Danfoss PK37, P4K0, PK75, P5K5, P7K5 Quick Manual

MAKING MODERN LIVING POSSIBLE

Quick Guide

VLT® HVAC Basic Drive

Cascade Controller

Contents

1 Quick Guide

2

1.1 Safety

2

1.1.1 Warnings 2

1.1.2 Safety Instructions 2

1.2 Introduction

2

1.2.1 Available Literature 2

1.2.2 Approvals 2

1.2.3 IT Mains 3

1.2.4 Avoid Unintended Start 3

1.2.5 Disposal Instruction 3

1.3 Installation

3

1.3.1 Before Starting Repair Work 3

1.3.2 Side-by-Side Installation 3

1.3.3 Mechanical Dimensions 4

1.3.4 Electrical Installation in General 5

1.3.5 Connecting to Mains and Motor 6

1.3.6 Fuses 7

1.3.7 EMC-Correct Electrical Installation 8

1.3.8 Control Terminals 10

1.3.9 Electrical Overview 11

1.4 Programming

12

1.4.1 Programming with the Local Control Panel (LCP) 12

1.4.3 The Start-up Wizard for Open Loop Applications 13

1.5 Cascade Controller

20

1.5.1 System Status and Operation 20

1.5.2 Start/Stop Conditions 21

1.6 Parameter Overview

22

1.7 Warnings and Alarms

28

1.8.1 Mains Supply 3x380-480 V AC 30

1.8.2 EMC Test Results 32

1.9 Special Conditions

35

1.9.1 Derating for Ambient Temperature and Switching Frequency 35

1.9.2 Derating for Low Air Pressure 35

Contents

VLT® HVAC Basic Drive Cascade Controller Quick Guide

MG18F202 - VLT® is a registered Danfoss trademark 1

1 Quick Guide

1.1 Safety

1.1.1 Warnings

WARNING

High Voltage Warning

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

WARNING

Electrical Hazard

Touching the electrical parts may be fatal - even after the
equipment has been disconnected from mains. Also make
sure that other voltage inputs have been disconnected
(linkage of DC intermediate circuit). Be aware that there
may be high voltage on the DC link even when the LEDs
are turned off. Before touching any potentially live parts of
the frequency converter, wait at least as stated in the table
below:

Voltage [V] Power range [kW] Minimum waiting time

[min]
3x400 0.37–7.5 4
3x400 11–90 15

CAUTION

Leakage Current:
The earth leakage current from the frequency converter
exceeds 3.5 mA. According to IEC 61800-5-1 a reinforced
Protective Earth connection must be ensured by means of
a min. 10 mm² Cu or an addtional PE wire - with the same
cable cross section as the Mains wiring - must be
terminated separately.
Residual Current Device:
This product can cause a DC current in the protective
conductor. Where a residual current device (RCD) is used
for extra protection, only an RCD of Type B (time delayed)
shall be used on the supply side of this product. See also
Danfoss Application Note on RCD, MN90GXYY.
Protective earthing of the frequency converter and the use
of RCDs must always follow national and local regulations.

Motor Thermal Protection:
Motor overload protection is possible by setting 1-90 Motor
Thermal Protection to the value Electronic Thermal Relay
(ETR) trip.

WARNING

Installation at high altitudes

For altitudes above 2 km, please contact Danfoss regarding
PELV.

1.1.2 Safety Instructions

•

Make sure the frequency converter is properly
connected to earth.

•

Do not remove mains connections, motor
connections or other power connections while
the frequency converter is connected to power.

•

Protect users against supply voltage.

•

Protect the motor against overloading according
to national and local regulations.

•

The earth leakage current exceeds 3.5 mA.

•

The [Off reset] key is not a safety switch. It does
not disconnect the frequency converter from
mains.

1.2

Introduction

1.2.1 Available Literature

This Quick Guide contains the basic information necessary
for installing and running the frequency converter. If more
information is needed, literature can be found on the
enclosed cd or downloaded from:
http://www.danfoss.com/Products/Literature/Technical
+Documentation.htm

1.2.2

Approvals

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1.2.3 IT Mains

CAUTION

IT Mains

Installation on isolated mains source, i.e. IT mains.
Max. supply voltage allowed when connected to mains:
440 V (3x380-480 V units).

On 380-480 V IP20 0,37-22 kW, open the RFI switch by
removing the screw on the side of the frequency converter
when at IT grid.

130BB612.10

1

Illustration 1.1 IP20 0,37-22 kW 380-480 V.
1: EMC screw

On all units, set 14-50 RFI filter to Off when operating in IT
mains.

CAUTION

If reinserted, only use M3x12 screw.

1.2.4 Avoid Unintended Start

While the frequency converter is connected to mains, the
motor can be started/stopped using digital commands, bus
commands, references or via the LCP.

•

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

•

To avoid unintended start, always press [Off reset]
before changing parameters.

1.2.5

Disposal Instruction

Equipment containing electrical components
must 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.

1.3 Installation

1.3.1 Before Starting Repair Work

1. Disconnect FC 111 from mains (and external DC
supply, if present.)

2. Wait as stated in the table below for discharge of
the DC-link:

Voltage [V] Power range [kW] Minimum waiting time

[min]
3x400 0.37–7.5 4
3x400 11–90 15

3. Remove motor cable

1.3.2

Side-by-Side Installation

The frequency converter can be mounted side-by-side and
requires the clearance above and below for cooling.

Power Clearance above/

below [mm/inch]

Frame IP class 3x380-480 V

H1 IP20 0.37-1.5 kW/

0.5-2 Hp

100/4

H2 IP20 2.2-4 kW/

3-5.4 Hp

100/4

H3 IP20 5.5-7.5 kW/

7.5-10 Hp

100/4

H4 IP20 11-15 kW/

15-20 Hp

100/4

H5 IP20 18.5-22 kW/

25-30 Hp

100/4

H6 IP20 30-45 kW/

40-60 Hp

200/7.9

H7 IP20 55-75 kW/

100-120 Hp

200/7.9

H8 IP20 90 kW/

125 Hp

225/8.9

NOTE

With IP21/Nema Type1 option kit mounted, a distance of
50 mm between the units is required.

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1.3.3 Mechanical Dimensions

A

a

b

B

C

 D

130BB614.10

e

f

a

d

e

130BC205.10

e

f

a

e

130BC246.10

Power Height [mm/inch] Width [mm/inch] Depth [mm/

inch]

Hole [mm]

Frame IP class 3x380-480 V A A incl.

Decoupling

plate

A B b C D

H1 IP20 0.37-1.5 kW/

0.5-2 Hp

195/7.7 273/10.7 183/7.2 75/3 56/2.2 168/6.6 4.5

H2 IP20 2.2-4 kW/

3-5.4 Hp

227/8.4 303/11.9 212/8.3 90/3.5 65/2.6 190/7.5 5.5

H3 IP20 5.5-7.5 kW/

7.5-10 Hp

255/10 329/13 240/9.4 100/3.9 74/2.9 206/8.1 5.5

H4 IP20 11-15 kW/

15-20 Hp

296/11.7 359/14.1 275/10.8 135/5.3 105/4.1 241/9.5 7

H5 IP20 18.5-22 kW/

25-30 Hp

334/13.1 402/15.8 314/12.4 150/5.9 120/4.7 255/10 7

H6 IP20 30-45 kW/

40-60 Hp

518/20.4 595/23.4

635/25

495/19.5 239/31.5 200/7.9 242/9.5 8.5

H7 IP20 55-75 kW/

100-120 Hp

550/21.7 630/24.8

690/27.2

521/20.5 313/12.3 270/10.6 335/13.2 8.5

H8 IP20 90 kW/

120 Hp

660/26 800/31.5 631/24.8 375/14.8 330/13 335/13.2 8.5

Table 1.1 Mechanical Dimensions

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1.3.4 Electrical Installation in General

All cabling must comply with national and local
regulations on cable cross-sections and ambient
temperature. Copper conductors required, (75°C)
recommended.

Power [kW] Torque [Nm]

Frame IP class 3x380-480 Line Motor DC connection Control

terminals

Earth Relay

H1 IP20 0.37-1.5 1.4 0.8 0.8 0.5 0.8 0.5
H2 IP20 2.2-4 1.4 0.8 0.8 0.5 0.8 0.5
H3 IP20 5.5-7.5 1.4 0.8 0.8 0.5 0.8 0.5
H4 IP20 11-15 1.2 1.2 1.2 0.5 0.8 0.5
H5 IP20 18.5-22 1.2 1.2 1.2 0.5 0.8 0.5
H6 IP20 30-45 4.5 4.5 - 0.5 3 0.5
H7 IP20 55 10 10 - 0.5 3 0.5
H7 IP20 75 14 14 - 0.5 3 0.5
H8 IP20 90

14

1

14

1

- 0.5 3 0.5

H8 IP20 90

24

2

24

2

- 0.5 3 0.5

1

Cable dimensions ≤95 mm

2

2

Cable dimensions >95 mm

2

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1.3.5 Connecting to Mains and Motor

The frequency converter is designed to operate all
standard three-phased asynchronous motors. For
maximum cross-section on wires please see 1.8.1 Mains
Supply 3x380-480 V AC.

•

Use a shielded/armored motor cable to comply
with EMC emission specifications, and connect
this cable to both the decoupling plate and the
motor metal.

•

Keep motor cable as short as possible to reduce
the noise level and leakage currents.

•

For further details on mounting of the
decoupling plate, please see instruction
MI02QXYY

•

Also see EMC-Correct Installation in the Design
Guide, MG18CXYY.

1. Mount the earth wires to earth terminal.

2. Connect motor to terminals U, V and W.

3. Mount mains supply to terminals L1, L2 and L3
and tighten.

130BB634.10

1

2

2

3

4

Motor

U

V

W

-DC
+DC

MAINS

Illustration 1.2 IP20 380-480 V 0.37-22 kW.

1

Line
2 Earth
3 Motor
4 Relays

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IP20 380-480 V 30-45 kW

1

95

99

L1 91 / L2 92 / L3 93

U 96 / V 97 / W 98

03 02 01

06 05 04

2

3

4

130BB762.10

1 Line
2 Motor
3 Earth
4 Relays

IP20 380-480 V 55-75 kW

1

2

3

4

130BB763.10

1

Line
2 Relays
3 Earth
4 Motor

IP20 380-480 V 90 kW

130BB764.10

1

2

3

4

98

97

96

99

95

93

92

91
L1

L1

L1

U

V

w

1 Line
2 Relays
3 Earth
4 Motor

1.3.6 Fuses

Branch circuit protection
In order to protect the installation against electrical and
fire hazard, all branch circuits in an installation, switch
gear, machines etc., must be short-circuit and overcurrent
protected according to national/international regulations.

Short circuit protection
Danfoss recommends using the fuses mentioned in the
following tables to protect service personnel or other
equipment in case of an internal failure in the unit or
short-circuit on DC-link. The frequency converter provides
full short circuit protection in case of a short-circuit on the
motor.

Overcurrent protection
Provide overload protection to avoid overheating of the
cables in the installation. Overcurrent protection must
always be carried out according to national regulations.
Fuses must be designed for protection in a circuit capable
of supplying a maximum of 100,000 A

rms

(symmetrical),

480 V maximum.

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Non UL compliance
If UL/cUL is not to be complied with, use the fuses
mentioned in Table 1.2, which will ensure compliance with
IEC 61800-5-1:
In case of malfunction, not following the fuse recommen­dation may result in damage to the frequency converter.

UL Non

UL

Bussmann Bussmann Bussmann Bussmann Max.

Fuse
Power
[kW]

Type RK5 Type RK1 Type J Type T Type

gG

3x380-480 V

0.37 FRS-R-10 KTS-R10 JKS-10 JJS-10 10

0.75 FRS-R-10 KTS-R10 JKS-10 JJS-10 10

1.5 FRS-R-10 KTS-R10 JKS-10 JJS-10 10

2.2 FRS-R-15 KTS-R15 JKS-15 JJS-15 16
3 FRS-R-15 KTS-R15 JKS-15 JJS-15 16
4 FRS-R-15 KTS-R15 JKS-15 JJS-15 16

5.5 FRS-R-25 KTS-R25 JKS-25 JJS-25 25

7.5 FRS-R-25 KTS-R25 JKS-25 JJS-25 25
11 FRS-R-50 KTS-R50 JKS-50 JJS-50 50
15 FRS-R-50 KTS-R50 JKS-50 JJS-50 50

18.5 FRS-R-80 KTS-R80 JKS-80 JJS-80 65
22 FRS-R-80 KTS-R80 JKS-80 JJS-80 65
30 FRS-R-80 KTS-R80 JKS-R80 JJS-R80 80
37 FRS-R-100 KTS-R100 JKS-R100 JJS-R100 100
45 FRS-R-125 KTS-R125 JKS-R125 JJS-R125 125
55 FRS-R-150 KTS-R150 JKS-R150 JJS-R150 150
75 FRS-R-200 KTS-R200 JKS-R200 JJS-R200 200
90 FRS-R-250 KTS-R250 JKS-R250 JJS-R250 250

Table 1.2 Recommended fuses

1.3.7

EMC-Correct Electrical Installation

General points to be observed to ensure EMC-correct
electrical installation.

•

Use only screened/armoured motor cables and
screened/armoured control cables.

•

Connect the screen to earth at both ends.

•

Avoid installation with twisted screen ends
(pigtails), since this ruins the screening effect at
high frequencies. Use the cable clamps provide­dinstead.

•

It is important to ensure good electrical contact
from the installation plate through the installation
screws to the metal cabinet of the frequency
converter.

•

Use starwashers and galvanically conductive
installation plates.

•

Do not use unscreened/unarmoured motor cables
in the installation cabinets.

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L1

L2

L3

PE

Min. 16 mm

2

Equalizing cable

Control cables

All cable entries in

one side of panel

Earthing rail

Cable insula­tion stripped

Output con­tactor etc.

Motor cable

Motor, 3 phases and

PLC etc.

Panel

Mains-supply

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

PLC

Protective earth

Reinforced protective earth

130BB761.10

Illustration 1.3 EMC-correct Electrical Installation

For North America use metal conduits instead of shielded cables.

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1.3.8 Control Terminals

IP20 380-480 V 0.37-22 kW:

130BB622.10

Illustration 1.4 Location of Control Terminals

1. Place a screwdriver behind the terminal cover to
activate snap.

2. Tilt the screwdriver outwards to open the cover.

IP20 380-480 V 30-90 kW.

130BB624.10

1. Place a screwdriver behind the terminal cover to
activate snap.

2. Tilt the screwdriver outwards to open the cover.

Digital input 18, 19 and 27 mode is set in 5-00 Digital Input
Mode (PNP is default value) and digital input 29 mode is
set in 5-03 Digital Input 29 Mode (PNP is default value).

Control terminals:
Illustration 1.5 shows all control terminals of the frequency
converter. Applying Start (term. 18), connection between
terminal 12-27 and an analog reference (term. 53 or 54
and 55) make the frequency converter run.

18

19

12 20 55

27 29 42 45 50 53 54

DIGI IN/OUT

DIGI IN/OUT

DIGI IN

DIGI IN

61 68 69

N

P

COMM. GND

+24V

0/4-20mA A OUT / DIG OUT 0/4-20mA A OUT / DIG OUT

COM A IN

COM DIG IN

10V/20mA IN

10V/20mA IN

10V OUT

130BB985.10

BUS TER.

OFF ON

Illustration 1.5 Control Terminals

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1.3.9 Electrical Overview

24V

0V

24V

0V

L1
L2
L3

3 Phase
power
input

PE

PE

+10Vdc

0-10Vdc-

0-10Vdc-

50 (+10V OUT)

54 (A IN)

53 (A IN)

55 (COM A IN/OUT)

0/4-20 mA

0/4-20 mA

42 0/4-20mA A OUT / DIG OUT

45 0/4-20mA A OUT / DIG OUT

18 (DIGI IN)

19 (DIGI IN)

27 (DIGI IN/DIGI OUT)

29 (DIGI IN/
DIGI OUT)

12 (+24V OUT)

24V (NPN)

20 (COM D IN)

OV (PNP)

24V (NPN)
OV (PNP)

24V (NPN)
OV (PNP)

24V (NPN)
OV (PNP)

Bus ter.

Bus ter.

RS-485
Interface

RS-485

(N PS-485) 69

(P RS-485) 68

(Com RS-485 ) 61

(PNP)-Source
(NPN)-Sink

ON=Terminated

OFF=Unterminated

ON

1 2

240V AC 3A

Not present on all power sizes

Do not connect shield to
61 on 116,117 and 118 unites

01

02

03

relay1

relay2

UDC+

UDC-

Motor

U

V

W

130BB984.10

06

05

04

240V AC 3A

NOTE

There is no access to UDC- and UDC+ on the following units:
IP20 380-480 V 30-90 kW

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