Danfoss VLT HVAC Basic Drive FC 101 Guide

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
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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
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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
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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
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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
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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
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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).
fM
The motor frequency.
fMAX
The maximum motor frequency.
fMIN
The minimum motor frequency.
fM,N
The rated motor frequency (nameplate data).
IM
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).
UM
The instantaneous motor voltage.
UM,N
The rated motor voltage (nameplate data).
Introduction Design Guide
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11

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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