Danfoss VLT FC 103 Bedienungsanleitung

ENGINEERING TOMORROW

Operating Guide

VLT® Refrigeration Drive FC 103

355–800 kW, Enclosure Sizes E1h–E4h

vlt-drives.danfoss.com

Contents

1 Introduction 4

1.1 Purpose of the Manual 4

1.2 Additional Resources 4

1.3 Manual and Software Version 4

1.4 Approvals and Certications 4

1.5 Disposal 4

2 Safety 5

2.1 Safety Symbols 5

2.2 Qualied Personnel 5

2.3 Safety Precautions 5

3 Product Overview 7

3.1 Intended Use 7

3.2 Power Ratings, Weights, and Dimensions 7

3.3 Interior View of Enclosures E1h and E2h 8

3.4 Interior View of Enclosures E3h and E4h 9

3.5 Control Shelf 10

3.6 Local Control Panel (LCP) 11

4 Mechanical Installation 13

4.1 Items Supplied 13

4.2 Tools Needed 13

4.3 Storage 13

4.4 Operating Environment 13

4.5 Installation and Cooling Requirements 15

4.6 Lifting the Unit 15

4.7 E1h/E2h Mechanical Installation 16

4.8 E3h/E4h Mechanical Installation 18

5 Electrical Installation 22

5.1 Safety Instructions 22

5.2 EMC-compliant Installation 22

5.3 Wiring Schematic 25

5.4 Connecting the Motor 26

5.5 Connecting the AC Mains 28

5.6 Connecting to Ground 30

5.7 Terminal Dimensions 32

5.8 Control Wiring 42

Contents Operating Guide

5.9 Pre-start Check List 47

6 Commissioning 49

6.1 Safety Instructions 49

6.2 Applying Power 49

6.3 LCP Menu 50

6.4 Programming the Drive 51

6.5 Testing Before System Start-up 54

6.6 System Start-up 55

6.7 Parameter Settings 55

7 Wiring Conguration Examples 57

7.1 Wiring for Open-loop Speed Control 57

7.2 Wiring for Start/Stop 58

7.3 Wiring for External Alarm Reset 60

7.4 Wiring for a Motor Thermistor 60

7.5 Wiring for Regeneration 61

8 Maintenance, Diagnostics, and Troubleshooting 62

8.1 Maintenance and Service 62

8.2 Heat Sink Access Panel 62

8.3 Status Messages 63

8.4 Warning and Alarm Types 66

8.5 List of Warnings and Alarms 66

8.6 Troubleshooting 76

9 Specications 79

9.1 Electrical Data 79

9.2 Mains Supply 83

9.3 Motor Output and Motor Data 83

9.4 Ambient Conditions 83

9.5 Cable Specications 84

9.6 Control Input/Output and Control Data 84

9.7 Fuses 87

9.8 Enclosure Dimensions 88

9.9 Enclosure Airow 104

9.10 Fastener Torque Ratings 105

10 Appendix 106

10.1 Abbreviations and Conventions 106

Contents VLT® Refrigeration Drive FC 103

10.2 International/North American Default Parameter Settings 107

10.3 Parameter Menu Structure 107

Index 112

Contents Operating Guide

1 Introduction

1.1 Purpose of the Manual

This operating guide provides information for safe instal-

lation and commissioning of the VLT®drives in an

enclosure size E (E1h, E2h, E3h, and E4h).

The operating guide is intended for use by qualied

personnel. To use the unit safely and professionally, read

and follow this operating guide. Pay particular attention to

the safety instructions and general warnings. Always keep

the operating guide with the drive.

VLT®is a registered trademark.

1.2 Additional Resources

Other resources are available to understand advanced E1h–

E4h drive functions and programming.

•The VLT

Refrigeration Drive FC 103 Programming

Guide provides greater detail on working with

parameters and refrigeration application

examples.

•The VLT

HVAC Drive FC 102, 90–1200 kW Design

Guide provides detailed capabilities and

functionality to design motor control systems for

refrigeration applications.

•The Safe Torque O Operating Guide provides

detailed specications, requirements, and instal-

lation instructions for the Safe Torque O

function.

Supplementary publications and manuals are available

from Danfoss. See www.danfoss.com/en/search/?lter=type

%3Adocumentation for listings.

1.3 Manual and Software Version

This manual is regularly reviewed and updated. All

suggestions for improvement are welcome. Table 1.1 shows

the version of the manual and the corresponding software

version.

Manual version Remarks Software

version

MG16P2xx Added output contactor

warning and other corrections.

1.51

Table 1.1 Manual and Software Version

1.4 Approvals and Certications

Table 1.2 Approvals and Certications

More approvals and certications are available. Contact the

local Danfoss oce or partner. Drives of voltage T7 (525–

690 V) are UL certied for only 525–690 V.

The drive complies with UL 61800-5-1 thermal memory

retention requirements. For more information, refer to the

section Motor Thermal Protection in the product-specic

design guide.

NOTICE

IMPOSED LIMITATIONS ON THE OUTPUT

FREQUENCY

From software version 1.10, the output frequency of the

drive is limited to 590 Hz due to export control

regulations.

1.4.1 Compliance with ADN

For compliance with the European Agreement concerning

International Carriage of Dangerous Goods by Inland

Waterways (ADN), refer to ADN-compliant Installation in the

design guide.

1.5 Disposal

Do not dispose of equipment containing

electrical components together with

domestic waste.

Collect it separately in accordance with

local and currently valid legislation.

Introduction VLT® Refrigeration Drive FC 103

2 Safety

2.1 Safety Symbols

The following symbols are used in this guide:

WARNING

Indicates a potentially hazardous situation that could

result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could

result in minor or moderate injury. It can also be used to

alert against unsafe practices.

NOTICE

Indicates important information, including situations that

can result in damage to equipment or property.

2.2 Qualied Personnel

Correct and reliable transport, storage, installation,

operation, and maintenance are required for the trouble-

free and safe operation of the drive. Only qualied

personnel are allowed to install or operate this equipment.

Qualied personnel are dened as trained sta, who are

authorized to install, commission, and maintain equipment,

systems, and circuits in accordance with pertinent laws and

regulations. Also, the personnel must be familiar with the

instructions and safety measures described in this manual.

2.3 Safety Precautions

WARNING

HIGH VOLTAGE

Drives contain high voltage when connected to AC mains

input, DC supply, load sharing, or permanent motors.

Failure to use qualied personnel to install, start up, and

maintain the drive can result in death or serious injury.

•Only qualied personnel must install, start up,

and maintain the drive.

WARNING

UNINTENDED START

When the drive is connected to the AC mains, DC supply,

or load sharing, the motor can start at any time.

Unintended start during programming, service, or repair

work can result in death, serious injury, or property

damage. The motor can start with an external switch, a

eldbus command, an input reference signal from the

LCP or LOP, via remote operation using MCT 10 Set-up

Software, or after a cleared fault condition.

To prevent unintended motor start:

•Press [O/Reset] on the LCP before

programming parameters.

•Disconnect the drive from the mains.

•Completely wire and assemble the drive, motor,

and any driven equipment before connecting

the drive to the AC mains, DC supply, or load

sharing.

WARNING

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain

charged even when the drive is not powered. High

voltage can be present even when the warning LED

indicator lights are o. Failure to wait 40 minutes after

power has been removed before performing service or

repair work can result in death or serious injury.

1. Stop the motor.

2. Disconnect AC mains and remote DC-link

supplies, including battery back-ups, UPS, and

DC-link connections to other drives.

3. Disconnect or lock motor.

4. Wait 40 minutes for the capacitors to discharge

fully.

5. Before performing any service or repair work,

use an appropriate voltage measuring device to

make sure that the capacitors are fully

discharged.

Safety Operating Guide

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the

drive properly can result in death or serious injury.

•Ensure the correct grounding of the equipment

by a certied electrical installer.

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment

can result in death or serious injury.

•Ensure that only trained and qualied personnel

install, start up, and maintain the drive.

•Ensure that electrical work conforms to national

and local electrical codes.

•Follow the procedures in this guide.

CAUTION

HOT SURFACES

The drive contains metal components that are still hot

even after the drive has been powered o. Failure to

observe the high temperature symbol (yellow triangle)

on the drive can result in serious burns.

•Be aware that internal components, such as

busbars, may be extremely hot even after the

drive has been powered o.

•Exterior areas marked by the high temperature

symbol (yellow triangle) are hot while the drive

is in use and immediately after being powered

o.

WARNING

INTERNAL FAILURE HAZARD

Under certain circumstances, an internal failure can

cause a component to explode. Failure to keep the

enclosure closed and properly secured can cause death

or serious injury.

•Do not operate the drive with the door open or

panels o.

•Ensure that the enclosure is properly closed and

secured during operation.

NOTICE

MAINS SHIELD SAFETY OPTION

A mains shield option is available for enclosures with a

protection rating of IP21/IP54 (Type 1/Type 12). The

mains shield is a cover installed inside the enclosure to

protect against the accidental touch of the power

terminals, according to BGV A2, VBG 4.

Safety VLT® Refrigeration Drive FC 103

3 Product Overview

3.1 Intended Use

The drive is an electronic motor controller that converts AC mains input into a variable AC waveform output. The frequency

and voltage of the output are regulated to control the motor speed or torque. The drive is designed to:

•Regulate motor speed in response to system feedback or to remote commands from external controllers.

•Monitor system and motor status.

•Provide motor overload protection.

The drive is designed for industrial and commercial environments in accordance with local laws and standards. Depending

on conguration, the drive can be used in standalone applications or form part of a larger system or installation.

NOTICE

In a residential environment, this product can cause radio interference, in which case supplementary mitigation

measures can be required.

Foreseeable misuse

Do not use the drive in applications which are non-compliant with specied operating conditions and environments. Ensure

compliance with the conditions specied in chapter 9 Specications.

3.2 Power Ratings, Weights, and Dimensions

Table 3.1 provides dimensions for standard congurations. For dimensions on optional congurations, see chapter 9 Speci-

cations.

Enclosure size E1h E2h E3h E4h

Rated power at 380–480 V [kW (hp)] 355–450

(500–600)

500–560

(650–750)

355–450

(500–600)

500–560

(650–750)

Rated power at 525–690 V [kW (hp)] 450–630

(450–650)

710–800

(750–950)

450–630

(450–650)

710–800

(750–950)

Enclosure protection rating IP21/Type 1

IP54/Type 12

IP21/Type 1

IP54/Type 12

IP20/

Chassis

IP20/

Chassis

Unit dimensions

Height [mm (in)] 2043 (80.4) 2043 (80.4) 1578 (62.1) 1578 (62.1)

Width [mm (in)] 602 (23.7) 698 (27.5) 506 (19.9) 604 (23.89)

Depth [mm (in)] 513 (20.2) 513 (20.2) 482 (19.0) 482 (19.0)

Weight [kg (lb)] 295 (650) 318 (700) 272 (600) 295 (650)

Shipping dimensions

Height [mm (in)] 2191 (86.3) 2191 (86.3) 1759 (69.3) 1759 (69.3)

Width [mm (in)] 768 (30.2) 768 (30.2) 746 (29.4) 746 (29.4)

Depth [mm (in)] 870 (34.3) 870 (34.3) 794 (31.3) 794 (31.3)

Weight [kg (lb)] – – – –

Table 3.1 Enclosure Power Ratings and Dimensions

Product Overview Operating Guide

3.3 Interior View of Enclosures E1h and E2h

130BF206.11

FASTENERTORQUE:

M10 19Nm (14FT-LB)

M12 35Nm (26FT-LB)

- REGEN 83

FASTENERTORQUE:

M10 19Nm (14FT-LB)

M12 35Nm (26FT-LB)

+ REGEN 82

511

1 Control shelf (see Illustration 3.3) 7 Fan power card

2 Local control panel (LCP) cradle 8 Space heater (optional)

3 RFI lter (optional) 9 Mains disconnect (optional)

4 Mains fuses (required for UL compliance, but otherwise

optional)

10 Brake/regeneration terminals (optional)

5 Mains terminals 11 Motor terminals

6 RFI shield termination 12 Ground terminals

Illustration 3.1 Interior View of Enclosure E1h (Enclosure E2h is Similar)

Product Overview VLT® Refrigeration Drive FC 103

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