Danfoss FC 101 Design guide

ENGINEERING TOMORROW

Design Guide

VLT® HVAC Basic Drive FC 101

vlt-drives.danfoss.com

Contents Design Guide

Contents

1 Introduction

1.1 Purpose of the Design Guide

1.2 Document and Software Version

1.3 Safety Symbols

1.4 Abbreviations

1.5 Additional Resources

1.6 Denitions

1.7 Power Factor

1.8 Regulatory Compliance

1.8.1 CE Mark 10

1.8.2 UL Compliance 10

1.8.3 RCM Mark Compliance 10

1.8.4 EAC 11

1.8.5 UkrSEPRO 11

2 Safety

2.1 Qualied Personnel

2.2 Safety Precautions

3 Product Overview

3.1 Advantages

3.1.1 Why use a Frequency Converter for Controlling Fans and Pumps? 14

3.1.2 The Clear Advantage - Energy Savings 14

3.1.3 Example of Energy Savings 14

3.1.4 Comparison of Energy Savings 15

3.1.5 Example with Varying Flow over 1 Year 16

3.1.6 Better Control 16

3.1.7 Star/Delta Starter or Soft Starter not Required 17

3.1.8 Using a Frequency Converter Saves Money 17

3.1.9 Without a Frequency Converter 18

3.1.10 With a Frequency Converter 19

3.1.11 Application Examples 19

3.1.12 Variable Air Volume 19

3.1.13 The VLT Solution 20

3.1.14 Constant Air Volume 21

3.1.15 The VLT Solution 21

3.1.16 Cooling Tower Fan 22

3.1.17 The VLT Solution 22

3.1.18 Condenser Pumps 23

3.1.19 The VLT Solution 23

Contents

VLT® HVAC Basic Drive FC 101

3.1.20 Primary Pumps 24

3.1.21 The VLT Solution 24

3.1.22 Secondary Pumps 26

3.1.23 The VLT Solution 26

3.2 Control Structures

3.2.1 Control Structure Open Loop 27

3.2.2 PM/EC+ Motor Control 27

3.2.3 Local (Hand On) and Remote (Auto On) Control 27

3.2.4 Control Structure Closed Loop 28

3.2.5 Feedback Conversion 28

3.2.6 Reference Handling 29

3.2.7 Tuning the Drive Closed-loop Controller 30

3.2.8 Manual PI Adjustment 30

3.3 Ambient Running Conditions

3.4 General Aspects of EMC

3.4.1 Overview of EMC Emissions 36

3.4.2 Emission Requirements 38

3.4.3 EMC Emission Test Results 39

3.4.4 Overview of Harmonics Emission 41

3.4.5 Harmonics Emission Requirements 41

3.4.6 Harmonics Test Results (Emission) 41

3.4.7 Immunity Requirements 43

3.5 Galvanic Isolation (PELV)

3.6 Earth Leakage Current

3.7 Extreme Running Conditions

3.7.1 Motor Thermal Protection (ETR) 44

3.7.2 Thermistor Inputs 45

4 Selection and Ordering

4.1 Type Code

4.2 Options and Accessories

4.2.1 Local Control Panel (LCP) 48

4.2.2 Mounting of LCP in Panel Front 48

4.2.3 IP21/NEMA Type 1 Enclosure Kit 49

4.2.4 Decoupling Plate 51

4.3 Ordering Numbers

4.3.1 Options and Accessories 51

4.3.2 Harmonic Filters 52

4.3.3 External RFI Filter 54

5 Installation

Contents Design Guide

5.1 Electrical Installation

5.1.1 Mains and Motor Connection 57

5.1.2 EMC-compliant Electrical Installation 62

5.1.3 Control Terminals 64

6 Programming

6.1 Introduction

6.2 Local Control Panel (LCP)

6.3 Menus

6.3.1 Status Menu 66

6.3.2 Quick Menu 66

6.3.3 Main Menu 80

6.4 Quick Transfer of Parameter Settings between Multiple Frequency Converters

6.5 Readout and Programming of Indexed Parameters

6.6 Initialization to Default Settings

7 RS485 Installation and Set-up

7.1 RS485

7.1.1 Overview 82

7.1.2 Network Connection 82

7.1.3 Frequency Converter Hardware Set-up 82

7.1.4 Parameter Settings for Modbus Communication 83

7.1.5 EMC Precautions 83

7.2 FC Protocol

7.2.1 Overview 84

7.2.2 FC with Modbus RTU 84

7.3 Parameter Settings to Enable the Protocol

7.4 FC Protocol Message Framing Structure

7.4.1 Content of a Character (Byte) 84

7.4.2 Telegram Structure 84

7.4.3 Telegram Length (LGE) 85

7.4.4 Frequency Converter Address (ADR) 85

7.4.5 Data Control Byte (BCC) 85

7.4.6 The Data Field 85

7.4.7 The PKE Field 85

7.4.8 Parameter Number (PNU) 86

7.4.9 Index (IND) 86

7.4.10 Parameter Value (PWE) 86

7.4.11 Data Types Supported by the Frequency Converter 87

7.4.12 Conversion 87

7.4.13 Process Words (PCD) 87

Contents

VLT® HVAC Basic Drive FC 101

7.5 Examples

7.5.1 Writing a Parameter Value 87

7.5.2 Reading a Parameter Value 88

7.6 Modbus RTU Overview

7.6.1 Introduction 88

7.6.2 Overview 88

7.6.3 Frequency Converter with Modbus RTU 89

7.7 Network Conguration

7.8 Modbus RTU Message Framing Structure

7.8.1 Introduction 89

7.8.2 Modbus RTU Telegram Structure 89

7.8.3 Start/Stop Field 90

7.8.4 Address Field 90

7.8.5 Function Field 90

7.8.6 Data Field 90

7.8.7 CRC Check Field 90

7.8.8 Coil Register Addressing 90

7.8.9 Access via PCD write/read 92

7.8.10 How to Control the Frequency Converter 93

7.8.11 Function Codes Supported by Modbus RTU 93

7.8.12 Modbus Exception Codes 93

7.9 How to Access Parameters

7.9.1 Parameter Handling 94

7.9.2 Storage of Data 94

7.9.3 IND (Index) 94

7.9.4 Text Blocks 94

7.9.5 Conversion Factor 94

7.9.6 Parameter Values 94

7.10 Examples

7.10.1 Read Coil Status (01 hex) 94

7.10.2 Force/Write Single Coil (05 hex) 95

7.10.3 Force/Write Multiple Coils (0F hex) 95

7.10.4 Read Holding Registers (03 hex) 96

7.10.5 Preset Single Register (06 hex) 96

7.10.6 Preset Multiple Registers (10 hex) 97

