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VLT® Refrigeration Drive FC 103 improves efficiency of compressors, condensers, evaporators and pumps

VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps
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VLT® Refrigeration Drive FC 103 improves efficiency of compressors, condensers, evaporators and pumps

Product catalog summary
Overview
The VLT® Refrigeration Drive FC 103 by Danfoss is engineered to enhance the efficiency and reliability of refrigeration systems, including components like compressors, condensers, evaporators, fans, and pumps. It aims to reduce lifecycle costs and improve system performance through integrated process control functions and a user-friendly commissioning environment.
Key Features
  • Achieves top efficiency of 98% with Automatic Energy Optimisation (AEO).
  • Offers a wide performance range and compatibility with various controllers, including Danfoss ADAP-KOOL®.
  • Includes integrated functions such as multi-zone cascade controller, floating condensing temperature control, and oil return management.
  • Facilitates easy installation with a quick menu and built-in wizard for swift commissioning.
Energy Efficiency
The drive supports speed control, significantly reducing power consumption and mechanical stress, leading to lower service and maintenance costs. It optimizes the energy efficiency ratio (EER) and coefficient of performance (COP) by allowing intelligent capacity control and stable operation under partial load conditions.
System Integration
  • Reduces the number of external components and integrates easily into existing systems.
  • Improves the energy balance and reduces the environmental footprint of refrigeration systems.
Advanced Control Features
  • Multi-zone pack controller for improved energy savings and stable operation.
  • Dedicated compressor features such as condensing temperature monitoring and direct entry of evaporator temperature.
  • Day/night control and neutral zone settings for optimized operation.
Commissioning and Maintenance
The drive offers a setup wizard using common refrigeration terms, making it easy for installers and technicians to program and troubleshoot. It reduces service costs by minimizing mechanical wear and extending service intervals.
Conclusion
The VLT® Refrigeration Drive FC 103 is a comprehensive solution for enhancing the efficiency and reliability of refrigeration systems, offering significant energy savings and reduced lifecycle costs through advanced control features and easy integration.
Additional Functionalities
  • Oil Boost Functionality: Increases compressor speed to return oil to the compressor, improving lubrication and system reliability.
  • Resonance Monitoring: Avoids frequency bands that cause resonances, reducing vibration noise and equipment wear.
  • Auto Tuning of PI Controllers: Optimizes 'P' and 'I' values for precise operation, reducing commissioning costs.
  • Floating Condensing Temperature: Adapts condensing temperature set point as outdoor temperatures drop, increasing cooling capacity and reducing power consumption.
  • Intelligent Functions: Handles logical rules and inputs from sensors for various functions like weekend operations and belt monitoring.
  • Dedicated Condenser and Evaporator Features: Includes 4 PID controllers for closed-loop control and extended I/O capacity.
  • Dry Pump Protection and End of Curve: Protects against situations where the pump runs without creating desired pressure.
  • Embedded Pump Cascade Controller: Distributes running hours evenly across pumps, minimizing wear.
  • Sleep Mode and Flow Compensation: Detects low/no flow situations, boosting system pressure before stopping to save energy.
  • Systematic Energy Savings: Combines energy-efficient power stages with advanced algorithms for high efficiency.
  • Free Choice of Motor Technology: Supports various motor types for optimal efficiency.
  • Safety and Simplified Installation: Features Safe Torque Off function for reliable stopping, reducing cabling costs.
  • Intuitive Setup and Efficient Service: User-friendly local control panel for easy setup and parameter configuration.
Specifications and Features
The VLT® Refrigeration Drive FC 103 supports multiple applications such as multi-compressor control and pump systems. It includes a built-in setup wizard for efficient installation and configuration, guiding users through parameter programming and offering an Automatic Motor Adaptation (AMA) feature for optimal motor performance.
Built-in Protection and Compliance
The drive includes built-in modules for EMC compliance, featuring scalable RFI filters and DC link chokes to minimize electromagnetic interference and harmonic distortion. It complies with standards like IEC 61000-3-2 and EN 55011, ensuring reduced installation costs and increased drive efficiency.
Performance Optimization
The drive is equipped with DC chokes to reduce mains interference and supports long motor cables up to 300 meters. It offers various filter solutions for harmonic mitigation, including the VLT® Advanced Harmonic Filter and VLT® Advanced Active Filter, to enhance grid and motor protection.
Installation and Design
The drive's design is optimized for easy installation and maintenance, with features like IP55/66 enclosures for demanding environments and IP20/UL TYPE 1 enclosures for panel installations. It includes intelligent cooling technology and accessories for efficient heat management.
Integration and Connectivity
Danfoss provides fieldbus drivers for easy integration into existing bus systems, enhancing productivity and allowing for future expansions. The drive supports various fieldbus options, making it adaptable to changing communication needs.
Case Study
The document briefly mentions the Helsinki Ice Stadium as an example of the drive's application in a real-world setting, highlighting its versatility and reliability in different environments.
Applications
  • Sabharwal Food Industries, India: Utilizes VLT® Refrigeration Drives FC 103 for screw compressors and evaporator fans to enhance system performance and energy efficiency.
  • Sainsbury, UK: Employs Danfoss Drives to maintain consistent temperatures in stores, supporting CO2 reduction goals.
  • Maersk Containers, Denmark: Uses VLT® drives for reliable temperature control in shipping containers globally.
  • Corman, Belgium: Implements VLT® drives to reduce operational costs and adapt to production line changes.
  • Grupo Bimbo, Mexico: Applies VLT® frequency converters for efficient control of cooling compressors, achieving a quick return on investment.
  • CUB Yatala Brewery, Australia: Achieves world-class energy efficiency in brine chilling with VLT® drives.
  • Versacold Group, Canada: Operates cold storage facilities with VLT® drives, enhancing storage quality for pharmaceuticals and groceries.
Technical Specifications
  • Power Supply: Supports various voltage ranges (200-690 V AC) and frequencies (50/60 Hz).
  • Output: Offers a wide range of output voltages and frequencies, with programmable digital and analog inputs/outputs.
  • Protection Features: Includes thermal motor protection, short-circuit, and earth fault protection.
  • Environmental Specifications: Designed for various enclosure types (IP00 to IP66) and withstands temperatures up to 55°C.
  • Communication: Supports multiple fieldbus communication protocols, including Modbus RTU and optional PROFIBUS and PROFINET.
Installation and Configuration
The document provides a connection diagram for typical installations, detailing terminal connections for power, motor, and communication interfaces.
Additional Options
Offers various power and control card options to extend drive functionality, including advanced filters and software tools for motion control and energy management.
Specifications
The document provides detailed specifications for the VLT® Refrigeration Drive, covering various voltage ranges (380-480 V AC, 525-600 V AC, and 525-690 V AC). It includes information on typical shaft output in kW and HP, output current (continuous and intermittent), output power at different voltages, maximum input current, and estimated power loss at rated maximum load. Efficiency is generally around 0.98, with some variations.
Enclosure Types and Conversion
Different enclosure types (IP20, IP21, IP55, IP66) are discussed, with conversion kits available for some types to achieve IP21 protection. The document references mechanical mounting and enclosure kits in the Design Guide.
Power Loss and Efficiency
Power loss is expected to be within ±15% of normal load conditions, with variations due to voltage and cable conditions. Lower efficiency motors increase power loss, and raising the switching frequency can significantly increase losses. Additional options and customer load can add up to 30 W to the losses.
Cable Specifications
Maximum cable cross-sections for mains, motor, brake, and load sharing are specified in mm² and AWG. The document provides details for different enclosure types and voltage ranges.
Weight and Dimensions
Weights for different enclosure types and frame sizes are provided in kg and lbs. The document includes specific weights for IP20, IP21, IP54, and other enclosure types.
Additional Technical Specifications
Includes output frequency range (0-590 Hz), heatsink overtemperature trip (110 °C), and control card ambient trip temperatures (75 °C and 85 °C). The document also covers constant-torque applications and starting torque requirements for various compressor types.
Recommendations and Considerations
Measurement inaccuracies are acknowledged, with a tolerance of ±5%. The document advises on the impact of motor efficiency and switching frequency on power loss. It also highlights the importance of using appropriate conversion kits for enclosure protection.
Technical Specifications Overview

1. Electrical Specifications:
- Current Ratings: Continuous and intermittent current ratings are provided for different voltages (550 V, 575 V, 690 V). For example, continuous current at 690 V is 630 A, while intermittent current at the same voltage is 693 A.
- Output Power: Continuous output power is specified in kVA for various voltages, with a maximum of 753 kVA at 690 V.
- Maximum Input Current: Detailed for each voltage, with a maximum of 607 A at 690 V.
- Efficiency: The system operates at an efficiency of 0.98.

