Danfoss VLT Refrigeration Drive FC 103 Operating Instructions Manual
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Danfoss VLT Refrigeration Drive FC 103 Operating Instructions Manual

1.1-90 kw
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MAKING MODERN LIVING POSSIBLE
Operating Instructions
®
VLT
Refrigeration Drive FC 103
1.1-90 kW
www.danfoss.com/drives

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Summary of Contents for Danfoss VLT Refrigeration Drive FC 103

  • Page 1 MAKING MODERN LIVING POSSIBLE Operating Instructions ® 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 MG16E302 Danfoss A/S © Rev. 2014-02-06 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. 2014-02-06 All rights reserved. MG16E302...

  • Page 5: Introduction

    Table 1.1 shows are non-compliant with specified operating conditions and the document version and the corresponding software environments. Ensure compliance with the conditions version. specified in chapter 8 Specifications. MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 6 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 1.1 Exploded View Enclosure Type A, IP20 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 7 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 1.2 Exploded View Enclosure Types B and C, IP55 and IP66 MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 8: Approvals And Certifications

    • Regulated 3-phase output Collect it separately in accordance with Output to motor power to the motor local and currently valid legislation. Table 1.4 Disposal Instruction Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...

  • Page 9: Safety

    380-500 1.1-7.5 kW 11-90 kW 525-600 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 MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 10 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. 2014-02-06 All rights reserved. MG16E302...

  • Page 11: Mechanical Installation

    Enclosure type and IP rating Maximum ambient temperature Certifications Discharge time (Warning) Illustration 3.1 Product Nameplate (Example) NOTICE Do not remove the nameplate from the frequency converter (loss of warranty). MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 12 Mount the unit vertically to a solid flat surface or chapter 8.9 Power Ratings, Weight and Dimensions) to the optional back plate to provide cooling airflow. Use the slotted mounting holes on the unit for wall mounting, when provided. Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 13 Mechanical Installation Operating Instructions Illustration 3.5 Top and Bottom Mounting Holes (B4, C3, C4) MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 14: Electrical Installation

    Risk of electrical interference, when the ground potential between the frequency converter and the system is different. Install equalising cables between the system components. Recommended cable cross-section: 16 mm Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...

  • Page 15: Wiring Schematic

    *Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the VLT Frequency Converters - Safe Torque Off Operating Instructions. **Do not connect cable screen. MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 16 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. Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...

  • Page 17: Access

    8.7 Connection Tightening Torques. 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] MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 18: Ac Mains Connection

    A 24 V DC supply voltage is recommended. - LC - Illustration 4.6 Example of Motor, Mains and Ground Wiring Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...

  • Page 19: Control Terminal Types

    Integrated RC-Filter for cable screen. ONLY for connecting the screen when experi- encing EMC problems. 68 (+) 8-3* RS-485 Interface. A control card switch is 69 (-) 8-3* provided for termination resistance. MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 20: Wiring To Control Terminals

    Remove the screw driver to fasten the control wire into the contact. Ensure the contact is firmly established and not loose. Loose control wiring can be the source of equipment faults or less than optimal operation. Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...

  • Page 21: Voltage/Current Input Selection (Switches)

    See the option-card ® Refer to VLT Frequency Converters Safe Torque Off documentation for installation and operation Operating Instructions for further information. instructions MG16E302 Danfoss A/S © Rev. 2014-02-06 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. 2014-02-06 All rights reserved. MG16E302...

  • Page 23: Commissioning

    27. See chapter 4.8.3 Enabling Motor Operation (Terminal 27) for details. MG16E302 Danfoss A/S © Rev. 2014-02-06 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. 2014-02-06 All rights reserved. MG16E302...

  • Page 25: Parameter Settings

    [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. MG16E302 Danfoss A/S © Rev. 2014-02-06 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. 2014-02-06 All rights reserved. MG16E302...

  • 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 of basic parameters). 1-25 Motor Nominal Speed Press [Main Menu] on the LCP. 1-39 Motor Poles MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 28: Automatic Energy Optimisation (Aeo)

    • The frequency converter builds a mathematical model of the motor for regulating output motor current. The procedure also tests the input phase balance of electrical power. It compares the Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...

  • Page 29: Checking Motor Rotation

    To change the direction of rotation, remove power to the frequency converter and wait for power to discharge. Reverse the connection of any 2 of the 3 motor wires on the motor or frequency converter side of the connection. MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 30: Application Set-Up Examples

    PT 1000 inputs (optional) Alarms Illustration 6.1 Standard Drawing of “Compressor with Internal Control” SmartStart input: • Bypass valve • Recycling time (start to start) • Min. Hz • Max. Hz Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 31 U V W PE 96 97 95 93 Cables Ltot. max. = 40 mm Illustration 6.2 Speed Control Using Analogue Reference (Open Loop) – Single Fan or Pump/Multiple Fans or Pumps in Parallel MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 32 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. 2014-02-06 All rights reserved. MG16E302...
  • Page 33 FC 103 12 18 Supply AKS33 Illustration 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. MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 34: Maintenance, Diagnostics And Troubleshooting

