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6 Embedded Application Controller “Thermo Control”

6.1 Introduction

The Residential Variable Speed Drive system is consisting of compressor, variable speed drive, application controller,
Electronic Expansion Valves (EEV), EEV controller and sensors.

Variable Speed Drive and EEV controller are set to be able to communicate using Modbus RTU protocol. Communication
details are available in the

Modbus Communication Set-up Manual

. Establishing the communication and configuring the

system requires individual parameters settings. These settings must be done through the OEM controller or any other PC
tool, using the Modbus communication.

This chapter describes the operation modes of the application controller. Included is also the parameter lists and parameter
descriptions.

6.2 Applications

6.2.1 Generic AC

Indoor

Outdoor

Modbus

OEM
control

Modbus

Air flow

Air flow

EIM 316

S4

S2 AC

24V

Galvanic
Isolation

S4

S2 AC

+24V

Drive

Po

Pc

Sd

Sd

Samb

Po

Pc

Samb

175ZB116.10

Illustration 6.1 Generic AC

Embedded Application Contro...

VLT

®

Inverter Scroll CDS 801 Operating Instructions

MG10V402 - VLT

®

is a registered Danfoss trademark

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Содержание VLT Inverter Scroll CDS 801

Страница 1: ...MAKING MODERN LIVING POSSIBLE Operating Instructions VLT Inverter Scroll CDS 801 ...

Страница 2: ......

Страница 3: ...l Resonances 12 3 Electrical Installation 13 3 1 Electrical Connection in General 13 3 2 Tightening Torque 13 3 3 Cable Quality and Dimensioning 13 3 4 Fuses Circuit Breakers 13 3 5 EMC Correct Installation 14 3 6 Electrical Connections 15 3 6 1 Routing of Motor and Supply Cable 15 3 6 2 Power Supply Connection Mains 16 3 6 3 Motor Compressor Connection 16 3 6 4 Sensor Connections 18 3 6 5 4 way R...

Страница 4: ...ns 31 6 2 1 Generic AC 31 6 2 2 Generic AC HP Reversible 32 6 2 3 Ground Source Heat Pump Reversible 33 6 3 Application Controller 33 6 3 1 Introduction 33 6 3 2 System Modes 33 6 3 2 1 Off 33 6 3 2 2 AC 33 6 3 2 3 HP 34 6 3 2 4 Defrost 34 6 3 3 Compressor Capacity Control 34 6 3 3 1 Single Loop Room Temperature Control 35 6 3 3 2 Open Loop External Speed Control 35 6 3 4 Condensing Pressure Contr...

Страница 5: ...r Register Overview Node 162 42 7 Fault Conditions Messages and Causes 44 8 Troubleshooting 47 9 Specifications 48 10 Special Operating Conditions 50 11 Maintenance 51 11 1 Replacement of Internal Cooling Fan 51 11 2 Cleaning 51 12 Service and Spare Parts 52 Index 53 Contents VLT Inverter Scroll CDS 801 Operating Instructions MG10V402 VLT is a registered Danfoss trademark 3 ...

Страница 6: ... and national rules and safety regulations 1 2 2 Safety Instructions Make sure the drive is properly connected to earth Do not remove the mains connector or motor compressor connector while the drive is connected to power Protect personnel against supply voltage Protect the variable speed drive against over current according to national and local regulations The earth leakage current exceeds 3 5 m...

Страница 7: ...nnect the variable speed drive from mains flip the circuit breaker or pull fuses 2 Wait for at least 5 minutes for discharge of the DC link capacitors 3 Remove motor compressor cable 1 7 ESD Precautions A variable speed drive is a sensible electronic device Electrostatic discharge ESD can cause a malfunction or destroy the frequency converter Do not touch components on the printed circuit board PC...

Страница 8: ...tic discharge PCB Printed circuit board AWG American wire gauge EEV Electronic expansion valve RTU Remote terminal unit OEM Original equipment manufacturer AC Air conditioning HP Heat pump RLA Rated load amperage AOC Application oriented controller MOC Motor oriented controller Table 1 2 Abbreviations General VLT Inverter Scroll CDS 801 Operating Instructions 6 MG10V402 VLT is a registered Danfoss...

