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Vacon 100 Applications Manual
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Vacon 100 Applications Manual

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Summary of Contents for Vacon 100

  • Page 1 100 hvac drives application manual...
  • Page 2 +’(*) , ! $%"#& 7VK\TMU[2 7A7(((+14) GMYZQVU YMSMIZM LI[M2 *,&))&(0 $" 0)*.- $## ! />1=>?<""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" % )&) D[IY[\W HQaIYL&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&& * )&* A<7 ?QUQ%HQaIYL &&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&& , %" 012;: 5=1<67219 84A<13 ! 7:>=;3?2>7;: """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""" ’ *&) =M‘WIL J\[[VUZ&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&& - *&* =M‘WIL LQZWSI‘&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&& . *&*&) ?IQU TMU\&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&...
  • Page 3 • 1 HVAC Application - Fault tracing ..................71 3.7.1 Fault appears ........................71 3.7.2 Fault codes ........................72 Fieldbus process data out....................75 Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
  • Page 4 Back/Reset button. Pressing this button, you can return to the previous question in RESET the Wizard. If pressed at the first question, the Startup Wizard will be cancelled. Once you have connected power to your Vacon 100 frequency converter, follow these instruc- tions to easily set up your drive. Suomi...
  • Page 5 • 3 VACON 100 - Startup Run Startup Wizard? STOP NotRDY Keypad Startup Wizard? Push the OK button unless you want to set all parameter values manually. Pump Choose your process STOP NotRDY Keypad Fan or Pump? Pump Motor Nominal...
  • Page 6 I/O A and the process unit ‘%’. PID mini wizard asks for the following values to be set: Keypad Setpoint 1 0.00...100.00% Gain 0.00...200.00% Integration time 0.00...600.00 s 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 7 • 5 Vacon graphical keypad - introduction ACON GRAPHICAL KEYPAD INTRODUCTION The control keypad is the interface between the Vacon 100 frequency converter and the user. It features an LCD display and 9 buttons. Keypad buttons Figure 1. Keypad buttons...
  • Page 8 ( 17 ) Activated group/item. Press OK to enter. Monitor ( 5 ) Parameters Number of items in the group ( 12 ) Figure 2. Main menu 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 9 • 7 Vacon graphical keypad - introduction Using the keypad 2.3.1 Editing values Change value of a parameter following the procedure below: 1. Locate the parameter. Edit 2. Enter the mode. 3. Set new value with the arrow buttons up/down. You can also move from digit to digit with the arrow buttons left/right if the value is numerical and change then the value with the arrow buttons up/down.
  • Page 10 2.3.4 Help texts The Vacon graphic keypad features instant help and information displays for various items. All parameters offer an instant help display. Select Help and press the OK button. Text information is also available for faults, alarms and the startup wizard.
  • Page 11 • 9 Vacon graphical keypad - introduction 2.3.5 Adding item to favourites You might need to refer to certain parameter values or other items often. Instead of locating Favourites them one by one in the menu structure, you may want to add them to a folder called where they can easily be reached.
  • Page 12 Software info I/O and hard- Basic I/O ware Slot D Slot E Real time clock Keypad RS-485 Ethernet User settings Language selections Parameter backup Favourites See chapter 2.3.5 Table 1. Keypad menus 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 13 • 11 Vacon graphical keypad - introduction 2.4.1 Quick setup The Quick Setup Menu includes the minimum set of most commonly used parameters during installation and commissioning. More detailed information on the parameters of this group you will find in chapter 3.3.
  • Page 14 2294 unit has been powered so far. No reset. Start command The number of times the P4.4.6 2295 counter power unit has been started. Table 2. Diagnostics menu, Total counters parameters 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 15 • 13 Vacon graphical keypad - introduction 2.4.4.5 Trip counters Code Parameter Unit Default Description P4.5.1 Energy counter (+) Varies 2296 Resettable energy counter. P4.5.2 Energy counter (-) Varies 2297 Resettable energy counter. P4.5.3 Operating time a d hh:min 2299 Resettable.
  • Page 16 D or E, no parameters are visible. Menu Function Note Slot D Settings Option board related settings. Monitoring Monitor option board-related info. Slot E Settings Option board related settings. Monitoring Monitor option board-related info. 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 17 • 15 Vacon graphical keypad - introduction 2.4.5.3 Real time clock Code Parameter Unit Default Description Status of battery. 1 = Not installed P5.4.1 Battery state 2205 2 = Installed 3 = Change battery P5.4.2 Time hh:mm:ss 2201 Current time of day P5.4.3...
  • Page 18 2 = Suomi 3 = Deutsch Table 8. User settings menu, General settings 2.4.6.1 Parameter backup Code Parameter Unit Default Description Restore factory 6.5.1 defaults Table 9. User settings menu, Parameter backup parameters 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 19 • 17 Vacon graphical keypad - introduction 2.4.7 Favourites Favourites are typically used to collect a set of parameters or monitoring signals from any of the keypad menus. You can add items or parameters to the Favourites folder, see chapter 2.3.5.
  • Page 20 3.6. Specific functions of Vacon HVAC drive The Vacon HVAC drive is an easy-to-use application for not only basic Pump and Fan applica- tions where only one motor and one drive is needed but also offers extensive possibilities for PID control.
  • Page 21 RS485 mitter To Relay board Differential receiver/trans- 1 or 2 RS485 mitter Selectable with DIP switches, see Vacon 100 Installa- tion Manual Table 10. Connection example, basic I/O board Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
  • Page 22 RO1/1 NC Relay output 1 RUN RO1/2 CM RO1/3 NO RO2/1 NC Relay output 2 FAULT RO2/2 CM RO2/3 NO TI1+ Thermistor input TI1- Table 12. Connection example, Relay board 2 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 23 • 21 VACON HVAC Drive Application HVAC Application - Quick setup parameter group The Quick Setup parameter group is a collection of parameters that are most commonly used during installation and commissioning. They are collected in the first parameter group so that they can be found fast and easily.
  • Page 24 VACON HVAC Drive Application vacon • 22 monitor group Vacon 100 AC drive provides you with a possibility to monitor the actual values of parameters and signals as well as statuses and measurements. Some of the values to be monitored are customizable.
  • Page 25 • 23 VACON HVAC Drive Application 3.4.3 Timer functions monitoring Here you can monitor values of timer functions and the Real Time Clock. Monitoring value Unit Description 2.3.1 TC 1, TC 2, TC 3 1703 Possible to monitor the statuses of the three Time Channels (TC) 2.3.2...
  • Page 26 Monitoring value Unit Description 2.6.1 Motors running The number of motors running when Multi-Pump function is used. 2.6.2 Autochange 1720 Informs the user if autochange is requested. Table 18. Multi-pump monitoring 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 27 • 25 VACON HVAC Drive Application Vacon HVAC Application - Application parameter lists Find the parameter menu and the parameter groups as guided below. STOP READY Keypad STOP READY Keypad Parameters Main Menu M3.1 Quick Setup Motor Settings ( 17 )
  • Page 28 ‘DigIN’ stands for digital input. ‘Slot_’ refers to the board; A and B are Vacon AC drive basic boards, D and E are option boards (see Figure 6). The parameter (signal) is not connected to any terminal, i.e. it is not used, if, in- stead of a letter, the word Slot is followed by a ‘0’...
  • Page 29 • 27 VACON HVAC Drive Application EXAMPLE: Control signal 2 A You want to connect the (parameter P3.5.1.2) to digital input DI2 on Basic I/O board. Control signal 2 A Locate the parameter (P3.5.1.2) on the keypad. STOP READY...
  • Page 30 This parameter sets the P3.1.1.1 Motor nominal voltage 180.0 690.0 Varies voltage at the field weaken- ing point to 100% * U nMotor . Note also used connection (Delta/Star). Find this value f n on the rat- Motor nominal fre- P3.1.1.2 0.00...
  • Page 31 • 29 VACON HVAC Drive Application 3.5.4 Group 3.2: Start/Stop setup Code Parameter Unit Default Description Selection of remote control Remote control place (start/stop) P3.2.1 place 0=I/O control 1=Fieldbus control 0=Stop button always enabled (Yes) P3.2.2 Keypad stop button...
  • Page 32 Basic preset frequency 0 P3.3.11 Preset frequency 0 P3.3.1 P3.3.2 5.00 when selected by Control ref- erence parameter (P3.3.3). 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 33 • 31 VACON HVAC Drive Application Select with digital input: P3.3.12 Preset frequency 1 P3.3.1 P3.3.2 10.00 Preset frequency selection B0 (P3.5.1.21) Select with digital input: P3.3.13 Preset frequency 2 P3.3.1 P3.3.2 15.00 Preset frequency selection B1 (P3.5.1.22) Select with digital inputs: P3.3.14...
  • Page 34 0 = Disabled The output frequency at Frequency to start DC P3.4.12 0,10 10,00 1,50 which the DC-braking is braking at ramp stop applied. Table 24. Ramp and brakes setup 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 35 A. It's also possible to connect the digital inputs to time channels which are also represented as terminals. NOTE! Apply Vacon TTF programming method to these parameters. For more de- tailed information, see chapter 3.5.2. Code...
  • Page 36 Motor 3 interlock TRUE = Active FALSE = Not active P3.5.1.30 Motor 4 interlock TRUE = Active FALSE = Not active P3.5.1.31 Motor 5 interlock TRUE = Active Table 25. Digital input settings 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 37 • 35 VACON HVAC Drive Application 3.5.7.2 Analogue inputs Code Parameter Unit Default Description Connect the AI1 signal to the analogue input of your choice P3.5.2.1 AI1 signal selection with this parameter. Programmable (TTF) P3.5.2.2 AI1 signal filter time 0.00...
  • Page 38 1 = 2…10V / 4…20mA P3.5.2.34 AI6 custom. min -160.00 160.00 0.00 See P3.5.2.16. P3.5.2.35 AI6 custom. max -160.00 160.00 100.00 See P3.5.2.17. P3.5.2.36 AI6 signal inversion See P3.5.2.18. Table 26. Analogue input settings 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 39 • 37 VACON HVAC Drive Application 3.5.7.3 Digital outputs, slot B (Basic) Code Parameter Unit Default Description Function selection for Basic R01: 0 = Not used 1 = Ready 2 = Run 3 = General fault 4 = General fault inverted...
  • Page 40 Shows only parameters for existing outputs in slot D/E. Application dynamic Selections as in Basic AO1 output list Not visible if no analogue output exists in slot D/E. Table 30. Slot D/E analogue outputs 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 41 • 39 VACON HVAC Drive Application 3.5.8 Group 3.7: Prohibit Frequencies In some systems it may be necessary to avoid certain frequencies due to mechanical reso- nance problems. By setting up prohibit frequencies it is possible to skip these ranges.
  • Page 42 P3.8.6 Supervision #2 mode 1627 See P3.8.2 P3.8.7 Supervision #2 limit Varies 40.00 1628 See P3.8.3 Supervision #2 limit P3.8.8 Varies 5.00 1629 See P3.8.4 hysteresis Table 32. Limits supervision settings 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 43 • 41 VACON HVAC Drive Application 3.5.10 Group 3.9: Protections Code Parameter Unit Default Description 0=No action 1=Alarm 2=Alarm, set preset fault fre- Response to Analogue P3.9.1 quency input low fault 3=Fault (Stop according to stop mode) 4=Fault (Stop by coasting)
  • Page 44 1 = Yes Autoreset permitted? Autoreset: Motor over- 3.10.11 0 = No temperature 1 = Yes Autoreset permitted? Autoreset: 3.10.12 0 = No External fault 1 = Yes Table 34. Autoreset settings 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 45 • 43 VACON HVAC Drive Application 3.5.12 Group 3.11: Timer functions The functions of this parameter group can be made the fullest advantage of if the battery (op- tion) has been installed and the Real Time Clock settings have been properly made during the Startup Wizard (see page 2 and page 3).
  • Page 46 1697 See Timer 1 P3.11.7.2 Assign to channel 1698 See Timer 1 3.11.8 TIMER 3 P3.11.8.1 Duration 72000 1699 See Timer 1 P3.11.8.2 Assign to channel 1700 See Timer 1 Table 35. Timer functions 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 47 3.5.13.1 Basic settings Code Parameter Unit Default Description If the value of the parameter is set to 100% a change of P3.12.1.1 PID gain 0.00 200.00 100.00 10% in the error value causes the controller output to change by 10%.
  • Page 48 Setpoint 1 boost Varies 0.0000 1071 with a digital input. Setpoint source 2 P3.12.2.11 See par. P3.12.2.4 selection Minimum value at analogue P3.12.2.12 Setpoint 2 minimum -200.00 200.00 0.00 1073 signal minimum. 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 49 • 47 VACON HVAC Drive Application Maximum value at analogue P3.12.2.13 Setpoint 2 maximum -200.00 200.00 100.00 1074 signal maximum. P3.12.2.14 Sleep frequency limit 2 0.00 320.00 0.00 1075 See P3.12.2.7. P3.12.2.15 Sleep delay 2 3000 1076 See P3.12.2.8.
  • Page 50 See P3.12.3.3 source selection Minimum value at analogue P3.12.3.7 Feedback 2 minimum -200.00 200.00 0.00 signal minimum. Maximum value at analogue P3.12.3.8 Feedback 2 maximum -200.00 200.00 100.00 signal maximum. Table 38. 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 51 The feedforward part does not use any feedback measurements of the actual controlled process value (water level in the example on page 62). Vacon feedfor- ward control uses other measurements which are indirectly affecting the controlled process value.
  • Page 52 Setpoint compensation = Max pensation compensation * (FreqOut- MinFreq)/(MaxFreq-MinFreq) P3.12.7.3 Enable setpoint 2 1531 See P3.12.7.1. Setpoint 2 max com- P3.12.7.4 Varies Varies Varies Varies 1532 See P3.12.7.2. pensation Table 41. 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 53 • 51 VACON HVAC Drive Application 3.5.14 Group 3.13: PID-controller 2 3.5.14.1 Basic settings For more detailed information, see chapter 3.5.13. Code Parameter Unit Default Description 0 = Disabled P3.13.1.1 Enable PID 1630 1 = Enabled P3.13.1.2 PID gain 0.00...
  • Page 54 1660 P3.13.4.3 Lower limit Varies Varies Varies Varies 1661 If the desired value is not P3.13.4.4 Delay 30000 1662 reached within this time a fault or alarm is activated. Table 45. 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 55 • 53 VACON HVAC Drive Application 3.5.15 Group 3.14: Multi-pump Multi-pump functionality allows you to control up to 4 motors (pumps, fans) with PID con- troller 1. The AC drive is connected to one motor which is the "regulating" motor connecting...
  • Page 56 • 54 HVAC Application - Additional parameter information Due to its user-friendliness and simplicity of use, the most parameters of the VACON HVAC Drive Application only require a basic description which is given in the parameter tables in chapter 3.5.
  • Page 57 • 55 VACON HVAC Drive Application Output Stop function Stop function frequency (P3.2.4) (P3.2.4) = coasting = ramp Ctrl signal 1 A/B 100K09 Figure 7. Start forward Output Stop function If Start and Stop pulses are frequency (P3.2.4) simultaneous the Stop pulse...
  • Page 58 UN INTERLOCK The drive cannot be started if any of the interlocks are open. The function could be used for a damper interlock, preventing the drive to start with damper closed. 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 59 • 57 VACON HVAC Drive Application 3.5.1.18 RESET FREQUENCY SELECTION 3.5.1.19 RESET FREQUENCY SELECTION 3.5.1.20 RESET FREQUENCY SELECTION Connect a digital input to these functions with the TTF programming method (see chapter 3.5.2) to be able to apply Preset frequencies 1 to 7 (see Table 47 and pages 31, 33 and 56).
  • Page 60 Multi-pump Motor 3 control Contactor control for function Multi-pump Motor 4 control Contactor control for function Multi-pump Motor 5 control Contactor control for function Table 48. Output signals via RO1 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 61 • 59 VACON HVAC Drive Application 3.9.2 ESPONSE TO EXTERNAL FAULT An alarm message or a fault action and message is generated by an external fault external fault signal in one of the programmable digital inputs (DI3 by default) using parameters P3.5.1.9 and P3.5.1.10.
  • Page 62 Par.3.10.3 Par.3.10.3 Par.3.10.3 Fault trigger Warning Reset 1 Reset 2 Autoreset Trial time Trial time Par. 3.10.4 Fault active Number of trials: (P3.10.5 = 2) 100K15.fh11 Figure 11. Automatic reset function 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 63 • 61 VACON HVAC Drive Application P3.12.1.9 EAD BAND HYSTERESIS P3.12.1.10 EAD BAND DELAY The PID controller output is locked if the actual value stays within the deadband area around the reference for a predefined time. This function will prevent unnecessary movement and wear on actuators, e.g.
  • Page 64 The feedforward part does not use any feedback measurements of the actual controlled process value (water level in the example on page 63). Vacon feedfor- ward control uses other measurements which are indirectly affecting the controlled process value.
  • Page 65 • 63 VACON HVAC Drive Application Level ref Outflow control Level control 100K20.fh11 Figure 14. Feedforward control P3.12.6.1 NABLE PROCESS SUPERVISION Actual value Upper limit P3.12.6.2) Reference Lower limit (P3.12.6.3) Delay (P3.12.6.4) 100K21.fh11 Regulating mode Alarm or fault Figure 15. Process supervision Upper and lower limits around the reference are set.
  • Page 66 (Position 2). However, sensors might, for example, be placed directly af- ter the pump. This will give the right pressure directly after the pump, but farther down in the pipe the pressure will drop depending on the flow. 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 67 • 65 VACON HVAC Drive Application P3.12.7.1 NABLE SETPOINT P3.12.7.2 ETPOINT MAX COMPENSATION The sensor is placed in Position 1. The pressure in the pipe will remain constant when we have no flow. However, with flow, the pressure will drop farther down in the pipe. This can be com- pensated by raising the setpoint as the flow increases.
  • Page 68 (parameters P3.5.1.27 to P3.5.1.31). If the input is closed (TRUE) the motor is available for the Multi Pump system, otherwise it will not be connected by the Multi Pump logic. 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 69 • 67 VACON HVAC Drive Application EXAMPLE OF THE INTERLOCK LOGIC: If the motor starting order is 1->2->3->4->5 Now, the interlock of motor 3 is removed, i.e. the value of parameter P3.5.1.29 is set to FALSE, the order changes to: 1->2->4->5.
  • Page 70 Figure 20 below. Every motor is controlled with one relay but the contactor logic takes care that the first con- nected motor is always connected to the drive and next to the mains. 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 71 • 69 VACON HVAC Drive Application Mains K1.1 K2.1 K3.1 Motor 1 Motor 2 Motor 3 Motor 1 control Motor 2 control Motor 3 control from relay from relay from relay K1.1 K2.1 K3.1 K1.1 K2.1 K3.1 100K26.fh11 Figure 20.
  • Page 72 Starting order/priority of motors: 1->2->3->4->5 --> Autochange --> Starting order/priority of motors: 2->3->4->5->1 --> Autochange --> Starting order/priority of motors: 3->4->5->1->2 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...

  • Page 73: Hvac Application - Fault Tracing

    • 71 VACON HVAC Drive Application HVAC Application - Fault tracing When an unusual operating condition is detected by the AC drive control diagnostics, the drive initiates a notification visible, for example, on the keypad. The keypad will show the code, the name and a short description of the fault or alarm.

  • Page 74: Fault Codes

    602 = Watchdog has reset the CPU 603 = Voltage of auxiliary power in power unit is too low 604 = Phase fault: Voltage of an output phase does not follow the reference 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...
  • Page 75 Too low temperature measured in power Check the heatsink for dust. unit’s heatsink or board. Heatsink temper- Frequency con- Check the ambient tempera- ature is over 100°C. verter overtem- ture. Fault ID: perature Make sure that the switching...
  • Page 76 (and the delay if set). Process supervi- PID controller: Feedback value outside of sion fault (PID2) supervision limits (and the delay if set). Table 49. Fault codes and descriptions 24-hour support +358 (0)40 837 1150 • Email: vacon@vacon.com...

  • Page 77: Fieldbus Process Data Out

    • 75 VACON HVAC Drive Application Fieldbus process data out Values to monitor through fieldbus are: Data Value Scale Process Data Out 1 Output frequency 0.01 Hz Process Data Out 2 Motor speed 1 rpm Process Data Out 3 Motor current 0.1 A...