Danfoss FC103-110-250Kw Operating Instructions Manual
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Danfoss FC103-110-250Kw Operating Instructions Manual

Danfoss FC103-110-250Kw Operating Instructions Manual

Vlt refrigeration drive 110-250 kw
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MAKING MODERN LIVING POSSIBLE
Operating Instructions
®
VLT
Refrigeration Drive 110-250 kW

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Summary of Contents for Danfoss FC103-110-250Kw

  • Page 1 MAKING MODERN LIVING POSSIBLE Operating Instructions ® Refrigeration Drive 110-250 kW...

  • Page 2: Table Of Contents

    3.5.6 Control Terminal Functions 3.6 Serial Communication 4 Start Up and Functional Test 4.1 Pre-start 4.2 Applying Power to the Frequency Converter 4.3 Basic Operational Programming 4.3.1 Set-up Wizard 4.4 Local-control Test MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 3 7.2.3 Compressor Pack 8 Status Messages 8.1 Status Display 8.2 Status Message Definitions Table 9 Warnings and Alarms 9.1 System Monitoring 9.2 Warning and Alarm Types 9.2.1 Warnings 9.2.2 Alarm Trip 9.2.3 Alarm Trip-lock MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 4 10 Basic Troubleshooting 10.1 Start Up and Operation 11 Specifications 11.1 General Specifications 11.2 Mains Supply 11.3 Fuse Specifications 11.3.1 Protection 11.3.2 Non UL Compliance 11.3.3 UL Compliance 11.3.4 Connection Tightening Torques Index MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 5: Safety

    20 minutes before doing any service or repair. Failure to wait the specified time after power has been removed prior to doing service or repair on the unit could result in death or serious injury. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 6: Introduction

    Serial bus terminal switch 14 Motor output terminals 96 (U), 97 (V), 98 (W) Analog switches (A53), (A54) 15 Mains input terminals 91 (L1), 92 (L2), 93 (L3) Relay 1 (01, 02, 03) Table 2.1 MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 7: Purpose Of The Manual

    Operation and monitoring functions are available as status indications to an outside control system or serial communication network. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 8 • User interface and external commands are monitored and performed • Status output and control can be provided Table 2.2 Frequency Converter Internal Components MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 9: Installation

    ® Design Guide for detailed information. Voltage Altitude Restrictions The high power Danfoss VLT frequency converters utilize a 380-480 V At altitudes above 3 km, contact Danfoss regarding back-channel cooling concept that removes heatsink PELV cooling air, which carries approximately 90% of the heat 525-600 V At altitudes above 2 km, contact Danfoss regarding out of the back channel of the frequency converters.

  • Page 10: Lifting

    Wiring the AC mains to the frequency converter Table 3.2 Airflow 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 MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 11 Failure to follow these optimum frequency converter and associated equipment guidelines could result in death or serious injury. performance. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 12 All wiring must comply with local and national regulations regarding cross-section and ambient temperature requirements. • Danfoss recommends that all power connections are made with a minimum 75 °C rated copper wire. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 13: Earth (Ground) Requirements

    RFI filtering, screened motor cables, and frequency converter power. EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3.5 mA. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 14: Earthing (Grounding) Ip20 Enclosures

    (grounding) points as shown in Illustration 3.6. (grounding) points as shown in Illustration 3.6. Illustration 3.5 Earthing (Grounding) Points for IP20 (Chassis) Illustration 3.6 Earthing (Grounding) for IP21/54 Enclosures. Enclosures MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 15: Motor Connection

    Gland plates are provided at the base of IP21/54 and higher (NEMA1/12) units. SECTION A-A SECTION B-B MAINS TERMINALS MOTOR TERMINALS MAINS TERMINAL MOTOR TERMINAL GROUND 88 3X M8x20 STUD WITH NUT Illustration 3.7 Terminal Locations D1h MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 16 SECTION A-A MOTOR TERMINALS AND MAINS TERMINALS BRAKE TERMINALS MAINS TERMINAL MOTOR TERMINAL 331.2 211.1 GROUND 168.4 168.4 GROUND GROUND 143.4 143.4 GROUND 4X M10x20 STUD WITH NUT Illustration 3.9 Terminal Locations D2h MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 17 VLT® Refrigeration Drive 110-250 kW Operating Instructions SECTION B-B SECTION A-A MOTOR TERMINALS AND MAINS TERMINALS BRAKE BRAKE TERMINALS TERMINALS BRAKE / REGEN TERMINAL MAINS TERMINAL 14.8 12.6 MOTOR TERMINAL Illustration 3.10 Terminal Locations D4h MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 18: Motor Cable

