Vacon 100 flow Instructions for use

vacon 100 flow
ac drives
application manual
®

PREFACE
DOCUMENT DETAILS
Document ID: DPD01083G
Date: 12.6.2017
Software version: FW0159V017
ABOUT THIS MANUAL
This manual is copyright of Vacon Ltd. All Rights Reserved. The manual is subject to change
without prior notice. The language of the original instructions is English.
In this manual, you can read about the functions of the VACON®AC drive and how to use the
drive. The manual has the same structure than the menu of the drive (chapters 1 and 4-8).
Chapter 1, Quick Startup Guide
•How to start the work with the control panel.
Chapter 2, Wizards
•Making a selection of the application configuration.
•Setting up an application quickly.
•The different applications with examples.
Chapter 3, User Interfaces
•The display types and how to use the control panel.
•The PC tool VACON®Live.
•The functions of the fieldbus.
Chapter 4, Monitoring menu
•Data on the monitoring values.
Chapter 5, Parameter menu
•A list of all the parameters of the drive.
Chapter 6, Diagnostics menu
Chapter 7, I/O and Hardware menu
Chapter 8, User settings, favourites and user level menus
Chapter 9, Monitoring value descriptions
Chapter 10, Parameter descriptions
PREFACE VACON · 3
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•How to use the parameters.
•Digital and analogue input programming.
•Application-specific functions.
Chapter 11, Fault tracing
•The faults and their causes.
•Resetting the faults.
Chapter 12, Appendix
•Data on the different default values of the applications.
This manual includes a large quantity of parameter tables. These instructions tell you how to
read the tables.
Index Min Max Unit Default ID DescriptionParameter
A B C D E F G H
A. The location of the parameter in the
menu, that is, the parameter number.
B. The name of the parameter.
C. The minimum value of the parameter.
D. The maximum value of the parameter.
E. The unit of the value of the parameter.
The unit shows if it is available.
F. The value that was set in the factory.
G. The ID number of the parameter.
H. A short description of the values of the
parameter and/or its function.
NOTE! You can download the English and French product manuals with applicable safety, warning and caution
information from http://drives.danfoss.com/knowledge-center/technical-documentation/.
REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l'en-
semble des informations de sécurité, avertissements et mises en garde applicables sur le site http://
drives.danfoss.com/knowledge-center/technical-documentation/.
VACON · 4 PREFACE
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FUNCTIONS OF THE VACON®AC DRIVE
•You can select the necessary application for your process: Standard, HVAC, PID control,
Multi-pump (single drive) or Multi-pump (multidrive). The drive automatically makes
some of the necessary settings, which makes the commissioning easy.
•Wizards for the first startup and the Fire mode.
•Wizards for each application: Standard, HVAC, PID control, Multi-pump (single drive) and
Multi-pump (multidrive).
•The FUNCT button for an easy change between the local and the remote control place.
The remote control place can be I/O or fieldbus. You can make a selection of the remote
control place with a parameter.
•8 preset frequencies.
•Motor pontentiometer functions.
•A flush function.
•2 ramp times that you can program, 2 supervisions and 3 ranges of prohibited
frequencies.
•A forced stop.
•A control page to operate and monitor of the most important values quickly.
•A fieldbus data mapping.
•An automatic reset.
•Different pre-heat modes to prevent condensation problems.
•A maximum output frequency of 320 Hz.
•A Real time clock and timer functions (an optional battery is necessary). It is possible to
program 3 time channels to get different functions on the drive.
•An external PID controller is available. You can use it, for example, to control a valve with
the I/O of the AC drive.
•A sleep mode function that automatically enables and disables the operation of the drive
to save energy.
•A 2-zone PID controller with 2 different feedback signals: minimum and maximum
control.
•2 setpoint sources for the PID control. You can make the selection with a digital input.
•A function for PID setpoint boost.
•A feedforward function to make the response to the process changes better.
•A process value supervision.
•A multi-pump control for the single drive and multidrive systems.
•The multimaster and multifollower modes in the multidrive system.
•A multi-pump system that uses a real time clock to autochange the pumps.
•A maintenance counter.
•Pump control functions: priming pump control, jockey pump control, pump impeller
auto-cleaning, pump input pressure supervision and frost protection function.
PREFACE VACON · 5
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VACON · 6
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TABLE OF CONTENTS
Preface
Document details 3
About this manual 3
Functions of the VACON®AC drive 5
1 Quick Startup Guide 12
1.1 Control panel and keypad 12
1.2 The displays 12
1.3 First startup 13
1.4 Description of the applications 14
1.4.1 Standard and HVAC applications 14
1.4.2 PID control application 22
1.4.3 Multi-pump (single drive) application 30
1.4.4 Multi-pump (multidrive) application 43
2 Wizards 77
2.1 Standard application wizard 77
2.2 HVAC application wizard 78
2.3 PID control application wizard 79
2.4 Multi-pump (single drive) application wizard 81
2.5 Multi-pump (multidrive) application wizard 84
2.6 Fire mode wizard 88
3 User interfaces 90
3.1 Navigation on the keypad 90
3.2 Using the graphical display 92
3.2.1 Editing the values 92
3.2.2 Resetting a fault 95
3.2.3 The FUNCT button 95
3.2.4 Copying the parameters 99
3.2.5 Comparing the parameters 100
3.2.6 Help texts 102
3.2.7 Using the Favourites menu 103
3.3 Using the text display 103
3.3.1 Editing the values 104
3.3.2 Resetting a fault 105
3.3.3 The FUNCT button 105
3.4 Menu structure 109
3.4.1 Quick setup 110
3.4.2 Monitor 110
3.5 VACON®Live 112
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4 Monitoring menu 113
4.1 Monitor group 113
4.1.1 Multimonitor 113
4.1.2 Trend curve 114
4.1.3 Basic 117
4.1.4 I/O 119
4.1.5 Temperature inputs 119
4.1.6 Extras and advanced 120
4.1.7 Timer functions monitoring 121
4.1.8 PID controller monitoring 122
4.1.9 External PID controller monitoring 123
4.1.10 Multi-pump monitoring 123
4.1.11 Maintenance counters 125
4.1.12 Fieldbus process data monitoring 125
4.1.13 Drive customizer monitoring 126
5 Parameters menu 127
5.1 Group 3.1: Motor settings 127
5.2 Group 3.2: Start/stop setup 131
5.3 Group 3.3: References 133
5.4 Group 3.4: Ramps and brakes setup 136
5.5 Group 3.5: I/O configuration 138
5.6 Group 3.6: Fieldbus data mapping 149
5.7 Group 3.7: Prohibit frequencies 150
5.8 Group 3.8: Supervisions 151
5.9 Group 3.9: Protections 152
5.10 Group 3.10: Automatic reset 158
5.11 Group 3.11: Application settings 159
5.12 Group 3.12: Timer functions 159
5.13 Group 3.13: PID controller 162
5.14 Group 3.14: External PID controller 174
5.15 Group 3.15: Multi-pump 177
5.16 Group 3.16: Maintenance counters 180
5.17 Group 3.17: Fire mode 181
5.18 Group 3.18: Motor preheat parameters 182
5.19 Group 3.19: Drive customizer 182
5.20 Group 3.21: Pump control 183
5.21 Group 3.23: Advanced harmonic filter 186
6 Diagnostics menu 187
6.1 Active faults 187
6.2 Reset faults 187
6.3 Fault history 187
6.4 Total counters 187
6.5 Trip counters 189
6.6 Software info 190
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7 I/O and hardware menu 191
7.1 Basic I/O 191
7.2 Option board slots 193
7.3 Real time clock 194
7.4 Power unit settings 194
7.5 Keypad 195
7.6 Fieldbus 196
8 User settings, favourites and user level menus 197
8.1 User settings 197
8.1.1 User settings 197
8.1.2 Parameter backup 198
8.2 Favourites 198
8.2.1 Adding an item to the Favourites 199
8.2.2 Removing an item from the Favourites 199
8.3 User levels 200
8.3.1 Changing the access code of the user levels 201
9 Monitoring value descriptions 203
9.1 Basic 203
9.2 I/O 204
9.3 Temperature inputs 205
9.4 Extras and advanced 206
9.5 Timer functions 208
9.6 PID controller 209
9.7 External PID controller 209
9.8 Multi-pump 210
9.9 Maintenance counters 211
9.10 Fieldbus data 211
9.11 Drive customizer 215
10 Parameter descriptions 217
10.1 Trend curve 217
10.2 Motor settings 218
10.2.1 Motor nameplate parameters 218
10.2.2 Motor control parameters 219
10.2.3 Motor limits 224
10.2.4 Open loop parameters 224
10.2.5 I/f start function 228
10.2.6 Torque stabilator function 229
10.3 Start/Stop setup 230
10.4 References 240
10.4.1 Frequency reference 240
10.4.2 Preset frequencies 241
10.4.3 Motor potentiometer parameters 245
10.4.4 Flushing parameters 246
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10.5 Ramps and brakes setup 247
10.5.1 Ramp 1 247
10.5.2 Ramp 2 248
10.5.3 Start magnetising 249
10.5.4 DC brake 250
10.5.5 Flux braking 250
10.6 I/O configuration 250
10.6.1 Programming of digital and analogue inputs 250
10.6.2 Default functions of programmable inputs 261
10.6.3 Digital inputs 261
10.6.4 Analogue inputs 267
10.6.5 Digital outputs 272
10.6.6 Analogue outputs 276
10.7 Fieldbus data map 280
10.8 Prohibit frequencies 281
10.9 Supervisions 283
10.10 Protections 283
10.10.1 General 283
10.10.2 Motor thermal protections 285
10.10.3 Motor stall protection 289
10.10.4 Underload (Dry pump) protection 291
10.10.5 Quick stop 293
10.10.6 AI low protection 294
10.11 Automatic reset 296
10.12 Application settings 298
10.13 Timer functions 298
10.14 PID controller 303
10.14.1 Basic settings 303
10.14.2 Setpoints 305
10.14.3 Feedback 306
10.14.4 Feedforward 306
10.14.5 Sleep function 308
10.14.6 Feedback supervision 310
10.14.7 Pressure loss compensation 312
10.14.8 Soft fill 313
10.14.9 Input pressure supervision 315
10.14.10 Sleep function when no demand is detected 317
10.14.11 Multi-setpoint 319
10.15 External PID controller 321
10.16 Multi-pump function 321
10.16.1 Multi-pump (multidrive) commissioning checklist 321
10.16.2 System configuration 323
10.16.3 Interlocks 328
10.16.4 Feedback sensor connection in a multi-pump system 329
10.16.5 Overpressure supervision 338
10.16.6 Pump runtime counters 339
10.16.7 Advanced settings 341
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10.17 Maintenance counters 342
10.18 Fire mode 343
10.19 Motor preheat function 346
10.20 Drive customizer 347
10.21 Pump control 348
10.21.1 Auto-cleaning 348
10.21.2 Jockey pump 350
10.21.3 Priming pump 352
10.21.4 Anti-blocking function 353
10.21.5 Frost protection 353
10.21.6 Flow switch 354
10.22 Counters 355
10.22.1 Operating time counter 355
10.22.2 Operating time trip counter 355
10.22.3 Run time counter 356
10.22.4 Power on time counter 356
10.22.5 Energy counter 357
10.22.6 Energy trip counter 358
10.23 Advanced harmonic filter 359
11 Fault tracing 360
11.1 A fault comes into view 360
11.1.1 Resetting with the Reset button 360
11.1.2 Resetting with a parameter in the graphical display 360
11.1.3 Resetting with a parameter in the text display 361
11.2 Fault history 362
11.2.1 Examining the Fault history in the graphical display 362
11.2.2 Examining the Fault history in the text display 363
11.3 Fault codes 365
12 Appendix 1 380
12.1 The default values of parameters in the different applications 380
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1 QUICK STARTUP GUIDE
1.1 CONTROL PANEL AND KEYPAD
The control panel is the interface between the AC drive and the user. With the control panel,
you can control the speed of a motor and monitor the status of the AC drive. You can also set
the parameters of the AC drive.
A B C
I
H D
G F E
Fig. 1: The buttons of the keypad
A. The BACK/RESET button. Use it to move
back in the menu, exit the Edit mode,
reset a fault.
B. The arrow button UP. Use it to scroll the
menu up and to increase a value.
C. The FUNCT button. Use it to change the
rotation direction of the motor, access
the control page, and change the control
place. See more in 3.3.3 The FUNCT
button.
D. The arrow button RIGHT.
E. The START button.
F. The arrow button DOWN. Use it to scroll
the menu down and to decrease a value.
G. The STOP button.
H. The arrow button LEFT. Use it to move
the cursor left.
I. The OK button. Use it to go into an active
level or item, or to accept a selection.
1.2 THE DISPLAYS
There are 2 display types: the graphical display and the text display. The control panel always
has the same keypad and buttons.
The display shows this data.
•The status of the motor and the drive.
•Faults in the motor and in the drive.
•Your location in the menu structure.
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STOP READY I/O
Main Menu
A B C D E
F
H
G
Quick Setup
( 17 )
Monitor
( 5 )
Parameters
( 12 )
M1ID:
Fig. 2: The graphical display
A. The first status field: STOP/RUN
B. The rotation direction of the motor
C. The second status field: READY/NOT
READY/FAULT
D. The alarm field: ALARM/-
E. The control place field: PC/IO/KEYPAD/
FIELDBUS
F. The location field: the ID number of the
parameter and the current location in
the menu
G. An activated group or item
H. The number of items in the group in
question
A B
F
C
D
E
Fig. 3: The text display. If the text is too long to show, the text scrolls automatically on the display.
A. The indicators of status
B. The indicators of alarm and fault
C. The name of the group or item of the
current location
D. The current location in the menu
E. The indicators of the control place
F. The indicators of the rotation direction
1.3 FIRST STARTUP
After you do power-up of the drive, the Startup wizard starts.
The Startup wizard tells you to give necessary data for the drive to control your procedure.
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1Language selection (P6.1) The selection is different in all the language
packages
2
Daylight saving* (P5.5.5)
Russia
US
EU
OFF
3Time* (P5.5.2) hh:mm:ss
4Year* (P5.5.4) yyyy
5Date* (P5.5.3) dd.mm.
* If a battery is installed, you see these steps
6
Run Startup Wizard?
Yes
No
Select Yes and push the OK button. If you select No, the AC drive moves away from the
Startup wizard.
To set the parameter values manually, select No and push the OK button.
7
Select the application (P1.2 Application, ID212)
Standard
HVAC
PID control
Multi-pump (single drive)
Multi-pump (multidrive)
To continue to the wizard of the application you selected in step 7, select Yes and push the OK
button. See the description of the application wizards in 2 Wizards.
If you select No and push the OK button, the Startup wizard stops and you must select all the
parameter values manually.
To start the Startup wizard again, you have 2 alternatives. Go to the parameter P6.5.1
Restore Factory Defaults or to the parameter B1.1.2 Startup Wizard. Then set the value to
Activate.
1.4 DESCRIPTION OF THE APPLICATIONS
Use the parameter P1.2 (Application) to make a selection of an application for the drive.
Immediately when the parameter P1.2 changes, a group of parameters get their preset
values.
1.4.1 STANDARD AND HVAC APPLICATIONS
Use the Standard and HVAC applications to control pumps or fans, for example.
It is possible to control the drive from the Keypad, Fieldbus or I/O terminal.
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When you control the drive with the I/O terminal, the frequency reference signal is connected
to AI1 (0…10V) or AI2 (4…20mA). The connection is specified by the type of the signal. There
are also 3 preset frequency references available. You can activate the preset frequency
references with DI4 and DI5. The start and stop signals of the drive are connected to DI1
(start forward) and DI2 (start reverse).
It is possible to configure all the drive outputs freely in all the applications. There are 1
analogue output (Output Frequency) and 3 relay outputs (Run, Fault, Ready) available on the
basic I/O board.
See the descriptions of the parameters in 10 Parameter descriptions.
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DI4 DI5
**)
*)
Modbus RTU,
N2, BACnet
1
6
2
3
4
5
18
19
30
12
7
13
8
9
10
14
15
16
21
22
23
11
17
A
B
24
25
26
32
33
28
29
mA
FAULT
RUN
RUN
AO1-
+24 Vin
24 Vout
GND
GND
DI1
DI2
DI3
DI4
DI5
DI6
R O1/1 NC
R O1/2 CM
R O1/3 NO
CM
CM
RS485
RS485
R O2/1 NC
R O2/2 CM
R O2/3 NO
R O3/2 CM
R O3/3 NO
Standard I/O board
Terminal Signal Description
+10Vref
AI1+
AI1-
AI2+
AI2-
24Vout
Reference output
Analogue input 1 +
Analogue input 1 -
Analogue input 2 +
Analogue input 2 -
24V auxiliary voltage
I/O ground
Digital input 1
Digital input 2
Digital input 3
Digital input 4
Digital input 5
Digital input 6
Common for DI1-DI6
Common for DI1-DI6
24V auxiliary voltage
I/O ground
Analogue output 1 +
Analogue output 1 -
24V auxiliary
input voltage
Output
frequency
0...20mA)
READY
Serial bus, negative
Serial bus, positive
Relay output 1
Relay output 2
Relay output 3
FAULT
Fault reset
AO1+
Frequency reference
(default 0...10V)
Frequency reference
(Default 4...20mA)
Start forward
Start reverse
External fault
Freq. ref.
Open
Closed
Open
Closed
Open
Open
Closed
Closed
Analog input 1
Preset Freq. 1
Preset Freq. 2
Preset Freq. 3
Reference-
potentiom-
eter
1...10kΩ
TI1+
TI1-
Thermistor input
Fig. 4: The default control connections of Standard and HVAC applications
* = Available only in VACON®100 X.
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** = For the DIP switch configurations in VACON®100 X, see the VACON 100®X Installation
manual.
A
B
C
Fig. 5: The DIP switch
A. Digital inputs
B. Float C. Connected to GND (default)
Table 2: M1.1 Wizards
Index Parameter Min Max Unit Default ID Description
1.1.1 Startup Wizard 0 1 0 1170
0 = Do not activate
1 = Activate
The selection Activate
starts the Startup wiz-
ard (see Table 1 The
Startup wizard).
1.1.2 Fire Mode Wizard 0 1 0 1672
The selection Activate
starts the Fire mode
wizard (see 2.6 Fire
mode wizard).
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Table 3: M1 Quick Setup
Index Parameter Min Max Unit Default ID Description
1.2 Application 0 4 0 212
0 = Standard
1 = HVAC
2 = PID Control
3 = Multi-pump (single
drive)
4 = Multi-pump (multi-
drive)
1.3 Minimum Frequency
Reference 0.00 P1.4 Hz 0.0 101 The minimum fre-
quency reference that
is accepted.
1.4 Maximum Frequency
Reference P1.3 320.0 Hz 50.0 / 60.0 102 The maximum fre-
quency reference that
is accepted.
1.5 Acceleration Time 1 0.1 3000.0 s 5.0 103
Gives the quantity of
time that is necessary
for the output fre-
quency to increase
from 0 frequency to the
maximum frequency.
1.6 Deceleration Time 1 0.1 3000.0 s 5.0 104
Gives the quantity of
time that is necessary
for the output fre-
quency to decrease
from the maximum
frequency to 0 fre-
quency.
1.7 Motor Current Limit IH*0.1 ISA Varies 107 The maximum motor current from the AC
drive.
1.8 Motor Type 0 2 0 650 0 = Induction Motor
1 = Permanent Magnet
Motor
2 = Reluctance Motor
1.9 Motor Nominal Volt-
age Varies Varies V Varies 110
Find this value Unon
the nameplate of the
motor.
NOTE!
Find out if the motor
connection is Delta or
Star.
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Table 3: M1 Quick Setup
Index Parameter Min Max Unit Default ID Description
1.10 Motor Nominal Fre-
quency 8.0 320.0 Hz 50 / 60 111 Find this value fnon
the nameplate of the
motor.
1.11 Motor Nominal
Speed 24 19200 Rpm Varies 112 Find this value nnon
the nameplate of the
motor.
1.12 Motor Nominal Cur-
rent IH* 0.1 IH* 2 A Varies 113 Find this value Inon
the nameplate of the
motor.
1.13 Motor Cos Phi
(Power Factor) 0.30 1.00 Varies 120 Find this value on the
nameplate of the
motor.
1.14 Energy Optimisation 0 1 0 666
The drive finds the
minimum motor cur-
rent to use less energy
and to lower the motor
noise. Use this function
with, for example, fan
and pump processes.
0 = Disabled
1 = Enabled
1.15 Identification 0 2 0 631
The identification run
calculates or measures
the motor parameters
that are necessary for
a good control of the
motor and speed.
0 = No action
1 = At standstill
2 = With rotation
Before you do the iden-
tification run, you must
set the motor name-
plate parameters.
1.16 Start Function 0 1 0 505 0 = Ramping
1 = Flying Start
1.17 Stop Function 0 1 0 506 0 = Coasting
1 = Ramping
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Table 3: M1 Quick Setup
Index Parameter Min Max Unit Default ID Description
1.18 Automatic Reset 0 1 0 731 0 = Disabled
1 = Enabled
1.19 Response to External
Fault 0 3 2 701
0 = No action
1 = Alarm
2 = Fault (Stop accord-
ing to stop mode)
3 = Fault (Stop by
coasting)
1.20 Response to AI Low
Fault 0 5 0 700
0 = No action
1 = Alarm
2 = Alarm+preset fault
frequency (P3.9.1.13)
3 = Alarm + previous
frequency
4 = Fault (Stop accord-
ing to stop mode)
5 = Fault (Stop by
coasting)
1.21 Remote Control
Place 0 1 0 172
The selection of the
remote control place
(start/stop).
0 = I/O control
1 = Fieldbus control
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