7.10.7 Read/Write Multiple Registers (17 hex) 97

7.11 Danfoss FC Control Prole

7.11.1 Control Word According to FC Prole (8-10 Protocol = FC Prole) 98

7.11.2 Status Word According to FC Prole (STW) 99

7.11.3 Bus Speed Reference Value 101

Contents Design Guide

8 General Specications

8.1 Mechanical Dimensions

8.1.1 Side-by-side Installation 102

8.1.2 Frequency Converter Dimensions 103

8.1.3 Shipping Dimensions 105

8.1.4 Field Mounting 106

8.2 Mains Supply Specications

8.2.1 3x200–240 V AC 107

8.2.2 3x380–480 V AC 108

8.2.3 3x525–600 V AC 112

8.3 Fuses and Circuit Breakers

8.4 General Technical Data

8.4.1 Mains Supply (L1, L2, L3) 115

8.4.2 Motor Output (U, V, W) 115

8.4.3 Cable Length and Cross-section 116

8.4.4 Digital Inputs 116

8.4.5 Analog Inputs 116

102

107

113

115

Index

8.4.6 Analog Output 116

8.4.7 Digital Output 117

8.4.8 Control Card, RS485 Serial Communication 117

8.4.9 Control Card, 24 V DC Output 117

8.4.10 Relay Output 117

8.4.11 Control Card, 10 V DC Output 118

8.4.12 Ambient Conditions 118

8.5 dU/Dt

119

122

Introduction

VLT® HVAC Basic Drive FC 101

1 Introduction

1.1 Purpose of the Design Guide

This design guide is intended for project and systems engineers, design consultants, and application and product specialists. Technical information is provided to understand the capabilities of the frequency converter for integration into motor control and monitoring systems. Details concerning operation, requirements, and recommendations for system integration are described. Information is proved for input power characteristics, output for motor control, and ambient operating conditions for the frequency converter.

Also included are:

Safety features.

•

Fault condition monitoring.

•

Operational status reporting.

•

Serial communication capabilities.

•

Programmable options and features.

•

Also provided are design details such as:

Site requirements.

•

Cables.

•

Fuses.

•

Control wiring.

•

Unit sizes and weights.

•

Other critical information necessary to plan for

•

system integration.

Reviewing the detailed product information in the design stage enables developing a well-conceived system with optimal functionality and

eciency.

with regards to backwards compatibility for H1–H5 and I2– I4 enclosure sizes. Refer to Table 1.2 for the limitations.

Software

compatibility

Old software

(OSS-le version 3.xx

and below)

New software

(OSS-le version 4.xx

or higher)

Hardware

compatibility

Old power card

(production week 33

2017 or before)

New power card

(production week 34

2017 or after)

Table 1.2 Software and Hardware Compatibility

Safety Symbols

1.3

The following symbols are used in this guide:

Old control card

(production week

33 2017 or before)

Yes No

No Yes

Old control card

(production week

33 2017 or before)

Yes (only software

version 3.xx or

below)

Yes (MUST update

software to version

3.xx or below, the

fan continuously

runs at full speed)

New control card

(production week

34 2017 or after)

New control card

(production week

34 2017 or after)

Yes (MUST update

software to version

4.xx or higher)

Yes (only software

version 4.xx or

higher)

WARNING

Indicates a potentially hazardous situation that could result in death or serious injury.

VLT® is a registered trademark.

Document and Software Version

1.2

This manual is regularly reviewed and updated. All suggestions for improvement are welcome.

CAUTION

Indicates a potentially hazardous situation that could result in minor or moderate injury. It can also be used to alert against unsafe practices.

NOTICE

Edition Remarks Software version

MG18C8xx Update to new SW & HW version. 4.2x

Table 1.1 Document and Software Version

From software version 4.0x and later (production week 33 2017 and after), the variable speed heat sink cooling fan function is implemented in the frequency converter for power sizes 22 kW (30 hp) 400 V IP20 and below, and 18.5 kW (25 hp) 400 V IP54 and below. This function requires software and hardware updates and introduces restrictions

Indicates important information, including situations that can result in damage to equipment or property.

Introduction Design Guide

1.4 Abbreviations

°C

°F

A Ampere/AMP

AC Alternating current

AMA Automatic motor adaptation

AWG American wire gauge

DC Direct current

EMC Electro magnetic compatibility

ETR Electronic thermal relay

FC Frequency converter

M,N

kg Kilogram

Hz Hertz

INV

LIM

M,N

VLT,MAX

VLT,N

kHz Kilohertz

LCP Local control panel

m Meter

mA Milliampere

MCT Motion control tool

mH Millihenry inductance

min Minute

ms Millisecond

nF Nanofarad

Nm Newton meters

M,N

PCB Printed circuit board

PELV Protective extra low voltage

Regen Regenerative terminals

RPM Revolutions per minute

s Second

LIM

M,N

V Volts

Table 1.3 Abbreviations

Additional Resources

1.5

VLT® HVAC Basic Drive FC 101 Quick Guide provides

•

basic information on mechanical dimensions, installation, and programming.

