MAKING MODERN LIVING POSSIBLE

Design Guide
VLT HVAC Drive

Contents

VLT HVAC Drive Design Guide

Contents 1 How to Read this Design Guide

1.1.1 Copyright, Limitation of Liability and Revision Rights 1.1.3 Approvals 1.1.4 Symbols 1.1.5 Abbreviations 1.1.6 Definitions 4 4 5 5 6 7 10 10 11 12 13 13 31 39 43 43 44 45 46 49 49 55 57 57 57 58 58 59 59 64 64 69 80 80 81 86

2 Introduction to VLT HVAC Drive

2.1 Safety 2.2 CE labelling 2.4 Aggressive Environments 2.5 Vibration and shock 2.6 Safe Stop 2.8 Control Structures 2.9 General aspects of EMC 2.10 Galvanic isolation (PELV)
2.10.1 PELV - Protective Extra Low Voltage

2.11 Earth Leakage Current 2.12 Brake Function 2.13 Extreme Running Conditions

3 VLT HVAC Drive Selection

3.1 Options and Accessories
3.1.10 MCB 112 VLT PTC Thermistor Card 3.1.11 Sensor Input Option MCB 114 3.1.11.1 Ordering Code Numbers and Parts Delivered 3.1.11.2 Electrical and Mechanical Specifications 3.1.11.3 Electrical Wiring 3.1.12 Frame Size F Panel Options 3.1.13 Brake Resistors 3.1.14 Remote Mounting Kit for LCP

4 How to Order
4.1 Ordering Form 4.2 Ordering Numbers

5 How to Install
5.1 Mechanical Installation
5.1.2 Mechanical Dimensions 5.1.5 Lifting

MG.11.BA.02 - VLT is a registered Danfoss trademark

Contents

VLT HVAC Drive Design Guide

5.2 Electrical Installation

5.2.2 Electrical Installation and Control Cables 5.2.9 Non UL Compliance Fuses

88 89 94 103 105 109 111 111 115 115 115 116 116 116 116 117 118 119 119 120 120 121 121 122 122 123 124 124 128 129 130 134 134 137 141 141 165 169

5.3 Final Set-Up and Test 5.4 Additional Connections 5.5 Installation of Misc. Connections 5.6 Safety 5.7 EMC-correct Installation

6 Application Examples
6.1.1 Start/Stop 6.1.2 Pulse Start/Stop 6.1.3 Potentiometer Reference 6.1.4 Automatic Motor Adaptation (AMA) 6.1.5 Smart Logic Control 6.1.6 Smart Logic Control Programming 6.1.7 SLC Application Example 6.1.8 BASIC Cascade Controller 6.1.9 Pump Staging with Lead Pump Alternation 6.1.10 System Status and Operation 6.1.11 Fixed Variable Speed Pump Wiring Diagram 6.1.12 Lead Pump Alternation Wiring Diagram 6.1.13 Cascade Controller Wiring Diagram 6.1.14 Start/Stop Conditions

7 RS-485 Installation and Set-up

7.1 RS-485 Installation and Set-up 7.2 FC Protocol Overview 7.3 Network Configuration 7.4 FC Protocol Message Framing Structure 7.5 Examples 7.6 Modbus RTU Overview 7.8 Modbus RTU Message Framing Structure 7.9 How to Access Parameters 7.10 Examples 7.11 Danfoss FC Control Profile

8 General Specifications and Troubleshooting

8.1 Mains Supply Tables 8.2 General Specifications 8.3 Efficiency

MG.11.BA.02 - VLT is a registered Danfoss trademark

Contents

VLT HVAC Drive Design Guide

8.4 Acoustic Noise 8.5 Peak Voltage on Motor 8.6 Special Conditions
8.7.1 Alarm Words 8.7.2 Warning Words 8.7.3 Extended Status Words 8.7.4 Fault Messages

169 170 174 179 180 181 182 188

Index

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Read this Design Gui...

VLT HVAC Drive Design Guide

1 1

1 How to Read this Design Guide

VLT HVAC Drive
Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former or present users of such revisions or changes.

This guide can be used with all VLT HVAC Drive frequency converters with software version 3.5.x. The actual software version number can be read from 15-43 Software Version.
1.1.1 Copyright, Limitation of Liability and Revision Rights
This publication contains information proprietary to Danfoss. By accepting and using this manual the user agrees that the information contained herein will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication with Danfoss equipment over a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries. Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical, hardware or software environment. Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or representation, neither expressed nor implied, with respect to this documentation, including its quality, performance, or fitness for a particular purpose. In no event shall Danfoss be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information contained in this manual, even if advised of the possibility of such damages. In particular, Danfoss is not responsible for any costs, including but not limited to those incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims by third parties.

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Read this Design Gui...

VLT HVAC Drive Design Guide

1.1.2 Available Literature for VLT HVAC Drive

Operating Instructions MG.11.Ax.yy provide the necessary information for getting the frequency converter up and running. Operating Instructions VLT HVAC Drive High Power, MG.11.Fx.yy Design Guide MG.11.Bx.yy entails all technical information about the frequency converter and customer design and applications. Programming Guide MG.11.Cx.yy provides information on how to programme and includes complete parameter descriptions. Mounting Instruction, Analog I/O Option MCB 109, MI.38.Bx.yy Application Note, Temperature Derating Guide, MN.11.Ax.yy PC-based Configuration Tool MCT 10, MG.10.Ax.yy enables the user to configure the frequency converter from a Windows based PC environment. Danfoss VLT Energy Box software at www.danfoss.com/BusinessAreas/DrivesSolutions then choose PC Software Download VLT HVAC Drive Drive Applications, MG.11.Tx.yy Operating Instructions VLT HVAC Drive Profibus, MG.33.Cx.yy Operating Instructions VLT HVAC Drive Device Net, MG.33.Dx.yy Operating Instructions VLT HVAC Drive BACnet, MG.11.Dx.yy Operating Instructions VLT HVAC Drive LonWorks, MG.11.Ex.yy Operating Instructions VLT HVAC Drive Metasys, MG.11.Gx.yy Operating Instructions VLT HVAC Drive FLN, MG.11.Zx.yy Output Filter Design Guide, MG.90.Nx.yy Brake Resistor Design Guide, MG.90.Ox.yy

1.1.3 Approvals

1 1

1.1.4 Symbols
Symbols used in this guide.

NOTE
Indicates something to be noted by the reader.

CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or equipment damage.

WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
* Indicates default setting

x = Revision number yy = Language code Danfoss technical literature is available in print from your local Danfoss Sales Office or online at: www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Read this Design Gui...

VLT HVAC Drive Design Guide

1 1

1.1.5 Abbreviations
Alternating current American wire gauge Ampere/AMP Automatic Motor Adaptation Current limit Degrees Celsius Direct current Drive Dependent Electro Magnetic Compatibility Electronic Thermal Relay frequency converter Gram Hertz Horsepower Kilohertz Local Control Panel Meter Millihenry Inductance Milliampere Millisecond Minute Motion Control Tool Nanofarad Newton Meters Nominal motor current Nominal motor frequency Nominal motor power Nominal motor voltage Parameter Protective Extra Low Voltage Printed Circuit Board Rated Inverter Output Current Revolutions Per Minute Regenerative terminals Second Synchronous Motor Speed Torque limit Volts The maximum output current The rated output current supplied by the frequency converter AC AWG A AMA ILIM C DC D-TYPE EMC ETR FC g Hz hp kHz LCP m mH mA ms min MCT nF Nm IM,N fM,N PM,N UM,N par. PELV PCB IINV RPM Regen sec. ns TLIM V IVLT,MAX IVLT,N

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Read this Design Gui...

VLT HVAC Drive Design Guide

1.1.6 Definitions
Drive: IVLT,MAX The maximum output current. IVLT,N The rated output current supplied by the frequency converter. UVLT, MAX The maximum output voltage. Input:
Control command Start and stop the connected motor with the LCP or the digital inputs. Functions are divided into two groups. Functions in group 1 have higher priority than functions in group 2. Group Reset, Coasting stop, Reset 1 and Coasting stop, Quickstop, DC braking, Stop and the "Off" key. Group Start, Pulse start, Reversing, 2 Start reversing, Jog and Freeze output

PM,N The rated motor power (nameplate data). TM,N The rated torque (motor). UM The instantaneous motor voltage. UM,N The rated motor voltage (nameplate data). Break-away torque
Torque Pull-out 175ZA078.10

1 1

Motor: fJOG The motor frequency when the jog function is activated (via digital terminals). fM The motor frequency. fMAX The maximum motor frequency. fMIN The minimum motor frequency. fM,N The rated motor frequency (nameplate data). IM The motor current. IM,N The rated motor current (nameplate data). nM,N The rated motor speed (nameplate data).
rpm

VLT The efficiency of the frequency converter is defined as the ratio between the power output and the power input. Start-disable command A stop command belonging to the group 1 control commands - see this group. Stop command See Control commands. References: Analog Reference A signal transmitted to the analog inputs 53 or 54, can be voltage or current. Bus Reference A signal transmitted to the serial communication port (FC port).

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Read this Design Gui...

VLT HVAC Drive Design Guide

1 1

Preset Reference A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references via the digital terminals. Pulse Reference A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33). RefMAX Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA) and the resulting reference. The maximum reference value set in 3-03 Maximum Reference. RefMIN Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4mA) and the resulting reference. The minimum reference value set in 3-02 Minimum Reference Miscellaneous: Analog Inputs The analog inputs are used for controlling various functions of the frequency converter. There are two types of analog inputs: Current input, 0-20 mA and 4-20 mA Voltage input, 0-10 V DC. Analog Outputs The analog outputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal. Automatic Motor Adaptation, AMA AMA algorithm determines the electrical parameters for the connected motor at standstill. Brake Resistor The brake resistor is a module capable of absorbing the brake power generated in regenerative braking. This regenerative braking power increases the intermediate circuit voltage and a brake chopper ensures that the power is transmitted to the brake resistor. CT Characteristics Constant torque characteristics used for screw and scroll refrigeration compressors. Digital Inputs The digital inputs can be used for controlling various functions of the frequency converter.

Digital Outputs The frequency converter features two Solid State outputs that can supply a 24 V DC (max. 40 mA) signal. DSP Digital Signal Processor. Relay Outputs: The frequency converter features two programmable Relay Outputs. ETR Electronic Thermal Relay is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature. GLCP: Graphical Local Control Panel (LCP102) Initialising If initialising is carried out (14-22 Operation Mode), the programmable parameters of the frequency converter return to their default settings. Intermittent Duty Cycle 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 noneperiodic duty. LCP The Local Control Panel (LCP)keypad makes up a complete interface for control and programming of the frequency converter. The control panelkeypad is detachable and can be installed up to 3 metres from the frequency converter, i.e. in a front panel by means of the installation kit option. The Local Control Panel is available in two versions: Numerical LCP101 (NLCP) Graphical LCP102 (GLCP)

lsb Least significant bit. MCM Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM 0.5067 mm2. msb Most significant bit. NLCP Numerical Local Control Panel LCP101

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Read this Design Gui...

VLT HVAC Drive Design Guide

On-line/Off-line Parameters Changes to on-line parameters are activated immediately after the data value is changed. Changes to off-line parameters are not activated until you enter [OK] on the LCP. PID Controller The PID controller maintains the desired speed, pressure, temperature, etc. by adjusting the output frequency to match the varying load. RCD Residual Current Device. Set-up You can save parameter settings in four Set-ups. Change between the four parameter Set-ups and edit one Set-up, while another Set-up is active. SFAVM Switching pattern called Stator Flux oriented Asynchronous V ector M odulation (14-00 Switching Pattern). Slip Compensation The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor speed almost constant. Smart Logic Control (SLC) 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). Trip A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency converter is protecting the motor, process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically. Trip may not be used for personal safety. Trip Locked A state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention, e.g. if the frequency converter is subject to a short circuit on the output. A locked trip can only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the frequency converter. Restart is

prevented until the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically. Trip locked may not be used for personal safety. VT Characteristics Variable torque characteristics used for pumps and fans. VVCplus If compared with standard voltage/frequency ratio control, Voltage Vector Control (VVCplus) improves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque. 60 AVM Switching pattern called 60Asynchronous Vector Modulation (See 14-00 Switching Pattern).

1 1

1.1.7 Power Factor

The power factor is the relation between I1 and IRMS.
Power factor =
3 U I 1 COS 3 U I RMS

The power factor for 3-phase control:

=

I 1 cos 1 I RMS

I1 since cos 1 = 1 I RMS

The power factor indicates to which extent the frequency converter imposes a load on the mains supply. The lower the power factor, the higher the IRMS for the same kW performance.
2 2 2 2 I RMS = I 1 + I 5 + I 7 + . . + I n

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 minimizes the imposed load on the mains supply.

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2 Introduction to VLT HVAC Drive

Installation at high altitudes

2 2
2.1 Safety 2.1.1 Safety Note

CAUTION

WARNING
The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor, frequency converter or fieldbus may cause death, serious personal injury or damage to the equipment. Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with. Safety Regulations 1. The frequency converter must be disconnected from mains if repair work is to be carried out. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs. 2. The [STOP/RESET] key on the LCP of the frequency converter does not disconnect the equipment from mains and is thus not to be used as a safety switch. Correct protective earthing of the equipment must be established, the user must be protected against supply voltage, and the motor must be protected against overload in accordance with applicable national and local regulations. The earth leakage currents are higher than 3.5 mA. Protection against motor overload is set by 1-90 Motor Thermal Protection. If this function is desired, set 1-90 Motor Thermal Protection to data value [ETR trip] (default value) or data value [ETR warning]. Note: The function is initialized at 1.16 x rated motor current and rated motor frequency. For the North American market: The ETR functions provide class 20 motor overload protection in accordance with NEC. Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs. Please note that the frequency converter has more voltage inputs than L1, L2 and L3, when load sharing (linking of DC intermediate circuit) and external 24 V DC have been installed. Check that all voltage inputs have been disconnected and that the necessary time has passed before commencing repair work.

380 - 500 V, enclosure A, B and C: At altitudes above 2 km, please contact Danfoss regarding PELV. 380 - 500 V, enclosure D, E and F: At altitudes above 3 km, please contact Danfoss regarding PELV. 525 - 690 V: At altitudes above 2 km, please contact Danfoss regarding PELV.

WARNING
Warning against Unintended Start 1. The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop, while the frequency converter is connected to mains. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not sufficient. While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] must always be activated; following which data can be modified. A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a temporary overload or a fault in the supply mains or the motor connection ceases.

2.

3.

3.

4. 5.

WARNING
Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains. Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back up. Refer to the Operating Instructions for further safety guidelines.

6.

WARNING
The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard, disconnect the frequency converter from the mains before carrying out maintenance. Wait at least as follows before doing service on the frequency converter:

7.

10

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

Voltage (V) 200 240 380 480 525 600 525 690

Min. Waiting Time (Minutes) 4 1.1 - 3.7 kW 1.1 - 7.5 kW 1.1 - 7.5 kW 15 5.5 - 45 kW 11 - 90 kW 11 - 90 kW 11 - 90 kW 45 - 400 kW 450 1400 kW 110 - 250 kW 315 1000 kW 20 30 40

The EMC directive came into effect January 1, 1996. Danfoss CE-labels in accordance with the directive and issues a declaration of conformity upon request. To carry out EMCcorrect installation, see the instructions in this Design Guide. In addition, we specify which standards our products comply with. We offer the filters presented in the specifications and provide other types of assistance to ensure the optimum EMC result. The frequency converter is most often used by professionals of the trade as a complex component forming part of a larger appliance, system or installation. It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer.

2 2

Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

2.1.2 Disposal Instruction

Equipment containing electrical components may not be disposed of together with domestic waste. It must be separately collected with electrical and electronic waste according to local and currently valid legislation.

2.2.2 What Is Covered

The EU "Guidelines on the Application of Council Directive 89/336/EEC" outline three typical situations of using a frequency converter. See below for EMC coverage and CE labelling. 1. The frequency converter is sold directly to the endconsumer. The frequency converter is for example sold to a DIY market. The end-consumer is a layman. He installs the frequency converter himself for use with a hobby machine, a kitchen appliance, etc. For such applications, the frequency converter must be CE labelled in accordance with the EMC directive. The frequency converter is sold for installation in a plant. The plant is built up by professionals of the trade. It could be a production plant or a heating/ ventilation plant designed and installed by professionals of the trade. Neither the frequency converter nor the finished plant has to be CE labelled under the EMC directive. However, the unit must comply with the basic EMC requirements of the directive. This is ensured by using components, appliances, and systems that are CE labelled under the EMC directive. The frequency converter is sold as part of a complete system. The system is being marketed as complete and could e.g. be an air-conditioning system. The complete system must be CE labelled in accordance with the EMC directive. The manufacturer can ensure CE labelling under the EMC directive either by using CE labelled components or by testing the EMC of the system. If he chooses to use only CE labelled components, he does not have to test the entire system.

2.2 CE labelling 2.2.1 CE Conformity and Labelling

What is CE Conformity and Labelling? The purpose of CE labelling is to avoid technical trade obstacles within EFTA and the EU. The EU has introduced the CE label as a simple way of showing whether a product complies with the relevant EU directives. The CE label says nothing about the specifications or quality of the product. Frequency converters are regulated by three EU directives: The machinery directive (2006/42/EC) Frequency converters with integrated safety function are now falling under the Machinery Directive. Danfoss CE-labels in accordance with the directive and issues a declaration of conformity upon request. Frequency converters without safety function do not fall under the machinery directive. However, if a frequency converter is supplied for use in a machine, we provide information on safety aspects relating to the frequency converter. The low-voltage directive (2006/95/EC) Frequency converters must be CE labelled in accordance with the low-voltage directive of January 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. The EMC directive (2004/108/EC) EMC is short for electromagnetic compatibility. The presence of electromagnetic compatibility means that the mutual interference between different components/appliances does not affect the way the appliances work.

2.

3.

MG.11.BA.02 - VLT is a registered Danfoss trademark

11

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.2.3 Danfoss Frequency Converter and CE Labelling

CE labelling is a positive feature when used for its original purpose, i.e. to facilitate trade within the EU and EFTA. However, CE labelling may cover many different specifications. Thus, you have to check what a given CE label specifically covers. The covered specifications can be very different and a CE label may therefore give the installer a false feeling of security when using a frequency converter as a component in a system or an appliance. Danfoss CE labels the frequency converters in accordance with the low-voltage directive. This means that if the frequency converter is installed correctly, we guarantee compliance with the low-voltage directive. Danfoss issues a declaration of conformity that confirms our CE labelling in accordance with the low-voltage directive. The CE label also applies to the EMC directive provided that the instructions for EMC-correct installation and filtering are followed. On this basis, a declaration of conformity in accordance with the EMC directive is issued. The Design Guide offers detailed instructions for installation to ensure EMC-correct installation. Furthermore, Danfoss specifies which our different products comply with. Danfoss provides other types of assistance that can help you obtain the best EMC result.

2 2

2.4 Aggressive Environments

A frequency converter contains a large number of mechanical and electronic components. All are to some extent vulnerable to environmental effects.

CAUTION
The frequency converter should not be installed in environments with airborne liquids, particles, or gases capable of affecting and damaging the electronic components. Failure to take the necessary protective measures increases the risk of stoppages, thus reducing the life of the frequency converter. Liquids can be carried through the air and condense in the frequency converter and may cause corrosion of components and metal parts. Steam, oil, and salt water may cause corrosion of components and metal parts. In such environments, use equipment with enclosure rating IP 54/55. As an extra protection, coated printed circuit boards can be ordered as an option. Airborne Particles such as dust may cause mechanical, electrical, or thermal failure in the frequency converter. A typical indicator of excessive levels of airborne particles is dust particles around the frequency converter fan. In very dusty environments, use equipment with enclosure rating IP 54/55 or a cabinet for IP 00/IP 20/TYPE 1 equipment. In environments with high temperatures and humidity, corrosive gases such as sulphur, nitrogen, and chlorine compounds will cause chemical processes on the frequency converter components. Such chemical reactions will rapidly affect and damage the electronic components. In such environments, mount the equipment in a cabinet with fresh air ventilation, keeping aggressive gases away from the frequency converter. An extra protection in such areas is a coating of the printed circuit boards, which can be ordered as an option.

2.2.4 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. It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer. As an aid to the installer, Danfoss has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for Power Drive systems are complied with, provided that the EMC-correct instructions for installation are followed, see the section EMC Immunity.

NOTE
Mounting frequency converters in aggressive environments increases the risk of stoppages and considerably reduces the life of the converter. Before installing the frequency converter, check the ambient air for liquids, particles, and gases. This is done by observing existing installations in this environment. Typical indicators of harmful airborne liquids are water or oil on metal parts, or corrosion of metal parts.

2.3 Air humidity

The frequency converter has been designed to meet the IEC/ EN 60068-2-3 standard, EN 50178 pkt. 9.4.2.2 at 50C.

12

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

Excessive dust particle levels are often found on installation cabinets and existing electrical installations. One indicator of aggressive airborne gases is blackening of copper rails and cable ends on existing installations. D and E enclosures have a stainless steel back-channel option to provide additional protection in aggressive environments. Proper ventilation is still required for the internal components of the drive. Contact Danfoss for additional information.

It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop. Prior to integration and use of Safe Stop in an installation, a thorough risk analysis on the installation must be carried out in order to determine whether the Safe Stop functionality and safety category are appropriate and sufficient.

2 2

WARNING
In order to install and use the Safe Stop function in accordance with the requirements of Safety Category 3 in EN 954-1, the related information and instructions of the relevant Design Guide must be followed! The information and instructions of the Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality!

2.5 Vibration and shock

The frequency converter has been tested according to the procedure based on the shown standards: 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

2.6 Safe Stop 2.6.1 Electrical terminals

The frequency converter can perform the safety function Safe Torque Off (As defined by draft CD IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).

MG.11.BA.02 - VLT is a registered Danfoss trademark

13

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2 2

3 Phase power input

91 (L1) 92 (L2) 93 (L3) 95 PE 88 (-) 89 (+) 50 (+10 V OUT) S201 53 (A IN) 1 2 ON S202 1 2 ON 54 (A IN) ON=0-20mA OFF=0-10V Switch Mode Power Supply 24Vdc 15mA 200mA + + -

(U) 96 (V) 97 (W) 98 (PE) 99

Motor

DC bus

(R+) 82 (R-) 81 relay1

Brake resistor

+10Vdc 0-10Vdc 0/4-20 mA 0-10Vdc 0/4-20 mA

03 02 01 240Vac, 2A

55 (COM A IN) 12 (+24V OUT) 13 (+24V OUT) 18 (D IN) 19 (D IN) 20 (COM D IN) 27 (D IN/OUT) 24V 0V 29 (D IN/OUT) 24V 0V 32 (D IN) 33 (D IN) * 37 (D IN) 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP) S801 RS-485 Interface 24V (NPN) 0V (PNP) S801 1 2 ON P 5-00 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP) relay2

06 05 04

240Vac, 2A 400Vac, 2A

(COM A OUT) 39 (A OUT) 42

Analog Output 0/4-20 mA

ON=Terminated OFF=Open

5V

0V (P RS-485) 68 (N RS-485) 69 RS-485

(COM RS-485) 61 (PNP) = Source (NPN) = Sink

Illustration 2.1 Diagram showing all electrical terminals. (Terminal 37 present for units with Safe Stop Function only.)

14

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA544.11

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2 2

MG.11.BA.02 - VLT is a registered Danfoss trademark

15

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2 2

To carry out an installation of a Category 0 Stop (EN60204) in conformity with Safety Category 3 (EN954-1), follow these instructions: 1. The bridge (jumper) between Terminal 37 and 24V DC must be removed. Cutting or breaking the jumper is not sufficient. Remove it entirely to avoid short-circuiting. See jumper on Illustration 2.2. 2. Connect terminal 37 to 24V DC by a short-circuit protected cable. The 24V DC voltage supply must be interruptible by an EN954-1 Category 3 circuit interrupt device. If the interrupt device and the frequency converter are placed in the same installation panel, you can use an unscreened cable instead of a screened one.

12

37

Illustration 2.2 Bridge jumper between terminal 37 and 24 VDC

Illustration 2.3 shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1). The circuit interrupt is caused by an opening door contact. The illustration also shows how to connect a non-safety related hardware coast.

16

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BT314.10

2.6.2 Safe Stop Installation

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

6 phase Coast

Mains

130BB566.10

Door contact

2 2

Safety device Cat.3 (Circuit interrupt device, possibly with release input) 12 37 Safe channel Recti er Control board Frequency Converter

R1

R2

Short-circuit protected cable (if not inside installation cabinet)

5Vdc

Inverter

Illustration 2.3 Essential aspects of an installation to achieve a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1).

2.7 Advantages
120
A 100 SYSTEM CURVE 130BA780.10 180

2.7.1 Why use a Frequency Converter for Controlling Fans and Pumps?
A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further information see the text and figure The Laws of Proportionality.
PRESSURE%

80 60 40 20 B FAN CURVE

2.7.2 The Clear Advantage - Energy Savings

The very clear advantage of using a frequency converter for controlling the speed of fans or pumps lies in the electricity savings. When comparing with alternative control systems and technologies, a frequency converter is the optimum energy control system for controlling fan and pump systems.

20

40

60

80 100 120 VOLUME%

140

160

Illustration 2.4 The graph is showing fan curves (A, B and C) for reduced fan volumes.

MG.11.BA.02 - VLT is a registered Danfoss trademark

17

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

130BA781.10

120 A 100 80 PRESSURE % 60 40 C 20 B FAN CURVE SYSTEM CURVE

100% 80%

2 2

50%

Flow ~n Pressure ~n2

25%

20

40

60

80 100 Voume %

120

140

160

180
12,5%

Power ~n3

50%

80% 100%

120 100 INPUT POWER % 80 60 40 20 ENERGY CONSUMED 20 40 60 80 100 Voume % 120 140 160 180
Q1 n1 = Q2 n2 H1 n1 2 Pressure : = H2 n2 P1 n1 3 Power : = P2 n2 Flow :

( ) ( )

Illustration 2.5 When using a frequency converter to reduce fan capacity to 60% - more than 50% energy savings may be obtained in typical applications.

2.7.3 Example of Energy Savings

As can be seen from the figure (the laws of proportionality), the flow is controlled by changing the RPM. By reducing the speed only 20% from the rated speed, the flow is also reduced by 20%. This is because the flow is directly proportional to the RPM. The consumption of electricity, however, is reduced by 50%. If the system in question only needs to be able to supply a flow that corresponds to 100% a few days in a year, while the average is below 80% of the rated flow for the remainder of the year, the amount of energy saved is even more than 50%.
The laws of proportionality Illustration 2.6 describes the dependence of flow, pressure and power consumption on RPM. Q = Flow Q1 = Rated flow Q2 = Reduced flow H = Pressure H1 = Rated pressure H2 = Reduced pressure P = Power P1 = Rated power P2 = Reduced power n = Speed regulation n1 = Rated speed n2 = Reduced speed

18

MG.11.BA.02 - VLT is a registered Danfoss trademark

175HA208.10 n

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.7.4 Comparison of Energy Savings

The Danfoss frequency converter solution offers major savings compared with traditional energy saving solutions. This is because the frequency converter is able to control fan speed according to thermal load on the system and the fact that the frequency converter has a build-in facility that enables the frequency converter to function as a Building Management System, BMS. The graph (Illustration 2.7) shows typical energy savings obtainable with 3 well-known solutions when fan volume is reduced to i.e. 60%. As the graph shows, more than 50% energy savings can be achieved in typical applications.
130BA782.10

2 2

Discharge damper

Less energy savings

Maximum energy savings IGV

Costlier installation

Illustration 2.6 The Three Common Energy Saving Systems.

100

Discharge Damper Solution

80

IGV Solution VLT Solution

Input power %

Energy consumed

60

40

Energy consumed

20

60

60

Energy consumed

60

Volume %

Illustration 2.7 Discharge dampers reduce power consumption somewhat. Inlet Guide Vans offer a 40% reduction but are expensive to install. The Danfoss frequency converter solution reduces energy consumption with more than 50% and is easy to install.

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA779.11

19

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.7.5 Example with Varying Flow over 1 Year

The example below is calculated on the basis of pump characteristics obtained from a pump datasheet. The result obtained shows energy savings in excess of 50% at the given flow distribution over a year. The pay back period depends on the price per kWh and price of frequency converter. In this example it is less than a year when compared with valves and constant speed.
Energy savings Pshaft=Pshaft output Flow distribution over 1 year m3/h Distribution % Valve regulation Consumpti on kWh 18.615 50.589 61.320 55.188 49.056 40.296 275.064 Frequency converter control Power A1 - C1 42,5 29,0 18,5 11,5 6,5 3,5 Consumptio n kWh 18.615 38.106 32.412 20.148 11.388 6.132 26.801

2 2

Hours Power A1 - B1

350 300 250 200 150 100

5 15 20 20 20 20

438 1314 1752 1752 1752 1752

42,5 38,5 35,0 31,5 28,0 23,0

100 8760

2.7.6 Better Control

If a frequency converter is used for controlling the flow or pressure of a system, improved control is obtained. A frequency converter can vary the speed of the fan or pump, thereby obtaining variable control of flow and pressure. Furthermore, a frequency converter can quickly adapt the speed of the fan or pump to new flow or pressure conditions in the system. Simple control of process (Flow, Level or Pressure) utilizing the built in PID control.

(mwg) 60 50 40 30

A 20 10 C 750rpm 0 100 200 300 1050rpm 1350rpm

1650rpm

175HA209.11

Hs

2.7.7 Cos Compensation

400

(m3 /h)

(kW) 60 50

Pshaft

A1
40 30 20 10

Generally speaking, the VLT HVAC Drive has a cos of 1 and provides power factor correction for the cos of the motor, which means that there is no need to make allowance for the cos of the motor when sizing the power factor correction unit.

1650rpm

B1
1050rpm 750rpm 200

1350rpm

2.7.8 Star/Delta Starter or Soft-starter not Required

When larger motors are started, it is necessary in many countries to use equipment that limits the start-up current. In more traditional systems, a star/delta starter or soft-starter is widely used. Such motor starters are not required if a frequency converter is used. As illustrated in the figure below, a frequency converter does not consume more than rated current.

C1
0 100

300

400 (m3 /h)

20

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

700 600 4 % Full load current 500 400 300 200 100 0 3

175HA227.10

800

2.7.11 With a Frequency Converter

Supply air Sensors PT

Return Flow Return

+ Flow

Fan M

V.A.V outlets

x3

2 1 0 12,5 25 37,5 50Hz Full load & speed

M VLT

Pump x3

M VLT

Pump x3 VLT Pressure control 0-10V or 0/4-20mA

Duct
Local D.D.C. control

Main B.M.S

Control temperature 0-10V or Mains 0/4-20mA Mains

Control temperature 0-10V or 0/4-20mA Mains

1 = VLT HVAC Drive 2 = Star/delta starter 3 = Soft-starter 4 = Start directly on mains

Illustration 2.8 The illustration shows a fan system controlled by frequency converters.

2.7.9 Using a Frequency Converter Saves Money

The example on the following page shows that a lot of equipment is not required when a frequency converter is used. It is possible to calculate the cost of installing the two different systems. In the example on the following page, the two systems can be established at roughly the same price.

2.7.10 Without a Frequency Converter

The figure shows a fan system made in the traditional way. D.D.C. = Direct Digital Control E.M.S. Energy = Management system

V.A.V. Sensor P
Cooling section

= =

Variable Air Volume Pressure

Heating section

Sensor T = Temperature
Inlet guide vane Fan section Supply air V.A.V Sensors PT outlets 175HA205.12

Fan M

Return

Flow 3-Port valve Bypass

Return Control Valve position

Flow 3-Port valve Bypass

Control Valve position Mechanical linkage and vanes x6

M x6 Starter

Pump

M x6 Starter

Pump

IGV Motor or actuator

Duct

Control Fuses LV supply P.F.C

Starter

Local D.D.C. control

Main B.M.S

Fuses LV supply P.F.C Mains Mains

Power Factor Correction Mains

Pressure control signal 0/10V

Temperature control signal 0/10V

MG.11.BA.02 - VLT is a registered Danfoss trademark

175HA206.11

Cooling section

Heating section

Fan section

2 2

21

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.7.12 Application Examples

The next few pages give typical examples of applications within HVAC. If you would like to receive further information about a given application, please ask your Danfoss supplier for an information sheet that gives a full description of the application. Variable Air Volume Ask for The Drive to...Improving Variable Air Volume Ventilation Systems MN.60.A1.02 Constant Air Volume Ask for The Drive to...Improving Constant Air Volume Ventilation Systems MN.60.B1.02 Cooling Tower Fan Ask for The Drive to...Improving fan control on cooling towers MN.60.C1.02 Condenser pumps Ask for The Drive to...Improving condenser water pumping systems MN.60.F1.02 Primary pumps Ask for The Drive to...Improve your primary pumping in primay/secondary pumping systems MN.60.D1.02 Secondary pumps Ask for The Drive to...Improve your secondary pumping in primay/secondary pumping systems MN.60.E1.02

2 2

22

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.7.13 Variable Air Volume

VAV or Variable Air Volume systems, are used to control both the ventilation and temperature to satisfy the requirements of a building. Central VAV systems are considered to be the most energy efficient method to air condition buildings. By designing central systems instead of distributed systems, a greater efficiency can be obtained. The efficiency comes from utilizing larger fans and larger chillers which have much higher efficiencies than small motors and distributed air-cooled chillers. Savings are also seen from the decreased maintenance requirements.

2 2

2.7.14 The VLT Solution

While dampers and IGVs work to maintain a constant pressure in the ductwork, a frequency converter solution saves much more energy and reduces the complexity of the installation. Instead of creating an artificial pressure drop or causing a decrease in fan efficiency, the frequency converter decreases the speed of the fan to provide the flow and pressure required by the system. Centrifugal devices such as fans behave according to the centrifugal laws. This means the fans decrease the pressure and flow they produce as their speed is reduced. Their power consumption is thereby significantly reduced. The return fan is frequently controlled to maintain a fixed difference in airflow between the supply and return. The advanced PID controller of the HVAC frequency converter can be used to eliminate the need for additional controllers.
130BB455.10 T

Cooling coil

Heating coil Filter

Frequency converter

Pressure signal VAV boxes Supply fan

D1

Flow D2 Frequency converter

Pressure transmitter

Return fan 3

Flow

D3

MG.11.BA.02 - VLT is a registered Danfoss trademark

23

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.7.15 Constant Air Volume

CAV, or Constant Air Volume systems are central ventilation systems usually used to supply large common zones with the minimum amounts of fresh tempered air. They preceded VAV systems and therefore are found in older multi-zoned commercial buildings as well. These systems preheat amounts of fresh air utilizing Air Handling Units (AHUs) with a heating coil, and many are also used to air condition buildings and have a cooling coil. Fan coil units are frequently used to assist in the heating and cooling requirements in the individual zones.

2 2

2.7.16 The VLT Solution

With a frequency converter, significant energy savings can be obtained while maintaining decent control of the building. Temperature sensors or CO2 sensors can be used as feedback signals to frequency converters. Whether controlling temperature, air quality, or both, a CAV system can be controlled to operate based on actual building conditions. As the number of people in the controlled area decreases, the need for fresh air decreases. The CO2 sensor detects lower levels and decreases the supply fans speed. The return fan modulates to maintain a static pressure setpoint or fixed difference between the supply and return air flows. With temperature control, especially used in air conditioning systems, as the outside temperature varies as well as the number of people in the controlled zone changes, different cooling requirements exist. As the temperature decreases below the setpoint, the supply fan can decrease its speed. The return fan modulates to maintain a static pressure set-point. By decreasing the air flow, energy used to heat or cool the fresh air is also reduced, adding further savings. Several features of the Danfoss HVAC dedicated frequency converter can be utilized to improve the performance of your 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. The frequency converter also includes a 3-zone, 3 setpoint PID controller which allows monitoring both temperature and air quality. Even if the temperature requirement is satisfied, the frequency converter will maintain enough supply air to satisfy the air quality sensor. The controller is capable of monitoring and comparing two feedback signals to control the return fan by maintaining a fixed differential air flow between the supply and return ducts as well.
130BB451.10 Temperature transmitter Pressure transmitter

Cooling coil

Heating coil Filter

Frequency converter

Temperature signal

Supply fan D1

D2 Frequency converter

Pressure signal

Return fan

D3

24

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.7.17 Cooling Tower Fan

Cooling Tower Fans are used to cool condenser water in water cooled chiller systems. Water cooled chillers provide the most efficient means of creating chilled water. They are as much as 20% more efficient than air cooled chillers. Depending on climate, cooling towers are often the most energy efficient method of cooling the condenser water from chillers. They cool the condenser water by evaporation. The condenser water is sprayed into the cooling tower onto the cooling towers fill to increase its surface area. The tower fan blows air through the fill and sprayed water to aid in the evaporation. Evaporation removes energy from the water dropping its temperature. The cooled water collects in the cooling towers basin where it is pumped back into the chillers condenser and the cycle is repeated.

2 2

2.7.18 The VLT Solution

With a frequency converter, the cooling towers fans can be controlled to the required speed to maintain the condenser water temperature. The frequency converters can also be used to turn the fan on and off as needed. Several features of the Danfoss HVAC dedicated frequency converter, the HVAC frequency converter 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. Also, when utilizing a gear-box to frequency control the tower fan, a minimum speed of 40-50% may be required. The customer programmable minimum frequency setting is available to maintain this minimum frequency even as the feedback or speed reference calls for lower speeds. Also as a standard feature, you can program the frequency converter to enter a sleep mode and stop the fan until a higher speed is required. Additionally, some cooling tower fans have undesireable frequencies that may cause vibrations. These frequencies can easily be avoided by programming the bypass frequency ranges in the frequency converter.

MG.11.BA.02 - VLT is a registered Danfoss trademark

25

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2 2

Frequency converter

Water Inlet

Temperature Sensor

BASIN

Water Outlet

Conderser Water pump CHILLER

Supply

26

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BB453.10

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.7.19 Condenser Pumps

Condenser Water pumps are primarily used to circulate water through the condenser section of water cooled chillers and their associated cooling tower. The condenser water absorbs the heat from the chiller's condenser section and releases it into the atmosphere in the cooling tower. These systems are used to provide the most efficient means of creating chilled water, they are as much as 20% more efficient than air cooled chillers.

2 2

2.7.20 The VLT Solution

Frequency converters can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump impeller. Using a frequency converter instead of a throttling valve simply saves the energy that would have been absorbed by the valve. 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.
130BB452.10 Throttling valve CHILLER Condenser Water pump Supply

Frequency converter Water Inlet

Flow or pressure sensor BASIN Water Outlet

MG.11.BA.02 - VLT is a registered Danfoss trademark

27

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.7.21 Primary Pumps

Primary pumps in a primary/secondary pumping system can be used to maintain a constant flow through devices that encounter operation or control difficulties when exposed to variable flow. The primary/secondary pumping technique decouples the primary production loop from the secondary distribution loop. This allows devices such as chillers to obtain constant design flow and operate properly while allowing the rest of the system to vary in flow. As the evaporator flow rate decreases in a chiller, the chilled water begins to become over-chilled. As this happens, the chiller attempts to decrease its cooling capacity. If the flow rate drops far enough, or too quickly, the chiller cannot shed its load sufficiently and the chillers low evaporator temperature safety trips the chiller requiring a manual reset. This situation is common in large installations especially when two or more chillers in parallel are installed if primary/ secondary pumping is not utilized.

2 2

2.7.22 The VLT Solution

Depending on the size of the system and the size of the primary loop, the energy consumption of the primary loop can become substantial. A frequency converter can be added to the primary system, to replace the throttling valve and/or trimming of the impellers, leading to reduced operating expenses. Two control methods are common: The first method uses a flow meter. Because the desired flow rate is known and is constant, a flow meter installed at the discharge of each chiller, can be used to control the pump directly. Using the built-in PID controller, the frequency converter will always maintain the appropriate flow rate, even compensating for the changing resistance in the primary piping loop as chillers and their pumps are staged on and off. The other method is local speed determination. The operator simply decreases the output frequency until the design flow rate is achieved. Using a frequency converter to decrease the pump speed is very similar to trimming the pump impeller, except it doesnt require any labor and the pump efficiency remains higher. The balancing contractor simply decreases the speed of the pump until the proper flow rate is achieved and leaves the speed fixed. The pump will operate at this speed any time the chiller is staged on. Because the primary loop doesnt have control valves or other devices that can cause the system curve to change and the variance due to staging pumps and chillers on and off is usually small, this fixed speed will remain appropriate. In the event the flow rate needs to be increased later in the systems life, the frequency converter can simply increase the pump speed instead of requiring a new pump impeller.

28

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

Flowmeter F

Flowmeter F

130BB456.10

2 2

CHILLER

Frequency converter

Frequency converter

MG.11.BA.02 - VLT is a registered Danfoss trademark

CHILLER

29

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.7.23 Secondary Pumps

Secondary pumps in a primary/secondary chilled water pumping system are used to distribute the chilled water to the loads from the primary production loop. The primary/secondary pumping system is used to hydronically de-couple one piping loop from another. In this case. The primary pump is used to maintain a constant flow through the chillers while allowing the secondary pumps to vary in flow, increase control and save energy. If the primary/secondary design concept is not used and a variable volume system is designed, when the flow rate drops far enough or too quickly, the chiller cannot shed its load properly. The chillers low evaporator temperature safety then trips the chiller requiring a manual reset. This situation is common in large installations especially when two or more chillers in parallel are installed.

2 2

2.7.24 The VLT Solution

While the primary-secondary system with two-way valves improves energy savings and eases system control problems, the true energy savings and control potential is realized by adding frequency converters. With the proper sensor location, the addition of frequency converters allows the pumps to vary their speed to follow the system curve instead of the pump curve. This results in the elimination of wasted energy and eliminates most of the over-pressurization, two-way valves can be subjected too. As the monitored loads are reached, the two-way valves close down. This increases the differential pressure measured across the load and two-way valve. As this differential pressure starts to rise, the pump is slowed to maintain the control head also called setpoint value. This set-point value is calculated by summing the pressure drop of the load and two way valve together under design conditions. 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 frequency converter running multiple pumps in parallel.
130BB454.10

P Frequency converter 3

CHILLER

CHILLER

Frequency converter

30

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.8 Control Structures 2.8.1 Control Principle

LC Filter + (5A) R+ 82 R81 U 96 V 97 88(-) Load sharing R inr Inrush W 98 M Brake Resistor 130BA193.13 Load sharing + 89(+) L1 91 L2 92 L3 93

2 2

P 14-50

LC Filter (5A)

Illustration 2.9 Control structures.

The frequency converter is a high performance unit for demanding applications. It can handle various kinds of motor control principles such as U/f special motor mode and VVCPLUS and can handle normal squirrel cage asynchronous motors. Short circuit behavior on this frequency converter depends on the 3 current transducers in the motor phases. In 1-00 Configuration Mode it can be selected if open or closed loop is to be used

2.8.2 Control Structure Open Loop

130BB153.10 To motor control P 4-10 Motor speed direction P 4-13 Motor speed high limit [RPM] P 4-14 Motor speed high limit [Hz] Remote Linked to hand/auto Local P 4-11 Motor speed low limit [RPM] 100% Reference P 3-4* Ramp 1 P 3-5* Ramp 2 Ramp

Reference handling Remote reference Auto mode Hand mode Local reference scaled to RPM or Hz LCP Hand on, o and auto on keys P 3-13 Reference site

100%

0%

-100% P 4-12 Motor speed low limit [Hz]

Illustration 2.10 Open Loop structure.

In the configuration shown in Illustration 2.10, 1-00 Configuration Mode is set to Open loop [0]. The resulting reference from the reference handling system or the local reference is received and fed through the ramp limitation and speed limitation before being sent to the motor control. The output from the motor control is then limited by the maximum frequency limit.

MG.11.BA.02 - VLT is a registered Danfoss trademark

31

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.8.3 Local (Hand On) and Remote (Auto On) Control

The frequency converter can be operated manually via the local control panel (LCP) or remotely via analog/digital inputs or serial bus. If allowed in 0-40 [Hand on] Key on LCP, 0-41 [Off] Key on LCP, 0-42 [Auto on] Key on LCP, and 0-43 [Reset] Key on LCP, it is possible to start and stop the frequency converter byLCP 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 up [] and down []. After pressing the [Auto On] key, the frequency converter goes into Auto mode and follows (as default) the Remote reference. In this mode, it is possible to control the frequency converter via the digital inputs and various serial interfaces (RS-485, USB, or an optional fieldbus). See more about starting, stopping, changing ramps and parameter set-ups etc. in par. group 5-1* (digital inputs) or par. group 8-5* (serial communication).
130BP046.10

2 2

Hand on

Auto on

Reset

Hand Off Auto LCP Keys Hand Hand -> Off Auto Auto -> Off All keys All keys

Reference Site 3-13 Reference Site Linked to Hand / Auto Linked to Hand / Auto Linked to Hand / Auto Linked to Hand / Auto Local Remote

Active Reference

Local Local Remote Remote Local Remote

The table shows under which conditions either the Local Reference or the Remote Reference is active. One of them is always active, but both can not be active at the same time. Local reference will force the configuration mode to open loop, independent on the setting of 1-00 Configuration Mode. Local Reference will be restored at power-down.

32

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.8.4 Control Structure Closed Loop

The internal controller allows the frequency converter to become an integral part of the controlled system. The frequency converter receives a feedback signal from a sensor in the system. It then compares this feedback to a set-point reference value and determines the error, if any, between these two signals. It then adjusts the speed of the motor to correct this error. For example, consider a pump application where the speed of a pump is to be controlled so that the static pressure in a pipe is constant. The desired static pressure value is supplied to the frequency converter as the set-point reference. A static pressure sensor measures the actual static pressure in the pipe and supplies this to the frequency converter as a feedback signal. If the feedback signal is greater than the set-point reference, the frequency converter will slow down to reduce the pressure. In a similar way, if the pipe pressure is lower than the set-point reference, the frequency converter will automatically speed up to increase the pressure provided by the pump.
130BA359.12

2 2

100% Ref. Handling (Illustration) + _ *[-1] PID 100% -100% 0% Scale to speed To motor control

Feedback Handling (Illustration)

P 20-81 PID Normal/Inverse Control

P 4-10 Motor speed direction

Illustration 2.11 Block Diagram of Closed Loop Controller

While the default values for the frequency converters Closed Loop controller will often provide satisfactory performance, the control of the system can often be optimized by adjusting some of the Closed Loop controllers parameters. It is also possible to autotune the PI constants.

MG.11.BA.02 - VLT is a registered Danfoss trademark

33

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.8.5 Feedback Handling

0% Setpoint 1 P 20-21 Setpoint 2 P 20-22 Setpoint 3 P 20-23 Multi setpoint min. Multi setpoint max. 0% 0% Setpoint to Reference Handling 130BA354.12

2 2

Feedback Feedback 1 Source P 20-00 Feedback 2 Source P 20-03 Feedback 3 Source P 20-06 Feedback conv. P 20-01 Feedback conv. P 20-04 Feedback conv. P 20-07 Feedback 1 Feedback 1 only Feedback 2 only Feedback 3 only Sum (1+2+3) Di erence (1-2) Average (1+2+3) Minimum (1|2|3) Maximum (1|2|3)

Feedback 2

0%

Feedback 3

Feedback Function P 20-20

Illustration 2.12 Block Diagram of Feedback Signal Processing

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. Single Zone, Single Setpoint Single Zone Single Setpoint is a basic configuration. Setpoint 1 is added to any other reference (if any, see Reference Handling) and the feedback signal is selected using 20-20 Feedback Function. Multi Zone, Single Setpoint Multi Zone Single Setpoint uses two or three feedback sensors but only one setpoint. The feedbacks can be added, subtracted (only feedback 1 and 2) or averaged. In addition, the maximum or minimum value may be used. Setpoint 1 is used exclusively in this configuration. If Multi Setpoint Min [13] is selected, the setpoint/feedback pair with the largest difference controls the speed of the drive. Multi Setpoint Maximum [14] attempts to keep all zones at or below their respective setpoints, while Multi Setpoint Min [13] attempts to keep all zones at or above their respective setpoints. Example: A two zone two setpoint application Zone 1 setpoint is 15 bar and the feedback is 5.5 bar. Zone 2 setpoint is 4.4 bar and the feedback is 4.6 bar. If Multi Setpoint Max [14] is selected, Zone 1s setpoint and feedback are sent to the PID controller, since this has the smaller difference (feedback is higher than setpoint, resulting in a negative difference). If Multi Setpoint Min [13] is selected, Zone 2s setpoint and feedback is sent to the PID controller, since this has the larger difference (feedback is lower than setpoint, resulting in a positive difference).

