Danfoss VLT FC 100 Instruction Manual Download

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MAKING MODERN LIVING POSSIBLE

Instruction Manual, 110–400 kW D-Frame

VLT

HVAC Drive FC 100

Summary of Contents for VLT FC 100

Page 1: ...MAKING MODERN LIVING POSSIBLE Instruction Manual 110 400 kW D Frame VLT HVAC Drive FC 100...

Page 2: ......

Page 3: ...drive is connected to AC line power the motor may be started with an external switch a serial bus command an input reference signal or a cleared fault condition Use appropriate caution to guard again...

Page 4: ...Safety VLT HVAC Drive D Frame Instruction Manual MG16D222 VLT is a registered Danfoss trademark...

Page 5: ...nding 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 7 2 4 3 1 Terminal Locations D1h D4h 3...

Page 6: ...Display Menu Keys 5 2 4 1 4 Navigation Keys 5 3 4 1 5 Operation Keys 5 3 4 2 Back Up 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...

Page 7: ...9 1 8 4 Warning and Alarm Definitions 9 3 8 5 Fault Messages 9 5 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 Gener...

Page 8: ...Contents VLT HVAC Drive D Frame Instruction Manual MG16D222 VLT is a registered Danfoss trademark...

Page 9: ...l 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...

Page 10: ...nect Contactor Line power disconnect with contactor Circuit breaker Figure 1 3 shows an example of an adjustable frequency drive with an options cabinet Table 1 2 lists the variants for the adjustable...

Page 11: ...aining chapters provide supplementary details These details include user interface detailed programming application examples startup troubleshooting and specifications 1 3 Additional Resources Other r...

Page 12: ...urrent Raise the power factor reflected back to the line Reduce harmonics on the AC input 5 Capacitor bank Stores the DC power Provides ride through protection for short power losses 6 Inverter Conver...

Page 13: ...D4h D4h D4h D4h 690 V D3h D3h D3h D4h D4h D4h D4h Table 1 4 kW Rated Adjustable Frequency Drives HP High Overload 100 125 150 200 250 300 350 350 HP Normal Overload 125 150 200 250 300 350 400 450 460...

Page 14: ...Introduction VLT HVAC Drive D Frame Instruction Manual 1 6 MG16D222 VLT is a registered Danfoss trademark 1 1...

Page 15: ...he same voltage Line power Adjustable frequency drive Motor Ensure that adjustable frequency drive output current rating is equal to or greater than motor full load current for peak motor performance...

Page 16: ...ependent Specific Control Card ambient temperature exceeded Frame Door fan top fan Heatsink fan D1h D3h 102 m3 hr 60 CFM 420 m3 hr 250 CFM D2h D4h 204 m3 hr 120 CFM 840 m3 hr 500 CFM Table 2 2 Airflow...

Page 17: ...cal equipment can be hazardous All electrical work must conform to national and local electrical codes It is strongly recommended that instal lation startup and maintenance be performed only by traine...

Page 18: ...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...

Page 19: ...ion The higher the current 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 carrie...

Page 20: ...ontrol wiring Use the clamps provided with the equipment for proper ground connections Do not ground one adjustable frequency drive to another in a daisy chain fashion Keep the ground wire connections...

Page 21: ...otor cables from multiple adjustable frequency drives separately Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out...

Page 22: ...irements 2 4 3 1 Terminal Locations D1h D4h A A B B 33 1 3 0 0 0 62 2 4 101 4 0 140 5 5 163 6 4 185 7 3 224 8 8 263 10 4 293 11 5 GROUND88 3 5 0 0 0 200 7 9 94 3 7 244 9 6 0 0 0 272 10 7 0 0 0 S U W R...

Page 23: ...ALS 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 L...

Page 24: ...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...

Page 25: ...21 8 7 260 10 2 GROUND 2X 118 4 6 0 0 GROUND 148 5 8 221 8 7 90 3 6 196 7 7 227 9 113 4 4 0 0 206 8 1 MAINS TERMINAL MOTOR TERMINAL BRAKE TERMINAL SECTION A A MAINS TERMINALS R S T U V W 3X M10X20 STU...

Page 26: ...Brake Option B B A A 0 0 0 96 3 8 195 7 7 227 8 9 GROUND 3X123 4 8 GROUND 153 6 0 458 18 0 0 0 0 46 1 8 50 2 0 99 3 9 147 5 8 182 7 2 193 7 6 221 8 7 249 9 8 260 10 2 146 5 8 0 0 0 286 11 2 0 0 0 113...

