Danfoss VLT HVAC Basic Drive FC 101 Design Manual
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Danfoss VLT HVAC Basic Drive FC 101 Design Manual

Danfoss VLT HVAC Basic Drive FC 101 Design Manual

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MAKING MODERN LIVING POSSIBLE
Design Guide
®
VLT
HVAC Basic Drive FC 101
www.danfoss.com/drives

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Summary of Contents for Danfoss VLT HVAC Basic Drive FC 101

  • Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® HVAC Basic Drive FC 101 www.danfoss.com/drives...

  • Page 3: Table Of Contents

    2.10 Ground Leakage Current 2.11 Extreme Running Conditions 3 Selection 3.1 Options and Accessories 3.1.1 Local Control Panel (LCP) 3.1.2 Mounting of LCP in Panel Front 3.1.3 IP21/TYPE 1 Enclosure Kit MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 4 7.1.3 Adjustable Frequency Drive Hardware Set-up 7.1.4 Adjustable Frequency Drive Parameter Settings for Modbus Communica- tion 7.1.5 EMC Precautions 7.2 Adjustable Frequency Protocol Overview 7.3 Network Configuration 7.4 FC Protocol Message Framing Structure Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 5 7.8.10 Function Codes Supported by Modbus RTU 7.8.11 Modbus Exception Codes 7.9 How to Access Parameters 7.9.1 Parameter Handling 7.9.2 Storage of Data 7.9.3 IND 7.9.4 Text Blocks 7.9.5 Conversion Factor MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 6 8.1.3 Line Power Supply 3x380–480 V AC 8.1.4 Line Power Supply 3x525–600 V AC 8.2 General Specifications 8.3 Acoustic Noise or Vibration 8.4 dU/Dt 8.5 Derating according to Ambient Temperature and Switching Frequency Index Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 7: Introduction

    The maximum output current DRIVE,MAX NOTICE! The rated output current supplied by the DRIVE,N adjustable frequency drive Indicates important information, including situations that may result in damage to equipment or property. Table 1.2 Abbreviations MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 8: Additional Resources

    0% value (typically 0 V, 0 mA, 4 mA) and the resulting reference. The minimum reference value set in The instantaneous motor voltage. 3-02 Minimum Reference The rated motor voltage (nameplate data). Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 9 The trip-lock function cable cross-section. 1 MCM ≡ 0.5067 mm may not be used as a personal safety measure. VT Characteristics Variable torque characteristics used for pumps and fans. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 10: Power Factor

    In addition, a high power factor indicates that the different harmonic currents are low. The adjustable frequency drive's built-in DC coils produce a high power factor, which minimizes the imposed load on the line power supply. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 11: Product Overview

    CAUTION Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be At altitudes above 6,600 ft [2 km], contact Danfoss complied with. regarding PELV. Safety Regulations...

  • Page 12: Ce Labeling

    Machinery Directive. However, if an adjustable frequency drive is not powered. To avoid electrical frequency drive is supplied for use in a machine, Danfoss hazards, disconnect AC line power, any permanent provides information on safety aspects relating to the magnet type motors, and any remote DC link power adjustable frequency drive.

  • Page 13: Air Humidity

    CE-labeled in accordance with the EMC directive. The manufacturer can ensure CE- rests with the installer. As an aid to the installer, Danfoss labeling under the EMC directive either by using has prepared EMC installation guidelines for the Power CE-labeled components or by testing the EMC of Drive system.

  • Page 14: Aggressive Environments

    NOTICE! Mounting adjustable frequency drives in aggressive environments increases the risk of stoppages and consid- erably reduces the life of the adjustable frequency drive. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 15 Figure 2.5 shows typical energy savings obtainable with directly proportional to the RPM. The consumption of three well-known solutions when fan volume is reduced to. electricity, however, is reduced by 50%. e.g., 60%. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 16 Discharge dampers reduce power consumption somewhat. achieved in typical applications. 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 17 Figure 2.8 Start-up Current Table 2.4 Result ® 1 VLT HVAC Basic Drive FC 101 2 Star/delta starter 3 Soft-starter 4 Start directly on line power Table 2.5 Legend to Figure 2.8 MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 18 2.6.9 Without an Adjustable Frequency Drive Figure 2.9 Traditional Fan System D.D.C. Direct Digital Control E.M.S. Energy Management system V.A.V. Variable Air Volume Sensor P Pressure Sensor T Temperature Table 2.6 Abbreviations used in Figure 2.9 Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 19 The next pages provide typical examples of applications within HVAC. For further information about a given application, ask the Danfoss supplier for an information sheet that gives a full description of the application. The following application notes can be downloaded from the Danfoss web page, www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm.
  • Page 20 HVAC Basic Drive 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 2.11 Variable Air Volume Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 21 Several features of the Danfoss dedicated adjustable frequency drive can be utilized to improve the performance of the 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 22 The adjustable frequency drives can also be used to turn the fan on and off as needed. Several features of the Danfoss dedicated adjustable frequency drive, the HVAC adjustable frequency drive can be utilized to improve the performance of cooling tower fans applications. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes insignificant.
  • Page 23 Product Overview Design Guide Frequency converter Water Inlet Temperature Sensor BASIN Water Outlet Conderser Water pump Supply Figure 2.13 Cooling Tower Fan MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 24 Frequency converter Water Inlet Flow or pressure sensor BASIN Water Outlet Throttling valve Condenser Water pump Supply Figure 2.14 Condenser Pumps Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 25 In the event the flow rate needs to 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. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 26 Product Overview Design Guide Flowmeter Flowmeter Frequency converter Frequency converter Figure 2.15 Primary Pumps Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 27 When running multiple pumps in parallel, they must run at the same speed to maximize energy savings, either with individual dedicated drives or one adjustable frequency drive running multiple pumps in parallel. Frequency converter Frequency converter Figure 2.16 Secondary Pumps MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 28: Control Structures

    The output from the motor control is then limited by the maximum frequency limit. 2.7.3 PM/EC+ Motor Control The Danfoss EC+ concept provides the possibility for using high efficient PM motors (permanent magnet motors) in IEC standard frame size operated by Danfoss adjustable frequency drives.

  • Page 29: Local (Hand On) And Remote (Auto On) Control

    Hand Off Auto Reset Figure 2.18 LCP Keys Local reference forces the configuration mode to open- loop, independent on the setting of 1-00 Configuration Mode. Local Reference is restored at power-down. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 30: Control Structure Closed-Loop

    Since the square root of pressure is proportional to flow, the square root of the pressure signal yields a value proportional to the flow. See Figure 2.20. Ref. signal Ref. P 20-01 Desired FB conversion Flow Flow signal Figure 2.20 Feedback Signal Conversion Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 31: Reference Handling

    External reference in % Remote reference in % Extern resource 3 No function Analog reference ±200 % Local bus reference ±200 % LCP potmeter 0~100 % Figure 2.21 Block Diagram Showing Remote Reference MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 32 Y is 3-14 Preset Relative Reference in [%]. If Y, 3-14 Preset Relative Reference, is set to 0%, the reference is not affected by the scaling. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 33: Closed-Loop Set-Up Wizard

    13.30 0220 20-93 PI Proportional Gain 00.50 6-25 T54 high Feedback 6-25 T54 high Feedback 0050 0050 20-94 PI integral time 0020.00 1-29 Automatic Motor Adaption Figure 2.22 Closed-loop Set-up Wizard MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 34 Changing this parameter affects the settings of other parameters. 1-29 Automatic Motor Adaption Performing an AMA optimizes motor (AMA) performance. 1-30 Stator Resistance (Rs) 0.000–99.990 Size related Set the stator resistance value. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 35 Select [1] Inverse to reduce the output speed. 20-83 PI Start Speed [Hz] 0–200 Hz Enter the motor speed to be attained as a start signal for commencement of PI control. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 36: Tuning The Drive Closed-Loop Controller

    Next, increase the PI integral time until the feedback signal stabilizes. Then increase of the integral time by 15– 50%. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 37: General Aspects Of Emc

    Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50 MHz (airborne) is especially generated by the control electronics. See chapter 5.2.4 EMC-compatible Electrical Installation for more information on EMC. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 38: Emission Requirements

    Class B (home and office) commercial and light industrial environments. Second environment EN/IEC 61000-6-4 Emission standard for industrial Class A Group 1 (industrial environment) environments. Table 2.10 Limits at Generic Emission Standards Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 39 [15–45 kW] 3x200– 240 V IP20 40–125 hp [30–90 kW] 3x380– 480 V IP20 1–25 [0.75–18.5 3x380– 480 V IP54 30–125 hp [22–90 kW] 3x380– 480 V IP54 Table 2.11 Test Results MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 40 Consequently, in plants with a high percentage of rectifier load, maintain harmonic currents at a low level to prevent an overload of the transformer and high temperature in the cables. Figure 2.24 Harmonic Currents Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 41 1 kW up to 16 A phase PWHD current. Actual 0.5–30 hp [0.37–22 kW], Table 2.14 Connected Equipment 44.4 40.8 380–480 V (typical) ≥120 Limit for R Table 2.16 Harmonic Current 0.5–30 hp [0.37–22 kW], 380–480 V MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 42 55.7 25.3 525–600 V V (typical) (typical) ≥120 Limit for R Table 2.19 Harmonic Current 25–125 hp [18.5–90 kW], Table 2.22 Harmonic Current 20–60 hp [15–45 kW], 200 V 525–600 V Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 43: Galvanic Isolation (Pelv)

    PELV offers protection by way of extra low voltage. Protection against electric shock is ensured when the electrical supply is of the PELV type and the installation is made as described in local/national regulations on PELV supplies. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 44: Ground Leakage Current

    (Alarm 16 Trip Lock). Installation at high altitude: To protect the adjustable frequency drive against a short At altitudes above 6,600 ft [2 km], contact Danfoss circuit at the load sharing and brake outputs see the regarding PELV.
  • Page 45 (ETR). coast. 2.11.1 Motor Thermal Protection This is the way Danfoss protects the motor from being overheated. It is an electronic feature that simulates a bimetal relay based on internal measurements. The charac- teristic is shown in Figure 2.27.
  • Page 46 If the motor is overloaded without reaching the temperature, the ETR shuts of the motor. ETR is activated in 1-90 Motor Thermal Protection. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 47: Selection

    Main Status Quick Menu Menu Menu Menu Menu Menu Com. Com. Warn. Warn. Alarm Alarm Figure 3.2 Place LCP on Panel Hand Auto Auto Hand Reset Reset Figure 3.1 Fit Gasket MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 48: Ip21/Type 1 Enclosure Kit

    If the enclosure kit is used, an IP20 unit is upgraded to comply with enclosure IP21/TYPE 1. Figure 3.3 Place Bracket on LCP Warn. Alarm Step 4 Connect cable to adjustable frequency drive. Figure 3.5 H1-H5 Figure 3.4 Connect Cable Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 49 IP20 3–10 hp 14.65 [372] 5.12 [130] 8.07 [205] 132B0220 132B0220 [2.2–7.5 kW] IP20 15–20 hp 18.7 [475] 6.5 [165] 9.8 [249] 132B0221 132B0221 [11–15 kW] Table 3.3 Enclosure Kit Specifications MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 50: Decoupling Plate

    132B0243 IP20 50–60 [37–45] 125 [90] 100–125 [75–90] 132B0209 Table 3.4 Decoupling Plate Specifications NOTICE! For H9 and H10 adjustable frequency drives, the decoupling plates are included in the accessory bag. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 51: How To Order

    The Drive Configurator automatically generates an 8-digit sales number to be delivered to your local sales office. Furthermore, a project list with several products can be established and sent to Danfoss sales representative. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 52 C0 options MCO 33–34 CX: No C options C1 options X: No C1 options C option software 36–37 XX: No options D options 38–39 DX: No D0 options Table 4.1 Type Code Descriptions Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 53: Ordering Numbers

    132B0202 132B0202 132B0204 132B0205 132B0205 132B0207 132B0242 132B0208 132B0243 132B0209 plate IP21 option 132B0212 132B0213 132B0214 132B0215 132B0216 132B0217 132B0218 132B0219 Nema Type 1 132B0222 132B0223 132B0224 132B0225 132B0226 132B0217 132B0218 132B0219 Table 4.2 Options and Accessories MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 54 THID level [%] Order number filter IP00 Code number filter IP20 Continuous [A] frequency [kHz] 34.6 130B1775 130B1487 130B1776 130B1488 130B1777 130B1491 130B1778 130B1492 130B1779 130B1493 130B1780 130B1494 130B1781 130B1495 Table 4.6 AHF Filters (10% current distortion) Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 55 FN3258-30-47 270 50 85 240 255 30 5.4 1 10.6 M5 1.9-2.2 132B0246 25–30 [18.5–22] FN3258-42-47 310 50 85 280 295 30 5.4 1 10.6 M5 1.9-2.2 132B0247 Table 4.7 RFI Filters - Details Figure 4.2 RFI Filter MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 56: How To Install

    [2.2–7.5] [269] [374] [257] [130] [110] [205] [11] [5.5] [6.6] IP20 15–20 15.71 16.5 14.96 5.51 9.76 0.47 0.28 26.46 [11–15] [399] [419] [380] [165] [140] [248] [12] [6.8] [7.5] [12] Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 57 [680] [648] [308] [272] [310] [19] [9.8] [45] IP54 100–125 30.32 29.1 15.57 13.15 13.19 0.39 2.56 [75–90] [770] [739] [370] [334] [335] [9.8] [65] Table 5.1 Dimensions Including decoupling plate MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 58 The amount of space for free air passage is listed in Table 5.2: Enclosure Clearance [mm] Frame IP class Above unit Below unit Table 5.2 Clearance Needed for Free Air Passage Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 59: Shipping Dimensions

    How to Install Design Guide 5.1.2 Shipping Dimensions MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 60: Electrical Data

    UDC+ on the following units: IP20 380–480 V 40–125 hp [30–90 kW] IP20 200–240 V 20–60 hp [15–45 kW] IP20 525–600 V 3–125 hp [2.2–90 kW] IP54 380–480 V 30–125 hp [22–90 kW] Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 61: Electrical Installation In General

    100–125 [75–90] 123.91/212.42 123.91/212.42 4.43 [0.5] 26.55 [3] 4.43 [0.5] [14/24] [14/24] Table 5.6 Details of Tightening Torques ≤ 0.1472 in Cable dimensions [95 mm Cable dimensions >0.1472 in [95 mm MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 62: Connecting To Line Power And Motor

    Figure 5.2 H1-H5 Frame IP20 200–240 V 0.34–15 hp [0.25–11 kW] and IP20 380–480 V 0.5–30 hp [0.37–22 kW]. 1 Line 2 Ground 3 Motor 4 Relays Table 5.7 Legend to Figure 5.2 Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 63 IP20 525–600 V 60–75 hp [45–55 kW] 1 Line 2 Motor 1 Line 3 Ground 2 Relays 4 Relays 3 Ground 4 Motor Table 5.8 Legend to Figure 5.3 Table 5.9 Legend to Figure 5.4 MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 64 IP20 200–240 V 50–60 hp [37–45 kW] IP20 525–600 V 100–125 hp [75–90 kW] Figure 5.6 H9 Frame IP20 600 V 3–10 hp [2.2–7.5 kW] 1 Line 2 Relays 3 Ground 4 Motor Table 5.10 Legend to Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 65 Figure 5.8 When mounting cables, first mount and tighten ground cable. Figure 5.7 Mount the two screws in the mounting plate, slide it into place and tighten fully Figure 5.9 Mount line power plug and tighten wires MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 66 2 Line in 3 Ground 4 Wire clamps 5 Motor 6 UDC 7 Relays 8 I/O Figure 5.11 H10 Frame Table 5.11 Legend to Figure 5.12 IP20 600 V 15–20 hp [11–15 kW] Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 67 5 Motor 4 Wire clamps 6 UDC 5 Motor 7 Relays 6 UDC 8 I/O 7 Relays 8 I/O Table 5.13 Legend to Figure 5.14 Table 5.12 Legend to Figure 5.13 MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 68 Figure 5.17 I6 Frame IP54 380-480 V 30–50 hp [22–37 kW] Figure 5.16 I6 Frame IP54 380-480 V 30–50 hp [22–37 kW] Figure 5.18 I6 Frame IP54 380-480 V 30–50 hp [22–37 kW] Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 69: Fuses And Circuit Breakers

    Circuit breakers must be designed for protection in a circuit capable of supplying a maximum of 10,000 Arms (symmetrical), 480 V maximum. NOTICE! In the event of malfunction, failure to follow the protection recommendation may result in damage to the adjustable frequency drive. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 70 Moeller NZMB1- FRS-R-150 KTN-R150 JKS-150 JJN-150 JGE3150FFG A160 FRS-R-150 KTN-R150 JKS-150 JJN-150 FRS-R-200 KTN-R200 JKS-200 JJN-200 Cutler-Hammer Moeller NZMB1- JGE3200FFG A200 FRS-R-200 KTN-R200 JKS-200 JJN-200 Table 5.14 Circuit Breakers and Fuses Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 71 JJS-15 PKZM0-16 FRS-R-15 KTS-R-15 JKS-15 JJS-15 PKZM0-16 FRS-R-15 KTS-R-15 JKS-15 JJS-15 PKZM0-25 FRS-R-25 KTS-R-25 JKS-25 JJS-25 PKZM0-25 FRS-R-25 KTS-R-25 JKS-25 JJS-25 PKZM4-63 FRS-R-50 KTS-R-50 JKS-50 JJS-50 PKZM4-63 FRS-R-50 KTS-R-50 JKS-50 JJS-50 MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 72 It is important to ensure good electrical contact from the installation plate through the installation screws to the metal cabinet of the adjustable frequency drive. • Use starwashers and galvanically conductive installation plates. • Do not use shielded/armored motor cables in the installation cabinets. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 73 Motor, 3 phases and Reinforced protective ground Protective ground Figure 5.20 EMC-compatible Electrical Installation NOTICE! For North America, use metal conduits instead of shielded cables. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 74: Control Terminals

    Digital input 18, 19 and 27 mode is set in 5-00 Digital Input Mode (PNP is default value) and digital input 29 mode is set in 5-03 Digital Input 29 Mode (PNP is default value). Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 75: How To Program

    Can also be used for setting local reference. 12 [OK]: For selecting a parameter and for accepting changes to parameter settings. Figure 6.1 Local Control Panel (LCP) Table 6.2 Legend to Figure 6.1 MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 76: Menus

    HVAC Basic Drive functions. The Quick Menu consists of: Push Back to skip it Set-up 1 • Wizard for open-loop applications Figure 6.3 Wizard • Closed-loop set-up wizard • Motor set-up • Changes made Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 77 AMA Failed Wizard completed Press OK ----- Press OK to accept Setup 1 Setup 1 Setup 1 0.0 Hz 0.0 kW Setup 1 AMA OK AMA failed Figure 6.4 Open-loop Set-up Wizard MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 78 1-37 d-axis Inductance (Ld) 1-39 Motor Poles 1-40 Back EMF at 1000 RPM 1-66 Min. Current at Low Speed 1-72 Start Function 1-73 Flying Start 4-19 Max Output Frequency 4-58 Missing Motor Phase Function Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 79 Limit [Hz] 4-14 Motor Speed High 0.0–400 Hz 65 Hz Enter the maximum limit for high speed. Limit [Hz] 4-19 Max Output 0–400 Size related Enter the maximum output frequency value. Frequency MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 80 Enter the current that corresponds to the high Current reference value. 6-19 Terminal 53 mode [0] Current Select if terminal 53 is used for current or voltage [1] Voltage input. Table 6.4 Open-loop Application Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 81 13.30 0220 20-93 PI Proportional Gain 00.50 6-25 T54 high Feedback 6-25 T54 high Feedback 0050 0050 20-94 PI integral time 0020.00 1-29 Automatic Motor Adaption Figure 6.5 Closed-loop Set-up Wizard MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 82 Changing this parameter affects the settings of other parameters. 1-29 Automatic Motor Adaption Performing an AMA optimizes motor (AMA) performance. 1-30 Stator Resistance (Rs) 0.000–99.990 Size related Set the stator resistance value. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 83 Select [1] Inverse to reduce the output speed. 20-83 PI Start Speed [Hz] 0–200 Hz Enter the motor speed to be attained as a start signal for commencement of PI control. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 84 AMA. 1-39 Motor Poles 2–100 Enter the number of motor poles 1-40 Back EMF at 1000 RPM 10–9000 Size related Line-Line RMS back EMF voltage at 1000 RPM Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 85 4-14 Motor Speed High Limit 0.0–400 Hz 2.56 [65] Enter the maximum limit for high [Hz] speed 4-19 Max Output Frequency 0–400 Size related Enter the maximum output frequency value Table 6.6 Motor Parameters MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 86: Main Menu

    Once the set-up of an adjustable frequency drive is If the parameter's value is changed back to the factory complete, Danfoss recommends to store the data in the settings from another different value, the parameter will LCP or on a PC via MCT 10 Set-up Software tool.

  • Page 87: Initialize The Adjustable Frequency Drive To Default Settings In Two Ways

    8-75 Intialisation Password 15-00 Operating hours to 15-05 Over Volt's 15-03 Power Up's 15-04 Over Temp's 15-05 Over Volt's 15-30 Alarm Log: Error Code 15-4* Drive identification parameters 1-06 Clockwise Direction MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 88: Installation And Set-Up

    Cable Shielded twisted pair (STP) Impedance [Ω] Cable length Max. 4,000 ft [1200 m] (including drop lines) (ft [m]) Max. 1,650 ft [500 m] station-to-station Table 7.1 Cable Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 89: Adjustable Frequency Drive Hardware Set-Up

    The factory setting for the dip switch is OFF. 8-37 Maximum If transmission is interrupted, specify a Inter-char delay maximum delay time between two received bytes to ensure timeout. Table 7.2 Modbus Communication Parameter Settings MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 90: Emc Precautions

    RS-485 communication cable must be kept Stop of the adjustable frequency drive in various away from motor and brake resistor cables. Normally, a ways: distance of 8 inches [200 mm] is sufficient, but Danfoss • Coast stop recommends keeping the greatest possible distance •...

  • Page 91: Fc Protocol Message Framing Structure

    0. A number of data bytes (variable, depending on the type of message) follows. A data control byte (BCC) completes the message. DATA Figure 7.4 MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 92: The Data Field

    PCD1 PCD2 high Figure 7.6 Parameter Block Text block The text block is used to read or write texts via the data block. PCD1 PCD2 Figure 7.7 Text Block Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 93: The Pke Field

    No response Parameter value transferred (word) Only the low byte is used as an index. Parameter value transferred (double word) Command cannot be performed text transferred Table 7.6 Response MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 94: Parameter Value (Pwe)

    Change 4-14 Motor Speed High Limit [Hz] to 100 Hz. Table 7.8 Data Types Write the data in EEPROM. PKE=E19E Hex - Write single word in 4-14 Motor Speed High Limit [Hz]: IND=0000 Hex PWEHIGH=0000 Hex PWELOW=03E8 Hex Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 95: Modbus Rtu Overview

    7.6 Modbus RTU Overview 7.6.1 Assumptions E19E 0000 H 0000 H 03E8 Danfoss assumes that the installed controller supports the high interfaces in this document, and strictly observes all Figure 7.9 Message requirements and limitations stipulated in the controller and adjustable frequency drive.

  • Page 96: Adjustable Frequency Drive With Modbus Rtu

    This permits a range of control options, including controlling the setpoint of the adjustable frequency drive when its internal PI controller is used. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 97: Modbus Rtu Message Structure

    This causes a timeout (no response from the follower), since the value in the final CRC field is not valid for the combined messages. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 98: Crc Check Field

    Parameter changes are written to the RAM of the adjustable frequency drive. Parameter changes are written to the RAM and EEPROM of the adjustable frequency drive. 66-65536 Reserved Table 7.14 Coil Register Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 99 20 bytes space reserved pr parameter in Modbus Map Table 7.17 Adress/Registers Value written in Modbus RTU message must be one, or less than register number, e.g., read Modbus Register 1 by writing value 0 in message. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 100: 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 7.19 Function Codes Table 7.20 Modbus Exception Codes Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 101: 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. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 102: Force/Write Single Coil (05 Hex)

    Error Check (CRC) Table 7.22 Response Table 7.24 Response NOTICE! Coils and registers are addressed explicit with an off-set of -1 in Modbus. For example, Coil 33 is addressed as Coil 32. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 103: Force/Write Multiple Coils (0F Hex)

    Data HI (Register 3031) Quantity of Coils HI Data LO (Register 3031) Quantity of Coils LO 10 (16 coils) Error Check (CRC) Error Check (CRC) Table 7.28 Response Table 7.26 Response MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 104: Preset Single Register (06 Hex)

    Error Check (CRC) Field Name Example (HEX) Table 7.30 Response Follower Address Function Starting Address HI Starting Address LO No. of Registers HI No. of registers LO Error Check (CRC) Table 7.32 Response Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 105: Danfoss Fc Control Profile

    Make a selection in 8-56 Preset Reference Select to define Bit 08, Jog how Bit 00/01 gates with the corresponding function on Bit 08=’1’: The output frequency is determined by 3-11 Jog the digital inputs. Speed [Hz]. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 106: Status Word According To Fc Profile (Stw) (8-30 Protocol = Fc Profile)

    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. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 107: Bus Speed Reference Value

    Par.3-03 Bit 12=’1’: The inverter stops because of overtemperature Min reference Max reference Figure 7.16 Reference and MAV but the unit does not trip and resumes operation once the overtemperature stops. MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 108: General Specifications And Troubleshooting

    80.5 100.1 (3x200–240 V) [A] Intermittent 10.6 14.3 21.8 25.3 36.3 45.8 57.6 67.8 88.6 110.1 130.9 (3x200–240 V) [A] Table 8.1 3x200–240 V AC, PK25–P45K 1) At rated load conditions Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 109: Line Power Supply 3X380-480 V Ac

    15.4 23.0 30.8 Continuous (3x440–480 V) [A] 10.0 12.6 19.1 24.0 Intermittent (3x440–480 V) [A] 11.0 13.9 21.0 26.4 Table 8.2 3x380–480 V AC, PK37–P11K, H1–H4 1) At rated load conditions MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 110 35.0 41.6 52.0 64.0 73.5 91.0 112.0 Intermittent (3x440–480 V) [A] 34.4 38.5 45.8 57.2 70.4 80.9 100.1 123.2 Table 8.3 3x380–480 V AC, P18K–P90K, H5–H8 1) At rated load conditions Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 111 36.3 Continuous (3x440–480 V) [A] 10.0 12.6 19.1 24.0 30.0 Intermittent (3x440–480 V) [A] 11.0 13.9 21.0 26.4 33.0 Table 8.4 3x380–480 V AC, PK75–P18K, I2–I4 1) At rated load conditions MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 112 Continuous (3x440–480 V) [A] 32.0 41.6 52.0 56.0 73.5 91.0 112.0 Intermittent (3x440–480 V) [A] 35.2 45.8 57.2 61.6 80.9 100.1 123.2 Table 8.5 3x380–480 V AC, P11K–P90K, I6–I8 1) At rated load conditions Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 113: Line Power Supply 3X380-480 V Ac

    Intermittent (3x380–440 V) [A] 4.07 12.0 15.4 23.0 30.8 Continuous (3x440–480 V) [A] 10.0 12.6 19.1 24.0 Intermittent (3x440–480 V) [A] 11.0 13.9 21.0 26.4 Table 8.6 PK75–P15K 1) At rated load conditions MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 114 Continuous (3x440–480 V) [A] 30.0 32.0 41.6 52.0 56.0 73.5 91.0 112.0 Intermittent (3x440–480 V) [A] 33.0 35.2 45.8 57.2 61.6 80.9 100.1 123.2 Table 8.7 P18K–P90K 1) At rated load conditions Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 115: Line Power Supply 3X525-600 V Ac

    36.4 43.3 58.1 70.0 91.7 Intermittent (3x551–600 V) [A] 13.9 16.9 20.8 26.2 31.6 40.0 47.7 63.9 77.0 100.9 Table 8.8 3x525–600 V AC, P2K2–P90K, H6–H10 1) At rated load conditions MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 116: General Specifications

    Maximum cross-section to control terminals, flexible cable 2.5 mm /14 AWG) Minimum cross-section to control terminals 0.05 mm /30 AWG *See chapter 8.1.2 Line Power Supply 3x380–480 V AC for more information. Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 117 1) Terminals 42 and 45 can also be programmed as analog output. Control card, RS-485 serial communication Terminal number 68 (P, TX+, RX+), 69 (N, TX-, RX-) Terminal number 61 Common for terminals 68 and 69 MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 118 EN/IEC 61800-5-1, UL 508C EMC standards, Emission EN 61800-3, EN 61000-6-3/4, EN 55011, IEC 61800-3 EMC standards, EN 61800-3, EN 61000-3-12, EN 61000-6-1/2, EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN Immunity 61000-4-5, EN 61000-4-6 Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...

  • Page 119: Acoustic Noise Or Vibration

    57.3 59.5 53.8 63.7 71.5 67.5 (75 kW 71.5 dB) 73.5 62.9 50.2 60.8 65.6 Table 8.9 Typical Values Measured at a Distance of 3.3 ft [1 m] from the Unit MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 120: Du/Dt

    82 [25] 0.293 1.026 2.801 164 [50] 0.422 1.040 1.971 16.4 [5] 0.168 0.81 3.857 400 V 7.5 hp [5.5 kW] 82 [25] 0.239 1.026 3.434 164 [50] 0.328 1.05 2.560 Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 121 1.254 0.46 1.12 1.948 400 V 75 hp [55 kW] 32.8 [10] 0.468 2.222 0.502 1.048 1.673 400 V 100 hp [75 kW] 32.8 [10] 0.52 1.212 1.869 0.51 1.272 1.992 MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 122: Derating According To Ambient Temperature And Switching Frequency

    Figure 8.1 200 V IP20 H1 0.34–1 hp [0.25–0.75 kW] 110% 110% 100% 100% [kHz] [kHz] Figure 8.4 400 V IP20 H2 3–5 hp [2.2–4.0 kW] Figure 8.2 400 V IP20 H1 0.5–2 hp [0.37–1.5 kW] Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 123 Figure 8.9 200 V IP20 H5 15 hp [11 kW] 110% 110% 100% 100% [kHz] [kHz] Figure 8.7 200 V IP20 H4 7.5–10 hp [5.5–7.5 kW] Figure 8.10 400 V IP20 H5 25–30 hp [18.5–22 kW] MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 124 Figure 8.15 200 V IP20 H7 30–40 hp [22–30 kW] 110% 110% 100% 100% [kHz] [kHz] Figure 8.13 400 V IP20 H6 60 hp [45 kW] Figure 8.16 400 V IP20 H7 75–100 hp [55–75 kW] Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 125 100 % 80 % 60 % 40 % 20 % [kHz] [kHz] Figure 8.19 400 V IP20 H8 125 hp [90 kW] Figure 8.22 600 V IP20 H9 7.5–10 hp [5.5–7.5 kW] MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 126 Figure 8.27 400 V IP54 I5 15–25 hp [11–18.5 kW] 110% 110% 100% 100% [kHz] [kHz] Figure 8.25 400 V IP54 I3 7.5–10 hp [5.5–7.5 kW] Figure 8.28 400 V IP54 I6 30–40 hp [22–30 kW] Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 127 Figure 8.29 400 V IP54 I6 50 hp [37 kW] 110% 100% [kHz] Figure 8.30 400 V IP54 I7 60–75 hp [45–55 kW] 110% 100% [kHz] Figure 8.31 400 V IP54 I8 100–125 hp [75–90 kW] MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.

  • Page 128: Index

    Control card, RS-485 serial communication......115 Flow meter....................23 Control potential.................. 25 Freeze output................... 6 Control Structure Closed-loop............28 Function Codes..................98 Control Structure Open-loop............26 Fuses and Circuit Breakers..............67 Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 129 Programming with................73 Local (Hand On) and Remote (Auto On) Control...... 27 Protection................12, 41, 42, 67 Local Control Panel (LCP)..............73 Protection and Features..............114 Local speed determination............... 23 Protocol Overview................88 MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 130 The EMC directive (89/336/EEC)............10 The low-voltage directive (73/23/EEC)......... 10 The machinery directive (98/37/EEC)..........10 Thermistor....................6 Throttling valve..................22 Tuning the Drive Closed-loop Controller........34 Two finger initialization..............85 Type Code String.................. 50 Danfoss A/S © Rev. 2014-01-14 All rights reserved. MG18C522...
  • Page 131 Index Design Guide MG18C522 Danfoss A/S © Rev. 2014-01-14 All rights reserved.
  • Page 132 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.

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