    (ground) capacity • Connect 3-phase AC input power wiring to currents in accordance with IEC 61800-3. terminals L1, L2, and L3 (see Illustration 3.11). MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 19: Control Wiring Connection

    50/60 Hz earth (ground) loops With very long control cables, earth loops (ground loops) may occur. To eliminate earth (ground) loops, connect one end of the screen-to-earth (ground) with a 100 nF capacitor (keeping leads short). MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 20: Control Terminal Types

    Thus, connect a large surface of the screen to earth (ground), for example with a cable clamp or a conductive cable gland. It may be necessary to apply potential- equalizing cables to maintain the same earth (ground) MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 21 Cable Screened twisted pair (STP) 120 Ω Impedance Max. cable length 1200 m (including drop lines) 500 m station-to-station Table 3.9 MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 22: Start Up And Functional Test

    Ensure that all switch and disconnect settings are in the proper positions. • Vibration Check that the unit is mounted solidly or that shock mounts are used, as necessary. • Check for an unusual amount of vibration. Table 4.1 Start Up Check List MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 23: Applying Power To The Frequency Converter

    Application Guide or to skip it (until it has been run, the min. of inactivity (no keys pressed). The wizard must be re- FC 103 will ask every time at start-up), thereafter in the entered through the Quick Menu as described below. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 24 This screen will automatically change to the first input screen of the Application Guide: Illustration 4.5 Current and nominal speed set-up Illustration 4.3 Illustration 4.4 Illustration 4.6 Min. and max. frequency set-up Illustration 4.7 MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 25 103 Lon. The frequency converter will change its speed depending upon this reference signal. Select sensor type Illustration 4.8 Choose with/without bypass valve Illustration 4.11 Settings for sensor Illustration 4.9 Select open or closed loop Illustration 4.12 Illustration 4.10 MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 26 Select fixed or floating setpoint Illustration 4.16 Illustration 4.13 Set setpoint Info: Set switch accordingly Illustration 4.14 Illustration 4.17 Set high/low limit for setpoint Select unit and conversion from pressure Illustration 4.15 Illustration 4.18 MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 27 • Run application- this mode starts the frequency converter in either hand/local mode or via an external control signal if open loop is selected in an earlier screen Illustration 4.21 Illustration 4.24 MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 28 Use the navigation keys to scroll to parameter frequency converter. group Q2 Quick Setup and press [OK]. Press [Main Menu] twice on the LCP. Use the navigation keys to scroll to parameter group 0-** Operation/Display and press [OK]. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 29: Local-Control Test

    This concludes the quick set-up procedure. Press [Status] • Enable overvoltage control in 2-17 Over-voltage to return to the operational display. Control. See 5.1.1 Local Control Panel for resetting the frequency converter after a trip. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 30: System Start Up

    Apply an external run command. Adjust the speed reference throughout the speed range. Remove the external run command. Note any problems. If warnings or alarms occur, see 9 Warnings and Alarms. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 31: User Interface

    Navigation keys for programming functions, moving the display cursor, and speed control in local operation. Also included are the status indicator lights. Operational mode keys and reset. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 32: Setting Lcp Display Values

    • For details about the frequency converter before it entered the alarm mode, select the alarm number using the navigation keys Auto Remote Running and press [OK]. Table 5.2 Illustration 5.3 MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 33: Navigation Keys

    LCP memory ALARM A fault condition causes the red alarm light to flash and an alarm text is displayed. Table 5.4 MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 34: Uploading Data To The Lcp

    Initialisation can be through 14-22 Operation Mode or manually. • Initialisation using 14-22 Operation Mode does not change frequency converter data such as operating hours, serial communication selections, MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 35: Programming

    [OK] after each action. 0.00 V Illustration 6.4 3-15 Reference 1 Source 14.7% 0.00A 1(1) References 5-1* 3-15 Reference Resource [1]] Analog input 53 Illustration 6.1 MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 36: Control Terminal Programming Examples

    Note that the scroll bar on the right in the last illustration of the display is at the bottom, indicating the procedure is complete. Illustration 6.8 shows the wiring connections used to enable this set up. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 37: International/North American Default Parameter Settings

