Danfoss FC 103 Operating guide

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MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® Refrigeration Drive FC 103

75-630 kW

www.danfoss.com/drives

Contents Operating Instructions

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Approvals and Certifications

1.4 Disposal Instruction

1.5 Product Overview

1.5.1 Interior Views 5

1.6 Internal Controller Functions

1.7 Enclosure Types and Power Ratings

2 Safety

2.1 Qualified Personnel

2.2 Safety Precautions

3 Installation

3.1 Pre-Installation

3.1.1 Planning the Installation Site 11

3.1.2 General Considerations 11

4 4 4 4 4 5

7 8

9 9 9

11 11

3.1.3 Tools Required for Installation 12

3.2 Pre-installation Checklist

3.3 Mechanical Installation

3.3.1 Cooling 12

3.3.2 Lifting 13

3.3.3 Mechanical Dimensions 14

3.4 Electrical Installation

3.4.1 General Requirements 25

3.4.2 Grounding Requirements 28

3.4.2.1 Leakage Current (>3.5 mA) 28

3.4.2.2 Grounding 29

3.4.3 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA 12) 31

3.4.4 Motor Connection 32

3.4.4.1 Terminal Locations: D1h-D4h 33

3.4.4.2 Terminal Locations: D5h-D8h 35

3.4.4.3 Terminal Locations: E1-E2 43

3.4.5 Motor Cable 47

12 12

3.4.6 Motor Rotation Check 48

3.4.7 AC Mains Connection 48

3.4.8 Shielding against Electrical Noise 49

3.5 Control Wiring Connection

3.5.1 Access 49

Contents Operating Instructions

3.5.2 Using Screened Control Cables 49

3.5.3 Grounding of Screened Control Cables 50

3.5.4 Control Terminal Types 51

3.5.5 Wiring to Control Terminals 51

3.5.6 Safe Torque Off (STO) 52

3.5.7 Control Terminal Functions 52

3.6 Serial Communication

3.7 Optional Equipment

3.7.1 Anti-condensation Heater 53

3.7.2 Mains Shield 53

4 Start-up and Functional Testing

4.1 Pre-start

4.1.1 Safety Inspection 54

4.2 Applying Power

4.3 Basic Operational Programming

4.3.1 Set-up Wizard 56

4.4 Automatic Motor Adaptation

4.5 Check Motor Rotation

4.6 Local-control Test

4.7 System Start-up

5 User Interface

5.1 Local Control Panel

53 53

54 54

56 56

61 61 61 62

63 63

5.1.1 LCP Layout 63

5.1.2 Setting LCP Display Values 65

5.1.3 Display Menu Keys 65

5.1.4 Navigation Keys 66

5.1.5 Operation Keys 66

5.2 Back-up and Copying Parameter Settings

5.2.1 Uploading Data to the LCP 67

5.2.2 Downloading Data from the LCP 67

5.3 Restoring Default Settings

5.3.1 Recommended Initialisation 67

5.3.2 Manual Initialisation 67

6 Programming

6.1 Introduction

6.2 Programming Example

6.3 Control Terminal Programming Examples

6.4 International/North American Default Parameter Settings

68 68 68 69 70

Contents Operating Instructions

6.5 Parameter Menu Structure

6.5.1 Main Menu Structure 72

6.6 Remote Programming with MCT 10 Set-up Software

7 Application Examples

7.1 Introduction

7.2 Application Examples

8 Status Messages

8.1 Status Display

8.2 Status Message Definitions

9 Warnings and Alarms

9.1 System Monitoring

9.2 Warning and Alarm Types

9.2.1 Warnings 83

9.2.2 Alarm Trip 83

9.2.3 Alarm Trip-lock 83

77 77 77

81 81 81

83 83 83

9.3 Warning and Alarm Displays

9.4 Warning and Alarm Definitions

9.5 Fault Messages

10 Basic Troubleshooting

10.1 Start-up and Operation

11 Specifications

11.1 Power-dependent Specifications

11.2 General Technical Data

11.3 Fuse Tables

11.3.1 Protection 102

11.3.2 Fuse Selection 102

11.3.3 Short Circuit Current Rating (SCCR) 104

11.3.4 Connection Tightening Torques 104

Index

83 84 85

92 92

95 95 98

102

105

Introduction Operating Instructions

1 Introduction

1.1 Purpose of the Manual

This manual provides detailed information for the installation and start-up of the frequency converter. Chapter 3 Installation provides requirements for mechanical and electrical installation, including:

Input

•

Motor

•

Control wiring

•

Serial communication wiring

•

Control terminal functions

•

Chapter 4 Start-up and Functional Testing provides detailed procedures for:

Start-up

•

Basic operational programming

•

Functional testing

•

The remaining chapters provide supplementary details. These details include:

User interface

•

Detailed programming

•

Application examples

•

Start-up

•

Troubleshooting

•

Specifications.

•

VLT® is a registered trademark.

1.2

Additional Resources

instructions supplied with those options for specific requirements. Contact the local Danfoss supplier or visit the Danfoss website:

www.danfoss.com/BusinessAreas/DrivesSolutions/ Documentations/VLT+Technical+Documentation.htm, for downloads or additional

information.

1.3 Approvals and Certifications

More approvals and certifications are available. Contact the local Danfoss partner.

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

For compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), refer to ADN-compliant Installation in the Design Guide.

1.4

Disposal Instruction

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

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

The VLT® Refrigeration Drive FC 103 Programming

•

Guide provides greater detail on working with parameters and many application examples.

The VLT® Refrigeration Drive FC 103 Design Guide

•

provides detailed capabilities and functionality to design motor control systems.

Supplemental publications and manuals are

•

available from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo-

lutions/Documentations/VLT+Technical +Documentation.htm for listings.

Optional equipment is available that may change

•

some of the procedures described. Refer to the

130BC252.11

13 (IP 20/Chassis)

(IP 21/54

NEMA 1/12)

130BC301.11

Introduction

Operating Instructions

1.5 Product Overview

A frequency converter is an electronic motor controller that converts DC into a variable AC waveform output. The frequency and voltage of the output are regulated to control the motor speed or torque. The frequency converter can vary the speed of the motor in response to system feedback, such as position sensors on a conveyor belt. The frequency converter can also regulate the motor by responding to remote commands from external controllers.

The frequency converter offers many control, monitoring and efficiency functions such as:

Monitoring the system and motor status

•

Issuing warnings or alarms for fault conditions

•

Starting and stopping the motor

•

Optimising energy efficiency

•

Operation and monitoring functions are available as status indications to an outside control system or serial communication network.

Interior Views

1.5.1

LCP (Local Control Panel) 9 Relay 2 (04, 05, 06)

1 2 RS-485 fieldbus

connector

3 Digital I/O and 24 V

supply 4 Analog I/O connector 12 Cable clamp (PE) 5 USB connector 13 Ground 6 Fieldbus terminal switch 14 Motor output terminals 96

7 Analog switches (A53),

(A54) 8 Relay 1 (01, 02, 03) 16 TB5 (IP21/54 only). Terminal

Illustration 1.2 Close-up View: LCP and Control Functions

10 Lifting ring

11 Mounting slot

(U), 97 (V), 98 (W)

15 Mains input terminals 91

(L1), 92 (L2), 93 (L3)

block for anti-condensation heater

Illustration 1.1 Interior Components - Enclosure Type D

130BB019.10

130BB020.10

Introduction Operating Instructions

Illustration 1.3 Compact IP21 (NEMA 1) and IP54 (NEMA 12) Enclosure Type E1

Illustration 1.4 Compact IP00 (Chassis) with Disconnect, Fuse and RFI Filter, Enclosure Type E2

AUX relay 5) Load sharing

1) 01 02 03 -DC +DC 04 05 06 88 89

2) Temp switch 6) SMPS fuse 106 104 105 7) Fan fuse

3) Mains 8) AUX fan R S T 100 101 102 103 91 92 93 L1 L2 L1 L2 L1 L2 L3 9) Mains ground

4) Brake 10) Motor

-R +R U V W 81 82 96 97 98 T1 T2 T3

Table 1.1 Legend to Illustration 1.3 and Illustration 1.4

Introduction Operating Instructions

1.6 Internal Controller Functions

Illustration 1.5 is a block diagram of the frequency converter's internal components.

Illustration 1.5 Frequency Converter Block Diagram

Area Title Functions

3-phase AC mains supply to the

1 Mains input

2 Rectifier

3 DC-bus

4 DC reactors

5 Capacitor bank

6 Inverter

7 Output to motor

8 Control circuitry

•

frequency converter

The rectifier bridge converts the

•

AC input to DC current to supply inverter power.

Intermediate DC-bus circuit

•

handles the DC current.

Filter the intermediate DC circuit

•

voltage.

Prove line transient protection.

•

Reduce RMS current.

•

Raise the power factor reflected

•

back to the line.

Reduce harmonics on the AC

•

input.

Stores the DC power.

•

Provides ride-through protection

•

for short power losses.

Converts the DC into a

•

controlled PWM AC waveform for a controlled variable output to the motor.

Regulated 3-phase output

•

power to the motor

Input power, internal

•

processing, output, and motor current are monitored to provide efficient operation and control.

User interface and external

•

commands are monitored and performed.

Status output and control can

•

be provided.

Table 1.2 Legend to Illustration 1.5

Introduction Operating Instructions

1.7 Enclosure Types and Power Ratings

Normal Overload [kW]

400 V D1h/

525 V D1h/

690 V D1h/

Table 1.3 kW Rated Frequency Converters

Normal Overload [hp]

55 75 90 110 132 160 200 250 315 355 400 450 500 560 630

D1h/

D1h/D3h/

D3h/

D5h/D6h

D5h/

D6h

D1h/

D3h/

D5h/

D6h

D1h/

D3h/

D5h/

D6h

75 100 125 150 200 250 300 350 400 450 500 550/

D6h

D1h/ D3h/ D5h/

D6h D1h/ D3h/ D5h/

D6h

D1h/ D3h/ D5h/

D6h D1h/ D3h/ D5h/

D6h

D2h/D4h/

D7h/D8h

D1h/D3h/

D5h/D6h

D2h/D4h/

D7h/D8h

D2h/D4h/

D7h/D8h

D2h/D4h/

D7h/D8h

D2h/ D4h/ D7h/

D8h D2h/ D4h/ D7h/

D8h

D2h/D4h/

D7h/D8h

D2h/D4h/

D7h/D8h

D2h/D4h/

D7h/D8h

E1/E2 E1/E2 E1/E2

E1/E2 E1/E2 E1/E2 E1/E2

E1/E2 E1/E2E1/E2 E1/E2

600 650

600

460 V D1h/D3h/

D5h/D6h

575 V D1h/D3h/

D5h/D6h

Table 1.4 Hp Rated Frequency Converters

D1h/ D3h/ D5h/ D6h

D1h/D3h/

D5h/D6h

D1h/D3h/

D5h/D6h

D1h/ D3h/ D5h/

D6h D1h/ D3h/ D5h/

D6h

D1h/ D3h/ D5h/

D6h D2h/ D4h/ D7h/

D8h

D2h/ D4h/ D7h/

D8h D2h/ D4h/ D7h/

D8h

D2h/ D4h/ D7h/

D8h D2h/ D4h/ D7h/

D8h

D2h/

D2h/ D4h/ D7h/

D8h

E1/E2 E1/E2E1/E2 D4h/ D7h/

D8h

E1/E2 E1/E2 E1/E2 E1/E2

Safety

2 Safety

Operating Instructions

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 can also be used to alert against unsafe practices.

NOTICE

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

2.1 Qualified Personnel

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

Qualified personnel are defined as trained staff, who are authorised 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

Safety Precautions

WARNING

HIGH VOLTAGE

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

Installation, start-up, and maintenance must be

•

performed by qualified personnel only.

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains, or DC power supply, the motor may start at any time. Unintended start during programming, service or repair work can result in death, serious injury, 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. To prevent unintended motor start:

Disconnect the frequency converter from mains.

•

Press [Off/Reset] on the LCP, before

•

programming parameters. The frequency converter, motor, and any driven

•

equipment must be fully wired and assembled when the frequency converter is connected to AC mains, or DC power supply.

WARNING

DISCHARGE TIME

The frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not powered. Failure to wait the specified time after power has been removed before performing service or repair work, could result in death or serious injury.

Stop the motor.

•

Disconnect the AC mains, permanent magnet

•

type motors, and remote DC-link power supplies, including battery back-ups, UPS, and DC-link connections to other frequency converters.

Wait for the capacitors to discharge fully before

•

performing any service or repair work. The duration of waiting time is specified in Table 2.1.

Voltage [V] Minimum waiting time (minutes)

20 40

380-480 110-315 kW 355-450 kW 525-690 55-400 kW 450-630 kW High voltage may be present even when the warning LED indicator lights are off.

2 2

Table 2.1 Discharge Time

Safety Operating Instructions

WARNING

LEAKAGE CURRENT HAZARD

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

Ensure correct grounding of the equipment by

•

a certified electrical installer.

WARNING

EQUIPMENT HAZARD

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

Ensure that only trained and qualified

•

personnel perform installation, start up, and maintenance.

Ensure that electrical work conforms to national

•

and local electrical codes. Follow the procedures in this manual.

•

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 frequency converter can result in serious injury, when the frequency converter is not properly closed.

Ensure that all safety covers are in place and

•

securely fastened, before applying power.

105

298

[11.7]

404

[15.9]

130BC519.10

130BC520.10

105

523

[20.6]

395

[15.6]

748

(29.5)

579

(22.8)

176FA276.12

≤105,0°

Installation Operating Instructions

3 Installation

3.1 Pre-Installation

3.1.1 Planning the Installation Site

NOTICE

Plan the installation site of the frequency converter before commencing the installation. Neglecting this may result in extra work during and after installation.

Select the best possible operation site by considering the following (see details on the following pages and the respective Design Guides):

Ambient operating temperature

•

Installation method

•

How to cool the unit

•

Position of the frequency converter

•

Cable routing

•

Ensure that the power source supplies the correct

•

voltage and necessary current. Ensure that the motor current rating is within the

•

maximum current from the frequency converter. If the frequency converter is without built-in

•

fuses, ensure that the external fuses are rated correctly.

3 3

Illustration 3.1 Front Clearance of IP21/IP54 Rated Enclosure Types D1h, D5h, and D6h

Voltage [V] Altitude restrictions

380-690 At altitudes above 2000 m, contact Danfoss

regarding PELV

Table 3.1 Installation at High Altitudes

General Considerations

3.1.2

Wire access

Ensure that proper cable access is present including necessary bending allowance. As the IP00/IP20 enclosure is open to the bottom, cables must be fixed to the back panel of the enclosure where the frequency converter is mounted, i.e. by using cable clamps.

CAUTION

All cable lugs/shoes must mount within the width of the terminal bus bar.

Space

Ensure proper space above and below the frequency converter to allow airflow and cable access. In addition space in front of the unit must be considered to enable opening of the panel door, see Illustration 3.1 to Illustration 3.3.

Illustration 3.2 Front Clearance of IP21/IP54 Rated Enclosure Types D2h, D7h, and D8h

Illustration 3.3 Front Clearance of IP21/IP54 Rated Enclosure Type E1

Installation

Operating Instructions

3.1.3 Tools Required for Installation

Drill with 10 or 12 mm drill

•

Tape measure

•

Wrench with relevant metric sockets (7-17 mm)

•

Extensions to wrench

•

Sheet metal punch for conduits or cable glands

•

in IP21/Nema 1 and IP54 units Lifting bar to lift the unit (rod or tube max. Ø 5

•

mm (1 inch), able to lift minimum 400 kg (880 lbs).

Crane or other lifting aid to place the frequency

•

converter in position A Torx T50 tool is needed to install the E1 in IP21

•

and IP54 enclosure types.

3.2 Pre-installation Checklist

Before unpacking the frequency converter, ensure

•

that the packaging is intact. If any damage has occurred, immediately contact the shipping company to claim the damage.

Unpack the frequency converter as close as

•

possible to the final installation site. Ensure the model number number on the

•

nameplate corresponds to the model number on the order.

Ensure that each of the following are rated for

•

the same voltage:

Mains (power)

•

Frequency converter

•

Motor

•

Ensure that the frequency converter output

•

current rating is equal to or greater than the motor full load current for peak motor performance.

Motor size and frequency converter

•

power must match for proper overload protection.

If frequency converter rating is less than

•

motor, full motor output cannot be achieved.

3.3

Mechanical Installation

3.3.1 Cooling

Provide top and bottom clearance for air cooling.

•

Generally, 225 mm (9 in) is required. Improper mounting can result in overheating and

•

reduced performance. Consider derating for temperatures starting

•

between 45 °C (113 °F) and 50 °C (122 °F) and elevation 1000 m (3300 ft) above sea level. See

VLT® Refrigeration Drive FC 103 Design Guide for detailed information.

The high-power frequency converters utilise a backchannel cooling concept that removes heat sink cooling air. Approximately 90% of the heat is lead out of the back channel of the frequency converters. The back-channel air can be redirected from the panel or room using one of the kits below.

Duct cooling

A back-channel cooling kit is available to direct the heat sink cooling air out of the panel when an IP20/chassis frequency converter is installed in a Rittal enclosure. Use of this kit reduces the heat in the panel and smaller door fans can be specified on the enclosure.

Cooling out the back (top and bottom covers)

The back-channel cooling air can be ventilated out of the room so that the heat from the back channel is not dissipated into the control room.

NOTICE

A door fan(s) is required on the enclosure to remove the heat not contained in the back channel of the frequency converters and any additional losses generated by other components inside the enclosure. Calculate the total required air flow so that the appropriate fans can be selected. A cooling clearance of 225 mm is required above the frequency converter.

Airflow

Secure the necessary airflow over the heat sink. The flow rate is shown in Table 3.2.

176FA245.10

Installation Operating Instructions

NOTICE

The fan runs for the following reasons:

AMA

•

DC hold

•

Pre-mag

•

DC brake

•

60% of nominal current is exceeded

•

Specific heat sink temperature exceeded (power

•

size dependent) Specific power card ambient temperature

•

exceeded (power size dependent) Specific control card ambient temperature

•

exceeded

Enclosure type Door fan/top fan Heat sink fan

D1h/D3h/D5h/D6h D2h/D4h/D7h/D8h E1 P450T7, P500T7

E1 P355-P450T4, P560-P630T7

E2 P450T7, P500T7

E2 P355-P450T4, P560-P630T7

Table 3.2 Airflow

102 m3/hr (60 CFM) 420 m3/hr (250 CFM) 204 m3/hr (120 CFM) 840 m3/hr (500 CFM) 340 m3/hr (200 CFM) 1105 m3/hr (650

CFM)

340 m3/hr (200 CFM) 1445 m3/hr (850

CFM)

255 m3/hr (150 CFM) 1105 m3/hr (650

CFM)

255 m3/hr (150 CFM) 1445 m3/hr (850

CFM)

Lifting

3.3.2

Always lift the frequency converter using the dedicated lifting eyes. Use a bar to avoid bending the lifting holes.

Illustration 3.4 Recommended Lifting Method

WARNING

RISK OF INJURY OR DEATH

The lifting bar must be able to handle the weight of the frequency converter to ensure that it will not break during lifting.

See Mechanical Dimensions for the weight of the

•

different enclosure types. Maximum diameter for bar is 2.5 cm (1 inch).

•

The angle from the top of the frequency

•

converter to the lifting cable should be 60° or greater.

Failure to follow recommendations could result in death or serious injury.

3 3

Installation Operating Instructions

3.3.3 Mechanical Dimensions

Enclosure type D1h D2h D3h D4h

110-160 kW

(380-480 V)

75-160 kW

IP NEMA Shipping dimensions [mm]

Drive dimensions [mm]

Max weight [kg] 98 164 98 164

Table 3.3 Mechanical Dimensions, Enclosure Types D1h-D4h

Enclosure type D5h D6h D7h D8h E1 E2

IP NEMA Shipping dimensions [mm]

Drive dimensions [mm]

Max weight [kg] 116 129 200 225 313 277

Height 587 587 587 587 Width 997 1170 997 1170 Depth 460 535 460 535 Height 901 1107 909 1122 Width 325 420 250 350 Depth 378 378 375 375

110-160 kW

(380-480 V)

75-160 kW

(525-690 V)

21/54

Type 1/12 Height 660 660 660 660 840 831 Width 1820 1820 2470 2470 2197 1705 Depth 510 510 590 590 736 736 Height 1324 1663 1978 2284 2000 1547 Width 325 325 420 420 600 585 Depth 381 381 386 406 494 498

(525-690 V)

21/54

Type 1/12

110-160 kW

(380-480 V)

75-160 kW

(525-690 V)

21/54

Type 1/12

200-315 kW

(380-480 V)

200-400 kW

(525-690 V)

21/54

Type 1/12

200-315 kW

(380-480 V)

200-400 kW

(525-690 V)

21/54

Type 1/12

110-160 kW

(380-480 V)

75-160 kW

(525-690 V)

Chassis

200-315 kW

(380-480 V)

200-400 kW

(525-690 V)

21/54

Type 1/12

355-450 kW

(380-480 V)

450-630 kW

(525-690 V)

21, 54

Type 12

200-315 kW

(380-480 V)

200-400 kW

(525-690 V)

Chassis

355-450 kW

(380-480 V)

450-630 kW

(525-690 V)

Chassis

Table 3.4 Mechanical Dimensions, Enclosure Types D5h-D8h, E1-E2

130

[5.1]

656

[25.8]

844

[33.2]

901

[35.5]

148 [5.8]

18 [0.7]

[3.2]

[0.8]

378

[14.9]

507

[20.0]

164

[6.5]

674

[26.5]

[3.9]

200

[7.9]

200

[7.9]

180

[7.1]

246

[9.7]

325

[12.8]

[3.1]

123

[4.8]

844

[33.2]

561

[22.1]

130BC515.11

33 [1.3]

63 [2.5]

24 [0.9]

22 [0.9]

25 [1.0]

11 [0.4]

10 [0.4]

11 [0.4]

130BD514.10

Installation Operating Instructions

All dimensions are in mm [in]

3 3

1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space inlet minimum 225 mm [8.9 in] 4 Floor

Illustration 3.5 Mechanical Dimensions, D1h

NOTICE

If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, the required ceiling clearance is 100 mm.

1 Bottom mounting slot detail

2 Top mounting hole detail

Illustration 3.6 Detail Dimensions, D1h

211 [8.3]

623

[24.5]

148

[5.8]

280

[11.0]

346

[13.6]

420

[16.5]

1051

[41.4]

1107 [43.6]

857

[33.7]

130

[5.1]

320

[12.6]

271

[10.7]

[0.8]

[0.7]

379

[14.9]

[3.8]

879

[34.6]

142

[5.6]

107

[4.2]

213

[8.4]

1050

[41.3]

718

[28.3]

130BC516.11

33 [1.3]

25 [1.0]

24 [0.9]

20 [0.8]

75 [2.9]

11 [0.4]

9 [0.3]

11 [0.4]

12 [0.5]

130BD515.10

Installation Operating Instructions

1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space inlet minimum 225 mm [8.9 in] 4 Floor

Illustration 3.7 Mechanical Dimensions, D2h

NOTICE

If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, the required ceiling clearance is 100 mm.

