Danfoss VLT HVAC Drive FC 102 Instruction Manual

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MAKING MODERN LIVING POSSIBLE

Instruction Manual

VLT

HVAC Drive FC 102

1.1–90 kW

www.DanfossDrives.com

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Page 1 MAKING MODERN LIVING POSSIBLE Instruction Manual ® HVAC Drive FC 102 1.1–90 kW www.DanfossDrives.com...
Page 5: Table Of Contents
4.8.3 Enabling Motor Operation (Terminal 27) 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 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 6 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 © 03/2015 All rights reserved. MG11AK22...
Page 7: 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 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 8 Motor output terminals 96 (U), 97 (V), 98 (W) Analog switches (A53), (A54) Line power input terminals 91 (L1), 92 (L2), 93 (L3) Relay 1 (01, 02, 03) Figure 1.1 Exploded View Enclosure Types B and C, IP55 and IP66 Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 9 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 1.2 Exploded View Enclosure Type A, IP20 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 10: Approvals And Certifications
Table 1.3 Approvals and Certifications circuit voltage • Prove line transient protection More approvals and certifications are available. Contact local Danfoss partner. Adjustable frequency drives of • Reduce RMS current enclosure type T7 (525–690 V) are not certified for UL. DC reactors •...
Page 11: Safety
Additionally, the personnel must be familiar driven equipment must be in operational with the instructions and safety measures described in this readiness when the adjustable frequency drive document. is connected to AC line power. MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 12 Leakage currents exceed 3.5 mA. Failure to ground the adjustable frequency drive properly can result in death or serious injury. • Ensure correct grounding of the equipment by a certified electrical installer. Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 13: 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) Serial number Figure 3.1 Product Nameplate (Example) MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 14: 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 © 03/2015 All rights reserved. MG11AK22...
Page 15: Electrical Installation
• Minimum cable cross-section: AWG 7 [10 mm See maximum fuse ratings in chapter 8.8 Fuses (or two rated ground wires terminated and Circuit Breakers. separately). MG11AK22 Danfoss A/S © 03/2015 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 © 03/2015 All rights reserved. MG11AK22...
Page 17: Wiring Schematic
*Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off ® Instruction Manual for Danfoss VLT Adjustable Frequency Drives. **Do not connect cable shield. MG11AK22 Danfoss A/S © 03/2015 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 © 03/2015 All rights reserved. MG11AK22...
Page 19: Access
Figure 4.4 Access to Wiring for IP55 and IP66 Enclosures 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] MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 20 Figure 4.6, Figure 4.7, Figure 4.8 and Figure 4.9 represent line power input, motor, and grounding for basic adjustable frequency drives. Actual configurations vary with unit types and optional equipment. Figure 4.7 Motor Connection for Enclosure Type A4/A5 (IP55/66/NEMA Type 12) Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 21: Ac Line Input Connection
IEC 61800-3. Figure 4.9 Motor, Line Power and Ground Wiring for Enclosure Types B and C Using Conduit Figure 4.10 Connecting to AC Line Power MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 22: Control Wiring
68 (+) RS-485 Interface. A • control card switch is 69 (-) Connector 4 is a USB port available for use with provided for the MCT 10 Set-up Software termination resistance. Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 23: Wiring To Control Terminals
27, do not remove that wiring. NOTICE! The adjustable frequency drive cannot operate without a signal on terminal 27 unless terminal 27 is re- programmed. Figure 4.13 Connecting Control Wires MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 24: Voltage/Current Input Selection (Switches)
120 Ω Max. cable 4,000 ft [1,200 m] (including drop lines) length (ft [m]) 1,650 ft [500 m] station-to-station Table 4.3 Cable Information Figure 4.14 Location of Terminals 53 and 54 Switches Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 25: 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. MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 27: Local Control Panel Operation
B. Display menu keys 0–21 Motor current C. Navigation keys and LEDs 0–22 Power [kW] 0–23 Frequency D. Operation keys and reset 0–24 kWh counter Table 5.1 Legend to Figure 5.1, Display Area MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 28 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. Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 29 Press [Reset] to return to operation mode. Press [OK] to accept the change. Press either [Back] twice to enter Status, or press [Main Menu] once to enter Main Menu. MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 30: Basic Programming
Motor data are required for the SmartStart set-up. The required data are normally available on the motor 0.0% 0.00A 1(1) nameplate. Basic Settings 0-03 Regional Settings [0] International Figure 5.4 Basic Settings Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 31: Asynchronous Motor Set-Up
