Danfoss FC 102 Design guide

Download

Page 1

ENGINEERING TOMORROW

Design Guide

VLT® HVAC Drive FC 102

355–1400 kW

vlt-drives.danfoss.com

Page 2

Page 3

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 Features

5.4 Basic Cascade Controller

5.5 Dynamic Braking Overview

5.6 Load Share Overview

5.7 Regen 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

6.9 Enclosure Built-in Options

Page 4

Contents

VLT® HVAC Drive FC 102

6.10 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

7.9 Airow for Enclosures E1–E2 and F1–F13

8 Exterior and Terminal Dimensions

8.1 E1 Exterior and Terminal Dimensions

8.2 E2 Exterior and Terminal Dimensions

8.3 F1 Exterior and Terminal Dimensions

8.4 F2 Exterior and Terminal Dimensions

8.5 F3 Exterior and Terminal Dimensions

8.6 F4 Exterior and Terminal Dimensions

8.7 F8 Exterior and Terminal Dimensions

8.8 F9 Exterior and Terminal Dimensions

8.9 F10 Exterior and Terminal Dimensions

8.10 F11 Exterior and Terminal Dimensions

8.11 F12 Exterior and Terminal Dimensions

8.12 F13 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

109

120

124

130

136

144

150

158

159

160

161

162

165

10.1 Safety Instructions

10.2 Wiring Schematic

10.3 Connections

10.4 Control Wiring and Terminals

10.5 Fuses and Circuit Breakers

10.6 Disconnects and Contactors

165

166

167

171

177

182

Page 5

Contents Design Guide

10.7 Motor

10.8 Braking

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

10.10 Leakage Current

10.11 IT Grid

10.12 Eciency

10.13 Acoustic Noise

10.14 dU/dt Conditions

10.15 Electromagnetic Compatibility (EMC) Overview

10.16 EMC-compliant Installation

10.17 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)

183

186

188

189

190

191

195

197

200

208

12.2 Wiring Congurations for Analog Speed Reference

12.3 Wiring Congurations for Start/Stop

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 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/Kits

13.3 Ordering Numbers for Filters and Brake Resistors

13.4 Spare Parts

208

209

210

211

212

213

214

216

220

223

14 Appendix

14.1 Abbreviations and Symbols

14.2 Denitions

14.3 RS485 Installation and Set-up

14.4 RS485: FC Protocol Overview

14.5 RS485: FC Protocol Telegram Structure

224

225

226

227

Page 6

Contents

VLT® HVAC Drive FC 102

14.6 RS485: FC Protocol Parameter Examples

14.7 RS485: Modbus RTU Overview

14.8 RS485: Modbus RTU Telegram Structure

14.9 RS485: Modbus RTU Message Function Codes

14.10 RS485: Modbus RTU Parameters

14.11 RS485: FC Control Prole

Index

231

232

233

236

237

244

Page 7

Introduction Design Guide

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.

1.2 Additional Resources

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

The operating guide provides detailed information

•

for the installation and start-up of the drive.

The programming guide provides greater detail on

•

how to work with parameters and includes many application examples.

The VLT

•

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

•

describes how to select the optimal brake resistor.

Safe Torque O Operating Guide

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

MG16C3xx Removed D1h–D8h content and

implemented new structure.

Table 1.1 Document and Software Version

5.11

1.4 Conventions

Numbered lists indicate procedures.

•

Bullet lists indicate other information and

•

description of illustrations.

Italicized text indicates:

•

- 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.

1 1

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

•

some of the information described in these publications. Be sure to see the instructions supplied with the options, for specic requirements.

Supplementary publications and manuals are available from Danfoss. See drives.danfoss.com/knowledge-center/ technical-documentation/ for listings.

Page 8

Safety

VLT® HVAC Drive FC 102

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.

WARNING

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be present even when the warning LED indicator lights are o. Failure to wait 40 minutes after power has been removed before performing service or repair work can result in death or serious injury.

1. Stop the motor.

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

3. Disconnect or lock motor.

4. Wait 40 minutes for the capacitors to discharge fully.

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

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.

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.

Ensure the correct grounding of the equipment

•

by a certied electrical installer.

WARNING

FIRE HAZARD

Brake resistors get hot during and after braking. Failure to place the brake resistor in a secure area can result in property damage and/or serious injury.

Ensure that the brake resistor is placed in a

•

secure environment to avoid re risk.

Do not touch the brake resistor during or after

•

braking to avoid serious burns.

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.

Page 9

e30bd832.10

Safety Design Guide

2.3.1 ADN-compliant Installation

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.

2 2

1, 2 Relay plugs

Illustration 2.1 Location of Relay Plugs

Page 10

Approvals and Certication...

VLT® HVAC Drive FC 102

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.

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.

Page 11

Approvals and Certication... Design Guide

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.

3.1.1.5 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

dierent marine classication societies have certied Danfoss drive series.

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

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 3

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.

3.1.1.7 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.

3.1.1.9 Marine

In order for ships and oil/gas platforms to receive a regulatory license and insurance, 1 or more marine certi- cation societies must certify these applications. Up to 12

Page 12

Approvals and Certication...

VLT® HVAC Drive FC 102

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

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:

50, Eleventh Edition.

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

•

Fibers

•

Lint

•

Dust and dirt

•

Light splashing

•

Seepage

•

Dripping and external condensation of noncorrosive liquids

•

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

Page 13

Approvals and Certication... Design Guide

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

3 3

Page 14

Product Overview

VLT® HVAC Drive FC 102

4 Product Overview

4.1 VLT® High-power Drives

The Danfoss 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. These drives come in 2 front-end congurations: 6-pulse and 12-pulse.

Benets of VLT® 6-pulse 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.

•

Benets of VLT® 12-pulse drives

The VLT® 12-pulse is a high components, which often require network analysis to avoid potential system resonance problems. The 12-pulse is built with

the same modular design as the popular 6-pulse VLT® drive. For more harmonic reduction methods, see the VLT® Advanced Harmonic Filter AHF 005/AHF 010 Design Guide.

The 12-pulse drives provide the same benets as the 6-pulse drives in addition to being:

Robust and highly stable in all network and operating conditions.

•

Ideal for applications where stepping down from medium voltage is required or where isolation from the grid is

•

needed.

Excellent input transient immunity.

•

Enclosure Size by Power Rating

4.2

315 450 – F8–F9 355 500 E1–E2 F8–F9 400 550 E1–E2 F8–F9 450 600 E1–E2 F8–F9 500 650 F1–F3 F10–F11 560 750 F1–F3 F10–F11 630 900 F1–F3 F10–F11 710 1000 F1–F3 F10–F11 800 1200 F2–F4 F12–F13 1000 1350 F2–F4 F12–F13

eciency AC drive that provides harmonic reduction without adding capacitive or inductive

Available enclosures

6-pulse 12-pulse

kW1)Hp

450 450 E1–E2 F8–F9 500 500 E1–E2 F8–F9 560 600 E1–E2 F8–F9 630 650 E1–E2 F8–F9 710 750 F1–F3 F10–F11 800 950 F1–F3 F10–F11

900 1050 F1–F3 F10–F11 1000 1150 F2–F4 F12–F13 1200 1350 F2–F4 F12–F13 1400 1550 F2–F4 F12–F13

Available enclosures

6-pulse 12-pulse

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).

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 15

Product Overview Design Guide

4.3 Overview of Enclosures, 380–480 V

Enclosure size E1 E2

Power rating

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

Front-end conguration

6-pulse S S 12-pulse – –

Protection rating

IP IP21/54 IP00 UL type Type 1/12 Chassis

Hardware options

4 4

Brake chopper (IGBTs) O O Safe Torque O O O Regen terminals O O Common motor terminals – – Emergency stop with Pilz safety relay – – Safe Torque O with Pilz safety relay – – No LCP – – Graphical LCP S S Numerical LCP O O Fuses O O Load share terminals O O Fuses + load share terminals O O Disconnect O O Circuit breakers – – Contactors – – Manual motor starters – – 30 A, fuse-protected terminals – – 24 V DC supply (SMPS, 5 A) O O External temperature monitoring – –

Dimensions

Height, mm (in) 2000 (78.8) 1547 (60.9) Width, mm (in) 600 (23.6) 585 (23.0) Depth, mm (in) 494 (19.4) 498 (19.5) Weight, kg (lb) 270–313 (595–690) 234–277 (516–611)

Table 4.3 E1–E2 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.

