Operating Instructions 12-Pulse High Power

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Operating Instructions 12-Pulse High PowerMAKING MODERN LIVING POSSIBLEwww.danfoss.com/drivesOperating Instructions 12-Pulse High PowerVLT HVAC Drive FC 100MG16B122*MG16B122*Rev. 2011-08-12MG16B122130R0218

ContentsVLT HVAC Drive 12-Pulse High Power Instruction ManualContents1 How to Read the Instruction Manual1-11.1.1 Copyright, Limitation of Liability and Revision Rights1-11.1.3 Approvals1-12 Safety2-12.1.1 High Voltage2-12.1.2 Safety Instructions2-12.1.5 Avoid Unintended Start2-22.1.6 Safe Stop2-22.1.8 IT Line Power2-33 Mechanical Installation3-13.1 Pre-installation3-13.1.1 Planning the Installation Site3-13.1.2 Receiving the Adjustable Frequency Drive3-13.1.3 Transportation and Unpacking3-13.1.4 Lifting3-13.1.5 Mechanical Dimensions3-33.2 Mechanical Installation3-73.2.3 Terminal Locations, F8-F133-83.2.4 Cooling and Airflow3-143.3 Frame size F Panel Options3-174 Electrical Installation4-14.1 Electrical Installation4-14.1.1 Power Connections4-14.1.6 Shielded Cables4-114.1.10 AC line input connections4-124.1.12 Fuses4-144.1.15 Motor Bearing Currents4-164.1.17 Control Cable Routing4-174.1.19 Electrical Installation, Control Terminals4-174.2 Connection Examples4-194.2.1 Start/Stop4-194.2.2 Pulse Start/Stop4-194.3.1 Electrical Installation, Control Cables4-214.3.2 Switches S201, S202, and S8014-244.4 Final Set-up and Test4-24MG.16.B1.22 - VLT is a registered Danfoss trademark

ContentsVLT HVAC Drive 12-Pulse High Power Instruction Manual4.5 Additional Connections4-254.5.1 Mechanical Brake Control4-254.5.3 Motor Thermal Protection4-265 How to Operate the Adjustable Frequency Drive5-15.1.2 How to Operate the GraphicalLCP (GLCP)5-15.1.6 Tips and Tricks5-66 How to Program6-16.1.2 Quick Menu Mode6-46.1.3 Function Set-ups6-86.2 Parameter lists6-326.2.1 Main Menu Structure6-326.2.2 0-** Operation and Display6-336.2.3 1-** Load / Motor6-356.2.4 2-** Brakes6-366.2.5 3-** Reference / Ramps6-376.2.6 4-** Limits / Warnings6-386.2.7 5-** Digital In / Out6-396.2.8 6-** Analog In / Out6-416.2.9 8-** Communication and Options6-436.2.10 9-** Profibus6-456.2.11 10-** CAN Fieldbus6-466.2.12 11-** LonWorks6-476.2.13 13-** Smart Logic Controller6-486.2.14 14-** Special Functions6-496.2.15 15-** FC Information6-506.2.16 16-** Data Readouts6-526.2.17 18-** Info & Readouts6-546.2.18 20-** FC Closed-loop6-556.2.19 21-** Ext. Closed-loop6-566.2.20 22-** Application Functions6-586.2.21 23-** Time-based Funtions6-606.2.22 24-** Application Functions 26-616.2.23 25-** Cascade Controller6-626.2.24 26-** Analog I / O Option MCB 1096-647 General Specifications7-18 Warnings and Alarms8-1MG.16.B1.22 - VLT is a registered Danfoss trademark

ContentsVLT HVAC Drive 12-Pulse High Power Instruction Manual8.1.1 Fault Messages9 Index8-59-1MG.16.B1.22 - VLT is a registered Danfoss trademark

ContentsVLT HVAC Drive 12-Pulse High Power Instruction ManualMG.16.B1.22 - VLT is a registered Danfoss trademark

