® Contents HVAC Drive Operating Instructions Contents 1 Introduction 1.1 Purpose of the Manual 1.2 Additional Resources 1.3 Document and Software Version 1.4 Intended Use 1.5 Block Diagram of the Frequency Converter 1.6 Enclosure Types and Power Ratings 1.7 Approvals and Certifications 1.8 Disposal Instruction 2 Safety 2.1 Safety Symbols...
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® Contents HVAC Drive Operating Instructions 5.3 Local Control Panel Operation 5.4 Basic Programming 5.4.1 Commissioning with SmartStart 5.4.2 Commissioning via [Main Menu] 5.4.3 Asynchronous Motor Setup 5.4.4 Permanent Magnet Motor Setup 5.4.5 Automatic Energy Optimization (AEO) 5.4.6 Automatic Motor Adaptation (AMA) 5.5 Checking Motor Rotation 5.6 Local-control Test 5.7 System Start-up...
Supplementary publications and manuals are available from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo- lutions/Documentations/VLT+Technical+Documentation.htm for listings. Disclosure, duplication and sale of this document, as well as communication of its content, are prohibited unless explicitly permitted.
Table 1.3 Approvals and Certifications circuit voltage More approvals and certifications are available. Contact • Prove line transient protection local Danfoss partner. The T7 (525-690 V) frequency • Reduce RMS current converters are not certified for UL. DC reactors •...
Safety ® HVAC Drive Operating Instructions 2 Safety WARNING 2.1 Safety Symbols UNINTENDED START! When the frequency converter is connected to AC mains, The following symbols are used in this document. the motor may start at any time. The frequency converter, motor, and any driven equipment must be in WARNING operational readiness.
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Safety ® HVAC Drive Operating Instructions WARNING EQUIPMENT HAZARD! Rotating shafts and electrical equipment can be hazardous. All electrical work must conform to national and local electrical codes. Installation, start-up, and maintenance are performed only by trained and qualified personnel. Failure to follow these guidelines could result in death or serious injury.
Serial number information on the nameplate correspond to the order confirmation. Table 3.1 Legend to Illustration 3.1 HVAC Drive NOTICE www.danfoss.com Do not remove the nameplate from the T/C: FC-102P3K0T4Z55H1UGCXXXSXXXXAXBXCXXXXDX P/N: 131U3930 S/N: 010102G290 frequency converter (loss of warranty). 3.0kW(400V) / 4.0HP(460V) 3.1.2 Storage...
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Mechanical Installation ® HVAC Drive Operating Instructions 3.1.3 Product Overview Illustration 3.2 Exploded View Enclosure Type A, IP20 Local control panel (LCP) Motor output terminals 96 (U), 97 (V), 98 (W) RS-485 serial bus connector (+68, -69) Relay 2 (01, 02, 03) Analog I/O connector Relay 1 (04, 05, 06) LCP input plug...
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Mechanical Installation ® HVAC Drive Operating Instructions FAN MOUNTING Illustration 3.3 Exploded View Enclosure Types B and C, IP55 and IP66 Local control panel (LCP) Relay 2 (04, 05, 06) Cover Lifting ring RS-485 serial bus connector Mounting slot Digital I/O and 24 V power supply Grounding clamp (PE) Analog I/O connector Cable screen connector...
Electrical Installation ® HVAC Drive Operating Instructions 4 Electrical Installation 4.1 Safety Instructions 4.3 Grounding WARNING See 2 Safety for general safety instructions. LEAKAGE CURRENT HAZARD! Leakage currents are higher than 3.5 mA. It is the WARNING responsibility of the user or certified electrical installer to INDUCED VOLTAGE! ensure correct grounding of the equipment.
A=Analog, D=Digital *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. MG11AJ02 - Rev. 2013-07-31...
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Electrical Installation ® HVAC Drive Operating Instructions Illustration 4.2 EMC-correct Electrical Connection Shielded cable Frequency converter Motor, 3-phase and PE Output contactor Mains, 3-phase and reinforced PE Grounding rail (PE) Control wiring Cable insulation (stripped) Equalising min. 16 mm (0.025 in) Table 4.1 Legend to Illustration 4.2 NOTICE EMC INTERFERENCE!
