Danfoss VLT HVAC Drive FC 102, VLT AutomationDrive FC 302 Series Operating Manual

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Operating Guide

VLT® HVAC Drive FC 102 110-800 kW, Enclosures D9h-D10h and E5h-E6h

Operating Guide | VLT® HVAC Drive FC 102

Contents

1 Introduction 8

1.1 Purpose of this Operating Guide 8

1.2 Additional Resources 8

1.3 Manual and Software Version 8

1.4 Approvals and Certifications 8

1.5 Disposal 9

2 Safety 10

2.1 Safety Symbols 10

2.2 Qualified Personnel 10

2.3 Safety Precautions 10

3 Product Overview 13

3.1 Intended Use 13

3.2 What is an Enclosed Drive? 13

3.3 Location of Options within an Enclosed Drive 16

3.4 Drive Identification 18

3.4.1 Identifying the Drive and Its Options 18

3.4.2 Enclosure Size Identification 20

3.4.3 Option Code Identification 20

3.5 Power Ratings and Dimensions for D9h–D10h and E5h–E6h Enclosures 24

3.6 Control Compartment and Local Control Panel 25

3.6.1 Control Compartment Overview 25

3.6.2 Control Compartment Door 26

3.6.3 Local Control Panel (LCP) 27

3.6.4 LCP Menu 29

4 Mechanical Installation 31

4.1 Items Supplied 31

4.2 Split Shipment 31

4.3 Tools Needed 32

4.4 Storage 32

4.5 Operating Environment 32

4.5.1 Operating Environment Overview 32

4.5.2 Gases within the Operating Environment 33

4.5.3 Dust within the Operating Environment 33

4.5.4 Potentially Explosive Atmospheres 33

4.6 Installation Requirements 34

4.7 Cooling Requirements 34

4.8 Airflow Rates 35

Operating Guide | VLT® HVAC Drive FC 102

4.9 Lifting the Drive 36

4.10 Combining Multiple Cabinets from a Split Shipment 37

4.11 Installing the Enclosed Drive 39

4.11.1 Creating an Entry for Cables 39

4.11.2 Installing the Drive with Back-channel Cooling Option 40

4.11.3 Securing the Cabinet(s) to the Floor 40

Contents

5 Electrical Installation 42

5.1 Safety Instructions 42

5.2 EMC-compliant Installation 42

5.3 Wiring Schematic for D9h and D10h Enclosed Drives 46

5.4 Wiring Schematic for E5h and E6h Enclosed Drives 47

5.5 Wiring Diagram Cross-reference 48

5.6 Split Shipment Wiring Harnesses 49

5.6.1 Connecting Wiring Harnesses 49

5.6.2 D10h Wiring Harness 50

5.6.3 E5h Wiring Harness 54

5.6.4 E6h Wiring Harness 60

5.7 Control Compartment Wiring 66

5.7.1 Safety Precautions 66

5.7.2 Control Compartment Interior View 67

5.7.3 Control Terminals 68

5.7.4 Relay Terminals 69

5.7.5 Option Card Terminals 69

5.7.6 Overview of Options Wiring 72

5.8 Connecting Motor, Mains, and Ground Cables 79

5.8.1 Power Cabling and Grounding Considerations 79

5.8.2 Connecting to the Mains 81

5.8.3 Connecting the Drive Module to the Motor 85

5.8.4 Connecting the Sine-wave Filter to the Motor 87

5.8.5 Connecting the dU/dt Filter to the Motor 89

5.8.6 Connecting to Ground 91

5.9 Installing Upstream Fuses 92

5.9.1 Upstream Fuse Considerations 92

5.9.2 Recommended Fuse Ratings for IEC Installation 92

5.9.3 Recommended Fuse Ratings for UL Installation 93

5.10 Enabling Motor Operation 94

5.11 Selecting the Voltage/Current Input Signal 94

5.12 Setting Up RS485 Serial Communication 95

5.13 Configuring the Passive Harmonic Filter (PHF) 96

5.14 Configuring the dU/dt Filter 96

5.15 Configuring the Sine-wave Filter 97

Operating Guide | VLT® HVAC Drive FC 102

5.16 MCCB Configuration 97

5.17 Safe Torque Off (STO) Wiring 98

Contents

6 Pre-start Check List 99

7 Commissioning 101

7.1 Applying Power to the Drive 101

7.2 Programming the Drive 101

7.2.1 Parameter Overview 101

7.2.2 Parameter Navigation 102

7.2.3 Programming Example for an Open-loop Application 102

7.2.4 Entering System Information 103

7.2.5 Configuring Automatic Energy Optimization 104

7.2.6 Configuring Automatic Motor Adaptation 105

7.3 Testing Before System Start-up 105

7.3.1 Testing Motor Rotation 105

7.3.2 Testing Encoder Rotation 106

7.4 Starting Up the Drive for the First Time 106

7.5 Parameter Settings 106

7.5.1 Parameter Setting Overview 106

7.5.2 Uploading and Downloading Parameter Settings 107

7.5.3 Restoring Factory Default Settings Using the Recommended Initialization 107

7.5.4 Restoring Factory Default Settings Using Manual Initialization 108

8 Wiring Configuration Examples 109

8.1 Application Examples 109

8.1.1 Wiring Configuration for Automatic Motor Adaptation (AMA) 109

8.1.2 Wiring Configuration for Automatic Motor Adaptation (AMA) without T27 110

8.1.3 Wiring Configuration: Speed 110

8.1.4 Wiring Configuration: Feedback 113

8.1.5 Wiring Configuration: Run/Stop 115

8.1.6 Wiring Configuration: Start/Stop 117

8.1.7 Wiring Configuration: External Alarm Reset 119

8.1.8 Wiring Configuration: RS485 120

8.1.9 Wiring Configuration: Motor Thermistor 120

8.1.10 Wiring for Regeneration 121

8.1.11 Wiring Configuration for a Relay Set-up with Smart Logic Control 122

8.1.12 Wiring Configuration for a Cascade Controller 122

8.1.13 Wiring Configuration for a Fixed Variable Speed Pump 124

8.1.14 Wiring Configuration for Lead Pump Alternation 125

9 Maintenance, Diagnostics, and Troubleshooting 126

9.1 Maintenance and Service 126

Operating Guide | VLT® HVAC Drive FC 102

9.2 Status Messages 126

9.2.1 Status Message Overview 126

9.2.2 Status Messages - Operating Mode 127

9.2.3 Status Messages - Reference Site 127

9.2.4 Status Messages - Operation Status 127

9.3 Warnings and Alarms 130

9.4 Troubleshooting 154

Contents

10 Specifications 157

10.1 Electrical Data 157

10.1.1 Electrical Data, 380–480 V AC 157

10.1.2 Electrical Data, 525–690 V AC 160

10.2 Mains Supply 163

10.3 Motor Output and Motor Data 163

10.3.1 Motor Output (U, V, W) 163

10.3.2 Torque Characteristics 163

10.4 Ambient Conditions 164

10.5 Control Cables 164

10.6 Control Input/Output and Control Data 165

10.6.1 Control Card, USB Serial Communication 165

10.6.2 STO Terminal XD2.19 (Terminal XD2.19 is Fixed PNP Logic) 165

10.6.3 Control Card, 24 V DC Output 165

10.6.4 Control Card, +10 V DC Output 165

10.6.5 Digital Outputs 166

10.6.6 Digital Inputs 166

10.6.7 Pulse/Encoder Inputs 166

10.6.8 Relay Outputs 167

10.6.9 Analog Output 167

10.6.10 Control Card, RS485 Serial Communication 168

10.6.11 Control Card Performance 168

10.6.12 Analog Inputs 168

10.7 Filter Specifications 169

10.7.1 Passive Harmonic Filter Specifications 169

10.7.2 Line Reactor Specifications 169

10.7.3 dU/dt Filter Specifications 170

10.7.4 Sine-wave Filter Specifications 171

10.8 Fuses and Circuit Breakers 172

10.8.1 Types of Fuses 172

10.8.2 Panel Fuses 172

10.8.3 Fusible Disconnect Switches 174

10.8.4 Non-fusible Disconnect Switches 175

10.8.5 Contactor Fuses 176

Operating Guide | VLT® HVAC Drive FC 102

10.8.6 Molded-case Circuit Breakers 177

10.9 Enclosure Dimensions 178

10.9.1 Pedestal Dimensions 178

10.9.2 D9h Enclosed Drive Dimension 179

10.9.3 D10h Enclosed Drive Dimensions 180

10.9.4 E5h Enclosed Drive Dimensions 181

10.9.5 E6h Enclosed Drive Dimensions 182

10.10 Enclosure Airflow 183

10.11 Fastener Torque Ratings 183

Contents

11 Appendix 184

11.1 Conventions 184

11.2 Abbreviations 184

11.3 International/North American Default Parameter Settings 186

11.4 Required Parameter Settings for Drive Options 187

11.5 Block Diagrams 188

11.6 Input Power Option Losses 191

11.6.1 Contactor Losses 191

11.6.2 Fusible Disconnect Losses 192

11.6.3 Non-fusible Disconnect Losses 193

11.6.4 MCCB Losses 194

11.6.5 Passive Harmonic Filter Losses 195

11.6.6 dU/dt Filter Losses 196

11.6.7 Sine-wave Filter Losses 197

089

Operating Guide | VLT® HVAC Drive FC 102

Introduction

1 Introduction

1.1 Purpose of this Operating Guide

This operating guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified personnel. Read and follow the instructions to use the drive safely and professionally. Pay particular attention to the safety instructions and general warnings. Always keep this operating guide available with the drive.

1.2 Additional Resources

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

• The programming guide provides greater detail on working with parameters and shows many application examples.

• The design guide provides detailed information about capabilities and functionality to design motor control systems.

• The Safe Torque Off Operating Guide provides detailed specifications, requirements, and installation instructions for the Safe Torque Off function.

• Supplementary publications and manuals are available from Danfoss.

See https://www.danfoss.com/en/search/?filter=type%3Adocumentation.

1.3 Manual and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome.

Table 1: Manual and Software Version

Version Remarks Software version

MG80G102 First version 5.32

1.4 Approvals and Certifications

The following list is a selection of possible type approvals and certifications for Danfoss drives:

The specific approvals and certification for the enclosed drive are on the nameplate of the drive. For more information, contact the local Danfoss office or partner.

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Themal memory retention requirement

This enclosed drive complies with UL 508C and UL 61800-5-1 thermal memory retention requirements. The enclosed drive is UL listed per UL508A and CSA 14 standards. For more information on UL 508C thermal memory retention requirements, refer to the Motor Thermal Protection section in the product-specific design guide.

Introduction

NOTI CE

OUTPUT FREQUENCY LIMIT

Due to export control regulations, the output frequency of the drive is limited to 590 Hz. For demands exceeding 590 Hz, contact Danfoss.

ADN-compliance

For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), refer to section ADN-compliant Installation in the product-specific design guide.

1.5 Disposal

Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with applicable local regulations.

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Operating Guide | VLT® HVAC Drive FC 102

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

DA NG ER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WA RN IN G

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CA UT IO N

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Safety

NO TI CE

Indicates a property damage message.

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

• Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

• Are familiar with the basic regulations concerning health and safety/accident prevention.

• Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in the operating guide of the unit.

• Have good knowledge of the generic and specialist standards applicable to the specific application.

2.3 Safety Precautions

WA RN IN G

LACK OF SAFETY AWARENESS

This document gives important information on how to prevent injury and damage to the equipment or your system. Ignoring them can lead to death, serious injury, or severe damage to the equipment.

Make sure to fully understand the dangers and safety measures incurred in your application.

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Operating Guide | VLT® HVAC Drive FC 102

WA RN IN G

DISCHARGE TIME

The drive contains DC-link capacitors and, if input filter options are present, extra capacitors and inductors. These components can remain charged even when the drive is not powered. High voltage can be present even when the warning indicator lights are off.

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 AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and

DC-link connections to other drives.

Wait for the capacitors to discharge fully. The minimum waiting time is specified both in the Discharge Time table and on

the nameplate on top of the drive.

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

are fully discharged.

Table 2: Discharge Time

Voltage [V] Minimum waiting time (minutes)

Safety

20 40

380–480 110–315 kW (150–450 hp) 355–560 kW (500–750 hp)

525–690 110–400 kW (125–400 hp) 450–800 kW (450–950 hp)

WA RN IN G

HIGH VOLTAGE

AC drives contain high voltage when connected to AC mains input. Failure to perform installation , start-up, and maintenance by qualified personnel can result in death or serious injury.

Only qualified personnel must perform installation, start-up, and maintenance.

WA RN IN G

UNINTENDED START

When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death, serious injury, and equipment, or property damage. The motor may start by activation of an external switch, a fieldbus command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condition.

Press [Off] on the LCP before programming parameters.

Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended

motor start.

Check that the drive, motor, and any driven equipment is in operational readiness.

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Operating Guide | VLT® HVAC Drive FC 102

WA RN IN G

LEAKAGE CURRENT HAZARD

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

Ensure the correct grounding of the equipment by a certified electrical installer.

WA RN IN G

ROTATING SHAFTS

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 guide.

CA UT IO N

HOT SURFACES

The drive contains metal components that are still hot even after the drive has been powered off. Failure to observe the high temperature symbol (yellow triangle) on the drive can result in serious burns.

Be aware that internal components, such as busbars, may be extremely hot even after the drive has been powered off.

Do not touch exterior areas that are marked by the high temperature symbol (yellow triangle). These areas are hot while the

drive is in use and immediately after being powered off.

Safety

CA UT IO N

INTERNAL FAILURE HAZARD

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

Ensure that all safety covers are in place and securely fastened before applying power.