2. Physical and Environmental Specifications:
- Dimensions and Weight: Detailed dimensions for various enclosures (A, B, C, D, E) are provided, including height, width, depth, and weight. For instance, enclosure E1 has a height of 2000 mm and a weight of 9.7 kg.
- Cooling Requirements: Air cooling specifications include air space inlet and outlet dimensions, with specific airflow rates for different enclosures.

3. Additional Specifications:
- Power Loss: Estimated power loss is provided for 600 V and 690 V, with values ranging from 5323 W to 8495 W.
- Temperature Limits: Heatsink overtemperature trip is set at 110 °C, and power card ambient trip at 85 °C.

4. Options and Accessories:
- Fieldbus Options: Includes VLT® PROFIBUS DP, VLT® PROFINET, and VLT® AK-LonWorks, each offering specific communication and control benefits.
- Functional Extensions: Options like VLT® General Purpose I/O, Relay Card, and Analog I/O are available to enhance control capabilities.
- External Power Supply: VLT® 24 V DC Supply Option is available to maintain control during power failures.

5. Ordering Information:
- Detailed type codes are provided for ordering, covering application, power size, AC line voltage, enclosure type, and additional features like RFI filters and braking options.
Introduction
Danfoss Drives is a leader in variable speed control of electric motors, offering products and services that enhance efficiency, usability, and reduce complexity. Their products are used globally across various industries, providing a competitive edge through quality and application-optimized solutions.
Product Options
The document outlines several options for VLT® drives, including:
  • BK VLT® General Purpose MCB 101
  • BP VLT® Relay Option MCB 105
  • B0 VLT® Analog I/O Option MCB 109
  • R VLT® Extended Relay Card MCB 113
  • D0 VLT® 24 V DC Supply Option MCB 107
It is noted that not all combinations of these options are possible, and users are directed to an online configurator for assistance.
Applications and Industries
VLT® and VACON® drives are suitable for a wide range of industries, including:
  • Marine and Offshore
  • Oil and Gas
  • Metals
  • Mining and Minerals
  • Pulp and Paper
  • Energy
  • Elevators and Escalators
  • Chemical
  • Food and Beverage
  • Water and Wastewater
  • HVAC
  • Refrigeration
  • Material Handling
  • Textile
These drives are designed for long lifetimes, top performance, and full-throttle process throughput.
Company Expertise
Danfoss Drives has been in operation since 1968, providing low and medium voltage AC drives compatible with all major motor brands and technologies. Their global presence ensures expert support is readily available in over 50 countries.
Conclusion
Danfoss Drives emphasizes innovation and high durability, making their products ideal for sustainable industries and demanding applications. Their commitment to customer goals and performance optimization is evident in their comprehensive product offerings and lifecycle services.
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Catalog excerpts

VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-1

VLT® Refrigeration Drive FC 103 improves efficiency of compressors, condensers, evaporators and pumps in Global Refrigeration. Dedicated solutions deliver higher energy efficiency, optimum system performance and enhanced reliability

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VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-3

VLT® Refrigeration Drive FC 103 reduces lifecycle costs For over 60 years the Danfoss Refrigeration team has specialised in the development of innovative and effective refrigeration technology solutions. Danfoss has now developed the ideal drive for refrigeration system compressors, condensers, evaporators, fans and pumps – the VLT® Refrigeration Drive FC 103. To help significantly reduce lifecycle costs of your refrigeration systems, the VLT® Refrigeration Drive FC 103 offers efficiency and reliability enhancing features, integrated process control functions and commissioning environment specifically...

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VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-4

Faster system payback with speed control Reducing the operating costs of refrigeration systems with quick payback is becoming increasingly important. Speed control of the electric drives used in these systems is a pragmatic and effective approach. Load-dependent speed control reduces power consumption and therefore saves money. With its functions specifically tailored for refrigeration technology, it reduces total life cycle costs in the application. The drive reduces the number of external components, required integrates easily into existing When you consider that energy costs amount to 90% or...

 Open the catalog to page 4
VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-5

VLT® OneGearDrive VLT® Micro Drive VLT® HVAC Drive VLT® AQUA Drive VLT® Integrated Servo Drive VLT® High Power Drives VLT® Advanced Active Filter VLT® Decentral Drive FCD 302 VLT® High Power Drives up to 1.4 MW V VL VLT® Refrigeration Drive VLT® Drive Motor FCM/FCP 106

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VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-6

Optimise compressor performance coefficient – Achieve system-wide energy efficiency The performance of a refrigeration system is expressed using the energy efficiency ratio (EER) or the coefficient of performance (COP). This is the ratio of the generated cooling or heating capacity to the power actually consumed, and is usually based on full-load operation. However, it is not enough to rate a refrigeration unit at just one load level, since most refrigeration systems operate under partial load conditions. This means that significant energy savings can be obtained using speed control. Refrigeration system...

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VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-7

Pumps in process cooling or air-conditioning systems • Coolant pump capacity according to demand • Stable coolant flow and pressure • Stand-alone control using VLT® Refrigeration Drive FC 103 • Operate from direct signal (0/4-20 mA or 0-10 V DC) Fans in process cooling or airconditioning systems • Optimized operation of air handling units • High efficiency • Airflow according to demand • Stand-alone control using VLT® Refrigeration Drive FC 103 • Operate from direct signal (0/4-20 mA or 0-10 V DC) Cold room The figure on the left shows the condensation temperature curve (red) and the evaporation temperature...

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VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-8

Multi-zone pack controller – Improved energy savings and stable operation Read the compressor status directly from the display. D = Variable speed control, O = Off, R = Mains operation, X = Deactivated There is a speed range in the interaction between the compressor and frequency converter that allows the system to save energy. The compressor should function within this range most of the time. If the difference between the maximum required performance and the average performance under partial load is too great, it is a good idea to use a cascade configuration. In many cases the required capital...

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VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-9

Commissioning is fast and easy using the the frequency converter display panel. The wizard that appears the first time the device is switched on guides the user through the necessary settings. The user only has to switch from external to internal control. If necessary, the wizard can be called up again from the Quick Menu. Configuring the necessary parameters is even easier with the wizard in theVLT® Motion Control Tool MCT 10 software. During operations, the FC 103 can show the compressor status on the frequency converter display panel and log the compressor’s operating time and number of starts....

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VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-11

Dedicated compressor features The VLT® Refrigeration Drive FC 103 is designed for operating piston, scroll, screw compressors and centrifugal compressors. Variable speed control allows the refrigeration capacity of a compressor to be adapted to exactly match the demand. Day/night control Compressors usually operate with different setpoints depending on the time of day. This in turn results in different evaporator fan speeds, resulting in reduced energy consumption. This function can be easily programmed with day/night control. Neutral Zone The FC 103 continues to control fixed speed compressors...

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VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-12

Dedicated condenser and evaporator features User-friendly, distributed intelligence and reduced power consumption are beneficial for condenser and evaporator applications. Floating condensing temperature optimises COP VLT® Refrigeration Drive FC 103 intelligently controls evaporative condensers or air-cooled condensers to optimise refrigeration system performance (COP) at lower energy consumption. The drive adapts condensing temperature set point as the outdoor temperature drops, lowering the set point to a new stable level. This functionality provides: • Increased cooling capacity at lower power...

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VLT® Refrigeration Drive FC 103  improves efficiency of compressors,  condensers, evaporators and pumps-13

Dedicated pump features The VLT® Refrigeration Drive FC 103 offers a vast number of pump-specific features developed in cooperation with OEMs, contractors and manufacturers around the world. Embedded Pump Cascade Controller The Pump Cascade Controller distributes running hours evenly across all pumps, keeps wear and tear on individual pumps to a minimum and ensures that all pumps are in great shape. Leakage or broken pipe Continuous liquid supply can be assured in the event of leakage or a broken pipe. For example, overload is prevented by reducing drive speed – and supply is secured at lower flow....

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.