Danfoss CDS 801 Operating guide

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MAKING MODERN LIVING POSSIBLE

OOperating Instructions

VLTp Inverter Scroll CDS 801

Contents

VLT® Inverter Scroll CDS 801 Operating Instructions

1 General

1.1 Coverage

1.1.1 Disclaimer 4

1.1.2 Coverage 4

1.2 Safety Instructions

1.3 Approvals

1.4 General Warning

1.5 Disposal Instruction

1.6 Before Commencing Repair Work

1.7 ESD Precautions

1.8 Product Identification

1.9 Unpacking the Drive

1.10 Table of Abbreviations

2 Mechanical Installation

2.1 Dimensions and Weight

2.2 Installation Orientation and Clearances

2.2.1 Surface Mounting 9

4 4

4 4 5 5 5 5 5 5 6

7 7 9

2.2.2 Structural Mounting 11

2.3 Air Circulation/Cooling

2.4 Condensation and Dripping Water

2.5 Vibration and Mechanical Resonances

3 Electrical Installation

3.1 Electrical Connection in General

3.2 Tightening Torque

3.3 Cable Quality and Dimensioning

3.4 Fuses/Circuit Breakers

3.5 EMC Correct Installation

3.6 Electrical Connections

3.6.1 Routing of Motor and Supply Cable 15

3.6.2 Power Supply Connection (Mains) 16

3.6.3 Motor (Compressor) Connection 16

3.6.4 Sensor Connections 18

3.6.5 4-way Reversing Valve Connection 18

3.6.6 Condenser Fan Motor Control Connection (EXT_FAN) 18

12 12 12

13 13 13 13 13 14 15

3.6.7 EEV Controller (HP Mode) Connection (EEV_2) 18

3.6.8 Serial Communication Cable Connection 19

3.6.9 Connector Specification 20

3.6.10 Allocation of Connector Pins 21

MG10V402 - VLT® is a registered Danfoss trademark 1

Contents

VLT® Inverter Scroll CDS 801 Operating Instructions

3.6.11 Overview Wiring Diagram 22

4 Serial Communication (Modbus RTU)

5 Commissioning

5.1 Initial Configuration of the Performer VSD sub-system

5.2 Drive Setup

5.2.1 Drive Parameters (Modbus Registers, node 162) 27

5.2.2 Drive Parameters (Modbus Registers, node 163) 28

5.3 Condenser Fan Speed Reference Output

5.4 Crankcase Heating

5.5 Ambient Temperature Source

5.6 Pressure sensor scaling

5.7 Normal Operation

6 Embedded Application Controller “Thermo Control”

6.1 Introduction

6.2 Applications

6.2.1 Generic AC 31

27 27 27

29 29 29 30 30

31 31 31

6.2.2 Generic AC/HP (Reversible) 32

6.2.3 Ground Source Heat Pump (Reversible) 33

6.3 Application Controller

6.3.1 Introduction 33

6.3.2 System Modes 33

6.3.2.1 Off 33

6.3.2.2 AC 33

6.3.2.3 HP 34

6.3.2.4 Defrost 34

6.3.3 Compressor Capacity Control 34

6.3.3.1 Single Loop Room Temperature Control 35

6.3.3.2 Open Loop/ External Speed Control 35

6.3.4 Condensing Pressure Control 36

6.3.4.1 AC Mode 36

6.3.4.2 HP Mode 38

6.3.4.3 Defrost Mode 39

6.3.5 Auxiliary Functions 39

6.3.5.1 Start-Up Sequence 39

6.3.5.2 Restart Timer 40

6.3.5.3 Compressor Safety Envelope 40

6.3.5.4 Oil Return 40

2 MG10V402 - VLT® is a registered Danfoss trademark

Contents

VLT® Inverter Scroll CDS 801 Operating Instructions

6.3.5.5 Derating 40

6.3.5.6 Discharge temperature cut out 41

6.3.5.7 Max Suction Pressure (MOP) 41

6.3.5.8 Frequency Cancelation 41

6.3.5.9 System Status 41

6.4 Thermo Controller Register Overview (Node 162)

7 Fault Conditions, Messages and Causes

8 Troubleshooting

9 Specifications

10 Special Operating Conditions

11 Maintenance

11.1 Replacement of Internal Cooling Fan

11.2 Cleaning

12 Service and Spare Parts

Index

51 51 51

MG10V402 - VLT® is a registered Danfoss trademark 3

General

VLT® Inverter Scroll CDS 801 Operating Instructions

1 General

1.1 Coverage

The earth leakage current exceeds 3.5 mA

•

A stop command does not disconnect power

•

from the drive

1.1.1 Disclaimer

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

Coverage

1.1.2

This instruction covers 3 different drive sizes with single phase 208-240 V power supply matching compressor sizes for

- 13 kW/3 t cooling capacity

- 16 kW/4 t cooling capacity

- 20 kW/5 t cooling capacity

from software version 1.09.

1.2

Safety Instructions

1.3 Approvals

The drive has been designed/approved in accordance with the following standards:

Safety UL/EN 60335-1, 60335-2-34 (UL 984) Household UL/EN 60730 Industrial EN 61800-3 (frequency converter standard) Software UL 1998 cl. B Polymerics UL 746 C EMC With ferrite: EN 55011 cl. A, EN 55014 Harmonics EN 61000-3-12, IEEE 519-1992 Surge EN 61642-12 Immunity EN 61000-6 Transient EN 61000-4 Corrosion UL 50E, ISO 9223, EN 61000-5-1, ASTM B117 Environment IEC 60721-3-3 cl. 3K4 Enclosure NEMA 250-2003

Table 1.1 Standards Complied to

The equipment complies with the flicker requirement according to IEC/EN61000-3-11 at 230 V nominal voltage under the condition that the service current capacity is permissible system impedance Z

≥

100 A per phase or a maximum

= 0.1892

MAX

1.2.1 High Voltage Warning

WARNING

The voltage of the variable speed drive is dangerous whenever it is connected to mains. Incorrect installation of the variable speed drive may cause damage to the equipment, serious injury or death. Consequently, it is essential to comply with the instructions in this manual as well as local and national rules and safety regulations.

1.2.2 Safety Instructions

Make sure the drive is properly connected to

•

earth Do not remove the mains connector or motor

•

(compressor) connector while the drive is connected to power

Protect personnel against supply voltage

•

Protect the variable speed drive against over-

•

current according to national and local regulations

4 MG10V402 - VLT® is a registered Danfoss trademark

130ZB121.10

IP00/CHASSIS -25

C/ -13 F to 52 C/125 F

PERFORMER

MADE IN DENMARK

CDS801 Variable Speed Drive

P/N: 176L7002 S/N: 010199D082

20 kW/5 TR cooling capacity

IN: 1x208-230V 50-60Hz 33A 6,7 kW

OUT: 3x270V 45-210Hz 33A

VSD

o o o o

CAUTION:

See manual before use.

Lire le manual avant utilisation

WARNING:

Stored charge, wait 5 min. before service.

Energia aimacenada, asperar 5 min. para descaega antes de lisar.

E337256

* 1 7 6 L 7 0 0 2 0 1 0 1 9 9 D 0 6 2 *

Charge stockée, attendre 5 min. avant l’emploi.

Leer manual antec deusar.

General

VLT® Inverter Scroll CDS 801 Operating Instructions

1.4 General Warning

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. Be aware that there may be high voltage on the DC link even when the LED is turned off. Before touching any potentially live parts of the drive, wait at least 1 minute.

CAUTION

Leakage Current The earth leakage current from the variable speed drive exceeds 3.5 mA. Grounding and bounding shall comply with UL 1995/NEC. Residual Current Device This product can cause a D.C. current in the protective earth, only an RCD of Type B (time delayed) shall be used in the supply side of this product. See also Application Note on RCD, MN90G. Protective earthing of the drive and the use of RCDs must always follow national and local regulations.

WARNING

Installation in high altitudes: At altitudes above 6000 ft (2000 m), contact Danfoss regarding SELV.

1 1

1.6 Before Commencing Repair Work

1. Disconnect the variable speed drive from mains (flip the circuit breaker or pull fuses).

2. Wait for at least 5 minutes for discharge of the DC-link capacitors.

3. Remove motor (compressor) cable.

1.7 ESD Precautions

A variable speed drive is a sensible electronic device. Electrostatic discharge (ESD) can cause a malfunction or destroy the frequency converter. Do not touch components on the printed circuit board (PCB). When handling the drive make sure that necessary ESD precautions are taken, i.e. wearing wrist straps, using antistatic mats etc.

1.8 Product Identification

A product identification label is placed on the drive chassis. It carries the ordering code i.e. 76L7002. The last 3 digits of the numeric string indicate the production date, i.e. 062 means week 6 in 2012. Do not remove the identification label from the drive (loss of warranty).

Avoid unintended start While the variable speed drive is connected to mains, the motor (compressor) can be started/stopped using serial communication commands.

- Disconnect the frequency converter from mains whenever personal safety considerations make it necessary to avoid unintended start.

1.5

Disposal Instruction

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

Illustration 1.1 Product Identification Label

1.9 Unpacking the Drive

NOTE

To avoid damage to the drive caused by electrostatic discharge, people handling the drive should wear wrist traps for proper grounding at all time!

MG10V402 - VLT® is a registered Danfoss trademark 5

General

VLT® Inverter Scroll CDS 801 Operating Instructions

1.10 Table of Abbreviations

VSD Variable speed drive VFD Variable frequency drive, also used instead of VSD EMC Electromagnetic compatibility RCD Residual current device SELV Safety extra low voltage ESD Electrostatic discharge PCB Printed circuit board AWG American wire gauge EEV Electronic expansion valve RTU Remote terminal unit OEM Original equipment manufacturer AC Air-conditioning HP Heat pump RLA Rated load amperage AOC Application oriented controller MOC Motor oriented controller

Table 1.2 Abbreviations

6 MG10V402 - VLT® is a registered Danfoss trademark

196 mm/7.7 in

374 mm/

14.7 in

175ZB032.13

394 mm/15.5 in

216 mm/8.5 in

255 mm/10 in

98 mm/

3.8 in

Mechanical Installation

2 Mechanical Installation

2.1 Dimensions and Weight

VLT® Inverter Scroll CDS 801 Operating Instructions

2 2

Illustration 2.1 Dimensions

MG10V402 - VLT® is a registered Danfoss trademark 7

236 mm/9.3 in

216 mm/8.5 in 394 mm/15.5 in

180 mm/

7.1 in

98 mm/

3.8 in

175ZB031.13

255 mm/10 in

180 mm/

7.1 in

Mechanical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

Illustration 2.2 Dimensions

Mounting holes: ¼ inch, Ø 6 mm Weight: 10.3 lbs/5.5 kg

8 MG10V402 - VLT® is a registered Danfoss trademark

175ZB036.10

175ZB037.10

Mechanical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

2.2 Installation Orientation and Clearances

2.2.1 Surface Mounting

The drive can be installed horizontally (see Illustration 2.4) or vertically (see Illustration 2.3) on any plain surface with the PCB pointing towards the surface. Typically, the 6 mounting holes in the side flaps of the chassis are used for installation.

For vertical installation, the upper two mounting holes can be used as suspension holes.

NOTE

If the drive is installed on a sheet metal surface, the clearance between the drive PCB and the mounting surface must be observed. As a minimum, sheet metal gauge 22, 33/1000 inch or 1 mm should be used. If electrical contact with the mounting surface can not be avoided an additional isolation foil should be used.

2 2

NOTE

For outdoor units, do not install the drive horizontally with the PCB in the top or bottom. Water condensing on the PCB cannot be properly drained.

Illustration 2.3 Horizontal Orientation

Illustration 2.4 Vertical Orientation

MG10V402 - VLT® is a registered Danfoss trademark 9

175ZB038.12

Mechanical Installation

To avoid insufficient cooling, do not install the drive with the cooling fan in the top, see Illustration 2.5.

