Danfoss VLT 6000 HVAC Series Leitfaden

Contents

Introduction to HVAC

Software version 4

Safety regulations 5

Warning against unintended start 5

Introduction to the Design Guide 7

Available literature 9

Fire mode 12

Star/delta starter or soft-starter not required 14

Control principle 16

CE labelling 17

The new standard 18

The new standard 19

The new standard 20

Choice of frequency converter 24

Unpacking and ordering a VLT frequency converter 27

Type code ordering number string 27

Ordering form 31

PC software and serial communication 32

PC Software tools 32

Fieldbus options 32

Profibus 33

LON - Local Operating Network 33

DeviceNet 33

Modbus RTU 33

Installation

Mains supply (L1, L2, L3) 43

Max. imbalance of supply voltage 43

Technical data, mains supply 3 x 200-240V 48

Technical data, mains supply 3 x 380-460V 49

Technical data, mains supply 3 x 525-600 V 54

Fuses 59

Mechanical dimensions 61

Mechanical installation 65

General information about electrical installation 68

High voltage warning 68

Earthing 68

Cables 68

Screened/armoured cables 69

Extra protection with regard to indirect contact 69

RFI switch 70

High voltage test 73

Heat emission from VLT 6000 HVAC 73

Ventilation of integrated VLT 6000 HVAC 73

EMC correct electrical installation 73

Use of EMC-correct cables 76

Electrical installation - earthing of control cables 77

VLT

6000 HVAC Series

MG.61.B5.02 - VLT

is a registered Danfoss trademark 1

Electrical installation, enclosures 78

Tightening-up torque and screw sizes 85

Mains connection 85

Motor connection 85

Direction of motor rotation 86

Motor cables 86

Motor thermal protection 87

Earth connection 87

Installation of 24 Volt external DC supply 87

DC bus connection 87

High-voltage relay 87

Control card 87

Electrical installation, control cables 88

Switches 1-4 89

Bus connection 89

Connection examples, VLT 6000 HVAC 90

Programming

Control unit LCP 92

Control keys for parameter setup 92

Indicator lamps 93

Local control 93

Display mode 94

Navigation between display modes 96

Changing data 97

Manual initialisation 97

Quick Menu 98

Operation and Display 001-017 100

The Setup configuration 100

Setup of user-defined readout 101

Load and Motor 100-117 107

Configuration 107

Motor power factor (Cos ø) 114

Reference handling 116

Reference type 119

Inputs and outputs 300-365 124

Analogue inputs 128

Analog/digital outputs 131

Relay outputs 135

Application functions 400-427 139

Sleep mode 141

PID for process control 146

PID overview 148

Feedback handling 148

Serial communication for FC protocol 155

Protocols 155

Telegram communication 155

Telegram build-up under FC protocol 156

Data character (byte) 157

VLT

6000 HVAC Series

2 MG.61.B5.02 - VLT

is a registered Danfoss trademark

Process word 161

Control word according to FC protocol 162

Status word as per FC protocol 163

Serial communication reference 164

Present output frequency 165

Serial communication 500 - 556 166

Extended status word, warning word, and alarm word 174

Service functions 600-631 176

Electrical installation of the relay card 181

Description of Real Time Clock 182

All about VLT 6000 HVAC

185

Status messages 185

List of warnings and alarms 187

Aggressive environments 194

Calculation of resulting reference 194

Galvanic isolation (PELV) 195

Earth leakage current 195

Extreme running conditions 196

Peak voltage on motor 197

Switching on the input 198

Acoustic noise 199

Derating for ambient temperature 199

Derating for air pressure 200

Derating for running at low speed 200

Derating for long motor cables or cables with larger cross-section 200

Derating for high switching frequency 200

Vibration and shock 201

Air humidity 201

Efficiency 202

Mains supply interference/harmonics 203

Power factor 203

(Emission, Immunity) 204

EMC Immunity 206

Definitions 208

Parameter overview and factory settings 210

Index

217

VLT

6000 HVAC Series

MG.61.B5.02 - VLT

is a registered Danfoss trademark 3

Software version VLT 6000 HVAC

Design Guide

Software version: 3.2x

This Design Guide can be used with all VLT 6000 HVAC frequency converters with software version 3.2x.

The software version number can be seen from parameter 624.

VLT

6000 HVAC Series

4 MG.61.B5.02 - VLT

is a registered Danfoss trademark

The voltage of the frequency converter is

dangerous whenever the equipment is

connected to mains. Incorrect installation

of the motor or the frequency converter

may cause damage to the equipment, se-

rious personal injury or death.

Consequently, the instructions in this

manual,aswell as nationalandlocal rules

and safety regulations, must be complied

with.

Safety regulations

1. The frequency converter must be disconnec-

ted 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 [OFF/STOP] key on the control panel 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 pro-

tected against supply voltage, and the motor

must be protected against overload in ac-

cordance with applicable national and local

regulations.

4. The earth leakage currents are higher than

3.5 mA.

5. Protectionagainst motor overloadis included

in the factory setting. Parameter 117, Motor

thermal protection default value is ETR trip 1.

Note: The function is initialised at 1.0 x rated

motor current and rated motor frequency

(see parameter 117, Motor thermal protec-

tion).

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.

7. Reliable galvanic isolation (PELV) is not

complied with if the RFI switch is placed in

OFF position. This means that all control in -

and outputs can only be considered low-volt-

age terminals with basic galvanic isolation.

8. Please note that the frequency converter has

morevoltageinputsthanL1,L2andL3, when

the DC-bus terminals are used.

Check that all voltage inputs have been dis-

connected and that the necessary time has

passed before repair work is commenced.

Warning against unintended start

1. The motor can be broughtto a stop bymeans

of digital commands, bus commands, refer-

ences or a local stop, while the frequency

converter is connected to mains.

Ifpersonalsafety considerationsmake it nec-

essary to ensure that no unintended start

occurs, these stop functions are not suffi-

cient.

2. While parameters are being changed, the

motor may start. Consequently, the stop key

[OFF/STOP] must always be activated, fol-

lowing which data can be modified.

3. A motor that has been stopped may start if

faults occur in the electronics of the frequen-

cy converter, or if a temporary overload or a

fault in the supply mains or the motor con-

nection ceases.

VLT

6000 HVAC Series

MG.61.B5.02 - VLT

is a registered Danfoss trademark 5

Introduction to HVAC

Warning:

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

VLT 6002 - 6005, 200-240 V: wait at least 4 minutes

VLT 6006 - 6062, 200-240 V : wait at least 15 minutes

VLT 6002 - 6005, 380-460 V: wait at least 4 minutes

VLT 6006 - 6072, 380-460 V: wait at least 15 minutes

VLT 6102 - 6352, 380-460 V: wait at least 20 minutes

VLT 6402 - 6602, 380-460 V: wait at least 40 minutes

VLT 6002 - 6006, 525-600 V: wait at least 4 minutes

VLT 6008 - 6027, 525-600 V: wait at least 15 minutes

VLT 6032 - 6072, 525-600 V: wait at least 30 minutes

VLT 6102 - 6402, 525-600 V: wait at least 20 minutes

VLT 6502 - 6652, 525-600 V: wait at least 30 minutes

VLT

6000 HVAC Series

6 MG.61.B5.02 - VLT

is a registered Danfoss trademark

Introduction to the Design Guide

This Design Guide is a tool intended to facilitate the sizing of systems in which VLT 6000 HVAC frequency

converters are used.

HVAC stands for Heating Ventilation Air-Conditioning.

This Design Guide progresses step-by-step through the different procedures required for selecting, installing and

programming a VLT 6000 HVAC.

The Design Guide forms part of the literature concept supplied with VLT 6000 HVAC. However, the DesignGuide

is the most comprehensive document available.

When a VLT 6000 HVAC is supplied, it is accompanied by Operating Instructions and a Quick Setup Guide. See

the section Other Literature.

Operating Instructions: Describe how to ensure optimum mechanical and electrical installation, and also

deal with commissioning and service. The Operating Instructions furthermore pro-

vide a description ofthe software parameters, thereby ensuring thatyou can easily

fit the VLT 6000 HVAC into your application.

Quick Setup Guide: Helps you get your VLT 6000 HVAC installed and commissioned quickly.

Design Guide: Used when designing systems with VLT 6000 HVAC. The Design Guide gives all

useful information about the VLT 6000 HVAC and HVAC systems. There is a se-

lection tool for you to choose the right VLT 6000 HVAC with the relevant options

andmodules. TheDesign Guide has examplesofthe most common types of HVAC

applications. In addition, the Design Guide has all information relating to Serial

Communication.

This Design Guide is split in four sections that have information about VLT 6000 HVAC.

Introduction to HVAC: This section tells you the advantages that can be obtained by using frequency

converters in HVAC systems. Furthermore, you can read about the way a fre-

quencyconverteroperatesandabouttheadvantagesoftheVLT6000HVAC,such

as AEO - Automatic Energy Optimisation, RFI filter and other HVAC-relevant func-

tions.

There are also examples of applications and information is given about Danfoss

and CE-labelling.

The specification section deals with the requirements relating to being allowed to

supply and install frequency converters. This section can be used in contract

documents, whereby the total list of requirements relating to frequency converters

is determined.

The section ends with an Ordering Guide that makes it easier for you to specify

and order a VLT 6000 HVAC.

VLT

6000 HVAC Series

MG.61.B5.02 - VLT

is a registered Danfoss trademark 7

Introduction to HVAC

Introduction to the Design Guide

Installation: This sectionshowsyouhowto carryoutcorrect mechanicalinstallationofa VLT

6000 HVAC.

In addition, the section has a description of how you ensure that the installation

of the VLT 6000 HVAC is EMC-correct. Furthermore, the section includes a list

of mains and motor connections, as well as a description of control card termi-

nals.

Programming: This section describes the control unit and the software parameters for the VLT

6000 HVAC. There is also a guide to the Quick Setup menu, which means that

you will be able to start using your application very quickly.

All about VLT 6000: This section has information about status, warning and fault indications from

the VLT 6000 HVAC. In addition, the section has technical data, service infor-

mation, factory settings and information on special conditions.

NB!

Thissymbol indicates somethingto beno-

ted by the reader.

This symbol indicates a general warning.

This symbol indicates a high-voltage

warning.

VLT

6000 HVAC Series

8 MG.61.B5.02 - VLT

is a registered Danfoss trademark

Available literature

Below is a list of the literature available for VLT 6000

HVAC. It must be noted that there may be deviations

from one country to the next.

Please also refer to our web site http://

drives.danfoss.com for information about new litera-

ture.

Supplied with the unit:

Operating instructions MG.61.AX.YY

Quick Setup MG.60.CX.YY

High Power Introduction Guide MI.90.JX.YY

Communication with VLT 6000 HVAC:

Profibus Manual MG.90.DX.YY

Metasys N2 Manual MG.60.FX.YY

LonWorks Manual MG.60.EX.YY

Landis/Staefa Apogee FLN Manual MG.60.GX.YY

Modbus RTU Manual MG.10.SX.YY

DeviceNet Manual MG.50.HX.YY

Instructions for VLT 6000 HVAC:

LCP Remote Kit IP20 MI.56.AX.51

LCP Remote Kit IP54 MI.56.GX.52

LC-filter MI.56.DX.51

IP20 terminal cover MI.56.CX.51

Various literature for VLT 6000 HVAC:

Operating Instructions MG.60.AX.YY

Design Guide MG.61.BX.YY

Data sheet MD.60.AX.YY

VLT 6000 HVAC Cascade Controller MG.60.IX.YY

X = version number YY = language version

Why use a frequency converter for controlling

fans and pumps?

A frequency converter takes advantageof the fact that centrifugal fans andpumps follow the laws of proportionality

for such fans and pumps. For further information see the text The Laws of Proportionality.

The clear advantage - energy savings

The very clear advantage of using a frequency converter for controlling the speed of fans or pumps lies in the

electricity savings to be obtained.

When comparing with alternative control systems and technologies, a frequency converter is the optimum energy

control system for controlling fan and pump systems.

Example of energy savings

As can be seen from thefigure (the laws of proportionality), the flow is controlled by changingthe rpm. By reducing

the speed only 20% from the rated speed, the flow is also reduced by 20%. This is because the flow is directly

proportional to the rpm. The consumption of electricity, however, is reduced by 50%.

If the system in question only needs to be able to supply a flow that corresponds to 100% a few days in a year,

while the average is below 80% of the rated flow for the remainder of the year, the amount of energy saved is even

more than 50%.

VLT

6000 HVAC Series

MG.61.B5.02 - VLT

is a registered Danfoss trademark 9

Introduction to HVAC

The laws of proportionality

This figure describes the dependence of flow, pres-

sure and power consumption on rpm.

Q = Flow P = Power

= Rated flow P

= Rated power

= Reduced flow P

= Reduced power

H = Pressure n = Speed regulation

= Rated pressure n

= Rated speed

= Reduced pressure n

= Reduced speed

Flow

Pressure

(

)

Power

(

)

Example with varying flow over 1 year

The example below is calculated on the basis of pump characteristics obtained from a pump datasheet. (45 kW).

The same examples of calculations can be used in the case of fan characteristics.

The result obtained is savings in excees of 50% at the

given flow distribution over a year, corresponding to 8,760 hours.

Typically, the example calculated below results in a pay-back period of one year - depending on the price per kWh

and the price of the frequency converter.

Pump characteristics Energy savings

This figure compares power control via valves and

without speed control with pressure control via a fre-

quency converter.

shaft

shaft output

Flow distribution over 1 year

VLT

6000 HVAC Series

10 MG.61.B5.02 - VLT

is a registered Danfoss trademark

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