Danfoss FC 102 Design guide

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ENGINEERING TOMORROW

Design Guide

VLT® HVAC Drive FC 102

110–800 kW, Enclosure Sizes D and E

vlt-drives.danfoss.com

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Contents Design Guide

Contents

1 Introduction

1.1 Purpose of the Design Guide

1.2 Additional Resources

1.3 Document and Software Version

1.4 Conventions

2 Safety

2.1 Safety Symbols

2.2 Qualied Personnel

2.3 Safety Precautions

3 Approvals and Certications

3.1 Regulatory/Compliance Approvals

3.2 Enclosure Protection Ratings

4 Product Overview

4.1 VLT® High-power Drives

4.2 Enclosure Size by Power Rating

4.3 Overview of Enclosures, 380–480 V

4.4 Overview of Enclosures, 525–690 V

4.5 Kit Availability

5 Product Features

5.1 Automated Operational Features

5.2 Custom Application Features

5.3 Specic VLT® HVAC Drive FC 102 Features

5.4 Basic Cascade Controller

5.5 Dynamic Braking Overview

5.6 Load Share Overview

5.7 Regen Overview

5.8 Back-channel Cooling Overview

6 Options and Accessories Overview

6.1 Fieldbus Devices

6.2 Functional Extensions

6.3 Motion Control and Relay Cards

6.4 Brake Resistors

6.5 Sine-wave Filters

6.6 dU/dt Filters

6.7 Common-mode Filters

6.8 Harmonic Filters

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Contents

VLT® HVAC Drive FC 102

6.9 High-power Kits

7 Specications

7.1 Electrical Data, 380–480 V

7.2 Electrical Data, 525–690 V

7.3 Mains Supply

7.4 Motor Output and Motor Data

7.5 Ambient Conditions

7.6 Cable Specications

7.7 Control Input/Output and Control Data

7.8 Enclosure Weights

8 Exterior and Terminal Dimensions

8.1 D1h Exterior and Terminal Dimensions

8.2 D2h Exterior and Terminal Dimensions

8.3 D3h Exterior and Terminal Dimensions

8.4 D4h Exterior and Terminal Dimensions

8.5 D5h Exterior and Terminal Dimensions

8.6 D6h Exterior and Terminal Dimensions

8.7 D7h Exterior and Terminal Dimensions

8.8 D8h Exterior and Terminal Dimensions

8.9 E1h Exterior and Terminal Dimensions

8.10 E2h Exterior and Terminal Dimensions

8.11 E3h Exterior and Terminal Dimensions

8.12 E4h Exterior and Terminal Dimensions

9 Mechanical Installation Considerations

9.1 Storage

9.2 Lifting the Unit

9.3 Operating Environment

9.4 Mounting Congurations

9.5 Cooling

9.6 Derating

10 Electrical Installation Considerations

10.1 Safety Instructions

100

110

121

127

133

140

147

148

149

153

10.2 Wiring Schematic

10.3 Connections

10.4 Control Wiring and Terminals

10.5 Fuses and Circuit Breakers

10.6 Motor

10.7 Braking

154

155

157

160

162

164

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Contents Design Guide

10.8 Residual Current Devices (RCD) and Insulation Resistance Monitor (IRM)

10.9 Leakage Current

10.10 IT Mains

10.11 Eciency

10.12 Acoustic Noise

10.13 dU/dt Conditions

10.14 Electromagnetic Compatibility (EMC) Overview

10.15 EMC-compliant Installation

10.16 Harmonics Overview

11 Basic Operating Principles of a Drive

11.1 Description of Operation

11.2 Drive Controls

12 Application Examples

12.1 Wiring Congurations for Automatic Motor Adaptation (AMA)

12.2 Wiring Congurations for Analog Speed Reference

12.3 Wiring Congurations for Start/Stop

167

168

169

175

178

181

184

194

195

12.4 Wiring Conguration for an External Alarm Reset

12.5 Wiring Conguration for Speed Reference Using a Manual Potentiometer

12.6 Wiring Conguration for Speed Up/Speed Down

12.7 Wiring Conguration for RS485 Network Connection

12.8 Wiring Conguration for a Motor Thermistor

12.9 Wiring Conguration for a Cascade Controller

12.10 Wiring Conguration for a Relay Set-up with Smart Logic Control

12.11 Wiring Conguration for a Fixed Variable Speed Pump

12.12 Wiring Conguration for Lead Pump Alternation

13 How to Order a Drive

13.1 Drive Congurator

13.2 Ordering Numbers for Options and Accessories

13.3 Ordering Numbers for Filters and Brake Resistors

13.4 Spare Parts

14 Appendix

14.1 Abbreviations and Symbols

196

197

198

199

200

202

205

209

210

14.2 Denitions

Index

211

212

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Introduction

VLT® HVAC Drive FC 102

1 Introduction

1.1 Purpose of the Design Guide

This design guide is intended for:

Project and systems engineers.

•

Design consultants.

•

Application and product specialists.

•

The design guide provides technical information to understand the capabilities of the drive for integration into motor control and monitoring systems.

VLT® is a registered trademark.

Document and Software Version

1.3

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

MG16Z2xx Added D1h–D8h content 5.11

Table 1.1 Document and Software Version

1.4 Conventions

1.2 Additional Resources

Numbered lists indicate procedures.

Other resources are available to understand advanced drive operation, programming, and directives compliance.

The operating guide provides detailed information

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for the installation and start-up of the drive.

The programming guide provides greater detail on

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how to work with parameters and includes many application examples.

The VLT

•

Guide describes how to use Danfoss drives in functional safety applications. This manual is supplied with the drive when the Safe Torque O option is present.

The VLT® Brake Resistor MCE 101 Design Guide

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describes how to select the optimal brake resistor.

FC Series - Safe Torque O Operating

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Bullet lists indicate other information and

•

description of illustrations.

Italicized text indicates:

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- Cross-reference.

- Link.

- Footnote.

- Parameter name, parameter group

name, parameter option.

All dimensions in drawings are in mm (in).

•

An asterisk (*) indicates a default setting of a

•

parameter.

The VLT® Advanced Harmonic Filters AHF 005/AHF

•

010 Design Guide describes harmonics, various mitigation methods, and the operating principle of the advanced harmonics lter. This guide also describes how to select the correct advanced harmonics lter for a particular application.

The Output Filters Design Guide explains why it is

•

necessary to use output lters for certain applications, and how to select the optimal dU/dt or sine-wave lter.

Optional equipment is available that can change

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some of the information described in these publications. For specic requirements, see the instructions supplied with the options.

Supplementary publications and manuals are available from Danfoss. See drives.danfoss.com/downloads/portal/#/ for listings.

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Safety Design Guide

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

Only qualied personnel are allowed to install or operate this equipment.

2 2

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 for the specied amount of time listed in Table 2.1 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 for the capacitors to discharge fully. Refer to Table 2.1.

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

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.

Safety Precautions

2.3

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.

Voltage Power rating

(normal overload)

380–480 110–315 kW

150–450 hp

380–480 355–560 kW

500–750 hp

525–690 75–400 kW

75–400 hp

525–690 450–800 kW

450–950 hp

Table 2.1 Discharge Time for Enclosures D1h–D8h and E1h–E4h

Enclosure Minutes to disharge

D1h–D8h 20

E1h–E4h 40

D1h–D8h 20

E1h–E4h 40

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.

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.

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e30bd832.10

Safety

2.3.1 ADN-compliant Installation

VLT® HVAC Drive FC 102

To prevent spark formation in accordance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), take precautions for drives with protection rating of IP00 (Chassis), IP20 (Chassis), IP21 (Type 1), or IP54 (Type 12).

Do not install a mains switch.

•

Ensure that parameter 14-50 RFI Filter is set to

•

[1] On.

Remove all relay plugs marked RELAY. See

•

Illustration 2.1.

Check which relay options are installed, if any.

•

The only allowed relay option is VLT® Extended Relay Card MCB 113.

1, 2 Relay plugs

Illustration 2.1 Location of Relay Plugs

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Approvals and Certication... Design Guide

3 Approvals and Certications

This section provides a brief description of the various approvals and certications that are found on Danfoss drives. Not all approvals are found on all drives.

3.1 Regulatory/Compliance Approvals

NOTICE

IMPOSED LIMITATIONS ON THE OUTPUT FREQUENCY

From software version 3.92 onwards, the output frequency of the drive is limited to 590 Hz due to export control regulations.

3.1.1.1 CE Mark

The CE mark (Communauté Européenne) indicates that the product manufacturer conforms to all applicable EU directives. The EU directives applicable to the design and manufacture of drives are listed in Table 3.1.

NOTICE

The CE mark does not regulate the quality of the product. Technical specications cannot be deduced from the CE mark.

EU Directive Version

Low Voltage Directive 2014/35/EU EMC Directive 2014/30/EU

Machinery Directive ErP Directive 2009/125/EC ATEX Directive 2014/34/EU RoHS Directive 2002/95/EC

2014/32/EU

EMC Directive

The purpose of the EMC (electromagnetic compatibility) Directive is to reduce electromagnetic interference and enhance immunity of electrical equipment and installations. The basic protection requirement of the EMC Directive is that devices that generate electromagnetic interference (EMI), or whose operation can be aected by EMI, must be designed to limit the generation of electromagnetic interference. The devices must have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

Electrical equipment devices used alone or as part of a system must bear the CE mark. Systems do not require the CE mark, but must comply with the basic protection requirements of the EMC Directive.

Machinery Directive

The aim of the Machinery Directive is to ensure personal safety and avoid property damage to mechanical equipment used in its intended application. The Machinery Directive applies to a machine consisting of an aggregate of interconnected components or devices of which at least 1 is capable of mechanical movement.

Drives with an integrated safety function must comply with the Machinery Directive. Drives without a safety function do not fall under the Machinery Directive. If a drive is integrated into a machinery system, Danfoss can provide information on safety aspects relating to the drive.

When drives are used in machines with at least 1 moving part, the machine manufacturer must provide a declaration stating compliance with all relevant statutes and safety measures.

3 3

Table 3.1 EU Directives Applicable to Drives

1) Machinery Directive conformance is only required for drives with

an integrated safety function.

NOTICE

Drives with an integrated safety function, such as Safe Torque O (STO), must comply with the Machinery Directive.

Declarations of conformity are available on request.

Low Voltage Directive

Drives must be CE-labeled in accordance with the Low Voltage Directive of January 1, 2014. The Low Voltage Directive applies to all electrical equipment in the 50– 1000 V AC and the 75–1500 V DC voltage ranges.

The aim of the directive is to ensure personal safety and avoid property damage when operating electrical equipment that is installed, maintained, and used as intended.

3.1.1.2 ErP Directive

The ErP Directive is the European Ecodesign Directive for energy-related products, including drives. The aim of the directive is to increase energy eciency and the level of protection of the environment, while increasing the security of the energy supply. Environmental impact of energy-related products includes energy consumption throughout the entire product life cycle.

3.1.1.3 UL Listing

The Underwriters Laboratory (UL) mark certies the safety of products and their environmental claims based on standardized testing. Drives of voltage T7 (525–690 V) are UL-certied for only 525–600 V. The drive complies with UL 61800-5-1 thermal memory retention requirements. For more information, refer to chapter 10.6.1 Motor Thermal Protection.

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Approvals and Certication...

VLT® HVAC Drive FC 102

3.1.1.4 CSA/cUL

The CSA/cUL approval is for AC drives of voltage rated at 600 V or lower. The standard ensures that, when the drive is installed according to the provided operating/installation

guide, the equipment meets the UL standards for electrical and thermal safety. This mark certies that the product performs to all required engineering specications and testing. A certicate of compliance is provided on request.

3.1.1.9 Marine

Marine applications - ships and oil/gas platforms - must be certied by 1 of more marine certication societies to

receive a regulatory license and insurance. Danfoss VLT HVAC Drive series drives are certied by up to 12 dierent marine classication societies.

To view or print marine approvals and certicates, go to the download area at drives.danfoss.com/industries/marine- and-oshore/marine-type-approvals/#/.

3.1.1.5 EAC

The EurAsian Conformity (EAC) mark indicates that the product conforms to all requirements and technical regulations applicable to the product per the EurAsian Customs Union, which is composed of the member states of the EurAsian Economic Union.

The EAC logo must be both on the product label and on the packaging label. All products used within the EAC area, must be bought at Danfoss inside the EAC area.

3.1.1.6 UKrSEPRO

UKrSEPRO certicate ensures quality and safety of both products and services, in addition to manufacturing stability according to Ukrainian regulatory standards. The UkrSepro certicate is a required document to clear customs for any products coming into and out of the territory of Ukraine.

3.1.2 Export Control Regulations

Drives can be subject to regional and/or national export control regulations.

An ECCN number is used to classify all drives that are subject to export control regulations. The ECCN number is provided in the documents accompanying the drive.

In case of re-export, it is the responsibility of the exporter to ensure compliance with the relevant export control regulations.

3.1.1.7 TÜV

TÜV SÜD is a European safety organization which certies the functional safety of the drive in accordance to EN/IEC 61800-5-2. The TÜV SÜD both tests products and monitors their production to ensure that companies stay compliant with their regulations.

3.1.1.8 RCM

The Regulatory Compliance Mark (RCM) indicates compliance with telecommunications and EMC/radiocommunications equipment per the Australian Communications and Media Authorities EMC labeling notice. RCM is now a single compliance mark covering both the A-Tick and the C-Tick compliance marks. RCM compliance is required for placing electrical and electronic devices on the market in Australia and New Zealand.

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Approvals and Certication... Design Guide

3.2 Enclosure Protection Ratings

The VLT® drive series are available in various enclosure protection to accommodate the needs of the application. Enclosure protection ratings are provided based on 2 international standards:

UL type validates that the enclosures meet NEMA (National Electrical Manufacturers Association) standards. The

•

construction and testing requirements for enclosures are provided in NEMA Standards Publication 250-2003 and UL 50, Eleventh Edition.

IP (Ingress Protection) ratings outlined by IEC (International Electrotechnical Commission) in the rest of the world.

•

Standard Danfoss VLT® drive series are available in various enclosure protections to meet the requirements of IP00 (Chassis), IP20 (Protected chassis) or IP21 (UL Type 1), or IP54 (UL Type 12). In this manual, UL Type is written as Type. For example, IP21/Type 1.

UL type standard

Type 1 – Enclosures constructed for indoor use to provide a degree of protection to personnel against incidental contact with the enclosed units and to provide a degree of protection against falling dirt.

Type 12 – General-purpose enclosures are intended for use indoors to protect the enclosed units against the following:

Fibers

•

Lint

•

Dust and dirt

•

Light splashing

•

Seepage

•

Dripping and external condensation of noncorrosive liquids

•

3 3

There can be no holes through the enclosure and no conduit knockouts or conduit openings, except when used with oilresistant gaskets to mount oil-tight or dust-tight mechanisms. Doors are also provided with oil-resistant gaskets. In addition, enclosures for combination controllers have hinged doors, which swing horizontally and require a tool to open.

IP standard

Table 3.2 provides a cross-reference between the 2 standards. Table 3.3 demonstrates how to read the IP number and then

denes the levels of protection. The drives meet the requirements of both.

NEMA and UL IP

Chassis IP00 Protected chassis IP20 Type 1 IP21 Type 12 IP54

Table 3.2 NEMA and IP Number Cross-reference

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Approvals and Certication...

VLT® HVAC Drive FC 102

1st digit 2nd digit

0 – No protection. 1 – Protected to 50 mm (2.0 in). No hands would be able to get into the enclosure. 2 – Protected to 12.5 mm (0.5 in). No ngers would be able to get into the enclosure. 3 – Protected to 2.5 mm (0.1 in). No tools would be able to get into the enclosure.

