Danfoss VLT HVAC Drive FC 102 Guide

MAKING MODERN LIVING POSSIBLE
Design Guide
VLT®HVAC Drive FC 102
110–1400 kW
www.danfoss.com/drives

Contents
1 How to Read this Design Guide 8
1.1 How to Read this Design Guide 8
1.1.1 Available Literature 8
2 Introduction 14
2.1 Safety 14
2.1.1 Safety Note 14
2.2 CE Labeling 15
2.2.1 CE Conformity and Labeling 15
2.2.2 What Is Covered 16
2.2.3 Danfoss Adjustable frequency drive and CE Labeling 16
2.2.4 Compliance with EMC Directive 2004/108/EC 16
2.3 Air Humidity 16
2.4 Aggressive Environments 17
2.5 Vibration and Shock 17
2.6 Safe Torque Off 17
2.6.1 Electrical Terminals 17
2.6.2 Safe Torque Off Installation 18
2.6.3 Approvals & Certificates 19
2.7 Advantages 19
2.7.1 Why Use an Adjustable Frequency Drive for Controlling Fans and Pumps? 19
2.7.2 The Clear Advantage - Energy Savings 20
2.7.3 Example of Energy Savings 20
2.7.4 Comparison of Energy Savings 21
2.7.5 Example with Varying Flow over 1 Year 21
2.7.6 Better Control 22
2.7.7 Cos φCompensation 23
2.7.8 Star/Delta Starter or Soft-starter not Required 23
2.7.9 Using an Adjustable Frequency Drive Saves Money 23
2.7.10 Without an Adjustable Frequency Drive 24
2.7.11 With an Adjustable Frequency Drive 25
2.7.12 Application Examples 25
2.7.13 Variable Air Volume 26
2.7.14 The VLT Solution 26
2.7.15 Constant Air Volume 27
2.7.16 The VLT Solution 27
2.7.17 Cooling Tower Fan 28
Contents Design Guide
MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.

2.7.18 The VLT Solution 28
2.7.19 Condenser Pumps 30
2.7.20 The VLT Solution 30
2.7.21 Primary Pumps 31
2.7.22 The VLT Solution 31
2.7.23 Secondary Pumps 33
2.7.24 The VLT Solution 33
2.8 Control Structures 34
2.8.1 Control Principle 34
2.8.2 Control Structure Open-loop 35
2.8.3 PM/EC+ Motor Control 36
2.8.4 Local (Hand On) and Remote (Auto On) Control 36
2.8.5 Control Structure Closed-loop 37
2.8.6 Feedback Handling 38
2.8.7 Feedback Conversion 39
2.8.8 Reference Handling 40
2.8.9 Example of Closed-loop PID Control 41
2.8.10 Programming Order 41
2.8.11 Tuning the Closed-loop Controller 43
2.8.12 Manual PID Adjustment 43
2.9 General aspects of EMC 43
2.9.1 General Aspects of EMC Emissions 43
2.9.2 Emission Requirements 45
2.9.3 EMC Test Results (Emission) 46
2.9.4 General Aspects of Harmonics Emission 46
2.9.5 Harmonics Emission Requirements 47
2.9.6 Harmonics Test Results (Emission) 47
2.9.7 Immunity Requirements 47
2.10 Galvanic Isolation (PELV) 49
2.11 Ground Leakage Current 50
2.12 Brake Function 51
2.12.1 Brake Resistor Selection 51
2.12.2 Brake Resistor Calculation 51
2.12.3 Control with Brake Function 52
2.12.4 Brake Resistor Cabling 52
2.13 Extreme Running Conditions 53
3 Selection 56
Contents Design Guide
Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122

3.1 Options and Accessories 56
3.1.1 General Purpose Input Output Module MCB 101 56
3.1.2 Digital Inputs - Terminal X30/1-4 57
3.1.3 Analog Voltage Inputs - Terminal X30/10-12 57
3.1.4 Digital Outputs - Terminal X30/5-7 57
3.1.5 Analog Outputs - Terminal X30/5+8 57
3.1.6 Relay Option MCB 105 58
3.1.7 24 V Backup Option MCB 107 (Option D) 60
3.1.8 Analog I/O Option MCB 109 61
3.1.9 MCB 112 VLT®PTC Thermistor Card 63
3.1.10 Sensor Input Option MCB 114 65
3.1.10.1 Electrical and Mechanical Specifications 65
3.1.10.2 Electrical Wiring 66
3.1.11 D-frame Options 66
3.1.11.1 Load Share Terminals 66
3.1.11.2 Regeneration Terminals 66
3.1.11.3 Anti-condensation Heater 66
3.1.11.4 Brake Chopper 66
3.1.11.5 Line Power Shield 66
3.1.11.6 Ruggedized Printed Circuit Boards 67
3.1.11.7 Heatsink Access Panel 67
3.1.11.8 Line Power Disconnect 67
3.1.11.9 Contactor 67
3.1.11.10 Circuit Breaker 67
3.1.12 F-frame Panel Options 68
3.1.13 Remote Mounting Kit for LCP 69
3.1.14 Output Filters 70
4 How to Order 71
4.1 Ordering Form 71
4.2 Ordering Numbers 74
4.2.1 Ordering Numbers: Options and Accessories 74
4.2.2 Advanced Harmonic Filters 76
4.2.3 Sine-Wave Filter Modules, 380–690 V AC 83
4.2.4 Ordering Numbers: dU/dt Filters 85
4.2.5 Ordering Numbers: Brake Resistors 85
5 How to Install 87
5.1 Mechanical Installation 87
Contents Design Guide
MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.

5.1.1 Mechanical Dimensions 87
5.1.2 Mechanical Dimensions, 12-Pulse Units 100
5.1.3 Mechanical Mounting 106
5.1.4 Pedestal Installation of D-frames 106
5.1.5 Pedestal Installation of F-frames 107
5.1.6 Lifting 108
5.1.7 Safety Requirements of Mechanical Installation 110
5.2 Electrical Installation 110
5.2.1 Cables General 110
5.2.2 Motor Cables 111
5.2.3 Electrical Installation of Motor Cables 112
5.2.4 Preparing Connector Plates for Cables 113
5.2.5 Connector/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 113
5.2.6 Connector/Conduit Entry, 12-Pulse - IP21 (NEMA 1) and IP54 (NEMA12) 118
5.2.7 Power Connections 122
5.2.8 Power Connections 12-Pulse Adjustable Frequency Drives 147
5.2.9 Fuses 150
5.2.10 Fuse Specifications 150
5.2.11 Control Terminals 151
5.2.12 Control Cable Terminals 151
5.2.13 Basic Wiring Example 151
5.2.14 Electrical Installation, Control Cables 153
5.2.15 12-Pulse Control Cables 156
5.2.16 Switches S201, S202, and S801 158
5.3 Final Set-up and Test 159
5.4 Additional Connections 160
5.4.1 Line Power Disconnects 160
5.4.2 Circuit Breakers 161
5.4.3 Line Power Contactors 162
5.4.4 Brake Resistor Temperature Switch 163
5.4.5 External Fan Supply 163
5.4.6 Relay Output D Frame 163
5.4.7 Relay Output E & F-Frame 164
5.5 Installation of Misc. Connections 166
5.6 Safety 168
5.6.1 High Voltage Test 168
5.6.2 Safety Ground Connection 168
5.7 EMC-compatible Installation 168
Contents Design Guide
Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122

5.7.1 Electrical Installation - EMC Precautions 168
5.7.2 Use of EMC-Compatible Cables 170
5.8 Residual Current Device 171
6 Application Examples 172
6.1.1 Start/Stop 172
6.1.2 Pulse Start/Stop 172
6.1.3 Potentiometer Reference 173
6.1.4 Automatic Motor Adaptation (AMA) 173
6.1.5 Smart Logic Control 174
6.1.6 Smart Logic Control Programming 174
6.1.7 SLC Application Example 175
6.1.8 BASIC Cascade Controller 177
6.1.9 Pump Staging with Lead Pump Alternation 178
6.1.10 System Status and Operation 178
6.1.11 Fixed Variable-speed Pump Wiring
Diagram 179
6.1.12 Lead Pump Alternation Wiring Diagram 179
6.1.13 Cascade Controller Wiring Diagram 179
6.1.14 Start/Stop Conditions 180
7 Installation and Set-up 181
7.1 Installation and Set-up 181
7.1.1 Network Connection 181
7.1.2 Hardware Set-up 182
7.1.3 Parameter Settings for Modbus Communication 182
7.1.4 EMC Precautions 182
7.2 FC Protocol Overview 183
7.3 Network Configuration 183
7.4 FC Protocol Message Framing Structure 183
7.4.1 Content of a Character (byte) 183
7.4.2 Message Structure 184
7.4.3 Length (LGE) 184
7.4.4 Address (ADR) 184
7.4.5 Data Control Byte (BCC) 185
7.4.6 The Data Field 185
7.4.7 The PKE Field 186
7.4.8 Parameter Number (PNU) 187
7.4.9 Index (IND) 187
Contents Design Guide
MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.

7.4.10 Parameter Value (PWE) 187
7.4.11 Data Types Supported by the Adjustable Frequency Drive 188
7.4.12 Conversion 188
7.4.13 Process Words (PCD) 189
7.5 Examples 189
7.5.1 Writing a Parameter Value 189
7.5.2 Reading a Parameter Value 189
7.6 Modbus RTU Overview 189
7.6.1 Assumptions 189
7.6.2 Prerequisite Knowledge 189
7.6.3 Modbus RTU Overview 190
7.6.4 Adjustable Frequency Drive with Modbus RTU 190
7.7 Network Configuration 191
7.7.1 Adjustable Frequency Drive with Modbus RTU 191
7.8 Modbus RTU Message Framing Structure 191
7.8.1 Adjustable Frequency Drive with Modbus RTU 191
7.8.2 Modbus RTU Message Structure 191
7.8.3 Start/Stop Field 191
7.8.4 Address Field 192
7.8.5 Function Field 192
7.8.6 Data Field 192
7.8.7 CRC Check Field 192
7.8.8 Coil Register Addressing 192
7.8.9 How to Control the Adjustable Frequency Drive 194
7.8.10 Function Codes Supported by Modbus RTU 195
7.8.11 Modbus Exception Codes 195
7.9 Parameter Access 195
7.9.1 Parameter Handling 195
7.9.2 Storage of Data 195
7.9.3 IND 196
7.9.4 Text Blocks 196
7.9.5 Conversion Factor 196
7.9.6 Parameter Values 196
7.10 Examples 196
7.10.1 Read Coil Status (01 HEX) 196
7.10.2 Force/Write Single Coil (05 HEX) 197
7.10.3 Force/Write Multiple Coils (0F HEX) 197
7.10.4 Read Holding Registers (03 HEX) 198
Contents Design Guide
Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122

7.10.5 Preset Single Register (06 HEX) 198
7.10.6 Preset Multiple Registers (10 HEX) 199
7.11 Danfoss FC Control Profile 199
7.11.1 Control Word According to FC Profile (8-10 Control Profile = FC profile) 199
8 General Specifications and Troubleshooting 204
8.1 General Specifications 204
8.1.1 Line Power Supply 3x380–480 V AC 204
8.1.2 Line Power Supply 3 x 525–690 V AC 206
8.1.3 12-Pulse Specifications 209
8.2 Efficiency 216
8.3 Acoustic Noise 216
8.4 Peak Voltage on Motor 217
8.5 Special Conditions 219
8.5.1 Purpose of Derating 219
8.5.2 Derating for Ambient Temperature 219
8.5.3 Automatic Adaptations to Ensure Performance 221
8.5.4 Derating for Low Air Pressure 221
8.5.5 Derating for Running at Low Speed 221
8.6 Troubleshooting 222
8.6.1 Alarm Words 227
8.6.2 Warning Words 228
8.6.3 Extended Status Words 229
8.6.4 Warning and Alarm Introduction 230
Index 237
Contents Design Guide
MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.

1 How to Read this Design Guide
1.1 How to Read this Design Guide
VLT®HVAC Drive
This guide can be used with all
VLT®HVAC Drive adjustable
frequency drives with software
version 3.9x.
The full software version number
can be read from
15-43 Software Version.
Table 1.1 Software Version Information
This contains information proprietary to Danfoss. By
accepting and using this manual, the reader agrees that
the information contained herein will be used solely for
operating units from Danfoss or equipment from other
vendors provided that such equipment is intended for
communication with Danfoss units over a serial communi-
cation 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 functions 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 change its contents without prior notice or
any obligation to notify former or present users of such
revisions or changes.
1.1.1 Available Literature
•The VLT
®
HVAC Drive Instruction Manual is shipped
with the unit and includes information on instal-
lation and startup.
•The VLT
®
HVAC Drive Design Guide includes all
technical information about the adjustable
frequency drive, frames D, E, and F, and customer
design and applications.
•The VLT
®
HVAC Drive Programming Guide provides
information on how to program and includes
complete parameter descriptions.
•Application Note, Temperature Derating Guide.
•PC-based configuration tool MCT 10, enables
configuration of the adjustable frequency drive
from a Windows™-based PC environment.
•Danfoss VLT®Energy Box software at
www.danfoss.com/BusinessAreas/DrivesSolutions/
Softwaredownload/
•Instruction Manual VLT®HVAC Drive BACnet.
•Instruction Manual VLT®HVAC Drive Metasys.
•Instruction Manual VLT®HVAC Drive FLN.
Danfoss technical literature is available in print from local
Danfoss sales offices or online at:
www.danfoss.com/BusinessAreas/DrivesSolutions/Documen-
tations/VLT+Technical+Documentation.htm
How to Read this Design Gui... Design Guide
8 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122
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