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

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MAKING MODERN LIVING POSSIBLE

Quick Guide

VLT® HVAC Basic Drive

Cascade Controller

Contents

1 Quick Guide

1.1 Safety

1.1.1 Warnings 2

1.1.2 Safety Instructions 2

1.2 Introduction

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

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

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

1.5.1 System Status and Operation 20

1.5.2 Start/Stop Conditions 21

1.6 Parameter Overview

1.7 Warnings and Alarms

1.8.1 Mains Supply 3x380-480 V AC 30

1.8.2 EMC Test Results 32

1.9 Special Conditions

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

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

 D

130BB614.10

130BC205.10

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

- 0.5 3 0.5

H8 IP20 90

- 0.5 3 0.5

Cable dimensions ≤95 mm

Cable dimensions >95 mm

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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

Motor

-DC +DC

MAINS

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

Line 2 Earth 3 Motor 4 Relays

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IP20 380-480 V 30-45 kW

L1 91 / L2 92 / L3 93

U 96 / V 97 / W 98

03 02 01

06 05 04

130BB762.10

1 Line 2 Motor 3 Earth 4 Relays

IP20 380-480 V 55-75 kW

130BB763.10

Line 2 Relays 3 Earth 4 Motor

IP20 380-480 V 90 kW

130BB764.10

91 L1

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

Bussmann Bussmann Bussmann Bussmann Max.

Fuse Power [kW]

Type RK5 Type RK1 Type J Type T Type

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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Min. 16 mm

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.

12 20 55

27 29 42 45 50 53 54

DIGI IN/OUT

DIGI IN

61 68 69

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 OUT

130BB985.10

BUS TER.

OFF ON

Illustration 1.5 Control Terminals

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1.3.9 Electrical Overview

24V

L1 L2 L3

3 Phase power input

+10Vdc

0-10Vdc-

50 (+10V OUT)

54 (A IN)

53 (A IN)

55 (COM A IN/OUT)

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)

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

1 2

240V AC 3A

Not present on all power sizes

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

relay1

relay2

UDC+

UDC-

Motor

130BB984.10

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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1.4 Programming

1.4.1 Programming with the Local Control Panel (LCP)

NOTE

The frequency converter can also be programmed from a PC via RS-485 com-port by installing the MCT 10 Set-up Software. This software can either be ordered using code number 130B1000 or downloaded from the Danfoss Web site: www.danfoss.com/BusinessAreas/DrivesSolutions/ softwaredownload

1.4.2 Local Control Panel (LCP)

The following instructions are valid for the FC 111 LCP. The LCP is divided into four functional sections.

A. Alphanumeric display B. Menu key C. Navigation keys and indicator lights (LEDs) D. Operation keys and indicator lights (LEDs)

Com

1-20 Motor Power [2] 0.12kW-0.16HP Setup 1

13 14

Status

Main Menu

Quick Menu

Hand

Oﬀ

Reset

Auto

Alarm

Warn

130BB765.10

A. Alpha Numeric Display The LCD-display is back-lit with 2 alpha-numeric lines. All data is displayed on the LCP.

A number of information can be read from the display.

1 Parameter number and name. 2 Parameter value. 3 Set-up number shows the active set-up and the edit set-

up. If the same set-up acts as both active and edit set-up, only that set-up number is shown (factory setting). When active and edit set-up differ, both numbers are shown in the display (Setup 12). The number flashing, indicates the edit set-up.

4 Motor direction is shown to the bottom left of the display

– indicated by a small arrow pointing either clockwise or counterclockwise.

5 The triangle indicates if the LCP is in status, quick menu or

main menu.

B. Menu Key Use the menu key to select between status, quick menu or main menu.

C. Navigation keys and indicator lights (LEDs)

6 Com led: Flashes when bus communication is communi-

cating. 7 Green LED/On: Control section is working. 8 Yellow LED/Warn.: Indicates a warning. 9 Flashing Red LED/Alarm: Indicates an alarm. 10 [Back]: For moving to the previous step or layer in the

navigation structure 11

Arrows [▲] [▼]: For maneuvering between parameter groups,

parameters and within parameters. Can also be used for

setting local reference. 12 [OK]: For selecting a parameter and for accepting changes to

parameter settings

D. Operation keys and indicator lights (LEDs)

[Hand On]: Starts the motor and enables control of the frequency converter via the LCP.

NOTE

Terminal 27 Digital Input (5-12 Terminal 27 Digital Input) has coast inverse as default setting. This means that [Hand On] will not start the motor if there is no 24 V to terminal 27. Connect terminal 12 to terminal

27.

14 [Off/Reset]: Stops the motor (off). If in alarm mode the

alarm will be reset.

15 [Auto On]: frequency converter is controlled either via

control terminals or serial communication.

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At power-up At the first power-up the user is asked to choose preferred language. Once selected this screen will never be shown again in the following powerups, but language can still be changed in 0-01 Language.

130BB628.10

Select Language [ 0 ] English Setup 1

1.4.3 The Start-up Wizard for Open Loop Applications

The built-in “wizard” menu guides the installer through the setup of the frequency converter in a clear and structured manner to setup an open loop application. An open loop application is here an application with a start signal, analog reference (voltage or current) and optionally also relay signals (but no feed back signal from the process applied).

+24V

DIG IN DIG IN

COM DIG IN

A OUT / D OUT A OUT / D OUT

18 19

27 29

50 53 54

01 02 03

04 05 06

0-10V

Start

+10V A IN A IN

COM

130BB674.10

Reference

The wizard will initially be shown after power up until any parameter has been changed. The wizard can always be accessed again through the quick menu. Press [OK] to start the wizard. If [Back] is pressed, the FC 111 will return to the status screen.

130BB629.10

Press OK to start Wizard Push Back to skip it Setup 1

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Setup 1

Setup 1 Setup 1 Setup 1

Setup 1

Setup 1Setup 1

Setup 1

[0] International

Set Motor Power

1.10 kW

Set Motor Voltage 50 V

Set Motor Frequency 50 Hz

Set Motor Current

4.66 A

Set Motor Nominal Speed 1420 RPM

Set Motor Speed Low Limit 0 Hz

Set Motor Speed Hig h Limit 65 Hz

Set Ramp 1 Ramp Up Time 0003 s

Set Ramp 1 Ramp Dow n Time 0003 s

Active Flying start? [0] Disable

Select Terminal 53 Mode [0] Voltage

Set Terminal 53 Low Voltage

0.07 V

Set Terminal 53 Hig h Voltage 10 V

Set Terminal 53 Low Current 4 mA

Set Terminal 53 Hig h Current 20 mA

AMA Failed

0.0 Hz

0.0 kW

Wizard completed Press OK to accept

Automatic Motor Adaption (AMA)

[1] Enable

Auto Motor Tuning OK Press OK

Select Function Rel ay 2 [0] Drive running

Select Function of Rela y 1 [0] Alarm

Set Maximum Referen ce 0050 Hz

Set Minimum Reference 0016 Hz

AMA running

-----

Status

Main Menu

Quick Menu

Hand

Oﬀ

Reset

Auto

Alarm

Warn

AMA failed

Do AMA

Status Screen

The Wizard can always be

reentered via the Quick Menu!

(Do not AMA)

Current

Voltage

Power Up Screen

At power up the user is asked to choose the prefered laguage.

Select language [1] English

0.0 Hz

0.0 kW

Setup 1

Status

Main Menu

Quick Menu

Hand

Oﬀ

Reset

Auto

Alarm

Warn

Press OK to start Wizard Press Back to skip it

Setup 1

Status

Main Menu

Quick Menu

Hand

Oﬀ

Reset

Auto

Alarm

Warn

The next screen will be

the Wizard screen.

Wizard Screen

AMA OK

32 33

130BC244.10

Select Regional Settings

- the HVAC FC 101 Wizard starts

Setup 1

200-240V/50Hz/Delta

Grid Type

Asynchronous Motor

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The FC 111 Start-up Wizard for Open Loop Applications

No & Name Range Default Function

0-03 Regional Settings [0] International

[1] US

0-06 GridType [0] 200-240 V/50 Hz/IT-grid

[1] 200-240 V/50 Hz/Delta [2] 200-240 V/50 Hz [10] 380-440 V/50 Hz/IT-grid [11] 380-440 V/50 Hz/Delta [12] 380-440 V/50 Hz [20] 440-480 V/50 Hz/IT-grid [21] 440-480 V/50 Hz/Delta [22] 440-480 V/50 Hz [30] 525-600 V/50 Hz/IT-grid [31] 525-600 V/50 Hz/Delta [32] 525-600 V/50 Hz [100] 200-240 V/60 Hz/IT-grid [101] 200-240 V/60 Hz/Delta [102] 200-240 V/60 Hz [110] 380-440 V/60 Hz/IT-grid [111] 380-440 V/60 Hz/Delta [112] 380-440 V/60 Hz [120] 440-480 V/60 Hz/IT-grid [121] 440-480 V/60 Hz/Delta [122] 440-480 V/60 Hz [130] 525-600 V/60 Hz/IT-grid [131] 525-600 V/60 Hz/Delta [132] 525-600 V/60 Hz

Size related

Select operating mode for restart upon reconnection of the frequency converter to mains voltage after power down

1-20 Motor Power 0.12-110 kW/0.16-150 hp Size related Enter motor power from nameplate data 1-22 Motor Voltage 50.0-1000.0 V Size related Enter motor voltage from nameplate data 1-23 Motor Frequency 20.0-400.0 Hz Size related Enter motor frequency from nameplate data 1-24 Motor Current 0.01-10000.00 A Size related Enter motor current from nameplate data 1-25 Motor Nominal Speed

100.0-9999.0 RPM Size related Enter motor nominal speed from nameplate data

4-12 Motor Speed Low Limit [Hz]

0.0-400 Hz 0 Hz Enter the minimum limit for low speed

4-14 Motor Speed High Limit [Hz]

0.0-400 Hz 65 Hz Enter the maximum limit for high speed

3-41 Ramp 1 Ramp up Time

0.05-3600.0 s Size related

Ramp up time from 0 to rated 1-23 Motor

Frequency

3-42 Ramp 1 Ramp Down Time

0.05-3600.0 s Size related

Ramp down time from rated 1-23 Motor Frequency to 0

1-73 Flying Start [0] Disabled

[1] Enabled

0 Select Enable to enable the frequency converter to

catch a spinning motor i.e. fan applications

6-19 Terminal 53 mode [0] Current

[1] Voltage

1 Select if terminal 53 is used for current- or voltage

input 6-10 Terminal 53 Low Voltage

0-10 V 0.07 V Enter the voltage that corresponds to the low

reference value 6-11 Terminal 53 High Voltage

0-10 V 10 V Enter the voltage that corresponds to the high

reference value 6-12 Terminal 53 Low Current

0-20 mA 4 Enter the current that corresponds to the low

reference value 6-13 Terminal 53 High Current

0-20 mA 20 Enter the current that corresponds to the high

reference value 3-02 Minimum Reference -4999-4999 0 The minimum reference is the lowest value

obtainable by summing all references

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No & Name Range Default Function

3-03 Maximum Reference -4999-4999 50 The maximum reference is the lowest obtainable

by summing all references 5-40 Function Relay [0] Function relay

See 5-40 Function Relay Alarm Select the function to control output relay 1

5-40 Function Relay [1] Function relay

See 5-40 Function Relay Drive running Select the function to control output relay 2

1-29 Automatic Motor Adaption (AMA)

See 1-29 Automatic Motor Adaption (AMA)

Off Performing an optimizes motor performance

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Closed Loop Set-up Wizard

6-29 Terminal 54 Mode

[1]

Voltage mode

6-25 Terminal 54 High Ref./Feedb. Value

0050

20-94 PI Integral Time

9999

Current

Voltage

This dialog is forced to be set to [2] Analog in 54

20-00 Feedback1 source

[2]

Analog in 54

3-10 Preset reference [0]

[1]

3-03 Max Reference

[1]

3-02 Min Reference

[1]

Asynchronous Motor

1-73 Flying Start

[0]

1-22 Motor Voltage

1-24 Motor current

4.66

1-25 Motor nominal speed

1420

RPM

3-41 Ramp 1 ramp-up time

0003

3-42 Ramp1 ramp-down time

0003

18a

0-06 Grid Type

[200-240 V/50 Hz]

4-12 Motor speed low limit

4-14 Motor speed high limit

130BC245.10

1-20 Motor Power

1.10

1-23 Motor frequency

6-22 Terminal 54 Low Current

4 mA

6-24 Terminal 54 Low Ref./Feedb. Value

0016

6-23 Terminal 54 High Current

6-25 Terminal 54 High Ref./Feedb. Value

0,01

20-81 PI Normal/Inverse Control

[0]

Normal

20-83 PI Start Speed

20-93 PI Proportional Gain

0,01

1-29 Automatic Motor Adaption

[1]

Enable

6-20 Terminal 54 Low Voltage

0,07

6-24 Terminal 54 Low Ref./Feedb. Value

6-21 Terminal 54 High Voltage

6-26

Terminal 54 Filter time constant

3-10 Preset reference is the set-point

Please note that Terminal 27 Digital Input (par. 5-12) has coast inverse as default setting. This means that AMA can not be performed if there is no 24V to terminal 27 so please connect terminal 12 to terminal 27.

0-01 Conﬁguration Mode

[0]

Open Loop

0-03 Regional Settings

[0]

International

3-16 Reference 2 Source

[0]

No function

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

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Closed Loop Set-up Wizard

No & Name Range Default Function

0-03 Regional Settings [0] International

[1] US

0-06 GridType [0]-[[132] please see

start-up wizard for open loop application

Size selected Select operating mode for restart upon

reconnection of the frequency converter to

mains voltage after power down 1-20 Motor Power 0.09-110 kW Size related Enter motor power from nameplate data 1-22 Motor Voltage 50.0-1000.0 V Size related Enter motor voltage from nameplate data 1-23 Motor Frequency 20.0-400.0 Hz Size related Enter motor frequency from nameplate data 1-24 Motor Current 0.01-10000.00 A Size related Enter motor current from nameplate data 1-25 Motor Nominal Speed 100.0-9999.0 RPM Size related Enter motor nominal speed from nameplate data 4-12 Motor Speed Low Limit [Hz] 0.0-400 Hz 0.0 Hz Enter the minimum limit for low speed 4-14 Motor Speed High Limit [Hz] 0.1-400 Hz 65 Hz Enter the maximum limit for high speed 3-41 Ramp 1 Ramp up Time 0.05-3600.0 s Size related Ramp up time from 0 to rated motor frequency,

1-23 Motor Frequency 3-42 Ramp 1 Ramp Down Time 0.05-3600.0 s Size related Ramp down time from rated motor frequency,

1-23 Motor Frequency to 0 1-73 Flying Start [0] Disabled

[1] Enabled

0 Select Enable to enable the frequency converter

to catch a spinning motor 3-02 Minimum Reference -4999-4999 0 The minimum reference is the lowest value

obtainable by summing all references 3-03 Maximum Reference -4999-4999 50 The maximum reference is the highest value

obtainable by summing all references 3-10 Preset Reference -100-100% 0 Enter the set point 6-29 Terminal 54 mode [0] Current

[1] Voltage

1 Select if terminal 54 is used for current- or

voltage input 6-20 Terminal 54 Low Voltage 0-10 V 0.07 V Enter the voltage that corresponds to the low

reference value 6-21 Terminal 54 High Voltage 0-10 V 10 V Enter the voltage that corresponds to the low

high reference value 6-22 Terminal 54 Low Current 0-20 mA 4 Enter the current that corresponds to the high

reference value 6-23 Terminal 54 High Current 0-20 mA 20 Enter the current that corresponds to the high

reference value 6-24 Terminal 54 Low Ref./Feedb. Value -4999-4999 0 Enter the feedback value that corresponds to the

voltage or current set in 6-20 Terminal 54 Low

Voltage/6-22 Terminal 54 Low Current 6-25 Terminal 54 High Ref./Feedb. Value -4999-4999 50 Enter the feedback value that corresponds to the

voltage or current set in 6-21 Terminal 54 High

Voltage/6-23 Terminal 54 High Current 6-26 Terminal 54 Filter Time Constant 0-10 s 0.01 Enter the filter time comstant 1-23 Motor Frequency [0] Normal

[1] Inverse

Select Normal [0] to set the process control to

increase the output speed when the process

error is positive. Select Inverse [1] to reduce the

output speed. 20-83 PI Start Speed [Hz] 0-200 Hz 0 Enter the motor speed to be attained as a start

signal for commencement of PI control 20-93 PI Proportional Gain 0-10 0.01 Enter the process controller proportional gain.

Quick control is obtained at high amplification.

However if amplification os too great, the

process may become unstable

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

18 MG18F202 - VLT® is a registered Danfoss trademark

No & Name Range Default Function

20-94 PI Integral Time 0.1-999.0 s 999.0 s Enter the process controller integral time. Obtain

quick control through a short integral time,

though if the integral time is too short, the

process becomes unstable. An excessively long

integral time disables the integral action. 1-29 Automatic Motor Adaption (AMA) Off Performing an optimizes motor performance

Motor Set-up The Quick Menu Motor Set-up guides through the needed motor parameters.

No & Name Range Default Function

0-03 Regional Settings

[0] International [1] US

0-06 GridType [0]-[132] please

see start-up wizard for open loop application

Size selected Select operating

mode for restart upon reconnection of the frequency converter to mains voltage after power

down 1-20 Motor Power

0.12-110 kW/

0.16-150 Hp

Size related Enter motor

power from

nameplate data 1-22 Motor Voltage

50.0-1000.0 V Size related Enter motor voltage from nameplate data

1-23 Motor Frequency

20.0-400.0 Hz Size related Enter motor frequency from nameplate data

1-24 Motor Current

0.01-10000.00ASize related Enter motor current from nameplate data

1-25 Motor Nominal Speed

100.0-9999.0

RPM

Size related Enter motor

nominal speed from nameplate data

4-12 Motor Speed Low Limit [Hz]

0.0-400 Hz 0.0 Hz Enter the minimum limit for low speed

4-14 Motor Speed High Limit [Hz]

0-400 Hz 65 Enter the

maximum limit for high speed

3-41 Ramp 1 Ramp up Time

0.05-3600.0 s Size related Ramp up time from 0 to rated motor frequency

1-23 Motor Frequency

No & Name Range Default Function

3-42 Ramp 1 Ramp Down Time

0.05-3600.0 s Size related Ramp down time from rated motor frequency

1-23 Motor Frequency to 0

1-73 Flying Start

[0] Disabled [1] Enabled

Select [1] Enable to enable the frequency converter to catch a spinning motor

Changes Made Changes Made lists all parameters changed since factory setting. Only the changed parameters in current edit-setup are listed in changes made.

If the parameters value is changed back to factory setting's value from another different value, the parameter will NOT be listed in Changes Made.

1. Press [Menu] key to enter the Quick Menu until indicator in display is placed above Quick Menu.

Press [▲] [▼] to select either FC 111 wizard, closed loop setup, motor setup or changes made, then press [OK].

Press [▲] [▼] to browse through the parameters in the Quick Menu.

4. Press [OK] to select a parameter.

Press [▲] [▼] to change the value of a parameter setting.

6. Press [OK] to accept the change.

7. Press either [Back] twice to enter “Status”, or press [Menu] once to enter “Main Menu”.

The Main Menu accesses all parameters.

1. Press [Menu] key until indicator in display is placed above “Main Menu”.

Press [▲] [▼] to browse through the parameter groups.

3. Press [OK] to select a parameter group.

Press [▲] [▼] to browse through the parameters in the specific group.

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

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5. Press [OK] to select the parameter.

Press [▲] [▼] to set/change the parameter value.

1.5 Cascade Controller

Constant Speed Pumps (2)

Variable Speed Pumps (1)

Motor starter

Frequency Converter with Cascade Controller

Pressure Sensor

130BA362.10

The Cascade Controller is used for pump applications where a certain pressure (“head”) or level needs to be maintained over a wide dynamic range. Running a large pump at variable speed over a wide for range is not an ideal solution because of low pump efficiency and because there is a practical limit of about 25% rated full load speed for running a pump.

In the Cascade Controller the frequency converter controls a variable speed motor as the variable speed pump (lead) and can stage up to two additional constant speed pumps on and off. By varying the speed of the initial pump, variable speed control of the entire system is provided. This maintains constant pressure while eliminating pressure surges, resulting in reduced system stress and quieter operation in pumping systems.

Fixed Lead Pump The motors must be of equal size. The Cascade Controller allows the frequency converter to control up to 5 equal size pumps using the drives two built-in relays and terminal 27, 29 (DI/DO). When the variable pump (lead) is connected directly to the frequency converter, the other 4 pumps are controlled by the two built-in relays and terminal 27, 29 (DI/DO). Lead pump alternation can not be chosen when lead pump is fixed.

Lead Pump Alternation The motors must be of equal size. This function makes it possible to cycle the frequency converter between the pumps in the system (when 25-57 Relays per Pump =1, maximum pump is 4. When 25-57 Relays per Pump =2, maximum pump is 3). In this operation the run time between pumps is equalized reducing the required pump maintenance and increasing reliability and lifetime of the system. The alternation of the lead pump can take place at a command signal or at staging (adding lag pump).

The command can be a manual alternation or an alternation event signal. If the alternation event is selected, the lead pump alternation takes place every time the event occurs. Selections include whenever an alternation timer expires, when the lead pump goes into sleep mode. Staging is determined by the actual system load.

25-55 Alternate if Load <= 50%= 1, if load >50% Alternation will not happen. If load <=50% Alternation will happen. When 25-55 Alternate if Load <= 50% = 0, Alternation will happen no matter with Load. Total pump capacity is determined as lead pump plus lag speed pumps capacities.

Bandwidth Management In cascade control systems, to avoid frequent switching of fixed speed pumps, the desired system pressure is kept within a bandwidth rather than at a constant level. The Staging Bandwidth provides the required bandwidth for operation. When a large and quick change in system pressure occurs, the Override Bandwidth overrides the Staging Bandwidth to prevent immediate response to a short duration pressure change. An Override Bandwidth Timer can be programmed to prevent staging until the system pressure has stabilized and normal control established.

When the Cascade Controller is enabled and running normally and the frequency converter issues a trip alarm, the system head is maintained by staging and destaging fixed speed pumps. To prevent frequent staging and destaging and minimize pressure fluxuations, a wider Fixed Speed Bandwidth is used instead of the Staging bandwidth.

1.5.1

System Status and Operation

Only when lead pump is working, the frequency converter can go into sleep mode. When the Cascade Controller is enabled, the operation status for each pump and the Cascade Controller is displayed by 25-81, Pump Status and 25-80, Cascade Status on the LCP. Cascade Controller information displayed includes:

•

Pumps Status, is a read out of the status for the relays assigned to each pump. The display shows pumps that are disabled, off, running on the frequency converter or running on the mains/ motor starter.

•

Cascade Status, is a read out of the status for the Cascade Controller. The display shows the Cascade Controller is disabled, all pumps are running off, fixed speed pumps are being staged/de-staged and lead pump alternation is occurring.

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

20 MG18F202 - VLT® is a registered Danfoss trademark

1.5.2 Start/Stop Conditions

Commands assigned to digital inputs. See Digital Inputs, parameter group 5-1*.

Variable speed pump (lead) Fixed speed pumps (lag) Start (SYSTEM START/STOP) Ramps up (if stopped and there is a

demand)

Staging (if stopped and there is a demand)

Lead Pump Start Ramps up if SYSTEM START is active Not affected Coast (EMERGENCY STOP) Coast to stop Cut out (correspond relays, terminal 27/29

and 42/45)

External Interlock Coast to stop Cut out (built-in relays are de-energized)

Function of buttons on LCP:

Variable speed pump (lead) Fixed speed pumps (lag) [Hand On] Ramps up (if stopped by a normal stop

command) or stays in operation if already running

Destaging (if running)

[Off] Ramps down Destaging [Auto On] Starts and stops according to commands via

terminals or serial bus cascade controller only can work when drive in "Auto ON" mode

Staging/Destaging

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

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1.6 Parameter Overview

Parameter Overview

0-** Operation / Display 0-0* Basic Settings

0-01 Language *[0] English [1] Deutsch [2] Francais [3] Dansk [4] Espanol [5] Italiano [28] Portuguese [255] No Text 0-03 Regional Settings *[0] International [1] US 0-04 Operating State at Powerup *[0] Resume [1] Forced stop, ref=old 0-06 GridType 0] 200-240 V/50 Hz/IT-grid [1] 200-240 V/50 Hz/Delta [2] 200-240 V/50 Hz [10] 380-440 V/50 Hz/IT-grid [11] 380-440 V/50 Hz/Delta [12] 380-440 V/50 Hz [20] 440-480 V/50 Hz/IT-grid [21] 440-480 V/50 Hz/Delta [22] 440-480 V/50 Hz [30] 525-600 V/50 Hz/IT-grid [31] 525-600 V/50 Hz/Delta [32] 525-600 V/50 Hz [100] 200-240 V/60 Hz/IT-grid [101] 200-240 V/60 Hz/Delta [102] 200-240 V/60 Hz [110] 380-440 V/60 Hz/IT-grid [111] 380-440 V/60 Hz/Delta [112] 380-440 V/60 Hz [120] 440-480 V/60 Hz/IT-grid [121] 440-480 V/60 Hz/Delta [122] 440-480 V/60 Hz [130] 525-600 V/60 Hz/IT-grid [131] 525-600 V/60 Hz/Delta [132] 525-600 V/60 Hz 0-07 Auto DC Braking IT [0] Off *[1] On

0-1* Set-up Operations

0-10 Active Set-up *[1] Set-up 1 [2] Set-up 2 [9] Multi Set-up

0-11 Programming Set-up [1] Set-up 1 [2] Set-up 2 *[9] Active Set-up 0-12 Link Setups [0] Not linked *[20] Linked

0-3* LCP Readout

0-30 Custom Readout Unit [0] None *[1] % [5] PPM [10] 1/Min [11] RPM [12] Pulse/s [20] l/s [21] l/min [22] l/h [23] m3/s [24] m3/min [25] m3/h [30] kg/s [31] kg/min [32] kg/h [33] t/min [34] t/h [40] m/s [41] m/min [45] m [60] Degree Celsius [70] mbar [71] bar [72] Pa [73] kPa [74] m Wg [80] kW [120] GPM [121] gal/s [122] gal/min [123] gal/h [124] CFM [127] ft3/h [140] ft/s [141] ft/min [160] Degree Fahr [170] psi [171] lb/in2 [172] in WG [173] ft WG [180] HP

0-31 Custom Readout Min Value

0.00 - 1,000,000.0, * 0.00 0-32 Custom Readout Max Value

0.00 - 1,000,000.0, * 100.00 0-37 Display Text 1 0-38 Display Text 2 0-39 Display Text 3

0-4* LCP Keypad

0-40 [Hand on] Key on LCP [0] Disabled *[1] Enabled 0-42 [Auto on] Key on LCP [0] Disabled *[1] Enabled 0-44 [Off / Reset] Key on LCP [0] Disable All *[1] Enable All [7] Enable Reset Only

0-5* Copy/Save

0-50 LCP Copy *[0] No copy [1] All to LCP [2] All from LCP [3] Size indep. from LCP 0-51 Set-up Copy *[0] No copy [1] Copy from setup 1 [2] Copy from setup 2 [9] Copy from Factory setup

0-6* Password

0-60 Main Menu Password 0 - 999, * 0

1-** Load and Motor 1-0* General Settings

1-00 Configuration Mode *[0] Open loop [3] Closed loop 1-01 Motor Control Principle [0] U/f *[1] VVC+ 1-03 Torque Characteristics *[1] Variable torque [3] Auto Energy Optim. 1-06 Clockwise Direction *[0] Normal [1] Inverse 1-20 Motor Power [2] 0.12 kW - 0.16 Hp [3] 0.18 kW - 0.25 Hp [4] 0.25 kW - 0.33 Hp [5] 0.37 kW - 0.50 Hp

[6] 0.55 kW - 0.75 Hp [7] 0.75 kW - 1.00 Hp [8] 1.10 kW - 1.50 Hp [9] 1.50 kW - 2.00 Hp [10] 2.20 kW - 3.00 Hp [11] 3.00 kW - 4.00 Hp [12] 3.70 kW - 5.00 Hp [13] 4.00 kW - 5.40 Hp [14] 5.50 kW - 7.50 Hp [15] 7.50 kW - 10.0 Hp [16] 11.00 kW - 15.00 Hp [17] 15.00 kW - 20 Hp [18] 18.5 kW - 25 Hp [19] 22 kW - 30 Hp [20] 30 kW - 40 Hp [21] 37 kW-50 Hp [22] 45 kW-60 Hp [23] 55 kW-75 Hp [24] 75 kW-100 Hp [25] 90 kW-120 Hp [26] 110 kW-150 Hp 1-22 Motor Voltage 50 - 1000 V 1-23 Motor Frequency 20 - 400, *(50) Hz 1-24 Motor Current

0.01 - (26.00), [A] 1-25 Motor Nominal Speed 100 rpm - 6000 rpm, 1-29 Automatic Motor Adaption () *[0] Off [1] Enable Complete [2] Enable Reduced

1-3* Adv. Motor Data I

1-30 Stator Resistance (Rs)

0.000 ohm - 99.990 ohm 1-33 Stator Leakage Reactance (X1)

0.000 ohm - 999.900 ohm 1-35 Main Reactance (Xh)

0.00 - 999.90 ohm 1-39 Motor Poles 2 - 100, * 4

1-4* Adv. Motor Data II

1-42 Motor Cable Length 0 - 150, * 50m 1-43 Motor Cable Length Feet 0 - 431, * 144

1-5* Load Indep. Setting

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

22 MG18F202 - VLT® is a registered Danfoss trademark

Parameter Overview 1-50 Motor Magnetisation at Zero Speed 0 - 300, * 100% 1-52 Min Speed Normal Magnetising [Hz]

0.0 - 10.0, * 0.0 1-55 U/f Characteristic - U 0 - 999 V, *0V 1-56 U/f Characteristic - F 0 - 400 Hz, *(0)

1-6* Load Depend. Setting

1-62 Slip Compensation

-400 - 399%, * 0% 1-63 Slip Compensation Time Constant

0.05 - 5.00 s, * 0.10 1-64 Resonance Dampening 0 - 500%, * 100 1-65 Resonance Dampening Time Constant

0.001 - 0.050 s, * 0.005

1-7* Start Adjustments

1-71 Start Delay

0.0 - 10.0 s, * 0.0 1-72 Start Function [0] DC Hold/delay time *[2] Coast/delay time 1-73 Flying Start *[0] Disabled [1] Enabled

1-8* Stop Adjustments

1-80 Function at Stop *[0] Coast [1] DC hold/MotorPreheat 1-82 Min Speed for Function at Stop [Hz]

0.0 - 20.0 Hz, * 0.0

1-9* Motor Temperature

1-90 Motor Thermal Protection *[0] No protection [1] Thermistor warning [2] Thermistor trip [3] ETR warning 1 [4] ETR trip 1 1-93 Thermistor Resource *[0] None [1] Analog input 53 [6] Digital input 29

2-** Brakes 2-0* DC-Brake

2-00 DC Hold/Motor Preheat Current 0 - 160%, * 50 2-01 DC Brake Current 0 - 150%, * 50 2-02 DC Braking Time

0.0 - 60.0 s, * 10.0

2-04 DC Brake Cut In Speed

0.0 - 400.0 Hz, * 0.0

2-1* Brake Energy Funct.

2-17 Over-voltage Control [0] Disabled *[2] Enabled

3-** Reference / Ramps 3-0* Reference Limits

3-02 Minimum Reference (-4999.000) - 4999.000, * 0.000 3-03 Maximum Reference (-4999.000) - 4999.000, * 50.000

3-1* References

3-10 Preset Reference

-100.00 - 100.00 %, * 0.00 3-11 Jog Speed [Hz]

0.0 - 400.0 Hz, * 5.0 3-14 Preset Relative Reference

-100.00 - 100.00, * 0.00 3-15 Reference Resource 1 [0] No function *[1] Analog in 53 [2] Analog in 54 [11] Local bus reference 3-16 Reference 2 Resource [0] No function [1] Analog in 53 *[2] Analog in 54 [11] Local bus reference 3-17 Reference 3 Resource [0] No function [1] Analog in 53 [2] Analog in 54 *[11] Local bus reference

3-4* Ramp 1

3-41 Ramp 1 Ramp up Time

0.05 - 3600.00 s, *Size related 3-42 Ramp 1 Ramp Down Time

0.05 - 3600.00 s, *Size related

3-5* Ramp 2

3-51 Ramp 2 Ramp up Time

0.05 - 3600.00 s, *Size related 3-52 Ramp 2 Ramp down Time

0.05 - 3600.00 s, *Size related

3-8* Other Ramps

3-80 Jog Ramp Time

0.05 - 3600.00 s, *Size related 3-81 Quick Stop Ramp Time

0.05 - 3600.00 s, *Size related

4-** Limits / Warnings 4-1* Motor Limits

4-10 Motor Speed Direction [0] Clockwise *[2] Both directions 4-12 Motor Speed Low Limit [Hz]

0.0 - 400 Hz, * 0.0 Hz

4-14 Motor Speed High Limit [Hz]

0.1 - 400 Hz, * 65.0 Hz 4-18 Current Limit 0 - 300%, * 110 4-19 Max Output Frequency

0.0 - 400.0 Hz, * 65.0

4-4* Adj. Warnings 2

4-40 Warning Freq. Low

0.0-400.0 Hz, *400.0 4-41 Warning Freq. High

0.0-400.0 Hz, *400.0

4-5* Adj. Warnings

4-50 Warning Current Low

0.00 - 194.00 A, * 0.00 4-51 Warning Current High

0.00 - 194.00 A, * 194.00 4-54 Warning Reference Low

-4999.000 - 4999.000, *-4999.000 4-55 Warning Reference High

-4999.000 - 4999.000, *4999.000 4-56 Warning Feedback Low

-4999.000 - 4999.000, *-4999.000 4-57 Warning Feedback High

-4999.000 - 4999.000, *4999.000 4-58 Missing Motor Phase Function [0] Off *[1] On 4-6* Speed Bypass 4-61 Bypass Speed From [Hz]

0.0 - 400.0, * 0.0 4-63 Bypass Speed To [Hz]

0.0 - 400.0, * 0.0 4-64 Semi-Auto Bypass Set-up *[0] Off [1] Enable

5-** Digital In/Out 5-0* Digital I/O mode

5-00 Digital Input Mode *[0] PNP [1] NPN 5-03 Digital Input 29 Mode *[0] PNP [1] NPN

5-1* Digital Inputs

5-10 Terminal 18 Digital Input [0] No operation [1] Reset [2] Coast inverse [3] Coast and reset inverse [4] Quick stop inverse [5] DC-brake inverse [6] Stop inverse [7] External Interlock *[8] Start

[9] Latched start [10] Reversing [11] Start reversing [14] Jog [16] Preset ref bit 0 [17] Preset ref bit 1 [18] Preset ref bit 2 [19] Freeze reference [20] Freeze output [21] Speed up [22] Speed down [23] Set-up select bit 0 [34] Ramp bit 0 [37] Fire mode [52] Run permissive [53] Hand Start [54] Auto start [60] Counter A (up) [61] Counter A (down) [62] Reset Counter A [63] Counter B (up) [64] Counter B (down) [65] Reset Counter B [120] Lead Pump Start [121] Lead Pump Alternation [130] Pump 1 Interlock [131] Pump 2 Interlock [132] Pump 3 Interlock [133] Pump 4 Interlock [134] Pump 5 Interlock 5-11 Terminal 19 Digital Input See par. 5-10, *[0] No operation 5-12 Terminal 27 Digital Input See par. 5-10, *[2] Coast inverse 5-13 Terminal 29 Digital Input See par. 5-10, *[14 Jog]

5-3* Digital Outputs

5-34 On Delay, Digital Output

0.00 - 600.00 s, *0.01 s 5-35 Off Delay, Digital Output

0.00 - 600.00 s, *0.01 s

5-4* Relays

5-40 Function Relay *[0] No operation [1] Control ready [2] Drive ready [3] Drive ready/remote control [4] Enable / no warning [5] VLT running [6] Running / no warning [7] Run in range/no warning [8] Run on ref/no warning [9] Alarm [10] Alarm or warning [12] Out of current range [13] Below current, low

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

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Parameter Overview [14] Above current, high [16] Below frequency, low [17] Above frequency, high [19] Below feedback, low [20] Above feedback, high [21] Thermal warning [22] Ready, no thermal warning [23] Remote, ready, no thermal warning [24] Ready, Voltage OK [25] Reverse [26] Bus OK [35] External Interlock [36] Control word bit 11 [37] Control word bit 12 [45] Bus Control [60] Comparator 0 [61] Comparator 1 [62] Comparator 2 [63] Comparator 3 [64] Comparator 4 [65] Comparator 5 [70] Logic rule 0 71] Logic rule 1 [72] Logic rule 2 [73] Logic rule 3 [74] Logic rule 4 [75] Logic rule 5 [80] SL digital output A [81] SL digital output B [82] SL digital output C [83] SL digital output D [160] No alarm [161] Running reverse [165] Local ref. active [166] Remote ref. active [167] Start command activ [168] Drive in hand mode [169] Drive in auto mode [193] Sleep Mode [194] Broken Belt Function [196] Fire Mode [198] Drive Bypass [211] Cascade Pump 1 [212] Cascade Pump 2 [213] Cascade Pump 3 [214] Cascade Pump 4 [215] Cascade Pump 55-41 On Delay, Relay

0.00 - 600.00 s, *0.01 s 5-42 Off Delay, Relay

0.00 - 600.00 s, *0.01 s

5-5* Pulse Input 5-9* Bus Controlled

5-90 Digital and Relay Bus Control

0 - 0xFFFFFFFF, * 0

6-** Analog In/Out 6-0* Analog I/O Mode

6-00 Live Zero Timeout Time 1 - 99s, * 10 6-01 Live Zero Timeout Function *[0] Off [1] Freeze output [2] Stop [3] Jogging [4] Max. speed [5] Stop and trip

6-1* Analog Input 53

6-10 Terminal 53 Low Voltage

0.00 - 10.00 V, * 0.07 6-11 Terminal 53 High Voltage

0.00 - 10.00 V, * 10.00 6-12 Terminal 53 Low Current

0.00 - 20.00, * 4.00 mA 6-13 Terminal 53 High Current

0.00 - 20.00, * 20.00 mA 6-14 Terminal 53 Low Ref./Feedb. Value

-4999.000 - 4999.000, * 0.000 6-15 Terminal 53 High Ref./ Feedb. Value

-4999.000 - 4999.000, * 50.000 6-16 Terminal 53 Filter Time Constant

0.01 - 10.00 s, * 0.01 6-19 Terminal 53 mode [0] Current mode *[1] Voltage mode

6-2* Analog Input 54

6-20 Terminal 54 Low Voltage

0.00 - 10.00V, * 0.07 6-21 Terminal 54 High Voltage

0.00 - 10.00V, * 10.00 6-22 Terminal 54 Low Current

0.00 - 20.00, * 4.00mA 6-23 Terminal 54 High Current

0.00 - 20.00, * 20.00mA 6-24 Terminal 54 Low Ref./Feedb. Value

-4999.000 - 4999.000, * 0.000 6-25 Terminal 54 High Ref./ Feedb. Value

-4999.000 - 4999.000, * 50.000 6-26 Terminal 54 Filter Time Constant

0.01 - 10.00, * 0.01 6-29 Terminal 54 mode [0] Current mode [0] Current mode *[1] Voltage mode

6-7* Analog Output 45

6-70 Terminal 45 Mode *[0] 0-20 mA [1] 4-20 mA [2] Digital Output 6-71 Terminal 45 Analog Output *[0] No operation [100] Output frequency [101] Reference [102] Feedback [103] Motor current [106] Power [139] Bus Control 6-72 Terminal 45 Digital Output *[0] No operation [1] Control ready [2] Drive ready [3] Drive ready/remote control [4] Standby / no warning [5] Drive running [6] Running / no warning [7] Run in range/no warning [8] Run on ref/no warning [9] Alarm [10] Alarm or warning [12] Out of current range [13] Below current, low [14] Above current, high [21] Thermal warning [22] Ready, no thermal warning [23] Remote, ready, no thermal warning [24] Ready, Voltage OK [25] Reverse [26] Bus OK [35] External Interlock [45] Bus Control [60] Comparator 0 [61] Comparator 1 [62] Comparator 2 [63] Comparator 3 [64] Comparator 4 [65] Comparator 5 [70] Logic rule 0 [71] Logic rule 1 [72] Logic rule 2 [73] Logic rule 3 [74] Logic rule 4 [75] Logic rule 5 [80] SL digital output A [81] SL digital output B [82] SL digital output C [83] SL digital output D [160] No alarm [161] Running reverse [165] Local ref. active [166] Remote ref. active

[167] Start command activ [168] Drive in hand mode [169] Drive in auto mode [193] Sleep Mode [194] Broken Belt Function [196] Fire Mode [198] Bypass Mode [200] Full capacity [201] Pump 1 running [202] Pump 2 running [203] Pump 3 running [204] Pump 4 running [205] Pump 5 running [211] Cascade Pump 1 [212] Cascade Pump 2 [213] Cascade Pump 3 [214] Cascade Pump 4 [215] Cascade Pump 5 6-73 Terminal 45 Output Min Scale

0.00 - 200.00%, * 0.00 6-74 Terminal 45 Output Max Scale

0.00 - 200.00%, * 100.00 6-76 Terminal 45 Output Bus Control

0.00 - 100.00%, * 0.00

6-9* Analog Output 42

6-90 Terminal 42 Mode *[0] 0-20 mA [1] 4-20 mA [2] Digital Output 6-91 Terminal 42 Analog Output *[0] No operation [100] Output frequency [101] Reference [102] Feedback [103] Motor current [105] TorquereltoRated [106] Power [139] Bus Control 6-92 Terminal 42 Digital Output *[0] No operation [1] Control ready [2] Drive ready [3] Drive ready/remote control [4] Enable / no warning [5] Drive running [6] Running / no warning [7] Run in range/no warning [8] Run on ref/no warning [9] Alarm [10] Alarm or warning [12] Out of current range [13] Below current, low [14] Above current, high [21] Thermal warning

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

24 MG18F202 - VLT® is a registered Danfoss trademark

Parameter Overview [22] Ready, no thermal warning [23] Remote, ready, no thermal warning [24] Ready, Voltage OK [25] Reverse [26] Bus OK [35] External Interlock [45] Bus Control [60] Comparator 0 [61] Comparator 1 [62] Comparator 2 [63] Comparator 3 [64] Comparator 4 [65] Comparator 5 [70] Logic rule 0 [71] Logic rule 1 [72] Logic rule 2 [73] Logic rule 3 [74] Logic rule 4 [75] Logic rule 5 [80] SL digital output A [81] SL digital output B [82] SL digital output C [83] SL digital output D [160] No alarm [161] Running reverse [165] Local ref. active [166] Remote ref. active [167] Start command activ [168] Drive in hand mode [169] Drive in auto mode [193] Sleep Mode [194] Broken Belt Function [196] Fire Mode [198] Drive Bypass [200] Full capacity [201] Pump 1 running [202] Pump 2 running [203] Pump 3 running [204] Pump 4 running [205] Pump 5 running [211] Cascade Pump 1 [212] Cascade Pump 2 [213] Cascade Pump 3 [214] Cascade Pump 4 [215] Cascade Pump 5 6-93 Terminal 42 Output Min Scale

0.00 - 200.00%, * 0.00 6-94 Terminal 42 Output Max Scale

0.00 - 200.00%, * 100.00 6-96 Terminal 42 Output Bus Control

0.00 - 100.00%, * 0.00

8-** Comm. and Options 8-0* Comm. General Settings

8-01 Control Site

*[0] Digital and ctrl.word [1] Digital only [2] Controlword only 8-02 Control Source [0] None *[1] FC Port 8-03 Control Timeout Time

0.1 - 6500.0s, * 1.0 8-04 Control Timeout Function *[0] Off [1] Freeze output [2] Stop [3] Jogging [4] Max. speed [5] Stop and trip [20] N2 Override Release 8-06 Reset Control Word Timeout *[0] No function [1] Do reset 8-3* FC Port Settings 8-30 Protocol *[0] FC [2] Modbus RTU [3] Metasys N2 [4] FLN [5] BACNet 8-31 Address 1 - 247 , * 1 8-32 FC Port Baud Rate [0] 2400 Baud [1] 4800 Baud *[2] 9600 Baud [3] 19200 Baud [4] 38400 Baud [5] 57600 Baud [6] 76800 Baud [7] 115200 Baud 8-33 FC Port Parity *[0] Even Parity, 1 Stop Bit [1] Odd Parity, 1 Stop Bit [2] No Parity, 1 Stop Bit [3] No Parity, 2 Stop Bits 8-35 Minimum Response Delay

0.001 - 0.500s, * 0.010 8-36 Max Response Delay

0.100 - 10.000s, *5.000 8-37 Max Inter-char delay

0.025 - 0.025s, * 0.025

8-5* Digital/Bus

8-50 Coasting Select [0] Digital input [1] Bus [2] Logic AND *[3] Logic OR 8-51 Quick Stop Select [0] Digital input

[1] Bus [2] Logic AND *[3] Logic OR 8-52 DC Brake Select [0] Digital input [1] Bus [2] Logic AND *[3] Logic OR 8-53 Start Select [0] Digital input [1] Bus [2] Logic AND *[3] Logic OR 8-54 Reversing Select [0] Digital input [1] Bus [2] Logic AND *[3] Logic OR 8-55 Set-up Select [0] Digital input [1] Bus [2] Logic AND *[3] Logic OR 8-56 Preset Reference Select [0] Digital input [1] Bus [2] Logic AND *[3] Logic OR

8-7* Bacnet

8-70 BACnet Device Instance 0 - 0x400000UL * 1 8-72 MS/TP Maxmaster 0 - 127, * 127 8-73 MS/TP Max Info Frames 1 - 65534, * 1 8-74 "I am" Service *[0] Send at power-up [1] Continuously 8-75 Intialisation Password

8-8* FC Port Diagnostics

8-80 Bus Message Count 0 - 65536, * 0 8-81 Bus Error Count 0 - 65536, * 0 8-82 Slave Message Rcvd 0 - 65536, * 0 8-83 Slave Error Count 0 - 65536, * 0 8-84 Slave Message Sent 0 - 65536, * 0 8-85 Slave Timeout Errors 0 - 65536, * 0 8-88 Reset FC port Diagnostics *[0] Do not reset [1] Reset counter

8-9* Bus Feedback 8-94 Bus feedback 1

-32768 - 32767, * 0

13-** Smart Logic 13-0* SLC Settings

13-00 SL Controller Mode *[0] Off [1] On 13-01 Start Event [0] False [1] True [2] Running [3] In range [4] On reference [7] Out of current range [8] Below I

low

[9] Above I

high

[16] Thermal warning [17] Mains out of range [18] Reversing [19] Warning [20] Alarm (trip) [21] Alarm (trip lock) [22] Comparator 0 [23] Comparator 1 [24] Comparator 2 [25] Comparator 3 [26] Logic rule 0 [27] Logic rule 1 [28] Logic rule 2 [29] Logic rule 3 [33] Digital input 18 [34] Digital input 19 [35] Digital input 27 [36] Digital input 29 *[39] Start command [40] Drive stopped [41] Reset trip [42] Auto reset trip [43] Key Ok [44] Key Reset [47] Key Up [48] Key Down [50] Comparator 4 [51] Comparator 5 [60] Logic rule 4 [83] Broken belt 13-02 Stop Event See par. 13-02, *[40] Drive stopped 13-03 Reset SLC *[0] Do not reset [1] Reset SLC

13-1* Comparators

13-10 Comparator Operand *[0] Disabled [1] Reference

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

MG18F202 - VLT® is a registered Danfoss trademark 25

1 1

Parameter Overview [2] Feedback [3] Motor speed [4] Motor current [6] Motor power [7] Motor voltage [8] DC-link voltage [12] Analog in 53 [13] Analog in 54 [20] Alarm number [30] Counter A [31] Counter B 13-11 Comparator Operator [0] Less Than *[1] Approx. Equal [2] GreaterThan 13-12 Comparator Value

-9999.0 - 9999.0, * 0.0

13-2* Timers

13-20 SL Controller Timer

0.00 - 3600.00, * 0.00

13-4* Logic Rules

13-40 Logic Rule Boolean 1 See par. 13-01, *[0] False 13-41 Logic Rule Operator 1 *[0] Disabled [1] AND [2] OR [3] AND NOT [4] OR NOT [5] NOT AND [6] NOT OR [7] NOT AND NOT [8] NOT OR NOT 13-42 Logic Rule Boolean 2 See par. 13-01, *[0] False 13-43 Logic Rule Operator 2 See par. 13-41, *[0] Disabled 13-44 Logic Rule Boolean 3 See par. 13-01, *[0] False

13-5* States

13-51 SL Controller Event See par. 13-01, *[0] False 13-52 SL Controller Action *[0] Disabled [1] No action [2] Select set-up 1 [3] Select set-up 2 [10] Select preset ref 0 [11] Select preset ref 1 [12] Select preset ref 2 [13] Select preset ref 3 [14] Select preset ref 4 [15] Select preset ref 5 [16] Select preset ref 6 [17] Select preset ref 7 [18] Select ramp 1

[19] Select ramp 2 [22] Run [23] Run reverse [24] Stop [25] Qstop [26] DC Brake [27] Coast [28] Freeze output [29] Start timer 0 [30] Start timer 1 [31] Start timer 2 [32] Set digital out A low [33] Set digital out B low [34] Set digital out C low [35] Set digital out D low [38] Set digital out A high [39] Set digital out B high [40] Set digital out C high [41] Set digital out D high [60] Reset Counter A [61] Reset Counter B [70] Start timer 3 [71] Start timer 4 [72] Start timer 5 [73] Start timer 6 [74] Start timer 7 [100] Reset Alarm

14-** Special Functions 14-0* Inverter Switching

14-01 Switching Frequency [0] Ran3 [1] Ran5 [2] 2.0 kHz [3] 3.0 kHz [4] 4.0 kHz [5] 5.0 kHz [6] 6.0 kHz [7] 8.0 kHz [8] 10.0 kHz [9] 12.0kHz [10] 16.0kHz 14-03 Overmodulation [0] Off *[1] On 14-08 Damping Gain Factor 0 - 100-%, * 96

14-1* Mains on/off

14-12 Function at Mains Imbalance *[0] Trip [1] Warning [2] Disabled [3] Derate

14-2* Reset Functions

14-20 Reset Mode *[0] Manual reset

[1] Automatic reset x 1 [2] Automatic reset x 2 [3] Automatic reset x 3 [4] Automatic reset x 4 [5] Automatic reset x 5 [6] Automatic reset x 6 [7] Automatic reset x 7 [8] Automatic reset x 8 [9] Automatic reset x 9 [10] Automatic reset x 10 [11] Automatic reset x 15 [12] Automatic reset x 20 [13] Infinite auto reset 14-21 Automatic Restart Time 0 - 600s, * 10 14-22 Operation Mode *[0] Normal operation [2] Initialisation 14-27 Action At Inverter Fault [0] Off *[1] On 14-28 Production Settings *[0] No action [1] Service reset [3] Software Reset 14-29 Service Code 0 - 0x7FFFFFFF, * 0

14-3* Current Limit Ctrl. 14-4* Energy Optimising

14-40 VT Level 40 - 90%, * 90% 14-41 AEO Minimum Magnetisation 40 - 75%, * 66

14-5* Environment

14-50 RFI Filter [0] Off *[1] On 14-51 DC-link Voltage Compensation [0] Off *[1] On 14-52 Fan Control *[0] Auto [4] Auto Low temp env 14-53 Fan Monitor [0] Disabled *[1] Warning [2] Trip 14-55 Output Filter *[0] No Filter [1] Sine-Wave Filter [3] Sine-Wave Filter with Feedback 14-63 Min Switch Frequency 1 - 16kHz, * 1

15-** Drive Information 15-0* Operating Data

15-00 Operating Hours 0 - 2147483647, * 0 15-01 Running Hours 0 - 2147483647, * 0 15-02 kWh Counter 0 - 65535, * 0 15-03 Power Up's 0 - 2147483647, * 0 15-04 Over Temp's 0 - 65535, * 0 15-05 Over Volt's 0 - 65535, * 0 15-06 Reset kWh Counter *[0] Do not reset [1] Reset counter 15-07 Reset Running Hours Counter *[0] Do not reset [1] Reset counter

15-3* Fault Log 15-30 Fault Log:

Error Code 0 - 255, * 0

15-4* Drive Identification

15-40 FC Type 15-41 Power Section 15-42 Voltage 15-43 Software Version 15-44 OrderedTypeCode 15-46 Frequency Converter Ordering No 15-47 Power Card Ordering No 15-48 LCP Id No 15-49 Software ID Control Card 15-50 Software ID Power Card 15-51 Frequency Converter Serial Number 15-53 Power Card Serial Number

16-** Data Readouts 16-0* General Status

16-00 Control Word 0 - 65535, * 0 16-01 Reference [Unit]

-4999.000 - 4999.000, * 0.000 16-02 Reference % -200.0 - 200.0, * 0.0 16-03 Status Word 0 - 65535, * 0 16-05 Main Actual Value [%]

-200.00 - 200.00, * 0.00 16-09 Custom Readout

0.00 - 9999.00, * 0.00

16-1* Motor Status 16-10 Power [kW]

0.000-4.294, 967.500, *0.000

16-11 Power [hp]

0.000 - 2.294, 967.500 *0.000

16-3* Drive Status

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

26 MG18F202 - VLT® is a registered Danfoss trademark

Parameter Overview 16-30 DC Link Voltage 0 - 65535, * 0 16-34 Heatsink Temp. 0 - 255, * 0 16-35 Inverter Thermal 0 - 255%, * 0 16-36 Inv. Nom. Current

0.00 - 655.35, * 0.00 16-37 Inv. Max. Current

0.00 - 655.35 16-38 SL Controller State 0 - 255, * 0

16-5* Ref. and Feedb.

16-50 External Reference

-200.0 - 200.0%, * 0.0 16-52 Feedback

-4999.000 - 4999.000, * 0.000 16-6* Inputs and Outputs 16-60 Digital input 0 - 65535, * 0 16-61 Terminal 53 Setting *[0] Current mode [1] Voltage mode 16-62 Analog Input 53

0.00 - 10.00, * 1.00 16-63 Terminal 54 Setting *[0] Current mode [1] Voltage mode 16-64 Analog Input 54

0.00 - 20.00, * 1.00 16-65 Analog Output 42 [mA]

0.00 - 20.00, * 0.00 16-61 Digital Output

16-72 Counter A

-32768 - 32767, * 0 16-73 Counter B

-32768 - 32767, * 0 16-79 Analog output 45 20 - 20mA, * 0

16-8* Fieldbus / FC Port

16-86 FC Port REF 1

-32768 - 32767, * 0

16-9* Diagnosis Readouts

16-90 Alarm Word 0 - 0xFFFFFFFFUL, * 0 16-91 Alarm Word 2 0 - 0xFFFFFFFFUL, * 0 16-92 Warning Word 0 - 0x7FFFFFFFUL, * 0 16-93 Warning Word 2 0 - 0x7FFFFFFFUL, * 0 16-94 Ext. Status Word 0 - 0x7FFFFFFFUL, * 0 16-95 Ext. Status Word 2 0 - 0x7FFFFFFFUL, * 0 18-**Extended Motor Data 18-1* Firemode Log 18-10 Firemode log: Event 0-255, *0

20-** FC Closed Loop 20-0* Feedback

20-00 Feedback 1 Source *[0] No function [1] Analog in 53 [2] Analog in 54 [100] Bus Feedback 1

20-01 Feedback 1 Conversion *[0] Linear [1] Square root

20-8* PI Basic Setting

20-81 Process PI Normal/ Inverse Control *[0] Normal [1] Inverse 20-83 Process PI Start Speed[Hz]

0.0 - 200.0, * 0.0 20-84 On Reference Bandwidth 0 - 200%, * 5

20-9* PI Controller

20-91 PI Anti Windup [0] Off *[1] On 20-93 PI Proportional Gain

0.00 - 10.00, * 0.01 20-94 PI Integral Time

0.10 - 9999.00s, * 9999.00 20-97 Process PI Feed Forward Factor 0 - 400%, * 0

22-** Appl. functions 22-4* Sleep mode

22-40 Minimum Run Time 0 - 600 s, * 10 22-41 Minimum Sleep Time 0 - 600 s, * 10 22-43 Wake-Up Speed [Hz]

0.0 - 400.0, * 100.0 22-44 Wake-Up Ref./FB difference 0 - 100%, * 10

22-45 Setpoint Boost

-100 - 100%, * 0 22-46 Maximum Boost Time 0 - 600 s, * 60 22-47 Sleep Speed [Hz]

0.0 - 400.0, * 0.0

22-6* Broken Belt Detection

22-60 Broken Belt Detection *[0] Off [1] Warning [2] Trip 22-61 Broken Belt Torque 5 - 100%, * 10 22-62 Broken Belt Delay 0 - 600 s, * 10

24-** Appl. functions 2 24-0* Fire mode

24-00 Fire Mode Function *[0] Disabled [1] Enabled Run Forward [2] Enabled Run Reverse [3] Enable-Coast [4] Enabled - Run Fwd/Rev 24-05 Fire Mode Preset Reference

-100 - 100%, * 0 24-09 Fire Mode Alarm Handling *[1] Trip, Critical Alarms [2] Trip, All Alarms/Test

24-1* Drive Bypass

24-10 Drive Bypass Function *[0] Disabled [2] Enabled (Fire Mode only) 24-11 Bypass Delay Timer 0 - 600 s, * 0

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

MG18F202 - VLT® is a registered Danfoss trademark 27

1 1

1.7 Warnings and Alarms

Fault

number

Alarm/

Warning

Bit

Number Fault text Warning Alarm

Trip

locked Cause of problem

2 16 Live zero error X X

Signal on terminal 53 or 54 is less than 50% of value set in

6-10 Terminal 53 Low Voltage, 6-12 Terminal 53 Low Current, 6-20 Terminal 54 Low Voltage or 6-22 Terminal 54 Low Current. See

also parameter group 6-0*

4 14 Mains ph. loss X X X

Missing phase on supply side or too high voltage imbalance. Check supply voltage. See 14-12 Function at Mains Imbalance

7 11 DC over volt X X Internediate circuit voltage exceeds limit.

8 10 DC under volt X X

Intermediate circuit voltage drops below “voltage warning low” limit.

9 9

Inverter overload X X More than 100% load for too long.

10 8

Motor ETR over X X

Motor is too hot due to more than 100% load for too long. See

1-90 Motor Thermal Protection

11 7 Motor th over X X

Thermistor or thermistor connection is disconnected. See

1-90 Motor Thermal Protection

13 5 Over Current X X X Inverter peak current limit is exceeded. 14 2 Earth Fault X X Discharge from output phases to ground. 16 12 Short Circuit X X Short-circuit in motor or on motor terminals.

17 4 Ctrl.word TO X X

No communication to frequency converter. See parameter group 8-0*

24 50 Fan Fault X X The fan is not working (Only on 400 V 30-90 kW units).

30 19 U phase loss X X

Motor phase U is missing. Check the phase. See 4-58 Missing Motor Phase Function.

31 20 V phase loss X X

Motor phase V is missing. Check the phase. See 4-58 Missing Motor Phase Function.

32 21 W phase loss X X

Motor phase W is missing. Check the phase. See 4-58 Missing Motor Phase Function.

38 17 Internal fault X X Contact your local Danfoss supplier.

40 10

Overload on Terminal 27, Digital Output X Overload on Terminal 27, Digital Output

41 11

Overload on Terminal 29, Digital Output X Overload on Terminal 29, Digital Output

44 28 Earth Fault X X Discharge from output phases to ground.

47 23

Control Voltage Fault X X X 24 V DC may be overloaded.

48 25

VDD1 Supply Low X X Control voltage low. Please contact your local Danfoss supplier

AMA Calibration failed X Contact your local Danfoss supplier.

51 15

AMA Unom,Inom X

The setting of motor voltage, motor current and motor power is presumably wrong. Check the settings.

52 AMA low Inom X The motor current is too low. Check the settings.

AMA big motor X The motor is too big for the AMA to be carried out

AMA small mot X The motor is too small for the AMA to be carried out

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

28 MG18F202 - VLT® is a registered Danfoss trademark

Fault

number

Alarm/

Warning

Bit

Number Fault text Warning Alarm

Trip

locked Cause of problem

AMA par. range X

The parameter values found from the motor are outside acceptable range

AMA user interrupt X The AMA has been interrupted by the user

57 AMA timeout X

Try to start the AMA again a number of times, until the AMA is carried out. Please note that repeated runs may heat the motor to a level where the resistance Rs and Rr are increased. In most cases, however, this is not critical

58 AMA internal X X Contact your local Danfoss supplier. 59 25 Current limit X The current is higher than the value in 4-18 Current Limit

60 44

External Interlock X

External interlock has been activated. To resume normal operation, apply 24 V DC to the terminal programmed for external interlock and reset the frequency converter (via serial communication, digital I/O, or by pressing reset button on keypad).

66 26

Heat sink Temperature Low X

This warning is based on the temperature sensor in the IGBT module (Only on 400 V 30-90 kW units).

69 1

Pwr. Card Temp X X X

The temperature sensor on the power card is either too hot or too cold.

Illegal power section configuration X X Internal fault. Contact your local Danfoss supplier.

80 29

Drive initialised X All parameter settings are initialized to default settings.

87 47

Auto DC Braking X The drive is auto DC braking

95 40 Broken Belt X X

Torque is below the torque level set for no load, indicating a broken belt. See parameter group 22-6*.

200 Fire Mode X Fire mode has been activated

202

Fire Mode Limits Exceeded X Fire Mode has suppressed one or more warranty voiding alarms

250 New sparepart X X

The power or switch mode power supply has been exchanged. (Only on 400 V 30-90 kW units). Contact your local Danfoss supplier

251 New Typecode X X

The frequency converter has a new type code (Only on 400 V 30-90 kW units). Contact your local Danfoss supplier.

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

MG18F202 - VLT® is a registered Danfoss trademark 29

1 1

1.8.1 Mains Supply 3x380-480 V AC

Frequency converter PK37 PK75 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K

Typical shaft output [kW] 0.37 0.75 1.5 2.2 3.0 4.0 5.5 7.5 11.0 15.0 18.5 22.0 30.0 37.0 45.0 55.0 75.0 90.0

Typical shaft output [hp] 0.5 1.0 2.0 3.0 4.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0 40.0 50.0 60.0 70.0 100.0 125.0

IP20 frame H1 H1 H1 H2 H2 H2 H3 H3 H4 H4 H5 H5 H6 H6 H6 H7 H7 H8

Max. cable size in terminals (mains, motor)

[mm

/AWG]

4/10 4/10 4/10 4/10 4/10 4/10 4/10 4/10 16/6 16/6 16/6 16/6 35/2 35/2 35/2 50/1 95/0 120/25

0MCM

Output current

RELAY 2

130BB632.10

40°C ambient temperature

Continuous

(3x380-440 V)

[A]

1.2 2.2 3.7 5.3 7.2 9.0 12.0 15.5 23.0 31.0 37.0 42.5 61.0 73.0 90.0 106.0 147.0 177.0

Intermittent

(3x380-440 V)

[A]

1.3 2.4 4.1 5.8 7.9 9.9 13.2 17.1 25.3 34.0 40.7 46.8 67.1 80.3 99.0 116.0 161.0 194.0

Continuous

(3x440-480 V)

[A]

1.1 2.1 3.4 4.8 6.3 8.2 11.0 14.0 21.0 27.0 34.0 40.0 52.0 65.0 80.0 105.0 130.0 160.0

Intermittent

(3x440-480 V)

[A]

1.2 2.3 3.7 5.3 6.9 9.0 12.1 15.4 23.1 29.7 37.4 44.0 57.2 71.5 88.0 115.0 143.0 176.0

Max. input current

RELAY 2

130BB633.10

Continuous

(3x380-440 V)

[A]

1.2 2.1 3.5 4.7 6.3 8.3 11.2 15.1 22.1 29.9 35.2 41.5 57.0 70.0 84.0 103.0 140.0 166.0

Intermittent

(3x380-440 V)

[A]

1.3 2.3 3.9 5.2 6.9 9.1 12.3 16.6 24.3 32.9 38.7 45.7 62.7 77.0 92.4 113.0 154.0 182.0

Continuous

(3x440-480 V)

[A]

1.0 1.8 2.9 3.9 5.3 6.8 9.4 12.6 18.4 24.7 29.3 34.6 49.2 60.6 72.5 88.6 120.9 142.7

Intermittent

(3x440-480 V)

[A]

1.1 2.0 3.2 4.3 5.8 7.5 10.3 13.9 20.2 27.2 32.2 38.1 54.1 66.7 79.8 97.5 132.9 157.0

Max. mains fuses

See 1.3.6 Fuses

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

30 MG18F202 - VLT® is a registered Danfoss trademark

Frequency converter PK37 PK75 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K

Estimated power loss [W], Best case/typical

13/15 16/21 46/57 46/58 66/83 95/118 104/13

159/19

248/27

353/37

412/45

475/52

780 893 1160 1130 1460 1780

Weight enclosure IP20 [kg] 2.0 2.0 2.1 3.3 3.3 3.4 4.3 4.5 7.9 7.9 9.5 9.5 24.5 24.5 24.5 36.0 36.0 51.0

Efficiency [%], Best case/Typical 1 97.8/97.

98.0/97

97.7/97

98.3/97

98.2/97.

98.0/97.

98.4/98

98.2/9

7.8

98.1/9

7.9

98.0/9

7.8

98.1/9

7.9

98.1/9

7.9

97.8 97.9 97.1 98.3 98.3 98.3

Output current

50°C ambient temperature

Continuous

(3x380-440 V)

[A]

1.04 1.93 3.7 4.85 6.3 8.4 10.9 14.0 20.9 28.0 34.1 38.0 48.8 58.4 72.0 74.2 102.9 123.9

Intermittent

(3x380-440 V)

[A]

1.1 2.1 4.07 5.4 6.9 9.2 12.0 15.4 23.0 30.8 37.5 41.8 53.7 64.2 79.2 81.6 113.2 136.3

Continuous

(3x440-480 V)

[A]

1.0 1.8 3.4 4.4 5.5 7.5 10.0 12.6 19.1 24.0 31.3 35.0 41.6 52.0 64.0 73.5 91.0 112.0

Intermittent

(3x440-480 V)

[A]

1.1 2.0 3.7 4.8 6.1 8.3 11.0 13.9 21.0 26.4 34.4 38.5 45.8 57.2 70.4 80.9 100.1 123.2

Quick Guide

VLT® HVAC Basic Drive Cascade Controller Quick Guide

MG18F202 - VLT® is a registered Danfoss trademark 31

1 1

1.8.2 EMC Test Results

The following test results have been obtained using a system with a frequency converter, a screened control cable, a control box with potentiometer, as well as a motor screened cable.

RFI Filter Type Conduct emission. Maximum shielded cable length Radiated emission

Industrial environment

Housing, trades and

light industries

Industrial

environment

Housing, trades and

light industries

EN 55011 Class A2 EN 55011 Class A1 EN 55011 Class B EN 55011 Class A1 EN 55011 Class B

Without external

filter

With

external

filter

Without external

filter [m]

With

external

filter [m]

Without external

filter [m]

With external filter [m]

Without external

filter

With

external

filter

Without external

filter

With

external

filter H4 RFI filter (Class A1)

0.37-22 kW 3x380-480 V IP20

25 50 20 Yes Yes -

H3 RFI filter (Class A1/B) 30-90 kW 3x380-480 V IP20

50 20 Yes -

Protection and features

•

Electronic thermal motor protection against overload.

•

Temperature monitoring of the heatsink ensures that the frequency converter trips in case of overtemperature.

•

The frequency converter is protected against short-circuits between motor terminals U, V, W.

•

If a motor phase is missing, the frequency converter trips and issues an alarm.

•

If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load).

•

Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high.

•

The frequency converter is protected against earth faults on motor terminals U, V, W.

Mains supply (L1, L2, L3) Supply voltage 380-480 V ±10% Supply frequency 50/60 Hz Max. imbalance temporary between mains phases 3.0% of rated supply voltage True Power Factor (λ) ≥0.9 nominal at rated load Displacement Power Factor (cosφ) near unity (>0.98) Switching on the input supply L1, L2, L3 (power-ups) enclosure frame H1-H5 Max. 2 times/min. Switching on the input supply L1, L2, L3 (power-ups) enclosure frame H6-H8 Max. 1 time/min. Environment according to EN 60664-1 overvoltage category III/pollution degree 2 The unit is suitable for use on a circuit capable of delivering not more than 100.000 RMS symmetrical Amperes, 240/480 V maximum.

Motor output (U, V, W) Output voltage 0-100% of supply voltage Output frequency 0-200 Hz (VVC

plus

), 0-400 Hz (u/f) Switching on output Unlimited Ramp times 0.05-3600 s

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32 MG18F202 - VLT® is a registered Danfoss trademark

Cable lengths and cross sections Max. motor cable length, screened/armoured (EMC correct installation) See 1.8.2 EMC Test Results Max. motor cable length, unscreened/unarmoured 50 m Max. cross section to motor, mains* Cross section DC terminals for filter feedback on enclosure frame H1-H3, I2, I3 4 mm2/11 AWG Cross section DC terminals for filter feedback on enclosure frame H4-H5 16 mm2/6 AWG Maximum cross section to control terminals, rigid wire 2.5 mm2/14 AWG) Maximum cross section to control terminals, flexible cable 2.5 mm2/14 AWG) Minimum cross section to control terminals 0.05 mm2/30 AWG *See 1.8.1 Mains Supply 3x380-480 V AC for more information

Digital inputs: Programmable digital inputs 4 Terminal number 18, 19, 27, 29 Logic PNP or NPN Voltage level 0-24 V DC Voltage level, logic '0' PNP <5 V DC Voltage level, logic '1' PNP >10 V DC Voltage level, logic '0' NPN >19 V DC Voltage level, logic '1' NPN <14 V DC Maximum voltage on input 28 V DC Input resistance, R

Approx. 4 k

Digital input 29 as thermistor input Fault: >2.9 kΩ and no fault: <800 Ω

Digital output Programmable digital outputs 2 Terminal number 27, 29

Voltage level at digital output 0-24 V DC Max. output current (SINK or Source) 40 mA

1) Terminals 27 and 29 can also be programmed as digital inputs.

Analog inputs Number of analog inputs 2 Terminal number 53, 54 Terminal 53 mode Parameter 6-19: 1 = voltage, 0 = current Terminal 54 mode Parameter 6-29: 1 = voltage, 0= current Voltage level 0-10 V Input resistance, R

approx. 10 kΩ Max. voltage 20 V Current level 0/4 to 20 mA (scalable) Input resistance, R

<500 Ω

Max. current 29 mA

Analog output Number of programmable analog outputs 2 Terminal number 42, 45

Current range at analog output 0/4-20 mA Max. load to common at analog output 500 Ω Max. voltage at analog output 17 V Accuracy on analog output Max. error: 0.4 % of full scale Resolution on analog output 10 bit

1) Terminal 42 and 45 can also be programmed as digital outputs.

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Digital output Number of digital outputs 2 Terminal number 42, 45

Voltage level at digital output (output current = 20 mA) 12 V DC Max Voltage level at digital output (output current < 4 mA) 17 V DC Max. output current 20 mA

Terminals 42 and 45 can also be programmed as analog outputs.

Control card, RS-485 serial communication Terminal number 68 (P, TX+, RX+), 69 (N, TX-, RX-) Terminal number 61 Common for terminals 68 and 69

Control card, 24 V DC output Terminal number 12 Max. load enclosure frame H1-H8, I2-I8 80 mA

Relay output Programmable relay output 2 Relay 01 and 02 01-03 (NC), 01-02 (NO), 04-06 (NC), 04-05 (NO) Max. terminal load (AC-1)1) on 01-02/04-05 (NO) (Resistive load) 250 V AC, 3 A Max. terminal load (AC-15)1) on 01-02/04-05 (NO) (Inductive load @ cosφ 0.4) 250 V AC, 0.2 A Max. terminal load (DC-1)1) on 01-02/04-05 (NO) (Resistive load) 30 V DC, 2 A Max. terminal load (DC-13)1) on 01-02/04-05 (NO) (Inductive load) 24 V DC, 0.1 A Max. terminal load (AC-1)1) on 01-03/04-06 (NC) (Resistive load) 250 V AC, 3 A Max. terminal load (AC-15)1) on 01-03/04-06 (NC) (Inductive load @ cosφ 0.4) 250 V AC, 0.2 A Max. terminal load (DC-1)1) on 01-03/04-06 (NC) (Resistive load)

30 V DC, 2 A

Min. terminal load on 01-03 (NC), 01-02 (NO) 24 V DC 10 mA, 24 V AC 20 mA

Environment according to EN 60664-1 Overvoltage category III/pollution degree 2

1) IEC 60947 parts 4 and 5. Control card, 10 V DC output

Terminal number 50 Output voltage 10.5 V ±0.5 V Max. load 25 mA

All inputs, outputs, circuits, DC supplies and relay contacts are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Surroundings Enclosure IP20 Enclosure kit available IP21, TYPE 1 Vibration test 1.0 g Max. relative humidity 5% - 95% (IEC 60721-3-3; Class 3K3 (non-condensing) during operation Aggressive environment (IEC 60721-3-3), coated (standard) frame H1-H5 Class 3C3 Aggressive environment (IEC 60721-3-3), non-coated frame H6-H10 Class 3C2 Aggressive environment (IEC 60721-3-3), coated (optional) frame H6-H10 Class 3C3 Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature See max. output current at 40/50° C in the tables mains supply

Derating for high ambient temperature, see 1.8 Special Conditions

Minimum ambient temperature during full-scale operation 0° C Minimum ambient temperature at reduced performance, enclosure frame H1-H5 -20° C Minimum ambient temperature at reduced performance, enclosure frame H6-H10 -10° C Temperature during storage/transport -30 - +65/70° C Maximum altitude above sea level without derating 1000 m Maximum altitude above sea level with derating 3000 m

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34 MG18F202 - VLT® is a registered Danfoss trademark

Derating for high altitude, see 1.8 Special Conditions Safety standards EN/IEC 61800-5-1, UL 508C EMC standards, Emission EN 61800-3, EN 61000-6-3/4, EN 55011, IEC 61800-3

EMC standards, Immunity

EN 61800-3, EN 61000-3-12, EN 61000-6-1/2, EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN

61000-4-5, EN 61000-4-6

1.9 Special Conditions

1.9.1 Derating for Ambient Temperature

and Switching Frequency

The ambient temperature measured over 24 hours should be at least 5°C lower than the max. ambient temperature. If the frequency converter is operated at high ambient temperature, the continuous output current should be decreased. For derating curve, see Design Guide MG18C3YY.

1.9.2 Derating for Low Air Pressure

The cooling capability of air is decreased at low air pressure. For altitudes above 2000 m, please contact Danfoss regarding PELV. Below 1000 m altitude no derating is necessary, but above 1000 m the ambient temperature or the maximum output current should be decreased. Decrease the output by 1% per 100 m altitude above 1000 m or reduce the max. ambient temperature by 1° per 200 m.

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www.danfoss.com/drives

*MG18F202*

130R0265 MG18F202 Rev. 2011-11-03

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

Specifications and Main Features

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