1 Top mounting hole detail 2 Bottom mounting slot detail

Illustration 3.8 Detail Dimensions, D2h

130BC517.11

250

[9.8]

844

[33.2]

889

[35.0]

909

[35.8]

130

[5.1]

656

[25.8]

200 [7.9]

180

[7.1]

495

[19.5]

660

[26.0]

[2.4]

148 [5.8]

[3.2]

[0.7]

375

[14.8]

[0.8]

200

[7.9]

77.5

[3.1]

122.5 [4.8]

[1.0]

844

[33.2]

128

[5.0]

1 2

33 [1.3]

25 [1.0]

24 [0.9]

20 [0.8]

40 [1.6]

11 [0.4]

9 [0.3]

11 [0.4]

130BD517.10

Installation Operating Instructions

3 3

1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space inlet minimum 225 mm [8.9 in] 4 Floor

Illustration 3.9 Mechanical Dimensions, D3h

NOTICE

If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, the required ceiling clearance is 100 mm.

1 Top mounting hole detail 2 Bottom mounting slot detail

Illustration 3.10 Detail Dimensions, D3h

130BC518.11

280

[11.0]

857

[33.7]

130

[5.1]

320

[12.6]

1051

[41.4]

1096

[43.1]

1122

[44.2]

148 [5.8]

18 [0.7]

142 [5.6]

375

[14.8]

611

[24.1]

176 [6.9]

868

[34.2]

[2.3]

271

[10.7]

350

[13.8]

107

[4.2]

213

[8.4]

[1.5]

1050

[41.3]

[0.8]

64 [2.5]

63 [2.5]

24 [0.9]

9 [0.3]

25 [1.0]

11 [0.4]

20 [0.8]

15 [0.6]

11 [0.4]

1 2

130BD518.10

Installation Operating Instructions

1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space inlet minimum 225 mm [8.9 in] 4 Floor

Illustration 3.11 Mechanical Dimensions, D4h

NOTICE

If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, the required ceiling clearance is 100 mm.

1 Top mounting hole detail 2 Bottom mounting slot detail

Illustration 3.12 Detail Dimensions, D4h

130BD463.10

149 [5.9]

731 [28.8]

1107 [43.6]

381 [15]

115 [4.5]

23 [0.9]

16.1 [6.3]

1277 [50.3]

123 [4.8]

1324 [52.1]

1276 [50.2]

200 [7.9]

78 [3.1]

123 [4.8]

78 [3.1]

200 [7.9]

220 [8.7]

130 [5.1]

200 [7.9]

1111 [43.7]

130 [5.1]

325

[12.8] 306 [12.1]

276 [10.9]

180 [7.1]

64 [2.5]

63 [2.5]

24 [0.9]

9 [0.3]

25 [1.0]

11 [0.4]

20 [0.8]

15 [0.6]

11 [0.4]

1 2

130BD518.10

Installation Operating Instructions

3 3

1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in]

Illustration 3.13 Mechanical Dimensions, D5h

NOTICE

If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, the required ceiling clearance is 100 mm.

1 Top mounting hole detail 2 Bottom mounting slot detail

Illustration 3.14 Detail Dimensions, D5h

130BD464.10

1447 [57.0]

909 [35.8]

159 [6.3]

381 [15.0]

115 [4.5]

23 [0.9]

1663 [65.5]

1615 [63.6]

1452 [57.2]

559 [22.0]

130 [5.1]

200 [7.9]

123 [4.8]

78 [3.1]

200 [7.9]

325 [12.8]

306 [12.1]

276 [10.9]

180 [7.1]

130 [5.1]

1617 [63.7]

181 [7.1]

200 [7.9]

78 [3.1]

123 [4.8]

63.5 [3]

63 [2.5]

24 [0.9]

9 [0.3]

25 [1.0]

11 [0.4]

20 [0.8]

15 [0.6]

1 2

11 [0.4]

130BD519.10

Installation Operating Instructions

1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space intlet minimum 225 mm [8.9 in] 4 Floor

Illustration 3.15 Mechanical Dimensions, D6h

NOTICE

If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, the required ceiling clearance is 100 mm.

1 Top mounting hole detail 2 Bottom mounting slot detail

Illustration 3.16 Detail Dimensions, D6h

1754 [69.1]

209 [8.2]

1282 [50.5]

386 [15.2]

156 [6.2]

23 [0.9]

25 [1]

161 [6.3]

1931 [76]

170 [4.2] 213 [8.4] 320 [12.6]

1978 [77.9]

1953 [76.9]

107 [4.2]

213 [8.4]

320 [12.6]

280 [11]

374 [14.7]

411 [16.2]

420 [16.5]

130 [5.1]

1760 [69.3]

130 [5.1]

668 [26.3]

130BD465.10

70 [2.8]

25 [1.0]

23 [0.9]

11 [0.4]

130BD520.10

Installation Operating Instructions

3 3

1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in]

Illustration 3.17 Mechanical Dimensions, D7h

NOTICE

If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, the required ceiling clearance is 100 mm.

Illustration 3.18 Top Mounting Hole Dimension Detail, D7h

1699 [66.9]

1400 [55.1]

215 [8.5]

2236 [88]

406 [16]

156 [6.2]

23 [0.9]

25 [1]

162 [6.4]

2284 [89.9]

2259 [88.9]

107 [4.2] 213 [8.4]

320 [12.6]

107 [4.2] 213 [8.4]

320 [12.6]

420 [16.5]

411 [16.2]

374 [14.7]

280 [11]

130 [5.1]

2065 [81.3]

973 [38.3]

130BD466.10

[2.8] 25 [1.0]

23 [0.9]

11 [0.4]

130BD521.10

Installation Operating Instructions

1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in]

Illustration 3.19 Mechanical Dimensions, D8h

NOTICE

If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, the required ceiling clearance is 100 mm.

Illustration 3.20 Top Mounting Hole Dimension Detail, D8h

225

8.86( )

1551

61.1( )

2000

(78.74)

727

28.6( )

2.8( )

164

600

(23.62)

198

7.8( )

145

5.7( )

494

19.4( )

392

15.4( )

538

21.2( )

160

6.3( )

1043

41.1( )

160

6.3( )

2.8( )

1.1( )

0.9( )

185

7.3( )

185

7.3( )

2.3( )

484

19.1()

2X13

0.5

( )

1.0

(

)

2.2( )

6.5( )

185

7.3( )

1.0( )

130BA444.10

SIDE CABLE ENTRY KNOCK-OFF PLATE

CABLE BASE

BOTTOM CABLE ENTRY

IP21 AND IP54 / UL AND NEMA TYPE 1 AND 12

Ø 25

Installation Operating Instructions

3 3

F Lifting eye detail

Illustration 3.21 Mechanical Dimensions, E1

130BA445.10

225

1320

585

269

156

498

539

1547

1502

160

1043

184

139

304

2X13

(2.5)

(23.0)

(52.0)

(6.2)

(19.5)

(10.6)

(21.2)

(60.9)

(5.5)

(12.0)

(7.3) (7.3)

(0.5)

(1.5)

120 (4.7)

(1.0)

(59.1)

(41.1)

(6.3)

(8.9)

225 (8.9)

(1.0)

(0.9)

(1.0)

(0.5)

IP00 / CHASSIS

Installation Operating Instructions

D Lifting eye detail E Rear mounting slots

Illustration 3.22 Mechanical Dimensions, E2

Installation

Operating Instructions

3.4 Electrical Installation

3.4.1 General Requirements

This section contains detailed instructions for wiring the frequency converter. The following tasks are described:

Wiring the motor to the frequency converter

•

output terminals. Wiring the AC mains to the frequency converter

•

input terminals. Connecting control and serial communication

•

wiring. After power has been applied, checking input

•

and motor power; programming control terminals for their intended functions.

WARNING

EQUIPMENT HAZARD

Rotating shafts and electrical equipment can be hazardous. All electrical work must conform to national and local electrical codes. It is strongly recommended that installation, start up, and maintenance are performed only by trained and qualified personnel. Failure to follow these guidelines could result in death or serious injury.

3 3

CAUTION

WIRING ISOLATION

Run input power, motor wiring, and control wiring in 3 separate metallic conduits, or use separated shielded cable for high frequency noise isolation. Failure to isolate power, motor, and control wiring could result in less than optimum performance of the frequency converter and associated equipment.

130BD599.11

3-phase power

input

DC bus

Switch Mode Power Supply

Motor

Analog Output

Interface

relay1

relay2

ON=Terminated OFF=Open

Brake resistor

91 (L1) 92 (L2) 93 (L3)

88 (-) 89 (+)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

0/4-20 mA

12 (+24 V OUT)

13 (+24 V OUT)

37 (D IN)

18 (D IN)

20 (COM D IN)

10 V DC 15 mA 130/200 mA

+ - + -

(U) 96 (V) 97 (W) 98 (PE) 99

(COM A OUT) 39

(A OUT) 42

(P RS-485) 68

(N RS-485) 69

(COM RS-485) 61

0 V

S801

0/4-20 mA

RS-485

+10 V DC

0/-10 V DC -

+10 V DC

+10 V DC 0/4-20 mA

0/-10 V DC-

240 V AC, 2 A

24 V DC

24 V (NPN)

0 V (PNP)

24 V (NPN)

19 (D IN)

24 V (NPN)

0 V (PNP)

24 V

0 V

(D IN/OUT)

0 V (PNP)

24 V (NPN)

(D IN/OUT)

0 V

24 V

24 V (NPN)

0 V (PNP)

24 V (NPN)

33 (D IN)

32 (D IN)

1 2

S201

S202

ON=0/4-20 mA OFF=0/-10 V DC +10 V DC

P 5-00

S801

(R+) 82

(R-) 81

: Chassis

240 V AC, 2 A

400 V AC, 2 A

: Ground

: Ground 1

: Ground 2

: PE

Installation

Operating Instructions

Illustration 3.23 Interconnect Diagram

A=Analog, D=Digital *Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the VLT® Frequency

Converters - Safe Torque Off Operating Instructions. **Do not connect cable screen.

Motor

Line Power

Stop

Start

Speed

Control

130BX370.10

Installation Operating Instructions

For safety, comply with the following requirements:

Electronic controls equipment is connected to

•

hazardous mains voltage. Take extreme to protect against electrical hazards when applying power to the unit.

Run motor cables from multiple frequency

•

converters separately. Induced voltage from output motor cables run together can charge equipment capacitors, even with the equipment turned off and locked out.

Field wiring terminals are not intended to receive

•

a conductor one size larger.

Overload and equipment protection

An electronically activated function within the

•

frequency converter provides overload protection for the motor. The overload calculates the level of increase to activate timing for the trip (controller output stop) function. The higher the current draw, the quicker the trip response. The overload provides Class 20 motor protection. See chapter 9 Warnings and Alarms for details on the trip function.

Because the motor wiring carries high frequency

•

current, it is important that wiring for mains, motor power, and control are run separately. Use metallic conduit or separated shielded wire. See Illustration 3.24. Failure to isolate power, motor, and control wiring could result in less than optimum equipment performance.

All frequency converters must be provided with

•

short-circuit and overcurrent protection. Input fusing is required to provide this protection, see Illustration 3.25. If not factory supplied, fuses must be provided by the installer as part of installation. See maximum fuse ratings in chapter 11.3.1 Protection.

3 3

Illustration 3.24 Example of Proper Electrical Installation using Conduit

L1L2L2L3L3

91 92 93

130BB460.11

Installation Operating Instructions

established, see (>3.5 mA).

A dedicated ground wire is required for input

•

power, motor power, and control wiring. Use the clamps provided with the equipment for

•

1 Fuses 2 Ground

Illustration 3.25 Frequency Converter Fuses

Wire Type and Ratings

All wiring must comply with local and national

•

regulations regarding cross-section and ambient temperature requirements.

Danfoss recommends that all power connections

•

are made with a minimum 75 °C rated copper wire.

Grounding Requirements

3.4.2

WARNING

GROUNDING HAZARD

For operator safety, it is important to ground

•

the frequency converter properly in accordance with national and local electrical codes as well as instructions contained within this document.

Do not use conduit connected to the frequency

•

converter as a replacement for proper grounding.

Ground currents are higher than 3.5 mA.

•

Failure to ground the frequency converter properly could result in death or serious injury.

3.4.2.1

Follow national and local codes regarding protective earthing of equipment with a leakage current >3.5 mA. Frequency converter technology implies high frequency switching at high power. This generates a leakage current in the ground connection. A fault current in the frequency converter at the output power terminals might contain a DC component, which can charge the filter capacitors and cause a transient ground current. The ground leakage current depends on various system configurations including RFI filtering, screened motor cables, and frequency converter power.

EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3.5 mA. Grounding must be reinforced in one of the following ways:

See EN 60364-5-54 § 543.7 for further information.

proper ground connections. Do not ground one frequency converter to

•

another in a daisy-chain fashion. Keep the ground wire connections as short as

•

possible. Use high-strand wire to reduce electrical noise.

•

Follow motor manufacturer wiring requirements.

•

Leakage Current (>3.5 mA)

Ground wire of at least 10 mm

•

2 separate ground wires both complying with the

•

dimensioning rules

chapter 3.4.2.1 Leakage Current

NOTICE

It is the responsibility of the user or certified electrical installer to ensure correct grounding of the equipment in accordance with national and local electrical codes and standards.

Follow all local and national electrical codes to

•

ground electrical equipment properly. Proper protective earthing for equipment with

•

ground currents higher than 3.5 mA must be

130BC303.10

130BC304.10

Installation Operating Instructions

3.4.2.2 Grounding

The frequency converter can be grounded using conduit or shielded cable. For grounding of the power connections, use the dedicated grounding points as shown in Illustration 3.26 to Illustration 3.28.

3 3

Illustration 3.26 Grounding Points for IP20 (Chassis) Enclosures

Illustration 3.27 Grounding for IP21/54 Enclosures.

176FA259.11

:ASTENER TORQUE: MM8 9.6 Nm (7FT-LB)

ASTENER TORQUE: M10 19 Nm (14FT-LB)

S/L2 92

T/L3 93

R/L1 91

W/T3 98

Installation Operating Instructions

1 Ground terminals

Illustration 3.28 Position of Ground Terminals IP00, Enclosure Type E

130BC521.10

205 [8.1]

138 [5.4]

274

[10.8]

[1.0]

137 [5.4]

130BC524.11

196 [7.7]

145 [5.7]

[1.0]

185 [7.3]

369 [14.5]

111 [4.4]

224 [8.8]

242

[9.5]

121

[4.8]

[1.7]

130BC550.11

Installation Operating Instructions

3.4.3 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA 12)

Cables are connected through the gland plate from the bottom. Remove the plate and plan where to place the entry for the glands or conduits. Illustration 3.29 to Illustration 3.33 show the cable entry points viewed from the bottom of various frequency converters.

NOTICE

Fit the gland plate to the frequency converter to ensure the specified protection degree.

3 3

Mains side

1 2 Motor side

Illustration 3.30 D2h, Bottom View

1 Mains side 2 Motor side

Illustration 3.29 D1h, Bottom View

Mains side

1 2 Motor side

Illustration 3.31 D5h & D6h, Bottom View

130BC552.11

222 [8.7]

115 [4.5]

337

[13.3]

169 [6.6]

[1.7]

-A-

176FA289.12

350

202.8

98.6

130.0

62.5

Installation Operating Instructions

Motor Connection

3.4.4

WARNING

INDUCED VOLTAGE

Induced voltage from output motor cables run together

1 Mains side 2 Motor side

Illustration 3.32 D7h & D8h, Bottom View

can charge equipment capacitors even with the equipment turned off and locked out.

Run output motor cables from multiple

•

frequency converters separately.

Failure to run output motor cables separately could result in death or serious injury.

For maximum cable sizes, see chapter 11.1 Power-

•

dependent Specifications. Comply with local and national electrical codes

•

for cable sizes. Gland plates are provided at the base of IP21/54

•

and higher (NEMA 1/12) units. Do not install power factor correction capacitors

•

between the frequency converter and the motor. Do not wire a starting or pole-changing device

•

between the frequency converter and the motor. Connect the 3-phase motor wiring to terminals

•

96 (U), 97 (V), and 98 (W). Ground the cable in accordance with the

•

instructions provided. Torque terminals in accordance with the

•

information provided in chapter 11.3.4 Connection Tightening Torques.

Follow motor manufacturer wiring requirements.

•

Mains side

1 2 Motor side

Illustration 3.33 E1, Bottom View

1.3[ ]

0.0[ ]

2.4[ ]

101

4.0[ ]

140

5.5[ ]

163

6.4[ ]

185

7.3[ ]

224

8.8[ ]

263

10.4[ ]

293

11.5[ ]

GROUND 88

3.5[ ]

0.0[ ]

200

7.9[ ]

3.7[ ]

244

9.6[ ] 0

0.0[ ]

272

10.7[ ]

0.0[ ]

R T V

3X M8x20 STUD WITH NUT

SECTION A-A

MAINS TERMINALS

MAINS TERMINAL

SECTION B-B

MOTOR TERMINALS

MOTOR

TERMINAL

130BC305.10

254.7

10[ ]

0.0

0[ ]

GROUND 143.4

6[ ]

0.0 0[ ]

GROUND 168.4

7[ ]

331.2 13[ ]

211.1 8[ ]

GROUND168.4

7[ ]

GROUND143.4

6[ ]

42.4

2[ ]

0.0

0[ ]

68.1

3[ ]

125.8

5[ ]

183.5

7[ ]

245.8

10[ ]

299.8

12[ ]

353.8

14[ ]

377.6

15[ ]

284.2

11[ ]

0.0

0[ ]

4X M10x20 STUD WITH NUT

SECTION B-B

MOTOR TERMINALS AND

BRAKE TERMINALS

MOTOR TERMINAL

SECTION A-A

MAINS TERMINALS

MAINS TERMINAL

130BC332.10

Installation Operating Instructions

3.4.4.1 Terminal Locations: D1h-D4h

3 3

Illustration 3.34 Terminal Locations D1h

Illustration 3.35 Terminal Locations D2h

3.3[ ]

0.0[ ]

188

7.4[ ]

244

9.6[ ] 0

0.0[ ]

290

11.4[ ]

272

10.7[ ]

0.0[ ]

0.9[ ]

0.0[ ] 62

2.4[ ]

101

4.0[ ]

145

5.7[ ]

184

7.2[ ]

223

8.8[ ]

152

6.0[ ] 217

8.5[ ]

292

11.5[ ]

BRAKE

SECTION A-A

MAINS TERMINALS

MAINS TERMINAL

SECTION B-B

MOTOR TERMINALS AND

BRAKE TERMINALS

MOTOR TERMINAL

BRAKE

TERMINAL

130BC302.10

1.3[ ]

0.0[ ] 91

3.6[ ]

149

5.8[ ]

211

8.3[ ]

265

10.4[ ]

319

12.6[ ]

200

7.9[ ]

0.0[ ]

319

12.6[ ]

376

14.8[ ]

293

11.5[ ]

255

10.0[ ]

0.0[ ]

306

12.1[ ]

284

11.2[ ]

0.0[ ]

236.8

9[ ]

BRAKE

TERMINALS

SECTION A-A

MAINS TERMINALS

MAINS TERMINAL

SECTION B-B

MOTOR TERMINALS AND

BRAKE TERMINALS

TERMINAL

BRAKE / REGEN

MOTOR TERMINAL

130BC333.10

Installation Operating Instructions

Illustration 3.36 Terminal Locations D3h

Illustration 3.37 Terminal Locations D4h

1.8[ ]

0[ ]

1.8[ ]

3.9[ ]

153

6[ ]

146

5.8[ ] 182

7.2[ ]

193

7.6[ ]

249

9.8[ ]

221

8.7[ ] 260

10.2[ ]

118

4.6[ ]

0[ ]

148

5.8[ ]

221

8.7[ ]

3.6[ ]

196

7.7[ ]

227

9[ ]

113

4.4[ ]

0[ ]

206

8.1[ ]

A-A

B-B

130BC535.11

Installation Operating Instructions

3.4.4.2 Terminal Locations: D5h-D8h

3 3

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

Illustration 3.38 Terminal Locations, D5h with Disconnect Option

1.3[ ]

0[ ]

2.4[ ]

101

4[ ]

140

5.5[ ]

163

6.4[ ]

185

7.3[ ]

191

7.5[ ]

224

8.8[ ]

256

10.1[ ]

263

10.4[ ]

293

11.5[ ]

511

20.1[ ]

0[ ]

517

20.4[ ]

623

24.5[ ]

727

28.6[ ]

246

9.7[ ]

0[ ]

293

11.5[ ]

274

10.8[ ]

0[ ]

B-B

A-A

130BC536.11

Installation Operating Instructions

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

Illustration 3.39 Terminal Locations, D5h with Brake Option

0.0[ ]

3.8[ ]

195

7.7[ ]

227

8.9[ ]

123

4.8[ ]

153

6.0[ ]

458

18.0[ ]

0.0[ ]

1.8[ ]

2.0[ ]

3.9[ ] 147

5.8[ ]

182

7.2[ ]

193

7.6[ ]

221

8.7[ ]

249

9.8[ ]

260

10.2[ ]

146

5.8[ ]

0.0[ ] 286

11.2[ ]

0.0[

113

4.4[ ]

]

206

8.1[ ]

B-B

A-A

130BC537.12

Installation Operating Instructions

3 3

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

Illustration 3.40 Terminal Locations, D6h with Contactor Option

3.9[ ] 153

6.0[ ]

0.0[ ]

225

8.9[ ]

1.8[ ]

0.0[ ] 286

11.2[ ] 0

0.0[ ] R

A-A

130BC538.12

Installation Operating Instructions

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

Illustration 3.41 Terminal Locations, D6h with Contactor and Disconnect Options

130BC542.11

BAA

372

14.7[ ]

412

16.2[ ]

395

15.6[ ]

515

20.3[ ]

0[ ]

2.6[ ]

3.7[ ]

131

5.1[ ]

151

5.9[ ]

195.5

8[ ]

238

9.4[ ]

292

11.5[ ]

346

13.6[ ]

1.9[ ]

198

7.8[ ]

368

14.5[ ]

545

21.4[ ]

0[ ]

119

4.7[ ] 276

10.9[ ]

0[ ]

B-B

A-A

Installation Operating Instructions

3 3

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

Illustration 3.42 Terminal Locations, D7h with Disconnect Option

130BC543.11

0[ ]

2.6[ ]

123

4.9[ ]

181

7.1[ ]

243

9.6[ ]

269

10.6[ ]

297

11.7[ ]

325

12.8[ ]

351

13.8[ ]

1.6[ ]

0[ ]

1009

39.7[ ]

1034

40.7[ ]

1082

42.6[ ]

1202

47.3[ ]

1260

49.6[ ]

375

14.8[ ]

290

11.4[ ]

0[ ]

257

10.1[ ]

309

12.1[ ]

0[ ]

B-B

A-A

Installation Operating Instructions

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

Illustration 3.43 Terminal Locations, D7h with Brake Option

2.7[ ]

0[ ]

123

4.9[ ]

177

7[ ]

238

9.4[ ]

292

11.5[ ]

346

13.6[ ]

1.9[ ]

378

14.9[ ]

198

7.8[ ]

378

14.9[ ]

0[ ]

418

16.5[ ]

898

35.3[ ]

401

15.8[ ]

521

20.5[ ]

3.7[ ]

151

5.9[ ]

119

4.7[ ]

0[ ]

252

9.9[ ]

127

5[ ]

0[ ]

A-A

B-B

130BC544.12

Installation Operating Instructions

3 3

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

Illustration 3.44 Terminal Locations, D8h with Contactor Option

567

22.3[ ]

0[ ]

2.3[ ]

0[ ]

123

4.9[ ]

188

7.4[ ]

246

9.7[ ]

0[ ]

C-C

130BC545.12

Installation

Operating Instructions

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

Illustration 3.45 Terminal Locations, D8h with Contactor and Disconnect Options

176FA278.10

0[0.0]

600[23.6]

525[20.7]

412[16.2]

300[11.8]

188[7.4]

75[3.0]

492[19.4]

323[12.7]

195[7.7]

0[0.0]

155[6.1]

193[7.6]

280[11.0]

371[14.6]

409[16.1]

Installation Operating Instructions

3.4.4.3 Terminal Locations: E1-E2

Terminal Locations - E1

Consider the following position of the terminals when designing the cable access.

