Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® HVAC Drive FC 102 1.1–90 kW www.danfoss.com/drives...
Page 3: Table Of Contents
3.1.11.1 Ordering Code Numbers and Parts Delivered 3.1.11.2 Electrical and Mechanical Specifications 3.1.11.3 Electrical Wiring 3.1.12 Remote Mounting Kit for LCP 3.1.13 IP21/IP41/ TYPE1 Enclosure Kit 3.1.14 IP21/Type 1 Enclosure Kit 3.1.15 Output Filters MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 4 6.4.6 Motor Bearing Currents 6.5 Control Cables and Terminals 6.5.1 Access to Control Terminals 6.5.2 Control Cable Routing 6.5.3 Control Terminals 6.5.4 Switches S201, S202, and S801 6.5.5 Electrical Installation, Control Terminals Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 5 7.1.9 Pump Staging with Lead Pump Alternation 7.1.10 System Status and Operation 7.1.11 Fixed Variable-speed Pump Wiring Diagram 7.1.12 Lead Pump Alternation Wiring Diagram 7.1.13 Cascade Controller Wiring Diagram 7.1.14 Start/Stop Conditions MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 6 8.8.2 Modbus RTU Message Structure 8.8.3 Start/Stop Field 8.8.4 Address Field 8.8.5 Function Field 8.8.6 Data Field 8.8.7 CRC Check Field 8.8.8 Coil Register Addressing 8.8.9 How to Control the Adjustable Frequency Drive Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 7 9.6.5 Derating for Ambient Temperature, Enclosure Type C 9.6.6 Automatic Adaptations to Ensure Performance 9.6.7 Derating for Low Air Pressure 9.6.8 Derating for Running at Low Speed 9.7 Troubleshooting 9.7.1 Alarm Words MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 9: How To Read This Design Guide
How to Read this Design Gui... Design Guide 1 How to Read this Design Guide ® In no event shall Danfoss be liable for direct, indirect, HVAC Drive special, incidental, or consequential damages arising out of FC 102 Series the use, or the inability to use information contained in this manual, even if advised of the possibility of such damages.
Page 10 Revolutions Per Minute Regenerative terminals Regen Second Synchronous Motor Speed Torque limit Volts The maximum output current VLT,MAX The rated output current supplied by the VLT,N adjustable frequency drive Table 1.3 Abbreviations Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 11 The rated motor speed (nameplate data). Pulse Reference A pulse frequency signal transmitted to the digital inputs The rated motor power (nameplate data). (terminal 29 or 33). MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 12 Switching pattern called Stator Flux-oriented Asynchronous Vector Modulation (14-00 Switching Pattern). Electronic Thermal Relay is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 13 ) improves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque. 60° AVM Switching pattern called 60° Asynchronous Vector Modulation (See 14-00 Switching Pattern). MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 14: Introduction To Vlt ® Hvac Drive
380–500 V, enclosure types A, B and C: At altitudes Consequently, the instructions in this manual, as well as above 6,600 ft [2 km], contact Danfoss regarding PELV. national and local rules and safety regulations, must be 525–690 V: At altitudes above 6,600 ft [2 km], contact complied with.
Page 15: Ce Labeling
Machinery Directive. 525–600 1.5–10 hp [1.1–7.5 kW] 15–125 hp [11–90 kW] Danfoss uses CE labels in accordance with the directive 525–690 15–125 hp [11–90 kW] and will issue a declaration of conformity upon request.
Page 16: Air Humidity
It could be a production or a with the installer. As an aid to the installer, Danfoss has heating/ventilation plant designed and installed prepared EMC installation guidelines for the Power Drive by professionals of the trade.
Page 17: Vibration And Shock
Proper ventilation is still required for the and after each change to the safety installation. internal components of the adjustable frequency drive. Contact Danfoss for additional information. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 18 Table 2.2 Abbreviations Related to Functional Safety SISTEMA Data 2.6.1 Terminal 37 Safe Torque Off Function Danfoss provides functional safety data via a data library for use with the SISTEMA calculation tool from IFA (Institute for Occupational Safety and Health of the...
Page 19 37 (Safe Torque Off) and either terminal 12 or 13 (24 V DC). The Safety monitoring relay must comply with Category 3/PL “d” (ISO 13849-1) or SIL 2 (EN 62061). MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 20 (see Figure 2.5). The contactor must be monitored through an auxiliary guided contact and connected to the reset input of the safety relay. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 21 (stops creating a rotational field in the motor). The response time is typically shorter than 10 ms for the complete performance range of the adjustable frequency drive. Figure 2.5 STO Category 4 Example MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 22 Automatic Restart means that Safe Torque Off is terminated and normal operation is resumed as soon as the 24 V DC is applied to Terminal 37, and no reset signal is required. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 23 (if connected) is activated, and Failure [A72]” and coasts the adjustable frequency drive if an LCP is mounted, the alarm “Safe Torque Off safely, without Automatic Restart. [A68]” is displayed. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 24: Advantages
Savings may Be Obtained in Typical Applications. 2.7.2 The Clear Advantage - Energy Savings The advantage of using an adjustable frequency drive for controlling the speed of fans or pumps lies in the electricity savings. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 25 Power ~n 12,5% Costlier installation Figure 2.11 The Three Common Energy Saving Systems 100% Figure 2.10 The Dependence of Flow, Pressure and Power Consumption on RPM Flow : Pressure : Power : MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 26 Design Guide Figure 2.12 Discharge dampers reduce power consumption somewhat. Inlet guide vans offer a 40% reduction but are expensive to install. The Danfoss adjustable frequency drive solution reduces energy consumption with more than 50% and is easy to install.
Page 27 Figure 2.14 An Adjustable Frequency Drive Does Not Consume More Than Rated Current ® 1 VLT HVAC Drive 2 Star/delta starter 3 Soft-starter 4 Start directly on line power Table 2.8 Legend to Figure 2.14 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 28 Direct Digital Control E.M.S. Energy Management system V.A.V. Variable Air Volume Sensor P Pressure Sensor T Temperature Table 2.9 Abbreviations used in Figure 2.15 and Figure 2.16 Figure 2.15 Traditional Fan System Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 29 Figure 2.16 Fan System Controlled by Adjustable Frequency Drives. 2.7.12 Application Examples The following pages give typical examples of applications within HVAC. For further information about a given application, ask a Danfoss supplier for an information sheet that gives a full description of the application. Variable Air Volume Ask for The Drive to...Improving Variable Air Volume Ventilation Systems MN.60.A1.02...
Page 30 PID controller of the HVAC can be used to eliminate the need for additional controllers. Pressure signal Frequency Cooling coil Heating coil converter VAV boxes Filter Supply fan Pressure transmitter Flow Frequency converter Return fan Flow Figure 2.17 The VLT Solution Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 31 Several features of the Danfoss HVAC dedicated adjustable frequency drive can be utilized 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 32 The adjustable frequency drives can also be used to turn the fan on and off as needed. Several features of the Danfoss HVAC dedicated adjustable frequency drive, the HVAC adjustable frequency drive can be utilized to improve the performance of a cooling tower fans application. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes insignificant.
Page 33 Introduction to VLT® HVAC D... Design Guide Frequency converter Water Inlet Temperature Sensor BASIN Water Outlet Conderser Water pump Supply Figure 2.19 The VLT Solution MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 34 Frequency converter Water Inlet Flow or pressure sensor BASIN Water Outlet Throttling valve Condenser Water pump Supply Figure 2.20 The VLT Solution Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 35 In the event the flow rate needs to be increased later in the systems life, the adjustable frequency drive can simply increase the pump speed instead of requiring a new pump impeller. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 37 Note that when running multiple pumps in parallel, they must run at the same speed to maximize energy savings, either with individual dedicated drives or one running multiple pumps in parallel. Frequency converter Frequency converter Figure 2.22 The VLT Solution MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 39 2.8.3 PM/EC+ Motor Control 2.8.4 Sizing of Adjustable Frequency Drive and PM motor The Danfoss EC+ concept provides the possibility for using high efficient PM motors in IEC standard enclosure types The low motor inductances of PM motors can cause operated by Danfoss adjustable frequency drives.
Page 40 Adjustable Frequency Drive 7.5 hp [5.5 kW] Power 7.5 hp [5.5 kW] 7.5 hp [5.5 kW] Current 12.5 A 13 A @ 400 V Table 2.13 Correctly Sized Adjustable Frequency Drive Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 41 Table 2.14 shows under which conditions either the local reference or the remote reference is active. One of them is always active, but both cannot be active at the same time. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 43 If [13] Multi Setpoint Min is selected, Zone 2’s setpoint and feedback is sent to the PID controller, since this has the larger difference (feedback is lower than setpoint, resulting in a positive difference). MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 44 Introduction to VLT® HVAC D... Design Guide 2.8.9 Reference Handling Details for Open-loop and Closed-loop operation Figure 2.29 Block Diagram Showing Remote Reference Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 45 [-10–+40 °C], 4–20 mA) connected to terminal 54. If Y, 3-14 Preset Relative Reference is set to 0%, the Switch S202 behind the LCP set to ON (current reference is affected by the scaling. input). MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 46 If the motor runs in the Check. wrong direction, remove power temporarily and reverse two of the motor phases 3) Make sure the adjustable frequency drive limits are set to safe values. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 47 Make sure that oscillations of the feedback signal are sufficiently dampened by the low-pass filter for the feedback signal (parameters 6-16, 6-26, 5-54 or 5-59 as required). MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 48: General Aspects Of Emc
Moreover, ensure good electrical contact from the mounting plate through the mounting screws to the adjustable frequency driver chassis. When non-shielded cables are used, some emission requirements are not complied with, although most immunity requirements are observed. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 50 1.5–125 hp [1.1–90 kW] FC 102 525–600 V Table 2.19 EMC Test Results (Emission) 1) Enclosure Type B 2) Enclosure Type C 3) Hx versions can be used according to EN/IEC 61800-3 category C4 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 52 If necessary, consult the distribution network operator. Other power sizes can be connected to the public supply network by consultation with the distribution network operator. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 53: Galvanic Isolation (Pelv)
EN 61800-5-1. The PELV galvanic isolation can be shown in six locations (see Figure 2.34): To maintain PELV all connections made to the control terminals must be PELV, e.g., thermistor must be reinforced/double insulated. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 54: Ground Leakage Current
Installation at high altitude: 380–500 V, enclosure types A, B and C: At altitudes above 6,600 ft [2 km], contact Danfoss regarding PELV. 525–690 V: At altitudes above 6,600 ft [2 km], contact Figure 2.36 Line Distortion Influences Leakage Current Danfoss regarding PELV.
Page 55: Brake Function
Figure 2.39 Intermittent Duty Cycle for the Resistor Figure 2.38 The Influence of the Cut-off Frequency of the RCD on What Is Responded to/Measured Danfoss offers brake resistors with duty cycle of 5%, 10% ® and 40% suitable for use with the VLT HVAC Drive See also RCD Application Note, MN90G.
Page 56 Make sure that the brake resistor can cope with a against overloading in connection with a fault in the voltage of 410 V, 820 V or 975 V, unless Danfoss brake adjustable frequency drive. resistors are used.
Page 57: Extreme Running Conditions
Incorrect slip compensation setting may cause imately 5-10 s. higher DC link voltage. Operation within the torque limit is limited in time (0–60 s) in 14-25 Trip Delay at Torque Limit. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 58 Introduction to VLT® HVAC D... Design Guide 2.13.1 Motor Thermal Protection This is the way Danfoss is protecting the motor from being overheated. It is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in Figure 2.40...
Page 59 < 800 Ω - > 2.7 kΩ Digital Analog < 3.0 kΩ - > 3.0 kΩ Table 2.26 Threshold Cut-out Values NOTICE! Ensure that the chosen supply voltage follows the specification of the thermistor element utilized. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 60: Selection
Selection Design Guide 3 Selection 3.1 Options and Accessories Danfoss offers a wide range of options and accessories for adjustable frequency drives. 3.1.1 Mounting Option Modules in Slot B Disconnect power to the adjustable frequency drive. For A2 and A3 enclosure types: Remove the LCP, the terminal cover, and the LCP frame from the adjustable frequency drive.
Page 61: General Purpose I/O Module Mcb
MCB 101 are galvanically isolated from other inputs/ outputs on the MCB 101, but not from these on the (NPN) control card of the adjustable frequency drive. 24V DC Figure 3.4 Principle Diagram MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 62: Digital Inputs - Terminal X30/1-4
3.1.6 Analog Outputs - Terminal X30/5+8 Number of analog outputs Output signal level Tolerance Max. impedance ±0.1 mA < 500 Ω 0/4–20 mA Table 3.4 Parameters for set-up: 6-6* and 16-77 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 63: Relay Option Mcb
Figure 3.5 Relay Option MCB 105 A2-A3-A4-B3 A5-B1-B2-B4-C1-C2-C3-C4 NOTICE! IMPORTANT! The label MUST be placed on the LCP frame as shown (UL-approved). Table 3.5 Legend to Figure 3.5 and Figure 3.6 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 64 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. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 65: Backup Option Mcb 107 (Option D)
Figure 3.9 Connection in the option slot. Mount the cable de-coupling plate. Attach the terminal cover and the LCP or blind Live part cover. PELV Table 3.6 Legend to Figure 3.9 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 66: Analog I/O Option Mcb
Figure 3.10 Connection to 24 V Backup Supplier (A2-A3). Figure 3.12 Principle Diagram for Analog I/O Mounted in Adjustable Frequency Drive. Figure 3.11 Connection to 24 V Backup Supplier (A5-C2). Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 67 3 Hz 2.4 Hz battery backup pack fails, the analog I/O option must be Max load ± 20 V continuously replaced. Impedance Approximately 5 kΩ Table 3.8 Analog inputs - terminal X42/1-6 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 68: Ptc Thermistor Card Mcb
MCB 112 PTC Thermistor Card Option B Code No.130B1137 Reference for 10, 12 20-28 VDC 10 mA 20-28 VDC 60 mA Control Terminals of FC302 Figure 3.13 Installation of MCB 112 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 69: Sensor Input Option Mcb
PT100/1000 temperature sensors. One in front, one in the back-end bearing, and one in the motor windings. The sensor input Option MCB 114 supports two or three-wire sensors with individual temperature limits for under/over temperature. An auto detection of sensor type PT100 or PT1000 takes place at power-up. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 70: Ordering Code Numbers And Parts Delivered
Galvanic Isolation The sensors to be connected are expected to be galvanically isolated from the AC line voltage level. IEC 61800-5-1 and UL508C Cabling Maximum signal cable length 1640 ft [500 m] Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 71: Electrical Wiring
Figure 3.16 LCP Kit with Graphical LCP, Fasteners, 10 ft [3 m] Cable and Gasket Ordering No. 130B1113 Figure 3.17 LCP Kit with Numerical LCP, Fasteners and Gasket Ordering no. 130B1114 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 72: Ip21/Ip41/ Type1 Enclosure Kit
If the enclosure kit is used, an IP20 unit is upgraded to comply with enclosure IP21/41 top/TYPE 1. ® The IP41 top can be applied to all standard IP20 VLT HVAC Drive variants. Figure 3.19 Enclosure Type A2 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 74: Output Filters
Brim reduce leakage currents in the cables. Base part Base cover Screw(s) Fan cover Top clip Table 3.14 Legend to Figure 3.21 and Figure 3.21 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 75: How To Order
Order the adjustable frequency drive as either standard or AC Line Voltage with integral options by sending a type code string Enclosure 13-15 describing the product a to the local Danfoss sales office, Enclosure type i.e.: Enclosure class Control supply voltage...
Page 76 X: Standard cable entries Adaptation O: European metric thread in cable entries (A4, A5, B1, B2 only) S: Imperial cable entries (A5, B1, B2 only) Adaptation Reserved Software release 24-27 Current software Software language Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 77: Ordering Numbers
Screw terminal blocks for replacing spring loaded terminals 130B1116 1 x 10-pin, 1 x 6-pin and 1 x 3-pin connectors Backplate A5 IP55/NEMA 12 130B1098 Backplate B1 IP21/IP55 / NEMA 12 130B3383 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 78 24 V DC backup 130B1208 External Options Ethernet IP Ethernet master Table 4.4 Ordering Information Options For information on serial communication bus and application option compatibility with older software versions, contact your Danfoss supplier. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 79 Accessory bag C3 Accessory bag, enclosure type C3 130B0981 Accessory bag C4 Accessory bag, enclosure type C4 130B0982 Small Accessory bag C4 Accessory bag, enclosure type C4 130B0983 Table 4.5 Accessories Ordering Information MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 80 175G6631 P250 + 175G6610 + 175G6632 2x 175G6610 2x 175G6632 P315 2x175G6611 2x175G6633 P355 175G6611 175G6633 P400 + 175G6688 + 175G6691 2x175G6688 2x175G6691 P450 Table 4.6 380–415 V AC, 50 Hz Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 81 2x175G6693 P500 Table 4.8 440–480 V AC, 60 Hz Matching the adjustable frequency drive and filter is pre-calculated based on 400 V/480 V, a typical motor load (4-pole) and 110% torque. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 82 130B2299 + 130B2300 P400 2x130B2335 2x130B2300 P450 130B2300 + 130B2301 P500 2x130B2301 P560 130B2301 + 130B2300 P630 2x130B2302 P710 Table 4.10 690 V AC, 50 Hz * For higher currents, contact Danfoss. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 83 Table 4.11 Line Power Supply 3x200 to 480 V AC When using sine-wave filters, the switching frequency should comply with filter specifications in 14-01 Switching Frequency. NOTICE! See also Output Filter Design Guide. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 84 Table 4.12 Line Power Supply 3 x 525–690 V AC NOTICE! When using sine-wave filters, the switching frequency should comply with filter specifications in 14-01 Switching Frequency. NOTICE! See also Output Filter Design Guide. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 85 P710 P800 130B2407 130B2394 1500 P800 P1M0 130B2407 130B2394 1500 P1M0 130B2410 130B2395 2300 Table 4.13 Line Power supply 3x380 to 3x480 V AC NOTICE! See also Output Filter Design Guide. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 86 2x130B2430 2x130B2421 1530 Table 4.14 Line Power Supply 3x525 to 3x690 V AC NOTICE! See also Output Filter Design Guide. 4.2.7 Ordering Numbers: Brake Resistors NOTICE! See Brake Resistor Design Guide. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 87: Mechanical Installation
[45 °C–55 °C], derating of the adjustable frequency drive becomes relevant, see chapter 9.6.2 Derating for Ambient Temperature. The service life of the adjustable frequency drive is reduced if derating for ambient temperature is not taken into account. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 92: Mechanical Mounting
2 in [50 mm]. For optimal cooling conditions, allow a free-air passage above and below the adjustable frequency drive. See Table 5.4. Figure 5.3 Proper Mounting with Backplate Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 93: Field Mounting
Table 5.6 Tightening torque for covers (lb/ft [Nm]) 5.1.5 Field Mounting For field mounting the IP21/IP4X top/TYPE 1 kits or IP54/55 units are recommended. Figure 5.5 Mounting on a Non-solid Back Wall MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 94: Electrical Installation
Furthermore, the terminal screw must be retightened after two days due to softness of the aluminum. It is crucial to keep the connection a gas-tight joint; otherwise, the aluminum surface will oxidize again. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 95 10.33 [14] (up to [37–45] [75–90] 4/0 AWG [95 mm 17.7 [24] (over 4/0 AWG [95 mm Load sharing, brake cables 10.33 [14] Relay 0.37–0.44 [0.5–0.6] Ground 1.48–2.21 [2–3] Table 6.1 Tightening-up Torque MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 96: Removal Of Knockouts For Extra Cables
CAUTION IT Line Power Do not connect 400 V adjustable frequency drives with RFI filters to line power supplies with a voltage between phase and ground of more than 440 V. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 97 Figure 6.4 Mounting Line Power Plug and Tightening Wires Figure 6.8 AC Line Input Connection Enclosure Types B1 and B2 (IP21/NEMA Type 1 and IP55/66/ NEMA Type 12) Figure 6.5 Tighten Support Bracket MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 98 Figure 6.11 AC Line Input Connection Enclosure Types C1 and C2 (IP21/NEMA Type 1 and IP55/66/NEMA Type 12). Figure 6.10 AC Line Input Connection Enclosure Type B4 (IP20) Figure 6.12 AC Line Input Connection Enclosure Type C3 (IP20). Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 99: Motor Connection
HF impedance. Connect the three-phase motor wiring to terminals 96 (U), 97 (V), and 98 (W), see Figure 6.14. Tighten terminals in accordance with the information provided in chapter 6.1.1 Torque. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 100 Figure 6.14 Motor Connection Figure 6.17 Motor Connection for Enclosure Type B4 Figure 6.15 Motor Connection for Enclosure Type B1 and B2 (IP21/NEMA Type 1, IP55/NEMA Type 12 and IP66/NEMA Type 4X) Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 101 (such as an adjustable frequency drive), fit a sine-wave filter on the output of the adjustable frequency drive. Figure 6.19 Motor Connection for Enclosure Type C3 and C4 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 102 [mm] 1) Line power 28.4 2) Motor 28.4 3) Brake/Load 28.4 Sharing 4) Control 22.5 Cable 5) Removed Table 6.5 Legend to Figure 6.23 ± 0.007 in [0.2 mm] 1) Tolerance Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 103 Table 6.7 Legend to Figure 6.25 5) Control 22.5 ± 0.007 in [0.2 mm] 1) Tolerance Cable 2) Knockout hole Table 6.9 Legend to Figure 6.27 ± 0.007 in [0.2 mm] 1) Tolerance MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 104 0.89 in [22.5 mm] Cable Table 6.11 Legend to Figure 6.29 5) Control 22.5 1) Knockout hole Cable Table 6.13 Legend to Figure 6.31 ± 0.007 in [0.2 mm] 1) Tolerance 2) Knockout hole Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 105 Table 6.15 Legend to Figure 6.33 5) Control 22.5 Cable ± 0.007 in [0.2 mm] 1) Tolerance 6) Control 22.5 Cable Table 6.17 Legend to Figure 6.35 ± 0.007 in [0.2 mm] 1) Tolerance MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 106: Relay Connection
Figure 6.37 Terminals for Relay Connection (Enclosure Types C1 and C2). Figure 6.36 Terminals for Relay Connection (Enclosure Types A1, A2 and A3). Figure 6.38 Terminals for Relay Connection (Enclosure Types A5, B1 and B2). Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 107: Fuses And Circuit Breakers
NOTICE! Fuses or circuit breakers are mandatory to comply with IEC The recommendations given do not cover branch circuit 60364. Danfoss recommend using a selection of the protection for UL. following. Short-circuit protection The fuses below are suitable for use on a circuit capable of...
Page 108: Fuse Tables
(40 [30]) gG-100 (40 [30]) 50–60 [37–45] aR-160 (50 [37]) aR-200 (50 [37]) NZMB2-A250 aR-200 (60 [45]) aR-250 (60 [45]) Table 6.19 200–240 V, Enclosure Types A, B and C Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 109 (50 [37]) gG-160 NZMB2-A200 gG-100 (60 [45]) gG-160 (75 [55]) 100–125 [75–90] aR-200 (100 [75]) aR-250 NZMB2-A250 aR-250 (125 [90]) Table 6.20 380–480 V, Enclosure Types A, B and C MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 110 75 [55] gG-100 (75 [55]) gG-160 (75–100 [55–75]) 100 [75] gG-125 (100 [75]) 60 [45] gG-80 gG-100 75 [55] gG-100 gG-125 Table 6.22 525–690 V, Enclosure Types A, B and C Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 111 Design Guide UL Compliance Fuses or circuit breakers are mandatory for compliance with NEC 2009. Danfoss recommends using a selection of the following The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240 V, or 480 V, or 500 V, or 600 V depending on the adjustable frequency drive voltage rating.
Page 112 JJS-100 60 [45] KTS-R-125 JKS-125 JJS-125 75 [55] KTS-R-150 JKS-150 JJS-150 100 [75] KTS-R-200 JKS-200 JJS-200 125 [0] KTS-R-250 JKS-250 JJS-250 Table 6.26 380–480 V, Enclosure Types A, B and C Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 113 100 [75] FWH-200 HSJ-200 A50-P-225 L50-S-225 125 [90] FWH-250 HSJ-250 A50-P-250 L50-S-250 Table 6.28 380–480 V, Enclosure Types A, B and C 1) Ferraz-Shawmut A50QS fuses may substitute for A50P fuses. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 114 Table 6.30 525–600 V, Enclosure Types A, B and C 1) 170M fuses shown from Bussmann use the -/80 visual indicator. –TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 115 JJS-125 2028220-125 KLS-150 A6K-125-R HST-125 125 [90] 150 A KTS-R-150 JKS-150 JJS-150 2028220-150 KLS-175 A6K-150-R HST-150 Table 6.32 *525–690 V, Enclosure Types B and C * UL compliance only 525–600 V MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 116: Disconnectors And Contactors
C1 60–75 hp [45–55 kW] Kraus&Naimer KG105 T303 C2 100 hp [75 kW] Kraus&Naimer KG160 T303 C2 125 hp [90 kW] Kraus&Naimer KG250 T303 Table 6.33 Terminal Connections for Various Enclosure Types Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 117: Additional Motor Information
Ex-e motors. Motor Figure 6.40 Terminal Connection for Clockwise and Counter- clockwise Rotation • Terminal U/T1/96 connected to U-phase • Terminal V/T2/97 connected to V-phase • Terminal W/T3/98 connected to W-phase MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 118: Parallel Connection Of Motors
Provide further motor protection, e.g., by thermistors in each motor winding or individual thermal relays. (Circuit breakers are not suitable as protection devices). Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 119 (less than 33 ft [10 m] each). d, e) Consider voltage drop across the motor cables. e) Be aware of the maximum motor cable length specified in Table 6.35. e) Use LC filter for long parallel cables. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 120: Direction Of Motor Rotation
The direction of motor rotation is changed by switching two motor phases. Motor rotation check can be performed using 1-28 Motor Rotation Check and following the steps shown in the display. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 121: Motor Insulation
Try to ensure the line voltage is balanced to ground. This can be difficult for IT, TT, TN-CS or Table 6.36 Motor Insulation Grounded leg systems. Use a dU/dt or sinus filter. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 122: Control Cables And Terminals
C3 and C4 Figure 6.45 Inside Location of Serial Communication Bus Figure 6.44 Enclosure Types A5, B1, B2, C1 and C2 Figure 6.46 Top Connection for Serial Communication Bus on IP00 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 123: Control Terminals
Use a 24 V DC supply of type PELV to ensure correct galvanic isolation (type PELV) on the control terminals of the adjustable frequency drive. Figure 6.48 Control Terminals (all Enclosure Types) MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 124: Switches S201, S202, And S801
Figure 6.51 Insert Screwdriver Insert the cable in the adjacent circular hole. Figure 6.49 Location of S201, S202 and S801 Switches Figure 6.52 Insert Cable Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 125: Basic Wiring Example
Default settings 18 = Start, 5-10 Terminal 18 Digital Input [9] 27 = Stop inverse, 5-12 Terminal 27 Digital Input [6] 37 = Safe Torque Off inverse Figure 6.54 Basic Wiring MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 126: Electrical Installation, Control Cables
(terminal 20, 55, 39) of the adjustable frequency drive to avoid ground currents from both groups affecting other groups. For example, switching on the digital input may disturb the analog input signal. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 127: Relay Output
To comply with EMC emission specifications, shielded/ armored cables are recommended. If an non-shielded/ unarmored cable is used, see chapter 2.9.2 EMC Test Results. Figure 6.59 Relay Outputs 1 and 2 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 128: Additional Connections
Size the brake cable cross-section to match the brake torque. Terminals 81 and 82 are brake resistor terminals. See Brake instructions for more information about safe installation. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 129: Pc Software
Both the harmonic distortion of Danfoss adjustable frequency drives as well as non-Danfoss adjustable frequency drives with additional harmonic reduction devices, such as Danfoss AHF filters and 12-18-pulse rectifiers, can be calculated. Ordering number: Order the CD containing the MCT 31 PC tool using code number 130B1031.
Page 130: Safety Ground Connection
(terminal 95), the cable cross-section must be at least 10 mm or two rated ground wires terminated separately. Figure 6.61 Location of Relay Plugs, Pos. 8 and 9 Manufacturer declaration is available upon request. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 131: Emc-Compatible Installation
EMC cable connectors instead. • Avoid using non-shielded/unarmored motor or control cables inside cabinets housing the adjustable frequency drive(s). Leave the shield as close to the connectors as possible. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 133: Use Of Emc-Compatible Cables
) is rarely stated by cable manufac- turers, but it is often possible to estimate transfer impedance (Z ) by assessing the physical design of the cable. Figure 6.64 Transfer Impedance MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 134: Grounding Of Shielded Control Cables
100 nF capacitor (keeping leads short). Min. 0.025 in [16 mm Equalizing cable 100nF <10 mm Table 6.42 Legend to Figure 6.68 Figure 6.66 Shield-to-ground Connected to a 100 nF Capacitor Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 135: Rfi Switch
1-24 Motor Current. 1-25 Motor Nominal Speed. Step 1. Locate the motor nameplate NOTICE! The motor is either star- (Y) or delta-connected (Δ). This information is located on the motor nameplate data. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 136 This number along with the description of the alarm assist in troubleshooting. If contacting Danfoss for service, make sure to mention number and alarm description. NOTICE! Unsuccessful AMA is often caused by incorrectly...
Page 137: Application Examples
5-10 Terminal 18 Digital Input = Start (default) 5-12 Terminal 27 Digital Input = coast inverse (default) Figure 7.1 Terminal 37: Available only with Safe Stop Function Figure 7.2 Terminal 37: Available Only with Safe Torque Off Function MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 138: Potentiometer Reference
SLC is designed to act from event send to or generated in small motors to more than 15 minutes on large motors. the adjustable frequency drive. The adjustable frequency drive then performs the pre-programmed action. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 139: Smart Logic Control Programming
When the last event/action has been executed, the sequence starts over again from event [1]/action [1]. Figure 7.4 shows an example with three events/actions: Figure 7.4 An Example with Three Events/Actions MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 140: 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] Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 141 Set the Smart Logic Control in 13-00 SL Controller Mode to ON. Start/stop command is applied on terminal 18. If stop signal is applied, the adjustable frequency drive will ramp down and go into free mode. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 142: Cascade Controller
(lead) is connected directly to the adjustable frequency drive, the other four pumps are controlled by the two built-in relays and terminal 27, 29 (DI/DO). Lead pump alternation cannot be selected when lead pump is fixed. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 143: Pump Staging With Lead Pump Alternation
When the programmed value of the timer expires, the lead pump is removed, avoiding a heat water- circulation problem. Figure 7.9 Fixed Variable-speed Pump Wiring Diagram MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 144: Lead Pump Alternation Wiring Diagram
• RELAY 2 controls contactor K4 for on/off control of the fixed-speed pump. • At alternation both relays de-energizes and now RELAY 2 is energized as the first relay. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 145: Cascade Controller Wiring Diagram
The wiring diagram shows an example with the built-in BASIC Cascade Controller with one variable-speed pump (lead) and two fixed-speed pumps, a 4–20 mA transmitter and System Safety Interlock. Figure 7.11 Cascade Controller Wiring Diagram MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 146: Start/Stop Conditions
Destaging [Auto On] Starts and stops according to commands via terminals or Staging/Destaging serial bus cascade controller only, can work when drive in "Auto ON" mode Table 7.2 LCP Key Functions Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 147: Installation And Set-Up
Terminal 68 is connected to the P signal (TX+, RX+), while terminal 69 is connected to the N signal (TX-,RX-). See drawings in chapter 6.8.3 Grounding of Shielded Control Cables. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 148 Table 8.2 Parameters Apply to the RS-485 Interface (FC port) 8.1.3 Adjustable Frequency Drive Parameter Settings for Modbus Communication The following parameters apply to the RS-485 interface (FC port): Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 149: Adjustable Frequency Protocol Overview
The FC protocol, also referred to as FC bus or Standard achieve interference-free operation of the RS-485 network. bus, is the Danfoss standard serial communication bus. It defines an access technique according to the master- Observe relevant national and local regulations, for follower principle for communications via a serial bus.
Page 150: Network Configuration
Table 8.4 Length of Messages in all. The 10 represents the fixed characters, while the “n’” is variable (depending on the length of the text). Figure 8.5 Content of a Character Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 151: Adjustable Frequency Drive Address (Adr)
8.4.5 Data Control Byte (BCC) The checksum is calculated as an XOR-function. Before the first byte in the message is received, the calculated checksum is 0. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 152: The Data Field
(six words) and also contains the process block. PCD1 PCD2 high Figure 8.8 Parameter Block Text block The text block is used to read or write texts via the data block. PCD1 PCD2 Figure 8.9 Text Block Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 153: The Pke Field
Only the low byte is used as an index. Bit no. Response No response Parameter value transferred (word) Parameter value transferred (double word) Command cannot be performed text transferred Table 8.6 Response Follower⇒ Master MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 154: Parameter Value (Pwe)
0 ms ⇒ conversion index -3 0.00 ms ⇒ conversion index -5 high Read text Fx xx 04 00 Write text Fx xx 05 00 Figure 8.11 Text via PWE Block Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 155: Process Words (Pcd)
PKE = 1155 Hex - Read parameter value in 3-41 Ramp 1 Ramp-up Time IND = 0000 Hex PWEHIGH = 0000 Hex PWELOW = 0000 Hex 1155 0000 0000 H 0000 high Figure 8.14 Parameter Value MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 156: Modbus Rtu Overview
Danfoss assumes that the installed controller supports the and send it in response, or a timeout occurs. interfaces in this document, and strictly observes all requirements and limitations stipulated in the controller 8.6.4 Adjustable Frequency Drive with...
Page 157: Network Configuration
This causes a timeout (no response from the follower), Error Check Field Cyclical Redundancy Check (CRC) since the value in the final CRC field is not valid for the combined messages. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 158: Address Field
This can include items such as coil or register addresses, the quantity of items to be handled and the count of actual data bytes in the field. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 159 (STW). 50210 Output data: Adjustable frequency drive main actual value register (MAV). Table 8.17 Holding Registers * Used to specify the index number to be used when accessing an indexed parameter. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 160: How To Control The Adjustable Frequency Drive
Return follower message Follower An unrecoverable error occurred while the count device failure server (or follower) was attempting to perform the requested action. Table 8.19 Function Codes Table 8.20 Modbus Exception Codes Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 161: How To Access Parameters
If the read request for a parameter is for fewer characters than the parameter stores, the response is padded with spaces. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 162: Force/Write Single Coil (05 Hex)
Table 8.22 Response Error Check (CRC) NOTICE! Table 8.24 Response Coils and registers are addressed explicitly with an off-set of -1 in Modbus. For example, Coil 33 is addressed as Coil 32. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 163: Force/Write Multiple Coils (0F Hex)
Quantity of Coils LO 10 (16 coils) (Register 3030) Error Check (CRC) Data HI (Register 3031) Table 8.26 Response Data LO (Register 3031) Error Check (CRC) Table 8.28 Example: Hex 0016E360=1.500.000=1500 RPM MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 164: Preset Single Register (06 Hex)
Table 8.30 Response Field Name Example (HEX) Slave Address Function Starting Address HI Starting Address LO No. of Registers HI No. of registers LO Error Check (CRC) Table 8.32 Response Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 165: Danfoss Fc Control Profile
Bit 07 = ’0’: No reset. Bit 07 = ’1’: Resets a trip. Reset is 3-10 Preset activated on the leading edge of the signal, i.e. when Reference [3] changing from logic ’0’ to logic ’1’. Table 8.34 Reference Values MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 166: Status Word According To Fc Profile (Stw) (8-10 Control Profile = Fc Profile)
Bit 03, No error/trip Bit 03 =’0’: The adjustable frequency drive is not in fault mode. Bit 03 = ’1’: The adjustable frequency drive trips. To re-establish operation, enter [Reset]. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 167: Bus Speed Reference Value
Bit 14 = ’0’: The motor current is lower than the torque limit selected in 4-18 Current Limit. Bit 14 = ’1’: The torque limit in 4-18 Current Limit is exceeded. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 168: General Specifications And Troubleshooting
[23] [27] [45] [65] Efficiency 0.968 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 Table 9.1 Line Power Supply 1 x 200–240 V AC - Normal Overload 110% for 1 Minute Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 169 [13.5] [13.5] 21.39/29.76 21.39/29.76 21.39/29.76 29.76 29.76 Weight enclosure IP66 (lb [kg]) [9.7/13.5] [9.7/13.5] [9.7/13.5] [13.5] [13.5] 0.96 0.96 0.96 0.96 0.96 Efficiency Table 9.2 Line Power Supply 3x200–240 V AC MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 171 Weight enclosure IP66 (lb [kg]) 29.76 29.76 29.76 29.76 29.76 [14.2] [14.2] [9.7/13.5] [9.7/13.5] [9.7/13.5] [9.7/13.5] [9.7/13.5] Efficiency 0.96 0.97 0.97 0.97 0.97 0.97 0.97 Table 9.4 Line Power Supply 3x380–480 V AC MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 172 (lb [kg]) [23] [23] [23] [27] [27] [45] [45] [45] [65] [65] 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.99 Efficiency Table 9.5 Line Power Supply 3x380–480 V AC Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 175 14.6 [6.6] 14.6 [6.6] 14.6 [6.6] 14.6 [6.6] 14.6 [6.6] 14.6 [6.6] 14.6 [6.6] 0.96 0.96 0.96 0.96 0.96 0.96 0.96 Efficiency Table 9.8 Line Power Supply 3x525–690 V AC IP20 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 176 [27] [27] [27] [27] [65] [65] [65] [65] [65] 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 Efficiency Table 9.9 Line Power Supply 3x525–690 V AC IP21-IP55/NEMA 1-NEMA 12 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 177 (Though typically only 4 W extra for a fully loaded control card or options for slot A or slot B, each). ± 5%). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for ( 5) Motor and line cable: 300 MCM/150 mm MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 178: General Specifications
Maximum cross-section to control terminals, cable with enclosed core 0.0008 in [0.5 mm ]/20 AWG Minimum cross-section to control terminals 0.00039 in [0.25 mm * See Line Power Supply tables for more information! Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 179 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 9.1 PELV Isolation of Analog Inputs MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 180 12, 13 Max. load 200 mA The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 181 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. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 182 The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is not galvanically isolated from protection ground. Use only isolated laptop/PC as connection to the USB connector on or an isolated USB cable/drive. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 183: Efficiency
To calculate the system efficiency, the efficiency of the adjustable frequency drive (η ) is multiplied by the efficiency of the motor (η MOTOR η = η x η SYSTEM MOTOR MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 184: Acoustic Noise
(ft [m]) [μsec] [kV] [kV/μsec] 16.4 [5] 0.13 0.510 3.090 164 [50] 0.23 0.590 2.034 330 [100] 0.54 0.580 0.865 500 [150] 0.66 0.560 0.674 Table 9.13 Adjustable frequency drive, P7K5, T2 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 185 Cable length AC linevoltage Vpeak (ft [m]) [μsec] [kV] [kV/μsec] 100 [30] 0.300 0.598 1.593 330 [100] 0.536 0.566 0.843 500 [150] 0.776 0.546 0.559 Table 9.20 Adjustable frequency drive, P45K, T2 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 186 Cable length AC linevoltage Vpeak (ft [m]) [μsec] [kV] [kV/μsec] 120 [36] 0.344 1.040 2.442 330 [100] 1.000 1.190 0.950 500 [150] 1.400 1.040 0.596 Table 9.26 Adjustable frequency drive, P18K, T4 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 187 Table 9.32 Adjustable frequency drive, P75K, T4 Rise time dU/dt Cable length AC linevoltage Vpeak (ft [m]) [μsec] [kV] [kV/μsec] 16.4 [5] 0.364 1.030 2.264 Table 9.33 Adjustable frequency drive, P90K, T4 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 188: Special Conditions
A1-A3 50°C, A4-A5 45°C A1-A3 55°C, A4-A5 50°C f sw (kHz) Figure 9.6 Derating of I for Different T AMB, MAX Enclosures Type A, using SFAVM and maximum 32 ft [10 m] motor cable Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 189: Derating For Ambient Temperature, Enclosure Type B
(110% over torque) 100% 45 C 50 C (kHz) Figure 9.11 Derating of I for different T AMB, MAX enclosure types B3 and B4, using SFAVM in normal overload mode (110% over torque) MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 190 600 V adjustable frequency Note: The graph is drawn with the current as absolute value drives, enclosure type B, SFAVM, NO and is valid for both high and normal overload. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 191: Derating For Ambient Temperature, Enclosure Type C
C1 & C2 45 C 50 C (kHz) Figure 9.20 Output current derating with switching frequency and ambient temperature for 600 V adjustable frequency drives, enclosure type C, 60° AVM, NO MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 192: Automatic Adaptations To Ensure Performance
Figure 9.22 Output current derating with switching frequency and ambient temperature for enclosure type C2, 60° AVM. Note: The graph is drawn with the current as absolute value and is valid for both high and normal overload. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 193: Derating For Low Air Pressure
A, B and C. At altitudes above AMB, MAX When a motor is connected to an adjustable frequency 6,600 ft [2 km], contact Danfoss regarding PELV. drive, it is necessary to make sure that the cooling of the motor is adequate.
Page 194: Troubleshooting
Via serial communication/optional serial communication bus. By resetting automatically using the Auto Reset ® function, which is a default setting for VLT HVAC Drive, see 14-20 Reset Mode in the FC 102 Programming Guide Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 195 1.8 V supply low Speed limit 1-86 AMA calibration failed AMA check U and I AMA low I AMA motor too big AMA motor too small AMA Parameter out of range MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 196 A trip lock is an action when an alarm occurs, which may cause damage to or connected parts. A trip lock situation can only be reset by power cycling. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 197: Live Zero Error (X) (X)
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. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 198: Alarm Words
Ground fault DESAT 40000000 PTC 1 Safe Stop [A71] 20000000 Drive initialized 80000000 Dangerous Failure [A72] 40000000 Safe Stop [A68] 80000000 Table 9.39 16-91 Alarm Word 2 Table 9.38 16-90 Alarm Word Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 199: Warning Words
20000000 Reserved 08000000 40000000 PTC 1 Safe Stop [W71] 10000000 80000000 Reserved 20000000 40000000 Safe Stop [W68] Table 9.41 16-93 Warning Word 2 80000000 Not used Table 9.40 16-92 Warning Word MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 200: Extended Status Words
Reserved 10000000 Reserved 80000000 Reserved 20000000 Reserved 40000000 Reserved Table 9.43 Extended Status Word 2, 16-95 Ext. Status Word 2 80000000 Reserved Table 9.42 Extended Status Word, 16-94 Ext. Status Word Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 201 The limit is dependent on the occurs when the motor runs with more than 100% frequency converter voltage rating. The unit is still active. overload for too long. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 202: Hardware Mismatch
Remove power to the adjustable frequency drive and increase the torque limit. Make sure that the repair the short circuit. system can operate safely at a higher torque. Check the application for excessive current draw on the motor. Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 203: Control Word Timeout (X) (X)
Cycle power to the adjustable frequency drive drive. and check that the fan operates briefly at start- Damaged heatsink fan. Dirty heatsink. Check the sensors on the heatsink and control card. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 204: Soft-Charge Fault
Check for loose or missing wiring The signal from the IGBT thermal sensor is not available on It may be necessary to contact your Danfoss supplier or the power card. The problem could be on the power card, service department. Note the code number for further on the gate drive card, or the ribbon cable between the troubleshooting directions.
Page 205: Overload Of Digital Output On X30/7
The cut-out temperature of the control card is 176 °F warning. When the speed is below the specified limit in [80 °C]. 1-86 Trip Speed Low [RPM] (except when starting or stopping), the adjustable frequency drive trips. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 206 Time is not set or the RTC clock has failed. Reset the clock from the MCB 112 is deactivated. When that happens, a in 0-70 Date and Time. reset signal must be sent (via Bus, Digital I/O, or by pressing [Reset]). Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 207 Reset the adjustable frequency drive for normal operation. WARNING 251, New type code The power card or other components have been replaced and the type code changed. Reset to remove the warning and resume normal operation. MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 208 Brake Resistor Cabling................ 55 Cooling conditions................90 Brake Resistor Calculation..............54 Cooling Tower Fan................30 Brake Resistors..................84 Copyright, Limitation of Liability and Revision Rights....7 Braking....................201 Cos φ Compensation................25 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 209 ETR......................118 Evaporator flow rate................33 Jog....................... 9, 164 Example of Closed-loop PID Control..........43 Extended Status Word..............198 Extended Status Word 2..............198 Knockouts....................94 External 24 V DC supply..............63 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 210 Motor thermal protection............... 165 Public supply network................ 50 Motor Thermal Protection............56, 115 Pulse Inputs..................178 Motor voltage..................182 Pulse Start/Stop.................. 135 Motor-generated Overvoltage............55 Pump impeller..................32 Multiple pumps..................35 Multi-zone control................64 Danfoss A/S © Rev. 06/2014 All rights reserved. MG11BC22...
Page 211 Soft-starter....................25 Warning against unintended start..........12 Software Version..................7 Warning Words................... 197 Software versions................. 76 What is CE Conformity and Labeling?........... 13 Star/Delta Starter.................. 25 Start/Stop....................135 Start/Stop Conditions............... 144 MG11BC22 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 212 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 FC 102 Series Design Manual

Table of Contents

1 How to Read this Design Guide

2 Introduction to VLT ® HVAC Drive

3 Selection

4 How to Order

5 Mechanical Installation

6 Electrical Installation

7 Application Examples

8 Installation and Set-Up

9 General Specifications and Troubleshooting

Table of Contents

Quick Links

Chapters

Troubleshooting

Related Manuals for Danfoss VLT FC 102 Series

Summary of Contents for Danfoss VLT FC 102 Series

Table of Contents