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Operating Guide | VLT® HVAC Drive FC 102

Product Overview

3 Product Overview

3.1 Intended Use

NO TI CE

OUTPUT FREQUENCY LIMIT

Due to export control regulations, the output frequency of the drive is limited to 590 Hz. For demands exceeding 590 Hz, contact Danfoss.

The enclosed drive 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. Depending on the configuration, the drive can be used in standalone applications or form part of a larger system or installation. The enclosed drive is designed to:

• Regulate motor speed in response to system feedback or remote commands from external controllers.

• Provide motor overload protection.

• Monitor system and motor status.

• Reduce harmonics and increase the power factor using the optional passive harmonic filter or line reactor.

• Reduce motor acoustic noise and protect motor insulation with the optional output filters.

• Reduce bearing current and shaft voltage with the optional common-mode filter.

• Reduce high-frequency, electromagnetic noise in the motor cables with the optional dU/dt filter.

• Provide sinusoidal output with optional sine-wave filter.

The enclosed drive is designed for residential, industrial, and commercial environments in accordance with local laws and standards. Do not use this drive in applications that are non-compliant with specified operating conditions and environments.

NO TI CE

RADIO INTERFERENCE

In a residential environment, this product can cause radio interference.

Take supplementary mitigation measures.

3.2 What is an Enclosed Drive?

The enclosed drive is an IP21/54 (NEMA 1/12) enclosure surrounding an IP20 (Protected Chassis) drive to form the basis of the system. There are 4 enclosed drive models with varying power ratings.

• D9h model: 110–160 kW (125–250 hp)

• D10h model: 200–400 kW (250–450 hp)

• E5h model: 355–630 kW (450–650 hp)

• E6h model: 500–800 kW (650–950 hp)

The enclosed drive is available with various power options and input and output filters to create a factory-built, custom drive. Some options and filters result in extra cabinets attached to the left or right side of the drive cabinet. These optional cabinets are shown with dotted lines, while the drive cabinet is shaded.

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Operating Guide | VLT® HVAC Drive FC 102

Product Overview

1 Input filter cabinet (passive harmonic filter or line reactor)

3 Sine-wave cabinet

Input power options

The D9h enclosure does not require an input power options cabinet – the input power options are placed in the drive cabinet.

Illustration 1: Possible Configurations for a D9h Enclosed Drive

(1)

2 Drives cabinet

4 Control compartment

1 Input filter cabinet (passive harmonic filter or line reactor)

3 Drive cabinet

Input power options cabinet

4 Sine-wave filter cabinet

(1)

5 Control compartment

If more than 1 input power option is ordered, the D10h enclosed drive requires an input power options cabinet. Otherwise the single input power option is placed below the control

compartment in the drive cabinet.

Illustration 2: Possible Configurations for a D10h Enclosed Drive

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Operating Guide | VLT® HVAC Drive FC 102

Product Overview

1 Input filter cabinet (passive harmonic filter or line reactor)

3 Drive cabinet

5 Control compartment

Illustration 3: Possible Configurations for an E5h or E6h Enclosed Drive

2 Input power options cabinet

4 Sine-wave filter cabinet

6 dU/dt filter cabinet

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Operating Guide | VLT® HVAC Drive FC 102

3.3 Location of Options within an Enclosed Drive

Product Overview

1 Passive harmonic filter (PHF)

3 Non-fusible disconnect

5 Molded-case circuit breaker (MCCB)

2 Line reactor

4 Fusible disconnect

6 Contactor

7 dU/dt filter

9 Sine-wave filter

Illustration 4: Visual Representation of a D9h Enclosure and the Locations of Available Options

8 Common-mode filter

10 Drive module (varies in power rating)

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Operating Guide | VLT® HVAC Drive FC 102

Product Overview

1 Passive harmonic filter (PHF)

3 Non-fusible disconnect

5 Molded-case circuit breaker (MCCB)

7 dU/dt filter

9 Sine-wave filter

2 Line reactor

4 Fusible disconnect

6 Contactor

8 Common-mode filter

10 Drive module (varies in power rating)

Illustration 5: Visual Representation of a D10h Enclosure and the Locations of Available Options

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Product Overview

1 Passive harmonic filter (PHF)

3 Non-fusible disconnect

5 Molded-case circuit breaker (MCCB)

7 dU/dt filter

9 Sine-wave filter

Illustration 6: Visual Representation of a E5h/E6h Enclosure and the Locations of Available Options

2 Line reactor

4 Fusible disconnect

6 Contactor

8 Common-mode filter

10 Drive module (varies in power rating)

3.4 Drive Identification

3.4.1 Identifying the Drive and Its Options

Context:

Enclosure size and specific options are used throughout this guide whenever procedures or components differ based on the drive and its options. Use the following steps to identify the enclosed drive:

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Product Overview

Procedure

1. Locate the type code (T/C) on the nameplate. The nameplate is found on the exterior of the drive by the bottom grill or on the

inside cabinet door that contains the control compartment.

2. Determine the type of enclosure by obtaining the following information from the type code:

A Product group and drive series (characters 1–6).

B Voltage rating (character 8).

C Model/power rating (characters 10–12).

3. Go to

table 3 and use the model number and voltage rating to find the enclosure size.

4. Obtain the following option codes from the type code.

A Low harmonic filter (character 7).

B Brake (character 15).

C Mains (character 16–17).

D Output filter (character 18).

E Extra empty cabinet (character 19).

F Cable infeed (character 20).

G Back-channel cooling (character 22).

H Auxiliary function (characters 22–23).

I Door-mounted options (characters 28–29).

5. Using the option codes, refer to

3.4.3 Option Code Identification to identify the installed options.

Example:

1 Type code.

3 Drive series

• 102 = VLT® HVAC Drive

• 202 = VLT® AQUA Drive

• 302 = VLT® AutomationDrive

2 Product group (PLV = enclosed drive)

4 Low harmonic filter option

6 Model/power rating

8 Option codes

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Operating Guide | VLT® HVAC Drive FC 102

5 Mains voltage

• 4 = 380–480 V

• 5 = 380–500 V

• 6 = 525–690 V

7 Build date (wwy, where ww = the week and y = the last digit

of the year)

Illustration 7: Using the Nameplate to Find the Enclosure Size and Installed Options

3.4.2 Enclosure Size Identification

Table 3: Model by Drive Voltage

Model Enclosure size (380–480 V) Enclosure size (525–690 V)

N110 D9h D9h

N132 D9h D9h

N160 D9h D9h

Product Overview

N200 D10h D10h

N250 D10h D10h

N315 D10h D10h

N355 E5h –

N400 E5h D10h

N450 E5h E5h

N500 E6h E5h

N560 E6h E5h

N630 – E5h

N710 – E6h

N800 – E6h

3.4.3 Option Code Identification

Table 4: Low-harmonic Filter Option Codes

Character position Option code Description

7 T None

A Active filter

P Passive filter, THDi=5%, 50 Hz

H Passive filter, THDi=8%, 50 Hz

L Passive filter, THDi=5%, 60 Hz

U Passive filter, THDi=8%, 60 Hz

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Table 5: Brake Option Codes

Character position Option code Description

15 X No brake IGBT

B Brake IGBT

T Safe Torque Off

U Brake IGBT + Safe Torque Off

Table 6: Mains Option Codes

Character position Option code Description

16–17 MX None

M1 Fusible disconnect

M2 Non-fusible disconnect

M3 Circuit breaker (MCCB)

M4 Contactor

Product Overview

M5 AC reactor

M6 Fuses

MA Fusible disconnect + contactor

MB Non-fusible disconnect + contactor

MC AC reactor + fusible disconnect

MD AC reactor + fusible disconnect + contactor

ME AC reactor + non-fusible disconnect

MF AC reactor + circuit breaker (MCCB)

MG AC reactor + contactor

MH AC reactor + non-fusible disconnect + contactor

Table 7: Output Filter Option Codes

Character position Option code Description

18 X None

D dU/dt

S Sine-wave

C Common-mode

1 Common-mode + dU/dt

2 Common-mode + sine-wave

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Table 8: Extra Cabinet Option Codes

Character position Option code Description

19 X None

4 400 mm (15.8 in), left-hand side

6 600 mm (23.6 in), left-hand side

A 400 mm (15.8 in), right-hand side

B 600 mm (23.6 in), right-hand side

Table 9: Cable Infeed Option Codes

Character position Option code Description

20 X Bottom

T Top

L Mains top, motor bottom

M Mains bottom, motor top

Product Overview

Table 10: Auxiliary Power Supply Codes

Character position Option code Description

21 X No supply

1 230 V AC external

2 230 V AC internal

4 230 V AC internal + 24 V DC internal

5 230 V AC external + 24 V DC internal

6 120 V AC external

7 120 V AC internal

8 120 V AC internal + 24 V DC internal

9 120 V AC external + 24 V DC internal

Table 11: Back-channel Cooling Option Codes

Character position Option code Description

22 X Bottom in, top out

1 Back in, back out

C Back in, top out

D Bottom in, back out

N None

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Table 12: Auxiliary Function Option Codes

Product Overview

Character position

Option code

Description

23–24 XX No auxiliary options

A1 AC socket+cabinet light

A2 Extended I/O terminals

A3 Cabinet heater

A4 Motor heater control

A5 Insulation monitor

AA AC socket + cabinet light + extended I/O terminals

AB AC socket + cabinet light + cabinet heater

AC AC socket + cabinet light + motor heater control

AD AC socket + cabinet light + insulation monitor

AE AC socket + cabinet light + extended I/O terminals + cabinet heater

AF AC socket + cabinet light + extended I/O terminals + motor heater control

AG AC socket + cabinet light + extended I/O terminals + insulation monitor

AH AC socket + cabinet light + extended I/O terminals + cabinet heater + motor heater control

AI AC socket + cabinet light + extended I/O terminals + cabinet heater + insulation monitor

AJ AC socket + cabinet light + extended I/O terminals + motor heater control + insulation monitor

AK AC socket + cabinet light + extended I/O terminals + cabinet heater + motor heater control + in-

sulation monitor

AL AC socket + cabinet light + cabinet heater + motor heater control

AM AC socket + cabinet light + cabinet heater + insulation monitor

AN AC socket + cabinet light + cabinet heater + motor heater control + insulation monitor

AO AC socket + cabinet light + motor heater control + insulation monitor

AP Extended I/O terminals + cabinet heater

AQ Extended I/O terminals + motor heater control

AR Extended I/O terminals + insulation monitor

AS Extended I/O terminals + cabinet heater + motor heater control

AT Extended I/O terminals + cabinet heater + insulation monitor

AU Extended I/O terminals + cabinet heater + motor heater control + insulation monitor

AV Extended I/O terminals + motor heater control + insulation monitor

AW Cabinet heater + motor heater control

AX Cabinet heater + insulation monitor

AY Cabinet heater + motor heater control + insulation monitor

AZ Motor heater control + insulation monitor

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Table 13: Door-mounted Option Codes

Product Overview

Character position

Option code

Description

28–29 XX None

D1 Indicator lights and reset button

D2 Emergency switch off + emergency push-button

D3 STO w/ emergency push-button (no functional safety)

D4 STO/SS1 w/ emergency push-button + safely limited speed (TTL encoder)

D5 STO/SS1 w/ emergency push-button + safely limited speed (HTL encoder)

DA Indicator lights and reset button + emergency switch off and emergency push-button

DB Indicator lights and reset button + STO w/ emergency push-button (no functional safety)

DC Indicator lights and reset button + STO/SS1 w/ emergency push-button + safely limited speed

(TTL encoder)

DE Indicator lights and reset button + STO/SS1 w/ emergency push-button + safely limited speed

(HTL encoder)

3.5 Power Ratings and Dimensions for D9h–D10h and E5h–E6h Enclosures

Table 14: Power Ratings and Dimensions for D9h–D10h and E5h–E6h Enclosures (Standard Configurations)

Enclosed drive D9h D10h E5h E6h

Rated power at 380–480 V [kW (hp)] 110–160 (150–

200–315 (300–450) 355–450 (500–600) 500–560 (650–750)

250)

Rated power at 525–690 V [kW (hp)] 110–160 (125–

200–400 (250–400) 450–630 (450–650) 710–800 (750–950)

200)

Protection rating IP21 (NEMA 1)/

IP54 (NEMA 12)

IP21 (NEMA 1)/IP54 (NEMA 12)

Drive cabinet D9h D10h E5h E6h

Height [mm (in)]

Width [mm (in)]

(1)

(2)

2100 (82.7) 2100 (82.7) 2100 (82.7) 2100 (82.7)

400 (15.8) 600 (23.6) 600 (23.6) 800 (31.5)

Depth [mm (in)] 600 (23.6) 600 (23.6) 600 (23.6) 600 (23.6)

Weight [kg (lb)]

(2)

280 (617) 355 (783) 400 (882) 431 (950)

Input filter cabinet D9h D10h E5h E6h

Height [mm (in)]

(1)

2100 (82.7) 2100 (82.7) 2100 (82.7) 2100 (82.7)

Width [mm (in)] 400 (15.8) 400 (15.8)/600 (23.6) 600 (23.6) 600 (23.6)/800 (31.5)

Depth [mm (in)] 600 (23.6) 600 (23.6) 600 (23.6) 600 (23.6)

Weight [kg (lb)] 410 (904) 410 (904)/530

(1168)

530 (1168) 530 (1168)/955

(2105)

Input power options cabinet D9h D10h E5h E6h

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Product Overview

Enclosed drive D9h D10h E5h E6h

Height [mm (in)]

(1)

– 2100 (82.7) 2100 (82.7) 2100 (82.7)

Width [mm (in)] – 600 (23.6) 600 (23.6) 600 (23.6)

Depth [mm (in)] – 600 (23.6) 600 (23.6) 600 (23.6)

Weight [kg (lb)] – 380 (838) 380 (838) 380 (838)

Sine-wave filter cabinet D9h D10h E5h E6h

Height [mm (in)]

(1)

2100 (82.7) 2100 (82.7) 2100 (82.7) 2100 (82.7)

Width [mm (in)] 600 (23.6) 600 (23.6) 1200 (47.2) 1200 (47.2)

Depth [mm (in)] 600 (23.6) 600 (23.6) 600 (23.6) 600 (23.6)

Weight [kg (lb)]

dU/dt filter cabinet D9h D10h E5h E6h

Height [mm (in)]

Width [mm (in)]

(1)

(3)

– – 2100 (82.7) 2100 (82.7)

– – 400 (15.8) 400 (15.8)

Depth [mm (in)] – – 600 (23.6) 600 (23.6)

Weight [kg (lb)] – – 240 (529) 240 (529)

Top entry/exit cabinet D9h D10h E5h E6h

Height [mm (in)]

Width [mm (in)]

(1)

(3)

2100 (82.7) 2100 (82.7) 2100 (82.7) 2100 (82.7)

400 (15.8) 400 (15.8) 400 (15.8) 400 (15.8)

Depth [mm (in)] 600 (23.6) 600 (23.6) 600 (23.6) 600 (23.6)

Weight [kg (lb)] 164 (362) 164 (362) 164 (362) 164 (362)

Cabinet height includes standard 100 mm (3.9 in) pedestal. A 200 mm (7.9 in) or 400 mm (15.8 in) pedestal is optional.