Page 16

Product Overview

Enclosure size F1 F2 F3 F4

Power rating

Output at 400 V (kW) 500–710 800–1000 500–710 800–1000 Output at 460 V (hp) 650–1000 1200–1350 650–1000 1200–1350

Front-end conguration

6-pulse S S S S 12-pulse – – – –

Protection rating

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

Hardware options

Stainless steel back channel O O O O Mains shielding – – – – Space heater and thermostat O O O O Cabinet light with power outlet O O O O RFI lter (Class A1) – – – – NAMUR terminals – – – – Insulation resistance monitor (IRM) – – O O Residual current monitor (RCM) – – O O Brake chopper (IGBTs) O O O O Safe Torque O O O O O Regen terminals O O O O Common motor terminals O O O O Emergency stop with Pilz safety relay – – O O Safe Torque O with Pilz safety relay O O O O No LCP – – – – Graphical LCP S S S S Numerical LCP – – – – Fuses O O O O Load share terminals O O O O Fuses + load share terminals O O O O Disconnect – – O O Circuit breakers – – O O Contactors – – O O Manual motor starters O O O O 30 A, fuse-protected terminals O O O O 24 V DC supply (SMPS, 5 A) O O O O External temperature monitoring O O O O

Dimensions

Height, mm (in) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) Width, mm (in) 1400 (55.1) 1800 (70.9) 2000 (78.7) 2400 (94.5) Depth, mm (in) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) Weight, kg (lb) 1017 (2242.1) 1260 (2777.9) 1318 (2905.7) 1561 (3441.5)

VLT® HVAC Drive FC 102

Table 4.4 F1–F4 Drives, 380–500 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.

Page 17

Product Overview Design Guide

Enclosure size F8 F9 F10 F11 F12 F13

Power rating

Output at 400 V (kW) 315–450 315–450 500–710 500–710 800–1000 800–1000 Output at 460 V (hp) 450–600 450–600 650–1000 650–1000 1200–1350 1200–1350

Front-end conguration

6-pulse – – – – – – 12-pulse S S S S S S

Protection rating

IP IP21/54 IP21/54 IP21/54 IP21/54 IP21/54 IP21/54 NEMA Type 1/12 Type 1/12 Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Stainless steel back channel – – – – – – Mains shielding – – – – – – Space heater and thermostat – – O O O O Cabinet light with power outlet RFI lter (Class A1) – O – – O O NAMUR terminals – – – – – – Insulation resistance monitor (IRM) Residual current monitor (RCM) Brake chopper (IGBTs) O O O O O O Safe Torque O O O O O O O Regen terminals – – – – – – Common motor terminals – – O O O O Emergency stop with Pilz safety relay Safe Torque O with Pilz safety relay No LCP – – – – – – Graphical LCP S S S S S S Numerical LCP – – – – – – Fuses O O O O O O Load share terminals – – – – – – Fuses + load share terminals – – – – – – Disconnect – O O O O O Circuit breakers – – – – – – Contactors – – – – – – Manual motor starters – – O O O O 30 A, fuse-protected terminals – – O O O O 24 V DC supply (SMPS, 5 A) O O O O O O External temperature monitoring

Dimensions

Height, mm (in) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) Width, mm (in) 800 (31.5) 1400 (55.2) 1600 (63.0) 2400 (94.5) 2000 (78.7) 2800 (110.2) Depth, mm (in) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) Weight, kg (lb) 447 (985.5) 669 (1474.9) 893 (1968.8) 1116 (2460.4) 1037 (2286.4) 1259 (2775.7)

– – O O O O

– O – – O O

– – – – – –

O O O O O O

– – O O O O

4 4

Table 4.5 F8–F13 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.

Page 18

Product Overview

VLT® HVAC Drive FC 102

4.4 Overview of Enclosures, 525–690 V

Enclosure size E1 E2

Power rating

Output at 690 V (kW) 450–630 450–630 Output at 575 V (hp) 450–650 450–650

Front-end conguration

6-pulse S S

12-pulse – –

Protection rating

IP IP21/54 IP00 UL type Type 1/12 Chassis

Hardware options

Stainless steel back channel – O Mains shielding O – Space heater and thermostat – – Cabinet light with power outlet – – RFI lter (Class A1) O O NAMUR terminals – – Insulation resistance monitor (IRM) – – Residual current monitor (RCM) – – Brake chopper (IGBTs) O O Safe Torque O S S Regen terminals O O Common motor terminals – – Emergency stop with Pilz safety relay – – Safe Torque O with Pilz safety relay – – No LCP – – Graphical LCP S S Numerical LCP O O Fuses O O Load share terminals O O Fuses + load share terminals O O Disconnect O O Circuit breakers – – Contactors – – Manual motor starters – – 30 A, fuse-protected terminals – – 24 V DC supply (SMPS, 5 A) O O External temperature monitoring – –

Dimensions

Height, mm (in) 2000 (78.8) 1547 (60.9) Width, mm (in) 600 (23.6) 585 (23.0) Depth, mm (in) 494 (19.4) 498 (19.5) Weight, kg (lb) 263–313 (580–690) 221–277 (487–611)

Table 4.6 E1–E2 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.

Page 19

Product Overview Design Guide

Enclosure size F1 F2 F3 F4

Power rating

Output at 690 V (kW) 710–900 1000–1400 710–900 1000–1400 Output at 575 V (hp) 750–1050 1150–1550 750–1050 1150–1550

Front-end conguration

6-pulse S S S S 12-pulse – – – –

Protection rating

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

Hardware options

Stainless steel back channel O O O O Mains shielding – – – – Space heater and thermostat O O O O Cabinet light with power outlet O O O O RFI lter (Class A1) – – O O NAMUR terminals – – – – Insulation resistance monitor (IRM) – – O O Residual current monitor (RCM) – – O O Brake chopper (IGBTs) O O O O Safe Torque O O O O O Regen terminals O O O O Common motor terminals O O O O Emergency stop with Pilz safety relay – – O O Safe Torque O with Pilz safety relay O O O O No LCP – – – – Graphical LCP S S S S Numerical LCP – – – – Fuses O O O O Load share terminals O O O O Fuses + load share terminals O O O O Disconnect – – O O Circuit breakers – – O O Contactors – – O O Manual motor starters O O O O 30 A, fuse-protected terminals O O O O 24 V DC supply (SMPS, 5 A) O O O O External temperature monitoring O O O O

Dimensions

4 4

Table 4.7 F1–F4 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.

Page 20

Product Overview

Enclosure size F8 F9 F10 F11 F12 F13

Power rating

Output at 690 V (kW) 450–630 450–630 710–900 710–900 1000–1400 1000–1400 Output at 575 V (hp) 450–650 450–650 750–1050 750–1050 1150–1550 1150–1550

Front-end conguration

6-pulse – – – – – – 12-pulse S S S S S S

Protection rating

IP IP21/54 IP21/54 IP21/54 IP21/54 IP21/54 IP21/54 NEMA Type 1/12 Type 1/12 Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Dimensions

Height, mm (in) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) Width, mm (in) 800 (31.5) 1400 (55.1) 1600 (63.0) 2400 (94.5) 2000 (78.7) 2800 (110.2) Depth, mm (in) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) Weight, kg (lb) 447 (985.5) 669 (1474.9) 893 (1968.8) 1116 (2460.4) 1037 (2286.4) 1259 (2775.7)

– – O O O O

– O – – O O

– – – – – –

O O O O O O

– – O O O O

VLT® HVAC Drive FC 102

Table 4.8 F8–F13 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.