Electrical Installation ® HVAC Drive Operating Instructions 4.5 Access 4.6 Motor Connection • Remove cover with a screw driver (See Illustration 4.3) or by loosening attaching screws WARNING (See Illustration 4.4). INDUCED VOLTAGE! Induced voltage from output motor cables that run together can charge equipment capacitors even with the equipment turned off and locked out.
Electrical Installation ® HVAC Drive Operating Instructions 4.8.1 Control Terminal Types Ground the cable in accordance with grounding instructions provided in 4.3 Grounding. Illustration 4.10 shows the removable frequency converter When supplied from an isolated mains source (IT connectors. Terminal functions and default settings are mains or floating delta) or TT/TN-S mains with a summarised in Table 4.3.
Electrical Installation ® HVAC Drive Operating Instructions Terminal description 68 (+) RS-485 Interface. A control card switch is 69 (-) provided for Default termination resistance. Terminal Parameter Setting Description Relays Digital Inputs/Outputs 01, 02, 03 5-40 [0] [0] Alarm Form C relay output. 12, 13 +24 V DC 24 V DC supply voltage.
Illustration 4.13 Location of Terminals 53 and 54 Switches 4.8.5 Safe Torque Off (STO) To run Safe Torque Off, additional wiring for the frequency converter is required, refer to Safe Torque Off Operating ® Instructions for Danfoss VLT Frequency Converters for further information. MG11AJ02 - Rev. 2013-07-31...
Electrical Installation ® HVAC Drive Operating Instructions 4.8.6 RS-485 Serial Communication Up to 32 nodes can be connected as a bus, or via drop cables from a common trunk line to 1 network segment. Repeaters can divide network segments. Each repeater functions as a node within the segment in which it is installed.
Electrical Installation ® HVAC Drive Operating Instructions 4.9 Installation Check List Before completing installation of the unit, inspect the entire installation as detailed in Table 4.5. Check and mark the items when completed. ☑ Inspect for Description • Auxiliary equipment Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on the input power side of the frequency converter or output side to the motor.
For commissioning via PC, install MCT 10 Set-up Software. The software is available for downloading at When the frequency converter is connected to AC mains, www.danfoss.com/BusinessAreas/DrivesSolutions/software- the motor may start at any time. The frequency download (basic version) or for ordering (advanced converter, motor, and any driven equipment must be in version, order number 130B1000).
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Commissioning ® HVAC Drive Operating Instructions 5.3.2 LCP Layout B. Display Menu Keys Menu keys are used for menu access for parameter set-up, toggling through status display modes during normal The LCP is divided into 4 functional groups (see operation, and viewing fault log data. Illustration 5.1).
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Commissioning ® HVAC Drive Operating Instructions 5.3.5 Changing Parameter Settings D. Operation Keys and Reset Operation keys are located at the bottom of the LCP. View Changes Function Quick Menu Q5 - Changes Made lists all parameters Hand On Starts the frequency converter in local changed from default settings.
Commissioning ® HVAC Drive Operating Instructions 5.4.2 Commissioning via [Main Menu] Recommended Initialisation Procedure, via 14-22 Operation Mode Recommended parameter settings are intended for start- Press [Main Menu] twice to access parameters. up and checkout purposes. Application settings may vary. Scroll to 14-22 Operation Mode and press [OK].
Commissioning ® HVAC Drive Operating Instructions Use the navigation keys to scroll to 1-30 Stator Resistance (Rs) 0-01 Language. Enter line to common stator winding resistance (Rs). If only line-line data are available, divide the Select language and press [OK]. line-line value with 2 to achieve the line to If a jumper wire is in place between control common (starpoint) value.
Commissioning ® HVAC Drive Operating Instructions 5.4.6 Automatic Motor Adaptation (AMA) Start the motor at nominal speed. If the application does plus not run well, check the VVC PM settings. Recommen- NOTICE dations in different applications can be seen in Table 5.6. AMA is not relevant for permanent magnet motors.