Page 27: ...RMINAL R S T SECTION A A MAINS TERMINALS 130BC538 11 TB6 Terminal block for contactor Figure 2 16 Terminal Locations D6h with Contactor and Disconnect Options Installation VLT HVAC Drive D Frame Instr...

Page 28: ...63 6 4 0 0 0 MAINS TERMINAL SECTION A A MAINS TERMINALS R S T 130BC541 10 Figure 2 17 Terminal Locations D6h with Circuit Breaker Option Installation VLT HVAC Drive D Frame Instruction Manual 2 14 MG1...

Page 29: ...5 545 21 4 0 0 119 4 7 276 10 9 0 0 MAINS TERMINAL BRAKE TERMINAL MOTOR TERMINAL 4X M10X20 STUD WITH NUT SECTION B B MOTOR TERMINALS SECTION A A MAINS TERMINALS BRAKE REGEN TEMINALS R S T U V W Figure...

Page 30: ...6 375 14 8 290 11 4 0 0 257 10 1 309 12 1 0 0 MOTOR TERMINAL BRAKE TERMINAL MAINS TERMINAL 4X M10X20 STUD WITH NUT SECTION B B MOTOR TERMINALS BRAKE REGEN TERMINALS SECTION A A MAINS TERMINALS R S T...

Page 31: ...127 5 0 0 MAINS TERMINAL MOTOR TERMINAL BRAKE TERMINAL 4X M10X20 STUD WITH NUT SECTION A A MAINS TERMINALs BRAKE REGEN TERMINALS SECTION B B MOTOR TERMINALS R S T U V W 130BC544 11 TB6 Terminal block...

Page 32: ...NAL SECTION C C MAINS TERMINALS 130BC545 11 R S T TB6 Terminal block for contactor Figure 2 21 Terminal Locations D8h with Contactor and Disconnect Options Installation VLT HVAC Drive D Frame Instruct...

Page 33: ...3 8 0 0 MAINS TERMINAL SECTION D D MAINS TERMINALS R S T 130BC546 10 Figure 2 22 Terminal Locations D8h with Circuit Breaker Option Installation VLT HVAC Drive D Frame Instruction Manual MG16D222 VLT...

Page 34: ...lay 2 4 6 AC Line Input Connection Size wiring is based upon the input current of the adjustable frequency drive Comply with local and national electrical codes for cable sizes Connect 3 phase AC inpu...

Page 35: ...ce ZT value is more effective than a shield with a higher transfer impedance ZT Transfer impedance ZT is rarely stated by cable manufac turers but it is often possible to estimate transfer impedance Z...

Page 36: ...hield to ground with a 100 nF capacitor keeping leads short 100nF FC PE PE PLC 130BB609 11 Figure 2 26 Avoid EMC noise on serial communication This terminal is connected to ground via an internal RC l...

Page 37: ...ng and 6 Application Examples for terminals and associated parameters It is important to confirm that the control terminal is programmed for the correct function See 5 Programming for details on acces...

Page 38: ...A terminal cover supplied with the adjustable frequency drive must be installed to maintain the IP20 rating of the enclosure Figure 2 32 shows both the covered and uncovered terminals 130BC547 10 Figu...

Page 39: ...CK11CE311N AC 1 525 690 V N75KT7 N160T7 GE CK95BE311N AC 3 N200T7 N400T7 GE CK11CE311N AC 3 Table 2 13 NOTE In applications requiring UL listing when the adjustable frequency drive is supplied with a...

Page 40: ...Installation VLT HVAC Drive D Frame Instruction Manual 2 26 MG16D222 VLT is a registered Danfoss trademark 2 2...

Page 41: ...rance is adequate to ensure proper airflow for cooling EMC considerations Check for proper installation regarding electromagnetic compatibility Environmental consider ations See equipment label for th...

Page 42: ...dicates that the unit is ready to operate but is missing an input signal on terminal 27 3 3 Basic Operational Programming For best performance adjustable frequency drives require basic operational pro...

Page 43: ...oll to parameter group Q2 Quick Set up and press OK 130BB847 10 Q1 My Personal Menu Q2 Quick Setup Q5 Changes Made Q6 Loggings 13 7 13 0A 1 1 Quick Menus Figure 3 4 8 Select language and press OK Then...

Page 44: ...that motor data is entered correctly Increase the ramp down time decel time in 3 42 Ramp 1 Ramp down Time Enable overvoltage control in 2 17 Over voltage Control NOTE The OVC algorithm does not work...

Page 45: ...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 Men...

Page 46: ...045 10 Status Quick Menu Main Menu Alarm Log Figure 4 4 Key Function Status Shows operational information In auto mode press to toggle between status readout displays Press repeatedly to scroll throug...

Page 47: ...the LCP 130BP046 10 Hand on Off Auto on Reset Figure 4 6 Key Function Hand On Starts the adjustable frequency drive in local control Use the navigation keys to control adjustable frequency drive spee...

Page 48: ...ialization 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 su...

Page 49: ...drive applications 5 2 Programming Example Here is an example for programming the adjustable frequency drive for a common application in open loop using the quick menu This procedure programs the adj...

Page 50: ...Q3 21 130BT765 10 6 11 Terminal 53 High Voltage 10 00 V 14 7 0 00A 1 1 Analog Reference Figure 5 7 9 6 14 Terminal 53 Low Ref Feedb Value Set minimum speed reference on terminal 53 at 20 Hz This tells...

Page 51: ...n change based on the selection in 0 03 Regional Settings The following example shows accessing Terminal 18 to see the default setting 1 Press Main Menu twice scroll to parameter group 5 Digital In Ou...

Page 52: ...eed 0 HighLim Speed 4 20 mA 14 20 Reset Mode Manual reset Infinite auto reset 22 85 Speed at Design Point RPM See Note 3 1 500 RPM 1 800 RPM 22 86 Speed at Design Point Hz 50 Hz 60 Hz Parameter Intern...

Page 53: ...on 2 11 Brake Resistor ohm 2 12 Brake Power Limit kW 2 13 Brake Power Monitoring 2 15 Brake Check 2 16 AC brake Max Current 2 17 Over voltage Control 2 18 Brake Check Condition 2 19 Over voltage Gain...

Page 54: ...ss PID I 7 40 Process PID I part Reset 7 41 Process PID Output Neg Clamp 7 42 Process PID Output Pos Clamp 7 43 Process PID Gain Scale at Min Ref 7 44 Process PID Gain Scale at Max Ref 7 45 Process PI...

Page 55: ...Slot B Option SW Version 15 74 Option in Slot C0 15 75 Slot C0 Option SW Version 15 76 Option in Slot C1 15 77 Slot C1 Option SW Version 15 9 Parameter Info 15 92 Defined Parameters 15 93 Modified Pa...

Page 56: ...ut 33 62 Terminal X59 2 Digital Input 33 63 Terminal X59 1 Digital Output 33 64 Terminal X59 2 Digital Output 33 65 Terminal X59 3 Digital Output 33 66 Terminal X59 4 Digital Output 33 67 Terminal X59...

Page 57: ...ply 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 avail...

Page 58: ...Programming VLT HVAC Drive D Frame Instruction Manual 5 10 MG16D222 VLT is a registered Danfoss trademark 5 5...

Page 59: ...ble complete AMA 5 12 Terminal 27 Digital Input 2 Coast inverse Default Value Notes comments Parameter group 1 2 Motor Data must be set according to motor Table 6 1 AMA with T27 Connected Parameters F...

Page 60: ...tion 5 19 Terminal 37 Safe Stop 1 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 Sto...

Page 61: ...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...

Page 62: ...ate in the above mentioned parameters Table 6 11 RS 485 Network Connection 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...

Page 63: ...uipment may then indicate that service may be required If the feedback error goes below the limit again within 5 sec then the adjustable frequency drive continues and the warning disappears But Relay...

Page 64: ...Application Examples VLT HVAC Drive D Frame Instruction Manual 6 6 MG16D222 VLT is a registered Danfoss trademark 6 6...

Page 65: ...als 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 c...

Page 66: ...ence was chosen as a function for a digital input parameter group 5 1 Digital Inputs The corresponding terminal is active The adjustable frequency drive saves the actual reference Changing the referen...

Page 67: ...y In Auto On Auto mode the adjustable frequency drive will start 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 68: ...Status Messages VLT HVAC Drive D Frame Instruction Manual 7 4 MG16D222 VLT is a registered Danfoss trademark 7 7...

Page 69: ...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 wil...

Page 70: ...tor 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 Warning...