Page 21

Product Overview Design Guide

4.5 Kit Availability

Kit description

USB in door O – O O O O O O O O O O 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) Top entry for motor cables – – O O O O O O O O O O Top entry for mains cables – – O O O O O O O O O O Top entry for mains cables with disconnect – – – – O O – – – – – – Top entry for eldbus cables – O – – – – – – – – – – Common motor terminals – – O O O O – – – – – – NEMA 3R enclosure – O – – – – – – – – – – Pedestal O O – – – – – – – – – – Input options plate O O – – – – – – – – – – IP20 conversion – O – – – – – – – – – – Out top (only) cooling – O – – – – – – – – – – Back-channel cooling (in-back/out-back) O O O O O O O O O O O O Back-channel cooling (in-bottom/out-top) – O – – – – – – – – – –

E1 E2 F1 F2 F3 F4 F8 F9 F10 F11 F12 F13

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

4 4

Table 4.9 Available Kits for Enclosures E1–E2, F1–F4, and F8–F13

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 Ordering Numbers for Options/Kits.

2) The graphical LCP comes standard with enclosures E1–E2, F1–F4, and F8–F13. If more than 1 graphical LCP is required, the kit is available for

purchase.

Page 22

Product Features

VLT® HVAC Drive FC 102

5 Product Features

Incorrect slip compensation setting causing

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 permitted 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 (rst 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

•

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.

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 23

Product Features Design Guide

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 Function at 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.

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

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 drives can also force the PWM pattern to SFAVM.

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.

5 5

Page 24

Product Features

VLT® HVAC Drive FC 102

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 10.15.1 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

5.1.13 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 25

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 Design Guide

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.

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

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.

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.

5 5

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 26

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

VLT® HVAC Drive FC 102

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.

•

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

Minimum motor frequency.

•

Maximum motor frequency.

•

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)

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 27

. . . . . .

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 Design Guide

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:

5 5

Illustration 5.4 Order of Execution when 4 Events/Actions are

Programmed

Page 28

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

VLT® HVAC Drive FC 102

Comparators

Specic VLT® HVAC Drive Features

5.3

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

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.

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.

When comparing with alternative control systems and technologies, a drive is the optimum energy control system for controlling fan and pump systems.

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 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 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 29

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 Design Guide

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, 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

 = 

Illustration 5.9 Laws of Proportionality

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.

5 5

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 30

500

[h]

1000

1500

2000

200100 300

/h]

400

175HA210.11

Product Features

VLT® HVAC Drive FC 102

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 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

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 31

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 Design Guide

5 5

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 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 32

- +

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

VLT® HVAC Drive FC 102

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

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 33

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 Design Guide

Cost with a drive

5 5

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

Illustration 5.15 Fan System Controlled by Drives

Page 34

Frequency converter

Cooling coil

Heating coil

Filter

Pressure signal

Supply fan

VAV boxes

Flow

Pressure transmitter

Return fan

130BB455.10

Product Features

5.3.4

VLT® HVAC Solutions

VLT® HVAC Drive FC 102

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.

Illustration 5.16 Drives Used in a Variable Air Volume System

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.

Page 35

Frequency converter

Pressure signal

Cooling coil

Heating coil

Filter

Pressure transmitter

Supply fan

Return fan

Temperature signal

Temperature transmitter

130BB451.10

Product Features Design Guide

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.

5 5

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

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

Page 36

Frequency converter

Water Inlet

Water Outlet

CHILLER

Temperature Sensor

BASIN

Conderser Water pump

Supply

130BB453.10

Product Features

VLT® HVAC Drive FC 102

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.

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.

Page 37

Frequency converter

Water Inlet

Water Outlet

BASIN

Flow or pressure sensor

Condenser Water pump

Throttling valve

Supply

CHILLER

130BB452.10

Product Features Design Guide

5 5

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 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

Page 38

Frequency converter

CHILLER

Flowmeter

F F

130BB456.10

Product Features

VLT® HVAC Drive FC 102

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.

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 39

Frequency converter

CHILLER

130BB454.10

Product Features Design Guide

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 one 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.

5 5

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 40

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

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.

VLT® HVAC Drive FC 102

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

o.

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

Whenever an alternation timer expires.

•

At a predened time of day.

•

When the lead pump goes into sleep mode.

•

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 minimize pressure uctuations, a wider xed speed bandwidth is used instead of the staging bandwidth.

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 41

Product Features Design Guide

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.

5 5

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 42

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

VLT® HVAC Drive FC 102

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. Only VLT® HVAC Drive drives used with other VLT® HVAC Drive 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.

•

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

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

Page 43

Product Features Design Guide

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.

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.

5 5

Returning excess energy back to the power grid is the most continuous braking.

ecient use of regenerated energy in applications using

Page 44

Options and Accessories Ove...

VLT® HVAC Drive FC 102

6 Options and Accessories Overview

6.1 Fieldbus Devices

This section describes the eldbus devices that are available with the VLT® HVAC Drive 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/Kits.

6.1.1

VLT® PROFIBUS DP-V1 MCA 101

The 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

6.1.2

VLT® DeviceNet MCA 104

prole state machines.

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 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 (exible

•

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.

The MCA 120 option 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 45

Options and Accessories Ove... Design Guide

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 option 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.

MCA 121

6.1.7

oers advanced features such as:

Built-in, high-performance switch enabling line-

•

topology, 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 series. For ordering

numbers, refer to chapter 13.2 Ordering Numbers for Options/Kits.

6.2.1

VLT® General Purpose I/O Module MCB 101

The MCA 122 option connects to Modbus TCP-based 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 MCB 101 option 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 MCB 105 option 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 46

Options and Accessories Ove...

VLT® HVAC Drive FC 102

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 MCB 114 option 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® AutomationDrive

series. For ordering numbers, refer to chapter 13.2 Ordering Numbers for Options/Kits.

6.3.1

VLT® Extended Relay Card MCB 113

The MCB 113 option adds 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 47

Options and Accessories Ove... Design Guide

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.

For ordering numbers refer to the Output Filters Design Guide.

lters reduce high-frequency common-

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.

Enclosure Built-in Options

6.9

The following built-in options are specied in the type code when ordering the drive.

Enclosure with corrosion-resistant back channel

For extra protection from corrosion in harsh environments, units can be ordered in an enclosure that includes a stainless steel back channel, heavier plated heat sinks, and an upgraded fan. This option is recommended in salt-air environments, such as those near the ocean.

Mains shielding

Lexan® shielding can be mounted in front of incoming power terminals and input plate to protect against physical contact when the enclosure door is open.

Space heaters and thermostat

Mounted in the cabinet interior of enclosure size F drives and controlled via an automatic thermostat, space heaters controlled via an automatic thermostat prevent condensation inside the enclosure.

The thermostat default settings turn on the heaters at 10 °C (50 °F) and turn them

o at 15.6 °C (60 °F).

Cabinet light with power outlet

To increase visibility during servicing and maintenance, a light can be mounted on the cabinet interior of enclosure F drives. The light housing includes a power outlet for temporarily powering laptop computers or other devices. Available in 2 voltages:

230 V, 50 Hz, 2.5 A, CE/ENEC

•

120 V, 60 Hz, 5 A, UL/cUL

•

RFI lters

VLT® drive series feature integrated Class A2 RFI lters as standard. If extra levels of RFI/EMC protection are required, they can be obtained using optional Class A1 RFI lters, which provide suppression of radio frequency interference and electromagnetic radiation in accordance with EN

55011. Marine use RFI lters are also available.

On enclosure size F drives, the Class A1 RFI lter requires the addition of the options cabinet.

Insulation resistance monitor (IRM)

Monitors the insulation resistance in ungrounded systems (IT systems in IEC terminology) between the system phase conductors and ground. There is an ohmic pre-warning and a main alarm setpoint for the insulation level. Associated with each setpoint is an SPDT alarm relay for external use. Only 1 insulation resistance monitor can be connected to each ungrounded (IT) system.

Integrated into the safe-stop circuit.

•

LCD display of insulation resistance.

•

Fault memory.

•

Info, test, and reset key.

•

Residual current device (RCD)

Uses the core balance method to monitor ground fault currents in grounded and high-resistance grounded systems (TN and TT systems in IEC terminology). There is a pre-warning (50% of main alarm setpoint) and a main alarm setpoint. Associated with each setpoint is an SPDT alarm relay for external use. Requires an external windowtype current transformer (supplied and installed by customer).

Integrated into the safe-stop circuit.

•

IEC 60755 Type B device monitors, pulsed DC,

•

and pure DC ground fault currents.

LED bar graph indicator of the ground fault

•

current level from 10–100% of the setpoint.

Fault memory.

•

Test and reset key.

•

Safe Torque

Available for drives with enclosure size F. Enables the Pilz relay to t in the enclosure without requiring an options cabinet. The relay is used in the external temperature monitoring option. If PTC monitoring is required, order the

VLT® PTC Thermistor Card MCB 112.

O with Pilz safety relay

Page 48

Options and Accessories Ove...

VLT® HVAC Drive FC 102

Emergency stop with Pilz safety relay

Includes a redundant 4-wire emergency stop push button mounted on the front of the enclosure, and a Pilz relay that monitors it along with the safe-stop circuit and contactor position. Requires a contactor and the options cabinet for drives with enclosure size F.

Brake chopper (IGBTs)

Brake terminals with an IGBT brake chopper circuit allow for the connection of external brake resistors. For detailed

data on brake resistors, see the VLT® Brake Resistor MCE 101

Design Guide, available at drives.danfoss.com/downloads/ portal/#/.

Regen terminals

Allow connection of regen units to the DC bus on the capacitor bank side of the DC-link reactors for regenerative braking. The enclosure size F regen terminals are sized for approximately 50% the power rating of the drive. Consult the factory for regen power limits based on the specic drive size and voltage.

Load sharing terminals

These terminals connect to the DC-bus on the of the DC-link reactor and allow for the sharing of DC bus power between multiple drives. For drives with enclosure size F, the load sharing terminals are sized for approximately 33% of the power rating of the drive. Consult the factory for load sharing limits based on the specic drive size and voltage.

Disconnect

A door-mounted handle allows for the manual operation of a power disconnect switch to enable and disable power to the drive, increasing safety during servicing. The disconnect is interlocked with the cabinet doors to prevent them from being opened while power is still applied.

Circuit breakers

A circuit breaker can be remotely tripped, but must be manually reset. Circuit breakers are interlocked with the cabinet doors to prevent them from being opened while power is still applied. When a circuit breaker is ordered as an option, fuses are also included for fast-acting current overload protection of the AC drive.

Contactors

An electrically-controlled contactor switch allows for the remote enabling and disabling of power to the drive. If the IEC emergency stop option is ordered, the Pilz relay monitors the auxiliary contact on the contactor.

Manual motor starters

Provide 3-phase power for electric cooling blowers that are often required for larger motors. Power for the starters is provided from the load side of any supplied contactor, circuit breaker, or disconnect switch. If a Class 1 RFI lter option is ordered, the input side of the RFI provides the power to the starter. Power is fused before each motor starter and is o when the incoming power to the drive is

o. Up to 2 starters are allowed. If a 30 A fuse-protected

rectier side

circuit is ordered, then only 1 starter is allowed. Starters are integrated into the safe-stop circuit. Features include:

Operation switch (on/o).

•

Short circuit and overload protection with test

•

function.

Manual reset function.

•

30 A, fuse-protected terminals

3-phase power matching incoming mains voltage

•

for powering auxiliary customer equipment.

Not available if 2 manual motor starters are

•

selected.

Terminals are o when the incoming power to

•

the drive is o.

Power for the terminals is provided from the load

•

side of any supplied contactor, circuit breaker, or disconnect switch. If a Class 1 RFI lter option is ordered, the input side of the RFI provides the power to the starter.

Common motor terminals

The common motor terminal option provides the busbars and hardware required to connect the motor terminals from the paralleled inverters to a single terminal (per phase) to accommodate the installation of the motor-side top entry kit.

This option is also recommended to connect the output of a drive to an output lter or output contactor. The common motor terminals eliminate the need for equal cable lengths from each inverter to the common point of the output lter (or motor).

24 V DC supply

5 A, 120 W, 24 V DC.

•

Protected against output overcurrent, overload,

•

short circuits, and overtemperature.

For powering customer-supplied accessory

•

devices such as sensors, PLC I/O, contactors, temperature probes, indicator lights, and/or other electronic hardware.

Diagnostics include a dry DC-ok contact, a green

•

DC-ok LED, and a red overload LED.

External temperature monitoring

Designed for monitoring temperatures of external system components, such as the motor windings and/or bearings. Includes 8 universal input modules plus 2 dedicated thermistor input modules. All 10 modules are integrated into the safe-stop circuit and can be monitored via a eldbus network, which requires the purchase of a separate module/bus coupler. A Safe Torque O brake option must be ordered when selecting external temperature monitoring.

Page 49

Options and Accessories Ove... Design Guide

Signal types

RTD inputs (including Pt100) – 3-wire or 4-wire.

•

Thermocouple.

•

Analog current or analog voltage.

•

More features

1 universal output – congurable for analog

•

voltage or analog current.

2 output relays (NO).

•

Dual-line LC display and LED diagnostics.

•

Sensor lead wire break, short circuit, and incorrect

•

polarity detection.

Sensor lead wire break, short circuit, and incorrect

•

polarity detection.

Interface set-up software.

•

If 3 PTC are required, the VLT® PTC Thermistor

•

Card MCB 112 option must be added.

Ordering numbers for enclosure built-in options can be found in chapter 13.1 Drive

Congurator.

6.10 High-power Kits

High-power kits, such as back-wall cooling, space heater, mains shield, are available. See chapter 13.2 Ordering Numbers for Options/Kits for a brief description and ordering numbers for all available kits.

Page 50

Specications

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] 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 E1/E2 E1/E2 E1/E2

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

Mains and motor [mm2 (AWG)]

Brake [mm2 (AWG)]

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 Control card overtemperature trip [°C (°F)]

2), 3)

P355 P400 P450

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

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

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

900 900 900

7532 8677 9473

6724 7819 8527

0.98 0.98 0.98

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

Table 7.1 Electrical Data for Enclosures E1/E2, 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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

VLT® HVAC Drive FC 102

Normal overload NO NO NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 500 560 630 710 Typical shaft output at 460 V [hp] 650 750 900 1000 Typical shaft output at 480 V [kW] 560 630 710 800

Enclosure size F1/F3 F1/F3 F1/F3 F1/F3

Output current (3-phase)

Continuous (at 400 V) [A] 880 990 1120 1260 Intermittent (60 s overload) (at 400 V) [A] 968 1089 1680 1890 Continuous (at 460/480 V) [A] 780 890 1050 1160 Intermittent (60 s overload) (at 460/480 V) [A] Continuous kVA (at 400 V) [kVA] 610 686 776 873 Continuous kVA (at 460 V) [kVA] 621 709 837 924 Continuous kVA (at 480 V) [kVA] 675 771 909 1005

Maximum input current

Continuous (at 400 V) [A] 848 954 1079 1214 Continuous (at 460/480 V) [A] 752 858 1012 1118

Maximum number and size of cables per phase

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)] (F1)

- Mains [mm2 (AWG)] (F3)

- Load share [mm2 (AWG)]

- Brake [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W] Maximum added losses A1 RFI, circuit breaker or disconnect, and contactor [W], (F3 only) Maximum panel options losses [W] 400 400 400 400

Eciency

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

2), 3)

P500 P560 P630 P710

858 979 1155 1276

8x150 (8x300

mcm)

8x240 (8x500

mcm)

8x456 (8x900

mcm)

8x120 (8x250

mcm)

8x185 (8x350

mcm)

1600 1600 2000 2000

10162 11822 12512 14674

8876 10424 11595 13213

963 1054 1093 1230

0.98 0.98 0.98 0.98

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

8x150 (8x300

mcm)

8x240 (8x500

mcm)

8x456 (8x900

mcm)

8x120 (8x250

mcm)

8x185 (8x350

mcm)

8x150 (8x300

mcm)

8x240 (8x500

mcm)

8x456 (8x900

mcm)

8x120 (8x250

mcm)

8x185 (8x350

mcm)

8x150 (8x300

8x240 (8x500

8x456 (8x900

8x120 (8x250

8x185 (8x350

mcm)

7 7

Table 7.2 Electrical Data for Enclosures F1/F3, 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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

Normal overload NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 800 1000 Typical shaft output at 460 V [hp] 1200 1350 Typical shaft output at 480 V [kW] 1000 1100

Enclosure size F2/F4 F2/F4

Output current (3-phase)

Continuous (at 400 V) [A] 1460 1720 Intermittent (60 s overload) (at 400 V) [A] Continuous (at 460/480 V) [A] 1380 1530 Intermittent (60 s overload)(at 460/480 V) [A] 1518 1683 Continuous kVA (at 400 V) [kVA] 1012 1192 Continuous kVA (at 460 V) [kVA] 1100 1219 Continuous kVA (at 480 V) [kVA] 1195 1325

Maximum input current

Continuous (at 400 V) [A] 1407 1658 Continuous (at 460/480 V) [A] 1330 1474

Maximum number and size of cables per phase

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)] (F2)

- Mains [mm2 (AWG)] (F4)

- Load share [mm2 (AWG)]

- Brake [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W] Maximum added losses A1 RFI, circuit breaker or disconnect, and contactor [W], (F4 only) 2280 2541 Maximum panel options losses [W] 400 400

Eciency

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

2), 3)

P800 P1000

1606 1892

12x150 (12x300

mcm) 8x240 (8x500 mcm) 8x240 (8x500 mcm)

8x456 (8x900 mcm) 8x456 (8x900 mcm)

4x120 (4x250 mcm) 4x120 (4x250 mcm)

6x185 (6x350 mcm) 6x185 (6x350 mcm)

2500 2500

17293 19278

16229 16624

0.98 0.98

85 (185) 85 (185)

12x150 (12x300

mcm)

Table 7.3 Electrical Data for Enclosures F2/F4, 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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

(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 F8/F9 F8/F9 F8/F9

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

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)]

- Brake [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 Control card overtemperature trip [°C (°F)]

2), 3)

P355 P400 P450

4x240 (4x500

mcm)

4x90 (4x3/0 mcm) 4x240 (4x500

2x185 (2x350

mcm)

700 700 700

7701 8879 9670

6953 8089 8803

0.98 0.98 0.98

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

4x240 (4x500

mcm)

2x185 (2x350

mcm)

4x240 (4x500

mcm)

4x240 (4x500

mcm)

2x185 (2x350

mcm)

7 7

Table 7.4 Electrical Data for Enclosures F8/F9, Mains Supply 6x380–480 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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 NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 500 560 630 710 Typical shaft output at 460 V [hp] 650 750 900 1000 Typical shaft output at 480 V [kW] 560 630 710 800

Enclosure size F10/F11 F10/F11 F10/F11 F10/F11

Output current (3-phase)

Continuous (at 400 V) [A] 880 990 1120 1260 Intermittent (60 s overload) (at 400 V) [A] 968 1089 1232 1386 Continuous (at 460/480 V) [A] 780 890 1050 1160 Intermittent (60 s overload) (at 460/480 V) [A] 858 979 1155 1276 Continuous kVA (at 400 V) [kVA] 610 686 776 873 Continuous kVA (at 460 V) [kVA] 621 709 837 924 Continuous kVA (at 480 V) [kVA] 675 771 909 1005

Maximum input current

Continuous (at 400 V) [A] 848 954 1079 1214

Continuous (at 460/480 V) [A] 752 858 1012 1118

Maximum number and size of cables per phase

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)]

- Brake [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W] Maximum added losses A1 RFI, circuit breaker or disconnect, and contactor [W], (F11 only) Maximum panel options losses [W] 400 400 400 400

Eciency

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

2), 3)

P500 P560 P630 P710

8x150 (8x300

mcm)

6x120 (6x250

mcm)

4x185 (4x350

mcm)

900 900 900 1500

10647 12338 13201 15436

9414 11006 12353 14041

963 1054 1093 1230

0.98 0.98 0.98 0.98

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

8x150 (8x300

mcm)

6x120 (6x250

mcm)

4x185 (4x350

mcm)

8x150 (8x300

mcm)

6x120 (6x250

mcm)

4x185 (4x350

mcm)

8x150 (8x300

6x120 (6x250

4x185 (4x350

mcm)

Table 7.5 Electrical Data for Enclosures F10/F11, Mains Supply 6x380–480 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 ±15% (tolerance relates to variety in voltage and cable conditions). These

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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

Page 55

Specications Design Guide

VLT® HVAC Drive FC 102

Normal overload NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 800 1000 Typical shaft output at 460 V [hp] 1200 1350 Typical shaft output at 480 V [kW] 1000 1100

Enclosure size F12/F13 F12/F13

Output current (3-phase)

Continuous (at 400 V) [A] 1460 1720 Intermittent (60 s overload) (at 400 V) [A] 1606 1892 Continuous (at 460/480 V) [A] 1380 1530 Intermittent (60 s overload)(at 460/480 V) [A] 1518 1683 Continuous kVA (at 400 V) [kVA] 1012 1192 Continuous kVA (at 460 V) [kVA] 1100 1219 Continuous kVA (at 480 V) [kVA] 1195 1325

Maximum input current

Continuous (at 400 V) [A] 1407 1658 Continuous (at 460/480 V) [A] 1330 1474

Maximum number and size of cables per phase

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)]

- Brake [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W] Maximum added losses A1 RFI, circuit breaker or disconnect, and contactor [W], (F4 only) 2280 2541 Maximum panel options losses [W] 400 400

Eciency

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

2), 3)

P800 P1000

12x150 (12x300

mcm) 6x120 (6x250 mcm) 6x120 (6x250 mcm)

6x185 (6x350 mcm) 6x185 (6x350 mcm)

1500 1500

18084 20358

17137 17752

0.98 0.98

85 (185) 85 (185)

12x150 (12x300

mcm)

7 7

Table 7.6 Electrical Data for Enclosures F12/F13, Mains Supply 6x380–480 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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 56

Specications

7.2 Electrical Data, 525–690 V

VLT® HVAC Drive FC 102

Normal overload NO NO NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 550 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 E1/E2 E1/E2 E1/E2 E1/E2

Output current (3-phase)

Continuous (at 550 V) [A] 470 523 596 630 Intermittent (60 s overload) (at 550 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 550 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 550 V) [A] 453 504 574 607 Continuous (at 575 V) [A] 434 482 549 607 Continuous (at 690 V) 434 482 549 607

Maximum number and size of cables per phase

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

- Brake [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 Control card overtemperature trip [°C (°F)]

2), 3)

P450 P500 P560 P630

4x240 (4x500

mcm)

2x185 (2x350

mcm)

700 700 900 900

5323 6010 7395 8209

5529 6239 7653 8495

0.98 0.98 0.98 0.98

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

4x240 (4x500

mcm)

2x185 (2x350

mcm)

4x240 (4x500

mcm)

2x185 (2x350

mcm)

4x240 (4x500

2x185 (2x350

mcm)

Table 7.7 Electrical Data for Enclosures E1/E2, 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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 57

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 550 V [kW] 560 670 750 Typical shaft output at 575 V [hp] 750 950 1050 Typical shaft output at 690 V [kW] 710 800 900

Enclosure size F1/F3 F1/F3 F1/F3

Output current (3-phase)

Continuous (at 550 V) [A] 763 889 988 Intermittent (60 s overload) (at 550 V) [A] 839 978 1087 Continuous (at 575/690 V) [A] 730 850 945 Intermittent (60 s overload) (at 575/690 V) [A] 803 935 1040 Continuous kVA (at 550 V) [kVA] 727 847 941 Continuous kVA (at 575 V) [kVA] 727 847 941 Continuous kVA (at 690 V) [kVA] 872 1016 1129

Maximum input current

Continuous (at 550 V) [A] 735 857 952 Continuous (at 575 V) [A] 704 819 911 Continuous (at 690 V) [A] 704 819 911

Maximum number and size of cables per phase

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)] (F1)

- Mains [mm2 (AWG)] (F3)

- Load share [mm2 (AWG)]

- Brake [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]

Estimated power loss at 690 V [W] Maximum added losses for circuit breaker or disconnect and contactor [W], (F3 only) Maximum panel options losses [W] 400 400 400

Eciency

Output frequency [Hz] 0–500 0–500 0–500 Control card overtemperature trip [°C (°F)]

2), 3)

P710 P800 P900

8x150 (8x300 mcm) 8x150 (8x300 mcm) 8x150 (8x300

mcm)

8x240 (8x500 mcm) 8x240 (8x500 mcm) 8x240 (8x500

mcm)

8x456 (4x900 mcm) 8x456 (4x900 mcm) 8x456 (4x900

mcm)

4x120 (4x250 mcm) 4x120 (4x250 mcm) 4x120 (4x250

mcm)

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

mcm) 1600 1600 1600

9500 10872 12316

9863 11304 12798

427 532 615

0.98 0.98 0.98

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

7 7

Table 7.8 Electrical Data for Enclosures F1/F3, 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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 58

Specications

VLT® HVAC Drive FC 102

Normal overload NO NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 550 V [kW] 850 1000 1100 Typical shaft output at 575 V [hp] 1150 1350 1550 Typical shaft output at 690 V [kW] 1000 1200 1400

Enclosure size F2/F4 F2/F4 F2/F4

Output current (3-phase)

Continuous (at 550 V) [A] 1108 1317 1479 Intermittent (60 s overload) (at 550 V) [A] 1219 1449 1627 Continuous (at 575/690 V) [A] 1060 1260 1415 Intermittent (60 s overload) (at 575/690 V) [A] 1166 1386 1557 Continuous kVA (at 550 V) [kVA] 1056 1255 1409 Continuous kVA (at 575 V) [kVA] 1056 1255 1409 Continuous kVA (at 690 V) [kVA] 1267 1506 1691

Maximum input current

Continuous (at 550 V) [A] 1068 1269 1425

Continuous (at 575 V) [A] 1022 1214 1364 Continuous (at 690 V) [A] 1022 1214 1364

Maximum number and size of cables per phase

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)] (F2)

- Mains [mm2 (AWG)] (F4)

- Load share [mm2 (AWG)]

- Brake [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]

Estimated power loss at 690 V [W] Maximum added losses for circuit breaker or disconnect and contactor [W], (F4 only) Maximum panel options losses [W] 400 400 400

Eciency

Output frequency [Hz] 0–500 0–500 0–500 Control card overtemperature trip [°C (°F)]

2), 3)

P1M0 P1M2 P1M4

12x150 (12x300

mcm) 8x240 (8x500 mcm) 8x240 (8x500 mcm) 8x240 (8x500 mcm)

8x456 (8x900 mcm) 8x456 (8x900 mcm) 8x456 (8x900 mcm)

4x120 (4x250 mcm) 4x120 (4x250 mcm) 4x120 (4x250 mcm)

6x185 (6x350 mcm) 6x185 (6x350 mcm) 6x185 (6x350 mcm)

1600 2000 2500

13731 16190 18536

14250 16821 19247

665 863 1044

0.98 0.98 0.98

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

12x150 (12x300

mcm)

12x150 (12x300

mcm)

Table 7.9 Electrical Data for Enclosures F2/F4, 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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 59

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 550 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 F8/F9 F8/F9 F8/F9 F8/F9

Output current (3-phase)

Maximum input current

Continuous (at 550 V) [A] 453 504 574 607 Continuous (at 575 V) [A] 434 482 549 607 Continuous (at 690 V) 434 482 549 607

Maximum number and size of cables per phase

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)]

- Brake [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 Control card overtemperature trip [°C (°F)]

2), 3)

P450 P500 P560 P630

4x240 (4x500

mcm)

4x85 (4x3/0

mcm)

2x185 (2x350

mcm)

630 630 630 630

5323 6010 7395 8209

5529 6239 7653 8495

0.98 0.98 0.98 0.98

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

4x240 (4x500

mcm)

4x85 (4x3/0

mcm)

2x185 (2x350

mcm)

4x240 (4x500

mcm)

4x85 (4x3/0

mcm)

2x185 (2x350

mcm)

4x240 (4x500

4x85 (4x3/0

2x185 (2x350

mcm)

7 7

Table 7.10 Electrical Data for Enclosures F8/F9, Mains Supply 6x525–690 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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 60

Specications

VLT® HVAC Drive FC 102

Normal overload NO NO NO

(Normal overload=110% current during 60 s) Typical shaft output at 550 V [kW] 560 670 750 Typical shaft output at 575 V [hp] 750 950 1050 Typical shaft output at 690 V [kW] 710 800 900

Enclosure size F10/F11 F10/F11 F10/F11

Output current (3-phase)

Maximum input current

Continuous (at 550 V) [A] 735 857 952

Continuous (at 575 V) [A] 704 819 911 Continuous (at 690 V) [A] 704 819 911

Maximum number and size of cables per phase

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)]

- Brake [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]

Estimated power loss at 690 V [W] Maximum added losses for circuit breaker or disconnect and contactor [W], (F11 only) Maximum panel options losses [W] 400 400 400

Eciency

Output frequency [Hz] 0–500 0–500 0–500 Control card overtemperature trip [°C (°F)]

2), 3)

P710 P800 P900

8x150 (8x300 mcm) 8x150 (8x300 mcm) 8x150 (8x300

mcm)

6x120 (4x900 mcm) 6x120 (4x900 mcm) 6x120 (4x900

mcm)

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

mcm)

900 900 900

9500 10872 12316

9863 11304 12798

427 532 615

0.98 0.98 0.98

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

Table 7.11 Electrical Data for Enclosures F10/F11, Mains Supply 6x525–690 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

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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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

drives.danfoss.com/knowledge-center/energy-

Page 61

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 550 V [kW] 850 1000 1100 Typical shaft output at 575 V [hp] 1150 1350 1550 Typical shaft output at 690 V [kW] 1000 1200 1400

Enclosure size F12/F13 F12/F13 F12/F13

Output current (3-phase)

Maximum input current

Continuous (at 550 V) [A] 1068 1269 1425 Continuous (at 575 V) [A] 1022 1214 1364 Continuous (at 690 V) [A] 1022 1214 1364

Maximum number and size of cables per phase

- Motor [mm2 (AWG)]

- Mains [mm2 (AWG)] (F12)

- Mains [mm2 (AWG)] (F13)

- Brake [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]

Estimated power loss at 690 V [W] Maximum added losses for circuit breaker or disconnect and contactor [W], (F13 only) Maximum panel options losses [W] 400 400 400

Eciency

Output frequency [Hz] 0–500 0–500 0–500 Control card overtemperature trip [°C (°F)]

2), 3)

P1M0 P1M2 P1M4

12x150 (12x300

mcm) 8x240 (8x500 mcm) 8x240 (8x500 mcm) 8x240 (8x500

8x456 (8x900 mcm) 8x456 (8x900 mcm) 8x456 (8x900

6x185 (6x350 mcm) 6x185 (6x350 mcm) 6x185 (6x350

1600 2000 2500

13731 16190 18536

14250 16821 19247

665 863 1044

0.98 0.98 0.98

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

12x150 (12x300

mcm)

12x150 (12x300

mcm)

7 7

Table 7.12 Electrical Data for Enclosures F12/F13, Mains Supply 6x525–690 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 (16.5 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.12 Eciency. 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 62

Specications

VLT® HVAC Drive FC 102

7.3 Mains Supply

Mains supply Supply terminals (6-pulse) L1, L2, L3 Supply terminals (12-pulse) L1-1, L2-1, L3-1, L1-2, L2-2, L3-2 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 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 E1/F1/F2/F3/F4/F8/F9/F10/F11/F12/F13 enclosures IP21/Type 1, IP54/Type 12 E2 enclosure IP00/Chassis Vibration test 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.

Page 63

Specications Design Guide

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.

•

IE2

7.6 Cable Specications

Cable lengths and cross-sections for control cables Maximum motor cable length, shielded 150 m (492 ft) Maximum motor cable length, unshielded 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 electrical data in chapter 7.1 Electrical Data, 380–480 V and chapter 7.2 Electrical Data, 525–690 V.