VLT® Inverter Scroll CDS 801 Operating Instructions

Illustration 2.5 Wrong Drive Orientation

10 MG10V402 - VLT® is a registered Danfoss trademark

175ZB041.10

175ZB042.10

Mechanical Installation

2.2.2 Structural Mounting

VLT® Inverter Scroll CDS 801 Operating Instructions

The drive can be integrated in any kind of mechanical structure of air conditioning equipment Illustration 2.6 and Illustration 2.7.

2 2

Illustration 2.7 Horizontal Installation in Mechanical Structure

CAUTION

During mechanical installation of the drive make sure that no screws can touch electrical parts on the PCB. Screws touching the electrical parts on the PCB can cause personal injury and product damage.

Illustration 2.6 Vertical Installation in Mechanical Structure

MG10V402 - VLT® is a registered Danfoss trademark 11

175ZB043.10

Mechanical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

2.3 Air Circulation/Cooling

2.5

The drive must be installed in a way that allows for free

airflow. However short circuiting the airflow (warm air reentering the drive’s cooling fan) must be avoided (see Illustration 2.8). A clearance of 5 inches (12.7 cm) must be observed in both ends of the drive chassis. Install the drive in a location where coldest possible air can be drawn into the drive, i.e. from the bottom part of an outdoor unit. Counter flow (static pressure) must not restrict the operation of the internal cooling fan of the drive.

Vibration and Mechanical Resonances

The mechanical structure (sheet metal) carrying the drive must be designed to withstand vibration and consequently resonances induced by the compressor or condenser fan. See vibration specification for the drive further down this document.

Also refer to 6.3.5.8 Frequency Cancelation explaining the possibility to program bypass frequencies in the drive to avoid mechanical resonances of the structure.

Illustration 2.8 Wrong Drive Airflow

2.4

Condensation and Dripping Water

The printed circuit board assembly of the drive is conformally coated and thus sufficiently protected against condensation during off time. Nevertheless, the drive should not be exposed to dripping water (rain) or condensing water slung around by the condenser fan. In outdoor units, it is recommendable to install the drive in a rain proof compartment.

12 MG10V402 - VLT® is a registered Danfoss trademark

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

3 Electrical Installation

3.1 Electrical Connection in General

NOTE

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper conductors required.

3.2 Tightening Torque

Power supply plug terminals 1.5 Nm/1.1 lbf ft Ground screw 3.0 Nm/2.2 lbf ft Motor plug (compressor) 1.5 Nm/1.1 lbf ft EMC clamp for motor cable 1.5 Nm/1.1 lbf ft

Proper temperature rating of the cable must be observed. In installations with ambient temperatures above 30 °C maximum current derating applies, therefore hightemperature cable with 90 °C conductor temperature, e.g. Nexans Rheyflex is recommended. Copper type cable only. Maximum cable length 2 m.

Cable specification for installations in North America: 3-wire cable, minimum cross section AWG 10, voltage rating 600 V, temperature rating 221 °F/105 °C, 2/64 moisture resistant UL style 1230 standard bare copper type. In North America, standards for radiated emission are currently not enforced. Furthermore, FCC parts 15 regulations explicitly exempt air-condition devices. Maximum cable length 7 ft. Local compressor grounding.

Table 3.1 Tightening Torque

3.3 Cable Quality and Dimensioning

Power supply cable There is no need for using shielded cable for the supply of the variable speed drive.

Motor cable The cable from the drive to the compressor (motor) must be shielded to comply with EMC regulations for conducted and radiated emissions in accordance with EN 55011 class A and EN 55014 (with ferrite). A proper ground connection of the shield in both ends is essential to obtain the best suppression of emissions. See also 3.6 Electrical Connections.

Power Supply Cable Specification Power connections must be made in accordance with local and national codes. 2-wire cable plus ground conductor, minimum AWG 10, voltage rating minimum 300 V, minimum temp. rating 105 °C/221°F

Min. circuit ampacity 4 t unit 35 A 5 t unit 40 A

Table 3.2 Power-supply Cable Specificatoin

Motor Cable Specification Depending on the desired level of EMC compliance according to European or North American standards for radiated emissions such as EN 55014/55011 or FCC part 15, a suitable cable connection drive and compressor must be selected. It is recommended to use shielded cable under all circumstances.

Cable specification for installations in the EU: 4-wire cable with protective earth (PE) and shield (min 80% coverage), minimum cross section 4 mm2 for 13 kW units and 6 mm2 for 16 and 20 kW units, voltage rating 600 V.

3 t unit 30 A

Min. circuit ampacity 13 kW/3 t unit 30 A 16 kW/4 t unit 35 A 20 kW/5 t unit 40 A

Table 3.3 Motor Cable Specification

Sensor and Transmitter Cables Refer to the documentation provided with the Danfoss sensors and transmitters. For serial communication connections, see 4 Serial Communication (Modbus RTU).

3.4

Fuses/Circuit Breakers

Branch circuit protection To protect the installation against electrical and fire hazard, all branch circuits in an installation must be short-circuited and over-current protected according to national and local regulations.

Short circuit protection Danfoss requires using the fuses mentioned in Table 3.4 to protect service personnel or other equipment in case of an internal failure in the unit or short-circuit on DC-link of the drive. The variable speed drive provides full short circuit protection in case of a short-circuit on the motor output in accordance with UL regulations.

Over-current protection Overload protection must be provided to avoid overheating of the cables in the installation. Over-current protection must always be carried out according to national regulations (NEC Article 430 “Motors, Motor Circuits and Controllers” and NEC Article 440 “Airconditioning and refrigeration equipment”).

MG10V402 - VLT® is a registered Danfoss trademark 13

Electrical Installation

Fuses

13 kW/3 t unit 176L0767 RLA 22A max. fuse amperage 30 A 16 kW/4 t unit 176L0766 RLA 28A max. fuse amperage 35 A 20 kW/5 t unit 176L0765 RLA 33A max. fuse amperage 40 A

VLT® Inverter Scroll CDS 801 Operating Instructions

Table 3.4 Fuses

NOTE

Fuses of type class RK5 must be used in US installations.

Recommended circuit breakers HVCR type fusible circuit breaker may be used, see rating above.

3.5 EMC Correct Installation

Follow these guidelines when compliance with EN 55011 cl. A or EN 55014 is required.

Good engineering practice to ensure EMC-correct electrical installation:

Use only shielded/braided screened/armored

•

motor cables and control cables. The shield should provide a minimum coverage of 80%. The shield material must be metal, not limited to but typically copper, aluminum, steel or lead. There are no special requirements for the mains cable.

Connect the shield to ground at both ends for

•

motor cables and control cables. Avoid terminating the shield with twisted ends

•

(pigtails). Such a termination increases the high frequency impedance of the screen, which reduces its effectiveness at high frequencies. Use low impedance cable clamps (delivered with the drive) and EMC glands instead.

Ensure good electrical contact between the de-

•

coupling plate and the metal chassis of the variable speed drive.

Where possible, avoid using unshielded/

•

unarmored motor or control cables inside cabinets housing the drive.

14 MG10V402 - VLT® is a registered Danfoss trademark

175ZB044.10

175ZB045.10

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

3.6 Electrical Connections

3.6.1 Routing of Motor and Supply Cable

Do not route supply, sensor and communication cables in parallel with the motor cable. Separate cables from each other as much as possible (see Illustration 3.2). Furthermore, the motor cable should be kept as short as possible. Do not route cables across the PCB (see Illustration 3.1).

Illustration 3.1 Wrong Routing of Motor and Supply Cables

Illustration 3.2 Cable Separation

MG10V402 - VLT® is a registered Danfoss trademark 15

175ZB052.11

L2/N

130ZB122.10

175ZB047.10

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

3.6.2 Power Supply Connection (Mains)

1. Connect the ground cable.

Connect L2 or L1 and N, see Illustration 3.3.

Mains cables must be dimensioned according to national and local standards.

Illustration 3.3 Power Supply Connections

Motor (Compressor) Connection

3.6.3

Danfoss offers different compressor models according to the desired level of EMC compliance for radiated emissions. Compressors for installations in the EU have a rectangular terminal box with provision for using EMC gland sets for shielded cable, while the models for installations in North America have a round shaped terminal box (see Illustration 3.4 and Illustration 3.5). The order of phases is inevitable in both cases. Always connect T1 on the drive with T1 on the compressor and T2 and T3 accordingly, see Illustration 3.7. Observe maximum current ratings for spade type angular cable connectors according to manufacturer’s product data.

Illustration 3.4 Motor (Compressor) Connection, EU Models

EU models: The terminal box provides punch outs on the right side for 25 mm glands and in the bottom for 28 mm glands. Connect wires for T1, T2, T3 and ground (PE) inside the terminal box and install EMC cable gland set accordingly.

NAM models: Connect wires for T1, T2, T3 and local grounding.

Illustration 3.5 Motor (Compressor) Connection, NAM Models

16 MG10V402 - VLT® is a registered Danfoss trademark

175ZB132.10

175ZB046.11

T3 T2 T1

130ZB123.10

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

Illustration 3.6 Connection Box, Europe/Asia

Illustration 3.7 Motor (Drive) Connection

Use of Ferrite on drive output terminals: To comply with the most stringent standard for radiated emissions (EN 55011 cl. B) a ferrite must be installed at the output terminals of the drive as shown in Illustration 3.8. The motor phase wires (T1, T2, T3) must be wound twice around the ferrite, while the PE wire is directly connected to the chassis, see Illustration 3.8.

Illustration 3.8 Wire Routing on Ferrite

MG10V402 - VLT® is a registered Danfoss trademark 17

175ZB048.11

P_C

P_O

S_D

S_AUX

S_AMBIENT

175ZB049.11

RLY_1

175ZB051.11

EXT_FAN

175ZB099.11

EEV_2

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

3.6.4 Sensor Connections

Connect the sensors as marked on the PCB, see Illustration 3.9: Aux. temperature sensor (S aux.) (if applicable) Compressor discharge temperature (Sd) Ambient temperature (S amb.) Compressor suction pressure (P0) Compressor discharge pressure (Pc)

Condenser Fan Motor Control

3.6.6 Connection (EXT_FAN)

Two different control signals are available, 0-10 V (max. current 20 mA) analogue output and 24 V PWM duty cycle with scalable frequency, see Modbus register description in 5 Commissioning. Connect the control signal of the condenser fan (or any other external device like a circulator pump) as shown and marked on the PCB, see Illustration 3.11.

Illustration 3.9 Sensor Connections

4-way Reversing Valve Connection

3.6.5

The relay for the 4-way reversing valve is connected as shown and marked on the PCB, see Illustration 3.10. Max. load: 250 V AC, 4 A 24 V DC, 4 A See 3.6.10 Allocation of Connector Pins.

Illustration 3.10 4-way Reversing Valve Connection

Illustration 3.11 Condenser Fan Motor Control Connection (EXTFan)

EEV Controller (HP Mode) Connection

3.6.7 (EEV_2)

Connect the EEV Controller as shown and marked on the PBC, see Illustration 3.12.

Illustration 3.12 EEV_2 Controller Connection

18 MG10V402 - VLT® is a registered Danfoss trademark

175ZB024.12

Shield

MASTER

EEV_1

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

3.6.8 Serial Communication Cable Connection

Connect the RS-485 cable(s) to the PCB of the Variable Speed Drive as follows, see Illustration 3.13:

1. Attach the positive (+) polarity wire to the screw terminal.

2. Attach the negative (-) polarity wire to the screw terminal.

3. Attach the drain cable to the drain terminal (D).

4. Attach the cable with the shield to the compression clamp on the chassis.

5. Connect the other end of the RS-485 cable to the OEM Controller ensuring that the polarity of the wires matches the polarity at the drive.