Set 0-02 Motor Speed Unit to [0] RPM. the motor does not turn, check installation, general programming and motor data. Check if start function in 1-70 PM Start Mode fits the application requirements. MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 32: Automatic Energy Optimization (Aeo)
Speed. 100% provides nominal torque as starting torque. and press [OK]. Scroll to parameter group 1-2* Motor Data and press [OK]. Scroll to 1-29 Automatic Motor Adaptation (AMA) and press [OK]. Select [1] Enable complete AMA and press [OK]. Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 33: Checking Motor Rotation
Press [Off]. Note any deceleration problems. In the event of acceleration or deceleration problems, see chapter 7.5 Troubleshooting. See chapter 7.4 List of Warnings and Alarms for resetting the adjustable frequency drive after a trip. MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 34: Application Set-Up Examples
≈ 5kΩ Notes/comments: A IN D IN 37 is an option. 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 © 03/2015 All rights reserved. MG11AK22...
Page 35 Speed Start (18) Reference Figure 6.2 Start/Stop Command with Safe Stop Start ( 18) Freeze ref ( 27) Speed up ( 29 ) Speed down ( 32 ) Figure 6.1 Speed Up/Down MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 36 Notes/comments: D IN 37 is an option. Table 6.6 Pulse Start/Stop Speed Table 6.7 Start/Stop with Reversing and Four Preset Speeds Latched Start (18) Stop Inverse (27) Figure 6.3 Latched Start/Stop Inverse Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 37 D IN 37 is an option. D IN D IN +10 V +10 V A IN A IN A IN A IN A OUT A OUT Table 6.8 External Alarm Reset RS-485 Table 6.9 RS-485 Network Connection MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 38 1-90 Motor Thermal Protection D IN should be set to [1] Thermistor warning. +10 V D IN 37 is an option. A IN A IN A OUT U - I Table 6.10 Motor Thermistor Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 39: Diagnostics And Troubleshooting
Coast inverse was selected as a function Figure 7.1 Status Display for a digital input (parameter group 5-1* Digital Inputs). The corresponding terminal is not connected. • Coast activated by serial communication MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 40 Protection mode can be restricted in Freeze output A freeze output command was given but the 14-26 Trip Delay at Inverter Fault. request motor remains stopped until a run permissive signal is received. Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 41: Warning And Alarm Types
An alarm occurred and the motor is stopped. Once the cause of the alarm is cleared, the adjustable frequency drive can be reset manually by pressing [Reset] or remotely by control terminals or serial communication. MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 42: List Of Warnings And Alarms
WARNING 5, DC link voltage high The intermediate circuit voltage (DC) is higher than the high-voltage warning limit. The limit is dependent on the adjustable frequency drive voltage rating. The unit is still active. Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 43 When running above the followed by an alarm. adjustable frequency drive continuous current rating, the counter increases. When running below the adjustable frequency drive continuous current rating, the counter decreases. MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 44 Check the sensors on the heatsink and control • card. 15-40 FC Type • 15-41 Power Section • 15-42 Voltage • 15-43 Software Version • 15-45 Actual Typecode String • 15-49 SW ID Control Card Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 45 Check for loose or missing wiring The trip and reset points are different based on the It may be necessary to contact your Danfoss supplier or adjustable frequency drive power size. service department. Note the code number for further troubleshooting directions.
Page 46 Check motor cables for short-circuits or leakage Parameter value outside of min/max limits currents. 1024-1284 Internal fault. Contact your Danfoss supplier or the Danfoss Service Department ALARM 46, Power card supply 1299 Option SW in slot A is too old The supply on the power card is out of range.
Page 47 The control card and power card are incompatible. To 4-19 Max Output Frequency. Check the application to check compatibility, contact the Danfoss supplier with the determine the cause. Possibly increase the output type code of the unit from the nameplate and the part frequency limit.
Page 48 Inspect the system for proper operation. WARNING 204, Locked rotor With an adjustable frequency drive operating multi-motors, an overload condition was detected. This could indicate a locked rotor. Inspect the motor for proper operation. Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 49: 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. MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 50 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 © 03/2015 All rights reserved. MG11AK22...
Page 51 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 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 52: Specifications
75 (167) 75 (167) 75 (167) [°C] ([°F]) 0.968 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 Efficiency Table 8.1 Mains Supply 1x200-240 V AC - Normal Overload 110% for 1 Minute, P1K1-P22K Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 53: Line Power Supply 3X200-240 V Ac
Max. cable cross-section with disconnect 6, 4, 4 (10, 12, 12) 0.96 0.96 0.96 0.96 0.96 Efficiency Table 8.2 Line Power Supply 3x200–240 V AC - Normal overload 110% for 1 minute, P1K1-P3K7 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 55: Line Power 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 8.4 Line Power Supply 3x380–480 V AC - Normal overload 110% for 1 minute, P1K1-P7K5 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 57: Line Power Supply 3X525-600 V Ac