Risk of personal injury or equipment damage exists. personal injury or equipment damage. Repair and service must be carried out by Danfoss authorized personnel only. Press [Hand On] to provide a local start command to the frequency converter.
Application Set-up Examples ® HVAC Drive Operating Instructions 6 Application Set-up Examples The examples in this section are intended as a quick Parameters reference for common applications. Function Setting +24 V • Parameter settings are the regional default values +24 V 6-12 Terminal 53 4 mA* unless otherwise indicated (selected in...
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Application Set-up Examples ® HVAC Drive Operating Instructions 6.1.2 Start/Stop Parameters Function Setting Parameters +24 V 5-10 Terminal 18 [8] Start* Function Setting +24 V Digital Input D IN +24 V 5-12 Terminal 27 [19] Freeze D IN 5-10 Terminal 18 [8] Start* +24 V Digital Input...
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Application Set-up Examples ® HVAC Drive Operating Instructions Parameters Parameters Function Setting Function Setting +24 V +24 V 5-10 Terminal 18 [9] Latched 5-10 Terminal 18 [8] Start +24 V +24 V Digital Input Start Digital Input D IN D IN D IN D IN 5-12 Terminal 27...
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Application Set-up Examples ® HVAC Drive Operating Instructions 6.1.4 RS-485 6.1.5 Motor Thermistor CAUTION Parameters Function Setting Use only thermistors with reinforced or double insulation +24 V to meet PELV insulation requirements. 8-30 Protocol +24 V 8-31 Address D IN Parameters D IN 8-32 Baud Rate...
Diagnostics and Troubleshoo... ® HVAC Drive Operating Instructions 7 Diagnostics and Troubleshooting This chapter describes the status messages, warnings and Remote The speed reference is given from external alarms and basic troubleshooting. signals, serial communication, or internal preset references. Local The frequency converter uses [Hand On] 7.1 Status Messages control or reference values from the LCP.
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Diagnostics and Troubleshoo... ® HVAC Drive Operating Instructions DC Stop The motor is held with a DC current (2-01 DC Motor check In 1-80 Function at Stop, Motor Check was Brake Current) for a specified time (2-02 DC selected. A stop command is active. To ensure Braking Time).
Diagnostics and Troubleshoo... ® HVAC Drive Operating Instructions condition is remedied, the frequency converter can be Sleep Mode The energy-saving function is enabled. This reset. It will then be ready to start operation again. means that at present the motor has stopped, but it will restart automatically when required.
Diagnostics and Troubleshoo... ® HVAC Drive Operating Instructions WARNING 5, DC link voltage high Warning LED Alarm LED The intermediate circuit voltage (DC) is higher than the Warning high-voltage warning limit. The limit is dependent on the Alarm On (Flashing) frequency converter voltage rating.
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54. Record the value of the following parameters and contact When using digital inputs 18 or 19, check that your Danfoss supplier: the thermistor is connected correctly between either terminal 18 or 19 (digital input PNP only) 15-40 FC Type and terminal 50.
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Diagnostics and Troubleshoo... ® HVAC Drive Operating Instructions WARNING/ALARM 17, Control word timeout WARNING/ALARM 26, Brake resistor power limit There is no communication to the frequency converter. The power transmitted to the brake resistor is calculated as The warning is only active when 8-04 Control Word Timeout a mean value over the last 120 seconds of run time.
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Check 5-32 Term X30/6 Digi Check for loose or missing wiring Out (MCB 101). It may be necessary to contact your Danfoss supplier or For X30/7, check the load connected to X30/7 or remove service department. Note the code number for further the short-circuit connection.
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Check the control card ALARM 50, AMA calibration failed WARNING 66, Heatsink temperature low Contact your Danfoss supplier or Danfoss Service The frequency converter is too cold to operate. This Department. warning is based on the temperature sensor in the IGBT module.
