Danfoss VLT HVAC Drive FC 102 User Manual Download

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ENGINEERING TOMORROW

Installation Guide

VLT

Parallel Drive Modules

250–1200 kW

vlt-drives.danfoss.com

Summary of Contents for VLT HVAC Drive FC 102

Page 1: ...ENGINEERING TOMORROW Installation Guide VLT Parallel Drive Modules 250 1200 kW vlt drives danfoss com...

Page 2: ......

Page 3: ...1 4 1 1 Items Supplied 11 4 1 2 Lifting the Unit 12 4 1 3 Storage 12 4 2 Requirements 14 4 2 1 Environmental 14 4 3 Installing the Drive Modules 16 4 4 Installing the Control Shelf 18 5 Electrical Ins...

Page 4: ...ection Switches 35 5 10 2 5 RS485 Serial Communication 36 5 10 3 Safe Torque Off STO 36 5 11 Relay Output 36 5 12 EMC Recommendations 37 6 Initial Start up 41 6 1 Pre start Check List 41 6 2 Safety In...

Page 6: ...ation examples troubleshooting and specifications Refer to the Programming Guide applicable to the particular series of VLT Parallel Drive Modules used in creating the drive system The programming gui...

Page 7: ...T When the drive system is connected to AC mains the motor can start at any time Unintended start during programming service or repair work can result in death serious injury or property damage The mo...

Page 8: ...tallation Ensure that electrical work conforms to national and local electrical codes Follow the procedures in this document WARNING DISCONNECT POWER BEFORE SERVICING Sometimes during installation AC...

Page 9: ...e based on the D4h frequency converter and can provide a greater power range in a smaller enclosure The basic kit is designed to allow the flexibility to either order components through Danfoss or fab...

Page 10: ...e 8 Ground terminals 2 MDCIC plug 9 Top fan 3 Microswitch to DC fuse 10 Drive module label See Illustration 4 2 4 Relays 1 and 2 11 Motor output terminals inside the unit 5 Brake fault jumper and conn...

Page 11: ...8 4 9 11 6 10 12 1 LCP cradle 7 MDCIC card 2 Control card underneath cover 8 Control shelf 3 Control terminal blocks 9 Switch mode power supply SMPS Note that an external 230 V supply is needed to po...

Page 12: ...able 3 5 DC Fuses The VLT Parallel Drive Modules kit contains 2 DC fuses per drive module These fuses on the supply side ensure that any damage is contained to inside the drive modules NOTICE Use of f...

Page 13: ...OPEN TYPE IP00 SCCR 100 kA at UL Voltage range 380 500 V Listed 36U0 E70524 IND CONT EQ UL Voltage range 380 500 V Max Tamb 55 C 131 F w Output Current Derating 123456H123 1 Type code 2 Code number 3...

Page 14: ...r Failure to take proper lifting precautions increases risk of death serious injury or equipment damage Never walk under suspended loads To guard against injury wear personal protective equipment such...

Page 16: ...supply Danfoss recommends using a 6 A 10 A or 16 A slow blow fuse when installing the external supply 4 2 3 Busbars If the Danfoss busbar kit is not used see Table 4 2 for the cross section measureme...

Page 17: ...e module is powered on In each drive module the power card provides DC voltage to power the fans The mixing fan is powered by 24 V DC from the main switch mode power supply The heat sink fan and the t...

Page 18: ...the unit with the 2 bottom mounting screws on the mounting panel 5 Verify that the drive module is correctly aligned on the mounting panel and then secure the bottom of the unit to the panel with the...

Page 20: ...o the connectors on the MDCIC 6 Route the 44 pin ribbon cables inside the cabinet 7 Connect the external brake fault wiring harness between the microswitch terminals and the brake jumper connector on...

Page 21: ...or applications Overcurrent protection Extra protective equipment such as short circuit protection or motor thermal protection between the drive modules and the motors is required for applications wit...

Page 22: ...ring not more than 100 kA rms symmetrical amperes at the drive nominal voltage 600 V maximum for 690 V units when protected by fuses with the standard configuration Refer to chapter 5 4 1 Fuse Selecti...

Page 23: ...24 V NPN D IN OUT 0 V 24 V 29 24 V NPN 0 V PNP 0 V PNP 24 V NPN 33 D IN 32 D IN 1 2 ON A53 U I S201 ON 2 1 A54 U I S202 ON 0 20 mA OFF 0 10 V 95 400 V AC 2A P 5 00 R 82 R 81 P RS485 68 N RS485 69 COM...

Page 24: ...00 Table 5 2 12 Pulse Drive Systems 380 500 V AC Number of drive modules FC 302 FC 102 FC 202 Recommended fuse maximum 4 N630 N710 aR 1600 4 N710 N800 aR 2000 4 N800 N900 aR 2500 4 N900 N1M0 aR 2500 4...

Page 25: ...aximum 4 N630 N710 1600 A 4 N710 N800 2000 A 4 N800 N900 2500 A 4 N900 N1M0 2500 A 4 N1M0 N1M2 2500 A Table 5 7 6 Pulse Drive Systems 525 690 V AC Number of drive modules FC 302 FC 102 FC 202 Recommen...

Page 26: ...tage of the VLT Parallel Drive Modules drive system can occur in the motor cable High peak voltages can severely stress the motor cable Use motor cables with rated voltage specifi cation of at least 0...

Page 27: ...k 10V 130BA153 11 PTC Thermistor OFF ON Illustration 5 4 PTC Thermistor Connection Analog Input with 10 V Supply Using a digital input and 24 V as supply PTC Thermistor OFF ON 24V 12 13 18 37 32 A 27...

Page 28: ...al switch opens Use 1 mm2 18 AWG reinforced and doubly insulated wire for the connection See Illustration 8 5 NOTICE Danfoss is not responsible for the failure of any Klixon thermal switch 5 7 3 Motor...

Page 29: ...st common point of a phase typically the motor terminals 2 Strip a section of the outer cable insulation 3 Connect the ground wire to the nearest protective earth terminal 4 Connect the 3 phase motor...

Page 30: ...minal Connections in 2 Drive Module Systems Illustration 8 9 and Illustration 8 10 show the bus bar connections for 6 pulse and 12 pulse 2 drive systems respectively If a common terminal design is use...

Page 31: ...ns wiring to terminals R 91 S 92 and T 93 using M10 screws 5 Tighten the mains terminals See chapter 7 9 1 Tightening Torques for Terminals 5 8 2 12 Pulse Disconnector Configuration This section descr...

Page 32: ...uired to reduce DC voltage below 50 V within 300 s 5 minutes 3036 2277 1822 1822 1518 1518 Power rating of resistor W 182 242 303 303 363 363 Energy dissipated by resistor J 7773 10365 12956 12956 155...

Page 33: ...der the drive modules do not function Place the corresponding current scaling card on each respective connector For systems with 4 drive modules Inverter 1 Inverter 2 Inverter 3 and Inverter 4 For sys...

Page 34: ...of drive modules used 130BE745 11 1 3 5 4 2 1 Microswitch cable 4 44 pin ribbon cable from MDCIC to drive module 4 2 Ferrite core 5 Bracket to support ribbon cable 3 44 pin ribbon cable from MDCIC to...

Page 35: ...ctions 1 Follow the designated control cable routing as shown in chapter 5 10 1 Control Cable Routing 2 Tie down all control wires 3 Connect the relevant options on the control card 5 10 2 1 Control T...

Page 36: ...mum commonly used for potentiometer or thermistor 42 Parameter 6 50 Terminal 42 Output Speed 0 high limit 50 10 V DC 53 Parameter group 6 1 Analog Input 1 Reference Analog input Selectable for voltage...

Page 37: ...do not remove that wiring 5 10 2 4 Voltage Current Input Selection Switches The analog mains terminals 53 and 54 allow the setting of the input signal to voltage 0 10 V or current 0 4 20 mA See Illus...

Page 38: ...to station m ft 500 1640 Total including drop lines m ft 1200 3937 Table 5 15 Cable Information 5 10 3 Safe Torque Off STO To run STO extra wiring for the drive system is required Refer to VLT Freque...

Page 39: ...at both ends for motor cables and for control cables Sometimes it is not possible to connect the shield in both ends If so connect the shield at the frequency converter See also chapter 5 12 2 Groundi...

Page 40: ...s cable Motor 3 phases and protective ground PLC etc Panel Output contactor etc Ground rail Cable insulation stripped All cable entries in 1 side of panel 130BA048 14 Illustration 5 13 EMC correct Ele...

Page 41: ...e between the individual shield conductors The shield coverage that is the physical area of the cable covered by the shield often stated as a percentage value Shield type that is braided or twisted pa...

Page 42: ...cables ground loops can occur To eliminate ground loops connect 1 end of the shield to ground with a 100 nF capacitor keeping leads short 100nF FC PE PE PLC 10 mm 130BB609 12 Illustration 5 16 Avoidin...

Page 43: ...d microswitch fixtures are correct Check the microswitch cabling and the connectors in the top of the drive module Cooling clearance Check that there is 225 mm 9 in of top clearance for adequate cooli...

Page 44: ...drive system and the motor 6 3 Applying Power WARNING UNINTENDED START When the drive system is connected to AC mains the motor can start at any time Unintended start during programming service or rep...

Page 45: ...r to the drive system and then reapply power Press RESET to clear the alarm NOTICE INCORRECT TYPECODE ENTERED If the wrong typecode is entered scroll to parameter 14 29 Service Code and enter 00006100...

Page 46: ...motor nameplate 4 Navigate to parameter 1 23 Motor Frequency and enter the current from the motor nameplate 5 Navigate to parameter 1 25 Motor Nominal Speed and enter the speed from the motor namepla...

Page 47: ...at 460 500 V 516 580 667 718 759 Power losses W Drive modules at 400 V 5825 6110 7069 7538 8468 Drive modules at 460 V 4998 5964 6175 6609 7140 AC bus bars at 400 V 550 555 561 565 575 AC bus bars at...

Page 48: ...810 10199 11632 13253 16463 Drive modules at 460 V 7628 9324 10375 12391 13958 AC bus bars at 400 V 665 680 695 722 762 AC bus bars at 460 V 656 671 683 710 732 DC bus bars during regeneration 218 232...

Page 49: ...90 434 482 549 607 Continuous at 690 V 352 400 434 482 549 607 Power losses W Drive modules at 575 V 4401 4789 5457 6076 6995 7431 Drive modules at 690 V 4352 4709 5354 5951 6831 7638 AC bus bars at 5...

Page 50: ...losses W Drive modules at 575 V 8683 10166 11406 12852 15762 Drive modules at 690 V 8559 9996 11188 12580 15358 AC bus bars at 575 V 644 653 661 672 695 DC bus bars during regeneration 198 208 218 23...

Page 51: ...67 718 711 759 Power losses W Drive modules at 400 V 4505 5825 5502 6110 6110 7069 6375 7538 7526 8468 Drive modules at 460 V 4063 4998 5384 5964 5271 6175 6070 6609 6604 7140 AC bus bars at 400 V 545...

Page 52: ...rive modules at 400 V 7713 8810 8918 10199 10181 11632 11390 13253 13479 16463 Drive modules at 460 V 6641 7628 7855 9324 9316 10375 12391 12391 12376 13958 AC bus bars at 400 V 655 665 665 680 680 69...