34

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.8.6 Feedback Conversion

In some applications it may be useful to convert the feedback signal. One example of this is using a pressure signal to provide flow feedback. Since the square root of pressure is proportional to flow, the square root of the pressure signal yields a value proportional to the flow. This is shown below.
Ref. signal Desired ow
P 20-01 P 20-04 P 20-07

2 2

Ref.+ -

PID FB Flow P Flow P

FB conversion

FB signal P

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA358.11

35

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.8.7 Reference Handling

Details for Open Loop and Closed Loop operation.
130BA357.12 P 1-00 Con guration mode Input command: Freeze ref. Open loop
Scale to RPM,Hz or %

2 2

P 3-14 Preset relative ref. Input command: Preset ref. bit0, bit1, bit2 [0] [1] [2] [3] P 3-10 Preset ref. [4] [5] [6] [7] P 3-04 Ref. function Y No function Analog inputs P 3-15 Ref. 1 source Frequency inputs Ext. closed loop outputs DigiPot on 200% o Input command: Ref. Preset 100%
Freeze ref. & increase/ decrease ref. Scale to Closed loop unit Relative X+X*Y /100

max ref. % 200% 200% % min ref.

Remote ref.

Closed loop

Input command: Speed up/ speed down No function Analog inputs P 3-16 Ref. 2 source Frequency inputs Ext. closed loop outputs DigiPot External reference in % No function Analog inputs P 3-17 Ref. 3 source Frequency inputs Ext. closed loop outputs DigiPot Setpoint Closed loop 200% 0% Open loop P 1-00 Con guration mode Increase 0/1 Decrease 0/1 Clear 0/1 DigiPot Digipot ref. 200% Ref. in %

From Feedback Handling

Bus reference

Illustration 2.13 Block Diagram Showing Remote Reference

36

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

The Remote Reference is comprised of:

Preset references. External references (analog inputs, pulse frequency inputs, digital potentiometer inputs and serial communication bus references). The Preset relative reference. Feedback controlled setpoint.

In a ventilation system, the temperature is to be maintained at a constant value. The desired temperature is set between -5 and +35C using a 0-10V potentiometer. Because this is a cooling application, if the temperature is above the set-point value, the speed of the fan must be increased to provide more cooling air flow. The temperature sensor has a range of -10 to +40C and uses a two-wire transmitter to provide a 4-20mA signal. The output frequency range of the frequency converter is 10 to 50Hz. 1. 2. Start/Stop via switch connected between terminals 12 (+24V) and 18. Temperature reference via a potentiometer (-5 to +35C, 0 10V) connected to terminals 50 (+10V), 53 (input) and 55 (common). Temperature feedback via transmitter (-10-40C, 4-20mA) connected to terminal 54. Switch S202 behind the LCP set to ON (current input).
130BA175.11

2 2

Up to 8 preset references can be programmed in the drive. The active preset reference can be selected using digital inputs or the serial communications bus. The reference can also be supplied externally, most commonly from an analog input. This external source is selected by one of the 3 Reference Source parameters (3-15 Reference 1 Source, 3-16 Reference 2 Source and 3-17 Reference 3 Source). Digipot is a digital potentiometer. This is also commonly called a Speed Up/Speed Down Control or a Floating Point Control. To set it up, one digital input is programmed to increase the reference while another digital input is programmed to decrease the reference. A third digital input can be used to reset the Digipot reference. All reference resources and the bus reference are added to produce the total External Reference. The External Reference, the Preset Reference or the sum of the two can be selected to be the active reference. Finally, this reference can by be scaled using 3-14 Preset Relative Reference. The scaled reference is calculated as follows:
Reference = X + X

3.

L1 L2 L3 N PE F1

91 92 93 95
Y ( 100 )

12 37

L1 L2 L3 PE

Where X is the external reference, the preset reference or the sum of these and Y is 3-14 Preset Relative Reference in [%]. If Y, 3-14 Preset Relative Reference is set to 0%, the reference will not be affected by the scaling.

18 50 53 55 54 Transmitter

V W PE

96 97 98 99

2.8.8 Example of Closed Loop PID Control

The following is an example of a Closed Loop Control for a ventilation system:
130BA218.10

M 3

Cold air 100kW Heat generating process

W n C Fan speed Temperature

Temperature transmitter

Heat

MG.11.BA.02 - VLT is a registered Danfoss trademark

37

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.8.9 Programming Order

Function 1) Make sure the motor runs properly. Do the following: Set the motor parameters using nameplate data. Run Automatic Motor Adaptation. 2) Check that the motor is running in the right direction. Run Motor Rotation Check. 1-28 If the motor runs in the wrong direction, remove power temporarily and reverse two of the motor phases. 60 sec. 60 sec. Depends on motor/load size! Also active in Hand mode. Clockwise [0] 10 Hz, Motor min speed 50 Hz, Motor max speed 50 Hz, Drive max output frequency Closed Loop [3] Bar [71] 0 Bar 10 Bar 1-2* 1-29 As specified by motor name plate Enable complete AMA [1] and then run the AMA function. Par. no. Setting

2 2

3) Make sure the frequency converter limits are set to safe values Check that the ramp settings are within capabilities of the 3-41 drive and allowed application operating specifications. 3-42

Prohibit the motor from reversing (if necessary) Set acceptable limits for the motor speed.

4-10 4-12 4-14 4-19 1-00 20-12 20-13 20-14

Switch from open loop to closed loop. 4) Configure the feedback to the PID controller. Select the appropriate reference/feedback unit. 5) Configure the set-point reference for the PID controller. Set acceptable limits for the set-point reference. Choose current or voltage by switches S201 / S202

6) Scale the analog inputs used for set-point reference and feedback. Scale Analog Input 53 for the pressure range of the potentiometer (0 - 10 Bar, 0 - 10 V). 6-10 6-11 6-14 6-15 0V 10 V (default) 0 Bar 10 Bar 4 mA 20 mA (default) 0 Bar 10 Bar See Optimization of the PID Controller, below.

Scale Analog Input 54 for pressure sensor (0 - 10 Bar, 4 - 20 6-22 mA) 6-23 6-24 6-25 7) Tune the PID controller parameters. Adjust the drives Closed Loop Controller, if needed. 8) Finished! Save the parameter setting to the LCP for safe keeping 0-50 20-93 20-94

All to LCP [1]

2.8.10 Tuning the Drive Closed Loop Controller

Once the frequency converter's Closed Loop Controller has been set up, the performance of the controller should be tested. In many cases, its performance may be acceptable using the default values of 20-93 PID Proportional Gain and 20-94 PID Integral Time. However, in some cases it may be helpful to optimize these parameter values to provide faster system response while still controlling speed overshoot.

38

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.8.11 Manual PID Adjustment

1. 2. Start the motor Set 20-93 PID Proportional Gain to 0.3 and increase it until the feedback signal begins to oscillate. If necessary, start and stop the drive or make step changes in the set-point reference to attempt to cause oscillation. Next reduce the PID Proportional Gain until the feedback signal stabilizes. Then reduce the proportional gain by 40-60%. Set 20-94 PID Integral Time to 20 sec. and reduce it until the feedback signal begins to oscillate. If necessary, start and stop the drive or make step changes in the set-point reference to attempt to cause oscillation. Next, increase the PID Integral Time until the feedback signal stabilizes. Then increase of the Integral Time by 15-50%. 20-95 PID Differentiation Time should only be used for very fast-acting systems. The typical value is 25% of 20-94 PID Integral Time. The differential function should only be used when the setting of the proportional gain and the integral time has been fully optimized. Make sure that oscillations of the feedback signal are sufficiently dampened by the low-pass filter for the feedback signal (par. 6-16, 6-26, 5-54 or 5-59 as required).

2 2

3.

4.

2.9 General aspects of EMC 2.9.1 General Aspects of EMC Emissions

Electrical interference is usually conducted at frequencies in the range 150kHz to 30MHz. Airborne interference from the frequency converter system in the range 30MHz to 1GHz is generated from the inverter, motor cable, and the motor. As shown in the illustration below, capacitive currents in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents. The use of a screened motor cable increases the leakage current (see illustration below) because screened cables have higher capacitance to earth than unscreened cables. If the leakage current is not filtered, it will cause greater interference on the mains in the radio frequency range below approximately 5MHz. Since the leakage current (I1) is carried back to the unit through the screen (I 3), there will in principle only be a small electro-magnetic field (I4) from the screened motor cable according to the below figure. The screen reduces the radiated interference but increases the low-frequency interference on the mains. The motor cable screen must be connected to the frequency converter enclosure as well as on the motor enclosure. This is best done by using integrated screen clamps so as to avoid twisted screen ends (pigtails). These increase the screen impedance at higher frequencies, which reduces the screen effect and increases the leakage current (I4). If a screened cable is used for fieldbus, relay, control cable, signal interface and brake, the screen must be mounted on the enclosure at both ends. In some situations, however, it will be necessary to break the screen to avoid current loops.
175ZA062.11 LINE FREQUENCY CONVERTER MOTOR CABLE SCREENED MOTOR

z z z z PE

L1 L2 L3 PE

CS

U V W PE I2 I3 CS Earth wire Screen CS I4 I4 I1

CS

CS

CS

Earth Plane

MG.11.BA.02 - VLT is a registered Danfoss trademark

39

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2 2

If the screen is to be placed on a mounting plate for the frequency converter, the mounting plate must be made of metal, because the screen currents have to be conveyed back to the unit. Moreover, ensure good electrical contact from the mounting plate through the mounting screws to the frequency converter chassis. When unscreened cables are used, some emission requirements are not complied with, although the immunity requirements are observed. In order to reduce the interference level from the entire system (unit + installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50MHz (airborne) is especially generated by the control electronics. Please see for more information on EMC.

2.9.2 Emission Requirements

According to the EMC product standard for adjustable speed frequency converters EN/IEC 61800-3:2004 the EMC requirements depend on the intended use of the frequency converter. Four categories are defined in the EMC product standard. The definitions of the 4 categories together with the requirements for mains supply voltage conducted emissions are given in Table 2.1.
Conducted emission requirement according to the limits given in EN 55011 Class B Class A Group 1

Category C1 C2

Definition Frequency converters installed in the first environment (home and office) with a supply voltage less than 1000V. Frequency converters installed in the first environment (home and office) with a supply voltage less than 1000V, which are neither plug-in nor movable and are intended to be installed and commissioned by a professional. Frequency converters installed in the second environment (industrial) with a supply voltage lower than 1000V. Frequency converters installed in the second environment with a supply voltage equal to or above 1000 V or rated current equal to or above 400A or intended for use in complex systems.

C3 C4

Class A Group 2 No limit line. An EMC plan should be made.

Table 2.1 Emission Requirements

When the generic emission standards are used the frequency converters are required to comply with the following limits
Environment First environment (home and office) Second environment (industrial environment) Generic standard EN/IEC 61000-6-3 Emission standard for residential, commercial and light industrial environments. EN/IEC 61000-6-4 Emission standard for industrial environments. Conducted emission requirement according to the limits given in EN 55011 Class B Class A Group 1

40

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2.9.3 EMC Test Results (Emission)

The following test results have been obtained using a system with a frequency converter (with options if relevant), a screened control cable, a control box with potentiometer, as well as a motor and motor screened cable. RFI filter type Conducted emission. Maximum shielded cable length. Industrial environment Housing, trades and light industries Radiated emission Industrial environment Housing, trades and light industries EN 55011 Class B

2 2

Standard H1 1.1-45kW 200-240V 1.1-9 kW 380-480V H2 1.1-3.7kW 200-240V 5.5-45kW 200-240V 1.1-7.5kW 380-480V 11-90kW 380-480V 110-1000kW 380-480V 11-90kW 525-690V 45-1400kW 525-690V H3 1.1-45kW 200-240V 1.1-90kW 380-480V H4 110-1000kW 380-480V 45-400kW 525-690V 11-90kW 525-690V Hx 1.1-90 kW 525-600 V T6 T4 T7 T7 T2 T4 T2 T2 T4 T4 T4 T7 T7 T2 T4

EN 55011 Class A2 150 m 150 m 5m 25 m 5m 25 m 150 m Yes 150 m 75 m 75 m 150 m 150 m No -

EN 55011 Class A1 150 m 150 m No No No No No No No 50 m 50 m 150 m 30 m Yes -

EN 55011 Class EN 55011 Class A1 B 50 m 50 m No No No No No No No 10 m 10 m No No No Yes Yes No No No No No No No Yes Yes Yes No Yes -

No No No No No No No No No No No No No No -

Table 2.2 EMC Test Results (Emission)

HX, H1, H2 or H3 is defined in the type code pos. 16 - 17 for EMC filters HX - No EMC filters built in the frequency converter (600V units only) H1 - Integrated EMC filter. Fulfil Class A1/B H2 - No additional EMC filter. Fulfil Class A2 H3 - Integrated EMC filter. Fulfil class A1/B (Frame size A1 only) H4 - Integrated EMC filter. Fulfil class A1

Harmonic currents Hz

I1 50Hz

I5 250Hz

I7 350Hz

The harmonics do not affect the power consumption directly but increase the heat losses in the installation (transformer, cables). Consequently, in plants with a high percentage of rectifier load, maintain harmonic currents at a low level to avoid overload of the transformer and high temperature in the cables.
175HA034.10

2.9.4 General Aspects of Harmonics Emission

A frequency converter takes up a non-sinusoidal current from mains, which increases the input current IRMS. A nonsinusoidal current is transformed by means of a Fourier analysis and split up into sine-wave currents with different frequencies, i.e. different harmonic currents I N with 50Hz as the basic frequency:

MG.11.BA.02 - VLT is a registered Danfoss trademark

41

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

NOTE
Some of the harmonic currents might disturb communication equipment connected to the same transformer or cause resonance in connection with power-factor correction batteries. To ensure low harmonic currents, the frequency converter is equipped with intermediate circuit coils as standard. This normally reduces the input current I RMS by 40%. The voltage distortion on the mains supply voltage depends on the size of the harmonic currents multiplied by the mains impedance for the frequency in question. The total voltage distortion THD is calculated on the basis of the individual voltage harmonics using this formula:
THD % = U
2 2 2 + U + ... + U 5 7 N

Provided that the short-circuit power of the supply Ssc is greater than or equal to:
SSC = 3 RSCE U mains I equ =
3 120 400 I equ

2 2

at the interface point between the users supply and the public system (Rsce). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to specified above. Other power sizes can be connected to the public supply network by consultation with the distribution network operator. Compliance with various system level guidelines: The harmonic current data in the table are given in accordance with IEC/EN61000-3-12 with reference to the Power Drive Systems product standard. They may be used as the basis for calculation of the harmonic currents' influence on the power supply system and for the documentation of compliance with relevant regional guidelines: IEEE 519 -1992; G5/4.

(UN% of U)

2.9.5 Harmonics Emission Requirements

Equipment connected to the public supply network
Options: 1 Definition: IEC/EN 61000-3-2 Class A for 3-phase balanced equipment (for professional equipment only up to 1kW total power). IEC/EN 61000-3-12 Equipment 16A-75A and professional equipment as from 1kW up to 16A phase current.

2.9.7 Immunity Requirements

The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss frequency converters comply with the requirements for the industrial environment and consequently comply also with the lower requirements for home and office environment with a large safety margin. In order to document immunity against electrical interference from electrical phenomena, the following immunity tests have been made on a system consisting of a frequency converter (with options if relevant), a screened control cable and a control box with potentiometer, motor cable and motor. The tests were performed in accordance with the following basic standards:

2.9.6 Harmonics Test Results (Emission)

Power sizes up to PK75 in T2 and T4 complies with IEC/EN 61000-3-2 Class A. Power sizes from P1K1 and up to P18K in T2 and up to P90K in T4 complies with IEC/EN 61000-3-12, Table 4. Power sizes P110 - P450 in T4 also complies with IEC/EN 61000-3-12 even though not required because currents are above 75A.
Individual Harmonic Current In/I1 (%) I5 Actual (typical) Limit for Rsce120 40 40 I7 20 25 I11 10 15 I13 8 10

Harmonic current distortion factor (%) THD Actual (typical) Limit for Rsce120 46 48 PWHD 45 46

EN 61000-4-2 (IEC 61000-4-2): Electrostatic discharges (ESD): Simulation of electrostatic discharges from human beings. EN 61000-4-3 (IEC 61000-4-3): Incoming electromagnetic field radiation, amplitude modulated simulation of the effects of radar and radio communication equipment as well as mobile communications equipment.

Table 2.3 Harmonics Test Results (Emission)

42

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

EN 61000-4-4 (IEC 61000-4-4): Burst transients: Simulation of interference brought about by switching a contactor, relay or similar devices. EN 61000-4-5 (IEC 61000-4-5): Surge transients: Simulation of transients brought about e.g. by lightning that strikes near installations.
Burst IEC 61000-4-4 B 4 kV CM 4 kV CM 4 kV CM 4 kV CM 2 kV CM 2 kV CM 2 kV CM 2 kV CM 2 kV CM 2 kV CM Surge IEC 61000-4-5 B 2 kV/2 DM 4 kV/12 CM 4 kV/2 1) 4 kV/2 2 kV/2 2 kV/2 1) 1) 1) 4 kV/2 1)

EN 61000-4-6 (IEC 61000-4-6): RF Common mode: Simulation of the effect from radio-transmission equipment joined by connection cables.

See Table 2.4.

2 2

Voltage range: 200-240V, 380-480V Basic standard ESD IEC 61000-4-2 B 8 kV AD 6 kV CD Radiated electromagnetic field IEC 61000-4-3 A 10 V/m RF common mode voltage IEC 61000-4-6 A 10VRMS 10VRMS 10VRMS 10VRMS 10VRMS 10VRMS 10VRMS 10VRMS 10VRMS 10VRMS

Acceptance criterion Line Motor Brake Load sharing Control wires Standard bus Relay wires Application and Fieldbus options LCP cable External 24 V DC Enclosure

2 kV/2 1) 2 kV/2 1) 2 kV/2 1) 0.5 kV/2 DM 1 kV/12 CM

Table 2.4 EMC Immunity Form

1) Injection on cable shield AD: Air Discharge CD: Contact Discharge CM: Common mode DM: Differential mode

The components that make up the electrical isolation, as described below, also comply with the requirements for higher isolation and the relevant test as described in EN 61800-5-1. The PELV galvanic isolation can be shown in six locations (see Illustration 2.14): In order to maintain PELV all connections made to the control terminals must be PELV, e.g. thermistor must be reinforced/double insulated. 1. 2. 3. 4. 5. 6. Power supply (SMPS) incl. signal isolation of UDC, indicating the intermediate current voltage. Gate drive that runs the IGBTs (trigger transformers/opto-couplers). Current transducers. Opto-coupler, brake module. Internal inrush, RFI, and temperature measurement circuits. Custom relays.

2.10 Galvanic isolation (PELV) 2.10.1 PELV - Protective Extra Low Voltage
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. All control terminals and relay terminals 01-03/04-06 comply with PELV (Protective Extra Low Voltage) (Does not apply to grounded Delta leg above 400V). Galvanic (ensured) isolation is obtained by fulfilling requirements for higher isolation and by providing the relevant creapage/clearance distances. These requirements are described in the EN 61800-5-1 standard.

MG.11.BA.02 - VLT is a registered Danfoss trademark

43

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

130BA056.10

2 2
6 5 4 1 2

b Cable length [m]

Illustration 2.15 Principle drawing showing how the leakage

a b

current is influenced by the cable length and power size. Pa > Pb.

Illustration 2.14 Galvanic Isolation

The leakage current also depends on the line distortion

Leakage current [mA] 130BB956.10

The functional galvanic isolation (a and b on drawing) is for the 24V back-up option and for the RS-485 standard bus interface.

THVD=0% THVD=5%

WARNING
Installation at high altitude: 380 - 500V, enclosure A, B and C: At altitudes above 2km, please contact Danfoss regarding PELV. 380 - 500V, enclosure D, E and F: At altitudes above 3km, please contact Danfoss regarding PELV. 525 - 690 V: At altitudes above 2km, please contact Danfoss regarding PELV.

Illustration 2.16 Principle drawing showing how the leakage current is influenced by line distortion.

WARNING
Touching the electrical parts could be fatal - even after the equipment has been disconnected from mains. Also make sure that other voltage inputs have been disconnected, such as load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up. Before touching any electrical parts, wait at least the amount of time indicated in the Safety Precautions section. Shorter time is allowed only if indicated on the nameplate for the specific unit.

NOTE
When a filter is used, turn off 14-50 RFI Filter when charging the filter, to avoid that a high leakage current makes the RCD switch. EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3,5mA. Earth grounding must be reinforced in one of the following ways:

2.11 Earth Leakage Current

Leakage Current Follow national and local codes regarding protective earthing of equipment with a leakage current > 3,5 mA. Frequency converter technology implies high frequency switching at high power. This will generate a leakage current in the earth connection. A fault current in the frequency converter at the output power terminals might contain a DC component which can charge the filter capacitors and cause a transient earth current. The earth leakage current is made up of several contributions and depends on various system configurations including RFI filtering, screened motor cables, and frequency converter power.

Earth ground wire (terminal 95) of at least 10mm2 Two separate earth ground wires both complying with the dimensioning rules

See EN/IEC61800-5-1 and EN50178 for further information. Using RCDs Where residual current devices (RCDs), also known as earth leakage circuit breakers (ELCBs), are used, comply with the following: Use RCDs of type B only which are capable of detecting AC and DC currents Use RCDs with an inrush delay to prevent faults due to transient earth currents Dimension RCDs according to the system configuration and environmental considerations

44

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BB955.10

Leakage current [mA]

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

Lleakage[mA]

RCD with high fcut-o

130BB958.10

RCD with low fcut-o

150 Hz 50 Hz Mains 3rd harmonics fs

fsw f [Hz] Cable

If the amount of kinetic energy transferred to the resistor in each braking period is not known, the average power can be calculated on the basis of the cycle time and braking time also called intermitted duty cycle. The resistor intermittent duty cycle is an indication of the duty cycle at which the resistor is active. The below figure shows a typical braking cycle. The intermittent duty cycle for the resistor is calculated as follows: Duty Cycle = tb / T T = cycle time in seconds tb is the braking time in seconds (as part of the total cycle time)
Load 130BA167.10

2 2

Illustration 2.17 Sketch of Main Contributions to Leakage Current.

100 Hz 2 kHz 100 kHz

Illustration 2.18 Principle Drawing Showing how the Cut-off Frequency of the RCD will Influence what is Responded to/ Measured.

130BB957.10

Leakage current [mA]

Speed

ta

tc

tb

to

ta

tc

tb

to

ta

See also RCD Application Note MN.90.GX.02

WARNING
Residual Current Device This product can cause a d.c. current in the protective conductor. Where a residual current device (RCD) is used for protection in case of direct or indirect contact, only an RCD of Type B is allowed on the supply side of this product. Otherwise, another protective measure shall be applied, such as separation from the environment by double or reinforced insulation, or isolation from the supply system by a transformer. See also Application Note Protection against Electrical Hazards MN.90.G2.02. Protective earthing of the frequency converter and the use of RCD's must always follow national and local regulations.

Time

Danfoss offers brake resistors with duty cycle of 5%, 10% and 40% suitable for use with the VLT HVAC Drive frequency converter 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. For further selection advice, please contact Danfoss.

2.12.2 Brake Resistor Calculation

The brake resistance is calculated as shown:
2 U dc Rbr = Ppeak where Ppeak = Pmotor x Mbr x motor x [W]

2.12 Brake Function 2.12.1 Selection of Brake Resistor

In certain applications, for instance in tunnel or underground railway station ventilation systems, it is desirable to bring the motor to a stop more rapidly than can be achieved through controlling via ramp down or by free-wheeling. In such applications, dynamic braking with a braking resistor may be utilized. Using a braking resistor ensures that the energy is absorbed in the resistor and not in the frequency converter.

As can be seen, the brake resistance depends on the intermediate circuit voltage (UDC). The brake function of the frequency converter is settled in 3 areas of mains power supply:

MG.11.BA.02 - VLT is a registered Danfoss trademark

45

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

Size

Brake active

2 2

Warning before cut out 405V 810V 1109V

Cut out (trip)

2.12.3 Control with Brake Function

The brake is protected against short-circuiting of the brake resistor, and the brake transistor is monitored to ensure that short-circuiting of the transistor is detected. A relay/digital output can be used for protecting the brake resistor against overloading in connection with a fault in the frequency converter. In addition, the brake makes it possible to read out the momentary power and the mean power for the latest 120 seconds. The brake can also monitor the power energizing and make sure it does not exceed a limit selected in 2-12 Brake Power Limit (kW). In 2-13 Brake Power Monitoring, select the function to carry out when the power transmitted to the brake resistor exceeds the limit set in 2-12 Brake Power Limit (kW).

3 x 200-240V 3 x 380-480V 3 x 525-690V

390V (UDC) 778V 1084V

410V 820V 1130V

NOTE
Check that the brake resistor can cope with a voltage of 410V, 820V or 975V - unless Danfoss brake resistors are used. Danfoss recommends the brake resistance Rrec, i.e. one that guarantees that the frequency converter is able to brake at the highest braking torque (Mbr(%)) of 110%. The formula can be written as:
2 U dc x 100 Rrec = Pmotor x M br (%) x x motor

NOTE
Monitoring the brake power is not a safety function; a thermal switch is required for that purpose. The brake resistor circuit is not earth leakage protected. Over voltage control (OVC) (exclusive brake resistor) can be selected as an alternative brake function in 2-17 Over-voltage Control. This function is active for all units. The function ensures that a trip can be avoided if the DC link voltage increases. This is done by increasing the output frequency to limit the voltage from the DC link. It is a very useful function, e.g. if the ramp-down time is too short since tripping of the frequency converter is avoided. In this situation the rampdown time is extended.

motor is typically at 0.90 is typically at 0.98 For 200V, 480V and 600V frequency converters, Rrec at 160% braking torque is written as:
200V : Rrec = Pmotor 375300 480V : Rrec = 1) Pmotor 2) Pmotor 630137 600V : Rrec = Pmotor 480V : Rrec = 690V : Rrec = 832664 428914 107780

Pmotor

1) For frequency converters 7.5kW shaft output 2) For frequency converters > 7.5kW shaft output

2.12.4 Brake Resistor Cabling

EMC (twisted cables/shielding) To reduce the electrical noise from the wires between the brake resistor and the frequency converter, the wires must be twisted. For enhanced EMC performance a metal screen can be used.

NOTE
The resistor brake circuit resistance selected should not be higher than that recommended by Danfoss. If a brake resistor with a higher ohmic value is selected, the braking torque may not be achieved because there is a risk that the frequency converter cuts out for safety reasons.

2.13 Extreme Running Conditions

Short Circuit (Motor Phase Phase) The frequency converter is protected against short circuits by means of current measurement in each of the three motor phases or in the DC link. A short circuit between two output phases will cause an overcurrent in the inverter. The inverter will be turned off individually when the short circuit current exceeds the permitted value (Alarm 16 Trip Lock). To protect the frequency converter against a short circuit at the load sharing and brake outputs please see the design guidelines. See certificate in the Certificates section.

NOTE
If a short circuit in the brake transistor occurs, power dissipation in the brake resistor is only prevented by using a mains switch or contactor to disconnect the mains for the frequency converter. (The contactor can be controlled by the frequency converter).

WARNING
Do not touch the brake resistor as it can get very hot while/ after braking.

46

MG.11.BA.02 - VLT is a registered Danfoss trademark

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

Switching on the Output 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. Motor-generated Over-voltage The voltage in the intermediate circuit is increased when the motor acts as a generator. This occurs in following cases: 1. The load drives the motor (at constant output frequency from the frequency converter), ie. the load generates energy. During deceleration ("ramp-down") if the moment of inertia is high, the friction is low and the rampdown time is too short for the energy to be dissipated as a loss in the frequency converter, the motor and the installation. Incorrect slip compensation setting may cause higher DC link voltage.

2000 1000 600 500 400 300 200 100 60 50 40 30 20 10

fOUT = 2 x f M,N fOUT = 0.2 x f M,N

175ZA052.12

t [s]

2 2

fOUT = 1 x f M,N(par. 1-23)

1.0 1.2 1.4 1.6 1.8 2.0

IM IM,N(par. 1-24)

Illustration 2.19 The X-axis is showing the ratio between Imotor and Imotor nominal. The Y-axis is showing the time in seconds before the ETR cuts off and trips the frequency converter. The curves are showing the characteristic nominal speed at twice the nominal speed and at 0,2x the nominal speed.

2.

3.

The control unit may attempt to correct the ramp if possible (2-17 Over-voltage Control. The inverter turns off to protect the transistors and the intermediate circuit capacitors when a certain voltage level is reached. See 2-10 Brake Function and 2-17 Over-voltage Control to select the method used for controlling the intermediate circuit voltage level. Mains Drop-out During a mains drop-out, the frequency converter keeps running until the intermediate circuit voltage drops below the minimum stop level, which is typically 15% below the frequency converter's lowest rated supply voltage. The mains voltage before the drop-out and the motor load determines how long it takes for the inverter to coast. Static Overload in VVCplus mode When the frequency converter is overloaded (the torque limit in 4-16 Torque Limit Motor Mode/4-17 Torque Limit Generator Mode is reached), the controls reduces the output frequency to reduce the load. If the overload is excessive, a current may occur that makes the frequency converter cut out after approx. 5-10 sec. Operation within the torque limit is limited in time (0-60 sec) in 14-25 Trip Delay at Torque Limit.

It is clear that at lower speed the ETR cuts of at lower heat due to less cooling of the motor. In that way the motor are protected from being over heated even at low speed. The ETR feature is calculating the motor temperature based on actual current and speed. The calculated temperature is visible as a read out parameter in 16-18 Motor Thermal in the frequency converter. The thermistor cut-out value is > 3k. Integrate a thermistor (PTC sensor) in the motor for winding protection. Motor protection can be implemented using a range of techniques: PTC sensor in motor windings; mechanical thermal switch (Klixon type); or Electronic Thermal Relay (ETR).
R () 175HA183.10 [C] -20C nominel -5C nominel nominel +5C

4000 3000 1330

550

250

2.13.1 Motor Thermal Protection

This is the way Danfoss is protecting the motor from being overheated. It is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in Illustration 2.19

MG.11.BA.02 - VLT is a registered Danfoss trademark

47

Introduction to VLT HVAC D...

VLT HVAC Drive Design Guide

2 2

Using a digital input and 24V as power supply: Example: The frequency converter trips when the motor temperature is too high. Parameter set-up: Set 1-90 Motor Thermal Protection to Thermistor Trip [2] Set 1-93 Thermistor Source to Digital Input 33 [6]
130BA151.11 +24V GND

Input Digital/analog Digital Digital Analog

Supply Voltage Threshold VCut-out Values Cut-out Values 24 10 10 < 6.6k - > 10.8k < 800 - > 2.7k < 3.0k - > 3.0k

NOTE
Check that the chosen supply voltage follows the specification of the used thermistor element. Summary With the Torque limit feature the motor is protected for being overloaded independent of the speed. With the ETR the motor is protected for being over heated and there is no need for any further motor protection. That means when the motor is heated up the ETR timer controls for how long time the motor can be running at the high temperature before it is stopped in order to prevent over heating. If the motor is overloaded without reaching the temperature where the ETR shuts of the motor, the torque limit is protecting the motor and application for being overloaded. ETR is activated in 1-90 Motor Thermal Protection and is controlled in 4-16 Torque Limit Motor Mode. The time before the torque limit warning trips the frequency converter is set in 14-25 Trip Delay at Torque Limit.

12 13 18 19 27 29 32 33 20 37

OFF

A B

PTC / Thermistor

ON <6.6 k >10.8 k R

Using a digital input and 10V as power supply: Example: The frequency converter trips when the motor temperature is too high. Parameter set-up: Set 1-90 Motor Thermal Protection to Thermistor Trip [2] Set 1-93 Thermistor Source to Digital Input 33 [6]
+10V 130BA152.10 OFF
12 13 18 19 27 29 32 33 20 37

39 42 50 53 54 55

ON PTC / Thermistor <800 >2.7 k R

Using an analog input and 10V as power supply: Example: The frequency converter trips when the motor temperature is too high. Parameter set-up: Set 1-90 Motor Thermal Protection to Thermistor Trip [2] Set 1-93 Thermistor Source to Analog Input 54 [2] Do not select a reference source.
+10V 130BA153.11 >3.0 k R

39 42 50 53 54 55

OFF

ON PTC / Thermistor <3.0 k

48

MG.11.BA.02 - VLT is a registered Danfoss trademark

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

3 VLT HVAC Drive Selection

130BA707.10
.9 .0 13 nt 00Hz 14 z 16 45C/1 rre cu 1150/60 -1000HMax e ag ak XN80V in 0 Tamb RK le h XXx380-4: 3x0-U/IP20 ENMA hig st .) 3 T IS D U N: and k tek min O AS IN IO / RCDFrans st (4 CH ADE M UTNUALUAL / : sk tek ENT UL CAEE MA MAN INGFran QUIPMTUPE IN S IR N rge / 61 L E SE VO AR cha 342 TRO EFU Wtored 76x1 1L CONFOR PR

3.1 Options and Accessories

Danfoss offers a wide range of options and accessories for the frequency converters.

3 3

A kV .1 11 A A F

S
D IA L TE STR UA S LIS DU AN ION IN E M AT IC SE PL AP

3.1.1 Mounting of Option Modules in Slot B

The power to the frequency converter must be disconnected. For A2 and A3 enclosures:

Remove the LCP (Local Control Panel), the terminal cover, and the LCP frame from the frequency converter. Fit the MCB1xx option card into slot B. Connect the control cables and relieve the cable by the enclosed cable strips. Remove the knock out in the extended LCP frame delivered in the option set, so that the option will fit under the extended LCP frame. Fit the extended LCP frame and terminal cover. Fit the LCP or blind cover in the extended LCP frame. Connect power to the frequency converter. Set up the input/output functions in the corresponding parameters, as mentioned in the section General Technical Data.

D
LCP Frame

Illustration 3.1 A2, A3 and B3 Enclosures

LCP Cradle

DC-

DC+

61 6 39 42 50
Remove

53 5

jumper

to activate

Safe Stop

12 13 18 19 27 28 32 38 2

For B1, B2, C1 and C2 enclosures:

Illustration 3.2 A5, B1, B2, B4, C1, C2, C3 and C4 Enclosures

Remove the LCP and the LCP cradle Fit the MCB 1xx option card into slot B Connect the control cables and relieve the cable by the enclosed cable strips Fit the cradle Fit the LCP

3.1.2 General Purpose Input Output Module MCB 101

MCB 101 is used for extension of the number of digital and analog inputs and outputs of the frequency converter. Contents: MCB 101 must be fitted into slot B in the frequency converter. MCB 101 option module

Extended LCP frame Terminal cover

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA708.10

49

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

MCB 101 General Purpose I/O SW. ver. XX.XX GND(1) DOUT3 DOUT4 COM DIN DIN7 DIN8 DIN9

B slot Code No. 130BXXXX GND(2) AOUT2

130BA208.10

FC Series

3.1.3 Digital Inputs - Terminal X30/1-4

Parameters for set-up: 5-16, 5-17 and 5-18 Numb Volta Voltage levels er of ge digital level inputs 3 0-24V PNP type: DC Common = 0V Logic 0: Input < 5V DC Logic 0: Input > 10V DC NPN type: Common = 24V Logic 0: Input > 19V DC Logic 0: Input < 14V DC Tolerance Max. Input impedance

AIN3 11

3 3

X30/

10

AIN4 12

24V

Galvanic isolation in the MCB 101 Digital/analog inputs are galvanically isolated from other inputs/outputs on the MCB 101 and in the control card of the frequency converter. Digital/analog outputs in the MCB 101 are galvanically isolated from other inputs/outputs on the MCB 101, but not from these on the control card of the frequency converter. If the digital inputs 7, 8 or 9 are to be switched by use of the internal 24V power supply (terminal 9) the connection between terminal 1 and 5 which is shown in Illustration 3.3 has to be established.
130BA209.10 Control card (FC 100/200/300) CPU General Purpose I/O option MCB 101 CAN BUS 0V 24V

28V Approx. 5k continuous 37V in minimum 10 sec.

3.1.4 Analog Voltage Inputs - Terminal X30/10-12

Parameters for set-up: 6-3*, 6-4* and 16-76 Number of analog Standardize Tolerance voltage inputs d input signal 2 0-10V DC 20V continuously Resol Max. Input ution impedance 10 bits Approx. 5K

CPU 0V DIG IN RIN= 5kohm COM DIN GND(1) DOUT3 DIG & ANALOG OUT 0/24VDC DOUT4 0/24VDC AOUT2 0/4-20mA 24V 24V ANALOG IN RIN= 10kohm GND(2)

DIN7

DIN8

DIN9

AIN3

AIN4

X30/

10

11

12

3.1.5 Digital Outputs - Terminal X30/5-7

Parameters for set-up: 5-32 and 5-33 Number of digital outputs 2 Output level 0 or 2 V DC Tolerance 4V Max.impeda nce 600

>600 ohm

<500 ohm

0-10 VDC

PLC (PNP) 0V 24V DC

>600 ohm

0-10 VDC

3.1.6 Analog Outputs - Terminal X30/5+8

Parameters for set-up: 6-6* and 16-77 Number of analog outputs 1 Output signal Tolerance level 0/4 - 20mA 0.1mA Max.impeda nce < 500

PLC (NPN) 24V DC 0V

Illustration 3.3 Principle Diagram

50

MG.11.BA.02 - VLT is a registered Danfoss trademark

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

3.1.7 Relay Option MCB 105

The MCB 105 option includes 3 pieces of SPDT contacts and must be fitted into option slot B. Electrical Data: Max terminal load (AC-1) 1) (Resistive load) Max terminal load (AC-15 ) 1) (Inductive load @ cos 0.4) Max terminal load (DC-1) 1) (Resistive load) Max terminal load (DC-13) 1) (Inductive load) Min terminal load (DC) Max switching rate at rated load/min load
1) IEC 947 part 4 and 5

240 V AC 2A 240 V AC 0.2 A 24 V DC 1 A 24 V DC 0.1 A 5 V 10 mA 6 min-1/20 sec-1

3 3

When the relay option kit is ordered separately the kit includes: Relay Module MCB 105

Extended LCP frame and enlarged terminal cover Label for covering access to switches S201, S202 and S801 Cable strips for fastening cables to relay module
130BA709.10

RK A M 0 32 EN A0 G4 D 00 15 A E IN BF 8 D 12 kV D R1 0 .1 A 0B N: .9A 11 M B2 S/ 14 0A 3F nt z 6. 11 T5 rre XP 0H 1 C/ cu e XX 00 0/6 0Hz 45 1 ag CIA 1 5 0 x ak N 0V 10 a le : XX -48 0- b M h C : X 0 in m hig T/ N x38 -U Ta .) d kst 0 in an te P/ : 3 3x 20 m k CD ns (4 IN T: IS/IP U t / R ra O AS L /F ks T L te CH UA AL EN U sk M E IN AN U an M N UIP UP Fr E MA / SE IR EQ T 61 L SE ge VO ar 42 RO FU ch 13 NT RE x1 CO R P 76 L O D IA L F TE STR UA S LIS DU AN ION IN E M AT IC SE PL AP

UT CA :

IO

AR W

ed or St

N:

NI

NG

61

68

39
Re mo ve

42

50
to

12

13

jum p

53

er

54

18

acti

19

vate

27

29

Saf eS top

32

33

20

LA

BE

L
9 6

DISMOUNT RELAY CARD TO ACCESS RS485 TERMINATION (S801) OR CURRENT/VOLTAGE SWITCHES (S201, S202)

A2-A3-B3
1)

A5-B1-B2-B4-C1-C2-C3-C4

IMPORTANT! The label MUST be placed on the LCP frame as shown (UL approved).

MG.11.BA.02 - VLT is a registered Danfoss trademark

51

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

DC-

DC+

3 3

61 6

LABE
1

39 42

50 53 5

Remov e jumpe

r to activat e Safe

Stop

12 13

18 19 27

28 32

38 2

DISMOUNT RELAY CARD TO ACCESS RS485 TERMINATION (S801) OR CURRENT/VOLTAGE SWITCHES (S201, S202)

WARNING
Warning Dual supply How to add the MCB 105 option: See mounting instructions in the beginning of section Options and Accessories

The power to the live part connections on relay terminals must be disconnected. Do not mix live parts with control signals (PELV). Select the relay functions in 5-40 Function Relay [6-8], 5-41 On Delay, Relay [6-8] and 5-42 Off Delay, Relay [6-8].

NB! (Index [6] is relay 7, index [7] is relay 8, and index [8] is relay 9)
130BA177.10

130BA162.10

Relay 7

Relay 8

Relay 9

NC 1 2 3 4 5 6 7

NC 8

NC 9 10 11 12

8-

9m

2m

1 2

NC 4 5

NC NC 8 9 10 11 12

1 2

NC 4 5

NC NC 8 9 10 11 12

NC 4 5

NC NC 8 9 10 11 12

LIVE PART

LIVE PART

PELV

PELV

PELV

PELV

LIVE PART

LIVE PART

LIVE PART

WARNING
Do not combine low voltage parts and PELV systems. At a single fault the whole system might become dangerous to touch and it could result in death or serious injury.

52

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA176.10

130BA710.10

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

3.1.8 24 V Back-Up Option MCB 107 (Option D)

External 24V DC Supply An external 24V DC supply can be installed for low-voltage supply to the control card and any option card installed. This enables full operation of the LCP (including the parameter setting) and fieldbusses without mains supplied to the power section. External 24V DC supply specification: Input voltage range Max. input current Average input current for the frequency converter Max cable length Input capacitance load Power-up delay The inputs are protected. Terminal numbers: Terminal 35: - external 24V DC supply. Terminal 36: + external 24V DC supply. Follow these steps: 1. Remove the LCP or Blind Cover 3. 4. 5. 6. Remove the Cable De-coupling Plate and the plastic cover underneath Insert the 24V DC Backup External Supply Option in the Option Slot Mount the Cable De-coupling Plate Attach the Terminal Cover and the LCP or Blind Cover.
311

3 3

24V DC 15 % (max. 37 V in 10sec.) 2.2A 0.9A 75m < 10uF < 0.6sec.
130BA216.10
35 36
9 6

When MCB 107, 24V backup option is supplying the control circuit, the internal 24V supply is automatically disconnected.
130BA028.11

Illustration 3.5 Connection to 24V Backup Supplier (A5-C2).

35

36

3.1.9 Analog I/O option MCB 109

The Analog I/O card is supposed to be used in e.g. the following cases:

35 36

Providing battery back-up of clock function on control card As general extension of analog I/O selection available on control card, e.g. for multi-zone control with three pressure transmitters Turning frequency converter into de-central I/O block supporting Building Management System with inputs for sensors and outputs for operating dampers and valve actuators

Illustration 3.4 Connection to 24V Backup Supplier (A2-A3).

MG.11.BA.02 - VLT is a registered Danfoss trademark

2.

Remove the Terminal Cover

53

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

Support Extended PID controllers with I/Os for set point inputs, transmitter/sensor inputs and outputs for actuators.
130BA405.11

Analog I/O configuration 3 x Analog Inputs, capable of handling following:

CONTROL CARD (FREQUENCY CONVERTER) CPU 0V ANALOG I/O OPTION MCB 109 CAN BUS 24 VDC

OR

0 - 10V DC 0-20mA (voltage input 0-10V) by mounting a 510 resistor across terminals (see NB!) 4-20mA (voltage input 2-10V) by mounting a 510 resistor across terminals (see NB) Ni1000 temperature sensor of 1000 at 0 C. Specifications according to DIN43760 Pt1000 temperature sensor of 1000 at 0 C. Specifications according to IEC 60751

3 3

CPU

RTC

3V LITHIUM BATTERY

ANALOG INPUT

ANALOG OUTPUT GND

3 x Analog Outputs supplying 0-10V DC.

0-10 VDC

0-10 VDC

0-10 VDC

AOUT

AOUT

AOUT

AIN

AIN

AIN

10

11

12

NOTE
Please note the values available within the different standard groups of resistors: E12: Closest standard value is 470, creating an input of 449.9 and 8.997V. E24: Closest standard value is 510, creating an input of 486.4 and 9.728V. E48: Closest standard value is 511, creating an input of 487.3 and 9.746V. E96: Closest standard value is 523, creating an input of 498.2 and 9.964V. Analog inputs - terminal X42/1-6 Parameter group for read out: 18-3*. See also VLT HVAC Drive Programming Guide. Parameter groups for set-up: 26-0*, 26-1*, 26-2* and 26-3*. See also VLT HVAC Drive Programming Guide.

0-10 VDC

0-10 VDC

0-10 VDC < 1 mA < 1 mA < 1 mA

Pt1000/ Ni 1000

Illustration 3.6 Principle diagram for Analog I/O mounted in frequency converter.

3 x Analog inputs Used as temperature sensor input

Operating range -50 to +150C

Resolution 11 bits

Accuracy -50C 1 Kelvin +150C 2 Kelvin 0.2% of full scale at cal. temperature

Sampling 3Hz

Max load -

Impedance -

Used as voltage input

0 - 10V DC

10 bits

2.4Hz

+/- 20V continuously

Approximately 5k

When used for voltage, analog inputs are scalable by parameters for each input. When used for temperature sensor, analog inputs scaling is preset to necessary signal level for specified temperature span. When analog inputs are used for temperature sensors, it is possible to read out feedback value in both C and F.

When operating with temperature sensors, maximum cable length to connect sensors is 80m non-screened / nontwisted wires. Analog outputs - terminal X42/7-12 Parameter group for read out and write: 18-3*. See also VLT HVAC Drive Programming Guide Parameter groups for set-up: 26-4*, 26-5* and 26-6*. See also VLT HVAC Drive Programming Guide

54

MG.11.BA.02 - VLT is a registered Danfoss trademark

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

3 x Analog Output Resolution outputs signal level Volt 0-10V DC 11 bits

Linearity 1% of full scale

Max load 1mA

Real-time clock (RTC) with back-up The data format of RTC includes year, month, date, hour, minutes and weekday. Accuracy of clock is better than 20 ppm at 25 C.

Analog outputs are scalable by parameters for each output. The function assigned is selectable via a parameter and have same options as for analog outputs on control card. For a more detailed description of parameters, please refer to the VLT HVAC Drive Programming Guide. The built-in lithium back-up battery lasts on average for minimum 10 years, when frequency converter is operating at 40 C ambient temperature. If battery pack back-up fails, analog I/O option must be exchanged.

3 3

3.1.10 MCB 112 VLT PTC Thermistor Card

The MCB 112 option makes it possible to monitor the temperature of an electrical motor through a galvanically isolated PTC thermistor input. It is a B-option for FC 102 with Safe Stop. For information on mounting and installation of the option, please see Mounting of Option Modules in Slot B earlier in this section. See also chapter Application Examples for different application possibilities. X44/ 1 and X44/ 2 are the thermistor inputs, X44/ 12 will enable safe stop of the FC 102 (T-37) if the thermistor values make it necessary and X44/ 10 will inform the FC 102 that a request for Safe Stop came from the MCB 112 in order to ensure a suitable alarm handling. One of the Digital Inputs of the FC 102 (or a DI of a mounted option) must be set to PTC Card 1 [80] in order to use the information from X44/ 10. 5-19 Terminal 37 Safe Stop Terminal 37 Safe Stop must be configured to the desired Safe Stop functionality (default is Safe Stop Alarm).
MS 220 DA Motor protection MCB 112 PTC Thermistor Card ZIEHL 130BA638.10 com NC 11 20 DO FOR SAFE STOP T37 12 37

Option B Code No.130B1137 Reference for 10, 12 20-28 VDC 10 mA 20-28 VDC 60 mA

11 10 12 NC NC NC T1 X44 1 T2 2 3 4 5

NC

NC

NC

NC 9

12

13

18 19 27 29 32 33 Control Terminals of FC302

TP
PTC M3~

TP

ATEX Certification with The MCB 112 has been certified for ATEX which means that the FC 102 together with the MCB 112 can now be used with motors in potentially explosive atmospheres. See the Operating Instructions for the MCB 112 for more information.