4 – Protected to 1.0 mm (0.04 in). No wires would be able to get into the enclosure. 5 – Protected against dust – limited entry. 6 – Protected totally against dust. – 0 No protection. – 1 Protected from vertical dripping water. – 2 – 3 – 4 Protected from splashing water. – 5 Protected from water jets. – 6 Protected from strong water jets. – 7 Protected from temporary immersion. – 8 Protected from permanent immersion.

Table 3.3 IP Number Breakdown

Level of protection

Protected from dripping water at 15° angle. Protected from water at 60° angle.

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Product Overview Design Guide

4 Product Overview

4.1

VLT® High-power Drives

The VLT® drives described in this manual are available as free-standing, wall-mounted, or cabinet-mounted units. Each VLT drive is congurable, compatible, and eciency-optimized for all standard motor types, which avoids the restrictions of motor-drive package deals.

Benets of VLT® drives

Available in various enclosure sizes and protection ratings.

•

98% eciency reduces operating costs.

•

Unique back-channel cooling design reduces the need for more cooling equipment, resulting in lower installation

•

and recurring costs.

Lower power consumption for control room cooling equipment.

•

Reduced ownership costs.

•

Consistent user interface across the entire range of Danfoss drives.

•

Application-oriented start-up wizards.

•

Multi-language user interface.

•

4.2 Enclosure Size by Power Rating

kW1)hp

110 150 D1h/D3h/D5h/D6h 132 200 D1h/D3h/D5h/D6h 160 250 D1h/D3h/D5h/D6h 200 300 D2h/D4h/D7h/D8h 250 350 D2h/D4h/D7h/D8h 315 450 D2h/D4h/D7h/D8h 355 500 E1h/E3h 400 600 E1h/E3h 450 600 E1h/E3h 500 650 E2h/E4h 560 750 E2h/E4h

Table 4.1 Enclosure Power Ratings, 380–480 V

1) All power ratings are taken at normal overload.

Output is measured at 400 V (kW) and 460 V (hp).

Available enclosures

kW1)hp

75 75 D1h/D3h/D5h/D6h

90 100 D1h/D3h/D5h/D6h 110 125 D1h/D3h/D5h/D6h 132 150 D1h/D3h/D5h/D6h 160 200 D1h/D3h/D5h/D6h 200 250 D2h/D4h/D7h/D8h 250 300 D2h/D4h/D7h/D8h 315 350 D2h/D4h/D7h/D8h 400 400 D2h/D4h/D7h/D8h 450 450 E1h/E3h 500 500 E1h/E3h 560 600 E1h/E3h 630 650 E1h/E3h 710 750 E2h/E4h 800 950 E2h/E4h

Available enclosures

4 4

Table 4.2 Enclosure Power Ratings, 525–690 V

1) All power ratings are taken at normal overload.

Output is measured at 690 V (kW) and 575 V (hp).

Page 14

Product Overview

VLT® HVAC Drive FC 102

4.3 Overview of Enclosures, 380–480 V

Enclosure size D1h D2h D3h D4h D5h D6h D7h D8h

Power rating

Output at 400 V (kW) 110–160 200–315 110–160 200–315 110–160 110–160 200–315 200–315 Output at 460 V (hp) 150–250 300–450 150–250 300–450 150–250 150–250 300–450 300–450

Protection rating

IP IP21/54 IP21/54 IP20 IP20 IP21/54 IP21/54 IP21/54 IP21/54

NEMA Type 1/12 Type 1/12 Type Chassis Type Chassis Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Stainless steel back channel Mains shielding O O – – O O O O Space heater O O – – O O O O RFI lter (Class A1) O O O O O O O O Safe torque o S S S S S S S S No LCP O O O O O O O O Numerical LCP O O O O O O O O Graphical LCP O O O O O O O O Fuses O O O O O O O O

Heat sink access Brake chopper – – O O O O O O Regeneration terminals – – O O O O O O Loadshare terminals – – O O – – – – Fuses + loadshare – – O O – – – – Disconnect – – – – – O – O Circuit breakers – – – – – O – O Contactors – – – – – O – O 24 V DC supply O O O O O O O O

Dimensions

Height, mm (in) 901 (35.5) 1107 (43.6) 909 (35.8)

Width, mm (in) 325 (12.8) 325 (12.8) 250 (9.8) 375 (14.8) 325 (12.8) 325 (12.8) 420 (16.5) 420 (16.5) Depth, mm (in) 379 (14.9) 379 (14.9) 375 (14.8) 375 (14.8) 381 (15.0) 381 (15.0) 386 (15.2) 406 (16.0) Weight, kg (lb) 62 (137) 125 (276) 62 (137)

O O O O O O O O

1004 (39.5)

108 (238)

1027 (40.4)

125 (276)

179 (395)

1324 (52.1) 1663 (65.5) 1978 (77.9) 2284 (89.9)

99 (218) 128 (282) 185 (408) 232 (512)

Table 4.3 D1h–D8h Drives, 380–480 V

1) All power ratings are taken at normal overload. Output is measured at 400 V (kW) and 460 V (hp).

2) S = standard, O = optional, and a dash indicates that the option is unavailable.

3) Heat sink access is not available with stainless steel back-channel option.

4) With optional load share and regen terminals.

Page 15

Product Overview Design Guide

Enclosure size E1h E2h E3h E4h

Power rating

Output at 400 V (kW) 355–450 500–560 355–450 500–560 Output at 460 V (hp) 500–600 650–750 500–600 650–750

Protection rating

IP IP21/54 IP21/54 UL type Type 1/12 Type 1/12 Chassis Chassis

Hardware options

Stainless steel back channel O O O O Mains shielding O O – – Space heater O O – – RFI lter (Class A1) O O O O Safe torque o S S S S No LCP O O O O Graphical LCP O O O O Fuses S S O O Heat sink access O O O O Brake chopper O O O O Regen terminals O O O O Load share terminals – – O O Fuses + load share – – O O Disconnect O O – – Circuit breakers – – – – Contactors – – – – 24 V DC supply (SMPS, 5 A) – – – –

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 (23.9) 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)

IP20

4 4

Table 4.4 E1h–E4h Drives, 380–480 V

1) All power ratings are taken at normal overload. Output is measured at 400 V (kW) and 460 V (hp).

2) If the enclosure is congured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20.

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

Page 16

Product Overview

VLT® HVAC Drive FC 102

4.4 Overview of Enclosures, 525–690 V

Enclosure size D1h D2h D3h D4h D5h D6h D7h D8h

Power rating

Output at 690 V (kW) 75–160 200–400 75–160 200–400 75–160 75–160 200–400 200–400 Output at 575 V (hp) 75–200 250–400 75–200 250–400 75–200 75–200 250–400 250–400

Protection rating

IP IP21/54 IP21/54 IP20 IP20 IP21/54 IP21/54 IP21/54 IP21/54

NEMA Type 1/12 Type 1/12 Type Chassis Type Chassis Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Stainless steel backchannel Mains shielding O O O O O O O O Space heater O O O O O O O O Safe torque o S S S S S S S S No LCP O O O O O O O O Numerical LCP O O O O O O O O Graphical LCP O O O O O O O O Fuses O O O O O O O O

Heat sink access Brake chopper – – O O O O O XO Regeneration terminals – – O O – – – – Loadshare terminals – – O O O O O O Fuses + loadshare – – O O – – – – Disconnect – – – – O O O O Circuit breakers – – – – – O – O Contactors – – – – – O – O 24 V DC supply O O O O O O O O

Dimensions

Height, mm (in) 901 (35.5) 1107 (43.6) 909 (35.8)

– – O O – – – –

O O O O O O O O

1004 (39.5)

108 (238)

1027 (40.4)

125 (276)

179 (395)

1324 (52.1) 1663 (65.5) 1978 (77.9) 2284 (89.9)

99 (218) 128 (282) 185 (408) 232 (512)

Table 4.5 D1h–D8h Drives, 525–690 V

1) All power ratings are taken at normal overload. Output is measured at 690 V (kW) and 575 V (hp).

2) S = standard, O = optional, and a dash indicates that the option is unavailable.

3) Heat sink access is not available with stainless steel back-channel option.

4) With optional load share and regen terminals.

Page 17

Product Overview Design Guide

Enclosure size E1h E2h E3h E4h

Power rating

Output at 690 V (kW) 450–630 710–800 450–630 710–800 Output at 575 V (hp) 450–650 750–950 450–650 750–950

Protection rating

IP IP21/54 IP21/54 UL type Type 1/12 Type 1/12 Chassis Chassis

Hardware options

Stainless steel back channel O O O O Mains shielding O O – – Space heater O O – – RFI lter (Class A1) – – – – Safe torque o S S S S No LCP O O O O Graphical LCP O O O O Fuses S S O O Heat sink access O O O O Brake chopper O O O O Regen terminals O O O O Load share terminals – – O O Fuses + load share – – O O Disconnect O O – – Circuit breakers – – – – Contactors – – – – 24 V DC supply (SMPS, 5 A) – – – –

Dimensions

IP20

4 4

Table 4.6 E1h–E4h Drives, 525–690 V

1) All power ratings are taken at normal overload. Output is measured at 690 V (kW) and 575 V (hp).

2) If the enclosure is congured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20.

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

Page 18

Product Overview

4.5 Kit Availability

VLT® HVAC Drive FC 102

Kit description

NEMA 3R outdoor weather shield O O – – – – – – – – – – NEMA 3R protection for in-back/out-back cooling kit USB in door O O O O O O O O S S – – LCP, numerical O O O O O O O O O O O O

LCP, graphical LCP cable, 3 m (9 ft) O O O O O O O O O O O O Mounting kit for numerical LCP (LCP, fasteners, gasket, and cable) Mounting kit for graphical LCP (LCP, fasteners, gasket, and cable) Mounting kit for all LCPs (fasteners, gasket, and cable) Mains shield – – – – – – – – O O – – Grounding bar – – – – – – – – O O – – Input plate option O O O O O O O O – – – – Terminal blocks O O O O O O O O O O O O Top entry for eldbus cables O O O O O O O O O O O O Pedestal O O – – O O O O S S – – In bottom/out-top cooling – – O O – – – – – – O O In bottom/out-back cooling O O O O – – – – – – O O In back/out-top cooling – – – – – – – – – – O O In back/out-back cooling O O O O O O O O O O O O Out top (only) cooling – – O O – – – – – – – –

D1h D2h D3h D4h D5h D6h D7h D8h E1h E2h E3h E4h

– – O O – – – – – – – –

O O O O O O O O O O O O

Table 4.7 Available Kits for Enclosures D1h–D8h and E1h–E4h

1) S = standard, O = optional, and a dash indicates that the kit is unavailable for that enclosure. For kit descriptions and part numbers, see

chapter 13.2.6 Ordering Numbers for D1h–D8h Kits and chapter 13.2.7 Ordering Numbers for E1h–E4h Kits.

2) The graphical LCP comes standard with enclosures D1h–D8h and E1h–E4h. If more than 1 graphical LCP is required, the kit is available for

purchase.

Page 19

Product Features Design Guide

5 Product Features

5.1 Automated Operational Features

Automated operational features are active when the drive is operating. Most of them require no programming or setup. The drive has a range of built-in protection functions to protect itself and the motor when it runs.

For details of any set-up required, in particular motor parameters, refer to the programming guide.

5.1.1 Short-circuit Protection

Motor (phase-to-phase)

The drive is protected against short circuits on the motor side by current measurement in each of the 3 motor phases. A short circuit between 2 output phases causes an overcurrent in the inverter. The inverter is turned o when the short circuit current exceeds the allowed value (Alarm 16, Trip Lock).

Mains side

A drive that works correctly limits the current it can draw from the supply. Still, it is recommended to use fuses and/or circuit breakers on the supply side as protection if there is component break-down inside the drive (1st fault). Mains side fuses are mandatory for UL compliance.

NOTICE

To ensure compliance with IEC 60364 for CE or NEC 2009 for UL, it is mandatory to use fuses and/or circuit breakers.

Brake resistor

The drive is protected from a short circuit in the brake resistor.

Load sharing

To protect the DC bus against short circuits and the drives from overload, install DC fuses in series with the load sharing terminals of all connected units.

5.1.2 Overvoltage Protection

Incorrect slip compensation setting causing

•

higher DC-link voltage.

Back EMF from PM motor operation. If coasted at

•

high RPM, the PM motor back EMF can potentially exceed the maximum voltage tolerance of the drive and cause damage. To help prevent this situation, the value of parameter 4-19 Max Output Frequency is automatically limited based on an internal calculation based on the value of parameter 1-40 Back EMF at 1000 RPM, parameter 1-25 Motor Nominal Speed, and parameter 1-39 Motor Poles.

NOTICE

To avoid motor overspeeds (for example, due to excessive windmilling eects), equip the drive with a brake resistor.

The overvoltage can be handled either using a brake function (parameter 2-10 Brake Function) and/or using overvoltage control (parameter 2-17 Over-voltage Control).

Brake functions

Connect a brake resistor for dissipation of surplus brake energy. Connecting a brake resistor allows a higher DC-link voltage during braking.

AC brake is an alternative to improving braking without using a brake resistor. This function controls an overmagnetization of the motor when the motor is acting as a generator. Increasing the electrical losses in the motor allows the OVC function to increase the braking torque without exceeding the overvoltage limit.

NOTICE

AC brake is not as eective as dynamic braking with a resistor.

Overvoltage control (OVC)

By automatically extending the ramp-down time, OVC reduces the risk of the drive tripping due to an overvoltage on the DC-link.

5 5

Motor-generated overvoltage

The voltage in the DC link is increased when the motor acts as a generator. This situation occurs in following cases:

The load rotates the motor at constant output

•

frequency from the drive, that is, the load generates energy.

During deceleration (ramp-down) if the inertia

•

moment is high, the friction is low, and the rampdown time is too short for the energy to be dissipated as a loss throughout the drive system.

NOTICE

OVC can be activated for a PM motor with all control core, PM VVC+, Flux OL, and Flux CL for PM Motors.

5.1.3 Missing Motor Phase Detection

The missing motor phase function (parameter 4-58 Missing Motor Phase Function) is enabled by default to avoid motor damage if a motor phase is missing. The default setting is 1000 ms, but it can be adjusted for faster detection.

Page 20

Product Features

VLT® HVAC Drive FC 102

5.1.4 Supply Voltage Imbalance Detection

Operation under severe supply voltage imbalance reduces the lifetime of the motor and drive. If the motor is operated continuously near nominal load, conditions are considered severe. The default setting trips the drive if there is supply voltage imbalance (parameter 14-12 Response to Mains Imbalance).

5.1.5 Switching on the Output

Adding a switch to the output between the motor and the drive is allowed, however fault messages can appear. Danfoss does not recommend using this feature for 525– 690 V drives connected to an IT mains network.

situation with open-loop PM control (parameter 30-22 Locked Rotor Detection).

ux control and PM VVC

5.1.8 Automatic Derating

The drive constantly checks for the following critical levels:

High temperature on the control card or heat

•

sink.

High motor load.

•

High DC-link voltage.

•

Low motor speed.

•

As a response to a critical level, the drive adjusts the switching frequency. For high internal temperatures and low motor speed, the drive can also force the PWM pattern to SFAVM.

5.1.6 Overload Protection

Torque limit

The torque limit feature protects the motor against overload, independent of the speed. Torque limit is controlled in parameter 4-16 Torque Limit Motor Mode and parameter 4-17 Torque Limit Generator Mode. The time before the torque limit warning trips is controlled in parameter 14-25 Trip Delay at Torque Limit.

Current limit

The current limit is controlled in parameter 4-18 Current Limit, and the time before the drive trips is controlled in parameter 14-24 Trip Delay at Current Limit.

Speed limit

Minimum speed limit: Parameter 4-11 Motor Speed Low Limit [RPM] or parameter 4-12 Motor Speed Low Limit [Hz]

limit the minimum operating speed range of the drive. Maximum speed limit: Parameter 4-13 Motor Speed High Limit [RPM] or parameter 4-19 Max Output Frequency limit the maximum output speed the drive can provide.

