Danfoss FC 102 Operating guide

MAKING MODERN LIVING POSSIBLE

Instruction Manual VLT® HVAC Drive FC 102

1.1–90 kW

www.DanfossDrives.com

Contents	Instruction Manual

Contents

1 Introduction	3
1.1 Purpose of the Manual	3
1.2 Additional Resources	3
1.3 Document and Software Version	3
1.4 Product Overview	3
1.5 Approvals and Certifications	6
1.6 Disposal	6
2 Safety	7
2.1 Safety Symbols	7
2.2 Qualified Personnel	7
2.3 Safety Precautions	7
3 Mechanical Installation	9
3.1 Unpacking	9
3.2 Installation Environments	9
3.3 Mounting	10
4 Electrical Installation	11
4.1 Safety Instructions	11
4.2 EMC-compliant Installation	11
4.3 Grounding	11
4.4 Wiring Schematic	13
4.5 Access	15
4.6 Motor Connection	15
4.7 AC Line Input Connection	17
4.8 Control Wiring	18
4.8.1 Control Terminal Types	18
4.8.2 Wiring to Control Terminals	19
4.8.3 Enabling Motor Operation (Terminal 27)	19
4.8.4 Voltage/Current Input Selection (Switches)	20
4.8.5 Safe Torque Off (STO)	20
4.8.6 RS-485 Serial Communication	20
4.9 Installation Check List	21
5 Commissioning	22
5.1 Safety Instructions	22
5.2 Applying Power	22
5.3 Local Control Panel Operation	23

MG11AK22

Danfoss A/S © 03/2015 All rights reserved.

Contents

VLT® HVAC Drive FC 102

5.4 Basic Programming	26
5.4.1 Commissioning with SmartStart	26
5.4.2 Commissioning via [Main Menu]	26
5.4.3 Asynchronous Motor Set-up	27
5.4.4 Permanent Magnet Motor Set-up	27
5.4.5 Automatic Energy Optimization (AEO)	28
5.4.6 Automatic Motor Adaptation (AMA)	28
5.5 Checking Motor Rotation	29
5.6 Local Control Test	29
5.7 System Start-up	29
6 Application Set-up Examples	30
7 Diagnostics and Troubleshooting	35
7.1 Maintenance and Service	35
7.2 Status Messages	35
7.3 Warning and Alarm Types	37
7.4 List of Warnings and Alarms	38
7.5 Troubleshooting	45
8 Speci•cations	48
8.1 Electrical Data	48
8.1.1 Line Power Supply 3x200–240 V AC	49
8.1.2 Line Power Supply 3x380–480 V AC	51
8.1.3 Line Power Supply 3x525–600 V AC	53
8.1.4 Line Power Supply 3 x 525–690 V AC	55
8.2 Line Power Supply	58
8.3 Motor Output and Motor Data	58
8.4 Ambient Conditions	59
8.5 Cable Specifications	59
8.6 Control Input/Output and Control Data	59
8.7 Connection Tightening Torques	63
8.8 Fuses and Circuit Breakers	63
8.9 Power Ratings, Weight and Dimensions	71
9 Appendix	73
9.1 Symbols, Abbreviations and Conventions	73
9.2 Parameter Menu Structure	73
Index	78

Danfoss A/S © 03/2015 All rights reserved.

MG11AK22

Introduction

Instruction Manual

1 1

1 Introduction

1.1 Purpose of the Manual

This instruction manual provides information for safe installation and commissioning of the adjustable frequency drive.

1.4 Product Overview

1.4.1 Intended Use

The adjustable frequency drive is an electronic motor controller intended for:

This instruction manual is intended for use by qualified personnel.

Read and follow the instruction manual to use the adjustable frequency drive safely and professionally, and pay particular attention to the safety instructions and general warnings. Keep this instruction manual available with the adjustable frequency drive at all times.

VLT® is a registered trademark.

•The regulation of motor speed in response to system feedback or to remote commands from external controllers. A power drive system consists of the adjustable frequency drive, the motor and equipment driven by the motor.

•System and motor status surveillance.

The adjustable frequency drive can also be used for motor protection.

1.2 Additional Resources

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

•The VLT® Programming Guide provides greater detail on working with parameters and many application examples.

•The VLT® Design Guide provides detailed information about capabilities and functionality to design motor control systems.

•Instructions for operation with optional equipment.

Supplementary publications and manuals are available from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/VLT+Technical+Documentation.htm for listings.

1.3 Document and Software Version

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
MG11AKxx	Replaces MG11AJxx	3.92

Table 1.1 Document and Software Version

Depending on configuration, the adjustable frequency drive can be used in standalone applications or form part of a larger appliance or installation.

The adjustable frequency drive is allowed for use in residential, industrial and commercial environments in accordance with local laws and standards.

NOTICE!

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

Foreseeable misuse

Do not use the adjustable frequency drive in applications which are non-compliant with specified operating conditions and environments. Ensure compliance with the conditions specified in chapter 8 Specifications.

