Johnson Controls VFD66 Series Manual

Product/Technical Bulletin VFD66
Issue Date January 5, 2010
© 2010 Johnson Controls, Inc. 1
VFD66 Series Condenser Fan Speed Controls
The VFD66 Series Condenser Fan Speed Controls
regulate the speed of three-phase condenser fan
motors in refrigeration and Heating, Ventilating, and
Air Conditioning (HVAC) systems by varying the
frequency and voltage of the power supplied to the
motor.
The VFD66 control accepts an input signal from the
P35 Pressure Transducer, P499 Electronic Pressure
Transducer, System 350
™ controls, or any other
device that provides a 0-5 VDC or 0-10 VDC analog
output signal.
The application-specific design of the VFD66 control
provides a simple interface, which makes the control
easy to understand and operate.
Figure 1: VFD66 Condenser Fan Speed Control
with NEMA 1 Enclosure
Features and Benefits
Isolated Input Circuitry Permits application with 0-5 VDC or 0-10 VDC
controllers, sensors, transducers, and
Johnson Controls System 350 controls
Simultaneous Acceptance
of Two Similar Inputs Allows use on dual refrigeration circuits
cooled by a single fan
Compact Design Provides installation ease and flexibility
Three-Phase, 208/230, or
400/460 VAC Models Handle three-phase motors ranging up to
10.6 amperes at 208/230 VAC or 5.5 amperes
at 400/460 VAC
Few End-User Settings Provide fast and easy installation and setup
Code No. LIT-125467 www.johnsoncontrols.com
Part No. 24-7664-1555, Rev. F

Application
IMPORTANT: The VFD66 Series Condenser Fan
Speed Controls are intended to control equipment
under normal operating conditions. Where failure or
malfunction of a VFD66 control could lead to an
abnormal operating condition that could cause
personal injury or damage to the equipment or other
property, other devices (limit or safety controls), or
systems (alarm or supervisory) intended to warn of
or protect against failure or malfunction of the
VFD66 control must be incorporated into and
maintained as part of the control system.
The VFD66 control accepts input signals from a variety
of pressure transducers, temperature sensors, and
low-voltage controllers to provide continuous response
to changing condenser load conditions.
The VFD66 control allows the system to:
maintain optimum condenser head pressure in low
ambient temperature conditions
eliminate short-cycling in low ambient temperatures or
changing load conditions
match the condenser fan speed to the load on the
condenser, which increases the efficiency of the
refrigeration system. This can reduce electricity cost
and help maintain a constant evaporator temperature.
Terminal
Access
Cover
Terminal
Cover
Screw
Heat
Sink
7-1/2
(190)
7
(177)
3 conduit openings
7/8-in. (22 mm) actual size
1/2-in. trade size 1/4-in. (6 mm)
mounting screws,
4 places
6-1/4
(159)
4-3/4
(120)
4-5/8
(117)
7-1/4
(184)
Diagnostic
Light-Emitting
Diodes (LEDs)
Figure 2: VFD66 NEMA 1 Enclosure Dimensions
The VFD66 control can also:
stabilize the condenser head pressures, which helps
optimize compressor operation and can reduce wear
and extend compressor life
eliminate the condenser fan short-cycling, which can
reduce motor repair and replacement costs
stabilize evaporator temperatures, which can extend
refrigerated product life and provide more consistent
comfort cooling
Mounting
!
CAUTION: Risk of Property Damage.
The VFD66 control can generate and dissipate
significant heat. Mount the control on a metal,
concrete, or cinderblock mounting surface. Mounting
the VFD66 control on surfaces made of wood or
other heat-sensitive material may result in damage
to the mounting surface.
Observe the following the guidelines when mounting a
VFD66 control:
Mount the VFD66 control on a vertical surface with the
heat sink fins oriented vertically and the conduit holes
facing down.
Provide a minimum of 4 in. (102 mm) clearance
around the heat sink.
Ensure that output power wiring between the VFD66
control and the motor does not exceed 50 ft (15 m).
Mount the VFD66 control indoors, in a location
protected from explosive vapors, corrosive gas, water,
and dust.
Ambient air temperature and installation altitude affect
the maximum output rating of the VFD66 controls (see
De-Rating the VFD66 Control for
High Temperatures and High Altitudes).
2 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin

Wiring Read this entire section, including the information on
emissions compliance, before wiring the
VFD66 control. Follow these guidelines when wiring
the VFD66 control:
!
WARNING: Risk of Electric Shock.
Disconnect the power supply before making
electrical connections. The printed circuit board and
its components are at AC line voltage. Contact with
components carrying hazardous voltage can cause
electric shock and may result in personal injury or
death.
•Use copper conductors only.
•Size field wiring based on 75°C.
Accessing the Interior
Remove the terminal access cover (Figure 2) to
access terminal blocks, jumper blocks, and internal
potentiometers (Figure 3).
!
WARNING: Risk of Electric Shock.
To avoid possible electric shock, wait at least 5
minutes after AC supply power has been
disconnected from the VFD66 control before
servicing the device. The VFD66 Condenser Fan
Speed Control remains electrically charged for a
period of time after power is removed. Failure to wait
until the VFD66 control fully discharges could cause
electric shock, personal injury, or death.
NEMA 1 Enclosure
Follow these steps to remove the terminal cover:
1. Remove the terminal cover screw and push
downward on the ventilation holes.
2. Pull outward on the top of the terminal access
cover.
J7 J8
TB3
1 2 34
TB1
L3 L2 L1
TB2
P1
T1 T2 T3
J5 J6 J2 J3 J4J9
Circuit
Board
(cropped
view)
Conduit
Entry
Bracket
Potentiometers
P2
Jumper
Blocks
for
Adjusting
VFD66
Control
Jumper Blocks for
Input Device Selection
Ground
Connection Terminals
Route wiring from input devices
through this conduit entry hole.
Input
Device
AC
Power
Input
Output
to
Fan
Motor
!
CAUTION: Risk of Property Damage.
Do not run low voltage cable in the same conduit or
wiring troughs with high voltage wires. Running low
and high voltage wires in the same conduit or wiring
troughs may damage the equipment or cause
system malfunction.
Figure 3: Jumper Block, Terminal Block, and
Potentiometer Locations
VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin 3

Table 1: Terminal Blocks
Terminal
Block Label Terminal Block Function Electrical Rating Terminal Terminal Function
L1 Line 1 Input
L2 Line 2 Input
TB1 Input Line-Voltage Supply Power
L3 Line 3 Input
T1 Line 1 Output
T2 Line 2 Output
TB2 Output Line-Voltage Power to Fan
Motor
See Technical
Specifications.
T3 Line 3 Output
1 5 VDC power supply
2 First signal input
3 Second signal input1
TB3 Low-voltage Input Signals,
0-5 VDC Power Supply 0-5 VDC or 0-10 VDC
4 Common
1 Switch contact
TB4 Alarm Output for User-Installed
Alarm Device 100 mA at 24 VAC/30 VDC 2 Switch contact
1. See Adjusting the Control Settings.
Wiring Input Devices to a VFD66
Connect the appropriate low-voltage input signal
device to Terminal Block TB3 (Figure 3). See Table 2,
Figure 4, Figure 5, and Figure 6 for additional
information on wiring specific
Johnson Controls/PENN™ input devices to the
VFD66 controls.
Table 2: Wiring Johnson Controls/PENN
Input Devices
Input Device Input Device
Terminal VFD66 Control TB3 Terminal
1 1
2 2 (or 3)1
P35AG-9200R
Transducer
3 4
V 2 (or 3)1
A350PS-1C or
P352PN Series
Controls C 4
Red 1
White 2 (or 3)1
P499 Series
Transducers
Black 4
1. Use Terminal 3 to connect an optional second
input device to the VFD66 (Figure 5).
TB3
2
2
13
3 4
P35 Transducer
1
Figure 4: Wiring P35 Transducers to VFD66
Terminal Block 3
White
(Second Output Signal)
Red (5 VDC Supply)
White
(Output Signal)
P499 Transducer
TB3
Black
(Common)
Second P499 Transducer
(Optional)
Red (5 VDC Supply)
Black
(Common)
1 2 3 4
Figure 5: Wiring P499 Transducers to VFD66
Terminal Block 3 (TB3)
4 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin

TB3
1
V
I
SN
VDC
C
24V
A350P Control
or P352PN Control
Second A350P Control
or P352PN Control
(if used)
2 4
C: Common (-)
V: 0-10 VDC Output
3
Figure 6: Wiring A350P Controls
or P352PN Controls to
VFD66 Terminal Block 3
Wiring an External Alarm to a VFD66 Control
Some models of the VFD66 controls feature an alarm
output. The Metal Oxide Silicon Field Effect Transistor
(MOSFET) alarm output activates when a permanent
fault condition occurs. See Table 12, Figure 3, and
Figure 7.
Visual
or Audible
External Alarm
Device
Alarm output
is rated for 100 mA
at 30 VDC/24 VAC.
2
1
24VAC/30 VDC
VFD66 Control
Terminal Block T 4B
Figure 7: Wiring the Alarm Output
Wiring VFD66 Input and Output Power
Select wire size for field wiring based on a wire
insulation temperature resistance rating of 167°F
(75°C), with a maximum wire size of 12 AWG. Use
only stranded copper wire, rated for at least 600 volts.
Maximum terminal tightening torque for all VFD66
controls electrical terminals is 5 lb·in (0.565 N·m).
Ensure that the motor(s) and VFD66 control are
securely and adequately grounded. Use the two
ground connection terminals on the conduit entry
bracket. (See Figure 3.) Use a ground connection
terminal similar to AMP Part Number 34162 for
16-14 AWG wire size or AMP Part Number 322455 for
12-10 AWG wire size.
Wiring Input Power
!
CAUTION: Risk of Property Damage.
Ensure that the power source conforms to the
requirements of the equipment. Failure to use a
correct power source may result in permanent
damage to the equipment.
IMPORTANT: Wiring line-voltage input power to the
wrong terminal block will damage the VFD66 control.
Wire input power ONLY to Terminal Block 1 (TB1).
The input line-voltage supply power to L1, L2, and L3
(Terminal Block 1) must be fused. Use fuses sized for
250% of the input current rating of the VFD66 control.
For example, if a VDF66 control is rated at 4 amperes
input current, use a 10-ampere fuse. Do not use fuses
with an extremely fast-opening characteristic (rectifier
fuses).
Wiring Output Power
IMPORTANT: The output phase rotation on TB2 at
T1(U), T2(V), T3(W) is ABC. If the motor rotation is
incorrect, interchange any two motor leads on TB2.
Do not make changes to the input power supply
wiring.
The length of output power wires between the
VFD66 control (TB2) and the motor must not exceed
50 ft (15 m).
Emissions Compliance
If the VFD66 control is used in commercial or
residential applications, FCC and DOC compliance
may require the addition of the items in Table 3 to
reduce electronic noise emissions. Installation of the
parts listed is required for EU Directive Compliance
(CE mark):
•72/23/EEC (Low Voltage Directive)
•89/336/EEC (EMC Directive)
VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin 5

Table 3: Emissions Compliance
Required Item Suggested Model
Axx, Bxx, Dxx,
and Fxx Schaffner® EMV AG
FN 258-7/291
EMI
Filter for
VFD
Types: Cxx and Exx Schaffner EMV AG
FN 258-16/29
Ferrite Core
(Two Required) Fair-Rite® No.
0443167251
Shielded Power Wiring Any 3-conductor, braided,
shielded cable
1. Contact Schaffner and Fair-Rite for local distributors.
TB3 TB1 TB2
1 2 34L1 L2 L3 T1 T2T3
L1
L1
L2
L2
L3
L3
E
Motor
EMI Filter
E
Shielded
Wiring
Separate input and output cables. Do not run input cables
alongside output cables. Do not bundle input and output
cables together.
Input
Device(s)
Ferrite Cores
2, 3 or 4 Conductor
Shielded Cables Alarm
Device
Figure 8: CE/FCC/DOC Compliance Wiring
Setup and Adjustments
This section describes how to set up the
VFD66 control. Remove the terminal access cover to
access the jumper blocks and internal potentiometers.
See Accessing the Interior.
Adjusting the Control Settings
!
WARNING: Risk of Electric Shock.
Disconnect power from the control before making
any adjustments. Do not touch any part of the
printed circuit board while power is applied. Failure
to follow these precautions can result in personal
injury or death.
Control settings are established by positioning
six jumpers and adjusting two potentiometers.
Factory default settings have all the jumpers in the
installed position and the potentiometers set fully
clockwise. (See Table 4, Figure 3 and Figure 9.)
Table 4: Jumper Settings by Function
Jumper
Block Function Jumper Removed1Jumper
Installed
J2
J3 Mode of
Operation See Selecting an Input Mode.
J4 Acceleration/
Deceleration
Time
5 Seconds 30 Seconds
J5 Internal/
External P1
J6 Internal/
External P2
Do not move the jumpers
from the factory-installed
position unless installing the
External Potentiometer
Replacement Cover.
J7 Input Signal
Type 0-10 VDC 0-5 VDC
J8 Number of
Input Signals
Used
Dual Single
J9 Maximum
Output
Frequency
50 Hz 60 Hz
1. Do not discard jumpers. See Figure 9.
To place a jumper in the removed position, reposition
the jumper so that it is connected to only one pin on
the jumper block. Keep the jumper because it may be
needed in the future. To place a jumper in the installed
position, place the jumper on both pins (Figure 9).
Jumper blocks J2 and J3 establish input modes and
work in conjunction with potentiometers P1 and P2.
See Selecting an Input Mode.
Jumper
Pins
Removed
(positioned
on one pin)
Installed
(positioned
on both pins)
Jumper
Block
Figure 9: Jumper Placement on Pins
Jumper blocks J5 and J6 have jumpers installed on
the two middle pins of each jumper block. These
jumpers activate the internal potentiometers. Moving
the jumpers from the factory-installed position disables
the internal potentiometers.
6 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin

Jumpers on J7 and J8 must be set for the correct input
voltage range and number of input devices. (See
Table 4.) Jumper block J7 sets the voltage range for
the input signal(s). If the jumper on jumper block J7 is
incorrectly set, the control may operate in an
unexpected manner. See Troubleshooting.
Jumper block J8 selects the number of input signals
used. When dual inputs are selected, Terminal 3 of
TB3 (TB3-3) is enabled. The VFD66 control varies the
speed of the fan motor in accordance with the higher
value of the two input signals received. If the jumper
on jumper block J8 is incorrectly set, the control may
operate in an unexpected manner. See
Troubleshooting.
Jumper block J9 selects maximum frequency output of
the control. Remove the jumper for 50 Hz motors,
typically used in Europe. Install the jumper for 60 Hz
motors, typically used in North America. Power to the
VFD66 control must be disconnected and reconnected
before frequency changes take effect.
De-Rating the VFD66 Control for
High Temperatures and High Altitudes
Ambient air temperature and altitude of the installation
affect the maximum output ampere rating of the
VFD66 control. High air temperature makes the heat
sink less effective in dissipating the generated heat.
High altitudes have thinner air than lower altitudes,
which is less effective in dissipating heat. The less
effective the heat sink is, the lower the maximum
output ampere rating of the VFD66 control.
Temperature De-Rating
For temperatures up to 122°F (50°C), the maximum
output ampere rating is unaffected by temperature. At
temperatures between 122°F (50°C) and 140°F
(60°C), the maximum output ampere rating is
decreased. The VFD66 controls are not designed to
operate in temperatures above 140°F (60°C).
See Figure 10 for temperature de-rating for
208/230 VAC models. See Figure 11 for temperature
de-rating for 400/460 VAC models.
A
mperes
Temperature
10.0
0
5.0
7.5
2.5
122 F
50 C
o
o
140 F
60 C
o
o
131 F
55 C
o
o
126 F
52 C
o
o
136 F
58 C
o
o
4.0
10.6
VFD66Axx Type
VFD66Cxx Type
VFD66Exx Type
Figure 10: 208/230 VAC Temperature De-Rating
A
mperes
Temperature
6.0
0
3.0
4.5
1.5
122 F
50 C
o
o
140 F
60 C
o
o
5.5
1.8
3.6
2.2
131 F
55 C
o
o
126 F
52 C
o
o
136 F
58 C
o
o
VFD66Fxx Type
VFD66Dxx Type
VFD66Bxx Type
Figure 11: 400/460 VAC Temperature De-Rating
Altitude De-Rating
See Table 5 for altitude multipliers. Use the following
formula to determine the adjusted rating:
Temperature
De-Rated
Maximum
Output
Amperes
XAltitude
Multiplier =
De-Rated
Maximum
Output
Amperes
VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin 7

8 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin
Table 5: Altitude Multipliers for De-Rating
Altitude Range Altitude Multiplier
0-3300 ft (0-1000 m) 1.0
3300-4300 ft (1000-1305 m) 0.97
4300-5300 ft (1305-1610 m) 0.94
5300-6300 ft (1610-1915 m) 0.91
6300-7300 ft (1915-2220 m) 0.88
7300-8300 ft (2220-2525 m) 0.86
8300-9300 ft (2525-2830 m) 0.83
9300-10300 ft (2830-3135 m) 0.80
10300-11300 ft (3135-3440 m) 0.78
De-Rating Examples
For these examples, the control used is a VFD66Exx
type. See Figure 10, Figure 11, and Table 5.
•If a VFD66Exx type (208/230 VAC) is used and
the temperature is below 122°F (50°C), the VFD66
control may be used for loads up to 10.6 amperes
at any altitude below 3,300 ft (1,000 m).
•If the temperature around the VFD66 control
reaches 140°F (60°C), the rating is different.
According to Figure 10, the VFD66 control is rated
for only 7.5 amperes at 140°F (60°C).
•If the VFD66 control is used in Denver, Colorado
(altitude 5200 ft), the output rating is reduced.
(See Table 5.) When the temperature is less than
122°F (50°C), the VFD66 control is rated for
9.96 amperes, as shown by the equation:
De-Rated Maximum Output Amperes = 10.6 Amperes
x 0.94 = 9.96 Amperes
•If the VFD66 control is used in Denver, Colorado
(altitude 5200 ft), and the ambient temperature
reaches 140°F (60°C), then the VFD66 control is
de-rated to a 7.5-ampere maximum current draw
due to the high ambient temperature and is further
de-rated to 7.05 amperes of current draw because
of high altitude.
De-rated Maximum Output Amperes = 7.5 Amperes x
0.94 = 7.05 Amperes
Commissioning
Table 6: Mode Selections According to Input Device
Input Device Input Type Input Mode J2 Jumper
Position J3 Jumper Position J7 Jumper Position1
Any2None2Manual Installed Installed NA
A350P Temperature Standard Installed Removed Removed
P352PN Pressure Standard Installed Removed Removed
P35AG-9200 Pressure Standard Installed Removed Installed
Any 0-5 VDC Devices Any3Standard Installed Removed Installed
Any 0-10 VDC Devices Any3Standard Installed Removed Removed
P499 or Other Electronic
Pressure Transducer Pressure Electronic Pressure
Transducer Removed Removed or Installed4Removed or Installed4
1. J7 jumper position depends on the input device connected.
2. Setting the input mode to manual ignores any connected input devices.
3. Input type varies with device.
4. Transducer may provide 0-5 VDC or 0-10 VDC signal. A 0-10 VDC transducer must be separately powered. Note that
a non-ratiometric transducer generates more error than ratiometric transducers.

Selecting an Input Mode
See Table 6 for the available input mode options for
the VFD66 control. The factory–set mode is Manual
Input mode.
Manual Input Mode
Manual Input mode allows the user to set a constant
motor speed. This can be used where manual control
is desired or while repairing input signal devices or
obtaining replacements. InManual Input mode, the input
device signals are disregarded. Motor speed is controlled
by adjusting the P1 potentiometer. Potentiometer P2 is
disregarded and adjusting P2 has no effect.
Table 7: Manual Input Mode
J2 Jumper
Position J3 Jumper Position P1: Motor Speed P2: Not
Used
Installed Installed Adjusts constant
speed of motor
(0-100%)
—
Standard Input Mode
Standard Input mode is the most commonly used
mode. The majority of input devices compatible with
the VFD66 controls are used with this mode. The input
device determines the setpoint and proportional band.
Table 8: Standard Input Mode
J2
Jumper
Position
J3
Jumper
Position
P1:
Minimum
Motor
Speed
P2: Motor
Action at
Minimum
Speed
CCW:
Motor idles.
Installed Removed Can be set at
0-50% of
maximum
motor speed. CW: Motor
shuts off.
P1 adjusts the minimum speed of the motor. The
minimum speed is adjustable from 0 to 50% of total
motor speed. Turning P1 Clockwise (CW) increases
minimum speed setting, Counterclockwise (CCW)
decreases minimum speed setting.
P2 determines whether the motor idles at minimum
speed or shuts off at minimum speed. P2 must be set
at full CCW or full CW position; intermediate settings
have no effect.
Figure 12 illustrates three possible motor speed
curves. When P2 is rotated fully CCW, the motor idles
at the minimum speed set by P1 at input values below
the end of the proportional band (Curve A in
Figure 12). When P2 is rotated fully CW, the motor
shuts off at the minimum speed set by P1 when the
input is below the bottom end of the proportional band
(Curve B in Figure 12).
In Curve C, the minimum motor speed (P1) is set at
0% of maximum motor speed and the position of
P2 has no effect.
Pressure or Temperature
RPM
100%
50%
Setpoint
Proportional Band
40%
30%
Minimum
Motor Speed
Setby P1
Idle
Curve B
P2=CW
P1=30%
Curve C
P2=CCW or CW
P1=0%
Curve A
P2=CCW
P1=40%
0%
Figure 12: Standard Input Mode
VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin 9

P2 adjusts the proportional band over which fan motor
speed is controlled.
Electronic Pressure Transducer Input Mode
IMPORTANT: Minimum motor speed and motor
action at minimum speed cannot be set in this mode. Figure 13 illustrates J3, P1, and P2 settings in
Electronic Pressure Transducer Input mode with a
P499 transducer (0-500 psi). If the jumper on J3 is in
the removed position, P1 adjusts the setpoint between
200-350 psi. The fan motor starts when pressure
reaches 200 psi (Setpoint – Proportional Band) and
maximum motor speed (100% RPM) is reached at
250 psi (Setpoint).
The VFD66 controls work with most 0-5 VDC or
0-10 VDC electronic pressure transducers. For best
results, use 0-5 VDC, ratiometric P499 Electronic
Pressure Transducers. Ratiometric transducers vary
the signal voltage from 10-90% of the 5 VDC supply
power as the pressure goes from minimum to
maximum of the transducer rating.
Pressure
RPM
100%
50%
Setpoint
Set by P1 and J3
25–100 psi
(50 psi)
Proportional Band
Setby P2
(200 psi) (250 psi)
Note: Non-ratiometric transducers generate more
error than ratiometric transducers. 0-10 VDC P499
transducers are not ratiometric.
The J7 jumper position sets the input signal voltage
range. Install the J7 jumper when using a 0-5 VDC
transducer. Remove the J7 jumper when using a
0-10 VDC transducer.
Note: Applications using 0-10 VDC transducers
require a separate 15 VDC power supply.
The J3 jumper position establishes the low or high
pressure range of P1 (Table 9). Figure 13: Electronic Pressure Transducer Input
Mode, 0-500 psi P499 Transducer
P1 adjusts the pressure setpoint and establishes the
pressure value at which the VFD66 controls drive the
fan motor at maximum speed.
10 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin