Danfoss VLT HVAC Leitfaden

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT® HVAC Drive

Contents

1 How to Read this Design Guide 5

1.1.1 Copyright, Limitation of Liability and Revision Rights 5

1.1.3 Approvals 6

1.1.4 Symbols 6

1.1.5 Abbreviations 6

1.1.6 Definitions 7

2 Introduction to VLT®HVAC Drive 10

2.1 Safety 10

2.2 CE labelling 11

2.4 Aggressive Environments 12

2.5 Vibration and shock 13

2.6 Safe Stop 13

2.8 Control Structures 31

2.8.3 PM/EC+ Motor Control 32

2.9 General aspects of EMC 39

2.9.1 General Aspects of EMC Emissions 39

2.9.2 Emission Requirements 40

2.9.7 Immunity Requirements 43

2.10 Galvanic Isolation (PELV) 45

2.10.1 PELV - Protective Extra Low Voltage 45

2.11 Earth Leakage Current 45

2.12 Brake Function 46

2.12.4 Brake Resistor Cabling 48

2.13 Extreme Running Conditions 48

3 VLT®HVAC Drive Selection 51

3.1 Options and Accessories 51

3.1.10 MCB 112 VLT®PTC Thermistor Card 57

3.1.11 Sensor Input Option MCB 114 59

3.1.11.1 Ordering Code Numbers and Parts Delivered 59

3.1.11.2 Electrical and Mechanical Specifications 59

3.1.11.3 Electrical Wiring 60

3.1.12 Frame Size F Panel Options 60

4 How to Order 66

4.1 Ordering Form 66

4.2 Ordering Numbers 71

4.2.2 Ordering Numbers: High Power Kits 73

Contents VLT®HVAC Drive Design Guide

MG11BB02 - VLT®is a registered Danfoss trademark 1

5 How to Install 81

5.1 Mechanical Installation 81

5.1.2 Mechanical Dimensions 82

5.1.5 Lifting 87

5.1.6 Safety Requirements of Mechanical Installation 88

5.2 Electrical Installation 89

5.2.2 Electrical Installation and Control Cables 90

5.2.6 Removal of Knockouts for Extra Cables 93

5.2.7 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 93

5.2.9 Non UL Compliance Fuses 96

5.3 Final Set-Up and Test 105

5.4 Additional Connections 107

5.4.1 Mains Disconnectors 107

5.4.5 Brake Resistor Temperature Switch 108

5.4.6 External Fan Supply 108

5.5 Installation of Misc. Connections 111

5.6 Safety 112

5.6.1 High Voltage Test 112

5.6.2 Safety Earth Connection 112

5.7 EMC-correct Installation 113

5.7.1 Electrical Installation - EMC Precautions 113

5.7.2 Use of EMC-Correct Cables 114

6 Application Examples 117

6.1.1 Start/Stop 117

6.1.2 Pulse Start/Stop 117

6.1.3 Potentiometer Reference 118

6.1.4 Automatic Motor Adaptation (AMA) 118

6.1.5 Smart Logic Control 118

6.1.6 Smart Logic Control Programming 118

6.1.7 SLC Application Example 119

6.1.8 BASIC Cascade Controller 120

6.1.9 Pump Staging with Lead Pump Alternation 121

6.1.10 System Status and Operation 121

6.1.11 Fixed Variable Speed Pump Wiring Diagram 122

6.1.12 Lead Pump Alternation Wiring Diagram 122

6.1.13 Cascade Controller Wiring Diagram 123

6.1.14 Start/Stop Conditions 123

7 RS-485 Installation and Set-up 124

Contents VLT®HVAC Drive Design Guide

2 MG11BB02 - VLT®is a registered Danfoss trademark

7.1 RS-485 Installation and Set-up 124

7.1.4 EMC Precautions 125

7.2 FC Protocol Overview 125

7.3 Network Configuration 126

7.4 FC Protocol Message Framing Structure 126

7.4.1 Content of a Character (byte) 126

7.4.2 Telegram Structure 126

7.4.3 Telegram Length (LGE) 127

7.4.4 Frequency Converter Address (ADR) 127

7.4.5 Data Control Byte (BCC) 127

7.4.6 The Data Field 127

7.4.7 The PKE Field 128

7.4.9 Index (IND) 129

7.4.10 Parameter Value (PWE) 129

7.4.12 Conversion 130

7.4.13 Process Words (PCD) 130

7.5 Examples 130

7.5.1 Writing a Parameter Value 130

7.5.2 Reading a Parameter Value 131

7.6 Modbus RTU Overview 131

7.6.1 Assumptions 131

7.6.2 What the User Should Already Know 131

7.6.3 Modbus RTU Overview 131

7.6.4 Frequency Converter with Modbus RTU 131

7.7.1 Frequency Converter with Modbus RTU 132

7.8 Modbus RTU Message Framing Structure 132

7.8.1 Frequency Converter with Modbus RTU 132

7.8.2 Modbus RTU Message Structure 132

7.8.3 Start/Stop Field 132

7.8.4 Address Field 133

7.8.5 Function Field 133

7.8.6 Data Field 133

7.8.7 CRC Check Field 133

7.8.8 Coil Register Addressing 133

7.8.9 How to Control the Frequency Converter 134

7.8.10 Function Codes Supported by Modbus RTU 134

7.8.11 Modbus Exception Codes 135

7.9 How to Access Parameters 135

7.9.1 Parameter Handling 135

7.9.2 Storage of Data 135

Contents VLT®HVAC Drive Design Guide

MG11BB02 - VLT®is a registered Danfoss trademark 3

7.9.3 IND 135

7.9.4 Text Blocks 135

7.9.5 Conversion Factor 135

7.9.6 Parameter Values 135

7.10 Examples 136

7.11 Danfoss FC Control Profile 138

8 General Specifications and Troubleshooting 142

8.1 Mains Supply Tables 142

8.2 General Specifications 158

8.3 Efficiency 162

8.4 Acoustic Noise 162

8.5 Peak Voltage on Motor 163

8.6 Special Conditions 167

8.7 Troubleshooting 169

8.7.1 Alarm Words 173

8.7.2 Warning Words 174

8.7.3 Extended Status Words 175

8.7.4 Fault Messages 176

Index 182

Contents VLT®HVAC Drive Design Guide

4 MG11BB02 - VLT®is a registered Danfoss trademark

1 How to Read this Design Guide

VLT®HVAC Drive

FC 100 Series

This guide can be used with all

VLT®HVAC Drive frequency

converters with software version

3.7x.

The actual software version

number can be read from

15-43 Software Version.

1.1.1 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 documen-

tation within this manual, Danfoss makes no warranty or

representation, 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.

1.1.2 Available Literature for VLT®HVAC

Drive

-Design Guide MG.11.Bx.yy entails all technical

information about the frequency converter and

customer design and applications.

-Programming Guide MG.11.Cx.yy provides

information on how to programme and includes

complete parameter descriptions.

-Application Note, Temperature Derating Guide,

MN.11.Ax.yy

-PC-based Configuration Tool MCT 10, MG.10.Ax.yy

enables the user to configure the frequency

converter from a Windows™based PC

environment.

-Danfoss VLT®Energy Box software at

www.danfoss.com/BusinessAreas/DrivesSolutions

then choose PC Software Download

-Operating Instructions VLT®HVAC Drive BACnet,

MG.11.Dx.yy

-Operating Instructions VLT®HVAC Drive Metasys,

MG.11.Gx.yy

-Operating Instructions VLT®HVAC Drive FLN,

MG.11.Zx.yy

x = Revision number

yy = Language code

Danfoss technical literature is available in print from your

local Danfoss Sales Office or online at:

www.danfoss.com/BusinessAreas/DrivesSolutions/Documen-

tations/Technical+Documentation.htm

How to Read this Design Gui... VLT®HVAC Drive Design Guide

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1.1.3 Approvals

1.1.4 Symbols

Symbols used in this guide.

NOTE

Indicates something to be noted by the reader.

CAUTION

Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury or

equipment damage.

WARNING

Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

*Indicates default setting

1.1.5 Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Automatic Motor Adaptation AMA

Current limit ILIM

Degrees Celsius °C

Direct current DC

Drive Dependent D-TYPE

Electro Magnetic Compatibility EMC

Electronic Thermal Relay ETR

frequency converter FC

Gram g

Hertz Hz

Horsepower hp

Kilohertz kHz

Local Control Panel LCP

Meter m

Millihenry Inductance mH

Milliampere mA

Millisecond ms

Minute min

Motion Control Tool MCT

Nanofarad nF

Newton Meters Nm

Nominal motor current IM,N

Nominal motor frequency fM,N

Nominal motor power PM,N

Nominal motor voltage UM,N

Permanent Magnet motor PM motor

Protective Extra Low Voltage PELV

Printed Circuit Board PCB

Rated Inverter Output Current IINV

Revolutions Per Minute RPM

Regenerative terminals Regen

Second sec.

Synchronous Motor Speed ns

Torque limit TLIM

Volts V

The maximum output current IVLT,MAX

The rated output current supplied by the

frequency converter

IVLT,N

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1.1.6 Definitions

Drive:

IVLT,MAX

The maximum output current.

IVLT,N

The rated output current supplied by the frequency

converter.

UVLT, MAX

The maximum output voltage.

Input:

Control command

Start and stop the

connected motor with the

LCP or the digital inputs.

Functions are divided into

two groups.

Functions in group 1 have

higher priority than

functions in group 2.

Group

Reset, Coasting stop, Reset

and Coasting stop, Quick-

stop, DC braking, Stop and

the "Off" key.

Group

Start, Pulse start, Reversing,

Start reversing, Jog and

Freeze output

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 rated motor speed (nameplate data).

PM,N

The rated motor power (nameplate data).

TM,N

The rated torque (motor).

The instantaneous motor voltage.

UM,N

The rated motor voltage (nameplate data).

Break-away torque

175ZA078.10

Pull-out

rpm

Torque

ηVLT

The efficiency of the frequency converter is defined 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 this group.

Stop command

See Control commands.

References:

Analog Reference

A signal transmitted to the analog inputs 53 or 54, can be

voltage or current.

Bus Reference

A signal transmitted to the serial communication port (FC

port).

How to Read this Design Gui... VLT®HVAC Drive Design Guide

MG11BB02 - VLT®is a registered Danfoss trademark 7

Preset Reference

A defined preset reference to be set from -100% to +100%

of the reference range. Selection of eight preset references

via the digital terminals.

Pulse Reference

A pulse frequency signal transmitted to the digital inputs

(terminal 29 or 33).

RefMAX

Determines the relationship between the reference input

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

resulting reference. The maximum reference value set in

3-03 Maximum Reference.

RefMIN

Determines the relationship between the reference input

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

reference. The minimum reference value set in

3-02 Minimum Reference

Miscellaneous:

Analog Inputs

The analog inputs are used for controlling various

functions of the frequency converter.

There are two 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

AMA algorithm determines the electrical parameters for

the connected motor at standstill.

Brake Resistor

The brake resistor is a module capable of absorbing the

brake power generated in regenerative braking. This

regenerative braking power increases the intermediate

circuit voltage and a brake chopper ensures that the

power is transmitted to the brake resistor.

CT Characteristics

Constant torque characteristics used for screw and scroll

refrigeration compressors.

Digital Inputs

The digital inputs can be used for controlling various

functions of the frequency converter.

Digital Outputs

The frequency converter features two Solid State outputs

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

DSP

Digital Signal Processor.

Relay Outputs:

The frequency converter features two 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.

GLCP:

Graphical Local Control Panel (LCP102)

Initialising

If initialising is carried out (14-22 Operation Mode), the

programmable parameters of the frequency converter

return to their default settings.

Intermittent Duty Cycle

An intermittent duty rating refers to a sequence of duty

cycles. Each cycle consists of an on-load and an off-load

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

periodic duty.

LCP

The Local Control Panel (LCP)keypad makes up a complete

interface for control and programming of the frequency

converter. The control panelkeypad is detachable and can

be installed up to 3 metres from the frequency converter,

i.e. in a front panel by means of the installation kit option.

The Local Control Panel is available in two versions:

-Numerical LCP101 (NLCP)

-Graphical LCP102 (GLCP)

lsb

Least significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for

cable cross-section. 1 MCM ≡0.5067 mm2.

msb

Most significant bit.

NLCP

Numerical Local Control Panel LCP101

How to Read this Design Gui... VLT®HVAC Drive Design Guide

8 MG11BB02 - VLT®is a registered Danfoss trademark

On-line/Off-line Parameters

Changes to on-line parameters are activated immediately

after the data value is changed. Changes to off-line

parameters are not activated until you enter [OK] on the

LCP.

PID Controller

The PID controller maintains the desired speed, pressure,

temperature, etc. by adjusting the output frequency to

match the varying load.

RCD

Residual Current Device.

Set-up

You can save parameter settings in four Set-ups. Change

between the four parameter Set-ups and edit one Set-up,

while another Set-up is active.

SFAVM

Switching pattern called Stator Flux oriented Asynchronous

V ector M odulation (14-00 Switching Pattern).

Slip Compensation

The frequency converter compensates for the motor slip

by giving the frequency a supplement that follows the

measured motor load keeping the motor speed almost

constant.

Smart Logic Control (SLC)

The SLC is a sequence of user defined actions executed

when the associated user defined events are evaluated as

true by the SLC.

Thermistor:

A temperature-dependent resistor placed where the

temperature is to be monitored (frequency converter or

motor).

Trip

A state entered in fault situations, e.g. if the frequency

converter is subject to an over-temperature or when the

frequency converter is protecting the motor, process or

mechanism. Restart is prevented until the cause of the

fault has disappeared and the trip state is cancelled by

activating reset or, in some cases, by being programmed

to reset automatically. Trip may not be used for personal

safety.

Trip Locked

A state entered in fault situations when the frequency

converter is protecting itself and requiring physical

intervention, e.g. if the frequency converter is subject to a

short circuit on the output. A locked trip can only be

cancelled by cutting off mains, removing the cause of the

fault, and reconnecting the frequency converter. Restart is

prevented until the trip state is cancelled by activating

reset or, in some cases, by being programmed to reset

automatically. Trip locked may not be used for personal

safety.

VT Characteristics

Variable torque characteristics used for pumps and fans.

VVCplus

If compared with standard voltage/frequency ratio control,

Voltage Vector Control (VVCplus) improves the dynamics

and the stability, both when the speed reference is

changed and in relation to the load torque.

60°AVM

Switching pattern called 60°Asynchronous Vector

Modulation (See 14-00 Switching Pattern).

1.1.7 Power Factor

The power factor is the relation between I1and IRMS.

Power

factor

3 ×

1 ×

COS

3 ×

IRMS

The power factor for 3-phase control:

1 ×

cos

ϕ1

IRMS

since

cos

ϕ1 = 1

The power factor indicates to which extent the frequency

converter imposes a load on the mains supply.

The lower the power factor, the higher the IRMS for the

same kW performance.

IRMS

2 +

2 + . . +

In addition, a high power factor indicates that the different

harmonic currents are low.

The frequency converters' built-in DC coils produce a high

power factor, which minimizes the imposed load on the

mains supply.

How to Read this Design Gui... VLT®HVAC Drive Design Guide

MG11BB02 - VLT®is a registered Danfoss trademark 9

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