    3-03 Maximum 50 Hz 60 Hz Q5-2 Since Factory Setti... Reference 3-04 Reference External/Preset Function Illustration 6.12 4-13 Motor Speed 1500 PM 1800 RPM High Limit [RPM] See Note 3 and 5 MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 38: Parameter Menu Structure

    • Press and hold [Main Menu] to enter a parameter number for direct access to that parameter • Details for common application set ups are provided in 7 Application Set-Up Examples MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 39: Quick Menu Structure

    Programming VLT® Refrigeration Drive 110-250 kW Operating Instructions 6.5.1 Quick Menu Structure MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 40 Programming VLT® Refrigeration Drive 110-250 kW Operating Instructions MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 41: Main Menu Structure

    Programming VLT® Refrigeration Drive 110-250 kW Operating Instructions MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 42 Programming VLT® Refrigeration Drive 110-250 kW Operating Instructions MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 43 Programming VLT® Refrigeration Drive 110-250 kW Operating Instructions MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 44 Programming VLT® Refrigeration Drive 110-250 kW Operating Instructions MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 45: Application Set-Up Examples

    • Setpoint type and set -up is thus completed in 10-15 easy steps • Cut in/cut out using just two keys on the LCP. • 400/230 V AC • Amps • MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 46 96 97 95 93 Cables type: LIYCY Ltot. max. = 40 mm Illustration 7.3 Pressure Control in Closed Loop – Stand Alone System - Single Fan or Pump/Multiple Fans or Pumps in Parallel MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 47: Compressor Pack

    Pressure Transmitter FC 103 12 18 Supply AKS33 Illustration 7.5 How to Connect the FC 103 and AKS33 for Closed Loop Applications NOTE To find out which parameters are relevant, run the Wizard. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 48: Status Messages

    2-12 Brake Power Limit (kW) is reached. • Coast Coast inverse was selected as a function for a digital input (parameter group 5-1*). The corresponding terminal is not connected. • Coast activated by serial communication MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 49 Changing the reference is now only Ref. high The sum of all active references is above the possible via terminal functions speed up and reference limit set in 4-55 Warning Reference speed down. High. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 50 Once the cause of the alarm is cleared, power must be cycled to the frequency converter. The frequency converter can then be reset manually by pressing [Reset] or remotely by control terminals or serial communication. Table 8.3 MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 51: Warnings And Alarms

    Illustration 9.2 A trip can be reset in any of 4 ways: • Press [Reset] • Digital reset input command • Serial communication reset input command • Auto reset MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 52 In addition to the text and alarm code on the frequency converter display, there are three status indicator lights. Warn. Alarm Hand Auto Off Reset Illustration 9.3 Warn. LED Alarm LED Warning Alarm ON (Flashing) Trip-Lock ON (Flashing) Table 9.1 MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 53: Warning And Alarm Definitions

    Overload of Digital Output On X30/6 5-32 Term X30/6 Digi Out (MCB 101) Overload of Digital Output On X30/7 5-33 Term X30/7 Digi Out (MCB 101) Pwr. card supply 24 V supply low 1.8 V supply low MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 54 Heatsink sensor Pwr.card supply Pwr.card temp Illegal PS config New spare parts New Type Code Table 9.2 Alarm/Warning Code List (X) Dependent on parameter Cannot be Auto reset via 14-20 Reset Mode MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 55: Fault Messages

    The intermediate circuit voltage (DC) is lower than the low Check if the motor is mechanically overloaded voltage warning limit. The limit is dependent on the frequency converter voltage rating. The unit is still active. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 56 If torque limit occurs while running, possibly short circuit. increase the torque limit. Be sure the system can WARNING/ALARM 17, Control word timeout operate safely at a higher torque. There is no communication to the frequency converter. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 57 2-13 Brake Power Monitoring, the frequency motor phase U. converter will trip when the dissipated braking power ALARM 31, Motor phase V missing reaches 100%. Motor phase V between the frequency converter and the motor is missing. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 58 H983x: option in slot x has issued a legal • Check for loose or missing wiring powerup-wait It may be necessary to contact your Danfoss supplier or 2304 Could not read any data from power EEPROM service department. Note the code number for further...
  • Page 59 Check for a defective control card. If an WARNING 62, Output frequency at maximum limit option card is present, check for an overvoltage condition. The output frequency is higher than the value set in 4-19 Max Output Frequency. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 60 The power card or other components have been replaced nameplate and the part numbers of the cards to check and the typecode changed. Reset to remove the warning compatibility. and resume normal operation. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 61: Basic Troubleshooting

    3-13 Reference Site. Set preset reference active? Terminal reference active in parameter connection correct? Scaling of group 3-1* References. Check for terminals correct? Reference signal correct wiring. Check scaling of available? terminals. Check reference signal. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 62 Rotate output motor leads one If imbalance leg stays on same converters position: U to V, V to W, W to U. output terminal, it is a problem with the unit. Contact the supplier. MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 63 Change switching pattern and acceptable limit. certain frequencies) frequency in parameter group 14-0*. Increase Resonance Dampening in 1-64 Resonance Dampening. Table 10.1 MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 64: Specifications

    Maximum cross section to control terminals, cable with enclosed core 0.5 mm /20 AWG Minimum cross section to control terminals 0.25 mm * See 11.2.1 Mains Supply 3x380-480 VAC - High Power for more information! MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 65 Bandwidth 200 Hz The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. PELV isolation +24V Control Mains High Motor voltage Functional isolation DC-Bus RS485 Illustration 11.1 MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 66 240 V AC, 0.2 A Max. terminal load (DC-1) on 4-5 (NO) (Resistive load) 80 V DC, 2 A Max. terminal load (DC-13) on 4-5 (NO) (Inductive load) 24 V DC, 0.1 A MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 67 EN 61800-3, EN 61000-6-3/4, EN 55011, IEC 61800-3 EN 61800-3, EN 61000-6-1/2, EMC standards, Immunity EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6 See section on special conditions in the Design Guide! MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 68 Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high. • The frequency converter is protected against earth faults on motor terminals U, V, W. MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 69: Mains Supply

    IP00 [kg] 0.98 Efficiency Output frequency 0-800 Hz 90 °C 110 °C 110 °C 110 °C Heatsink overtemp. trip 110°C 60 °C Power card ambient trip Table 11.1 Mains Supply 3x380-480 VAC MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 70 Motors with lower efficiency will also add to the power loss in the frequency converter and opposite. If the switching frequency is increased comed to the default setting, the power losses may rise significantly. LCP and MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 71 (Though typical only 4 W extra for a fully loaded control card, or options for slot A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (±5%). MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 72: Fuse Specifications

    Short-circuit Protection: The frequency converter must be protected against short- circuit to avoid electrical or fire hazard. Danfoss recommends using the fuses mentioned below to protect service personnel and equipment in case of an internal failure in the frequency conveter. The frequency converter provides full short-circuit protection in case of a short- circuit on the motor output.

  • Page 73: Ul Compliance

    Regen Earth (Ground) 8.5-20.5 Nm Brake (75-181 in-lbs) D2h/D4h Mains Motor 19-40 Nm Regen (168-354 in- Load sharing lbs) Earth (ground) Brake 8.5-20.5 Nm (75-181 in-lbs) Table 11.5 Torque for Terminals MG16F102 - VLT® is a registered Danfoss trademark...

  • Page 74: Index

    Terminals............28, 32, 47, 49, 35, 19 Full Load Current..................8 Wiring................10, 11, 12, 21 Wiring Connection................18 Functional Testing................6, 29 Cooling Fuse Specifications................71 Cooling....................8 Fuses.................... 21, 57, 60 Clearance.................... 21 Fusing....................11, 21 MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 75 Supply (L1, L2, L3)................63 Supply 3 X 525- 690 VAC............... 69 Protection Voltage................... 31, 32, 48 Protection................... 71 And Features..................67 Manual Initialisation................33 Pulse Inputs.................... 65 MCT 10 Set-up Software..............19 Mechanical Installation................. 8 MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 76 Speed Reference..............29, 35, 47 Start Up.................. 6, 33, 34, 60 Status Messages..................... 47 Mode..................... 47 Stop Command..................48 Supply Voltage................ 18, 19, 57 Surroundings..................66 Switching Frequency................48 System Feedback..................6 Temperature Limits................21 MG16F102 - VLT® is a registered Danfoss trademark...
  • Page 77 130R0384 MG16F102 Rev. 2012-02-20 *MG16F102*...

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