Danfoss FC103-110-250Kw Manuale utente

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT®Refrigeration Drive 110-250 kW

Contents

1 Safety 4

2 Introduction 5

2.1 Exploded Views 5

2.2 Purpose of the Manual 6

2.3 Additional Resources 6

2.4 Product Overview 6

2.5 Internal Controller Functions 6

3 Installation 8

3.1 Planning the Installation Site 8

3.2 Pre-Installation Checklist 8

3.3 Mechanical Installation 8

3.3.1 Cooling 8

3.3.2 Lifting 9

3.4 Electrical Installation 9

3.4.1 General Requirements 9

3.4.2 Earth (Ground) Requirements 12

3.4.2.1 Leakage Current (>3.5 mA) 12

3.4.2.2 Earthing (Grounding) IP20 Enclosures 13

3.4.2.3 Earthing (Grounding) IP21/54 Enclosures 13

3.4.3 Motor Connection 14

3.4.3.1 Motor Cable 17

3.4.3.2 Motor Rotation Check 17

3.4.4 AC Mains Input Connection 17

3.5 Control Wiring Connection 18

3.5.1 Access 18

3.5.2 Using Screened Control Cables 18

3.5.3 Earthing (Grounding) of Screened Control Cables 18

3.5.4 Control Terminal Types 19

3.5.5 Wiring to Control Terminals 19

3.5.6 Control Terminal Functions 19

3.6 Serial Communication 19

4 Start Up and Functional Test 21

4.1 Pre-start 21

4.2 Applying Power to the Frequency Converter 22

4.3 Basic Operational Programming 22

4.3.1 Set-up Wizard 22

4.4 Local-control Test 28

Contents VLT® Refrigeration Drive 110-250 kW Operating Instructions

MG16F102 - VLT® is a registered Danfoss trademark 1

4.5 System Start Up 29

5 User Interface 30

5.1 Local Control Panel 30

5.1.1 LCP Layout 30

5.1.2 Setting LCP Display Values 31

5.1.3 Display 31

5.1.4 Navigation Keys 32

5.1.5 Operation Keys 32

5.2 Back Up and Copying Parameter Settings 32

5.2.1 Uploading Data to the LCP 33

5.2.2 Downloading Data from the LCP 33

5.3 Restoring Default Settings 33

5.3.1 Recommended Initialisation 33

5.3.2 Manual Initialisation 33

6 Programming 34

6.1 Introduction 34

6.2 Programming Example 34

6.3 Control Terminal Programming Examples 35

6.4 International/North American Default Parameter Settings 36

6.5 Parameter Menu Structure 37

6.5.1 Quick Menu Structure 38

6.5.2 Main Menu Structure 40

7 Application Set-Up Examples 44

7.1 Introduction 44

7.2 Set-up Examples 44

7.2.1 Compressor 44

7.2.2 Single or Multiple Fans or Pumps 44

7.2.3 Compressor Pack 46

8 Status Messages 47

8.1 Status Display 47

8.2 Status Message Definitions Table 47

9 Warnings and Alarms 50

9.1 System Monitoring 50

9.2 Warning and Alarm Types 50

9.2.1 Warnings 50

9.2.2 Alarm Trip 50

9.2.3 Alarm Trip-lock 50

Contents VLT® Refrigeration Drive 110-250 kW Operating Instructions

2 MG16F102 - VLT® is a registered Danfoss trademark

9.3 Warning and Alarm Displays 50

9.4 Warning and Alarm Definitions 52

9.5 Fault Messages 54

10 Basic Troubleshooting 60

10.1 Start Up and Operation 60

11 Specifications 63

11.1 General Specifications 63

11.2 Mains Supply 68

11.3 Fuse Specifications 71

11.3.1 Protection 71

11.3.2 Non UL Compliance 71

11.3.3 UL Compliance 72

11.3.4 Connection Tightening Torques 72

Index 73

Contents VLT® Refrigeration Drive 110-250 kW Operating Instructions

MG16F102 - VLT® is a registered Danfoss trademark 3

1 Safety

WARNING

HIGH VOLTAGE!

Frequency converters contain high voltage when

connected to AC mains input power. Installation, start up,

and maintenance should be performed by qualified

personnel only. Failure to perform installation, start up, and

maintenance by qualified personnel could result in death

or serious injury.

High Voltage

Frequency converters are connected to hazardous mains

voltages. Extreme care should be taken to protect against

shock. Only trained personnel familiar with electronic

equipment should install, start, or maintain this equipment.

WARNING

UNINTENDED START!

When the frequency converter is connected to AC mains,

the motor may start at any time. The frequency converter,

motor, and any driven equipment must be in operational

readiness. Failure to be in operational readiness when the

frequency converter is connected to AC mains could result

in death, serious injury, equipment, or property damage.