How to Read the Instruction.VLT HVAC Drive 12-Pulse High Power Instruction Manual1 11 How to Read the Instruction Manual1.1.1 Copyright, Limitation of Liability andRevision RightsThis publication contains information proprietary toDanfoss. By accepting and using this manual, the useragrees that the information contained herein will be usedsolely for operating equipment from Danfoss or equipmentfrom other vendors provided that such equipment isintended for communication with Danfoss equipment overa serial communication link. This publication is protectedunder the copyright laws of Denmark and most othercountries.Danfoss does not warrant that a software programproduced according to the guidelines provided in thismanual will function properly in every physical, hardwareor software environment.Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty orrepresentation, neither expressed nor implied, with respectto this documentation, including its quality, performance,or fitness for a particular purpose.In no event shall Danfoss be liable for direct, indirect,special, incidental, or consequential damages arising out ofthe use, or the inability to use information contained inthis manual, even if advised of the possibility of suchdamages. In particular, Danfoss is not responsible for anycosts, including but not limited to those incurred as aresult of lost profits or revenue, loss or damage ofequipment, loss of computer programs, loss of data, thecosts to substitute these, or any claims by third parties.Danfoss reserves the right to revise this publication at anytime and to make changes to its contents without priornotice or any obligation to notify former or present usersof such revisions or changes.1.1.2 SymbolsWARNINGIndicates a high-voltage warning. 1.1.3 Approvals1.1.4 Available Literature for VLT HVACDrive-Instruction Manual MG.16.Bx.yy provides thenecessary information for getting the Adjustablefrequency drive up and running.-Design Guide MG.11.Bx.yy provides all technicalinformation about the Adjustable frequency driveand customer design and applications.-Programming Guide MG.11.Cx.yy providesinformation on how to program and includescomplete parameter descriptions.-Mounting Instruction, Analog I/O Option MCB109, MI.38.Bx.yy-Application Note, Temperature Derating Guide,MN.11.Ax.yy-PC-based Configuration Tool MCT 10, MG.10.Ax.yyenables the user to configure the Adjustablefrequency drive from a Windows -based PCenvironment.-Danfoss VLT Energy Box software n choose PC Software Download-VLT HVAC Drive Drive Applications, MG.11.Tx.yy-Instruction Manual VLT HVAC Drive Profibus,MG.33.Cx.yy-Instruction Manual VLT HVAC Drive Device Net,MG.33.Dx.yy-Instruction Manual VLT HVAC Drive BACnet,MG.11.Dx.yySymbols used in this manualNOTE!Indicates something to be noted by the reader.CAUTIONIndicates a general warning.Indicates default settingMG.16.B1.22 - VLT is a registered Danfoss trademark1-1

1 1How to Read the Instruction.VLT HVAC Drive 12-Pulse High Power Instruction Manual-Instruction Manual VLT HVAC Drive LonWorks,MG.11.Ex.yy-Instruction Manual VLT HVAC Drive Metasys,MG.11.Gx.yy-Instruction Manual VLT HVAC Drive FLN,MG.11.Zx.yy-Output Filter Design Guide, MG.90.Nx.yy-Brake Resistor Design Guide, MG.90.Ox.yyx Revision numberyy Language codeDanfoss technical literature is available in print from yourlocal Danfoss Sales Office or online ocumentations/Technical Documentation.htm1.1.5 Abbreviations and StandardsAbbreviations:aAWGAuto TuneTerms:AccelerationICurrentJoule FFCfkHzEnergyft-lb, BtuAdjustable Frequency DriveFrequencyHzHzKilohertzkHzkHzLocal Control PanelmsMillisecondminMinuteMCTMotion Control ToolMotor Type DependentNmNewton metersIM,NNominal motor currentfM,NNominal motor frequencyPM,NNominal motor powerUM,NNominal motor voltagepar.ParameterPELVProtective Extra Low VoltageWattPowerPascalPressurein-lbsWBtu/hr, hpPa N/m²psi, psf, ft of waterRated Inverter Output CurrentRevolutions Per MinuteSRSize RelatedTTemperatureCFtTimess, hrVVTLIMUTorque limitVoltageTable 1.1 Abbreviation and standards table1-2J N mFahrenheitMilliampereIINVAmpLine power supply with star point in transformerfloating to ground.mARPMACurrent limitLCPM-TYPEft/s2American wire gaugeCelsiusIT line powerI-P units:m/s2Automatic Motor Tuning CILIMSI units:MG.16.B1.22 - VLT is a registered Danfoss trademark

How to Read the Instruction.VLT HVAC Drive 12-Pulse High Power Instruction Manual1 11.1.6 Disposal InstructionsEquipment containing electrical componentsmay not be disposed of together with domesticwaste.It must be separately collected with electricaland electronic waste according to local andcurrently valid legislation.MG.16.B1.22 - VLT is a registered Danfoss trademark1-3

1 1How to Read the Instruction.1-4VLT HVAC Drive 12-Pulse High Power Instruction ManualMG.16.B1.22 - VLT is a registered Danfoss trademark

SafetyVLT HVAC Drive 12-Pulse High Power Instruction Manual2 Safety2 2CautionThe adjustable frequency drive DC link capacitors remaincharged after power has been disconnected. To avoid theelectrical shock hazard, disconnect the adjustable frequencydrive from line power before carrying out maintenance. Beforeservicing the adjustable frequency drive, wait the minimumamount of time indicated below:380–500 V425–1350 hp40 minutes[315–1000 kW]525–690 V535–1875 hp30 minutes[400–1400 kW]VLT HVAC DriveInstruction ManualSoftware version: 3.5xThis instruction manual can be used for all VLT HVAC Driveadjustable frequency drives with software version 3.5x.The software version number can be seen from 15-43 SoftwareVersion.2.1.1 High VoltageWARNINGThe voltage of the adjustable frequency drive is dangerouswhenever the adjustable frequency drive is connected toline power. Incorrect installation or operation of the motoror adjustable frequency drive may cause damage to theequipment, serious personal injury or death. Theinstructions in this manual must therefore be observed, inaddition to applicable local and national rules and safetyregulations.WARNINGInstallation at high altitudes380–500V: At altitudes above 9,843 feet [3 km], pleasecontact Danfoss regarding PELV.525–690V: At altitudes above 6561 ft [2 km], please contactDanfoss regarding PELV.2.1.2 Safety Instructions Make sure the adjustable frequency drive isproperly grounded. Protect users against supply voltage. Protect the motor against overloading accordingto national and local regulations. Motor overload protection is not included in thedefault settings. To add this function, set1-90 Motor Thermal Protection to value ETR trip orETR warning. For the North American market: ETRfunctions provide class 20 motor overloadprotection in accordance with NEC. The ground leakage current exceeds 3.5mA.The [OFF] key is not a safety switch. It does notdisconnect the adjustable frequency drive fromline power.2.1.3 General WarningWARNINGWarning:Touching the electrical parts may be fatal - even after theequipment has been disconnected from line power.Make sure that other voltage inputs have been disconnected, such as load sharing (linkage of DC intermediatecircuit), as well as the motor connection for kinetic backup.When using the adjustable frequency drive: wait at least 40minutes.Shorter time is allowed only if indicated on the nameplatefor the specific unit.CAUTIONLeakage CurrentThe ground leakage current from the adjustable frequencydrive exceeds 3.5 mA. To ensure that the ground cable hasa good mechanical connection to the ground connection(terminal 95), the cable cross-section must be at least 0.016in2 [10 mm2] or 2 rated ground wires terminatedseparately. For proper grounding for EMC, see sectionGrounding in the How to Install chapter.Residual Current DeviceThis product can cause DC current in the protectiveconductor. Where a residual current device (RCD) is usedfor extra protection, only an RCD of Type B (time delayed)shall be used on the supply side of this product. See alsoRCD Application Note MN.90.Gx.02 (x version number).Protective grounding of the adjustable frequency drive andthe use of RCDs must always follow national and localregulations.MG.16.B1.22 - VLT is a registered Danfoss trademark2-1

VLT HVAC Drive 12-Pulse High Power Instruction Manual2.1.4 Before Commencing Repair Work1.Disconnect the adjustable frequency drive fromline power.2.Disconnect DC bus terminals 88 and 89 from loadshare applications3.Wait for the discharge of the DC link. See periodof time on the warning label.4.Remove motor cableSafe Stop functionality and safety category are appropriateand sufficient. In order to install and use the Safe Stopfunction in accordance with the requirements of SafetyCategory 3 in EN 954-1, the related information andinstructions of the Design Guide must be followed! Theinformation and instructions of the Instruction Manual arenot sufficient for a correct and safe use of the safe stopfunctionality!2.1.7 Safe Stop Installation2.1.5 Avoid Unintended StartWhile the adjustable frequency drive is connected to linepower, the motor can be started/stopped using digitalcommands, bus commands, references or via the LocalControl Panel (LCP): Disconnect the adjustable frequency drive fromline power whenever personal safety considerations make it necessary to avoid an unintendedstart. To avoid unintended start, always activate the[OFF] key before changing parameters. An electronic fault, temporary overload, a fault inthe line power supply, or lost motor connectionmay cause a stopped motor to start. Theadjustable frequency drive with safe stopprovides protection against unintended start, ifSafe Stop Terminal 37 is deactivated or disconnected.To carry out an installation of a Category 0 Stop(EN60204) in conformity with Safety Category 3 (EN954-1),follow these instructions:1.The bridge (jumper) between Terminal 37 and24V DC must be removed. Cutting or breakingthe jumper is not sufficient. Remove it entirely toavoid short-circuiting. See jumper on Figure 2.1.2.Connect terminal 37 to 24 V DC by a shortcircuit-protected cable. The 24 V DC voltagesupply must be interruptible by an EN954-1category 3 circuit interrupt device. If the interruptdevice and the Adjustable frequency drive areplaced in the same installation panel, you can usean non-shielded cable instead of a shielded one.130BT314.102 2Safety12372.1.6 Safe StopThe Adjustable frequency drive can perform the safetyfunction Safe Torque Off (As defined by draft CD IEC61800-5-2) or Stop Category 0 (as defined in EN 60204-1).It is designed and approved suitable for the requirementsof Safety Category 3 in EN 954-1. This functionality is calledSafe Stop. Prior to integration and use of Safe Stop in aninstallation, a thorough risk analysis on the installationmust be carried out in order to determine whether the2-2Figure 2.1 Bridge jumper between terminal 37 and 24 VDCFigure 2.2 shows a Stopping Category 0 (EN 60204-1) withsafety Category 3 (EN 954-1). The circuit interrupt is causedby an opening door contact. The illustration also showshow to connect a non-safety related hardware coast.MG.16.B1.22 - VLT is a registered Danfoss trademark

VLT HVAC Drive 12-Pulse High Power Instruction ManualDoor contact130BB566.10SafetyMains6 phaseCoastSafety device Cat.3 (Circuit interruptdevice, possibly with release input)12FrequencyConverterR2R137Short-circuit protected cable(if not inside installation erMFigure 2.2 Essential aspects of an installation to achieve a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1).2.1.8 IT Line Power14-50 RFI 1 can be used to disconnect the internal RFIcapacitors from the RFI filter to ground in the 380–500Vadjustable frequency drives. If this is done, it will reducethe RFI performance to A2 level. For the 525–690Vadjustable frequency drives, 14-50 RFI 1 has no function.The RFI switch cannot be opened.MG.16.B1.22 - VLT is a registered Danfoss trademark2-32 2

SafetyVLT HVAC Drive 12-Pulse High Power Instruction Manual2 22-4MG.16.B1.22 - VLT is a registered Danfoss trademark

Mechanical InstallationVLT HVAC Drive 12-Pulse High Power Instruction Manual3 Mechanical Installation3 33.1.4 Lifting3.1 Pre-installation3.1.1 Planning the Installation SiteNOTE!Always lift the adjustable frequency drive using thededicated lifting holes. For all D and E2 (IP00) enclosures,use a bar to avoid bending the lifting holes of theadjustable frequency drive.130BB753.10Before performing the installation, it is important to planthe installation of the adjustable frequency drive.Neglecting this may result in extra work during and afterinstallation.Select the best possible operation site by considering thefollowing (see details on the following pages and in therespective Design Guides): Ambient operating temperature Installation methodHow to cool the unitPosition of the adjustable frequency drive.Cable routingEnsure the power source supplies the correctvoltage and necessary current. Ensure that the motor current rating is within themaximum current from the adjustable frequencydrive. If the adjustable frequency drive is without builtin fuses, ensure that the external fuses are ratedcorrectly.Figure 3.1 Recommended lifting method, frame size F8.3.1.2 Receiving the Adjustable FrequencyDriveWhen receiving the adjustable frequency drive, make surethat the packaging is intact, and look for any damage thatmight have occurred to the unit during transport. Ifdamage has occurred, immediately contact the shippingcompany to make a damage claim.3.1.3 Transportation and UnpackingBefore unpacking the adjustable frequency drive, it isrecommended to unload it as close as possible to the finalinstallation site.Remove the box and handle the adjustable frequency driveon the pallet, as long as possible.MG.16.B1.22 - VLT is a registered Danfoss trademark3-1

VLT HVAC Drive 12-Pulse High Power Instruction Manual130BB688.10Mechanical Installation3 3NOTE!Note the plinth is provided in the same packaging as theadjustable frequency drive but is not attached duringshipment. The plinth is required to allow airflow to thedrive to provide proper cooling. The F frames should bepositioned on top of the plinth in the final installationlocation. The angle from the top of the drive to the liftingcable should be 140 F [60 C] or greater.In addition to the drawings above a spreader bar is anacceptable way to lift the F Frame.130BB689.10Figure 3.2 Recommended lifting method, frame size F9/F10.Figure 3.3 Recommended lifting method, frame size F11/F12/F13.3-2MG.16.B1.22 - VLT is a registered Danfoss trademark

228022051497All dimensions in mm800IP/54NEMA 121050m3/Hr618CFMIP/21NEMA 11400m3/Hr824CFM6071160CFM1970m3/Hr130BB754.10IP 21/54 - NEMA 1/121400F9CFM927m3/Hr1575NEMA 12IP/54CFM1236m3/Hr2100NEMA 1IP/21607CFM1160m3/Hr1970IP 21/54 - NEMA 1/12130BB568.10F8Mechanical InstallationVLT HVAC Drive 12-Pulse High Power Instruction Manual3.1.5 Mechanical Dimensions3 3220514972280MG.16.B1.22 - VLT is a registered Danfoss trademark3-3

228022051497All dimensions in mm1600F10m3/HrCFMCFM232039401236m3/Hr2100NEMA 12IP/54CFM1648m3/Hr2800NEMA 1IP/21607IP 21/54 - NEMA 1/122400F111854CFM3150m3/HrIP/54NEMA 122472CFM4200m3/HrIP/21NEMA 1607IP 21/54 - NEMA 1/123940m3/Hr2320CFM130BB570.103-4130BB569.103 3Mechanical InstallationVLT HVAC Drive 12-Pulse High Power Instruction Manual228022051497MG.16.B1.22 - VLT is a registered Danfoss trademark

F12IP/21NEMA 1228022051854CFM3150m3/HrIP/54NEMA 00F13IP/21NEMA 11854CFM3150m3/HrIP/54NEMA 122472CFM4200m3/Hr607IP 21/54 - NEMA 1/124925m3/Hr2900CFM130BB572.10IP 21/54 - NEMA 1/1222801497All dimensions in mm2000Mechanical InstallationVLT HVAC Drive 12-Pulse High Power Instruction Manual3 322051497MG.16.B1.22 - VLT is a registered Danfoss trademark3-5

VLT HVAC Drive 12-Pulse High Power Instruction Manual3 3High overload ratedpower - 160% onsHeightF9425–600 hp [315–450 kW](380–500 V)535–850 hp [400–630 kW](525–690 V)21, 54Type 1291.5 in [2324 mm]91.5 in [2324 mm]F10F11F10F11675–950 hp [500–710 kW](380–500 V)950–1200 hp [710–900 kW](525–690 V)21, 54Type 1291.5 in [2324 mm]F12F13F13F12130BB692.10F9 F8130BB691.10Mechanical dimensions, frame sizes E and FFrame sizeF8130BB690.10Mechanical Installation1075–1350 hp [800–1000 kW](380–500 V)1350–1875 hp [1000–1400 kW](525–690 V)21, 54Type 1291.5 in [2324 mm]91.5 in [2324 mm]91.5 in [2324 mm]85 in [2160 mm]116.5 in [2960 mm]44.49 in [1130 mm]44.49 in [1130 mm]Width38.2 in [970 mm]61.7 in [1568 mm]69.3 in [1760 mm]Depth44.49 in [1130 mm]44.49 in [1130 mm]44.49 in [1130 mm]100.75 in [2559mm]44.49 in [1130 mm]Height86.8 in [2204 mm]86.8 in [2204 mm]86.8 in [2204 mm]86.8 in [2204 mm]86.8 in [2204 mm]86.8 in [2204 mm]Width31.50 in [800 mm]55.1 in [1400 mm]63 in [1600 mm]86.6 in [2200 mm]78.74 in

- Instruction Manual VLT HVAC Drive LonWorks, MG.11.Ex.yy - Instruction Manual VLT HVAC Drive Metasys, MG.11.Gx.yy - Instruction Manual VLT HVAC Drive FLN, MG.11.Zx.yy - Output Filter Design Guide, MG.90.Nx.yy - Brake Resistor Design Guide, MG.90.Ox.yy x Revision number yy Language code Danfoss technical literature is available in print .

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