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1	Introduction	VLT® HVAC Drive FC 102
	1
	1.4.2 Exploded Views
				12	13
	2		11
			10	DC-	DC+
	1
			9	<![if ! IE]> <![endif]>04 05 06
				<![if ! IE]> <![endif]>01 02 03
		8
			Remove jumper to activate Safe Stop
			Max. 24 Volt !
		3	7

4

6

5

<![if ! IE]>

<![endif]>130BB493.10

	19	17	16
		18

FAN MOUNTING

QDF-30

14

15

1	Local control panel (LCP)	11	Relay 2 (04, 05, 06)
2	Cover	12	Lifting ring
3	RS-485 serial bus connector	13	Mounting slot
4	Digital I/O and 24 V power supply	14	Grounding clamp (PE)
5	Analog I/O connector	15	Cable shield connector
6	Cable shield connector	16	Brake terminal (-81, +82)
7	USB connector	17	Load sharing terminal (DC bus) (-88, +89)
8	Serial bus terminal switch	18	Motor output terminals 96 (U), 97 (V), 98 (W)
9	Analog switches (A53), (A54)	19	Line power input terminals 91 (L1), 92 (L2), 93 (L3)
10	Relay 1 (01, 02, 03)

Figure 1.1 Exploded View Enclosure Types B and C, IP55 and IP66

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MG11AK22

Introduction

Instruction Manual

1 1

1

2

3

4

18

5

17

16

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<![endif]>130BB492.10

6

15

	8		7
			8
	14		9
			10
	13		11
			12
1	Local control panel (LCP)	10	Motor output terminals 96 (U), 97 (V), 98 (W)
2	RS-485 serial bus connector (+68, -69)	11	Relay 2 (01, 02, 03)
3	Analog I/O connector	12	Relay 1 (04, 05, 06)
4	LCP input plug	13	Brake (-81, +82) and load sharing (-88, +89) terminals
5	Analog switches (A53), (A54)	14	Line power input terminals 91 (L1), 92 (L2), 93 (L3)
6	Cable shield connector	15	USB connector
7	Decoupling plate	16	Serial bus terminal switch
8	Grounding clamp (PE)	17	Digital I/O and 24 V power supply
9	Shielded cable grounding clamp and strain relief	18	Cover

Figure 1.2 Exploded View Enclosure Type A, IP20

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5

				Introduction	VLT® HVAC Drive FC 102
1		1

1.4.3Block Diagram of the Adjustable Frequency Drive

Figure 1.3 is a block diagram of the internal components of the adjustable frequency drive. See Table 1.2 for their functions.

Figure 1.3 Adjustable Frequency Drive Block Diagram

	Area	Title		Functions
			•	3-phase AC line power supply
	1	Line power input		to the adjustable frequency
				drive
			•	The rectifier bridge converts
	2	Rectifier		the AC input to DC current to
				supply inverter power
	3	DC bus	•	Intermediate DC bus circuit
				handles the DC current
			•	Filter the intermediate DC
				circuit voltage
			•	Prove line transient protection
	4	DC reactors	•	Reduce RMS current
			•	Raise the power factor
				reflected back to the line
			•	Reduce harmonics on the AC
				input
			•	Stores the DC power
	5	Capacitor bank	•	Provides ride-through
				protection for short power
				losses
			•	Converts the DC into a
	6	Inverter		controlled PWM AC waveform
				for a controlled variable
				output to the motor
	7	Output to motor	•	Regulated 3-phase output
				power to the motor

Area	Title		Functions
		•	Input power, internal
			processing, output, and motor
			current are monitored to
			provide efficient operation
			and control
8	Control circuitry	•	User interface and external
			commands are monitored and
			performed
		•	Status output and control can
			be provided
Table 1.2 Legend to Figure 1.3

1.4.4 Enclosure Types and Power Ratings

For enclosure types and power ratings of the adjustable frequency drives, refer to chapter 8.9 Power Ratings, Weight and Dimensions.

1.5 Approvals and Certifications

Table 1.3 Approvals and Certi•cations

More approvals and certifications are available. Contact local Danfoss partner. Adjustable frequency drives of enclosure type T7 (525–690 V) are not certified for UL.

The adjustable frequency drive complies with UL508C thermal memory retention requirements. For more information, refer to the section Motor Thermal Protection in the Design Guide.

1.6 Disposal

Do not dispose of equipment containing electrical components together with domestic waste.

Collect it separately in accordance with local and currently valid legislation.

6

Danfoss A/S © 03/2015 All rights reserved.

MG11AK22

Safety	Instruction Manual

2 Safety

2.1 Safety Symbols

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation which could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which could result in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTICE!

Indicates important information, including situations that may result in damage to equipment or property.

2.2 Qualified Personnel

Correct and reliable transport, storage, installation, operation and maintenance are required for the troublefree and safe operation of the adjustable frequency drive. Only qualified personnel is allowed to install or operate this equipment.

Qualified personnel is defined as trained staff, who are authorized to install, commission, and maintain equipment, systems and circuits in accordance with pertinent laws and regulations. Additionally, the personnel must be familiar with the instructions and safety measures described in this document.