Electronic thermal relay (ETR)

ETR is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in Illustration 5.1.

Voltage limit

The inverter turns o to protect the transistors and the DC link capacitors when a certain hard-coded voltage level is reached.

Overtemperature

The drive has built-in temperature sensors and reacts immediately to critical values via hard-coded limits.

5.1.7 Locked Rotor Protection

There can be situations when the rotor is locked due to excessive load or other factors. The locked rotor cannot produce enough cooling, which in turn can overheat the motor winding. The drive is able to detect the locked rotor

NOTICE

The automatic derating is dierent when

parameter 14-55 Output Filter is set to [2] Sine-Wave Filter Fixed.

5.1.9 Automatic Energy Optimization

Automatic energy optimization (AEO) directs the drive to monitor the load on the motor continuously and adjust the output voltage to maximize eciency. Under light load, the voltage is reduced and the motor current is minimized. The motor benets from:

Increased eciency.

•

Reduced heating.

•

Quieter operation.

•

There is no need to select a V/Hz curve because the drive automatically adjusts motor voltage.

5.1.10 Automatic Switching Frequency Modulation

The drive generates short electrical pulses to form an AC wave pattern. The switching frequency is the rate of these pulses. A low switching frequency (slow pulsing rate) causes audible noise in the motor, making a higher switching frequency preferable. A high switching frequency, however, generates heat in the drive that can limit the amount of current available to the motor.

Automatic switching frequency modulation regulates these conditions automatically to provide the highest switching frequency without overheating the drive. By providing a regulated high switching frequency, it quiets motor operating noise at slow speeds, when audible noise control is critical, and produces full output power to the motor when required.

Page 21

Product Features Design Guide

5.1.11 Automatic Derating for High Switching Frequency

The drive is designed for continuous, full-load operation at switching frequencies between 1.5–2 kHz for 380–480 V, and 1–1.5 kHz for 525–690 V. The frequency range depends on power size and voltage rating. A switching frequency exceeding the maximum allowed range generates increased heat in the drive and requires the output current to be derated.

An automatic feature of the drive is load-dependent switching frequency control. This feature allows the motor to

benet from as high a switching frequency as the load

allows.

5.1.12 Power Fluctuation Performance

The drive withstands mains uctuations such as:

Transients.

•

Momentary drop-outs.

•

Short voltage drops.

•

Surges.

•

The drive automatically compensates for input voltages ±10% from the nominal to provide full rated motor voltage and torque. With auto restart selected, the drive automatically powers up after a voltage trip. With ying start, the drive synchronizes to motor rotation before start.

information regarding EMC performance, see chapter 10.14.1 EMC Test Results.

5.1.16 Galvanic Isolation of Control Terminals

All control terminals and output relay terminals are galvanically isolated from mains power, which completely protects the controller circuitry from the input current. The output relay terminals require their own grounding. This isolation meets the stringent protective extra-low voltage (PELV) requirements for isolation.

The components that make up the galvanic isolation are:

Supply, including signal isolation.

•

Gatedrive for the IGBTs, trigger transformers, and

•

optocouplers.

The output current Hall eect transducers.

•

5.2 Custom Application Features

Custom application functions are the most common features programmed in the drive for enhanced system performance. They require minimum programming or setup. See the programming guide for instructions on activating these functions.

5.2.1 Automatic Motor Adaptation

5 5

5.1.13 Resonance Damping

Resonance damping eliminates the high-frequency motor resonance noise. Automatic or manually selected frequency damping is available.

5.1.14 Temperature-controlled Fans

Sensors in the drive regulate the operation of the internal cooling fans. Often, the cooling fans do not run during low load operation, or when in sleep mode or standby. These sensors reduce noise, increase eciency, and extend the operating life of the fan.

5.1.15 EMC Compliance

Electromagnetic interference (EMI) and radio frequency interference (RFI) are disturbances that can aect an electrical circuit due to electromagnetic induction or radiation from an external source. The drive is designed to comply with the EMC product standard for drives IEC 61800-3 and the European standard EN 55011. Motor cables must be shielded and properly terminated to comply with the emission levels in EN 55011. For more

Automatic motor adaptation (AMA) is an automated test procedure used to measure the electrical characteristics of the motor. AMA provides an accurate electronic model of the motor, allowing the drive to calculate optimal performance and eciency. Running the AMA procedure also maximizes the automatic energy optimization feature of the drive. AMA is performed without the motor rotating and without uncoupling the load from the motor.

5.2.2 Built-in PID Controller

The built-in proportional, integral, derivative (PID) controller eliminates the need for auxiliary control devices. The PID controller maintains constant control of closedloop systems where regulated pressure, ow, temperature, or other system requirements must be maintained.

The drive can use 2 feedback signals from 2 devices, allowing the system to be regulated with dierent feedback requirements. The drive makes control decisions by comparing the 2 signals to optimize system performance.

dierent

Page 22

1.21.0 1.4

100

1.81.6 2.0

2000

500

200

400 300

1000

600

t [s]

175ZA052.12

OUT

= 2 x f

M,N

OUT

= 0.2 x f

M,N

OUT

= 1 x f

M,N

(par. 1-23)

IMN(par. 1-24)

Product Features

VLT® HVAC Drive FC 102

5.2.3 Motor Thermal Protection

Motor thermal protection can be provided via:

Direct temperature sensing using a

•

- PTC- or KTY sensor in the motor

windings and connected on a standard AI or DI.

- PT100 or PT1000 in the motor windings and motor bearings, connected on VLT

Sensor Input Card MCB 114.

Mechanical thermal switch (Klixon type) on a DI.

•

Built-in electronic thermal relay (ETR).

•

ETR calculates motor temperature by measuring current, frequency, and operating time. The drive shows the thermal load on the motor in percentage and can issue a warning at a programmable overload setpoint. Programmable options at the overload allow the drive to stop the motor, reduce output, or ignore the condition. Even at low speeds, the drive meets I2t Class 20 electronic motor overload standards.

PTC Thermistor input on VLT® PTC Thermistor Card MCB 112 (ATEX approved).

enter a specic curve to protect the Ex-e motor. See the programming guide for set-up instructions.

5.2.4 Motor Thermal Protection for Ex-e Motors

The drive is equipped with an ATEX ETR thermal monitoring function for operation of Ex-e motors according to EN-60079-7. When combined with an ATEX approved

PTC monitoring device such as the VLT® PTC Thermistor Card MCB 112 or an external device, the installation does not require an individual approval from an approbated organization.

The ATEX ETR thermal monitoring function enables use of an Ex-e motor instead of a more expensive, larger, and heavier Ex-d motor. The function ensures that the drive limits motor current to prevent overheating.

Requirements related to the Ex-e motor

Ensure that the Ex-e motor is approved for

•

operation in hazardous zones (ATEX zone 1/21, ATEX zone 2/22) with drives. The motor must be certied for the specic hazardous zone.

Install the Ex-e motor in zone 1/21 or 2/22 of the

•

hazardous zone, according to motor approval.

NOTICE

Install the drive outside the hazardous zone.

Ensure that the Ex-e motor is equipped with an

•

ATEX-approved motor overload protection device. This device monitors the temperature in the motor windings. If there is a critical temperature level or a malfunction, the device switches o the motor.

The VLT® PTC Thermistor MCB 112 option provides ATEX-approved monitoring of motor temperature. It is a prerequisite that the drive is equipped

Illustration 5.1 ETR Characteristics

The X-axis shows the ratio between I nominal. The Y-axis shows the time in seconds before the ETR cuts o and trips the drive. The curves show the characteristic nominal speed, at twice the nominal speed and at 0.2 x the nominal speed. At lower speed, the ETR cuts o at lower heat due to less cooling of the motor. In that way, the motor is protected from being overheated even at low speed. The ETR feature calculates the motor temperature based on actual current and speed. The calculated temperature is visible as a readout parameter in parameter 16-18 Motor Thermal. A special version of the ETR is also available for EX-e motors in ATEX areas. This function makes it possible to

motor

and I

motor

Sine-wave lter is required when the following

•

apply:

with 3–6 PTC thermistors in series according to DIN 44081 or 44082.

- Alternatively, an external ATEX-approved PTC protection device can be used.

- Long cables (voltage peaks) or increased mains voltage produce voltages exceeding the maximum allowable voltage at motor terminals.

- Minimum switching frequency of the drive does not meet the requirement stated by the motor manufacturer. The minimum switching frequency of the

Page 23

130BD888.10

CONVERTER SUPPLY VALID FOR 380 - 415V FWP 50Hz 3 ~ Motor

MIN. SWITCHING FREQ. FOR PWM CONV. 3kHz l = 1.5XI

M,N

tOL = 10s tCOOL = 10min

MIN. FREQ. 5Hz MAX. FREQ. 85 Hz

PWM-CONTROL

f [Hz]

Ix/I

M,N

PTC °C DIN 44081/-82

Manufacture xx

EN 60079-0 EN 60079-7

СЄ 1180 Ex-e ll T3

5 15 25 50 85

0.4 0.8 1.0 1.0 0.95

xЗ

2 3 4

Product Features Design Guide

drive is shown as the default value in parameter 14-01 Switching Frequency.

Compatibility of motor and drive

For motors certied according to EN-60079-7, a data list including limits and rules is supplied by the motor manufacturer as a datasheet, or on the motor nameplate. During planning, installation, commissioning, operation, and service, follow the limits and rules supplied by the manufacturer for:

Minimum switching frequency.

•

Maximum current.

•

Minimum motor frequency.

•

Maximum motor frequency.

•

Illustration 5.2 shows where the requirements are indicated on the motor nameplate.

5.2.5 Mains Drop-out

During a mains drop-out, the drive keeps running until the DC-link voltage drops below the minimum stop level. The minimum stop level is typically 15% below the lowest rated supply voltage. The mains voltage before the dropout and the motor load determines how long it takes for the drive to coast.

The drive can be to dierent types of behavior during mains drop-out:

Trip lock once the DC link is exhausted.

•

Coast with ying start whenever mains return

•

(parameter 1-73 Flying Start).

Kinetic back-up.

•

Controlled ramp down.

•

Flying start

This selection makes it possible to catch a motor that is spinning freely due to a mains drop-out. This option is relevant for centrifuges and fans.

Kinetic back-up

This selection ensures that the drive runs as long as there is energy in the system. For short mains drop-out, the operation is restored after mains return, without bringing the application to a stop or losing control at any time. Several variants of kinetic back-up can be selected.

Congure the behavior of the drive at mains drop-out in

parameter 14-10 Mains Failure and parameter 1-73 Flying Start.

congured (parameter 14-10 Mains Failure)

5 5

1 Minimum switching frequency 2 Maximum current 3 Minimum motor frequency 4 Maximum motor frequency

Illustration 5.2 Motor Nameplate showing Drive Requirements

When matching drive and motor, Danfoss species the following extra requirements to ensure adequate motor thermal protection:

For further information, see the application example in chapter 12 Application Examples.

Do not exceed the maximum allowed ratio

•

between drive size and motor size. The typical value is I

Consider all voltage drops from drive to motor. If

•

the motor runs with lower voltage than listed in the U/f characteristics, current can increase, triggering an alarm.

VLT, n

≤2xI

m,n

5.2.6 Automatic Restart

The drive can be programmed to restart the motor automatically after a minor trip, such as momentary power loss or uctuation. This feature eliminates the need for manual resetting, and enhances automated operation for remotely controlled systems. The number of restart attempts and the duration between attempts can be limited.

5.2.7 Full Torque at Reduced Speed

The drive follows a variable V/Hz curve to provide full motor torque even at reduced speeds. Full output torque can coincide with the maximum designed operating speed of the motor. This drive diers from variable torque drives and constant torque drives. Variable torque drives provide reduced motor torque at low speed. Constant torque drives provide excess voltage, heat, and motor noise at less than full speed.

Page 24

. . . . . .

Par. 13-11 Comparator Operator

Par. 13-43 Logic Rule Operator 2

Par. 13-51 SL Controller Event

Par. 13-52 SL Controller Action

130BB671.13

Coast Start timer Set Do X low Select set-up 2 . . .

Running Warning Torque limit Digital input X 30/2 . . .

= TRUE longer than..

. . . . . .

130BA062.14

State 1 13-51.0 13-52.0

State 2 13-51.1 13-52.1

Start event P13-01

State 3 13-51.2 13-52.2

State 4 13-51.3 13-52.3

Stop event P13-02

Product Features

VLT® HVAC Drive FC 102

5.2.8 Frequency Bypass

In some applications, the system can have operational speeds that create a mechanical resonance. This mechanical resonance can generate excessive noise and possibly damage mechanical components in the system. The drive has 4 programmable bypass-frequency bandwidths. The bandwidths allow the motor to step over speeds that induce system resonance.

5.2.9 Motor Preheat

To preheat a motor in a cold or damp environment, a small amount of DC current can be trickled continuously into the motor to protect it from condensation and cold starts. This function can eliminate the need for a space heater.

5.2.10 Programmable Set-ups

The drive has 4 set-ups that can be independently programmed. Using multi-setup, it is possible to switch between independently programmed functions activated by digital inputs or a serial command. Independent set-ups are used, for example, to change references, or for day/ night or summer/winter operation, or to control multiple motors. The LCP shows the active set-up.

Set-up data can be copied from drive to drive by downloading the information from the removable LCP.

5.2.11 Smart Logic Control (SLC)

Smart logic control (SLC) is a sequence of user-dened actions (see parameter 13-52 SL Controller Action [x]) executed by the SLC when the associated user-dened event (see parameter 13-51 SL Controller Event [x]) is evaluated as TRUE by the SLC. The condition for an event can be a particular status, or that the output from a logic rule or a comparator operand becomes TRUE. The condition leads to an associated action as shown in Illustration 5.3.

Illustration 5.3 SLC Event and Action

Events and actions are each numbered and linked in pairs (states), which means that when event [0] is fullled (attains the value TRUE), action [0] is executed. After the 1 action is executed, the conditions of the next event are evaluated. If this event is evaluated as true, then the corresponding action is executed. Only 1 event is evaluated at any time. If an event is evaluated as false, nothing happens in the SLC during the current scan interval and no other events are evaluated. When the SLC starts, it only evaluates event [0] during each scan interval. Only when event [0] is evaluated as true, the SLC executes action [0] and starts evaluating the next event. It is possible to program 1–20 events and actions. When the last event/action has been executed, the sequence starts over again from event [0]/action [0]. Illustration 5.4 shows an example with 4 event/actions:

Illustration 5.4 Order of Execution when 4 Events/Actions are

Programmed

Page 25

Par. 13-11 Comparator Operator

TRUE longer than.

. . .

Par. 13-10 Comparator Operand

Par. 13-12 Comparator Value

130BB672.10

. . . . . .

Par. 13-43 Logic Rule Operator 2

Par. 13-41 Logic Rule Operator 1

Par. 13-40 Logic Rule Boolean 1

Par. 13-42 Logic Rule Boolean 2

Par. 13-44 Logic Rule Boolean 3

130BB673.10

120

100

20 40 60 80 100 120 140 160 180

120

100

0 20 40 60 80 100 120 140 160 180

Volume %

INPUT POWER % PRESSURE %

SYSTEM CURVE

FAN CURVE

130BA781.11

ENERGY CONSUMED

Product Features Design Guide

Comparators

Comparators are used for comparing continuous variables (output frequency, output current, analog input, and so on) to xed preset values.

Illustration 5.5 Comparators

Logic rules

Combine up to 3 boolean inputs (TRUE/FALSE inputs) from timers, comparators, digital inputs, status bits, and events using the logical operators AND, OR, and NOT.

5.3

Specic VLT® HVAC Drive FC 102 Features

A drive takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such applications. For further information, see chapter 5.3.1 Using a Drive for Energy Savings.