ATmosphre EXplosive (ATEX)

MG.11.BA.02 - VLT is a registered Danfoss trademark

DO 10

55

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

3 3

Electrical Data Resistor connection: PTC compliant with DIN 44081 and DIN 44082 Number Shut-off value Reset value Trigger tolerance Collective resistance of the sensor loop Terminal voltage Sensor current Short circuit Power consumption Testing conditions: EN 60 947-8 Measurement voltage surge resistance Overvoltage category Degree of pollution Measurement isolation voltage Vbis Reliable galvanic isolation until Vi Perm. ambient temperature Moisture EMC resistance EMC emissions Vibration resistance Shock resistance Safety system values: EN 61508 for Tu = 75C ongoing SIL HFT PFD (for yearly functional test) SFF s + DD DU Ordering number 130B1137

1..6 resistors in series 3.3.... 3.65 ... 3.85 1.7 .... 1.8 ... 1.95 6C < 1.65 2.5V for R 3.65, 9V for R = 1mA 20 R 40 60 mA

6000V III 2 690V 500V -20C ... +60C EN 60068-2-1 Dry heat 5 --- 95%, no condensation permissible EN61000-6-2 EN61000-6-4 10 ... 1000Hz 1.14g 50g

2 for maintenance cycle of 2 years 1 for maintenance cycle of 3 years 0 4.10 *10-3 90% 8515 FIT 932 FIT

56

MG.11.BA.02 - VLT is a registered Danfoss trademark

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

3.1.11 Sensor Input Option MCB 114

The sensor input option card MCB 114 can be used in the following cases:

Sensor input for temperature transmitters PT100 and PT1000 for monitoring bearing temperatures As general extension of analog inputs with one additional input for multi-zone control or differential pressure measurements Support extended PID controllers with I/Os for set point, transmitter/sensor inputs

The option can generate an alarm if the measured temperature is either below low limit or above high limit specified by the user. The individual measured temperature on each sensor input can be read out in the display or by readout parameters. If an alarm occurs, the relays or digital outputs can be programmed to be active high by selecting [21] Thermal Warning in parameter group 5-**. A fault condition has a common warning/alarm number associated with it, which is Alarm/Warning 20, Temp. input error. Any present output can be programmed to be active in case the warning or alarm appears.

3 3

Typical motors, designed with temperature sensors for protecting bearings from being overloaded, are fitted with 3 PT100/1000 temperature sensors. One in front, one in the back end bearing, and one in the motor windings. The Danfoss Option MCB 114 supports 2- or 3-wire sensors with individual temperature limits for under/over temperature. An auto detection of sensor type, PT100 or PT1000 takes place at power up.

3.1.11.1 Ordering Code Numbers and Parts Delivered

Standard version code no: 130B1172. Coated version code no: 130B1272.

3.1.11.2 Electrical and Mechanical Specifications

Analog Input Number of analog inputs Format Wires Input impedance Sample rate 3rd order filter The option is able to supply the analog sensor with 24V DC (terminal 1). Temperature Sensor Input Number of analog inputs supporting PT100/1000 Signal type Connection Frequency PT100 and PT1000 input Resolution Temperature range: 1 0-20mA or 4-20mA 2 <200 1kHz 100Hz at 3dB

3 PT100/1000 PT 100 2 or 3 wire/PT1000 2 or 3 wire 1Hz for each channel 10 bit -50 - 204C -58 - 399F

Galvanic Isolation The sensors to be connected are expected to be galvanically isolated from the mains voltage level IEC 61800-5-1 and UL508C Cabling Maximum signal cable length

500m

MG.11.BA.02 - VLT is a registered Danfoss trademark

57

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

3.1.11.3 Electrical Wiring

Input voltage range 380V-440V 441V-490V 491V-550V

Tap to select 400V 460V 525V 575V 660V 690V

3 3
130BB326.10

MCB 114 Sensor Input

SW. ver. xx.xx
VDD I IN

Option B
Code No. 130B1272

551V-625V 626V-660V 661V-690V

GND TEMP WIRE GND TEMP WIRE GND TEMP WIRE GND 1 1 2 2 3 3

X48/ 1

9 10 11 12

4-20mA 2 or 3 wire

2 or 3 wire

2 or 3 wire

2 or 3 wire

NAMUR Terminals NAMUR is an international association of automation technology users in the process industries, primarily chemical and pharmaceutical industries in Germany. Selection of this option provides terminals organized and labeled to the specifications of the NAMUR standard for drive input and output terminals. This requires MCB 112 PTC Thermistor Card and MCB 113 Extended Relay Card. RCD (Residual Current Device) Uses the core balance method to monitor ground fault currents in grounded and high-resistance grounded systems (TN and TT systems in IEC terminology). There is a prewarning (50% of main alarm set-point) and a main alarm setpoint. Associated with each set-point is an SPDT alarm relay for external use. Requires an external window-type current transformer (supplied and installed by customer).

Terminal 1 2 3 4, 7, 10 5, 8, 11 6, 9, 12

Name VDD I in GND Temp 1, 2, 3 Wire 1, 2, 3 GND

Function 24V DC to supply 4-20mA sensor 4-20mA input Analog input GND Temperature input 3rd wire input if 3 wire sensors are used Temp. input GND

3.1.12 Frame Size F Panel Options

Space Heaters and Thermostat Mounted on the cabinet interior of frame size F frequency converters, space heaters controlled via automatic thermostat help control humidity inside the enclosure, extending the lifetime of drive components in damp environments. The thermostat default settings turn on the heaters at 10 C (50 F) and turn them off at 15.6 C (60 F). Cabinet Light with Power Outlet A light mounted on the cabinet interior of frame size F frequency converters increase visibility during servicing and maintenance. The housing the light includes a power outlet for temporarily powering tools or other devices, available in two voltages:

Integrated into the drives safe-stop circuit IEC 60755 Type B device monitors AC, pulsed DC, and pure DC ground fault currents LED bar graph indicator of the ground fault current level from 10100% of the set-point Fault memory TEST / RESET button

Insulation Resistance Monitor (IRM) Monitors the insulation resistance in ungrounded systems (IT systems in IEC terminology) between the system phase conductors and ground. There is an ohmic pre-warning and a main alarm set-point for the insulation level. Associated with each set-point is an SPDT alarm relay for external use. Note: only one insulation resistance monitor can be connected to each ungrounded (IT) system.

230V, 50Hz, 2.5A, CE/ENEC 120V, 60Hz, 5A, UL/cUL

Integrated into the drives safe-stop circuit LCD display of the ohmic value of the insulation resistance Fault Memory INFO, TEST, and RESET buttons

Transformer Tap Setup If the Cabinet Light & Outlet and/or the Space Heaters & Thermostat are installed Transformer T1 requires it taps to be set to the proper input voltage. A 380-480/ 500 V drive will initially be set to the 525 V tap and a 525-690 V drive will be set to the 690 V tap to insure no over-voltage of secondary equipment occurs if the tap is not changed prior to power being applied. See the table below to set the proper tap at terminal T1 located in the rectifier cabinet. For location in the drive, see illustration of rectifier in the Power Connections section.

IEC Emergency Stop with Pilz Safety Relay Includes a redundant 4-wire emergency-stop push-button mounted on the front of the enclosure and a Pilz relay that monitors it in conjunction with the drives safe-stop circuit and the mains contactor located in the options cabinet.

58

MG.11.BA.02 - VLT is a registered Danfoss trademark

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

Operation switch (on/off) Short-circuit and overload protection with test function Manual reset function 3-phase power matching incoming mains voltage for powering auxiliary customer equipment Not available if two manual motor starters are selected Terminals are off when the incoming power to the drive is off Power for the fused protected terminals will be provided from the load side of any supplied contactor, circuit breaker, or disconnect switch.

Panel cut out

30 Ampere, Fuse-Protected Terminals

3.1.13 Brake Resistors

In applications where the motor is used as a brake, energy is generated in the motor and send back into the frequency converter. If the energy can not be transported back to the motor it will increase the voltage in the converter DC-line. In applications with frequent braking and/or high inertia loads this increase may lead to an over voltage trip in the converter and finally a shut down. 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 variety of different resistors that are specially designed to our frequency converters. See the section Control with brake function for the dimensioning of brake resistors. Code numbers can be found in the section How to order.

3.1.14 Remote Mounting Kit for LCP

The LCP can be moved to the front of a cabinet by using the remote built-in kit. The enclosure is the IP66. The fastening screws must be tightened with a torque of max. 1Nm.
Technical data Enclosure: Max. cable length between and unit: Communication std: IP66 front 3m RS-485

MG.11.BA.02 - VLT is a registered Danfoss trademark

129,5 0.5 mm (5.1 0.04 in)

Manual Motor Starters Provide 3-phase power for electric blowers often required for larger motors. Power for the starters is provided from the load side of any supplied contactor, circuit breaker, or disconnect switch. Power is fused before each motor starter, and is off when the incoming power to the drive is off. Up to two starters are allowed (one if a 30A, fuse-protected circuit is ordered). Integrated into the drives safe-stop circuit. Unit features include:

Ma

(0 R2

.08

130BA139.11

64,5 0.5 mm (2.54 0.04 in)

Min 72(2.8)

3 3

59

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

Ordering no. 130B1113

130BA138.10

Ordering no. 130B1114

130BA200.10

3 3

Illustration 3.7 LCP Kit with Graphical LCP, Fasteners, 3m Cable and Gasket. LCP Kit without LCP is also available. Ordering number: 130B1117 For IP55 units the ordering number is 130B1129.

Illustration 3.8 LCP Kit with Numerical LCP, Fastenes and Gasket.

3.1.15 IP21/IP41/ TYPE 1 Enclosure Kit

IP 21/IP 41 top/ TYPE 1 is an optional enclosure element available for IP20 Compact units, enclosure size A2-A3, B3+B4 and C3+C4. If the enclosure kit is used, an IP20 unit is upgraded to comply with enclosure IP21/ 41 top/TYPE 1. The IP41 top can be applied to all standard IP20 VLT HVAC Drive variants.

60

MG.11.BA.02 - VLT is a registered Danfoss trademark

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

A Top cover B Brim C Base part D Base cover E Screw(s) Place the top cover as shown. If an A or B option is used the brim must be fitted to cover the top inlet. Place the base part C at the bottom of the drive and use the clamps from the accessory bag to correctly fasten the cables. Holes for cable glands: Size A2: 2x M25 and 3xM32 Size A3: 3xM25 and 3xM32

130BT323.10

130BT324.10

3 3

D
D

E
E

A2 Enclosure
130BB045.10

A3 Enclosure
130BB044.10 A

Dimensions Enclosure type A2 A3 B3 B4 C3 C4 Height (mm) A 372 372 475 670 755 950 Width (mm) B 90 130 165 255 329 391 Depth (mm) C* 205 205 249 246 337 337

B C

B C

* If option A/B is used, the depth will increase (see section Mechanical Dimensions for details)

A2, A3, B3

B4, C3, C4

MG.11.BA.02 - VLT is a registered Danfoss trademark

61

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

3 3

A Top cover B Brim C Base part D Base cover E Screw(s) F - Fan cover G - Top clip When option module A and/or option module B is/are used, the brim (B) must be fitted to the top cover (A).

130BT620.12

A B

Autom

VLT ati

on Drive

Automa tionDriv e

VLT

D F

B3 Enclosure

B4 - C3 - C4 Enclosure

NOTE
Side-by-side installation is not possible when using the IP 21/ IP 4X/ TYPE 1 Enclosure Kit

62

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BT621.12

VLT HVAC Drive Selection

VLT HVAC Drive Design Guide

3.1.16 Output Filters

The high speed switching of the frequency converter produces some secondary effects, which influence the motor and the enclosed environment. These side effects are addressed by two different filter types, the du/dt and the Sine-wave filter. dU/dt filters Motor insulation stresses are often caused by the combination of rapid voltage and current increase. The rapid energy changes can also be reflected back to the DC-line in the inverter and cause shut down. The du/dt filter is designed to reduce the voltage rise time/the rapid energy change in the motor and by that intervention avoid premature aging and flashover in the motor insulation. du/dt filters have a positive influence on the radiation of magnetic noise in the cable that connects the drive to the motor. The voltage wave form is still pulse shaped but the du/dt ratio is reduced in comparison with the installation without filter. Sine-wave filters Sine-wave filters are designed to let only low frequencies pass. High frequencies are consequently shunted away which results in a sinusoidal phase to phase voltage waveform and sinusoidal current waveforms. With the sinusoidal waveforms the use of special frequency converter motors with reinforced insulation is no longer needed. The acoustic noise from the motor is also damped as a consequence of the wave condition. Besides the features of the du/dt filter, the sine-wave filter also reduces insulation stress and bearing currents in the motor thus leading to prolonged motor lifetime and longer periods between services. 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.

3 3

MG.11.BA.02 - VLT is a registered Danfoss trademark

63

How to Order

VLT HVAC Drive Design Guide

4 How to Order
Example of Drive Configurator interface set-up: The numbers shown in the boxes refer to the letter/figure number of the Type Code String - read from left to right.
Product groups Power rating Phases Mains Voltage Enclosure Enclosure type Enclosure class Control supply voltage Hardware configuration RFI filter 16-17 18 19 20 21 22 23 24-27 28 29-30 31-32 33-34 35 36-37 38-39 Brake Display (LCP) Coating PCB Mains option Adaptation A Adaptation B Software release Software language A options B options C0 options, MCO C1 options C option software D options 1-3 8-10 11 12 13-15

4.1 Ordering Form 4.1.1 Drive Configurator

It is possible to design a frequency converter according to the application requirements by using the ordering number system. Order the frequency converter as either standard or with integral options by sending a type code string describing the product a to the local Danfoss sales office, i.e.: FC-102P18KT4E21H1XGCXXXSXXXXAGBKCXXXXDX The meaning of the characters in the string can be located in the pages containing the ordering numbers in the chapter How to Select Your VLT. In the example above, a Profibus LON works option and a General purpose I/O option is included in the frequency converter. Ordering numbers for frequency converter standard variants can also be located in the chapter How to Select Your VLT. From the Internet based Drive Configurator, you can configure the right frequency converter for the right application and generate the type code string. 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. The Drive Configurator can be found on the global Internet site: www.danfoss.com/drives.

4 4

frequency converter series 4-6

64

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Order

VLT HVAC Drive Design Guide

4.1.2 Type Code String low and medium power

F C 0 P T H X X S X X X X A B C D 130BA052.14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Description
Product group & FC Series Power rating Number of phases

Pos
1-6 8-10 11

Possible choice
FC 102 1.1- 90 kW (P1K1 - P90K) Three phases (T) T T T T 2: 4: 6: 7: 200-240 V AC 380-480 V AC 525-600 VAC 525-690V AC

Description
Adaptation Adaptation Software release Software language

Pos
22 23 24-27 28

Possible choice
X: Standard 0: European metric thread in cable entries. Reserved Actual software AX: No options A0: MCA 101 Profibus DP V1 A4: MCA 104 DeviceNet AG: MCA 108 Lonworks AJ: MCA 109 BACnet gateway AL: MCA 120 Profinet AN: MCA 121 EtherNet/IP AQ: MCA 122 Modbus TCP BX: No option BK: MCB 101 General purpose I/O option BP: MCB 105 Relay option BO: MCB 109 Analog I/O option B2: MCB 112 PTC Thermistor Card B4: MCB 114 Sensor input option CX: No options X: No options XX: Standard software DX: No option D0: DC back-up

4 4

Mains voltage

11-12

Enclosure

13-15

E20: IP20 E21: IP21/NEMA Type 1 E55: IP55/NEMA Type 12 E66: IP66 P21: IP21/NEMA Type 1 w/ backplate P55: IP55/NEMA Type 12 w/ backplate Z55: A4 Frame IP55 Z66: A4 Frame IP66 H1: RFI filter class A1/B H2: RFI filter class A2 H3: RFI filter class A1/B (reduced cable length) Hx: No RFI filter X: No brake chopper included B: Brake chopper included T: Safe Stop U: Safe + brake G: Graphical Local Control Panel (GLCP) N: Numeric Local Control Panel (NLCP) X: No Local Control Panel X. No coated PCB C: Coated PCB X: No Mains disconnect switch and Load Sharing 1: With Mains disconnect switch (IP55 only) 8: Mains disconnect and Load Sharing D: Load Sharing See Chapter 8 for max. cable sizes.

A options

29-30

B options

31-32

RFI filter

16-17

Brake

18

C0 options MCO C1 options C option software D options

33-34 35 36-37 38-39

Display

19

Table 4.1 Type Code Description.

Coating PCB

20

Mains option

21

The various Options and Accessories are described further in the VLT HVAC Drive Design Guide, MG.11.BX.YY.

MG.11.BA.02 - VLT is a registered Danfoss trademark

65

How to Order

VLT HVAC Drive Design Guide

4.1.3 Type Code String High Power

Ordering type code frame sizes D and E Description Product group+series Power rating Phases Mains voltage Enclosure Pos 1-6 8-10 11 11-12 13-15 Possible choice FC 102 45-560 kW Three phases (T) T 4: 380-500 VAC T 7: 525-690 VAC E00: IP00/Chassis C00: IP00/Chassis w/ stainless steel back channel E0D: IP00/Chassis, D3 P37K-P75K, T7 C0D: IP00/Chassis w/ stainless steel back channel, D3 P37K-P75K, T7 E21: IP 21/ NEMA Type 1 E54: IP 54/ NEMA Type 12 E2D: IP 21/ NEMA Type 1, D1 P37K-P75K, T7 E5D: IP 54/ NEMA Type 12, D1 P37K-P75K, T7 E2M: IP 21/ NEMA Type 1 with mains shield E5M: IP 54/ NEMA Type 12 with mains shield RFI filter 16-17 H2: RFI filter, class A2 (standard) H4: RFI filter class A11) H6: RFI filter Maritime use2) Brake 18 B: Brake IGBT mounted X: No brake IGBT R: Regeneration terminals (E frames only) G: Graphical Local Control Panel LCP N: Numerical Local Control Panel (LCP) X: No Local Control Panel (D frames IP00 and IP 21 only) C: Coated PCB X. No coated PCB (D frames 380-480/500 V only) X: No mains option 3: Mains disconnect and Fuse 5: Mains disconnect, Fuse and Load sharing 7: Fuse A: Fuse and Load sharing D: Load sharing Adaptation Adaptation Software release Software language A options 22 23 24-27 28 29-30 AX: No options A0: MCA 101 Profibus DP V1 A4: MCA 104 DeviceNet BX: No option BK: MCB 101 General purpose I/O option BP: MCB 105 Relay option BO: MCB 109 Analog I/O option B2: MCB 112 PTC Thermistor Card B4: MCB 114 Sensor input option CX: No options X: No options XX: Standard software DX: No option D0: DC backup Reserved Reserved Actual software

4 4

Display

19

Coating PCB Mains option

20 21

B options

31-32

C0 options C1 options C option software D options

33-34 35 36-37 38-39

The various options are described further in this Design Guide. 1): Available for all D frames. E frames 380-480/500 VAC only 2) Consult factory for applications requiring maritime certification 66 MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Order

VLT HVAC Drive Design Guide

Ordering type code frame size F

Description Pos Possible choice

Product group Drive series Power rating Phases Mains voltage Enclosure

1-3 4-6 8-10 11 1112 1315 500 - 1400 kW Three phases (T) T 5: 380-500 VAC T 7: 525-690 VAC E21: IP 21/ NEMA Type 1 E54: IP 54/ NEMA Type 12 L2X: IP21/NEMA 1 with cabinet light & IEC 230V power outlet L5X: IP54/NEMA 12 with cabinet light & IEC 230V power outlet L2A: IP21/NEMA 1 with cabinet light & NAM 115V power outlet L5A: IP54/NEMA 12 with cabinet light & NAM 115V power outlet H21: IP21 with space heater and thermostat H54: IP54 with space heater and thermostat R2X: IP21/NEMA1 with space heater, thermostat, light & IEC 230V outlet R5X: IP54/NEMA12 with space heater, thermostat, light & IEC 230V outlet R2A: IP21/NEMA1 with space heater, thermostat, light, & NAM 115V outlet R5A: IP54/NEMA12 with space heater, thermostat, light, & NAM 115V outlet H2: RFI filter, class A2 (standard) H4: RFI filter, class A12, 3) HE: RCD with Class A2 RFI filter2) HF: RCD with class A1 RFI filter2, 3) HG: IRM with Class A2 RFI filter2) HH: IRM with class A1 RFI filter2, 3) HJ: NAMUR terminals and class A2 RFI filter1) HK: NAMUR terminals with class A1 RFI filter1, 2, 3) HL: RCD with NAMUR terminals and class A2 RFI filter1, 2) HM: RCD with NAMUR terminals and class A1 RFI filter1, 2, 3) HN: IRM with NAMUR terminals and class A2 RFI filter1, 2) HP: IRM with NAMUR terminals and class A1 RFI filter1, 2, 3)

4 4

RFI filter

1617

Brake

18

B: Brake IGBT mounted X: No brake IGBT R: Regeneration terminals M: IEC Emergency stop push-button (with Pilz safety relay)4) N: IEC Emergency stop push-button with brake IGBT and brake terminals P: IEC Emergency stop push-button with regeneration terminals4)
4)

Display Coating PCB Mains option

19 20 21

G: Graphical Local Control Panel LCP C: Coated PCB X: No mains option 32): Mains disconnect and Fuse 52): Mains disconnect, Fuse and Load sharing 7: Fuse A: Fuse and Load sharing D: Load sharing E: Mains disconnect, contactor & fuses2) F: Mains circuit breaker, contactor & fuses
2)

G: Mains disconnect, contactor, loadsharing terminals & fuses2) H: Mains circuit breaker, contactor, loadsharing terminals & fuses2) J: Mains circuit breaker & fuses
2) 2)

K: Mains circuit breaker, loadsharing terminals & fuses

MG.11.BA.02 - VLT is a registered Danfoss trademark

67

How to Order

VLT HVAC Drive Design Guide

Ordering type code frame size F

A options 29-30 AX: No options A0: MCA 101 Profibus DP V1 A4: MCA 104 DeviceNet AG: MCA 108 Lonworks AJ: MCA 109 BACnet Gateway AL: MCA 120 Profinet AN: MCA 121 Ethernet/IP BX: No option BK: MCB 101 General purpose I/O option BP: MCB 105 Relay option BO: MCB 109 Analog I/O option CX: No options X: No options XX: Standard software DX: No option D0: DC backup

4 4

B options

31-32

C0 options C1 options C option software D options

33-34 35 36-37 38-39

The various options are described further in this Design Guide.

68

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Order

VLT HVAC Drive Design Guide

4.2 Ordering Numbers 4.2.1 Ordering Numbers: Options and Accessories

Type Description Ordering no.
130B1064 130B1122 130B1123

Type

Description

Ordering no.

Miscellaneous hardware I
DC link connector IP 21/4X top/ TYPE 1 kit IP 21/4X top/ TYPE 1 kit IP 21/4X top/ TYPE 1 kit IP 21/4X top/ TYPE 1 kit IP 21/4X top/ TYPE 1 kit IP 21/4X top/ TYPE 1 kit IP21/4X top IP21/4X top IP 21/4X top IP 21/4X top IP 21/4X top IP 21/4X top Panel Through Mount Kit Panel Through Mount Kit Panel Through Mount Kit Panel Through Mount Kit Panel Through Mount Kit Terminal block for DC link connnection on A2/A3 IP21/NEMA1 Top + bottom A2 IP21/NEMA1 Top + bottom A3 IP21/NEMA1 Top + bottom B3 130B1187 IP21/NEMA1 Top + bottom B4 130B1189 IP21/NEMA1 Top + bottom C3 130B1191 IP21/NEMA1 Top + bottom C4 130B1193 IP21 Top Cover A2 IP21 Top Cover A3 IP21 Top Cover B3 IP21 Top Cover B4 IP21 Top Cover C3 IP21 Top Cover C4 Enclosure, frame size A5 Enclosure, frame size B1 Enclosure, frame size B2 Enclosure, frame size C1 Enclosure, frame size C2 130B1132 130B1133 130B1188 130B1190 130B1192 130B1194 130B1028 130B1046 130B1047 130B1048

Miscellaneous hardware I
Terminal blocks Screw terminal blocks for replacing spring loaded terminals 1 pc 10 pin 1 pc 6 pin and 1 pc 3 pin connectors 130B1116 Backplate Backplate Backplate Backplate Backplate Backplate Backplate Backplate Backplate Backplate LCPs and kits LCP 101 LCP 102 LCP cable LCP kit Numerical Local Control Panel (NLCP) Separate LCP cable, 3 m Panel mounting kit including graphical LCP, fasteners, 3 m cable and gasket 130B1124 A5 IP55 / NEMA 12 B1 IP21 / IP55 / NEMA 12 B2 IP21 / IP55 / NEMA 12 C1 IP21 / IP55 / NEMA 12 C2 IP21 / IP55 / NEMA 12 A5 IP66 B1 IP66 B2 IP66 C1 IP66 C2 IP66 130B1098 130B3383 130B3397 130B3910 130B3911 130B3242 130B3434 130B3465 130B3468 130B3491

4 4

Graphical Local Control Panel (GLCP) 130B1107 175Z0929 130B1113

LCP kit LCP kit

Panel mounting kit including 130B1114 numerical LCP, fasteners and gasket Panel mounting kit for all LCPs including fasteners, 3 m cable and gasket Panel mounting kit for all LCPs including fasteners and gasket without cable 130B1117

LCPkit 130B1049 130B1112 LCP kit

Front mounting kit, IP55 enclosures 130B1129 130B1170

Profibus D-Sub Connector kit for IP20 9 Profibus top entry kit

Top entry kit for Profibus connection 176F1742 - D + E enclosures

Table 4.2 Options can be ordered as factory built-in options, see ordering information.

MG.11.BA.02 - VLT is a registered Danfoss trademark

69

How to Order

VLT HVAC Drive Design Guide

Type Options for Slot A MCA 101 MCA 104 MCA 108 MCA 109 MCA 120 MCA 121 MCA 122 Options for Slot B MCB 101 MCB 105 MCB 109 MCB 112 MCB 114 Option for Slot D MCB 107 External Options Ethernet IP

Description

Comments Ordering no. Coated

Profibus option DP V0/V1 DeviceNet option Lonworks BACnet gateway for build-in. Not to be used with Relay Option MCB 105 card Profinet Ethernet Modbus TCP General purpose Input Output option Relay option Analog I/O option and battery back-up for real-time clock ATEX PTC Sensor input - unocated Sensor input - coated 24 V DC back-up Ethernet master

130B1200 130B1202 130B1206 130B1244 130B1135 130B1219 130B1119

4 4

130B1243 130B1137 130B1172 130B1272 130B1208

For information on fieldbus and application option compatibility with older software versions, please contact your Danfoss supplier.

70

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Order

VLT HVAC Drive Design Guide

Type Spare Parts Control board FC Control board FC Fan A2 Fan A3 Fan A5 Fan B1 Fan B2 Fan B3 Fan B4 Fan B4 Fan C1 Fan C2 Fan C3 Fan C4 Miscellaneous hardware II Accessory bag A2 Accessory bag A3 Accessory bag A5 Accessory bag B1 Accessory bag B2 Accessory bag B3 Accessory bag B4 Accessory bag B4 Accessory bag C1 Accessory bag C2 Accessory bag C3 Accessory bag C4 Accessory bag C4

Description Ordering no. With Safe Stop Function Without Safe Stop Function Fan, frame size A2 Fan, frame size A3 Fan, frame size A5 Fan external, frame size B1 Fan external, frame size B2 Fan external, frame size B3 Fan external, 18.5/22 kW Fan external 22/30 kW Fan external, frame size C1 Fan external, frame size C2 Fan external, frame size C3 Fan external, frame size C4 Accessory bag, frame size A2 Accessory bag, frame size A3 Accessory bag, frame size A5 Accessory bag, frame size B1 Accessory bag, frame size B2 Accessory bag, frame size B3 Accessory bag, frame size B4 Accessory bag, frame size B4 Accessory bag, frame size C1 Accessory bag, frame size C2 Accessory bag, frame size C3 Accessory bag, frame size C4 Accessory bag, frame size C4 130B1150 130B1151 130B1009 130B1010 130B1017 130B3407 130B3406 130B3563 130B3699 130B3701 130B3865 130B3867 130B4292 130B4294 130B1022 130B1022 130B1023 130B2060 130B2061 130B0980 130B1300 130B1301 130B0046 130B0047 130B0981 130B0982 130B0983 Small Big Small Big Comments

4 4

MG.11.BA.02 - VLT is a registered Danfoss trademark

71

How to Order

VLT HVAC Drive Design Guide

4.2.2 Ordering Numbers: High Power Kits

Kit NEMA-3R (Rittal Enclosures) Description D3 Frame D4 Frame E2 Frame NEMA-3R (Welded Enclosures) D3 Frame D4 Frame E2 Frame Pedestal Back Channel Duct Kit (Top & Bottom) D Frames D3 1800mm D4 1800mm D3 2000mm D4 2000mm E2 2000mm E2 2200mm Back Channel Duct Kit (Top Only) IP00 Top & Bottom Covers (Welded Enclosures) IP00 Top & Bottom Covers (Rittal Enclosures) IP00 Motor Cable Clamp D3/D4 Frames E2 Frame D3/D4 Frames E2 Frame D3 Frames D4 Frames E2 Frame D3 Frame D4 Frame E2 Frame IP00 Terminal Cover Mains Shield Input Plates Loadshare Top Entry Sub D or Shield Termination IP00 to IP20 Kits USB Extension Kit D3/D4 Frame D1/D2 Frames E1 Frame See Instr D1/D3 Frame D2/D4 Frame D3/D4/E2 Frames D3/D4 Frames E2 Frames D Frames E Frames F Frames 176F8456 176F8455 176F1742 176F1779 176FXXXX 130B1155 130B1156 176F1784 175R5964 175R1108 175R1108 177R0091 177R0091 177R0091 Ordering Number 176F4600 176F4601 176F1852 176F0296 176F0295 176F0298 176F1827 176F1824 176F1823 176F1826 176F1825 176F1850 176F0299 176F1775 176F1776 176F1862 176F1861 176F1781 176F1782 176F1783 176F1774 176F1746 176F1745 176F1779 176F0799 176F1851 175R5795 175R5637 175R1108 175R5923 175R1109 175R0076 175R1106 175R1107 175R5642 175R5640 175R1068 Instruction Number 175R5922

4 4

4.2.3 Ordering Numbers: Harmonic Filters

Harmonic filters are used to reduce mains harmonics.

AHF 010: 10% current distortion AHF 005: 5% current distortion

72

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Order

VLT HVAC Drive Design Guide

380-415 VAC, 50 Hz IAHF,N [A] 10 19 26 35 43 72 101 144 180 217 289 324 370 506 578 648 694 740 380 - 415 VAC, 60 Hz IAHF,N [A] 10 19 26 35 43 72 101 144 180 217 289 324 370 506 578 648 694 740 Typical Motor Used [HP] 1.1 - 4 5.5 - 7.5 11 15 - 18.5 22 30 - 37 45 - 55 75 90 110 132 160 200 250 315 355 400 450 Danfoss Ordering Number AHF 005 130B2540 130B2460 130B2461 130B2462 130B2463 130B2464 130B2465 130B2466 130B2467 130B2468 130B2469 130B2470 130B2471 130B2468 + 130B2469 2x 130B2469 2x130B2470 130B2470 + 130B2471 2x130B2471 AHF 010 130B2541 130B2472 130B2473 130B2474 130B2475 130B2476 130B2477 130B2478 130B2479 130B2480 130B2481 130B2482 130B2483 130B2480 + 130B2481 2x 130B2481 2x130B2482 130B2482 + 130B2483 130B2483 Frequency Converter Size P1K1 - P4K0 P5K5 - P7K5 P11K P15K, P18K P22K P30K - P37K P45K - P55K P75K P90K P110 P132 P160 P200 P250 P315 P355 P400 P450 Typical Motor Used [kW] 1.1 - 4 5.5 - 7.5 11 15 - 18.5 22 30 - 37 45 - 55 75 90 110 132 160 200 250 315 355 400 450 Danfoss Ordering Number AHF 005 175G6600 175G6601 175G6602 175G6603 175G6604 175G6605 175G6606 175G6607 175G6608 175G6609 175G6610 175G6611 175G6688 175G6609 + 175G6610 2x 175G6610 2x175G6611 175G6611 + 175G6688 2x175G6688 AHF 010 175G6622 175G6623 175G6624 175G6625 175G6626 175G6627 175G6628 175G6629 175G6630 175G6631 175G6632 175G6633 175G6691 175G6631 + 175G6632 2x 175G6632 2x175G6633 175G6633 + 175G6691 2x175G6691 P200 P250 P315 P355 P400 P450 Frequency ConverterSize P1K1, P4K0 P5K5 - P7K5 P11K P15K - P18K P22K P30K - P37K P45K - P55K P75K P90K P110 P132 - P160

4 4

MG.11.BA.02 - VLT is a registered Danfoss trademark

73

How to Order

VLT HVAC Drive Design Guide

440-480 VAC, 60 Hz IAHF,N [A] 10 19 26 35 43 72 101 144 180 217 289 370 434 506 578 648 694 740 Typical Motor Used [HP] 1.5 - 7.5 10 - 15 20 25 - 30 40 50 - 60 75 100 - 125 150 200 250 350 350 450 500 550-600 600 650 Danfoss Ordering Number AHF 005 130B2538 175G6612 175G6613 175G6614 175G6615 175G6616 175G6617 175G6618 175G6619 175G6620 175G6621 175G6690 2x175G6620 175G6620 + 175G6621 2x 175G6621 2x175G6689 175G6689 + 175G6690 2x175G6690 AHF 010 130B2539 175G6634 175G6635 175G6636 175G6637 175G6638 175G6639 175G6640 175G6641 175G6642 175G6643 175G6693 2x175G6642 175G6642 + 175G6643 2x 175G6643 2x175G6692 175G6692 + 175G6693 2x175G6693 Frequency Converter Size P1K1 - P5K5 P7K5 - P11K P15K P18K - P22K P30K P37K - P45K P55K P75K - P90K P110 P132 P160 P200 P250 P315 P355 P400 P450 P500

4 4

Matching the frequency converter and filter is pre-calculated based on 400V/480V and on a typical motor load (4 pole) and 110 % torque.
500-525 VAC, 50 Hz IAHF,N [A] 10 19 26 35 43 72 101 144 180 217 289 324 397 434 506 578 613 Typical Motor Used [kW] 1.1 - 7.5 11 15 -18.5 22 30 37 -45 55 75 - 90 110 132 160 - 200 250 315 355 400 450 500 Danfoss Ordering Number AHF 005 175G6644 175G6645 175G6646 175G6647 175G6648 175G6649 175G6650 175G6651 175G6652 175G6653 175G6654 175G6655 175G6652 + 175G6653 2x175G6653 175G6653 + 175G6654 2X 175G6654 175G6654 + 175G6655 AHF 010 175G6656 175G6657 175G6658 175G6659 175G6660 175G6661 175G6662 175G6663 175G6664 175G6665 175G6666 175G6667 175G6641 + 175G6665 2x175G6665 175G6665 + 175G6666 2X 175G6666 175G6666 + 175G6667 Frequency Converter Size P1K1 - P7K5 P11K P15K - P18K P22K P30K P45K - P55K P75K P90K - P110 P132 P160 P200 - P250 P315 P400 P450 P500 P560 P630

74

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Order

VLT HVAC Drive Design Guide

690 VAC, 50 Hz IAHF,N [A] 43 72 101 144 180 217 288 324 397 434 505 576 612 730 Typical Motor Used [kW] 45 45 - 55 75 - 90 110 132 160 200 - 250 315 400 450 500 560 630 710 Danfoss Ordering Number AHF 005 130B2328 130B2330 130B2331 130B2333 130B2334 130B2335 2x130B2333 130B2334 + 130B2335 130B2334 + 130B2335 2x130B2335 * * * * AHF 010 130B2293 130B2295 130B2296 130B2298 130B2299 130B2300 130B2301 130B2302 130B2299 + 130B2300 2x130B2300 130B2300 + 130B2301 2x130B2301 130B2301 + 130B2300 2x130B2302 P37K - P45K P55K - P75K P90K - P110 P132 P160 P200 - P250 P315 P400 P450 P500 P560 P630 P710 Frequency Converter Size

4 4

Table 4.3 * For higher currents, please contact Danfoss.

MG.11.BA.02 - VLT is a registered Danfoss trademark

75

How to Order

VLT HVAC Drive Design Guide

4.2.4 Ordering Numbers: Sine Wave Filter Modules, 200-500 VAC

Mains supply 3 x 200 to 480 [VAC] Frequency Converter Size Minimum switching frequency [kHz] 200-240 [VAC] 380-440 [VAC] 440-480 [VAC] P1K1 P1K5 P2K2 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K P110 P132 P160 P200 P250 P315 P355 P400 P450 P500 P560 P630 P710 P800 P1M0 P11K P15K P18K P22K P30K P37K P55K P75K P90K P110 P132 P160 P200 P250 P315 P315 P355 P400 P450 P500 P560 P630 P710 P800 P1M0 P3K0 P4K0 P5K5 P7K5 P1K1 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 5 5 5 5 5 5 5 5 4 4 4 4 3 3 3 3 3 3 3 3 3 3 3 2 2 2 2 2 2 2 2 2 2 2 Maximum output frequency [Hz] 120 120 120 120 120 120 120 120 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 Rated filter current at 50 Hz [A] 4.5 4.5 8 8 10 17 17 17 24 38 38 48 62 75 115 115 180 180 260 260 410 410 480 660 660 750 750 880 880 1200 1200 1500 1500 1700

Part No. IP20 130B2441 130B2441 130B2443 130B2443 130B2444 130B2446 130B2446 130B2446 130B2447 130B2448 130B2448 130B2307 130B2308 130B2309 130B2310 130B2310 130B2311 130B2311 130B2312 130B2313 130B2313 130B2314 130B2314 130B2315 130B2315 130B2316 130B2316 130B2317 130B2317 130B2318 130B2318 2x130B2317 2x130B2317 2x130B2318

Part No. IP00 130B2406 130B2406 130B2408 130B2408 130B2409 130B2411 130B2411 130B2411 130B2412 130B2413 130B2413 130B2281 130B2282 130B2283 130B2284 130B2284 130B2285 130B2285 130B2286 130B2287 130B2287 130B2288 130B2288 130B2289 130B2289 130B2290 130B2290 130B2291 130B2291 130B2292 130B2292 2x130B2291 2x130B2291 2x130B2292

4 4

When using Sine-wave filters, the switching frequency should comply with filter specifications in 14-01 Switching Frequency.

NOTE
See also Output Filter Design Guide, MG.90.Nx.yy

76

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Order

VLT HVAC Drive Design Guide

4.2.5 Ordering Numbers: Sine-Wave Filter Modules, 525-600/690 VAC

Mains supply 3 x 525 to 690[V AC] Frequency Converter Size 525-600 [VAC] P1K1 P1K5 P2k2 P3K0 P4K0 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K P45K P55K P75K P90K P110 P132 P160 P200 P250 P315 P355 P400 P450 P500 P560 P630 P710 P800 P900 P1M0 P1M2 P1M4 690 [VAC] Minimum switching frequency [kHz] 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 Maximum output frequency [Hz] 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 Rated filter current at 50 Hz [A] 13 13 13 13 13 13 13 28 28 28 28 45 76 76 115 115 165 165 260 260 303 430 430 430 530 530 660 660 765 940 940 1320 1320 1479

Part No. IP20 130B2341 130B2341 130B2341 130B2341 130B2341 130B2341 130B2341 130B2342 130B2342 130B2342 130B2342 130B2343 130B2344 130B2344 130B2345 130B2345 130B2346 130B2346 130B2347 130B2347 130B2348 130B2370 130B2370 130B2370 130B2371 130B2371 130B2381 130B2381 130B2382 130B2383 130B2383 130B2384 130B2384 2x130B2382

Part No. IP00 130B2321 130B2321 130B2321 130B2321 130B2321 130B2321 130B2321 130B2322 130B2322 130B2322 130B2322 130B2323 130B2324 130B2324 130B2325 130B2325 130B2326 130B2326 130B2327 130B2327 130B2329 130B2341 130B2341 130B2341 130B2342 130B2342 130B2337 130B2337 130B2338 130B2339 130B2339 130B2340 130B2340 2x130B2338

4 4

NOTE
When using Sine-wave filters, the switching frequency should comply with filter specifications in 14-01 Switching Frequency.

NOTE
See also Output Filter Design Guide, MG.90.Nx.yy

MG.11.BA.02 - VLT is a registered Danfoss trademark

77

How to Order

VLT HVAC Drive Design Guide

4.2.6 Ordering Numbers: dU/dt Filters, 380-480V AC

Mains supply 3x380 to 3x480V AC
Frequency Converter Size 380-439[VAC] 440-480 [VAC] P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K P110 P132 P160 P200 P250 P315 P355 P400 P450 P500 P560 P630 P710 P800 P1M0 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K P110 P132 P160 P200 P250 P315 P355 P400 P450 P500 P560 P630 P710 P800 P1M0 Minimum switching frequency [kHz] 4 4 4 4 3 3 3 3 3 3 3 3 3 3 3 2 2 2 2 2 2 2 2 2 2 2 Maximum output frequency [Hz] 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 Part No. IP20 Part No. IP00 130B2396 130B2397 130B2397 130B2397 130B2398 130B2398 130B2399 130B2399 130B2400 130B2400 130B2401 130B2401 130B2402 130B2402 130B2277 130B2278 130B2278 130B2278 130B2278 130B2405 130B2405 130B2407 130B2407 130B2407 130B2407 130B2410 130B2385 130B2386 130B2386 130B2386 130B2387 130B2387 130B2388 130B2388 130B2389 130B2389 130B2390 130B2390 130B2391 130B2391 130B2275 130B2276 130B2276 130B2276 130B2276 130B2393 130B2393 130B2394 130B2394 130B2394 130B2394 130B2395 Rated filter current at 50 Hz [A] 24 45 45 45 75 75 110 110 182 182 280 280 400 400 500 750 750 750 750 910 910 1500 1500 1500 1500 2300

4 4

NOTE
See also Output Filter Design Guide, MG.90.Nx.yy

78

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Order

VLT HVAC Drive Design Guide

4.2.7 Ordering Numbers: dU/dt Filters, 525-600/690V AC

Frequency Converter Size 525-600[V AC] 690[V AC] P1K1 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K P45K P55K P75K P90K P110 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630 P710 P800 P900 P1M0 P1M2 P1M4 Minimum switching frequency [kHz] 4 4 4 4 4 4 3 3 3 3 3 3 3 3 3 3 3 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Maximum output frequency [Hz] 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 Part No. IP20 Part No. IP00 130B2423 130B2423 130B2423 130B2423 130B2424 130B2424 130B2425 130B2425 130B2426 130B2426 130B2427 130B2427 130B2425 130B2425 130B2426 130B2426 130B2427 130B2427 130B2428 130B2428 130B2429 130B2238 130B2238 130B2239 130B2239 130B2274 130B2274 130B2430 130B2431 130B2431 130B2431 130B2431 2x130B2430 130B2414 130B2414 130B2414 130B2414 130B2415 130B2415 130B2416 130B2416 130B2417 130B2417 130B2418 130B2418 130B2416 130B2416 130B2417 130B2417 130B2418 130B2418 130B2419 130B2419 130B2420 130B2235 130B2235 130B2236 130B2236 130B2280 130B2280 130B2421 130B2422 130B2422 130B2422 130B2422 2x130B2421 Rated filter current at 50 Hz [A] 28 28 28 28 45 45 75 75 115 115 165 165 75 75 115 115 165 165 260 260 310 430 430 530 530 630 630 765 1350 1350 1350 1350 1530

4 4

NOTE
See also Output Filter Design Guide, MG.90.Nx.yy

4.2.8 Ordering numbers: Brake resistors

NOTE
See Brake Resistor Design Guide, MG.90.Ox.yy

MG.11.BA.02 - VLT is a registered Danfoss trademark

79

How to Install

VLT HVAC Drive Design Guide

5 How to Install

5.1 Mechanical Installation 5.1.1 Mechanical Front Views

A2
130BA809.10

A3
130BA810.10

A4
130BB458.10

A5
130BA811.10

B1
130BA812.10

B2
130BA813.10

5 5

IP20/21*

IP20/21*

IP55/66
C B b e

IP55/66

IP21/55/66

IP21/55/66

f A c d e b a

Top and bottom mounting holes. B3

130BA826.10

B4
130BA827.10

C1
130BA814.10

C2
130BA815.10

130BA648.11

C3
130BA828.10

C4
130BA829.10

IP20/21*

IP20/21*

IP21/55/66
e

IP21/55/66
130BA715.11

IP20/21*

IP20/21*

Top and bottom mounting holes. (B4+C3+C4 only) Accessory bags containing necessary brackets, screws and connectors are included with the frequency converter upon delivery. * IP21 can be established with a kit as described in the section: IP 21/ IP 4X/ TYPE 1 Enclosure Kit in the Design Guide.

80

MG.11.BA.02 - VLT is a registered Danfoss trademark

Mechanical Dimensions A3 3.0-3.7 5.5-7.5 1.1-7.5 21 20 Type 1 Chassis 372 375 350 90 130 90 70 205 220 8.0 11 5.5 9 5.3 6.6 7.0 9.7 14 23 9 9 6 9 9 5.5 5.5 6.5 6.5 9 11 11 12 12 19 9 9 27 8.0 8.0 8.2 8.2 12 12 19 220 220 175 200 260 260 205 205 175 200 260 260 248 262 8 12 6.8 7.9 12 110 110 171 215 210 210 140 200 242 242 8.5 15 23.5 130 130 200 242 242 242 165 231 170 170 242 242 242 205 231 130 130 200 242 242 242 165 231 308 308 308 272 310 310 12 19 9.0 9.8 45 257 350 401 402 454 624 380 495 648 268 375 390 420 480 650 399 520 680 374 419 595 770 739 370 370 370 334 335 335 12 19 9.0 9.8 65 246 372 390 420 480 650 350 460 680 770 490 630 550 521 308 308 308 270 333 333 8.5 17 35 21 55/66 Type 1 55/66 Type 12 21/ 55/66 Type 1/12 21/ 55/66 Type 1/12 20 Chassis 20 Chassis 21/ 55/66 Type 1/12 21/ 55/66 Type 1/12 20 Chassis 20 Chassis 600 800 660 631 370 370 370 330 333 333 8.5 17 50 1.1-2.2 1.1-3.7 1.1-4.0 1.1-7.5 1.1-7.5 5.5-11 11-18.5 11-18.5 15 22-30 11-30 11-30 5.5-11 11-18.5 11-18.5 15-18.5 22-37 22-37 18.5-30 37-55 37-55 37-45 75-90 37-90 37-90 22-30 45-55 45-55 37-45 75-90 75-90 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4

How to Install

Frame size (kW):

A2

200-240V 380-480V 525-600V 525-690V

1.1-2.2 1.1-4.0

IP NEMA

20 Chassis

5.1.2 Mechanical Dimensions

Height (mm)

Enclosure

A**

246

..with de-coupling plate

A2

374

Back plate

A1

268

Distance between mount. holes

257

Width (mm)

Enclosure

90

With one C option

130

Back plate

90

Distance between mount. holes

70

Depth (mm)

VLT HVAC Drive Design Guide

Without option A/B

205

With option A/B

C*

220

Screw holes (mm)

MG.11.BA.02 - VLT is a registered Danfoss trademark

8.0

Diameter

11

Diameter

5.5

Max weight (kg)

4.9

* Depth of enclosure will vary with different options installed.

** The free space requirements are above and below the bare enclosure height measurement A. See section Mechanical Mounting for further information.

81

5 5

5 5

130BA819.10

130BA816.10

130BA817.10

130BA820.10

130BA818.10

130BA821.10

130BA885.10

Bottom mounting hole:

130BA880.10 d e

IP21/54 Lifting eye:

a c b

130BA959.10

IP21/54

Lifting eye and mounting holes:

a b

130BA878.10

VLT HVAC Drive Design Guide

b d

j
c

Enclosure F1

Enclosure F2

130BA881.10

130BA879.10

130BB003.13

61.4

BACK

130BA651.10

All measurements in mm
70.4 FRONT

361.7

130BB004.13

624 (24.6)

14

25

130BB006.10

MG.11.BA.02 - VLT is a registered Danfoss trademark

578 (22.8) 776 (30.6)
578 [22.8]

624 [24.6]

Base plate mount:

20.0 560.0 20.0

Enclosure F3

Enclosure F4

2X578 [22.8]

776 [30.6]

2x579 (22.8)

578 (22.8)

130BB005.13

579 [22.8]

130BB092.10

82 D4 E1 E2 F1/F3 F2/F4

How to Install

D1

D2

D3

F3 F1

F4 F3

IP21/54

IP21/54

IP00

IP00

IP21/54

IP00

Mechanical dimensions D2 160-250 200-400 21/54 Type 1/12 1730 650 570 570 570 736 736 927 927 650 650 840 831 1569 1962 2159 927 1220 1490 2197 1705 2324 2324 2324 00 Chassis 00 Chassis 21/54 Type 1/12 00 Chassis 21/54 Type 1/12 21/54 Type 1/12 21/54 Type 1/12 21/54 Type 1/12 2324 2559 927 110-132 45-160 160-250 200-400 315-450 450-630 315-450 450-630 500-710 710-900 800-1000 1000-1400 500-710 710-900 800-1000 1000-1400 D3 D4 E1 E2 F1 F2 F3 F4

How to Install

Enclosure size (kW)

D1

380-480 VAC 525-690 VAC

110-132 45-160

IP NEMA

21/54 Type 1/12

Shipping dimensions (mm):

Width

1730

Height

650

Depth

570

FCDrive dimensions: (mm) 1589 420 380 22/0.9 25/1.0 25/1.0 20/0.8 11/0.4 22/0.9 10/0.4 51/2.0 25/1.0 49/1.9 11/0.4 151 91 138 11/0.4 11/0.4 313 277 1004 1246 1299 1541 49/1.9 49/1.9 25/1.0 25/1.0 51/2.0 51/2.0 10/0.4 10/0.4 22/0.9 22/0.9 11/0.4 11/0.4 20/0.8 20/0.8 27/1.1 13/0.5 25/1.0 25/1.0 25/1.0 25/1.0 25/1.0 25/1.0 25/1.0 25/1.0 22/0.9 22/0.9 56/2.2 23/0.9 375 375 494 494 607 408 408 600 585 1400 1046 1327 2000 1547 2281 2281 1800 607 2281 2000 607 2281 2400 607

Height

Back plate

1209

Width

Back plate Depth

420

C Dimensions brackets (mm/inch)

380

Centre hole to edge

22/0.9

Centre hole to edge

25/1.0

Hole diameter

25/1.0

VLT HVAC Drive Design Guide

20/0.8

11/0.4

22/0.9

MG.11.BA.02 - VLT is a registered Danfoss trademark

10/0.4

51/2.0

25/1.0

49/1.9

Hole diameter

11/0.4

Max weight (kg)

104

Please contact Danfoss for more detailed information and CAD drawings for your own planning purposes.

83

5 5

5 5

03 02 01

06 05 04

E F

10

10

06

5.1.3 Accessory Bags

06

130BT339.10

RELAY 1

ISOA0021

Frame sizes A1, A2 and A3

RELAY 1 RELAY 2

61 68

39 42 50

39 42 50 53 54 5

WARNIN
Risk of Electric Disconn Shock ect mains - Dual supply and loadsha ring before service

G:

130BT348.10

WARNING

WARNING:
Risk of Electric Disconnect Shock - Dual supply mains and loadsharing before service

STORED CHARGE 15 MIN. AFTER DO NOT TOUCH UNTIL DISCONNECT CHARGE ION RESIDUELLE. ATTENDRE 15 MIN. APRES DECONNEXIO N

61 68

Risk of Electric Disconnect Shock - Dual supply mains and loadsharing before service

WARNING

39 42 50 53 54

95 99

95

RELAY 1

RELAY 2

99

service

VLT HVAC Drive Design Guide

Frame size B3

Frame size B4

130BT347.10

Risk of Electric Shock - Dual Discunnect supply mains and loadsharing before

WARNING

130BT346.10

Frame size C3

Frame size C4

1 + 2 only available in units with brake chopper. For DC link connection (Load sharing) the connector 1 can be ordered separately (Code no. 130B1064)

MG.11.BA.02 - VLT is a registered Danfoss trademark Frame size A5

06 05 04

An eight pole connector is included in accessory bag for FC 102 without Safe Stop.

130BT349.10

61 68

53 54 5

06 05 04

03 02 01

03 02 01

06 05 04

03 02 01

06 05 04

U V 96 9 W 7 98

03 02 01

L1 L 2 91 9 L3 2 93

RELAY 1

130BT309.10

130BT330.10

G I

Risk of Electric Shock - Dual supply Disconnect mains and loadsharing before service

WARNING:

Frame sizes B1 and B2

Frame sizes C1 and C2

RELAY 1 RELAY 2

61 68

39 42 50 53

54 5

130BA406.10

06 05 04

03 02 01

84
A B
61 68 6
39 42 50 53 54 5

Accessory Bags: Find the following parts included in the frequency converter accessory bags
C D

How to Install

How to Install

VLT HVAC Drive Design Guide

5.1.4 Mechanical Mounting

All A, B and C enclosures allow side-by-side installation. Exception: If a IP21 kit is used, there has to be a clearance between the enclosures. For enclosures A2, A3, B3,B4 and C3 the minimum clearance is 50mm, for C4 it is 75mm. For optimal cooling conditions allow a free air passage above and below the frequency converter. See Table 5.1.
130BA419.10

Enclosure: a/b (mm) Enclosure: a/b (mm)

A2 100 B4 200

A3 100 C1 200

A5 100 C2 225

B1 200 C3 200

B2 200 C4 225

B3 200

Table 5.1 Air Passage for Different Enclosures

5 5

1. 2.

Drill holes in accordance with the measurements given. Provide screws suitable for the surface on which you want to mount the frequency converter. Retighten all four screws.
130BA219.10 130BA228.10

IP66 Drive A

Base plate Fibre Washer

Table 5.2 When mounting enclosure sizes A5, B1, B2, B3, B4, C1, C2, C3 and C4 on a non-solid back wall, the drive must be provided with a back plate A due to insufficient cooling air over the heat sink.

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA392.10

85

How to Install

VLT HVAC Drive Design Guide

Always lift the frequency converter in the dedicated lifting eyes. For all D and E2 (IP00) enclosures, use a bar to avoid bending the lifting holes of the frequency converter.
176FA245.10

5 5
Illustration 5.1 Recommended Lifting Method, Frame Sizes D and E. Illustration 5.3 Recommended Lifting Method, Frame Size F2 (460V, 1000 to 1200 HP, 575/690V, 1250 to 1350 HP).

The lifting bar must be able to handle the weight of the frequency converter. See Mechanical Dimensions for the weight of the different frame sizes. Maximum diameter for bar is 2.5 cm (1 inch). The angle from the top of the drive to the lifting cable should be 60C or greater.
130BA832.11

Illustration 5.4 Recommended Lifting Method, Frame Size F3 (460V, 600 to 900 HP, 575/690V, 900 to 1150 HP).

Illustration 5.2 Recommended Lifting Method, Frame Size F1 (460V, 600 to 900 HP, 575/690V, 900 to 1150 HP).

Illustration 5.5 Recommended Lifting Method, Frame Size F4 (460V, 1000 to 1200 HP, 575/690V, 1250 to 1350 HP).

86

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA835.11

130BA833.11

WARNING

130BA834.11

5.1.5 Lifting

How to Install

VLT HVAC Drive Design Guide

NOTE
The plinth is provided in the same packaging as the frequency converter but is not attached to frame sizes F1-F4 during shipment. The plinth is required to allow airflow to the drive to provide proper cooling. The F frames should be positioned on top of the plinth in the final installation location. The angle from the top of the drive to the lifting cable should be 60C or greater. In addition to the drawings above a spreader bar is an acceptable way to lift the F Frame.

5.1.6 Safety Requirements of Mechanical Installation

WARNING
Pay attention to the requirements that apply to integration and field mounting kit. Observe the information in the list to avoid serious injury or equipment damage, especially when installing large units.

The frequency converter is cooled by means of air circulation. To protect the unit from overheating, it must be ensured that the ambient temperature does not exceed the maximum temperature stated for the frequency converter and that the 24-hour average temperature is not exceeded. Locate the maximum temperature and 24-hour average in the paragraph Derating for Ambient Temperature. If the ambient temperature is in the range of 45 C - 55 C, derating of the frequency converter will become relevant, see Derating for Ambient Temperature. The service life of the frequency converter is reduced if derating for ambient temperature is not taken into account.

CAUTION

5 5

5.1.7 Field Mounting

IP 21/IP 4X top/TYPE 1 kits or IP 54/55 units are recommended.

MG.11.BA.02 - VLT is a registered Danfoss trademark

87

How to Install

VLT HVAC Drive Design Guide

5.2 Electrical Installation 5.2.1 Cables General

NOTE
For the VLT HVAC Drive High Power series mains and motor connections, please see VLT HVAC Drive High Power Operating Instructions MG.11.FX.YY.

NOTE
Cables General All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper (60/75 C) conductors are recommended. Details of terminal tightening torques.
Power (kW) Enclo200-240V 380-480V 525-600V 525-690V sure A2 A3 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4 D1/D3 D2/D4 E1/E2 F1/F33) F2/F43) 1.1 - 3.0 3.7 1.1-2.2 1.1 - 3.7 5.5 - 11 15 5.5 - 11 15 - 18.5 18.5 - 30 37 - 45 22 - 30 37 - 45 1.1 - 4.0 5.5 - 7.5 1.1-4 1.1 - 7.5 22 30 22 - 37 37 - 55 75 - 90 45 - 55 75 - 90 110-132 160-250 315-450 500-710 800-1000 1.1 - 7.5 11 30 30 90 45-160 200-400 450-630 710-900 1000-1400 22 30 22 - 37 37 - 55 75 - 90 45 - 55 75 - 90 11 - 18.5 11 - 18.5 1.1 - 4.0 5.5 - 7.5 Mains 1.8 1.8 1.8 1.8 1.8 2.5 4.52) 1.8 4.5 10 14/241) 10 14/24 19 19 19 19 19
1)

5 5

Torque (Nm) Motor 1.8 1.8 1.8 1.8 1.8 2.5 4.52) 1.8 4.5 10 14/241) 10 14/24 19 19 19 19 19
1)

DC connection 1.8 1.8 1.8 1.8 1.5 3.7 3.7 1.8 4.5 10 14 10 14 9.6 9.6 19 19 19

Brake 1.8 1.8 1.8 1.8 1.5 2.5 3.7 1.8 4.5 10 14 10 14 9.6 9.6 9.6 9.6 9.6

Earth 3 3 3 3 3 3 3 3 3 3 3 3 3 19 19 19 19 19

Relay 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6

11 - 18.5 11 - 18.5

Table 5.3 Tightening of Terminals

1) For different cable dimensions x/y, where x 95mm2 and y 95mm2. 2) Cable dimensions above 18.5kW 35mm2 and below 22kW 10mm2. 3) For data on the F frame sizes consult FC 100 High Power Operating Instructions.

88

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Install

VLT HVAC Drive Design Guide

5.2.2 Electrical Installation and Control Cables

130BA544.11 Motor Brake resistor

3 Phase power input

91 (L1) 92 (L2) 93 (L3) 95 PE 88 (-) 89 (+) 50 (+10 V OUT) S201 53 (A IN) 1 2 ON S202 1 2 ON 54 (A IN) ON=0-20mA OFF=0-10V Switch Mode Power Supply 24Vdc 15mA 200mA + + -

(U) 96 (V) 97 (W) 98 (PE) 99

DC bus

(R+) 82 (R-) 81 relay1

+10Vdc 0-10Vdc 0/4-20 mA 0-10Vdc 0/4-20 mA

5 5
240Vac, 2A

03 02 01

55 (COM A IN) 12 (+24V OUT) 13 (+24V OUT) 18 (D IN) 19 (D IN) 20 (COM D IN) 27 (D IN/OUT) 24V 0V 29 (D IN/OUT) 24V 0V 32 (D IN) 33 (D IN) * 37 (D IN) 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP) S801 RS-485 Interface 24V (NPN) 0V (PNP) S801 1 2 ON P 5-00 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP) relay2

06 05 04

240Vac, 2A 400Vac, 2A

(COM A OUT) 39 (A OUT) 42

Analog Output 0/4-20 mA

ON=Terminated OFF=Open

5V

0V (P RS-485) 68 (N RS-485) 69 RS-485

(COM RS-485) 61 (PNP) = Source (NPN) = Sink

Illustration 5.6 Diagram Showing all Electrical Terminals. (Terminal 37 Present for Units with Safe Stop Function only.)

MG.11.BA.02 - VLT is a registered Danfoss trademark

89

How to Install

VLT HVAC Drive Design Guide

Terminal number 1+2+3 4+5+6 12 13 18 19 20 27 29 32 33 37 42 53 54 Table 5.4 Terminal Connections

Terminal description Terminal 1+2+3-Relay1 Terminal 4+5+6-Relay2 Terminal 12 Supply Terminal 13 Supply Terminal 18 Digital Input Terminal 19 Digital Input Terminal 20 Terminal 27 Digital Input/Output Terminal 29 Digital Input/Output Terminal 32 Digital Input Terminal 33 Digital Input Terminal 37 Digital Input Terminal 42 Analog Output Terminal 53 Analog Input Terminal 54 Analog Input

Parameter number 5-40 5-40 5-10 5-11 5-12/5-30 5-13/5-31 5-14 5-15 6-50 3-15/6-1*/20-0* 3-15/6-2*/20-0*

Factory default No operation No operation +24 V DC +24 V DC Start No operation Common Coast inverse Jog No operation No operation Safe Stop Speed 0-HighLim Reference Feedback

5 5

Very long control cables and analog signals may, in rare cases and depending on installation, result in 50/60 Hz earth loops due to noise from mains supply cables. If this occurs, break the screen or insert a 100 nF capacitor between screen and chassis.

If it is necessary to split the screen to install a motor isolator or motor relay, the screen must be continued with the lowest possible HF impedance.

NOTE
The common of digital / analog inputs and outputs should be connected to separate common terminals 20, 39, and 55. This will avoid ground current interference among groups. For example, it avoids switching on digital inputs disturbing analog inputs.

F frame Requirements F1/F3 requirements: Motor phase cable quantities must be multiples of 2, resulting in 2, 4, 6, or 8 (1 cable is not allowed) to obtain equal amount of wires attached to both inverter module terminals. The cables are required to be equal length within 10% between the inverter module terminals and the first common point of a phase. The recommended common point is the motor terminals. F2/F4 requirements: Motor phase cable quantities must be multiples of 3, resulting in 3, 6, 9, or 12 (1 or 2 cables are not allowed) to obtain equal amount of wires attached to each inverter module terminal. The wires are required to be equal length within 10% between the inverter module terminals and the first common point of a phase. The recommended common point is the motor terminals. Output junction box requirements: The length, minimum 2.5 meters, and quantity of cables must be equal from each inverter module to the common terminal in the junction box.

NOTE
Control cables must be screened/armoured.

5.2.3 Motor Cables

See section General Specifications for maximum dimensioning of motor cable cross-section and length.

Use a screened/armoured motor cable to comply with EMC emission specifications. Keep the motor cable as short as possible to reduce the noise level and leakage currents. Connect the motor cable screen to both the decoupling plate of the frequency converter and to the metal cabinet of the motor. Make the screen connections with the largest possible surface area (cable clamp). This is done by using the supplied installation devices in the frequency converter. Avoid mounting with twisted screen ends (pigtails), which will spoil high frequency screening effects.

NOTE
If a retrofit application requires unequal amount of wires per phase, please consult the factory for requirements and documentation or use the top/bottom entry side cabinet busbar option.

5.2.4 Electrical Installation of Motor Cables

Screening of cables Avoid installation with twisted screen ends (pigtails). They spoil the screening effect at higher frequencies. If it is necessary to break the screen to install a motor isolator or motor contactor, the screen must be continued at the lowest possible HF impedance.

90

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Install

VLT HVAC Drive Design Guide

Cable length and cross-section The frequency converter has been tested with a given length of cable and a given cross-section of that cable. If the crosssection is increased, the cable capacitance - and thus the leakage current - may increase, and the cable length must be reduced correspondingly. Switching frequency When frequency converters are used together with Sinewave filters to reduce the acoustic noise from a motor, the switching frequency must be set according to the Sine-wave filter instruction in 14-01 Switching Frequency. Aluminium conductors Aluminium conductors are not recommended. Terminals can accept aluminium conductors but the conductor surface has to be clean and the oxidation must be removed and sealed by neutral acid free Vaseline grease before the conductor is connected. 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.

M32 A

M25

M32 B

M32 C

130BB325.10

M25

18

Illustration 5.9 Cable entry holes for enclosure B1. The suggested use of the holes are purely recommendations and other solutions are possible.

5 5

5.2.5 Enclosure Knock-outs

130BB118.10

42.9 A

33.1 B

42.9 C

26.3

Illustration 5.10 Cable entry holes for enclosure B2. The suggested use of the holes are purely recommendations and other solutions are possible.

130BA609.11

26.3

17

M40 A

M20

M32 B

M40 C

33,1 A

21

33,1 B

33,1 C

Illustration 5.11 Cable entry holes for enclosure B2. The suggested use of the holes are purely recommendations and other solutions are possible.

Illustration 5.8 Cable entry holes for enclosure B1. The suggested use of the holes are purely recommendations and other solutions are possible.

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BB324.10

Illustration 5.7 Cable entry holes for enclosure A5. The suggested use of the holes are purely recommendations and other solutions are possible.

M25

130BA610.11

26.3

17

91

How to Install

VLT HVAC Drive Design Guide

130BA643.11

M15

M25

M16

M25

5.2.7 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12)

Cables are connected through the gland plate from the bottom. Remove the plate and plan where to place the entry for the glands or conduits. Prepare holes in the marked area on the drawing.

NOTE
M63 A M63 C M50 B

5 5

Illustration 5.12 Cable entry holes for enclosure C1. The suggested use of the holes are purely recommendations and other solutions are possible.

The gland plate must be fitted to the frequency converter to ensure the specified protection degree, as well as ensuring proper cooling of the unit. If the gland plate is not mounted, the frequency converter may trip on Alarm 69, Pwr. Card Temp Cable entries viewed from the bottom of the frequency converter - 1) Mains side 2) Motor side

130BA644.10

M63 A

M63 C

M50 B

Illustration 5.14 Example of Proper Installation of Gland Plate.

35

Legend: A: Line in
202.8 62.5

B: Brake/load sharing C: Motor out D: Free space

5.2.6 Removal of Knockouts for Extra Cables

350

1.

Remove cable entry from the frequency converter (Avoiding foreign parts falling into the frequency converter when removing knockouts) 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.

Illustration 5.15 Frame Sizes D1 + D2

2. 3. 4. 5.

92

MG.11.BA.02 - VLT is a registered Danfoss trademark

98.6

130.0

176FA289.11

Illustration 5.13 Cable entry holes for enclosure C2. The suggested use of the holes are purely recommendations and other solutions are possible.

130BB073.10

M16

M25

M16

M25

How to Install

VLT HVAC Drive Design Guide

35

37.7 (1.485) 2X 216.5 535.0 (8.524) (21.063) 2X 281.3 (11.075) 35.5 (1.398) 36.2 (1.425)

634.7 (24.989) 2X 460.0 (18.110)

199.5 (7.854) 258.5 (10.177) 533.0 (20.984) 597.0 (23.504) 1130.0 (44.488) 1192.8 (46.961)

202.8

62.5

130.0

98.6

130BA843.12

176FA289.11

1265.3 (49.815)

593.0 (23.346)

1925.8 (75.819)

5 5
130BA839.10 199.5 (7.854) 258.2 (10.167) 1 994.3 (39.146)

350

Illustration 5.19 Frame Size F3

Illustration 5.16 Frame Size E1

37.7 (1.485) 634.7 (24.989) 2X 460.0 (18.110) 1252.8 (49.321)

F1-F4: Cable entries viewed from the bottom of the frequency converter - 1) Place conduits in marked areas
593.0 (23.346) 37.7 (1.485) 1 130BA837.12 668.3 (26.311) 460.0 (18.110) 199.5 (7.854) 258.5 (10.177) 533.0 (20.984) 595.8 (23.457) 35.5 (1.398) 1328.8 (52.315)

2X 216.5 (8.524) 535.0 (21.063) 2X 281.8 (11.096) 35.5 (1.398) 533.0 (20.984) 597.0 (23.504) 1130.0 (44.488) 1191.8 (46.921)

36.2 (1.425)

535.0 (21.063)

216.5 (8.524) 281.8 (11.096)

2324.8 (91.528)

Illustration 5.20 Frame Size F4

36.2 (1.425)

5.2.8 Fuses
A frequency converter that works correctly limits the current it can draw from the supply. Still, it is recommended to use fuses and/ or Circuit Breakers on the supply side as protection in case of component break-down inside the frequency converter (first fault).

Illustration 5.17 Frame Size F1

655.9 [25.825] 37.7 [1.485] 460.0 [18.110]

130BA841.12

994.3 [39.146]

535.0 [21.063]

216.5 [8.524]

199.5 [7.854] 258.2 [10.167]

NOTE
This is mandatory in order to ensure compliance with IEC 60364 for CE or NEC 2009 for UL.

281.8 [11.096]

35.5 [1.398]

533.0 [20.984] 36.2 [1.425] 594.8 [23.417]

1 1727.8 [68.024]

WARNING
Personnel and property must be protected against the consequence of component break-down internally in the frequency converter. Branch Circuit Protection In order to protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines etc., must be protected against short-circuit and over-current according to national/international regulations.

Illustration 5.18 Frame Size F2

NOTE
The recommendations given do not cover Branch circuit protection for UL!

MG.11.BA.02 - VLT is a registered Danfoss trademark

93

How to Install

VLT HVAC Drive Design Guide

Short-circuit protection: Danfoss recommends using the fuses/Circuit Breakers listed in and to protect service personnel and property in case of component break-down in the frequency converter. Over current protection: The frequency converter provides overload protection to limit threats to human life, property damage and to avoid

fire hazard due to overheating of the cables in the installation. The frequency converter is equipped with an internal over current protection (4-18 Current Limit) that can be used for upstream overload protection (UL-applications excluded). Moreover, fuses or Circuit Breakers can be used to provide the over current protection in the installation. Over current protection must always be carried out according to national regulations.

5.2.9 Non UL Compliance Fuses

Non-UL compliance fuses
Frequency converter 200-240 V - T2 1K1-1K5 2K2 3K0 3K7 5K5 7K5 11K 15K 18K5 22K 30K 37K 45K 380-480 V - T4 1K1-1K5 2K2-3K0 4K0-5K5 7K5 11K-15K 18K 22K 30K 37K 45K 55K 75K 90K 10A1 16A1 25A1 35A1 63A1 63A1 63A1 80A1 100A1 125A1 160A1 250A1 250A1 380-500 380-500 380-500 380-500 380-500 380-500 380-500 380-500 380-500 380-500 380-500 380-500 380-500 type gG type gG type gG type gG type gG type gG type gG type gG type gG type gG type gG type aR type aR 16A1 25A1 25A1 35A1 50A1 63A1 63A1 80A1 125A1 125A1 160A1 200A1 250A1 200-240 200-240 200-240 200-240 200-240 200-240 200-240 200-240 200-240 200-240 200-240 200-240 200-240 type gG type gG type gG type gG type gG type gG type gG type gG type gG type gG type gG type aR type aR Max. fuse size Voltage (V) Type

5 5

1) Max. fuses - see national/international regulations for selecting an applicable fuse size. Table 5.5 Non-UL Fuses 200V to 480V

If UL/cUL is not to be complied with, Danfoss recommends using the following fuses, which will ensure compliance with EN50178:
Frequency Converter P110 - P250 P315 - P450 Table 5.6 Compliance with EN50178 Voltage (V) 380 - 480 380 - 480 Type type gG type gR

94

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Install

VLT HVAC Drive Design Guide

UL compliance fuses
Frequency converter 200-240V kW K25-K37 K55-1K1 1K5 2K2 3K0 3K7 5K5 7K5 11K 15K 18K5 22K 30K 37K 45K Type RK1 KTN-R05 KTN-R10 KTN-R15 KTN-R20 KTN-R25 KTN-R30 KTN-R50 KTN-R50 KTN-R60 KTN-R80 KTN-R125 KTN-R125 FWX-150 FWX-200 FWX-250 Type J JKS-05 JKS-10 JKS-15 JKS-20 JKS-25 JKS-30 JKS-50 JKS-60 JKS-60 JKS-80 JKS-150 JKS-150 Type T JJN-05 JJN-10 JJN-15 JJN-20 JJN-25 JJN-30 JJN-50 JJN-60 JJN-60 JJN-80 JJN-125 JJN-125 Type RK1 5017906-005 5017906-010 5017906-015 5012406-020 5012406-025 5012406-030 5012406-050 5012406-050 5014006-063 5014006-080 2028220-125 2028220-125 2028220-150 2028220-200 2028220-250 Type RK1 KLN-R005 KLN-R10 KLN-R15 KLN-R20 KLN-R25 KLN-R30 KLN-R50 KLN-R60 KLN-R60 KLN-R80 KLN-R125 KLN-R125 L25S-150 L25S-200 L25S-250 Type CC ATM-R05 ATM-R10 ATM-R15 ATM-R20 ATM-R25 ATM-R30 A2K-60R A2K-80R A2K-125R A2K-125R A25X-150 A25X-200 A25X-250 Type RK1 A2K-05R A2K-10R A2K-15R A2K-20R A2K-25R A2K-30R A2K-50R A2K-50R A2K-60R A2K-80R A2K-125R A2K-125R A25X-150 A25X-200 A25X-250 Bussmann Bussmann Bussmann SIBA Littel fuse FerrazShawmut FerrazShawmut

5 5

Table 5.7 UL Fuses, 200-240V Frequency converter kW K37-1K1 1K5-2K2 3K0 4K0 5K5 7K5 11K 15K 18K 22K 30K 37K 45K 55K 75K 90K FerrazShawmut Type CC ATM-R6 ATM-R10 ATM-R16 ATM-R20 ATM-R25 ATM-R30 FerrazShawmut Type RK1 A6K-6R A6K-10R A6K-16R A6K-20R A6K-25R A6K-30R A6K-40R A6K-40R A6K-50R A6K-60R A6K-80R A6K-100R A6K-125R A6K-150R A50-P225 A50-P250

Bussmann

Bussmann

Bussmann

SIBA

Littel fuse

380-480V, 525-600V Type RK1 KTS-R6 KTS-R10 KTS-R15 KTS-R20 KTS-R25 KTS-R30 KTS-R40 KTS-R40 KTS-R50 KTS-R60 KTS-R80 KTS-R100 KTS-R125 KTS-R150 FWH-220 FWH-250 Type J JKS-6 JKS-10 JKS-15 JKS-20 JKS-25 JKS-30 JKS-40 JKS-40 JKS-50 JKS-60 JKS-80 JKS-100 JKS-150 JKS-150 Type T JJS-6 JJS-10 JJS-15 JJS-20 JJS-25 JJS-30 JJS-40 JJS-40 JJS-50 JJS-60 JJS-80 JJS-100 JJS-150 JJS-150 Type RK1 5017906-006 5017906-010 5017906-016 5017906-020 5017906-025 5012406-032 5014006-040 5014006-040 5014006-050 5014006-063 2028220-100 2028220-125 2028220-125 2028220-160 2028220-200 2028220-250 Type RK1 KLS-R6 KLS-R10 KLS-R16 KLS-R20 KLS-R25 KLS-R30 KLS-R40 KLS-R40 KLS-R50 KLS-R60 KLS-R80 KLS-R100 KLS-R125 KLS-R150 L50S-225 L50S-250

Table 5.8 UL Fuses, 380-600V

KTS-fuses from Bussmann may substitute KTN for 240V frequency converters. FWH-fuses from Bussmann may substitute FWX for 240V frequency converters. KLSR fuses from LITTEL FUSE may substitute KLNR fuses for 240V frequency converters. L50S fuses from LITTEL FUSE may substitute L50S fuses for 240V frequency converters. A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240V frequency converters. A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240V frequency converters.

MG.11.BA.02 - VLT is a registered Danfoss trademark

95

How to Install

VLT HVAC Drive Design Guide

UL Compliance 380-480V, frame sizes D, E and F The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240V, or 480V, or 500V, or 600V depending on the drive voltage rating. With the proper fusing the drive Short Circuit Current Rating (SCCR) is 100,000 Arms.
Bussmann E1958 JFHR2** FWH300 FWH350 FWH400 FWH500 FWH600 Bussmann E4273 T/JDDZ** JJS300 JJS350 JJS400 JJS500 JJS600 SIBA E180276 JFHR2 2061032.315 2061032.35 2061032.40 2061032.50 2062032.63 LittelFuse E71611 JFHR2** L50S-300 L50S-350 L50S-400 L50S-500 L50S-600 FerrazShawmut E60314 JFHR2** A50-P300 A50-P350 A50-P400 A50-P500 A50-P600 Bussmann E4274 H/JDDZ** NOS300 NOS350 NOS400 NOS500 NOS600 Bussmann E125085 JFHR2* 170M3017 170M3018 170M4012 170M4014 170M4016 Internal Option Bussmann 170M3018 170M3018 170M4016 170M4016 170M4016

Size/ Type P110 P132 P160 P200 P250

5 5

Table 5.9 Frame Size D, Line Fuses, 380-480V Size/ Type P315 P355 P400 P450 Bussma nn PN* 170M4 017 170M6 013 170M6 013 170M6 013 Bussmann PN* 170M8611 170M8611 170M6467 170M6467 170M8611 170M6467

Rating 700A, 700V 900A, 700V 900A, 700V 900A, 700V

Ferraz 6.9URD31D08A0 700 6.9URD33D08A0 900 6.9URD33D08A0 900 6.9URD33D08A0 900

Siba 20 610 32.700 20 630 32.900 20 630 32.900 20 630 32.900

Size/Type P500 P560 P630 P710 P800 P1M0

Rating 1100A, 1000V 1100A, 1000V 1400A, 700V 1400A, 700V 1100A, 1000V 1400A, 700V

Siba 20 781 32.1000 20 781 32.1000 20 681 32.1400 20 681 32.1400 20 781 32.1000 20 681 32.1400

Table 5.10 Frame Size E, Line Fuses, 380-480V Internal Bussmann Option 170M7082 170M7082 170M7082 170M7082 170M7083 170M7083

Size/ Type P500 P560 P630 P710 P800 P1M0

Bussmann PN* 170M7081 170M7081 170M7082 170M7082 170M7083 170M7083

Rating 1600A, 700V 1600A, 700V 2000A, 700V 2000A, 700V 2500A, 700V 2500A, 700V

Siba 20 695 32.1600 20 695 32.1600 20 695 32.2000 20 695 32.2000 20 695 32.2500 20 695 32.2500

Table 5.12 Frame Size F, Inverter Module DC Link Fuses, 380-480V

*170M fuses from Bussmann shown use the -/80 visual indicator, -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for external use **Any minimum 500V UL listed fuse with associated current rating may be used to meet UL requirements.

Table 5.11 Frame Size F, Line Fuses, 380-480V

96

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Install

VLT HVAC Drive Design Guide

525-690V, frame sizes D, E and F

Bussm ann E1250 85 JFHR2 170M 3013 170M 3014 170M 3015 170M 3015 170M 3016 170M 3017 170M 3018 170M 4011 170M 4012 170M 4014 170M 5011 SIBA E18027 6 JFHR2 20610 32.125 20610 32.16 20610 32.2 20610 32.2 20610 32.25 20610 32.315 20610 32.35 20610 32.35 20610 32.4 20610 32.5 20620 32.55 FerrazShawmut E76491 JFHR2 6.6URD30D08 A0125 6.6URD30D08 A0160 6.6URD30D08 A0200 6.6URD30D08 A0200 6.6URD30D08 A0250 6.6URD30D08 A0315 6.6URD30D08 A0350 6.6URD30D08 A0350 6.6URD30D08 A0400 6.6URD30D08 A0500 6.6URD32D08 A550

Size/ Type Internal Option Bussmann 170M3015 170M3015 170M3015 170M3015 170M3018 170M3018 170M3018 170M5011 P800 170M5011 P900 170M5011 P1M0 170M5011 P1M2 P1M4 Siba 20 610 32.700 20 610 32.700 20 630 32.900 20 630 32.900 Size/Type P710 P710 P800 P900 P1M0 P1M2 P1M4

Bussman n PN* 170M708 1 170M708 1 170M708 1 170M708 1 170M708 2 170M708 3

Rating 1600A, 700V 1600A, 700V 1600A, 700V 1600A, 700V 2000A, 700V 2500A, 700V

Siba 20 695 32.1600 20 695 32.1600 20 695 32.1600 20 695 32.1600 20 695 32.2000 20 695 32.2500

Internal Bussmann Option 170M7082 170M7082 170M7082 170M7082 170M7082 170M7083

Size/ Type

Amps

P45K P55K P75K P90K P110 P132 P160 P200 P250 P315 P400

125 160 200 200 250 315 350 350 400 500 550

5 5

Table 5.15 Frame Size F, Line Fuses, 525-690V Bussmann PN* 170M8611 170M8611 170M8611 170M8611 170M8611 170M8611

Rating 1100A, 1000V 1100A, 1000V 1100A, 1000V 1100A, 1000V 1100A, 1000V 1100A, 1000V

Siba 20 781 32. 1000 20 781 32. 1000 20 781 32. 1000 20 781 32. 1000 20 781 32. 1000 20 781 32.1000

Table 5.13 Frame Size D, E and F 525-690V Size/ Type P450 P500 P560 P630 Bussman n PN* 170M401 7 170M401 7 170M601 3 170M601 3

Rating 700 A, 700 V 700 A, 700 V 900 A, 700 V 900 A, 700 V

Ferraz 6.9URD31 D08A0700 6.9URD31 D08A0700 6.9URD33 D08A0900 6.9URD33 D08A0900

Table 5.16 Frame size F, Inverter Module DC Link Fuses, 525-690V

*170M fuses from Bussmann shown use the -/80 visual indicator, -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for external use. Suitable for use on a circuit capable of delivering not more than 100 000 rms symmetrical amperes, 500/600/690 Volts maximum when protected by the above fuses. Supplementary fuses
Frame size D, E and F Table 5.17 SMPS Fuse Bussmann PN* KTK-4 Rating 4 A, 600 V

Table 5.14 Frame Size E, 525-690V

MG.11.BA.02 - VLT is a registered Danfoss trademark

97

How to Install

VLT HVAC Drive Design Guide

Size/Type P110-P315, 380-480 V P45K-P500, 525-690 V P355-P1M0, 380-480 V P560-P1M4, 525-690 V

Bussmann PN* KTK-4 KTK-4

LittelFuse

Rating 4 A, 600 V 4 A, 600 V

Frame size F

Bussmann PN* LPJ-30 SP or SPI

Rating 30 A, 600 V

Alternative Fuses Any listed Class J Dual Element, Time Delay, 30 A

KLK-15 KLK-15

15A, 600 V 15A, 600 V Table 5.20 30 A Fuse Protected Terminal Fuse

Frame size Table 5.18 Fan Fuses Bussmann PN* 2.5-4.0 A LPJ-6 SP or SPI Alternative Fuses Any listed Class J Dual Element, Time Delay, 6A Any listed Class J Dual Element, Time Delay, 10 A Any listed Class J Dual Element, Time Delay, 10 A Any listed Class J Dual Element, Time Delay, 15 A Any listed Class J Dual Element, Time Delay, 15 A Any listed Class J Dual Element, Time Delay, 20A Any listed Class J Dual Element, Time Delay, 25 A Any listed Class J Dual Element, Time Delay, 20 A F Rating 6 A, 600 V

Bussmann PN* LPJ-6 SP or SPI

Rating 6 A, 600 V

Alternative Fuses Any listed Class J Dual Element, Time Delay, 6 A

5 5

Size/Type P500P1M0, 380-480 V

Table 5.21 Control Transformer Fuse Frame size F Table 5.22 NAMUR Fuse Alternative Fuses Any listed Class CC, 6 A Bussmann PN* GMC-800MA Rating 800 mA, 250 V

P710P1M4, 525-690 V

LPJ-10 SP or 10 A, 600 V SPI

Frame size F

Bussmann PN* LP-CC-6

Rating 6 A, 600 V

P500P1M0, 380-480 V

4.0-6.3 A

LPJ-10 SP or 10 A, 600 V SPI

Table 5.23 Safety Relay Coil Fuse with PILS Relay

P710P1M4, 525-690 V

LPJ-15 SP or 15 A, 600 V SPI

P500P1M0, 380-480 V

6.3 - 10 A

LPJ-15 SP or 15 A, 600 V SPI

P710P1M4, 525-690 V

LPJ-20 SP or 20 A, 600 V SPI

P500P1M0, 380-480 V

10 - 16 A

LPJ-25 SP or 25 A, 600 V SPI

P710P1M4, 525-690 V

LPJ-20 SP or 20 A, 600 V SPI

Table 5.19 Manual Motor Controller Fuses

98

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Install

VLT HVAC Drive Design Guide

130BT311.10

1. 2. 3. 4.

10 pole plug digital I/O. 3 pole plug RS485 Bus. 6 pole analog I/O. USB Connection.
1.

9 - 10 mm (0.37 in)

130BA150.10

Drawing reference numbers:

2.

3.

130BT306.10

130BA012.11

130BT312.10

5.2.10 Control Terminals

5 5

39
69
4

42

50

53

54

55

61

68

12

13

18

19

27

29

32

33

20

37

Illustration 5.21 Control Terminals (all Enclosures)

5.2.11 Control Cable Terminals

To mount the cable to the terminal: 1. Strip isolation of 9-10mm 2. 3. 4. Insert a screw driver1) in the rectangular hole. Insert the cable in the adjacent circular hole. Remove the screw driver. The cable is now mounted to the terminal.

To remove the cable from the terminal: 1. Insert a screw driver1) in the square hole. 2.
1)

Pull out the cable.

Max. 0.4 x 2.5mm

MG.11.BA.02 - VLT is a registered Danfoss trademark

99

How to Install

VLT HVAC Drive Design Guide

1. 2.

Mount terminals from the accessory bag to the front of the frequency converter. Connect terminals 18 and 27 to +24 V (terminal 12/13)

12

13

18

19

27

29

32

33

20

37

Default settings: 18 = latched start 27 = stop inverse

Start Stop inverse Safe Stop

5 5
Speed

Start (18) Start (27)

Illustration 5.22 Terminal 37 available with Safe Stop Function only!

100

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA156.12

+24V

P 5 - 12 [6]

P 5 - 10[9]

5.2.12 Basic Wiring Example

How to Install

VLT HVAC Drive Design Guide

5.2.13 Electrical Installation, Control Cables

130BA544.11 Motor Brake resistor

3 Phase power input

91 (L1) 92 (L2) 93 (L3) 95 PE 88 (-) 89 (+) 50 (+10 V OUT) S201 53 (A IN) 1 2 ON S202 1 2 ON 54 (A IN) ON=0-20mA OFF=0-10V Switch Mode Power Supply 24Vdc 15mA 200mA + + -

(U) 96 (V) 97 (W) 98 (PE) 99

DC bus

(R+) 82 (R-) 81 relay1

+10Vdc 0-10Vdc 0/4-20 mA 0-10Vdc 0/4-20 mA

5 5

03 02 01 240Vac, 2A

55 (COM A IN) 12 (+24V OUT) 13 (+24V OUT) 18 (D IN) 19 (D IN) 20 (COM D IN) 27 (D IN/OUT) 24V 0V 29 (D IN/OUT) 24V 0V 32 (D IN) 33 (D IN) * 37 (D IN) 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP) S801 RS-485 Interface 24V (NPN) 0V (PNP) S801 1 2 ON P 5-00 24V (NPN) 0V (PNP) 24V (NPN) 0V (PNP) relay2

06 05 04

240Vac, 2A 400Vac, 2A

(COM A OUT) 39 (A OUT) 42

Analog Output 0/4-20 mA

ON=Terminated OFF=Open

5V

0V (P RS-485) 68 (N RS-485) 69 RS-485

(COM RS-485) 61 (PNP) = Source (NPN) = Sink

Illustration 5.23 Diagram Showing all Electrical Terminals.

Very long control cables and analog signals may in rare cases and depending on installation result in 50/60 Hz earth loops due to noise from mains supply cables. If this occurs, you may have to break the screen or insert a 100 nF capacitor between screen and chassis. The digital and analog in- and outputs must be connected separately to the frequency converter common inputs (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.

NOTE
Control cables must be screened/armoured.

MG.11.BA.02 - VLT is a registered Danfoss trademark

101

How to Install

VLT HVAC Drive Design Guide

See section entitled Earthing of Screened/Armoured Control Cables for the correct termination of control cables.
130BA681.10

BUS TER. OFF-ON

A53 A54 U- I U- I

VLT

5.2.14 Switches S201, S202, and S801

Switches S201 (A53) and S202 (A54) are used to select a current (0-20 mA) or a voltage (0 to 10 V) configuration of the analog input terminals 53 and 54 respectively. Switch S801 (BUS TER.) can be used to enable termination on the RS-485 port (terminals 68 and 69). See drawing Diagram showing all electrical terminals in section Electrical Installation. Default setting: S201 (A53) = OFF (voltage input) S202 (A54) = OFF (voltage input) S801 (Bus termination) = OFF

NOTE
It is recommended to only change switch position at power off.

102

MG.11.BA.02 - VLT is a registered Danfoss trademark

N O

5 5

130BT310.10
1 2

1.

Use a clamp from the accessory bag to connect the screen to the frequency converter decoupling plate for control cables.

How to Install

VLT HVAC Drive Design Guide

5.3 Final Set-Up and Test

To test the set-up and ensure that the frequency converter is running, follow these steps. Step 1. Locate the motor name plate The motor is either star- (Y) or delta- connected (). This information is located on the motor name plate data. Step 2. Enter the motor name plate data in this parameter list. To access this list first press the [QUICK MENU] key then select Q2 Quick Setup.
1. 2. 3. 4. 5. Motor Power [kW] or Motor Power [HP] Motor Voltage Motor Frequency Motor Current Motor Nominal Speed 1-20 Motor Power [kW] 1-21 Motor Power [HP] 1-22 Motor Voltage 1-23 Motor Frequency 1-24 Motor Current 1-25 Motor Nominal Speed
130BT307.10

Performing an AMA will ensure optimum performance. The AMA measures the values from the motor model equivalent diagram. 1. Connect terminal 27 to terminal 12 or set 5-12 Terminal 27 Digital Input to 'No function' (5-12 Terminal 27 Digital Input [0]) Activate the AMA 1-29 Automatic Motor Adaptation (AMA). Choose between complete or reduced AMA. If an LC filter is mounted, run only the reduced 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.

2. 3.

4. 5.

5 5

Stop the AMA during operation 1. Press the [OFF] key - the frequency converter enters into alarm mode and the display shows that the AMA was terminated by the user.

Successful AMA 1. 2. The display shows Press [OK] to finish AMA. Press the [OK] key to exit the AMA state.

Unsuccessful AMA 1. The frequency converter enters into alarm mode. A description of the alarm can be found in the Troubleshooting section. "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.

2.

BAUER D-7 3734 ESLINGEN 3~ MOTOR NR. 1827421 2003

Unsuccessful AMA is often caused by incorrectly registered motor name plate data or too big difference between the motor power size and the frequency converter power size. Step 4. Set speed limit and ramp time
Y 50 3,6 V Hz A

S/E005A9 1,5 n 31,5 n 1400 COS 0,80 /min. /min. KW 400

Set up the desired limits for speed and ramp time.

Minimum Reference Maximum Reference 3-02 Minimum Reference 3-03 Maximum Reference

1,7L B IP 65 H1/1A

Step 3. Activate the Automatic Motor Adaptation (AMA)

MG.11.BA.02 - VLT is a registered Danfoss trademark

103

How to Install

VLT HVAC Drive Design Guide

Motor Speed Low Limit

4-11 Motor Speed Low Limit [RPM] or 4-12 Motor Speed Low Limit [Hz] 4-13 Motor Speed High Limit [RPM] or 4-14 Motor Speed High Limit [Hz]

Motor Speed High Limit

Ramp-up Time 1 [s] Ramp-down Time 1 [s]

3-41 Ramp 1 Ramp Up Time 3-42 Ramp 1 Ramp Down Time

5 5

104

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Install

VLT HVAC Drive Design Guide

5.4 Additional Connections 5.4.1 Mains Disconnectors

Assembling of IP55/NEMA Type 12 (A5 housing) with mains disconnector Mains switch is placed on left side on frame sizes B1, B2, C1 and C2. Mains switch on A5 frames is placed on right side
130BT338.10

5 5

F OF

Frame size A5 B1 B2

Type Kraus&Naimer KG20A T303 Kraus&Naimer KG64 T303 Kraus&Naimer KG64 T303

Terminal connections
130BB182.10 L1 L2 L3 31 43

T1

T2

T3

32

44

C1 C1 C2 C2

37 kW 45-55 kW 75 kW 90 kW

Kraus&Naimer Kraus&Naimer Kraus&Naimer Kraus&Naimer

KG100 KG105 KG160 KG250

T303 T303 T303 T303

T1

T2

T3

14

MG.11.BA.02 - VLT is a registered Danfoss trademark

105

130BB181.10

L1

L2

L3

13

How to Install

VLT HVAC Drive Design Guide

5.4.2 Mains Disconnectors - Frame Size D, E and F

Frame size D1/D3 D2/D4 E1/E2 E1/E2 F3 F3 F4 Power & Voltage P110-P132 380-480V & P110-P160 525-690V P160-P250 380-480V & P200-P400 525-690V P315 380-480V & P450P630 525-690V P355-P450 380-480V P500 380-480V & P710P800 525-690V P560-P710 380-480V & P900 525-690V P800-P1M0 380-480V & P1M0-P1M4 525-690V Type ABB OETL-NF200A or OT200U12-91 ABB OETL-NF400A or OT400U12-91 ABB OETL-NF600A ABB OETL-NF800A Merlin Gerin NPJF36000S12AAYP Merlin Gerin NRK36000S20AAYP Merlin Gerin NRK36000S20AAYP

A KLIXON switch must be installed that is `normally closed'. If this function is not used, 106 and 104 must be short-circuited together. Normally closed: 104-106 (factory installed jumper) Normally open: 104-105
Terminal No. 106, 104, 105 Function Brake resistor temperature switch.

NOTE
If the temperature of the brake resistor gets too high and the thermal switch drops out, the frequency converter will stop braking. The motor will start coasting.
175ZA877.10 106 NC 104 C 105 NO

5 5

5.4.3 F Frame circuit breakers

Frame size F3 F3 F4 F4 Power & Voltage P500 380-480V & P710-P800 525-690V P560-P710 380-480V & P900 525-690V P800 380-480V & P1M0P1M4 525-690V P1M0 380-480V Type Merlin Gerin NPJF36120U31AABSCYP Merlin Gerin NRJF36200U31AABSCYP Merlin Gerin NRJF36200U31AABSCYP Merlin Gerin NRJF36250U31AABSCYP

5.4.6 External Fan Supply

Frame size D-E-F In case the frequency converter is supplied by DC or if the fan must run independently of the power supply, an external power supply can be applied. The connection is made on the power card.
Terminal No. 100, 101 102, 103 Function Auxiliary supply S, T Internal supply S, T

5.4.4 F Frame Mains Contactors

Frame size F3 F3 F4 Power & Voltage P500-P560 380-480V & P710-P900 525-690V P 630-P710380-480V P800-P1M0 380-480V & P1M0-P1M4 525-690V Type Eaton XTCE650N22A Eaton XTCEC14P22B Eaton XTCEC14P22B

The connector located on the power card provides the connection of line voltage for the cooling fans. The fans are connected from factory to be supplied form a common AC line (jumpers between 100-102 and 101-103). If external supply is needed, the jumpers are removed and the supply is connected to terminals 100 and 101. A 5 Amp fuse should be used for protection. In UL applications this should be LittleFuse KLK-5 or equivalent.

5.4.7 Relay Output

Relay 1

5.4.5 Brake Resistor Temperature Switch

Frame size D-E-F Torque: 0.5-0.6 Nm (5 in-lbs) Screw size: M3 This input can be used to monitor the temperature of an externally connected brake resistor. If the input between 104 and 106 is established, the frequency converter will trip on warning / alarm 27, Brake IGBT. If the connection is closed between 104 and 105, the frequency converter will trip on warning / alarm 27, Brake IGBT.

Relay 2

Terminal 01: common Terminal 02: normal open 240V AC Terminal 03: normal closed 240V AC

Terminal 04: common Terminal 05: normal open 400V AC Terminal 06: normal closed 240V AC

106

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Install

VLT HVAC Drive Design Guide

Additional relay outputs can be added to the frequency converter by using option module MCB 105.
130BA047.10

relay1 03

130BA170.10

Relay 1 and relay 2 are programmed in 5-40 Function Relay, 5-41 On Delay, Relay, and 5-42 Off Delay, Relay.

240Vac, 2A 02

5 5

01

relay2 06 240Vac, 2A

LC lter

05 400Vac, 2A

04

5.4.8 Parallel Connection of Motors

The frequency converter can control several parallelconnected motors. The total current consumption of the motors must not exceed the rated output current IINV for the frequency converter. When motors are connected in parallel, 1-29 Automatic Motor Adaptation (AMA) cannot be used. Problems may arise at start and at low RPM values if motor sizes are widely different because small motors' relatively high ohmic resistance in the stator calls for a higher voltage at start and at low RPM values. The electronic thermal relay (ETR) of the frequency converter cannot be used as motor protection for the individual motor of systems with parallel-connected motors. Provide further motor protection by e.g. thermistors in each motor or individual thermal relays. (Circuit breakers are not suitable as protection).

MG.11.BA.02 - VLT is a registered Danfoss trademark

107

How to Install

VLT HVAC Drive Design Guide

5.4.9 Direction of Motor Rotation

The default setting is clockwise rotation with the frequency converter output connected as follows. Terminal 96 connected to U-phase Terminal 97 connected to V-phase Terminal 98 connected to W-phase The direction of motor rotation is changed by switching two motor phases. Motor rotation check can be performed using 1-28 Motor Rotation Check and following the steps shown in the display.
130HA036.10

5.4.11 Motor Insulation

For motor cable lengths the maximum cable length listed in the General Specifications tables the following motor insulation ratings are recommended because the peak voltage can be up to twice the DC link voltage, 2.8 times the mains voltage, due to transmission line effects in the motor cable. If a motor has lower insulation rating it recommended to use a du/dt or sine wave filter.
Nominal Mains Voltage UN 420 V 420 V < UN 500 V 500 V < UN 600 V 600 V < UN 690 V Motor Insulation Standard ULL = 1300 V Reinforced ULL = 1600 V Reinforced ULL = 1800 V Reinforced ULL = 2000 V

5 5

5.4.12 Motor Bearing Currents

It is generally recommended that motors of a rating 110kW or higher operating via Variable Frequency Drives should have NDE (Non-Drive End) insulated bearings installed to eliminate circulating bearing currents due to the physical size of the motor. To minimize DE (Drive End) bearing and shaft currents proper grounding of the drive, motor, driven machine, and motor to the driven machine is required. Although failure due to bearing currents is low and very dependent on many different items, for security of operation the following are mitigation strategies which can be implemented. Standard Mitigation Strategies: 1. Use an insulated bearing 2. Apply rigorous installation procedures Ensure the motor and load motor are aligned Strictly follow the EMC Installation guideline Reinforce the PE so the high frequency impedance is lower in the PE than the input power leads Provide a good high frequency connection between the motor and the frequency converter for instance by screened cable which has a 360 connection in the motor and the frequency converter Make sure that the impedance from frequency converter to building ground is lower that the grounding impedance of the machine. This can be difficult for pumps- Make a direct earth connection between the motor and load motor. 3. 4. Apply conductive lubrication Try to ensure the line voltage is balanced to ground. This can be difficult for IT, TT, TN-CS or Grounded leg systems

96

97

98

96

97

98

5.4.10 Motor Thermal Protection

The electronic thermal relay in the frequency converter has received the UL-approval for single motor protection, when 1-90 Motor Thermal Protection is set for ETR Trip and 1-24 Motor Current is set to the rated motor current (see motor name plate).

108

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Install

VLT HVAC Drive Design Guide

5.

Use an insulated bearing as recommended by the motor manufacturer (note: Motors from reputable manufacturers will typically have these fitted as standard in motors of this size)

5.5.2 How to Connect a PC to the Frequency Converter

To control or program the frequency converter from a PC, install the PC-based Configuration Tool MCT 10 Set-up Software. The PC is connected via a standard (host/device) USB cable, or via the RS-485 interface as shown in the VLT HVAC Drive Design Guide, chapter How to Install > Installation of misc. connections.

If found to be necessary and after consultation with Danfoss: 6. Lower the IGBT switching frequency 7. 8. 9. 10. Modify the inverter waveform, 60 AVM vs. SFAVM Install a shaft grounding system or use an isolating coupling between motor and load Use minimum speed settings if possible Use a dU/dt or sinus filter

NOTE
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 an isolated laptop as PC connection to the USB connector on the frequency converter.
130BT308.11

5 5

5.5 Installation of Misc. Connections 5.5.1 RS-485 Bus Connection

One or more frequency converters can be connected to a control (or master) using the RS-485 standardized interface. Terminal 68 is connected to the P signal (TX+, RX+), while terminal 69 is connected to the N signal (TX-,RX-). If more than one frequency converter is connected to a master, use parallel connections.
130BA060.11 RS 232 USB RS 485 + 68 69 68 69 68 69

Illustration 5.24 For control cable connections, see section on Control Terminals.

In order to avoid potential equalizing currents in the screen, earth the cable screen via terminal 61, which is connected to the frame via an RC-link. Bus termination The RS-485 bus must be terminated by a resistor network at both ends. For this purpose, set switch S801 on the control card for "ON". For more information, see the paragraph Switches S201, S202, and S801. Communication protocol must be set to 8-30 Protocol.

PC-based Configuration Tool MCT 10 Set-up Software All frequency converters are equipped with a serial communication port. Danfoss provides a PC tool for communication between PC and frequency converter, PCbased Configuration Tool MCT 10 Set-up Software. MCT 10 Set-up Software MCT 10 Set-up Software has been designed as an easy to use interactive tool for setting parameters in our frequency converters. The PC-based Configuration Tool MCT 10 Set-up Software will be useful for:

Planning a communication network off-line. MCT 10 Set-up Software contains a complete frequency converter database Commissioning frequency converters on line

MG.11.BA.02 - VLT is a registered Danfoss trademark

109

How to Install

VLT HVAC Drive Design Guide

Saving settings for all frequency converters Replacing a frequency converter in a network Expanding an existing network Future developed drives will be supported

Ordering number: Please order the CD containing the PC-based Configuration Tool MCT 10 Set-up Software using code number 130B1000. MCT 10 Set-up Software can also be downloaded from the Danfoss Internet: http://www.danfoss.com/BusinessAreas/ DrivesSolutions/Softwaredownload/DDPC+Software +Program.htm.

5 5

The PC-based Configuration Tool MCT 10 Set-up Software supports 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. See Operating Instructions, MG.33.Cx.yy and MN.90.Ex.yy for more information about the features supported by the Profibus DP V1 functions. Save Drive Settings: 1. Connect a PC to the unit via USB com port 2. 3. 4. Open PC-based Configuration Tool MCT 10 Set-up Software Choose Read from drive Choose Save as

5.5.3 MCT 31
MCT 31 The MCT 31 harmonic calculation PC tool enables easy estimation of the harmonic distortion in a given application. Both the harmonic distortion of Danfoss frequency converters as well as non-Danfoss frequency converters with different additional harmonic reduction devices, such as Danfoss AHF filters and 12-18-pulse rectifiers, can be calculated. Ordering number: Please order your CD containing the MCT 31 PC tool using code number 130B1031. MCT 31 can also be downloaded from the Danfoss Internet: http://www.danfoss.com/BusinessAreas/DrivesSolutions/ Softwaredownload/DDPC+Software+Program.htm.

All parameters are now stored in the PC. Load Drive Settings: 1. Connect a PC to the unit via USB com port 2. 3. 4. 5. Open PC-based Configuration Tool MCT 10 Set-up Software Choose Open stored files will be shown Open the appropriate file Choose Write to drive

All parameter settings are now transferred to the frequency converter. A separate manual for PC-based Configuration Tool MCT 10 Set-up Software is available. The PC-based Configuration Tool MCT 10 Set-up Software modules The following modules are included in the software package:
MCT 10 Set-up Software Setting parameters Copy to and from frequency converters Documentation and print out of parameter settings incl. diagrams Ext. User Interface Preventive Maintenance Schedule Clock settings Timed Action Programming Smart Logic Controller Set-up

110

MG.11.BA.02 - VLT is a registered Danfoss trademark

How to Install

VLT HVAC Drive Design Guide

5.6 Safety 5.6.1 High Voltage Test

Carry out a high voltage test by short-circuiting terminals U, V, W, L1, L2 and L3. Energize maximum 2.15 kV DC for 380-500V frequency converters and 2.525 kV DC for 525-690V frequency converters for one second between this short-circuit and the chassis. 80%. The screen material must be metal, not limited to but typically copper, aluminium, steel or lead. There are no special requirements for the mains cable.

WARNING
When running high voltage tests of the entire installation, interrupt the mains and motor connection if the leakage currents are too high.

5.6.2 Safety Earth Connection

The frequency converter has a high leakage current and must be earthed appropriately for safety reasons according to EN 50178.

Installations using rigid metal conduits are not required to use screened cable, but the motor cable must be installed in conduit separate from the control and mains cables. Full connection of the conduit from the drive to the motor is required. The EMC performance of flexible conduits varies a lot and information from the manufacturer must be obtained. Connect the screen/armour/conduit to earth at both ends for motor cables as well as for control cables. In some cases, it is not possible to connect the screen in both ends. If so, connect the screen at the frequency converter. See also Earthing of Braided Screened/Armoured Control Cables. Avoid terminating the screen/armour with twisted ends (pigtails). It increases the high frequency impedance of the screen, which reduces its effectiveness at high frequencies. 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.

5 5

WARNING
The earth leakage current from the frequency converter exceeds 3.5 mA. To ensure a good mechanical connection from the earth cable to the earth connection (terminal 95), the cable cross-section must be at least 10 mm2 or 2 rated earth wires terminated separately.

5.7 EMC-correct Installation 5.7.1 Electrical Installation - EMC Precautions

The following is a guideline to good engineering practice when installing frequency converters. Follow these guidelines to comply with EN 61800-3 First environment. If the installation is in EN 61800-3 Second environment, i.e. industrial networks, or in an installation with its own transformer, deviation from these guidelines is allowed but not recommended. See also paragraphs CE Labelling, General Aspects of EMC Emission and EMC Test Results. Good engineering practice to ensure EMC-correct electrical installation: Use only braided screened/armoured motor cables and braided screened/armoured control cables. The screen should provide a minimum coverage of

Leave the screen as close to the connectors as possible. Illustration 5.25 shows an example of an EMC-correct electrical installation of an IP 20 frequency converter. The frequency converter is fitted in an installation cabinet with an output contactor and connected to a PLC, which is installed in a separate cabinet. Other ways of doing the installation may have just as good an EMC performance, provided the above guide lines to engineering practice are followed. If the installation is not carried out according to the guideline and if unscreened cables and control wires are used, some emission requirements are not complied with, although the immunity requirements are fulfilled. See the paragraph EMC test results.

MG.11.BA.02 - VLT is a registered Danfoss trademark

111

How to Install

VLT HVAC Drive Design Guide

PLC etc.

Panel

5 5

Output contactor etc. PLC Earthing rail

Cable insulation stripped

Min. 16 mm2 Equalizing cable

All cable entries in Control cables one side of panel

Mains-supply L1 L2 L3 PE Reinforced protective earth

Min. 200mm between control cables, motor cable and mains cable

Motor cable

Motor, 3 phases and Protective earth

Illustration 5.25 EMC-correct Electrical Installation of a Frequency Converter in Cabinet.

L3 N PE F1

130BA175.11

L1 L2

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 (ZT). The screen of a cable is normally designed to reduce the transfer of electric noise; however, a screen with a lower transfer impedance (ZT) value is more effective than a screen with a higher transfer impedance (ZT). Transfer impedance (ZT) is rarely stated by cable manufacturers but it is often possible to estimate transfer impedance (ZT) by assessing the physical design of the cable.

91 92 93 95 L1 L2 L3 PE

12 37 18 50 53 55 54 Transmitter

V W PE

96 97 98 99

M 3

Illustration 5.26 Electrical Connection Diagram.

112

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA048.13

How to Install

VLT HVAC Drive Design Guide

Transfer impedance, Z t mOhm/m 10 10 10 10 10

The contact resistance between the individual screen conductors. The screen coverage, i.e. the physical area of the cable covered by the screen - often stated as a percentage value. Screen type, i.e. braided or twisted pattern. Aluminium-clad with copper wire. Twisted copper wire or armoured steel wire cable. Single-layer braided copper wire with varying percentage screen coverage. This is the typical Danfoss reference cable. Double-layer braided copper wire. Twin layer of braided copper wire with a magnetic, screened/armoured intermediate layer. Cable that runs in copper tube or steel tube. Lead cable with 1.1mm wall thickness.

a. b. c.

d 1 10 10 10 e

The lower the Z the better the cable screening performance

175ZA166.13

Transfer impedance (ZT) can be assessed on the basis of the following factors: The conductibility of the screen material.

5 5

d. e. f. g.

0,01

0,1

10

100 MHz g

MG.11.BA.02 - VLT is a registered Danfoss trademark

113

How to Install

VLT HVAC Drive Design Guide

FC

Generally speaking, control cables must be braided screened/armoured and the screen must be connected by means of a cable clamp at both ends to the metal cabinet of the unit.
PLC etc.

PE

PE

The drawing below indicates how correct earthing is carried out and what to do if in doubt. a. Correct earthing Control cables and cables for serial communication must be fitted with cable clamps at both ends to ensure the best possible electrical contact. Wrong earthing Do not use twisted cable ends (pigtails). They increase the screen impedance at high frequencies. Protection with respect to earth potential between PLC and frequency converter If the earth potential between the frequency converter and the PLC (etc.) is different, electric noise may occur that will disturb the entire system. Solve this problem by fitting an equalising cable, next to the control cable. Minimum cable crosssection: 16 mm 2. For 50/60 Hz earth loops If very long control cables are used, 50/60 Hz earth loops may occur. Solve this problem by connecting one end of the screen to earth via a 100nF capacitor (keeping leads short). Cables for serial communication Eliminate low-frequency noise currents between two frequency converters by connecting one end of the screen to terminal 61. This terminal is connected to earth via an internal RC link. Use twisted-pair cables to reduce the differential mode interference between the conductors.
PE PE PE PE Min. 16mm2 Equalizing cable PLC etc.

FC

5 5

PE

PE

PLC etc. FC

b.

c.

FC

d.

PE 100nF

PE

FC

FC

e.

69 68 61 PE

68 69

5.8 Residual Current Device

Use RCD relays, multiple protective earthing or earthing as extra protection, provided that local safety regulations are complied with. If an earth fault appears, a DC content may develop in the faulty current. If RCD relays are used, local regulations must be observed. 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.

114

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA051.11

5.7.3 Earthing of Screened/Armoured Control Cables

PLC etc.

Application Examples

VLT HVAC Drive Design Guide

6 Application Examples
6.1.1 Start/Stop
Terminal 18 = start/stop 5-10 Terminal 18 Digital Input [8] Start Terminal 27 = No operation 5-12 Terminal 27 Digital Input [0] No operation (Default coast inverse 5-10 Terminal 18 Digital Input = Start (default) 5-12 Terminal 27 Digital Input = coast inverse (default)
130BA155.12 P 5-10 [8] P 5-12 [0] +24V +24V

6.1.2 Pulse Start/Stop

Terminal 18 = start/stop 5-10 Terminal 18 Digital Input [9] Latched start Terminal 27= Stop 5-12 Terminal 27 Digital Input [6] Stop inverse 5-10 Terminal 18 Digital Input = Latched start 5-12 Terminal 27 Digital Input = Stop inverse
130BA156.12 P 5 - 12 [6] P 5 - 10[9]

6 6

12 13 18 19 27 29 32 33 20 37

12

13

18

19

27

29

32

33

20

37

Start/Stop

Safe Stop

Speed

Start

Stop inverse

Safe Stop

Speed Start/Stop [18]

Illustration 6.1 Terminal 37: Available only with Safe Stop Function!

Start (18) Start (27)

Illustration 6.2 Terminal 37: Available only with Safe Stop Function

MG.11.BA.02 - VLT is a registered Danfoss trademark

115

Application Examples

VLT HVAC Drive Design Guide

6.1.3 Potentiometer Reference

Voltage reference via a potentiometer. 3-15 Reference 1 Source [1] = Analog Input 53 6-10 Terminal 53 Low Voltage = 0V 6-11 Terminal 53 High Voltage = 10V 6-14 Terminal 53 Low Ref./Feedb. Value = 0 RPM 6-15 Terminal 53 High Ref./Feedb. Value = 1.500 RPM Switch S201 = OFF (U)
130BA287.10 +10V/30mA

current of the frequency converter. AMA can be carried out on up to one oversize motor.

It is possible to carry out a reduced AMA test with a Sine-wave filter installed. Avoid carrying out a complete AMA with a Sine-wave filter. If an overall setting is required, remove the Sine-wave filter while running a total AMA. After completion of the AMA, reinsert the Sine-wave filter. If motors are coupled in parallel, use only reduced AMA if any. Avoid running a complete AMA when using synchronous motors. If synchronous motors are applied, run a reduced AMA and manually set the extended motor data. The AMA function does not apply to permanent magnet motors. The frequency converter does not produce motor torque during an AMA. During an AMA, it is imperative that the application does not force the motor shaft to run, which is known to happen with e.g. wind milling in ventilation systems. This disturbs the AMA function.

6 6

Speed RPM P 6-15

39 42 50 53 54 55

Ref. voltage P 6-11 10V

1 kW

6.1.5 Smart Logic Control

A useful facility in the VLT HVAC Drive frequency converter is the Smart Logic Control (SLC). In applications where a PLC is generating a simple sequence the SLC may take over elementary tasks from the main control. SLC is designed to act from event send to or generated in the frequency converter. The frequency converter will then perform the pre-programmed action.

6.1.4 Automatic Motor Adaptation (AMA)

AMA is an algorithm to measure the electrical motor parameters on a motor at standstill. This means that AMA itself does not supply any torque. AMA is useful when commissioning systems and optimising the adjustment of the frequency converter to the applied motor. This feature is particularly used where the default setting does not apply to the connected motor. 1-29 Automatic Motor Adaptation (AMA) allows a choice of complete AMA with determination of all electrical motor parameters or reduced AMA with determination of the stator resistance Rs only. The duration of a total AMA varies from a few minutes on small motors to more than 15 minutes on large motors. Limitations and preconditions: For the AMA to determine the motor parameters optimally, enter the correct motor nameplate data in 1-20 Motor Power [kW] to 1-28 Motor Rotation Check.

6.1.6 Smart Logic Control Programming

The Smart Logic Control (SLC) is essentially a sequence of user defined actions (see 13-52 SL Controller Action) executed by the SLC when the associated user defined event (see 13-51 SL Controller Event) is evaluated as TRUE by the SLC. Events and actions are each numbered and are linked in pairs called states. This means that when event [1] is fulfilled (attains the value TRUE), action [1] is executed. After this, the conditions of event [2] will be evaluated and if evaluated TRUE, action [2]will be executed and so on. Events and actions are placed in array parameters. Only one event will be evaluated at any time. If an event is evaluated as FALSE, nothing happens (in the SLC) during the present scan interval and no other events will be evaluated. This means that when the SLC starts, it evaluates event [1] (and only event [1]) each scan interval. Only when event [1] is evaluated TRUE, the SLC executes action [1] and starts evaluating event [2].

For the best adjustment of the frequency converter, carry out AMA on a cold motor. Repeated AMA runs may lead to a heating of the motor, which results in an increase of the stator resistance, Rs. Normally, this is not critical. AMA can only be carried out if the rated motor current is minimum 35% of the rated output

116

MG.11.BA.02 - VLT is a registered Danfoss trademark

Application Examples

VLT HVAC Drive Design Guide

It is possible to program from 0 to 20 events and actions. When the last event / action has been executed, the sequence starts over again from event [1] / action [1]. The illustration shows an example with three events / actions:

State 1 Event 1/ Action 1 Stop event P13-02 State 4 Event 4/ Action 4

State 2 Event 2/ Action 2 Stop event P13-02

State 3 Event 3/ Action 3 Stop event P13-02

6.1.7 SLC Application Example

One sequence 1: Start ramp up run at reference speed 2 sec ramp down and hold shaft until stop.
130BA157.11

130BA062.13

Start event P13-01

6 6

Max. ref. P 3-03 Preset ref.(0) P 3-10(0)

State 2

State 3

State 1 Preset ref.(1) P 3-10(1) 2 sec 2 sec

Term 18 P 5-10(start)

Set the ramping times in 3-41 Ramp 1 Ramp Up Time and 3-42 Ramp 1 Ramp Down Time to the wanted times
tramp = tacc nnorm ( par . 1 25) ref RPM

Set term 27 to No Operation (5-12 Terminal 27 Digital Input) Set Preset reference 0 to first preset speed (3-10 Preset Reference [0]) in percentage of Max reference speed (3-03 Maximum Reference). Ex.: 60% Set preset reference 1 to second preset speed (3-10 Preset Reference [1] Ex.: 0 % (zero). Set the timer 0 for constant running speed in 13-20 SL Controller Timer [0]. Ex.: 2 sec.

Set Event 1 in 13-51 SL Controller Event [1] to True [1] Set Event 2 in 13-51 SL Controller Event [2] to On Reference [4] Set Event 3 in 13-51 SL Controller Event [3] to Time Out 0 [30] Set Event 4 in 13-51 SL Controller Event [4] to False [0] Set Action 1 in 13-52 SL Controller Action [1] to Select preset 0 [10] Set Action 2 in 13-52 SL Controller Action [2] to Start Timer 0 [29] Set Action 3 in 13-52 SL Controller Action [3] to Select preset 1 [11] Set Action 4 in 13-52 SL Controller Action [4] to No Action [1]

MG.11.BA.02 - VLT is a registered Danfoss trademark

117

Application Examples

VLT HVAC Drive Design Guide

Start command

Event 1 True (1) Action 1 Select Preset (10)

State 0 Stop command Event 2 On Reference (4) Action 2 Start Timer (29)

Event 4 False (0) Action 4 No Action (1)

State 1

6 6

State 2

Event 3 Time Out (30) Action 3 Select Preset ref. (11)

Set the Smart Logic Control in 13-00 SL Controller Mode to ON. Start / stop command is applied on terminal 18. If stop signal is applied the frequency converter will ramp down and go into free mode.

6.1.8 BASIC Cascade Controller

130BA362.10 Constant Speed Pumps (2)

In the BASIC Cascade Controller the frequency converter controls a variable speed motor as the variable speed pump (lead) and can stage up to two additional constant speed pumps on and off. By varying the speed of the initial pump, variable speed control of the entire system is provided. This maintains constant pressure while eliminating pressure surges, resulting in reduced system stress and quieter operation in pumping systems. Fixed Lead Pump The motors must be of equal size. The BASIC Cascade Controller allows the frequency converter to control up to 3 equal size pumps using the drives two built-in relays. When the variable pump (lead) is connected directly to the frequency converter, the other 2 pumps are controlled by the two built-in relays. When lead pump alternations is enabled, pumps are connected to the built-in relays and the frequency converter is capable of operating 2 pumps. Lead Pump Alternation The motors must be of equal size. This function makes it possible to cycle the frequency converter between the pumps in the system (maximum of 2 pumps). In this operation the run time between pumps is equalized reducing the required pump maintenance and increasing reliability and lifetime of the system. The alternation of the lead pump can take place at a command signal or at staging (adding another pump). The command can be a manual alternation or an alternation event signal. If the alternation event is selected, the lead pump alternation takes place every time the event occurs. Selections include whenever an alternation timer expires, at a predefined time of day or when the lead pump goes into

Variable Speed Pumps (1)

Pressure Sensor

Motor starter

Frequency Converter with Cascade Controller

The BASIC Cascade Controller is used for pump applications where a certain pressure (head) or level needs to be maintained over a wide dynamic range. Running a large pump at variable speed over a wide for range is not an ideal solution because of low pump efficiency and because there is a practical limit of about 25% rated full load speed for running a pump.

118

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA148.11

Application Examples

VLT HVAC Drive Design Guide

sleep mode. Staging is determined by the actual system load. A separate parameter limits alternation only to take place if total capacity required is > 50%. Total pump capacity is determined as lead pump plus fixed speed pumps capacities. Bandwidth Management In cascade control systems, to avoid frequent switching of fixed speed pumps, the desired system pressure is kept within a bandwidth rather than at a constant level. The Staging Bandwidth provides the required bandwidth for operation. When a large and quick change in system pressure occurs, the Override Bandwidth overrides the Staging Bandwidth to prevent immediate response to a short duration pressure change. An Override Bandwidth Timer can be programmed to prevent staging until the system pressure has stabilized and normal control established. When the Cascade Controller is enabled and running normally and the frequency converter issues a trip alarm, the system head is maintained by staging and destaging fixed speed pumps. To prevent frequent staging and destaging and minimize pressure fluxuations, a wider Fixed Speed Bandwidth is used instead of the Staging bandwidth.

the fixed speed pump will be cut out (de-staged). The lead pump continues to ramp up and then ramps down to a stop and the two relays are cut out. After a time delay, the relay for the fixed speed pump cuts in (staged) and this pump becomes the new lead pump. The new lead pump ramps up to maximum speed and then down to minimum speed when ramping down and reaching the staging frequency, the old lead pump is now cut in (staged) on the mains as the new fixed speed pump. If the lead pump has been running at minimum frequency (fmin) for a programmed amount of time, with a fixed speed pump running, the lead pump contributes little to the system. When the programmed value of the timer expires, the lead pump is removed, avoiding a deal heat water circulation problem.

6 6

6.1.10 System Status and Operation

If the lead pump goes into Sleep Mode, the function is displayed on the LCP. It is possible to alternate the lead pump on a Sleep Mode condition. When the Cascade Controller is enabled, the operation status for each pump and the Cascade Controller is displayed on the LCP. Information displayed includes:
130BA364.10

6.1.9 Pump Staging with Lead Pump Alternation

f max Destaging freq. f min Alternation command/PID stops Mains operation Time PID contr. starts Mains operation 5s Time

Pumps Status, is a read out of the status for the relays assigned to each pump. The display shows pumps that are disabled, off, running on the frequency converter or running on the mains/ motor starter. Cascade Status, is a read out of the status for the Cascade Controller. The display shows the Cascade Controller is disabled, all pumps are off, and emergency has stopped all pumps, all pumps are running, fixed speed pumps are being staged/destaged and lead pump alternation is occurring. De-stage at No-Flow ensures that all fixed speed pumps are stopped individually until the no-flow status disappears.

f max Staging freq.

With lead pump alternation enabled, a maximum of two pumps are controlled. At an alternation command, the lead pump will ramp to minimum frequency (fmin) and after a delay will ramp to maximum frequency (fmax). When the speed of the lead pump reaches the destaging frequency,

MG.11.BA.02 - VLT is a registered Danfoss trademark

119

Application Examples

VLT HVAC Drive Design Guide

6.1.11 Fixed Variable Speed Pump Wiring Diagram

130BA376.10 L1/L2/L3 L1/L2/L3 L1/L2/L3

Power Section

RELAY 1

6 6

6.1.12 Lead Pump Alternation Wiring Diagram

130BA377.13 L1/L2/L3 FC L1/L2/L3 L1/L2/L3

R1 R2

RELAY 2

k3 k2 K1

k3 k1 K2 K3

K1 K4

K1 K3 K4

Every pump must be connected to two contactors (K1/K2 and K3/K4) with a mechanical interlock. Thermal relays or other motor protection devices must be applied according to local regulation and/or individual demands.

RELAY 1 (R1) and RELAY 2 (R2) are the built-in relays in the frequency converter. When all relays are de-energized, the first built in relay to be energized will cut in the contactor corresponding to the pump controlled by the relay. E.g. RELAY 1 cuts in contactor K1, which becomes the lead pump. K1 blocks for K2 via the mechanical interlock preventing mains to be connected to the output of the frequency converter (via K1). Auxiliary break contact on K1 prevents K3 to cut in. RELAY 2 controls contactor K4 for on/off control of the fixed speed pump. At alternation both relays de-energizes and now RELAY 2 will be energized as the first relay.

120

MG.11.BA.02 - VLT is a registered Danfoss trademark

Application Examples

VLT HVAC Drive Design Guide

6.1.13 Cascade Controller Wiring Diagram

The wiring diagram shows an example with the built in BASIC Cascade Controller with one variable speed pump (lead) and two fixed speed pumps, a 4-20 mA transmitter and System Safety Interlock.
130BA378.10

Power Card
RELAY 2 (cascade pump 2.) RELAY 1 (cascade pump 1.)

Control Card
D IN1/D OUT (Safety Interlock) A IN1 A IN2 (Feedback 1 res.) D IN1/D OUT COM A OUT

+ 24V OUT

+ 10V OUT

+24V OUT

COM D IN

MOTOR 96 U 97 V 98 W PE 91 L1

MAINS 92 L2 93 L3 01 02 03 04 05 06

12

13

18

19

27

29

32

33

20

39

42

50

53

54

55

COM A IN

A OUT1

D IN 1 (Start)

D IN 1

D IN 1

D IN1

System Start/ Stop

System Safety Interlock

6 6

From Motor Control Circuitry N Pressure Transmitter 4-20 mA, 24 V dc

L1 L2 L3 PE

6.1.14 Start/Stop Conditions

Commands assigned to digital inputs. See Digital Inputs, parameter group 5-1*.
Variable speed pump (lead) Start (SYSTEM START /STOP) Lead Pump Start Coast (EMERGENCY STOP) Safety Interlock Ramps up if SYSTEM START is active Coast to stop Coast to stop Fixed speed pumps Not affected Cut out (built in relays are de-energized) Cut out (built in relays are de-energized)

Ramps up (if stopped and there is a demand) Staging (if stopped and there is a demand)

Function of buttons on LCP:

Variable speed pump (lead) Hand On Ramps up (if stopped by a normal stop command) or stays in operation if already running Ramps down Fixed speed pumps Destaging (if running)

Off Auto On

Ramps down

Starts and stops according to commands via Staging/Destaging terminals or serial bus

MG.11.BA.02 - VLT is a registered Danfoss trademark

121

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

7 RS-485 Installation and Set-up

7.1 RS-485 Installation and Set-up
130BB022.10 61 68 69

7.1.1 Overview
RS-485 is a two-wire bus interface compatible with multidrop network topology, i.e. nodes can be connected as a bus, or via drop cables from a common trunk line. A total of 32 nodes can be connected to one network segment. Repeaters divide network segments. Please note that each repeater functions as a node within the segment in which it is installed. Each node connected within a given network must have a unique node address, across all segments. Terminate each segment at both ends, using either the termination switch (S801) of the frequency converters or a biased termination resistor network. Always use screened twisted pair (STP) cable for bus cabling, and always follow good common installation practice. Low-impedance earth connection of the screen at every node is important, including at high frequencies. Thus, connect a large surface of the screen to earth, for example with a cable clamp or a conductive cable gland. It may be necessary to apply potential-equalizing cables to maintain the same earth potential throughout the network. Particularly in installations with long cables. To prevent impedance mismatch, always use the same type of cable throughout the entire network. When connecting a motor to the frequency converter, always use screened motor cable.
Cable: Screened twisted pair (STP) Impedance: 120 Cable length: Max. 1200m (including drop lines) Max. 500m station-to-station

7 7

Illustration 7.1 Network Terminal Connection

61 68 69

39

42

50

53

54

55

Remove jumper to enable Safe Stop 12 13 18 19 27 29 32 33 20 37

7.1.2 Network Connection

Connect the frequency converter to the RS-485 network as follows (see also diagram): 1. Connect signal wires to terminal 68 (P+) and terminal 69 (N-) on the main control board of the frequency converter. 2. Connect the cable screen to the cable clamps.

Illustration 7.2 Control Card Terminals

NOTE
Screened, twisted-pair cables are recommended in order to reduce noise between conductors.

122

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BB021.10

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

7.1.3 Frequency Converter Hardware Setup

Use the terminator dip switch on the main control board of the frequency converter to terminate the RS-485 bus.
130BA272.11

ON S801 1 2

The RS-485 communication cable must be kept away from motor and brake resistor cables to avoid coupling of high frequency noise from one cable to another. Normally a distance of 200mm (8 inches) is sufficient, but keeping the greatest possible distance between the cables is generally recommended, especially where cables run in parallel over long distances. When crossing is unavoidable, the RS-485 cable must cross motor and brake resistor cables at an angle of 90 degrees.
130BA080.10
Fieldbus cable

Illustration 7.3 Terminator Switch Factory Setting

The factory setting for the dip switch is OFF.

7.1.4 Frequency Converter Parameter Settings for Modbus Communication

The following parameters apply to the RS-485 interface (FCport):
Parameter 8-30 Protocol 8-31 Address Function Select the application protocol to run on the RS-485 interface Set the node address. Note: The address range depends on the protocol selected in 8-30 Protocol 8-32 Baud Rate Set the baud rate. Note: The default baud rate depends on the protocol selected in 8-30 Protocol 8-33 Parity / Stop Bits 8-35 Minimum Response Delay Set the parity and number of stop bits. Note: The default selection depends on the protocol selected in 8-30 Protocol Specify a minimum delay time between receiving a request and transmitting a response. This can be used for overcoming modem turnaround delays. Specify a maximum delay time between transmitting a request and receiving a response. Specify a maximum delay time between two received bytes to ensure time-out if transmission is interrupted.

7 7
Min.200mm

90 crossing

Brake resistor

7.2 FC Protocol Overview

The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss standard fieldbus. It defines an access technique according to the master-slave principle for communications via a serial bus. One master and a maximum of 126 slaves can be connected to the bus. The master selects the individual slaves via an address character in the telegram. A slave itself can never transmit without first being requested to do so, and direct message transfer between the individual slaves is not possible. Communications occur in the half-duplex mode. The master function cannot be transferred to another node (single-master system).

8-36 Maximum Response Delay 8-37 Maximum Inter-Char Delay

7.1.5 EMC Precautions

The following EMC precautions are recommended in order to achieve interference-free operation of the RS-485 network. Relevant national and local regulations, for example regarding protective earth connection, must be observed.

MG.11.BA.02 - VLT is a registered Danfoss trademark

123

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

The physical layer is RS-485, thus utilizing the RS-485 port built into the frequency converter. The FC protocol supports different telegram formats:

control options, including controlling the setpoint of the frequency converter when its internal PID controller is used.

A short format of 8 bytes for process data. A long format of 16 bytes that also includes a parameter channel. A format used for texts.

7.3 Network Configuration 7.3.1 Frequency Converter Set-up

Set the following parameters to enable the FC protocol for the frequency converter.
Parameter Number Setting 8-30 Protocol 8-31 Address 8-32 Baud Rate 8-33 Parity / Stop Bits FC 1 - 126 2400 - 115200 Even parity, 1 stop bit (default)

7.2.1 FC with Modbus RTU

The FC protocol provides access to the Control Word and Bus Reference of the frequency converter. The Control Word allows the Modbus master to control several important functions of the frequency converter:

7 7

Start Stop of the frequency converter in various ways: Coast stop Quick stop DC Brake stop Normal (ramp) stop Reset after a fault trip Run at a variety of preset speeds Run in reverse Change of the active set-up Control of the two relays built into the frequency converter

7.4 FC Protocol Message Framing Structure 7.4.1 Content of a Character (byte)

Each character transferred begins with a start bit. Then 8 data bits are transferred, corresponding to a byte. Each character is secured via a parity bit. This bit is set at "1" when it reaches parity. Parity is when there is an equal number of 1s in the 8 data bits and the parity bit in total. A stop bit completes a character, thus consisting of 11 bits in all.
195NA036.10

The Bus Reference is commonly used for speed control. It is also possible to access the parameters, read their values, and where possible, write values to them. This permits a range of

Start bit

Even Stop Parity bit

7.4.2 Telegram Structure

Each telegram has the following structure: 1. 2. 3. Start character (STX)=02 Hex A byte denoting the telegram length (LGE) A byte denoting the frequency converter address (ADR)

A number of data bytes (variable, depending on the type of telegram) follows. A data control byte (BCC) completes the telegram.
195NA099.10

STX

LGE

ADR

DATA

BCC

124

MG.11.BA.02 - VLT is a registered Danfoss trademark

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

7.4.3 Telegram Length (LGE)

The telegram length is the number of data bytes plus the address byte ADR and the data control byte BCC. The length of telegrams with 4 data bytes is The length of telegrams with 12 data bytes is The length of telegrams containing texts is
1)

LGE = 4 + 1 + 1 = 6 bytes LGE = 12 + 1 + 1 = 14 bytes 101)+n bytes

The 10 represents the fixed characters, while the n is variable (depending on the length of the text).

7.4.4 Frequency Converter Address (ADR)

Two different address formats are used. The address range of the frequency converter is either 1-31 or 1-126. 1. Address format 1-31: 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 2. Address format 1-126: Bit 7 = 1 (address format 1-126 active) Bit 0-6 = frequency converter address 1-126 Bit 0-6 = 0 Broadcast The slave returns the address byte unchanged to the master in the response telegram.

7 7

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.

7.4.6 The Data Field

The structure of data blocks depends on the type of telegram. There are three telegram types, and the type applies for both control telegrams (master=>slave) and response telegrams (slave=>master). The 3 types of telegram are: Process block (PCD) The PCD is made up of a data block of 4 bytes (2 words) and contains: Control word and reference value (from master to slave) Status word and present output frequency (from slave to master)
130BA269.10

STX

LGE

ADR

PCD1

PCD2

BCC

MG.11.BA.02 - VLT is a registered Danfoss trademark

125

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

Parameter block The parameter block is used to transfer parameters between master and slave. The data block is made up of 12 bytes (6 words) and also contains the process block.
STX LGE ADR PKE IND

PWEhigh

PWElow

PCD1

PCD2

BCC

Text block The text block is used to read or write texts via the data block.
STX LGE ADR PKE IND Ch1 Ch2 Chn PCD1 PCD2 BCC 130BA270.10

7.4.7 The PKE Field

The PKE field contains two sub-fields: Parameter command and response AK, and Parameter number PNU:
130BA268.10

7 7

PKE

IND

PWEhigh

PWElow

AK 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

PNU

Bits no. 12-15 transfer parameter commands from master to slave and return processed slave responses to the master.
Parameter commands master slave Bit no. 15 0 0 0 0 1 1 1 14 0 0 0 0 1 1 1 13 0 0 1 1 0 1 1 12 0 1 0 1 1 0 1 No command Read parameter value Write parameter value in RAM (word) Write parameter value in RAM (double word) Write parameter value in RAM and EEprom (double word) Write parameter value in RAM and EEprom (word) Read/write text Parameter command

Parameter commands and replies

Parameter number

126

MG.11.BA.02 - VLT is a registered Danfoss trademark

130BA271.10

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

Response slave master Bit no. 15 0 0 0 0 1 14 0 0 0 1 1 13 0 0 1 1 1 12 0 1 0 1 1 No response Parameter value transferred (word) Parameter value transferred (double word) Command cannot be performed text transferred Response

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):
PWE low (Hex) 0 1 2 3 4 5 11 82 83 Fault Report The parameter number used does not exit There is no write access to the defined parameter Data value exceeds the parameter's limits The sub index used does not exit The parameter is not the array type The data type does not match the defined parameter Data change in the defined parameter is not possible in the frequency converter's present mode. Certain parameters can only be changed when the motor is turned off There is no bus access to the defined parameter Data change is not possible because factory setup is selected

7 7

7.4.8 Parameter Number (PNU)

Bits no. 0-11 transfer parameter numbers. The function of the relevant parameter is defined in the parameter description in .

corresponds to Danish, select the data value by entering the value in the PWE block. See Example - Selecting a data value. Serial communication is only capable of reading parameters containing data type 9 (text string). 15-40 FC Type to 15-53 Power Card Serial Number contain data type 9. For example, read the unit size and mains voltage range in 15-40 FC Type. When a text string is transferred (read), the length of the telegram is variable, and the texts are of different lengths. The telegram length is defined in the second byte of the telegram, LGE. When using text transfer the index character indicates whether it is a read or a write command. To read a text via the PWE block, set the parameter command (AK) to F Hex. The index character high-byte must be 4. Some parameters contain text that can be written to via the serial bus. To write a text via the PWE block, set the parameter command (AK) to F Hex. The index characters high-byte must be 5.
130BA275.10 PKE Read text Write text Fx xx Fx xx IND 04 00 05 00 PWE high PWE low

7.4.9 Index (IND)

The index is used together with the parameter number to read/write-access parameters with an index, e.g. 15-30 Alarm Log: Error Code. The index consists of 2 bytes, a low byte and a high byte. Only the low byte is used as an index.

7.4.10 Parameter Value (PWE)

The parameter value block consists of 2 words (4 bytes), and the value depends on the defined command (AK). The master prompts for a parameter value when the PWE block contains no value. To change a parameter value (write), write the new value in the PWE block and send from the master to the slave. When a slave responds to a parameter request (read command), the present parameter value in the PWE block is transferred and returned to the master. If a parameter contains not a numerical value but several data options, e.g. 0-01 Language where [0] corresponds to English, and [4]

MG.11.BA.02 - VLT is a registered Danfoss trademark

127

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

7.4.11 Data Types Supported by the Frequency Converter

Unsigned means that there is no operational sign in the telegram.
Data types 3 4 5 6 7 9 10 13 33 35 Description Integer 16 Integer 32 Unsigned 8 Unsigned 16 Unsigned 32 Text string Byte string Time difference Reserved Bit sequence

Conversion index 100 75 74 67 6 5 4 3 2 1 0 -1 -2 -3 -4 -5 -6 -7 Table 7.1 Conversion table

Conversion factor

1000000 100000 10000 1000 100 10 1 0.1 0.01 0.001 0.0001 0.00001 0.000001 0.0000001

7 7

7.4.12 Conversion
The various attributes of each parameter are displayed in the section Factory Settings. Parameter values are transferred as whole numbers only. Conversion factors are therefore used to transfer decimals. 4-12 Motor Speed Low Limit [Hz] has a conversion factor of 0.1. To preset the minimum frequency to 10 Hz, transfer the value 100. A conversion factor of 0.1 means that the value transferred is multiplied by 0.1. The value 100 is thus perceived as 10.0. Examples: 0s --> conversion index 0 0.00s --> conversion index -2 0ms --> conversion index -3 0.00ms --> conversion index -5

7.4.13 Process Words (PCD)

The block of process words is divided into two blocks of 16 bits, which always occur in the defined sequence.
PCD 1 Control telegram (master slave Control word) Control telegram (slave master) Status word PCD 2 Reference-value Present output frequency

7.5 Examples 7.5.1 Writing a Parameter Value

Change 4-14 Motor Speed High Limit [Hz] to 100 Hz. 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 - Data value 1000, corresponding to 100 Hz, see Conversion. The telegram will look like this:
130BA092.10

E19E PKE

H 0000 IND

H 0000 PWE high

H 03E8 PWE low

128

MG.11.BA.02 - VLT is a registered Danfoss trademark

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

NOTE
4-14 Motor Speed High Limit [Hz] is a single word, and the parameter command for write in EEPROM is E. Parameter number 4-14 is 19E in hexadecimal. The response from the slave to the master will be:
130BA093.10

7.6.3 Modbus RTU Overview

Regardless of the type of physical communication networks, the Modbus RTU Overview describes the process a controller uses to request access to another device. This process includes how the Modbus RTU responds to requests from another device, and how errors are detected and reported. It also establishes a common format for the layout and contents of message fields. During communications over a Modbus RTU network, the protocol determines: How each controller learns its device address Recognizes a message addressed to it Determines which actions to take Extracts any data or other information contained in the message If a reply is required, the controller constructs the reply message and sends it. Controllers communicate using a master-slave technique in which only one device (the master) can initiate transactions (called queries). The other devices (slaves) respond by supplying the requested data to the master, or by taking the action requested in the query. The master can address individual slaves, or can initiate a broadcast message to all slaves. Slaves return a message (called a response) to queries that are addressed to them individually. No responses are returned to broadcast queries from the master. The Modbus RTU protocol establishes the format for the masters query by placing into it the device (or broadcast) address, a function code defining the requested action, any data to be sent, and an error-checking field. The slaves response message is also constructed using Modbus protocol. It contains fields confirming the action taken, any data to be returned, and an error-checking field. If an error occurs in receipt of the message, or if the slave is unable to perform the requested action, the slave will construct an error message, and send it in response, or a time-out occurs.

119E PKE

H 0000 IND

H 0000 PWE high

H 03E8 PWE low

7.5.2 Reading a Parameter Value

Read the value in 3-41 Ramp 1 Ramp Up Time PKE = 1155 Hex - Read parameter value in 3-41 Ramp 1 Ramp Up Time IND = 0000 Hex PWEHIGH = 0000 Hex PWELOW = 0000 Hex
130BA094.10

7 7

1155 PKE

H 0000 IND

0000 PWE high

H 0000 PWE low

If the value in 3-41 Ramp 1 Ramp Up Time is 10 s, the response from the slave to the master will be:
130BA267.10

1155 PKE

H 0000 IND

H 0000 PWE high

H 03E8 PWE low

3E8 Hex corresponds to 1000 decimal. The conversion index for 3-41 Ramp 1 Ramp Up Time is -2, i.e. 0.01. 3-41 Ramp 1 Ramp Up Time is of the type Unsigned 32.

7.6 Modbus RTU Overview 7.6.1 Assumptions

Danfoss assumes that the installed controller supports the interfaces in this document, and strictly observe all requirements and limitations stipulated in the controller and frequency converter.

7.6.4 Frequency Converter with Modbus RTU

The frequency converter communicates in Modbus RTU format over the built-in RS-485 interface. Modbus RTU provides access to the Control Word and Bus Reference of the frequency converter. The Control Word allows the Modbus master to control several important functions of the frequency converter:

7.6.2 What the User Should Already Know

The Modbus RTU (Remote Terminal Unit) is designed to communicate with any controller that supports the interfaces defined in this document. It is assumed that the user has full knowledge of the capabilities and limitations of the controller.

Start Stop of the frequency converter in various ways: Coast stop Quick stop

MG.11.BA.02 - VLT is a registered Danfoss trademark

129

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

DC Brake stop Normal (ramp) stop

7.8.2 Modbus RTU Message Structure

The transmitting device places a Modbus RTU message into a frame with a known beginning and ending point. This allows receiving devices to begin at the start of the message, read the address portion, determine which device is addressed (or all devices, if the message is broadcast), and to recognise when the message is completed. Partial messages are detected and errors set as a result. Characters for transmission must be in hexadecimal 00 to FF format in each field. The frequency converter continuously monitors the network bus, also during silent intervals. When the first field (the address field) is received, each frequency converter or device decodes it to determine which device is being addressed. Modbus RTU messages addressed to zero are broadcast messages. No response is permitted for broadcast messages. A typical message frame is shown below. Typical Modbus RTU Message Structure
Start T1-T2-T3T4 Address 8 bits Function 8 bits Data N x 8 bits CRC check 16 bits End T1-T2-T3T4

Reset after a fault trip Run at a variety of preset speeds Run in reverse Change the active set-up Control the frequency converters built-in relay

The Bus Reference is commonly used for speed control. It is also possible to access the parameters, read their values, and where possible, write values to them. This permits a range of control options, including controlling the setpoint of the frequency converter when its internal PI controller is used.

7.7 Network Configuration 7.7.1 Frequency Converter with Modbus RTU

To enable Modbus RTU on the frequency converter, set the following parameters:
Parameter Number 8-30 Protocol 8-31 Address 8-33 Parity / Stop Bits Parameter name Protocol Address Parity/Stop bits Setting Modbus RTU 1 - 247 2400 - 115200 Even parity, 1 stop bit (default)

7 7

7.8.3 Start/Stop Field

Messages start with a silent period of at least 3.5 character intervals. This is implemented as a multiple of character intervals at the selected network baud rate (shown as Start T1-T2-T3-T4). The first field to be transmitted is the device address. Following the last transmitted character, a similar period of at least 3.5 character intervals marks the end of the message. A new message can begin after this period. The entire message frame must be transmitted as a continuous stream. If a silent period of more than 1.5 character intervals occurs before completion of the frame, the receiving device flushes the incomplete message and assumes that the next byte will be the address field of a new message. Similarly, if a new message begins prior to 3.5 character intervals after a previous message, the receiving device will consider it a continuation of the previous message. This will cause a timeout (no response from the slave), since the value in the final CRC field will not be valid for the combined messages.

8-32 Baud Rate Baud Rate

7.8 Modbus RTU Message Framing Structure 7.8.1 Frequency Converter with Modbus RTU
The controllers are set up to communicate on the Modbus network using RTU (Remote Terminal Unit) mode, with each byte in a message containing 2 4-bit hexadecimal characters. The format for each byte is shown below.
Start bit Data byte Stop/ parity Stop

7.8.4 Address Field

Coding System 8-bit binary, hexadecimal 0-9, A-F. 2 hexadecimal characters contained in each 8bit field of the message 1 8 1 1 start bit data bits, least significant bit sent first bit for even/odd parity; no bit for no parity stop bit if parity is used; 2 bits if no parity

Bits Per Byte

Error Check Field

Cyclical Redundancy Check (CRC)

The address field of a message frame contains 8 bits. Valid slave device addresses are in the range of 0 247 decimal. The individual slave devices are assigned addresses in the range of 1 247. (0 is reserved for broadcast mode, which all slaves recognize.) A master addresses a slave by placing the slave address in the address field of the message. When the slave sends its response, it places its own address in this address field to let the master know which slave is responding.

130

MG.11.BA.02 - VLT is a registered Danfoss trademark

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

7.8.5 Function Field

The function field of a message frame contains 8 bits. Valid codes are in the range of 1-FF. Function fields are used to send messages between master and slave. When a message is sent from a master to a slave device, the function code field tells the slave what kind of action to perform. When the slave responds to the master, it uses the function code field to indicate either a normal (error-free) response, or that some kind of error occurred (called an exception response). For a normal response, the slave simply echoes the original function code. For an exception response, the slave returns a code that is equivalent to the original function code with its most significant bit set to logic 1. In addition, the slave places a unique code into the data field of the response message.

This tells the master what kind of error occurred, or the reason for the exception. Please also refer to the sections Function Codes Supported by Modbus RTU and Exception Codes.

7.8.6 Data Field

The data field is constructed using sets of two hexadecimal digits, in the range of 00 to FF hexadecimal. These are made up of one RTU character. The data field of messages sent from a master to slave device contains additional information which the slave must use to take the action defined by the function code. This can include items such as coil or register addresses, the quantity of items to be handled, and the count of actual data bytes in the field.

7.8.7 CRC Check Field

Messages include an error-checking field, operating on the basis of a Cyclical Redundancy Check (CRC) method. The CRC field checks the contents of the entire message. It is applied regardless of any parity check method used for the individual characters of the message. The CRC value is calculated by the transmitting device, which appends the CRC as the last field in the message. The receiving device recalculates a CRC during receipt of the message and compares the calculated value to the actual value received in the CRC field. If the two values are unequal, a bus time-out results. 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.

7 7

MG.11.BA.02 - VLT is a registered Danfoss trademark

131

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

7.8.8 Coil Register Addressing

In Modbus, all data are organized in coils and holding registers. Coils hold a single bit, whereas holding registers hold a 2-byte word (i.e. 16 bits). All data addresses in Modbus messages are referenced to zero. The first occurrence of a data item is addressed as item number zero. For example: The coil known as coil 1 in a programmable controller is addressed as coil 0000 in the data address field of a Modbus message. Coil 127 decimal is addressed as coil 007EHEX (126 decimal).
Coil Number 1-16 17-32 33-48 49-64 65 Description Frequency converter control word (see table below) Frequency converter speed or set-point reference Range 0x0 0xFFFF (-200% ... ~200%) Frequency converter status word (see table below) Open loop mode: Frequency converter output frequency Closed loop mode: frequency converter feedback signal Parameter write control (master to slave) 0= 1= 66-65536 Coil 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 0 Preset reference LSB Preset reference MSB DC brake Coast stop Quick stop Freeze freq. Ramp stop No reset No jog Ramp 1 Data not valid Relay 1 off Relay 2 off Set up LSB Set up MSB No reversing Reversing No DC brake No coast stop No quick stop No freeze freq. Start Reset Jog Ramp 2 Data valid Relay 1 on Relay 2 on 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Reserved 1 Coil 33 34 0 Control not ready frequency converter not ready Coasting stop No alarm Not used Not used Not used No warning Not at reference Hand mode Out of freq. range Stopped Not used No voltage warning Not in current limit No thermal warning 1 Control ready frequency converter ready Safety closed Alarm Not used Not used Not used Warning At reference Auto mode In frequency range Running Not used Voltage warning Current limit Thermal warning Parameter changes are written to the RAM of the frequency converter Parameter changes are written to the RAM and EEPROM of the frequency converter.

Holding register 40001 is addressed as register 0000 in the data address field of the message. The function code field already specifies a holding register operation. Therefore, the 4XXXX reference is implicit. Holding register 40108 is addressed as register 006BHEX (107 decimal).

Signal Direction Master to slave Master to slave Slave to master Slave to master Master to slave

7 7

frequency converter control word (FC profile)

frequency converter status word (FC profile)

132

MG.11.BA.02 - VLT is a registered Danfoss trademark

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

Holding registers Register Number 00001-00006 00007 00008 00009 00010-00990 01000-01990 02000-02990 03000-03990 04000-04990 ... 49000-49990 50000 50010 ... 50200 50210 Description Reserved Last error code from an FC data object interface Reserved Parameter index* 000 parameter group (parameters 001 through 099) 100 parameter group (parameters 100 through 199) 200 parameter group (parameters 200 through 299) 300 parameter group (parameters 300 through 399) 400 parameter group (parameters 400 through 499) ... 4900 parameter group (parameters 4900 through 4999) Input data: frequency converter control word register (CTW). Input data: Bus reference register (REF). ... Output data: frequency converter status word register (STW). Output data: frequency converter main actual value register (MAV).

7 7

* Used to specify the index number to be used when accessing an indexed parameter.

7.8.9 How to Control the Frequency Converter

This section describes codes which can be used in the function and data fields of a Modbus RTU message.
Function Function Code Subfunction code 1 2 10 Sub-function

7.8.10 Function Codes Supported by Modbus RTU

Modbus RTU supports use of the following function codes in the function field of a message.
Function Read coils Read holding registers Write single coil Write single register Write multiple coils Write multiple registers Get comm. event counter Report slave ID Function Code 1 hex 3 hex 5 hex 6 hex F hex 10 hex B hex 11 hex

Diagnostic 8 s

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

11 12 13 14

7.8.11 Modbus Exception Codes

For a full explanation of the structure of an exception code response, please refer to , Function Field. Modbus Exception Codes
Co Name de 1 Meaning

Illegal function The function code received in the query is not an allowable action for the server (or slave). This may be because the function code is only applicable to newer devices, and was not implemented in the unit selected. It could also indicate that the server (or slave) is in the wrong state to process a request of this type, for example because it is not configured and is being asked to return register values.

MG.11.BA.02 - VLT is a registered Danfoss trademark

133

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

Modbus Exception Codes

2 Illegal data address The data address received in the query is not an allowable address for the server (or slave). More specifically, the combination of reference number and transfer length is invalid. For a controller with 100 registers, a request with offset 96 and length 4 would succeed, a request with offset 96 and length 5 will generate exception 02. A value contained in the query data field is not an allowable value for server (or slave). This indicates a fault in the structure of the remainder of a complex request, such as that the implied length is incorrect. It specifically does NOT mean that a data item submitted for storage in a register has a value outside the expectation of the application program, since the Modbus protocol is unaware of the significance of any particular value of any particular register. An unrecoverable error occurred while the server (or slave) was attempting to perform the requested action.

7.9.5 Conversion Factor

The different attributes for each parameter can be seen in the section on factory settings. Since a parameter value can only be transferred as a whole number, a conversion factor must be used to transfer decimals. Please refer to the Parameters section.

Illegal data value

7.9.6 Parameter Values

Standard Data Types Standard data types are int16, int32, uint8, uint16 and uint32. They are stored as 4x registers (40001 4FFFF). The parameters are read using function 03HEX "Read Holding Registers." Parameters are written using the function 6HEX "Preset Single Register" for 1 register (16 bits), and the function 10HEX "Preset Multiple Registers" for 2 registers (32 bits). Readable sizes range from 1 register (16 bits) up to 10 registers (20 characters). Non standard Data Types Non standard data types are text strings and are stored as 4x registers (40001 4FFFF). The parameters are read using function 03HEX "Read Holding Registers" and written using function 10HEX "Preset Multiple Registers." Readable sizes range from 1 register (2 characters) up to 10 registers (20 characters).

7 7
4 Slave device failure

7.9 How to Access Parameters 7.9.1 Parameter Handling

The PNU (Parameter Number) is translated from the register address contained in the Modbus read or write message. The parameter number is translated to Modbus as (10 x parameter number) DECIMAL.

7.10 Examples
The following examples illustrate various Modbus RTU commands. If an error occurs, please refer to the Exception Codes section.

7.9.2 Storage of Data

The Coil 65 decimal determines whether data written to the frequency converter are stored in EEPROM and RAM (coil 65 = 1) or only in RAM (coil 65 = 0).

7.10.1 Read Coil Status (01 HEX)

Description This function reads the ON/OFF status of discrete outputs (coils) in the frequency converter. Broadcast is never supported for reads. Query The query message specifies the starting coil and quantity of coils to be read. Coil addresses start at zero, i.e. coil 33 is addressed as 32. Example of a request to read coils 33-48 (Status Word) from slave device 01.

7.9.3 IND
The array index is set in Holding Register 9 and used when accessing array parameters.

7.9.4 Text Blocks

Parameters stored as text strings are accessed in the same way as the other parameters. The maximum text block size is 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.

134

MG.11.BA.02 - VLT is a registered Danfoss trademark

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

Field Name Slave Address Function Starting Address HI Starting Address LO No. of Points HI No. of Points LO Error Check (CRC)

Example (HEX) 01 (frequency converter address) 01 (read coils) 00 20 (32 decimals) Coil 33 00 10 (16 decimals) -

Response The normal response is an echo of the query, returned after the coil state has been forced.
Field Name Slave Address Function Force Data HI Force Data LO Quantity of Coils HI Quantity of Coils LO Error Check (CRC) Example (HEX) 01 05 FF 00 00 01 -

Response The coil status in the response message is packed as one coil per bit of the data field. Status is indicated as: 1 = ON; 0 = OFF. The LSB of the first data byte contains the coil addressed in the query. The other coils follow toward the high order end of this byte, and from low order to high order in subsequent bytes. If the returned coil quantity is not a multiple of eight, the remaining bits in the final data byte will be padded with zeros (toward the high order end of the byte). The Byte Count field specifies the number of complete bytes of data.
Field Name Slave Address Function Byte Count Data (Coils 40-33) Data (Coils 48-41) Error Check (CRC) Example (HEX) 01 (frequency converter address) 01 (read coils) 02 (2 bytes of data) 07 06 (STW=0607hex) -

7.10.3 Force/Write Multiple Coils (0F HEX)

This function forces each coil in a sequence of coils to either ON or OFF. When broadcast the function forces the same coil references in all attached slaves. The query message specifies the coils 17 to 32 (speed setpoint) to be forced.

7 7

NOTE
Coil addresses start at zero, i.e. coil 17 is addressed as 16.
Field Name Slave Address Function Coil Address HI Coil Address LO Quantity of Coils HI Quantity of Coils LO Byte Count Force Data HI (Coils 8-1) Force Data LO (Coils 10-9) Error Check (CRC) Example (HEX) 01 (frequency converter address) 0F (write multiple coils) 00 10 (coil address 17) 00 10 (16 coils) 02 20 00 (ref. = 2000hex) -

NOTE
Coils and registers are addressed explicit with an off-set of -1 in Modbus. I.e. Coil 33 is addressed as Coil 32.

7.10.2 Force/Write Single Coil (05 HEX)

Description This function forces a writes a coil to either ON or OFF. When broadcast the function forces the same coil references in all attached slaves. Query The query message specifies the coil 65 (parameter write control) to be forced. Coil addresses start at zero, i.e. coil 65 is addressed as 64. Force Data = 00 00HEX (OFF) or FF 00HEX (ON).
Field Name Slave Address Function Coil Address HI Coil Address LO Force Data HI Force Data LO Error Check (CRC) Example (HEX) 01 (frequency converter address) 05 (write single coil) 00 40 (64 decimal) Coil 65 FF 00 (FF 00 = ON) -

Response The normal response returns the slave address, function code, starting address, and quantity of coiles forced.
Field Name Slave Address Function Coil Address HI Coil Address LO Quantity of Coils HI Quantity of Coils LO Error Check (CRC) Example (HEX) 01 (frequency converter address) 0F (write multiple coils) 00 10 (coil address 17) 00 10 (16 coils) -

MG.11.BA.02 - VLT is a registered Danfoss trademark

135

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

7.10.4 Read Holding Registers (03 HEX)

Description This function reads the contents of holding registers in the slave. Query The query message specifies the starting register and quantity of registers to be read. Register addresses start at zero, i.e. registers 1-4 are addressed as 0-3. Example: Read 3-03 Maximum Reference, register 03030.
Field Name Slave Address Function Starting Address HI Starting Address LO No. of Points HI No. of Points LO Error Check (CRC) Example (HEX) 01 03 (read holding registers) 0B (Register address 3029) 05 (Register address 3029) 00 02 - (Par. 3-03 is 32 bits long, i.e. 2 registers) -

Example: Write to , register 1000.

Field Name Slave Address Function Register Address HI Register Address LO Preset Data HI Preset Data LO Error Check (CRC) Example (HEX) 01 06 03 (Register address 999) E7 (Register address 999) 00 01 -

Response Response The normal response is an echo of the query, returned after the register contents have been passed.
Field Name Slave Address Function Register Address HI Register Address LO Preset Data HI Preset Data LO Error Check (CRC) Example (HEX) 01 06 03 E7 00 01 -

7 7

Response The register data in the response message are packed as two bytes per register, with the binary contents right justified within each byte. For each register, the first byte contains the high order bits and the second contains the low order bits. Example: Hex 0016E360 = 1.500.000 = 1500 RPM.
Field Name Slave Address Function Byte Count Data HI (Register 3030) Data LO (Register 3030) Data HI (Register 3031) Data LO (Register 3031) Error Check (CRC) Example (HEX) 01 03 04 00 16 E3 60 -

7.10.6 Preset Multiple Registers (10 HEX)

Description This function presets values into a sequence of holding registers. Query The query message specifies the register references to be preset. Register addresses start at zero, i.e. register 1 is addressed as 0. Example of a request to preset two registers (set parameter 1-24 = 738 (7.38 A)):
Field Name Slave Address Function Starting Address HI Starting Address LO No. of Registers HI No. of registers LO Byte Count Write Data HI (Register 4: 1049) Write Data LO (Register 4: 1049) Write Data HI (Register 4: 1050) Write Data LO (Register 4: 1050) Error Check (CRC) Example (HEX) 01 10 04 19 00 02 04 00 00 02 E2 -

7.10.5 Preset Single Register (06 HEX)

Description This function presets a value into a single holding register. Query The query message specifies the register reference to be preset. Register addresses start at zero, i.e. register 1 is addressed as 0.

136

MG.11.BA.02 - VLT is a registered Danfoss trademark

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

Response The normal response returns the slave address, function code, starting address, and quantity of registers preset.
Field Name Slave Address Function Starting Address HI Starting Address LO No. of Registers HI No. of registers LO Error Check (CRC) Example (HEX) 01 10 04 19 00 02 -

Programmed ref. value 1 2 3 4

Parameter 3-10 Preset Reference [0] 3-10 Preset Reference [1] 3-10 Preset Reference [2] 3-10 Preset Reference [3]

Bit 01 0 0 1 1

Bit 00 0 1 0 1

NOTE
Make a selection in 8-56 Preset Reference Select to define how Bit 00/01 gates with the corresponding function on the digital inputs. Bit 02, DC brake: Bit 02 = 0 leads to DC braking and stop. Set braking current and duration in 2-01 DC Brake Current and 2-02 DC Braking Time. Bit 02 = 1 leads to ramping. Bit 03, Coasting: Bit 03 = 0: The frequency converter immediately "lets go" of the motor, (the output transistors are "shut off") and it coasts to a standstill. Bit 03 = 1: The frequency converter starts the motor if the other starting conditions are met. Make a selection in 8-50 Coasting Select to define how Bit 03 gates with the corresponding function on a digital input. Bit 04, Quick stop: Bit 04 = 0: Makes the motor speed ramp down to stop (set in 3-81 Quick Stop Ramp Time). Bit 05, Hold output frequency Bit 05 = 0: The present output frequency (in Hz) freezes. Change the frozen output frequency only by means of the digital inputs (5-10 Terminal 18 Digital Input to 5-15 Terminal 33 Digital Input) programmed to Speed up and Slow down.

7.11 Danfoss FC Control Profile 7.11.1 Control Word According to FC Profile (8-10 Control Profile = FC profile)
130BA274.10 Master-slave CTW Speed ref.

7 7

Bit no.:

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Bit 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15

Bit value = 0 Reference value Reference value DC brake Coasting Quick stop Hold output frequency Ramp stop No function No function Ramp 1 Data invalid No function No function Parameter set-up Parameter set-up No function

Bit value = 1 external selection lsb external selection msb Ramp No coasting Ramp use ramp Start Reset Jog Ramp 2 Data valid Relay 01 active Relay 02 active selection lsb selection msb Reverse

NOTE
If Freeze output is active, the frequency converter can only be stopped by the following:

Explanation of the Control Bits Bits 00/01 Bits 00 and 01 are used to choose between the four reference values, which are pre-programmed in 3-10 Preset Reference according to the following table:

Bit 03 Coasting stop Bit 02 DC braking Digital input (5-10 Terminal 18 Digital Input to 5-15 Terminal 33 Digital Input) programmed to DC braking, Coasting stop, or Reset and coasting stop.

Bit 06, Ramp stop/start: Bit 06 = 0: Causes a stop and makes the motor speed ramp down to stop via the selected ramp down parameter. Bit 06

MG.11.BA.02 - VLT is a registered Danfoss trademark

137

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

= 1: Permits the frequency converter to start the motor, if the other starting conditions are met. Make a selection in 8-53 Start Select to define how Bit 06 Ramp stop/start gates with the corresponding function on a digital input. Bit 07, Reset: Bit 07 = 0: No reset. Bit 07 = 1: Resets a trip. Reset is activated on the signals leading edge, i.e. when changing from logic 0 to logic 1. Bit 08, Jog: Bit 08 = 1: The output frequency is determined by 3-19 Jog Speed [RPM]. Bit 09, Selection of ramp 1/2: Bit 09 = "0": Ramp 1 is active (3-41 Ramp 1 Ramp Up Time to 3-42 Ramp 1 Ramp Down Time). Bit 09 = "1": Ramp 2 (3-51 Ramp 2 Ramp Up Time to 3-52 Ramp 2 Ramp Down Time) is active. Bit 10, Data not valid/Data valid: Tell the frequency converter whether to use or ignore the control word. Bit 10 = 0: The control word is ignored. Bit 10 = 1: The control word is used. This function is relevant because the telegram always contains the control word, regardless of the telegram type. Thus, you can turn off the control word if you do not want to use it when updating or reading parameters. Bit 11, Relay 01: Bit 11 = "0": Relay not activated. Bit 11 = "1": Relay 01 activated provided that Control word bit 11 is chosen in 5-40 Function Relay. Bit 12, Relay 04: Bit 12 = "0": Relay 04 is not activated. Bit 12 = "1": Relay 04 is activated provided that Control word bit 12 is chosen in 5-40 Function Relay. Bit 13/14, Selection of set-up: Use bits 13 and 14 to choose from the four menu set-ups according to the shown table: .
Set-up 1 2 3 4 Bit 14 0 0 1 1 Bit 13 0 1 0 1

Bit 15 Reverse: Bit 15 = 0: No reversing. Bit 15 = 1: Reversing. In the default setting, reversing is set to digital in 8-54 Reversing Select. Bit 15 causes reversing only when Ser. communication, Logic or or Logic and is selected.

7 7

The function is only possible when Multi Set-Ups is selected in 0-10 Active Set-up. Make a selection in 8-55 Set-up Select to define how Bit 13/14 gates with the corresponding function on the digital inputs.

138

MG.11.BA.02 - VLT is a registered Danfoss trademark

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

7.11.2 Status Word According to FC Profile (STW) (8-10 Control Profile = FC profile)
130BA273.10 Slave-master STW Output freq.

Bit 04, No error/error (no trip): Bit 04 = 0: The frequency converter is not in fault mode. Bit 04 = 1: The frequency converter shows an error but does not trip. Bit 05, Not used: 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.

Bit no.:

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Bit 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15

Bit = 0 Control not ready Drive not ready Coasting No error No error Reserved No error No warning Speed reference Local operation Out of frequency limit No operation Drive OK Voltage OK Torque OK Timer OK

Bit = 1 Control ready Drive ready Enable Trip Error (no trip) Triplock Warning Speed = reference Bus control Frequency limit OK In operation Stopped, auto start Voltage exceeded Torque exceeded Timer exceeded

Bit 07, No warning/warning: Bit 07 = 0: There are no warnings. Bit 07 = 1: A warning has occurred. Bit 08, Speed reference/speed = reference: Bit 08 = 0: The motor is running but the present speed is different from the preset speed reference. It might e.g. be the case when the speed ramps up/down during start/stop. Bit 08 = 1: The motor speed matches the preset speed reference. Bit 09, Local operation/bus control: Bit 09 = 0: [STOP/RESET] is activate on the control unit or Local control in 3-13 Reference Site is selected. You cannot control the frequency converter via serial communication. Bit 09 = 1 It is possible to control the frequency converter via the fieldbus / serial communication. Bit 10, Out of frequency limit: Bit 10 = 0: The output frequency has reached the value in 4-11 Motor Speed Low Limit [RPM] or 4-13 Motor Speed High Limit [RPM]. Bit 10 = "1": The output frequency is within the defined limits. Bit 11, No operation/in operation: Bit 11 = 0: The motor is not running. Bit 11 = 1: The frequency converter has a start signal or the output frequency is greater than 0 Hz. Bit 12, Drive OK/stopped, autostart: Bit 12 = 0: There is no temporary over temperature on the inverter. Bit 12 = 1: The inverter stops because of over temperature but the unit does not trip and will resume operation once the over temperature stops. Bit 13, Voltage OK/limit exceeded: Bit 13 = 0: There are no voltage warnings. Bit 13 = 1: The DC voltage in the frequency converters intermediate circuit is too low or too high.

7 7

Explanation of the Status Bits Bit 00, Control not ready/ready: Bit 00 = 0: The frequency converter trips. Bit 00 = 1: The frequency converter controls are ready but the power component does not necessarily receive any power supply (in case of external 24 V supply to controls). Bit 01, Drive ready: Bit 01 = 1: The frequency converter is ready for operation but the coasting command is active via the digital inputs or via serial communication. Bit 02, Coasting stop: Bit 02 = 0: The frequency converter releases the motor. Bit 02 = 1: The frequency converter starts the motor with a start command. Bit 03, No error/trip: Bit 03 = 0 : The frequency converter is not in fault mode. Bit 03 = 1: The frequency converter trips. To re-establish operation, enter [Reset].

MG.11.BA.02 - VLT is a registered Danfoss trademark

139

RS-485 Installation and Set...

VLT HVAC Drive Design Guide

Bit 14, Torque OK/limit exceeded: Bit 14 = 0: The motor current is lower than the torque limit selected in 4-18 Current Limit. Bit 14 = 1: The torque limit in 4-18 Current Limit is exceeded. Bit 15, Timer OK/limit exceeded:

Bit 15 = 0: The timers for motor thermal protection and thermal protection are not exceeded 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.

7.11.3 Bus Speed Reference Value

Speed reference value is transmitted to the frequency converter in a relative value in %. The value is transmitted in the form of a 16-bit word; in integers (0-32767) the value 16384 (4000 Hex) corresponds to 100%. Negative figures are formatted by means of 2s complement. The Actual Output frequency (MAV) is scaled in the same way as the bus reference.
16bit CTW Slave-master STW Actual output freq. Speed ref. 130BA276.10 Master-slave

7 7
-100% (C000hex)

The reference and MAV are scaled as follows:

130BA277.10 0% (0hex) 100% (4000hex)

Par.3-00 set to (1) -max- +max Reverse Forward

Par.3-03 Max reference

Par.3-03 Max reference

0% (0hex)

100% (4000hex)

Par.3-00 set to (0) min-max Forward

Par.3-02 Min reference

Par.3-03 Max reference

140

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

8 General Specifications and Troubleshooting

8.1 Mains Supply Tables
Mains supply 200-240V AC - Normal overload 110% for 1 minute Frequency Converter Typical Shaft Output [kW] IP20/Chassis (A2+A3 may be converted to IP21 using a conversion kit. (Please see also items Mechanical mounting in Operating Instructions and IP21/Type 1 Enclosure kit in the Design Guide.)) IP55/NEMA 12 IP66/NEMA 12 Typical Shaft Output [hp] at 208V Output current Continuous (3 x 200-240V) [A] Intermittent (3 x 200-240V) [A] Continuous kVA (208V AC) [kVA] Max. cable size: (mains, motor, brake) [mm2 /AWG] Max. input current Continuous (3 x 200-240V) [A] Intermittent (3 x 200-240V) [A] Max. pre-fuses1) [A] Environment Estimated power loss at rated max. load [W] Weight enclosure IP20 Weight enclosure IP21 Weight enclosure IP55 Weight enclosure IP66 Efficiency Table 8.1 Mains Supply 200-240V AC
3) 4) 2)

P1K1 1.1

P1K5 1.5

P2K2 2.2

P3K0 3

P3K7 3.7

A2

A2

A2

A3

A3

A5 A5 1.5

A5 A5 2.0

A5 A5 2.9

A5 A5 4.0

A5 A5 4.9

6.6 7.3 2.38

7.5 8.3 2.70

10.6 11.7 3.82

12.5 13.8 4.50

16.7 18.4 6.00

130BA058.10

8 8

4/10

5.9 6.5 20

6.8 7.5 20

9.5 10.5 20

11.3 12.4 32

15.0 16.5 32

130BA057.10

63 4.9 5.5 13.5 13.5 0.96

82 4.9 5.5 13.5 13.5 0.96

116 4.9 5.5 13.5 13.5 0.96

155 6.6 7.5 13.5 13.5 0.96

185 6.6 7.5 13.5 13.5 0.96

[kg] [kg] [kg] [kg]

MG.11.BA.02 - VLT is a registered Danfoss trademark

141

General Specifications and ...

VLT HVAC Drive Design Guide

Mains supply 200-240V AC - Normal overload 110% for 1 minute Frequency Converter Typical Shaft Output [kW] IP20/Chassis (A2+A3 may be converted to IP21 using a conversion kit. (Please see also items Mechanical mounting in Operating Instructions and IP21/Type 1 Enclosure kit in the Design Guide.)) IP55/NEMA 12 IP66/NEMA 12 Typical Shaft Output [hp] at 208V Output current Continuous (3 x 200-240V) [A] Intermittent (3 x 200-240V) [A] Continuous kVA (208V AC) [kVA] Max. cable size: (mains, motor, brake) [mm2 /AWG] Max. input current Continuous (3 x 200-240V) [A]
130BA057.10
2)

P1K1 1.1

P1K5 1.5

P2K2 2.2

P3K0 3

P3K7 3.7

A2

A2

A2

A3

A3

A4/A5 A5 1.5

A4/A5 A5 2.0

A4/A5 A5 2.9

A5 A5 4.0

A5 A5 4.9

130BA058.10

6.6 7.3 2.38

7.5 8.3 2.70

10.6 11.7 3.82

12.5 13.8 4.50

16.7 18.4 6.00

4/10

8 8

5.9 6.5 20

6.8 7.5 20

9.5 10.5 20

11.3 12.4 32

15.0 16.5 32

Intermittent (3 x 200-240V) [A] Max. pre-fuses1) [A] Environment Estimated power loss at rated max. load [W] Weight enclosure IP20 Weight enclosure IP21 Weight enclosure IP55 Weight enclosure IP66 Efficiency
3) 4)

63 4.9 5.5 9.7/13.5 9.7/13.5 0.96

82 4.9 5.5 9.7/13.5 9.7/13.5 0.96

116 4.9 5.5 9.7/13.5 9.7/13.5 0.96

155 6.6 7.5 13.5 13.5 0.96

185 6.6 7.5 13.5 13.5 0.96

[kg] [kg] [kg] [kg]

Table 8.2 Mains Supply 200-240V AC

142

MG.11.BA.02 - VLT is a registered Danfoss trademark

Mains supply 3 x 200-240V AC - Normal overload 110% for 1 minute

IP20/Chassis (B3+4 and C3+4 may be converted to IP21 using a conversion kit. (Please see also items B3 B3 B3 B4 B4 C3 C3 C4 C4

General Specifications and ...

Mechanical mounting in Operating Instructions and IP21/Type 1 Enclosure kit in the Design Guide.)) IP21/NEMA 1 IP55/NEMA 12 IP66/NEMA 12 B1 B1 B1 P5K5 5.5 7.5 10 15 20 25 30 40 P7K5 7.5 P11K 11 P15K 15 P18K 18.5 P22K 22 P30K 30 P37K 37 50 B1 B1 B1 B1 B1 B1 B2 B2 B2 C1 C1 C1 C1 C1 C1 C1 C1 C1 C2 C2 C2 C2 C2 C2 P45K 45 60

Frequency Converter Typical Shaft Output [kW]

Typical Shaft Output [hp] at 208V

Output current 24.2 16/6 35/2 30.8 46.2 59.4 74.8 88.0 35/2 115 143 70/3/0 170 185/ kcmil350

Continuous (3 x 200-240V) [A]

22.0 24.2 63 63 63 30.8 46.2 59.4 80

28.0

42.0

54.0

68.0 74.8 125

80.0 88.0 125

104.0 114.0 160

130.0 143.0 200

154.0 169.0 250

VLT HVAC Drive Design Guide

130BA058.10

Continuous (3 x 200-240V) [A] Intermittent (3 x 200-240V) [A]

Max. pre-fuses1) [A] Environment: Estimated power loss

4)

MG.11.BA.02 - VLT is a registered Danfoss trademark 269 12 23 23 23 0.96 26.6 8.7 12 23 23 23 0.96 33.9 11.1 310 447 12 23 23 23 0.96 50.8 16.6 602 23.5 27 27 27 0.96 65.3 21.4 737 23.5 45 45 45 0.96 82.3 26.9 845 35 45 45 45 0.97 96.8 31.7 [kg] [kg] [kg] [kg] 10/7 35/2 50/1/0 (B4=35/2)

at rated max. load [W] Weight enclosure IP20 Weight enclosure IP21 Weight enclosure IP55 Weight enclosure IP66

1140 35 45 45 45 0.97 127 41.4

1353 50 65 65 65 0.97 157 51.5

1636 50 65 65 65 0.97 187 61.2

Efficiency 3) Intermittent (3 x 200-240V) [A] Continuous kVA (208V AC) [kVA]

Max. cable size: 95/4/0 120/250 MCM

(mains, motor, brake)

[mm2 /AWG]

2)

143

Table 8.3 Mains Supply 3 x 200-240V AC

8 8

8 8

130BA058.10

130BA057.10

144 P1K1 1.1 1.5 2.0 2.9 4.0 5.0 7.5 10 P1K5 1.5 P2K2 2.2 P3K0 3 P4K0 4 P5K5 5.5 P7K5 7.5 A2 A2 A2 A2 A2 A3 A3 A4/A5 A4/A5 3 3.3 2.7 3.0 2.1 2.4 2.8 2.7 3.9 3.8 5.0 5.0 6.9 6.5 4.1 4.5 3.4 3.7 5.6 6.2 4.8 5.3 7.2 7.9 6.3 6.9 10 11 8.2 9.0 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A5 A5 13 14.3 11 12.1 9.0 8.8 A5 A5 16 17.6 14.5 15.4 11.0 11.6
2)

Mains Supply 3 x 380-480V AC - Normal overload 110% for 1 minute

Frequency Converter Typical Shaft Output [kW]

Typical Shaft Output [hp] at 460V

General Specifications and ...

IP20/Chassis (A2+A3 may be converted to IP21 using a conversion kit. (Please see also items

Mechanical mounting in Operating Instructions and IP 1/Type 1 Enclosure kit in the Design Guide.)) IP55/NEMA 12 IP66/NEMA 12

Output current

Continuous (3 x 380-440V) [A] Intermittent (3 x 380-440V) [A] Continuous (3 x 441-480V) [A] Intermittent (3 x 441-480V) [A]

Continuous kVA (400V AC) [kVA] Continuous kVA (460V AC) [kVA] Max. cable size: (mains, motor, brake) 4/10

[[mm2/ AWG]

Max. input current 2.7 3.0 2.7 3.0 10 3.1 3.4 10 4.1 3.7 5.0 5.5 4.3 4.7 20 6.5 7.2 5.7 6.3 20 9.0 9.9 7.4 8.1 20 11.7 12.9 9.9 10.9 32 14.4 15.8 13.0 14.3 32

VLT HVAC Drive Design Guide

MG.11.BA.02 - VLT is a registered Danfoss trademark

4)

Continuous (3 x 380-440V ) [A]

Intermittent (3 x 380-440V ) [A] Continuous (3 x 441-480V) [A] Intermittent (3 x 441-480V) [A]

Max. pre-fuses1)[A] Environment Estimated power loss 58 4.8

at rated max. load [W]

62 4.9 9.7/13.5 9.7/13.5 0.96 9.7/13.5 9.7/13.5 0.97

88 4.9 9.7/13.5 9.7/13.5 0.97

116 4.9 9.7/13.5 9.7/13.5 0.97

124 4.9 9.7/13.5 9.7/13.5 0.97

187 6.6 14.2 14.2 0.97

255 6.6 14.2 14.2 0.97

Weight enclosure IP20 [kg]

Weight enclosure IP21 [kg]

Weight enclosure IP55 [kg]

Weight enclosure IP66 [kg]

Efficiency

3)

Table 8.4 Mains Supply 3 x 380-480V AC

Mains Supply 3 x 380-480V AC - Normal overload 110% for 1 minute P11K 11 15 B3 B1 B1 B1 24 26.4 21 23.1 16.6 16.7 22.2 21.5 26 27.1 30.5 31.9 42.3 41.4 50.6 51.8 62.4 63.7 32 35.2 27 29.7 37.5 41.3 34 37.4 44 48.4 40 44 61 67.1 52 61.6 73 80.3 65 71.5 90 99 80 88 106 117 105 116 73.4 83.7 147 162 130 143 102 104 B1 B1 B1 B1 B1 B1 B2 B2 B2 B2 B2 B2 C1 C1 C1 C1 C1 C1 C1 C1 C1 C2 C2 C2 B3 B3 B4 B4 B4 C3 C3 C4 C4 C2 C2 C2 177 195 160 176 123 128 20 25 30 40 50 60 75 100 125 P15K 15 P18K 18.5 P22K 22 P30K 30 P37K 37 P45K 45 P55K 55 P75K 75 P90K 90

Frequency Converter Typical Shaft Output [kW]

Typical Shaft Output [hp] at 460 V

General Specifications and ...

IP20/Chassis (B3+4 and C3+4 may be converted to IP21 using a conversion kit (Please contact Danfoss)

IP21/NEMA 1 IP55/NEMA 12 IP66/NEMA 12

Output current

130BA058.10

Continuous (3 x 380-439V) [A] Intermittent (3 x 380-439V) [A] Continuous (3 x 440-480V) [A] Intermittent (3 x 440-480V) [A]

Continuous kVA (400V AC) [kVA] Continuous kVA 460V AC) [kVA]

Max. cable size: 10/7 16/6 35/2 35/2 50/1/0 (B4=35/2) 35/2 95/ 4/0 70/3/0 120/ MCM250 185/ kcmil350

(mains, motor, brake) [mm2/

AWG]

2)

VLT HVAC Drive Design Guide

With mains disconnect switch included:

Max. input current 22 24.2 19 20.9 63 63 63 31.9 25 27.5 37.4 31 34.1 44 36 39.6 63 29 34 40 55 60.5 47 51.7 80 66 72.6 59 64.9 100 82 90.2 73 80.3 125 96 106 95 105 160 133 146 118 130 250 161 177 145 160 250

130BA057.10

MG.11.BA.02 - VLT is a registered Danfoss trademark

4)

Continuous (3 x 380-439V) [A]

Intermittent (3 x 380-439V) [A] Continuous (3 x 440-480V) [A] Intermittent (3 x 440-480V) [A]

Max. pre-fuses1)[A]

Environment 278 12 23 23 23 0.98 12 23 23 23 0.98 392 465 12 23 23 23 0.98 525 23.5 27 27 27 0.98 698 23.5 27 27 27 0.98 739 23.5 45 45 45 0.98 843 35 45 45 45 0.98 1083 35 45 45 45 0.98 1384 50 65 65 65 0.98 1474 50 65 65 65 0.99

Estimated power loss IP20 IP21 IP55 IP66 [kg] [kg] [kg] [kg]

at rated max. load [W]

Weight Weight Weight Weight

enclosure enclosure enclosure enclosure

Efficiency

3)

145

Table 8.5 Mains Supply 3 x 380-480V AC

8 8

General Specifications and ...

VLT HVAC Drive Design Guide

Mains supply 200-240V AC - Normal overload 110% for 1 minute Frequency Converter Typical Shaft Output [kW] IP20/Chassis (A2+A3 may be converted to IP21 using a conversion kit. (Please see also items Mechanical mounting in Operating Instructions and IP21/Type 1 Enclosure kit in the Design Guide.)) IP55/NEMA 12 IP66/NEMA 12 Typical Shaft Output [hp] at 208V Output current Continuous (3 x 200-240V) [A] Intermittent (3 x 200-240V) [A] Continuous kVA (208V AC) [kVA] Max. cable size: (mains, motor, brake) [mm2 /AWG] Max. input current Continuous (3 x 200-240V) [A] Intermittent (3 x 200-240V) [A] Max. pre-fuses1) [A] Environment Estimated power loss at rated max. load [W] Weight enclosure IP20 Weight enclosure IP21 Weight enclosure IP55 Weight enclosure IP66 Efficiency Table 8.6 Mains Supply 200-240V AC
3) 4) 2)

P1K1 1.1

P1K5 1.5

P2K2 2.2

P3K0 3

P3K7 3.7

A2

A2

A2

A3

A3

A5 A5 1.5

A5 A5 2.0

A5 A5 2.9

A5 A5 4.0

A5 A5 4.9

6.6 7.3 2.38

7.5 8.3 2.70

10.6 11.7 3.82

12.5 13.8 4.50

16.7 18.4 6.00

130BA058.10

4/10

8 8

5.9 6.5 20

6.8 7.5 20

9.5 10.5 20

11.3 12.4 32

15.0 16.5 32

130BA057.10

63 4.9 5.5 13.5 13.5 0.96

82 4.9 5.5 13.5 13.5 0.96

116 4.9 5.5 13.5 13.5 0.96

155 6.6 7.5 13.5 13.5 0.96

185 6.6 7.5 13.5 13.5 0.96

[kg] [kg] [kg] [kg]

146

MG.11.BA.02 - VLT is a registered Danfoss trademark

Mains Supply 3 x 380-480V AC - Normal overload 110% for 1 minute P1K1 1.1 1.5 2.0 2.9 4.0 5.0 7.5 10 P1K5 1.5 P2K2 2.2 P3K0 3 P4K0 4 P5K5 5.5 P7K5 7.5

Frequency Converter Typical Shaft Output [kW]

Typical Shaft Output [hp] at 460V

General Specifications and ...

IP20/Chassis (A2+A3 may be converted to IP21 using a conversion kit. (Please see also items A2 A2 A2 A2 A2 A3

Mechanical mounting in Operating Instructions and IP21/Type 1 Enclosure kit in the Design Guide.)) IP55/NEMA 12 IP66/NEMA 12 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5 A5 A5

A3

A5 A5

Output current 3 3.3 2.7 3.0 2.1 2.4 2.8 2.7 3.9 3.8 5.0 5.0 6.9 6.5 4.1 4.5 3.4 3.7 5.6 6.2 4.8 5.3 7.2 7.9 6.3 6.9 10 11 8.2 9.0 13 14.3 11 12.1 9.0 8.8 16 17.6 14.5 15.4 11.0 11.6

130BA058.10

Continuous (3 x 380-440V) [A] Intermittent (3 x 380-440V) [A] Continuous (3 x 441-480V) [A] Intermittent (3 x 441-480V) [A]

Continuous kVA (400V AC) [kVA] Continuous kVA (460V AC) [kVA] Max. cable size: (mains, motor, brake)
2)

[[mm2/ AWG]

4/10

Max. input current 2.7 3.0 2.7 3.0 10 3.1 3.4 10 4.1 3.7 5.0 5.5 4.3 4.7 20 6.5 7.2 5.7 6.3 20 9.0 9.9 7.4 8.1 20 11.7 12.9 9.9 10.9 32 14.4 15.8 13.0 14.3 32

VLT HVAC Drive Design Guide

130BA057.10

MG.11.BA.02 - VLT is a registered Danfoss trademark

4)

Continuous (3 x 380-440V) [A]

Intermittent (3 x 380-440V) [A] Continuous (3 x 441-480V) [A] Intermittent (3 x 441-480V) [A]

Max. pre-fuses1)[A] Environment Estimated power loss 58 4.8

at rated max. load [W]

62 4.9 9.7/13.5 9.7/13.5 0.96 9.7/13.5 9.7/13.5 0.97

88 4.9 9.7/13.5 9.7/13.5 0.97

116 4.9 9.7/13.5 9.7/13.5 0.97

124 4.9 9.7/13.5 9.7/13.5 0.97

187 6.6 14.2 14.2 0.97

255 6.6 14.2 14.2 0.97

Weight enclosure IP20 [kg]

Weight enclosure IP21 [kg]

Weight enclosure IP55 [kg]

Weight enclosure IP66 [kg]

Efficiency

3)

147

Table 8.7 Mains Supply 3 x 380-480V AC

8 8

8 8

130BA058.10

130BA057.10

148 P11K 11 15 B3 B1 B1 B1 24 26.4 21 23.1 16.6 16.7 22.2 21.5 26 27.1 30.5 31.9 42.3 41.4 50.6 51.8 62.4 63.7 32 35.2 27 29.7 37.5 41.3 34 37.4 44 48.4 40 44 61 67.1 52 61.6 73 80.3 65 71.5 90 99 80 88 106 117 105 116 73.4 83.7 147 162 130 143 102 104 B1 B1 B1 B1 B1 B1 B2 B2 B2 B2 B2 B2 C1 C1 C1 C1 C1 C1 C1 C1 C1 C2 C2 C2 B3 B3 B4 B4 B4 C3 C3 C4 C4 C2 C2 C2 177 195 160 176 123 128 20 25 30 40 50 60 75 100 125 P15K 15 P18K 18.5 P22K 22 P30K 30 P37K 37 P45K 45 P55K 55 P75K 75 P90K 90 10/7 16/6 35/2 35/2 50/1/0 (B4=35/2) 35/2 95/ 4/0 70/3/0 120/ MCM250 185/ kcmil350 22 24.2 19 20.9 63 63 63 31.9 25 27.5 37.4 31 34.1 44 36 39.6 63 29 34 40 55 60.5 47 51.7 80 66 72.6 59 64.9 100 82 90.2 73 80.3 125 96 106 95 105 160 133 146 118 130 250 161 177 145 160 250
4)

Mains Supply 3 x 380-480V AC - Normal overload 110% for 1 minute

Frequency Converter Typical Shaft Output [kW]

Typical Shaft Output [hp] at 460V

General Specifications and ...

IP20/Chassis (B3+4 and C3+4 may be converted to IP21 using a conversion kit (Please contact Danfoss)

IP21/NEMA 1 IP55/NEMA 12 IP66/NEMA 12

Output current

Continuous (3 x 380-439V) [A] Intermittent (3 x 380-439V) [A] Continuous (3 x 440-480V) [A] Intermittent (3 x 440-480V) [A]

Continuous kVA (400V AC) [kVA] Continuous kVA 460V AC) [kVA]

Max. cable size:

(mains, motor, brake) [mm2/

AWG]

2)

VLT HVAC Drive Design Guide

With mains disconnect switch included:

Max. input current

MG.11.BA.02 - VLT is a registered Danfoss trademark 278 12 23 23 23 0.98 12 23 23 23 0.98 392 465 12 23 23 23 0.98 525 23.5 27 27 27 0.98 698 23.5 27 27 27 0.98 739 23.5 45 45 45 0.98 843 35 45 45 45 0.98 IP20 IP21 IP55 IP66 [kg] [kg] [kg] [kg]

Continuous (3 x 380-439V) [A]

Intermittent (3 x 380-439V) [A] Continuous (3 x 440-480V) [A] Intermittent (3 x 440-480V) [A]

Max. pre-fuses1)[A]

Environment 1083 35 45 45 45 0.98 1384 50 65 65 65 0.98 1474 50 65 65 65 0.99

Estimated power loss

at rated max. load [W]

Weight Weight Weight Weight

enclosure enclosure enclosure enclosure

Efficiency

3)

Table 8.8 Mains Supply 3 x 380-480V AC

Mains supply 3 x 525-600V AC Normal overload 110% for 1 minute P1K1 1.1 A3 A3 A5 A5 A3 A3 A5 A5 A3 A3 A5 A5 A3 A3 A5 A5 A2 A2 A5 A5 A3 A3 A5 A5 A3 A3 A5 A5 A3 A3 A5 A5 B3 B1 B1 B1 B3 B1 B1 B1 B3 B1 B1 B1 B4 B2 B2 B2 B4 B2 B2 B2 B4 C1 C1 C1 C3 C1 C1 C1 C3 C1 C1 C1 C4 C2 C2 C2 C4 C2 C2 C2 1.5 2.2 3 3.7 4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 P1K5 P2K2 P3K0 P3K P4K0 7 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K

Size:

Typical Shaft Output [kW]

General Specifications and ...

IP20/Chassis IP21/NEMA 1 IP55/NEMA 12 IP66/NEMA 12

Output current 2.6 2.9 2.4 2.6 2.5 2.4 2.7 3.9 4.9 6.1 9.0 11.0 17.9 21.9 26.9 2.8 3.9 5.0 6.1 9.0 11.0 18.1 21.9 26.7 34.3 33.9 3.0 4.3 5.4 6.7 9.9 12.1 20 24 30 37 45 41 40.8 2.7 3.9 4.9 6.1 9.0 11.0 18 22 27 34 41 52 57 51.4 51.8 3.2 4.5 5.7 7.0 10.5 12.7 21 25 31 40 47 59 72 62 68 61.9 61.7 2.9 4.1 5.2 6.4 9.5 11.5 19 23 28 36 43 54 65 87 96 83 91 82.9 82.7 105 116 100 110 100 99.6 137 151 131 144 130.5 130.5 120/ MCM2 50 10/ 7 25/ 4 50/ 1/0 95/ 4/0 150/ MCM2 16/ 6 35/ 2 50/ 1/0 95/ 4/0

130BA058.10

VLT HVAC Drive Design Guide

Continuous (3 x 525-550V) [A] Intermittent (3 x 525-550V) [A] Continuous (3 x 525-600V) [A] Intermittent (3 x 525-600V) [A] Continuous kVA (525V AC) [kVA] Continuous kVA (575 V AC) [kVA] Max. cable size, IP21/55/66 (mains, motor, brake) 4/ 10

MG.11.BA.02 - VLT is a registered Danfoss trademark 4/ 10 4/10 16/6

[mm2]/[AWG]

2)

Max. cable size, IP20 (mains, motor, brake)

[mm2]/[AWG]

2)

With mains disconnect switch included:

35/2

50 5) 185/ 70/3/0 kcmil 350

Table 8.9

5)

With brake and load sharing 95/4/0

149

8 8

8 8

130BA057.10

150 P4K0 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K 2.4 2.7 10 10 20 20 20 32 32 63 63 63 63 80 100 125 160 3.0 4.5 5.7 6.4 9.5 11.5 19 23 28 36 43 54 65 87 105 250 2.7 4.1 5.2 5.8 8.6 10.4 17.2 20.9 25.4 32.7 39 49 59 78.9 95.3 124.3 137 250 50 6.5 13.5 0.97 0.97 0.97 0.97 0.97 0.97 0.97 0.98 0.98 0.98 0.98 0.98 13.5 13.5 13.5 13.5 13.5 14.2 14.2 23 23 23 27 27 27 0.98 6.5 6.5 6.5 6.5 6.6 6.6 12 12 12 23.5 23.5 23.5 65 92 122 145 195 261 300 400 475 525 700 750 850 35 45 0.98 1100 35 45 0.98 1400 50 65 0.98 1500 50 65 0.98

Mains supply 3 x 525-600V ACNormal overload 110% for 1 minute - continued P3K Size: P1K1 P1K5 P2K2 P3K0 7

Max. input current

General Specifications and ...

Continuous (3 x 525-600V) [A] Intermittent (3 x 525-600V) [A]

Max. pre-fuses1) [A] Environment: Estimated power loss

at rated max. load [W] Weight enclosure IP20 [kg] Weight enclosure IP21/55 [kg]

4)

Efficiency

4)

VLT HVAC Drive Design Guide

MG.11.BA.02 - VLT is a registered Danfoss trademark

Table 8.10

5)

With brake and load sharing 95/4/0

Mains supply 3 x 525-600V AC Normal overload 110% for 1 minute P1K1 1.1 A3 A3 A5 A5 A3 A3 A5 A5 A3 A3 A5 A5 A3 A3 A5 A5 A2 A2 A5 A5 A3 A3 A5 A5 A3 A3 A5 A5 A3 A3 A5 A5 B3 B1 B1 B1 B3 B1 B1 B1 B3 B1 B1 B1 B4 B2 B2 B2 B4 B2 B2 B2 B4 C1 C1 C1 C3 C1 C1 C1 C3 C1 C1 C1 C4 C2 C2 C2 C4 C2 C2 C2 1.5 2.2 3 3.7 4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 P1K5 P2K2 P3K0 P3K P4K0 7 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K

Size:

Typical Shaft Output [kW]

General Specifications and ...

IP20/Chassis IP21/NEMA 1 IP55/NEMA 12 IP66/NEMA 12

Output current 2.6 2.9 2.4 2.6 2.5 2.4 2.7 3.9 4.9 6.1 9.0 11.0 17.9 21.9 26.9 2.8 3.9 5.0 6.1 9.0 11.0 18.1 21.9 26.7 34.3 33.9 3.0 4.3 5.4 6.7 9.9 12.1 20 24 30 37 45 41 40.8 2.7 3.9 4.9 6.1 9.0 11.0 18 22 27 34 41 52 57 51.4 51.8 3.2 4.5 5.7 7.0 10.5 12.7 21 25 31 40 47 59 72 62 68 61.9 61.7 2.9 4.1 5.2 6.4 9.5 11.5 19 23 28 36 43 54 65 87 96 83 91 82.9 82.7 105 116 100 110 100 99.6 137 151 131 144 130.5 130.5 120/ MCM2 50 10/ 7 25/ 4 50/ 1/0 95/ 4/0 150/ MCM2 16/ 6 35/ 2 50/ 1/0 95/ 4/0

130BA058.10

VLT HVAC Drive Design Guide

Continuous (3 x 525-550V) [A] Intermittent (3 x 525-550V) [A] Continuous (3 x 525-600V) [A] Intermittent (3 x 525-600V) [A] Continuous kVA (525V AC) [kVA] Continuous kVA (575V AC) [kVA] Max. cable size, IP21/55/66 (mains, motor, brake) 4/ 10

MG.11.BA.02 - VLT is a registered Danfoss trademark 4/ 10 4/10 16/6

[mm2]/[AWG]

2)

Max. cable size, IP20 (mains, motor, brake)

[mm2]/[AWG]

2)

With mains disconnect switch included:

35/2

50 5) 185/ 70/3/0 kcmil 350

Table 8.11

5)

With brake and load sharing 95/ 4/0

151

8 8

8 8

130BA057.10

152 P4K0 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K 2.4 2.7 10 10 20 20 20 32 32 63 63 63 63 80 100 125 160 3.0 4.5 5.7 6.4 9.5 11.5 19 23 28 36 43 54 65 87 105 250 2.7 4.1 5.2 5.8 8.6 10.4 17.2 20.9 25.4 32.7 39 49 59 78.9 95.3 124.3 137 250 50 6.5 13.5 0.97 0.97 0.97 0.97 0.97 0.97 0.97 0.98 0.98 0.98 0.98 0.98 13.5 13.5 13.5 13.5 13.5 14.2 14.2 23 23 23 27 27 27 0.98 6.5 6.5 6.5 6.5 6.6 6.6 12 12 12 23.5 23.5 23.5 65 92 122 145 195 261 300 400 475 525 700 750 850 35 45 0.98 1100 35 45 0.98 1400 50 65 0.98 1500 50 65 0.98

Mains supply 3 x 525-600V ACNormal overload 110% for 1 minute - continued P3K Size: P1K1 P1K5 P2K2 P3K0 7

Max. input current

General Specifications and ...

Continuous (3 x 525-600V) [A] Intermittent (3 x 525-600V) [A]

Max. pre-fuses1) [A] Environment: Estimated power loss

at rated max. load [W] Weight enclosure IP20 [kg] Weight enclosure IP21/55 [kg]

4)

Efficiency

4)

VLT HVAC Drive Design Guide

MG.11.BA.02 - VLT is a registered Danfoss trademark

Table 8.12

5)

With brake and load sharing 95/4/0

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 380-480V AC P110 Typical Shaft output at 400V [kW] Typical Shaft output at 460V [HP] Enclosure IP21 Enclosure IP54 Enclosure IP00 Output current Continuous (at 400V) [A] Intermittent (60 sec overload) (at 400V) [A] Continuous (at 460/480V) [A] Intermittent (60 sec overload) (at 460/480V) [A] Continuous KVA (at 400V) [KVA] Continuous KVA (at 460V) [KVA] Continuous (at 400V) [A] Continuous (at 460/480V) [A] Max. cable size, mains motor, brake and load share [mm2 (AWG2))] Max. external prefuses [A] 1 Estimated power loss at rated max. load [W]
4)
130BA229.10

P132 132 200 D1 D1 D3

P160 160 250 D2 D2 D4

P200 200 300 D2 D2 D4

P250 250 350 D2 D2 D4

110 150 D1 D1 D3

212

260

315

395

480

233

286

347

435

528

130BA230.10

190

240

302

361

443

209

264

332

397

487

147 151

180 191

218 241

274 288

333 353

8 8

Max. input current 204 251 304 381 463

183

231

291

348

427

2 x 70 (2 x 2/0)

2 x 70 (2 x 2/0)

2 x 150 (2 x 300 mcm)

2 x 150 (2 x 300 mcm)

2 x 150 (2 x 300 mcm)

300

350

400

500

630

3234

3782

4213

5119

5893

, 400V Estimated power loss at rated max. load [W] , 460V Weight, enclosure IP21, IP54 [kg] Weight, enclosure IP00 [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card ambient trip

2947

3665

4063

4652

5634

4)

96

104

125

136

151

82

91

112 0.98 0 - 800Hz

123

138

90C

110C

110C 60C

110 C

110C

MG.11.BA.02 - VLT is a registered Danfoss trademark

153

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 380-480V AC P315 Typical Shaft output at 400V [kW] Typical Shaft output at 460V [HP] Enclosure IP21 Enclosure IP54 Enclosure IP00 Output current Continuous (at 400V) [A] Intermittent (60 sec overload) (at 400V) [A] Continuous (at 460/480V) [A] Intermittent (60 sec overload) (at 460/480V) [A] Continuous KVA (at 400V) [KVA] Continuous KVA (at 460V) [KVA] Continuous (at 400V) [A]
130BA229.10

P355 355 500 E1 E1 E2

P400 400 600 E1 E1 E2

P450 450 600 E1 E1 E2

315 450 E1 E1 E2

600

658

745

800

130BA230.10

660

724

820

880

540

590

678

730

594

649

746

803

8 8
Max. input current

416 430

456 470

516 540

554 582

590

647

733

787

Continuous (at 460/480V) [A]

531

580

667

718

Max. cable size, mains, motor and load share [mm2 (AWG2))] Max. cable size, brake [mm2 (AWG2)) Max. external pre-fuses [A] 1 Estimated power loss at rated max. load [W] 400V Estimated power loss at rated max. load [W] 460V
4)

4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 700

4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 900

4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 900

4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 900

6790

7701

8879

9670

4)

6082

6953

8089

8803

Weight, enclosure IP21, IP54 [kg] Weight, enclosure IP00 [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card ambient trip

263 221

270 234 0.98 0 - 600Hz 110C 68C

272 236

313 277

154

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 380-480V AC P500 Typical Shaft output at 400V [kW] Typical Shaft output at 460V [HP] Enclosure IP21, 54 without/ with options cabinet Output current Continuous (at 400V) [A] Intermittent (60 sec overload) (at 400V) [A] Continuous (at 460/480V) [A] Intermittent (60 sec overload) (at 460/480V) [A] Continuous KVA (at 400V) [KVA] Continuous KVA (at 460V) [KVA] Continuous (at 400V) [A] Continuous (at 460/480V) [A] Max. cable size,motor [mm2 (AWG2))] Max. cable size,mains F1/F2 [mm2 (AWG2))] Max. cable size,mains F3/F4 [mm2 (AWG2))] Max. cable size, loadsharing [mm2 (AWG2))] Max. cable size, brake [mm2 (AWG2)) Max. external pre-fuses [A] 1 Est. power loss at rated max. load [W]4) , 400V, F1 & F2 Est. power loss at rated max. load [W] 4) , 460V, F1 & F2 Max added losses of A1 RFI, Circuit Breaker or Disconnect, & Contactor, F3 & F4 Max Panel Options Losses Weight, enclosure IP21, IP54 [kg] Weight Rectifier Module [kg] Weight Inverter Module [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card ambient trip 1600 10647 9414 12338 11006 13201 12353 4x185 (4x350 mcm) 2000 15436 14041 18084 17137
130BA230.10

P560 560 750 F1/F3

P630 630 900 F1/F3

P710 710 1000 F1/F3

P800 800 1200 F2/F4

P1M0 1000 1350 F2/F4

500 650 F1/F3

880 968 780 858 610 621

990 1089 890 979 686 709

1120 1232 1050 1155 776 837

1260 1386 1160 1276 873 924

1460 1606 1380 1518 1012 1100

1720 1892 1530 1683 1192 1219

Max. input current 857 759 964 867 1090 1022 1227 1129 1422 1344 1675 1490

8 8

130BA229.10

8x150 (8x300 mcm) 8x240 (8x500 mcm) 8x456 (8x900 mcm) 4x120 (4x250 mcm)

12x150 (12x300 mcm)

6x185 (6x350 mcm) 2500 20358 17752

963

1054

1093 400

1230

2280

2541

1004/ 1299 102 102

1004/ 1299 102 102

1004/ 1299 102 102 0.98

1004/ 1299 102 136

1246/ 1541 136 102

1246/ 1541 136 102

0-600Hz 95C 68C

MG.11.BA.02 - VLT is a registered Danfoss trademark

155

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 380-480V AC P110 Typical Shaft output at 400V [kW] Typical Shaft output at 460V [HP] Enclosure IP21 Enclosure IP54 Enclosure IP00 Output current Continuous (at 400V) [A] Intermittent (60 sec overload) (at 400V) [A] Continuous (at 460/480V) [A] Intermittent (60 sec overload) (at 460/480V) [A] Continuous KVA (at 400V) [KVA] Continuous KVA (at 460V) [KVA] Continuous (at 400V) [A] Continuous (at 460/480V) [A] Max. cable size, mains motor, brake and load share [mm2 (AWG2))] Max. external prefuses [A] 1 Estimated power loss at rated max. load [W]
4)
130BA229.10

P132 132 200 D1 D1 D3

P160 160 250 D2 D2 D4

P200 200 300 D2 D2 D4

P250 250 350 D2 D2 D4

110 150 D1 D1 D3

212

260

315

395

480

233

286

347

435

528

130BA230.10

190

240

302

361

443

209

264

332

397

487

8 8
Max. input current

147 151

180 191

218 241

274 288

333 353

204

251

304

381

463

183

231

291

348

427

2 x 70 (2 x 2/0)

2 x 70 (2 x 2/0)

2 x 150 (2 x 300 mcm)

2 x 150 (2 x 300 mcm)

2 x 150 (2 x 300 mcm)

300

350

400

500

630

3234

3782

4213

5119

5893

, 400V Estimated power loss at rated max. load [W] , 460V Weight, enclosure IP21, IP54 [kg] Weight, enclosure IP00 [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card ambient trip

2947

3665

4063

4652

5634

4)

96

104

125

136

151

82

91

112 0.98 0 - 800Hz

123

138

90C

110C

110C 60C

110 C

110C

156

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 380-480V AC P315 Typical Shaft output at 400V [kW] Typical Shaft output at 460V [HP] Enclosure IP21 Enclosure IP54 Enclosure IP00 Output current Continuous (at 400V) [A] Intermittent (60 sec overload) (at 400V) [A] Continuous (at 460/480V) [A] Intermittent (60 sec overload) (at 460/480V) [A] Continuous KVA (at 400V) [KVA] Continuous KVA (at 460V) [KVA] Continuous (at 400V) [A]
130BA229.10

P355 355 500 E1 E1 E2

P400 400 600 E1 E1 E2

P450 450 600 E1 E1 E2

315 450 E1 E1 E2

600

658

745

800

130BA230.10

660

724

820

880

540

590

678

730

594

649

746

803

416 430

456 470

516 540

554 582

8 8

Max. input current 590 647 733 787

Continuous (at 460/480V) [A]

531

580

667

718

Max. cable size, mains, motor and load share [mm2 (AWG2))] Max. cable size, brake [mm2 (AWG2)) Max. external pre-fuses [A] 1 Estimated power loss at rated max. load [W] 400V Estimated power loss at rated max. load [W] 460V
4)

4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 700

4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 900

4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 900

4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 900

6790

7701

8879

9670

4)

6082

6953

8089

8803

Weight, enclosure IP21, IP54 [kg] Weight, enclosure IP00 [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card ambient trip

263 221

270 234 0.98 0 - 600Hz 110C 68C

272 236

313 277

MG.11.BA.02 - VLT is a registered Danfoss trademark

157

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 380-480V AC P500 Typical Shaft output at 400V [kW] Typical Shaft output at 460V [HP] Enclosure IP21, 54 without/ with options cabinet Output current Continuous (at 400V) [A] Intermittent (60 sec overload) (at 400V) [A] Continuous (at 460/480V) [A] Intermittent (60 sec overload) (at 460/480V) [A] Continuous KVA (at 400V) [KVA] Continuous KVA (at 460V) [KVA] Continuous (at 400V) [A] Continuous (at 460/ 480 V) [A] Max. cable size,motor [mm2 (AWG2))] Max. cable size,mains F1/F2 [mm2 (AWG2))] Max. cable size,mains F3/F4 [mm2 (AWG2))] Max. cable size, loadsharing [mm2 (AWG2))] Max. cable size, brake [mm2 (AWG2)) Max. external pre-fuses [A] 1 Est. power loss at rated max. load [W]4) , 400V, F1 & F2 Est. power loss at rated max. load [W] 4) , 460V, F1 & F2 Max added losses of A1 RFI, Circuit Breaker or Disconnect, & Contactor, F3 & F4 Max Panel Options Losses Weight, enclosure IP21, IP54 [kg] Weight Rectifier Module [kg] Weight Inverter Module [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card ambient trip 1600 10647 9414 12338 11006 13201 12353 4x185 (4x350 mcm) 2000 15436 14041 18084 17137
130BA230.10

P560 560 750 F1/F3

P630 630 900 F1/F3

P710 710 1000 F1/F3

P800 800 1200 F2/F4

P1M0 1000 1350 F2/F4

500 650 F1/F3

880 968 780 858 610 621

990 1089 890 979 686 709

1120 1232 1050 1155 776 837

1260 1386 1160 1276 873 924

1460 1606 1380 1518 1012 1100

1720 1892 1530 1683 1192 1219

8 8

Max. input current 857 759 964 867 1090 1022 1227 1129 1422 1344 1675 1490

130BA229.10

8x150 (8x300 mcm) 8x240 (8x500 mcm) 8x456 (8x900 mcm) 4x120 (4x250 mcm)

12x150 (12x300 mcm)

6x185 (6x350 mcm) 2500 20358 17752

963

1054

1093 400

1230

2280

2541

1004/ 1299 102 102

1004/ 1299 102 102

1004/ 1299 102 102 0.98

1004/ 1299 102 136

1246/ 1541 136 102

1246/ 1541 136 102

0-600Hz 95C 68C

158

MG.11.BA.02 - VLT is a registered Danfoss trademark

P11K 11 10 B2 B2 14 15.4 13 14.3 13.3 12.9 15.5 35 1/0 95 4/0 18.1 17.9 21.5 21.9 21.9 26.3 26.7 26.9 32.3 34.3 33.8 40.6 41 40.8 49 51.4 51.8 62.1 61.9 61.7 74.1 19.8 24.2 29.7 37.4 45.1 57.2 68.2 18 22 27 34 41 52 62 83 91.3 82.9 82.7 99.2 20.9 25.3 30.8 39.6 47.3 59.4 71.5 95.7 19 23 28 36 43 54 65 87 105 115.5 100 110 100 99.6 119.5

General Specifications and ...

Normal overload P15K 15 16.4 B2 B2 P30K 30 33 B2 B2 P37K 37 40 C2 C2 P45K 45 50 C2 C2 P55K 55 60 C2 C2 P75K 75 75 C2 C2 P90K 90 100 C2 C2

110% for 1 minute P18K P22K 18.5 22 20.1 24 B2 B2 B2 B2

130BA058.10

8.1.1 Mains Supply 3 x 525-690V AC

15 16.5 63 201 27 27 27 27 27 27 27 27 27 27 285 335 375 430 592 65 65 63 63 63 80 100 21.5 26.4 31.9 39.6 53.9

19.5

24

29

36

49

59 64.9 125 720 65 65

71 78.1 160 880 65 65

87 95.7 160 1200 65 65

99 108.9 160 1440 65 65

130BA057.10

VLT HVAC Drive Design Guide

Size: Typical Shaft Output [kW] Typical Shaft Output [HP] at 575V IP21/NEMA 1 IP55/NEMA 12 Output current Continuous (3 x 525-550V) [A] Intermittent (3 x 525-550V) [A] Continuous (3 x 551-690V) [A] Intermittent (3 x 551-690V) [A] Continuous kVA (550V AC) [kVA] Continuous kVA (575V AC) [kVA] Continuous kVA (690V AC) [kVA] Max. cable size (mains, motor, brake) [mm2]/[AWG] 2) Max. input current Continuous (3 x 525-690V) [A] Intermittent (3 x 525-690V) [A] Max. pre-fuses1) [A] Environment: Estimated power loss at rated max. load [W] 4) Weight: IP21 [kg]

MG.11.BA.02 - VLT is a registered Danfoss trademark

IP55 [kg]

0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 Efficiency 4) 1) For type of fuse see section Fuses 2) American Wire Gauge 3) Measured using 5 m screened motor cables at rated load and rated frequency 4) The typical power loss is at normal load conditions and expected to be within +/- 15% (tolerance relates to variety in voltage and cable conditions). Values are based on a typical motor efficiency (eff2/eff3 border line). Lower efficiency motors will also add to the power loss in the frequency converter and vice versa. If the switching frequency is raised from nominal the power losses may rise significantly. LCP and typical control card power consumptions are included. Further options and customer load may add up to 30 Watts to the losses. (Though typically only 4 Watts extra for a fully loaded control card or options for slot A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). 5) Motor and mains cable: 300MCM/150mm2

Table 8.13 Mains Supply 3 x 525-690V AC

159

8 8

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 525-690V AC P110 Typical Shaft output at 550V [kW] Typical Shaft output at 575V [HP] Typical Shaft output at 690V [kW] Enclosure IP21 Enclosure IP54 Enclosure IP00 Output current Continuous (at 550V) [A] Intermittent (60 sec overload) (at 550V) [A] Continuous (at 575/690V) [A] Intermittent (60 sec overload) (at 575/690V) [A] Continuous KVA (at 550V) [KVA] Continuous KVA (at 575V) [KVA] Continuous KVA (at 690V) [KVA] Max. input current Continuous (at 550V) [A] Continuous (at 575V) [A] Continuous (at 690V) [A] Max. cable size, mains motor, load share and brake [mm2 (AWG)] Max. external pre-fuses [A] 1 Estimated power loss at rated max. load [W]
4)
130BA229.10
130BA230.10

P132 110 150 132 D1 D1 D3

P160 132 200 160 D1 D1 D3

P200 160 250 200 D2 D2 D4

P250 200 300 250 D2 D2 D4

90 125 110 D1 D1 D2

137 151

162 178 155

201 221 192

253 278 242

303 333 290

131

171 144 131 130 157 154 154 185

211

266

319

8 8

191 191 229

241 241 289

289 289 347

130

158

198

245

299

124

151

189

234

286

128

155

197

240

296

2 x 70 (2 x 2/0)

2 x 150 (2 x 300 mcm)

250

315

350

350

400

2533

2963

3430

4051

4867

, 600V Estimated power loss at rated max. load [W]

4)

2662

3430

3612

4292

5156

, 690V Weight, Enclosure IP21, IP54 [kg] Weight, Enclosure IP00 [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card ambient trip 85C

96 82

104 91 0.98 0 - 60Hz 90C 110C 60C

125 112

136 123

110 C

110 C

160

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 525-690V AC P315 Typical Shaft output at 550V [kW] Typical Shaft output at 575V [HP] Typical Shaft output at 690V [kW] Enclosure IP21 Enclosure IP54 Enclosure IP00 Output current Continuous (at 550V) [A] Intermittent (60 sec overload) (at 550V) [A] Continuous (at 575/690V) [A] Intermittent (60 sec overload) (at 575/690V) [A] Continuous KVA (at 550V) [KVA] Continuous KVA (at 575V) [KVA] Continuous KVA (at 690V) [KVA] Max. input current Continuous (at 550V) [A]
130BA229.10
130BA230.10

P400 315 400 400 D2 D2 D4

P450 355 450 450 E1 E1 E2

250 350 315 D2 D2 D4

360 396 344 378 343 343 411

418 460 400 440 398 398 478

470 517 450 495 448 448 538

8 8

355

408

453

Continuous (at 575V) [A]

339

390

434

Continuous (at 690V) [A] Max. cable size, mains, motor and load share [mm2 (AWG)] Max. cable size, brake [mm2 (AWG)] Max. external pre-fuses [A] Estimated power loss
1

352 2 x 150 (2 x 300 mcm) 2 x 150 (2 x 300 mcm) 500 5493 5821 151 138

400 2 x 150 (2 x 300 mcm) 2 x 150 (2 x 300 mcm) 550 5852 6149 165 151 0.98

434 4 x 240 (4 x 500 mcm) 2 x 185 (2 x 350 mcm) 700 6132 6440 263 221

at rated max. load [W] 4) , 600V Estimated power loss at rated max. load [W] 4) , 690V Weight, enclosure IP21, IP54 [kg] Weight, enclosure IP00 [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card ambient trip

0 - 600 Hz 110C 60C

0 - 500 Hz 110C 60C

0 - 500 Hz 110C 68C

MG.11.BA.02 - VLT is a registered Danfoss trademark

161

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 525-690V AC P500 Typical Shaft output at 550V [kW] Typical Shaft output at 575V [HP] Typical Shaft output at 690V [kW] Enclosure IP21 Enclosure IP54 Enclosure IP00 Output current Continuous (at 550V) [A] Intermittent (60 sec overload) (at 550V) [A] Continuous (at 575/690V) [A] Intermittent (60 sec overload) (at 575/690V) [A] Continuous KVA (at 550V) [KVA] Continuous KVA (at 575V) [KVA] Continuous KVA (at 690V) [KVA] Max. input current Continuous (at 550V) [A]
130BA229.10
130BA230.10

P560 450 600 560 E1 E1 E2

P630 500 650 630 E1 E1 E2

400 500 500 E1 E1 E2

523 575 500 550 498 498 598

596 656 570 627 568 568 681

630 693 630 693 600 627 753

8 8

504

574

607

Continuous (at 575V) [A]

482

549

607

Continuous (at 690V) [A] Max. cable size, mains, motor and load share [mm2 (AWG)] Max. cable size, brake [mm2 (AWG)] Max. external pre-fuses [A] Estimated power loss Estimated power loss at rated max. load [W] 4) , 690V Weight, enclosure IP21, IP54 [kg] Weight, enclosure IP00 [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card ambient trip
1

482 4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 700 6903 7249 263 221

549 4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 900 8343 8727 272 236 0.98 0 - 500Hz 110C 68C

607 4x240 (4x500 mcm) 2 x 185 (2 x 350 mcm) 900 9244 9673 313 277

at rated max. load [W] 4) , 600V

162

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

Mains Supply 3 x 525-690V AC P710 Typical Shaft output at 550V [kW] Typical Shaft output at 575V [HP] Typical Shaft output at 690V [kW] Enclosure IP21, 54 without/ with options cabinet Output current Continuous (at 550V) [A] Intermittent (60 s overload, at 550V) [A] Continuous (at 575/690V) [A] Intermittent (60 s overload, at 575/690V) [A] Continuous KVA (at 550V) [KVA] Continuous KVA (at 575V) [KVA] Continuous KVA (at 690V) [KVA]
130BA230.10

P800 670 950 800 F1/ F3

P900 750 1050 900 F1/ F3

P1M0 850 1150 1000 F2/F4

P1M2 1000 1350 1200 F2/ F4

P1M4 1100 1550 1400 F2/F4

560 750 710 F1/ F3

763 839 730 803 727 727 872

889 978 850 935 847 847 1016

988 1087 945 1040 941 941 1129

1108 1219 1060 1166 1056 1056 1267

1317 1449 1260 1386 1255 1255 1506

1479 1627 1415 1557 1409 1409 1691

8 8

MG.11.BA.02 - VLT is a registered Danfoss trademark

163

General Specifications and ...

VLT HVAC Drive Design Guide

Max. input current Continuous (at 550V) [A] Continuous (at 575V) [A] Continuous (at 690V) [A] Max. cable size,motor [mm2 (AWG2))] Max. cable size,mains F1/F2 [mm2 (AWG2))] Max. cable size,mains F3/F4 [mm2 (AWG2))] Max. cable size, loadsharing [mm2 (AWG2))] Max. cable size, brake [mm2 (AWG2)) Max. external pre-fuses [A] Est. power loss
1)
130BA229.10

743 711 711

866 828 828 8x150 (8x300 mcm)

962 920 920

1079 1032 1032

1282 1227 1227 12x150 (12x300 mcm)

1440 1378 1378

8x240 (8x500 mcm) 8x456 8x900 mcm 4x120 (4x250 mcm) 4x185 (4x350 mcm) 1600 10771 12272 13835 15592 6x185 (6x350 mcm) 2000 18281 2500 20825

8 8

at rated max. load [W] 4), 600V, F1 & F2 Est. power loss at rated max. load [W] 4), 690V, F1 & F2 Max added losses of Circuit Breaker or Disconnect & Contactor, F3 & F4 Max Panel Options Losses Weight,enclosure IP21, IP54 [kg] Weight, Rectifier Module [kg] Weight, Inverter Module [kg] Efficiency4) Output frequency Heatsink overtemp. trip Power card amb. trip

11315

12903

14533

16375

19207

21857

427

532

615

665

863

1044

1004/ 1299 102 102

1004/ 1299 102 102

400 1004/ 1299 1246/ 1541 102 136 0.98 0-500Hz 95C 68C 136 102

1246/ 1541 136 102

1280/1575 136 136

1) For type of fuse see section Fuses. 2) American Wire Gauge. 3) Measured using 5m screened motor cables at rated load and rated frequency. 4) The typical power loss is at nominal load conditions and expected to be within +/-15% (tolerence relates to variety in voltage and cable conditions). Values are based on a typical motor efficiency (eff2/eff3 border line). Motors with lower efficiency will also add to the power loss in the frequency converter and opposite. If the switching frequency is increased comed to the default setting, the power losses may rise significantly. LCP and typical control card power consumptions are included. Further options and customer load may add up to 30W to the losses. (Though typical only 4W extra for a fully loaded control card, or options for slot A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/-5%).

164

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

8.2 General Specifications

Mains supply (L1, L2, L3): Supply voltage 200-240V 10%, 380-480V 10%, 525-690V 10%

Mains voltage low / mains drop-out: During low mains voltage or a mains drop-out, the FC continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the FC's lowest rated supply voltage. Power-up and full torque cannot be expected at mains voltage lower than 10% below the FC's lowest rated supply voltage. Supply frequency Max. imbalance temporary between mains phases True Power Factor () Displacement Power Factor (cos) near unity Switching on input supply L1, L2, L3 (power-ups) enclosure type A Switching on input supply L1, L2, L3 (power-ups) enclosure type B, C Switching on input supply L1, L2, L3 (power-ups) enclosure type D, E, F Environment according to EN60664-1 Motor output (U, V, W): Output voltage Output frequency Switching on output Ramp times
*

50/60Hz 5% 3.0% of rated supply voltage 0.9 nominal at rated load (> 0.98) maximum twice/min. maximum once/min. maximum once/2 min. overvoltage category III / pollution degree 2

The unit is suitable for use on a circuit capable of delivering not more than 100.000 RMS symmetrical Amperes, 480/600 V maximum. 0 - 100% of supply voltage 0 - 1000Hz* Unlimited 1 - 3600 sec.

8 8

Dependent on power size. maximum 110% for 1 min.* maximum 135% up to 0.5 sec.* maximum 110% for 1 min.*

Torque characteristics: Starting torque (Constant torque) Starting torque Overload torque (Constant torque) *Percentage relates to the frequency converter's nominal torque. Cable lengths and cross sections: Max. motor cable length, screened/armoured Max. motor cable length, unscreened/unarmoured Max. cross section to motor, mains, load sharing and brake * Maximum cross section to control terminals, rigid wire Maximum cross section to control terminals, flexible cable Maximum cross section to control terminals, cable with enclosed core Minimum cross section to control terminals * See Mains Supply tables for more information! Digital inputs: Programmable digital inputs Terminal number Logic Voltage level Voltage level, logic'0' PNP Voltage level, logic'1' PNP Voltage level, logic '0' NPN Voltage level, logic '1' NPN Maximum voltage on input Input resistance, Ri

VLT HVAC Drive: 150m VLT HVAC Drive: 300m 1.5mm2/16 AWG (2 x 0.75mm2) 1mm2/18 AWG 0.5mm2/20 AWG 0.25mm2

4 (6) 18, 19, 27 29 32, 33, PNP or NPN 0 - 24V DC < 5V DC > 10V DC > 19V DC < 14V DC 28V DC approx. 4 k
1), 1),

All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. 1) Terminals 27 and 29 can also be programmed as output.

MG.11.BA.02 - VLT is a registered Danfoss trademark

165

General Specifications and ...

VLT HVAC Drive Design Guide

Analog inputs: Number of analog inputs Terminal number Modes Mode select Voltage mode Voltage level Input resistance, Ri Max. voltage Current mode Current level Input resistance, Ri Max. current Resolution for analog inputs Accuracy of analog inputs Bandwidth

2 53, 54 Voltage or current Switch S201 and switch S202 Switch S201/switch S202 = OFF (U) : 0 to + 10V (scaleable) approx. 10k 20V Switch S201/switch S202 = ON (I) 0/4 to 20mA (scaleable) approx. 200 30mA 10 bit (+ sign) Max. error 0.5% of full scale : 200Hz

The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
130BA117.10 PELV isolation +24V 18 Control

8 8

Mains

37 Functional isolation RS485

High voltage

Motor

DC-Bus

Pulse inputs: Programmable pulse inputs Terminal number pulse Max. frequency at terminal, 29, 33 Max. frequency at terminal, 29, 33 Min. frequency at terminal 29, 33 Voltage level Maximum voltage on input Input resistance, Ri Pulse input accuracy (0.1 - 1 kHz) Analog output: Number of programmable analog outputs Terminal number Current range at analog output Max. resistor load to common at analog output Accuracy on analog output Resolution on analog output Control card, RS-485 serial communication: Terminal number Terminal number 61

2 29, 33 110kHz (Push-pull driven) 5kHz (open collector) 4Hz see section on Digital input 28V DC approx. 4k Max. error: 0.1% of full scale 1 42 0/4 - 20mA 500 Max. error: 0.8% of full scale 8 bit

The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. 68 (P,TX+, RX+), 69 (N,TX-, RX-) Common for terminals 68 and 69

The RS-485 serial communication circuit is functionally seated from other central circuits and galvanically isolated from the supply voltage (PELV). Digital output: Programmable digital/pulse outputs Terminal number Voltage level at digital/frequency output
166 MG.11.BA.02 - VLT is a registered Danfoss trademark

2 27, 29 1) 0 - 24V

General Specifications and ...

VLT HVAC Drive Design Guide

Max. output current (sink or source) Max. load at frequency output Max. capacitive load at frequency output Minimum output frequency at frequency output Maximum output frequency at frequency output Accuracy of frequency output Resolution of frequency outputs 1) Terminal 27 and 29 can also be programmed as input.

40mA 1 k 10nF 0Hz 32kHz Max. error: 0.1% of full scale 12 bit

The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Control card, 24 V DC output: Terminal number Max. load 12, 13 : 200mA

The 24V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs. Relay outputs: Programmable relay outputs Relay 01 Terminal number Max. terminal load (AC-1)1) on 1-3 (NC), 1-2 (NO) (Resistive load) Max. terminal load (AC-15)1) (Inductive load @ cos 0.4) Max. terminal load (DC-1)1) on 1-2 (NO), 1-3 (NC) (Resistive load) Max. terminal load (DC-13)1) (Inductive load) Relay 02 Terminal number Max. terminal load (AC-1)1) on 4-5 (NO) (Resistive load)2)3) Max. terminal load (AC-15)1) on 4-5 (NO) (Inductive load @ cos 0.4) Max. terminal load (DC-1)1) on 4-5 (NO) (Resistive load) Max. terminal load (DC-13)1) on 4-5 (NO) (Inductive load) Max. terminal load (AC-1)1) on 4-6 (NC) (Resistive load) Max. terminal load (AC-15)1) on 4-6 (NC) (Inductive load @ cos 0.4) Max. terminal load (DC-1)1) on 4-6 (NC) (Resistive load) Max. terminal load (DC-13)1) on 4-6 (NC) (Inductive load) Min. terminal load on 1-3 (NC), 1-2 (NO), 4-6 (NC), 4-5 (NO) Environment according to EN 60664-1 2 1-3 (break), 1-2 (make) 240V AC, 2A 240V AC, 0.2 A 60V DC, 1A 24V DC, 0.1A 4-6 (break), 4-5 (make) 400V AC, 2 A 240V AC, 0.2 A 80V DC, 2 A 24V DC, 0.1A 240V AC, 2 A 240V AC, 0.2A 50V DC, 2 A 24V DC, 0.1 A 24V DC 10mA, 24V AC 20mA overvoltage category III/pollution degree 2

8 8

1) IEC 60947 parts 4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV). 2) Overvoltage Category II 3) UL applications 300V AC 2A Control card, 10 V DC output: Terminal number Output voltage Max. load The 10V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Control characteristics: Resolution of output frequency at 0 - 1000Hz System response time (terminals 18, 19, 27, 29, 32, 33) Speed control range (open loop) Speed accuracy (open loop) All control characteristics are based on a 4-pole asynchronous motor Surroundings: Enclosure type Enclosure type Enclosure type Enclosure type A B1/B2 B3/B4 C1/C2 IP 20/Chassis, IP 21kit/Type 1, IP55/Type12, IP 66/Type12 IP 21/Type 1, IP55/Type12, IP 66/12 IP20/Chassis IP 21/Type 1, IP55/Type 12, IP66/12 : +/- 0.003Hz : 2ms 1:100 of synchronous speed 30 - 4000 rpm: Maximum error of 8 rpm 50 10.5V0.5V 25mA

MG.11.BA.02 - VLT is a registered Danfoss trademark

167

General Specifications and ...

VLT HVAC Drive Design Guide

Enclosure type C3/C4 IP20/Chassis Enclosure type D1/D2/E1 IP21/Type 1, IP54/Type12 Enclosure type D3/D4/E2 IP00/Chassis Enclosure type F1/F3 IP21, 54/Type1, 12 Enclosure type F2/F4 IP21, 54/Type1, 12 IP21/NEMA 1/IP 4X on top of enclosure Enclosure kit available enclosure type D Vibration test enclosure A, B, C 1.0g Vibration test enclosure D, E, F 0.7 g Relative humidity 5% - 95% (IEC 721-3-3; Class 3K3 (non-condensing) during operation Aggressive environment (IEC 60068-2-43) H2S test class Kd Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature (at 60 AVM switching mode) - with derating max. 55 C1) - with full output power of typical EFF2 motors (up to 90% output current) - at full continuous FC output current
1)

max. 50 C1) max. 45 C1) 0C - 10C -25 - +65/70C 1000m 3000m

For more information on derating see the Design Guide, section on Special Conditions.

8 8

Minimum ambient temperature during full-scale operation Minimum ambient temperature at reduced performance Temperature during storage/transport Maximum altitude above sea level without derating Maximum altitude above sea level with derating Derating for high altitude, see section on special conditions EMC standards, Emission EMC standards, Immunity See section on special conditions! Control card performance: Scan interval Control card, USB serial communication: USB standard USB plug

EN 61800-3, EN 61000-6-3/4, EN 55011, IEC 61800-3 EN 61800-3, EN 61000-6-1/2, EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6

: 5ms 1.1 (Full speed) USB type B device plug

CAUTION

Connection to PC is carried out via a standard host/device USB cable. The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is not galvanically isolated from protection earth. Use only isolated laptop/PC as connection to the USB connector on frequency converter or an isolated USB cable/converter.

168

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

Relative E ciency

Protection and Features Electronic thermal motor protection against overload. Temperature monitoring of the heatsink ensures that the frequency converter trips if the temperature reaches 95C 5C. An overload temperature cannot be reset until the temperature of the heatsink is below 70C 5C (Guideline these temperatures may vary for different power sizes, enclosures etc.). The frequency converter has an auto derating function to avoid it's heatsink reaching 95C. The frequency converter is protected against shortcircuits on motor terminals U, V, W. If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load). Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high. The frequency converter is protected against earth faults on motor terminals U, V, W.

1.0 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0% 50% 100% load 100% % Speed 75% load 150% 50% load

200% 25% load

Illustration 8.1 Typical Efficiency Curves

Example: Assume a 55kW, 380-480V AC frequency converter at 25% load at 50% speed. The graph is showing 0,97 - rated efficiency for a 55kW FC is 0.98. The actual efficiency is then: 0.97x0.98=0.95. Efficiency of the motor (MOTOR ) The efficiency of a motor connected to the frequency converter depends on magnetizing level. In general, the efficiency is just as good as with mains operation. The efficiency of the motor depends on the type of motor. In the range of 75-100% of the rated torque, the efficiency of the motor is practically constant, both when it is controlled by the frequency converter and when it runs directly on mains. In small motors, the influence from the U/f characteristic on efficiency is marginal. However, in motors from 11kW and up, the advantages are significant. In general, the switching frequency does not affect the efficiency of small motors. Motors from 11kW and up have their efficiency improved (1-2%). This is because the sine shape of the motor current is almost perfect at high switching frequency. Efficiency of the system (SYSTEM) To calculate the system efficiency, the efficiency of the frequency converter (VLT) is multiplied by the efficiency of the motor (MOTOR): SYSTEM = VLT x MOTOR

130BB252.11

1.01

8 8

8.3 Efficiency
Efficiency of the frequency converter (VLT) The load on the frequency converter has little effect on its efficiency. In general, the efficiency is the same at the rated motor frequency fM,N, even if the motor supplies 100% of the rated shaft torque or only 75%, i.e. in case of part loads. This also means that the efficiency of the frequency converter does not change even if other U/f characteristics are chosen. However, the U/f characteristics influence the efficiency of the motor. 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 30m. Frequency converter efficiency calculation Calculate the efficiency of the frequency converter at different loads based on Illustration 8.1. The factor in this graph must be multiplied with the specific efficiency factor listed in the specification tables:

8.4 Acoustic Noise

The acoustic noise from the frequency converter comes from three sources: 1. DC intermediate circuit coils. 2. 3. Integral fan. RFI filter choke.

MG.11.BA.02 - VLT is a registered Danfoss trademark

169

General Specifications and ...

VLT HVAC Drive Design Guide

The typical values measured at a distance of 1 m from the unit:

At reduced fan speed (50%) [dBA] Full fan speed [dBA] *** 51 51 54 61 58 59.4 53 52 55 56.4 74 73 73 82 78 60 60 63 67 70 70.5 62.8 62 65 67.3 76 74 74 83 80

Enclosure A2 A3 A5 B1 B2 B3 B4 C1 C2 C3 C4 D1/D3 D2/D4 E1/E2* ** F1/F2/F3/F4

The natural induction causes an overshoot UPEAK in the motor voltage before it stabilizes itself at a level depending on the voltage in the intermediate circuit. The rise time and the peak voltage UPEAK affect the service life of the motor. If the peak voltage is too high, especially motors without phase coil insulation are affected. If the motor cable is short (a few metres), the rise time and peak voltage are lower. If the motor cable is long (100m), the rise time and peak voltage increases. In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply (such as a frequency converter), fit a sine-wave filter on the output of the frequency converter. To obtain approximate values for cable lengths and voltages not mentioned below, use the following rules of thumb: 1. 2. 3. Rise time increases/decreases proportionally with cable length. UPEAK = DC link voltage x 1.9 (DC link voltage = Mains voltage x 1.35).
dU dt =

8 8

* 315kW, 380-480V AC and 450-500kW, 525-690V AC only. ** Remaining E1/E2 power sizes. *** For D, E and F sizes, reduced fan speed is at 87%, measured at 200V.

0.8 U PEAK

Risetime

Data are measured according to IEC 60034-17. Cable lengths are in metres.

8.5 Peak Voltage on Motor

When a transistor in the inverter bridge switches, the voltage across the motor increases by a du/dt ratio depending on: the motor cable (type, cross-section, length screened or unscreened) inductance
Mains voltage [V] 240 240 240 240 Rise time [sec] 0.226 0.262 0.650 0.745 Vpeak [kV] 0.616 0.626 0.614 0.612 dU/dt [kV/sec] 2.142 1.908 0.757 0.655

Frequency Converter, P5K5, T2 Cable length [m] 36 50 100 150 Frequency Converter, P7K5, T2 Cable length [m] 5 50 100 150 Mains voltage [V] 230 230 230 230 Rise time [sec] 0.13 0.23 0.54 0.66 011893-0001 0.510 0.590 0.580 0.560 dU/dt [kV/sec] 3.090 2.034 0.865 0.674

170

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

Frequency Converter, P11K, T2 Cable length [m] 36 136 150 Frequency Converter, P15K, T2 Cable length [m] 30 100 150 Frequency Converter, P18K, T2 Cable length [m] 36 136 150 Frequency Converter, P22K, T2 Cable length [m] 36 136 150 Frequency Converter, P30K, T2 Cable length [m] 15 50 150 Frequency Converter, P37K, T2 Cable length [m] 30 100 150 Frequency Converter, P45K, T2 Cable length [m] 30 100 150 Mains voltage [V] 240 240 240 Rise time [sec] 0.300 0.536 0.776 Vpeak [kV] 0.598 0.566 0.546 dU/dt [kV/sec] 1.593 0.843 0.559 Mains voltage [V] 240 240 240 Rise time [sec] 0.300 0.536 0.776 Vpeak [kV] 0.598 0.566 0.546 dU/dt [kV/sec] 1.593 0.843 0.559 Mains voltage [V] 240 240 240 Rise time [sec] 0.194 0.252 0.444 Vpeak [kV] 0.626 0.574 0.538 dU/dt [kV/sec] 2.581 1.929 0.977 Mains voltage [V] 240 240 240 Rise time [sec] 0.244 0.560 0.720 Vpeak [kV] 0.608 0.580 0.574 dU/dt [kV/sec] 1.993 0.832 0.661 Mains voltage [V] 240 240 240 Rise time [sec] 0.244 0.568 0.720 Vpeak [kV] 0.608 0.580 0.574 dU/dt [kV/sec] 1.993 0.832 0.661 Mains voltage [V] 240 240 240 Rise time [sec] 0.556 0.592 0.708 Vpeak [kV] 0.650 0.594 0.575 dU/dt [kV/sec] 0.935 0.807 0.669 240 240 240 Rise time [sec] 0.264 0.536 0.568 Vpeak [kV] 0.624 0.596 0.568 dU/dt [kV/sec] 1.894 0.896 0.806

8 8

MG.11.BA.02 - VLT is a registered Danfoss trademark

171

General Specifications and ...

VLT HVAC Drive Design Guide

Frequency Converter, P1K5, T4 Cable length [m] 5 50 150 Frequency Converter, P4K0, T4 Cable length [m] 5 50 150 Frequency Converter, P7K5, T4 Cable length [m] 5 50 150 Frequency Converter, P11K, T4 Cable length [m] 15 100 150 Frequency Converter, P15K, T4 Cable length [m] 36 100 150 Frequency Converter, P18K, T4 Cable length [m] 36 100 150 Frequency Converter, P22K, T4 Cable length [m] 36 100 150 Mains voltage [V] 400 400 400 Rise time [sec] 0.232 0.410 0.430 Vpeak [kV] 0.950 0.980 0.970 dU/dt [kV/sec] 3.534 1.927 1.860 Mains voltage [V] 400 400 400 Rise time [sec] 0.344 1.000 1.400 Vpeak [kV] 1.040 1.190 1.040 dU/dt [kV/sec] 2.442 0.950 0.596 Mains voltage [V] 400 400 400 Rise time [sec] 0.422 0.464 0.896 Vpeak [kV] 1.060 0.900 1.000 dU/dt [kV/sec] 2.014 1.616 0.915 Mains voltage [V] 400 400 400 Rise time [sec] 0.408 0.364 0.400 Vpeak [kV] 0.718 1.050 0.980 dU/dt [kV/sec] 1.402 2.376 2.000 Mains voltage [V] 400 400 400 Rise time [sec] 0.04755 0.207 0.6742 Vpeak [kV] 0.739 1.040 1.030 dU/dt [kV/sec] 8.035 4.548 2.828 Mains voltage [V] 400 400 400 Rise time [sec] 0.172 0.310 0.370 1.190 Vpeak [kV] 0.890 dU/dt [kV/sec] 4.156 2.564 1.770 Mains voltage [V] 400 400 400 Rise time [sec] 0.640 0.470 0.760 Vpeak [kV] 0.690 0.985 1.045 dU/dt [kV/sec] 0.862 0.985 0.947

8 8

172

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

Frequency Converter, P30K, T4 Cable length [m] 15 100 150 Frequency Converter, P37K, T4 Cable length [m] 5 50 100 150 Frequency Converter, P45K, T4 Cable length [m] 36 50 100 150 Frequency Converter, P55K, T4 Cable length [m] 10 Frequency Converter, P75K, T4 Cable length [m] 5 Mains voltage [V] 480 Rise time [sec] 0.371 Vpeak [kV] 1.170 dU/dt [kV/sec] 2.466 Mains voltage [V] 400 Rise time [sec] 0.350 Vpeak [kV] 0.932 dU/dt [kV/sec] 2.130 Mains voltage [V] 400 400 400 400 Rise time [sec] 0.254 0.465 0.815 0.890 Vpeak [kV] 1.056 1.048 1.032 1.016 dU/dt [kV/sec] 3.326 1.803 1.013 0.913 Mains voltage 480 480 480 480 Rise time [sec] 0.270 0.435 0.840 0.940 Vpeak [kV] 1.276 1.184 1.188 1.212 dU/dt [kV/sec] 3.781 2.177 1.131 1.031 Mains voltage [V] 400 400 400 Rise time [sec] 0.271 0.440 0.520 Vpeak [kV] 1.000 1.000 0.990 dU/dt [kV/sec] 3.100 1.818 1.510

8 8

Frequency Converter, P90K, T4 Cable length [m] 5 Mains voltage [V] 400 Rise time [sec] 0.364 Vpeak [kV] 1.030 dU/dt [kV/sec] 2.264

High Power Range:

Frequency Converter, P110 - P250, T4 Cable length [m] 30 Mains voltage [V] 400 Rise time [sec] 0.34 Vpeak [kV] 1.040 dU/dt [kV/sec] 2.447

Frequency Converter, P315 - P1M0, T4 Cable length [m] 30 30 30 30 1) With Danfoss dU/dt filter. Mains voltage [V] 500 400 500 400
1 1

Rise time [sec] 0.71 0.61 0.80 0.82

Vpeak [kV] 1.165 0.942 0.906 0.760

dU/dt [kV/sec] 1.389 1.233 0.904 0.743

MG.11.BA.02 - VLT is a registered Danfoss trademark

173

General Specifications and ...

VLT HVAC Drive Design Guide

Frequency Converter, P110 - P400, T7

Cable length [m] 30 30 30 1) With Danfoss dU/dt filter.

Mains voltage [V] 690 575 690

1)

Rise time [sec] 0.38 0.23 1.72

Vpeak [kV] 1.513 1.313 1.329

dU/dt [kV/sec] 3.304 2.750 0.640

Frequency Converter, P450 - P1M4, T7 Cable length [m] 30 30 30 1) With Danfoss dU/dt filter. Mains voltage [V] 690 575 690
1)

Rise time [sec] 0.57 0.25 1.13

Vpeak [kV] 1.611 1.629

dU/dt [kV/sec] 2.261 2.510 1.150

8.6 Special Conditions 8.6.1 Purpose of Derating

Derating must be taken into account when using the frequency converter at low air pressure (heights), at low speeds, with long motor cables, cables with a large cross section or at high ambient temperature. The required action is described in this section. Below 1000m altitude no derating is necessary but above 1000m the ambient temperature (TAMB) or max. output current (Iout) should be derated in accordance with the shown diagram.
130BA418.11 D TAMB, MAX (K) at 100% Iout B and C A enclosure enclosure 0K -5 K -9 K 0K -3.3 K -6 K

8 8

8.6.2 Derating for Ambient Temperature

90% frequency converter output current can be maintained up to max. 50 C ambient temperature. With a typical full load current of EFF 2 motors, full output shaft power can be maintained up to 50 C. For more specific data and/or derating information for other motors or conditions, please contact Danfoss.

Max.Iout (%) at TAMB, MAX 100% 91% 82%

1 km

2 km

3 km

Altitude (km)

Illustration 8.2 Derating of output current versus altitude at TAMB,

MAX

8.6.3 Automatic Adaptations to Ensure Performance

The frequency converter constantly checks for critical levels of internal temperature, load current, high voltage on the intermediate circuit and low motor speeds. As a response to a critical level, the frequency converter can adjust the switching frequency and / or change the switching pattern in order to ensure the performance of the frequency converter. The capability to automatically reduce the output current extends the acceptable operating conditions even further.

for frame sizes A, B and C. At altitudes above 2km, please

contact Danfoss regarding PELV.

An alternative is to lower the ambient temperature at high altitudes and thereby ensure 100% output current at high altitudes. As an example of how to read the graph, the situation at 2 km is elaborated. At a temperature of 45 C (TAMB, MAX - 3.3 K), 91% of the rated output current is available. At a temperature of 41.7 C, 100% of the rated output current is available.

8.6.4 Derating for Low Air Pressure

The cooling capability of air is decreased at lower air pressure.

174

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

95

130BB008.10

IOUT(%) 100

power is proportional to the cube of the speed, there is no need for additional cooling or de-rating of the motor. In the graphs shown below, the typical VT curve is below the maximum torque with de-rating and maximum torque with forced cooling at all speeds.
Maximum load for a standard motor at 40 C driven by a frequency converter type VLT FCxxx

90

85

500

1000

1500

2000

2500

3000

Altitude (meters above sea level)*

100 80

1)

130BB009.10

(C) 45

T%

60 40 20

Amb. Temp.

40

HO

10

20

30

40

50 v%

60

70

80

90

100 110

35

NO

Legend: Typical torque at VT load Max torque with forced cooling Max torque Note 1) Over-syncronous speed operation will result in the available motor torque decreasing inversely proportional with the increase in speed. This must be considered during the design phase to avoid over-loading of the motor.

130BA893.10

80

120

30

500

1000 1500 2000 2500 Altitude (meters above sea level)*

3000

8 8

Derating of output current versus altitude at TAMB, MAX for frame sizes D, E and F.

8.6.5 Derating for Running at Low Speed

When a motor is connected to a frequency converter, it is necessary to check that the cooling of the motor is adequate. The level of heating depends on the load on the motor, as well as the operating speed and time. Constant torque applications (CT mode) A problem may occur at low RPM values in constant torque applications. In a constant torque application s a motor may over-heat at low speeds due to less cooling air from the motor integral fan. Therefore, if the motor is to be run continuously at an RPM value lower than half of the rated value, the motor must be supplied with additional air-cooling (or a motor designed for this type of operation may be used). An alternative is to reduce the load level of the motor by choosing a larger motor. However, the design of the frequency converter puts a limit to the motor size. Variable (Quadratic) torque applications (VT) In VT applications such as centrifugal pumps and fans, where the torque is proportional to the square of the speed and the

A warning or an alarm is signalled by the relevant LED on the front of the frequency converter and indicated by a code on the display. A warning remains active until its cause is no longer present. Under certain circumstances operation of the motor may still be continued. Warning messages may be critical, but are not necessarily so. In the event of an alarm, the frequency converter will have tripped. Alarms must be reset to restart operation once their cause has been rectified. This may be done in four ways: 1. By using the [RESET] control button on the LCP. 2. 3. 4. Via a digital input with the Reset function. Via serial communication/optional fieldbus. By resetting automatically using the [Auto Reset] function, which is a default setting for VLT HVAC Drive Drive, see 14-20 Reset Mode in the FC 100 Programming Guide

MG.11.BA.02 - VLT is a registered Danfoss trademark

175

General Specifications and ...

VLT HVAC Drive Design Guide

NOTE
After a manual reset using the [RESET] button on the LCP, the [AUTO ON] or [HAND ON] button must be pressed to restart the motor. If an alarm cannot be reset, the reason may be that its cause has not been rectified, or the alarm is trip-locked (see also table on following page).

CAUTION
Alarms that are trip-locked offer additional protection, means that the mains supply must be switched off before the alarm can be reset. After being switched back on, the frequency converter is no longer blocked and may be reset as described above once the cause has been rectified. Alarms that are not trip-locked can also be reset using the automatic reset function in 14-20 Reset Mode (Warning: automatic wake-up is possible!) If a warning and alarm is marked against a code in the table on the following page, this means that either a warning occurs before an alarm, or it can be specified whether it is a warning or an alarm that is to be displayed for a given fault. This is possible, for instance, in 1-90 Motor Thermal Protection. 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. Warning
X (X) (X) (X) X X X X X (X) (X) X X X X X X (X) (X) X X X X X (X) X X X (X) X (X) X (X) (X) (X) X X X X (X) X (X) X (X) (X) (X) X X X X X X (X) (X) (X) X 4-58 4-58 4-58 2-15 2-13 14-53 (X) X X X X X 8-04 1-90 1-90 (X) (X) (X) 6-01 1-80 14-12

8 8

No. Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 10 Volts low Live zero error No motor Mains phase loss DC link voltage high DC link voltage low DC over voltage DC under voltage Inverter overloaded Motor ETR over temperature Motor thermistor over temperature Torque limit Over Current Earth fault Hardware mismatch Short Circuit Control word timeout Start failed Internal Fan Fault External Fan Fault Brake resistor short-circuited Brake resistor power limit Brake chopper short-circuited Brake check Drive over temperature Motor phase U missing Motor phase V missing Motor phase W missing Inrush fault Fieldbus communication fault Out of frequency range Mains failure Phase Imbalance

Alarm/ Trip

Alarm/Trip Lock

Parameter Reference

176

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

No. Description
38 39 40 41 42 42 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 62 64 65 66 67 69 70 71 72 73 76 79 80 91 92 93 94 95 96 97 98 Internal fault Heatsink sensor Overload of Digital Output Terminal 27 Overload of Digital Output Terminal 29 Overload of Digital Output On X30/6 Overload of Digital Output On X30/7 Pwr. card supply 24 V supply low 1.8 V supply low Speed limit AMA calibration failed AMA check Unom and Inom AMA low Inom AMA motor too big AMA motor too small AMA Parameter out of range AMA interrupted by user AMA timeout AMA internal fault Current limit External Interlock Output Frequency at Maximum Limit Voltage Limit Control Board Over-temperature Heat sink Temperature Low Option Configuration has Changed Pwr. Card Temp Illegal FC configuration PTC 1 Safe Stop Dangerous Failure Safe Stop Auto Restart Power Unit Setup Illegal PS config Drive Initialized to Default Value Analog input 54 wrong settings NoFlow Dry Pump End of Curve Broken Belt Start Delayed Stop Delayed Clock Fault

Warning

Alarm/ Trip
X X

Alarm/Trip Lock
X X

Parameter Reference

(X) (X) (X) (X) X X X X X (X) X X X X X X X X X X X X X X X X X X X1) X1) X X X X X X X X X X X X X X X X X X X X X X X X

5-00, 5-01 5-00, 5-02 5-32 5-33

1-86

8 8

22-2* 22-2* 22-5* 22-6* 22-7* 22-7* 0-7*

201 Fire M was Active 202 Fire M Limits Exceeded 203 Missing Motor 204 Locked Rotor 243 Brake IGBT 244 Heatsink temp 245 Heatsink sensor 246 Pwr.card supply 247 Pwr.card temp 248 Illegal PS config X X X X X X X X X X X X X

MG.11.BA.02 - VLT is a registered Danfoss trademark

177

General Specifications and ...

VLT HVAC Drive Design Guide

No. Description
250 New spare parts 251 New Type Code Table 8.14 Alarm/Warning code list

Warning

Alarm/ Trip
X

Alarm/Trip Lock
X X

Parameter Reference

(X) Dependent on parameter 1) Can not be Auto reset via 14-20 Reset Mode A trip is the action when an alarm has appeared. The trip will coast the motor and can be reset by pressing the reset button or make a reset by a digital input (parameter group 5-1* [1]). The original event that caused an alarm cannot damage the frequency converter or cause dangerous conditions. A trip lock is an action when an alarm occurs, which may cause damage to frequency converter or connected parts. A Trip Lock situation can only be reset by a power cycling.
Alarm Word and Extended Status Word Bit 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Hex 00000001 00000002 00000004 00000008 00000010 00000020 00000040 00000080 00000100 00000200 00000400 00000800 00001000 00002000 00004000 00008000 00010000 00020000 00040000 00080000 00100000 00200000 00400000 00800000 01000000 02000000 04000000 08000000 10000000 20000000 40000000 Dec 1 2 4 8 16 32 64 128 256 512 1024 2048 4096 8192 16384 32768 65536 131072 262144 524288 1048576 2097152 4194304 8388608 16777216 33554432 67108864 134217728 268435456 536870912 1073741824 Alarm Word Brake Check Pwr. Card Temp Earth Fault Ctrl.Card Temp Ctrl. Word TO Over Current Torque Limit Motor Th Over Motor ETR Over Inverter Overld. DC under Volt DC over Volt Short Circuit Inrush Fault Mains ph. Loss AMA Not OK Live Zero Error Internal Fault Brake Overload U phase Loss V phase Loss W phase Loss Fieldbus Fault 24 V Supply Low Mains Failure 1.8V Supply Low Brake Resistor Brake IGBT Option Change Drive Initialized Safe Stop

LED indication Warning Alarm Trip locked yellow flashing red yellow and red

8 8

Warning Word Brake Check Pwr. Card Temp Earth Fault Ctrl.Card Temp Ctrl. Word TO Over Current Torque Limit Motor Th Over Motor ETR Over Inverter Overld. DC under Volt DC over Volt DC Voltage Low DC Voltage High Mains ph. Loss No Motor Live Zero Error 10V Low Brake Overload Brake Resistor Brake IGBT Speed Limit Fieldbus Fault 24V Supply Low Mains Failure Current Limit Low Temp Voltage Limit Unused Unused Unused

Extended Status Word Ramping AMA Running Start CW/CCW Slow Down Catch Up Feedback High Feedback Low Output Current High Output Current Low Output Freq High Output Freq Low Brake Check OK Braking Max Braking Out of Speed Range OVC Active

Table 8.15 Description of Alarm Word, Warning Word and Extended Status Word

178

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

The alarm words, warning words and extended status words can be read out via serial bus or optional fieldbus for diagnosis. See also 16-90 Alarm Word, 16-92 Warning Word and 16-94 Ext. Status Word.

8.7.1 Alarm Words

16-90 Alarm Word
Bit (Hex) 00000001 00000002 00000004 00000008 00000010 00000020 00000040 00000080 00000100 00000200 00000400 00000800 00001000 00002000 00004000 00008000 00010000 00020000 00040000 00080000 00100000 00200000 00400000 00800000 01000000 02000000 04000000 08000000 10000000 20000000 40000000 80000000 Alarm Word (16-90 Alarm Word) Brake check Power card over temperature Earth fault Ctrl. card over temperature Control word timeout Over current Torque limit Motor thermistor over temp. Motor ETR over temperature Inverter overloaded DC link under voltage DC link over voltage Short circuit Inrush fault Mains phase loss AMA not OK Live zero error Internal fault Brake overload Motor phase U is missing Motor phase V is missing Motor phase W is missing Fieldbus fault 24V supply fault Mains failure 1.8V supply fault Brake resistor short circuit Brake chopper fault Option change Drive initialised Safe Stop Not used

16-91 Alarm Word 2

Bit (Hex) 00000001 00000002 00000004 00000008 00000010 00000020 00000040 00000080 00000100 00000200 00000400 00000800 00001000 00002000 00004000 00008000 00010000 00020000 00040000 00080000 00100000 00200000 00400000 00800000 01000000 02000000 04000000 08000000 10000000 20000000 40000000 80000000 Alarm Word 2 (16-91 Alarm Word 2) Service Trip, read / Write Reserved Service Trip, Typecode / Sparepart Reserved Reserved No Flow Dry Pump End of Curve Broken Belt Not used Not used Reserved Reserved Reserved Reserved Reserved Reserved Not used Fans error ECB error Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved

8 8

MG.11.BA.02 - VLT is a registered Danfoss trademark

179

General Specifications and ...

VLT HVAC Drive Design Guide

8.7.2 Warning Words

16-92 Warning Word
Bit (Hex) 00000001 00000002 00000004 00000008 00000010 00000020 00000040 00000080 00000100 00000200 00000400 00000800 00001000 00002000 00004000 00008000 00010000 00020000 00040000 00080000 00100000 00200000 00400000 00800000 01000000 02000000 04000000 08000000 10000000 20000000 40000000 80000000 Warning Word (16-92 Warning Word) Brake check Power card over temperature Earth fault Ctrl. card over temperature Control word timeout Over current Torque limit Motor thermistor over temp. Motor ETR over temperature Inverter overloaded DC link under voltage DC link over voltage DC link voltage low DC link voltage high Mains phase loss No motor Live zero error 10V low Brake resistor power limit Brake resistor short circuit Brake chopper fault Speed limit Fieldbus comm. fault 24V supply fault Mains failure Current limit Low temperature Voltage limit Encoder loss Output frequency limit Not used Not used

16-93 Warning Word 2

Bit (Hex) 00000001 00000002 00000004 00000008 00000010 00000020 00000040 00000080 00000100 00000200 00000400 00000800 00001000 00002000 00004000 00008000 00010000 00020000 00040000 00080000 00100000 00200000 00400000 00800000 01000000 02000000 04000000 08000000 10000000 20000000 40000000 80000000 Warning Word 2 (16-93 Warning Word 2) Start Delayed Stop Delayed Clock Failure Reserved Reserved No Flow Dry Pump End of Curve Broken Belt Not used Reserved Reserved Reserved Reserved Reserved Reserved Reserved Not used Fans warning ECB warning Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved

8 8

180

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

8.7.3 Extended Status Words

Extended status word, 16-94 Ext. Status Word
Bit (Hex) 00000001 00000002 00000004 00000008 00000010 00000020 00000040 00000080 00000100 00000200 00000400 00000800 00001000 00002000 00004000 00008000 00010000 00020000 00040000 00080000 00100000 00200000 00400000 00800000 01000000 02000000 04000000 08000000 10000000 20000000 40000000 80000000 Extended Status Word (16-94 Ext. Status Word) Ramping AMA tuning Start CW/CCW Not used Not used Feedback high Feedback low Output current high Output current low Output frequency high Output frequency low Brake check OK Braking max Braking Out of speed range OVC active AC brake Password Timelock Password Protection Reference high Reference low Local Ref./Remote Ref. Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved

Extended status word 2, 16-95 Ext. Status Word 2

Bit (Hex) 00000001 00000002 00000004 00000008 00000010 00000020 00000040 00000080 00000100 00000200 00000400 00000800 00001000 00002000 00004000 00008000 00010000 00020000 00040000 00080000 00100000 00200000 00400000 00800000 01000000 02000000 04000000 08000000 10000000 20000000 40000000 80000000 Extended Status Word 2 (16-95 Ext. Status Word 2) Off Hand / Auto Not used Not used Not used Relay 123 active Start Prevented Control ready Drive ready Quick Stop DC Brake Stop Standby Freeze Output Request Freeze Output Jog Request Jog Start Request Start Start Applied Start Delay Sleep Sleep Boost Running Bypass Fire Mode Reserved Reserved Reserved Reserved Reserved Reserved

8 8

MG.11.BA.02 - VLT is a registered Danfoss trademark

181

General Specifications and ...

VLT HVAC Drive Design Guide

8.7.4 Fault Messages

The warning/alarm information below defines the warning/ alarm condition, provides the probable cause for the condition, and details a remedy or troubleshooting procedure. WARNING 1, 10 Volts low The control card voltage is below 10V from terminal 50. Remove some of the load from terminal 50, as the 10V supply is overloaded. Max. 15mA or minimum 590 . This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer. Troubleshooting Remove the wiring from terminal 50. If the warning clears, the problem is with the customer wiring. If the warning does not clear, replace the control card. WARNING/ALARM 2, Live zero error This warning or alarm will only appear if programmed by the user in 6-01 Live Zero Timeout Function. The signal on one of the analog inputs is less than 50% of the minimum value programmed for that input. This condition can be caused by broken wiring or faulty device sending the signal. Troubleshooting Check connections on all the analog input terminals. Control card terminals 53 and 54 for signals, terminal 55 common. MCB 101 terminals 11 and 12 for signals, terminal 10 common. MCB 109 terminals 1, 3, 5 for signals, terminals 2, 4, 6 common). Check that the frequency converter programming and switch settings match the analog signal type. Perform Input Terminal Signal Test. WARNING/ALARM 4, Mains phase loss A phase is missing on the supply side, or the mains voltage imbalance is too high. This message also appears for a fault in the input rectifier on the frequency converter. Options are programmed at 14-12 Function at Mains Imbalance. Troubleshooting Check the supply voltage and supply currents to the frequency converter. WARNING 5, DC link voltage high The intermediate circuit voltage (DC) is higher than the high voltage warning limit. The limit is dependent on the frequency converter voltage rating. The frequency converter is still active. WARNING 6, DC link voltage low The intermediate circuit voltage (DC) is lower than the low voltage warning limit. The limit is dependent on the frequency converter voltage rating. The frequency converter is still active. WARNING/ALARM 7, DC overvoltage If the intermediate circuit voltage exceeds the limit, the frequency converter trips after a time.

Troubleshooting Connect a brake resistor Extend the ramp time Change the ramp type Activate functions in 2-10 Brake Function Increase 14-26 Trip Delay at Inverter Fault WARNING/ALARM 8, DC under voltage If the intermediate circuit voltage (DC) drops below the under voltage limit, the frequency converter checks if a 24V DC backup supply is connected. If no 24V DC backup supply is connected, the frequency converter trips after a fixed time delay. The time delay varies with unit size. Troubleshooting Check that the supply voltage matches the frequency converter voltage. Perform Input voltage test Perform soft charge and rectifier circuit test WARNING/ALARM 9, Inverter overload The frequency converter is about to cut out because of an overload (too high current for too long). The counter for electronic, thermal inverter protection gives a warning at 98% and trips at 100%, while giving an alarm. The frequency converter cannot be reset until the counter is below 90%. The fault is that the frequency converter is overloaded by more than 100% for too long. Troubleshooting Compare the output current shown on the LCP with the frequency converter rated current. Compare the output current shown on the LCP with measured motor current. Display the Thermal Drive Load on the LCP and monitor the value. When running above the frequency converter continuous current rating, the counter should increase. When running below the frequency converter continuous current rating, the counter should decrease. See the derating section in the Design Guide for more details if a high switching frequency is required. WARNING/ALARM 10, Motor overload temperature According to the electronic thermal protection (ETR), the motor is too hot. Select whether the frequency converter gives a warning or an alarm when the counter reaches 100% in 1-90 Motor Thermal Protection. The fault occurs when the motor is overloaded by more than 100% for too long. Troubleshooting Check for motor overheating. Check if the motor is mechanically overloaded Check that the motor current set in 1-24 Motor Current is correct.

8 8

182

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

Ensure that Motor data in parameters 1-20 through 1-25 are set correctly. If an external fan is in use, check in 1-91 Motor External Fan that it is selected. Running AMA in 1-29 Automatic Motor Adaptation (AMA) may tune the frequency converter to the motor more accurately and reduce thermal loading. WARNING/ALARM 11, Motor thermistor over temp The thermistor might be disconnected. Select whether the frequency converter gives a warning or an alarm in 1-90 Motor Thermal Protection. Troubleshooting Check for motor overheating. Check if the motor is mechanically overloaded. When using terminal 53 or 54, check that the thermistor is connected correctly between either terminal 53 or 54 (analog voltage input) and terminal 50 (+10V supply) and that the terminal switch for 53 or 54 is set for voltage. Check 1-93 Thermistor Source selects terminal 53 or 54. When using digital inputs 18 or 19, check that the thermistor is connected correctly between either terminal 18 or 19 (digital input PNP only) and terminal 50. Check 1-93 Thermistor Source selects terminal 18 or 19. WARNING/ALARM 12, Torque limit The torque has exceeded the value in 4-16 Torque Limit Motor Mode or the value in 4-17 Torque Limit Generator Mode. 14-25 Trip Delay at Torque Limit can change this from a warning only condition to a warning followed by an alarm. Troubleshooting If the motor torque limit is exceeded during ramp up, extend the ramp up time. If the generator torque limit is exceeded during ramp down, extend the ramp down time. If torque limit occurs while running, possibly increase the torque limit. Be sure the system can operate safely at a higher torque. Check the application for excessive current draw on the motor. WARNING/ALARM 13, Over current The inverter peak current limit (approx. 200% of the rated current) is exceeded. The warning lasts about 1.5 sec., then the frequency converter trips and issues an alarm. This fault may be caused by shock loading or fast acceleration with high inertia loads. If extended mechanical brake control is selected, trip can be reset externally.

Troubleshooting Remove power and check if the motor shaft can be turned. Check that the motor size matches the frequency converter. Check parameters 1-20 through 1-25 for correct motor data. ALARM 14, Earth (ground) fault There is current from the output phases to earth, either in the cable between the frequency converter and the motor or in the motor itself. Troubleshooting Remove power to the frequency converter and repair the earth fault. Check for earth faults in the motor by measuring the resistance to ground of the motor leads and the motor with a megohmmeter. ALARM 15, Hardware mismatch A fitted option is not operational with the present control board hardware or software. Record the value of the following parameters and contact your Danfoss supplier: 15-40 FC Type 15-41 Power Section 15-42 Voltage 15-43 Software Version 15-45 Actual Typecode String 15-49 SW ID Control Card 15-50 SW ID Power Card 15-60 Option Mounted 15-61 Option SW Version ALARM 16, Short circuit There is a short circuit in the motor or motor wiring. Remove power to the frequency converter and repair the short circuit. WARNING/ALARM 17, Control word timeout There is no communication to the frequency converter. The warning will only be active when 8-04 Control Timeout Function is NOT set to [0] OFF. If 8-04 Control Timeout Function is set to Stop and Trip, a warning appears and the frequency converter ramps down until it stops then displays an alarm. Troubleshooting Check connections on the serial communication cable. Increase 8-03 Control Timeout Time Check operation of the communication equipment. Verify proper installation based on EMC requirements.

8 8

MG.11.BA.02 - VLT is a registered Danfoss trademark

183

General Specifications and ...

VLT HVAC Drive Design Guide

ALARM 18, Start failed The speed has not been able to exceed 1-77 Compressor Start Max Speed [RPM] during start within the allowed time. (set in 1-79 Compressor Start Max Time to Trip). This may be caused by a blocked motor. WARNING 23, Internal fan fault The fan warning function checks if the fan is running. The fan warning can be disabled in 14-53 Fan Monitor. Troubleshooting Check for proper fan operation. Cycle power to the frequency converter and check that the fan operates briefly at start up. Check the sensors on the heatsink and control card. WARNING 24, External fan fault The fan warning function checks if the fan is running. The fan warning can be disabled in 14-53 Fan Monitor. Troubleshooting Check for proper fan operation. Cycle power to the frequency converter and check that the fan operates briefly at start up. Check the sensors on the heatsink and control card. WARNING 25, Brake resistor short circuit The brake resistor is monitored during operation. If a short circuit occurs, the brake function is disabled and the warning appears. The frequency converter is still operational but without the brake function. Remove power to the frequency converter and replace the brake resistor (see 2-15 Brake Check). WARNING/ALARM 26, Brake resistor power limit The power transmitted to the brake resistor is calculated as a mean value over the last 120 seconds of run time. The calculation is based on the intermediate circuit voltage and the brake resistance value set in 2-16 AC brake Max. Current. The warning is active when the dissipated braking is higher than 90% of the brake resistance power. If Trip [2] is selected in 2-13 Brake Power Monitoring, the frequency converter will trip when the dissipated braking power reaches 100%. WARNING/ALARM 27, Brake chopper fault The brake transistor is monitored during operation and if a short circuit occurs, the brake function is disabled and a warning is issued. The frequency converter is still operational but, since the brake transistor has short-circuited, substantial power is transmitted to the brake resistor, even if it is inactive. Remove power to the frequency converter and remove the brake resistor. WARNING/ALARM 28, Brake check failed The brake resistor is not connected or not working. Check 2-15 Brake Check. ALARM 29, Heatsink temp The maximum temperature of the heatsink has been exceeded. The temperature fault will not reset until the temperature falls below the reset heatsink temperature. The

trip and reset points are based on the frequency converter power size. Troubleshooting Check for the following conditions. Ambient temperature too high. Motor cable too long. Incorrect airflow clearance above and below the frequency converter. Blocked airflow around the frequency converter. Damaged heatsink fan. Dirty heatsink. ALARM 30, Motor phase U missing Motor phase U between the frequency converter and the motor is missing. Remove power from the frequency converter and check motor phase U. ALARM 31, Motor phase V missing Motor phase V between the frequency converter and the motor is missing. Remove power from the frequency converter and check motor phase V. ALARM 32, Motor phase W missing Motor phase W between the frequency converter and the motor is missing. Remove power from the frequency converter and check motor phase W. ALARM 33, Inrush fault Too many power-ups have occurred within a short time period. Let the unit cool to operating temperature. WARNING/ALARM 34, communication fault Communication between the and the communication option card is not operating. WARNING/ALARM 36, Mains failure This warning/alarm is only active if the supply voltage to the frequency converter is lost and 14-10 Mains Failure is NOT set to [0] No Function. Check the fuses to the frequency converter and mains power supply to the unit. ALARM 38, Internal fault When an internal fault occurs, a code number defined in the table below is displayed. Troubleshooting Cycle power to the frequency converter. Check that the option is properly installed. Check for loose or missing wiring. It may be necessary to contact your Danfoss supplier or service department. Note the code number for further troubleshooting directions.

8 8

184

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

No.
0 256-258 512-519 783 1024-1284 1299 1300 1302 1315 1316 1318 1379-2819 2820 2821 2822 3072-5122 5123 5124 5125 5126 5376-6231

Text
Serial port cannot be initialised. Contact yourDanfoss supplier or DanfossService Department. Power EEPROM data is defect or too old Internal fault. Contact yourDanfoss supplier or Danfoss Service Department. Parameter value outside of min/max limits Internal fault. Contact your Danfoss supplier or the Danfoss Service Department. Option SW in slot A is too old Option SW in slot B is too old Option SW in slot C1 is too old Option SW in slot A is not supported (not allowed) Option SW in slot B is not supported (not allowed) Option SW in slot C1 is not supported (not allowed) Internal fault. Contact yourDanfoss supplier or DanfossService Department. LCP stack overflow Serial port overflow USB port overflow Parameter value is outside its limits Option in slot A: Hardware incompatible with control board hardware Option in slot B: Hardware incompatible with control board hardware Option in slot C0: Hardware incompatible with control board hardware Option in slot C1: Hardware incompatible with control board hardware Internal fault. Contact yourDanfoss supplier or DanfossService Department.

ALARM 45, Earth fault 2 Earth (ground) fault on start up. Troubleshooting Check for proper earthing (grounding) and loose connections. Check for proper wire size. Check motor cables for short-circuits or leakage currents. ALARM 46, Power card supply The supply on the power card is out of range. There are three power supplies generated by the switch mode power supply (SMPS) on the power card: 24V, 5V, +/18V. When powered with 24V DC with the MCB 107 option, only the 24V and 5V supplies are monitored. When powered with three phase mains voltage, all three supplied are monitored. Troubleshooting Check for a defective power card. Check for a defective control card. Check for a defective option card. If a 24V DC power supply is used, verify proper supply power. WARNING 47, 24V supply low The 24 V DC is measured on the control card. The external 24V DC backup power supply may be overloaded, otherwise contact your Danfoss supplier. WARNING 48, 1.8V supply low The 1.8V DC supply used on the control card is outside of allowable limits. The power supply is measured on the control card. Check for a defective control card. If an option card is present, check for an overvoltage condition. WARNING 49, Speed limit When the speed is not within the specified range in 4-11 Motor Speed Low Limit [RPM] and 4-13 Motor Speed High Limit [RPM], the frequency converter will show a warning. When the speed is below the specified limit in 1-86 Trip Speed Low [RPM] (except when starting or stopping) the frequency converter will trip. ALARM 50, AMA calibration failed Contact yourDanfoss supplier or DanfossService Department. ALARM 51, AMA check Unom and Inom The settings for motor voltage, motor current, and motor power are wrong. Check the settings in parameters 1-20 to 1-25. ALARM 52, AMA low Inom The motor current is too low. Check the setting in 4-18 Current Limit. ALARM 53, AMA motor too big The motor is too big for the AMA to operate. ALARM 54, AMA motor too small The motor is too small for the AMA to operate.

8 8

ALARM 39, Heatsink sensor No feedback from the heatsink temperature sensor. The signal from the IGBT thermal sensor is not available on the power card. The problem could be on the power card, on the gate drive card, or the ribbon cable between the power card and gate drive card. WARNING 40, Overload of digital output terminal 27 Check the load connected to terminal 27 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and 5-01 Terminal 27 Mode. WARNING 41, Overload of digital output terminal 29 Check the load connected to terminal 29 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and 5-02 Terminal 29 Mode. WARNING 42, Overload of digital output on X30/6 or overload of digital output on X30/7 For X30/6, check the load connected to X30/6 or remove short-circuit connection. Check 5-32 Term X30/6 Digi Out (MCB 101). For X30/7, check the load connected to X30/7 or remove short-circuit connection. Check 5-33 Term X30/7 Digi Out (MCB 101).

MG.11.BA.02 - VLT is a registered Danfoss trademark

185

General Specifications and ...

VLT HVAC Drive Design Guide

ALARM 55, AMA Parameter out of range The parameter values of the motor are outside of the acceptable range. AMAwill not run. ALARM 56, AMA interrupted by user The AMA has been interrupted by the user. ALARM 57, AMA timeout Try to restart AMA again. Repeated restarts may over heat the motor. ALARM 58, AMA internal fault Contact your Danfoss supplier. WARNING 59, Current limit The current is higher than the value in 4-18 Current Limit. Ensure that Motor data in parameters 1-20 through 1-25 are set correctly. Possibly increase the current limit. Be sure the system can operate safely at a higher limit. ALARM 60, External interlock A digital input signal is indicating a fault condition external to the frequency converter. An external interlock has commanded the frequency converter to trip. Clear the external fault condition. To resume normal operation, apply 24V DC to the terminal programmed for external interlock. Reset the frequency converter. WARNING 62, Output frequency at maximum limit The output frequency has reached the value set in 4-19 Max Output Frequency. Check the application to determine the cause. Possibly increase the output frequency limit. Be sure the system can operate safely at a higher output frequency. The warning will clear when the output drops below the maximum limit. WARNING/ALARM 65, Control card over temperature The cutout temperature of the control card is 80 C. Troubleshooting Check that the ambient operating temperature is within limits. Check for clogged filters. Check fan operation. Check the control card. WARNING 66, Heatsink temperature low The frequency converter is too cold to operate. This warning is based on the temperature sensor in the IGBT module. Increase the ambient temperature of the unit. Also, a trickle amount of current can be supplied to the frequency converter whenever the motor is stopped by setting 2-00 DC Hold/Preheat Current at 5% and 1-80 Function at Stop. ALARM 67, Option module configuration has changed One or more options have either been added or removed since the last power down. Check that the configuration change is intentional and reset the frequency converter.

ALARM 68, Safe stop activated Loss of the 24V DC signal on terminal 37 has caused the frequency converter to trip. To resume normal operation, apply 24V DC to terminal 37 and reset the frequency converter. ALARM 69, Power card temperaturePower card temperature The temperature sensor on the power card is either too hot or too cold. Troubleshooting Check that the ambient operating temperature is within limits. Check for clogged filters. Check fan operation. Check the power card. ALARM 70, Illegal FC configuration The control card and power card are incompatible. Contact your supplier with the typecode of the unit from the nameplate and the part numbers of the cards to check compatibility. ALARM 80, Drive initialised to default value Parameter settings are initialised to default settings after a manual reset. Reset the unit to clear the alarm. ALARM 92, No flow A no-flow condition has been detected in the system. 22-23 No-Flow Function is set for alarm. Troubleshoot the system and reset the frequency converter after the fault has been cleared. ALARM 93, Dry pump A no-flow condition in the system with the frequency converter operating at high speed may indicate a dry pump. 22-26 Dry Pump Function is set for alarm. Troubleshoot the system and reset the frequency converter after the fault has been cleared. ALARM 94, End of curve Feedback is lower than the set point. This may indicate leakage in the system. 22-50 End of Curve Function is set for alarm. Troubleshoot the system and reset the frequency converter after the fault has been cleared. ALARM 95, Broken belt Torque is below the torque level set for no load, indicating a broken belt. 22-60 Broken Belt Function is set for alarm. Troubleshoot the system and reset the frequency converter after the fault has been cleared. ALARM 96, Start delayed Motor start has been delayed due to short-cycle protection. 22-76 Interval between Starts is enabled. Troubleshoot the system and reset the frequency converter after the fault has been cleared. WARNING 97, Stop delayed Stopping the motor has been delayed due to short cycle protection. 22-76 Interval between Starts is enabled. Troubleshoot the system and reset the frequency converter after the fault has been cleared.

8 8

186

MG.11.BA.02 - VLT is a registered Danfoss trademark

General Specifications and ...

VLT HVAC Drive Design Guide

WARNING 98, Clock fault Time is not set or the RTC clock has failed. Reset the clock in 0-70 Date and Time. WARNING, 200 Fire mode This indicates the frequency controller is operating in fire mode. The warning clears when fire mode is removed. See the fire mode data in the alarm log. WARNING 201, Fire mode was active This indicates the frequency controller had entered fire mode. Cycle power to the unit to remove the warning. See the fire mode data in the alarm log. WARNING 202, Fire mode limits exceeded While operating in fire mode one or more alarm conditions has been ignored which would normally trip the unit. Operating in this condition voids unit warranty. Cycle power to the unit to remove the warning. See the fire mode data in the alarm log. WARNING 203, Missing motor With a frequency converter operating multi-motors, an under-load condition was detected. This could indicate a missing motor. Inspect the system for proper operation. WARNING 204, Locked rotor With a frequency converter operating multi-motors, an overload condition was detected. This could indicate a locked rotor. Inspect the motor for proper operation. WARNING 250, New spare part A component in the frequency converter has been replaced. Reset the frequency converter for normal operation. WARNING 251, New typecode A component in the frequency converter has been replaced and the typecode changed. Reset the frequency converter for normal operation.

8 8

MG.11.BA.02 - VLT is a registered Danfoss trademark

187

Index

VLT HVAC Drive Design Guide

Index A

Abbreviations........................................................................................... 6 Accessory Bags...................................................................................... 84 Acoustic Noise..................................................................................... 169 Aggressive Environments.................................................................. 12 Air Humidity........................................................................................... 12 Alarm Words........................................................................................ 179 Alarm/Warning Code List................................................................ 178 Alarms And Warnings....................................................................... 175 Aluminium Conductors...................................................................... 91 AMA........................................................................................................ 116 Analog I/O Option MCB 109........................................................................ 53 I/O Selection...................................................................................... 53 Inputs.............................................................................. 7, 182, 8, 165 Output............................................................................................... 166 Outputs - Terminal X30/5+8........................................................ 50 Voltage Inputs - Terminal X30/10-12........................................ 50 Application Examples......................................................................... 22 Automatic Adaptations To Ensure Performance..................................... 174 Motor Adaptation.......................................................................... 116 Motor Adaptation (AMA)............................................................ 103 AWG..................................................................................... 141, 142, 146

Cable Clamp................................................................................................. 114 Clamps............................................................................................... 111 Length And Cross-section............................................................. 91 Lengths And Cross Sections...................................................... 165 Caution..................................................................................................... 10 CAV System............................................................................................. 24 CE Conformity And Labelling........................................................... 11 Central VAV Systems........................................................................... 23 Clearance.............................................................................................. 184 Clockwise Rotation............................................................................ 108 Closed Loop Control For A Ventilation System......................... 37 CO2 Sensor.............................................................................................. 24 Coasting................................................................................... 139, 7, 137 Communication Option................................................................... 184 Comparison Of Energy Savings....................................................... 19 Condenser Pumps................................................................................ 27 Conducted Emission........................................................................... 41 Constant Air Volume.......................................................................................... 24 Torque Applications (CT Mode)............................................... 175 Control Cable Terminals................................................................................ 99 Cables............................................................... 111, 90, 101, 89, 101 Card Performance......................................................................... 168 Card, 10 V DC Output................................................................... 167 Card, 24 V DC Output................................................................... 167 Card, RS-485 Serial Communication:...................................... 166 Card, USB Serial Communication:............................................ 168 Characteristics................................................................................ 167 Potential.............................................................................................. 30 Structure Closed Loop.................................................................... 33 Structure Open Loop...................................................................... 31 Terminals............................................................................................. 99 Word................................................................................................... 137 Cooling Cooling.............................................................................................. 175 Conditions.......................................................................................... 85 Tower Fan........................................................................................... 25 Copyright, Limitation Of Liability And Revision Rights............. 4 Cos Compensation.......................................................................... 20 Current Limit.................................................................................................... 183 Rating................................................................................................. 182

BACnet...................................................................................................... 70 Balancing Contractor.......................................................................... 28 Basic Wiring Example....................................................................... 100 Battery Back-up Of Clock Function................................................ 53 Better Control........................................................................................ 20 Brake Function.............................................................................................. 46 Power............................................................................................... 8, 46 Resistor................................................................................................ 45 Resistor Cabling................................................................................ 46 Resistor Calculation......................................................................... 45 Resistor Temperature Switch.................................................... 106 Resistors................................................................................. 59, 79, 59 Braking................................................................................................... 184 Branch Circuit Protection................................................................... 93 Break-away Torque................................................................................. 7 Building Management System..................................................................... 53 Management System, BMS........................................................... 19 Bypass Frequency Ranges................................................................. 25

Dampers................................................................................................... 23 Data Types Supported By The Frequency Converter............ 128 DC Brake................................................................................................... 137 Link..................................................................................................... 182 Definitions................................................................................................. 7

188

MG.11.BA.02 - VLT is a registered Danfoss trademark

Index

VLT HVAC Drive Design Guide

Derating Derating............................................................................................ 182 For Ambient Temperature......................................................... 174 For Low Air Pressure..................................................................... 174 For Running At Low Speed........................................................ 175 DeviceNet................................................................................................ 70 Differential Pressure............................................................................ 30 Digital Input................................................................................................... 183 Inputs - Terminal X30/1-4............................................................. 50 Inputs:................................................................................................ 165 Output............................................................................................... 166 Outputs - Terminal X30/5-7.......................................................... 50 Direction Of Motor Rotation.......................................................... 108 Disposal Instruction............................................................................. 11 Drive Configurator............................................................................... 64 DU/dt Filters........................................................................................... 63

FC Profile................................................................................................. 137 With Modbus RTU......................................................................... 124 Feedback..................................................................................... 185, 186 Field Mounting...................................................................................... 87 Final Set-Up And Test....................................................................... 103 Flow Meter.............................................................................................. 28 Frame Size F Panel Options.............................................................. 58 Freeze Output.......................................................................................... 7 Frequency Converter Hardware Setup........................................................ 123 Converter Set-up........................................................................... 124 Converter With Modbus RTU.................................................... 129 Function Codes Supported By Modbus RTU............................ 133 Fuse Tables............................................................................................. 96 Fuses................................................................................................ 184, 93

Earth Leakage Current............................................................... 111, 44 Earthing Earthing............................................................................................. 114 Of Screened/Armoured Control Cables................................ 114 Efficiency............................................................................................... 169 Electrical Installation......................................................................... 89, 90, 101 Installation - EMC Precautions.................................................. 111 Terminals............................................................................................. 13 Elegram Length (LGE)....................................................................... 125 EMC EMC..................................................................................................... 183 Directive 89/336/EEC...................................................................... 12 Precautions...................................................................................... 123 Test Results......................................................................................... 41 Emission Requirements...................................................................... 40 Enclosure Knock-outs......................................................................... 91 Energy Savings............................................................................... 20, 18 Equalising Cable,................................................................................ 114 ETR........................................................................................................... 107 Evaporator Flow Rate.......................................................................... 28 Example Of Closed Loop PID Control............................................ 37 Extended Status Word..................................................................................... 181 Status Word 2.................................................................................. 181 External 24V DC Supply................................................................................... 53 Fan Supply....................................................................................... 106 Extreme Running Conditions........................................................... 46

General Aspects Of EMC Emissions............................................................ 39 Aspects Of Harmonics Emission................................................. 41 Specifications.................................................................................. 165 Gland/Conduit Entry - IP21 (NEMA 1) And IP54 (NEMA12)......... 92

Harmonic Filters.................................................................................... 72 Harmonics Emission Requirements................................................................. 42 Test Results (Emission)................................................................... 42 High Power Series Mains And Motor Connections........................ 88 Voltage Test..................................................................................... 111 Hold Output Frequency................................................................... 137 How To Connect A PC To The Frequency Converter.................. 109 To Control The Frequency Converter..................................... 133

I/Os For Set Point Inputs.................................................................... 54 IEC Emergency Stop With Pilz Safety Relay................................. 58 IGVs............................................................................................................ 23 Immunity Requirements.................................................................... 42 Index (IND)............................................................................................ 127 Input Terminals.......................................................................................... 182 Voltage.............................................................................................. 182 Installation Installation....................................................................................... 183 At High Altitudes.............................................................................. 10 Insulation Resistance Monitor (IRM).............................................. 58 Intermediate Circuit.......................................................... 47, 169, 170

Fan System Controlled By Frequency Converters.................... 21 Fault Messages.................................................................................... 182

MG.11.BA.02 - VLT is a registered Danfoss trademark

189

Index

VLT HVAC Drive Design Guide

IP 21/Type 1 Enclosure Kit................................................................. 60 IP21/IP41/ TYPE 1 Enclosure Kit....................................................... 60

Motor-generated Over-voltage....................................................... 47 Multiple Pumps..................................................................................... 30 Multi-zone Control............................................................................... 53

Jog....................................................................................................... 7, 138

Name Plate Data................................................................................. 103

NAMUR..................................................................................................... 58 Network Connection......................................................................... 122 Ni1000 Temperature Sensor............................................................. 54 Non-UL Fuses 200V To 480V............................................................. 94

Laws Of Proportionality...................................................................... 18 LCP........................................................................................................... 7, 8 Lead Pump Alternation Wiring Diagram................................... 120 Leakage Current.................................................................................... 44 Lifting........................................................................................................ 86 Literature.................................................................................................... 5 Load Drive Settings........................................................................... 110 Local (Hand On) And Remote (Auto On) Control............................. 32 Speed Determination..................................................................... 28 Low Evaporator Temperature.......................................................... 28

Options And Accessories................................................................... 49 Ordering Numbers.............................................................................................. 64 Numbers: DU/dt Filters, 380-480V AC...................................... 78 Numbers: DU/dt Filters, 525-600/690V AC............................. 79 Numbers: Harmonic Filters........................................................... 72 Numbers: High Power Kits............................................................ 72 Numbers: Options And Accessories.......................................... 69 Numbers: Sine Wave Filter Modules, 200-500 VAC............. 76 Numbers: Sine-Wave Filter Modules, 525-600/690 VAC.......... 77 Output Current.............................................................................................. 182 Filters.................................................................................................... 63 Performance (U, V, W).................................................................. 165 Outputs For Actuators........................................................................ 54

Mains Disconnectors................................................................................. 105 Drop-out.............................................................................................. 47 Supply............................................ 9, 141, 146, 142, 149, 151, 159 Supply 3 X 525-690V AC.............................................................. 160 Voltage..................................................................................... 182, 185 Manual Motor Starters................................................................................... 59 PID Adjustment................................................................................ 39 MCB 105 Option.................................................................................... 51 MCT 31................................................................................................... 110 Mechanical Dimensions................................................................................. 83, 81 Dimensions - High Power............................................................. 82 Mounting............................................................................................ 85 Modbus Communication............................................................................. 123 Exception Codes............................................................................ 133 Moment Of Inertia................................................................................ 47 Motor Bearing Currents............................................................................ 108 Cables......................................................................................... 111, 90 Current..................................................................................... 182, 185 Data........................................................................................... 183, 186 Leads.................................................................................................. 183 Name Plate....................................................................................... 103 Name Plate Data............................................................................ 103 Output............................................................................................... 165 Parameters....................................................................................... 116 Phases.................................................................................................. 46 Power................................................................................................. 185 Protection............................................................................... 107, 169 Rotation............................................................................................ 108 Thermal Protection....................................................... 140, 47, 108 Voltage.............................................................................................. 170
190

Parallel Connection Of Motors...................................................... 107 Parameter Number (PNU)................................................................................ 127 Values................................................................................................. 134 Pay Back Period..................................................................................... 20 PC Software Tools.............................................................................. 109 PC-based Configuration Tool MCT 10 Set-up Software....... 109 Peak Voltage On Motor.................................................................... 170 PELV - Protective Extra Low Voltage.............................................. 43 PLC........................................................................................................... 114 Potentiometer Reference................................................................ 116 Power Factor...................................................................................................... 9 Factor Correction............................................................................. 20 Primary Pumps...................................................................................... 28 Principle Diagram................................................................................. 54 Profibus Profibus................................................................................................ 70 DP-V1................................................................................................. 110 Programmable Minimum Frequency Setting............................ 25

MG.11.BA.02 - VLT is a registered Danfoss trademark

Index

VLT HVAC Drive Design Guide

Programming Programming.................................................................................. 182 Order..................................................................................................... 38 Protection Protection............................................................................. 12, 43, 45 And Features................................................................................... 169 Protocol Overview............................................................................. 123 Pt1000 Temperature Sensor............................................................. 54 Public Supply Network....................................................................... 42 Pulse Inputs................................................................................................. 166 Start/Stop......................................................................................... 115 Pump Impeller....................................................................................... 27

Set Speed Limit And Ramp Time.................................................. 103 Short Circuit (Motor Phase Phase).............................................. 46 Sine-wave Filters................................................................................... 63 Smart Logic Control................................................................................... 116 Logic Control Programming...................................................... 116 Soft-starter.............................................................................................. 20 Software Version.................................................................................................... 4 Versions............................................................................................... 70 Space Heaters And Thermostat....................................................... 58 Star/Delta Starter.................................................................................. 20 Start/Stop Start/Stop......................................................................................... 115 Conditions........................................................................................ 121 Static Overload In VVCplus Mode................................................... 47 Status Word.......................................................................................... 139 Stopping Category 0 (EN 60204-1)................................................. 17 Successful AMA................................................................................... 103 Supply Voltage.......................................................................... 182, 184 Surroundings:...................................................................................... 167 Switches S201, S202, And S801..................................................... 102 Switching Frequency................................................................................. 182, 91 On The Output.................................................................................. 47 Symbols...................................................................................................... 5 System Status And Operation....................................................... 119

Radiated Emission................................................................................ 41 Rated Motor Speed................................................................................ 7 RCD RCD................................................................................................... 9, 45 (Residual Current Device)............................................................. 58 Read Holding Registers (03 HEX).................................................. 136 Real-time Clock (RTC).......................................................................... 55 Reference Handling............................................................................. 36 Relay Option MCB 105............................................................................... 51 Output............................................................................................... 106 Outputs............................................................................................. 167 Removal Of Knockouts For Extra Cables...................................... 92 Reset.................................................................................... 182, 184, 186 Residual Current Device........................................................... 45, 114 Return Fan............................................................................................... 23 Rise Time............................................................................................... 170 RS-485 Bus Connection.................................................................... 109

The Clear Advantage - Energy Savings............................................. 17 EMC Directive (2004/108/EC)....................................................... 11 Low-voltage Directive (2006/95/EC)......................................... 11 Machinery Directive (2006/42/EC)............................................. 11 Thermistor........................................................................................ 183, 9 Throttling Valve..................................................................................... 27 Tightening Of Terminals.................................................................... 88 Torque Characteristics..................................................................... 165 Transmitter/sensor Inputs................................................................. 54 Troubleshooting....................................................................... 182, 175 Tuning The Drive Closed Loop Controller................................... 38 Type Code String High Power................................................................ 66 Code String Low And Medium Power...................................... 65

Safe Stop....................................................................................................... 13 Stop Installation............................................................................... 16 Safety Category 3 (EN 954-1)..................................................................... 17 Earth Connection........................................................................... 111 Note...................................................................................................... 10 Regulations........................................................................................ 10 Requirements Of Mechanical Installation............................... 87 Save Drive Settings............................................................................ 110 Screened/armoured.......................................................................... 101 Screened/armoured............................................................................ 90 Screening Of Cables............................................................................ 90 Secondary Pumps................................................................................. 30 Serial Communication.......................................................... 114, 168, 183 Communication Port......................................................................... 7

UL Fuses, 200-240V.............................................................................. 95 Unsuccessful AMA............................................................................. 103 USB Connection.................................................................................... 99 Use Of EMC-Correct Cables............................................................ 112

MG.11.BA.02 - VLT is a registered Danfoss trademark

191

Index

VLT HVAC Drive Design Guide

Variable (Quadratic) Torque Applications (VT)..................................... 175 Air Volume.......................................................................................... 23 Control Of Flow And Pressure..................................................... 20 Varying Flow Over 1 Year................................................................... 20 VAV............................................................................................................ 23 Vibration And Shock............................................................................ 13 Vibrations................................................................................................ 25 Voltage Level....................................................................................... 165 VVCplus....................................................................................................... 9

Warning Against Unintended Start............................................................. 10 Words................................................................................................. 180 What Is CE Conformity And Labelling?................................................ 11 Is Covered........................................................................................... 11

192

MG.11.BA.02 - VLT is a registered Danfoss trademark

www.danfoss.com/drives

130R0084

MG11BA02

*MG11BA02*

Rev. 2010-12-17