Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® HVAC Drive FC 102 110–1400 kW www.danfoss.com/drives...
Page 3: Table Of Contents
2.1 Safety 2.1.1 Safety Note 2.2 CE Labeling 2.2.1 CE Conformity and Labeling 2.2.2 What Is Covered 2.2.3 Danfoss Adjustable frequency drive and CE Labeling 2.2.4 Compliance with EMC Directive 2004/108/EC 2.3 Air Humidity 2.4 Aggressive Environments 2.5 Vibration and Shock 2.6 Safe Torque Off...
Page 4 2.10 Galvanic Isolation (PELV) 2.11 Ground Leakage Current 2.12 Brake Function 2.12.1 Brake Resistor Selection 2.12.2 Brake Resistor Calculation 2.12.3 Control with Brake Function 2.12.4 Brake Resistor Cabling 2.13 Extreme Running Conditions 3 Selection Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 5 4.2.1 Ordering Numbers: Options and Accessories 4.2.2 Advanced Harmonic Filters 4.2.3 Sine-Wave Filter Modules, 380–690 V AC 4.2.4 Ordering Numbers: dU/dt Filters 4.2.5 Ordering Numbers: Brake Resistors 5 How to Install 5.1 Mechanical Installation MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 6 5.4.5 External Fan Supply 5.4.6 Relay Output D Frame 5.4.7 Relay Output E & F-Frame 5.5 Installation of Misc. Connections 5.6 Safety 5.6.1 High Voltage Test 5.6.2 Safety Ground Connection 5.7 EMC-compatible Installation Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 7 7.4.1 Content of a Character (byte) 7.4.2 Message Structure 7.4.3 Length (LGE) 7.4.4 Address (ADR) 7.4.5 Data Control Byte (BCC) 7.4.6 The Data Field 7.4.7 The PKE Field 7.4.8 Parameter Number (PNU) 7.4.9 Index (IND) MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 8 7.9.5 Conversion Factor 7.9.6 Parameter Values 7.10 Examples 7.10.1 Read Coil Status (01 HEX) 7.10.2 Force/Write Single Coil (05 HEX) 7.10.3 Force/Write Multiple Coils (0F HEX) 7.10.4 Read Holding Registers (03 HEX) Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
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 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 10: 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 any obligation to notify former or present users of such revisions or changes.
Page 11 Second sec. Synchronous Motor Speed Torque limit Volts The maximum output current DRIVE,MAX The rated output current supplied by the DRIVE,N adjustable frequency drive Table 1.3 Abbreviations used in this Manual MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 12 The rated motor frequency (nameplate data). input. Start-disable command The motor current. A stop command belonging to the group 1 control commands. The rated motor current (nameplate data). Stop command See control commands parameter group. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 13 The operation can be either periodic duty or non- mA, or a digital signal. periodic duty. Automatic Motor Adaptation, AMA AMA algorithm determines the electrical parameters for the connected motor at standstill. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 15 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 line power supply. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 16: Introduction
For installation in altitudes above 10,000 ft [3 km] (350– passed before removing motor and line power 500 V), or 6,600 feet [2 km] (525–690 V), contact Danfoss plugs. regarding PELV. Do not use [Stop/Reset] as a safety switch. It does Warning against unintended start not disconnect the unit from line power.
Page 17: Ce Labeling
1997. The directive applies to all electrical equipment and Table 2.1 DC Capacitor Discharge Times appliances used in the 50–1000 V AC and the 75–1500 V DC voltage ranges. Danfoss CE labels in accordance with 2.1.2 Disposal Instructions the directive and issues a declaration of conformity upon request.
Page 18: What Is Covered
EMC directive. with the installer. As an aid to the installer, Danfoss has The adjustable frequency drive is sold as part of a prepared EMC installation guidelines for the power drive complete system, such as an air-conditioning system.
Page 19: Aggressive Environments
Proper ventilation is still required for the caused by foreign objects. internal components of the drive. Contact Danfoss for more information. Liquids can be carried through the air and condense in the 2.5 Vibration and Shock adjustable frequency drive and may cause corrosion of components and metal parts.
Page 21: Approvals & Certificates
An adjustable frequency drive takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such applications. For further information, see chapter 2.7.3 Example of Energy Savings. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 22: The Clear Advantage - Energy Savings
Power: 100% Figure 2.3 Energy Saved with Reduced Fan Capacity Flow ~n Pressure ~n Power ~n 12,5% 100% Figure 2.5 Laws of Proportionality Figure 2.4 Fan Curves for Reduced Fan Volumes. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 23: Comparison Of Energy Savings
Discharge dampers reduce power consumption. Inlet guide vanes offer a 40% reduction but are expensive to install. The Danfoss adjustable frequency drive solution reduces energy consumption by more than 50% and is easy to install. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 24: Better Control
Furthermore, an adjustable frequency drive 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. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 25: Cos Φ Compensation
It is possible to calculate the cost of installing the two different systems. The two systems shown in Figure 2.9 and Figure 2.10 can be established at roughly the same price. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 26: Without An Adjustable Frequency Drive
2.7.10 Without an Adjustable Frequency Drive Figure 2.9 Traditional Fan System Direct Digital Control Variable Air Volume Sensor P Pressure Energy Management System Sensor T Temperature Table 2.7 Legend to Figure 2.9 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 27: With An Adjustable Frequency Drive
Figure 2.10 Fan System Controlled by Adjustable Frequency Drives 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 28: Variable Air Volume
Pressure signal Frequency Cooling coil Heating coil converter VAV boxes Filter Supply fan Pressure transmitter Flow Frequency converter Return fan Flow Figure 2.11 Adjustable Frequency Drives Used in a VAV System Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 29: 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 dedicated adjustable frequency drive 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 30: Cooling Tower Fan
The adjustable frequency drives can also be used to turn the fan on and off as needed. With the Danfoss HVAC adjustable frequency drive, 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 31 Introduction Design Guide Frequency converter Water Inlet Temperature Sensor BASIN Water Outlet Conderser Water pump Supply Figure 2.13 Adjustable Frequency Drives Used with a Cooling Tower Fan MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 32: Condenser Pumps
Frequency converter Water Inlet Flow or pressure sensor BASIN Water Outlet Throttling valve Condenser Water pump Supply Figure 2.14 Adjustable Frequency Drive used with a Condenser Pump Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 33: Primary Pumps
If the flow rate must be increased later in the life of the system, the adjustable frequency drive can simply increase the pump speed instead of requiring a new pump impeller. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 34 Introduction Design Guide Flowmeter Flowmeter Frequency converter Frequency converter Figure 2.15 Adjustable Frequency Drives used with Primary Pumps in a Primary/Secondary Pump System Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 35: Secondary Pumps
Frequency converter Frequency converter Figure 2.16 Adjustable Frequency Drives used with Secondary Pumps in a Primary/Secondary Pump System MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 36: Control Structures
93-1 (L3-1) (U) 96 (V) 97 (W) 98 (PE) 99 Motor 91-2 (L1-2) 3 Phase (R+) 82 Brake power 92-2 (L2-2) input resistor 93-2 (L3-2) (R-) 81 Figure 2.18 Control Structure, 12-pulse Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 38: Pm/Ec+ Motor Control
2.8.3 PM/EC+ Motor Control 2.8.4 Local (Hand On) and Remote (Auto On) Control The Danfoss EC+ concept provides the possibility for using high efficiency PM motors in IEC standard frame size The adjustable frequency drive can be operated manually operated by Danfoss adjustable frequency drives.
Page 39: Control Structure Closed-Loop
While the default values for the closed-loop controller often provide satisfactory performance, the control of the system can often be optimized by adjusting some of the closed-loop controller parameters. It is also possible to auto tune the PI constants. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 40: Feedback Handling
Multi Setpoint Min is selected, the setpoint and feedback of Zone 1 are sent to the PID controller, since this has the larger difference (feedback is lower than setpoint, resulting in a positive difference). Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 41: 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 Figure 2.23. Figure 2.23 Feedback Conversion MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 42: 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. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 43: Example Of Closed-Loop Pid Control
This example assumes an induction motor is used, so 2.8.9 Example of Closed-loop PID Control 1-10 Motor Construction = [0] Asynchron. Figure 2.25 Closed-loop Control for a Ventilation System MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 44 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 2.9 Programming Order Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 45: Tuning The Closed-Loop Controller
If a shielded cable is used for serial communication bus, relay, control cable, signal interface and brake, the shield must be mounted on the enclosure at both ends. In some situations, however, it will be necessary to break the shield to avoid current loops. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 46 Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50 MHz (airborne) is generated by the control electronics. See chapter 5.7 EMC-compatible Installation for more information on EMC. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 47: 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 2.12 Emission Requirements, Generic Standards MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 48: Emc Test Results (Emission)
A non-sinusoidal current is transformed by means of a Fourier analysis and split up into sine-wave currents with different frequencies with 50 Hz as the basic frequency: Harmonic currents Table 2.14 Harmonic Currents Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 49: Harmonics Emission Requirements
1.5 hp [1 kW] up to 16 A large safety margin. phase current. Table 2.15 Equipment Connected to the Public Supply Network MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 50 8 kV AD — — 10 V/m — 6 kV CD Table 2.16 EMC Immunity Form 1) Injection on cable shield 2) AD–Air discharge 3) CD–Contact discharge 4) CM–Common mode 5) DM–Differential mode Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 51: Galvanic Isolation (Pelv)
Installation at high altitude: 380–480 V, enclosure A, B and C: At altitudes above 6,600 ft [2 km], contact Danfoss regarding PELV. 380–480 V, enclosure D, E and F: At altitudes above 10,000 ft [3 km], contact Danfoss regarding PELV.
Page 52: Ground Leakage Current
AC and DC currents • Use RCDs with a soft-charge delay to prevent faults due to transient ground currents • Dimension RCDs according to the system configu- ration and environmental considerations Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 53: Brake Function
100 Hz 2 kHz 100 kHz Time Figure 2.33 Typical Braking Cycle Danfoss offers brake resistors with duty cycle of 10% and ® 40% suitable for use with the VLT HVAC Drive adjustable Figure 2.32 Effect of the RCD frequency frequency drive series.
Page 54: Control With Brake Function
Check that the brake resistor can cope with a voltage of The brake is protected against short-circuiting of the brake 820 V or 1130 V - unless Danfoss brake resistors are resistor, and the brake transistor is monitored to ensure used.
Page 55: Extreme Running Conditions
The curves are showing the characteristic WARNING nominal speed at twice the nominal speed and at 0.2x the nominal speed. The adjustable frequency drive must be equipped with a break chopper. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 56 The adjustable frequency drive 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] Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 58: Selection
If the digital inputs 7, 8 or 9 are to be switched using the internal 24 V power supply (terminal 9), the connection Danfoss offers a wide range of options and accessories. between terminals 1 and 5, which is shown in Figure 3.2 has to be established.
Page 59: 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 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 60: Relay Option Mcb
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]. NOTICE! (Index [6] is relay 7, index [7] is relay 8, and index [8] is relay 9) Relay 7 Relay 8 Relay 9 Figure 3.3 Relay Locations Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 61 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. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 62: Backup Option Mcb 107 (Option D)
Attach the terminal cover and the LCP or blind cover When MCB 107, 24 V backup option supplies the control circuit, the internal 24 V supply is automatically disconnected. Figure 3.6 Connection to 24 V Backup Supplier (A2-A3). Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 63: Analog I/O Option Mcb
[0°C]. Specifications according to IEC 60751 • Supporting extended PID controllers with I/Os for 3 x Analog outputs supplying 0–10 V DC. setpoint inputs, transmitter/sensor inputs and outputs for servos MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 64 The function assigned is selectable via a parameter and has the same options as analog outputs on the control card. ® For a more detailed description of parameters, refer to the VLT HVAC Drive FC 102 Programming Guide. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 65: Mcb 112 Vlt ® Ptc Thermistor Card
MCB 112 can be used with motors in potentially explosive atmospheres. See the MCB 112 Instruction Manual for more information. ATmosphère EXplosive (ATEX) Table 3.8 ATEX Logo MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 66 EN 61508 for Tu = 167°F [75°C] ongoing 2 for maintenance cycle of 2 years 1 for maintenance cycle of 3 years PFD (for yearly functional test) 4.10 *10 λ + λ 8494 FIT λ 934 FIT Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 67: 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 backend 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 68: Electrical Wiring
3.1.11.5 Line Power Shield The line power shield is a Lexan cover installed inside the enclosure to provide protection according to VBG-4 accident-prevention requirements. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 69: Ruggedized Printed Circuit Boards
380–500 N110T5–N132T5 ABB T5L400TW N160T5 ABB T5LQ400TW N200T5 ABB T6L600TW N250T5 ABB T6LQ600TW N315T5 ABB T6LQ800TW 525–690 N75KT7–N160T7 ABB T5L400TW N200T7–N315T7 ABB T6L600TW N400T7 ABB T6LQ600TW Table 3.12 Circuit Breaker Information MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 70: F-Frame Panel Options
Selecting this option provides terminals organized and the options cabinet. 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. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 71: Remote Mounting Kit For Lcp
The resistor is selected based on its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide variety of different resistors that are specifically designed for Danfoss adjustable frequency drives.
Page 73: How To Order
AC line voltage 10-11 with integral options by sending a type code string Enclosure 12-14 describing the product to the local Danfoss sales office. RFI filter 15-16 Brake The type code is a string of characters describing the Display (LCP)
Page 74 E: Line power disconnect + contactor + fuses J: Circuit breaker + fuses Adaptation X: Standard cable entries Q: Heatsink access panel Adaptation X: No adaptation Software release 24–27 Current software Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 75 BO:MCB 109 Analog I/O option BY: MCO 101 Extended Cascade Control options 33–34 CX: No options options X: No options 5: MCO 102 Advanced Cascade Control C option software 36–37 XX: Standard software MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 76: Ordering Numbers
Front mounting kit, IP55 enclosures 130B1129 LCP kit Panel mounting kit for all LCPs including fasteners and gasket - without 130B1170 cable Table 4.4 Options can be ordered as factory built-in options Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 77 130B1208 External Options Ethernet IP Ethernet master Table 4.5 A, B, D Slot & External Options For information on serial communication bus and application option compatibility with older software versions, contact your Danfoss supplier. Type Description Spare Parts Ordering no.
Page 78: Advanced Harmonic Filters
130B1391 350 [250] N350 1852 1542 <77 130B1261 130B1228 [N250] 2x130B1448 2x130B1370 450 [315] N450 2576 1810 <80 2x130B1259 2x130B1216 [N315] Table 4.7 Advanced Harmonic Filters 380–415 V, 50 Hz, D-frame Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 79 130B3094 350 [250] N350 1850 1542 <77 130B2873 130B2856 [N250] 2x130B3133 2x130B3092 450 [315] N450 2576 1810 <80 2x130B2871 2x130B2819 [N315] Table 4.9 Advanced Harmonic Filters, 380–415 V, 60 Hz, D-frame MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 80 130B3165 130B2259 130B1786 N250 1852 1542 <77 130B1769 130B1751 130B1900+ 130B1783+ N315 2482 1769 <80 130B2200 130B1784 130B1765+ 130B1497+ 130B1766 130B1498 Table 4.11 Advanced Harmonic Filters 440–480 V, 60 Hz, D-frame Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 81 N250 1852 1288 <75 130B5260 130B5226 2x130B5273 130B5244 N315 2812 1542 <75 2x130B5258 130B5227 2x130B5273 130B5245 N400 2812 1852 <75 2x130B5258 130B5228 Table 4.13 Advanced Harmonic Filters, 600 V, 60 Hz MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 82 P900 6040 4626 4x130B5259 3x130B5227 4x130B5275 3x130B5244 1098 1150 P1M0 1032 7408 4626 4x130B5260 3x130B5227 4x130B5244 1580 1350 P1M2 1227 6168 4x130B5227 Table 4.14 Advanced Harmonic Filters, 600 V, 60 Hz Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 83 2x130B5042 130B5334 [N355] 130B5042 130B5330 +130B5066 +130B5331 N550 N550 475 [355] 413 650 [500] 2916 2127 [N400] [N400] 130B5197 130B5292 +130B5198 +130B5293 Table 4.15 Advanced Harmonic Filters, 500–690 V, 50 Hz MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 84 4118 [750] [P800] [1000] [P900] 2x130B5199 2x130B5294 +2x130B5197 +130B5295 6x130B5042 3x130B5333 1150 1098 P1M0 1079 P1M0 1032 8436 4626 6x130B5197 3x130B5295 [850] Table 4.16 Advanced Harmonic Filters, 500–690 V, 50 Hz Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 85: Sine-Wave Filter Modules, 380-690 V Ac
1160 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 4.17 Sine-Wave Filter Modules, 380–500 V MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 86 Table 4.18 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. 2014-01-13 All rights reserved. MG16C122...
Page 87: Ordering Numbers: Du/Dt Filters
4.2.5 Ordering Numbers: Brake Resistors For brake resistor selection information, refer to the Brake Resistor Design Guide. Use this table to determine the minimum resistance applicable to each adjustable frequency drive size. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 88 =Nominal resistance required to achieve 150% braking torque. br,nom Larger adjustable frequency drives include multiple inverter modules with a brake chopper in each inverter. Connect equal resistors to each brake chopper. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 89: How To Install
Figure 5.2 Detail Dimensions, D1h drive, the required ceiling clearance is 4 in [100 mm]. Bottom mounting slot detail Top mounting hole detail Table 5.2 Legend to Figure 5.2 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 90 Figure 5.4 Detail Dimensions, D2h drive, the required ceiling clearance is 4 in [100 mm]. Top mounting hole detail Bottom mounting slot detail Table 5.4 Legend to Figure 5.4 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 91 Figure 5.6 Detail Dimensions, D3h drive, the required ceiling clearance is 4 in [100 mm]. Top mounting hole detail Bottom mounting slot detail Table 5.6 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 92 Figure 5.8 Detail Dimensions, D4h drive, the required ceiling clearance is 4 in [100 mm]. Top mounting hole detail Bottom mounting slot detail Table 5.8 Legend to Figure 5.8 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 93 4 in [100 mm]. [0.9] [0.4] [0.3] Figure 5.10 Detail Dimensions, D5h Top mounting hole detail Bottom mounting slot detail Table 5.10 Legend to Figure 5.10 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 94 Figure 5.12 Detail Dimensions, D6h drive, the required ceiling clearance is 4 in [100 mm]. Top mounting hole detail Bottom mounting slot detail Table 5.12 Legend to Figure 5.12 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 95 If using a kit to direct the airflow from the heatsink to the outside vent on the back of the adjustable frequency drive, the required ceiling clearance is 4 in [100 mm]. Figure 5.14 Top Mounting Hole Dimension Detail, D7h MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 96 If using a kit to direct the airflow from the heatsink to the outside vent on the back of the adjustable frequency drive, the required ceiling clearance is 4 in [100 mm]. Figure 5.16 Top Mounting Hole Dimension Detail, D8h Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 98 How to Install Design Guide Figure 5.18 Mechanical Dimensions, E2 Lifting eye detail Rear mounting slots Table 5.16 Legend to Figure 5.18 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 99 Design Guide 1804 225.0 Ø29 (71.0) (8.85) (1.1) 2281 (89.8) 2206 (86.9) 1499 (59.0) (23.8) Figure 5.19 Mechanical Dimensions, F2 1 Minimum clearance from ceiling Table 5.17 Legend to Figure 5.19 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 100 Design Guide 225.0 2401 Ø29 (8.85) (94.5) (1.1) 2280 (89.7) 2205 (86.8) 1497 (58.9) (23.8) Figure 5.20 Mechanical Dimensions, F4 1 Minimum clearance from ceiling Table 5.18 Legend to Figure 5.20 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 101 16.54 [420] [mm]) Depth 15.0 [381] 15.0 [381] 15.20 [386] 15.98 [406] Max weight (lbs [kg]) 255.74 [116] 284.40 [129] 440.92 [200] 496.04 [225] Table 5.20 Mechanical Dimensions, Frame Size D5h-D8h MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 102: Mechanical Dimensions, 12-Pulse Units
2905.69 [1318] 3441.42 [1561] Table 5.21 Mechanical Dimensions, Frame Size E1-E2, F1-F4 5.1.2 Mechanical Dimensions, 12-Pulse Units IP/21 NEMA 1 1400 m3/Hr 1970 m3/Hr 1160 Figure 5.21 Mechanical Dimensions (mm), F8 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 107 102.36 [2600] (in [mm]) Depth 23.86 [606] Max weight (lbs [kg]) 985.47 [447] 1474.89 [669] 1968.73 [893] 2460.36 [1116] 2286.19 [1037] 2775.62 [1259] Table 5.22 Mechanical Dimensions, 12-Pulse Units, Frame Sizes F8-F13 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 108: Mechanical Mounting
The D7h and D8h adjustable frequency drives are shipped with a pedestal and a wall spacer. Before securing the enclosure to the wall, install the pedestal behind the mounting flange as shown in Figure 5.27. Figure 5.27 Wall Mounting Spacer Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 109: Pedestal Installation Of F-Frames
Install each M10x30 mm bolt with captive lock washer and flat washer through the base plate and into the threaded hole in the base. Install four bolts per cabinet. Refer to Figure 5.30 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 110: Lifting
Dimensions for the weight of each frame size. Maximum diameter for the bar is 1 in [2.5 cm]. The angle from the top of the drive to the lifting cable should be 60° or greater. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 111 The pedestal allows proper airflow and cooling to the adjustable frequency drive. See chapter 5.1.5 Pedestal Installation of F-frames. Figure 5.34 Recommended Lifting Method, Frame Sizes F3, F4, F11, F12 and F13 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 112: Safety Requirements Of Mechanical Installation
VLT HVAC Drive High Power Instruction Manual. NOTICE! Cables General All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper (140–167°F [60–75°C]) conductors are recommended. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 113: Motor Cables
Avoid mounting with twisted shield ends (pigtails), which will spoil high frequency shielding effects. • If it is necessary to split the shield to install a motor isolator or motor relay, the shield must be continued with the lowest possible HF impedance. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 114: Electrical Installation Of Motor Cables
8 ft [2.5 m], and quantity of cables must be equal from each inverter module to the common terminal in the junction box. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 115: Preparing Connector Plates For Cables
The connector plate must be fitted to the adjustable frequency drive to ensure the specified degree of 1 Line Power Side protection. 2 Motor Side Table 5.26 Legend to Figure 5.36 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 116 Figure 5.38 D5h & D6h, Bottom View 1 Line Power Side 1 Line Power Side 2 Motor Side 2 Motor Side Table 5.27 Legend to Figure 5.37 Table 5.28 Legend to Figure 5.38 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 117 (7.854) 535.0 (21.063) 281.8 258.5 (11.096) (10.177) 533.0 35.5 36.2 (20.984) (1.398) (1.425) 595.8 (23.457) 1328.8 (52.315) Figure 5.41 F1, Bottom View Cable conduit entry Table 5.31 Legend to Figure 5.41 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 118 [7.854] 535.0 [21.063] 281.8 258.2 [11.096] [10.167] 533.0 35.5 [20.984] [1.398] 36.2 594.8 [1.425] [23.417] 1727.8 [68.024] Figure 5.42 F2, Bottom View Cable conduit entry Table 5.32 Legend to Figure 5.42 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 119 2X 281.8 (10.167) (11.096) 533 (20.984) 35.5 (1.398) 597.0 (23.504) 36.2 1130.0 (44.488) (1.425) 1191.8 (46.921) 2324.8 (91.528) Figure 5.44 F4, Bottom View Cable conduit entry Table 5.34 Legend to Figure 5.44 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 120: Connector/Conduit Entry, 12-Pulse - Ip21 (Nema 1) And Ip54 (Nema12)
258.5 [10.177 ] 35.5 [ 1 ] 36.5 733.0 [ 28.858 ] [ 1.437 ] Figure 5.45 Frame Size F8 Place conduits in shaded areas Table 5.35 Legend to Figure 5.45 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 121 533,0 [1.47] [ 20.98 ] 603,0 [ 23.74 ] 1336,0 36.5 [ 52.60 ] [1.44] Figure 5.46 Frame Size F9 Place conduits in shaded areas Table 5.36 Legend to Figure 5.46 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 122 1600 . 0 [ 62 . 992 ] 2333 . 0 [ 91 . 850 ] Figure 5.48 Frame Size F11 Place conduits in shaded areas Table 5.38 Legend to Figure 5.48 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 123 [ 60 . 354 ] 1600 . 0 [ 62 . 992 ] 2733 . 0 [ 107 . 598 ] Figure 5.50 Frame Size F13 Place conduits in shaded areas Table 5.40 Legend to Figure 5.50 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 124: Power Connections
If it is necessary to break the shield to install a motor isolator or Figure 5.52 Motor Cable Connection contactor, continue the shield at the lowest possible HF impedance. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 125 14 Motor output terminals 96 (U), 97 (V), 98 (W) Analog switches (A53), (A54) 15 Line power input terminals 91 (L1), 92 (L2), 93 (L3) Relay 1 (01, 02, 03) Table 5.42 Legend to Figure 5.53 and Figure 5.54 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 126 Terminal Locations - D1h/D2h Take the following position of the terminals into consideration when designing the cable access. Figure 5.55 Position of Ground Terminals IP21 (NEMA Type 1) and IP54 (NEMA Type 12), D1h/D2h Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 127 Take the following position of the terminals into consideration when designing the cable access. Figure 5.56 Position of Ground Terminals IP20 (Chassis), D3h/D4h Ground Terminals Table 5.43 Legend to Figure 5.55 and Figure 5.56 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 128 Take the following position of the terminals into consideration when designing the cable access. 9 [ ] 0 [ ] Figure 5.57 Terminal Locations, D5h with Disconnect Option Line Power Terminals Motor Terminals Brake Terminals Ground Terminals Table 5.44 Legend to Figure 5.57 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 129 Design Guide 28.6 24.5 20.4 20.1 0 [ ] Figure 5.58 Terminal Locations, D5h with Brake Option Line Power Terminals Motor Terminals Brake Terminals Ground Terminals Table 5.45 Legend to Figure 5.58 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 130 Take the following position of the terminals into consideration when designing the cable access. 18.0 Figure 5.59 Terminal Locations, D6h with Contactor Option Line Power Terminals Motor Terminals TB6 Terminal block for contactor Ground Terminals Brake Terminals Table 5.46 Legend to Figure 5.59 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 131 Design Guide Figure 5.60 Terminal Locations, D6h with Contactor and Disconnect Options Brake Terminals Ground Terminals TB6 Terminal block for contactor Line Power Terminals Motor Terminals Table 5.47 Legend to Figure 5.60 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 132 How to Install Design Guide 18.4 Figure 5.61 Terminal Locations, D6h with Circuit Breaker Option Line Power Terminals Motor Terminals Brake Terminals Ground Terminals Table 5.48 Legend to Figure 5.61 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 133 21.4 20.3 16.2 15.6 14.7 0 [ ] Figure 5.62 Terminal Locations, D7h with Disconnect Option Line Power Terminals Ground Terminals Motor Terminals Brake Terminals Table 5.49 Legend to Figure 5.62 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 134 42.6 1034 40.7 1009 39.7 0 [ ] Figure 5.63 Terminal Locations, D7h with Brake Option Line Power Terminals Motor Terminals Brake Terminals Ground Terminals Table 5.50 Legend to Figure 5.63 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 135 0 [ ] Figure 5.64 Terminal Locations, D8h with Contactor Option TB6 Terminal block for contactor Brake Terminals Motor Terminals Line Power Terminals Ground Terminals Table 5.51 Legend to Figure 5.64 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 136 22.3 Figure 5.65 Terminal Locations, D8h with Contactor and Disconnect Options TB6 Terminal block for contactor Motor Terminals Line Power Terminals Ground Terminals Brake Terminals Table 5.52 Legend to Figure 5.65 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 137 How to Install Design Guide 23.8 Figure 5.66 Terminal Locations, D8h with Circuit Breaker Option Line Power Terminals Motor Terminals Brake Terminals Ground Terminals Table 5.53 Legend to Figure 5.66 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 138 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] Figure 5.67 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions Front View of Unit Table 5.54 Legend to Figure 5.67 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 139 How to Install Design Guide 19 Nm [14 FTa 453[17.8] 0[0.0] Figure 5.68 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions (Detail B) MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 140 431 (17.0) 562 (22.1) [355/450–500/630 KW] (690 V) 450/475–550/600 hp [315/355-400/450 kW] 371 (14.6) 371 (14.6) 341 (13.4) 431 (17.0) 431 (17.0) 455 (17.9) (400 V) Table 5.55 Legend to Figure 5.69 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 141 FASTENER TORQUE M8 9.6 Nm (7 FT-LB) FASTENER TORQUE M8 9.6 Nm (7 FT-LB) R/L1 91 S/L2 92 T/L3 93 186[7.3] U/T1 96 V/T2 97 W/T3 98 17[0.7] 0[0.0] Figure 5.70 IP00 Enclosure Power Connection Positions MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 142 How to Install Design Guide R 81 019Nm (14 F) 147(5.8) 0(0.0) Figure 5.71 IP00 Enclosure Power Connection Positions Figure 5.72 IP00 Enclosure Power Connections, Position of Disconnect Switch Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 143 423 (16.7) 256 (10.1) [355/450–500/630 KW] (690 V) 450/475–550/600 hp [315/355-400/450 kW] 383 (15.1) 244 (9.6) 334 (13.1) 424 (16.7) 109 (4.3) 149 (5.8) (400 V) Table 5.56 Power Connections, E2 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 144 Motor Terminals Right Side Brake Terminals Table 5.57 Legend to Figure 5.74 DC ‘-’ 1739.1 805.0 765.0 1694.1 DC ‘+’ 1654.1 710.0 Figure 5.75 Regeneration Terminal Locations - F1 and F3 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 145 Right Side Left Side Ground bar Table 5.58 Legend to Figure 5.76 DC ‘-’ 1739.1 1203.2 1163.2 1694.1 DC ‘+’ 1654.1 1098.1 Figure 5.77 Regeneration Terminal Locations - F2 and F4 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 146 Figure 5.78 Terminal Locations - Rectifier. Connector Plate is 1.65 in [42 mm] below .0 Level. Left Side Load share Terminal (-) Front Side Ground bar Right Side Load share Terminal (+) Table 5.59 Legend to Figure 5.78 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 147 Figure 5.79 Terminal Locations - Options Cabinet. Connector Plate is 1.65 in [42 mm] below .0 Level. Left Side Right Side Front Side Ground bar Table 5.60 Legend to Figure 5.79 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 148 600 hp [450 kW] (480 V), 850–950 hp [630– 34.9 86.9 122.2 174.2 710 kW] (690 V) 650–1075 hp [500–800 kW] (480 V), 1075– 46.3 98.3 119.0 171.0 1350 hp [800–1000 kW] (690 V) Table 5.62 Dimension for Terminal Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 149: Power Connections 12-Pulse Adjustable Frequency Drives
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 Figure 5.81 AC line input connections NOTICE! For more information, see chapter 5.7 EMC-compatible Installation. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 150 If one of the 6-pulse modular rectifiers becomes inoperable, it is possible to operate the adjustable frequency drive at reduced load with a single 6-pulse rectifier. Contact Danfoss for reconnection details. No paralleling of line power cabling is shown here. A 12-pulse adjustable frequency drive used as a 6-pulse should have line cables of equal numbers and lengths.
Page 151 Protective Ground 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 adjustable frequency drive. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 152: Fuses
Short circuit protection: The adjustable frequency drive must be protected against short circuit in order to prevent electrical or fire hazard. Danfoss recommends using the fuses mentioned in Table 5.65 and Table 5.66 to protect service personnel or other equipment in case of an internal failure.
Page 153: Control Terminals
To remove the cable from the terminal: Insert a screwdriver in the square hole. Pull out the cable. Wiring to Control Terminals 9 - 10 mm (0.37 in) Figure 5.84 Strip Isolation MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 155: 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 Figure 5.88 Interconnect Diagram for D-frames MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 156 How to Install Design Guide Figure 5.89 Interconnect Diagram E-frames and F-frames (6-pulse) *Safe Torque Off (STO) input available with STO function only Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 157 Control cables must be shielded. Use a clamp from the accessory bag to connect the shield to the adjustable frequency drive decoupling plate for control cables. Figure 5.90 Shielded Control Cable MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 158: 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 Figure 5.91 Control Cable Diagram Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 159 Table 5.68 F-frame Numbers of Terminals Terminal 37 is the input to be used for safe torque off. For instructions on safe torque off installation, refer to chapter 2.6 Safe Torque Off. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 160: Switches S201, S202, And S801
Change the switch position at power off only. Figure 5.93 Input Polarity of Control Terminals, PNP NPN (Sink) Digital input wiring Figure 5.94 Input Polarity of Control Terminals, NPN Figure 5.95 Switch Location Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 161: Final Set-Up And Test
Unsuccessful AMA is often caused by incorrectly registered cos 0,80 motor nameplate data or too big a difference between the motor power size and the adjustable frequency drive 1,7L power size. IP 65 H1/1A Figure 5.96 Motor Nameplate MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 162: Additional Connections
ABB OT400U03 D5h/D6h N200–N400 ABB OT600U03 P630–P710 Merlin Gerin NPJF36000S12AAYP P800 Merlin Gerin NRKF36000S20AAYP P900–P1M2 Merlin Gerin NRKF36000S20AAYP Table 5.73 Line Power Disconnects, D, E and F- frame Adjustable Frequency Drives Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 163: Circuit Breakers
6000 380–480 N250 ABB T6LQ600TW 6000 380–480 N315 ABB T6LQ800TW 8000 525–690 N75K–N160 ABB T5L400TW 4000 525–690 N200–N315 ABB T6L600TW 6000 525–690 N400 ABB T6LQ600TW 6000 Table 5.75 D-frame Circuit Breakers MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 164: Line Power Contactors
Eaton XTCEC14P22B P900 525–690 V Eaton XTCE820N22A P710-P800 380–500 V & P1M2 525–690 V Eaton XTCEC14P22B Table 5.78 F-frame Contactors NOTICE! Customer-supplied 230 V supply is required for line power contactors. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 165: Brake Resistor Temperature Switch
100 and 101. Use a 5 Amp fuse for protection. In UL applications, use a Littelfuse KLK-5 or equivalent. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 166: Relay Output E & F-Frame
Motor Adaptation (AMA) cannot be used. Figure 5.99 Correct Parallel Motor Connection Small motors have relatively high ohmic resistance in the stator, which can cause problems at start and low RPM. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 167 Although failure due to bearing currents is rare, if it occurs, use the following mitigation strategies. Figure 5.100 Changing Motor Rotation MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 168: Installation Of Misc. Connections
S202, and S801. • Use minimum speed settings, if possible. • Use a dU/dt or sinus filter Communication protocol must be set to 8-30 Protocol. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 169 Connect a PC to the unit via the USB com port. All adjustable frequency drives are equipped with a serial communication port. Danfoss provides a PC tool for Open PC-based configuration tool MCT 10 Set-up communication between PC and adjustable frequency Software drive, PC-based configuration tool MCT 10 Set-up Software.
Page 171 If the installation is not carried out according to the guidelines, and if non-shielded cables and control wires are used, some emission requirements will not be fulfilled, although the immunity requirements will be. Figure 5.103 EMC-compatible Electrical Installation of an Adjustable Frequency Drive in Cabinet MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 172: Use Of Emc-Compatible Cables
) by assessing the physical design of the cable. Transfer impedance (Z ) can be assessed by the following: • The conductibility of the shield material. • The contact resistance between the individual shield conductors. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 173: Residual Current Device
2.11 Ground Leakage Current for more information. Incorrect grounding Protection from potential between PLC and adjustable frequency drive 50/60 Hz ground loops Cables for Serial Communication Table 5.84 Legend to Figure 5.106 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 174: Application Examples
5-12 Terminal 27 Digital Input = coast inverse 5-12 Terminal 27 Digital Input = Stop inverse (default) Figure 6.1 Terminal 37: Available only with STO Function Figure 6.2 Terminal 37: Available only with STO Function Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 175: Potentiometer Reference
PM non-salient SPM). 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. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 176: Smart Logic Control
When the last event/action has been executed, the sequence starts over again from event [1]/action [1]. Figure 6.4 shows an example with three events/actions: Figure 6.4 Example of Events and Actions Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 177: Slc Application Example
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] Set Action 4 in 13-52 SL Controller Action [4] to No Action [1] MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 178 Set the Smart Logic Control in 13-00 SL Controller Mode to ON. A start/stop command is applied on terminal 18. If stop signal is applied, the adjustable frequency drive will ramp down and go into free mode. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 179: Basic Cascade Controller
To prevent frequent staging pumps. and destaging and minimize pressure fluctuations, a wider fixed-speed bandwidth is used instead of the staging bandwidth. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 180: Pump Staging With Lead Pump Alternation
When the programmed value of the timer expires, the lead pump is removed, avoiding a water circulation problem. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 181: Fixed Variable-Speed Pump Wiring Diagram
Diagram BASIC cascade controller with one variable-speed pump (lead) and two fixed-speed pumps, a 4–20 mA transmitter L1/L2/L3 L1/L2/L3 L1/L2/L3 and system safety interlock. Figure 6.10 Lead Pump Alternation Wiring Diagram MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 182: Start/Stop Conditions
Starts and stops according to commands via Staging/Destaging terminals or serial bus. Cascade controller can only work when the adjustable frequency drive is in "Auto ON" mode Table 6.2 Function of LCP Keys Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 183: Installation And Set-Up
+), while terminal 69 is connected to the N signal (TX-,RX-). See chapter 5.6.2 Safety Ground Connection chapter 5.7.3 Grounding of Shielded/Armored Control Cables If more than one adjustable frequency drive is connected to a master, use parallel connections. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 184: Hardware Set-Up
8-37 Maximum Specify a maximum delay time between Inter-Char Delay two received bytes to ensure timeout if transmission is interrupted. Table 7.2 RS-485 Parameters Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 185: Fc Protocol Overview
The FC protocol, also referred to as FC bus or standard and, where possible, write values to them. This permits a bus, is the Danfoss standard serial communication bus. It range of control options, including controlling the setpoint defines an access technique according to the master-slave of the adjustable frequency drive when its internal PID principle for communications via a serial bus.
Page 186: Message Structure
Bit 7 = 1 (address format 1-126 active) Bit 0-6 = adjustable frequency drive address 1-126 Bit 0-6 = 0 Broadcast The slave returns the address byte unchanged to the master in the response message. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 187: Data Control Byte (Bcc)
PCD1 PCD2 high Figure 7.8 Example Parameter Block Text block The text block is used to read or write texts via the data block. PCD1 PCD2 Figure 7.9 Example Text Block MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 188: The Pke Field
Table 7.4 Parameter Commands, Master to Slave Bit no. Response No response Parameter value transferred (word) Parameter value transferred (double word) Command cannot be performed text transferred Table 7.5 Response, Slave to Master Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 189: Parameter Number (Pnu)
The length is defined in the second byte of the message, LGE. When using text transfer the index character indicates whether it is a read or a write command. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 190: Data Types Supported By The Adjustable Frequency Drive
Unsigned 8 1000 Unsigned 16 Unsigned 32 Text string Byte string Time difference 0.01 Reserved 0.001 Bit sequence 0.0001 Table 7.7 Supported Data Types 0.00001 0.000001 0.0000001 Table 7.8 Conversion Table Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 191: Process Words (Pcd)
7.6 Modbus RTU Overview 7.6.1 Assumptions NOTICE! Danfoss assumes that the installed controller supports the 4-14 Motor Speed High Limit [Hz] is a single word, and the interfaces in this document, and strictly observes all parameter command for write in EEPROM is “E”.
Page 192: Modbus Rtu Overview
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 timeout occurs. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 193: Network Configuration
This causes a timeout (no response from the slave), since the value in the final CRC field is not valid for the combined messages. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 194: Address Field
This can include items such • Coil or register addresses • Quantity of items to be handled • Count of actual data bytes in the field Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 195 Data valid Relay 1 off Relay 1 on Relay 2 off Relay 2 on Set up LSB Set up MSB No reversing Reversing control word (FC profile) Table 7.16 Coil Descriptions MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 196: How To Control The Adjustable Frequency Drive
* Used to specify the index number to be used when accessing an indexed parameter. 7.8.9 How to Control the Adjustable Frequency Drive This section describes codes that can be used in the function and data fields of a Modbus RTU message. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 197: Function Codes Supported By Modbus Rtu
(or slave) is in the wrong state to process a request of this type, because it is not configured and is being asked to return register values, for example. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 198: Ind
The following examples illustrate various Modbus RTU Data (coils 40-33) commands. If an error occurs, refer to chapter 8 General Data (coils 48-41) 06 (STW=0607hex) Specifications and Troubleshooting. Error check (CRC) Table 7.23 Master Response Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 199: Force/Write Single Coil (05 Hex)
Quantity of coils HI Force data LO Quantity of coils LO 10 (16 coils) Quantity of coils HI Error check (CRC) Quantity of coils LO Error check (CRC) Table 7.27 Response Table 7.25 Response MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 200: Read Holding Registers (03 Hex)
Error check (CRC) Slave address Function Table 7.31 Response Byte count Data HI (Register 3030) Data LO (Register 3030) Data HI (Register 3031) Data LO (Register 3031) Error check (CRC) Table 7.29 Response Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 201: Preset Multiple Registers (10 Hex)
Field Name Example (HEX) Slave address Table 7.34 Bit Definitions Function Starting address HI Starting address LO No. of registers HI No. of registers LO Error check (CRC) Table 7.33 Response MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 202 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. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 203 Bit 02, Coasting stop: Bit 02=’0’: The adjustable frequency drive releases the motor. Bit 02 = ’1’: The adjustable frequency drive starts the motor with a start command. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 204 Bit 12=’0’: There is no temporary overtemperature on the inverter. Bit 12=’1’: The inverter stops because of overtem- perature but the unit does not trip and resumes operation once the overtemperature stops. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 205 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 Figure 7.19 Reference and MAV scaling MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 206: General Specifications And Troubleshooting
272 [598] Weight, enclosure IP54 kg [lbs] [594] 0.98 Efficiency Output frequency [Hz] 0–590 Heatsink overtemp. trip [°C] Power card ambient trip [°C] Table 8.1 Line Power Supply 3x380–480 V AC Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 207 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). MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 208: Line Power Supply 3 X 525-690 V Ac
Weight, enclosures IP20, IP21, 62 [135] IP54 kg [lbs] 0.98 Efficiency Output frequency [Hz] 0–590 Heatsink overtemp. trip [°C] Power card ambient trip [°C] Table 8.3 Line Power Supply 3 x 525–690 V AC Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 209 Weight, enclosure IP20, IP21, IP54 kg [lbs] 125 [275] 0.98 Efficiency Output frequency [Hz] 0–590 0–525 Heatsink overtemp. trip [°C] Power card ambient trip [°C] Table 8.4 Line Power Supply 3 x 525–690 V AC MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 211: 12-Pulse Specifications
(690) Weight enclosure IP 54 kg (lbs) Efficiency 0.98 Output Frequency 0–590 Hz Heatsink overtemp. trip 110°C 95°C Power card ambient trip 85°C Table 8.7 Line Power Supply 380–480 V AC MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 213 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 *Percentage relates to nominal torque. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 214 The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. PELV isolation +24V Control Mains High Motor voltage Functional isolation DC-Bus RS485 Figure 8.1 PELV Isolation of Analog Inputs Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 215 4 Hz Voltage level see Digital Inputs Maximum voltage on input 28 V DC Input resistance, R approx. 4 kΩ Pulse input accuracy (0.1–1 kHz) Max. error: 0.1% of full scale MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 216 System response time (terminals 18, 19, 27, 29, 32, 33) Speed control range (open-loop) 1:100 of synchronous speed 30–4000 rpm: Maximum error of ±8 rpm Speed accuracy (open-loop) All control characteristics are based on a 4-pole asynchronous motor Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 217 The USB connection is not galvanically isolated from ground protection. Use only an isolated laptop/PC as connection to the USB connector on the adjustable frequency drive or an isolated USB cable/converter. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 218: Efficiency
All other E-frame Units frequency drive depends on magnetizing level. In general, the efficiency is just as good as with line power operation. The efficiency of the motor depends on the type of motor. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 219: Peak Voltage On Motor
PEAK (DC link voltage = AC line voltage x 1.35). UPEAK 0.8 × dU / dt = Rise time Data are measured according to IEC 60034-17. Cable lengths are in meters. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 220 (ft [m]) voltage [V] [μsec] [kV] [kV/μsec] 100 [30] 0.57 1.611 2.261 100 [30] 0.25 2.510 100 [30] 1.13 1.629 1.150 1) With Danfoss dU/dt filter. Table 8.13 P450–P1M4, T7/525–690 V Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 221: Special Conditions
P355 to P1M0 380–480 V 45 C 40 C 45 C 50 C 50 C 55 C 55 C Table 8.14 Derating Tables for Adjustable Frequency Drives Rated 380–480 V (T4) MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 222 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 Adjustable Frequency Drives Rated 525–690 V (T7) Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 223: Automatic Adaptations To Ensure Performance
If the motor runs continuously at an RPM value lower than half of the rated value, additional air-cooling is needed. A motor designed for this type of operation may also be used. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 224: Troubleshooting
Note 1) Oversynchronous 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 overloading the motor. Table 8.16 Legend to Figure 8.6 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 225 Brake chopper fault Brake check 2-15 Heatsink temp Motor phase U missing 4-58 Motor phase V missing 4-58 Motor phase W missing 4-58 Inrush fault Fieldbus communication fault Out of frequency range MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 226 22-6* Start delayed 22-7* Stop delayed 22-7* Clock fault 0-7* 104 Mixing fan fault 14-53 201 Fire M was active 202 Fire M limits exceeded 203 Missing motor 204 Locked rotor Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 227 A trip lock situation can only be reset by power cycling. Warning yellow Alarm flashing red Trip locked yellow and red Table 8.18 LED Indications MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 228 The alarm words, warning words and extended status words can be read out via serial bus or optional serial communication bus for diagnosis. See also 16-90 Alarm Word, 16-92 Warning Word and 16-94 Ext. Status Word. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 229: Alarm Words
20000000 Drive initialized 20000000 Reserved 40000000 Safe torque off [A68] 40000000 PTC 1 Safe Torque Off [A71] 80000000 80000000 Dangerous Failure [A72] Table 8.20 Alarm Word Table 8.21 Alarm Word 2 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 230: 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 8.22 Warning Words Table 8.23 Warning Words 2 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 231: Extended Status Words
08000000 Reserved 08000000 Reserved 10000000 Reserved 10000000 Reserved 20000000 Reserved 20000000 Reserved 40000000 Reserved 40000000 Reserved 80000000 Reserved 80000000 Reserved Table 8.24 Extended Status Word Table 8.25 Extended Status Word 2 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 232: Warning And Alarm Introduction
Options are programmed at 14-12 Function at Mains Imbalance. Troubleshooting Check the supply voltage and supply currents to the adjustable frequency drive. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 233 53 or 54 is set for voltage. Check that measuring the resistance to ground of the motor 1-93 Thermistor Source selects terminal 53 or 54. leads and the motor with a megohmmeter. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 235 Check for loose or missing wiring The trip and reset points are different based on the adjustable frequency drive power size. If necessary, contact the Danfoss supplier or service department. Note the code number for further trouble- Troubleshooting shooting directions.
Page 236 Increase the current limit, if necessary. Be Check for a defective option card. sure that the system can operate safely at a higher limit. If a 24 V DC power supply is used, verify proper supply power. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 237 22-60 Broken Belt Function is set for alarm. Check for clogged filters. Troubleshoot the system and reset the after the fault has been cleared. Check fan operation. Check the power card. MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 238 Inspect the system for proper operation. WARNING 204, Locked rotor With an adjustable frequency drive operating multi-motors, an overload condition was detected. This could indicate a locked rotor. Inspect the motor for proper operation. Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 239: Index
Brake Function..................52 Constant torque applications (CT mode)........221 Brake Resistor Cabling................ 52 Control Cable Terminals..............151 Brake Resistor Calculation..............51 Control cables................155, 168 Brake Resistor Selection..............51 Control Cables................153, 156 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 240 Dimensions 6-Pulse................87 Filter................15, 70, 73, 85, 218 Dimensions Shipping..............99, 105 Filters....................76, 83 Direction of motor rotation............165 Final Set-up and Test................ 159 Discharge Time..................15 Flow meter....................31 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 241 Insulation Resistance Monitor (IRM)..........68 Modbus Communication..............182 Interconnect Diagram............. 153, 154 Modbus Exception Codes............... 195 Intermediate circuit............53, 216, 217 Modbus RTU................183, 189 Intermittent Duty Cycle..............11 Moment of inertia................. 53 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 242 Pulse Start/Stop.................. 172 Output Performance (U, V, W)............211 Pump....................21, 30 Output Switching................. 53 Pump impeller..................30 Outputs for servos................61 Overcurrent protection..............150 Radiated emission................46 Rated motor speed................10 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 243 Tuning the Closed-loop Controller..........43 Shielded....................155 Type Code String.................. 72 Shielding................112, 122, 149 Shielding of cables................122 Unsuccessful AMA................159 Shielding of Cables................149 USB Connection.................. 151 Short circuit..................232 MG16C122 Danfoss A/S © Rev. 2014-01-13 All rights reserved.
Page 244 VT Characteristics................. 13 Voltage Vector ControlVVCplus............13 Warning against unintended start..........14 Warning Words................... 228 Weight............99, 105, 205, 206, 208, 209 What is CE conformity and labeling?..........15 What Is Covered..................16 Danfoss A/S © Rev. 2014-01-13 All rights reserved. MG16C122...
Page 246 Danfoss shall not be responsible for any errors in catalogs, brochures or other printed material. Danfoss reserves the right to alter its products at any time without notice, provided that alterations to products already on order shall not require material changes in specifications previously agreed upon by Danfoss and the Purchaser. 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