Danfoss FC 101 Operating guide

Operating Guide

VLT® HVAC Basic Drive FC 101 Liquid Cooled

vlt-drives.danfoss.com

VLT® HVAC Basic Drive FC 101 Liquid Cooled

 

Operating Guide

Contents

Contents

1 Introduction

6

1.1

Purpose of this Operating Guide

6

1.2

Additional Resources

6

 

1.2.1 Other Resources

6

 

1.2.2 MCT 10 Setup Software Support

6

1.3

Document and Software Version

6

1.4

Product Identification

6

1.5

Disposal

7

1.6

CE Declaration

8

2 Safety

9

2.1

Safety Symbols

9

2.2

Qualified Personnel

9

2.3

Safety Precautions

9

2.4

Motor Thermal Protection

10

3 Installation

 

11

3.1

Mechanical Installation

11

 

3.1.1

Side-by-side Installation

11

 

3.1.2

Drive Dimensions

11

 

3.1.3 Drive Mounting Bracket Details

13

 

3.1.4

Assembly

14

 

3.1.5 Thermal Switch Mating Connector Details (H3 & H4)

17

 

3.1.6

Liquid Cooling

17

 

3.1.7

Servicing the Drive

18

3.2

Electrical Installation

20

 

3.2.1

Tightening Torques

20

 

3.2.2

IT Mains

 

20

 

3.2.3 Mains and Motor Connection

21

 

 

3.2.3.1

Introduction

21

 

 

3.2.3.2 Connecting to Mains and Motor

21

 

 

3.2.3.3 Relays and Terminals on Enclosure Sizes H3–H4

22

 

3.2.4 Fuses and Circuit Breakers

22

 

 

3.2.4.1

Branch Circuit Protection

22

 

 

3.2.4.2

Short-circuit Protection

22

 

 

3.2.4.3

Overcurrent Protection

22

 

 

3.2.4.4

CE Compliance

22

 

 

 

Danfoss A/S © 2021.11

 

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

 

Operating Guide

Contents

 

 

 

 

3.2.4.5 Recommendation of Fuses and Circuit Breakers

23

3.2.5

EMC-correct Electrical Installation

23

3.2.6

Control Terminals

24

3.2.7

Electrical Wiring

25

3.2.8 Acoustic Noise or Vibration

26

4 Programming

27

4.1

Local Control Panel (LCP)

27

4.2

Set-up Wizard

28

 

4.2.1

Setup Wizard Introduction

28

 

4.2.2 Set-up Wizard for Open-loop Applications

29

 

4.2.3 Set-up Wizard for Closed-loop Applications

34

 

4.2.4

Motor Set-up

39

 

4.2.5

Changes Made Function

42

 

4.2.6

Changing Parameter Settings

42

 

4.2.7 Accessing All Parameters via the Main Menu

43

4.3

Parameter List

44

5

Warnings and Alarms

46

 

5.1

List of Warnings and Alarms

46

6

Specifications

49

 

6.1

Mains Supply 3x380–480 V AC

49

 

6.2

EMC Emission Test Results

50

 

6.3

Special Conditions

50

 

 

6.3.1

Derating for Ambient Temperature and Switching Frequency

50

 

 

6.3.2

Derating for Low Air Pressure and High Altitudes

51

 

6.4

General Technical Data

51

 

 

6.4.1

Protection and Features

51

 

 

6.4.2

Mains Supply (L1, L2, L3)

51

 

 

6.4.3

Motor Output (U, V, W)

51

 

 

6.4.4

Cable Length and Cross-section

52

 

 

6.4.5

Digital Inputs

52

 

 

6.4.6

Analog Inputs

52

 

 

6.4.7

Analog Outputs

52

 

 

6.4.8

Digital Output

53

 

 

6.4.9

RS485 Serial Communication

53

 

 

6.4.10

24 V DC Output

53

 

 

6.4.11

Relay Output

53

 

 

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

 

Operating Guide

Contents

 

 

6.4.12 10 V DC Output

54

6.4.13

Ambient Conditions

54

6.4.14

Thermal Switch (Fan Failure Detection)

54

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AQ304733610490en-000201/130R0902 | 5

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Introduction

 

 

1 Introduction

1.1 Purpose of this Operating Guide

This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified personnel.

Read and follow the instructions to use the drive safely and professionally.

Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive. VLT® is a registered trademark for Danfoss A/S.

1.2 Additional Resources

1.2.1 Other Resources

Other resources are available to understand advanced drive functions and programming.

The VLT® HVAC Basic Drive FC 101 Programming Guide provides information on how to program and includes complete parameter descriptions.

The VLT® HVAC Basic Drive FC 101 Design Guide provides all technical information about the drive. It also lists options and accessories.

The technical documentation is available in electronic form online at www.danfoss.com.

1.2.2 MCT 10 Setup Software Support

Download the software from the service and support section on www.danfoss.com.

During the installation process of the software, enter access code 81463800 to activate the VLT® HVAC Basic Drive FC 101 Liquid Cooled functionality. A license key is not required for using the VLT® HVAC Basic Drive FC 101 Liquid Cooled functionality.

The latest software does not always contain the latest updates for drives. Contact the local sales office for the latest drive updates (in the form of *.upd files), or download the drive updates from the service and support section on www.danfoss.com.

1.3 Document and Software Version

The Operating Guide is regularly reviewed and updated. All suggestions for improvement are welcome.

Table 1: Document and Software Version

Edition

Remarks

Software version

 

 

 

AQ304733610490, version 0201

Technical data are updated.

4.41

 

 

 

1.4 Product Identification

Type code

Locate the type code (T/C) on the product label. The product label is found on the top surface of the drive.

Table 2: Basic String Definition

Description

Position

Characters

Possible choice

 

 

 

 

 

Product group

Character 1-3

FC-

 

VLT® HVAC Drive FC-

 

 

 

 

 

VLT series

Character 4-6

101

 

101 [Basic version]

 

 

 

 

 

Power

Character 7

P

 

Power (standard design)

 

 

 

 

 

Power size

Character 8-10

7K5

 

7.5 kW/10 hp

 

 

 

 

 

 

 

11K

 

11 kW/15 hp

 

 

 

 

 

 

 

15K

 

15 kW/20 hp

 

 

 

 

 

Voltage

Character 11-12

T4

 

3-phase 380–480 V AC

 

 

 

 

 

Enclosure

Character 13-15

W20(1)

 

IP20/chassis

 

 

 

 

 

 

 

 

 

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

 

 

 

Operating Guide

 

 

Introduction

 

 

 

 

 

 

 

 

 

 

Description

Position

Characters

Possible choice

 

 

 

 

 

Hardware, RFI filter

Character 16-17

H4

RFI class A1 (C2)

 

 

 

 

 

Hardware, brake & stop

Character 18

X

No brake chopper

 

 

 

 

 

Hardware, display

Character 19

X

No display (blind cover)

 

 

 

 

 

Hardware, coating

Character 20

C

Coated PCB

 

 

 

 

 

Hardware, mains options

Character 21

X

No mains option

 

 

 

 

 

Hardware, adaptation A

Character 22

X

Standard cable entries

 

 

 

 

 

Hardware, adaptation B

Character 23

X

No adaptation

 

 

 

 

 

Software or hardware special version for specific customer

Character 24-27

SXXX

Latest release – std. software

 

 

 

 

 

Software, language set

Character 28

X

Standard language pack

 

 

 

 

 

Options A

Character 29-30

AX

No option

 

 

 

 

 

Options B

Character 31-32

BX

No option

 

 

 

 

 

Options C: C0/E0 options

Character 33-34

CX

No selection

 

 

 

 

 

Options C: C1 options/A/B in C option adaptor

Character 35

X

No selection

 

 

 

 

 

Options C: C option software/E1 options)

Character 36-37

XX

No software option

 

 

 

 

 

Options D

Character 38-39

DX

No option

 

 

 

 

 

 

 

 

 

 

1 W units denote liquid cooled size variants.

VLT

R

HVAC Basic Drive LC

 

 

www.danfoss.com

T/C: FC-101P7K5T4w20H4XXCXXXSXXXXAXBXCXXXXDX

P/N: 136U4167

S/N: 905314A418

Illustration 1: Example of Type Code

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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.

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Danfoss FC 101 Operating guide

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Introduction

 

 

1.6 CE Declaration

8 | Danfoss A/S © 2021.11

AQ304733610490en-000201 / 130R0902

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Safety

 

 

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

D A N G E R

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

N O T I C E

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

Are familiar with the basic regulations concerning health and safety/accident prevention.

Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in the Operating Guide.

Have good knowledge of the generic and specialist standards applicable to the specific application.

2.3 Safety Precautions

W A R N I N G

HIGH VOLTAGE

AC drives contain high voltage when connected to AC mains input , DC supply , or load sharing. Failure to perform installation, start-up, and maintenance by qualified personnel can result in death or serious injury.

-Only qualified personnel must perform installation, start-up, and maintenance.

W A R N I N G

UNINTENDED START

When the drive is connected to AC mains, DC supply, or load sharing, the motor may start at any time. Unintended start during programming, service, or repair work can result in death, serious injury, or property damage. Start the motor with an external switch, a fieldbus command, an input reference signal from the local control panel (LCP), via remote operation using MCT 10 software, or after a cleared fault condition.

-Disconnect the drive from the mains.

-Press [Off/Reset] on the LCP before programming parameters.

-Ensure that the drive is fully wired and assembled when it is connected to AC mains, DC supply, or load sharing.

Danfoss A/S © 2021.11

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Safety

 

 

W A R N I N G

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 indicator lights are off.

Failure to wait the specified time after power has been removed before performing service or repair work could result in death or serious injury.

-Stop the motor.

-Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and DC-link connections to other drives.

-Wait for the capacitors to discharge fully. The minimum waiting time is specified in the table Discharge time and is also visible on the nameplate on top of the drive.

-Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors are fully discharged.

Table 3: Discharge Time

Voltage [V]

Power range [kW (hp)]

Minimum waiting time (minutes)

 

 

 

3x400

7.5 (10)

4

 

 

 

3x400

11 (15)

15

 

 

 

3x400

15 (20)

15

 

 

 

W A R N I N G

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 certified electrical installer.

W A R N I N G

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

-Ensure that only trained and qualified personnel perform installation, start-up, and maintenance.

-Ensure that electrical work conforms to national and local electrical codes.

-Follow the procedures in this manual.

C A U T I O N

INTERNAL FAILURE HAZARD

An internal failure in the drive can result in serious injury when the drive is not properly closed.

-Ensure that all safety covers are in place and securely fastened before applying power.

2.4 Motor Thermal Protection

Procedure

1.Set parameter 1-90 Motor Thermal Protection to [4] ETR trip 1 to enable the motor thermal protection function.

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Installation

 

 

3 Installation

3.1 Mechanical Installation

3.1.1 Side-by-side Installation

The drive can be mounted side by side but requires clearance above and below for cooling.

 

 

 

 

 

Air out

100.00

Cooling clearance

[3.94]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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100.00

Cooling clearance

 

 

[3.94]

 

 

 

Air in

 

 

 

 

 

 

 

 

 

 

Illustration 2: Clearance Required for Cooling

Table 4: Clearance Required for Cooling

Size

IP class

3x380–480 V [kW (hp)]

Clearance above/below [mm (in)]

 

 

 

 

H3

IP20

7.5 (10)

100 (3.94)

 

 

 

 

H4

IP20

11–15 (15–20)

100 (3.94)

 

 

 

 

3.1.2 Drive Dimensions

 

J

 

 

B

 

C

b

e

 

 

 

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<![if ! IE]>

<![endif]>a A

d

 

<![if ! IE]>

<![endif]>G H

 

<![if ! IE]>

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e

K

L

Illustration 3: Dimensions

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

 

 

 

 

 

Operating Guide

 

 

 

 

 

Installation

 

 

 

 

 

 

 

Table 5: Dimensions, Enclosure Sizes H3–H4

 

 

 

 

 

 

 

 

 

 

 

 

 

Enclosure Size

 

H3

 

 

H4

 

 

 

 

 

IP class

 

IP20

IP20

 

 

 

 

 

Power [kW (hp)]

3x380–480 V

7.5

(10)

11–15 (15–20)

 

 

 

 

 

 

Height [mm (in)]

A

255

(10.0)

296

(11.7)

 

 

 

 

 

 

 

a

240

(9.4)

275

(10.8)

 

 

 

 

 

 

G

276.5 (10.9)

315

(12.4)

 

 

 

 

 

 

 

H

333

(13.1)

382

(15.0)

 

 

 

 

 

 

Width [mm (in)]

B

100

(3.9)

135

(5.3)

 

 

 

 

 

 

b

74 (2.9)

105

(4.1)

 

 

 

 

 

 

J

114

(4.5)

149.5 (5.9)

 

 

 

 

 

 

Depth [mm (in)]

C

206

(8.1)

241

(9.5)

 

 

 

 

Mounting hole [mm (in)]

d

11 (0.43)

12.6 (0.50)

 

 

 

 

 

 

e

5.5

(0.22)

7 (0.28)

 

 

 

 

 

 

f

8.1

(0.32)

8.4 (0.33)

 

 

 

 

 

Copper tube [mm (in)]

K

9.6

(0.38)

15.9 (0.63)

 

 

 

 

 

L

40 (1.57)

40 (1.57)

 

 

 

 

 

Maximum weight kg (lb)

 

4.4

(9.7)

7.8 (17.19)

 

 

 

 

 

 

 

The dimensions are only for the physical units.

C A U T I O N

DRIVE HANDLING

-Ensure that drive is not lifted by holding copper tube at any circumstances.

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Installation

 

 

3.1.3 Drive Mounting Bracket Details

 

 

 

B

 

C

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e

 

 

j

i

 

 

 

a

 

 

 

 

 

c

g

 

 

 

A

 

d

h

 

 

 

 

 

l

 

See

 

Detail A

 

 

Scale 2.000

 

detail

 

 

 

 

 

A

 

 

 

b

 

Cutout for

 

 

copper tube clearance

 

f

 

 

 

 

 

k

m

 

 

 

 

n

 

 

 

D

 

 

o

p

 

Illustration 4: Drive Mounting Bracket Details

Table 6: Drive Mounting Bracket Details

Enclosure size

 

H3

H4

 

 

 

 

IP class

 

IP20

IP20

 

 

 

 

Power [kW (hp)]

3x380-480 V

7.5 (10)

11–15 (15–20)

 

 

 

 

Drive mounting [mm (in)]

A

239.60 (9.43)

275 (10.83)

 

 

 

 

 

B

74 (2.91)

105 (4.13)

 

 

 

 

 

C

M5 x 0.8

M6 x 1.0

 

 

 

 

 

D

35 (1.38)

40 (1.57)

 

 

 

 

Holder plate mounting [mm (in)]

a

142.1 (5.59)

149.1 (5.87)

 

 

 

 

 

b

26.1 (1.03)

45.2 (1.78)

 

 

 

 

 

c

25 (0.98)

35 (1.38)

 

 

 

 

 

d

50 (1.97)

70 (2.76)

 

 

 

 

 

e

10 (0.39)

10 (0.39)

 

 

 

 

 

f

39.1 (1.54)

62.6 (2.46)

 

 

 

 

 

g

20 (0.79)

30 (1.18)

 

 

 

 

 

 

 

Danfoss A/S © 2021.11

 

AQ304733610490en-000201 / 130R0902 | 13

VLT® HVAC Basic Drive FC 101 Liquid Cooled

 

 

 

 

Operating Guide

 

 

 

Installation

 

 

 

 

 

 

 

 

 

 

Enclosure size

 

 

H3

H4

 

 

 

 

 

 

 

h

40 (1.58)

60 (2.36)

 

 

 

 

 

 

 

i

4.5 (0.18)

4.5 (0.18)

 

 

 

 

 

Clearance cutout [mm (in)]

 

j

122 (4.80)

120 (4.72)

 

 

 

 

 

 

 

k

46.5 (1.83)

73 (2.87)

 

 

 

 

 

 

 

l

108 (4.25)

143 (5.63)

 

 

 

 

 

 

 

m

60 (2.36)

70 (2.76)

 

 

 

 

 

 

 

n

8 (0.32)

7 (0.28)

 

 

 

 

 

 

 

o

60 (2.36)

70 (2.76)

 

 

 

 

 

 

 

p

20 (0.79)

25 (0.98)

 

 

 

 

 

 

 

 

 

 

N O T I C E

 

 

All the mounting screws need to be aligned before applying full torque.

 

 

 

 

 

 

 

3.1.4 Assembly

Procedure

1.Assemble the drive with mounting bracket.

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Installation

 

 

2.Fix the drive with 4xM5/M6 (H3/H4) screws.

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Table 7: Drive Mounting Torque Details

Enclosure size

H3

H4

 

 

 

IP class

IP20

IP20

 

 

 

Drive mounting screw

M5x0.8

M6x1.0

 

 

 

Torque [Nm (lb-in)]

2.5–3.5 (22.13–30.98)

4.0–6.0 (35.40–53.10)

 

 

 

3.Support the copper tube with the tie wrap and fix it with 3xM4 screws.

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

 

 

Operating Guide

 

Installation

 

 

 

 

 

 

 

 

 

Table 8: Holder Plate Mounting Torque Details

 

 

 

Enclosure size

H3

H4

 

 

 

 

 

IP class

IP20

IP20

 

 

 

 

 

Holder plate mounting screw

M4x0.7

M4x0.7

 

 

 

 

 

Torque [Nm (lb-in)]

2.0 (17.70)

2.0 (17.70)

 

 

 

 

 

 

 

 

4.Remove the existing holder plate mounting screw.

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5.Mount the drive and connect it to the application.

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VLT® HVAC Basic Drive FC 101 Liquid Cooled

 

Operating Guide

Installation

3.1.5 Thermal Switch Mating Connector Details (H3 & H4)

Table 9: Thermal Switch Mating Connector Details (H3 & H4)

Part Description

Manufacturer

Manufacturer P/N

 

 

 

Micro-fit 3.0 receptacle housing, single row, 2 circuits

Molex

0436450200

 

 

 

Micro-fit 3.0 crimp terminal, male, 20-24 AWG

Molex

0430310001

 

 

 

3.1.6 Liquid Cooling

Table 10: Liquid Cooling

Power [kW (hp)]

Cooling agent

Copper tube size [mm (in)]

Flow rate (Kg/Hr)

 

 

 

 

 

 

 

 

 

 

Minimum

Maximum

 

 

 

 

 

 

7.5 (10)

Refrigerant (R410-A)(1)

9.55 (0.375)

90

157.5

 

 

 

 

 

 

11 (15)

 

 

15.88 (0.625)

96

143.5

 

 

 

 

 

 

15 (20)

 

 

15.88 (0.625)

130

190

 

 

 

 

 

 

 

 

 

 

 

 

1 Cooling agent for the system is in scope of customers.

C A U T I O N

BRAZING OF COPPER TUBE

During brazing of the drive copper tubes with the system, the temperature around IGBT and cold plate portion rises.

-Pay attention to the temperature during brazing of the copper tube, see the following illustration.

-Ensure that drive enclosure is not exposed to flame during brazing.

1

2

Illustration 5: Brazing

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3

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