VLT® HVAC Basic Drive FC 101 Programming Guide

•

provides information on how to program, and includes complete parameter descriptions.

Danfoss VLT® Energy Box software. Select PC

•

Software Download at www.danfoss.com/en/ service-and-support/downloads/dds/vlt-energy-box/.

Degrees Celsius

Degrees Fahrenheit

Nominal motor frequency

Rated inverter output current

Current limit

Nominal motor current

The maximum output current

The rated output current supplied by the

frequency converter

Synchronous motor speed

Nominal motor power

Torque limit

Nominal motor voltage

Energy Box software allows energy

VLT consumption comparisons of HVAC fans and pumps driven by Danfoss frequency converters and alternative methods of ow control. Use this tool to accurately project the costs, savings, and payback of using Danfoss frequency converters on HVAC fans, pumps, and cooling towers.

Danfoss technical literature is available in electronic form on the documentation CD that is shipped with the product, or in print from your local Danfoss sales oce.

MCT 10 Set-up Software support

Download the software from www.danfoss.com/en/serviceand-support/downloads/dds/vlt-motion-control-tool-mct-10/.

During the installation process of the software, enter access code 81463800 to activate the FC 101 functionality. A license key is not required for using the FC 101 functionality.

The latest software does not always contain the latest updates for frequency converters. Contact the local sales oce for the latest frequency converter updates (in the form of *.upd les), or download the frequency converter updates from www.danfoss.com/en/service-and-support/ downloads/dds/vlt-motion-control-tool-mct-10/#Overview.

Denitions

1.6

Frequency converter I

VLT, MAX

The maximum output current.

VLT,N

The rated output current supplied by the frequency converter.

VLT, MAX

The maximum output voltage.

Input

The connected motor can start and stop via LCP and digital inputs. Functions are divided into 2 groups, as described in Table 1.4. Functions in group 1 have higher priority than functions in group 2.

Group 1

Group 2

Table 1.4 Control Commands

Reset, coast stop, reset and coast stop, quick

stop, DC brake, stop, and [O].

Start, pulse start, reversing, start reversing, jog,

and freeze output.

Motor f

JOG

The motor frequency when the jog function is activated (via digital terminals).

The motor frequency.

MAX

The maximum motor frequency.

1 1

175ZA078.10

Pull-out

RPM

Torque

Introduction

VLT® HVAC Basic Drive FC 101

MIN

The minimum motor frequency.

M,N

The rated motor frequency (nameplate data).

The motor current.

M,N

The rated motor current (nameplate data).

M,N

The nominal motor speed (nameplate data).

M,N

The rated motor power (nameplate data).

The instantaneous motor voltage.

M,N

The rated motor voltage (nameplate data).

Break-away torque

Preset reference

A dened preset reference to be set from -100% to +100% of the reference range. Selection of 8 preset references via the digital terminals.

Ref

MAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20 mA) and the resulting reference. The maximum reference value set in parameter 3-03 Maximum Reference.

Ref

MIN

Determines the relationship between the reference input at 0% value (typically 0 V, 0 mA, 4 mA) and the resulting reference. The minimum reference value is set in parameter 3-02 Minimum Reference.

Analog inputs

The analog inputs are used for controlling various functions of the frequency converter. There are 2 types of analog inputs:

Current input: 0–20 mA and 4–20 mA

•

Voltage input: 0–10 V DC

•

Analog outputs

The analog outputs can supply a signal of 0–20 mA, 4– 20 mA, or a digital signal.

Automatic motor adaptation, AMA

The AMA algorithm determines the electrical parameters for the connected motor at standstill and compensates for the resistance based on the length of the motor cable.

Digital inputs

The digital inputs can be used for controlling various functions of the frequency converter.

Digital outputs

Illustration 1.1 Break-away Torque

The frequency converter provides 2 solid-state outputs that can supply a 24 V DC (maximum 40 mA) signal.

Relay outputs

VLT

The eciency of the frequency converter is dened as the ratio between the power output and the power input.

Start-disable command

A stop command belonging to the group 1 control commands, see Table 1.4.

Stop command

See Table 1.4.

Analog reference

A signal transmitted to the analog inputs 53 or 54. It can be voltage or current.

•

Current input: 0–20 mA and 4–20 mA

Voltage input: 0–10 V DC

Bus reference

A signal transmitted to the serial communication port (FC port).

The frequency converter provides 2 programmable relay outputs.

ETR

Electronic thermal relay is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature and prevent overheating of the motor.

Initializing

If initializing is carried out (parameter 14-22 Operation Mode), the programmable parameters of the frequency

converter return to their default settings. Parameter 14-22 Operation Mode does not initialize communication parameters, fault log, or re mode log.

Intermittent duty cycle

An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an o-load period. The operation can be either periodic duty or noneperiodic duty.

Introduction Design Guide

LCP

The local control panel (LCP) makes up a complete interface for control and programming of the frequency converter. The control panel is detachable on IP20 units and xed on IP54 units. It can be installed up to 3 m (9.8 ft) from the frequency converter, that is, in a front panel with the installation kit option.

Lsb

Least signicant bit.

MCM

Short for mille circular mil, an American measuring unit for cable cross-section. 1 MCM = 0.5067 mm2.

Msb

Most signicant bit.

On-line/O-line parameters

Changes to on-line parameters are activated immediately after the data value is changed. Press [OK] to activate o- line parameters.

PI controller

The PI controller maintains the desired speed, pressure, temperature, and so on, by adjusting the output frequency to match the varying load.

RCD

Residual current device.

Set-up

Parameter settings in 2 set-ups can be saved. Change between the 2 parameter set-ups and edit 1 set-up, while another set-up is active.

Slip compensation

The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor speed almost constant.

Smart logic control (SLC)

The SLC is a sequence of user-dened actions executed when the associated user-dened events are evaluated as true by the SLC.

Thermistor

A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).

Trip

A state entered in fault situations, for example, if the frequency converter is subject to an overtemperature or when the frequency converter is protecting the motor, process, or mechanism. Restart is prevented until the cause of the fault does not exist and the trip state is canceled by activating reset or, sometimes, by being programmed to reset automatically. Do not use trip for personal safety.

Trip lock

A state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention, for example, if the frequency converter is subject to a short circuit on the output. A locked trip can only be canceled by cutting o mains, removing the cause of the fault, and reconnecting the frequency converter. Restart is prevented until the trip state is canceled by activating reset or, sometimes, by being programmed to reset automatically. Do not use trip lock for personal safety.

VT characteristics

Variable torque characteristics used for pumps and fans.

VVC

If compared with standard voltage/frequency ratio control, voltage vector control (VVC+) improves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque.

Power Factor

1.7

The power factor indicates to which extent the frequency converter imposes a load on the mains supply. The power factor is the ratio between I1 and I fundamental current, and I

RMS

, where I1 is the

RMS

is the total RMS current including harmonic currents. The lower the power factor, the higher the I

Powerfactor =

for the same kW performance.

RMS

3 × U × I1× cosϕ

3 × U × I

RMS

The power factor for 3-phase control:

Power factor =

= I

 + I

RMS

I1 × cosϕ1

RMS

 + I

 +  .  .  + I

sincecosϕ1 = 1

RMS

A high-power factor indicates that the dierent harmonic currents are low. The frequency converters built-in DC coils produce a highpower factor, which minimizes the imposed load on the mains supply.

1 1

Introduction

VLT® HVAC Basic Drive FC 101

1.8 Regulatory Compliance

Frequency converters are designed in compliance with the directives described in this section.

1.8.1 CE Mark

The CE mark (Communauté Européenne) indicates that the product manufacturer conforms to all applicable EU directives. The EU directives applicable to the design and manufacture of frequency converters are listed in Table 1.5.

NOTICE

The CE mark does not regulate the quality of the product. Technical specications cannot be deduced from the CE mark.

CE mark, but must comply with the basic protection requirements of the EMC directive.

1.8.1.3 ErP Directive

The ErP directive is the European Ecodesign Directive for energy-related products. The directive sets ecodesign requirements for energy-related products, including frequency converters. The directive aims at increasing energy eciency and the level of protection of the environment, while increasing the security of the energy supply. Environmental impact of energy-related products includes energy consumption throughout the entire product life cycle.

1.8.2 UL Compliance

UL-listed

NOTICE

Frequency converters with an integrated safety function must comply with the machinery directive.

EU directive Version

Low Voltage Directive 2014/35/EU

EMC Directive 2014/30/EU

ErP Directive

Illustration 1.2 UL

NOTICE

IP54 units are not certied for UL.

Table 1.5 EU Directives Applicable to Frequency Converters

Declarations of conformity are available on request.

1.8.1.1 Low Voltage Directive

The low voltage directive applies to all electrical equipment in the 50–1000 V AC and the 75–1600 V DC voltage ranges.

The aim of the directive is to ensure personal safety and avoid property damage, when operating electrical equipment that is installed and maintained correctly in its intended application.

1.8.1.2 EMC Directive

The purpose of the EMC (electromagnetic compatibility) directive is to reduce electromagnetic interference and enhance immunity of electrical equipment and installations. The basic protection requirement of the EMC Directive 2014/30/EU states that devices that generate electromagnetic interference (EMI), or whose operation could be aected by EMI, must be designed to limit the generation of electromagnetic interference and shall have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

Electrical equipment devices used alone or as part of a system must bear the CE mark. Systems do not require the

The frequency converter complies with UL 508C thermal memory retention requirements. For more information, refer to the section Motor Thermal Protection in the product-specic design guide.

1.8.3 RCM Mark Compliance

Illustration 1.3 RCM Mark

The RCM Mark label indicates compliance with the applicable technical standards for Electromagnetic Compatibility (EMC). An RCM Mark label is required for placing electrical and electronic devices on the market in Australia and New Zealand. The RCM Mark regulatory arrangements only deal with conducted and radiated emission. For frequency converters, the emission limits specied in EN/IEC 61800-3 apply. A declaration of conformity can be provided on request.

089

Introduction Design Guide

1.8.4 EAC

Illustration 1.4 EAC Mark

The EurAsian Conformity (EAC) mark indicates that the product conforms to all requirements and technical regulations applicable to the product per the EurAsian Customs Union, which is composed of the member states of the EurAsian Economic Union.

The EAC logo must be both on the product label and on the packaging label. All products used within the EAC area, must be bought at Danfoss inside the EAC area.

1.8.5 UkrSEPRO

Illustration 1.5 UkrSEPRO

1 1

UKrSEPRO certicate ensures quality and safety of both products and services, in addition to manufacturing stability according to Ukrainian regulatory standards. The UkrSepro certicate is a required document to clear customs for any products coming into and out of the territory of Ukraine.

Safety

VLT® HVAC Basic Drive FC 101

2 Safety

2.1 Qualied Personnel

Correct and reliable transport, storage, installation, operation, and maintenance are required for the troublefree and safe operation of the frequency converter. Only qualied personnel are allowed to install or operate this equipment.

Qualied personnel are dened as trained sta, who are authorized to install, commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Also, the personnel must be familiar with the instructions and safety measures described in this guide.

2.2 Safety Precautions

WARNING

HIGH VOLTAGE

Frequency converters contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation, start-up, and maintenance by qualied personnel can result in death or serious injury.

Only qualied personnel must perform instal-

•

lation, start-up, and maintenance.

Before performing any service or repair work,

•

use an appropriate voltage measuring device to make sure that there is no remaining voltage on the frequency converter.

WARNING

UNINTENDED START

When the drive is connected to AC mains, DC supply, or load sharing, the motor can start at any time. Unintended start during programming, service, or repair work can result in death, serious injury, or property damage. The motor can start with an external switch, a eldbus command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up Software, or after a cleared fault condition.

