Danfoss VLT Series Design Manual
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Danfoss VLT Series Design Manual

Hvac drive
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Download this manual See also: Programming Manual, Installation Manual
VLT
®
HVAC Drive Design Guide
Contents
How to Read this Design Guide
®
MG.11.B2.02 - VLT
is a registered Danfoss trademark
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Summary of Contents for Danfoss VLT Series

  • Page 1: Table Of Contents

    Efficiency Peak Voltage on Motor Special Conditions Purpose of derating Automatic adaptations to ensure performance Mechanical Dimension Options and Accessories 4. How to Order Ordering form Type Code String Ordering Numbers ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 2 Examples Modbus RTU Overview VLT HVAC with Modbus RTU Modbus RTU Message Framing Structure How to Access Parameters Examples Danfoss FC Control Profile 8. Troubleshooting Status messages Alarms and warnings Index ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 3 Illustration 5.19: EMC-correct electrical installation of an IP20 frequency converter. Illustration 6.1: Terminal 37: Available only with Safe Stop Function! Illustration 6.2: Terminal 37: Available only with Safe Stop Function! Illustration 7.1: Network Terminal Connection ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 4 Table 5.3: UL fuses 200 - 240 V Table 5.4: UL fuses 380 - 600 V Table 8.1: Alarm/Warning code list Table 8.2: Description of Alarm Word, Warning Word and Extended Status Word ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 5: How To Read This Design Guide

    HVAC Drive Programming Guide MG.11.CX.YY provides information on how to programme and includes complete parameter descriptions. X = Revision number YY = Language code Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/ DrivesSolutions/Documentations/Technical+Documentation. 1.1.1. Approvals ® MG.11.B2.02 - VLT...

  • Page 6: Symbols

    Nominal motor current Nominal motor frequency Nominal motor power Nominal motor voltage Parameter par. Protective Extra Low Voltage PELV Printed Circuit Board Rated Inverter Output Current Revolutions Per Minute Second Torque limit Volts ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 7: Definitions

    The minimum motor frequency. The rated motor frequency (nameplate data). The motor current. The rated motor current (nameplate data). The rated motor speed (nameplate data). The rated motor power (nameplate data). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 8 20mA) and the resulting reference. The maximum reference value set in par. 3-03. Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4mA) and the resulting reference. The minimum reference value set in par. 3-02. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 9 An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an off-load period. The operation can be either periodic duty or none-periodic duty. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 10 The SLC is a sequence of user defined actions executed when the associated user defined events are evaluated as true by the SLC. Thermistor: A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 11 In addition, a high power factor indicates that the different harmonic currents are low. The frequency converters' built-in DC coils produce a high power factor, which minimises the imposed load on the mains supply. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 12 ® 2. Introduction to VLT HVAC Drive HVAC Drive Design Guide ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 13: Introduction To Vlt Hvac Drive

    Design Guide Software version: 1.xx This Design Guide can be used for all VLT HVAC frequency converters with software version 1.xx. The software version number can be seen from parameter 15-43. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 14: Ce Labelling

    1, 1997. The directive applies to all electrical equipment and appliances used in the 50 - 1000 V AC and the 75 - 1500 V DC voltage ranges. Danfoss CE-labels in accordance with the directive and issues a declaration of conformity upon request.

  • Page 15: Air Humidity

    The Design Guide offers detailed instructions for installation to ensure EMC-correct installation. Furthermore, Danfoss specifies which our different products comply with. Danfoss gladly provides other types of assistance that can help you obtain the best EMC result. 2.3.4. Compliance with EMC Directive 89/336/EEC As mentioned, the frequency converter is mostly used by professionals of the trade as a complex component forming part of a larger appliance, system, or installation.

  • Page 16: Vibration And Shock

    The frequency converter complies with requirements that exist for units mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors. IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970 IEC/EN 60068-2-64: Vibration, broad-band random ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 17 = Rated power = Reduced flow = Reduced power H = Pressure n = Speed regulation = Rated pressure = Rated speed = Reduced pressure = Reduced speed Flow Pressure Power ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 18 42,5 18.615 42,5 18.615 1314 38,5 50.589 29,0 38.106 1752 35,0 61.320 18,5 32.412 1752 31,5 55.188 11,5 20.148 1752 28,0 49.056 11.388 1752 23,0 40.296 6.132 Σ 8760 275.064 26.801 ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 19 In the example on the following quency converter is used. It is possible to page, the two systems can be established at roughly the same price. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 20 V.A.V. = Variable Air Volume Sensor P = Pressure Sensor T = Temperature 2.7.10. With a frequency converter The figure shows a fan system controlled by VLT HVAC Drive frequency converters. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 21 2. Introduction to VLT HVAC Drive 2.7.11. Application examples The next few pages give typical examples of Danfoss supplier for an information sheet that applications within HVAC. gives a full description of the application. If you would like to receive further information...
  • Page 22 The advanced PID controller of the VLT HVAC Drive can be used to eliminate the need for additional controllers. Pressure signal Cooling coil Heating coil VAV boxes Filter Supply fan Pressure transmitter Flow Return fan Flow ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 23 Several features of Danfoss HVAC dedicated frequency converter, the VLT HVAC Drive can be utilized to improve the performance of your CAV system. One concern of controlling a ventilation system is poor air quality.
  • Page 24 The frequency converters can also be used to turn the fan on and off as needed. Several features of Danfoss HVAC dedicated drive, the VLT HVAC Drive can be utilized to improve the performance of your cooling tower fans application. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes small.
  • Page 25 This can amount to savings of 15-20% or more. Trimming the pump impeller is irreversible, thus if the conditions change and higher flow is required the impeller must be replaced. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 26 In the event the flow rate needs to be increased later in the systems life, the frequency converter can simply increase the pumps speed instead of requiring a new pump impeller. Flowmeter Flowmeter ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 27 Please 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 drive running multiple pumps in parallel. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 28: Vlt Hvac Controls

    LCP using the [Hand ON] and [Off] keys. Alarms can be reset via the [RESET] key. After pressing the [Hand On] key, the frequency converter goes into Hand mode and follows (as default) the Local reference set by using the LCP arrow keys. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 29 (i.e. Open Loop or Closed loop) is used when the Remote reference is active (see table above for the conditions). Reference Handling Local Reference ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 30: Pid

    The figure is a block diagram of the drive’s Closed Loop Controller. The details of the Ref- erence Handling block and Feedback Handling block are described in their respective sections below. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 31 This table summarizes the parameters that are needed to set up the drive’s Closed Loop Controller when a single feedback signal with no conversion is compared to a single setpoint. This is the most common type of Closed Loop Controller. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 32 On Reference Bandwidth par. This determines how close the feedback must be to the 20-84 setpoint reference for the drive to indicate that the feedback is equal to the setpoint. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 33 Large values of Lowpass Filter Time will provide more filter- ing, but may cause the controller to not respond to actual variations in the feedback signal. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 34 50 (+10 V), 53 (input) and 55 (common). 3. Temperature feedback via transmitter (-10-40°C, 4-20 mA) connected to terminal 54. Switch S202 behind the Local Control Panel set to ON (current input). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 35 Adjust the drive’s Closed Loop Controller, if 20-93 See Optimization of the PID Controller, needed. 20-94 below. 8) Finished! All to LCP Save the parameter setting to the LCP for 0-50 safe keeping ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 36: Illustration 2

    Time (par. 20 95) is also set necessary PID control parameters. to Off (0 s, in this case). Increase the value of the PID Pro- portional Gain (par 20-93) until the ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 37 Experience has shown that the control setting according to Ziegler Nichols rule provides a good closed loop response for many systems. If necessary, the operator can do the final tuning of the control iteratively to modify the response of the control loop. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 38 ® 2. Introduction to VLT HVAC Drive HVAC Drive Design Guide 2.9.3. Reference Handling A block diagram of how the drive produces the Remote Reference is shown below. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 39 A block diagram of how the drive processes the feedback signal is shown below. Feedback handling can be configured to work with applications requiring advanced control, such as multiple setpoints and multiple feedbacks. Three types of control are common. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 40 Temperature − + 1 ) − pressure where A1, A2 and A3 are refrigerant-specific constants. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 41: 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. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 42: Table 2.1: Emc Test Results (Emission, Immunity)

    The tests were performed in accordance with the following basic standards: • EN 61000-4-2 (IEC 61000-4-2): Electrostatic discharges (ESD)Simulation of electrostatic discharges from human beings. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 43: Table 2.2: Immunity

    8 kV AD — — 10 V/m — 6 kV CD AD: Air Discharge CD: Contact Discharge CM: Common mode DM: Differential mode 1. Injection on cable shield. Table 2.2: Immunity ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 44: Galvanic Isolation (Pelv)

    Custom relays. Illustration 2.2: Galvanic isolation The functional galvanic isolation (a and b on drawing) is for the 24 V back-up option and for the RS 485 standard bus interface. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 45: Earth Leakage Current

    The intermittent duty cycle for the resistor is calculated as follows: Duty Cycle = t T = cycle time in seconds is the braking time in seconds (as part of the total cycle time) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 46 HVAC Drive Design Guide Danfoss offers brake resistors with duty cycle of 5%, 10% and 40% suitable for use with the VLT® FC102 HVAC drive series. If a 10% duty cycle resistor is applied, this is able of absorbing braking power upto 10% of the cycle time with the remaining 90% being used to dissipate heat from the resistor.

  • Page 47: Mechanical Brake Control

    Switching on the output between the motor and the frequency converter is fully permitted. You cannot damage the frequency converter in any way by switching on the output. However, fault messages may appear. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 48 Operation within the torque limit is limited in time (0-60 s) in par. 14-25. 2.15.1. Motor Thermal Protection The motor temperature is calculated on the basis of motor current, output frequency, and time or thermistor. See par. 1-90 in the chap- How to Programme ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 49: Vlt Hvac Selection

    Weight enclosure IP20 [kg] Weight enclosure IP21 [kg] Weight enclosure IP55 [kg] 13.5 13.5 13.5 13.5 13.5 Weight enclosure IP 66 [kg] 13.5 13.5 13.5 13.5 13.5 Efficiency 0.96 0.96 0.96 0.96 0.96 ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 50 Environment Estimated power loss at rated max. load [W] Weight enclosure IP20 [kg] Weight enclosure IP21 [kg] Weight enclosure IP55 [kg] Weight enclosure IP 66 [kg] Efficiency 0.96 0.96 0.96 0.96 ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 51 1140 1353 1636 at rated max. load [W] Weight enclosure IP20 [kg] Weight enclosure IP21 [kg] Weight enclosure IP55 [kg] Weight enclosure IP 66 [kg] 0.96 0.97 0.97 0.97 0.97 Efficiency ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 52 Weight enclosure IP 55 [kg] 13.5 13.5 13.5 13.5 13.5 14.2 14.2 Weight enclosure IP 66 [kg] 13.5 13.5 13.5 13.5 13.5 14.2 14.2 Efficiency 0.96 0.97 0.97 0.97 0.97 0.97 0.97 ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 53 A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 54: General Specifications

    Maximum cross section to control terminals, flexible cable 1 mm /18 AWG Maximum cross section to control terminals, cable with enclosed core 0.5 mm /20 AWG Minimum cross section to control terminals 0.25 mm ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 55 10 bit (+ sign) Accuracy of analog inputs Max. error 0.5% of full scale Bandwidth : 200 Hz The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 56 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. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 57 Speed control range (open loop) 1:100 of synchronous speed Speed accuracy (open loop) 30 - 4000 rpm: Maximum error of ±8 rpm All control characteristics are based on a 4-pole asynchronous motor ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 58 The efficiency declines a little when the switching frequency is set to a value of above 5 kHz. The efficiency will also be slightly reduced if the mains voltage is 480 V, or if the motor cable is longer than 30 m. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 59 (η MOTOR η ) = η x η SYSTEM MOTOR Based on the graph outlined above, it is possible to calculate the system efficiency at different speeds. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 60: Peak Voltage On Motor

    If the motor cable is long (100 m), the rise time and peak voltage increases. If very small motors are used without phase coil insulation, connect an LC filter to the frequency converter. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 61: Efficiency

    ) is multiplied by the efficiency of the motor (η MOTOR η ) = η x η SYSTEM MOTOR Calculate the efficiency of the system at different loads based on the graph above. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 62: Peak Voltage On Motor

    If the motor cable is long (100 m), the rise time and peak voltage increases. If very small motors are used without phase coil insulation, connect an LC filter to the frequency converter. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 63: Special Conditions

    Illustration 3.4: Derating of I for different T AMB, AMB, for enclosure A, using 60 PWM and maximum for enclosure A, using SFAVM and maximum 10 m motor cable 10 m motor cable ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 64: Illustration 3.5: Derating Of I

    ) should be derated in accordance with the shown diagram. Illustration 3.9: Derating of output current versus altitude at T . By altitudes above 2 km, please AMB, MAX contact Danfoss Drives regarding PELV. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 65: Automatic Adaptations To Ensure Performance

    The capability to automatically reduce the output current extends the acceptable operating conditions even further. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 66: Mechanical Dimension

    ® 3. VLT HVAC Selection HVAC Drive Design Guide 3.7. Mechanical Dimension ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 67 9 mm 9 mm 9 mm 9 mm 9 mm 17.6 mm 18 mm 13.5/14.2 4.9 kg 5.3 kg 6.6 kg 7.0 kg 23 kg 27 kg 43 kg 61 kg weight ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 68: Options And Accessories

    3. VLT HVAC Selection HVAC Drive Design Guide 3.8. Options and Accessories Danfoss offers a wide range of options and accessories for the VLT frequency converters. 3.8.1. Mounting of Option Modules in Slot B The power to the frequency converter must be disconnected.

  • Page 69: Illustration 3.10: Principle Diagram

    If the digital inputs 7, 8 or 9 are to be switched by use of the internal 24 V power supply (terminal 9) the connection between terminal 1 and 5 which is illustrated in the drawing has to be estab- lished. Illustration 3.10: Principle Diagram ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 70 3.8.6. Analog outputs - Terminal X30/5+8 Parameters for set-up: 6-6* and 16-77 Number of analog outputs Output signal level Tolerance Max. load 0/4 - 20 mA ± 0.1 mA < 500 ohm ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 71 • Select the relay functions in par. 5-40 [6-8], 5-41 [6-8] and 5-42 [6-8]. NB (Index [6] is relay 7, index [7] is relay 8, and index [8] is relay 9) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 72 ® 3. VLT HVAC Selection HVAC Drive Design Guide Do not combine low voltage parts and PELV systems. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 73: Illustration 3.11: Connection To 24 V Back-Up Supplier (A2-A3)

    When MCB 107, 24 V back-up option is sup- plying the control circuit, the internal 24 V supply is automatically disconnected. Illustration 3.12: Connection to 24 V back-up sup- plier (A5-C2). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 74: Illustration 3.13: Principle Diagram For Analog I/O Mounted In Frequency Converter

    Ni1000 temperature sensor of 1000 Ω at 0° C. Specifications according to DIN43760 • Pt1000 temperature sensor of 1000 Ω at 0° C. Specifications according to IEC 60751 3 x Analog Outputs supplying 0-10 VDC. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 75 Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected in respect to its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide verity of different resistors that are specially designed to our drive code How to order numbers can be found in section ®...
  • Page 76 Holes for cable glands: Size A2: 2x M25 and 3xM32 Size A3: 3xM25 and 3xM32 ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 77 Sine-wave filters enable use of longer motor cables in applications where the motor is installed far from the drive. The length is unfortunately limited because the filter does not reduce leakage currents in the cables. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 78 ® 4. How to Order HVAC Drive Design Guide ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 79: How To Order

    The Drive Configurator will automatically generate an eight-digit sales number to be delivered to your local sales office. Furthermore, you can establish a project list with several products and send it to a Danfoss sales representative.

  • Page 80: Type Code String

    ® 4. How to Order HVAC Drive Design Guide 4.1.2. Type Code String Description Possible choice Product group & VLT Series FC 102 Power rating 8-10 1.1 - 90 kW (1K1 - 90K) Number of phases Three phases (T) Mains voltage...

  • Page 81: Ordering Numbers

    1) Only IP21 / > 11 kW Options can be ordered as factory built-in options, see ordering information. For information on fieldbus and application option combatibility with older software versions, please contact your Danfoss supplier. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 82 175Z4609 P22K Compact IP20 61 A / 54 A 110% 60 Hz 250 W 175Z4610 When using Sine Wave filters, the switching frequency must be minimum 4.5 kHz (see par. 14-01). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 83: How To Install

    101/301 units. For DC link connection (Load sharing) the connector 1 can be ordered sepa- rately (Code no 130B1064) An eight pole connector is included in accessory bag for FC 101/301 without Safe Stop. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 84 The service life of the frequency converter is reduced if derating for ambient temperature is not taken into account. 5.1.4. Field Mounting For field mounting the IP 21/IP 4X top/TYPE 1 kits or IP 54/55 units (planned) are recommended. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 85: Electrical Installation

    Cable entry has to be supported around the knockout you intend to remove. The knockout can now be removed with a strong mandrel and a hammer. Remove burrs from the hole. Mount Cable entry on frequency converter. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 86: Illustration 5.1: How To Connect To Mains And Earthing (A2 And A3 Enclosure)

    (B1 and B2 enclosure). Illustration 5.4: How to connect to mains and earthing (C1 and C2 enclosure). Check that mains voltage corresponds to the mains voltage of the frequency con- verter name plate. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 87: Illustration 5.5: Terminals For Mains And Earthing

    For IT mains and delta earth (grounded leg), mains voltage may exceed 440 V be- tween phase and earth. Illustration 5.5: Terminals for mains and earthing. Illustration 5.6: How to connect to mains and earthing with disconnector (A5 enclosure). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 88: Illustration 5.9: Motor Connection For

    MOTOR. Fasten screened cable to decoupling plate with screws and washers from the accessory bag. Illustration 5.8: Motor connection for enclosures A2 and A3 Illustration 5.9: Motor connection for enclosure A5 ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 89: Illustration 5.10: Motor Connection For Enclosure B1 And B2

    3 wires out of motor 6 wires out of motor, Delta-connected 6 wires out of motor, Star-connected U2, V2, W2 to be interconnected separately (optional terminal block) Earth connection ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 90 Furthermore, the terminal screw must be retightened after two days due to the softness of the aluminium. It is crucial to keep the connection a gas tight joint, otherwise the aluminium surface will oxidize again. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 91 600 V maximum. Non UL compliance If UL/cUL is not to be complied with, Danfoss recommends using the fuses mentioned in table 4.2, which will ensure compliance with EN50178: In case of malfunction, not following the recommendation may result in unnecessary damage to the frequency converter.

  • Page 92: Table 5.3: Ul Fuses 200 - 240 V

    L50S fuses from LITTEL FUSE may substitute L50S fuses for 240 V frequency converters. A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V frequency convert- ers. A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V frequency convert- ers. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 93: Access To Control Terminals

    Illustration 5.12: A1, A2 and A3 enclosures 5.2.9. Control Terminals Drawing reference numbers: 10 pole plug digital I/O. 3 pole plug RS485 Bus. 6 pole analog I/O. USB Connection. Illustration 5.14: Control terminals (all enclosures) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 94: Electrical Installation, Control Terminals

    Connect terminals 18 and 27 to +24 V (terminal 12/13) Default settings: 18 = latched start 27 = stop inverse Illustration 5.15: Terminal 37 available with Safe Stop Function only! ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 95: Illustration 5.16: Terminal 37: Safe Stop Input Available With Safe Stop Function Only

    (terminal 20, 55, 39) to avoid ground currents from both groups to affect other groups. For example, switching on the digital input may disturb the analog input signal. Control cables must be screened/armoured. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 96 69). Diagram showing all electrical See drawing terminals Electrical Installation. in section Default setting: S201 (A53) = OFF (voltage input) S202 (A54) = OFF (voltage input) S801 (Bus termination) = OFF ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 97: Final Set-Up And Test

    AMA, or remove the LC filter during the AMA procedure. Press the [OK] key. The display shows “Press [Hand on] to start”. Press the [Hand on] key. A progress bar indicates if the AMA is in progress. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 98 "Report Value” in the [Alarm Log] shows the last measuring sequence carried out by the AMA, before the frequency converter entered alarm mode. This number along with the description of the alarm will assist you in troubleshooting. If you contact Danfoss Service, make sure to mention number and alarm description.

  • Page 99: Additional Connections

    5. How to Install 5.4. Additional Connections 5.4.1. DC bus connection The DC bus terminal is used for DC back-up, Please contact Danfoss if you require further with the intermediate circuit being supplied information. from an external source. Terminal numbers: 88, 89 5.4.2.

  • Page 100: Illustration 5.17: Terminals For Relay Connection

    HVAC Drive Design Guide Terminals for relay connection Terminals for relay connection (A2 and A3 enclosures). (A5, B1 and B2 enclosures). Illustration 5.17: Terminals for relay connection (C1 and C2 enclosures). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 101 Provide fur- ther motor protection by e.g. thermistors in each motor or individual thermal relays. (Cir- cuit breakers are not suitable as protection). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 102 The electronic thermal relay in the frequency converter has received the UL-approval for single Motor Thermal Protection ETR Trip motor protection, when par. 1-90 is set for and par. 1-24 Motor current, I is set to the rated motor current (see motor name plate). ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 103: Installation Of Misc. Connections

    The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is connected to protection earth on the frequency converter. Use only isolated laptop as PC connection to the USB connector on the VLT HVAC Drive. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 104: Illustration 5.18: Usb Connection

    MCT 10 Set-up Software support Profibus DP-V1 via a Master class 2 connection. It makes it possible to on line read/write parameters in a frequency converter via the Profibus network. This will eliminate the need for an extra communication network. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 105 Open MCT 10 Set-up Software tion in a given application. Both the harmonic distortion of Danfoss frequency converters as Choose “Read from drive” well as non-Danfoss frequency converters Choose “Save as” with different additional harmonic reduction All parameters are now stored in the PC.

  • Page 106: Safety

    Use low impedance cable clamps or EMC cable glands instead. • Avoid using unscreened/unarmoured motor or control cables inside cabinets housing the drive(s), whenever this can be avoided. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 107: Illustration 5.19: Emc-Correct Electrical Installation Of An Ip20 Frequency Converter

    EMC test results quirements are fulfilled. See the paragraph Illustration 5.19: EMC-correct electrical installation of an IP20 frequency converter. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 108 HVAC Drive Design Guide 5.7.2. Use of EMC-Correct Cables Danfoss recommends braided screened/armoured cables to optimise EMC immunity of the control cables and the EMC emission from the motor cables. The ability of a cable to reduce the in- and outgoing radiation of electric noise depends on the transfer impedance (Z ).
  • Page 109 61. This terminal is connected to earth via an internal RC link. Use twisted-pair cables to reduce the differential mode inter- ference between the conductors. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 110: Mains Supply Interference/Harmonics

    If RCD relays are used, you must observe local regulations. Relays must be suitable for protection of 3-phase equipment with a bridge rectifier and for a brief discharge on power-up see section Earth Leakage Current for further information. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 111: Application Examples

    Stop inverse Terminal 27= Stop par. 5-12 [6] Digital Input Latched Par. 5-10 start Par. 5-12 Digital Input Stop in- verse Illustration 6.2: Terminal 37: Available only with Safe Stop Function! ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 112 This disturbs the AMA function. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 113 SLC is designed to act from event send to or generated in the VLT HVAC Drive . The frequency converter will then perform the pre-programmed action. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 114 Set Action 2 in par. 13-52 [2] to [29] Select preset 1 Set Action 3 in par. 13-52 [3] to [11] No Action Set Action 4 in par. 13-52 [4] to ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 115 Set the Smart Logic Control in par. 13-00 to ON. Start / stop command is applied on terminal 18. If stop signal is applied the frequency converter will ramp down and go into free mode. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 116 Fixed operating 2 pumps. Speed Bandwidth is used instead of the Stag- ing bandwidth. Lead Pump Alternation ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 117 • Destage at No-Flow ensures that all fixed speed pumps are stopped individually until the no-flow status disappears. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 118 The wiring diagram shows an example with variable speed pump (lead) and two fixed the built in BASIC cascade controller with one speed pumps, a 4-20 mA transmitter and Sys- tem Safety Interlock. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 119 Destaging (if running) mal stop command) or stays in operation if already running Ramps down Ramps down Auto On Starts and stops according to Staging/Destaging commands via terminals or se- rial bus ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 120 ® 7. RS-485 Installation and Set-up HVAC Drive Design Guide ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 121: Installation And Set-Up

    When connecting a motor to the frequency converter, always use screened motor cable. Cable: Screened twisted pair (STP) Impedance: 120 Ohm Cable length: Max. 1200 m (including drop lines) Max. 500 m station-to-station ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 122: Illustration 7.1: Network Terminal Connection

    Use the terminator dip switch on the main control board of the frequency converter to terminate the RS-485 bus. Terminator Switch Factory Setting The factory setting for the dip switch is OFF. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 123 When crossing is un- avoidable, the RS-485 cable must cross motor and brake re- sistor cables at an angle of 90 degrees. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 124: Fc Protocol Overview

    HVAC Drive Design Guide 7.2. FC Protocol Overview The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss Drives standard field- bus. It defines an access technique according to the master-slave principle for communications via a serial bus.
  • Page 125 7. RS-485 Installation and Set-up Parameter Num- Parameter name Setting 8-30 Protocol 8-31 Address 1 - 126 8-32 Baud Rate 2400 - 115200 8-33 Parity/Stop bits Even parity, 1 stop bit (default) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 126: Fc Protocol Message Framing Structure

    Bit 7 = 0 (address format 1-31 active) Bit 6 is not used Bit 5 = 1: Broadcast, address bits (0-4) are not used Bit 5 = 0: No Broadcast Bit 0-4 = Frequency converter address 1-31 ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 127 The slave returns the address byte unchanged to the master in the response telegram. 7.4.5. Data Control Byte (BCC) The checksum is calculated as an XOR-function. Before the first byte in the telegram is received, the Calculated Checksum is 0. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 128 The text block is used to read or write texts via the data block. 7.4.7. The PKE Field The PKE field contains two sub-fields: Parameter command and response AK, and Parameter number PNU: ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 129 Command cannot be performed text transferred If the command cannot be performed, the slave sends this response: 0111 Command cannot be performed - and issues the following fault report in the parameter value (PWE): ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 130 The index is used together with the parameter number to read/write-access parameters with an Error Code index, e.g. par. 15-30 . The index consists of 2 bytes, a low byte and a high byte. Only the low byte is used as an index. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 131 Description Integer 16 Integer 32 Unsigned 8 Unsigned 16 Unsigned 32 Text string Byte string Time difference Reserved Bit sequence Unsigned means that there is no operational sign in the telegram. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 132 The block of process words is divided into two blocks of 16 bits, which always occur in the defined sequence. PCD 1 PCD 2 Control telegram (master⇒ Control word slave) Reference-value Control telegram (slave ⇒master) Status word Present outp. frequency ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 133: Examples

    These operating instructions assume that the installed controller supports the interfaces in this document and that all the requirements stipulated in the controller, as well as the frequency con- verter, are strictly observed, along with all limitations therein. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 134 This permits a range of control options, including controlling the setpoint of the frequency converter when its internal PID con- troller is used. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 135: Vlt Hvac With Modbus Rtu

    No response is permitted for broadcast messages. A typical message frame is shown below. Start Address Function Data CRC check T1-T2-T3-T4 8 bits 8 bits N x 8 bits 16 bits T1-T2-T3-T4 Typical Modbus RTU Message Structure ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 136 The error-checking field contains a 16-bit binary value implemented as two 8-bit bytes. When this is done, the low-order byte of the field is appended first, followed by the high-order byte. The CRC high-order byte is the last byte sent in the message. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 137 Set up MSB No voltage warn- Voltage warning No reversing Reversing Frequency converter control word Not in current Current limit (FC profile) limit thermal Thermal warning warning Frequency converter status word (FC profile) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 138 Sub-function code Diagnostics Restart communication Return diagnostic register Clear counters and diagnostic register Return bus message count Return bus communication error count Return bus exception error count Return slave message count ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 139: How To Access Parameters

    20 characters. If a read request for a parameter is for more characters than the parameter stores, the response is truncated. If the read request for a parameter is for fewer characters than the parameter stores, the response is space filled. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 140: Examples

    If the returned coil quantity is not a multiple Data (Coils 40-33) of eight, the remaining bits in the final data Data (Coils 48-41) 06 (STW=0607hex) byte will be padded with zeros (toward the Error Check (CRC) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 141 The normal response is an echo of the query, Slave Address returned after the coil state has been forced. Function Force Data HI Force Data LO Quantity of Coils HI 00 Quantity of Coils LO 01 Error Check (CRC) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 142 01 (frequency converter address) Function 0F (write multiple coils) Coil Address HI Coil Address LO 10 (coil address 17) Quantity of Coils HI Quantity of Coils LO 10 (16 coils) Error Check (CRC) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 143 Slave Address Function Byte Count Data HI (Register 40001) Data LO (Register 40001) Data HI (Register 40002) Data LO (Register 40002) Data HI (Register 40003) Data LO (Register 40003) Error Check (CRC) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 144 Response The normal response is an echo of the query, returned after the register contents have been passed. Field Name Example (HEX) Slave Address Function Register Address HI Register Address LO Preset Data HI Preset Data LO Error Check (CRC) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 145 The normal response returns the slave address, function code, starting address, and quantity of registers preset. Field Name Example (HEX) Slave Address Function Starting Address HI Starting Address LO No. of Registers HI No. of registers LO Error Check (CRC) ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 146: Danfoss Fc Control Profile

    ® 7. RS-485 Installation and Set-up HVAC Drive Design Guide 7.11. Danfoss FC Control Profile 7.11.1. Control Word According to FC Profile(Par. 8-10 = FC profile) Bit value = 0 Bit value = 1 Reference value external selection lsb Reference value...
  • Page 147 Thus, you can turn off the control word if you do not want to use it when updating or reading parameters. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 148 Bit 15 = ’0’: No reversing. Bit 15 = ’1’: Reversing. In the default setting, reversing is set to digital in par. 8-54 Reversing Select . Bit 15 causes reversing only when Ser. communication, Logic or or Logic and is selected. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 149 Bit 05 is not used in the status word. Bit 06, No error / triplock: Bit 06 = ’0’: The frequency converter is not in fault mode. Bit 06 = “1”: The frequency converter is tripped and locked. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 150 100%. Bit 15 = ’1’: One of the timers exceeds 100%. All bits in the STW are set to ’0’ if the connection between the Interbus option and the frequency converter is lost, or an internal communication problem has occurred. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 151 2’s complement. The Actual Output frequency (MAV) is scaled in the same way as the bus reference. The reference and MAV are scaled as follows: ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 152 ® 8. Troubleshooting HVAC Drive Design Guide ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 153: Troubleshooting

    After an alarm or trip, the motor carries on coasting, and the alarm and warning flash on the frequency converter. Once the problem has been rectified, only the alarm continues flashing. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 154: Table 8.1: Alarm/Warning Code List

    Option Configuration has Changed Safe Stop Activated Drive Initialised to Default Value Table 8.1: Alarm/Warning code list (X) Dependent on parameter LED indication Warning yellow Alarm flashing red Trip locked yellow and red ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 155: Table 8.2: Description Of Alarm Word, Warning Word And Extended Status Word

    No motor has been connected to the output of WARNING 6 the frequency converter. DC link voltage low The intermediate circuit voltage (DC) is below the undervoltage limit of the control system. The frequency converter is still active. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 156 100%, while giving an alarm. You motor itself. cannot reset the frequency converter until the Turn off the frequency converter and remove counter is below 90%. the earth fault. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 157 Motor phase W missing: Too long motor cable Motor phase W between the frequency con- verter and the motor is missing. Turn off the frequency converter and check motor phase W. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 158 ALARM 56 AMA interrupted by user: ALARM 38 The AMA has been interrupted by the user. Internal fault: Contact your local Danfoss supplier. ALARM 57 AMA timeout: WARNING 47 Try to start the AMA again a number of times, 24 V supply low: until the AMA is carried out.
  • Page 159 Actual combination of control board and pow- er board is illegal. ALARM 80 Drive Initialised to Default Value: Parameter settings are initialised to default setting after a manual (three-finger) reset or via par. 14-22. ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

  • Page 160: Index

    Brake resistors Braking Time Break-away torque Building Management System Cable clamp cable clamps Cable length and cross-section Cable lengths and cross sections Clockwise rotation Closed Loop (PID) Controller Coasting Coasting 7, 147 ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 161 Disposal Instruction Drive Configurator Du/dt filters Earth connection Earth leakage current Earth Leakage Current earthing Earthing of Screened/Armoured Control Cables Efficiency 58, 61 Electrical Installation 90, 95 Electrical Installation - EMC Precautions ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 162 46, 48, 60, 62, 155 KTY sensor LC filter 7, 10, 28, 76 Leakage Current Load Drive Settings Local (Hand On) and Remote (Auto On) Control Mains plug connector Mains supply Mains Supply ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 163 Ordering Numbers: Options and Accessories Ordering Numbers: Sine Wave Filter Modules Output Filters Output performance (U, V, W) Outputs for actuators Parallel Connection of Motors PC Software tools Potentiometer Reference Power Factor ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 164 Set speed limit and ramp time Side-by-side installation Sine-wave filters Smart Logic Control Software versions Start/Stop Status Word Successful AMA Surroundings Switches S201, S202, and S801 Switching frequency System Status and Operation Thermistor Torque characteristics ® MG.11.B2.02 - VLT is a registered Danfoss trademark...
  • Page 165 ® HVAC Drive Design Guide Index Transmitter/sensor inputs Type Code String Unsuccessful AMA USB Connection Use of EMC-Correct Cables Vibration and Shock Voltage level VVCplus ® MG.11.B2.02 - VLT is a registered Danfoss trademark...

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