5.3.1 Using a Drive for Energy Savings

The clear advantage of using a drive for controlling the speed of fans and pumps lies in the electricity savings. When comparing with alternative control systems and technologies, a drive is the optimum energy control system for controlling fan and pump systems.

5 5

Illustration 5.6 Logic Rules

5.2.12 Safe Torque O

The Safe Torque O (STO) function is used to stop the drive in emergency stop situations. The drive can use the STO function with asynchronous, synchronous, and permanent magnet motors.

For more information about Safe Torque O, including installation and commissioning, refer to the VLT® FC Series -

Safe Torque O Operating Guide.

Liability conditions

The customer is responsible for ensuring that personnel know how to install and operate the Safe Torque O function by:

concerning health, safety, and accident

Reading and understanding the safety regulations

•

prevention.

Understanding the generic and safety guidelines

•

provided in the VLT® FC Series - Safe Torque O Operating Guide.

Having a good knowledge of the generic and

•

safety standards for the specic application.

Illustration 5.7 Energy Saved with Reduced Fan Capacity

Page 26

130BA780.11

SYSTEM CURVE

FAN CURVE

PRESSURE %

100

120

20 40 60 80 100 120 140 160 180

VOLUME %

100%

50%

25%

12,5%

50% 100%

80%

175HA208.10

Power ~n

Pressure ~n

Flow ~n

130BA779.12

0 60 0 60 0 60

100

Discharge Damper Solution

IGV Solution

VLT Solution

Energy consumed

Input power %

Volume %

Product Features

VLT® HVAC Drive FC 102

Illustration 5.8 Fan Curves for Reduced Fan Volumes

Example of energy savings

Illustration 5.9 describes the dependence of ow, pressure, and power consumption on RPM. As seen in Illustration 5.9,

Illustration 5.9 Laws of Proportionality

the ow is controlled by changing the RPM. Reducing the speed only 20% from the rated speed also reduces the ow by 20%. The ow is directly proportional to the RPM. The consumption of electricity, however, is reduced by 50%.

If the system only runs at 100% ow a few days per year, while the average is below 80% of the rated ow, the amount of energy saved is even more than 50%.

Flow:

Pressure:

Power:

Q Flow P Power Q1Rated ow P1Rated power Q2Reduced ow P2Reduced power H Pressure n Speed control H1Rated pressure n1Rated speed H2Reduced pressure n2Reduced speed

 = 

Comparison of energy savings

The Danfoss drive solution

oers major savings compared with traditional energy saving solutions. The drive regulates fan speed according to thermal load on the system and functions as a building management system (BMS).

The graph (Illustration 5.10) shows typical energy savings obtainable with 3 well-known solutions when fan volume is reduced to 60%. As the graph shows, more than 50% energy savings can be achieved in typical applications.

Table 5.1 Laws of Proportionality Denitions

Illustration 5.10 3 Common Energy Saving Systems

Discharge dampers reduce power consumption. Inlet guide vanes oer a 40% reduction but are expensive to install. The Danfoss drive solution reduces energy consumption by more than 50% and is easy to install.

Page 27

500

[h]

1000

1500

2000

200100 300

/h]

400

175HA210.11

Product Features Design Guide

Example with varying ow over 1 year

Illustration 5.11 is based on pump characteristics obtained from a pump datasheet. The result obtained shows energy savings of more than 50% at the given ow distribution over a year. The payback period depends on the price per kWh and the price of the drive. In this example, it is less than a year when compared with valves and constant speed.

Illustration 5.11 Flow Distribution Over 1 Year

5 5

m3/h

Distribution Valve regulation Drive control

% Hours Power Consumption Power Consumption

A1-B

kWh A1-C

350 5 438 42.5 18615 42.5 18615 300 15 1314 38.5 50589 29.0 38106 250 20 1752 35.0 61320 18.5 32412 200 20 1752 31.5 55188 11.5 20148 150 20 1752 28.0 49056 6.5 11388 100 20 1752 23.0 40296 3.5 6132

Σ 100 8760 – 275064 – 26801

Table 5.2 Energy Savings Calculation

kWh

Page 28

175HA209.11

0 100 200 300 400

(mwg)

750rpm

1050rpm

1350rpm

1650rpm

(kW)

200100 300

(

m3 /h

)

(

m3 /h

)

400

750rpm

1050rpm

1350rpm

1650rpm

shaft

Full load

% Full-load current

& speed

500

100

0 12,5 25 37,5 50Hz

200

300

400

600

700

800

175HA227.10

Product Features

VLT® HVAC Drive FC 102

Illustration 5.12 Energy Savings in a Pump Application

5.3.2 Using a Drive for Better Control

If a drive is used for controlling the ow or pressure of a system, improved control is obtained. A drive can vary the speed of the fan or pump, obtaining variable control of ow and pressure utilizing the built-in PID control. Furthermore, a drive can quickly adapt the speed of the fan or pump to new ow or pressure conditions in the system.

Cos φ compensation

Typically, the VLT® HVAC Drive FC 102 has a cos φ of 1 and provides power factor correction for the cos φ of the motor, which means there is no need to make allowance for the cos φ of the motor when sizing the power factor correction unit.

Star/delta starter or soft starter not required

When larger motors are started, it is necessary in many countries to use equipment that limits the start-up current. In more traditional systems, a star/delta starter or soft starter is widely used. Such motor starters are not required if a drive is used. As illustrated in Illustration 5.13, a drive does not consume more than rated current.

VLT® HVAC Drive FC 102 2 Star/delta starter 3 Soft starter 4 Start directly on mains

Illustration 5.13 Current Consumption with a Drive

Page 29

- +

x6 x6

175HA205.12

Valve position

Starter

Fuses

supply

P.F.C

Flow

3-Port valve

Bypass

Return

Control

Supply air

V.A.V

outlets

Duct

P.F.C

Mains

Fuses

Starter

Bypass

supply

Return

valve

3-Port

Flow

Control

Valve position

Starter

Power Factor Correction

Mains

IGV

Mechanical linkage and vanes

Fan

Motor or actuator

Main B.M.S

Local D.D.C. control

Sensors PT

Pressure control signal 0/10V

Temperature control signal 0/10V

Control

Mains

Cooling section Heating section

Fan sectionInlet guide vane

Pump Pump

Product Features Design Guide

5.3.3 Using a Drive to Save Money

The drive eliminates the need for some equipment that would normally be used. The 2 systems shown in Illustration 5.14 and Illustration 5.15 can be established at roughly the same price.

Cost without a drive

5 5

DDC Direct digital control VAV Variable air volume Sensor P Pressure EMS Energy management system Sensor T Temperature

Illustration 5.14 Traditional Fan System

Page 30

175HA206.11

Pump

Flow

Return

Supply air

V.A.V

outlets

Duct

Mains

Pump

Return

Flow

Mains

Fan

Main B.M.S

Local D.D.C. control

Sensors

Mains

Cooling section Heating section

Fan section

Pressure control 0-10V or 0/4-20mA

Control temperature 0-10V or 0/4-20mA

VLT

- +

VLT

x3 x3

Product Features

VLT® HVAC Drive FC 102

Cost with a drive

DDC Direct digital control VAV Variable air volume BMS Building management system

Illustration 5.15 Fan System Controlled by Drives

5.3.4

VLT® HVAC Drive FC 102 Solutions

5.3.4.1 Variable Air Volume

Variable air volume systems (VAV) are used to control both the ventilation and temperature to fulll the requirements of a building. Central VAV systems are considered to be the most energy-ecient method to air condition buildings. Central systems are more ecient than distributed systems. The eciency comes from using larger fans and chillers, which have higher eciencies than small motors and distributed air-cooled chillers. Savings are also realized from the decreased maintenance requirements.

VLT® solution

While dampers and IGVs work to maintain a constant pressure in the ductwork, a drive solution saves more energy and reduces the complexity of the installation. Instead of creating an articial pressure drop or a decrease in fan eciency, the drive decreases the speed of the fan to provide the ow and pressure required by the system. Centrifugal devices, such as fans, decrease the pressure and ow they produce as their speed is reduced. Their power consumption is reduced. The return fan is frequently controlled to maintain a xed dierence in airow between the supply and return. The advanced PID controller of the HVAC drive can be used to eliminate the need for more controllers.

Page 31

Frequency converter

Cooling coil

Heating coil

Filter

Pressure signal

Supply fan

VAV boxes

Flow

Pressure transmitter

Return fan

130BB455.10

Product Features Design Guide

Illustration 5.16 Drives Used in a Variable Air Volume System

5 5

For more information, consult the Danfoss supplier for the Variable Air Volume: Improving VAV Ventilation Systems application note.

5.3.4.2 Constant Air Volume

Constant air volume (CAV) systems are central ventilation systems used to supply large common zones with the minimum amounts of fresh tempered air. They preceded VAV systems and are found in older multi-zoned commercial buildings as well. These systems preheat fresh air with air handling units (AHUs) that have heating coils. Many are also used for air conditioning buildings and have a cooling coil. Fan coil units are often used to help with the heating and cooling requirements in the individual zones.

VLT® solution

With a drive, signicant energy savings can be obtained while maintaining decent control of the building. Temperature sensors or CO2 sensors can be used as feedback signals to drives. Whether controlling temperature, air quality, or both, a CAV system can be controlled to operate based on actual building conditions. As the number of people in the controlled area decreases, the need for fresh air decreases. The CO2 sensor detects lower levels and decreases the supply fan speed. The return fan modulates to maintain a static pressure setpoint or xed dierence between the supply and return airows.

Temperature control needs vary based on outside temperature and number of people in the controlled zone. As the temperature decreases below the setpoint, the supply fan can decrease its speed. The return fan modulates to maintain a static pressure setpoint. Decreasing the airow, reduces the energy used to heat or cool the fresh air, resulting in further savings.

Several features of the Danfoss HVAC dedicated drive can be used to improve the performance of a CAV system. One concern of controlling a ventilation system is poor air quality. The programmable minimum frequency can be set to maintain a minimum amount of supply air regardless of the feedback or reference signal. The drive also includes a 3-zone, 3 setpoint PID controller which allows monitoring both temperature and air quality. Even if the temperature requirement is satised, the drive maintains enough supply air to satisfy the air quality sensor. The controller can monitor and compare 2 feedback signals to control the return fan by maintaining a xed dierential airow between the supply and return ducts.

Page 32

Frequency converter

Pressure signal

Cooling coil

Heating coil

Filter

Pressure transmitter

Supply fan

Return fan

Temperature signal

Temperature transmitter

130BB451.10

Product Features

VLT® HVAC Drive FC 102

Illustration 5.17 Drive Used in a Constant Air Volume System

For more information, consult the Danfoss supplier for the Constant Air Volume: Improving CAV Ventilation Systems application note.

5.3.4.3 Cooling Tower Fan

Cooling tower fans are used to cool condenser water in water-cooled chiller systems. Water-cooled chillers provide the most ecient means of creating chilled water. They are as much as 20% more ecient than air cooled chillers. Depending on climate, cooling towers are often the most energy-ecient method of cooling the condenser water from chillers.

Cooling towers cool the condenser water by evaporation. The condenser water is sprayed into the cooling tower onto the ll to increase its surface area. The tower fan blows air through the ll and sprayed water to aid in the evaporation. Evaporation removes energy from the water, dropping its temperature. The cooled water collects in the basin of the cooling tower where it is pumped back into the chiller condenser and the cycle is repeated.

VLT® solution

With a drive, the cooling tower fans can be controlled to the required speed to maintain the condenser water temperature. The drives can also be used to turn the fan on and

fans drop below a certain speed, the cooling eect decreases. When using a gearbox to drive the tower fan, a minimum speed of 40–50% could be required. The customer programmable minimum frequency setting is available to maintain this minimum frequency even as the feedback or speed reference calls for lower speeds.

The drive can be programmed to enter a sleep mode and stop the fan until a higher speed is required. Additionally, some cooling tower fans have undesirable frequencies that can cause vibrations. These frequencies can easily be avoided by programming the bypass frequency ranges in the drive.

o as needed. With the Danfoss VLT® HVAC Drive, as the cooling tower

Page 33

Frequency converter

Water Inlet

Water Outlet

CHILLER

Temperature Sensor

BASIN

Conderser Water pump

Supply

130BB453.10

Product Features Design Guide

5 5

Illustration 5.18 Drives Used with a Cooling Tower Fan

For more information, consult the Danfoss supplier for the Cooling Tower Fan: Improving Fan Control on Cooling Towers application note.

Page 34

Frequency converter

Water Inlet

Water Outlet

BASIN

Flow or pressure sensor

Condenser Water pump

Throttling valve

Supply

CHILLER

130BB452.10

Product Features

VLT® HVAC Drive FC 102

5.3.4.4 Condenser Pumps

Condenser water pumps are primarily used to circulate water through the condenser section of water-cooled chillers and their associated cooling tower. The condenser water absorbs the heat from the condenser section and releases it into the atmosphere in the cooling tower. These systems provide the most ecient means of creating chilled water. They are as much as 20% more ecient than air cooled chillers.

VLT® solution

Drives can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump impeller.

Using a drive instead of a throttling valve saves the energy that the valve would otherwise have absorbed. This change can amount to savings of 15–20% or more. Trimming the pump impeller is irreversible. If the conditions change and higher ow

is required, the impeller must be replaced.

Illustration 5.19 Drive Used with a Condenser Pump

For more information, consult the Danfoss supplier for the Condenser Pumps: Improving Condenser Water Pumping Systems application note.

5.3.4.5 Primary Pumps

Primary pumps in a primary/secondary pumping system can maintain a constant ow through devices that encounter operation or control diculties when exposed to variable ow. The primary/secondary pumping technique decouples the primary production loop from the secondary distribution loop. Decoupling allows devices such as chillers to obtain constant design ow and operate properly while allowing the rest of the system to vary in ow. As the evaporator ow rate decreases in a chiller, the water begins to become overchilled. As the water becomes overchilled, the chiller attempts to decrease its cooling capacity. If the ow rate drops far enough, or too quickly, the chiller cannot shed its load suciently

Page 35

Frequency converter

CHILLER

Flowmeter

F F

130BB456.10

Product Features Design Guide

and the low evaporator temperature safety trips the chiller, requiring a manual reset. This situation is common in large installations, especially when 2 or more chillers in parallel are installed if primary/secondary pumping is not used.

VLT® solution

A drive can be added to the primary system, to replace the throttling valve and/or trimming of the impellers, leading to reduced operating expenses. Two control methods are common:

A ow meter installed at the discharge of each chiller can control the pump directly because the desired ow rate

•

is known and constant. Using the PID controller, the drive always maintains the appropriate ow rate, even compensating for the changing resistance in the primary piping loop as chillers and their pumps are staged on and o.

The operator can use local speed determination by decreasing the output frequency until the design ow rate is

•

achieved. Using a drive to decrease the pump speed is similar to trimming the pump impeller, but more ecient. The balancing contractor simply decreases the speed of the pump until the proper ow rate is achieved and leaves the speed xed. The pump operates at this speed any time the chiller is staged on. Because the primary loop lacks control valves or other devices that can change the system curve, and the variance due to staging pumps and chillers on and o is small, this xed speed remains appropriate. If the ow rate must be increased later in the life of the system, the drive can simply increase the pump speed instead of requiring a new pump impeller.

5 5

Illustration 5.20 Drives Used with Primary Pumps in a Primary/Secondary Pump System

For more information, consult the Danfoss supplier for the Primary Pumps: Improving Primary Pumping in Pri/Sec System application note.

Page 36

Frequency converter

CHILLER

130BB454.10

Product Features

VLT® HVAC Drive FC 102

5.3.4.6 Secondary Pumps

Secondary pumps in a primary/secondary chilled water pumping system are used to distribute the chilled water to the loads from the primary production loop. The primary/secondary pumping system is used to de-couple 1 piping loop from another hydronically. In this case, the primary pump maintains a constant ow through the chillers, allowing the secondary pumps to vary ow, which increases control and save energy.