Page 71: ...tor 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 Moto...

Page 72: ...X 80 Drive Initialized to Default Value X 91 Analog input 54 wrong settings X 92 No Flow X X 22 2 No Flow Detection 93 Dry Pump X X 22 2 No Flow Detection 94 End of Curve X X 22 5 End of Curve 95 Brok...

Page 73: ...er than the high voltage warning 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 D...

Page 74: ...e matches sensor wiring If using a KTY sensor check the programming of 1 95 KTY Sensor Type 1 96 KTY Thermistor Resource and 1 97 KTY Threshold level match sensor wiring WARNING ALARM 12 Torque limit...

Page 75: ...be disabled in 14 53 Fan Monitor 0 Disabled Troubleshooting Check fan resistance Check soft charge fuses WARNING 25 Brake resistor short circuit The brake resistor is monitored during operation If a s...

Page 76: ...No Function Check the fuses to the adjustable frequency drive and line power supply to the unit ALARM 38 Internal fault When an internal fault occurs a code number defined in the table below is displa...

Page 77: ...al from the IGBT thermal sensor is not available on the power card The problem could be on the power card on the gate drive card or the ribbon cable between the power card and gate drive card WARNING...

Page 78: ...higher than the actual DC link voltage WARNING ALARM 65 Control card over temperature The control card has reached its trip temperature of 167 F 75 C WARNING 66 Heatsink temperature low The adjustable...

Page 79: ...guration The scaling card is the incorrect part number or not installed Also MK102 connector on the power card could not be installed ALARM 80 Drive initialized to default value Parameter settings are...

Page 80: ...Warnings and Alarms VLT HVAC Drive D Frame Instruction Manual 8 12 MG16D222 VLT is a registered Danfoss trademark 8 8...

Page 81: ...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 diffe...

Page 82: ...ction 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 si...

Page 83: ...A to B 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...

Page 84: ...Basic Troubleshooting VLT HVAC Drive D Frame Instruction Manual 9 4 MG16D222 VLT is a registered Danfoss trademark 9 9...

Page 85: ...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 204 251 304 381 381 463 463 567 Continuous at 460 500 V A 183 231 291 348 348 427 427 5...

Page 86: ...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 moto...

Page 87: ...60 3848 6 182 4610 6 906 5150 Weight enclosure IP21 IP54 kg lbs 125 275 Weight enclosure IP20 kg lbs 125 275 Efficiency 0 98 Output frequency 0 590 Hz Heatsink overtemp trip 230 F 110 C Power card amb...

Page 88: ...tics 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 dr...

Page 89: ...riven 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 k...

Page 90: ...n 1 3 NC resistive load 240 V AC 2 A Max terminal load AC 15 1 on 1 3 NC inductive load cos 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 o...

Page 91: ...de 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 1...

Page 92: ...nal regulations Short circuit Protection The adjustable frequency drive must be protected against short circuit to avoid electrical or fire hazard Danfoss recommends using the fuses mentioned below to...

Page 93: ...9URD32D08A0550 A070URD32KI0550 N250 T7 170M4015 20 620 31 550 6 9URD32D08A0550 A070URD32KI0550 N315 T7 170M4015 20 620 31 550 6 9URD32D08A0550 A070URD32KI0550 N400 T7 170M4015 20 620 31 550 6 9URD32D0...

Page 94: ...ing Torques When tightening all electrical connections it is very important to tighten with the correct torque Too low or too high torque results in a bad electrical connection Use a torque wrench to...

Page 95: ...ance 10 7 Card 10 V DC Output 10 7 Card 24 V DC Output 10 6 Card RS 485 Serial Communication 10 5 Card USB Serial Communication 10 7 Characteristics 10 7 Signal 5 1 System 1 3 Terminal Functions 2 23...

Page 96: ...fting 2 2 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 4 Mode 3 4 Operation 4 1 Start 3 4 M Main Menu 5 1 4 2 Manual Initialization 4 4 Mechanic...

Page 97: ...1 Control Cables 2 22 Wire 2 5 Short Circuit 8 7 Smart Application Set up SAS 3 2 Specifications 1 3 Speed Reference 2 23 3 4 5 1 Start Up 9 1 Startup 1 3 5 1 Start up 4 4 Status Messages 7 1 Mode 7 1...

Page 98: ...www danfoss com drives MG16D222 130R0290 MG16D222 Rev 2012 12 14...

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