3 3

Illustration 3.46 IP21 (NEMA 1) and IP54 (NEMA 12) Enclosure Power Connection Positions

176FA272.10

0[0.0]

55[2.2]

91[3.6]

139[5.5]

175[6.9]

0[0.0]

453[17.8]

A A A A

-R 81

19 Nm [14 FTa

Installation Operating Instructions

Illustration 3.47 IP21 (NEMA 1) and IP54 (NEMA 12) Enclosure Power Connection Positions (Detail B)

0 0.0[ ]

51 2.0[ ]

226 8.9[ ]

266 10.5[ ]

441 17.4[ ]

0 0.0[ ]

28 1.1[ ]

167 6.6[ ] 195 7.7[ ]

0 0.0[ ]

176FA279.11

Installation Operating Instructions

3 3

Illustration 3.48 IP21 (NEMA 1) and IP54 (NEMA 12) Enclosure Power Connection Position of Disconnect Switch

Enclosure

types

IP54/IP21 UL AND NEMA1/NEMA12 A B C D E F

Unit type Dimensions [mm]/(inch)

450-630 KW (690 V) 396 (15.6) 267 (10.5) 332 (13.1) 397 (15.6) 528 (20.8) N/A 355-450 kW (400 V) 408 (16.1) 246 (9.7) 326 (12.8) 406 (16.0) 419 (16.5) 459 (18.1)

Table 3.5 Dimensions for Disconnect Terminal

176FA280.10

585[23.0]

518[20.4]

405[15.9]

68[2.7]

0[0.0]

186[7.3]

0[0.0]

181[7.1]

293[11.5]

409[16.1]

371[14.6]

280[11.0]

192[7.6]

154[6.1]

17[0.7]

R/L1 91

S/L2 92

U/T1 96 V/T2 97

T/L3 93

W/T3 98

FASTENER TORQUE M8 9.6 Nm (7 FT-LB) FASTENER TORQUE M8 9.6 Nm (7 FT-LB)

176FA282.10

0(0.0)

47(1.9)

83(3.3)

131(5.2)

167(6.6)

0(0.0)

147(5.8)

A A A A

019Nm (14 F)

R 81

Installation Operating Instructions

Terminal locations - enclosure type E2

Consider the following position of the terminals when designing the cable access.

Illustration 3.49 IP00 Enclosure Power Connection Positions

Illustration 3.50 IP00 Enclosure Power Connection Positions

0.0[ ]

0 0.0[ ]

176FA281.11

Installation Operating Instructions

3 3

Illustration 3.51 IP00 Enclosure Power Connections Positions of Disconnect Switch

NOTICE

Power connections can be made to positions A or B

Enclosure

type

Table 3.6 Dimensions for Disconnect Terminal

3.4.5

250/315 kW (400 V) AND 355/450-500/630

315/355-400/450 kW (400 V) 408 (16.1) 239 (9.4) 319 (12.5) 399 (15.7) 113 (4.4) 153 (6.0)

Motor Cable

Connect the motor to terminals U/T1/96, V/T2/97, W/T3/98. Ground to terminal 99. All types of 3-phase asynchronous standard motors can be used with a frequency converter unit. The factory setting is for clockwise rotation with the frequency converter output connected as follows:

Terminal no. Function

96, 97, 98, Mains U/T1, V/T2, W/T3 99 Ground

Unit type Dimensions [mm]/(inch)

IPOO/CHASSIS A B C D E F

KW (690 V)

396 (15.6) 268 (10.6) 333 (13.1) 398 (15.7) 221 (8.7) N/A

Table 3.7 Terminals for Motor Cable Connection

175HA036.11

U1V

96 97 98

Motor

2V2

U1V

96 97 98

Motor

2V2

130BC254.10

Installation Operating Instructions

3.4.6 Motor Rotation Check

The direction of rotation can be changed by switching 2 phases in the motor cable, or by changing the setting of 4-10 Motor Speed Direction.

Terminal U/T1/96 connected

•

to U-phase

Terminal V/T2/97 connected

•

to V-phase

Terminal W/T3/98

•

connected to W-phase

Table 3.8 Wiring for Changing Motor Direction

A motor rotation check can be performed using 1-28 Motor Rotation Check and following the steps shown in the

display.

AC Mains Connection

3.4.7

All frequency converters may be used with an

•

isolated input source as well as with ground reference power lines. When supplied from an

Mains connection

2 Motor connection

isolated mains source (IT mains or floating delta) or TT/TN-S mains with a grounded leg (grounded

Illustration 3.52 Connecting to AC Mains

delta), set 14-50 RFI Filter to [0] Off. When off, the internal RFI filter capacitors between the chassis and the intermediate circuit are isolated. Isolating the capacitors prevents damage to the intermediate circuit and reduces ground capacity currents in accordance with IEC 61800-3.

Size wiring is based upon the input current of the

•

frequency converter. Comply with local and national electrical codes

•

for cable sizes.

1. Ground the cable in accordance with the instructions provided.

2. Connect 3-phase AC input power wiring to terminals L1, L2, and L3 (see Illustration 3.52).

175ZT975.10

Installation Operating Instructions

3.4.8 Shielding against Electrical Noise

To ensure best EMC performance, mount the EMC metal cover before mounting the mains power cable.

NOTICE

The EMC metal cover is only included in units with an RFI filter.

Illustration 3.53 Mounting of EMC Shield.

3.5.2

Using Screened Control Cables

Danfoss recommends braided screened/armoured cables to optimise EMC immunity of the control cables and the EMC emission from the motor cables.

The ability of a cable to reduce the incoming and outgoing radiation of electric noise depends on the transfer impedance (ZT). The screen of a cable is normally designed to reduce the transfer of electric noise; however, a screen with a lower transfer impedance (ZT) value is more effective than a screen with a higher transfer impedance (ZT).

Transfer impedance (ZT) is rarely stated by cable manufacturers, but it is often possible to estimate transfer impedance (ZT) by assessing the physical design of the cable.

Transfer impedance (ZT) can be assessed on the basis of the following factors:

The conductibility of the screen material.

•

The contact resistance between the individual

•

screen conductors. The screen coverage, i.e. the physical area of the

•

cable covered by the screen - often stated as a percentage value.

Screen type, i.e. braided or twisted pattern.

•

3 3

3.5 Control Wiring Connection

Isolate control wiring from high power

•

components in the frequency converter. If the frequency converter is connected to a

•

thermistor for PELV isolation, optional thermistor control wiring must be reinforced/double insulated. A 24 V DC supply voltage is recommended.

Access

3.5.1

All terminals to the control cables are located underneath the LCP on the inside of the frequency converter. To access, open the door (IP21/54) or remove the front panel (IP20).

175ZA166.13

0,01 0,1 1 10 100 MHz

10

10

10

10

10

10

10

10

The lower the Z the better the cable screening performance

Transfer impedance, Z

mOhm/m

PLC

130BB922.12

PE PE

<10 mm

100nF

PLC

<10 mm

130BB609.12

130BB923.12

PE PE

69 68 61

<10 mm

130BB924.12

PE PE

<10 mm

Installation Operating Instructions

Min. 16 mm

2 Equalizing cable

Illustration 3.55 Correct Screening

50/60 Hz ground loops

With very long control cables, ground loops may occur. To eliminate ground loops, connect one end of the screen-toground with a 100 nF capacitor (keeping leads short).

Illustration 3.56 Avoiding Ground Loops

a Aluminium-clad with copper wire b Twisted copper wire or armoured steel wire cable c Single-layer braided copper wire with varying percentage

screen coverage (this is the typical Danfoss reference

cable). d Double-layer braided copper wire e Twin layer of braided copper wire with a magnetic,

screened/armoured intermediate layer f Cable that runs in copper tube or steel tube g Lead cable with 1.1 mm wall thickness

Avoid EMC noise on serial communication

This terminal is connected to ground via an internal RC link. Use twisted-pair cables to reduce interference between conductors. The recommended method is shown below:

Illustration 3.54 Cable Screening Performance

Grounding of Screened Control

3.5.3 Cables

Correct screening

The preferred method in most cases is to secure control and serial communication cables with screening clamps provided at both ends to ensure best possible high frequency cable contact. If the ground potential between the frequency converter and the PLC is different, electric noise may occur that disturbs the entire system. Solve this problem by fitting an equalizing cable next to the control cable. Minimum cable cross section: 16 mm2.

Min. 16 mm

2 Equalizing cable

Illustration 3.57 Avoiding EMC Noise

Alternatively, the connection to terminal 61 can be omitted:

Min. 16 mm

2 Equalizing cable

Illustration 3.58 Screening without Using Terminal 61

130BA012.12

130BT306.10

Installation Operating Instructions

3.5.4 Control Terminal Types

Terminal functions and default settings are summarised in chapter 3.5.7 Control Terminal Functions.

Some options available for ordering with the unit

•

may provide additional terminals. See the manual provided with the equipment option.

3.5.5 Wiring to Control Terminals

Terminal plugs can be removed for easy access.

Illustration 3.60 Removal of Control Terminals

Tie down all control wires to the designated control cable routing as shown in Illustration 3.60. Remember to connect the shields in a way which ensures optimum electrical immunity.

3 3

Fieldbus connection

Connections are made to the relevant options on the control card. For details, see the relevant fieldbus

Illustration 3.59 Control Terminal Locations

instruction. The cable must be placed in the provided path inside the frequency converter and tied down with other control wires (see Illustration 3.61).

Connector 1 provides:

•

4 programmable digital input terminals

2 additional digital terminals

programmable as either input or output 24 V DC terminal supply voltage

A common wire for optional customer

supplied 24 V DC voltage

Connector 2 terminals (+)68 and (-)69 are for an

•

RS-485 serial communications connection.

Connector 3 provides

•

2 analog inputs

1 analog output

10 V DC supply voltage

Common wires for the inputs and

output

Connector 4 is a USB port available for use with

•

the MCT 10 Set-up Software. Also provided are 2 Form C relay outputs which

•

are located on the power card.

176FA246.10

U/T1 96

-DC 88

R/L1 91

S/L2 92

T/L3 93

+DC 89

V/T2 97

W/13

130BT310.11

Installation Operating Instructions

The default terminal programming is intended to

•

initiate frequency converter functioning in a typical operational mode.

3.5.7.1 Terminal 53 and 54 Switches

Analog input terminals 53 and 54 can select

•

either voltage (0 to 10 V) or current (0/4-20 mA) input signals.

Remove power to the frequency converter before

•

changing switch positions. Set switches A53 and A54 to select the signal

•

type. U selects voltage, I selects current. The switches are accessible when the LCP has

•

been removed (see Illustration 3.62).

NOTICE

Some option cards available for the unit may cover these switches and must be removed to change switch settings. Always remove power to the unit before removing option cards. Observe the discharge time in Table 2.1.

Terminal 53 default is for a speed reference signal

•

Illustration 3.61 Control Card Wiring Path for E-enclosures

In the Chassis (IP00) and NEMA 1 units, it is also possible to connect the fieldbus from the top of the unit. On the NEMA 1 unit, a cover plate must be removed. Kit number for fieldbus top connection: 176F1742

in open loop, which is set in 16-61 Terminal 53

Switch Setting

Terminal 54 default is for a feedback signal in

•

closed loop, which is set in 16-63 Terminal 54 Switch Setting

Safe Torque Off (STO)

3.5.6

Safe Torque Off is an option. To run Safe Torque Off, additional wiring for the frequency converter is required.

Refer to VLT® Frequency Converters Safe Torque Off Operating Instructions for further information.

Control Terminal Functions

3.5.7

Frequency converter functions are commanded by receiving control input signals.

Each terminal must be programmed for the

•

function it is supporting in the parameters associated with that terminal. See

chapter 6 Programming and chapter 7 Application Examples for terminals and associated parameters.

It is important to confirm that the control

•

terminal is programmed for the correct function. See chapter 6 Programming for details on accessing parameters and programming.

Illustration 3.62 Location of Terminals 53 and 54 Switches and Bus Termination Switch

Installation Operating Instructions

3.6 Serial Communication

3.7.2

Mains Shield

RS-485 is a 2-wire bus interface compatible with multi-drop network topology, i.e. nodes can be connected as a bus, or via drop cables from a common trunk line. A total of 32 nodes can be connected to 1 network segment. Repeaters divide network segments. Each repeater functions as a node within the segment it is installed in. Each node connected within a given network must have a unique node address across all segments.

Terminate each segment at both ends, using

•

either the termination switch (S801) of the frequency converter or a biased termination resistor network.

Always use screened twisted pair (STP) cable for

•

bus cabling. Always follow good common installation practice.

•

Low-impedance ground connection of the screen at every node is important, including at high frequencies.

Connect a large surface of the screen to ground,

•

for example with a cable clamp or a conductive cable gland. It may be necessary to apply potential-equalizing cables to maintain the same ground potential throughout the network. Particularly in installations with long cables.

To prevent impedance mismatch, always use the

•

same type of cable throughout the entire network.

When connecting a motor to the frequency

•

converter, always use screened motor cable.

The mains shield is a Lexan cover installed inside the enclosure to provide protection according to BGV A3 (former VBG-4) accident-prevention requirements.

NOTICE

Mains shield is only available for IP21/IP54 (NEMA 1/ NEMA 12).

3 3

Cable Impedance Max. cable length [m] 1200 (including drop lines)

Table 3.9 Cable Information

3.7

Optional Equipment

Screened twisted pair (STP) 120 Ω

500 station-to-station

3.7.1 Anti-condensation Heater

An anti-condensation heater can be installed inside the frequency converter to prevent condensation from forming inside the enclosure when the unit is turned off. The heater is controlled by customer-supplied 230 V AC. For best results, only operate the heater when the unit is not running.

Start-up and Functional Tes... Operating Instructions

4 Start-up and Functional Testing

4.1 Pre-start

4.1.1 Safety Inspection

WARNING

HIGH VOLTAGE

If input and output connections have been connected improperly, there is potential for high voltage on these terminals. If power leads for multiple motors are improperly run in same conduit, there is potential for leakage current to charge capacitors within the frequency converter, even when disconnected from mains input.

For initial start-up, make no assumptions about power components.

•

Follow pre-start procedures.

•

Failure to follow pre-start procedures could result in personal injury or damage to equipment.

1. Switch off the Input power to the unit and ensure that it is locked out. Do not rely on the frequency converter disconnect switches for input power isolation.

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

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

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

5. Check for proper grounding of the frequency converter as well as the motor.

6. Inspect the frequency converter for loose connections on terminals.

7. Record the following motor-nameplate data

7a Power 7b Voltage 7c Frequency 7d Full load current 7e Nominal speed.

These values are needed to program the motor nameplate data later.

8. Confirm that the supply voltage matches the voltage of the frequency converter and the motor.

CAUTION

Before applying power to the unit, inspect the entire installation as detailed in Table 4.1. Check mark those items when completed.

Inspect for Description

Auxiliary equipment

Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers on the input

•

power side of the frequency converter 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 frequency converter.

•

Remove power factor correction caps on motors, if present.

•

☑

Start-up and Functional Tes... Operating Instructions

Inspect for Description

Cable routing

Control wiring

Cooling clearance

EMC considerations

Environmental considerations

Fusing and circuit breakers

Grounding

Input and output power wiring

Panel interior

Switches

Vibration

Use separate metallic conduits for each of the following:

•

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.

•

Use shielded or twisted pair cable. Ensure that the shield is terminated correctly.

•

Measure that top and bottom clearance is adequate to ensure proper air flow for cooling.

•

Check for proper installation regarding electromagnetic compatibility.

•

See equipment label for the maximum ambient operating temperature limits.

•

Humidity levels must be 5–95%, non-condensing.

•

Check for proper fusing or circuit breakers.

•

Check that all fuses are inserted firmly and in operational condition and that all circuit breakers are

•

in the open position.

The unit requires a ground wire from its chassis to the building ground.

•

Check for good ground connections that are tight and free of oxidation.

•

Grounding to conduit or mounting the back panel to a metal surface is not sufficient.

•

Check for loose connections.

•

Check that motor and mains are in separate conduit or separated screened cables.

•

Inspect that the unit interior is free of debris and corrosion.

•

Ensure that all switch and disconnect settings are in the proper positions.

•

Check that the unit is mounted solidly or that shock mounts are used, as necessary.

•

Check for an unusual amount of vibration.

•

☑

Input power

Motor wiring

Control wiring

4 4

Table 4.1 Start-up Checklist

130BC951.10

Start-up and Functional Tes...

Operating Instructions

4.2 Applying Power

WARNING

HIGH VOLTAGE

Frequency converters contain high voltage when connected to AC mains.

Only qualified personnel should perform instal-

•

lation, start-up and maintenance.

Failure to comply could result in death or serious injury.

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains, the motor may start at any time.

Ensure that the frequency converter, motor, and

•

any driven equipment are in operational readiness.

Failure to comply could result in death, serious injury, equipment, or property damage.

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 should be closed or cover mounted.

4. Apply power to the unit. DO NOT start the frequency converter at this time. For units with a disconnect switch, turn to the ON position to apply power to the frequency converter.

NOTICE

If the status line at the bottom of the display reads AUTO REMOTE COASTING or Alarm 60 External Interlock is displayed, this indicates that the unit is ready to operate, but is missing an input signal on terminal 27.

The built-in wizard menu guides the installer through the set-up of the frequency converter in a clear and structured manner, and has been constructed with reference to the industries refrigeration engineers, to ensure that the text and language is known within that specific business area.

At start-up, the FC 103 asks the user to run the VLT® Drive Application Guide or to skip it (until it has been run, the FC 103 asks every time at start-up), thereafter in the event of power failure, the application guide is accessed via the Quick Menu screen. If [Cancel] is pressed, the FC 103 returns to the status screen. An automatic timer cancels the wizard after 5 min. of inactivity (no keys pressed). The wizard must be reentered via the Quick Menu when it has been run once. Answering the questions on the screens takes the user though a complete set-up for the FC 103. Most standard refrigeration applications can be set up by using this application guide. Access advanced features via the menu structure (Quick Menu or Main Menu) in the frequency converter.

The FC 103 Wizard covers all standard settings for:

Compressors

•

Single fan and pump

•

Condenser fans

•

These applications are then further expanded to allow control of the frequency converter via its own internal PID controllers or from an external control signal.

After completing set-up, re-run the wizard or start the application

The application guide can be cancelled at any time by pressing [Back]. The application guide can be re-entered via the Quick Menu. When re-entering the application guide, either keep previous changes to the factory set-up or restore default values.

On power-up, the FC 103 launches an application guide. In the event of power failure, the application guide is accessed via the Quick Menu screen.

4.3 Basic Operational Programming

4.3.1 Set-up Wizard

NOTICE

RISK OF EQUIPMENT DAMAGE

Always stop the frequency converter before using the wizard. Failure to stop the frequency converter may cause equipment damage.

Illustration 4.1 Quick Menu Screen

If [Cancel] is pressed, the FC 103 returns to the status screen. An automatic timer cancels the wizard after 5 min. of inactivity (no keys pressed). Re-enter the wizard via the Quick Menu as described in this section.

130BC952.10

130BC953.10

130BC954.10

Start-up and Functional Tes...

If [OK] is pressed, the application guide starts with the following screen:

Illustration 4.2 Start-up of Application Guide

Operating Instructions

NOTICE

Numbering of steps in wizard (e.g. 1/12) can change depending on choices in the workflow.

This screen automatically changes to the first input screen of the application guide:

Illustration 4.6 Current and Nominal Speed Set-up

4 4

Illustration 4.7 Min. and Max. Frequency Set-up

Illustration 4.3 Language Selection

Illustration 4.4 Application Selection

Compressor pack set-up

As an example, see screens below for a compressor pack set-up:

Illustration 4.5 Voltage and Frequency Set-up

Illustration 4.8 Min. Time between 2 Starts

Illustration 4.9 Select with/without Bypass Valve

Illustration 4.10 Select Open Loop or Closed Loop

Start-up and Functional Tes... Operating Instructions

NOTICE

Internal/closed loop: The FC 103 controls the application directly using the internal PID control and needs an input from an external input, such as a temperature or other sensor, which is wired directly into the frequency converter and controls from the sensor signal. External/open loop: The FC 103 takes its control signal from another controller (such as a pack controller), which

gives the frequency converter e.g. 0-10 V, 4-20 mA or FC 103 Lon. The frequency converter changes its speed depending on this reference signal.

Illustration 4.11 Select Sensor Type

Illustration 4.14 Info: Set Switch Accordingly

Illustration 4.15 Select Unit and Conversion from Pressure

Illustration 4.12 Settings for Sensor

Illustration 4.13 Info: 4-20 mA Feedback Chosen - Connect Accordingly

Illustration 4.16 Select Fixed or Floating Setpoint

Illustration 4.17 Set Setpoint

Illustration 4.18 Set High/Low Limit for Setpoint

130BC955.10

130BP956.10

130BC957.10

Start-up and Functional Tes...

Illustration 4.19 Set Cut Out/In Value

Illustration 4.20 Select Pack Control Set-up

Operating Instructions

After completing set-up, re-run the wizard or start the application. Select between the following options:

Re-run wizard

•

Go to main menu

•

Go to status

•

Run AMA - Note this is a reduced AMA if

•

compressor application is selected, and full AMA if single fan and pump is selected.

If condenser fan is selected in application NO

•

AMA can be run. Run application - this mode starts the frequency

•

converter in either hand/local mode or via an external control signal if open loop is selected in an earlier screen.

4 4

Illustration 4.21 Set Number of Compressors in Pack

Illustration 4.22 Info: Connect Accordingly

Illustration 4.23 Info: Setup Completed

Illustration 4.24 Run Application

The application guide can be cancelled at any time by pressing [Back]. The application guide can be re-entered via the Quick Menu:

Illustration 4.25 Quick Menus

When re-entering the application guide, select between previous changes to the factory set-up or restore default values.

