Danfoss VLT FC 102 User Manual
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Danfoss VLT FC 102 User Manual

Parallel drive modules 250–1200 kw
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Download this manual See also: Programming Manual, Instruction Manual
ENGINEERING TOMORROW
User Guide
®
VLT
Parallel Drive Modules
250–1200 kW
vlt-drives.danfoss.com

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Summary of Contents for Danfoss VLT FC 102

  • Page 1 ENGINEERING TOMORROW User Guide ® Parallel Drive Modules 250–1200 kW vlt-drives.danfoss.com...

  • Page 3: Table Of Contents

    4.5 Testing Before System Startup 4.5.1 Motor Rotation 4.5.2 Encoder Rotation 4.5.3 Local Control Test 4.6 System Startup 4.7 Parameter Settings 4.7.1 Uploading and Downloading Parameter Settings 4.7.2 Restoring Factory Default Settings MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 4 7.1.2 VLT AQUA Drive FC 202 ® 7.1.3 VLT AutomationDrive FC 302 7.2 Connection Tightening Torques 7.3 Fuses and Circuit Breakers 7.3.1 Protection 7.3.2 Fuse Selection 7.3.2.1 Recommended Fuses for CE Compliance Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 5 7.3.2.2 Recommended Fuses for UL Compliance 7.3.3 Fuse Replacement 7.3.4 Short Circuit Current Rating (SCCR) 8 Appendix 8.1 Symbols, Abbreviations, and Conventions 8.2 International/North American Default Parameter Settings 8.3 Parameter Menu Structure 8.3.1 Main Menu Structure Index MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 6: Introduction

    • ® The VLT FC Series, D-frame Service Manual contains detailed service information, including ® information applicable to the VLT Parallel Drive Modules. Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 7: Safety

    DC voltage on each drive module is fully discharged. • If an external discharge resistor is not installed, wait 20 minutes for the capacitors to discharge fully before performing any service or repair work. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 8 INTERNAL FAILURE HAZARD Missing or incorrectly placed safety covers in the drive system can result in serious injury. • Ensure that all safety covers are in place and securely fastened before applying power. Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 9: Product Overview

    Illustration 3.1 shows the busbar option kit. The installer can use other connection methods, including locally manufactured busbars or electrical cables. The installer is responsible for the details of the drive system construction, including connections and proper grounding. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 10 In this view EMI/EMC shields and other protective shields are shown removed so that the parts of the drive system can be made visible. Some of these shields reduce EMI/EMC emissions, while other shields provide physical protection against the high-voltage electrical hazard. Illustration 3.1 Drive System Overview Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 11 The mains input busbars are part of the busbar kit, which can be ordered from Danfoss as an option. However, the installer may choose to fabricate the busbars locally, or use cables in place of busbars.
  • Page 12 AC voltage output to the motor. The motor output busbars are part of the busbar kit, which can be ordered from Danfoss as an option. However, the installer may choose to fabricate the busbars locally, or use cables in place of busbars.

  • Page 13: Drive Module

    Drive module data label. Refer to the VLT Parallel Drive Modules Installation Guide for details. ® Product label Drive module product label. Refer to the VLT Parallel Drive Modules Installation Guide for details. Illustration 3.3 Drive Module Overview MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 14 In a drive system, a ribbon cable links the power card to the MDCIC on the control shelf. The MDCIC provides supervision over the drive modules in the system. Table 3.1 Single Drive Module - Simplified Block Diagram Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 15: Control Shelf

    Label describing the drive system at the top-level. For details, refer to the VLT Parallel Drive Modules Installation Guide. Relay terminal blocks Terminal blocks for connecting the relay cable from the relay connector on the top plate of drive module 1. Illustration 3.5 Control Shelf MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 16: Commissioning

    Apply power to the drive system. DO NOT start the drive system now. For units with a disconnect switch, turn the switch to the ON position to apply power to the drive system. Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 17: Local Control Panel (Lcp)

    Reference % provide speed control in local (hand) operation. The [unit] display brightness can be adjusted by pressing [Status] and ▲ ▼ ] keys. Table 4.1 Legend to Illustration 4.1, LCP Display Area MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 18: Menus

    Parameter 0-24 Display Line 3 Large Feedback [Unit] Parameter 15-51 Frequency Converter Serial – Table 4.5 Legend to Illustration 4.1, LCP Operation Keys, and Number Reset Table 4.7 Q1 My Personal Menu Settings, FC 202 Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 19: Programming The Drive System

    For example: 0-** Operation/Display Parameter group 0-0* Basic Settings Parameter sub-group Parameter 0-01 Language Parameter Parameter 0-02 Motor Speed Unit Parameter Parameter 0-03 Regional Settings Parameter Table 4.10 Example of Parameter Group Hierarchy MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 20: Entering System Information

    [OK]. (This action changes the default settings for several basic parameters). Danfoss has a software program available for developing, storing, and transferring drive system programming. The Press [Quick Menu] on the LCP. MCT 10 Set-up Software allows the installer or operator to...

  • Page 21: Q3 Function Set-Ups

    Scroll to parameter group 5-1* Digital Inputs and then press [OK]. During this procedure, the drive system builds a mathematical model of the motor for regulating output motor current. The procedure also tests the input phase MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 22: Testing Before System Startup

    RPM value that causes the motor to rotate slowly. Press [OK]. If the motor rotation is wrong, change parameter 1-06 Clockwise Direction to [1] Inverse. Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 23: System Startup

    • Fault log, alarm log, and other monitoring downloading the stored parameter settings. functions. • Custom settings that are stored in the LCP are not changed when restoring the factory default settings. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 24 Hold approximately 5 s or until an audible click is heard and the drive system’s cooling fan starts. Factory default parameter settings are restored during startup. As a result, startup takes slightly longer than normal. Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 25: Application Set-Up Examples

    D IN *=Default value D IN Notes/comments: D IN Set parameter group 1-2* Motor Data according to motor +10 V nameplate. A IN A IN A OUT Table 5.2 AMA without T27 Connected MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 26: Rs485 Network Connection

    5 s, the drive system continues and the warning disappears. However, relay 1 is still triggered until [Reset] is pressed on the LCP. Table 5.4 Using SLC to Set a Relay Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 27: Mechanical Brake Control

    *=Default value Table 5.5 Mechanical Brake Control (Open Loop) 1-76 Current Speed Time 1-71 2-21 1-71 2-21 Start (18) Start reversing (19) Relay output Open Closed Illustration 5.1 Mechanical Brake Control (Open Loop) MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 28 0 RPM A OUT erminal 53 Low Ref./Feedb. Value Parameter 6-15 T 1500 RPM U - I erminal 53 High Ref./Feedb. Value *=Default value Notes/comments: Table 5.8 Speed Reference (using a Manual Potentiometer) Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 29: Start/Stop

    Table 5.10 Start/Stop Command with Safe Torque Off (STO) Option Table 5.11 Pulse Start/Stop Speed Speed Start/Stop (18) Illustration 5.3 Start/Stop Command with Safe Torque Off Latched Start (18) (STO) Stop Inverse (27) Illustration 5.4 Latched Start/Stop Inverse MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 30: External Alarm Reset

    * = Default value D IN Notes/comments: Table 5.14 Motor Thermistor D IN D IN D IN D IN D IN +10 V A IN A IN A OUT Table 5.13 External Alarm Reset Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 31: Connection Examples For Control Of Motor With External Signal Provider

    Input [22] Speed down. Terminal 27= Parameter 5-12 Terminal 27 Digital Input [6] Stop inverse. +24V Terminal 37 = Safe Torque Off. Par. 5-10 Par. 5-12 Par. 5-13 Par. 5-14 Illustration 5.7 Speed Control Parameters MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 32: Potentiometer Reference

    Terminal 53, Low ref./feedback = 0 RPM. Terminal 53, High ref./feedback = 1500 RPM. Switch S201 = OFF (U). Speed RPM 39 42 53 54 P 6-15 Ref. voltage P 6-11 10V Illustration 5.8 Potentiometer Voltage Reference Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 33: Maintenance, Diagnostics, And Troubleshooting

    The navigation keys on the LCP can be used to control the drive system. Stop commands, reset, reversing, DC brake, and other signals applied to the control terminals can override local control. Table 6.1 Operating Mode MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 34 • The jog function is activated via the serial communication. • The jog function was selected as a reaction for a monitoring function (for example, No signal). The monitoring function is active. Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 35 Run request A start command has been given, but the motor is stopped until a run permissive signal is received via digital input. Running The drive system is driving the motor. MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 36: Warning And Alarm Types

    (see also Table 6.4). Alarms that are trip locked offer extra protection, meaning that the mains supply must be switched off before the alarm can be reset. After being switched back on, the Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 37 Parameter 4-58 Missing Motor Phase Function Inrush fault – Fieldbus communication fault – – Option fault – – – Mains failure – – Imbalance of supply voltage – – Internal fault – MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 38 – Illegal option combination – – – No safety option – – – Option detection – – – Mechanical brake sliding – – – Feedback monitor – Parameter 17-61 Feedback Signal Monitoring Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 39 A trip lock is an action when an alarm occurs, which could damage the frequency converter or connected parts. A trip lock situation can only be reset by a power cycling. Warning Yellow Alarm Flashing red Trip locked Yellow and red Table 6.5 Indicator Light MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 40 Password timelock number of allowed password trials exceeded - timelock active 18 00040000 262144 Brake overload Fans error Brake overload Fans warn Password protection (A26) (W26) 0-61 = ALL_NO_ACCESS OR BUS_NO_ACCESS OR BUS_READONLY Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 41 PTC thermi- Unused (A74) stor (W74) 31 80000000 2147483648 Mech. brake low Dangerous Extended status Protection mode (A63) failure (A72) word Table 6.6 Description of Alarm Word, Warning Word, and Extended Status Word MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 42 The unit is still active. motor is too hot. Select whether the frequency converter issues a warning or an alarm when the counter is >90% if parameter 1-90 Motor Thermal Protection is set to warning Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 43 • If the generator torque limit is exceeded during ALARM 15, Hardware mismatch ramp-down, extend the ramp-down time. A fitted option is not operational with the present control card hardware or software. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 44 Remove the power to the drive system and then • Remove the power from the drive system and replace the brake resistor (see then check motor phase V. parameter 2-15 Brake Check). Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 45 Internal fault. Contact the Danfoss supplier or • Check for loose or missing wiring. Danfoss service department. It may be necessary to contact the Danfoss supplier or service department. Note the code number for further Table 6.7 Internal Fault Codes troubleshooting directions.
  • Page 46 ALARM 45, Earth fault 2 (except when starting or stopping), the drive system trips. Ground fault. ALARM 50, AMA calibration failed Troubleshooting Contact the Danfoss supplier or Danfoss service • Check for proper grounding and loose department. connections. ALARM 51, AMA check U and I •...
  • Page 47 ALARM 70, Illegal FC configuration measurement from feedback device. The control card and the power card are incompatible. To check compatibility, contact a Danfoss supplier with the Troubleshooting • type code of the drive system from its nameplate and the Check the settings for warning/alarm/disabling in part numbers of the cards.
  • Page 48 4 = Fourth drive module from left (in 4-module 1 = Left drive module. module systems). 2 = Second drive module from left. Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 49 A component in the drive system has been replaced. Troubleshooting • Reset the drive system to restore normal operation. WARNING 251, New typecode The power card or other components are replaced, and the type code has changed. MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 50: Troubleshooting

    3-1* • Is terminal connection correct? References. Check for correct • Is scaling of terminals correct? wiring. Check the terminals for scaling. Check the reference • Is reference signal available? signal. Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 51 Rotate the output motor cables 1 position: U to V, V If the imbalanced leg stays on to W, and W to U. the same output terminal, the problem is with the unit. Contact a Danfoss supplier. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 52 Change the switching pattern and frequency in the system. level. or vibrations parameter group 14-0* Inverter Switching. at certain Increase resonance damping in frequencies) parameter 1-64 Resonance Dampening. Table 6.8 Troubleshooting Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 53: Running In Reduced Power Mode

    Disconnect the frequency converters from the AC mains, 230 V supply, and motor lines. • After the lines have been disconnected, wait 20 minutes for the capacitors to discharge. MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 54: Configuring The Drive System For Reduced Power Mode

    Reapply mains power to the input terminals. On the control shelf, disconnect and remove the The LCP restarts, displaying warning 77, Reduced 44-pin ribbon cable leading from the failed drive power mode. module to the MDCIC. Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 55: Wiring Configurations

    Illustration 6.7 Configuring 4-drive System with Failure of Drive Module 2 Illustration 6.12 Configuring 2-drive System with Failure of Drive Module 2 Illustration 6.8 Configuring 4-drive System with Failure of Drive Module 3 MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 56: Specifications

    700 A, 600 V – Table 7.1 FC 102, 380–480 V AC Mains Supply (2-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 57 1500 A Table 7.2 FC 102, 380–480 V AC Mains Supply (4-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 58 700 V, 630 A Table 7.3 FC 102, 525–690 V AC Mains Supply (2-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 59 700 V, 1500 A Table 7.4 FC 102, 525–690 V AC Mains Supply (4-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 60: Vlt ® Aqua Drive Fc 202

    600 V, 900 A Table 7.5 FC 202, 380–480 V AC Mains Supply (2-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 61 600 V, 1500 A Table 7.6 FC 202, 380–480 V AC Mains Supply (4-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 62 700 V, 550 A Table 7.7 FC 202, 525–690 V AC Mains Supply (2-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 63 700 V, 630 A Table 7.8 FC 202, 525–690 V AC Mains Supply (2-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 64 700 V, 900 A Table 7.9 FC 202, 525–690 V AC Mains Supply (4-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 65: Vlt ® Automationdrive Fc 302

    600 V, 900 A Table 7.10 FC 302, 380–500 V AC Mains Supply (2-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 66 600 V, 1500 A Table 7.11 FC 302, 380–500 V AC Mains Supply (4-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 67 700 V, 550 A Table 7.12 FC 302, 525–690 V AC Mains Supply (2-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 68 700 V, 630 A Table 7.13 FC 302, 525–690 V AC Mains Supply (2-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 69 700 V, 1500 A Table 7.14 FC 302, 525–690 V AC Mains Supply (4-module System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 70: Connection Tightening Torques

    Avoid electrical or fire hazards by protecting the drive system against short circuits. To protect service personnel and equipment against an internal failure in the unit, Danfoss recommends using the fuses described in chapter 7.3.2 Fuse Selection. The drive system provides full short-circuit protection against a short circuit on the motor output.

  • Page 71: Recommended Fuses For Ce Compliance

    N710 N800 aR-2500 aR-2500 N900 N1M0 aR-2500 aR-2500 N800 N1M0 aR-2500 aR-2500 N1M0 N1M2 aR-2500 aR-2500 Table 7.17 6-Pulse Drive Systems (380–500 V AC) Table 7.19 6-Pulse Drive Systems (525–690 V AC) MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 72: Recommended Fuses For Ul Compliance

    7.3.1 Protection. For more information on the recommended fuses for CE or UL compliance, see chapter 7.3.2.1 Recommended Fuses for CE Compliance or chapter 7.3.2.2 Recommended Fuses for UL Compliance, respectively. Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 73: Appendix

    Multipoint communications standard using a 2-wire, twisted-pair bus Second (time) SCCR Short circuit current rating SL controller Switched-mode power supply Safe Torque Off Total harmonic distortion Uninterruptible power supply Universal serial bus Volt Table 8.1 Symbols and Abbreviations MG37L202 Danfoss A/S © 08/2017 All rights reserved.

  • Page 74: International/North American Default Parameter Settings

    Certain parameters are specific to the drive system. For a list of these parameters and all other system parameters, including descriptions, refer to the programming guide applicable to the series of drive modules used in creating the drive system. Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 75: Main Menu Structure

    Appendix User Guide MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 76 ® Appendix Parallel Drive Modules Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 77 Appendix User Guide MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 78 ® Appendix Parallel Drive Modules Danfoss A/S © 08/2017 All rights reserved. MG37L202...

  • Page 79: Index

    Current Warning....................43 DC......................12 Limit...................... 50 High voltage................5, 6, 14, 51 Output current.................. 40 Rating....................40 Indicator lights..................16 Initialization.................... 21 DC current....................32 DC link....................... 40 Default settings..................21 MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 80 Safe Torque Off Warning....................45 Open loop....................19 Safety......................6 Optional equipment................14 Serial communication..........16, 31, 32, 33, 34 Output Service...................... 31 Current....................32 Setpoint....................33 Terminal....................14 Set-up....................15, 21 Overcurrent..................... 33 Danfoss A/S © 08/2017 All rights reserved. MG37L202...
  • Page 81 Thermistor....................23 Torque Limit...................... 41 Torque limit..................... 50 Transient protection................12 Trip......................28 Unintended motor rotation..............6 Unintended start................5, 14 Voltage imbalance................40 Voltage reference via potentiometer..........30 Warning....................34 Windmilling....................6 MG37L202 Danfoss A/S © 08/2017 All rights reserved.
  • Page 82 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products 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 respective companies.

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Vlt aqua drive fc 202Vlt automationdrive fc 302

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