Danfoss VLT HVAC Design Manual Download Page 1

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Contents

1 How to Read this Design Guide

Approvals

Symbols

Abbreviations

Definitions

2 Introduction to VLT HVAC Drive

Safety

CE labelling

Aggressive Environments

Vibration and shock

Safe Stop

Control Structures

General aspects of EMC

Galvanic isolation (PELV)

PELV - Protective Extra Low Voltage

Earth Leakage Current

Brake Function

Extreme Running Conditions

3 VLT HVAC Drive Selection

Options and Accessories

Frame Size F Panel Options

4 How to Order

Ordering Numbers

5 How to Install

Mechanical dimensions

Lifting

Electrical Installation

Electrical installation and control cables

Final Set-Up and Test

105

Additional Connections

107

Installation of misc. connections

111

Safety

113

EMC-correct Installation

114

Residual Current Device

117

6 Application Examples

119

VLT

HVAC Drive Design Guide

Contents

MG.11.B9.02 - VLT

is a registered Danfoss trademark

Summary of Contents for VLT HVAC

Page 1: ...Leakage Current 44 Brake Function 45 Extreme Running Conditions 47 3 VLT HVAC Drive Selection 51 Options and Accessories 51 Frame Size F Panel Options 59 4 How to Order 65 Ordering Numbers 69 5 How to...

Page 2: ...485 Installation and Set up 129 FC Protocol Overview 131 Network Configuration 131 FC Protocol Message Framing Structure 132 Examples 137 Modbus RTU Overview 138 Modbus RTU Message Framing Structure...

Page 3: ...al hardware or software environment Although Danfoss has tested and reviewed the documentation within this manual Danfoss makes no warranty or representation neither expressed nor implied with respect...

Page 4: ...Solutions then choose PC Software Download VLT VLT HVAC Drive Drive Applications MG 11 Tx yy Operating Instructions VLT HVAC Drive Profibus MG 33 Cx yy Operating Instructions VLT HVAC Drive Device Net...

Page 5: ...Nominal motor current IM N Nominal motor frequency fM N Nominal motor power PM N Nominal motor voltage UM N Parameter par Protective Extra Low Voltage PELV Printed Circuit Board PCB Rated Inverter Out...

Page 6: ...otor frequency when the jog function is activated via digital terminals fM The motor frequency fMAX The maximum motor frequency fMIN The minimum motor frequency fM N The rated motor frequency nameplat...

Page 7: ...elationship between the reference input at 100 full scale value typically 10 V 20mA and the resulting reference The maximum reference value set in par 3 03 Maximum Reference RefMIN Determines the rela...

Page 8: ...e parameters of the frequency converter return to their default settings Intermittent Duty Cycle An intermittent duty rating refers to a sequence of duty cycles Each cycle consists of an on load and a...

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

Page 10: ...different harmonic currents are low The frequency converters built in DC coils produce a high power factor which minimizes the imposed load on the mains supply 1 How to Read this Design Guide VLT HVA...

Page 11: ...nce with applicable national and local regulations 4 The earth leakage currents are higher than 3 5 mA 5 Protection against motor overload is set by par 1 90 Motor Thermal Protection If this function...

Page 12: ...gized Failure to follow recommendations could result in death or serious injury Warning Touching the electrical parts may be fatal even after the equipment has been disconnected from mains Also make s...

Page 13: ...ted that the responsibility for the final EMC properties of the appliance system or installation rests with the installer 2 2 2 What Is Covered The EU Guidelines on the Application of Council Directiv...

Page 14: ...onments with airborne liquids particles or gases capable of affecting and damaging the electronic components Failure to take the necessary protective measures increases the risk of stoppages thus redu...

Page 15: ...d band random 2 6 Safe Stop 2 6 1 Electrical terminals The frequency converter can perform the safety function Safe Torque Off As defined by draft CD IEC 61800 5 2 or Stop Category 0 as defined in EN...

Page 16: ...Diagram showing all electrical terminals Terminal 37 present for units with Safe Stop Function only 2 Introduction to VLT HVAC Drive VLT HVAC Drive Design Guide 16 MG 11 B9 02 VLT is a registered Dan...

Page 17: ...VLT HVAC Drive Design Guide 2 Introduction to VLT HVAC Drive MG 11 B9 02 VLT is a registered Danfoss trademark 17 2...

Page 18: ...e jumper on illustration 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 i...

Page 19: ...the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps For further information see the text The Laws of Proportionality page 19 2 7 2 The Clear Advantage E...

Page 20: ...is reduced by 50 If the system in question only needs to be able to supply a flow that corresponds to 100 a few days in a year while the average is below 80 of the rated flow for the remainder of the...

Page 21: ...t the frequency converter has a build in facility that enables the frequency converter to function as a Building Manage ment System BMS The graph Illustration 2 7 illustrates typical energy savings ob...

Page 22: ...d on the basis of pump characteristics ob tained from a pump datasheet The result obtained shows energy savings in excess of 50 at the given flow distribution over a year The pay back period depends o...

Page 23: ...requency converter can vary the speed of the fan or pump thereby obtaining variable control of flow and pressure Furthermore a frequency converter can quickly adapt the speed of the fan or pump to new...

Page 24: ...ly on mains 2 7 9 Using a Frequency Converter Saves Money The example on the following page shows that a lot of equipment is not required when a frequency converter is used It is possible to calculate...

Page 25: ...ation Systems MN 60 A1 02 Constant Air Volume Ask 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...

Page 26: ...reduces the complexity of the installation Instead of creating an artificial pressure drop or causing a decrease in fan efficiency the frequency converter decreases the speed of the fan to provide th...

Page 27: ...ditioning systems as the outside temperature 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...

Page 28: ...e frequency converters can also be used to turn the fan on and off as needed Several features of the Danfoss HVAC dedicated frequency converter the HVAC frequency converter can be utilized to improve...

Page 29: ...fficient than air cooled chillers 2 7 20 The VLT Solution Frequency converters can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump impelle...

Page 30: ...l 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 be used to control the pump d...

Page 31: ...and eases system control problems the true energy savings and control potential is realized by adding frequency converters With the proper sensor location the addition of frequency converters allows...

Page 32: ...ation Mode it can be selected if open or closed loop is to be used 2 8 2 Control Structure Open Loop Illustration 2 9 Open Loop structure In the configuration shown in the illustration above par 1 00...

Page 33: ...ys Remote Remote The table shows under which conditions either the Local Reference or the Remote Reference is active One of them is always active but both can not be active at the same time Local refe...

Page 34: ...wo or three feedback sensors but only one setpoint The feedbacks can be added subtracted only feedback 1 and 2 or averaged In addition the maximum or minimum value may be used Setpoint 1 is used exclu...

Page 35: ...ing a pressure signal 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 be...

Page 36: ...for Open Loop and Closed Loop operation A block diagram of how the drive produces the Remote Reference is shown below 2 Introduction to VLT HVAC Drive VLT HVAC Drive Design Guide 36 MG 11 B9 02 VLT is...

Page 37: ...total External Reference The External Reference the Preset Reference or the sum of the two can be selected to be the active reference Finally this reference can by be scaled using par 3 14 Preset Rela...

Page 38: ...e in Hand mode Prohibit the motor from reversing if necessary 4 10 Clockwise 0 Set acceptable 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 outp...

Page 39: ...6 6 26 5 54 or 5 59 as required 2 9 General aspects of EMC 2 9 1 General Aspects of EMC Emissions Electrical interference is usually conducted at frequences in the range 150 kHz to 30 MHz Airborne int...

Page 40: ...nducted emission requirement according to the limits given in EN55011 C1 frequency converters installed in the first environment home and office with a supply voltage less than 1000 V Class B C2 frequ...

Page 41: ...filters build in the frequency converter 600 V units only H1 Integrated EMC filter Fulfil Class A1 B H2 No additional EMC filter Fulfil Class A2 H3 Integrated EMC filter Fulfil class A1 B Frame size...

Page 42: ...sure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power Ssc greater than or equal to specified above Other...

Page 43: ...Fieldbus op tions 2 kV CM 2 kV 2 1 10 VRMS LCP cable 2 kV CM 2 kV 2 1 10 VRMS External 24 V DC 2 kV CM 0 5 kV 2 DM 1 kV 12 CM 10 VRMS Enclosure 8 kV AD 6 kV CD 10 V m AD Air Discharge CD Contact Disch...

Page 44: ...tion for kinetic back up Before touching any electrical parts wait at least the amount of time indicated in the Safety Precautions section Shorter time is allowed only if indicated on the nameplate fo...

Page 45: ...cycle The intermittent duty cycle for the resistor is calculated as follows Duty Cycle tb T T cycle time in seconds tb is the braking time in seconds as part of the total cycle time Danfoss offers bra...

Page 46: ...erters 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 converters 7...

Page 47: ...urrent measurement in each of the three motor phases or in the DC link A short circuit between two output phases will cause an overcurrent in the inverter The inverter will be turned off individually...

Page 48: ...nominal The Y axis is showing the time in seconds before the ETR cuts off and trips the drive The curves are showing the characteristic nominal speed at twice the nominal speed and at 0 2x the nomina...

Page 49: ...Digital 24 V 6 6 k 10 8 k Digital 10 V 800 2 7 k Analog 10 V 3 0 k 3 0 k NB Check that the chosen supply voltage follows the specification of the used thermistor element Summary With the Torque limit...

Page 50: ...3 VLT HVAC Drive Selection VLT HVAC Drive Design Guide 50 MG 11 B9 02 VLT is a registered Danfoss trademark 3...

Page 51: ...me delivered in the option set so that the option will fit under the extended LCP frame Fit the extended LCP frame and terminal cover Fit the LCP or blind cover in the extended LCP frame Connect power...

Page 52: ...outputs on the MCB 101 and in the control card of the frequency converter Digital analog outputs in the MCB 101 are galvanically isolated from other inputs outputs on the MCB 101 but not from these on...

Page 53: ...et up 6 3 6 4 and 16 76 Number of analog voltage inputs Standardized input signal Tolerance Resolution Max Input impedance 2 0 10 V DC 20 V continuously 10 bits Approx 5 K ohm 3 1 5 Digital Outputs Te...

Page 54: ...rminal load DC 5 V 10 mA Max switching rate at rated load min load 6 min 1 20 sec 1 1 IEC 947 part 4 and 5 When the relay option kit is ordered separately the kit includes Relay Module MCB 105 Extende...

Page 55: ...inals must be disconnected Do not mix live parts high voltage with control signals PELV Select the relay functions in par 5 40 Function Relay 6 8 par 5 41 On Delay Relay 6 8 and par 5 42 Off Delay Rel...

Page 56: ...up delay 0 6 s The inputs are protected Terminal numbers Terminal 35 external 24 V DC supply Terminal 36 external 24 V DC supply Follow these steps 1 Remove the LCP or Blind Cover 2 Remove the Termin...

Page 57: ...s for set point inputs transmitter sensor inputs and outputs for actuators Illustration 3 4 Principle diagram for Analog I O mounted in frequency converter Analog I O configuration 3 x Analog Inputs c...

Page 58: ...nputs are used for temperature sensors it is possible to read out feedback value in both C and F When operating with temperature sensors maximum cable length to connect sensors is 80 m non screened no...

Page 59: ...Current Device Uses the core balance method to monitor ground fault currents in grounded and high resistance grounded systems TN and TT systems in IEC termi nology There is a pre warning 50 of main a...

Page 60: ...ng temperatures of external system components such as the motor windings and or bearings Includes eight universal input modules plus two dedicated thermistor input modules All ten modules are integrat...

Page 61: ...designed to our frequency converters See the section Control with brake function for the dimensioning of brake resistors Code numbers can be found in the section How to order 3 1 12 Remote Mounting Ki...

Page 62: ...s used the brim must be fit ted to cover the top inlet Place the base part C at the bottom of the drive and use the clamps from the acces sory bag to correctly fasten the cables Holes for cable glands...

Page 63: ...option module B is are used the brim B must be fitted to the top cover A B3 Enclosure B4 C3 C4 Enclosure Side by side installation is not possible when using the IP 21 IP 4X TYPE 1 Enclosure Kit VLT H...

Page 64: ...dt ratio is reduced in comparison with the installation without filter Sine wave filters Sine wave filters are designed to let only low frequencies pass High frequencies are consequently shunted away...

Page 65: ...cation 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 proje...

Page 66: ...Mains option 21 X No Mains disconnect switch and Load Sharing 1 With Mains disconnect switch IP55 only 8 Mains disconnect and Load Sharing D Load Sharing See Chapter 8 for max cable sizes Adaptation 2...

Page 67: ...LCP N Numerical Local Control Panel LCP X No Local Control Panel D frames IP00 and IP 21 only Coating PCB 20 C Coated PCB X No coated PCB D frames 380 480 500 V only Mains option 21 X No mains option...

Page 68: ...class A1 RFI filter1 2 3 HN IRM with NAMUR terminals and class A2 RFI filter1 2 HP IRM with NAMUR terminals and class A1 RFI filter1 2 3 Brake 18 B Brake IGBT mounted X No brake IGBT R Regeneration t...

Page 69: ...20 130B1112 Profibus top entry kit Top entry kit for Profibus connection D E enclosures 176F1742 Terminal blocks Screw terminal blocks for replacing spring loaded terminals 1 pc 10 pin 1 pc 6 pin and...

Page 70: ...7 Fan B1 Fan external frame size B1 130B3407 Fan B2 Fan external frame size B2 130B3406 Fan B3 Fan external frame size B3 130B3563 Fan B4 Fan external 18 5 22 kW 130B3699 Fan B4 Fan external 22 30 kW...

Page 71: ...rames 176F1862 175R1106 Welded Enclosures E2 Frame 176F1861 IP00 Top Bottom Covers D3 Frames 176F1781 175R0076 Rittal Enclosures D4 Frames 176F1782 E2 Frame 176F1783 IP00 Motor Cable Clamp D3 Frame 17...

Page 72: ...80 90 130B2467 130B2479 P90K 217 110 130B2468 130B2480 P110 289 132 130B2469 130B2481 P132 324 160 130B2470 130B2482 P160 370 200 130B2471 130B2483 P200 506 250 130B2468 130B2469 130B2480 130B2481 P25...

Page 73: ...175G6666 P500 578 450 2X 175G6654 2X 175G6666 P560 613 500 175G6654 175G6655 175G6666 175G6667 P630 690 VAC 50 Hz IAHF N A Typical Motor Used kW Danfoss ordering number Frequency converter size AHF 0...

Page 74: ...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 75: ...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 76: ...0K 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...

Page 77: ...130B2416 75 P55K P75K 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...

Page 78: ...5 How to Install VLT HVAC Drive Design Guide 78 MG 11 B9 02 VLT is a registered Danfoss trademark 5...

Page 79: ...5 How to Install Page intentionally left blank VLT HVAC Drive Design Guide 5 How to Install MG 11 B9 02 VLT is a registered Danfoss trademark 79 5...

Page 80: ...om mounting holes B4 C3 C4 only Accessory bags containing necessary brackets screws and connectors are included with the drives upon delivery All measurements in mm IP21 can be established with a kit...

Page 81: ...ure B 90 90 130 130 242 242 242 165 231 308 370 308 370 With one C option B 130 130 170 170 242 242 242 205 231 308 370 308 370 Back plate B 90 90 130 130 242 242 242 165 231 308 370 308 370 Distance...

Page 82: ...ttom mount ing hole Lifting eye and mounting holes Lifting eye IP21 54 IP21 54 Enclosure F1 Enclosure F2 All measurements in mm Base plate mount Enclosure F3 Enclosure F4 5 How to Install VLT HVAC Dri...

Page 83: ...281 2281 2281 Width Back plate B 420 420 408 408 600 585 1400 1800 2000 2400 Depth C 380 380 375 375 494 494 607 607 607 607 Dimensions brackets mm inch Centre hole to edge a 22 0 9 22 0 9 22 0 9 22 0...

Page 84: ...Frame size B4 Frame size C3 Frame size C4 1 2 only available in units with brake chopper For DC link connection Load sharing the connector 1 can be ordered separately Code no 130B1064 An eight pole c...

Page 85: ...A2 A3 A5 B1 B2 B3 B4 C1 C2 C3 C4 a mm 100 100 100 200 200 200 200 200 225 200 225 b mm 100 100 100 200 200 200 200 200 225 200 225 1 Drill holes in accordance with the measurements given 2 You must p...

Page 86: ...t be able to handle the weight of the frequency converter See Mechanical Dimensions for the weight of the different frame sizes Maximum diameter for bar is 2 5 cm 1 inch The angle from the top of the...

Page 87: ...uipment damage especially when installing large units The frequency converter is cooled by means of air circulation To protect the unit from overheating it must be ensured that the ambient temperature...

Page 88: ...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 11 18 5 18 5 37 18 5 37 4 5 4 5 4 5 4 5 3 0 6 C1 18 5 30 37 55 10 10 10 10 3 0 6 C2 37 45 75 90 14 241 14 241 14 14 3 0 6 C3 18 5 30 37 55 3...

Page 89: ...nput 5 10 Start 19 Terminal 19 Digital Input 5 11 No operation 20 Terminal 20 Common 27 Terminal 27 Digital Input Output 5 12 5 30 Coast inverse 29 Terminal 29 Digital Input Output 5 13 5 31 Jog 32 Te...

Page 90: ...btain equal amount of wires attached to both inverter module terminals The cables are required to be equal length within 10 between the inverter module terminals and the first common point of a phase...

Page 91: ...must be retightened after two days due to the softness of the aluminium It is crucial to keep the connection a gas tight joint otherwise the aluminium surface will oxidize again 5 2 5 Enclosure knock...

Page 92: ...e entry holes for enclosure B2 The suggested use of the holes are purely recommendations and other solutions are possible Illustration 5 14 Cable entry holes for enclosure C1 The suggested use of the...

Page 93: ...d with a strong mandrel and a hammer 4 Remove burrs from the hole 5 Mount Cable entry on frequency converter 5 2 7 Gland Conduit Entry IP21 NEMA 1 and IP54 NEMA12 Cables are connected through the glan...

Page 94: ...tion of the gland plate Frame size D1 D2 Frame size E1 Cable entries viewed from the bottom of the frequency converter 1 Mains side 2 Motor side 5 How to Install VLT HVAC Drive Design Guide 94 MG 11 B...

Page 95: ...rame size F3 Frame size F4 F1 F4 Cable entries viewed from the bottom of the frequency converter 1 Place conduits in marked areas VLT HVAC Drive Design Guide 5 How to Install MG 11 B9 02 VLT is a regi...

Page 96: ...The frequency converter provides full short circuit protection in case of a short circuit on the motor output Over current protection Provide overload protection to avoid fire hazard due to overheatin...

Page 97: ...type gG 7K5 35A1 380 500 V type gG 11K 15K 63A1 380 500 V type gG 18K 63A1 380 500 V type gG 22K 63A1 380 500 V type gG 30K 80A1 380 500 V type gG 37K 100A1 380 500 V type gG 45K 125A1 380 500 V type...

Page 98: ...R6 JKS 6 JJS 6 5017906 006 KLS R6 ATM R6 A6K 6R 1K5 2K2 KTS R10 JKS 10 JJS 10 5017906 010 KLS R10 ATM R10 A6K 10R 3K0 KTS R15 JKS 15 JJS 15 5017906 016 KLS R16 ATM R16 A6K 16R 4K0 KTS R20 JKS 20 JJS 2...

Page 99: ...0 170M7082 P800 170M7083 2500 A 700 V 20 695 32 2500 170M7083 P1M0 170M7083 2500 A 700 V 20 695 32 2500 170M7083 Table 5 10 Frame size F Line fuses 380 480 V Size Type Bussmann PN Rating Siba P500 170...

Page 100: ...e for use on a circuit capable of delivering not more than 100 000 rms symmetrical amperes 500 600 690 Volts maximum when protected by the above fuses Supplementary fuses Frame size Bussmann PN Rating...

Page 101: ...afety Relay Coil Fuse with PILS Relay 5 2 9 Control Terminals Drawing reference numbers 1 10 pole plug digital I O 2 3 pole plug RS485 Bus 3 6 pole analog I O 4 USB Connection Illustration 5 18 Contro...

Page 102: ...fre quency converter 2 Connect terminals 18 and 27 to 24 V terminal 12 13 Default settings 18 latched start 27 stop inverse Illustration 5 19 Terminal 37 available with Safe Stop Func tion only 5 How...

Page 103: ...es If this occurs you may have to break the screen or insert a 100 nF capacitor between screen and chassis The digital and analog in and outputs must be connected separately to the frequency converter...

Page 104: ...urrent 0 20 mA or a voltage 0 to 10 V configuration of the analog input terminals 53 and 54 respectively Switch S801 BUS TER can be used to enable termination on the RS 485 port terminals 68 and 69 Se...

Page 105: ...rent 5 Motor Nominal Speed par 1 25 Motor Nominal Speed Step 3 Activate the Automatic Motor Adaptation AMA Performing an AMA will ensure optimum performance The AMA measures the values from the motor...

Page 106: ...g If you contact Danfoss Service make sure to mention number and alarm description Unsuccessful AMA is often caused by incorrectly registered motor name plate data or too big difference between the mo...

Page 107: ...2 90 kW Kraus Naimer KG250 T303 5 4 2 Mains Disconnectors Frame Size D E and F Frame size Power Voltage Type D1 D3 P110 P132 380 480V P110 P160 525 690V ABB OETL NF200A or OT200U12 91 D2 D4 P160 P250...

Page 108: ...blished the frequency converter will trip on warning alarm 27 Brake IGBT If the connection is closed between 104 and 105 the frequency converter will trip on warning alarm 27 Brake IGBT Normally close...

Page 109: ...ts by using option module MCB 105 5 4 8 Parallel Connection of Motors The frequency converter can control several parallel connected motors The total current consumption of the motors must not exceed...

Page 110: ...ge Motor Insulation UN 420 V Standard ULL 1300 V 420 V UN 500 V Reinforced ULL 1600 V 500 V UN 600 V Reinforced ULL 1800 V 600 V UN 690 V Reinforced ULL 2000 V 5 4 12 Motor Bearing Currents It is gene...

Page 111: ...hile terminal 69 is connected to the N signal TX RX If more than one frequency converter is connected to a master use par allel connections In order to avoid potential equalizing currents in the scree...

Page 112: ...n Tool MCT 10 supports Profibus DP V1 via a Master class 2 connection It makes it possible to on line read write parameters in a frequency converter via the Profibus network This will eliminate the ne...

Page 113: ...ed Ordering number Please order your CD containing the MCT 31 PC tool using code number 130B1031 MCT 31 can also be downloaded from the Danfoss Internet http www danfoss com BusinessAreas DrivesSoluti...

Page 114: ...he screen armour conduit to earth at both ends for motor cables as well as for control cables In some cases it is not possible to connect the screen in both ends If so connect the screen at the freque...

Page 115: ...MC correct electrical installation of a frequency converter in cabinet Illustration 5 23 Electrical connection diagram VLT HVAC Drive Design Guide 5 How to Install MG 11 B9 02 VLT is a registered Danf...

Page 116: ...e cable Transfer impedance 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...

Page 117: ...s section 16 mm 2 d For 50 60 Hz earth loops If very long control cables are used 50 60 Hz earth loops may occur Solve this problem by connecting one end of the screen to earth via a 100nF capacitor k...

Page 118: ...6 Application Examples VLT HVAC Drive Design Guide 118 MG 11 B9 02 VLT is a registered Danfoss trademark 6...

Page 119: ...lt Illustration 6 1 Terminal 37 Available only with Safe Stop Function 6 1 2 Pulse Start Stop Terminal 18 start stop par 5 10 Terminal 18 Digital Input 9 Latched start Terminal 27 Stop par 5 12 Termin...

Page 120: ...crease of the stator resistance Rs Normally this is not critical AMA can only be carried out if the rated motor current is minimum 35 of the rated output current of the frequency converter AMA can be...

Page 121: ...SE nothing happens in the SLC during the present scan interval and no other events will be evaluated This means that when the SLC starts it evaluates event 1 and only event 1 each scan interval Only w...

Page 122: ...et Event 3 in par 13 51 SL Controller Event 3 to Time Out 0 30 Set Event 4 in par 13 51 SL Controller Event 1 to False 0 Set Action 1 in par 13 52 SL Controller Action 1 to Select preset 0 10 Set Acti...

Page 123: ...es it possible to cycle the frequency converter between the pumps in the system maximum of 2 pumps In this operation the run time between pumps is equalized reducing the required pump maintenance and...

Page 124: ...ump has been running at minimum frequency fmin for a programmed amount of time with a fixed speed pump running the lead pump contributes little to the system When the programmed value of the timer exp...

Page 125: ...and K3 K4 with a mechanical interlock Thermal relays or other motor protection devices must be applied according to local regulation and or individual demands RELAY 1 R1 and RELAY 2 R2 are the built...

Page 126: ...gram The wiring diagram shows an example with the built in BASIC cascade controller with one variable speed pump lead and two fixed speed pumps a 4 20 mA transmitter and System Safety Interlock 6 1 14...

Page 127: ...and or stays in operation if already running Destaging if running Off Ramps down Ramps down Auto On Starts and stops according to commands via ter minals or serial bus Staging Destaging VLT HVAC Drive...

Page 128: ...7 RS 485 Installation and Set up VLT HVAC Drive Design Guide 128 MG 11 B9 02 VLT is a registered Danfoss trademark 7...

Page 129: ...surface of the screen to ground for example by means of a cable clamp or a conductive cable gland It may be necessary to apply potential equalizing cables to maintain the same ground potential through...

Page 130: ...nd transmitting a response This can be used for overcoming modem turnaround delays 8 36 Max response delay Specify a maximum delay time between transmitting a request and receiving a response 8 37 Max...

Page 131: ...annel A third telegram format is used for texts 7 2 1 FC with Modbus RTU The FC protocol provides access to the Control Word and Bus Reference of the frequency converter The Control Word allows the Mo...

Page 132: ...ing the telegram length LGE and a byte denoting the frequency converter address ADR A number of data bytes variable depending on the type of telegram follows The telegram is completed by a data contro...

Page 133: ...0 7 4 6 The Data Field The structure of data blocks depends on the type of telegram There are three telegram types and the type applies for both control telegrams mas ter slave and response telegrams...

Page 134: ...0 0 0 1 Read parameter value 0 0 1 0 Write parameter value in RAM word 0 0 1 1 Write parameter value in RAM double word 1 1 0 1 Write parameter value in RAM and EEprom double word 1 1 1 0 Write param...

Page 135: ...ts for a parameter value when the PWE block contains no value To change a parameter value write write the new value in the PWE block and send from the master to the slave When a slave responds to a pa...

Page 136: ...ow Limit Hz has a conversion factor of 0 1 To preset the minimum frequency to 10 Hz transfer the value 100 A conversion factor of 0 1 means that the value transferred is multiplied by 0 1 The value 10...

Page 137: ...4 14 is 19E in hexadecimal The response from the slave to the master will be 7 5 2 Reading a Parameter Value Read the value in par 3 41 Ramp 1 Ramp Up Time PKE 1155 Hex Read parameter value in par 3...

Page 138: ...slaves or can initiate a broadcast message to all slaves Slaves return a message called a response to queries that are addressed to them individually No responses are returned to broadcast queries fro...

Page 139: ...ine which device is addressed or all devices if the message is broadcast and to recognise when the message is completed Partial messages are detected and errors set as a result Characters for transmis...

Page 140: ...7 8 6 Data Field The data field is constructed using sets of two hexadecimal digits in the range of 00 to FF hexadecimal These are made up of one RTU character The data field of messages sent from a m...

Page 141: ...op 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 Out of freq range In...

Page 142: ...ble action for the server or slave This may be because the function code is only applicable to newer devices and was not implemented in the unit selected It could also indicate that the server or slav...

Page 143: ...tes for each parameter can be seen in the section on factory settings Since a parameter value can only be transferred as a whole number a conversion factor must be used to transfer decimals Please ref...

Page 144: ...e The coil status in the response message is packed as one coil per bit of the data field Status is indicated as 1 ON 0 OFF The LSB of the first data byte contains the coil addressed in the query The...

Page 145: ...d Name Example HEX Slave Address 01 frequency converter address Function 05 write single coil Coil Address HI 00 Coil Address LO 40 64 decimal Coil 65 Force Data HI FF Force Data LO 00 FF 00 ON Error...

Page 146: ...00 Coil Address LO 10 coil address 17 Quantity of Coils HI 00 Quantity of Coils LO 10 16 coils Byte Count 02 Force Data HI Coils 8 1 20 Force Data LO Coils 10 9 00 ref 2000hex Error Check CRC Respons...

Page 147: ...ss 3029 No of Points HI 00 No of Points LO 02 Par 3 03 is 32 bits long i e 2 registers Error Check CRC Response The register data in the response message are packed as two bytes per register with the...

Page 148: ...tion 06 Register Address HI 03 Register address 999 Register Address LO E7 Register address 999 Preset Data HI 00 Preset Data LO 01 Error Check CRC Response Response The normal response is an echo of...

Page 149: ...Address LO 19 No of Registers HI 00 No of registers LO 02 Byte Count 04 Write Data HI Register 4 1049 00 Write Data LO Register 4 1049 00 Write Data HI Register 4 1050 02 Write Data LO Register 4 1050...

Page 150: ...f the Control Bits Bits 00 01 Bits 00 and 01 are used to choose between the four reference values which are pre programmed in par 3 10 Preset Reference according to the following table Programmed ref...

Page 151: ...ther starting conditions are met Make a selection in par 8 53 Start Select to define how Bit 06 Ramp stop start gates with the corresponding function on a digital input Bit 07 Reset Bit 07 0 No reset...

Page 152: ...eference Speed reference 09 Local operation Bus control 10 Out of frequency limit Frequency limit OK 11 No operation In operation 12 Drive OK Stopped auto start 13 Voltage OK Voltage exceeded 14 Torqu...

Page 153: ...Limit RPM or par 4 13 Motor Speed High Limit RPM Bit 10 1 The output frequency is within the defined limits Bit 11 No operation in operation Bit 11 0 The motor is not running Bit 11 1 The frequency co...

Page 154: ...t word in integers 0 32767 the value 16384 4000 Hex corresponds to 100 Negative figures are formatted by means of 2 s complement The Actual Output frequency MAV is scaled in the same way as the bus re...

Page 155: ...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 mains motor brake mm2 AWG 2 4 10 Max input current Continuous 3 x 200...

Page 156: ...C kVA 8 7 11 1 16 6 21 4 26 9 31 7 41 4 51 5 61 2 Max cable size mains motor brake mm 2 AWG 2 10 7 35 2 50 1 0 B4 35 2 95 4 0 120 250 MCM With mains disconnect switch included 16 6 35 2 35 2 70 3 0 18...

Page 157: ...inuous kVA 400 V AC kVA 2 1 2 8 3 9 5 0 6 9 9 0 11 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 mm 2 AWG 2 4 10 Max input current Continuous 3 x 380 440...

Page 158: ...7 21 5 27 1 31 9 41 4 51 8 63 7 83 7 104 128 Max cable size mains motor brake mm 2 AWG 2 10 7 35 2 50 1 0 B4 35 2 95 4 0 120 MCM250 With mains disconnect switch included 16 6 35 2 35 2 70 3 0 185 kcmi...

Page 159: ...VA 2 4 2 7 3 9 4 9 6 1 9 0 11 0 17 9 21 9 26 9 33 9 40 8 51 8 61 7 82 7 99 6 130 5 Max cable size IP 21 55 66 mains motor brake mm 2 AWG 2 4 10 10 7 25 4 50 1 0 95 4 0 120 MCM25 0 Max cable size IP 20...

Page 160: ...353 Max input current Continuous at 400 V A 204 251 304 381 463 Continuous at 460 480 V A 183 231 291 348 427 Max cable size mains motor brake and load share mm2 AWG2 2 x 70 2 x 2 0 2 x 70 2 x 2 0 2...

Page 161: ...7 733 787 Continuous at 460 480 V A 531 580 667 718 Max cable size mains 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...

Page 162: ...or mm2 AWG2 8x150 8x300 mcm 12x150 12x300 mcm Max cable size mains mm2 AWG2 8x240 8x500 mcm Max cable size loadsharing mm2 AWG2 4x120 4x250 mcm Max cable size brake mm2 AWG2 4x185 4x350 mcm 6x185 6x35...

Page 163: ...575 V KVA 54 73 86 108 130 Continuous KVA at 690 V KVA 65 87 103 129 157 Max input current Continuous at 550 V A 60 77 89 110 130 Continuous at 575 V A 58 74 85 106 124 Continuous at 690 V A 58 77 87...

Page 164: ...690 V KVA 185 229 289 347 Max input current Continuous at 550 V A 158 198 245 299 Continuous at 575 V A 151 189 234 286 Continuous at 690 V A 155 197 240 296 Max cable size mains mo tor load share and...

Page 165: ...0 V A 355 408 453 Continuous at 575 V A 339 390 434 Continuous at 690 V A 352 400 434 Max cable size mains 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...

Page 166: ...t current Continuous at 550 V A 504 574 607 Continuous at 575 V A 482 549 607 Continuous at 690 V A 482 549 607 Max cable size mains motor and load share mm2 AWG 4x240 4x500 mcm 4x240 4x500 mcm 4x240...

Page 167: ...350 mcm 6x185 6x350 mcm Max external pre fuses A 1 1600 2000 2500 Est power loss at rated max load W 4 600 V F1 F2 10771 12272 13835 15592 18281 20825 Est power loss at rated max load W 4 690 V F1 F2...

Page 168: ...hough typical only 4W 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 169: ...times 1 3600 sec Dependent on power size Torque characteristics Starting torque Constant torque maximum 110 for 1 min Starting torque maximum 135 up to 0 5 sec Overload torque Constant torque maximum...

Page 170: ...llector Min frequency at terminal 29 33 4 Hz Voltage level see section on Digital input Maximum voltage on input 28 V DC Input resistance Ri approx 4 k Pulse input accuracy 0 1 1 kHz Max error 0 1 of...

Page 171: ...ax terminal load DC 1 1 on 4 5 NO Resistive load 80 V DC 2 A Max terminal load DC 13 1 on 4 5 NO Inductive load 24 V DC 0 1A Max terminal load AC 1 1 on 4 6 NC Resistive load 240 V AC 2 A Max terminal...

Page 172: ...Minimum ambient temperature at reduced performance 10 C Temperature during storage transport 25 65 70 C Maximum altitude above sea level without derating 1000 m Maximum altitude above sea level with d...

Page 173: ...of the frequency converter does not change even if other U f characteristics are chosen However the U f characteristics influence the efficiency of the motor The efficiency declines a little when the...

Page 174: ...only Remaining E1 E2 power sizes For D E and F sizes reduced fan speed is at 87 measured at 200 V 8 5 Peak Voltage on Motor When a transistor in the inverter bridge switches the voltage across the mot...

Page 175: ...3 0 510 3 090 50 230 0 23 0 590 2 034 100 230 0 54 0 580 0 865 150 230 0 66 0 560 0 674 Frequency Converter P11K T2 Cable length m Mains voltage V Rise time sec Vpeak kV dU dt kV sec 36 240 0 264 0 62...

Page 176: ...ns voltage V Rise time sec Vpeak kV dU dt kV sec 30 240 0 300 0 598 1 593 100 240 0 536 0 566 0 843 150 240 0 776 0 546 0 559 Frequency Converter P1K5 T4 Cable length m Mains voltage V Rise time sec V...

Page 177: ...peak kV dU dt kV sec 36 400 0 232 0 950 3 534 100 400 0 410 0 980 1 927 150 400 0 430 0 970 1 860 Frequency Converter P30K T4 Cable length m Mains voltage V Rise time sec Vpeak kV dU dt kV sec 15 400...

Page 178: ...Cable length m Mains voltage V Rise time sec Vpeak kV dU dt kV sec 30 500 0 71 1 165 1 389 30 400 0 61 0 942 1 233 30 500 1 0 80 0 906 0 904 30 400 1 0 82 0 760 0 743 Table 8 6 1 With Danfoss dU dt fi...

Page 179: ...cy and or change the switching pattern in order to ensure the performance of the frequency converter The capability to automatically reduce the output current extends the acceptable operating conditio...

Page 180: ...hoosing a larger motor However the design of the frequency converter puts a limit to the motor size Variable Quadratic torque applications VT In VT applications such as centrifugal pumps and fans wher...

Page 181: ...an alarm cannot be reset the reason may be that its cause has not been rectified or the alarm is trip locked see also table on following page Alarms that are trip locked offer additional protection me...

Page 182: ...missing X X X 4 58 33 Inrush fault X X 34 Fieldbus 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 Ove...

Page 183: ...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 8 8 Alarm Warning code list X Dependent on parameter 1 Can not be Auto res...

Page 184: ...0 32768 AMA 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...

Page 185: ...pply fault 04000000 Brake resistor short circuit 08000000 Brake chopper fault 10000000 Option change 20000000 Drive initialized 40000000 Safe Stop 80000000 Not used Alarm word 2 par 16 91 Alarm Word 2...

Page 186: ...failure 02000000 Current limit 04000000 Low temperature 08000000 Voltage limit 10000000 Encoder loss 20000000 Output frequency limit 40000000 Not used 80000000 Not used Warning word 2 par 16 93 Warni...

Page 187: ...00000 Reserved 10000000 Reserved 20000000 Reserved 40000000 Reserved 80000000 Reserved Extended status word 2 par 16 95 Ext Status Word 2 Bit Hex Extended Status Word 2 par 16 95 Ext Status Word 2 000...

Page 188: ...ange the ramp type Activate functions in par 2 10 Brake Function Increase par 14 26 Trip Delay at Inverter Fault WARNING ALARM 8 DC under voltage If the intermediate circuit voltage DC drops below the...

Page 189: ...17 Control word timeout There is no communication to the frequency converter The warning will only be active when par 8 04 Control Word Timeout Function is NOT set to OFF If par 8 04 Control Word Tim...

Page 190: ...reading EEPROM data 515 Application Orientated Control cannot recognize the EE PROM data 516 Cannot write to the EEPROM because a write command is on progress 517 Write command is under time out 518...

Page 191: ...V and 5 V supplies are monitored When powered with three phase mains voltage all three sup plied are monitored WARNING 47 24 V supply low The 24 V DC is measured on the control card The external V DC...

Page 192: ...70 Illegal FC Configuration Actual combination of control board and power board is illegal WARNING ALARM 71 PTC 1 safe stop Safe Stop has been activated from the MCB 112 PTC Thermistor Card motor too...

Page 193: ...ule 2 middle inverter module in F2 or F4 drive 2 right inverter module in F1 or F3 drive 3 right inverter module in F2 or F4 drive 5 rectifier module ALARM 246 Power card supply This alarm is only for...

Page 194: ...og Voltage Inputs Terminal X30 10 12 53 Application Examples 25 Automatic Adaptations To Ensure Performance 179 Automatic Motor Adaptation 120 Automatic Motor Adaptation ama 105 Awg 155 B Bacnet 70 Ba...

Page 195: ...l Communication 172 Control Characteristics 171 Control Potential 31 Control Structure Closed Loop 33 Control Structure Open Loop 32 Control Terminals 101 Control Word 150 Cooling 180 Cooling Conditio...

Page 196: ...est 105 Flow Meter 30 Frame Size F Panel Options 1 Freeze Output 6 Frequency Converter Hardware Setup 130 Frequency Converter Set up 131 Frequency Converter With Modbus Rtu 138 Function Codes Supporte...

Page 197: ...Mcb 105 Option 54 Mct 10 Set up Software 112 Mct 31 113 Mechanical Dimensions 81 83 Mechanical Dimensions High Power 82 Mechanical Mounting 85 Modbus Communication 130 Modbus Exception Codes 142 Mome...

Page 198: ...ra Low Voltage 43 Plc 117 Potentiometer Reference 120 Power Factor 9 Power Factor Correction 23 Primary Pumps 30 Principle Diagram 57 Profibus 70 Profibus Dp v1 112 Programmable Minimum Frequency Sett...

Page 199: ...itches S201 S202 And S801 104 Switching Frequency 91 Switching On The Output 47 System Status And Operation 124 T Telegram Length lge 132 The Clear Advantage Energy Savings 19 The Emc Directive 89 336...

Page 200: ...ning Against Unintended Start 12 Warning Word 186 Warning Word 2 186 What Is Ce Conformity And Labelling 13 What Is Covered 13 Index VLT HVAC Drive Design Guide 200 MG 11 B9 02 VLT is a registered Dan...

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