Danfoss VLT HVAC Drive FC 100 Series Design Manual Download

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Introduction to VLT® HVAC D...

VLT

HVAC Drive Design Guide

2-46

MG11BB22 - VLT

is a registered Danfoss trademark

Summary of Contents for VLT HVAC Drive FC 100 Series

Page 1: ...Immunity Requirements 2 37 2 10 Galvanic Isolation PELV 2 39 2 10 1 PELV Protective Extra Low Voltage 2 39 2 11 Ground Leakage Current 2 39 2 12 Brake Function 2 40 2 12 4 Brake Resistor Cabling 2 42...

Page 2: ...isc Connections 5 32 5 6 Safety 5 34 5 6 1 High Voltage Test 5 34 5 6 2 Safety Ground Connection 5 34 5 7 EMC correct Installation 5 34 5 7 1 Electrical Installation EMC Precautions 5 34 5 7 2 Use of...

Page 3: ...5 1 Writing a Parameter Value 7 9 7 5 2 Reading a Parameter Value 7 10 7 6 Modbus RTU Overview 7 10 7 6 1 Assumptions 7 10 7 6 2 What the User Should Already Know 7 10 7 6 3 Modbus RTU Overview 7 10...

Page 4: ...ol Profile 7 19 8 General Specifications and Troubleshooting 8 1 8 1 Line Power Supply Tables 8 1 8 2 General Specifications 8 17 8 3 Efficiency 8 21 8 4 Acoustic noise 8 21 8 5 Peak voltage on motor...

Page 5: ...rticular 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...

Page 6: ...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 Magn...

Page 7: ...otor 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...

Page 8: ...tant torque characteristics used for screw and scroll refrigeration compressors Digital Inputs The digital inputs can be used for controlling various functions of the Adjustable frequency drive Digita...

Page 9: ...atically Trip may not be used for personal safety Trip Locked A state entered in fault situations when the Adjustable frequency drive is protecting itself and requiring physical intervention e g if th...

Page 10: ...How to Read this Design Gui VLT HVAC Drive Design Guide 1 6 MG11BB22 VLT is a registered Danfoss trademark 1 1...

Page 11: ...er supply has been disconnected and that the necessary time has passed before removing motor and line power plugs 7 Please note that the Adjustable frequency drive has more voltage inputs than L1 L2 a...

Page 12: ...provide information on safety aspects relating to the Adjustable frequency drive The low voltage directive 2006 95 EC Adjustable frequency drives must be CE labeled in accordance with the Low voltage...

Page 13: ...lies to the EMC directive provided that the instructions for EMC correct installation and filtering are followed On this basis a declaration of conformity in accordance with the EMC directive is issue...

Page 14: ...r corrosion of metal parts Excessive dust particle levels are often found on instal lation cabinets and existing electrical installations One indicator of aggressive airborne gases is the blackening o...

Page 15: ...Diagram showing all electrical terminals Terminal 37 present for units with safe stop function only Introduction to VLT HVAC D VLT HVAC Drive Design Guide MG11BB22 VLT is a registered Danfoss tradema...

Page 16: ...Figure 2 2 Introduction to VLT HVAC D VLT HVAC Drive Design Guide 2 6 MG11BB22 VLT is a registered Danfoss trademark 2 2...

Page 17: ...jumper inFigure 2 4 2 Connect terminal 37 to 24 V DC by a short circuit protected cable The 24 V DC voltage supply must be interruptible by an EN954 1 category 3 circuit interrupt device If the inter...

Page 18: ...Why use a Adjustable Frequency Drive for Controlling Fans and Pumps A Adjustable frequency drive takes advantage of the fact that centrifugal fans and pumps follow the laws of propor tionality for suc...

Page 19: ...a flow corresponding to 100 a few days each year while the average is below 80 of the rated flow for the remainder of the year the amount of energy saved is even greater than 50 The laws of proportio...

Page 20: ...the Adjustable frequency drive to function as a Building Management System BMS The graph Figure 2 10 shows typical energy savings obtainable with three well known solutions when fan volume is reduced...

Page 21: ...s offer a 40 reduction but are expensive to install The Danfoss Adjustable frequency drive solution reduces energy consumption with more than 50 and is easy to install Introduction to VLT HVAC D VLT H...

Page 22: ...lling the flow or pressure of a system improved control is obtained A Adjustable frequency drive can vary the speed of the fan or pump thereby obtaining variable control of flow and pressure Furthermo...

Page 23: ...uency Drive The figure shows a fan system made in the traditional way D D C Direct Digital Control E M S Energy Management system V A V Variable Air Volume Sensor P Pressure Sensor T Temperature Table...

Page 24: ...sk for The Drive to Improving Constant Air Volume Ventilation Systems MN 60 B1 02 Cooling Tower Fan Ask for The Drive to Improving fan control on cooling towers MN 60 C1 02 Condenser pumps Ask for The...

Page 25: ...tallation Instead of creating an artificial pressure drop or causing a decrease in fan efficiency the Adjustable frequency drive decreases the speed of the fan to provide the flow and pressure require...

Page 26: ...side temperature varies and the number of people in the controlled zone changes different cooling requirements arise As the temperature decreases below the setpoint the supply fan can decrease its spe...

Page 27: ...he condenser water temperature The adjustable frequency drives can also be used to turn the fan on and off as needed Several features of the Danfoss HVAC dedicated Adjustable frequency drive the HVAC...

Page 28: ...Water Inlet Water Outlet CHILLER Temperature Sensor BASIN Conderser Water pump Supply 130BB453 10 Figure 2 17 Introduction to VLT HVAC D VLT HVAC Drive Design Guide 2 18 MG11BB22 VLT is a registered D...

Page 29: ...drives can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump impeller Using a Adjustable frequency drive instead of a throttling valve simp...

Page 30: ...es Two control methods are common The first method uses a flow meter Because the desired flow rate is known and constant a flow meter installed at the discharge of each chiller can be used to control...

Page 31: ...cy converter Frequency converter CHILLER CHILLER Flowmeter Flowmeter F F 130BB456 10 Figure 2 19 Introduction to VLT HVAC D VLT HVAC Drive Design Guide MG11BB22 VLT is a registered Danfoss trademark 2...

Page 32: ...vings and control potential is realized by adding adjustable frequency drives With the proper sensor location the addition of adjustable frequency drives allows the pumps to vary their speed to follow...

Page 33: ...n the motor phases In 1 00 Configuration Mode it can be selected if open loop or closed loop is to be used 2 8 2 Control Structure Open loop 130BB153 10 100 0 100 100 P 3 13 Reference site Local refer...

Page 34: ...and 0 43 Reset Key on LCP it is possible to start and stop the Adjustable frequency drive byLCP using the Hand ON and Off keys Alarms can be reset via the RESET key After pressing the Hand ON key the...

Page 35: ...measures the actual static pressure in the pipe and supplies this to the Adjustable frequency drive as a feedback signal If the feedback signal is greater than the setpoint reference the Adjustable fr...

Page 36: ...n 13 is selected the setpoint feedback pair with the largest difference controls the speed of the adjustable frequency drive Multi Setpoint Maximum 14 attempts to keep all zones at or below their resp...

Page 37: ...nal to provide flow feedback Since the square root of pressure is proportional to flow the square root of the pressure signal yields a value proportional to the flow This is shown in Figure 2 26 Figur...

Page 38: ...andling Details for Open loop and Closed loop Operation Figure 2 27 Block Diagram Showing Remote Reference Introduction to VLT HVAC D VLT HVAC Drive Design Guide 2 28 MG11BB22 VLT is a registered Danf...

Page 39: ...ing 3 14 Preset Relative Reference The scaled reference is calculated as follows Reference X X Y 100 Where X is the external reference the preset reference or the sum of these and Y is 3 14 Preset Rel...

Page 40: ...Figure 2 29 Introduction to VLT HVAC D VLT HVAC Drive Design Guide 2 30 MG11BB22 VLT is a registered Danfoss trademark 2 2...

Page 41: ...limits for the motor speed 4 12 4 14 4 19 10 Hz Motor min speed 50 Hz Motor max speed 50 Hz Drive max output frequency Switch from open loop to closed loop 1 00 Closed loop 3 4 Configure the feedback...

Page 42: ...9 as required 2 9 General aspects of EMC 2 9 1 General Aspects of EMC Emissions Electrical interference is usually conducted at frequencies in the range 150 kHz to 30 MHz Airborne interference from th...

Page 43: ...ustable frequency drives EN IEC 61800 3 2004 the EMC requirements depend on the intended use of the Adjustable frequency drive Four categories are defined in the EMC product standard The definitions o...

Page 44: ...imits given in EN 55011 First environment home and office EN IEC 61000 6 3 Emission standard for residential commercial and light industrial environments Class B Second environment industrial environm...

Page 45: ...hp 11 90kW 380 480 V T4 82 ft 25 m No No No No 150 1350 hp 110 1000 kW 380 480 V T4 492 ft 150 m No No No No 15 125 hp 11 90 kW 525 690 V T7 Yes No No No No 60 1900 hp 45 1400 kW 525 690 V T7 492 ft...

Page 46: ...5 Harmonics Emission Requirements Equipment connected to the public supply network Options Definition 1 IEC EN 61000 3 2 Class A for 3 phase balanced equipment for professional equipment only up to 1...

Page 47: ...al phenomena the following immunity tests have been made on a system consisting of a Adjustable frequency drive with options if relevant a shielded control cable and a control box with potenti ometer...

Page 48: ...CM 4kV 2 1 10VRMS Control wires 2kV CM 2kV 2 1 10VRMS Standard bus 2kV CM 2kV 2 1 10VRMS Relay wires 2kV CM 2kV 2 1 10VRMS Application and serial communication options 2kV CM 2kV 2 1 10VRMS LCP cable...

Page 49: ...056 10 1 3 2 5 4 6 b a M Figure 2 32 Galvanic Isolation The functional galvanic isolation a and b on drawing is for the 24V backup option and for the RS 485 standard bus interface WARNING Installation...

Page 50: ...with the following Use RCDs of type B only which are capable of detecting AC and DC currents Use RCDs with an inrush delay to prevent faults due to transient ground currents Dimension RCDs according t...

Page 51: ...function of the Adjustable frequency drive is settled in three areas of line power supply Size Brake active Warning before cut out Cut out trip 3 x 200 240V 390V UDC 405V 410V 3 x 380 480V 778V 810V 8...

Page 52: ...tor when 1 10 Motor Construction is set to 1 PM non salient SPM 2 12 4 Brake Resistor Cabling EMC twisted cables shielding To reduce the electrical noise from the wires between the brake resistor and...

Page 53: ...he load If the overload is excessive a current may occur that makes the Adjustable frequency drive cut out after approx 5 10 sec Operation within the torque limit is limited in time 0 60 sec in 14 25...

Page 54: ...r supply Example The Adjustable frequency drive trips when the motor temperature is too high Parameter set up Set 1 90 Motor Thermal Protection to Thermistor Trip 2 Set 1 93 Thermistor Source to Analo...

Page 55: ...nd application for becoming overloaded ETR is activated in 1 90 Motor Thermal Protection and is controlled in 4 16 Torque Limit Motor Mode The time before the torque limit warning trips the Adjustable...

Page 56: ...Introduction to VLT HVAC D VLT HVAC Drive Design Guide 2 46 MG11BB22 VLT is a registered Danfoss trademark 2 2...

Page 57: ...relieve the cable by the enclosed cable strips Fit the cradle Fit the LCP LCP Frame A B D 130BA707 10 X X X N 1 1 0 0 3 x 3 8 0 4 8 0 V 5 0 6 0 H z 1 4 9 A O U T 3 x 0 U i n 0 1 0 0 0 H z 1 6 0 A 1 1...

Page 58: ...OG OUT ANALOG IN CPU CAN BUS CPU Control card FC 100 200 300 General Purpose I O option MCB 101 PLC PNP PLC NPN Figure 3 4 Principle Diagram 3 1 3 Digital Inputs Terminal X30 1 4 Parameters for set up...

Page 59: ...A709 10 1 LABEL DISMOUNT RELAY CARD TO ACCESS RS485 TERMINATION S801 OR CURRENT VOLTAGE SWITCHES S201 S202 Rem ove jumper to activate Sa fe Stop 12 13 18 19 27 29 33 32 20 39 42 50 53 54 61 68 C A U T...

Page 60: ...he mounting instructions at the beginning of the section Options and Accessories The power to the live part connections on relay terminals must be disconnected Do not mix live parts with control signa...

Page 61: ...tion Input voltage range 24V DC 15 max 37 V in 10 sec Max input current 2 2A Average input current for the Adjustable frequency drive 0 9A Max cable length 246 ft 75m Input capacitance load 10uF Power...

Page 62: ...s Support extended PID controllers with I Os for setpoint inputs transmitter sensor inputs and outputs for servos Figure 3 10 Principle diagram for Analog I O mounted in Adjustable frequency drive Ana...

Page 63: ...ded non twisted wires Analog outputs terminal X42 7 12 Parameter group for read out and write 18 3 See also VLT HVAC Drive Programming Guide MG11XYY Parameter groups for set up 26 4 26 5 and 26 6 See...

Page 64: ...Alarm MS 220 DA 11 10 20 28 VDC 10 mA 12 20 28 VDC 60 mA com ZIEHL X44 12 13 18 19 27 29 32 33 20 37 3 NC 4 NC 5 NC 6 NC 7 NC 8 NC 9 NC 10 11 NC 12 1 T1 2 T2 TP TP PTC M3 130BA638 10 DO Motor protect...

Page 65: ...gree 2 Measurement isolation voltage Vbis 690V Reliable galvanic isolation until Vi 500V Perm ambient temperature 4 F 20 C 140 F 60 C EN 60068 2 1 Dry heat Moisture 5 95 no condensation permissible EM...

Page 66: ...alarm occurs the relays or digital outputs can be programmed to be active high by selecting 21 Thermal Warning in parameter group 5 A fault condition has a common warning alarm number associated with...

Page 67: ...in the rectifier cabinet Input voltage range Tap to select 380 440 V 400V 441 490 V 460V 491 550 V 525V 551 625 V 575V 626 660 V 660V 661 690 V 690V Table 3 11 Transformer Tap Set up NAMUR Terminals...

Page 68: ...for the fused protected terminals will be provided from the load side of any supplied contactor circuit breaker or disconnect switch In applications where the motor is used as a brake energy is genera...

Page 69: ...ordering number is 130B1129 Table 3 13 3 1 13 IP21 IP41 TYPE 1 Enclosure Kit IP 21 IP 41 top TYPE 1 is an optional enclosure element available for IP20 Compact units enclosure size A2 A3 B3 B4 and C3...

Page 70: ...Size A3 3xM25 and 3xM32 A2 Enclosure A3 Enclosure Table 3 14 Dimensions Enclosure type Height in mm A Width in mm B Depth in mm C A2 14 6 372 3 5 90 8 1 205 A3 14 6 372 5 1 130 8 1 205 B3 18 7 475 6...

Page 71: ...ted to the top cover A E F D C B A VLT Automation Drive 130BT620 12 130BT621 12 D C VLT AutomationDrive A G B3 Enclosure B4 C3 C4 Enclosure Table 3 17 NOTE Side by side installation is not possible wh...

Page 72: ...du dt ratio is reduced in comparison with the installation without filter Sine wave filters Sine wave filters are designed to allow only low frequencies to pass High frequencies are consequently shun...

Page 73: ...application and generate the type code string The drive configurator will automatically generate an eight digit sales number to be delivered to your local sales office Furthermore you can establish a...

Page 74: ...nel NLCP X No Local Control Panel Coating PCB 20 X No coated PCB C Coated PCB Line power option 21 X No line power disconnect switch and load sharing 1 With line power disconnect switch IP55 only 8 Li...

Page 75: ...e IGBT R Regeneration terminals E frames only Display 19 G Graphical Local Control Panel LCP N Numerical Local Control Panel LCP X No Local Control Panel D frames IP00 and IP 21 only Coating PCB 20 C...

Page 76: ...outlet R5X IP54 NEMA12 with space heater thermostat light IEC 230V outlet R2A IP21 NEMA1 with space heater thermostat light NAM 115V outlet R5A IP54 NEMA12 with space heater thermostat light NAM 115V...

Page 77: ...Line power circuit breaker load sharing terminals fuses 2 A options 29 30 AX No options A0 MCA 101 Profibus DP V1 A4 MCA 104 DeviceNet AG MCA 108 Lonworks AJ MCA 109 BACnet Gateway AL MCA 120 Profine...

Page 78: ...p entry kit for Profibus connection D E enclosures 176F1742 Type Description Ordering no Miscellaneous hardware I Terminal blocks Screw terminal blocks for replacing spring loaded terminals 1 x 10 pin...

Page 79: ...Input Output option MCB 105 Relay option MCB 109 Analog I O option and battery backup for real time clock 130B1243 MCB 112 ATEX PTC 130B1137 MCB 114 Sensor input uncoated 130B1172 Sensor input coated...

Page 80: ...iscellaneous hardware II Accessory bag A2 Accessory bag frame size A2 130B1022 Accessory bag A3 Accessory bag frame size A3 130B1022 Accessory bag A5 Accessory bag frame size A5 130B1023 Accessory bag...

Page 81: ...IP00 Top Bottom Covers D3 Frames 176F1781 177R0076 Rittal Enclosures D4 Frames 176F1782 E2 Frame 176F1783 IP00 Motor Cable Clamp D3 Frame 176F1774 175R1109 D4 Frame 176F1746 E2 Frame 176F1745 IP00 Te...

Page 82: ...P400 740 450 2x175G6688 2x175G6691 P450 Table 4 9 380 415 V AC 60 Hz IAHF N A Typical Motor Used HP Danfoss Ordering Number Adjustable Frequency Drive Size AHF 005 AHF 010 10 1 1 4 130B2540 130B2541...

Page 83: ...ing the Adjustable frequency drive and filter is pre calculated based on 400V 480V and on a typical motor load 4 pole and 110 torque 500 525 V AC 50 Hz IAHF N A Typical Motor Used kW Danfoss Ordering...

Page 84: ...30B2299 P132 217 160 130B2335 130B2300 P160 288 200 250 2x130B2333 130B2301 P200 P250 324 315 130B2334 130B2335 130B2302 P315 397 400 130B2334 130B2335 130B2299 130B2300 P400 434 450 2x130B2335 2x130B...

Page 85: ...0 130B2310 130B2284 115 P30K P55K P75K 3 100 130B2310 130B2284 115 P37K P75K P90K 3 100 130B2311 130B2285 180 P45K P90K P110 3 100 130B2311 130B2285 180 P110 P132 3 100 130B2312 130B2286 260 P132 P160...

Page 86: ...115 P75K P90K 2 100 130B2345 130B2325 115 P90K P110 2 100 130B2346 130B2326 165 P132 2 100 130B2346 130B2326 165 P160 2 100 130B2347 130B2327 260 P200 2 100 130B2347 130B2327 260 P250 2 100 130B2348...

Page 87: ...K P90K 3 100 130B2400 130B2389 182 P110 P110 3 100 130B2401 130B2390 280 P132 P132 3 100 130B2401 130B2390 280 P160 P160 3 100 130B2402 130B2391 400 P200 P200 3 100 130B2402 130B2391 400 P250 P250 3 1...

Page 88: ...130B2416 75 P55K P75K 3 100 130B2426 130B2417 115 P75K P90K 3 100 130B2426 130B2417 115 P90K P110 3 100 130B2427 130B2418 6 5 165 P132 2 100 130B2427 130B2418 6 5 165 P160 2 100 130B2428 130B2419 260...

Page 89: ...10 130BA814 10 130BA815 10 130BA828 10 130BA829 10 IP20 21 IP20 21 IP21 55 66 IP21 55 66 IP20 21 IP20 21 a e f 130BA715 11 Top and bottom mounting holes B4 C3 C4 only Accessory bags containing necess...

Page 90: ...205 9 1 231 12 1 308 14 6 370 12 1 308 14 6 370 Backplate B 3 5 90 3 5 90 5 1 130 5 1 130 7 87 200 9 5 242 9 5 242 9 5 242 6 5 165 9 1 231 12 1 308 14 6 370 12 1 308 14 6 370 Distance between mount ho...

Page 91: ...nting holes a c b j k i e h f 130BA878 10 g d b c a 130BA881 10 Lifting eye 130BA879 10 c b a IP21 54 IP21 54 Enclosure F1 130BB003 13 578 22 8 776 30 6 Enclosure F2 130BB005 13 624 24 6 579 22 8 578...

Page 92: ...2281 89 8 2281 89 8 2281 89 8 2281 Width Backplate B 16 5 420 16 5 420 16 1 408 16 1 408 23 6 600 23 585 55 1 1400 70 8 1800 78 7 2000 94 5 2400 Depth C 15 380 15 380 14 8 375 14 8 375 19 4 494 19 4 4...

Page 93: ...RNI NG Risk of Electric Shock Dual supply Disconnect mains and loadsharing before service 99 95 61 68 39 50 53 54 5 42 03 02 01 06 05 04 130BT348 10 Risk of Electric Shock Dual supply Disconn ect main...

Page 94: ...Enclosure B4 C1 C2 C3 C4 a b in mm 7 87 200 7 87 200 8 86 225 7 87 200 8 86 225 Table 5 6 Air Passage for Different Enclosures 1 Drill holes in accordance with the measurements given 2 Provide screws...

Page 95: ...Maximum diameter for bar is 1 in 2 5 cm The angle from the top of the drive to the lifting cable should be 60 C or greater 130BA832 11 Figure 5 3 Recommended Lifting Method Frame Size F1 460V 600 900...

Page 96: ...ment damage especially when installing large units CAUTION The Adjustable frequency drive is cooled by means of air circulation To protect the unit from overheating it must be ensured that the ambient...

Page 97: ...3 0 6 B2 15 22 30 22 30 11 30 2 5 4 52 2 5 4 52 3 7 3 7 2 5 3 7 3 3 0 6 0 6 B3 5 5 11 11 18 5 11 18 5 1 8 1 8 1 8 1 8 3 0 6 B4 15 18 5 22 37 22 37 4 5 4 5 4 5 4 5 3 0 6 C1 18 5 30 37 55 37 55 10 10 1...

Page 98: ...and Control Cables Figure 5 7 Diagram Showing all Electrical Terminals Terminal 37 Present for Units with Safe Stop Function only How to Install VLT HVAC Drive Design Guide 5 10 MG11BB22 VLT is a reg...

Page 99: ...pecifications Keep the motor cable as short as possible to reduce the noise level and leakage currents Connect the motor cable shield to both the de coupling plate of the Adjustable frequency drive an...

Page 100: ...conductors Aluminum conductors are not recommended Terminals can accept aluminum conductors but the conductor surface has to be clean and the oxidation must be removed and sealed by neutral acid free...

Page 101: ...le entry must be supported around the knockout you intend to remove 3 The knockout can now be removed with a strong mandrel and a hammer 4 Remove burrs from the hole 5 Mount Cable entry on Adjustable...

Page 102: ...1 485 460 0 18 110 655 9 25 825 994 3 39 146 216 5 8 524 36 2 1 425 281 8 11 096 1 130BA841 12 535 0 Figure 5 19 Frame Size F2 1 130BA843 12 37 7 1 485 535 0 21 063 35 5 1 398 36 2 1 425 533 0 20 984...

Page 103: ...ional regulations NOTE The recommendations given do not cover branch circuit protection for UL Short circuit protection Danfoss recommends using the fuses circuit breakers listed in and to protect ser...

Page 104: ...00 type gG 7K5 35A1 380 500 type gG 11K 15K 63A1 380 500 type gG 18K 63A1 380 500 type gG 22K 63A1 380 500 type gG 30K 80A1 380 500 type gG 37K 100A1 380 500 type gG 45K 125A1 380 500 type gG 55K 160A...

Page 105: ...erraz Shawmut Ferraz Shawmut 380 480V 525 600V kW Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1 K37 1K1 KTS R6 JKS 6 JJS 6 5017906 006 KLS R6 ATM R6 A6K 6R 1K5 2K2 KTS R10 JKS 10 JJS 10 50...

Page 106: ...cy drives A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240V adjustable frequency drives A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240V adjustable frequency drives How to Install...

Page 107: ...0 P400 170M6 013 900A 700V 6 9URD33D08A0 900 20 630 32 900 P450 170M6 013 900A 700V 6 9URD33D08A0 900 20 630 32 900 Table 5 15 Frame Size E Line Fuses 380 480V Size Type Bussmann PN Rating Siba Intern...

Page 108: ...ble 5 19 Frame Size E 525 690V Size Type Bussmann PN Rating Siba Internal Bussmann Option P710 170M7081 1600A 700V 20 695 32 1600 170M7082 P800 170M7081 1600A 700V 20 695 32 1600 170M7082 P900 170M708...

Page 109: ...20 A 600 V Any listed Class J Dual Element Time Delay 20 A P500 P1M0 380 480 V 10 16 A LPJ 25 SP or SPI 25 A 600 V Any listed Class J Dual Element Time Delay 25 A Size Type Bussmann PN Rating Alterna...

Page 110: ...trip isolation of 0 34 0 39 in 9 10 mm 2 Insert a screw driver1 in the rectangular hole 3 Insert the cable in the adjacent circular hole 4 Remove the screwdriver The cable is now mounted to the termin...

Page 111: ...djustable frequency drive 2 Connect terminals 18 and 27 to 24 V terminal 12 13 Default settings 18 latched start 27 stop inverse Figure 5 24 Terminal 37 available with Safe Stop Function only How to I...

Page 112: ...to break the shield or insert a 100 nF capacitor between shield and chassis The digital and analog in and outputs must be connected separately to the Adjustable frequency drive common inputs terminal...

Page 113: ...It is recommended to only change switch position at power off 130BT310 10 1 2 N O VLT BUS TER OFF ON A53 A54 U I U I Figure 5 27 5 3 Final Set Up and Test To test the set up and ensure that the Adjus...

Page 114: ...exit the AMA state Unsuccessful AMA 1 The Adjustable frequency drive enters into alarm mode A description of the alarm can be found in the Troubleshooting section 2 Report Value in the Alarm Log shows...

Page 115: ...338 10 OFF Figure 5 29 Frame size Type Terminal connections A5 Kraus Naimer KG20A T303 L1 T1 L2 T2 L3 T3 31 32 43 44 130BB182 10 B1 Kraus Naimer KG64 T303 B2 Kraus Naimer KG64 T303 C1 37 kW Kraus Naim...

Page 116: ...monitor the temperature of an externally connected brake resistor If the input between 104 and 106 is established the Adjustable frequency drive will trip on warning alarm 27 Brake IGBT If the connect...

Page 117: ...ormal open 240V AC Terminal 03 normal closed 240V AC Relay 2 Terminal 04 common Terminal 05 normal open 400V AC Terminal 06 normal closed 240V AC Relay 1 and relay 2 are programmed in 5 40 Function Re...

Page 118: ...y different because small motors relatively high ohmic resistance in the stator calls for a higher voltage at start and at low RPM values The electronic thermal relay ETR of the Adjustable frequency d...

Page 119: ...er Nominal AC Line Voltage Motor Insulation UN 420 V Standard ULL 1300V 420V UN 500 V Reinforced ULL 1600V 500V UN 600 V Reinforced ULL 1800V 600V UN 690 V Reinforced ULL 2000V Table 5 40 5 4 12 Motor...

Page 120: ...y drive is connected to a master use parallel connections 130BA060 11 68 69 68 69 68 69 RS 485 RS 232 USB Figure 5 34 In order to avoid potential equalizing currents in the shield ground the cable shi...

Page 121: ...com port 2 Open PC based Configuration Tool MCT 10 Set up Software 3 Choose Open Stored files will be shown 4 Open the appropriate file 5 Choose Write to drive All parameter settings are now transfer...

Page 122: ...opper aluminum steel or lead There are no special requirements for the line cable Installations using rigid metal conduits are not required to contain shielded cable but the motor cable must be instal...

Page 123: ...outgoing radiation of electric noise depends on the transfer impedance ZT The shield of a cable is normally designed to reduce the transfer of electric noise however a shield with a lower transfer im...

Page 124: ...rn a Aluminum clad with copper wire b Twisted copper wire or armored steel wire cable c Single layer braided copper wire with varying percentage shield coverage This is the typical Danfoss reference c...

Page 125: ...e cross section 0 025 in2 16 mm2 d For 50 60 Hz ground loops If very long control cables are used 50 60 Hz ground loops may occur Solve this problem by connecting one end of the shield to ground via a...

Page 126: ...How to Install VLT HVAC Drive Design Guide 5 38 MG11BB22 VLT is a registered Danfoss trademark 5 5...

Page 127: ...e default Figure 6 1 Terminal 37 Available only with Safe Stop Function 6 1 2 Pulse Start Stop Terminal 18 start stop 5 10 Terminal 18 Digital Input 9 Latched start Terminal 27 Stop 5 12 Terminal 27 D...

Page 128: ...equency drive AMA can be carried out on up to one oversize motor It is possible to carry out a reduced AMA test with a sine wave filter installed Avoid carrying out a complete AMA with a sine wave fil...

Page 129: ...it evaluates event 1 and only event 1 each scan interval Only when event 1 is evaluated TRUE the SLC executes action 1 and starts evaluating event 2 It is possible to program from 0 to 20 events and...

Page 130: ...nt 3 to Time Out 0 30 Set Event 4 in 13 51 SL Controller Event 4 to False 0 Set Action 1 in 13 52 SL Controller Action 1 to Select preset 0 10 Set Action 2 in 13 52 SL Controller Action 2 to Start Tim...

Page 131: ...alternation or an alternation event signal If the alternation event is selected the lead pump alternation takes place every time the event occurs Selections include whenever an alternation timer expir...

Page 132: ...ncludes Pumps Status is a readout of the status for the relays assigned to each pump The display shows pumps that are disabled off running on the Adjustable frequency drive or running on line power th...

Page 133: ...omes the lead pump K1 blocks for K2 via the mechanical interlock preventing line power from being connected to the output of the Adjustable frequency drive via K1 Auxiliary break contact on K1 prevent...

Page 134: ...igital Inputs parameter group 5 1 Variable speed pump lead Fixed speed pumps Start SYSTEM START STOP Ramps up if stopped and there is a demand Staging if stopped and there is a demand Lead Pump Start...

Page 135: ...op command or stays in operation if already running De staging if running Off Ramps down De staging Auto On Starts and stops according to commands sent via terminals or serial bus Staging De staging T...

Page 136: ...Application Examples VLT HVAC Drive Design Guide 6 10 MG11BB22 VLT is a registered Danfoss trademark 6 6...

Page 137: ...d potential throughout the network particularly in installations with long cables To prevent impedance mismatch always use the same type of cable throughout the entire network When connecting a motor...

Page 138: ...for overcoming modem turnaround delays 8 36 Maximum Response Delay Specify a maximum delay time between transmitting a request and receiving a response 8 37 Maximum Inter Char Delay Specify a maximum...

Page 139: ...A short format of 8 bytes for process data A long format of 16 bytes that also includes a parameter channel A format used for texts 7 2 1 FC with Modbus RTU The FC protocol provides access to the con...

Page 140: ...secured via a parity bit This bit is set at 1 when it reaches parity Parity is when there is an equal number of 1s in the 8 data bits and the parity bit in total A stop bit completes a character thus...

Page 141: ...uency drive address 1 31 2 Address format 1 126 Bit 7 1 address format 1 126 active Bit 0 6 Adjustable frequency drive address 1 126 Bit 0 6 0 Broadcast The slave returns the address byte unchanged to...

Page 142: ...ata block PKE IND 130BA270 10 ADR LGE STX PCD1 PCD2 BCC Ch1 Ch2 Chn Figure 7 9 7 4 7 The PKE Field The PKE field contains two sub fields Parameter command and response AK and parameter number PNU 15 1...

Page 143: ...e is no write access to the defined parameter 2 Data value exceeds the parameter s limits 3 The sub index used does not exit 4 The parameter is not the array type 5 The data type does not match the de...

Page 144: ...ers containing data type 9 text string 15 40 FC Type to 15 53 Power Card Serial Number contain data type 9 For example read the unit size and AC line voltage range in 15 40 FC Type When a text string...

Page 145: ...version index 0 0 00s conversion index 2 0ms conversion index 3 0 00ms conversion index 5 Conversion index Conversion factor 100 75 74 67 6 1000000 5 100000 4 10000 3 1000 2 100 1 10 0 1 1 0 1 2 0 01...

Page 146: ...erview Regardless of the type of physical communication networks the Modbus RTU Overview describes the process a controller uses to request access to another device This process includes how the Modbu...

Page 147: ...mits a range of control options including controlling the setpoint of the Adjustable frequency drive when its internal PI controller is used 7 7 Network Configuration 7 7 1 Adjustable Frequency Drive...

Page 148: ...cognize A master addresses a slave by placing the slave address in the address field of the message When the slave sends its response it places its own address in this address field to let the master...

Page 149: ...losed loop mode Adjustable frequency drive feedback signal Slave to master 65 Parameter write control master to slave Master to slave 0 Parameter changes are written to the RAM of the Adjustable frequ...

Page 150: ...h 399 04000 04990 400 parameter group parameters 400 through 499 49000 49990 4900 parameter group parameters 4900 through 4999 50000 Input data Adjustable frequency drive control word register CTW 500...

Page 151: ...le because it is not configured and is being asked to return register values 2 Illegal data address The data address received in the query is not an allowable address for the server or slave More spec...

Page 152: ...rs 20 characters 7 10 Examples The following examples illustrate various Modbus RTU commands If an error occurs please refer to the Exception Codes section 7 10 1 Read Coil Status 01 HEX Description T...

Page 153: ...on forces the same coil references in all attached slaves The query message specifies the coils 17 to 32 speed setpoint to be forced NOTE Coil addresses start at zero i e coil 17 is addressed as 16 Fi...

Page 154: ...sage specifies the register reference to be preset Register addresses start at zero i e register 1 is addressed as 0 Example Write to 1 00 Configuration Mode register 1000 Field Name Example HEX Slave...

Page 155: ...Ramp 03 Coasting No coasting 04 Quick stop Ramp 05 Hold output frequency use ramp 06 Ramp stop Start 07 No function Reset 08 No function Jog 09 Ramp 1 Ramp 2 10 Data invalid Data valid 11 No function...

Page 156: ...changing from logic 0 to logic 1 Bit 08 Jog Bit 08 1 The output frequency is determined by 3 19 Jog Speed RPM Bit 09 Selection of ramp 1 2 Bit 09 0 Ramp 1 is active 3 41 Ramp 1 Ramp Up Time to 3 42 Ra...

Page 157: ...ablish operation enter Reset Bit 04 No error error no trip Bit 04 0 The Adjustable frequency drive is not in fault mode Bit 04 1 The Adjustable frequency drive shows an error but does not trip Bit 05...

Page 158: ...4 Torque OK limit exceeded Bit 14 0 The motor current is lower than the torque limit selected in 4 18 Current Limit Bit 14 1 The torque limit in 4 18 Current Limit is exceeded Bit 15 Timer OK limit ex...

Page 159: ...scaled in the same way as the bus reference Actual output freq STW Slave master Speed ref CTW Master slave 16bit 130BA276 10 Figure 7 18 The reference and MAV are scaled as follows Reverse Forward Pa...

Page 160: ...RS 485 Installation and Set VLT HVAC Drive Design Guide 7 24 MG11BB22 VLT is a registered Danfoss trademark 7 7...

Page 161: ...5 10 6 12 5 16 7 Intermittent 3 x 200 240 V A 7 3 8 3 11 7 13 8 18 4 Continuous kVA 208 V AC kVA 2 38 2 70 3 82 4 50 6 00 Max cable size line power motor brake mm2 AWG 2 4 10 Max input current 130BA05...

Page 162: ...200 240 V A 22 0 28 0 42 0 54 0 68 0 80 0 104 0 130 0 154 0 Intermittent 3 x 200 240 V A 24 2 30 8 46 2 59 4 74 8 88 0 114 0 143 0 169 0 Max pre fuses 1 A 63 63 63 80 125 125 160 200 250 Environment...

Page 163: ...2 4 2 7 3 8 5 0 6 5 8 8 11 6 Max cable size line power motor brake mm 2 AWG 2 4 10 Max input current 130BA057 10 Continuous 3 x 380 440 V A 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermittent 3 x 380 440 V A 3...

Page 164: ...0 120 MCM250 With line power disconnect switch included 16 6 35 2 35 2 70 3 0 185 kcmil350 Max input current 130BA057 10 Continuous 3 x 380 439V A 22 29 34 40 55 66 82 96 133 161 Intermittent 3 x 380...

Page 165: ...7 7 0 10 5 12 7 21 25 31 40 47 59 72 96 116 151 Continuous 3 x 525 600 V A 2 4 2 7 3 9 4 9 6 1 9 0 11 0 18 22 27 34 41 52 62 83 100 131 Intermittent 3 x 525 600 V A 2 6 3 0 4 3 5 4 6 7 9 9 12 1 20 24...

Page 166: ...20 20 20 32 32 63 63 63 63 80 100 125 160 250 250 Environment Estimated power loss at rated max load W 4 50 65 92 122 145 195 261 300 400 475 525 700 750 850 1100 1400 1500 Weight enclosure IP20 kg 6...

Page 167: ...ous at 400 V A 204 251 304 381 463 Continuous at 460 480 V A 183 231 291 348 427 Max cable size line power motor brake and load share mm2 AWG2 2 x 70 2 x 2 0 2 x 70 2 x 2 0 2 x 150 2 x 300 mcm 2 x 150...

Page 168: ...667 718 Max cable size line power motor and load share mm2 AWG2 4x240 4x500 mcm 4x240 4x500 mcm 4x240 4x500 mcm 4x240 4x500 mcm Max cable size brake mm2 AWG2 2 x 185 2 x 350 mcm 2 x 185 2 x 350 mcm 2...

Page 169: ...6 8x900 mcm Max cable size loadsharing mm2 AWG2 4x120 4x250 mcm Max cable size brake mm2 AWG2 4x185 4x350 mcm 6x185 6x350 mcm Max external pre fuses A 1 1600 2000 2500 Est power loss at rated max load...

Page 170: ...5 0 50 430 0 58 592 0 79 720 0 97 880 1 18 1200 1 61 1440 1 93 Weight IP21 lb kg 59 5 27 59 5 27 59 5 27 59 5 27 59 5 27 143 3 65 143 3 65 143 3 65 143 3 65 143 3 65 IP55 lb kg 59 5 27 59 5 27 59 5 27...

Page 171: ...130BA229 10 Continuous at 550V A 130 158 198 245 299 Continuous at 575V A 124 151 189 234 286 Continuous at 690V A 128 155 197 240 296 Max cable size line power motor load share and brake mm2 AWG 2 x...

Page 172: ...434 Continuous at 690V A 352 400 434 Max cable size line power motor and load share mm2 AWG 2 x 150 2 x 300 mcm 2 x 150 2 x 300 mcm 4 x 240 4 x 500 mcm Max cable size brake mm2 AWG 2 x 150 2 x 300 mc...

Page 173: ...574 607 Continuous at 575V A 482 549 607 Continuous at 690V A 482 549 607 Max cable size line power motor and load share mm2 AWG 4x240 4x500 mcm 4x240 4x500 mcm 4x240 4x500 mcm Max cable size brake m...

Page 174: ...ent 130BA230 10 Continuous at 550V A 763 889 988 1108 1317 1479 Intermittent 60 s overload at 550V A 839 978 1087 1219 1449 1627 Continuous at 575 690V A 730 850 945 1060 1260 1415 Intermittent 60 s o...

Page 175: ...osses 400 0 54 Weight enclosure IP21 IP54 lb kg 2213 2863 1004 1299 2213 2863 1004 1299 2213 2863 1004 1299 2747 3397 1246 1541 2747 3397 1246 1541 2822 3472 1280 1575 Weight Rectifier Module lb kg 22...

Page 176: ...ough typical only 4 W extra for a fully loaded control card or options for slot A or slot B each Although measurements are made with state of the art equipment some measurement inaccuracy must be allo...

Page 177: ...t voltage 0 100 of supply voltage Output frequency 0 1000Hz Switching on output Unlimited Ramp times 1 3600 sec Dependent on power size Torque characteristics Starting torque Constant torque maximum 1...

Page 178: ...age terminals Mains Functional isolation PELV isolation Motor DC Bus High voltage Control 24V RS485 18 37 130BA117 10 Figure 8 1 Pulse inputs Programmable pulse inputs 2 Terminal number pulse 29 33 Ma...

Page 179: ...sistive load 240V AC 2A Max terminal load AC 15 1 Inductive load cos 0 4 240V AC 0 2 A Max terminal load DC 1 1 on 1 2 NO 1 3 NC Resistive load 60V DC 1A Max terminal load DC 13 1 Inductive load 24V D...

Page 180: ...cal EFF2 motors up to 90 output current max 122 F 50 C 1 at full continuous FC output current max 113 F 45 C 1 1 For more information on derating see 8 6 Special Conditions Minimum ambient temperature...

Page 181: ...ncy calculation Calculate the efficiency of the Adjustable frequency drive at different loads based on Figure 8 2 The factor in this graph must be multiplied with the specific efficiency factor listed...

Page 182: ...s too high motors without phase coil insulation are especially affected If the motor cable is short by a few yards the rise time and peak voltage are lower If the motor cable is long 328 ft 100 m the...

Page 183: ...807 492 1 150 240 0 708 0 575 0 669 Table 8 20 Adjustable Frequency Drive P18K T2 Cable length ft m AC line voltage V Rise time sec Vpeak kV dU dt kV sec 118 1 36 240 0 244 0 608 1 993 446 2 136 240...

Page 184: ...985 492 1 150 400 0 760 1 045 0 947 Table 8 26 Adjustable Frequency Drive P4K0 T4 Cable length ft m AC line voltage V Rise time sec Vpeak kV dU dt kV sec 16 4 5 400 0 172 0 890 4 156 164 50 400 0 310...

Page 185: ...se time sec Vpeak kV dU dt kV sec 118 1 36 400 0 232 0 950 3 534 328 100 400 0 410 0 980 1 927 492 1 150 400 0 430 0 970 1 860 Table 8 32 Adjustable Frequency Drive P30K T4 Cable length ft m AC line v...

Page 186: ...0 2 466 Table 8 37 Adjustable Frequency Drive P90K T4 Cable length ft m AC line voltage V Rise time sec Vpeak kV dU dt kV sec 16 4 5 400 0 364 1 030 2 264 Table 8 38 High Power Range Adjustable Freque...

Page 187: ...please contact Danfoss 8 6 3 Automatic Adaptations to Ensure Performance The Adjustable frequency drive constantly checks for critical levels of internal temperature load current high voltage on the...

Page 188: ...choosing a larger motor However the design of the Adjustable frequency drive puts a limit to the motor size Variable quadratic torque applications VT In VT applications such as centrifugal pumps and...

Page 189: ...arked against a code in the table on the following page this means that either a warning occurs before an alarm or it can be specified whether it is a warning or an alarm that is to be displayed for a...

Page 190: ...A calibration failed X 51 AMA check Unom and Inom X 52 AMA low Inom X 53 AMA motor too big X 54 AMA motor too small X 55 AMA Parameter out of range X 56 AMA interrupted by user X 57 AMA timeout X 58 A...

Page 191: ...ia 14 20 Reset Mode A trip is the action when an alarm has appeared The trip will coast the motor and can be reset by pressing the reset button or make a reset by a digital input parameter group 5 1 1...

Page 192: ...ctive 16 00010000 65536 Live Zero Error Live Zero Error 17 00020000 131072 Internal Fault 10 V low 18 00040000 262144 Brake Overload Brake Overload 19 00080000 524288 U phase Loss Brake Resistor 20 00...

Page 193: ...uit 08000000 Brake chopper fault 10000000 Earth fault DESAT 20000000 Drive initialized 40000000 Safe Stop A68 80000000 Table 8 47 16 91 Alarm Word 2 Bit Hex Alarm Word 2 16 91 Alarm Word 2 00000001 00...

Page 194: ...0000000 Safe Stop W68 80000000 Not used Table 8 49 16 93 Warning Word 2 Bit Hex Warning Word 2 16 93 Warning Word 2 00000001 00000002 00000004 Clock Failure 00000008 Reserved 00000010 Reserved 0000002...

Page 195: ...000 Reserved 10000000 Reserved 20000000 Reserved 40000000 Reserved 80000000 Reserved Table 8 51 Extended status word 2 16 95 Ext Status Word 2 Bit Hex Extended Status Word 2 16 95 Ext Status Word 2 00...

Page 196: ...is still active WARNING 6 DC link voltage low The intermediate circuit voltage DC is lower than the low voltage warning limit The limit is dependent on the Adjustable frequency drive voltage rating Th...

Page 197: ...Generator Mode 14 25 Trip Delay at Torque Limit can change this from a warning only condition to a warning followed by an alarm Troubleshooting If the motor torque limit is exceeded during ramp up ext...

Page 198: ...n the heatsink and control card WARNING 25 Brake resistor short circuit The brake resistor is monitored during operation If a short circuit occurs the brake function is disabled and the warning appear...

Page 199: ...rtment No Text 1299 Option SW in slot A is too old 1300 Option SW in slot B is too old 1302 Option SW in slot C1 is too old 1315 Option SW in slot A is not supported not allowed 1316 Option SW in slot...

Page 200: ...all for the AMA to operate ALARM 55 AMA Parameter out of range The parameter values of the motor are outside of the acceptable range AMA will not run 56 ALARM AMA interrupted by user The AMA has been...

Page 201: ...een cleared ALARM 93 Dry pump A no flow condition in the system with the Adjustable frequency drive operating at high speed may indicate a dry pump 22 26 Dry Pump Function is set for alarm Troubleshoo...

Page 202: ...frequency drive for normal operation WARNING 251 New type code The power card or other components have been replaced and the type code changed Reset to remove the warning and resume normal operation...

Page 203: ...Building Management System 2 6 Management System BMS 1 10 Bypass Frequency Ranges 1 17 C Cable Clamp 4 37 Clamps 4 34 Length And Cross section 4 12 Lengths And Cross sections 7 17 Caution 1 2 CAV Sys...

Page 204: ...ly 4 28 Extreme Running Conditions 1 42 F Fan System Controlled By Adjustable Frequency Drives 1 13 Fault Messages 7 36 FC Profile 6 19 With Modbus RTU 6 3 Feedback 7 39 7 41 Field Mounting 4 8 Final...

Page 205: ...a 7 37 7 40 Nameplate 4 25 Output 7 17 Parameters 5 2 Phases 1 42 Power 7 40 Protection 4 30 7 21 Rotation 4 31 Thermal Protection 6 22 1 43 4 31 Voltage 7 22 Motor generated Overvoltage 1 42 Multiple...

Page 206: ...Connection 4 32 S Safe Stop 1 4 Stop Installation 1 7 Safety Category 3 EN 954 1 1 8 Ground Connection 4 34 Note 1 1 Regulations 1 1 Requirements Of Mechanical Installation 4 8 Save Drive Settings 4...

Page 207: ...tring High Power 3 3 Code String Low And Medium Power 3 2 U UL Fuses 200 240V 4 17 Unsuccessful AMA 4 26 USB Connection 4 22 Use Of EMC Correct Cables 4 35 V Variable quadratic Torque Applications VT...

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Summary of Contents for VLT HVAC Drive FC 100 Series

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