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Diagnostics and Troubleshoo... ® HVAC Drive Operating Instructions ALARM 93, Dry pump WARNING 250, New spare part A no-flow condition in the system with the frequency A component in the frequency converter has been converter operating at high speed may indicate a dry replaced.
Diagnostics and Troubleshoo... ® HVAC Drive Operating Instructions 7.4 Troubleshooting Symptom Possible cause Test Solution Missing input power See Table 4.5 Check the input power source. Missing or open fuses or circuit See open fuses and tripped circuit breaker Follow the recommendations provided. breaker tripped in this table for possible causes No power to the LCP...
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Diagnostics and Troubleshoo... ® HVAC Drive Operating Instructions Symptom Possible cause Test Solution Possible incorrect parameter Check the settings of all motor parameters, Check settings in parameter group 1-6* Motor speed settings including all motor compensation settings. Analog I/O mode. For closed-loop unstable For closed-loop operation, check PID operation, check settings in parameter...
Switching on output Unlimited Ramp times 1-3600 s 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...
Specifications ® HVAC Drive Operating Instructions Max. 50 °C (24-hour average maximum 45 °C) Ambient temperature 0 °C Minimum ambient temperature during full-scale operation - 10 °C Minimum ambient temperature at reduced performance -25 to +65/70 °C Temperature during storage/transport Maximum altitude above sea level without derating 1000 m Derating for high altitude, see special conditions in the Design Guide...
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Specifications ® HVAC Drive Operating Instructions Except Safe Torque Off input Terminal 37. See for further information about terminal 37 and Safe Torque Off. When using a contactor with a DC coil inside in combination with Safe Torque Off , it is important to make a return way for the current from the coil when turning it off.
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Specifications ® HVAC Drive Operating Instructions 500 Ω Max. load GND - analog output 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. Control card, RS-485 serial communication Terminal number 68 (P,TX+, RX+), 69 (N,TX-, RX-)
Specifications ® HVAC Drive Operating Instructions 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. Control characteristics ±...
Specifications ® HVAC Drive Operating Instructions 8.8 Fuse Specifications It is recommended to use fuses and/or circuit breakers on the supply side as protection in case of component break-down inside the frequency converter (first fault). NOTICE This is mandatory in order to ensure compliance with IEC 60364 for CE or NEC 2009 for UL. The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), depending on the frequency converter voltage rating.
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Specifications ® HVAC Drive Operating Instructions Recommended max. fuse Power Ferraz- Ferraz- Ferraz- Ferraz- Bussmann SIBA Littel fuse Littel fuse [kW] Shawmut Shawmut Shawmut Shawmut Type RK1 Type RK1 Type JFHR2 JFHR2 Type CC Type RK1 JFHR2 5017906-010 KLN-R-10 ATM-R-10 A2K-10-R FWX-10 HSJ-10...
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Specifications ® HVAC Drive Operating Instructions Recommended max. fuse Ferraz- Ferraz- Ferraz- Ferraz- Power SIBA Littel fuse Bussmann Littel fuse Shawmut Shawmut Shawmut Shawmut [kW] Type RK1 Type RK1 JFHR2 JFHR2 Type CC Type RK1 JFHR2 5017906-006 KLS-R-6 ATM-R-6 A6K-6-R FWH-6 HSJ-6 1.5-2.2...
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Specifications ® HVAC Drive Operating Instructions 3x525-690 V Recommended max. fuse Power Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann [kW] Type RK1 Type J Type T Type CC Type CC Type CC [kW] KTS-R-5 JKS-5 JJS-6 FNQ-R-5 KTK-R-5 LP-CC-5 1.5-2.2 KTS-R-10 JKS-10 JJS-10 FNQ-R-10...
Appendix ® HVAC Drive Operating Instructions 9 Appendix 9.1 Symbols and Abbreviations Alternating Current Automatic Energy Optimization American Wire Gauge Automatic Motor Adaptation °C Degrees Celsius Direct Current Electro Magnetic Compatibility Electronic Thermal Relay Frequency Converter Local Control Panel Motion Control Tool Ingress Protection Nominal Motor Current Nominal Motor Frequency...
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