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

1

Introduction 6

1.1

Purpose of this Operating Guide 6

Additional Resources 6

1.2

Other Resources 6

1.2.1

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

Safety 9

2

Safety Symbols 9

2.1

Qualified Personnel 9

2.2

Contents

Safety Precautions 9

2.3

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

3.2.3.3

3.2.4

Fuses and Circuit Breakers 22

3.2.4.1

3.2.4.2

3.2.4.3

3.2.4.4

Connecting to Mains and Motor 21

Relays and Terminals on Enclosure Sizes H3–H4 22

Branch Circuit Protection 22

Short-circuit Protection 22

Overcurrent Protection 22

CE Compliance 22

AQ304733610490en-000201/130R0902 | 3Danfoss A/S © 2021.11

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

3.2.4.5

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

Recommendation of Fuses and Circuit Breakers 23

Contents

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

AQ304733610490en-000201/130R09024 | Danfoss A/S © 2021.11

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

6.4.12

6.4.13

6.4.14

Contents

10 V DC Output 54

Ambient Conditions 54

Thermal Switch (Fan Failure Detection) 54

AQ304733610490en-000201/130R0902 | 5Danfoss A/S © 2021.11

Edition

Remarks

Software version

AQ304733610490, version 0201

Technical data are updated.

4.41

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

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

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

AQ304733610490en-000201 / 130R09026 | Danfoss A/S © 2021.11

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

VLT

R

HVAC Basic Drive LC
www.danfoss.com

T/C: FC-101P7K5T4w20H4XXCXXXSXXXXAXBXCXXXXDX
P/N: 136U4167 S/N: 905314A418

e30bu968.10

Do not dispose of equipment containing electrical components together with domestic waste.
Collect it separately in accordance with local and currently valid legislation.

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Introduction

1

W units denote liquid cooled size variants.

Illustration 1: Example of Type Code

1.5 Disposal

AQ304733610490en-000201 / 130R0902 | 7Danfoss A/S © 2021.11

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

1.6 CE Declaration

Introduction

AQ304733610490en-000201 / 130R09028 | Danfoss A/S © 2021.11

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

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).

Safety

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.

-

AQ304733610490en-000201 / 130R0902 | 9Danfoss A/S © 2021.11

Voltage [V]

Power range [kW (hp)]

Minimum waiting time (minutes)

3x400

7.5 (10)

4

3x400

11 (15)

15

3x400

15 (20)

15

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

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.

AQ304733610490en-000201 / 130R090210 | Danfoss A/S © 2021.11

100.00
[3.94]

100.00

[3.94]

Cooling clearance

Cooling clearance

Air in

Air out

e30bu377.10

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)

e

f

a

d

e

e30bu391.10

C

J

B

b

K

a

A

G

H

L

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

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.

Installation

Illustration 2: Clearance Required for Cooling

Table 4: Clearance Required for Cooling

3.1.2 Drive Dimensions

Illustration 3: Dimensions

AQ304733610490en-000201 / 130R0902 | 11Danfoss A/S © 2021.11

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)

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Table 5: Dimensions, Enclosure Sizes H3–H4

Installation

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.

-

AQ304733610490en-000201 / 130R090212 | Danfoss A/S © 2021.11

See
detail
A

Detail A
Scale 2.000

Cutout for
copper tube clearance

A

B

C

D

a

b
f

k

m

c

d

g

h

e

i

j

l

n

o

p

e30bu970.10

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)

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

3.1.3 Drive Mounting Bracket Details

Installation

Illustration 4: Drive Mounting Bracket Details

Table 6: Drive Mounting Bracket Details

AQ304733610490en-000201 / 130R0902 | 13Danfoss A/S © 2021.11

Enclosure size

H3H4h

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)

e30bu378.10

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

N O T I C E

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

Installation

3.1.4 Assembly

Procedure

1.

Assemble the drive with mounting bracket.

AQ304733610490en-000201 / 130R090214 | Danfoss A/S © 2021.11

e30bu379.10

Enclosure size

H3H4IP 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)

e30bu380.10

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

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

Installation

Table 7: Drive Mounting Torque Details

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

AQ304733610490en-000201 / 130R0902 | 15Danfoss A/S © 2021.11

Enclosure size

H3H4IP class

IP20

IP20

Holder plate mounting screw

M4x0.7

M4x0.7

Torque [Nm (lb-in)]

2.0 (17.70)

2.0 (17.70)

e30bu381.10

e30bu401.10

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

Table 8: Holder Plate Mounting Torque Details

4.

Remove the existing holder plate mounting screw.

Installation

5.

Mount the drive and connect it to the application.

AQ304733610490en-000201 / 130R090216 | Danfoss A/S © 2021.11

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

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

e30bu969.10

2 3

VLT® HVAC Basic Drive FC 101 Liquid Cooled

Operating Guide

3.1.5 Thermal Switch Mating Connector Details (H3 & H4)

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

3.1.6 Liquid Cooling

Table 10: Liquid Cooling

Installation

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.

-

Illustration 5: Brazing

AQ304733610490en-000201 / 130R0902 | 17Danfoss A/S © 2021.11