If the primary/secondary design concept is not used and a variable volume system is designed, when the ow rate drops far enough or too quickly, the chiller cannot shed its load properly. The low evaporator temperature safety then trips the chiller, requiring a manual reset. This situation is common in large installations especially when 2 or more chillers in parallel are installed.

VLT® solution

While the primary/secondary system with 2-way valves improves energy and system control, using drives increases the energy savings and control potential further. With the proper sensor location, the addition of drives allows the pumps to match their speed to the system curve instead of the pump curve, which eliminates wasted energy and most of the overpressurization to which 2-way valves can be subjected.

As the monitored loads are reached, the 2-way valves close down, increasing the dierential pressure measured across the load and 2-way valve. As this dierential pressure starts to rise, the pump is slowed to maintain the control head also called setpoint value. This setpoint value is calculated by summing the pressure drop of the load and 2-way valve together under design conditions.

NOTICE

When running multiple pumps in parallel, they must run at the same speed to increase energy savings, either with individual dedicated drives, or 1 drive running multiple pumps in parallel.

Illustration 5.21 Drives Used with Secondary Pumps in a Primary/Secondary Pump System

For more information, consult the Danfoss supplier for the Secondary Pumps: Improving Secondary Pumping in Pri/Sec System application note.

Page 37

Constant Speed Pumps (2)

Variable Speed Pumps (1)

Motor starter

Drive with Cascade Controller

Pressure Sensor

e30ba362.11

Time

Mains operation

Destaging freq.

Alternation command/PID stops

Staging freq.

Mains operation

PID contr. starts

130BA364.10

max

min

Product Features Design Guide

5.4 Basic Cascade Controller

The basic cascade controller is used for pump applications where a certain pressure (head) or level must be maintained over a wide dynamic range. Running a large pump at variable speed over a wide range is not an ideal solution because of low pump eciency at lower speed. In a practical way, the limit is 25% of the rated full-load speed for the pump.

In the basic cascade controller, the drive controls a variable speed (lead) motor as the variable speed pump and can stage up to 2 more constant speed pumps on and Connect the additional constant speed pumps directly to mains or via soft starters. By varying the speed of the initial pump, variable speed control of the entire system is provided. The variable speed maintains constant pressure, which results in reduced system stress, and quieter operation in pumping systems.

o.

Whenever an alternation timer expires.

•

At a predened time of day.

•

When the lead pump goes into sleep mode.

•

The actual system load determines staging.

A separate parameter limits alternation only to take place if total capacity required is >50%. Total pump capacity is determined as lead pump plus xed speed pumps capacities.

Bandwidth management

In cascade control systems, to avoid frequent switching of xed-speed pumps, the desired system pressure is kept within a bandwidth rather than at a constant level. The staging bandwidth provides the required bandwidth for operation. When a large and quick change in system pressure occurs, the override bandwidth overrides the staging bandwidth to prevent immediate response to a short duration pressure change. An override bandwidth timer can be programmed to prevent staging until the system pressure has stabilized and normal control is established.

When the cascade controller is enabled and the drive issues a trip alarm, the system head is maintained by staging and destaging xed-speed pumps. To prevent frequent staging and destaging and to minimize pressure uctuations, a wider xed speed bandwidth is used instead of the staging bandwidth.

5 5

Illustration 5.22 Basic Cascade Controller

Fixed lead pump

The motors must be of equal size. The basic cascade controller allows the drive to control up to 3 equal pumps using the 2 built-in relays in the drive. When the variable pump (lead) is connected directly to the drive, the 2 builtin relays control the other 2 pumps. When lead pump alternations are enabled, pumps are connected to the built-in relays and the drive can operate 2 pumps.

Lead pump alternation

The motors must be of equal size. This function makes it possible to cycle the drive between the pumps in the system (maximum of 2 pumps). In this operation, the runtime between pumps is equalized, reducing the required pump maintenance and increasing reliability and lifetime of the system. The alternation of the lead pump can take place at a command signal or at staging (adding another pump).

The command can be a manual alternation or an alternation event signal. If the alternation event is selected, the lead pump alternation takes place every time the event occurs. Selections include:

5.4.1.1 Pump Staging with Lead Pump Alternation

With lead pump alternation enabled, a maximum of 2 pumps are controlled. At an alternation command, the PID stops, the lead pump ramps to minimum frequency (f and, after a delay, it ramps to maximum frequency (f When the speed of the lead pump reaches the destaging frequency, the xed-speed pump is cut out (destaged). The lead pump continues to ramp up and then ramps down to a stop and the 2 relays are cut out.

Illustration 5.23 Lead Pump Alternation

After a time delay, the relay for the

xed-speed pump cuts in (staged) and this pump becomes the new lead pump. The new lead pump ramps up to maximum speed and then down to minimum speed. When ramping down and reaching the staging frequency, the old lead pump is now cut in (staged) on the mains as the new xed-speed pump.

max

min

)

Page 38

Product Features

VLT® HVAC Drive FC 102

If the lead pump has been running at minimum frequency (f

) for a programmed amount of time, with a xed-

min

speed pump running, the lead pump contributes little to the system. When the programmed value of the timer expires, the lead pump is removed, avoiding water heating problems.

5.4.1.2 System Status and Operation

If the lead pump goes into sleep mode, the function is shown on the LCP. It is possible to alternate the lead pump

on a sleep mode condition.

When the cascade controller is enabled, the LCP shows the operation status for each pump and the cascade controller. Information shown includes:

Pump status is a readout of the status for the

•

relays assigned to each pump. The display shows pumps that are disabled, o, running on the drive, or running on the mains/motor starter.

Cascade status is a readout of the status for the

•

cascade controller. The display shows the following:

- Cascade controller is disabled.

- All pumps are o.

- An emergency has stopped all pumps.

- All pumps are running.

- Fixed-speed pumps are being staged/

destaged.

- Lead pump alternation is occurring.

Destage at no-ow ensures that all xed-speed

•

pumps are stopped individually until the no-ow status disappears.

Dynamic Braking Overview

5.5

Dynamic braking slows the motor using 1 of the following methods:

AC brake

•

The brake energy is distributed in the motor by changing the loss conditions in the motor (parameter 2-10 Brake Function = [2]). The AC brake function cannot be used in applications with high cycling frequency since this situation overheats the motor.

DC brake

•

An overmodulated DC current added to the AC current works as an eddy current brake (parameter 2-02 DC Braking Time ≠ 0 s).

Resistor brake

•

A brake IGBT keeps the overvoltage under a certain threshold by directing the brake energy from the motor to the connected brake resistor (parameter 2-10 Brake Function = [1]). For more

information on selecting a brake resistor, see VLT Brake Resistor MCE 101 Design Guide.

For drives equipped with the brake option, a brake IGBT along with terminals 81(R-) and 82(R+) are included for connecting an external brake resistor.

The function of the brake IGBT is to limit the voltage in the DC link whenever the maximum voltage limit is exceeded. It limits the voltage by switching the externally mounted resistor across the DC bus to remove excess DC voltage present on the bus capacitors.

External brake resistor placement has the advantages of selecting the resistor based on application need, dissipating the energy outside of the control panel, and protecting the drive from overheating if the brake resistor is overloaded.

The brake IGBT gate signal originates on the control card and is delivered to the brake IGBT via the power card and gatedrive card. Also, the power and control cards monitor the brake IGBT for a short circuit. The power card also monitors the brake resistor for overloads.

Page 39

130BF758.10

380 V

2x aR-1000 A 2x aR-1500 A

3x 1.2%

315 kW 500 kW

3x 1.2%

3x Class L-800 A

3x Class L-1200 A

Common mains disconnect switch

Mains connecting point for additional drives in the load sharing application

DC connecting point for additional drives in the load sharing application

91 92 93

96 97 98

82 81 82 81

Product Features Design Guide

5.6 Load Share Overview

Load share is a feature that allows the connection of DC circuits of several drives, creating a multiple-drive system to run 1 mechanical load. Load share provides the following benets:

Energy savings

A motor running in regenerative mode can supply drives that are running in motoring mode.

Reduced need for spare parts

Usually, only 1 brake resistor is needed for the entire drive system instead of 1 brake resistor for per drive.

Power back-up

If there is mains failure, all linked drives can be supplied through the DC link from a back-up. The application can continue running or go though a controlled shutdown process.

Preconditions

The following preconditions must be met before load sharing is considered:

The drive must be equipped with load sharing terminals.

•

Product series must be the same. Use only VLT® HVAC Drive FC 102 drives with other VLT® HVAC Drive FC 102

•

drives.

Drives must be placed physically close to one another to allow the wiring between them to be no longer than

•

25 m (82 ft).

Drives must have the same voltage rating.

•

When adding a brake resistor in a load sharing conguration, all drives must be equipped with a brake chopper.

•

Fuses must be added to load share terminals.

•

5 5

For a diagram of a load share application in which best practices are applied, see Illustration 5.24.

Illustration 5.24 Diagram of a Load Share Application Where Best Practices are Applied

Page 40

Product Features

Load sharing

Units with the built-in load sharing option contain terminals (+) 89 DC and (–) 88 DC. Within the drive, these terminals connect to the DC bus in front of the DC-link reactor and bus capacitors.

The load sharing terminals can connect in 2 dierent congurations.

Terminals tie the DC-bus circuits of multiple drives together. This conguration allows a unit that is in a

•

regenerative mode to share its excess bus voltage with another unit that is running a motor. Load sharing in this manner can reduce the need for external dynamic brake resistors, while also saving energy. The number of units that can be connected in this way is innite, as long as each unit has the same voltage rating. In addition, depending on the size and number of units, it may be necessary to install DC reactors and DC fuses in the DC-link connections, and AC reactors on the mains. Attempting such a conguration requires specic considerations.

The drive is powered exclusively from a DC source. This conguration requires:

•

- A DC source.

- A means to soft charge the DC bus at power-up.

VLT® HVAC Drive FC 102

5.7 Regen Overview

Regen typically occurs in applications with continuous braking such as cranes/hoists, downhill conveyors, and centrifuges where energy is pulled out of a decelerated motor.

The excess energy is removed from the drive using 1 of the following options:

Brake chopper allows the excess energy to be dissipated in the form of heat within the brake resistor coils.

•

Regen terminals allow a third-party regen unit to be connected to the drive, allowing the excess energy to be

•

returned to the power grid.

Returning excess energy back to the power grid is the most ecient use of regenerated energy in applications using continuous braking.

Page 41

130BG068.10

225 mm (8.9 in)

130BG069.10

225 mm (8.9 in)

Product Features Design Guide

5.8 Back-channel Cooling Overview

A unique back-channel duct passes cooling air over the heat sinks with minimal air passing through the electronics area. There is an IP54/Type 12 seal between the back-channel cooling duct and the electronics area of the VLT® drive. This back-

channel cooling allows 90% of the heat losses to be exhausted directly outside the enclosure. This design improves reliability and prolongs component life by dramatically reducing interior temperatures and contamination of the electronic components. Dierent back-channel cooling kits are available to redirect the airow based on individual needs.

5.8.1 Airow for D1h–D8h Enclosures

5 5

Illustration 5.25 Standard Airow Conguration for Enclosures D1h/D2h (Left), D3h/D4h (Center), and D5h–D8h (Right).

Illustration 5.26 Optional Airow Conguration Using Back-channel Cooling Kits for Enclosures D1h–D8h.

(Left) In-bottom/out-back cooling kit for enclosures D1h/D2h.

(Center) In-bottom/out-top cooling kit for enclosures D3h/D4h.

(Right) In-back/out-back cooling kit for enclosures D5–D8h.

Page 42

225 mm (8.9 in)

130BF699.10

225 mm (8.9 in)

130BF700.10

Product Features

VLT® HVAC Drive FC 102

5.8.2 Airow for E1h–E4h Enclosures

Illustration 5.27 Standard Airow Conguration for E1h/E2h (Left) and E3h/E4h (Right)

Illustration 5.28 Optional Airow Conguration Through the Back Wall for E1h/E2h (Left) and E3h/E4h (Right)

Page 43

Options and Accessories Ove... Design Guide

6 Options and Accessories Overview

6.1 Fieldbus Devices

This section describes the eldbus devices that are available with the VLT® HVAC Drive FC 102 series. Using a

eldbus device reduces system cost, delivers faster and more ecient communication, and provides an easier user interface. For ordering numbers, refer to chapter 13.2 Ordering Numbers for Options and Accessories.

6.1.1

VLT® PROFIBUS DP-V1 MCA 101

The VLT® PROFIBUS DP-V1 MCA 101 provides:

Wide compatibility, a high level of availability,

•

support for all major PLC vendors, and compatibility with future versions.

Fast, ecient communication, transparent instal-

•

lation, advanced diagnosis, and parameterization and auto-conguration of process data via a GSD

le.

Acyclic parameterization using PROFIBUS DP-V1,

•

PROFIdrive, or Danfoss FC prole state machines.

6.1.2

VLT® DeviceNet MCA 104

6.1.4

VLT® BACnet MCA 109

The open communications protocol for worldwide building automation use. The BACnet protocol is an international protocol that eciently integrates all parts of building automation equipment from the actuator level to the building management system.

BACnet is the world standard for building

•

automation.

International standard ISO 16484-5.

•

With no license fees, the protocol can be used in

•

building automation systems of all sizes.

The BACnet option lets the drive communicate

•

with building management systems running the BACnet protocol.

BACnet is typically used for heating, ventilation,

•

cooling, and climate equipment control.

The BACnet protocol easily integrates into

•

existing control equipment networks.

6.1.5

VLT® PROFINET MCA 120

The VLT® DeviceNet MCA 104 provides:

Support of the ODVA AC drive prole supported

•

via I/O instance 20/70 and 21/71 secures compatibility to existing systems.

Benets from ODVA’s strong conformance testing

•

policies that ensure products are interoperable.

6.1.3

VLT® LonWorks MCA 108

LonWorks is a eldbus system developed for building automation. It enables communication between individual units in the same system (peer-to-peer) and thus supports decentralizing of control.

No need for large main station (master/slave).

•

Units receive signals directly.

•

Supports Echelon free-topology interface

•

cabling and installation).

Supports embedded I/Os and I/O options (easy

•

implementation of de-central I/Os).

Sensor signals can quickly be moved to another

•

controller via bus cables.

Certied as compliant with LonMark version 3.4

•

specications.

(exible

The VLT® PROFINET MCA 120 combines the highest performance with the highest degree of openness. The option is designed so that many of the features from the

VLT® PROFIBUS MCA 101 can be reused, minimizing user eort to migrate PROFINET and securing the investment in a PLC program.

Same PPO types as the VLT® PROFIBUS DP V1

•

MCA 101 for easy migration to PROFINET.

Built-in web server for remote diagnosis and

•

reading out of basic drive parameters.

Supports MRP.

•

Supports DP-V1. Diagnostic allows easy, fast, and

•

standardized handling of warning and fault information into the PLC, improving bandwidth in the system.

Supports PROFIsafe when combined with VLT

•

Safety Option MCB 152.

Implementation in accordance with Conformance

•

Class B.

Page 44

Options and Accessories Ove...

VLT® HVAC Drive FC 102

6.1.6

VLT® EtherNet/IP MCA 121

Ethernet is the future standard for communication at the factory oor. The VLT® EtherNet/IP MCA 121 is based on

the newest technology available for industrial use and handles even the most demanding requirements. EtherNet/IP™ extends standard commercial Ethernet to the Common Industrial Protocol (CIP™) – the same upper-layer protocol and object model found in DeviceNet.

This option

•

6.1.7

oers advanced features such as: Built-in, high-performance switch enabling linetopology, which eliminates the need for external switches.

DLR Ring (from October 2015).

Advanced switch and diagnosis functions.

Built-in web server.

E-mail client for service notication.

Unicast and Multicast communication.

VLT® Modbus TCP MCA 122

magnet motors in parallel and monitor points required in typical HVAC applications. Besides standard functionality, the MCA 125 option features:

COV (change of value).

•

Read/write property multiple.

•

Alarm/warning notications

•

Ability to change BACnet object names for user-

•

friendliness.

BACnet Loop object.

•

Segmented data transfer.

•

Trending, based on time or event.

•

6.2 Functional Extensions

This section describes the functional extension options that are available with the VLT® HVAC Drive FC 102 series. For

ordering numbers, refer to chapter 13.2 Ordering Numbers for Options and Accessories.

6.2.1

VLT® General Purpose I/O Module MCB 101

The VLT® Modbus TCP MCA 122 connects to Modbus TCPbased networks. It handles connection intervals down to 5 ms in both directions, positioning it among the fastest performing Modbus TCP devices in the market. For master redundancy, it features hot swapping between 2 masters.

Other features include:

Built-in web-server for remote diagnosis and

•

reading out basic drive parameters.

Email notication that can be congured to send

•

an email message to 1 or more recipients when certain alarms or warnings occur, or when they are cleared.

Dual master PLC connection for redundancy.

•

6.1.8

VLT® BACnet/IP MCA 125

The VLT® BACnet/IP MCA 125 option allows quick and easy integration of the drive into building management systems (BMS) using the BACnet/IP protocol or by running BACnet on Ethernet. It can read and share data points and transfer actual and requested values to and from the systems.

The MCA 125 option has 2 Ethernet connectors, enabling daisy-chain conguration with no need for external switches. The embedded 3-port managed switch of the

VLT® BACnet/IP MCA 125 option comprises 2 external and 1 internal Ethernet port. This switch allows the use of a line structure for the Ethernet cabling. This option makes it possible to control multiple high-eciency permanent

The VLT® General Purpose I/O Module MCB 101 oers an extended number of control inputs and outputs:

3 digital inputs 0–24 V: Logic 0 < 5 V; Logic 1 >

•

10 V.

2 analog inputs 0–10 V: Resolution 10 bits plus

•

sign.

2 digital outputs NPN/PNP push-pull.

•

1 analog output 0/4–20 mA.

•

Spring-loaded connection.

•

6.2.2

VLT® Relay Card MCB 105

The VLT® Relay Card MCB 105 extends relay functions with 3 more relay outputs.

Protects control cable connection.

•

Spring-loaded control wire connection.

•

Maximum switch rate (rated load/minimum load)

6 minutes-1/20 s-1.

Maximum terminal load

AC-1 resistive load: 240 V AC, 2 A.

6.2.3

VLT® Analog I/O Option MCB 109

The VLT® Analog I/O Option MCB 109 is easily tted in the drive for upgrading to advanced performance and control using the additional inputs/outputs. This option also upgrades the drive with a battery back-up supply for the

Page 45

Options and Accessories Ove... Design Guide

drive’s built-in clock. This battery back-up provides stable use of all timed actions used by the drive.

3 analog inputs, each congurable as both

•

voltage and temperature input.

Connection of 0–10 V analog signals as well as

•

PT1000 and NI1000 temperature inputs.

3 analog outputs, each congurable as 0–10 V

•

outputs.

6.2.4

VLT® PTC Thermistor Card MCB 112

The VLT® PTC Thermistor Card MCB 112 provides extra motor monitoring compared to the built-in ETR function and thermistor terminal.

Protects the motor from overheating.

•

ATEX-approved for use with Ex-d motors.

•

Uses Safe Torque O function, which is approved

•

in accordance with SIL 2 IEC 61508.

6.2.5

VLT® Sensor Input Option MCB 114

The VLT® Sensor Input Option MCB 114 protects the motor from being overheated by monitoring the temperature of motor bearings and windings.

3 self-detecting sensor inputs for 2 or 3-wire

•

PT100/PT1000 sensors.

1 extra analog input 4–20 mA.

•

Motion Control and Relay Cards

6.3

Brake Resistors

6.4

In applications where the motor is used as a brake, energy is generated in the motor and sent back into the drive. If the energy cannot be transported back to the motor, it increases the voltage in the drive DC line. In applications with frequent braking and/or high inertia loads, this increase can lead to an overvoltage trip in the drive and, nally, a shutdown. Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected based on its ohmic value, its power dissipation rate, and its physical size. Danfoss oers a wide variety of dierent resistors that are specially designed to Danfoss drives. For ordering numbers and more information on how to dimension brake resistors, refer to

the VLT® Brake Resistor MCE 101 Design Guide.

6.5 Sine-wave Filters

When a drive controls a motor, resonance noise is heard from the motor. This noise, which is the result of the motor design, occurs every time an inverter switch in the drive is activated. The frequency of the resonance noise thus corresponds to the switching frequency of the drive.

Danfoss supplies a sine-wave lter to dampen the acoustic motor noise. The lter reduces the ramp-up time of the voltage, the peak load voltage (U current (ΔI) to the motor, which means that current and voltage become almost sinusoidal. The acoustic motor noise is reduced to a minimum.

The ripple current in the sine-wave lter coils also causes some noise. Solve the problem by integrating the lter in a cabinet or enclosure.

), and the ripple

PEAK

This section describes the motion control and relay card options that are available with the VLT® HVAC Drive FC 102

series. For ordering numbers, refer to chapter 13.2 Ordering Numbers for Options and Accessories.

6.3.1

VLT® Extended Relay Card MCB 113

The VLT® Extended Relay Card MCB 113adds inputs/ outputs for increased exibility.

7 digital inputs.

•

2 analog outputs.

•

4 SPDT relays.

•

Meets NAMUR recommendations.

•

Galvanic isolation capability.

•

For ordering numbers and more information on sine-wave lters, refer to the Output Filters Design Guide.

dU/dt Filters

6.6

Danfoss supplies dU/dt lters which are dierential mode, low-pass lters that reduce motor terminal phase-to-phase peak voltages and reduce the rise time to a level that lowers the stress on the insulation at the motor windings. This is a typical issue with set-ups using short motor cables.

Compared to sine-wave o frequency above the switching frequency.

For ordering numbers and more information on dU/dt

lters, refer to the Output Filters Design Guide.

lters, the dU/dt lters have a cut-

Page 46

Options and Accessories Ove...

VLT® HVAC Drive FC 102

6.7 Common-mode Filters

High-frequency common-mode cores (HF-CM cores) reduce electromagnetic interference and eliminate bearing damage by electrical discharge. They are special nanocrystalline magnetic cores that have superior ltering performance compared to regular ferrite cores. The HF-CM core acts like a common-mode inductor between phases and ground.

Installed around the 3 motor phases (U, V, W), the common mode mode currents. As a result, high-frequency electromagnetic interference from the motor cable is reduced.

lters reduce high-frequency common-

For ordering numbers refer to the Output Filters Design Guide.

6.8 Harmonic Filters

The VLT® Advanced Harmonic Filters AHF 005 & AHF 010 should not be compared with traditional harmonic trap lters. The Danfoss harmonic lters have been specially designed to match the Danfoss drives.

By connecting the AHF 005 or AHF 010 in front of a Danfoss drive, the total harmonic current distortion generated back to the mains is reduced to 5% and 10%.

For ordering numbers and more information on how to dimension brake resistors, refer to the VLT® Advanced

Harmonic Filters AHF 005/AHF 010 Design Guide.

High-power Kits

6.9

High-power kits, such as back-wall cooling, space heater, mains shield, are available for these enclosures. See

chapter 13.2 Ordering Numbers for Options and Accessories

for a brief description and ordering numbers for all available kits.

Page 47

Specications Design Guide

7 Specications

7.1 Electrical Data, 380–480 V

VLT® HVAC Drive FC 102

Normal overload NO NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 110 132 160 Typical shaft output at 460 V [hp] 150 200 250 Typical shaft output at 480 V [kW] 132 160 200

Enclosure size D1h/D3h/D5h/D6h

Output current (3-phase)

Continuous (at 400 V) [A] 212 260 315 Intermittent (60 s overload) (at 400 V)[A] 233 286 347 Continuous (at 460/480 V) [A] 190 240 302 Intermittent (60 s overload) (at 460/480 V) [kVA] 209 264 332 Continuous kVA (at 400 V) [kVA] 147 180 218 Continuous kVA (at 460 V) [kVA] 151 191 241 Continuous kVA (at 480 V) [kVA] 165 208 262

Maximum input current

Continuous (at 400 V) [A] 204 251 304 Continuous (at 460/480 V) [A] 183 231 291

Maximum number and size of cables per phase

- Mains, motor, brake, and load share [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)]

2), 3)

N110K N132 N160

2x95 (2x3/0) 2x95 (2x3/0) 2x95 (2x3/0)

315 350 400

2559 2954 3770

2261 2724 3628

0.98 0.98 0.98

110 (230) 110 (230) 110 (230)

75 (167) 75 (167) 75 (167)

7 7

Table 7.1 Electrical Data for Enclosures D1h/D3h/D5h/D6h, Mains Supply 3x380–480 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 7.5 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 48

Specications

VLT® HVAC Drive FC 102

Normal overload NO NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 200 250 315 Typical shaft output at 460 V [hp] 300 350 450 Typical shaft output at 480 V [kW] 250 315 355

Enclosure size D2h/D4h/D7h/D8h

Output current (3-phase)

Continuous (at 400 V) [A] 395 480 588 Intermittent (60 s overload) (at 400 V)[A] 435 528 647 Continuous (at 460/480 V) [A] 361 443 535 Intermittent (60 s overload) (at 460/480 V) [kVA] 397 487 589 Continuous kVA (at 400 V) [kVA] 274 333 407 Continuous kVA (at 460 V) [kVA] 288 353 426 Continuous kVA (at 480 V) [kVA] 313 384 463

Maximum input current

Continuous (at 400 V) [A] 381 463 567

Continuous (at 460/480 V) [A] 348 427 516

Maximum number and size of cables per phase

- Mains, motor, brake, and load share [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)]

2), 3)

N200 N250 N315

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

550 630 800

4116 5137 6674

3569 4566 5714

0.98 0.98 0.98

110 (230) 110 (230) 110 (230)

80 (176) 80 (176) 80 (176)

Table 7.2 Electrical Data for Enclosures D2h/D4h/D7h/D8h, Mains Supply 3x380–480 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 7.5 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 49

Specications Design Guide

VLT® HVAC Drive FC 102

Normal overload NO NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 355 400 450 Typical shaft output at 460 V [hp] 500 600 600 Typical shaft output at 480 V [kW] 400 500 530

Enclosure size E1h/E3h E1h/E3h E1h/E3h

Output current (3-phase)

Continuous (at 400 V) [A] 658 745 800 Intermittent (60 s overload) (at 400 V) [A] 724 820 880 Continuous (at 460/480 V) [A] 590 678 730 Intermittent (60 s overload) (at 460/480 V) [A] 649 746 803 Continuous kVA (at 400 V) [kVA] 456 516 554 Continuous kVA (at 460 V) [kVA] 470 540 582 Continuous kVA (at 480 V) [kVA] 511 587 632

Maximum input current

Continuous (at 400 V) [A] 634 718 771 Continuous (at 460/480 V) [A] 569 653 704

Maximum number and size of cables per phase (E1h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)]

- Brake or regeneration [mm2 (AWG)]

Maximum number and size of cables per phase (E3h)

- Mains and motor [mm2 (AWG)]

- Brake [mm2 (AWG)]

- Load share or regeneration [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W]

Eciency

Output frequency 0–590 Hz 0–590 Hz 0–590 Hz Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)] Power card overtemperature trip [°C (°F)] Fan power card overtemperature trip [°C (°F)] Active in-rush card overtemperature trip [°C (°F)]

2), 3)

N355 N400 N450

5x240 (5x500 mcm) 5x240 (5x500 mcm) 5x240 (5x500 mcm)

4x240 (4x500 mcm) 4x240 (4x500 mcm) 4x240 (4x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm) 4x185 (4x350 mcm)

800 800 800

6928 8036 8783

5910 6933 7969

0.98 0.98 0.98

110 (230) 110 (230) 110 (230)

80 (176) 80 (176) 80 (176) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185)

7 7

Table 7.3 Electrical Data for Enclosures E1h/E3h, Mains Supply 3x380–480 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 7.5 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 50

Specications

VLT® HVAC Drive FC 102

Normal overload NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 500 560 Typical shaft output at 460 V [hp] 650 750 Typical shaft output at 480 V [kW] 560 630

Enclosure size E2h/E4h E2h/E4h

Output current (3-phase)

Continuous (at 400 V) [A] 880 990 Intermittent (60 s overload) (at 400 V) [A] 968 1089 Continuous (at 460/480 V) [A] 780 890 Intermittent (60 s overload) (at 460/480 V) [A] 858 979 Continuous kVA (at 400 V) [kVA] 610 686 Continuous kVA (at 460 V) [kVA] 621 709 Continuous kVA (at 480 V) [kVA] 675 771

Maximum input current

Continuous (at 400 V) [A] 848 954

Continuous (at 460/480 V) [A] 752 848

Maximum number and size of cables per phase (E2h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)]

- Brake or regeneration [mm2 (AWG)]

Maximum number and size of cables per phase (E4h)

- Mains and motor [mm2 (AWG)]

- Brake [mm2 (AWG)]

- Load share or regeneration [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W]

Eciency

Output frequency 0–590 Hz 0–590 Hz Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)] Power card overtemperature trip [°C (°F)] Fan power card overtemperature trip [°C (°F)] Active in-rush card overtemperature trip [°C (°F)]

2), 3)

N500 N560

6x240 (6x500 mcm) 6x240 (6x500 mcm)

5x240 (5x500 mcm) 5x240 (5x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm)

1200 1200

9473 11102

7809 9236

0.98 0.98

110 (230) 100 (212)

80 (176) 80 (176) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185)

Table 7.4 Electrical Data for Enclosures E2h/E4h, Mains Supply 3x380–480 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 7.5 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 51

Specications Design Guide

7.2 Electrical Data, 525–690 V

VLT® HVAC Drive FC 102

Normal overload NO NO NO NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 525 V [kW] 55 75 90 110 132 Typical shaft output at 575 V [hp] 75 100 125 150 200 Typical shaft output at 690 V [kW] 75 90 110 132 160

Enclosure size D1h/D3h/D5h/D6h

Output current (3-phase)

Continuous (at 525 V) [A] 90 113 137 162 201 Intermittent (60 s overload) (at 525 V) [A] 99 124 151 178 221 Continuous (at 575/690 V) [A] 86 108 131 155 192 Intermittent (60 s overload)(at 575/690 V) [A] 95 119 144 171 211 Continuous kVA (at 525 V) [kVA] 82 103 125 147 183 Continuous kVA (at 575 V) [kVA] 86 108 131 154 191 Continuous kVA (at 690 V) [kVA] 103 129 157 185 230

Maximum input current

Continuous (at 525 V) [A] 87 109 132 156 193 Continuous (at 575/690 V) 83 104 126 149 185

Maximum number and size of cables per phase

- Mains, motor, brake, and load share [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 575 V [W]

Estimated power loss at 690 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 0–590 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)]

2), 3)

N75K N90K N110K N132 N160

2x95 (2x3/0) 2x95 (2x3/0) 2x95 (2x3/0) 2x95 (2x3/0) 2x95 (2x3/0)

160 315 315 315 315

1162 1428 1740 2101 2649

1204 1477 1798 2167 2740

0.98 0.98 0.98 0.98 0.98

110 (230) 110 (230) 110 (230) 110 (230) 110 (230)

75 (167) 75 (167) 75 (167) 75 (167) 75 (167)

7 7

Table 7.5 Electrical Data for Enclosures D1h/D3h/D5h/D6h, Mains Supply 3x525–690 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 7.5 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 52

Specications

VLT® HVAC Drive FC 102

High/normal overload NO NO NO NO

(Normal overload=110% current during 60 s) Typical Shaft output at 525 V [kW] 160 200 250 315 Typical Shaft output at 575 V [hp] 250 300 350 400 Typical Shaft output at 690 V [kW] 200 250 315 400

Enclosure size D2h/D4h/D7h/D8h

Output current (3-phase)

Continuous (at 525 V) [A] 253 303 360 418 Intermittent (60 s overload) (at 525 V)[A] 278 333 396 460 Continuous (at 575/690 V) [A] 242 290 344 400 Intermittent (60 s overload) (at 575/690 V) [A] 266 219 378 440 Continuous kVA (at 525 V) [kVA] 230 276 327 380 Continuous kVA (at 575 V) [kVA] 241 289 343 398 Continuous kVA (at 690 V) [kVA] 289 347 411 478

Maximum input current

Continuous (at 525 V) [A] 244 292 347 403

Continuous (at 575/690 V) 233 279 332 385

Maximum number and size of cables per phase

- Mains, motor, brake, and load share [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 575 V [W]

Estimated power loss at 690 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)]

2), 3)

N200 N250 N315 N400

2x185 (2x350) 2x185 (2x350) 2x185 (2x350) 2x185 (2x350)

550 550 550 550

3074 3723 4465 5028

3175 3851 4614 5155

0.98 0.98 0.98 0.98

110 (230) 110 (230) 110 (230) 110 (230)

80 (176) 80 (176) 80 (176) 80 (176)

Table 7.6 Electrical Data for Enclosures D2h/D4h/D7h/D8h, Mains Supply 3x525–690 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 7.5 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 53

Specications Design Guide

VLT® HVAC Drive FC 102

Normal overload NO NO NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 525 V [kW] 355 400 450 500 Typical shaft output at 575 V [hp] 450 500 600 650 Typical shaft output at 690 V [kW] 450 500 560 630

Enclosure size E1h/E3h E1h/E3h E1h/E3h E1h/E3h

Output current (3-phase)

Continuous (at 525 V) [A] 470 523 596 630 Intermittent (60 s overload) (at 525 V) [A] 517 575 656 693 Continuous (at 575/690 V) [A] 450 500 570 630 Intermittent (60 s overload) (at 575/690 V) [A] 495 550 627 693 Continuous kVA (at 525 V) [kVA] 448 498 568 600 Continuous kVA (at 575 V) [kVA] 448 498 568 627 Continuous kVA (at 690 V) [kVA] 538 598 681 753

Maximum input current

Continuous (at 525 V) [A] 453 504 574 607 Continuous (at 575/690 V) [A] 434 482 549 607

Maximum number and size of cables per phase (E1h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)]

- Brake or regeneration [mm2 (AWG)]

Maximum number and size of cables per phase (E3h)

- Mains and motor [mm2 (AWG)]

- Brake [mm2 (AWG)]

- Load share or regeneration [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]

Estimated power loss at 690 V [W]

Eciency

Output frequency [Hz] 0–500 0–500 0–500 0–500 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)] Power card overtemperature trip [°C (°F)] Fan power card overtemperature trip [°C (°F)] Active in-rush card overtemperature trip [°C (°F)]

2), 3)

N450 N500 N560 N630

5x240 (5x500 mcm) 5x240 (5x500 mcm) 5x240 (5x500 mcm) 6x240 (6x500 mcm)

4x240 (4x500 mcm) 4x240 (4x500 mcm) 4x240 (4x500 mcm) 5x240 (5x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm) 6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm) 4x185 (4x350 mcm) 4x185 (4x350 mcm)

800 800 800 800

6062 6879 8076 9208

5939 6715 7852 8921

0.98 0.98 0.98 0.98

110 (230) 110 (230) 110 (230) 110 (230)

80 (176) 80 (176) 80 (176) 80 (176) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185)

85 (185) 85 (185) 85 (185) 85 (185)

7 7

Table 7.7 Electrical Data for Enclosures E1h/E3h, Mains Supply 3x525–690 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 7.5 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 54

Specications

VLT® HVAC Drive FC 102

Normal overload NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 525 V [kW] 560 670 Typical shaft output at 575 V [hp] 750 950 Typical shaft output at 690 V [kW] 710 800

Enclosure size E2h/E4h E2h/E4h

Output current (3-phase)

Continuous (at 525 V) [A] 763 889 Intermittent (60 s overload) (at 525 V) [A] 839 978 Continuous (at 575/690 V) [A] 730 850 Intermittent (60 s overload) (at 575/690 V) [A] 803 935 Continuous kVA (at 525 V) [kVA] 727 847 Continuous kVA (at 575 V) [kVA] 727 847 Continuous kVA (at 690 V) [kVA] 872 1016

Maximum input current

Continuous (at 525 V) [A] 735 857

Continuous (at 575/690 V) [A] 704 819

Maximum number and size of cables per phase (E2h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)]

- Brake or regeneration [mm2 (AWG)]

Maximum number and size of cables per phase (E4h)

- Mains and motor [mm2 (AWG)]

- Brake [mm2 (AWG)]

- Load share or regeneration [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]

Estimated power loss at 690 V [W]

Eciency

Output frequency [Hz] 0–500 0–500 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)] Power card overtemperature trip [°C (°F)] Fan power card overtemperature trip [°C (°F)] Active in-rush card overtemperature trip [°C (°F)]

2), 3)

N710 N800

6x240 (6x500 mcm) 6x240 (6x500 mcm)

5x240 (5x500 mcm) 5x240 (5x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm)

1200 1200

10346 12723

10066 12321

0.98 0.98

110 (230) 110 (230)

80 (176) 80 (176) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185)

Table 7.8 Electrical Data for Enclosures E2h/E4h, Mains Supply 3x525–690 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 7.5 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 55

Specications Design Guide

7.3 Mains Supply

Mains supply (L1, L2, L3) Supply voltage 380–480 V ±10%, 525–690 V ±10%

Mains voltage low/mains voltage drop-out: During low mains voltage or a mains drop-out, the drive continues until the DC-link voltage drops below the minimum stop level, which corresponds typically to 15% below the lowest rated supply voltage of the drive. Power-up and full torque cannot be expected at mains voltage lower than 10% below the lowest rated supply voltage of the drive.

Supply frequency 50/60 Hz ±5% Maximum imbalance temporary between mains phases 3.0% of rated supply voltage True power factor (λ) ≥0.9 nominal at rated load Displacement power factor (cos Φ) near unity (>0.98) Switching on input supply L1, L2, L3 (power ups) Maximum 1 time/2 minute Environment according to EN60664-1 Overvoltage category III/pollution degree 2

The drive is suitable for use on a circuit capable of delivering up to 100 kA short circuit current rating (SCCR) at 480/600 V.

1) Calculations based on UL/IEC61800-3.

7.4 Motor Output and Motor Data

Motor output (U, V, W) Output voltage 0–100% of supply voltage Output frequency 0–590 Hz Output frequency in ux mode 0–300 Hz Switching on output Unlimited Ramp times 0.01–3600 s

1) Dependent on voltage and power.

Torque characteristics Starting torque (constant torque) Maximum 150% for 60 s Overload torque (constant torque) Maximum 150% for 60 s

1) Percentage relates to the nominal current of the drive.

2) Once every 10 minutes.

1), 2)

7.5 Ambient Conditions

Environment D1h/D2h/D5h/D6h/D7h/D8h/E1h/E2h enclosure IP21/Type 1, IP54/Type 12 D3h/D4h/E3h/E4h enclosure IP20/Chassis Vibration test (standard/ruggedized) 0.7 g/1.0 g Relative humidity 5%–95% (IEC 721-3-3; Class 3K3 (non-condensing) during operation) Aggressive environment (IEC 60068-2-43) H2S test Class Kd Aggressive gases (IEC 60721-3-3) Class 3C3 Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature (at SFAVM switching mode)

- with derating Maximum 55 °C (131 °F)

- with full output power of typical EFF2 motors (up to 90% output current) Maximum 50 °C (122 °F)

- at full continuous FC output current Maximum 45 °C (113 °F) Minimum ambient temperature during full-scale operation 0 °C (32 °F) Minimum ambient temperature at reduced performance -10 °C (14 °F) Temperature during storage/transport -25 to +65/70 °C (13 to 149/158 °F) Maximum altitude above sea level without derating 1000 m (3281 ft) Maximum altitude above sea level with derating 3000 m (9842 ft)

1) For more information on derating, see chapter 9.6 Derating.

7 7

Page 56

Specications

EMC standards, Emission EN 61800-3 EMC standards, Immunity EN 61800-3 Energy eciency class

1) Determined according to EN 50598-2 at:

Rated load.

•

90% rated frequency.

•

Switching frequency factory setting.

•

Switching pattern factory setting.

•

VLT® HVAC Drive FC 102

IE2

7.6 Cable Specications

Cable lengths and cross-sections for control cables Maximum motor cable length, shielded/armored 150 m (492 ft) Maximum motor cable length, unshielded/unarmored 300 m (984 ft) Maximum cross-section to motor, mains, load sharing, and brake See chapter 7 Specications Maximum cross-section to control terminals, rigid wire 1.5 mm2/16 AWG (2x0.75 mm2)

Maximum cross-section to control terminals, exible cable 1 mm2/18 AWG Maximum cross-section to control terminals, cable with enclosed core 0.5 mm2/20 AWG Minimum cross-section to control terminals 0.25 mm2/23 AWG

1) For power cables, see chapter 7.1 Electrical Data, 380–480 V and chapter 7.2 Electrical Data, 525–690 V.

7.7 Control Input/Output and Control Data

Digital inputs Programmable digital inputs 4 (6) Terminal number 18, 19, 271), 291), 32, 33 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic 0 PNP <5 V DC Voltage level, logic 1 PNP >10 V DC Voltage level, logic 0 NPN >19 V DC Voltage level, logic 1 NPN <14 V DC Maximum voltage on input 28 V DC Input resistance, R

All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

1) Terminals 27 and 29 can also be programmed as outputs.

Approximately 4 kΩ

Analog inputs Number of analog inputs 2 Terminal number 53, 54 Modes Voltage or current Mode select Switches A53 and A54 Voltage mode Switch A53/A54=(U) Voltage level -10 V to +10 V (scaleable) Input resistance, R Maximum voltage ±20 V Current mode Switch A53/A54=(I) Current level 0/4 to 20 mA (scaleable) Input resistance, R Maximum current 30 mA Resolution for analog inputs 10 bit (+ sign) Accuracy of analog inputs Maximum error 0.5% of full scale Bandwidth 100 Hz

The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Approximately 10 kΩ

Approximately 200 Ω

Page 57

Mains

Functional isolation

PELV isolation

Motor

DC-bus

High voltage

Control

+24 V

RS485

130BA117.10

Specications Design Guide

Illustration 7.1 PELV Isolation

Pulse inputs Programmable pulse inputs 2 Terminal number pulse 29, 33 Maximum frequency at terminal 29, 33 (push-pull driven) 110 kHz Maximum frequency at terminal 29, 33 (open collector) 5 kHz Minimum frequency at terminal 29, 33 4 Hz Voltage level See chapter 7.7.1 Digital Inputs Maximum voltage on input 28 V DC Input resistance, R

Approximately 4 kΩ

Pulse input accuracy (0.1–1 kHz) Maximum error: 0.1% of full scale

7 7

Analog output Number of programmable analog outputs 1 Terminal number 42 Current range at analog output 0/4–20 mA Maximum resistor load to common at analog output 500 Ω Accuracy on analog output Maximum error: 0.8% of full scale Resolution on analog output 8 bit

The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control card, RS485 serial communication Terminal number 68 (P, TX+, RX+), 69 (N, TX-, RX-) Terminal number 61 Common for terminals 68 and 69

The RS485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage (PELV).

Digital output Programmable digital/pulse outputs 2 Terminal number 27, 29 Voltage level at digital/frequency output 0–24 V Maximum output current (sink or source) 40 mA Maximum load at frequency output 1 kΩ Maximum capacitive load at frequency output 10 nF Minimum output frequency at frequency output 0 Hz Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Maximum error: 0.1% of full scale Resolution of frequency outputs 12 bit

1) Terminals 27 and 29 can also be programmed as inputs.

The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Page 58

Specications

Control card, 24 V DC output Terminal number 12, 13 Maximum 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.

Relay outputs Programmable relay outputs 2 Maximum cross-section to relay terminals 2.5 mm2 (12 AWG) Minimum cross-section to relay terminals 0.2 mm2 (30 AWG) Length of stripped wire 8 mm (0.3 in) Relay 01 terminal number 1–3 (break), 1–2 (make) Maximum terminal load (AC-1)1) on 1–2 (NO) (Resistive load) Maximum terminal load (AC-15)1) on 1–2 (NO) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 1–2 (NO) (Resistive load) 80 V DC, 2 A Maximum terminal load (DC-13)1) on 1–2 (NO) (Inductive load) 24 V DC, 0.1 A Maximum terminal load (AC-1)1) on 1–3 (NC) (Resistive load) 240 V AC, 2 A

Maximum terminal load (AC-15)1) on 1–3 (NC) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 1–3 (NC) (Resistive load) 50 V DC, 2 A Maximum terminal load (DC-13)1) on 1–3 (NC) (Inductive load) 24 V DC, 0.1 A Minimum terminal load on 1–3 (NC), 1–2 (NO) 24 V DC 10 mA, 24 V AC 2 mA Environment according to EN 60664-1 Overvoltage category III/pollution degree 2 Relay 02 terminal number 4–6 (break), 4–5 (make) Maximum terminal load (AC-1)1) on 4–5 (NO) (Resistive load) Maximum terminal load (AC-15)1) on 4–5 (NO) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 4–5 (NO) (Resistive load) 80 V DC, 2 A Maximum terminal load (DC-13)1) on 4–5 (NO) (Inductive load) 24 V DC, 0.1 A Maximum terminal load (AC-1)1) on 4–6 (NC) (Resistive load) 240 V AC, 2 A Maximum terminal load (AC-15)1) on 4–6 (NC) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 4–6 (NC) (Resistive load) 50 V DC, 2 A Maximum terminal load (DC-13)1) on 4–6 (NC) (Inductive load) 24 V DC, 0.1 A Minimum terminal load on 4–6 (NC), 4–5 (NO) 24 V DC 10 mA, 24 V AC 2 mA Environment according to EN 60664-1 Overvoltage category III/pollution degree 2

The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).

1) IEC 60947 part 4 and 5.

2) Overvoltage Category II.

3) UL applications 300 V AC 2 A.

VLT® HVAC Drive FC 102

2), 3)

400 V AC, 2 A

Control card, +10 V DC output Terminal number 50 Output voltage 10.5 V ±0.5 V Maximum load 25 mA

The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control characteristics Resolution of output frequency at 0–1000 Hz ±0.003 Hz System response time (terminals 18, 19, 27, 29, 32, 33) ≤2 m/s Speed control range (open loop) 1:100 of synchronous speed Speed accuracy (open loop) 30–4000 RPM: Maximum error of ±8 RPM

All control characteristics are based on a 4-pole asynchronous motor.

Page 59

Specications Design Guide

Control card performance Scan interval 5 M/S

Control card, USB serial communication USB standard 1.1 (full speed) USB plug USB type B device plug

NOTICE

Connection to PC is carried out via a standard host/device USB cable. The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is not galvanically isolated from ground. Use only isolated laptop/PC as connection to the USB connector on the drive or an isolated USB cable/converter.

7.8 Enclosure Weights

Enclosure 380–480/500 V 525–690 V

D1h 62 (137) 62 (137) D2h 125 (276) 125 (276) D3h 62 (137)

108 (238)

D4h 125 (276)

179 (395) D5h 99 (218) 99 (218) D6h 128 (282) 128 (282) D7h 185 (408) 185 (408) D8h 232 (512) 232 (512)

62 (137)

108 (238)

125 (276)

179 (395)

7 7

Table 7.9 Enclosure D1h–D8h Weights, kg (lb)

1) With optional load share and regen terminals.

