Danfoss FC 102 Design guide

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Page 1

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT® HVAC Drive FC 102

1.1–90 kW

www.danfoss.com/drives

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Contents Design Guide

Contents

1 How to Read this Design Guide

2 Introduction to VLT® HVAC Drive

2.1 Safety

2.2 CE Labeling

2.3 Air humidity

2.4 Aggressive Environments

2.5 Vibration and Shock

2.6 Safe Torque Off

2.7 Advantages

2.8 Control Structures

2.9 General Aspects of EMC

2.10 Galvanic Isolation (PELV)

2.11 Ground Leakage Current

2.12 Brake Function

2.13 Extreme Running Conditions

3 Selection

12 12 13 14 14 15 15 22 36 46 51 52 53 55

3.1 Options and Accessories

3.1.1 Mounting Option Modules in Slot B 58

3.1.2 General Purpose I/O Module MCB 101 59

3.1.3 Digital Inputs - Terminal X30/1-4 60

3.1.4 Analog Voltage Inputs - Terminal X30/10-12 60

3.1.5 Digital Outputs - Terminal X30/5-7 60

3.1.6 Analog Outputs - Terminal X30/5+8 60

3.1.7 Relay Option MCB 105 61

3.1.8 24 V Backup Option MCB 107 (Option D) 63

3.1.9 Analog I/O option MCB 109 64

3.1.10 PTC Thermistor Card MCB 112 66

3.1.11 Sensor Input Option MCB 114 67

3.1.11.1 Ordering Code Numbers and Parts Delivered 68

3.1.11.2 Electrical and Mechanical Specifications 68

3.1.11.3 Electrical Wiring 69

3.1.12 Remote Mounting Kit for LCP 69

3.1.13 IP21/IP41/ TYPE1 Enclosure Kit 70

3.1.14 IP21/Type 1 Enclosure Kit 70

3.1.15 Output Filters 72

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Contents Design Guide

4 How to Order

4.1 Ordering Form

4.2 Ordering Numbers

5 Mechanical Installation

5.1 Mechanical Installation

5.1.1 Safety Requirements of Mechanical Installation 85

5.1.2 Mechanical Dimensions 86

5.1.3 Accessory Bags 89

5.1.4 Mechanical Mounting 90

5.1.5 Field Mounting 91

6 Electrical Installation

6.1 Connections - Enclosure Types A, B and C

6.1.1 Torque 92

6.1.2 Removal of Knockouts for Extra Cables 94

6.1.3 Connection to Line and Grounding 94

73 73 75

85 85

6.1.4 Motor Connection 97

6.1.5 Relay Connection 104

6.2 Fuses and Circuit Breakers

6.2.1 Fuses 105

6.2.2 Recommendations 105

6.2.3 CE Compliance 105

6.2.4 Fuse Tables 106

6.3 Disconnectors and Contactors

6.4 Additional Motor Information

6.4.1 Motor Cable 115

6.4.2 Motor Thermal Protection 115

6.4.3 Parallel Connection of Motors 116

6.4.4 Direction of Motor Rotation 118

6.4.5 Motor Insulation 119

6.4.6 Motor Bearing Currents 119

6.5 Control Cables and Terminals

6.5.1 Access to Control Terminals 120

105

114 115

120

6.5.2 Control Cable Routing 120

6.5.3 Control Terminals 121

6.5.4 Switches S201, S202, and S801 122

6.5.5 Electrical Installation, Control Terminals 122

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Contents Design Guide

6.5.6 Basic Wiring Example 123

6.5.7 Electrical Installation, Control Cables 124

6.5.8 Relay Output 125

6.6 Additional Connections

6.6.1 DC Bus Connection 126

6.6.2 Load Sharing 126

6.6.3 Installation of Brake Cable 126

6.6.4 How to Connect a PC to the Adjustable Frequency Drive 126

6.6.5 PC Software 127

6.6.6 MCT 31 127

6.7 Safety

6.7.1 High Voltage Test 127

6.7.2 Grounding 127

6.7.3 Safety Ground Connection 128

6.7.4 ADN-compliant Installation 128

6.8 EMC-compatible Installation

6.8.1 Electrical Installation - EMC Precautions 129

6.8.2 Use of EMC-Compatible Cables 131

6.8.3 Grounding of Shielded Control Cables 132

6.8.4 RFI Switch 133

126

127

129

6.9 Residual Current Device

6.10 Final Set-up and Test

7 Application Examples

7.1 Application Examples

7.1.1 Start/Stop 135

7.1.2 Pulse Start/Stop 135

7.1.3 Potentiometer Reference 136

7.1.4 Automatic Motor Adaptation (AMA) 136

7.1.5 Smart Logic Control 136

7.1.6 Smart Logic Control Programming 137

7.1.7 SLC Application Example 138

7.1.8 Cascade Controller 140

7.1.9 Pump Staging with Lead Pump Alternation 141

7.1.10 System Status and Operation 141

7.1.11 Fixed Variable-speed Pump Wiring Diagram 141

7.1.12 Lead Pump Alternation Wiring Diagram 142

7.1.13 Cascade Controller Wiring Diagram 143

133 133

135 135

7.1.14 Start/Stop Conditions 144

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Contents Design Guide

8 Installation and Set-up

8.1 Installation and Set-up

8.2 Adjustable Frequency Protocol Overview

8.3 Network Configuration

8.4 FC Protocol Message Framing Structure

8.4.1 Content of a Character (byte) 148

8.4.2 Message Structure 148

8.4.3 Message Length (LGE) 148

8.4.4 Adjustable Frequency Drive Address (ADR) 149

8.4.5 Data Control Byte (BCC) 149

8.4.6 The Data Field 150

8.4.7 The PKE Field 151

8.4.8 Parameter Number (PNU) 151

8.4.9 Index (IND) 151

8.4.10 Parameter Value (PWE) 152

8.4.11 Data Types Supported by the Adjustable Frequency Drive 152

8.4.12 Conversion 152

145 145 147 148 148

8.4.13 Process Words (PCD) 153

8.5 Examples

8.5.1 Writing a Parameter Value 153

8.5.2 Reading a Parameter Value 153

8.6 Modbus RTU Overview

8.6.1 Assumptions 154

8.6.2 What the User Should Already Know 154

8.6.3 Modbus RTU Overview 154

8.6.4 Adjustable Frequency Drive with Modbus RTU 154

8.7 Network Configuration

8.8 Modbus RTU Message Framing Structure

8.8.1 Adjustable Frequency Drive with Modbus RTU 155

8.8.2 Modbus RTU Message Structure 155

8.8.3 Start/Stop Field 155

8.8.4 Address Field 156

8.8.5 Function Field 156

8.8.6 Data Field 156

153

154

155 155

8.8.7 CRC Check Field 156

8.8.8 Coil Register Addressing 156

8.8.9 How to Control the Adjustable Frequency Drive 158

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Contents Design Guide

8.8.10 Function Codes Supported by Modbus RTU 158

8.8.11 Modbus Exception Codes 158

8.9 How to Access Parameters

8.9.1 Parameter Handling 159

8.9.2 Storage of Data 159

8.9.3 IND 159

8.9.4 Text Blocks 159

8.9.5 Conversion Factor 159

8.9.6 Parameter Values 159

8.10 Examples

8.10.1 Read Coil Status (01 HEX) 159

8.10.2 Force/Write Single Coil (05 HEX) 160

8.10.3 Force/Write Multiple Coils (0F HEX) 161

8.10.4 Read Holding Registers (03 HEX) 161

8.10.5 Preset Single Register (06 HEX) 162

8.10.6 Preset Multiple Registers (10 HEX) 162

8.11 Danfoss FC Control Profile

8.11.1 Control Word According to FC Profile (8-10 Control Profile = FC profile) 163

8.11.2 Status Word According to FC Profile (STW) (8-10 Control Profile = FC profile) 164

159

163

8.11.3 Bus Speed Reference Value 165

9 General Specifications and Troubleshooting

9.1 Line Power Supply Tables

9.2 General Specifications

9.3 Efficiency

9.4 Acoustic noise

9.5 Peak voltage on motor

9.6 Special Conditions

9.6.1 Purpose of Derating 186

9.6.2 Derating for Ambient Temperature 186

9.6.3 Derating for Ambient Temperature, Enclosure Type A 186

9.6.4 Derating for Ambient Temperature, Enclosure Type B 187

9.6.5 Derating for Ambient Temperature, Enclosure Type C 189

9.6.6 Automatic Adaptations to Ensure Performance 190

9.6.7 Derating for Low Air Pressure 191

9.6.8 Derating for Running at Low Speed 191

9.7 Troubleshooting

166 166 176 181 182 182 186

192

9.7.1 Alarm Words 196

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Contents Design Guide

9.7.2 Warning Words 197

9.7.3 Extended Status Words 198

Index

206

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How to Read this Design Gui... Design Guide

1 How to Read this Design Guide

VLT® HVAC Drive

FC 102 Series

This guide can be used with all

VLT® HVAC Drive adjustable

frequency drives with software

version 3.9x.

The actual software version

number can be read from

15-43 Software Version.

Table 1.1 Software Version

This publication contains information proprietary to Danfoss. By accepting and using this manual, the user agrees that the information contained herein will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication with Danfoss equipment over a serial communication link. This publication is protected under the copyright laws of Denmark and most other countries.

Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical, hardware or software environment.

Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or representation, neither expressed nor implied, with respect to this documentation, including its quality, performance, or fitness for a particular purpose.

In no event shall Danfoss be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information contained in this manual, even if advised of the possibility of such damages. In particular, Danfoss is not responsible for any costs, including but not limited to those incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims by third parties.

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

Design Guide contains all the technical

•

information about the adjustable frequency drive and customer design and applications.

The Programming Guide provides information on

•

how to program and includes complete parameter descriptions.

Application Note, Temperature Derating Guide.

•

MCT 10 Set-up Software Instruction Manual enables

•

the user to configure the adjustable frequency drive from a Windows™-based PC environment.

Danfoss VLT® Energy Box software at

•

www.danfoss.com/BusinessAreas/DrivesSolutions

then choose PC Software Download.

VLT® HVAC Drive BACnet, Instruction Manual.

•

VLT

•

Danfoss technical literature is available in print from local Danfoss Sales Offices or online at:

www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm

HVAC Drive Metasys, Instruction Manual.

VLT® HVAC Drive FLN, Instruction Manual.

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How to Read this Design Gui...

Table 1.2

Design Guide

The adjustable frequency drive complies with UL508C thermal memory retention requirements. For more information, refer to chapter 6.4.2 Motor Thermal Protection.

The following symbols are used in this document.

WARNING

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

CAUTION

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

NOTICE!

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

Alternating current AC American wire gauge AWG Ampere/AMP A Automatic Motor Adaptation AMA Current limit I Degrees Celsius Direct current DC Drive Dependent D-TYPE Electro Magnetic Compatibility EMC Electronic Thermal Relay ETR Adjustable frequency drive FC Gram g Hertz Hz Horsepower hp Kilohertz kHz Local Control Panel LCP Meter m Millihenry Inductance mH Milliampere mA Millisecond ms Minute min Motion Control Tool MCT Nanofarad nF Newton Meters Nm Nominal motor current I Nominal motor frequency f Nominal motor power P Nominal motor voltage U Permanent Magnet motor PM motor Protective Extra Low Voltage PELV Printed Circuit Board PCB Rated Inverter Output Current I Revolutions Per Minute RPM Regenerative terminals Regen Second s Synchronous Motor Speed n Torque limit T Volts V The maximum output current I The rated output current supplied by the adjustable frequency drive

LIM

°C

M,N

INV

LIM

VLT,MAX

VLT,N

Table 1.3 Abbreviations

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175ZA078.10

Pull-out

rpm

Torque

How to Read this Design Gui...

Design Guide

1.1.1 Definitions

Adjustable Frequency Drive:

VLT,MAX

The maximum output current.

VLT,N

The rated output current supplied by the adjustable frequency drive.

VLT, MAX

The maximum output voltage.

Input:

M,N

The rated torque (motor).

The instantaneous motor voltage.

M,N

The rated motor voltage (nameplate data).

Break-away torque

Control command

Start and stop the connected motor with the LCP or the digital inputs. Functions are divided into two groups. Functions in group 1 have higher priority than functions in group 2.

Table 1.4 Function Groups

Group 1 Reset, Coasting stop, Reset

and Coasting stop, Quick stop, DC braking, Stop and the "Off" key

Group 2 Start, Pulse start, Reversing,

Start reversing, Jog and Freeze output

Motor:

JOG

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

The motor frequency.

MAX

The maximum motor frequency.

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 rated motor speed (nameplate data).

M,N

The rated motor power (nameplate data).

Figure 1.1 Break-away Torque

VLT

The efficiency of the adjustable frequency drive is defined as the ratio between the power output and the power input.

Start-disable command

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

Stop command

See Control commands.

References:

Analog Reference

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

Bus Reference

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

Preset Reference

A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references via the digital terminals.

Pulse Reference

A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33).

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How to Read this Design Gui...

Design Guide

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 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 set in

3-02 Minimum Reference

Miscellaneous:

Advanced Vector Control Analog Inputs

The analog inputs are used for controlling various functions of the adjustable frequency drive. There are two types of analog inputs: Current input, 0–20 mA and 4–20 mA Voltage input, 0–10 V DC.

Analog Outputs

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

Automatic Motor Adaptation, AMA

AMA algorithm determines the electrical parameters for the connected motor at standstill.

Brake Resistor

The brake resistor is a module capable of absorbing the braking energy generated in regenerative braking. This regenerative braking energy increases the intermediate circuit voltage and a brake chopper ensures that the power is transmitted to the brake resistor.

CT Characteristics

Constant torque characteristics used for screw and scroll refrigeration compressors.

Digital Inputs

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

Digital Outputs

The adjustable frequency drive features two solid state outputs that can supply a 24 V DC (max. 40 mA) signal.

DSP

Digital Signal Processor.

Relay Outputs

The adjustable frequency drive features two programmable relay outputs.

ETR

Electronic Thermal Relay is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature.

GLCP

Graphical Local Control Panel (LCP102).

Initializing

If initialization is carried out (14-22 Operation Mode), the programmable parameters of the adjustable frequency drive return to their default settings.

Intermittent Duty Cycle

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

LCP

The Local Control Panel makes up a complete interface for control and programming of the adjustable frequency drive. The LCP is detachable and can be installed up to 10 ft [3 m] from the adjustable frequency drive, i.e., in a front panel by means of the installation kit option. The LCP is available in two versions:

Numerical LCP101 (NLCP)

•

Graphical LCP102 (GLCP)

•

lsb

Least significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM ≡ 0.00078 in2 [0.5067 mm2].

msb

Most significant bit.

NLCP

Numerical Local Control Panel LCP 101.

Online/Offline Parameters

Changes to online parameters are activated immediately after the data value is changed. Press [OK] to activate changes to offline parameters.

PID Controller

The PID controller maintains the desired speed, pressure, temperature, etc. by adjusting the output frequency to match the varying load.

RCD

Residual Current Device.

Set-up

Save parameter settings in four set-ups. Change between the two parameter set-ups and edit one set-up, while another set-up is active.

SFAVM

Switching pattern called Stator Flux-oriented Asynchronous Vector Modulation (14-00 Switching Pattern).

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How to Read this Design Gui... Design Guide

Slip Compensation

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

Smart Logic Control (SLC)

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

Thermistor

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

Trip

A state entered in fault situations, e.g., if the adjustable frequency drive is subject to an overtemperature or when the adjustable frequency drive is protecting the motor, process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is canceled by activating reset or, in some cases, by being programmed to reset automatically. Trip may not be used for personal safety.

Trip Locked

A state entered in fault situations when the adjustable frequency drive is protecting itself and requiring physical intervention, e.g., if the adjustable frequency drive is subject to a short circuit on the output. A locked trip can only be canceled by cutting off line power, removing the cause of the fault, and reconnecting the adjustable frequency drive. Restart is prevented until the trip state is canceled by activating reset or, in some cases, by being programmed to reset automatically. The trip-lock function may not be used as a personal safety measure.

VT Characteristics

Variable torque characteristics used for pumps and fans.

plus

VVC

If compared with standard voltage/frequency ratio control, Voltage Vector Control (VVC

plus

) improves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque.

60° AVM

Switching pattern called 60° Asynchronous Vector Modulation (See 14-00 Switching Pattern).

1.1.2

Power Factor

The power factor is the relation between I1 and I

3 × U ×

1 ×

COS

Power factor

3 × U ×

RMS

The power factor for 3-phase control:

cos

ϕ1

since cos

RMS

ϕ1 =1

The power factor indicates to which extent the adjustable frequency drive imposes a load on the line power supply. The lower the power factor, the higher the I

RMS

for the

same kW performance.

RMS

+ . . +

In addition, a high power factor indicates that the different harmonic currents are low. The adjustable frequency drive's built-in DC coils produce a high power factor, which minimizes the imposed load on the line power supply.

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Introduction to VLT® HVAC D...

Introduction to VLT® HVAC Drive

Design Guide

2.1 Safety

2.1.1 Safety Note

WARNING

The voltage of the adjustable frequency drive is dangerous whenever connected to line power. Incorrect installation of the motor, adjustable frequency drive or serial communication bus may cause death, serious personal injury or damage to the equipment. Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.

Safety Regulations

1. Disconnect the adjustable frequency drive from line power if repair work is to be carried out. Make sure that the line power supply has been disconnected and that the necessary time has elapsed before removing motor and line power plugs.

2. The [Stop/Reset] key on the LCP of the adjustable frequency drive does not disconnect the equipment from line power and is thus not to be used as a safety switch.

3. Established correct protective grounding of the equipment, protect the user against supply voltage, and protect the motor against overload in accordance with applicable national and local regulations.

4. The ground leakage currents are higher than

3.5 mA.

5. Protection against motor overload is set by 1-90 Motor Thermal Protection. If this function is desired, set 1-90 Motor Thermal Protection to data value [ETR trip] (default value) or data value [ETR warning]. Note: The function is initialized at 1.16 x rated motor current and rated motor frequency. For the North American market: The ETR functions provide class 20 motor overload protection in accordance with NEC.

6. Do not remove the plugs for the motor and line power supply while the adjustable frequency drive is connected to line power. Make sure that the line power supply has been disconnected and that the necessary time has elapsed before removing motor and line power plugs.

7. Note that the adjustable frequency drive has more voltage inputs than L1, L2 and L3 when load sharing (linking of DC intermediate circuit) and external 24 V DC have been installed. Make sure that all voltage inputs have been disconnected and that the necessary time has passed before commencing repair work.

Installation at high altitudes

CAUTION

380–500 V, enclosure types A, B and C: At altitudes above 6,600 ft [2 km], contact Danfoss regarding PELV. 525–690 V: At altitudes above 6,600 ft [2 km], contact Danfoss regarding PELV.

WARNING

Warning against unintended start

1. The motor can be stopped with digital commands, bus commands, references or a local stop, while the adjustable frequency drive is connected to line power. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not sufficient.

2. While parameters are being changed, the motor may start. Consequently, the [Reset] key must always be activated; after which data can be modified.

3. A motor that has been stopped may start if faults occur in the electronics of the adjustable frequency drive, or if a temporary overload or a fault in the line power or the motor connection ceases.

WARNING

Touching the electrical parts may be fatal - even after the equipment has been disconnected from line power.

Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic backup. Refer to the Instruction Manual for further safety guidelines.

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Introduction to VLT® HVAC D...

Design Guide

2.1.2 Caution

WARNING

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

Voltage [V] Min. waiting time (minutes)

4 15

200–240 1.5–5 hp [1.1–3.7 kW] 7.5–60 hp [5.5–45 kW] 380–480 1.5–10 hp [1.1–7.5 kW] 15–125 hp [11–90 kW] 525–600 1.5–10 hp [1.1–7.5 kW] 15–125 hp [11–90 kW] 525–690 15–125 hp [11–90 kW] Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

Table 2.1 Discharge Time

Disposal Instruction

2.1.3

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

2.2 CE Labeling

2 2

2.2.1 CE Conformity and Labeling

What is CE Conformity and Labeling?

The purpose of CE labeling is to avoid technical trade obstacles within the EFTA and the EU. The EU has introduced the CE label as a simple way of showing whether a product complies with the relevant EU directives. The CE label says nothing about the specifications or quality of the product. Adjustable frequency drives are regulated by three EU directives.

The machinery directive (2006/42/EC)

Adjustable frequency drives with the integrated safety function are now falling under the Machinery Directive. Danfoss uses CE labels in accordance with the directive and will issue a declaration of conformity upon request. Adjustable frequency drives without the safety function do not fall under the machinery directive. However, if an adjustable frequency drive is supplied for use in a machine, we provide information on its safety aspects.

The low-voltage directive (2006/95/EC)

Adjustable frequency drives must be CE labeled in accordance with the Low-voltage Directive of January 1,

1997. The directive applies to all electrical equipment and appliances used in the 50–1,000 V AC and the 75–1,500 V DC voltage ranges. Danfoss CE labels in accordance with the directive and issues a declaration of conformity upon request.

The EMC directive (2004/108/EC)

EMC is short for electromagnetic compatibility. The presence of electromagnetic compatibility means that the mutual interference between different components/ appliances does not affect the way the appliances work. The EMC directive came into effect January 1, 1996. Danfoss CE labels in accordance with the directive and issues a declaration of conformity upon request. To carry out EMC-compatible installation, see the instructions in this Design Guide. In addition, Danfoss specifies which standards our products comply with. Danfoss offers the filters presented in the specifications and provide other types of assistance to ensure the optimum EMC result.

The adjustable frequency drive is most often used by professionals of the trade as a complex component forming part of a larger appliance, system or installation. It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer.

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Introduction to VLT® HVAC D...

Design Guide

2.2.2 What Is Covered

The EU "Guidelines on the Application of Council Directive 2004/108/EC" outline three typical situations of using an

adjustable frequency drive.

1. The adjustable frequency drive is sold directly to the end user. For such applications, the adjustable frequency drive must be CE labeled in accordance with the EMC directive.

2. The adjustable frequency drive is sold as part of a system. It is being marketed as complete system, e.g., an air-conditioning system. The complete system must be CE labeled in accordance with the EMC directive. The manufacturer can ensure CE labeling under the EMC directive by testing the EMC of the system. The components of the system do not need to be CE marked.

3. The adjustable frequency drive is sold for installation in a plant. It could be a production or a heating/ventilation plant designed and installed by professionals of the trade. The adjustable frequency drive must be CE labeled under the EMC directive. The finished plant should not bear the CE mark. However, the installation must comply with the essential requirements of the directive. This is assumed by using appliances and systems that are CE labeled under the EMC directive

Danfoss Adjustable frequency drive

2.2.3

The CE label also applies to the EMC directive provided that the instructions for EMC-compatible installation and filtering are followed. On this basis, a declaration of conformity in accordance with the EMC directive is issued.

This Design Guide offers detailed instructions for installation to ensure EMC-compatible installation. Furthermore, Danfoss specifies with what the different products comply.

Danfoss provides other types of assistance that can help obtain the best EMC result.

2.2.4 Compliance with EMC Directive 2004/108/EC

As mentioned, the adjustable frequency drive is mostly used by professionals of the trade as a complex component forming part of a larger appliance, system or installation. Note that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer. As an aid to the installer, Danfoss has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for Power Drive systems are complied with, provided that the EMCcompatible instructions for installation are followed, see.

2.3

Air humidity

The adjustable frequency drive has been designed to meet the IEC/EN 60068-2-3 standard, EN 50178 pkt. 9.4.2.2 at 122 °F [50 °C].

2.4

Aggressive Environments

and CE Labeling

An adjustable frequency drive contains a large number of

The purpose of CE labeling is to facilitate trade within the EU and EFTA.

mechanical and electronic components. All are to some extent vulnerable to environmental effects.

However, CE labeling may cover many different specifications. Thus, check what a given CE label specifically covers.

The covered specifications can be very different and a CE label may therefore give the installer a false feeling of security when using an adjustable frequency drive as a component in a system or an appliance.

Danfoss CE labels the adjustable frequency drives in accordance with the low-voltage directive. This means that if the adjustable frequency drive is installed correctly, Danfoss guarantees compliance with the low-voltage directive. Danfoss issues a declaration of conformity that confirms our CE labeling in accordance with the lowvoltage directive.

CAUTION

Do not install the adjustable frequency drive in environments with airborne liquids, particles, or gases capable of affecting and damaging the electronic components. Failure to take the necessary protective measures increases the risk of stoppages, thus reducing the life of the adjustable frequency drive.

Degree of protection as per IEC 60529

The Safe Torque Off function may only be installed and operated in a control cabinet with degree of protection IP54 or higher (or equivalent environment). This is required to avoid cross faults and short circuits between terminals, connectors, tracks and safety-related circuitry caused by foreign objects.

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Introduction to VLT® HVAC D... Design Guide

Liquids can be carried through the air and condense in the adjustable frequency drive and may cause corrosion of components and metal parts. Steam, oil, and salt water may cause corrosion of components and metal parts. In such environments, use equipment with enclosure rating IP 54/55. As an extra protection, coated printed circuit boards can be ordered as an option.

Airborne particles such as dust may cause mechanical, electrical or thermal failure in the adjustable frequency drive. A typical indicator of excessive levels of airborne particles is the presence of dust particles around the adjustable frequency drive fan. In very dusty environments, use equipment with enclosure rating IP 54/55 or a cabinet for IP 00/IP 20/TYPE 1 equipment.

In environments with high temperatures and humidity, corrosive gases such as sulfur, nitrogen, and chlorine compounds cause chemical processes on the adjustable frequency drive components.

Such chemical reactions rapidly affect and damage the electronic components. In such environments, mount the equipment in a cabinet with fresh air ventilation, keeping aggressive gases away from the adjustable frequency drive. An extra protection in such areas is a coating of the printed circuit boards, which can be ordered as an option.

NOTICE!

Mounting adjustable frequency drives in aggressive environments increases the risk of stoppages and considerably reduces the life of the adjustable frequency drive.

Before installing the adjustable frequency drive, check the ambient air for liquids, particles and gases. This is done by observing existing installations in this environment. Typical indicators of harmful airborne liquids are water or oil on metal parts, or corrosion of metal parts.

Excessive dust particle levels are often found on installation cabinets and existing electrical installations. One indicator of aggressive airborne gases is the blackening of copper rails and cable ends on existing installations.

D and E enclosure types have a stainless steel backchannel option to provide additional protection in aggressive environments. Proper ventilation is still required for the internal components of the adjustable frequency drive. Contact Danfoss for additional information.

2.5

Vibration and Shock

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

IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970

•

IEC/EN 60068-2-64: Vibration, broad-band random

•

The adjustable frequency drive complies with requirements that exist for units mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors.

2.6 Safe Torque Off

The FC 102 can perform the safety function Safe Torque Off (STO, as defined by EN IEC 61800-5-21) and Stop Category 0 (as defined in EN 60204-12). Before integrating and using Safe Torque Off in an installation, a thorough risk analysis on the installation must be carried out in order to determine whether the Safe Torque Off functionality and safety levels are appropriate and sufficient. It is designed and approved as suitable for the requirements of:

Category 3 in EN ISO 13849-1

•

Performance Level "d" in EN ISO 13849-1:2008

•

SIL 2 Capability in IEC 61508 and EN 61800-5-2

•

SILCL 2 in EN 62061

•

1) Refer to EN IEC 61800-5-2 for details of Safe torque off (STO) function.

2) Refer to EN IEC 60204-1 for details of stop category 0 and 1.

Activation and Termination of Safe Torque Off

The Safe Torque Off (STO) function is activated by removing the voltage at Terminal 37 of the Safe Inverter. By connecting the Safe Inverter to external safety devices providing a safe delay, an installation for a Safe Torque Off Category 1 can be obtained. The Safe Torque Off function of FC 102 can be used for asynchronous, synchronous motors and permanent magnet motors. See examples in chapter 2.6.1 Terminal 37 Safe Torque Off Function.

WARNING

After installation of Safe Torque Off (STO), a commissioning test as specified in section Safe Torque Off Commissioning Test must be performed. A passed commissioning test is mandatory after first installation and after each change to the safety installation.

2 2

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Introduction to VLT® HVAC D...

Design Guide

Safe Torque Off Technical Data

The following values are associated to the different types of safety levels:

Reaction time for T37

Maximum reaction time: 20 ms

•

Reaction time = delay between de-energizing the STO input and switching off the output bridge.

Data for EN ISO 13849-1

Performance Level "d"

•

MTTFd (Mean Time To Dangerous Failure):

•

14,000 years DC (Diagnostic Coverage): 90%

•

Category 3

•

Lifetime 20 years

•

Data for EN IEC 62061, EN IEC 61508, EN IEC 61800-5-2

SIL 2 Capability, SILCL 2

•

PFH (Probability of dangerous Failure per Hour) =

•

1E-10/h SFF (Safe Failure Fraction) > 99%

•

HFT (Hardware Fault Tolerance) = 0

•

(1001 architecture) Lifetime 20 years

•

Data for EN IEC 61508 low demand

PFDavg for 1-year proof test: 1E-10

•

PFDavg for 3-year proof test: 1E-10

•

PFDavg for 5-year proof test: 1E-10

•

No maintenance of the STO functionality is needed. Take security measures, e.g., only skilled personnel must be

able to access and install in closed cabinets.

SISTEMA Data

Danfoss provides functional safety data via a data library for use with the SISTEMA calculation tool from IFA (Institute for Occupational Safety and Health of the German Social Accident Insurance), as well as data for manual calculation. The library is complete and continually extended.

Abbrev. Ref. Description

Cat. EN ISO

13849-1 FIT Failure In Time: 1E-9 hours HFT IEC 61508 Hardware Fault Tolerance: HFT = n

MTTFd EN ISO

13849-1 PFH IEC 61508 Probability of Dangerous Failures per

PFD IEC 61508 Average probability of failure on

PL EN ISO

13849-1

SFF IEC 61508 Safe Failure Fraction [%]; Percentage

SIL IEC 61508 Safety Integrity Level STO EN

61800-5-2 SS1 EN 61800

-5-2

Table 2.2 Abbreviations Related to Functional Safety

Terminal 37 Safe Torque Off Function

2.6.1

The FC 102 is available with Safe Torque Off functionality via control terminal 37. Safe Torque Off disables the control voltage of the power semiconductors of the adjustable frequency drive output stage which in turn prevents generating the voltage required to rotate the motor. When the Safe Torque Off (T37) is activated, the adjustable frequency drive issues an alarm, trips the unit, and coasts the motor to a stop. Manual restart is required. The Safe Torque Off function can be used for stopping the adjustable frequency drive in emergency stop situations. In the normal operating mode when Safe Torque Off is not required, use the adjustable frequency drive’s regular stop function instead. When automatic restart is used – the requirements according to ISO 12100-2 paragraph 5.3.2.5 must be fulfilled.

Category, level “B, 1-4”

means that n+1 faults could cause a loss of the safety function Mean Time To Failure - dangerous. Unit: years

Hour. This value shall be considered if the safety device is operated in high demand (more often than once per year) or continuous mode of operation, where the frequency of demands for operation made on a safety-related system is greater than one per year

demand, value used for low demand operation Discrete level used to specify the ability of safety related parts of control systems to perform a safety function under foreseeable conditions. Levels a-e

part of safe failures and dangerous detected failures of a safety function or a subsystem related to all failures

Safe Torque Off

Safe Stop 1

Page 19

Introduction to VLT® HVAC D...

Design Guide

Liability Conditions

It is the user’s responsibility to ensure that personnel installing and operating the Safe Torque Off function:

Read and understand the safety regulations

•

concerning health and safety/accident prevention Understand the generic and safety guidelines

•

given in this description and the extended description in the Design Guide

Have a good knowledge of the generic and safety

•

standards applicable to the specific application

Standards

Use of Safe Torque Off on terminal 37 requires that the user satisfies all provisions for safety including relevant laws, regulations and guidelines. The optional Safe Torque Off function complies with the following standards.

IEC 60204-1: 2005 category 0 – uncontrolled stop IEC 61508: 1998 SIL2 IEC 61800-5-2: 2007 – safe torque off (STO)

function IEC 62061: 2005 SIL CL2 ISO 13849-1: 2006 Category 3 PL d ISO 14118: 2000 (EN 1037) – prevention of

unexpected startup

The information and instructions of the Instruction Manual are not sufficient for a proper and safe use of the Safe Torque Off functionality. The related information and instructions in the relevant Design Guide must be followed.

Protective Measures

Safety engineering systems may only be installed

•

and commissioned by qualified and skilled personnel

The unit must be installed in an IP54 cabinet or

•

in an equivalent environment. In special applications, a higher IP degree may be necessary

The cable between terminal 37 and the external

•

safety device must be short-circuit-protected according to ISO 13849-2 table D.4

If any external forces influence the motor axis

•

(e.g., suspended loads), additional measures (e.g., a safety holding brake) are required to eliminate hazards.

Safe Torque Off Installation and Set-up

WARNING

SAFE TORQUE OFF FUNCTION!

The Safe Torque Off function does NOT isolate AC line voltage to the adjustable frequency drive or auxiliary circuits. Perform work on electrical parts of the adjustable frequency drive or the motor only after isolating the AC line voltage supply and waiting the length of time specified under Safety in this manual. Failure to isolate the AC line voltage supply from the unit and waiting the time specified could result in death or serious injury.

It is not recommended to stop the adjustable

•

frequency drive by using the Safe Torque Off function. If a running adjustable frequency drive is stopped by using the function, the unit trips and stops by coasting. If this is not acceptable, e.g., causes danger, the adjustable frequency drive and machinery must be stopped using the appropriate stopping mode before using this function. Depending on the application, a mechanical brake may be required.

Concerning synchronous and permanent magnet

•

motor adjustable frequency drives in case of a multiple IGBT power semiconductor failure: In spite of the activation of the Safe Torque Off function, the adjustable frequency drive system can produce an alignment torque which maximally rotates the motor shaft by 180/p degrees. p denotes the pole pair number.

This function is suitable for performing

•

mechanical work on the adjustable frequency drive system or affected area of a machine only. It does not provide electrical safety. This function should not be used as a control for starting and/or stopping the adjustable frequency drive.

Meet the following requirements to perform a safe installation of the adjustable frequency drive:

1. Remove the jumper wire between control terminals 37 and 12 or 13. Cutting or breaking the jumper is not sufficient to avoid shortcircuiting. (See jumper on Figure 2.1.)

2. Connect an external safety monitoring relay via a NO safety function (the instruction for the safety device must be followed) to terminal 37 (Safe Torque Off) and either terminal 12 or 13 (24 V DC). The Safety monitoring relay must comply with Category 3/PL “d” (ISO 13849-1) or SIL 2 (EN 62061).

2 2

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Introduction to VLT® HVAC D...

Figure 2.1 Jumper between Terminal 12/13 (24 V) and 37

Design Guide

Safe Torque Off Commissioning Test

After installation and before first operation, perform a commissioning test of the installation making use of Safe Torque Off. Also, perform the test after each modification of the installation.

Example with STO

A safety relay evaluates the E-Stop button signals and triggers an STO function on the adjustable frequency drive in the event of an activation of the E-Stop button (See Figure 2.3). This safety function corresponds to a category 0 stop (uncontrolled stop) in accordance with IEC 60204-1. If the function is triggered during operation, the motor runs down in an uncontrolled manner. The power to the motor is safely removed, so that no further movement is possible. It is not necessary to monitor plant at a standstill. If an external force effect is to be anticipated, provide additional measures to safely prevent any potential movement (e.g., mechanical brakes).

NOTICE!

For all applications with Safe Torque Off, it is important that short circuit in the wiring to T37 can be excluded. This can be done as described in EN ISO 13849-2 D4 by the use of protected wiring, (shielded or segregated).

Figure 2.2 Installation to Achieve a Stopping Category 0 (EN 60204-1) with Safety Cat. 3/PL “d” (ISO 13849-1) or SIL 2 (EN 62061).

1 Safety relay (cat. 3, PL d or SIL2 2 Emergency stop button 3 Reset button 4 Short-circuit protected cable (if not inside installation

IP54 cabinet)

Table 2.3 Legend to Figure 2.2

Example with SS1

SS1 correspond to a controlled stop, stop category 1 according to IEC 60204-1 (see Figure 2.4). When activating the safety function, a normal controlled stop is performed. This can be activated through terminal 27. After the safe delay time has expired on the external safety module, the STO is triggered and terminal 37 is set low. Ramp-down is performed as configured in the adjustable frequency drive. If the adjustable frequency drive is not stopped after the safe delay time, the activation of STO coasts the adjustable frequency drive.

NOTICE!

When using the SS1 function, the brake ramp of the adjustable frequency drive is not monitored with respect to safety.

Example with Category 4/PL e application

Where the safety control system design requires two channels for the STO function to achieve Category 4/PL e, one channel can be implemented by Safe Torque Off T37 (STO) and the other by a contactor which may be connected in either the adjustable frequency drive input or output power circuits and controlled by the safety relay (see Figure 2.5). The contactor must be monitored through an auxiliary guided contact and connected to the reset input of the safety relay.

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18 37

130BB969.10

130BB970.10

130BC001.10

Introduction to VLT® HVAC D...

Design Guide

Paralleling of Safe Torque Off inputs via one safety relay

Safe Torque Off inputs T37 (STO) may be connected directly if the situation is required to control multiple adjustable frequency drives from the same control line via one safety relay (see Figure 2.6). Connecting inputs increases the probability of a fault in the unsafe direction, since a fault in one adjustable frequency drive might result in all adjustable frequency drives becoming enabled. The probability of a fault for T37 is so low, that the resulting probability still meets the requirements for SIL2.

2 2

Figure 2.6 Paralleling of Multiple Adjustable Frequency Drives Example

Figure 2.3 STO Example

1 Safety relay 2 Emergency stop button 3 Reset button 4 24 V DC

Table 2.4 Legend to Figure 2.3 to Figure 2.6

WARNING

Safe Torque Off activation (i.e., removal of 24 V DC voltage supply to terminal 37) does not provide electrical safety. The Safe Torque Off function itself is therefore not sufficient to implement the Emergency Off function as defined by EN 60204-1. Emergency Off

Figure 2.4 SS1 Example

requires measures of electrical isolation, e.g., by switching off line power via an additional contactor.

1. Activate the Safe Torque Off function by removing the 24 V DC voltage supply to the terminal 37.

2. After activation of Safe Torque Off (i.e., after the response time), the adjustable frequency drive coasts (stops creating a rotational field in the motor). The response time is typically shorter than 10 ms for the complete performance range of the adjustable frequency drive.

Figure 2.5 STO Category 4 Example

Page 22

Introduction to VLT® HVAC D... Design Guide

The adjustable frequency drive is guaranteed not to restart

creation of a rotational field by an internal fault (in accordance with Cat. 3 PL d acc. EN ISO 13849-1 and SIL 2 acc. EN 62061). After activation of Safe Torque Off, the adjustable frequency drive display shows the text Safe Torque Off activated. The associated help text says "Safe Torque Off has been activated". This means that the Safe Torque Off has been activated, or that normal operation has not been resumed yet after Safe Torque Off activation.

NOTICE!

The requirements of Cat. 3/PL “d” (ISO 13849-1) are only fulfilled while 24 V DC supply to terminal 37 is kept removed or low by a safety device, which itself fulfills Cat. 3/PL “d” (ISO 13849-1). If external forces act on the motor, e.g., in case of vertical axis (suspended loads) and an unwanted movement, for example caused by gravity, could cause a hazard, the motor must not be operated without additional measures for fall protection. For example, mechanical brakes must be installed additionally.

To resume operation after activation of Safe Torque Off, first reapply 24 V DC voltage to terminal 37 (text Safe Torque Off activated is still displayed), then create a reset signal (via bus, Digital I/O, or [Reset] key on inverter).

By default, the Safe Torque Off functions is set to an Unintended Restart Prevention behavior. This means, in order to terminate Safe Torque Off and resume normal operation, the 24 V DC must first be reapplied to Terminal

37. Subsequently, send a reset signal (via Bus, Digital I/O, or [Reset] key).

WARNING

Automatic Restart Behavior is only allowed in one of the two situations:

1. The Unintended Restart Prevention is implemented by other parts of the Safe Torque Off installation.

2. A presence in the dangerous zone can be physically excluded when Safe Torque Off is not activated. In particular, paragraph 5.3.2.5 of ISO 12100-2 2003 must be observed.

2.6.2 Installation of External Safety Device in Combination with MCB 112

If the ex-certified thermistor module MCB 112, which uses Terminal 37 as its safety-related switch-off channel, is connected, then the output X44/12 of MCB 112 must be AND-ed with the safety-related sensor (such as emergency stop button, safety-guard switch, etc.) that activates Safe Torque Off. This means that the output to Safe Torque Off terminal 37 is HIGH (24 V) only if both the signal from MCB 112 output X44/12 and the signal from the safety-related sensor are HIGH. If at least one of the two signals is LOW, the output to Terminal 37 must be LOW, too. The safety device with this AND logic itself must conform to IEC 61508, SIL 2. The connection from the output of the safety device with safe AND logic to Safe Torque Off terminal 37 must be short-circuit protected. See Figure 2.7.

The Safe Torque Off function can be set to an Automatic Restart Behavior by setting the value of 5-19 Terminal 37 Safe Stop from default value [1] to value [3]. If a MCB 112 Option is connected to the adjustable frequency drive, then Automatic Restart Behavior is set by values [7] and [8]. Automatic Restart means that Safe Torque Off is terminated and normal operation is resumed as soon as the 24 V DC is applied to Terminal 37, and no reset signal is required.

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130BA967.11

121110987654321

37203332292 719181312

DI DI

SIL 2

Safe St op

Digital Input

e.g. Par 5-15

PTC Sensor

X44/

Par. 5-19

Terminal 37 Safe Stop

Safety Device

Safe I nput

Safe Out put

Safe AN D Input

Manual R estart

PTC Thermist or Card

MCB112

Non- Haz ardous AreaHazardous

Area

Introduction to VLT® HVAC D...

Design Guide

Figure 2.7 Figure of the essential aspects for installing a combination of a Safe Torque Off application and an MCB 112 application. The diagram shows a Restart input for the external Safety Device. This means that in this installation,

5-19 Terminal 37 Safe Stop might be set to value [7] PTC 1 & Relay W or [8] [8] PTC 1 & Relay A/W. Refer to MCB 112 Instruction Manual for further details.

Selections

[6] PTC 1 & Relay A to [9] PTC 1 & Relay W/A must

be selected for the combination of external safety device and MCB 112.

NOTICE!

Note that selections [7] PTC 1 & Relay W and [8] PTC 1 & Relay A/W open up for automatic restart when the

external safety device is de-activated again.

This is only allowed in the following cases:

The unintended restart prevention is

•

implemented by other parts of the Safe Torque Off installation.

A presence in the dangerous zone can be

•

physically excluded when Safe Torque Off is not activated. In particular, paragraph 5.3.2.5 of ISO 12100-2 2003 must be observed.

See MCB 112 Instruction Manual for further information.

Safe Torque Off Commissioning Test

2.6.3

After installation and before first operation, perform a commissioning test of an installation or application making use of Safe Torque Off. Moreover, perform the test after each modification of the installation or application which the Safe Torque Off is part of.

2 2

Parameter settings for external safety device in combination with MCB112

If MCB 112 is connected, then additional selections ([4] PTC 1 Alarm to [9] PTC 1 & Relay W/A) become possible for 5-19 Terminal 37 Safe Stop. Selections [1] Safe Torque Off Alarm and [3] Safe Torque Off Warning are still available but

are not to be used as these are for installations without MCB 112 or any external safety devices. If [1] Safe Torque Off Alarm or [3] Safe Torque Off Warning should be selected by mistake and MCB 112 is triggered, then the adjustable frequency drive reacts with an alarm ”Dangerous Failure [A72]” and coasts the adjustable frequency drive safely, without Automatic Restart. Selections [4] PTC 1 Alarm and [5] PTC 1 Warning are not to be selected when an external safety device is used. These selections are for when only MCB 112 uses the Safe Torque Off. If selection [4] PTC 1 Alarm or [5] PTC 1 Warning is selected by mistake and the external safety device triggers Safe Torque Off, the adjustable frequency drive issues an alarm ”Dangerous Failure [A72]” and coasts the adjustable frequency drive safely, without Automatic Restart.

NOTICE!

A passed commissioning test is mandatory after first installation and after each change to the safety installation.

The commissioning test (select one of cases 1 or 2 as applicable):

Case 1: Restart prevention for Safe Torque Off is required (i.e., Safe Torque Off only where 5-19 Terminal 37 Safe Stop is set to default value [1], or combined Safe Torque Off and MCB112 where 5-19 Terminal 37 Safe Stop is set to [6] or [9]):

1.1 Remove the 24 V DC voltage supply to terminal 37 using the interrupt device while the motor is driven by the FC 102 (i.e., the line power supply is not interrupted). The test step is passed if the motor reacts with a coast and the mechanical brake (if connected) is activated, and if an LCP is mounted, the alarm “Safe Torque Off [A68]” is displayed.

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Introduction to VLT® HVAC D... Design Guide

1.2 Send reset signal (via Bus, Digital I/O, or

The commissioning test is passed if all four test steps 1.1,

1.2, 1.3 and 1.4 are passed.

Case 2: Automatic Restart of Safe Torque Off is wanted and allowed (i.e., Safe Torque Off only where 5-19 Terminal 37 Safe Stop is set to [3], or combined Safe Torque Off and MCB112 where 5-19 Terminal 37 Safe Stop is set to [7] or [8]):

The test step is passed if the motor becomes operational again. The commissioning test is passed if both test steps

2.1 and 2.2 are passed.

[Reset] key). The test step is passed if the motor remains in the Safe Torque Off state, and the mechanical brake (if connected) remains activated.

1.3 Reapply 24 V DC to terminal 37. The test step is passed if the motor remains in the coasted state, and the mechanical brake (if connected) remains activated.

1.4 Send reset signal (via Bus, Digital I/O, or [Reset] key). The test step is passed if the motor becomes operational again.

2.1 Remove the 24 V DC voltage supply to terminal 37 by the interrupt device while the motor is driven by the FC 102 (i.e., line power supply is not interrupted). The test step is passed if the motor reacts with a coast and the mechanical brake (if connected) is activated, and if an LCP is mounted, the warning “Safe Torque Off [W68]” is displayed.

2.2 Reapply 24 V DC to terminal 37.

Compared to alternative control systems and technologies, an adjustable frequency drive is the optimum energy control system for controlling fan and pump systems.

Figure 2.8 Fan Curves (A, B and C) for Reduced Fan Volumes

NOTICE!

See warning on the restart behavior in chapter 2.6.1 Terminal 37 Safe Torque Off Function.

2.7 Advantages

2.7.1 Why use an adjustable frequency drive for controlling fans and pumps?

An adjustable frequency drive takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further information, see the text and figure The Laws of Proportionality.

2.7.2

The Clear Advantage - Energy Savings

The advantage of using an adjustable frequency drive for controlling the speed of fans or pumps lies in the electricity savings.

Figure 2.9 When Using an Adjustable Frequency Drive to Reduce Fan Capacity to 60% - More Than 50% Energy Savings may Be Obtained in Typical Applications.

Page 25

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

Introduction to VLT® HVAC D... Design Guide

2.7.3 Example of Energy Savings

As shown in the figure (the laws of proportionality), the flow is controlled by changing the RPM. By reducing the rated speed by only 20%, the flow is also reduced by 20%. This is because the flow is directly proportional to the RPM. The consumption of electricity, however, is reduced by 50%. If the system in question only needs to be able to supply a flow corresponding to 100% a few days each year, while the average is below 80% of the rated flow for the remainder of the year, the amount of energy saved is even greater than 50%.

The laws of proportionality

Figure 2.10 describes the dependence of flow, pressure and power consumption on RPM. Q = Flow P = Power Q1 = Rated flow P1 = Rated power Q2 = Reduced flow P2 = Reduced power H = Pressure n = Speed regulation H1 = Rated pressure n1 = Rated speed H2 = Reduced pressure n2 = Reduced speed

Comparison of Energy Savings

2.7.4

The Danfoss adjustable frequency drive solution offers major savings compared with traditional energy saving solutions. This is because the adjustable frequency drive is able to control fan speed according to thermal load on the system and the fact that the adjustable frequency drive has a built-in facility that enables the adjustable frequency drive to function as a Building Management System, BMS.

Figure 2.12 shows typical energy savings obtainable with three well-known solutions when fan volume is reduced to, e.g., 60%. Figure 2.12 shows more than 50% energy savings can be achieved in typical applications.

2 2

Table 2.5 Abbreviations Used in Equation

Figure 2.10 The Dependence of Flow, Pressure and Power Consumption on RPM

Flow

Pressure

Power

Figure 2.11 The Three Common Energy Saving Systems

Page 26

500

[h]

1000

1500

2000

200100 300

/h]

400

175HA210.11

Introduction to VLT® HVAC D...

Design Guide

Figure 2.12 Discharge dampers reduce power consumption somewhat. Inlet guide vans offer a 40% reduction but are expensive to install. The Danfoss adjustable frequency drive solution reduces energy consumption with more than 50% and is easy to install.

Figure 2.13 Example with Varying Flow

Example with Varying Flow over 1

2.7.5 Year

The example below is calculated on the basis of pump characteristics obtained from a pump datasheet. The result obtained shows energy savings in excess of 50% at the given flow distribution over a year. The payback period depends on the price per kWh and price of adjustable frequency drive. In this example, it is less than a year when compared with valves and constant speed.

Flow distribution over 1 year P

shaft=Pshaft output

Table 2.6 Energy Savings

Distri-

m3/

bution

% Hours Power Consumption Power Consump-

Valve regulation Adjustable frequency

drive control

tion

A1–B

kWh A1–C

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 2.7 Consumption

Better Control

2.7.6

If an adjustable frequency drive is used for controlling the flow or pressure of a system, improved control is obtained. An adjustable frequency drive can vary the speed of the fan or pump, thereby obtaining variable control of flow and pressure. Furthermore, an adjustable frequency drive can quickly adapt the speed of the fan or pump to new flow or pressure conditions in the system. Simple control of process (flow, level, or pressure) utilizing the built-in PID control.

Page 27

Full load

% Full load current

& speed

500

100

0 12,5 25 37,5 50Hz

200

300

400

600

700

800

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Introduction to VLT® HVAC D...

2.7.7

Cos φ Compensation

Design Guide

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

2.7.8 Star/Delta Starter or Soft-starter not Required

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

As illustrated in Figure 2.14, an adjustable frequency drive does not consume more than rated current.

2 2

Figure 2.14 An Adjustable Frequency Drive Does Not Consume More Than Rated Current

1 VLT® HVAC Drive 2 Star/delta starter 3 Soft-starter 4 Start directly on line power

Table 2.8 Legend to Figure 2.14

Page 28

Introduction to VLT® HVAC D... Design Guide

2.7.9 Using an Adjustable Frequency Drive Saves Money

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

2.7.10 Without an Adjustable Frequency Drive

D.D.C. = Direct Digital Control E.M.S. = Energy Management system

V.A.V. = Variable Air Volume

Sensor P = Pressure Sensor T = Temperature

Table 2.9 Abbreviations used in Figure 2.15 and Figure 2.16

Figure 2.15 Traditional Fan System

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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

Introduction to VLT® HVAC D...

Design Guide

2.7.11 With an Adjustable Frequency Drive

2 2

Figure 2.16 Fan System Controlled by Adjustable Frequency Drives.

2.7.12

Application Examples

The following pages give typical examples of applications within HVAC. For further information about a given application, ask a Danfoss supplier for an information sheet that gives a full description of the application.

Variable Air Volume

Ask for The Drive to...Improving Variable Air Volume Ventilation Systems MN.60.A1.02

Constant Air Volume

Ask for The Drive to...Improving Constant Air Volume Ventilation Systems MN.60.B1.02

Cooling Tower Fan

Ask for The Drive to...Improving fan control on cooling towers MN.60.C1.02

Condenser pumps

Ask for The Drive to...Improving condenser water pumping systems MN.60.F1.02

Primary pumps

Ask for The Drive to...Improve your primary pumping in primary/secondary pumping systems MN.60.D1.02

Secondary pumps

Ask for The Drive to...Improve your secondary pumping in primary/secondary pumping systems MN.60.E1.02

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Frequency converter

Cooling coil

Heating coil

Filter

Pressure signal

Supply fan

VAV boxes

Flow

Pressure transmitter

Return fan

130BB455.10

Introduction to VLT® HVAC D... Design Guide

2.7.13 Variable Air Volume

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

2.7.14 The VLT Solution

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

Figure 2.17 The VLT Solution

Page 31

Frequency converter

Pressure signal

Cooling coil

Heating coil

Filter

Pressure transmitter

Supply fan

Return fan

Temperature signal

Temperature transmitter

130BB451.10

Introduction to VLT® HVAC D... Design Guide

2.7.15 Constant Air Volume

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

2.7.16 The VLT Solution

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

With temperature control (especially used in air conditioning systems), as the outside temperature varies and the number of people in the controlled zone changes, different cooling requirements arise. 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 flow, energy used to heat or cool the fresh air is also reduced, adding further savings. Several features of the Danfoss HVAC dedicated adjustable frequency drive can be utilized to improve the performance of a 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 adjustable frequency drive also includes a 3-zone, 3-setpoint PID controller which allows monitoring of both temperature and air quality. Even if the temperature requirement is satisfied, the adjustable frequency drive will maintain enough supply air to satisfy the air quality sensor. The adjustable frequency drive is capable of monitoring and comparing two feedback signals to control the return fan by maintaining a fixed differential air flow between the supply and return ducts as well.

2 2

Figure 2.18 The VLT Solution

Page 32

Introduction to VLT® HVAC D... Design Guide

2.7.17 Cooling Tower Fan

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

2.7.18 The VLT Solution

With an adjustable frequency drive, the cooling towers fans can be set to the speed required to maintain the condenser water temperature. The adjustable frequency drives can also be used to turn the fan on and off as needed.

Several features of the Danfoss HVAC dedicated adjustable frequency drive, the HVAC adjustable frequency drive can be utilized to improve the performance of a cooling tower fans application. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes insignificant. Also, when utilizing a gear box to frequency control the tower fan, a minimum speed of 40–50% may be required. The customer programmable minimum frequency setting is available to maintain this minimum frequency even as the feedback or speed reference calls for lower speeds.

Also as a standard feature, program the adjustable frequency drive 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 adjustable frequency drive.

Page 33

Frequency converter

Water Inlet

Water Outlet

CHILLER

Temperature Sensor

BASIN

Conderser Water pump

Supply

130BB453.10

Introduction to VLT® HVAC D... Design Guide

2 2

Figure 2.19 The VLT Solution

Page 34

Frequency converter

Water Inlet

Water Outlet

BASIN

Flow or pressure sensor

Condenser Water pump

Throttling valve

Supply

CHILLER

130BB452.10

Introduction to VLT® HVAC D... Design Guide

2.7.19 Condenser Pumps

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

2.7.20 The VLT Solution

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

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

Figure 2.20 The VLT Solution

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Introduction to VLT® HVAC D... Design Guide

2.7.21 Primary Pumps

Primary pumps in a primary/secondary pumping system can be used to maintain a constant flow through devices that encounter operation or control difficulties when exposed to variable flow. The primary/secondary pumping technique decouples the “primary” production loop from the “secondary” distribution loop. This allows devices such as chillers to obtain constant design flow and operate properly, while allowing the rest of the system to vary in flow.

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

2.7.22 The VLT Solution

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

The first method uses a flow meter. Because the desired flow rate is known and constant, a flow meter installed at the discharge of each chiller can be used to control the pump directly. Using the built-in PID controller, the adjustable frequency drive always maintains the appropriate flow rate, even compensating for the changing resistance in the primary piping loop as chillers and their pumps are staged on and off.

2 2

The other method is local speed determination. The operator simply decreases the output frequency until the design flow rate is achieved. Using an adjustable frequency drive to decrease the pump speed is very similar to trimming the pump impeller, except it does not require any labor and the pump efficiency remains higher. The balancing contractor simply decreases the speed of the pump until the proper flow rate is achieved and leaves the speed fixed. The pump 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 off is usually small, this fixed speed remains appropriate. In the event the flow rate needs to be increased later in the systems life, the adjustable frequency drive can simply increase the pump speed instead of requiring a new pump impeller.

Page 36

Frequency converter

CHILLER

Flowmeter

F F

130BB456.10

Introduction to VLT® HVAC D... Design Guide

Figure 2.21 The VLT Solution

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Frequency converter

CHILLER

130BB454.10

Introduction to VLT® HVAC D... Design Guide

2.7.23 Secondary Pumps

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

2.7.24 The VLT Solution

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

2 2

Note that when running multiple pumps in parallel, they must run at the same speed to maximize energy savings, either with individual dedicated drives or one running multiple pumps in parallel.

Figure 2.22 The VLT Solution

Page 38

Inrush

R inr

Load sharing -

Load sharing +

LC Filter (5A)

LC Filter + (5A)

Brake Resistor

130BA193.14

L2 92

L1 91

L3 93

89(+)

88(-)

R+ 82

R81

U 96

V 97

W 98

P 14-50 R Filter

130BB153.10

100%

-100%

100%

P 3-13 Reference site

Local reference scaled to RPM or Hz

Auto mode

Hand mode

LCP Hand on, o and auto on keys

Linked to hand/auto

Local

Remote

Reference

Ramp

P 4-10 Motor speed direction

To motor control

Reference handling Remote reference

P 4-13 Motor speed high limit [RPM]

P 4-14 Motor speed high limit [Hz]

P 4-11 Motor speed low limit [RPM]

P 4-12 Motor speed low limit [Hz]

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

Introduction to VLT® HVAC D...

Design Guide

2.8 Control Structures

2.8.1 Control Principle

Figure 2.23 Control Structures

The adjustable frequency drive is a high-performance unit for demanding applications. It can handle various kinds of motor control principles such as U/f special motor mode and VVC

plus

and can handle normal squirrel cage asynchronous motors.

Short circuit behavior on this adjustable frequency drive depends on the three current transducers in the motor phases.

Select between open-loop and closed-loop in 1-00 Configuration Mode.

Control Structure Open-loop

2.8.2

Figure 2.24 Open-loop Structure

In the configuration shown in Figure 2.24, 1-00 Configuration 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.

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Introduction to VLT® HVAC D... Design Guide

2.8.3 PM/EC+ Motor Control

The Danfoss EC+ concept provides the possibility for using high efficient PM motors in IEC standard enclosure types operated by Danfoss adjustable frequency drives. The commissioning procedure is comparable to the existing one for asynchronous (induction) motors by utilizing the Danfoss VVC

Customer advantages:

Free choice of motor technology (permanent

•

magnet or induction motor) Installation and operation as known for induction

•

motors Manufacturer independent when choosing system

•

components (e.g., motors) Best system efficiency by choosing best

•

components Possible retrofit of existing installations

•

Power range: 1.5–30 hp [1.1–22 kW]

•

Current limitations:

Currently only supported up to 30 hp [22 kW]

•

Currently limited to non-salient type PM motors

•

LC filters not supported together with PM motors

•

Over Voltage Control algorithm is not supported

•

with PM motors Kinetic backup algorithm is not supported with

•

PM motors AMA algorithm is not supported with PM motors

•

No missing motor phase detection

•

No stall detection

•

No ETR function

•

plus

PM control strategy.

Sizing of Adjustable Frequency Drive

2.8.4 and PM motor

The low motor inductances of PM motors can cause current ripples in the adjustable frequency drive.

To select the right adjustable frequency drive for a given PM motor, ensure that:

The adjustable frequency drive can deliver the

•

required power and current in all operating conditions.

The power rating of the adjustable frequency

•

drive is equal to or higher than the power rating of the motor.

Size the adjustable frequency drive for a constant

•

100% operating load with sufficient safety margin.

The current (A) and the typical power rating (kW) for a PM motor can be found in chapter 9.1 Line Power Supply Tables for different voltages.

2 2

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Introduction to VLT® HVAC D...

Design Guide

Sizing examples for nominal power rating

Example 1

•

PM motor size: 1.5 kW / 2.9 A Line power: 3 x 400 V

Adjustable

Frequency Drive

P1K1 1.1 1.5 3.0 3.3 2.7 3.0 P1K5 1.5 2.0 4.1 4.5 3.4 3.7

Table 2.10 Sizing Data for 1.5 and 2 hp [1.1 and 1.5 kW] Adjustable Frequency Drives

Typical [kW] Typical [hp] at

460 V

Continuous

[A]

(3x380–440 V)

Intermitted

[A]

(3x380–440 V)

Continuous

[A]

(3x441–480 V)

Intermitted

[A]

(3x441–480 V)

The current rating of the PM motor (2.9 A) matches the current rating of both the 1.5 hp [1.1 kW] adjustable frequency drive (3 A @ 400 V) and the 2 hp [1.5 kW] adjustable frequency drive (4.1 A @ 400 V). However, since the power rating of the motor is 2 hp [1.5 kW], the 2 hp [1.5 kW] adjustable frequency drive is the correct choice.

Power 2 hp [1.5 kW] 2 hp [1.5 kW]

Current 2.9 A 4.1 A @ 400V

Table 2.11 Correctly Sized Adjustable Frequency Drive

Motor Adjustable Frequency Drive 2 hp [1.5 kW]

Example 2

PM motor size: 7.5 hp [5.5 kW] / 12.5 A

•

Line power: 3 x 400 V

•

Adjustable

Frequency Drive

P4K0 4.0 5.0 10.0 11.0 8.2 9.0 P5K5 5.5 7.5 13.0 14.3 11.0 12.1

Typical [kW] Typical [hp] at

460 V

Continuous

[A]

(3x380–440 V)

Intermitted

[A]

(3x380–440 V)

Continuous

[A]

(3x441–480 V)

Intermitted

[A]

(3x441–480 V)

Table 2.12 Sizing Data for 5 and 7.5 hp [4.0 and 5.5 kW] Adjustable Frequency Drives

The current rating of the PM motor (12.5 A) matches the current rating of the 7.5 hp [5.5 kW] adjustable frequency drive (13 A @ 400 V), not the current rating of the 5 hp [4.0 kW] adjustable frequency drive (10 A @ 400 V). Since the power rating of the motor is 7.5 hp [5.5 kW], the 7.5 hp [5.5 kW] adjustable frequency drive is the correct choice.

Power 7.5 hp [5.5 kW] 7.5 hp [5.5 kW]

Current 12.5 A 13 A @ 400 V

Table 2.13 Correctly Sized Adjustable Frequency Drive

Motor Adjustable Frequency Drive 7.5 hp [5.5 kW]

Page 41

130BP046.10

Hand

O

Auto

Reset

Introduction to VLT® HVAC D... Design Guide

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

The adjustable frequency drive can be operated manually via the local control panel (LCP) or remotely via analog/digital inputs or serial bus. If allowed in 0-40 [Hand on] Key on LCP, 0-41 [Off] Key on LCP, 0-42 [Auto on] Key on LCP, and 0-43 [Reset] Key on LCP, it is possible to start and stop the adjustable frequency drive by LCP using the [Hand On] and [Off] keys. Alarms can be reset via the [Reset] key. After pressing [Hand On], the adjustable frequency drive goes into Hand Mode and follows (as default) the local reference set by using

[▲] and [▼].

After pressing [Auto On], the adjustable frequency drive goes into Auto mode and follows (as default) the remote reference. In this mode, it is possible to control the adjustable frequency drive via the digital inputs and various serial interfaces (RS-485, USB, or an optional serial communication bus). See more about starting, stopping, changing ramps and parameter set-ups, etc.,in parameter group 5-1* Digital Inputs or parameter group 8-5* Serial Communication.

Local reference forces the configuration mode to openloop, independent on the setting of 1-00 Configuration Mode.

Local reference is restored at power-down.

2.8.6 Control Structure Closed-loop

The internal controller allows the adjustable frequency drive to become an integral part of the controlled system. The adjustable frequency drive receives a feedback signal from a sensor in the system. It then compares this feedback to a setpoint reference value and determines the error, if any, between these two signals. It then adjusts the speed of the motor to correct this error.

For example, consider a pump application where the speed of a pump is to be controlled so that the static pressure in a pipe is constant. The desired static pressure value is supplied to the adjustable frequency drive as the setpoint reference. A static pressure sensor measures the actual static pressure in the pipe and supplies this to the adjustable frequency drive as a feedback signal. If the feedback signal is greater than the setpoint reference, the adjustable frequency drive slows down to reduce the pressure. In a similar way, if the pipe pressure is lower than the setpoint reference, the adjustable frequency drive automatically speed up to increase the pressure provided by the pump.

2 2

Figure 2.25 Operation Keys

Hand Off Auto LCP Keys

Hand Linked to Hand/

Hand ⇒ Off

Auto Linked to Hand/

Auto ⇒ Off

All keys Local Local All keys Remote Remote

Table 2.14 Conditions for Either Local or Remote Reference

3-13 Reference Site Active Reference

Local Auto Linked to Hand/ Auto

Auto Linked to Hand/ Auto

Local

Remote

Table 2.14 shows under which conditions either the local reference or the remote reference is active. One of them is always active, but both cannot be active at the same time.

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Introduction to VLT® HVAC D... Design Guide

Figure 2.26 Block Diagram of Closed-loop Controller

While the default values for the adjustable frequency drive’s closed-loop controller often provides satisfactory performance, the control of the system can often be optimized by adjusting some of the closed-loop controller’s parameters. It is also possible to autotune the PI constants.

Feedback Handling

2.8.7

Figure 2.27 Block Diagram of Feedback Signal Processing

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Introduction to VLT® HVAC D... Design Guide

Feedback handling can be configured to work with applications requiring advanced control, such as multiple setpoints and multiple feedbacks. Three types of control are common.

Single Zone, Single Setpoint

Single Zone, Single Setpoint is a basic configuration. Setpoint 1 is added to any other reference (if any, see Reference Handling) and the feedback signal is selected using 20-20 Feedback Function.

Multi-zone, Single Setpoint

Multi-zone, Single Setpoint uses two or three feedback sensors, but only one setpoint. Feedback can be added, subtracted (only feedback 1 and 2) or averaged. In addition, the maximum or minimum value may be used. Setpoint 1 is used exclusively in this configuration.

If [5] Multi Setpoint Min is selected, the setpoint/feedback pair with the largest difference controls the speed of the adjustable frequency drive. [6] Multi Setpoint Max attempts to keep all zones at or below their respective setpoints, while [5] Multi Setpoint Min attempts to keep all zones at or above their respective setpoints.

Example

A two-zone two setpoint application Zone 1 setpoint is 15 bar and the feedback is 5.5 bar. Zone 2 setpoint is

4.4 bar and the feedback is 4.6 bar. If [14] Multi Setpoint Max is selected, Zone 1’s setpoint and feedback are sent to the PID controller, since this has the smaller difference (feedback is higher than setpoint, resulting in a negative difference). If [13] Multi Setpoint Min is selected, Zone 2’s setpoint and feedback is sent to the PID controller, since this has the larger difference (feedback is lower than setpoint, resulting in a positive difference).

Feedback Conversion

2.8.8

In some applications, it may be useful to convert the feedback signal. One example of this is using a pressure signal to provide flow feedback. Since the square root of pressure is proportional to flow, the square root of the pressure signal yields a value proportional to the flow. This is shown in Figure 2.28.

Figure 2.28 Feedback Conversion

2 2

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Introduction to VLT® HVAC D... Design Guide

2.8.9 Reference Handling

Details for Open-loop and Closed-loop operation

Figure 2.29 Block Diagram Showing Remote Reference

Page 45

Introduction to VLT® HVAC D... Design Guide

The remote reference is comprised of:

Preset references.

•

External references (analog inputs, pulse

•

frequency inputs, digital potentiometer inputs and serial communication bus references).

The preset relative reference.

•

Feedback controlled setpoint.

•

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

2.8.10

In a ventilation system, the temperature is to be maintained at a constant value. The desired temperature is set between 23–95 °F [-5–+35 °C] using a 0–10 V potentiometer. Because this is a cooling application, if the temperature is above the setpoint value, the speed of the fan must be increased to provide more cooling air flow. The temperature sensor has a range of 14–104 °F [-10–+40 °C] and uses a two-wire transmitter to provide a 4–20 mA signal. The output frequency range of the adjustable frequency drive is 10 to 50 Hz.

Example of Closed-loop PID Control

Figure 2.30 Closed-loop Control for a Ventilation System

2 2

The scaled reference is calculated as follows:

Reference

= X + X ×

Where X is the external reference, the preset reference or the sum of these and Y is 3-14 Preset Relative Reference in [%].

If Y, 3-14 Preset Relative Reference is set to 0%, the reference is affected by the scaling.

100

1. Start/Stop via switch connected between terminals 12 (+24 V) and 18.

2. Temperature reference via a potentiometer (23–95 °F [-5–+35 °C], 0 to 10 V) connected to terminals 50 (+10 V), 53 (input) and 55 (common).

3. Temperature feedback via transmitter (14–104 °F [-10–+40 °C], 4–20 mA) connected to terminal 54. Switch S202 behind the LCP set to ON (current input).

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Introduction to VLT® HVAC D... Design Guide

Function Para--

Check that the ramp settings are within capabilities of the adjustable frequency drive and allowed application operating specifications. Prohibit the motor from reversing (if necessary). Set acceptable limits for the motor speed.

Switch from open-loop to closed-loop.

4) Configure the feedback to the PID controller. Select the appropriate reference/feedback unit.

5) Configure the setpoint reference for the PID controller. Set acceptable limits for the setpoint reference. Select current or voltage by switches S201 / S202.

6) Scale the analog inputs used for setpoint reference and

Figure 2.31 Example of Closed-loop PID Control

2.8.11

Programming Order

NOTICE!

In this example, it is assumed that an induction motor is used, i.e., that 1-10 Motor Construction = [0] Asynchron.

Function Para--

meter

1) Make sure the motor runs properly. Do the following: Set the motor parameters using nameplate data. Run Automatic Motor Adaptation.

2) Check that the motor is running in the right direction. Run Motor Rotation Check.

3) Make sure the adjustable frequency drive limits are set to safe values.

1-2* As specified by motor

1-29

1-28 If the motor runs in the

Setting

nameplate

[1] Enable complete AMA

and then run the AMA function

wrong direction, remove power temporarily and reverse two of the motor phases

feedback. Scale Analog Input 53 for the pressure range of the potentiometer (0–10 Bar, 0–10 V). Scale Analog Input 54 for pressure sensor (0–10 Bar, 4–20 mA).

7) Tune the PID controller parameters. Adjust the adjustable frequency drive’s closedloop controller, if needed.

8) Save to finish. Save the parameter settings to the LCP for safekeeping.

Table 2.15 Programming Order

meter

3-41 3-42

4-10

4-12 4-14 4-19

1-00

20-12

20-13 20-14

6-10 6-11 6-14 6-15 6-22 6-23 6-24 6-25

20-93 20-94

0-50

Setting

60 s 60 s Depends on motor/load size! Also active in hand mode.

[0] Clockwise

10 Hz, Motor min speed 50 Hz, Motor max speed 50 Hz, Drive max output

frequency [3] Closed-loop

[71] Bar

0 Bar 10 Bar

0 V 10 V (default) 0 Bar 10 Bar 4 mA 20 mA (default) 0 Bar 10 Bar

See Optimization of the PID Controller, below

[1] All to LCP

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Introduction to VLT® HVAC D... Design Guide

2.8.12 Tuning the Adjustable Frequency Drive Closed-loop Controller

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

2.8.13 Manual PID Adjustment

1. Start the motor.

Set 20-93 PID Proportional Gain to 0.3 and increase it until the feedback signal begins to oscillate. If necessary, start and stop the adjustable frequency drive or make step changes in the setpoint reference to attempt to cause oscillation. Next reduce the PID proportional gain until the feedback signal stabilizes. Then reduce the proportional gain by 40–60%.

Set 20-94 PID Integral Time to 20 s and reduce it until the feedback signal begins to oscillate. If necessary, start and stop the adjustable frequency drive or make step changes in the setpoint reference to attempt to cause oscillation. Next, increase the PID integral time until the feedback signal stabilizes. Then increase of the integral time by 15–50%.

20-95 PID Differentiation Time should only be used for very fast-acting systems. The typical value is 25% of 20-94 PID Integral Time. The differential function should only be used when the setting of the proportional gain and the integral time has been fully optimized. Make sure that oscillations of the feedback signal are sufficiently dampened by the low-pass filter for the feedback signal (parameters 6-16, 6-26, 5-54 or 5-59 as required).

2 2

Page 48

175ZA062.12

Introduction to VLT® HVAC D...

Design Guide

2.9 General Aspects of EMC

Electrical interference is usually conducted at frequencies in the range 150 kHz to 30 MHz. Airborne interference from the adjustable frequency drive system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor. As shown in Figure 2.32, capacitance in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents. The use of a shielded motor cable increases the leakage current (see Figure 2.32) because shielded cables have higher capacitance to ground than non-shielded cables. If the leakage current is not filtered, it causes greater interference on the line power in the radio frequency range below approximately 5 MHz. Since the leakage current (I1) is carried back to the unit through the shield (I3), there is in principle only a small electro-magnetic field (I4) from the shielded motor cable according to Figure 2.32.

The shield reduces the radiated interference, but increases the low-frequency interference in the line power supply. Connect the motor cable shield to the adjustable frequency drive enclosure as well as on the motor enclosure. This is best done by using integrated shield clamps so as to avoid twisted shield ends (pigtails) Pigtails increase the shield impedance at higher frequencies, which reduces the shield effect and increases the leakage current (I4). If a shielded cable is used for relay, control cable, signal interface and brake, mount the shield on the enclosure at both ends. In some situations, however, it is necessary to break the shield to avoid current loops.

Figure 2.32 Situation that Generates Leakage Currents

1 Ground wire 4 Adjustable frequency drive 2 Shield 5 Shielded motor cable 3 AC line power supply 6 Motor

Table 2.16 Legend to Figure 2.32

If the shield is to be placed on a mounting plate for the adjustable frequency drive, the mounting plate must be made of metal, to convey the shield currents back to the unit. Moreover, ensure good electrical contact from the mounting plate through the mounting screws to the adjustable frequency driver chassis.

When non-shielded cables are used, some emission requirements are not complied with, although most immunity requirements are observed.

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Introduction to VLT® HVAC D... Design Guide

To reduce the interference level from the entire system (unit+installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50 MHz (airborne) is especially generated by the control electronics. See for more information on EMC.

2.9.1 Emission Requirements

According to the EMC product standard for adjustable speed adjustable frequency drives EN/IEC 61800-3:2004, the EMC requirements depend on the intended use of the adjustable frequency drive. Four categories are defined in the EMC product standard. The definitions of the four categories together with the requirements for line power supply voltage conducted emissions are given in Table 2.17.

Conducted emission requirement

Category Definition

C1 Adjustable frequency drives

installed in the first environment (home and office) with a supply voltage less than 1000 V.

C2 Adjustable frequency drives

installed in the first environment (home and office) with a supply voltage less than 1000 V, which are neither plug-in nor movable and are intended to be installed and commissioned by a professional.

C3 Adjustable frequency drives

installed in the second environment (industrial) with a supply voltage lower than 1000 V.

C4 Adjustable frequency drives

installed in the second environment with a supply voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems.

according to the limits given in EN 55011

Class B

Class A Group 1

Class A Group 2

No limit line. An EMC plan should be made.

When the generic (conducted) emission standards are used the adjustable frequency drives are required to comply with the following limits.

Conducted emission

Environment Generic standard

First environment (home and office) Second environment (industrial environment)

Table 2.18 Limits at Generic Emission Standards

EMC Test Results

2.9.2

EN/IEC 61000-6-3 Emission standard for residential, commercial and light industrial environments. EN/IEC 61000-6-4 Emission standard for industrial environments.

requirement according to the limits given in EN 55011

Class B

Class A Group 1

The following test results have been obtained using a system with an adjustable frequency drive, a shielded control cable, a control box with potentiometer, as well as a motor and shielded motor cable at nominal switching frequency. In Table 2.19, the maximum motor cable lengths for compliance are stated.

2 2

Table 2.17 Emission Requirements

Page 50

Introduction to VLT® HVAC D...

Design Guide

RFI filter type Conducted emission Radiated emission

Standards and requirements

EN 55011 Class B

Housing,

trades and

industries

EN/IEC 61800-3 Category C1

environment

Home and

Cable length (ft [m]) Cable length (ft [m])

light

First

office

Class A

Group 1

Industrial

environ-

ment

Category C2

First

environment

Home and

office

Class A

Group 2

Industrial

environ-

ment

Category C3

Second

environment

Industrial

Class B

Housing,

trades and

light

industries

Category C1

First

environment

home and

office

Class A

Group 1

Industrial

environment

Category C2

First

environment

home and

office

Class A

Group 2

Industrial

environment

Category C3

Second

environment

Industrial

FC 102

1.5–30 hp [1.1–22 kW] 220–240 V

1.5–60 hp [1.1–45 kW] 200–240 V

1.5–125 hp [1.1–90 kW] 380–480 V

164 [50] 492 [150] 492 [150] No Yes N/A

164 [50] 492 [150] 492 [150] No Yes Yes

FC 102 1.5–30 hp [1.1–22 kW]

220–240 V

1.5–5 hp [1.1–3.7 kW] 200–240 V

7.5–60 hp [5.5–45 kW] 200–240 V

1.5–10 hp [1.1–7.5 kW] 380–500 V

15–125 hp [11–90 kW]

380–500 V

15–30 hp [11–22 kW]

525–690 V

1, 4)

40–125 hp [30–90 kW]

525–690 V

2, 4)

No No 82 [25] No No N/A

No No 16.4 [5] No No No

No No 82 [25] No No No

No No 16.4 [5] No No No

No No 82 [25] No No No

FC 102

1.5–60 hp [1.1–45 kW] 200–240 V

1.5–125 hp [1.1–90 kW] 380–480 V

33 [10] 164 [50] 250 [75] No Yes Yes

FC 102

15–40 hp [11–30 kW]

525–690 V

50–125 hp [37–90 kW]

525–690 V

1.5–125 hp [1.1–90 kW] 525–600 V

No 330 [100] 330 [100] No Yes Yes

No 492 [150] 492 [150] No Yes Yes

No No No No No No

Table 2.19 EMC Test Results (Emission)

1) Enclosure Type B

2) Enclosure Type C

3) Hx versions can be used according to EN/IEC 61800-3 category C4

Page 51

175HA034.10

Introduction to VLT® HVAC D... Design Guide

4) T7, 50–125 hp [37–90 kW] complies with class A group 1 with 82 ft [25 m] motor cable. Some restrictions for the installation apply (contact Danfoss for details). HX, H1, H2, H3, H4 or H5 is defined in the type code pos. 16-17 for EMC filters HX - No EMC filters built in the adjustable frequency drive (600 V units only) H1 - Integrated EMC filter. Fulfill EN 55011 Class A1/B and EN/IEC 61800-3 Category 1/2 H2 - No additional EMC filter. Fulfill EN 55011 Class A2 and EN/IEC 61800-3 Category 3 H3 - Integrated EMC filter. Fulfill EN 55011 class A1/B and EN/IEC 61800-3 Category 1/2 H4 - Integrated EMC filter. Fulfill EN 55011 class A1 and EN/IEC 61800-3 Category 2 H5 – Marine versions. Fulfill same emissions levels as H2 versions

2.9.3 General Aspects of Harmonics Emission

2 2

An adjustable frequency drive takes up a non-sinusoidal current from the line power, which increases the input current I A non-sinusoidal current is transformed with a Fourier analysis and split into sine-wave currents with different frequencies, that is, different harmonic currents In with 50 Hz basic frequency:

Hz 50 250 350

Table 2.20 Harmonic Currents

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

Figure 2.33 Harmonic Currents

NOTICE!

Some of the harmonic currents might disturb communication equipment connected to the same transformer or cause resonance with power-factor correction batteries.

RMS

To ensure low harmonic currents, the adjustable frequency drive is equipped with intermediate circuit coils as standard. This normally reduces the input current I

by 40%.

RMS

The voltage distortion on the line power supply voltage depends on the size of the harmonic currents multiplied by the line power impedance for the frequency in question. The total voltage distortion THD is calculated based on the individual voltage harmonics using this formula:

THD

% =

+ ... +

(UN% of U)

Page 52

Introduction to VLT® HVAC D...

Design Guide

2.9.4 Harmonics Emission Requirements

Equipment connected to the public supply network

Compliance with various system level guidelines: The harmonic current data in Table 2.22 are given in accordance with IEC/EN61000-3-12 with reference to the Power Drive Systems product standard. The data may be

Options Definition

1 IEC/EN 61000-3-2 Class A for 3-phase balanced

equipment (for professional equipment only up to 1 kW total power).

2 IEC/EN 61000-3-12 Equipment 16 A-75 A and profes-

sional equipment as from 1 kW up to 16 A phase current.

Table 2.21 Connected Equipment

used to calculate the harmonic currents' influence on the power supply system and to document compliance with relevant regional guidelines: IEEE 519 -1992; G5/4.

2.9.6 Immunity Requirements

The immunity requirements for adjustable frequency drives depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office

Harmonics Test Results (Emission)

2.9.5

environment. All Danfoss adjustable frequency drives comply with the requirements for the industrial

Power sizes up to PK75 in T2 and T4 comply with IEC/EN 61000-3-2 Class A. Power sizes from P1K1 and up to P18K in T2 and up to P90K in T4 comply with IEC/EN

environment and consequently comply also with the lower requirements for home and office environment with a large safety margin.

61000-3-12, Table 4. Power sizes P110 - P450 in T4 also comply with IEC/EN 61000-3-12 even though not required because currents are above 75 A.

To document immunity against electrical interference from electrical phenomena, the following immunity tests have been made in accordance with following basic standards:

Actual (typical) Limit for R

≥120

sce

Actual (typical) Limit for R

≥120

sce

Table 2.22 Harmonics Test Results (Emission)

If the short-circuit power of the supply Ssc is greater than or equal to:

= 3 ×

SCE

at the interface point between the user’s supply and the public system (R

It is the responsibility of the installer or user of the

Individual harmonic current In/I1 (%)

40 20 10 8

40 25 15 10

Harmonic current distortion factor (%)

line power

sce

THD PWHD

46 45

48 46

equ

= 3 × 120 × 400 ×

equ

EN 61000-4-2 (IEC 61000-4-2): Electrostatic

•

discharges (ESD): Simulation of electrostatic discharges from human beings.

EN 61000-4-3 (IEC 61000-4-3): Incoming electro-

•

magnetic field radiation, amplitude modulated simulation of the effects of radar and radio communication equipment as well as mobile communications equipment.

EN 61000-4-4 (IEC 61000-4-4): Electrical

•

interference: Simulation of interference brought about by switching a contactor, relay or similar devices.

EN 61000-4-5 (IEC 61000-4-5): Surge transients:

•

Simulation of transients brought about, e.g., by lightning that strikes near installations.

EN 61000-4-6 (IEC 61000-4-6): RF Common

•

mode: Simulation of the effect from radiotransmission equipment joined by connection cables.

See Table 2.23.

equipment to ensure that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to what is specified above. If necessary, consult the distribution network operator. Other power sizes can be connected to the public supply network by consultation with the distribution network operator.

Page 53

Introduction to VLT® HVAC D...

Design Guide

Basic standard Electrical

interference

IEC 61000-4-4

Surge

IEC 61000-4-5

ESD

IEC

61000-4-2

Radiated electromagnetic

field

IEC 61000-4-3

RF common mode voltage IEC 61000-4-6

Acceptance criterion B B B A A Voltage range: 200–240 V, 380–500 V, 525–600 V, 525–690 V

Line

Motor

4 kV CM

4 kV CM Brake 4 kV CM Load sharing 4 kV CM Control wires

2 kV CM Standard bus 2 kV CM Relay wires 2 kV CM Application and serial

communication options LCP cable External 24 V DC

Enclosure

2 kV CM

2 V CM

— —

2 kV/2 Ω DM

4 kV/12 Ω CM

4 kV/2 Ω 4 kV/2 Ω 4 kV/2 Ω 2 kV/2 Ω 2 kV/2 Ω 2 kV/2 Ω

2 kV/2 Ω

0.5 kV/2 Ω DM 1 kV/12 Ω CM

— —

— — — — — — — — — — — —

— —

8 kV AD 6 kV CD

10 V

10 V 10 V 10 V 10 V 10 V 10 V

10 V

10 V/m —

Table 2.23 EMC Immunity Form

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

2 2

RMS

2.10

Galvanic Isolation (PELV)

2.10.1 PELV - Protective Extra Low Voltage

PELV offers protection by way of extra low voltage. Protection against electric shock is ensured when the electrical supply is of the PELV type and the installation is made as described in local/national regulations on PELV supplies.

All control terminals and relay terminals 01-03/04-06 comply with PELV (Protective Extra Low Voltage), with the exception of the grounded Delta leg above 400 V.

Galvanic (ensured) isolation is obtained by fulfilling requirements for higher isolation and by providing the relevant creepage/clearance distances. These requirements are described in the EN 61800-5-1 standard.

The components that make up the electrical isolation, as described below, also comply with the requirements for higher isolation and the relevant test as described in EN 61800-5-1. The PELV galvanic isolation can be shown in six locations (see Figure 2.34):

To maintain PELV all connections made to the control terminals must be PELV, e.g., thermistor must be reinforced/double insulated.

Page 54

130BC968.10

1325 4

130BB955.12

Leakage current

Motor cable length

130BB956.12

THVD=0%

THVD=5%

Leakage current

Introduction to VLT® HVAC D... Design Guide

1. Power supply (SMPS) incl. signal isolation of UDC,

indicating the voltage of intermediate DC link circuit.

2. Gate drive that runs the IGBTs (trigger transformers/opto-couplers).

3. Current transducers.

4. Opto-coupler, brake module.

5. Internal soft-charge, RFI and temperature measurement circuits.

6. Custom relays.

7. Mechanical brake.

2.11 Ground Leakage Current

Follow national and local codes regarding protective grounding of equipment with a leakage current > 3.5 mA. Adjustable frequency drive technology implies high frequency switching at high power. This generates a leakage current in the ground connection. A fault current in the adjustable frequency drive at the output power terminals might contain a DC component which can charge the filter capacitors and cause a transient ground current. The ground leakage current is made up from several contributions and depends on various system configurations including RFI filtering, shielded motor cables and adjustable frequency drive power.

Figure 2.35 Cable Length and Power Size Influence on Leakage Current. Pa > Pb

Figure 2.34 Galvanic Isolation

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

WARNING

Installation at high altitude: 380–500 V, enclosure types A, B and C: At altitudes above 6,600 ft [2 km], contact Danfoss regarding PELV. 525–690 V: At altitudes above 6,600 ft [2 km], contact Danfoss regarding PELV.

WARNING

Touching the electrical parts could be fatal - even after the equipment has been disconnected from line power. Also make sure that other voltage inputs have been disconnected, such as load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic backup. Before touching any electrical parts, wait at least the amount of time indicated in Table 2.19. Shorter time is allowed only if indicated on the nameplate for the specific unit.

Figure 2.36 Line Distortion Influences Leakage Current

NOTICE!

When a filter is used, turn off 14-50 RFI 1 when charging the filter to avoid that a high leakage current makes the RCD switch.

Page 55

130BB958.12

Cable

150 Hz

3rd harmonics

50 Hz

Mains

RCD with low f

cut-

RCD with high f

cut-

Leakage current

Frequency

130BB957.11

Leakage current [mA]

100 Hz

2 kHz

100 kHz

to ta

130BA167.10

Load

Time

Speed

Introduction to VLT® HVAC D...

Design Guide

EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3.5 mA. Grounding must be reinforced in one of the following ways:

Ground wire (terminal 95) of at least 0.016 in

•

[10 mm2] Two separate ground wires both complying with

•

the dimensioning rules

See EN/IEC61800-5-1 and EN50178 for further information.

Using RCDs

Where residual current devices (RCDs), also known as ground leakage circuit breakers (GLCBs), are used, comply with the following:

Use RCDs of type B only which are capable of

•

detecting AC and DC currents Use RCDs with a soft-charge delay to prevent

•

faults due to transient ground currents Dimension RCDs according to the system configu-

•

ration and environmental considerations

2.12

Brake Function

2.12.1 Selection of Brake Resistor

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

If the amount of kinetic energy transferred to the resistor in each braking period is not known, the average power can be calculated on the basis of the cycle time and braking time, also known as the intermitted duty cycle. The resistor intermittent duty cycle is an indication of the duty cycle at which the resistor is active. Figure 2.39 shows a typical braking cycle.

The intermittent duty cycle for the resistor is calculated as follows:

2 2

Duty Cycle = tb / T

T = cycle time in seconds tb is the braking time in seconds (as part of the total cycle time)

Figure 2.37 Main Contributions to Leakage Current

Figure 2.39 Intermittent Duty Cycle for the Resistor Figure 2.38 The Influence of the Cut-off Frequency of the RCD on What Is Responded to/Measured

Danfoss offers brake resistors with duty cycle of 5%, 10% and 40% suitable for use with the VLT® HVAC Drive

See also Output Filter Design Guide.

Page 84

How to Order Design Guide

4.2.4 Ordering Numbers: Sine-Wave Filter Modules, 525–600/690 V AC

Adj. Frequency Drive Size

525–600 [V AC] 690 [V AC]

P1K1 2 100 130B2341 130B2321 13 P1K5 2 100 130B2341 130B2321 13

P2k2 2 100 130B2341 130B2321 13 P3K0 2 100 130B2341 130B2321 13 P4K0 2 100 130B2341 130B2321 13 P5K5 2 100 130B2341 130B2321 13 P7K5 2 100 130B2341 130B2321 13 P11K 2 100 130B2342 130B2322 28 P15K 2 100 130B2342 130B2322 28 P18K 2 100 130B2342 130B2322 28 P22K 2 100 130B2342 130B2322 28 P30K 2 100 130B2343 130B2323 45 P37K P45K 2 100 130B2344 130B2324 76 P45K P55K 2 100 130B2344 130B2324 76 P55K P75K 2 100 130B2345 130B2325 115 P75K P90K 2 100 130B2345 130B2325 115 P90K P110 2 100 130B2346 130B2326 165

P132 2 100 130B2346 130B2326 165 P160 2 100 130B2347 130B2327 260 P200 2 100 130B2347 130B2327 260 P250 2 100 130B2348 130B2329 303 P315 2 100 130B2370 130B2341 430 P355 1.5 100 130B2370 130B2341 430 P400 1.5 100 130B2370 130B2341 430 P450 1.5 100 130B2371 130B2342 530 P500 1.5 100 130B2371 130B2342 530 P560 1.5 100 130B2381 130B2337 660 P630 1.5 100 130B2381 130B2337 660 P710 1.5 100 130B2382 130B2338 765 P800 1.5 100 130B2383 130B2339 940 P900 1.5 100 130B2383 130B2339 940 P1M0 1.5 100 130B2384 130B2340 1320 P1M2 1.5 100 130B2384 130B2340 1320 P1M4 1.5 100 2x130B2382 2x130B2338 1479

Minimum switching

frequency [kHz]

Maximum output

frequency [Hz]

Part No. IP20 Part No. IP00

Rated filter

current at

50 Hz [A]

Table 4.12 Line Power Supply 3 x 525–690 V AC

NOTICE!

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

NOTICE!

See also Output Filter Design Guide.

Page 85

How to Order Design Guide

4.2.5 Ordering Numbers: dU/dt Filters, 380–480 V AC

Adj. Frequency Drive Size

380–439 [V AC] 440–480 [V AC]

P11K P11K 4 100 130B2396 130B2385 24 P15K P15K 4 100 130B2397 130B2386 45 P18K P18K 4 100 130B2397 130B2386 45 P22K P22K 4 100 130B2397 130B2386 45 P30K P30K 3 100 130B2398 130B2387 75 P37K P37K 3 100 130B2398 130B2387 75 P45K P45K 3 100 130B2399 130B2388 110 P55K P55K 3 100 130B2399 130B2388 110 P75K P75K 3 100 130B2400 130B2389 182 P90K P90K 3 100 130B2400 130B2389 182 P110 P110 3 100 130B2401 130B2390 280 P132 P132 3 100 130B2401 130B2390 280 P160 P160 3 100 130B2402 130B2391 400 P200 P200 3 100 130B2402 130B2391 400 P250 P250 3 100 130B2277 130B2275 500 P315 P315 2 100 130B2278 130B2276 750 P355 P355 2 100 130B2278 130B2276 750 P400 P400 2 100 130B2278 130B2276 750

P450 2 100 130B2278 130B2276 750 P450 P500 2 100 130B2405 130B2393 910 P500 P560 2 100 130B2405 130B2393 910 P560 P630 2 100 130B2407 130B2394 1500 P630 P710 2 100 130B2407 130B2394 1500 P710 P800 2 100 130B2407 130B2394 1500 P800 P1M0 2 100 130B2407 130B2394 1500

P1M0 2 100 130B2410 130B2395 2300

Minimum switching

frequency [kHz]

Maximum output

frequency [Hz]

Part No. IP20 Part No. IP00

Rated filter current at

50 Hz [A]

4 4

Table 4.13 Line Power supply 3x380 to 3x480 V AC

NOTICE!

See also Output Filter Design Guide.

Page 86

How to Order Design Guide

4.2.6 Ordering Numbers: dU/dt Filters, 525–600/690 V AC

Adj. Frequency Drive Size

525–600 [V AC] 690 [V AC]

P1K1 4 100 130B2423 130B2414 28 P1K5 4 100 130B2423 130B2414 28 P2K2 4 100 130B2423 130B2414 28

P3K0 4 100 130B2423 130B2414 28 P4K0 4 100 130B2424 130B2415 45 P5K5 4 100 130B2424 130B2415 45 P7K5 3 100 130B2425 130B2416 75 P11K 3 100 130B2425 130B2416 75 P15K 3 100 130B2426 130B2417 115 P18K 3 100 130B2426 130B2417 115 P22K 3 100 130B2427 130B2418 165 P30K 3 100 130B2427 130B2418 165 P37K P45K 3 100 130B2425 130B2416 75 P45K P55K 3 100 130B2425 130B2416 75 P55K P75K 3 100 130B2426 130B2417 115 P75K P90K 3 100 130B2426 130B2417 115 P90K P110 3 100 130B2427 130B2418 165

P132 2 100 130B2427 130B2418 165 P160 2 100 130B2428 130B2419 260 P200 2 100 130B2428 130B2419 260 P250 2 100 130B2429 130B2420 310 P315 2 100 130B2238 130B2235 430 P400 2 100 130B2238 130B2235 430 P450 2 100 130B2239 130B2236 530 P500 2 100 130B2239 130B2236 530 P560 2 100 130B2274 130B2280 630 P630 2 100 130B2274 130B2280 630 P710 2 100 130B2430 130B2421 765 P800 2 100 130B2431 130B2422 1350 P900 2 100 130B2431 130B2422 1350 P1M0 2 100 130B2431 130B2422 1350 P1M2 2 100 130B2431 130B2422 1350 P1M4 2 100 2x130B2430 2x130B2421 1530

Minimum switching

frequency [kHz]

Maximum output

frequency [Hz]

Part No. IP20 Part No. IP00

Rated filter current at 50

Hz [A]

Table 4.14 Line Power Supply 3x525 to 3x690 V AC

NOTICE!

See also Output Filter Design Guide.

4.2.7 Ordering Numbers: Brake Resistors

NOTICE!

See Brake Resistor Design Guide.

Page 87

Mechanical Installation Design Guide

5 Mechanical Installation

5.1 Mechanical Installation

5.1.1 Safety Requirements of Mechanical Installation

WARNING

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

CAUTION

The adjustable frequency drive is cooled by air circulation. To protect the unit from overheating, it must be ensured that the ambient temperature does not exceed the

maximum temperature stated for the adjustable frequency drive, and that the 24-hour average temperature is not exceeded. Locate the maximum temperature and 24-hour average in chapter 9.6.2 Derating for Ambient Temperature.

If the ambient temperature is in the range of 113–131 °F [45 °C–55 °C], derating of the adjustable frequency drive becomes relevant, see chapter 9.6.2 Derating for Ambient Temperature. The service life of the adjustable frequency drive is reduced if derating for ambient temperature is not taken into account.

5 5

Page 88

130BA809.10

130BA810.10

130BB458.10

130BA811.10

130BA812.10

130BA813.10

130BA826.10

130BA827.10

130BA814.10

130BA815.10

130BA828.10

130BA829.10

130BA648.12

130BA715.12

Mechanical Installation Design Guide

5.1.2 Mechanical Dimensions

(B4, C3 and C4 only)

Top and bottom mounting holes

* A5 in IP55/66 only

A2 A3 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4

IP20/21 IP20/21 IP55/66 IP55/66 IP21/55/66 IP21/55/66 IP20 IP20 IP21/55/66 IP21/55/66 IP20 IP20

Accessory bags containing necessary brackets, screws and connectors are included with the adjustable frequency drives upon delivery.

Table 5.1 Mechanical Dimensions

Page 89

Mechanical Installation Design Guide

50–60

[37–45]

30–40

[22–30]

50–60

[37–45]

25–40

[18–30]

11–25

[15–18]

7.5–15

[5.5–11]

[15]

7.5–15

[5.5–11]

[75–90]

100–125

60–75

[45–55]

[75–90]

100–125

50–75

[37–55]

30–50

[22–37]

15–25

[11–18]

30–40

[22–30]

15–25

[11–18]

[75–90]

100–125

60–75

[45–55]

[75–90]

100–125

50–75

[37–55]

30–50

[22–37]

15–25

[11–18]

30–40

[22–30]

15–25

[11–18]

50–125

[37–90]

[11–30]

Chassis

Type 1/

21/55/66

Type 1/

21/55/66

Chassis

Type 1/

21/55/66

Type 1/

21/ 55/66

Type 12

25.98

21.65

30.32

26.77

20.47

15.71

25.59

18.90

[660]

[550]

[770]

[680]

[520]

[399]

[650]

[480]

31.5

24.8

23.43

16.54

[800]

[630]

[595]

[420]

24.84

20.51

29.1

25.51

19.50

14.96

24.57

17.87

[631]

[521]

[739]

[648]

[495]

[380]

[624]

[454]

14.57

12.13

14.57

12.13

9.06

6.5

9.53

[370]

[308]

[370]

[308]

[230]

[165]

[242]

14.57

12.13

14.57

12.13

9.06

8.07

9.53

[370]

[308]

[370]

[308]

[230]

[205]

[242]

14.57

12.13

14.57

12.13

9.06

8.86

9.53

[370]

[308]

[370]

[308]

[230]

[225]

[242]

10.63

13.15

10.71

7.87

5.51

8.27

[330]

[270]

[334]

[272]

[200]

[140]

[210]

12.99

13.19

12.21

9.53

9.8

10.24

[333]

[335]

[310]

[242]

[249]

[260]

12.99

13.19

12.21

9.53

10.32

10.24

[333]

[335]

5 5

[310]

[242]

[262]

[260]

1.5–5

1.5–3

4–5

200–240 V 1.5–3

1.5–10

[1.1–3.7]

1.5–5

[1.1–2.2]

7.5–10

[3–3.7]

1.5–5

[1.1–2.2]

380–480/

1.5–10

[1.1–7.5]

[1.1–4]

[5.5–7.5]

[1.1–4.0]

525–600 V 1.5–10

500 V

[1.1–7.5]

525–690 V 15–40

55/66

Type 12

55/66

Type 12

Type 1

Chassis

Type 1

Chassis

16.54

15.35

14.76

10.6

14.76

10.60

[420]

[390]

[375]

[268]

[375]

[268]

- - - - -

14.72

[374]

15.83

15.80

13.80

10.12

13.80

10.12

[402]

[401]

[350]

[257]

[350]

[257]

9.53

7.87

5.12

3.54

[242]

[200]

[130]

[90]

9.53

6.69

5.12

[242]

[170]

[130]

9.53

7.48

5.91

[242]

[190]

[150]

8.47

6.73

4.33

2.76

[215]

[171]

[110]

[70]

7.87

6.89

18.15

8.07

18.15

8.07

[200]

[175]

[207]

[205]

[207]

[205]

7.87

6.89

8.74

8.66

8.74

8.66

[200]

[175]

[222]

[220]

[222]

[220]

Depth without

option A/B

With option A/B C

Height (in [mm])

Enclosure Type A2 A3 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4

Rated

Power

(hp [kW])

NEMA

Height of backplate A

Height with decoupling

plate for serial communi-

cation bus cables

Distance between

mounting holes

Width (in [mm])

Width of backplate B

Width of backplate with

one C option

two C options

mounting holes

Depth (in [mm])

Distance between

Page 90

Mechanical Installation Design Guide

50–125

[37–90]

[11–30]

Chassis

Type 1/

21/55/66

Type 1/

21/55/66

Chassis

Type 1/

21/55/66

Type 1/

21/ 55/66

Type 12

0.49

0.47

[12.5]

[12]

50–60

30–40

50–60

[37–45]

100–125

60–75

[22–30]

[37–45]

100–125

[75–90]

100–125

60–75

[45–55]

[75–90]

100–125

[75–90]

[45–55]

[75–90]

50–75

25–40

[18–30]

11–25

[15–18]

7.5–15

[5.5–11]

[15]

7.5–15

[5.5–11]

[37–55]

30–50

[22–37]

15–25

[11–18]

30–40

[22–30]

15–25

[11–18]

50–75

[37–55]

30–50

[22–37]

15–25

[11–18]

30–40

[22–30]

15–25

[11–18]

ø0.75

0.47

ø0.75

[ø19]

[12]

[ø19]

0.34

ø0.35

0.34

0.27

ø0.35

[8.5]

[ø9]

[8.5]

[6.8]

[ø9]

0.67

0.39

0.59

0.31

0.35

[17]

[9.8]

[15]

[7.9]

[9]

110.2

77.2

143.3

99.21

26.5

59.53

50.7

[50]

[35]

[65]

[45]

[23.5]

[12]

[27]

[23]

1.5–5

1.5–3

4–5

200–240 V 1.5–3

1.5–10

[1.1–3.7]

1.5–5

[1.1–2.2]

7.5–10

[3–3.7]

1.5–5

[1.1–2.2]

380–480/

1.5–10

[1.1–7.5]

[1.1–4]

[5.5–7.5]

[1.1–4.0]

500 V

525–600 V 1.5–10

[1.1–7.5]

525–690 V 15–40

55/66

Type 12

Type 1

Chassis

Type 1

Chassis

0.33

0.32

[8.25]

8.0]

[8.0]

ø0.47

ø0.43

[ø12]

[ø11]

ø0.26

ø0.22

[ø6.5]

[ø5.5]

0.35

0.24

0.26

0.35

[9]

[6]

[6.5]

[9]

30/31.5

[13.5/14.2]

21.5

[9.7]

15.5

[7.0]

14.6

[6.6]

[5.3]

11.68

10.8

[4.9]

Enclosure Type A2 A3 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4

Rated

Power

(hp [kW])

NEMA

Screw holes (in [mm])

Max weight lbs [kg]

Front cover tightening torque [Nm]

Plastic cover (low IP) Click Click - - Click Click Click Click Click Click 2.0 2.0

Metal cover (IP55/66) - - 1.5 1.5 2.2 2.2 - - 2.2 2.2 2.0 2.0

Table 5.2 Weight and Dimensions

Page 91

RELAY 1

10

130BT309.10

130BT339.10

130BT330.10

130BA406.10

61 68 6

39 42 50 53 54 5

03 02 01

06 05 04

C D

J K

WARNING:

Risk of Electric Shock - Dual supply

Disconnect mains and loadsharing before service

ISOA0021

RELAY 1

RELAY 2

130BT346.10

WARNING:

Risk of Electric Shock - Dual supply

Discunnect mains and loadsharing before service

130BT347.10

WARNING:

Risk of Electric Shock - Dual supply

Disconnect mains and loadsharing before service

130BT348.10

Risk of Electric Shock - Dual supply

Disconnect mains and loadsharing before service

WARNING:

RELAY 1

RELAY 2

130BT349.10

RELAY 1

RELAY 2

WARNING

STORED CHARGE DO NOT TOUCH UNTIL

15 MIN. AFTER DISCONNECTION

CHARGE RESIDUELLE. ATTENDRE 15 MIN. APRES DECONNEXION

WARNING

Risk of Electric Shock - Dual supply

Disconnect mains and loadsharing before service

Mechanical Installation Design Guide

5.1.3 Accessory Bags

5 5

Enclosure type A1, A2 and A3 Enclosure type A56 Enclosure type B1 and B2 Enclosure type C1 and C2

Enclosure type B3 Enclosure type B4 Enclosure type C3 Enclosure type C4

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

Table 5.3 Parts included in Accessory Bags

An 8-pole connector is included in accessory bag for FC 102 without Safe Torque Off.

Page 92

130BD389.11

B3 B3

130BA419.10

130BA219.11

Mechanical Installation Design Guide

5.1.4 Mechanical Mounting

All enclosure types allow side-by-side installation except when a IP21/IP4X/TYPE 1 Enclosure Kit is used (see chapter 3.1 Options and Accessories).

Side-by-side mounting

IP20 A and B enclosures can be arranged side-by-side with no clearance required between them, but the mounting order is important. Figure 5.1 shows how to mount the

frames correctly.

Figure 5.1 Correct Side-by-side Mounting

If the IP 21 Enclosure kit is used on enclosure type A2 or A3, there must be a clearance between the adjustable frequency drives of min. 2 in [50 mm].

For optimal cooling conditions, allow a free-air passage above and below the adjustable frequency drive. See Table 5.4.

Figure 5.2 Clearance

Enclosure type

a (ins [mm]) 3.94 [100] 7.87 [200] 8.86 [225] b (ins [mm]) 3.94 [100] 7.87 [200] 8.86 [225]

Table 5.4 Air Passage for Different Enclosure Types

A2/A3/A4/A5/B1 B2/B3/B4/C1/C3 C2/C4

1. Drill holes in accordance with the measurements given.

2. Provide screws suitable for the surface for mounting the adjustable frequency drive. Retighten all four screws.

Figure 5.3 Proper Mounting with Backplate

Page 93

130BA228.11

130BA392.11

Mechanical Installation Design Guide

Figure 5.4 Proper Mounting with Railings

Item Description

1 Backplate

Mounting enclosure types A4, A5, B1, B2, C1 and C2 on a non-solid back wall, the adjustable frequency drive must be provided with a backplate, “1”, due to insufficient cooling air over the heatsink.

Enclosure IP20 IP21 IP55 IP66

A2 * * - A3 * * - -

A4/A5 - - 1.48 [2] 1.48 [2]

B1 - * 1.62 [2.2] 1.62 [2.2] B2 - * 1.62 [2.2] 1.62 [2.2] B3 * - - -

B4 1.48 [2] - - C1 - * 1.62 [2.2] 1.62 [2.2] C2 - * 1.62 [2.2] 1.62 [2.2] C3 1.48 [2] - - C4 1.48 [2] - - -

* = No screws to tighten

- = Does not exist

5 5

Table 5.5 Legend to Figure 5.4

Figure 5.5 Mounting on a Non-solid Back Wall

Table 5.6 Tightening torque for covers (lb/ft [Nm])

Field Mounting

5.1.5

For field mounting the IP21/IP4X top/TYPE 1 kits or IP54/55 units are recommended.

Page 94

Electrical Installation Design Guide

6 Electrical Installation

6.1 Connections - Enclosure Types A, B and C

6.1.1 Torque

NOTICE!

Cables General All cabling must comply with national and local regulations on cable cross-sections and ambient

temperature. Copper (167 °F [75 °C]) conductors are recommended.

Aluminum Conductors

Terminals can accept aluminum conductors, but the conductor surface must be clean, and the oxidation must be removed and sealed by neutral acid-free Vaseline grease before the conductor is connected. Furthermore, the terminal screw must be retightened after two days due to softness of the aluminum. It is crucial to keep the connection a gas-tight joint; otherwise, the aluminum surface will oxidize again.

Page 95

Electrical Installation Design Guide

Enclosure type

A2 1.5–3

A3 4–5

A4 1.5–3

A5 1.5–5

B1 7.5–15

B2 20

B3 7.5–15

B4 11–25

C1 25–40

C2 50–60

C3 30–40

C4 50–60

200–240 V (hp [kW])

[1.1–2.2]

[3–3.7]

[1.1–2.2]

[1.1–3.7]

[5.5–11]

[15]

[5.5–11]

[15–18]

[18–30]

[37–45]

[22–30]

[37–45]

380–480 V (hp [kW])

1.5–5 [1.1–4]

7.5–10 [5.5–7.5]

1.5–5 [1.1–4]

1.5–10 [1.1–7.5] 15–25 [11–18]

30–40 [22–30]

15–25 [11–18]

30–50 [22–37]

50–75 [37–55]

100–125 [75–90]

60–75 [45–55]

100–125 [75–90]

525–690 V (hp [kW])

- Line power, brake resistor, load sharing, motor cables 1.33 [1.8]

15–40 [11–30]

- Line power, brake resistor, load sharing, motor cables 1.33 [1.8]

- Line power, brake resistor, load sharing, motor cables 3.32 [4.5]

- Line power, brake resistor, load sharing cables 7.38 [10]

50–125 [37–90]

- Line power, brake resistor, load sharing, motor cables 7.38 [10]

- Line power, motor cables 10.33 [14] (up to

Cable for Tightening up torque

(lb/ft [Nm])

Relay 0.37–0.44 [0.5–0.6] Ground 1.48–2.21 [2–3] Line power, brake resistor, load sharing cables 3.32 [4.5] Motor cables 3.32 [4.5] Relay 0.37–0.44 [0.5–0.6] Ground 1.48–2.21 [2–3]

Relay 0.37–0.44 [0.5–0.6] Ground 1.48–2.21 [2–3]

Motor cables 7.38 [10] Relay 0.37–0.44 [0.5–0.6] Ground 1.48–2.21 [2–3] Line power, motor cables 10.33 [14] (up to

4/0 AWG [95 mm2])

17.7 [24] (over 4/0 AWG

[95 mm2]) Load sharing, brake cables 10.33 [14] Relay 0.37–0.44 [0.5–0.6] Ground 1.48–2.21 [2–3]

Relay 0.37–0.44 [0.5–0.6] Ground 1.48–2.21 [2–3]

4/0 AWG [95 mm2])

17.7 [24] (over 4/0 AWG

[95 mm2]) Load sharing, brake cables 10.33 [14] Relay 0.37–0.44 [0.5–0.6] Ground 1.48–2.21 [2–3]

6 6

Table 6.1 Tightening-up Torque

Page 96

-DC+DC

BR- BR+ U V W

M A I N S

RELAY 1 RELAY 2

- LC +

130BA261.10

Electrical Installation Design Guide

6.1.2 Removal of Knockouts for Extra Cables

1. Remove the cable entry from the adjustable frequency drive (this prevents foreign parts from

CAUTION

The ground connection cable cross-section must be at least 10 mm2 or 2 x rated line power wires terminated separately according to EN 50178.

falling into the adjustable frequency drive when removing knockouts).

2. Cable entry has to be supported around the

The AC line input connection is fitted to the line power switch if this is included.

knockout to be removed.

3. The knockout can now be removed with a strong mandrel and a hammer.

4. Remove burrs from the hole.

5. Mount the cable entry on the adjustable frequency drive.

Connection to Line and Grounding

6.1.3

Figure 6.1 AC line input connections

NOTICE!

The plug connector for power can be plugged on adjustable frequency drives of up to 10 hp [7.5 kW].

1. Fit the two screws in the de-coupling plate, slide it into place and tighten the screws.

2. Make sure the adjustable frequency drive is properly grounded. Connect to ground connection (terminal 95). Use screw from the accessory bag.

3. Place plug connector 91 (L1), 92 (L2), 93 (L3) from the accessory bag onto the terminals labeled MAINS at the bottom of the adjustable frequency drive.

4. Attach the line wires to the line power plug connector.

5. Support the cable with the enclosed supporting brackets.

AC line input connection for enclosure types A1, A2 and A3:

Figure 6.2 Fitting the Mounting Plate

NOTICE!

Ensure that AC line voltage corresponds to the AC line voltage on the nameplate.

CAUTION

IT Line Power Do not connect 400 V adjustable frequency drives with RFI filters to line power supplies with a voltage between phase and ground of more than 440 V.

Page 97

130BA262.10

I N S

+DC

BR-

BR+

RELAY 1 RELAY 2

130BA263.10

INS

+DC

BR-

BR+

RELAY 1 RELAY 2

+DC

BR-

BR+

MAINS

L1 L2 L3

91 92 93

RELAY 1 RELAY 2

- LC -

130BA264.10

L 1

L 2

L 3

130BT336.10

130BT335.10

130BT332.10

Electrical Installation Design Guide

AC line input connector enclosure type A4/A5 (IP55/66)

Figure 6.6 Connecting to Line Power and Grounding without Disconnector

6 6

Figure 6.3 Tightening the Ground Cable

Figure 6.4 Mounting Line Power Plug and Tightening Wires

Figure 6.7 Connecting to Line Power and Grounding with Disconnector

When disconnector is used (enclosure type A4/A5), the PE must be mounted on the left side of the adjustable frequency drive.

Figure 6.8 AC Line Input Connection Enclosure Types B1 and B2 (IP21/NEMA Type 1 and IP55/66/ NEMA Type 12)

Figure 6.5 Tighten Support Bracket

Page 98

130BA725.10

L1 91

L2 92

L3 93

L1 91

L2 92

L3 93

U 96

V 97

W 98

DC-88

DC+89

R-81

R+82

130BA714.10

130BA389.10

91 L1

92 L2

93 L3

91 92 93

96 97 98

88 89

81 82

130BA718.10

Electrical Installation Design Guide

Figure 6.9 AC Line Input Connection Enclosure Type B3

(IP20)

Figure 6.10 AC Line Input Connection Enclosure Type B4 (IP20)

Figure 6.11 AC Line Input Connection Enclosure Types C1 and C2 (IP21/NEMA Type 1 and IP55/66/NEMA Type 12).

Figure 6.12 AC Line Input Connection Enclosure Type C3 (IP20).

Page 99

DC-

DC+

R-

R+

130BA719.10

Electrical Installation

Design Guide

Cable length and cross-section

The adjustable frequency drive has been tested with a given length of cable and a given cross-section of that cable. If the cross-section is increased, the cable capacitance - and thus the leakage current - may increase, thereby requiring that the cable length is reduced accordingly. Keep the motor cable as short as possible to reduce the noise level and leakage currents.

Switching frequency

When adjustable frequency drives are used with sine-wave filters to reduce the acoustic noise from a motor, the

Figure 6.13 AC Line Input Connection Enclosure Type C4 (IP20).

switching frequency must be set according to the sinewave filter instruction in 14-01 Switching Frequency.

6 6

1. Fasten decoupling plate to the bottom of the

Usually the power cables for line power are non-shielded cables.

adjustable frequency drive with screws and washers from the accessory bag.

2. Attach motor cable to terminals 96 (U), 97 (V),

Motor Connection

6.1.4

NOTICE!

To comply with EMC emission specifications, shielded/ armored cables are required. For more information, see chapter 2.9.2 EMC Test Results.

98 (W).

3. Connect to ground connection (terminal 99) on decoupling plate with screws from the accessory bag.

4. Insert plug connectors 96 (U), 97 (V), 98 (W) (up to 10 hp [7.5 kW]) and motor cable to terminals labeled MOTOR.

See chapter 9 General Specifications and Troubleshooting for correct dimensioning of motor cable cross-section and length.

5. Fasten shielded cable to the decoupling plate with screws and washers from the accessory bag.

All types of three-phase asynchronous standard motors can

Shielding of cables:

Avoid installation with twisted shield ends (pigtails). They spoil the shielding effect at higher frequencies. If it is necessary to break the shield to install a motor isolator or motor contactor, the shield must be continued at the

be connected to the adjustable frequency drive. Normally, small motors are star-connected (230/400 V, Y). Large motors are normally delta-connected (400/690 V, Δ). Refer to the motor nameplate for correct connection mode and voltage.

lowest possible HF impedance. Connect the motor cable shield to both the decoupling plate on the adjustable frequency drive and to the metal housing on the motor. Make the shield connections with the largest possible surface area (cable clamp). This is done by using the supplied installation devices in the adjustable frequency drive. If it is necessary to split the shield to install a motor isolator or motor relay, continue the shield with the lowest possible HF impedance.

Procedure

1. Strip a section of the outer cable insulation.

2. Position the stripped wire under the cable clamp to establish mechanical fixation and electrical contact between cable shield and ground.

3. Connect ground wire to the nearest grounding terminal in accordance with grounding instructions.

4. Connect the three-phase motor wiring to terminals 96 (U), 97 (V), and 98 (W), see Figure 6.14.

5. Tighten terminals in accordance with the information provided in chapter 6.1.1 Torque.

Page 100

130BD531.10

130BT333.10

130BA726.10

DC-

DC+

R-

R+

130BA721.10

Electrical Installation Design Guide

Figure 6.16 Motor Connection for Enclosure Type B3

Figure 6.14 Motor Connection

Figure 6.17 Motor Connection for Enclosure Type B4

Figure 6.15 Motor Connection for Enclosure Type B1 and B2 (IP21/NEMA Type 1, IP55/NEMA Type 12 and IP66/NEMA Type 4X)