Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® HVAC Drive FC 102 110-1400 kW www.danfoss.com/drives...
Page 3: Table Of Contents
2.7.13 Variable Air Volume 2.7.14 The VLT Solution 2.7.15 Constant Air Volume 2.7.16 The VLT Solution 2.7.17 Cooling Tower Fan 2.7.18 The VLT 2.7.19 Condenser Pumps 2.7.20 The VLT Solution 2.7.21 Primary Pumps MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 4 3.1.1 General Purpose Input Output Module MCB 101 3.1.2 Digital Inputs - Terminal X30/1-4 3.1.3 Analog Voltage Inputs - Terminal X30/10-12 3.1.4 Digital Outputs - Terminal X30/5-7 3.1.5 Analog Outputs - Terminal X30/5+8 3.1.6 Relay Option MCB 105 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 5 5.1.4 Pedestal Installation of D-frames 5.1.5 Pedestal Installation of F-frames 5.1.6 Lifting 5.1.7 Safety Requirements of Mechanical Installation 5.2 Electrical Installation 5.2.1 Cables General 5.2.2 Motor Cables 5.2.3 Electrical Installation of Motor Cables MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 6 5.7.1 Electrical Installation - EMC Precautions 5.7.2 Use of EMC-Correct Cables 5.8 Residual Current Device 6 Application Examples 6.1.1 Start/Stop 6.1.2 Pulse Start/Stop 6.1.3 Potentiometer Reference 6.1.4 Automatic Motor Adaptation (AMA) 6.1.5 Smart Logic Control Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 7 7.5.1 Writing a Parameter Value 7.5.2 Reading a Parameter Value 7.6 Modbus RTU Overview 7.6.1 Assumptions 7.6.2 Prerequisite Knowledge 7.6.3 Modbus RTU Overview 7.6.4 Frequency Converter with Modbus RTU 7.7 Network Configuration MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 8 8.1.2 Mains Supply 3x525-690 V AC 8.1.3 12-Pulse Specifications 8.2 Efficiency 8.3 Acoustic Noise 8.4 Peak Voltage on Motor 8.5 Special Conditions 8.5.1 Purpose of Derating 8.5.2 Derating for Ambient Temperature Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 9 8.5.4 Derating for Low Air Pressure 8.5.5 Derating for Running at Low Speed 8.6 Troubleshooting 8.6.1 Alarm Words 8.6.2 Warning Words 8.6.3 Extended Status Words 8.6.4 Warning and Alarm Introduction Index MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 10: How To Read This Design Guide
How to Read this Design Gui... Design Guide 1 How to Read this Design Guide 1.1 How to Read This Design Guide Danfoss reserves the right to revise this publication at any time and to change its contents without prior notice or ® HVAC Drive any obligation to notify former or present users of such revisions or changes.
Page 11 Rated Inverter Output Current Revolutions Per Minute The rated motor speed (nameplate data). Regenerative terminals Regen Second sec. The rated motor power (nameplate data). Synchronous Motor Speed Torque limit The rated torque (motor). MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 12 GLCP Pulse Reference Graphical local control panel (LCP102) A pulse frequency signal transmitted to the digital inputs ® (terminal 29 or 33). Hiperface ® Hiperface is a registered trademark by Stegmann. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 13 Modulation (See 14-00 Switching Pattern). The power factor is the relation between I and I 3 × U × I 1 × COS ϕ Power factor = 3 × U × IRMS MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 14 In addition, a high power factor indicates that the different harmonic currents are low. The built-in DC coils produce a high power factor, which minimizes the imposed load on the mains supply. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 15: Introduction
525-690 450-1200 High voltage can be present even when the warning LED • Follow the procedures in these Operating indicator lights are off. Instructions. Table 2.1 Discharge Time MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 16: Ce Labelling
50–1000 V AC and the 75–1500 V DC voltage properly closed. ranges. Danfoss CE-labels in accordance with the directive • and issues a declaration of conformity upon request.
Page 17: Danfoss Frequency Converter And Ce Labelling
NOTICE with the installer. As an aid to the installer, Danfoss has prepared EMC installation guidelines for the power drive Mounting frequency converters in aggressive system. Following EMC-correct installation instructions...
Page 18: Vibration And Shock
D and E enclosures have a stainless steel back-channel option to provide more protection in aggressive environments. Proper ventilation is still required for the SYSTEM CURVE internal components of the drive. Contact Danfoss for more information. 2.5 Vibration and Shock FAN CURVE...
Page 19: Example Of Energy Savings
40% reduction but are expensive to install. The Danfoss frequency converter solution reduces energy Flow ~n consumption by more than 50% and is easy to install. Pressure ~n Power ~n 12,5% 100% Illustration 2.3 Laws of Proportionality MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 20: Example With Varying Flow Over One Year
38.5 50,589 29.0 38,106 1752 35.0 61,320 18.5 32,412 1752 31.5 55,188 11.5 20,148 1752 28.0 49,056 11,388 1752 23.0 40,296 6,132 Σ 8760 275,064 26,801 Table 2.4 Energy Savings Calculation Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 21: Better Control
φ of the motor, which means there is no need to make allowance for the cos φ of the motor when sizing the power factor correction unit. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 22: Saves Money
Power P.F.C P.F.C signal Factor 0/10V Correction Mains Mains Mains Direct Digital Control Variable Air Volume Sensor P Pressure Energy Management System Sensor T Temperature Illustration 2.8 Traditional Fan System Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 23: With A Frequency Converter
0-10V 0/4-20mA Control Control temperature temperature 0-10V 0-10V 0/4-20mA 0/4-20mA Mains Mains Mains Direct Digital Control Variable Air Volume Building Management System Illustration 2.9 Fan System Controlled by Frequency Converters MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 24: Application Examples
Design Guide 2.7.12 Application Examples The next few pages give typical examples of applications within HVAC. For further information about a given application, consult the Danfoss supplier for an application note that gives a full description of the application. •...
Page 25: Constant Air Volume
Decreasing the air flow, reduces the energy used to heat or cool the fresh air, resulting in further savings. Several features of the Danfoss HVAC dedicated frequency converter can be used to improve the performance of a 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.
Page 26: Cooling Tower Fan
The frequency converters can also be used to turn the fan on and off as needed. With the Danfoss HVAC frequency converter, as the cooling tower fans drop below a certain speed, the cooling effect decreases. When using a gear-box to frequency control the tower fan, a minimum speed of 40–50% could be required.
Page 27 Introduction Design Guide Frequency converter Water Inlet Temperature Sensor BASIN Water Outlet Conderser Water pump Supply Illustration 2.12 Frequency Converters Used with a Cooling Tower Fan MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 28: Condenser Pumps
Frequency converter Water Inlet Flow or pressure sensor BASIN Water Outlet Throttling valve Condenser Water pump Supply Illustration 2.13 Frequency Converter used with a Condenser Pump Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 29: Primary Pumps
If the flow rate must be increased later in the life of the system, the frequency converter can simply increase the pump speed instead of requiring a new pump impeller. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 30: Danfoss A/S © Rev. 05/2014 All Rights Reserved
Introduction Design Guide Flowmeter Flowmeter Frequency converter Frequency converter Illustration 2.14 Frequency Converters used with Primary Pumps in a Primary/Secondary Pump System Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 31: Secondary Pumps
When running multiple pumps in parallel, they must run at the same speed to increase energy savings, either with individual dedicated frequency converters, or one frequency converter running multiple pumps in parallel. Frequency converter Frequency converter Illustration 2.15 Frequency Converters used with Secondary Pumps in a Primary/Secondary Pump System MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 32: Control Structures
Short circuit behaviour on this frequency converter depends on the 3 current transducers in the motor phases. In 1-00 Configuration Mode, it can be selected if using open or closed loop. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 33: Control Structure Open Loop
The maximum frequency limit curbs output from the motor control. 2.8.3 PM/EC+ Motor Control The Danfoss EC+ concept provides the possibility for using high efficiency PM motors in IEC standard frame size operated by Danfoss frequency converters.
Page 34: Local (Hand On) And Remote (Auto On) Control
Auto Auto Linked to Hand/ Remote Auto Auto -> Off Linked to Hand/ Remote Auto All keys Local Local All keys Remote Remote Table 2.5 Conditions for Local or Remote Reference Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 35: Control Structure Closed Loop
Average (1+2+3) P 20-03 Minimum (1|2|3) Maximum (1|2|3) Feedback conv. Feedback 3 Feedback 3 Source P 20-07 P 20-06 Feedback Function P 20-20 Illustration 2.21 Block Diagram of Feedback Signal Processing MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 36: Feedback Conversion
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 2.22. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 37: Reference Handling
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. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 38: Example Of Closed Loop Pid Control
50 (+10 V) 53 (input) 55 (common) Temperature feedback via transmitter (-10 to 40 °C, 4–20 mA) connected to terminal 54. Switch S202 behind the LCP set to ON (current input). Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 39: Programming Order
Adjust the closed loop controller, if needed. 20-93 See Optimization of the PID Controller, below. 20-94 8) Finished Save the parameter setting to the LCP 0-50 [1] All to LCP Table 2.6 Programming Order MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 40: Tuning The Closed Loop Controller
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. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 41 This type of power drive system is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected when used on such a network. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 42: Emc Emission Requirements
EN/IEC 61000-6-3 Emission standard for residential, commercial Class B (home and office) and light industrial environments. Second environment EN/IEC 61000-6-4 Emission standard for industrial environments. Class A Group 1 (industrial environment) Table 2.8 Emission Requirements, Generic Standards Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 44: Harmonics Emission Requirements
They may be used as the basis for calculation of the influence harmonic currents have on the power supply system and for the documentation of compliance with relevant regional guidelines: IEEE 519 -1992; G5/4. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 45: Immunity Requirements
All Danfoss frequency converters comply with the requirements for the industrial environment and consequently comply with the lower requirements for home and office environment with a large safety margin.
Page 46: Galvanic Isolation (Pelv)
Internal inrush, RFI, and temperature measurement circuits Custom relays Functional Galvanic Isolation Functional Galvanic Isolation Illustration 2.27 Galvanic Isolation Motor cable length Illustration 2.28 Cable Length and Power Size Influence on Leakage Current. Pa > Pb Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 47: Brake Function
If the amount of kinetic energy transferred to the resistor in each braking period is not known, calculate the average power on the basis of the cycle time and braking time (intermittent duty cycle). The resistor intermittent duty MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 48: Brake Resistor Calculation
NOTICE The resistor brake circuit resistance selected should not Time be higher than that recommended by Danfoss. If a brake Illustration 2.32 Typical Braking Cycle resistor with a higher ohmic value is selected, the braking torque may not be achieved because the frequency converter may cut out for safety reasons.
Page 49: Brake Resistor Cabling
ETR cuts off and trips the frequency converter. The curves are showing the characteristic • Back-EMF (electromotive force) from PM motor operation. If coasted at high rpm, the PM motor MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 50 PTC / Thermistor <6.6 k Ω >10.8 k Ω techniques: PTC sensor in motor windings; mechanical Illustration 2.35 Digital Input and 24 V Power Supply thermal switch (Klixon type); or (ETR). Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 51 < 3.0 kΩ - > 3.0 kΩ Table 2.15 Threshold Cut-out Values by Input and Voltage NOTICE Check that the chosen supply voltage follows the specifi- cation of the thermistor element used. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 52: Selection
Galvanic isolation in the MCB 101 Digital/analog inputs are galvanically isolated from other Danfoss offers a wide range of options and accessories. inputs/outputs on the MCB 101 and in the control card of the frequency converter. Digital/analog outputs in the MCB 3.1.1 General Purpose Input Output...
Page 53: Digital Inputs - Terminal X30/1-4
Parameters for set-up: 6-6* and 16-77 Number of analog outputs Output signal level Tolerance Max. Impedance < 500 Ω 0/4 - 20 mA ± 0.1 mA Table 3.4 Analog Outputs - Terminal X30/5+8 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 54: Relay Option Mcb
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. Illustration 3.4 Correct Installation Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 55: Back-Up Option Mcb 107 (Option D)
When MCB 107, 24 V backup option is supplying the control circuit, the internal 24 V supply is automatically disconnected. Illustration 3.7 Connection to 24 V Backup Supplier (A5-C2). Illustration 3.6 Connection to 24 V Backup Supplier (A2-A3). MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 56: Analog I/O Option Mcb
510 Ω resistor across terminals length to connect sensors is 80 m non-screened / non- twisted wires. • Ni 1000 temperature sensor of 1000 Ω at 0 °C. Specifications according to DIN43760 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 57: Vlt ® Ptc Thermistor Card Mcb
≤ 2.5 V for R ≤ 3.65 Ω, ≤ 9 V for R = ∞ Terminal voltage ≤ 1 mA Sensor current 20 Ω ≤ R ≤ 40 Ω Short circuit Power consumption 60 mA MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 58 10 ... 1000Hz 1.14 g Shock resistance 50 g Safety system values EN 61508:2010 for Tu = 75 °C ongoing ® Refer to VLT Frequency Converters Safe Torque Off Operating Instructions for safety system values. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 59: Vlt ® Sensor Input Option Mcb
Typical motors, designed with temperature sensors to protect 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.
Page 60: D-Frame Options
Cover (Left) and without Cover (Right) An optional heat sink access panel is available to facilitate cleaning of the heat sink. Debris buildup is typical in environments prone to airborne contaminants, such as the textile industry. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 61: Mains Disconnect
400 V 441 V-490 V 460 V 491 V-550 V 525 V 551 V-625 V 575 V 626 V-660 V 660 V 661 V-690 V 690 V Table 3.11 Transformer Tap Setup MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 62: Remote Mounting Kit For Lcp
An resistor is selected based on its ohmic value, its power SPDT alarm relay for external use is associate with each dissipation rate and its physical size. Danfoss offers a wide setpoint. variety of different resistors that are specifically designed NOTICE for Danfoss frequency converters.
Page 63: Output Filters
The length is limited because the filter does not reduce Illustration 3.12 LCP Kit with Numerical LCP, Fasteners and leakage currents in the cables. Gasket Ordering no. 130B1114 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 64: How To Order
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. The type code is a string of characters describing the configuration, for example:...
Page 66 X: Standard cable entries Q: Heatsink access panel Adaptation X: No adaptation Software release 24–27 Actual software Software language 1): Available for all D frames. Table 4.2 Ordering Type Code for D-frame Frequency Converters Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 67 DX: No option D0: DC backup 1) Available for all E frames 380-480/500 V AC only 2) Consult factory for applications requiring maritime certification Table 4.3 Ordering Type Code for E-Frame Frequency Converters MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 68 N: IEC Emergency stop push button with brake IGBT and brake terminals P: IEC Emergency stop push button with regeneration terminals Display G: Graphical Local Control Panel LCP Coating PCB C: Coated PCB Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 69 5: MCO 102 Advanced Cascade Control C option software 36–37 XX: Standard software D options 38–39 DX: No option D0: DC backup Table 4.4 Ordering Type Code for F-Frame Frequency Converters MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 70: Ordering Numbers
24 V DC back-up 130B1208 External options Ethernet IP Ethernet master Table 4.6 A, B, D Slot & External Options For information on fieldbus and application option compatibility with older software versions, contact your Danfoss supplier. Type Description Spare parts Ordering no. Comments...
Page 71: Advanced Harmonic Filters
1440 P800 1422 5556 4626 <80 3x1301261 3x130B1228 2x130B1449+2x130B1469 2x130B1389+2x130B1391 1720 1000 P1000 1675 6724 5434 <80 2x130B1260+2x130B1261 2x130B1217+2x130B1228 Table 4.9 Advanced Harmonic Filters 380-415 V, 50 Hz, E- and F-frames MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 72 3x130B3094 1440 P800 1422 5556 4626 <80 3x130B2873 3x130B2856 2x130B3134+2x130B3135 2x130B3093+2x130B3094 1722 P1M0 1675 6724 5434 <80 2x130B2872+2x130B2873 2x130B2855+2x130B2856 Table 4.11 Advanced Harmonic Filters, 380-415 V, 60 Hz, E- and F-frames Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 73 P800 1344 5556 4626 <80 3x130B1769 3x130B1751 2x130B2257+2x130B2259 2x130B17852x130B1785 1582 1350 P1M0 1490 6516 5988 <80 2x130B1768+2x130B1768 +2x130B1786 2x130B1499+2x130B1751 Table 4.13 Advanced Harmonic Filters, 440-480 V, 60 Hz, E- and F-frames MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 74 P900 6040 4626 4x130B5259 3x130B5227 4x130B5275 3x130B5244 1098 1150 P1M0 1032 7408 4626 4x130B5260 3x130B5227 4x130B5244 1580 1350 P1M2 1227 6168 4x130B5227 Table 4.15 Advanced Harmonic Filters, 600 V, 60 Hz Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 75 2x130B5197 130B5295 2x130B5042 130B5334 N355 381 2812 1852 130B5042 130B5330 +130B5066 +130B5331 N400 413 N400 395 2916 2127 130B5197 130B5292 +130B5198 +130B5293 Table 4.16 Advanced Harmonic Filters, 500-690 V, 50 Hz MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 76 P800 962 1000 P900 920 6516 4118 2x130B5199 2x130B5294 +2x130B5197 +130B5295 6x130B5042 3x130B5333 1098 P1M0 1079 P1M0 1032 8436 4626 6x130B5197 3x130B5295 Table 4.17 Advanced Harmonic Filters, 500-690 V, 50 Hz Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 77: Sine-Wave Filter Modules, 380-690 V Ac
F2/F4, F12/F13 3X130B3188 3X130B3189 1460 F2/F4, F12/F13 1200 1380 1000 1380 F2/F4, F12/F13 3X130B3191 3X130B3192 1000 1720 1350 1530 1100 1530 F2/F4, F12/F13 Table 4.18 Sine Wave Filter Modules, 380-500 V MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 78 Table 4.19 Sine Wave Filter Modules 525-690 V NOTICE When using sine-wave filters, ensure that the switching frequency complies with filter specifications in 14-01 Switching Frequency. See also Advanced Harmonic Filters Design Guide. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 79: Ordering Numbers: Du/Dt Filters
1000 1317 1350 1260 1200 1260 F2/F4, F12/F13 1100 1479 1550 1415 1400 1415 F2/F4, F12/F13 3x130B2853 3x130B2854 Table 4.20 dU/dt Filter Ordering Numbers NOTICE See also Output Filter Design Guide MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 80: Ordering Numbers: Brake Resistors
=Nominal resistance required to achieve 150% braking torque. br, nom 1) Larger frequency converters include multiple inverter modules with a brake chopper in each inverter. Connect equal resistors to each brake chopper. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 81: How To Install
100 mm. [0.9] [0.4] [0.4] [0.9] 1 Bottom mounting slot detail 2 Top mounting hole detail Illustration 5.2 Detail Dimensions, D1h MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 82 [0.4] [0.8] the required ceiling clearance is 100 mm. [0.5] [1.0] [0.4] [0.9] [0.3] 1 Top mounting hole detail 2 Bottom mounting slot detail Illustration 5.4 Detail Dimensions, D2h Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 83 [0.4] [0.8] the required ceiling clearance is 100 mm. [1.0] [0.9] [0.4] [0.3] 1 Top mounting hole detail 2 Bottom mounting slot detail Illustration 5.6 Detail Dimensions, D3h MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 84 [0.4] [0.6] the required ceiling clearance is 100 mm. [0.8] [0.9] [0.4] [0.3] 1 Top mounting hole detail 2 Bottom mounting slot detail Illustration 5.8 Detail Dimensions, D4h Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 85 [0.4] [0.6] the required ceiling clearance is 100 mm. [0.8] [0.9] [0.4] [0.3] 1 Top mounting hole detail 2 Bottom mounting slot detail Illustration 5.10 Detail Dimensions, D5h MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 86 63.5 the required ceiling clearance is 100 mm. [0.6] [0.3] [0.8] [1.0] [0.9] [0.4] 1 Top mounting hole detail 2 Bottom mounting slot detail Illustration 5.12 Detail Dimensions, D6h Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 87 If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, [0.4] [0.9] [1.0] the required ceiling clearance is 100 mm. Illustration 5.14 Top Mounting Hole Dimension Detail, D7h MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 88 If using a kit to direct the airflow from the heat sink to the outside vent on the back of the frequency converter, [1.0] [0.9] the required ceiling clearance is 100 mm. [0.4] Illustration 5.16 Top Mounting Hole Dimension Detail, D8h Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 89 1043 41.1 2000 (78.74) 1551 61.1 28.6 SIDE CABLE ENTRY KNOCK-OFF PLATE CABLE BASE BOTTOM CABLE ENTRY 15.4 (23.62) 19.4 21.2 Ø 25 Lifting eye detail Illustration 5.17 Mechanical Dimensions, E1 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 90 (8.9) 1043 (41.1) 1547 1502 1320 (60.9) (59.1) (52.0) (6.3) (10.6) (6.2) (8.9) (21.2) (23.0) (0.9) (1.0) (1.0) (1.0) (0.5) Lifting eye detail Rear mounting slots Illustration 5.18 Mechanical Dimensions, E2 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 91 How to Install Design Guide 1804 225.0 Ø29 (71.0) (8.85) (1.1) 2281 (89.8) 2206 (86.9) 1499 (59.0) (23.8) Minimum clearance from ceiling Illustration 5.19 Mechanical Dimensions, F2 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 92 How to Install Design Guide 225.0 2401 Ø29 (8.85) (94.5) (1.1) 2280 (89.7) 2205 (86.8) 1497 (58.9) (23.8) Minimum clearance from ceiling Illustration 5.20 Mechanical Dimensions, F4 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 93 Height 2000 1547 2204 2204 2204 2204 Drive dimensions Width 1400 1800 2000 2400 [mm] Depth Max weight [kg] 1017 1260 1318 1561 Table 5.3 Mechanical Dimensions, Frame Size E1-E2, F1-F4 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 94: Mechanical Dimensions, 12-Pulse Units
How to Install Design Guide 5.1.2 Mechanical Dimensions, 12-Pulse Units IP/21 NEMA 1 1400 m3/Hr 1970 m3/Hr 1160 Illustration 5.21 Mechanical Dimensions (mm), F8 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 99 [mm] Depth 1130 Height 2204 Drive dimensions Width 1400 1600 2200 2000 2600 [mm] Depth Max weight [kg] 1116 1037 1259 Table 5.4 Mechanical Dimensions, 12-Pulse Units, Frame Sizes F8-F13 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 100: Mechanical Mounting
Fasten 2 M5 screws through the back pedestal flange into the pedestal drive mounting bracket. Fasten 4 M5 screws through the front pedestal flange into the front gland plate mounting holes. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 101: Pedestal Installation Of F-Frames
2.5 cm (1 inch). The angle from bolts per cabinet. Refer to Illustration 5.30 the top of the drive to the lifting cable should be 60° or greater. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 102 How to Install Design Guide Illustration 5.32 Recommended Lifting Method, E-frame Size Illustration 5.31 Recommended Lifting Method, D-frame Size Illustration 5.33 Recommended Lifting Method, Frame Sizes F1, F2, F9 and F10 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 103: Safety Requirements Of Mechanical Installation
Illustration 5.34 Recommended Lifting Method, Frame Sizes F3, F4, F11, F12 and F13 5.1.8 Field Mounting IP 21/IP 4X top/TYPE 1 kits or IP 54/55 units are recommended. Illustration 5.35 Recommended Lifting Method, Frame Size F8 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 104: Electrical Installation
Keep the motor cable as short as possible to screening effects. reduce the noise level and leakage currents. • If it is necessary to split the screen to install a motor isolator or motor relay, the screen must be Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 105: Electrical Installation Of Motor Cables
Remove debris from the hole. terminal in the junction box. Mount the cable entry on the frequency converter. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 106: Gland/Conduit Entry - Ip21 (Nema 1) And Ip54 (Nema12)
Illustration 5.37 D2h, Bottom View [9.5] [4.8] [8.1] [1.7] 1 Mains side 2 Motor side [8.8] Illustration 5.36 D1h, Bottom View [4.4] 1 Mains side 2 Motor side Illustration 5.38 D5h & D6h, Bottom View Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 107 [1.398] 36.2 594.8 [1.425] [23.417] 1727.8 [68.024] 62.5 202.8 130.0 1 Cable conduit entry 98.6 Illustration 5.42 F2, Bottom View 1 Mains side 2 Motor side Illustration 5.40 E1, Bottom View MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 108: Gland/Conduit Entry, 12-Pulse - Ip21 (Nema 1) And Ip54 (Nema12)
35.5 (1.398) 597.0 (23.504) 36.2 1130.0 (44.488) Place conduits in shaded areas (1.425) 1191.8 (46.921) 2324.8 (91.528) Illustration 5.45 Frame Size F8 1 Cable conduit entry Illustration 5.44 F4, Bottom View Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 109 Illustration 5.46 Frame Size F9 593.0 70.0 [23.346] [2.756] 199.5 [7.854] 535.0 [21.063] 258.5 [10.177] 36.5 37.2 [1.437] [1.466] 733.0 [28.858] 800.0 [31.496] 1533.0 [60.354] Place conduits in shaded areas Illustration 5.47 Frame Size F10 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 110 [39.146] 593.0 70.0 [23.346] [2.756] 199.5 [7.854] 535.0 [21.063] 258.5 [10.177] 36.5 37.2 [1.437] 733.0 [1.466] [28.858] 800.0 [32] 1933.0 [76] Place conduits in shaded areas Illustration 5.49 Frame Size F12 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 111: Power Connections
Make the screen connections with the largest possible surface area (cable clamp) by using the installation devices within the frequency converter. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 112 In motors without phase insulation, paper or other insulation reinforcement suitable for operation with voltage supply, fit a sine-wave filter on the output of the frequency converter. Motor Motor Illustration 5.52 Motor Cable Connection Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 113 14 Motor output terminals 96 (U), 97 (V), 98 (W) Analog switches (A53), (A54) 15 Mains input terminals 91 (L1), 92 (L2), 93 (L3) Relay 1 (01, 02, 03) Table 5.8 Legend to Illustration 5.53 and Illustration 5.54 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 114 Terminal Locations - D1h/D2h Take the following position of the terminals into consideration when designing the cable access. Illustration 5.55 Position of Ground Terminals IP21 (NEMA Type 1) and IP54 (NEMA Type 12), D1h/D2h Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 115 Take the following position of the terminals into consideration when designing the cable access. Illustration 5.56 Position of Ground Terminals IP20 (Chassis), D3h/D4h Ground Terminals Table 5.9 Legend to Illustration 5.55 and Illustration 5.56 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 116 Take the following position of the terminals into consideration when designing the cable access. 9 [ ] 0 [ ] Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.57 Terminal Locations, D5h with Disconnect Option Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 117 How to Install Design Guide 28.6 24.5 20.4 20.1 0 [ ] Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.58 Terminal Locations, D5h with Brake Option MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 118 Take the following position of the terminals into consideration when designing the cable access. 18.0 Mains Terminals Motor Terminals TB6 Terminal block for contactor Ground Terminals Brake Terminals Illustration 5.59 Terminal Locations, D6h with Contactor Option Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 119 How to Install Design Guide Brake Terminals Ground Terminals TB6 Terminal block for contactor Mains Terminals Motor Terminals Illustration 5.60 Terminal Locations, D6h with Contactor and Disconnect Options MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 120 How to Install Design Guide 18.4 Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.61 Terminal Locations, D6h with Circuit Breaker Option Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 121 Take the following position of the terminals into consideration when designing the cable access. 21.4 20.3 16.2 15.6 14.7 0 [ ] Mains Terminals Ground Terminals Motor Terminals Brake Terminals Illustration 5.62 Terminal Locations, D7h with Disconnect Option MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 122 Design Guide 1260 49.6 1202 47.3 1082 42.6 1034 40.7 1009 39.7 0 [ ] Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.63 Terminal Locations, D7h with Brake Option Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 123 Take the following position of the terminals into consideration when designing the cable access. 35.3 20.5 16.5 15.8 14.9 0 [ ] TB6 Terminal block for contactor Brake Terminals Motor Terminals Mains Terminals Ground Terminals Illustration 5.64 Terminal Locations, D8h with Contactor Option MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 124 How to Install Design Guide 22.3 TB6 Terminal block for contactor Motor Terminals Mains Terminals Ground Terminals Brake Terminals Illustration 5.65 Terminal Locations, D8h with Contactor and Disconnect Options Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 125 How to Install Design Guide 23.8 Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.66 Terminal Locations, D8h with Circuit Breaker Option MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 126 Take the following position of the terminals into consideration when designing the cable access. 492[19.4] 323[12.7] 0[0.0] 195[7.7] Front View of Unit Illustration 5.67 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 127 How to Install Design Guide 19 Nm [14 FTa 453[17.8] 0[0.0] Illustration 5.68 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions (Detail B) MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 128 315/355-400/450 kW (400 V) 371 (14.6) 371 (14.6) 341 (13.4) 431 (17.0) 431 (17.0) 455 (17.9) Illustration 5.69 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Position of Disconnect Switch Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 129 T/L3 93 186[7.3] U/T1 96 V/T2 97 W/T3 98 17[0.7] 0[0.0] Illustration 5.70 IP00 Enclosure Power Connection Positions R 81 019Nm (14 F) 147(5.8) 0(0.0) Illustration 5.71 IP00 Enclosure Power Connection Positions MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 130 Each terminal allows use of up to 4 cables with cable lugs or use of standard box lugs. Ground is connected to a relevant termination point in the frequency converter. 104[4.1] 35[1.4] 10[0.4] 0[0.0] Illustration 5.73 Terminal in Detail Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 131 Front Side Ground bar Left Side Motor Terminals Right Side Brake Terminals Illustration 5.74 Terminal Locations - Inverter Cabinet - F1 and F3. Gland Plate is 42 mm below .0 Level. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 132 180.3 [7.10] 0.0 [0.00] Front Side Right Side Left Side Ground bar Illustration 5.76 Terminal Locations - Inverter Cabinet - F2 and F4. Gland Plate is 42 mm below .0 Level. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 133 432.5 [17.03] 81.4 [3.20] Left Side Loadshare Terminal (-) Front Side Ground bar Right Side Loadshare Terminal (+) Illustration 5.78 Terminal Locations - Rectifier. Gland Plate is 42 mm below .0 Level. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 134 Take the following position of the terminals into consideration when designing the cable access. 1031.4[40.61] 939.0[36.97] 134.6[5.30] 0.0[0.00] 0.0[1.75] 244.4[1.75] 244.4[9.62] Left Side Right Side Front Side Ground bar Illustration 5.79 Terminal Locations - Options Cabinet. Gland Plate is 42 mm below .0 Level. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 135 Power size 450 kW (480 V), 630-710 kW (690 V) 34.9 86.9 122.2 174.2 500-800 kW (480 V), 800-1000 kW (690 V) 46.3 98.3 119.0 171.0 Table 5.11 Dimension for Terminal MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 136: Power Connections 12-Pulse Frequency Converters
91-1 (L1-1) 6 Phase 92-1 (L2-1) power 93-1 (L3-1) input 91-2 (L1-2) 92-2 (L2-2) 93-2 (L3-2) 95 PE Illustration 5.81 Mains Connection NOTICE For more information, see chapter 5.7 EMC-correct Installation. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 137 4) If one of the 6-pulse modular rectifiers becomes inoperable, it is possible to operate the frequency converter at reduced load with a single 6-pulse rectifier. Contact Danfoss for reconnection details. 5) No paralleling of mains cabling is shown here. A 12-pulse frequency converter used as a 6-pulse should have mains cables of equal numbers and lengths.
Page 138 1) Protective Earth Connection NOTICE In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply, fit a sine-wave filter on the output of the frequency converter. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 139: Fuses
Short circuit protection The frequency converter must be protected against short-circuit to avoid electrical or fire hazard. Danfoss recommends using the fuses mentioned in Table 5.13 and Table 5.14 to protect service personnel or other equipment in case of an internal failure.
Page 140: Control Terminals
Control cable torque value is 0.5-0.6 Nm (5 in-lbs.) Illustration 5.86 Control Cable Terminals To remove the cable from the terminal: Insert a screw driver in the square hole. Pull out the cable. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 141: Basic Wiring Example
Default settings: 18 = latched start 27 = stop inverse Start Stop inverse Safe Stop Speed Start (18) Start (27) Illustration 5.87 Terminal 37 available with Safe Torque Off Function only. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 142: Electrical Installation, Control Cables
0 V (PNP) 24 V (NPN) (COM RS-485) 61 33 (D IN) 0 V (PNP) (PNP) = Source (NPN) = Sink 37 (D IN) - option Illustration 5.88 Interconnect Diagram for D-frames Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 143 (terminal 20, 55, 39) to avoid ground currents from both groups to affect other groups. For example, switching on the digital input disturbs the analogue input signal. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 144 How to Install Design Guide Use a clamp from the accessory bag to connect the screen to the frequency converter de-coupling plate for control cables. Illustration 5.90 Screened Control Cable Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 145: 12-Pulse Control Cables
11 12 13 14 11 12 13 14 15 16 17 18 15 16 17 18 15 16 17 18 15 16 17 18 15 16 17 18 Illustration 5.91 Control Cable Diagram MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 146 2 F10/F11, 2 sets of terminals chapter 2.6 Safe Torque Off (STO). 3 F12/F13, 3 sets of terminals 4 F14/F15, 4 sets of terminals Table 5.15 F-frame Numbers of Terminals Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 147: Switches S201, S202, And S801
Change the switch position at power off only. Illustration 5.93 Input Polarity of Control Terminals, PNP NPN (Sink) Digital input wiring Illustration 5.94 Input Polarity of Control Terminals, NPN Illustration 5.95 Switch Location MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 148: Final Set-Up And Test
D5h/D6h N75K-N160 ABB OT400U03 D5h/D6h N200-N400 ABB OT600U03 P630-P710 Merlin Gerin NPJF36000S12AAYP P800 Merlin Gerin NRKF36000S20AAYP P900-P1M2 Merlin Gerin NRKF36000S20AAYP Table 5.17 Mains Disconnects, D, E and F- frame Frequency Converters Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 149 ABB OT400U12-121 P560 ABB OT400U12-121 P630 ABB OETL-NF600A P710 ABB OETL-NF600A P800 ABB OT800U21 P900 ABB OT800U21 P1M0 Merlin Gerin NPJF36000S12AAYP P1M2 Merlin Gerin NPJF36000S12AAYP Table 5.18 Mains Disconnects, 12-Pulse Frequency Converters MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 150: Circuit Breakers
N110-N160 380-480 V GE CK95BE311N N55-N132 525-690 V GE CK95CE311N N75-N160 525-690 V GE CK95BE311N N160-N250 380-500 V N200-N315 380-480 V GE CK11CE311N N160-N315 525-690 V N200-N400 525-690 V Table 5.21 D-frame Contactors Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 151: Brake Resistor Temperature Switch
Terminal 06: normally closed 240 V AC Relay 1 and relay 2 are programmed in 5-40 Function Relay, 5-41 On Delay, Relay, and 5-42 Off Delay, Relay. Use option module MCB 105 for additional relay outputs. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 152: Relay Output E & F-Frame
Provide further motor protection by e.g. thermistors in each motor or individual thermal relays. (Circuit breakers are not suitable as protection). Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 153: Motor Thermal Protection
MCB 112 PTC Thermistor Card option. This card provides Illustration 5.99 Correct Parallel Motor Connection ATEX certificate to protect motors in explosion hazardous areas, Zone 1/21 and Zone 2/22. When 1-90 Motor Thermal MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 154: Motor Insulation
In order to avoid potential equalizing currents in the screen, ground the cable screen via terminal 61, which is Ensure that the impedance from connected to the frame via an RC-link. frequency converter to building ground Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 155: How To Connect A Pc To The Frequency Converter
Illustration 5.102 USB Connection to Frequency Converter 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, PC- based configuration tool MCT 10 Set-up Software.
Page 156: Safety
130B1031. cables. The screen should provide a minimum MCT 31 can also be downloaded from the Danfoss coverage of 80%. The screen material is metal, Internet: www.danfoss.com/BusinessAreas/DrivesSolutions/ typically copper, aluminium, steel or lead. There Softwaredownload/.
Page 157 Illustration 5.103 shows an example of an EMC-correct although the immunity requirements are fulfilled. electrical installation of an IP 20 frequency converter. The frequency converter is fitted in an installation cabinet with MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 158 Motor cable between con- trol cables, motor cable and Mains-supply mains cable Motor, 3 phases and Reinforced protective earth Protective earth Illustration 5.103 EMC-correct Electrical Installation of a Frequency Converter in Cabinet Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 159: Use Of Emc-Correct Cables
The contact resistance between the individual screen conductors. • The screen coverage, which is the physical area of the cable covered by the screen, often stated as a percentage value. • Braided or twisted screen type. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 160 Equalizing cable PLC etc. 100nF Correct grounding b Incorrect grounding Protection from potential between PLC and frequency converter d 50/60 Hz ground loops Cables for Serial Communication Illustration 5.106 Grounding Examples Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 161: Residual Current Device
If using RCD relays, observe local regulations. Relays must be suitable for protecting 3-phase equipment with a bridge rectifier and for a brief discharge on power-up. See chapter 2.11 Ground Leakage Current for more information. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 162: Application Examples
Speed Start Stop inverse Safe Stop Speed Start/Stop [18] Illustration 6.1 Terminal 37: Available only with STO Function Start (18) Start (27) Illustration 6.2 Terminal 37: Available only with STO Function Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 164: Slc Application Example
Set Event 4 in 13-51 SL Controller Event [4] to (3-10 Preset Reference [1] Ex.: 0 % (zero). False [0] Set the timer 0 for constant running speed in 13-20 SL Controller Timer [0]. Ex.: 2 sec. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 165 Set the Smart Logic Control in 13-00 SL Controller Mode to A start/stop command is applied on terminal 18. If stop signal is applied the frequency converter will ramp down and go into free mode. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 166: Basic Cascade Controller
(adding another pump). frequency, the fixed speed pump is cut out (de-staged). The lead pump continues to ramp up and then ramps down to a stop and the 2 relays are cut out. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 167: System Status And Operation
• When all relays are de-energised, the first built in relay to be energised cuts in the contactor corresponding to the pump controlled by the relay. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 168 Auxiliary break contact on K1 prevents K3 to cut • RELAY 2 controls contactor K4 for on/off control of the fixed speed pump. • At alternation both relays de-energise and now Relay 2 is energised as the first relay. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 169: Cascade Controller Wiring Diagram
4-20 mA transmitter and system safety interlock. Power Card Control Card MOTOR MAINS System System Start/ Safety Stop Interlock From Motor Control Circuitry Pressure Transmitter 4-20 mA, 24 V dc Illustration 6.11 Cascade Controller Wiring Diagram MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 170: Start/Stop Conditions
Starts and stops according to commands via Staging/Destaging terminals or serial bus cascade controller only can work when the frequency converter is in "Auto ON" mode Table 6.2 Function of LCP Keys Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 171: Installation And Set-Up
69 is connected to the N signal (TX-,RX-). See chapter 5.6.2 Safety Ground Connection and chapter 5.7.3 Grounding of Screened/Armoured Control Cables. If more than one frequency converter is connected to a master, use parallel connections. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 172: Frequency Converter Hardware Setup
The FC protocol, also referred to as FC bus or standard 8-37 Maximum Specify a maximum delay time between bus, is the Danfoss standard fieldbus. It defines an access Inter-Char Delay two received bytes to ensure time-out if technique according to the master-slave principle for transmission is interrupted communications via a serial bus.
Page 173: Network Configuration
A byte denoting the frequency converter address is used. (ADR) A number of data bytes (variable, depending on the type of telegram) follows. A data control byte (BCC) completes the telegram. DATA Illustration 7.6 Example Telegram MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 174: Telegram Length (Lge)
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) Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 175: The Pke Field
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Illustration 7.10 PKE Sub-fields Bits no. 12-15 transfer parameter commands from master to slave and return processed slave responses to the master. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 176 Data change in the defined parameter is not possible in the 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 Table 7.6 Faults Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 177: Parameter Number (Pnu)
Some parameters contain text that can be written 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.” MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 178: Process Words (Pcd)
3E8 Hex corresponds to 1000 decimal. The conversion index for 3-41 Ramp 1 Ramp Up Time is -2, or 0.01. 3-41 Ramp 1 Ramp Up Time is of the type Unsigned 32. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 179: Modbus Rtu Overview
7.6.1 Assumptions 7.6.4 Frequency Converter with Modbus Danfoss assumes that the installed controller supports the interfaces in this document, and strictly observes all requirements and limitations stipulated in the controller The frequency converter communicates in Modbus RTU and frequency converter.
Page 180: Modbus Rtu Message Framing Structure
8 bits N x 8 16 bits T1-T2-T3- error occurred, or the reason. Refer to bits chapter 7.8.11 Modbus Exception Codes for more information. Table 7.13 Typical Modbus RTU Message Structure Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 181: Data Field
Master to slave Parameter changes are written to the RAM of the frequency converter Parameter changes are written to the RAM and EEPROM of the frequency converter. 66-65536 Reserved Table 7.14 Coil Descriptions MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 182 Output data: frequency converter status word register (STW). 50210 Output data: frequency converter main actual value register (MAV). Table 7.17 Holding Registers * Used to specify the index number to be used when accessing an indexed parameter. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 183: How To Control The Frequency Converter
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. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 184: Text Blocks
The query message specifies the starting coil and quantity Data = 00 00HEX (OFF) or FF 00HEX (ON). of coils to be read. Coil addresses start at zero, i.e. coil 33 is addressed as 32. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 185: Force/Write Multiple Coils (0F Hex)
Quantity of coils HI Quantity of coils LO 10 (16 coils) Byte count Force data HI (Coils 8-1) Force data LO 00 (ref. = 2000 hex) (Coils 16-9) Error check (CRC) Table 7.25 Query MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 186: Preset Single Register (06 Hex)
Error check (CRC) Field Name Example (HEX) Slave address Table 7.32 Response Function Register address HI Register address LO Preset data HI Preset data LO Error check (CRC) Table 7.30 Response Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 187: Danfoss Fc Control Profile
Table 7.34 Explanation of the Control Bits from logic ’0’ to logic ’1’, for example. Bit 08, Jog Bit 08 = ’1’: The output frequency is determined by 3-19 Jog Speed [RPM]. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 188 [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. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 189 100%. 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. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 190 Forward (1) -max- +max Par.3-03 Par.3-03 Max reference Max reference 100% (0hex) (4000hex) Par.3-00 set to Forward (0) min-max Par.3-02 Par.3-03 Max reference Min reference Illustration 7.19 Reference and MAV scaling Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 191: General Specifications And Troubleshooting
Weight, enclosure IP54, kg [lbs.] 0.98 Efficiency Output frequency [Hz] 0-590 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *Normal overload=110% current for 60 s Table 8.1 Mains Supply 3x380-480 V AC MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 192 A or slot B, each). 4) Measured using 5 m screened motor cables at rated load and rated frequency. 5) Wiring terminals on N132, N160, and N315 frequency converters cannot receive cables one size larger. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 193: Mains Supply 3X525-690 V Ac
Weight, enclosure IP20/IP21/IP54, kg [lbs.] 62 [135] 0.98 Efficiency Output frequency [Hz] 0-590 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *Normal overload=110% current for 60 s. Table 8.3 Mains Supply 3x525-690 V AC MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 194 272 [600] 0.98 Efficiency Output frequency [Hz] 0-590 0-525 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *Normal overload=110% current for 60 s. Table 8.4 Mains Supply 3x525-690 V AC Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 195 D1h ratings+disconnect and/or brake chopper 166 [255] D1h ratings+contactor and/or circuit breaker 129 [285] D2h ratings+disconnect and/or brake chopper 200 [440] D2h ratings+contactor and/or circuit breaker 225 [496] Table 8.6 D5h–D8h Weights MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 196: 12-Pulse Specifications
[595] [600] [690] Weight enclosure IP 54 kg [lbs.] Efficiency 0.98 Output Frequency [Hz] 0-590 Heatsink overtemp. trip [°C] Power card ambient trip [°C] Table 8.7 Mains Supply 380-480 V AC Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 197 Further options and customer load can add up to 30 W to the losses (though typically only 4 W extra for a fully loaded control card or options for slot A or slot B, each) 4) Measured using 5 m screened motor cables at rated load and rated frequency MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 198 Starting torque (constant torque) maximum 110% for 1 minute Starting torque maximum 135% up to 0.5 s Overload torque (constant torque) maximum 110% for 1 minute 1) Percentage relates to nominal torque. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 199 Accuracy on analogue output Max. error: 0.8% of full scale Resolution on analogue output 8 bit The analogue output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 200 4-5 (NO) (Inductive load @ cosφ 0.4) Max. terminal load (AC-15) 240 V AC, 0.2 A Max. terminal load (DC-1) on 4-5 (NO) (Resistive load) 80 V DC, 2 A Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 201 See chapter 8.5 Special Conditions for more information. Control card performance Scan interval 5 ms Control card, USB serial communication USB standard 1.1 (Full speed) USB plug USB type B “device” plug MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 202: Efficiency
Example: Assume a 55 kW, 380-480 V AC frequency converter at 25% load at 50% speed. The graph shows 0.97. Rated efficiency for a 55 kW FC is 0.98. The actual efficiency is then: 0.97x0.98=0.95. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 203: Acoustic Noise
1) With Danfoss dU/dt filter. insulation reinforcement suitable for operation with voltage supply (such as a frequency converter), fit a sine- Table 8.13 P450-P1M4, T7/525-690 V wave filter on the output of the frequency converter. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 204: Special Conditions
Normal overload NO, 110% 60 AVM Normal overload NO, 110% SFAVM model D-Frame N110 to N315 525-690 V 40 C 45 C 45 C 50 C 50 C 55 C 55 C Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 205 E & F-Frame P450 to P1M0 525-690 V 45 C 40 C 50 C 45 C 55 C 50 C 55 C Table 8.15 Derating Tables for Frequency Converters Rated 525–690 V (T7) MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 206: Automatic Adaptations To Ensure Performance
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 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 207 This must be considered during the design phase to avoid over-loading of the motor. Illustration 8.6 Maximum Load for a Standard Motor at 40 °C Driven by a Frequency Converter MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 208: Troubleshooting
Motor thermistor over temperature 1-90 Torque limit Over Current Earth fault Hardware mismatch Short Circuit Control word timeout 8-04 Start failed Internal Fan Fault External Fan Fault 14-53 Brake resistor short-circuited Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 209 Safe torque off auto restart Power unit setup Illegal PS config Drive initialized to default value Analogue input 54 wrong settings NoFlow 22-2* Dry pump 22-2* End of curve 22-5* Broken belt 22-6* MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 210 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. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 211 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. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 212: Alarm Words
20000000 Drive initialised 20000000 Reserved 40000000 Safe torque off [A68] 40000000 PTC 1 Safe Torque Off [A71] 80000000 80000000 Dangerous Failure [A72] Table 8.19 Alarm Word Table 8.20 Alarm Word 2 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 213: Warning Words
10000000 Reserved 20000000 20000000 Reserved 40000000 Safe torque off [W68] 40000000 PTC 1 Safe Torque Off [W71] 80000000 Not used 80000000 Reserved Table 8.21 Warning Words Table 8.22 Warning Words 2 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 214: Extended Status Words
08000000 Reserved 08000000 Reserved 10000000 Reserved 10000000 Reserved 20000000 Reserved 20000000 Reserved 40000000 Reserved 40000000 Reserved 80000000 Reserved 80000000 Reserved Table 8.23 Extended Status Word Table 8.24 Extended Status Word 2 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 215: Warning And Alarm Introduction
The limit is dependent on the gives a warning or an alarm when the counter reaches frequency converter voltage rating. The unit is still active. 100% in 1-90 Motor Thermal Protection. The fault occurs MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 216 If 8-04 Control Word Timeout Function is set to Stop and on the motor. Trip, a warning appears and the frequency converter ramps down until it stops then displays an alarm. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 217 90% of the brake resistance power. If [2] Trip is selected in 2-13 Brake Power Monitoring, the frequency converter trips when the dissipated braking power reaches 100%. MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 218 • Check for loose or missing wiring WARNING 42, Overload of digital output on X30/6 or If necessary, contact the Danfoss supplier or service overload of digital output on X30/7 department. Note the code number for further trouble- For X30/6, check the load connected to X30/6 or remove shooting directions.
Page 219 The cutout temperature of the control card is 80 °C. Thermistor Card enables X44/10 but safe torque off is not enabled. Furthermore, if the MCB 112 is the only device using safe torque off (specified through selection [4] or [5] MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 220 The mixing-fan fault can be configured as a warning or an alarm trip by parameter 14-53 (Fan Monitor). Troubleshooting Cycle power to the frequency converter to determine if the warning/alarm returns. Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 221: Index
Constant torque applications, CT mode........204 Brake resistor calculation..............46 Control cable terminals..............138 Brake resistor selection............... 45 Control cables............140, 141, 143, 154 Brake resistor temperature switch..........149 Control card performance.............. 199 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 222 Filters....................69, 75 Direction, motor rotation..............151 Flow meter....................27 Discharge time..................13 Freeze output................... 9 Disconnect..... 59, 67, 114, 117, 119, 122, 126, 128, 146 Frequency converter set-up............171 Disposal instruction................14 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 223 Intermediate circuit..............47, 201 Modbus exception codes..............181 Intermittent Duty Cycle..............11 Modbus RTU................171, 177 IRM, insulation resistance monitor..........60 Modbus RTU, frequency converter with........177 Moment of inertia................. 47 Motor cables..................154 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 224 Parameter number, PNU..............175 Reference handling................35 Parameter value.................. 182 Reference, analog................. 10 Pay back period..................18 Reference, binary.................. 10 PC software tools................153 Reference, bus..................10 PC-based configuration tool............153 Reference, preset.................. 10 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 225 Side-by-side installation..............98 Variable (Quadratic) Torque Applications (VT)......205 Sine-wave filter..............61, 110, 136 Variable air volume................22 Slip compensation................11 Variable control, flow and pressure..........19 Smart Logic Control................161 MG16C202 Danfoss A/S © Rev. 05/2014 All rights reserved.
Page 226 Vibration and Shock................16 Vibrations....................24 Voltage imbalance................213 Voltage level..................198 VT Characteristics................. 11 VVC+......................11 Warning word..................211 Warnings....................206 Weight............91, 97, 191, 192, 193, 194 Windmilling.................... 14 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16C202...
Page 228 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies.

Danfoss VLT HVAC Drive FC 102 Design Manual

1 How to Read this Design Guide

2 Introduction

3 Selection

4 How to Order

5 How to Install

6 Application Examples

7 Installation and Set-Up

8 General Specifications and Troubleshooting

Index

Quick Links

Troubleshooting

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Summary of Contents for Danfoss VLT HVAC Drive FC 102

Table of Contents