Danfoss VLT 6000 HVAC Design guide

Design Guide

VLT® 6000 HVAC

Contents

VLT

6000 HVAC Series

Introduction to HVAC

Software version 4 Safety regulations 5 Warning against unintended start 5 Introduction to the Design Guide 7 Available literature 8 Fire mode 11 Star/delta starter or soft-starter not required 15 Control principle 17 CE labelling 18 The new standard 19 The new standard 20 The new standard 21 Choice of frequency converter 25 Unpacking and ordering a VLT frequency converter 28 Type code ordering number string 28 Ordering form 32 PC software and serial communication 33 PC Software tools 33 Fieldbus options 33 Profibus 34 LON - Local Operating Network 34 DeviceNet 34 Modbus RTU 34

Installation

Mains supply (L1, L2, L3) 41 Max. imbalance of supply voltage 41 Technical data, mains supply 3 x 200-240V 46 Technical data, mains supply 3 x 380-460V 47 Technical data, mains supply 3 x 525-600 V 52 Fuses 57 Mechanical dimensions 60 Mechanical installation 64 General information about electrical installation 67 High voltage warning 67 Earthing 67 Cables 67 Screened/armoured cables 68 Extra protection with regard to indirect contact 68 RFI switch 69 High voltage test 72 Heat emission from VLT 6000 HVAC 72 Ventilation of integrated VLT 6000 HVAC 72 EMC correct electrical installation 72 Use of EMC-correct cables 74 Electrical installation - earthing of control cables 75

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Electrical installation, enclosures 76 Tightening-up torque and screw sizes 83 Mains connection 83 Motor connection 83 Direction of motor rotation 84 Motor cables 84 Motor thermal protection 85 Earth connection 85 Installation of 24 Volt external DC supply 85 DC bus connection 85 High-voltage relay 85 Control card 85 Electrical installation, control cables 86 Switches 1-4 87 Bus connection 87 Connection examples, VLT 6000 HVAC 88

6000 HVAC Series

Programming

Control unit LCP 90 Control keysfor parameter setup 90 Indicator lamps 91 Local control 91 Display mode 92 Navigation between display modes 94 Changing data 95 Manual initialisation 95 Quick Menu 96 Operation and Display 001-017 98 The Setup configuration 98 Setup of user-defined readout 99 Load and Motor 100-117 105 Configuration 105 Motor power factor (Cos ø) 111 Reference handling 113 Reference type 116 Inputs and outputs 300-365 121 Analogue inputs 125 Analog/digital outputs 128 Relay outputs 132 Application functions 400-427 135 Sleep mode 136 PID for process control 141 PID overview 143 Feedback handling 143 Serial communication for FC protocol 150 Protocols 150 Telegram communication 150 Telegram build-up under FC protocol 151 Data character (byte) 152

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Process word 156 Control word according to FC protocol 157 Status word as per FC protocol 158 Serial communication reference 159 Present output frequency 160 Serial communication 500 - 556 161 Extended status word, warning word, and alarm word 168 Service functions 600-631 171 Electrical installation of the relay card 176 Description of Real Time Clock 177

6000 HVAC Series

All about VLT 6000 HVAC

Status messages 180 List of warnings and alarms 182 Aggressive environments 189 Calculation of resulting reference 189 Galvanic isolation (PELV) 190 Earth leakage current 190 Extreme running conditions 191 Peak voltage on motor 192 Switching on the input 192 Acoustic noise 193 Derating for ambient temperature 193 Derating for air pressure 194 Derating for running at low speed 194 Derating for long motor cables or cables with larger cross-section 194 Derating for high switching frequency 194 Vibration and shock 195 Air humidity 195 Efficiency 196 Mains supply interference/harmonics 197 Power factor 197 (Emission) 197 EMC Immunity 199 Definitions 201 Parameter overview and factory settings 203

180

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210

VLT

6000 HVAC Series

Software version

VLT 6000 HVAC

Design Guide

Software version: 3.2x

This Design Guide can be used with all VLT 6000 HVAC frequency converters with software version 3.2x. The software version number can be seen from parameter 624.

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

The Protective Extra Low Voltage (PELV) requirements stated in IEC 61800-5-1 are not fulfilled at altitudes above 2000 m (6562 ft.). For 200V frequency converters the requirements are not fulfilled at altitudes above 5000 m (16 404 ft.). Please contact Danfoss Drives for further information.

Safety regulations

1. The frequency converter must be disconnected from mains if repair work is to be carried out. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.

2. The [OFF/STOP] key on the control panel of the frequency converter does the equipment from mains and is thus be used as a safety switch.

3. Correct protective earthing of the equipment must be established, the user must be protected against supply voltage, and the motor must be protected against overload in accordance with applicable national and local regulations.