Without options.

The E5h and E6h enclosures contain 2 sine-wave cabinets. The provided width is the total of both cabinets.

3.6 Control Compartment and Local Control Panel

3.6.1 Control Compartment Overview

The control compartment is a self-contained space that can be accessed without opening the drive enclosure. The control compartment contains the following:

• Local control panel (LCP).

• Terminals for option cards.

• Optional auxiliary components and related wiring.

• Terminals for internal connections.

• Terminals for control cabling.

• Product nameplate.

• Buttons and indicator lights (on the exterior door).

For wiring and terminal descriptions, see 5.7.2 Control Compartment Interior View.

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3.6.2 Control Compartment Door

Product Overview

1 Local control panel (LCP)

3 Fault indicator light

2 Emergency push-button

4 Run indicator light

5 Insulation fault indicator light

7 0–1 Start switch

6 USB slot

8 Reset button

9 Nameplate

Illustration 8: Exterior Door of Control Compartment (Shown with All Options)

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Auto

Reset

Hand

Off

Status

Quick Menu

Main

Alarm

Log

Back

Cancel

Info

Status

1(1)

0.00 kW

Off Remote Stop

0.0 Hz

Alarm

Warn.

0.00 A

0 RPM

0.0 %

A1.1 A1.2

A1.3 A2

C4 C5

D1 D2

Operating Guide | VLT® HVAC Drive FC 102

3.6.3 Local Control Panel (LCP)

Product Overview

Illustration 9: Graphical Local Control Panel (LCP)

A. Display area

Each display readout has a parameter associated with it. See table 15. The information shown on the LCP can be customized for specific applications. Refer to My Personal Menu in the LCP Menu section.

Table 15: LCP Display Area

Callout Parameter Default setting

A1.1 Parameter 0-20 Display Line 1.1 Small ReferenceSpeed [%]

A1.2 Parameter 0-21 Display Line 1.2 Small Motor current [A]

A1.3 Parameter 0-22 Display Line 1.3 Small Power [kW]

A2 Parameter 0-23 Display Line 2 Large Frequency [Hz]

A3 Parameter 0-24 Display Line 3 Large kWh counter

B. Menu keys

Menu keys are used to access the menu for setting up parameters, toggling through status display modes during normal operation, and viewing fault log data.

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Table 16: LCP Menu Keys

Product Overview

Callout Key Function

B1 Status Shows operational information.

B2 Quick Menu Allows access to parameters for initial set-up instructions. Also provides detailed application steps. Refer

to Quick Menu Mode in the LCP Menu section.

B3 Main Menu Allows access to all parameters. Refer to Main Menu Mode in the LCP Menu section.

B4 Alarm Log Shows a list of current warnings and the last 10 alarms.

C. Navigation keys

Navigation keys are used for programming functions and moving the display cursor. The navigation keys also provide speed control in local (hand) operation. The display brightness can be adjusted by pressing [Status] and [▵]/[▿] keys.

Table 17: LCP Navigation Keys

Callout Key Function

C1 Back Reverts to the previous step or list in the menu structure.

C2 Cancel Cancels the last change or command as long as the display mode has not changed.

C3 Info Shows a definition of the function being shown.

C4 OK Accesses parameter groups or enables an option.

C5 [▵][▹] [▿] [◃] Moves between items in the menu.

D. Indicator lights

Indicator lights identify the drive status and provides a visual notification of warning or fault conditions.

Table 18: LCP Indicator Lights

Callout Indicator Light Function

D1 On Green Activates when the drive receives power from the mains voltage or a 24 V external supply.

D2 Warn. Yellow Activates when warning conditions are active. Text appears in the display area identifying the

problem.

D3 Alarm Red Activates during a fault condition. Text appears in the display area identifying the problem.

E. Operation keys and reset

The operation keys are found toward the bottom of the local control panel.

Table 19: LCP Operation Keys and Reset

Callout Key Function

E1 [Hand On] Starts the drive in local control. An external stop signal by control input or serial communication overrides

the local [Hand On].

E2 Off Stops the motor but does not remove power to the drive.

E3 Reset Resets the drive manually after a fault has been cleared.

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Q1 My Personal Menu Q2 Quick Setup

Q3 Function Setups Q4 Smart Start

0.0% 0.00

Quick Menus

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Operating Guide | VLT® HVAC Drive FC 102

Callout Key Function

E4 Auto On Puts the system in remote operational mode so it can respond to an external start command by control

terminals or serial communication.

Product Overview

3.6.4 LCP Menu

Quick Menus

The Quick Menus mode provides a list of menus used to configure and operate the drive. Select the Quick Menus mode by pressing the [Quick Menus] key. The resulting readout appears on the LCP display.

Illustration 10: Quick Menu View

Q1 My Personal Menu

The Personal Menu is used to determine what is shown in the display area. Refer to 3.6.3 Local Control Panel (LCP). This menu can also show up to 50 pre-programmed parameters. These 50 parameters are manually entered using parameter 0-25 My Personal Menu.

Q2 Quick Setup

The parameters found in the Q2 Quick Setup contain basic system and motor data that are always necessary for configuring the drive.

7.2.4 Entering System Information for the set-up procedures.

See

Q3 Function Setups

The parameters found in the Q3 Function Setups contain data for fan, compressor, and pump functions. This menu also includes parameters for LCP display, digital preset speeds, scaling of analog references, closed-loop single zone, and multizone applications.

Q4 Smart Setup

Q4 Smart Setup guides the user through typical parameter settings used to configure 1 of the following 3 applications:

• Mechanical brake.

• Conveyor.

• Pump/fan.

The [Info] key can be used to see help information for various selections, settings, and messages.

Q5 Changes Made

Select Q5 Changes Made for information about:

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O-** Operation / Display 1-** Load and Motor

2-** Brakes 3-** Reference / Ramps

0.0% 0.00 A

Main Menu

1(1)

Operating Guide | VLT® HVAC Drive FC 102

• The 10 most recent changes.

• Changes made from default setting.

Q6 Loggings

Use Q6 Loggings for fault finding. To get information about the display line readout, select Loggings. The information is shown as graphs. Only parameters selected in parameter 0-20 Display Line 1.1 Small through parameter 0-24 Display Line 3 Large can be viewed. It is possible to store up to 120 samples in the memory for later reference.

Table 20: Logging Parameter Examples

Q6 Loggings

Parameter 0-20 Display Line 1.1 Small Reference [%]

Parameter 0-21 Display Line 1.2 Small Motor Current [A]

Parameter 0-22 Display Line 1.3 Small Power [kW]

Parameter 0-23 Display Line 2 Large Frequency

Parameter 0-24 Display Line 3 Large kWh Counter

Product Overview

Main Menu

The Main Menu mode is used to:

• List the parameter groups available to the drive and drive options.

• Change parameter values.

Illustration 11: Main Menu View

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Mechanical Installation

4 Mechanical Installation

4.1 Items Supplied

Items supplied can vary according to product configuration.

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

• Visually check the packaging and the drive for damage caused by inappropriate handling during shipment. File any claim for damage with the carrier. Retain damaged parts for clarification.

1 Type code

3 Power rating

5 Output voltage, frequency, and current (at low/high voltages)

Illustration 12: Example of a Product Nameplate for E6h Enclosure (IEC Version on Left, UL Version on Right)

2 Part number and serial number

4 Input voltage, frequency, and current (at low/high voltages)

6 Discharge time

NO TI CE

WARRANTY

Removing the nameplate from the drive can result in the loss of warranty.

4.2 Split Shipment

Depending on what options are ordered with an enclosed drive, the drive can consist of 5 cabinets and measure 3400 mm (134 in) in width, which can be difficult to transport and handle. In cases where an enclosed drive exceeds 1800 mm (71 in) in width, the cabinets are separated and shipped in multiple boxes. All necessary fasteners needed for reassembly are provided in the delivery. To reassemble a split shipment, refer to 4.10 Combining Multiple Cabinets from a Split Shipment and 5.6.1 Connecting Wiring Harnesses.

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Mechanical Installation

4.3 Tools Needed

• I-beam and hooks rated to lift the weight of the drive. Refer to the Power Ratings, Weight, and Dimensions section.

• Crane or other lifting aid to place the unit into position.

• Drill with 10 mm or 12 mm drill bits.

• Tape measurer.

• Various sizes of Phillips and flat bladed screwdrivers.

• Wrench with relevant metric sockets (7–17 mm).

• Wrench extensions.

• Torx drives (T25 and T50).

• Sheet metal punch for cable entry plate.

4.4 Storage

Store the drive in a dry location. Keep the equipment sealed in its packaging until installation. Refer to the Ambient Conditions section for recommended ambient temperature.

Periodic forming (capacitor charging) is not necessary during storage unless storage exceeds 12 months.

4.5 Operating Environment

4.5.1 Operating Environment Overview

In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/NEMA protection rating of the equipment matches the installation environment. Refer to the Ambient Conditions section.

NO TI CE

CONDENSATION

Moisture can condense on the electronic components and cause short circuits.

Avoid installation in areas subject to frost.

Install an optional space heater when the drive is colder than the ambient air.

Operating in standby mode reduces the risk of condensation as long as the power dissipation keeps the circuitry free of

moisture.

NO TI CE

EXTREME AMBIENT CONDITIONS

Hot or cold temperatures compromise unit performance and longevity.

Do not operate in environments where the ambient temperature exceeds 55 °C (131 °F).

The drive can operate at temperatures down to -10 °C (14 °F). However, proper operation at rated load is only guaranteed at

0 °C (32 °F) or higher.

Provide extra air conditioning for the cabinet or installation site when the temperature exceeds ambient temperature limits.

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Mechanical Installation

4.5.2 Gases within the Operating Environment

Aggressive gases, such as hydrogen sulphide, chlorine, or ammonia can damage the electrical and mechanical components. The unit uses conformal-coated circuit boards to reduce the effects of aggressive gases.

For conformal coating class specifications and ratings, see the Ambient Conditions section.

4.5.3 Dust within the Operating Environment

When installing the drive in dusty environments, keep the following free from dust buildup:

• Electronic components.

• Heat sink.

• Fans.

Periodic maintenance

When dust accumulates on electronic components, it acts as a layer of insulation. This layer reduces the cooling capacity of the components, and the components become warmer. The hotter environment decreases the life of the electronic components. Dust can also accumulate on fan blades, causing an imbalance which prevents the fan from properly cooling the unit. Dust buildup can also damage fan bearings and cause premature fan failure.

For more information, refer to the Maintenance and Service section.

4.5.4 Potentially Explosive Atmospheres

WA RN IN G

EXPLOSIVE ATMOSPHERE

Installing the drive in a potentially explosive atmosphere can lead to death, personal injury, or property damage.

Install the unit in a cabinet outside of the potentially explosive area.

Use a motor with ATEX protection class d or class e.

• Class d (if a spark occurs, it is contained in a protected area).

• Class e (prohibits any occurrence of a spark).

Install a PTC temperature sensor to monitor the motor temperature.

Install short motor cables.

Use sine-wave output filters when shielded motor cables are not used.

As required by the EU Directive 94/9/EC, any electrical or electronic device intended for use in an environment with a potentially explosive mixture of air, flammable gas, or dust must be ATEX-certified. Systems operated in this environment must fulfill the following special conditions to comply with the ATEX protection class:

Motors with class d protection

Does not require approval. Special wiring and containment are required.

Motors with class e protection

When combined with an ATEX-approved PTC monitoring device like the VLT® PTC Thermistor Card MCB 112, installation does not need an individual approval from an approbated organization.

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Motors with class d/e protection

The motor itself has an e ignition protection class, while the motor cabling and connection environment is in compliance with the d classification. To attenuate the high peak voltage, use a sine-wave filter at the drive output.

Mechanical Installation

NO TI CE

MOTOR THERMISTOR SENSOR MONITORING

VLT® AutomationDrive units with the VLT® PTC Thermistor Card MCB 112 option are PTB-certified for potentially explosive atmospheres.

4.6 Installation Requirements

NO TI CE

OVERHEATING

Improper mounting can result in overheating and reduced performance.

Install the drive according to the installation and cooling requirements.

• Locate the unit as near to the motor as possible. For the maximum motor cable length, see 10.5 Control Cables.

• Ensure unit stability by mounting the unit to a solid surface.

• Ensure that the strength of the mounting location supports the unit weight.

• Ensure that there is enough space around the unit for proper cooling. Refer to 10.10 Enclosure Airflow.

• Ensure enough access to open the door.

• Ensure cable entry from the bottom.

4.7 Cooling Requirements

NO TI CE

OVERHEATING

Improper mounting can result in overheating and reduced performance.

Install the drive following the installation and cooling requirements.

• Ensure that top and bottom clearance for air cooling is provided. Clearance requirement: 225 mm (9 in).

• Provide sufficient airflow flow rate. See 4.8 Airflow Rates.

• 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 the product-specific design guide for detailed information.

The enclosed drive, excluding the input power options cabinet, utilizes a back-channel cooling concept that removes the air used to cool the heat sink. The heat sink cooling air carries approximately 90% of the heat out of the back channel of the drive. A back-channel cooling option allows the cooling air to be brought into and vented out of the room where the drive is installed.

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4.8 Airflow Rates

Table 21: Airflow Rates for D9h Enclosure

Mechanical Installation

Cabinet

Back-channel fan [m3/hr (cfm)] Drive module top fan [m3/hr (cfm)] Cabinet door fan [m3/hr (cfm)]

PHF/line reactor 450 (265) – –

Drive 420 (250) 102 (60) 150 (90)

dU/dt – – –

Sine-wave 900 (530) – –

Top entry/top exit – – –

Table 22: Airflow Rates for D10h Enclosure

Cabinet

Back-channel fan [m3/hr (cfm)] Drive module top fan [m3/hr (cfm)] Cabinet door fan [m3/hr (cfm)]

PHF/line reactor 450 (265) – –

Input options – – 510 (310)

Drive 840 (500) 204 (120) 315 (185)

dU/dt – – –

Sine-wave 900 (530) – –

Top entry/top exit – – –

Table 23: Airflow Rates for E5h Enclosure

Cabinet

Back-channel fan [m3/hr (cfm)] Drive module top fan [m3/hr (cfm)] Cabinet door fan [m3/hr (cfm)]

PHF/line reactor 765 (450) – –

Input options – – 510 (310)

Drive 994 (585) 595 (350) 335 (200)

dU/dt 665 (392) – –

Sine-wave 2x900 (530) – –

Top entry/top exit – – –

Table 24: Airflow Rates for E6h Enclosure

Cabinet

Back-channel fan [m3/hr (cfm)] Drive module top fan [m3/hr (cfm)] Cabinet door fan [m3/hr (cfm)]

PHF/line reactor 1285 (755) – –

Input options – – 510 (310)

Drive 1053–1206 (620–710) 629 (370) 430 (255)

dU/dt 665 (392) – –

Sine-wave 2x900 (530) – –

Top entry/top exit – – –

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Mechanical Installation

4.9 Lifting the Drive

WA RN IN G

HEAVY WEIGHT

The weight of the drive is heavy. Failure to follow local safety regulations for lifting heavy weights may cause death, personal injury, or property damage.

Ensure that the lifting equipment is in proper working condition.

Check the weight of the drive and verify that the lifting equipment can safely lift the weight.

Ensure that the angle from the top of the drive to the lifting cable is 65° or greater.

Test lift the drive approximately 610 mm (24 in) to verify the proper center of gravity lift point. Reposition the lifting point if

the unit is not level.

Never walk under suspended loads.

Illustration 13: Recommended Lifting Method

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Mechanical Installation

4.10 Combining Multiple Cabinets from a Split Shipment

Procedure

1. Make sure the cabinets are in the right order and place them side by side. For the proper order, refer to 3.2 What is an Enclosed

Drive?.

2. Attach the cabinets to one another:

A Remove the Rittal back cover from each cabinet.

B Secure the back side of the cabinets to one another using the back brackets. See

C Secure the front side of the cabinets to one another using the front brackets. See illustration 14.

D Secure the lifting eyelets to the top of the cabinets. See illustration 15.

E Join the grounding bars using the connector piece (see the shaded piece in illustration 16).

Example:

illustration 14.

1 Front brackets 2 Back brackets

Illustration 14: Bracket Mounting Points for Cabinets

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Illustration 15: Connecting the Lifting Eyelet Between Cabinets

Mechanical Installation

Illustration 16: Connecting the Grounding Bar Between Cabinets

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Mechanical Installation

4.11 Installing the Enclosed Drive

4.11.1 Creating an Entry for Cables

Procedure

1. Locate the cabinets that contain the motor and mains terminals.

2. Open the cabinet doors and remove any protective covers placed over the terminals.

3. Create the cable openings.

- For IEC versions, cut the grommet openings just enough to pass the cables through them.

- For UL versions, cut or drill openings in the cable entry plate and fit with appropriate UL conduits, according to the mains and motor cable sizes.

4. Terminate the shields properly.

- Use the metallic glands to terminate the output cable shields.

- Use the flex sheets to firmly terminate the shields. For certain configurations, Danfoss supplies the flex sheets.

Example:

Illustration 17: Installing Motor and Mains Cables Through an IP54 (IEC version) Cable Entry Plate

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Mechanical Installation

4.11.2 Installing the Drive with Back-channel Cooling Option

Procedure

1. Select an area in which to install the enclosure. Do not install the enclosure in an airtight space. The drive receives approximately

5–10% of intake air from the front of the cabinet.

2. Measure the duct openings in the back of the cabinets and create corresponding openings in the wall where the enclosure will be located.

3. If the enclosed drive is configured with a cabinet heater, connect the cabinet heater supply cable to the correct terminals in the control compartment. Refer to 5.7.2 Control Compartment Interior View.

4. Move the enclosure near the wall, lining up the enclosure ducts with the openings in the wall.

5. Make sure to provide an airtight seal for between the duct and wall opening.

Example:

Illustration 18: Cabinet Airflow with the Back-channel Option (Duct Adapter Flanges not Provided with Option)

4.11.3 Securing the Cabinet(s) to the Floor

Context:

There are 3 methods to secure the cabinet to the floor:

• Use the 4 mounting points at the base of the pedestal.

• Use the 2 mounting points at the front base of the pedestal and the 2 mounting points at the upper back of the cabinet.

• To use the mounting bracket, first attach it to the floor by sliding the edge of the cabinet pedestal under the mounting bracket. Then secure the 2 mounting holes to the front base of the pedestal.

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Example:

Mechanical Installation

A The 4 mounting points at the base of the pedestal

C The 2 mounting points at the upper back of the cabinet

Illustration 19: Cabinet Mounting Points

B The 2 mounting points at the front base of the pedestal

D The 2 mounting points in the mounting bracket

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Electrical Installation

5 Electrical Installation

5.1 Safety Instructions

See 2.3 Safety Precautions for general safety warnings.

NO TI CE

APPLICATIONS WITH MULTIPLE MOTORS

To provide overcurrent protection, extra protective equipment such as short-circuit protection or motor thermal protection between drive and motor is required for applications with multiple motors.

NO TI CE

WIRE TYPE AND RATINGS

All wiring must comply with local and national regulations regarding cross-section and ambient temperature requirements. For power connections, minimum 75 °C (167 °F) rated copper wire is recommended.

WA RN IN G

INDUCED VOLTAGE

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

Run output motor cables separately.

Use shielded cables.

WA RN IN G

SHOCK HAZARD

The drive can cause a DC current in the PE conductor. Failure to use a Type B residual current-operated protective device (RCD) may lead to the RCD not providing the intended protection and therefore may result in death or serious injury.

When an RCD is used for protection against electrical shock, only a Type B device is allowed on the supply side.

CA UT IO N

MOTOR OVERLOAD

Protection against motor overload is not included in the default setting. For the North American market, the ETR function provides class 20 motor overload protection in accordance with NEC. Failure to set the ETR function means that motor overload protection is not provided and property damage can occur if the motor overheats.

Enable the ETR function by setting parameter 1-90 Motor Thermal Protection to [ETR trip] or [ETR warning].

5.2 EMC-compliant Installation

To obtain an EMC-compliant installation, be sure to follow all electrical installation instructions.

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Also, remember to practice the following:

• When using relays, control cables, a signal interface, fieldbus, or brake, connect the shield to the enclosure at both ends. If the ground path has high impedance, is noisy, or is carrying current, break the shield connection on 1 end to avoid ground current loops.

• Convey the currents back to the unit using a metal mounting plate. Ensure good electrical contact from the mounting plate by securely fastening the mounting screws to the drive chassis.

• Use shielded cables for motor output cables. An alternative is unshielded motor cables within metal conduit.

• Ensure that motor and brake cables are as short as possible to reduce the interference level from the entire system.

• Avoid placing cables with a sensitive signal level alongside motor and brake cables.

• For communication and command/control lines, follow the particular communication protocol standards. For example, USB must use shielded cables, but RS485/ethernet can use shielded UTP or unshielded UTP cables.

• Ensure that all control terminal connections are rated protective extra low voltage (PELV).

Electrical Installation

NO TI CE

TWISTED SHIELD ENDS (PIGTAILS)

Twisted shield ends increase the shield impedance at higher frequencies, which reduces the shield effect and increases the leakage current.

Use integrated shield clamps instead of twisted shield ends.

NO TI CE

SHIELDED CABLES

If shielded cables or metal conduits are not used, the unit and the installation do not meet regulatory limits on radio frequency (RF) emission levels.

NO TI CE

EMC INTERFERENCE

Failure to isolate power, motor, and control cables can result in unintended behavior or reduced performance.

Use shielded cables for motor and control wiring.

Provide a minimum 200 mm (7.9 in) separation between mains input, motor cables, and control cables.

NO TI CE

INSTALLATION AT HIGH ALTITUDE

There is a risk for overvoltage. Isolation between components and critical parts could be insufficient, and may not comply with PELV requirements.

Use external protective devices or galvanic isolation. For installations above 2000 m (6500 ft) altitude, contact Danfoss

regarding protective extra low voltage (PELV) compliance.

NO TI CE

PROTECTIVE EXTRA LOW VOLTAGE (PELV) COMPLIANCE

Prevent electric shock by using PELV electrical supply and complying with local and national PELV regulations.

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Electrical Installation

1 Programmable logic controller (PLC)

3 Control cables

5 Mains supply

7 Star washers

9 Motor cable (shielded)

Minimum 16 mm2 (6 AWG) equalizing cable

4 Minimum 200 mm (7.9 in) between control cables, motor

cables, and mains cables

6 Bare (unpainted) surface

8 Brake cable (shielded)

10 Mains cable (unshielded)

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

11 Output contactor, and so on.

13 Common ground busbar. Follow local and national

requirements for cabinet grounding.

15 Metal box

17 Motor

Illustration 20: Example of Proper EMC Installation

12 Cable insulation stripped

14 Brake resistor

16 Connection to motor

18 EMC cable gland

AQ262141314214en-000101 / 130R0880 | 45

1 2

(NC)

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

18 (D IN)

15 mA

200 mA

(U) 96

(PE) 99

0/4-20 mA

0 V DC - 10 V DC

0/4–20 mA

02 01

05 04

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

19 (D IN)

24 V (NPN) 0 V (PNP)

24 V

0 V

0 V (PNP)

24 V (NPN)

0 V

24 V

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

33 (D IN)

32 (D IN)

1 2

A53 U-I (S201)

A54 U-I (S202)

ON=0–20 mA OFF=0–10 V

95 (PE)

P 5-00

(R+) 82 (R-) 81

+ - + -

0 V

5 V

S801

Switch mode

power supply

ON=Terminated OFF=Open

(NPN) = Sink

37 (D IN) - option

e30bg569.10

Drive

Control compartment

XD2 Terminal

block

XD2.21 XD2.23 XD2.22 XD2.24

XD2.26 XD2.25

XD2.4 XD2.

XD2.2 XD2.3

XD2.1

XD2.19

XD2.17

XD2.16

XD2.15

XD2.14

XD2.18

XD2.13

XD2.12

XD2.11

XD2.10

XD2.9

XD2.8

XD2.7

XD2.6

cabinet

(V) 97

(W) 98

240 V AC, 2A 400 V AC, 2A

Brake temp

RS485

(PNP) = Source

(COM RS485) 61

(N RS485) 69

(P RS485) 68

RS485 Interface

OFF-ON

S801/Bus term.

(COM A OUT) 39

(A OUT) 42

10 V DC

24 V DC

3-phase

50 (+10 V OUT)

+10 V DC

power input

0 V DC - 10 V DC

0/4–20 mA

29 (D IN/OUT)

27 (D IN/OUT)

20 (COM D IN)

13 (+24 V OUT)

12 (+24 V OUT)

55 (COM A IN)

54 (A IN)

53 (A IN)

Motor

Brake resistor (option)

Relay1

Relay2

Analog output

Operating Guide | VLT® HVAC Drive FC 102

5.3 Wiring Schematic for D9h and D10h Enclosed Drives

Electrical Installation

Terminal 37 (optional) is used for Safe Torque Off. Refer to the VLT® FC Series - Safe Torque Off Operating Guide for installation instructions.

Illustration 21: Basic Wiring Schematic for Enclosures D9h and D10h

AQ262141314214en-000101 / 130R0880

1 2

(NC)

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

18 (D IN)

15 mA

200 mA

(U) 96

(PE) 99

0/4-20 mA

0 V DC - 10 V DC

0/4–20 mA

02 01

05 04

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

19 (D IN)

24 V (NPN) 0 V (PNP)

24 V

0 V

0 V (PNP)

24 V (NPN)

0 V

24 V

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

33 (D IN)

32 (D IN)

1 2

A53 U-I (S201)

A54 U-I (S202)

ON=0–20 mA OFF=0–10 V

95 (PE)

P 5-00

(R+) 82 (R-) 81

+ - + -

0 V

5 V

S801

Switch mode

power supply

ON=Terminated OFF=Open

(NPN) = Sink

= =

37 (D IN) - option

e30bu149.10

Drive

Control compartment

XD2 Terminal

block

XD2.21 XD2.23 XD2.22 XD2.24

XD2.26 XD2.25

XD2.4 XD2.

XD2.2 XD2.3

XD2.1

XD2.19

XD2.17

XD2.16

XD2.15

XD2.14

XD2.18

XD2.13

XD2.12

XD2.11

XD2.10

XD2.9

XD2.8

XD2.7

XD2.6

cabinet

(V) 97

(W) 98

240 V AC, 2A 400 V AC, 2A

Brake temp

RS485

(PNP) = Source

(COM RS485) 61

(N RS485) 69

(P RS485) 68

RS485 Interface

OFF-ON

S801/Bus term.

(COM A OUT) 39

(A OUT) 42

10 V DC

24 V DC

3-phase

50 (+10 V OUT)

+10 V DC

power input

0 V DC - 10 V DC

0/4–20 mA

29 (D IN/OUT)

27 (D IN/OUT)

20 (COM D IN)

13 (+24 V OUT)

12 (+24 V OUT)

55 (COM A IN)

54 (A IN)

53 (A IN)

Motor

Brake resistor

Relay1

Relay2

Analog output

(R-) 83

Regen+

Regen-

Regen (option)

(option)

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

5.4 Wiring Schematic for E5h and E6h Enclosed Drives

Terminal 37 (optional) is used for Safe Torque Off. Refer to the VLT® FC Series - Safe Torque Off Operating Guide for installation instructions.

Illustration 22: Wiring Schematic for Enclosures E5h and E6h

AQ262141314214en-000101 / 130R0880 | 47

e30bu100.10

12 13 18 19 27 29 32 33

39696861 42 50 53 54 55

R 1 R 2

01 02 03 04 05

XD2

Operating Guide | VLT® HVAC Drive FC 102

5.5 Wiring Diagram Cross-reference

Electrical Installation

1 User-accessible terminals (control compartment)

3 Analog input/output terminals (drive module)

2 Serial communication terminals (drive module)

4 Digital input/output terminals (drive module)

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

5 Relay terminals (drive module)

Illustration 23: Serial Communication, Digital Input/Output, Analog Input/Output, and Relay Terminals Cross-reference

Electrical Installation

5.6 Split Shipment Wiring Harnesses

5.6.1 Connecting Wiring Harnesses

Context:

Procedure

1. Connect the wiring harnesses according to how the enclosed drive is split. Each wiring harness in the enclosed drive is labeled.

Refer to the illustrations in this section for label names and descriptions.

A Connect the fan supply wiring harness.

B Connect the thermal protection harness.

C If applicable, connect the PHF contactor harnesses.

D If applicable, connect the cabinet heater harness.

2. Connect the output filter cables. Refer to the illustrations in this section.

- For the sine-wave filter option, there is 1 set of cables for each sine-wave filter. One end of each cable is already connected to the filter, the other end is bundled in the sine-wave filter cabinet. Connect the unattached sine-wave cable ends to the motor terminals inside the drive cabinet.

- For the dU/dt filter option, the unattached filter cables are bundled inside the dU/dt filter cabinet. Connect the unattached cable ends to the motor terminals within the drive cabinet.

3. Connect the input filter cables. Refer to the illustrations in this section.

- For the passive harmonic filter (PHF) option, the filter cables are bundled inside the input filter cabinet. First connect the unattached PHF cable ends (R/S/T) to the corresponding terminals in the input power options cabinet. Then connect the unattached PHF cable ends (L1R/L2S/L3T) to the R/S/T terminals in the drive cabinet.

- For the line reactor option, the line reactor cables are bundled inside the input filter cabinet. First connect the unattached line reactor cable ends (R/S/T) to the corresponding terminals in the input power options cabinet. Then connect the unattached line reactor cable ends (L1R/L2S/L3T) to the R/S/T terminals in the drive cabinet.

AQ262141314214en-000101 / 130R0880 | 49

-XDL.1

-XD4.1

-XD11.1

e30bu179.10

Operating Guide | VLT® HVAC Drive FC 102

5.6.2 D10h Wiring Harness

Electrical Installation

1 DC-link harness to fan supply in output filter cabinet

3 Additional terminal connections

Illustration 24: Split Shipment Electrical Connections (Input Filter Cabinet + Input Power Options Cabinet + D10h Drive Cabinet)

2 Cabinet heater supply harness to output filter cabinet

4 Thermal protection wiring harness to output filter cabinet

AQ262141314214en-000101 / 130R0880

e30bu181.10

-XD4.1

-XD11.1

-XDL.1

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Additional terminal connections

3 DC-link harness to fan supply in drive cabinet

2 Thermal protection wiring harness to drive cabinet

4 Cabinet heater supply harness to drive cabinet

5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive

cabinet

Illustration 25: Split Shipment Electrical Connections (dU/dt Cabinet + Top Exit Cabinet)

AQ262141314214en-000101 / 130R0880 | 51

e30bu182.10

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet

Illustration 26: Split Shipment Electrical Connections (Top Exit Cabinet)

AQ262141314214en-000101 / 130R0880

e30bu183.10

-XD4.1

-XD11.1

-XDL.1

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Additional terminal connections

3 DC-link harness to fan supply in drive cabinet

2 Thermal protection wiring harness to drive cabinet

4 Cabinet heater supply harness to drive cabinet

5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive

cabinet

Illustration 27: Split Shipment Electrical Connections (D10h Sine-wave Cabinet)

AQ262141314214en-000101 / 130R0880 | 53

e30bu180.10

-XDL.1

-XD4.1

-XD11.3

-XD4.4

-XD4.3

2 3

L1R

L3T

L2S

Operating Guide | VLT® HVAC Drive FC 102

5.6.3 E5h Wiring Harness

Electrical Installation

1 Thermal protection wiring harness to input power options

cabinet

3 PHF contactor 2 supply harness to input power options

cabinet (only with PHF option)

(R/S/T) in the drives cabinet

7 Cabinet heater supply harness to input power options

5 Output terminal cables (L1R/L2S/L3T) to mains terminals

2 PHF contactor 1 supply harness to input power options

cabinet (only with PHF option)

4 Input terminal cables (R/S/T) to mains terminals (R/S/T) in the

input power options cabinet

6 DC-link harness to fan supply in the input power options

cabinet

8 Additional terminal connections

cabinet

Illustration 28: Split Shipment Electrical Connections (Input Filter Cabinet)

AQ262141314214en-000101 / 130R0880

e30bu181.10

-XD4.1

-XD11.1

-XDL.1

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Additional terminal connections

3 DC-link harness to fan supply in drive cabinet

2 Thermal protection wiring harness to drive cabinet

4 Cabinet heater supply harness to drive cabinet

5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive

cabinet

Illustration 29: Split Shipment Electrical Connections (dU/dt Cabinet + Top Exit Cabinet)

AQ262141314214en-000101 / 130R0880 | 55

e30bu182.10

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet

Illustration 30: Split Shipment Electrical Connections (Top Exit Cabinet)

AQ262141314214en-000101 / 130R0880

e30bu188.10

-XD4.1

-XD11.1

-XDL.1

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Additional terminal connections

3 DC-link harness to fan supply in drive cabinet

2 Thermal protection wiring harness to drive cabinet

4 Cabinet heater supply harness to drive cabinet

5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive

cabinet

Illustration 31: Split Shipment Electrical Connections (E5h/E6h Sine-wave Cabinets)

AQ262141314214en-000101 / 130R0880 | 57

e30bu186.10

-XDL.1

-XD4.1

-XD11.1

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Motor cables (U/V/W) to motor terminals (U/V/W) in output

2 DC-link harness to fan supply in output filter cabinet

filter cabinet

4 Additional terminal connections

3 Cabinet heater supply harness to output filter cabinet

5 Thermal protection wiring harness to output filter cabinet

Illustration 32: Split Shipment Electrical Connections (Input Filter Cabinet + Input Power Options Cabinet + E5h Drive Cabinet)

AQ262141314214en-000101 / 130R0880

e30bu187.10

-XDL.1

-XD4.1

-XD11.1

-XD4.1

-XD4.3

-XD11.3

-XDL.1

2 3

L1R

L3T

L2S

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Cabinet heater supply harness to input filter cabinet

3 Thermal protection harness to input filter cabinet

2 DC-link harness to fan supply in input filter cabinet

4 PHF contactor 1 supply harness to input filter cabinet (only

with PHF option)

5 Mains cables (R/S/T) to input terminals (R/S/T) in the input

filter cabinet

7 DC-link harness to fan supply to output filter cabinet

9 Available terminal connections

Illustration 33: Split Shipment Electrical Connections (Input Power Options Cabinet + E5h Drive Cabinet)

6 Mains cables (L1R/L2S/L3T) to output terminals (L1R/L2S/L3T)

in the input filter cabinet

8 Cabinet heater supply harness to output filter cabinet

10 Thermal protection wiring harness to output filter cabinet

AQ262141314214en-000101 / 130R0880 | 59

e30bu180.10

-XDL.1

-XD4.1

-XD11.3

-XD4.4

-XD4.3

2 3

L1R

L3T

L2S

Operating Guide | VLT® HVAC Drive FC 102

5.6.4 E6h Wiring Harness

Electrical Installation

1 Thermal protection wiring harness to input power options

cabinet

3 PHF contactor 2 supply harness to input power options

cabinet (only with PHF option)

(R/S/T) in the drives cabinet

7 Cabinet heater supply harness to input power options

5 Output terminal cables (L1R/L2S/L3T) to mains terminals

2 PHF contactor 1 supply harness to input power options

cabinet (only with PHF option)

4 Input terminal cables (R/S/T) to mains terminals (R/S/T) in the

input power options cabinet

6 DC-link harness to fan supply in the input power options

cabinet

8 Additional terminal connections

cabinet

Illustration 34: Split Shipment Electrical Connections (Input Filter Cabinet)

AQ262141314214en-000101 / 130R0880

e30bu181.10

-XD4.1

-XD11.1

-XDL.1

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Additional terminal connections

3 DC-link harness to fan supply in drive cabinet

2 Thermal protection wiring harness to drive cabinet

4 Cabinet heater supply harness to drive cabinet

5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive

cabinet

Illustration 35: Split Shipment Electrical Connections (dU/dt Cabinet + Top Exit Cabinet)

AQ262141314214en-000101 / 130R0880 | 61

e30bu182.10

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet

Illustration 36: Split Shipment Electrical Connections (Top Exit Cabinet)

AQ262141314214en-000101 / 130R0880

e30bu188.10

-XD4.1

-XD11.1

-XDL.1

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Additional terminal connections

3 DC-link harness to fan power supply in drive cabinet

2 Thermal protection wiring harness to drive cabinet

4 Cabinet heater supply harness to drive cabinet

5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive

cabinet

Illustration 37: Split Shipment Electrical Connections (E5h/E6h Sine-wave Cabinets)

AQ262141314214en-000101 / 130R0880 | 63

e30bu185.10

-XD4.1

7 8

5 6

-XD4.4

-XD11.3

-XDL.1

L1R

L3T

L2S

-XD4.3

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

2 Thermal protection wiring harness to input filter cabinet

4 Cabinet heater supply harness to input filter cabinet

6 PHF contactor 2 supply harness to input filter cabinet (only

with PHF option)

8 Mains cables (L1R/L2S/L3T) to output terminals (L1R/L2S/L3T)

in the input filter cabinet

1 Additional terminal connections

3 DC-link harness to fan supply in the input filter cabinet

5 PHF contactor 1 supply harness to input filter cabinet (only

with PHF option)

7 Mains cables (R/S/T) to input terminals (R/S/T) in the input

filter cabinet

Illustration 38: Split Shipment Electrical Connections (Input Power Options Cabinet + E6h Drive Cabinet + Top Exit Cabinet)

AQ262141314214en-000101 / 130R0880

e30bu184.10

-XDL.1

-XD4.1

-XD11.1

-XD4.3

-XD11.3

-XDL.1

2 3

-XD4.4

L1R

L3T

L2S

-XD4.1

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Cabinet heater supply harness to input filter cabinet

3 Thermal protection wiring harness in the input filter cabinet

5 PHF contactor 2 supply harness to PHF cabinet (only with

PHF option)

7 Mains cables (L1R/L2S/L3T) to output terminals (L1R/L2S/L3T)

in the input filter cabinet

9 Cabinet heater supply harness to output filter cabinet

11 Thermal protection wiring harness to output filter cabinet

Illustration 39: Split Shipment Electrical Connections (Input Power Options Cabinet + E6h Drive Cabinet)

2 DC-link harness to fan supply to input filter cabinet

4 PHF contactor 1 supply harness to PHF cabinet (only with

PHF option)

6 Mains cables R, S, T to input terminals (R/S/T) in the input

filter cabinet

8 DC-link harness to fan supply in output filter cabinet

10 Available terminal connections

AQ262141314214en-000101 / 130R0880 | 65

e30bu148.10

R S T U V W

L1R

L2S

L3T

R S

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

Illustration 40: Connecting Motor and Mains Cables (Example Shows a PHF Cabinet + Input Power Options Cabinet + E6h Drive Cabinet + Sinewave Cabinets)

5.7 Control Compartment Wiring

5.7.1 Safety Precautions

WA RN IN G

HIGH VOLTAGE

The mains disconnect switch does not disconnect the external voltage supply. Failure to disconnect the external voltage supply before touching any components in the control compartment can result in death or serious injury.

Only qualified personnel must install, start up, and maintain the drive.

Disconnect the external voltage supply.

AQ262141314214en-000101 / 130R0880

e30bu140.10

21 22

7 8

10 11

12 13

4 5

Operating Guide | VLT® HVAC Drive FC 102

5.7.2 Control Compartment Interior View

Electrical Installation

1 24 V DC supply (-TB7)

3 Local control panel (LCP). See 3.6.3 Local Control Panel (LCP).

5 Protection terminal block set (-XD11)

7 Contactor control circuit terminal block (-XD0)

9 Customer terminal block/option C0 terminal block (-XDW)

11 Thermal trip indicator relay, output filter cabinet (-KFJ.2)

13 PHF capacitor connect/disconnect contactor relay (-QAF)

15 AC circuit protection MCB (-FC6)

2 Insulation monitor (-BE1)

4 RJ45 terminal blocks 1 and 2 (-RJ45_1 and RJ45_2)

6 Socket outlet (-XD10)

8 Cabinet heater terminal block (-XD4)

10 Thermal trip indicator relay, input power options cabinet (-

KFJ.1)

12 Thermal trip indicator relay, input filter cabinet (-KFJ.3)

14 +24 DC supply protection MCB (-FC7)

16 AC distribution circuit terminal block (-XD1)

AQ262141314214en-000101 / 130R0880 | 67

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

17 Auxiliary relay for heater (-QAM)

19 Cabinet light/socket outlet protection MCB (-FCC)

21 DC distribution circuit terminal block (-XD3)

23 AC fan supply terminal block set (-XDY)

25 Basic I/O terminal block and option A, B, D card terminal

block set (-XD2)

27 Grounding clamp for the shield termination of wires.

Illustration 41: Layout of Control Compartment Interior with All Options

18 Contactor control circuit protection MCB (-FC10)

20 Cabinet heater(s) circuit protection MCB (-FCE)

22 Motor heater circuit protection MCB (-FCN)

24 Option C2 terminal block set (-XDF)

26 Door components terminal block set (-XDJ)

5.7.3 Control Terminals

Table 25: Serial Communication Terminals

XD2 terminal

1 – – Integrated RC-filter for cable shield. Used only for connecting the shield in

2 Parameter group 8-3* FC

Parameter Default

Setting

– RS485 interface. A switch (BUS TER.) is provided on the control card for bus

Port Settings

Description

case of EMC problems.

termination resistance. See Illustration 5.22.

3 Parameter group 8-3* FC

Port Settings

Table 26: Digital Input/Output Terminal Descriptions

XD2 terminal

10, 11 – +24 V DC 24 V DC supply voltage for digital inputs and external trans-

12 Parameter 5-10 Terminal 18 Digital

13 Parameter 5-11 Terminal 19 Digital

16 Parameter 5-14 Terminal 32 Digital

17 Parameter 5-15 Terminal 33 Digital

14 Parameter 5-12 Terminal 27 Digital

15 Parameter 5-13 Terminal 29 Digital

18 – – Common for digital inputs and 0 V potential for 24 V supply.

Parameter Default setting Description

Input

–

ducers. Maximum output current 200 mA for all 24 V loads.

[8] Start Digital inputs.

[10] Reversing

[0] No operation

[2] Coast inverse For digital input or output. Default setting is input.

[14] JOG

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

XD2 terminal

19 – STO When not using the optional STO feature, a jumper wire is re-

Table 27: Analog Input/Output Terminal Descriptions

XD2 terminal

4 – – Common for analog output.

5 Parameter 6-50 Terminal 42 Out-

6 – +10 V DC 10 V DC analog supply voltage for potentiometer or thermis-

7 Parameter group 6-1* Analog In-

8 Parameter group 6-2* Analog In-

9 – – Common for analog input.

Parameter Default setting Description

quired between terminal 10 (or 11) and terminal 19. This setup allows the drive to operate with factory default programming values.

Parameter Default setting Description

[0] No operation Programmable analog output. 0–20 mA or 4–20 mA at a maxi-

put

Reference Analog input. For voltage (V) or current (mA).

put 1

Feedback

put 2

mum of 500 Ω.

tor. 15 mA maximum.

5.7.4 Relay Terminals

Table 28: Relay Terminal Descriptions

XD2 terminal Parameter Default setting Description

21, 22, 23 Parameter 5-40 Function Relay [0] [0] No operation Form C relay outputs. For AC or DC voltage.

24, 25, 26 Parameter 5-40 Function Relay [1] [0] No operation

5.7.5 Option Card Terminals

The option cards extend the functionality of drives and provide a high variety of interfaces to automation systems. When the option cards are specified in the type code, they are mounted in slots A, B, C, and D of the control card within the drive module. The option card wiring is routed to a terminal block within the control compartment. For more details, refer to the installation/operating guide for the respective option card.

NO TI CE

OPTION CARD INSTALLATION

If the option card is ordered along with the drive using the type code, the factory installs the option card and its wiring. If the option is ordered separately, the customer is responsible for installing the option card and the wiring extensions to the control compartment.

AQ262141314214en-000101 / 130R0880 | 69

Operating Guide | VLT® HVAC Drive FC 102

Table 29: Option A Terminal Connections

Option card terminal Corresponding terminal within the control compartment

1 XD2.40

2 XD2.41

3 XD2.42

4 XD2.43

5 XD2.44

Table 30: Option B Terminal Connections

Option card terminal Corresponding terminal within the control compartment

1 XD2.46

2 XD2.47

3 XD2.48

4 XD2.49

Electrical Installation

5 XD2.50

6 XD2.51

7 XD2.52

8 XD2.53

9 XD2.54

10 XD2.55

11 XD2.56

12 XD2.57

Table 31: Option C1 Terminal Connections

Option card terminal Corresponding terminal within the control compartment

X46.1 XDF.1

X46.2 XDF.2

X46.3 XDF.3

X46.4 XDF.4

X46.5 XDF.5

X46.6 XDF.6

X46.7 XDF.7

X46.8 XDF.8

X46.9 XDF.9

X46.10 XDF.10

X46.11 XDF.11

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

Option card terminal Corresponding terminal within the control compartment

X46.12 XDF.12

X46.13 XDF.13

X46.14 XDF.14

X58.1 XDF.15

X58.2 XDF.16

X45.1 XDF.17

X45.2 XDF.18

X45.3 XDF.19

X45.4 XDF.20

X47.1 XDF.21

X47.2 XDF.22

X47.3 XDF.23

X47.4 XDF.24

Electrical Installation

X47.5 XDF.25

X47.6 XDF.26

X47.7 XDF.27

X47.8 XDF.28

X47.9 XDF.29

X47.10 XDF.30

X47.11 XDF.31

X47.12 XDF.32

Table 32: Option D Terminal Connections

Option card terminal Corresponding terminal within the control compartment

35 XD2.28

36 XD2.29

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-XD1.1

-FC6

-XD1

10 A

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

5.7.6 Overview of Options Wiring

5.7.6.1 Auxiliary Supply Terminals

Table 33: Auxiliary Supply Codes

Character position Option code Description

21 1 230 V AC external

5 230 V AC external + 24 V DC internal

6 120 V AC external

9 120 V AC external + 24 V DC internal

The auxiliary supply terminal option provides an external voltage supply to the –XD1.1 terminal. The external supply must be shortcircuit protected. The power of the external supply depends on other selected cabinet options.

Illustration 42: Auxiliary AC Supply Terminals

WA RN IN G

HIGH VOLTAGE

Disconnect the external voltage supply.

Only qualified personnel must install, start up, and maintain the drive.

5.7.6.2 Auxiliary Voltage Transformer

Table 34: Auxiliary Supply Codes

Character position Option code Description

21 2 230 V AC internal

4 230 V AC internal + 24 V DC internal

7 120 V AC internal

8 120 V AC internal + 24 V DC internal

The auxiliary voltage transformer is an option fitted internally that allows for the supply to be tapped from the mains. If the enclosed drive is specified with a fused disconnect, the supply for the auxiliary voltage transformer is taken from between the drive and the fused disconnect. This configuration allows the control voltage to be disconnected with the main switch.

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e30bu192.10

L1-L2

-FC4

-TA4

-FC6

-XD1

4 A

e30bu194.10

L1-L2

-FC7

-TB7

24 V

-XD1

2 A

60 W

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

The transformer has multiple tappings on the primary side for the standard range of voltages on which the drive operates. The factory default wiring connects to the highest voltage tapping on the primary side, and the trip settings for the -FC4 terminal is set accordingly. The customer can change the tapping provided the correct voltage is applied and the thermal magnetic circuit breaker is set accordingly.

Illustration 43: Auxiliary Voltage Transformer Terminals

NO TI CE

AUXILIARY COMPONENT FAILURE

Incorrect voltage or incorrect tapping installation will cause other auxiliary components in the control compartment to fail.

When tapping the transformer, make sure to apply the correct voltage for the drive.

Use the correct tapping and trip settings.

5.7.6.3 +24 DC External Supply

Table 35: Auxiliary Supply Codes

Character position Option code Description

21 4 230 V AC internal+24 V DC internal

5 230 V AC external+24 V DC internal

8 120 V AC internal+24 V DC internal

9 120 V AC external+24 V DC internal

The 24 V DC external supply option enables other auxiliary options to be connected to a 24 V DC supply within the control compartment.

Illustration 44: 24 V DC External Supply Terminals

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-XD1

-FCC

-XD10

-XD1

2 A

Operating Guide | VLT® HVAC Drive FC 102

5.7.6.4 AC Customer Socket

Table 36: Auxiliary Function Option Codes

Electrical Installation

Character position

Option code

Description

23–24 A1 AC socket + cabinet light

AA AC socket + cabinet light + extended I/O terminals

AB AC socket + cabinet light + cabinet heater

AC AC socket + cabinet light + motor heater control

AD AC socket + cabinet light + insulation monitor

AE AC socket + cabinet light + extended I/O terminals + cabinet heater

AF AC socket + cabinet light + extended I/O terminals + motor heater control

AG AC socket + cabinet light + extended I/O terminals + insulation monitor

AH AC socket + cabinet light + extended I/O terminals + cabinet heater + motor heater control

AI AC socket + cabinet light + extended I/O terminals + cabinet heater + insulation monitor

AJ AC socket + cabinet light + extended I/O terminals + motor heater control + insulation monitor

AK AC socket + cabinet light + extended I/O terminals + cabinet heater + motor heater control + insu-

lation monitor

AL AC socket + cabinet light + cabinet heater + motor heater control

AM AC socket + cabinet light + cabinet heater + insulation monitor

AN AC socket + cabinet light + cabinet heater + motor heater control + insulation monitor

AO AC socket + cabinet light + motor heater control + insulation monitor

The socket provides a supply for measurement tools, equipment, or a computer. The socket type is CEE 7/3 ("Schuko", Type F) or NEMA 5-15 grounded (Type B). The default voltage is 230 V AC (IEC variant) and 115 V AC (UL variant). When using an external supply, the maximum output power is 450 VA (IEC variant) and 230 VA (UL variant). When using a transformer supply, the maximum output power is 200 VA for both variants.

Illustration 45: AC Customer Socket Terminals

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Operating Guide | VLT® HVAC Drive FC 102

5.7.6.5 Extended I/O Terminals

Table 37: Auxiliary Function Option Codes

Electrical Installation

Character position

23–24 A2 Extended I/O terminals

Option code

AA AC socket+cabinet light + extended I/O terminals

AE AC socket+cabinet light + extended I/O terminals + cabinet heater

AF AC socket+cabinet light + extended I/O terminals + motor heater control

AG AC socket+cabinet light + extended I/O terminals + insulation monitor

AH AC socket+cabinet light + extended I/O terminals + cabinet heater + motor heater control

AI AC socket+cabinet light + extended I/O terminals + cabinet heater + insulation monitor

AJ AC socket+cabinet light + extended I/O terminals + motor heater control + insulation monitor

AK AC socket+cabinet light + extended I/O terminals + cabinet heater + motor heater control + insula-

AP Extended I/O terminals + cabinet heater

AQ Extended I/O terminals + motor heater control

AR Extended I/O terminals + insulation monitor

AS Extended I/O terminals + cabinet heater + motor heater control

AT Extended I/O terminals + cabinet heater + insulation monitor

AU Extended I/O terminals + cabinet heater + motor heater control + insulation monitor

Description

tion monitor

AV Extended I/O terminals + motor heater control + insulation monitor

The extended I/O terminal option includes 25 control terminals (-XDW) in the control compartment for use by the customer. If the enclosed drive is configured with any option C1 card, the -XDW terminal block is used for the option C1 card wiring.

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-XD1

-FCE

-QAM

-XD4

6 A

-EB1.4

-EB1.3

-EB1.2

-EB1.1

-XD4

Operating Guide | VLT® HVAC Drive FC 102

5.7.6.6 Cabinet Heater

Table 38: Auxiliary Function Option Codes

Electrical Installation

Character position

Option code

Description

23–24 A3 Cabinet heater

AB AC socket + cabinet light + cabinet heater

AE AC socket + cabinet light + extended I/O terminals + cabinet heater

AH AC socket + cabinet light + extended I/O terminals + cabinet heater + motor heater control

AI AC socket + cabinet light + extended I/O terminals + cabinet heater + insulation monitor

AK AC socket + cabinet light + extended I/O terminals + cabinet heater + motor heater control + insu-

lation monitor

AL AC socket + cabinet light + cabinet heater + motor heater control

AM AC socket + cabinet light + cabinet heater + insulation monitor

AN AC socket + cabinet light + cabinet heater + motor heater control + insulation monitor

AP Extended I/O terminals + cabinet heater

AS Extended I/O terminals + cabinet heater + motor heater control

AT Extended I/O terminals + cabinet heater + insulation monitor

AU Extended I/O terminals + cabinet heater + motor heater control + insulation monitor

AW Cabinet heater + motor heater control

AX Cabinet heater + insulation monitor

AY Cabinet heater + motor heater control + insulation monitor

The cabinet heater option increases the inside temperature of the cabinet above the ambient temperature, preventing condensation in the cabinet. Each cabinet has 1 cabinet heater. The heater element is self regulating. The external supply is connected to terminal XD1.1. When the drive is not in run state, the control relay +QAM changes the supply to the output terminals (-XD4). When the drive is in run state, the control relay disconnects the supply to the cabinet heater. The function is disabled when MCB –FCE is open.

Illustration 46: Cabinet Heater Terminals

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e30bu189.10

-XD1

-FCE

-QAM

-XD4

6 A

-EB1.4

-EB1.3

-EB1.2

-EB1.1

-XD4

Operating Guide | VLT® HVAC Drive FC 102

5.7.6.7 Motor Heater Control

Table 39: Auxiliary Function Option Codes

Electrical Installation

Character position

Option code

Description

23–24 A4 Motor heater control

AC AC socket + cabinet light + motor heater control

AF AC socket + cabinet light + extended I/O terminals + motor heater control

AH AC socket + cabinet light + extended I/O terminals + cabinet heater + motor heater control

AJ AC socket + cabinet light + extended I/O terminals + motor heater control + insulation monitor

AK AC socket + cabinet light + extended I/O terminals + cabinet heater + motor heater control + insu-

lation monitor

AL AC socket + cabinet light + cabinet heater + motor heater control

AN AC socket + cabinet light + cabinet heater + motor heater control + insulation monitor

AO AC socket + cabinet light + motor heater control + insulation monitor

AQ Extended I/O terminals + motor heater control

AS Extended I/O terminals + cabinet heater + motor heater control

AU Extended I/O terminals + cabinet heater + motor heater control + insulation monitor

AV Extended I/O terminals + motor heater control + insulation monitor

AW Cabinet heater + motor heater control

AY Cabinet heater + motor heater control + insulation monitor

AZ Motor heater control + insulation monitor

The motor heater option provides the ability to control the supply for the motor anti-condensation heater. The 24 V DC external supply is connected to terminal -XD1.1 in the lower part of the cabinet. When the drive is not in run state, the control relay +QAM changes the external supply to the -XDN output terminals. When the drive is in run state, the control relay disconnects the external supply to the motor heater. The function is disabled when MCB –FCN is open.

Illustration 47: Motor Heater Control (Heater Element not Included)

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Operating Guide | VLT® HVAC Drive FC 102

5.7.6.8 Insulation Monitor

Table 40: Auxiliary Function Option Codes

Electrical Installation

Character position

23–24 A5 Insulation monitor

Option code

AD AC socket+cabinet light + insulation monitor

AG AC socket+cabinet light + extended I/O terminals + insulation monitor

AI AC socket+cabinet light + extended I/O terminals + cabinet heater + insulation monitor

AJ AC socket+cabinet light + extended I/O terminals + motor heater control + insulation monitor

AK AC socket+cabinet light + extended I/O terminals + cabinet heater + motor heater control + insula-

AM AC socket+cabinet light + cabinet heater + insulation monitor

AN AC socket+cabinet light + cabinet heater + motor heater control + insulation monitor

AO AC socket+cabinet light + motor heater control + insulation monitor

AR Extended I/O terminals + insulation monitor

AT Extended I/O terminals + cabinet heater + insulation monitor

AU Extended I/O terminals + cabinet heater + motor heater control + insulation monitor

AV Extended I/O terminals + motor heater control + insulation monitor

AX Cabinet heater + insulation monitor

AY Cabinet heater + motor heater control + insulation monitor

Description

tion monitor

AZ Motor heater control + insulation monitor

The insulation monitor option monitors the supply and insulation faults within the insulation level in an IT supply network with an insulation monitor in the control compartment.

5.7.6.9 Indicator Lights and Reset Buttons

Table 41: Door-mounted Option Codes

Character position

28–29 D1 Indicator lights and reset button

The indicator light and reset button option includes indicator lights on the control compartment door for run and fault states of the AC drive. The door also has a button for the reset function of the drive.

Option code

DA Indicator lights and reset button + emergency switch off and emergency push-button

DB Indicator lights and reset button + STO w/ emergency push-button (no functional safety)

DC Indicator lights and reset button + STO/SS1 w/ emergency push-button + safely limited speed

DE Indicator lights and reset button + STO/SS1 w/ emergency push-button + safely limited speed

Description

(TTL encoder)

(HTL encoder)

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

5.7.6.10 Emergency Switch Off

Table 42: Door-mounted Option Codes

Character position Option code Description

28–29 D2 Emergency switch off + emergency push-button

DA Indicator lights and reset button + emergency switch off and emergency push-button

The emergency switch off option uses an input contactor to disconnect the drive from mains. Pushing the emergency stop pushbutton on the control compartment door opens the control circuit of the input contactor.

5.7.6.11 STO with Emergency Push-button on Door

Table 43: Door-mounted Option Codes

Character position Option code Description

28–29 D3 STO w/ emergency push-button (no functional safety)

DB Indicator lights and reset button + STO w/ emergency push-button (no functional safety)

This option provides the STO (safe torque off) function via an emergency push-button mounted on the door of the control compartment. The control terminals of the control card are extended from inside the drive module and routed out to the terminal block set -XD2 in the control compartment. The emergency push-button is wired between terminals -XD2.10 and -XD2.19.

Activating the emergency push-button prevents the unit from generating the voltage required to rotate the motor. The option provides:

• Safe Torque Off (STO), as defined by EN IEC 61800-5-2.

• Stop Category 0, as defined in EN 60204-1.

5.8 Connecting Motor, Mains, and Ground Cables

5.8.1 Power Cabling and Grounding Considerations

Motor and mains connections

• Size the wiring according to the input current of the drive. For maximum wire sizes, see the Electrical Data section.

• Comply with local and national electrical codes for cable sizes.

• Follow motor manufacturer wiring requirements.

• Motor wiring knockouts or access panels are provided on the pedestal of IP21/IP54 (NEMA 1/NEMA 12) units.

• Do not wire a starting or pole-changing device (for example Dahlander motor or slip ring induction motor) between the drive and the motor.

Ground connection

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7 8

1 2

Operating Guide | VLT® HVAC Drive FC 102

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

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

• Do not ground 1 drive to another in a daisy chain fashion.

• Keep the ground wire connections as short as possible.

• Follow motor manufacturer wiring requirements.

• Minimum cable cross-section: 10 mm2 (6 AWG) (or 2 rated ground wires terminated separately).

• Tighten the terminals in accordance with the information provided in 10.11 Fastener Torque Ratings.

EMC-compliant Installation

Refer to 5.2 EMC-compliant Installation.

Electrical Installation

1 Cable 1

3 Connection bushing

5 Cable 2

7 Cable 1 lug

9 Terminal connector

Illustration 48: Different Ways of Connecting Multiple Cables to 1 Terminal

2 Cable 2

4 Cable 1

6 Cable 3

8 Bolt holder on the connector

10 Cable 2 lug

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

5.8.2 Connecting to the Mains

Context:

If the enclosed drive is not configured with an input filter or input power option, connect the mains to the drive module. Otherwise, connect the mains to the input power option.

Procedure

1. Strip a section of the outer cable insulation.

2. Fasten a connector/cable lug to the end of the stripped cable.

3. Create an electrical connection between the cable shield and ground by securing the stripped wire under the cable clamp.

4. Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions provided in

Connecting to Ground.

5. Connect the 3-phase AC input power cables to terminals R (L1), S (L2), and T (L3).

6. When supplied from an isolated mains source (IT mains or floating delta) or TT/TN-S mains with a grounded leg (grounded delta),

ensure that parameter 14-50 RFI Filter is set to [0] Off to avoid damage to the DC link and to reduce ground capacity currents.

7. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings.

5.8.6

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5 6

Operating Guide | VLT® HVAC Drive FC 102

Example:

Electrical Installation

1 Cabinet screen (lower)

3 Brake and load share terminals

2 Terminal cover

4 Mains terminals

5 Ground terminals

Illustration 49: Connection Points for Mains to Drive Module

6 Grounding bar

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Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Cabinet screen (lower)

3 DC terminals

Illustration 50: Connection Points for Mains to Input Power Option (Enclosed Drive Configured without Power Options Cabinet)

2 Input power terminals (contactor option is shown)

4 Grounding bar

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4 5

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

1 Factory cables connecting contactor to drive input terminals

3 Cabinet screen (lower)

2 Cabinet screen (upper)

4 Input power terminals (disconnect option is shown)

5 Grounding bar

Illustration 51: Connection Points for Mains to Input Power Option (Enclosed Drive Configured with Power Options Cabinet)

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

5.8.3 Connecting the Drive Module to the Motor

Procedure

1. Strip a section of the outer cable insulation.

2. Fasten a connector/cable lug to the end of the stripped cable.

3. Create an electrical connection between the cable shield and ground by securing the stripped wire under the cable clamp.

4. Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions provided in

Connecting to Ground.

5. Connect the 3-phase AC motor cables to terminals U (T1), V (T2), and W (T3).

6. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings.

5.8.6

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5 6

Operating Guide | VLT® HVAC Drive FC 102

Example:

Electrical Installation

1 Cabinet screen (lower)

3 Terminal cover

2 DC terminals

4 Motor terminals

5 Ground terminals on drive module

Illustration 52: Connection Points for Drive Module to Motor

6 Grounding bar

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

5.8.4 Connecting the Sine-wave Filter to the Motor

Procedure

1. Strip a section of the outer cable insulation.

2. Fasten a connector/cable lug to the end of the stripped cable.

3. Create an electrical connection between the cable shield and ground by securing the stripped wire under the cable clamp.

4. Connect the ground cable to the nearest grounding terminal in accordance with the grounding instructions provided in

Connecting to Ground.

5. Connect the 3-phase AC motor cable to the sine-wave terminals U, V, and W.

- If the enclosed drive has 1 sine-wave filter cabinet, run 1 set of motor cables to the cabinet.

- If the enclosed drive has 2 sine-wave filter cabinets, run 2 sets of motor cables, 1 set to each sine-wave filter cabinet.

NO TI CE

- Each sine-wave cabinet must have the same number of motor phase cables and they must be in quantities of 2 (for example, 2, 4, 6, or 8). 1 cable is not allowed. The cables are required to be equal length.

6. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings.

5.8.6

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Operating Guide | VLT® HVAC Drive FC 102

Example:

Electrical Installation

1 DC bus terminals

2 Motor terminals

3 Grounding bar

Illustration 53: Connection Points for the Sine-wave Filter to Motor

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

5.8.5 Connecting the dU/dt Filter to the Motor

Procedure

1. Strip a section of the outer cable insulation.

2. Fasten a connector/cable lug to the end of the stripped cable.

3. Create an electrical connection between the cable shield and ground by securing the stripped wire under the cable clamp.

4. Connect the ground cable to the nearest grounding terminal in accordance with the grounding instructions provided in

Connecting to Ground.

5. Connect the 3-phase AC motor wiring to the dU/dt terminals U (T1), V (T2), and W (T3).

6. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings.

5.8.6

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Operating Guide | VLT® HVAC Drive FC 102

Example:

Electrical Installation

1 Cabinet screen (upper)

3 Factory-installed power cables from the drive module

5 Motor terminals

2 Cabinet screen (lower)

4 Factory-installed cables

6 Grounding bar

Illustration 54: Connection Points for the dU/dt Filter to Motor

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2 3

Operating Guide | VLT® HVAC Drive FC 102

5.8.6 Connecting to Ground

Context:

WA RN IN G

LEAKAGE CURRENT HAZARD

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

Ensure the correct grounding of the equipment by a certified electrical installer.

NO TI CE

POTENTIAL EQUALIZATION

There is a risk of burst transient when the ground potential between the drive and the control system is different.

Install equalizing cables between the system components. Recommended cable cross-section: 16 mm2 (5 AWG).

1. Strip a section of the outer cable insulation.

2. Fasten a connector/cable lug to the end of the stripped cable.

3. Connect the ground cable to the nearest grounding terminal.

4. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings.

Electrical Installation

Example:

1 Symbol indicating grounding terminals

3 Grounding bar (provided in every cabinet)

Illustration 55: Connection Grounding Points

2 Grounding points on drive module

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Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

5.9 Installing Upstream Fuses

5.9.1 Upstream Fuse Considerations

Factory fuse options like a fusible disconnector or MCCB protect the busbars and circuits within the drive. To protect the cables, an installer should use separate F1 fuses for upstream protection.

• Danfoss recommends the fuse type gG (IEC 60269-1) for the mains fuses. Use only fuses with a sufficient voltage rating according to the mains voltage. Do not use larger fuses than what is recommended. These fuses are selected for short-circuit protection only.

• Operation time of the fuse must be less than 0.4 s. The operation time must also agree with the fuse type and the impedance of the supply circuit.

• The recommended mains cable and fuse sizes are valid up to a cable length of 100 m, with mains having a short-circuit current of 20 kA. Recommended cable sizes are shown in the Electrical Data section.

• Danfoss recommends the use of FC1 fuses to meet short-circuit protection for any enclosed drives supplied with only the nonfusible disconnect, a non-fusible disconnect and contactor, or a contactor only option.

5.9.2 Recommended Fuse Ratings for IEC Installation

Table 44: Recommended Fuse Ratings for IEC Installation, 380–480 V

Drive model Fuse P/N Fuse size Rated cur-

rent [A]

N110K Mersen NH1GG50V250 1 250 6.8 250 500 gG/gL

N132 Mersen NH2GG50V315 2 315 7 315 500 gG/gL

N160 Mersen NH2GG50V355 2 355 8.5 355 500 gG/gL

N200 Mersen NH3GG50V425 3 425 10 425 500 gG/gL

N250 Mersen NH3AGG50V630 3 630 13 630 500 gG/gL

N315 Mersen NH3AGG50V630 3 630 13 630 500 gG/gL

N355 Mersen NH4GG50V800 4 800 18 800 500 gG/gL

N400 Mersen NH4GG50V1000 4 1000 25 1000 500 gG/gL

N450 Mersen NH4GG50V1000 4 1000 25 1000 500 gG/gL

N500 Mersen NH4GG50V1000 4 1000 25 1000 500 gG/gL

N560 Mersen NH4GG50V1250 4 1250 33 1250 500 gG/gL

Table 45: Recommended Fuse Ratings for IEC Installation, 525–690 V

Drive model Fuse P/N Fuse size Rated cur-

rent [A]

Minimum SCCR [kA]

Maximum fuse rating F1 [A]

Minimum voltage rating [V]

Type F1

N110 Mersen NH2GG69V250 2 250 6.5 250 690 gG/gL

N132 Mersen NH2GG69V250 2 250 6.5 250 690 gG/gL

N160K Mersen NH2GG69V250 2 250 6.5 250 690 gG/gL

N200 Mersen NH2GG69V315 2 315 7.5 315 690 gG/gL

AQ262141314214en-000101 / 130R0880

Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

Drive model Fuse P/N Fuse size Rated cur-

rent [A]

N250 Mersen NH3GG69V355 3 355 8.5 355 690 gG/gL

N315 Mersen NH3GG69V425 3 425 9.5 425 690 gG/gL

N400 Mersen NH3GG69V500 3 500 12 500 690 gG/gL

N450 Mersen NH3GG69V500 3 500 12 500 690 gG/gL

N500 Mersen NH4GG69V630 4 630 14 630 690 gG/gL

N560 Mersen NH4GG69V800 4 800 19 800 690 gG/gL

N630 Mersen NH4GG69V800 4 800 19 800 690 gG/gL

N710 ABB OFAA4GG1000 4 1000 25 1000 690 gG/gL

N800 ABB OFAA4GG1000 4 1000 25 1000 690 gG/gL

Minimum SCCR [kA]

Maximum fuse rating F1 [A]

Minimum voltage rating [V]

Type F1

5.9.3 Recommended Fuse Ratings for UL Installation

The table values are calculated using correction factors for a 40 °C (104 °F) ambient operating condition and using cables with a minimum insulation rating of 90 °C (194 °F).

UL Approval is valid for maximum input voltage of 600 V. Per UL508A, the short-circuit current rating (SCCR) is as follows:

• Enclosed drives with a fusible disconnect or fusible disconnect and contactor option have 65 kA SCCR at the rated voltage.

• Enclosed drives with single switchgear (mains contactor only or non-fusible disconnect only option) have a 5 kA SCCR, but can reach 65 kA if the recommended Class fuses are used upstream.

• Enclosed drives with the MCCB option have a 65 kA interrupting rating for 380–480 V, and a 50 kA interrupting rating for525–690 V.

Table 46: Recommended Fuse Ratings for UL Installation, 380–480 V

Drive mod-elFuse P/N Maximum

current [A]

N110 Mersen A4J300 300 4000 9000 300 500 Class J

N132 Mersen A4J350 350 4600 10000 350 500 Class J

N160 Mersen A4J400 400 5000 10400 400 500 Class J

N200 Mersen A4J500 500 8000 11500 500 500 Class J

N250 Mersen A4J600 600 9000 12000 600 500 Class J

N315 Mersen AABY750 750 11500 28000 750 500 Class J

N355 Mersen A4BY800 800 12000 28000 800 500 Class J

N400 Mersen A4BY1000 1000 15000 35000 1000 500 Class J

N450 Mersen A4BY1000 1000 15000 35000 1000 500 Class J

N500 Mersen A4BY1000 1100 18500 42000 1100 500 Class J

Cutoff current [A]

Peak let thru [A]

Maximum fuse rating F1 [A]

Minimum voltage rating [V]

Class F1

N560 Mersen A4BY1200 1200 19000 42000 1200 500 Class J

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Operating Guide | VLT® HVAC Drive FC 102

Table 47: Recommended Fuse Ratings for UL Installation, 525–690 V

Electrical Installation

Drive model Fuse P/N Maximum

current [A]

N110 Mersen A4J300 175 2400 5400 175 600 Class L

N132 Mersen A4J350 200 2700 6 200 600 Class L

N160 Mersen A4J400 250 3200 7500 250 600 Class L

N200 Mersen A4J500 350 4600 10000 350 600 Class L

N250 Mersen A4J600 400 5000 10400 400 600 Class L

N315 Mersen AABY750 500 8000 11500 500 600 Class L

N400 Mersen A4BY800 600 9000 12000 600 600 Class L

N450 Mersen A4BY1000 600 9000 12000 600 600 Class L

N500 Mersen A4BY1000 650 11500 28000 750 600 Class L

N560 Mersen A4BY1200 750 11500 28000 750 600 Class L

N6300 Mersen A4BY1200 800 12000 28000 800 600 Class L

N710 Mersen A4BY1200 1000 15000 35000 1000 600 Class L

N800 Mersen A4BY1200 1100 18500 42000 1100 600 Class L

Cutoff current [A]

Peak let thru [A]

Maximum fuse rating F1 [A]

Minimum voltage rating [V]

Class F1

5.10 Enabling Motor Operation

Context:

If the status line at the bottom of the LCP reads AUTO REMOTE COAST, the unit is ready to operate but is missing an input signal from terminal XD2.14 in the control compartment. Digital input terminal XD2.14 is designed to receive a 24 V DC external interlock command that allows the drive to operate when using factory default programming values.

NO TI CE

FACTORY-INSTALLED OPTIONAL EQUIPMENT

Do not remove factory-installed wiring to terminal XD2.14. If the drive does not run, refer to the documentation for the optional equipment that is wired into terminal XD2.14.

Procedure

1. When no interlock device is used, use a push-in type jumper (WAGO 2002-433) between terminal XD2.11 and XD2.14 in the control

compartment. This wire provides an internal 24 V signal on terminal XD2.14. The drive is ready for operation.

5.11 Selecting the Voltage/Current Input Signal

Context:

The analog input terminals XD2.7 and XD2.8 in the control compartment allow setting of input signal to voltage (0–10 V) or current (0/4–20 mA).

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BUS TER.

OFF-ON

A53 A54

U- I U- I

1 2

N O

1 2

N O

1 2

N O

1 2

N O

Operating Guide | VLT® HVAC Drive FC 102

• Terminal XD2.7: Speed reference signal in open loop (see parameter 16-61 Terminal 53 Switch Setting).

• Terminal XD2.8: Feedback signal in closed loop (see parameter 16-63 Terminal 54 Switch Setting).

Procedure

1. Disconnect power to the drive.

2. Remove the LCP (local control panel).

3. Remove any optional equipment covering the switches.

4. Set switches A53 and A54 to select the signal type (U = voltage, I = current).

Example:

Electrical Installation

Illustration 56: Location of Switches A53 and A54

5.12 Setting Up RS485 Serial Communication

5.12.1 RS485 Features

RS485 is a 2-wire bus interface compatible with multi-drop network topology. This interface contains the following features:

• Either Danfoss FC or Modbus RTU communication protocol can be used.

• Functions can be programmed remotely using the protocol software and RS485 connection or in parameter group 8-** Communications and Options.

• Selecting a specific communication protocol changes various default parameter settings to match the specifications of the protocol, making more protocol-specific parameters available.

• Option cards for the drive are available to provide more communication protocols. See the option card documentation for installation and operation instructions.

• A switch (BUS TER) is provided on the control card for bus termination resistance.

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RS485

XD2.3

XD2.1

XD2.2

Operating Guide | VLT® HVAC Drive FC 102

5.12.2 Configuring RS485 Serial Communication

Procedure

1. Connect RS485 serial communication wiring to terminals (+) XD2.2 and (-) XD2.3.

- Use shielded serial communication cable.

- Properly ground the wiring. Refer to

2. Select the protocol type in parameter 8-30 Protocol.

3. Select the drive address in parameter 8-31 Address.

4. Select the baud rate in parameter 8-32 Baud Rate.

Example:

5.8.6 Connecting to Ground.

Electrical Installation

Illustration 57: RS485 Wiring Connection

5.13 Configuring the Passive Harmonic Filter (PHF)

Context:

NO TI CE

EQUIPMENT DAMAGE

Failure to use the correct settings can result in the AC drive overheating, resulting in damage to the AC drive and its surroundings.

Verify that the value in parameter 5-02 Terminal 29 Mode is set to [1] Output.

Verify that the value in parameter 5-31 Terminal 29 is set to [188] AHF Capacitor Connect.

Procedure

1. Set parameter 5-02 Terminal 29 Mode to [1] Output.

2. Set parameter 5-31 Terminal 29 to [188] AHF Capacitor Connect.

5.14 Configuring the dU/dt Filter

Context:

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Operating Guide | VLT® HVAC Drive FC 102

Electrical Installation

NO TI CE

EQUIPMENT DAMAGE

Failure to use the correct settings for the D9h and D10h enclosures can result in the AC drive overheating, resulting in damage to the AC drive and its surroundings.

For the D9h and D10h enclosures, verify that the value in parameter 14-52 Fan Control is set to [3] 100%. E5h and

E6h enclosures are not required to use the 100% setting.

Procedure

1. Set parameter 14-52 Output Filter to [3] 100%.

5.15 Configuring the Sine-wave Filter

Context:

NO TI CE

EQUIPMENT DAMAGE

Failure to use the correct settings can result in the AC drive overheating, resulting in damage to the AC drive and its surroundings.

Verify that the value in parameter 14-55 Output Filter matches the type of output filter being used.

Procedure

1. Set parameter 14-55 Output Filter to [1] Sine-wave.

5.16 MCCB Configuration

The molded-case circuit breaker (MCCB) offers the following trip settings:

• Protection against overload (L). The drive trips when there is an overload with inverse long-time delay trip according to the IEC 60947-2 Standard (I2t=k).

• Protection against short circuit with time delay (S). The drive trips when there is a short circuit, with long inverse time-delay trip (I2t=k ON) or a constant trip time (I2t=k OFF).

• Instantaneous protection against short circuit (I). The drive trips immediately if there is a short circuit. The trip function (L) is always available and either (S) or (I) can be selected by the DIP switch[S/I] on the trip unit of the MCCB.

Factory default settings are provided for functions L and I.

• Overcurrent setting (L) is done at 100% of the 1.5 times high overload FLA (I1).

• Time delay (t1) is selected as 12 s for 6 times of I1.

• Short circuit instant trip setting (I) is followed. Short circuit trip with time delay (S) is ignored with the factory settings.

• Short circuit instant trip setting (I) is targeted at 300% of the 100% normal overload FLA (I3) of the drive.

• Neutral setting (N) is 100%.

• Frequency of operation is set at 50 Hz from the factory.

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Operating Guide | VLT® HVAC Drive FC 102

Illustration 58: MCCB Factory Default Settings

Electrical Installation

5.17 Safe Torque Off (STO) Wiring

The Safe Torque Off (STO) function is a component in a safety control system. STO prevents the unit from generating the voltage required to rotate the motor. To run the STO function, more wiring for the drive is required. Refer to the VLT® FC Series - Safe Torque Off

Operating Guide.

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Operating Guide | VLT® HVAC Drive FC 102

Pre-start Check List

6 Pre-start Check List

6.1 Pre-start Check List

Motor

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

• Confirm that the supply voltage matches the voltage of the drive and the motor.

Switches

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

Auxiliary equipment

• Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that reside on the input power side of the drive or output side to the motor. Ensure that they are ready for full-speed operation.

• Check function and installation of any sensors used for feedback to the drive.

• Remove any power factor correction caps on motor.

• Adjust any power factor correction caps on the mains side and ensure that they are dampened.

Cable/wire routing

• Ensure that motor wiring, brake wiring (if equipped), and control wiring are separated or shielded or in 3 separate metallic conduits for high-frequency interference isolation.

Control wiring

• Check for broken or damaged wires and loose connections.

• Check that control wiring is isolated from high-power 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.

Input and output power wiring

• Check for loose connections.

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

Grounding

• Make sure that a proper ground is used. Grounding to conduit or mounting the back panel to a metal surface is not a suitable grounding.

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

Fuses and circuit breakers

• Check for proper fusing or circuit breakers.

• Check that all fuses are inserted firmly and are in operational condition.

• Check that all circuit breakers (if used) are in the open position.

Cooling clearance

• Look for any obstructions in the airflow path.

• Measure top and bottom clearance of the drive to verify that there is at least 225 mm (9 in) of clearance for adequate airflow.

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Operating Guide | VLT® HVAC Drive FC 102

Ambient conditions

• Check that requirements for ambient conditions are met. See the Ambient Conditions section.

Interior of drive

• Inspect that the unit interior is free of dirt, metal chips, moisture, and corrosion.

• Verify that all installation tools have been removed from unit interior.

• For enclosures with a IP20/Chassis protection rating, ensure that the unit is mounted to an unpainted, metal surface.

Vibration

• Ensure that the unit is mounted solidly, or that shock mounts are used, if necessary.

• Check for an unusual amount of vibration.

Pre-start Check List

AQ262141314214en-000101 / 130R0880

Danfoss VLT HVAC Drive FC 102, VLT AutomationDrive FC 302 Series Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Introduction

Safety

Product Overview

Mechanical Installation

Electrical Installation

23–24 A2 Extended I/O terminals

23–24 A3 Cabinet heater

23–24 A4 Motor heater control

23–24 A5 Insulation monitor

Pre-start Check List