Danfoss VLT HVAC Drive FC 100 Series Guide

Contents
1. How to Read this Design Guide
3
Copyright, Limitation of Liability and Revision Rights 3
Approvals 4
Symbols 4
Abbreviations 5
Definitions 5
2. Introduction to VLT HVAC Drive 11
Safety 11
CE labelling 12
Air humidity 13
Aggressive Environments 14
Vibration and shock 14
VLT HVAC Drive Controls 28
PID 30
General aspects of EMC 39
Galvanic isolation (PELV) 41
PELV - Protective Extra Low Voltage 41
Control with brake function 42
Extreme running conditions 45
Safe Stop 48
3. VLT HVAC Drive Selection 51
Options and Accessories 51
4. How to Order 61
Ordering Numbers 63
5. How to Install 71
Mechanical Dimensions 72
Electrical Installation 79
Final Set-Up and Test 104
Additional Connections 106
DC bus connection 106
Brake Connection Option 106
Relay Connection 107
Installation of misc. connections 111
Safety 113
EMC-correct Installation 114
Mains supply interference/Harmonics 118
Residual Current Device 118
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6. Application Examples 119
Start/Stop 119
Pulse Start/Stop 119
Potentiometer Reference 120
Automatic Motor Adaptation (AMA) 120
Smart Logic Control Programming 120
SLC Application Example 121
BASIC Cascade Controller 122
Pump Staging with Lead Pump Alternation 123
System Status and Operation 123
Fixed Variable Speed Pump Wiring Diagram 124
Lead Pump Alternation Wiring Diagram 124
Cascade Controller Wiring Diagram 124
Start/Stop conditions 125
7. RS-485 Installation and Set-up 127
RS-485 Installation and Set-up 127
FC Protocol Overview 129
Network Configuration 130
FC Protocol Message Framing Structure 130
Examples 134
Modbus RTU Overview 135
Modbus RTU Message Framing Structure 137
How to Access Parameters 140
Examples 142
Danfoss FC Control Profile 148
8. General Specifications and Troubleshooting 153
General Specifications 153
Efficiency 164
Acoustic noise 165
Peak voltage on motor 165
Special Conditions 166
Alarms and warnings 167
Alarm words 171
Warning words 172
Extended status words 173
Fault messages 174
Index
177
Contents VLT
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HVAC Drive Design Guide
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1. How to Read this Design Guide
VLT HVAC Drive
FC 100 Series
Software version: 2.8.x
This guide can be used with all VLT HVAC Drive frequency converters
with software version 2.8.x.
The actual software version number can be read from
par. 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 documentation 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.
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1.1.2. Available Literature
-Operating Instructions MG.11.Ax.yy provide the neccessary information for getting the frequency converter up and running.
-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.
-Mounting Instruction, Analog I/O Option MCB109, MI.38.Bx.yy
-PC-based Configuration Tool MCT 10, MG.10.Ax.yy enables the user to configure the frequency converter from a Windows™based PC environ-
ment.
-Danfoss VLT Energy Box software at
www.danfoss.com/BusinessAreas/DrivesSolutions then choose PC Software Download
-VLT 6000 HVAC Application Booklet, MN.60.Ix.yy
-Operating Instructions VLT HVAC Drive BACnet, MG.11.Dx.yy
-Operating Instructions VLT HVAC Drive Profibus, MG.33.Cx.yy.
-Operating Instructions VLT HVAC Drive Device Net, MG.33.Dx.yy
-Operating Instructions VLT HVAC Drive LonWorks, MG.11.Ex.yy
-Operating Instructions VLT HVAC Drive High Power, MG.11.Fx.yy
-Operating Instructions VLT HVAC Drive Metasys, MG.11.Gx.yy
x = Revision number
yy = Language code
Danfoss technical literature is also available online at
www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm .
1.1.3. Approvals
1.1.4. Symbols
Symbols used in this guide.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
*Indicates default setting
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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
drive FC
Gram g
Hertz Hz
Kilohertz kHz
Local Control Panel
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
Parameter par.
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Rated Inverter Output Current IINV
Revolutions Per Minute RPM
Regenerative terminals Regen
Second s
Synchronous Motor Speed ns
Torque limit TLIM
Volts V
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
You can start and stop the connected motor by means of
LCP and the digital inputs.
Functions are divided into two groups.
Functions in group 1 have higher priority than functions in
group 2.
Group 1 Reset, Coasting stop, Reset and Coasting stop, Quick-
stop, DC braking, Stop and the "Off" key.
Group 2 Start, Pulse start, Reversing, Start reversing, Jog and
Freeze output
Motor:
fJOG
The motor frequency when the jog function is activated (via digital terminals).
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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 rated motor speed (nameplate data).
PM,N
The rated motor power (nameplate data).
TM,N
The rated torque (motor).
UM
The instantaneous motor voltage.
UM,N
The rated motor voltage (nameplate data).
Break-away 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.
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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).
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 par. 3-03.
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 par. 3-02.
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.
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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 (par. 14-22), 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) makes up a complete interface for control and programming of the frequency converter. The control panel 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 mm
󳞉2.
msb
Most significant bit.
NLCP
Numerical Local Control Panel LCP101
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 (par. 14-00).
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.
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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 par. 14-00).
1.1.7. Power Factor
The power factor is the relation between I1and IRMS.
Power factor =
3× U × I
1× COS ϕ
3× U × IRMS
The power factor for 3-phase control:
=
I
1×
cos ϕ1
IRMS
=
I
1
IRMS
since cos
ϕ1=1
The power factor indicates to which extent the frequency converter im-
poses a load on the mains supply.
The lower the power factor, the higher the IRMS for the same kW per-
formance.
IRMS = I
2
1+
I
2
5+
I
2
7+..+
I
2
n
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 minimises the imposed load on the mains supply.
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2. Introduction to VLT HVAC Drive VLT
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