Danfoss VLT FC 103 Mode d’emploi

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT®Refrigeration Drive FC 103

1.1–90 kW

vlt-drives.danfoss.com

Contents

1 Introduction 7

1.1 Purpose of the Design Guide 7

1.2 Organisation 7

1.3 Additional Resources 7

1.4 Abbreviations, Symbols and Conventions 8

1.5 Safety Symbols 9

1.6 Denitions 9

1.7 Document and Software Version 10

1.8 Approvals and Certications 10

1.8.1 CE Mark 10

1.8.1.1 Low Voltage Directive 10

1.8.1.2 EMC Directive 10

1.8.1.3 Machinery Directive 11

1.8.1.4 ErP Directive 11

1.8.2 C-tick Compliance 11

1.8.3 UL Compliance 11

1.8.4 Marine Compliance (ADN) 11

1.8.5 Export Control Regulations 12

1.9 Safety 12

1.9.1 General Safety Principles 12

2 Product Overview 14

2.1 Introduction 14

2.2 Description of Operation 17

2.3 Sequence of Operation 18

2.3.1 Rectier Section 18

2.3.2 Intermediate Section 18

2.3.3 Inverter Section 18

2.4 Control Structures 19

2.4.1 Control Structure Open Loop 19

2.4.2 Control Structure Closed Loop 19

2.4.3 Local (Hand On) and Remote (Auto On) Control 20

2.4.4 Reference Handling 21

2.4.5 Feedback Handling 23

2.5 Automated Operational Functions 24

2.5.1 Short-circuit Protection 24

2.5.2 Overvoltage Protection 24

2.5.3 Missing Motor Phase Detection 24

2.5.4 Mains Phase Imbalance Detection 25

Contents Design Guide

2.5.5 Switching on the Output 25

2.5.6 Overload Protection 25

2.5.7 Automatic Derating 25

2.5.8 Automatic Energy Optimisation 25

2.5.9 Automatic Switching Frequency Modulation 25

2.5.10 Automatic Derating for High Switching Frequency 26

2.5.11 Automatic Derating for Overtemperature 26

2.5.12 Auto Ramping 26

2.5.13 Current Limit Circuit 26

2.5.14 Power Fluctuation Performance 26

2.5.15 Motor Soft Start 26

2.5.16 Resonance Damping 26

2.5.17 Temperature-controlled Fans 26

2.5.18 EMC Compliance 26

2.5.19 Current Measurement on All Three Motor Phases 27

2.5.20 Galvanic Isolation of Control Terminals 27

2.6 Custom Application Functions 27

2.6.1 Automatic Motor Adaptation 27

2.6.2 Motor Thermal Protection 27

2.6.3 Mains Drop-out 27

2.6.4 Built-in PID Controllers 28

2.6.5 Automatic Restart 28

2.6.6 Flying Start 28

2.6.7 Full Torque at Reduced Speed 28

2.6.8 Frequency Bypass 28

2.6.9 Motor Preheat 28

2.6.10 Four Programmable Set-ups 29

2.6.11 DC Braking 29

2.6.12 Sleep Mode 29

2.6.13 Run Permissive 29

2.6.14 Smart Logic Control (SLC) 29

2.6.15 Safe Torque O Function 30

2.7 Fault, Warning and Alarm Functions 31

2.7.1 Operation at Overtemperature 31

2.7.2 High and Low Reference Warning 31

2.7.3 High and Low Feedback Warning 31

2.7.4 Phase Imbalance or Phase Loss 31

2.7.5 High Frequency Warning 31

2.7.6 Low Frequency Warning 31

2.7.7 High Current Warning 31

Contents VLT®Refrigeration Drive FC 103

2.7.8 Low Current Warning 31

2.7.9 No Load/Broken Belt Warning 31

2.7.10 Lost Serial Interface 32

2.8 User Interfaces and Programming 32

2.8.1 Local Control Panel 32

2.8.2 PC Software 33

2.8.2.1 MCT 10 Set-up Software 33

2.8.2.2 VLT®Harmonics Calculation Software MCT 31 33

2.8.2.3 Harmonic Calculation Software (HCS) 33

2.9 Maintenance 34

2.9.1 Storage 34

3 System Integration 35

3.1 Ambient Operating Conditions 35

3.1.1 Humidity 35

3.1.2 Temperature 36

3.1.3 Cooling 36

3.1.4 Motor-generated Overvoltage 37

3.1.5 Acoustic Noise 37

3.1.6 Vibration and Shock 37

3.1.7 Aggressive Atmospheres 37

3.1.8 IP Rating Denitions 38

3.1.9 Radio Frequency Interference 39

3.1.10 PELV and Galvanic Isolation Compliance 39

3.2 EMC, Harmonics, and Ground Leakage Protection 40

3.2.1 General Aspects of EMC Emissions 40

3.2.2 EMC Test Results (Emission) 42

3.2.3 Emission Requirements 43

3.2.4 Immunity Requirements 43

3.2.5 Motor Insulation 44

3.2.6 Motor Bearing Currents 44

3.2.7 Harmonics 45

3.2.8 Ground Leakage Current 47

3.3 Energy Eciency 49

3.3.1 IE and IES Classes 50

3.3.2 Power Loss Data and Eciency Data 50

3.3.3 Losses and Eciency of a Motor 51

3.3.4 Losses and Eciency of a Power Drive System 51

3.4 Mains Integration 51

3.4.1 Mains Congurations and EMC Eects 51

Contents Design Guide

3.4.2 Low-frequency Mains Interference 52

3.4.3 Analysing Mains Interference 53

3.4.4 Options for Reducing Mains Interference 53

3.4.5 Radio Frequency Interference 53

3.4.6 Classication of the Operating Site 53

3.4.7 Use with Isolated Input Source 54

3.4.8 Power Factor Correction 54

3.4.9 Input Power Delay 54

3.4.10 Mains Transients 54

3.4.11 Operation with a Standby Generator 54

3.5 Motor Integration 55

3.5.1 Motor Selection Considerations 55

3.5.2 Sine-wave and dU/dt Filters 55

3.5.3 Proper Motor Grounding 55

3.5.4 Motor Cables 55

3.5.5 Motor Cable Shielding 56

3.5.6 Connection of Multiple Motors 56

3.5.7 Motor Thermal Protection 57

3.5.8 Output Contactor 58

3.5.9 Energy Eciency 58

3.6 Additional Inputs and Outputs 59

3.6.1 Wiring Schematic 59

3.6.2 Relay Connections 60

3.6.3 EMC-compliant Electrical Connection 61

3.7 Mechanical Planning 62

3.7.1 Clearance 62

3.7.2 Wall Mounting 63

3.7.3 Access 63

3.8 Options and Accessories 63

3.8.1 Communication Options 66

3.8.2 Input/Output, Feedback, and Safety Options 66

3.8.3 Sine-wave Filters 66

3.8.4 dU/dt Filters 66

3.8.5 Harmonic Filters 66

3.8.6 IP21/NEMA Type 1 Enclosure Kit 67

3.8.7 Common-mode Filters 69

3.8.8 Remote Mounting Kit for LCP 69

3.8.9 Mounting Bracket for Enclosure Sizes A5, B1, B2, C1, and C2 70

3.9 Serial Interface RS485 71

3.9.1 Overview 71

Contents VLT®Refrigeration Drive FC 103

3.9.2 Network Connection 72

3.9.3 RS485 Bus Termination 72

3.9.4 EMC Precautions 73

3.9.5 FC Protocol Overview 73

3.9.6 Network Conguration 73

3.9.7 FC Protocol Message Framing Structure 73

3.9.8 FC Protocol Examples 77

3.9.9 Modbus RTU Protocol 78

3.9.10 Modbus RTU Message Framing Structure 79

3.9.11 Access to Parameters 82

3.9.12 FC Drive Control Prole 83

3.10 System Design Checklist 89

4 Application Examples 91

4.1 Application Examples 91

4.2 Selected Application Features 91

4.2.1 SmartStart 91

4.2.2 Start/Stop 92

4.2.3 Pulse Start/Stop 92

4.2.4 Potentiometer Reference 93

4.3 Application Set-up Examples 93

5 Special Conditions 99

5.1 Derating 99

5.2 Manual Derating 99

5.3 Derating for Long Motor Cables or Cables with Larger Cross-section 99

5.4 Derating for Ambient Temperature 100

6 Type Code and Selection 104

6.1 Ordering 104

6.1.1 Introduction 104

6.1.2 Type Code 104

6.2 Options, Accessories, and Spare Parts 105

6.2.1 Ordering Numbers: Options and Accessories 105

6.2.2 Ordering Numbers: Harmonic Filters 107

6.2.3 Ordering Numbers: Sine-wave Filter Modules, 200–480 V AC 107

6.2.4 Ordering Numbers: Sine-wave Filter Modules, 525-600/690 V AC 108

6.2.5 Harmonic Filters 109

6.2.6 Sine-wave Filters 111

6.2.7 dU/dt Filters 113

6.2.8 Common Mode Filters 114

Contents Design Guide

7 Specications 115

7.1 Electrical Data 115

7.1.1 Mains Supply 3x200–240 V AC 115

7.1.2 Mains Supply 3x380–480 V AC 117

7.1.3 Mains Supply 3x525–600 V AC 119

7.2 Mains Supply 121

7.3 Motor Output and Motor Data 121

7.4 Ambient Conditions 122

7.5 Cable Specications 122

7.6 Control Input/Output and Control Data 123

7.7 Connection Tightening Torque 126

7.8 Fuses and Circuit Breakers 127

7.9 Power Ratings, Weight, and Dimensions 132

7.10 dU/dt Testing 133

7.11 Acoustic Noise Ratings 135

7.12 Selected Options 135

7.12.1 VLT®General Purpose I/O Module MCB 101 135

7.12.2 VLT®Relay Card MCB 105 136

7.12.3 VLT®Extended Relay Card MCB 113 138

8 Appendix - Selected Drawings 140

8.1 Mains Connection Drawings 140

8.2 Motor Connection Drawings 143

8.3 Relay Terminal Drawings 145

8.4 Cable Entry Holes 146

Index 151

Contents VLT®Refrigeration Drive FC 103

1 Introduction

1.1 Purpose of the Design Guide

This design guide for VLT®Refrigeration Drive FC 103

frequency converters is intended for:

•Project and systems engineers.

•Design consultants.

•Application and product specialists.

The design guide provides technical information to

understand the capabilities of the frequency converter for

integration into motor control and monitoring systems.

The purpose of the design guide is to provide design

considerations and planning data for integration of the

frequency converter into a system. The design guide caters

for selection of frequency converters and options for a

diversity of applications and installations.

Reviewing the detailed product information in the design

stage enables developing a well-conceived system with

optimal functionality and eciency.

VLT®is a registered trademark.

1.2 Organisation

Chapter 1 Introduction: The general purpose of the design

guide and compliance with international directives.

Chapter 2 Product Overview: The internal structure and

functionality of the frequency converter and operational

features.

Chapter 3 System Integration: Environmental conditions;

EMC, harmonics, and ground leakage; mains input; motors

and motor connections; other connections; mechanical

planning; and descriptions of options and accessories

available.

Chapter 4 Application Examples: Samples of product

applications and guidelines for use.

Chapter 5 Special Conditions: Details on unusual operational

environments.

Chapter 6 Type Code and Selection: Procedures for ordering

equipment and options to meet the intended use of the

system.

Chapter 7 Specications: A compilation of technical data in

table and graphics format.

Chapter 8 Appendix - Selected Drawings: A compilation of

graphics illustrating:

•Mains and motor connections

•Relay terminals

•Cable entries

1.3 Additional Resources

Resources available to understand advanced operation of

the frequency converter, programming, and directives

compliance:

•The VLT

Refrigeration Drive FC 103 Operating

Instructions (referenced as operating instructions in

this manual) provide detailed information for the

installation and start-up of the frequency

converter.

•The VLT

Refrigeration Drive FC 103 Design Guide

provides information required for design and

planning for integration of the frequency

converter into a system.

•The VLT

Refrigeration Drive FC 103 Programming

Guide (referenced as programming guide in this

manual) provides greater detail about how to

work with parameters and many application

examples.

•The VLT

Safe Torque O Operating Instructions

describe how to use Danfoss frequency

converters in functional safety applications. This

manual is supplied with the frequency converter

when the STO option is present.

Supplemental publications and manuals are available for

download from vlt-drives.danfoss.com/Products/Detail/

Technical-Documents.

NOTICE

Optional equipment is available that may change some

of the information described in these publications. Be

sure to see the instructions supplied with the options for

specic requirements.

Contact a Danfoss supplier or visit www.danfoss.com for

more information.

Introduction Design Guide

1.4 Abbreviations, Symbols and

Conventions

60°AVM 60°asynchronous vector modulation

A Ampere/AMP

AC Alternating current

AD Air discharge

AEO Automatic energy optimisation

AI Analog input

AMA Automatic motor adaptation

AWG American wire gauge

°CDegrees celsius

CD Constant discharge

CDM Complete drive module: the frequency converter,

feeding section and auxiliaries

CM Common mode

CT Constant torque

DC Direct current

DI Digital input

DM Dierential mode

D-TYPE Drive dependent

EMC Electromagnetic compatibility

EMF Electromotive force

ETR Electronic thermal relay

fJOG Motor frequency when jog function is activated.

fMMotor frequency

fMAX Maximum output frequency, the frequency

converter applies on its output.

fMIN Minimum motor frequency from the frequency

converter

fM,N Nominal motor frequency

FC Frequency converter

g Gramme

Hiperface®Hiperface®is a registered trademark by Stegmann

HO High overload

hp Horse power

HTL HTL encoder (10–30 V) pulses - High-voltage

transistor logic

Hz Hertz

IINV Rated inverter output current

ILIM Current limit

IM,N Nominal motor current

IVLT,MAX Maximum output current

IVLT,N Rated output current supplied by the frequency

converter

kHz Kilohertz

LCP Local control panel

lsb Least signicant bit

m Meter

mA Milliampere

MCM Mille circular mil

MCT Motion control tool

mH Inductance in milli Henry

mm Millimeter

ms Millisecond

msb Most signicant bit

ηVLT Eciency of the frequency converter dened as

ratio between power output and power input.

nF Capacitance in nano Farad

NLCP Numerical local control panel

Nm Newton meter

NO Normal overload

nsSynchronous motor speed

Online/

Oine

Parameters

Changes to online parameters are activated

immediately after the data value is changed.

Pbr,cont. Rated power of the brake resistor (average power

during continuous braking).

PCB Printed circuit board

PCD Process data

PDS Power drive system: a CDM and a motor

PELV Protective extra low voltage

PmFrequency converter nominal output power as

high overload (HO).

PM,N Nominal motor power

PM motor Permanent magnet motor

Process PID PID (Proportional Integrated Dierential) regulator

that maintains the speed, pressure, temperature,

and so on.

Rbr,nom Nominal resistor value that ensures a brake power

on the motor shaft of 150/160% for 1 minute

RCD Residual current device

Regen Regenerative terminals

Rmin Minimum permissible brake resistor value by

frequency converter

RMS Root mean square

RPM Revolutions per minute

Rrec Recommended brake resistor resistance of

Danfoss brake resistors

s Second

SFAVM Stator ux-oriented asynchronous vector

modulation

STW Status word

SMPS Switch mode power supply

THD Total harmonic distortion

TLIM Torque limit

TTL TTL encoder (5 V) pulses - transistor transistor

logic

UM,N Nominal motor voltage

V Volts

VT Variable torque

VVC+Voltage vector control plus

Table 1.1 Abbreviations

Introduction VLT®Refrigeration Drive FC 103

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