MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT® Refrigeration Drive 110-250 kW
Contents VLT® Refrigeration Drive 110-250 kW Operating Instructions
Contents
1 Safety
2 Introduction
2.1 Exploded Views
2.2 Purpose of the Manual
2.3 Additional Resources
2.4 Product Overview
2.5 Internal Controller Functions
3 Installation
3.1 Planning the Installation Site
3.2 Pre-Installation Checklist
3.3 Mechanical Installation
3.3.1 Cooling 8
3.3.2 Lifting 9
3.4 Electrical Installation
3.4.1 General Requirements 9
3.4.2 Earth (Ground) Requirements 12
4
5
5
6
6
6
6
8
8
8
8
9
3.4.2.1 Leakage Current (>3.5 mA) 12
3.4.2.2 Earthing (Grounding) IP20 Enclosures 13
3.4.2.3 Earthing (Grounding) IP21/54 Enclosures 13
3.4.3 Motor Connection 14
3.4.3.1 Motor Cable 17
3.4.3.2 Motor Rotation Check 17
3.4.4 AC Mains Input Connection 17
3.5 Control Wiring Connection
3.5.1 Access 18
3.5.2 Using Screened Control Cables 18
3.5.3 Earthing (Grounding) of Screened Control Cables 18
3.5.4 Control Terminal Types 19
3.5.5 Wiring to Control Terminals 19
3.5.6 Control Terminal Functions 19
3.6 Serial Communication
4 Start Up and Functional Test
4.1 Pre-start
18
19
21
21
4.2 Applying Power to the Frequency Converter
4.3 Basic Operational Programming
4.3.1 Set-up Wizard 22
4.4 Local-control Test
MG16F102 - VLT® is a registered Danfoss trademark 1
22
22
28
Contents VLT® Refrigeration Drive 110-250 kW Operating Instructions
4.5 System Start Up
5 User Interface
5.1 Local Control Panel
5.1.1 LCP Layout 30
5.1.2 Setting LCP Display Values 31
5.1.3 Display 31
5.1.4 Navigation Keys 32
5.1.5 Operation Keys 32
5.2 Back Up and Copying Parameter Settings
5.2.1 Uploading Data to the LCP 33
5.2.2 Downloading Data from the LCP 33
5.3 Restoring Default Settings
5.3.1 Recommended Initialisation 33
5.3.2 Manual Initialisation 33
6 Programming
6.1 Introduction
29
30
30
32
33
34
34
6.2 Programming Example
6.3 Control Terminal Programming Examples
6.4 International/North American Default Parameter Settings
6.5 Parameter Menu Structure
6.5.1 Quick Menu Structure 38
6.5.2 Main Menu Structure 40
7 Application Set-Up Examples
7.1 Introduction
7.2 Set-up Examples
7.2.1 Compressor 44
7.2.2 Single or Multiple Fans or Pumps 44
7.2.3 Compressor Pack 46
8 Status Messages
8.1 Status Display
8.2 Status Message Definitions Table
9 Warnings and Alarms
34
35
36
37
44
44
44
47
47
47
50
9.1 System Monitoring
9.2 Warning and Alarm Types
9.2.1 Warnings 50
9.2.2 Alarm Trip 50
9.2.3 Alarm Trip-lock 50
2 MG16F102 - VLT® is a registered Danfoss trademark
50
50
Contents VLT® Refrigeration Drive 110-250 kW Operating Instructions
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 General Specifications
11.2 Mains Supply
11.3 Fuse Specifications
11.3.1 Protection 71
11.3.2 Non UL Compliance 71
11.3.3 UL Compliance 72
11.3.4 Connection Tightening Torques 72
Index
50
52
54
60
60
63
63
68
71
73
MG16F102 - VLT® is a registered Danfoss trademark 3
Safety VLT® Refrigeration Drive 110-250 kW Operating Instructions
11
1 Safety
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains input power. Installation, start up,
and maintenance should be performed by qualified
personnel only. Failure to perform installation, start up, and
maintenance by qualified personnel could result in death
or serious injury.
High Voltage
Frequency converters are connected to hazardous mains
voltages. Extreme care should be taken to protect against
shock. Only trained personnel familiar with electronic
equipment should install, start, or maintain this equipment.
WARNING
UNINTENDED START!
When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency converter,
motor, and any driven equipment must be in operational
readiness. Failure to be in operational readiness when the
frequency converter is connected to AC mains could result
in death, serious injury, equipment, or property damage.
Unintended Start
When the frequency converter is connected to the AC
mains, the motor may be started by means of an external
switch, a serial bus command, an input reference signal, or
a cleared fault condition. Use appropriate cautions to
guard against an unintended start.
WARNING
DISCHARGE TIME!
Frequency converters contain DC link capacitors that can
remain charged even when AC mains is disconnected. To
avoid electrical hazards, remove AC mains from the
frequency converter and wait 20 minutes before doing any
service or repair. Failure to wait the specified time after
power has been removed prior to doing service or repair
on the unit could result in death or serious injury.
4 MG16F102 - VLT® is a registered Danfoss trademark
1
15
14
8
9
12
13 (IP 20/Chassis)
13
(IP 21/54
NEMA 1/12)
11
10
130BC252.10
130BC301.10
1
2
3
4
5
6
7
8
9
Introduction VLT® Refrigeration Drive 110-250 kW Operating Instructions
2 Introduction
2.1 Exploded Views
2 2
Illustration 2.2 Close-up View: LCP and Control Functions
Illustration 2.1 D1 Interior Components
LCP (Local Control Panel) 9 Relay 2 (04, 05, 06)
1
2 RS-485 serial bus connector 10 Lifting ring
3 Digital I/O and 24 V power supply 11 Mounting slot
4 Analog I/O connector 12 Cable clamp (PE)
5 USB connector 13 Earth (ground)
6 Serial bus terminal switch 14 Motor output terminals 96 (U), 97 (V), 98 (W)
7 Analog switches (A53), (A54) 15 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
8 Relay 1 (01, 02, 03)
Table 2.1
MG16F102 - VLT® is a registered Danfoss trademark 5
Introduction VLT® Refrigeration Drive 110-250 kW Operating Instructions
2.2 Purpose of the Manual
22
This manual is intended to provide detailed information for
the installation and start up of the frequency converter.
provides requirements for mechanical and electrical installation, including input, motor, control and serial
communications wiring, and control terminal functions.
provides detailed procedures for start up, basic operational
programming, and functional testing. The remaining
chapters provide supplementary details. These details
include user interface, detailed programming, application
examples, start-up troubleshooting, and specifications.
2.5
Internal Controller Functions
Illustration 2.3 is a block diagram of the frequency
converter's internal components. See Table 2.2 for their
functions.
2.3 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
Illustration 2.3 Frequency Converter Block Diagram
®
The VLT
•
detail on working with parameters and many
application examples.
The VLT
•
detailed capabilities and functionality to design
motor control systems.
Supplemental publications and manuals are
•
available from Danfoss.
See http://www.danfoss.com/Products/Literature/
Technical+Documentation.htm for listings.
Optional equipment is available that may change
•
some of the procedures described. Reference the
instructions supplied with those options for
specific requirements. Contact the local Danfoss
supplier or visit the Danfoss website for
downloads or additional information.
2.4
Product Overview
A frequency converter is an electronic motor controller
that converts AC mains input 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.
In addition, the frequency converter monitors the system
and motor status, issues warnings or alarms for fault
conditions, starts and stops the motor, optimizes energy
efficiency, and offers many more control, monitoring, and
efficiency functions. Operation and monitoring functions
are available as status indications to an outside control
system or serial communication network.
Programming Guide provides greater
®
Design Guide is intended to provide
Area Title Functions
1 Mains input
2 Rectifier
3 DC bus
4 DC reactors
5 Capacitor bank
6 Inverter
7 Output to motor
Three-phase AC mains power
•
supply to the frequency
converter
The rectifier bridge converts
•
the AC input to DC voltage to
supply inverter power
Intermediate DC-bus circuit
•
handles the DC current
Filter the intermediate DC
•
circuit current
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 three-phase output
•
power to the motor
6 MG16F102 - VLT® is a registered Danfoss trademark
Introduction VLT® Refrigeration Drive 110-250 kW Operating Instructions
Area Title Functions
8 Control circuitry
Table 2.2 Frequency Converter Internal Components
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
2 2
MG16F102 - VLT® is a registered Danfoss trademark 7
3
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
3 Installation
3.1 Planning the Installation Site
Ensure that frequency converter output current
CAUTION
Before performing the installation it is important to plan
the installation of the frequency converter. 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 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.
Voltage
380-480 V At altitudes above 3 km, contact Danfoss regarding
525-600 V At altitudes above 2 km, contact Danfoss regarding
Table 3.1 Installation in High Altitudes
Altitude Restrictions
PELV
PELV.
•
rating is equal to or greater than 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
Top and bottom clearance for air cooling must be
•
provided. Generally, 225 mm (9 in) is required.
Improper mounting can result in over heating
•
and reduced performance
Derating for temperatures starting between 45 °C
•
(113 °F) and 50 °C (122 °F) and elevation 1000 m
(3300 ft) above sea level must be considered. See
®
Design Guide for detailed information.
VLT
The high power Danfoss VLT frequency converters utilize a
back-channel cooling concept that removes heatsink
cooling air, which carries approximately 90% of the heat
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.
NOTE
3.2
Pre-Installation Checklist
Before unpacking the frequency converter, ensure
•
the packaging is intact. If any damage has
occurred, immediately contact the shipping
company to claim the damage.
Before unpacking the frequency converter, locate
•
it as close as possible to the final installation site.
Compare the model number on the nameplate to
•
what was ordered to verify the proper
equipment.
Ensure each of the following are rated for the
•
same voltage:
Mains (power)
•
Frequency converter
•
Motor
•
8 MG16F102 - VLT® is a registered Danfoss trademark
For ordering numbers, see the VLT High Power Drives
Selection Guide, PB.56.B1.02.
Duct cooling
A back-channel cooling kit is available to direct the
heatsink cooling air out of the panel when an IP20/chassis
frequency converters 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.
130BC253.10
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
A door fan(s) is required on the enclosure to remove the
heat not contained in the backchannel of the frequency
converters and any additional losses generated by other
components inside the enclosure. The total required air
flow must be calculated so that the appropriate fans can
be selected.
Airflow
The necessary airflow over the heat sink must be secured.
The flow rate is shown in Table 3.2.
The fan runs for the following reasons:
AMA
•
DC Hold
•
Pre-Mag
•
DC Brake
•
60% of nominal current is exceeded
•
Specific heatsink temperature exceeded (power
•
size dependent).
Specific Power Card ambient temperature
•
exceeded (power size dependent)
Specific Control Card ambient temperature
•
exceeded
Lifting
3.3.2
Always lift the frequency converter using the dedicated
lifting eyes. Use a bar to avoid bending the lifting holes.
Illustration 3.1 Position Lifting Straps where Indicated
CAUTION
The angle from the top of the frequency converter to the
lifting cables should be 60 ° or greater.
3.4 Electrical Installation
3
3
Enclosure
protection
IP21/NEMA 1 D1 and D2
IP00/Chassis
* Airflow per fan. Frame size F contains multiple fans.
Table 3.2 Airflow
Frame Door fan(s)/top
fan
170 m3/hr (100
CFM)
D3 and D4
255 m3/hr (150
CFM)
Heatsink fan(s)
765 m3/hr
(450 CFM)
765 m3/hr
(450 CFM)
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
MG16F102 - VLT® is a registered Danfoss trademark 9
91 (L1)
92 (L2)
93 (L3)
PE
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)
18 (D IN)
20 (COM D IN)
15mA 200 mA
(U) 96
(V) 97
(W) 98
(PE) 99
(COM A OUT) 39
(A OUT) 42
0/4-20 mA
03
0-10 V DC
+10 V DC
0-10 V DC
0/4-20 mA
240 V AC, 2A
24 V DC
02
01
05
04
06
240 V AC, 2A
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
19 (D IN)
24 V (NPN)
0 V (PNP)
27
24 V
0 V
(D IN/OUT)
0 V (PNP)
24 V (NPN)
(D IN/OUT)
0 V
24 V
29
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
S201
ON
21
S202
ON=0-20mA
OFF=0-10V
95
400 V AC, 2A
P 5-00
(R+) 82
(R-) 81
+ - + -
130BD010.10
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V
5V
S801
RS-485
RS-485
21
ON
S801
3 Phase
power
input
DC bus
Switch Mode
Power Supply
Motor
Analog Output
Interface
relay1
relay2
ON=Terminated
OFF=Open
Brake
resistor
(NPN) = Sink
(PNP) = Source
3
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
Illustration 3.2 Wiring Diagram
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 be performed only by
trained and qualified personnel. Failure to follow these
guidelines could result in death or serious injury.
CAUTION
WIRING ISOLATION!
Run input power, motor wiring and control wiring in three
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 frequency converter and associated equipment
performance.
10 MG16F102 - VLT® is a registered Danfoss trademark
Motor
Line Power
Stop
Start
Speed
Control
130BX370.10
L1
L1L2L2L3L3
GND
91 92 93
Fuses
130BB460.10
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
For personal safety, comply with the following
requirements
Electronic controls equipment is connected to
•
hazardous mains voltage. Extreme care should be
taken 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 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 3.3. 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 over-current protection. Input
fusing is required to provide this protection, see
Illustration 3.4. If not factory supplied, fuses must
be provided by the installer as part of installation.
See maximum fuse ratings in 11.3.1 Protection.
Illustration 3.3 Example of Proper Electrical Installation Using
Conduit
3
3
Illustration 3.4 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.
MG16F102 - VLT® is a registered Danfoss trademark 11
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
3
3.4.2 Earth (Ground) Requirements
WARNING
EARTHING (GROUNDING) HAZARD!
For operator safety, it is important to earth (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. Earth (ground) currents are higher than 3.5 mA.
Failure to earth (ground) the frequency converter properly
could result in death or serious injury.Earthing (grounding)
hazard
NOTE
It is the responsibility of the user or certified electrical
installer to ensure correct earthing (grounding) of the
equipment in accordance with national and local electrical
codes and standards.
Follow all local and national electrical codes to
•
earth (ground) electrical equipment properly.
Proper protective earthing (grounding) for
•
equipment with earth (ground) currents higher
than 3.5 mA must be established, see
3.4.2.1 Leakage Current (>3.5 mA).
A dedicated earth wire (ground wire) is required
•
for input power, motor power and control wiring.
Use the clamps provided with the equipment for
•
proper earth connections (ground connections).
Do not earth (ground) one frequency converter to
•
another in a “daisy chain” fashion.
Keep the earth (ground) wire connections as
•
short as possible.
Using high-strand wire to reduce electrical noise
•
is recommended.
Follow motor manufacturer wiring requirements.
•
3.4.2.1
Leakage Current (>3.5 mA)
Earthing (grounding) must be reinforced in one of the
following ways:
Earth (ground) wire of at least 10 mm
•
Two separate earth (ground) wires both
•
complying with the dimensioning rules.
See EN 60364-5-54 § 543.7 for further information.
Using RCDs
Where residual current devices (RCDs)–also known as earth
leakage circuit breakers (ELCBs)–are used, comply with the
following: residual current devices (RCDs)
Use RCDs of type B only, which are capable of
•
detecting AC and DC currents.
Use RCDs with an inrush delay to prevent faults
•
due to transient earth currents.
Dimension RCDs according to the system configu-
•
ration and environmental considerations.
2
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 will generate a leakage
current in the earth 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 earth current. The earth
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.
12 MG16F102 - VLT® is a registered Danfoss trademark
130BC303.10
130BC304.10
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
3.4.2.2 Earthing (Grounding) IP20
Enclosures
The frequency converter can be earthed (grounded) using
conduit or shielded cable. For earthing (grounding) of the
power connections, use the dedicated earthing
(grounding) points as shown in Illustration 3.6.
3.4.2.3
Earthing (Grounding) IP21/54
Enclosures
The frequency converter can be earthed (grounded) using
conduit or shielded cable. For earthing (grounding) of the
power connections, use the dedicated earthing
(grounding) points as shown in Illustration 3.6.
3
3
Illustration 3.5 Earthing (Grounding) Points for IP20 (Chassis)
Enclosures
Illustration 3.6 Earthing (Grounding) for IP21/54 Enclosures.
MG16F102 - VLT® is a registered Danfoss trademark 13
A
A
B
B
33
1.3[ ]
0
0.0[ ]
62
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
0.0[ ]
200
7.9[ ]
94
3.7[ ]
244
9.6[ ]
0
0.0[ ]
272
10.7[ ]
0
0.0[ ]
S
U
W
R T V
3X M8x20 STUD
WITH NUT
SECTION A-A
MAINS TERMINALS
MAINS TERMINAL
SECTION B-B
MOTOR TERMINALS
MOTOR
TERMINAL
130BC305.10
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
3
3.4.3 Motor Connection
WARNING
INDUCED VOLTAGE!
Run output 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. Failure to
run output motor cables separately could result in death
or serious injury.
For maximum cable sizes, see 11.2 Mains Supply.
•
Comply with local and national electrical codes
•
for cable sizes.
Gland plates are provided at the base of IP21/54
•
and higher (NEMA1/12) 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).
Earth (ground) the cable in accordance with the
•
instructions provided.
Torque terminals in accordance with the
•
information provided in 11.3.4 Connection
Tightening Torques
Follow motor manufacturer wiring requirements.
•
Illustration 3.7 Terminal Locations D1h
14 MG16F102 - VLT® is a registered Danfoss trademark
A
A
B
B
83
3.3[ ]
0
0.0[ ]
188
7.4[ ]
244
9.6[ ]
0
0.0[ ]
290
11.4[ ]
272
10.7[ ]
0
0.0[ ]
22
0.9[ ]
0
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[ ]
R
S
T
U
V
W
BRAKE
SECTION A-A
MAINS TERMINALS
MAINS
TERMINAL
SECTION B-B
MOTOR TERMINALS AND
BRAKE TERMINALS
MOTOR TERMINAL
BRAKE
TERMINAL
130BC302.10
B
B
A
A
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[ ]
R
S
T
U
V
W
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 VLT® Refrigeration Drive 110-250 kW Operating Instructions
3
3
Illustration 3.8 Terminal Locations D3h
Illustration 3.9 Terminal Locations D2h
MG16F102 - VLT® is a registered Danfoss trademark 15
A
A
B
B
33
1.3[ ]
0
0.0[ ]
91
3.6[ ]
149
5.8[ ]
211
8.3[ ]
265
10.4[ ]
319
12.6[ ]
200
7.9[ ]
0
0.0[ ]
319
12.6[ ]
376
14.8[ ]
293
11.5[ ]
255
10.0[ ]
0
0.0[ ]
306
12.1[ ]
284
11.2[ ]
0
0.0[ ]
236.8
9[ ]
R
S
T
U
V
W
BRAKE
TERMINALS
SECTION A-A
MAINS TERMINALS
MAINS TERMINAL
SECTION B-B
MOTOR TERMINALS AND
BRAKE TERMINALS
TERMINAL
BRAKE / REGEN
MOTOR TERMINAL
130BC333.10
3
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
Illustration 3.10 Terminal Locations D4h
16 MG16F102 - VLT® is a registered Danfoss trademark
96 97
U V
96 97 98
U V W
98
W
130HA036.10
130BC254.10
2
1
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
3.4.3.1 Motor Cable
The motor must be connected to terminals U/T1/96, V/
T2/97, W/T3/98. Earth (ground) to terminal 99. All types of
three-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, 99 Mains U/T1, V/T2, W/T3
Earth (ground)
Table 3.3
3
3
3.4.3.2
The direction of rotation can be changed by switching two
phases in the motor cable or by changing the setting of
4-10 Motor Speed Direction.
•
•
•
Table 3.4
A motor rotation check can be performed using1-28 Motor
Rotation Check and following the steps shown in the
display.
3.4.4
Motor Rotation Check
Terminal U/T1/96 connected
to U-phase
Terminal V/T2/97 connected
to V-phase
Terminal W/T3/98
connected to W-phase
AC Mains Input Connection
Size wiring is based upon the input current of the
•
frequency converter.
Comply with local and national electrical codes
•
for cable sizes.
Connect 3-phase AC input power wiring to
•
terminals L1, L2, and L3 (see Illustration 3.11).
Illustration 3.11 Connecting to AC Mains
Mains connection
1
2 Motor connection
Table 3.5
Earth (ground) the cable in accordance with the
•
instructions provided.
All frequency converters may be used with an
•
isolated input source as well as with earth
(ground) reference power lines. When supplied
from an isolated mains source (IT mains or
floating delta) or TT/TN-S mains with a grounded
leg (grounded delta), set 14-50 RFI Filter to OFF.
When off, the internal RFI filter capacitors
between the chassis and the intermediate circuit
are isolated to avoid damage to the intermediate
circuit and to reduce earth (ground) capacity
currents in accordance with IEC 61800-3.
MG16F102 - VLT® is a registered Danfoss trademark 17
1
2
PE
FC
PE
PLC
130BB922.11
PE PE
100nF
FC
PE
PE
PLC
130BB609.11
PE
FC
PE
FC
130BB923.11
PE PE
69
68
61
69
68
61
1
2
PE
FC
PE
FC
130BB924.11
PE PE
69
69
68
68
1
2
3
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
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.
3.5.1 Access
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).
Using Screened Control Cables
3.5.2
Danfoss recommends braided screened/armoured cables to
optimise EMC immunity of the control cables and the EMC
emission from the motor cables.
Earthing (Grounding) of Screened
3.5.3
Control Cables
Illustration 3.13
Avoid EMC noise on serial communication
This terminal is connected to earth (ground) via an internal
RC link. Use twisted-pair cables to reduce interference
between conductors. The recommended method is shown
below:
Illustration 3.14
1
Min. 16 mm
2 Equalizing cable
Table 3.7
2
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 earth (ground) potential
between the frequency converter and the PLC is different,
electric noise may occur that will disturb the entire system.
Solve this problem by fitting an equalizing cable next to
the control cable. Minimum cable cross section: 16 mm2.
Illustration 3.12
1
Min. 16 mm
2 Equalizing cable
Table 3.6
2
Alternatively, the connection to terminal 61 can be
omitted:
Illustration 3.15
1
Min. 16 mm
2 Equalizing cable
Table 3.8
2
50/60 Hz earth (ground) loops
With very long control cables, earth loops (ground loops)
may occur. To eliminate earth (ground) loops, connect one
end of the screen-to-earth (ground) with a 100 nF
capacitor (keeping leads short).
18 MG16F102 - VLT® is a registered Danfoss trademark
1
4
2
3
130BA012.11
61
68
69
39
42
50
53
54
55
12
13
18
19
27
29
32
33
20
37
130BT306.10
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
3.5.4 Control Terminal Types
Terminal functions and default settings are summarized in
3.5.6 Control Terminal Functions.
Illustration 3.16 Control Terminal Locations
Connector 1 provides four programmable digital
•
input terminals, two additional digital terminals
programmable as either input or output, a 24 V
DC terminal supply voltage, and a common for
optional customer supplied 24 V DC voltage.
Connector 2 terminals (+)68 and (-)69 are for an
•
RS-485 serial communications connection.
Connector 3 provides two analog inputs, one
•
analog output, 10 V DC supply voltage, and
commons for the inputs and output.
Connector 4 is a USB port available for use with
•
the MCT 10 Set-up Software.
Also provided are two Form C relay outputs that
•
are in various locations depending upon the
frequency converter configuration and size.
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 3.17
3.5.6 Control Terminal Functions
Frequency converter functions are commanded by
receiving control input signals.
Each terminal must be programmed for the
•
function it will be supporting in the parameters
associated with that terminal. See and for
terminals and associated parameters.
It is important to confirm that the control
•
terminal is programmed for the correct function.
See for details on accessing parameters and
programming.
The default terminal programming is intended to
•
initiate frequency converter functioning in a
typical operational mode.
3.6
Serial Communication
RS-485 is a two-wire bus interface compatible with multidrop 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 one network segment.
Repeaters divide network segments. Each repeater
functions as a node within the segment in which it is
installed. Each node connected within a given network
must have a unique node address across all segments.
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, and always follow
good common installation practice.
Low-impedance earth (ground) connection of the screen at
every node is important, including at high frequencies.
Thus, connect a large surface of the screen to earth
(ground), for example with a cable clamp or a conductive
cable gland. It may be necessary to apply potentialequalizing cables to maintain the same earth (ground)
3
3
MG16F102 - VLT® is a registered Danfoss trademark 19
3
Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions
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.
Cable Screened twisted pair (STP)
Impedance
Max. cable length 1200 m (including drop lines)
Table 3.9
120 Ω
500 m station-to-station
20 MG16F102 - VLT® is a registered Danfoss trademark
Start Up and Functional Tes... VLT® Refrigeration Drive 110-250 kW Operating Instructions
4 Start Up and Functional Test
4.1 Pre-start
CAUTION
Before applying power to the unit, inspect the entire
installation as detailed in Table 4.1. Check mark those items
when completed.
4 4
Inspect for Description
Auxiliary equipment
Cable routing
Control wiring
Cooling clearance
EMC considerations
Environmental considerations
Fusing and circuit
breakers
Earthing (Grounding)
Input and output power
wiring
Panel interior
Switches
Vibration
Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may
•
reside 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 motor(s), if present.
•
Ensure that input power, motor wiring , and control wiring are separated or in three separate
•
metallic conduits for high frequency noise isolation.
Check for broken or damaged wires and loose connections.
•
Check that control wiring is isolated from power and motor wiring for noise immunity.
•
Check the voltage source of the signals, if necessary.
•
The use of shielded cable or twisted pair is recommended. Ensure that the shield is terminated
•
correctly.
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 an earth wire(ground wire) from its chassis to the building earth (ground).
•
Check for good earth connections(ground connections) that are tight and free of oxidation.
•
Earthing (grounding) to conduit or mounting the back panel to a metal surface is not a
•
suitable earth (ground).
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 dirt, metal chips, moisture, 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.
•
☑
Table 4.1 Start Up Check List
MG16F102 - VLT® is a registered Danfoss trademark 21
130BC951.10
Start Up and Functional Tes... VLT® Refrigeration Drive 110-250 kW Operating Instructions
4.2 Applying Power to the Frequency Converter
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains. Installation, start-up and
maintenance should be performed by qualified personnel
44
only. Failure to perform installation, start-up and
maintenance by qualified personnel 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. The frequency converter,
motor, and any driven equipment must be in operational
readiness. Failure to be in operational readiness when the
frequency converter is connected to AC mains could result
in death, serious injury, equipment, or property damage.
1. Confirm input voltage is balanced within 3%. If
not, correct input voltage imbalance before
proceeding. Repeat procedure after voltage
correction.
2. Ensure optional equipment wiring, if present,
matches installation application.
3. Ensure that all operator devices are in the OFF
position. Panel doors 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.
event of power failure the application guide is accessed
through the Quick menu screen.
If [Cancel] is pressed, the FC 103 will return to the status
screen. An automatic timer will cancel the wizard after 5
min. of inactivity (no keys pressed). The wizard must be reentered through 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 setup by using this
Application Guide. Advanced features must be accessed
though 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 to be controlled via the
frequency converter's own internal PID controllers or from
an external control signal.
After completing set-up, choose to re-run wizard or start
application
The Application Guide can be cancelled at any time by
pressing [Back]. The Application Guide can be re-entered
through the Quick Menu. When re-entering the Application
Guide, the user will be asked to keep previous changes to
the factory set-up or to restore default values.
NOTE
If the status line at the bottom of the LCP reads AUTO
REMOTE COAST, this indicates that the unit is ready to
operate but is missing an input signal on terminal 27.
The FC 103 will start up initially with the Application guide
thereafter in the event of power failure the application
guide is accessed through the Quick menu screen.
The following screen will be presented:
4.3 Basic Operational Programming
4.3.1 Set-up Wizard
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 used makes complete
sense to the installer.
At start-up the FC 103 asks the user run the VLT Drive
Application Guide or to skip it (until it has been run, the
FC 103 will ask every time at start-up), thereafter in the
22 MG16F102 - VLT® is a registered Danfoss trademark
Illustration 4.1
If [Cancel] is pressed, the FC 103 will return to the status
screen. An automatic timer will cancel the wizard after 5
min. of inactivity (no keys pressed). The wizard must be reentered through the Quick Menu as described below.
130BC952.10
130BC953.10
130BC954.10
Start Up and Functional Tes... VLT® Refrigeration Drive 110-250 kW Operating Instructions
If [OK] is pressed, the Application Guide will start with the
following screen:
Illustration 4.2
NOTE
Numbering of steps in wizard (e.g. 1/12) can change
depending on choices in the workflow.
This screen will automatically change to the first input
screen of the Application Guide:
Compressor pack set-up
As an example, see screens below for a compressor pack
set-up:
Voltage and frequency set-up
4 4
Illustration 4.5
Current and nominal speed set-up
Illustration 4.3
Illustration 4.4
Illustration 4.6
Min. and max. frequency set-up
Illustration 4.7
MG16F102 - VLT® is a registered Danfoss trademark 23
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