Vacon 100 HVAC Instructions for use

vacon 100 hvac
ac drives
application manual
®

PREFACE
Document ID: DPD01696K
Date: 11.04.2016
Software version: FW0065V032
ABOUT THIS MANUAL
This manual is copyright of Vacon Ltd. All Rights Reserved. The manual is subject to change
without prior notice.
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
•Setting up an application quickly.
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
Chapter10, Parameter descriptions
•How to use the parameters.
•Digital and analogue input programming.
•Application-specific functions.
PREFACE VACON · 3
24-HOUR SUPPORT [phone] · EMAIL: [email protected]

Chapter 11, Fault tracing
•The faults and their causes.
•Resetting the faults.
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
I
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.
I. When the symbol shows, you can find
more data about the parameter in
Chapter Parameter descriptions.
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
TEL. [phone] · FAX [phone]

FUNCTIONS OF THE VACON®AC DRIVE
•Wizards for startup, PID control, multipump and fire mode to make the commissioning
easy.
•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.
•Run interlock input (Damper interlock). Drive does not start before this input is activated.
•A control page to operate and monitor of the most important values quickly.
•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 multipump control.
•A pressure loss compensation to compensate pressure losses in the pipework for
example when the sensor is incorrectly placed near the pump or fan.
PREFACE VACON · 5
24-HOUR SUPPORT [phone] · EMAIL: [email protected]

VACON · 6
TEL. [phone] · FAX [phone]

TABLE OF CONTENTS
Preface
About this manual 3
Functions of the Vacon®AC drive 5
1 Quick Startup Guide 11
1.1 Control panel and keypad 11
1.2 The displays 11
1.3 First start-up 12
1.4 Description of the applications 13
1.4.1 Vacon HVAC application 13
2 Wizards 20
2.1 PID mini-wizard 20
2.2 Multi-pump mini-wizard 21
2.3 Fire mode wizard 22
3 User interfaces 24
3.1 Navigation on the keypad 24
3.2 Using the graphical display 26
3.2.1 Editing the values 26
3.2.2 Resetting a fault 29
3.2.3 The Funct button 29
3.2.4 Copying the parameters 33
3.2.5 Comparing the parameters 35
3.2.6 Help texts 36
3.2.7 Using the Favourites menu 37
3.3 Using the text display 37
3.3.1 Editing the values 38
3.3.2 Resetting a fault 39
3.3.3 The Funct button 39
3.4 Menu structure 42
3.4.1 Quick setup 43
3.4.2 Monitor 43
3.5 Vacon Live 44
4 Monitoring menu 46
4.1 Monitor group 46
4.1.1 Multimonitor 46
4.1.2 Basic 47
4.1.3 Timer functions monitoring 49
4.1.4 PID1 controller monitoring 50
4.1.5 PID2 controller monitoring 51
4.1.6 Multi-pump monitoring 51
4.1.7 Fieldbus process data monitoring 52
5 Parameters menu 53
5.1 Group 3.1: Motor settings 53
5.2 Group 3.2: Start/stop setup 56
TABLE OF CONTENTS VACON · 7
24-HOUR SUPPORT [phone] · EMAIL: [email protected]

5.3 Group 3.3: Control reference settings 58
5.4 Group 3.4: Ramp and brakes setup 60
5.5 Group 3.5: I/O configuration 61
5.6 Group 3.6: Fieldbus data mapping 69
5.7 Group 3.7: Prohibit frequencies 70
5.8 Group 3.8: Limit supervisions 71
5.9 Group 3.9: Protections 72
5.10 Group 3.10: Automatic reset 74
5.11 Group 3.11: Timer functions 75
5.12 Group 3.12: PID-controller 1 78
5.13 Group 3.13: PID-controller 2 83
5.14 Group 3.14: Multipump 86
5.15 Group 3.16: Fire mode 87
5.16 Group 3.17: Application settings 88
5.17 Group 3.18: kWh pulse output settings 88
6 Diagnostics menu 89
6.1 Active faults 89
6.2 Reset faults 89
6.3 Fault history 89
6.4 Total counters 90
6.5 Trip counters 91
6.6 Software info 92
7 I/O and hardware menu 93
7.1 Basic I/O 93
7.2 Option board slots 95
7.3 Real time clock 96
7.4 Power unit settings 96
7.5 Keypad 98
7.6 Fieldbus 98
8 User settings, favourites and user level menus 99
8.1 User settings 99
8.1.1 Parameter backup 100
8.2 Favourites 101
8.2.1 Adding an item to the Favourites 101
8.2.2 Removing an item from the Favourites 102
8.3 User levels 103
8.3.1 Changing the access code of the user levels 103
9 Monitoring value descriptions 105
9.1 Basic 105
9.2 Timer functions 107
9.3 PID1 Controller 108
9.4 PID2 Controller 109
9.5 Multi-pump 109
9.6 Fieldbus data 110
VACON · 8 TABLE OF CONTENTS
TEL. [phone] · FAX [phone]

10 Parameter descriptions 112
10.1 Motor settings 112
10.1.1 Motor nameplate parameters 112
10.1.2 Motor control parameters 113
10.2 Start/Stop setup 117
10.3 References 124
10.3.1 Frequency reference 124
10.3.2 Preset frequencies 125
10.3.3 Motor potentiometer parameters 127
10.4 Ramps and brakes setup 128
10.5 I/O configuration 131
10.5.1 Programming of digital and analogue inputs 131
10.5.2 Digital inputs 137
10.5.3 Analogue inputs 142
10.5.4 Digital outputs 143
10.5.5 Analogue outputs 145
10.6 Fieldbus data map 148
10.7 Prohibit frequencies 149
10.8 Limit supervisions 151
10.9 Protections 152
10.9.1 Motor thermal protections 153
10.9.2 Motor stall protection 155
10.9.3 Underload (Dry pump) protection 157
10.10 Automatic reset 160
10.11 Timer functions 162
10.11.1 Timer functions 162
10.12 PID controller 1 166
10.12.1 Basic settings 166
10.12.2 Setpoints 168
10.12.3 Feedback 169
10.12.4 Feedforward 170
10.12.5 Process supervision 171
10.12.6 Pressure loss compensation 173
10.13 PID controller 2 174
10.13.1 Basic settings 174
10.14 Multi-pump function 175
10.15 Fire mode 183
10.16 Application settings 186
10.17 kWh Pulse output 186
TABLE OF CONTENTS VACON · 9
24-HOUR SUPPORT [phone] · EMAIL: [email protected]

11 Fault tracing 187
11.1 A fault comes into view 187
11.1.1 Resetting with the Reset button 187
11.1.2 Resetting with a parameter in the graphical display 187
11.1.3 Resetting with a parameter in the text display 188
11.2 Fault history 189
11.2.1 Examining the Fault history in the graphical display 189
11.2.2 Examining the Fault history in the text display 190
11.3 Fault codes 192
VACON · 10 TABLE OF CONTENTS
TEL. [phone] · FAX [phone]

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 Table 12 Control
reference settings.
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.
QUICK STARTUP GUIDE VACON · 11
24-HOUR SUPPORT [phone] · EMAIL: [email protected] 1

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 START-UP
The Start-up wizard tells you to give necessary data for the drive to control your procedure.
VACON · 12 QUICK STARTUP GUIDE
1 TEL. [phone] · FAX [phone]

1Language selection The selection is different in all the language
packages
2
Daylight saving*
Russia
US
EU
OFF
3Time* hh:mm:ss
4Date* dd.mm.
5Year* yyyy
* If a battery is installed, you see these questions.
6
Run Startup wizard?
Yes
No
To set the parameter values manually, make the selection No and push the OK button.
7
Make a selection of a process
Pump
Fan
8Set a value for Motor Nominal Speed (so that it
agrees with the nameplate) Range: 24-19200
9Set a value for Motor Nominal Current Range: Varies
10 Set a value for Minimum frequency Range: 0.00-50.00
11 Set a value for Maximum frequency Range: 0.00-320.00
After these selections, the Start-up wizard is completed. To start the Start-up wizard again,
you have 2 alternatives. Go to the parameter P6.5.1 Restore Factory Defaults or to the
parameter P1.19 Start-up Wizard. Then set the value to Activate.
1.4 DESCRIPTION OF THE APPLICATIONS
1.4.1 VACON HVAC APPLICATION
The Vacon HVAC drive contains a preloaded application for instant use.
It is possible to control the drive from the keypad, Fieldbus, PC or I/O terminal.
QUICK STARTUP GUIDE VACON · 13
24-HOUR SUPPORT [phone] · EMAIL: [email protected] 1

+
-
1
6
2
3
4
5
18
19
30
12
7
13
8
9
10
14
15
16
11
17
A
B
mA
AO1-/GND
+24 V
in
24 V
out
GND
GND
DI1
DI2
DI3
DI4
DI5
DI6
CM
CM
RS485
RS485
Standard I/O board
Terminal Signal Description
+10 V
ref
AI1+
AI1-
AI2+
AI2-
24 V
out
Reference output
24 V aux. voltage
I/O ground
Digital input 1
Digital input 2
Digital input 3
Digital input 4
Digital input 5
Digital input 6
Common A for DIN1-DIN6 **)
Common A for DIN1-DIN6 **)
24 V aux. voltage
I/O ground
Analogue signal (+output)
Analogue output common
Output
frequency
Serial bus, negative
Serial bus, positive
Fault
AO1+
Voltage
Current
Start REV
Fault reset
Preset freq select 1
Preset freq select 2
Start FWD
Reference
potentiometer
1-10kΩ
2-wire
transmitter
Remote
reference
4-20mA/2-10V
(programmable)
Analogue input,
voltage or current *)
Analogue input
common (current)
Analogue input,
voltage or current *)
Analogue input
common (current)
24 V auxiliary input voltage
To Relay board 1 or 2
Fig. 4: The control connections example for the standard I/O board
* = You can use DIP switches to select these. See Vacon 100 Installation Manual, Wall-
mounted Drives.
** = You can isolate the digital inputs from the ground with a DIP switch.
VACON · 14 QUICK STARTUP GUIDE
1 TEL. [phone] · FAX [phone]

21
22
23
24
25
26
32
33
RUN RUN
FAULT
READY
Relay output 1
Relay output 2
Relay output 3
From Standard I/O board
Terminal Signal
Default
Relay board 1
From term.
#6 or 12
From term.
#13
RO1/1 NC
RO1/2 CM
RO1/3 NO
RO2/1 NC
RO2/2 CM
RO2/3 NO
RO3/1 CM
RO3/2 NO
Fig. 5: The control connection example for the relay board 1
NOTE!
Not available for Vacon 100 X.
TI1+
TI1-
21
22
23
24
25
26
28
29
RUN RUN
FAULT
Relay output 1
Relay output 2
From Standard I/O board
Terminal Signal
Default
Relay board 2
From term.
#12
From term.
#13
Thermistor input
RO1/1 NC
RO1/2 CM
RO1/3 NO
RO2/1 NC
RO2/2 CM
RO2/3 NO
Fig. 6: The control connection example for the relay board 2
NOTE!
The only option for Vacon 100 X.
You can also isolate the digital inputs (terminals 8-10 and 14-16) on the standard I/O board
from ground. To do this, set the dip switch on the control board to position OFF. See the
figure below to find the switches and to make applicable selections for your requirements.
NOTE!
For the DIP switch configurations in Vacon 100 X, see the Vacon 100 X Installation
manual.
QUICK STARTUP GUIDE VACON · 15
24-HOUR SUPPORT [phone] · EMAIL: [email protected] 1

Digital inputs
Floating
Connected to GND
(Default!)
Fig. 7: The DIP switch
VACON · 16 QUICK STARTUP GUIDE
1 TEL. [phone] · FAX [phone]

Table 2: Quick Setup parameter group
Index Parameter Min Max Unit Default ID Description
P1.1 Motor Nominal Volt-
age Varies Varies V Varies 110
Find this value Unon
the nameplate of the
motor.
See P3.1.1.1.
P1.2 Motor Nominal Fre-
quency 8.0 320.0 Hz 50 111
Find this value fnon
the nameplate of the
motor.
See P3.1.1.2.
P1.3 Motor Nominal
Speed 24 19200 rpm Varies 112 Find this value nnon
the nameplate of the
motor.
P1.4 Motor Nominal Cur-
rent Varies Varies A Varies 113 Find this value Inon
the nameplate of the
motor.
P1.5 Motor Cos Phi 0.30 1.00 Varies 120 Find this value on the nameplate of the
motor.
P1.6 Motor nominal power Varies Varies kW Varies 116 Find this value nnon the nameplate of the
motor.
P1.7 Motor Current Limit Varies Varies A Varies 107 The maximum motor current from the AC
drive.
P1.8 Minimum Frequency 0.00 P1.9 Hz Varies 101 The minimum fre- quency reference that
is acceptable.
P1.9 Maximum Frequency P1.8 320.00 Hz 50.00 102 The maximum fre- quency reference that
is acceptable.
P1.10 I/O Control Refer-
ence A Selection 1 8 6 117
The selection of the
frequency reference
source when the con-
trol place is I/O A.
See P3.3.3 for selec-
tions.
P1.11 Preset frequency 1 P3.3.1 300.00 Hz 10.00 105
Select with the digital
input: Preset frequency
selection 0 (P3.5.1.15)
(Default = Digital Input
4)
QUICK STARTUP GUIDE VACON · 17
24-HOUR SUPPORT [phone] · EMAIL: [email protected] 1

Table 2: Quick Setup parameter group
Index Parameter Min Max Unit Default ID Description
P1.12 Preset frequency 2 P3.3.1 300.00 Hz 15.00 106
Select with the digital
input: Preset frequency
selection 1 (P3.5.1.16)
(Default = Digital Input
5)
P1.13 Acceleration Time 1 0.1 3000.0 s 20.0 103
Gives the quantity of
time that is necessary
for the output fre-
quency to increase
from zero frequency to
the maximum fre-
quency.
P1.14 Deceleration Time 1 0.1 3000.0 s 20.0 104
Gives the quantity of
time that is necessary
for the output fre-
quency to decrease
from the maximum
frequency to zero fre-
quency.
P1.15 Remote Control
Place 1 2 1 172
The selection of the
remote control place
(start/stop).
0 = I/O control
1 = Fieldbus control
P1.16 Automatic Reset 0 1 0 731 0 = Disabled
1 = Enabled
P1.17 Thermistor Fault 0 3 0 732
0 = No action
1 = Alarm
2 = Fault (Stop accord-
ing to stop mode)
3 = Fault (Stop by
coasting)
P1.18 PID Mini-Wizard * 0 1 0 1803 0 = Inactive
1 = Activate
See
P1.19 Multi-pump Wizard * 0 1 0
0 = Inactive
1 = Activate
See Chapter 2.2 Multi-
pump mini-wizard.
VACON · 18 QUICK STARTUP GUIDE
1 TEL. [phone] · FAX [phone]

Table 2: Quick Setup parameter group
Index Parameter Min Max Unit Default ID Description
P1.20 Startup Wizard ** 0 1 0 1171
0 = Inactive
1 = Activate
See Chapter 1.3 First
start-up.
P1.21 Fire Mode Wizard ** 0 1 0 1672 0 = Inactive
1 = Activate
* = The parameter is only visible on the graphical keypad.
** = The parameter is only visible on the graphical and the text keypad.
QUICK STARTUP GUIDE VACON · 19
24-HOUR SUPPORT [phone] · EMAIL: [email protected] 1

2 WIZARDS
2.1 PID MINI-WIZARD
The application wizard helps you to set the basic parameters that are related to the
application.
To start the PID mini-wizard, set the value Activate to parameter P1.17 PID Mini-Wizard in the
Quick Setup menu.
The default settings tell you to use the PID controller in the one feedback / one setpoint
mode. The default control place is I/O A, and the default process unit is %.
1Make selections for Process unit (P3.12.1.4) More than 1 selection.
If your selection is other than %, you see the next questions. If your selection is %, the wizard
goes directly to question 5.
2Set a value for Process Unit Min (P3.12.1.5) The range depends on the selection in ques-
tion 1.
3Set a value for Process Unit Max (P3.12.1.6) The range depends on the selection in ques-
tion 1.
4Set a value for Process Unit Decimals (P3.12.1.7) Range: 0-4
5Set a value for Feedback 1 Source Selection
(P3.12.3.3) See Table 34 Feedback settings .
If you make a selection of an analogue input signal, you see the question 6. With other
selections, the wizard goes to question 7.
6
Set the signal range of the analogue input
0 = 0-10V / 0…20mA
1 = 2-10V / 4…20mA
See Table 15 Analogue input settings.
7
Set a value for Error Inversion (P3.12.1.8)
0 = Normal
1 = Inverted
8Set a value for Setpoint Source Selection (P3.12.2.4) See Table 33 Setpoint settings.
If you make a selection of an analogue input signal, you see the question 9. With other
selections, the wizard goes to question 11.
If you set Keypad Setpoint 1 or Keypad Setpoint 2 for the value, the wizard goes directly to
question 10.
VACON · 20 WIZARDS
2 TEL. [phone] · FAX [phone]