Page 53: ...339 339 490 366 434 Continuous at 690 V 296 352 352 400 366 434 Power losses W Drive modules at 575 V 3688 4401 4081 4789 4502 5457 Drive modules at 690 V 3669 4352 4020 4709 4447 5354 AC bus bars at...

Page 54: ...482 482 549 549 607 Continuous at 690 V 395 482 482 549 549 607 Power losses W Drive modules at 575 V 4892 6076 6016 6995 6941 7431 Drive modules at 690 V 4797 5951 5886 6831 6766 7638 AC bus bars at...

Page 55: ...1 711 828 828 920 1032 1032 1032 1227 Power losses W Drive modules at 575 V 7469 8683 8668 10166 10163 11406 11292 12852 12835 15762 Drive modules at 690 V 7381 8559 8555 9996 9987 11188 11077 12580 1...

Page 56: ...0 500 V 427 516 531 580 580 667 667 718 711 759 Power losses W Drive modules at 400 V 4505 5825 5502 6110 6110 7069 6375 7538 7526 8468 Drive modules at 460 V 4063 4998 5384 5964 5721 6175 6070 6609 6...

Page 57: ...ses W Drive modules at 400 V 7713 8810 8918 10199 10181 11632 11390 13253 13479 16463 Drive modules at 460 V 6641 7628 7855 9324 9316 10375 12391 12391 12376 13958 AC bus bars at 400 V 655 665 665 680...

Page 58: ...9 339 490 366 434 395 482 Continuous at 690 V 296 352 352 400 366 434 395 482 Power losses W Drive modules at 600 V 3688 4401 4081 4789 4502 5457 4892 6076 Drive modules at 690 V 3669 4352 4020 4709 4...

Page 59: ...V 482 549 549 607 Continuous at 690 V 482 549 549 607 Power losses W Drive modules at 600 V 6016 6995 6941 7431 Drive modules at 690 V 5886 6831 6766 7638 AC bus bars at 575 V 546 550 550 553 DC bus...

Page 60: ...828 828 920 1032 1032 1032 1227 Power losses W Drive modules at 600 V 7469 8683 8668 10166 10163 11406 11292 12852 12835 15762 Drive modules at 690 V 7381 8559 8555 9996 9987 11188 11077 12580 12551...

Page 61: ...96 V 97 W 98 Output voltage 0 100 of supply voltage Output frequency 0 590 Hz Switching on output Unlimited Ramp times 1 3600 s Torque characteristics Overload torque constant torque Maximum 150 for 6...

Page 62: ...ible or rigid wire without cable end sleeves 1 5 mm2 16 AWG Maximum cross section to control terminals flexible wire with cable end sleeves 1 mm2 18 AWG Maximum cross section to control terminals flex...

Page 63: ...ch S201 and switch S202 Voltage mode Switch S201 switch S202 OFF U Voltage level 10 V to 10 V scalable Input resistance Ri Approximately 10 k Maximum voltage 20 V Current mode Switch S201 switch S202...

Page 64: ...of frequency outputs 12 bit 1 Terminals 27 and 29 can also be programmed as input The digital output is galvanically isolated from the supply voltage PELV and other high voltage terminals Control card...

Page 65: ...ange open loop 1 100 of synchronous speed Speed control range closed loop 1 1000 of synchronous speed Speed accuracy open loop 30 4000 RPM Error 8 RPM Speed accuracy closed loop depending on resolutio...

Page 66: ...41 3 280 11 0 107 4 2 213 8 4 320 12 6 271 10 7 95 3 7 130BE654 11 376 14 8 Illustration 7 2 VLT Parallel Drive Modules Installation Dimensions Description Module weight kg lb Length x width x depth m...

Page 67: ...4 Illustration 7 3 Drive Module Terminal Dimensions Front View 130BE749 10 Section A A Mains Terminals Section B B Motor and Brake Terminals Brake terminal Motor terminal Mains terminal 284 11 2 0 0...

Page 68: ...Torx 7 mm hex 1 0 9 M5 T25 Torx 8 mm hex 2 3 20 M6 T30 Torx 10 mm hex 4 0 35 M8 T40 Torx 13 mm hex 9 6 85 M10 T50 Torx 17 mm hex 19 1 169 M12 hex bolts only 18 mm or 19 mm hex 19 1 169 Table 7 16 Gen...

Page 69: ...atibility ETR Electronic thermal relay FC Frequency converter IP Ingress protection LCP Local control panel MCT Motion control tool MDCI C Multi drive control interface PCB Printed circuit board PELV...

Page 70: ...e 1 6 Disconnector 1 2 Drive module 2 7 Brake fault 3 Supplementary fuses 8 Drive module 3 4 Mains input bus bars 9 Drive module 4 5 Brake fault 10 Disconnector 2 Illustration 8 1 Connection of 12 Pul...

Page 71: ...44 43 DC DC MK102 130BE735 10 1 2 3 4 1 Auxiliary contact disconnector 1 3 Klixon switch 2 Auxiliary contact disconnector 2 4 BRF connector Illustration 8 2 BRF Connection with 12 Pulse Disconnector I...

Page 72: ...1 2 8 7 6 11 10 9 2 1 1 2 44 43 DC DC MK102 130BE736 10 1 2 1 BRF jumper pre installed 2 BRF connector Illustration 8 3 BRF Jumper Connection Appendix VLT Parallel Drive Modules 70 Danfoss A S 08 201...

Page 73: ...R 91 S 92 T 93 U 96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R 1 Drive module 3 Common brake resistor 2 Brake terminals Illustration 8 4 Connection of Common Br...

Page 74: ...0 1 2 1 2 1 2 8 7 6 11 10 9 2 1 1 2 44 43 DC DC MK102 1 2 3 1 Klixon switch 3 Ferrite core 2 BRF connector Illustration 8 5 Klixon Switch Connection Appendix VLT Parallel Drive Modules 72 Danfoss A S...

Page 75: ...cradle 8 Terminal block 2 Ribbon cable from LCP to MDCIC 9 Cable to remote mounted LCP 3 44 pin cable to the drive module 1 at MK 111 10 Analog I O terminals 4 44 pin cable to the drive module 3 at M...

Page 76: ...R BASE DRIVE BASE DRIVE BASE DRIVE BASE DRIVE 3 4 1 2 1 Mains input bus bars 3 Discharge resistor 2 Mains contactor disconnector auxiliary contacts 4 Discharge contactor Illustration 8 7 Discharge Re...

Page 77: ...92 T 93 U 96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R 130BE741 11 1 Drive module 3 Individual brake resistors 2 Brake terminals Illustration 8 8 Connection of...

Page 78: ...ule 7 Connection to brake 3 Mains input bus bars connecting both drive modules 8 Motor output bus bars connecting both drive modules 4 Connection to mains 9 Connection to motor output 5 DC link bus ba...

Page 79: ...5 DC link bus bars connecting both drive modules 2 Drive module 6 DC terminals 3 Motor output bus bars connecting both drive modules 7 Connection to brake 4 Connection to mains input 8 Connection to m...

Page 80: ...rake 3 Mains input bus bars connecting 2 drive modules 8 Motor output bus bars connecting 2 drive modules 4 Connection to mains input 9 Connection to motor output 5 DC link bus bars connecting all 4 d...

Page 81: ...h 42 Disposal 4 E Electronic thermal relay 19 EMC Electrical installation guidelines 37 EMC 40 Precautions 37 Energy efficiency 59 Energy efficiency class 59 ETR 19 External controllers 7 F Fans 15 Fe...

Page 82: ...6 Safety 5 42 Serial communication 7 33 34 40 Shielded twisted pair STP 36 Short circuit protection 22 Speed reference 35 STO 36 Supply voltage 33 34 42 Switch 35 Symbols 67 System feedback 7 T Termin...

Page 84: ...ucts already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the resp...

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