The two 3-pole connectors are marked on the circuit board as “Master” which connects to the OEM Controller, and “EEV_1” which connects to the indoor EEV Controller (separate internal Danfoss bus).

The compression clamp is suitable to two sets of cable. Make sure to establish a good connection between the shield and the compression clamp and the chassis.

Illustration 3.13 Serial Communication Connection Cable

When selecting a transmission line for RS-485, it is necessary to examine the required distance of the cable and the data rate of the system. Losses in a transmission line are a combination of AC losses (skin effect), DC conductor loss, leakage, and AC losses in the dielectric. In high-quality cable, the conductor losses and the dielectric losses are on the same order of magnitude.

The recommended maximum Modbus cable length between the drive and the OEM Controller should not exceed 100 ft (30 m).

While the RS-485 specification does not specify cabling, the recommendation is 24 AWG shielded twisted-pair cable with a shunt capacitance of 16 pF/ft and 100 Ω impedance.It is also possible to use the same cable commonly in the twisted-pair Ethernet cabling. This cable is commonly referred to as Category 5 cable. The cable has a maximum capacitance of 17 pF/ft (14.5 pF/ft typical) and characteristic impedance of 100 Ω.

MG10V402 - VLT® is a registered Danfoss trademark 19

175ZB055.10

175ZB033.10

175ZB054.10

175ZB034.10

175ZB056.10

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

3.6.9 Connector Specification

All counterpart plugs listed in Table 3.5 are of female type, all connectors installed on the PCB are of male type.

Connector Poles Manufacturer Type Color Remarks Supply (L1,L2) 2 Phoenix Contact PC 16/2-ST-10,16 Green Marked L1, L2 Motor (T1, T2,T3) 3 Phoenix Contact PC 16/3-ST-10,16 Green Marked T1, T2, T3 Indoor EEV Controller (EEV_1) 3 Dinkel EC381R-4620-03P Green Marked RS-485, +, -, D Modbus Master bus (MASTER) 3 Dinkel EC381R-4620-03P Green Marked RS-485, +, -, D Outdoor EEV Controller (EEV_2) 4 Molex 39-01-2040 White Condenser fan speed ref. (EXT_FAN) 4 Molex 39-01-2040 White Ambient temperature (S_AMBIENT) 2 Molex 39-01-2020 White Auxiliary temperature (S_AUX) 2 Molex 39-01-2020 White Compressor discharge temp. (S_D) 2 Molex 39-01-2020 White Compressor suction pressure (P_0) 4 Molex 39-01-2040 White Compressor discharge pressure (P_C) 4 Molex 39-01-2040 White Reversing valve relay (RLY_1) 3 Molex 39-01-4030 White Cooling fan (INT_FAN) 3 Molex 39-01-4030 White Crimping contact Manufacturer Type All connectors Molex 39-00-0213 Alternative manufacturer see manuf. reference lists

Table 3.5 Connector Specification

Illustration 3.14 2-pole Connector

Illustration 3.15 3-pole Connector

Illustration 3.16 4-pole Connector

Illustration 3.17 Bus Connector

20 MG10V402 - VLT® is a registered Danfoss trademark

Illustration 3.18 Crimping Contact

1 12

234

1 12 2

EEV_2 1 Ground 2 + (RS485) 3 - (RS485) 4 +24V

EXT_FAN 1 Ground 2 0-10V 3 PWM 4 not used

S_AMBIENT, S_AUX, S_D 1 PT1000 2 PT1000

P_O 1 Ground 2 Signal 3 +5V 4 not used

P_C 1 Ground 2 Signal 3 +5V 4 not used

RLY_1 1 NC 2 COM 3 NO

175ZB057.10

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

3.6.10 Allocation of Connector Pins

The position of the connector pins for sensors, transmitters, serial communication, etc. is shown in Illustration 3.19.

NOTE

All connections are seen from the cable side

Illustration 3.19 Allocation of Connector Pins

MG10V402 - VLT® is a registered Danfoss trademark 21

Main power supply

208-230V 60 Hz

distribution

Condenser

fan motor

i.e. ECM 142

High-pressure

switch

Safety

circuit

breaker

Fuse

Optional

Not scope of Danfoss delivery

Compressor,

order of phases

must be observed!

Chassis

L1 L2

Modbus serial

communication

with OEM controller

Modbus serial

communication

with indoor EEV

controller

EEV_1

EEV_2

MASTER

EXT_FAN

S_AMBIENT

S_AUX

S_D

P_O

P_C

RLY_1

Inverter PCA

Outdoor unit

Indoor unit

temp. sensor

PT 1000(S2)

Schematic Wiring Diagram

Air-Conditioning System

Agenda:

Low voltage

High voltage

Prefabricated cable

Screended cable

Power supply

indoor EEV

controller

18-30 v AC/DC

EEV

Outdoor

unit

EEV

Controller

OEM

Controller

(Thermostat)

Ambient temperature

sensor PT 1000(S. amb.)

Compr. dischange temp.

sensor PT 1000(Sd)

Compressor suction pressure sensor (Po)

Compressor discharge

pressure sensor (Pc)

Aux. temperature

sensor PT 1000

175ZB100.10

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

3.6.11 Overview Wiring Diagram

The following 3 wiring diagrams show typical system configurations for an AC system (see Illustration 3.20), a combined AC/HP system (see Illustration 3.21) and a ground source heat pump system (see Illustration 3.22), with all Danfoss components.

Illustration 3.20 AC only System

22 MG10V402 - VLT® is a registered Danfoss trademark

Main power supply

208-230V 60 Hz

distribution

Condenser

fan motor

i.e. ECM 142

High-pressure

switch

Not scope of Danfoss delivery

Compressor,

order of phases

must be observed!

Modbus serial

communication

with OEM controller

Modbus serial

communication

with indoor EEV

controller

Inverter PCA

Outdoor unit

Ambient temperature

sensor PT 1000(S. amb.)

Compr. dischange temp.

sensor PT 1000(Sd)

Compressor suction pressure sensor (Po)

Compressor discharge

pressure sensor (Pc)

Aux. temperature

sensor PT 1000

L1 L2

EEV_1

EEV_2

MASTER

EXT_FAN

S_AMBIENT

S_AUX

S_D

P_O

P_C

RLY_1

Safety

circuit

breaker

Chassis

Fuse

Optional

Indoor unit

temp. sensor

PT 1000(S2)

Schematic Wiring Diagram

Combined Air-Conditioning

and Heat Pump System

Agenda:

Low voltage

High voltage

Prefabricated cable

Screended cable

Power supply

indoor EEV

controller

18-30 v AC/DC

175ZB101.10

EEV

Outdoor

unit

EEV

Controller

EEV

Outdoor

unit

EEV

Controller

OEM

Controller

(Thermostat)

4-way

reversing

valve

Coil

supply according

to coil

i.e. 230 or 24VAC

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

Illustration 3.21 Combined AC/HP System

MG10V402 - VLT® is a registered Danfoss trademark 23

Main power supply

208-230V 60 Hz

distribution

High-pressure

switch

Not scope of Danfoss delivery

Compressor,

order of phases

must be observed!

Safety

circuit

breaker

4-way

reversing

valve

Coil

L1 L2

Chassis

T1 T2 T3

Inverter PCA

EEV_1

EEV_2

MASTER

EXT_FAN

S_AMBIENT

S_AUX

S_D

P_O

P_C

RLY_1

Modbus serial

communication with

EEV controller

Modbus serial

communication with

OEM controller

Compact unit

Schematic Wiring Diagram

Combined Air-Conditioning

and ground source Heat

Pump System

Agenda:

Low voltage

High voltage

Prefabricated cable

Screended cable

175ZB102.12

Indoor unit

temp. sensor

PT 1000(S2)

EEV

unit

EEV

Controller

OEM

Controller

(Thermostat)

Ambient temperature

sensor PT 1000(S. amb.)

Compr. discharge temp.

sensor PT 1000(Sd)

Compressor suction

pressure sensor (Po)

Compressor discharge

pressure sensor (Pc)

Aux. temperature

sensor PT 1000

supply according

to coil type

i.e. 230 or 24VAC

Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

Illustration 3.22 Ground Source Heat Pump System with one EEV

24 MG10V402 - VLT® is a registered Danfoss trademark

OEM

Controller,

Modbus

Master

Indoor EEV Controller for AC operation

Modbus node #165

RS 485

Interfaces

Application control

Microprocessor

Modbus node #162

Motor control

Microprocessor

Modbus node #163

Outdoor EEV

Controller for

Heatpump operation

Modbus node #164

Drive PCB

Internal bus

Outdoor sectionIndoor section

175ZB023.12

Serial Communication (Modbu...

VLT® Inverter Scroll CDS 801 Operating Instructions

4 Serial Communication (Modbus RTU)

General The serial communication bus is used to receive Modbus Slave Messages from an external source. In normal operation, this will be a Modbus Master usually called the “OEM Controller”. When not in service, the OEM or manufacturing can access the device for configuration or service, see Illustration 4.1 and Illustration 4.2.

NOTE

The Modbus communication is available after the drive has performed an internal test routine, approximately 15 seconds after power up.

The Modbus implementation has been designed to conform to the Modbus Standard Protocol.

For details, refer to

Modbus Application Protocol Specification, V1.1b

•

Modbus Over Serial Line Specification and Implementation Guide, V1.02

•

Modicon Modbus Protocol Reference Guide

•

PI–MBUS–300 Rev. J

4 4

Also visit www.modbus.org

For details about setting up the Modbus serial communication, refer to the Modbus RTU Communication Setup Manual.

Illustration 4.1 Modbus Communication Set-up, for AC only, and Combined AC/HP Systems

MG10V402 - VLT® is a registered Danfoss trademark 25

OEM

Controller,

Modbus

Master

EEV

Controller

Modbus node #165

RS 485

Interfaces

Application control

Microprocessor

Modbus node #162

Motor control

Microprocessor

Modbus node #163

Drive PCB

Internal bus

175ZB129.10

Serial Communication (Modbu...

VLT® Inverter Scroll CDS 801 Operating Instructions

Illustration 4.2 Modbus Communication Set-up for Ground Source Heat Pump Systems

26 MG10V402 - VLT® is a registered Danfoss trademark

Commissioning

VLT® Inverter Scroll CDS 801 Operating Instructions

5 Commissioning

5.1 Initial Configuration of the Performer VSD sub-system

System components offered by the OEM, such as outdoor units, indoor units/air handlers, evaporator modules or furnaces are often manufactured in different locations and first merged into a complete system at the end user’s site. Furthermore, numerous combinations of such components are feasible. Therefore it is extremely important to prepare the components during manufacturing for a late merge in the field.

Alternatively, the configuration of each individual component can be made in the field. This can be done with Danfoss Update tool or Modbus tool allowing programming the drive, application controller and EEV Controller via the serial communication interface (Modbus RTU).

This functionality can also be incorporated in the OEM Controller by establishing a protected service menu, allowing accessing all Modbus registers.

Individual solutions can be worked out in cooperation with the product support team.

5.2

Drive Setup

The variable speed drive including the embedded application controller and the EEV Controller(s) can be individually configured by setting various parameters (Modbus registers). This manual is limited to the drive parameters. For the application controller and the EEV Controller(s), refer to the separately provided documentation.

NOTE

Changing the setting of some registers requires re-booting before the setting becomes effective. For details, refer to the Modbus RTU Communication Setup Manual.

The timeouts and response times of Modbus messages to and from the drive is in accordance with the Modbus standard.

5.2.1

Drive Parameters (Modbus Registers, node 162)

Register 40001-40010, PCA Bar Code (read only) These registers (10) allow reading the bar code information on the PCA, which is also found on the product identification label on the drive chassis.

Register 40011-40020, Ordering code (read only) These registers (10) allow reading the Danfoss ordering code, which is also found on the product identification label on the drive chassis, typically starting with 176L…..

Register 40021 and 40022, Operation Time Counter (read only) These registers allow reading the accumulated time the drive has been powered. The value is given in seconds.

Register 40101-40110, AOC Software Version (read only) These registers (10) allow reading the software version number for the application oriented microprocessor.

Register 40111-40120, AOC Registers Version (read only) These registers (10) allow reading the registers version number for the application oriented microprocessor.

Register 40121 and 40122, Drive Status These registers describe the exact operation condition of the system in a 32 bit structure. See separate description in 7 Fault Conditions, Messages and Causes.

Register 40131, OEM Reset Setting this register to logic “1” resets the drive to the OEM defaults (configuration defaults set by the OEM in production) stored in the EEPROM.

Register 40132, Danfoss Reset Setting this register to logic “1” resets the drive to the Danfoss defaults (factory defaults as listed in this manual and Modbus register map files)

Register 40133, Overwrite Defaults Setting this register to logic “1” allows overwriting the factory defaults. This should only be done with assistance from Danfoss.

NOTE

Do not set registers 40132 and 40133 to logic “1” at the same time.

5 5

In the following chapters, the drive parameters are described by the register number.

MG10V402 - VLT® is a registered Danfoss trademark 27

Commissioning

VLT® Inverter Scroll CDS 801 Operating Instructions

Register 40134, Test Register This register has been created as a test tool to verify proper Modbus communication. To test the communication, write any value between 0 and 65535 to the register and verify that the same value is successfully reported back from the slave node (drive).

Register 40135, Drive Reboot Setting this register to logic “1” initiates a reboot sequence; this equals cycling power to the drive.

serial communication.

Value 0 9600 kbps 1 19200 kbps

Register 40146, EEV Indoor Unit Address (def. 165, min 1, max 247) This register allows setting the bus address (node address) of the EEV Controller in the indoor unit. The default address is 165 and can be set to a value between 1 and

247.

NOTE

Must be set to the same value on EEV Controllers.

Register 40147, EEV Outdoor Unit Address (def. 164, min 1, max 247) This register allows setting the bus address (node address) of the EEV Controller in the outdoor unit (if applicable, in systems with 2 EEV’s only). The default address is 164 and can be set to a value between 1 and 247.

NOTE

Table 5.1 OEM Baud Rate

Value 0 None 1 Odd 2 Even (default)

Table 5.2 OEM Parity

Value 1 1 stop bit (default) 2 2 stop bits

Must be set to the same value on EEV controllers.

Register 40148, OEM Communication Timeout (def. 20 sec, min 0 sec, max. 3600 sec) The time set in this register determines the duration from loosing communication with the OEM controller to stopping the system. When communication is reestablished, the drive will resume operation automatically. Setting this register to 0 sec. means that the drive will not stop in case of loosing communication.

Registers 40499 and 40500, Sensor S_AUX These registers allow reading the temperature reading of the auxiliary sensor input S_AUX in degrees centigrade (°C); in case a PT 1000 sensor is connected.

Register 40501-40550, OEM Data registers Danfoss has established 50 OEM registers that the OEM customer can use freely to store product information. All registers are of type unsigned 16.

Drive Parameters

Table 5.3 OEM Stop Bits

5.2.2 (Modbus Registers, node 163)

247) This register allows setting the bus address (node address) of the application oriented microprocessor of the drive. The default address is 162 and can be set to a value between 1 and 247.

247) This register allows setting the bus address (node address) of the motor oriented microprocessor of the drive. The default address is 163 and can be set to a value between 1 and 247.

NOTE

The same address must be set in MOC register 40145.

28 MG10V402 - VLT® is a registered Danfoss trademark

Register 40101-40110, MOC Software Version (read only) These registers (10) allow reading the software version number for the motor control oriented microprocessor.

Register 40111 and 40120, MOC Registers Version (read only) These registers (10) allow reading the register version number for the motor control oriented microprocessor.

Register 40131, OEM Reset Setting this register to logic “1” resets the drive to the OEM defaults (configuration defaults set by the OEM in production) stored in the EEPROM.

Register 40132, Danfoss Reset Setting this register to logic “1” resets the drive to the Danfoss defaults (factory defaults as listed in this manual and Modbus register map files)

Commissioning

VLT® Inverter Scroll CDS 801 Operating Instructions

Register 40133, Overwrite Defaults Setting this register to logic “1” allows overwriting the factory defaults. This should only be done with assistance from Danfoss.

247) This register allows setting the bus address (node address) of the motor control oriented microprocessor of the drive. The default address is 163 and can be set to a value between 1 and 247.

Register 40201 and 40202, Compressor Power Consumption in kWh (read only) These registers allow reading the power consumption of the compressor.

Register 40203 and 40204, Compressor Power in kW (read only) These registers allow reading the input power to the compressor.

Register 40205 and 40206, Supply Voltage (read only) These registers allow reading the supply voltage (line voltage) applied to the drive.

Register 40207 and 40208, Inverter Temperature (read only) These registers allow reading the internal inverter temperature measured in the power module of the drive in °C.

Register 40209 and 40210, UDC Voltage (read only) These registers allow reading the DC voltage in the intermediate circuit of the drive.

Register 40211 and 40212, Internal Fan Speed (read only) These registers allow reading the speed of the integrated cooling fan in the drive in a percentage.

5.3

Condenser Fan Speed Reference Output

When the condenser fan speed control mode is selected in the application controller the drive calculates the optimum fan speed for efficiency optimization and provides a speed reference output signal for the variable speed condenser fan motor. When the speed control is deselected the output can be used to control any other external device such as a circulator pump in a ground source heat pump, simply by using the Modbus external speed register and the control signal describe hereinafter.

The following signals are simultaneously available:

Analog output 0-10 V

•

Frequency duty cycle output 24 V PWM, 0-10 kHz

•

Reg. 41609 and 41610, Outdoor fan capacity PCT min

Reg. 41611 and 41612, Outdoor fan capacity PCT max

Reg. 41613 and 41614, Outdoor fan control signal freq

5.4 Crankcase Heating

The variable speed drive comprises an electronic crankcase heating, by injecting a DC voltage to the compressor motor. The resulting current heats the motor windings and therewith effectively prevents refrigerant from accumulating in the compressor sump. An additional heating belt is not required.

Register 40479 and 40480 Crankcase heating on temperature (min 50 °F/10 °C, max +77 °F/+25 °C) This register allows setting the temperature at which the crankcase heating is activated. Setting register 40481 to value "0" deactivates the crankcase heating function permanently (default is "1"/ON).

The temperature equals the ambient temperature measured by the drive in the outdoor unit.

NOTE

The crankcase heating is not active when power is disconnected to the drive as well as when the compressor is in operation. Crank case heating will also not be active when drive is stopped because of an alarm.

The power consumption of the crankcase heating is approximately 40 W.

5.5

Ambient Temperature Source

The ambient temperature value can be provided from a sensor connected directly to the drive, or it can be sent to the unit via Modbus from the OEM controller.

Register 40216, Thermo in Ambient Temperature An internal analog value from the ambient temperature sensor connected to the drive at the S_Amb input. (-999 °C if not connected).

Register 40225, Thermo In External Ambient Temperature The OEM controller writes the ambient temperature via Modbus. When using the Modbus ambient temperature signal, the OEM controller it must update the signal at least every 60 s. Otherwise the drive goes into safe mode.

Register 40484, Thermo Setup Ambient Temperature Source Selects the source of ambient temperature used by software control algorithms (Crankcase Heating and Outdoor Fan Control).

5 5

MG10V402 - VLT® is a registered Danfoss trademark 29

Commissioning

VLT® Inverter Scroll CDS 801 Operating Instructions

0 = 40216 Thermo In Ambient Temperature 1 = 40225 Thermo In External Ambient

Temperature

Default value of the register is 0, and therefore a temperature sensor must be connected to the drive as default unless this register is set to 1. It is important that the ambient temperature value is a true measurement of the ambient temperature outside the enclosure containing the compressor and the drive. This value is used for (crankcase heating and fan control).

5.6 Pressure sensor scaling

When using other pressure sensors than Danfoss AKS sensors (specified in the sensor selection guide), the pressure configuration registers must be changed to match the range of the used sensors.

Register 41601 and 41602, Suction pressure min Register 41603 and 41604, Suction pressure max Register 41605 and 41606, Condenser pressure

min Register 41607 and 41608, Condenser pressure

max

All pressure calculations in the drive is done in an absolute pressure scale (atmospheric pressure = 1bar). Example: Absolute pressure range 0-20 bar ⇒ pressure min = 0 and pressure max = 20.

Optional Commands:

Optional available information: The drive and the EEV Controller(s) allow reading a large number of data to be polled by the Modbus Master (OEM Controller), such as:

Setpoint and room temperature (in closed loop

•

operation) Capacity request (in open loop operation)

•

Dehumidification Mode

•

Product identification

•

Operation status (alarms and warnings)

•

Operation data

•

Power consumption

•

Compressor speed

•

Pressure and temperature values

•

Etc.

•

If a pressure sensor with a gage pressure range is used (atmospheric pressure = 0 bar), the min and max pressure must be added with 1 to compensate for the offset in the range when configuring the sensor. Example: gage pressure scale 0-20 bar ⇒ pressure min = 1 and pressure max = 21.

5.7

Normal Operation

NOTE

After connecting power to the drive, wait at least 15 seconds until the initialization is completed before accessing the Modbus communication.

Mandatory commands: To operate the system a minimum number of commands must be provided by the OEM Controller:

Start

•

Stop

•

Reboot

•

30 MG10V402 - VLT® is a registered Danfoss trademark

Indoor

Outdoor

Modbus

OEM control

Modbus

Air ﬂow

EIM 316

S2 AC

24V

Galvanic Isolation

S2 AC

+24V

Drive

Samb

175ZB116.10

Embedded Application Contro...

VLT® Inverter Scroll CDS 801 Operating Instructions

6 Embedded Application Controller “Thermo Control”

6.1 Introduction

The Residential Variable Speed Drive system is consisting of compressor, variable speed drive, application controller, Electronic Expansion Valves (EEV), EEV controller and sensors.

Variable Speed Drive and EEV controller are set to be able to communicate using Modbus RTU protocol. Communication details are available in the Modbus Communication Set-up Manual. Establishing the communication and configuring the system requires individual parameters settings. These settings must be done through the OEM controller or any other PC tool, using the Modbus communication.

This chapter describes the operation modes of the application controller. Included is also the parameter lists and parameter descriptions.

6.2 Applications

6.2.1 Generic AC

Illustration 6.1 Generic AC

MG10V402 - VLT® is a registered Danfoss trademark 31

OutdoorModbus

Indoor

S2 AC

Air ﬂow

OEM control

S2 HP

+24VModbus

Modbus

Drive

Galvanic isolation

24V

S2 AC

EIM 316

S2 HP

Samb

175ZB117.10

Embedded Application Contro...

6.2.2 Generic AC/HP (Reversible)

VLT® Inverter Scroll CDS 801 Operating Instructions

Illustration 6.2 Generic AC/HP (Reversible)

32 MG10V402 - VLT® is a registered Danfoss trademark

175ZB118.10

Drive

OEM control

Samb

ModBus +24V

Embedded Application Contro...

VLT® Inverter Scroll CDS 801 Operating Instructions

6.2.3 Ground Source Heat Pump (Reversible)

Illustration 6.3 Ground Source Heat Pump (Reversible)

6.3

Application Controller

6.3.1 Introduction

The Thermo Controller is an integrated part of the VLT Inverter Scroll CDS 801 system. The purpose of the application controller is to control the speed of the compressor to a given load of the system. It also controls the speed of the condenser fan (outdoor unit), both in A/C mode, Defrost and HP mode. It is possible to select various control modes for the compressor and the condenser fan. It communicates with the EEV controllers, the OEM controller and sets the relay for the 4-way valve. The Thermo Controller has several built-in safety functions to protect the compressor.

The following paragraphs describe the application controller functionality and safety functions.

System Modes

6.3.2

System modes are:

Off

•

AC (cooling)

•

HP (heating)

•

Defrost

•

MG10V402 - VLT® is a registered Danfoss trademark 33

The system mode is selected by setting a value in the THERMO_IN_MODE register.

6.3.2.1 Off

To set the system off:

set THERMO_IN_MODE = 0

The compressor and condenser fan shut down and the indoor and outdoor EEVs close the valves.

The application controller continuously polls the EEVs for their status register. If the status register polling fails, the EEVs go into autonomous mode and attempt to control superheat.

In autonomous mode, the EEV attempts to control the superheat without Modbus communication. If an additional suction pressure sensor is not connected to the EIM316, the EIM316 will not have a suction pressure signal, and will go in to error mode (Valve opening = 80 % of average value).

6.3.2.2

In cooling mode, the Indoor EEV is active and receives the suction pressure signal over the Modbus from the Thermo Control controller. The outdoor EEV is inactive.

Embedded Application Contro...

VLT® Inverter Scroll CDS 801 Operating Instructions

In AC mode, the system sets the 4-way valve to operate the indoor unit as evaporator and the outdoor unit as condenser.

The indoor EEV controller actively controls the superheat on the indoor evaporator.

The outdoor EEV valve will be closed. The Thermo Control controller continuously polls the EEVs

for their status register. If the status register polling fails, the EEVs go into autonomous mode and attempt to control superheat.

To set the system in AC mode:

set THERMO_IN_MODE = 1

When conditions for start up are met:

The restart timer has elapsed

•

The requested compressor speed is higher than

•

the minimum allowed speed

The system go into a start-up sequence. The start-up sequence is described in 6.3.5.1 Start-Up Sequence.

6.3.2.3

To set the system in Defrost mode: set THERMO_IN_MODE = 3

There is no specific control algorithms for defrosting, compressor speed and fan speed must be handled by the OEM controller. However, the limitations from the compressor protection is different from AC mode. This allows the OEM controller to execute a defrosting sequence with good performance.

6.3.3 Compressor Capacity Control

The compressor speed control can be done through different strategies. The compressor control strategy is selected by setting the THERMO_IN_COMPRESSOR_MODE.

In Heat Pump mode, the outdoor EEV is active, and receives the suction pressure signal over the Modbus from the Thermo Control controller. The indoor EEV is inactive.

In HP mode, the system sets the 4-way valve to operate the indoor unit as condenser and the outdoor unit as evaporator.

The outdoor EEV controller actively controls the superheat on the outdoor evaporator.

The indoor EEV valve will be closed. The Thermo Control controller continuously polls the EEVs

for their status register. If the status register polling fails, the EEVs go into autonomous mode and attempt to control superheat.

To set the system in HP mode:

set THERMO_IN_MODE = 2

When conditions for start up are met:

The restart timer has elapsed

•

The requested compressor speed is higher than

•

the minimum allowed speed,

The system go into a start-up sequence. The start-up sequence is described in 6.3.5.1 Start-Up Sequence.

6.3.2.4

The purpose of Defrost mode is to allow the OEM controller to perform an efficient defrost routine. In Defrost mode, the EEVs and 4-way valve work identically to AC mode.

34 MG10V402 - VLT® is a registered Danfoss trademark

Defrost

Drive

AC/HP

system

Compressor Room

Troom

Setpoint

175ZB107.10

Drive

AC/HP

system

Compressor Room

External

speed command

Troom

175ZB108.10

Embedded Application Contro...

VLT® Inverter Scroll CDS 801 Operating Instructions

6.3.3.1 Single Loop Room Temperature Control

In single temperature control, the Inverter Scroll CDS 801 system attempts to maintain a temperature, typically a room temperature, see Illustration 6.4.

The reference and the room temperature are sent from the OEM controller. The Thermo Control controller calculates the necessary compressor speed and condenser fan speed. To set the compressor control to single temperature closed loop control: Set THERMO_IN_COMPRESSOR_MODE = 0

The Thermo Control controller reads the reference from THERMO_IN_ROOM_TEMPERATURE_SET_POINT and the actual room temperature from THERMO_IN_ROOM_TEMPERATURE.

Illustration 6.4 Single Loop Room Temperature Control

6.3.3.2 Open Loop/ External Speed Control

In external speed control (see Illustration 6.5), the compressor speed is set externally from the OEM controller through the Modbus.

When in external speed mode, the compressor derating and safety envelope functions are still active and takes precedence over the external speed signal.

To set the compressor speed control into external speed control:

Set THERMO_IN_COMPRESSOR_MODE = 2

The external speed % is set in the THERMO_IN_COMPRESSOR_EXTERNAL_SPEED_PCT register.

Illustration 6.5 Open Loop/External Speed Control

0% Speed request = 0 Hz, and start will not be allowed until 60 s later. (control restart timer). 1% Speed request = 15 Hz 100% Speed request = 70 Hz, see Illustration 6.6 Can be overruled by derating functions (explained in 6.3.5.5 Derating).

MG10V402 - VLT® is a registered Danfoss trademark 35

10 100

Compressor speed

[Hz

]

Speed request

[%]

130ZB124.10

Embedded Application Contro...

Illustration 6.6 Compressor Speed vs. Speed Request

Condensing Pressure Control

6.3.4

VLT® Inverter Scroll CDS 801 Operating Instructions

The outdoor fan speed control can be done through different strategies. The fan control strategy is chosen by setting the THERMO_IN_FAN_MODE register. The fan speed control strategy depends also on the system mode: AC vs. HP. If the system is in AC mode, the outdoor fan controls the condensing pressure/temperature. This temperature has to be higher than the ambient temperature, so that the condenser can reject heat. If the system is in HP mode, the outdoor fan controls the evaporator pressure/temperature. This temperature has to be lower than the ambient temperature, so that the evaporator can absorb heat. Fan speed control is illustrated in Table 6.1.

Mode THERMO_IN_FAN_MODE System mode = AC (and defrost) System mode = HP

Optimal COP 0 Pc,ref = f(P0) P0 = f(Pc)

Delta T 1 Tc,ref = Tamb + delta T

External Speed 2 Fan speed = THERMO_IN_FAN_EXTERNAL_SPEED_PCT

Bypass 3 Fan speed = THERMO_IN_FAN_EXTERNAL_SPEED_PCT

Table 6.1 Condensing Pressure Control

6.3.4.1

AC Mode

(delta T = 7K)

T0,ref = Tamb – delta T

(delta T = f(T0min, Tamb))

In AC mode, the fan controls condensing pressure, since the outdoor unit works as condenser. Optimal Pressure Ratio Control

In Optimal COP mode, the fan speed control attempts to maintain a constant pressure ratio

Pc/P0 = constant

across the compressor, see Illustration 6.7. This ratio is the theoretically optimal pressure ratio for the Inverter Scroll CDS 801 compressor.

To run Optimal COP mode:

Set THERMO_IN_FAN_MODE = 0

36 MG10V402 - VLT® is a registered Danfoss trademark

2.09 P 2 TP 0 Tc set FanMotor

Condensing

Unit

P 2 T PcTc

175ZB109.10

Tamb + Delta T FanMotor

Condensing

Unit

P 2 T PcTc

175ZB110.10

175ZB130.10

FanMotor

Condensing

Unit

External

speed setpoint

Fan Protection

FanMotor

Condensing

Unit

External

speed command

175ZB111.10

Embedded Application Contro...

Illustration 6.7 AC Mode

VLT® Inverter Scroll CDS 801 Operating Instructions

Delta T Control In Delta T mode, the fan speed control attempts to maintain a temperature difference of Delta T to ambient temperature, see Illustration 6.8.

In AC mode, the fan speed control attempts to maintain condensing temperature Delta T above ambient temperature. To run Delta T mode:

Set THERMO_IN_FAN_MODE = 1

The temperature difference Delta T is set through the register THERMO_SETUP_DELTA_TEMP.

Illustration 6.8 Delta T Control

Open Loop/External Speed Control In external speed control, the fan speed is set externally from the OEM controller through the Modbus. The speed can be overruled by the fan protection functions like min and max condensing pressure derating, see Illustration 6.9.

To set the fan speed control in to external speed control:

Set THERMO_IN_FAN_MODE = 2

protection functions, and will never be overruled by functions like min and max condensing pressure derating, see Illustration 6.10. To set the fan speed control in to bypass:

Set THERMO_IN_FAN_MODE = 3

The external speed % is set in the THERMO_IN_FAN_EXTERNAL_SPEED_PCT register.

Illustration 6.10 Bypass Fan Speed Control

Illustration 6.9 Open Loop/External Speed Control

Bypass fan speed control In Bypass speed control, the fan speed is set externally from the OEM controller through the Modbus. In the bypass mode the external speed is bypassing the fan

MG10V402 - VLT® is a registered Danfoss trademark 37

---- ----- 2

P 2 TPc T 0 set FanMotor Evaporator

P 2 T P0T 0

175ZB112.10

Tamb - Delta T FanMotor Evaporator

P 2 T P 0T 0

175ZB113.10

Embedded Application Contro...

VLT® Inverter Scroll CDS 801 Operating Instructions

6.3.4.2 HP Mode

In HP mode the fan controls evaporator pressure since the outdoor unit works as an evaporator. Optimal Pressure Ratio Control

In Optimal COP mode, the fan speed control attempts to maintain a constant pressure ratio

Pc/P0 = constant

across the compressor, see Illustration 6.11. This ratio is the theoretically optimal pressure ratio for the compressor. To run optimal COP mode:

Set THERMO_IN_FAN_MODE = 0

Illustration 6.11 HP Mode

Delta T Control In Delta T mode, the fan speed control attempts to maintain a temperature difference of Delta T to ambient temperature, see Illustration 6.12.

In HP mode, the fan speed control attempts to maintain evaporator temperature Delta T below ambient temperature. To run Delta T mode:

Set THERMO_IN_FAN_MODE = 1

The temperature difference Delta T is set through the register THERMO_SETUP_DELTA_TEMP.

Illustration 6.12 Delta T Control

38 MG10V402 - VLT® is a registered Danfoss trademark

130ZB126.10

T0,ref

T ambientT0 min + 10 K T0 Min + 20K

T ambient

T ambient DeltaTemp

Delta T

Performe r VSD Opera ting Envelope

105

115

125

135

145

155

-40 -30 -20 -10 0 10 20 30 40 50 60 70 80

Satura ted e vapora ting tem p

. (°F)

Saturated condensing temp. (

°F

)

-40 -36 -32 -28 -24 -20 -16 -12 -8 -4 0 4 8 12 16 20 24

900-4200

Line 1

Line 5

Line 6

Line 7

Line 14

A10

T 0MinLine

175ZB127.10

175ZB125.10

FanMotor

Evaporating

Unit

External

speed setpoint

Fan Protection

FanMotor Evaporator

External

speed command

175ZB114.10

Embedded Application Contro...

VLT® Inverter Scroll CDS 801 Operating Instructions

To transfer heat to the evaporator, a temperature difference is needed (evaporator temperature must be lower than the ambient temperature). Under cold ambient conditions this brings the suction pressure close(r) to the edge of the operating envelope. It is therefore important to make the temperature difference between evaporator and ambient as small as possible under cold conditions. The Delta T, (or the T0

) is therefore made dependent on

ref

the ambient temperature, see Illustration 6.13. Illustration 6.13 shows how the set point for the Delta T control mode in HP system mode is a function of ambient temperature and T0 approaches the T0

. As the ambient temperature

min

line (see Illustration 6.14), the Delta T

min

is lowered. This is done to prevent too low evaporator temperatures when the ambient temperature is low.

To set the fan speed control to external speed control:

Set THERMO_IN_FAN_MODE = 2

The external speed % is set in the THERMO_IN_FAN_EXTERNAL_SPEED_PCT register.

Illustration 6.15 Open Loop/External Speed Control

Bypass fan speed control In Bypass speed control, the fan speed is set externally from the OEM controller through the Modbus. In bypass mode, the external speed is bypassing the fan protection functions, and will never be overruled by functions like min and max condensing pressure derating, see Illustration 6.16. To set the fan speed control in to Bypass:

Set THERMO_IN_FAN_MODE = 3

The external speed % is set in the THERMO_IN_FAN_EXTERNAL_SPEED_PCT register.

Illustration 6.13 T0

Illustration 6.14 Definition of T0 leftmost line(s) of the envelope

Open Loop/ External Speed Control In external speed control, the fan speed is set externally from the OEM controller through the Modbus. The speed can be overruled by the fan protection functions like min and max condensing pressure derating, see Illustration 6.15.

= f(Tambient) in HP mode (Delta T)

ref

min

Illustration 6.16 Bypass Fan Speed Control

6.3.4.3 Defrost Mode

In Defrost mode the fan controls condensing pressure, since the outdoor unit works as a condenser. The same fan control options like in AC are available, when defrosting the outdoor coil.

Auxiliary Functions

6.3.5

6.3.5.1 Start-Up Sequence

When the system starts up from idle in AC or HP mode, the compressor follows a start up sequence, see Illustration 6.17. This sequence is defined by a ramp (2.7 Hz/s), start speed (THERMO_SETUP_START_UP_SPEED_HZ)

line. The T0

line is the

min

and hold time for start speed (THERMO_SETUP_START_UP_HOLD_TIME_SEC).

MG10V402 - VLT® is a registered Danfoss trademark 39

Time

speed

Start speed

hold time

Start Speed

175ZB115.11

Ramp

175ZB131.10

100

110

120

130

140

150

160

-30 -20 -10 0 10 20 30 40 50 60 70 80

Saturated condensing

temp. ( °F)

Saturated evaporating temp. (° F)

Performer VSD Operating Envelope

900-4200 RPM

1100-4200 RPM

1300-4200 RPM

1500-4200 RPM

1800-4200 RPM

900-4200 RPM

1100-4200 RPM

1300-4200 RPM

2200-3300 RPM

2300-2850 RPM

2400 RPM Derated

2100-3750 RPM

1500-4200 RPM

900-4200 RPM (defrost)

Embedded Application Contro...

Illustration 6.17 Start-up Sequence

VLT® Inverter Scroll CDS 801 Operating Instructions

Illustration 6.18 Compressor Safety Envelope

When switching to and from Defrost mode, the start speed hold time is disabled. The compressor then ramps up continuously to the compressor speed setpoint and skips the start speed hold time. This allows for a more efficient defrosting.

6.3.5.2

Restart Timer

To increase compressor lifetime, there is a minimum time between compressor starts. This restart time (at least 1 minute) is defined by

Restart time register: THERMO_SETUP_RESTART_TIME_SEC When switching to and from Defrost mode, the restart

timer is disabled. This results in a quick switch in system mode and allows for a more efficient defrosting of the outdoor coil.

If the system mode is changed, or compressor is stopped and started too frequently, the drive will stop and raise an alarm. Only 6 compressor restarts within 600 s are allowed, there after the system will stop and raise an alarm.

6.3.5.3

Given the allowed ranges of suction pressure and condensing pressure, the compressor safety envelope defines the speed range (min and max RPM) that the compressor is allowed to run at, however limited by the over all compressor speed range 900-4200 RPM, see Illustration 6.18.

40 MG10V402 - VLT® is a registered Danfoss trademark

Compressor Safety Envelope

The compressor safety envelope takes precedence over any requested compressor capacity and external speed request. Crossing from one envelope to another will not stop the drive if it is running at a low compressor speed. Instead, the compressor speeds up to the minimum speed of the newly entered envelope.

When operating in Defrost mode, the envelope limits are extended to allow for a lower saturated condensing temperature (> 20 °F), which can be necessary when defrosting the outdoor coil. Because the envelope has an extension for defrosting, there is also a maximum duration of defrost allowed. The system can only operate for 1800 s in Defrost mode. If the OEM controller does not terminate the defrosting before the timer has elapsed, the system stops and raises an alarm.

6.3.5.4

Oil Return

The scroll compressor needs oil to be protected against wear. When running, oil leaves the compressor together with the refrigerant. The rate of oil loss is estimated as a function of compressor speed.

The oil return is executed if the speed stays below the oil return speed for a time defined by THERMO_SETUP_OIL_LOSS_TRIG_TIME_SEC. The oil return sequence is defined by the oil return speed THERMO_SETUP_OIL_RETURN_SPEED_HZ and the oil return hold time THERMO_SETUP_OIL_RETURN_HOLD_TIME_SEC.

6.3.5.5

Derating

The purpose of the derating functions is to keep the compressor and drive within the specified operating conditions, while still providing cooling/heating.

Embedded Application Contro...

VLT® Inverter Scroll CDS 801 Operating Instructions

Derating is not an error condition. It only means that the requested speed cannot be accomodated at the moment, to keep the compressor and drive within specified operating limits.

Drive Power Derating The compressor speed is limited to keep the drive power below its maximum power limit. This limit is a function of the line voltage input to drive.

In AC mode, the fan speed will be increased to keep the drive power below its maximum limit. This is done to lower condensing pressure and thereby power consumption.

Drive Temperature Derating The compressor speed is limited to keep the drive temperature below its maximum limit.

Max Condensing Pressure Derating The compressor speed is limited to keep the condensing pressure below its maximum limit. The maximum condensing pressure is a function of suction pressure, and part of the envelope protection.

In AC mode, the fan speed is increased to keep the condensing pressure below its maximum limit.

Min Condensing Pressure Derating In AC mode, the fan has control over the condensing pressure. When the condensing pressure is lower than minimum, the fan speed decreases.

Min Suction Pressure Derating If the suction pressure is lower than the minimum suction pressure, then the compressor speed decreases.

In HP mode, the fan speed also increases if the suction pressure is lower than the minimum.

6.3.5.8

Variable speed systems sometimes are characterized by showing mechanical resonances at critical compressor speeds. Therefore Danfoss has established parameters to set 5 bypass speeds with individual bandwidths. If a mechanical resonance occurs, i.e. at 1600 RPM compressor speed, this speed can be set to one of the bypass frequencies. To define the bandwidth, a bypass range can be set, i.e. 200 RPM. In this example the compressor would not be operated between 1500 and 1700 RPM. If the system demand requires a speed of more than 1500 RPM, the drive remains at 1500 RPM, until the system demand exceeds 1600 RPM; then the speed is increased to 1700 RPM and vice versa.

Critical bypass speed can be set individually in the field using a Modbus service tool; however, it is recommended to search for resonances in the design phase of variable speed air-conditioning or heat pump systems.

The bypass speed can be set within the entire operation range of the drive from 900-4200 RPM. The controller can skip five speed ranges. Each range is specified as a centre frequency and a bandwidth.

6.3.5.9

The system status is expressed in the content of several Modbus registers. Also refer to 7 Fault Conditions, Messages and Causes.

Frequency Cancelation

System Status

6.3.5.6

The discharge temperature is for 90 s allowed to be above the max. discharge temperature, after that the drive will stop and go into a safe mode condition. When the temperature has dropped below the allowed max. temperature, the drive automatically restarts when the restart timer has elapsed.

6.3.5.7

When the suction pressure exceeds the maximum operating pressure, the EEV controller decreases its opening degree. If the suction pressure exceeds the maximum operating pressure for more than 90 s, the controller stops the compressor and restarts after the restart time has elapsed.

Discharge temperature cut out

Max Suction Pressure (MOP)

MG10V402 - VLT® is a registered Danfoss trademark 41

Embedded Application Contro...

VLT® Inverter Scroll CDS 801 Operating Instructions

6.4 Thermo Controller Register Overview (Node 162)

All registers with name type of THERMO_SETUP_XXXXXX are stored in eeprom and can only be overwritten 1 million times. The same applies for 40201 - THERMO_IN_COMPRESSOR_MODE and 40202 - THERMO_IN_FAN_MODE, see Table 6.2.

Address Name Description

40201 THERMO_IN_MODE System control mode:

0 = off 1 = AC 2 = HP 3 = Defrost

40202 THERMO_IN_COMPRESSOR_MODE Compressor capacity control:

0 = Single loop ; Room temp. control 2 = External speed control

40203 THERMO_IN_FAN_MODE Condenser/outdoor fan control:

0 = Optimal compressor COP 1 = Delta T 2 = External speed control 3 = Bypass

40204 THERMO_IN_PC Condensing pressure [bar] from sensor connected to drive

(absolute)

40206 THERMO_IN_P0 Suction pressure [bar] from sensor connected to drive

(absolute) 40208 THERMO_IN_ROOM_TEMPERATURE 40210 THERMO_IN_ROOM_TEMPERATURE_SET_POINT 40212 THERMO_IN_COMPRESSOR_EXTERNAL_SPEED_PCT Compressor external speed % command from OEM controller

40213 THERMO_IN_FAN_EXTERNAL_SPEED_PCT Condenser outdoor fan external speed % command from OEM

40214 THERMO_IN_DISCHARGE_TEMPERATURE

40216 THERMO_IN_AMBIENT_TEMPERATURE 40218 THERMO_IN_S4 40220 THERMO_IN_DRIVE_TEMPERATURE 40222 THERMO_IN_LINE_VOLT Input voltage to drive 40224 THERMO_IN_OIL_RETURN_SWITCH_ON 0: off, 1: on, will be reset to off when drive has been powered

40225 THERMO_IN_EXTERNAL_AMBIENT_TEMPERATURE

40301 THERMO_OUT_COMPRESSOR_SPEED_HZ Compressor speed command to motor control/drive 40303 THERMO_OUT_FAN_SPEED_PCT Fan speed command to outdoor fan

40305 THERMO_OUT_FOUR_WAY_VALVE Four way valve control to set the system in AC or HP mode 40306 THERMO_OUT_START_EEV_INDOOR Command register to indoor EEV

40307 THERMO_OUT_START_EEV_OUTDOOR Command register to outdoor EEV

Room temperature [°C] from OEM controller

Room temperature [°C] setpoint from OEM controller

0% = off

1% = Min speed. 100% = Max speed

controller

Compressor discharge temperature [°C] from sensor connected

to drive

Ambient temperature [°C] from sensor connected to drive

Temperature [°C] signal from indoor EEV (not active yet)

Drive temperature [°C]

off

[°C] Ambient temperature provided via Modbus from OEM

controller.

0% to 100%

0 = stop

1 = start

0 = stop

1 = start

42 MG10V402 - VLT® is a registered Danfoss trademark

Embedded Application Contro...

VLT® Inverter Scroll CDS 801 Operating Instructions

Address Name Description

40308 THERMO_OUT_TRACKING_ERROR_PCT If the compressor is running in external speed % control mode

the tracking error is calculated

The Tracking error is the difference between actual compressor

speed % and external speed % command

If not running external speed, the tracking error is set to 0

40309 THERMO_OUT_POWER_PCT Actual Drive power in % of nominal power 40401 THERMO_SETUP_UNITTYPE Unit type:

0 = 3 Ton

1 = 4 Ton

2 = 5 Ton

40402 THERMO_SETUP_SYSTEM_CONFIGURATION System Configuration

1 = ID1 (not active)

2 = ID2 AC/HP reversible

3 = ID3 (not active)

4 = ID4 GSHP reversible

5 = ID5 (not active)

6 = ID6 AC only

40403 THERMO_SETUP_COMPRESSOR_MINIMUM_SPEED_HZ Minimum compressor speed 40404 THERMO_SETUP_COMPRESSOR_MAXIMUM_SPPED_HZ Maximum compressor speed 40405 THERMO_SETUP_DELTA_HZ_PER_SEC Allowed speed rate of change in Hz pr. s 40407 THERMO_SETUP_DELTA_TEMP Delta temperature setting for fan “Delta T” control mode 40409 THERMO_SETUP_OIL_LOSS_TRIG_TIME_SEC When running below oil return speed for more than this time,

oil return is initiated

40410 THERMO_SETUP_OIL_RETURN_SPEED_HZ Defined oil return speed 40411 THERMO_SETUP_OIL_RETURN_HOLD_TIME_SEC Hold time for running at oil return speed 40412 THERMO_SETUP_START_UP_SPEED_HZ Start up speed for system 40413 THERMO_SETUP_START_UP_HOLD_TIME_SEC Hold time for start up speed 40414 THERMO_SETUP_RESTART_TIME_SEC Minimum Time between repeated starts 40415 THERMO_SETUP_CANCEL_CENTER_HZ_1 Centre frequency #1 for speed range cancellation 40416 THERMO_SETUP_CANCEL_BANDWIDTH_HZ_1 Bandwidth #1 for speed range cancellation 40417 THERMO_SETUP_CANCEL_CENTER_HZ_2 Centre frequency #2 for speed range cancellation 40418 THERMO_SETUP_CANCEL_BANDWIDTH_HZ_2 Bandwidth #2for speed range cancellation 40419 THERMO_SETUP_CANCEL_CENTER_HZ_3 Centre frequency #3 for speed range cancellation 40420 THERMO_SETUP_CANCEL_BANDWIDTH_HZ_3 Bandwidth #3 for speed range cancellation 40421 THERMO_SETUP_CANCEL_CENTER_HZ_4 Centre frequency #4 for speed range cancellation 40422 THERMO_SETUP_CANCEL_BANDWIDTH_HZ_4 Bandwidth #4 for speed range cancellation 40423 THERMO_SETUP_CANCEL_CENTER_HZ_5 Centre frequency #5 for speed range cancellation 40424 THERMO_SETUP_CANCEL_BANDWIDTH_HZ_5 Bandwidth #5 for speed range cancellation 40425 THERMO_SETUP_PI_COMPRESSOR_AC_KP Proportional gain for AC compressor capacity controller 40427 THERMO_SETUP_PI_COMPRESSOR_AC_TN Integration time for AC compressor capacity controller 40428 THERMO_SETUP_PI_COMPRESSOR_AC_TT Tracking time constant for AC compressor capacity controller 40429 THERMO_SETUP_PI_COMPRESSOR_HP_KP Proportional gain for HP compressor capacity controller 40431 THERMO_SETUP_PI_COMPRESSOR_HP_TN Integration time for HP compressor capacity controller 40432 THERMO_SETUP_PI_COMPRESSOR_HP_TT Tracking time constant for HP compressor capacity controller 41609 OUTDOOR_FAN_CAPACITY_PCT_MIN Minimum duty cycle that will be output by the fan controller 41611 OUTDOOR_FAN_CAPACITY_PCT_MAX Maximum duty cycle that will be output by the fan controller 41613 OUTDOOR_FAN_CONTROL_SIGNAL_FREQUENCY Set frequency of the condenser fan PWM signal 40479 THERMO_SETUP_CRANK_CASE_HEATING_ON_TEMP Ambient temperature where crankcase heating is activated

Table 6.2 Thermo Controller Register Overview (Node 162)

MG10V402 - VLT® is a registered Danfoss trademark 43

Fault Conditions, Messages ...

VLT® Inverter Scroll CDS 801 Operating Instructions

7 Fault Conditions, Messages and Causes

The variable speed drive is featuring Modbus registers reflecting the exact operating conditions of the system:

Normal Operation Status (reg. 40121 and 40122),

•

the system operates without limitations. Derating Status (reg. 40123 and 40124), the

•

system cannot operate at the quested capacity. Safe Mode Status (reg. 40125 and 40126), the

•

system has encountered a condition that has made operation unsafe, e.g. loss of communication with the EEV controller or a sensor signal. In Safe Mode, the drive is running a constant speed of 2400 RPM until the problem is resolved

The statuses are expressed by individual sticky bits, which are set logic “1” as long as the particular status is present, see the following detailed explanations.

Normal Status (reg. 40121 and 40122): Bit 0, Compressor Running Whenever the compressor is running, this bit will be set. This is independent of control mode, speed or other operation conditions.

Bit 3, Crankcase heating The crankcase heater is active; the drive injects a DC voltage into the compressor motor.

Bit 4, Control Start-up The system is performing a start-up sequence, e.g. for proper oil distribution and is not (yet) following the required speed reference. During start-up, the compressor runs at 2400 RPM for 60 s and then returns to the requested speed.

Bit 5, Control Oil Return The system has been running at less than 2400 RPM for 30 minutes and is automatically performing an oil return sequence. The thermo controller will ignore the requested reference and runs the compressor at 2400 RPM for 60 s to distribute oil in the system and then returns to normal operation.

and then automatically resumes normal operation.

Alarm Status (Fault) (reg. 40127 and 40128), the

•

system has encountered a severe exceptional condition and the compressor has been stopped. The alarm bit remains logic “one” for at least 120 s and the system will afterwards attempt to return to normal operation when the bit becomes logic “zero”. In some cases (see individual alarms), the drive goes into a trip lock condition. To restart the system, it is necessary to cycle power to the drive or perform a reboot (register 40135). A reset alone does not clear this condition!

Bit 6, Restart time When the compressor is stopped, but system still powered on, the restart timer is activated. The restart timer will not allow the compressor to restart before 60 s after it was stopped.

Bit 28, Derating Active The system is in a derating condition, read the Derating Status register for more information.

Bit 29, Safe Mode Active The system is in a Safe Mode condition, read the Safe Mode Status register for more information.

Bit 30, Alarm Active The system is in an Alarm condition, read the Alarm Status register for more information.

Bit 31, Alarm Trip Lock Active The system is in an Alarm Trip Lock condition, read the Alarm Status register for more information.

Derating status (reg. 40123 and 40124): Bit 0, Derating - Drive Temperature High The temperature measured in the drive’s power electronics has reached a critical level and the drive cannot maintain full capacity output. Therefore the drive slows the compressor down until the temperature is no longer critical. When temperatures have normalized the drive attempts to return to normal operation.

Bit 2, Derating - Suction Pressure Low The suction pressure (P0) has reached a critical low value. To make the suction pressure recover, the drive has slowed down the compressor. When the pressure has normalized the drive will attempt to return to normal operation.

Bit 4, Derating - Condenser Pressure Low The condenser pressure (Pc) has reached a critical low value. To increase the condenser pressure, the drive has slowed down the condenser fan speed. When the pressure has normalized the drive will attempt to return to normal operation. This function is only available in AC mode and system configurations with condenser fan control.

Bit 5, Derating - Condenser Pressure High The condenser pressure (Pc) has reached a critical high value. To decrease the condenser pressure, the drive has slowed down the compressor. When the pressure has normalized the drive will attempt to return to normal operation.

Bit 6, Derating – Output Power Limit The supply voltage has dropped below 208 V or an extreme operating condition, e.g. high condensing pressure has activated the derating function limiting the output power of the drive. The drive returns to normal operation when the supply voltage has recovered or operating conditions have normalized.

44 MG10V402 - VLT® is a registered Danfoss trademark

Fault Conditions, Messages ...

VLT® Inverter Scroll CDS 801 Operating Instructions

Safe Mode Status (reg. 40125 and 40126): Bit 0, Safe Mode - EEV Indoor Failure The communication with the indoor EEV controller has been interrupted and the EEV controller has switched to autonomous mode to maintain the superheating. The bit remains logic “one” for at least 60 s after the communication is reestablished, and the system will return to normal operation when the bit becomes logic “zero”. For information about EEV autonomous mode see EEV manual.

Bit 1, Safe Mode - EEV Outdoor Failure The communication with the outdoor EEV controller has been interrupted and the EEV controller has switched to autonomous mode to maintain the superheating. The bit remains logic “one” for at least 60 s after the communication is reestablished and the system will return to normal operation when the bit becomes logic “zero”. For information about EEV autonomous mode see EEV manual.

Bit 2, Safe Mode - Ambient Temperature Invalid The reading of the ambient temperature sensor (S amb.) is not within the specified sensor range of -60 to +100 °C (-76 to +212 °F). Possible causes are faulty wiring or a defect sensor. The bit remains logic “one” for at least 60 s and the system will afterwards return to normal operation when the bit becomes logic “zero”.

Bit 3, Safe Mode - Ambient Temperature not updated 40225 - External Ambient Temperature is selected as ambient temperature source and has not been updated within the last 60 s.

Alarm Status (reg. 40127 and 40128): Bit 0, Alarm Peripherals Error More than one Safe Mode condition is present.

Bit 1, Alarm Out of Envelope The compressor has been operating outside the largest possible operation envelope for too long time (60 or 90 s depending on which envelope limit is violated). The system will restart by itself after the restart timer has elapsed (60 s). If 10 subsequent “Out of envelope” alarms occur because of a low suction pressure (P0), the drive will go into trip lock condition to prevent damage to the system.

Bit 2, Alarm - Over Current The drive has encountered an over current event and has stopped operation. An over current can be triggered by a phase loss, locked compressor rotor, an earth fault, a short circuiting or a major drive error. An Earth fault triggers an immediate trip lock, while other occurrences may happen several times to trigger a trip lock condition.

Bit 3, Alarm – DC Link Voltage High The drive has encountered an over voltage event (more than 450 V) and has stopped operation. An over voltage condition can happen due to a mains failure. 10 subsequent occurrences trigger a trip lock.

Bit 4, Alarm - Drive Temperature High The drive has encountered an over temperature condition and has stopped operation. An over temperature occurs

when the temperature measured inside the drive has reached a critical level (> 115 °C/239 °F). Possible causes are insufficient cooling due to a defect cooling fan, blocked air circulation or extreme high ambient temperature. This is an immediate trip lock condition.

Bit 5, Alarm – Supply Voltage Low The supply voltage has dropped below 180 V and the drive has stopped the compressor. When the supply voltage has recovered, the drive resumes operation with derating of the output power.

Bit 6, Alarm - Discharge Temperature High The compressor discharge temperature (Sd) has exceeded 138 °C/280 °F and the system has been stopped. When the temperature has normalized the drive will attempt to return to normal operation. 10 subsequent occurrences trigger a trip lock.

Bit 7, Alarm – Discharge Temperature Invalid The reading of the discharge temperature sensor (Sd) is not within the specified sensor range of -60 °C to +200 °C (-76 °F to +392 °F). Possible causes are faulty wiring or a defect sensor. The system will stop operation and return to normal operation, when the problem has been fixed.

Bit 8, Alarm – OEM Communication Timeout The OEM controller (thermostat) failed to read data within a given time, set in register 40148. The drive stops operating the system unless the time is set to 0 s, which disables this function. The drive automatically resumes operation when the communication has recovered and data is received from the OEM controller, though waiting 2 minutes after communication has been reestablished.

Bit 9, Alarm – MOC Safety When the motor-control-oriented micro processor safety routines have encountered a fault (error) condition, the system stops for safety reasons and goes to a trip lock condition immediately.

Bit 10, Alarm – DC Link Voltage Low The DC Link voltage in the drive has reached a critical low level and the drive has stopped operation. When the DC link voltage has recovered, the drive resumes operation.

Bit 11, Alarm – Suction Pressure Invalid The reading of the suction pressure transmitter is not within the specified sensor range of 0 to 16 bar (0 to 232 psi). Possible causes are faulty wiring or a defect transmitter. The system stops operation and returns to normal operation, when the problem has been resolved.

Bit 12, Alarm - Condenser Pressure Invalid The reading of the condenser pressure transmitter is not within the specified sensor range of 0 to 50 bar (0 to 725 psi). Possible causes are faulty wiring or a defect transmitter. The system stops operation and returns to normal operation, when the problem has been resolved.

Bit 13, Alarm – Condenser Pressure Low If the condenser pressure remains at a critical low level after the start-up sequence, the drive reports an alarm.

7 7

MG10V402 - VLT® is a registered Danfoss trademark 45

Fault Conditions, Messages ...

This alarm indicated that the system has encountered a loss of charge. If this alarm is subsequently reported 10 times the drive goes into a trip lock condition.

Bit 14, Alarm - Defrosting Timeout If the system has operated in system Defrost mode for more than 1800 s, the system stops. The drive enters a trip lock condition.

Bit 15, Alarm - Restart too frequently The amount of times that the compressor speed has been 0 Hz within 600 s is counted. When the counter reaches the count of 6, the drive enters a trip lock condition.

Bit 31, Alarm – Internal Error The drive has encountered an internal error, e.g. missing communication between the microprocessors. The drive goes immediately into a trip lock condition. It is likely that the drive will not recover from this condition!

VLT® Inverter Scroll CDS 801 Operating Instructions

When operation the system in an open loop configuration (by means sending a speed reference to the Performer VSD application controller) the temperature controller in the Modbus Master (thermostat) controller should feature an Anti-Wind-up function that is activated whenever the drive is in derating mode! In derating mode, the system cannot satisfy the requested compressor speed and the integrator of the PID-controller should be stopped until the system has returned to normal operation.

NOTE

46 MG10V402 - VLT® is a registered Danfoss trademark

Troubleshooting

8 Troubleshooting

Problem Check Yes/no Action

The system does not start

VLT® Inverter Scroll CDS 801 Operating Instructions

Is the green LED on the drive PCB lit?

Is the green LED is blinking?

Improper wiring between drive and compressor?

Does the drive respond to queries from the master controller?

Is a system status present that prevents the drive from starting? (read status register no. 40121)

No Check power supply to drive. If power is applied

properly, but the LED is not lit, there is an internal

fault in the drive. Replace the drive. Yes Power is applied. Check next issue Yes The drive indicates a problem. Read the status

phases No Check next issue No

Yes Check next issue Yes

Is the baud rate set correctly?

•

Is the parity set correctly?

•

Is the number of stop bits set correctly?

•

Are the node addresses correct? (Default: Drive

•

162 and 163, EEVs 164 and 165)

Is the cable between motor and drive properly

•

shielded?

Cycle power to the drive (remove power for at

•

least 1 minute)

Read the alarm register again and check if an

•

alarm is still present. If yes, remove alarm conditions

Supply voltage low: Check power supply

•

Over temperature: Let the system cool

•

down

Over current: Replace compressor

•

EEV indoor failure: Check wiring to

•

indoor EEV controller

EEV outdoor failure: Check wiring to

•

outdoor EEV controller

Ambient temperature invalid: Check

•

wiring and function of ambient temperature sensor

If discharge temerature invalid, check

•

wiring and function of duscharge temperature sensor

If suction pressure invalid, check wiring

•

and function of suction pressure transmitter

If condenser pressure invalid, check

•

wiring and function of condenser pressure transmitter

If internal fault, replace drive

•

8 8

Table 8.1 Troubleshooting Guide

MG10V402 - VLT® is a registered Danfoss trademark 47

Specifications

VLT® Inverter Scroll CDS 801 Operating Instructions

9 Specifications

Supply Rated supply voltage 208-230/240 V (L1, L2) (min 180 V, max 264 V) Mains frequency 50/60 Hz, single phase Rated load amperage (RLA) (208 V): 22A, 13 kW/3 t unit

28A, 16 kW/4 t unit 33A, 20 kW/5 t unit

Power Factor @230 V, full load > 0.98 (98%) THiD < 22% THvD < 3% (at typical mains impedance) Earth leakage current (drive and compressor) <10 mA Stand-by power consumption 5W

Input power (at 208 V) 13 kW/3 ton unit 4.5 kW 16 kW/4 ton unit 5.6 kW 20 kW/5 ton unit 6.7 kW

Cable length The maximum allowable cable length between drive and compressor is 7 ft/2 m Analog inputs (sensor inputs)

Temperature Pt 1000 sensor (AKS11) Pressure Ratio metric input 0.5-4.5 V, input resistance 10 kΩ (AKS32)

Digital output (condenser fan motor control), EXT_FAN: PWM signal speed reference, duty cycle 15-100% speed.

Reversing valve relay, RLY_1: NC/NO 3-pole relay, max. terminal load 250 V AC/24 V DC, 4 A

EEV Controller output (outdoor unit), EEV_2: Internal power supply 24 V DC with ground RS-485 serial interface (Modbus)

RS-485 serial communication interface, MASTER and EEV_1: According to Electronics Industry Association (EIA) standard.

Minimum power cycling time The variable speed drive is equipped with an inrush circuit, limiting the starting (inrush) current when the system is powered up.

CAUTION

Frequent cycling of power to the drive can damage the drive! Wait at least 5 minutes between cycles (connecting and disconnecting power to the drive). The OEM must place an equivalent notice on the unit!

Internal cooling fan High performance variable speed cooling fan, supply voltage 16 V. Nominal operating point 74 CFM (126 m3/h) @ 89Pa static pressure.

48 MG10V402 - VLT® is a registered Danfoss trademark

Specifications

VLT® Inverter Scroll CDS 801 Operating Instructions

Environment

Enclosure The enclosure type of the variable speed drive is open chassis (IP00, no NEMA rating, according to NEMA 250-2003)

Storage conditions Minimum storage temperature -35 °F/-30 °C Maximum storage temperature 140 °F/60 °C Maximum storage humidity 95% rH, non condensing

Operating temperature Maximum temperature at cooling fan inlet 125 °F/52 °C (for full capacity) Maximum temperature at cooling fan inlet 138 °F/60 °C (with capacity derating) Minimum ambient temperature -13 °F/-25 °C

Humidity According to IEC 60721-3-3, class 3K4, 95% rH

Altitude The max. operation altitude (referring to the ambient barometric pressure) is 6000 ft/2000 m

Corrosion The variable speed drive has been designed to comply with corrosion standard ASTM B117

Pollution The variable speed drive has been designed to comply with IEC 61800-1, IEC 61800-2, IEC 61800-4 and 61800-5-1. Pollution degree 2

Vibration IEC 60068-2-6, 2007, environmental testing - Part 2-6: Tests - Test Fc: Vibration (sinusoidal) IEC 60068-2-64, 1993, test Fh: vibration, broad-band Random (digital control) and guidance IEC 60605 series, equipment reliability testing Test level: Short term testing: 1.14 g RMS. Long term testing : 0.99 g RMS.

Bump

Level 40 g, half-sinusoidal Duration 10 ms No. of pulses 500 in each direction (x-y-z)

- of these, 250 along the positive direction, 250 along the negative direction. Total: 1500 pulses.

9 9

Table 9.1 Bump Specifications

Shock

Level 200 g, half-sinusoidal Duration 1 ms No. of pulses 6 in each direction (x-y-z)

- of these, 3 along the positive direction, 3 along the negative direction. Total: 18 pulses.

Table 9.2 Shock Specifications

Immunity In accordance with frequency converter standard IEC 61800-3

Harmonics IEC 61000-3-12 and IEEE 519-1992

EMC EN 55011 class A and EN 55014 (with ferrite)

MG10V402 - VLT® is a registered Danfoss trademark 49

Special Operating Condition...

VLT® Inverter Scroll CDS 801 Operating Instructions

10 Special Operating Conditions

Derating at high ambient temperature/insufficient cooling The drive is featuring an automatic derating function that is activated when the internal temperature measured in the drive reaches a certain threshold. This temperature is not necessarily directly related to the ambient temperature. In such case, the drive reduces the speed of the compressor to reduce heat losses in the drive. If the overtemperature does not clear, the drive eventually will stop and report a fault condition. Possible causes could also be a malfunction of the cooling fan or blocked airflow (leaves). See also 11 Maintenance.

Derating at high installation altitude/low air pressure In case of installing the drive in an altitude greater than 2000 m/6000 ft. cooling may become insufficient, if the ambient temperature is at maximum at the same time (a very unlikely coincidence).

Derating under unusual refrigeration process conditions See Operating Instructions for the application controller.

50 MG10V402 - VLT® is a registered Danfoss trademark

175ZB058.11

175ZB035.11

Maintenance

VLT® Inverter Scroll CDS 801 Operating Instructions

11 Maintenance

The Danfoss variable speed drive is maintenance-free over its entire lifetime, except the internal cooling fan, that eventually must be replaced depending on operation hours and conditions. When an over-temperature alarm occurs (see 7 Fault Conditions, Messages and Causes), a possible cause could be a worn out or excessively contaminated cooling fan that does not provide sufficient air flow across the heat sink. If so, the fan must be replaced with an original spare part.

11.1 Replacement of Internal Cooling Fan

NOTE

Disconnect power to the variable speed drive and wait for 5 minutes before commencing maintenance! The fan is connected to high potential!

1. Carefully unplug the supply cable by lifting the lock and retracting the plug (do not pull the cable to retract the plug), see Illustration 11.2.

2. Lift the flat on the air duct to unlock the fan and remove the fan (no tools required - see Illustration 11.1).

3. Insert the plug of the new fan, make sure the plug is locked.

4. Insert the new fan and click it onto the air duct.

5. Check that the fan runs properly after reconnecting power and resuming operation.

Illustration 11.1 Unlock and Remove the Fan

Illustration 11.2 Unplug the Supply Cable

11.2 Cleaning

It is recommended to periodically check the drive and especially the cooling fan for contamination with dust, debris (i.e. leaves), insects etc.

NOTE

Do NOT use a water hose, high-pressure cleaner or compressed air for cleaning purposes! Using a water hose, high-pressure cleaner or compressed air for cleaning, can damage the drive.

To clean the inlet grid, use a soft cloth or brush to wipe of dust and dirt. Check proper function after cleaning.

MG10V402 - VLT® is a registered Danfoss trademark 51

Service and Spare Parts

VLT® Inverter Scroll CDS 801 Operating Instructions

12 Service and Spare Parts

Service policy The Danfoss variable speed drive is not field repairable. In case of malfunction or damage (i.e. caused by lightning), the entire drive must be replaced with an original spare part.

WARNING

ELECTRICAL HAZARD

Disconnect power and wait at least 4 minutes to discharge the DC-link capacitors before conducting service. Failure to disconnecting power and observing the waiting time can result in personal injury or death.

Spare part list

Replacement drive 13 kW/3 t unit 176L0767 Replacement drive 16 kW/4 t unit 176L0766 Replacement drive 20 kW/5 t unit 176L0765 Internal cooling fan all sizes (176L0767/176L0766/176L0765) 176L7003

1212

52 MG10V402 - VLT® is a registered Danfoss trademark

Index

VLT® Inverter Scroll CDS 801 Operating Instructions

Index

Altitude..................................................................................................... 49

Ampacity.................................................................................................. 13

Cleaning................................................................................................... 51

Clearances................................................................................................. 9

Compression Clamp............................................................................ 19

Condensation........................................................................................ 12

Connector................................................................................................ 20

Cooling..................................................................................................... 10

Corrosion................................................................................................. 49

Crankcase Heating............................................................................... 29

Disposal Instruction............................................................................... 5

Dripping Water...................................................................................... 12

Wiring Diagram..................................................................................... 22

Electrostatic Discharge......................................................................... 5

Enclosure................................................................................................. 49

Humidity.................................................................................................. 49

Identification Label................................................................................ 5

Input Power............................................................................................ 48

Mains Cables.......................................................................................... 16

Modicon................................................................................................... 25

Motor Cable............................................................................................ 15

Over-current Protected...................................................................... 13

Pollution................................................................................................... 49

Power Factor.......................................................................................... 48

Shielded Cable....................................................................................... 13

MG10V402 - VLT® is a registered Danfoss trademark 53

*MG10V402*

130R0194 MG10V402 Rev. 2013-02-08

Danfoss CDS 801 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual