 10 3 Line Power Supply 3 x 525 690 V AC The typical power loss is at nominal load conditions and expected to be within 15 tolerance relates to variety in vol...

Page 82: ...istics Starting torque Constant torque maximum 110 for 60 s Starting torque maximum 135 up to 0 5 s Overload torque Constant torque maximum 110 for 60 s Percentage relates to the adjustable frequency drive s nominal torque Cable lengths and cross sections Max motor cable length shielded armored 500 ft 150 m Max motor cable length unshielded unarmored 1 000 ft 300 m Max cross section to motor line ...

Page 83: ...17 10 Figure 10 1 Pulse inputs Programmable pulse inputs 2 Terminal number pulse 29 33 Max frequency at terminal 29 33 110 kHz push pull driven Max frequency at terminal 29 33 5 kHz open collector Min frequency at terminal 29 33 4 Hz Voltage level see 10 2 1 Digital Inputs Maximum voltage on input 28 V DC Input resistance Ri approx 4 kΩ Pulse input accuracy 0 1 1 kHz Max error 0 1 of full scale An...

Page 84: ...Max terminal load DC 1 1 on 1 2 NO resistive load 80 V DC 2 A Max terminal load DC 13 1 on 1 2 NO inductive load 24 V DC 0 1 A Max terminal load AC 1 1 on 1 3 NC resistive load 240 V AC 2 A Max terminal load AC 15 1 on 1 3 NC inductive load cosφ 0 4 240 V AC 0 2 A Max terminal load DC 1 1 on 1 3 NC resistive load 50 V DC 2 A Max terminal load DC 13 1 on 1 3 NC inductive load 24 V DC 0 1 A Min term...

Page 85: ... the Design Guide section on Special Conditions Minimum ambient temperature during full scale operation 32 F 0 C Minimum ambient temperature at reduced performance 14 F 10 C Temperature during storage transport 13 149 158 F 25 to 65 70 C Maximum altitude above sea level without derating 3 300 ft 1 000 m Maximum altitude above sea level with derating 10 000 ft 3 000 m 1 For more information on dera...

Page 86: ...as an auto derating function to avoid its heatsink reaching 203 F 95 C The adjustable frequency drive is protected against short circuits on motor terminals U V W If a line phase is missing the adjustable frequency drive trips or issues a warning depending on the load Monitoring of the intermediate circuit voltage ensures that the adjustable frequency drive trips if the intermediate circuit voltag...

Page 87: ...to national regulations 10 3 2 Fuse Selection Danfoss recommends using the following fuses which will ensure compliance with EN50178 In case of malfunction not following the recommendation may result in unnecessary damage to the adjustable frequency drive The fuses below are suitable for use on a circuit capable of delivering 100 000 Arms symmetrical N110 N315 380 480 V type aR N75K N400 525 690 V...

Page 88: ...ust be used 10 3 3 Short Circuit Current Rating SCCR The Short Circuit Current Rating SCCR of the adjustable frequency drives is 100 000 amps at all voltages 380 690 V If the adjustable frequency drive is supplied with a line power disconnect the SCCR of the adjustable frequency drive is 100 000 amps at all voltages 380 690 V 10 3 4 Connection Tightening Torques When tightening all electrical conn...

Page 89: ...3 Card 8 6 Card Performance 10 7 Card 10 V DC Output 10 7 Card 24 V DC Output 10 6 Card RS 485 Serial Communication 10 6 Card USB Serial Communication 10 7 Characteristics 10 7 Signal 5 1 5 2 7 1 System 1 2 Terminal Functions 2 15 Terminal Types 2 14 Terminals 3 9 4 3 7 1 5 3 2 15 Wiring 2 3 2 5 2 6 3 2 Wiring Connection 2 12 Cooling Cooling 2 2 Clearance 3 2 Copying Parameter Settings 4 3 Current...

Page 90: ... Isolated Line Power 2 12 L Leakage Current 3 1 Current 3 5 MA 2 6 Lifting 2 3 Line Power 2 5 Power Supply L1 L2 L3 10 4 Local Control 4 1 4 3 7 1 Control Panel 4 1 Control Test 3 10 Mode 3 10 Operation 4 1 Start 3 10 M Main Menu 4 2 5 1 Manual Initialization 4 4 Mechanical Installation 2 2 Menu Keys 4 1 4 2 Structure 4 3 5 4 Motor Cable 2 11 Cables 2 5 2 8 3 10 Connection 2 8 Current 1 3 3 9 4 2 ...

Page 91: ... S Safety Inspection 3 1 Serial Communication 1 2 2 13 2 14 4 3 7 1 2 16 Setpoint 7 1 Set up 3 11 4 2 Shielded Cable 2 3 3 2 Control Cables 2 13 Wire 2 5 Short Circuit 8 8 Specifications 1 2 Speed Reference 2 15 3 11 5 2 6 1 6 0 7 1 Startup 5 1 Start up 1 2 4 4 9 1 Status Messages 7 1 Mode 7 1 Stop Command 7 1 Supply Voltage 2 12 2 14 3 1 8 9 10 5 Surroundings 10 7 Switching Frequency 7 1 System F...

Page 92: ...W Warning And Alarm Definitions 8 3 Wire Type And Ratings 2 6 Wiring To Control Terminals 2 15 Index VLT Refrigeration Drive Instruction Manual 12 4 MG16J122 VLT is a registered Danfoss trademark ...

Page 93: ...Index VLT Refrigeration Drive Instruction Manual MG16J122 VLT is a registered Danfoss trademark 12 5 ...

Page 94: ...www danfoss com drives MG16J122 130R0414 MG16J122 Rev 2013 04 22 ...

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Summary of Contents for VLT FC 103

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Danfoss VLT FC 103, Instruction Manual

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Summary of Contents for VLT FC 103

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