Danfoss VLT Flow Drive FC 111 Leitfaden

Design Guide

VLT® Flow Drive FC 111

vlt-drives.danfoss.com

1.1

1.2

1.2.1

1.2.2

1.3

1.4

1.4.1

1.4.2

2.1

2.2

2.3

3.1

3.1.1

3.1.1.1

3.1.1.2

3.1.1.3

3.1.1.4

3.1.1.5

3.1.1.6

3.1.1.7

3.1.1.8

3.1.1.9

3.1.2

3.1.2.1

3.1.2.2

3.1.2.3

3.1.2.4

3.1.2.5

3.1.2.6

3.1.3

3.1.4

3.1.5

Contents

Introduction 10

Purpose of this Design Guide 10

Additional Resources 10

Other Resources 10

MCT 10 Set-up Software Support 10

Document and Software Version 10

Regulatory Compliance 10

Introduction 10

CE Mark 10

Safety 12

Safety Symbols 12

Qualified Personnel 12

Safety Precautions 12

Product Overview 14

Advantages 14

Why Use a Drive for Controlling Fans and Pumps? 14

The Clear Advantage - Energy Savings 14

Example of Energy Savings 15

Comparison of Energy Savings 15

Example with Varying Flow over 1 Year 17

Better Control 18

Star/Delta Starter or Soft Starter not Required 18

Using a Drive Saves Money 18

Traditional Fan System without a Drive 19

Fan System Controlled by Drives 20

Application Examples 20

Variable Air Volume 20

Constant Air Volume 21

Cooling Tower Fan 22

Condenser Pumps 23

Primary Pumps 24

Secondary Pumps 25

Check Valve Monitoring 26

Dry Pump Detection 26

End of Curve Detection 26

Contents

VLT® Flow Drive FC 111

Design Guide

3.1.6

3.2

3.2.1

3.2.2

3.2.3

3.2.4

3.2.5

3.2.6

3.2.7

3.2.8

3.2.9

3.3

3.3.1

3.3.2

3.3.2.1

3.3.2.2

3.3.3

3.4

3.4.1

3.4.2

3.4.3

3.4.4

3.4.4.1

3.4.4.2

3.4.5

3.4.6

3.4.7

3.5

3.6

3.6.1

3.7

3.7.1

3.7.2

3.7.3

3.7.3.1

3.7.3.2

Time-based Functions 26

Control Structures 26

Introduction 26

Control Structure Open Loop 27

PM/EC+ Motor Control 27

Local (Hand On) and Remote (Auto On) Control 27

Control Structure Closed Loop 28

Feedback Conversion 28

Reference Handling 28

Tuning the Drive Closed-loop 29

Adjusting the Manual PI 29

Ambient Running Conditions 30

Air Humidity 30

Acoustic Noise or Vibration 30

Acoustic Noise 30

Vibration and Shock 31

Aggressive Environments 31

General Aspects of EMC 31

Overview of EMC Emissions 31

Emission Requirements 32

EMC Emission Test Results 33

Harmonics Emission 34

Harmonics Emission Requirements 34

Harmonics Test Results (Emission) 35

Harmonics Emission Requirements 34

Harmonics Test Results (Emission) 36

Immunity Requirements 37

Galvanic Isolation (PELV) 37

Ground Leakage Current 38

Using a Residual Current Device (RCD) 40

Extreme Running Conditions 41

Introduction 41

Motor Thermal Protection (ETR) 42

Thermistor Inputs 42

Example with Digital Input and 10 V Power Supply 43

Example with Analog Input and 10 V Power Supply 43

Contents

VLT® Flow Drive FC 111

Design Guide

4.1

4.2

4.2.1

4.2.2

4.2.3

4.3

4.3.1

4.3.2

4.3.3

5.1

5.2

5.2.1

5.3

5.3.1

5.3.2

5.3.3

5.3.4

5.3.5

5.3.6

5.4

5.4.1

5.4.2

5.4.3

5.4.4

6.1

6.2

6.3

6.4

6.4.1

6.4.2

6.4.3

6.4.4

6.4.5

6.5

Selection and Ordering 45

Type Code 45

Options and Accessories 46

Local Control Panel (LCP) 46

IP21 Enclosure Kit 46

Decoupling Plate 48

Ordering Numbers 49

Options and Accessories 49

Harmonic Filters 50

External RFI Filter 51

Mechanical Installation Considerations 53

Power Ratings, Weights, and Dimensions 53

Mechanical Installation H1-H8 55

Side-by-side Installation 55

Mechanical Installation H13-H14 56

Tools Needed 56

Installation and Cooling Requirements 56

Lifting the Drive 57

Wall Mounting the Drive 58

Creating Cable Openings 59

Back-channel Cooling 59

Derating 60

Manual Derating and Automatic Derating 60

Derating for Low-speed Operation 60

Derating for Low Air Pressure and High Altitudes 60

Derating for Ambient Temperature and Switching Frequency 60

Electrical Installation Considerations 63

Safety Instructions 63

Electrical Wiring 64

EMC-compliant Electrical Installation 64

Relays and Terminals 66

Relays and Terminals on Enclosure Sizes H1–H5 66

Relays and Terminals on Enclosure Size H6 67

Relays and Terminals on Enclosure Size H7 67

Relays and Terminals on Enclosure Size H8 68

Relays and Terminals on Enclosure Size H13–H14 69

View of Control Shelf 69

Contents

VLT® Flow Drive FC 111

Design Guide

6.6

6.7

6.8

6.8.1

6.8.2

6.8.3

6.8.4

6.9

6.9.1

6.9.2

6.9.3

6.9.4

6.9.5

6.10

6.11

6.11.1

6.11.2

6.11.3

6.12

6.12.1

6.12.2

6.12.3

6.12.4

7.1

7.2

7.2.1

7.2.2

7.2.2.1

7.2.2.2

7.2.2.3

7.2.2.4

7.2.2.5

7.2.2.6

7.2.2.7

7.2.2.8

7.2.3

Fastener Tightening Torques 70

IT Mains 71

Mains and Motor Connection 72

Introduction 72

Connecting to the Ground 72

Connecting the Motor 73

Connecting the AC Mains 73

Fuses and Circuit Breakers 73

Branch Circuit Protection 73

Short-circuit Protection 73

Overcurrent Protection 74

CE Compliance 74

Recommendation of Fuses and Circuit Breakers 74

Control Terminals 75

Efficiency 76

Efficiency of the Drive 76

Efficiency of the Motor 77

Efficiency of the System 77

dU/dt Conditions 77

dU/dt Overview 77

dU/dt Test Results for H1–H8 77

High-power Range 80

dU/dt Test Results for H13–H14 80

Programming 81

Local Control Panel (LCP) 81

Menus 82

Status Menu 82

Quick Menu 82

Quick Menu Introduction 82

Setup Wizard Introduction 83

Setup Wizard for Open-loop Applications 84

Setup Wizard for Closed-loop Applications 89

Motor Setup 94

Changes Made Function 97

Changing Parameter Settings 98

Accessing All Parameters via the Main Menu 98

Main Menu 98

Contents

VLT® Flow Drive FC 111

Design Guide

7.3

7.3.1

7.3.2

7.4

7.5

7.5.1

7.5.2

8.1

8.1.1

8.1.2

8.1.3

8.1.4

8.1.5

8.2

8.2.1

8.2.2

8.3

8.4

8.4.1

8.4.2

8.4.3

8.4.4

8.4.5

8.4.6

8.4.7

8.4.8

8.4.9

8.4.10

8.4.11

8.4.12

8.4.13

8.5

8.5.1

8.5.2

8.6

8.6.1

Quick Transfer of Parameter Settings between Multiple Drives 98

Transferring Data from the Drive to the LCP 98

Transferring Data from the LCP to the Drive 98

Readout and Programming of Indexed Parameters 99

Initialization to Default Settings 99

Recommended Initialization 99

Two-finger Initialization 99

RS485 Installation and Set-up 101

RS485 101

Overview 101

Connecting the Drive to the RS485 Network 102

Hardware Set-up 102

Parameter Settings for Modbus Communication 103

EMC Precautions 103

FC Protocol 104

Overview 104

FC with Modbus RTU 104

Network Configuration 105

FC Protocol Message Framing Structure 105

Content of a Character (byte) 105

Telegram Structure 105

Telegram Length (LGE) 105

Drive Address (ADR) 106

Data Control Byte (BCC) 106

The Data Field 106

The PKE Field 107

Parameter Number (PNU) 108

Index (IND) 108

Parameter Value (PWE) 108

Data Types Supported by the Drive 109

Conversion 109

Process Words (PCD) 110

Examples 110

Writing a Parameter Value 110

Reading a Parameter Value 110

Modbus RTU 111

Prerequisite Knowledge 111

Contents

VLT® Flow Drive FC 111

Design Guide

8.6.2

8.6.3

8.7

8.8

8.8.1

8.8.2

8.8.3

8.8.4

8.8.5

8.8.6

8.8.7

8.8.8

8.8.8.1

8.8.8.2

8.8.8.3

8.8.8.4

8.8.8.5

8.8.9

8.8.10

8.8.10.1

8.8.10.2

8.8.10.3

8.9

8.9.1

8.9.2

8.9.3

8.9.4

8.9.5

8.9.6

8.10

8.10.1

8.10.2

8.10.3

8.10.4

8.10.5

8.10.6

8.10.7

8.10.8

Modbus RTU Overview 111

Drive with Modbus RTU 111

Network Configuration 112

Modbus RTU Message Framing Structure 112

Modbus RTU Message Byte Format 112

Modbus RTU Telegram Structure 113

Start/Stop Field 113

Address Field 113

Function Field 113

Data Field 113

CRC Check Field 113

Coil Register Addressing 114

Introduction 114

Coil Register 114

Drive Control Word (FC Profile) 114

Drive Status Word (FC Profile) 115

Address/Registers 115

Access via PCD Write/read 116

How to Control the Drive 117

Introduction 117

Function Codes Supported by Modbus RTU 117

Modbus Exception Codes 118

How to Access Parameters 118

Parameter Handling 118

Storage of Data 118

IND (Index) 119

Text Blocks 119

Conversion Factor 119

Parameter Values 119

Examples 119

Introduction 119

Read Coil Status (01 hex) 119

Force/Write Single Coil (05 hex) 120

Force/Write Multiple Coils (0F hex) 121

Read Holding Registers (03 hex) 122

Preset Single Register (06 hex) 122

Preset Multiple Registers (10 hex) 123

Read/Write Multiple Registers (17 hex) 124

Contents

VLT® Flow Drive FC 111

Design Guide

8.11

8.11.1

8.11.2

8.11.3

8.11.4

8.11.5

9.1

9.1.1

9.2

9.2.1

9.2.2

9.2.3

9.2.4

9.2.5

9.2.6

9.2.7

9.2.8

9.2.9

9.2.10

9.2.11

9.2.12

9.2.13

9.2.14

10.1

10.2

10.2.1

10.2.2

10.2.3

10.2.4

10.2.5

Danfoss FC Control Profile 125

Control Word According to FC Profile (8-10 Protocol = FC Profile) 125

Explanation of Each Control Bit 126

Status Word According to FC Profile (STW) 128

Explanation of Each Status Bit 128

Bus Speed Reference Value 130

General Specifications 131

Mains Supply 131

3x380–480 V AC 131

General Technical Data 133

Protection and Features 133

Mains Supply 133

Motor Output (U, V, W) 133

Cable Length and Cross-section 134

Digital Inputs 134

Analog Inputs 134

Analog Outputs 135

Digital Output 135

RS485 Serial Communication 135

24 V DC Output 135

Relay Output 135

10 V DC Output 136

Ambient Conditions (H1–H8) 136

Ambient Conditions (H13–H14) 137

Appendix 138

Abbreviations 138

Definitions 139

AC Drive 139

Input 139

Motor 139

References 141

Miscellaneous 141

Contents

VLT® Flow Drive FC 111

Design Guide

•

1 Introduction

1.1 Purpose of this Design Guide

This Design Guide is intended for qualified personnel, such as:

Project and systems engineers.

Design consultants.

Application and product specialists.

The Design Guide provides technical information to understand the capabilities of the VLT® Flow Drive FC 111 for integration into

motor control and monitoring systems. Its purpose is to provide design considerations and planning data for integration of the

drive into a system. It caters for selection of drives and options for a diversity of applications and installations. Reviewing the de-

tailed product information in the design stage enables developing a well-conceived system with optimal functionality and efficien-

cy.

This manual is targeted at a worldwide audience. Therefore, wherever occurring, both SI and imperial units are shown.

VLT®is a registered trademark for Danfoss A/S.

1.2 Additional Resources

1.2.1 Other Resources

Other resources are available to understand advanced drive functions and programming.

VLT® Flow Drive FC 111 Operating Guide provides basic information on mechanical dimensions, installation, and programming.

VLT® Flow Drive FC 111 Programming Guide provides information on how to program, and includes complete parameter de-

scriptions.

Danfoss VLT® Energy Box software. Select PC Software Download at www.danfoss.com.

VLT® Energy Box software allows energy consumption comparisons of HVAC fans and pumps driven by Danfoss drives and alterna-

tive methods of flow control. Use this tool to accurately project the costs, savings, and payback of using Danfoss drives on HVAC

fans, pumps, and cooling towers.

Supplementary publications and manuals are available from Danfoss website www.danfoss.com.

1.2.2 MCT 10 Set-up Software Support

Download the software from the service and support section on www.danfoss.com.

During the installation process of the software, enter access code 81462700 to activate the VLT® Flow Drive FC 111 functionality. A

license key is not required for using the VLT® Flow Drive FC 111 functionality.

The latest software does not always contain the latest updates for drives. Contact the local sales office for the latest drive updates (in

the form of *.OSS files).

1.3 Document and Software Version

This guide is regularly reviewed and updated. All suggestions for improvement are welcome.

The original language of this manual is English.

Table 1: Document and Software Version

Edition

Remarks

Software version

AJ363928382091, version 0101

First edition.

65.00

1.4 Regulatory Compliance

1.4.1 Introduction

AC drives are designed in compliance with the directives described in this section.

1.4.2 CE Mark

The CE mark (Communauté Européenne) indicates that the product manufacturer conforms to all applicable EU directives. The EU

directives applicable to the design and manufacture of drives are listed in the following table.

Introduction

VLT® Flow Drive FC 111

Design Guide

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