Enclosure 380–480/500 V 525–690 V

E1h 295 (650) 295 (650) E2h 318 (700) 318 (700) E3h 272 (600) 272 (600) E4h 295 (650) 295 (650)

Table 7.10 Enclosure E1h–E4h Weights, kg (lb)

Page 60

130BE982.10

667 (26.3)

500 (19.7)

164 (6.5)

99 (3.9)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

8 Exterior and Terminal Dimensions

8.1 D1h Exterior and Terminal Dimensions

8.1.1 D1h Exterior Dimensions

Illustration 8.1 Front View of D1h

Page 61

378 (14.9)

82 (3.2)

148 (5.8)

20 (0.8)

844 (33.2)

561 (22.1)

18 (0.7)

130BF797.10

Exterior and Terminal Dimen... Design Guide

Illustration 8.2 Side View of D1h

8 8

Page 62

200 (7.9)

246 (9.7)

893 (35.2)

656 (25.8)

200 (7.9)

844 (33.2)

130 (5.1)

180 (7.1)

325 (12.8)

123 (4.8)

78 (3.1)

63 (2.5)

11 (0.4)

20 (0.8)

9 (0.3)

24 (0.9)

33 (1.3)

25 (1.0)

11 (0.4)

130BF798.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

Illustration 8.3 Back View of D1h

Page 63

130BF669.10

404 (15.9)

298 (11.7)

105

130BF607.10

205 (8.1)

138 (5.4)

274 (10.8)

27 (1.0)

137 (5.4)

Exterior and Terminal Dimen... Design Guide

Illustration 8.4 Door Clearance for D1h

8 8

1 Mains side 2 Motor side

Illustration 8.5 Gland Plate Dimensions for D1h

Page 64

88 (3.5)

0.0

200 (7.9)

130BF342.10

0.0

94 (3.7)

293 (11.5)

263 (10.4)

33 (1.3)

62 (2.4)

101 (4.0)

140 (5.5)

163 (6.4)

185 (7.3)

224 (8.8)

Exterior and Terminal Dimen...

8.1.2 D1h Terminal Dimensions

VLT® HVAC Drive FC 102

1 Mains terminals 3 Motor terminals 2 Ground terminals – –

Illustration 8.6 D1h Terminal Dimensions (Front View)

Page 65

130BF343.10

244 (9.6)

272 (10.7)

0.0

1 2

M10

32 (1.3)

13 (0.5)

32 (1.3)

13 (0.5)

Exterior and Terminal Dimen... Design Guide

1 Mains terminals 2 Motor terminals

Illustration 8.7 D1h Terminal Dimensions(Side Views)

8 8

Page 66

130BF321.10

96 (3.8)

211 (8.3)

602 (23.7)

871 (34.3)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

8.2 D2h Exterior and Terminal Dimensions

8.2.1 D2h Exterior Dimensions

Illustration 8.8 Front View of D2h

Page 67

130BF799.10

1050 (41.3)

718 (28.3)

148 (5.8)

18 (0.7)

378 (14.9)

142 (5.6)

20 (0.8)

Exterior and Terminal Dimen... Design Guide

Illustration 8.9 Side View of D2h

8 8

Page 68

1099 (43.3)

1051 (41.4)

107 (4.2)

320 (12.6)

213 (8.4)

857 (33.7)

130 (5.1)

420 (16.5)

346 (13.6)

280 (11.0)

271 (10.7)

9 (0.3)

20 (0.8)

11 (0.4)

75 (2.9)

24 (0.9)

11 (0.4)

33 (1.3)

130BF800.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

Illustration 8.10 Back View of D2h

Page 69

395 (15.6)

523 (20.6)

105

130BF670.10

130BF608.10

27 (1.0)

185 (7.3)

369 (14.5)

196 (7.7)

145 (5.7)

Exterior and Terminal Dimen... Design Guide

Illustration 8.11 Door Clearance for D2h

8 8

1 Mains side 2 Motor side

Illustration 8.12 Gland Plate Dimensions for D2h

Page 70

130BF345.10

143 (5.6)

168 (6.6)

331 (13.0)

211 (8.3)

168 (6.6)

143 (5.6)

42 (1.6)

68 (2.7)

126 (5.0)

184 (7.2)

246 (9.7)

300 (11.8)

354 (13.9)

378 (14.9)

0.0

Exterior and Terminal Dimen...

8.2.2 D2h Terminal Dimensions

VLT® HVAC Drive FC 102

1 Mains terminals 3 Motor terminals 2 Ground terminals – –

Illustration 8.13 D2h Terminal Dimensions (Front View)

Page 71

130BF346.10

0.0

1 2

255 (10.0)

284 (11.2)

M10

15 (0.6)

38 (1.5)

19 (0.8)

15 (0.6)

18 (0.7)

35 (1.4)

M10

Exterior and Terminal Dimen... Design Guide

8 8

1 Mains terminals 2 Motor terminals

Illustration 8.14 D2h Terminal Dimensions (Side Views)

Page 72

130BF322.10

61 (2.4)

128 (5.0)

495 (19.5)

660 (26.0)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

8.3 D3h Exterior and Terminal Dimensions

8.3.1 D3h Exterior Dimensions

Illustration 8.15 Front View of D3h

Page 73

148 (5.8)

20 (0.8)

130BF801.10

844 (33.2)

39 (1.5)

375 (14.8)

82 (3.2)

18 (0.7)

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.16 Side View of D3h

Page 74

656 (25.8)

200 (7.9)

130 (5.1)

889 (35.0)

909 (35.8)

844 (33.2)

78 (3.1)

123 (4.8)

250 (9.8)

180 (7.1)

33 (1.3)

11 (0.4)

25 (1.0)

11 (0.4)

20 (0.8)

9 (0.3)

24 (0.9)

25 (1.0)

M10

130BF802.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

Illustration 8.17 Back View of D3h

Page 75

130BF341.10

83 (3.3)

0.0

188 (7.4)

22 (0.9)

62 (2.4)

101 (4.0)

145 (5.7)

184 (7.2)

223 (8.8)

152 (6.0)

217 (8.5)

292 (11.5)

0.0

Exterior and Terminal Dimen... Design Guide

8.3.2 D3h Terminal Dimensions

1 Mains terminals 3 Motor terminals 2 Brake terminals 4 Ground terminals

Illustration 8.18 D3h Terminal Dimensions (Front View)

8 8

Page 76

M10

13 (0.5)

32 (1.3)

59 (2.3)

12 (0.5)

10 (0.4)

38 (1.5)

M10

244 (9.6)

290 (11.4)

272 (10.7)

130BF344.10

0.0

M10

13 (0.5)

32 (1.3)

145 (5.7)

182 (7.2)

3X M8x18

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 and 6 Bottom brake/regen terminals 3 and 5 Mains terminals 2 and 7 Motor terminals 4 Ground terminals

Illustration 8.19 D3h Terminal Dimensions (Side Views)

Page 77

130BF323.10

176 (6.9)

611 (24.1)

59 (2.3)

868 (34.2)

Exterior and Terminal Dimen... Design Guide

8.4 D4h Exterior and Terminal Dimensions

8.4.1 D4h Enclosure Dimensions

8 8

Illustration 8.20 Front View of D4h

Page 78

130BF803.10

20 (0.8)

148 (5.8)

18 (0.7)

1050 (41.3)

39 (1.5)

375 (14.8)

142 (5.6)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

Illustration 8.21 Side Dimensions for D4h

Page 79

130BF804.10

857 (33.7)

320 (12.6)

280 (11.0)

350 (13.8)

107 (4.2)

213 (8.4)

1122 (44.2)

1096 (43.1)

1051 (41.4)

271 (10.7)

130 (5.1)

25 (1.0)

33 (1.3)

11 (0.4)

40 (1.6)

11 (0.4)

9 (0.3)

20 (0.8)

24 (0.9)

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.22 Back Dimensions for D4h

Page 80

33 (1.3)

91 (3.6)

149 (5.8)

211 (8.3)

265 (10.4)

319 (12.6)

200 (7.9)

319 (12.6)

376 (14.8)

293 (11.5)

237 (9.3)

130BF347.10

0.0

o.o

Exterior and Terminal Dimen...

8.4.2 D4h Terminal Dimensions

VLT® HVAC Drive FC 102

1 Mains terminals 3 Motor terminals 2 Brake terminals 4 Ground terminals

Illustration 8.23 D4h Terminal Dimensions (Front View)

Page 81

91 (3.6)

13 (0.5)

200 (7.9)

259 (10.2)

3X M10X20

M10

19 (0.8)

38 (1.5)

255 (10.0)

306 (12.1)

284 (11.2)

130BF348.10

0.0

M10

22 (0.9)

35 (1.4)

15 (0.6)

18 (0.7)

M10

16 (0.6)

32 (1.3)

19 (0.7)

Exterior and Terminal Dimen... Design Guide

1 and 6 Brake/regeneration terminals 3 and 5 Mains terminals 2 and 7 Motor terminals 4 Ground terminals

8 8

Illustration 8.24 D4h Terminal Dimensions(Side Views)

Page 82

149 (5.9)

733 (28.9)

1107 (43.6)

130BF324.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

8.5 D5h Exterior and Terminal Dimensions

8.5.1 D5h Exterior Dimensions

Illustration 8.25 Front View of D5h

Page 83

130BF805.10

161 (6.3)

23 (0.9)

115 (4.5)

381 (15.0)

1277 (50.3)

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.26 Side View of D5h

Page 84

130BF806.10

1276 (50.2)

64 (2.5)

M10

325 (12.8)

306 (12.1)

276 (10.9)

180 (7.1)

130 (5.1)

123 (4.8)

78 (3.1)

200 (7.9)

1324 (52.1)

1111 (43.7)

130 (5.1)

123 (4.8)

78 (3.1

200 (7.9)

220 (8.7)

25 (1)

4X 11 (0.4)

63 (2.5)

15 (0.6)

11 (0.4)

24 (0.9)

20 (0.8)

9 (0.3)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

Illustration 8.27 Back View of D5h

Page 85

130BF828.10

433 (17.0)

670 (26.4)

218 (8.6)

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.28 Heat Sink Access Dimensions for D5h

Page 86

130BF669.10

404 (15.9)

298 (11.7)

105

111 (4.4)

224 (8.8)

242 (9.5)

121 (4.8)

43 (1.7)

1 2

130BF609.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

Illustration 8.29 Door Clearance for D5h

1 Mains side 2 Motor side

Illustration 8.30 Gland Plate Dimensions for D5h

Page 87

130BF349.10

0.0

45 (1.8)

46 (1.8)

99 (3.9)

153 (6.0)

146 (5.8)

182 (7.2)

193 (7.6)

249 (9.8)

221 (8.7)

260 (10.2)

118 (4.6)

148 (5.8)

90 (3.6)

196 (7.7)

227 (9.0)

221 (8.7)

Exterior and Terminal Dimen... Design Guide

8.5.2 D5h Terminal Dimensions

1 Mains terminals 3 Brake terminals 2 Ground terminals 4 Motor terminals

Illustration 8.31 D5h Terminal Dimensions with Disconnect Option (Front View)

8 8

Page 88

0.0

113 (4.4)

206 (8.1)

130BF350.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals 3 Motor terminals 2 Brake terminals – –

Illustration 8.32 D5h Terminal Dimensions with Disconnect Option (Side Views)

Page 89

130BF351.10

0.0

33 (1.3)

0.0

62 (2.4)

101 (4.0)

140 (5.5)

163 (6.4)

185 (7.3)

191 (7.5)

224 (8.8)

256 (10.1)

263 (10.4)

293 (11.5)

511 (20.1)

517 (20.4)

623 (24.5)

727 (28.6)

Exterior and Terminal Dimen... Design Guide

8 8

1 Mains terminals 3 Motor terminals 2 Brake terminals 4 Ground terminals

Illustration 8.33 D5h Terminal Dimensions with Brake Option (Front View)

Page 90

130BF352.10

246 (9.7)

293 (11.5)

274 (10.8)

0.0

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals 3 Motor terminals 2 Brake terminals – –

Illustration 8.34 D5h Terminal Dimensionswith Brake Option (Side Views)

Page 91

159 (6.3)

130BF325.10

909 (35.8)

1447 (57.0)

Exterior and Terminal Dimen... Design Guide

8.6 D6h Exterior and Terminal Dimensions

8.6.1 D6h Exterior Dimensions

8 8

Illustration 8.35 Front View of D6h

Page 92

130BF807.10

1617 (63.7)

181 (7.1)

23 (0.9)

115 (4.5)

381 (15.0)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

Illustration 8.36 Side View of D6h

Page 93

M10

25 (1)

4X 11 (0.4)

63 (2.5)

15 (0.6)

130BF808.10

325 (12.8)

306 (12.1)

276 (10.9)

180 (7.1)

130 (5.1)

1452 (57.2)

200 (7.9)

559 (22.0)

130 (5.1)

200 (7.9)

78 (3.1)

123 (4.8)

1615 (63.6)

1663 (65.5)

200 (7.9)

78 (3.1)

123 (4.8)

24 (0.9)

20 (0.8)

9 (0.1)

64 (3.0)

11 (0.4)

M10

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.37 Back View of D6h

Page 94

130BF829.10

433 (17.0)

1009 (39.7)

218 (8.6)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

Illustration 8.38 Heat Sink Access Dimensions for D6h

Page 95

130BF669.10

404 (15.9)

298 (11.7)

105

111 (4.4)

224 (8.8)

242 (9.5)

121 (4.8)

43 (1.7)

1 2

130BF609.10

Exterior and Terminal Dimen... Design Guide

Illustration 8.39 Door Clearance for D6h

8 8

1 Mains side 2 Motor side

Illustration 8.40 Gland Plate Dimensions for D6h

Page 96

130BF353.10

0.0

96 (3.8)

195 (7.7)

227 (8.9)

123 (4.8)

153 (6.0)

458 (18.0)

0.0

46 (1.8)

50 (2.0)

99 (3.9)

147 (5.8)

182 (7.2)

193 (7.6)

221 (8.7)

249 (9.8)

260 (10.2)

146 (5.8)

Exterior and Terminal Dimen...

8.6.2 D6h Terminal Dimensions

VLT® HVAC Drive FC 102

1 Mains terminals 4 Brake terminals 2 Ground terminals 5 Motor terminals 3 TB6 terminal block for contactor – –

Illustration 8.41 D6h Terminal Dimensions with Contactor Option (Front View)

Page 97

130BF534.10

0.0

286 (11.2)

113 (4.4)

206 (8.1)

Exterior and Terminal Dimen... Design Guide

1 Mains terminals 3 Motor terminals 2 Brake terminals – –

Illustration 8.42 D6h Terminal Dimensions with Contactor Option (Side Views)

8 8

Page 98

130BF355.10

99 (3.9)

153 (6.0)

0.0

225 (8.9)

45 (1.8)

0.0

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals 4 Brake terminals 2 Ground terminals 5 Motor terminals 3 TB6 terminal block for contactor – –

Illustration 8.43 D6h Terminal Dimensions with Contactor and Disconnect Options (Front View)

Page 99

130BF356.10

0.0

286 (11.2)

Exterior and Terminal Dimen... Design Guide

1 Brake terminals 3 Motor terminals 2 Mains terminals – –

Illustration 8.44 D6h Terminal Dimensions with Contactor and Disconnect Options (Side Views)

8 8

Page 100

130BF357.10

467 (18.4)

0.0

52 (2.1)

0.0

99 (3.9)

145 (5.7)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals 3 Brake terminals 2 Ground terminals 4 Motor terminals

Illustration 8.45 D6h Terminal Dimensions with Circuit Breaker Option (Front View)

Danfoss FC 102 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual