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Daikin PE-ADDA200 Service And Installation Manual
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Daikin PE-ADDA200 Service And Installation Manual

Daikin PE-ADDA200 Service And Installation Manual

Compressor inverter
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SERVICE AND INSTALLATION MANUAL
Revision History
Rev: 0.4
Rev: 0.3
Rev: 0.2
Rev: 0.1
Rev: 0.0
Compressor Inverter
PE-ADDA200
Date
07/07/2022
18/02/2021
25/11/2020
20/05/2020
16/04/2020

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Summary of Contents for Daikin PE-ADDA200

  • Page 1 SERVICE AND INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Revision History Date Rev: 0.4 07/07/2022 Rev: 0.3 18/02/2021 Rev: 0.2 25/11/2020 Rev: 0.1 20/05/2020 Rev: 0.0 16/04/2020...

  • Page 2: Table Of Contents

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Table of content INTRODUCTION ..............................4 Purpose of the service manual ......................4 Abbreviations ............................4 SAFETY ................................4 General ..............................4 Avoid electrocution..........................5 Residual risks ............................6 GENERAL SPECIFICATIONS ..........................7 Product Identification ..........................
  • Page 3 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.1.2 Inverter supply ..........................31 9.1.3 Start a project ..........................32 9.1.4 Download application file ........................ 34 9.1.5 Project tree ............................35 9.1.6 Connect/disconnect communication ....................36 9.1.7 View instrument ..........................36 9.1.8...

  • Page 4: Introduction

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 1 INTRODUCTION 1.1 Purpose of the service manual This manual provides information on safe installation and start-up of Variable Frequency Drives (VFDs) specific for Daikin Applied Europe Compressors. VFDs are composed of a semi-controlled bridge rectifier, a DC-link, and IGBT power modules. Electronic boards perform power module control and protections.

  • Page 5: Avoid Electrocution

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 2.2 Avoid electrocution Only personnel qualified in accordance with IEC (International Electrotechnical Commission) recommendations may be permitted access to electrical components. It is particularly recommended that all sources of electricity to the unit be shut off before any work is begun. Shut off main power supply at the main circuit breaker or isolator.

  • Page 6: Residual Risks

     PE-ADDA200 product may only be installed in machines designated by the manufacturer Daikin Applied Europe S.p.A. In case of use outside the specifications set out in this manual, the manufacturer's responsibilities Daikin Applied Europe S.p.A. they come to decay.

  • Page 7: General Specifications

    Compressor Inverter PE-ADDA200 3 GENERAL SPECIFICATIONS PE-ADDA200 is a Variable Frequency Drive (VFD) specific for Daikin Applied Europe Series Screw Compressors. The VFD is composed of a semi-controlled bridge rectifier, a DC-link, and IGBT power modules. Electronic boards perform power module control and protections.

  • Page 8: Directives And Standards

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 3.2 Directives and Standards The product is designed according to the following directives.  2014/35/EU Voltage Directive (LVD) https://ec.europa.eu/growth/single market/europeanstandards/harmonised-standards/low-voltage_en  2014/30/UE Electromagnetic Compatibility (EMC) https://ec.europa.eu/growth/single- market/europeanstandards/harmonised-standards/electromagnetic-compatibility_en  DIRECTIVE 2011/65/EU RoHS...

  • Page 9: Individuation Of Parts

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 3.3 Individuation of Parts VFD replaceable parts are shown in the picture below (Fig. 4). Fig. 4 VFD replaceable parts highlighted Tab. 1VFD replaceable parts Dwg Ref Part No. (PE-ADDA200) Description...

  • Page 10: Technical Data

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 4 TECHNICAL DATA 4.1 Specification Tab. 2 Inverter Specification Description PE-ADDA200 Power Supply 380…480Vac±10%; 50/60Hz±5% Mains Unbalance Max 2% of rated supply voltage Line Reactor (external) 59 µH Rated Input Current 420 A...

  • Page 11: Transportation

    The VFD is designed to be used in TN (grounded neutral point) networks. If installing the VFD in other types of grounded systems, contact your Daikin Applied representative for instructions. See Par. 7.2 for more details. OTHER INFORMATIONS (FOR UL STD 60730-1 / CSA STD E60730-1)
  • Page 12 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 These automation inverters are made of two macro components (the electronics and the capacitors) which must be transported separately. Necessary Personal Protection Equipment (PPE) Page 12 of 51 Daikin Applied Europe S.p.A...

  • Page 13: Installation On The Compressor

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 6 INSTALLATION ON THE COMPRESSOR 6.1 Mounting 1. Mount the connection bars to the compressor using the M10x45 screws and the lock washers without tightening them. 2. Fix the inverter output bars with the compressor connection bars using the M8x25 screws+split and flat washers and tighten them at 25 Nm as shown in Fig.

  • Page 14: Capacitor Bank Mounting

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 6.2 Capacitor Bank mounting Fig. 6 Capacitor Bank mounting Connection Screw size Tightening Torque (Nm) DC LINK M6x16 7 ELECTRICAL INSTALLATION Once opened, the inverter has no protection against direct contact with live parts. Disconnect the power supply and wait for at least 20 minutes before opening the inverter enclosure.

  • Page 15: Power Connections

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200  The cable shielding must not be interrupted.  The cables should be kept as short as possible.  Route cables using grounded, metal cable trays or cable ducts. Sections of cable tray or ducts must be connected together with as large areas as possible.

  • Page 16: Short Circuit Protection Devices

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 7.1.3 Short Circuit protection devices Short circuit protection is achieved by means of external fuses or automatic circuit breakers. Semiconductor fuses ensure the power module is not damaged in case of short circuit, however other protection devices such as circuit breakers or general type fuses can be used, provided that the system is designed to limit damage to the inverter only, ensuring safety of personnel and machinery.

  • Page 17: Line Reactor

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Fig. 8 Surge overload current of the rectifier power modules Interrupting Capacity: the interrupting (or breaking) capacity must be greater than the prospective symmetrical short circuit current. This requirement is typically easily met.

  • Page 18: Connections To The Inverter Input Terminals

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 7.1.5 Connections to the inverter input terminals Three large aluminium terminals are available to connect the inverter to the line reactor. These are shown in Fig. 9 (L1, L2, L3). Fig. 9 AC input terminals (L1, L2, L3) and available PE connections At start-up, the inverter detects the phase sequence;...

  • Page 19: Power Cables

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 7.1.6 Power Cables Suitable cables shall be used to supply the inverter. At least two cables per phase must be used (e.g. 2x 180 mm the input terminals can hold up to 4 cables per phase (see § 7.1.5)). Their cross-sectional area shall be chosen according to the rated input current of the inverter (see Tab.
  • Page 20 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Fig. 11 Filters ground connections removal Page 20 of 51 Daikin Applied Europe S.p.A...

  • Page 21: Control Connections (Reg Card)

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 7.3 Control Connections (REG Card) Fig. 12 Signal Connectors Cable connection size: 0.25 – 1.5 mm Cable CN16 – CN17 connection size: 0.25 – 2.5 mm Use 75 °C (Cu) copper cables or better. The cables should be shielded and twisted-pair. Max cable length for control and signal cables for the Control board is 10m.
  • Page 22 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Fig. 13 Control Connections layout Page 22 of 51 Daikin Applied Europe S.p.A...
  • Page 23 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Tab. 5 Control Connection Table Connector Pin Description Electrical Features P1_IN– 0-5Vdc signal Rin = 30kΩ REG-CN1 P1_IN – 5Vdc supply +5V , 10mA (output reference) P1_IN – GND P2_IN – 0-5Vdc signal Rin = 30kΩ...

  • Page 24: Power Connections (Pwr)

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Tx/Rx+ (2) REG-CN14 Tx/Rx- (2) Isolated Serial Line 2 (external termination) - RJ45 GND_ISO Tx/Rx+ (1) REG-CN15 Tx/Rx- (1) Isolated Serial Line 1 (point-point termination) - RJ45 GND_ISO STO1 24V_STO1 (Safe Torque Off)

  • Page 25: Fan Control

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Tab. 6 230Vac solenoid valve connectors Connector Pin Description Electrical Features 230V – N PWR-CN12 230V – L 100-240Vac – 10VA valve Valve SSR output PWR-CN13 Valve SSR output Cable connection size: AWG18 (0.807 mm 2 ) Provide adequate protection for the EV circuit using fuses as in Tab.

  • Page 26: Maintenance

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 8 Maintenance The maintenance of the product includes the interventions (inspection, verification, control, adjustment and replacement) that are necessary following normal use. For a good maintenance:  Use only original spare parts; use tools suitable for the purpose and in good condition.

  • Page 27: Scheduled Maintenance

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 8.1 Scheduled maintenance Scheduled maintenance includes inspections, checks and interventions monitoring:  General conditions of the product;  Power sources (electric);  Product cleaning. The following table lists a series of checks and interventions to be performed at the recommended time intervals.

  • Page 28: Corrective Maintenance

    C45=1. 8.2 Corrective maintenance Any request for corrective maintenance must be sent to the manufacturer Daikin Applied Europe S.p.A., who will decide how to proceed. It is recommended not to intervene independently, if the intervention falls outside what is reported in chapter 7.1.

  • Page 29: Vfd Control

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 VFD CONTROL In standard Modbus control, the VFD will be controlled exclusively via serial communication with the following exceptions:  Start/Stop command is given through a digital hard-wired contact  High Pressure Switch will be wired directly to the STO digital input 9.1 VFDNav...

  • Page 30: Physical Connection

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.1.1 Physical connection To connect the PC with the inverter it is necessary to use the USB to RS485 converter kit (DAE cod.: PE-1KIT0013). Fig. 15 PC connection kit PE-1KIT0013 Fig. 16 RJ45 connector for wiring PE-1KIT0013 to VFD Page 30 of 51 Daikin Applied Europe S.p.A...

  • Page 31: Inverter Supply

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.1.2 Inverter supply There is an alternative way to feed only the regulation card DAE_REG002, providing +5V with USB-C connector: Fig. 17 USB-C connector In this mode the serial connection is available to read the alarm history and if necessary, change some parameters or the drive firmware.

  • Page 32: Start A Project

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.1.3 Start a project Fig. 18 There are three different ways to start a project:  Selecting one of the last projects opened it in the upper part of the window ...
  • Page 33 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Fig. 20 At the end a list of the found devices is shown. Click on the “Add” button to start the project. This is the most common situation but, after scanning is completed, different cases may appear: Fig.

  • Page 34: Download Application File

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.1.4 Download application file To download the application file into the VFD, select the application in the project tree and press the right mouse button to show the available options: select “PLC download” to start the download.

  • Page 35: Project Tree

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.1.5 Project tree The project Tree shows all the folders and groups parameters by meaning. The first subdivision is between core parameters and application parameters. Application parameters are related to current application, instead core parameters are related to the core and for this reason are always the same.

  • Page 36: Connect/Disconnect Communication

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.1.6 Connect/disconnect communication Click on the button in the toolbar to connect/disconnect communication Fig. 26 The connection status is shown in the bottom right 9.1.7 View instrument There are two different ways to show the parameters value in continuity: Toolbar: View/Monitor It is possible to drag and drop as many parameters the user wants in the Monitor window.

  • Page 37: Read/Write Parameters

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.1.8 Read/Write Parameters It is possible to read/write the parameters individually or all together. When a parameter value is shown in red it means that its value hasn’t been refreshed. The value is written in black after it has been updated.

  • Page 38: How To Download Alarm Logs

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 The Firmware upgrade page is opened: Fig. 28 Select the core file (.ldr) and start the download by clicking on the “Download” button. Fig. 29 A scroll bar shows the download progress.
  • Page 39 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200  To load the desired alarm log, press the corresponding “Load trace” button and wait the end of automatic procedure: SoftScope is opened and data related to alarm log are loaded.

  • Page 40: Vfd Protections - Vfdnav Service Software Required

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.2 VFD Protections – VFDNav service software required The VFD includes the following protections:  VFD Current Overload  VFD Over Current with solid state short circuit protection  VFD Heatsink High Temperature ...

  • Page 41: Vfd Heatsink High/Low Temperature - Vfdnav Service Software Required

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 9.4 VFD Heatsink High/Low Temperature – VFDNav service software required VFD heatsink temperature is constantly kept at 40°C by refrigerant cooling. In case of malfunctioning or abnormal operation, temperature may rise or drop to dangerous values. A warning and a successive alarm protect the inverter, according to the following thresholds: Tab.

  • Page 42: Vfd Communication

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 10 VFD COMMUNICATION 10.1 Modbus RTU Configuration Tab. 13 Protocol Modbus – RTU Address User defined. Default is 1. Modbus Rate 19200 kbps Parity Stop Bits All VFD’s come from factory with a default address set to 1. In case a different address has to be set, there are two options to set the VFD Modbus address: 10.2 Modbus Parameters...
  • Page 43 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Number of solenoid cycles D38-D39 0x2017 48215 Motor power 0x2019 48217 Run command 0x201A 48218 Speed reference P230 0x201B 48219 DC Min warning threshold P232 0x201C 48220 DC Max warning threshold...
  • Page 44 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 VFD Warning Word (Bit 0 to 15) Tab. 16 Status DC Bus undervoltage DC Bus overvoltage VFD thermal overload Motor thermal overload VFD overcurrent Radiator too cold VFD current limit VFD torque limit...

  • Page 45: Troubleshooting

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 11 TROUBLESHOOTING Tab. 17 ALARM REMARK DESCRIPTION CORRECTIVE ACTION Contact FACTORY Motor During start a small anisotropy was measured. Try to repeat the A.0.0.H A0.0 Anisotropy too small anisotrophy start. If the motor has to work in limit for a long time, disable this...
  • Page 46 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 ALARM REMARK DESCRIPTION CORRECTIVE ACTION A4.2H A4.2 One slave VFD goes in alarm Try to understand why the slave is in alarm A4.3H A4.3 communication The VFD output current, filtered with...
  • Page 47 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 ALARM DESCRIPTION CORRECTIVE ACTION Check the motor load. Reducing it may prevent the safety Contact FACTORY switch cutting in. The motor electronic overload Motor I2t safety switch has cut in due to Check the thermal current setting, and correct if necessary (P70).
  • Page 48 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 ALARM DESCRIPTION CORRECTIVE ACTION Contact FACTORY A.C.0.H A12.0 C29 different from 1 Software Check and enable connection C29 “VFD software enable” alarm A.C.1.H A12.1 Run whitout RUN without Power Soft start An input phase is missing.

  • Page 49: Communication Problems

    Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 11.1 Communication Problems First of all check that chiller controller settings and communication wirings are correct. With chiller powered off and termination resistors off, the following resistance values should be measured: Tab.
  • Page 50 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Note that the multimeter must have the diode test function and this must be selected for the test: it is important that the polarity be respected during the test, as diodes have a polarity-dependant conductibility.
  • Page 51 Rev. 0.3 SERVICE and INSTALLATION MANUAL Compressor Inverter PE-ADDA200 Fig. 34 While testing the diode in reverse bias, thus reversing the test leads as shown in above example for the W- phse of the inverter (still with the diode test mode selected on the multimeter) the multimeter should indicate OL (open switch).