2 2

2.3 Safety Precautions

WARNING

HIGH VOLTAGE

Adjustable frequency drives contain high voltage when connected to AC line power input, DC power supply, or load sharing. Failure to perform installation, start-up, and maintenance by quali•ed personnel can result in death or serious injury.

•Installation, start-up, and maintenance must be performed by quali•ed personnel only.

WARNING

UNINTENDED START

When the adjustable frequency drive is connected to AC line power, the motor may start at any time, causing risk of death, serious injury, equipment, or property damage. The motor can start by means of an external switch, a serial bus command, an input reference signal from the LCP, or after a cleared fault condition.

•Disconnect the adjustable frequency drive from line power whenever personal safety considerations make it necessary to avoid unintended motor start.

•Press [Off] on the LCP before programming parameters.

•The adjustable frequency drive, motor, and any driven equipment must be in operational readiness when the adjustable frequency drive is connected to AC line power.

MG11AK22

Danfoss A/S © 03/2015 All rights reserved.

7

Safety

VLT® HVAC Drive FC 102

	2	2	WARNING
			DISCHARGE TIME

The adjustable frequency drive contains DC link capacitors that can remain charged even when the adjustable frequency drive is not powered. Failure to wait the speci•ed time after power has been removed before performing service or repair work could result in death or serious injury.

1.Stop motor.

2.Disconnect AC line power, permanent magnet type motors, and remote DC link power supplies, including battery backups, UPS, and DC link connections to other adjustable frequency drives.

3.Wait for the capacitors to discharge fully before performing any service or repair work. The duration of waiting time is speci•ed in Table 2.1.

Voltage [V] Minimum waiting time (minutes)

	4	7	15
200–240	1.5–5 hp		7.5–60 hp
	[1.1–3.7 kW]		[5.5–45 kW]
380–480	1.5–10 hp		15–125 hp
	[1.1–7.5 kW]		[11–90 kW]
525–600	1.5–10 hp		15–125 hp
	[1.1–7.5 kW]		[11–90 kW]
525–690		1.5–10 hp	15–125 hp
		[1.1–7.5 kW]	[11–90 kW]

High voltage may be present even when the warning LED indicator lights are off.

Table 2.1 Discharge Time

WARNING

LEAKAGE CURRENT HAZARD

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

•Ensure correct grounding of the equipment by a certi•ed electrical installer.

WARNING

EQUIPMENT HAZARD

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

•Ensure that only trained and quali•ed personnel perform installation, start-up, and maintenance.

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

•Follow the procedures in this manual.

CAUTION

UNINTENDED MOTOR ROTATION WINDMILLING

Unintended rotation of permanent magnet motors can result in serious injury or equipment damage.

•Ensure that permanent magnet motors are blocked to prevent unintended rotation.

CAUTION

INTERNAL FAILURE HAZARD

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

•Before applying power, ensure all safety covers are in place and securely fastened.

8

Danfoss A/S © 03/2015 All rights reserved.

MG11AK22

Mechanical Installation	Instruction Manual

3 Mechanical Installation

3.1 Unpacking

3.1.1 Items Supplied

Items supplied may vary according to product configuration.

•Make sure the items supplied and the information on the nameplate correspond to the order confirmation.

•Check the packaging and the adjustable frequency drive visually for damage caused by inappropriate handling during shipment. File any claim for damage with the carrier. Retain damaged parts for clarification.

2	VLT	R	HVAC Drive	10		<![if ! IE]> <![endif]>130BD511.10
1			www.danfoss.com
	T/C: FC-102P3K0T4Z55H1UGCXXXSXXXXAXBXCXXXXDX
3	P/N: 131U3930		S/N: 010102G290
	3.0kW(400V) / 4.0HP(460V)
4				8
	IN: 3x380-480V 50/60Hz 6.5/5.7A
5
	OUT: 3x0-Vin 0-590Hz 7.2/6.3A
6				7
	Type 12 / IP55 Tamb.45 oC/113 oF

* 1 3 1 U 3 9 3 0 0 1 0 1 0 2 G 2 9 0 *	MADE IN DENMARK
Listed 76X1 E134261 Ind. Contr. Eq.

CAUTION:

See manual for special condition/mains fuse

9voir manual de conditions speclales/fusibles`

WARNING:

Stored charge, wait 4 min. Charge residuelle,` attendez 4 min.

	3 3
NOTICE!

Do not remove the nameplate from the adjustable frequency drive (loss of warranty).

3.1.2 Storage

Ensure that requirements for storage are fulfilled. Refer to chapter 8.4 Ambient Conditions for further details.

3.2 Installation Environments

NOTICE!

In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/Type rating of the equipment matches the installation environment. Failure to meet requirements for ambient conditions can reduce lifetime of the adjustable frequency drive. Ensure that requirements for air humidity, temperature and altitude are met.

Vibration and Shock

The adjustable frequency drive complies with requirements for units mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors.

For detailed ambient conditions specifications, refer to chapter 8.4 Ambient Conditions.

