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Danfoss VLT HVAC Drive FC 102 Operating Instructions Manual

1.1-90 kw
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Download this manual See also: Programming Manual, Operating Instructions Manual
MAKING MODERN LIVING POSSIBLE
Operating Instructions
®
VLT
HVAC Drive FC 102
1.1-90 kW
www.danfoss.com/drives

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Summary of Contents for Danfoss VLT HVAC Drive FC 102

  • Page 1 MAKING MODERN LIVING POSSIBLE Operating Instructions ® HVAC Drive FC 102 1.1-90 kW www.danfoss.com/drives...

  • Page 3: Table Of Contents

    4.8.4 Voltage/Current Input Selection (Switches) 4.8.5 Safe Torque Off (STO) 4.8.6 RS-485 Serial Communication 4.9 Installation Check List 5 Commissioning 5.1 Safety Instructions 5.2 Applying Power 5.3 Local Control Panel Operation 5.4 Basic Programming MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 4 8.6 Control Input/Output and Control Data 8.7 Connection Tightening Torques 8.8 Fuses and Circuit Breakers 8.9 Power Ratings, Weight and Dimensions 9 Appendix 9.1 Symbols, Abbreviations and Conventions 9.2 Parameter Menu Structure Index Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 5: Introduction

    This manual is regularly reviewed and updated. All suggestions for improvement are welcome. Table 1.1 shows the document version and the corresponding software version. Edition Remarks Software version MG11AKxx Replaces MG11AJxx 3.92 Table 1.1 Document and Software Version MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 6 Motor output terminals 96 (U), 97 (V), 98 (W) Analog switches (A53), (A54) Mains input terminals 91 (L1), 92 (L2), 93 (L3) Relay 1 (01, 02, 03) Illustration 1.1 Exploded View Enclosure Types B and C, IP55 and IP66 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 7 Decoupling plate Serial bus terminal switch Grounding clamp (PE) Digital I/O and 24 V power supply Screened cable grounding clamp and strain relief Cover Illustration 1.2 Exploded View Enclosure Type A, IP20 MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 8: Approvals And Certifications

    • Regulated 3-phase output domestic waste. Output to motor power to the motor Collect it separately in accordance with local and currently valid legislation. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 9: Safety

    525-600 1.1-7.5 kW 11-90 kW 525-690 1.1-7.5 kW 11-90 kW High voltage may be present even when the warning LED indicator lights are off. Table 2.1 Discharge Time MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 10 An internal failure in the frequency converter can result in serious injury, when the frequency converter is not properly closed. • Before applying power, ensure all safety covers are in place and securely fastened. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 11: Mechanical Installation

    Enclosure type and IP rating Maximum ambient temperature Certifications Discharge time (Warning) Serial number Illustration 3.1 Product Nameplate (Example) NOTICE Do not remove the nameplate from the frequency converter (loss of warranty). MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 12: Mounting

    Ensure that the lifting device is suitable for the task. • If necessary, plan for a hoist, crane, or forklift with the appropriate rating to move the unit. • For lifting, use hoist rings on the unit, when provided. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 13: Electrical Installation

    See chapter 8.1 Electrical Data and chapter 8.5 Cable Specifi- different. Install equalising cables between the system cations for recommended wire sizes and types. components. Recommended cable cross-section: 16 mm MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 14: Wiring Schematic

    *Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off ® Operating Instructions for Danfoss VLT Frequency Converters. **Do not connect cable screen. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 15 Failure to isolate power, motor and control cables can result in unintended behaviour or reduced performance. Minimum 200 mm (7.9 in) clearance between power, motor and control cables is required. MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 16: Access

    Illustration 4.4 Access to Wiring for IP55 and IP66 Enclosures See Table 4.1 before tightening the covers. Enclosure IP55 IP66 A4/A5 B1/B2 C1/C2 No screws to tighten for A2/A3/B3/B4/C3/C4. Table 4.1 Tightening Torques for Covers [Nm] Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 17: Ac Mains Connection

    For maximum wire sizes, see chapter 8.1 Electrical Data. • Comply with local and national electrical codes for cable sizes. Illustration 4.6 Motor Connection for Enclosure Type A2 and MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 18: Control Wiring

