Danfoss VLT HVAC Basic Drive FC 101 Leitfaden

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT®HVAC Basic Drive FC 101

vlt-drives.danfoss.com

Contents

1 Introduction 6

1.1 Purpose of the Design Guide 6

1.2 Document and Software Version 6

1.3 Safety Symbols 6

1.4 Abbreviations 6

1.5 Additional Resources 7

1.6 Denitions 7

1.7 Power Factor 9

1.8 Regulatory Compliance 9

1.8.1 CE Mark 9

1.8.2 UL Compliance 10

1.8.3 RCM Mark Compliance 10

2 Safety 11

2.1 Qualied Personnel 11

2.2 Safety Precautions 11

3 Product Overview 13

3.1 Advantages 13

3.1.1 Why use a Frequency Converter for Controlling Fans and Pumps? 13

3.1.2 The Clear Advantage - Energy Savings 13

3.1.3 Example of Energy Savings 13

3.1.4 Comparison of Energy Savings 14

3.1.5 Example with Varying Flow over 1 Year 15

3.1.6 Better Control 15

3.1.7 Star/Delta Starter or Soft Starter not Required 16

3.1.8 Using a Frequency Converter Saves Money 16

3.1.9 Without a Frequency Converter 17

3.1.10 With a Frequency Converter 18

3.1.11 Application Examples 19

3.1.12 Variable Air Volume 19

3.1.13 The VLT Solution 19

3.1.14 Constant Air Volume 20

3.1.15 The VLT Solution 20

3.1.16 Cooling Tower Fan 21

3.1.17 The VLT Solution 21

3.1.18 Condenser Pumps 22

3.1.19 The VLT Solution 22

3.1.20 Primary Pumps 23

3.1.21 The VLT Solution 23

Contents Design Guide

3.1.22 Secondary Pumps 25

3.1.23 The VLT Solution 25

3.2 Control Structures 26

3.2.1 Control Structure Open Loop 26

3.2.2 PM/EC+ Motor Control 26

3.2.3 Local (Hand On) and Remote (Auto On) Control 26

3.2.4 Control Structure Closed Loop 27

3.2.5 Feedback Conversion 28

3.2.6 Reference Handling 29

3.2.7 Tuning the Drive Closed-loop Controller 30

3.2.8 Manual PI Adjustment 30

3.3 Ambient Running Conditions 30

3.4 General Aspects of EMC 36

3.4.1 Overview of EMC Emissions 36

3.4.2 Emission Requirements 37

3.4.3 EMC Emission Test Results 39

3.4.4 Overview of Harmonics Emission 40

3.4.5 Harmonics Emission Requirements 40

3.4.6 Harmonics Test Results (Emission) 40

3.4.7 Immunity Requirements 42

3.5 Galvanic Isolation (PELV) 42

3.6 Earth Leakage Current 43

3.7 Extreme Running Conditions 43

3.7.1 Motor Thermal Protection (ETR) 44

3.7.2 Thermistor Inputs 44

4 Selection and Ordering 46

4.1 Type Code 46

4.2 Options and Accessories 47

4.2.1 Local Control Panel (LCP) 47

4.2.2 Mounting of LCP in Panel Front 47

4.2.3 IP21/NEMA Type 1 Enclosure Kit 48

4.2.4 Decoupling Plate 49

4.3 Ordering Numbers 50

4.3.1 Options and Accessories 50

4.3.2 Harmonic Filters 51

4.3.3 External RFI Filter 52

5 Installation 53

5.1 Electrical Installation 53

5.1.1 Electrical Installation in General 54

Contents VLT®HVAC Basic Drive FC 101

5.1.2 Mains and Motor Connection 55

5.1.3 EMC-compliant Electrical Installation 60

5.1.4 Control Terminals 62

6 Programming 63

6.1 Introduction 63

6.2 Local Control Panel (LCP) 63

6.3 Menus 64

6.3.1 Status Menu 64

6.3.2 Quick Menu 64

6.3.3 Main Menu 78

6.4 Quick Transfer of Parameter Settings between Multiple Frequency Converters 78

6.5 Readout and Programming of Indexed Parameters 79

6.6 Initialization to Default Settings 79

7 RS485 Installation and Set-up 80

7.1 RS485 80

7.1.1 Overview 80

7.1.2 Network Connection 80

7.1.3 Frequency Converter Hardware Set-up 81

7.1.4 Parameter Settings for Modbus Communication 81

7.1.5 EMC Precautions 82

7.2 FC Protocol 82

7.2.1 Overview 82

7.2.2 FC with Modbus RTU 82

7.3 Parameter Settings to Enable the Protocol 83

7.4 FC Protocol Message Framing Structure 83

7.4.1 Content of a Character (Byte) 83

7.4.2 Telegram Structure 83

7.4.3 Telegram Length (LGE) 83

7.4.4 Frequency Converter Address (ADR) 83

7.4.5 Data Control Byte (BCC) 83

7.4.6 The Data Field 83

7.4.7 The PKE Field 84

7.4.8 Parameter Number (PNU) 84

7.4.9 Index (IND) 84

7.4.10 Parameter Value (PWE) 85

7.4.11 Data Types Supported by the Frequency Converter 85

7.4.12 Conversion 85

7.4.13 Process Words (PCD) 85

7.5 Examples 85

Contents Design Guide

7.5.1 Writing a Parameter Value 85

7.5.2 Reading a Parameter Value 86

7.6 Modbus RTU Overview 86

7.6.1 Introduction 86

7.6.2 Overview 86

7.6.3 Frequency Converter with Modbus RTU 87

7.7 Network Conguration 87

7.8 Modbus RTU Message Framing Structure 87

7.8.1 Introduction 87

7.8.2 Modbus RTU Telegram Structure 87

7.8.3 Start/Stop Field 88

7.8.4 Address Field 88

7.8.5 Function Field 88

7.8.6 Data Field 88

7.8.7 CRC Check Field 88

7.8.8 Coil Register Addressing 88

7.8.9 Access via PCD write/read 90

7.8.10 How to Control the Frequency Converter 91

7.8.11 Function Codes Supported by Modbus RTU 91

7.8.12 Modbus Exception Codes 91

7.9 How to Access Parameters 92

7.9.1 Parameter Handling 92

7.9.2 Storage of Data 92

7.9.3 IND (Index) 92

7.9.4 Text Blocks 92

7.9.5 Conversion Factor 92

7.9.6 Parameter Values 92

7.10 Examples 92

7.10.1 Read Coil Status (01 hex) 92

7.10.2 Force/Write Single Coil (05 hex) 93

7.10.3 Force/Write Multiple Coils (0F hex) 94

7.10.4 Read Holding Registers (03 hex) 94

7.10.5 Preset Single Register (06 hex) 94

7.10.6 Preset Multiple Registers (10 hex) 95

7.10.7 Read/Write Multiple Registers (17 hex) 95

7.11 Danfoss FC Control Prole 96

7.11.1 Control Word According to FC Prole (8–10 Protocol = FC Prole) 96

7.11.2 Status Word According to FC Prole (STW) 97

7.11.3 Bus Speed Reference Value 98

8 General Specications 100

Contents VLT®HVAC Basic Drive FC 101

8.1 Mechanical Dimensions 100

8.1.1 Side-by-side Installation 100

8.1.2 Frequency Converter Dimensions 101

8.1.3 Shipping Dimensions 103

8.1.4 Field Mounting 104

8.2 Mains Supply Specications 105

8.2.1 3x200–240 V AC 105

8.2.2 3x380–480 V AC 106

8.2.3 3x525–600 V AC 110

8.3 Fuses and Circuit Breakers 111

8.4 General Technical Data 113

8.4.1 Mains Supply (L1, L2, L3) 113

8.4.2 Motor Output (U, V, W) 113

8.4.3 Cable Length and Cross-section 113

8.4.4 Digital Inputs 114

8.4.5 Analog Inputs 114

8.4.6 Analog Output 114

8.4.7 Digital Output 114

8.4.8 Control Card, RS485 Serial Communication 115

8.4.9 Control Card, 24 V DC Output 115

8.4.10 Relay Output 115

8.4.11 Control Card, 10 V DC Output 115

8.4.12 Ambient Conditions 115

8.5 dU/Dt 116

Index 119

Contents Design Guide

1 Introduction

1.1 Purpose of the Design Guide

This design guide is intended for project and systems

engineers, design consultants, and application and product

specialists. Technical information is provided to understand

the capabilities of the frequency converter for integration

into motor control and monitoring systems. Details

concerning operation, requirements, and recommendations

for system integration are described. Information is proved

for input power characteristics, output for motor control,

and ambient operating conditions for the frequency

converter.

Also included are:

•Safety features.

•Fault condition monitoring.

•Operational status reporting.

•Serial communication capabilities.

•Programmable options and features.

Also provided are design details such as:

•Site requirements.

•Cables.

•Fuses.

•Control wiring.

•Unit sizes and weights.

•Other critical information necessary to plan for

system integration.

Reviewing the detailed product information in the design

stage enables developing a well-conceived system with

optimal functionality and eciency.

VLT®is a registered trademark.

1.2 Document and Software Version

This manual is regularly reviewed and updated. All

suggestions for improvement are welcome.

Edition Remarks Software version

MG18C7xx Update to new software version 2.8x

Table 1.1 Document and Software Version

1.3 Safety Symbols

The following symbols are used in this guide:

WARNING

Indicates a potentially hazardous situation that could

result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could

result in minor or moderate injury. It can also be used to

alert against unsafe practices.

NOTICE

Indicates important information, including situations that

can result in damage to equipment or property.

1.4 Abbreviations

°CDegrees Celsius

°FDegrees Fahrenheit

A Ampere/AMP

AC Alternating current

AMA Automatic motor adaptation

AWG American wire gauge

DC Direct current

EMC Electro magnetic compatibility

ETR Electronic thermal relay

FC Frequency converter

fM,N Nominal motor frequency

kg Kilogram

Hz Hertz

IINV Rated inverter output current

ILIM Current limit

IM,N Nominal motor current

IVLT,MAX The maximum output current

IVLT,N The rated output current supplied by the

frequency converter

kHz Kilohertz

LCP Local control panel

m Meter

mA Milliampere

MCT Motion control tool

mH Millihenry inductance

min Minute

ms Millisecond

nF Nanofarad

Nm Newton meters

nsSynchronous motor speed

Introduction VLT®HVAC Basic Drive FC 101

PM,N Nominal motor power

PCB Printed circuit board

PELV Protective extra low voltage

Regen Regenerative terminals

RPM Revolutions per minute

s Second

TLIM Torque limit

UM,N Nominal motor voltage

V Volts

Table 1.2 Abbreviations

1.5 Additional Resources

•VLT

HVAC Basic Drive FC 101 Quick Guide provides

basic information on mechanical dimensions,

installation, and programming.

•VLT

HVAC Basic Drive FC 101 Programming Guide

provides information on how to program, and

includes complete parameter descriptions.

•Danfoss VLT®Energy Box software. Select PC

Software Download at www.danfoss.com/Busines-

sAreas/DrivesSolutions.

VLT®Energy Box software allows energy

consumption comparisons of HVAC fans and

pumps driven by Danfoss frequency converters

and alternative methods of ow control. Use this

tool to accurately project the costs, savings, and

payback of using Danfoss frequency converters

on HVAC fans, pumps, and cooling towers.

Danfoss technical literature is available in electronic form

on the documentation CD that is shipped with the

product, or in print from your local Danfoss sales oce.

MCT 10 Set-up Software support

Download the software from www.danfoss.com/Busines-

sAreas/DrivesSolutions/Software+MCT10/

MCT10+Downloads.htm.

During the installation process of the software, enter

access code 81463800 to activate FC 101 functionality. A

licence key is not required for using FC 101 functionality.

The latest software does not always contain the latest

updates for frequency converters. Contact the local sales

oce for the latest frequency converter updates (in the

form of *.upd les), or download the frequency converter

updates from www.danfoss.com/BusinessAreas/DrivesSo-

lutions/fc101driveupdates.

1.6 Denitions

Frequency converter

IVLT, MAX

The maximum output current.

IVLT,N

The rated output current supplied by the frequency

converter.

UVLT, MAX

The maximum output voltage.

Input

The connected motor can start and stop via LCP and

digital inputs. Functions are divided into 2 groups, as

described in Table 1.3. Functions in group 1 have higher

priority than functions in group 2.

Group 1 Reset, coast stop, reset and coast stop, quick

stop, DC brake, stop, and [O].

Group 2 Start, pulse start, reversing, start reversing, jog,

and freeze output.

Table 1.3 Control Commands

Motor

fJOG

The motor frequency when the jog function is activated

(via digital terminals).

The motor frequency.

fMAX

The maximum motor frequency.

fMIN

The minimum motor frequency.

fM,N

The rated motor frequency (nameplate data).

The motor current.

IM,N

The rated motor current (nameplate data).

nM,N

The nominal motor speed (nameplate data).

PM,N

The rated motor power (nameplate data).

The instantaneous motor voltage.

UM,N

The rated motor voltage (nameplate data).

Introduction Design Guide

Break-away torque

175ZA078.10

Pull-out

rpm

Torque

Illustration 1.1 Break-away Torque

ηVLT

The eciency of the frequency converter is dened as the

ratio between the power output and the power input.

Start-disable command

A stop command belonging to the group 1 control

commands, see Table 1.3.

Stop command

See Table 1.3.

Analog reference

A signal transmitted to the analog inputs 53 or 54. It can

be voltage or current.

•Current input: 0–20 mA and 4–20 mA

•Voltage input: 0–10 V DC

Bus reference

A signal transmitted to the serial communication port (FC

port).

Preset reference

A dened preset reference to be set from -100% to +100%

of the reference range. Selection of 8 preset references via

the digital terminals.

RefMAX

Determines the relationship between the reference input at

100% full scale value (typically 10 V, 20 mA) and the

resulting reference. The maximum reference value set in

parameter 3-03 Maximum Reference.

RefMIN

Determines the relationship between the reference input at

0% value (typically 0 V, 0 mA, 4 mA) and the resulting

reference. The minimum reference value is set in

parameter 3-02 Minimum Reference.

Analog inputs

The analog inputs are used for controlling various

functions of the frequency converter.

There are 2 types of analog inputs:

•Current input: 0–20 mA and 4–20 mA

•Voltage input: 0–10 V DC

Analog outputs

The analog outputs can supply a signal of 0–20 mA, 4–

20 mA, or a digital signal.

Automatic motor adaptation, AMA

The AMA algorithm determines the electrical parameters

for the connected motor at standstill and compensates for

the resistance based on the length of the motor cable.

Digital inputs

The digital inputs can be used for controlling various

functions of the frequency converter.

Digital outputs

The frequency converter provides 2 solid-state outputs that

can supply a 24 V DC (maximum 40 mA) signal.

Relay outputs

The frequency converter provides 2 programmable relay

outputs.

ETR

Electronic thermal relay is a thermal load calculation based

on present load and time. Its purpose is to estimate the

motor temperature and prevent overheating of the motor.

Initializing

If initializing is carried out (parameter 14-22 Operation

Mode), the programmable parameters of the frequency

converter return to their default settings.

Parameter 14-22 Operation Mode does not initialize

communication parameters, fault log, or re mode log.

Intermittent duty cycle

An intermittent duty rating refers to a sequence of duty

cycles. Each cycle consists of an on-load and an o-load

period. The operation can be either periodic duty or none-

periodic duty.

LCP

The local control panel (LCP) makes up a complete

interface for control and programming of the frequency

converter. The control panel is detachable on IP20 units

and xed on IP54 units. It can be installed up to 3 m (9.8

ft) from the frequency converter, that is, in a front panel

with the installation kit option.

Lsb

Least signicant bit.

MCM

Short for mille circular mil, an American measuring unit for

cable cross-section. 1 MCM = 0.5067 mm2.

Msb

Most signicant bit.

On-line/O-line parameters

Changes to on-line parameters are activated immediately

after the data value is changed. Press [OK] to activate o-

line parameters.

Introduction VLT®HVAC Basic Drive FC 101

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