	1	Type code
	2	Order number
	3	Power rating
	4	Input voltage, frequency and current
		(at low/high voltages)
	5	Output voltage, frequency and current
		(at low/high voltages)
	6	Enclosure type and IP rating
	7	Maximum ambient temperature
	8	Certifications
	9	Discharge time (Warning)
	10	Serial number

Figure 3.1 Product Nameplate (Example)

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9

Mechanical Installation

VLT® HVAC Drive FC 102

			3.3 Mounting
				NOTICE!
3		3	Improper mounting can result in overheating and
			reduced performance.

Cooling

•Ensure that top and bottom clearance for air cooling is provided. See Figure 3.2 for clearance requirements.

a	<![if ! IE]> <![endif]>130BD528.10

a

Figure 3.2 Top and Bottom Cooling Clearance

Enclosure	A2-A5	B1-B4	C1, C3	C2, C4
a (ins [mm])	3.94 [100]	7.87 [200]	7.87 [200]	8.86 [225]

Table 3.1 Minimum Airflow Clearance Requirements

Lifting

•To determine a safe lifting method, check the weight of the unit, see chapter 8.9 Power Ratings, Weight and Dimensions.

•Ensure that the lifting device is suitable for the task.

•If necessary, plan for a hoist, crane, or forklift with the appropriate rating to move the unit.

•For lifting, use hoist rings on the unit, when provided.

Mounting

1.Ensure that the strength of the mounting location supports the unit weight. The adjustable frequency drive allows side-by-side installation.

2.Place the unit as near to the motor as possible. Keep the motor cables as short as possible.

3.Mount the unit vertically to a solid flat surface or to the optional backplate to provide cooling airflow.

4.Use the slotted mounting holes on the unit for wall mounting, when provided.

Mounting with backplate and railings

<![if ! IE]>

<![endif]>130BD504.10

Figure 3.3 Proper Mounting with Backplate

NOTICE!

Backplate is required when mounted on railings.

NOTICE!

All A, B, and C enclosures allow side-by-side installation. Exception: if an IP21 kit is used, there has to be a clearance between the enclosures:

•	For enclosures A2, A3, A4, B3, B4 and C3, the
	minimum clearance is 2 ins [50 mm].
•	For enclosure C4, the minimum clearance is 3
	ins [75 mm].

10

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MG11AK22

Electrical Installation	Instruction Manual

4 Electrical Installation

4.1 Safety Instructions

See chapter 2 Safety for general safety instructions.

WARNING

INDUCED VOLTAGE

Induced voltage from output motor cables that run together can charge equipment capacitors even with the equipment turned off and locked out. Failure to run output motor cables separately or use shielded cables or metal conduits could result in death or serious injury.

•run output motor cables separately, or

•use shielded cables or metal conduits.

Wire Type and Ratings
•	All wiring must comply with local and national
	regulations regarding cross-section and ambient	4	4
	temperature requirements.

•Power connection wire recommendation: minimum 167°F [75°C] rated copper wire.

See chapter 8.1 Electrical Data and chapter 8.5 Cable Specifications for recommended wire sizes and types.

4.2 EMC-compliant Installation

To obtain an EMC-compliant installation, follow the instructions provided in chapter 4.3 Grounding,

chapter 4.4 Wiring Schematic, chapter 4.6 Motor Connection, and chapter 4.8 Control Wiring.

CAUTION

SHOCK HAZARD

The adjustable frequency drive can cause a DC current in the PE conductor. Failure to follow the recommendation below means the RCD may not provide the intended protection.

•When a residual current-operated protective device (RCD) is used for protection against electrical shock, only an RCD of Type B is permitted on the supply side.

NOTICE!

The adjustable frequency drive is supplied with Class 20 motor overload protection.

Overcurrent Protection

•Additional protective equipment such as shortcircuit protection or motor thermal protection between adjustable frequency drive and motor is required for applications with multiple motors.

•Input fusing is required to provide short circuit and overcurrent protection. If not factorysupplied, fuses must be provided by the installer. See maximum fuse ratings in chapter 8.8 Fuses and Circuit Breakers.

4.3 Grounding

WARNING

LEAKAGE CURRENT HAZARD

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

•Ensure correct grounding of the equipment by a certi•ed electrical installer.

For electrical safety

•Ground the adjustable frequency drive in accordance with applicable standards and directives.

•Use a dedicated ground wire for input power, motor power and control wiring.

•Do not ground one adjustable frequency drive to another in a “daisy chain” fashion.

•Keep the ground wire connections as short as possible.

•Follow the motor manufacturer wiring requirements.

•Minimum cable cross-section: AWG 7 [10 mm2] (or two rated ground wires terminated separately).

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11

Electrical Installation

VLT® HVAC Drive FC 102

For EMC-compliant installation

•

4	4	•
		•

Establish electrical contact between cable shield and adjustable frequency drive enclosure by using metal cable connectors or by using the clamps provided on the equipment (see chapter 4.6 Motor Connection).

Use high-strand wire to reduce electrical interference.

Do not use pigtails.

NOTICE!