Страница 9: ... 196 mm 7 7 in 374 mm 14 7 in 175ZB032 13 394 mm 15 5 in 216 mm 8 5 in 255 mm 10 in 98 mm 3 8 in Illustration 2 1 Dimensions Mechanical Installation VLT Inverter Scroll CDS 801 Operating Instructions MG10V402 VLT is a registered Danfoss trademark 7 2 2 ...

Страница 10: ... 98 mm 3 8 in 175ZB031 13 255 mm 10 in 180 mm 7 1 in Illustration 2 2 Dimensions Mounting holes inch Ø 6 mm Weight 10 3 lbs 5 5 kg Mechanical Installation VLT Inverter Scroll CDS 801 Operating Instructions 8 MG10V402 VLT is a registered Danfoss trademark 2 2 ...

Страница 11: ...al surface the clearance between the drive PCB and the mounting surface must be observed As a minimum sheet metal gauge 22 33 1000 inch or 1 mm should be used If electrical contact with the mounting surface can not be avoided an additional isolation foil should be used NOTE For outdoor units do not install the drive horizontally with the PCB in the top or bottom Water condensing on the PCB cannot ...

Страница 12: ... the drive with the cooling fan in the top see Illustration 2 5 175ZB038 12 Illustration 2 5 Wrong Drive Orientation Mechanical Installation VLT Inverter Scroll CDS 801 Operating Instructions 10 MG10V402 VLT is a registered Danfoss trademark 2 2 ...

Страница 13: ... Structure 175ZB042 10 Illustration 2 7 Horizontal Installation in Mechanical Structure CAUTION During mechanical installation of the drive make sure that no screws can touch electrical parts on the PCB Screws touching the electrical parts on the PCB can cause personal injury and product damage Mechanical Installation VLT Inverter Scroll CDS 801 Operating Instructions MG10V402 VLT is a registered ...

Страница 14: ...s conformally coated and thus sufficiently protected against condensation during off time Nevertheless the drive should not be exposed to dripping water rain or condensing water slung around by the condenser fan In outdoor units it is recommendable to install the drive in a rain proof compartment 2 5 Vibration and Mechanical Resonances The mechanical structure sheet metal carrying the drive must b...

Страница 15: ...ved In installations with ambient temperatures above 30 C maximum current derating applies therefore high temperature cable with 90 C conductor temperature e g Nexans Rheyflex is recommended Copper type cable only Maximum cable length 2 m Cable specification for installations in North America 3 wire cable minimum cross section AWG 10 voltage rating 600 V temperature rating 221 F 105 C 2 64 moistur...

Страница 16: ...erage of 80 The shield material must be metal not limited to but typically copper aluminum steel or lead There are no special requirements for the mains cable Connect the shield to ground at both ends for motor cables and control cables Avoid terminating the shield with twisted ends pigtails Such a termination increases the high frequency impedance of the screen which reduces its effectiveness at ...

Страница 17: ... possible see Illustration 3 2 Furthermore the motor cable should be kept as short as possible Do not route cables across the PCB see Illustration 3 1 175ZB044 10 Illustration 3 1 Wrong Routing of Motor and Supply Cables 175ZB045 10 Illustration 3 2 Cable Separation Electrical Installation VLT Inverter Scroll CDS 801 Operating Instructions MG10V402 VLT is a registered Danfoss trademark 15 3 3 ...

Страница 18: ...he order of phases is inevitable in both cases Always connect T1 on the drive with T1 on the compressor and T2 and T3 accordingly see Illustration 3 7 Observe maximum current ratings for spade type angular cable connectors according to manufacturer s product data T1 C T3 A T2 B T1 C T3 A T2 B 130ZB122 10 Illustration 3 4 Motor Compressor Connection EU Models EU models The terminal box provides pun...

Страница 19: ...ons EN 55011 cl B a ferrite must be installed at the output terminals of the drive as shown in Illustration 3 8 The motor phase wires T1 T2 T3 must be wound twice around the ferrite while the PE wire is directly connected to the chassis see Illustration 3 8 130ZB123 10 Illustration 3 8 Wire Routing on Ferrite Electrical Installation VLT Inverter Scroll CDS 801 Operating Instructions MG10V402 VLT i...

Страница 20: ...ve Connection 3 6 6 Condenser Fan Motor Control Connection EXT_FAN Two different control signals are available 0 10 V max current 20 mA analogue output and 24 V PWM duty cycle with scalable frequency see Modbus register description in 5 Commissioning Connect the control signal of the condenser fan or any other external device like a circulator pump as shown and marked on the PCB see Illustration 3...

Страница 21: ...EV_1 Illustration 3 13 Serial Communication Connection Cable When selecting a transmission line for RS 485 it is necessary to examine the required distance of the cable and the data rate of the system Losses in a transmission line are a combination of AC losses skin effect DC conductor loss leakage and AC losses in the dielectric In high quality cable the conductor losses and the dielectric losses...

Страница 22: ...White Auxiliary temperature S_AUX 2 Molex 39 01 2020 White Compressor discharge temp S_D 2 Molex 39 01 2020 White Compressor suction pressure P_0 4 Molex 39 01 2040 White Compressor discharge pressure P_C 4 Molex 39 01 2040 White Reversing valve relay RLY_1 3 Molex 39 01 4030 White Cooling fan INT_FAN 3 Molex 39 01 4030 White Crimping contact Manufacturer Type All connectors Molex 39 00 0213 Alter...

Страница 23: ... 4 1 2 3 4 1 1 2 2 3 3 4 EEV_2 1 Ground 2 RS485 3 RS485 4 24V EXT_FAN 1 Ground 2 0 10V 3 PWM 4 not used S_AMBIENT S_AUX S_D 1 PT1000 2 PT1000 P_O 1 Ground 2 Signal 3 5V 4 not used P_C 1 Ground 2 Signal 3 5V 4 not used RLY_1 1 NC 2 COM 3 NO 175ZB057 10 Illustration 3 19 Allocation of Connector Pins Electrical Installation VLT Inverter Scroll CDS 801 Operating Instructions MG10V402 VLT is a register...

Страница 24: ...us serial communication with indoor EEV controller EEV_1 EEV_2 MASTER EXT_FAN S_AMBIENT S_AUX S_D P_O P_C RLY_1 Inverter PCA Outdoor unit Indoor unit Indoor unit temp sensor PT 1000 S2 Schematic Wiring Diagram Air Conditioning System Agenda Low voltage High voltage Prefabricated cable Screended cable Power supply indoor EEV controller 18 30 v AC DC EEV Outdoor unit EEV Controller OEM Controller Th...

Страница 25: ...T1 T2 T3 L1 L2 EEV_1 EEV_2 MASTER EXT_FAN S_AMBIENT S_AUX S_D P_O P_C RLY_1 Safety circuit breaker Chassis Fuse Fuse Optional Indoor unit Indoor unit temp sensor PT 1000 S2 Schematic Wiring Diagram Combined Air Conditioning and Heat Pump System Agenda Low voltage High voltage Prefabricated cable Screended cable Power supply indoor EEV controller 18 30 v AC DC 175ZB101 10 EEV Outdoor unit EEV Contr...

Страница 26: ...ir Conditioning and ground source Heat Pump System Agenda Low voltage High voltage Prefabricated cable Screended cable 175ZB102 12 Indoor unit temp sensor PT 1000 S2 EEV unit EEV Controller OEM Controller Thermostat Ambient temperature sensor PT 1000 S amb Compr discharge temp sensor PT 1000 Sd Compressor suction pressure sensor Po Compressor discharge pressure sensor Pc Aux temperature sensor PT ...

Страница 27: ...ol Specification V1 1b Modbus Over Serial Line Specification and Implementation Guide V1 02 Modicon Modbus Protocol Reference Guide PI MBUS 300 Rev J Also visit www modbus org For details about setting up the Modbus serial communication refer to the Modbus RTU Communication Setup Manual OEM Controller Modbus Master Indoor EEV Controller for AC operation Modbus node 165 RS 485 Interfaces Applicatio...

Страница 28: ...or Modbus node 162 Motor control Microprocessor Modbus node 163 Drive PCB Internal bus 175ZB129 10 Illustration 4 2 Modbus Communication Set up for Ground Source Heat Pump Systems Serial Communication Modbu VLT Inverter Scroll CDS 801 Operating Instructions 26 MG10V402 VLT is a registered Danfoss trademark 4 4 ...

Страница 29: ...cribed by the register number 5 2 1 Drive Parameters Modbus Registers node 162 Register 40001 40010 PCA Bar Code read only These registers 10 allow reading the bar code information on the PCA which is also found on the product identifi cation label on the drive chassis Register 40011 40020 Ordering code read only These registers 10 allow reading the Danfoss ordering code which is also found on the...

Страница 30: ...ter 40147 EEV Outdoor Unit Address def 164 min 1 max 247 This register allows setting the bus address node address of the EEV Controller in the outdoor unit if applicable in systems with 2 EEV s only The default address is 164 and can be set to a value between 1 and 247 NOTE Must be set to the same value on EEV controllers Register 40148 OEM Communication Timeout def 20 sec min 0 sec max 3600 sec ...

Страница 31: ...egister and the control signal describe hereinafter The following signals are simultaneously available Analog output 0 10 V Frequency duty cycle output 24 V PWM 0 10 kHz Reg 41609 and 41610 Outdoor fan capacity PCT min Reg 41611 and 41612 Outdoor fan capacity PCT max Reg 41613 and 41614 Outdoor fan control signal freq 5 4 Crankcase Heating The variable speed drive comprises an electronic crankcase...

Страница 32: ...ssure range 0 20 bar pressure min 0 and pressure max 20 If a pressure sensor with a gage pressure range is used atmospheric pressure 0 bar the min and max pressure must be added with 1 to compensate for the offset in the range when configuring the sensor Example gage pressure scale 0 20 bar pressure min 1 and pressure max 21 5 7 Normal Operation NOTE After connecting power to the drive wait at lea...

Страница 33: ...nfiguring the system requires individual parameters settings These settings must be done through the OEM controller or any other PC tool using the Modbus communication This chapter describes the operation modes of the application controller Included is also the parameter lists and parameter descriptions 6 2 Applications 6 2 1 Generic AC Indoor Outdoor Modbus OEM control Modbus Air flow Air flow EI...

Страница 34: ... HP 24V Modbus Modbus Drive Galvanic isolation 24V S2 AC S4 EIM 316 EIM 316 S2 HP Pc Po Sd Samb Pc P0 Sd Samb 175ZB117 10 Illustration 6 2 Generic AC HP Reversible Embedded Application Contro VLT Inverter Scroll CDS 801 Operating Instructions 32 MG10V402 VLT is a registered Danfoss trademark 6 6 ...

Страница 35: ...unctions 6 3 2 System Modes System modes are Off AC cooling HP heating Defrost The system mode is selected by setting a value in the THERMO_IN_MODE register 6 3 2 1 Off To set the system off set THERMO_IN_MODE 0 The compressor and condenser fan shut down and the indoor and outdoor EEVs close the valves The application controller continuously polls the EEVs for their status register If the status r...

Страница 36: ... The Thermo Control controller continuously polls the EEVs for their status register If the status register polling fails the EEVs go into autonomous mode and attempt to control superheat To set the system in HP mode set THERMO_IN_MODE 2 When conditions for start up are met The restart timer has elapsed The requested compressor speed is higher than the minimum allowed speed The system go into a st...

Страница 37: ...xternal Speed Control In external speed control see Illustration 6 5 the compressor speed is set externally from the OEM controller through the Modbus When in external speed mode the compressor derating and safety envelope functions are still active and takes precedence over the external speed signal To set the compressor speed control into external speed control Set THERMO_IN_COMPRESSOR_MODE 2 Th...

Страница 38: ...at Fan speed control is illustrated in Table 6 1 Mode THERMO_IN_FAN_MODE System mode AC and defrost System mode HP Optimal COP 0 Pc ref f P0 P0 f Pc Delta T 1 Tc ref Tamb delta T delta T 7K T0 ref Tamb delta T delta T f T0min Tamb External Speed 2 Fan speed THERMO_IN_FAN_EXTERNAL_SPEED_PCT Bypass 3 Fan speed THERMO_IN_FAN_EXTERNAL_SPEED_PCT Table 6 1 Condensing Pressure Control 6 3 4 1 AC Mode In ...

Страница 39: ...ressure derating see Illustration 6 9 To set the fan speed control in to external speed control Set THERMO_IN_FAN_MODE 2 The external speed is set in the THERMO_IN_FAN_EXTERNAL_SPEED_PCT register 175ZB130 10 FanMotor Condensing Unit External speed setpoint P Fan Protection c Illustration 6 9 Open Loop External Speed Control Bypass fan speed control In Bypass speed control the fan speed is set exte...

Страница 40: ... T0 175ZB112 10 Illustration 6 11 HP Mode Delta T Control In Delta T mode the fan speed control attempts to maintain a temperature difference of Delta T to ambient temperature see Illustration 6 12 In HP mode the fan speed control attempts to maintain evaporator temperature Delta T below ambient temperature To run Delta T mode Set THERMO_IN_FAN_MODE 1 The temperature difference Delta T is set thro...

Страница 41: ...ternally from the OEM controller through the Modbus The speed can be overruled by the fan protection functions like min and max condensing pressure derating see Illustration 6 15 To set the fan speed control to external speed control Set THERMO_IN_FAN_MODE 2 The external speed is set in the THERMO_IN_FAN_EXTERNAL_SPEED_PCT register 175ZB125 10 FanMotor Evaporating Unit External speed setpoint P Fa...

Страница 42: ...0 4200 RPM 1300 4200 RPM 2200 3300 RPM 2300 2850 RPM 2400 RPM Derated 2100 3750 RPM 1500 4200 RPM 900 4200 RPM defrost Illustration 6 18 Compressor Safety Envelope The compressor safety envelope takes precedence over any requested compressor capacity and external speed request Crossing from one envelope to another will not stop the drive if it is running at a low compressor speed Instead the compr...

Страница 43: ...x temperature the drive automatically restarts when the restart timer has elapsed 6 3 5 7 Max Suction Pressure MOP When the suction pressure exceeds the maximum operating pressure the EEV controller decreases its opening degree If the suction pressure exceeds the maximum operating pressure for more than 90 s the controller stops the compressor and restarts after the restart time has elapsed 6 3 5 ...

Страница 44: ...ed 100 Max speed 40213 THERMO_IN_FAN_EXTERNAL_SPEED_PCT Condenser outdoor fan external speed command from OEM controller 40214 THERMO_IN_DISCHARGE_TEMPERATURE Compressor discharge temperature C from sensor connected to drive 40216 THERMO_IN_AMBIENT_TEMPERATURE Ambient temperature C from sensor connected to drive 40218 THERMO_IN_S4 Temperature C signal from indoor EEV not active yet 40220 THERMO_IN...

Страница 45: ...CENTER_HZ_2 Centre frequency 2 for speed range cancellation 40418 THERMO_SETUP_CANCEL_BANDWIDTH_HZ_2 Bandwidth 2for speed range cancellation 40419 THERMO_SETUP_CANCEL_CENTER_HZ_3 Centre frequency 3 for speed range cancellation 40420 THERMO_SETUP_CANCEL_BANDWIDTH_HZ_3 Bandwidth 3 for speed range cancellation 40421 THERMO_SETUP_CANCEL_CENTER_HZ_4 Centre frequency 4 for speed range cancellation 40422...

Страница 46: ... time When the compressor is stopped but system still powered on the restart timer is activated The restart timer will not allow the compressor to restart before 60 s after it was stopped Bit 28 Derating Active The system is in a derating condition read the Derating Status register for more information Bit 29 Safe Mode Active The system is in a Safe Mode condition read the Safe Mode Status registe...

Страница 47: ...n An over temperature occurs when the temperature measured inside the drive has reached a critical level 115 C 239 F Possible causes are insufficient cooling due to a defect cooling fan blocked air circulation or extreme high ambient temperature This is an immediate trip lock condition Bit 5 Alarm Supply Voltage Low The supply voltage has dropped below 180 V and the drive has stopped the compresso...

Страница 48: ... g missing communication between the microprocessors The drive goes immediately into a trip lock condition It is likely that the drive will not recover from this condition NOTE When operation the system in an open loop configuration by means sending a speed reference to the Performer VSD application controller the temperature controller in the Modbus Master thermostat controller should feature an ...

Страница 49: ... Check next issue Is a system status present that prevents the drive from starting read status register no 40121 Yes Cycle power to the drive remove power for at least 1 minute Read the alarm register again and check if an alarm is still present If yes remove alarm conditions Supply voltage low Check power supply Over temperature Let the system cool down Over current Replace compressor EEV indoor ...

Страница 50: ...y cycle 15 100 speed Reversing valve relay RLY_1 NC NO 3 pole relay max terminal load 250 V AC 24 V DC 4 A EEV Controller output outdoor unit EEV_2 Internal power supply 24 V DC with ground RS 485 serial interface Modbus RS 485 serial communication interface MASTER and EEV_1 According to Electronics Industry Association EIA standard Minimum power cycling time The variable speed drive is equipped w...

Страница 51: ...0 4 and 61800 5 1 Pollution degree 2 Vibration IEC 60068 2 6 2007 environmental testing Part 2 6 Tests Test Fc Vibration sinusoidal IEC 60068 2 64 1993 test Fh vibration broad band Random digital control and guidance IEC 60605 series equipment reliability testing Test level Short term testing 1 14 g RMS Long term testing 0 99 g RMS Bump Level 40 g half sinusoidal Duration 10 ms No of pulses 500 in...

Страница 52: ...ve eventually will stop and report a fault condition Possible causes could also be a malfunction of the cooling fan or blocked airflow leaves See also 11 Maintenance Derating at high installation altitude low air pressure In case of installing the drive in an altitude greater than 2000 m 6000 ft cooling may become insufficient if the ambient temperature is at maximum at the same time a very unlike...

Страница 53: ...tration 11 2 2 Lift the flat on the air duct to unlock the fan and remove the fan no tools required see Illustration 11 1 3 Insert the plug of the new fan make sure the plug is locked 4 Insert the new fan and click it onto the air duct 5 Check that the fan runs properly after reconnecting power and resuming operation 175ZB058 11 Illustration 11 1 Unlock and Remove the Fan 175ZB 035 11 Illustration...

Страница 54: ...charge the DC link capacitors before conducting service Failure to disconnecting power and observing the waiting time can result in personal injury or death Spare part list Replacement drive 13 kW 3 t unit 176L0767 Replacement drive 16 kW 4 t unit 176L0766 Replacement drive 20 kW 5 t unit 176L0765 Internal cooling fan all sizes 176L0767 176L0766 176L0765 176L7003 Service and Spare Parts VLT Invert...

Страница 55: ...uction 5 Dripping Water 12 E Electrostatic Discharge 5 Enclosure 49 H Humidity 49 I Identification Label 5 Input Power 48 M Mains Cables 16 Modicon 25 Motor Cable 15 O Over current Protected 13 P Pollution 49 Power Factor 48 S Shielded Cable 13 W Wiring Diagram 22 Index VLT Inverter Scroll CDS 801 Operating Instructions MG10V402 VLT is a registered Danfoss trademark 53 ...

Страница 56: ... MG10V402 130R0194 MG10V402 Rev 2013 02 08 ...

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