Unintended Start

When the frequency converter is connected to the AC

mains, the motor may be started by means of an external

switch, a serial bus command, an input reference signal, or

a cleared fault condition. Use appropriate cautions to

guard against an unintended start.

WARNING

DISCHARGE TIME!

Frequency converters contain DC link capacitors that can

remain charged even when AC mains is disconnected. To

avoid electrical hazards, remove AC mains from the

frequency converter and wait 20 minutes before doing any

service or repair. Failure to wait the specified time after

power has been removed prior to doing service or repair

on the unit could result in death or serious injury.

Safety VLT® Refrigeration Drive 110-250 kW Operating Instructions

4 MG16F102 - VLT® is a registered Danfoss trademark

2 Introduction

2.1 Exploded Views

15 14

13 (IP 20/Chassis)

(IP 21/54

NEMA 1/12)

130BC252.10

Illustration 2.1 D1 Interior Components

130BC301.10

Illustration 2.2 Close-up View: LCP and Control Functions

1LCP (Local Control Panel) 9 Relay 2 (04, 05, 06)

2 RS-485 serial bus connector 10 Lifting ring

3 Digital I/O and 24 V power supply 11 Mounting slot

4 Analog I/O connector 12 Cable clamp (PE)

5 USB connector 13 Earth (ground)

6 Serial bus terminal switch 14 Motor output terminals 96 (U), 97 (V), 98 (W)

7 Analog switches (A53), (A54) 15 Mains input terminals 91 (L1), 92 (L2), 93 (L3)

8 Relay 1 (01, 02, 03)

Table 2.1

Introduction VLT® Refrigeration Drive 110-250 kW Operating Instructions

MG16F102 - VLT® is a registered Danfoss trademark 5

2.2 Purpose of the Manual

This manual is intended to provide detailed information for

the installation and start up of the frequency converter.

provides requirements for mechanical and electrical instal-

lation, including input, motor, control and serial

communications wiring, and control terminal functions.

provides detailed procedures for start up, basic operational

programming, and functional testing. The remaining

chapters provide supplementary details. These details

include user interface, detailed programming, application

examples, start-up troubleshooting, and specifications.

2.3 Additional Resources

Other resources are available to understand advanced

frequency converter functions and programming.

•The VLT

Programming Guide provides greater

detail on working with parameters and many

application examples.

•The VLT

Design Guide is intended to provide

detailed capabilities and functionality to design

motor control systems.

•Supplemental publications and manuals are

available from Danfoss.

See http://www.danfoss.com/Products/Literature/

Technical+Documentation.htm for listings.

•Optional equipment is available that may change

some of the procedures described. Reference the

instructions supplied with those options for

specific requirements. Contact the local Danfoss

supplier or visit the Danfoss website for

downloads or additional information.

2.4 Product Overview

A frequency converter is an electronic motor controller

that converts AC mains input into a variable AC waveform

output. The frequency and voltage of the output are

regulated to control the motor speed or torque. The

frequency converter can vary the speed of the motor in

response to system feedback, such as position sensors on a

conveyor belt. The frequency converter can also regulate

the motor by responding to remote commands from

external controllers.

In addition, the frequency converter monitors the system

and motor status, issues warnings or alarms for fault

conditions, starts and stops the motor, optimizes energy

efficiency, and offers many more control, monitoring, and

efficiency functions. Operation and monitoring functions

are available as status indications to an outside control

system or serial communication network.

2.5 Internal Controller Functions

Illustration 2.3 is a block diagram of the frequency

converter's internal components. See Table 2.2 for their

functions.

Illustration 2.3 Frequency Converter Block Diagram

Area Title Functions

1 Mains input •Three-phase AC mains power

supply to the frequency

converter

2 Rectifier •The rectifier bridge converts

the AC input to DC voltage to

supply inverter power

3 DC bus •Intermediate DC-bus circuit

handles the DC current

4 DC reactors •Filter the intermediate DC

circuit current

•Prove line transient protection

•Reduce RMS current

•Raise the power factor

reflected back to the line

•Reduce harmonics on the AC

input

5 Capacitor bank •Stores the DC power

•Provides ride-through

protection for short power

losses

6 Inverter •Converts the DC into a

controlled PWM AC waveform

for a controlled variable

output to the motor

7 Output to motor •Regulated three-phase output

power to the motor

Introduction VLT® Refrigeration Drive 110-250 kW Operating Instructions

6 MG16F102 - VLT® is a registered Danfoss trademark

Area Title Functions

8 Control circuitry •Input power, internal

processing, output, and motor

current are monitored to

provide efficient operation

and control

•User interface and external

commands are monitored and

performed

•Status output and control can

be provided

Table 2.2 Frequency Converter Internal Components

Introduction VLT® Refrigeration Drive 110-250 kW Operating Instructions

MG16F102 - VLT® is a registered Danfoss trademark 7

3 Installation

3.1 Planning the Installation Site

CAUTION

Before performing the installation it is important to plan

the installation of the frequency converter. Neglecting this

may result in extra work during and after installation.

Select the best possible operation site by considering the

following (see details on the following pages, and the

respective Design Guides):

•Ambient operating temperature

•Installation method

•How to cool the unit

•Position of the frequency converter

•Cable routing

•Ensure the power source supplies the correct

voltage and necessary current

•Ensure that the motor current rating is within the

maximum current from the frequency converter

•If the frequency converter is without built-in

fuses, ensure that the external fuses are rated

correctly.

Voltage Altitude Restrictions

380-480 V At altitudes above 3 km, contact Danfoss regarding

PELV

525-600 V At altitudes above 2 km, contact Danfoss regarding

PELV.

Table 3.1 Installation in High Altitudes

3.2 Pre-Installation Checklist

•Before unpacking the frequency converter, ensure

the packaging is intact. If any damage has

occurred, immediately contact the shipping

company to claim the damage.

•Before unpacking the frequency converter, locate

it as close as possible to the final installation site.

•Compare the model number on the nameplate to

what was ordered to verify the proper

equipment.

•Ensure each of the following are rated for the

same voltage:

•Mains (power)

•Frequency converter

•Motor

•Ensure that frequency converter output current

rating is equal to or greater than motor full load

current for peak motor performance.

•Motor size and frequency converter

power must match for proper overload

protection.

•If frequency converter rating is less than

motor, full motor output cannot be

achieved.

3.3 Mechanical Installation

3.3.1 Cooling

•Top and bottom clearance for air cooling must be

provided. Generally, 225 mm (9 in) is required.

•Improper mounting can result in over heating

and reduced performance

•Derating for temperatures starting between 45 °C

(113 °F) and 50 °C (122 °F) and elevation 1000 m

(3300 ft) above sea level must be considered. See

VLT

Design Guide for detailed information.

The high power Danfoss VLT frequency converters utilize a

back-channel cooling concept that removes heatsink

cooling air, which carries approximately 90% of the heat

out of the back channel of the frequency converters. The

back-channel air can be redirected from the panel or room

using one of the kits below.

NOTE

For ordering numbers, see the VLT High Power Drives

Selection Guide, PB.56.B1.02.

Duct cooling

A back-channel cooling kit is available to direct the

heatsink cooling air out of the panel when an IP20/chassis

frequency converters is installed in a Rittal enclosure. Use

of this kit reduces the heat in the panel and smaller door

fans can be specified on the enclosure.

Cooling out the back (top and bottom covers)

The back channel cooling air can be ventilated out of the

room so that the heat from the back channel is not

dissipated into the control room.

Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions

8 MG16F102 - VLT® is a registered Danfoss trademark

A door fan(s) is required on the enclosure to remove the

heat not contained in the backchannel of the frequency

converters and any additional losses generated by other

components inside the enclosure. The total required air

flow must be calculated so that the appropriate fans can

be selected.

Airflow

The necessary airflow over the heat sink must be secured.

The flow rate is shown in Table 3.2.

The fan runs for the following reasons:

•AMA

•DC Hold

•Pre-Mag

•DC Brake

•60% of nominal current is exceeded

•Specific heatsink temperature exceeded (power

size dependent).

•Specific Power Card ambient temperature

exceeded (power size dependent)

•Specific Control Card ambient temperature

exceeded

Enclosure

protection

Frame Door fan(s)/top

fan

Heatsink fan(s)

IP21/NEMA 1 D1 and D2 170 m3/hr (100

CFM)

765 m3/hr

(450 CFM)

IP00/Chassis D3 and D4 255 m3/hr (150

CFM)

765 m3/hr

(450 CFM)

* Airflow per fan. Frame size F contains multiple fans.

Table 3.2 Airflow

3.3.2 Lifting

Always lift the frequency converter using the dedicated

lifting eyes. Use a bar to avoid bending the lifting holes.

130BC253.10

Illustration 3.1 Position Lifting Straps where Indicated

CAUTION

The angle from the top of the frequency converter to the

lifting cables should be 60 °or greater.

3.4 Electrical Installation

3.4.1 General Requirements

This section contains detailed instructions for wiring the

frequency converter. The following tasks are described:

•Wiring the motor to the frequency converter

output terminals

•Wiring the AC mains to the frequency converter

input terminals

•Connecting control and serial communication

wiring

•After power has been applied, checking input

and motor power; programming control terminals

for their intended functions

Installation VLT® Refrigeration Drive 110-250 kW Operating Instructions

MG16F102 - VLT® is a registered Danfoss trademark 9

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