6, 4, 4 (12, 12, 12) disconnect Line power disconnect switch 4/12 included 0.97 0.97 0.97 0.97 0.97 0.97 0.97 Efficiency Table 8.6 Line Power Supply 3x525–600 V AC - Normal overload 110% for 1 minute, P1K1-P7K5 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 59: Line Power Supply 3 X 525-690 V Ac
Max. cable cross-section with disconnect 6, 4, 4 (10, 12, 12) Efficiency 0.96 0.96 0.96 0.96 0.96 0.96 0.96 Table 8.8 Line Power Supply 3x525–690 V AC - Normal overload 110% for 1 minute, P1K1-P7K5 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 60 Max. cable size with line power disconnect [mm ]/(AWG) 16, 10, 10 (6, 8, 8) 0.98 0.98 0.98 0.98 0.98 Efficiency Table 8.9 Line Power Supply 3 x 525–690 V AC - Normal overload 110% for 1 minute, P11K-P30K Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 61 4) Applies for dimensioning of frequency converter cooling. If the switching frequency is higher than the default setting, the power losses may increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/ vltenergyefficiency.
Page 62: Line Power Supply
Switching on output Unlimited Ramp times 1–3600 s 1) From software version 3.92, 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 60 s Starting torque maximum 135% up to 0.5 s...
Page 63: Ambient Conditions
Voltage level, logic '1' NPN <14 V DC Maximum voltage on input 28 V DC Pulse frequency ranges 0–110 kHz (Duty cycle) Min. pulse width 4.5 ms Input resistance, R Approx. 4 kΩ MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 64 20 Hz/100 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 Figure 8.1 PELV Isolation Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 65 24 V +1, -3 V Max. load 200 mA The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs. MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 66 The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB ground connection is not galvanically isolated from protection ground. Use only an isolated laptop as PC connection to the USB connector on the adjustable frequency drive. Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 67: Connection Tightening Torques
The fuses below are suitable for use on a circuit capable of delivering 100,000 A (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 A MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 68 (30 [22]) aR-160 (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 8.12 200–240 V, Enclosure Types A, B and C Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 69 50–75 [37–55] gG-80 (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 8.13 380–480 V, Enclosure Types A, B and C MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 70 (50 [37]) 60 [45] gG-80 (60 [45]) gG-125 (60 [45]) 75 [55] gG-100 (75 [55]) gG-160 (75–100 [55–75]) 100 [75] gG-125 (100 [75]) Table 8.15 525–690 V, Enclosure Types A, B and C Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 71 JKS-80 JJN-80 25–30 KTN-R-125 JKS-125 JJN-125 [18.5–22] 40 [30] KTN-R-150 JKS-150 JJN-150 50 [37] KTN-R-200 JKS-200 JJN-200 60 [45] KTN-R-250 JKS-250 JJN-250 Table 8.17 3x200–240 V, Enclosure Types A, B and C MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 72 JKS-100 JJS-100 60 [45] KTS-R-125 JKS-125 JJS-125 75 [55] KTS-R-150 JKS-150 JJS-150 100 [75] KTS-R-200 JKS-200 JJS-200 125 [90] KTS-R-250 JKS-250 JJS-250 Table 8.19 3x380–480 V, Enclosure Types A, B and C Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 73 2028220-125 KLS-125 A6K-125-R HSJ-125 100 [75] KTS-R-150 JKS-150 JJS-150 2028220-150 KLS-150 A6K-150-R HSJ-150 125 [90] KTS-R-175 JKS-175 JJS-175 2028220-200 KLS-175 A6K-175-R HSJ-175 Table 8.21 3x525–600 V, Enclosure Types A, B and C MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 74 HST-100 100 [75] 125 A KTS-R-125 JKS-125 JJS-125 2028220-125 KLS-150 A6K-125-R HST-125 125 [90] 150 A KTS-R-150 JKS-150 JJS-150 2028220-150 KLS-175 A6K-150-R HST-150 Table 8.23 3x525–690 V, Enclosure Types B and C Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 77: 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 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 82: Index
Communication option..............41 Fuse..................... 11, 41 Conduit..................... 21 Fuses.................... 21, 45, 63 Control card.................... 38 Control card, USB serial communication........62 Control signal..................35 Ground connections................21 Control terminal................24, 27 Ground wire.................... 11 Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 83 Programming............. 19, 23, 24, 25, 38 Manual initialization................26 Pulse start/stop..................32 MCT 10....................18, 23 Menu key..................23, 24 Menu structure..................24 Qualified personnel................7 Motor cable..................... 11 Quick menu..................23, 24 MG11AK22 Danfoss A/S © 03/2015 All rights reserved.
Page 84 Start/stop command................31 Start-up....................25 Status mode................... 35 STO......................20 Storage......................9 Supply voltage................. 18, 22, 41 Switch....................... 20 Switching frequency................36 Symbols....................73 System feedback..................3 Terminal 53..................... 20 Terminal 54..................... 20 Danfoss A/S © 03/2015 All rights reserved. MG11AK22...
Page 86 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 VLT HVAC Drive FC 102 Instruction Manual

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