7 7

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.

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 4 kΩ

Approximately 10 kΩ

Approximately 200 Ω

Page 64

Mains

Functional isolation

PELV isolation

Motor

DC-bus

High voltage

Control

+24 V

RS485

130BA117.10

Specications

Illustration 7.1 PELV Isolation

VLT® HVAC Drive FC 102

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 Digital Inputs in chapter 7.7 Control Input/Output and Control Data 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

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 65

Specications Design Guide

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.

2), 3)

400 V AC, 2 A

7 7

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 66

Specications

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

VLT® HVAC Drive FC 102

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

E1 270–313 kg (595–690 lb) 263–313 kg (580–690 lb) E2 234–277 kg (516–611 lb) 221–277 kg (487–611 lb)

Table 7.13 Enclosure E1–E2 Weights, kg (lb)

Enclosure 380–480/500 V 525–690 V

F1 1017 kg (2242.1 lb) 1017 kg (2242.1 lb) F2 1260 kg (2777.9 lb) 1260 kg (2777.9 lb) F3 1318 kg (2905.7 lb) 1318 kg (2905.7 lb) F4 1561 kg (3441.5 lb) 1561 kg (3441.5 lb) F8 447 kg (985.5 lb) 447 kg (985.5 lb) F9 669 kg (1474.9 lb) 669 kg (1474.9 lb) F10 893 kg (1968.8 lb) 893 kg (1968.8 lb) F11 1116 kg (2460.4 lb) 1116 kg (2460.4 lb) F12 1037 kg (2286.4 lb) 1037 kg (2286.4 lb) F13 1259 kg (2775.7 lb) 1259 kg (2775.7 lb)

Table 7.14 Enclosure F1–F13 Weights, kg (lb)

Page 67

e30bg051.10

e30bg052.10

1 2

Specications Design Guide

7.9 Airow for Enclosures E1–E2 and F1–F13

7 7

Front channel airow, 340 m3/hr (200 cfm)

2 Back-channel airow,

1105 m3/hr (650 cfm) or 1444 m3/hr (850 cfm)

Illustration 7.2 Airow for Enclosure E1

Front channel airow, 255 m3/hr (150 cfm)

2 Back-channel airow,

1105 m3/hr (650 cfm) or 1444 m3/hr (850 cfm)

Illustration 7.3 Airow for Enclosure E2

Page 68

e30bg053.10

Specications

VLT® HVAC Drive FC 102

1 Front channel airow

- IP21/Type 1, 700 m3/hr (412 cfm)

- IP54/Type 12, 525 m3/hr (309 cfm)

Back-channel airow, 985 m3/hr (580 cfm)

Illustration 7.4 Airow for Enclosure F1–13

Page 69

130BF328.10

600 (23.6)

2000 (78.7)

538 (21.2)

494 (19.4)

579 (22.8)

748

(29.5)

Exterior and Terminal Dimen... Design Guide

8 Exterior and Terminal Dimensions

8.1 E1 Exterior and Terminal Dimensions

8.1.1 E1 Exterior Dimensions

8 8

Illustration 8.1 Front, Side, and Door Clearance Dimensions for E1

Page 70

130BF611.10

35 (1.4)

350 (13.8)

203 (8.0)

99 (3.9)

130 (5.1)

62 (2.4)

104 (4.1)

35 (1.4)

10 (0.4)

0 (0.0)

40 (1.6)

78 (3.1)

0 (0.0)

26 (1.0)

130BF647.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains side 2 Motor side

Illustration 8.2 Gland Plate Dimensions for E1/E2

8.1.2 E1 Terminal Dimensions

Power cables are heavy and hard to bend. To ensure easy installation of the cables, consider the optimum placement of the drive. Each terminal allows up to 4 cables with cable lugs or a standard box lug. Ground is connected to a relevant termination point in the drive.

Illustration 8.3 Detailed Terminal Dimensions for E1/E2

Page 71

130BF595.10

195 (7.7)

0.0

323 (12.7)

492 (19.4)

75 (3.0)

0.0

188 (7.4)

300 (11.8)

412 (16.2)

525 (20.7)

600 (23.6)

546 (21.5)

510 (20.1)

462 (18.2)

426 (16.8)

453 (17.8)

Exterior and Terminal Dimen... Design Guide

8 8

1 Mains terminals 3 Regen/load share terminals 2 Brake terminals 4 Motor terminals

Illustration 8.4 Terminal Dimensions for E1, Front View

Page 72

130BF596.10

154 (6.1)

0.0

192 (7.6)

280 (11.0)

371 (14.6)

409 (16.1)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals 2 Brake terminals 3 Motor terminals – –

Illustration 8.5 Terminal Dimensions for E1, Side View

Page 73

130BF597.10

562 (22.1)

253 (9.9)

342 (13.5)

431 (17.0)

0.0

Exterior and Terminal Dimen... Design Guide

1 Mains terminals – –

Illustration 8.6 Terminal Dimensions for E1 with Disconnect (380–480/500 V Models: P315; 525–690 V Models: P355–P560), Front View

8 8

Page 74

130BF598.10

0.0

51 (2.0)

226 (8.9)

266 (10.5)

441 (17.4)

0.0

28 (1.1)

167 (6.6)

195 (7.7)

381 (15.0)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals – –

Illustration 8.7 Terminal Dimensions for E1 with Disconnect (380–480/500 V Models: P315; 525–690 V Models: P355–P560), Side View

Page 75

416 (16.4)

455 (17.9)

251 (9.9)

341 (13.4)

431 (17.0)

0.0

130BF599.10

Exterior and Terminal Dimen... Design Guide

1 Mains terminals – –

Illustration 8.8 Terminal Dimensions for E1 with Disconnect (380–480/500 V Models: P355–P400), Front View

8 8

Page 76

130BF600.10

0.0

51 (2.0)

226 (8.9)

266 (10.5)

441 (17.4)

0.0

28 (1.1)

167 (6.6) 195 (7.7)

371 (14.6)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals – –

Illustration 8.9 Terminal Dimensions for E1 with Disconnect (380–480/500 V Models: P355–P400), Side View

Page 77

130BF329.10

585 (23.0)

1547 (60.9)

538

(21.2)

498 (19.5)

Exterior and Terminal Dimen... Design Guide

8.2 E2 Exterior and Terminal Dimensions

8.2.1 E2 Exterior Dimensions

Illustration 8.10 Front, Side, and Door Clearance Dimensions for E2

8 8

Page 78

130BF611.10

35 (1.4)

350 (13.8)

203 (8.0)

99 (3.9)

130 (5.1)

62 (2.4)

104 (4.1)

35 (1.4)

10 (0.4)

0 (0.0)

40 (1.6)

78 (3.1)

0 (0.0)

26 (1.0)

130BF647.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains side 2 Motor side

Illustration 8.11 Gland Plate Dimensions for E1/E2

8.2.2 E2 Terminal Dimensions

Illustration 8.12 Detailed Terminal Dimensions for E1/E2

Page 79

130BF601.10

R/L1 91

S/L2 92

U/T1 96 V/T2 97

T/L3 93

W/T3 98

F ASTENER T OR QUE M8 9.6 N m (7 FT -LB) F ASTENER T OR QUE M8 9.6 N m (7 FT -LB)

186 (7.3)

17 (0.7)

585 (23.0)

518 (20.4)

405 (15.9)

293 (11.5)

181 (7.1)

68 (2.7)

0.0

147 (5.8)

583(22.9)

502 (19.8)

454 (17.9)

418 (16.4)

Exterior and Terminal Dimen... Design Guide

8 8

1 Mains terminals 3 Motor terminals 2 Brake terminals 4 Regen/load share terminals

Illustration 8.13 Terminal Dimensions for E2, Front View

Page 80

409 (16.1)

371 (14.6)

280 (11.0)

192 (7.6)

154 (6.1)

0.0

130BF602.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals 2 Brake terminals 3 Motor terminals – –

Illustration 8.14 Terminal Dimensions for E2, Side View

Page 81

256 (10.1)

0.0

245 (9.6)

0.0

334 (13.1)

423 (16.7)

130BF603.10

Exterior and Terminal Dimen... Design Guide

1 Mains terminals – –

Illustration 8.15 Terminal Dimensions for E2 with Disconnect (380–480/500 V Models: P315; 525–690 V Models: P355–P560), Front

View

8 8

Page 82

381 (15.0)

0.0

130BF604.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals – –

Illustration 8.16 Terminal Dimensions for E2 with Disconnect (380–480/500 V Models: P315; 525–690 V Models: P355–P560), Side

View

Page 83

256 (10.1)

0.0

149 (5.8)

245 (9.6)

0.0

334 (13.1)

423 (16.7)

130BF605.10

Exterior and Terminal Dimen... Design Guide

1 Mains terminals – –

Illustration 8.17 Terminal Dimensions for E2 with Disconnect (380–480/500 V Models: P355–P400), Front View

8 8

Page 84

381 (15.0)

0.0

130BF606.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals – –

Illustration 8.18 Terminal Dimensions for E2 with Disconnect (380–480/500 V Models: P355–P400), Side View

Page 85

130BF375.10

2280

(89.7)

2204

(86.8)

1400 (55.2)

606

(23.9)

578 (22.8)

776

(30.6)

Exterior and Terminal Dimen... Design Guide

8.3 F1 Exterior and Terminal Dimensions

8.3.1 F1 Exterior Dimensions

8 8

Illustration 8.19 Front, Side, and Door Clearance Dimensions for F1

Page 86

130BF612.10

216 (8.6)

668 (26.3)

38 (1.5)

593 (23.3)

460 (18.1)

535 (21.1)

282 (11.1)

36 (1.4)

533 (21.0)

596 (23.4)

1329 (52.3)

200 (7.9)

258 (10.2)

36 (1.4)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains side 2 Motor side

Illustration 8.20 Gland Plate Dimensions for F1

Page 87

130BF583.10

CH22

Exterior and Terminal Dimen... Design Guide

8.3.2 F1 Terminal Dimensions

8 8

1 Mains terminals 2 Ground bar

Illustration 8.21 Terminal Dimensions for F1–F4 Rectier Cabinet, Front View

Page 88

0.0

130BF584.10

70 (2.8)

194 (7.6)

343 (13.5)

38 (1.5)

0.0

90 (3.6)

137 (5.4)

189 (7.4)

432 (17.0)

380 (15.0)

436 (17.2)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains terminals 3 Load share terminals (–) 2 Load share terminals (+) – –

Illustration 8.22 Terminal Dimensions for F1–F2 Rectier Cabinet, Side View

Page 89

130BF373.10

54 (2.1)

169 (6.7)

284 (11.2)

407 (16.0)

522 (20.6)

637 (25.1)

198 (7.8)

234 (9.2)

282 (11.1)

318 (12.5)

551 (21.7)

587 (23.1)

635 (25.0)

671 (26.4)

204.1 (8.0)

497. (19.6)

572 (22.5)

129.1 (5.1)

0.0

Exterior and Terminal Dimen... Design Guide

1 Brake terminals 3 Ground bar 2 Motor terminals – –

Illustration 8.23 Terminal Dimensions for F1/F3 Inverter Cabinet, Front View

8 8

Page 90

130BF374.10

287 (11.3)

253 (10.0)

0.0

339 (13.4)

308 (12.1)

466 (18.3)

44 (1.8)

244 (9.6)

180 (7.1)

287 (11.3)

0.0

339 (13.4)

466 (18.3)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Brake terminals 3 Ground bar 2 Motor terminals – –

Illustration 8.24 Terminal Dimensions for F1/F3 Inverter Cabinet, Side View

Page 91

1739 (68.5)

0.0

805 (31.7)

0.0

765 (30.1)

710 (28.0)

1694 (66.7)

1654 (65.1)

130BF365.10

Exterior and Terminal Dimen... Design Guide

1 DC – 2 DC +

Illustration 8.25 Terminal Dimensions for F1/F3 Regeneration Terminals, Front View

8 8

Page 92

130BF330.11

2280

(89.7)

2204

(86.8)

1800 (70.9)

606

(23.9)

579 (22.8)

578

(22.8)

624

(24.6)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

8.4 F2 Exterior and Terminal Dimensions

8.4.1 F2 Exterior Dimensions

Illustration 8.26 Front, Side, and Door Clearance Dimensions for F2

Page 93

533 (21.0)

594 (23.4)

1728 (68.0)

36 (1.4)

258 (10.2)

200 (7.9)

38 (1.5) 460 (18.1)

994 (39.1)

216 (8.5)

36 (1.4)

282 (11.1)

130BF613.10

535 (21.1)

656 (25.8)

Exterior and Terminal Dimen... Design Guide

1 Mains side 2 Motor side

Illustration 8.27 Gland Plate Dimensions for F2

8 8

Page 94

130BF583.10

CH22

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

8.4.2 F2 Terminal Dimensions

1 Mains terminals 2 Ground bar

Illustration 8.28 Terminal Dimensions for F1–F4 Rectier Cabinet, Front View

Page 95

0.0

130BF584.10

70 (2.8)

194 (7.6)

343 (13.5)

38 (1.5)

0.0

90 (3.6)

137 (5.4)

189 (7.4)

432 (17.0)

380 (15.0)

436 (17.2)

Exterior and Terminal Dimen... Design Guide

1 Mains terminals 3 Load share terminals (–) 2 Load share terminals (+) – –

Illustration 8.29 Terminal Dimensions for F1–F2 Rectier Cabinet, Side View

8 8

Page 96

210 (8.3)

0.0

66 (2.6)

181 (7.1)

296 (11.7)

431 (17.0)

546 (21.5)

661 (26.0)

796 (31.3)

911 (35.8)

1026 (40.4)

246 (9.7)

294 (11.6)

330 (13.0)

575 (22.6)

611 (24.0)

659 (25.9)

695 (27.4)

939 (37.0)

975 (38.4)

1023 (40.3)

1059 (41.7)

144 (5.7)

219 (8.6)

512 (20.2)

587 (23.1)

880 (34.7)

955 (37.6)

130BF363.10

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Brake terminals 3 Ground bar 2 Motor terminals – –

Illustration 8.30 Terminal Dimensions for F2/F4 Inverter Cabinet, Front View

Page 97

130BF364.10

287 (11.3)

339 (13.4)

253 (10.0)

0.0

287 (11.3)

0.0

339 (13.4)

466 (18.3)

308 (12.1)

180 (7.1)

0.0

Exterior and Terminal Dimen... Design Guide

1 Brake terminals 3 Ground bar 2 Motor terminals – –

Illustration 8.31 Terminal Dimensions for F2/F4 Inverter Cabinet, Side View

8 8

Page 98

130BF366.10

1203 (47.4)

0.0

1163 (45.8)

1098 (43.2)

1739 (68.4) 1694 (66.7)

1654 (65.1)

0.0

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 DC – 2 DC +

Illustration 8.32 Terminal Dimensions for F2/F4 Regeneration Terminals, Front View

Page 99

130BF376.10

2280

(89.7)

2204 (86.8)

2000 (78.8)

606

(23.9)

578 (22.8)

776 (30.6)

Exterior and Terminal Dimen... Design Guide

8.5 F3 Exterior and Terminal Dimensions

8.5.1 F3 Exterior Dimensions

8 8

Illustration 8.33 Front, Side, and Door Clearance Dimensions for F3

Page 100

1265 (49.8) 593 (23.3)

130BF614.10

38 (1.5)

200 (7.9)

259 (10.2)

635 (25.0)

535 (21.1)

533 (21.0)

597 (23.5)

1130 (44.5)

1193 (47.0)

1926 (75.8)

36 (1.4)

2x 460 (18.1)

2x 216 (8.5)

2x 281 (11.1)

Exterior and Terminal Dimen...

VLT® HVAC Drive FC 102

1 Mains side 2 Motor side

Illustration 8.34 Gland Plate Dimensions for F3

Danfoss FC 102 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual