Danfoss ADAP-KOOL AKD 102 User manual

Contents

1 Introduction

1.1.2 Copyright, Limitation of Liability and Revision Rights 4

1.1.6 Type Code String 6

2 Safety

2.1.2 High Voltage Warning 7

2.1.5 Before Commencing Repair Work 8

2.1.6 Special Conditions 9

2.1.7 Safe Stop of the Frequency Converter 9

2.1.8 IT Mains 11

3 Application Guide

3.1.1 ADAP-KOOL

Drive Application Guide 12

3.1.2 Application Descriptions 17

4 Mechanical Installation

4.1 Before starting 19

4.1.2 Mechanical Dimensions 20

4.2 How to Install 23

5 Electrical Installation

5.1 How to Connect 25

5.1.2 Electrical Installation and Control Cables 26

5.1.5 Mains Wiring Overview 30

5.1.11 Motor Wiring Overview 36

5.1.19 How to Test Motor and Direction of Rotation 41

6 How to Operate the Frequency Converter

6.1.2 How to Operate the Graphical LCP (GLCP) 45

6.1.6 Tips and Tricks 52

7 How to Programme the Frequency Converter

7.1 How to Programme 54

7.2 Parameter list 80

7.2.1 0-** Operation and Display 81

7.2.2 1-** Load / Motor 83

7.2.3 2-** Brakes 84

7.2.4 3-** Reference / Ramps 85

7.2.5 4-** Limits / Warnings 86

7.2.6 5-** Digital In / Out 87

7.2.7 6-** Analog In / Out 89

Contents ADAP-KOOL

Drive Operating Instructions

MG.11.L4.02 - ADAP-KOOL

Drive 1

7.2.8 8-** Communication and Options 91

7.2.9 11-** ADAP-KOOL LON 92

7.2.10 13-** Smart Logic Controller 93

7.2.11 14-** Special Functions 94

7.2.12 15-** FC Information 95

7.2.13 16-** Data Readouts 97

7.2.14 18-** Info & Readouts 99

7.2.15 20-** FC Closed Loop 100

7.2.16 21-** Ext. Closed Loop 101

7.2.17 22-** Application Functions 103

7.2.18 23-** Time Based Funtions 105

7.2.19 25-** Pack Controller 106

7.2.20 26-** Analog I / O Option MCB 109 107

7.2.21 28-** Compressor Functions 108

8 Troubleshooting

109

8.1.1 Warning/Alarm list 112

9 Specifications

116

9.1 General Specifications 116

9.2 Special Conditions 124

Index

128

Contents ADAP-KOOL

Drive Operating Instructions

2 MG.11.L4.02 - ADAP-KOOL

Drive

1Introduction

1.1 Introduction

The AKD 102 ADAP-KOOL Drive from Danfoss Food Retail has been designed with our refrigeration customers clearly in

mind. The drive is designed to make commissioning and installation a simple and easy task. The built in “wizard” set up

menu guides the installer through the set up of the drive 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.

The AKD 102 drive comes with a common user interface which covers all power ratings between 1.1- 250 kW. Thus ensuring

that once you have learnt how to commission one drive you understand how to commission them all. Included on this local

control panel is an “info” button which is essentially a built in drive instruction manual which help the user to both gain

information and also suggests other parameters which may need to be changed. The AKD 102 also features a built in “pack

controller” controlled via the drives own standard software. This allows the drive to control the lead compressor via variable

speed and the bringing on line of another 2 compressors in fixed speed mode. This leads to extremely efficient pack design

which also adds the energy efficiency of variable speed control. Using the drive in this way eliminates the need for an

external pack controller thus giving financial savings to the customer.

The drive can be supplied in either of two protection classes IP21(IP20 up to 7,5kW) or IP55 (IP66 on request); this insures

that our customers benefit from having the most robust of designs supplied directly from the factory, without the need for

additional cabinets in which to house the drive. The AKD also benefits from the inclusion of having built in RFI filters as

standard which means that the problems associated with radio interference and long cable runs are no problem for our

customers.

The modular construction of the AKD means that you only have to pay for what you need. Each AKD is manufactured only

when we receive a customer order and so is built exactly to customer specification with any chosen options added at this

stage. But by using this manufacturing and design philosophy it means that should options such as ADAP-KOOL Lon be

required at some future date they are a simple retrofit inside of the drive which can be done by anyone with extreme ease.

Warranty: Each AKD comes with 18 months warranty from date of manufacture or 12 months from date of documented

installation, whichever comes first thus ensuring that our Food Retail customers have complete peace of mind when

choosing AKD as their drive of choice.

1.1.1 Software Version and Approvals: ADAP-KOOL

Drive

ADAP-KOOL

Drive

Operating Instructions

Software version: 2.xx

This Operating Instructions can be used for all ADAP-KOOL

Drive frequency converters with software version 2.xx.

The software version number can be seen from parameter 15-43.

Introduction ADAP-KOOL

Drive Operating Instructions

MG.11.L4.02 - ADAP-KOOL

Drive 3

1.1.2 Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to Danfoss. By accepting and using this manual the user agrees that the

information contained herein will be used solely for operating equipment from Danfoss or equipment from other vendors

provided that such equipment is intended for communication with Danfoss equipment over a serial communication link.