    The motor is held by a DC current set in 2-00 DC Hold/ Preheat Current. Table 7.1 to Table 7.3 describe the displayed status messages. Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 35 In Auto On mode, the frequency converter reaction for a monitoring function (e.g. No starts the motor with a start signal from a signal). The monitoring function is active. digital input or serial communication. MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 36: Warning And Alarm Types

    The control card voltage is below 10 V from terminal 50. Remove some of the load from terminal 50, as the 10 V supply is overloaded. Max. 15 mA or minimum 590 Ω. Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 37 (AMA) tunes the frequency converter to the • Increase 14-26 Trip Delay at Inverter Fault motor more accurately and reduces thermal • loading. If the alarm/warning occurs during a power sag, use kinetic back-up (14-10 Mains Failure) MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 38 Start Max Speed [RPM] during start within the allowed time. converter. (set in 1-79 Compressor Start Max Time to Trip). This may be • Check parameters 1-20 to 1-25 for correct motor caused by a blocked motor. data. Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 39 Check for loose or missing wiring • Check the sensors on the heat sink and control It may be necessary to contact your Danfoss supplier or card. service department. Note the code number for further troubleshooting directions.
  • Page 40 An external interlock has Check for a defective control card. commanded the frequency converter to trip. Clear the • Check for a defective option card. external fault condition. To resume normal operation, Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 41 The control card and power card are incompatible. To WARNING 251, New typecode check compatibility, contact the Danfoss supplier with the The power card or other components have been replaced type code of the unit from the nameplate and the part and the typecode changed.

  • Page 42: Troubleshooting

    Reference input signal not Check reference input signal scaling in 6-0* Program correct settings. maximum scaled correctly Analog I/O Mode and parameter group 3-1* speed References. Reference limits in parameter group 3-0* Reference Limit. Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 43 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 MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 44: 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 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 45 Specifications Operating Instructions MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 46: 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 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 47 Specifications Operating Instructions MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 48: 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 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 49 Specifications Operating Instructions MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 50: Mains Supply

    Switching on output Unlimited Ramp times 1-3600 s From software version 1.10 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 1 min.

  • Page 51: Ambient Conditions

    Voltage level, logic'1' PNP >20 V DC Maximum voltage on input 28 V DC Typical input current at 24 V 50 mA rms Typical input current at 20 V 60 mA rms MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 52 The pulse and encoder inputs (terminals 29, 32, 33) are galvanically isolated from the supply voltage (PELV) and other high- voltage terminals. 1) Pulse inputs are 29 and 33 2) Encoder inputs: 32 = A, and 33 = B Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 53 Min. terminal load on 1-3 (NC), 1-2 (NO), 4-6 (NC), 4-5 (NO) 24 V DC 10 mA, 24 V AC 20 mA Environment according to EN 60664-1 overvoltage category III/pollution degree 2 IEC 60947 part 4 and 5 MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 54: Connection Tightening Torques

    55-75 14/24 14/24 18-22 37-45 37-45 30-37 55-75 55-75 14/24 14/24 Table 8.7 Tightening of Terminals For different cable dimensions x/y, where x ≤ 95 mm and y ≥ 95 mm Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...

  • Page 55: 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 8.8 200-240 V, Enclosure Types A, B and C MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 56 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 8.10 525-600 V, Enclosure Types A, B and C Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 57 2) FWH-fuses from Bussmann may substitute FWX for 240 V frequency converters. 3) A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V frequency converters. 4) A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V frequency converters. MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 58 KLS-R-200 A6K-200-R FWH-200 HSJ-200 A50-P-225 L50-S-225 2028220-250 KLS-R-250 A6K-250-R FWH-250 HSJ-250 A50-P-250 L50-S-250 Table 8.14 3x380-480 V, Enclosure Types A, B and C 1) Ferraz-Shawmut A50QS fuses may substitute A50P fuses. Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 59 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 8.15 3x525-600 V, Enclosure Types A, B and C MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.

  • Page 60: Power Ratings, Weight And Dimensions

    Specifications Operating Instructions 8.9 Power Ratings, Weight and Dimensions Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...

  • Page 61: 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 MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 62 Appendix Operating Instructions Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 63 Appendix Operating Instructions MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 64 Appendix Operating Instructions Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...

  • Page 65: Index

    Input current..................16 Cooling....................... 9 Input disconnect................... 16 Cooling clearance................. 20 Input power..........6, 12, 14, 16, 20, 21, 34, 40 Current limit................... 41 Input power wiring................20 Current rating..................35 MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 66 Multiple frequency converters............12 Safe Torque Off..................19 Screened cable................14, 20 Serial communication..........17, 23, 32, 33, 34 Nameplate....................9 Service...................... 32 Navigation key................. 22, 23, 25 Setpoint....................33 Navigation keys..................32 Danfoss A/S © Rev. 2014-02-06 All rights reserved. MG16E302...
  • Page 67 Trips......................34 Unintended start................7, 21 Vibration..................... 9 Voltage imbalance................35 Voltage level................... 49 VVC+......................25 Warnings....................34 Weight...................... 58 Windmilling....................8 Wire size....................12 Wire sizes....................15 Wiring schematic.................. 13 MG16E302 Danfoss A/S © Rev. 2014-02-06 All rights reserved.
  • Page 68 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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