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Operating Instructions

1. Installation SECTION A A MAINS TERMINALS SECTION Ha Fa MOTOR TERMINALS AND a A 7 NIS BRAKE BRAKE TERMINALS m mh N o a B Q T L y BRAKE i 2 ES EH h TERMINAL SIII O d O N GR 292 Jal 2 e O O 11151 q R A Z el ele IRI 188 o o 74 J MAINS TERMINAL e d lo ojlo d 83 2 O P MOTOR TERMINAL E e 1331 o los o e e 4 pa perd T Mrs HA TE o n P e L DT TTD d o N of ne B A x Nw e oc is S x N co SNS oc S N Bis Da o 3 8 o o ac s lt EIS ER 2 Illustration 3 8 Terminal Locations D3h o SECTION B B SECTION A A MOTOR TERMINALS AND d MAINS TERMINALS A BRAKE TERMINALS 9 a 2 z EN S L Ex E f MAINS TERMINAE MOTOR TERMINAL EE e el 15 eu 331 2 ka o 13 le le 4 211 4 Eg 8 GROUND168 4 o 7 168 4 GROUND GROUND143 4 7 ii 6 143 4 GROUND 6 tpe 2 4X M10x20 STUD La j 0 0 VV TH NUT 101 oc N No gs aS 22 ou amp L aL DN DE N 00 S ot be O 5 245 8 0 0
2. Installation VLT Refrigeration Drive 110 250 kW Operating Instructions S R i KKK EN 5 91 L1 U 96 E o 3 7 92 12 5 00976 rop 2 input 93 L3 K 4 4K W 98 Bp 95 pE N AS PE 99 E od SE Motor Z777 DC bus T 880 Switch Mode 89 Power Supply 4K z mm S 24V DC R 82 Brake 15mA 200 mA resistor BER 50 10V OUT TOT m m S201 ry 53 AINN 9 LAS ON 0 20mA relay1 0 4 20 mA S202 OFF 0 10V 03 yi ni o 0 10V DC EAIN J z 02 240V AC 2A 0 4 20 mA jm 55 COM A IN 01 gt relay2 12 24 V OUT 069 240 AC 2A 13 24V OUT d Y ba 400 V AC 2A 24V NPN o0 d 18 D IN yov PNP A 24 V NPN E OY 19 DIN OV PNP jen A OUT 39 Analog Output 0 4 20 mA 20 COM DIN y AOUT 42 1 27 DIN OUT 25 S801 24V ON Terminated OFF Open ov 5V 29 D IN OUT 77 Lee 10 PNP J j S801 id ov 85 485 P RS 485 68 TT RS 485 24 V NPN Interface Keen 32 D IN 0V PNP N RS 485 69 FI 24 V NPN COM RS 485 61 COM RS 485 61 i p DIN 0V PNP i j ul PNP Source j j NPN Sink A A l Illustra
3. Basic Troubleshooting VLT Refrigeration Drive 110 250 kW Operating Instructions Symptom Motor running in vvrong direction Motor is not reaching maximum speed Motor speed unstable Motor runs rough Motor vvill not brake Open povver fuses or circuit breaker trip Mains current imbalance greater than 306 Motor current imbalance greater than 306 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 vvrong Check output limits in 4 73 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 settings For closed loop operation check settings in loop operation check PID settings parameter group 20 0 Feedback Possible over magnetization Check for i
4. 14 O 1 O Illustration 2 2 Close up View LCP and Control Functions 13 IP 21 54 NEMA 1 12 13 IP 20 Chassis Illustration 2 1 D1 Interior Components LCP Local Control Panel 9 Relay 2 04 05 06 RS 485 serial bus connector Lifting ring Digital 1 O and 24 V power supply Mounting slot Analog I O connector Cable clamp PE 1 2 3 4 Earth ground 6 7 8 Serial bus terminal switch 14 Motor output terminals 96 U 97 V 98 W Analog switches A53 A54 15 Relay 1 01 02 03 Table 2 1 Mains input terminals 91 L1 92 L2 93 L3 MG16F102 VLT is a registered Danfoss trademark 5 Introduction 2 2 Purpose of the Manual This manual is intended to provide detailed information for the installation and start up of the frequency converter provides requirements for mechanical and electrical instal lation including input motor control and serial communications wiring and control terminal functions provides detailed procedures for start up basic operational programming and functional testing The remaining chapters provide supplementary details These details include user interface detailed programming application examples start up troubleshooting and specifications 2 3 Additional Resources Other resources are available to understand advanced frequency converter functions and programming The
5. 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 yellow 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 bee
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8. nn Gr nan n oti aa 54 Power CONNECTION EEN 11 BACCO TEE 6 14 21 Pre Installation Checklist 8 Programming Protection PrOteCtilOn do linia And Features P ls elpnputea eer ee t degt 65 74 MG16F102 VLT is a registered Danfoss trademark Index Q Quick Men UE 31 34 36 31 SOT e EE 28 R Ramp down Time 28 Ramp p Time ee EE 28 Reference 4 44 47 48 31 Relay 5 evar 19 65 Remote COmilal E 6 Referehces a 48 Ree O 30 33 49 50 54 59 32 Residual Current Devices RCDs 12 Restoring Default Settings 33 REL Filter nett saa N one iut 17 RMS C entamin a eer e ss 6 E TE 19 Run Command Permissive S Screened Control 65 18 Serial Communication 6 18 19 32 47 48 49 50 19 67 Short det 55 SpecifiCatiO 58 i asin Au n Kana k l Ra di 6 63 Speed References uu u cada keya dima k ai n 29 35 47 Start HT E 6 33 34 60 Status Mess ainia iia 47 Mod ee ED EE 47 Stop Commanden 48 Supply Voltage 2 18 19 57 KITS s TT 5 la l
9. Illustration 3 16 Control Terminal Locations Connector 1 provides four programmable digital input terminals two additional digital terminals programmable as either input or output a 24 V DC terminal supply voltage and a common for optional customer supplied 24 V DC voltage Connector 2 terminals 68 and 69 are for an RS 485 serial communications connection Connector 3 provides two analog inputs one analog output 10 V DC supply voltage and Commons Tor the inputs and output e Connector 4 is a USB port available for use with the MCT 10 Set up Software Also provided are two Form C relay outputs that are in various locations depending upon the frequency converter configuration and size Some options available for ordering with the unit may provide additional terminals See the manual provided with the equipment option VLT Refrigeration Drive 110 250 kW Operating Instructions 3 5 5 VViring to Control Terminals Terminal plugs can be removed for easy access 130BT306 10 Illustration 3 17 3 5 6 Control Terminal Functions Frequency converter functions are commanded by receiving control input signals Each terminal must be programmed for the function it will be supporting in the parameters associated with that terminal See and for terminals and associated parameters It is important to confirm that the control terminal is programmed for the correct function S
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11. Darfi Warnings and Alarms VLT Refrigeration Drive 110 250 kW Operating Instructions No Description Warning Alarm Trip Alarm Trip Lock Parameter Reference 49 Speed limit X X 1 86 Compressor Min Speed for Trip RPM wind AMA check Uso and b n OA AMA ow len EXCEL AMA motor tog big H x AMA motor too small j gt AMA Parameter rd J x j O ul un wn O 9 NI x bx ix x gt lt s AWA interupted by ser s7_ awavimeot 5 m AWA menasi TT X x 59 jure im _ x TT TT 60 AA Output Frequency at Maximum ume X TT a vem A as Heat sink Tempersturetow X 1 67 Option Configuration has Changed x 69 par Cara temp OA 70 Illegal FC configuration X n er sse L n pesos T L9 m mese Azo sar 76 Power Unit Setup X x pessime i m mega escon oo X L o 30 Drive nales to Defaut vawe x T g Analog input 54 wrong seins T x gt 0 x 245 A 246 CEDE as E VERSE 250 New spare parts X Table 9 2 Alarm Warning Code List X Dependent on parameter Cannot be Auto reset via 14 20 Reset Mode MG16F102 VLT is a registered Danfoss trademark 53 Warnings and Alarms 9 5 Fault Mess
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13. z o Description Waming Alarm Trip Alarm Trip Lock Parameter Reference Mains phase loss X 14 12 Function at Mains Imbalance T1 DCinks tas q 5sdxi DCovervolage 7Txi DC under votage 7Txi x feet E DX II DN x 14 Earth ground fault E gt 27 erake chopper x x SSS gt 30 Motor phase U missing X X X 4 58 Missing Motor Phase 31 Motor phase V missing 4 58 Missing Motor Phase 32 4 58 Missing Motor Phase 33 Inrush fault 34 Fieldbus communication fault 35 Out of frequency range N W co N 9 UN x gt x gt gt gt lt Wi fik Function Ii x 5 5 6 IMPRIME 5 00 Digital I O Mode 5 01 Terminal 27 Mode 5 00 Digital I O Mode 5 02 Terminal 29 Mode x N r Ho 1 36 Mains failure 37 Phase Imbalance 38 Internal fault 39 Heatsink sensor 40 Overload of Digital Output Terminal 27 X 41 Overload of Digital Output Terminal 29 42 Overload of Digital Output On X30 6 42 Overload of Digital Output On X30 7 46 Pwr card supply 47 24 V supply low 48 1 8 V supply low E 5 32 Term X30 6 Digi Out MCB 101 5 33 Term X30 7 Digi Out MCB 101 E 2 52 MG16F102 VLT is a registered Danfoss trademark
14. CH je gal el il Voltage and frequency set up Illustration 4 2 NOTE Numbering of steps in wizard e g 1 12 can change depending on choices in the workflow This screen will automatically change to the first input screen of the Application Guide Illustration 4 5 en Lo o U a m Current and nominal speed set up Illustration 4 3 130BC954 10 Illustration 4 4 Illustration 4 6 Min and max frequency set up Illustration 4 7 MG16F102 VLT is a registered Danfoss trademark 23 Start Up and Functional Tes VLT Refrigeration Drive 110 250 kW Operating Instructions Min time between two starts NOTE 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 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 10 V 4 20 mA or FC 103 Lon The frequency converter will change its speed depending upon this reference signal 130BA791 10 Select sensor type Illustration 4 8 Choose with without bypass valve 130BA794 10 Illustration 4 11 130BA792 10 Illustration 4 9 Settings for sensor Select o
15. Accuracy of analog Inputs Max error 0 5 of full scale Bandwidth 200 Hz The analog inputs are galvanically isolated from the supply voltage PELV and other high voltage terminals PELV isolation S 24V 5 TE Control Mains Q m i High E 37 voltage Motor Functional isolation RS485 2 DC Bus Illustration 11 1 64 MG16F102 VLT is a registered Danfoss trademark Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions Pulse inputs Programmable pulse inputs 2 Analog output Number of programmable analog outputs 1 The analog 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 seated 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 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 Relay outputs Programmable relay outputs 2 MG16F102 VL
16. Illustration 7 1 Standard Drawing of Compressor with Internal Control VVizard input Bypass valve Recycling time start to start Min Hz Max Hz Setpoint Cut in cut out 400 230 V AC Amps RPM VLT Refrigeration Drive 110 250 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 dim 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 44 MG16F102 VLT is a registered Danfoss trademark Application Set Up Examples VLT Refrigeration Drive 110 250 kW Operating Instructions F1 gL UR 130BA761 11
17. 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 group 5 1 The corresponding terminal is active The frequency converter saves the actual reference Changing the reference is now only possible via terminal
18. or an external 24 V supply The information displayed on the LCP can be customized for user application Each display readout has a parameter associated with it Options are selected in the quick menu Q3 13 Display Settings Display 2 has an alternate larger display option The frequency converter status at the bottom line of the display is generated automatically and is not selectable Display Parameter number 1 Default setting 1 1 0 20 Motor RPMs 1 2 0 21 Motor current 1 3 0 22 Motor power kW 2 0 23 Motor frequency 3 0 24 Reference in percent Table 5 1 a 799 RPM 783 364 kw E A 7 0 000 y 53 2 Ey Auto Remote raping Ge Illustration 5 2 x 1 1 207RPM 5 25A 24 4 kW 6 9 Auto Remote Running G KE 0 G Illustration 5 3 5 1 3 Display Menu keys are used for menu access for parameter set up toggling through status display modes during normal operation and vievving fault log data Status Quick Main Alarm Menu Menu Log 130BP045 10 Illustration 5 4 Key Status Quick Menu Main Menu Alarm Log Table 5 2 Function Shovvs operational information e In Auto mode press to toggle between status read out displays e Press repeatedly to scroll through each status display Press Status plus 4 or Y to adjust the display brightness e The symbol in the upper
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20. 0 125 8 Illustration 3 9 Terminal Locations D2h MG16F102 VLT is a registered Danfoss trademark 15 VLT Refrigeration Drive 110 250 kW Operating Instructions Installation lt 2 e J SECTION B B SECTION A A A S gt o bl MOTOR TERMINALS AND MAINS TERMINALS paw NL BRAKE ITOR TERMINALS A 9 TERMINALS MP en Lo li 1 BRAKE REGEN 4 SUE MAINS TERMINAL 3 6 TERMINAL Uu A 319 a o dus N Jo IL D Le o jo 12 6 N MOTOR TERMINAL N 200 R 79 M S 11 L2 9 Em o o oF d P 1 1 u 2 00 SS Ke 4 E 2 _ N d o Lo 42 S E e m lt 6 lt ou S ei on 85825 33 13 149 58 265 104 Illustration 3 10 Terminal Locations D4h 16 MG16F102 VLT is a registered Danfoss trademark Installation 3 4 3 1 Motor Cable The motor must be connected to terminals U T1 96 V T2 97 W T3 98 Earth ground to terminal 99 All types of three phase asynchronous standard motors can be used with a frequency converter unit The factory setting is for clockwise rotation
21. 110 250 kW Operating Instructions 4 4 Local 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 4 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 e If warnings or alarms occur see e Check that motor data is entered correctly e Increase the ramp up time in 3 47 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 Check that motor data is entered correctly Increase the ramp down time in 3 42 Ramp 1 Ramp Down Time Enable overvoltag
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23. 14 Earth ground fault There is current from the output phases to earth either in the cable between the frequency converter and the motor or in the motor itself Troubleshooting e 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 Perform current sensor test ALARM 15 Hardware mismatch A fitted option is not operational with the present control board hardware or software Record the value of the following parameters and contact 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 e 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 MG16F102 VLT is a registered Danfoss trademark 55 Warnings and Alarms The warning will only be active when 8 04 Control Timeout Function is NOT set to OFF If 8 04 Control Timeout Function is set to Stop and Trip a warning appears and the frequency converter ramps down until it trips then displays an alarm Troublesho
24. 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 MG16F102 VLT is a registered Danfoss trademark 45 Application Set Up Examples VLT Refrigeration Drive 110 250 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 46 MG16F102 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 see Illustration 8 1 ml s 799RPM 7 83A 364kW 2 0 000 S 53 2 l Auto Remote Ramping
25. 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 is 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 MG16F102 VLT is a registered Danfoss trademark 47 Status Messages p VLT Refrigeration Drive 110 250 kW Operating Instructions Current High Current Low DC Hold DC Stop Feedback high Feedback low Freeze output Freeze output request Freeze ref 48 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 using 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
26. 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 110 250 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 internal preset references Local The frequency converter uses Hand On control or reference values from the LCP Table 8 2 Operation status AC Brake
27. V kW Typical Shaft output at 150 200 250 300 350 460 V HP Continuous 212 260 315 395 480 at 400 V A Intermittent 60 s overload 233 286 347 435 528 at 400 V A Continuous 190 240 302 361 443 at 460 480 V A Intermittent 60 s overload 209 264 332 397 487 at 460 480 V A Continuous KVA 147 180 218 274 333 at 400 V KVA Continuous KVA 151 191 241 288 353 at 460 V KVA Continuous 463 at 400 V A Continuous 183 231 291 348 427 at 460 480 V A Max cable size mains 2x70 2x70 2x150 2x150 2 150 motor brake and load 2 x 2 0 2 x 2 0 2 x 300 mcm 2 x 300 mcm 2 x 300 mcm share mm2 AWG Max external pre fuses A Estimated power loss at rated max load W 4 3234 3782 4213 5119 5893 400 V Estimated power loss at rated max load W 4 2947 3665 4063 4652 5634 460 V Weight enclosure IP21 IP54 kg Weight 82 91 112 123 138 enclosure IP00 kg 630 151 Efficiency 0 98 Output frequency 0 800 Hz Power card ambient trip 60 C Table 11 1 Mains Supply 3x380 480 VAC 68 MG16F102 VLT is a registered Danfoss trademark p Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions P132 P160 P200 P250 Typical Shaft output at 575 V HP 150 300 Typical Shaft output at 600 V kW 132 160 250 Output current Continuous 303 at 550 V A Inter
28. amount of vibration Table 4 1 Start Up Check List MG16F102 VLT is a registered Danfoss trademark 21 Start Up and Functional Tes VLT Refrigeration Drive 110 250 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 perform installation start up and maintenance by qualified personnel 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 be in operational readiness when the frequency converter is connected to AC mains could result in death serious injury equipment or property damage 1 Confirm input voltage is balanced within 3 If not correct input voltage imbalance before proceeding Repeat procedure after voltage correction 2 Ensure optional equipment wiring if present matches installation application 3 Ensure that all operator devices are in the OFF position Panel doors closed or cover mounted 4 Apply power to the unit DO NOT start the frequency converter at this time For units with a disconnect switch turn to the ON position
29. 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 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 VLT Refrigeration Drive 110 250 kW Operating Instructions 1107 RPM 3 84 A 1 1 Main menu 0 vs Operation Display 130BP066 10 1 xx 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 10 Cx 0 0 Basic Settings 0 1 Set up Opperations n 0 2 LCP Display 0 3 LCP Custom Readout gt 130BP087 10 Illustration 4 27 4 Use navigation keys to scroll to 0 03 Regional Settings and press OK 0 096 0 00A 1 00 0 03 Regional Settings EI 2 130BP088 10 0 International 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 for a number of basic parameters See 6 4 International N
30. ani 18 Exploded VieVsi 5 External Command EEN 7 47 Controllers 6 Interlock 36 Ve can u a a aa 34 F Fault Qa ei n n aaa 31 Feedback a a eege 21 58 48 Floating Delta iza ee ed aa aei i 17 Frequency Converter Block Diagram 6 A 5 n ell 8 Functional Testing 6 29 Fuse Specifications enrii EATA 71 ALICE C Ee ite 21 57 60 Sloe cinc 11 21 MG16F102 VLT is a registered Danfoss trademark 73 Index G Ground S elen de 12 21 Reie 18 ULC 12 21 Gro nded Delta o eR aad 17 EI rell ag eter 12 21 H Hand sE ic DD escort vcio s 32 eure 47 28 32 HarrmonicS u a beet rene alisado 6 EC 61830053 E 17 Induced V lta L 11 Ip ETC eT ici nacida 33 Input CU tun tere teo ee cer er S eU 17 Povver 10 12 21 50 60 7 Signal 35 Signals 19 Terminals 54 Vol me 22 50 Installation Installation cis 6 11 21 8 22 SIG s maa aus ee 8 Isolated Mains 17 L Leakage Current 53 5 MA 25 12 Bu Le D 9 Local COT OL K2 n ay WA a e U D aQ Y 30 32 47 Control Panel zs s da ees 30 ilo 28 OP STATI OM RO Q 30 Ki CC
31. comply with local and national regulations regarding cross section and ambient temperature requirements Danfoss recommends that all power connections are made with a minimum 75 C rated copper wire MG16F102 VLT is a registered Danfoss trademark 11 Installation 3 4 2 Earth Ground Requirements AWARNING EARTHING GROUNDING HAZARD For operator safety it is important to earth ground the frequency converter properly in accordance with national and local electrical codes as well as instructions contained within this document Do not use conduit connected to the frequency converter as a replacement for proper grounding Earth ground currents are higher than 3 5 mA Failure to earth ground the frequency converter properly could result in death or serious injury Earthing grounding hazard NOTE It is the responsibility of the user or certified electrical installer to ensure correct earthing grounding of the equipment in accordance with national and local electrical codes and standards Follow all local and national electrical codes to earth ground electrical equipment properly Proper protective earthing grounding for equipment with earth ground currents higher than 3 5 mA must be established see 3 4 2 1 Leakage Current gt 3 5 mA A dedicated earth wire ground wire is required for input power motor power and control wiring Use the clamps provided with the equipment for
32. 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 r 14 7 0 00A 1 1 Analog Reference Q3 21 6 10 Terminal 53 Low 130BT764 10 Voltage 0 00 V Illustration 6 4 34 MG16F102 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 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
33. cycled The motor will coast to a stop The frequency converter logic vvill continue to operate and monitor the frequency converter status Remove input povver to the frequency converter and correct the cause of the fault then restore povver This action puts the frequency converter into a trip condition as described above and may be reset in any of those 4 vvays 9 3 VVarning and Alarm Displays n l 2 0 0Hz 0 000psi 0 00A Y 0 0Hz Es 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 a 0 0Hz 0 000kW 0 00A 0 0Hz 0 Auto Remote Illustration 9 2 50 MG16F102 VLT is a registered Danfoss trademark VVarnings and Alarms VLT Refrigeration Drive 110 250 kW Operating Instructions n addition to the text and alarm code on the frequency converter display there are three status indicator lights 130BB467 10 VVarn NES Illustration 9 3 Warn LED Alarm LED ON Facing Trip Lock ON Flashing Table 9 1 MG16F102 VLT is a registered Danfoss trademark 51 VVarnings and Alarms VLT Refrigeration Drive 110 250 kW Operating Instructions 9 4 Warning and Alarm Definitions Table 9 2 defines vvhether a vvarning is issued prior to an alarm and vvhether the alarm trips the unit or trip locks the unit
34. 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 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 supplied 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 fre
35. 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 ALARM 38 Internal fault When an internal fault occurs a code number defined in the table below is displayed 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 eat VLT Refrigeration Drive 110 250 kW Operating Instructions 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 Control board EEPROM data is defective or too old 513 Communication time out reading EEPROM data 514 Communication time out reading EEPROM data 515 Application oriented control cannot recognize the EEPROM data 516 Cannot write to the EEPROM because a write command is on progress 517 Write command is under time out 518 Failure in the EEPROM 519 Missing or invalid barcode data in EE
36. necessary The use of shielded cable or twisted pair is recommended Ensure that the shield is terminated correctly Cooling clearance e 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 See equipment label for the maximum ambient operating temperature limits ations e Humidity levels must be 5 95 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 Earthing 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 e Check for loose connections wiring e 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 corrosion Switches e 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
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38. to apply power to the frequency converter NOTE If the status line at the bottom of the LCP reads AUTO REMOTE COAST this indicates that the unit is ready to operate but is missing an input signal on terminal 27 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 Advanced features must be accessed though the menu structure Quick Menu or Main Menu in the frequency converter The FC 103 Wizard covers all standard settings for Compressors Single fan and pum
39. to an outside control system or serial communication network VLT Refrigeration Drive 110 250 kW Operating Instructions 2 5 Internal Controller Functions Illustration 2 3 is a block diagram of the frequency converter s internal components See Table 2 2 for their functions e 21910725 1 Illustration 2 3 Frequency Converter Block Diagram Area Title Functions 1 Mains input e Three phase AC mains power supply to the frequency converter 2 Rectifier The rectifier bridge converts the AC input to DC voltage to supply inverter power 3 DC bus e Intermediate DC bus circuit handles the DC current e Filter the intermediate DC circuit current e Prove line transient protection e Reduce RMS current e Raise the power factor reflected back to the line e Reduce harmonics on the AC input 5 Capacitor bank e Stores the DC power e Provides ride through protection for short power losses 6 Inverter e Converts the DC into a controlled PWM AC waveform for a controlled variable output to the motor 7 Output to motor e Regulated three phase output power to the motor 6 MG16F102 VLT is a registered Danfoss trademark p Introduction VLT Refrigeration Drive 110 250 kW Operating Instructions Area Title Functions 8 Control circuitry e Input power internal processing output and motor current are monitored to provide efficient operation and contro
40. 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 60 MG16F102 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 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
41. 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 MG16F102 VLT is a registered Danfoss trademark 33 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 for details on using the LCP function keys Parameters may also be accessed through a PC using the MCT 10 Setup Software go to www VLT software com The quick menu is intended for initial start up Q2 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 th
42. 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 110 250 kW Operating Instructions 130BC958 10 e A53 ER 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 for control terminal parameter number and default setting Default 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 B
43. 0 2 Wd DAA cS V quand exyejg DA 0 2 uon n suo 1010 L ck quan e y 1d PIOH DA 00 C uon e es 1070W 0s 7 SEI 0 2 uonpedq siv ol RI S sonsuopereu anbio 6l v 92JnOS JOjsluJeUu 6 L uoneinfiuo 8Ll v uej JeuJo3X3 JOJOW 16 1 s 5um3 s e19uan Liv UOH293jOJg 9 JOOW 06 L 103011 pue peo 6 1 28 1 98 1 28 1 L8 L 08 1 8 1 6 1 8 1 LL 6 1 CLL st un WW e o WW e Hi Lo j 9 Y O L GCL 821 421 FCL cct 121 Dall 11 91 411 vil OM OL L all 90 1 0 1 00 1 x0 L jnopeey sul pue eje 68 0 skeq BurJoM UON Jeuonippv 8 0 skeg buppoM Jeuonippy 8 0 skeg DubpJoM 18 0 67 0 pug 1 50 22 0 pegs eumnjeuiuns ISQ 97 0 eumnjeuuns ISd 0 jeuuoj 2 0 yewo ejeq 12 0 eui pue a1eq 07 0 s um s 10 2 0 p1oMsseq O M DU V V I8uosij d O 55922 99 0 p4OMsSeq NU W Jeuosieqd 89 0 psomssed O M DU N Ule O 55922 9 0 p41oMsseg nu W UIBIN 09 0 Ppuomssed 9 0 Ado gt dnaes s 0 421 08 0 AES Ado2 En 421 uo Kay ssedKg e ud Sb 0 401 uo Sy Deseu JO Fi 0 401 uo Kay esed 0 d21 uo Key uo ony 0 d21uo A M YO Lb 0 d21 uo Kay uo pueH 04 0 ped y 421 xb 0 3x l Aejds q 6 0 z at Aejdsiq 88 0 L 3x l ejdsig 26 0 9n eA inopeey uilojisn Z 0 9n eA UIW 1nopeey ulo3sn 1 0 n n Nopeay uoisn 0 0 ynopeay uojs
44. 305 Missing SW version from power unit 2314 Missing power unit data from power unit 2315 Missing SW version from power unit 2316 Missint lo statepage from power unit 2324 Power card configuration is determined to be incorrect at power up 2325 A power card has stopped communicating while main power is applied 2326 Power card configuration is determined to be incorrect after the delay for power cards to register 2327 Too many power card locations have been registered as present 2330 Power size information between the power cards does not match 2561 No communication from DSP to ATACD 2562 No communication from ATACD to DSP state running 2816 Stack overflow control board module 2817 Scheduler slow tasks 2818 Fast tasks 2819 Parameter thread 2820 LCP stack overflow 2821 Serial port overflow 2822 USB port overflow 2836 cfListMempool too small MG16F102 VLT is a registered Danfoss trademark 57 Warnings and Alarms No Text 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 C0 Hardware incompatible with control board hardware 5126 Option in slot C1 Hardware incompatible with control board hardware 5376 6231 Out of memory Table 9 3 ALARM 39 Heatsink sensor No
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47. AUOD APY qp q qulodyas z 3ulodi s uon un quiodyas aeqpae4 qp z u l y q WNWIXEW 2212 1212 02 12 CLT 6L LZ 8112 MG16F102 VLT is a registered Danfoss trademark 42 VLT Refrigeration Drive 110 250 kW Operating Instructions Programming yes Jossaiduo gt p e q UO uon2efuj 1013405 uon2efu J9 oJ3u05 p peo1 1soW WNWIXeW Od 23U3 3J9Y UinullulW Od Od quiodyas Od Od 19540 OdP uoneziundo Od 16 82 06 82 6 87 18 82 98 82 98 82 v8 8c 8 8 28 82 18 82 8 87 43 MG16F102 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 Reference pass Ke 63 Feedback Night setback 4 20 mA 2 0 10V PT 1000 inputs optional Alarms
48. H 350A 120 610 A5005350 4 6 9URD31D08A0350 A070URD31KI0350 pec qe 31 400 N200 170M4015 LA50QS500 4 FWH 500A 20 610 A50QS500 4 6 9URD31D08A0550 A070URD31KI0550 250 170M4016 LA50QS600 4 FWH 600A 20 610 A50QS600 4 6 9URD31D08A0630 A070URD31KI0630 315 170M4017 LA50QS800 4 L50S 800 FWH 800A 120 610 A50QS800 4 6 9URD32D08A0800 A070URD31KI0800 31 800 Table 11 4 Alternative Fuse Options 11 3 4 Connection Tightening Torques When tightening all electrical connections it is very important to tighten with the correct torque Too low or too high torque results in a bad electrical connection Use a torque wrench to ensure correct torque Always use a torque wrench to tighten the bolts Frame Size Terminal Torque Bolt size D1h D3h Mains 19 40 Nm Motor 168 354 in M10 Load sharing lbs Regen Earth Ground 8 5 20 5 Nm pg Brake 75 181 in lbs D2h D4h Mains Motor 19 40 Nm Regen 168 354 in M10 Load sharing Ibs Earth ground Brake 8 5 20 5 Nm M8 75 181 in lbs Table 11 5 Torque for Terminals 72 MG16F102 VLT is a registered Danfoss trademark Index Index A AC ele 6 17 MANS nin ii arica 6 Mains Input Connection 17 VUES TI diia 6 A DD DD gg REA 9 Alarm Automatic Motor Adaptation 47 PUTO TOS TH 30 B Braking ee aten 56 47 C Cable Lengths And Cross Sect
49. MAKING MODERN LIVING POSSIBLE Operating Instructions VLT Refrigeration Drive 110 250 kW THE REAL DRIVE Contents VLT Refrigeration Drive 110 250 kW Operating Instructions Contents MG16F102 VLT is a registered Danfoss trademark Contents VLT Refrigeration Drive 110 250 kW Operating Instructions 4 5 System Start Up 29 2 MG16F102 VLT is a registered Danfoss trademark Contents VLT Refrigeration Drive 110 250 kW Operating Instructions 9 3 Warning and Alarm Displays 50 MG16F102 VLT is a registered Danfoss trademark Safety VLT Refrigeration Drive 110 250 kW Operating Instructions 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 converters are connected to hazardous mains voltages Extreme care should be taken to protect against shock Only trained personnel familiar with electronic equipment should install start or maintain this equipment 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 w
50. PROM 783 Parameter value outside of min max limits 1024 1279 A centelegram that has to be sent couldn t be sent 1281 Digital signal processor flash timeout 1282 Power micro software version mismatch 1283 Power EEPROM data version mismatch 1284 Cannot read digital signal processor software version 1299 Option SW in slot A is too old No Text 1300 Option SW in slot B is too old 1301 Option SW in slot CO 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 1317 Option SW in slot CO is not supported not allowed 1318 Option SW in slot C1 is not supported not allowed 1379 Option A did not respond when calculating platform version 1380 Option B did not respond when calculating platform version 1381 Option CO did not respond when calculating platform version 1382 Option C1 did not respond when calculating platform version 1536 An exception in the application oriented control is registered Debug information written in LCP 1792 DSP watchdog is active Debugging of power part data motor oriented control data not transferred correctly 2049 Power data restarted 2064 2072 HO81x option in slot x has restarted 2080 2088 HO82x option in slot x has issued a powerup wait 2096 2104 H983x option in slot x has issued a legal powerup wait 2304 Could not read any data from power EEPROM 2
51. SABESSAN API JUNO 1043 sng unon abessay sng sonsoubeiq 1104 24 Lage aualajay 19S9Jd pajas dn 195 179195 Bulssanay P S UAS Pees 1e4g 20 Lage Bunseo sng jeu6id peas 424 424 uonpe es uue 5eje1 yas 0 DW 53 1ey 1334 ulnuuixeyy Ke q suods q uunuulxelJ ey q asuodsay unuutuiy SWI epo pejeuins3 syg dois Aed pneg ssouppy 10301014 s um s Hod 24 MLS PJOM snieis lHodd 101002 sbunjes 1onuo2 1 sieuD uonpolunuludo buue34 1nopeay 196611 sisoubeiq inoaui 01002 1959Y no uull o puq uon un 1no ul l 10nuo9 SWI 3noaul 01002 DINOS 1onuo NS 0nu02 sBunjas e19uan suondo pue uuo 1 5 4 1no uuil INAINO 8 0 X 10 Ionuo2 sng indino 8 06 9 e s XBW 8 0 X 1 3129S UNA 8 0 X 41 MG16F102 VLT is a registered Danfoss trademark zH douq p ds 1ufiN dolg peads 1uBIN peqies 3UBIN sng 211 1uBiN eq lqeu3 Joyesipuy sng 1ufiN Aeq sbumes 14BIN Aeg 9497 uon y Bu u eM 95397 Bulu eM n n 95Jnos abieyrsig suon un soss qdulo2 195914 Oe 11 JOULE L Ionuo2 sng LL ZYX euw 9je s XEVV 11
52. T is a registered Danfoss trademark 65 Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions Max terminal load AC 1 1 on 4 6 NC Resistive load 240 V AC 2A 1 IEC 60947 parts 4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation PELV 2 Overvoltage Category Il 3 UL applications 300 V AC 2 A Control card 10 V DC output Terminal number 50 The 10 V DC supply is galvanically isolated from the supply voltage PELV and 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 Surroundings Enclosure frame size D and E IP00 IP21 IP54 Derating for high altitude see section on special conditions in the Design Guide EMC standards Emission EN 61800 3 EN 61000 6 3 4 EN 55011 IEC 61800 3 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 66 MG16F102 VLT is a registered Danfoss trademark Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions Control card performance Scan interval 5 ms 0000000505 A I USB standard 1 1 Full speed Gee oe E 0 00 VE CAUTION Connection to PC is carried out via a standard ho
53. VLT Programming Guide provides greater detail on working with parameters and many application examples The VLT Design Guide is intended to provide detailed capabilities and functionality to design motor control systems Supplemental publications and manuals are available from Danfoss See http www danfoss com Products Literature Technical Documentation htm for listings Optional equipment is available that may change some of the procedures described Reference the instructions supplied with those options for specific requirements Contact the local Danfoss supplier or visit the Danfoss website for downloads or additional information 2 4 Product Overview A frequency converter is an electronic motor controller that converts AC mains input into a variable AC waveform output The frequency and voltage of the output are regulated to control the motor speed or torque The frequency converter can vary the speed of the motor in response to system feedback such as position sensors on a conveyor belt The frequency converter can also regulate the motor by responding to remote commands from external controllers In addition the frequency converter monitors the system and motor status issues warnings or alarms for fault conditions starts and stops the motor optimizes energy efficiency and offers many more control monitoring and efficiency functions Operation and monitoring functions are available as status indications
54. Y sensor check the programming of 1 95 KTY Sensor Type 1 96 KTY Thermistor Resource and 1 97 KTY Threshold level match sensor wiring WARNING ALARM 12 Torque limit The torque has 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 VLT Refrigeration Drive 110 250 kW Operating Instructions Check the application for excessive current draw on the motor WARNING ALARM 13 Over current The inverter peak current limit approximately 200 of the rated current is exceeded The warning lasts about 1 5 secs then the frequency converter trips and issues an alarm This fault may be caused by shock loading or fast acceleration with high inertia loads 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
55. ages 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 the analog signal type Perform Input Terminal Signal Test WARNING ALARM 3 No motor No motor has been connected to the output of the frequency c
56. and speed combination demands a motor voltage higher than the actual DC link voltage 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 Check fan operation 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 Troubleshooting The heatsink temperature measured as 0 C could indicate that the temperature sensor is defective causing the fan speed to increase to the maximum If the sensor wire between the IGBT and the gate drive card is disconnected this warning would result Also check the IGBT thermal sensor 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 Safe stop has been activated To resume normal operation apply 24 V DC to terminal 37 then send a reset signal via Bus Digital 1 O or by pressing the reset key ALARM 69 Powe
57. bles and the EMC emission from the motor cables 1 Min 16 mm 3 5 3 Earthing Grounding of Screened Control Cables Table 3 7 Correct screening Alternatively the connection to terminal 61 can be The preferred method in most cases is to secure control omitted and serial communication cables with screening clamps provided at both ends to ensure best possible high re 3 FC frequency cable contact If the earth ground potential med Els between the frequency converter and the PLC is different 2 2 69 E electric noise may occur that will disturb the entire system PE PE Solve this problem by fitting an equalizing cable next to Tt the control cable Minimum cable cross section 16 mm2 2 Illustration 3 15 PLC FC 9 J 1 Min 16 mm 9 PE PE Equalizing cable PE 57 02 PE 4 Table 3 8 2 130BB922 11 Illustration 3 12 1 Min 16 mm Equalizing cable Table 3 6 50 60 Hz earth ground loops With very long control cables earth loops ground loops may occur To eliminate earth ground loops connect one end of the screen to earth ground with a 100 nF capacitor keeping leads short 18 MG16F102 VLT is a registered Danfoss trademark Installation 3 5 4 Control Terminal Types Terminal functions and default settings are summarized in 3 5 6 Control Terminal Functions 130BA012 11
58. ce 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 36 MG16F102 VLT is a registered Danfoss trademark Programming VLT Refrigeration Drive 110 250 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 95 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 programming 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 ente
59. dE 28 M Main MeRU a reed eerte aan A 34 31 Mains MAIS k aS RS 11 Supply L1 L2 L3 63 Supply 3 X 525 690 VAC 69 Voltage gua unn i RE es 31 32 48 Manual lnitialisation 33 MCT 10 Set Up 5 5 19 Mechanical installation 8 VLT Refrigeration Drive 110 250 kW Operating Instructions Menu KEY CN 30 31 SUCH m DP 32 38 Motor AA ER lee Connection Current RE EE Frequency Output Povver Protection Rotation Rotation Check Kl e E Sta STC WIM DEE Mounting Multiple Frequency Converter 11 14 N Navigation 27 34 47 30 32 Noise lsolation 10 21 Open LOOP BEE 34 Operation Keys 32 Optional 22 6 Output DEES ege 48 54 Performance U V VV 63 Ehre DEN 37 Overcurrent ec eter ete e ya ee PEU A A s si 48 Overload Protection 8 11 uu it ib 28 48 P Parameter Setting 32 REIMEN 18
60. e control in 2 17 Over voltage Control See 5 1 1 Local Control Panel for resetting the frequency converter after a trip 28 MG16F102 VLT is a registered Danfoss trademark Start Up and Functional Tes VLT Refrigeration Drive 110 250 kW Operating Instructions NOTE 4 2 Applying Power to the Frequency Converter through in this chapter concludes the procedures for applying power to the frequency converter basic programming set up and functional testing 4 5 System Start Up The procedure in this section requires user wiring and application programming to be completed See for application set up information The following procedure is recommended after application set up by the user is completed ACAUTION 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 MG16F102 VLT is a registered Danfoss trademark 29 Darfi User Interface VLT Refrigeration Drive 110 250
61. e 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 1 Source xx 14 7 0 00A 1 1 95 oo References 5 1 amp en 3 15 Reference Resource WI Analog input 53 Illustration 6 1 VLT Refrigeration Drive 110 250 kW Operating Instructions 2 3 02 Minimum Reference Set minimum internal frequency converter reference to 0 Hz This sets the minimum frequency converter 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
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63. eakage circuit breakers ELCBs are used comply with the following residual current devices RCDs Use RCDs of type B only which are capable of detecting AC and DC currents Use RCDs with an inrush delay to prevent faults due to transient earth currents Dimension RCDs according to the system configu ration and environmental considerations 12 MG16F102 VLT is a registered Danfoss trademark p Installation VLT Refrigeration Drive 110 250 kW Operating Instructions 3 4 2 2 Earthing Grounding IP20 3 4 2 3 Earthing Grounding IP21 54 Enclosures Enclosures The frequency converter can be earthed grounded using The frequency converter can be earthed grounded using conduit or shielded cable For earthing grounding of the conduit or shi
64. ections This vvarning vvill be generated on power cycle when the frequency converter is set to run with fewer inverters and will remain on ALARM 79 Illegal power section configuration The scaling card is the incorrect part number or not installed Also MK102 connector on the power card could not be installed 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 81 CSIV corrupt CSIV file has syntax errors ALARM 82 CSIV parameter error CSIV failed to init a parameter WARNING ALARM 104 Mixing fan fault The fan monitor checks that the fan is spinning at drive power up or whenever the mixing fan is turned on If the fan is not operating then the fault is annunciated The mixing fan fault can be configured as a warning or an alarm trip by 14 53 Fan Monitor Troubleshooting Cycle power to the frequency converter to determine if the warning alarm returns 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 operation MG16F102 VLT is a registered Danfoss trademark 59 Basic Troubleshooting 10 Basic Troubleshooting 10 1 Start Up and Operation p VLT Refrigeratio
65. ectronically activated function within the frequency converter provides overload protection for the motor The overload calculates the level of TE increase to activate timing for the trip controller O Stop output stop function The higher the current O Start T UU draw the quicker the trip response The overload No provides Class 20 motor protection See for details on the trip function 2 N Motor Control Because the motor wiring carries high frequency Illustration 3 3 Example of Proper Electrical Installation Using current it is important that wiring for mains Conduit motor power and control are run separately Use metallic conduit or separated shielded wire See Illustration 3 3 Failure to isolate power motor and control wiring could result in less than 7 DIO optimum equipment performance ala 130BB460 10 91 92 93 All frequency converters must be provided with Fuses j short circuit and over current protection Input o O fusing is required to provide this protection see Oe Illustration 3 4 If not factory supplied fuses must be provided by the installer as part of installation u E0 O See maximum fuse ratings in 11 3 1 Protection VZ GND Illustration 3 4 Frequency Converter Fuses Wire Type and Ratings All wiring must
66. ed 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 gives a warning at 98 and trips at 100 while giving an alarm The frequency converter cannot be reset until the counter is below 90 The fault is that the frequency converter is overloaded by more than 100 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 should increase When running below the frequency converter continuous current rating the counter should decrease WARNING ALARM 10 Motor overload temperature According to the electronic thermal protection ETR the motor is too hot Select whether the frequency converter gives a warning or an alarm when the counter reaches 100 in 1 90 Motor Thermal Protection The fault occurs when the motor is overloaded by more than 100 for too long Troubleshooting Check for motor overhea
67. eded 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 Troubleshooting 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 For the D E and F Frame sizes this alarm is based on the temperature measured by the heatsink sensor mounted inside the IGBT modules For the F Frame sizes this alarm can also be caused by the thermal sensor in the Rectifier module Troubleshooting Check fan resistance Check soft charge fuses IGBT thermal sensor 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 56 MG16F102 VLT is a registered Danfoss trademark Warnings and Alarms 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
68. ee for details on accessing parameters and programming The default terminal programming is intended to initiate frequency converter functioning in a typical operational mode 3 6 Serial Communication RS 485 is a two wire bus interface compatible with 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 Each repeater functions as a node within the segment in which it is installed Each node connected within a given network must have a unique node address across all segments Terminate each segment at both ends using either the termination switch S801 of the frequency converter or a biased termination resistor network Always use screened twisted pair STP cable for bus cabling and always follow good common installation practice Low impedance earth ground connection of the screen at every node is important including at high frequencies Thus connect a large surface of the screen to earth ground for example with a cable clamp or a conductive cable gland It may be necessary to apply potential equalizing cables to maintain the same earth ground MG16F102 VLT is a registered Danfoss trademark 19 Denpi Installation VLT Refrigeration Drive 110 250 kW Operating Instructions potential throughout the network Particularly in instal lations with long cables T
69. eg grounded delta set 14 50 RFI Filter to OFF When off the internal RFI filter capacitors between the chassis and the intermediate circuit are isolated to avoid damage to the intermediate circuit and to reduce earth ground capacity currents in accordance with IEC 61800 3 MG16F102 VLT is a registered Danfoss trademark 17 Installation VLT Refrigeration Drive 110 250 kW Operating Instructions 3 5 Control Wiring Connection PLC FC Isolate control wiring from high power JE E components in the frequency converter 100nF PE S 130BB609 11 Illustration 3 13 If the frequency converter is connected to a thermistor for PELV isolation optional thermistor control wiring must be reinforced double insulated A 24 V DC supply voltage is recommended Avoid EMC noise on serial communication This terminal is connected to earth ground via an internal RC link Use twisted pair cables to reduce interference between conductors The recommended method is shown below 3 5 1 Access All terminals to the control cables are located underneath the LCP on the inside of the frequency converter To access open the door IP21 54 or remove the front panel IP20 130BB923 11 3 5 2 Using Screened Control Cables Illustration 3 14 Danfoss recommends braided screened armoured cables to optimise EMC immunity of the control ca
70. ei e N H 66 Switching ttes 48 System 6 T Temperature Limits 21 VLT Refrigeration Drive 110 250 kW Operating Instructions Terminal KT 34 Locations D1h jJ 14 Locations A ang eye ein re en 15 Programm ng c r s 19 Programming 15 35 Thermistor Thermistor Control Wiring Torque Characteristics Ain nene a a Gene 63 For Terminals tette aS anek ed 72 A AE 28 Transient aa l sel 6 d Ria de 11 Troubleshooting 6 54 60 U Uploading Data To The 33 User Interface 30 Using Screened Control 65 5 5 18 V Voltage li ada CO arabian da AA TET Ahar EE 54 A 64 W Warnings And Alarms a 50 Wire Type And Ratings 11 Wiring To Control Terminals 19 MG16F102 VLT is a registered Danfoss trademark 75 www danfoss com drives Danfoss can accept no responsibility for possible errors in catalogues brochures and othe
71. elded cable For earthing grounding of the power connections use the dedicated earthing power connections use the dedicated earthing grounding points as shown in Illustration 3 6 grounding points as shown in Illustration 3 6 ji n m fi EA s LU vane vun I S 2 A 221 Des oR D HH IA TII A Ei 2 V 9 d 2 Je 7 O E H r d r L H Illustration 3 5 Earthing Grounding Points for IP20 Chassis Illustration 3 6 Earthing Grounding for IP21 54 Enclosures Enclosures MG16F102 VLT is a registered Danfoss trademark 13 Installation VLT Refrigeration Drive 110 250 kW Operating Instructions 3 4 3 Motor Connection Do not install power factor correction capacitors between the frequency converter and the motor AWARNING Do not wire a starting or pole changing device between the frequency converter and the motor INDUCED VOLTAGE Run output motor cables from multiple frequency Connect the 3 phase motor wiring to terminals converters separately Induced voltage from output motor 96 U 97 V and 98 W cables run together can charge equipment capacitors even Earth ground the cable in accordance with the with the equipment turned off and locked out Failure to instructions provided run output motor cables separately could result in death S Torque terminals in accordance with the or serious inju
72. esistor power limit The power transmitted to the brake resistor is calculated as a mean value over the last 120 s of run time The calculation is based on the intermediate circuit voltage and the brake resistance value set in 2 16 AC brake Max Current The warning is active when the dissipated braking is higher than 90 of the brake resistance power If 2 Trip is selected in 2 13 Brake Power Monitoring the frequency converter will trip when the dissipated braking power reaches 100 VLT Refrigeration Drive 110 250 kW Operating Instructions AWARNING There is a risk of substantial power being transmitted to the brake resistor if the brake transistor is short circuited 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 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 This alarm warning could also occur should the brake resistor overheat Terminals 104 and 106 are available as brake resistors Klixon inputs WARNING ALARM 28 Brake check failed The brake resistor is not connected or not working Check 2 15 Brake Check ALARM 29 Heatsink temp The maximum temperature of the heatsink has been exce
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75. 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 WARNING 40 Overload of digital output terminal 27 Check the load connected to terminal 27 or remove short circuit connection Check 5 00 Digital I O 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 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 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 ove
76. gle fan and pump is selected If condenser fan is selected in application NO AMA can be run Run application this mode starts the frequency converter in either hand local mode or via an external control signal if open loop is selected in an earlier screen Illustration 4 24 26 MG16F102 VLT is a registered Danfoss trademark Start Up and Functional Tes 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 03 Function Setups 04 Wizard Illustration 4 25 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 running for best performance Basic operational programming requires entering motor nameplate data for the motor being operated
77. hen the frequency converter is connected to AC mains could result in death serious injury equipment or property damage Unintended Start When the frequency converter is connected to the AC mains the motor may be started by means of an external switch a serial bus command an input reference signal or a cleared fault condition Use appropriate cautions to guard against an unintended start 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 and wait 20 minutes before doing any service or repair Failure to wait the specified time after power has been removed prior to doing service or repair on the unit could result in death or serious injury 4 MG16F102 VLT is a registered Danfoss trademark Denpi p Introduction VLT Refrigeration Drive 110 250 kW Operating Instructions 2 Introduction 2 1 Exploded Views 130BC252 10 O 11 O 1308C301 10
78. immediately contact the shipping company to claim the damage Before unpacking the frequency converter locate it as close as possible to the final installation site Compare the model number on the nameplate to what was ordered to verify the proper equipment Ensure each of the following are rated for the same voltage Mains power Frequency converter Motor eat VLT Refrigeration Drive 110 250 kW Operating Instructions e Ensure that frequency converter output current rating is equal to or greater than motor full load current for peak motor performance Motor size and frequency converter power must match for proper overload protection If frequency converter rating is less than motor full motor output cannot be achieved 3 3 Mechanical Installation 3 3 1 Cooling Top and bottom clearance for air cooling must be provided Generally 225 mm 9 in is required Improper mounting can result in over heating and reduced performance Derating for temperatures starting between 45 C 113 F and 50 C 122 F and elevation 1000 m 3300 ft above sea level must be considered See VLT Design Guide for detailed information The high power Danfoss VLT frequency converters utilize a back channel cooling concept that removes heatsink cooling air which carries approximately 90 of the heat out of the back channel of the frequency converters The back channel air can be redirected fr
79. 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 control terminals or serial communication Table 8 3 MG16F102 VLT is a registered Danfoss trademark 49 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 perf
80. ions 63 Commissioning 21 Communication Option Cond uit 11 21 Connection Tightening Torques 72 Control Gables EE 18 CO BEE 54 Card Performance a eb e Naye eee 67 Card 10 V DC Output 66 Card 24 V DC Output 2 65 Card RS 485 Serial Communication 65 Card USB Serial Communication 67 Characteristics r sa n 66 Signal 34 35 47 SIV SOT E 6 Terminal Functions 19 Terminal Types stetit e t ete E rtt 19 A ttes 28 32 47 49 35 19 Cooling GOOG M 8 Clearance CR ente pe dede tb EK N 21 VLT Refrigeration Drive 110 250 kW Operating Instructions Copying Parameter Settings sse 32 Current M M M 28 8 54 D DC ITT dE 6 48 ED DE 54 Voltage cee 6 Bi ATI su O 8 Digital aiT iii ide 19 49 55 Inputs xxt daa eter NY 49 36 64 A RR 65 Discharge Ti g sue 4 Disconnect 5 5 22 Downloading Data From The 5 33 Duct COOMA 8 Earth CONNECHON CN 12 21 Loops Electrical instalation s aty yama at tao 9 KEEN 12 e 18 21 Equalizing
81. kW Operating Instructions 5 User Interface 5 1 1 LCP Layout 5 1 Local Control Panel V The LCP is divided into four functional groups see The local control panel LCP is the combined display and Illustration 5 1 keypad on the front of the unit The LCP is the user interface to the frequency converter o N Ne OQ The LCP has several user functions 2 en Status fo Start stop and control speed when in local 1234rpm 10A 435Hz control Display operational data status warnings and Y 43 5 Hz cautions Programming frequency converter functions Run OK Manually reset the frequency converter after a fault when auto reset is inactive b Quick Main Alarm Status Menu Menu Log Warn 4 9 L Alarm on on Illustration 5 1 LCP a Display area b Display menu keys for changing the display to show status options programming or error message history c 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 keys and reset 30 MG16F102 VLT is a registered Danfoss trademark User interface VLT Refrigeration Drive 110 250 kW Operating Instructions 5 1 2 Setting LCP Display Values The display area is activated vvhen the frequency converter receives povver from mains voltage a DC bus terminal
82. l e User interface and external commands are monitored and performed e Status output and control can be provided Table 2 2 Frequency Converter Internal Components MG16F102 VLT is a registered Danfoss trademark 7 Installation 3 Installation 3 1 Planning the Installation Site CAUTION Before performing the installation it is important to plan the installation of the frequency converter Neglecting this may result in extra work during and after installation Select the best possible operation site by considering the following see details on the following pages and the respective Design Guides Ambient operating temperature Installation method How to cool the unit Position of the frequency converter Cable routing Ensure the power source supplies the correct voltage and necessary current Ensure that the motor current rating is within the maximum current from the frequency converter If the frequency converter is without built in fuses ensure that the external fuses are rated correctly Voltage Altitude Restrictions 380 480 V At altitudes above 3 km contact Danfoss regarding PELV 525 600 V At altitudes above 2 km contact Danfoss regarding PELV Table 3 1 Installation in High Altitudes 3 2 Pre Installation Checklist e Before unpacking the frequency converter ensure the packaging is intact If any damage has occurred
83. mittent 60 s overload 535 at 550 V A Continuous 290 at 575 600 V A Intermittent 60 s overload 519 at 575 600 V A Continuous KVA 289 at 550 V KVA Continuous KVA 289 at 575 V KVA Continuous KVA 347 at 600 V KVA Continuous 299 at 550 V A Continuous 286 at 575 V A Continuous 296 at 600 V A Max cable size mains motor load share and 2 x 150 2 x 300 2 x 150 2 x 300 2 x 70 2 x 2 0 2 x 70 2 x 2 0 brake mm2 AWG mcm mcm Max external pre fuses A 515 400 Estimated power loss 2963 MES 4051 4867 at rated max load W 600 V Estimated power loss at rated max load W 600 V Weight Enclosure IP21 IP54 kg Weight 123 Enclosure IPOO kg 3430 3612 4292 5156 Efficiency 0 98 Output frequency 0 600 Hz Power card ambient trip 60 C Table 11 2 Mains Supply 3x525 600 V AC 1 For type of fuse see 11 3 Fuse Specifications 2 American Wire Gauge 3 Measured using 5 m screened motor cables at rated load and rated frequency 4 The typical power loss is at nominal load conditions and expected to be within 15 tolerence relates to variety in voltage and cable conditions Values are based on a typical motor efficiency eff2 eff3 border line Motors with lower efficiency will also add to the power loss in the frequency converter and opposite If the switching frequency is increa
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85. n Drive 110 250 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 M 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 is 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
86. n 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 32 MG16F102 VLT is a registered Danfoss trademark 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 Press OK Select All to LCP Ur Sa 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 t
87. ncorrect 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 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
88. ntermediate 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 480 600 V maximum Motor output U V W Output voltage 0 100 of supply voltage Voltage and power dependent Torque characteristics Starting torque Constant torque manne maximum 110 for 1 min Starting torque s Maximum 135 up to 0 5 5 Overload torque Constant torque maximum 110 for 1 min Percentage relates to the frequency converter s nominal torque Cable lengths and cross sections Max motor cable length screened armoured 150m See 11 2 1 Mains Supply 3x380 480 VAC High Power for more information MG16F102 VLT is a registered Danfoss trademark 63 Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions Digital inputs Programmable digital inputs 4 6 Voltage level logic Voltage level logic 1 NPN supply voltage PELV and other high voltage terminals 1 Terminals 27 and 29 can also be programmed as output Analog inputs Number of analog inputs 2 Resolution for analog inputs eee O Dit Sign
89. o 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 Max cable length 1200 m including drop lines 500 m station to station Table 3 9 20 MG16F102 VLT is a registered Danfoss trademark p Start Up and Functional Tes VLT Refrigeration Drive 110 250 kW Operating Instructions 4 Start Up and Functional Test 4 1 Pre start CAUTION Before applying power to the unit inspect the entire installation as detailed in Table 4 1 Check mark those items when completed Inspect for Description IZ 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 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
90. o 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 VLT Refrigeration Drive 110 250 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 twice to access parameters 2 Scroll to 14 22 Operation Mode 5 3 Press OK 4 Scroll to Initialisation 5 Press OK 6 Remove power to the unit and wait for the display to turn off 7 Apply power to the
91. om the panel or room using one of the kits below NOTE For ordering numbers see the VLT High Power Drives Selection Guide PB 56 B1 02 Duct cooling A back channel cooling kit is available to direct the heatsink cooling air out of the panel when an IP20 chassis frequency converters is installed in a Rittal enclosure Use of this kit reduces the heat in the panel and smaller door fans can be specified on the enclosure Cooling out the back top and bottom covers The back channel cooling air can be ventilated out of the room so that the heat from the back channel is not dissipated into the control room 8 MG16F102 VLT is a registered Danfoss trademark Installation A door fan s is required on the enclosure to remove the heat not contained in the backchannel of the frequency converters and any additional losses generated by other components inside the enclosure The total required air flow must be calculated so that the appropriate fans can be selected Airflow The necessary airflow over the heat sink must be secured The flow rate is shown in Table 3 2 The fan runs for the following reasons AMA DC Hold Pre Mag DC Brake 60 of nominal current is exceeded Specific heatsink temperature exceeded power size dependent Specific Power Card ambient temperature exceeded power size dependent Specific Control Card ambient temperature exceeded Enclosure Frame Door fan s top Heat
92. onverter 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 12 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 VLT Refrigeration Drive 110 250 kW Operating Instructions VVARNING ALARM 7 DC overvoltage If the intermediate circuit voltage exceeds the limit the frequency converter trips after a time Troubleshooting Connect a brake resistor Extend the ramp time Change the ramp type Activate the functions in 2 10 Brake Function Increase 14 26 Trip Delay at Inverter Fault WARNING ALARM 8 DC under voltage If the intermediate circuit voltage DC link drops below the under voltage limit the frequency converter checks if a 24 V DC backup supply is connected If no 24 V DC backup supply is connected the frequency converter trips after a fix
93. ormance 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 9 2 1 Warnings A warning is issued when an alarm condition is impending or when an abnormal operating condition is present and may result in the frequency converter issuing an alarm A warning clears by itself when the abnormal condition is removed 9 2 2 Alarm Trip An alarm is issued when the frequency converter is tripped that is the frequency converter suspends operation to prevent frequency converter or system damage The motor 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 be reset in any of 4 ways Press Reset Digital reset input command Serial communication reset input command Auto reset VLT Refrigeration Drive 110 250 kW Operating Instructions 9 2 3 Alarm Trip lock An alarm that causes the frequency converter to trip lock requires that input power be
94. orth 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 MG16F102 VLT is a registered Danfoss trademark 27 Start Up and Functional Tes 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 1 24 Motor Current 1 25 Motor Nominal Speed 0 0 Hz 0 00kVV 10 Q 1 21 Motor Power kW 130BT772 10 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 display VLT Refrigeration Drive
95. otection to avoid fire hazard due to overheating of the cables in the installation The frequency converter is equipped with an internal over current protection that can be used for upstream overload protection UL applications excluded See 4 78 Current Limit Moreover fuses or circuit breakers can be used to provide the over current protection in the installation Over current protection must always be carried out according to national regulations 11 3 2 Non UL Compliance If UL CUL is not to be complied with we recommend using the following fuses which will ensure compliance with EN50178 In case of malfunction not following the recommendation may result in unnecessary damage to the frequency converter N110 N250 380 500 V type gG N315 380 500 V type gR Table 11 3 MG16F102 VLT is a registered Danfoss trademark 71 p Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions 11 3 3 UL Compliance 380 500 V The fuses below are suitable for use on a circuit capable of delivering 100 000 Arms symmetrical With the proper fusing the drive Short Circuit Current Rating SCCR is 100 000 Arms Power Fuse Options Size Bussman Littelfuse PN Littelfuse Bussmann Siba PN Ferraz Shawmut Ferraz Shawmut PN Ferraz Shawmut PN N110 170M2619 LA50QS300 4 L50S 300 FWH 300A 20 610 A5005300 4 6 9URD31D08A0315 A070URD31KI0315 7 10 O7 0O OCO7O 132 170M2620 LA50QS350 4 L50S 350 FW
96. oting Check connections on the serial communication cable Increase 8 03 Control Timeout Time Check the operation of the communication equipment Verify a proper installation 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 fan resistance Check soft charge fuses WARNING 24 External fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning can be disabled in 14 53 Fan Monitor 0 Disabled Troubleshooting Check fan resistance Check soft charge fuses WARNING 25 Brake resistor short circuit The brake resistor is monitored during operation If a short circuit occurs the brake function is disabled and the warning appears The frequency converter is still operational but without the brake function Remove power to the frequency converter and replace the brake resistor see 2 15 Brake Check WARNING ALARM 26 Brake r
97. p 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 Mus ard Press OK 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 22 MG16F102 VLT is a registered Danfoss trademark Start Up and Functional Tes VLT Refrigeration Drive 110 250 kW Operating Instructions If OK is pressed the Application Guide will start with the Compressor pack set up following screen As an example see screens below for a compressor pack set up o CH
98. pen or closed loop 130BA795 10 Illustration 4 12 130BA793 10 Illustration 4 10 24 MG16F102 VLT is a registered Danfoss trademark p Start Up and Functional Tes VLT Refrigeration Drive 110 250 kW Operating Instructions Info 4 20 mA feedback chosen connect accordingly Select fixed or floating setpoint 130BA796 10 130BA799 10 Illustration 4 13 Illustration 4 16 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 MG16F102 VLT is a registered Danfoss trademark 25 Start Up and Functional Tes Set cut out in value 130BA802 10 Illustration 4 19 Choose pack control set up 130BA803 10 Illustration 4 20 Set number of compressors in pack o Kei N o a a m 130BA804 10 Illustration 4 21 o LO wn o Y a e VLT Refrigeration Drive 110 250 kW Operating Instructions nfo Connect accordingly Illustration 4 22 nfo Setup completed 130BA806 10 Illustration 4 23 After completing set up choose to re run wizard or start application Select between the following options Re run wizard e Go to main menu Go to status Run AMA Note this is a reduced AMA if compressor application is selected and full AMA if sin
99. proper earth connections ground connections Do not earth ground one frequency converter to another in a daisy chain fashion Keep the earth ground wire connections as short as possible Using high strand wire to reduce electrical noise is recommended Follow motor manufacturer wiring requirements 3 4 2 1 Leakage Current 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 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 VLT Refrigeration Drive 110 250 kW Operating Instructions Earthing grounding must be reinforced in one of the follovving vvays Earth ground wire of at least 10 mm2 e 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 l
100. quency 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 e 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 MG16F102 VLT is a registered Danfoss trademark p Status Messages VLT Refrigeration Drive 110 250 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 The motor is driven by the frequency converter Speed high Motor speed is above the value set in 4 53 Warning Speed High Speed low Motor speed is below the value set
101. r a parameter number for direct access to that parameter Details for common application set ups are provided in 7 Application Set Up Examples MG16F102 VLT is a registered Danfoss trademark 37 VLT Refrigeration Drive 110 250 kW Operating Instructions Programming 6 5 1 Quick Menu Structure abelyo MOT s Jeuruue OL 9 qpeeJ4 e uaJejay WUNWIXe 21 12 qp 4 3u 1 J u WINWIUIW ELO HUT x eqpees s us13jau 21 02 Muf 9 Jnos yoeqp 4 80 07 UOISJ9AUO peqpeeJ Z0 0Z au jeibau ules jeuoniodoJd q ZH p ds ues q Wdy p ds ues q 101002 ASJBAU EULHON uonounJ 1noaull 0197 BAIT 10 9 Buluniomy Cid 62 07 94597 3eqpeeJ WUNUWIXEN v oc 9497 yoeqp z UJnUJIUIW 7 0c buey 1ndino q e ueuuoped d doo paso lutod 195 UJ uoz l5uls 0 O s5uma s doo p so 2 D en eA qp 4 J t YBIH ES jeuruue 1 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 LZ 0 jews CL eur Aejdsiq 02 0 sbumes Aejdsiq 1 0 pug su n eu u ns Sq 44 0 92Jnos y eqp 4 90 02 YUN NOS z eqpee4 60 07 UOISIBAUOD Z peqpee4J 70 07 924nog C p edqpeej 0 0c Muf anos 35eqp d 20 02 UOISJ9AUO eqpaeJ 10 0Z 92Jnos eqpee4 00 02 inos z eoueJajay 91 92JnOS
102. r card temperature The temperature sensor on the power card is either too hot or too cold Troubleshooting Check the operation of the door fans Check that the filters for the door fans are not blocked Check that the gland plate is properly installed on IP21 IP 54 NEMA 1 12 frequency converters 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 VLT Refrigeration Drive 110 250 kW Operating Instructions ALARM 72 Dangerous failure Safe Stop vvith Trip Lock Unexpected signal levels on safe stop and digital input from the MCB 112 PTC thermistor card VVARNING 73 Safe stop auto restart Safe stopped VVith automatic restart enabled the motor may start vvhen the fault is cleared VVARNING 76 Povver unit setup The required number of povver units does not match the detected number of active povver units Troubleshooting VVhen replacing an F frame module this vvill occur if the povver specific data in the module povver card does not match the rest of the frequency converter Please confirm the spare part and its povver card are the correct part number 77 VVARNING Reduced povver mode This vvarning indicates that the frequency converter is operating in reduced povver mode i e less than the allovved number of inverter s
103. r 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 130R0384 MG16F102 III 7 MG 1 6 F 1 Q 2
104. rakes 3 8 Reference Ramps 4 Limits Warnings pe Digital In Out v Illustration 6 9 MG16F102 VLT is a registered Danfoss trademark 35 Programming VLT Refrigeration Drive 110 250 kW Operating Instructions 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 Parameter 4 14 Motor Speed High Limit Hz See Note 4 4 19 Max Output Frequency 4 53 VVarning Speed High 5 12 Terminal 27 Digital Input 5 40 Function Relay nternational default parameter value 132 Hz 1500 RPM North American default parameter value 60 Hz 120 Hz 1800 RPM External interlock 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 International North American Default Parameter Settings 6 4 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 6 15 Terminal 53 High Ref Feedb Value 6 50 Terminal 42 Ou
105. right corner of the display shows the direction of motor rotation and which set up is active This is not programmable Allows access to programming parameters for initial set up instructions and many detailed application instructions e Press to access Q2 Quick Setup for sequenced instructions to program the basic frequency controller set up e Follow the sequence of parameters as presented for the function set up Allows access to all programming parameters e Press twice to access top level index e Press once to return to the last location accessed e Press to enter a parameter number for direct access to that parameter Displays a list of current warnings the last 10 alarms and the maintenance log e For details about the frequency converter before it entered the alarm mode select the alarm number using the navigation keys and press OK MG16F102 VLT is a registered Danfoss trademark 31 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 130BT117 10 Warn Alarm Illustration 5 5 VLT Refrigeration Drive 110 250 kW Operating Instructions 5 1 5 Operation Keys Operation keys are found at the bottom of the LCP Illustration 5 6
106. rloaded 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 VLT Refrigeration Drive 110 250 kW Operating Instructions VVARNING 49 Speed limit VVhen the speed is not vvithin 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 VVhen the speed is belovv the specified limit in 1 86 Compressor Min Speed for Trip RPM except when starting or stopping the frequency converter vvill trip ALARM 50 AMA calibration failed Contact your Danfoss supplier or Danfoss Service Department ALARM 51 AMA check Unom and nom The settings for motor voltage motor current and motor povver are vvrong Check the settings in parameters 1 20 to 1 25 ALARM 52 AMA lovv nom 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 in
107. ry information provided in 11 3 4 Connection Tightening Torques For maximum cable sizes see 11 2 Mains Supply Follow motor manufacturer wiring requirements Comply with local and national electrical codes for cable sizes Gland plates are provided at the base of IP21 54 and higher NEMA1 12 units SECTION A A E e MAINS TERMINALS SECTION B B a MOTOR TERMINALS m Y we 5 e is MAINS TERMINAL 4 9 MOTOR S TERMINAL 200 7 9 ri 9 GROUND88 v lel 4 ET a 3 5 5 H LB TS 3 M8x20 STUD LU 2 la h ji WITH NUT ne 0 E 10 01 ga 25 pe 2 ze s SD CU 5 of bio Sh ee gI Illustration 3 7 Terminal Locations D1h 14 MG16F102 VLT is a registered Danfoss trademark VLT Refrigeration Drive 110 250 kW Operating Instructions
108. s epooed poW vonelado au 3 e1say 2neuoiny 1959Y suonduny jesay e uejequu SUIe 3e uonounJ 3jne4 sureyy ye o6e3JoA suey aunyiey su eW HO UO sulew wopuey WMd Aduanbas4 waned Bulu2 lMS suon un4 enads uonoy s llonu02 1S 1lu A3 18 04100 1S s e s ue oog any 21601 Z 101619600 am 21601 z ue oog ajny 21607 L Joje1ado am 21607 ue oog ajny 21607 se ny 21607 JWI 19 1011U0 1S 5 enjeA Joyesedwo gt J0 eJ9d0 1ol1e1eduuop pues do Jsojyesedwo gt ssoyeseduio gt DIS 1959 quanq dois jua 3 HRS poN s llonuo2 1S s um s 915 21507 yews S n 8A eieq 31015 55922 UleJed NOT UO S A M SAJONUOT 6S F1 EMA 29 71 26 71 15 71 06 71 Sl Cv vi 11 Ob yL c vi LE vL 06 71 EL 621 8 71 9271 Scl Cvl cci LC vt Cl cL vL LL VL OL vL lvl vO vL 60 71 10 71 00 71 0 1 24 61 15 61 S EL v El cv tl 17 61 Ov EL si l 02 21 CEL CL EL 01 21 41 61 20 21 20 81 10 21 00 21 40 21 LZ LL 81 11 UOISIASY JIX paom Burulem NOT llJo1d eAug suon un4 NOT QI uon N I SHO AUOT yoeqp q sng C yoeqp q sng L y eqp q sng p ds z Bor sng p ds Bor sng yoeqpaa Dor sng uno sonsoubeiq 5104 3 INO3WI BAe S 1u s sabessay anes JUNO 10113 e e S DAOU
109. sed comed to the default setting the power losses may rise significantly LCP and MG16F102 VLT is a registered Danfoss trademark 69 Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions typical control card power consumptions are included Further options and customer load may add up to 30 W to the losses Though typical only 4 W extra for a fully loaded control card or options for slot A or slot B each Although measurements are made with state of the art equipment some measurement inaccuracy must be allowed for 5 70 MG16F102 VLT is a registered Danfoss trademark Denpi Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions 11 3 Fuse Specifications 11 3 1 Protection Branch Circuit Protection In order to protect the installation against electrical and fire hazard all branch circuits in an installation switch gear machines etc must be short circuited and over current protected according to national international regulations Short circuit Protection The frequency converter must be protected against short circuit to avoid electrical or fire hazard Danfoss recommends using the fuses mentioned below to protect service personnel and equipment in case of an internal failure in the frequency conveter The frequency converter provides full short circuit protection in case of a short circuit on the motor output Over current Protection Provide overload pr
110. sink fan s protection fan IP21 NEMA 1 D1 and D2 170 m3 hr 100 765 m hr CFM 450 CFM D3 and D4 3 2 IPOO Chassis 255 m hr 150 765 m hr CFM 450 CFM Airflow per fan Frame size F contains multiple fans Table 3 2 Airflow MG16F102 VLT is a registered Danfoss trademark VLT Refrigeration Drive 110 250 kW Operating Instructions 3 3 2 Lifting Alvvays lift the frequency converter using the dedicated lifting eyes Use a bar to avoid bending the lifting holes 130BC253 10 Illustration 3 1 Position Lifting Straps where Indicated CAUTION The angle from the top of the frequency converter to the lifting cables should be 60 or greater 3 4 Electrical Installation 3 4 1 General Requirements This section contains detailed instructions for wiring the frequency converter The following tasks are described Wiring the motor to the frequency converter output terminals Wiring the AC mains to the frequency converter input terminals Connecting control and serial communication wiring After power has been applied checking input and motor power programming control terminals for their intended functions
111. smes duind sn3e3S apeose gt smes ey q suleyy uo uny Aejaq dung 3x N unu uoneul liy 3e epo 5u 5e s 0S gt peo J 938UJ9 V UILL p UY P Ad uonegui 1 V 9njeA wI uoneuJe3 v 3UJI uoneuJe3 v 1u A3 uoneuJei v uoneujeyy dung pee s5um s uoneuieyy zH p ds bulbeisaq Wdy p ds 6u 6e1s q zH p ds urbes Wd p ds Burbers plouse u Bu 5e seq plouse u Buibeis Aejaq dn due Aejaq umog due sbumes 5ul5e3s aw uonounj ebeyseq ebei1segq euin uon unj 6e1s uonounj e5e s NO 4 ON 1V ebe1seq SLL MJO Aejaq Buibexsag Mas fejeg 6u 6e1s Mas upiwpueg p d YpIMpueg yipimpueg Duibeis sbumes upiwpueg sduung Jo JequinN dung pee paxi4 Bull 42 dung eis 1030W Jo oJ3u0 25 2 s5um s uu 1s s FEIER Sbul es 150 sbuiwes A54 uq 1ueunsaAu 1507 b9uy 1032844 adUaJajay 1 MOd Jaoyuno x eq eq ejeq ug Dau 1959y ejeq uig snonunuo 1 s t enjeA uig uinuuuiy dois pou d Daul Meis p H d Daul 06 Sc x6 SC 98 SC 98 92 r8 S 8 SC 28 52 18 92 08 92 8 S 6S S 89 42 95 42 49 92 79 52 25 92 CS ST LS SZ 0S S ST Lv ST 9v Sc Eech 5 Dech eh 17 92 Or Sc VST 06 92 62 42 82 52 20 42 92 52 42 92 vC ST 22 52 CC ST 12 82 02 52 C SC 90 SC S0 S Y0 sc 20 42 00 52 x0 SC ve tc 8 EC 28 62 18 62 08 22 x8 C 29 62 99 62 49 62 V9 ET EREE ejeq utg Dou ejeq uig snon
112. st device USB cable The USB connection is galvanically isolated from the supply voltage PELV and other high voltage terminals The USB connection is not galvanically isolated from protection earth Use only isolated laptop PC as connection to the USB connector on the frequency converter or an isolated USB cable 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 is protected against earth faults on motor terminals U V W MG16F102 VLT is a registered Danfoss trademark 67 p Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions 11 2 Mains Supply P110 P132 P160 P200 P250 Typical Shaft output at 110 132 160 200 250 400
113. ternal fault Try to restart AMA again a number of times until the AMA is carried out Note that repeated runs may heat the motor to a level where the resistance Rs and Rr are increased In most cases hovvever this is not critical ALARM 58 AMA internal fault Contact your Danfoss supplier VVARNING 59 Current limit The current is higher than the value in 4 18 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 External interlock has been activated To resume normal operation apply 24 V DC to the terminal programmed for external interlock and reset the frequency converter via serial communication digital I O or by pressing Reset WARNING ALARM 61 Tracking error An error between calculated motor speed and speed measurement from feedback device The function Warning Alarm Disable is set in 4 30 Motor Feedback Loss Function Accepted error setting in 4 37 Motor Feedback Speed Error and the allowed time the error occur setting in 4 32 Motor Feedback Loss Timeout During a commissioning procedure the function may be effective WARNING 62 Output frequency at maximum limit The output frequency is higher than the value set in 4 19 Max Output Frequency 58 MG16F102 VLT is a registered Danfoss trademark Warnings and Alarms ALARM 64 Voltage Limit The load
114. ting Check if the motor is mechanically overloaded 54 MG16F102 VLT is a registered Danfoss trademark Warnings and Alarms Check that the motor current set in 1 24 Motor Current is correct 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 The thermistor might be disconnected Select whether the frequency converter gives a warning or an alarm in 1 90 Motor Thermal Protection Troubleshooting Check for motor overheating Check if the motor is mechanically overloaded Check that the thermistor is connected correctly between either terminal 53 or 54 analog voltage input and terminal 50 10 V supply and 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 If a KTY sensor is used check for correct connection between terminals 54 and 55 If using a thermal switch or thermistor check that the programming if 1 93 Thermistor Resource matches sensor wiring If using a KT
115. tion 3 2 Wiring Diagram AWARNING EQUIPMENT HAZARD Rotating shafts and electrical equipment can be hazardous All electrical work must conform to national and local CAUTION WIRING ISOLATION Run input power motor wiring and control wiring in three separate metallic conduits or use separated shielded cable 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 for high frequency noise isolation Failure to isolate power motor and control wiring could result in less than optimum frequency converter and associated equipment performance 10 MG16F102 VLT is a registered Danfoss trademark Installation VLT Refrigeration Drive 110 250 kW Operating Instructions 7777 comply with the following il III 130BX370 10 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 h output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out Eloi Field wiring terminals are not intended to receive a conductor one size larger Overload and Equipment Protection An el
116. 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 MG16F102 VLT is a registered Danfoss trademark 61 p Basic Troubleshooting VLT Refrigeration Drive 110 250 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 62 MG16F102 VLT is a registered Danfoss trademark Darfi Specifications VLT Refrigeration Drive 110 250 kW Operating Instructions 11 Specifications 11 1 General Specifications Mains supply L1 L2 L3 Supply voltage 380 480 V 10 Mains voltage low mains drop out During low mains voltage or a mains drop out the frequency converter continues until the i
117. tput l 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 1 23 Motor Frequency 230 V 400 V 575 V 1208 V 460 V 575 V 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 14 20 Reset Mode 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 1500 RPM and for a 2 poled motor 3000 RPM The corresponding values for North America is 1800 and 3600 RPM 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 Sin
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121. with the frequency converter output connected as follows Terminal No Function 96 97 98 99 Mains U T1 V T2 W T3 Earth ground Table 3 3 3 4 3 2 Motor Rotation Check The direction of rotation can be changed by switching two phases in the motor cable or by changing the setting of 4 10 Motor Speed Direction e Terminal U T1 96 connected T to U phase v v w O 130HA036 10 e Terminal V T2 97 connected to V phase Terminal W T3 98 97 connected to Table 3 4 A motor rotation check can be performed using1 28 Motor Rotation Check and following the steps shown in the display 3 4 4 AC Mains Input Connection Size wiring is based upon the input current of the frequency converter Comply with local and national electrical codes for cable sizes Connect 3 phase AC input power wiring to terminals L1 L2 and L3 see Illustration 3 11 Darfi VLT Refrigeration Drive 110 250 kW Operating Instructions 130BC254 10 Illustration 3 11 Connecting to AC Mains 1 Mains connection Table 3 5 Earth ground the cable in accordance with the instructions provided All frequency converters may be used with an isolated input source as well as with earth ground reference power lines When supplied from an isolated mains source IT mains or floating delta or TT TN S mains with a grounded l

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