This publication is protected under the Copyright laws of Denmark and most other countries.

Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will

function properly in every physical, hardware or software environment.

Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or represen-

tation, neither expressed nor implied, with respect to 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 of the use, or

the inability to use information contained in this manual, even if advised of the possibility of such damages. In particular,

Danfoss is not responsible for any costs, including but not limited to those incurred as a result of lost profits or revenue,

loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims by third

parties.

Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or

any obligation to notify former or present users of such revisions or changes.

1.1.3 Available Literature

-Operating Instructions MG.11.Lx.yy provide the neccessary information for getting the drive up and running.

-Design Guide MG.11.Mx.yy entails all technical information about the drive and customer design and applications.

-Programming Guide MG.11.Nx.yy provides information on how to programme and includes complete parameter

descriptions.

-Operating Instructions AKD102 High Power, MG.11.Ox.yy

-Operating InstructionsAKD LonWorks, MG.11.Px.yy

x = Revision number

yy = Language code

Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/

Technical+Documentation.htm.

Introduction ADAP-KOOL

Drive Operating Instructions

4 MG.11.L4.02 - ADAP-KOOL

Drive

1.1.4 Abbreviations and Standards

Abbreviations: Terms: SI-units: I-P units:

aAcceleration m/s2ft/s2

AWG American wire gauge

Auto Tune Automatic Motor Tuning

°CCelsius

ICurrent AAmp

ILIM Current limit

Joule Energy J = Nm ft-lb, Btu

°FFahrenheit

FC Frequency Converter

f Frequency Hz Hz

kHz Kilohertz kHz kHz

LCP Local Control Panel

mA Milliampere

ms Millisecond

min Minute

MCT Motion Control Tool

M-TYPE Motor Type Dependent

Nm Newton Metres in-lbs

IM,N Nominal motor current

fM,N Nominal motor frequency

PM,N Nominal motor power

UM,N Nominal motor voltage

par. Parameter

PELV Protective Extra Low Voltage

Watt Power WBtu/hr, hp

Pascal Pressure Pa = N/m psi, psf, ft of water

IINV Rated Inverter Output Current

RPM Revolutions Per Minute

SR Size Related

TTemperature CF

tTime ss,hr

TLIM Torque limit

UVoltage V V

Table 1.1 Abbreviation and standards table.

1.1.5 Frequency Converter Identification

Below is an example of an identification label. This label is situated on the frequency converter and shows the type and

options fitted to the unit. See table 2.1 for details of how to read theType code string (T/C).

Illustration 1.1 This example shows an identification label.

NOTE

Please have T/C (type code) number and serial number ready before contacting Danfoss.

Introduction ADAP-KOOL

Drive Operating Instructions

MG.11.L4.02 - ADAP-KOOL

Drive 5

1.1.6 Type Code String



Description Pos Possible choice

Product group & VLT Series 1-6 AKD102

Power rating 8-10 1.1 - 250 kW (P1K1 - P250)

Number of phases 11 Three phases (T)

Mains voltage 11-12 T 2: 200-240 VAC

T 4: 380-480 VAC

Enclosure 13-15

E20: IP20

E21: IP 21/NEMA Type 1

E55: IP 55/NEMA Type 12

E66: IP66

P21: IP21/NEMA Type 1 w/backplate

P55: IP55/NEMA Type 12 w/backplate

RFI filter 16-17

H1: RFI filter class A1/B

H2: RFI filter class A2

H4: RFI filter class A2/A1

Display 19 G: Graphical Local Control Panel (GLCP)

X: No Local Control Panel

Coating PCB 20 C: Coated PCB

Mains option 21 X: No Mains disconnect switch

1: With Mains disconnect switch (IP55 only)

Adaptation 22 Reserved

Adaptation 23 Reserved

Software release 24-27 Actual software

Software language 28

A options 29-30 AX: No options

AZ: MCA 107AKD LonWorks

B options 31-32

BX: No option

BK: MCB 101 General purpose I/O option

BP: MCB 105 Relay option

BO:MCB 109 Analog I/O option

C0 options MCO 33-34 CX: No options

C1 options 35 X: No options

C option software 36-37 XX: Standard software

D options 38-39 DX: No option

D0: DC back-up MCB107

Table 1.2 Type code description.

The various options are described further in the ADAP-KOOL

Drive AKD102 Design Guide, MG.11.Mx.yy.

Introduction ADAP-KOOL

Drive Operating Instructions

6 MG.11.L4.02 - ADAP-KOOL

Drive

2Safety

2.1.1 Symbols

Symbols used in this manual:

NOTE

Indicates something to be noted by the reader.

CAUTION

Indicates a general warning.

WARNING

Indicates a high-voltage warning.

✮Indicates default setting

2.1.2 High Voltage Warning

WARNING

The voltage of the frequency converter and the MCO 101 option card is dangerous whenever it is connected to mains.

Incorrect installation of the motor or frequency converter may causedeath, serious injury or damage to the equipment.

Consequently, it is essential to comply with the instructions in this manual as well as local and national rules and safety

regulations.

2.1.3 Safety Note

WARNING

The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor,

frequency converter or fieldbus may cause death, serious personal injury or damage to the equipment. Consequently, the

instructions in this manual, as well as national and local rules and safety regulations, must be complied with.

Safety Regulations

1. The frequency converter must be disconnected from mains if repair work is to be carried out. Check that the mains

supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.

2. The [STOP/RESET] key on the LCP of the frequency converter does not disconnect the equipment from mains and

is thus not to be used as a safety switch.

3. Correct protective earthing of the equipment must be established, the user must be protected against supply

voltage, and the motor must be protected against overload in accordance with applicable national and local

regulations.

4. The earth leakage currents are higher than 3.5 mA.

5. Protection against motor overload is set by 1-90 Motor Thermal Protection. If this function is desired, set 1-90 Motor

Thermal Protection to data value [ETR trip] (default value) or data value [ETR warning]. Note: The function is

initialized at 1.16 x rated motor current and rated motor frequency. For the North American market: The ETR

functions provide class 20 motor overload protection in accordance with NEC.

6. Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains.

Check that the mains supply has been disconnected and that the necessary time has passed before removing

motor and mains plugs.

Safety ADAP-KOOL

Drive Operating Instructions

MG.11.L4.02 - ADAP-KOOL

Drive 7

7. Please note that the frequency converter has more voltage inputs than L1, L2 and L3, when load sharing (linking

of DC intermediate circuit) and external 24 V DC have been installed. Check that all voltage inputs have been

disconnected and that the necessary time has passed before commencing repair work.

Installation at high altitudes

WARNING

Installation at high altitude:

380 - 500 V, enclosure A, B and C: At altitudes above 2 km, please contact Danfoss regarding PELV.

380 - 500 V, enclosure D, E and F: At altitudes above 3 km, please contact Danfoss regarding PELV.

WARNING

Warning against Unintended Start

1. The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop,

while the frequency converter is connected to mains. If personal safety considerations make it necessary to ensure

that no unintended start occurs, these stop functions are not sufficient.

2. While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] must always

be activated; following which data can be modified.

3. A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a

temporary overload or a fault in the supply mains or the motor connection ceases.

WARNING

Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains.

Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC

intermediate circuit), as well as the motor connection for kinetic back up. Refer to the Operating Instructions for further

safety guidelines.

2.1.4 Caution

Caution

The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard, disconnect the

frequency converter from the mains before carrying out maintenance. Wait at least as follows before doing service on the frequency converter:

Voltage Minimum Waiting Time

4 min. 15 min.

200 - 240 V 1.1 - 3.7 kW 5.5 - 45 kW

380 - 480 V 1.1 - 7.5 kW 11 - 90 kW

Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

2.1.5 Before Commencing Repair Work

1. Disconnect the frequency converter from mains

2. Disconnect DC bus terminals 88 and 89

3. Wait at least the time mentioned in section General Warning above

4. Remove motor cable

Safety ADAP-KOOL

Drive Operating Instructions

8 MG.11.L4.02 - ADAP-KOOL

Drive

2.1.6 Special Conditions

Electrical ratings:

The rating indicated on the nameplate (Illustration 2.1) of the frequency converter is based on a typical 3-phase mains

power supply, within the specified voltage, current and temperature range, which is expected to be used in most

applications.

The frequency converters also support other special applications, which affect the electrical ratings of the frequency

converter.

Special conditions which affect the electrical ratings might be:

□Single phase applications

□High temperature applications which require de-rating of the electrical ratings

□Marine applications with more severe environmental conditions.

Other applications might also affect the electrical ratings.

Consult the relevant clauses in these instructions and in the AKD102 Design Guide, MG.11.Mx.yy for information about the

electrical ratings.

Installation requirements:

The overall electrical safety of the frequency converter requires special installation considerations regarding:

□Fuses and circuit breakers for over-current and short-circuit protection

□Selection of power cables (mains, motor, brake, loadsharing and relay)

□Grid configuration (IT,TN, grounded leg, etc.)

□Safety of low-voltage ports (PELV conditions).

Consult the relevant clauses in these instructions and in the AKD102 Design Guide for information about the installation

requirements.

2.1.7 Safe Stop of the Frequency Converter

For versions fitted with a Safe Stop terminal 37 input, the frequency converter can perform the safety function Safe Torque

Off (As defined by draft CD IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).

It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe

Stop. Prior to integration and use of Safe Stop in an installation, a thorough risk analysis on the installation must be carried

out in order to determine whether the Safe Stop functionality and safety category are appropriate and sufficient. In order to

install and use the Safe Stop function in accordance with the requirements of Safety Category 3 in EN 954-1, the related

information and instructions of the AKD102 Design Guide MG.11.MX.YY must be followed! The information and instructions of

the Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality!

Safety ADAP-KOOL

Drive Operating Instructions

MG.11.L4.02 - ADAP-KOOL

Drive 9

130BA491

Illustration 2.1 This certificate also covers AKD102

Safety ADAP-KOOL

Drive Operating Instructions

10 MG.11.L4.02 - ADAP-KOOL

Drive

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