NOTICE

If the system requirement is to have the internal pack controller for 3 compressors plus bypass valve connected, specify FC 103 with the extra relay card (MCB

105) mounted inside the frequency converter. Programme the bypass valve to operate from one of the extra relay outputs on the MCB 105 board. This is needed because the standard relay outputs in the FC 103 are used to control the compressors in the pack.

130BP066.10

1107 RPM

0 -

Operation/Display

1 -

Load/Motor

2 -

Brakes

3 -

Reference / Ramps

3.84 A 1 (1)

Main menu

Operation / Display

0.0%

0-0

Basic Settings

0-1

Set-up Operations

0-2

LCP Display

0-3

LCP Custom Readout

0.00A 1(1)

130BP087.10

0-0

Basic Settings

0.0%

0-03 Regional Settings

[0] International

0.00A 1(1)

130BP088.10

130BB847.10

Q1 My Personal Menu

Q2 Quick Setup

Q5 Changes Made

Q6 Loggings

13.7% 13.0A 1(1)

Quick Menus

Start-up and Functional Tes...

Operating Instructions

4.3.2 Required Initial Frequency Converter Programming

NOTICE

If the wizard is run, ignore the following.

Frequency converters require basic operational programming before running for best performance. This

requires entering motor-nameplate data for the motor being operated and the minimum and maximum motor speeds. Enter data in accordance with the following procedure. Parameter settings recommended are intended for start-up and checkout purposes. Application settings may vary. See chapter 5 User Interface for detailed instructions on entering data via the LCP.

Enter data with power ON, but before operating the frequency converter.

1. Press [Main Menu] twice on the LCP.

2. Press the navigation keys to scroll to parameter

group 0-** Operation/Display and press [OK].

Illustration 4.28 Basic Settings

Press the navigation keys to select [0] Interna- tional or [1] North America as appropriate and press [OK]. (This changes the default settings for a number of basic parameters. See

chapter 6.4 International/North American Default Parameter Settings for a complete list.)

6. Press [Quick Menu] on the LCP.

7. Press the navigation keys to scroll to parameter

group Q2 Quick Setup and press [OK].

Illustration 4.26 Main Menu

3. Press the navigation keys to scroll to parameter

group 0-0* Basic Settings and press [OK].

Illustration 4.27 Operation/Display

4. Press the navigation keys to scroll to

0-03 Regional Settings and press [OK].

Illustration 4.29 Quick Menus

8. Select the language and press [OK].

9. A jumper wire should be in place between control terminals 12 and 27. If this is the case, leave 5-12 Terminal 27 Digital Input at factory default. Otherwise select No Operation. For frequency converters with an optional Danfoss bypass, no jumper wire is required.

10.

Set 3-02 Minimum Reference

11.

Set 3-03 Maximum Reference

12.

Set 3-41 Ramp 1 Ramp Up Time

13.

Set 3-42 Ramp 1 Ramp Down Time

14.

Set 3-13 Reference Site. Linked to Hand/Auto* Local Remote.

Start-up and Functional Tes...

Operating Instructions

4.4 Automatic Motor Adaptation

Automatic motor adaptation (AMA) is a test procedure, which measures the electrical characteristics of the motor to optimise compatibility between the frequency converter and the motor.

The frequency converter builds a mathematical

•

model of the motor for regulating output motor current. The procedure also tests the input phase balance of electrical power. It compares the motor characteristics with the data entered in parameters 1-20 to 1-25.

The motor shaft does not turn and no harm is

•

done to the motor while running the AMA. Some motors may be unable to run the complete

•

version of the test. In that case, select [2] Enable reduced AMA.

If an output filter is connected to the motor,

•

select Enable reduced AMA. If warnings or alarms occur, see

•

chapter 9 Warnings and Alarms

Run this procedure on a cold motor for best

•

results.

3. Press [OK].

Scroll to 1-28 Motor Rotation Check.

5. Press [OK].

Scroll to [1] Enable.

The following text appears: Note! Motor may run in wrong direction.

7. Press [OK].

8. Follow the on-screen instructions.

To change the direction of rotation, remove power to the frequency converter and wait for the discharge time to elapse, see Table 2.1. Reverse the connection of any 2 of the 3 motor cables on the motor or frequency converter side of the connection.

4.6 Local-control Test

CAUTION

MOTOR START

Ensure that the motor, system and any attached equipment are ready for start. It is the responsibility of the user to ensure safe operation under any condition. Failure to ensure that the motor, system, and any attached equipment is ready for start could result in personal injury or equipment damage.

4 4

NOTICE

The AMA algorithm does not work when using PM motors.

To run AMA

1. Press [Main Menu] to access parameters.

Scroll to parameter group 1-** Load and Motor.

3. Press [OK].

Scroll to parameter group 1-2* Motor Data.

5. Press [OK].

Scroll to 1-29 Automatic Motor Adaptation (AMA).

7. Press [OK].

Select [1] Enable complete AMA.

9. Press [OK].

10. Follow the on-screen instructions.

11. The test runs automatically and indicates when it is complete.

4.5

Check Motor Rotation

Before running the frequency converter, check the motor rotation. The motor runs briefly at 5 Hz or the minimum frequency set in 4-12 Motor Speed Low Limit [Hz].

1. Press [Quick Menu].

Scroll to Q2 Quick Setup.

NOTICE

The [Hand On] key provides a local start command to the frequency converter. The [Off] key provides the stop function. When operating in local mode, [▲] and [▼] increase and decrease the speed output of the frequency converter. [◄] and [►] move the display cursor in the numeric display.

1. Press [Hand On].

2. Accelerate the frequency converter by pressing [▲] to full speed. Moving the cursor left of the

decimal point provides quicker input changes.

3. Note any acceleration problems.

4. Press [Off].

5. Note any deceleration problems.

If acceleration problems were encountered:

If warnings or alarms occur, see

•

chapter 9 Warnings and Alarms. Check that motor data is entered correctly.

•

Increase the ramp-up time in 3-41 Ramp 1 Ramp

•

Up Time. Increase the current limit in 4-18 Current Limit.

•

Increase the torque limit in 4-16 Torque Limit

•

Motor Mode.

Start-up and Functional Tes...

If deceleration problems were encountered:

If warnings or alarms occur, see

•

chapter 9 Warnings and Alarms. Check that motor data is entered correctly.

•

Increase the ramp-down time in 3-42 Ramp 1

•

Ramp Down Time. Enable overvoltage control in 2-17 Over-voltage

•

Control.

See chapter 5.1.1 Local Control Panel for resetting the frequency converter after a trip.

Operating Instructions

NOTICE

Chapter 4.2 Applying Power and chapter 4.3 Basic Operational Programming conclude the procedures for

applying power to the frequency converter, basic programming, set-up, and functional testing.

4.7 System Start-up

The procedure in this section requires user-wiring and application programming to be completed. Chapter 7 Application Examples is intended to help with this task. Other aids to application set-up are listed in chapter 1.2 Additional Resources. The following procedure is recommended after application set-up by the user is completed.

CAUTION

MOTOR START

Ensure that the motor, system and any attached equipment is ready for start. It is the responsibility of the user to ensure safe operation under any condition. Failure to do so could result in personal injury or equipment damage.

1. Press [Auto On].

2. Ensure that the external control functions are properly wired to the frequency converter and all programming is completed.

3. Apply an external run command.

4. Adjust the speed reference throughout the speed range.

5. Remove the external run command.

6. Note any problems.

If warnings or alarms occur, see chapter 9 Warnings and Alarms.

130BD512.10

Auto

Reset

Hand

O

Status

Quick

Main

Alarm

Log

Back

Cancel

Info

Status

1(1)

0.00 kW

O Remote Stop

0.0Hz

Alarm

Warn.

0.00 A

0.0 %

2605 kWh

18 19 20 21

User Interface

5 User Interface

5.1 Local Control Panel

Operating Instructions

5.1.1

LCP Layout

The local control panel (LCP) is the combined display and keypad on the front of the unit. The LCP is the user interface to the frequency converter.

The LCP has several user functions.

Start, stop, and control speed when in local

•

control Display operational data, status, warnings and

•

cautions Programming frequency converter functions

•

Manually reset the frequency converter after a

•

fault when auto-reset is inactive

An optional numeric LCP (NLCP) is also available. The NLCP operates in a manner similar to the LCP. See the Programming Guide, for details on use of the NLCP.

The LCP is divided into 4 functional groups (see Illustration 5.1).

A. Display area B. Display menu keys C. Navigation keys and indicator lights (LEDs) D. Operation keys and reset

5 5

Illustration 5.1 Local Control Panel (LCP)

A. Display Area

The display area is activated when the frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V DC supply.

The information displayed on the LCP can be customised for user application. Select options in the Quick Menu Q3-13 Display Settings.

User Interface Operating Instructions

Callout Display Parameter number Default setting

1 1.1 0-20 Reference % 2 1.2 0-21 Motor current 3 1.3 0-22 Power [kW] 4 2 0-23 Frequency 5 3 0-24 kWh counter

Table 5.1 Legend to Illustration 5.1, Display Area

B. Display Menu Keys

Menu keys are used for menu access for parameter set-up, toggling through status display modes during normal

operation, and viewing fault log data.

Callout Key Function

6 Status Shows operational information. 7 Quick Menu Allows access to programming

parameters for initial set-up instructions and many detailed application instructions.

8 Main Menu Allows access to all programming

parameters.

9 Alarm Log Displays a list of current warnings, the

last 10 alarms, and the maintenance log.

Table 5.2 Legend to Illustration 5.1, Display Menu Keys

C. Navigation Keys and Indicator Lights (LEDs)

Navigation keys are used for programming functions and moving the display cursor. The navigation keys also provide speed control in local (hand) operation. There are also 3 frequency converter status indicator lights in this area.

Callout Key Function

10 Back Reverts to the previous step or list in the

menu structure.

11 Cancel Cancels the last change or command as

long as the display mode has not changed.

12 Info Press for a definition of the function being

displayed.

13 Navigation

keys

14 OK Press to access parameter groups or to

Press to move between items in the menu.

enable a choice.

Callout Indicator Light Function

15 ON Green The ON light activates when the

frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V supply.

16 WARN Yellow When a warning is issued, the

yellow WARN light comes on and text appears in the display area identifying the problem.

17 ALARM Red A fault condition causes the red

alarm light to flash and an alarm text is displayed.

Table 5.4 Legend to Illustration 5.1, Indicator Lights (LEDs)

D. Operation Keys and Reset

Operation keys are located at the bottom of the LCP.

Callout Key Function

18 Hand On Starts the frequency converter in local

control.

An external stop signal by control

•

input or serial communication overrides the local hand on.

19 Off Stops the motor but does not remove

power to the frequency converter.

20 Auto On Puts the system in remote operational

mode.

Responds to an external start

•

command by control terminals or serial communication.

21 Reset Resets the frequency converter manually

after a fault has been cleared.

Table 5.5 Legend to Illustration 5.1, Operation Keys and Reset

NOTICE

The display contrast can be adjusted by pressing [Status] and [▲]/[▼] keys.

Table 5.3 Legend to Illustration 5.1, Navigation Keys

1.1

1.3

1.2

130BT831.10

0.0%

Oﬀ Remote Stop

1 (1)

0.00 kw0.00 A

0.0Hz

2605kWh

Status

130BP045.10

Status

Quick Menu

Main

Alarm

Log

User Interface

Operating Instructions

5.1.2 Setting LCP Display Values

The display area is activated when the frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V DC supply.

The information displayed on the LCP can be customised for user application.

Each display readout has a parameter associated

•

with it. Options are selected in the quick menu Q3-13

•

Display Settings. Display 2 has an alternate larger display option.

•

The frequency converter status at the bottom line

•

of the display is generated automatically and is not selectable.

Display Parameter number Default setting

1.1 0-20 Reference %

1.2 0-21 Motor current

1.3 0-22 Power [kW] 2 0-23 Frequency 3 0-24 kWh counter

Illustration 5.2 Display Readouts

Display Menu Keys

5.1.3

Menu keys are used for menu access for parameter set-up, toggling through status display modes during normal operation, and viewing fault log data.

Illustration 5.3 Menu Keys

Key Function Status

Quick Menu

Main Menu

Alarm Log

Shows operational information.

In Auto mode, press to toggle between

•

status readout displays.

Press repeatedly to scroll through each

•

status display.

•

Press [Status] plus [▲] or [▼] to adjust the display brightness.

The symbol in the upper right corner of the

•

display shows the direction of motor rotation and which set-up is active. This is not programmable.

Allows access to programming parameters for initial set-up instructions and many detailed application instructions.

Press to access Q2 Quick Set-up for

•

sequenced instructions to program the basic frequency controller set-up.

Follow the sequence of parameters as

•

presented for the function set-up.

Allows access to all programming parameters.

Press twice to access top-level index.

•

Press once to return to the last location

•

accessed.

Press to enter a parameter number for

•

direct access to that parameter.

Displays a list of current warnings, the last 10 alarms, and the maintenance log.

For details about the frequency converter

•

before it entered the alarm mode, select the alarm number using the navigation keys and press [OK].

5 5

Table 5.6 Function Description Menu Keys

130BT117.10

Back

Info

Warn

Alarm

Cancel

130BP046.10

Hand

O

Auto

Reset

User Interface

Operating Instructions

5.1.4 Navigation Keys

Navigation keys are used for programming functions and

5.1.5

Operation Keys

Operation keys are located at the bottom of the LCP. moving the display cursor. The navigation keys also provide speed control in local (hand) operation. There are also 3 frequency converter status indicator lights in this area.

Illustration 5.5 Operation Keys

Illustration 5.4 Navigation Keys

Key Function Back

Cancel

Info

Navigation Keys OK

Table 5.7 Navigation Keys Functions

Light Indicator Function

Green ON The ON light activates when the

Yellow WARN When warning conditions are met,

Red ALARM A fault condition causes the red

Reverts to the previous step or list in the menu structure. Cancels the last change or command as long as the display mode has not changed. Press for a definition of the function being displayed. Press the 4 navigation keys to move between items in the menu. Press to access parameter groups or to enable a choice.

frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V supply.

the yellow WARN light comes on and text appears in the display area identifying the problem.

alarm light to flash and an alarm text is displayed.

Key Function Hand On

Off

Auto On

Reset

Table 5.9 Operation Keys Functions

5.2

Back-up and Copying Parameter

Starts the frequency converter in local control.

Use the navigation keys to control frequency

•

converter speed.

An external stop signal by control input or

•

serial communication overrides the local hand on.

Stops the motor, but does not remove power to the frequency converter. Puts the system in remote operational mode.

Responds to an external start command by

•

control terminals or serial communication.

Speed reference is from an external source.

•

Resets the frequency converter manually after a fault has been cleared.

Settings

Programming data is stored internally in the frequency

converter.

The data can be uploaded into the LCP memory

•

as a storage back up. Once stored in the LCP, the data can be

•

downloaded back into the frequency converter. Data can also be downloaded into other

•

frequency converters by connecting the LCP into those units and downloading the stored settings. (This is a quick way to program multiple units with the same settings).

Initialisation of the frequency converter to restore

•

factory default settings does not change data stored in the LCP memory.

Table 5.8 Indicator Lights Functions

User Interface

Operating Instructions

WARNING

UNINTENDED START

Disconnect the frequency converter from mains.

•

Press [Off/Reset] on the LCP, before

•

programming parameters. The frequency converter, motor, and any driven

•

equipment must be fully wired and assembled when the frequency converter is connected to AC mains, or DC power supply.

Uploading Data to the LCP

5.2.1

1. Press [Off] to stop the motor before uploading or downloading data.

Go to 0-50 LCP Copy.

3. Press [OK].

Select All to LCP.

5. Press [OK]. A progress bar shows the uploading process.

6. Press [Hand On] or [Auto On] to return to normal operation.

Downloading Data from the LCP

5.2.2

Restoring the frequency converter parameter settings back to default values is done by initialisation of the frequency converter. Initialisation can be carried out via 14-22 Operation Mode or manually.

Initialisation using 14-22 Operation Mode does not

•

change frequency converter data such as operating hours, serial communication selections, personal menu settings, fault log, alarm log, and other monitoring functions.

Using 14-22 Operation Mode is generally

•

recommended. Manual initialisation erases all motor,

•

programming, localisation, and monitoring data and restores factory default settings.

Recommended Initialisation

5.3.1

1. Press [Main Menu] twice to access parameters.

Scroll to 14-22 Operation Mode.

3. Press [OK].

Scroll to Initialisation.

5. Press [OK].

6. Remove power to the unit and wait for the display to turn off.

7. Apply power to the unit.

Default parameter settings are restored during start-up. This may take slightly longer than normal.

8. Alarm 80 is displayed.

9. Press [Reset] to return to operation mode.

5 5

Manual Initialisation

1. Press [Off] to stop the motor before uploading or downloading data.

Go to 0-50 LCP Copy.

3. Press [OK].

Select All from LCP.

5. Press [OK]. A progress bar shows the downloading process.

6. Press [Hand On] or [Auto On] to return to normal operation.

5.3

Restoring Default Settings

NOTICE

Initialisation restores the unit to factory default settings. Any programming, motor data, localisation, and monitoring records are lost. Uploading data to the LCP provides a back-up before initialisation.

5.3.2

1. Remove power to the unit and wait for the display to turn off.

2. Press and hold [Status], [Main Menu], and [OK] at the same time and apply power to the unit.

Factory default parameter settings are restored during start-up. This may take slightly longer than normal.

Manual initialisation does not reset the following frequency converter information:

15-00 Operating hours

•

15-03 Power Up's

•

15-04 Over Temp's

•

15-05 Over Volt's

•

5-1*

130BB848.10

3-15 Reference Resource

[

]] Analog input 53

14.7% 0.00A 1(1)

References

Q3-21

130BT762.10

3-02 Minimum Reference

0.000 Hz

14.7% 0.00A 1(1)

Analog Reference

Q3-21

130BT763.11

3-03 Maximum Reference

50.000 Hz

14.7% 0.00A 1(1)

Analog Reference

Q3-21

130BT764.10

6-10 Terminal 53 Low

Voltage

0.00 V

14.7% 0.00A 1(1)

Analog Reference

Programming Operating Instructions

6 Programming

6.1 Introduction

The frequency converter is programmed for its application functions using parameters. Parameters are accessed by pressing either [Quick Menu] or [Main Menu] on the LCP. (See chapter 5.1 Local Control Panel for details on using the LCP function keys). Parameters may also be accessed via a PC using the MCT 10 Set-up Software (see

chapter 6.6.1 Remote Programming with MCT 10 Set-up Software).

3-02 Minimum Reference. Set the minimum internal frequency converter reference to 0 Hz. (This sets the minimum frequency converter speed at 0 Hz).

The Quick Menu is intended for initial start-up (Q2-** Quick Set-up) and detailed instructions for common frequency

Illustration 6.2 Programming Example Step 2

converter applications (Q3-** Function Set-up). Step-by-step instructions are provided. These instructions enable the user to walk through the parameters used for programming applications in their proper sequence. Data entered in a parameter can change the options available in the parameters following that entry. The Quick Menu presents easy guidelines for getting most systems up and

3-03 Maximum Reference. Set the maximum internal frequency converter reference to 60 Hz. (This sets the maximum frequency converter speed at 60 Hz. Note that 50/60 Hz is a regional variation).

running.

The Main Menu accesses all parameters and allows for advanced frequency converter applications.

6.2

Programming Example

Here is an example for programming the frequency converter for a common application in open loop using the Quick Menu.

This procedure programs the frequency converter

•

to receive a 0-10 V DC analog control signal on input terminal 53.

The frequency converter responds by providing

•

Illustration 6.3 Programming Example Step 3

6-10 Terminal 53 Low Voltage. Set the minimum external voltage reference on terminal 53 to 0 V. (This sets the minimum input signal at 0 V).

6-60 Hz output to the motor proportional to the input signal (0-10 V DC=6-60 Hz).

Select the following parameters using the navigation keys to scroll to the titles and press [OK] after each action.

3-15 Reference 1 Source

Illustration 6.4 Programming Example Step 4

Illustration 6.1 Programming Example Step 1

Q3-21

130BT765.10

6-11 Terminal 53 High

Voltage

10.00 V

14.7% 0.00A 1(1)

Analog Reference

130BT773.11

Q3-21

14.7 % 0.00 A 1(1)

Analog Reference

6 - 14 Terminal 53 Low Ref./Feedb. Value

000020.000

130BT774.11

Q3-21

14.7 % 0.00 A 1(1)

Analog Reference

6 - 15 Terminal 53 High Ref./Feedb. Value

50.000

6-1*

A53

U - I

130BC958.10

0-10V

130BT768.10

2-** Brakes

3-** Reference / Ramps

4-** Limits / Warnings

5-** Digital In/Out

14.6% 0.00A 1(1)

Main Menu

Programming Operating Instructions

6-11 Terminal 53 High Voltage. Set the maximum external voltage reference on Terminal 53 to 10 V. (This sets the maximum input signal at 10 V).

Illustration 6.5 Programming Example Step 5

6-14 Terminal 53 Low Ref./Feedb. Value. Set the minimum speed reference on terminal 53 to 6 Hz. (This tells the frequency converter that the minimum voltage received on terminal 53 (0 V) equals 6 Hz output).

Illustration 6.8 Wiring Example for External Device Providing 0-10 V Control Signal (Frequency Converter Left, External Device Right)

6 6

6.3 Control Terminal Programming Examples

Illustration 6.6 Programming Example Step 6

6-15 Terminal 53 High Ref./Feedb. Value. Set the maximum speed reference on terminal 53 to 60 Hz. (This tells the frequency converter that the maximum voltage received on terminal 53 (10 V) equals 60 Hz output).

Illustration 6.7 Programming Example Step 7

Control terminals can be programmed.

Each terminal has specified functions it is capable

•

of performing. Parameters associated with the terminal enable

•

the function. For proper frequency converter functioning, the

•

control terminals must be:

Wired properly

Programmed for the intended function

Receiving a signal

See Table 6.1 for control terminal parameter number and default setting. (Default setting can change based on the selection in 0-03 Regional Settings).

The following example shows accessing terminal 18 to see the default setting.

1. Press [Main Menu] twice, scroll to parameter

group 5-** Digital In/Out Parameter Data Set and press [OK].

With an external device providing a 0-10 V control signal connected to frequency converter terminal 53, the system is now ready for operation. Note that the scroll bar on the right in the last illustration of the display is at the bottom, indicating the procedure is complete.

Illustration 6.8 shows the wiring connections used to enable this set-up.

Illustration 6.9 Main Menu Display Example

130BT769.10

5-0* Digital I/O mode

5-1* Digital Inputs

5-4* Relays

5-5* Pulse Input

14.7% 0.00A 1(1)

Digital In/Out

5-**

5-1*

130BT770.10

5-10 Terminal 18 Digital

Input

[

]] Start

14.7% 0.00A 1(1)

Digital Inputs

Programming

Operating Instructions

Scroll to parameter group 5-1* Digital Inputs and press [OK].

