Danfoss MG16N102 VLT Refrigeration Drive FC 103 Low Harmonic Drive Instruction Manual

: June 1, 2024
: Danfoss

Table of Contents

Danfoss MG16N102 VLT Refrigeration Drive FC 103 Low Harmonic Drive
Specifications
Product Usage Instructions
FAQs
Introduction
Safety
Mechanical Installation
Electrical Installation
Commissioning
Application Examples
Diagnostics and Troubleshooting
Troubleshooting
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

Danfoss MG16N102 VLT Refrigeration Drive FC 103 Low Harmonic Drive

Danfoss-MG16N102-VLT-Refrigeration-Drive-FC-103-Low-Harmonic-Drive-
PRO

Specifications

Mechanical Dimensions: Refer to manual for detailed dimensions
General Technical Data: Available in the manual
Fuses:
- Non-UL compliance
- Fuse Tables
- Supplementary Fuses
General Torque Tightening Values: Refer to manual for values

Product Usage Instructions

1. Safety

Before installing or using the product, familiarize yourself
with the safety symbols, qualified personnel requirements, and
safety precautions outlined in the manual.

2. Mechanical Installation

Follow the equipment pre-installation checklist provided. Unpack
all items supplied and proceed with mounting, considering cooling,
airflow, lifting, cable entry, anchoring, and terminal locations as
per enclosure sizes.

3. Electrical Installation

Adhere to safety instructions during electrical installation.
Ensure EMC compliant installation and proper power connections. Pay
attention to grounding and input options.

4. Commissioning

Follow safety instructions while commissioning. Apply power as
instructed and familiarize yourself with the local control panel
operation including parameter settings and data management.

5. Diagnostics and Troubleshooting

Refer to the status messages, warning and alarm types,
definitions, and troubleshooting guidelines provided in the manual
to effectively diagnose and resolve issues.

FAQs

Q: Where can I find additional resources for advanced functions?
- A: Additional resources for advanced functions and programming can be found on vlt-drives.danfoss.com/Support/TechnicalDocumentation/.
Q: What should I do if I encounter an alarm or warning message?
- A: Refer to the manual for detailed definitions of alarm and warning messages along with troubleshooting steps to address them effectively.

“`

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT® Refrigeration Drive FC 103 Low Harmonic Drive
vlt-drives.danfoss.com

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

10 Appendix B

111

10.1 Abbreviations and Conventions

111

Index

112

4

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Introduction

1 Introduction

Operating Instructions

11

1.1 Purpose of the Manual
The purpose of this manual is to provide information for the installation and operation of a VLT® Refrigeration Drive FC 103 Low Harmonic. The manual includes relevant safety information for installation and operation. chapter 1 Introduction, chapter 2 Safety, chapter 3 Mechanical Installation, and chapter 4 Electrical Installation introduce the unit functions and cover proper mechanical and electrical installation procedures. There are chapters on start-up and commissioning, applications and basic troubleshooting. Chapter 8 Specifications provides a quick reference for ratings and dimensions, as well as other operating specifications. This manual provides a basic knowledge of the unit and explains set-up and basic operation. VLT® is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced functions and programming.
· The VLT® Refrigeration Drive FC 103 Programming
Guide provides greater detail on working with parameters and many application examples.
· The VLT® Refrigeration Drive FC 103 Design Guide
provides detailed capabilities and functionality to design motor control systems.
· Supplemental publications and manuals are
available from Danfoss. See vlt- drives.danfoss.com/Support/TechnicalDocumentation/ for listings.
· Optional equipment may change some of the
procedures described. Reference the instructions supplied with those options for specific requirements. Contact the local Danfoss supplier or visit the Danfoss website: vltdrives.danfoss.com/Support/TechnicalDocumentation/ for downloads or additional information.
· The VLT® Active Filter AAF 006 Operating
Instructions provide additional information about the filter portion of the low harmonic drive.

1.3 Product Overview
1.3.1 Intended Use
A frequency converter is an electronic motor controller that converts AC mains input into a variable AC waveform output. The frequency and voltage of the output are regulated to control the motor speed or torque. The frequency converter can vary the speed of the motor in response to system feedback, such as with position sensors on a conveyor belt. The frequency converter can also regulate the motor by responding to remote commands from external controllers.
The frequency converter:
· Monitors the system and motor status. · Issues warnings or alarms for fault conditions. · Starts and stops the motor. · Optimises energy efficiency.
Operation and monitoring functions are available as status indications to an outside control system or serial communication network.
A low harmonic drive (LHD) is a single unit that combines the frequency converter with an advanced active filter (AAF) for harmonic mitigation. The frequency converter and filter are packaged together in an integrated system, but each functions independently. In this manual, there are separate specifications for the frequency converter and the filter. Since the frequency converter and filter are in the same enclosure, the unit is transported, installed, and operated as a single entity.

MG16N102

5

130BB406.11

Introduction

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

11

1.3.2 Working Principle
The low harmonic drive is a high-power frequency converter with an integrated active filter. An active filter is a device that actively monitors harmonic distortion levels and injects compensative harmonic current onto the line to cancel the harmonics.

Soft-Charge Resistor

Mains 380 to 500 VAC

Optional RFI

Optional Manual Disconnect

Optional Fuses

HI Reactor Lm Lac Lm Lac Lm

Lac

AC Contactor

Converter Side Filter

Lc

Ir

Lc

Is

Lc

It

3

Relay 12

Control & AUX

Feedback

Cef

Capacitor

Cef

Current Sensors AF Current

Ref

Sensors

Power Stage

Illustration 1.1 Basic Layout for the Low Harmonic Drive

3 Main’s CTs

VLT Drive

Low harmonic drives are designed to draw an ideal sinusoidal current waveform from the supply grid with a power factor of 1. Where traditional non-linear load draws pulse-shaped currents, the low harmonic drive compensates that via the parallel filter path, lowering the stress on the supply grid. The low harmonic drive meets the highest harmonic standards with a THDi less than 5% at full load for <3% pre-distortion on a 3% unbalanced 3-phase grid.

6

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Operating Instructions

1.3.3 Exploded View Drawings

1 2 3
7 4

6
5 6

8

130BE136.10

11

1 Local control panel (LCP) 2 Control card assembly 3 Power card assembly 4 Terminal cover sheet

5 Input/output terminal assembly 6 Capacitor bank assembly 7 D1/D2 assembly 8 EOC assembly

Illustration 1.2 Enclosure Size D1n/D2n, Frequency Converter Enclosure

MG16N102

7

130BE110.10

Introduction
11
1

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

2 3
21 22

20
17 4

19

5

10

18

6 7
8 9

23
16 11

12

15

13

14

1 Local control panel (LCP) 2 Active filter card (AFC) 3 Metal oxide varistor (MOV) 4 Soft charge resistors 5 AC capacitors discharge board 6 Mains contactor 7 LC inductor 8 AC capicators 9 Mains bus bar to frequency converter input 10 IGBT fuses 11 RFI filter 12 Fuses
Illustration 1.3 Enclosure Size D1n/D2n, Filter Enclosure

13 Mains fuses 14 Mains disconnect 15 Mains terminals 16 Heat sink fan 17 DC capacitor bank 18 Current transformer 19 RFI differential mode filter 20 RFI common mode filter 21 HI inductor 22 Power card 23 Gate drive card

8

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130BX168.10

Introduction

Operating Instructions
3 2 1

4
5
6 7

25
24 23 22 21

8 9
11 10
12

20

13

14 15 16

19
1 Control card 2 Control input terminals 3 Local control panel (LCP) 4 Control card C option 5 Mounting bracket 6 Power card mounting plate 7 Power card 8 IGBT gate drive card 9 Upper capacitor bank assembly 10 Soft charge fuses 11 DC inductor 12 Fan transformer 13 IGBT module

17
18
14 SCR and diode 15 Fan inductor (not on all units) 16 Soft charge resistor assembly 17 IGBT output bus bar 18 Fan assembly 19 Output motor terminals 20 Current sensor 21 Mains AC power input terminals 22 Input terminal mounting plate 23 AC input bus bar 24 Soft charge card 25 Lower capacitor bank assembly

Illustration 1.4 Enclosure Size E9, Frequency Converter Enclosure

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9

130BD572.11

Introduction
11
1
2 21
20
19

16 15

13

14

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

3
4
18 17

5 6 7 8
9 10

12

11

1 Local control panel (LCP) 2 Active filter card (AFC) 3 Mains contactors 4 Soft charge resistors 5 RFI differential mode filter 6 RFI common mode filter 7 Current transformer (CT) 8 Mains bus bars to drive output 9 AC capacitors 10 RFI 11 Lower DC capacitor bank

12 AC capacitor current transducers 13 Heat sink fan 14 Mains terminals 15 Mains disconnect 16 Mains fuses 17 LC inductor 18 HI inductor 19 Power card 20 Control card 21 LCP cradle

Illustration 1.5 Enclosure Size E9, Filter Enclosure

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Operating Instructions
1 2
6 5
3 4

130BX334.11

11

1 Contactor 2 RFI filter 3 Mains AC power input terminals
Illustration 1.6 Enclosure Size F18, Input Options Cabinet

4

Circuit breaker or disconnect (if purchased)

5

AC mains/line fuses (if purchased)

6

Mains disconnect

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130BD573.10

Introduction

11

1 2

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

18 17

3 4
16 15 14 13

12

5
6 7
8 9 10
11

1 Local control panel (LCP) 2 Active filter card (AFC) 3 Soft charge resistors 4 Metal oxide varistor (MOV) 5 AC capacitors discharge board 6 LC inductor 7 HI inductor 8 Mixing fan 9 IGBT fuses

10 Mains bus bars to frequency converter input 11 Heat sink fans 12 Mains terminals (R/L1, S/L2, T/L3) from options cabinet 13 RFI differential mode filter 14 RFI common mode filter 15 Mains contactor 16 Power card 17 Control card 18 LCP cradle

Illustration 1.7 Enclosure Size F18, Filter Cabinet

12

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Introduction
13 12

Operating Instructions
1 2

11

10 9

1 Rectifier module 2 DC bus bar 3 SMPS fuse 4 (Optional) back AC fuse mounting bracket 5 (Optional) middle AC fuse mounting bracket 6 (Optional) front AC fuse mounting bracket 7 Module lifting eye bolts (mounted on a vertical strut)
Illustration 1.8 Enclosure Size F18, Rectifier Cabinet

8 Module heat sink fan 9 Fan door cover 10 SMPS fuse 11 Power card 12 Panel connectors 13 Control card

3 4 5

130BX331.11

11

6 7

8

MG16N102

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130BX330.11

Introduction
11
1
16 15
14 13 12 11 10

VLT® Refrigeration Drive FC 103 Low Harmonic Drive
2
3

5

4

6

7

9

8

1 Fan transformer 2 DC-link inductor 3 Top cover plate 4 MDCIC board 5 Control card 6 SMPS fuse and fan fuse 7 Motor output bus bar 8 Brake output bus bar

Illustration 1.9 Enclosure Size F18, Inverter Cabinet

9 Fan door cover 10 Module heat sink fan 11 Inverter module 12 Panel connectors 13 DC fuse 14 Mounting bracket 15 (+) DC bus bar 16 (-) DC bus bar

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Operating Instructions

1.4 Enclosure Sizes and Power Ratings

Enclosure size

D1n

D2n

E9

F18

Enclosure protection
Frequency converter dimensions [mm/inch] Frequency converter weights [kg/lbs]

IP NEMA Height Width Depth Maximum weight Shipping weight

21/54 Type 1/Type 12
1740/68.5 915/36.02 380/14.96
353/777
416/917

Table 1.1 Mechanical Dimensions, Enclosure Sizes D, E, and F

1.5 Approvals and Certifications 1.5.1 Approvals

21/54 Type 1/Type 12
1740/68.5 1020/40.16 380/14.96
413/910
476/1050

21/54 Type 1/Type 12
2000.7/78.77 1200/47.24 493.5/19.43
676/1490
840/1851

21/54 Type 1/Type 12
2278.4/89.70 2792/109.92 605.8/23.85
1900/4189
2345/5171

1.6.2 Harmonic Analysis
Since harmonics increase heat losses, it is important to design systems with harmonics in mind to prevent overloading the transformer, inductors, and wiring.

When necessary, perform an analysis of the system harmonics to determine equipment effects.

Table 1.2 Compliance Marks: CE, UL, and C-Tick
1.5.2 Compliance with ADN
For compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), refer to ADN-compliant Installation in the Design Guide.
1.6 Harmonics Overview
1.6.1 Harmonics
Non-linear loads such as found with 6-pulse frequency converters do not draw current uniformly from the power line. This non-sinusoidal current has components which are multiples of the fundamental current frequency. These components are referred to as harmonics. It is important to control the total harmonic distortion on the mains supply. Although the harmonic currents do not directly affect electrical energy consumption, they generate heat in wiring and transformers and can impact other devices on the same power line.

A non-sinusoidal current is transformed with a Fourier series analysis into sine-wave currents at different frequencies, that is, different harmonic currents IN with 50 Hz or 60 Hz as the fundamental frequency.

Abbreviation f1 I1 U1 In Un n

Description Fundamental frequency (50 Hz or 60 Hz) Current at the fundamental frequency Voltage at the fundamental frequency Current at the nth harmonic frequency Voltage at the nth harmonic frequency Harmonic order

Table 1.3 Harmonics-related Abbreviations

Current Frequency [Hz]

Fundamental current (I1) I1 50

Harmonic current (In)

I5

I7

I11

250

350

550

Table 1.4 Fundamental and Harmonic Currents

Current Input current

Harmonic current

IRMS

I1

I5

I7

I11-49

1.0 0.9 0.5 0.2 <0.1

Table 1.5 Harmonic Currents Compared to the RMS Input Current

The voltage distortion on the mains supply voltage depends on the size of the harmonic currents multiplied

11

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Introduction

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

11

by the mains impedance for the frequency in question. The total voltage distortion (THDi) is calculated based on the individual voltage harmonics using this formula:

THDi =

U25 + U27 + … + U2n U

1.6.3 Effect of Harmonics in a Power Distribution System

In Illustration 1.10, a transformer is connected on the primary side to a point of common coupling PCC1, on the medium voltage supply. The transformer has an impedance Zxfr and feeds a number of loads. The point of common coupling where all loads are connected is PCC2. Each load is connected through cables that have an impedance Z1, Z2, Z3.

Harmonic currents drawn by non-linear loads cause distortion of the voltage because of the voltage drop on the impedances of the distribution system. Higher impedances result in higher levels of voltage distortion.

Current distortion relates to apparatus performance and it relates to the individual load. Voltage distortion relates to system performance. It is not possible to determine the voltage distortion in the PCC knowing only the harmonic performance of the load. To predict the distortion in the PCC, the configuration of the distribution system and relevant impedances must be known.

A commonly used term for describing the impedance of a

grid is the short-circuit ratio Rsce. Rsce is defined as the ratio

between the short circuit apparent power of the supply at

the PCC (Ssc) and the rated apparent power of the load

(Sequ).

Rsce

=

Ssc Sequ

where

Ssc =

U2 Z supply

and

Sequ = U × Iequ

Negative effects of harmonics
· Harmonic currents contribute to system losses (in
cabling and transformer).
· Harmonic voltage distortion causes disturbance
to other loads and increases losses in other loads.

PCC Point of common coupling

MV

Medium voltage

LV

Low voltage

Zxfr

Transformer impedance

Z#

Modeling resistance and inductance in the wiring

Illustration 1.10 Small Distribution System

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Operating Instructions

1.6.4 IEC Harmonic Standards

The mains voltage is rarely a uniform sinusoidal voltage with constant amplitude and frequency because loads that draw non-sinusoidal currents from the mains have non-linear characteristics.

Harmonics and voltage fluctuations are two forms of low-frequency mains interference. They have a different appearance at their origin than at any other point in the mains system when a load is connected. So, a range of influences must be determined collectively when assessing the effects of mains interference. These influences include the mains feed, structure, and loads.

Mains interference can cause the following:

Undervoltage warnings
· Incorrect voltage measurements due to distortion of the sinusoidal mains voltage.
· Cause incorrect power measurements because only RMS-true measuring takes harmonic content into account.

Higher functional losses
· Harmonics reduce the active power, apparent power, and reactive power.
· Distort electrical loads resulting in audible interference in other devices, or in worst case, even destruction.
· Shorten the lifetime of devices as a result of heating.

In most of Europe, the basis for the objective assessment of the quality of mains power is the Electromagnetic Compatibility of Devices Act (EMVG). Compliance with these regulations ensures that all devices and networks connected to electrical distribution systems fulfil their intended purpose without generating problems.

Standard EN 61000-2-2, EN 61000-2-4, EN 50160 EN 61000-3-2, 61000-3-12 EN 50178

Definition Define the mains voltage limits required for public and industrial power grids Regulate mains interference generated by connected devices in lower current products Monitors electronic equipment for use in power installations

Table 1.6 EN Design Standards for Mains Power Quality

There are 2 European standards that address harmonics in the frequency range from 0 Hz to 9 kHz:

EN 6100022 (Compatibility Levels for Low-Frequency Conducted Disturbances and Signalling in Public Low-Voltage Power Supply Systems) states the requirements for compatibility levels for PCC (point of common coupling) of low-voltage AC systems on a public supply network. Limits are specified only for harmonic voltage and total harmonic distortion of the voltage. EN 6100022 does not define limits for harmonic currents. In situations where the total harmonic distortion THD(V)=8%, PCC limits are identical to those limits specified in the EN 6100024 Class 2.

EN 6100024 (Compatibility Levels for Low-Frequency Conducted Disturbances and Signalling in Industrial Plants) states the requirements for compatibility levels in industrial and private networks. The standard further defines the following 3 classes of electromagnetic environments:
· Class 1 relates to compatibility levels that are less than the public supply network, which affects equipment
sensitive to disturbances (lab equipment, some automation equipment, and certain protection devices).
· Class 2 relates to compatibility levels that are equal to the public supply network. The class applies to PCCs on the
public supply network and to IPCs (internal points of coupling) on industrial or other private supply networks. Any equipment designed for operation on a public supply network is allowed in this class.
· Class 3 relates to compatibility levels greater than the public supply network. This class applies only to IPCs in
industrial environments. Use this class where the following equipment is found:

11

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Introduction

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

11

– Large converters – Welding machines – Large motors starting frequently – Loads that change quickly

Typically, a class cannot be defined ahead of time without taking into account the intended equipment and processes to be used in the environment. VLT® Refrigeration Drive FC 103 Low Harmonic observes the limits of Class 3 under typical supply system conditions (RSC>10 or Vk Line<10%).

Harmonic order (h) 5 7 11 13 17
17h49

Class 1 (Vh%) 3 3 3 3 2
2.27 x (17/h) 0.27

Table 1.7 Compatibility Levels for Harmonics

Class 2 (Vh%) 6 5 3.5 3 2
2.27 x (17/h) 0.27

THD(V)

Class 1 5%

Class 2 8%

Table 1.8 Compatibility Levels for the Total Harmonic Voltage Distortion THD(V)

Class 3 (Vh%) 8 7 5 4.5 4
4.5 x (17/h) 0.5
Class 3 10%

1.6.5 IEEE Harmonic Standards

The IEEE 519 standard (Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems) provides specific limits for harmonic voltages and currents for individual components within the supply network. The standard also provides limits for the sum of all loads at the point of common coupling (PCC).

To determine permissible harmonic voltage levels, IEEE 519 uses a ratio between the supply short-circuit current and the maximum current of the individual load. For permissible harmonic voltage levels for individual loads, see Table 1.9. For permissible levels for all loads connected to the PCC, see Table 1.10.

ISC/IL (RSCE) 10 20 50 100 1000

Permissible individual harmonic voltages 2.53% 2.02.5% 1.01.5% 0.51%
0.050.1%

Table 1.9 Permissible Voltage THD at the PCC for Each Individual Load

Typical areas Weak grid 12 large loads A few high-output loads 520 medium- output loads Strong grid

Voltage at the PCC VLine69 kV

Permissible individual harmonic voltages 3%

Table 1.10 Permissible Voltage THD at the PCC for all Loads

Permissible THD(V) 5%

Limit harmonic currents to specified levels, as shown in Table 1.11. IEEE 519 utilises a ratio between the supply short-circuit current and the maximum current consumption at the PCC, averaged over 15 minutes or 30 minutes. In certain instances when dealing with harmonic limits containing low harmonic numbers, the IEEE 519 limits are lower than the 61000-2-4 limits. Low harmonic drives observe the total harmonic distortion as defined in IEEE 519 for all Rsce. Each individual harmonic current fulfills table 10-3 in IEEE 519 for Rsce20.

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Introduction

Operating Instructions

ISC/IL (RSCE)

h<11

11h<17

17h<23

23h<35

<20 20<50 50<100 100<1000 >1000

4%

2.0%

7%

3.5%

10%

4.5%

12%

5.5%

15%

7.0%

Table 1.11 Permissible Harmonic Currents at the PCC

1.5% 2.5% 4.0% 5.0% 6.0%

0.6% 1.0% 1.5% 2.0% 2.5%

The VLT® Refrigeration Drive FC 103 Low Harmonic complies with the following standards:

· IEC61000-2-4 · IEC61000-3-4 · IEEE 519 · G5/4

35h
0.3% 0.5% 0.7% 1.0% 1.4%

Total demand distortion TDD
5% 8% 12% 15% 20%

11

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Safety

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

22

Safety

2.1 Safety Symbols
The following symbols are used in this document:
WARNING
Indicates a potentially hazardous situation which could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which could result in minor or moderate injury. It may also be used to alert against unsafe practices.
NOTICE
Indicates important information, including situations that may result in damage to equipment or property.
2.2 Qualified Personnel
Correct and reliable transport, storage, installation, operation, and maintenance are required for the safe operation of the frequency converter. Only qualified personnel are allowed to install or operate this equipment.
Qualified personnel is defined as trained staff, who are authorised to install, commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Additionally, qualified personnel are familiar with the instructions and safety measures described in this document.
2.3 Safety Precautions
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when connected to AC mains input power. Qualified personnel only should perform installation, start up, and maintenance. Failure to perform installation, start up, and maintenance by qualified personnel could result in death or serious injury.

WARNING
UNINTENDED START
When the frequency converter is connected to AC mains, the motor may start at any time. The frequency converter, motor, and any driven equipment must be in operational readiness. Failure to be in operational readiness when the frequency converter is connected to AC mains could result in death, serious injury, equipment, or property damage.

WARNING
DISCHARGE TIME
Frequency converters contain DC-link capacitors that can remain charged even when the frequency converter is not powered. To avoid electrical hazards, disconnect AC mains, any permanent magnet type motors, and any remote DC-link power supplies, including battery backups, UPS, and DC-link connections to other frequency converters. Wait for the capacitors to fully discharge before performing any service or repair work. The amount of wait time is listed in the Discharge Time table. Failure to wait the specified time after power has been removed before doing service or repair could result in death or serious injury.

Voltage [V] 380-480

Power ranges for normal overload operation [kW] 160250 315710

Table 2.1 Discharge Times

Minimum waiting time (minutes) 20 40

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Operating Instructions

Mechanical Installation

3.1 Equipment Pre-Installation Checklist
3.1.1 Planning the Installation Site
CAUTION
It is important to plan the installation of the frequency converter. Neglecting to plan may result in extra work during and after installation.
Select the best possible operation site by considering the following:
· Ambient operating temperature. · Installation method. · How to cool the unit. · Position of the frequency converter. · Cable routing. · Ensure that the power source supplies the correct
voltage and necessary current.
· Ensure that the motor current rating is within the
maximum current from the frequency converter.
· If the frequency converter is without built-in
fuses, ensure that the external fuses are rated correctly.

3.1.2 Equipment Pre-Installation Checklist
· Before unpacking the frequency converter,
examine the packaging for signs of damage. If the unit is damaged, refuse delivery, and immediately contact the shipping company to claim the damage.
· Before unpacking the frequency converter, locate
it as close as possible to the final installation site.
· Compare the model number on the nameplate to
what was ordered to verify the proper equipment.
· Ensure that each of the following are rated for
the same voltage:
– Mains (power)
– Frequency converter
– Motor
· Ensure that the output current rating is equal to
or greater than the motor full load current for peak motor performance.
– Motor size and frequency converter power must match for proper overload protection.
– If the frequency converter rating is less than that of the motor, full motor output is impossible.

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Mechanical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

33

3.2 Unpacking 3.2.1 Items Supplied

Items supplied may vary according to product configuration.

· Make sure that the items supplied and the
information on the nameplate correspond to the order confirmation.
· Check the packaging and the frequency converter
visually for damage caused by inappropriate handling during shipment. File any claim for damage with the carrier. Retain damaged parts for clarification.

130BD600.10

VLT R

Automation Drive www.danfoss.com

1

2

T/C: FC-302PK37T2E20H1BGXXXXSXXXXA6BKC4XXXD0 3

P/N: 131X3537

S/N: 010122G430

4

0.37kW/ 0.50HP

5

9

IN: 3×200-240V 50/60Hz 2.2A

6

OUT: 3×0-Vin 0-1000Hz 2.4A

7

CHASSIS/ IP20 Tamb.50o C/122o F

8

1 3 1 X 3 5 3 7 0 1 0 1 2 2 G 4 3 0 * MADE IN DENMARK

Listed 76X1 E134261 Ind. Contr. Eq.

CAUTION:

See manual for special condition/mains fuse

10

voir manual de conditions speclales/fusibles

WARNING: Stored charge, wait 4 min. Charge residuelle, attendez 4 min.

` `

1 Type code 2 Code number 3 Serial number 4 Power rating
Input voltage, frequency, and current (at low/high 5
voltages) Output voltage, frequency, and current (at low/high 6 voltages) 7 Enclosure type and IP rating 8 Maximum ambient temperature 9 Certifications 10 Discharge time (Warning)
Illustration 3.1 Product Nameplate (Example)

NOTICE
Do not remove the nameplate from the frequency converter (loss of warranty).

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Operating Instructions

3.3 Mounting 3.3.1 Cooling and Airflow

Cooling Obtain cooling by taking air in through the plinth in the front and out of the top, in and out the back of the unit, or by combining the cooling possibilities.
Back cooling The backchannel air can also be ventilated in and out the back. This offers a solution where the backchannel could take air from outside the facility and return the heat losses outside the facility, thus reducing air- conditioning requirements.
Airflow Secure the necessary airflow over the heat sink. The flow rate is shown in Table 3.1.

Enclosure protection
IP21/NEMA 1 IP54/NEMA 12

Enclosure size D1n D2n E9
F18

Door fan/top fan airflow Total airflow of multiple fans 3 door fans, 442 m3/h 2+1=2×170+102 3 door fan, 544 m3/h 2+1=2×170+204 4 door fans, 680 m3/h (400 cfm) (2+2, 4×170=680)
6 door fans, 3150 m3/h (1854 cfm) (6×525=3150)

Heat sink fan Total airflow for multiple fans 2 heat sink fans, 1185 m3/h (1+1=765+544) 2 heat sink fans, 1605 m3/h (1+1=765+840) 2 heat sink fans, 2675 m3/h (1574 cfm) (1+1, 1230+1445=2675) 5 heat sink fans, 4485 m3/h (2639 cfm) 2+1+2, ((2×765)+(3×985)=4485)

Table 3.1 Heat Sink Air Flow

NOTICE
For the frequency converter section, the fan runs for the following reasons:
· AMA. · DC hold. · Pre-mag. · DC brake. · 60% of nominal current is exceeded. · Specific heat sink temperature exceeded (power
size dependent).
· Specific power card ambient temperature
exceeded (power size dependent).
· Specific control card ambient temperature
exceeded.
Once the fan is started, it runs for minimum 10 minutes.

NOTICE
For the active filter, the fan runs for the following reasons:
· Active filter running. · Active filter not running, but mains current
exceeding the limit (power size dependent).
· Specific heat sink temperature exceeded (power
size dependent).
· Specific power card ambient temperature
exceeded (power size dependent).
· Specific control card ambient temperature
exceeded.
Once the fan is started, it runs for minimum 10 minutes.
External ducts If additional duct work is added externally to the Rittal cabinet, calculate the pressure drop in the ducting. Use Illustration 3.2, Illustration 3.3, and Illustration 3.4 to derate the frequency converter according to the pressure drop.

33

MG16N102

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Mechanical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

130BE111.10

33

Drive Derating

(%) 90

80

70

60

50

40

30

20

10

0 0 0.5 4.9 13 27.3 45.9 66 89.3 115.7 147

Pressure Increase

(Pa)

Illustration 3.2 D-Enclosure Derating vs. Pressure Change Frequency Converter Air Flow: 450 cfm (765 m3/h)

130BB007.10

3.3.2 Lifting
Lift the frequency converter using the dedicated lifting eyes. For all D-frames, use a bar to avoid bending the lifting holes of the frequency converter.
1

Drive Derating

(%) 90

80

70

60

50

40 30

20

10

0 0 0.2 0.6 2.2 5.8 11.4 18.1 30.8 69.5 152.8 210.8

Pressure Change

(Pa)

Illustration 3.3 E-Enclosure Derating vs. Pressure Change Frequency Converter Air Flow: 850 cfm (1445 m3/h)

(%) 90 80 70 60 50 40 30
20 10 0
0 25 50 75 100 125 150 175 200 225 Pressure Change
Illustration 3.4 F-Enclosure Derating vs. Pressure Change Frequency Converter Air Flow: 580 cfm (985 m3/h)

130BB190.10

130BB011.10

1

Lifting holes

Illustration 3.5 Recommended Lifting Method, Enclosure Size D1n/D2n

Lifting Holes

Illustration 3.6 Recommended Lifting Method, Enclosure Size E9
WARNING
The lifting bar must be able to handle the weight of the frequency converter. See chapter 8.2 Mechanical Dimensions for the weight of the different enclosure sizes. Maximum diameter for the bar is 2.5 cm (1 inch). The angle from the top of the frequency converter to the lifting cable should be 60° or greater.

Drive Derating

130BC170.10

24

MG16N102

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Operating Instructions

130BD574.10

1 2

1 Lifting holes for the filter 2 Lifting holes for the frequency converter
Illustration 3.7 Recommended Lifting Method, Enclosure Size F18
NOTICE
A spreader bar is also an acceptable way to lift the Fframe.
NOTICE
The F18 pedestal is packaged separately and included in the shipment. Mount the frequency converter on the pedestal in its final location. The pedestal allows proper airflow and cooling.

33

MG16N102

25

130BE112.10

Mechanical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

33

3.3.3 Cable Entry and Anchoring

Cables enter the unit through gland plate openings in the bottom. Illustration 3.8, Illustration 3.9, Illustration 3.10, and Illustration 3.11 show gland entry locations and detailed views of anchoring hole dimensions.

Bottom view, D1n/D2n
560.0 [22.0]

327.4 [12.9]

289.4

20.0

[11.4] [0.8]

64.5

40.0

[2.5] [1.6]

227.8 [9.0]

246.0 [9.7]

220.0 [8.7]

235.0 [9.3]

1
350.0 [13.8]

1

Cable entry locations

Illustration 3.8 Cable Entry Diagram, Enclsoure Size D1n

240.0 [9.4] 397.3 [15.6]

42.3 [1.7] 8X 25.0 [1.0] 8X 14.0 [0.6]

26

MG16N102

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Operating Instructions

130BE113.10

64.5 [2.5] 227.8 246.0 [9.0] [9.7]

560.0 [22.0] 1 390.0 [15.4]

1

Cable entry locations

Illustration 3.9 Cable Entry Diagram, Enclsoure Size D2n

422.4 [16.6] 384.8 [15.1]

18.6

27.5

[0.7] [1.1]

220.0 235.0 [8.7] [9.3]

33

330.0

40.4

[13.0] [1.6]

470.4 [18.5]

8X 25.0 [1.0] 8X 14.0 [0.6]

MG16N102

27

130BC586.10

Mechanical Installation Bottom view, enclosure size E9

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

33

1

Cable entry locations

Illustration 3.10 Cable Entry Diagram, E9

28

MG16N102

Mechanical Installation Bottom view, F18
1

Operating Instructions

130BC587.10

33

2

3

4

6
1 Mains cable entry 2 Option enclosure 3 Filter enclosure Illustration 3.11 Cable Entry Diagram, F18

5
4 Motor cable entry 5 Inverter enclosure 6 Rectifier enclosure

MG16N102

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130BE114.10

Mechanical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

3.3.4 Terminal Locations for Enclosure Size D1n/D2n

33

784.6 [30.9]

78.3 [3.1] 39.2 [1.5]

245.8 [9.7]

29.0

[1.1]

1080.5

[42.5]

476.0 [18.7]

483.0 [19.0]

267.4 [10.5] MAINS INPUT TERMINALS

266.2 [10.5]

88.0 [3.5] 204.0 [8.0] 259.7 [10.2] 695.9 [27.4]

Illustration 3.12 Terminal Locations, Enclosure Size D1n

83.5 [3.3] 167.0 [6.6]

121.3 [4.8] MOTOR OUTPUT TERMINALS

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MG16N102

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Operating Instructions
845.7 [33.3] 54.0 [2.1]

108.0 [4.3]

130BE115.10

257.6 [10.1] 33

29.0 [1.1] 476.0 [18.7]

1005.1 [39.6] 486.8 [19.2]

268.9 [10.6] MAINS INPUT TERMINALS

88.0 [3.5]

266.2

204.0

[10.5] [8.0]

259.7

83.5

[10.2] [3.3]

786.7 [31.0]

Illustration 3.13 Terminal Locations, Enclosure Size D2n

167.0 [6.6]

Allow for bend radius of heavy power cables.
NOTICE
All D-frames are available with standard input terminals, fuse, or disconnect switch.

121.8 [4.8] MOTOR OUTPUT TERMINALS

MG16N102

31

130BC604.10

Mechanical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

3.3.5 Terminal Locations for Enclosure Size E9

33

90.0 [3.5] 518.0 [20.4]

517.5 [20.4]

383 [15.1]

MAINS INPUT TERMINAL

168.7 [6.6] 180.0 [7.1]

90.0 [3.5] 323.3 [12.7] 368.3 [14.5] 900.0 [35.4]

Illustration 3.14 Terminal Locations, Enclsoure Size E9

112.5 [4] 225.0 [8.9]

Allow for bend radius of heavy power cables.
NOTICE
All E-frames are available with standard input terminals, fuse, or disconnect switch.

153.8 [6.1] MOTOR OUTPUT TERMINAL

176FA271.10

104[4.1] 35[1.4] 10[0.4] 0[0.0] Illustration 3.15 Close-up Terminal Diagrams

78[3.1] 40[1.6] 0[0.0] 26[1.0] 0[0.0] 26[1.0]

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Operating Instructions

3.3.6 Terminal Locations for Enclsoure Size F18
Consider the position of the terminals when designing the cable access.
F-frame units have 4 interlocked cabinets:
· Input options cabinet (not optional for LHD) · Filter cabinet · Rectifier cabinet · Inverter cabinet
See chapter 1.3.3 Exploded View Drawings for exploded views of each cabinet. Mains inputs are located in the input option cabinet, which conducts power to the rectifier via interconnecting bus bars. Output from the unit is from the inverter cabinet. No connection terminals are located in the rectifier cabinet. Interconnecting bus bars are not shown.

1

2

3

33

130BA851.12

1031.4[40.61] 939.0[36.97]

134.6[5.30] 0.0[0.00]

4
0.0[1.75] 244.4[1.75] 244.4[9.62]

0.0[0.00] 75.3[2.96] 150.3[5.92] 154.0[6.06] 219.6[18.65] 294.6[11.60] 344.0[13.54] 3639[14.33] 438.9[17.28] 0.0[0.00] 76.4[3.01] 128.4[5.05] 119.0[4.69] 171.0[6.73]

1

Right side cut-away

2

Front view

3

Left side cut-away

4

Ground bar

Illustration 3.16 Input Option Cabinet, Enclosure Size F18 – Fuses Only

The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right.

MG16N102

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130BA852.11

Mechanical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

33

134.6 [5.30] 0.0 [0.00]

532.9 [20.98] 436.9 [17.20] 1

0.0 [0.00] 44.4 [1.75]

244.4 [9.62]

35 24

0.0 [0.00] 104.3 [4.11] 179.3 [7.06] 154.0 [6.06] 219.6 [8.65] 294.6 [11.60] 344.0 [13.54] 334.8 [13.18] 409.8 [16.14] 0.0 [0.00]

500 kW1)(mm [in.])

1

Ground bar

2

34.9 [1.4]

3

86.9 [3.4]

4

122.2 [4.8]

5

174.2 [6.9]

Disconnect location and related dimensions vary with kilowatt rating.

560710 kW1)(mm [in.])
46.3 [1.8] 98.3 [3.9] 119 [4.7] 171 [6.7]

Illustration 3.17 Input Option Cabinet with Circuit Breaker, Enclosure Size F18

The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right.

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MG16N102

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Operating Instructions

2
308.3 [12.1] 253.1 [10.0] 180.3 [7.1] 3 1
.0 [.0] 44.40 [1.75] 244.40 [9.62]

130BA849.13

33

465.6 [18.3] 339.4 [13.4] 287.4 [11.3] .0 [.0]

.0 [.0] 287.4 [11.3] 339.4 [13.4] 465.6 [18.3]

522.3 [20.6] 637.3 [25.1]

198.1[7.8] 169.4 [6.7] 234.1 [9.2] 282.1 [11.1] 284.4 [11.2] 318.1 [12.5] 407.3 [16.0]

.0 [.0] 54.4[2.1]

497.1 [19.6] 551.0 [21.7] 572.1 [22.5] 587.0 [23.1] 635.0 [25.0] 671.0 [26.4]

129.1 [5.1] 204.1 [8.0]

1

Front view

2

Left side view

3

Right side view

Illustration 3.18 Inverter Cabinet, Enclosure Size F18

The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right.

3.3.7 Torque

Enclosure size

Terminal

Correct torque is imperative for all electrical connections. The correct values are listed in Table 3.2. Incorrect torque results in a bad electrical connection. Use a torque wrench to ensure correct torque.

Mains

Motor D
Regen

Brake

Mains

Motor

E

Regen

Brake

Mains Motor

F

Brake

Regen

Torque [Nm] (inlbs) 1940 (168354) 8.520.5 (75181)
1940 (168354)
8.520.5 (75181) 1940 (168354) 8.520.5 (75181) 8.520.5 (75181)

Bolt size M10 M8 M10 M8 M10 M8 M8

Table 3.2 Torque for Terminals

MG16N102

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Electrical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

Electrical Installation

44

4.1 Safety Instructions
See chapter 2 Safety for general safety instructions.
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned off and locked out. Failure to run output motor cables separately or to use screened cables could result in death or serious injury.
· Run output motor cables separately, or · Use screened cables.
CAUTION
SHOCK HAZARD
The frequency converter can cause a DC current in the PE conductor. Failure to follow the recommendation may lead to the RCD not providing the intended protection.
· When a residual current-operated protective
device (RCD) is used for protection against electrical shock, only an RCD of Type B is permitted on the supply side.
Overcurrent protection
· Extra protective equipment, such as short-circuit
protection or motor thermal protection between frequency converter and motor, is required for applications with multiple motors.
· Input fusing is required to provide short circuit
and overcurrent protection. If not factorysupplied, the installer must provide fuses. See maximum fuse ratings in chapter 8.4 Fuses.
Wire type and ratings
· All wiring must comply with local and national
regulations regarding cross-section and ambient temperature requirements.
· Power connection wire recommendation:
Minimum 75 °C rated copper wire.
See chapter 8.1 Power-Dependent Specifications and chapter 8.3 General Technical Data for recommended wire sizes and types.

4.2 EMC Compliant Installation
To obtain an EMC-compliant installation, follow the instructions provided in chapter 4.3 Power Connections, chapter 4.4 Grounding, chapter 4.6 Motor Connection, and chapter 4.8 Control Wiring.
4.3 Power Connections
NOTICE
Cables, general information. All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. UL applications require 75 °C copper conductors. For non-UL applications, 75 and 90 °C copper conductors are thermally acceptable.
The power cable connections are located as shown in Illustration 4.1. Dimension cable cross-section in accordance with the current ratings and local legislation. See chapter 8.3.1 Cable lengths and cross-sections for details.
For protection of the frequency converter, use the recommended fuses if there are no built-in fuses. Fuse recommendations are provided in chapter 8.4 Fuses. Ensure that proper fusing is made according to local regulation.
If included, the mains connection is fitted to the mains switch.

130BA026.10

3 Phase power input

91 (L1) 92 (L2) 93 (L3) 95 PE

Illustration 4.1 Power Cable Connections

NOTICE
To comply with EMC emission specifications, screened/ armoured cables are recommended. If an unscreened/ unarmoured cable is used, see chapter 4.7.3 Power and Control Wiring for Unscreened Cables.
See chapter 8 Specifications for correct dimensioning of motor cable cross- section and length.

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MG16N102

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Operating Instructions

Screening of cables Avoid installation with twisted screen ends (pigtails). They spoil the screening effect at higher frequencies. If breaking the screen is necessary to install a motor isolator or contactor, continue the screen at the lowest possible HF impedance.
Connect the motor cable screen to both the de-coupling plate of the frequency converter and to the metal housing of the motor.
Make the screen connections with the largest possible surface area (cable clamp). Use the installation devices within the frequency converter.
Cable-length and cross-section The frequency converter has been EMC-tested with a given cable length. To reduce the noise level and leakage currents, keep the motor cable as short as possible.
Switching frequency When frequency converters are used with sine-wave filters to reduce the acoustic noise from a motor, set the switching frequency according to parameter 14-01 Switching Frequency.

Termi 96 97 98 99

nal

numb

er

Motor voltage 0100% of mains

U V W PE1) voltage.

3 wires out of motor

U1 V1 W1

Delta-connected

PE1)

W2 U2 V2

6 wires out of motor

Star-connected U2, V2, W2

U1 V1 W1 PE1) U2, V2, and W2 to be interconnected

separately.

Table 4.1 Terminal Connections 1) Protective earth connection

175ZA114.11

Motor

U

V

W

2

Motor

U

V

W

2

U

V

W

1

U 1

V 1

W 1

FC

96

97

98

FC

96

97

98

Illustration 4.2 Y and Delta Terminal Configurations

4.4 Grounding
WARNING
GROUNDING HAZARD!
For operator safety, it is important to ground the frequency converter properly in accordance with national and local electrical codes as well as instructions contained within this document. Do not use conduit connected to the frequency converter as a replacement for proper grounding. Ground currents are higher than 3.5 mA. Failure to ground the frequency converter properly could result in death or serious injury.
NOTICE
It is the responsibility of the user or certified electrical installer to ensure correct grounding of the equipment in accordance with national and local electrical codes and standards.
· Follow all local and national electrical codes to
ground electrical equipment properly.
· Establish proper protective earthing for
equipment with ground currents higher than 3.5 mA, see chapter 4.4.1 Leakage Current (>3.5 mA).
· A dedicated ground wire is required for input
power, motor power, and control wiring.
· Use the clamps provided with the equipment for
proper ground connections.
· Do not ground one frequency converter to
another in a “daisy chain” fashion.
· Keep the ground wire connections as short as
possible.
· Using high-strand wire to reduce electrical noise
is recommended.
· Follow motor manufacturer wiring requirements.
4.4.1 Leakage Current (>3.5 mA)
Follow national and local codes regarding protective earthing of equipment with a leakage current >3.5 mA. Frequency converter technology implies high frequency switching at high power. This generates a leakage current in the ground connection. A fault current in the frequency converter at the output power terminals might contain a DC component, which can charge the filter capacitors and cause a transient ground current. The earth leakage current depends on various system configurations including RFI filtering, screened motor cables, and frequency converter power.

44

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EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3.5 mA. Grounding must be reinforced in 1 of the following ways:
· Ground wire of at least 10 mm2. · 2 separate ground wires both complying with the
dimensioning rules.
See EN 60364-5-54 § 543.7 for further information.
4.5 Input Options
4.5.1 Extra Protection (RCD)
ELCB relays, multiple protective grounding, or standard grounding provide extra protection, if local safety regulations are followed.
In the case of a ground fault, a DC component develops in the fault current.
If using ELCB relays, observe local regulations. Relays must be suitable for protection of 3-phase equipment with a bridge rectifier and for a brief discharge on power-up.
4.5.2 RFI Switch
Mains supply isolated from ground If the frequency converter is supplied from an isolated mains source or TT/TN-S mains with grounded leg, turn off the RFI switch via parameter 14-50 RFI Filter on both frequency converter and the filter. For further reference, see IEC 364-3. When optimum EMC performance is needed, parallel motors are connected, or the motor cable length is above 25 m, set parameter 14-50 RFI Filter to [ON]. In OFF, the internal RFI capacitors (filter capacitors) between the enclosure and the DC link are cut off to avoid damage to the intermediate circuit and reduce ground capacity currents (IEC 61800-3). Refer to the application note VLT on IT mains. It is important to use isolation monitors that work together with power electronics (IEC 61557-8).
4.5.3 Screened Cables
It is important to connect screened cables properly to ensure high EMC immunity and low emissions.
Connection can be made using either cable glands or clamps:
· EMC cable glands: Generally available cable
glands can be used to ensure an optimum EMC connection.
· EMC cable clamp: Clamps allowing easy
connection are supplied with the unit.

4.6 Motor Connection 4.6.1 Motor Cable

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

Terminal number 96, 97, 98 99

Function Mains U/T1, V/T2, W/T3 Ground

Table 4.2 Terminal Functions

· Terminal U/T1/96 connected to U-phase. · Terminal V/T2/97 connected to V-phase. · Terminal W/T3/98 connected to W-phase.
The direction of rotation can be changed by switching 2 phases in the motor cable or by changing the setting of parameter 4-10 Motor Speed Direction.

To check motor rotation, select parameter 1-28 Motor Rotation Check and follow the steps on the display.

38

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Operating Instructions

Motor

U

V

W

2

U

V

W

1

FC

96

97

98

Motor

U

V

W

2

U

V

W

1

FC

96

97

98

Illustration 4.3 Motor Rotation Check
F-frame requirements Use motor phase cables in quantities of 2, resulting in 2, 4, 6, or 8 to obtain an equal number of wires on both inverter module terminals. The cables are required to be of equal length within 10% between the inverter module terminals and the first common point of a phase. The recommended common point is the motor terminals. Output junction box requirements The length, minimum 2.5 m, and quantity of cables must be equal from each inverter module to the common terminal in the junction box.
NOTICE
If a retrofit application requires an unequal number of wires per phase, consult the factory or use the top/ bottom entry side cabinet option instruction.
4.6.2 Brake Cable
Frequency converters with factory installed brake chopper option.
(Only standard with letter B in position 18 in the type code).

175HA036.11

The connection cable to the brake resistor must be screened, and the maximum length from frequency converter to the DC bar is limited to 25 m.

Terminal number 81, 82

Function Brake resistor terminals

Table 4.3 Terminal Functions

Connect the screen with cable clamps to the conductive back plate of the frequency converter and the metal cabinet of the brake resistor. Size the brake cable cross-section to match the brake torque.

WARNING
Note that voltages up to 790 V DC, depending on the supply voltage, are possible on the terminals.

F-frame requirements Connect the brake resistors to the brake terminals in each inverter module.
4.6.3 Motor Insulation

For motor cable lengths the maximum cable length, the motor insulation ratings listed in Table 4.4 are recommended. The peak voltage can be twice the DC-link voltage or 2.8 times mains voltage, due to transmission line effects in the motor cable. If a motor has lower insulation rating, use a dU/dt or sine wave filter.

Nominal mains voltage UN420 V 420 V<UN500 V

Motor insulation Standard ULL=1300 V Reinforced ULL=1600 V

Table 4.4 Recommended Motor Insulation Ratings

4.6.4 Motor Bearing Currents

Motors with a rating of 110 kW or higher combined with frequency converters are best with NDE (non-drive end) insulated bearings to eliminate circulating bearing currents caused by motor size. To minimise DE (drive end) bearing and shaft currents, proper grounding is required for:
· The frequency converter. · The motor. · Motor-driven machine. · Motor to the driven machine.
Although failure due to bearing currents is infrequent, use the following strategies to reduce the likelihood:

44

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Electrical Installation

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44

· Use an insulated bearing. · Apply rigorous installation procedures. · Ensure that the motor and load motor are
aligned.
· Strictly follow the EMC installation guideline. · Reinforce the PE so the high frequency
impedance is lower in the PE than the input power leads.
· Provide a good high frequency connection
between the motor and the frequency converter.
· Ensure that the impedance from frequency
converter to building ground is lower than the grounding impedance of the machine. Make a direct ground connection between the motor and load motor.
· Apply conductive lubrication. · Balance the line voltage to ground. · Use an insulated bearing as recommended by the
motor manufacturer.
NOTICE
Motors from reputable manufacturers typically have insulated bearings as standard in motors of this size.
If necessary, and after consultation with Danfoss:
· Lower the IGBT switching frequency. · Modify the inverter waveform, 60° AVM vs.
SFAVM.
· Install a shaft grounding system or use an
isolating coupling between motor and load.
· Use minimum speed settings if possible. · Use a dU/dt or sine-wave filter.
4.7 AC Mains Connection
4.7.1 Mains Connection

Connect mains to terminals 91, 92, and 93 on the far left of the unit. Ground is connected to the terminal on the right of terminal 93.

Terminal number 91, 92, 93 94

Function
Mains R/L1, S/L2, T/L3 Ground

Table 4.5 Terminal Functions

Ensure sufficient current supply to the frequency converter.

If the unit is without built-in fuses, ensure that the appropriate fuses have the correct current rating.

4.7.2 External Fan Supply
NOTICE
Applicable for E and F enclosures only.

If the frequency converter is supplied by DC, or the fan must run independently of the supply, use an external supply. Make the connection on the power card.

Terminal number 100, 101 102, 103

Function
Auxiliary supply S, T Internal supply S, T

Table 4.6 Terminal Functions

The connector on the power card provides the connection of line voltage for the cooling fans. The fans are connected from the factory to be supplied from a common AC line (jumpers between 100102 and 101103). If external supply is needed, remove the jumpers and connect the supply to terminals 100 and 101. Protect with a 5 A fuse. In UL applications, use a LittelFuse KLK-5 or equivalent.

4.7.3 Power and Control Wiring for Unscreened Cables

WARNING
INDUCED VOLTAGE Induced voltage from coupled output motor cables charges equipment capacitors even with the equipment turned off and locked out. Run motor cables from multiple frequency converters separately. Failure to run output cables separately could result in death or serious injury.

CAUTION
COMPROMISED PERFORMANCE The frequency converter runs less efficiently if wiring is not isolated properly. To isolate high frequency noise, place the following in separate metallic conduits:
· Power wiring · Motor wiring · Control wiring
Failure to isolate these connections could result in less than optimum controller and associated equipment performance.

Because the power wiring carries high-frequency electrical pulses, it is important to run input power and motor power in separate conduit. If incoming power wiring is in the same conduit as motor wiring, these pulses can couple

40

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Operating Instructions

electrical noise back onto the power grid. Isolate control wiring from high- voltage power wiring. See Illustration 4.4. When screened/armoured cable is not used, at least 3 separate conduits are connected to the panel options cabinet.

44

130BX370.10

Stop Start Speed

Line Power

Motor

Control
Illustration 4.4 Example of Proper Electrical Installation Using Conduit

MG16N102

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Electrical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

44

4.7.4 Mains Disconnects

Frame size D E E F F

Power & Voltage 160-250 kw 380-480 V
315 kW 380-480 V 355-450 kW 380-480 V
500 kW 380-480 V 560-710 kW 380-480 V

Table 4.7 Recommended Mains Disconnects

4.7.5 F-Frame Circuit Breakers

Frame size F F

Power & Voltage 500 kW 380-480 V 560-710kW 380-480 V

Table 4.8 Recommended Circuit Breakers

4.7.6 F-Frame Mains Contactors

Frame size F F

Power & Voltage 500-560 kW 380-480 V 630-710 kW380-480 V

Table 4.9 Recommended Contactors

Type OT400U12-9 or ABB OETL-NF400A
ABB OETL-NF600A ABB OETL-NF800A Merlin Gerin NPJF36000S12AAYP Merlin Gerin NRK36000S20AAYP
Type Merlin Gerin NPJF36120U31AABSCYP Merlin Gerin NRJF36200U31AABSCYP
Type Eaton XTCE650N22A Eaton XTCEC14P22B

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MG16N102

130BE138.10 130BE137.10

Electrical Installation

Operating Instructions

4.8 Control Wiring
4.8.1 Control Cable Routing
Tie down all control wires to the designated control cable routing as shown in Illustration 4.5, Illustration 4.6, Illustration 4.7, and Illustration 4.8. Remember to connect the shields in a proper way to ensure optimum electrical immunity.
Fieldbus connection Connections are made to the relevant options on the control card. For details, see the relevant fieldbus instruction. The cable must either be entered through the access point in the top or be placed in the provided path inside the frequency converter and tied down with other control wires (see Illustration 4.5, Illustration 4.6, and Illustration 4.7).

44

Illustration 4.6 Control Card Wiring Path for Enclosure Size D2n

Illustration 4.5 Control Card Wiring Path for Enclosure Size D1n

MG16N102

43

130BB187.10

Electrical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

44 1

Illustration 4.7 Control Card Wiring Path for Enclosure Size E9

1 Routing path for the control card wiring inside the frequency converter enclosure.
Illustration 4.8 Control Card Wiring Path for Enclosure Size F18

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Operating Instructions

4.8.2 Access to Control Terminals
All terminals for the control cables are located beneath the LCP (both filter and frequency converter LCPs). They are accessed by opening the door of the unit.
4.8.3 Electrical Installation, Control Terminals
To connect the cable to the terminal: 1. Strip insulation by about 910 mm.

To remove the cable from the terminal: 1. Insert a screwdriver (maximum 0.4 x 2.5 mm) in the square hole.
2. Pull out the cable.

130BT311.10

44

130BA150.10

9 – 10 mm (0.37 in)
Illustration 4.9 Length to Strip the Insulation
2. Insert a screwdriver (maximum 0.4 x 2.5 mm) in the square hole.
3. Insert the cable in the adjacent circular hole.

Illustration 4.11 Removing the Screwdriver after Cable Insertion

130BT312.10

130BT306.10

Illustration 4.12 Control Terminal Locations
Illustration 4.10 Inserting the Cable in the Terminal Block 4. Remove the screwdriver. The cable is now mounted in the terminal.

MG16N102

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130BE195.10

Electrical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

4.8.4 Electrical Installation, Control Cables

44

3 Phase power After HI inductor
+10 VDC 0 VDC – 10 VDC
0/4-20 mA 0 VDC – 10 VDC
0/4-20 mA

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

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

50 (+10 V OUT) A53 U-I (S201)
53 (A IN)
A54 U-I (S202) 54 (A IN)

Switch Mode Power Supply 10 VDC 24 VDC 15 mA 200 mA +- + –
ON=0-20 mA OFF=0-10 V

(R+) 82 (R-) 81
Relay1 03 02

ON 12
ON ON 12 12

55 (COM A IN) 12 (+24 V OUT) 13 (+24 V OUT) 18 (D IN) 19 (D IN) 20 (COM D IN) 27 (D IN/OUT)

P 5-00
24 V (NPN) 0 V (PNP)
24 V (NPN) 0 V (PNP)

24 V (NPN)

24 V

0 V (PNP)

01 Relay2
06
05
04

(COM A OUT) 39

(A OUT) 42

S801/Bus Term.

OFF-ON

ON=Terminated

OFF=Open

1

0 V 29 (D IN/OUT)
24 V
0 V 32 (D IN) 33 (D IN)

24 V (NPN) 0 V (PNP)
24 V (NPN) 0 V (PNP) 24 V (NPN) 0 V (PNP)

5 V

2

S801

0 V

RS-485 Interface

(P RS-485) 68 (N RS-485) 69

(COM RS-485) 61

37 (D IN) – option

Motor Brake resistor
240 VAC, 2A 400 VAC, 2A (E & F frame only) 240 VAC, 2A 400 VAC, 2A
Analog Output 0/4-20 mA
HI inductor Temperature feed back (NC)
RS-485
(PNP) = Source (NPN) = Sink

Illustration 4.13 Terminal Diagram for the Frequency Converter Side

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Operating Instructions

130BE196.10

Mains 380 to 500 VAC
+10Vdc -10Vdc +10Vdc 0/4-20 mA -10Vdc +10Vdc 0/4-20 mA

Soft-Charge Resistor

91 (L1)

HI Reactor
Lm

AC Contactor

Converter Side

Filter

Lc

Ir

Power Stage

Lac

92 (L2) Optional Optional Optional Lm

RFI

Manual Fuses

Disconnect

Lac

93 (L3)

Lm

Lac

Relay 12

Control & Cef Cef Cef

AUX Ref Feedback

Ref Ref

Lc

Is

Lc

It

3

Capacitor Current Sensors

3
AF Current Sensors

VLT Drive

50 (+10 V OUT)

53 (A IN)

S201

54 (A IN)

S202

55 (COM A IN) 12 (+24V OUT) 13 (+24V OUT)

18 (D IN)

19 (D IN) 20 (COM D IN) 27 (D IN/OUT)

29 (D IN/OUT)

32 (D IN) 33 (D IN)

ON 12
ON ON 12 12

Switch Mode Power Supply
10Vdc 24Vdc 15mA 130/200mA
+- + –

3 Main’s CTs

ON/I=0-20mA OFF/U=0-10V
P 5-00 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP)
24V (NPN) 0V (PNP) 24V
0V 24V (NPN) 0V (PNP)
24V
0V 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP)

relay1 03
02
01 relay2
06
05
04

(COM A OUT) 39 (A OUT) 42

S801

ON=Terminated OFF=Open

5V

240Vac, 2A
240Vac, 2A 400Vac, 2A
Analog Output 0/4-20 mA

S801

0V

RS-485 Interface

(N RS-485) 69 (P RS-485) 68

(COM RS-485) 61

RS-485
(PNP) = Source (NPN) = Sink

Illustration 4.14 Terminal Diagram for the Filter Side

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VLT® Refrigeration Drive FC 103 Low Harmonic Drive

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4.8.5 Safe Torque Off (STO)

To run STO, additional wiring for the frequency converter is required. Refer to VLT® Frequency Converters Safe Torque Off Operating Instructions for further information.
4.9 Additional Connections
4.9.1 Serial Communication

RS485 is a 2-wire bus interface compatible with multi-drop network topology, that is nodes can be connected as a bus, or via drop cables from a common trunk line. A total of 32 nodes can be connected to 1 network segment. Repeaters divide networks.

NOTICE
Each repeater functions as a node within the segment in which it is installed. Each node connected within a given network must have a unique node address across all segments.

Terminate each segment at both ends, using either the termination switch (S801) of the frequency converters or a biased termination resistor network. Always use screened twisted pair (STP) cable for bus cabling, and always follow good common installation practice. Low-impedance ground connection of the screen at every node is important, including at high frequencies. Thus, connect a large surface of the screen to ground, for example with a cable clamp or a conductive cable gland. It may be necessary to apply potential- equalizing cables to maintain the same ground potential throughout the network, particularly in installations with long cables. To prevent impedance mismatch, always use the same type of cable throughout the entire network. When connecting a motor to the frequency converters, always use screened motor cable.

Cable Impedance Cable length [m]

Screened twisted pair (STP) 120 Maximum 1200 (including drop lines) Maximum 500 station-to-station

Table 4.10 Cable Recommendations

4.9.2 Mechanical Brake Control
In hoisting/lowering applications, it is necessary to be able to control an electro-mechanical brake:
· Control the brake using any relay output or
digital output (terminal 27 or 29).
· Keep the output closed (voltage-free) as long as
the frequency converter is unable to support the motor, due to the load being too heavy, for example.
· Select [32] Mechanical brake control in parameter
group 5-4* Relays for applications with an electromechanical brake.
· The brake is released when the motor current
exceeds the preset value in parameter 2-20 Release Brake Current.
· The brake engages when the output frequency is
less than the frequency set in parameter 2-21 Activate Brake Speed [RPM] or parameter 2-22 Activate Brake Speed [Hz], only if the frequency converter completes a stop command.
If the frequency converter is in alarm mode or in an overvoltage situation, the mechanical brake immediately cuts in.
4.9.3 Parallel Connection of Motors
The frequency converter can control several parallelconnected motors. The total current consumption of the motors must not exceed the rated output current IM,N for the frequency converter.

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Operating Instructions

NOTICE
Installations with cables connected in a common joint as in Illustration 4.15 are only recommended for short cable lengths.
NOTICE
When motors are connected in parallel, parameter 1-29 Automatic Motor Adaptation (AMA) cannot be used.
NOTICE
The electronic thermal relay (ETR) of the frequency converter cannot be used as motor protection for the individual motor in systems with parallel- connected motors. Provide further motor protection with thermistors in each motor or individual thermal relays. Circuit breakers are not suitable as protection.
LC filter
Illustration 4.15 Installations with Cables Connected in a Common Joint
Problems are possible at start and at low RPM values if motor sizes vary widely. The relatively high ohmic resistance in the stator of small motors calls for a higher voltage at start and at low RPM values.

130BA170.11

4.9.4 Motor Thermal Protection
The electronic thermal relay in the frequency converter has received UL- approval for single motor protection, when parameter 1-90 Motor Thermal Protection is set for [4] ETR Trip 1 and parameter 1-24 Motor Current is set to the rated motor current (see motor nameplate).
For the North American market: The ETR functions provide class 20 motor overload protection in accordance with NEC.
For motor thermal protection, it is also possible to use the VLT® PTC Thermistor Card MCB 112. This card provides ATEX certification to protect motors in explosion hazardous areas, Zone 1/21 and Zone 2/22. When parameter 1-90 Motor Thermal Protection is set to [20] ATEX ETR and MCB 112 are combined, it is possible to control an Ex-e motor in explosion hazardous areas. Consult the Programming Guide for details on how to set up the frequency converter for safe operation of Ex-e motors.
4.9.5 Voltage/Current Input Selection (Switches)
The analog mains terminals 53 and 54 allow setting of input signal to voltage (010 V) or current (0/420 mA). See Illustration 4.13 and Illustration 4.14 for the location of the control terminals within the low harmonic drive.
Default parameter settings:
· Terminal 53: Speed reference signal in open loop
(see parameter 16-61 Terminal 53 Switch Setting).
· Terminal 54: Feedback signal in closed loop (see
parameter 16-63 Terminal 54 Switch Setting).
NOTICE
REMOVE POWER
Remove power to the low harmonic drive before changing switch positions.
1. Remove the LCP (see Illustration 4.16). 2. Remove any optional equipment covering the
switches. 3. Set switches A53 and A54 to select the signal
type. U selects voltage, I selects current.

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MG16N102

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Electrical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

NO 130BE063.10 130BT307.10

12

1
44

3 2
1 Bus termination switch 2 A54 switch 3 A53 switch
Illustration 4.16 Bus Termination Switch, A53, and A54 Switch Locations

4.10 Final Set-up and Test
Before operating the frequency converter, perform a final test of the installation:

1. Locate the motor name plate to find out whether the motor is star- (Y) or delta- connected ().
2. Enter the motor name plate data in the parameter list. Access the list by pressing the [Quick Menu] key and selecting Q2 Quick Set-up. See Table 4.11.

Parameter 1-20 Motor Power [kW]

Parameter 1-21 Motor Power [HP]

Parameter 1-22 Motor Voltage

Parameter 1-23 Motor Frequency

Parameter 1-24 Motor Current

Parameter 1-25 Motor Nominal Speed

Table 4.11 Quick Set-up Parameters

BAUER D-7 3734 ESLINGEN 3~ MOTOR NR. 1827421 2003

S/E005A9

1,5

KW

n 31,5

/min.

400

Y

V

n 1400

/min.

50

Hz

COS 0,80

3,6

A

1,7L

B

IP 65

H1/1A

Illustration 4.17 Motor Nameplate

3. Perform an automatic motor adaptation (AMA) to ensure optimum performance.
3a Connect terminal 27 to terminal 12 or set parameter 5-12 Terminal 27 Digital Input to [0] No operation.
3b Activate the AMA in parameter 1-29 Automatic Motor Adaptation (AMA).
3c Select either complete or reduced AMA. If an LC filter is mounted, run only the reduced AMA, or remove the LC filter during the AMA procedure.
3d Press [OK]. The display shows Press [Hand On] to start.
3e Press [Hand On]. A progress bar indicates whether the AMA is in progress.
3f Press [Off] – the frequency converter enters alarm mode and the display shows that the user terminated AMA.

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Operating Instructions

Stop the AMA during operation Successful AMA
· The display shows Press [OK] to finish AMA. · Press [OK] to exit the AMA state.
Unsuccessful AMA
· The frequency converter enters into alarm mode.
Find a description of the alarm in chapter 7 Diagnostics and Troubleshooting.
· Report value in the alarm log shows the last
measuring sequence carried out by the AMA before the frequency converter entered alarm mode. This number, along with the description of the alarm, helps with troubleshooting. Mention the number and alarm description when contacting Danfoss service personnel.
Unsuccessful AMA is the result of incorrectly registered motor nameplate data or too large a difference between the motor power size and the frequency converter power size.
Set up the desired limits for speed and ramp time

Minimum reference Maximum reference

Parameter 3-02 Minimum Reference Parameter 3-03 Maximum Reference

Table 4.12 Reference Parameters

Motor speed low limit Motor speed high limit Table 4.13 Speed Limits

Parameter 4-11 Motor Speed Low Limit [RPM] or parameter 4-12 Motor Speed Low Limit [Hz] Parameter 4-13 Motor Speed High Limit [RPM] or parameter 4-14 Motor Speed High Limit [Hz]

Ramp-up time 1 [s] Ramp-down time 1 [s] Table 4.14 Ramp Times

Parameter 3-41 Ramp 1 Ramp Up Time Parameter 3-42 Ramp 1 Ramp Down Time

4.11 F-frame Options
Space heaters and thermostat There are space heaters mounted on the cabinet interior of F-frame frequency converters. These heaters are controlled by an automatic thermostat and help control humidity inside the enclosure. The thermostat default settings turn on the heaters at 10 °C (50 °F) and turn them off at 15.6 °C (60 °F).

Cabinet light with power outlet A light mounted on the cabinet interior of F-frame frequency converters increases visibility during servicing and maintenance. The housing includes a power outlet for temporarily powering tools or other devices, available in 2 voltages:
· 230 V, 50 Hz, 2.5 A, CE/ENEC · 120 V, 60 Hz, 5 A, UL/cUL
Transformer tap set-up If the cabinet light, outlet, and/or the space heaters, and thermostat are installed, transformer T1 requires its taps to be set to the proper input voltage. A 380480/500 V frequency converter is initially set to the 525 V tap to ensure that no overvoltage of secondary equipment occurs if the tap is not changed before applying power. See Table 4.15 to set the proper tap at terminal T1 located in the rectifier cabinet.

Input voltage range [V] 380440 441500

Tap to select [V] 400 460

Table 4.15 Transformer Tap Set-up

NAMUR terminals NAMUR is an international association of automation technology users in the process industries, primarily chemical and pharmaceutical industries in Germany. Selecting this option, provides terminals organised and labeled to the specifications of the NAMUR standard for frequency converters input and output terminals. This requires VLT® PTC Thermistor Card MCB 112 and VLT® Extended Relay Card MCB 113.
RCD (residual current device) Uses the core balance method to monitor ground fault currents in grounded and high-resistance grounded systems (TN and TT systems in IEC terminology). There is a pre-warning (50% of main alarm set- point) and a main alarm set-point. Associated with each set-point is an SPDT alarm relay for external use. Requires an external windowtype current transformer (supplied and installed by the customer).
· Integrated into the frequency converter safe
torque off circuit.
· IEC 60755 Type B device monitors AC, pulsed DC,
and pure DC ground fault currents.
· LED bar graph indicator of the ground fault
current level from 10100% of the setpoint.
· Fault memory. · TEST/RESET key.
Insulation resistance monitor (IRM) Monitors the insulation resistance in ungrounded systems (IT systems in IEC terminology) between the system phase conductors and ground. There is an ohmic pre-warning and a main alarm setpoint for the insulation level. An SPDT

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Electrical Installation

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

44

alarm relay for external use is associated with each setpoint.
NOTICE
Only 1 insulation resistance monitor can be connected to each ungrounded (IT) system.
· Integrated into the frequency converter Safe
Torque Off circuit.
· LCD display of the ohmic value of the insulation
resistance.
· Fault memory. · INFO, TEST, and RESET keys.
IEC emergency stop with Pilz safety relay Includes a redundant 4-wire emergency-stop push button mounted on the front of the enclosure and a Pilz relay that monitors it in conjunction with the frequency converter STO (Safe Torque Off) circuit and the mains contactor located in the options cabinet.
Manual motor starters Provide 3-phase power for electric blowers often required for larger motors. Power for the starters is provided from the load side of any supplied contactor, circuit breaker, or disconnect switch. Power is fused before each motor starter, and is off when the incoming power to the frequency converters is off. Up to 2 starters are allowed (1 if a 30 A, fuse- protected circuit is ordered), and are integrated into the frequency converter STO circuit. Unit features include:
· Operation switch (on/off). · Short-circuit and overload protection with test
function.
· Manual reset function.
30 A, fuse-protected terminals
· 3-phase power matching incoming mains voltage
for powering auxiliary customer equipment.
· Not available if 2 manual motor starters are
selected.
· Terminals are off when the incoming power to
the frequency converter is off.
· Power for the fused protected terminals is
provided from the load side of any supplied contactor, circuit breaker, or disconnect switch.
In applications where the motor is used as a brake, energy is generated in the motor and sent back into the frequency converter. If the energy cannot be transported back to the motor, it increases the voltage in the frequency converter DC line. In applications with frequent braking and/or high inertia loads, this increase may lead to an overvoltage trip in the frequency converter and finally a shut down. Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected based on its ohmic value, its power dissipation

rate, and its physical size. Danfoss offers a wide variety of different resistors that are specifically designed for Danfoss frequency converters.

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Operating Instructions

Commissioning

5.1 Safety Instructions
See chapter 2 Safety for general safety instructions.
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when connected to AC mains input power. Failure to perform installation, start-up, and maintenance by qualified personnel could result in death or serious injury.
· Installation, start-up, and maintenance must be
performed by qualified personnel only.
Before applying power: 1. Close the cover properly. 2. Check that all cable glands are firmly tightened. 3. Ensure that input power to the unit is off and locked out. Do not rely on the frequency converter disconnect switches for input power isolation. 4. Verify that there is no voltage on input terminals L1 (91), L2 (92), and L3 (93), phase-to-phase, and phase-to-ground. 5. Verify that there is no voltage on output terminals 96 (U), 97 (V), and 98 (W), phase-tophase, and phase-to-ground. 6. Confirm continuity of the motor by measuring values on U-V (9697), V-W (9798), and W-U (98 96). 7. Check for proper grounding of the frequency converter as well as the motor. 8. Inspect the frequency converter for loose connections on the terminals. 9. Confirm that the supply voltage matches the voltage of the frequency converter and the motor.

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VLT® Refrigeration Drive FC 103 Low Harmonic Drive

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5.1.1 Pre-start

CAUTION
Before applying power to the unit, inspect the entire installation as detailed in Table 5.1. Check mark those items when completed.

Inspect for

Description

Auxiliary equipment

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

power side of the frequency converter or output side to the motor. Ensure that they are ready for

full speed operation.

· Check function and installation of any sensors used for feedback to the frequency converter.

· Remove power factor correction capacitors on motors, if present.

Cable routing

· Use separate metallic conduits for each of the following:

– Input power

– Motor wiring

– Control wiring

Control wiring

· Check for broken or damaged wires and loose connections.

· Check that control wiring is isolated from power and motor wiring for noise immunity.

· Check the voltage source of the signals.

· Use screened or twisted pair cable. Ensure that the screen is terminated correctly.

Cooling clearance

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

EMC considerations

· Check for proper installation regarding electromagnetic compatibility.

Environmental consider- · See equipment label for the maximum ambient operating temperature limits.

ations

· Humidity levels must be 595%, non-condensing.

Fusing and circuit breakers

· Check for proper fusing or circuit breakers.
· Check that all fuses are inserted firmly and in operational condition, and that all circuit breakers are
in the open position.

Grounding

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

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

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

Input and output power · Check for loose connections.

wiring

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

Panel interior

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

Switches

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

Vibration

· Check that the unit is mounted solidly or that shock mounts are used as necessary. · Check for an unusual amount of vibration.

Table 5.1 Start-up Checklist

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Operating Instructions

5.2 Applying Power
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when connected to AC mains. Installation, start-up, and maintenance should be performed by qualified personnel only. Failure to comply could result in death or serious injury.
WARNING
UNINTENDED START!
When the frequency converter is connected to AC mains, the motor may start at any time. The frequency converter, motor, and any driven equipment must be in operational readiness. Failure to comply could result in death, serious injury, equipment, or property damage.
1. Confirm that the input voltage is balanced within 3%. If not, correct input voltage imbalance before proceeding.
2. Ensure that optional equipment wiring, if present, matches the installation application.
3. Ensure that all operator devices are off. Panel doors should be closed or cover mounted.
4. Apply power to the unit. Do not start the frequency converter at this time. For units with a disconnect switch, turn the switch on to apply power.
NOTICE
If the status line at the bottom of the LCP reads AUTO REMOTE COASTING or Alarm 60 External Interlock is displayed, the unit is ready to operate but is missing an input signal on terminal 27.
5.3 Local Control Panel Operation
5.3.1 Local Control Panel
The local control panel (LCP) is the combined display and keypad on the front of the unit. The low harmonic drive includes 2 LCPs: 1 to control the frequency converter side and 1 to control the filter side.
The LCP has several functions:
· Control speed of frequency converter when in
local mode.
· Start and stop in local mode. · Display operational data, status, warnings, and
alarms.

Back 130BD512.10

· Programme frequency converter and active filter
functions.
· Manually reset the frequency converter or active
filter after a fault when auto-reset is inactive.
NOTICE
For commissioning via PC, install the VLT® Motion Control Tool MCT 10. The software is available for download (basic version) or for ordering (advanced version, order number 130B1000). For more information and downloads, see www.danfoss.com/BusinessAreas/ DrivesSolutions/Software+MCT10/MCT10+Downloads.htm.
5.3.2 LCP Layout
The LCP is divided into 4 functional groups (see Illustration 5.1).
A. Display area B. Display menu keys C. Navigation keys and indicator lights (LEDs) D. Operation keys and reset

1 Status

3 1(1)

0.0 %

0.00 A

0.00 kW

2 A

0.0Hz

5

2605 kWh

4

Off Remote Stop

6

9

B Status

Quick Menu

Main Menu

Alarm Log

7 8

Info Cancel

11

10

C

12

On

OK

15 Warn.

16

13

Alarm

17

D Hand on

Off

Auto on

Reset

14

18

19

20

21

Illustration 5.1 Local Control Panel (LCP)

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

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VLT® Refrigeration Drive FC 103 Low Harmonic Drive

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

Callout 1 2 3 4 5

Display 1.1 1.2 1.3 2 3

Parameter number 0-20 0-21 0-22 0-23 0-24

Default setting Reference % Motor current Power [kW] Frequency kWh counter

Table 5.2 Legend to Illustration 5.1, Display Area (Frequency Converter Side)

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

Callout 6 7
8 9

Key

Function

Status Shows operational information.

Quick Menu Allows access to programming

parameters for initial set-up instructions

and many detailed application

instructions.

Main Menu Allows access to all programming

parameters.

Alarm Log Displays a list of current warnings, the

last 10 alarms, and the maintenance log.

Table 5.3 Legend to Illustration 5.1, Display Menu Keys

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

Callout 10 11
12 13 14

Key Function Back Reverts to the previous step or list in the
menu structure. Cancel Cancels the last change or command as
long as the display mode has not changed. Info Press for a definition of the function being displayed. Navigation Press to move between items in the menu. keys OK Press to access parameter groups or to enable an option.

Table 5.4 Legend to Illustration 5.1, Navigation Keys

Callout 15
16 17

Indicator ON
WARN ALARM

Light Green
Yellow Red

Function The ON light activates when the frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V supply. When a warning is issued, the yellow WARN light comes on and text appears in the display area identifying the problem. A fault condition causes the red alarm light to flash and an alarm text is displayed.

Table 5.5 Legend to Illustration 5.1, Indicator Lights (LEDs)

D. Operation keys and reset Operation keys are located at the bottom of the LCP.

Callout 18
19 20
21

Key Hand On

Function
Starts the frequency converter in local control.
· An external stop signal by control
input or serial communication overrides the local hand on.

Off Auto On

Stops the operation but does not remove power to the frequency converter.
Puts the system in remote operational mode.
· Responds to an external start
command by control terminals or serial communication.

Reset

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

Table 5.6 Legend to Illustration 5.1, Operation Keys and Reset

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

5.3.3 Parameter Settings

Establishing the correct programming for applications often requires setting functions in several related parameters. Details for parameters are provided in chapter 9 Appendix A – Parameters.

Programming data is stored internally in the frequency converter.
· For back-up, upload data into the LCP memory. · To download data to another frequency
converter, connect the LCP to that unit and download the stored settings.

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Operating Instructions

· Restoring factory default settings does not
change data stored in the LCP memory.
5.3.4 Uploading/Downloading Data to/from the LCP
1. Press [Off] to stop operation before uploading or downloading data.
2. Press [Main Menu] parameter 0-50 LCP Copy and press [OK].
3. Select [1] All to LCP to upload data to the LCP or select [2] All from LCP to download data from the LCP.
4. Press [OK]. A progress bar shows the uploading or downloading progress.
5. Press [Hand On] or [Auto On] to return to normal operation.
5.3.5 Changing Parameter Settings
Access and change parameter settings from the Quick Menu or from the Main Menu. The Quick Menu only gives access to a limited number of parameters.
1. Press [Quick Menu] or [Main Menu] on the LCP.
2. Press [] [] to browse through the parameter groups, press [OK] to select a parameter group.
3. Press [] [] to browse through the parameters, press [OK] to select a parameter.
4. Press [] [] to change the value of a parameter setting.
5. Press [] [] to shift digit when a decimal parameter is in the editing state.
6. Press [OK] to accept the change.
7. Press either [Back] twice to enter Status, or press [Main Menu] once to enter the Main Menu.
View changes Quick Menu Q5 – Changes Made lists all parameters changed from default settings.
· The list only shows parameters, which are
changed in the current edit set-up.
· Parameters, which were reset to default values,
are not listed.
· The message Empty indicates that no parameters
are changed.

5.3.6 Restoring Default Settings
NOTICE
Risk of losing programming and monitoring records by restoration of default settings. To provide a back-up, upload data to the LCP before initialisation.
Restoring the default parameter settings is done by initialisation of the frequency converter. Initialisation is carried out through parameter 14-22 Operation Mode (recommended) or manually.
· Initialisation using parameter 14-22 Operation
Mode does not reset frequency converter settings, such as operating hours, serial communication selections, personal menu settings, fault log, alarm log, and other monitoring functions.
· Manual initialisation erases all motor,
programming, localisation, and monitoring data, and restores factory default settings.
Recommended initialisation procedure, via parameter 14-22 Operation Mode
1. Press [Main Menu] twice to access parameters.
2. Scroll to parameter 14-22 Operation Mode and press [OK].
3. Scroll to [2] Initialisation and press [OK].
4. Remove power to the unit and wait for the display to turn off.
5. Apply power to the unit.
Default parameter settings are restored during start-up. This may take slightly longer than normal.
6. Alarm 80 is displayed.
7. Press [Reset] to return to operation mode.
Manual initialisation procedure
1. Remove power to the unit and wait for the display to turn off.
2. Press and hold [Status], [Main Menu], and [OK] at the same time while applying power to the unit (approximately 5 s or until audible click and fan starts).
Factory default parameter settings are restored during start-up. This may take slightly longer than normal.
Manual initialisation does not reset the following frequency converter information:
· Parameter 15-00 Operating hours · Parameter 15-03 Power Up’s · Parameter 15-04 Over Temp’s · Parameter 15-05 Over Volt’s

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130BP066.10

130BP087.10

Commissioning

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

55

5.4 Basic Programming
5.4.1 VLT® Low Harmonic Drive Programming
The low harmonic drive includes 2 LCPs: 1 to control the frequency converter side and 1 to control the filter side. Because of this unique design, the detailed parameter information for the product is found in 2 places.
Detailed programming information for the frequency converter portion can be found in the relevant programming guide. Detailed programming information for the filter can be found in the VLT® Active Filter AAF 006 Operating Instructions. The remaining sections in this chapter apply to the frequency converter side. The active filter of the low harmonic drives is pre-configured for optimal performance and must only be turned on by pressing its [Hand On] key after the frequency converter side is commissioned.
5.4.2 Commissioning with SmartStart
The SmartStart wizard enables fast configuration of basic motor and application parameters.
· SmartStart starts automatically at first power-up
or after initialisation of the frequency converter.
· Follow the on-screen instructions to complete the
commissioning of the frequency converter. Always reactivate SmartStart by selecting Quick Menu Q4 – SmartStart.
· For commissioning without use of the SmartStart
wizard, refer to chapter 5.4.3 Commissioning via [Main Menu] or the programming guide.
NOTICE
Motor data is required for the SmartStart set-up. The required data is normally available on the motor nameplate.
5.4.3 Commissioning via [Main Menu] Recommended parameter settings are intended for startup and check-out purposes. Application settings may vary.
Enter data with power ON, but before operating the frequency converter.
1. Press [Main Menu] on the LCP.
2. Press the navigation keys to scroll to parameter group 0-** Operation/Display and press [OK].

1107 RPM

3.84 A

1 (1)

Main Menu

0 – Operation/Display 1 – Load/Motor 2 – Brakes 3 – Reference / Ramps

Illustration 5.2 Main Menu

3. Press the navigation keys to scroll to parameter group 0-0* Basic Settings and press [OK].

0.0%

0.00A

Operation / Display

0-0 Basic Settings 0-1 Set-up Operations 0-2 LCP Display 0-3 LCP Custom Readout

1(1)
0-**

Illustration 5.3 Operation/Display

4. Press the navigation keys to scroll to parameter 0-03 Regional Settings and press [OK].

0.0% Basic Settings

0.00A

0-03 Regional Settings

1(1) 0-0*

[0] International
Illustration 5.4 Basic Settings
5. Press the navigation keys to select [0] International or [1] North America as appropriate and press [OK]. (This changes the default settings for a number of basic parameters).
6. Press [Main Menu] on the LCP. 7. Press the navigation keys to scroll to
parameter 0-01 Language. 8. Select the language and press [OK]. 9. If a jumper wire is in place between control
terminals 12 and 27, leave parameter 5-12 Terminal 27 Digital Input at factory default. Otherwise, select [0] No Operation in parameter 5-12 Terminal 27 Digital Input.

130BP088.10

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Operating Instructions

10. Make the application-specific settings in the following parameters: 10a Parameter 3-02 Minimum Reference. 10b Parameter 3-03 Maximum Reference. 10c Parameter 3-41 Ramp 1 Ramp Up Time. 10d Parameter 3-42 Ramp 1 Ramp Down Time. 10e Parameter 3-13 Reference Site. Linked to Hand/Auto Local Remote.
5.4.4 Asynchronous Motor Set-up
Enter the following motor data. The information can be found on the motor nameplate.
1. Parameter 1-20 Motor Power [kW] or parameter 1-21 Motor Power [HP].
2. Parameter 1-22 Motor Voltage. 3. Parameter 1-23 Motor Frequency. 4. Parameter 1-24 Motor Current. 5. Parameter 1-25 Motor Nominal Speed. When running in flux control principle, or for optimum performance in VVC+ mode, extra motor data is required to set up the following parameters. Find the data in the motor datasheet (this data is typically not available on the motor nameplate). Run a complete AMA using parameter 1-29 Automatic Motor Adaptation (AMA) [1] Enable Complete AMA or enter the parameters manually. Parameter 1-36 Iron Loss Resistance (Rfe) is always entered manually. 1. Parameter 1-30 Stator Resistance (Rs). 2. Parameter 1-31 Rotor Resistance (Rr). 3. Parameter 1-33 Stator Leakage Reactance (X1). 4. Parameter 1-34 Rotor Leakage Reactance (X2). 5. Parameter 1-35 Main Reactance (Xh). 6. Parameter 1-36 Iron Loss Resistance (Rfe).
Application-specific adjustment when running VVC+ VVC+ is the most robust control mode. In most situations, it provides optimum performance without further adjustments. Run a complete AMA for best performance. Application- specific adjustment when running Flux Flux control principle is the preferred control principle for optimum shaft performance in dynamic applications. Perform an AMA since this control mode requires precise motor data. Depending on the application, further adjustments may be required. See Table 5.7 for application-related recommendations.

Application Low-inertia applications High-inertia applications
High load at low speed
No-load application Flux sensorless control principle only

Settings Keep calculated values. Parameter 1-66 Min. Current at Low Speed. Increase current to a value between default and maximum depending on the application. Set ramp times matching the application. Too fast ramp up causes an overcurrent or overtorque. Too fast ramp down causes an overvoltage trip. Parameter 1-66 Min. Current at Low Speed. Increase current to a value between default and maximum depending on the application. Adjust parameter 1-18 Min. Current at No Load to achieve smoother motor operation by reducing torque ripple and vibration. Adjust parameter 1-53 Model Shift Frequency. Example 1: If the motor oscillates at 5 Hz and dynamics performance is required at 15 Hz, set parameter 1-53 Model Shift Frequency to 10 Hz. Example 2: If the application involves dynamic load changes at low speed, reduce parameter 1-53 Model Shift Frequency. Observe the motor behaviour to make sure that the model shift frequency is not reduced too much. Symptoms of inappropriate model shift frequency are motor oscillations or frequency converter tripping.

Table 5.7 Recommendations for Flux Applications

5.4.5 Permanent Magnet Motor Set-up

NOTICE
Only use permanent magnet (PM) motor with fans and pumps.

Initial programming steps
1. Activate PM motor operation in parameter 1-10 Motor Construction, select [1] PM, non-salient SPM.
2. Set parameter 0-02 Motor Speed Unit to [0] RPM.

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Commissioning

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

55

Programming motor data After selecting PM motor in parameter 1-10 Motor Construction, the PM motor-related parameters in parameter groups 1-2 Motor Data, 1-3 Adv. Motor Data, and 1-4* are active. Find the necessary data on the motor nameplate and in the motor data sheet. Program the following parameters in the listed order:
1. Parameter 1-24 Motor Current.
2. Parameter 1-26 Motor Cont. Rated Torque.
3. Parameter 1-25 Motor Nominal Speed.
4. Parameter 1-39 Motor Poles.
5. Parameter 1-30 Stator Resistance (Rs). Enter line-to-common stator winding resistance (Rs). If only line-line data are available, divide the line-line value with 2 to achieve the line to common (starpoint) value. It is also possible to measure the value with an ohmmeter, which takes the resistance of the cable into account. Divide the measured value by 2 and enter the result.
6. Parameter 1-37 d-axis Inductance (Ld). Enter line-to-common direct axis inductance of the PM motor. If only line-line data are available, divide the lineline value with 2 to achieve the line-common (starpoint) value. It is also possible to measure the value with an inductancemeter, which takes the inductance of the cable into account. Divide the measured value by 2 and enter the result.
7. Parameter 1-40 Back EMF at 1000 RPM Enter line-line back EMF of PM Motor at 1000 RPM mechanical speed (RMS value). Back EMF is the voltage generated by a PM motor when no frequency converter is connected and the shaft is turned externally. Back EMF is normally specified for nominal motor speed or for 1000 RPM measured between 2 lines. If the value is not available for a motor speed of 1000 RPM, calculate the correct value as follows: If back EMF is for example 320 V at 1800 RPM, it can be calculated at 1000 RPM as follows: Back EMF = (Voltage/RPM)x1000 = (320/1800)x1000 = 178. Program this value for parameter 1-40 Back EMF at 1000 RPM.
Test motor operation
1. Start the motor at low speed (100200 RPM). If the motor does not turn, check installation, general programming, and motor data.
2. Check if start function in parameter 1-70 PM Start Mode fits the application requirements.

Rotor detection This function is the recommended choice for applications where the motor starts from standstill, for example pumps or conveyors. On some motors, a sound is heard when the impulse is sent out. This does not harm the motor.
Parking This function is the recommended choice for applications where the motor is rotating at slow speed for example windmilling in fan applications. Parameter 2-06 Parking Current and parameter 2-07 Parking Time can be adjusted. Increase the factory setting of these parameters for applications with high inertia.
Start the motor at nominal speed. If the application does not run well, check the VVC+ PM settings. Table 5.7 shows recommendations in different applications.

Application Low-inertia applications ILoad/IMotor <5
Low-inertia applications 50>ILoad/IMotor >5 High-inertia applications ILoad/IMotor > 50
High load at low speed <30% (rated speed)

Settings Increase parameter 1-17 Voltage filter time const. by factor 510 Reduce parameter 1-14 Damping Gain. Reduce parameter 1-66 Min. Current at Low Speed (<100%). Keep the calculated values.
Increase parameter 1-14 Damping Gain, parameter 1-15 Low Speed Filter Time Const., and parameter 1-16 High Speed Filter Time Const.. Increase parameter 1-17 Voltage filter time const.. Increase parameter 1-66 Min. Current at Low Speed (>100% for a prolonged time can overheat the motor).

Table 5.8 Recommendations in Different Applications

If the motor starts oscillating at a certain speed, increase parameter 1-14 Damping Gain. Increase the value in small steps. Depending on the motor, a good value for this parameter can be 10% or 100% higher than the default value.

Adjust starting torque in parameter 1-66 Min. Current at Low Speed. 100% provides nominal torque as starting torque.
5.4.6 Automatic Energy Optimisation (AEO)

NOTICE
AEO is not relevant for permanent magnet motors.

AEO is a procedure which minimises voltage to the motor, thereby reducing energy consumption, heat, and noise.

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Operating Instructions

To activate AEO, set parameter 1-03 Torque Characteristics to [2] Auto Energy Optim. CT or [3] Auto Energy Optim. VT.
5.4.7 Automatic Motor Adaptation (AMA)
AMA is a procedure which optimises compatibility between the frequency converter and the motor.
· The frequency converter builds a mathematical
model of the motor for regulating output motor current. The procedure also tests the input phase balance of electrical power. It compares the motor characteristics with the entered nameplate data.
· The motor shaft does not turn and no harm is
done to the motor while running the AMA.
· Some motors may be unable to run the complete
version of the test. In that case, select [2] Enable reduced AMA.
· If an output filter is connected to the motor,
select [2] Enable reduced AMA.
· If warnings or alarms occur, see
chapter 7 Diagnostics and Troubleshooting.
· Run this procedure on a cold motor for best
results.
To run AMA 1. Press [Main Menu] to access parameters.
2. Scroll to parameter group 1-* Load and Motor and press [OK].
3. Scroll to parameter group 1-2 Motor Data and press [OK].
4. Scroll to parameter 1-29 Automatic Motor Adaptation (AMA) and press [OK].
5. Select [1] Enable complete AMA and press [OK].
6. Follow the on-screen instructions.
7. The test runs automatically and indicates when it is complete.
8. The advanced motor data is entered in parameter group 1-3* Adv. Motor Data.
5.5 Checking Motor Rotation
NOTICE
Risk of damage to pumps/compressors caused by motor running in wrong direction. Before running the frequency converter, check the motor rotation.
The motor runs briefly at 5 Hz or the minimum frequency set in parameter 4-12 Motor Speed Low Limit [Hz].

1. Press [Main Menu].
2. Scroll to parameter 1-28 Motor Rotation Check and press [OK].
3. Scroll to [1] Enable.
The following text appears: Note! Motor may run in wrong direction.
4. Press [OK].
5. Follow the on-screen instructions.
NOTICE
To change the direction of rotation, remove power to the frequency converter and wait for power to discharge. Reverse the connection of any 2 of the 3 motor wires on the motor or frequency converter side of the connection.
5.6 Local-control Test
1. Press [Hand On] to provide a local start command to the frequency converter.
2. Accelerate the frequency converter by pressing [] to full speed. Moving the cursor left of the decimal point provides quicker input changes.
3. Note any acceleration problems.
4. Press [Off]. Note any deceleration problems.
In the event of acceleration or deceleration problems, see . See chapter 7.3 Warning and Alarm Definitions for Frequency Converter for resetting the frequency converter after a trip.
5.7 System Start-up
The procedure in this section requires wiring and application programming to be completed. The following procedure is recommended after application set-up is completed.
1. Press [Auto On].
2. Apply an external run command.
3. Adjust the speed reference throughout the speed range.
4. Remove the external run command.
5. Check the sound and vibration levels of the motor to ensure that the system is working as intended.
If warnings or alarms occur, see chapter 7.3 Warning and Alarm Definitions for Frequency Converter or chapter 7.4 Warnings and Alarm Definitions – Active Filter.

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Application Examples

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

6 Application Examples

66

6.1 Introduction
The examples in this section are intended as a quick reference for common applications.
· Parameter settings are the regional default values
unless otherwise indicated (selected in parameter 0-03 Regional Settings).
· Parameters associated with the terminals and
their settings are shown next to the drawings.
· Required switch settings for analog terminals A53
or A54 are also shown.
NOTICE
When using the optional STO feature, a jumper wire may be required between terminal 12 (or 13) and terminal 37 for the frequency converter to operate with factory default programming values.

NOTICE
The following examples refer only to the frequency converter control card (right LCP), not the filter.

6.2 Application Examples 6.2.1 Speed

FC

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10 V

50

A IN

53

A IN

54

COM

55

A OUT 42

COM

39

U – I

Parameters

Function

Setting

Parameter 6-10 T 0.07 V*

erminal 53 Low

Voltage

Parameter 6-11 T 10 V*

erminal 53 High

Voltage

Parameter 6-14 T 0 Hz

erminal 53 Low

Ref./Feedb. Value

Parameter 6-15 T 50 Hz

erminal 53 High

Ref./Feedb. Value

= Default value

Notes/comments:

–

D IN 37 is an option.

-10 – +10V

A53
Table 6.1 Analog Speed Reference (Voltage)

130BB926.10 130BB683.10

FC

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10 V

50

A IN

53

A IN

54

COM

55

A OUT

42

COM

39

U – I

Parameters

130BB927.10

Function

Setting

Parameter 6-12 T 4 mA*

erminal 53 Low

Current

Parameter 6-13 T 20 mA*

erminal 53 High

Current

Parameter 6-14 T 0 Hz

erminal 53 Low

Ref./Feedb. Value

Parameter 6-15 T 50 Hz

erminal 53 High

Ref./Feedb. Value

= Default value

Notes/comments:
–
4 – 20mA D IN 37 is an option.

A53

Table 6.2 Analog Speed Reference (Current)

FC

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10 V

50

A IN

53

A IN

54

COM

55

A OUT

42

COM

39

Parameters

Function

Setting

Parameter 6-10 T 0.07 V*

erminal 53 Low

Voltage

Parameter 6-11 T 10 V*

erminal 53 High

Voltage

Parameter 6-14 T 0 Hz

erminal 53 Low

Ref./Feedb. Value

Parameter 6-15 T 1500 Hz

erminal 53 High

Ref./Feedb. Value 5k

= Default value

Notes/comments:

D IN 37 is an option.

U – I

A53 Table 6.3 Speed Reference (Using a Manual Potentiometer)

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MG16N102

130BB804.10 130BB802.10

Application Examples

Operating Instructions

FC

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10 V

50

A IN

53

A IN

54

COM

55

A OUT

42

COM

39

Parameters

Function

Setting

Parameter 5-10 T [8] Start*

erminal 18

Digital Input

Parameter 5-12 T [19] Freeze

erminal 27

Reference

Digital Input

Parameter 5-13 T [21] Speed Up

erminal 29

Digital Input

Parameter 5-14 T [22] Speed

erminal 32

Down

Digital Input

= Default value

Notes/comments:

D IN 37 is an option.

6.2.2 Start/Stop

FC

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10

50

A IN

53

A IN

54

COM

55

A OUT

42

COM

39

Parameters

Function

Setting

Parameter 5-10 T [8] Start

erminal 18

Digital Input

Parameter 5-12 T [0] No

erminal 27

operation

Digital Input

Parameter 5-19 T [1] Safe Stop

erminal 37 Safe Alarm

Stop

= Default value

Notes/comments:

If parameter 5-12 Terminal 27

Digital Input is set to [0] No

operation, a jumper wire to

terminal 27 is not needed.

D IN 37 is an option.

66

Table 6.4 Speed Up/Down

Table 6.5 Start/Stop Command with Safe Stop Option
Speed

130BB840.11 130BB805.11

Speed Reference
Start ( 18) Freeze ref ( 27) Speed up ( 29 ) Speed down ( 32 )
Illustration 6.1 Speed Up/Down

Start (18)
Illustration 6.2 Start/Stop Command with Safe Stop

MG16N102

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Application Examples

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

66

FC

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10 V

50

A IN

53

A IN

54

COM

55

A OUT

42

COM

39

Parameters

Function

Setting

Parameter 5-10 T [9] Latched

erminal 18

Start

Digital Input

Parameter 5-12 T [6] Stop

erminal 27

Inverse

Digital Input

= Default value

Notes/comments:

If parameter 5-12 Terminal 27

Digital Input is set to [0] No

operation, a jumper wire to

terminal 27 is not needed.

D IN 37 is an option.

Table 6.6 Pulse Start/Stop
Speed

Latched Start (18) Stop Inverse (27)
Illustration 6.3 Latched Start/Stop Inverse

130BB806.10 130BB928.10

130BB803.10 130BB934.10

FC

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10 V

50

A IN

53

A IN

54

COM

55

A OUT

42

COM

39

Parameters

Function

Setting

Parameter 5-10 Ter [8] Start

minal 18 Digital

Input

Parameter 5-11 Ter [10]

minal 19 Digital Reversing

Input

Parameter 5-12 Ter [0] No minal 27 Digital operation Input Parameter 5-14 Ter [16] Preset minal 32 Digital ref bit 0 Input Parameter 5-15 Ter [17] Preset minal 33 Digital ref bit 1 Input Parameter 3-10 Pre set Reference Preset reference 0 25% Preset reference 1 50% Preset reference 2 75% Preset reference 3 100% * = Default value Notes/comments: D IN 37 is an option.

Table 6.7 Start/Stop with Reversing and 4 Preset Speeds
6.2.3 External Alarm Reset

FC

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10 V

50

A IN

53

A IN

54

COM

55

A OUT

42

COM

39

Parameters

Function

Setting

Parameter 5-11 T [1] Reset

erminal 19

Digital Input

= Default value

Notes/comments:

D IN 37 is an option.

Table 6.8 External Alarm Reset

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MG16N102

Application Examples

Operating Instructions

6.2.4 RS485

FC

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10 V

50

A IN

53

A IN

54

COM

55

A OUT

42

COM

39

130BB685.10

Parameters

Function

Setting

Parameter 8-30 P

rotocol

FC*

Parameter 8-31 A 1*

ddress

Parameter 8-32 B 9600*

aud Rate

= Default value

Notes/comments: Select protocol, address, and baud rate in the abovementioned parameters. D IN 37 is an option.

R1

01 02 03

R2

04

05

06

RS-485

61 +
68
69 –

Table 6.9 RS485 Network Connection

6.2.5 Motor Thermistor
WARNING
THERMISTOR INSULATION
Risk of personal injury or equipment damage.
· Use only thermistors with reinforced or double
insulation to meet PELV insulation requirements.

VLT

+24 V

12

+24 V

13

D IN

18

D IN

19

COM

20

D IN

27

D IN

29

D IN

32

D IN

33

D IN

37

+10 V

50

A IN

53

A IN

54

COM

55

A OUT

42

COM

39

130BB686.12

Parameters

Function

Setting

Parameter 1-90 [2] Thermistor

Motor Thermal trip

Protection

Parameter 1-93 T [1] Analog

hermistor Source input 53

= Default Value

Notes/comments: If only a warning is required, parameter 1-90 Motor Thermal Protection should be set to [1] Thermistor warning. D IN 37 is an option.

U – I

A53

Table 6.10 Motor Thermistor

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65

Diagnostics and Troubleshoo…

VLT® Refrigeration Drive FC 103 Low Harmonic Drive

Diagnostics and Troubleshooting

7.1 Status Messages
When the frequency converter is in Status mode, status messages are generated automatically and appear in the bottom line of the display (see Illustration 7.1). Refer to the VLT® Refrigeration Drive FC 103 Programming Guide for detailed descriptions of the displayed status messages.

130BB037.11

Status 799RPM

7.83A 0.000 53.2%

1(1) 36.4kW

77

Auto Remote Hand Local Off

1

2

Ramping Stop Running Jogging . . . Stand by
3

1 Operation mode 2 Reference site 3 Operation status
Illustration 7.1 Status Display

7.2 Warning and Alarm Types
The frequency converter monitors the condition of its input power, output, and motor factors, as well as other system performance indicators. A warning or alarm does not necessarily indicate a problem internally in the frequency converter. In many cases, it indicates failure conditions from:
· Input voltage. · Motor load. · Motor temperature. · External signals. · Other areas monitored by internal logic.
Investigate as indicated in the alarm or warning.
7.2.1 Warnings
A warning is issued when an alarm condition is impending or when an abnormal operating condition is present and may result in the frequency converter issuing an alarm. A warning clears by itself when the abnormal condition is removed.

7.2.2 Alarm Trip
An alarm is issued when the frequency converter is tripped, that is, the frequency converter suspends operation to prevent frequency converter or system damage. The motor coasts to a stop, if the alarm trip is on the frequency converter side. The frequency converter logic continues to operate and monitors the frequency converter status. After the fault condition is remedied, reset the frequency converter. It is then ready to restart operation.
A trip can be reset in any of 4 ways:
· Press [Reset] on the LCP. · Digital reset input command. · Serial communication reset input command. · Auto reset.
7.2.3 Alarm Trip-lock
An alarm that causes the frequency converter to trip-lock requires that input power is cycled. If the alarm trip is on the frequency converter side, the motor coasts to a stop. The frequency converter logic continues to operate and monitors the frequency converter status. Remove input power to the frequency converter and correct the cause of the fault, then restore power. This action puts the frequency converter into a trip condition as described in chapter 7.2.2 Alarm Trip and may be reset in any of the 4 ways.
7.3 Warning and Alarm Definitions for Frequency Converter
The following warning/alarm information defines each warning/alarm condition, provides the probable cause for the condition, and details a remedy or troubleshooting procedure.
WARNING 1, 10 Volts low The control card voltage is <10 V from terminal 50. Remove some of the load from terminal 50, as the 10 V supply is overloaded. Maximum 15 mA or minimum 590 .
A short circuit in a connected potentiometer or incorrect wiring of the potentiometer can cause this condition.
Troubleshooting
· Remove the wiring from terminal 50. If the
warning clears, the problem is with the wiring. If the warning does not clear, replace the control card.

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Diagnostics and Troubleshoo…

Operating Instructions

WARNING/ALARM 2, Live zero error This warning or alarm only appears if programmed in parameter 6-01 Live Zero Timeout Function. The signal on 1 of the analog inputs is less than 50% of the minimum value programmed for that input. Broken wiring or a faulty device sending the signal can cause this condition.

Troubleshooting

· Check the connections on all the analog mains
terminals.
– Control card terminals 53 and 54 for signals, terminal 55 common.
– VLT® General Purpose I/O MCB 101 terminals 11 and 12 for signals, terminal 10 common.
– VLT® Analog I/O Option MCB 109 terminals 1, 3, and 5 for signals, terminals 2, 4, and 6 common.
· Check that the frequency converter programming
and switch settings match the analog signal type.
· Perform an input terminal signal test.
WARNING/ALARM 3, No motor No motor has been connected to the output of the frequency converter.
WARNING/ALARM 4, Mains phase loss A phase is missing on the supply side, or the mains voltage imbalance is too high. This message also appears for a fault in the input rectifier on the frequency converter. Options are programmed in parameter 14-12 Function at Mains Imbalance.
Troubleshooting
· Check the supply voltage and supply currents to
the frequency converter.
WARNING 5, DC link voltage high The DC-link voltage (DC) is higher than the high-voltage warning limit. The limit depends on the frequency converter voltage rating. The unit is still active.
WARNING 6, DC link voltage low The DC-link voltage (DC) is lower than the low- voltage warning limit. The limit depends on the frequency converter voltage rating. The unit is still active.
WARNING/ALARM 7, DC overvoltage If the DC-link voltage exceeds the limit, the frequency converter trips after a time.
Troubleshooting
· Connect a brake resistor. · Extend the ramp time. · Change the ramp type. · Activate the functions in parameter 2-10 Brake
Function.

· Increase parameter 14-26 Trip Delay at Inverter
Fault.
· If the alarm/warning occurs during a power sag,
use kinetic back-up (parameter 14-10 Mains Failure).
WARNING/ALARM 8, DC under voltage If the DC-link voltage drops below the undervoltage limit, the frequency converter checks if a 24 V DC back-up supply is connected. If no 24 V DC back-up supply is connected, the frequency converter trips after a fixed time delay. The time delay varies with unit size.
Troubleshooting
· Check that the supply voltage matches the
frequency converter voltage.
· Perform an input voltage test. · Perform a soft charge circuit test.
WARNING/ALARM 9, Inverter overload The frequency converter has run with more than 100% overload for too long and is about to cut out. The counter for electronic thermal inverter protection issues a warning at 98% and trips at 100%, while giving an alarm. The frequency converter cannot be reset until the counter is below 90%.
Troubleshooting
· Compare the output current shown on the LCP
with the frequency converter rated current.
· Compare the output current shown on the LCP
with the measured motor current.
· Show the thermal frequency converter load on
the LCP and monitor the value. When running above the frequency converter continuous current rating, the counter increases. When running below the frequency converter continuous current rating, the counter decreases.
WARNING/ALARM 10, Motor overload temperature According to the electronic thermal protection (ETR), the motor is too hot. Select whether the frequency converter issues a warning or an alarm when the counter reaches 100% in parameter 1-90 Motor Thermal Protection. The fault occurs when the motor runs with more than 100% overload for too long.
Troubleshooting
· Check for motor overheating. · Check if the motor is mechanically overloaded. · Check that the motor current set in
parameter 1-24 Motor Current is correct.
· Ensure that the motor data in parameters 120 to
125 are set correctly.
· If an external fan is in use, check that it is
selected in parameter 1-91 Motor External Fan.

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· Running AMA in parameter 1-29 Automatic Motor
Adaptation (AMA) tunes the frequency converter to the motor more accurately and reduces thermal loading.
WARNING/ALARM 11, Motor thermistor overtemp The thermistor may be disconnected. Select whether the frequency converter issues a warning or an alarm in parameter 1-90 Motor Thermal Protection.
Troubleshooting
· Check for motor overheating. · Check if the motor is mechanically overloaded. · Check that the thermistor is connected correctly
between either terminal 53 or 54 (analog voltage input) and terminal 50 (+10 V supply). Also check that the terminal switch for 53 or 54 is set for voltage. Check that parameter 1-93 Thermistor Resource is set to terminal 53 or 54.
· When using digital inputs 18 or 19, check that
the thermistor is connected correctly between either terminal 18 or 19 (digital input PNP only) and terminal 50.
· If a KTY sensor is used, check for correct
connection between terminals 54 and 55.
· If using a thermal switch or thermistor, check that
the programming of parameter 1-93 Thermistor Resource matches sensor wiring.
· If using a KTY sensor, check the programming of
parameter 1-95 KTY Sensor Type, parameter 1-96 KTY Thermistor Resource, and parameter 1-97 KTY Threshold level match sensor wiring.
WARNING/ALARM 12, Torque limit The torque has exceeded the value in parameter 4-16 Torque Limit Motor Mode or the value in parameter 4-17 Torque Limit Generator Mode. Parameter 14-25 Trip Delay at Torque Limit can change this warning from a warning-only condition to a warning followed by an alarm.
Troubleshooting
· If the motor torque limit is exceeded during
ramp-up, extend the ramp-up time.
· If the generator torque limit is exceeded during
ramp-down, extend the ramp-down time.
· If torque limit occurs while running, increase the
torque limit. Make sure that the system can operate safely at a higher torque.
· Check the application for excessive current draw
on the motor.
WARNING/ALARM 13, Over current The inverter peak current limit (approximately 200% of the rated current) is exceeded. The warning lasts approximately 1.5 s, then the frequency converter trips and issues an

alarm. Shock loading or quick acceleration with high-inertia loads can cause this fault. If the acceleration during rampup is quick, the fault can also appear after kinetic back-up. If extended mechanical brake control is selected, a trip can be reset externally.
Troubleshooting
· Remove the power and check if the motor shaft
can be turned.
· Check that the motor size matches the frequency
converter.
· Check that the motor data is correct in
parameters 120 to 125.
ALARM 14, Earth (ground) fault There is current from the output phases to ground, either in the cable between the frequency converter and the motor, or in the motor itself.
Troubleshooting
· Remove the power to the frequency converter
and repair the ground fault.
· Check for ground faults in the motor by
measuring the resistance to the ground of the motor cables and the motor with a megohmmeter.
· Perform a current sensor test.
ALARM 15, Hardware mismatch A fitted option is not operational with the present control board hardware or software.
Record the value of the following parameters and contact Danfoss:
· Parameter 15-40 FC Type. · Parameter 15-41 Power Section. · Parameter 15-42 Voltage. · Parameter 15-43 Software Version. · Parameter 15-45 Actual Typecode String. · Parameter 15-49 SW ID Control Card. · Parameter 15-50 SW ID Power Card. · Parameter 15-60 Option Mounted. · Parameter 15-61 Option SW Version (for each
option slot).
ALARM 16, Short circuit There is short-circuiting in the motor or motor wiring.
Troubleshooting
· Remove the power to the frequency converter
and repair the short circuit.
WARNING/ALARM 17, Control word timeout There is no communication with the frequency converter. The warning is only active when parameter 8-04 Control Word Timeout Function is not set to [0] Off.

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Operating Instructions

If parameter 8-04 Control Word Timeout Function is set to [2] Stop and [26] Trip, a warning appears and the frequency converter ramps down until it trips and then displays an alarm.
Troubleshooting
· Check the connections on the serial communi-
cation cable.
· Increase parameter 8-03 Control Word Timeout
Time
· Check the operation of the communication
equipment.
· Verify a proper installation based on EMC
requirements.
WARNING/ALARM 22, Hoist mechanical brake Report value shows what kind it is. 0 = The torque reference was not reached before timeout (parameter 2-27 Torque Ramp Up Time). 1 = Expected brake feedback not received before timeout (parameter 2-23 Activate Brake Delay, parameter 2-25 Brake Release Time).
WARNING 23, Internal fan fault The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ([0] Disabled).
Troubleshooting
· Check the fan resistance. · Check the soft charge fuses.
WARNING 24, External fan fault The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ([0] Disabled).
Troubleshooting
· Check the fan resistance. · Check the soft charge fuses.
WARNING 25, Brake resistor short circuit The brake resistor is monitored during operation. If a short circuit occurs, the brake function is disabled and the warning appears. The frequency converter is still operational, but without the brake function.
Troubleshooting
· Remove the power to the frequency converter
and replace the brake resistor (see parameter 2-15 Brake Check).
WARNING/ALARM 26, Brake resistor power limit The power transmitted to the brake resistor is calculated as a mean value over the last 120 s of run time. The calculation is based on the intermediate circuit voltage and the brake resistance value set in parameter 2-16 AC brake Max. Current. The warning is active when the dissipated braking is >90% of the brake resistance power. If [2] Trip is

selected in parameter 2-13 Brake Power Monitoring, the frequency converter trips when the dissipated braking power reaches 100%.
WARNING
If the brake transistor is short-circuited, there is a risk of substantial power being transmitted to the brake resistor.
WARNING/ALARM 27, Brake chopper fault This alarm/warning could occur if the brake resistor overheats. Terminals 104 and 106 are available as brake resistors Klixon inputs.
NOTICE
This signal feedback is used by LHD to monitor the temperature of the HI inductor. This fault indicates that Klixon opened on the HI inductor at the active filter side.
WARNING/ALARM 28, Brake check failed The brake resistor is not connected or not working. Check parameter 2-15 Brake Check.
ALARM 29, Heat Sink temp The maximum temperature of the heat sink has been exceeded. The temperature fault resets when the temperature falls below a defined heat sink temperature. The trip and reset points vary based on the frequency converter power size.
Troubleshooting Check for the following conditions.
· Ambient temperature too high. · Motor cables too long. · Incorrect airflow clearance above and below the
frequency converter.
· Blocked airflow around the frequency converter. · Damaged heat sink fan. · Dirty heat sink.
For D, E, and F enclosures, this alarm is based on the temperature measured by the heat sink sensor mounted inside the IGBT modules. For the F enclosures, the thermal sensor in the rectifier module can also cause this alarm.
Troubleshooting
· Check the fan resistance. · Check the soft charge fuses. · Check the IGBT thermal sensor.
ALARM 30, Motor phase U missing Motor phase U between the frequency converter and the motor is missing.
Troubleshooting
· Remove the power from the frequency converter
and check motor phase U.

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ALARM 31, Motor phase V missing Motor phase V between the frequency converter and the motor is missing.
Troubleshooting
· Remove the power from the frequency converter
and check motor phase V.
ALARM 32, Motor phase W missing Motor phase W between the frequency converter and the motor is missing.
Troubleshooting
· Remove the power from the frequency converter
and check motor phase W.
ALARM 33, Inrush fault Too many power-ups have occurred within a short time period.
Troubleshooting
· Let the unit cool to operating temperature.
WARNING/ALARM 34, Fieldbus communication fault The fieldbus on the communication option card is not working.
WARNING/ALARM 36, Mains failure This warning/alarm is only active if the supply voltage to the frequency converter is lost and parameter 14-10 Mains Failure is not set to option [0] No Function. Check the fuses to the frequency converter and mains supply to the unit.
ALARM 38, Internal fault When an internal fault occurs, a code number defined in Table 7.1 is displayed.
Troubleshooting
· Cycle the power. · Check that the option is properly installed. · Check for loose or missing wiring.
It may be necessary to contact Danfoss Service or the supplier. Note the code number for further troubleshooting directions.

Number 0
256258 512
513 514 515
516
517 518 519

Text The serial port cannot be initialised. Contact the Danfoss supplier or Danfoss Service. The power EEPROM data is defective or too old. The control board EEPROM data is defective or too old. Communication time-out reading EEPROM data. Communication time-out reading EEPROM data. Application-oriented control cannot recognise the EEPROM data. Cannot write to the EEPROM because a write command is in progress. The write command is under timeout. Failure in the EEPROM. Missing or invalid barcode data in EEPROM.

Number Text 783 Parameter value outside of minimum/maximum limits.
10241279 A CAN telegram could not be sent. 1281 Digital signal processor flash timeout. 1282 Power micro software version mismatch. 1283 Power EEPROM data version mismatch. 1284 Cannot read digital signal processor software version. 1299 The option software in slot A