4. The earth leakage currents are higher than

3.5 mA.

not disconnect

not to

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Warning against unintended start

6000 HVAC Series

Note: The function is initialised at 1.0 x rated motor current and rated motor frequency (see parameter 117, Motor thermal protec- tion).

6. Do

7. Reliable galvanic isolation (PELV) is not

8. Please note that the frequency converter has

1. The motor can be brought to a stop by means

2. While parameters are being changed, the

3. A motor that has been stopped may start if

not remove the plugs for the motor and mains supply while the frequency converter is connected to mains. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.

complied with if the RFI switch is placed in OFF position. This means that all control in and outputs can only be considered low-voltage terminals with basic galvanic isolation.

more voltage inputs than L1, L2 and L3, when the DC-bus terminals are used. Check that connected and that the necessary time has passed before repair work is commenced.

of digital commands, bus commands, references or a local stop, while the frequency converter is connected to mains. If personal safety considerations make it necessary to ensure that no unintended start occurs, cient.

motor may start. Consequently, [OFF/STOP] must always be activated, following which data can be modified.

faults occur in the electronics of the frequency converter, or if a temporary overload or a fault in the supply mains or the motor connection ceases.

all voltage inputs have been dis-

these stop functions are not suffi-

the stop key

Introduction to HVAC

5. Protection against motor overload is included in the factory setting. Parameter 117, Motor thermal protection default value is ETR trip 1.

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6000 HVAC Series

Warning:

Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains. VLT 6002 - 6005, 200-240 V: wait at least 4 minutes VLT 6006 - 6062, 200-240 V : wait at least 15 minutes VLT 6002 - 6005, 380-460 V: wait at least 4 minutes VLT 6006 - 6072, 380-460 V: wait at least 15 minutes VLT 6102 - 6352, 380-460 V: wait at least 20 minutes VLT 6402 - 6602, 380-460 V: wait at least 40 minutes VLT 6002 - 6006, 525-600 V: wait at least 4 minutes VLT 6008 - 6027, 525-600 V: wait at least 15 minutes VLT 6032 - 6072, 525-600 V: wait at least 30 minutes VLT 6102 - 6402, 525-600 V: wait at least 20 minutes VLT 6502 - 6652, 525-600 V: wait at least 30 minutes

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Introduction to the Design Guide

This Design Guide is a tool intended to facilitate the sizing of systems in which VLT 6000 HVAC frequency converters are used. HVAC stands for Heating Ventilation Air-Conditioning.

This Design Guide progresses step-by-step through the different procedures required for selecting, installing and programming a VLT 6000 HVAC.

The Design Guide forms part of the literature concept supplied with VLT 6000 HVAC. However, the Design Guide is the most comprehensive document available. When a VLT 6000 HVAC is supplied, it is accompanied by Operating Instructions and a Quick Setup Guide. See the section Other Literature.

Operating Instructions:

Quick Setup Guide:

Design Guide:

This Design Guide is split in four sections that have information about VLT 6000 HVAC.

Introduction to HVAC:

There are also examples of applications and information is given about Danfoss

The specification section deals with the requirements relating to being allowed to

The section ends with an Ordering Guide that makes it easier for you to specify

Describe how to ensure optimum mechanical and electrical installation, and also deal with commissioning and service. The Operating Instructions furthermore provide a description of the software parameters, thereby ensuring that you can easily fit the VLT 6000 HVAC into your application.

Helps you get your VLT 6000 HVAC installed and commissioned quickly.

Used when designing systems with VLT 6000 HVAC. The Design Guide gives all useful information about the VLT 6000 HVAC and HVAC systems. There is a selection tool for you to choose the right VLT 6000 HVAC with the relevant options and modules. The Design Guide has examples of the most common types of HVAC applications. In addition, the Design Guide has all information relating to Serial Communication.

This section tells you the advantages that can be obtained by using frequency converters in HVAC systems. Furthermore, you can read about the way a frequency converter operates and about the advantages of the VLT 6000 HVAC, such as AEO - Automatic Energy Optimisation, RFI filter and other HVAC-relevant functions.

and CE-labelling.

supply and install frequency converters. This section can be used in contract documents, whereby the total list of requirements relating to frequency converters is determined.

and order a VLT 6000 HVAC.

6000 HVAC Series

Introduction to HVAC

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Introduction to the Design Guide

VLT

6000 HVAC Series

Installation:

This section shows you how to carry out correct mechanical installation of a VLT 6000 HVAC. In addition, the section has a description of how you ensure that the installation of the VLT 6000 HVAC is EMC-correct. Furthermore, the section includes a list of mains and motor connections, as well as a description of control card terminals.

Programming:

This section describes the control unit and the software parameters for the VLT 6000 HVAC. There is also a guide to the Quick Setup menu, which means that you will be able to start using your application very quickly.

All about VLT 6000:

This section has information about status, warning and fault indications from the VLT 6000 HVAC. In addition, the section has technical data, service information, factory settings and information on special conditions.

NB!

This symbol indicates something to be noted by the reader.

This symbol indicates a general warning.

This symbol indicates a high-voltage warning.

Available literature

Below is a list of the literature available for VLT 6000 HVAC. It must be noted that there may be deviations from one country to the next.

Please also refer to our web site http://drives.danfoss.com for information about new literature.

Supplied with the unit:

Operating instructions MG.61.AX.YY Quick Setup MG.60.CX.YY High Power Introduction Guide MI.90.JX.YY

Communication with VLT 6000 HVAC:

Profibus Manual MG.90.DX.YY Metasys N2 Manual MG.60.FX.YY LonWorks Manual MG.60.EX.YY Landis/Staefa Apogee FLN Manual MG.60.GX.YY Modbus RTU Manual MG.10.SX.YY DeviceNet Manual MG.50.HX.YY

Instructions for VLT 6000 HVAC:

LCP Remote Kit IP20 MI.56.AX.51 LCP Remote Kit IP54 MI.56.GX.52 Sine wave-filter MI.56.DX.51 IP20 terminal cover MI.56.CX.51

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Various literature for VLT 6000 HVAC:

Operating Instructions MG.60.AX.YY Design Guide MG.61.BX.YY Data sheet MD.60.AX.YY VLT 6000 HVAC Cascade Controller MG.60.IX.YY X = version number YY = language version

Why use a frequency converter for controlling fans and pumps?

A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further information see the text The Laws of Proportionality.

The clear advantage - energy savings

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

6000 HVAC Series

Introduction to HVAC

The graph is showing fan curves (A, B and C) for

reduced fan volumes.

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When using a frequency converter to reduce fan

capacity to 60% - more than 50% energy savings

may be obtained in typical applications.

VLT

Example of energy savings

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

The laws of proportionality

The figure below describes the dependence of flow, pressure and power consumption on rpm.

Q = Flow P = Power

= Rated flow P1 = Rated power

= Reduced flow P2 = Reduced power

H = Pressure n = Speed regulation

= Rated pressure n1 = Rated speed

= Reduced pressure n2 = Reduced speed

6000 HVAC Series

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

Flow

Pressure

Power

Example with varying flow over 1 year

Energy savings

shaft=Pshaft output

Flow distribution over 1 year

(

)

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6000 HVAC Series

Introduction to HVAC

m3/h

350 5 438 42,5 18.615 42,5 18.615 300 15 1314 38,5 50.589 29,0 38.106 250 20 1752 35,0 61.320 18,5 32.412 200 20 1752 31,5 55.188 11,5 20.148 150 20 1752 28,0 49.056 6,5 11.388 100 20 1752 23,0 40.296 3,5 6.132

Distribution Valve regulation Frequency converter control % Hours Power Consumption Power Consumption

A1 - B

Σ 100 8760 275.064 26.801

kWh A1 - C

Fire mode

over pressure and result in damage to

NB!

Please note the frequency converter is only one component of the HVAC system. Correct function of Fire Mode depends on the correct design and selection of system components. Ventilation systems working in life safety applications have to be approved by the local fire Authorities. Non-

interruption of the frequency converter due to Fire Mode operation may cause

HVAC system and components, including dampers and air ducts. The frequency converter itself may be damaged and it may cause damage or fire. Danfoss A/S accepts no responsibility for errors, malfunctions personal injury or any damage to the frequency converter itself or components herein, HVAC systems and components herein or other property when the frequen-

kWh

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cy converter has been programmed for Fire Mode. In no event shall Danfoss be liable to the end user or any other party for any direct or indirect, special or consequential damage or loss suffered by such party, which has occurred due to the frequency converter being programmed and operated in Fire Mode

The Fire Mode function is made to ensure the VLT 6000 can run without interruption. This means most alarms and warnings will not cause a trip and trip lock is disabled. This is useful in case of fire or other emergencies. Until the motor wires or the frequency converter itself are destroyed every attempt is made to keep running. A warning will flash when these limits have been exceeded. If the warning still flashes after a power cycle please contact your local Danfoss supplier. In the following is a table to show the alarms and when the frequency converter changes state depend-

VLT

6000 HVAC Series

ing on selection in parameter 430. Trip and lock ([0] in parameter 430) are valid in normal operation mode. Fire Mode trip and reset ([1] or [2] in parameter 430) means that a reset is automatically performed without the need of manual resetting. Go to Fire Mode bypass ([3] in parameter 430) is valid in case one of the mentioned alarms causes a trip. After the in parameter 432 selected time delay has passed an output is set. This output is programmed in parameter 319, 321, 323 or

326. If a relay option is fitted it can also be selected in parameter 700, 703, 706 or 709. In parameter 300 and 301 it can be selected if the logic, for the Fire Mode activation, shall be active high or low. Please note parameter 430 must be different to [0] for the Fire Mode to be enabled. To be able to use Fire Mode please also note that input 27 must be “high” and no coast bit present via fieldbus. To ensure that no coast can interrupt Fire Mode via fieldbus please select Digital Input [0] in par. 503. Then coasting via fieldbus disabled.

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No. Description TRIP

[0]

2 Live zero fault

(LIVE ZERO ERROR)

4 Mains imbalance

(MAINS IMBALANCE)

7 Overvoltage

(DC LINK OVERVOLT)

8 Undervoltage

(DC LINK UNDERVOLT)

9 Inverter overloaded

(INVERTER TIME)

10 Motor overloaded

(MOTOR TIME)

11 Motor thermistor(MOTOR

THERMISTOR)

12 Current limit

(CURRENT LIMIT)

13 Overcurrent

(OVERCURRENT)

14 Earth fault

(EARTH FAULT)

15 Switch mode fault

(SWITCH MODE FAULT)

16 Short-circuit

(CURR.SHORT CIRCUIT)

17 Serial communication timeout

(STD BUSTIMEOUT)

18 HPFB bus timeout

(HPFB TIMEOUT)

22 Auto-optimation fault

(AMA FAULT)

29 Heat-sink temperature too high

(HEAT SINK OVERTEMP.)

30 Motor phase U missing

(MISSING MOT.PHASE U)

31 Motor phase V missing

(MISSING MOT.PHASE V)

32 Motor phase W missing

(MISSING MOT.PHASE W)

34 HPFB communication fault

(HPFB TIMEOUT)

37 Inverter fault (GATE DRIVE

FAULT)

60 Safety stop

(EXTERNAL FAULT)

63 Output current low

(I MOTOR < I LOW)

80 Fire mode was active

(FIRE MODE WAS ACTIVE)

99 Unknown fault

(UNKNOWN FAULT)

x x x

x x x x

x x x

x x x x

x x

LOCK

[0]

FIRE MODE Trip & reset

[1], [2]

Go to FIRE MODE BYPASS [3]

Introduction to HVAC

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6000 HVAC Series

Better control

If a frequency converter is used for controlling the flow or pressure of a system, improved control is obtained. A frequency converter can vary the speed of the fan or pump, thereby obtaining variable control of flow and pressure. Furthermore, a frequency converter can quickly adapt the speed of the fan or pump to new flow or pressure conditions in the system. Simple control of process (Flow, Level or Pressure) utilizing the built in PID control.

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6000 HVAC Series

Simpler installation when using a frequency converter

A frequency converter can replace a traditional control system, in which mechanical dampers and valves are used for controlling flow or pressure. The great advantage involved in using a frequency converter is that the system becomes simpler, since a lot of the mechanical and electrical equipment is no longer required.

V-belts no longer required

In mechanical control systems, where the fan is driven by V-belts, it is necessary to change belt pulleys in order to adjust the fan speed to match the necessary maximum load. Using a frequency converter, the Vbelts can be replaced by directly driven motors, whose speed is changed simply by means of the frequency converter. The efficiency of the system improves and the entire installation takes up less space. There is no dust from the V-belt and less maintenance.

Regulating dampers and valves no longer required

Since the flow or pressure can be controlled by means of the frequency converter, no regulating dampers and valves are required in the system.

Cos φ compensation

Introduction to HVAC

Generally speaking, a frequency converter with a cos φ of 1 provides power factor correction for the cos φ of the motor, which means that there is no need to make allowance for the cos φ of the motor when sizing the power factor correction unit.

Star/delta starter or soft-starter not required

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

As illustrated in the figure below, a frequency converter does not consume more than rated current.

1 = VLT 6000 HVAC 2 = Star/delta starter 3 = Soft-starter 4 = Start directly on mains

Using a frequency converter saves money

The example on the following page shows that a lot of equipment is not required when a frequency converter is used. It is possible to calculate the cost of installing the two different systems. In the example on the following

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6000 HVAC Series

page, the two systems can be established at roughly the same price.

Without a frequency converter

The figure shows a fan system made in the traditional way. D.D.C. = Direct Digital Control E.M.S. = Energy Management system

V.A.V. = Variable Air Volume

Sensor P = Pressure Sensor T = Temperature

With a frequency converter

The figure shows a fan system controlled by VLT 6000 HVAC frequency converters.

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Control principle

A frequency converter rectifies AC voltage from mains into DC voltage, after which this DC voltage is converted into a AC current with a variable amplitude and frequency.

1. Mains voltage 3 x 200 - 240 V AC, 50 / 60 Hz. 3 x 380 - 460 V AC, 50 / 60 Hz. 3 x 525 - 600 V AC, 50 / 60 Hz.

2. Rectifier A three-phase rectifier bridge that rectifies AC current into DC current.

3. Intermediate circuit DC voltage = 1.35 x mains voltage [V].

4. Intermediate circuit coils Even out the intermediate circuit voltage and reduce the harmonic current feedback to the mains supply.

The motor is thus supplied with variable voltage and frequency, which enables infinitely variable speed control of three-phased, standard AC motors.

Introduction to HVAC

5. Intermediate circuit capacitors Even out the intermediate circuit voltage.

6. Inverter Converts DC voltage into variable AC voltage with a variable frequency.

7. Motor voltage Variable AC voltage, 0-100% of mains supply voltage.

8. Control card This is where to find the computer that controls the inverter which generates the pulse pattern by which the DC voltage is converted into variable AC voltage with a variable frequency.

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6000 HVAC Series

CE labelling

What is CE labelling?

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

The machinery directive (98/37/EEC)

All machines with critical moving parts are covered by the machinery directive, which came into force on 1 January 1995. Since a frequency converter is largely electrical, it does not fall under the machinery directive. However, if a frequency converter is supplied for use in a machine, we provide information on safety aspects relating to the frequency converter. We do this by means of a manufacturer's declaration.

The low-voltage directive (73/23/EEC)

Frequency converters must be CE labelled in accordance with the low-voltage directive, which came into force on 1 January 1997. The directive applies to all electrical equipment and appliances used in the 50 1000 Volt AC and the 75 - 1500 Volt DC voltage ranges. Danfoss CE labels in accordance with the directive and issues a declaration of conformity upon request.

The EMC directive (89/336/EEC)

EMC is short for electromagnetic compatibility. The presence of electromagnetic compatibility means that the mutual interference between different components/appliances is so small that the functioning of the appliances is not affected. The EMC directive came into force on 1 January 1996. Danfoss CE labels in accordance with the directive and issues a declaration of conformity upon request. In order that EMC-correct installation can be carried out, this manual gives detailed instructions for installation. In addition, we specify the standards which our different products comply with. We offer the filters that can be seen from the specifications and provide other types of assistance to ensure the optimum EMC result.

In the great majority of cases, the frequency converter is used by professionals of the trade as a complex component forming part of a larger appliance, system or installation. It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer.

NOTE: VLT 6001-6072, 525-600 V are not CE labelled.

Application examples

The next few pages give typical examples of applications within HVAC. If you would like to receive further information about a given application, please ask your Danfoss supplier for an information sheet that gives a full description of the application.

Variable Air Volume

3 x 200/208/220/230/240 V ±10%

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

Constant Air Volume

3 x 200/208/220/230/240 V ±10%

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

Cooling Tower Fan

3 x 200/208/220/230/240 V ±10%

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

Condenser pumps

3 x 200/208/220/230/240 V ±10%

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

Primary pumps

3 x 200/208/220/230/240 V ±10%

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

Secondary pumps

3 x 200/208/220/230/240 V ±10%

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

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Variable Air Volume

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

The new standard

While dampers and IGVs work to maintain a constant pressure in the ductwork, a frequency converter solution saves much more energy and reduces the complexity of the installation. Instead of creating an artificial pressure drop or causing a decrease in fan efficiency, the frequency converter decreases the speed of the fan to provide the flow and pressure required by the system. Centrifugal devices such as fans behave according to the centrifugal laws. This means the fans decrease the

Cooling coil

Heating coil

Filter

pressure and flow they produce as their speed is reduced. Their power consumption is thereby significantly reduced. The return fan is frequently controlled to maintain a fixed difference in airflow between the supply and return. The advanced PID controller of the VLT 6000 HVAC can be used to eliminate the need for additional controllers.

Pressure signal

VAV boxes

Supply fan

Pressure transmitter

Flow

Introduction to HVAC

Return fan

Flow

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6000 HVAC Series

Constant Air Volume

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

The new standard

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

With temperature control, especially used in air conditioning systems, as the outside temperature varies as well as the number of people in the controlled zone changes, different cooling requirements exist. As the temperature decreases below the set-point, the supply fan can decrease its speed. The return fan modulates to maintain a static pressure set-point. By decreasing the air flow, energy used to heat or cool the fresh air is also reduced, adding further savings. Several features of Danfoss HVAC dedicated frequency converter, the VLT 6000 HVAC can be utilized to improve the performance of your CAV system. One concern of controlling a ventilation system is poor air quality. The programmable minimum frequency can be set to maintain a minimum amount of supply air regardless of the feedback or reference signal. The frequency converter also includes a two zone, 2 setpoint PID controller which allows monitoring both temperature and air quality. Even if the temperature requirement is satisfied, the drive will maintain enough supply air to satisfy the air quality sensor. The controller is capable of monitoring and comparing two feedback signals to control the return fan by maintaining a fixed differential air flow between the supply and return ducts as well.

Cooling coil

Heating coil

Temperature signal

Filter

Supply fan

Temperature transmitter

Pressure signal

Return fan

Pressure transmitter

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6000 HVAC Series

Cooling Tower Fan

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

The new standard

With a frequency converter, the cooling towers fans can be controlled to the required speed to maintain the condenser water temperature.T frequency converters can also be used to turn the fan on and off as needed.

Several features of Danfoss HVAC dedicated drive, the VLT 6000 HVAC can be utilized to improve the performance of your cooling tower fans application. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes small. Also, when utilizing a gear-box to frequency converter the tower fan, a minimum speed of 40-50% may be required.

Water Inlet

The customer programmable minimum frequency setting of the is available to maintain this minimum frequency even as the feedback or speed reference calls for lower speeds.

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

Introduction to HVAC

BASIN

Water Outlet

Temperature Sensor

Conderser Water pump

CHILLER

Supply

MG.61.B6.02 - VLT

is a registered Danfoss trademark 21

VLT

6000 HVAC Series

Condenser pumps

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

The VLT solution

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

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

22 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Primary pumps

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

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

The VLT solution

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

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

Introduction to HVAC

The other method is local speed determination. The operator simply decreases the output frequency until the design flow rate is achieved. Using a frequency converter to decrease the pump speed is very similar to trimming the pump impeller, except it doesn’t require any labor and the pump efficiency remains higher. The balancing contractor simply decreases the speed of the pump until the proper flow rate is achieved and leaves the speed fixed. The pump will operate at this speed any time the chiller is staged on. Because the primary loop doesn’t have control valves or other devices that can cause the system curve to change and the variance due to staging pumps and chillers on and off is usually small, this fixed speed will remain appropriate. In the event the flow rate needs to be increased later in the systems life, the frequency converter can simply increase the pump speed instead of requiring a new pump impeller.

Flowmeter

CHILLER

Flowmeter

CHILLER

MG.61.B6.02 - VLT

is a registered Danfoss trademark 23

VLT

6000 HVAC Series

Secondary pumps

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

The VLT solution

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

NB!

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

24 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Choice of frequency converter

The frequency converter should be chosen on the basis of the given motor current at maximum load on the system. The rated output current I

must be equal

VLT,N

Choose mains voltage for 50/60 Hz:

- 200-240 V three-phase AC voltage

- 380-460 V three-phase AC voltage

- 525-600 V three-phase AC voltage

to or higher than the required motor current.

VLT 6000 HVAC is available for three mains voltage ranges: 200-240 V, 380-460 V, and 525-600 V.

Mains voltage 200 - 240 V

Typical shaft output

VLT type [kW] [HP] [A] [kVA] 6002 6003 1.5 2.0 7.5 3.1 6004 2.2 3.0 10.6 4.4 6005 3.0 4.0 12.5 5.2 6006 4.0 5.0 16.7 6.9 6008 5.5 7.5 24.2 10.1 6011 7.5 10 30.8 12.8 6016 11 15 46.2 19.1 6022 15 20 59.4 24.7 6027 18.5 25 74.8 31.1 6032 22 30 88.0 36.6 6042 30 40 115/104* 43.2 6052 37 50 143/130* 54.0 6062 45 60 170/154* 64.0

*The first figure is for a motor voltage of 200-230 V. The next figure is for a motor voltage of 231-240 V.

VLT,N

1.1 1.5 6.6 2.7

Max continuous output current Max continuous output power

VLT,N

at 240 V S

VLT,N

Introduction to HVAC

Mains voltage 380 - 415 V

VLT type [kW] [A] [kVA] 6002 6003 1.5 4.1 2.9 6004 2.2 5.6 4.0 6005 3.0 7.2 5.2 6006 4.0 10.0 7.2 6008 5.5 13.0 9.3 6011 7.5 16.0 11.5 6016 11 24.0 17.3 6022 15 32.0 23.0 6027 18.5 37.5 27.0 6032 22 44.0 31.6 6042 30 61.0 43.8 6052 37 73.0 52.5 6062 45 90.0 64.7 6072 55 106 73.4 6102 75 147 102 6122 90 177 123 6152 110 212 147 6172 132 260 180 6222 160 315 218 6272 200 395 274 6352 250 480 333 6402 315 600 416 6502 355 658 456 6552 400 745 516 6602 450 800 554

Typical shaft output Max continuous output current Max continuous output power

VLT.N

1.1 3.0 2.2

VLT.N

at 400 V S

VLT.N

MG.61.B6.02 - VLT

is a registered Danfoss trademark 25

VLT

6000 HVAC Series

Mains voltage 440-460 V

Typical shaft output Max continuous output current Max continuous output power

VLT.N

at 460 V S

VLT type [HP] [ A] [kVA] 6002

1.5 3.0 2.4 6003 2.0 3.4 2.7 6004 3.0 4.8 3.8 6005 - 6.3 5.0 6006 5.0 8.2 6.5 6008 7.5 11.0 8.8 6011 10 14.0 11.2 6016 15 21.0 16.7 6022 20 27.0 21.5 6027 25 34.0 27.1 6032 30 40.0 31.9 6042 40 52.0 41.4 6052 50 65.0 51.8 6062 60 77.0 61.3 6072 75 106 84.5 6102 100 130 104 6122 125 160 127 6152 150 190 151 6172 200 240 191 6222 250 302 241 6272 300 361 288 6352 350 443 353 6402 450 540 430 6502 500 590 470 6552 600 678 540 6602 600 730 582

VLT.N

Mains voltage 525 V

Typical shaft output Max. constant output current, 525 V Max. constant output power

VLT.N

at 525 V S

VLT type [kW] [ A] [kVA] 6002

1.1 2.6 2.3 6003 1.5 2.9 2.5 6004 2.2 4.1 3.6 6005 3.0 5.2 4.5 6006 4.0 6.4 5.5 6008 5.5 9.5 8.2 6011 7.5 11.5 10.0 6016 11 18 15.6 6022 15 23 20 6027 18.5 28 24 6032 22 34 29 6042 30 43 37 6052 37 54 47 6062 45 65 56 6072 55 81 70 6102 75 113 98 6122 90 137 119 6152 110 162 140 6172 132 201 174 6222 160 253 219 6272 200 303 262 6352 250 360 312 6402 315 418 362 6502 400 523 498 6602 450 596 568 6652 500 630 600

VLT.N

26 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

Mains voltage 575 - 600 V

VLT type [kW] [ A] [kVA] 6002 6003 1.5 2.7 2.7 6004 2.2 3.9 3.9 6005 3.0 4.9 4.9 6006 4.0 6.1 6.1 6008 5.5 9 9.0 6011 7.5 11 11.0 6016 11 17 16.9 6022 15 22 22 6027 18.5 27 27 6032 22 32 32 6042 30 41 41 6052 37 52 52 6062 45 62 62 6072 55 77 77 6102 75 108 108 6122 90 131 130 6152 110 155 154 6172 132 192 289 6222 160 242 241 6272 200 290 288 6352 250 344 343 6402 315 400 398 6502 400 500 498 6602 450 570 568 6652 500 630 627

Typical shaft output Max. constant output current, 575 V Max. constant output kVA,

VLT.N

1.1 2.4 2.4

VLT.N

6000 HVAC Series

575

VLT.N

Introduction to HVAC

MG.61.B6.02 - VLT

is a registered Danfoss trademark 27

VLT

6000 HVAC Series

Unpacking and ordering a VLT frequency converter

If you are in doubt as to which frequency converter you have received and which options it contains, use the following to find out.

Type code ordering number string

On the basis of your order, the frequency converter is given an ordering number that can be seen from the nameplate on the unit. The number may look as follows:

VLT-6008-H-T4-B20-R3-DL-F10-A00-C0

This means that the frequency converter ordered is a VLT 6008 for three-phase mains voltage of 380-460 V (T4) in Bookstyle enclosure IP 20 (B20). The hardware variant is with integral RFI filter, classes A & B (R3). The frequency converter features a control unit (DL) with a PROFIBUS option card (F10). No option card (A00) and no conformal coating (C0) Character no. 8 ( H) indicates the application range of the unit: H = HVAC.

IP 00: This enclosure is only available for the larger power sizes of the VLT 6000 HVAC series. It is recommended for installation in standard cabinets. IP 20 Bookstyle: This enclosure is designed for cabinet installation. It takes up a minimum of space and can be fitted side-by-side without installation of extra cooling equipment. IP 20/NEMA 1: This enclosure is used as standard enclosure for VLT 6000 HVAC. It is ideal for cabinet installation in areas where a high degree of protection is required. This enclose also permits side-by-side installation. IP 54: This enclosure can be fitted direct to the wall. Cabinets are not required. IP 54 units can also be installed side-by-side.

Hardware variant The units in the programme are available in the following hardware variants: ST: Standard unit with or without control unit. With-

out DC terminals, except for VLT 6042-6062, 200-240 V

VLT 6016-6072, 525-600 V SL: Standard unit with DC terminals. EX: Extended unit with control unit, DC terminals,

connection of external 24 V DC supply for back-

up of control PCB. DX: Extended unit with control unit, DC terminals,

built-in mains fuses and disconnector, connec-

tion of external 24 V DC supply for back-up of

control PCB. PF: Standard unit with 24 V DC supply for back-up

of control PCB and built-in main fuses. No DC

terminals. PS: Standard unit with 24 V DC supply for back-up

of control PCB. No DC terminals. PD: Standard unit with 24 V DC supply for back-up

of control PCB, built-in main fuses and discon-

nect. No DC terminals.

RFI filter Bookstyle units always come with an integral RFI filter that complies with EN 55011-B with 20 m screened/armoured motor cable and EN 55011-A1 with 150 m screened/armoured motor cable. Units for mains voltage of 240 V and a motor power of up to and including 3.0 kW (VLT 6005) and units for a mains voltage of 380-460 V and a motor power of up to 7.5 kW (VLT 6011) are always supplied with an integral class A1 & B filter. Units for higher motor power than these (3.0 and 7.5 kW, respectively) can be ordered either with or without an RFI filter.

Control unit (keypad and display) All types of units in the programme, except for IP21 VLT 6402-6602, 380-460 V, VLT 6502-6652, 525-600 V and IP 54 units, can be ordered either with or without the control unit. IP 54 units always come with a control unit. All types of units in the programme are available with built-in application options including a relay card with four relays or a cascade controller card.

Conformal Coating All types of units in the programme are available with or without conformal coating of the PCB. VLT 6402-6602, 380-460 V and VLT 6102-6652, 525-600 V are only available coated.

28 MG.61.B6.02 - VLT

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VLT

6000 HVAC Series

200-240 V

Typecode

Position in string

1.1 kW/1.5 HP 6002 X X X X X

1.5 kW/2.0 HP 6003 X X X X X

2.2 kW/3.0 HP 6004 X X X X X

3.0 kW/4.0 HP 6005 X X X X X

4.0 kW/5.0 HP 6006 X X X X X X

5.5 kW/7.5 HP 6008 X X X X X X

7.5 kW/10 HP 6011 X X X X X X 11 kW/15 HP 6016 X X X X X X 15 kW/20 HP 6022 X X X X X X

18.5 kW/25 HP 6027 X X X X X X 22 kW/30 HP 6032 X X X X X X 30 kW/40 HP 6042 X X X X X X 37 kW/50 HP 6052 X X X X X X 45 kW/60 HP 6062 X XXX XX

9-10

C00

11-13

B20

11-13

C20

11-13

CN1

11-13

C54

11-13ST14-15SL14-15R016-17R116-17R316-17

380-460 V

Typecode

Position in string

9-10

1.1 kW/1.5 HP 6002 X X X X X

1.5 kW/2.0 HP 6003 X X X X X

2.2 kW/3.0 HP 6004 X X X X X

3.0 kW/4.0 HP 6005 X X X X X

4.0 kW/5.0 HP 6006 X X X X X

5.5 kW/7.5 HP 6008 X X X X X

7.5 kW/10 HP 6011 X X X X X 11 kW/15 HP 6016 X X X X X X 15 kW/20 HP 6022 X X X X X X

18.5 kW/25 HP 6027 X X X X X X 22 kW/30 HP 6032 X X X X X X 30 kW/40 HP 6042 X X X X X X 37 kW/50 HP 6052 X X X X X X 45 kW/60 HP 6062 X X X X X X 55 kW/75 HP 6072 X X X X X X 75 kW/100 HP 6102 X X X X X X 90 kW/125 HP 6122 X X X X X X 110 kW/150 HP 6152 X X X X X X X X X X X 132 kW/200 HP 6172 X X X X X X X X X X X 160 kW/250 HP 6222 X X X X X X X X X X X 200 kW/300 HP 6272 X X X X X X X X X X X 250 kW/350 HP 6352 X X X X X X X X X X X 315 kW/450 HP 6402 X X X X X X X X X X X 355 kW/500 HP 6502 X X X X X X X X X X X 400 kW/550 HP 6552 X X X X X X X X X X X 450 kW/600 HP 6602 X XXX XXXXXXX

C00

11-13

B20

11-1

C20

11-1

CN1

11-1

C54

11-13

14-1

14-15

14-1

14-15

14-1

16-1

16-17

16-1

Introduction to HVAC

Voltage

T2: 200-240 VAC T4: 380-460 VAC

Enclosure

C00: Compact IP 00 B20: Bookstyle IP 20

NB!

NEMA 1 exceeds IP 20

MG.61.B6.02 - VLT

C20: Compact IP 20 CN1: Compact NEMA 1 C54: Compact IP 54

Hardware variant

ST: Standard SL: Standard with DC terminals EX: Extended with 24 V supply and DC terminals DX: Extended with 24 V supply, DC terminals, disconnect and fuse

is a registered Danfoss trademark 29

PS: Standard with 24 V supply PD: Standard with 24 V supply, fuse and disconnect PF: Standard with 24 V supply and fuse

RFI filter

R0: Without filter R1: Class A1 filter R3: Class A1 and B filter

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