Illustration 6.10 Parameter Group Display Example

Scroll to 5-10 Terminal 18 Digital Input. Press [OK] to access function choices. The default setting

Illustration 6.11 Function Choice Display Example

Start is shown.

6.4 International/North American Default Parameter Settings

Setting 0-03 Regional Settings to [0] International or [1] North America changes the default settings for some parameters. Table 6.1 lists those parameters that are effected.

Parameter International default

parameter value

0-03 Regional Settings 0-71 Date Format DD-MM-YYYY MM/DD/YYYY 0-72 Time Format 24 h 12 h 1-20 Motor Power [kW] 1-21 Motor Power [HP] 1-22 Motor Voltage 230 V/400 V/575 V 208 V/460 V/575 V 1-23 Motor Frequency 3-03 Maximum Reference 3-04 Reference Function

International North America

See Note 1 See Note 1

See Note 2 See Note 2

50 Hz 60 Hz

Sum External/Preset

North American

default parameter

value

Parameter International default

parameter value

4-13 Motor Speed High Limit [RPM] See Note 3 4-14 Motor Speed High Limit [Hz] See Note 4 4-19 Max Output Frequency 4-53 Warning Speed High 5-12 Terminal 27 Digital Input 5-40 Function Relay [2] Drive ready No alarm 6-15 Terminal 53 High Ref./Feedb. Value 6-50 Terminal 42 Output

14-20 Reset Mode

22-85 Speed at Design Point [RPM] See Note 3 22-86 Speed at Design Point [Hz]

Table 6.1 International/North American Default Parameter Settings

Note 1: 1-20 Motor Power [kW] is only visible when 0-03 Regional Settings is set to [0] International. Note 2: 1-21 Motor Power [HP], is only visible when 0-03 Regional Settings is set to [1] North America. Note 3: This parameter is only visible when 0-02 Motor Speed Unit is set to [0] RPM. Note 4: This parameter is only visible when 0-02 Motor Speed Unit is set to [1] Hz. Note 5: The default value depends on the number of motor poles. For a 4 poled motor, the international default value is 1500 RPM and for a 2 poled motor, 3000 RPM. The corresponding values for North America is 1800 and 3600 RPM.

1500 RPM 1800 RPM

50 Hz 60 Hz

100 Hz 120 Hz

1500 RPM 1800 RPM

Coast inverse External interlock

50 60

Output frequency Speed 4-20 mA

Manual reset Infinite auto reset 1500 RPM 1800 RPM

50 Hz 60 Hz

Changes made to default settings are stored and available for viewing in the Quick Menu along with any programming entered into parameters.

1. Press [Quick Menu].

Scroll to Q5 Changes Made and press [OK].

Select Q5-2 Since Factory Setting to view all programming changes or Q5-1 Last 10 Changes for the most recent.

North American

default parameter

value

130BB850.10

Q5-1 Last 10 Changes

Q5-2 Since Factory Setti...

25.9% 0.00A 1(1)

Changes Made

130BP089.10

Q1 My Personal Menu

Q2 Quick Setup

Q3 Function Setups

Q5 Changes Made

25.9% 0.00A 1(1)

Quick Menus

Programming

Illustration 6.12 Changes Made

6.4.1 Parameter Data Check

1. Press [Quick Menu].

Scroll to Q5 Changes Made and press [OK].

Operating Instructions

6 6

Illustration 6.13 Q5 Changes Made

Select Q5-2 Since Factory Setting to view all programming changes or Q5-1 Last 10 Changes for the most recent.

6.5

Parameter Menu Structure

Establishing the correct programming for applications often requires setting functions in several related parameters. These parameter settings provide the frequency converter with the system details it needs to operate properly. System details may include such things as:

Input and output signal types

•

Programming terminals

•

Minimum and maximum signal ranges

•

Custom displays

•

Automatic restart

•

Other features

•

See the LCP display to view detailed parameter

•

programming and setting options. Press [Info] in any menu location to view

•

additional details for that function. Press and hold [Main Menu] to enter a parameter

•

number for direct access to that parameter. Details for common application set-ups are

•

provided in chapter 7 Application Examples.

Programming Operating Instructions

5-68 Pulse Output Max Freq #X30/6

5-8* I/O Options

5-80 AHF Cap Reconnect Delay

5-9* Bus Controlled

5-90 Digital & Relay Bus Control

5-94 Pulse Out #27 Timeout Preset

5-93 Pulse Out #27 Bus Control

5-96 Pulse Out #29 Timeout Preset

5-95 Pulse Out #29 Bus Control

5-98 Pulse Out #X30/6 Timeout Preset

5-97 Pulse Out #X30/6 Bus Control

6-** Analog In/Out

6-0* Analog I/O Mode

6-01 Live Zero Timeout Function

6-00 Live Zero Timeout Time

6-02 Fire Mode Live Zero Timeout Function

6-1* Analog Input 53

6-10 Terminal 53 Low Voltage

6-12 Terminal 53 Low Current

6-11 Terminal 53 High Voltage

6-14 Terminal 53 Low Ref./Feedb. Value

6-13 Terminal 53 High Current

6-16 Terminal 53 Filter Time Constant

6-15 Terminal 53 High Ref./Feedb. Value

6-17 Terminal 53 Live Zero

6-2* Analog Input 54

6-21 Terminal 54 High Voltage

6-20 Terminal 54 Low Voltage

6-23 Terminal 54 High Current

6-22 Terminal 54 Low Current

6-25 Terminal 54 High Ref./Feedb. Value

6-24 Terminal 54 Low Ref./Feedb. Value

6-27 Terminal 54 Live Zero

6-26 Terminal 54 Filter Time Constant

6-3* Analog Input X30/11

6-30 Terminal X30/11 Low Voltage

6-31 Terminal X30/11 High Voltage

6-35 Term. X30/11 High Ref./Feedb. Value

6-34 Term. X30/11 Low Ref./Feedb. Value

6-37 Term. X30/11 Live Zero

6-36 Term. X30/11 Filter Time Constant

6-4* Analog Input X30/12

6-40 Terminal X30/12 Low Voltage

6-41 Terminal X30/12 High Voltage

6-45 Term. X30/12 High Ref./Feedb. Value

6-44 Term. X30/12 Low Ref./Feedb. Value

6-47 Term. X30/12 Live Zero

6-46 Term. X30/12 Filter Time Constant

6-5* Analog Output 42

6-51 Terminal 42 Output Min Scale

6-50 Terminal 42 Output

6-52 Terminal 42 Output Max Scale

6-54 Terminal 42 Output Timeout Preset

6-53 Terminal 42 Output Bus Control

6-60 Terminal X30/8 Output

6-6* Analog Output X30/8

6-61 Terminal X30/8 Min. Scale

6-62 Terminal X30/8 Max. Scale

6-63 Terminal X30/8 Output Bus Control

4-19 Max Output Frequency

4-5* Adj. Warnings

4-50 Warning Current Low

4-51 Warning Current High

1-87 Compressor Min. Speed for Trip [Hz]

1-9* Motor Temperature

1-90 Motor Thermal Protection

1-91 Motor External Fan

4-53 Warning Speed High

4-52 Warning Speed Low

1-93 Thermistor Source

2-** Brakes

4-56 Warning Feedback Low

4-55 Warning Reference High

4-54 Warning Reference Low

2-01 DC Brake Current

2-0* DC-Brake

2-00 DC Hold/Preheat Current

4-58 Missing Motor Phase Function

4-57 Warning Feedback High

2-03 DC Brake Cut In Speed [RPM]

2-02 DC Braking Time

4-6* Speed Bypass

4-60 Bypass Speed From [RPM]

2-06 Parking Current

2-04 DC Brake Cut In Speed [Hz]

4-61 Bypass Speed From [Hz]

2-07 Parking Time

4-63 Bypass Speed To [Hz]

4-62 Bypass Speed To [RPM]

2-1* Brake Energy Funct.

2-10 Brake Function

4-64 Semi-Auto Bypass Set-up

5-** Digital In/Out

2-16 AC brake Max. Current

2-17 Over-voltage Control

5-0* Digital I/O mode

5-00 Digital I/O Mode

3-** Reference / Ramps

3-0* Reference Limits

5-02 Terminal 29 Mode

5-01 Terminal 27 Mode

5-1* Digital Inputs

3-04 Reference Function

3-02 Minimum Reference

3-03 Maximum Reference

5-13 Terminal 29 Digital Input

5-12 Terminal 27 Digital Input

5-10 Terminal 18 Digital Input

5-11 Terminal 19 Digital Input

3-13 Reference Site

3-1* References

3-10 Preset Reference

3-11 Jog Speed [Hz]

5-16 Terminal X30/2 Digital Input

5-14 Terminal 32 Digital Input

5-15 Terminal 33 Digital Input

3-16 Reference 2 Source

3-14 Preset Relative Reference

3-15 Reference 1 Source

5-17 Terminal X30/3 Digital Input

5-18 Terminal X30/4 Digital Input

3-17 Reference 3 Source

3-19 Jog Speed [RPM]

5-19 Terminal 37 Safe Stop

5-3* Digital Outputs

3-4* Ramp 1

3-41 Ramp 1 Ramp Up Time

5-30 Terminal 27 Digital Output

5-31 Terminal 29 Digital Output

3-42 Ramp 1 Ramp Down Time

3-5* Ramp 2

5-32 Term X30/6 Digi Out (MCB 101)

3-51 Ramp 2 Ramp Up Time

5-33 Term X30/7 Digi Out (MCB 101)

3-52 Ramp 2 Ramp Down Time

5-4* Relays

5-40 Function Relay

3-8* Other Ramps

3-80 Jog Ramp Time

5-41 On Delay, Relay

3-81 Quick Stop Ramp Time

5-42 Off Delay, Relay

5-5* Pulse Input

3-82 Starting Ramp Up Time

3-9* Digital Pot.Meter

5-50 Term. 29 Low Frequency

5-51 Term. 29 High Frequency

5-52 Term. 29 Low Ref./Feedb. Value

3-90 Step Size

3-91 Ramp Time

3-92 Power Restore

5-53 Term. 29 High Ref./Feedb. Value

3-93 Maximum Limit

5-55 Term. 33 Low Frequency

5-54 Pulse Filter Time Constant #29

3-94 Minimum Limit

3-95 Ramp Delay

5-58 Term. 33 High Ref./Feedb. Value

5-56 Term. 33 High Frequency

5-57 Term. 33 Low Ref./Feedb. Value

4-** Limits / Warnings

4-1* Motor Limits

4-10 Motor Speed Direction

5-59 Pulse Filter Time Constant #33

5-6* Pulse Output

4-12 Motor Speed Low Limit [Hz]

4-11 Motor Speed Low Limit [RPM]

5-60 Terminal 27 Pulse Output Variable

4-13 Motor Speed High Limit [RPM]

5-62 Pulse Output Max Freq #27

4-14 Motor Speed High Limit [Hz]

5-65 Pulse Output Max Freq #29

5-63 Terminal 29 Pulse Output Variable

4-16 Torque Limit Motor Mode

4-17 Torque Limit Generator Mode

5-66 Terminal X30/6 Pulse Output Variable

4-18 Current Limit

1-0* General Settings

1-00 Configuration Mode

1-03 Torque Characteristics

1-1* Motor Selection

Structure

6.5.1 Main Menu

1-10 Motor Construction

1-1* VVC+ PM

1-14 Damping Gain

1-15 Low Speed Filter Time Const.

0-** Operation / Display

0-0* Basic Settings

0-01 Language

0-02 Motor Speed Unit

1-17 Voltage filter time const.

1-16 High Speed Filter Time Const.

0-03 Regional Settings

0-04 Operating State at Power-up

1-2* Motor Data

1-20 Motor Power [kW]

0-05 Local Mode Unit

0-1* Set-up Operations

0-10 Active Set-up

1-21 Motor Power [HP]

1-22 Motor Voltage

1-23 Motor Frequency

0-11 Programming Set-up

0-12 This Set-up Linked to

1-25 Motor Nominal Speed

1-24 Motor Current

0-14 Readout: Prog. Set-ups / Channel

0-13 Readout: Linked Set-ups

1-28 Motor Rotation Check

1-26 Motor Cont. Rated Torque

0-2* LCP Display

0-20 Display Line 1.1 Small

1-29 Automatic Motor Adaptation (AMA)

0-22 Display Line 1.3 Small

0-21 Display Line 1.2 Small

1-3* Adv. Motor Data

0-23 Display Line 2 Large

1-30 Stator Resistance (Rs)

1-31 Rotor Resistance (Rr)

0-25 My Personal Menu

0-24 Display Line 3 Large

1-36 Iron Loss Resistance (Rfe)

1-35 Main Reactance (Xh)

0-3* LCP Custom Readout

1-37 d-axis Inductance (Ld)

0-30 Custom Readout Unit

1-39 Motor Poles

0-31 Custom Readout Min Value

0-32 Custom Readout Max Value

1-40 Back EMF at 1000 RPM

1-46 Position Detection Gain

0-37 Display Text 1

1-5* Load Indep. Setting

1-50 Motor Magnetisation at Zero Speed

0-38 Display Text 2

0-39 Display Text 3

1-52 Min Speed Normal Magnetising [Hz]

1-51 Min Speed Normal Magnetising [RPM]

0-4* LCP Keypad

0-40 [Hand on] Key on LCP

1-59 Flystart Test Pulses Frequency

1-58 Flystart Test Pulses Current

0-42 [Auto on] Key on LCP

0-41 [Off] Key on LCP

1-61 High Speed Load Compensation

1-6* Load Depen. Setting

1-60 Low Speed Load Compensation

0-43 [Reset] Key on LCP

0-5* Copy/Save

0-50 LCP Copy

0-51 Set-up Copy

1-63 Slip Compensation Time Constant

1-64 Resonance Dampening

1-65 Resonance Dampening Time Constant

0-6* Password

0-60 Main Menu Password

0-61 Access to Main Menu w/o Password

1-66 Min. Current at Low Speed

0-65 Personal Menu Password

1-62 Slip Compensation

1-7* Start Adjustments

1-70 PM Start Mode

1-71 Start Delay

1-72 Start Function

Password

0-67 Bus Password Access

0-66 Access to Personal Menu w/o

0-7* Clock Settings

1-73 Flying Start

0-70 Set Date and Time

1-75 Start Speed [Hz]

1-74 Start Speed [RPM]

0-71 Date Format

0-72 Time Format

1-79 Compressor Start Max Time to Trip

1-78 Compressor Start Max Speed [Hz]

1-76 Start Current

1-77 Compressor Start Max Speed [RPM]

1-8* Stop Adjustments

1-80 Function at Stop

0-79 Clock Fault

0-81 Working Days

0-82 Additional Working Days

0-77 DST/Summertime End

0-76 DST/Summertime Start

0-74 DST/Summertime

1-81 Min Speed for Function at Stop [RPM]

0-83 Additional Non-Working Days

1-86 Compressor Min. Speed for Trip [RPM]

1-82 Min Speed for Function at Stop [Hz]

0-89 Date and Time Readout

1-** Load and Motor

Programming Operating Instructions

15-76 Option in Slot C1/E1

15-77 Slot C1/E1 Option SW Version

15-8* Operating Data II

15-81 Preset Fan Running Hours

15-80 Fan Running Hours

15-9* Parameter Info

15-92 Defined Parameters

15-93 Modified Parameters

15-99 Parameter Metadata

16-** Data Readouts

16-0* General Status

16-00 Control Word

16-01 Reference [Unit]

16-02 Reference [%]

16-03 Status Word

16-05 Main Actual Value [%]

16-09 Custom Readout

16-1* Motor Status

16-10 Power [kW]

16-11 Power [hp]

16-13 Frequency

16-12 Motor Voltage

16-14 Motor current

16-15 Frequency [%]

16-16 Torque [Nm]

16-17 Speed [RPM]

16-18 Motor Thermal

16-22 Torque [%]

16-3* Drive Status

16-30 DC Link Voltage

16-32 Brake Energy /s

16-33 Brake Energy /2 min

16-34 Heatsink Temp.

16-35 Inverter Thermal

16-36 Inv. Nom. Current

16-37 Inv. Max. Current

16-38 SL Controller State

16-40 Logging Buffer Full

16-39 Control Card Temp.

16-49 Current Fault Source

16-41 LCP Bottom Statusline

16-5* Ref. & Feedb.

16-53 Digi Pot Reference

16-54 Feedback 1 [Unit]

16-50 External Reference

16-52 Feedback[Unit]

16-55 Feedback 2 [Unit]

16-56 Feedback 3 [Unit]

16-6* Inputs & Outputs

16-60 Digital Input

16-62 Analog Input 53

16-61 Terminal 53 Switch Setting

16-64 Analog Input 54

16-63 Terminal 54 Switch Setting

16-65 Analog Output 42 [mA]

16-66 Digital Output [bin]

16-67 Pulse Input #29 [Hz]

16-68 Pulse Input #33 [Hz]

16-69 Pulse Output #27 [Hz]

6 6

14-59 Actual Number of Inverter Units

14-6* Auto Derate

12-95 Broadcast Storm Filter

12-96 Port Config

9-52 Fault Situation Counter

9-53 Profibus Warning Word

14-61 Function at Inverter Overload

14-62 Inv. Overload Derate Current

14-60 Function at Over Temperature

15-** Drive Information

12-98 Interface Counters

12-99 Media Counters

13-** Smart Logic

13-0* SLC Settings

9-64 Device Identification

9-65 Profile Number

9-67 Control Word 1

9-63 Actual Baud Rate

15-0* Operating Data

15-00 Operating hours

13-01 Start Event

13-00 SL Controller Mode

9-68 Status Word 1

9-70 Programming Set-up

15-01 Running Hours

13-02 Stop Event

9-71 Profibus Save Data Values

15-04 Over Temp's

15-05 Over Volt's

15-06 Reset kWh Counter

13-12 Comparator Value

13-10 Comparator Operand

13-11 Comparator Operator

9-80 Defined Parameters (1)

9-81 Defined Parameters (2)

9-82 Defined Parameters (3)

15-07 Reset Running Hours Counter

13-2* Timers

13-20 SL Controller Timer

9-83 Defined Parameters (4)

9-84 Defined Parameters (5)

15-03 Power Up's

15-02 kWh Counter

13-03 Reset SLC

13-1* Comparators

9-72 ProfibusDriveReset

9-75 DO Identification

15-08 Number of Starts

15-1* Data Log Settings

15-10 Logging Source

15-11 Logging Interval

13-41 Logic Rule Operator 1

13-4* Logic Rules

13-40 Logic Rule Boolean 1

9-91 Changed Parameters (2)

9-92 Changed Parameters (3)

9-90 Changed Parameters (1)

15-12 Trigger Event

15-13 Logging Mode

13-43 Logic Rule Operator 2

13-42 Logic Rule Boolean 2

9-93 Changed Parameters (4)

9-94 Changed Parameters (5)

15-14 Samples Before Trigger

15-2* Historic Log

15-20 Historic Log: Event

13-44 Logic Rule Boolean 3

13-5* States

13-51 SL Controller Event

9-99 Profibus Revision Counter

11-** LonWorks

11-2* LON Param. Access

15-22 Historic Log: Time

15-21 Historic Log: Value

13-52 SL Controller Action

14-** Special Functions

11-21 Store Data Values

11-9* AK LonWorks

15-23 Historic log: Date and Time

15-3* Alarm Log

15-30 Alarm Log: Error Code

14-0* Inverter Switching

14-00 Switching Pattern

14-01 Switching Frequency

11-91 AK Service Pin

11-98 Alarm Text

11-90 VLT Network Address

15-34 Alarm Log: Status

15-35 Alarm Log: Alarm Text

15-32 Alarm Log: Time

15-33 Alarm Log: Date and Time

15-31 Alarm Log: Value

14-04 PWM Random

14-03 Overmodulation

11-99 Alarm Status

12-** Ethernet

14-1* Mains On/Off

14-10 Mains Failure

14-11 Mains Voltage at Mains Fault

12-01 IP Address

12-0* IP Settings

12-00 IP Address Assignment

15-4* Drive Identification

14-12 Function at Mains Imbalance

12-02 Subnet Mask

15-41 Power Section

15-42 Voltage

15-40 FC Type

14-21 Automatic Restart Time

14-2* Reset Functions

14-20 Reset Mode

12-03 Default Gateway

12-04 DHCP Server

12-05 Lease Expires

15-43 Software Version

15-44 Ordered Typecode String

14-23 Typecode Setting

14-22 Operation Mode

12-06 Name Servers

12-07 Domain Name

15-45 Actual Typecode String

15-46 Frequency Converter Ordering No

14-26 Trip Delay at Inverter Fault

14-25 Trip Delay at Torque Limit

12-08 Host Name

12-09 Physical Address

15-50 SW ID Power Card

15-47 Power Card Ordering No

15-48 LCP Id No

15-49 SW ID Control Card

14-29 Service Code

14-28 Production Settings

14-30 Current Lim Ctrl, Proportional Gain

14-3* Current Limit Ctrl.

12-10 Link Status

12-11 Link Duration

12-12 Auto Negotiation

12-1* Ethernet Link Parameters

15-53 Power Card Serial Number

15-51 Frequency Converter Serial Number

14-32 Current Lim Ctrl, Filter Time

14-31 Current Lim Ctrl, Integration Time

12-13 Link Speed

12-14 Link Duplex

15-62 Option Ordering No

15-61 Option SW Version

15-6* Option Ident

15-60 Option Mounted

14-42 Minimum AEO Frequency

14-4* Energy Optimising

14-40 VT Level

14-41 AEO Minimum Magnetisation

12-81 HTTP Server

12-82 SMTP Service

12-8* Other Ethernet Services

12-80 FTP Server

15-63 Option Serial No

15-70 Option in Slot A

15-71 Slot A Option SW Version

14-43 Motor Cosphi

14-5* Environment

14-50 RFI Filter

12-89 Transparent Socket Channel Port

12-90 Cable Diagnostic

12-9* Advanced Ethernet Services

15-74 Option in Slot C0/E0

15-75 Slot C0/E0 Option SW Version

15-73 Slot B Option SW Version

15-72 Option in Slot B

14-53 Fan Monitor

14-55 Output Filter

14-52 Fan Control

14-51 DC Link Compensation

12-94 Broadcast Storm Protection

12-92 IGMP Snooping

12-93 Cable Error Length

12-91 Auto Cross Over

9-45 Fault Code

9-47 Fault Number

9-28 Process Control

6-64 Terminal X30/8 Output Timeout Preset

8-** Comm. and Options

8-0* General Settings

8-01 Control Site

8-02 Control Source

8-03 Control Timeout Time

8-04 Control Timeout Function

8-07 Diagnosis Trigger

8-06 Reset Control Timeout

8-05 End-of-Timeout Function

8-1* Control Settings

8-10 Control Profile

8-13 Configurable Status Word STW

8-3* FC Port Settings

8-30 Protocol

8-31 Address

8-32 Baud Rate

8-33 Parity / Stop Bits

8-35 Minimum Response Delay

8-36 Maximum Response Delay

8-37 Maximum Inter-Char Delay

8-4* Adv. Protocol Set.

8-45 BTM Transaction Command

8-43 PCD Read Configuration

8-42 PCD Write Configuration

8-40 Telegram Selection

8-46 BTM Transaction Status

8-47 BTM Timeout

8-5* Digital/Bus

8-50 Coasting Select

8-52 DC Brake Select

8-53 Start Select

8-54 Reversing Select

8-55 Set-up Select

8-56 Preset Reference Select

8-8* FC Port Diagnostics

8-80 Bus Message Count

8-81 Bus Error Count

8-82 Slave Message Count

8-83 Slave Error Count

8-9* Bus Jog / Feedback

8-90 Bus Jog 1 Speed

8-91 Bus Jog 2 Speed

8-94 Bus Feedback 1

8-96 Bus Feedback 3

8-95 Bus Feedback 2

9-** PROFIdrive

9-00 Setpoint

9-07 Actual Value

9-15 PCD Write Configuration

9-18 Node Address

9-22 Telegram Selection

9-16 PCD Read Configuration

9-27 Parameter Edit

9-23 Parameters for Signals

9-44 Fault Message Counter

Programming Operating Instructions

25-20 Neutral Zone [unit]

25-21 + Zone [unit]

25-22 - Zone [unit]

25-23 Fixed Speed neutral Zone [unit]

25-24 + Zone Delay

25-25 - Zone Delay

25-26 ++ Zone Delay

25-27 -- Zone Delay

25-31 Stage Function

25-3* Staging Functions

25-30 Destage At No-Flow

25-33 Destage Function

25-32 Stage Function Time

25-34 Destage Function Time

25-4* Staging Settings

25-43 Destaging Threshold

25-44 Staging Speed [RPM]

25-42 Staging Threshold

25-45 Staging Speed [Hz]

25-46 Destaging Speed [RPM]

25-47 Destaging Speed [Hz]

25-8* Status

25-80 Pack Status

25-81 Compressor Status

25-82 Lead Compressor

25-83 Relay Status

25-84 Compressor ON Time

25-85 Relay ON Time

25-86 Reset Relay Counters

25-87 Inverse Interlock

25-88 Pack capacity [%]

25-9* Service

25-90 Compressor Interlock

25-91 Manual Alternation

26-** Analog I/O Option

26-0* Analog I/O Mode

26-00 Terminal X42/1 Mode

26-02 Terminal X42/5 Mode

26-01 Terminal X42/3 Mode

26-1* Analog Input X42/1

26-10 Terminal X42/1 Low Voltage

26-14 Term. X42/1 Low Ref./Feedb. Value

26-11 Terminal X42/1 High Voltage

26-16 Term. X42/1 Filter Time Constant

26-15 Term. X42/1 High Ref./Feedb. Value

26-17 Term. X42/1 Live Zero

26-2* Analog Input X42/3

26-20 Terminal X42/3 Low Voltage

26-21 Terminal X42/3 High Voltage

26-24 Term. X42/3 Low Ref./Feedb. Value

26-26 Term. X42/3 Filter Time Constant

26-25 Term. X42/3 High Ref./Feedb. Value

26-27 Term. X42/3 Live Zero

26-3* Analog Input X42/5

26-30 Terminal X42/5 Low Voltage

26-34 Term. X42/5 Low Ref./Feedb. Value

26-31 Terminal X42/5 High Voltage

26-36 Term. X42/5 Filter Time Constant

26-35 Term. X42/5 High Ref./Feedb. Value

22-90 Flow at Rated Speed

22-89 Flow at Design Point

22-88 Pressure at Rated Speed

22-77 Minimum Run Time

22-75 Short Cycle Protection

22-76 Interval between Starts

21-42 Ext. 2 Integral Time

21-40 Ext. 2 Normal/Inverse Control

21-41 Ext. 2 Proportional Gain

22-78 Minimum Run Time Override

22-79 Minimum Run Time Override Value

22-8* Flow Compensation

21-43 Ext. 2 Differentation Time

21-44 Ext. 2 Dif. Gain Limit

21-5* Ext. CL 3 Ref./Fb.

22-84 Speed at No-Flow [Hz]

22-82 Work Point Calculation

22-83 Speed at No-Flow [RPM]

22-81 Square-linear Curve Approximation

22-80 Flow Compensation

21-54 Ext. 3 Feedback Source

21-53 Ext. 3 Reference Source

21-52 Ext. 3 Maximum Reference

21-50 Ext. 3 Ref./Feedback Unit

21-51 Ext. 3 Minimum Reference

22-87 Pressure at No-Flow Speed

22-86 Speed at Design Point [Hz]

22-85 Speed at Design Point [RPM]

21-57 Ext. 3 Reference [Unit]

21-58 Ext. 3 Feedback [Unit]

21-55 Ext. 3 Setpoint

21-59 Ext. 3 Output [%]

21-6* Ext. CL 3 PID

23-** Time-based Functions

21-60 Ext. 3 Normal/Inverse Control

21-61 Ext. 3 Proportional Gain

23-0* Timed Actions

23-00 ON Time

21-63 Ext. 3 Differentation Time

21-62 Ext. 3 Integral Time

23-01 ON Action

23-02 OFF Time

23-03 OFF Action

21-64 Ext. 3 Dif. Gain Limit

22-** Appl. Functions

22-0* Miscellaneous

23-04 Occurrence

23-1* Maintenance

23-10 Maintenance Item

23-11 Maintenance Action

22-21 Low Power Detection

22-00 External Interlock Delay

22-2* No-Flow Detection

22-20 Low Power Auto Set-up

23-13 Maintenance Time Interval

23-14 Maintenance Date and Time

23-12 Maintenance Time Base

22-23 No-Flow Function

22-24 No-Flow Delay

22-22 Low Speed Detection

23-16 Maintenance Text

23-1* Maintenance Reset

23-15 Reset Maintenance Word

22-26 Dry Pump Function

22-27 Dry Pump Delay

22-3* No-Flow Power Tuning

23-5* Energy Log

23-50 Energy Log Resolution

22-30 No-Flow Power

22-31 Power Correction Factor

23-51 Period Start

23-53 Energy Log

22-33 Low Speed [Hz]

22-32 Low Speed [RPM]

23-54 Reset Energy Log

23-6* Trending

22-35 Low Speed Power [HP]

22-34 Low Speed Power [kW]

23-62 Timed Bin Data

23-60 Trend Variable

23-61 Continuous Bin Data

22-38 High Speed Power [kW]

22-36 High Speed [RPM]

22-37 High Speed [Hz]

23-63 Timed Period Start

22-39 High Speed Power [HP]

23-64 Timed Period Stop

23-65 Minimum Bin Value

22-4* Sleep Mode

22-40 Minimum Run Time

23-66 Reset Continuous Bin Data

22-41 Minimum Sleep Time

23-67 Reset Timed Bin Data

23-8* Payback Counter

22-43 Wake-up Speed [Hz]

22-42 Wake-up Speed [RPM]

23-80 Power Reference Factor

23-81 Energy Cost

23-82 Investment

22-45 Setpoint Boost

22-46 Maximum Boost Time

22-44 Wake-up Ref./FB Difference

23-83 Energy Savings

23-84 Cost Savings

22-5* End of Curve

22-50 End of Curve Function

25-** Pack Controller

25-0* System Settings

25-00 Pack Controller

22-60 Broken Belt Function

22-51 End of Curve Delay

22-6* Broken Belt Detection

25-06 Number of Compressors

25-04 Compressor Cycling

25-2* Zone Settings

22-62 Broken Belt Delay

22-61 Broken Belt Torque

22-7* Short Cycle Protection

20-32 User Defined Refrigerant A2

16-70 Pulse Output #29 [Hz]

20-33 User Defined Refrigerant A3

16-71 Relay Output [bin]

20-42 Cut-in Value

20-41 Cut-out Value

20-4* Thermostat/Pressostat

20-40 Thermostat/Pressostat Function

16-72 Counter A

16-73 Counter B

16-75 Analog In X30/11

16-76 Analog In X30/12

20-71 PID Performance

20-72 PID Output Change

20-7* PID Autotuning

20-70 Closed Loop Type

16-77 Analog Out X30/8 [mA]

16-82 Fieldbus REF 1

16-80 Fieldbus CTW 1

16-8* Fieldbus & FC Port

20-73 Minimum Feedback Level

16-84 Comm. Option STW

20-74 Maximum Feedback Level

16-85 FC Port CTW 1

20-79 PID Autotuning

20-82 PID Start Speed [RPM]

20-8* PID Basic Settings

20-81 PID Normal/ Inverse Control

16-86 FC Port REF 1

16-9* Diagnosis Readouts

16-90 Alarm Word

16-91 Alarm Word 2

20-84 On Reference Bandwidth

20-83 PID Start Speed [Hz]

16-92 Warning Word

16-93 Warning Word 2

20-93 PID Proportional Gain

20-9* PID Controller

20-91 PID Anti Windup

16-96 Maintenance Word

16-94 Ext. Status Word

16-95 Ext. Status Word 2

20-96 PID Diff. Gain Limit

20-95 PID Differentiation Time

20-94 PID Integral Time

18-** Info and Readouts

18-0* Maintenance Log

18-00 Maintenance Log: Item

21-** Ext. Closed Loop

21-0* Ext. CL Autotuning

21-00 Closed Loop Type

18-03 Maintenance Log: Date and Time

18-02 Maintenance Log: Time

18-01 Maintenance Log: Action

21-04 Maximum Feedback Level

21-02 PID Output Change

21-03 Minimum Feedback Level

21-01 PID Performance

18-12 Fire Mode Log: Date and Time

18-1* Fire Mode Log

18-10 FireMode Log:Event

18-11 Fire Mode Log: Time

21-09 PID Autotuning

21-1* Ext. CL 1 Ref./Fb.

21-10 Ext. 1 Ref./Feedback Unit

21-11 Ext. 1 Minimum Reference

18-32 Analog Input X42/5

18-31 Analog Input X42/3

18-3* Inputs & Outputs

18-30 Analog Input X42/1

21-14 Ext. 1 Feedback Source

21-13 Ext. 1 Reference Source

21-12 Ext. 1 Maximum Reference

18-35 Analog Out X42/11 [V]

18-34 Analog Out X42/9 [V]

18-33 Analog Out X42/7 [V]

21-17 Ext. 1 Reference [Unit]

21-18 Ext. 1 Feedback [Unit]

21-15 Ext. 1 Setpoint

20-** Drive Closed Loop

20-0* Feedback

20-00 Feedback 1 Source

21-19 Ext. 1 Output [%]

21-2* Ext. CL 1 PID

21-20 Ext. 1 Normal/Inverse Control

21-21 Ext. 1 Proportional Gain

20-03 Feedback 2 Source

20-04 Feedback 2 Conversion

20-01 Feedback 1 Conversion

20-02 Feedback 1 Source Unit

21-22 Ext. 1 Integral Time

20-05 Feedback 2 Source Unit

21-23 Ext. 1 Differentation Time

20-06 Feedback 3 Source

21-24 Ext. 1 Dif. Gain Limit

21-3* Ext. CL 2 Ref./Fb.

21-30 Ext. 2 Ref./Feedback Unit

21-31 Ext. 2 Minimum Reference

20-12 Reference/Feedback Unit

20-07 Feedback 3 Conversion

20-08 Feedback 3 Source Unit

20-2* Feedback/Setpoint

21-34 Ext. 2 Feedback Source

21-33 Ext. 2 Reference Source

21-32 Ext. 2 Maximum Reference

20-20 Feedback Function

20-21 Setpoint 1

20-22 Setpoint 2

21-37 Ext. 2 Reference [Unit]

21-38 Ext. 2 Feedback [Unit]

21-35 Ext. 2 Setpoint

20-23 Setpoint 3

20-25 Setpoint Type

20-3* Feedback Adv. Conv

21-39 Ext. 2 Output [%]

21-4* Ext. CL 2 PID

20-30 Refrigerant

20-31 User Defined Refrigerant A1

Programming Operating Instructions

6 6

31-19 Remote Bypass Activation

31-11 Bypass Running Hours

31-10 Bypass Status Word

26-37 Term. X42/5 Live Zero

26-4* Analog Out X42/7

26-40 Terminal X42/7 Output

26-41 Terminal X42/7 Min. Scale

26-42 Terminal X42/7 Max. Scale

26-44 Terminal X42/7 Timeout Preset

26-43 Terminal X42/7 Bus Control

26-5* Analog Out X42/9

26-50 Terminal X42/9 Output

26-51 Terminal X42/9 Min. Scale

26-52 Terminal X42/9 Max. Scale

26-54 Terminal X42/9 Timeout Preset

26-53 Terminal X42/9 Bus Control

26-6* Analog Out X42/11

26-60 Terminal X42/11 Output

26-61 Terminal X42/11 Min. Scale

26-62 Terminal X42/11 Max. Scale

26-64 Terminal X42/11 Timeout Preset

26-63 Terminal X42/11 Bus Control

28-** Compressor Functions

28-1* Oil Return Management

28-10 Oil Return Management

28-11 Low Speed Running Time

28-13 Boost Duration

28-12 Fixed Boost Interval

28-2* Discharge Temperature Monitor

28-20 Temperature Source

28-21 Temperature Unit

28-24 Warning Level

28-25 Warning Action

28-26 Emergency Level

28-27 Discharge Temperature

28-72 Enable Day/Night Via Bus

28-7* Day/Night Settings

28-71 Day/Night Bus Indicator

28-74 Night Speed Drop [RPM]

28-73 Night Setback

28-76 Night Speed Drop [Hz]

28-75 Night Speed Drop Override

28-8* P0 Optimization

28-82 P0

28-81 dP0 Offset

28-83 P0 Setpoint

28-84 P0 Reference

28-85 P0 Minimum Reference

28-87 Most Loaded Controller

28-86 P0 Maximum Reference

28-9* Injection Control

28-90 Injection On

28-91 Delayed Compressor Start

30-** Special Features

30-2* Adv. Start Adjust

30-22 Locked Rotor Protection

30-23 Locked Rotor Detection Time [s]

31-** Bypass Option

31-00 Bypass Mode

31-02 Bypass Trip Time Delay

31-01 Bypass Start Time Delay

31-03 Test Mode Activation

Programming Operating Instructions

6.6 Remote Programming with

MCT 10 Set-up Software

Danfoss has a software program available for developing, storing, and transferring frequency converter programming. The MCT 10 Set-up Software allows the user to connect a PC to the frequency converter and perform live programming rather than using the LCP. Additionally, all frequency converter programming can be done off-line and simply downloaded to the frequency converter. Or the entire frequency converter profile can be loaded onto the PC for back-up storage or analysis.

The USB connector or RS-485 terminal are available for connecting the PC to the frequency converter.

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB929.10

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB930.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

-10 - +10V

130BB926.10

Application Examples

7 Application Examples

Operating Instructions

7.1 Introduction

Parameters

Function Setting

The examples in this section are intended as a quick reference for common applications.

Parameter settings are the regional default values

•

unless otherwise indicated (selected in 0-03 Regional Settings).

Parameters associated with the terminals and

•

their settings are shown next to the drawings. Where switch settings for analog terminals A53 or

•

A54 are required, these are also shown.

1-29 Automatic Motor Adaptation (AMA) 5-12 Terminal 27 Digital Input

[1] Enable complete AMA [0] No operation

* = Default Value

Notes/comments:

Parameter group 1-2* must be set according to motor. D IN 37 is an option.

7.2 Application Examples

Parameters

Function Setting

1-29 Automatic Motor Adaptation (AMA) 5-12 Terminal 27 Digital Input

[1] Enable complete AMA [2]* Coast inverse

Table 7.2 AMA without T27 Connected

* = Default Value Notes/comments: Parameter group 1-2* must be set according to motor. D IN 37 is an option.

Parameters

Function Setting

6-10 Terminal 53 Low Voltage 6-11 Terminal 53

0.07 V* 10 V*

High Voltage 6-14 Terminal 53

0 Hz

Low Ref./Feedb. Value 6-15 Terminal 53

50 Hz

High Ref./Feedb. Value

Table 7.1 AMA with T27 Connected

Table 7.3 Analog Speed Reference (Voltage)

* = Default Value

Notes/comments:

D IN 37 is an option.

7 7

130BB927.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

4 - 20mA

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BB802.10

130BB805.11

Speed

Start (18)

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB803.10

Speed

130BB806.10

Latched Start (18)

Stop Inverse (27)

Application Examples Operating Instructions

Parameters

Function Setting

6-12 Terminal 53

4 mA*

Low Current 6-13 Terminal 53

20 mA*

High Current 6-14 Terminal 53 Low Ref./Feedb. Value 6-15 Terminal 53 High Ref./Feedb. Value

* = Default Value

Notes/comments:

D IN 37 is an option.

0 Hz

50 Hz

Illustration 7.1 Start/Stop Command with Safe Torque Off

Parameters

Function Setting

5-10 Terminal 18 Digital Input 5-12 Terminal 27 Digital Input

[9] Latched Start [6] Stop Inverse

* = Default Value

Notes/comments:

If 5-12 Terminal 27 Digital Input is set to [0] No operation, a jumper wire to terminal 27 is not needed.

Table 7.4 Analog Speed Reference (Current)

D IN 37 is an option.

Parameters

Function Setting

5-10 Terminal 18

[8] Start*

Digital Input 5-12 Terminal 27 Digital Input 5-19 Terminal 37 Safe Stop

[0] No operation [1] Safe Stop Alarm

Table 7.6 Pulse Start/Stop

* = Default Value

Notes/comments:

If 5-12 Terminal 27 Digital Input is set to [0] No operation, a jumper wire to terminal 27 is not needed. D IN 37 is an option.

Table 7.5 Start/Stop Command with Safe Torque Off Option

Illustration 7.2 Latched Start/Stop Inverse

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB934.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BB928.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

≈ 5kΩ

130BB683.10

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB804.10

Application Examples

Operating Instructions

Parameters

Function Setting

5-10 Terminal 18

[8] Start

Digital Input 5-11 Terminal 19 Digital Input

5-12 Terminal 27 Digital Input 5-14 Terminal 32 Digital Input 5-15 Terminal 33 Digital Input 3-10 Preset

[10] Reversing*

[0] No operation [16] Preset ref bit 0 [17] Preset ref bit 1

Reference

Preset ref. 0 Preset ref. 1 Preset ref. 2 Preset ref. 3

25% 50% 75% 100%

Parameters

Function Setting

6-10 Terminal 53 Low Voltage 6-11 Terminal 53

0.07 V* 10 V*

High Voltage 6-14 Terminal 53

0 Hz

Low Ref./Feedb. Value 6-15 Terminal 53

1500 Hz

High Ref./Feedb. Value

* = Default Value

Notes/comments:

D IN 37 is an option.

7 7

* = Default Value

Notes/comments:

D IN 37 is an option.

Table 7.9 Speed Reference (using a Manual Potentiometer)

Table 7.7 Start/Stop with Reversing and 4 Preset Speeds

Parameters

Function Setting

5-11 Terminal 19

[1] Reset

Digital Input

* = Default Value

Notes/comments:

D IN 37 is an option.

5-10 Terminal 18 Digital Input 5-12 Terminal 27 Digital Input 5-13 Terminal 29 Digital Input 5-14 Terminal 32 Digital Input

Parameters

Function Setting

[8] Start*

[19] Freeze Reference [21] Speed Up [22] Speed Down

* = Default Value

Table 7.8 External Alarm Reset

Table 7.10 Speed Up/Down

Notes/comments:

D IN 37 is an option.

S t a r t ( 1 8 )

F r e e z e r e f ( 2 7 )

S p e e d u p ( 2 9 )

S p e e d d o w n ( 3 2 )

S p e e d

R e f e r e n c e

130BB840.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

R1R2

61 68 69

RS-485

130BB685.10

130BB686.12

VLT

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

A53

U - I

D IN

Application Examples Operating Instructions

Parameters

Function Setting

1-90 Motor Thermal Protection 1-93 Thermistor Source

[2] Thermistor trip [1] Analog input 53

* = Default Value

Notes/comments:

If only a warning is desired,

1-90 Motor Thermal Protection

Illustration 7.3 Speed Up/Down

should be set to [1] Thermistor warning.

D IN 37 is an option.

8-30 Protocol

8-31 Address 8-32 Baud Rate

Parameters

Function Setting

FC* 1* 9600*

NOTICE

Danfoss recommends using 24 V DC as thermistor supply voltage.

* = Default Value

Notes/comments:

Select protocol, address and baud rate in the above

Table 7.12 Motor Thermistor

mentioned parameters. D IN 37 is an option.

Table 7.11 RS-485 Network Connection

CAUTION

Thermistors must use reinforced or double insulation to meet PELV insulation requirements.

Status

799RPM 7.83A 36.4kW

0.000

53.2%

1(1)

Auto Hand O

Remote Local

Ramping Stop Running Jogging . . . Stand by

130BB037.11

1 2 3

Status Messages Operating Instructions

8 Status Messages

8.1 Status Display

When the frequency converter is in Status mode, status messages are generated automatically and appear in the bottom line of the display (see Illustration 8.1).

Operation mode (see Table 8.1)

Reference site (see Table 8.2)

Operation status (see Table 8.3)

Illustration 8.1 Status Display

8.2 Status Message Definitions

Table 8.1, Table 8.2 and Table 8.3 define the meaning of the status message display words.

Off

Auto On The frequency converter is controlled from the

Hand On The frequency converter can be controlled by

Table 8.1 Operation Mode

Remote

Local The frequency converter uses [Hand On]

The frequency converter does not react to any control signal until [Auto On] or [Hand On] is pressed.

control terminals and/or the serial communication.

the navigation keys on the LCP. Stop commands, reset, reversing, DC brake, and other signals applied to the control terminals can override local control.

The speed reference is given from external signals, serial communication, or internal preset references.

control or reference values from the LCP.

AC Brake

AMA finish OK Automatic motor adaptation (AMA) was

AMA ready AMA is ready to start. Press [Hand On] to start. AMA running AMA process is in progress. Coast

Ctrl. Ramp-down Control ramp-down was selected in

Current High The frequency converter output current is

Current Low The frequency converter output current is

DC Hold

DC Stop

Feedback high The sum of all active feedbacks is above the

Feedback low The sum of all active feedbacks is below the

AC Brake was selected in 2-10 Brake Function. The AC brake overmagnetises the motor to achieve a controlled slow down.

carried out successfully.

Coast inverse was selected as a function

•

for a digital input (parameter group 5-1* Digital Inputs). The corresponding terminal

is not connected.

Coast activated by serial communication

•

14-10 Mains Failure.

The mains voltage is below the value set

•

in 14-11 Mains Voltage at Mains Fault at mains fault

The frequency converter ramps down the

•

motor using a controlled ramp-down

above the limit set in 4-51 Warning Current High.

below the limit set in 4-52 Warning Speed Low DC hold is selected in 1-80 Function at Stop and a stop command is active. The motor is held by a DC current set in 2-00 DC Hold/ Preheat Current. The motor is held with a DC current (2-01 DC

Brake Current) for a specified time (2-02 DC Braking Time).

DC brake is activated in 2-03 DC Brake Cut

•

In Speed [RPM] and a stop command is active.

DC brake (inverse) is selected as a function

•

for a digital input (parameter group 5-1* Digital Inputs). The corresponding terminal

is not active.

The DC brake is activated via serial

•

communication.

feedback limit set in 4-57 Warning Feedback High.

feedback limit set in 4-56 Warning Feedback Low.

8 8

Table 8.2 Reference Site

Status Messages

Operating Instructions

Freeze output The remote reference is active, which holds

the present speed.

Freeze output was selected as a function

•

for a digital input (parameter group 5-1* Digital Inputs). The corresponding terminal

is active. Speed control is only possible via the terminal functions speed up and speed down.

Hold ramp is activated via serial communi-

•

cation.

Freeze output request

Freeze ref.

Jog request A jog command has been given, but the

Jogging The motor is running as programmed in

Motor check

OVC control Overvoltage control was activated in

Power Unit Off (For frequency converters with an external 24

A freeze output command has been given, but the motor remains stopped until a run permissive signal is received. Freeze Reference was selected as a function for a digital input (parameter group 5-1* Digital Inputs). The corresponding terminal is active. The frequency converter saves the actual reference. Changing the reference is now only possible via terminal functions speed up and speed down.

motor is stopped until a run permissive signal is received via a digital input.

3-19 Jog Speed [RPM].

Jog was selected as function for a digital

•

input (parameter group 5-1* Digital Inputs). The corresponding terminal (e.g. terminal

29) is active.

The Jog function is activated via the serial

•

communication.

The Jog function was selected as a

•

reaction for a monitoring function (e.g. No signal). The monitoring function is active.

In 1-80 Function at Stop, Motor Check was selected. A stop command is active. To ensure that a motor is connected to the frequency converter, a permanent test current is applied to the motor.

2-17 Over-voltage Control. The connected motor is supplying the frequency converter with generative energy. The overvoltage control adjusts the V/Hz ratio to run the motor in controlled mode and to prevent the frequency converter from tripping.

V power supply installed only). Mains supply to the frequency converter is removed, but the control card is supplied by the external 24 V.

Protection md Protection mode is active. The unit has

detected a critical status (an overcurrent or overvoltage).

To avoid tripping, switching frequency is

•

reduced to 4 kHz.

If possible, protection mode ends after

•

approximately 10 s.

Protection mode can be restricted in

•

14-26 Trip Delay at Inverter Fault.

Ramping The motor is accelerating/decelerating using

the active ramp-up/down. The reference, a limit value or a standstill is not yet reached.

Ref. high The sum of all active references is above the

reference limit set in 4-55 Warning Reference High.

Ref. low The sum of all active references is below the

reference limit set in 4-54 Warning Reference Low.

Run on ref. The frequency converter is running in the

reference range. The feedback value matches the setpoint value.

Run request A start command has been given, but the

motor is stopped until a run permissive signal is received via digital input.

Running The motor is driven by the frequency

converter.

Speed high Motor speed is above the value set in

4-53 Warning Speed High.

Speed low Motor speed is below the value set in

4-52 Warning Speed Low.

Standby In Auto On mode, the frequency converter

starts the motor with a start signal from a digital input or serial communication.

Start delay

Start fwd/rev Start forward and start reverse were selected

Stop The frequency converter has received a stop

Trip An alarm occurred and the motor is stopped.

Trip lock An alarm occurred and the motor is stopped.

In 1-71 Start Delay, a delay starting time was set. A start command is activated and the motor starts after the start delay time expires.

as functions for 2 different digital inputs (parameter group 5-1* Digital Inputs). The motor starts in forward or reverse depending on which corresponding terminal is activated.

command from the LCP, digital input, or serial communication.

Once the cause of the alarm is cleared, the frequency converter can be reset manually by pressing [Reset] or remotely by control terminals or serial communication.

Once the cause of the alarm is cleared, power must be cycled to the frequency converter. The frequency converter can then be reset manually by pressing [Reset] or remotely by control terminals or serial communication.

Table 8.3 Operation Status

130BP085.11

Status

0.0Hz 0.000psi 0.00A

0.0Hz

1:0 - Oﬀ

!Live zero error [W2]

Oﬀ Remote Stop

!1(1)

130BP086.11

Status

0.0Hz 0.000kW 0.00A

0.0Hz 0

Earth Fault [A14]

Auto Remote Trip

1(1)

130BD812.10

Back

Cancel

Info

Alarm

Warn.

130BB467.11

Warnings and Alarms Operating Instructions

9 Warnings and Alarms

9.1 System Monitoring

The frequency converter monitors the condition of its input power, output, and motor factors as well as other system performance indicators. A warning or alarm may not necessarily indicate a problem internal to the frequency converter itself. In many cases, it indicates failure conditions from input voltage, motor load or temperature, external signals, or other areas monitored by the frequency converter’s internal logic. Be sure to investigate those areas exterior to the frequency converter as indicated in the alarm or warning.

9.2 Warning and Alarm Types

9.2.1 Warnings

A warning is issued when an alarm condition is impending, or when an abnormal operating condition is present and may result in the frequency converter issuing an alarm. A warning clears itself when the abnormal condition is removed.

Alarm Trip

9.2.2

An alarm is issued when the frequency converter is tripped, that is, the frequency converter suspends operation to prevent frequency converter or system damage. The motor coasts to a stop. The frequency converter logic continues to operate and monitor the frequency converter status. After the fault condition is corrected, the frequency converter can be reset. It is then ready to start operation again.

9.3

Warning and Alarm Displays

Illustration 9.1 Warning Display Example

An alarm or trip-lock alarm flashes in the display along with the alarm number.

Illustration 9.2 Alarm Display Example

In addition to the text and alarm code on the frequency converter display, there are 3 status indicator lights.

9 9

A trip can be reset in any of 4 ways:

Pressing [Reset]

•

Digital reset input command

•

Serial communication reset input command

•

Auto reset

•

Alarm Trip-lock

9.2.3

An alarm that causes the frequency converter to trip-lock requires that input power is cycled. The motor coasts to a stop. The frequency converter logic continues to operate and monitor the frequency converter status. Remove input power to the frequency converter and correct the cause of

Warning ON OFF Alarm OFF ON (Flashing) Trip-Lock ON ON (Flashing)

Warn. LED Alarm LED

the fault, then restore power. This action puts the frequency converter into a trip condition as described

above and may be reset in any of those 4 ways.

Illustration 9.3 Indicator Lights

Warnings and Alarms Operating Instructions

9.4 Warning and Alarm Definitions

Table 9.1 defines whether a warning is issued before an alarm, and whether the alarm trips the unit or trip locks the unit.

No. Description Warning Alarm/Trip Alarm/Trip lock Parameter reference

1 10 Volts low X 2 Live zero error (X) (X) 6-01 Live Zero Timeout

Function

4 Mains phase loss (X) (X) (X) 14-12 Function at Mains

Imbalance 5 DC link voltage high X 6 DC link voltage low X 7 DC over voltage X X 8 DC under voltage X X 9 Inverter overloaded X X 10 Motor ETR over temperature (X) (X) 1-90 Motor Thermal Protection 11 Motor thermistor over temperature (X) (X) 1-90 Motor Thermal Protection 12 Torque limit X X 13 Over Current X X X 14 Earth (ground) fault X X X 15 Hardware mismatch X X 16 Short Circuit X X 17 Control word timeout (X) (X) 8-04 Control Timeout Function

18 Start Failed X

19 Discharge Temperature High X

23 Internal Fan Fault X 24 External Fan Fault X 14-53 Fan Monitor 29 Drive over temperature X X X 30 Motor phase U missing (X) (X) (X) 4-58 Missing Motor Phase

31 Motor phase V missing (X) (X) (X) 4-58 Missing Motor Phase

32 Motor phase W missing (X) (X) (X) 4-58 Missing Motor Phase

33 Inrush fault X X 34 Fieldbus communication fault X X 35 Out of frequency range X X 36 Mains failure X X 38 Internal fault X X 39 Heatsink sensor X X 40 Overload of Digital Output Terminal 27 (X) 5-00 Digital I/O Mode,

41 Overload of Digital Output Terminal 29 (X) 5-00 Digital I/O Mode,

42 Overload of Digital Output On X30/6 (X) 5-32 Term X30/6 Digi Out (MCB

42 Overload of Digital Output On X30/7 (X) 5-33 Term X30/7 Digi Out (MCB

46 Pwr. card supply X X 47 24 V supply low X X X 48 1.8 V supply low X X

1-77 Compressor Start Max

Speed [RPM],

1-79 Pump Start Max Time to

Trip

28-25 Warning Action

28-26 Emergency Level

Function

5-01 Terminal 27 Mode

5-02 Terminal 29 Mode

101)

Warnings and Alarms Operating Instructions

No. Description Warning Alarm/Trip Alarm/Trip lock Parameter reference

49 Speed limit X (X) 1-86 Trip Speed Low [RPM] 50 AMA calibration failed X 51 AMA check U 52 AMA low I 53 AMA motor too big X 54 AMA motor too small X 55 AMA Parameter out of range X 56 AMA interrupted by user X 57 AMA timeout X 58 AMA internal fault X X 59 Current limit X 60 External Interlock X 62 Output Frequency at Maximum Limit X 64 Voltage Limit X 65 Control board overtemperature X X X 66 Heat sink Temperature Low X 67 Option Configuration has Changed X 68

Safe Stop 69 Pwr.card temp X X 70 Illegal FC configuration X 77 Reduced Power Mode 79 Illegal PS config X X 80 Drive Initialized to Default Value X 91 Analog input 54 wrong settings X 92 NoFlow X X 22-2* No-Flow Detection 93 Dry Pump X X 22-2* No-Flow Detection 94 End of Curve X X 22-5* End of Curve 95 Broken Belt X X 22-6* Broken Belt Detection 96 Start Delayed X 22-7* Short Cycle Protection 97 Stop Delayed X 22-7* Short Cycle Protection 98 Clock Fault X 0-7* Clock Settings 99 Locked rotor 104 Mixing Fan Fault X X 250 New spare parts X 251 New Type Code X X

nom

and I

nom

X X

(X) (X)

5-19 Terminal 37 Digital Input

14-53 Fan Monitor

9 9

Table 9.1 Alarm/Warning Code List

(X) Dependent on parameter

Cannot be Auto reset via 14-20 Reset Mode

9.5

Fault Messages

The following warning/alarm information defines each warning/alarm condition, provides the probable cause for the condition, and details a remedy or troubleshooting procedure.

WARNING 1, 10 Volts low

The control card voltage is below 10 V from terminal 50. Remove some of the load from terminal 50, as the 10 V supply is overloaded. Max. 15 mA or minimum 590 Ω.

This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer.

Troubleshooting

Remove the wiring from terminal 50. If the

•

warning clears, the problem is with the customer wiring. If the warning does not clear, replace the control card.

WARNING/ALARM 2, Live zero error

This warning or alarm only appears if programmed by the user in 6-01 Live Zero Timeout Function. The signal on one of the analog inputs is less than 50% of the minimum value programmed for that input. Broken wiring or faulty device sending the signal can cause this condition.

Warnings and Alarms

Operating Instructions

Troubleshooting

Check connections on all the analog input

•

terminals. Control card terminals 53 and 54 for signals, terminal 55 common. MCB 101 terminals 11 and 12 for signals, terminal 10 common. MCB 109 terminals 1, 3, 5 for signals, terminals 2, 4, 6 common).

Check that the frequency converter programming

•

and switch settings match the analog signal type.

Perform an input terminal signal test.

•

WARNING/ALARM 3, No motor

No motor has been connected to the output of the frequency converter.

WARNING/ALARM 4, Mains phase loss

A phase is missing on the supply side, or the mains voltage imbalance is too high. This message also appears for a fault in the input rectifier on the frequency converter. Options are programmed in 14-12 Function at Mains Imbalance.

Troubleshooting

Check the supply voltage and supply currents to

•

WARNING 5, DC link voltage high

The intermediate circuit voltage (DC) is higher than the high voltage warning limit. The limit is dependent on the frequency converter voltage rating. The unit is still active.

WARNING 6, DC link voltage low

The intermediate circuit voltage (DC) is lower than the low voltage warning limit. The limit is dependent on the frequency converter voltage rating. The unit is still active.

WARNING/ALARM 7, DC overvoltage

If the intermediate circuit voltage exceeds the limit, the frequency converter trips after a time.

Troubleshooting

WARNING/ALARM 8, DC under voltage

If the intermediate circuit voltage (DC link) drops below the under voltage limit, the frequency converter checks if a 24 V DC back-up supply is connected. If no 24 V DC backup supply is connected, the frequency converter trips after a fixed time delay. The time delay varies with unit size.

Troubleshooting

the frequency converter.

Connect a brake resistor.

•

Extend the ramp time.

•

Change the ramp type.

•

Activate the functions in 2-10 Brake Function.

•

Increase the value in 14-26 Trip Delay at Inverter

•

Fault.

Check that the supply voltage matches the

•

frequency converter voltage. Perform an input voltage test.

•

WARNING/ALARM 9, Inverter overload

The frequency converter is about to cut out because of an overload (too high current for too long). The counter for electronic, thermal inverter protection gives a warning at 98% and trips at 100%, while giving an alarm. The frequency converter cannot be reset until the counter is below 90%. The fault is that the frequency converter is overloaded by more than 100% for too long.

Troubleshooting

WARNING/ALARM 10, Motor overload temperature

According to the electronic thermal protection (ETR), the motor is too hot. Select whether the frequency converter gives a warning or an alarm when the counter reaches 100% in 1-90 Motor Thermal Protection. The fault occurs when the motor is overloaded by more than 100% for too long.

Troubleshooting

WARNING/ALARM 11, Motor thermistor over temp

The thermistor might be disconnected. Select whether the frequency converter gives a warning or an alarm in 1-90 Motor Thermal Protection.

Troubleshooting

Perform a soft charge circuit test.

•

Compare the output current shown on the LCP

•

with the frequency converter rated current. Compare the output current shown on the LCP

•

with measured motor current. Display the Thermal Drive Load on the LCP and

•

monitor the value. When running above the frequency converter continuous current rating, the counter should increase. When running below the frequency converter continuous current rating, the counter should decrease.

Check for motor overheating.

•

Check if the motor is mechanically overloaded.

•

Check that the motor current set in 1-24 Motor

•

Current is correct Ensure that motor data in parameters 1-20 to

•

1-25 are set correctly. If an external fan is in use, ensure that is is

•

selected in 1-91 Motor External Fan. Running AMA in 1-29 Automatic Motor Adaptation

•

(AMA) tunes the frequency converter to the motor more accurately and reduces thermal loading.

Check for motor overheating.

•

Check if the motor is mechanically overloaded.

•

Check that the thermistor is connected correctly

•

between either terminal 53 or 54 (analog voltage input) and terminal 50 (+10 V supply) and that

Warnings and Alarms

Operating Instructions

the terminal switch for 53 or 54 is set for voltage. Check 1-93 Thermistor Source selects terminal 53 or 54.

When using digital inputs 18 or 19, check that

•

the thermistor is connected correctly between either terminal 18 or 19 (digital input PNP only) and terminal 50.

If using a thermal switch or thermistor, check that

•

the programming if matches sensor wiring.

WARNING/ALARM 12, Torque limit

The torque has exceeded the value in 4-16 Torque Limit Motor Mode or the value in 4-17 Torque Limit Generator Mode. 14-25 Trip Delay at Torque Limit can change this from

a warning only condition to a warning followed by an alarm.

Troubleshooting

If the motor torque limit is exceeded during ramp

•

up, extend the ramp up time. If the generator torque limit is exceeded during

•

ramp down, extend the ramp down time. If torque limit occurs while running, possibly

•

increase the torque limit. Be sure the system can operate safely at a higher torque.

Check the application for excessive current draw

•

on the motor.

WARNING/ALARM 13, Over current

The inverter peak current limit (approximately 200% of the rated current) is exceeded. The warning lasts about 1.5 s, then the frequency converter trips and issues an alarm. This fault may be caused by shock loading or fast acceleration with high inertia loads. If extended mechanical brake control is selected, trip can be reset externally.

Troubleshooting

Remove power and check if the motor shaft can

•

be turned. Check that the motor size matches the frequency

•

converter. Check parameters 1-20 to 1-25 for correct motor

•

data.

ALARM 14, Earth (ground) fault

There is current from the output phases to ground, either in the cable between the frequency converter and the motor or in the motor itself.

Troubleshooting:

Remove power to the frequency converter and

•

repair the ground fault. Check for ground faults in the motor by

•

measuring the resistance to ground of the motor leads and the motor with a megohmmeter.

Perform current sensor test.

•

ALARM 15, Hardware mismatch

A fitted option is not operational with the present control board hardware or software.

Record the value of the following parameters and contact the Danfoss supplier:

15-40 FC Type

•

15-41 Power Section

•

15-42 Voltage

•

15-43 Software Version

•

15-45 Actual Typecode String

•

15-49 SW ID Control Card

•

15-50 SW ID Power Card

•

15-60 Option Mounted

•

15-61 Option SW Version (for each option slot)

•

ALARM 16, Short circuit

There is short-circuiting in the motor or motor wiring.

Remove power to the frequency converter and

•

repair the short circuit.

WARNING/ALARM 17, Control word timeout

There is no communication to the frequency converter. The warning is only active when 8-04 Control Timeout Function is NOT set to OFF. If 8-04 Control Timeout Function is set to [5] Stop and trip, a warning appears and the frequency converter ramps down until it trips then displays an alarm.

Troubleshooting

Check connections on the serial communication

•

cable. Increase the value in 8-03 Control Timeout Time.

•

Check the operation of the communication

•

equipment. Verify a proper installation based on EMC

•

requirements.

ALARM 18, Start failed

The speed has not exceeded 1-77 Compressor Start Max Speed [RPM] during start within the allowed time. (set in 1-79 Pump Start Max Time to Trip). This may be caused by a

blocked motor.

Warning/Alarm 19, Discharge Temperature High

Warning: The discharge temperature exceeds the level programmed in 28-25 Warning Action.

Alarm: The discharge temperature exceeds the level programmed in 28-26 Emergency Level.

WARNING 23, Internal fan fault

The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in 14-53 Fan Monitor ([0] Disabled).

9 9

Warnings and Alarms Operating Instructions

Troubleshooting

Check fan resistance.

•

Check soft charge fuses.

•

WARNING 24, External fan fault

The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in 14-53 Fan Monitor ([0] Disabled).

Troubleshooting

Check fan resistance.

•

Check soft charge fuses.

•

ALARM 29, Heat Sink temp

The maximum temperature of the heat sink has been exceeded. The temperature fault does not reset until the temperature drops below a defined heat sink temperature. The trip and reset points are different based on the frequency converter power size.

Troubleshooting

Check for the following conditions

Ambient temperature too high

•

Motor cable too long

•

Incorrect airflow clearance above and below the

•

This alarm is based on the temperature measured by the heat sink sensor mounted inside the IGBT modules.

Troubleshooting

ALARM 30, Motor phase U missing

Motor phase U between the frequency converter and the motor is missing.

Troubleshooting

ALARM 31, Motor phase V missing

Motor phase V between the frequency converter and the motor is missing.

Troubleshooting

ALARM 32, Motor phase W missing

Motor phase W between the frequency converter and the motor is missing.

Troubleshooting

frequency converter Blocked airflow around the frequency converter

•

Damaged heat sink fan

•

Dirty heat sink

•

Check fan resistance.

•

Check soft charge fuses.

•

Check IGBT thermal sensor.

•

Remove power from the frequency converter and

•

check motor phase U.

Remove power from the frequency converter and

•

check motor phase V.

Remove power from the frequency converter and

•

check motor phase W.

ALARM 33, Inrush fault

Too many power-ups have occurred within a short time period.

Troubleshooting

Let the unit cool to operating temperature.

•

WARNING/ALARM 34, Fieldbus communication fault

The fieldbus on the communication option card is not working.

WARNING/ALARM 35, Option fault

Option fault. Please contact your supplier.

WARNING/ALARM 36, Mains failure

This warning/alarm is only active if the supply voltage to the frequency converter is lost and 14-10 Mains Failure is NOT set to [0] No Function.

Troubleshooting

Check the fuses to the frequency converter and

•

mains power supply to the unit.

ALARM 38, Internal fault

When an internal fault occurs, a code number defined in Table 9.2 is displayed.

Troubleshooting

Cycle power.

•

Check that the option is properly installed.

•

Check for loose or missing wiring.

•

It may be necessary to contact the Danfoss supplier or service department. Note the code number for further troubleshooting directions.

No. Text

0 Serial port cannot be initialised. Contact the

Danfoss supplier or Danfoss Service Department.

256-258 Power EEPROM data is defective or too old.

512 Control board EEPROM data is defective or too

old. 513 Communication time out reading EEPROM data 514 Communication time out reading EEPROM data 515 Application oriented control cannot recognize the

EEPROM data. 516 Cannot write to the EEPROM because a write

command is on progress. 517 Write command is under time-out. 518 Failure in the EEPROM 519 Missing or invalid barcode data in EEPROM 783 Parameter value outside of min/max limits

1024-1279 A CAN telegram that has to be sent can not be

sent.

1281 Digital signal processor flash time-out 1282 Power micro software version mismatch 1283 Power EEPROM data version mismatch 1284 Cannot read digital signal processor software

version.

1299 Option SW in slot A is too old.

Warnings and Alarms

Operating Instructions

No. Text

1300 Option SW in slot B is too old. 1315 Option SW in slot A is not supported (not

allowed).

1316 Option SW in slot B is not supported (not

allowed).

1317 Option SW in slot C0 is not supported (not

allowed).

1318 Option SW in slot C1 is not supported (not

allowed).

1379 Option A did not respond when calculating

platform version.

1380 Option B did not respond when calculating

platform version.

1381 Option C0 did not respond when calculating

platform version.

1382 Option C1 did not respond when calculating

platform version.

1536 An exception in the application oriented control is

registered. Debug information written in LCP.

1792 DSP watchdog is active. Debugging of power part

data, motor oriented control data not transferred correctly.

2049 Power data restarted. 2064-2072 H081x: option in slot x has restarted. 2080-2088 H082x: option in slot x has issued a power-up-

wait.

2096-2104 H983x: option in slot x has issued a legal power-

up-wait. 2304 Could not read any data from power EEPROM. 2305 Missing SW version from power unit 2314 Missing power unit data from power unit 2315 Missing SW version from power unit 2316 Missint lo_statepage from power unit 2324 Power card configuration is determined to be

incorrect at power-up. 2325 A power card has stopped communicating while

main power is applied. 2326 Power card configuration is determined to be

incorrect after the delay for power cards to

registered as present. 2330 Power size information between the power cards

does not match. 2561 No communication from DSP to ATACD 2562 No communication from ATACD to DSP (state

running) 2816 Stack overflow control board module 2817 Scheduler slow tasks 2818 Fast tasks 2819 Parameter thread 2820 LCP stack overflow 2821 Serial port overflow 2822 USB port overflow

No. Text

2836 cfListMempool too small

3072-5122 Parameter value is outside its limits.

5123 Option in slot A: Hardware incompatible with

control board hardware.

5124 Option in slot B: Hardware incompatible with

Control board hardware.

5376-6231 Out of memory

Table 9.2 Internal Fault Code Numbers

ALARM 39, Heat sink sensor

No feedback from the heat sink temperature sensor. The signal from the IGBT thermal sensor is not available on

the power card. The problem could be on the power card, on the gate drive card, or the ribbon cable between the power card and gate drive card.

WARNING 40, Overload of digital output terminal 27

Check the load connected to terminal 27 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and 5-01 Terminal 27 Mode.

WARNING 41, Overload of digital output terminal 29

Check the load connected to terminal 29 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and 5-02 Terminal 29 Mode.

WARNING 42, Overload of digital output on X30/6 or overload of digital output on X30/7

For X30/6, check the load connected to X30/6 or remove the short-circuit connection. Check 5-32 Term X30/6 Digi Out (MCB 101).

For X30/7, check the load connected to X30/7 or remove the short-circuit connection. Check 5-33 Term X30/7 Digi Out (MCB 101).

ALARM 46, Power card supply

The supply on the power card is out of range. There are 3 power supplies generated by the switch mode

power supply (SMPS) on the power card: 24 V, 5 V, and ±18 V. When powered with 24 V DC with the MCB 107 option, only the 24 V and 5 V supplies are monitored. When powered with 3-phase mains voltage, all 3 supplies are monitored.

WARNING 47, 24 V supply low

The 24 V DC is measured on the control card. The external 24 V DC back-up power supply may be overloaded, otherwise contact Danfoss.

WARNING 48, 1.8 V supply low

The 1.8 V DC supply used on the control card is outside of allowable limits. The power supply is measured on the control card. Check for a defective control card. If an option card is present, check for an overvoltage condition.

WARNING 49, Speed limit

When the speed is not within the specified range in

4-11 Motor Speed Low Limit [RPM] and 4-13 Motor Speed High Limit [RPM], the frequency converter shows a warning.

9 9

Warnings and Alarms

Operating Instructions

When the speed is below the specified limit in 1-86 Trip Speed Low [RPM] (except when starting or stopping) the

frequency converter trips.

ALARM 50, AMA calibration failed

Contact the Danfoss supplier or Danfoss Service Department.

ALARM 51, AMA check U

The settings for motor voltage, motor current, and motor power are wrong. Check the settings in parameters 1-20 to 1-25.

ALARM 52, AMA low I

The motor current is too low. Check the settings.

ALARM 53, AMA motor too big

The motor is too big for the AMA to operate.

ALARM 54, AMA motor too small

The motor is too small for the AMA to operate.

ALARM 55, AMA Parameter out of range

The parameter values of the motor are outside of the acceptable range. AMA does not run.

ALARM 56, AMA interrupted by user

The user has interrupted the AMA.

ALARM 57, AMA internal fault

Try to restart AMA again a number of times, until the AMA is carried out. Note that repeated runs may heat the motor to a level where the resistance Rs and Rr are increased. In most cases, however, this is not critical.

ALARM 58, AMA internal fault

Contact Danfoss.

WARNING 59, Current limit

The current is higher than the value in 4-18 Current Limit.

Troubleshooting

Ensure that motor data in parameters 1-20 to

•

1-25 are set correctly. Possibly increase the current limit. Be sure that

•

the system can operate safely at a higher limit.

WARNING 60, External interlock

External interlock has been activated. To resume normal operation, apply 24 V DC to the terminal programmed for external interlock and reset the frequency converter (via serial communication, digital I/O, or by pressing [Reset]).

WARNING 61, Tracking error

An error has been detected between the calculated motor speed and the speed measurement from the feedback device. The function for Warning/Alarm/ Disable is set in

4-30 Motor Feedback Loss Function, error setting in 4-31 Motor Feedback Speed Error, and the allowed error time in 4-32 Motor Feedback Loss Timeout. During a commissioning

procedure the function may be effective.

WARNING 62, Output frequency at maximum limit

The output frequency is higher than the value set in 4-19 Max Output Frequency.

nom

and I

nom

ALARM 63, Mechanical brake low

The actual motor current has not exceeded the release brake current within the start delay time window.

ALARM 64, Voltage Limit

The load and speed combination demands a motor voltage higher than the actual DC-link voltage.

WARNING/ALARM 65, Control card over temperature

The control card has reached its trip temperature of 75 °C.

WARNING 66, Heat sink temperature low

The frequency converter is too cold to operate. This warning is based on the temperature sensor in the IGBT module. Increase the ambient temperature of the unit. Also, a trickle amount of current can be supplied to the frequency converter whenever the motor is stopped by setting

2-00 DC Hold/Preheat Current at 5% and 1-80 Function at Stop

Troubleshooting

The heat sink temperature measured as 0 °C

•

could indicate that the temperature sensor is defective, causing the fan speed to increase to the maximum. If the sensor wire between the IGBT and the gate drive card is disconnected, this warning would result. Also, check the IGBT thermal sensor.

ALARM 67, Option module configuration has changed

One or more options have either been added or removed since the last power-down. Check that the configuration change is intentional and reset the unit.

ALARM 68, Safe Stop activated

Safe Torque Off has been activated.

Troubleshooting

To resume normal operation, apply 24 V DC to

•

terminal 37, then send a reset signal (via bus, digital I/O, or by pressing [Reset]).

ALARM 69, Power card temperature

The temperature sensor on the power card is either too hot or too cold.

Troubleshooting

Check the operation of the door fans.

•

Check that the filters for the door fans are not

•

blocked. Check that the gland plate is properly installed

•

on IP21/IP54 (NEMA 1/12) frequency converters.

ALARM 70, Illegal FC configuration

The control card and power card are incompatible.

Troubleshooting

Contact the supplier with the type code of the

•

unit from the nameplate and the part numbers of the cards to check compatibility.

Warnings and Alarms Operating Instructions

WARNING 77, Reduced power mode

This warning indicates that the frequency converter is operating in reduced power mode (i.e. less than the allowed number of inverter sections). This warning is generated on power cycle when the frequency converter is set to run with fewer inverters and remains on.

ALARM 79, Illegal power section configuration

The scaling card is the incorrect part number or not installed. Also MK102 connector on the power card could not be installed.

ALARM 80, Drive initialised to default value

Parameter settings are initialised to default settings after a manual reset.

Troubleshooting

Reset the unit to clear the alarm.

•

ALARM 91, Analog input 54 wrong settings

Switch S202 has to be set in position OFF (voltage input) when a KTY sensor is connected to analog input terminal

54.

ALARM 92, No flow

A no-flow condition has been detected in the system. 22-23 No-Flow Function is set for alarm.

Troubleshooting

Troubleshoot the system and reset the frequency

•

converter after the fault has been cleared.

ALARM 93, Dry pump

A no-flow condition in the system with the frequency converter operating at high speed may indicate a dry pump. 22-26 Dry Pump Function is set for alarm.

Troubleshooting

Troubleshoot the system and reset the frequency

•

converter after the fault has been cleared.

ALARM 94, End of curve

Feedback is lower than the set point. This may indicate leakage in the system. 22-50 End of Curve Function is set for alarm.

Troubleshooting

Troubleshoot the system and reset the frequency

•

converter after the fault has been cleared.

ALARM 95, Broken belt

Torque is below the torque level set for no load, indicating a broken belt. 22-60 Broken Belt Function is set for alarm.

Troubleshooting

Troubleshoot the system and reset the frequency

•

converter after the fault has been cleared.

ALARM 96, Start delayed

Motor start has been delayed due to short-cycle protection. 22-76 Interval between Starts is enabled.

Troubleshooting

Troubleshoot the system and reset the frequency

•

converter after the fault has been cleared.

WARNING 97, Stop delayed

Stopping the motor has been delayed due to short -cycle protection. 22-76 Interval between Starts is enabled.

Troubleshooting

Troubleshoot the system and reset the frequency

•

converter after the fault has been cleared.

WARNING 98, Clock fault

Time is not set or the RTC clock has failed.

Troubleshooting

Reset the clock in 0-70 Date and Time.

•

ALARM 99, Locked rotor

Rotor is blocked.

WARNING/ALARM 104, Mixing fan fault

The fan monitor checks that the fan is spinning at frequency converter power-up or whenever the mixing fan is turned on. If the fan is not operating, then the fault is annunciated. The mixing-fan fault can be configured as a warning or an alarm trip by 14-53 Fan Monitor.

Troubleshooting

Cycle power to the frequency converter to

•

determine if the warning/alarm returns.

ALARM 220, Overload trip

Motor overload has tripped. Indicates excess motor load.

Troubleshooting

Check motor and driven load.

•

To reset, press [Off Reset].

•

Then, to restart the system press [Auto on] or

•

[Hand on].

WARNING 250, New spare part

A component in the frequency converter has been replaced. Reset the frequency converter for normal operation.

WARNING 251, New typecode

The power card or other components have been replaced and the typecode changed.

Troubleshooting

Reset to remove the warning and resume normal

•

operation.

9 9

Basic Troubleshooting Operating Instructions

10 Basic Troubleshooting

10.1 Start-up and Operation

Symptom Possible cause Test Solution

Missing input power Missing or open fuses or circuit breaker tripped

No power to the LCP Check the LCP cable for proper

Shortcut on control voltage (terminal 12 or 50) or at control

Display dark/No function

1010

Intermittent display

Motor not running

terminals

Wrong LCP (LCP from VLT® 2800 or 5000/6000/8000/ FCD or FCM) Wrong contrast setting

Display (LCP) is defective Test using a different LCP. Replace the faulty LCP or

Internal voltage supply fault or SMPS is defective Overloaded power supply (SMPS) due to improper control wiring or a fault within the frequency converter

Service switch open or missing motor connection

No mains power with 24 V DC option card

LCP Stop Check if [Off] has been pressed. Press [Auto On] or [Hand On]

Missing start signal (Standby)

Motor coast signal active (Coasting)

Wrong reference signal source Check reference signal: Local,

See Table 4.1. See Open fuses and Tripped circuit breaker in this table for possible causes.

connection or damage. Check the 24 V control voltage supply for terminals 12/13 to 20-39 or 10 V supply for terminals 50 to

55. LCP 102 (P/N 130B1107)

Contact supplier.

To rule out a problem in the control wiring, disconnect all control wiring by removing the terminal blocks.

Check if the motor is connected and the connection is not interrupted (by a service switch or other device). If the display is functioning but no output, check that mains power is applied to the frequency converter.

Check 5-10 Terminal 18 Digital Input for correct setting for terminal 18 (use default setting). Check . for correct setting for terminal 27 (use default setting).

remote or bus reference? Preset reference active? Terminal connection correct? Scaling of terminals correct? Reference signal available?

Check the input power source. Follow the recommendations provided.

Replace the faulty LCP or connection cable. Wire the terminals properly.

Press [Status] + [▲]/[▼] to adjust the contrast.

connection cable.

If the display stays lit, then the problem is in the control wiring. Check the wiring for shorts or incorrect connections. If the display continues to cut out, follow the procedure for display dark. Connect the motor and check the service switch.

Apply mains power to run the unit.

(depending on operation mode) to run the motor. Apply a valid start signal to start the motor.

Apply 24 V on terminal 27 or program this terminal to no operation. Program correct settings. Check 3-13 Reference Site. Set preset reference active in parameter group 3-1* References. Check for correct wiring. Check scaling of terminals. Check reference signal.

Basic Troubleshooting Operating Instructions

Symptom Possible cause Test Solution

Motor running in wrong direction

Motor is not reaching maximum speed

Motor speed unstable

Motor runs rough

Motor does not brake

Open power fuses or circuit breaker trip

Mains current imbalance greater than 3%

Motor current imbalance greater than 3%

Motor rotation limit

Active reversing signal Check if a reversing command is

Wrong motor phase connection

Frequency limits set wrong

Reference input signal not scaled correctly

Possible incorrect parameter settings

Possible overmagnetisation Check for incorrect motor settings

Possible incorrect settings in the brake parameters. Possible too short ramp down times Phase-to-phase short Motor or panel has a short phase

Motor overload Motor is overloaded for the

Loose connections Perform pre-start-up check for

Problem with mains power (See

Alarm 4 Mains phase loss

description) Problem with the frequency converter

Problem with motor or motor wiring

Problem with the frequency converters

Check that 4-10 Motor Speed Direction is programmed correctly.

programmed for the terminal in parameter group 5-1* Digital inputs.

Check output limits in 4-13 Motor

Speed High Limit [RPM], 4-14 Motor Speed High Limit [Hz] and 4-19 Max Output Frequency.

Check reference input signal scaling in parameter groups 6-0*

Analog I/O Mode and 3-1* References. Reference limits in parameter group 3-0* Reference Limit.

Check the settings of all motor parameters, including all motor compensation settings. For closed loop operation, check PID settings.

in all motor parameters.

Check brake parameters. Check ramp time settings.

to phase. Check motor and panel phase for shorts.

application.

loose connections. Rotate input power leads into the frequency converter one position: A to B, B to C, C to A. Rotate input power leads into the frequency converter one position: A to B, B to C, C to A. Rotate output motor leads one position: U to V, V to W, W to U.

Rotate output motor leads one position: U to V, V to W, W to U.

Program correct settings.

Deactivate reversing signal.

See chapter 3.4.6 Motor Rotation Check in this manual. Program correct limits.

Program correct settings.

Check settings in parameter group 1-6* Load Depen. Setting. For closed loop operation, check settings in parameter group 20-0* Feedback. Check motor settings in parameter groups 1-2* Motor Data, 1-3* Adv

Motor Data, and 1-5* Load Indep. Setting. Check parameter groups 2-0* DC Brake and 3-0* Reference Limits.

Eliminate any shorts detected.

Perform startup test and verify motor current is within specifications. If motor current is exceeding nameplate full load current, motor may run only with reduced load. Review the specifications for the application. Tighten loose connections.

If imbalanced leg follows the wire, it is a power problem. Check mains power supply. If imbalance leg stays on same input terminal, it is a problem with the unit. Contact the supplier. If imbalanced leg follows the wire, the problem is in the motor or motor wiring. Check motor and motor wiring. If imbalance leg stays on same output terminal, it is a problem with the unit. Contact the supplier.

10 10

Basic Troubleshooting Operating Instructions

Symptom Possible cause Test Solution

Bypass critical frequencies by using parameters in parameter group 4-6* Speed Bypass.

Acoustic noise or vibration (e.g. a fan blade is making noise or vibrations at certain frequencies)

Table 10.1 Troubleshooting

Resonances, e.g. in the motor/fan system

Turn off overmodulation in 14-03 Overmodulation. Change switching pattern and frequency in parameter group 14-0* Inverter Switching. Increase Resonance Dampening in 1-64 Resonance Damping.

Check if noise and/or vibration have been reduced to an acceptable limit.

1010

Specifications Operating Instructions

11 Specifications

11.1 Power-dependent Specifications

Normal Load* NO NO NO NO NO NO NO NO NO

Typical Shaft output at 400 V [kW] 110 132 160 200 250 315 355 400 450 Typical Shaft output at 460 V [hp] 150 200 250 300 350 450 500 550 600 Enclosure IP21 D1h D1h D1h D2h D2h D2h E1 E1 E1 Enclosure IP54 D1h D1h D1h D2h D2h D2h E1 E1 E1 Enclosure IP20 D3h D3h D3h D4h D4h D4h - - Enclosure IP00 - - - - - - E2 E2 E2

Output current

Continuous (at 400 V) [A] 212 260 315 395 480 588 658 745 800 Intermittent (60 s overload) (at 400 V)[A] 233 286 347 435 528 647 724 820 880 Continuous (at 460/480 V) [A] 190 240 302 361 443 535 590 678 730 Intermittent (60 s overload) (at 460/480 V) [kVA] Continuous kVA (at 400 V) [kVA] 147 180 218 274 333 407 456 516 554 Continuous kVA (at 460 V) [kVA] 151 191 241 288 353 426 470 540 582

Max. Input current

Continuous (at 400 V) [A] 204 251 304 381 463 567 647 733 787 Continuous (at 460/480 V) [A] 183 231 291 348 427 516 580 667 718 Max. external mains fuses [A] 315 350 400 550 630 800 900

Max. cable size

Max. cable size: mains, motor and load share mm (AWG)] Max. cable size: brake mm (AWG)] 2 x95 (2x3/0) 2x185 (2x350) 2x185 (2x350 mcm) Estimated power loss at 400 V [W] 2555 2949 3764 4109 5129 6663 7532 8677 9473 Estimated power loss at 460 V [W] 2257 2719 3612 3561 4558 5703 6724 7819 8527 Weight, enclosure IP21, IP54 kg (lbs.)

Weight, enclosure IP20 kg (lbs.) 62 (135) 125 (275) - - Weight, enclosure IP00 kg (lbs)

Efficiency 0.98 Output frequency [Hz] 0-590 Hz Heat sink overtemp. trip [°C] Power card ambient trip [°C] *Normal overload=110% current for 60 s

N110 N132 N160 N200 N250 N315 P355 P400 P450

209 264 332 397 487 588 649 746 803

2 x95 (2x3/0) 2x185 (2x350) 4x240 (4x500 mcm)

62 (135) 125 (275)

110

75 85

270

(594)

234

(515)

272

(598)

236

(519)

277

(609)

313

(689)

11 11

Table 11.1 Mains Supply 3x380-480 V AC

Specifications Operating Instructions

Normal Load* NO NO NO NO NO NO

Typical Shaft output at 550 V [kW] 55 75 90 110 132 160 Typical Shaft output at 575 V [hp] 75 100 125 150 200 250 Typical Shaft ouptut at 690 V [kW] 75 90 110 132 160 200 Enclosure IP21 D1h D1h D1h D1h D1h D2h Enclosure IP54 D1h D1h D1h D1h D1h D2h Enclosure IP20 D3h D3h D3h D3h D3h D4h Enclosure IP00 - - - - - -

Output current

Continuous (at 550 V) [A] 90 113 137 162 201 253 Intermittent (60 s overload) (at 550 V)[A] 99 124 151 178 221 278 Continuous (at 575/690 V) [A] 86 108 131 155 192 242 Intermittent (60 s overload) (at 575/690 V) [kVA] 95 119 144 171 211 266 Continuous kVA (at 550 V) [kVA] 86 108 131 154 191 241 Continuous kVA (at 575 V) [kVA] 86 108 130 154 191 241 Continuous kVA (at 690 V) [kVA] 103 129 157 185 229 289

Max. Input current

Continuous (at 550 V) [A] 89 110 130 158 198 245 Continuous (at 575 V) [A] 85 106 124 151 189 234 Continuous (at 690 V) [A] 87 109 128 155 197 240 Max. cable size: mains, motor and load share [mm (AWG)] Max. cable size: brake [mm (AWG)] 2x95 (2x3/0) Max. external mains fuses [A] 160 315 315 315 350 350 Estimated power loss at 575 V [W] 1161 1426 1739 2099 2646 3071 Estimated power loss at 690 V [W] 1203 1476 1796 2165 2738 3172 Weight, enclosure IP21, IP54 kg (lbs.) 62 (135) 125 (275) Weight, enclosure IP20 kg (lbs.) 62 (135) 125 (275)

1111

Weight, enclosure IP00 kg (lbs.) Efficiency 0.98 Output frequency 0-590 Hz Heat sink overtemp. trip Power card ambient trip *Normal overload=110% current for 60 s

N75K N90K N110 N132 N160 N200

2x95 (2x3/0)

110 °C

75 °C

Table 11.2 Mains Supply 3x525-690 V AC

Specifications

Operating Instructions

Normal Load* NO NO NO NO NO NO NO

Typical Shaft output at 550 V [kW] 200 250 315 355 400 450 500 Typical Shaft output at 575 V [hp] 300 350 400 450 500 600 650 Typical Shaft ouTput at 690 V [kW] 250 315 400 450 500 560 630 Enclosure IP21 D2h D2h D2h E1 E1 E1 E1 Enclosure IP54 D2h D2h D2h E1 E1 E1 E1 Enclosure IP20 D4h D4h D4h - - - Enclosure IP00 - - - E2 E2 E2 E2

Output current

Continuous (at 550 V) [A] 303 360 418 470 523 596 630 Intermittent (60 s overload) (at 550 V)[A] 333 396 460 517 575 656 693 Continuous (at 575/690 V) [A] 290 344 400 450 500 570 630 Intermittent (60 s overload) (at 575/690 V) [kVA] 319 378 440 495 550 627 693 Continuous kVA (at 550 V) [kVA] 289 343 398 448 498 568 600 Continuous kVA (at 575 V) [kVA] 289 343 398 448 498 568 627 Continuous kVA (at 690 V) [kVA] 347 411 478 538 598 681 753

Max. Input current

Continuous (at 550 V) [A] 299 355 408 453 504 574 607 Continuous (at 575 V) [A] 286 339 390 434 482 549 607 Continuous (at 690 V) [A] 296 352 400 434 482 549 607 Max. cable size: mains, motor and load share, mm (AWG) 2x185 (2x350 mcm)

Max. cable size: brake, mm (AWG) 2x185 (2x350 mcm) Max. external mains fuses [A] 400 500 550 700 700 900 900 Estimated power loss at 575 V [W] 3719 4460 5023 5323 6010 7395 8209 Estimated power loss at 690 V [W] 3848 4610 5150 5529 6239 7653 8495 Weight, enclosure IP21, IP54 kg (lbs.) 125 (275) Weight, enclosure IP20 kg (lbs.) 125 (275) Weight, enclosure IP00 kg (lbs.) - 221 (487) 221 (487) 236 (520) 277 (611) Efficiency 0.98 Output frequency [Hz] 0-590 0-525 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *Normal overload=110% current for 60 s

N250 N315 N400 P450 P500 P560 P630

4x240 (4x500 mcm)

110 95 110

80 85

11 11

Table 11.3 Mains Supply 3x525-690 V AC

The typical power loss is at nominal load conditions and expected to be within ±15% (tolerance relates to variety

•

in voltage and cable conditions). The losses are based on the default switching frequency. The losses increase significantly at higher switching

•

frequencies.

Specifications

Operating Instructions

11.2 General Technical Data

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

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

Supply frequency 50/60 Hz ±5% Max. 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 one time/2 min Environment according to EN60664-1 overvoltage category III/pollution degree 2

The unit is suitable for use on a circuit capable of delivering not more than 100000 RMS symmetrical Amperes, 480/600 V

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) From software version 1.10 the output frequency of the frequency converter is limited to 590 Hz. Contact local Danfoss partner for further information.

Torque characteristics Starting torque (Constant torque) maximum 110% for 60 s Starting torque maximum 135% up to 0.5 s Overload torque (Constant torque) maximum 110% for 60 s

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1) Percentage relates to the frequency converter's nominal torque

Cable lengths and cross-sections Max. motor cable length, screened/armoured 150 m Max. motor cable length, unscreened/unarmoured 300 m Max. cross section to motor and mains

Maximum cross section to control terminals, rigid wire 1.5 mm2/16 AWG (2x0.75 mm2) Maximum cross section to control terminals, flexible 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 mm

1) Depending on voltage and power.

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 <14V DC Maximum voltage on input 28 V DC Input resistance, R

aprrox. 4 kΩ

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 output.

Danfoss FC 103 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual