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MAKING MODERN LIVING POSSIBLE
Design Guide
VLT® HVAC Drive
Contents
VLT
®
HVAC Drive Design Guide
Contents
1 How to Read this Design Guide
1.1.1 Copyright, Limitation of Liability and Revision Rights
2 Introduction to VLT
HVAC Drive
2.1 Safety
2.2 CE labelling
2.4 Aggressive Environments
2.5 Vibration and shock
2.6 Safe Stop
2.8 Control Structures
2.9 General aspects of EMC
2.9.1 General Aspects of EMC Emissions
2.10 Galvanic Isolation (PELV)
2.10.1 PELV - Protective Extra Low Voltage
2.11 Earth Leakage Current
2.12 Brake Function
2.13 Extreme Running Conditions
3 VLT
HVAC Drive Selection
3.1 Options and Accessories
3.1.11 Sensor Input Option MCB 114
3.1.11.1 Ordering Code Numbers and Parts Delivered
3.1.11.2 Electrical and Mechanical Specifications
3.1.12 Frame Size F Panel Options
4 How to Order
4.1 Ordering Form
4.2 Ordering Numbers
4.2.2 Ordering Numbers: High Power Kits
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Contents
VLT
®
HVAC Drive Design Guide
5 How to Install
5.1 Mechanical Installation
5.1.6 Safety Requirements of Mechanical Installation
5.2 Electrical Installation
5.2.2 Electrical Installation and Control Cables
5.2.6 Removal of Knockouts for Extra Cables
5.2.7 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12)
5.3 Final Set-Up and Test
5.4 Additional Connections
5.4.5 Brake Resistor Temperature Switch
5.5 Installation of Misc. Connections
5.6 Safety
5.7 EMC-correct Installation
5.7.1 Electrical Installation - EMC Precautions
5.7.2 Use of EMC-Correct Cables
6 Application Examples
6.1.4 Automatic Motor Adaptation (AMA)
6.1.6 Smart Logic Control Programming
6.1.8 BASIC Cascade Controller
6.1.9 Pump Staging with Lead Pump Alternation
6.1.10 System Status and Operation
6.1.11 Fixed Variable Speed Pump Wiring Diagram
6.1.12 Lead Pump Alternation Wiring Diagram
6.1.13 Cascade Controller Wiring Diagram
7 RS-485 Installation and Set-up
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Contents
VLT
®
HVAC Drive Design Guide
7.1 RS-485 Installation and Set-up
7.2 FC Protocol Overview
7.3 Network Configuration
7.4 FC Protocol Message Framing Structure
7.4.1 Content of a Character (byte)
7.4.4 Frequency Converter Address (ADR)
7.5 Examples
7.5.1 Writing a Parameter Value
7.5.2 Reading a Parameter Value
7.6 Modbus RTU Overview
7.6.2 What the User Should Already Know
7.6.4 Frequency Converter with Modbus RTU
7.7.1 Frequency Converter with Modbus RTU
7.8 Modbus RTU Message Framing Structure
7.8.1 Frequency Converter with Modbus RTU
7.8.2 Modbus RTU Message Structure
7.8.8 Coil Register Addressing
7.8.9 How to Control the Frequency Converter
7.8.10 Function Codes Supported by Modbus RTU
7.9 How to Access Parameters
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Contents
VLT
®
HVAC Drive Design Guide
7.10 Examples
7.11 Danfoss FC Control Profile
8 General Specifications and Troubleshooting
8.1 Mains Supply Tables
8.2 General Specifications
8.3 Efficiency
8.4 Acoustic Noise
8.5 Peak Voltage on Motor
8.6 Special Conditions
8.7 Troubleshooting
Index
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How to Read this Design Gui...
VLT
®
HVAC Drive Design Guide
1 How to Read this Design Guide
VLT
®
HVAC Drive
FC 100 Series
This guide can be used with all
VLT
®
HVAC Drive frequency converters with software version
3.7x.
The actual software version number can be read from
15-43 Software Version.
1.1.1 Copyright, Limitation of Liability and
Revision Rights
This publication contains information proprietary to
Danfoss. By accepting and using this manual the user agrees that the information contained herein will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication with Danfoss equipment over a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries.
Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical, 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 to this documentation, including its quality, performance, or fitness for a particular purpose.
In no event shall Danfoss be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information contained in this manual, even if advised of the possibility of such damages. In 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 data, the costs to substitute these, or any claims by third parties.
Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former or present users of such revisions or changes.
1.1.2 Available Literature for VLT
®
HVAC
Drive
-
-
-
Design Guide MG.11.Bx.yy entails all technical information about the frequency converter and customer design and applications.
Programming Guide MG.11.Cx.yy provides information on how to programme and includes complete parameter descriptions.
Application Note, Temperature Derating Guide,
MN.11.Ax.yy
PC-based Configuration Tool MCT 10, MG.10.Ax.yy
enables the user to configure the frequency converter from a Windows ™ based PC environment.
-
-
Danfoss VLT
®
Energy Box software at
www.danfoss.com/BusinessAreas/DrivesSolutions
then choose PC Software Download
Operating Instructions VLT
®
HVAC Drive BACnet,
MG.11.Dx.yy
-
-
Operating Instructions VLT
®
HVAC Drive Metasys,
MG.11.Gx.yy
Operating Instructions VLT
®
HVAC Drive FLN,
MG.11.Zx.yy
x = Revision number yy = Language code
Danfoss technical literature is available in print from your local Danfoss Sales Office or online at:
www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm
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1.1.3 Approvals
1.1.4 Symbols
Symbols used in this guide.
NOTE
Indicates something to be noted by the reader.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or equipment damage.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
*
Indicates default setting
VLT
®
HVAC Drive Design Guide
1.1.5 Abbreviations
Alternating current
American wire gauge
Ampere/AMP
Automatic Motor Adaptation
Current limit
Degrees Celsius
Direct current
Drive Dependent
Electro Magnetic Compatibility
Electronic Thermal Relay frequency converter
Gram
Hertz
Horsepower
Kilohertz
Local Control Panel
Meter
Millihenry Inductance
Milliampere
Millisecond
Minute
Motion Control Tool
Nanofarad
Newton Meters
Nominal motor current
Nominal motor frequency
Nominal motor power
Nominal motor voltage
Permanent Magnet motor
Protective Extra Low Voltage
Printed Circuit Board
Rated Inverter Output Current
Revolutions Per Minute
Regenerative terminals
Second
Synchronous Motor Speed
Torque limit
Volts
The maximum output current
The rated output current supplied by the frequency converter
AC
AWG
A
AMA
I
LIM
°C
DC
D-TYPE
EMC mH mA ms min
MCT nF
Nm
I
M,N f
M,N hp kHz
LCP m
ETR
FC g
Hz
P
M,N
U
M,N
PM motor
PELV
PCB
I
INV
RPM
Regen sec.
n s
T
LIM
V
I
VLT,MAX
I
VLT,N
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®
HVAC Drive Design Guide
1.1.6 Definitions
Drive:
I
VLT,MAX
The maximum output current.
I
VLT,N
The rated output current supplied by the frequency converter.
U
VLT, MAX
The maximum output voltage.
Input:
Control command
Start and stop the connected motor with the
LCP or the digital inputs.
Functions are divided into two groups.
Functions in group 1 have higher priority than functions in group 2.
Group
1
Group
2
Reset, Coasting stop, Reset and Coasting stop, Quickstop, DC braking, Stop and the "Off" key.
Start, Pulse start, Reversing,
Start reversing, Jog and
Freeze output
Motor: f
JOG
The motor frequency when the jog function is activated
(via digital terminals).
f
M
The motor frequency.
f
MAX
The maximum motor frequency.
f
MIN
The minimum motor frequency.
f
M,N
The rated motor frequency (nameplate data).
I
M
The motor current.
I
M,N
The rated motor current (nameplate data).
n
M,N
The rated motor speed (nameplate data).
P
M,N
The rated motor power (nameplate data).
T
M,N
The rated torque (motor).
U
M
The instantaneous motor voltage.
U
M,N
The rated motor voltage (nameplate data).
Break-away torque
Torque
Pull-out rpm
η
VLT
The efficiency of the frequency converter is defined as the ratio between the power output and the power input.
Start-disable command
A stop command belonging to the group 1 control commands - see this group.
Stop command
See Control commands.
References:
Analog Reference
A signal transmitted to the analog inputs 53 or 54, can be voltage or current.
Bus Reference
A signal transmitted to the serial communication port (FC port).
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Preset Reference
A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references via the digital terminals.
Pulse Reference
A pulse frequency signal transmitted to the digital inputs
(terminal 29 or 33).
Ref
MAX
Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA) and the resulting reference. The maximum reference value set in
3-03 Maximum Reference.
Ref
MIN
Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4mA) and the resulting reference. The minimum reference value set in
3-02 Minimum Reference
Miscellaneous:
Analog Inputs
The analog inputs are used for controlling various functions of the frequency converter.
There are two types of analog inputs:
Current input, 0-20 mA and 4-20 mA
Voltage input, 0-10 V DC.
Analog Outputs
The analog outputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal.
Automatic Motor Adaptation, AMA
AMA algorithm determines the electrical parameters for the connected motor at standstill.
Brake Resistor
The brake resistor is a module capable of absorbing the brake power generated in regenerative braking. This regenerative braking power increases the intermediate circuit voltage and a brake chopper ensures that the power is transmitted to the brake resistor.
CT Characteristics
Constant torque characteristics used for screw and scroll refrigeration compressors.
Digital Inputs
The digital inputs can be used for controlling various functions of the frequency converter.
Digital Outputs
The frequency converter features two Solid State outputs that can supply a 24 V DC (max. 40 mA) signal.
DSP
Digital Signal Processor.
Relay Outputs:
The frequency converter features two programmable Relay
Outputs.
ETR
Electronic Thermal Relay is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature.
GLCP:
Graphical Local Control Panel (LCP102)
Initialising
If initialising is carried out (14-22 Operation Mode), the programmable 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 an off-load period. The operation can be either periodic duty or noneperiodic duty.
LCP
The Local Control Panel (LCP)keypad makes up a complete interface for control and programming of the frequency converter. The control panelkeypad is detachable and can be installed up to 3 metres from the frequency converter, i.e. in a front panel by means of the installation kit option.
The Local Control Panel is available in two versions:
-
Numerical LCP101 (NLCP)
Graphical LCP102 (GLCP) lsb
Least significant bit.
MCM
Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM ≡ 0.5067 mm
2
.
msb
Most significant bit.
NLCP
Numerical Local Control Panel LCP101
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HVAC Drive Design Guide
On-line/Off-line Parameters
Changes to on-line parameters are activated immediately after the data value is changed. Changes to off-line parameters are not activated until you enter [OK] on the
LCP.
PID Controller
The PID controller maintains the desired speed, pressure, temperature, etc. by adjusting the output frequency to match the varying load.
RCD
Residual Current Device.
Set-up
You can save parameter settings in four Set-ups. Change between the four parameter Set-ups and edit one Set-up, while another Set-up is active.
SFAVM
Switching pattern called Stator Flux oriented Asynchronous
V ector M odulation (14-00 Switching Pattern).
Slip Compensation
The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor speed almost constant.
Smart Logic Control (SLC)
The SLC is a sequence of user defined actions executed when the associated user defined events are evaluated as true by the SLC.
Thermistor:
A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).
Trip
A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency converter is protecting the motor, process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating reset or, in some cases, by being programmed to reset 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 the frequency converter is subject to a short circuit on the output. A locked trip can only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the frequency converter. Restart is prevented until the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically. Trip locked may not be used for personal safety.
VT Characteristics
Variable torque characteristics used for pumps and fans.
VVC plus
If compared with standard voltage/frequency ratio control,
Voltage Vector Control (VVC plus
) improves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque.
60
° AVM
Switching pattern called 60
°Asynchronous Vector
Modulation (See 14-00 Switching Pattern).
1.1.7 Power Factor
The power factor is the relation between I
1
and I
RMS
.
Power factor =
3 ×
U × I1 × COSϕ
3 × U × IRMS
The power factor for 3-phase control:
=
I1 × cosϕ1
IRMS
=
I1
IRMS since cosϕ1 = 1
The power factor indicates to which extent the frequency converter imposes a load on the mains supply.
The lower the power factor, the higher the I
RMS
for the same kW performance.
IRMS = I1
2 + I
In addition, a high power factor indicates that the 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.
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2.1 Safety
2.1.1 Safety Note
WARNING
The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor, frequency converter or fieldbus may cause death, serious personal injury or damage to the equipment.
Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.
Safety Regulations
1.
The frequency converter must be disconnected from mains if repair work is to be carried out.
Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.
2.
The [STOP/RESET] key on the LCP of the frequency converter does not disconnect the equipment from mains and is thus not to be used as a safety switch.
3.
4.
Correct protective earthing of the equipment must be established, the user must be protected against supply voltage, and the motor must be protected against overload in accordance with applicable national and local regulations.
The earth leakage currents are higher than 3.5
mA.
5.
6.
7.
Protection against motor overload is set by
1-90 Motor Thermal Protection. If this function is desired, set 1-90 Motor Thermal Protection to data value [ETR trip] (default value) or data value [ETR warning]. Note: The function is initialized at 1.16
x rated motor current and rated motor frequency.
For the North American market: The ETR functions provide class 20 motor overload protection in accordance with NEC.
Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.
Please 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 inputs have been disconnected and that the necessary time has passed before commencing repair work.
Installation at high altitudes
CAUTION
380 - 500 V, enclosure A, B and C: At altitudes above 2 km, please contact Danfoss regarding PELV.
380 - 500 V, enclosure D, E and F: At altitudes above 3 km, please contact Danfoss regarding PELV.
525 - 690 V: At altitudes above 2 km, please contact
Danfoss regarding PELV.
WARNING
Warning against Unintended Start
1.
2.
3.
The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop, while the frequency converter is connected to mains. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not sufficient.
While parameters are being changed, the motor may start. Consequently, the stop key [STOP/
RESET] must always be activated; following which data can be modified.
A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a temporary overload or a fault in the supply mains or the motor connection ceases.
WARNING
Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains.
Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing
(linkage of DC intermediate circuit), as well as the motor connection for kinetic back up. Refer to the Operating
Instructions for further safety guidelines.
WARNING
The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard, disconnect the frequency converter from the mains before carrying out maintenance. Wait at least as follows before doing service on the frequency converter:
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Voltage
(V)
200 -
240
380 -
480
525 -
600
525 -
690
4
1.1 - 3.7
kW
1.1 - 7.5
kW
1.1 - 7.5
kW
Min. Waiting Time (Minutes)
15
5.5 - 45 kW
11 - 90 kW
11 - 90 kW
11 - 90 kW
20
110 - 250 kW
45 - 400 kW
30
450 -
1400 kW
40
315 -
1000 kW
Be aware that there may be high voltage on the DC link even when the LEDs are turned off.
2.1.2 Disposal Instruction
Equipment containing electrical components may not be disposed of together with domestic waste.
It must be separately collected with electrical and electronic waste according to local and currently valid legislation.
2.2 CE labelling
2.2.1 CE Conformity and Labelling
What is CE Conformity and Labelling?
The purpose of CE labelling is to avoid technical trade obstacles within EFTA and the EU. The EU has introduced the CE label as a simple way of showing whether a product complies with the relevant EU directives. The CE label says nothing about the specifications or quality of the product. Frequency converters are regulated by three
EU directives:
The machinery directive (2006/42/EC)
Frequency converters with integrated safety function are now falling under the Machinery Directive. Danfoss CElabels in accordance with the directive and issues a declaration of conformity upon request. Frequency converters without safety function do not fall under the machinery directive. However, if a frequency converter is supplied for use in a machine, we provide information on safety aspects relating to the frequency converter.
The low-voltage directive (2006/95/EC)
Frequency converters must be CE labelled in accordance with the low-voltage directive of January 1, 1997. The directive applies to all electrical equipment and appliances used in the 50 - 1000 V AC and the 75 - 1500 V DC voltage ranges. Danfoss CE-labels in accordance with the directive and issues a declaration of conformity upon request.
The EMC directive (2004/108/EC)
EMC is short for electromagnetic compatibility. The presence of electromagnetic compatibility means that the mutual interference between different components/ appliances does not affect the way the appliances work.
The EMC directive came into effect January 1, 1996.
Danfoss CE-labels in accordance with the directive and issues a declaration of conformity upon request. To carry out EMC-correct installation, see the instructions in this
Design Guide. In addition, we specify which standards our products comply with. We offer the filters presented in the specifications and provide other types of assistance to ensure the optimum EMC result.
The frequency converter is most often used by professionals of the trade as a complex component forming part of a larger appliance, system or installation. It must be noted 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 Directive
2004/108/EC" outline three typical situations of using a frequency converter. See below for EMC coverage and CE labelling.
1.
2.
3.
The frequency converter is sold directly to the end-consumer. The frequency converter is for example sold to a DIY market. The end-consumer is a layman. He installs the frequency converter himself for use with a hobby machine, a kitchen appliance, etc. For such applications, the frequency converter must be CE labelled in accordance with the EMC directive.
The frequency converter is sold for installation in a plant. The plant is built up by professionals of the trade. It could be a production plant or a heating/ventilation plant designed and installed by professionals of the trade. Neither the frequency converter nor the finished plant has to be CE labelled under the EMC directive. However, the unit must comply with the basic EMC requirements of the directive. This is ensured by using components, appliances, and systems that are CE labelled under the EMC directive.
The frequency converter is sold as part of a complete system. The system is being marketed as complete and could e.g. be an air-conditioning system. The complete system must be CE labelled in accordance with the EMC directive. The manufacturer can ensure CE labelling under the
EMC directive either by using CE labelled components or by testing the EMC of the system.
If he chooses to use only CE labelled components, he does not have to test the entire system.
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2.2.3 Danfoss Frequency Converter and CE
Labelling
CE labelling is a positive feature when used for its original purpose, i.e. to facilitate trade within the EU and EFTA.
However, CE labelling may cover many different specifications. Thus, you have to check what a given CE label specifically covers.
The covered specifications can be very different and a CE label may therefore give the installer a false feeling of security when using a frequency converter as a component in a system or an appliance.
Danfoss CE labels the frequency converters in accordance with the low-voltage directive. This means that if the frequency converter is installed correctly, we guarantee compliance with the low-voltage directive. Danfoss issues a declaration of conformity that confirms our CE labelling in accordance with the low-voltage directive.
The CE label also applies to the EMC directive provided that the instructions for EMC-correct installation and filtering are followed. On this basis, a declaration of conformity in accordance with the EMC directive is issued.
The Design Guide offers detailed instructions for installation to ensure EMC-correct installation. Furthermore,
Danfoss specifies which our different products comply with.
Danfoss provides other types of assistance that can help you obtain the best EMC result.
2.2.4 Compliance with EMC Directive
2004/108/EC
As mentioned, the frequency converter is mostly used by professionals of the trade as a complex component forming part of a larger appliance, system, or installation. It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer. As an aid to the installer, Danfoss has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for Power
Drive systems are complied with, provided that the EMCcorrect instructions for installation are followed, see the section EMC Immunity.
2.3 Air humidity
The frequency converter has been designed to meet the
IEC/EN 60068-2-3 standard, EN 50178 pkt. 9.4.2.2 at 50
°C.
2.4 Aggressive Environments
A frequency converter contains a large number of mechanical and electronic components. All are to some extent vulnerable to environmental effects.
CAUTION
The frequency converter should not be installed in environments 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 reducing the life of the frequency converter.
Degree of protection as per IEC 60529
The safe Stop function may only be installed and operated in a control cabinet with degree of protection IP54 or higher (or equivalent environment). 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 and condense in the frequency converter and may cause corrosion of components and metal parts. Steam, oil, and salt water may cause corrosion of components and metal parts. In such environments, use equipment with enclosure rating IP
54/55. As an extra protection, coated printed circuit boards can be ordered as an option.
Airborne Particles such as dust may cause mechanical, electrical, or thermal failure in the frequency converter. A typical indicator of excessive levels of airborne particles is dust particles around the frequency converter fan. In very dusty environments, use equipment with enclosure rating
IP 54/55 or a cabinet for IP 00/IP 20/TYPE 1 equipment.
In environments with high temperatures and humidity, corrosive gases such as sulphur, nitrogen, and chlorine compounds will cause chemical processes on the frequency converter components.
Such chemical reactions will rapidly affect and damage the electronic components. In such environments, mount the equipment in a cabinet with fresh air ventilation, keeping aggressive gases away from the frequency converter.
An extra protection in such areas is a coating of the printed circuit boards, which can be ordered as an option.
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NOTE
Mounting frequency converters in aggressive environments increases the risk of stoppages and considerably reduces the life of the converter.
Before installing the frequency converter, check the ambient air for liquids, particles, and gases. This is done by observing existing installations in this environment. Typical indicators of harmful airborne liquids are water or oil on metal parts, or corrosion of metal parts.
Excessive dust particle levels are often found on installation cabinets and existing electrical installations. One indicator of aggressive airborne gases is blackening of copper rails and cable ends on existing installations.
D and E enclosures have a stainless steel back-channel option to provide additional protection in aggressive environments. Proper ventilation is still required for the internal components of the drive. Contact Danfoss for additional information.
2.5 Vibration and shock
The frequency converter has been tested according to the procedure based on the shown standards:
The frequency converter complies with requirements that exist for units mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors.
•
IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970
•
IEC/EN 60068-2-64: Vibration, broad-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 60204-1).
It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called
Safe Stop. Prior to integration and use of Safe Stop in an installation, a thorough risk analysis on the installation must be carried out in order to determine whether the
Safe Stop functionality and safety category are appropriate and sufficient.
WARNING
In order to install and use the Safe Stop function in accordance with the requirements of Safety Category 3 in
EN 954-1, the related information and instructions of the relevant Design Guide must be followed! The information and instructions of the Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality!
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2 2 power input
DC bus
+10Vdc
0-10Vdc
0/4-20 mA
0-10Vdc
0/4-20 mA
91 (L1)
92 (L2)
93 (L3)
95
PE
88 (-)
89 (+)
50 (+10 V OUT)
S201
53 (A IN)
1S202
54 (A IN)
55 (COM A IN)
12 (+24V OUT)
13 (+24V OUT)
18 (D IN)
19 (D IN)
20 (COM D IN)
27 (D IN/OUT)
ON=0-20mA
OFF=0-10V
+
Switch Mode
Power Supply
15mA
+
24Vdc
200mA
-
P 5-00
24V (NPN)
0V (PNP)
24V (NPN)
0V (PNP)
(U) 96
(V) 97
(W) 98
(PE) 99
(R+) 82
(R-) 81 relay1
03
02
01 relay2
06
05
04
(COM A OUT) 39
(A OUT) 42
Brake resistor
240Vac, 2A
240Vac, 2A
400Vac, 2A
Motor
Analog Output
0/4-20 mA
24V
24V (NPN)
0V (PNP)
S801
ON=Terminated
OFF=Open
0V
5V
29 (D IN/OUT)
24V (NPN)
0V (PNP)
24V
0V
RS-485
Interface
S801
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V
RS-485
32 (D IN)
33 (D IN)
*
37 (D IN)
24V (NPN)
0V (PNP)
24V (NPN)
0V (PNP)
(PNP) = Source
(NPN) = Sink
Illustration 2.1 Diagram showing all electrical terminals. (Terminal 37 present for units with Safe Stop Function only.)
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2.6.2 Safe Stop Installation
To carry out an installation of a Category 0 Stop
(EN60204) in conformity with Safety Category 3 (EN954-1), follow these instructions:
1.
The bridge (jumper) between Terminal 37 and
24V DC must be removed. Cutting or breaking the jumper is not sufficient. Remove it entirely to avoid short-circuiting. See jumper
2.
Connect terminal 37 to 24V DC by a short-circuit protected cable. The 24V DC voltage supply must be interruptible by an EN954-1 Category 3 circuit interrupt device. If the interrupt device and the frequency converter are placed in the same installation panel, you can use an unscreened cable instead of a screened one.
16
12
37
Illustration 2.2 Bridge jumper between terminal 37 and 24V DC
Illustration 2.3 shows a Stopping Category 0 (EN 60204-1)
with safety Category 3 (EN 954-1). The circuit interrupt is caused by an opening door contact. The illustration also shows how to connect a non-safety related hardware coast.
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Coast
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6 phase
Mains
Safety device Cat.3 (Circuit interrupt device, possibly with release input)
Short-circuit protected cable
(if not inside installation cabinet)
12
37
Frequency
Converter
Safe channel
5Vdc
R
1
R
2
Control board
Rectifier
Inverter
2 2
M
Illustration 2.3 Essential aspects of an installation to achieve a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1).
2.7 Advantages
2.7.1 Why use a Frequency Converter for Controlling Fans and Pumps?
A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further information see the text and figure The Laws of Proportionality.
2.7.2 The Clear Advantage - Energy Savings
The very clear advantage of using a frequency converter for controlling the speed of fans or pumps lies in the electricity savings.
When comparing with alternative control systems and technologies, a frequency converter is the optimum energy control system for controlling fan and pump systems.
120
100
80
60
40
20
C
B
A
SYSTEM CURVE
FAN CURVE
0 20 40 60 80 100 120 140 160 180
VOLUME%
Illustration 2.4 The graph is showing fan curves (A, B and C) for reduced fan volumes.
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120
100
80
60
40
20
0
C
B
A
SYSTEM CURVE
FAN CURVE
20 40 60 80 100 120 140 160 180
Voume %
100%
80%
50%
25%
12,5%
120
100
80
60
40
20
ENERGY
CONSUMED
0 20 40 60 80 100 120 140 160 180
Voume %
Illustration 2.5 When using a frequency converter to reduce fan capacity to 60% - more than 50% energy savings may be obtained in typical applications.
2.7.3 Example of Energy Savings
As can be seen from the figure (the laws of proportionality), the flow is controlled by changing the RPM. By reducing the speed only 20% from the rated speed, the flow is also reduced by 20%. This is because the flow is directly proportional to the RPM. The consumption of electricity, however, 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 year, the amount of energy saved is even more than 50%.
The laws of proportionality
Illustration 2.6 describes the dependence of flow, pressure and
power consumption on RPM.
Q = Flow
Q
1
= Rated flow
Q
2
= Reduced flow
H = Pressure
H
1
= Rated pressure
H
2
= Reduced pressure
P = Power
P
P n n
1
2 n = Speed regulation
1
2
= Rated power
= Reduced power
= Rated speed
= Reduced speed
Flow :
Q1
Q2
= n1 n2
Pressure :
Power :
P1
P2
H1
H2
=
= n2
( n1
( n1
) n2
3
2
)
Flow ~n
Pressure ~n
2
50%
Power ~n 3
80% 100% n
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2.7.4 Comparison of Energy Savings
The Danfoss frequency converter solution offers major 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 frequency converter has a build-in facility that enables the frequency converter to function as a Building Management
System, BMS.
to i.e. 60%.
As the graph shows, more than 50% energy savings can be achieved in typical applications.
2 2
Discharge damper
Less energy savings
Maximum energy savings
IGV
Costlier installation
Illustration 2.6 The Three Common Energy Saving Systems.
60
40
100
80
Discharge Damper Solution
IGV Solution
VLT Solution
20
0
0 60 0 60 0 60
Volume %
Illustration 2.7 Discharge dampers reduce power consumption somewhat. Inlet Guide Vans offer a 40% reduction but are expensive to install. The Danfoss frequency converter solution reduces energy consumption with more than 50% and is easy to install.
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2.7.5 Example with Varying Flow over 1 Year
The example below is calculated on the basis of pump characteristics obtained 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 on the price per kWh and price of frequency converter. In this example it is less than a year when compared with valves and constant speed.
Energy savings
P shaft
=P shaft output
Flow distribution over 1 year
(mwg)
60
H s
50
40
30
20
10
B
0 100
C
750rpm
200
1050rpm
300
A
1350rpm
1650rpm
400
( m 3 /h
)
(kW)
60
P shaft
50
40
30
20
10
0
B 1
1350rpm
C 1
750rpm
100
1050rpm
200 300
A 1
1650rpm
400
( m 3 /h
) m
3
/h
Distribution
Valve regulation
% Hours Power Consumpti on
A
1
- B
1 kWh
350 5 438 42,5
300 15 1314 38,5
250 20 1752 35,0
200 20 1752 31,5
150 20 1752 28,0
100 20 1752 23,0
Σ 100 8760
18.615
50.589
61.320
55.188
49.056
40.296
275.064
Frequency converter control
Power Consumptio n
A
1
- C
1 kWh
42,5
29,0
18,5
11,5
6,5
3,5
18.615
38.106
32.412
20.148
11.388
6.132
26.801
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 frequency 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 flow or pressure conditions in the system.
Simple control of process (Flow, Level or Pressure) utilizing the built in PID control.
2.7.7 Cos
φ Compensation
Generally speaking, the VLT
®
HVAC Drive has a cos
φ of 1 and provides power factor correction for the cos
φ of the motor, which means that there is no need to make allowance for the cos
φ of the motor when sizing the power factor correction unit.
2.7.8 Star/Delta Starter or Soft-starter not
Required
When larger motors are started, it is necessary in many countries to use equipment that limits the start-up current.
In more traditional systems, a star/delta starter or softstarter is widely used. Such motor starters are not required if a frequency converter is used.
As illustrated in the figure below, a frequency converter does not consume more than rated current.
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800
700
600
500
400
300
200
100
0
0 12,5
4
1
25
3
2
37,5 50Hz
Full load
& speed
1 = VLT
®
HVAC Drive
2 = Star/delta starter
3 = Soft-starter
4 = Start directly 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 the cost of installing the two different systems. In the example on the following page, the two systems can be established at roughly the same price.
2.7.10 Without a Frequency Converter
The figure shows a fan system made in the traditional way.
D.D.C.
=
Direct Digital
Control
E.M.S.
=
Energy
Management system
V.A.V.
= Variable Air Volume
Sensor P = Pressure
Sensor
T
= Temperature
Cooling section Heating section
+
Return Flow
3-Port valve
Bypass
Return
Control
Flow
3-Port
Bypass
Control
Inlet guide vane Fan section
Fan
M x6
IGV
Motor or actuator
P.F.C
M x6
Pump
Starter
Fuses
LV supply
Mains
M x6
Pump
Starter
Fuses
Mains
P.F.C
Control
Starter
Mains
Factor
Correction control
0/10V
Duct
D.D.C.
control
V.A.V
outlets
Temperature control signal
0/10V
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2.7.11 With a Frequency Converter
Cooling section Heating section Fan section
Return
-
Flow Return
+
Flow x3
M
Pump x3
VLT
M
Pump x3
VLT VLT
Duct
V.A.V
outlets
Mains
0-10V
0/4-20mA
Mains
Mains
Illustration 2.8 The illustration shows a fan system controlled by frequency converters.
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2.7.12 Application Examples
The next few pages give typical examples of applications within HVAC.
If you would like to receive further information about a given application, please ask your Danfoss supplier for an information sheet that gives a full description of the application.
Variable Air Volume
Ask for The Drive to...Improving Variable Air Volume Ventilation 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 towers MN.60.C1.02
Condenser pumps
Ask for The Drive to...Improving condenser water pumping systems MN.60.F1.02
Primary pumps
Ask for The Drive to...Improve your primary pumping in primay/secondary pumping systems MN.60.D1.02
Secondary pumps
Ask for The Drive to...Improve your secondary pumping in primay/secondary pumping systems MN.60.E1.02
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2.7.13 Variable Air Volume
VAV or Variable Air Volume systems, are used to control both the ventilation and temperature to satisfy the requirements of a building. Central VAV systems are considered to be the most energy efficient method to air condition buildings. By designing central systems instead of distributed systems, a greater efficiency can be obtained.
The efficiency comes from utilizing larger fans and larger chillers which have much higher efficiencies than small motors and distributed air-cooled chillers. Savings are also seen from the decreased maintenance requirements.
2.7.14 The VLT Solution
While dampers and IGVs work to maintain a constant pressure in the ductwork, a frequency converter solution saves much more energy and 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 the flow and pressure required by the system.
Centrifugal devices such as fans behave according to the centrifugal laws. This means the fans decrease the pressure and flow they produce as their speed is reduced. Their power consumption is thereby significantly reduced.
The return fan is frequently controlled to maintain a fixed difference in airflow between the supply and return. The advanced PID controller of the HVAC frequency converter can be used to eliminate the need for additional controllers.
2 2
D1
D2
Cooling coil
Heating coil
Filter
Frequency converter
Pressure signal
Supply fan
3
Flow
Pressure transmitter
Frequency converter
Return fan
3
Flow
VAV boxes
T
D3
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2.7.15 Constant Air Volume
CAV, or Constant Air Volume systems are central ventilation systems usually used to supply large common zones with the minimum amounts of fresh tempered air. They preceded VAV systems and therefore are found in older multi-zoned commercial buildings as well. These systems preheat amounts of fresh air utilizing Air Handling Units (AHUs) with a heating coil, and many are also used to air condition buildings and have a cooling coil. Fan coil units are frequently used to assist in the heating and cooling requirements in the individual zones.
2.7.16 The VLT Solution
With a frequency converter, significant energy savings can be obtained while maintaining decent control of the building.
Temperature sensors or CO
2 sensors can be used as feedback signals to frequency converters. Whether controlling temperature, air quality, or both, a CAV system can be controlled to operate based on actual building conditions. As the number of people in the controlled area decreases, the need for fresh air decreases. The CO
2
sensor detects lower levels and decreases the supply fans speed. The return fan modulates to maintain a static pressure setpoint or fixed difference between the supply and return air flows.
With temperature control, especially used in air conditioning 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, the supply fan can decrease its speed. The return fan modulates to maintain a static pressure set-point. By decreasing the air flow, energy used to heat or cool the fresh air is also reduced, adding further savings.
Several features of the Danfoss HVAC dedicated frequency converter can be utilized to improve the performance of your
CAV system. One concern of controlling a ventilation system is poor air quality. The programmable minimum frequency can be set to maintain a minimum amount of supply air regardless of the feedback or reference signal. The frequency converter also includes a 3-zone, 3 setpoint PID controller which allows monitoring both temperature and air quality. Even if the temperature requirement is satisfied, the frequency converter will maintain enough supply air to satisfy the air quality sensor. The controller is capable of monitoring and comparing two feedback signals to control the return fan by maintaining a fixed differential air flow between the supply and return ducts as well.
Cooling coil
Heating coil
Filter
Frequency converter
Temperature signal
Supply fan
D1
Temperature transmitter
D2
Pressure signal
Frequency converter
Return fan
D3
Pressure transmitter
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2.7.17 Cooling Tower Fan
Cooling Tower Fans are used to cool condenser water in water cooled chiller systems. Water cooled chillers provide the most efficient means of creating chilled water. They are as much as 20% more efficient than air cooled chillers. Depending on climate, cooling towers are often the most energy efficient method of cooling the condenser water from chillers.
They cool the condenser water by evaporation.
The condenser water is sprayed into the cooling tower onto the cooling towers “fill” to increase its surface area. The tower fan blows air through the fill and sprayed water to aid in the evaporation. Evaporation removes energy from the water dropping its temperature. The cooled water collects in the cooling towers basin where it is pumped back into the chillers condenser and the cycle is repeated.
2.7.18 The VLT Solution
With a frequency converter, the cooling towers fans can be controlled to the required 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, the HVAC frequency converter can be utilized to improve the performance of your cooling tower fans application. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes small. Also, when utilizing a gear-box to frequency control the tower fan, a minimum speed of 40-50% may be required.
The customer programmable minimum frequency setting is available to maintain this minimum frequency even as the feedback or speed reference calls for lower speeds.
Also as a standard feature, you can program the frequency converter to enter a “sleep” mode and stop the fan until a higher speed is required. Additionally, some cooling tower fans have undesireable frequencies that may cause vibrations.
These frequencies can easily be avoided by programming the bypass frequency ranges in the frequency converter.
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Frequency converter
Water Inlet
BASIN
Water Outlet
Temperature
Sensor
Conderser
Water pump
Supply
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2.7.19 Condenser Pumps
Condenser Water pumps are primarily used to circulate water through the condenser section of water cooled chillers and their associated cooling tower. The condenser water absorbs the heat from the chiller's condenser section and releases it into the atmosphere in the cooling tower. These systems are used to provide the most efficient means of creating chilled water, they are as much as 20% more efficient 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 impeller.
Using a frequency converter instead of a throttling valve simply saves the energy that would have been absorbed by the valve. This can amount to savings of 15-20% or more. Trimming the pump impeller is irreversible, thus if the conditions change and higher flow is required the impeller must be replaced.
2 2
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Water
Inlet
BASIN
Flow or pressure sensor
Water
Outlet
Condenser
Water pump
Throttling valve
Supply
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2.7.21 Primary Pumps
Primary pumps in a primary/secondary pumping system can be used to maintain a constant flow through devices that encounter operation or control difficulties when exposed to variable flow. The primary/secondary pumping technique decouples the “primary” production loop from the “secondary” distribution loop. This allows devices such as chillers to obtain constant design flow and operate properly while allowing the rest of the system to vary in flow.
As the evaporator flow rate decreases in a chiller, the chilled water begins to become over-chilled. As this happens, the chiller attempts to decrease its cooling capacity. If the flow rate drops far enough, or too quickly, the chiller cannot shed its load sufficiently and the chiller’s low evaporator temperature safety trips the chiller requiring a manual reset. This situation is common in large installations especially when two or more chillers in parallel are installed if primary/ secondary pumping is not utilized.
2.7.22 The VLT Solution
Depending on the size of the system and the size of the primary loop, the energy consumption of the primary loop can become substantial.
A frequency converter can be added to the primary system, to replace the throttling valve and/or trimming of the impellers, leading to reduced operating expenses. Two 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 be used to control the pump directly. Using the built-in PID controller, the frequency converter will always maintain the appropriate flow rate, even compensating for the changing resistance in the primary piping loop as chillers and their pumps are staged on and off.
The other method is local speed determination. The operator simply decreases the output frequency until the design flow rate is achieved.
Using a frequency converter to decrease the pump speed is very similar to trimming the pump impeller, except it doesn’t require any labor and the pump efficiency remains higher. The balancing contractor simply decreases the speed of the pump until the proper flow rate is achieved and leaves the speed fixed. The pump will operate at this speed any time the chiller is staged on. Because the primary loop doesn’t have control valves or other devices that can cause the system curve to change and the variance due to staging pumps and chillers on and off is usually small, this fixed speed will remain appropriate. In the event the flow rate needs to be increased later in the systems life, the frequency converter can simply increase the pump speed instead of requiring a new pump impeller.
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F
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F
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2.7.23 Secondary Pumps
Secondary pumps in a primary/secondary chilled water pumping system are used to distribute the chilled water to the loads from the primary production loop. The primary/secondary pumping system is used to hydronically de-couple one piping loop from another. In this case. The primary pump is used to maintain a constant flow through the chillers while allowing the secondary pumps to vary in flow, increase control and save energy.
If the primary/secondary design concept is not used and a variable volume system is designed, when the flow rate drops far enough or too quickly, the chiller cannot shed its load properly. The chiller’s low evaporator temperature safety then trips the chiller requiring a manual reset. This situation is common in large installations especially when two or more chillers in parallel are installed.
2.7.24 The VLT Solution
While the primary-secondary system with two-way valves improves energy savings 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 the pumps to vary their speed to follow the system curve instead of the pump curve.
This results in the elimination of wasted energy and eliminates most of the over-pressurization, two-way valves can be subjected too.
As the monitored loads are reached, the two-way valves close down. This increases the differential pressure measured across the load and two-way valve. As this differential pressure starts to rise, the pump is slowed to maintain the control head also called setpoint value. This set-point value is calculated by summing the pressure drop of the load and two way valve together under design conditions.
Please note that when running multiple pumps in parallel, they must run at the same speed to maximize energy savings, either with individual dedicated drives or one frequency converter running multiple pumps in parallel.
P
3
Frequency converter
Frequency converter
3
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2.7.25 Why use a Frequency Converter for Controlling Fans and Pumps?
A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further information see the text and figure The Laws of Proportionality.
2.8 Control Structures
2.8.1 Control Principle
Load sharing +
89(+)
LC Filter +
(5A)
L1 91
L2 92
L3 93
R+
82
U 96
V 97
W 98
M
P 14-50
88(-)
Load sharing -
R inr Inrush
LC Filter -
(5A)
Illustration 2.9 Control structures.
The frequency converter is a high performance unit for demanding applications. It can handle various kinds of motor control principles such as U/f special motor mode and VVC plus
and can handle normal squirrel cage asynchronous motors.
Short circuit behavior on this frequency converter depends on the 3 current transducers in the motor phases.
In 1-00 Configuration Mode it can be selected if open or closed loop is to be used
2.8.2 Control Structure Open Loop
Reference handling
Remote reference
Auto mode
Hand mode
Remote
Linked to hand/auto
Local
Local reference scaled to
RPM or Hz
LCP Hand on, off and auto on keys
P 3-13
Reference site
Illustration 2.10 Open Loop structure.
Reference
P 4-13
Motor speed high limit [RPM]
P 4-14
Motor speed high limit [Hz]
P 4-11
Motor speed low limit [RPM]
P 4-12
Motor speed low limit [Hz]
P 3-4* Ramp 1
P 3-5* Ramp 2
Ramp
100%
0%
100%
-100%
To motor control
P 4-10
Motor speed direction
the reference handling system or the local reference is received and fed through the ramp limitation and speed limitation before being sent to the motor control.
The output from the motor control is then limited by the maximum frequency limit.
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2.8.3 PM/EC+ Motor Control
The Danfoss EC+ concept provides the possibitily for using high efficient PM motors in IEC standard frame size operated by Danfoss frequency converters.
The commissioning procedure is comparable to the existing one for asynchronous (induction) motors by utilising the Danfoss VVC plus
PM control strategy.
Customer advantages:
•
Free choice of motor technology (permanent magnet or induction motor)
•
Installation and operation as know on induction motors
•
Manufacturer independent when choosing system components (e.g. motors)
•
Best system efficiency by choosing best components
•
Possible retrofit of existing installations
•
High power range: 1,1 -1400 kW for Induction motors and 1,1 – 22 KW for PM motors
Current limitations:
•
Currently only supported up to 22 Kw
•
Currently limited to non salient type PM motors
•
LC filters not supported together with PM motors
•
Over Voltage Control algorithm is not supported with PM motors
•
Kinetic backup algorithm is not supported with
PM motors
•
AMA algorithm is not supported with PM motors
•
No missing motorphase detection
•
No stall detection
•
No ETR function
2.8.4 Local (Hand On) and Remote (Auto
On) Control
The frequency converter can be operated manually via the local control panel (LCP) or remotely via analog/digital inputs or serial bus.
If allowed in 0-40 [Hand on] Key on LCP, 0-41 [Off] Key on
LCP, 0-42 [Auto on] Key on LCP, and 0-43 [Reset] Key on LCP, it is possible to start and stop the frequency converter byLCP using the [Hand ON] and [Off] keys. Alarms can be reset via the [RESET] key. After pressing the [Hand ON] key, the frequency converter goes into Hand Mode and follows
(as default) the Local reference set by using the LCP arrow keys up [
▲
] and down [
▼
].
After pressing the [Auto On] key, the frequency converter goes into Auto mode and follows (as default) the Remote reference. In this mode, it is possible to control the frequency converter via the digital inputs and various serial interfaces (RS-485, USB, or an optional fieldbus). See more about starting, stopping, changing ramps and parameter set-ups etc. in parameter group 5-1* (digital inputs) or parameter group 8-5* (serial communication).
Hand on
Off
Auto on
Reset
Hand Off
Auto
LCP Keys
Hand
Reference Site
3-13 Reference Site
Active Reference
Hand -> Off
Auto
Auto -> Off
All keys
All keys
Linked to Hand /
Auto
Linked to Hand /
Auto
Linked to Hand /
Auto
Linked to Hand /
Auto
Local
Remote
Local
Local
Remote
Remote
Local
Remote
Table 2.1 Conditions for either Local or Remote Reference
Table 2.1 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 reference will force the configuration mode to open loop, independent on the setting of 1-00 Configuration
Mode.
Local Reference will be restored at power-down.
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2.8.5 Control Structure Closed Loop
The internal controller allows the frequency converter to become an integral part of the controlled system. The frequency converter receives a feedback signal from a sensor in the system. It then compares this feedback to a set-point reference value and determines the error, if any, between these two signals. It then adjusts the speed of the motor to correct this error.
For example, consider a pump application where the speed of a pump is to be controlled so that the static pressure in a pipe is constant. The desired static pressure value is supplied to the frequency converter as the set-point reference. A static pressure sensor measures the actual static pressure in the pipe and supplies this to the frequency converter as a feedback signal. If the feedback signal is greater than the set-point reference, the frequency converter will slow down to reduce the pressure. In a similar way, if the pipe pressure is lower than the set-point reference, the frequency converter will automatically speed up to increase the pressure provided by the pump.
100%
0%
Ref.
Handling
(Illustration)
+
_
Feedback
Handling
(Illustration)
*[-1]
P 20-81
PID Normal/Inverse
Control
Illustration 2.11 Block Diagram of Closed Loop Controller
PID
100%
-100%
P 4-10
Motor speed direction
Scale to speed
To motor control
While the default values for the frequency converter’s Closed Loop controller will often provide satisfactory performance, the control of the system can often be optimized by adjusting some of the Closed Loop controller’s parameters. It is also possible to autotune the PI constants.
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2.8.6 Feedback Handling
0%
Setpoint to
Reference
Handling
Setpoint 1
P 20-21
Setpoint 2
P 20-22
Setpoint 3
P 20-23
Multi setpoint min.
Multi setpoint max.
0%
0%
Feedback
Feedback 1 Source
P 20-00
Feedback 2 Source
P 20-03
Feedback 3 Source
P 20-06
Feedback conv.
P 20-01
Feedback conv.
P 20-04
Feedback conv.
P 20-07
Feedback 1
Feedback 2
Feedback 3
Feedback 1 only
Feedback 2 only
Feedback 3 only
Sum (1+2+3)
Difference (1-2)
Average (1+2+3)
Minimum (1|2|3)
Maximum (1|2|3)
0%
Feedback Function
P 20-20
Illustration 2.12 Block Diagram of Feedback Signal Processing
Feedback handling can be configured to work with applications requiring advanced control, such as multiple setpoints and multiple feedbacks. Three types of control are common.
Single Zone, Single Setpoint
Single Zone Single Setpoint is a basic configuration. Setpoint 1 is added to any other reference (if any, see Reference
Handling) and the feedback signal is selected using 20-20 Feedback Function.
Multi Zone, Single Setpoint
Multi Zone Single Setpoint uses two 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 exclusively in this configuration.
If Multi Setpoint Min [13] is selected, the setpoint/feedback pair with the largest difference controls the speed of the frequency converter.Multi Setpoint Maximum [14] attempts to keep all zones at or below their respective setpoints, while
Multi Setpoint Min [13] attempts to keep all zones at or above their respective setpoints.
Example:
A two zone two setpoint application Zone 1 setpoint is 15 bar and the feedback is 5.5 bar. Zone 2 setpoint is 4.4 bar and the feedback is 4.6 bar. If Multi Setpoint Max [14] is selected, Zone 1’s setpoint and feedback are sent to the PID controller, since this has the smaller difference (feedback is higher than setpoint, resulting in a negative difference). If Multi Setpoint
Min [13] is selected, Zone 2’s setpoint and feedback is sent to the PID controller, since this has the larger difference
(feedback is lower than setpoint, resulting in a positive difference).
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2.8.7 Feedback Conversion
In some applications it may be useful to convert the feedback signal. One example of this is using 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 in Illustration 2.13.
Ref.
+
P 20-01
P 20-04
-
FB conversion
FB
PID
Flow
P
P
P
Flow
Illustration 2.13 Feedback Conversion
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2.8.8 Reference Handling
Details for Open Loop and Closed Loop operation.
P 3-14
Preset relative ref.
No function
Analog inputs
Frequency inputs
Ext. closed loop outputs
DigiPot
[3]
[4]
[5]
[0]
[1]
[2]
[6]
[7]
No function
Analog inputs
Frequency inputs
Ext. closed loop outputs
DigiPot
External reference in %
No function
Analog inputs
Frequency inputs
Ext. closed loop outputs
DigiPot
Setpoint
Closed loop
±200%
From Feedback Handling
0%
Open loop
Bus reference
Illustration 2.14 Block Diagram Showing Remote Reference
Input command:
Freeze ref.
P 1-00
Configuration mode
Open loop
Scale to
RPM,Hz or %
P 3-04
Ref. function
Y
X
Relative
X+X*Y
/100
±200%
±200% on
±200% off
Input command:
Ref. Preset max ref.
%
±100%
& increase/
Input command:
Speed up/ speed down
Ref. in %
Scale to
Closed loop unit
Closed loop
Increase
0/1
Decrease
0/1
Clear
0/1
DigiPot
Digipot ref.
±200%
Remote ref.
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The Remote Reference is comprised of:
•
Preset references.
•
External references (analog inputs, pulse frequency inputs, digital potentiometer inputs and serial communication bus references).
•
The Preset relative reference.
•
Feedback controlled setpoint.
Up to 8 preset references can be programmed in the drive.
The active preset reference can be selected using digital inputs or the serial communications bus. The reference can also be supplied externally, most commonly from an analog input. This external source is selected by one of the
3 Reference Source parameters (3-15 Reference 1 Source,
3-16 Reference 2 Source and 3-17 Reference 3 Source).
Digipot is a digital potentiometer. This is also commonly called a Speed Up/Speed Down Control or a Floating Point
Control. To set it up, one digital input is programmed to increase the reference while another digital input is programmed to decrease the reference. A third digital input can be used to reset the Digipot reference. All reference resources and the bus reference are added to produce the 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 3-14 Preset Relative
Reference.
The scaled reference is calculated as follows:
Reference = X + X ×
(
Y
100
)
Where X is the external reference, the preset reference or the sum of these and Y is 3-14 Preset Relative Reference in
[%].
If Y, 3-14 Preset Relative Reference is set to 0%, the reference will not be affected by the scaling.
2.8.9 Example of Closed Loop PID Control
The following is an example of a Closed Loop Control for a ventilation system:
In a ventilation system, the temperature is to be maintained at a constant value. The desired temperature is set between -5 and +35°C using a 0-10V potentiometer.
Because this is a cooling application, if the temperature is above the set-point value, the speed of the fan must be increased to provide more cooling air flow. The temperature sensor has a range of -10 to +40°C and uses a two-wire transmitter to provide a 4-20mA signal. The output frequency range of the frequency converter is 10 to
50Hz.
1.
2.
3.
L1
L2
L3
N
PE
F1
Start/Stop via switch connected between terminals 12 (+24V) and 18.
Temperature reference via a potentiometer (-5 to
+35
°C, 0 10V) connected to terminals 50 (+10V),
53 (input) and 55 (common).
Temperature feedback via transmitter (-10-40
°C,
4-20mA) connected to terminal 54. Switch S202 behind the LCP set to ON (current input).
91 92 93 95
L1 L2 L3 PE
U V W PE
96 97 98 99
3
M
12
37
18
50
53
55
54
Transmitter
2 2
Cold air
100kW
Heat process
W n °C
Temperature transmitter
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2.8.10 Programming Order
NOTE
In this example it is assumed an induction motor is used, i.e. that 1-10 Motor Construction = [0] Asynchron.
Function
1) Make sure the motor runs properly. Do the following:
Set the motor parameters using nameplate data.
Run Automatic Motor Adaptation.
Par. no.
1-2*
1-29
2) Check that the motor is running in the right direction.
Run Motor Rotation Check.
1-28
Setting
As specified by motor name plate
Enable complete AMA [1] and then run the AMA function.
If the motor runs in the wrong direction, remove power temporarily and reverse two of the motor phases.
3) Make sure the frequency converter limits are set to safe values
Check that the ramp settings are within capabilities of the drive and allowed application operating specifications.
3-41
3-42
Prohibit the motor from reversing (if necessary)
Set acceptable limits for the motor speed.
4-10
4-12
4-14
4-19
1-00 Switch from open loop to closed loop.
4) Configure the feedback to the PID controller.
Select the appropriate reference/feedback unit.
5) Configure the set-point reference for the PID controller.
20-12
Set acceptable limits for the set-point reference.
20-13
20-14
Choose current or voltage by switches S201 / S202
6) Scale the analog inputs used for set-point reference and feedback.
Scale Analog Input 53 for the pressure range of the potentiometer (0 - 10 Bar, 0 - 10 V).
Scale Analog Input 54 for pressure sensor (0 - 10 Bar, 4 -
20 mA)
6-10
6-11
6-14
6-15
6-22
6-23
6-24
6-25
7) Tune the PID controller parameters.
Adjust the drive’s Closed Loop Controller, if needed.
20-93
20-94
8) Finished!
Save the parameter setting to the LCP for safe keeping 0-50
60 sec.
60 sec.
Depends on motor/load size!
Also active in Hand mode.
Clockwise [0]
10 Hz, Motor min speed
50 Hz, Motor max speed
50 Hz, Drive max output frequency
Closed Loop [3]
Bar [71]
0 Bar
10 Bar
0 V
10 V (default)
0 Bar
10 Bar
4 mA
20 mA (default)
0 Bar
10 Bar
See Optimization of the PID Controller, below.
All to LCP [1]
2.8.11 Tuning the Drive Closed Loop Controller
Once the frequency converter's Closed Loop Controller has been set up, the performance of the controller should be tested.
In many cases, its performance may be acceptable 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 optimize these parameter values to provide faster system response while still controlling speed overshoot.
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2.8.12 Manual PID Adjustment
1.
2.
3.
4.
Start the motor
Set 20-93 PID Proportional Gain to 0.3 and increase it until the feedback signal begins to oscillate. If necessary, start and stop the drive or make step changes in the set-point reference to attempt to cause oscillation. Next reduce the PID Proportional Gain until the feedback signal stabilizes. Then reduce the proportional gain by 40-60%.
Set 20-94 PID Integral Time to 20 sec. and reduce it until the feedback signal begins to oscillate. If necessary, start and stop the drive or make step changes in the set-point reference to attempt to cause oscillation. Next, increase the PID Integral Time until the feedback signal stabilizes. Then increase of the Integral Time by 15-50%.
20-95 PID Differentiation Time should only be used for very fast-acting systems. The typical value is 25% of
20-94 PID Integral Time. The differential function should only be used when the setting of the proportional gain and the integral time has been fully optimized. Make sure that oscillations of the feedback signal are sufficiently dampened by the low-pass filter for the feedback signal (parameters 6-16, 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 frequencies in the range 150kHz to 30MHz. Airborne interference from the frequency converter system in the range 30MHz to 1GHz is generated from the inverter, motor cable, and the motor.
generate leakage currents.
capacitance to earth than unscreened cables. If the leakage current is not filtered, it will cause greater interference on the mains in the radio frequency range below approximately 5MHz. Since the leakage current (I
1
) is carried back to the unit through the screen (I
3
), there will in principle only be a small electro-magnetic field (I
4
) from the screened motor cable according to the below figure.
The screen reduces the radiated interference but increases the low-frequency interference on the mains. The motor cable screen must be connected to the frequency converter enclosure as well as on the motor enclosure. This is best done by using integrated screen clamps so as to avoid twisted screen ends (pigtails). These increase the screen impedance at higher frequencies, which reduces the screen effect and increases the leakage current (I
4
).
If a screened cable is used for fieldbus, relay, control cable, signal interface and brake, the screen must be mounted on the enclosure at both ends. In some situations, however, it will be necessary to break the screen to avoid current loops.
LINE
FREQUENCY
CONVERTER
MOTOR CABLE SCREENED MOTOR
2 2
C
S z z z z
PE
L1
L2
L3
PE
C
S
U
V
W
PE
C
S
I
4
I
2
I
3
I
1
Earth Plane
Illustration 2.15 Situation that Generates Leakage Currents
C
S
Earth wire
Screen
I
4
C
S
C
S
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If the screen is to be placed on a mounting plate for the frequency converter, the mounting plate must be made of metal, because the screen currents have to be conveyed back to the unit. Moreover, ensure good electrical contact from the mounting plate through the mounting screws to the frequency converter chassis.
When unscreened cables are used, some emission requirements are not complied with, although the immunity requirements are observed.
In order to reduce the interference level from the entire system (unit + installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50MHz (airborne) is especially generated by the control electronics. Please see for more information on EMC.
2.9.2 Emission Requirements
According to the EMC product standard for adjustable speed frequency converters EN/IEC 61800-3:2004 the EMC requirements depend on the intended use of the frequency converter. Four categories are defined in the EMC product standard. The definitions of the 4 categories together with the requirements for mains supply voltage conducted emissions
Category Definition
Conducted emission requirement according to the limits given in EN
55011
Class B C1
C2
C3
C4
Frequency converters installed in the first environment (home and office) with a supply voltage less than 1000V.
Frequency converters installed in the first environment (home and office) with a supply voltage less than 1000V, which are neither plug-in nor movable and are intended to be installed and commissioned by a professional.
Frequency converters installed in the second environment (industrial) with a supply voltage lower than 1000V.
Frequency converters installed in the second environment with a supply voltage equal to or above 1000V or rated current equal to or above 400A or intended for use in complex systems.
Table 2.2 Emission Requirements
Class A Group 1
Class A Group 2
No limit line.
An EMC plan should be made.
When the generic emission standards are used the frequency converters are required to comply with the following limits
Environment
First environment
(home and office)
Second environment
(industrial environment)
Generic standard
EN/IEC 61000-6-3 Emission standard for residential, commercial and light industrial environments.
EN/IEC 61000-6-4 Emission standard for industrial environments.
Conducted emission requirement according to the limits given in EN 55011
Class B
Class A Group 1
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2.9.3 EMC Test Results (Emission)
The following test results have been obtained using a system with a frequency converter (with options if relevant), a screened control cable, a control box with potentiometer, as well as a motor and motor screened cable.
RFI filter type Conducted emission.
Maximum shielded cable length.
Radiated emission
Standard
Industrial environment
EN 55011 Class
A2
EN 55011
Class A1
Housing, trades and light industries
EN 55011 Class
B
Industrial environment
EN 55011 Class
A1
Housing, trades and light industries
EN 55011 Class B
H1
1.1-45kW 200-240V
1.1-9 kW 380-480V
T2
T4
150 m
150 m
150 m
150 m
50 m
50 m
Yes
Yes
No
No
H2
H3
1.1-3.7kW 200-240V
5.5-45kW 200-240V
1.1-7.5kW 380-480V
11-90kW 380-480V
110-1000kW 380-480V
11-90kW 525-690V
45-1400kW 525-690V
1.1-45kW 200-240V
1.1-90kW 380-480V
H4
110-1000kW 380-480V
45-400kW 525-690V
11-90kW 525-690V
Hx
1.1-90 kW 525-600 V
T4
T7
T7
T2
T2
T4
T4
T2
T4
T4
T7
T7
T6
5 m
25 m
5 m
25 m
150 m
Yes
150 m
75 m
75 m
150 m
150 m
No
-
No
No
No
No
No
No
No
50 m
50 m
150 m
30 m
Yes
-
No
No
No
No
No
No
No
10 m
10 m
No
No
No
-
No
No
No
No
No
No
No
Yes
Yes
Yes
No
Yes
-
No
No
No
No
No
No
No
No
No
No
No
No
-
Table 2.3 EMC Test Results (Emission)
HX, H1, H2 or H3 is defined in the type code pos. 16 - 17 for EMC filters
HX - No EMC filters built in the frequency converter (600V 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 A1 only)
H4 - Integrated EMC filter. Fulfil class A1
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2.9.4 General Aspects of Harmonics
Emission
A frequency converter takes up a non-sinusoidal current from mains, which increases the input current I
RMS
. A nonsinusoidal current is transformed by means of a Fourier analysis and split up into sine-wave currents with different frequencies, i.e. different harmonic currents I n
with 50Hz as the basic frequency:
Harmonic currents
Hz
I
1
50Hz
I
5
250Hz
I
7
350Hz
The harmonics do not affect the power consumption directly but increase the heat losses in the installation
(transformer, cables). Consequently, in plants with a high percentage of rectifier load, maintain harmonic currents at a low level to avoid overload of the transformer and high temperature in the cables.
NOTE
Some of the harmonic currents might disturb communication equipment connected to the same transformer or cause resonance in connection with power-factor correction batteries.
To ensure low harmonic currents, the frequency converter is equipped with intermediate circuit coils as standard. This normally reduces the input current I
RMS
by 40%.
The voltage distortion on the mains supply voltage depends on the size of the harmonic currents multiplied by the mains impedance for the frequency in question.
The total voltage distortion THD is calculated on the basis of the individual voltage harmonics using this formula:
THD % = U 25 + U
(U
N
% of U)
2
7 + ... + U
2
N
42
2.9.5 Harmonics Emission Requirements
Equipment connected to the public supply network
Options: Definition:
1 IEC/EN 61000-3-2 Class A for 3-phase balanced equipment (for professional equipment only up to
1kW total power).
2 IEC/EN 61000-3-12 Equipment 16A-75A and professional equipment as from 1kW up to 16A phase current.
2.9.6 Harmonics Test Results (Emission)
Power sizes up to PK75 in T2 and T4 complies with IEC/EN
61000-3-2 Class A. Power sizes from P1K1 and up to P18K in T2 and up to P90K in T4 complies with IEC/EN
61000-3-12, Table 4. Power sizes P110 - P450 in T4 also complies with IEC/EN 61000-3-12 even though not required because currents are above 75A.
Actual
(typical)
Limit for
R sce
≥120
Actual
(typical)
Limit for
R sce
≥120
I
5
40
40
Individual Harmonic Current I n
/I
1
(%)
48
I
7
20
25
I
11
10
15
Table 2.4 Harmonics Test Results (Emission)
46
I
13
8
10
Harmonic current distortion factor (%)
THD PWHD
46 45
Provided that the short-circuit power of the supply S sc
is greater than or equal to:
SSC = 3 × RSCE × Umains × Iequ = 3 × 120 × 400 × Iequ at the interface point between the user’s supply and the public system (R sce
).
It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S sc greater than or equal to specified above.
Other power sizes can be connected to the public supply network by consultation with the distribution network operator.
Compliance with various system level guidelines:
The harmonic current data in the table are given in accordance with IEC/EN61000-3-12 with reference to the
Power Drive Systems product standard. They may be used as the basis for calculation of the harmonic currents'
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2.9.7 Immunity Requirements
The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss frequency converters comply with the requirements for the industrial environment and consequently comply also with the lower requirements for home and office environment with a large safety margin.
In order to document immunity against electrical interference from electrical phenomena, the following immunity tests have been made on a system consisting of a frequency converter (with options if relevant), a screened control cable and a control box with potentiometer, motor cable and motor.
The tests were performed in accordance with the following basic standards:
•
EN 61000-4-2 (IEC 61000-4-2): Electrostatic discharges (ESD): Simulation of electrostatic discharges from human beings.
•
EN 61000-4-3 (IEC 61000-4-3): Incoming electromagnetic field radiation, amplitude modulated simulation of the effects of radar and radio communication equipment as well as mobile communications 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:
Simulation of transients brought about e.g. by lightning that strikes near installations.
•
EN 61000-4-6 (IEC 61000-4-6): RF Common mode:
Simulation of the effect from radio-transmission equipment joined by connection cables.
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Voltage range: 200-240V, 380-480V
Basic standard Burst
IEC 61000-4-4
Acceptance criterion
Line
Motor
Brake
Load sharing
Control wires
Standard bus
Relay wires
Application and Fieldbus options
LCP cable
External 24V DC
B
4kV CM
4kV CM
4kV CM
4kV CM
2kV CM
2kV CM
2kV CM
2kV CM
2kV CM
2V CM
Enclosure
—
Table 2.5 EMC Immunity Form
1) Injection on cable shield
AD: Air Discharge
CD: Contact Discharge
CM: Common mode
DM: Differential mode
Surge
IEC 61000-4-5
B
2kV/2Ω DM
4kV/12Ω CM
4kV/2Ω
1)
4kV/2Ω
1)
4kV/2Ω
1)
2kV/2Ω
1)
2kV/2Ω
1)
2kV/2Ω
1)
2kV/2Ω 1)
2kV/2Ω
1)
0.5kV/2Ω DM
1 kV/12Ω CM
—
ESD
IEC
61000-4-2
B
—
—
—
—
—
—
—
—
—
—
8kV AD
6 kV CD
Radiated electromagnetic field
IEC 61000-4-3
A
—
—
—
—
—
—
—
—
—
—
10V/m
RF common mode voltage
IEC 61000-4-6
A
10V
RMS
10V
RMS
10V
RMS
10V
RMS
10V
RMS
10V
RMS
10V
RMS
10V
RMS
10V
RMS
10V
RMS
—
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2.10 Galvanic Isolation (PELV)
2.10.1 PELV - Protective Extra Low Voltage
PELV offers protection by way of extra low voltage.
Protection against electric shock is ensured when the electrical supply is of the PELV type and the installation is made as described in local/national regulations on PELV supplies.
All control terminals and relay terminals 01-03/04-06 comply with PELV (Protective Extra Low Voltage) (Does not apply to grounded Delta leg above 400V).
Galvanic (ensured) isolation is obtained by fulfilling requirements for higher isolation and by providing the relevant creapage/clearance distances. These requirements are described in the EN 61800-5-1 standard.
The components that make up the electrical isolation, as described below, also comply with the requirements for higher isolation and the relevant test as described in EN
61800-5-1.
The PELV galvanic isolation can be shown in six locations
In order to maintain PELV all connections made to the control terminals must be PELV, e.g. thermistor must be reinforced/double insulated.
1.
2.
3.
4.
5.
6.
Power supply (SMPS) incl. signal isolation of U
DC
, indicating the intermediate current voltage.
Gate drive that runs the IGBTs (trigger transformers/opto-couplers).
Current transducers.
Opto-coupler, brake module.
Internal inrush, RFI, and temperature measurement circuits.
Custom relays.
3
M
The functional galvanic isolation (a and b on drawing) is for the 24V back-up option and for the RS-485 standard bus interface.
WARNING
Installation at high altitude:
380 - 500V, enclosure A, B and C: At altitudes above 2km, please contact Danfoss regarding PELV.
380 - 500V, enclosure D, E and F: At altitudes above 3km, please contact Danfoss regarding PELV.
525 - 690V: At altitudes above 2km, please contact Danfoss regarding PELV.
WARNING
Touching the electrical parts could be fatal - even after the equipment has been disconnected from mains.
Also make sure that other voltage inputs have been disconnected, such as load sharing (linkage of DC intermediate circuit), as well as the motor connection 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 for the specific unit.
2.11 Earth Leakage Current
2.11.1
Follow national and local codes regarding protective earthing of equipment with a leakage current > 3,5 mA.
Frequency converter technology implies high frequency switching at high power. This will generate a leakage current in the earth connection. A fault current in the frequency converter at the output power terminals might contain a DC component which can charge the filter capacitors and cause a transient earth current.
The earth leakage current is made up of several contributions and depends on various system configurations including RFI filtering, screened motor cables, and frequency converter power.
Leakage current [mA] a
2 2
6
5 4 1 2 a
Illustration 2.16 Galvanic Isolation b b
Cable length [m]
Illustration 2.17 Cable Length and Power Size Influence on
Leakage Current. Pa > Pb.
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Leakage current [mA]
THVD=0%
THVD=5%
VLT
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HVAC Drive Design Guide
Leakage current [mA]
100 Hz
2 kHz
100 kHz
Illustration 2.18 Line Distortion Influences Leakage Current.
Illustration 2.20 The influence of the cut-off frequency of the
RCD on what is responded to/measured.
NOTE
When a filter is used, turn off 14-50 RFI Filter when charging the filter, to avoid that a high leakage current makes the RCD switch.
EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3.5mA.
Earth grounding must be reinforced in one of the following ways:
•
Earth ground wire (terminal 95) of at least 10mm 2
•
Two separate earth ground wires both complying with the dimensioning rules
See EN/IEC61800-5-1 and EN50178 for further information.
Using RCDs
Where residual current devices (RCDs), also known as earth leakage circuit breakers (ELCBs), are used, comply with the following:
Use RCDs of type B only which are capable of detecting AC and DC currents
Use RCDs with an inrush delay to prevent faults due to transient earth currents
Dimension RCDs according to the system configuration and environmental considerations
L leakage
[mA]
RCD with low f cut-off
RCD with high f cut-off
See also RCD Application Note, MN.90.GX.02.
2.12 Brake Function
2.12.1 Selection of Brake Resistor
In certain applications, for instance in tunnel or underground railway station ventilation systems, it is desirable to bring the motor to a stop more rapidly than can be achieved through controlling via ramp down or by free-wheeling. In such applications, dynamic braking with a braking resistor may be utilized. Using a braking resistor ensures that the energy is absorbed in the resistor and not in the frequency converter.
If the amount of kinetic energy transferred to the resistor in each braking period is not known, the average power can be calculated on the basis of the cycle time and braking time also called intermitted duty cycle. The resistor intermittent duty cycle is an indication of the duty cycle at which the resistor is active. The below figure shows a typical braking cycle.
The intermittent duty cycle for the resistor is calculated as follows:
Duty Cycle = t b
/ T
T = cycle time in seconds t b
is the braking time in seconds (as part of the total cycle time)
50 Hz
Mains
150 Hz
3rd harmonics f s
f sw
Cable f [Hz]
Illustration 2.19 Main Contributions to Leakage Current.
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Load
Speed ta tc tb to ta tc tb to ta
Time
Danfoss offers brake resistors with duty cycle of 5%, 10% and 40% suitable for use with the VLT
®
HVAC Drive frequency converter series. If a 10% duty cycle resistor is applied, this is able of absorbing braking power upto 10% of the cycle time with the remaining 90% being used to dissipate heat from the resistor.
For further selection advice, please contact Danfoss.
2.12.2 Brake Resistor Calculation
The brake resistance is calculated as shown:
Rbr Ω =
Udc
Ppeak where
P peak
= P motor
x M br
x η motor
x η[W]
As can be seen, the brake resistance depends on the intermediate circuit voltage (U
DC
).
The brake function of the frequency converter is settled in
3 areas of mains power supply:
Size
3 x 200-240V
3 x 380-480V
3 x 525-600V
3 x 525-690V
Brake active Warning before cut out
390V (U
DC
)
778V
943V
405V
810V
965V
1084V 1109V
Cut out (trip)
410V
820V
975V
1130V
NOTE
Check that the brake resistor can cope with a voltage of
410V, 820V or 975V - unless Danfoss brake resistors are used.
Danfoss recommends the brake resistance R rec
, i.e. one that guarantees that the frequency converter is able to brake at the highest braking torque (M br(%)
) of 110%. The formula can be written as:
Rrec Ω =
Udc
Pmotor x Mbr (%) x x motor
η motor
is typically at 0.90
η is typically at 0.98
For 200V, 480V and 600V frequency converters, R rec
at
160% braking torque is written as:
200 V : Rrec =
480 V : Rrec =
107780
Pmotor
375300
Pmotor
Ω
Ω 1)
480
600
690
V : Rrec =
V : Rrec =
V : Rrec =
428914
Pmotor
630137
Pmotor
832664
Pmotor
Ω 2)
Ω
Ω
1) For frequency converters ≤ 7.5kW shaft output
2) For frequency converters > 7.5kW shaft output
NOTE
The resistor brake circuit resistance selected should not be higher than that recommended by Danfoss. If a brake resistor with a higher ohmic value is selected, the braking torque may not be achieved because there is a risk that the frequency converter cuts out for safety reasons.
NOTE
If a short circuit in the brake transistor occurs, power dissipation in the brake resistor is only prevented by using a mains switch or contactor to disconnect the mains for the frequency converter. (The contactor can be controlled by the frequency converter).
WARNING
Do not touch the brake resistor as it can get very hot while/after braking.
2 2
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2.12.3 Control with Brake Function
The brake is protected against short-circuiting of the brake resistor, and the brake transistor is monitored to ensure that short-circuiting of the transistor is detected. A relay/ digital output can be used for protecting the brake resistor against overloading in connection with a fault in the frequency converter.
In addition, the brake makes it possible to read out the momentary power and the mean power for the latest 120 seconds. The brake can also monitor the power energizing and make sure it does not exceed a limit selected in
2-12 Brake Power Limit (kW). In 2-13 Brake Power Monitoring, select the function to carry out when the power transmitted to the brake resistor exceeds the limit set in
2-12 Brake Power Limit (kW).
NOTE
Monitoring the brake power is not a safety function; a thermal switch is required for that purpose. The brake resistor circuit is not earth leakage protected.
Over voltage control (OVC) (exclusive brake resistor) can be selected as an alternative brake function in 2-17 Over-
voltage Control. This function is active for all units. The function ensures that a trip can be avoided if the DC link voltage increases. This is done by increasing the output frequency to limit the voltage from the DC link. It is a very useful function, e.g. if the ramp-down time is too short since tripping of the frequency converter is avoided. In this situation the ramp-down time is extended.
OVC can not be activated when running a PM motor
(when 1-10 Motor Construction is set to [1] PM non salient
SPM).
2.12.4 Brake Resistor Cabling
EMC (twisted cables/shielding)
To reduce the electrical noise from the wires between the brake resistor and the frequency converter, the wires must be twisted.
For enhanced EMC performance a metal screen can be used.
2.13 Extreme Running Conditions
Short Circuit (Motor Phase – Phase)
The frequency converter is protected against short circuits by means of current 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 when the short circuit current exceeds the permitted value
(Alarm 16 Trip Lock).
To protect the frequency converter against a short circuit at the load sharing and brake outputs please see the design guidelines.
See certificate in 2.6.1 Electrical terminals.
Switching on the Output
Switching on the output between the motor and the frequency converter is fully permitted. Switching on the output does not damage the frequency converter in any way. However, fault messages may appear.
Motor-generated Over-voltage
The voltage in the intermediate circuit is increased when the motor acts as a generator. This occurs in following cases:
1.
2.
3.
The load drives the motor (at constant output frequency from the frequency converter), ie. the load generates energy.
During deceleration ("ramp-down") if the moment of inertia is high, the friction is low and the rampdown time is too short for the energy to be dissipated as a loss in the frequency converter, the motor and the installation.
Incorrect slip compensation setting may cause higher DC link voltage.
4.
Back-EMF from PM motor operation. If coasted at high rpm the PM motor back-EMF may potentially exceed the maximum voltage tolerance of the frequency converter and cause damage. To help prevent this, the value of
4-19 Max Output Frequency is automatically limited based on an internal calculation based on the value of 1-40 Back EMF at 1000 RPM,
1-25 Motor Nominal Speed and 1-39 Motor Poles.
If it is possible that the motor may overspeed
(e.g. due to excessive windmilling effects) then it is recommended to equip a brake resistor.
WARNING
The frequency converter must be equipped with a break chopper.
The control unit may attempt to correct the ramp if possible (2-17 Over-voltage Control.
The inverter turns off to protect the transistors and the intermediate circuit capacitors when a certain voltage level is reached.
See 2-10 Brake Function and 2-17 Over-voltage Control to select the method used for controlling the intermediate circuit voltage level.
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NOTE
OVC can not be activated when running a PM motor
(when1-10 Motor Construction is set to [1] PM non salient
SPM).
Mains Drop-out
During a mains drop-out, the frequency converter keeps running until the intermediate circuit voltage drops below the minimum stop level, which is typically 15% below the frequency converter's lowest rated supply voltage. The mains voltage before the drop-out and the motor load determines how long it takes for the inverter to coast.
Static Overload in VVC plus
mode
When the frequency converter is overloaded (the torque limit in 4-16 Torque Limit Motor Mode/4-17 Torque Limit
Generator Mode is reached), the controls reduces the output frequency to reduce the load.
If the overload is excessive, a current may occur that makes the frequency converter cut out after approx. 5-10 sec.
Operation within the torque limit is limited in time (0-60 sec.) in 14-25 Trip Delay at Torque Limit.
2.13.1 Motor Thermal Protection
This is the way Danfoss is protecting the motor from being overheated. It is an electronic feature that simulates a bimetal relay based on internal measurements. The charac-
teristic is shown in Illustration 2.21
t [s]
2000
1000
600
500
400
300
200
100
60
50
40
30
20
10 fOUT = 1 x f M,N(par. 1-23) fOUT = 2 x f M,N fOUT = 0.2 x f M,N
1.0
1.2
1.4
1.6
1.8
2.0
I
MN
I
M
(par. 1-24)
Illustration 2.21 The X-axis is showing the ratio between I motor and I motor
nominal. The Y-axis is showing the time in seconds before the ETR cuts off and trips the frequency converter. 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 the motor. In that way the motor are protected from being over heated even at low speed.
The ETR feature is calculating the motor temperature based on actual current and speed. The calculated temperature is visible as a read out parameter in
16-18 Motor Thermal in the frequency converter.
The thermistor cut-out value is > 3k
Ω.
Integrate a thermistor (PTC sensor) in the motor for winding protection.
Motor protection can be implemented using a range of techniques: PTC sensor in motor windings; mechanical thermal switch (Klixon type); or Electronic Thermal Relay
(ETR).
R
(Ω)
4000
3000
1330
550
250
-20°C nominel -5°C
nominel
nominel +5°C
[°C]
2 2
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Using a digital input and 24V as power supply:
Example: The frequency converter trips when the motor temperature is too high.
Parameter set-up:
Set 1-90 Motor Thermal Protection to Thermistor Trip [2]
Set 1-93 Thermistor Source to Digital Input 33 [6]
12 13 18 19 27 29 32 33 20 37
PTC / Thermistor
ON
<6.6 k Ω >10.8 k Ω
Using a digital input and 10V as power supply:
Example: The frequency converter trips when the motor temperature is too high.
Parameter set-up:
Set 1-90 Motor Thermal Protection to Thermistor Trip [2]
Set 1-93 Thermistor Source to Digital Input 33 [6]
R
39 42 50 53 54 55
OFF
OFF
Input
Digital/analog
Digital
Digital
Analog
Supply Voltage V
Cut-out Values
24
10
10
Threshold
Cut-out Values
< 6.6k
Ω - > 10.8kΩ
< 800
Ω - > 2.7kΩ
< 3.0k
Ω - > 3.0kΩ
NOTE
Check that the chosen supply voltage follows the specification of the used thermistor element.
Summary
With the Torque limit feature the motor is protected for being overloaded independent of the speed. With the ETR the motor is protected for being over heated and there is no need for any further motor protection. That means when the motor is heated up the ETR timer controls for how long time the motor can be running at the high temperature before it is stopped in order to prevent over heating. If the motor is overloaded without reaching the temperature where the ETR shuts of the motor, the torque limit is protecting the motor and application for being overloaded.
ETR is activated in 1-90 Motor Thermal Protection and is controlled in 4-16 Torque Limit Motor Mode. The time before the torque limit warning trips the frequency converter is set in 14-25 Trip Delay at Torque Limit.
12 13 18 19 27 29 32 33 20 37
PTC / Thermistor
ON
<800 Ω >2.7 kΩ
R
Using an analog input and 10V as power supply:
Example: The frequency converter trips when the motor temperature is too high.
Parameter set-up:
Set 1-90 Motor Thermal Protection to Thermistor Trip [2]
Set 1-93 Thermistor Source to Analog Input 54 [2]
Do not select a reference source.
39 42 50 53 54 55
OFF
PTC / Thermistor
ON
<3.0 k Ω
>3.0 k Ω
R
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3 VLT ®
HVAC Drive Selection
3.1 Options and Accessories
Danfoss offers a wide range of options and accessories for the frequency converters.
3.1.1 Mounting of Option Modules in Slot B
The power to the frequency converter must be disconnected.
For A2 and A3 enclosures:
•
Remove the LCP (Local Control Panel), the terminal cover, and the LCP frame from the frequency converter.
•
Fit the MCB1xx option card into slot B.
•
Connect the control cables and relieve the cable by the enclosed cable strips.
Remove the knock out in the extended LCP frame 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 to the frequency converter.
•
Set up the input/output functions in the corresponding parameters, as mentioned in
For B1, B2, C1 and C2 enclosures:
•
Remove the LCP and the LCP cradle
•
Fit the MCB 1xx option card into slot B
•
Connect the control cables and relieve the cable by the enclosed cable strips
•
Fit the cradle
•
Fit the LCP
LCP
Frame
Illustration 3.1 A2, A3 and B3 Enclosures
LCP
Cradle
616
39
42 50 53
5
12
Remove jump er to activate S
13
18 19 27
28 32 38 afe Stop
2
APPLIC
ANU
OUT
XXXN1100
: 3x0-Uin 0-1000H
Stored char ge /
ONTR
ANU
ANU AL / R
“Fran
OL EQUIP sk t ekst ransk t ekst age cur
” (4 min.) z 14.9A
ax 45C/113F rent
A
DC-
DC+
A
B
D
Illustration 3.2 A5, B1, B2, B4, C1, C2, C3 and C4 Enclosures
3.1.2 General Purpose Input Output
Module MCB 101
MCB 101 is used for extension of the number of digital and analog inputs and outputs of the frequency converter.
Contents: MCB 101 must be fitted into slot B in the frequency converter.
•
MCB 101 option module
•
Extended LCP frame
•
Terminal cover
3 3
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MCB 101
General Purpose I/O
SW. ver. XX.XX
FC Series
B slot
Code No. 130BXXXX
X30/ 1 2 3 4 5 6 7 8 9 10 11 12
Galvanic isolation in the MCB 101
Digital/analog inputs are galvanically isolated from other inputs/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 the control card of the frequency converter.
If the digital inputs 7, 8 or 9 are to be switched by use of the internal 24V power supply (terminal 9) the connection
between terminal 1 and 5 which is shown in Illustration 3.3
has to be established.
Control card (FC 100/200/300)
CPU
General Purpose
I/O option MCB 101
0V 24V
DIG IN
0V
CPU
DIG &
ANALOG
OUT
24V
ANALOG
IN
3.1.3 Digital Inputs - Terminal X30/1-4
Parameters for set-up: 5-16, 5-17 and 5-18
Numb er of digital inputs
Volta ge level
Voltage levels Tolerance Max. Input impedance
3 0-24V
DC
PNP type:
Common = 0V
Logic “0”: Input <
5V DC
Logic “0”: Input >
10V DC
NPN type:
Common = 24V
Logic “0”: Input >
19V DC
Logic “0”: Input <
14V DC
± 28V continuous
± 37V in minimum
10 sec.
Approx. 5kΩ
3.1.4 Analog Voltage Inputs - Terminal
X30/10-12
Parameters for set-up: 6-3*, 6-4* and 16-76
Number of analog voltage inputs
Standardized input signal
Tolerance Reso lutio n
2 0-10V DC ± 20V continuously
10 bits
Max. Input impedance
Approx. 5K
Ω
X30/
1 2 3 4 5 6
DOUT4 0/24VDC AOUT2 0/4-20mA 24V
7 8 9 10 11 12
PLC
(PNP)
0V 24V DC
PLC
(NPN)
24V DC 0V
Illustration 3.3 Principle Diagram
0-10
VDC
0-10
VDC
3.1.5 Digital Outputs - Terminal X30/5-7
Parameters for set-up: 5-32 and 5-33
Number of digital outputs
2
Output level Tolerance Max.impedan
0 or 2 V DC ± 4V ce
≥ 600
Ω
3.1.6 Analog Outputs - Terminal X30/5+8
Parameters for set-up: 6-6* and 16-77
Number of analog outputs
1
Output signal level
0/4 - 20mA
Tolerance
± 0.1mA
Max.imp
edance
< 500
Ω
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3.1.7 Relay Option MCB 105
The MCB 105 option includes 3 pieces of SPDT contacts and must be fitted into option slot B.
Electrical Data:
Max terminal load (AC-1) 1) (Resistive load)
Max terminal load (AC-15 )
1)
(Inductive load @ cosφ 0.4)
Max terminal load (DC-1) 1) (Resistive load)
Max terminal load (DC-13)
1)
(Inductive load)
Min terminal load (DC)
Max switching rate at rated load/min load
1) IEC 947 part 4 and 5
When the relay option kit is ordered separately the kit includes:
•
Relay Module MCB 105
•
Extended LCP frame and enlarged terminal cover
•
Label for covering access to switches S201, S202 and S801
•
Cable strips for fastening cables to relay module
APPLIC
ANU
OUT
T/C : CIA
IN: 3x380-480V 50/60H
: 3x0-Uin 0-1000H
XXXPT5B20BR1DBF00A00
Stored char
ONT
VOIR M ge /
CAUTION:
ANU
AL / F
“Fransk t
ROL EQUIP ekst ransk t ekst
” (4 min.)
Tamb M
SEE M
ANU
AL / R
CD and high leak age cur rent
ARK
240 V AC 2A
240 V AC 0.2 A
24 V DC 1 A
24 V DC 0.1 A
5 V 10 mA
6 min
-1
/20 sec
-1
3 3
1
LABEL
DISMOUNT RELAY CARD TO ACCESS RS485
SWITCHES (S201, S202)
A2-A3-B3 A5-B1-B2-B4-C1-C2-C3-C4
1) IMPORTANT! The label MUST be placed on the LCP frame as shown (UL approved).
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68
12
13
Remo
18
19
39
42 ve jumper t
50
53
54
27
29 o ac tivate S afe S top
32
33
20
9Ø
Ø6
9Ø
53
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DC-
DC+
3 3
1
LABEL
DISMOUNT RELAY CARD TO ACCESS RS485
TERMINATION (S801) OR CURRENT/VOLTAGE
SWITCHES (S201, S202)
616
39
42 50
53
5 per to activate S afe Stop
12
13
18 19 27
28 32 38 2
WARNING
Warning Dual supply
How to add the MCB 105 option:
•
See mounting instructions in the beginning of section Options and Accessories
•
The power to the live part connections on relay terminals must be disconnected.
•
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].
NB! (Index [6] is relay 7, index [7] is relay 8, and index [8] is relay 9)
2mm
Relay 7 Relay 8 Relay 9
8-9mm
1 2 3
NC
4 5 6 7
NC
8
NC
9 10 11 12
1
NC NC NC
2 3 4 5 6 7 8 9 10 11 12 1
NC NC NC
2 3 4 5 6 7 8 9 10 11 12 1
NC NC NC
2 3 4 5 6 7 8 9 10 11 12
LIVE
PART
LIVE
PART
PELV PELV PELV PELV LIVE
PART
LIVE
PART
LIVE
PART
WARNING
Do not combine low voltage parts and PELV systems. At a single fault the whole system might become dangerous to touch and it could result in death or serious injury.
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3.1.8 24 V Back-Up Option MCB 107 (Option D)
External 24V DC Supply
An external 24V DC supply can be installed for low-voltage supply to the control card and any option card installed. This enables full operation of the LCP (including the parameter setting) and fieldbusses without mains supplied to the power section.
External 24V DC supply specification:
Input voltage range
Max. input current
Average input current for the frequency converter
Max cable length
Input capacitance load
Power-up delay
The inputs are protected.
24V DC ±15 % (max. 37 V in 10sec.)
2.2A
0.9A
75m
< 10uF
< 0.6sec.
Terminal numbers:
Terminal 35: - external 24V DC supply.
Terminal 36: + external 24V DC supply.
Follow these steps:
1.
Remove the LCP or Blind Cover
2.
3.
Remove the Terminal Cover
Remove the Cable De-coupling Plate and the plastic cover underneath
4.
Insert the 24V DC Backup External Supply Option in the Option Slot
Mount the Cable De-coupling Plate 5.
6.
Attach the Terminal Cover and the LCP or Blind
Cover.
When MCB 107, 24V backup option is supplying the control circuit, the internal 24V supply is automatically disconnected.
90
06
90
311
35 36
3 3
35 36
35
36
Illustration 3.4 Connection to 24V Backup Supplier (A2-A3).
Illustration 3.5 Connection to 24V Backup Supplier (A5-C2).
3.1.9 Analog I/O option MCB 109
The Analog I/O card is supposed to be used in e.g. the following cases:
•
Providing battery back-up of clock function on control card
•
As general extension of analog I/O selection available on control card, e.g. for multi-zone control with three pressure transmitters
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•
Turning frequency converter into de-central I/O block supporting Building Management System with inputs for sensors and outputs for operating dampers and valve actuators
•
Support Extended PID controllers with I/Os for set point inputs, transmitter/sensor inputs and outputs for actuators.
CONTROL CARD (FREQUENCY CONVERTER)
CPU
0 V
ANALOG I/O
OPTION MCB 109
CPU RTC
24 VDC
3V
BATTERY
ANALOG INPUT ANALOG OUTPUT
1 2 3
4 5
6
7
8 9 10 11 12
Pt1000/
Ni 1000
Illustration 3.6 Principle diagram for Analog I/O mounted in frequency converter.
Analog I/O configuration
3 x Analog Inputs, capable of handling following:
•
0 - 10V DC
OR
•
0-20mA (voltage input 0-10V) by mounting a
510
Ω resistor across terminals (see NB!)
•
4-20mA (voltage input 2-10V) by mounting a
510
Ω resistor across terminals (see NB)
•
Ni1000 temperature sensor of 1000
Ω at 0° C.
Specifications according to DIN43760
•
Pt1000 temperature sensor of 1000
Ω at 0° C.
Specifications according to IEC 60751
3 x Analog Outputs supplying 0-10V DC.
NOTE
Please note the values available within the different standard groups of resistors:
E12: Closest standard value is 470
Ω, creating an input of
449.9
Ω and 8.997V.
E24: Closest standard value is 510
Ω, creating an input of
486.4
Ω and 9.728V.
E48: Closest standard value is 511
Ω, creating an input of
487.3
Ω and 9.746V.
E96: Closest standard value is 523
Ω, creating an input of
498.2
Ω and 9.964V.
Analog inputs - terminal X42/1-6
Parameter group for read out: 18-3*. See also VLT
®
HVAC
Drive Programming Guide, MG11CXYY.
Parameter groups for set-up: 26-0*, 26-1*, 26-2* and 26-3*.
See also VLT
®
HVAC Drive Programming Guide, MG11CXYY.
3 x Analog inputs
Used as temperature sensor input
Used as voltage input
Operating range
-50 to +150°C
0 - 10V DC
Resolution
11 bits
10 bits
When used for voltage, analog inputs are scalable by parameters for each input.
When used for temperature sensor, analog inputs scaling is preset to necessary signal level for specified temperature span.
When analog inputs are used for temperature sensors, it is possible to read out feedback value in both
°C and °F.
Accuracy
-50°C
±1 Kelvin
+150°C
±2 Kelvin
0.2% of full scale at cal.
temperature
Sampling
3Hz
2.4Hz
Max load
-
+/- 20V continuously
Impedance
-
Approximately
5k
Ω
When operating with temperature sensors, maximum cable length to connect sensors is 80m non-screened / nontwisted wires.
Analog outputs - terminal X42/7-12
Parameter group for read out and write: 18-3*. See also
VLT
®
HVAC Drive Programming Guide, MG11XYY
Parameter groups for set-up: 26-4*, 26-5* and 26-6*. See also VLT
®
HVAC Drive Programming Guide, MG11XYY
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HVAC Drive Design Guide
3 x Analog outputs
Volt
Output signal level
Resolution Linearity
0-10V DC 11 bits 1% of full scale
Max load
1mA
Analog outputs are scalable by parameters for each output.
The function assigned is selectable via a parameter and have same options as for analog outputs on control card.
For a more detailed description of parameters, please refer to the VLT
®
HVAC Drive Programming Guide, MG11CXYY.
3.1.10 MCB 112 VLT
®
PTC Thermistor Card
The MCB 112 option makes it possible to monitor the temperature of an electrical motor through a galvanically isolated PTC thermistor input. It is a B-option for FC 102 with Safe Stop.
For information on mounting and installation of the option, please see earlier in this section. See also
6 Application Examples for different application possibilities.
X44/ 1 and X44/ 2 are the thermistor inputs, X44/ 12 will enable safe stop of the FC 102 (T-37) if the thermistor values make it necessary and X44/ 10 will inform the FC
102 that a request for Safe Stop came from the MCB 112 in order to ensure a suitable alarm handling. One of the
Digital Inputs of the FC 102 (or a DI of a mounted option) must be set to PTC Card 1 [80] in order to use the information from X44/ 10. 5-19 Terminal 37 Safe Stop
Terminal 37 Safe Stop must be configured to the desired
Safe Stop functionality (default is Safe Stop Alarm).
Real-time clock (RTC) with back-up
The data format of RTC includes year, month, date, hour, minutes and weekday.
Accuracy of clock is better than
± 20 ppm at 25 °C.
The built-in lithium back-up battery lasts on average for minimum 10 years, when frequency converter is operating at 40
°C ambient temperature. If battery pack back-up fails, analog I/O option must be exchanged.
MS 220 DA
Motor protection
ZIEHL
MCB 112 PTC Thermistor Card
X44
1 2
Option B
Code No.130B1137
3 4
11
Reference for 10, 12
10
20-28 VDC
12
20-28 VDC
10 mA
60 mA
5 6 7
DO FOR SAFE ST
8 9 10 11 12
T
P
PTC
M3~
T
P
12 13 18 19 27 29 32 33 20 37
Control Terminals of FC302
ATEX Certification with
The MCB 112 has been certified for ATEX which means that the FC 102 together with the MCB 112 can now be used with motors in potentially explosive atmospheres. See the Operating Instructions for the MCB 112 for more information.
3 3
ATmosphère EXplosive (ATEX)
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3 3
Electrical Data
Resistor connection
PTC compliant with DIN 44081 and DIN 44082
Number
Shut-off value
Reset value
Trigger tolerance
Collective resistance of the sensor loop
Terminal voltage
Sensor current
Short circuit
Power consumption
Testing conditions
EN 60 947-8
Measurement voltage surge resistance
Overvoltage category
Pollution degree
Measurement isolation voltage Vbis
Reliable galvanic isolation until Vi
Perm. ambient temperature
Moisture
EMC resistance
EMC emissions
Vibration resistance
Shock resistance
Safety system values
EN 61508 for Tu = 75
°C ongoing
SIL
HFT
PFD (for yearly functional test)
SFF
λ s
+
λ
DD
λ
DU
Ordering number 130B1137
1..6 resistors in series
3.3
Ω.... 3.65Ω ... 3.85Ω
1.7
Ω .... 1.8Ω ... 1.95Ω
± 6°C
< 1.65
Ω
≤ 2.5V for R ≤ 3.65Ω, ≤ 9V for R = ∞
≤ 1mA
20
Ω ≤ R ≤ 40Ω
60 mA
6000V
III
2
690V
500V
-20
°C ... +60°C
EN 60068-2-1 Dry heat
5 --- 95%, no condensation permissible
EN61000-6-2
EN61000-6-4
10 ... 1000Hz 1.14g
50g
2 for maintenance cycle of 2 years
1 for maintenance cycle of 3 years
0
4.10 *10
-3
78%
8494 FIT
934 FIT
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3.1.11 Sensor Input Option MCB 114
The sensor input option card MCB 114 can be used in the following cases:
•
Sensor input for temperature transmitters PT100 and PT1000 for monitoring bearing temperatures
•
As general extension of analog inputs with one additional input for multi-zone control or differential pressure measurements
•
Support extended PID controllers with I/Os for set point, transmitter/sensor inputs
The option can generate an alarm if the measured temperature is either below low limit or above high limit specified by the user. The individual measured temperature on each sensor 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 5-**.
A fault condition has a common warning/alarm number associated with it, which is Alarm/Warning 20, Temp. input error. Any present output can be programmed to be active in case the warning or alarm appears.
Typical motors, designed with temperature sensors for protecting bearings from being overloaded, are fitted with
3 PT100/1000 temperature sensors. One in front, one in the back end bearing, and one in the motor windings. The
Danfoss Option MCB 114 supports 2- or 3-wire sensors with individual temperature limits for under/over temperature. An auto detection of sensor type, PT100 or
PT1000 takes place at power up.
3.1.11.1 Ordering Code Numbers and Parts
Delivered
Standard version code no: 130B1172.
Coated version code no: 130B1272.
3.1.11.2 Electrical and Mechanical Specifications
Analog Input
Number of analog inputs
Format
Wires
Input impedance
Sample rate
3rd order filter
The option is able to supply the analog sensor with 24V
DC (terminal 1).
Temperature Sensor Input
Number of analog inputs supporting PT100/1000
Signal type
Connection
Frequency PT100 and PT1000 input
Resolution
Temperature range
1
0-20mA or 4-20mA
2
<200
Ω
1kHz
100Hz at 3dB
3
PT100/1000
PT 100 2 or 3 wire/PT1000 2 or 3 wire
1Hz for each channel
10 bit
-50 - 204
°C
-58 - 399
°F
Galvanic Isolation
The sensors to be connected are expected to be galvanically isolated from the mains voltage level IEC 61800-5-1 and UL508C
Cabling
Maximum signal cable length 500m
3 3
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3.1.11.3 Electrical Wiring
MCB 114
Sensor Input Option B
SW. ver. xx.xx
VDD I IN
Code No. 130B1272
GND TEMP WIRE
1 1
GND TEMP WIRE
2 2
GND TEMP WIRE
3 3
GND
X48/ 1
2 3 4 5 6 7 8 9 10 11 12
4-20mA
2 or 3 wire
2 or 3 wire
2 or 3 wire
2 or 3 wire
Terminal
1
2
3
4, 7, 10
5, 8, 11
6, 9, 12
Name
VDD
I in
GND
Temp 1, 2, 3
Wire 1, 2, 3
GND
Function
24V DC to supply
4-20mA sensor
4-20mA input
Analog input GND
Temperature input
3 rd wire input if 3 wire sensors are used
Temp. input GND
3.1.12 Frame Size F Panel Options
Space Heaters and Thermostat
Mounted on the cabinet interior of frame size F frequency converters, space heaters controlled via automatic thermostat help control humidity inside the enclosure, extending the lifetime of drive components in damp environments. The thermostat default settings turn on the heaters at 10
° C (50° F) and turn them off at 15.6° C (60°
F).
Cabinet Light with Power Outlet
A light mounted on the cabinet interior of frame size F frequency converters increase visibility during servicing and maintenance. The housing the light includes a power outlet for temporarily powering tools or other devices, available in two voltages:
•
230V, 50Hz, 2.5A, CE/ENEC
•
120V, 60Hz, 5A, UL/cUL
Transformer Tap Set-up
If the Cabinet Light & Outlet and/or the Space Heaters &
Thermostat are installed Transformer T1 requires it taps to be set to the proper input voltage. A 380-480/ 500 V drive will initially be set to the 525 V tap and a 525-690 V drive will be set to the 690 V tap to insure no over-voltage of secondary equipment occurs if the tap is not changed
prior to power being applied. See Table 3.1 to set the
proper tap at terminal T1 located in the rectifier cabinet.
Input voltage range
380V-440V
441V-490V
491V-550V
551V-625V
626V-660V
661V-690V
Table 3.1 Transformer Tap Set-up
Tap to select
400V
460V
525V
575V
660V
690V
NAMUR Terminals
NAMUR is an international association of automation technology users in the process industries, primarily chemical and pharmaceutical industries in Germany.
Selection of this option provides terminals organized and labeled to the specifications of the NAMUR standard for drive input and output terminals. This requires MCB 112
PTC Thermistor Card and MCB 113 Extended Relay Card.
RCD (Residual 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 terminology). There is a pre-warning (50% of main alarm set-point) and a main alarm set-point. Associated with each set-point is an SPDT alarm relay for external use. Requires an external “windowtype” current transformer (supplied and installed by customer).
•
Integrated into the frequency converter safe-stop circuit
•
IEC 60755 Type B device monitors AC, pulsed DC, and pure DC ground fault currents
•
LED bar graph indicator of the ground fault current level from 10–100% of the set-point
•
Fault memory
•
TEST / RESET button
Insulation Resistance Monitor (IRM)
Monitors the insulation resistance in ungrounded systems
(IT systems in IEC terminology) between the system phase conductors and ground. There is an ohmic pre-warning and a main alarm set-point for the insulation level.
Associated with each set-point is an SPDT alarm relay for external use. Note: only one insulation resistance monitor can be connected to each ungrounded (IT) system.
•
Integrated into the drive’s safe-stop circuit
•
LCD display of the ohmic value of the insulation resistance
•
Fault Memory
•
INFO, TEST, and RESET buttons
IEC Emergency Stop with Pilz Safety Relay
Includes a redundant 4-wire emergency-stop push-button mounted on the front of the enclosure and a Pilz relay that monitors it in conjunction with the frequency converter
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HVAC Drive Design Guide safe-stop circuit and the mains contactor located in the options cabinet.
Manual Motor Starters
Provide 3-phase power for electric blowers often required for larger motors. Power for the starters is provided from the load side of any supplied contactor, circuit breaker, or disconnect switch. Power is fused before each motor starter, and is off when the incoming power to the drive is off. Up to two starters are allowed (one if a 30A, fuseprotected circuit is ordered). Integrated into the frequency converter safe-stop circuit.
Unit features include:
•
Operation switch (on/off)
•
Short-circuit and overload protection with test function
•
Manual reset function
30 Ampere, Fuse-Protected Terminals
•
3-phase power matching incoming mains voltage for powering auxiliary customer equipment
•
Not available if two manual motor starters are selected
•
Terminals are off when the incoming power to the drive is off
•
Power for the fused protected terminals will be provided from the load side of any supplied contactor, circuit breaker, or disconnect switch.
In applications where the motor is used as a brake, energy is generated in the motor and send back into the frequency converter. If the energy can not be transported back to the motor it will increase the voltage in the converter DC-line. In applications with frequent braking and/or high inertia loads this increase may lead to an over voltage trip in the converter and finally a shut down. Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected in respect to its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide variety of different resistors that are specially 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 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.
1Nm.
Technical data
Enclosure:
Max. cable length between and unit:
Communication std:
IP66 front
3m
RS-485
64,5± 0.5 mm
(2.54± 0.04 in)
Max R2(0.08)
Panel cut out
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VLT
®
HVAC Drive Selection
Ordering no. 130B1113
VLT
®
HVAC Drive Design Guide
Ordering no. 130B1114
Illustration 3.7 LCP Kit with Graphical LCP, Fasteners, 3m Cable and Gasket.
LCP Kit without LCP is also available. Ordering number: 130B1117
For IP55 units the ordering number is 130B1129.
Illustration 3.8 LCP Kit with Numerical LCP, Fastenes and Gasket.
3.1.13 IP21/IP41/ TYPE 1 Enclosure Kit
IP 21/IP 41 top/ TYPE 1 is an optional enclosure element available for IP20 Compact units, enclosure size A2-A3, B3+B4 and
C3+C4.
If the enclosure kit is used, an IP20 unit is upgraded to comply with enclosure IP21/ 41 top/TYPE 1.
The IP41 top can be applied to all standard IP20 VLT
®
HVAC Drive variants.
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A – Top cover
B – Brim
C – Base part
D – Base cover
E – Screw(s)
Place the top cover as shown. If an A or B option is used the brim must be fitted to cover the top inlet. Place the base part C at the bottom of the drive and use the clamps from the accessory bag to correctly fasten the cables. Holes for cable glands:
Size A2: 2x M25 and
3xM32
Size A3: 3xM25 and
3xM32
B
D
VLT
®
HVAC Drive Design Guide
A
C
B
D
A
E
A2 Enclosure
Dimensions
Enclosure type
A2
A3
B3
B4
Height (mm)
A
372
372
475
670
Width (mm)
B
90
130
165
255
Depth (mm)
C*
205
205
249
246
C3
C4
755
950
329
391
337
337
* If option A/B is used, the depth will increase (see section
Mechanical Dimensions for details)
C
B
E
A
A2, A3, B3
A3 Enclosure
C
B
B4, C3, C4
A
C
3 3
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3 3
A – Top cover
B – Brim
C – Base part
D – Base cover
E – Screw(s)
F - Fan cover
G - Top clip
When option module A and/or option module B is/are used, the brim (B) must be fitted to the top cover (A).
B
VLT® tion Drive
A
VLT
®
HVAC Drive Design Guide
A
VLT
® ive
C
D
F
D
C
E
B3 Enclosure
NOTE
Side-by-side installation is not possible when using the IP 21/ IP 4X/ TYPE 1 Enclosure Kit
B4 - C3 - C4 Enclosure
G
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3.1.14 Output Filters
The high speed switching of the frequency converter produces some secondary effects, which influence the motor and the enclosed environment. These side effects are addressed by two different filter types, the du/dt and the Sine-wave filter.
dU/dt filters
Motor insulation stresses are often caused by the combination of rapid voltage and current increase. The rapid energy changes can also be reflected back to the
DC-line in the inverter and cause shut down. The du/dt filter is designed to reduce the voltage rise time/the rapid energy change in the motor and by that intervention avoid premature aging and flashover in the motor insulation.
du/dt filters have a positive influence on the radiation of magnetic noise in the cable that connects the drive 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
Sine-wave filters are designed to let only low frequencies pass. High frequencies are consequently shunted away which results in a sinusoidal phase to phase voltage waveform and sinusoidal current waveforms.
With the sinusoidal waveforms the use of special frequency converter motors with reinforced insulation is no longer needed. The acoustic noise from the motor is also damped as a consequence of the wave condition.
Besides the features of the du/dt filter, the sine-wave filter also reduces insulation stress and bearing currents in the motor thus leading to prolonged motor lifetime and longer periods between services. Sine-wave filters enable use of longer motor cables in applications where the motor is installed far from the drive. The length is unfortunately limited because the filter does not reduce leakage currents in the cables.
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®
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4 How to Order
4 4
4.1 Ordering Form
4.1.1 Drive Configurator
It is possible to design a frequency converter according to the application requirements by using the ordering number system.
Order the frequency converter as either standard or with integral options by sending a type code string describing the product a to the local Danfoss sales office, i.e.:
FC-102P18KT4E21H1XGCXXXSXXXXAGBKCXXXXDX
The meaning of the characters in the string can be located
in the pages containing the ordering numbers in 3
Selection. In the example above, a Profibus LON works
option and a General purpose I/O option is included in the frequency converter.
Ordering numbers for frequency converter standard variants can also be located in the chapter How to Select
Your VLT.
From the Internet based Drive Configurator, you can configure the right frequency converter for the right application and generate the type code string. The Drive
Configurator will automatically generate an eight-digit sales number to be delivered to your local sales office.
Furthermore, you can establish a project list with several products and send it to a Danfoss sales representative.
The Drive Configurator can be found on the global
Internet site: www.danfoss.com/drives.
Example of Drive Configurator interface set-up:
The numbers shown in the boxes refer to the letter/figure number of the Type Code String - read from left to right.
Product groups 1-3 frequency converter series 4-6
Power rating
Phases
Mains Voltage
Enclosure
Enclosure type
8-10
11
12
13-15
Enclosure class
Control supply voltage
Hardware configuration
RFI filter
Brake
Display (LCP)
Coating PCB
16-17
18
19
20
Mains option
Adaptation A
Adaptation B
Software release
Software language
A options
B options
C0 options, MCO
C1 options
C option software
D options
21
22
23
24-27
28
29-30
31-32
33-34
35
36-37
38-39
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4.1.2 Type Code String low and medium power
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F C 0 P T H
21 22
X
23
X
24
S
25 26 27
X X X
28 29
X A
30 31
B
32 33
C
34 35 36 37 38 39
D
Description
Product group & FC
Series
Power rating
Number of phases
Mains voltage
Enclosure
RFI filter
Brake
Display
Coating PCB
Mains option
Pos
1-6
8-10
11
11-12
13-15
16-17
18
19
20
21
Possible choice
FC 102
1.1- 90kW (P1K1 - P90K)
Three phases (T)
T 2: 200-240V AC
T 4: 380-480V AC
T 6: 525-600V AC
T 7: 525-690V AC
E20: IP20
E21: IP21/NEMA Type 1
E55: IP55/NEMA Type 12
E66: IP66
P21: IP21/NEMA Type 1 w/ backplate
P55: IP55/NEMA Type 12 w/ backplate
Z55: A4 Frame IP55
Z66: A4 Frame IP66
H1: RFI filter class A1/B
H2: RFI filter class A2
H3: RFI filter class A1/B
(reduced cable length)
Hx: No RFI filter
X: No brake chopper included
B: Brake chopper included
T: Safe Stop
U: Safe + brake
G: Graphical Local Control
Panel (GLCP)
N: Numeric Local Control
Panel (NLCP)
X: No Local Control Panel
X. No coated PCB
C: Coated PCB
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.
Description
Adaptation
Adaptation
Software release
Software language
A options
B options
C0 options MCO
C1 options
C option software
D options
Pos Possible choice
22
X: Standard
0: European metric thread in cable entries.
23 Reserved
24-27 Actual software
28
29-30
AX: No options
A0: MCA 101 Profibus DP V1
A4: MCA 104 DeviceNet
AG: MCA 108 Lonworks
AJ: MCA 109 BACnet gateway
AL: MCA 120 Profinet
AN: MCA 121 EtherNet/IP
AQ: MCA 122 Modbus TCP
31-32
BX: No option
BK: MCB 101 General purpose
I/O option
BP: MCB 105 Relay option
BO: MCB 109 Analog I/O option
B2: MCB 112 PTC Thermistor
Card
B4: MCB 114 Sensor input option
33-34 CX: No options
35 X: No options
36-37 XX: Standard software
38-39
DX: No option
D0: DC back-up
Table 4.1 Type Code Description
4 4
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4 4
4.1.3 Type Code String High Power
Ordering type code frame sizes D and E
Description
Product group+series
Power rating
Phases
Mains voltage
Enclosure
RFI filter
Brake
Display
Pos
1-6
8-10
11
11-12
13-15
16-17
18
19
Possible choice
FC 102
45-560kW
Three phases (T)
T 4: 380-500V AC
T 7: 525-690V AC
E00: IP00/Chassis
C00: IP00/Chassis w/ stainless steel back channel
E0D: IP00/Chassis, D3 P37K-P75K, T7
C0D: IP00/Chassis w/ stainless steel back channel, D3 P37K-P75K, T7
E21: IP 21/ NEMA Type 1
E54: IP 54/ NEMA Type 12
E2D: IP 21/ NEMA Type 1, D1 P37K-P75K, T7
E5D: IP 54/ NEMA Type 12, D1 P37K-P75K, T7
E2M: IP 21/ NEMA Type 1 with mains shield
E5M: IP 54/ NEMA Type 12 with mains shield
H2: RFI filter, class A2 (standard)
H4: RFI filter class A1 1)
H6: RFI filter Maritime use 2)
B: Brake IGBT mounted
X: No brake IGBT
R: Regeneration terminals (E frames only)
G: Graphical Local Control Panel LCP
N: Numerical Local Control Panel (LCP)
X: No Local Control Panel (D frames IP00 and IP 21 only)
Coating PCB
Mains option
Adaptation
Adaptation
Software release
Software language
A options
B options
20
21
22
23
24-27
28
29-30
31-32
C: Coated PCB
X. No coated PCB (D frames 380-480/500V only)
X: No mains option
3: Mains disconnect and Fuse
5: Mains disconnect, Fuse and Load sharing
7: Fuse
A: Fuse and Load sharing
D: Load sharing
Reserved
Reserved
Actual software
AX: No options
A0: MCA 101 Profibus DP V1
A4: MCA 104 DeviceNet
BX: No option
BK: MCB 101 General purpose I/O option
BP: MCB 105 Relay option
BO: MCB 109 Analog I/O option
B2: MCB 112 PTC Thermistor Card
B4: MCB 114 Sensor input option
C
0
options
C
1
options
33-34
35
CX: No options
X: No options
C option software
D options
36-37
38-39
XX: Standard software
DX: No option
D0: DC backup
The various options are described further in this Design Guide.
1): Available for all D frames. E frames 380-480/500V AC only
2) Consult factory for applications requiring maritime certification
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Ordering type code frame size F
Description Pos Possible choice
Product group
Drive series
Power rating
Phases
Mains voltage
Enclosure
RFI filter
Brake
Display
Coating PCB
Mains option
19
20
21
11-
12
13-
15
1-3
4-6
8-10
11
16-
17
18
500 - 1400kW
Three phases (T)
T 5: 380-500V AC
T 7: 525-690V AC
E21: IP 21/ NEMA Type 1
E54: IP 54/ NEMA Type 12
L2X: IP21/NEMA 1 with cabinet light & IEC 230V power outlet
L5X: IP54/NEMA 12 with cabinet light & IEC 230V power outlet
L2A: IP21/NEMA 1 with cabinet light & NAM 115V power outlet
L5A: IP54/NEMA 12 with cabinet light & NAM 115V power outlet
H21: IP21 with space heater and thermostat
H54: IP54 with space heater and thermostat
R2X: IP21/NEMA1 with space heater, thermostat, light & IEC 230V outlet
R5X: IP54/NEMA12 with space heater, thermostat, light & IEC 230V outlet
R2A: IP21/NEMA1 with space heater, thermostat, light, & NAM 115V outlet
R5A: IP54/NEMA12 with space heater, thermostat, light, & NAM 115V outlet
H2: RFI filter, class A2 (standard)
H4: RFI filter, class A1
2, 3)
HE: RCD with Class A2 RFI filter
2)
HF: RCD with class A1 RFI filter
2, 3)
HG: IRM with Class A2 RFI filter
2)
HH: IRM with class A1 RFI filter
2, 3)
HJ: NAMUR terminals and class A2 RFI filter
1)
HK: NAMUR terminals with class A1 RFI filter
1, 2, 3)
HL: RCD with NAMUR terminals and class A2 RFI filter
1, 2)
HM: RCD with NAMUR terminals and class A1 RFI filter 1, 2, 3)
HN: IRM with NAMUR terminals and class A2 RFI filter 1, 2)
HP: IRM with NAMUR terminals and class A1 RFI filter 1, 2, 3)
B: Brake IGBT mounted
X: No brake IGBT
R: Regeneration terminals
M: IEC Emergency stop push-button (with Pilz safety relay) 4)
N: IEC Emergency stop push-button with brake IGBT and brake terminals 4)
P: IEC Emergency stop push-button with regeneration terminals 4)
G: Graphical Local Control Panel LCP
C: Coated PCB
X: No mains option
3 2) : Mains disconnect and Fuse
5 2) : Mains disconnect, Fuse and Load sharing
7: Fuse
A: Fuse and Load sharing
D: Load sharing
E: Mains disconnect, contactor & fuses 2)
F: Mains circuit breaker, contactor & fuses 2)
G: Mains disconnect, contactor, loadsharing terminals & fuses 2)
H: Mains circuit breaker, contactor, loadsharing terminals & fuses
2)
J: Mains circuit breaker & fuses
2)
K: Mains circuit breaker, loadsharing terminals & fuses
2)
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Ordering type code frame size F
A options
B options
29-30
31-32
AX: No options
A0: MCA 101 Profibus DP V1
A4: MCA 104 DeviceNet
AG: MCA 108 Lonworks
AJ: MCA 109 BACnet Gateway
AL: MCA 120 Profinet
AN: MCA 121 Ethernet/IP
BX: No option
BK: MCB 101 General purpose I/O option
BP: MCB 105 Relay option
BO: MCB 109 Analog I/O option
C
0
options
C
1
options
33-34
35
CX: No options
X: No options
C option software
D options
36-37
38-39
XX: Standard software
DX: No option
D0: DC backup
The various options are described further in this Design Guide.
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4.2 Ordering Numbers
4.2.1 Ordering Numbers: Options and Accessories
Type Description Ordering no.
Miscellaneous hardware I
DC link connector
Terminal block for DC link connnection on A2/A3
IP21/NEMA1 Top + bottom A2 IP 21/4X top/
TYPE 1 kit
IP 21/4X top/
TYPE 1 kit
IP 21/4X top/
TYPE 1 kit
IP 21/4X top/
TYPE 1 kit
IP 21/4X top/
TYPE 1 kit
IP 21/4X top/
TYPE 1 kit
IP21/4X top
IP21/4X top
IP 21/4X top
IP 21/4X top
IP 21/4X top
IP 21/4X top
Panel Through
Mount Kit
Panel Through
Mount Kit
Panel Through
Mount Kit
IP21/NEMA1 Top + bottom A3
IP21/NEMA1 Top + bottom B3
IP21/NEMA1 Top + bottom B4
IP21/NEMA1 Top + bottom C3
IP21/NEMA1 Top + bottom C4
IP21 Top Cover A2
IP21 Top Cover A3
IP21 Top Cover B3
IP21 Top Cover B4
IP21 Top Cover C3
IP21 Top Cover C4
Enclosure, frame size A5
Enclosure, frame size B1
Enclosure, frame size B2
Panel Through
Mount Kit
Panel Through
Mount Kit
Profibus D-Sub
9
Profibus top entry kit
Enclosure, frame size C1
Enclosure, frame size C2
Connector kit for IP20
Top entry kit for Profibus connection - D + E enclosures
130B1064
130B1122
130B1123
130B1187
130B1189
130B1191
130B1193
130B1132
130B1133
130B1188
130B1190
130B1192
130B1194
130B1028
130B1046
130B1047
130B1048
130B1049
130B1112
176F1742
Type Description Ordering no.
Miscellaneous hardware I
Terminal blocks Screw terminal blocks for replacing spring loaded terminals
1 pc 10 pin 1 pc 6 pin and 1 pc 3 pin connectors
Backplate
Backplate
Backplate
Backplate
Backplate
Backplate
A5 IP55 / NEMA 12
B1 IP21 / IP55 / NEMA 12
B2 IP21 / IP55 / NEMA 12
C1 IP21 / IP55 / NEMA 12
C2 IP21 / IP55 / NEMA 12
A5 IP66
Backplate
Backplate
Backplate
Backplate
LCPs and kits
LCP 101
B1 IP66
B2 IP66
C1 IP66
C2 IP66
LCP 102
LCP cable
LCP kit
LCP kit
LCP kit
LCPkit
LCP kit
Numerical Local Control Panel
(NLCP)
Graphical Local Control Panel
(GLCP)
Separate LCP cable, 3 m
Panel mounting kit including graphical LCP, fasteners, 3 m cable and gasket
Panel mounting kit including numerical LCP, fasteners and gasket
130B1124
130B1107
175Z0929
130B1113
130B1114
Panel mounting kit for all LCPs including fasteners, 3 m cable and gasket
130B1117
Front mounting kit, IP55 enclosures 130B1129
Panel mounting kit for all LCPs including fasteners and gasket without cable
130B1170
130B1116
130B1098
130B3383
130B3397
130B3910
130B3911
130B3242
130B3434
130B3465
130B3468
130B3491
Table 4.2 Options can be ordered as factory built-in options, see ordering information.
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Type
Options for Slot A
MCA 101
MCA 104
MCA 108
MCA 109
MCA 120
MCA 121
Options for Slot B
MCB 101
MCB 105
MCB 109
MCB 112
MCB 114
Description
Profibus option DP V0/V1
DeviceNet option
Lonworks
BACnet gateway for build-in. Not to be used with Relay Option MCB 105 card
Profinet
Ethernet
General purpose Input Output option
Relay option
Analog I/O option and battery back-up for real-time clock
ATEX PTC
Sensor input - unocated
Sensor input - coated
Comments
Ordering no.
Coated
130B1200
130B1202
130B1206
130B1244
130B1135
130B1219
130B1243
130B1137
130B1172
130B1272
Option for Slot D
MCB 107
External Options
Ethernet IP
24 V DC back-up
Ethernet master
130B1208
For information on fieldbus and application option compatibility with older software versions, please contact your Danfoss supplier.
Fan B2
Fan B3
Fan B4
Fan B4
Fan C1
Fan C2
Fan C3
Type
Spare Parts
Control board FC
Control board FC
Fan A2
Fan A3
Fan A5
Fan B1
Fan C4
Miscellaneous hardware II
Accessory bag A2
Accessory bag A3
Accessory bag A5
Accessory bag B1
Accessory bag B2
Accessory bag B3
Accessory bag B4
Accessory bag B4
Accessory bag C1
Accessory bag C2
Accessory bag C3
Accessory bag C4
Accessory bag C4
Description
With Safe Stop Function
Without Safe Stop Function
Fan, frame size A2
Fan, frame size A3
Fan, frame size A5
Fan external, frame size B1
Fan external, frame size B2
Fan external, frame size B3
Fan external, 18.5/22 kW
Fan external 22/30 kW
Fan external, frame size C1
Fan external, frame size C2
Fan external, frame size C3
Fan external, frame size C4
Accessory bag, frame size A2
Accessory bag, frame size A3
Accessory bag, frame size A5
Accessory bag, frame size B1
Accessory bag, frame size B2
Accessory bag, frame size B3
Accessory bag, frame size B4
Accessory bag, frame size B4
Accessory bag, frame size C1
Accessory bag, frame size C2
Accessory bag, frame size C3
Accessory bag, frame size C4
Accessory bag, frame size C4
Ordering no.
Comments
130B1150
130B1151
130B1009
130B1010
130B1017
130B3407
130B3406
130B3563
130B3699
130B3701
130B3865
130B3867
130B4292
130B4294
130B1022
130B1022
130B1023
130B2060
130B2061
130B0980
130B1300
130B1301
130B0046
130B0047
130B0981
130B0982
130B0983
Small
Big
Small
Big
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4.2.2 Ordering Numbers: High Power Kits
Kit
NEMA-3R (Rittal Enclosures)
NEMA-3R (Welded Enclosures)
Pedestal
Back Channel Duct Kit
(Top & Bottom)
Back Channel Duct Kit
(Top Only)
IP00 Top & Bottom Covers
(Welded Enclosures)
IP00 Top & Bottom Covers
(Rittal Enclosures)
IP00 Motor Cable Clamp
IP00 Terminal Cover
Mains Shield
Input Plates
Loadshare
Top Entry Sub D or Shield Termination
IP00 to IP20 Kits
USB Extension Kit
Description
D3 Frame
D4 Frame
E2 Frame
D3 Frame
D4 Frame
E2 Frame
D Frames
D3 1800mm
D4 1800mm
D3 2000mm
D4 2000mm
E2 2000mm
E2 2200mm
D3/D4 Frames
E2 Frame
D3/D4 Frames
E2 Frame
D3 Frames
D4 Frames
E2 Frame
D3 Frame
D4 Frame
E2 Frame
D3/D4 Frame
D1/D2 Frames
E1 Frame
See Instr
D1/D3 Frame
D2/D4 Frame
D3/D4/E2 Frames
D3/D4 Frames
E2 Frames
D Frames
E Frames
F Frames
4.2.3 Ordering Numbers: Harmonic Filters
Harmonic filters are used to reduce mains harmonics.
•
AHF 010: 10% current distortion
•
AHF 005: 5% current distortion
Ordering Number
176F4600
176F4601
176F1852
176F0296
176F0295
176F0298
176F1827
176F1824
176F1823
176F1826
176F1825
176F1850
176F0299
176F1775
176F1776
176F1862
176F1861
176F1781
176F1782
176F1783
176F1774
176F1746
176F1745
176F1779
176F0799
176F1851
176F8456
176F8455
176F1884
176F1779
176F1884
130B1155
130B1156
176F1784
Instruction Number
175R5922
175R1068
175R5642
175R5640
175R1107
175R1106
177R0076
175R1109
175R1108
175R5923
175R5795
175R5637
175R5964
175R1108
177R0091
4 4
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4 4
380-415 VAC, 50 Hz
I
AHF,N
[A] Typical Motor Used [kW]
506
578
648
43
72
101
144
180
10
19
26
35
217
289
324
370
694
740
1.1 - 4
5.5 - 7.5
11
15 - 18.5
22
30 - 37
45 - 55
75
90
110
132
160
200
250
315
355
400
450
380 - 415 VAC, 60 Hz
I
AHF,N
[A] Typical Motor Used [HP]
578
648
694
740
289
324
370
506
101
144
180
217
10
19
26
35
43
72
1.1 - 4
5.5 - 7.5
11
15 - 18.5
22
30 - 37
45 - 55
75
90
110
132
160
200
250
315
355
400
450
VLT
®
HVAC Drive Design Guide
175G6609
175G6610
175G6611
175G6688
175G6609
+ 175G6610
2x 175G6610
2x175G6611
175G6611
+ 175G6688
2x175G6688
Danfoss Ordering Number
AHF 005 AHF 010
175G6600
175G6601
175G6622
175G6623
175G6602
175G6603
175G6604
175G6605
175G6624
175G6625
175G6626
175G6627
175G6606
175G6607
175G6608
175G6628
175G6629
175G6630
175G6631
175G6632
175G6633
175G6691
175G6631
+ 175G6632
2x 175G6632
2x175G6633
175G6633
+ 175G6691
2x175G6691
Frequency ConverterSize
P1K1, P4K0
P5K5 - P7K5
P11K
P15K - P18K
P22K
P30K - P37K
P45K - P55K
P75K
P90K
P110
P132 - P160
P200
P250
P315
P355
P400
P450
Danfoss Ordering Number
AHF 005 AHF 010
130B2540
130B2460
130B2541
130B2472
130B2461
130B2462
130B2463
130B2464
130B2473
130B2474
130B2475
130B2476
130B2465
130B2466
130B2467
130B2468
130B2469
130B2470
130B2471
130B2468
+ 130B2469
2x 130B2469
2x130B2470
130B2470
+ 130B2471
2x130B2471
130B2477
130B2478
130B2479
130B2480
130B2481
130B2482
130B2483
130B2480
+ 130B2481
2x 130B2481
2x130B2482
130B2482
+ 130B2483
130B2483
Frequency Converter Size
P1K1 - P4K0
P5K5 - P7K5
P11K
P15K, P18K
P22K
P30K - P37K
P45K - P55K
P75K
P90K
P110
P132
P160
P200
P250
P315
P355
P400
P450
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440-480 VAC, 60 Hz
I
AHF,N
[A] Typical Motor Used [HP]
506
578
648
694
740
217
289
370
434
43
72
101
144
180
10
19
26
35
200
250
350
350
450
500
550-600
600
650
1.5 - 7.5
10 - 15
20
25 - 30
40
50 - 60
75
100 - 125
150
Danfoss Ordering Number
AHF 005 AHF 010
130B2538
175G6612
130B2539
175G6634
175G6613
175G6614
175G6615
175G6616
175G6635
175G6636
175G6637
175G6638
175G6617
175G6618
175G6619
175G6639
175G6640
175G6641
175G6620
175G6621
175G6690
2x175G6620
175G6620 + 175G6621
2x 175G6621
2x175G6689
175G6689 + 175G6690
2x175G6690
175G6642
175G6643
175G6693
2x175G6642
175G6642 + 175G6643
2x 175G6643
2x175G6692
175G6692 + 175G6693
2x175G6693
Frequency Converter Size
P132
P160
P200
P250
P315
P355
P400
P450
P500
P1K1 - P5K5
P7K5 - P11K
P15K
P18K - P22K
P30K
P37K - P45K
P55K
P75K - P90K
P110
Matching the frequency converter and filter is pre-calculated based on 400V/480V and on a typical motor load (4 pole) and
110 % torque.
500-525 VAC, 50 Hz
I
AHF,N
[A] Typical Motor Used [kW]
10
19
289
324
397
434
506
578
613
101
144
180
217
26
35
43
72
1.1 - 7.5
11
15 -18.5
22
30
37 -45
55
75 - 90
110
132
160 - 200
250
315
355
400
450
500
Danfoss Ordering Number
AHF 005 AHF 010
175G6644
175G6645
175G6656
175G6657
175G6646
175G6647
175G6648
175G6649
175G6650
175G6651
175G6652
175G6653
175G6654
175G6655
175G6652 + 175G6653
2x175G6653
175G6653 + 175G6654
2X 175G6654
175G6654 + 175G6655
175G6658
175G6659
175G6660
175G6661
175G6662
175G6663
175G6664
175G6665
175G6666
175G6667
175G6641 + 175G6665
2x175G6665
175G6665 + 175G6666
2X 175G6666
175G6666 + 175G6667
Frequency Converter Size
P1K1 - P7K5
P11K
P15K - P18K
P22K
P30K
P45K - P55K
P75K
P90K - P110
P132
P160
P200 - P250
P315
P400
P450
P500
P560
P630
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690 VAC, 50 Hz
I
AHF,N
[A] Typical Motor Used [kW]
180
217
288
324
397
43
72
101
144
434
505
576
612
730
45
45 - 55
75 - 90
110
132
160
200 - 250
315
400
450
500
560
630
710
Table 4.3 * For higher currents, please contact Danfoss.
Danfoss Ordering Number
AHF 005 AHF 010
130B2328
130B2330
130B2293
130B2295
130B2331
130B2333
130B2334
130B2335
130B2296
130B2298
130B2299
130B2300
2x130B2333
130B2334 + 130B2335
130B2334 + 130B2335
130B2301
130B2302
130B2299 + 130B2300
2x130B2335
*
*
*
*
2x130B2300
130B2300 + 130B2301
2x130B2301
130B2301 + 130B2300
2x130B2302
Frequency Converter Size
P37K - P45K
P55K - P75K
P90K - P110
P132
P160
P200 - P250
P315
P400
P450
P500
P560
P630
P710
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HVAC Drive Design Guide
4.2.4 Ordering Numbers: Sine Wave Filter Modules, 200-500 VAC
Mains supply 3 x 200 to 480 [VAC]
Frequency Converter Size
200-240 [VAC] 380-440 [VAC] 440-480 [VAC]
Minimum switching frequency [kHz]
P18K
P22K
P30K
P37K
P45K
P1K5
P2K2
P3K0
P4K0
P5K5
P7K5
P11K
P15K
P200
P250
P315
P355
P400
P450
P500
P37K
P45K
P55K
P75K
P90K
P110
P132
P160
P560
P630
P710
P800
P1M0
P1K1
P1K5
P2K2
P3K0
P4K0
P5K5
P7K5
P11K
P15K
P18K
P22K
P30K
P1K1
P1K5
P2K2
P3K0
P4K0
P5K5
P7K5
P11K
P15K
P18K
P22K
P30K
P37K
P55K
P75K
P90K
P110
P132
P160
P200
P250
P315
P315
P355
P400
P450
P500
P560
P630
P710
P800
P1M0
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
Maximum output frequency [Hz]
120
120
120
120
120
120
120
120
100
100
100
100
100
100
100
100
100
100
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
2
2
2
2
2
5
5
5
5
5
5
5
5
4
4
4
4
3
Part No. IP20 Part No. IP00
Rated filter current at 50 Hz [A]
130B2309
130B2310
130B2310
130B2311
130B2311
130B2312
130B2313
130B2313
130B2314
130B2314
130B2315
130B2315
130B2316
130B2316
130B2317
130B2317
130B2441
130B2441
130B2443
130B2443
130B2444
130B2446
130B2446
130B2446
130B2447
130B2448
130B2448
130B2307
130B2308
130B2318
130B2318
130B2292
130B2292
2x130B2317 2x130B2291
2x130B2317 2x130B2291
2x130B2318 2x130B2292
130B2406
130B2406
130B2408
130B2408
130B2409
130B2411
130B2411
130B2411
130B2412
130B2413
130B2413
130B2281
130B2282
130B2283
130B2284
130B2284
130B2285
130B2285
130B2286
130B2287
130B2287
130B2288
130B2288
130B2289
130B2289
130B2290
130B2290
130B2291
130B2291
750
750
880
880
410
480
660
660
180
260
260
410
75
115
115
180
1200
1200
1500
1500
1700
10
17
17
17
4.5
4.5
8
8
24
38
38
48
62
When using Sine-wave filters, the switching frequency should comply with filter specifications in 14-01 Switching Frequency.
NOTE
See also Output Filter Design Guide, MG.90.Nx.yy
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4 4
4.2.5 Ordering Numbers: Sine-Wave Filter Modules, 525-600/690 VAC
Mains supply 3 x 525 to 690[V AC]
Frequency Converter Size
525-600 [VAC] 690 [VAC]
P55K
P75K
P90K
P15K
P18K
P22K
P30K
P37K
P45K
P1K1
P1K5
P2k2
P3K0
P4K0
P5K5
P7K5
P11K
P355
P400
P450
P500
P560
P630
P710
P800
P75K
P90K
P110
P132
P160
P200
P250
P315
P45K
P55K
P900
P1M0
P1M2
P1M4
Minimum switching frequency [kHz]
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
2
2
2
2
2
2
2
2
1.5
1.5
1.5
1.5
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Part No. IP20
130B2345
130B2345
130B2346
130B2346
130B2347
130B2347
130B2348
130B2370
130B2370
130B2370
130B2371
130B2371
130B2381
130B2381
130B2382
130B2383
130B2341
130B2341
130B2341
130B2341
130B2341
130B2341
130B2341
130B2342
130B2342
130B2342
130B2342
130B2343
130B2344
130B2344
130B2383
130B2384
130B2384
2x130B2382
Maximum output frequency [Hz]
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
NOTE
When using Sine-wave filters, the switching frequency should comply with filter specifications in 14-01 Switching Frequency.
NOTE
See also Output Filter Design Guide, MG.90.Nx.yy
Part No. IP00
660
660
765
940
430
430
530
530
260
260
303
430
115
115
165
165
Rated filter current at 50 Hz
[A]
13
13
13
13
13
13
28
45
76
76
13
28
28
28
940
1320
1320
1479
130B2325
130B2325
130B2326
130B2326
130B2327
130B2327
130B2329
130B2341
130B2341
130B2341
130B2342
130B2342
130B2337
130B2337
130B2338
130B2339
130B2321
130B2321
130B2321
130B2321
130B2321
130B2321
130B2321
130B2322
130B2322
130B2322
130B2322
130B2323
130B2324
130B2324
130B2339
130B2340
130B2340
2x130B2338
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4.2.6 Ordering Numbers: dU/dt Filters, 380-480V AC
Mains supply 3x380 to 3x480V AC
Frequency Converter Size
380-439[VAC] 440-480 [VAC]
Minimum switching frequency [kHz]
P11K
P15K
P18K
P22K
P30K
P37K
P11K
P15K
P18K
P22K
P30K
P37K
4
4
4
4
3
3
P250
P315
P355
P400
P450
P500
P560
P630
P45K
P55K
P75K
P90K
P110
P132
P160
P200
P710
P800
P1M0
P250
P315
P355
P400
P450
P500
P560
P45K
P55K
P75K
P90K
P110
P132
P160
P200
P630
P710
P800
P1M0
2
2
2
2
2
2
3
2
3
3
3
3
3
3
3
3
2
2
2
2
Maximum output frequency [Hz]
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
NOTE
See also Output Filter Design Guide, MG.90.Nx.yy
130B2396
130B2397
130B2397
130B2397
130B2398
130B2398
130B2399
130B2399
130B2400
130B2400
130B2401
130B2401
130B2402
130B2402
130B2277
130B2278
130B2278
130B2278
130B2278
130B2405
130B2405
130B2407
130B2407
130B2407
130B2407
130B2410
130B2385
130B2386
130B2386
130B2386
130B2387
130B2387
130B2388
130B2388
130B2389
130B2389
130B2390
130B2390
130B2391
130B2391
130B2275
130B2276
130B2276
130B2276
130B2276
130B2393
130B2393
130B2394
130B2394
130B2394
130B2394
130B2395
Part No. IP20 Part No. IP00
Rated filter current at 50
Hz [A]
24
45
45
45
75
75
500
750
750
750
750
910
910
1500
280
280
400
400
110
110
182
182
1500
1500
1500
2300
4 4
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4 4
4.2.7 Ordering Numbers: dU/dt Filters, 525-600/690V AC
P400
P450
P500
P560
P630
P710
P800
P900
P1M0
P1M2
P1M4
P75K
P90K
P110
P132
P160
P200
P250
P315
P45K
P55K
Mains supply 3x525 to 3x690V AC
Frequency Converter Size
525-600[V AC] 690[V AC]
Minimum switching frequency [kHz]
P1K1
P1K5
P2K2
P3K0
P4K0
P5K5
4
4
4
4
4
4
P55K
P75K
P90K
P7K5
P11K
P15K
P18K
P22K
P30K
P37K
P45K
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
2
3
3
3
3
3
3
3
3
3
3
Maximum output frequency [Hz]
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
130B2423
130B2423
130B2423
130B2423
130B2424
130B2424
130B2425
130B2425
130B2426
130B2426
130B2427
130B2427
130B2425
130B2425
130B2426
130B2426
130B2427
130B2427
130B2428
130B2428
130B2429
130B2238
130B2238
130B2239
130B2239
130B2274
130B2274
130B2430
130B2431
130B2431
130B2235
130B2236
130B2236
130B2280
130B2280
130B2421
130B2422
130B2422
130B2431
130B2431
130B2422
130B2422
2x130B2430 2x130B2421
130B2414
130B2414
130B2414
130B2414
130B2415
130B2415
130B2416
130B2416
130B2417
130B2417
130B2418
130B2418
130B2416
130B2416
130B2417
130B2417
130B2418
130B2418
130B2419
130B2419
130B2420
130B2235
Part No. IP20 Part No. IP00
Rated filter current at 50
Hz [A]
28
28
28
28
45
45
260
260
310
430
115
115
165
165
165
165
75
75
75
75
115
115
630
765
1350
1350
430
530
530
630
1350
1350
1530
NOTE
See also Output Filter Design Guide, MG.90.Nx.yy
4.2.8 Ordering Numbers: Brake Resistors
NOTE
See Brake Resistor Design Guide, MG.90.Ox.yy
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5 How to Install
5.1 Mechanical Installation
5.1.1 Mechanical Front Views
A2 A3
VLT
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HVAC Drive Design Guide
A4 A5 B1 B2
5 5
IP20/21* IP20/21*
B3 B4
IP55/66 IP55/66
C
B b e f a c
A d e a b
Top and bottom mounting holes.
C1 C2
IP21/55/66 IP21/55/66
C3 C4
IP20/21* IP20/21* IP21/55/66 e
IP21/55/66 f
IP20/21* IP20/21* a
Top and bottom mounting holes. (B4+C3+C4 only)
Accessory bags containing necessary brackets, screws and connectors are included with the frequency converter upon delivery.
* IP21 can be established with a kit as described in the section: IP 21/ IP 4X/ TYPE 1 Enclosure Kit in the Design Guide.
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How to Install
5.1.2 Mechanical Dimensions
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130BB092.10
VLT
®
HVAC Drive Design Guide
579 [22.8]
130BB005.13
624 [24.6]
578 [22.8]
130BA959.10
130BB003.13
578 (22.8)
624 (24.6)
130BB006.10
2x579 (22.8)
5 5
130BB004.13
776 [30.6]
130BA819.10
130BA818.10
130BA820.10
130BA821.10
130BA817.10
130BA816.10
130BA885.10
130BA880.10
130BA879.10
130BA881.10
130BA878.10
130BA651.10
61.4
361.7
70.4
25
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5.1.3 Accessory Bags
130BA406.10
39 42 50 53 54 5
06 05 04
03 02 01
ARNING: t mains and loadshar
ISOA0021
VLT
®
HVAC Drive Design Guide
RELA
RELA
130BT349.10
OUCH UNTIL
ONNEXION
GE DO NO
WARNING STORED CHAR
15 MIN. AFTER DISC
GE RESIDUELLE
TENDRE 15 MIN. APRES DEC ual supply
ARNING
Risk of Elec tric Shoc t mains and loadshar
130BT330.10
130BT348.10
ARNING:
Risk of Elec tric Shock - D t mains and loadshar onnec ual supply ing bef e ser
130BT339.10
130BT347.10
ARNING:
t mains a
130BT309.10
010
06
010
06
RE
LA
Y 1
RE
LA
Y 1
L1
L2
L3
91
92
93
V
W
U 96
97
98
130BT346.10
39 RELA
Y 1
RELA
Shock
ARNING: unnec adsha
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5.1.4 Mechanical Mounting
All A, B and C enclosures allow side-by-side installation.
Exception: If a IP21 kit is used, there has to be a clearance between the enclosures. For enclosures A2, A3, B3,B4 and
C3 the minimum clearance is 50mm, for C4 it is 75mm.
For optimal cooling conditions allow a free air passage
above and below the frequency converter. See Table 5.1.
Enclosure: A2 a/b (mm) 100
Enclosure: B4 a/b (mm) 200
A3
100
C1
200
A5
100
C2
225
B1
200
C3
200
Table 5.1 Air Passage for Different Enclosures
B2
200
C4
225
B3
200 a
86 b
1.
2.
Drill holes in accordance with the measurements given.
Provide screws suitable for the surface on which you want to mount the frequency converter. Retighten all four screws.
A
A
Table 5.2 When mounting enclosure sizes A5, B1, B2, B3, B4, C1, C2, C3 and C4 on a non-solid back wall, the frequency converter must be provided with a back plate A due to insufficient cooling air over the heat sink.
IP66 Drive
Base plate
A
Fibre
Washer
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5.1.5 Lifting
Always lift the frequency converter in the dedicated lifting eyes. For all D and E2 (IP00) enclosures, use a bar to avoid bending the lifting holes of the frequency converter.
Illustration 5.1 Recommended Lifting Method, Frame Sizes D and
E .
WARNING
The lifting bar must 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 drive to the lifting cable should be 60
°C or greater.
Illustration 5.3 Recommended Lifting Method, Frame Size F2
(460V, 1000 to 1200 HP, 575/690V, 1250 to 1350 HP)
5 5
Illustration 5.4 Recommended Lifting Method, Frame Size F3
(460V, 600 to 900 HP, 575/690V, 900 to 1150 HP)
Illustration 5.2 Recommended Lifting Method, Frame Size F1
(460V, 600 to 900 HP, 575/690V, 900 to 1150 HP)
Illustration 5.5 Recommended Lifting Method, Frame Size F4
(460V, 1000 to 1200 HP, 575/690V, 1250 to 1350 HP)
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NOTE
The plinth is provided in the same packaging as the frequency converter but is not attached to frame sizes F1-
F4 during shipment. The plinth is required to allow airflow to the frequency converter to provide proper cooling. The
F frames should be positioned on top of the plinth in the final installation location. The angle from the top of the drive to the lifting cable should be 60
°C or greater.
In addition to the drawings above a spreader bar is an acceptable way to lift the F Frame.
5.1.6 Safety Requirements of Mechanical
Installation
WARNING
Pay attention to the requirements that apply to integration and field mounting kit. Observe the information in the list to avoid serious injury or equipment damage, especially when installing large units.
CAUTION
The frequency converter is cooled by means of air circulation.
To protect the unit from overheating, it must be ensured 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 24-hour average in
8.6.2 Derating for Ambient Temperature.
If the ambient temperature is in the range of 45
°C - 55 °
C, derating of the frequency converter will become
relevant, see 8.6.2 Derating for Ambient Temperature.
The service life of the frequency converter is reduced if derating for ambient temperature is not taken into account.
5.1.7 Field Mounting
IP 21/IP 4X top/TYPE 1 kits or IP 54/55 units are recommended.
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5.2 Electrical Installation
5.2.1 Cables General
NOTE
For the VLT
®
HVAC Drive High Power series mains and motor connections, please see VLT
®
HVAC Drive High Power
Operating Instructions MG.11.FX.YY.
NOTE
Cables General
All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper
(60/75
°C) conductors are recommended.
Details of terminal tightening torques.
Power (kW)
Enclosure
200-240V 380-480V 525-600V 525-690V
A2 1.1 - 3.0
1.1 - 4.0
1.1 - 4.0
A3
A4
B2
3.7
1.1-2.2
5.5 - 7.5
5.5 - 7.5
1.1-4
A5 1.1 - 3.7
1.1 - 7.5
1.1 - 7.5
B1 5.5 - 11 11 - 18.5 11 - 18.5
-
15
22
30
22
30
B3 5.5 - 11 11 - 18.5 11 - 18.5
B4 15 - 18.5
22 - 37 22 - 37
C1 18.5 - 30 37 - 55 37 - 55
C2
C3
C4
D1/D3
D2/D4
E1/E2
37 - 45
22 - 30
75 - 90
45 - 55 45 - 55
37 - 45 75 - 90 75 - 90
110-132
160-250
315-450
75 - 90
-
30
90
-
-
-
-
11
30
-
45-160
200-400
450-630
F1/F3 3)
F2/F4 3)
500-710
800-1000
710-900
1000-1400
Mains
1.8
1.8
1.8
1.8
1.8
2.5
4.5
2)
1.8
4.5
10
14/24 1)
10
14/24
1)
19
19
19
19
19
Motor
1.8
1.8
1.8
1.8
1.8
2.5
4.5
2)
1.8
4.5
10
14/24 1)
10
14/24
1)
19
19
19
19
19
Table 5.3 Tightening of Terminals
1) For different cable dimensions x/y, where x
≤ 95mm
2 and y
≥ 95mm
2 .
2) Cable dimensions above 18.5kW
≥ 35mm
2 and below 22kW
≤ 10mm
2 .
3) For data on the F frame sizes consult FC 100 High Power Operating Instructions.
10
14
9.6
9.6
19
19
19
Torque (Nm)
DC connection
1.8
Brake
1.8
1.8
4.5
10
1.8
1.8
1.8
1.5
3.7
3.7
1.8
4.5
10
1.8
1.8
1.8
1.5
2.5
3.7
14 14
10
14
9.6
9.6
9.6
9.6
9.6
Earth
3
3
3
3
3
3
3
3
3
3
3
3
3
19
19
19
19
19
Relay
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
5 5
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5.2.2 Electrical Installation and Control Cables
5 5 power input
DC bus
+10Vdc
0-10Vdc
0/4-20 mA
0-10Vdc
0/4-20 mA
91 (L1)
92 (L2)
93 (L3)
95
PE
88 (-)
89 (+)
50 (+10 V OUT)
S201
53 (A IN)
1S202
54 (A IN)
55 (COM A IN)
12 (+24V OUT)
13 (+24V OUT)
18 (D IN)
19 (D IN)
20 (COM D IN)
27
(D IN/OUT)
ON=0-20mA
OFF=0-10V
24V
0V
+
Switch Mode
Power Supply
15mA
+
24Vdc
200mA
-
P 5-00
24V (NPN)
0V (PNP)
24V (NPN)
0V (PNP)
24V (NPN)
0V (PNP)
29 (D IN/OUT)
24V
24V (NPN)
0V (PNP)
32 (D IN)
33 (D IN)
*
37 (D IN)
0V
24V (NPN)
0V (PNP)
24V (NPN)
0V (PNP)
S801
5V
(R+) 82
(R-) 81
ON=Terminated
OFF=Open
(U) 96
(V) 97
(W) 98
(PE) 99
RS-485
Interface
S801
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V relay1
03
02 relay2
01
06
05
04
(COM A OUT) 39
(A OUT) 42
Brake resistor
240Vac, 2A
240Vac, 2A
400Vac, 2A
Motor
Analog Output
0/4-20 mA
RS-485
(PNP) = Source
(NPN) = Sink
Illustration 5.6 Diagram Showing all Electrical Terminals. (Terminal 37 Present for Units with Safe Stop Function only.)
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37
42
53
54
27
29
32
33
13
18
19
20
Terminal number
1+2+3
4+5+6
12
Table 5.4 Terminal Connections
Terminal description
Terminal 1+2+3-Relay1
Terminal 4+5+6-Relay2
Terminal 12 Supply
Terminal 13 Supply
Terminal 18 Digital Input
Terminal 19 Digital Input
Terminal 20
Terminal 27 Digital Input/Output
Terminal 29 Digital Input/Output
Terminal 32 Digital Input
Terminal 33 Digital Input
Terminal 37 Digital Input
Terminal 42 Analog Output
Terminal 53 Analog Input
Terminal 54 Analog Input
Very long control cables and analog signals may, in rare cases and depending on installation, result in 50/60 Hz earth loops due to noise from mains supply cables.
If this occurs, break the screen or insert a 100 nF capacitor between screen and chassis.
NOTE
The common of digital / analog inputs and outputs should be connected to separate common terminals 20, 39, and
55. This will avoid ground current interference among groups. For example, it avoids switching on digital inputs disturbing analog inputs.
NOTE
Control cables must be screened/armoured.
5.2.3 Motor Cables
See section General Specifications for maximum dimensioning of motor cable cross-section and length.
•
Use a screened/armoured motor cable to comply with EMC emission specifications.
•
Keep the motor cable as short as possible to reduce the noise level and leakage currents.
•
Connect the motor cable screen to both the decoupling plate of the frequency converter and to the metal cabinet of the motor.
•
Make the screen connections with the largest possible surface area (cable clamp). This is done by using the supplied installation devices in the frequency converter.
Parameter number
5-40
5-40
-
-
5-10
5-11
-
5-12/5-30
5-13/5-31
5-14
5-15
-
6-50
3-15/6-1*/20-0*
3-15/6-2*/20-0*
Factory default
No operation
No operation
+24 V DC
+24 V DC
Start
No operation
Common
Coast inverse
Jog
No operation
No operation
Safe Stop
Speed 0-HighLim
Reference
Feedback
•
Avoid mounting with twisted screen ends
(pigtails), which will spoil high frequency screening effects.
•
If it is necessary to split the screen to install a motor isolator or motor relay, the screen must be continued with the lowest possible HF impedance.
F frame Requirements
F1/F3 requirements: Motor phase cable quantities must be multiples of 2, resulting in 2, 4, 6, or 8 (1 cable is not allowed) to obtain 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. The recommended common point is the motor terminals.
F2/F4 requirements: Motor phase cable quantities must be multiples of 3, resulting in 3, 6, 9, or 12 (1 or 2 cables are not allowed) to obtain equal amount of wires attached to each inverter module terminal. The wires are required to be equal length within 10% between the inverter module terminals and the first common point of a phase. The recommended common point is the motor terminals.
Output junction box requirements: The length, minimum
2.5 meters, and quantity of cables must be equal from each inverter module to the common terminal in the junction box.
NOTE
If a retrofit application requires unequal amount of wires per phase, please consult the factory for requirements and documentation or use the top/bottom entry side cabinet busbar option.
5 5
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5.2.4 Electrical Installation of Motor Cables
Screening of cables
Avoid installation with twisted screen ends (pigtails). They spoil the screening effect at higher frequencies.
If it is necessary to break the screen to install a motor isolator or motor contactor, the screen must be continued at the lowest possible HF impedance.
Cable length and cross-section
The frequency converter has been tested with a given length of cable and a given cross-section of that cable. If the cross-section is increased, the cable capacitance - and thus the leakage current - may increase, and the cable length must be reduced correspondingly.
Switching frequency
When frequency converters are used together with Sinewave filters to reduce the acoustic noise from a motor, the switching frequency must be set according to the Sinewave filter instruction in 14-01 Switching Frequency.
Aluminium conductors
Aluminium conductors are not recommended. Terminals can accept aluminium conductors but the conductor surface has to be clean and the oxidation must be removed and sealed by neutral acid free Vaseline grease before the conductor is connected.
Furthermore, the terminal screw 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-outs
Ø26.3
Ø17
Ø33,1
A
Ø21
Ø33,1
B
Ø33,1
C
Illustration 5.8 Cable entry holes for enclosure B1. The suggested use of the holes are purely recommendations and other solutions are possible.
D M25 Ø18 D
M32
A
M25 M32
B
M32
C
Illustration 5.9 Cable entry holes for enclosure B1. The suggested use of the holes are purely recommendations and other solutions are possible.
Ø26.3
Ø17
Ø26.3
Illustration 5.7 Cable entry holes for enclosure A5. The suggested use of the holes are purely recommendations and other solutions are possible.
Ø42.9
A
Ø33.1
B
Ø42.9
C
Illustration 5.10 Cable entry holes for enclosure B2. The suggested use of the holes are purely recommendations and other solutions are possible.
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How to Install
M25
M40
A
M20 M32
B
M40
C
Illustration 5.11 Cable entry holes for enclosure B2. The suggested use of the holes are purely recommendations and other solutions are possible.
M15 M25 M16
D
VLT
®
HVAC Drive Design Guide
M25
M63
A
M63
C
M50
B
Illustration 5.12 Cable entry holes for enclosure C1. The suggested use of the holes are purely recommendations and other solutions are possible.
5.2.6 Removal of Knockouts for Extra
Cables
1.
2.
3.
4.
5.
Remove cable entry from the frequency converter
(Avoiding foreign parts falling into the frequency converter when removing knockouts)
Cable entry has to be supported around the knockout you intend to remove.
The knockout can now be removed with a strong mandrel and a hammer.
Remove burrs from the hole.
Mount Cable entry on frequency converter.
5.2.7 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12)
Cables are connected through the gland plate from the bottom. Remove the plate and plan where to place the entry for the glands or conduits. Prepare holes in the marked area on the drawing.
NOTE
The gland plate must be fitted to the frequency converter to ensure the specified protection degree, as well as ensuring proper cooling of the unit. If the gland plate is not mounted, the frequency converter may trip on Alarm
69, Pwr. Card Temp
Cable entries viewed from the bottom of the frequency converter - 1) Mains side 2) Motor side
5 5
M16 M25 M16 M25
Illustration 5.14 Example of Proper Installation of Gland Plate.
M63
A
M63
C
M50
B
Illustration 5.13 Cable entry holes for enclosure C2. The suggested use of the holes are purely recommendations and other solutions are possible.
Legend:
A: Line in
B: Brake/load sharing
C: Motor out
D: Free space
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How to Install
35
1
350
Illustration 5.15 Frame Sizes D1 + D2
1
35
2
2
VLT
®
HVAC Drive Design Guide
37.7
[1.485]
655.9
[25.825]
460.0
[18.110]
535.0
[21.063]
216.5
[8.524]
281.8
[11.096]
35.5
[1.398]
36.2
[1.425]
533.0
[20.984]
594.8
[23.417]
Illustration 5.18 Frame Size F2
1727.8
[68.024]
994.3
[39.146]
593.0
(23.346)
350
Illustration 5.16 Frame Size E1
F1-F4: Cable entries viewed from the bottom of the frequency converter - 1) Place conduits in marked areas
1
(20.984)
597.0
36.2
(1.425)
(44.488)
1192.8
(46.961)
1925.8
(75.819)
Illustration 5.19 Frame Size F3
37.7
(1.485)
2X 460.0
(18.110)
1252.8
(49.321)
2X 281.8
(11.096)
(20.984)
597.0
1191.8
(46.921)
2324.8
(91.528)
Illustration 5.20 Frame Size F4
1
199.5
[7.854]
258.2
[10.167]
1
1
533.0
595.8
Illustration 5.17 Frame Size F1
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5.2.8 Fuses
A frequency converter that works correctly limits the current it can draw from the supply. Still, it is recommended to use fuses and/ or Circuit Breakers on the supply side as protection in case of component breakdown inside the frequency converter (first fault).
NOTE
This is mandatory in order to ensure compliance with IEC
60364 for CE or NEC 2009 for UL.
WARNING
Personnel and property must be protected against the consequence of component break-down internally in the frequency converter.
Branch Circuit Protection
In order to protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines etc., must be protected against short-circuit and over-current according to national/international regulations.
NOTE
The recommendations given do not cover Branch circuit protection for UL!
Short-circuit protection:
Danfoss recommends using the fuses/Circuit Breakers listed in and to protect service personnel and property in case of component break-down in the frequency converter.
Over current protection:
The frequency converter provides overload protection to limit threats to human life, property damage and to avoid fire hazard due to overheating of the cables in the installation. The frequency converter is equipped with an internal over current protection (4-18 Current Limit) that can be used for upstream overload protection (ULapplications excluded). Moreover, fuses or Circuit Breakers can be used to provide the over current protection in the installation. Over current protection must always be carried out according to national regulations.
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5 5
5.2.9 Non UL Compliance Fuses
Non-UL compliance fuses
Frequency converter
200-240 V - T2
1K1-1K5
Max. fuse size
2K2
3K0
3K7
5K5
7K5
11K
15K
18K5
22K
30K
37K
45K
16A
1
25A
1
25A
1
35A
1
50A
1
63A
1
63A
1
80A
1
125A
1
125A
1
160A
1
200A
1
250A
1
380-480 V - T4
1K1-1K5
2K2-3K0
4K0-5K5
7K5
11K-15K
18K
22K
30K
10A
1
16A
1
25A
1
35A
1
63A
1
63A
1
63A
1
80A
1
37K
45K
55K
75K
100A
1
125A
1
160A
1
250A
1
90K
250A
1
1) Max. fuses - see national/international regulations for selecting an applicable fuse size.
Voltage (V)
200-240
200-240
200-240
200-240
200-240
200-240
200-240
200-240
200-240
200-240
200-240
200-240
200-240
380-500
380-500
380-500
380-500
380-500
380-500
380-500
380-500
380-500
380-500
380-500
380-500
380-500
Table 5.5 Non-UL Fuses 200V to 480V
Type
If UL/cUL is not to be complied with, Danfoss recommends using the following fuses, which will ensure compliance with
EN50178: type gG type gG type gG type gG type gG type gG type gG type gG type gG type gG type gG type aR type aR type gG type gG type gG type gG type gG type gG type gG type gG type gG type gG type gG type aR type aR
Frequency Converter
P110 - P250
P315 - P450
Voltage (V)
380 - 480
380 - 480
Type type gG type gR
Table 5.6 Compliance with EN50178
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UL compliance fuses
Frequency converter
200-240V
7K5
11K
15K
18K5
22K
30K
37K
45K kW
K25-K37
K55-1K1
1K5
2K2
3K0
3K7
5K5
Bussmann
Type RK1
KTN-R05
KTN-R10
KTN-R15
KTN-R20
KTN-R25
KTN-R30
KTN-R50
KTN-R50
KTN-R60
KTN-R80
KTN-R125
KTN-R125
FWX-150
FWX-200
FWX-250
Table 5.7 UL Fuses, 200-240V
Bussmann
JKS-60
JKS-60
JKS-80
JKS-150
JKS-150
-
-
-
Type J
JKS-05
JKS-10
JKS-15
JKS-20
JKS-25
JKS-30
JKS-50
Bussmann
JJN-60
JJN-60
JJN-80
JJN-125
JJN-125
-
-
-
Type T
JJN-05
JJN-10
JJN-15
JJN-20
JJN-25
JJN-30
JJN-50
SIBA
Type RK1
5017906-005
5017906-010
5017906-015
5012406-020
5012406-025
5012406-030
5012406-050
5012406-050
5014006-063
5014006-080
2028220-125
2028220-125
2028220-150
2028220-200
2028220-250
Littel fuse
Type RK1
KLN-R005
KLN-R10
KLN-R15
KLN-R20
KLN-R25
KLN-R30
KLN-R50
KLN-R60
KLN-R60
KLN-R80
KLN-R125
KLN-R125
L25S-150
L25S-200
L25S-250
Ferraz-
Shawmut
37K
45K
55K
75K
90K
15K
18K
22K
30K
Frequency converter
Bussmann
380-480V, 525-600V kW Type RK1
K37-1K1
1K5-2K2
3K0
4K0
KTS-R6
KTS-R10
KTS-R15
KTS-R20
5K5
7K5
11K
KTS-R25
KTS-R30
KTS-R40
KTS-R40
KTS-R50
KTS-R60
KTS-R80
KTS-R100
KTS-R125
KTS-R150
FWH-220
FWH-250
Table 5.8 UL Fuses, 380-600V
Bussmann
JKS-40
JKS-50
JKS-60
JKS-80
JKS-100
JKS-150
JKS-150
-
-
Type J
JKS-6
JKS-10
JKS-15
JKS-20
JKS-25
JKS-30
JKS-40
Bussmann
JJS-40
JJS-50
JJS-60
JJS-80
JJS-100
JJS-150
JJS-150
-
-
Type T
JJS-6
JJS-10
JJS-15
JJS-20
JJS-25
JJS-30
JJS-40
SIBA
Type RK1
5017906-006
5017906-010
5017906-016
5017906-020
5017906-025
5012406-032
5014006-040
5014006-040
5014006-050
5014006-063
2028220-100
2028220-125
2028220-125
2028220-160
2028220-200
2028220-250
Littel fuse
Type RK1
KLS-R6
KLS-R10
KLS-R16
KLS-R20
KLS-R25
KLS-R30
KLS-R40
KLS-R40
KLS-R50
KLS-R60
KLS-R80
KLS-R100
KLS-R125
KLS-R150
L50S-225
L50S-250
Ferraz-
Shawmut
KTS-fuses from Bussmann may substitute KTN for 240V frequency converters.
FWH-fuses from Bussmann may substitute FWX for 240V frequency converters.
KLSR fuses from LITTEL FUSE may substitute KLNR fuses for 240V frequency converters.
L50S fuses from LITTEL FUSE may substitute L50S fuses for 240V frequency converters.
A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240V frequency converters.
A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240V frequency converters.
-
-
-
-
Type CC
ATM-R6
ATM-R10
ATM-R16
ATM-R20
ATM-R25
ATM-R30
-
Type CC
ATM-R05
ATM-R10
ATM-R15
ATM-R20
ATM-R25
ATM-R30
-
-
A2K-60R
A2K-80R
A2K-125R
A2K-125R
A25X-150
A25X-200
A25X-250
Ferraz-
Shawmut
Type RK1
A6K-6R
A6K-10R
A6K-16R
A6K-20R
A6K-25R
A6K-30R
A6K-40R
A6K-40R
A6K-50R
A6K-60R
A6K-80R
A6K-100R
A6K-125R
A6K-150R
A50-P225
A50-P250
Ferraz-
Shawmut
Type RK1
A2K-05R
A2K-10R
A2K-15R
A2K-20R
A2K-25R
A2K-30R
A2K-50R
A2K-50R
A2K-60R
A2K-80R
A2K-125R
A2K-125R
A25X-150
A25X-200
A25X-250
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5 5
UL Compliance
380-480V, frame sizes D, E and F
The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240V, or 480V, or 500V, or 600V depending on the drive voltage rating. With the proper fusing the drive Short Circuit Current Rating (SCCR) is
100,000 Arms.
Size/
Type
P110
P132
P160
P200
P250
Bussmann
E1958
JFHR2**
FWH-
300
FWH-
350
FWH-
400
FWH-
500
FWH-
600
Bussmann
E4273
T/JDDZ**
JJS-
400
JJS-
500
JJS-
300
JJS-
350
JJS-
600
SIBA
E180276
JFHR2
2061032.315
2061032.35
2061032.40
2061032.50
2062032.63
LittelFuse
E71611
JFHR2**
L50S-300
L50S-350
L50S-400
L50S-500
L50S-600
Ferraz-
Shawmut
E60314
JFHR2**
A50-P300
A50-P350
A50-P400
A50-P500
A50-P600
Bussmann
E4274
H/JDDZ**
NOS-
300
NOS-
350
NOS-
400
NOS-
500
NOS-
600
Bussmann
E125085
JFHR2*
170M3017
170M3018
170M4012
170M4014
170M4016
Internal
Option
Bussmann
170M3018
170M3018
170M4016
170M4016
170M4016
Table 5.9 Frame Size D, Line Fuses, 380-480V
Size/
Type
Bussma nn PN*
P315 170M4
017
P355 170M6
013
P400 170M6
013
P450 170M6
013
Rating
700A,
700V
900A,
700V
900A,
700V
900A,
700V
Ferraz
6.9URD31D08A0
700
6.9URD33D08A0
900
6.9URD33D08A0
900
6.9URD33D08A0
900
Siba
20 610 32.700
20 630 32.900
20 630 32.900
20 630 32.900
Table 5.10 Frame Size E, Line Fuses, 380-480V
Size/
Type
Bussmann
PN*
Rating
P500
P560
P630
P710
170M7081 1600A,
700V
170M7081 1600A,
700V
170M7082 2000A,
700V
170M7082 2000A,
700V
P800 170M7083 2500A,
700V
P1M0 170M7083 2500A,
700V
Siba
Internal
Bussmann
Option
20 695 32.1600
170M7082
20 695 32.1600
20 695 32.2000
20 695 32.2000
20 695 32.2500
20 695 32.2500
170M7082
170M7082
170M7082
170M7083
170M7083
Table 5.11 Frame Size F, Line Fuses, 380-480V
Size/Type
P500
P560
P630
P710
P800
P1M0
Bussmann
PN*
170M8611
170M8611
170M6467
170M6467
170M8611
170M6467
Rating
1100A,
1000V
1100A,
1000V
1400A,
700V
1400A,
700V
1100A,
1000V
1400A,
700V
Siba
20 781 32.1000
20 781 32.1000
20 681 32.1400
20 681 32.1400
20 781 32.1000
20 681 32.1400
Table 5.12 Frame Size F, Inverter Module DC Link Fuses, 380-480V
*170M fuses from Bussmann shown use the -/80 visual indicator, -
TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for external use
**Any minimum 500V UL listed fuse with associated current rating may be used to meet UL requirements.
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525-690V, frame sizes D, E and F
Size/
Type
Bussm ann
E1250
85
JFHR2
P45K 170M
3013
P55K 170M
3014
P75K 170M
3015
P90K 170M
3015
P110 170M
3016
P132 170M
3017
P160 170M
3018
P200 170M
4011
P250 170M
4012
P315 170M
4014
P400 170M
5011
Amps
SIBA
E18027
6
JFHR2
125 20610
32.125
160 20610
32.16
200 20610
32.2
200 20610
32.2
250 20610
32.25
315 20610
32.315
350 20610
32.35
350 20610
32.35
400 20610
32.4
500 20610
32.5
550 20620
32.55
Ferraz-
Shawmut
E76491
JFHR2
6.6URD30D08
A0125
6.6URD30D08
A0160
6.6URD30D08
A0200
6.6URD30D08
A0200
6.6URD30D08
A0250
6.6URD30D08
A0315
6.6URD30D08
A0350
6.6URD30D08
A0350
6.6URD30D08
A0400
6.6URD30D08
A0500
6.6URD32D08
A550
Table 5.13 Frame Size D, E and F 525-690V
Size/
Type
P450
P500
P560
P630
Bussmann
PN*
Rating
170M4017 700 A,
700 V
170M4017 700 A,
700 V
170M6013 900 A,
700 V
170M6013 900 A,
700 V
Ferraz
6.9URD31
D08A070
0
6.9URD31
D08A070
0
6.9URD33
D08A090
0
6.9URD33
D08A090
0
Table 5.14 Frame Size E, 525-690V
Internal
Option
Bussmann
170M3015
170M3015
170M3015
170M3015
170M3018
170M3018
170M3018
170M5011
170M5011
170M5011
170M5011
Siba
20 610 32.700
20 610 32.700
20 630 32.900
20 630 32.900
Size/
Type
P710
P800
P900
P1M0
P1M2
P1M4
Bussmann
PN*
Rating
170M7081 1600A,
700V
170M7081 1600A,
700V
170M7081 1600A,
700V
170M7081 1600A,
700V
170M7082 2000A,
700V
170M7083 2500A,
700V
Siba
Internal
Bussmann
Option
20 695 32.1600
170M7082
20 695 32.1600
20 695 32.1600
20 695 32.1600
20 695 32.2000
20 695 32.2500
170M7082
170M7082
170M7082
170M7082
170M7083
Table 5.15 Frame Size F, Line Fuses, 525-690V
Size/Type
P710
P800
P900
P1M0
P1M2
P1M4
Bussmann
PN*
170M8611
170M8611
170M8611
170M8611
170M8611
170M8611
Rating
1100A,
1000V
1100A,
1000V
1100A,
1000V
1100A,
1000V
1100A,
1000V
1100A,
1000V
Siba
20 781 32. 1000
20 781 32. 1000
20 781 32. 1000
20 781 32. 1000
20 781 32. 1000
20 781 32.1000
Table 5.16 Frame size F, Inverter Module DC Link Fuses, 525-690V
*170M fuses from Bussmann shown use the -/80 visual indicator, -
TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for external use.
Suitable 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
D, E and F
Table 5.17 SMPS Fuse
Bussmann PN*
KTK-4
Rating
4 A, 600 V
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5 5
Size/Type
P110-P315,
380-480 V
P45K-P500,
525-690 V
P355-P1M0,
380-480 V
P560-P1M4,
525-690 V
Bussmann PN*
KTK-4
KTK-4
Table 5.18 Fan Fuses
LittelFuse
KLK-15
KLK-15
Rating
4 A, 600 V
4 A, 600 V
15A, 600 V
15A, 600 V
Size/Type
P500-
P1M0,
380-480 V
Bussmann
PN*
2.5-4.0 A LPJ-6 SP or
SPI
P710-
P1M4,
525-690 V
P500-
P1M0,
380-480 V
P710-
P1M4,
525-690 V
P500-
P1M0,
380-480 V
P710-
P1M4,
525-690 V
P500-
P1M0,
380-480 V
P710-
P1M4,
525-690 V
4.0-6.3 A
6.3 - 10 A
10 - 16 A
LPJ-10 SP or SPI
LPJ-10 SP or SPI
LPJ-15 SP or SPI
LPJ-15 SP or SPI
LPJ-20 SP or SPI
LPJ-25 SP or SPI
LPJ-20 SP or SPI
Rating
Alternative
Fuses
6 A, 600 V Any listed
Class J Dual
Element,
Time Delay,
6A
10 A, 600 V Any listed
Class J Dual
Element,
Time Delay,
10 A
10 A, 600 V Any listed
Class J Dual
Element,
Time Delay,
10 A
15 A, 600 V Any listed
Class J Dual
Element,
Time Delay,
15 A
15 A, 600 V Any listed
Class J Dual
Element,
Time Delay,
15 A
20 A, 600 V Any listed
Class J Dual
Element,
Time Delay,
20A
25 A, 600 V Any listed
Class J Dual
Element,
Time Delay,
25 A
20 A, 600 V Any listed
Class J Dual
Element,
Time Delay,
20 A
Table 5.19 Manual Motor Controller Fuses
Frame size
F
Bussmann PN*
LPJ-30 SP or
SPI
Rating
30 A, 600 V
Alternative
Fuses
Any listed
Class J Dual
Element, Time
Delay, 30 A
Table 5.20 30 A Fuse Protected Terminal Fuse
Frame size
F
Bussmann PN*
LPJ-6 SP or SPI
Rating
6 A, 600 V
Alternative
Fuses
Any listed
Class J Dual
Element, Time
Delay, 6 A
Table 5.21 Control Transformer Fuse
Frame size
F
Table 5.22 NAMUR Fuse
Bussmann PN*
GMC-800MA
Rating
800 mA, 250 V
Frame size
F
Bussmann PN*
LP-CC-6
Rating
6 A, 600 V
Alternative
Fuses
Any listed
Class CC, 6 A
Table 5.23 Safety Relay Coil Fuse with PILS Relay
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5.2.10 Control Terminals
Drawing reference numbers:
3.
4.
1.
2.
10 pole plug digital I/O.
3 pole plug RS485 Bus.
6 pole analog I/O.
USB Connection.
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1.
9 - 10 mm
(0.37 in)
2.
3.
39
42
50
53
54
55
3
2
61
68
69
12
13
4
18
19
27
29
32
33
20
37
1
Illustration 5.21 Control Terminals (all Enclosures)
5.2.11 Control Cable Terminals
To mount the cable to the terminal:
1.
Strip isolation of 9-10mm
2.
Insert a screw driver 1) in the rectangular hole.
3.
4.
Insert the cable in the adjacent circular hole.
Remove the screw driver. The cable is now mounted to the terminal.
To remove the cable from the terminal:
1.
Insert a screw driver
1)
in the square hole.
2.
Pull out the cable.
1) Max. 0.4 x 2.5mm
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5.2.12 Basic Wiring Example
1.
2.
Mount terminals from the accessory bag to the front of the frequency converter.
Connect terminals 18 and 27 to +24 V (terminal
12/13)
Default settings:
18 = latched start
27 = stop inverse
12 13 18 19 27 29 32 33 20 37
Speed
Start Stop inverse Safe Stop
Start (18)
Start (27)
Illustration 5.22 Terminal 37 available with Safe Stop Function only!
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5.2.13 Electrical Installation, Control Cables
power input
DC bus
+10Vdc
0-10Vdc
0/4-20 mA
0-10Vdc
0/4-20 mA
91 (L1)
92 (L2)
93 (L3)
95
PE
88 (-)
89 (+)
50 (+10 V OUT)
S201
53 (A IN)
1S202
54 (A IN)
55 (COM A IN)
12 (+24V OUT)
13 (+24V OUT)
18 (D IN)
19 (D IN)
20 (COM D IN)
27
(D IN/OUT)
ON=0-20mA
OFF=0-10V
24V
0V
+
Switch Mode
Power Supply
15mA
+
24Vdc
200mA
-
P 5-00
24V (NPN)
0V (PNP)
24V (NPN)
0V (PNP)
24V (NPN)
0V (PNP)
29 (D IN/OUT)
24V
24V (NPN)
0V (PNP)
32 (D IN)
33 (D IN)
*
37 (D IN)
0V
24V (NPN)
0V (PNP)
24V (NPN)
0V (PNP)
S801
5V
(R+) 82
(R-) 81
ON=Terminated
OFF=Open
(U) 96
(V) 97
(W) 98
(PE) 99
RS-485
Interface
S801
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V relay1
03
02 relay2
01
06
05
04
(COM A OUT) 39
(A OUT) 42
Brake resistor
240Vac, 2A
240Vac, 2A
400Vac, 2A
Motor
Analog Output
0/4-20 mA
RS-485
(PNP) = Source
(NPN) = Sink
Illustration 5.23 Diagram Showing all Electrical Terminals.
Very long control cables and analog signals may in rare cases and depending on installation result in 50/60 Hz earth loops due to noise from mains supply cables.
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 common inputs (terminal
20, 55, 39) to avoid ground currents from both groups to affect other groups. For example, switching on the digital input may disturb the analog input signal.
NOTE
Control cables must be screened/armoured.
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1.
Use a clamp from the accessory bag to connect the screen to the frequency converter decoupling plate for control cables.
See section entitled 5.7.3 Earthing of Screened/Armoured
Control Cables for the correct termination of control cables.
5.2.14 Switches S201, S202, and S801
Switches S201 (A53) and S202 (A54) are used to select a current (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).
Default setting:
S201 (A53) = OFF (voltage input)
S202 (A54) = OFF (voltage input)
S801 (Bus termination) = OFF
NOTE
It is recommended to only change switch position at power off.
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5.3 Final Set-Up and Test
To test the set-up and ensure that the frequency converter is running, follow these steps.
Step 1. Locate the motor name plate
The motor is either star- (Y) or delta- connected (
Δ). This information is located on the motor name plate data.
Step 2. Enter the motor name plate data in this parameter list.
To access this list first press the [QUICK MENU] key then select “Q2 Quick Setup”.
1.
4.
5.
2.
3.
Motor Power [kW] or Motor Power [HP]
Motor Voltage
Motor Frequency
Motor Current
Motor Nominal Speed
1-20 Motor Power [kW]
1-21 Motor Power [HP]
1-22 Motor Voltage
1-23 Motor Frequency
1-24 Motor Current
1-25 Motor Nominal
Speed
BAUER D-7 3734 ESLINGEN
3~ MOTOR NR. 1827421 2003
S/E005A9 n2 31,5
1,5
/min. n1 1400
COS 0,80
/min.
KW
400
1,7L
B IP 65 H1/1A
Y
50
3,6
V
Hz
A
Step 3. Activate the Automatic Motor Adaptation (AMA)
Performing an AMA will ensure optimum performance. The
AMA measures the values from the motor model equivalent diagram.
1.
2.
Connect terminal 27 to terminal 12 or set
5-12 Terminal 27 Digital Input to 'No function'
(5-12 Terminal 27 Digital Input [0])
Activate the AMA 1-29 Automatic Motor
Adaptation (AMA).
3.
4.
5.
Choose between complete or reduced AMA. If an
LC filter is mounted, run only the reduced AMA, or remove the LC filter during the AMA procedure.
Press the [OK] key. The display shows “Press
[Hand On] to start”.
Press the [Hand On] key. A progress bar indicates if the AMA is in progress.
Stop the AMA during operation
1.
Press the [OFF] key - the frequency converter enters into alarm mode and the display shows that the AMA was terminated by the user.
Successful AMA
1.
2.
The display shows “Press [OK] to finish AMA”.
Press the [OK] key to exit the AMA state.
Unsuccessful AMA
1.
2.
The frequency converter enters into alarm mode.
A description of the alarm can be found in the
Troubleshooting section.
"Report Value” in the [Alarm Log] shows the last measuring sequence carried out by the AMA, before the frequency converter entered alarm mode. This number along with the description of the alarm will assist you in troubleshooting. 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 motor power size and the frequency converter power size.
Step 4. Set speed limit and ramp time
Set up the desired limits for speed and ramp time.
Minimum Reference
Maximum Reference
3-02 Minimum Reference
3-03 Maximum Reference
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Motor Speed Low Limit
Motor Speed High Limit
Ramp-up Time 1 [s]
Ramp-down Time 1 [s]
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4-11 Motor Speed Low Limit
[RPM] or 4-12 Motor Speed Low
Limit [Hz]
4-13 Motor Speed High Limit
[RPM] or 4-14 Motor Speed High
Limit [Hz]
3-41 Ramp 1 Ramp Up Time
3-42 Ramp 1 Ramp Down Time
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5.4 Additional Connections
5.4.1 Mains Disconnectors
Assembling of IP55/NEMA Type 12 (A5 housing) with mains disconnector
Mains switch is placed on left side on frame sizes B1, B2,
C1 and C2. Mains switch on A5 frames is placed on right side
OFF
Frame size
A5
B1
B2
Type
Kraus&Naimer KG20A T303
Kraus&Naimer KG64 T303
Kraus&Naimer KG64 T303
Terminal connections
L1 L2 L3 31 43
C1 37 kW
C1 45-55 kW
C2 75 kW
C2 90 kW
Kraus&Naimer KG100 T303
Kraus&Naimer KG105 T303
Kraus&Naimer KG160 T303
Kraus&Naimer KG250 T303
5.4.2 Mains Disconnectors - Frame Size D, E and F
Frame size
D1/D3
D2/D4
E1/E2
E1/E2
F3
F3
F4
Power & Voltage
P110-P132 380-480V &
P110-P160 525-690V
P160-P250 380-480V &
P200-P400 525-690V
P315 380-480V & P450-
P630 525-690V
P355-P450 380-480V
P500 380-480V & P710-
P800 525-690V
P560-P710 380-480V &
P900 525-690V
P800-P1M0 380-480V &
P1M0-P1M4 525-690V
Type
ABB OETL-NF200A or
OT200U12-91
ABB OETL-NF400A or
OT400U12-91
ABB OETL-NF600A
ABB OETL-NF800A
Merlin Gerin
NPJF36000S12AAYP
Merlin Gerin
NRK36000S20AAYP
Merlin Gerin
NRK36000S20AAYP
T1
L1
T2
L2
T3
L3
32
13
44
T1 T2 T3 14
5.4.3 F Frame circuit breakers
Frame size
F3
F3
F4
Power & Voltage
P500 380-480V & P710-
P800 525-690V
P560-P710 380-480V &
P900 525-690V
P800 380-480V & P1M0-
P1M4 525-690V
F4 P1M0 380-480V
Type
Merlin Gerin
NPJF36120U31AABSCYP
Merlin Gerin
NRJF36200U31AABSCYP
Merlin Gerin
NRJF36200U31AABSCYP
Merlin Gerin
NRJF36250U31AABSCYP
5.4.4 F Frame Mains Contactors
Frame size
F3
F3
F4
Power & Voltage
P500-P560 380-480V &
P710-P900 525-690V
P 630-P710380-480V
P800-P1M0 380-480V &
P1M0-P1M4 525-690V
Type
Eaton XTCE650N22A
Eaton XTCEC14P22B
Eaton XTCEC14P22B
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5.4.5 Brake Resistor Temperature Switch
Frame size D-E-F
Torque: 0.5-0.6 Nm (5 in-lbs)
Screw size: M3
This input can be used to monitor the temperature of an externally connected brake resistor. If the input between
104 and 106 is established, 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”.
A KLIXON switch must be installed that is `normally closed'. If this function is not used, 106 and 104 must be short-circuited together.
Normally closed: 104-106 (factory installed jumper)
Normally open: 104-105
Terminal No.
106, 104, 105
Function
Brake resistor temperature switch.
NOTE
If the temperature of the brake resistor gets too high and the thermal switch drops out, the frequency converter will stop braking. The motor will start coasting.
106
NC
104
C
105
NO
5.4.7 Relay Output
Relay 1
•
Terminal 01: common
•
Terminal 02: normal open 240V AC
•
Terminal 03: normal closed 240V AC
Relay 2
•
Terminal 04: common
•
Terminal 05: normal open 400V AC
•
Terminal 06: normal closed 240V AC
Relay 1 and relay 2 are programmed in 5-40 Function Relay,
5-41 On Delay, Relay, and 5-42 Off Delay, Relay.
Additional relay outputs can be added to the frequency converter by using option module MCB 105.
relay1
03
02
240Vac, 2A
5.4.6 External Fan Supply
Frame size D,E,F
In case the frequency converter is supplied by DC or if the fan must run independently of the power supply, an external power supply can be applied. The connection is made on the power card.
Terminal No.
100, 101
102, 103
Function
Auxiliary supply S, T
Internal supply S, T
The connector located on the power card provides the connection of line voltage for the cooling fans. The fans are connected from factory to be supplied form a common
AC line (jumpers between 100-102 and 101-103). If external supply is needed, the jumpers are removed and the supply is connected to terminals 100 and 101. A 5 Amp fuse should be used for protection. In UL applications this should be LittleFuse KLK-5 or equivalent.
relay2
05
04
01
06
240Vac, 2A
400Vac, 2A
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5.4.8 Parallel Connection of Motors
The frequency converter can control several parallelconnected motors. The total current consumption of the motors must not exceed the rated output current I
INV
for the frequency converter.
When motors are connected in parallel, 1-29 Automatic
Motor Adaptation (AMA) cannot be used.
Problems may arise at start and at low RPM values if motor sizes are widely different because small motors' relatively high ohmic resistance in the stator calls for a higher voltage at start and at low RPM values.
The electronic thermal relay (ETR) of the frequency converter cannot be used as motor protection for the individual motor of systems with parallel-connected motors. Provide further motor protection by e.g.
thermistors in each motor or individual thermal relays.
(Circuit breakers are not suitable as protection).
LC filter
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5.4.9 Direction of Motor Rotation
The default setting is clockwise rotation with the frequency converter output connected as follows.
Terminal 96 connected to U-phase
Terminal 97 connected to V-phase
Terminal 98 connected to W-phase
The direction of motor rotation is changed by switching two motor phases.
Motor rotation check can be performed using 1-28 Motor
Rotation Check and following the steps shown in the display.
U
96
U
96
V
97
V
97
W
98
W
98
5.4.10 Motor Thermal Protection
The electronic thermal relay in the frequency converter has received the UL-approval for single motor protection, when 1-90 Motor Thermal Protection is set for ETR Trip and
1-24 Motor Current is set to the rated motor current (see motor name plate).
5.4.11 Motor Insulation
For motor cable lengths
≤ the maximum cable length listed in the General Specifications tables the following motor insulation ratings are recommended because the peak voltage can be up to twice the DC link voltage, 2.8
times the mains voltage, due to transmission line effects in the motor cable. If a motor has lower insulation rating it recommended to use a du/dt or sine wave filter.
Nominal Mains Voltage
U
N
≤ 420 V
420V < U
N
≤ 500 V
500V < U
N
≤ 600 V
600V < U
N
≤ 690 V
Motor Insulation
Standard U
LL
= 1300V
Reinforced U
LL
= 1600V
Reinforced U
LL
= 1800V
Reinforced U
LL
= 2000V
5.4.12 Motor Bearing Currents
It is generally recommended that motors of a rating 110 kW or higher operating via frequency converters should have NDE (Non-Drive End) insulated bearings installed to eliminate circulating bearing currents due to the physical size of the motor. To minimize DE (Drive End) bearing and shaft currents proper grounding of the drive, motor, driven machine, and motor to the driven machine is required.
Although failure due to bearing currents is low and very dependent on many different items, for security of operation the following are mitigation strategies which can be implemented.
Standard Mitigation Strategies:
1.
Use an insulated bearing
2.
Apply rigorous installation procedures
Ensure the motor and load motor are aligned
Strictly follow the EMC Installation guideline
3.
4.
Reinforce the PE so the high frequency impedance is lower in the PE than the input power leads
Provide a good high frequency connection between the motor and the frequency converter for instance by screened cable which has a 360
° connection in the motor and the frequency converter
Make sure that the impedance from frequency converter to building ground is lower that the grounding impedance of the machine. This can be difficult for pumps- Make a direct earth connection between the motor and load motor.
Apply conductive lubrication
Try to ensure the line voltage is balanced to ground. This can be difficult for IT, TT, TN-CS or
Grounded leg systems
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5.
Use an insulated bearing as recommended by the motor manufacturer (note: Motors from reputable manufacturers will typically have these fitted as standard in motors of this size)
If found to be necessary and after consultation with
Danfoss:
6.
Lower the IGBT switching frequency
7.
Modify the inverter waveform, 60
° AVM vs.
SFAVM
8.
Install a shaft grounding system or use an isolating coupling between motor and load
9.
Use minimum speed settings if possible
10.
Use a dU/dt or sinus filter
5.5 Installation of Misc. Connections
5.5.1 RS-485 Bus Connection
One or more frequency converters can be connected to a control (or master) using the RS-485 standardized interface.
Terminal 68 is connected to the P signal (TX+, RX+), while terminal 69 is connected to the N signal (TX-,RX-).
If more than one frequency converter is connected to a master, use parallel connections.
5.5.2 How to Connect a PC to the
Frequency Converter
To control or program the frequency converter from a PC, install the PC-based Configuration Tool MCT 10 Set-up
Software.
The PC is connected via a standard (host/device) USB
cable, or via the RS-485 interface as shown in 5.5.1 Bus
NOTE
The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
The USB connection is connected to protection earth on the frequency converter. Use only an isolated laptop as PC connection to the USB connector on the frequency converter.
5 5
RS 232
USB
RS 485
+
-
68 69 68 69 68 69
Illustration 5.24 For control cable connections, see section on
Control Terminals.
In order to avoid potential equalizing currents in the screen, earth the cable screen via terminal 61, which is connected to the frame via an RC-link.
For EMC correct installation, refer to 5.7 EMC-correct Instal-
Bus termination
The RS-485 bus must be terminated by a resistor network at both ends. For this purpose, set switch S801 on the control card for "ON".
For more information, see 5.2.14 Switches S201, S202, and
Communication protocol must be set to 8-30 Protocol.
PC-based Configuration Tool MCT 10 Set-up Software
All frequency converters are equipped with a serial communication port. Danfoss provides a PC tool for communication between PC and frequency converter, PCbased Configuration Tool MCT 10 Set-up Software.
MCT 10 Set-up Software
MCT 10 Set-up Software has been designed as an easy to use interactive tool for setting parameters in our frequency converters.
The PC-based Configuration Tool MCT 10 Set-up Software will be useful for:
•
Planning a communication network off-line. MCT
10 Set-up Software contains a complete frequency converter database
•
Commissioning frequency converters on line
•
Saving settings for all frequency converters
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•
Replacing a frequency converter in a network
•
Expanding an existing network
•
Future developed drives will be supported
The PC-based Configuration Tool MCT 10 Set-up Software 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 need for an extra communication network.
See Operating Instructions, MG.33.Cx.yy and MN.90.Ex.yy for more information about the features supported by the
Profibus DP V1 functions.
Save Drive Settings:
1.
Connect a PC to the unit via USB com port
2.
Open PC-based Configuration Tool MCT 10 Set-up
Software
3.
4.
Choose “Read from drive”
Choose “Save as”
All parameters are now stored in the PC.
Load Drive Settings:
1.
Connect a PC to the unit via USB com port
2.
Open PC-based Configuration Tool MCT 10 Set-up
Software
3.
4.
5.
Choose “Open”– stored files will be shown
Open the appropriate file
Choose “Write to drive”
All parameter settings are now transferred to the frequency converter.
A separate manual for PC-based Configuration Tool MCT
10 Set-up Software is available.
The PC-based Configuration Tool MCT 10 Set-up Software modules
The following modules are included in the software package:
MCT 10 Set-up Software
Setting parameters
Copy to and from frequency converters
Documentation and print out of parameter settings incl. diagrams
Ext. User Interface
Preventive Maintenance Schedule
Clock settings
Timed Action Programming
Smart Logic Controller Set-up
Ordering number:
Please order the CD containing the PC-based Configuration
Tool MCT 10 Set-up Software using code number
130B1000.
MCT 10 Set-up Software can also be downloaded from the
Danfoss Internet: http://www.danfoss.com/BusinessAreas/
DrivesSolutions/Softwaredownload/DDPC+Software
+Program.htm.
5.5.3 MCT 31
The MCT 31 harmonic calculation PC tool enables easy estimation of the harmonic distortion in a given application. Both the harmonic distortion of Danfoss frequency converters as well as non-Danfoss frequency converters with different additional harmonic reduction devices, such as Danfoss AHF filters and 12-18-pulse rectifiers, can be calculated.
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/DrivesSo-
lutions/Softwaredownload/DDPC+Software+Program.htm.
5.6 Safety
5.6.1 High Voltage Test
Carry out a high voltage test by short-circuiting terminals
U, V, W, L
1
, L
2
and L
3
. Energize maximum 2.15 kV DC for
380-500V frequency converters and 2.525 kV DC for
525-690V frequency converters for one second between this short-circuit and the chassis.
WARNING
When running high voltage tests of the entire installation, interrupt the mains and motor connection if the leakage currents are too high.
5.6.2 Safety Earth Connection
The frequency converter has a high leakage current and must be earthed appropriately for safety reasons according to EN 50178.
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WARNING
The earth leakage current from the frequency converter exceeds 3.5 mA. To ensure a good mechanical connection from the earth cable to the earth connection (terminal 95), the cable cross-section must be at least 10 mm
2
or 2 rated earth wires terminated separately.
5.7 EMC-correct Installation
5.7.1 Electrical Installation - EMC
Precautions
The following is a guideline to good engineering practice when installing frequency converters. Follow these guidelines to comply with EN 61800-3 First environment. If the installation is in EN 61800-3 Second environment, i.e.
industrial networks, or in an installation with its own transformer, deviation from these guidelines is allowed but
not recommended. See also 2.2 CE labelling, 2.9.1 General
Aspects of EMC Emissions and 2.9.3 EMC Test Results
Good engineering practice to ensure EMC-correct electrical installation:
•
Use only braided screened/armoured motor cables and braided screened/armoured control cables. The screen should provide a minimum coverage of 80%. The screen material must be metal, not limited to but typically copper, aluminium, steel or lead. There are no special requirements for the mains cable.
•
Installations using rigid metal conduits are not required to use screened cable, but the motor cable must be installed in conduit separate from the control and mains cables. Full connection of the conduit from the drive to the motor is required. The EMC performance of flexible conduits varies a lot and information from the manufacturer must be obtained.
•
Connect the 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 frequency converter. See also
5.7.3 Earthing of Screened/Armoured Control
•
Avoid terminating the screen/armour with twisted ends (pigtails). It increases the high frequency impedance of the screen, which reduces its effectiveness at high frequencies. Use low impedance cable clamps or EMC cable glands instead.
•
Avoid using unscreened/unarmoured motor or control cables inside cabinets housing the drive(s), whenever this can be avoided.
Leave the screen as close to the connectors as possible.
Illustration 5.25 shows an example of an EMC-correct
electrical installation of an IP20 frequency converter. The frequency converter is fitted in an installation cabinet with an output contactor and connected to a PLC, which is installed in a separate cabinet. Other ways of doing the installation may have just as good an EMC performance, provided the above guide lines to engineering practice are followed.
If the installation is not carried out according to the guideline and if unscreened cables and control wires are used, some emission requirements are not complied with, although the immunity requirements are fulfilled. See
2.9.3 EMC Test Results (Emission).
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PLC etc.
Panel
5 5
PLC
Min. 16 mm
2
Equalizing cable
All cable entries in one side of panel
Control cables
Mains-supply
Min. 200mm between control cables, motor cable and mains cable
Motor cable
L1
L2
L3
PE
Reinforced protective earth
Illustration 5.25 EMC-correct Electrical Installation of a Frequency Converter in Cabinet.
Motor, 3 phases and
Protective earth
Output contactor etc.
Earthing rail
Cable insulation stripped
L1
L2
L3
N
PE
F1
91 92 93 95
L1 L2 L3 PE
U V W PE
96 97 98 99
12
37
18
50
53
55
54
Transmitter
5.7.2 Use of EMC-Correct Cables
Danfoss recommends braided screened/armoured cables to optimise EMC immunity of the control cables and the EMC emission from the motor cables.
The ability of a cable to reduce the in- and outgoing radiation of electric noise depends on the transfer impedance (Z
T
). The screen of a cable is normally designed to reduce the transfer of electric noise; however, a screen with a lower transfer impedance (Z
T
) value is more effective than a screen with a higher transfer impedance
(Z
T
).
Transfer impedance (Z
T
) is rarely stated by cable manufacturers but it is often possible to estimate transfer impedance (Z
T
) by assessing the physical design of the cable.
3
M
Illustration 5.26 Electrical Connection Diagram.
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c.
a.
Transfer impedance (Z
T
) 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 physical area of the cable covered by the screen - often stated as a percentage value.
Screen type, i.e. braided or twisted pattern.
Aluminium-clad with copper wire.
Twisted copper wire or armoured steel wire cable.
Single-layer braided copper wire with varying percentage screen coverage.
This is the typical Danfoss reference cable.
d.
e.
f.
g.
Double-layer braided copper wire.
Twin layer of braided copper wire with a magnetic, screened/armoured intermediate layer.
Cable that runs in copper tube or steel tube.
Lead cable with 1.1mm wall thickness.
103
102
101
Transfer impedance, Z mOhm/m
105 t
104
1
10ˉ1
10ˉ2
10ˉ3
0,01 0,1 1 10 100 MHz a b c d f e g
5 5
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5.7.3 Earthing of Screened/Armoured
Control Cables
Generally speaking, control cables must be braided screened/armoured and the screen must be connected by means of a cable clamp at both ends to the metal cabinet of the unit.
The drawing below indicates how correct earthing is carried out and what to do if in doubt.
a.
b.
c.
d.
e.
Correct earthing
Control cables and cables for serial communication must be fitted with cable clamps at both ends to ensure the best possible electrical contact.
Wrong earthing
Do not use twisted cable ends (pigtails). They increase the screen impedance at high frequencies.
Protection with respect to earth potential between PLC and frequency converter
If the earth potential between the frequency converter and the PLC (etc.) is different, electric noise may occur that will disturb the entire system. Solve this problem by fitting an equalising cable, next to the control cable.
Minimum cable cross-section: 16 mm
2
.
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 (keeping leads short).
Cables for serial communication
Eliminate low-frequency noise currents between two frequency converters by connecting one end of the screen to terminal 61. This terminal is connected to earth via an internal RC link. Use twisted-pair cables to reduce the differential mode interference between the conductors.
5.8 Residual Current Device
Use RCD relays, multiple protective earthing or earthing as extra protection, provided that local safety regulations are complied with.
If an earth fault appears, a DC content may develop in the faulty current.
If RCD relays are used, local regulations must be observed.
Relays must be suitable for protection of 3-phase equipment with a bridge rectifier and for a brief discharge
on power-up see 2.11 Earth Leakage Current for further
information.
PLC etc.
PLC etc.
PLC etc.
PE PE b
PLC etc.
PE
PE PE
PE
Min. 16mm 2
Equalizing cable
FC c
PE
100nF
69
68
61
FC
PE PE
PE
PE
FC
FC
FC
FC
68
69 a d e
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6 Application Examples
6.1.1 Start/Stop
Terminal 18 = start/stop 5-10 Terminal 18 Digital Input [8]
Start
Terminal 27 = No operation 5-12 Terminal 27 Digital Input
[0] No operation (Default coast inverse
5-10 Terminal 18 Digital Input = Start (default)
5-12 Terminal 27 Digital Input = coast inverse
(default)
6.1.2 Pulse Start/Stop
Terminal 18 = start/stop 5-10 Terminal 18 Digital Input [9]
Latched start
Terminal 27= Stop 5-12 Terminal 27 Digital Input [6] Stop
inverse
5-10 Terminal 18 Digital Input = Latched start
5-12 Terminal 27 Digital Input = Stop inverse
6 6
12 13 18 19 27 29 32 33 20 37
12 13 18 19 27 29 32 33 20 37
Start/Stop Safe Stop
Speed
Start/Stop
[18]
Illustration 6.1 Terminal 37: Available only with Safe Stop
Function
Speed
Start Stop inverse Safe Stop
Start (18)
Start (27)
Illustration 6.2 Terminal 37: Available only with Safe Stop
Function
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6.1.3 Potentiometer Reference
Voltage reference via a potentiometer.
3-15 Reference 1 Source [1] = Analog Input 53
6-10 Terminal 53 Low Voltage = 0V
6-11 Terminal 53 High Voltage = 10V
6-14 Terminal 53 Low Ref./Feedb. Value = 0 RPM
6-15 Terminal 53 High Ref./Feedb. Value = 1.500
RPM
Switch S201 = OFF (U)
Speed RPM
P 6-15
Ref. voltage
P 6-11 10V
39 42 50 53 54 55
1 kW
6.1.4 Automatic Motor Adaptation (AMA)
AMA is an algorithm to measure the electrical motor parameters on a motor at standstill. This means that AMA itself does not supply any torque.
AMA is useful when commissioning systems and optimising the adjustment of the frequency converter to the applied motor. This feature is particularly used where the default setting does not apply to the connected motor.
1-29 Automatic Motor Adaptation (AMA) allows a choice of complete AMA with determination of all electrical motor parameters or reduced AMA with determination of the stator resistance Rs only.
The duration of a total AMA varies from a few minutes on small motors to more than 15 minutes on large motors.
Limitations and preconditions:
•
For the AMA to determine the motor parameters optimally, enter the correct motor nameplate data in 1-20 Motor Power [kW] to 1-28 Motor
Rotation Check.
•
For the best adjustment of the frequency converter, carry out AMA on a cold motor.
Repeated AMA runs may lead to a heating of the motor, which results in an increase 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 carried out on up to one oversize motor.
•
It is possible to carry out a reduced AMA test with a Sine-wave filter installed. Avoid carrying out a complete AMA with a Sine-wave 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 are coupled in parallel, use only reduced AMA if any.
•
Avoid running a complete AMA when using synchronous motors. If synchronous motors are applied, run a reduced AMA and manually set the extended motor data. The AMA function does not apply to permanent magnet motors.
•
The frequency converter does not produce motor torque during an AMA. During an AMA, it is imperative that the application does not force the motor shaft to run, which is known to happen with e.g. wind milling in ventilation systems. This disturbs the AMA function.
•
AMA can not be activated when running a PM motor (when 1-10 Motor Construction is set to [1]
PM non salient SPM).
6.1.5 Smart Logic Control
A useful facility in the VLT
®
HVAC Drive frequency converter is the Smart Logic Control (SLC).
In applications where a PLC is generating a simple sequence the SLC may take over elementary tasks from the main control.
SLC is designed to act from event send to or generated in the frequency converter. The frequency converter will then perform the pre-programmed action.
6.1.6 Smart Logic Control Programming
The Smart Logic Control (SLC) is essentially a sequence of user defined actions (see 13-52 SL Controller Action) executed by the SLC when the associated user defined
event (see 13-51 SL Controller Event) is evaluated as TRUE by the SLC.
Events and actions are each numbered and are linked in pairs called states. This means that when event [1] is fulfilled (attains the value TRUE), action [1] is executed.
After this, the conditions of event [2] will be evaluated and if evaluated TRUE, action [2]will be executed and so on.
Events and actions are placed in array parameters.
Only one event will be evaluated at any time. If an event is evaluated as FALSE, nothing happens (in the SLC) during
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Only when event [1] is evaluated TRUE, the SLC executes
action [1] and starts evaluating event [2].
It is possible to program from 0 to 20 events and actions.
When the last event / action has been executed, the sequence starts over again from event [1] / action [1]. The illustration shows an example with three events / actions:
Event 4/
Action 4
Event 1/
Action 1 State 2
Event 2/
Action 2
Stop event P13-02
Event 3/
Action 3
Stop event P13-02
6.1.7 SLC Application Example
One sequence 1:
Start – ramp up – run at reference speed 2 sec – ramp down and hold shaft until stop.
Max. ref.
P 3-03
Preset ref.(0)
P 3-10(0)
State 2 State 3
6 6
State 1
Preset ref.(1)
P 3-10(1)
2 sec 2 sec
Term 18
P 5-10(start)
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 Operation (5-12 Terminal 27 Digital Input)
Set Preset reference 0 to first preset speed (3-10 Preset
Reference [0]) in percentage of Max reference speed
(3-03 Maximum Reference). Ex.: 60%
Set preset reference 1 to second preset speed (3-10 Preset
Reference [1] Ex.: 0 % (zero).
Set the timer 0 for constant running speed in 13-20 SL
Controller Timer [0]. Ex.: 2 sec.
Set Event 1 in 13-51 SL Controller Event [1] to True [1]
Set Event 2 in 13-51 SL Controller Event [2] to On Reference
[4]
Set Event 3 in 13-51 SL Controller Event [3] to Time Out 0
[30]
Set Event 4 in 13-51 SL Controller Event [4] to False [0]
Set Action 1 in 13-52 SL Controller Action [1] to Select preset
0 [10]
Set Action 2 in 13-52 SL Controller Action [2] to Start Timer
0 [29]
Set Action 3 in 13-52 SL Controller Action [3] to Select preset
1 [11]
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Set Action 4 in 13-52 SL Controller Action [4] to No Action
[1]
Start command
Event 1 True (1)
Action 1 Select Preset (10)
State 0
Stop command
Event 4 False (0)
Action 4 No Action (1)
Event 2 On Reference (4)
Action 2 Start Timer (29)
State 1
State 2 Event 3 Time Out (30)
Action 3 Select Preset ref. (11)
Set the Smart Logic Control in 13-00 SL Controller Mode to
ON.
Start / stop command is applied on terminal 18. If stop signal is applied the frequency converter will ramp down and go into free mode.
6.1.8 BASIC Cascade Controller
Constant Speed
Pumps (2)
120
Variable Speed
Pumps (1)
Motor starter
Pressure Sensor
Frequency Converter with
Cascade Controller
The BASIC Cascade Controller is used for pump applications where a certain pressure (“head”) or level needs to be maintained over a wide dynamic range.
Running a large pump at variable speed over a wide for range is not an ideal solution because of low pump efficiency and because there is a practical limit of about
25% rated full load speed for running a pump.
In the BASIC Cascade Controller the frequency converter controls a variable speed motor as the variable speed pump (lead) and can stage up to two additional constant speed pumps on and off. By varying the speed of the initial pump, variable speed control of the entire system is provided. This maintains constant pressure while eliminating pressure surges, resulting in reduced system stress and quieter operation in pumping systems.
Fixed Lead Pump
The motors must be of equal size. The BASIC Cascade
Controller allows the frequency converter to control up to
3 equal size pumps using the drives two built-in relays.
When the variable pump (lead) is connected directly to the frequency converter, the other 2 pumps are controlled by the two built-in relays. When lead pump alternations is enabled, pumps are connected to the built-in relays and the frequency converter is capable of operating 2 pumps.
Lead Pump Alternation
The motors must be of equal size. This function makes 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 increasing reliability and lifetime of the system. The alternation of the lead pump can take place at a command signal or at staging (adding another pump).
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The command can be a manual alternation or an alternation event signal. If the alternation event is selected, the lead pump alternation takes place every time the event occurs. Selections include whenever an alternation timer expires, at a predefined time of day or when the lead pump goes into sleep mode. Staging is determined by the actual system load.
A separate parameter limits alternation only to take place if total capacity required is > 50%. Total pump capacity is determined as lead pump plus fixed speed pumps capacities.
Bandwidth Management
In cascade control systems, to avoid frequent switching of fixed speed pumps, the desired system pressure is kept within a bandwidth rather than at a constant level. The
Staging Bandwidth provides the required bandwidth for operation. When a large and quick change in system pressure occurs, the Override Bandwidth overrides the
Staging Bandwidth to prevent immediate response to a short duration pressure change. An Override Bandwidth
Timer can be programmed to prevent staging until the system pressure has stabilized and normal control established.
When the Cascade Controller is enabled and running normally and the frequency converter issues a trip alarm, the system head is maintained by staging and destaging fixed speed pumps. To prevent frequent staging and destaging and minimize pressure fluxuations, a wider Fixed
Speed Bandwidth is used instead of the Staging bandwidth.
6.1.9 Pump Staging with Lead Pump
Alternation
Alternation command/PID stops f max
Destaging freq.
f min
Mains operation
Time f max
Staging freq.
Mains operation
5s
Time
With lead pump alternation enabled, a maximum of two pumps are controlled. At an alternation command, the lead pump will ramp to minimum frequency (fmin) and after a delay will ramp to maximum frequency (fmax).
When the speed of the lead pump reaches the destaging frequency, the fixed speed pump will be cut out (destaged). The lead pump continues to ramp up and then ramps down to a stop and the two relays are cut out.
After a time delay, the relay for the fixed speed pump cuts in (staged) and this pump becomes the new lead pump.
The new lead pump ramps up to maximum speed and then down to minimum speed when ramping down and reaching the staging frequency, the old lead pump is now cut in (staged) on the mains as the new fixed speed pump.
If the lead pump 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 expires, the lead pump is removed, avoiding a deal heat water circulation problem.
6.1.10 System Status and Operation
If the lead pump goes into Sleep Mode, the function is displayed on the LCP. It is possible to alternate the lead pump on a Sleep Mode condition.
When the Cascade Controller is enabled, the operation status for each pump and the Cascade Controller is displayed on the LCP. Information displayed includes:
•
Pumps Status, is a read out of the status for the relays assigned to each pump. The display shows pumps that are disabled, off, running on the frequency converter or running on the mains/ motor starter.
•
Cascade Status, is a read out of the status for the
Cascade Controller. The display shows the
Cascade Controller is disabled, all pumps are off, and emergency has stopped all pumps, all pumps are running, fixed speed pumps are being staged/de-staged and lead pump alternation is occurring.
•
De-stage at No-Flow ensures that all fixed speed pumps are stopped individually until the no-flow status disappears.
6 6
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6.1.11 Fixed Variable Speed Pump Wiring Diagram
L1/L2/L3 L1/L2/L3 L1/L2/L3
•
Auxiliary break contact on K1 prevents K3 to cut in.
•
RELAY 2 controls contactor K4 for on/off control of the fixed speed pump.
•
At alternation both relays de-energizes and now
RELAY 2 will be energized as the first relay.
6 6
6.1.12 Lead Pump Alternation Wiring
Diagram
L1/L2/L3
L1/L2/L3
L1/L2/L3
FC
K1 k3 k2 k3 k1
K2
K3
K1
K4
K1
K3
K4
Every pump must be connected to two contactors (K1/K2 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-in relays in the frequency converter.
•
When all relays are de-energized, the first built in relay to be energized will cut in the contactor corresponding to the pump controlled by the relay. E.g. RELAY 1 cuts in contactor K1, which becomes the lead pump.
•
K1 blocks for K2 via the mechanical interlock preventing mains to be connected to the output of the frequency converter (via K1).
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6.1.13 Cascade Controller Wiring Diagram
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.
Power Card Control Card
96
U
97
V
MOTOR
98
W
PE
(cascade pump 1.) (cascade pump 2.)
91
L1
MAINS
92
L2
93
L3
01 02 03 04 05 06 12 13 18 19 27 29 32 33 20 39 42 50 53 54 55
System
Start/
Stop
System
Safety
Interlock
From Motor Control Circuitry
N
Pressure
Transmitter
4-20 mA,
24 V dc
P
L1
L2
L3
PE
6 6
M M M
6.1.14 Start/Stop Conditions
Commands assigned to digital inputs. See Digital Inputs, parameter group 5-1*.
Start (SYSTEM START /STOP)
Lead Pump Start
Coast (EMERGENCY STOP)
External Interlock
Function of buttons on LCP:
Hand On
Variable speed pump (lead)
Ramps up (if stopped and there is a demand)
Ramps up if SYSTEM START is active
Coast to stop
Coast to stop
Off
Auto On
Fixed speed pumps
Staging (if stopped and there is a demand)
Not affected
Cut out (built in relays are de-energized)
Cut out (built in relays are de-energized)
Variable speed pump (lead)
Ramps up (if stopped by a normal stop command) or stays in operation if already running
Ramps down
Starts and stops according to commands via terminals or serial bus
Fixed speed pumps
Destaging (if running)
Destaging
Staging/Destaging
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7 RS-485 Installation and Set-up
7 7
7.1 RS-485 Installation and Set-up
RS-485 is a two-wire bus interface compatible with multidrop network topology, i.e. nodes can be connected as a bus, or via drop cables from a common trunk line. A total of 32 nodes can be connected to one network segment.
Repeaters divide network segments. Please note that each repeater functions as a node within the segment in which it is installed. Each node connected within a given network must have a unique node address, across all segments.
Terminate each segment at both ends, using either the termination switch (S801) of the frequency converters or a biased termination resistor network. Always use screened twisted pair (STP) cable for bus cabling, and always follow good common installation practice.
Low-impedance earth connection of the screen at every node is important, including at high frequencies. Thus, connect a large surface of the screen to earth, for example with a cable clamp or a conductive cable gland. It may be necessary to apply potential-equalizing cables to maintain the same earth potential throughout the network - particularly in installations with long cables.
To prevent impedance mismatch, always use the same type of cable throughout the entire network. When connecting a motor to the frequency converter, always use screened motor cable.
Cable: Screened twisted pair (STP)
Impedance: 120
Ω
Cable length: Max. 1200 m (including drop lines)
Max. 500 m station-to-station
7.1.1 Network Connection
One or more frequency converters can be connected to a control (or master) using the RS-485 standardized interface.
Terminal 68 is connected to the P signal (TX+, RX+), while terminal 69 is connected to the N signal (TX-,RX-). See
drawings in 5.7.3 Earthing of Screened/Armoured Control
If more than one frequency converter is connected to a master, use parallel connections.
RS 232
USB
RS 485
-
+
68 69 68 69 68 69
In order to avoid potential equalizing currents in the screen, earth the cable screen via terminal 61, which is connected to the frame via an RC-link.
61 68 69 39 42 50 53 54 55
Remove jumper to enable Safe Stop
12 13 18 19 27 29 32 33 20 37
Illustration 7.1 Control Card Terminals
7.1.2 Frequency Converter Hardware Setup
Use the terminator dip switch on the main control board of the frequency converter to terminate the RS-485 bus.
124
ON
1 2
Illustration 7.2 Terminator Switch Factory Setting
The factory setting for the dip switch is OFF.
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7.1.3 Frequency Converter Parameter
Settings for Modbus Communication
The following parameters apply to the RS-485 interface
(FC-port):
Parameter
8-30 Protocol
8-31 Address
8-32 Baud Rate
8-33 Parity / Stop
Bits
8-35 Minimum
Response Delay
8-36 Maximum
Response Delay
8-37 Maximum
Inter-Char Delay
Function
Select the application protocol to run on the RS-485 interface
Set the node address. Note: The address range depends on the protocol selected in
8-30 Protocol
Set the baud rate. Note: The default baud rate depends on the protocol selected in
8-30 Protocol
Set the parity and number of stop bits.
Note: The default selection depends on the protocol selected in 8-30 Protocol
Specify a minimum delay time between receiving a request and transmitting a response. This can be used for overcoming modem turnaround delays.
Specify a maximum delay time between transmitting a request and receiving a response.
Specify a maximum delay time between two received bytes to ensure time-out if transmission is interrupted.
7.1.4 EMC Precautions
The following EMC precautions are recommended in order to achieve interference-free operation of the RS-485 network.
Relevant national and local regulations, for example regarding protective earth connection, must be observed.
The RS-485 communication cable must be kept away from motor and brake resistor cables to avoid coupling of high frequency noise from one cable to another. Normally a distance of 200mm (8 inches) is sufficient, but keeping the greatest possible distance between the cables is generally recommended, especially where cables run in parallel over long distances. When crossing is unavoidable, the RS-485 cable must cross motor and brake resistor cables at an angle of 90 degrees.
Min.200mm
90° crossing
7.2 FC Protocol Overview
The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss standard fieldbus. It defines an access technique according to the master-slave principle for communications via a serial bus.
One master and a maximum of 126 slaves can be connected to the bus. The master selects the individual slaves via an address character in the telegram. A slave itself can never transmit without first being requested to do so, and direct message transfer between the individual slaves is not possible. Communications occur in the halfduplex mode.
The master function cannot be transferred to another node
(single-master system).
The physical layer is RS-485, thus utilizing the RS-485 port built into the frequency converter. The FC protocol supports different telegram formats:
•
A short format of 8 bytes for process data.
•
A long format of 16 bytes that also includes a parameter channel.
•
A format used for texts.
7.2.1 FC with Modbus RTU
The FC protocol provides access to the Control Word and
Bus Reference of the frequency converter.
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The Control Word allows the Modbus master to control several important functions of the frequency converter:
•
Start
•
Stop of the frequency converter in various ways:
Coast stop
Quick stop
DC Brake stop
Normal (ramp) stop
•
Reset after a fault trip
•
Run at a variety of preset speeds
•
Run in reverse
•
Change of the active set-up
•
Control of the two relays built into the frequency converter
The Bus Reference is commonly used for speed control. It is also possible to access the parameters, read their values, and where possible, write values to them. This permits a range of control options, including controlling the setpoint of the frequency converter when its internal PID controller is used.
7.3 Network Configuration
7.3.1 Frequency Converter Set-up
Set the following parameters to enable the FC protocol for the frequency converter.
Parameter Number Setting
8-30 Protocol
FC
8-31 Address
8-32 Baud Rate
8-33 Parity / Stop
Bits
1 - 126
2400 - 115200
Even parity, 1 stop bit (default)
7.4 FC Protocol Message Framing Structure
7.4.1 Content of a Character (byte)
Each character transferred begins with a start bit. Then 8 data bits are transferred, corresponding to a byte. Each 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 character, thus consisting of 11 bits in all.
7.4.2 Telegram Structure
Each telegram has the following structure:
1.
2.
Start character (STX)=02 Hex
A byte denoting the telegram length (LGE)
3.
A byte denoting the frequency converter address
(ADR)
A number of data bytes (variable, depending on the type of telegram) follows.
A data control byte (BCC) completes the telegram.
STX LGE ADR DATA BCC
Start bit
0 1 2 3 4 5 6 7 Even Stop
Parity bit
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7.4.3 Telegram Length (LGE)
The telegram length is the number of data bytes plus the address byte ADR and the data control byte BCC.
The length of telegrams with 4 data bytes is
The length of telegrams with 12 data bytes is
The length of telegrams containing texts is
LGE = 4 + 1 + 1 = 6 bytes
LGE = 12 + 1 + 1 = 14 bytes
10
1)
+n bytes
1)
The 10 represents the fixed characters, while the “n’” is variable (depending on the length of the text).
7.4.4 Frequency Converter Address (ADR)
Two different address formats are used.
The address range of the frequency converter is either 1-31 or 1-126.
1. Address format 1-31:
Bit 7 = 0 (address format 1-31 active)
Bit 6 is not used
Bit 5 = 1: Broadcast, address bits (0-4) are not used
Bit 5 = 0: No Broadcast
Bit 0-4 = frequency converter address 1-31
2. Address format 1-126:
Bit 7 = 1 (address format 1-126 active)
Bit 0-6 = frequency converter address 1-126
Bit 0-6 = 0 Broadcast
The slave returns the address byte unchanged to the master in the response telegram.
7.4.5 Data Control Byte (BCC)
The checksum is calculated as an XOR-function. Before the first byte in the telegram is received, the Calculated Checksum is
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 (master=>slave) and response telegrams (slave=>master).
The 3 types of telegram are:
Process 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 slave)
Status word and present output frequency (from slave to master)
7 7
STX LGE ADR PCD1 PCD2 BCC
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Parameter block
The parameter block is used to transfer parameters between master and slave. The data block is made up of 12 bytes (6 words) and also contains the process block.
STX LGE ADR PKE IND
PWE high
PWE low
PCD1 PCD2 BCC
Text block
The text block is used to read or write texts via the data block.
STX LGE ADR PKE IND Ch1 Ch2 Chn PCD1 PCD2 BCC
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7.4.7 The PKE Field
The PKE field contains two sub-fields: Parameter command and response AK, and Parameter number PNU:
PKE IND
PWE high
PWE low
AK
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
PNU
Bits no. 12-15 transfer parameter commands from master to slave and return processed slave responses to the master.
0
1
0
0
1
1
Parameter commands master
⇒ slave
Bit no.
15
0
14
0
13
0
12
0
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
0
0
1
Parameter command
No command
Read parameter value
Write parameter value in RAM (word)
Write parameter value in RAM (double word)
Write parameter value in RAM and EEprom (double word)
Write parameter value in RAM and EEprom (word)
Read/write text
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0
0
0
0
1
Response slave
⇒master
Bit no.
15 14
0
0
0
1
1
13
1
1
0
0
1
12
0
1
0
1
1
Response
No response
Parameter value transferred (word)
Parameter value transferred (double word)
Command cannot be performed text transferred
If the command cannot be performed, the slave sends this response:
0111 Command cannot be performed
- and issues the following fault report in the parameter value (PWE):
PWE low (Hex)
0
1
2
5
11
3
4
82
83
Fault Report
The parameter number used does not exit
There is no write access to the defined parameter
Data value exceeds the parameter's limits
The sub index used does not exit
The parameter is not the array type
The data type does not match the defined parameter
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
There is no bus access to the defined parameter
Data change is not possible because factory setup is selected
7.4.8 Parameter Number (PNU)
Bits no. 0-11 transfer parameter numbers. The function of the relevant parameter is defined in the parameter description in .
7.4.9 Index (IND)
The index is used together with the parameter number to read/write-access parameters with an index, e.g.
15-30 Alarm Log: Error Code. The index consists of 2 bytes, a low byte and a high byte.
[4] corresponds to Danish, select the data value by entering the value in the PWE block. See Example -
Selecting a data value. Serial communication is only capable of reading parameters containing data type 9 (text string).
15-40 FC Type to 15-53 Power Card Serial Number contain data type 9.
For example, read the unit size and mains voltage range in
15-40 FC Type. When a text string is transferred (read), the length of the telegram is variable, and the texts are of different lengths. The telegram length is defined in the second byte of the telegram, LGE. When using text transfer the index character indicates whether it is a read or a write command.
Only the low byte is used as an index.
7.4.10 Parameter Value (PWE)
The parameter value block consists of 2 words (4 bytes), and the value depends on the defined command (AK). The master prompts 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.
To read a text via the PWE block, set the parameter command (AK) to ’F’ Hex. The index character high-byte must be “4”.
Some parameters contain text that can be written to via the serial bus. To write a text via the PWE block, set the parameter command (AK) to ’F’ Hex. The index characters high-byte must be “5”.
When a slave responds to a parameter request (read command), the present parameter value in the PWE block is transferred and returned to the master. If a parameter contains not a numerical value but several data options, e.g. 0-01 Language where [0] corresponds to English, and
Read text
Write text
PKE
Fx xx
Fx xx
IND
04 00
PWE high
PWE low
05 00
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7.4.11 Data Types Supported by the
Frequency Converter
Unsigned means that there is no operational sign in the telegram.
13
33
35
6
7
9
10
4
5
Data types
3
Description
Integer 16
Integer 32
Unsigned 8
Unsigned 16
Unsigned 32
Text string
Byte string
Time difference
Reserved
Bit sequence
7.4.12 Conversion
The various attributes of each parameter are displayed in the section Factory Settings. Parameter values are transferred as whole numbers only. Conversion factors are therefore used to transfer decimals.
4-12 Motor Speed Low 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 100 is thus perceived as 10.0.
Examples:
0s --> conversion index 0
0.00s --> conversion index -2
0ms --> conversion index -3
0.00ms --> conversion index -5
-5
-6
-7
-1
-2
-3
-4
1
0
3
2
5
4
67
6
Conversion index
100
75
74
Table 7.1 Conversion Table
Conversion factor
1000000
100000
10000
1000
100
10
1
0.1
0.01
0.001
0.0001
0.00001
0.000001
0.0000001
7.4.13 Process Words (PCD)
The block of process words is divided into two blocks of
16 bits, which always occur in the defined sequence.
PCD 1
Control telegram (master
⇒ slave Control word)
Control telegram (slave
⇒ master) Status word
PCD 2
Reference-value
Present output frequency
7.5 Examples
7.5.1 Writing a Parameter Value
Change 4-14 Motor Speed High Limit [Hz] to 100 Hz.
Write the data in EEPROM.
PKE = E19E Hex - Write single word in 4-14 Motor Speed
High Limit [Hz]
IND = 0000 Hex
PWEHIGH = 0000 Hex
PWELOW = 03E8 Hex - Data value 1000, corresponding to
100 Hz, see Conversion.
The telegram will look like this:
E19E H 0000 H 0000 H 03E8 H
PKE IND PWE high
PWE
low
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NOTE
4-14 Motor Speed High Limit [Hz] is a single word, and the parameter command for write in EEPROM is “E”. Parameter number 4-14 is 19E in hexadecimal.
The response from the slave to the master will be:
119E H 0000 H 0000 H 03E8 H
PKE
IND PWE high
PWE low
7.5.2 Reading a Parameter Value
Read the value in 3-41 Ramp 1 Ramp Up Time
PKE = 1155 Hex - Read parameter value in 3-41 Ramp 1
Ramp Up Time
IND = 0000 Hex
PWEHIGH = 0000 Hex
PWELOW = 0000 Hex
1155 H 0000 H 0000 H 0000 H
PKE IND PWE
high
PWE low
If the value in 3-41 Ramp 1 Ramp Up Time is 10 s, the response from the slave to the master will be:
1155 H 0000 H 0000 H 03E8 H
PKE
IND
PWE high
PWE low
3E8 Hex corresponds to 1000 decimal. The conversion index for 3-41 Ramp 1 Ramp Up Time is -2, i.e. 0.01.
3-41 Ramp 1 Ramp Up Time is of the type Unsigned 32.
7.6 Modbus RTU Overview
7.6.1 Assumptions
Danfoss assumes that the installed controller supports the interfaces in this document, and strictly observe all requirements and limitations stipulated in the controller and frequency converter.
7.6.2 What the User Should Already Know
The Modbus RTU (Remote Terminal Unit) is designed to communicate with any controller 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.
7.6.3 Modbus RTU Overview
Regardless of the type of physical communication networks, the Modbus RTU Overview describes the process a controller uses to request access to another device. This process includes how the Modbus RTU responds to requests from another device, and how errors are detected and reported. It also establishes a common format for the layout and contents of message fields.
During communications over a Modbus RTU network, the protocol determines:
How each controller learns its device address
Recognizes a message addressed to it
Determines which actions to take
Extracts any data or other information contained in the message
If a reply is required, the controller constructs the reply message and sends it.
Controllers communicate using a master-slave technique in which only one device (the master) can initiate transactions (called queries). The other devices (slaves) respond by supplying the requested data to the master, or by taking the action requested in the query.
The master can address individual 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 from the master. The Modbus RTU protocol establishes the format for the master’s query by placing into it the device (or broadcast) address, a function code defining the requested action, any data to be sent, and an error-checking field. The slave’s response message is also constructed using Modbus protocol. It contains fields confirming the action taken, any data to be returned, and an error-checking field. If an error occurs in receipt of the message, or if the slave is unable to perform the requested action, the slave will construct an error message, and send it in response, or a time-out occurs.
7.6.4 Frequency Converter with Modbus
RTU
The frequency converter communicates in Modbus RTU format over the built-in RS-485 interface. Modbus RTU provides access to the Control Word and Bus Reference of the frequency converter.
The Control Word allows the Modbus master to control several important functions of the frequency converter:
•
Start
•
Stop of the frequency converter in various ways:
Coast stop
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Quick stop
DC Brake stop
Normal (ramp) stop
•
Reset after a fault trip
•
Run at a variety of preset speeds
•
Run in reverse
•
Change the active set-up
•
Control the frequency converter’s built-in relay
The Bus Reference is commonly used for speed control. It is also possible to access the parameters, read their values, and where possible, write values to them. This permits a range of control options, including controlling the setpoint of the frequency converter when its internal PI controller is used.
7.7 Network Configuration
7.7.1 Frequency Converter with Modbus
RTU
To enable Modbus RTU on the frequency converter, set the following parameters
Parameter
8-30 Protocol
8-31 Address
8-32 Baud Rate
Setting
Modbus RTU
1 - 247
2400 - 115200
8-33 Parity / Stop Bits Even parity, 1 stop bit (default)
7.8 Modbus RTU Message Framing
Structure
7.8.1 Frequency Converter with Modbus
RTU
The controllers are set up to communicate 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 7.2.
Start bit
Data byte Stop/ parity
Stop
Coding System
Bits Per Byte
8-bit binary, hexadecimal 0-9, A-F. 2 hexadecimal characters contained in each 8bit field of the message
1 start bit
8 data bits, least significant bit sent first
1 bit for even/odd parity; no bit for no parity
1 stop bit if parity is used; 2 bits if no parity
Error Check Field Cyclical Redundancy Check (CRC)
7.8.2 Modbus RTU Message Structure
The transmitting device places a Modbus RTU message into a frame with a known beginning and ending point.
This allows receiving devices to begin at the start of the message, read the address portion, determine 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 transmission must be in hexadecimal 00 to FF format in each field. The frequency converter continuously monitors the network bus, also during ‘silent’ intervals. When the first field (the address field) is received, each frequency converter or device decodes it to determine which device is being addressed.
Modbus RTU messages addressed to zero are broadcast messages. No response is permitted for broadcast
messages. A typical message frame is shown in Table 7.2.
Start Address Function Data CRC check
T1-T2-T3-
T4
8 bits 8 bits N x 8 bits
Table 7.2 Typical Modbus RTU Message Structure
End
16 bits T1-T2-T3-
T4
7.8.3 Start/Stop Field
Messages start with a silent period of at least 3.5 character intervals. This is implemented as a multiple of character intervals at the selected network baud rate (shown as Start
T1-T2-T3-T4). The first field to be transmitted is the device address. Following the last transmitted character, a similar period of at least 3.5 character intervals marks the end of the message. A new message can begin after this period.
The entire message frame must be transmitted as a continuous stream. If a silent period of more than 1.5
character intervals occurs before completion of the frame, the receiving device flushes the incomplete message and assumes that the next byte will be the address field of a new message. Similarly, if a new message begins prior to
3.5 character intervals after a previous message, the receiving device will consider it a continuation of the previous message. This will cause a time-out (no response from the slave), since the value in the final CRC field will not be valid for the combined messages.
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7.8.4 Address Field
The address field of a message frame contains 8 bits. Valid slave device addresses are in the range of 0 – 247 decimal.
The individual slave devices are assigned addresses in the range of 1 – 247. (0 is reserved for broadcast mode, which all slaves recognize.) A master addresses a slave by placing the slave address in the address field of the message.
When the slave sends its response, it places its own address in this address field to let the master know which slave is responding.
7.8.5 Function Field
The function field of a message frame contains 8 bits. Valid codes are in the range of 1-FF. Function fields are used to send messages between master and slave. When a message is sent from a master to a slave device, the function code field tells the slave what kind of action to perform. When the slave responds to the master, it uses the function code field to indicate either a normal (errorfree) response, or that some kind of error occurred (called an exception response). For a normal response, the slave simply echoes the original function code. For an exception response, the slave returns a code that is equivalent to the original function code with its most significant bit set to logic 1. In addition, the slave 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. Please also refer to 7.8.10 Function Codes
Supported by Modbus RTU and 7.8.11 Modbus Exception
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 master to slave device contains additional information which the slave must use to take the action
Coil Number
1-16
17-32
33-48
49-64
65
66-65536 defined by the function code. This can include items such as coil or register addresses, the quantity of items to be handled, and the count of actual data bytes in the field.
7.8.7 CRC Check Field
Messages include an error-checking field, operating on the basis of a Cyclical Redundancy Check (CRC) method. The
CRC field checks the contents of the entire message. It is applied regardless of any parity check method used for the individual characters of the message. The CRC value is calculated by the transmitting device, which appends the
CRC as the last field in the message. The receiving device recalculates a CRC during receipt of the message and compares the calculated value to the actual value received in the CRC field. If the two values are unequal, a bus timeout results. The error-checking field contains a 16-bit binary value implemented as two 8-bit bytes. When this is done, the low-order byte of the field is appended first, followed by the high-order byte. The CRC high-order byte is the last byte sent in the message.
7.8.8 Coil Register Addressing
In Modbus, all data are organized in coils and holding registers. Coils hold a single bit, whereas holding registers hold a 2-byte word (i.e. 16 bits). All data addresses in
Modbus messages are referenced to zero. The first occurrence of a data item is addressed as item number zero. For example: The coil known as ‘coil 1’ in a programmable controller is addressed as coil 0000 in the data address field of a Modbus message. Coil 127 decimal is addressed as coil 007EHEX (126 decimal).
Holding register 40001 is addressed as register 0000 in the data address field of the message. The function code field already specifies a ‘holding register’ operation. Therefore, the ‘4XXXX’ reference is implicit. Holding register 40108 is addressed as register 006BHEX (107 decimal).
Description
Frequency converter control word (see table below)
Frequency converter speed or set-point reference Range 0x0 – 0xFFFF (-200% ...
~200%)
Frequency converter status word (see table below)
Open loop mode: Frequency converter output frequency Closed loop mode: frequency converter feedback signal
Parameter write control (master to slave)
0 = Parameter changes are written to the RAM of the frequency converter
1 = Parameter changes are written to the RAM and EEPROM of the frequency converter.
Reserved
Signal Direction
Master to slave
Master to slave
Slave to master
Slave to master
Master to slave
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04
05
06
07
Coil
01
02
03
08
09
10
11
0
Preset reference LSB
Preset reference MSB
DC brake
Coast stop
Quick stop
Freeze freq.
Ramp stop
No reset
No jog
Ramp 1
Data not valid
1
No DC brake
No coast stop
No quick stop
No freeze freq.
Start
Reset
Jog
Ramp 2
Data valid
12
13
14
15
Relay 1 off
Relay 2 off
Set up LSB
Set up MSB
Relay 1 on
Relay 2 on
16 No reversing Reversing
Frequency converter control word (FC profile)
Coil
33
34
39
40
41
42
43
35
36
37
38
0
Control not ready frequency converter not ready
Coasting stop
No alarm
Not used
Not used
Not used
No warning
Not at reference
Hand mode
Out of freq. range
1
Control ready frequency converter ready
Safety closed
Alarm
Not used
Not used
Not used
Warning
At reference
Auto mode
In frequency range
44
45
46
47
Stopped
Not used
No voltage warning
Not in current limit
Running
Not used
Voltage warning
Current limit
48 No thermal warning Thermal warning
Frequency converter status word (FC profile)
Holding registers
Register Number
00001-00006
00007
00008
00009
00010-00990
01000-01990
02000-02990
03000-03990
04000-04990
...
49000-49990
50000
50010
...
50200
50210
Description
Reserved
Last error code from an FC data object interface
Reserved
Parameter index*
000 parameter group (parameters 001 through 099)
100 parameter group (parameters 100 through 199)
200 parameter group (parameters 200 through 299)
300 parameter group (parameters 300 through 399)
400 parameter group (parameters 400 through 499)
...
4900 parameter group (parameters 4900 through 4999)
Input data: frequency converter control word register (CTW).
Input data: Bus reference register (REF).
...
Output data: frequency converter status word register (STW).
Output data: frequency converter main actual value register (MAV).
* Used to specify the index number to be used when accessing an indexed parameter.
7.8.9 How to Control the Frequency
Converter
This section describes codes which can be used in the function and data fields of a Modbus RTU message.
7.8.10 Function Codes Supported by
Modbus RTU
Function
Read coils
Read holding registers
Write single coil
Write single register
Write multiple coils
Write multiple registers
Get comm. event counter
Report slave ID
Modbus RTU supports use of the following function codes in the function field of a message.
Function Code
1 hex
3 hex
5 hex
6 hex
F hex
10 hex
B hex
11 hex
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Function Function
Code
Diagnostic s
8 1
2
Subfunction code
10
11
12
13
14
Sub-function
Restart communication
Return diagnostic register
Clear counters and diagnostic register
Return bus message count
Return bus communication error count
Return bus exception error count
Return slave message count
7.8.11 Modbus Exception Codes
For a full explanation of the structure of an exception code
response, please refer to 7.8.5 Function Field.
Co de
1
2
3
Name
Illegal function
Illegal data address
Illegal data value
4 Slave device failure
Modbus Exception Codes
Meaning
The function code received in the query is not an allowable 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 slave) is in the wrong state to process a request of this type, for example because it is not configured and is being asked to return register values.
The data address received in the query is not an allowable address for the server (or slave). 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 4 would succeed, a request with offset 96 and length
5 will generate exception 02.
A value contained in the query data field is not an allowable value for server (or slave).
This indicates a fault in the structure of the remainder of a complex request, such as that the implied length is incorrect. It specifically does NOT mean that a data item submitted for storage in a register has a value outside the expectation of the application program, since the Modbus protocol is unaware of the significance of any particular value of any particular register.
An unrecoverable error occurred while the server (or slave) was attempting to perform the requested action.
7.9 How to Access Parameters
7.9.1 Parameter Handling
The PNU (Parameter Number) is translated from the register address contained in the Modbus read or write message. The parameter number is translated to Modbus as (10 x parameter number) DECIMAL.
7.9.2 Storage of Data
The Coil 65 decimal determines whether data written to the frequency converter are stored in EEPROM and RAM
(coil 65 = 1) or only in RAM (coil 65 = 0).
7.9.3 IND
The array index is set in Holding Register 9 and used when accessing array parameters.
7.9.4 Text Blocks
Parameters stored as text strings are accessed in the same way as the other parameters. The maximum text block size is 20 characters. If a read request for a parameter is for more characters than the parameter stores, the response is truncated. If the read request for a parameter is for fewer characters than the parameter stores, the response is space filled.
7.9.5 Conversion Factor
The different attributes 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.
7.9.6 Parameter Values
Standard Data Types
Standard data types are int16, int32, uint8, uint16 and uint32. They are stored as 4x registers (40001 – 4FFFF). The parameters are read using function 03HEX "Read Holding
Registers." Parameters are written using the function 6HEX
"Preset Single Register" for 1 register (16 bits), and the function 10HEX "Preset Multiple Registers" for 2 registers
(32 bits). Readable sizes range from 1 register (16 bits) up to 10 registers (20 characters).
Non 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 10HEX "Preset Multiple Registers." Readable
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7 7 sizes range from 1 register (2 characters) up to 10 registers
(20 characters).
7.10 Examples
The following examples illustrate various Modbus RTU commands. If an error occurs, please refer to the Exception
Codes section.
7.10.1 Read Coil Status (01 HEX)
Description
This function reads the ON/OFF status of discrete outputs
(coils) in the frequency converter. Broadcast is never supported for reads.
Query
The query message specifies the starting coil and quantity of coils to be read. Coil addresses start at zero, i.e. coil 33 is addressed as 32.
Example of a request to read coils 33-48 (Status Word) from slave device 01.
Field Name
Slave Address
Function
Starting Address HI
Starting Address LO
No. of Points HI
No. of Points LO
Error Check (CRC)
Example (HEX)
01 (frequency converter address)
01 (read coils)
00
20 (32 decimals) Coil 33
00
-
10 (16 decimals)
Response
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 other coils follow toward the high order end of this byte, and from ‘low order to high order’ in subsequent bytes.
If the returned coil quantity is not a multiple of eight, the remaining bits in the final data byte will be padded with zeros (toward the high order end of the byte). The Byte
Count field specifies the number of complete bytes of data.
Field Name
Slave Address
Function
Byte Count
Data (Coils 40-33)
Data (Coils 48-41)
Error Check (CRC)
Example (HEX)
01 (frequency converter address)
01 (read coils)
02 (2 bytes of data)
-
07
06 (STW=0607hex)
NOTE
Coils and registers are addressed explicit with an off-set of
-1 in Modbus.
I.e. Coil 33 is addressed as Coil 32.
7.10.2 Force/Write Single Coil (05 HEX)
Description
This function forces a writes a coil to either ON or OFF.
When broadcast the function forces the same coil references in all attached slaves.
Query
The query message specifies the coil 65 (parameter write control) to be forced. Coil addresses start at zero, i.e. coil
65 is addressed as 64. Force Data = 00 00HEX (OFF) or FF
00HEX (ON).
Field Name
Slave Address
Function
Coil Address HI
Coil Address LO
Force Data HI
Force Data LO
Error Check (CRC)
Example (HEX)
01 (frequency converter address)
05 (write single coil)
00
40 (64 decimal) Coil 65
FF
-
00 (FF 00 = ON)
Response
The normal response is an echo of the query, returned after the coil state has been forced.
Field Name
Slave Address
Function
Force Data HI
Force Data LO
Quantity of Coils HI
Quantity of Coils LO
Error Check (CRC)
00
00
-
01
Example (HEX)
01
05
FF
7.10.3 Force/Write Multiple Coils (0F HEX)
This function forces each coil in a sequence of coils to either ON or OFF. When broadcast the function forces the same coil references in all attached slaves.
The query message specifies the coils 17 to 32 (speed setpoint) to be forced.
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NOTE
Coil addresses start at zero, i.e. coil 17 is addressed as 16.
Field Name
Slave Address
Function
Coil Address HI
Coil Address LO
Quantity of Coils HI
Quantity of Coils LO
Byte Count
Force Data HI
(Coils 8-1)
Force Data LO
(Coils 10-9)
Error Check (CRC)
Example (HEX)
01 (frequency converter address)
0F (write multiple coils)
00
10 (coil address 17)
00
10 (16 coils)
02
20
-
00 (ref. = 2000hex)
Response
The normal response returns the slave address, function code, starting address, and quantity of coiles forced.
Field Name
Slave Address
Function
Coil Address HI
Coil Address LO
Quantity of Coils HI
Quantity of Coils LO
Error Check (CRC)
Example (HEX)
01 (frequency converter address)
0F (write multiple coils)
-
00
10 (coil address 17)
00
10 (16 coils)
7.10.4 Read Holding Registers (03 HEX)
Description
This function reads the contents of holding registers in the slave.
Query
The query message specifies the starting register and quantity of registers to be read. Register addresses start at zero, i.e. registers 1-4 are addressed as 0-3.
Example: Read 3-03 Maximum Reference, register 03030.
Field Name
Slave Address
Function
Starting Address HI
Starting Address LO
No. of Points HI
No. of Points LO
Error Check (CRC)
Example (HEX)
01
03 (read holding registers)
0B (Register address 3029)
05 (Register address 3029)
00
-
02 - (Par. 3-03 is 32 bits long, i.e.
2 registers)
Response
The register data in the response message are packed as two bytes per register, with the binary contents right justified within each byte. For each register, the first byte contains the high order bits and the second contains the low order bits.
Example: Hex 0016E360 = 1.500.000 = 1500 RPM.
Field Name
Slave Address
Function
Byte Count
Data HI
(Register 3030)
Data LO
(Register 3030)
Data HI
(Register 3031)
Data LO
(Register 3031)
Error Check
(CRC)
-
Example (HEX)
01
03
04
00
16
E3
60
7.10.5 Preset Single Register (06 HEX)
Description
This function presets a value into a single holding register.
Query
The query message specifies the register reference to be preset. Register addresses start at zero, i.e. register 1 is addressed as 0.
Example: Write to , register 1000.
Field Name
Slave Address
Function
Register Address HI
Register Address LO
Preset Data HI
Preset Data LO
Error Check (CRC)
Example (HEX)
01
06
03 (Register address 999)
E7 (Register address 999)
00
-
01
Response
Response The normal response is an echo of the query, returned after the register contents have been passed.
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Field Name
Slave Address
Function
Register Address HI
Register Address LO
Preset Data HI
Preset Data LO
Error Check (CRC)
E7
00
-
01
Example (HEX)
01
06
03
7.10.6 Preset Multiple Registers (10 HEX)
Description
This function presets values into a sequence of holding registers.
Query
The query message specifies the register references to be preset. Register addresses start at zero, i.e. register 1 is addressed as 0. Example of a request to preset two registers (set parameter 1-24 = 738 (7.38 A)):
Field Name
Slave Address
Function
Starting Address HI
Starting Address LO
No. of Registers HI
No. of registers LO
Byte Count
Write Data HI
(Register 4: 1049)
Write Data LO
(Register 4: 1049)
Write Data HI
(Register 4: 1050)
Write Data LO
(Register 4: 1050)
Error Check (CRC) -
02
E2
19
00
02
04
00
Example (HEX)
01
10
04
00
Response
The normal response returns the slave address, function code, starting address, and quantity of registers preset.
Field Name
Slave Address
Function
Starting Address HI
Starting Address LO
No. of Registers HI
No. of registers LO
Error Check (CRC)
19
00
-
02
Example (HEX)
01
10
04
7.11 Danfoss FC Control Profile
7.11.1 Control Word According to FC
Profile (8-10 Control Profile = FC profile)
Master-slave
CTW Speed ref.
Bit no.:
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
06
07
08
09
10
11
12
13
14
15
03
04
05
Bit
00
01
02
Bit value = 0
Reference value
Reference value
DC brake
Coasting
Quick stop
Hold output frequency
Ramp stop
No function
No function
Ramp 1
Data invalid
No function
No function
Parameter set-up
Parameter set-up
No function
Bit value = 1 external selection lsb external selection msb
Ramp
No coasting
Ramp use ramp
Start
Reset
Jog
Ramp 2
Data valid
Relay 01 active
Relay 02 active selection lsb selection msb
Reverse
Explanation of the Control Bits
Bits 00/01
Bits 00 and 01 are used to choose between the four reference values, which are pre-programmed in 3-10 Preset
Reference according to the following table:
Programmed ref.
value
1
Parameter
2
3
4
3-10 Preset
Reference [0]
3-10 Preset
Reference [1]
3-10 Preset
Reference [2]
3-10 Preset
Reference [3]
0
1
Bit 01
0
1
1
0
Bit 00
0
1
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NOTE
Make 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 current and duration in 2-01 DC Brake Current and 2-02 DC
Braking Time. Bit 02 = ’1’ leads to ramping.
Bit 03, Coasting:
Bit 03 = ’0’: The frequency converter immediately "lets go" of the motor, (the output transistors are "shut off") and it coasts to a standstill. Bit 03 = ’1’: The frequency converter starts the motor if the other starting conditions are met.
Make a selection in 8-50 Coasting Select to define how Bit
03 gates with the corresponding function on a digital input.
Bit 04, Quick stop:
Bit 04 = ’0’: Makes the motor speed ramp down to stop
(set in 3-81 Quick Stop Ramp Time).
Bit 05, Hold output frequency
Bit 05 = ’0’: The present output frequency (in Hz) freezes.
Change the frozen output frequency only by means of the digital inputs (5-10 Terminal 18 Digital Input to
5-15 Terminal 33 Digital Input) programmed to Speed up and Slow down.
NOTE
If Freeze output is active, the frequency converter can only be stopped by the following:
•
Bit 03 Coasting stop
•
Bit 02 DC braking
•
Digital input (5-10 Terminal 18 Digital Input to
5-15 Terminal 33 Digital Input) programmed to DC
braking, Coasting stop, or Reset and coasting stop.
Bit 06, Ramp stop/start:
Bit 06 = ’0’: Causes a stop and makes the motor speed ramp down to stop via the selected ramp down parameter.
Bit 06 = ’1’: Permits the frequency converter to start the motor, if the other starting conditions are met.
Make a selection in 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. Bit 07 = ’1’: Resets a trip. Reset is activated on the signal’s leading edge, i.e.
when changing from logic ’0’ to logic ’1’.
Bit 08, Jog:
Bit 08 = ’1’: The output frequency is determined by
3-19 Jog Speed [RPM].
Bit 09, Selection of ramp 1/2:
Bit 09 = "0": Ramp 1 is active (3-41 Ramp 1 Ramp Up Time to 3-42 Ramp 1 Ramp Down Time). Bit 09 = "1": Ramp 2
(3-51 Ramp 2 Ramp Up Time to 3-52 Ramp 2 Ramp Down
Time) is active.
Bit 10, Data not valid/Data valid:
Tell the frequency converter whether to use or ignore the control word. Bit 10 = ’0’: The control word is ignored. Bit
10 = ’1’: The control word is used. This function is relevant because the telegram always contains the control word, regardless of the telegram type. Thus, you can turn off the control word if you do not want to use it when updating or reading parameters.
Bit 11, Relay 01:
Bit 11 = "0": Relay not activated. Bit 11 = "1": Relay 01 activated provided that Control word bit 11 is chosen in
5-40 Function Relay.
Bit 12, Relay 04:
Bit 12 = "0": Relay 04 is not activated. Bit 12 = "1": Relay 04 is activated provided that Control word bit 12 is chosen in
5-40 Function Relay.
Bit 13/14, Selection of set-up:
Use bits 13 and 14 to choose from the four menu set-ups according to the shown table.
Set-up
1
2
3
4
Bit 14
0
0
1
1
Bit 13
0
1
0
1
The function is only possible when Multi Set-Ups is selected in 0-10 Active Set-up.
Make a selection in 8-55 Set-up Select to define how Bit
13/14 gates with the corresponding 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 when Ser. communication, Logic or or Logic and is selected.
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7.11.2 Status Word According to FC Profile
(STW) (8-10 Control Profile = FC profile)
Slave-master
STW Output freq.
Bit no.:
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
07
08
09
10
03
04
05
06
11
12
13
14
15
Bit
00
01
02
Bit = 0
Control not ready
Drive not ready
Coasting
No error
No error
Reserved
No error
No warning
Speed ≠ reference
Local operation
Out of frequency limit
No operation
Drive OK
Voltage OK
Torque OK
Timer OK
Bit = 1
Control ready
Drive ready
Enable
Trip
Error (no trip)
-
Triplock
Warning
Speed = reference
Bus control
Frequency limit OK
In operation
Stopped, auto start
Voltage exceeded
Torque exceeded
Timer exceeded
Explanation of the Status Bits
Bit 00, Control not ready/ready:
Bit 00 = ’0’: The frequency converter trips. Bit 00 = ’1’: The frequency converter controls are ready but the power component does not necessarily receive any power supply
(in case of external 24V supply to controls).
Bit 01, Drive ready:
Bit 01 = ’1’: The frequency converter is ready for operation but the coasting command is active via the digital inputs or via serial communication.
Bit 02, Coasting stop:
Bit 02 = ’0’: The frequency converter releases the motor. Bit
02 = ’1’: The frequency converter starts the motor with a start command.
Bit 03, No error/trip:
Bit 03 = ’0’ : The frequency converter is not in fault mode.
Bit 03 = ’1’: The frequency converter trips. To re-establish operation, enter [Reset].
Bit 04, No error/error (no trip):
Bit 04 = ’0’: The frequency converter is not in fault mode.
Bit 04 = “1”: The frequency converter shows an error but does not trip.
Bit 05, Not used:
Bit 05 is not used in the status word.
Bit 06, No error / triplock:
Bit 06 = ’0’: The frequency converter is not in fault mode.
Bit 06 = “1”: The frequency converter is tripped and locked.
Bit 07, No warning/warning:
Bit 07 = ’0’: There are no warnings. Bit 07 = ’1’: A warning has occurred.
Bit 08, Speed≠ reference/speed = reference:
Bit 08 = ’0’: The motor is running but the present speed is different from the preset speed reference. It might e.g. be the case when the speed ramps up/down during start/ stop. Bit 08 = ’1’: The motor speed matches the preset speed reference.
Bit 09, Local operation/bus control:
Bit 09 = ’0’: [STOP/RESET] is activate on the control unit or
Local control in 3-13 Reference Site is selected. You cannot control the frequency converter via serial communication.
Bit 09 = ’1’ It is possible to control the frequency converter via the fieldbus / serial communication.
Bit 10, Out of frequency limit:
Bit 10 = ’0’: The output frequency has reached the value in
4-11 Motor Speed Low Limit [RPM] or 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 converter has a start signal or the output frequency is greater than 0 Hz.
Bit 12, Drive OK/stopped, autostart:
Bit 12 = ’0’: There is no temporary over temperature on the inverter. Bit 12 = ’1’: The inverter stops because of over temperature but the unit does not trip and will resume operation once the over temperature stops.
Bit 13, Voltage OK/limit exceeded:
Bit 13 = ’0’: There are no voltage warnings. Bit 13 = ’1’: The
DC voltage in the frequency converter’s intermediate circuit is too low or too high.
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Bit 14, Torque OK/limit exceeded:
Bit 14 = ’0’: The motor current is lower than the torque limit selected in 4-18 Current Limit. Bit 14 = ’1’: The torque limit in 4-18 Current Limit is exceeded.
Bit 15, Timer OK/limit exceeded:
Bit 15 = ’0’: The timers for motor thermal protection and thermal protection are not exceeded 100%. Bit 15 = ’1’:
One of the timers exceeds 100%.
All bits in the STW are set to ’0’ if the connection between the Interbus option and the frequency converter is lost, or an internal communication problem has occurred.
7.11.3 Bus Speed Reference Value
Speed reference value is transmitted to the frequency converter in a relative value in %. The value is transmitted in the form of a 16-bit 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 reference.
Master-slave
Speed ref.
16bit
CTW
Slave-master
STW
Actual output freq.
The reference and MAV are scaled as follows:
-100%
(C000hex)
Par.3-00 set to
(1) -max- +max
Reverse
Par.3-03
Max reference
0%
(0hex)
0
Forward
100%
(4000hex)
Par.3-03
Max reference
7 7
0%
(0hex)
100%
(4000hex)
Par.3-00 set to
(0) min-max
Forward
Par.3-02
Min reference
Par.3-03
Max reference
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8 General Specifications and Troubleshooting
8 8
8.1 Mains Supply Tables
Mains supply 200 - 240 VAC - Normal overload 110% for 1 minute
Frequency Converter
Typical Shaft Output [kW]
IP 20 / Chassis
(A2+A3 may be converted to IP21 using a conversion kit. (Please see also items Mechanical mounting in Operating Instructions and IP 21/Type 1 Enclosure kit in the Design Guide.))
IP 55 / NEMA 12
IP 66 / NEMA 12
Typical Shaft Output [hp] at 208 V
Output current
Continuous
(3 x 200-240 V ) [A]
Intermittent
(3 x 200-240 V ) [A]
Continuous kVA (208 V AC) [kVA]
Max. cable size:
(mains, motor, brake)
[mm
2
/AWG]
2)
Max. input current
Continuous
(3 x 200-240 V ) [A]
Intermittent
(3 x 200-240 V ) [A]
Max. pre-fuses
1)
[A]
Environment
Estimated power loss at rated max. load [W]
4)
Weight enclosure IP20 [kg]
Weight enclosure IP21 [kg]
Weight enclosure IP55 [kg]
Weight enclosure IP 66 [kg]
Efficiency
3)
P1K1
1.1
A2
A4/A5
A5
1.5
6.6
7.3
2.38
5.9
6.5
20
63
4.9
5.5
9.7/13.5
9.7/13.5
0.96
Table 8.1 Mains Supply 200 - 240 VAC
P1K5
1.5
A2
A4/A5
A5
2.0
7.5
8.3
2.70
6.8
7.5
20
82
4.9
5.5
9.7/13.5
9.7/13.5
0.96
P2K2
2.2
A2
A4/A5
A5
2.9
10.6
11.7
3.82
4/10
9.5
10.5
20
116
4.9
5.5
9.7/13.5
9.7/13.5
0.96
P3K0
3
A3
A5
A5
4.0
12.5
13.8
4.50
11.3
12.4
32
155
6.6
7.5
13.5
13.5
0.96
P3K7
3.7
A3
A5
A5
4.9
16.7
18.4
6.00
185
6.6
7.5
13.5
13.5
0.96
15.0
16.5
32
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8.1.1 Mains Supply High Power
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Mains Supply 3 x 380 - 480 VAC
Max. input current
Typical Shaft output at 400 V [kW]
Typical Shaft output at 460 V [HP]
Enclosure IP21
Enclosure IP54
Enclosure IP00
Output current
Continuous
(at 400 V) [A]
Intermittent (60 sec overload)
(at 400 V) [A]
Continuous
(at 460/ 480 V) [A]
Intermittent (60 sec overload)
(at 460/ 480 V) [A]
Continuous KVA
(at 400 V) [KVA]
Continuous KVA
(at 460 V) [KVA]
Continuous
(at 400 V ) [A]
Continuous
(at 460/ 480 V) [A]
Max. cable size, mains motor, brake and load share [mm
2
(AWG
2)
)]
Max. external prefuses [A]
1
Estimated power loss at rated max. load
[W] 4) , 400 V
Estimated power loss at rated max. load
[W] 4) , 460 V
Weight, enclosure IP21, IP 54
[kg]
Weight, enclosure IP00 [kg]
Efficiency 4)
Output frequency
Heatsink overtemp.
trip
Power card ambient trip
204
183
2 x 70
(2 x 2/0)
300
3234
2947
96
82
90
°C
212
233
190
209
147
151
P110
110
150
D1
D1
D3
315
347
302
332
218
241
P160
160
250
D2
D2
D4
304
291
260
286
240
264
180
191
P132
132
200
D1
D1
D3
251
231
2 x 70
(2 x 2/0)
350
3782
3665
104
91
110
°C
4063
125
112
0.98
0 - 800 Hz
110
°C
60
°C
2 x 150
(2 x 300 mcm)
2 x 150
(2 x 300 mcm)
2 x 150
(2 x 300 mcm)
400
4213
500
5119
630
5893
4652
136
123
5634
151
138
110
°C
110
°C
395
435
361
397
274
288
P200
200
300
D2
D2
D4
381
348
480
528
443
487
333
353
P250
250
350
D2
D2
D4
463
427
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Mains Supply 3 x 380 - 480 VAC
Max. input current
Typical Shaft output at
400 V [kW]
Typical Shaft output at
460 V [HP]
Enclosure IP21
EnclosureIP54
Enclosure IP00
Output current
Continuous
(at 400 V) [A]
Intermittent (60 sec overload)
(at 400 V) [A]
Continuous
(at 460/ 480 V) [A]
Intermittent (60 sec overload)
(at 460/ 480 V) [A]
Continuous KVA
(at 400 V) [KVA]
Continuous KVA
(at 460 V) [KVA]
Continuous
(at 400 V ) [A]
590
Continuous
(at 460/ 480 V) [A]
531
Max. cable size, mains, motor and load share
[mm 2 (AWG 2) )]
Max. cable size, brake
[mm 2 (AWG 2) )
Max. external pre-fuses
[A] 1
Estimated power loss at rated max. load [W]
4) , 400 V
Estimated power loss at rated max. load [W]
4) , 460 V
Weight, enclosure IP21, IP 54 [kg]
Weight, enclosure IP00 [kg]
Efficiency
4)
Output frequency
Heatsink overtemp. trip
Power card ambient trip
4x240
(4x500 mcm)
2 x 185
(2 x 350 mcm)
700
6790
6082
263
221
600
660
540
594
416
430
P315
315
450
E1
E1
E2
658
724
590
649
456
470
P355
355
500
E1
E1
E2
647
580
745
820
678
746
516
540
P400
400
600
E1
E1
E2
733
667 718
4x240
(4x500 mcm)
2 x 185
(2 x 350 mcm)
900
7701
4x240
(4x500 mcm)
2 x 185
(2 x 350 mcm)
900
8879
4x240
(4x500 mcm)
2 x 185
(2 x 350 mcm)
900
9670
6953 8089
270
234
0.98
0 - 600 Hz
110
°C
68
°C
272
236
8803
313
277
800
880
730
803
554
582
P450
450
600
E1
E1
E2
787
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Mains Supply 3 x 380 - 480 VAC
Typical Shaft output at 400 V
[kW]
Typical Shaft output at 460 V
[HP]
Enclosure IP21, 54 without/ with options cabinet
Output current
Max. input current
Continuous
(at 400 V) [A]
Intermittent (60 sec overload)
(at 400 V) [A]
Continuous
(at 460/ 480 V) [A]
Intermittent (60 sec overload)
(at 460/ 480 V) [A]
Continuous KVA
(at 400 V) [KVA]
Continuous KVA
(at 460 V) [KVA]
Continuous
(at 400 V ) [A]
Continuous (at 460/ 480 V) [A]
Max. cable size,motor [mm
2
(AWG
2)
)]
Max. cable size,mains F1/F2
[mm
2
(AWG
2)
)]
Max. cable size,mains F3/F4
[mm
2
(AWG
2)
)]
Max. cable size, loadsharing
[mm
2
(AWG
2)
)]
Max. cable size, brake [mm
2
(AWG
2)
)
Max. external pre-fuses [A]
1
Est. power loss at rated max.
load [W] 4) , 400 V, F1 & F2
Est. power loss at rated max.
load [W] 4) , 460 V, F1 & F2
Max added losses of A1 RFI,
Circuit Breaker or Disconnect,
& Contactor, F3 & F4
Max Panel Options Losses
Weight, enclosure IP21, IP 54 [kg]
Weight Rectifier
Module [kg]
Weight Inverter
Module [kg]
Efficiency 4)
Output frequency
Heatsink overtemp. trip
Power card ambient trip
P500
500
650
F1/F3
880
968
780
858
610
621
9414
963
1004/ 1299
102
102
P560
560
750
F1/F3
990
1089
890
979
686
709
P710
710
1000
F1/F3
1260
1386
1160
1276
873
924
857
759
10647
1600
964 1090 1227
867
8x150
(8x300 mcm)
1022
8x240
(8x500 mcm)
8x456
(8x900 mcm)
4x120
(4x250 mcm)
1129
4x185
(4x350 mcm)
2000
12338 13201 15436
11006
1054
1004/ 1299
102
102
P630
630
900
F1/F3
1120
1232
1050
1155
776
837
12353
1093
102
102
400
1004/ 1299
95
°C
68
°C
14041
1230
1004/ 1299
0.98
0-600 Hz
102
136
P800
800
1200
F2/F4
1460
1606
1380
1518
1012
1100
1422
1344
1350
F2/F4
1720
1892
1530
1683
1192
1219
12x150
(12x300 mcm)
18084
17137
2280
136
102
6x185
1246/ 1541
P1M0
1000
1675
1490
(6x350 mcm)
2500
20358
17752
2541
1246/ 1541
136
102
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8.1.2 Mains Supply 3 x 525 - 690V AC
95 4/0
35 1/0
152
Continuous (3 Intermittent (3 Continuous (3 Intermittent (3
130BA058.10
Continuous (3 Intermittent (3 Environment: Estimated Weight: IP21
130BA057.10
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®
is a registered Danfoss trademark
General Specifications and ...
VLT
®
HVAC Drive Design Guide
Mains Supply 3 x 525-690V AC
Max. input current
Typical Shaft output at 550V [kW]
Typical Shaft output at 575V [HP]
Typical Shaft output at 690V [kW]
Enclosure IP21
Enclosure IP54
Enclosure IP00
Output current
Continuous
(at 550V) [A]
Intermittent (60 sec overload)(at 550V) [A]
Continuous(at 575/690V) [A]
Intermittent (60 sec overload) (at 575/690V) [A]
Continuous KVA(at 550V) [KVA]
Continuous KVA(at 575V) [KVA]
Continuous KVA(at 690V) [KVA]
Continuous (at 550V) [A]
137
151
131
144
131
130
157
130
P110
90
125
110
D1
D1
D2
162
178
155
171
154
154
185
158
P132
110
150
132
D1
D1
D3
253
278
242
266
241
241
289
245
P200
160
250
200
D2
D2
D4
201
221
192
211
191
191
229
198
P160
132
200
160
D1
D1
D3
303
333
290
319
289
289
347
299
P250
200
300
250
D2
D2
D4
Continuous (at 575V) [A] 124 151 189 234 286
Continuous (at 690V) [A]
Max. cable size, mains motor, load share and brake
[mm 2 (AWG)]
Max. external pre-fuses [A] 1
Estimated power loss at rated max. load [W] 4) ,
600V
Estimated power loss at rated max. load [W]
4)
,
690V
Weight, Enclosure IP21, IP54 [kg]
Weight, Enclosure IP00 [kg]
Efficiency
4)
Output frequency
Heatsink overtemp. trip
Power card ambient trip
128
250
2533
155
2 x 70 (2 x 2/0)
315
2963
197
350
3430
240 296
2 x 150 (2 x 300 mcm)
350
4051
400
4867
2662
85
°C
96
82
3430
90
°C
3612
104
91
0.98
0 - 600 Hz
110
°C
60
°C
4292
125
112
110
°C
5156
136
123
110
°C
8 8
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®
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154
General Specifications and ...
VLT
®
HVAC Drive Design Guide
8 8
Mains Supply 3 x 525-690V AC
Max. input current
Typical Shaft output at 550V
[kW]
Typical Shaft output at 575V
[HP]
Typical Shaft output at 690V
[kW]
Enclosure IP21
Enclosure IP54
Enclosure IP00
Output current
Continuous
(at 550V) [A]
Intermittent (60 sec overload)
(at 550V) [A]
Continuous
(at 575/690V) [A]
Intermittent (60 sec overload)
(at 575/690V) [A]
Continuous KVA
(at 550V) [KVA]
Continuous KVA
(at 575V) [KVA]
Continuous KVA
(at 690V) [KVA]
Continuous
(at 550V) [A]
343
343
411
360
396
344
378
P315
250
350
315
D2
D2
D4
355
Continuous
(at 575V) [A]
339 390
Continuous
(at 690V) [A]
Max. cable size, mains, motor and load share [mm
2
(AWG)]
Max. cable size, brake [mm
2
(AWG)]
Max. external pre-fuses [A]
1
Estimated power loss at rated max. load [W]
4)
,
600V
Estimated power loss at rated max. load [W]
4)
,
690V
Weight, enclosure IP21, IP54 [kg]
Weight, enclosure IP00 [kg]
Efficiency
4)
Output frequency
Heatsink overtemp. trip
Power card ambient trip
352
2 x 150
(2 x 300 mcm)
2 x 150
(2 x 300 mcm)
500
5493
5821
151
138
0 - 600 Hz
110
°C
60
°C
MG11BB02 - VLT
®
is a registered Danfoss trademark
400
2 x 150
(2 x 300 mcm)
2 x 150
(2 x 300 mcm)
550
5852
6149
165
151
0.98
0 - 500 Hz
110
°C
60
°C
398
398
478
418
460
400
440
P400
315
400
400
D2
D2
D4
408
434
434
4 x 240
(4 x 500 mcm)
2 x 185
(2 x 350 mcm)
700
6132
6440
263
221
0 - 500 Hz
110
°C
68
°C
448
448
538
470
517
450
495
P450
355
450
450
E1
E1
E2
453
General Specifications and ...
VLT
®
HVAC Drive Design Guide
Mains Supply 3 x 525-690V AC
Max. input current
Typical Shaft output at 550V
[kW]
Typical Shaft output at 575V
[HP]
Typical Shaft output at 690V
[kW]
Enclosure IP21
Enclosure IP54
Enclosure IP00
Output current
Continuous
(at 550V) [A]
Intermittent (60 sec overload)
(at 550V) [A]
Continuous
(at 575/690V) [A]
Intermittent (60 sec overload)
(at 575/690V) [A]
Continuous KVA
(at 550V) [KVA]
Continuous KVA
(at 575V) [KVA]
Continuous KVA
(at 690V) [KVA]
Continuous
(at 550V) [A]
498
498
598
523
575
500
550
P500
400
500
500
E1
E1
E2
504
568
568
681
596
656
570
627
P560
450
600
560
E1
E1
E2
574
Continuous
(at 575V) [A]
482 549 607
Continuous
(at 690V) [A]
Max. cable size, mains, motor and load share [mm 2 (AWG)]
Max. cable size, brake [mm
2
(AWG)]
Max. external pre-fuses [A]
1
Estimated power loss at rated max. load [W]
4)
, 600
V
Estimated power loss at rated max. load [W]
4)
,
690V
Weight, enclosure IP21, IP54 [kg]
Weight, enclosure IP00 [kg]
Efficiency
4)
Output frequency
Heatsink overtemp. trip
Power card ambient trip
482
4x240 (4x500 mcm)
2 x 185
(2 x 350 mcm)
700
6903
7249
263
221
MG11BB02 - VLT
®
is a registered Danfoss trademark
549
4x240 (4x500 mcm)
2 x 185
(2 x 350 mcm)
900
8343
607
4x240 (4x500 mcm)
2 x 185
(2 x 350 mcm)
900
9244
8727
272
236
0.98
0 - 500Hz
110
°C
68
°C
9673
313
277
155
600
627
753
630
693
630
693
P630
500
650
630
E1
E1
E2
607
8 8
General Specifications and ...
VLT
®
HVAC Drive Design Guide
8 8
Mains Supply 3 x 525-690V AC
Typical Shaft output at 550V
[kW]
Typical Shaft output at 575V
[HP]
Typical Shaft output at 690V
[kW]
Enclosure IP21, 54 without/ with options cabinet
Output current
Continuous
(at 550V) [A]
Intermittent (60 s overload, at
550V) [A]
Continuous
(at 575/690V) [A]
Intermittent (60 s overload, at
575/690V) [A]
Continuous KVA
(at 550V) [KVA]
Continuous KVA
(at 575V) [KVA]
Continuous KVA
(at 690V) [KVA]
P710
560
750
710
F1/ F3
727
727
872
763
839
730
803
847
847
1016
889
978
850
935
P800
670
950
800
F1/ F3
941
941
1129
988
1087
945
1040
P900
750
1050
900
F1/ F3
1255
1255
1506
1317
1449
1260
1386
P1M2
1000
1350
1200
F2/ F4
1056
1056
1267
1108
1219
1060
1166
P1M0
850
1150
1000
F2/F4
1409
1409
1691
1479
1627
1415
1557
P1M4
1100
1550
1400
F2/F4
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®
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General Specifications and ...
VLT
®
HVAC Drive Design Guide
Mains Supply 3 x 525-690V AC
P710 P800 P900 P1M0 P1M2 P1M4
Max. input current
Continuous
(at 550V) [A]
Continuous
(at 575V) [A]
Continuous
(at 690V) [A]
Max. cable size,motor [mm
2
(AWG
2)
)]
Max. cable size,mains F1/F2
[mm
2
(AWG
2)
)]
Max. cable size,mains F3/F4
[mm
2
(AWG
2)
)]
Max. cable size, loadsharing
[mm
2
(AWG
2)
)]
Max. cable size, brake [mm
2
(AWG 2) )
Max. external pre-fuses [A] 1)
Est. power loss at rated max. load [W] 4) , 600V,
F1 & F2
Est. power loss at rated max. load [W] 4) , 690V,
F1 & F2
Max added losses of Circuit
Breaker or Disconnect &
Contactor, F3 & F4
Max Panel Options Losses
Weight,enclosure IP21, IP54
[kg]
Weight, Rectifier
Module [kg]
Weight, Inverter
Module [kg]
Efficiency 4)
Output frequency
Heatsink overtemp. trip
Power card amb. trip
743
711
711
10771
11315
427
828
8x150
(8x300 mcm)
4x185
(4x350 mcm)
1600
8x240
(8x500 mcm)
8x456
8x900 mcm
4x120
(4x250 mcm)
0.98
0-500Hz
95
68
°C
°C
1227
12x150
(12x300 mcm)
6x185
(6x350 mcm)
2000
1440
1378
1378
2500
20825
21857
1044
400
1004/ 1299 1004/ 1299 1004/ 1299 1246/ 1541 1246/ 1541 1280/1575
102
102
866
828
12272
12903
532
102
102
962
920
920
13835
14533
615
102
136
1079
1032
1032
15592
16375
665
136
102
1282
1227
18281
19207
863
136
102
136
136
1) For type of fuse see 5.2.8 Fuses
2) American Wire Gauge.
3) Measured using 5m screened motor cables at rated load and rated frequency.
4) The typical power loss is at nominal load conditions and expected to be within +/-15% (tolerence relates to variety in voltage and cable conditions). Values are based on a typical motor efficiency (eff2/eff3 border line).
Motors with lower efficiency will also add to the power loss in the frequency converter and opposite. If the switching frequency is increased comed to the default setting, the power losses may rise significantly. LCP and typical control card power consumptions are included. Further options and customer load may add up to 30W to the losses. (Though 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 allowed for (+/-5%).
8 8
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®
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General Specifications and ...
VLT
®
HVAC Drive Design Guide
8 8
8.2 General Specifications
Mains supply (L1, L2, L3)
Supply voltage 200-240 V
±10%, 380-480 V ±10%, 525-690 V ±10%
Mains voltage low / mains drop-out:
During low mains voltage or a mains drop-out, the FC continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the FC's lowest rated supply voltage. Power-up and full torque cannot be expected at mains voltage lower than 10% below the FC's lowest rated supply voltage.
Supply frequency
Max. imbalance temporary between mains phases
True Power Factor ()
Displacement Power Factor (cos) near unity
Switching on input supply L1, L2, L3 (power-ups)
≤ enclosure type A
Switching on input supply L1, L2, L3 (power-ups)
≥ enclosure type B, C
Switching on input supply L1, L2, L3 (power-ups)
≥ enclosure type D, E, F
Environment according to EN60664-1
50/60 Hz
±5%
3.0 % of rated supply voltage
≥ 0.9 nominal at rated load
(> 0.98) maximum twice/min.
maximum once/min.
maximum once/2 min.
overvoltage category III / pollution degree 2
The unit is suitable for use on a circuit capable of delivering not more than 100.000 RMS symmetrical Amperes, 480/600 V maximum.
Motor output (U, V, W)
Output voltage
Output frequency
Switching on output
Ramp times
0 - 100% of supply voltage
0 - 1000Hz
*
Unlimited
1 - 3600 sec.
* Dependent on power size.
Torque characteristics
Starting torque (Constant torque)
Starting torque
Overload torque (Constant torque) maximum 110% for 1 min.
* maximum 135% up to 0.5 sec.
* maximum 110% for 1 min.
*
*Percentage relates to the frequency converter's nominal torque.
Cable lengths and cross sections
Max. motor cable length, screened/armoured
Max. motor cable length, unscreened/unarmoured
Max. cross section to motor, mains, load sharing and brake *
Maximum cross section to control terminals, rigid wire
Maximum cross section to control terminals, flexible cable
Maximum cross section to control terminals, cable with enclosed core
Minimum cross section to control terminals
VLT
VLT
®
®
HVAC Drive: 150 m
HVAC Drive: 300 m
1.5 mm
2
/16 AWG (2 x 0.75 mm
2
)
1 mm
2
/18 AWG
0.5 mm
2
/20 AWG
0.25 mm
2
* See Mains Supply tables for more information!
Digital inputs
Programmable digital inputs
Terminal number
Logic
Voltage level
Voltage level, logic'0' PNP
Voltage level, logic'1' PNP
Voltage level, logic '0' NPN
Voltage level, logic '1' NPN
Maximum voltage on input
Input resistance, R i
4 (6)
18, 19, 27
1)
, 29
1)
, 32, 33,
PNP or NPN
0 - 24V DC
< 5 V DC
> 10 V DC
> 19 V DC
< 14 V DC
28 V DC approx. 4 k
Ω
All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
1) Terminals 27 and 29 can also be programmed as output.
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®
HVAC Drive Design Guide
Analog inputs
Number of analog inputs
Terminal number
Modes
Mode select
Voltage mode
Voltage level
Input resistance, R
Max. voltage
Current mode
Current level
Input resistance, R i
Max. current
Resolution for analog inputs
Accuracy of analog inputs
Bandwidth i
2
53, 54
Voltage or current
Switch S201 and switch S202
Switch S201/switch S202 = OFF (U)
: 0 to + 10V (scaleable) approx. 10 k
Ω
± 20V
Switch S201/switch S202 = ON (I)
0/4 to 20mA (scaleable) approx. 200
Ω
30mA
10 bit (+ sign)
Max. error 0.5% of full scale
200Hz
The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
PELV isolation
+24V
18
Control
Mains
High voltage
Motor
37
Functional isolation
RS485
DC-Bus
8 8
Pulse inputs
Programmable pulse inputs
Terminal number pulse
Max. frequency at terminal, 29, 33
Max. frequency at terminal, 29, 33
Min. frequency at terminal 29, 33
Voltage level
Maximum voltage on input
Input resistance, R i
Pulse input accuracy (0.1 - 1 kHz)
Analog output
Number of programmable analog outputs
Terminal number
Current range at analog output
Max. resistor load to common at analog output
Accuracy on analog output
Resolution on analog output
2
29, 33
110kHz (Push-pull driven)
5kHz (open collector)
4Hz see section on Digital input
28V DC approx. 4k
Ω
Max. error: 0.1% of full scale
1
42
0/4 - 20mA
500
Ω
Max. error: 0.8% of full scale
8 bit
The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
Control card, RS-485 serial communication
Terminal number
Terminal number 61
68 (P,TX+, RX+), 69 (N,TX-, RX-)
Common for terminals 68 and 69
The RS-485 serial communication circuit is functionally seated from other central circuits and galvanically isolated from the supply voltage (PELV).
Digital output
Programmable digital/pulse outputs
Terminal number
Voltage level at digital/frequency output
2
27, 29 1)
0 - 24V
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®
HVAC Drive Design Guide
8 8
Max. output current (sink or source)
Max. load at frequency output
Max. capacitive load at frequency output
Minimum output frequency at frequency output
Maximum output frequency at frequency output
Accuracy of frequency output
Resolution of frequency outputs
1) Terminal 27 and 29 can also be programmed as input.
The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
Control card, 24 V DC output
Terminal number
Max. load
40mA
1 k
Ω
10nF
0Hz
32kHz
Max. error: 0.1% of full scale
12 bit
12, 13
200mA
The 24V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs.
Relay outputs
Programmable relay outputs
Relay 01 Terminal number
Max. terminal load (AC-1)
1)
on 1-3 (NC), 1-2 (NO) (Resistive load)
Max. terminal load (AC-15) 1) (Inductive load
@ cosφ 0.4)
Max. terminal load (DC-1)
1)
on 1-2 (NO), 1-3 (NC) (Resistive load)
Max. terminal load (DC-13) 1) (Inductive load)
Relay 02 Terminal number
Max. terminal load (AC-1) 1) on 4-5 (NO) (Resistive load) 2)3)
Max. terminal load (AC-15)
1)
on 4-5 (NO) (Inductive load
@ cosφ 0.4)
Max. terminal load (DC-1) 1) on 4-5 (NO) (Resistive load)
Max. terminal load (DC-13)
1)
on 4-5 (NO) (Inductive load)
Max. terminal load (AC-1) 1) on 4-6 (NC) (Resistive load)
Max. terminal load (AC-15)
1)
on 4-6 (NC) (Inductive load
@ cosφ 0.4)
Max. terminal load (DC-1) 1) on 4-6 (NC) (Resistive load)
Max. terminal load (DC-13)
1)
on 4-6 (NC) (Inductive load)
Min. terminal load on 1-3 (NC), 1-2 (NO), 4-6 (NC), 4-5 (NO)
Environment according to EN 60664-1
2
1-3 (break), 1-2 (make)
240V AC, 2A
240V AC, 0.2 A
60V DC, 1A
24V DC, 0.1A
4-6 (break), 4-5 (make)
400V AC, 2 A
240V AC, 0.2 A
80V DC, 2 A
24V DC, 0.1A
240V AC, 2 A
240V AC, 0.2A
50V DC, 2 A
24V DC, 0.1 A
24V DC 10mA, 24V AC 20mA overvoltage category III/pollution degree 2
1) IEC 60947 parts 4 and 5
The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).
2) Overvoltage Category II
3) UL applications 300V AC 2A
Control card, 10 V DC output
Terminal number
Output voltage
Max. load
All control characteristics are based on a 4-pole asynchronous motor
Surroundings
Enclosure type A
Enclosure type B1/B2
Enclosure type B3/B4
Enclosure type C1/C2
50
10.5V
±0.5V
25mA
The 10V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
Control characteristics
Resolution of output frequency at 0 - 1000Hz
System response time (terminals 18, 19, 27, 29, 32, 33)
Speed control range (open loop)
Speed accuracy (open loop)
+/- 0.003Hz
≤ 2ms
1:100 of synchronous speed
30 - 4000 rpm: Maximum error of
±8 rpm
IP 20/Chassis, IP 21kit/Type 1, IP55/Type12, IP 66/Type12
IP 21/Type 1, IP55/Type12, IP 66/12
IP20/Chassis
IP 21/Type 1, IP55/Type 12, IP66/12
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®
HVAC Drive Design Guide
Enclosure type C3/C4
Enclosure type D1/D2/E1
Enclosure type D3/D4/E2
Enclosure type F1/F3
Enclosure type F2/F4
Enclosure kit available ≤ enclosure type D
Vibration test enclosure A, B, C
Vibration test enclosure D, E, F
Relative humidity
Aggressive environment (IEC 60068-2-43) H
2
S test
Test method according to IEC 60068-2-43 H2S (10 days)
Ambient temperature (at 60 AVM switching mode)
- with derating
IP20/Chassis
IP21/Type 1, IP54/Type12
IP00/Chassis
IP21, 54/Type1, 12
IP21, 54/Type1, 12
IP21/NEMA 1/IP 4
X
on top of enclosure
1.0 g
0.7 g
5% - 95% (IEC 721-3-3; Class 3K3 (non-condensing) during operation class Kd max. 55
° C
1)
- with full output power of typical EFF2 motors (up to 90% output current)
- at full continuous FC output current max. 50
° C
1)
max. 45
° C
1)
1)
For more information on derating see 8.6 Special Conditions
Minimum ambient temperature during full-scale operation
Minimum ambient temperature at reduced performance
Temperature during storage/transport
Maximum altitude above sea level without derating
Maximum altitude above sea level with derating
Derating for high altitude, see 8.6 Special Conditions
EMC standards, Emission
EMC standards, Immunity
0 °C
- 10 °C
-25 - +65/70 °C
1000 m
3000 m
EN 61800-3, EN 61000-6-3/4, EN 55011, IEC 61800-3
EN 61800-3, EN 61000-6-1/2,
EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6
Control card performance
Scan interval
Control card, USB serial communication
USB standard
USB plug
5ms
1.1 (Full speed)
USB type B “device” plug
CAUTION
Connection to PC is carried out via a standard host/device USB cable.
The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
The USB connection is not galvanically isolated from protection earth. Use only isolated laptop/PC as connection to the USB connector on frequency converter or an isolated USB cable/converter.
8 8
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®
HVAC Drive Design Guide
8 8
Protection and Features
•
Electronic thermal motor protection against overload.
•
Temperature monitoring of the heatsink ensures that the frequency converter trips if the temperature reaches 95
°C ± 5°C. An overload temperature cannot be reset until the temperature of the heatsink is below 70
°C ± 5°C
(Guideline - these temperatures may vary for different power sizes, enclosures etc.). The frequency converter has an auto derating function to avoid it's heatsink reaching 95
°C.
•
The frequency converter is protected against short-circuits on motor terminals U, V, W.
•
If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load).
•
Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high.
•
The frequency converter is protected against earth faults on motor terminals U, V, W.
8.3 Efficiency
Efficiency of the frequency converter (η
VLT
)
The load on the frequency converter has little effect on its efficiency. In general, the efficiency is the same at the rated motor frequency f
M,N
, even if the motor supplies
100% of the rated shaft torque or only 75%, i.e. in case of part loads.
This also means that the efficiency 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 switching frequency is set to a value of above 5 kHz. The efficiency will also be slightly reduced if the mains voltage is 480V, or if the motor cable is longer than 30m.
Frequency converter efficiency calculation
Calculate the efficiency of the frequency converter at
different loads based on Illustration 8.1. The factor in this
graph must be multiplied with the specific efficiency factor listed in the specification tables:
1.01
1.0
0.99
0.98
0.97
0.96
0.95
0.94
0.93
0.92
0% 50% 100%
% Speed
150% 200%
100% load 75% load 50% load 25% load
Illustration 8.1 Typical Efficiency Curves
Example: Assume a 55kW, 380-480V AC frequency converter at 25% load at 50% speed. The graph is showing
0,97 - rated efficiency for a 55kW FC is 0.98. The actual efficiency is then: 0.97x0.98=0.95.
Efficiency of the motor (η
MOTOR
)
The efficiency of a motor connected to the frequency converter depends on magnetizing level. In general, the efficiency is just as good as with mains operation. The efficiency of the motor depends on the type of motor.
In the range of 75-100% of the rated torque, the efficiency of the motor is practically constant, both when it is controlled by the frequency converter and when it runs directly on mains.
In small motors, the influence from the U/f characteristic on efficiency is marginal. However, in motors from 11kW and up, the advantages are significant.
In general, the switching frequency does not affect the efficiency of small motors. Motors from 11kW and up have their efficiency improved (1-2%). This is because the sine shape of the motor current is almost perfect at high switching frequency.
Efficiency of the system (
η
SYSTEM
)
To calculate the system efficiency, the efficiency of the frequency converter (η
VLT
) is multiplied by the efficiency of the motor (
η
MOTOR
):
η
SYSTEM
=
η
VLT
x
η
MOTOR
8.4 Acoustic Noise
The acoustic noise from the frequency converter comes from three sources:
1.
DC intermediate circuit coils.
2.
Integral fan.
3.
RFI filter choke.
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General Specifications and ...
VLT
®
HVAC Drive Design Guide
The typical values measured at a distance of 1 m from the unit:
B2
B3
B4
A2
A3
A5
B1
Enclosure
At reduced fan speed (50%) [dBA]
***
51
51
54
61
58
59.4
53
Full fan speed
[dBA]
60
60
63
67
70
70.5
62.8
C1
C2
C3
C4
D1/D3
D2/D4
E1/E2*
**
52
55
56.4
-
74
73
73
82
62
65
67.3
-
76
74
74
83
F1/F2/F3/F4 78 80
* 315kW, 380-480V AC and 450-500kW, 525-690V AC only.
** Remaining E1/E2 power sizes.
*** For D, E and F sizes, reduced fan speed is at 87%, measured at 200V.
8.5 Peak Voltage on Motor
When a transistor in the inverter bridge switches, the voltage across the motor increases by a du/dt ratio depending on:
the motor cable (type, cross-section, length screened or unscreened)
inductance
The natural induction causes an overshoot U
PEAK
in the motor voltage before it stabilizes itself at a level depending on the voltage in the intermediate circuit. The rise time and the peak voltage U
PEAK
affect the service life of the motor. If the peak voltage is too high, especially motors without phase coil insulation are affected. If the motor cable is short (a few metres), the rise time and peak voltage are lower.
If the motor cable is long (100m), the rise time and peak voltage increases.
In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply (such as a frequency converter), fit a sinewave filter on the output of the frequency converter.
To obtain approximate values for cable lengths and voltages not mentioned below, use the following rules of thumb:
1.
Rise time increases/decreases proportionally with cable length.
2.
3.
U
PEAK
= DC link voltage x 1.9
(DC link voltage = Mains voltage x 1.35).
dU
/
dt =
0.8 × UPEAK
Risetime
Data are measured according to IEC 60034-17.
Cable lengths are in metres.
8 8
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General Specifications and ...
8 8
Frequency Converter, P5K5, T2
Cable length [m]
36
Mains voltage [V]
240
50
100
150
240
240
240
Frequency Converter, P7K5, T2
Cable length [m]
5
50
100
150
Mains voltage [V]
230
230
230
230
Frequency Converter, P11K, T2
Cable length [m]
36 240
136
150
240
240
Frequency Converter, P15K, T2
Cable length [m]
Mains voltage [V]
30
100
150
240
240
240
Frequency Converter, P18K, T2
Cable length [m]
36
Mains voltage [V]
240
136
150
240
240
Frequency Converter, P22K, T2
Cable length [m]
Mains voltage [V]
36
136
150
240
240
240
Frequency Converter, P30K, T2
Cable length [m]
15
50
150
Mains voltage [V]
240
240
240
VLT
®
HVAC Drive Design Guide
Rise time
[
μsec]
0.226
0.262
0.650
0.745
Rise time
[
μsec]
0.244
0.568
0.720
Rise time
[
μsec]
0.244
0.560
0.720
Rise time
[
μsec]
0.194
0.252
0.444
Rise time
[
μsec]
0.13
0.23
0.54
0.66
Rise time
[
μsec]
0.264
0.536
0.568
Rise time
[
μsec]
0.556
0.592
0.708
Vpeak
[kV]
0.616
0.626
0.614
0.612
Vpeak
[kV]
0.608
0.580
0.574
Vpeak
[kV]
0.608
0.580
0.574
011893-0001
0.510
0.590
0.580
0.560
Vpeak
[kV]
0.624
0.596
0.568
Vpeak
[kV]
0.650
0.594
0.575
Vpeak
[kV]
0.626
0.574
0.538
dU/dt
[kV/
μsec]
2.142
1.908
0.757
0.655
dU/dt
[kV/
μsec]
1.993
0.832
0.661
dU/dt
[kV/
μsec]
1.993
0.832
0.661
dU/dt
[kV/
μsec]
2.581
1.929
0.977
dU/dt
[kV/
μsec]
3.090
2.034
0.865
0.674
dU/dt
[kV/
μsec]
1.894
0.896
0.806
dU/dt
[kV/
μsec]
0.935
0.807
0.669
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General Specifications and ...
Frequency Converter, P37K, T2
Cable length [m]
30
Mains voltage [V]
240
100
150
240
240
Frequency Converter, P45K, T2
Cable length [m]
Mains voltage [V]
30
100
150
240
240
240
Frequency Converter, P1K5, T4
Cable length [m]
5
50
150
Mains voltage [V]
400
400
400
Frequency Converter, P4K0, T4
Cable length [m]
5
50
150
Mains voltage [V]
400
400
400
Frequency Converter, P7K5, T4
Cable length [m]
5
50
150
Mains voltage [V]
400
400
400
Frequency Converter, P11K, T4
Cable length [m]
15
100
150
Mains voltage [V]
400
400
400
Frequency Converter, P15K, T4
Cable length [m]
Mains voltage [V]
36
100
150
400
400
400
VLT
®
HVAC Drive Design Guide
Rise time
[
μsec]
0.408
0.364
0.400
Rise time
[
μsec]
0.422
0.464
0.896
Rise time
[
μsec]
0.172
0.310
0.370
Rise time
[
μsec]
0.04755
0.207
0.6742
Rise time
[
μsec]
0.300
0.536
0.776
Rise time
[
μsec]
0.300
0.536
0.776
Rise time
[
μsec]
0.640
0.470
0.760
Vpeak
[kV]
0.690
0.985
1.045
Vpeak
[kV]
0.890
1.190
Vpeak
[kV]
0.739
1.040
1.030
Vpeak
[kV]
0.718
1.050
0.980
Vpeak
[kV]
1.060
0.900
1.000
Vpeak
[kV]
0.598
0.566
0.546
Vpeak
[kV]
0.598
0.566
0.546
dU/dt
[kV/
μsec]
1.402
2.376
2.000
dU/dt
[kV/
μsec]
2.014
1.616
0.915
dU/dt
[kV/
μsec]
4.156
2.564
1.770
dU/dt
[kV/
μsec]
8.035
4.548
2.828
dU/dt
[kV/
μsec]
1.593
0.843
0.559
dU/dt
[kV/
μsec]
1.593
0.843
0.559
dU/dt
[kV/
μsec]
0.862
0.985
0.947
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®
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8 8
General Specifications and ...
8 8
Frequency Converter, P18K, T4
Cable length [m]
36
Mains voltage [V]
400
100
150
400
400
Frequency Converter, P22K, T4
Cable length [m]
Mains voltage [V]
36
100
150
400
400
400
Frequency Converter, P30K, T4
Cable length [m]
15
100
150
Mains voltage [V]
400
400
400
Frequency Converter, P37K, T4
Cable length [m]
5
50
100
150
Mains voltage
480
480
480
480
Frequency Converter, P45K, T4
Cable length [m]
Mains voltage [V]
36
50
100
150
400
400
400
400
Frequency Converter, P55K, T4
Cable length [m]
10
Mains voltage [V]
400
Frequency Converter, P75K, T4
Cable length [m]
5
Mains voltage [V]
480
Frequency Converter, P90K, T4
Cable length [m]
5
Mains voltage [V]
400
VLT
®
HVAC Drive Design Guide
Rise time
[
μsec]
0.364
Rise time
[
μsec]
0.270
0.435
0.840
0.940
Rise time
[
μsec]
0.254
0.465
0.815
0.890
Rise time
[
μsec]
0.350
Rise time
[
μsec]
0.371
Rise time
[
μsec]
0.344
1.000
1.400
Rise time
[
μsec]
0.232
0.410
0.430
Rise time
[
μsec]
0.271
0.440
0.520
Vpeak
[kV]
1.056
1.048
1.032
1.016
Vpeak
[kV]
1.276
1.184
1.188
1.212
Vpeak
[kV]
0.932
Vpeak
[kV]
1.170
Vpeak
[kV]
1.040
1.190
1.040
Vpeak
[kV]
0.950
0.980
0.970
Vpeak
[kV]
1.000
1.000
0.990
Vpeak
[kV]
1.030
166 MG11BB02 - VLT
®
is a registered Danfoss trademark dU/dt
[kV/
μsec]
3.781
2.177
1.131
1.031
dU/dt
[kV/
μsec]
3.326
1.803
1.013
0.913
dU/dt
[kV/
μsec]
2.130
dU/dt
[kV/
μsec]
2.466
dU/dt
[kV/
μsec]
2.442
0.950
0.596
dU/dt
[kV/
μsec]
3.534
1.927
1.860
dU/dt
[kV/
μsec]
3.100
1.818
1.510
dU/dt
[kV/
μsec]
2.264
General Specifications and ...
VLT
®
HVAC Drive Design Guide
High Power Range:
Frequency Converter, P110 - P250, T4
Cable length [m]
30
Mains voltage [V]
400
Frequency Converter, P315 - P1M0, T4
Cable length [m]
30
30
30
30
1) With Danfoss dU/dt filter.
Mains voltage [V]
500
400
500
400 1
1
Frequency Converter, P110 - P400, T7
Rise time
[
μsec]
0.34
Rise time
[
μsec]
0.71
0.61
0.80
0.82
Cable length [m]
30
30
30
1) With Danfoss dU/dt filter.
Mains voltage [V]
690
575
690 1)
Rise time
[
μsec]
0.38
0.23
1.72
Frequency Converter, P450 - P1M4, T7
Cable length [m]
30
30
30
1) With Danfoss dU/dt filter.
Mains voltage [V]
690
575
690 1)
Rise time
[
μsec]
0.57
0.25
1.13
8.6 Special Conditions
8.6.1 Purpose of Derating
Take derating into account when using the frequency converter at low air pressure (heights), at low speeds, with long motor cables, cables with a large cross section or at high ambient temperature. The required action is described in this section.
8.6.2 Derating for Ambient Temperature
90% frequency converter output current can be maintained up to max. 50
°C ambient temperature.
With a typical full load current of EFF 2 motors, full output shaft power can be maintained up to 50
°C.
For more specific data and/or derating information for other motors or conditions, please contact Danfoss.
Vpeak
[kV]
1.040
Vpeak
[kV]
1.165
0.942
0.906
0.760
Vpeak
[kV]
1.513
1.313
1.329
Vpeak
[kV]
1.611
1.629
dU/dt
[kV/
μsec]
2.447
dU/dt
[kV/
μsec]
1.389
1.233
0.904
0.743
dU/dt
[kV/
μsec]
3.304
2.750
0.640
dU/dt
[kV/
μsec]
2.261
2.510
1.150
8.6.3 Automatic Adaptations to Ensure
Performance
The frequency converter constantly checks for critical levels of internal temperature, load current, high voltage on the intermediate circuit and low motor speeds. As a response to a critical level, the frequency converter can adjust the switching frequency 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 conditions even further.
8.6.4 Derating for Low Air Pressure
The cooling capability of air is decreased at lower air pressure.
8 8
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General Specifications and ...
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®
HVAC Drive Design Guide
8 8
Below 1000m altitude no derating is necessary but above
1000m the ambient temperature (T
AMB
) or max. output current (I out
) should be derated in accordance with the shown diagram.
Max.I
out
(%) at T
AMB, MAX
100%
91%
82%
D T
AMB, MAX at 100% I out
(K)
A enclosure
0 K 0 K
-5 K -3.3 K
-9 K -6 K
1 km 2 km 3 km
Altitude (km)
Illustration 8.2 Derating of output current versus altitude at T
AMB,
MAX
for frame sizes A, B and C. At altitudes above 2km, please contact Danfoss regarding PELV.
95
90
85
80
0
An alternative is to lower the ambient temperature at high altitudes and thereby ensure 100% output current at high altitudes. As an example of how to read the graph, the situation at 2 km is elaborated. At a temperature of 45
° C
(T
AMB, MAX
- 3.3 K), 91% of the rated output current is available. At a temperature of 41.7
° C, 100% of the rated output current is available.
I
OUT
(%)
100
500 1000 1500 2000
Altitude (meters above sea level)*
2500 3000
(°C)
45
40
HO
35
NO
30
0 500 1000 1500 2000
Altitude (meters above sea level)*
2500 3000
Derating of output current versus altitude at T
AMB, MAX
for frame sizes D, E and F.
168
8.6.5 Derating for Running at Low Speed
When a motor is connected to a frequency converter, it is necessary to check that the cooling of the motor is adequate.
The level of heating depends on the load on the motor, as well as the operating speed and time.
Constant torque applications (CT mode)
A problem may occur at low RPM values in constant torque applications. In a constant torque application s a motor may over-heat at low speeds due to less cooling air from the motor integral fan.
Therefore, if the motor is to be run continuously at an RPM value lower than half of the rated value, the motor must be supplied with additional air-cooling (or a motor designed for this type of operation may be used).
An alternative is to reduce the load level of the motor by choosing 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, where the torque is proportional to the square of the speed and the power is proportional to the cube of the speed, there is no need for additional cooling or de-rating of the motor.
In the graphs shown below, the typical VT curve is below the maximum torque with de-rating and maximum torque with forced cooling at all speeds.
100
80
60
40
120
Maximum load for a standard motor at 40
°C driven by a frequency converter type VLT FCxxx
1)
20
0
0 10 20 30 40 50 60 70 80 90 100 110 v %
Legend:
─ ─ ─ ─Typical torque at VT load ─•─•─•─ Max torque with forced cooling
‒‒‒‒‒Max torque
Note 1) Over-syncronous speed operation will result in the available motor torque decreasing inversely proportional with the increase in speed. This must be considered during the design phase to avoid over-loading of the motor.
MG11BB02 - VLT
®
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General Specifications and ...
VLT
®
HVAC Drive Design Guide
8.7 Troubleshooting
A warning or an alarm is signalled by the relevant LED on the front of the frequency converter and indicated by a code on the display.
A warning remains active until its cause is no longer present. Under certain circumstances operation of the motor may still be continued. Warning messages may be critical, but are not necessarily so.
In the event of an alarm, the frequency converter will have tripped. Alarms must be reset to restart operation once their cause has been rectified.
This may be done in four ways:
1.
By using the [RESET] control button on the LCP.
2.
3.
Via a digital input with the “Reset” function.
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 Reset Mode in the FC 100
Programming Guide MGxxyy
NOTE
After a manual reset using the [RESET] button on the LCP, the [Auto On] or [Hand On] button must be pressed to restart the motor.
No. Description
7
8
5
6
3
4
1
2
10 Volts low
Live zero error
No motor
Mains phase loss
DC link voltage high
DC link voltage low
DC over voltage
DC under voltage
9 Inverter overloaded
10 Motor ETR over temperature
11 Motor thermistor over temperature
12 Torque limit
13 Over Current
14 Earth fault
15 Hardware mismatch
16 Short Circuit
17 Control word timeout
18 Start failed
23 Internal Fan Fault
24 External Fan Fault
25 Brake resistor short-circuited
26 Brake resistor power limit
(X)
X
X
X
(X)
Warning Alarm/
Trip
X
X
(X)
(X)
X
X
X
X
X
X
(X)
(X)
(X)
X
X
X
X
(X)
(X)
X
X
X
X
X
(X)
(X)
(X)
X
(X)
If an alarm cannot be reset, the reason may be that its cause has not been rectified, or the alarm is trip-locked
CAUTION
Alarms that are trip-locked offer additional protection, means that the mains supply must be switched off before the alarm can be reset. After being switched back on, the frequency converter is no longer blocked and may be reset as described above once the cause has been rectified.
Alarms that are not trip-locked can also be reset using the automatic reset function in 14-20 Reset Mode (Warning: automatic wake-up is possible!)
If a warning and alarm is marked against a code in the table on the following page, this means that either a warning occurs before an alarm, or it can be specified whether it is a warning or an alarm that is to be displayed for a given fault.
This is possible, for instance, in 1-90 Motor Thermal
Protection. After an alarm or trip, the motor carries on coasting, and the alarm and warning flash on the frequency converter. Once the problem has been rectified, only the alarm continues flashing.
NOTE
No missing motorphase detection (no 30-32) and no stall detection is active when 1-10 Motor Construction is set to
[1] PM non salient SPM.
Alarm/Trip Lock
X
X
X
X
(X)
Parameter Reference
1-90
1-90
6-01
1-80
14-12
8-04
14-53
2-13
8 8
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General Specifications and ...
8 8
No. Description
27 Brake chopper short-circuited
28 Brake check
29 Drive over temperature
30 Motor phase U missing
31 Motor phase V missing
32 Motor phase W missing
33 Inrush fault
34 Fieldbus communication fault
35 Out of frequency range
36 Mains failure
37 Phase Imbalance
38 Internal fault
39 Heatsink sensor
40 Overload of Digital Output Terminal 27
41 Overload of Digital Output Terminal 29
42 Overload of Digital Output On X30/6
42 Overload of Digital Output On X30/7
46 Pwr. card supply
47 24 V supply low
48 1.8 V supply low
49 Speed limit
50 AMA calibration failed
51 AMA check U nom
and I nom
52 AMA low I nom
53 AMA motor too big
54 AMA motor too small
55 AMA Parameter out of range
56 AMA interrupted by user
57 AMA timeout
58 AMA internal fault
59 Current limit
60 External Interlock
62 Output Frequency at Maximum Limit
64 Voltage Limit
65 Control Board Over-temperature
66 Heat sink Temperature Low
67 Option Configuration has Changed
68 Safe Stop
69 Pwr. Card Temp
70 Illegal FC configuration
71 PTC 1 Safe Stop
72 Dangerous Failure
73 Safe Stop Auto Restart
76 Power Unit Setup
79 Illegal PS config
80 Drive Initialized to Default Value
91 Analog input 54 wrong settings
92 NoFlow
93 Dry Pump
94 End of Curve
95 Broken Belt
96 Start Delayed
VLT
®
HVAC Drive Design Guide
Warning Alarm/
Trip
X X
(X) (X)
X
X
X
X
X
X
X
X
X
X
X
(X)
X
X
X
(X)
(X)
(X)
X
(X)
X
X
X
X
(X)
(X)
(X)
X
X
X 1)
X
X
1)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
(X)
(X)
(X)
X
X
(X)
X
X
X
Parameter Reference
22-2*
22-2*
22-5*
22-6*
22-7*
5-19
2-15
5-00, 5-01
5-00, 5-02
5-32
5-33
4-58
4-58
4-58
1-86
Alarm/Trip Lock
X
X
X
X
X
X
1)
X
X
X
X
X
(X)
(X)
(X)
X
X
170 MG11BB02 - VLT
®
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General Specifications and ...
VLT
®
HVAC Drive Design Guide
No. Description
97 Stop Delayed
98 Clock Fault
201 Fire M was Active
202 Fire M Limits Exceeded
203 Missing Motor
204 Locked Rotor
243 Brake IGBT
244 Heatsink temp
245 Heatsink sensor
246 Pwr.card supply
247 Pwr.card temp
248 Illegal PS config
250 New spare parts
251 New Type Code
Table 8.8 Alarm/Warning code list
(X) Dependent on parameter
1) Can not be Auto reset via 14-20 Reset Mode
A trip is the action when an alarm has appeared. The trip will coast the motor and can be reset by pressing the reset button or make a reset by a digital input (parameter group
5-1* [1]). The original event that caused an alarm cannot damage the frequency converter or cause dangerous conditions. A trip lock is an action when an alarm occurs, which may cause damage to frequency converter or connected parts. A Trip Lock situation can only be reset by a power cycling.
Warning Alarm/
Trip
X
X
X
X
X
X
X
X
X
X
X
Alarm/Trip Lock
LED indication
Warning
Alarm
Trip locked
X
X
X
X
X
X
X yellow flashing red yellow and red
Parameter Reference
22-7*
0-7*
8 8
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®
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General Specifications and ...
VLT
®
HVAC Drive Design Guide
8 8
22
23
24
25
18
19
20
21
14
15
16
17
10
11
12
13
26
27
28
29
30
31
8
9
6
7
4
5
2
3
0
1
Alarm Word and Extended Status Word
Bit Hex Dec
00000001
00000002
1
2
00000004
00000008
00000010
00000020
16
32
4
8
00000040
00000080
00000100
00000200
64
128
256
512
00000400
00000800
00001000
00002000
00004000
00008000
00010000
00020000
00040000
00080000
00100000
00200000
00400000
00800000
01000000
02000000
04000000
08000000
10000000
20000000
40000000
80000000
67108864
134217728
268435456
536870912
1073741824
2147483648
262144
524288
1048576
2097152
4194304
8388608
16777216
33554432
1024
2048
4096
8192
16384
32768
65536
131072
Table 8.9 Description of Alarm Word, Warning Word and Extended Status Word
Alarm Word
Brake Check
Pwr. Card Temp
Earth Fault
Ctrl.Card Temp
Ctrl. Word TO
Over Current
Torque Limit
Motor Th Over
Motor ETR Over
Inverter Overld.
DC under Volt
DC over Volt
Short Circuit
Inrush Fault
Mains ph. Loss
AMA Not OK
Live Zero Error
Internal Fault
Brake Overload
U phase Loss
V phase Loss
W phase Loss
Fieldbus Fault
24 V Supply Low
Mains Failure
1.8V Supply Low
Warning Word
Brake Check
Pwr. Card Temp
Earth Fault
Ctrl.Card Temp
Ctrl. Word TO
Over Current
Torque Limit
Motor Th Over
Motor ETR Over
Inverter Overld.
DC under Volt
DC over Volt
DC Voltage Low
DC Voltage High
Mains ph. Loss
No Motor
Live Zero Error
10V Low
Brake Overload
Brake Resistor
Brake IGBT
Speed Limit
Fieldbus Fault
24V Supply Low
Mains Failure
Current Limit
Brake Resistor
Brake IGBT
Option Change
Drive Initialized
Low Temp
Voltage Limit
Unused
Unused
Safe Stop Unused
Mech. brake low (A63) Extended Status Word
The alarm words, warning words and extended status words can be read out via serial bus or optional fieldbus for diagnosis. See also 16-90 Alarm Word, 16-92 Warning Word and 16-94 Ext. Status Word.
Extended Status Word
Ramping
AMA Running
Start CW/CCW
Slow Down
Catch Up
Feedback High
Feedback Low
Output Current High
Output Current Low
Output Freq High
Output Freq Low
Brake Check OK
Braking Max
Braking
Out of Speed Range
OVC Active
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8.7.1 Alarm Words
16-90 Alarm Word
Bit
(Hex)
00000001
00000002
00000004
00000008
00000010
00000020
00000040
00000080
00000100
00000200
00000400
00000800
00001000
00002000
00004000
00008000
00010000
00020000
00040000
00080000
00100000
00200000
00800000
01000000
02000000
04000000
08000000
10000000
20000000
40000000
80000000
Alarm Word
(16-90 Alarm Word)
Power card over temperature
Earth fault
Control word timeout
Over current
Motor thermistor over temp.
Motor ETR over temperature
Inverter overloaded
DC link under voltage
DC link over voltage
Short circuit
Mains phase loss
AMA not OK
Live zero error
Internal fault
Motor phase U is missing
Motor phase V is missing
Motor phase W is missing
Control Voltage Fault
VDD, supply low
Brake resistor short circuit
Brake chopper fault
Earth fault DESAT
Drive initialised
Safe Stop [A68]
16-91 Alarm Word 2
00008000
00010000
00020000
00040000
00080000
00100000
00200000
00400000
00800000
01000000
02000000
04000000
08000000
10000000
20000000
40000000
Bit
(Hex)
00000001
00000002
00000004
00000008
00000010
00000020
00000040
00000080
00000100
00000200
00000400
00000800
00001000
00002000
00004000
80000000
Alarm Word 2
(16-91 Alarm Word 2)
Reserved
Service Trip, Typecode / Sparepart
Reserved
Reserved
Broken Belt
Not used
Not used
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Not used
Fans error
ECB error
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
PTC 1 Safe Stop [A71]
Dangerous Failure [A72]
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8.7.2 Warning Words
16-92 Warning Word
00008000
00010000
00020000
00040000
00080000
00100000
00200000
00400000
00800000
01000000
02000000
04000000
08000000
10000000
20000000
40000000
Bit
(Hex)
00000001
00000002
00000004
00000008
00000010
00000020
00000040
00000080
00000100
00000200
00000400
00000800
00001000
00002000
00004000
80000000
No motor
Live zero error
Current limit
Safe Stop [W68]
Warning Word
(16-92 Warning Word)
Power card over temperature
Earth fault
Control word timeout
Over current
Motor thermistor over temp.
Motor ETR over temperature
Inverter overloaded
DC link under voltage
DC link over voltage
Mains phase loss
Not used
16-93 Warning Word 2
00008000
00010000
00020000
00040000
00080000
00100000
00200000
00400000
00800000
01000000
02000000
04000000
08000000
10000000
20000000
40000000
Bit
(Hex)
00000001
00000002
00000004
00000008
00000010
00000020
00000040
00000080
00000100
00000200
00000400
00000800
00001000
00002000
00004000
80000000
Warning Word 2
(16-93 Warning Word 2)
Clock Failure
Reserved
Reserved
End of Curve
Broken Belt
Not used
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Not used
Fans warning
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
PTC 1 Safe Stop [W71]
Reserved
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8.7.3 Extended Status Words
Extended status word, 16-94 Ext. Status Word
00008000
00010000
00020000
00040000
00080000
00100000
00200000
00400000
00800000
01000000
02000000
04000000
08000000
10000000
20000000
40000000
Bit
(Hex)
00000001
00000002
00000004
00000008
00000010
00000020
00000040
00000080
00000100
00000200
00000400
00000800
00001000
00002000
00004000
80000000
Extended Status Word
(16-94 Ext. Status Word)
Ramping
AMA tuning
Start CW/CCW
Not used
Not used
Feedback high
Feedback low
Output current high
Output current low
Output frequency high
Output frequency low
Brake check OK
Braking max
Braking
Out of speed range
OVC active
AC brake
Password Timelock
Password Protection
Reference high
Reference low
Local Ref./Remote Ref.
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Extended status word 2, 16-95 Ext. Status Word 2
00008000
00010000
00020000
00040000
00080000
00100000
00200000
00400000
00800000
01000000
02000000
04000000
08000000
10000000
20000000
Bit
(Hex)
00000001
00000002
00000004
00000008
00000010
00000020
00000040
00000080
00000100
00000200
00000400
00000800
00001000
00002000
00004000
40000000
80000000
Jog Request
Jog
Start Request
Start
Start Applied
Start Delay
Sleep
Sleep Boost
Running
Bypass
Fire Mode
Reserved
Reserved
Reserved
Reserved
Extended Status Word 2 (16-95 Ext. Status
Word 2)
Off
Hand / Auto
Not used
Not used
Not used
Relay 123 active
Start Prevented
Control ready
Drive ready
Quick Stop
DC Brake
Stop
Standby
Freeze Output Request
Freeze Output
Reserved
Reserved
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8.7.4 Fault Messages
The warning/alarm information below defines each warning/alarm condition, provides the probable cause for the condition, and details a remedy or troubleshooting procedure.
WARNING 1, 10 Volts low
The control card voltage is below 10V from terminal 50.
Remove some of the load from terminal 50, as the 10V supply is overloaded. Max. 15mA or minimum 590
Ω.
This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer.
Troubleshooting
Remove the wiring from terminal 50. If the warning clears, the problem is with the customer wiring. If the warning does not clear, replace the control card.
WARNING/ALARM 2, Live zero error
This warning or alarm will only appear if programmed by the user in 6-01 Live Zero Timeout Function. The signal on one of the analog inputs is less than 50% of the minimum value programmed for that input. This condition can be caused by broken wiring or faulty device sending the signal.
Troubleshooting
Check connections on all the analog input terminals. Control card terminals 53 and 54 for signals, terminal 55 common. MCB 101 terminals
11 and 12 for signals, terminal 10 common. MCB
109 terminals 1, 3, 5 for signals, terminals 2, 4, 6 common).
Check that the frequency converter programming and switch settings match the analog signal type.
Perform Input Terminal Signal Test.
WARNING/ALARM 4, Mains phase loss
A phase is missing on the supply side, or the mains voltage imbalance is too high. This message also appears for a fault in the input rectifier on the frequency converter.
Options are programmed at 14-12 Function at Mains
Imbalance.
Troubleshooting
Check the supply voltage and supply currents to the frequency converter.
WARNING 5, DC link voltage high
The intermediate circuit voltage (DC) is higher than the high voltage warning limit. The limit is dependent on the frequency converter voltage rating. The unit is still active.
WARNING 6, DC link voltage low
The intermediate circuit voltage (DC) is lower than the low voltage warning limit. The limit is dependent on the frequency converter voltage rating. The unit is still active.
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 the ramp type
Activate the functions in 2-10 Brake Function
Increase 14-26 Trip Delay at Inverter Fault
WARNING/ALARM 8, DC under voltage
If the intermediate circuit voltage (DC link) drops below the under voltage limit, the frequency converter checks if a
24V DC backup supply is connected. If no 24V DC backup supply is connected, the frequency converter trips after a fixed time delay. The time delay varies with unit size.
Troubleshooting
Check that the supply voltage matches the frequency converter voltage.
Perform input voltage test
Perform soft charge circuit test
WARNING/ALARM 9, Inverter overload
The frequency converter is about to cut out because of an overload (too high current for too long). The counter for electronic, thermal inverter protection gives a warning at
98% and trips at 100%, while giving an alarm. The frequency converter cannot be reset until the counter is below 90%.
The fault is that the frequency converter is overloaded by more than 100% for too long.
Troubleshooting
Compare the output current shown on the LCP with the frequency converter rated current.
Compare the output current shown on the LCP with measured motor current.
Display the Thermal Drive Load on the LCP and monitor the value. When running above the frequency converter continuous current rating, the counter should increase. When running below the frequency converter continuous current rating, the counter should decrease.
See the derating section in the Design Guide for more details if a high switching frequency is required.
WARNING/ALARM 10, Motor overload temperature
According to the electronic thermal protection (ETR), the motor is too hot. Select whether the frequency converter gives a warning or an alarm when the counter reaches
100% in 1-90 Motor Thermal Protection. The fault occurs when the motor is overloaded by more than 100% for too long.
Troubleshooting
Check for motor overheating.
Check if the motor is mechanically overloaded
Check that the motor current set in 1-24 Motor
Current is correct.
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Ensure that Motor data in parameters 1-20 through 1-25 are set correctly.
If an external fan is in use, check in 1-91 Motor
External Fan that it is selected.
Running AMA in 1-29 Automatic Motor Adaptation
(AMA) may tune the frequency converter to the motor more accurately and reduce thermal loading.
WARNING/ALARM 11, Motor thermistor over temp
The thermistor might be disconnected. Select whether the frequency converter gives a warning or an alarm in
1-90 Motor Thermal Protection.
Troubleshooting
Check for motor overheating.
Check if the motor is mechanically overloaded.
When using terminal 53 or 54, check that the thermistor is connected correctly between either terminal 53 or 54 (analog voltage input) and terminal 50 (+10V supply) and that the terminal switch for 53 or 54 is set for voltage. Check
1-93 Thermistor Source selects terminal 53 or 54.
When using digital inputs 18 or 19, check that the thermistor is connected correctly between either terminal 18 or 19 (digital input PNP only) and terminal 50. Check 1-93 Thermistor Source selects terminal 18 or 19.
WARNING/ALARM 12, Torque limit
The torque has exceeded the value in 4-16 Torque Limit
Motor Mode or the value in 4-17 Torque Limit Generator
Mode. 14-25 Trip Delay at Torque Limit can change this from a warning only condition to a warning followed by an alarm.
Troubleshooting
If the motor torque limit is exceeded during ramp up, extend the ramp up time.
If the generator torque limit is exceeded during ramp down, extend the ramp down time.
If torque limit occurs while running, possibly increase the torque limit. Be sure the system can operate safely at a higher torque.
Check the application for excessive current draw on the motor.
WARNING/ALARM 13, Over current
The inverter peak current limit (approximately 200% of the rated current) is exceeded. The warning lasts about 1.5
secs., then the frequency converter trips and issues an alarm. This fault may be caused by shock loading or fast acceleration with high inertia loads. If extended mechanical brake control is selected, trip can be reset externally.
Troubleshooting
Remove power and check if the motor shaft can be turned.
Check that the motor size matches the frequency converter.
Check parameters 1-20 through 1-25. for correct motor data.
ALARM 14, Earth (ground) fault
There is current from the output phases to earth, either in the cable between the frequency converter and the motor or in the motor itself.
Troubleshooting:
Remove power to the frequency converter and repair the earth fault.
Check for earth faults in the motor by measuring the resistance to ground of the motor leads and the motor with a megohmmeter.
ALARM 15, Hardware mismatch
A fitted option is not operational with the present control board hardware or software.
Record the value of the following parameters and contact your Danfoss supplier:
15-40 FC Type
15-41 Power Section
15-42 Voltage
15-43 Software Version
15-45 Actual Typecode String
15-49 SW ID Control Card
15-50 SW ID Power Card
15-60 Option Mounted
15-61 Option SW Version (for each option slot)
ALARM 16, Short circuit
There is short-circuiting in the motor or motor wiring.
Remove power to the frequency converter and repair the short circuit.
WARNING/ALARM 17, Control word timeout
There is no communication to the frequency converter.
The warning will only be active when 8-04 Control Word
Timeout Function is NOT set to OFF.
If 8-04 Control Word Timeout Function is set to Stop and
Trip, a warning appears and the frequency converter ramps down until it stops then displays an alarm.
Troubleshooting
Check connections on the serial communication cable.
Increase 8-03 Control Word Timeout Time
Check the operation of the communication equipment.
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Verify a proper installation based on EMC requirements.
ALARM 18, Start failed
The speed has not been able to exceed 1-77 Compressor
Start Max Speed [RPM] during start within the allowed time.
(set in 1-79 Compressor Start Max Time to Trip). This may be caused by a blocked motor.
WARNING 23, Internal fan fault
The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in 14-53 Fan Monitor ([0] Disabled).
For the D, E, and F Frame filters, the regulated voltage to the fans is monitored.
Troubleshooting
Check for proper fan operation.
Cycle power to the frequency converter and check that the fan operates briefly at start up.
Check the sensors on the heatsink and control card.
WARNING 24, External fan fault
The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in 14-53 Fan Monitor ([0] Disabled).
Troubleshooting
Check for proper fan operation.
Cycle power to the frequency converter and check that the fan operates briefly at start up.
Check the sensors on the heatsink and control card.
WARNING 25, Brake resistor short circuit
The brake resistor is monitored during operation. If a short circuit occurs, the brake function is disabled and the warning appears. The frequency converter is still operational but without the brake function. Remove power to the frequency converter and replace the brake resistor
(see 2-15 Brake Check).
WARNING/ALARM 26, Brake resistor power limit
The power transmitted to the brake resistor is calculated as a mean value over the last 120 seconds of run time. The calculation is based on the intermediate circuit voltage and the brake resistance value set in 2-16 AC brake Max.
Current. The warning is active when the dissipated braking is higher than 90% of the brake resistance power. If Trip [2] is selected in 2-13 Brake Power Monitoring, the frequency converter will trip when the dissipated braking power reaches 100%.
WARNING/ALARM 27, Brake chopper fault
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 brake transistor has shortcircuited, substantial power is transmitted to the brake resistor, even if it is inactive.
Remove power to the frequency converter and remove the brake resistor.
WARNING/ALARM 28, Brake check failed
The brake resistor is not connected or not working.
Check 2-15 Brake Check.
ALARM 29, Heatsink temp
The maximum temperature of the heatsink has been exceeded. The temperature fault will not reset until the temperature falls below a defined heatsink temperature.
The trip and reset points are different based on the frequency converter power size.
Troubleshooting
Check for the following conditions.
Ambient temperature too high.
Motor cable too long.
Incorrect airflow clearance above and below the frequency converter
Blocked airflow around the frequency converter.
Damaged heatsink fan.
Dirty heatsink.
ALARM 30, Motor phase U missing
Motor phase U between the frequency converter and the motor is missing.
Remove power from the frequency converter and check motor phase U.
ALARM 31, Motor phase V missing
Motor phase V between the frequency converter and the motor is missing.
Remove power from the frequency converter and check motor phase V.
ALARM 32, Motor phase W missing
Motor phase W between the frequency converter and the motor is missing.
Remove power from the frequency converter and check motor phase W.
ALARM 33, Inrush fault
Too many power-ups have occurred within a short time period. Let the unit cool to operating temperature.
WARNING/ALARM 34, communication fault
The fieldbus on the communication option card is not working.
WARNING/ALARM 36, Mains failure
This warning/alarm is only active if the supply voltage to the frequency converter is lost and 14-10 Mains Failure is
NOT set to [0] No Function. Check the fuses to the frequency converter and mains power supply to the unit.
ALARM 38, Internal fault
When an internal fault occurs, a code number defined in the table below is displayed.
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Troubleshooting
Cycle power
Check that the option is properly installed
Check for loose or missing wiring
It may be necessary to contact your Danfoss supplier or service department. Note the code number for further troubleshooting directions.
No.
0
Text
Serial port cannot be initialised. Contact your
Danfoss supplier or Danfoss Service Department.
256-258 Power EEPROM data is defective or too old
512-519 Internal fault. Contact your Danfoss supplier or
Danfoss Service Department.
783 Parameter value outside of min/max limits
1024-1284 Internal fault. Contact your Danfoss supplier or the
Danfoss Service Department.
1299
1300
Option SW in slot A is too old
Option SW in slot B is too old
1302
1315
1316
1318
Option SW in slot C1 is too old
Option SW in slot A is not supported (not allowed)
Option SW in slot B is not supported (not allowed)
Option SW in slot C1 is not supported (not allowed)
1379-2819 Internal fault. Contact your Danfoss supplier or
Danfoss Service Department.
2820
2821
LCP stack overflow
Serial port overflow
2822 USB port overflow
3072-5122 Parameter value is outside its limits
5123
5124
Option in slot A: Hardware incompatible with control board hardware
Option in slot B: Hardware incompatible with control board hardware
5125
5126
Option in slot C0: Hardware incompatible with control board hardware
Option in slot C1: Hardware incompatible with control board hardware
5376-6231 Internal fault. Contact your Danfoss supplier or
Danfoss Service Department.
ALARM 39, Heatsink sensor
No feedback from the heatsink temperature sensor.
The signal from the IGBT thermal sensor 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 terminal 27
Check the load connected to terminal 27 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and
5-01 Terminal 27 Mode.
WARNING 41, Overload of digital output terminal 29
Check the load connected to terminal 29 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and
5-02 Terminal 29 Mode.
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WARNING 42, Overload of digital output on X30/6 or overload of digital output on X30/7
For X30/6, check the load connected to X30/6 or remove the short-circuit connection. Check 5-32 Term X30/6 Digi
Out (MCB 101).
For X30/7, check the load connected to X30/7 or remove the short-circuit connection. Check 5-33 Term X30/7 Digi
Out (MCB 101).
ALARM 45, Earth fault 2
Earth (ground) fault on start up.
Troubleshooting
Check for proper earthing (grounding) and loose connections.
Check for proper wire size.
Check motor cables for short-circuits or leakage currents.
ALARM 46, Power card supply
The supply on the power card is out of range.
There are three power supplies generated by the switch mode power supply (SMPS) on the power card: 24V, 5V,
+/- 18V. When powered with 24V DC with the MCB 107 option, only the 24V and 5V supplies are monitored. When powered with three phase mains voltage, all three supplies are monitored.
Troubleshooting
Check for a defective power card.
Check for a defective control card.
Check for a defective option card.
If a 24V DC power supply is used, verify proper supply power.
WARNING 47, 24V supply low
The 24 V DC is measured on the control card. The external
24V DC backup power supply may be overloaded, otherwise contact your Danfoss supplier.
WARNING 48, 1.8V supply low
The 1.8V DC supply used on the control card is outside of allowable limits. The power supply is measured on the control card. Check for a defective control card. If an option card is present, check for an overvoltage condition.
WARNING 49, Speed limit
When the speed is not within the specified range in
4-11 Motor Speed Low Limit [RPM] and 4-13 Motor Speed
High Limit [RPM], the frequency converter will show a warning. When the speed is below the specified limit in
1-86 Trip Speed Low [RPM] (except when starting or stopping) the frequency converter will trip.
ALARM 50, AMA calibration failed
Contact your Danfoss supplier or Danfoss Service
Department.
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ALARM 51, AMA check U nom
and I nom
The settings for motor voltage, motor current, and motor power are wrong. Check the settings in parameters 1-20 to
1-25.
ALARM 52, AMA low I nom
The motor current is too low. Check the setting in
4-18 Current Limit.
ALARM 53, AMA motor too big
The motor is too big for the AMA to operate.
ALARM 54, AMA motor too small
The motor is too small for the AMA to operate.
ALARM 55, AMA Parameter out of range
The parameter values of the motor are outside of the acceptable range. AMA will not run.
56 ALARM, AMA interrupted by user
The AMA has been interrupted by the user.
ALARM 57, AMA internal fault
Try to restart AMA again. Repeated restarts may over heat the motor.
ALARM 58, AMA internal fault
Contact your Danfoss supplier.
WARNING 59, Current limit
The current is higher than the value in 4-18 Current Limit.
Ensure that Motor data in parameters 1-20 through 1-25 are set correctly. Possibly increase the current limit. Be sure the system can operate safely at a higher limit.
WARNING 60, External interlock
A digital input signal is indicating a fault condition external to the frequency converter. An external interlock has commanded the frequency converter to trip. Clear the external fault condition. To resume normal operation, apply 24V DC to the terminal programmed for external interlock. Reset the frequency converter.
WARNING 62, Output frequency at maximum limit
The output frequency has reached the value set in
4-19 Max Output Frequency. Check the application to determine the cause. Possibly increase the output frequency limit. Be sure the system can operate safely at a higher output frequency. The warning will clear when the output drops below the maximum limit.
WARNING/ALARM 65, Control card over temperature
The cutout temperature of the control card is 80
° C.
Troubleshooting
•
Check that the ambient operating temperature is within limits.
•
Check for clogged filters.
•
Check fan operation.
•
Check the control card.
WARNING 66, Heatsink temperature low
The frequency converter is too cold to operate. This warning is based on the temperature sensor in the IGBT module.
180
Increase the ambient temperature of the unit. Also, a trickle amount of current can be supplied to the frequency converter whenever the motor is stopped by setting
2-00 DC Hold/Preheat Current at 5% and 1-80 Function at
Stop
ALARM 67, Option module configuration has changed
One or more options have either been added or removed since the last power-down. Check that the configuration change is intentional and reset the unit.
ALARM 68, Safe stop activated
Loss of the 24V DC signal on terminal 37 has caused the filter to trip. To resume normal operation, apply 24V DC to terminal 37 and reset the filter.
The temperature sensor on the power card is either too hot or too cold.
Troubleshooting
Check that the ambient operating temperature is within limits.
Check for clogged filters.
Check fan operation.
Check the power card.
ALARM 70, Illegal FC configuration
The control card and power card are incompatible. Contact your supplier with the type code of the unit from the nameplate and the part numbers of the cards to check compatibility.
ALARM 71, PTC 1 safe stop
Safe Stop has been activated from the MCB 112 PTC
Thermistor Card (motor too warm). Normal operation can be resumed when the MCB 112 applies 24V DC to T-37 again (when the motor temperature reaches an acceptable level) and when the Digital Input from the MCB 112 is deactivated. When that happens, a reset signal must be is be sent (via Bus, Digital I/O, or by pressing [RESET]).
ALARM 72, Dangerous failure
Safe Stop with Trip Lock. The Dangerous Failure Alarm is issued if the combination of safe stop commands is unexpected. This is the case if the MCB 112 VLT PTC
Thermistor Card enables X44/10 but safe stop is somehow not enabled. Furthermore, if the MCB 112 is the only device using safe stop (specified through selection [4] or
[5] in 5-19 Terminal 37 Safe Stop), an unexpected combination is activation of safe stop without the X44/10 being activated. The following table summarizes the unexpected combinations that lead to Alarm 72. Note that if X44/10 is activated in selection 2 or 3, this signal is ignored! However, the MCB 112 will still be able to activate
Safe Stop.
ALARM 80, Drive initialised to default value
Parameter settings are initialised to default settings after a manual reset. Reset the unit to clear the alarm.
MG11BB02 - VLT
®
is a registered Danfoss trademark
General Specifications and ...
VLT
®
HVAC Drive Design Guide
ALARM 92, No flow
A no-flow condition has been detected in the system.
22-23 No-Flow Function is set for alarm. Troubleshoot the system and reset the frequency converter after the fault has been cleared.
ALARM 93, Dry pump
A no-flow condition in the system with the frequency converter operating at high speed may indicate a dry pump. 22-26 Dry Pump Function is set for alarm.
Troubleshoot the system and reset the frequency converter after the fault has been cleared.
ALARM 94, End of curve
Feedback is lower than the set point. This may indicate leakage in the system. 22-50 End of Curve Function is set for alarm. Troubleshoot the system and reset the frequency converter after the fault has been cleared.
ALARM 95, Broken belt
Torque is below the torque level set for no load, indicating a broken belt. 22-60 Broken Belt Function is set for alarm.
Troubleshoot the system and reset the frequency converter after the fault has been cleared.
ALARM 96, Start delayed
Motor start 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 fault has been cleared.
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 fault has been cleared.
WARNING 98, Clock fault
Time is not set or the RTC clock has failed. Reset the clock in 0-70 Date and Time.
WARNING 200, Fire mode
This indicates the frequency converter is operating in fire mode. The warning clears when fire mode is removed. See the fire mode data in the alarm log.
WARNING 201, Fire mode was active
This indicates the frequency converter had entered fire mode. Cycle power to the unit to remove the warning. See the fire mode data in the alarm log.
WARNING 202, Fire mode limits exceeded
While operating in fire mode one or more alarm conditions have been ignored which would normally trip the unit.
Operating in this condition voids unit warranty. Cycle power to the unit to remove the warning. See the fire mode data in the alarm log.
WARNING 203, Missing motor
With a frequency converter operating multi-motors, an under-load condition was detected. This could indicate a missing motor. Inspect the system for proper operation.
WARNING 204, Locked rotor
With a frequency converter operating multi-motors, an overload condition was detected. This could indicate a locked rotor. Inspect the motor for proper operation.
WARNING 250, New spare part
A component in the frequency converter has been replaced. Reset the frequency converter for normal operation.
WARNING 251, New typecode
The power card or other components have been replaced and the typecode changed. Reset to remove the warning and resume normal operation.
8 8
MG11BB02 - VLT
®
is a registered Danfoss trademark 181
Index
VLT
®
HVAC Drive Design Guide
Index
................................................................................................................ 45
Abbreviations...................................................................................... 6
AMA.................................................................................................... 118
AWG.................................................................................................... 142
BACnet................................................................................................. 72
Braking.............................................................................................. 178
Caution................................................................................................ 10
Coasting.............................................................................. 140, 7, 139
Cooling.............................................................................................. 168
Dampers.............................................................................................. 23
Definitions............................................................................................. 7
Derating............................................................................................ 176
DeviceNet........................................................................................... 72
Earthing............................................................................................. 116
Efficiency........................................................................................... 162
ETR...................................................................................................... 109
Feedback................................................................................. 179, 181
Fuses........................................................................................... 178, 95
IGVs....................................................................................................... 23
Jog.................................................................................................. 7, 139
LCP....................................................................................................... 7, 8
Lifting................................................................................................... 87
Literature............................................................................................... 5
NAMUR................................................................................................ 60
PLC...................................................................................................... 116
Profibus................................................................................................ 72
Programming.................................................................................. 176
Protection.................................................................................... 12, 45
RCD.......................................................................................................... 9
Reset......................................................................................... 176, 180
Screened/armoured..................................................................... 103
Screened/armoured........................................................................ 91
Soft-starter.......................................................................................... 20
Start/Stop......................................................................................... 117
Surroundings:................................................................................. 160
Symbols.................................................................................................. 6
Thermistor................................................................................... 177, 9
Troubleshooting................................................................... 176, 169
VAV........................................................................................................ 23
Vibrations............................................................................................ 25
VVCplus.................................................................................................. 9
A
Abbreviations........................................................................................... 6
Accessory Bags...................................................................................... 85
Acoustic Noise..................................................................................... 162
Aggressive Environments.................................................................. 12
Air Humidity........................................................................................... 12
Alarm Words........................................................................................ 173
Alarm/Warning Code List................................................................ 171
Alarms And Warnings....................................................................... 169
Aluminium Conductors...................................................................... 92
AMA........................................................................................................ 118
Analog
I/O Option MCB 109........................................................................ 55
I/O Selection...................................................................................... 55
Inputs.............................................................................. 7, 176, 8, 159
Output............................................................................................... 159
Outputs - Terminal X30/5+8........................................................ 52
Voltage Inputs - Terminal X30/10-12........................................ 52
Application Examples......................................................................... 22
Automatic
Adaptations To Ensure Performance..................................... 167
Motor Adaptation.......................................................................... 118
Motor Adaptation (AMA)............................................................ 105
AWG........................................................................................................ 142
B
BACnet...................................................................................................... 72
Balancing Contractor.......................................................................... 28
Basic Wiring Example....................................................................... 102
Battery Back-up Of Clock Function................................................ 55
Better Control........................................................................................ 20
Brake
Function.............................................................................................. 48
Power............................................................................................... 8, 48
Resistor................................................................................................ 46
Resistor Cabling................................................................................ 48
Resistor Calculation......................................................................... 47
Resistor Temperature Switch.................................................... 108
Resistors....................................................................................... 61, 80
Braking................................................................................................... 178
Branch Circuit Protection................................................................... 95
Break-away Torque................................................................................. 7
Building
Management System..................................................................... 56
Management System, BMS........................................................... 19
Bypass Frequency Ranges................................................................. 25
C
Cable
Clamp................................................................................................. 116
Clamps............................................................................................... 113
Length And Cross-section............................................................. 92
Lengths And Cross Sections...................................................... 158
Caution..................................................................................................... 10
CAV System............................................................................................. 24
CE Conformity And Labelling........................................................... 11
Central VAV Systems........................................................................... 23
Clockwise Rotation............................................................................ 110
Closed Loop Control For A Ventilation System......................... 37
CO2 Sensor.............................................................................................. 24
Coasting................................................................................... 140, 7, 139
Communication Option................................................................... 178
Comparison Of Energy Savings....................................................... 19
182 MG11BB02 - VLT
®
is a registered Danfoss trademark
Index
VLT
®
HVAC Drive Design Guide
Condenser Pumps................................................................................ 27
Conducted Emission........................................................................... 41
Constant
Air Volume.......................................................................................... 24
Torque Applications (CT Mode)............................................... 168
Control
Cable Terminals.............................................................................. 101
Cables............................................................... 113, 91, 103, 90, 103
Card Performance......................................................................... 161
Card, 10 V DC Output................................................................... 160
Card, 24 V DC Output................................................................... 160
Card, RS-485 Serial Communication:...................................... 159
Card, USB Serial Communication............................................. 161
Characteristics................................................................................ 160
Potential.............................................................................................. 30
Structure Closed Loop.................................................................... 33
Structure Open Loop...................................................................... 31
Terminals.......................................................................................... 101
Word................................................................................................... 138
Cooling
Cooling.............................................................................................. 168
Conditions.......................................................................................... 86
Tower Fan........................................................................................... 25
Copyright, Limitation Of Liability And Revision Rights............. 5
Cos Φ Compensation.......................................................................... 20
Current Rating..................................................................................... 176
Earthing
Earthing............................................................................................. 116
Of Screened/Armoured Control Cables................................ 116
Efficiency............................................................................................... 162
Electrical
Installation......................................................................... 90, 92, 103
Installation - EMC Precautions.................................................. 113
Terminals............................................................................................. 13
EMC
Directive 2004/108/EC................................................................... 12
Precautions...................................................................................... 125
Test Results......................................................................................... 41
Emission Requirements...................................................................... 40
Enclosure Knock-outs......................................................................... 92
Energy Savings............................................................................... 20, 18
Equalising Cable,................................................................................ 116
ETR........................................................................................................... 109
Evaporator Flow Rate.......................................................................... 28
Example Of Closed Loop PID Control............................................ 37
Extended
Status Word..................................................................................... 175
Status Word 2.................................................................................. 175
External
24V DC Supply................................................................................... 55
Fan Supply....................................................................................... 108
Extreme Running Conditions........................................................... 48
D
Dampers................................................................................................... 23
Data Types Supported By The Frequency Converter............ 130
DC
Brake................................................................................................... 139
Link..................................................................................................... 176
Definitions................................................................................................. 7
Derating
Derating............................................................................................ 176
For Ambient Temperature......................................................... 167
For Low Air Pressure..................................................................... 167
For Running At Low Speed........................................................ 168
DeviceNet................................................................................................ 72
Differential Pressure............................................................................ 30
Digital
Input................................................................................................... 177
Inputs - Terminal X30/1-4............................................................. 52
Inputs:................................................................................................ 158
Output............................................................................................... 159
Outputs - Terminal X30/5-7.......................................................... 52
Direction Of Motor Rotation.......................................................... 110
Disposal Instruction............................................................................. 11
Drive Configurator............................................................................... 66
DU/dt Filters........................................................................................... 65
E
Earth Leakage Current...................................................................... 113
F
Fan System Controlled By Frequency Converters.................... 21
Fault Messages.................................................................................... 176
FC
Profile................................................................................................. 138
With Modbus RTU......................................................................... 125
Feedback..................................................................................... 179, 181
Field Mounting...................................................................................... 88
Final Set-Up And Test....................................................................... 105
Flow Meter.............................................................................................. 28
Frame Size F Panel Options.............................................................. 60
Freeze Output.......................................................................................... 7
Frequency
Converter Hardware Setup........................................................ 124
Converter Set-up........................................................................... 126
Converter With Modbus RTU.................................................... 131
Function Codes Supported By Modbus RTU............................ 134
Fuse Tables............................................................................................. 98
Fuses................................................................................................ 178, 95
G
General
Aspects Of EMC Emissions............................................................ 39
Aspects Of Harmonics Emission................................................. 42
Specifications.................................................................................. 158
MG11BB02 - VLT
®
is a registered Danfoss trademark 183
Index
VLT
®
HVAC Drive Design Guide
I
Gland/Conduit Entry - IP21 (NEMA 1) And IP54 (NEMA12)... 93
H
Harmonic Filters.................................................................................... 73
Harmonics
Emission Requirements................................................................. 42
Test Results (Emission)................................................................... 42
High
Power Series Mains And Motor Connections........................ 89
Voltage Test..................................................................................... 112
Hold Output Frequency................................................................... 139
How
To Connect A PC To The Frequency Converter.................. 111
To Control The Frequency Converter..................................... 134
I/Os For Set Point Inputs.................................................................... 56
IEC Emergency Stop With Pilz Safety Relay................................. 60
IGVs............................................................................................................ 23
Immunity Requirements.................................................................... 43
Index (IND)............................................................................................ 129
Input Terminals................................................................................... 176
Installation At High Altitudes........................................................... 10
Insulation Resistance Monitor (IRM).............................................. 60
Intermediate Circuit.......................................................... 48, 162, 163
IP 21/Type 1 Enclosure Kit................................................................. 63
IP21/IP41/ TYPE 1 Enclosure Kit....................................................... 62
Manual
Motor Starters................................................................................... 61
PID Adjustment................................................................................ 39
MCB 105 Option.................................................................................... 53
MCT 31................................................................................................... 112
Mechanical
Dimensions................................................................................. 84, 82
Dimensions - High Power............................................................. 83
Mounting............................................................................................ 86
Modbus
Communication............................................................................. 125
Exception Codes............................................................................ 135
Moment Of Inertia................................................................................ 48
Motor
Bearing Currents............................................................................ 110
Cables......................................................................................... 113, 91
Current..................................................................................... 176, 180
Data........................................................................................... 177, 180
Name Plate....................................................................................... 105
Name Plate Data............................................................................ 105
Output............................................................................................... 158
Parameters....................................................................................... 118
Phases.................................................................................................. 48
Power................................................................................................. 180
Protection............................................................................... 109, 162
Rotation............................................................................................ 110
Thermal Protection....................................................... 141, 49, 110
Voltage.............................................................................................. 163
Motor-generated Over-voltage....................................................... 48
Multiple Pumps..................................................................................... 30
Multi-zone Control............................................................................... 55
J
Jog....................................................................................................... 7, 139
L
Laws Of Proportionality...................................................................... 18
LCP........................................................................................................... 7, 8
Lead Pump Alternation Wiring Diagram................................... 122
Lifting........................................................................................................ 87
Literature.................................................................................................... 5
Load Drive Settings........................................................................... 112
Local
(Hand On) And Remote (Auto On) Control............................. 32
Speed Determination..................................................................... 28
Low Evaporator Temperature.......................................................... 28
M
Mains
Disconnectors................................................................................. 107
Drop-out.............................................................................................. 49
Supply........................................................................ 9, 142, 146, 152
Supply 3 X 525-690V AC.............................................................. 153
N
Name Plate Data................................................................................. 105
NAMUR..................................................................................................... 60
Network Connection......................................................................... 124
Ni1000 Temperature Sensor............................................................. 56
Non-UL Fuses 200V To 480V............................................................. 96
O
Options And Accessories................................................................... 51
Ordering
Numbers.............................................................................................. 66
Numbers: DU/dt Filters, 380-480V AC...................................... 79
Numbers: DU/dt Filters, 525-600/690V AC............................. 80
Numbers: Harmonic Filters........................................................... 73
Numbers: High Power Kits............................................................ 73
Numbers: Options And Accessories.......................................... 71
Numbers: Sine Wave Filter Modules, 200-500 VAC............. 77
Numbers: Sine-Wave Filter Modules, 525-600/690 VAC.... 78
Output
Current.............................................................................................. 176
Filters.................................................................................................... 65
Performance (U, V, W).................................................................. 158
Outputs For Actuators........................................................................ 56
184 MG11BB02 - VLT
®
is a registered Danfoss trademark
Index
VLT
®
HVAC Drive Design Guide
P
Parallel Connection Of Motors...................................................... 109
Parameter
Number (PNU)................................................................................ 129
Values................................................................................................. 135
Pay Back Period..................................................................................... 20
PC Software Tools.............................................................................. 111
PC-based Configuration Tool MCT 10 Set-up Software....... 111
Peak Voltage On Motor.................................................................... 163
PELV - Protective Extra Low Voltage.............................................. 45
PLC........................................................................................................... 116
Potentiometer Reference................................................................ 118
Power
Factor...................................................................................................... 9
Factor Correction............................................................................. 20
Primary Pumps...................................................................................... 28
Principle Diagram................................................................................. 56
Profibus
Profibus................................................................................................ 72
DP-V1................................................................................................. 112
Programmable Minimum Frequency Setting............................ 25
Programming
Programming.................................................................................. 176
Order..................................................................................................... 38
Protection
Protection.................................................................................... 12, 45
And Features................................................................................... 162
Protocol Overview............................................................................. 125
Pt1000 Temperature Sensor............................................................. 56
Public Supply Network....................................................................... 42
Pulse
Inputs................................................................................................. 159
Start/Stop......................................................................................... 117
Pump Impeller....................................................................................... 27
R
Radiated Emission................................................................................ 41
Rated Motor Speed................................................................................ 7
RCD
RCD.......................................................................................................... 9
(Residual Current Device)............................................................. 60
Read Holding Registers (03 HEX).................................................. 137
Real-time Clock (RTC).......................................................................... 57
Reference Handling............................................................................. 36
Relay
Option MCB 105............................................................................... 53
Output............................................................................................... 108
Outputs............................................................................................. 160
Removal Of Knockouts For Extra Cables...................................... 93
Reset.............................................................................................. 176, 180
Residual Current Device.................................................................. 116
Return Fan............................................................................................... 23
Rise Time............................................................................................... 163
RS-485 Bus Connection.................................................................... 111
S
Safe
Stop....................................................................................................... 13
Stop Installation............................................................................... 16
Safety
Category 3 (EN 954-1)..................................................................... 17
Earth Connection........................................................................... 112
Note...................................................................................................... 10
Regulations........................................................................................ 10
Requirements Of Mechanical Installation............................... 88
Save Drive Settings............................................................................ 112
Screened/armoured.......................................................................... 103
Screened/armoured............................................................................ 91
Screening Of Cables............................................................................ 92
Secondary Pumps................................................................................. 30
Serial
Communication.................................................................... 116, 161
Communication Port......................................................................... 7
Set Speed Limit And Ramp Time.................................................. 105
Short Circuit (Motor Phase – Phase).............................................. 48
Sine-wave Filters................................................................................... 65
Smart
Logic Control................................................................................... 118
Logic Control Programming...................................................... 118
Soft-starter.............................................................................................. 20
Software
Version.................................................................................................... 5
Versions............................................................................................... 72
Space Heaters And Thermostat....................................................... 60
Star/Delta Starter.................................................................................. 20
Start/Stop
Start/Stop......................................................................................... 117
Conditions........................................................................................ 123
Static Overload In VVCplus Mode................................................... 49
Status Word.......................................................................................... 140
Stopping Category 0 (EN 60204-1)................................................. 17
Successful AMA................................................................................... 105
Supply Voltage.................................................................................... 178
Surroundings:...................................................................................... 160
Switches S201, S202, And S801..................................................... 104
Switching
Frequency................................................................................. 176, 92
On The Output.................................................................................. 48
Symbols...................................................................................................... 6
System Status And Operation....................................................... 121
MG11BB02 - VLT
®
is a registered Danfoss trademark 185
Index
VLT
®
HVAC Drive Design Guide
T
Telegram Length (LGE).................................................................... 127
The
Clear Advantage - Energy Savings............................................. 17
EMC Directive (2004/108/EC)....................................................... 11
Low-voltage Directive (2006/95/EC)......................................... 11
Machinery Directive (2006/42/EC)............................................. 11
Thermistor........................................................................................ 177, 9
Throttling Valve..................................................................................... 27
Tightening Of Terminals.................................................................... 89
Torque Characteristics..................................................................... 158
Transmitter/sensor Inputs................................................................. 56
Troubleshooting....................................................................... 176, 169
Tuning The Drive Closed Loop Controller................................... 38
Type
Code String High Power................................................................ 68
Code String Low And Medium Power...................................... 67
U
UL Fuses, 200-240V.............................................................................. 97
Unsuccessful AMA............................................................................. 105
USB Connection.................................................................................. 101
Use Of EMC-Correct Cables............................................................ 114
V
Variable
(Quadratic) Torque Applications (VT)..................................... 168
Air Volume.......................................................................................... 23
Control Of Flow And Pressure..................................................... 20
Varying Flow Over 1 Year................................................................... 20
VAV............................................................................................................ 23
Vibration And Shock............................................................................ 13
Vibrations................................................................................................ 25
Voltage Level....................................................................................... 158
VVCplus....................................................................................................... 9
W
Warning
Against Unintended Start............................................................. 10
Words................................................................................................. 174
What
Is CE Conformity And Labelling?................................................ 11
Is Covered........................................................................................... 11
186 MG11BB02 - VLT
®
is a registered Danfoss trademark
www.danfoss.com/drives
130R0084 MG11BB02
*MG11BB02*
Rev. 2011-08-19
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