Danfoss FC 111 Design guide

Design Guide
VLT® Flow Drive FC 111
vlt-drives.danfoss.com
VLT® Flow Drive FC 111
Design Guide

Contents

1
1.1
Purpose of this Design Guide 10
Additional Resources 10
1.2
Other Resources 10
1.2.1
1.2.2
MCT 10 Set-up Software Support 10
1.3
Document and Software Version 10
1.4
Regulatory Compliance 10
1.4.1
Introduction 10
1.4.2
CE Mark 10
Safety 12
2
Safety Symbols 12
2.1
Qualified Personnel 12
2.2
Contents
Safety Precautions 12
2.3
Product Overview 14
3
3.1
Advantages 14
3.1.1
Why Use a Drive for Controlling Fans and Pumps? 14
3.1.1.1
3.1.1.2
3.1.1.3
3.1.1.4
3.1.1.5
3.1.1.6
3.1.1.7
3.1.1.8
3.1.1.9
3.1.2
Application Examples 20
3.1.2.1
3.1.2.2
The Clear Advantage - Energy Savings 14
Example of Energy Savings 15
Comparison of Energy Savings 15
Example with Varying Flow over 1 Year 17
Better Control 18
Star/Delta Starter or Soft Starter not Required 18
Using a Drive Saves Money 18
Traditional Fan System without a Drive 19
Fan System Controlled by Drives 20
Variable Air Volume 20
Constant Air Volume 21
3.1.2.3
3.1.2.4
3.1.2.5
3.1.2.6
3.1.3
Check Valve Monitoring 26
3.1.4
Dry Pump Detection 26
3.1.5
End of Curve Detection 26
Cooling Tower Fan 22
Condenser Pumps 23
Primary Pumps 24
Secondary Pumps 25
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VLT® Flow Drive FC 111
Design Guide
3.1.6
3.2
Control Structures 26
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
3.2.9
3.3
Ambient Running Conditions 30
3.3.1
3.3.2
Contents
Time-based Functions 26
Introduction 26
Control Structure Open Loop 27
PM/EC+ Motor Control 27
Local (Hand On) and Remote (Auto On) Control 27
Control Structure Closed Loop 28
Feedback Conversion 28
Reference Handling 28
Tuning the Drive Closed-loop 29
Adjusting the Manual PI 29
Air Humidity 30
Acoustic Noise or Vibration 30
3.3.2.1
3.3.2.2
3.3.3
Aggressive Environments 31
3.4
General Aspects of EMC 31
3.4.1
Overview of EMC Emissions 31
3.4.2
Emission Requirements 32
3.4.3
EMC Emission Test Results 33
3.4.4
Harmonics Emission 34
3.4.4.1
3.4.4.2
3.4.5
Harmonics Emission Requirements 34
3.4.6
Harmonics Test Results (Emission) 36
3.4.7
Immunity Requirements 37
3.5
Galvanic Isolation (PELV) 37
3.6
Ground Leakage Current 38
3.6.1
Using a Residual Current Device (RCD) 40
Acoustic Noise 30
Vibration and Shock 31
Harmonics Emission Requirements 34
Harmonics Test Results (Emission) 35
3.7
Extreme Running Conditions 41
3.7.1
Introduction 41
3.7.2
Motor Thermal Protection (ETR) 42
3.7.3
Thermistor Inputs 42
3.7.3.1
3.7.3.2
Example with Digital Input and 10 V Power Supply 43
Example with Analog Input and 10 V Power Supply 43
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VLT® Flow Drive FC 111
Design Guide
4
Selection and Ordering 45
Type Code 45
4.1
4.2
Options and Accessories 46
Local Control Panel (LCP) 46
4.2.1
4.2.2
IP21 Enclosure Kit 46
4.2.3
Decoupling Plate 48
4.3
Ordering Numbers 49
4.3.1
Options and Accessories 49
4.3.2
Harmonic Filters 50
4.3.3
External RFI Filter 51
5
Mechanical Installation Considerations 53
5.1
Power Ratings, Weights, and Dimensions 53
5.2
Mechanical Installation H1-H8 55
5.2.1
Side-by-side Installation 55
Contents
5.3
Mechanical Installation H13-H14 56
5.3.1
Tools Needed 56
5.3.2
Installation and Cooling Requirements 56
5.3.3
Lifting the Drive 57
5.3.4
Wall Mounting the Drive 58
5.3.5
Creating Cable Openings 59
5.3.6
Back-channel Cooling 59
5.4
Derating 60
5.4.1
Manual Derating and Automatic Derating 60
5.4.2
Derating for Low-speed Operation 60
5.4.3
Derating for Low Air Pressure and High Altitudes 60
5.4.4
Derating for Ambient Temperature and Switching Frequency 60
6
Electrical Installation Considerations 63
6.1
Safety Instructions 63
6.2
Electrical Wiring 64
6.3
EMC-compliant Electrical Installation 64
6.4
Relays and Terminals 66
6.4.1
Relays and Terminals on Enclosure Sizes H1–H5 66
6.4.2
Relays and Terminals on Enclosure Size H6 67
6.4.3
Relays and Terminals on Enclosure Size H7 67
6.4.4
Relays and Terminals on Enclosure Size H8 68
6.4.5
Relays and Terminals on Enclosure Size H13–H14 69
6.5
View of Control Shelf 69
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VLT® Flow Drive FC 111
Design Guide
6.6
Fastener Tightening Torques 70
6.7
IT Mains 71
6.8
Mains and Motor Connection 72
6.8.1
6.8.2
6.8.3
6.8.4
6.9
Fuses and Circuit Breakers 73
6.9.1
6.9.2
6.9.3
6.9.4
6.9.5
6.10
Control Terminals 75
Contents
Introduction 72
Connecting to the Ground 72
Connecting the Motor 73
Connecting the AC Mains 73
Branch Circuit Protection 73
Short-circuit Protection 73
Overcurrent Protection 74
CE Compliance 74
Recommendation of Fuses and Circuit Breakers 74
6.11
Efficiency 76
6.11.1
Efficiency of the Drive 76
6.11.2
Efficiency of the Motor 77
6.11.3
Efficiency of the System 77
6.12
dU/dt Conditions 77
6.12.1
dU/dt Overview 77
6.12.2
dU/dt Test Results for H1–H8 77
6.12.3
High-power Range 80
6.12.4
dU/dt Test Results for H13–H14 80
7
Programming 81
7.1
Local Control Panel (LCP) 81
7.2
Menus 82
7.2.1
Status Menu 82
7.2.2
Quick Menu 82
7.2.2.1
7.2.2.2
Quick Menu Introduction 82
Setup Wizard Introduction 83
7.2.2.3
7.2.2.4
7.2.2.5
7.2.2.6
7.2.2.7
7.2.2.8
7.2.3
Main Menu 98
Setup Wizard for Open-loop Applications 84
Setup Wizard for Closed-loop Applications 89
Motor Setup 94
Changes Made Function 97
Changing Parameter Settings 98
Accessing All Parameters via the Main Menu 98
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VLT® Flow Drive FC 111
Design Guide
7.3
Quick Transfer of Parameter Settings between Multiple Drives 98
7.3.1
Transferring Data from the Drive to the LCP 98
7.3.2
Transferring Data from the LCP to the Drive 98
7.4
Readout and Programming of Indexed Parameters 99
7.5
Initialization to Default Settings 99
7.5.1
Recommended Initialization 99
7.5.2
Two-finger Initialization 99
8
RS485 Installation and Set-up 101
8.1
RS485 101
8.1.1
Overview 101
8.1.2
Connecting the Drive to the RS485 Network 102
8.1.3
Hardware Set-up 102
8.1.4
Parameter Settings for Modbus Communication 103
8.1.5
EMC Precautions 103
Contents
8.2
FC Protocol 104
8.2.1
Overview 104
8.2.2
FC with Modbus RTU 104
8.3
Network Configuration 105
8.4
FC Protocol Message Framing Structure 105
8.4.1
Content of a Character (byte) 105
8.4.2
Telegram Structure 105
8.4.3
Telegram Length (LGE) 105
8.4.4
Drive Address (ADR) 106
8.4.5
Data Control Byte (BCC) 106
8.4.6
The Data Field 106
8.4.7
The PKE Field 107
8.4.8
Parameter Number (PNU) 108
8.4.9
Index (IND) 108
8.4.10
Parameter Value (PWE) 108
8.4.11
Data Types Supported by the Drive 109
8.4.12
Conversion 109
8.4.13
Process Words (PCD) 110
8.5
Examples 110
8.5.1
Writing a Parameter Value 110
8.5.2
Reading a Parameter Value 110
8.6
Modbus RTU 111
8.6.1
Prerequisite Knowledge 111
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VLT® Flow Drive FC 111
Design Guide
8.6.2
8.6.3
8.7
Network Configuration 112
8.8
Modbus RTU Message Framing Structure 112
8.8.1
8.8.2
8.8.3
8.8.4
8.8.5
8.8.6
8.8.7
8.8.8
Contents
Modbus RTU Overview 111
Drive with Modbus RTU 111
Modbus RTU Message Byte Format 112
Modbus RTU Telegram Structure 113
Start/Stop Field 113
Address Field 113
Function Field 113
Data Field 113
CRC Check Field 113
Coil Register Addressing 114
8.8.8.1
8.8.8.2
Introduction 114
Coil Register 114
8.8.8.3
8.8.8.4
8.8.8.5
8.8.9
Access via PCD Write/read 116
8.8.10
How to Control the Drive 117
8.8.10.1
8.8.10.2
8.8.10.3
8.9
How to Access Parameters 118
8.9.1
Parameter Handling 118
8.9.2
Storage of Data 118
8.9.3
IND (Index) 119
8.9.4
Text Blocks 119
8.9.5
Conversion Factor 119
8.9.6
Parameter Values 119
8.10
Examples 119
Drive Control Word (FC Profile) 114
Drive Status Word (FC Profile) 115
Address/Registers 115
Introduction 117
Function Codes Supported by Modbus RTU 117
Modbus Exception Codes 118
8.10.1
Introduction 119
8.10.2
Read Coil Status (01 hex) 119
8.10.3
Force/Write Single Coil (05 hex) 120
8.10.4
Force/Write Multiple Coils (0F hex) 121
8.10.5
Read Holding Registers (03 hex) 122
8.10.6
Preset Single Register (06 hex) 122
8.10.7
Preset Multiple Registers (10 hex) 123
8.10.8
Read/Write Multiple Registers (17 hex) 124
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VLT® Flow Drive FC 111
Design Guide
8.11
Danfoss FC Control Profile 125
8.11.1
Control Word According to FC Profile (8-10 Protocol = FC Profile) 125
8.11.2
Explanation of Each Control Bit 126
8.11.3
Status Word According to FC Profile (STW) 128
8.11.4
Explanation of Each Status Bit 128
8.11.5
Bus Speed Reference Value 130
9
General Specifications 131
9.1
Mains Supply 131
9.1.1
3x380–480 V AC 131
9.2
General Technical Data 133
9.2.1
Protection and Features 133
9.2.2
Mains Supply 133
9.2.3
Motor Output (U, V, W) 133
9.2.4
Cable Length and Cross-section 134
Contents
9.2.5
Digital Inputs 134
9.2.6
Analog Inputs 134
9.2.7
Analog Outputs 135
9.2.8
Digital Output 135
9.2.9
RS485 Serial Communication 135
9.2.10
24 V DC Output 135
9.2.11
Relay Output 135
9.2.12
10 V DC Output 136
9.2.13
Ambient Conditions (H1–H8) 136
9.2.14
Ambient Conditions (H13–H14) 137
10
Appendix 138
10.1
Abbreviations 138
10.2
Definitions 139
10.2.1
AC Drive 139
10.2.2
Input 139
10.2.3
Motor 139
10.2.4
References 141
10.2.5
Miscellaneous 141
AJ363928382091en-000101/130R0983 | 9Danfoss A/S © 2021.04
Edition
Remarks
Software version
AJ363928382091, version 0101
First edition.
65.00
VLT® Flow Drive FC 111
Design Guide
Introduction

1 Introduction

1.1 Purpose of this Design Guide

This Design Guide is intended for qualified personnel, such as:
Project and systems engineers.
Design consultants.
Application and product specialists.
The Design Guide provides technical information to understand the capabilities of the VLT® Flow Drive FC 111 for integration into motor control and monitoring systems. Its purpose is to provide design considerations and planning data for integration of the drive into a system. It caters for selection of drives and options for a diversity of applications and installations. Reviewing the de­tailed product information in the design stage enables developing a well-conceived system with optimal functionality and efficien­cy.
This manual is targeted at a worldwide audience. Therefore, wherever occurring, both SI and imperial units are shown. VLT® is a registered trademark for Danfoss A/S.

1.2 Additional Resources

1.2.1 Other Resources
Other resources are available to understand advanced drive functions and programming.
VLT® Flow Drive FC 111 Operating Guide provides basic information on mechanical dimensions, installation, and programming.
VLT® Flow Drive FC 111 Programming Guide provides information on how to program, and includes complete parameter de­scriptions.
Danfoss VLT® Energy Box software. Select PC Software Download at
VLT® Energy Box software allows energy consumption comparisons of HVAC fans and pumps driven by Danfoss drives and alterna­tive methods of flow control. Use this tool to accurately project the costs, savings, and payback of using Danfoss drives on HVAC fans, pumps, and cooling towers.
Supplementary publications and manuals are available from Danfoss website www.danfoss.com.
www.danfoss.com.
1.2.2 MCT 10 Set-up Software Support
Download the software from the service and support section on www.danfoss.com. During the installation process of the software, enter access code 81462700 to activate the VLT® Flow Drive FC 111 functionality. A
license key is not required for using the VLT® Flow Drive FC 111 functionality. The latest software does not always contain the latest updates for drives. Contact the local sales office for the latest drive updates (in
the form of *.OSS files).

1.3 Document and Software Version

This guide is regularly reviewed and updated. All suggestions for improvement are welcome. The original language of this manual is English.
Table 1: Document and Software Version

1.4 Regulatory Compliance

1.4.1 Introduction
AC drives are designed in compliance with the directives described in this section.
1.4.2 CE Mark
The CE mark (Communauté Européenne) indicates that the product manufacturer conforms to all applicable EU directives. The EU directives applicable to the design and manufacture of drives are listed in the following table.
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EU directive
Version
Low Voltage Directive
2014/35/EU
EMC Directive
2014/30/EU
ErP Directive
VLT® Flow Drive FC 111
Design Guide
Introduction
N O T I C E
The CE mark does not regulate the quality of the product. Technical specifications cannot be deduced from the CE mark.
N O T I C E
Drives with an integrated safety function must comply with the machinery directive.
Table 2: EU Directives Applicable to Drives
Declarations of conformity are available on request.
1.4.2.1 Low Voltage Directive
The aim of the Low Voltage Directive is to protect persons, domestic animals and property against dangers caused by the electrical equipment, when operating electrical equipment that is installed and maintained correctly, in its intended application. The directive applies to all electrical equipment in the 50–1000 V AC and the 75–1500 V DC voltage ranges.
1.4.2.2 EMC Directive
The purpose of the EMC (electromagnetic compatibility) Directive is to reduce electromagnetic interference and enhance immunity of electrical equipment and installations. The basic protection requirement of the EMC Directive states that devices that generate electromagnetic interference (EMI), or whose operation could be affected by EMI, must be designed to limit the generation of elec­tromagnetic interference and shall have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended. Electrical equipment devices used alone or as part of a system must bear the CE mark. Systems do not require the CE mark, but must comply with the basic protection requirements of the EMC Directive.
1.4.2.3 ErP Directive
The ErP Directive is the European Ecodesign Directive for energy-related products. The directive sets ecodesign requirements for energy-related products, including drives, and aims at reducing the energy consumption and environmental impact of products by establishing minimum energy-efficiency standards.
AJ363928382091en-000101 / 130R0983 | 11Danfoss A/S © 2021.04
VLT® Flow Drive FC 111
Design Guide

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:
D A N G E R
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
W A R N I N G
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
C A U T I O N
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
N O T I C E
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
Safety

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, as­semble, install, program, commission, maintain, and decommission this equipment.
Persons with proven skills:
Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.
Are familiar with the basic regulations concerning health and safety/accident prevention.
Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in the Operating Guide.
Have good knowledge of the generic and specialist standards applicable to the specific application.

2.3 Safety Precautions

W A R N I N G
HAZARDOUS VOLTAGE
AC drives contain hazardous voltage when connected to the AC mains or connected on the DC terminals. Failure to perform
installation, start-up, and maintenance by skilled personnel can result in death or serious injury.
Only skilled personnel must perform installation, start-up, and maintenance.
-
W A R N I N G
UNINTENDED START
When the drive is connected to AC mains, DC supply, or load sharing, the motor may start at any time. Unintended start during
programming, service, or repair work can result in death, serious injury, or property damage. Start the motor with an external
switch, a fieldbus command, an input reference signal from the local control panel (LCP), via remote operation using MCT 10
software, or after a cleared fault condition.
Disconnect the drive from the mains.
-
Press [Off/Reset] on the LCP before programming parameters.
-
Ensure that the drive is fully wired and assembled when it is connected to AC mains, DC supply, or load sharing.
-
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Voltage [V]
Power range [kW (hp)]
Minimum waiting time (minutes)
3x400
0.37–7.5 (0.5–10)
4
3x400
11–90 (15–125)
15
3x400
110–315 (150–450)
20
VLT® Flow Drive FC 111
Design Guide
Safety
W A R N I N G
DISCHARGE TIME
The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be
present even when the warning indicator lights are off.
Failure to wait the specified time after power has been removed before performing service or repair work could result in death or
serious injury.
Stop the motor.
-
Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and
-
DC-link connections to other drives.
Wait for the capacitors to discharge fully. The minimum waiting time is specified in the table Discharge time and is also visible
-
on the nameplate on the top of the drive.
Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors
-
are fully discharged.
Table 3: Discharge Time
W A R N I N G
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.
Ensure that the minimum size of the ground conductor complies with the local safety regulations for high touch current
-
equipment.
W A R N I N G
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment can result in death or serious injury.
Ensure that only trained and qualified personnel perform installation, start-up, and maintenance.
-
Ensure that electrical work conforms to national and local electrical codes.
-
Follow the procedures in this manual.
-
C A U T I O N
INTERNAL FAILURE HAZARD
An internal failure in the drive can result in serious injury when the drive is not properly closed.
Ensure that all safety covers are in place and securely fastened before applying power.
-
AJ363928382091en-000101 / 130R0983 | 13Danfoss A/S © 2021.04
e30ba780.11
SYSTEM CURVE
FAN CURVE
PRESSURE%
A
B
C
0
20
40
60
80
100
120
20
40
60 80 100 120 140 160 180
VOLUME%
120
100
80
60
40
20
0
20
40
60
80 100 120 140 160 180
120
100
80
60
40
20
0
20
40
60 80 100 120 140 160 180
Volume %
Volume %
INPUT POWER % PRESSURE %
SYSTEM CURVE
FAN CURVE
A
B
C
e30ba781.11
ENERGY CONSUMED
VLT® Flow Drive FC 111
Design Guide
Product Overview

3 Product Overview

3.1 Advantages

3.1.1 Why Use a Drive for Controlling Fans and Pumps?
A 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 3.1.1.2 Example of Energy Savings.
3.1.1.1 The Clear Advantage - Energy Savings
The clear advantage of using a drive for controlling the speed of fans or pumps lies in the electricity savings. When comparing with alternative control systems and technologies, a drive is the optimum energy control system for controlling
fan and pump systems.
Illustration 1: Fan Curves (A, B, and C) for Reduced Fan Volumes
Illustration 2: Energy Savings with Drive Solution
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n
100%
50%
25%
12,5%
50% 100%
80%
80%
e75ha208.10
P o w er ~n
3
P r essur e ~n
2
Fl o w ~n
Q = Flow
P = Power
Q1 = Rated flow
P1 = Rated power
Q2 = Reduced flow
P2 = Reduced power
H = Pressure
n = Speed control
H1 = Rated pressure
n1 = Rated speed
H2 = Reduced pressure
n2 = Reduced speed
VLT® Flow Drive FC 111
Design Guide
Product Overview
When using a drive to reduce fan capacity to 60% - more than 50% energy savings may be obtained in typical applications.
3.1.1.2 Example of Energy Savings
As shown in the following illustration, the flow is controlled by changing the RPM. By reducing the speed by only 20% from the rated speed, the flow is also reduced by 20%. This is because the flow is directly proportional to the RPM. The consumption of elec­tricity, however, is reduced by 50%.
If the system in question only needs to be able to supply a flow that corresponds to 100% a few days in a year, while the average is below 80% of the rated flow for the remainder of the year, the amount of energy saved is even more than 50%.
The following illustration describes the dependence of flow, pressure, and power consumption on RPM.
Illustration 3: Laws of Proportionally
Q
n
1
1
Flow:
Pressure:
Power:
Table 4: The Laws of Proportionality
=
Q
n
2
2
H
1
=
H
2
P
1
=
P
2
2
n
1
n
2
3
n
1
n
2
3.1.1.3 Comparison of Energy Savings
The Danfoss drive solution offers major savings compared with traditional energy saving solutions such as discharge damper solu­tion and inlet guide vanes (IGV) solution. This is because the drive is able to control fan speed according to thermal load on the system, and the drive has a built-in facility that enables the drive to function as a building management system, BMS.
The illustration in 3.1.1.2 Example of Energy Savings shows typical energy savings obtainable with 3 well-known solutions when fan volume is reduced to 60%. As the graph shows, more than 50% energy savings can be achieved in typical applications.
AJ363928382091en-000101 / 130R0983 | 15Danfoss A/S © 2021.04
e30ba782.10
1
2
3
4
5
1
Discharge damper
2
Less energy savings
3
Maximum energy savings
4
IGV5Costlier installation
e30ba779.12
0 60 0 60 0 60
0
20
40
60
80
100
Discharge Damper Solution
IGV Solution
VLT Solution
Energy consumed
Energy consumed
Energy consumed
Input power %
Volume %
VLT® Flow Drive FC 111
Design Guide
Product Overview
Illustration 4: The 3 Common Energy Saving Systems
Illustration 5: Energy Savings
Discharge dampers reduce power consumption. Inlet guide vanes offer a 40% reduction, but are expensive to install. The Danfoss drive solution reduces energy consumption with more than 50% and is easy to install. It also reduces noise, mechanical stress, and wear-and-tear, and extends the life span of the entire application.
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500
[h]
t
1000
1500
2000
200100
300
[m3 /h]
400
Q
e75ha210.11
e75ha209.11
60
50
40
30
20
10
H
s
0
100
200 300 400
(m w g)
B
C
A
750r pm
1050r pm
1350r pm
1650r pm
0
10
20
30
(kW
)
40
50
60
200
100
300 ( m 3 /h )
( m
3
/h )
400
750r
pm
1050r pm
1350r pm
1650r pm
P
shaf
t
C
1
B
1
A
1
m3/h
Distribution
Valve regulation
Drive control
%
Hours
Power
Consumption
Power
Consumption
A1 - B
1
kWh
A1 - C
1
kWh
VLT® Flow Drive FC 111
Design Guide
Product Overview
3.1.1.4 Example with Varying Flow over 1 Year
This example is calculated based on pump characteristics obtained from a pump datasheet. The result obtained shows energy sav­ings of more than 50% at the given flow distribution over a year. The payback period depends on the price per kWh and the price of drive. In this example, it is less than a year when compared with valves and constant speed.
Energy savings
P
= P
shaft
shaft output
Illustration 6: Flow Distribution over 1 Year
Illustration 7: Energy
Table 5: Result
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3505438
42.5
18.615
42.5
18.615
300151314
38.5
50.589
29.0
38.106
250201752
35.0
61.320
18.5
32.412
200201752
31.5
55.188
11.5
20.148
150201752
28.0
49.056
6.5
11.388
100201752
23.0
40.296
3.5
6.132
Σ
100
8760–275.064
26.801
F ull load
% F ull load cur r en t
& speed
500
100
0
0
12,5 25 37,5 50H z
200
300
400
600
700
800
4
3
2
1
e75ha227.10
1
VLT® Flow Drive FC 111
2
Star/delta starter
3
Soft starter
4
Start directly on mains
VLT® Flow Drive FC 111
Design Guide
Product Overview
3.1.1.5 Better Control
If a drive is used for controlling the flow or pressure of a system, improved control is obtained. A drive can vary the speed of the fan or pump, obtaining variable control of flow and pressure. Furthermore, a 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 PI control.
3.1.1.6 Star/Delta Starter or Soft Starter not Required
When larger motors are started, it is necessary in many countries to use equipment that limits the start-up current. In more tradi­tional systems, a star/delta starter or soft starter is widely used. Such motor starters are not required if a drive is used.
As shown in the following illustration, a drive does not consume more than rated current.
Illustration 8: Start-up Current
3.1.1.7 Using a Drive Saves Money
The example in 3.1.1.8 Traditional Fan System without a Drive and 3.1.1.9 Fan System Controlled by Drives shows that a drive repla­ces other equipment. It is possible to calculate the cost of installing the 2 different systems. In the example, the 2 systems can be established at roughly the same price.
Use the VLT® Energy Box software that is introduced in chapter Additional Resources to calculate the cost savings that can be ach­ieved by using a drive.
AJ363928382091en-000101 / 130R098318 | Danfoss A/S © 2021.04
M
- +
M
M
x6 x6
x6
e75ha205.12
Valve posi­tion
Starter
Fuses
LV
supply
P.F.C
Flow
3-Port valve
Bypass
Return
Control
Supply air
V.A.V outlets
Duct
P.F.C
Mains
Fuses
Starter
Bypass
supply
LV
Return
valve
3-Port
Flow
Control
Valve posi­tion
Starter
Power Factor Correction
Mains
IGV
Mechanical linkage and vanes
Fan
Motor or actuator
Main B.M.S
Local D.D.C. control
Sensors PT
Pressure control signal 0/10V
Temperature control signal 0/10V
Control
Mains
Cooling section Heating section
Fan sectionInlet guide vane
Pump Pump
D.D.C.
Direct digital control
E.M.S.
Energy management system
V.A.V.
Variable air volume
Sensor P
Pressure
Sensor T
Temperature
VLT® Flow Drive FC 111
Design Guide
3.1.1.8 Traditional Fan System without a Drive
Product Overview
Illustration 9: Traditional Fan System without a Drive
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e75ha206.11
Pump
Flow
Return
Supply air
V.A.V outlets
Duct
Mains
Pump
Return
Flow
Mains
Fan
Main B.M.S
Local D.D.C. control
Sensors
Mains
Cooling section
Heating section
Fan section
Pressure control 0-10V or 0/4-20mA
Control temperature 0-10V or 0/4-20mA
Control temperature 0-10V or 0/4-20mA
VLT
M
- +
VLT
M
M
PT
VLT
x3 x3
x3
D.D.C.
Direct digital control
E.M.S.
Energy management system
V.A.V.
Variable air volume
Sensor P
Pressure
Sensor T
Temperature
VLT® Flow Drive FC 111
Design Guide
3.1.1.9 Fan System Controlled by Drives
Product Overview
Illustration 10: Fan System Controlled by Drives
3.1.2 Application Examples
The following sections give typical examples of applications.
3.1.2.1 Variable Air Volume
VAV or variable air volume systems, control both the ventilation and temperature to satisfy the requirements of a building. Central VAV systems are considered to be the most energy efficient method to air condition buildings. By designing central systems instead of distributed systems, a greater efficiency can be obtained.
The efficiency comes from utilizing larger fans and larger chillers which have much higher efficiencies than small motors and distrib­uted air-cooled chillers. Savings are also seen from the decreased maintenance requirements.
The VLT Solution
While dampers and IGVs work to maintain a constant pressure in the ductwork, a drive 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 drive 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 that the fans decrease the pressure and flow they produce as their speed is reduced. Their power consumption is thereby significantly reduced. The PI controller of the drive can be used to eliminate the need for additional controllers.
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D1
D2
D3
C
ooling c oil
Hea ting c oil
F
ilt
er
P r essur e sig nal
Supply fan
V A V bo x es
Fl o w
Fl o w
P r essur e tr ansmitt er
R etur n fan
3
3
T
e30bb455.10
Drive
Drive
VLT® Flow Drive FC 111
Design Guide
Illustration 11: Variable Air Volume
Product Overview
3.1.2.2 Constant Air Volume
CAV, or constant air volume systems, are central ventilation systems usually used to supply large common zones with the minimum amounts of fresh tempered air. They preceded VAV systems and are therefore found in older multi-zoned commercial buildings as well. These systems preheat amounts of fresh air utilizing air handling units (AHUs) with a heating coil, and many are also used to air condition buildings and have a cooling coil. Fan coil units are frequently used to assist in the heating and cooling requirements in the individual zones.
The VLT Solution
With a 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 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 airflows.
With temperature control, especially used in air conditioning systems, as the outside temperature varies as well as the number of people in the controlled zone changes, different cooling requirements exist. As the temperature decreases below the setpoint, the supply fan can decrease its speed. The return fan modulates to maintain a static pressure 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 dedicated drive can be utilized to improve the performance of the CAV system. One concern of controlling a ventilation system is poor air quality. The programmable minimum frequency can be set to maintain a minimum amount of supply air regardless of the feedback or reference signal. The drive also includes a PI controller, which allows monitoring both temperature and air quality. Even if the temperature requirement is fulfilled, the drive maintains enough supply air to satisfy the air quality sensor. The controller is capable of monitoring and comparing 2 feedback signals to control the return fan by main­taining a fixed differential airflow between the supply and return ducts as well.
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P r essur e sig nal
C ooling c oil
Hea ting c oil
D1
D2
D3
F ilt er
P r essur e tr ansmitt er
Supply fan
R etur n fan
T emper a tur e sig nal
T emper a tur e tr ansmitt er
e30bb451.10
Drive
Drive
VLT® Flow Drive FC 111
Design Guide
Illustration 12: Constant Air Volume
Product Overview
3.1.2.3 Cooling Tower Fan
Cooling tower fans 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 until the cooling towers fill to increase its surface area. The tower fan blows air through the fill and sprayed water to aid in the evaporation. Evaporation removes energy from the water dropping its temperature. The cooled water collects in the cooling towers basin where it is pumped back into the chillers condenser and the cycle is repeated.
The VLT Solution
With a drive, the cooling towers fans can be controlled to the required speed to maintain the condenser-water temperature. The drives can also be used to turn the fan on and off as needed.
Several features of the Danfoss dedicated drive can be utilized to improve the performance of cooling tower fans applications. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes small. Also, when utilizing a gearbox to frequency control the tower fan, a minimum speed of 40–50% is required.
The customer programmable minimum frequency setting is available to maintain this minimum frequency even as the feedback or speed reference calls for lower speeds.
Also as a standard feature, the drive can be programmed to enter a sleep mode and stop the fan until a higher speed is required. Additionally, some cooling tower fans have undesirable frequencies that may cause vibrations. These frequencies can easily be avoi­ded by programming the bypass frequency ranges in the drive.
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W a t er I nlet
W a t er Outlet
CHILLER
T emper a tur e S ensor
BASIN
C onderser W a t er pump
Supply
e30bb453.10
Drive
VLT® Flow Drive FC 111
Design Guide
Product Overview
Illustration 13: Cooling Tower Fan
3.1.2.4 Condenser Pumps
Condenser water pumps are primarily used to circulate water through the condenser section of water cooled chillers and their asso­ciated cooling tower. The condenser water absorbs the heat from the chiller's condenser section and releases it into the atmosphere in the cooling tower. These systems are used to provide the most efficient means of creating chilled water, they are as much as 20% more efficient than air cooled chillers.
The VLT Solution
Drives can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump im­peller.
Using a 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.
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Wa t e
r
I
nlet
Wa
t e
r
Outlet
BASIN
F
lo w or pr essur
e sensor
C ondenser W a t er pump
T hr ottling v alv e
Supply
CHILLER
e30bb452.10
Drive
VLT® Flow Drive FC 111
Design Guide
Product Overview
Illustration 14: Condenser Pumps
3.1.2.5 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 overchilled. 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 safety trips the chiller requiring a manual reset. This situation is common in large installations especially when 2 or more chillers in parallel are installed if primary/ secondary pumping is not utilized.
The VLT Solution
Depending on the size of the system and the size of the primary loop, the energy consumption of the primary loop can become substantial.
A drive can be added to the primary system to replace the throttling valve and/or trimming of the impellers, leading to reduced operating expenses. 2 control methods are common:
Flow meter
Because the desired flow rate is known and is constant, a flow meter installed at the discharge of each chiller, can be used to control the pump directly. Using the built-in PI controller, the 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.
Local speed determination
The operator simply decreases the output frequency until the design flow rate is achieved. Using a 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. If the flow rate needs to be increased later in the sys­tem’s life, the drive can simply increase the pump speed instead of requiring a new pump impeller.
AJ363928382091en-000101 / 130R098324 | Danfoss A/S © 2021.04
CHILLER
CHILLER
F
lo
wmet er
F lo wmet er
F F
e30bb456.10
Drive
Drive
VLT® Flow Drive FC 111
Design Guide
Product Overview
Illustration 15: Primary Pumps
3.1.2.6 Secondary Pumps
Secondary pumps in a primary/secondary chilled water pumping system distribute the chilled water to the loads from the primary production loop. The primary/secondary pumping system is used to hydronically de-couple 1 piping loop from another. In this case, the primary pump is used to maintain a constant flow through the chillers while allowing the secondary pumps to vary in flow, increase control and save energy.
If the primary/secondary concept is not used in the design of a variable volume system when the flow rate drops far enough or too quickly, the chiller cannot shed its load properly. The chiller’s low evaporator temperature safety then trips the chiller requiring a manual reset. This situation is common in large installations especially when 2 or more chillers in parallel are installed.
The VLT Solution
While the primary-secondary system with 2-way valves improves energy savings and eases system control problems, the true ener­gy savings and control potential is realized by adding drives.
With the proper sensor location, the addition of 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 overpressurization that 2-way valves can be subjected to.
As the monitored loads are reached, the 2-way valves close down. This increases the differential pressure measured across the load and the 2-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 the pressure drop of the load and the 2-way valve together under design condi­tions.
N O T I C E
When running multiple pumps in parallel, they must run at the same speed to maximize energy savings, either with individual
dedicated drives or 1 drive running multiple pumps in parallel.
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CHILLER
CHILLER
3
3
P
e30bb454.10
Drive
Drive
VLT® Flow Drive FC 111
Design Guide
Product Overview
Illustration 16: Secondary Pumps
3.1.3 Check Valve Monitoring
In the pump application system, a damaged check valve is hard to detect, which therefore causes low efficiency of the whole sys­tem. VLT® Flow Drive FC 111 has the ability to monitor the status of check valves in the system. After enabling the check valve moni­toring function via setting the parameter 22-04 Check Valve Monitor to [1] Enabled, once a damaged check valve is detected, the drive trips warning 159, Check Valve Failure.
3.1.4 Dry Pump Detection
In the pump application system, the drive monitors the operation status of the system to detect whether there is water on pump's suction side. If the pump runs at maximum speed and consumes little power, then it can be assumed that there is no water on the pump's suction side. Via setting the parameter 22-26 Dry Pump Function to warning or alarm, once the dry pump condition is detec­ted, the drive trips warning/alarm 93, dry pump.
3.1.5 End of Curve Detection
In the pump application system, the drive monitors the operation status of the system to detect whether the pressure side of pump is subject to a major leakage. If the pump runs at maximum speed for a defined time period, but the pressure is below the set point, then it can be considered to reflect the end of curve situation. Via setting the parameter 22-50 End of Curve Function to warning or alarm, once the end of curve condition is detected, the drive trips warning/alarm 94, end of curve.
3.1.6 Time-based Functions
In some application scenarios, there are requirements to control the motor running for a specific time, in a specific direction and a specific speed within a specific time interval. For example, checking the motor status in fire mode or exercising pumps, fans, and compressors.
For detailed parameter settings, refer to the parameter group 23-** Time-based Functions in the drive's Programming Guide.

3.2 Control Structures

3.2.1 Introduction
There are two control modes for the drive:
Open loop.
Closed loop.
Select [0] Open loop or [1] Closed loop in parameter 1-00 Configuration Mode.
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100%
0%
-100%
100%
A ut o mode
Hand mode
L ocal
P 4-10 M ot or speed dir ec tion
P 4-14 M ot or speed high limit [H z]
P 4-12 M ot or speed lo w limit [H z]
Reference handling Remote reference
Local reference scaled to Hz
LCP Hand on, off and auto on keys
Remote
Reference
P 3-4* Ramp 1 P 3-5* Ramp 2
Ramp
To motor control
e30bb892.11
Hand
On
On
e30bb893.11
Off Auto
Reset
VLT® Flow Drive FC 111
Design Guide
Product Overview
3.2.2 Control Structure Open Loop
Illustration 17: Open-loop Structure
In the configuration shown in the above illustration, parameter 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.
3.2.3 PM/EC+ Motor Control
The Danfoss EC+ concept provides the possibility for using high-efficient PM motors (permanent magnet motors) in IEC standard enclosure sizes operated by Danfoss drives.
The commissioning procedure is comparable to the existing one for asynchronous (induction) motors by utilizing the Danfoss VVC PM control strategy.
Customer advantages:
Free choice of motor technology (permanent magnet or induction motor).
Installation and operation as know on induction motors.
Manufacturer independent when selecting system components (for example, motors).
Best system efficiency by selecting best components.
Possible retrofit of existing installations.
Power range: 0.37–90 kW (0.5–121 hp) (400 V) for induction motors and 0.37–22 kW (0.5–30 hp) (400 V) for PM motors.
Current limitations for PM motors:
Currently only supported up to 22 kW (30 hp).
LC filters are not supported with PM motors.
Kinetic back-up algorithm is not supported with PM motors.
Support only complete AMA of the stator resistance Rs in the system.
No stall detection (supported from software version 62.80).
3.2.4 Local (Hand On) and Remote (Auto On) Control
The drive can be operated manually via the local control panel (LCP) or remotely via analog/digital inputs or serial bus. If allowed in parameter 0-40 [Hand on] Key on LCP, parameter 0-44 [Off/Reset] Key on LCP, and parameter 0-42 [Auto on] Key on LCP, it is possible to start and stop the drive via LCP by pressing [Hand On] and [Off/Reset]. Alarms can be reset via the [Off/Reset] key.
+
Illustration 18: LCP Keys
Local reference forces the configuration mode to open loop, independent on the setting of parameter 1-00 Configuration Mode.
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7-30 PI
Nor mal/I n v erse
C on tr ol
PI
F eedback
P 4-10
M ot or speed
dir ec tion
T o mot or c on tr ol
e30bb894.11
S
100%
0%
-100%
100%
*[-1]
_
+
Reference
Scale to speed
e30bb895.10
+
-
PI
P
P
P
Ref. signal
Desired flow
FB conversion
Ref.
FB
Flow
FB signal
Flow
P 20-01
VLT® Flow Drive FC 111
Design Guide
Product Overview
Local reference is restored at power-down.
3.2.5 Control Structure Closed Loop
The internal controller allows the drive to become a part of the controlled system. The 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 2 signals. It then adjusts the speed of the motor to correct this error.
For example, consider a compressor application where the speed of the compressor is to be controlled to ensure a constant suction pressure in an evaporator. The suction pressure value is supplied to the drive as the setpoint reference. A pressure sensor measures the actual suction pressure in the evaporator and supplies the data to the drive as a feedback signal. If the feedback signal is greater than the setpoint reference, the drive speeds up the compressor to reduce the pressure. In a similar way, if the suction pressure is lower than the setpoint reference, the drive automatically slows down the compressor to increase the pressure.
Illustration 19: Control Structure Closed Loop
While the default values for the closed-loop controller of the drive often provide satisfactory performance, the control of the system can often be optimized by adjusting parameters.
3.2.6 Feedback Conversion
In some applications, it may be useful to convert the feedback signal. One example of this is using a pressure signal to provide flow feedback. Since the square root of pressure is proportional to flow, the square root of the pressure signal yields a value proportional to the flow. See the following illustration.
Illustration 20: Feedback Signal Conversion
3.2.7 Reference Handling
Details for open-loop and closed-loop operation.
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Speed open loop
mode
Input command:
freeze reference
Process control
Scale to Hz
Scale to process unit
Remote reference/ setpoint
±200% Feedback handling
Remote reference in %
maxRefPCT
minRefPct
min-max ref
Freeze reference & increase/ decrease reference
±100%
Input commands:
Speed up/speed down
±200%
Relative reference = X+X*Y/100
±200%
External reference in %
±200%
Parameter choise: Reference resource 1,2,3
±100%
Preset reference
Input command: preset ref bit0, bit1, bit2
+
+
Relative scalling reference
Intern resource
Preset relative reference
±100%
Preset reference 0 ±100%
Preset reference 1 ±100%
Preset reference 2 ±100% Preset reference 3 ±100% Preset reference 4 ±100% Preset reference 5 ±100%
Preset reference 6 ±100% Preset reference 7 ±100%
External resource 1 No function
Analog reference ±200 %
Local bus reference ±200 % Pulse input reference ±200 %
Pulse input reference ±200 %
Pulse input reference ±200 %
External resource 2
No function Analog reference ±200 %
Local bus reference ±200 %
External resource 3 No function
Analog reference ±200 %
Local bus reference ±200 %
Y
X
e30be842.10
VLT® Flow Drive FC 111
Design Guide
Product Overview
Illustration 21: Block Diagram Showing Remote Reference
The remote reference consists of:
Preset references.
External references (analog inputs and serial communication bus references).
The preset relative reference.
Feedback-controlled setpoint.
Up to 8 preset references can be programmed in the drive. The active preset reference can be selected using digital inputs or the serial communications bus. The reference can also be supplied externally, most commonly from an analog input. This external source is selected by 1 of the 3 reference source parameters (parameter 3-15 Reference 1 Source, parameter 3-16 Reference 2 Source, and parameter 3-17 Reference 3 Source). 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 2 can be selected to be the active reference. Finally, this refer­ence can by be scaled using parameter 3-14 Preset Relative Reference.
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 parameter 3-14 Preset Relative Reference in [%].
If Y, parameter 3-14 Preset Relative Reference, is set to 0%, the reference is not affected by the scaling.
3.2.8 Tuning the Drive Closed-loop
Once the drive's closed-loop controller has been set up, test the performance of the controller. Often, its performance may be ac­ceptable using the default values of parameter 20-93 PI Proportional Gain and parameter 20-94 PI Integral Time. However, sometimes it may be helpful to optimize these parameter values to provide faster system response while still controlling speed overshoot.
3.2.9 Adjusting the Manual PI
Procedure
1.
Start the motor.
100
Y
AJ363928382091en-000101 / 130R0983 | 29Danfoss A/S © 2021.04
Enclosure size
Level [dBA]
(1)
H1
43.6H250.2H353.8H464H563.7H671.5H767.5 (75 kW (100 hp) 71.5 dB)
H8
73.5
H1373H14
75
VLT® Flow Drive FC 111
Design Guide
2.
Set parameter 20-93 PI Proportional Gain to 0.3 and increase it until the feedback signal begins to oscillate. If necessary, start and stop the drive or make step changes in the setpoint reference to attempt to cause oscillation.
3.
Reduce the PI proportional gain until the feedback signal stabilizes.
4.
Reduce the proportional gain by 40–60%.
5.
Set parameter 20-94 PI Integral Time to 20 s and reduce it until the feedback signal begins to oscillate. If necessary, start and stop the drive or make step changes in the setpoint reference to attempt to cause oscillation.
Increase the PI integral time until the feedback signal stabilizes.
6.
Increase the integral time by 15–50%.
7.
Product Overview

3.3 Ambient Running Conditions

3.3.1 Air Humidity
The drive has been designed to meet the IEC/EN 60068-2-3 standard, EN 50178 9.4.2.2 at 50 °C (122 °F).
3.3.2 Acoustic Noise or Vibration
If the motor or the equipment driven by the motor - for example, a fan - makes noise or vibrations at certain frequencies, configure the following parameters or parameter groups to reduce or eliminate the noise or vibrations:
Parameter group 4-6* Speed Bypass.
Set parameter 14-03 Overmodulation to [0] Off.
Switching pattern and switching frequency parameter group 14-0* Inverter Switching.
Parameter 1-64 Resonance Dampening.
3.3.2.1 Acoustic Noise
The acoustic noise from the drive comes from 3 sources:
DC-link coils.
Integral fan.
RFI filter choke.
Table 6: Typical Values Measured at a Distance of 1 m (3.28 ft) from the Unit
1
The values are measured under the background of 35 dBA noise and the fan running with full speed.
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