Danfoss VLT HVAC Drive FC 102 User Manual Download

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ENGINEERING TOMORROW

User 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 User Guide VLT Parallel Drive Modules 250 1200 kW vlt drives danfoss com...

Page 2: ......

Page 3: ...Panel LCP 15 4 3 1 Overview 15 4 3 2 Layout 15 4 3 3 Menus 16 4 4 Programming the Drive System 17 4 4 1 Entering System Information 18 4 4 2 Q3 Function Set ups 19 4 4 3 Control Terminal Programming...

Page 4: ...ing 31 6 1 Maintenance and Service 31 6 2 Periodic Maintenance 31 6 3 Status Messages 31 6 4 Warning and Alarm Types 34 6 5 List of Warnings and Alarms 34 6 5 1 Warnings Alarm Messages 34 6 6 Troubles...

Page 5: ...uit Current Rating SCCR 70 8 Appendix 71 8 1 Symbols Abbreviations and Conventions 71 8 2 International North American Default Parameter Settings 72 8 3 Parameter Menu Structure 72 8 3 1 Main Menu Str...

Page 6: ...icular series of VLT Parallel Drive Modules used in creating the drive system The programming guide describes in greater detail how to work with parameters and provides application examples The VLT FC...

Page 7: ...ork can result in death serious injury or property damage The motor can start via any of the following An external switch A fieldbus command An input reference signal from the LCP A cleared fault cond...

Page 8: ...information WARNING EQUIPMENT HAZARD Contact with rotating shafts and electrical equipment can result in death or serious injury Ensure that only trained and qualified personnel are allowed to perform...

Page 9: ...misuse Do not use the drive system in applications that are not compliant with specified operating conditions and environments Ensure compliance with the conditions specified in chapter 7 Specificatio...

Page 10: ...ntrol card with the power card in each drive module 4 LCP The local control module shown mounted on the cabinet door Allows the operator to monitor and control the system and motor 5 Protective shield...

Page 11: ...e constructed with 4 drive modules See chapter 3 3 Drive Module 3 Mains input busbars The input terminals of the individual drive modules are connected to the mains input busbars with the use of flexi...

Page 12: ...the motor output busbars with the use of flexible busbars By doing so the output busbars join the output terminals of the individual drive modules in parallel and provide a connection to the motor cab...

Page 13: ...ing harnesses 130BE758 10 1 2 3 Area Title Functions 1 Drive module 2 or 4 drive modules can be used in a drive system according to the power requirements 2 Data label Drive module data label Refer to...

Page 14: ...t Raise the power factor reflected back to the line Reduce harmonics on the AC input 5 Capacitor bank Stores the DC power and provides ride through protection for short power losses 6 Inverter section...

Page 15: ...nents Allows the connection of an external control device 2 LCP cradle Cradle where the LCP may optionally be installed 3 Control terminal blocks Terminal blocks for connecting control wiring 4 Top le...

Page 16: ...d 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 motor can start via any of the follow...

Page 17: ...302 A1 1 0 20 Reference Reference unit Speed RPM A1 2 0 21 Motor current Analog input 53 Motor current A1 3 0 22 Power kW Motor current Power kW A2 0 23 Frequency Frequency Frequency A3 0 24 kWh coun...

Page 18: ...nually after a fault has been cleared Table 4 5 Legend to Illustration 4 1 LCP Operation Keys and Reset 4 3 3 Menus 4 3 3 1 Quick Menu Mode The LCP provides access to all parameters listed under the Q...

Page 19: ...4 3 3 6 Main Menu Mode The LCP provides access to the Main Menu mode Select the Main Menu mode by pressing the Main Menu key The resulting readout appears on the LCP display 130BP066 12 Keypad Set Up...

Page 20: ...m To enter basic system information into the drive system use the following steps Recommended parameter settings are intended for startup and check out purposes Application settings vary 1 Press Main...

Page 21: ...kes 3 Reference Ramps 4 Limits Warnings 5 Digital In Out 14 6 0 00A 1 1 Main Menu Illustration 4 4 Main Menu Display Example 2 Scroll to parameter group 5 1 Digital Inputs and then press OK 130BT769 1...

Page 22: ...arrow key and then enter an RPM value that causes the motor to rotate slowly 3 Press OK 4 If the motor rotation is wrong change parameter 1 06 Clockwise Direction to 1 Inverse 4 5 2 Encoder Rotation...

Page 23: ...turn and downloading the stored parameter settings Custom settings that are stored in the LCP are not changed when restoring the factory default settings 4 7 1 Uploading and Downloading Parameter Sett...

Page 24: ...itoring data before restoring factory default settings It does not however reset the following information Parameter 15 00 Operating hours Parameter 15 03 Power Up s Parameter 15 04 Over Temp s Parame...

Page 25: ...ved if short circuits occur between the motor windings and the sensor Use reinforced or double insulation to ensure PELV compliance 5 2 1 Automatic Motor Adaptation AMA Parameters FC 24 V 24 V D IN D...

Page 26: ...otor Feedback Loss Timeout 5 s Parameter 7 00 S peed PID Feedback Source 2 MCB 102 Parameter 17 11 Resolution PPR 1024 Parameter 13 00 SL Controller Mode 1 On Parameter 13 01 Start Event 19 Warning Pa...

Page 27: ...nominal slip of the motor Default value Table 5 5 Mechanical Brake Control Open Loop Start 18 Start reversing 19 Relay output Speed Time Current 1 71 1 71 2 21 2 21 1 76 Open Closed 130BB842 10 Illust...

Page 28: ...7 V Parameter 6 11 T erminal 53 High Voltage 10 V Parameter 6 14 T erminal 53 Low Ref Feedb Value 0 RPM Parameter 6 15 T erminal 53 High Ref Feedb Value 1500 RPM Default value Notes comments Table 5 8...

Page 29: ...Option 130BB805 12 Speed Start Stop 18 Illustration 5 3 Start Stop Command with Safe Torque Off STO 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 1...

Page 30: ...COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 130BB928 11 Function Setting Parameter 5 11 T erminal 19 Digital Input 1 Reset Default value Notes comments Table 5 13 External Alarm Reset 5 2 8 M...

Page 31: ...tart Terminal 27 Parameter 5 12 Terminal 27 Digital Input 6 Stop inverse Terminal 37 Safe Torque Off 12 13 18 37 130BA156 12 32 27 19 29 33 20 P 5 12 6 P 5 10 9 24V Speed Start Stop inverse Safe Stop...

Page 32: ...High voltage 10 V Terminal 53 Low ref feedback 0 RPM Terminal 53 High ref feedback 1500 RPM Switch S201 OFF U 130BA154 11 55 50 39 42 53 54 Speed RPM P 6 15 1 k 10V 30mA Ref voltage P 6 11 10V Illustr...

Page 33: ...status messages are generated automatically and appear in the bottom line of the LCP display see Illustration 6 1 Status messages are defined in Table 6 1 to Table 6 3 Status 799RPM 7 83A 36 4kW 0 00...

Page 34: ...vated in parameter 2 03 DC Brake Cut In Speed RPM and a stop command is active DC brake inverse is selected as a function for a digital input parameter group 5 1 Digital Inputs The corresponding termi...

Page 35: ...it set in parameter 4 54 Warning Reference Low Run on ref The drive system is running in the reference range The feedback value matches the setpoint value Run request A start command has been given bu...

Page 36: ...000kW 0 00A 0 0Hz 0 Earth Fault A14 Auto Remote Trip 1 1 Illustration 6 2 Alarm Display Example In addition to the text and alarm code in the LCP there are 3 status indicator lights B a c k C a n c e...

Page 37: ...ter 14 12 Response to Mains Imbalance 5 DC link voltage high X 6 DC link voltage low X 7 DC overvoltage X X 8 DC undervoltage X X 9 Inverter overloaded X X 10 Motor ETR overtemperature X X Parameter 1...

Page 38: ...put frequency at maximum limit X 63 Mechanical brake low X Parameter 2 20 Release Brake Current 64 Voltage limit X 65 Control board overtemperature X X X 66 Heat sink temperature low X 67 Option confi...

Page 39: ...17 85 Homing Timout 214 No sensor input X 220 Configuration File Version not supported X 246 Pwr card supply X 250 New spare part X 251 New type code X X 430 PWM Disabled X Table 6 4 Alarm Warning Co...

Page 40: ...over A10 Reserved Motor ETR over W10 Reserved Output current low current parameter 4 50 Warning Current Low 9 00000200 512 Inverter overld A9 Discharge high Inverter Overld W9 Discharge high Output f...

Page 41: ...24 01000000 16777216 Mains failure A36 Reserved Mains failure W36 Reserved Unused 25 02000000 33554432 1 8 V supply low A48 Current limit A59 Current limit W59 Reserved Unused 26 04000000 67108864 Br...

Page 42: ...oltage low The DC link voltage DC is lower than the low voltage warning limit The limit depends on the drive system s voltage rating The unit is still active WARNING ALARM 7 DC overvoltage If the volt...

Page 43: ...time If torque limit occurs while running increase the torque limit Make sure that the system can operate safely at a higher torque Check the application for excessive current draw on the motor WARNI...

Page 44: ...istor power limit The power transmitted to the brake resistor is calculated as a mean value over the last 120 s of run time The calculation is based on the DC link voltage and the brake resistor value...

Page 45: ...the Danfoss supplier or Danfoss service department 783 Parameter value outside of minimum maximum limits 1024 1284 Internal fault Contact the Danfoss supplier or Danfoss service department 1299 The o...

Page 46: ...d 5 V supplies are monitored When powered with 3 phase mains voltage all 3 supplies are monitored Troubleshooting Check for a defective power card Check for a defective control card Check for a defect...

Page 47: ...ing parameter 2 00 DC Hold Preheat Current at 5 and parameter 1 80 Function at Stop ALARM 67 Option module configuration has changed One or more options have either been added or removed since the las...

Page 48: ...larm 1 Left drive module 2 Second drive module from left 3 Third drive module from left in 4 module module systems 4 Fourth drive module from left in 4 module module systems ALARM 244 Heat sink temper...

Page 49: ...ly for multi drive systems It is equivalent to alarm 79 Illegal power section configuration The report value in the alarm log indicates which drive module generated the alarm 1 Left drive module 2 Sec...

Page 50: ...incorrect connections If the display continues to cut out follow the procedure for Display is dark or not functioning Motor is not running Service switch is open or the motor connection is missing Che...

Page 51: ...parameters Possibly ramp down times are too short Check brake parameters Check ramp time settings Check parameter groups 2 0 DC Brake and 3 0 Reference Limits Open power fuses or tripped circuit break...

Page 52: ...tly Increase the ramp down time in parameter 3 42 Ramp 1 Ramp Down Time Enable overvoltage control in parameter 2 17 Over voltage Control Acoustic noise or vibration for example a fan blade is making...

Page 53: ...locked to prevent unintended rotation WARNING DISCHARGE TIME The drive module contains DC link capacitors Once mains power has been applied to the drive these capacitors can remain charged even after...

Page 54: ...nd remove the 44 pin ribbon cable leading from the failed drive module to the MDCIC 6 On the control shelf disconnect and remove the 44 pin ribbon cable leading from the failed drive module to the MDC...

Page 55: ...4 Illustration 6 8 Configuring 4 drive System with Failure of Drive Module 3 130BE870 10 1 2 3 4 1 2 3 4 Illustration 6 9 Configuring 4 drive System with Failure of Drive Module 4 130BE868 10 1 2 1 2...

Page 56: ...ontinuous at 460 V kVA 426 470 540 582 621 Continuous at 500 V kVA 463 511 587 632 675 Input current A Continuous at 400 V 567 647 733 787 875 Continuous at 460 500 V 516 580 667 718 759 Power losses...

Page 57: ...71 909 1005 1195 1325 Input current A Continuous at 400 V 964 1090 1227 1422 1675 Continuous at 460 500 V 867 1022 1129 1344 1490 Power losses W Drive modules at 400 V 8810 10199 11632 13253 16463 Dri...

Page 58: ...98 568 600 Continuous at 575 V kVA 343 398 448 498 568 627 Continuous at 690 V kVA 411 478 538 598 681 753 Input current A Continuous at 550 V 355 408 453 504 574 607 Continuous at 575 V 339 490 434 4...

Page 59: ...6 Continuous at 690 V 872 1016 1129 1267 1506 Input current A Continuous at 550 V 743 866 962 1079 1282 Continuous at 575 V 711 828 920 1032 1227 Continuous at 690 V 711 828 920 1032 1227 Power losses...

Page 60: ...582 582 621 Continuous at 500 V kVA 384 463 468 511 511 587 587 632 632 675 Input current A Continuous at 400 V 463 567 590 647 647 733 684 787 779 857 Continuous at 460 500 V 427 516 531 580 580 667...

Page 61: ...500 V kVA 675 771 771 909 909 1005 1005 1195 1195 1325 Input current A Continuous at 400 V 857 964 964 1090 1090 1227 1127 1422 1422 1675 Continuous at 460 V 759 867 867 1022 1022 1129 1129 1344 1344...

Page 62: ...43 398 376 448 Continuous at 575 V 289 343 343 398 378 448 Continuous at 690 V 347 411 411 478 454 538 Input current A Continuous at 550 V 299 355 355 408 381 453 Continuous at 575 V 286 339 339 490 3...

Page 63: ...409 498 498 568 568 600 Continuous at 575 V kVA 408 498 598 568 568 627 Continuous at 690 V kVA 490 598 598 681 681 753 Input current A Continuous at 550 V 413 504 504 574 574 607 Continuous at 575 V...

Page 64: ...1056 1255 Continuous at 690 V kVA 753 872 872 1016 1016 1129 1129 1267 1267 1506 Input current A Continuous at 550 V 642 743 743 866 866 962 1079 1079 1079 1282 Continuous at 575 V 613 711 711 828 828...

Page 65: ...6 456 456 516 482 554 554 610 Continuous at 460 V kVA 353 426 430 470 470 540 540 582 582 621 Continuous at 500 V kVA 384 463 468 511 511 587 587 632 632 675 Input current A Continuous at 400 V 463 56...

Page 66: ...4 1100 1100 1219 Continuous at 500 V kVA 675 771 771 909 909 1005 1005 1195 1195 1325 Input current A Continuous at 400 V 857 964 964 1090 1090 1227 1227 1422 1422 1675 Continuous at 460 500 V 759 867...

Page 67: ...3 398 376 448 409 498 Continuous at 575 V kVA 289 343 343 398 378 448 408 498 Continuous at 690 V kVA 347 411 411 478 454 538 490 598 Input current A Continuous at 550 V 299 355 355 408 381 453 413 50...

Page 68: ...VA 498 568 568 600 Continuous at 575 V kVA 498 568 568 627 Continuous at 690 V kVA 598 681 681 753 Input current A Continuous at 550 V 504 574 574 607 Continuous at 575 V 482 549 549 607 Continuous at...

Page 69: ...1 1056 1056 1255 Continuous at 690 V kVA 753 872 872 1016 1016 1129 1129 1267 1267 1506 Input current A Continuous at 550 V 642 743 743 866 866 962 1079 1079 1079 1282 Continuous at 575 V 613 711 711...

Page 70: ...d fire hazards all branch circuits in an installation switch gear and machines must be protected against short circuits and overcurrent according to national or international regulations Short circuit...

Page 71: ...aR 2500 4 N800 N1M0 aR 2500 aR 2500 Table 7 17 6 Pulse Drive Systems 380 500 V AC Drive modules in system FC 302 modules kW FC 102 and FC 202 modules kW Recommended fuse Recommended fuse maximum 2 N2...

Page 72: ...302 modules kW FC 102 and FC 202 modules kW Recommended fuse maximum 2 N250 N315 aR 550 2 N315 N355 aR 630 2 N355 N400 aR 630 2 N400 N500 aR 630 2 N500 N560 aR 630 2 N560 N630 aR 900 4 N630 N710 aR 90...

Page 73: ...ontrol tool MDCIC Multi drive control interface card PC Personal computer PELV Protective extra low voltage PID Proportional integral derivative PM Motor Permanent magnet motor PTC thermistor Positive...

Page 74: ...ed High Limit Hz 4 50 Hz 60 Hz Parameter 4 19 Max Output Frequency 100 Hz 120 Hz Parameter 4 53 Warning Speed High 1500 RPM 1800 RPM Parameter 5 12 Terminal 27 Digital Input Coast inverse External int...

Page 75: ...2 Power Factor Reference 2 53 Reactive Current Reference 2 54 Reactive Current Reference Resource 2 55 Reactive Current Ramp Up Time 2 56 Reactive Current Ramp Down Time 2 57 DC Link Voltage Reference...

Page 76: ...13 Warning Parameter 10 14 Net Reference 10 15 Net Control 10 2 COS Filters 10 20 COS Filter 1 10 21 COS Filter 2 10 22 COS Filter 3 10 23 COS Filter 4 10 3 Parameter Access 10 30 Array Index 10 31 St...

Page 77: ...18 71 Mains Current 18 72 Regen kWh 18 73 Regen Total Time 18 74 Mains Voltage 18 75 Mains Frequency 18 78 AIC Alarm Word 18 79 AIC Warning Word 20 Drive Closed Loop 20 0 Feedback 20 00 Feedback 1 Sou...

Page 78: ...25 50 Lead Pump Alternation 25 51 Alternation Event 25 52 Alternation Time Interval 25 53 Alternation Timer Value 25 54 Alternation Predefined Time 25 55 Alternate if Load 50 25 56 Staging Mode at Alt...

Page 79: ...ng 40 D DC current 32 DC link 40 Default settings 21 Digital input 19 33 Discharge time 5 51 Disconnect switch 14 Disposal instruction 4 Drive module block diagram 12 E Efficient parameter set up for...

Page 80: ...Output Current 32 Terminal 14 Overcurrent 33 Overheating 41 Overtemperature 41 Overvoltage 33 50 P PELV 23 28 Phase loss 40 Potentiometer 26 Potentiometer reference 30 Power card Warning 45 Power fact...

Page 81: ...ltage 14 Switching frequency 33 Symbols 71 T Terminals Input 40 Programming example 19 Terminal 37 23 Terminal 53 19 Tightening 68 Thermistor 23 Torque Limit 41 Torque limit 50 Transient protection 12...

Page 82: ...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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