    A 24 V DC supply voltage is recommended. 4.8.1 Control Terminal Types Illustration 4.10 and Illustration 4.11 show the removable frequency converter connectors. Terminal functions and default settings are summarised in Table 4.2. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 19: Wiring To Control Terminals

    Open the contact by inserting a small screw Switches A53 and A54 driver into the slot above the contact and push select mA or V. the screw driver slightly upwards. Common for analog input Table 4.2 Terminal Description MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 20: Enabling Motor Operation (Terminal 27)

    The frequency converter cannot operate without a signal additional wiring for the frequency converter is required. on terminal 27 unless terminal 27 is re-programmed. ® Refer to VLT Frequency Converters Safe Torque Off Operating Instructions for further information. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 21: Rs-485 Serial Communication

    Use the same type of cable throughout the entire network to prevent impedance mismatch. Cable Screened twisted pair (STP) 120 Ω Impedance Max. cable 1200 (including drop lines) length [m] 500 station-to-station Table 4.4 Cable Information MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 22: Installation Check List

    POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE Risk of personal injury when the frequency converter is not properly closed. • Before applying power, ensure all safety covers are in place and securely fastened. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 23: Commissioning

    27. See chapter 4.8.3 Enabling Motor Operation (Terminal 27) for details. MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 24: Local Control Panel Operation

    Callout Function Status Shows operational information. Quick Menu Allows access to programming parameters for initial set-up instructions and many detailed application instructions. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 25 [2] All from LCP to download data from the LCP. Press [OK]. A progress bar shows the uploading or downloading process. Press [Hand On] or [Auto On] to return to normal operation. MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 26: Basic Programming

    Manual initialisation erases all motor, NOTICE programming, localisation, and monitoring data and restores factory default settings. Motor data are required for the SmartStart set-up. The required data are normally available on the motor nameplate. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 27: Commissioning Via [Main Menu]

    [1] North America as appropriate and press [OK]. 1-26 Motor Cont. Rated Torque (This changes the default settings for a number 1-25 Motor Nominal Speed of basic parameters). 1-39 Motor Poles Press [Main Menu] on the LCP. MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 28: Automatic Energy Optimisation (Aeo)

    2-06 Parking Current and 2-07 Parking Time can be adjusted. Increase the factory setting of these parameters for applications with high inertia. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 29: Automatic Motor Adaptation (Ama)

    Before running the Warnings and Alarms. frequency converter, check the motor rotation. The motor runs briefly at 5 Hz or the minimum frequency set in 4-12 Motor Speed Low Limit [Hz]. MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 30: Application Set-Up Examples

    ≈ 5kΩ D IN 37 is an option. A IN U - I A OUT U - I Table 6.1 Analog Speed Reference (Voltage) Table 6.3 Speed Reference (Using a Manual Potentiometer) Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 31 F r e e z e r e f ( 2 7 ) S p e e d u p ( 2 9 ) S p e e d d o w n ( 3 2 ) Illustration 6.1 Speed Up/Down MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 32 D IN D IN 37 is an option. D IN D IN D IN D IN D IN +10 V A IN A IN A OUT Table 6.8 External Alarm Reset Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 33 [1] Thermistor +10 V warning. A IN D IN 37 is an option. A IN RS-485 A OUT U - I Table 6.9 RS-485 Network Connection Table 6.10 Motor Thermistor MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 34: Diagnostics And Troubleshooting

    The frequency converter is controlled from the and a stop command is active. The motor is control terminals and/or the serial communi- held by a DC current set in 2-00 DC Hold/ cation. Preheat Current. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 35 The Jog function was selected as a converter. reaction for a monitoring function (e.g. No Sleep Mode The energy-saving function is enabled. The signal). The monitoring function is active. motor has stopped, but restarts automatically when required. MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 36: Warning And Alarm Types

    After the fault condition is remedied, the frequency converter can be reset. It is then ready to start operation again. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 37: List Of Warnings And Alarms

    WARNING/ALARM 7, DC overvoltage • Check that the motor current set in 1-24 Motor If the intermediate circuit voltage exceeds the limit, the Current is correct. frequency converter trips after a time. MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 38 Increase 8-03 Control Word Timeout Time. quick, the fault can also appear after kinetic back-up. • Check the operation of the communication If extended mechanical brake control is selected, trip can equipment. be reset externally. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 39 The frequency converter is still operational but, since the brake transistor has short- MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 40 Check 5-33 Term X30/7 Digi • Check for loose or missing wiring Out (MCB 101). It may be necessary to contact your Danfoss supplier or ALARM 45, Earth fault 2 service department. Note the code number for further Ground fault.
  • Page 41 Possibly increase the current limit. Be sure that The control card and power card are incompatible. To check compatibility, contact the Danfoss supplier with the the system can operate safely at a higher limit. type code of the unit from the nameplate and the part WARNING 60, External interlock numbers of the cards.

  • Page 42: Troubleshooting

    Intermittent wiring or a fault within the the terminal blocks. short circuits or incorrect connections. If display frequency converter the display continues to cut out, follow the procedure for display dark. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 43 Possible incorrect settings in Check brake parameters. Check ramp-time Check parameter group 2-0* DC Brake and Motor will not the brake parameters. Possible settings. 3-0* Reference Limits. brake too short ramp-down times MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 44 Change switching pattern and frequency in or vibrations parameter group 14-0* Inverter Switching. at certain Increase Resonance Dampening in frequencies) 1-64 Resonance Dampening. Table 7.5 Troubleshooting Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 45: Specifications

    Max. cable cross-section with disconnect 6, 4, 4 (10, 12, 12) Efficiency 0.96 0.96 0.96 0.96 0.96 Table 8.1 Mains Supply 3x200-240 V AC - Normal overload 110% for 1 minute, P1K1-P3K7 MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 46 Specifications Operating Instructions Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 47: Mains Supply 3X380-480 V Ac

    Max. cable cross-section with 6, 4, 4 (10, 12, 12) disconnect 0.96 0.97 0.97 0.97 0.97 0.97 0.97 Efficiency Table 8.3 Mains Supply 3x380-480 V AC - Normal overload 110% for 1 minute, P1K1-P7K5 MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 48 Specifications Operating Instructions Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 49: Mains Supply 3X525-600 V Ac

    6, 4, 4 (12, 12, 12) disconnect Mains disconnect switch included: 4/12 Efficiency 0.97 0.97 0.97 0.97 0.97 0.97 0.97 Table 8.5 Mains Supply 3x525-600 V AC - Normal overload 110% for 1 minute, P1K1-P7K5 MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 50 Specifications Operating Instructions Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 51: Mains Supply 3X525-690 V Ac

    Max. cable size with mains disconnect [mm ]/(AWG) 16, 10, 10 (6, 8, 8) 0.98 0.98 0.98 0.98 0.98 Efficiency Table 8.8 Mains Supply 3 x 525-690 V AC - Normal overload 110% for 1 minute, P11K-P30K MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 52 6) A2+A3 may be converted to IP21 using a conversion kit. See also Mechanical mounting and IP21/Type 1 Enclosure kit in the Design Guide. 7) B3+4 and C3+4 may be converted to IP21 using a conversion kit. See also Mechanical mounting and IP21/Type 1 Enclosure kit in the Design Guide. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 53: Mains Supply

    Switching on output Unlimited Ramp times 1-3600 s 1) From software version 3.92 the output frequency of the frequency converter is limited to 590 Hz. Contact local Danfoss partner for further information. Torque characteristics Starting torque (Constant torque) maximum 110% for 60 s Starting torque maximum 135% up to 0.5 s...

  • Page 54: Cable Specifications

    This can be done by using a freewheel diode (or, alternatively, a 30 or 50 V MOV for quicker response time) across the coil. Typical contactors can be bought with this diode. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 55 Accuracy on analog output Max. error: 0.5% of full scale Resolution on analog output 12 bit The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 56 Control card, 10 V DC output Terminal number 10.5 V ±0.5 V Output voltage Max. load 15 mA The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 57: Connection Tightening Torques

    14/24 22-30 45-55 45-55 45-55 37-45 75-90 75-90 14/24 14/24 Table 8.10 Tightening of Terminals 1) For different cable dimensions x/y, where x ≤ 95 mm and y ≥ 95 mm MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 58: Fuses And Circuit Breakers

    (18.5) gG-160 (18.5-22) NZMB2-A200 gG-80 (22) aR-160 (30) gG-100 (30) 37-45 aR-160 (37) aR-200 (37) NZMB2-A250 aR-200 (45) aR-250 (45) Table 8.11 200-240 V, Enclosure Types A, B and C Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 59 NZMB1-A100 gG-63 (30) 37-55 gG-63 (37) gG-160 (37-45) NZMB2-A200 gG-100 (45) aR-250 (55) aR-160 (55) 75-90 aR-200 (75-90) aR-250 NZMB2-A250 Table 8.13 525-600 V, Enclosure Types A, B and C MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 60 JKS-50 JJN-50 KTN-R-60 JKS-60 JJN-60 KTN-R-80 JKS-80 JJN-80 18.5-22 KTN-R-125 JKS-125 JJN-125 KTN-R-150 JKS-150 JJN-150 KTN-R-200 JKS-200 JJN-200 KTN-R-250 JKS-250 JJN-250 Table 8.15 3x200-240 V, Enclosure Types A, B and C Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 61 KTS-R-60 JKS-60 JJS-60 KTS-R-80 JKS-80 JJS-80 KTS-R-100 JKS-100 JJS-100 KTS-R-125 JKS-125 JJS-125 KTS-R-150 JKS-150 JJS-150 KTS-R-200 JKS-200 JJS-200 KTS-R-250 JKS-250 JJS-250 Table 8.17 3x380-480 V, Enclosure Types A, B and C MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 62 KTS-R-125 JKS-125 JJS-125 2028220-125 KLS-125 A6K-125-R HSJ-125 KTS-R-150 JKS-150 JJS-150 2028220-150 KLS-150 A6K-150-R HSJ-150 KTS-R-175 JKS-175 JJS-175 2028220-200 KLS-175 A6K-175-R HSJ-175 Table 8.19 3x525-600 V, Enclosure Types A, B and C Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 63 5014006-100 KLS-R-100 A6K-100-R HST-100 125 A KTS-R-125 JKS-125 JJS-125 2028220-125 KLS-150 A6K-125-R HST-125 150 A KTS-R-150 JKS-150 JJS-150 2028220-150 KLS-175 A6K-150-R HST-150 Table 8.21 3x525-690 V, Enclosure Types B and C MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 64: Power Ratings, Weight And Dimensions

    Specifications Operating Instructions 8.9 Power Ratings, Weight and Dimensions Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...

  • Page 65: Appendix

    Table 9.1 Symbols and Abbreviations Conventions Numbered lists indicate procedures. Bullet lists indicate other information and description of illustrations. Italicised text indicates • cross reference • link • parameter name 9.2 Parameter Menu Structure MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 66 Appendix Operating Instructions Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 67 Appendix Operating Instructions MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 68 Appendix Operating Instructions Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 69 Appendix Operating Instructions MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.

  • Page 70: Index

    Grounding................14, 16, 20, 21 Control terminal................23, 25 Control terminals................32, 34 Control wiring..............11, 13, 18, 20 Hand On.................... 23, 32 Control word timeout................. 36 Harmonics....................6 Conventions................... 63 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 71 Motor data..............25, 27, 36, 39, 42 Reference................22, 28, 32, 33 Motor output..................51 Relays......................17 Motor power................11, 22, 39 Remote commands................3 Motor protection..................3 Remote reference................. 33 Motor rotation..................27 MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 72 Terminal 53..................... 18 Terminal 54..................... 18 Thermal protection................6 Thermistor..................16, 31 Thermistor control wiring..............16 Tightening of Terminals..............55 Torque...................... 36 Torque limit.................... 42 Transient protection................6 Trip lock....................34 Trips......................34 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11AK02...
  • Page 73 Index Operating Instructions MG11AK02 Danfoss A/S © Rev. 06/2014 All rights reserved.
  • Page 74 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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