POTENTIAL EQUALIZATION

Risk of electrical interference, when the ground potential between the adjustable frequency drive and the system is different. Install equalizing cables between the system components. Recommended cable cross-section: AWG 6 [16 mm2].

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Danfoss A/S © 03/2015 All rights reserved.

MG11AK22

Electrical Installation	Instruction Manual

4.4 Wiring Schematic

3-phase	91 (L1)							(U) 96
power	92 (L2)							(V) 97
input	93 (L3)							(W) 98
	95	PE						(PE) 99
DC bus	88 (-)				Switch Mode
					Power Supply
	89 (+)
				10 V DC			24 V DC	(R+) 82
	50 (+10 V OUT)			15 mA		130/200 mA
+10 V DC				+	-	+	-	(R-) 81
		S201
0/-10 V DC-
	53 (A IN)		<![if ! IE]> <![endif]>ON
+10 V DC		<![if ! IE]> <![endif]>2 1		ON=0/4–20 mA				relay1
0/4–20 mA		S202						03
				OFF=0/-10 V DC -
0/-10 V DC-
	54 (A IN)		<![if ! IE]> <![endif]>ON
				+10 V DC
+10 V DC								02
		<![if ! IE]> <![endif]>21
0/4–20 mA
	55 (COM A IN)							01
	12 (+24 V OUT)							relay2
								06
	13 (+24 V OUT)			P 5-00				05

18 (D IN)		24 V (NPN)				04
		0 V (PNP)
19 (D IN)		24 V (NPN)				(COM A OUT) 39
		0 V (PNP)
20	(COM D IN)					(A OUT) 42
27	(D IN/OUT)	24 V (NPN)
		0 V (PNP)	S801		ON=Terminated
		24 V	<![if ! IE]> <![endif]>2 1	<![if ! IE]> <![endif]>ON
					OFF=Open
		0 V	5 V
29	(D IN/OUT)	24 V (NPN)
		0 V (PNP)
		24 V
				S801		0 V
		0 V	RS-485			(N RS-485) 69
		24 V (NPN)	Interface
32 (D IN)
		0 V (PNP)				(P RS-485) 68
33 (D IN)		24 V (NPN)				(COM RS-485) 61	**
		0 V (PNP)
*37 (D IN)

Motor

Brake resistor

240 V AC, 2 A

240 V AC, 2 A

400 V AC, 2 A

Analog Output 0/4–20 mA

RS-485

: Chassis

: Ground

<![if ! IE]>

<![endif]>130BD552.10

4 4

Figure 4.1 Basic Wiring Schematic

A=Analog, D=Digital

*Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off Instruction Manual for Danfoss VLT® Adjustable Frequency Drives.

**Do not connect cable shield.

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Electrical Installation

VLT® HVAC Drive FC 102

		2	<![if ! IE]> <![endif]>130BD529.12
4	4		3
	1
			4
			5
			u
			v
	9		w
	10	11	PE
	L1
	L2
	L3
	PE
		8
		6
			7

1	PLC	6	Cable connector
2	Adjustable frequency drive	7	Motor, 3-phase and PE
3	Output contactor	8	Line power, 3-phase and reinforced PE
4	Grounding rail (PE)	9	Control wiring
5	Cable insulation (stripped)	10	Equalizing min. 0.025 in2 [16 mm2]

Figure 4.2 EMC-compliant Electrical Connection

NOTICE!

EMC INTERFERENCE

Run cables for input power, motor wiring and control wiring in three separate metallic conduits. Failure to isolate power, motor and control cables can result in unintended behavior or reduced performance. Minimum 7.9 in [200 mm] clearance between power, motor and control cables is required.

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MG11AK22

Electrical Installation	Instruction Manual

4.5Access

•Remove cover with a screwdriver (See Figure 4.3) or by loosening attaching screws (See Figure 4.4).

<![if ! IE]>

<![endif]>130BT248.10

Figure 4.3 Access to Wiring for IP20 and IP21 Enclosures

<![if ! IE]>

<![endif]>130BT334.10

Figure 4.4 Access to Wiring for IP55 and IP66 Enclosures

See Table 4.1 before tightening the covers.

Enclosure	IP55	IP66
A4/A5	2	2
B1/B2	2.2	2.2
C1/C2	2.2	2.2

No screws to tighten for A2/A3/B3/B4/C3/C4.

Table 4.1 Tightening Torques for Covers [Nm]

4.6 Motor Connection

WARNING

INDUCED VOLTAGE!

Induced voltage from output motor cables that run together can charge equipment capacitors even with the

equipment turned off and locked out. Failure to run 4 4 output motor cables separately or use shielded cables or

metal conduits could result in death or serious injury.

•Comply with local and national electrical codes for cable sizes. For maximum wire sizes, see chapter 8.1 Electrical Data.

•Follow the motor manufacturer wiring requirements.

•Motor wiring knockouts or access panels are provided at the base of IP21 (NEMA1/12) and higher units.

•Do not wire a starting or pole-changing device (e.g., Dahlander motor or slip ring induction motor) between the adjustable frequency drive and the motor.