To prevent unintended motor start:

Press [O/Reset] on the LCP before

•

programming parameters.

Disconnect the drive from the mains.

•

Completely wire and assemble the drive, motor,

•

and any driven equipment before connecting the drive to AC mains, DC supply, or load sharing.

WARNING

DISCHARGE TIME

The frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not powered. High voltage can be present even when the warning LED indicator lights are o. Failure to wait the specied time after power has been removed before performing service or repair work can result in death or serious injury.

Stop the motor.

•

Disconnect AC mains and remote DC-link power

•

supplies, including battery back-ups, UPS, and DC-link connections to other frequency converters.

Disconnect or lock PM motor.

•

Wait for the capacitors to discharge fully. The

•

minimum duration of waiting time is specied in Table 2.1.

Before performing any service or repair work,

•

use an appropriate voltage measuring device to make sure that the capacitors are fully discharged.

Voltage [V] Power range [kW (hp)] Minimum waiting time

(minutes)

3x200 0.25–3.7 (0.33–5) 4

3x200 5.5–11 (7–15) 15

3x400 0.37–7.5 (0.5–10) 4

3x400 11–90 (15–125) 15

3x600 2.2–7.5 (3–10) 4

3x600 11–90 (15–125) 15

Table 2.1 Discharge Time

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the frequency converter properly can result in death or serious injury.

Ensure the correct grounding of the equipment

•

by a certied electrical installer.

Safety Design Guide

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

Ensure that only trained and qualied personnel

•

perform installation, start-up, and maintenance.

Ensure that electrical work conforms to national

•

and local electrical codes.

Follow the procedures in this manual.

•

CAUTION

INTERNAL FAILURE HAZARD

An internal failure in the frequency converter can result in serious injury when the frequency converter is not properly closed.

Ensure that all safety covers are in place and

•

securely fastened before applying power.

2 2

130BA780.11

SYSTEM CURVE

FAN CURVE

PRESSURE %

100

120

20 40 60 80 100 120 140 160 180

VOLUME %

120

100

20 40 60 80 100 120 140 160 180

120

100

0 20 40 60 80 100 120 140 160 180

Volume %

INPUT POWER % PRESSURE %

SYSTEM CURVE

FAN CURVE

130BA781.11

ENERGY CONSUMED

Product Overview

3 Product Overview

3.1 Advantages

VLT® HVAC Basic Drive FC 101

3.1.1 Why use a Frequency Converter for Controlling Fans and Pumps?

A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further information, see chapter 3.1.3 Example of Energy Savings.

3.1.2 The Clear Advantage - Energy Savings

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

Illustration 3.1 Fan Curves (A, B, and C) for Reduced Fan

Volumes

Illustration 3.2 Energy Savings with Frequency Converter

Solution

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

3.1.3 Example of Energy Savings

As shown in Illustration 3.3, the ow is controlled by changing the RPM. By reducing the speed by only 20% from the rated speed, the ow is also reduced by 20%. This is because the ow is directly proportional to the RPM. The consumption of electricity, however, is reduced by 50%. If the system in question only needs to be able to supply a ow that corresponds to 100% a few days in a year, while the average is below 80% of the rated ow for the remainder of the year, the amount of energy saved is even more than 50%.

100%

50%

25%

12,5%

50% 100%

80%

175HA208.10

Power ~n

Pressure ~n

Flow ~n

130BA782.10

Discharge damper

Less energy savings

IGV

Costlier installation

Maximum energy savings

130BA779.12

0 60 0 60 0 60

100

Discharge Damper Solution

IGV Solution

VLT Solution

Energy consumed

Input power %

Volume %

Product Overview Design Guide

Illustration 3.3 describes the dependence of ow, pressure, and power consumption on RPM.

Illustration 3.3 Laws of Proportionally

3 3

Flow: 

Pressure: 

Power:

P P

 = 

H H

 = 

Q = Flow P = Power

Q1 = Rated ow P1 = Rated power

Q2 = Reduced ow P2 = Reduced power

H = Pressure n = Speed control

H1 = Rated pressure n1 = Rated speed

H2 = Reduced pressure n2 = Reduced speed

Table 3.1 The Laws of Proportionality

3.1.4 Comparison of Energy Savings

The Danfoss frequency converter solution oers major savings compared with traditional energy saving solutions such as discharge damper solution and inlet guide vanes (IGV) solution. This is because the frequency converter is able to control fan speed according to thermal load on the system, and the frequency converter has a built-in facility that enables the frequency converter to function as a building management system, BMS.

Illustration 3.3 shows typical energy savings obtainable with 3 well-known solutions when fan volume is reduced to 60%. As the graph shows, more than 50% energy savings can be achieved in typical applications.

Illustration 3.4 The 3 Common Energy Saving Systems

Illustration 3.5 Energy Savings

Discharge dampers reduce power consumption. Inlet guide vanes oer a 40% reduction, but are expensive to install. The Danfoss frequency converter solution reduces energy consumption with more than 50% and is easy to install. It also reduces noise, mechanical stress, and wear-and-tear, and extends the life span of the entire application.

500

[h]

1000

1500

2000

200100 300

/h]

400

175HA210.11

175HA209.11

0 100 200 300 400

(mwg)

750rpm

1050rpm

1350rpm

1650rpm

(kW)

200100 300

(

m3 /h

)

(

m3 /h

)

400

750rpm

1050rpm

1350rpm

1650rpm

shaft

Product Overview

VLT® HVAC Basic Drive FC 101

3.1.5 Example with Varying Flow over 1 Year

This example is calculated based on pump characteristics obtained from a pump datasheet.

The result obtained shows energy savings of more than 50% at the given ow distribution over a year. The payback period depends on the price per kWh and the price of frequency converter. In this example, it is less than a year when compared with valves and constant speed.

Energy savings

= P

shaft

shaft output

Illustration 3.6 Flow Distribution over 1 Year

Illustration 3.7 Energy

Distri-

m3/

bution

% Hours Power

A1 - B

Valve regulation

Consump-

tion

kWh A1 - C

Frequency converter

control

Power

Consump-

tion

kWh

350 5 438 42.5 18.615 42.5 18.615

300 15 1314 38.5 50.589 29.0 38.106

250 20 1752 35.0 61.320 18.5 32.412

200 20 1752 31.5 55.188 11.5 20.148

150 20 1752 28.0 49.056 6.5 11.388

100 20 1752 23.0 40.296 3.5 6.132

100 8760 – 275.064 – 26.801

Table 3.2 Result

3.1.6 Better Control

If a frequency converter is used for controlling the ow or pressure of a system, improved control is obtained. A frequency converter can vary the speed of the fan or pump, obtaining variable control of ow and pressure. Furthermore, a frequency converter can quickly adapt the speed of the fan or pump to new ow or pressure conditions in the system. Simple control of process (ow, level, or pressure) utilizing the built-in PI control.

Full load

% Full-load current

& speed

500

100

0 12,5 25 37,5 50Hz

200

300

400

600

700

800

175HA227.10

Product Overview Design Guide

3.1.7 Star/Delta Starter or Soft Starter not Required

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

As illustrated in Illustration 3.8, a frequency converter does not consume more than rated current.

3.1.8 Using a Frequency Converter Saves Money

The example in chapter 3.1.9 Without a Frequency Converter shows that a frequency converter replaces other equipment. It is possible to calculate the cost of installing the 2 dierent systems. In the example, the 2 systems can be established at roughly the same price.

Use the VLT® Energy Box software that is introduced in chapter 1.5 Additional Resources to calculate the cost savings that can be achieved by using a frequency converter.

3 3

VLT® HVAC Basic Drive FC 101

2 Star/delta starter

3 Soft starter

4 Start directly on mains

Illustration 3.8 Start-up Current

- +

x6 x6

175HA205.12

Valve position

Starter

Fuses

supply

P.F.C

Flow

3-Port valve

Bypass

Return

Control

Supply air

V.A.V

outlets

Duct

P.F.C

Mains

Fuses

Starter

Bypass

supply

Return

valve

3-Port

Flow

Control

Valve position

Starter

Power Factor Correction

Mains

IGV

Mechanical linkage and vanes

Fan

Motor or actuator

Main B.M.S

Local D.D.C. control

Sensors PT

Pressure control signal 0/10V

Temperature control signal 0/10V

Control

Mains

Cooling section Heating section

Fan sectionInlet guide vane

Pump Pump

Product Overview

VLT® HVAC Basic Drive FC 101

3.1.9 Without a Frequency Converter

D.D.C. Direct digital control

E.M.S. Energy management system

V.A.V. Variable air volume

Sensor P Pressure

Sensor T Temperature

Illustration 3.9 Traditional Fan System

175HA206.11

Pump

Flow

Return

Supply air

V.A.V

outlets

Duct

Mains

Pump

Return

Flow

Mains

Fan

Main B.M.S

Local D.D.C. control

Sensors

Mains

Cooling section Heating section

Fan section

Pressure control 0-10V or 0/4-20mA

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

VLT

- +

VLT

x3 x3

Product Overview Design Guide

3.1.10 With a Frequency Converter

3 3

D.D.C. Direct digital control

E.M.S. Energy management system

V.A.V. Variable air volume

Sensor P Pressure

Sensor T Temperature

Illustration 3.10 Fan System Controlled by Frequency Converters

3.1.11 Application Examples

The following sections give typical examples of applications within HVAC.

3.1.12 Variable Air Volume

VAV or variable air volume systems, control both the ventilation and temperature to fulll the requirements of a building. Central VAV systems are considered to be the most energy-ecient method to air condition buildings. By designing central systems instead of distributed systems, a greater eciency can be obtained. The eciency comes from utilizing larger fans and larger chillers which have much higher eciencies than small motors and distributed air-cooled chillers. Savings are also seen from the decreased maintenance requirements.

Frequency converter

Cooling coil

Heating coil

Filter

Pressure signal

Supply fan

VAV boxes

Flow

Pressure transmitter

Return fan

130BB455.10

Product Overview

VLT® HVAC Basic Drive FC 101

3.1.13 The VLT Solution

Centrifugal devices such as fans behave according to the centrifugal laws. This means that the fans decrease the

While dampers and IGVs work to maintain a constant pressure in the ductwork, a frequency converter solution saves much more energy and reduces the complexity of the installation. Instead of creating an articial pressure

drop or causing a decrease in fan eciency, the frequency

pressure and ow they produce as their speed is reduced. Their power consumption is thereby signicantly reduced.

The PI controller of the VLT® HVAC Basic Drive FC 101 can be used to eliminate the need for additional controllers.

converter decreases the speed of the fan to provide the ow and pressure required by the system.

Illustration 3.11 Variable Air Volume

Frequency converter

Pressure signal

Cooling coil

Heating coil

Filter

Pressure transmitter

Supply fan

Return fan

Temperature signal

Temperature transmitter

130BB451.10

Product Overview Design Guide

3.1.14 Constant Air Volume

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

3.1.15 The VLT Solution

With a frequency converter, signicant energy savings can be obtained while maintaining decent control of the building. Temperature sensors or CO2 sensors can be used as feedback signals to frequency converters. Whether controlling temperature, air quality, or both, a CAV system can be controlled to operate based on actual building conditions. As the number of people in the controlled area decreases, the need for fresh air decreases. The CO2 sensor detects lower levels and decreases the supply fans speed. The return fan modulates to maintain a static pressure setpoint or

airows.

xed dierence between the supply and return

With temperature control, especially used in air conditioning systems, as the outside temperature varies as well as the number of people in the controlled zone changes, dierent cooling requirements exist. As the temperature decreases below the setpoint, the supply fan can decrease its speed. The return fan modulates to maintain a static pressure setpoint. By decreasing the air ow, energy used to heat or cool the fresh air is also reduced, adding further savings. Several features of the Danfoss HVAC dedicated frequency converter can be utilized to improve the performance of the CAV system. One concern of controlling a ventilation system is poor air quality. The programmable minimum frequency can be set to maintain a minimum amount of supply air regardless of the feedback or reference signal. The frequency converter also includes a PI controller, which allows monitoring both temperature and air quality. Even if the temperature requirement is fullled, the frequency converter maintains enough supply air to satisfy the air quality sensor. The controller is capable of monitoring and comparing 2 feedback signals to control the return fan by maintaining a xed dierential airow between the supply and return ducts as well.

3 3

Illustration 3.12 Constant Air Volume

Frequency converter

Water Inlet

Water Outlet

CHILLER

Temperature Sensor

BASIN

Conderser Water pump

Supply

130BB453.10

Product Overview

VLT® HVAC Basic Drive FC 101

3.1.16 Cooling Tower Fan

Several features of the Danfoss HVAC dedicated frequency converter can be utilized to improve the performance of

Cooling tower fans cool condenser-water in water-cooled chiller systems. Water-cooled chillers provide the most ecient means of creating chilled water. They are as much as 20% more ecient than air cooled chillers. Depending

on climate, cooling towers are often the most energy ecient method of cooling the condenser-water from chillers. They cool the condenser water by evaporation.

cooling tower fans applications. As the cooling tower fans drop below a certain speed, the eect the fan has on cooling the water becomes small. Also, when utilizing a gearbox to frequency control the tower fan, a minimum speed of 40–50% is required. The customer programmable minimum frequency setting is available to maintain this minimum frequency even as the feedback or speed reference calls for lower speeds.

The condenser water is sprayed into the cooling tower until the cooling towers ll to increase its surface area. The tower fan blows air through the ll and sprayed water to aid in the evaporation. Evaporation removes energy from the water dropping its temperature. The cooled water collects in the cooling towers basin where it is pumped back into the chillers condenser and the cycle is repeated.

Also as a standard feature, the frequency converter can be programmed to enter a sleep mode and stop the fan until a higher speed is required. Additionally, some cooling tower fans have undesirable frequencies that may cause vibrations. These frequencies can easily be avoided by programming the bypass frequency ranges in the frequency converter.

3.1.17 The VLT Solution

With a frequency converter, the cooling tower fans can be controlled to the required speed to maintain the condenser-water temperature. The frequency converters can also be used to turn the fan on and o as needed.

Illustration 3.13 Cooling Tower Fan

Frequency converter

Water Inlet

Water Outlet

BASIN

Flow or pressure sensor

Condenser Water pump

Throttling valve

Supply

CHILLER

130BB452.10

Product Overview Design Guide

3.1.18 Condenser Pumps

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

3.1.19 The VLT Solution

Frequency converters can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump impeller.

Using a frequency converter instead of a throttling valve simply saves the energy that would have been absorbed by the valve. This can amount to savings of 15–20% or more. Trimming the pump impeller is irreversible, thus if the conditions change and higher ow is required the impeller must be replaced.

3 3

Illustration 3.14 Condenser Pumps

Product Overview

VLT® HVAC Basic Drive FC 101

3.1.20 Primary Pumps

Primary pumps in a primary/secondary pumping system can be used to maintain a constant ow through devices that encounter operation or control diculties when

exposed to variable ow. The primary/secondary pumping technique decouples the primary production loop from the secondary distribution loop. This allows devices such as chillers to obtain constant design ow and operate properly while allowing the rest of the system to vary in

ow.

As the evaporator ow rate decreases in a chiller, the chilled water begins to become overchilled. As this happens, the chiller attempts to decrease its cooling capacity. If the ow rate drops far enough, or too quickly, the chiller cannot shed its load suciently and the chiller’s safety trips the chiller requiring a manual reset. This situation is common in large installations especially when 2 or more chillers in parallel are installed if primary/ secondary pumping is not utilized.

3.1.21 The VLT Solution

Depending on the size of the system and the size of the primary loop, the energy consumption of the primary loop can become substantial. A frequency converter can be added to the primary system to replace the throttling valve and/or trimming of the impellers, leading to reduced operating expenses. 2 control methods are common:

Flow meter

Because the desired ow meter installed at the discharge of each chiller, can be used to control the pump directly. Using the built-in PI controller, the frequency converter always maintains the appropriate ow rate, even compensating for the changing resistance in the primary piping loop as chillers and their pumps are staged on and o.

Local speed determination

The operator simply decreases the output frequency until the design ow rate is achieved. Using a frequency converter to decrease the pump speed is very similar to trimming the pump impeller, except it does not require any labor, and the pump eciency remains higher. The balancing contractor simply decreases the speed of the pump until the proper ow rate is achieved and leaves the speed xed. The pump operates at this speed any time the chiller is staged on. Because the primary loop does not have control valves or other devices that can cause the system curve to change, and the variance due to staging pumps and chillers on and o is usually small, this xed speed remains appropriate. If the ow rate needs to be increased later in the system’s life, the frequency converter can simply increase the pump speed instead of requiring a new pump impeller.

ow rate is known and is constant, a

Frequency converter

CHILLER

Flowmeter

F F

130BB456.10

Product Overview Design Guide

3 3

Illustration 3.15 Primary Pumps

Frequency converter

CHILLER

130BB454.10

Product Overview

VLT® HVAC Basic Drive FC 101

3.1.22 Secondary Pumps

With the proper sensor location, the addition of frequency converters allows the pumps to vary their speed to follow

Secondary pumps in a primary/secondary chilled water pumping system distribute the chilled water to the loads from the primary production loop. The primary/secondary pumping system is used to hydronically de-couple 1 piping

loop from another. In this case, the primary pump is used to maintain a constant ow through the chillers while allowing the secondary pumps to vary in ow, increase control and save energy. If the primary/secondary concept is not used in the design of a variable volume system when the ow rate drops far enough or too quickly, the chiller cannot shed its load

the system curve instead of the pump curve. This results in the elimination of wasted energy and eliminates most of the overpressurization that 2-way valves can be subjected to. As the monitored loads are reached, the 2-way valves close down. This increases the dierential pressure measured across the load and the 2-way valve. As this dierential pressure starts to rise, the pump is slowed to maintain the control head also called setpoint value. This setpoint value is calculated by summing the pressure drop of the load and the 2-way valve together under design conditions.

properly. The chiller’s low evaporator temperature safety then trips the chiller requiring a manual reset. This situation is common in large installations especially when 2 or more chillers in parallel are installed.

NOTICE

When running multiple pumps in parallel, they must run at the same speed to maximize energy savings, either with individual dedicated frequency converters or 1

3.1.23 The VLT Solution

frequency converter running multiple pumps in parallel.

While the primary-secondary system with 2-way valves improves energy savings and eases system control problems, the true energy savings and control potential is realized by adding frequency converters.

Illustration 3.16 Secondary Pumps

130BB892.10

100%

-100%

100%

Local reference scaled to Hz

Auto mode

Hand mode

LCP Hand on, oﬀ and auto on keys

Local

Remote

Reference

Ramp

P 4-10 Motor speed direction

To motor control

Reference handling Remote reference

P 4-14 Motor speed high limit [Hz]

P 4-12 Motor speed low limit [Hz]

P 3-4* Ramp 1 P 3-5* Ramp 2

Hand On

Oﬀ Reset

Auto On

130BB893.10

Product Overview Design Guide

3.2 Control Structures

Select [0] Open loop or [1] Closed loop in parameter 1-00 Conguration Mode.

3.2.1 Control Structure Open Loop

Illustration 3.17 Open-loop Structure

3 3

In the conguration shown in Illustration 3.17, parameter 1-00 Conguration Mode is set to [0] Open loop.

The resulting reference from the reference handling system or the local reference is received and fed through the ramp limitation and speed limitation before being sent to the motor control. The output from the motor control is then limited by the maximum frequency limit.

Current limitations for PM motors:

induction motors and 0.37–22 kW (0.5–30 hp) (400 V) for PM motors.

Currently only supported up to 22 kW (30 hp).

•

LC lters are not supported with PM motors.

•

Kinetic back-up algorithm is not supported with

•

PM motors.

3.2.2 PM/EC+ Motor Control

Support only complete AMA of the stator

•

resistance Rs in the system.

The Danfoss EC+ concept provides the possibility for using high-ecient PM motors (permanent magnet motors) in IEC standard enclosure sizes operated by Danfoss

No stall detection (supported from software

•

version 2.80).

frequency converters. The commissioning procedure is comparable to the existing one for asynchronous (induction) motors by

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

utilizing the Danfoss VVC+ PM control strategy.

The frequency converter can be operated manually via the

Customer advantages:

Free choice of motor technology (permanent

•

magnet or induction motor).

Installation and operation as know on induction

•

motors.

Manufacturer independent when selecting system

•

components (for example, motors).

Best system eciency by selecting best

•

components.

Possible retrot of existing installations.

•

Power range: 45 kW (60 hp) (200 V ), 0.37–90 kW

•

(0.5–121 hp) (400 V), 90 kW (121 hp) (600 V) for

local control panel (LCP) or remotely via analog/digital inputs or serial bus. If allowed in parameter 0-40 [Hand on]

Key on LCP, parameter 0-44 [O/Reset] Key on LCP, and parameter 0-42 [Auto on] Key on LCP, it is possible to start

and stop the frequency converter via LCP by pressing [Hand On] and [O/Reset]. Alarms can be reset via the [O/Reset] key.

Illustration 3.18 LCP Keys

7-30 PI

Normal/Inverse

Control

Reference

Feedback

Scale to speed

P 4-10

Motor speed

direction

To motor

control

130BB894.11

100%

-100%

100%

*[-1]

130BB895.10

Ref. signal

Desired

ow

FB conversion

Ref.

Flow

FB signal

Flow

P 20-01

Product Overview

VLT® HVAC Basic Drive FC 101

Local reference forces the conguration mode to openloop, independent on the setting of parameter 1-00 Conguration Mode.

For example, consider a pump application where the speed of a pump is to be controlled to ensure a constant static pressure in a pipe. The static pressure value is supplied to the frequency converter as the setpoint reference. A static

Local reference is restored at power-down.

pressure sensor measures the actual static pressure in the pipe and supplies this data to the frequency converter as a

3.2.4 Control Structure Closed Loop

The internal controller allows the frequency converter to become a part of the controlled system. The frequency converter receives a feedback signal from a sensor in the system. It then compares this feedback to a setpoint

feedback signal. If the feedback signal is greater than the setpoint reference, the frequency converter slows the pump down to reduce the pressure. In a similar way, if the pipe pressure is lower than the setpoint reference, the frequency converter automatically speeds the pump up to increase the pressure provided by the pump.

reference value and determines the error, if any, between these 2 signals. It then adjusts the speed of the motor to correct this error.

Illustration 3.19 Control Structure Closed-loop

While the default values for the closed-loop controller of

3.2.5 Feedback Conversion

the frequency converter often provide satisfactory performance, the control of the system can often be optimized by adjusting parameters.

In some applications, it may be useful to convert the feedback signal. One example of this is using a pressure signal to provide ow feedback. Since the square root of pressure is proportional to ow, the square root of the pressure signal yields a value proportional to the ow. See Illustration 3.20.

Illustration 3.20 Feedback Signal Conversion

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Danfoss FC 101 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual