Danfoss FC 103 Instruction Manual

Vlt refrigeration drive 1.1–90 kw

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MAKING MODERN LIVING POSSIBLE

Instruction Manual

VLT

Refrigeration Drive FC 103

1.1–90 kW

www.danfoss.com/drives

Table of Contents

Troubleshooting

Summary of Contents for Danfoss FC 103

Page 1 MAKING MODERN LIVING POSSIBLE Instruction Manual ® Refrigeration Drive FC 103 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 MG16E322 Danfoss A/S © Rev. 2014-04-10 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 Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 6: 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 MG16E3xx Replaces MG16E2xx 1.21 Table 1.1 Document and Software Version Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 7 Decoupling plate Serial bus terminal switch Grounding clamp (PE) Digital I/O and 24 V power supply Shielded cable grounding clamp and strain relief Cover Figure 1.1 Exploded View Enclosure Type A, IP20 MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 8 Analog switches (A53), (A54) Line power input terminals 91 (L1), 92 (L2), 93 (L3) Relay 1 (01, 02, 03) Figure 1.2 Exploded View Enclosure Types B and C, IP55 and IP66 Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 9: Approvals And Certifications
PWM AC waveform local and currently valid legislation. Inverter for a controlled variable output to the motor Table 1.4 Disposal Instruction • Regulated 3-phase output Output to motor power to the motor MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 10: Safety
Additionally, the personnel must be familiar readiness when the adjustable frequency drive with the instructions and safety measures described in this is connected to AC line power. document. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 11 Leakage currents exceed 3.5 mA. Failure to ground the adjustable frequency drive properly could result in death or serious injury. • Ensure correct grounding of the equipment by a certified electrical installer. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 12: Mechanical Installation
Input voltage, frequency and current (at low/high voltages) Output voltage, frequency and current (at low/high voltages) Enclosure type and IP rating Maximum ambient temperature Certifications Discharge time (Warning) Figure 3.1 Product Nameplate (Example) Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 13: 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. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 14 Mechanical Installation Instruction Manual Figure 3.4 Top and Bottom Mounting Holes (See chapter 8.9 Power Ratings, Weight and Dimensions) Figure 3.5 Top and Bottom Mounting Holes (B4, C3, C4) Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 15: Electrical Installation
See maximum fuse ratings in chapter 8.8 Fuses • Minimum cable cross-section: AWG 7 [10 mm and Circuit Breakers. (or two rated ground wires terminated separately). MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 16 Risk of electrical interference, when the ground potential between the adjustable frequency drive and the system is different. Install equalizing cables between the system components. Recommended cable cross-section: AWG 6 [16 mm Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 17: Wiring Schematic
*Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the VLT Adjustable Frequency Drives - Safe Torque Off Instruction Manual. **Do not connect cable shield. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 18 Run cables for input power, motor wiring and control wiring in three separate metallic conduits. Failure to isolate power, motor and control cables can result in unintended behavior or reduced performance. Minimum 7.9 in [200 mm] clearance between power, motor and control cables is required. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 19: Access
8.7 Connection See Table 4.1 before tightening the covers. Tightening Torques. 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] MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 20: Ac Line Power Connection
A 24 V DC supply voltage is recommended. - LC - Figure 4.6 Example of Motor, Line Power and Ground Wiring Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 21: Control Terminal Types
Connector 4 is a USB port available for use with mA or V. the MCT 10 Set-up Software Common for analog input. Serial Communication Integrated RC filter for cable shield. ONLY for connecting the shield when experiencing EMC problems. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 22: Wiring To Control Terminals
The adjustable frequency drive cannot operate without a into the slot above the contact and push the signal on terminal 27 unless terminal 27 is re- screwdriver slightly upwards. programmed. Figure 4.9 Connecting Control Wires Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 23: Voltage/Current Input Selection (Switches)
Safe Torque Off provide additional communication protocols. See ® Instruction Manual for Danfoss VLT Adjustable Frequency the option-card documentation for installation Drives for further information. and operation instructions. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 24: Installation Check List
POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE Risk of personal injury when the adjustable frequency drive is not properly closed. • Before applying power, ensure all safety covers are in place and securely fastened. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 26: Local Control Panel Operation
Display Parameter number Default setting D. Operation keys and reset 0-20 Reference % 0-21 Motor current 0-22 Power [kW] 0-23 Frequency 0-24 kWh counter Table 5.1 Legend to Figure 5.1, Display Area Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 27 Table 5.5 Legend to Figure 5.1, Operation Keys and Reset enable a choice. NOTICE! Table 5.3 Legend to Figure 5.1, Navigation Keys The display contrast can be adjusted by pressing [Status] ▲ ▼ and [ ] keys. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 28: Parameter Settings
[OK] to select a parameter group. ▲ ▼ Press [ ] to browse through the parameters, press [OK] to select a parameter. ▲ ▼ Press [ ] to change the value of a parameter setting. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 29: Basic Programming
15-05 Over Volts 1107 RPM 3.84 A 1 (1) Main Menu 0 - ** Operation/Display 1 - ** Load/Motor 2 - ** Brakes 3 - ** Reference / Ramps Figure 5.2 Main Menu MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 30: Asynchronous Motor Set-Up
If only line-line data are available, divide the line- 3-42 Ramp 1 Ramp-down Time line value by 2 to achieve the line-common 3-13 Reference Site. Linked to Hand/Auto Local (starpoint) value. Remote. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 31: Automatic Energy Optimization (Aeo)
To activate AEO, set parameter 1-03 Torque Characteristics to [2] Auto Energy Optim. CT or [3] Auto Energy Optim. VT. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 32: Automatic Motor Adaptation (Ama)
7.5 Troubleshooting. See chapter 7.4 List of Warnings The test runs automatically and indicate when it and Alarms and chapter 7.4 List of Warnings and Alarms for is complete. resetting the adjustable frequency drive after a trip. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 33: System Start-Up
Check sound and vibration level of the motor to ensure that the system is working as intended. If warnings or alarms occur, see or chapter 7.4 List of Warnings and Alarms. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 34: Application Set-Up Examples
SmartStart are common refrigeration type and set up is thus completed in 10-15 easy steps using just two keys of the LCP. Supply -1/12 Bar Refrigerant Rxxx Reference Feedback Night setback 0/4-20 mA 0-10 V PT 1000 inputs (optional) Alarms Figure 6.1 Standard Drawing of “Compressor with Internal Control” Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 35 U V W PE 96 97 95 93 Cables Ltot. max. = 40 mm Figure 6.2 Speed Control Using Analog Reference (Open-loop) – Single Fan or Pump/Multiple Fans or Pumps in Parallel MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 36 Lapp Oelflex SERVO 2YSLCY-J9 • Lapp Oelflex SERVO 2YSLCYK-J9 • HELU TOPFLEX-EWV-2YSLCY-J • HELU TOPFLEX-EWV-UV 2YSLCYK-J • HELU TOPFLEX-EWV-3PLUS 2YSLCY-J • HELU TOPFLEX-EWV-UV-3PLUS 2YSLCYK-J • Faber Kabel EWV-Motorleitung 2YSL(St)Cyv • nexans MOTIONLINE RHEYFLEX-EWV 2XSLSTCY-J Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 37 Figure 6.4 P Pressure Transmitter FC 103 12 18 Supply AKS33 Figure 6.5 How to Connect the FC 103 and AKS33 for Closed- loop Applications NOTICE! To find out which parameters are relevant, run the SmartStart. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 38: Maintenance, Diagnostics And Troubleshooting
Reference site (see Table 7.2) Operation status (see Table 7.3) Current High The adjustable frequency drive output current is above the limit set in 4-51 Warning Current Figure 7.1 Status Display High. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 39 The feedback value matches the setpoint value. Run request A start command was given but the motor remains stopped until a run permissive signal is received via digital input. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 40: Warning And Alarm Types
NOTICE! Status 1(1) In auto/remote mode, the adjustable frequency drive 0.0Hz 0.000kW 0.00A requires external commands to execute functions. 0.0Hz Earth Fault [A14] Auto Remote Trip Figure 7.2 Alarm Display Example Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 41: List Of Warnings And Alarms
If no 24 V DC backup supply is connected, the adjustable frequency drive trips after a fixed time delay. The time delay varies with unit size. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 42 If extended mechanical brake control is selected, trip can • Running AMA in 1-29 Automatic Motor Adaptation be reset externally. (AMA) tunes the adjustable frequency drive to the motor more accurately and reduces thermal loading. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 43 If 8-04 Control Word Timeout Function is set to [5] Stop and adjustable frequency drive power size. Trip, a warning appears and the adjustable frequency drive ramps down until it stops then displays an alarm. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 44 Check for loose or missing wiring circuit connection. Check 5-00 Digital I/O Mode and 5-01 Terminal 27 Mode. It may be necessary to contact your Danfoss supplier or service department. Note the code number for further troubleshooting directions. Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 45 Be sure the system can operate safely at a option card is present, check for an overvoltage condition. higher output frequency. The warning clears when the output drops below the maximum limit. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 46 The control card and power card are incompatible. To A component in the adjustable frequency drive has been check compatibility, contact the Danfoss supplier with the replaced. Reset the adjustable frequency drive for normal type code of the unit from the nameplate and the part operation.
Page 47: Troubleshooting
Active reversing signal Check if a reversing command is Deactivate reversing signal. programmed for the terminal in parameter group 5-1* Digital inputs. Wrong motor phase connection See chapter 5.5 Checking Motor Rotation. MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 48 Increase the ramp-down time in 3-42 Ramp frequency incorrectly chapter 7.4 List of Warnings and Alarms 1 Ramp-down Time. Enable overvoltage drive Check that motor data are entered correctly control in 2-17 Over-voltage Control. deceleration problems Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 49 Turn off overmodulation in 14-03 Overmo- making noise dulation. or vibrations Change switching pattern and frequency in at certain parameter group 14-0* Inverter Switching. frequencies) Increase Resonance Dampening in 1-64 Resonance Dampening. Table 7.5 Troubleshooting MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 50: 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 Line Power Supply 3x200–240 V AC - Normal overload 110% for 1 minute, P1K1-P3K7 Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 52: Line Power Supply 3X380-480 V Ac
6, 4, 4 (10, 12, 12) disconnect Efficiency 0.96 0.97 0.97 0.97 0.97 0.97 0.97 Table 8.3 Line Power Supply 3x380–480 V AC - Normal overload 110% for 1 minute, P1K1-P7K5 Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 54: Line Power Supply 3X525-600 V Ac
Line power disconnect switch 4/12 included Efficiency 0.97 0.97 0.97 0.97 0.97 0.97 0.97 Table 8.5 Line Power Supply 3x525–600 V AC - Normal overload 110% for 1 minute, P1K1-P7K5 Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 56: Line Power Supply
Environment according to EN60664-1 Overvoltage category III/pollution degree 2 The unit is suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical Amperes, 240/500/600/690 V maximum. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 57: Motor Output And Motor Data
Switching on output Unlimited Ramp times 1–3600 s As of software version 1.10, the output frequency of the adjustable frequency drive is limited to 590 Hz. Contact local Danfoss partner for further information. Torque characteristics Starting torque (Constant torque) maximum 110% for 1 min.
Page 58: Control Input/Output And Control Data
10 bit (+ sign) Accuracy of analog inputs Max. error 0.5% of full scale Bandwidth 100 Hz The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 59 68 (P,TX+, RX+), 69 (N,TX-, RX-) Terminal number 61 Common for terminals 68 and 69 The RS-485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage (PELV). MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 60 IEC 60947 part 4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV). Overvoltage Category II UL applications 300 V AC 2A Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 61: Connection Tightening Torques
26.55 [3] 5.31 [0.6] [14/24] [14/24] Table 8.7 Tightening of Terminals ≤ 4/0 AWG [95 mm ≥ 4/0 AWG [95 mm For different cable dimensions x/y, where x ] and y MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 62: Fuses And Circuit Breakers
The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), depending on the adjustable frequency drive voltage rating. With the proper fusing the adjustable frequency drive Short Circuit Current Rating (SCCR) is 100,000 Arms. Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 63 (40 [30]) gG-100 (40 [30]) 50–60 [37–45] aR-160 (50 [37]) aR-200 (50 [37]) NZMB2-A250 aR-200 (60 [45]) aR-250 (60 [45]) Table 8.8 200–240 V, Enclosure Types A, B and C MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 64 (50 [37]) gG-160 NZMB2-A200 gG-100 (60 [45]) gG-160 (75 [55]) 100–125 [75–90] aR-200 (100 [75]) aR-250 NZMB2-A250 aR-250 (125 [90]) Table 8.9 380–480 V, Enclosure Types A, B and C Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 65 (50 [37]) gG-160 (50–60 [37–45]) NZMB2-A200 gG-100 (60 [45]) aR-250 (75 [55]) aR-160 (75 [55]) 100–125 [75–90] aR-200 (100–125 [75–90]) aR-250 NZMB2-A250 Table 8.10 525–600 V, Enclosure Types A, B and C MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 66 KS-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 8.12 3x200-240 V, Enclosure Types A, B and C Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 67 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 8.14 3x380-480 V, Enclosure Types A, B and C MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 68 KTS-R-125 JKS-125 JJS-125 2028220-125 KLS-R-125 A6K-125-R HSJ-125 KTS-R-150 JKS-150 JJS-150 2028220-150 KLS-R-150 A6K-150-R HSJ-150 KTS-R-175 JKS-175 JJS-175 2028220-200 KLS-R-175 A6K-175-R HSJ-175 Table 8.16 3x525-600 V, Enclosure Types A, B and C Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 71: Appendix
Table 9.1 Symbols and Abbreviations Conventions Numbered lists indicate procedures. Bullet lists indicate other information and description of figures. Italicized text indicates • cross reference • link • parameter name 9.2 Parameter Menu Structure MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 75 Control terminal................25, 28 Heatsink....................42 Control terminals................36, 38 High voltage................8, 23, 36 Control wiring..............13, 16, 20, 22 Control word timeout................. 41 Conventions................... 69 IEC 61800-3..................... 18 Cooling..................... 11 MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 76 Remote reference................. 37 Motor rotation..................30 Reset............... 24, 25, 27, 38, 40, 44 Motor speed................... 27 RFI filter....................18 Motor status....................4 RMS current....................7 Motor wiring..................16, 22 RS-485 serial communication............21 Danfoss A/S © Rev. 2014-04-10 All rights reserved. MG16E322...
Page 77 Thermistor control wiring..............18 Tightening of Terminals..............59 Torque...................... 40 Torque characteristics................. 55 Torque limit.................... 46 Transient protection................7 Trip lock....................38 Trips......................38 Unintended start................8, 23 Vibration....................10 Voltage imbalance................39 MG16E322 Danfoss A/S © Rev. 2014-04-10 All rights reserved.
Page 78 Danfoss shall not be responsible for any errors in catalogs, brochures or other printed material. Danfoss reserves the right to alter its products at any time without notice, provided that alterations to products already on order shall not require material changes in specifications previously agreed upon by Danfoss and the Purchaser. All trademarks in this material are property of the respective companies.

Danfoss FC 103 Instruction Manual

1 Introduction

2 Safety

3 Mechanical Installation

4 Electrical Installation

5 Commissioning

6 Application Set-Up Examples

7 Maintenance, Diagnostics and Troubleshooting

8 Specifications

9 Appendix

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Troubleshooting

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Summary of Contents for Danfoss FC 103

Table of Contents