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VLT® Refrigeration Drive 1.1

1. Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 2 x o E a S O 6 8 3 1 nun Q 000 G d 000 0000 00000000000 3 L pooooooo 1 4 m 56 Jo RAG Se A EE ewe 5 a G o QTY Get 9 lt e 6 C 4 9 16 Lal L1 L2 1 L3 U PE W pE Illustration 3 5 Typical Electrical Connection PLC 6 Min 200 mm 7 9 in between control cables motor and mains 1 Output contactor Generally not recommended EHH Mains 3 phase and reinforced PE fan grounding ral P Cable insulation stripped o Equalising min 16 mm 0 025 in Table 3 2 NOTE Use min 10 mm cables for optimal EMC 12 MG16E102 VLT is a registered Danfoss trademark Installation 3 4 1 Requirements AWARNING EQUIPMENT HAZARD Rotating shafts and electrical equipment can be hazardous All electrical work must conform to national and local electrical codes It is strongly recommended that instal lation start up and maintenance be performed only by trained and qualified personnel Failure to follow these guidelines could result in death or serious injury CAUTION WIRING ISOLATION Run input power motor wiring and control wiring in three separate metallic c
2. s eee TlJelelellellejlsileT 7 elele lo elelelel E S ul n E Eg lli lo rn z 95 x 99 4 k Illustration 3 14 ll Il ll ll ll DU gY Um ry 2 Mount cable clamp to ensure 360 connection e SP d between chassis and screen note the outer insulation of the motor cable is removed under the clamp e d 5 a Illustration 3 13 Motor Mains and Earth Wiring for B C and D Frame Sizes Illustration 3 15 16 MG16E102 VLT is a registered Danfoss trademark Installation 3 4 4 2 Motor Connection for A4 A5 First terminate the motor earth then place motor U V and W wires in terminal and tighten Ensure that the outer insulation of the motor cable is removed under the EMC clamp N m m E sal o gal Illustration 3 16 3 4 4 3 Motor Connection for B1 and B2 First terminate the motor earth then place motor U V and VV vvires in terminal and tighten Ensure that the outer insulation of the motor cable is removed under the EMC clamp VLT Refrigeration Drive 1 1 90 kW Operating Instructions O e 130BT333 10 Illustration 3 17 3 4 4 4 Motor Connection for C1 and C2
3. 38 P Param ter Settihg L ss s 41 M Phase LOS a a m n n RR i iere t e nA ERN 64 Main dE E 44 A0 j Power Mains Connections DIETE 13 S Connection For A2 And A 3 18 Connection For B1 And B32 20 Power dependent Connection For C1 And 2 20 Pre start Melete P rr n 40 41 58 Programming Manual lnitialisation 42 Menu U 3940 Q UC atenas 1 ke teeta M ee 41 48 Quick Men WE e Wa 40 44 46 40 KE De gg 36 R Ramp down Time a 38 Ramp up Ue as serene pepe diea ee RERO aa qaa 38 RED DA RH IR 14 88 MG16E102 VLT is a registered Danfoss trademark Index Reference edunt lana das Relay Outputs Remote Commands Reference O er E decane Resetux susu mM e iT Restoring Default Setting EE 42 RFIFilteE edito a RS corde eet cete 18 RMS Cu rtent ta iii 7 AA iia ais 27 Run COMMANA eT 38 POr ISS Vid He ae ka WA WE 58 S Safety Inspecti n EEN 28 Serial Communication 7 11 21 22 41 57 58 59 60 Set o
4. Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 3 4 5 3 Mains Connection for B1 and B2 3 4 5 4 Mains Connection for C1 and C2 How to connect to mains and earthing for B1 and B2 How to connect to mains and earthing x P dd pv lt x lt Illustration 3 26 NOTE For correct cable dimensions see 11 2 General Technical NT Data Illustration 3 27 20 MG16E102 VLT is a registered Danfoss trademark Installation 3 4 6 Control Wiring 3 4 6 1 Control Terminal Types Illustration 3 28 shows the removable frequency converter connectors Terminal functions and default settings are summarized in Table 3 4 130BA012 11 Illustration 3 28 Control Terminal Locations Connector 1 provides four programmable digital inputs terminals two additional digital terminals programmable as either input or output a 24 V DC terminal supply voltage and a common for optional customer supplied 24 V DC voltage Connector 2 terminals 68 and 69 are for an RS 485 serial communications connection Connector 3 provides two analog inputs one analog output 10 V DC supply voltage and commons for the inputs and output Connector 4 is a USB port available for use with the frequency converter Also provided are two Form C relay outputs that are in various locations depending upon the frequency converter configuration and size Some options available f
5. aaa eee 9 Digital Ju el LEE 59 65 23 Ta o1 cert 21 59 46 Disconnect SWE mc TEDE E 30 SIE 28 Downloading Data From The 42 Earth L de E 29 WAG cc ooi e cab qaa BER E ARI WR RRA 29 Br a u pi J lo JWA MAN ODAN 29 Electrical W n be K ini W 14 Jer D 29 EN50178 Fuses 200 V To 480V 85 External CONAM Sienna qa au n E n aaa R 7 57 Controlle S dot 7 Interlock 23 46 M 44 F Fault Eg 40 Feedback d 23 29 67 58 68 Five Ways Of 5 5 55 43 Floating T S 18 Frequency E TE 21 Converter Block 2222 7 Full Load Curtent 9 28 Functional Testing 7 38 IA ete eei esie ete 29 66 70 85 FUSING RM 13 29 G Ground el r Ja c i sj E 14 29 ele 22 UV 14 29 Grounded Delta canarias 18 Grounding GIOUD n Ginori ninii Using Shielded Cable MG16E102 VLT is a registered Danfoss trademark 87 Index VLT Refrigeration Drive 1 1 90 kW Operating Instructions Motor AAA EE 9 13 15 37 H Hand Hordem y an y
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7. control terminals or serial communication Table 8 3 MG16E102 VLT is a registered Danfoss trademark 59 Warnings and Alarms 9 Warnings and Alarms 9 1 System Monitoring The frequency converter monitors the condition of its input power output and motor factors as well as other system performance indicators A warning or alarm may not necessarily indicate a problem internal to the frequency converter itself In many cases it indicates failure conditions from input voltage motor load or temperature external signals or other areas monitored by the frequency converter s internal logic Be sure to investigate those areas exterior to the frequency converter as indicated in the alarm or warning 9 2 Warning and Alarm Types 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 Alarms 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 will coast to a stop The frequency converter logic will continue to operate and monitor the frequency converter status After the fault condition is remedied the frequency converter can be reset It will then be ready to start operation again A trip can
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10. Reference pass Ke 63 Feedback Night setback 4 20 mA 2 0 10V PT 1000 inputs optional Alarms Illustration 7 1 Standard Drawing of Compressor with Internal Control Wizard input e Bypass valve Recycling time start to start Min Hz Max Hz Setpoint Cut in cut out 400 230 V AC Amps rpm p VLT Refrigeration Drive 1 1 90 kW Operating Instructions Where switch settings for analog terminals A53 or A54 are required these are also shown 7 2 Set up Examples 7 2 1 Compressor The wizard guides the user through the set up of a refrig eration compressor by asking him to input data about the compressor and the refrigeration system on which the frequency converter will be running All terminology and units used within the wizard are common refrigeration type and set up is thus completed in 10 15 easy steps using just two keys of the LCP De N Y g 130BA759 11 7 2 2 Single or Multiple Fans or Pumps The wizard guides through the process of setting up of a refrigeration condenser fan or pump Enter data about the condenser or pump and the refrigeration system on which the frequency converter will be running All terminology and units used within the wizard are common refrigeration type and set up is thus completed in 10 15 easy steps using just two keys on the LCP 54 MG16E102 VLT is a registere
11. Troubleshooting Cycle power Check that the option is properly installed Check for loose or missing wiring It may be necessary to contact your Danfoss supplier or service department Note the code number for further troubleshooting directions No Text 0 Serial port cannot be initialised Contact your Danfoss supplier or Danfoss Service Department 256 258 Power EEPROM data is defective or too old 512 519 lnternal fault Contact your Danfoss supplier or Danfoss Service Department 783 Parameter value outside of min max limits 1024 1284 Internal fault Contact your Danfoss supplier or the Danfoss Service Department 1299 Option SW in slot A is too old 1300 Option SW in slot B is too old 1302 Option SW in slot C1 is too old 1315 Option SW in slot A is not supported not allowed 1316 Option SW in slot B is not supported not allowed 1318 Option SW in slot C1 is not supported not allowed 1379 2819 Internal fault Contact your Danfoss supplier or Danfoss Service Department 2820 LCP stack overflow 2821 Serial port overflow 2822 USB port overflow 3072 5122 Parameter value is outside its limits 5123 Option in slot A Hardware incompatible with control board hardware 5124 Option in slot B Hardware incompatible with control board hardware 5125 Option in slot CO Hardware incompatible with control board hardware 5126 Option in slot C1 Hardware incompatible with control board hardware 5376 6231 Internal
12. le elle ollelfell ll lTell S bakan lt eee lola lo lola o lo d 1 amp 9 7 1 i 95 99 e e 4 is DD I gw ll ll ll nu e so l TL 2 o O Illustration 3 18 First terminate the motor earth then Place motor U V and W wires in terminal and tighten Ensure that the outer insulation of the motor cable is removed under the EMC clamp MG16E102 VLT is a registered Danfoss trademark 17 Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 3 4 5 AC Mains Connection Z OW Size wiring based upon the input current of the frequency converter For maximum wire sizes see 11 1 Power dependent Specifications 130BA261 10 Comply with local and national electrical codes for cable sizes Connect 3 phase AC input power wiring to terminals L1 L2 and L3 see Illustration 3 19 Depending on the configuration of the equipment input power will be connected to the mains input terminals or the input disconnect o e m E ca m Illustration 3 20 Illustration 3 19 Connecting to AC Mains 2 When mounting cables first mount and tighten earth cable Ground the cable in accordance with grounding instructions provided in 3 4 2 Earth Grounding Requirements 130BA262 10 All frequency converters may be used with an isolated input source as well as with ground reference power lines When
13. Quick Set Up and detailed instructions for common frequency converter applications Q3 Function Set Up Step by step instructions are provided These instructions enable the user to walk through the parameters used for programming applications in their proper sequence Data entered in a parameter can change the options available in the parameters following that entry The quick menu presents easy guidelines for getting most systems up and running The main menu accesses all parameters and allows for advanced frequency converter applications 6 2 Programming Example Here is an example for programming the frequency converter for a common application in open loop using the quick menu This procedure programs the frequency converter to receive a 0 10 V DC analog control signal on input terminal 53 The frequency converter will respond by providing 6 60 Hz output to the motor propor tional to the input signal 0 10 V DC 6 60 Hz Select the following parameters using the navigation keys to scroll to the titles and press OK after each action 1 3 15 Reference Resource 1 xx 2 14 7 0 00A 10 lt oo References 5 1 m o m 3 15 Reference Resource WI Analog input 53 Illustration 6 1 p VLT Refrigeration Drive 1 1 90 kW Operating Instructions 2 3 02 Minimum Reference Set minimum internal frequency converter reference to 0 Hz This sets the minimum frequency conver
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15. p VLT Refrigeration Drive 1 1 90 kW Operating Instructions Safe Stop installation and set up AWARNING SAFE STOP FUNCTION The Safe Stop function does NOT isolate mains voltage to the frequency converter or auxiliary circuits Perform work on electrical parts of the frequency converter or the motor only after isolating the mains voltage supply and waiting the length of time specified in 1 Safety Failure to isolate the mains voltage supply from the unit and waiting the time specified could result in death or serious injury It is not recommended to stop the frequency converter by using the Safe Torque Off function If a running frequency converter is stopped by using the function the unit will trip and stop by coasting If this is not acceptable e g causes danger the frequency converter and machinery must be stopped using the appropriate stopping mode before using this function Depending on the application a mechanical brake may be required Concerning synchronous and permanent magnet motor frequency converters in case of a multiple IGBT power semiconductor failure In spite of the activation of the Safe Torque Off function the frequency converter system can produce an alignment torque which maximally rotates the motor shaft by 180 p degrees p denotes the pole pair number This function is suitable for performing mechanical work on the frequency converter system or affected area of a machine only It does no
16. a 91 L1 Al j U 96 r 9 ase 1 EN 93 l was OTE input dK AK HK P 4 95 PES N K AS PE 99 x ico Y Motor 7 7 DC bus T 88 0 Switch Mode 89 Power Supply 4K vi 24Vdc R 82 Brake 15mA 200mA resistor ide 50 4 10 V OUT 3 u ETSI 5201 ry 0 10Vdc amp 53 A IN NI 9 LEY H ON 0 20mA relay1 E 5202 OFF 0 10V 03 PUTO 54 A IN 9 240Vac 2A 0 10Vdc I i 02 x 0 4 20 mA 55 COM A IN oy relay2 12 24V OUT 06 240 2A 1 13 24V OUT a oe pooh op 400Vac 2A 24V NPN ov PNP a 24V NPN Y 19 DIN OV PNP 1777 39 Analog Output Ly 0 4 20 mA BE COM DIN 24V NPN 27 DIN OUT oV PD S801 F24V ER ON Terminated xl OFF Open 0V 5V 24V NPN RE 29 D IN OUT 25 zan 24V 2 S801 ev ov uv 5 P RS 485 68 17 RS 485 24V NPN Interface ji Sy i 32 D IN OV PNP N RS 485 69 FIT 24V NPN Com RS 485 61 COM RS 485 61 2 33 DIN 0V PNP I I PNP Source NPN Sink 37 DIN m Illustration 3 4 Basic Wiring Schematic Drawing NOTE For additional information see Table 3 4 MG16E102 VLT is a registered Danfoss trademark 11
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18. 40 M ne lal RY DD HHHH HHHH HHHH 59 SOU D M 38 40 Shielded lE EE 9 13 29 MEG MEM E 13 Short gr 65 Sleep Moe ii aaa 59 Spechfications ENEE 7 10 73 Speed Reference een 23 38 45 57 SISICUB2 na aaa aaa e a 7 42 44 Status MOTE aiii ia 57 Stop Command a a au aaa asla 58 Supply 21 28 66 Switching Frequency 58 Symbols ae ertet teer b K N 4 System Feedback s notch S Sau EE Monitoring E Start UJ c T Temperature Limits 29 Terminal S b RAN E AR tuti SENIORI 44 23 44 Lr c aaa R ua awawanki aY 23 Programming Examples 45 Tightening Of 86 Torque Characteristics octets a deeper dpa 80 Bien orte ese o LT res Ms ied tanqa 38 Transient Protection 7 VLT Refrigeration Drive 1 1 90 kW Operating Instructions tS e et eerie Wa d t k l emek 60 Troubleshooting eerte tenent tents 7 64 U Uploading Data To The 42 Voltage Imbalarige u ina 64 Level oes SEE ANGE YS GA au A 80 W Warning And Alarm D
19. 8 8 8 5 7 7 8 5 10 14 10 14 B1 5 5 7 5 11 15 8 8 8 8 8 5 5 8 5 10 10 1 For different cable dimensions x y where x lt 95 mm and y 2 95 mm 86 MG16E102 VLT is a registered Danfoss trademark Index Index A AS aS a tuii wan Pee O Wa aQ awa pe PPS 23 Lr a OS 23 AC Fa el erp 7 18 Mains 7 11 18 WAV Tola na DEE H Alarm Log 40 Alarm Warning Code List 63 Alarm iia di iii 60 AMA dI e NE atlas A 65 68 Analog vsi cin ita 21 64 OUTPUT EE 21 rie 64 Approvalss 4jy a irae eiie ia 4 Auto Auto k drei te acia 41 Mii adi 40 Onun ar E 41 57 59 Automatic Motor Adaptation 37 57 AUtO TOO E 39 B Back Plate 210 Braking O 66 57 C Circuit Breakers oie eee REP PER AE 29 Clearance La TTT AA 9 R q lir EE 9 Closed NET ee Rege e tenth 23 Communication 66 aT uere 13 29 0 Control Cablesk a a 22 Cooling ere ji uo et E Wa uwa Sas 9 Clear Ceci heec rr 29 Copying Parameter Setting 41 Current Sua ua 38 9 64 VLT Refrigeration Drive 1 1 90 kW Operating Instructions D DC CUNO isc a G Ee 7 58 Tal z 64
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21. Relay 2 04 05 06 5 Cable strain relief PE ground 6 Cable sran ele ground 16 Brake terminal 31 82 7 Load sharing terminal DC bus 88 89 8 Serial bus terminal switch 18 Motor output terminals 96 U 97 V 98 W 9 1 Analog switches A53 A54 19 Mains input terminals 91 L1 92 L2 93 L3 0 Relay 1 01 02 03 Table 2 2 6 MG16E102 VLT is a registered Danfoss trademark Introduction 2 1 Purpose of the Manual This manual is intended to provide detailed information for the installation and start up of the frequency converter 3 Installation provides requirements for mechanical and electrical installation including input motor control and serial communications wiring and control terminal functions 4 Start Up and Functional Test 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 2 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 changing temper
22. Start Up and Functional Tes VLT Refrigeration Drive 1 1 90 kW Operating Instructions Current and nominal speed set up o CH CH IJ gal m Illustration 4 2 NOTE Numbering of steps in wizard e g 1 12 can change depending on choices in the workflow This screen will automatically change to the first input Illustration 4 6 screen of the Application Guide Min and max frequency set up 130BC953 10 Illustration 4 3 Illustration 4 7 130BC954 10 Illustration 4 4 Min time between two starts Compressor pack set up As an example see screens below for a compressor pack set up Voltage and frequency set up 130BA791 10 Illustration 4 8 Illustration 4 5 MG16E102 VLT is a registered Danfoss trademark 31 p Start Up and Functional Tes VLT Refrigeration Drive 1 1 90 kW Operating Instructions Choose with without bypass valve Select sensor type 130BA792 10 130BA794 10 Illustration 4 9 Illustration 4 11 Select open or closed loop Settings for sensor 130BA793 10 130BA795 10 Illustration 4 10 Illustration 4 12 NOTE Info 4 20 mA feedback chosen connect accordingly Internal Closed loop The FC 103 will control the application directly using the internal PID control within the frequency converter and needs an input from an external input such as a temperature or other sensor which is wired directly into the frequency converter and controls
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25. provided at both ends to ensure best possible high frequency cable contact If the earth potential between the frequency converter and the PLC is different electric noise may occur that will disturb the entire system Solve this problem by fitting an equalizing cable next to the control cable Minimum cable cross section 16 mm PLC FC a al qi N en en m PE PE Illustration 3 31 50 60 Hz ground loops With very long control cables ground loops may occur To eliminate ground loops connect one end of the screen to ground with a 100 nF capacitor keeping leads short PLC FC E n 100nF PE E 130BB609 11 Illustration 3 32 Avoid EMC noise on serial communication This terminal is connected to earth via an internal RC link Use twisted pair cables to reduce interference between conductors The recommended method is shown below 22 MG16E102 VLT is a registered Danfoss trademark Installation 130BB923 11 Illustration 3 33 Alternatively the connection to terminal 61 can be omitted 130BB924 11 Illustration 3 34 3 4 6 4 Jumper Terminals 12 and 27 A jumper wire may be required between terminal 12 or 13 and terminal 27 for the frequency converter to operate when using factory default programming values Digi
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27. 1 electrical standards the following fuses are recommended Frequency converter 200 240 V T2 18K5 125A 200 240 type 9G 22K 125A 200 240 type 9G 30K 160A 200 240 type 9G 37K 200A 200 240 type aR 45K 250A 200 240 type aR 380 480 V T4 7K5 35A 380 500 type 9G 11K 15K 63A 380 500 type 9G 37K 100A 380 500 type 9G 45K 125A 380 500 type gG 55K 160A 380 500 type gG 75K 250A 380 500 type aR 90K 250A 380 500 type aR 1 Max fuses see national international regulations for selecting an applicable fuse size Maximum fuse size Voltage Type Table 11 8 EN50178 fuses 200 V to 480 V 11 3 2 Substitute Fuses for 240 V Original fuse Manufacturer Substitute fuses os Busmann Fe A2KR FERRAZ SHAWMUT A6KR A25X FERRAZ SHAWMUT A50X Table 11 9 MG16E102 VLT is a registered Danfoss trademark 85 Specifications VLT Refrigeration Drive 1 1 90 kW Operating Instructions 11 4 Connection Tightening Torques Power kW Torque Nm Enclo 380 480 500 200 240 V 525 600 V 525 690 V connecti sure V 1 2 1 1 0 A5 1 1 3 7 1 1 7 5 1 D o 1 1 1 1 3 3 1 4 C n A i 7 8 14 1 1 1 1 1 3 3 1 4 see mec AREA 7 1 NN E XE Y 22 2 22 4 5 4 B3 5 5 7 5 11 15 11 15 1 8 1 c sa os m s T l E 10 G wm s re J a o e a ws ses ss oar wann wa Table 11 10 Tightening of Terminals 8
28. 3 13 Reference Site Set preset reference active in parameter group 3 1 References Check for correct wiring Check scaling of terminals Check reference signal Basic Troubleshooting p VLT Refrigeration Drive 1 1 90 kW Operating Instructions Symptom Motor running in wrong direction Motor is not reaching maximum speed Motor speed unstable Motor runs rough Motor will not brake Open power fuses or circuit breaker trip Mains current imbalance greater than 396 Motor current imbalance greater than 396 Possible Cause Test Solution Motor rotation limit Check that 4 70 Motor Speed Program correct settings Direction is programmed correctly Active reversing signal Check if a reversing command is Deactivate reversing signal programmed for the terminal in parameter group 5 1 Digital inputs Frequency limits set wrong Check output limits in 4 713 Motor Program correct limits Speed High Limit RPM 4 14 Motor Speed High Limit Hz and 4 19 Max Output Frequency Reference input signal not scaled Check reference input signal Program correct settings scaling in 6 Analog I O mode and parameter group 3 1 References Reference limits in parameter group 3 0 Possible incorrect parameter Check the settings of all motor Check settings in parameter group settings parameters including all motor 1 6 Analog I O mode For closed compensation sett
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31. B to C C to A the unit Contact the supplier Problem with motor or motor Rotate output motor leads one If imbalanced leg follows the wire wiring position U to V V to W W to U the problem is in the motor or motor wiring Check motor and motor wiring Problem with the frequency Rotate output motor leads one If imbalance leg stays on same converters position U to V V to W W to U output terminal it is a problem with the unit Contact the supplier MG16E102 VLT is a registered Danfoss trademark 71 Darfi Basic Troubleshooting VLT Refrigeration Drive 1 1 90 kW Operating Instructions Symptom Possible Cause Test Solution Bypass critical frequencies by using parameters in parameter group 4 6 Acoustic noise or vibration Turn off over modulation in N Check if noise and or vibration e g a fan blade is making Resonances e g in the motor fan 74 03 Overmodulation 1 s have been reduced to an noise or vibrations at system Change switching pattern and gus acceptable limit certain frequencies frequency in parameter group 14 0 Increase Resonance Dampening in 1 64 Resonance Dampening Table 10 1 72 MG16E102 VLT is a registered Danfoss trademark p Specifications VLT Refrigeration Drive 1 1 90 kW Operating Instructions 11 Specifications 11 1 Power dependent Specifications Mains supply 200 240
32. Danfoss trademark VLT Refrigeration Drive 1 1 90 kW Operating Instructions Programming indino 8 06 jeuruue 8 06 1ndino Bojeuy 13114 3nd3no Bojeuy yasalg MOWIL andino Zp RUI usa L 04100 sng nd no Zy jeulWaL ayers xew indino Zy Jeune ayeos UNA indino Zy 641 indino Zp euro v indino Bojeuy 0J89Z ZL OEX WAL 3ue3suo SUI CL OEX WEL enjeA qp 41 4Y YBIH ZL OEX uu l MOT 21 06 WAL UD 21 06 2 MOT ZL O X Jeuruue 21 06 indu Bojeuy 019Z BAIT LL OEX WEL 1uejsuo awl 19114 LL OEX WAL YBIH LL OEX uu l enjeA qpae4 jed MOT LL OEX WEL abeyon UBIH LL O X abeyon MOT LL O X euro L 11 06 indu Bojeuy O1 Z au tS euw 1uejsuo ulll 19214 S Puru qp 3 J ti YBIH tS euro y nlPA QP994 J9 MOT tS JU911 YBIH ps eure L JU341N MOT tS 1 abeyon ps euro L 9beyoA MOT tS jeuruJa L Fe 1ndul Bojeuy O1 Z BAI ES euiuJo 1uejsuo SUI 19214 S 1 qp 3 J ti ubiH ES euro l ANJLA Qp994 J9 MOT ES uan YBIH es euius L 1u8JJn MOT ES fEUlUM L 9beyoA ES euro L 9beyoA MOT ES jeuruJa Ce indu 6ojeuy UONIUNY 1no ulll 0J97 SAN POW uon un4 1noauJl 0197 A OUI INO3UWI OJ9Z BAIT 3pow 1
33. Inputs Outputs Default Terminal Parameter Setting e Description RS 485 Interface A 69 control card switch is provided for termination resistance Relays 01 02 03 Form C relay output 04 05 06 5 40 5 Running Usable for AC or DC voltage and resistive or inductive loads Table 3 4 Terminal Description 3 4 6 2 Wiring to Control Terminals Control terminal connectors can be unplugged from the frequency converter for ease of installation as shown in Illustration 3 29 o s m ts m Illustration 3 29 Unplugging Control Terminals 1 Open the contact by inserting a small screwdriver into the slot above or below the contact as shown in Illustration 3 30 2 Insert the bared control wire into the contact 3 Remove the screwdriver to fasten the control wire into the contact 4 Ensure the contact is firmly established and not loose Loose control wiring can be the source of equipment faults or less than optimal operation See 11 1 Power dependent Specifications for control terminal wiring sizes See 7 Application Set Up Examples for typical control wiring connections p VLT Refrigeration Drive 1 1 90 kW Operating Instructions 130BA310 10 Illustration 3 30 Connecting Control Wiring 3 4 6 3 Using Screened Control Cables Correct screening The preferred method in most cases is to secure control and serial communication cables with screening clamps
34. control Test ACAUTION MOTOR START Ensure that the motor system and any attached equipment are ready for start It is the responsibility of the user to ensure safe operation under any condition Failure to ensure that the motor system and any attached equipment is ready for start could result in personal injury or equipment damage NOTE The Hand On key provides a local start command to the frequency converter The Off key provides the stop function When operating in local mode 4 and Y increase and decrease the speed output of the frequency converter lt and gt move the display cursor in the numeric display 1 Press Hand On 2 Accelerate the frequency converter by pressing 4 to full speed Moving the cursor left of the decimal point provides quicker input changes 3 Note any acceleration problems 4 Press Off 5 Note any deceleration problems If acceleration problems were encountered If warnings or alarms occur see 9 Warnings and Alarms Check that motor data is entered correctly Increase the ramp up time in 3 41 Ramp 1 Ramp Up Time Increase current limit in 4 18 Current Limit Increase torque limit in 4 16 Torque Limit Motor Mode If deceleration problems were encountered If warnings or alarms occur see 9 Warnings and Alarms Check that motor data is entered correctly Increase the ramp down time in 3 42 Ramp 1 Ramp Down Time Enable overv
35. electrical codes as well as instructions contained within this document Ground currents are higher than 3 5 mA Failure to ground the frequency converter properly could result in death or serious injury NOTE It is the responsibility of the user or certified electrical installer to ensure correct grounding earthing of the equipment in accordance with national and local electrical codes and standards Follow all local and national electrical codes to ground electrical equipment properly Proper protective grounding for equipment with ground currents higher than 3 5 mA must be established see 3 4 2 1 Leakage Current gt 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 3 4 2 1 Leakage Current gt 3 5 mA Follow national and local codes regarding protective earthing of equipment with a leakage current gt 3 5 mA Frequency converter technology implies high frequency switching at high power This will generate a leakage current in the earth connection A fault current in the frequency converter at the output power terminals might contain a DC
36. fault Contact your Danfoss supplier or Danfoss Service Department Table 9 3 Internal Fault Codes ALARM 39 Heatsink sensor No feedback from the heatsink temperature sensor The signal from the IGBT thermal sensor is not available on the power card The problem could be on the power card on the gate drive card or the ribbon cable between the power card and gate drive card p VLT Refrigeration Drive 1 1 90 kW Operating Instructions WARNING 40 Overload of digital output terminal 27 Check the load connected to terminal 27 or remove short circuit connection Check 5 00 Digital VO Mode and 5 01 Terminal 27 Mode WARNING 41 Overload of digital output terminal 29 Check the load connected to terminal 29 or remove short circuit connection Check 5 00 Digital I O Mode and 5 02 Terminal 29 Mode WARNING 42 Overload of digital output on X30 6 or overload of digital output on X30 7 For X30 6 check the load connected to X30 6 or remove the short circuit connection Check 5 32 Term X30 6 Digi Out MCB 101 For X30 7 check the load connected to X30 7 or remove the short circuit connection Check 5 33 Term X30 7 Digi Out MCB 101 ALARM 45 Earth fault 2 Earth ground fault on start up Troubleshooting Check for proper earthing grounding and loose connections Check for proper wire size Check motor cables for short circuits or leakage currents ALARM
37. from the sensor signal External Open loop The FC 103 takes its control signal from another controller such as a pack controller which gives the frequency converter e g 0 10v 4 20 mA or FC 103 Lon The frequency converter will change its speed depending upon this reference signal 130BA796 10 Illustration 4 13 32 MG16E102 VLT is a registered Danfoss trademark Start Up and Functional Tes VLT Refrigeration Drive 1 1 90 kW Operating Instructions Info Set switch accordingly Set setpoint 130BA797 10 130BA800 10 Illustration 4 14 Illustration 4 17 Select unit and conversion from pressure Set high low limit for setpoint 130BA798 10 130BA801 10 Illustration 4 15 Illustration 4 18 Select fixed or floating setpoint Set cut out in value 130BA799 10 130BA802 10 Illustration 4 16 Illustration 4 19 MG16E102 VLT is a registered Danfoss trademark 33 p Start Up and Functional Tes VLT Refrigeration Drive 1 1 90 kW Operating Instructions Choose pack control set up Info Set up completed 130BA803 10 130BA806 10 Illustration 4 20 Illustration 4 23 Set number of compressors in pack After completing set up choose to re run wizard or start application Select between the following options Re run wizard Go to main menu Go to status Run AMA Note this is a reduced AMA if compressor application is selected and full AMA if single fan and pump is selected If cond
38. 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 AWARNING 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 before doing any service or repair and wait the amount of time specified in Table 1 1 Failure to wait the specified time after power has been removed before doing service or repair on the unit could result in death or serious injury Voltage V Minimum waiting time minutes 4 s 200 240 5 5 37 kW 380 480 11 75 kW 525 600 11 75 kw High voltage may be present even when the warning LEDs are off Table 1 1 Discharge Time p VLT Refrigeration Drive 1 1 90 kW Operating Instructions Symbols The following symbols are used in this manual AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices CAUTION Indicat
39. motor 3000RPM The corresponding values for North America is 1800 and 3600RPM respectively Changes made to default settings are stored and available for viewing in the quick menu along with any programming entered into parameters 1 Press Quick Menu 2 Scroll to Q5 Changes Made and press OK 3 Select Q5 2 Since Factory Setting to view all programming changes or Q5 1 Last 10 Changes for the most recent be 25 9 0 00A 1 1 Changes Made Q5 Q5 1 Last 10 Changes 130BB850 10 105 2 Since Factory Setti j Illustration 6 12 46 MG16E102 VLT is a registered Danfoss trademark p Programming VLT Refrigeration Drive 1 1 90 kW Operating Instructions 6 4 1 Parameter Data Check 1 Press Quick Menu 2 Scroll to Q5 Changes Made and press OK 25 9 0 00A 1 1 Q1 My Personal Menu 130BP089 10 Ob Q2 Quick Setup Q3 Function Setups 105 Changes Made E Illustration 6 13 3 Select Q5 2 Since Factory Setting to view all programming changes or Q5 1 Last 10 Changes for the most recent 6 5 Parameter Menu Structure Establishing the correct programming for applications often requires setting functions in several related parameters These parameter settings provide the frequency converter with system details it needs to operate properly System details may include such things as input and output signal types pr
40. option refer to relevant documentation NOTE The AKM programming software can be downloaded from www danfoss com 5 5 Remote Programming with MCT 10 Set up Software Danfoss has a software program available for developing storing and transferring frequency converterprogramming The MCT 10 Set up Software allows the user to connect a PC to the frequency converter and perform live programming rather than using the LCP Additionally all frequency converter programming can be done off line and simply downloaded to the frequency converter Or the entire frequency converter profile can be loaded onto the PC for back up storage or analysis The USB connector or RS 485 terminal are available for connecting to the frequency converter MCT 10 Set up Software is available for free download at www VLT software com A CD is also available by requesting part number 130B1000 A user s manual provides detailed operation instructions MG16E102 VLT is a registered Danfoss trademark 43 Programming 6 Programming 6 1 Introduction The frequency converter is programmed for its application functions using parameters Parameters are accessed by pressing either Quick Menu or Main Menu on the LCP See 5 User Interface for details on using the LCP function keys Parameters may also be accessed through a PC using the MCT 10 Set up Software go to www VLT software com The quick menu is intended for initial start up Q2
41. over heating tightening specifications and reduced performance Use the slotted mounting holes on the unit for wall mounting when provided 130BA219 10 I Illustration 3 2 Proper Mounting with Back Plate Item A is a back plate properly installed for required airflow to cool the unit 10 MG16E102 VLT is a registered Danfoss trademark p Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 3 4 Electrical Installation This section contains detailed instructions for wiring the Connecting control and serial communication frequency converter The following tasks are described wiring After power has been applied checking input Wiring the motor to the frequency converter and motor power programming control terminals output terminals for their intended functions e Wiring the AC mains to the frequency converter Illustration 3 4 shows a basic electrical connection input terminals enne y KKK
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43. running for best performance Basic operational programming requires entering motor nameplate data for the motor being operated and the minimum and maximum motor speeds Enter data in accordance with the following procedure Parameter settings recommended are intended for start up and checkout purposes Application settings may vary See 5 User Interface for detailed instructions on entering data through the LCP Enter data with power ON but before operating the frequency converter 1 Press Main Menu twice on the LCP 2 Use the navigation keys to scroll to parameter group 0 Operation Display and press OK F3 o 1107 RPM 3 84A 1 1 E B 8 o xx Operation Display 1 xe Load Motor 2 Brakes 3 xx Reference Ramps Illustration 4 26 3 Use navigation keys to scroll to parameter group 0 0 Basic Settings and press OK 0 0 0 00A 18 Ta S 0 0 Basic Settings 5 0 1 Set up Opperations 2 0 2 LCP Display 0 3 LCP Custom Readout Illustration 4 27 4 Use navigation keys to scroll to 0 03 Regional Settings and press OK 7 o 0 0 0 00A 1 1 Basic Settings 0 0 5 a 0 03 Regional Settings en 0 International v Illustration 4 28 5 Use navigation keys to select 0 International or 1 North America as appropriate and press OK This changes the default settings f
44. supplier or Danfoss Service Department ALARM 51 AMA check Unom and Inom The settings for motor voltage motor current and motor power are wrong Check the settings in parameters 1 20 to 1 25 ALARM 52 AMA low Inom The motor current is too low Check the settings ALARM 53 AMA motor too big The motor is too big for the AMA to operate ALARM 54 AMA motor too small The motor is too small for the AMA to operate ALARM 55 AMA Parameter out of range The parameter values of the motor are outside of the acceptable range AMA will not run 56 ALARM AMA interrupted by user The user has interrupted the AMA ALARM 57 AMA internal fault Try to restart AMA again Repeated restarts can over heat the motor ALARM 58 AMA internal fault Contact your Danfoss supplier WARNING 59 Current limit The current is higher than the value in 4 78 Current Limit Ensure that Motor data in parameters 1 20 through 1 25 are set correctly Possibly increase the current limit Be sure that the system can operate safely at a higher limit WARNING 60 External interlock A digital input signal is indicating a fault condition external to the frequency converter An external interlock has commanded the frequency converter to trip Clear the external fault condition To resume normal operation apply 24 V DC to the terminal programmed for external interlock Reset the frequency converter WARNING 62 Output frequency at maximum limit The output
45. 1 Pulse inputs are 29 and 33 2 Encoder inputs 32 A and 33 B Analog output Number of programmable analog outputs 1 The analogue output is galvanically isolated from the supply voltage PELV and other high voltage terminals Control card RS 485 serial communication Terminal number 68 P TX RX 69 N TX RX The RS 485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage PELV Digital output Programmable digital pulse outputs 2 1 Terminal 27 and 29 can also be programmed as input The digital output is galvanically isolated from the supply voltage PELV and other high voltage terminals Control card 24 V DC output Terminal number 12 13 The 24 V DC supply is galvanically isolated from the supply voltage PELV but has the same potential as the analog and digital inputs and outputs 82 MG16E102 VLT is a registered Danfoss trademark Specifications VLT Refrigeration Drive 1 1 90 kW Operating Instructions Relay outputs Programmable relay outputs 1 IEC 60947 part 4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation PELV 2 Overvoltage Category II 3 UL applications 300 V AC 2A Control card 10 V DC output Terminal NUMBER O A Os 50 Max load 15 mA The 10 V DC supply is galvanically isolated from the supply voltage PELV and
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47. 13 5 9 7 13 5 9 7 13 5 13 5 13 5 A4 A5 Weight enclosure IP66 kg A4 A5 Efficiency 3 096 096 096 096 096 Table 11 1 Mains Supply 200 240 V AC 9 7 13 5 9 7 13 5 9 7 13 5 13 5 13 5 MG16E102 VLT is a registered Danfoss trademark 73 VLT Refrigeration Drive 1 1 90 kW Operating Instructions Specifications DV A 092 002 6 Iddns suiew z LL eiqer 160 49 49 49 03 09114 2 S8l 9691 0691 L T19 yo Std e PUPI 64 994 e1nsopopue 1uBI A B gt SSdI ensopopue 1uBI A 631 Lzd inso 5u 1uBI A B gt 0zdl inso 3u IYBISM p pn 3u yms 32euuoosip sUleL YUM 0 S6 9 8 9 91 OL OL rd IN2WO00 OSL 1 0S Ier SE 8 8 OL OL WOWOOE OSL 1 0S c SE OL OL ESEL z EZ LEL 209 Lev OLE i i ad 0021 ovol T ozy 082 oom som cep 1 T m Ee Oe o SK N TE 2 A 15 b a j g ig T j ig j b D gt e j pj ig j ig j j J 2 0 D o e j u ig II 981 SL LL GL SS vr ec SC 3814 614 4 Syd SASd DMv zww Buieys peo exe1q uon s sso qe2 XE 99JI SSdl 1241 DAAV Uu 1030 SUIELU UOIIDAS SSOID lqe XE 9941 SSdI 1241 Buueus peo pue 101010 ye1q suleuu uon es ssoJ qe2 Xew ozdl peo xeuu Daig 1e sso Jamod p leuuns3 suone yi eds jeuonippy
48. 14 7 96 0 00 A 1 1 Analog Reference Q3 21 6 14 Terminal 53 Low Ref Feedb Value 130BT773 11 000020 000 Illustration 6 6 7 6 15 Terminal 53 High Ref Feedb Value Set maximum speed reference on Terminal 53 at 60 Hz This tells the frequency converter that the maximum voltage received on Terminal 53 10 V equals 60 Hz output 14 7 96 0 00A 10 Analog Reference Q3 21 6 15 Terminal 53 High Ref Feedb Value 130BT774 11 50 000 Illustration 6 7 With an external device providing a 0 10 V control signal connected to frequency converter terminal 53 the system is now ready for operation Note that the scroll bar on the right in the last illustration of the display is at the bottom indicating the procedure is complete Illustration 6 8 shows the wiring connections used to enable this set up VLT Refrigeration Drive 1 1 90 kW Operating Instructions 130BC958 10 e A53 55 1 e ee N Illustration 6 8 Wiring Example for External Device Providing 0 10 V Control Signal Frequency Converter Left External Device Right 6 3 Control Terminal Programming Examples Control terminals can be programmed Each terminal has specified functions it is capable of performing Parameters associated with the terminal enable the function See Table 3 4 for control terminal parameter number and default setting Defa
49. 2 18 22 98 22 98 22 v8 cc 28 22 28 22 18 22 08 22 8 CC 6 22 81 22 11 22 9 22 SL CC 41 22 29 22 19 22 09 22 9 CC 15 22 09 22 SCC 9v cc REC C V C cv cc 17 22 22 CC 66 22 86 22 16 22 96 22 dH paads o1 Mx J9M0d p ds mo7 ZH p ds wo Wdy p ds moq J032e4 uon22410 J9MOd J9MOd MO J ON Duiun J9MOd MO 4 ON ey q dung Aiq uon un dung Ad Aejaq MO 4 ON Uuonounj MO 4 ON uonp2aieg p ds oj uonpajeg JeMod MO dn jas OMY JaMog MO uon ejeg MO 4 ON SUI J93 IJ 4 Aey q 120 4914 euj lxg sno ue 3sIW suopuny Iddy Mur 4129 iq 3x3 sui 1X3 eui Je15e1u 3x3 ules jeuongodoJd 3x3 104002 3SI9AU J8UMON 1X3 014 D PG nd no xa Brun peqpasy 3x3 fun XQ qujodyas 3x3 peqpeeJ 3X3 nos e uaJajay 1x3 93U9 9J98 WNWIXEW DI 92usJejay WNWIUIW 3x3 n n peqpae jed 3X3 q4 jeu 12 XI Mur 4120 e 3x3 oul c 3X3 oul cx ules feuonuodolq Z X3 1011002 5 Z 1X3 did ID PG 96 ndino z 1x3 Brun peqpaej z xa iun 92U219JeH C 1X3 qulodyas z 1x3 yDeqpae4 Z 1x3 92JnOS 22U9J3J2H C 1X3 VUNWIXEIA Z 3x3 92U3J9JeMy UJhnUJIUIW c 3X3 n n peqpee3 jed c X3 4 12 PG
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51. 46 Power card supply The supply on the power card is out of range There are three power supplies generated by the switch mode power supply SMPS on the power card 24 V 5 V 18 V When powered with 24 V DC with the MCB 107 option only the 24 V and 5 V supplies are monitored When powered with three phase mains voltage all three supplies are monitored Troubleshooting Check for a defective power card Check for a defective control card Check for a defective option card If a 24 V DC power supply is used verify proper supply power WARNING 47 24 V supply low The 24 V DC is measured on the control card The external 24 V DC backup power supply may be overloaded otherwise contact your Danfoss supplier WARNING 48 1 8 V supply low The 1 8 V DC supply used on the control card is outside of allowable limits The power supply is measured on the control card Check for a defective control card If an option card is present check for an overvoltage condition WARNING 49 Speed limit When the speed is not within the specified range in 4 11 Motor Speed Low Limit RPM and 4 13 Motor Speed High Limit RPM the frequency converter shows a warning When the speed is below the specified limit in 1 86 Trip MG16E102 VLT is a registered Danfoss trademark 67 Warnings and Alarms Speed Low RPM except when starting or stopping the frequency converter will trip ALARM 50 AMA calibration failed Contact your Danfoss
52. BT117 10 Warn Alarm Illustration 5 5 p VLT Refrigeration Drive 1 1 90 kW Operating Instructions 5 1 5 Operation Keys Operation keys are found at the bottom of the LCP Illustration 5 6 130BP046 10 Key Function Hand On Starts the frequency converter in local control e Use the navigation keys to control frequency converter speed e An external stop signal by control input or serial communication overrides the local hand on Off Stops the motor but does not remove power to the frequency converter Auto On Puts the system in remote operational mode e Responds to an external start command by control terminals or serial communication e Speed reference is from an external source Reset Resets the frequency converter manually after a 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 Use the four navigation keys to move between Keys items in the menu OK Use to access parameter groups or to enable a choice Table 5 3 Light Indicator Function Green The ON light activates when the frequency converter receives power from mains voltage a DC bus terminal or an external 24 V supply Yellow When warning conditions are met the yell
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54. J tu WNWIXEW qp 43 5u 1 J u WNWIUIN Mun 2 HUN anos yDeQpae4 UOISJ9AUO 3D2eqp 4 x eqpeeJ yup anos z yDeQpae4 MG16E102 VLT is a registered Danfoss trademark 52 VLT Refrigeration Drive 1 1 90 kW Operating Instructions yes Jossaidwo gt p e q UO uonp ul 1013405 uon2efu 19104140 papeo 1501 92uaJ9JaH WNWIXEW Od 92uaJejey WINWIUIN Od 2IU3I9J9Y Od quiodyas Od Od 19540 OdP uoneziundo Od ZH dog p ds 14bIN doiq p ds 1ubIN ypeqias 346 sng etA 1ubiN feq lqeu3 J0 e gt 1pu sng 1ubiN Aeq s um s 146IN Aeq Programming L6 87 06 87 6 87 18 82 98 82 98 82 v8 8c 8 8 28 82 18 82 8 87 91 87 SL 87 8C 21 82 11 82 44 82 53 MG16E102 VLT is a registered Danfoss trademark Application Set Up Examples 7 Application Set Up Examples 7 1 Introduction NOTE A jumper wire may be required between terminal 12 or 13 and terminal 37 for the frequency converter to operate when using factory default programming values The examples in this section are intended as a quick reference for common applications Parameter settings are the regional default values unless otherwise indicated selected in 0 03 Regional Settings Parameters associated with the terminals and their settings are shown next to the drawings Supply 1 12 Bar Refrigerant Rxxx
55. MAKING MODERN LIVING POSSIBLE Operating Instructions VLT Refrigeration Drive 1 1 90 kw THE REAL DRIVE Contents VLT Refrigeration Drive 1 1 90 kW Operating Instructions Contents MG16E102 VLT is a registered Danfoss trademark Contents VLT Refrigeration Drive 1 1 90 kW Operating Instructions 4 Start Up and Functional Test 28 2 MG16E102 VLT is a registered Danfoss trademark Contents VLT Refrigeration Drive 1 1 90 kW Operating Instructions 7 2 2 Single or Multiple Fans or Pumps 54 MG16E102 VLT is a registered Danfoss trademark Safety 1 Safety AWARNING 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 converts 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 AWARNING 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
56. Press OK Select All to LCP Ur des b Press OK A progress bar shows the uploading process 6 Press Hand On or Auto On to return to normal operation 5 2 2 Downloading Data from the LCP 1 Press Off to stop the motor before uploading or downloading data 2 Go to 0 50 LCP Copy 3 Press OK 4 Select All from LCP 5 Press OK A progress bar shows the downloading process 6 Press Hand On or Auto On to return to normal operation 5 3 Restoring Default Settings CAUTION Initialisation restores the unit to factory default settings Any programming motor data localization and monitoring records will be lost Uploading data to the LCP provides a backup before initialisation Restoring the frequency converter parameter settings back to default values is done by initialisation of the frequency converter Initialisation can be through 14 22 Operation Mode or manually Initialisation using 14 22 Operation Mode does not change frequency converter data such as operating hours serial communication selections p VLT Refrigeration Drive 1 1 90 kW Operating Instructions personal menu settings fault log alarm log and other monitoring functions Using 14 22 Operation Mode is generally recommended Manual initialisation erases all motor programming localization and monitoring data and restores factory default settings 5 3 1 Recommended Initialisation 1 Press Main Menu tw
57. Terminal 37 is fixed PNP logic Voltage level 0 24 V DC All digital inputs are galvanically isolated from the supply voltage PELV and other high voltage terminals Terminals 27 and 29 can also be programmed as output 2 Except Safe Stop input Terminal 37 3 See 3 4 6 6 Terminal 37 for further information about terminal 37 and Safe Stop When using a contactor with a DC coil inside in combination with Safe Stop it is important to make a return way for the current from the coil when turning it off This can be done by using a freewheel diode or alternatively a 30 or 50 V MOV for quicker response time across the coil Typical contactors can be bought with this diode Analog inputs ___ Switch 201 switch 202 ON Inpu Max current Accuracy of analog Bandwidth The analog inputs are galvanically isolated from the supply voltage PELV and other high voltage terminals PELV isolation ES xi Control E Mai 5 18 Mains a pS x i High E 37 voltage Motor Functional isolation RS485 z DC Bus Illustration 11 1 MG16E102 VLT is a registered Danfoss trademark 81 Specifications VLT Refrigeration Drive 1 1 90 kW Operating Instructions Pulse inputs Programmable pulse 2 1 The pulse and encoder inputs terminals 29 32 33 are galvanically isolated from the supply voltage PELV and other high voltage terminals
58. V AC Normal overload 11096 for 1 minute Frequency converter P1K1 P1K5 P2K2 P3KO P3K7 Typical Shaft Output kW 1 1 1 5 2 2 P20 Chassis A2 A3 may be converted to IP21 using a conversion kit See m AD also Mechanical mounting and IP21 Type 1 Enclosure kit in the Design Guide w N A3 P55 Type 12 PAS A4 A5 A4 A5 A A5 A4 A5 A4 A5 A4 A5 Typical Shaft Output HP at 208 V 9 5 4 9 gt A Continuous 7 5 10 6 12 5 16 7 3x200 240 V A Intermittent 7 3 8 3 11 7 13 8 18 4 3x200 240 V A 0 2 9 5 0 1 2 38 2 7 3 8 4 50 Continuous kVA 208 V AC kVA 0 Max input current Continuous 5 9 6 8 11 3 3x200 240 V A 5 Intermittent ER 6 5 7 1 12 4 3x200 240 V A Additional specifications Estimated power loss 63 82 116 155 185 at rated max load W IP20 IP21 max cable cross 130BA058 10 d 0 15 0 130BA057 4 4 4 12 12 12 min 0 2 24 section mains motor brake and load sharing mm AWG IP55 IP66 max cable cross section mains motor brake and 4 4 4 12 12 12 load sharing mm AWG Max cable cross section with 6 4 4 10 12 12 disconnect Weight enclosure IP20 kg 4 9 4 9 66 6 6 Weight enclosure IP21 kg 5 5 5 5 7 5 Weight enclosure IP55 kg 9 7
59. XBW d1 SW SsJe1se Ww d L SW e2ueijsu e i ag JUDY uvg Palas 2U31 4 Y 1 s 1d payas dn 195 Lage Bulssanay P S UAS Pees 1e4g 20 Lage Bunseo sng jeu6id peas 424 424 uonpe es uue 5eje1 yas 0 DW 53 sey D sa uy ulnuuixeyy Aejaq suods q uunuulxelJ ey q asuodsay uinuulu W SWI epo pejeuins3 sug dois Aed pneg SseJppy 10301014 s um s Hod 24 MLS PJOM snieis 4 101002 sbunjes 1onuo2 1951 uone3lunuuuuoD 1inope u 196611 sisoubeig inoaui 01002 1959Y uon un 1no uuil Jo pu3 uonp un 1no ul l Jo uo2 SWI 1Jno uu l 031402 DINOS 0 1402 AUS 0nuo sBunjas e19uan suondo pue uuo 1 5 4 1no uuil 3ndino 8 0 X euro 013005 sng 1ndino 8 0EX euro 2 XEVV 8 0 X euro TE S ui 8 0 X euro 51 MG16E102 VLT is a registered Danfoss trademark VLT Refrigeration Drive 1 1 90 kW Operating Instructions Programming eDgeupsiq 9197 K2ueBJeuu3 uon y Bu u eM 9 9 Bulu eM n n aunjyesadway inos aunyesadwa eunjejeduua abueyrsiq suon un soss qdulo2 195914 Oe 11 013005 sng LL ZyX euw 9je s XEVV 11 ais UNA LL zeX indino L1 ZtX Ieuluu l LL ZYX MO Bojeuy jasald MOWIL 6 zpx Jual 01305 sng 6 zpX Eu
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61. al preset references Local The frequency converter uses Hand On control or reference values from the LCP Table 8 2 Operation Status AC Brake AC Brake was selected in 2 70 Brake Function The AC brake over magnetizes the motor to achieve a controlled slow down AMA finish OK Automatic motor adaptation AMA was carried out successfully AMA ready AMA is ready to start Press Hand On to start AMA running AMA process is in progress Braking The brake chopper is in operation Generative Braking max Coast energy is absorbed by the brake resistor The brake chopper is in operation The power limit for the brake resistor defined in 2 12 Brake Power Limit kW has been reached e Coast inverse was selected as a function for a digital input parameter group 5 1 The corresponding terminal is not connected e Coast activated by serial communication MG16E102 VLT is a registered Danfoss trademark 57 Status Messages VLT Refrigeration Drive 1 1 90 kW Operating Instructions Current High Current Low DC Hold DC Stop Feedback high Feedback low Freeze output Freeze output request Freeze ref 58 Operation Status Ctrl Ramp down Control Ramp down was selected in 14 10 Mains Failure e The mains voltage is below the value set in 14 11 Mains Voltage at Mains Fault at mains fault e The frequency converter ramps down the motor u
62. ature or pressure for controlling fan compressor or pump motors 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 3 Internal Frequency Converter Controller Functions Illustration 2 3 is a block diagram of the frequency converter s internal components See Table 2 3 for their functions e TLOLOWZSZL Illustration 2 3 Frequency Converter Block Diagram p VLT Refrigeration Drive 1 1 90 kW Operating Instructions Area Title 1 Mains input 2 Rectifier 3 DC bus DC reactors 5 Capacitor bank Inverter Oo 7 Output to motor 8 Control circuitry MG16E102 VLT is a registered Danfoss trademark Functions Three phase AC mains power supply to the frequency converter The rectifier bridge converts the AC input to DC current to supply inverter power Intermediate DC bus circuit handles the DC current Filter the intermediate DC circuit voltage Prove line transient protection Reduce RMS current Raise the power factor reflected back to the line R
63. ay 130BT772 10 p VLT Refrigeration Drive 1 1 90 kW Operating Instructions 4 4 PM Motor Setup CAUTION Do only use PM motor with fans and pumps Set up the basic motor parameters E 1 10 Motor Construction 1 14 Damping Gain 1 15 Low Speed Filter Time Const 1 16 High Speed Filter Time Const 1 17 Voltage filter time const 1 24 Motor Current 1 25 Motor Nominal Speed e 1 26 Motor Cont Rated Torque 1 30 Stator Resistance Rs 1 37 d axis Inductance Ld 1 39 Motor Poles 1 40 Back EMF at 1000 RPM 1 66 Min Current at Low Speed 4 13 Motor Speed High Limit RPM 4 19 Max Output Frequency NOTE Advanced motor data Stator resistance and d axis inductance values are often described differently in technical specifications For programming resistance and d axis inductance values in frequency converters always use line to common starpoint values This is valid for both asynchronous and PM motors 36 MG16E102 VLT is a registered Danfoss trademark Start Up and Functional Tes Par Stator 1 30 Resistance This parameter gives stator winding resistance Rs similar to asynchronous Line to motor stator resistance When line line common data where stator resistance is measured between any two lines are available divide it with 2 Par d axis This parameter gives direct axis 1 37 Inductance inductance of the PM motor When line Line to line data are available d
64. ay uo pueH 04 0 ped y 421 F 0 3x l Aejdsiq 6 0 z at Aejds q 88 0 L xe ejdsig 26 0 9n eA inopeey uilojisn Z 0 9n eA UIW 1nopeey ulo3sn 1 0 n n Nopeay uoisn 0 0 ynopeay uojsn 421 0 nu W jeuosjed N SZ 0 36187 aun ejdsig Fo 36187 Z eur Aejdsiq 0 pews CL eur Aejdsiq 22 0 pews CL eur Aejdsiq 2 0 pews UL eur Aejdsiq 02 0 fe dsiq 421 2 0 puuey sdn 5 3nopeey 1 0 sdn jas p yur 3nope q ELO o Dour dn 195 SII 21 0 dn jas Bu uuuu e 8o d 1 0 dnaes aMPY 01 0 suonejedo dn s 1 0 Muf 9pow 16501 S0 0 dn j amp og 1e age Bunelado 0 0 sbuniesg jeuoibay 0 0 wun peeds 1030W 0 0 ebenbue1 10 0 sbumes 2156 40 0 ejds q uopgiacdo 1n1 2n41 nue ule eg MG16E102 VLT is a registered Danfoss trademark 50 VLT Refrigeration Drive 1 1 90 kW Operating Instructions Programming uolsi Auo2 Z peqpae4 3DNOS z n inos xpeqpaeJ UOISISAUO peqpae4 yeqpae4 3peqp 4 doo p sor eAug un inopeay ssayosuas qpaej 9 Jeu 01 8vx 1ndul duis L 8yX indu duet v 8vx indu d l r vw z ggx Indu Bojeuy A LL CvX O Bojeuy A 6 cvx MO Bojeuy A Z cvX MO Bojeuy S cvx indu bojeuy yX 1ndul Bojeuy 1 1ndul Bojeuy s nd no gt sindu w pue a1eq 607 epo uul 607 epo l4 quanq 607 epo 3414 501 POW 9114 eui pue a1eq 507 e ueuaiureWw 607 e
65. be reset in any of 4 ways Press Reset on the LCP Digital reset input command Serial communication reset input command Auto reset Trip lock An alarm that causes the frequency converter to trip lock requires that input power is cycled The motor will coast to a stop The frequency converter logic will continue to operate and monitor 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 above and may be reset in any of those 4 ways p VLT Refrigeration Drive 1 1 90 kW Operating Instructions 9 3 Warning and Alarm Displays n l 0 0Hz 0 000psi 0 00A Y 0 0Hz s 1 0 Off a ILive zero error W2 Off Remote Stop Illustration 9 1 An alarm or trip lock alarm will flash on display along with the alarm number aj 2 0 0Hz 0 000kW 0 00A 0 0Hz s 0 2 Auto Remote Trip Illustration 9 2 In addition to the text and alarm code on the frequency converter LCP there are three status indicator lights SS 130BB467 10 On Warn m Illustration 9 3 60 MG16E102 VLT is a registered Danfoss trademark VVarnings and Alarms VLT Refrigeration Drive 1 1 90 kW Operating Instructions Alarm LED Warning OFF Alarm ON Flashing Trip Lock ON Flas
66. brake resistor see 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 seconds of run time The calculation is based on the intermediate circuit voltage and the brake resistance value set in 2 76 AC brake Max Current The warning is active when the dissipated braking is higher than 9096 of the brake resistance power If Trip 2 is selected in 2 13 Brake Power Monitoring the frequency converter will trip when the dissipated braking power reaches 10096 WARNING ALARM 27 Brake chopper fault The brake transistor is monitored during operation and if a short circuit occurs the brake function is disabled and a warning is issued The frequency converter is still p VLT Refrigeration Drive 1 1 90 kW Operating Instructions operational but since the brake transistor has short circuited substantial power is transmitted to the brake resistor even if it is inactive Remove power to the frequency converter and remove the brake resistor WARNING ALARM 28 Brake check failed The brake resistor is not connected or not working Check 2 75 Brake Check ALARM 29 Heatsink temp The maximum temperature of the heatsink has been exceeded The temperature fault will not reset until the temperature falls below a defined heatsink temperature The trip and reset points are different based on the frequency converter power size Troubleshooti
67. component which can charge the filter capacitors and cause a transient earth current The earth leakage current depends on various system configurations including RFI filtering screened motor cables and frequency converter power EN IEC61800 5 1 Power Drive System Product Standard requires special care if the leakage current exceeds 3 5 mA p VLT Refrigeration Drive 1 1 90 kW Operating Instructions Earth grounding must be reinforced in one of the following ways Earth ground wire of at least 10 mm2 Two separate earth ground wires both complying with the dimensioning rules See EN 60364 5 54 8 543 7 for further information Using RCDs Where residual current devices RCDs also known as earth leakage circuit breakers ELCBs are used comply with the following Use RCDs of type B only which are capable of detecting AC and DC currents Use RCDs with an inrush delay to prevent faults due to transient earth currents Dimension RCDs according to the system configu ration and environmental considerations 3 4 2 2 Grounding Using Shielded Cable Earthing grounding clamps are provided for motor wiring see Illustration 3 8 130BA266 10 Illustration 3 8 Grounding with Shielded Cable 3 4 3 Access ACAUTION Device damage through contamination Do not leave the frequency converter unconvered Remove access cover plate with a screw driver See Illustration 3 9 Or remove front cove
68. d Danfoss trademark p Application Set Up Examples VLT Refrigeration Drive 1 1 90 kW Operating Instructions F1 gL UR 130BA761 11 91 92 93 Control signal 0 10 Vor 4 20 mA Start Motors insulation class B minimum Motor U V W PE 96 97 95 93 Cables type LIYCY Ltot max 40 mm 130BA760 11 91 92 93 FC 103 Alarm Motor U V W PE r 96 97 95 93 X l Cables type LIYCY Ltot max 40 mm Illustration 7 3 Pressure Control in Closed Loop Stand Alone System Single Fan or Pump Multiple Fans or Pumps in Parallel MG16E102 VLT is a registered Danfoss trademark 55 Darfi Application Set Up Examples VLT Refrigeration Drive 1 1 90 kW Operating Instructions 7 2 3 Compressor Pack 130BA807 10 Illustration 7 4 Po Pressure Transmitter 130BA808 12 FC 103 1218 27 20 37 55 54 U V W Supply E 4 1 2 AKS33 Illustration 7 5 How to Connect the FC 103 and AKS33 for Closed Loop Applications NOTE To find out which parameters are relevant run the Wizard 56 MG16E102 VLT is a registered Danfoss trademark Status Messages 8 Status Messages 8 1 Status Display When the frequency converter is in status mode status messages are generated automatically from within the frequency converter and appear in the bottom line of the display se
69. d features must be accessed though the menu structure Quick Menu or Main Menu in the frequency converter The FC 103 Wizard covers all standard settings for Compressors Single fan and pump Condenser fans These applications are then further expanded to allow control of the frequency converter to be controlled via the frequency converter s own internal PID controllers or from an external control signal After completing set up choose to re run wizard or start application The Application Guide can be cancelled at any time by pressing Back The Application Guide can be re entered through the Quick Menu When re entering the Application Guide the user will be asked to keep previous changes to the factory set up or to restore default values The FC 103 will start up initially with the Application guide thereafter in the event of power failure the application guide is accessed through the Quick menu screen The following screen will be presented MI T Wizard Press to run the YLT Drive Application Guide or Cancel to skip it Illustration 4 1 If Cancel is pressed the FC 103 will return to the status screen An automatic timer will cancel the wizard after 5 min of inactivity no keys pressed The wizard must be re entered through the Quick Menu as described below If OK is pressed the Application Guide will start with the following screen 30 MG16E102 VLT is a registered Danfoss trademark p
70. d which set up is active This is 3 0 24 Reference in percent not programmable Table 5 1 Quick Menu Allows access to programming parameters for initial set up instructions and many detailed 10 application instructions 799 RPM 7 83 A 36 4 kw 5 Press to access 2 Quick Setup for e a Oy a sequenced instructions to program the basic 0 000 frequency controller set up eyl 53 2 e Follow the sequence of parameters as de presented for the function set up Auto Remote R mping Allows access to all programming parameters e Press twice to access top level index Z f Main Menu e Press once to return to the last location Illustration 5 2 accessed e Press to enter a parameter number for direct access to that parameter mm S 207RPM 525A 244 kW Alarm Log Displays a list of current warnings the last 10 SCH 2 alarms and the maintenance log 6 9 a e For details about the frequency converter before it entered the alarm mode select the alarm number using the navigation keys Auto Remote Running 12 and press OK po Table 5 2 Illustration 5 3 40 MG16E102 VLT is a registered Danfoss trademark User Interface 5 1 4 Navigation Keys Navigation keys are used for programming functions and moving the display cursor The navigation keys also provide speed control in local hand operation Three frequency converter status indicator lights are also located in this area 130
71. e Illustration 8 1 o ml s 799RPM 7 83A 364kW 2 0 000 S 53 2 l Auto Remote Ramping Hand Local Stop Off Running Jogging Stand by a b c Illustration 8 1 Status Display a The first part of the status line indicates where the stop start command originates b The second part of the status line indicates where the speed control originates The last part of the status line gives the present frequency converter status These show the operational mode the frequency converter is in NOTE In auto remote mode the frequency converter requires external commands to execute functions p VLT Refrigeration Drive 1 1 90 kW Operating Instructions 8 2 Status Message Definitions Table The next three tables define the meaning of the status message display words Operation Mode Off The frequency converter does not react to any control signal until Auto On or Hand On is pressed Auto On The frequency converter is controlled from the control terminals and or the serial communi cation Hand On The frequency converter can be controlled by the navigation keys on the LCP Stop commands reset reversing DC brake and other signals applied to the control terminals can override local control Table 8 1 Reference Site Remote The speed reference is given from external signals serial communication or intern
72. e extended description in the Design Guide Have a good knowledge of the generic and safety standards applicable to the specific application User is defined as integrator operator servicing maintenance staff Standards Use of Safe Stop on terminal 37 requires that the user satisfies all provisions for safety including relevant laws regulations and guidelines The optional Safe Stop function complies with the following standards EN 954 1 1996 Category 3 IEC 60204 1 2005 category 0 uncontrolled stop IEC 61508 1998 SIL2 IEC 61800 5 2 2007 safe torque off STO function IEC 62061 2005 SIL CL2 ISO 13849 1 2006 Category 3 PL d ISO 14118 2000 EN 1037 prevention of unexpected start up The information and instructions of the instruction manual are not sufficient for a proper and safe use of the Safe Stop functionality The related information and instructions of the relevant Design Guide must be followed Protective measures Safety engineering systems may only be installed and commissioned by qualified and skilled personnel The unit must be installed in an IP54 cabinet or in an equivalent environment The cable between terminal 37 and the external safety device must be short circuit protected according to ISO 13849 2 table D 4 If any external forces influence the motor axis e g suspended loads additional measures e g a safety holding brake are required in order to eliminate hazards
73. e unit DO NOT start the frequency converter at this time For units with a disconnect switch turn to the ON position to apply power to the frequency converter NOTE If the status line at the bottom of the LCP reads AUTO REMOTE COASTING or Alarm 60 External Interlock is displayed this indicates that the unit is ready to operate but is missing an input signal on terminal 27 See Illustration 3 36 for details 4 3 Basic Operational Programming 4 3 1 Set up Wizard The built in wizard menu guides the installer through the set up of the frequency converter in a clear and structured manner and has been constructed with reference to the industries refrigeration engineers to ensure that the text and language used makes complete sense to the installer At start up the FC 103 asks the user run the VLT Drive Application Guide or to skip it until it has been run the FC 103 will ask every time at start up thereafter in the event of power failure the application guide is accessed through the Quick menu screen If Cancel is pressed the FC 103 will return to the status screen An automatic timer will cancel the wizard after 5 min of inactivity no keys pressed The wizard must be re entered through the Quick Menu when it has been run once Answering the questions on the screens takes the user though a complete set up for the FC 103 Most standard refrigeration applications can be setup by using this Application Guide Advance
74. ed Danfoss trademark p User Interface VLT Refrigeration Drive 1 1 90 kW Operating Instructions 5 User Interface 5 1 Local Control Pane The local control panel LCP is the combined display and 5 1 1 LCP Layout keypad on the front of the unit The LCP is the user interface to the frequency converter The LCP is divided into four functional groups see Illustration 5 1 The LCP has several user functions o Start stop and control speed when in local S 5 control ES m Display operational data status warnings and Statue fa cautions 1234rpm 1 0A 43 5Hz Programming frequency converter functions Manually reset the frequency converter after a a 43 5 Hz fault when auto reset is inactive An optional numeric LCP NLCP is also available The NLCP Run OK operates in a manner similar to the LCP See the Programming Guide for details on use of the NLCP Status Menu Menu Quick Main s 3 NOTE The display contrast can be adjusted by pressing Status and 4 v key Warn Alarm Illustration 5 1 LCP a Display area b Display menu keys for changing the display to show status options programming or error message history Navigation keys for programming functions moving the display cursor and speed control in local operation Also included are the status indicator lights d Operational mode ke
75. educe harmonics on the AC input Stores the DC power Provides ride through protection for short power losses Converts the DC into a controlled PWM AC waveform for a controlled variable output to the motor Regulated three phase output power to the motor 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 3 Frequency Converter Internal Components p Introduction VLT Refrigeration Drive 1 1 90 kW Operating Instructions 2 4 Frame Sizes and Power Ratings Frame Size kW Table 2 4 Frames Sizes and Power Ratings 8 MG16E102 VLT is a registered Danfoss trademark Installation 3 Installation 3 1 3 2 Pre installation Check List Installation Site Check List The frequency converter relies on the ambient air for cooling Observe the limitations on ambient air temperature for optimal operation Ensure that the installation location has sufficient support strength to mount the frequency converter Keep the frequency converter interior free from dust and dirt Ensure that the components stay as clean as possible In construction areas provide a protective covering Optional IP55 TYPE 12 or IP66 NEMA 4 enclosures may be necessary Keep the manual drawings and diagrams acce
76. efinitions 62 And Alarm Displays a qa aaa 60 And Alarm Typ Sissies 60 Vd E 60 Wire SIZO co u aan 14 15 MG16E102 VLT is a registered Danfoss trademark 89 www danfoss com drives Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 130R0380 MG16E102 III M G 1 6 E 1 Q 2 x
77. enser fan is selected in application NO AMA can be run 130BA804 10 Run application this mode starts the frequency Illustration 4 21 converter in either hand local mode or via an external control signal if open loop is selected in an earlier screen Info Connect accordingly Illustration 4 22 o Kei n a a e 130BC955 10 Illustration 4 24 The Application Guide can be cancelled at any time by pressing Back The Application Guide can be re entered through the Quick Menu 130BC957 10 Illustration 4 25 34 MG16E102 VLT is a registered Danfoss trademark Start Up and Functional Tes VLT Refrigeration Drive 1 1 90 kW Operating Instructions When re entering the Application Guide select between previous changes to the factory set up or restore default values NOTE If the system requirement is to have the internal pack controller for 3 compressors plus by pass valve connected there is the need to specify FC 103 with the extra relay card MCB 105 mounted inside the frequency converter The bypass valve must be programmed to operate from one of the extra relay outputs on the MCB 105 board This is needed because the standard relay outputs in the FC 103 are used to control the compressors in the pack 4 3 2 Required Initial Frequency Converter Programming NOTE If the wizard is run ignore the following Frequency converters require basic operational programming before
78. erload of Digital Output On X30 6 X 5 32 Term X30 6 Digi Out MCB igi X 5 33 Term X30 7 Digi Out MCB 42 Overload of Digital Output On X30 7 46 Pwr card supply 47 24V supply low 101 4 62 MG16E102 VLT is a registered Danfoss trademark p Warnings and Alarms VLT Refrigeration Drive 1 1 90 kW Operating Instructions No Description Warning Alarm Trip Alarm Trip Lock Parameter Reference e raveuppylow ST 5 5 5 gt AMA check Un and bs H x x AVA mooro5g x AA motor oo mal x WIN gt x 54 X 5 N gt lt Amor H j TT m a A 6 6 6 6 gt lt seni terk H TT output Frequency at Maximum it X 1 X X X Qn l BRIN gt x x gt lt ge Heatsink Temperaturelow 2 x TT TT TT s Option Configuration has hanged x 69 Pwr Card Temp X X p es o n eses HH p mgs gt 73 Safe Stop Auto Restart Da 7 Reduced Pees ee 8 T m Wega Seong T x X m Dive tized Gebake x g Analog input 54 wrong sin T 9 w gt 2 a gt lt gt 250 New spare parts Table 9 2 Alarm Warning C
79. es a situation that may result in equipment or property damage only accidents NOTE Indicates highlighted information that should be regarded with attention to avoid mistakes or operate equipment at less than optimal performance Approvals Table 1 2 4 MG16E102 VLT is a registered Danfoss trademark p Introduction VLT Refrigeration Drive 1 1 90 kW Operating Instructions 2 Introduction 130BB492 10 Illustration 2 1 Exploded View A Size 1 LCP 10 Motor output terminals 96 U 97 V 98 W 4 Brake 81 82 and load sharing 88 89 terminals 5 Analog switches A53 A54 Mains input terminals 91 L1 92 L2 93 L3 7 Serial bus terminal switch Table 2 1 MG16E102 VLT is a registered Danfoss trademark 5 Introduction VLT Refrigeration Drive 1 1 90 kW Operating Instructions 130BB493 10 a Sis Y ra y Ha Bo Hur H 18 45 Illustration 2 2 Exploded View B and C Sizes 15 1 LCP 11
80. et Control board After installation and before first operation perform a commissioning test of the installation making use of Safe Stop Moreover perform the test after each modification of the installation 26 MG16E102 VLT is a registered Danfoss trademark p Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 3 4 7 Serial Communication RS 485 is a two wire bus interface compatible with multi drop network topology i e nodes can be connected as a bus or via drop cables from a common trunk line A total of 32 nodes can be connected to one network segment Repeaters divide network segments Note that 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 earth ground connection of the screen at every node is important including at high frequencies Thus connect a large surface of the screen to earth ground for example with a cable clamp or a conductive cable gland It may be necessary to apply potential equalizing cables to maintain the same earth ground potential throughout the n
81. etwork Particularly in instal lations with long cables To prevent impedance mismatch always use the same type of cable throughout the entire network When connecting a motor to the frequency converter always use screened motor cable Cable Screened twisted pair STP Cable length 1 Max 1200 m including drop lines Max 500 m station to station Table 3 6 MG16E102 VLT is a registered Danfoss trademark 27 Start Up and Functional Tes VLT Refrigeration Drive 1 1 90 kW Operating Instructions 4 Start Up and Functional Test 4 1 Pre start 4 1 1 Safety Inspection d AWARNING HIGH VOLTAGE If input and output connections have been connected improperly there is potential for high voltage on these terminals If power leads for multiple motors are improperly run in same conduit there is potential for leakage current to charge capacitors within the frequency converter even when disconnected from mains input For initial start up make no assumptions about power components Follow pre start procedures Failure to follow pre start procedures could result in personal injury or damage to equipment 1 Input power to the unit must be OFF and locked out Do not rely on the frequency converter disconnect switches for input power isolation 2 Verify that there is no voltage on input terminals L1 91 L2 92 and L3 93 phase to phase and phase to ground 3 Verify that there is no voltage on output term
82. frequency has reached the value set in 4 19 Max Output Frequency Check the application to determine the cause Possibly increase the output frequency limit Be sure the system can operate safely at a higher output frequency The warning will clear when the output drops below the maximum limit WARNING ALARM 65 Control card over temperature The cutout temperature of the control card is 80 C Troubleshooting Check that the ambient operating temperature is within limits Check for clogged filters e Check fan operation p VLT Refrigeration Drive 1 1 90 kW Operating Instructions e Check the control card WARNING 66 Heatsink temperature low The frequency converter is too cold to operate This warning is based on the temperature sensor in the IGBT module Increase the ambient temperature of the unit Also a trickle amount of current can be supplied to the frequency converter whenever the motor is stopped by setting 2 00 DC Hold Preheat Current at 5 and 1 80 Function at Stop ALARM 67 Option module configuration has changed One or more options have either been added or removed since the last power down Check that the configuration change is intentional and reset the unit ALARM 68 Safe Stop activated Loss of the 24 V DC signal on terminal 37 has caused the filter to trip To resume normal operation apply 24 V DC to terminal 37 and reset the filter ALARM 69 Power card temperature The temperature sensor on the
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84. h 08 X lddns suleyy 75 MG16E102 VLT is a registered Danfoss trademark VLT Refrigeration Drive 1 1 90 kW Operating Instructions Specifications 660 49 49 49 0S DEU S8l FLE L 091 ELA 111 191 82 cl 9 1 091 461 111 CO CO yo 421 1064 WOW 002 OSL 1 0S Y SC 9 8 9 91 OL OL DV A 08b 08 X Iddns sule t LL eiqer So sso so so so eso so sso so MODE AA TE I 2 j 1 10 B3 29Ji sinsopus MM a O ERE DE RR By ssi sinsopus 5 0 REC CENE RI UM EAD 12 62 61 01 TT EX Lai sinsopus DD a EE 11 01 Bx ozal sinsopus zu Buueys peo oe uon s sso qe2 NEU 9941 SSdI 1241 DMV zww 1030W sureuJ uon s sso 9 qe XLW 9941 SSdI LZdl Duueus peo pue ioloui 99610 OL OL 0 6 0 0146 Z SE 9 91 pepnj ul DIS 12euuoosip suwu YUM 0 WOW 00 OSL L OS c s 8 8 OL OL SUIELU uon2os ssoJ lqe Xew OZdI M peo xeu pa1e1 1esso amod p leuuns3 FRE L 2801 tv8 DEL 869 suone yi ads jeuonippy v A 8 1u lluuu lul V A snonunuo V A 6 7 O8EXE 1ueniuue1u V A 6 b 08 X snonunuo DL ZSOVEOEL Wan yndul NEW xob ye sa sos tcp soe 9c i VAI OV A 007 WAY snonu
85. he motor is driven by the frequency converter Sleep Mode The energy saving function is enabled This means that at present the motor has stopped but that it will restart automatically when required Speed high Motor speed is above the value set in 4 53 Warning Speed High Speed low Motor speed is below the value set in 4 52 Warning Speed Low Standby In Auto On mode the frequency converter will start the motor with a start signal from a digital input or serial communication Start delay In 1 71 Start Delay a delay starting time was set A start command is activated and the motor will start after the start delay time expires Start fwd rev Start forward and start reverse were selected as functions for two different digital inputs parameter group 5 1 The motor will start in forward or reverse depending on which corresponding terminal is activated Stop The frequency converter has received a stop command from the LCP digital input or serial communication Trip An alarm occurred and the motor is stopped Once the cause of the alarm is cleared the frequency converter can be reset manually by pressing Reset or remotely by control terminals or serial communication Trip lock An alarm occurred and the motor is stopped Once the cause of the alarm is cleared power must be cycled to the frequency converter The frequency converter can then be reset manually by pressing Reset or remotely by
86. high frequency noise isolation 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 if necessary The use of shielded cable or twisted pair is recommended Ensure that the shield is terminated correctly Cooling clearance Measure that top and bottom clearance is adequate to ensure proper air flow for cooling EMC considerations e Check for proper installation regarding electromagnetic compatibility Environmental consider e See equipment label for the maximum ambient operating temperature limits ations e Humidity levels must be 5 9596 non condensing Fusing and circuit Check for proper fusing or circuit breakers 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 an earth wire ground wire from its chassis to the building earth ground Check for good earth connections ground connections that are tight and free of oxidation Earthing grounding to conduit or mounting the back panel to a metal surface is not a suitable earth ground 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 dirt metal chips moisture and corr
87. hing Table 9 1 MG16E102 VLT is a registered Danfoss trademark 61 p Warnings and Alarms VLT Refrigeration Drive 1 1 90 kW Operating Instructions 9 4 Warning and Alarm Definitions Table 9 2 defines whether a warning is issued before an alarm and whether the alarm trips the unit or trip locks the unit No Description Warning Alarm Trip Alarm Trip Lock Parameter Reference Tewl SSCS x 2 Live zero error X X 6 01 Live Zero Timeout 4 Mains phase loss X X X 14 12 Function at Mains 5 e 2 amp _ Ociinkvotagelow T 7 8 gt lt EC p ease A oos a 14 Earth Ground fault x EE 00 yx 1 7 m sme T m Intemal Fan Fuk x 25 Brake resto soare x 27 srate chopper shoer x x J 2 30 Motor phase U missing X X X 4 58 Missing Motor Phase Function 31 Motor phase V missing X X X 4 58 Missing Motor Phase gt x x gt lt gt gt 8 04 Control Timeout Function Function 32 Motor phase W missing X 4 58 Missing Motor Phase Function 33 Inrush fault 34 Fieldbus communication fault 35 Out of frequency range 36 Mains failure 37 Phase Imbalance 38 Internal fault 39 Heatsink sensor 40 Overload of Digital Output Terminal 27 X 5 00 Digital I O Mode 5 01 Terminal 27 Mode 41 Overload of Digital Output Terminal 29 X 5 00 Digital 1 O Mode 42 Ov
88. ice to access parameters Scroll to 14 22 Operation Mode Press OK Scroll to Initialisation Press OK Qu SUL er SS Remove power to the unit and wait for the display to turn off 7 Apply power to the unit Default parameter settings are restored during start up This may take slightly longer than normal 8 Alarm 80 is displayed 9 Press Reset to return to operation mode 5 3 2 Manual Initialisation 1 Remove power to the unit and wait for the display to turn off 2 Press and hold Status Main Menu and OK at the same time and apply power to the unit Factory default parameter settings are restored during start up This may take slightly longer than normal Manual initialisation does not the following frequency converter information 15 00 Operating Hours 15 03 Power Up s 15 04 Over Temp s 15 05 Over Volt s 42 MG16E102 VLT is a registered Danfoss trademark User Interface VLT Refrigeration Drive 1 1 90 kW Operating Instructions 5 4 How to Operate 5 4 1 Five Ways of Operating The frequency converter can be operated in 5 ways 1 Graphical Local Control Panel GLCP 2 RS 485 serial communication or USB both for PC connection 3 Via AK Lon gt Gateway gt AKM programming softvvare 4 Via AK Lon gt system manager gt service tool programming software 5 Via MCT 10 Set up Software see 5 5 Remote Programming with If the frequency converter is fitted with fieldbus
89. inals 96 U 97 V and 98 W phase to phase and phase to ground 4 Confirm continuity of the motor by measuring ohm values on U V 96 97 V W 97 98 and W U 98 96 5 Check for proper grounding of the frequency converter as well as the motor 6 Inspect the frequency converter for loose connections on terminals 7 Record the following motor nameplate data power voltage frequency full load current and nominal speed These values are needed to program motor nameplate data later 8 Confirm that the supply voltage matches voltage of frequency converter and motor 28 MG16E102 VLT is a registered Danfoss trademark p Start Up and Functional Tes VLT Refrigeration Drive 1 1 90 kW Operating Instructions CAUTION Before applying power to the unit inspect the entire installation as detailed in Table 4 1 Check mark those items when completed Inspect for Description Fal Auxiliary equipment e Look for auxiliary equipment switches disconnects or input fuses circuit breakers that may reside on the input power side of the frequency converter or output side to the motor Ensure that they are ready for full speed operation Check function and installation of any sensors used for feedback to the frequency converter Remove power factor correction caps on motor s if present Cable routing Ensure that input power motor wiring and control wiring are separated or in three separate metallic conduits for
90. ings For closed loop operation check settings in loop operation check PID settings parameter group 20 0 Feedback Possible over magnetization Check for incorrect motor settings Check motor settings in parameter in all motor parameters groups 1 2 Motor data 1 3 Adv motor data and 1 5 Load indep setting Possible incorrect settings in the Check brake parameters Check Check parameter group 2 0 DC brake parameters Possible too ramp time settings brake and 3 0 Reference limits short ramp down times Phase to phase short Motor or panel has a short phase Eliminate any shorts detected to phase Check motor and panel phase for shorts Motor overload Motor is overloaded for the Perform startup test and verify application motor current is within specifi cations If motor current is exceeding nameplate full load current motor may run only with reduced load Review the specifi cations for the application Loose connections Perform pre startup check for loose Tighten loose connections connections Problem with mains power See Rotate input power leads into the lf imbalanced leg follows the wire Alarm 4 Mains phase loss frequency converter one position A it is a power problem Check mains description to B B to C C to A power supply Problem with the frequency Rotate input power leads into the lf imbalance leg stays on same converter frequency converter one position A input terminal it is a problem with to B
91. ip 0 7 WOW 00 NDW OSE 021 OSL S81 c c L S S OS 8 8 9 OL OL 91 UMA U01925 SS0J9 a qeo xey OMY zww Buneys peo pue yeiq SUIELU uon s sso lqe xeu OZdl DMV zUJUJ uoi es 55012 9 qe Xew 99 dl SSdI LZdl zww buueus peo pue e eJq sulew uon es SSO12 lqE pu 99 dl SSdl LZdl 6 IM WOW 00 OSL L yo 8 8 OL OL WOW 00 OSL L T 2 88 OL OL 0 1 S6 m 8 8 9 OL OL OL suone yi eds jeuonippy v A 009 ScSX ZEL SOL 28 S9 vs tV 9 82 EZ 6l 1u nluu lu v A 009 S7SXE Evel snonunuo VM Ov A SZS SOEL VA SNonunuo Iv Ov A SZS 4021 VA snonulju0D v A 009 Szsx yil HERE LEL v A 009 SZSX snonunuo GCSX LSL v A 0SS SCSX 1u nlluu lul v A 0SS SCSX snonunuo 2 F 1 00 1 0921 1516 KET m sim RE 2 s ox 1 10 TT eee a z ibo 18 A Tari 2 HESE E ED a HETE MEX NN MAW ZEN E HAN HAWI TEM Te 1 2 SS T r a a a 06 Z ISO ION II A sar rej Ali zl xod sd era wea x wea weld sta xu OL 7SOV80E L juauno indu xew OL 8SOVE0EL V 1uauno indmo Xv VW3N 99dl ZL 9d L ssd
92. ivide it with 2 common Par Back EMF at 1 40 1000RPM This parameter gives back EMF across stator terminal of PM Motor at 1000RPM RMS Line to mechanical speed specifically It is Line Value defined between line to line and expressed in RMS Value In case the PM Motor specifications provides this value related to another motor speed the voltage must be recalculated for 1000 RPM Table 4 2 Back EMF Back EMF is the voltage generated by a PM motor when no frequency converter is connected and the shaft is turned externally Technical specifications usually notes this voltage related to nominal motor speed or to 1000 RPM measured between two lines 4 5 Automatic Motor Adaptation Automatic motor adaptation AMA is a test procedure that measures the electrical characteristics of the motor to optimize compatibility between the frequency converter and the motor The frequency converter builds a mathematical model of the motor for regulating output motor current The procedure also tests the input phase balance of electrical power It compares the motor characteristics with the data entered in parameters 1 20 to 1 25 It does not cause the motor to run or harm to the motor Some motors may be unable to run the complete version of the test In that case select 2 Enable reduced AMA If an output filter is connected to the motor select Enable reduced AMA If warnings or alarms occ
93. l L WWAN LZdl sissey 07dl MA 1ndinO yeys jeoid 1 ZIS SINUIW 10 0LL PEOH AO eUHON DY A 009 scsxe Ajddns sulew MG16E102 VLT is a registered Danfoss trademark 78 lons nstruct ing 1 90 kW Operati VLT Refrigeration Drive 1 Specifications 11 1 1 Mains Supply 3x525 690 V AC V 1ojs 10 suondo JO pJe ojluo2 papeoy AII e Joy enxe M y Auo pe gt idA1 u6nou s sso v o M 0 01 dn ppe Aew peo JaWO snd pue suondo Jay NY p pni ul suonduunsuoo mod pae ouo e3Id 3 pue 421 Kpuedpuubis asi Lew s sso amod ay jeulwou uJoJJ pastel 51 A3u nb uj Bu u31IAS 2U JI esI A DA pue 1 M AUO ADUANbAL au ui sso JaMOd aui 0 ppe osje IM sJo30uJ ASU DIJJ 1 M07 ADUAIDYJa 1070W 152142 e uo paseq ale sanjeA suonipuo lqe pue Be1 oA u 3 HPA Sajeja e2ueJa 03 WSL aq papadxa pue suonipuo peo euuiou qe si sso J3MOH edu au pe1eJ pue peo payed 1e s lqe 4o oul lu s Dursn peunseey 860 S9 49 091 6801 66 CH 001 06 06d 0697 10 pamojje aq 1snuu Koe1n22eui 1u ui mse ui 5 jusudinba ye y JO 181S YUM epeui aie sjueulsJnseaug ybnouyy seo sso so so eso sso so 860 so REES s s s s Z x Z Z a s se s s zz eli lt vz B ea E 1ub ev
94. l load current for peak motor performance Motor size and frequency converter power must match for proper overload Z Illustration 3 1 Top and Bottom Cooling Clearance Enclosure aims we xe xe zs gt Table 3 1 Minimum Airflow Clearance Requirements protection If frequency converter rating is less than motor full motor output cannot be achieved A1 A5 B1 B4 C1 C3 C2 C4 MG16E102 VLT is a registered Danfoss trademark 9 p Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 3 3 2 Lifting 00 N e Check the weight of the unit to determine a safe 5 es lifting method c em SS Ensure that the lifting device is suitable for the O task If necessary plan for a hoist crane or forklift with the appropriate rating to move the unit A For lifting use hoist rings on the unit when provided i 3 3 3 Mounting TT Mount the unit vertically Illustration 3 3 Proper Mounting with Railings The frequency converter allows side by side installation NOTE Ensure that the strength of the mounting location Back plate is needed when mounted on railings will support the unit weight Mount the unit to a solid flat surface or to the optional back plate to provide cooling airflow see Illustration 3 2 and Illustration 3 3 3 3 4 Tightening Torques See 11 4 Connection Tightening Torques for proper Improper mounting can result in
95. ng Check for the following conditions Ambient temperature too high Motor cable too long Incorrect airflow clearance above and below the frequency converter Blocked airflow around the frequency converter Damaged heatsink fan Dirty heatsink ALARM 30 Motor phase U missing Motor phase U between the frequency converter and the motor is missing Remove power from the frequency converter and check motor phase U ALARM 31 Motor phase V missing Motor phase V between the frequency converter and the motor is missing Remove 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 Remove power from the frequency converter and check motor phase W ALARM 33 Inrush fault Too many power ups have occurred within a short time period 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 14 10 Mains Failure is NOT set to 0 No Function Check the fuses to the frequency converter and mains power supply to the unit 66 MG16E102 VLT is a registered Danfoss trademark Warnings and Alarms ALARM 38 Internal fault When an internal fault occurs a code number defined in Table 9 3 is displayed
96. ng Instructions 11 2 General Technical Data Mains supply Supply Terminals L1 L2 L3 Mains voltage low mains drop out During low mains voltage or a mains drop out the frequency converter continues until the intermediate circuit voltage drops below the minimum stop level which corresponds typically to 1596 below the frequency converter s lowest rated supply voltage Power up and full torque cannot be expected at mains voltage lower than 1096 below the frequency converter s lowest rated supply voltage Supply frequency 50 60 Hz 5 The unit is suitable for use on a circuit capable of delivering not more than 100 000 RMS symmetrical Amperes 240 500 600 690 V maximum Motor output U V W Output voltag 7 Voltage and power dependent Torque characteristics Starting torque Constant torque maximum 11096 for 1 min Starting torque maximum 135 up to 0 5 sec Overload torque Constant torque maximum 110 for 1 min Percentage relates to FC 103 s nominal torque Cable lengths and cross sections for control cables otor cable d 150m For power cables see electrical data tables Digital inputs Programmable digital inputs 4 6 80 MG16E102 VLT is a registered Danfoss trademark p Specifications VLT Refrigeration Drive 1 1 90 kW Operating Instructions Voltage level logic 1 NPN 14 V DC Duty cycle Min pulse width 4 5 ms Safe Stop Terminal 375
97. nstallation based on EMC requirements ALARM 18 Start failed The speed has not been able to exceed AP 70 Compressor Start Max Speed RPM during start within the allowed time set in AP 72 Compressor Start Max Time to Trip This may be caused by a blocked motor WARNING 23 Internal fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning can be disabled in 14 53 Fan Monitor 0 Disabled For the D E and F Frame filters the regulated voltage to the fans is monitored Troubleshooting Check for proper fan operation Cycle power to the frequency converter and check that the fan operates briefly at start up Check the sensors on the heatsink and control card WARNING 24 External fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning can be disabled in 14 53 Fan Monitor 0 Disabled Troubleshooting Check for proper fan operation Cycle power to the frequency converter and check that the fan operates briefly at start up Check the sensors on the heatsink and control card 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 Remove power to the frequency converter and replace the
98. nuo e 9 e su s9 w v Z te V 08b Obbx eme oi o o o e o Z VI A 08b vbxE snonunuo BESTEN HET EDE HEZ E HEY ESI RE TEA esee TERE UE a g Ee E w se V 6 08x snonunuo juan 3ndino i i o a ig ts a Xi VW3N 99d 2 i b b a a ig i J s 21 ad 1 ssd 55051 BEE AN ee SEE L 124 ssojueq 1291002 se d UN UOISJ9AU03 sa e Bulsn 241 0 pexieAuo aq Aew pue veg SISSEU OZd EEL SEE EE an A 09 12 qH indino eus GAL 981 MA ndino yeys 22104 d n dech id LENLEd sed z A8Ld AL Ld fouenbaJ4 2 nu u 011 PEOH AO EUHON DY A 08r 08 x g lddns sure i OU 8S0V80 L MG16E102 VLT is a registered Danfoss trademark 76 VLT Refrigeration Drive 1 1 90 kW Operating Instructions Specifications 0 v s6 buueus peo pue axe1q YUM lt SLL lqeL zo so s o s wo 2 e u pi Cri TR ss Cj 7 TE ss zs osa ose DERE EC RE BEL BEK s EE civ DapnDut YDUMs 12euuoosip SUIBIA
99. ode List X Dependent on parameter 1 Cannot be Auto reset via 14 20 Reset Mode MG16E102 VLT is a registered Danfoss trademark 63 Warnings and Alarms The warning alarm information below defines each warning alarm condition provides the probable cause for the condition and details a remedy or troubleshooting procedure WARNING 1 10 Volts low The control card voltage is below 10 V from terminal 50 Remove some of the load from terminal 50 as the 10 V supply is overloaded Max 15 mA or minimum 590 Q This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer Troubleshooting Remove the wiring from terminal 50 If the warning clears the problem is with the customer wiring If the warning does not clear replace the control card WARNING ALARM 2 Live zero error This warning or alarm only appears if programmed by the user in 6 01 Live Zero Timeout Function The signal on one of the analog inputs is less than 50 of the minimum value programmed for that input Broken wiring or faulty device sending the signal can cause this condition Troubleshooting Check connections on all the analog input terminals Control card terminals 53 and 54 for signals terminal 55 common MCB 101 terminals 11 and 12 for signals terminal 10 common MCB 109 terminals 1 3 5 for signals terminals 2 4 6 common Check that the frequency converter programming and switch settings match
100. ogramming terminals minimum and maximum signal ranges custom displays automatic restart and other features See the LCP display to view detailed parameter programming and setting options Press Info in any menu location to view additional details for that function e Press and hold Main Menu to enter a parameter number for direct access to that parameter Details for common application set ups are provided in 7 Application Set Up Examples MG16E102 VLT is a registered Danfoss trademark 47 VLT Refrigeration Drive 1 1 90 kW Operating Instructions Programming 6 5 1 Quick Menu Structure BE30A MOT s Jeuruue OL 9 qpaeJj e uaJejay uinuuiXelW 21 02 qp934 23U319J98 UJnDUJIUIW 1 0Z Yun x eqpees s us13jau 21 02 Muf 9 Jnos yoeqp 4 80 07 UOISJ9AUO peqpeeJ 20 0Z au jeibau ulen jeuon1odojg q ZH peeds ues q wat paads ues q 101002 ASJBAU JPuJON uonounJ 1no uui 0197 BAIT LO 9 Dummong Cid 62 07 94597 3eqpeeJ WUNUWIXEN v oc 9497 yoeqp z UJnUJIUIW 7 0c buey 1ndino q e ueuuoped ed doo paso 1ulod 195 ul euoz l5uls oe eo sbulnjas doo paso D en eA qpeed joy YBIH ES jeuruue SL 9 INILA MOT Ee jeuruua y L 9 1uaun YBIH ES jeuruue 61 9 JUN 407 ES JeuruJs ZL 9 29 lqe1 z aun Aejds q 62 0 jews CL eur ejdsig 22 0 yews CL eur Aedsiq 2 0 jews CL eur Aejdsiq 02 0 sbumes Aejd
101. oltage control in 2 17 Over voltage Control NOTE The OVC algorithm does not work when using PM motors p VLT Refrigeration Drive 1 1 90 kW Operating Instructions See 5 1 1 Local Control Panel Keypad for resetting the frequency converter after a trip NOTE 4 1 Pre start through 4 7 Local control Test in this chapter concludes the procedures for applying power to the frequency converter basic programming set up and functional testing 4 8 System Start Up The procedure in this section requires user wiring and application programming to be completed 7 Application Set Up Examples is intended to help with this task Other aids to application set up are listed in 7 Application Set Up Examples The following procedure is recommended after application set up by the user is completed A CAUTION MOTOR START Ensure that the motor system and any attached equipment is ready for start It is the responsibility of the user to ensure safe operation under any condition Failure to do so could result in personal injury or equipment damage 1 Press Auto On 2 Ensure that external control functions are properly wired to the frequency converter and all programming is completed 3 Apply an external run command 4 Adjust the speed reference throughout the speed range 5 Remove the external run command 6 Note any problems If warnings or alarms occur see 9 Warnings and Alarms 38 MG16E102 VLT is a register
102. on MG16E102 VLT is a registered Danfoss trademark 69 Basic Troubleshooting 10 Basic Troubleshooting 10 1 Start Up and Operation p VLT Refrigeration Drive 1 1 90 kW Operating Instructions Symptom Possible Cause breaker tripped Shortcut on control voltage terminals Display dark No function a fault within the frequency Intermittent display converter Service switch open or missing motor connection No mains power with 24 V DC option card LCP Stop Missi tart signal Standb Motor nob running issing start signal Standby Motor coast signal active Coasting Wrong reference signal source terminal 12 or 50 or at control Wrong LCP LCP from VLT 2800 or 5000 6000 8000 FCD or FCM due to improper control wiring or Test Missing input power See Table 4 1 Check the input power source Missing or open fuses or circuit See open fuses and tripped circuit breaker in this table for possible causes No power to the LCP Check the LCP cable for proper connection or damage Check the 24 V control voltage supply for terminal 12 13 to 20 39 or 10 V supply for terminal 50 to AR Nu Display LCP is defective Test using a different LCP Internal voltage supply fault or Contact supplier SMPS is defective Overloaded power supply SMPS To rule out a problem in the control wiring disconnect all control wiring by removing the terminal blocks Check if the motor i
103. onduits or use separated shielded cable for high frequency noise isolation Failure to isolate power motor and control wiring could result in less than optimum frequency converter and associated equipment performance For your safety comply with the following requirements Electronic controls equipment is connected to hazardous mains voltage Extreme care should be taken to protect against electrical hazards when applying power to the unit Run motor cables from multiple frequency converters separately Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out Overload and Equipment Protection An electronically activated function within the frequency converter provides overload protection for the motor The overload calculates the level of increase to activate timing for the trip controller output stop function The higher the current draw the quicker the trip response The overload provides Class 20 motor protection See 9 Warnings and Alarms for details on the trip function Because the motor wiring carries high frequency current it is important that wiring for mains motor power and control are run separately Use metallic conduit or separated shielded wire Failure to isolate power motor and control wiring could result in less than optimum equipment performance See Illustration 3 6 VLT Refrigeration Drive 1 1 90 kW Opera
104. onnection to the USB connector on the frequency converter Protection and Features Electronic thermal motor protection against overload Temperature monitoring of the heatsink ensures that the frequency converter trips if the temperature reaches a predefined level An overload temperature cannot be reset until the temperature of the heatsink is below the values stated in the tables on the following pages Guideline these temperatures may vary for different power sizes frame sizes enclosure ratings etc The frequency converter is protected against short circuits on motor terminals U V W If a mains phase is missing the frequency converter trips or issues a warning depending on the load Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high The frequency converter constantly checks for critical levels of internal temperature load current high voltage on the intermediate circuit and low motor speeds As a response to a critical level the frequency converter can adjust the switching frequency and or change the switching pattern in order to ensure the performance of the frequency converter 84 MG16E102 VLT is a registered Danfoss trademark p Specifications VLT Refrigeration Drive 1 1 90 kW Operating Instructions 11 3 Fuse Tables 11 3 1 Branch Circuit Protection Fuses For compliance with IEC EN 61800 5
105. or a number of basic parameters See 6 4 International North American Default Parameter Settings for a complete list 6 Press Quick Menu on the LCP 7 Use the navigation keys to scroll to parameter group Q2 Quick Setup and press OK x 13 7 13 0A 1 1 Q1 My Personal Menu 130BB847 10 02 Quick Setup Q5 Changes Made Q6 Loggings v Illustration 4 29 8 Select language and press OK Then enter the motor data in parameters 1 20 1 21 through 1 25 The information can be found on the motor nameplate 1 20 Motor Power kW or 1 21 Motor Power HP 1 22 Motor Voltage 1 23 Motor Frequency MG16E102 VLT is a registered Danfoss trademark 35 Start Up and Functional Tes 1 24 Motor Current 1 25 Motor Nominal Speed 0 0 Hz 0 00kVV 101 a 1 21 Motor Power kW Ew v Illustration 4 30 9 A jumper wire should be in place between control terminals 12 and 27 If this is the case leave 5 12 Terminal 27 Digital Input at factory default Otherwise select No Operation For frequency converters with an optional Danfoss bypass no jumper wire is required 10 3 02 Minimum Reference 11 3 03 Maximum Reference 12 3 41 Ramp 1 Ramp Up Time 13 3 42 Ramp 1 Ramp Down Time 14 3 13 Reference Site Linked to Hand Auto Local Remote This concludes the quick set up procedure Press Status to return to the operational displ
106. or ordering with the unit may provide additional terminals See the manual provided with the equipment option See 11 2 General Technical Data for terminal ratings details VLT Refrigeration Drive 1 1 90 kW Operating Instructions p Terminal Description Digital Inputs Outputs Default Terminal Parameter Setting Description 12 13 24 V DC 24 V DC supply voltage Maximum output current is 200 mA total for all 24 V loads Useable for digital inputs and external transducers s 13 33 5 15 0 No operation 27 5 12 2 Coast Selectable for either inverse digital input or 29 5 13 0 No output Default setting 20 Common for digital inputs and 0 V potential for 24 V supply 37 Safe Torque Optional Safe input aa Off STO Used for STO Analog Inputs Outputs 39 Common for analog output 42 Programmable analog output The analog signal is 0 20 mA or 4 20 mA at a maximum of 500 Q 50 10 V DC analog supply voltage 15 mA maximum commonly used for potenti ometer or thermistor 53 Reference Analog input 54 Feedback Selectable for voltage or current Switches A53 and A54 select mA or V 55 Common for analog input Serial Communication 61 Integrated RC Filter for MG16E102 VLT is a registered Danfoss trademark cable screen ONLY for connecting the screen when experiencing EMC problems 21 Installation Terminal Description Digital
107. osion Switches Ensure that all switch and disconnect settings are in the proper positions Vibration e Check that the unit is mounted solidly or that shock mounts are used as necessary e Check for an unusual amount of vibration Table 4 1 Start Up Check List MG16E102 VLT is a registered Danfoss trademark 29 p Start Up and Functional Tes VLT Refrigeration Drive 1 1 90 kW Operating Instructions 4 2 Applying Power to the Frequency Converter AWARNING 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 AWARNING 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 Repeat this procedure after the voltage correction 2 Ensure that optional equipment wiring if present matches the installation application 3 Ensure that all operator devices are in the OFF position Panel doors should be closed or cover mounted 4 Apply power to th
108. other high voltage terminals Control characteristics Resolution of output frequency at 0 1000 Hz 0 003 Hz All control characteristics are based on a 4 pole asynchronous motor MG16E102 VLT is a registered Danfoss trademark 83 p Specifications VLT Refrigeration Drive 1 1 90 kW Operating Instructions Environment Enclosure IP20 Type 1 IP212 Type 1 IP55 Type 12 IP66 1 Only for lt 3 7 kW 200 240 V lt 7 5 kW 380 480 V 2 As enclosure kit for lt 3 7 kW 200 240 V lt 7 5 kW 380 480 V 3 Derating for high ambient temperature see special conditions in the Design Guide Minimum ambient temperature during full scale operation 0 C Derating for high altitude see special conditions in the Design Guide 5vX1 f 7U7U U71t1U0U7V7 fP7T7 I If T t F Y M EN 61800 37 EN 61000 673 4 EN 55011 EN 61800 3 EN 61000 6 1 2 EMC standards Immunity EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 See section on special conditions in the Design Guide Control card performance Scan interval 1 ms Control card USB serial communication USB standard 1 1 Full speed Connection to PC is carried out via a standard host device USB cable The USB connection is galvanically isolated from the supply voltage PELV and other high voltage terminals The USB ground connection is not galvanically isolated from protection earth Use only an isolated laptop as PC c
109. oup 5 1 The corresponding terminal is active The frequency converter saves the actual reference Changing the reference is now only possible via terminal functions Speed Up and Speed Down Jog request Jogging Motor check OVC control PowerUnit Off Protection md QStop Operation Status A jog command has been given but the motor will be stopped until a run permissive signal is received via a digital input The motor is running as programmed in 3 19 Jog Speed RPM e Jog was selected as function for a digital input parameter group 5 1 The corresponding terminal e g Terminal 29 is active e The Jog function is activated via the serial communication e The Jog function was selected as a reaction for a monitoring function e g No signal The monitoring function is active In 1 80 Function at Stop Motor Check was selected A stop command is active To ensure that a motor is connected to the frequency converter a permanent test current is applied to the motor Overvoltage control was activated in 2 17 Over voltage Control 2 Enabled The connected motor is supplying the frequency converter with generative energy The overvoltage control adjusts the V Hz ratio to run the motor in controlled mode and to prevent the frequency converter from tripping For frequency converters with an external 24 V power supply installed only Mains supply to the frequency converter is removed but the control card is s
110. ow WARN light comes on and text appears in the display area identifying the problem Red A fault condition causes the red alarm light to flash and an alarm text is displayed Table 5 4 fault has been cleared Table 5 5 5 2 BackUp and Copying Parameter Settings Programming data is stored internally in the frequency converter The data can be uploaded into the LCP memory as a storage back up e Once stored in the LCP the data can be downloaded back into the frequency converter e Data can also be downloaded into other frequency converters by connecting the LCP into those units and downloading the stored settings This is a quick way to program multiple units with the same settings e Initialisation of the frequency converter to restore factory default settings does not change data stored in the LCP memory MG16E102 VLT is a registered Danfoss trademark 41 User Interface AWARNING 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 or equipment or property damage 5 2 1 Uploading Data to the LCP 1 Press Off to stop the motor before uploading or downloading data Go to 0 50 LCP Copy
111. power card is either too hot or too cold Troubleshooting Check that the ambient operating temperature is within limits Check for clogged filters Check fan operation Check the power card ALARM 70 Illegal frequency converter configuration The control card and power card are incompatible Contact your supplier with the type code of the unit from the nameplate and the part numbers of the cards to check compatibility ALARM 80 Drive initialised to default value Parameter settings are initialised to default settings after a manual reset Reset the unit to clear the alarm ALARM 92 No flow A no flow condition has been detected in the system 22 23 No Flow Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM 93 Dry pump A no flow condition in the system with the frequency converter operating at high speed may indicate a dry pump 22 26 Dry Pump Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM 94 End of curve Feedback is lower than the set point This may indicate leakage in the system 22 50 End of Curve Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared 68 MG16E102 VLT is a registered Danfoss trademark Warnings and Alarms VLT Refrigeration Drive 1 1 90 kW Operating Instructions ALARM 95 Broken bel
112. quency 4 53 Warning Speed High 5 12 Terminal 27 Digital Input 5 40 Function Relay 6 15 Terminal 53 High Ref Feedb Value 6 50 Terminal 42 Output 14 20 Reset Mode International default parameter value 132 Hz 1500 RPM North American default parameter value 60 Hz 120 Hz 1800 RPM External interlock Speed 4 20 mA Parameter International North American default parameter default parameter value value 0 03 Regional International North America 1 20 Motor Power See Note 1 See Note 1 kW 1 21 Motor Power See Note 2 See Note 2 HP 1 22 Motor Voltage 230 V 400 V 575 V 1208 V 460 V 575 V 1 23 Motor 50 Hz 60 Hz Frequency 17 1500 m 1800 RPM 3 03 Maximum Reference 3 04 Reference Function 4 13 Motor Speed High Limit RPM See Note 3 and 5 Table 6 1 International North American Default Parameter Settings Note 1 1 20 Motor Power kW is only visible when 0 03 Regional Settings is set to 0 International Note 2 1 21 Motor Power HP is only visible when 0 03 Regional Settings is set to 1 North America Note 3 This parameter is only visible when 0 02 Motor Speed Unit is set to 0 RPM Note 4 This parameter is only visible when 0 02 Motor Speed Unit is set to 1 Hz Note 5 The default value depends on the number of motor poles For a 4 poled motor the international default value is 1500RPM and for a 2 poled
113. r and the motor or in the motor itself Troubleshooting Remove power to the frequency converter and repair the earth fault Check for earth faults in the motor by measuring the resistance to ground of the motor leads and the motor with a megohmmeter 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 your Danfoss supplier 15 40 FC Type 15 41 Power Section 15 42 Voltage 15 43 Software Version 15 45 Actual Typecode String 15 49 SW ID Control Card 15 50 SW ID Power Card 15 60 Option Mounted 15 61 Option SW Version for each option slot ALARM 16 Short circuit There is short circuiting in the motor or motor wiring Remove power to the frequency converter and repair the short circuit WARNING ALARM 17 Control word timeout There is no communication to the frequency converter The warning will only be active when 8 04 Control Word Timeout Function is NOT set to 0 Off If 8 04 Control Word Timeout Function is set to 5 Stop and Trip a warning appears and the frequency converter ramps down until it stops then displays an alarm Troubleshooting Check connections on the serial communication cable Increase 8 03 Control Word Timeout Time MG16E102 VLT is a registered Danfoss trademark 65 Warnings and Alarms Check the operation of the communication equipment Verify a proper i
114. r by loosening attaching screws See Illustration 3 10 14 MG16E102 VLT is a registered Danfoss trademark p Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 3 4 4 Motor Connection AWARNING INDUCED VOLTAGE Run output motor cables from multiple frequency converters separately Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out Failure to run output motor cables separately could result in death or serious injury 130BT248 10 For maximum wire sizes see 11 1 Power dependent Specifications Comply with local and national electrical codes Illustration 3 9 Control Wiring Access for A2 A3 B3 B4 C3 and for cable sizes C4 Enclosures Motor wiring knockouts or access panels are provided at the base of IP21 and higher NEMA1 12 units e Do not install power factor correction capacitors between the frequency converter and the motor 130BT334 10 e Do not wire a starting or pole changing device between the frequency converter and the motor Connect the 3 phase motor wiring to terminals 96 U 97 V and 98 W Ground the cable in accordance with grounding instructions provided Torque terminals in accordance with the information provided in Follow motor manufacturer wiring requirements The three following illustrations
115. re ye o6e3JoA suey aunyiey su eW HO UO sulew wopuey WMd Aduanbas4 waned 19119AU suo puny enads uonoy s llonu02 1S 1lu A3 18 04100 1S ue oog any 21607 Z 101619600 ajny 31607 Z ueajoog ajny 21607 L Joyesado any 21607 ueajoog ajny 21607 s jny 21607 JWI 49 OJ3u0 1S 5 enjeA Joyesedwio gt 10161900 Jo esedwo puelado o e edu o sioyeseduio gt DIS 1959 1u A3 dois lu A3 Yes poN 19101140 1S s um s 515 21507 Hews S n 8A eieq 31035 Ssa22y Uleled NOT UOISIADY SHOAAUO1 uoisiA9H AIX paom Bujulem NOT 4 e ug suon und NOT QI uounaN di SHOMAUOT SVL ev vl Wei 1 1 L 6 1 1671 06 71 EL 6cvi 8271 9 1 9271 CCPL cCvl LC vL Cl cL vL LL VL 01 F lvl vO vL 0 v 10 71 00 7 20 1 24 61 L t SEL Yi ev cv tl 17 61 Ov si l 02 21 CEL CL EL LLE L OL EL 41 61 20 21 20 81 10 21 00 21 LZ LL Clb 81 11 SL LL OL LL LLL 00 11 x0 LL BT yoeqp q sng C yoeqp q sng L y eqp q sng paads z Bor sng paads Bor sng yoeqpaa Dor sng uno sonsoubeiq 5404 3 1no uu l ALIS quas sabessay anes JUNO 10113 e e S DAOU SABESSAN a e s JUNO 1043 sng unon abessay sng sonsoubeiq 1104 24 pJomssed uonesi eniul 3IAJ S WY L SeuJeJ4 OJU
116. represent mains input motor and earth grounding for basic frequency converters Actual configurations vary with unit types and optional equipment Illustration 3 10 Control Wiring Access for A4 A5 B1 B2 C1 and C2 Enclosures See Table 3 3 before tightening the covers a Frame IP20 IP66 m A4 A5 S 2 B1 2 2 B2 S 2 2 C1 2 2 C2 5 2 2 No screws to tighten Does not exist Table 3 3 Tightening Torques for Covers Nm Illustration 3 11 Motor Mains and Earth Wiring for A Frame Sizes MG16E102 VLT is a registered Danfoss trademark 15 p Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 3 4 4 1 Motor Connection for A2 and A3 4 ere e lelTollellolTollo 8 Pe M d e x Follow these drawings step by step for connecting the K 1 SEI motor to the frequency converter AME STU 1 First terminate the motor earth then place motor E E U V and W wires in plug and tighten S 9 20 d IMS ll d Up Ze U e Illustration 3 12 Motor Mains and Earth Wiring for B C and D Frame Sizes Using Shielded Cable
117. s 98 1 ue Duuu El L ZH 1utod ubisaq 1e peeds 98 22 Wd 1utoq uftsa 1e peeds sg zz ZH MO 4 ON 1e p ds 78 22 dn jas om 1 MOd MOT 0Z ZZ suo oun duing Ly 0 uoldaJIg p ds 1030W 01 F s nsuae eeu INDIO 0 L dn jas ssed g oyny lwas 9 7 Aejaq 199 u yo1g 29 22 29 lqe L uonounj peqpasy 02 02 UDIH peqpasy DutuieM S F MOT Du 9S F Aejay uon un4 Or S indy jeut6iq 62 Ieuluu l S indy jeybiq zz Ieuluu l ZL S 9pow 6c 24101 1 ZO S apow LZ Ieuluu LO S eui ung lnullulyy 22 51 U33IMI9Q eAJ 1u 9 7Z uon olq P D MOUS S 7Z fejeg HAS LC s nsuos ejeu nbiol 0 L suol oun Jossaidwo gt zr D Hess DULU 6 1 s nsue eeu INDIO 0 L p ds 1e MO 4 06 22 julog uDiseqg 12 MOJ4 68 22 peeds pajey 1e ainssald 88 22 p ds wo J ON 1e lnss id 8 ZZ WdY MO 4 ON 3e p ds 68 22 uone n 5je 10104 HOM 28 22 uonew Ixoaddy ann Jeaul asenbs 18 22 uoljesuadwo gt 08 22 fejeg dung Aig 2 22 uonounJ dung Aig 92 22 SUI 15009 WNWIXEW 9 22 15009 1utodies 22 94 3498 dn exeM 22 ZH p ds dn ayem Et Wdy p ds dn exyeM zr zc sui dee s uinuulul W Ly 7Z au ung WNWIUIW Or zz Aejaq M0 J ON vZ cc uonbounj M0 J ON 22 22 uon q p ds MOT 22 22 uon q JIMOJ MOT LZ ZZ 1uaun 1e u id ploH DA 00 Z dois ye uonounj 08 1 ey q HAS 12 1 yes Bu ld El L
118. s when the motor runs with more than 10096 overload for too long Troubleshooting Check for motor overheating Check if the motor is mechanically overloaded Check that the motor current set in 1 24 Motor Current is correct 64 MG16E102 VLT is a registered Danfoss trademark Warnings and Alarms Ensure that Motor data in parameters 1 20 through 1 25 are set correctly If an external fan is in use check in 1 91 Motor External Fan that it is selected Running AMA in 1 29 Automatic Motor Adaptation AMA tunes the frequency converter to the motor more accurately and reduces thermal loading WARNING ALARM 11 Motor thermistor over temp Check whether the thermistor is disconnected Select whether the frequency converter issues a warning or an alarm in 1 90 Motor Thermal Protection Troubleshooting Check for motor overheating Check if the motor is mechanically overloaded When using terminal 53 or 54 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 1 93 Thermistor Source selects terminal 53 or 54 When using digital inputs 18 or 19 check that the thermistor is connected correctly between either terminal 18 or 19 digital input PNP only and terminal 50 Check 1 93 Thermistor Source selects terminal 18 or 19 WARNING ALARM 12 Torque limit The torque ha
119. s connected and the connection is not interrupted by a service switch or other device If the display is functioning but no output check that mains power is applied to the frequency converter Check if Off has been pressed Check 5 10 Terminal 18 Digital Input for correct setting for terminal 18 use default setting Check 5 12 Coast inv for correct setting for terminal 27 use default setting Check reference signal Local remote or bus reference Preset reference active Terminal connection correct Scaling of terminals correct Reference signal available 70 MG16E102 VLT is a registered Danfoss trademark Solution Follow the recommendations provided Replace the faulty LCP or connection cable Wire the terminals properly Use only LCP 101 P N 130B1124 or LCP 102 P N 130B1107 Press Status 4 to adjust the contrast Replace the faulty LCP or connection cable If the display stays lit then the problem is in the control wiring Check the wiring for shorts or incorrect connections If the display continues to cut out follow the procedure for display dark Connect the motor and check the service switch Apply mains power to run the unit Press Auto On or Hand On depending on operation mode to run the motor Apply a valid start signal to start the motor Apply 24 V on terminal 27 or program this terminal to No operation Program correct settings Check
120. s exceeded the value in 4 16 Torque Limit Motor Mode or the value in 4 17 Torque Limit Generator Mode 14 25 Trip Delay at Torque Limit can change this from a warning only condition to a warning followed by an alarm Troubleshooting If the motor torque limit is exceeded during ramp up extend the ramp up time If the generator torque limit is exceeded during ramp down extend the ramp down time If torque limit occurs while running possibly increase the torque limit Be sure the system can operate safely at a higher torque Check the application for excessive current draw on the motor WARNING ALARM 13 Over current The inverter peak current limit approximately 20096 of the rated current is exceeded The warning lasts about 1 5 s then the frequency converter trips and issues an alarm This fault may be caused by shock loading or quick acceleration with high inertia loads It may also appear after kinetic back up if the acceleration during ramp up is p VLT Refrigeration Drive 1 1 90 kW Operating Instructions quick If extended mechanical brake control is selected trip can be reset externally Troubleshooting Remove power and check if the motor shaft can be turned Check that the motor size matches the frequency converter Check parameters 1 20 through 1 25 for correct motor data ALARM 14 Earth ground fault There is current from the output phases to earth either in the cable between the frequency converte
121. s if a 24 V DC backup supply is connected If no 24 V DC backup supply is connected the frequency converter trips after a fixed time delay The time delay varies with unit size Troubleshooting Check that the supply voltage matches the frequency converter voltage Perform input voltage test Perform soft charge circuit test WARNING ALARM 9 Inverter overload The frequency converter is about to cut out because of an overload too high current for too long The counter for electronic thermal inverter protection issues a warning at 9896 and trips at 10096 while giving an alarm The frequency converter cannot be reset until the counter is below 9096 The fault is that the frequency converter has run with more than 10096 overload for too long Troubleshooting Compare the output current shown on the LCP with the frequency converter rated current Compare the output current shown on the LCP with measured motor current Display the Thermal Drive Load on the LCP and monitor the value When running above the frequency converter continuous current rating the counter 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 10096 in 1 90 Motor Thermal Protection The fault occur
122. sing a controlled ramp down The frequency converter output current is above the limit set in 4 57 Warning Current High The frequency converter output current is below the limit set in 4 52 Warning Speed Low DC hold is selected in 1 80 Function at Stop and a stop command is active The motor is held by a DC current set in 2 00 DC Hold Preheat Current The motor is held with a DC current 2 01 DC Brake Current for a specified time 2 02 DC Braking Time e DC Brake is activated in 2 03 DC Brake Cut In Speed RPM and a Stop command is active e DC Brake inverse is selected as a function for a digital input parameter group 5 1 The corresponding terminal is not active e The DC Brake is activated via serial communication The sum of all active feedbacks is above the feedback limit set in 4 57 Warning Feedback High The sum of all active feedbacks is below the feedback limit set in 4 56 Warning Feedback Low The remote reference is active which holds the present speed e Freeze output was selected as a function for a digital input parameter group 5 1 The corresponding terminal is active Speed control is only possible via the terminal functions Speed Up and Speed Down e Hold ramp is activated via serial communi cation A freeze output command has been given but the motor will remain stopped until a run permissive signal is received Freeze Reference was chosen as a function for a digital input parameter gr
123. siq 61 6 puq 1 0 44 0 92Jnos y32eqp d 90 02 YUN NOS z eqpee4 S0 0Z UOISIBAUOD Z peqpee4J 70 07 924nog C p edqpeej 0 0c Muf anos 35eqp d 20 02 UOISJ9AUO eqpaeJ 10 07 92Jnos eqpee4 00 02 inos z eoueJajay 91 inos sdUaIAJaYy S1 epo uoneinbiyuo 00 1 ApV uoz njnw 22 6 Bu un o nv did 62 07 9497 eqpeeJ unuuxeiw v 0c 9 91 peqpae4 uinuuiunw 6 02 buey 3ndino did 2 02 9 ueuuoged did 1 02 d L doo p sol 02 02 3UJI J 3noauul 0497 SAI 00 9 O1 Z BAI tS 2414 2 9 JUBISUO 3UJI 19114 Fe 8UIUJ91 9c 9 n 8A qpee4 jeu YBIH tS 4 SZ 9 qpea4 Jeu MOT tS Jeuiuua 77 9 1 MOT tS 77 9 ANILA qpeed jeu YBIH ES 24111 SL 9 9n eA qpas jeu MOT ES Jeuruue y L 9 yuan uBIH ES Ieuluu 1 9 juaun Ee euluu l ZL 9 ebeyoA YIH ES jeurue 11 9 eDeyoA MOT s Jeurue 01 9 qp 3 3zu 1u J u WUNWIXBIN 7L 0Z UJDUJIUIW L 0Z n n 21 02 pol uoneinBiuuo2 00 1 julod 195 3x3 euoz ajbuls 16 O dul 2 q uled leuonuodola ZH p ds ues q Wdy pasds ues q 043005 JPUJ4ON Old 18 07 L 1utodies 12 02 uonounj 1noaull 0197 N7 LO 9 NOS 0197 BAI 00 9 0J97 AAI tS JeUIWAaL 2 9 1 815402 eu ps ug 97 9 enjeA
124. ssible for detailed installation and operation instructions It is important that the manual is available for equipment operators Locate equipment as near to the motor as possible Keep motor cables as short as possible y Check the motor characteristics for actual Z p VLT Refrigeration Drive 1 1 90 kW Operating Instructions 3 3 Mechanical Installation 3 3 1 Cooling To provide cooling airflow mount the unit to a solid flat surface or to the optional back plate see 3 3 3 Mounting Top and bottom clearance for air cooling must be provided Generally 100 225 mm 4 10 in is required See Illustration 3 1 for clearance requirements Improper mounting can result in over heating and reduced performance Derating for temperatures starting between 40 C 104 F and 50 C 122 F and elevation 1000 m 3300 ft above sea level must be considered See the equipment Design Guide for detailed information tolerances Do not exceed 300 m 1000 ft for unshielded motor leads 130BA419 10 150 m 500 ft for shielded cable Compare the model number of unit on the nameplate to what was ordered to verify the proper equipment Ensure each of the following are rated for same voltage Mains power Frequency converter Motor Ensure that the frequency converter output current rating is equal to or greater than motor ful
125. supplied from an isolated mains source IT mains or floating delta or TT TN S mains with a grounded leg grounded delta set 14 50 RFI Filter to 0 Off When off the internal RFI filter capacitors between the chassis and the intermediate circuit are isolated to avoid damage to the intermediate circuit and to reduce earth capacity currents in accordance with IEC 61800 3 3 4 5 1 Mains Connection for A2 and A3 1 First mount the two screws on the mounting plate slide it into place and tighten fully Illustration 3 21 18 MG16E102 VLT is a registered Danfoss trademark VLT Refrigeration Drive 1 1 90 kW Operating Instructions Installation 3 4 5 2 Mains Connection for A4 A5 AWARNING The earth connection cable cross section must be at least How to connect to mains and earthing without mains disconnect switch NOTE 10 mm or 2 rated mains wires terminated separately according to EN 50178 IEC 61800 5 1 Bn A cable clamp is used 019 190 1 OL E9CVEOEL Then mount mains plug and tighten wires 3 AV TAN L AVI Illustration 3 24 How to connect to mains and earthing with mains disconnect switch 0156618021 Finally tighten support bracket on mains wires Illustration 3 22 4 Illustration 3 25 Illustration 3 23 19 MG16E102 VLT is a registered Danfoss trademark p
126. t Torque is below the torque level set for no load indicating a broken belt 22 60 Broken Belt Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM 96 Start delayed Motor start has been delayed due to short cycle protection 22 76 Interval between Starts is enabled Troubleshoot the system and reset the frequency converter after the fault has been cleared WARNING 97 Stop delayed Stopping the motor has been delayed due to short cycle protection 22 76 Interval between Starts is enabled Troubleshoot the system and reset the frequency converter after the fault has been cleared WARNING 98 Clock fault Time is not set or the RTC clock has failed Reset the clock in 0 70 Date and Time WARNING 203 Missing motor With a frequency converter operating multi motors an under load condition was detected This could indicate a missing motor Inspect the system for proper operation WARNING 204 Locked rotor With a frequency converter operating multi motors an overload condition was detected This could indicate a locked rotor Inspect the motor for proper operation WARNING 250 New spare part A component in the frequency converter has been replaced Reset the frequency converter for normal operation WARNING 251 New typecode The power card or other components have been replaced and the typecode changed Reset to remove the warning and resume normal operati
127. t provide electrical safety This function should not be used as a control for starting and or stopping the frequency converter The following requirements have to be meet to perform a safe installation of the frequency converter 1 Remove the jumper wire between control terminals 37 and 12 or 13 Cutting or breaking the jumper is not sufficient to avoid short circuiting See jumper on Illustration 3 36 2 Connect an external safety monitoring relay via a NO safety function the instruction for the safety device must be followed to terminal 37 Safe Stop and either terminal 12 or 13 24 V DC The safety monitoring relay must comply with Category 3 EN 954 1 PL d ISO 13849 1 24 MG16E102 VLT is a registered Danfoss trademark p Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 130BA874 10 Illustration 3 36 Jumper between Terminal 12 13 24 V and 37 MG16E102 VLT is a registered Danfoss trademark 25 Installation VLT Refrigeration Drive 1 1 90 kW Operating Instructions 37 1308 749 10 1 Safety device Cat 3 circuit interrupt device possibly 7 Inverter with release input Table 3 5 Safe Stop commissioning test Frequency converter Ho Safe channel Short circuit protected cable if not inside installation cabin
128. tal input terminal 27 is designed to receive a 24 V DC external interlock command In many applications the user wires an external interlock device to terminal 27 When no interlock device is used wire a jumper between control terminal 12 recommended or 13 to terminal 27 This provides in internal 24 V signal on terminal 27 No signal present prevents the unit from operating When the status line at the bottom of the LCP reads AUTO REMOTE COASTING or Alarm 60 External Interlock is displayed this indicates that the unit is ready to operate but is missing an input signal on terminal 27 When factory installed optional equipment is wired to terminal 27 do not remove that wiring 3 4 6 5 Terminal 53 and 54 Switches Analog input terminals 53 and 54 can select either voltage 0 to 10 V or current 0 4 20 mA input signals Remove power to the frequency converter before changing switch positions Set switches A53 and A54 to select the signal type U selects voltage selects current p VLT Refrigeration Drive 1 1 90 kW Operating Instructions The switches are accessible when the LCP has been removed see Illustration 3 35 Note that some option cards available for the unit may cover these switches and must be removed to change switch settings Always remove power to the unit before removing option cards Terminal 53 default is for a speed reference signal in open loop set in 16 61 Terminal 53 Swi
129. tch Setting Terminal 54 default is for a feedback signal in closed loop set in 16 63 Terminal 54 Switch Setting s 130BT310 10 VLT Illustration 3 35 Location of Terminals 53 and 54 Switches 3 4 6 6 Terminal 37 Terminal 37 Safe Stop function The frequency converter is available with optional safe stop functionality via control terminal 37 Safe Stop disables the control voltage of the power semiconductors of the frequency converter output stage which in turn prevents generating the voltage required to rotate the motor When the Safe Stop T37 is activated the frequency converter issues an alarm trips the unit and coasts the motor to a stop Manual restart is required The Safe Stop function can be used for stopping the frequency converter in emergency stop situations In the normal operating mode when Safe Stop is not required use the frequency converter s regular stop function instead When automatic restart is used the requirements according to ISO 12100 2 paragraph 5 3 2 5 must be fulfilled MG16E102 VLT is a registered Danfoss trademark 23 Installation Liability conditions It is the responsibility of the user to ensure personnel installing and operating the Safe Stop function Read and understand the safety regulations concerning health and safety accident prevention Understand the generic and safety guidelines given in this description and th
130. ter speed at 0 Hz xx 14 7 0 00A 1 1 Analog Reference Q3 21 130BT762 10 3 02 Minimum Reference 0 000 Hz Illustration 6 2 3 3 03 Maximum Reference Set maximum internal frequency converter reference to 60 Hz This sets the maximum frequency converter speed at 60 Hz Note that 50 60 Hz is a regional variation x 14 7 0 00A 1 1 Analog Reference Q3 21 A 130BT763 11 3 03 Maximum Reference 50 000 Hz Illustration 6 3 4 6 10 Terminal 53 Low Voltage Set minimum external voltage reference on Terminal 53 at 0 V This sets the minimum input signal at 0 V K 14 7 0 00A 1 1 i n Analog Reference Q3 21 5 5 6 10 Terminal 53 Lovv Voltage 0 00 V Illustration 6 4 44 MG16E102 VLT is a registered Danfoss trademark Programming 5 6 11 Terminal 53 High Voltage Set maximum external voltage reference on Terminal 53 at 10 V This sets the maximum input signal at 10 V S 2 14 7 0 00A 1 1 5 N Analog Reference Q3 21 5 en 6 11 Terminal 53 High m Voltage 10 00 V Y Illustration 6 5 6 6 14 Terminal 53 Low Ref Feedb Value Set minimum speed reference on Terminal 53 at 6Hz This tells the frequency converter that the minimum voltage received on Terminal 53 0 V equals 6 Hz output
131. the analog signal type Perform Input Terminal Signal Test 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 at 14 72 Function at Mains Imbalance Troubleshooting Check the supply voltage and supply currents to the frequency converter WARNING 5 DC link voltage high The intermediate circuit voltage DC is higher than the high voltage warning limit The limit is dependent on the frequency converter voltage rating The unit is still active WARNING 6 DC link voltage low The intermediate circuit voltage DC is lower than the low voltage warning limit The limit is dependent on the frequency converter voltage rating The unit is still active WARNING ALARM 7 DC overvoltage If the intermediate circuit voltage exceeds the limit the frequency converter trips after a time p VLT Refrigeration Drive 1 1 90 kW Operating Instructions Troubleshooting Connect a brake resistor Extend the ramp time Change the ramp type Activate the functions in 2 70 Brake Function Increase 14 26 Trip Delay at Inverter Fault If the alarm warning occurs during a power sag the solution is to use kinetic back up 14 10 WARNING ALARM 8 DC under voltage If the intermediate circuit voltage DC link drops below the under voltage limit the frequency converter check
132. ting Instructions N e O m A e Stop Start Speed Line Power 4 J L Motor ER L Separate Conduit Control Illustration 3 6 Proper Electrical Installation Using Conduit All frequency converters must be provided with short circuit and over current protection Input fusing is required to provide this protection see Illustration 3 7 If not factory supplied fuses must be provided by the installer as part of installation See maximum fuse ratings in 11 1 Power dependent Specifications 220 L1 L2 L3 130BB460 10 91 92 93 Fuses L1 T Y L2 L3 GND Illustration 3 7 Frequency Converter Fuses Wire Type and Ratings All wiring must comply with local and national regulations regarding cross section and ambient temperature requirements Danfoss recommends that all power connections be made with a minimum 75 C rated copper wire MG16E102 VLT is a registered Danfoss trademark 13 3 Installation See 11 1 Power dependent Specifications for recommended wire sizes 3 4 2 Earth Grounding Requirements AWARNING GROUNDING HAZARD For operator safety it is important to ground the frequency converter properly in accordance with national and local
133. ult setting can change based on the selection in 0 03 Regional Settings The following example shows accessing Terminal 18 to see the default setting 1 Press Main Menu twice scroll to parameter group 5 Digital In Out Parameter Data Set and press OK K e 14 6 0 00A 0 si a 2 Brakes 3 8 Reference Ramps 4 Limits Warnings pe Digital In Out v Illustration 6 9 MG16E102 VLT is a registered Danfoss trademark 45 Programming 2 Scroll to parameter group 5 1 Digital Inputs and press OK exa 14 796 0 00A 1 1 Digital In Out 5 5 5 0 Digital I O mode a pe Digital Inputs 5 4 Relays 5 5 Pulse Input v Illustration 6 10 3 Scroll to 5 10 Terminal 18 Digital Input Press OK to access function choices The default setting Start is shown 2 14 7 0 00A 1 1 e n Digital Inputs 5 1 m zl 5 10 Terminal 18 Digital Input EW Start Illustration 6 11 6 4 International North American Default Parameter Settings Setting 0 03 Regional Settings to 0 International or 1 North America changes the default settings for some parameters Table 6 1 lists those parameters that are effected VLT Refrigeration Drive 1 1 90 kW Operating Instructions p Parameter 4 14 Motor Speed High Limit Hz See Note 4 4 19 Max Output Fre
134. upplied by the external 24 V Protection mode is active The unit has detected a critical status an overcurrent or overvoltage e To avoid tripping switching frequency is reduced to 4 kHz If possible protection mode ends after approximately 10 s e Protection mode can be restricted in 14 26 Trip Delay at Inverter Fault The motor is decelerating using 3 87 Quick Stop Ramp Time Quick stop inverse was chosen as a function for a digital input parameter group 5 1 The corresponding terminal is not active e The quick stop function was activated via serial communication Ramping Ref high The motor is accelerating decelerating using the active Ramp Up Down The reference a limit value or a standstill is not yet reached The sum of all active references is above the reference limit set in 4 55 Warning Reference High MG16E102 VLT is a registered Danfoss trademark Status Messages VLT Refrigeration Drive 1 1 90 kW Operating Instructions Operation Status Ref low The sum of all active references is below the reference limit set in 4 54 Warning Reference Low Run on ref The frequency converter is running in the reference range The feedback value matches the setpoint value Run request A start command has been given but the motor is stopped until a run permissive signal is received via digital input Running T
135. ur see 9 Warnings and Alarms Run this procedure on a cold motor for best results p VLT Refrigeration Drive 1 1 90 kW Operating Instructions NOTE The AMA algorithm does not work when using PM motors To run AMA 1 Press Main Menu to access parameters Scroll to parameter group 1 Load and Motor Press OK Scroll to parameter group 1 2 Motor Data Press OK Scroll to 1 29 Automatic Motor Adaptation AMA Press OK Select 1 Enable complete AMA Press OK Nos 1004 24 E SY e o Follow on screen instructions The test will run automatically and indicate when it is complete 4 6 Check Motor Rotation Before running the frequency converter check the motor rotation The motor will run briefly at 5 Hz or the minimum frequency set in 4 72 Motor Speed Low Limit Hz T Press Quick Menu Scroll to Q2 Quick Setup Press OK Press OK 2 3 4 Scroll to 1 28 Motor Rotation Check 5 6 Scroll to 1 Enable The following text will appear Note Motor may run in wrong direction 7 Press OK 8 Follow the on screen instructions To change the direction of rotation remove power to the frequency converter and wait for power to discharge Reverse the connection of any two of the three motor cables on the motor or frequency converter side of the connection MG16E102 VLT is a registered Danfoss trademark 37 Start Up and Functional Tes 4 7 Local
136. v eui pue ai Do 2uoisiH awit 607 21018 ANJLA 507 2110151 quan Do 2uo1slH 607 uoisiH 196611 a 0j9g sejduies poyy 5ul55o7 quanq 1966u en13 u 6ui6601 amos 5ul55o7 sbumes 607 eead SeS JO JIQUINN Jajuno gt sinoH Bujuuny Lesen J9JUNO YM 1959Y S3JOA Sdual sdn samod J3JUNO YMA sinoH Buluuny sInoH Bune edo ejeg 5unes do UND 216190 PEOH AQ AUT PpEOH AQ 4 H AUI 18 uonbunj ainjyesaduia 1e q ony SUP JO JaquINN ENDY 19114 andino JO3UO A UE 01005 ueq uoljesuadwo gt yur 50 19414 Uu 9 S 29 91 19 51 09 S x9 SL 6S S 9S S SS SL S SL LS S OS SL 6v S 8v S 17 61 Kies Sv S v S cvs 17 91 We xv Sl 26 91 TES LE S 06 51 91 EZ S 22 91 lcs 0Z S CSL YSI EL S 21 91 LL S 01 5 41 61 80 51 L0 S 90 SL S0 S v0 S 0 SL ue LO S 00 SL x0 SL 29 71 19 71 09 71 9 1 6S VL SS vL S rL REL 15 71 06 71 jyu uuuollAu3 udso 402011 ADuanbas4 O3V ulnullu W uonespaubey ulnululy A T LA Buisiuundo Ab1auy au Ja HD WIT Juan euin uone1B6 uul 1419 WIT JUN uleg jeuonjodoJd HD ur auaun 32 atur uan APO adIAJas sbunies uon npold ney sayaau 3e Aejag dul yu nbiol ye Aejag dir Bunjas epooed apoyy uonei do aw 3 e1say WeWOINY 1959Y suomun jesay e uejequu SUIe 3e uonbunJ yney su
137. ys and reset MG16E102 VLT is a registered Danfoss trademark 39 p User Interface VLT Refrigeration Drive 1 1 90 kW Operating Instructions 5 1 2 Setting LCP Display Values 5 1 3 Display The display area is activated when the frequency converter Menu keys are used for menu access for parameter set up receives power from mains voltage a DC bus terminal or toggling through status display modes during normal an external 24 V supply operation and viewing fault log data The information displayed on the LCP can be customized 2 icati Quick Main Alarm s for user application Status 7 Me ph o Each display readout has a parameter associated Illustration 5 4 7 with it Options are selected in the quick menu Q3 13 Display Settings Key Function Shows operational information Display 2 has an alternate larger display option Status In Auto mode press to toggle between The frequency converter status at the bottom line of the display is generated automatically and is not selectable status read out displays e Press repeatedly to scroll through each status display Display Parameter number 1 Default setting Press Status plus A or v to adjust the 1 1 0 20 Motor RPMs display brightness 1 2 0 21 Motor current 13 0 22 Motor power kW 2 7 in hn 7 id corner of the ispla ows t irecti oto 2 0 23 Motor frequency i del SO WERA rotation an

VLT® Refrigeration Drive 1.1

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VLT&reg; Refrigeration Drive 1.1

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VLT® Refrigeration Drive 1.1