Danfoss VLT HVAC Drive FC 102 User Manual Download

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MAKING MODERN LIVING POSSIBLE

Design Guide

VLT

HVAC Drive FC 102

1.1-90 kW

www.danfoss.com/drives

Summary of Contents for VLT HVAC Drive FC 102

Page 1: ...MAKING MODERN LIVING POSSIBLE Design Guide VLT HVAC Drive FC 102 1 1 90 kW www danfoss com drives...

Page 2: ......

Page 3: ...3 Digital Inputs Terminal X30 1 4 53 3 1 4 Analog Voltage Inputs Terminal X30 10 12 53 3 1 5 Digital Outputs Terminal X30 5 7 53 3 1 6 Analog Outputs Terminal X30 5 8 53 3 1 7 Relay Option MCB 105 54...

Page 4: ...pliance 95 6 2 4 Fuse Tables 96 6 3 Disconnectors and Contactors 104 6 4 Additional Motor Information 104 6 4 1 Motor Cable 104 6 4 2 Motor Thermal Protection 105 6 4 3 Parallel Connection of Motors 1...

Page 5: ...1 Start Stop 122 7 1 2 Pulse Start Stop 122 7 1 3 Potentiometer Reference 123 7 1 4 Automatic Motor Adaptation AMA 123 7 1 5 Smart Logic Control 123 7 1 6 Smart Logic Control Programming 123 7 1 7 SLC...

Page 6: ...RTU Overview 136 8 6 4 Frequency Converter with Modbus RTU 137 8 7 Network Configuration 137 8 8 Modbus RTU Message Framing Structure 137 8 8 1 Frequency Converter with Modbus RTU 137 8 8 2 Modbus RTU...

Page 7: ...ng 147 9 1 Mains Supply Tables 147 9 2 General Specifications 156 9 3 Efficiency 160 9 4 Acoustic Noise 160 9 5 Peak Voltage on Motor 161 9 6 Special Conditions 164 9 6 1 Purpose of Derating 164 9 6 2...

Page 8: ...n particular Danfoss is not responsible for any costs including but not limited to those incurred as a result of lost profits or revenue loss or damage of equipment loss of computer programs loss of d...

Page 9: ...nic Thermal Relay ETR Frequency converter FC Gram g Hertz Hz Horsepower hp Kilohertz kHz Local Control Panel LCP Meter m Millihenry Inductance mH Milliampere mA Millisecond ms Minute min Motion Contro...

Page 10: ...eplate data Break away torque 175ZA078 10 Pull out rpm Torque Illustration 1 1 Break away Torque VLT The efficiency of the frequency converter is defined as the ratio between the power output and the...

Page 11: ...one periodic duty LCP The Local Control Panel makes up a complete interface for control and programming of the frequency converter The LCP is detachable and can be installed up to 3 metres from the fr...

Page 12: ...mps and fans VVCplus If compared with standard voltage frequency ratio control Voltage Vector Control VVCplus improves the dynamics and the stability both when the speed reference is changed and in re...

Page 13: ...lugs 7 Note that the frequency converter has more voltage inputs than L1 L2 and L3 when load sharing linking of DC intermediate circuit and external 24 V DC have been installed Check that all voltage...

Page 14: ...tive and issues a declaration of conformity upon request To carry out EMC correct installation see the instructions in this Design Guide In addition Danfoss specifies which standards our products comp...

Page 15: ...nvironment This is required to avoid cross faults and short circuits between terminals connectors tracks and safety related circuitry caused by foreign objects Liquids can be carried through the air a...

Page 16: ...chronous motors and permanent magnet motors See examples in chapter 2 6 1 Terminal 37 Safe Torque Off Function WARNING After installation of Safe Torque Off STO a commis sioning test as specified in s...

Page 17: ...Torque Off is not required use the frequency converter s regular stop function instead When automatic restart is used the requirements according to ISO 12100 2 paragraph 5 3 2 5 must be fulfilled Lia...

Page 18: ...converter Meet the following requirements to perform a safe instal lation of the frequency converter 1 Remove the jumper wire between control terminals 37 and 12 or 13 Cutting or breaking the jumper i...

Page 19: ...afety Example with Category 4 PL e application Where the safety control system design requires 2 channels for the STO function to achieve Category 4 PL e one channel can be implemented by Safe Torque...

Page 20: ...he motor must not be operated without additional measures for fall protection E g mechanical brakes must be installed additionally To resume operation after activation of Safe Torque Off first reapply...

Page 21: ...are for when only MCB 112 uses the Safe Torque Off If selection 4 PTC 1 Alarm or 5 PTC 1 Warning is selected by mistake and the external safety device triggers Safe Torque Off the frequency converter...

Page 22: ...CE See warning on the restart behaviour in chapter 2 6 1 Terminal 37 Safe Torque Off Function 2 7 Advantages 2 7 1 Why use a Frequency Converter for Controlling Fans and Pumps A frequency converter ta...

Page 23: ...or savings compared with traditional energy saving solutions This is because the frequency converter is able to control fan speed according to thermal load on the system and the fact that the frequenc...

Page 24: ...296 3 5 6 132 100 8760 275 064 26 801 Table 2 7 Consumption 2 7 6 Better Control If a frequency converter is used for controlling the flow or pressure of a system improved control is obtained A freque...

Page 25: ...M x6 x6 x6 175HA205 12 Valve posi tion Starter Fuses LV supply P F C Flow 3 Port valve Bypass Return Control Supply air V A V outlets Duct P F C Mains Fuses Starter Bypass supply LV Return valve 3 Po...

Page 26: ...ve 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 Drive to Impr...

Page 27: ...f the installation Instead of creating an artificial pressure drop or causing a decrease in fan efficiency the decreases the speed of the fan to provide the flow and pressure required by the system Ce...

Page 28: ...erature varies as well as the number of people in the controlled zone changes different cooling requirements exist As the temperature decreases below the set point the supply fan can decrease its spee...

Page 29: ...red speed to maintain the condenser water temperature The frequency converters can also be used to turn the fan on and off as needed Several features of the Danfoss HVAC dedicated frequency converter...

Page 30: ...Inlet Water Outlet CHILLER Temperature Sensor BASIN Conderser Water pump Supply 130BB453 10 Illustration 2 19 The VLT Solution Introduction to VLT HVAC D Design Guide 28 Danfoss A S Rev 06 2014 All ri...

Page 31: ...can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump impeller Using a frequency converter instead of a throttling valve simply saves the en...

Page 32: ...ed operating expenses 2 control methods are common The first method uses a flow meter Because the desired flow rate is known and is constant a flow meter installed at the discharge of each chiller can...

Page 33: ...verter Frequency converter CHILLER CHILLER Flowmeter Flowmeter F F 130BB456 10 Illustration 2 21 The VLT Solution Introduction to VLT HVAC D Design Guide MG11BC02 Danfoss A S Rev 06 2014 All rights re...

Page 34: ...oblems the true energy savings and control potential is realised by adding frequency converters With the proper sensor location the addition of frequency converters allows the pumps to vary their spee...

Page 35: ...00 100 P 3 13 Reference site Local reference scaled to RPM or Hz Auto mode Hand mode LCP Hand on off and auto on keys Linked to hand auto Local Remote Reference Ramp P 4 10 Motor speed direction To mo...

Page 36: ...rgin The current A and the typical power rating kW for a PM motor can be found in chapter 9 1 Mains Supply Tables for different voltages Sizing examples for nominal power rating Example 1 PM motor siz...

Page 37: ...or Remote Reference Table 2 14 shows under which conditions either the local reference or the remote reference is active One of them is always active but both cannot be active at the same time Local...

Page 38: ...Minimum 1 2 3 Maximum 1 2 3 Setpoint to Reference Handling 0 0 0 0 130BA354 12 Illustration 2 27 Block Diagram of Feedback Signal Processing Feedback handling can be configured to work with applicatio...

Page 39: ...sent to the PID controller since this has the larger difference feedback is lower than setpoint resulting in a positive difference 2 8 8 Feedback Conversion In some applications it may be useful to co...

Page 40: ...Illustration 2 29 Block Diagram Showing Remote Reference The remote reference is comprised of Preset references External references analog inputs pulse frequency inputs digital potentiometer inputs a...

Page 41: ...tween terminals 12 24 V and 18 2 Temperature reference via a potentiometer 5 to 35 C 0 to 10 V connected to terminals 50 10 V 53 input and 55 common 3 Temperature feedback via transmitter 10 to 40 C 4...

Page 42: ...able using the default values of 20 93 PID Proportional Gain and 20 94 PID Integral Time However in some cases it may be helpful to optimise these parameter values to provide faster system response wh...

Page 43: ...at higher frequencies which reduces the screen effect and increases the leakage current I4 If a screened cable is used for relay control cable signal interface and brake mount the screen on the enclo...

Page 44: ...A Group 1 C3 Frequency converters installed in the second environment industrial with a supply voltage lower than 1000 V Class A Group 2 C4 Frequency converters installed in the second environment wit...

Page 45: ...V No No 25 No No No 1 1 7 5 kW 380 500 V No No 5 No No No 11 90 kW 380 500 V4 No No 25 No No No 11 22 kW 525 690 V 1 4 No No 25 No No No 30 90 kW 525 690 V 2 4 No No 25 No No No H3 FC 102 1 1 45 kW 20...

Page 46: ...ns Definition 1 IEC EN 61000 3 2 Class A for 3 phase balanced equipment for professional equipment only up to 1 kW total power 2 IEC EN 61000 3 12 Equipment 16 A 75 A and profes sional equipment as fr...

Page 47: ...ions equipment EN 61000 4 4 IEC 61000 4 4 Burst transients Simulation of interference brought about by switching a contactor relay or similar devices EN 61000 4 5 IEC 61000 4 5 Surge transients Simula...

Page 48: ...68 10 1 3 2 5 4 6 b a M 7 Illustration 2 34 Galvanic Isolation The functional galvanic isolation a and b on drawing is for the 24 V back up option and for the RS 485 standard bus interface WARNING Ins...

Page 49: ...ge current Frequency Illustration 2 37 Main Contributions to Leakage Current 130BB957 11 Leakage current mA 100 Hz 2 kHz 100 kHz Illustration 2 38 The Influence of the Cut off Frequency of the RCD on...

Page 50: ...equency converters Rrec at 160 braking torque is written as 200V Rrec 107780 Pmotor 480V Rrec 375300 Pmotor 1 480V Rrec 428914 Pmotor 2 600V Rrec 630137 Pmotor 690V Rrec 832664 Pmotor 1 For frequency...

Page 51: ...Switching on the output between the motor and the frequency converter is permitted Fault messages may appear Enable flying start to catch a spinning motor Motor generated overvoltage The voltage in t...

Page 52: ...er The curves are showing the characteristic nominal speed at twice the nominal speed and at 0 2x the nominal speed It is clear that at lower speed the ETR cuts of at lower heat due to less cooling of...

Page 53: ...t out Values NOTICE Check that the chosen supply voltage follows the specifi cation of the used thermistor element Summary With the torque limit feature the motor is protected for being overloaded ind...

Page 54: ...he cable by the enclosed cable strips 4 Fit the cradle 5 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 1 k V...

Page 55: ...NALOG OUT ANALOG IN CPU CAN BUS CPU Control card FC 100 200 300 General Purpose I O option MCB 101 PLC PNP PLC NPN Illustration 3 4 Principle Diagram 3 1 3 Digital Inputs Terminal X30 1 4 Numb er of d...

Page 56: ...activ ate Sa fe Stop 12 13 18 19 27 29 33 32 20 39 42 50 53 54 61 68 C A U T I O N S E E M A N U A L R C D a n d h ig h le a k a g e c u rr e n t V O IR M A N U A L F ra n sk te k st W A R N I N G S t...

Page 57: ...part connections on relay terminals Do not mix live parts with control signals PELV Select the relay functions in 5 40 Function Relay 6 8 5 41 On Delay Relay 6 8 and 5 42 Off Delay Relay 6 8 NOTICE I...

Page 58: ...C 15 max 37 V in 10 s Max input current 2 2 A Average input current for the frequency converter 0 9 A Max cable length 75 m Input capacitance load 10 uF Power up delay 0 6 s Table 3 7 External 24 V DC...

Page 59: ...BUS CPU CONTROL CARD FREQUENCY CONVERTER ANALOG I O OPTION MCB 109 ANALOG OUTPUT RTC Pt1000 Ni 1000 3V LITHIUM BATTERY 1 2 3 4 5 6 7 8 9 10 11 12 AIN AIN AIN AOUT 0 V 24 VDC 130BA405 11 AOUT AOUT GND...

Page 60: ...Max load Volt 0 10 V DC 11 bits 1 of full scale 1 mA Table 3 9 Analog outputs terminal X42 7 12 Analog outputs are scalable by parameters for each output The function assigned is selectable via a par...

Page 61: ...with DIN 44081 and DIN 44082 Number 1 6 resistors in series Shut off value 3 3 3 65 3 85 Reset value 1 7 1 8 1 95 Trigger tolerance 6 C Collective resistance of the sensor loop 1 65 Terminal voltage...

Page 62: ...or input can be read out in the display or by readout parameters If an alarm occurs the relays or digital outputs can be programmed to be active high by selecting 21 Thermal Warning in parameter group...

Page 63: ...3 1 12 Remote Mounting Kit for LCP The LCP can be moved to the front of a cabinet by using the remote built in kit The enclosure is the IP66 The fastening screws must be tightened with a torque of max...

Page 64: ...tion 3 19 Enclosure Type A2 B A E C D 130BT324 10 Illustration 3 20 Enclosure Type A3 A Top cover B Brim C Base part D Base cover E Screw s Table 3 12 Legend to Illustration 3 19 and Illustration 3 20...

Page 65: ...es see chapter 5 1 2 Mechanical Dimensions for details E F D C B A 130BT620 12 Illustration 3 21 Enclosure Type B3 130BT621 12 D C A G Illustration 3 22 Enclosure Types B4 C3 C4 A Top cover B Brim C B...

Page 66: ...able that connects the frequency converter to the motor The voltage wave form is still pulse shaped but the dU dt ratio is reduced in comparison with the installation without filter Sine wave filters...

Page 67: ...ive Configurator The Drive Configurator automatically generates an 8 digit sales number to be delivered to the local sales office Furthermore establish a project list with several products and send it...

Page 68: ...cal Control Panel Coating PCB 20 X No coated PCB C Coated PCB Mains option 21 X No Mains disconnect switch and Load Sharing 1 With Mains disconnect switch IP55 only 8 Mains disconnect and Load Sharing...

Page 69: ...b 9 Connector kit for IP20 130B1112 Profibus top entry kit Top entry kit for Profibus connection D E enclosure types 176F1742 Terminal blocks Screw terminal blocks for replacing spring loaded terminal...

Page 70: ...nput Output option MCB 105 Relay option MCB 109 Analog I O option and battery back up for real time clock 130B1243 MCB 112 ATEX PTC 130B1137 MCB 114 Sensor input unocated 130B1172 Sensor input coated...

Page 71: ...0B1022 Accessory bag A4 Accessory bag for frame A4 w o thread 130B0536 Accessory bag A5 Accessory bag enclosure type A5 130B1023 Accessory bag B1 Accessory bag enclosure type B1 130B2060 Accessory bag...

Page 72: ...0 2x175G6688 2x175G6691 P450 Table 4 6 380 415 V AC 50 Hz IAHF N A Typical Motor Used hp Danfoss Ordering Number Frequency converter size AHF 005 AHF 010 10 1 1 4 130B2540 130B2541 P1K1 P4K0 19 5 5 7...

Page 73: ...Hz Matching the frequency converter and filter is pre calculated based on 400 V 480 V and on a typical motor load 4 pole and 110 torque IAHF N A Typical Motor Used kW Danfoss Ordering Number Frequency...

Page 74: ...132 217 160 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 2x130B2300 P450...

Page 75: ...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 3 100 130B2313 130B228...

Page 76: ...2345 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 130B2329 303 P315 2 100 1...

Page 77: ...2389 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 3 100 130B2277 130B2275 500 P...

Page 78: ...3 100 130B2426 130B2417 115 P75K P90K 3 100 130B2426 130B2417 115 P90K P110 3 100 130B2427 130B2418 165 P132 2 100 130B2427 130B2418 165 P160 2 100 130B2428 130B2419 260 P200 2 100 130B2428 130B2419 2...

Page 79: ...red that the ambient temperature does not exceed the maximum temperature stated for the frequency converter and that the 24 hour average temperature is not exceeded Locate the maximum temperature and...

Page 80: ...IP21 55 66 IP21 55 66 IP20 IP20 IP21 55 66 IP21 55 66 IP20 IP20 C a b 130BA648 12 f e B A a d e b c a e f 130BA715 12 Accessory bags containing necessary brackets screws and connectors are included w...

Page 81: ...B 90 90 130 130 200 242 242 242 165 230 308 370 308 370 Width of back plate with one C option B 130 130 170 170 242 242 242 205 230 308 370 308 370 Width of back plate with 2 C options B 150 150 190 1...

Page 82: ...loadsharin g 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 mains and loadsha ring before service WAR NIN G RELAY 1 RELAY 2 61...

Page 83: ...e type A2 or A3 there must be a clearance between the frequency converters of min 50 mm For optimal cooling conditions allow a free air passage above and below the frequency converter See Table 5 4 a...

Page 84: ...converter must be provided with a back plate 1 due to insufficient cooling air over the heat sink Enclosure IP20 IP21 IP55 IP66 A2 A3 A4 A5 2 2 B1 2 2 2 2 B2 2 2 2 2 B3 B4 2 C1 2 2 2 2 C2 2 2 2 2 C3...

Page 85: ...5 7 5 A4 1 1 2 2 1 1 4 A5 1 1 3 7 1 1 7 5 B1 5 5 11 11 18 Mains Brake resistor load sharing Motor cables 1 8 Relay 0 5 0 6 Ground 2 3 B2 15 22 30 11 30 Mains Brake resistor load sharing cables 4 5 Mo...

Page 86: ...bottom of the frequency converter 4 Attach mains wires to the mains plug connector 5 Support the cable with the supporting enclosed brackets NOTICE Check that mains voltage corresponds to the mains vo...

Page 87: ...llustration 6 7 Connecting to Mains and Earthing with Discon nector When disconnector is used enclosure type A4 A5 the PE must be mounted on the left side of the frequency converter 130BT332 10 Illust...

Page 88: ...ooting for correct dimensioning of motor cable cross section and length Screening of cables Avoid installation with twisted screen ends pigtails They spoil the screening effect at higher frequencies I...

Page 89: ...minals labelled MOTOR 5 Fasten screened cable to decoupling plate with screws and washers from the accessory bag All types of 3 phase asynchronous standard motors can be connected to the frequency con...

Page 90: ...92 L2 93 L3 96 U 97 V 98 W 88 DC 89 DC 81 R 8 R 130BA390 11 99 95 Illustration 6 18 Motor Connection Enclosure Typee C1 and C2 IP21 NEMA Type 1 and IP55 66 NEMA Type 12 130BA740 10 DC DC R R 88 89 81...

Page 91: ...s are purely recommen dations and other solutions are possible Unused cable entry holes can be sealed with rubber grommets for IP21 Tolerance 0 2 mm 4 5 1 3 2 130BB656 10 Illustration 6 21 A2 IP21 Hol...

Page 92: ...2 5 M20 5 Removed Table 6 5 Legend to Illustration 6 23 1 Tolerance 0 2 mm 4 2 3 5 1 130BB665 10 Illustration 6 24 A4 IP55 Threaded Gland Holes Hole Number and recommended use Nearest metric 1 Mains M...

Page 93: ...8 Legend to Illustration 6 26 1 Knock out hole 1 4 5 3 2 130BB659 10 Illustration 6 27 B1 IP21 Hole Number and recommended use Dimensions1 Nearest metric UL in mm 1 Mains 1 34 7 M32 2 Motor 1 34 7 M32...

Page 94: ...2 5 M20 Table 6 12 Legend to Illustration 6 30 1 Tolerance 0 2 mm 4 3 5 2 1 130BB668 10 Illustration 6 31 B2 IP55 Hole Number and recommended use Dimensions1 Nearest metric UL in mm 1 Mains 1 1 4 44 2...

Page 95: ...ric UL in mm 1 Mains 2 63 3 M63 2 Motor 2 63 3 M63 3 Brake Load Sharing 1 1 2 50 2 M50 4 Control Cable 3 4 28 4 M25 5 Control Cable 1 2 22 5 M20 Table 6 16 Legend to Illustration 6 34 1 Tolerance 0 2...

Page 96: ...36 Illustration 6 36 Terminals for Relay Connection Enclosure Types A1 A2 and A3 130BA391 12 RELAY 1 RELAY 2 06 05 04 03 02 01 DC Illustration 6 37 Terminals for Relay Connection Enclosure Types C1 a...

Page 97: ...erter and other equipment The tables in chapter 6 2 4 Fuse Tables list the recommended rated current Recommended fuses are of the type gG for small to medium power sizes For larger powers aR fuses are...

Page 98: ...160 30 NZMB2 A200 150 C4 37 45 aR 160 37 aR 200 45 aR 200 37 aR 250 45 NZMB2 A250 250 A4 1 1 2 2 gG 10 1 1 1 5 gG 16 2 2 gG 32 PKZM0 25 25 A5 0 25 3 7 gG 10 0 25 1 5 gG 16 2 2 3 gG 20 3 7 gG 32 PKZM0...

Page 99: ...250 90 aR 250 NZMB2 A250 250 Table 6 20 380 480 V Enclosure Types A B and C Enclosure type Power kW Recommended fuse size Recommended Max fuse Recommended circuit breaker Moeller Max trip level A A3...

Page 100: ...gG 25 gG 25 gG 25 gG 25 gG 25 gG 25 gG 25 B2 11 15 18 22 30 gG 25 11 gG 32 15 gG 32 18 gG 40 22 gG 63 30 gG 63 gG 80 30 C2 37 45 55 75 gG 63 37 gG 80 45 gG 100 55 gG 125 75 gG 100 37 gG 125 45 gG 160...

Page 101: ...30 KTK R 30 LP CC 30 5 5 7 5 KTN R 50 KS 50 JJN 50 11 KTN R 60 JKS 60 JJN 60 15 KTN R 80 JKS 80 JJN 80 18 5 22 KTN R 125 JKS 125 JJN 125 30 KTN R 150 JKS 150 JJN 150 37 KTN R 200 JKS 200 JJN 200 45 K...

Page 102: ...MUT may substitute A25X for 240 V frequency converters Recommended max fuse Power kW Bussmann Type RK1 Bussmann Type J Bussmann Type T Bussmann Type CC Bussmann Type CC Bussmann Type CC 1 1 KTS R 6 JK...

Page 103: ...LS R 125 A6K 125 R 55 2028220 160 KLS R 150 A6K 150 R 75 2028220 200 KLS R 200 A6K 200 R 90 2028220 250 KLS R 250 A6K 250 R Table 6 27 380 500 V Enclosure Types A B and C Recommended max fuse Power kW...

Page 104: ...e Power kW SIBA Type RK1 Littel fuse Type RK1 Ferraz Shawmut Type RK1 Ferraz Shawmut J 1 1 5017906 005 KLS R 005 A6K 5 R HSJ 6 1 5 2 2 5017906 010 KLS R 010 A6K 10 R HSJ 10 3 5017906 016 KLS R 015 A6K...

Page 105: ...max fuse Power kW Max prefuse Bussmann E52273 RK1 JDDZ Bussmann E4273 J JDDZ Bussmann E4273 T JDDZ SIBA E180276 RK1 JDDZ LittelFuse E81895 RK1 JDDZ Ferraz Shawmut E163267 E2137 RK1 JDDZ Ferraz Shawmu...

Page 106: ...L2 T2 L3 T3 13 14 130BB181 10 C1 45 55 kW Kraus Naimer KG105 T303 C2 75 kW Kraus Naimer KG160 T303 C2 90 kW Kraus Naimer KG250 T303 Table 6 33 Terminal Connections for Various Enclosure Types 6 4 Add...

Page 107: ...in explosion hazardous areas Zone 1 21 and Zone 2 22 When 1 90 Motor Thermal Protection is set to 20 ATEX ETR is combined with the use of MCB 112 it is possible to control an Ex e motor in explosion h...

Page 108: ...gths NOTICE When motors are connected in parallel 1 02 Flux Motor Feedback Source cannot be used and 1 01 Motor Control Principle must be set to Special motor characteristics U f 130BB838 12 a b c d e...

Page 109: ...ected motors Provide further motor protection by e g thermistors in each motor or individual thermal relays Circuit breakers are not suitable as protection 6 4 4 Direction of Motor Rotation The defaul...

Page 110: ...and load motor 3 Lower the IGBT switching frequency 4 Modify the inverter waveform 60 AVM vs SFAVM 5 Install a shaft grounding system or use an isolating coupling 6 Apply conductive lubrication 7 Use...

Page 111: ...m 5 in lbs Screw size M3 No Function 35 36 24 V external DC supply Table 6 37 24 V External DC Supply 24 V DC external supply can be used as low voltage supply to the control card and any option cards...

Page 112: ...rminals 68 and 69 Default setting S201 A53 OFF voltage input S202 A54 OFF voltage input S801 Bus termination OFF NOTICE When changing the function of S201 S202 or S801 be careful not to use force for...

Page 113: ...Max 0 4 x 2 5 mm 6 5 6 Basic Wiring Example 1 Mount terminals from the accessory bag to the front of the frequency converter 2 Connect terminals 18 and 27 to 24 V terminal 12 13 Default settings 18 S...

Page 114: ...R 82 R 81 Chassis PE 240 V AC 2 A 400 V AC 2 A Ground 1 Ground 2 Ground Illustration 6 55 Basic Wiring Schematic A Analog D Digital Terminal 37 optional is used for Safe Torque Off For Safe Torque Of...

Page 115: ...33 20 37 24 VDC 0 VDC 130BT107 11 Illustration 6 57 Input Polarity NPN Sink NOTICE To comply with EMC emission specifications screened armoured cables are recommended If an unscreened unarmoured cable...

Page 116: ...oltages up to 1099 V DC may occur on the terminals Load Sharing calls for extra equipment and safety considerations For further information see load sharing Instructions WARNING Note that mains discon...

Page 117: ...pen MCT 10 Set up Software 3 Select the USB port in the network section 4 Select copy 5 Select the project section 6 Select paste 7 Select save as All parameters are now stored Data transfer from PC t...

Page 118: ...mm2 or 2 rated ground wires terminated separately 6 7 4 ADN compliant Installation Units with ingress protection rating IP55 NEMA 12 or higher prevent spark formation and are classified as limited exp...

Page 119: ...s housing the frequency converter s Leave the screen as close to the connectors as possible Illustration 6 62 shows an example of an EMC correct electrical installation of an IP20 frequency converter...

Page 120: ...ance ZT can be assessed on the basis of the following factors The conductibility of the screen material The contact resistance between the individual screen conductors The screen coverage i e the phys...

Page 121: ...6 41 Legend to Illustration 6 67 Alternatively the connection to terminal 61 can be omitted PE FC PE FC 130BB924 12 PE PE 69 69 68 68 1 2 10 mm Illustration 6 68 Terminal 61 not Connected 1 Min 16 mm...

Page 122: ...erforming an AMA ensures optimum performance The AMA measures the values from the motor model equivalent diagram 1 Connect terminal 37 to terminal 12 if terminal 37 is available 2 Connect terminal 27...

Page 123: ...limit and ramp times Set up the desired limits for speed and ramp time 3 02 Minimum Reference 3 03 Maximum Reference 4 11 Motor Speed Low Limit RPM or 4 12 Motor Speed Low Limit Hz 4 13 Motor Speed Hi...

Page 124: ...art Stop 18 Illustration 7 1 Terminal 37 Available only with Safe Stop Function 7 1 2 Pulse Start Stop Terminal 18 start stop 5 10 Terminal 18 Digital Input 9 Latched start Terminal 27 Stop 5 12 Termi...

Page 125: ...out a complete AMA with a Sine wave filter If an overall setting is required remove the Sine wave filter while running a total AMA After completion of the AMA reinsert the Sine wave filter If motors...

Page 126: ...eed 2 sec ramp down and hold shaft until stop Set the ramping times in 3 41 Ramp 1 Ramp Up Time and 3 42 Ramp 1 Ramp Down Time to the wanted times tramp tacc nnorm par 1 25 ref RPM Set term 27 to No O...

Page 127: ...able speed motor as the variable speed pump lead and can stage up to 2 additional constant speed pumps on and off By varying the speed of the initial pump variable speed control of the entire system i...

Page 128: ...th lead pump alternation enabled a maximum of 2 pumps are controlled At an alternation command the lead pump ramps to minimum frequency fmin and after a delay will ramp to maximum frequency fmax When...

Page 129: ...nd or individual demands RELAY 1 R1 and RELAY 2 R2 are the built in relays in the frequency converter When all relays are de energised the first built in relay to be energised cuts in the contactor co...

Page 130: ...erlock Feedback 1 res Control Card System Start Stop From Motor Control Circuitry System Safety Interlock Pressure Transmitter 4 20 mA L1 L2 L3 PE N 130BA378 10 P 24 V dc 12 13 18 19 27 29 32 33 20 39...

Page 131: ...al Interlock Coast to stop Cut out built in relays are de energised Table 7 1 Commands Assigned to Digital Inputs LCP keys Variable speed pump lead Fixed speed pumps lag Hand On Ramps up if stopped by...

Page 132: ...h long cables To prevent impedance mismatch always use the same type of cable throughout the entire network When connecting a motor to the frequency converter always use screened motor cable Cable Scr...

Page 133: ...earth connection Keep the RS 485 communication cable away from motor and brake resistor cables to avoid coupling of high frequency noise from one cable to another Normally a distance of 200 mm 8 inche...

Page 134: ...character is 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 ch...

Page 135: ...cess block PCD The PCD is made up of a data block of 4 bytes 2 words and contains Control word and reference value from master to follower Status word and present output frequency from follower to mas...

Page 136: ...ch the defined parameter 11 Data change in the defined parameter is not possible in the frequency converter s present mode Certain parameters can only be changed when the motor is turned off 82 There...

Page 137: ...ring 13 Time difference 33 Reserved 35 Bit sequence Table 8 8 Data Types and Description 8 4 12 Conversion The various attributes of each parameter are displayed in factory setting Parameter values ar...

Page 138: ...roller that supports the interfaces defined in this document It is assumed that the user has full knowledge of the capabilities and limitations of the controller 8 6 3 Modbus RTU Overview Regardless o...

Page 139: ...on the Modbus network using RTU Remote Terminal Unit mode with each byte in a message containing 2 4 bit hexadecimal characters The format for each byte is shown in Table 8 12 Start bit Data byte Stop...

Page 140: ...ion the follower places a unique code into the data field of the response message This tells the master what kind of error occurred or the reason for the exception Also refer to chapter 8 8 10 Functio...

Page 141: ...eady 35 Coasting stop Safety closed 36 No alarm Alarm 37 Not used Not used 38 Not used Not used 39 Not used Not used 40 No warning Warning 41 Not at reference At reference 42 Hand mode Auto mode 43 Ou...

Page 142: ...llowable address for the server or follower More specifically the combination of reference number and transfer length is invalid For a controller with 100 registers a request with offset 96 and length...

Page 143: ...standard data types Non standard data types are text strings and are stored as 4x registers 40001 4FFFF The parameters are read using function 03HEX Read Holding Registers and written using function 1...

Page 144: ...e coils 17 to 32 speed set point to be forced Field Name Example HEX Follower Address 01 frequency converter address Function 0F write multiple coils Coil Address HI 00 Coil Address LO 10 coil address...

Page 145: ...gister address 999 Preset Data HI 00 Preset Data LO 01 Error Check CRC Table 8 29 Query Response The normal response is an echo of the query returned after the register contents have been passed Field...

Page 146: ...a selection in 8 56 Preset Reference Select to define how Bit 00 01 gates with the corresponding function on the digital inputs Bit 02 DC brake Bit 02 0 leads to DC braking and stop Set braking curren...

Page 147: ...ding function on the digital inputs Bit 15 Reverse Bit 15 0 No reversing Bit 15 1 Reversing In the default setting reversing is set to digital in 8 54 Reversing Select Bit 15 causes reversing only whe...

Page 148: ...overtemperature but the unit does not trip and resumes operation once the overtemperature stops Bit 13 Voltage OK limit exceeded Bit 13 0 There are no voltage warnings Bit 13 1 The DC voltage in the f...

Page 149: ...3 8 18 4 Continuous kVA 208 V AC kVA 2 38 2 70 3 82 4 50 6 00 Max cable size mains motor brake mm2 AWG 2 4 10 Max input current 130BA057 10 Continuous 3x200 240 V A 5 9 6 8 9 5 11 3 15 0 Intermittent...

Page 150: ...ittent 3x200 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 Estimated power loss at rated max load W 4 269 310 447 602 737 845 11...

Page 151: ...0 Continuous kVA 460 V AC kVA 2 4 2 7 3 8 5 0 6 5 8 8 11 6 Max cable size mains motor brake mm2 AWG 2 4 10 Max input current 130BA057 10 Continuous 3x380 440 V A 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermit...

Page 152: ...AC kVA 16 7 21 5 27 1 31 9 41 4 51 8 63 7 83 7 104 128 Max cable size mains motor brake mm2 AWG 2 10 7 35 2 50 1 0 B4 35 2 95 4 0 120 MCM2 50 With mains disconnect switch included 16 6 35 2 35 2 70 3...

Page 153: ...2 4 5 5 7 7 0 10 5 12 7 21 25 31 40 47 59 72 96 116 151 Continuous 3x525 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 3x525 600 V A 2 6 3 0 4 3 5 4 6 7 9 9 12 1 20...

Page 154: ...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 155: ...VA 690 V AC 1 9 2 6 3 8 5 4 6 6 9 12 Max input current Continuous 3x525 550 V A 1 9 2 4 3 5 4 4 5 5 8 10 Intermittent 3x525 550 V A 2 1 2 6 3 8 8 4 6 0 8 8 11 Continuous kVA 3x551 690 V A 1 4 2 0 2 9...

Page 156: ...9 82 9 100 Continuous kVA 575 V AC kVA 12 9 17 9 21 9 26 9 33 8 40 8 51 8 61 7 82 7 99 6 Continuous kVA 690 V AC kVA 15 5 21 5 26 3 32 3 40 6 49 62 1 74 1 99 2 119 5 Max input current Continuous 3x525...

Page 157: ...chapter 6 2 Fuses and Circuit Breakers 2 American Wire Gauge 3 Measured using 5 m screened motor cables at rated load and rated frequency 4 The typical power loss is at normal load conditions and exp...

Page 158: ...z Switching on output Unlimited Ramp times 1 3600 s Dependent on power size Torque characteristics Starting torque Constant torque maximum 110 for 1 min Starting torque maximum 135 up to 0 5 s Overloa...

Page 159: ...l number pulse 29 33 Max frequency at terminal 29 33 110 kHz Push pull driven Max frequency at terminal 29 33 5 kHz open collector Min frequency at terminal 29 33 4 Hz Voltage level see chapter 9 2 1...

Page 160: ...r 4 6 break 4 5 make Max terminal load AC 1 1 on 4 5 NO Resistive load 2 3 400 V AC 2 A Max terminal load AC 15 1 on 4 5 NO Inductive load cos 0 4 240 V AC 0 2 A Max terminal load DC 1 1 on 4 5 NO Res...

Page 161: ...m ambient temperature during full scale operation 0 C Minimum ambient temperature at reduced performance 10 C Temperature during storage transport 25 65 70 C Maximum altitude above sea level without d...

Page 162: ...sed on Illustration 9 2 The factor in this graph must be multiplied with the specific efficiency factor listed in the specification tables 1 0 0 99 0 98 0 97 0 96 0 95 0 93 0 92 0 50 100 200 0 94 Rela...

Page 163: ...einforcement suitable for operation with voltage supply such as a frequency converter fit a sine wave filter on the output of the frequency converter To obtain approximate values for cable lengths and...

Page 164: ...sec Vpeak kV dU dt kV sec 15 240 0 194 0 626 2 581 50 240 0 252 0 574 1 929 150 240 0 444 0 538 0 977 Table 9 17 Frequency converter P30K T2 Cable length m Mains voltage V Rise time sec Vpeak kV dU d...

Page 165: ...Vpeak kV dU dt kV sec 36 400 0 422 1 060 2 014 100 400 0 464 0 900 1 616 150 400 0 896 1 000 0 915 Table 9 24 Frequency converter P15K T4 Cable length m Mains voltage V Rise time sec Vpeak kV dU dt kV...

Page 166: ...nditions 9 6 1 Purpose of Derating Take derating into account when using the frequency converter at low air pressure high altitudes at low speeds with long motor cables cables with a large cross secti...

Page 167: ...45 C A4 A5 40 C A1 A3 50 C A4 A5 45 C A1 A3 55 C A4 A5 50 C 0 0 130BD640 10 fsw kHz Illustration 9 6 Derating of Iout for Different TAMB MAX for Enclosures Type A using SFAVM and maximum 10 m motor ca...

Page 168: ...lustration 9 11 Derating of Iout for different TAMB MAX for enclosure types B3 and B4 using SFAVM in Normal overload mode 110 over torque 9 6 4 2 Enclosure Type B T6 60 AVM Pulse Width Modulation 1 2...

Page 169: ...erating for Ambient Temperature Enclosure Type C 9 6 5 1 Enclosure Type C T2 T4 and T5 60 AVM Pulse Width Modulation 130BA397 10 2 20 4 6 8 10 12 14 16 40 60 80 100 110 fsw kHz 0 0 Iout NO 45 C 50 C 5...

Page 170: ...uency Asyncron Vector Modulation 1 2 4 6 8 20 10 40 60 80 90 100 o 50 C o 45 C 110 fsw kHz 0 0 lout C1 C2 NO 130BB827 10 Illustration 9 21 Output current derating with switching frequency and ambient...

Page 171: ...t versus altitude at TAMB MAX for enclosure types A B and C At altitudes above 2000 m contact Danfoss regarding PELV 80 0 500 100 95 90 85 1000 1500 2000 2500 3000 Altitude meters above sea level 130B...

Page 172: ...igital input with the Reset function 3 Via serial communication optional fieldbus 4 By resetting automatically using the Auto Reset function which is a default setting for VLT HVAC Drive see 14 20 Res...

Page 173: ...dbus communication fault X X 35 Out of frequency range X X 36 Mains failure X X 37 Phase Imbalance X X 38 Internal fault X X 39 Heatsink sensor X X 40 Overload of Digital Output Terminal 27 X 5 00 5 0...

Page 174: ...temp X X X 245 Heatsink sensor X X 246 Pwr card supply X X 247 Pwr card temp X X 248 Illegal PS config X X 250 New spare parts X 251 New Type Code X X Table 9 34 Alarm Warning Code List X Dependent on...

Page 175: ...Not OK No Motor OVC Active 16 00010000 65536 Live Zero Error Live Zero Error 17 00020000 131072 Internal Fault 10V Low 18 00040000 262144 Brake Overload Brake Overload 19 00080000 524288 U phase Loss...

Page 176: ...0 Brake chopper fault 10000000 Earth fault DESAT 20000000 Drive initialised 40000000 Safe Stop A68 80000000 Table 9 37 16 90 Alarm Word Bit Hex Alarm Word 2 16 91 Alarm Word 2 00000001 00000002 Reserv...

Page 177: ...Stop W68 80000000 Not used Table 9 39 16 92 Warning Word Bit Hex Warning Word 2 16 93 Warning Word 2 00000001 00000002 00000004 Clock Failure 00000008 Reserved 00000010 Reserved 00000020 00000040 0000...

Page 178: ...0 Reserved 40000000 Reserved 80000000 Reserved Table 9 41 Extended Status Word 16 94 Ext Status Word Bit Hex Extended Status Word 2 16 95 Ext Status Word 2 00000001 Off 00000002 Hand Auto 00000004 Not...

Page 179: ...WARNING ALARM 7 DC overvoltage If the intermediate circuit voltage exceeds the limit the frequency converter trips after a time Troubleshooting Connect a brake resistor Extend the ramp time Change th...

Page 180: ...sts about 1 5 s then the frequency converter trips and issues an alarm Shock loading or quick acceleration with high inertia loads can cause this fault If the acceleration during ramp up is quick the...

Page 181: ...ault The brake transistor is monitored during operation and if a short circuit occurs the brake function is disabled and a warning is issued The frequency converter is still operational but since the...

Page 182: ...is not available on the power card The problem could be on the power card on the gate drive card or the ribbon cable between the power card and gate drive card WARNING 40 Overload of digital output t...

Page 183: ...t frequency The warning will clear when the output drops below the maximum limit WARNING ALARM 65 Control card over temperature The cut out temperature of the control card is 80 C Troubleshooting Chec...

Page 184: ...d WARNING 97 Stop delayed Stopping the motor has been delayed due to short cycle protection 22 76 Interval between Starts is enabled Troubleshoot the system and reset the frequency converter after the...

Page 185: ...stem BMS 21 Bypass frequency ranges 27 C Cable clamps 117 Cable Lengths and Cross Sections 156 Caution 11 CAV system 26 CE Conformity and Labelling 12 Central VAV systems 25 Clockwise rotation 107 Clo...

Page 186: ...C with Modbus RTU 132 Feedback 180 182 Fieldbus connection 108 Flow meter 30 Freeze output 8 Frequency Converter Hardware Setup 130 Frequency Converter Set up 132 Front cover tightening torque 79 Func...

Page 187: ...umbers Harmonic Filters 69 Ordering Numbers Options and Accessories 67 Output current 177 Output Filters 64 Output Performance U V W 156 Outputs for actuators 57 P Parameter Number PNU 134 Parameter V...

Page 188: ...hing on the Output 49 System Status and Operation 126 T Telegram Length LGE 132 The Clear Advantage Energy Savings 20 The EMC directive 2004 108 EC 12 The low voltage directive 2006 95 EC 12 The machi...

Page 190: ...es to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property o...

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