Procedure

1.Strip a section of the outer cable insulation.

2.Position the stripped wire under the cable clamp to establish mechanical fixation and electrical contact between cable shield and ground.

3.Connect ground wire to the nearest grounding terminal in accordance with grounding instructions provided in chapter 4.3 Grounding, see Figure 4.5.

4.Connect the 3-phase motor wiring to terminals 96 (U), 97 (V), and 98 (W), see Figure 4.5.

5.Tighten terminals in accordance with the information provided in chapter 8.7 Connection Tightening Torques.

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Electrical Installation

			W
		V	98
	U
		97
	96

4 4

VLT® HVAC Drive FC 102

<![if ! IE]> <![endif]>130BD531.10

<![if ! IE]> <![endif]>130BT302.12

MOTOR

	99	MOTOR
		U V W

Figure 4.5 Motor Connection

Figure 4.6, Figure 4.7, Figure 4.8 and Figure 4.9 represent line power input, motor, and grounding for basic adjustable frequency drives. Actual configurations vary with unit types and optional equipment.

Figure 4.6 Motor Connection for Enclosure Type A2 and A3

		W	<![if ! IE]> <![endif]>130BT337.10
	V	98
U
	97
96

Figure 4.7 Motor Connection for Enclosure Type A4/A5 (IP55/66/NEMA Type 12)

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					88	89	81	<![if ! IE]> <![endif]>130BA390.11
								8
					DC-	DC+	R-	R+
91	92	93	96	97
L1	L2	L3			98
			U	V
					W
95			99

Figure 4.8 Motor, Line Power and Ground Wiring for Enclosure Types B and C Using Shielded Cable

88	89	91	9
DC+	DC-	R-	R+

	91	92	93	96	97	99
	L1	L2	L3
				U	V
						W
	95			99

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<![endif]>130BB477.10

4.7 AC Line Input Connection

•	Size wiring based upon the input current of the
	adjustable frequency drive. For maximum wire
	sizes, see chapter 8.1 Electrical Data.
•	Comply with local and national electrical codes
	for cable sizes.	4	4
Procedure

1.Connect 3-phase AC input power wiring to terminals L1, L2, and L3 (see Figure 4.10).

2.Depending on the configuration of the equipment, input power will be connected to the line power input terminals or the input disconnect.

3.Ground the cable in accordance with grounding instructions provided in chapter 4.3 Grounding.

4.When supplied from an isolated line power source (IT line power or floating delta) or TT/TN-S line power with a grounded leg (grounded delta), ensure that 14-50 RFI Filter is set to OFF to avoid damage to the intermediate circuit and to reduce ground capacity currents in accordance with IEC 61800-3.

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<![endif]>130BT336.10

		3
	2 L
1	L	93
L	92
91

Figure 4.9 Motor, Line Power and Ground Wiring for Enclosure
Types B and C Using Conduit	Figure 4.10 Connecting to AC Line Power

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Electrical Installation

VLT® HVAC Drive FC 102

4.8	Control Wiring
•	Isolate control wiring from high power
	components in the adjustable frequency drive.
•	When the adjustable frequency drive is
	connected to a thermistor, ensure that the
4 4	thermistor control wiring is shielded and
	reinforced/double insulated. A 24 V DC supply

voltage is recommended.

4.8.1 Control Terminal Types

Figure 4.11 and Figure 4.12 show the removable adjustable frequency drive connectors. Terminal functions and default settings are summarized in Table 4.2.

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2

3

4

1

Figure 4.11 Control Terminal Locations

	1				<![if ! IE]> <![endif]>130BB931.10
	12 13	18	19 27 29 32 33 20 37
	2		3
	61 68	69	39 42	50 53 54 55

Figure 4.12 Terminal Numbers

•Connector 1 provides four programmable digital inputs terminals, two additional digital terminals programmable as either input or output, a 24 V DC terminal supply voltage, and a common for optional customer supplied 24 V DC voltage

•Connector 2 terminals (+) 68 and (-) 69 are for an RS-485 serial communication connection

•Connector 3 provides two analog inputs, one analog output, 10 V DC supply voltage, and commons for the inputs and output

•Connector 4 is a USB port available for use with

the MCT 10 Set-up Software

Terminal description

Terminal		Parameter	Default	Description
			setting
		Digital Inputs/Outputs
12, 13		-	+24 V DC	24 V DC supply voltage
				for digital inputs and
				external transducers.
				Maximum output
				current 200 mA for all
				24 V loads.
18		5-10	[8] Start	Digital inputs.
19		5-11	[0] No
			operation
32		5-14	[0] No
			operation
33		5-15	[0] No
			operation
27		5-12	[2] Coast	For digital input or
			inverse	output. Default setting
				is input.
29		5-13	[14] JOG
20		-		Common for digital
				inputs and 0 V
				potential for 24 V
				supply.
37		-	Safe Torque	Safe input (optional).
			Off (STO)	Used for STO.
		Analog Inputs/Outputs
39		-		Common for analog
				output.
42		6-50	Speed 0 -	Programmable analog
			High Limit	output. 0–20 mA or
				4–20 mA at a maximum
				of 500 Ω
50		-	+10 V DC	10 V DC analog supply
				voltage for potenti-
				ometer or thermistor.
				15 mA maximum
53		6-1	Reference	Analog input. For
				voltage or current.
54		6-2	Feedback
				Switches A53 and A54
				select mA or V.
55		-		Common for analog
				input.
		Serial Communication
61		-		Integrated RC filter for
				cable shield. ONLY for
				connecting the shield
				in the event of EMC
				problems.
68	(+)	8-3		RS-485 Interface. A
				control card switch is
69	(-)	8-3
				provided for
				termination resistance.

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Terminal description

		Default
Terminal	Parameter	setting	Description
		Relays
01, 02, 03	5-40 [0]	[9] Alarm	Form C relay output.
			For AC or DC voltage
04, 05, 06	5-40 [1]	[5] Running
			and resistive or
			inductive loads.
Table 4.2 Terminal Description

Additional terminals:

•two form C relay outputs. Location of the outputs depends on adjustable frequency drive configuration.

•Terminals located on built-in optional equipment. See the manual provided with the equipment option.

4.8.2 Wiring to Control Terminals

Control terminal connectors can be unplugged from the adjustable frequency drive for ease of installation, as shown in Figure 4.11.

NOTICE!

Keep control wires as short as possible and separate from high power cables to minimize interference.

1.Open the contact by inserting a small screwdriver into the slot above the contact and push the screwdriver slightly upwards.

12	13 18	19				<![if ! IE]> <![endif]>130BD546.10
			27	29
					32	33
1
	10	mm			2

Figure 4.13 Connecting Control Wires

2.Insert the bared control wire into the contact.

3.Remove the screwdriver to fasten the control wire into the contact.

4.Ensure the contact is firmly established and not loose. Loose control wiring can be the source of equipment faults or less than optimal operation.

See chapter 8.5 Cable Specifications for control terminal 4 4 wiring sizes and chapter 6 Application Set-up Examples for

typical control wiring connections.

4.8.3Enabling Motor Operation (Terminal 27)

A jumper wire may be required between terminal 12

(or 13) and terminal 27 for the adjustable frequency drive to operate when using factory default programming values.

•Digital input terminal 27 is designed to receive an 24 V DC external interlock command. In many applications, the user wires an external interlock device to terminal 27.

•When no interlock device is used, wire a jumper between control terminal 12 (recommended) or 13 to terminal 27. This provides an internal 24 V signal on terminal 27.

•When the status line at the bottom of the LCP reads AUTO REMOTE COAST, this indicates that the unit is ready to operate but is missing an input signal on terminal 27.

•When factory installed optional equipment is wired to terminal 27, do not remove that wiring.

NOTICE!

The adjustable frequency drive cannot operate without a signal on terminal 27 unless terminal 27 is reprogrammed.

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Electrical Installation VLT® HVAC Drive FC 102

4.8.4 Voltage/Current Input Selection	4.8.5 Safe Torque Off (STO)
(Switches)

The analog input terminals 53 and 54 allow setting of input signal to voltage (0–10 V) or current (0/4–20 mA).

			Default parameter settings:
4		4	•	Terminal 53: speed reference signal in open-loop
				(see 16-61 Terminal 53 Switch Setting).
			•	Terminal 54: feedback signal in closed-loop (see
				16-63 Terminal 54 Switch Setting).

NOTICE!

Disconnect power to the adjustable frequency drive before changing switch positions.

1.Remove the local control panel (see Figure 4.14).

2.Remove any optional equipment covering the switches.

3.Set switches A53 and A54 to select the signal type. U selects voltage, I selects current.

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<![if ! IE]> <![endif]>1	<![if ! IE]> <![endif]>O
<![if ! IE]> <![endif]>2	<![if ! IE]> <![endif]>N

	BUSTER.	A53 A54
	OFF-ON
		U- I	U- I

VLT

Safe Torque off is an option. To run Safe Torque Off, additional wiring for the adjustable frequency drive is required. Refer to the Safe Torque Off Instruction Manual for further information.

4.8.6 RS-485 Serial Communication

Up to 32 nodes can be connected as a bus, or via drop cables from a common trunk line to one network segment. Repeaters can divide network segments. Each repeater functions as a node within the segment in which it is installed. Each node connected within a given network must have a unique node address across all segments.

•Connect RS-485 serial communication wiring to terminals (+) 68 and (-) 69.

•Terminate each segment at both ends, using either the termination switch (bus term on/off, see Figure 4.14) on the adjustable frequency drives, or a biased termination resistor network.

•Connect a large surface of the shield to ground, for example with a cable clamp or a conductive cable connector.

•Apply potential-equalizing cables to maintain the same ground potential throughout the network.

•Use the same type of cable throughout the entire network to prevent impedance mismatch.

Cable	Shielded twisted pair (STP)
Impedance	120 Ω
Max. cable	4,000	ft [1,200 m] (including drop lines)
length (ft [m])	1,650	ft [500 m] station-to-station

Table 4.3 Cable Information

Figure 4.14 Location of Terminals 53 and 54 Switches

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4.9 Installation Check List

Before completing installation of the unit, inspect the entire installation as detailed in Table 4.4. Check and mark the items when completed.

Inspect for	Description
Auxiliary equipment	•	Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on the			4		4
		input power side of the adjustable frequency drive or output side to the motor. Ensure that they are ready
		for full-speed operation.
	•	Check function and installation of any sensors used for feedback to the adjustable frequency drive.
	•	Remove any power factor correction caps on motor(s).
	•	Adjust any power factor correction caps on the line power side and ensure that they are dampened.
Cable routing	•	Ensure that motor wiring and control wiring are separated or shielded or in three separate metallic
		conduits for high-frequency interference isolation.
Control wiring	•	Check for broken or damaged wires and loose connections.
	•	Check that control wiring is isolated from power and motor wiring for noise immunity.
	•	Check the voltage source of the signals, if necessary.
	•	The use of shielded cable or twisted pair is recommended. Ensure that the shield is terminated correctly.
Cooling clearance	•	Measure that top and bottom clearance is adequate to ensure proper air flow for cooling, see
		chapter 3.3 Mounting.
Ambient conditions	•	Check that requirements for ambient conditions are met.
Fusing and circuit	•	Check for proper fusing or circuit breakers.
breakers	•	Check that all fuses are inserted firmly and are in operational condition and that all circuit breakers are in
		the open position.
Grounding	•	Check for sufficient ground connections that are tight and free of oxidation.
	•	Grounding to conduit or mounting the back panel to a metal surface is not a suitable grounding.
Input and output	•	Check for loose connections.
power wiring	•	Check that motor and line power are in separate conduits or separated shielded cables.
Panel interior	•	Make sure that the unit interior is free of dirt, metal chips, moisture, and corrosion.
	•	Check that the unit is mounted on an unpainted, metal surface.
Switches	•	Ensure that all switch and disconnect settings are in the proper positions.
Vibration	•	Check that the unit is mounted solidly or that shock mounts are used, as necessary.
	•	Check for an unusual amount of vibration.

Table 4.4 Installation Check List

CAUTION

POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE

Risk of personal injury when the adjustable frequency drive is not properly closed.

•Before applying power, ensure all safety covers are in place and securely fastened.

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Commissioning

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5 Commissioning

5.1 Safety Instructions

See chapter 2 Safety for general safety instructions.

WARNING

5 5 HIGH VOLTAGE

Adjustable frequency drives contain high voltage when connected to AC line input power. Failure to perform installation, start-up, and maintenance by quali•ed personnel could result in death or serious injury.

•Installation, start-up, and maintenance must be performed by quali•ed personnel only.

Before applying power:

1.Close cover properly.

2.Check that all cable connectors are firmly tightened.

3.Ensure that input power to the unit is OFF and locked out. Do not rely on the adjustable frequency drive disconnect switches for input power isolation.

4.Verify that there is no voltage on input terminals L1 (91), L2 (92), and L3 (93), phase-to-phase and phase-to-ground.

5.Verify that there is no voltage on output terminals 96 (U), 97 (V), and 98 (W), phase-to- phase and phase-to-ground.

6.Confirm continuity of the motor by measuring ohm values on U-V (96-97), V-W (97-98), and W-U (98-96).

7.Check for proper grounding of the adjustable frequency drive as well as the motor.

8.Inspect the adjustable frequency drive for loose connections on terminals.

9.Confirm that the supply voltage matches voltage of adjustable frequency drive and motor.

5.2 Applying Power

WARNING

UNINTENDED START

When the adjustable frequency drive is connected to AC line power, the motor may start at any time, causing risk of death, serious injury, equipment, or property damage. The motor can start by means of an external switch, a serial bus command, an input reference signal from the LCP, or after a cleared fault condition.

•Disconnect the adjustable frequency drive from line power whenever personal safety considerations make it necessary to avoid unintended motor start.

•Press [Off] on the LCP before programming parameters.

•The adjustable frequency drive, motor, and any driven equipment must be in operational readiness when the adjustable frequency drive is connected to AC line power.

Apply power to the adjustable frequency drive using the following steps:

1.Confirm that the input voltage is balanced within 3%. If not, correct input voltage imbalance before proceeding. Repeat this procedure after the voltage correction.

2.Ensure that optional equipment wiring, if present, matches the installation application.

3.Ensure that all operator devices are in the OFF position. Panel doors must be closed or cover mounted.

4.Apply power to the unit. DO NOT start the adjustable frequency drive now. For units with a disconnect switch, turn to the ON position to apply power to the adjustable frequency drive.

NOTICE!

When the status line at the bottom of the LCP reads AUTO REMOTE COASTING or Alarm 60 External Interlock is displayed, this message indicates that the unit is ready to operate but is missing an input signal on, for example, terminal 27. See chapter 4.8.3 Enabling Motor Operation (Terminal 27) for details.

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