Danfoss VLT Guía

VLT® Refrigeration Drive Design Guide MG16G102

MAKING MODERN LIVING POSSIBLE

DDesign Guide

VLTpRefrigeration Drive

www.danfoss.com/drives

*MG16G102*

130R0385 MG16G102 Rev. 2012-03-02

Contents

1 How to Read this Design Guide

1.1.2 Approvals & Certificates 5

1.1.3 Legal Information 5

1.1.5 Symbols 5

1.1.6 Abbreviations 6

1.1.7 Definitions 6

2 Introduction

2.1.2 Caution 11

2.2 CE labelling 11

2.3 Air Humidity 12

2.4 Aggressive Environments 12

2.5 Vibration and shock 13

2.6 Safe Stop 13

2.8 Control Structures 20

2.8.1 Control Principle 20

2.9 General Aspects of EMC 25

2.9.1 General Aspects of EMC Emissions 25

2.9.2 Emission Requirements 26

2.9.7 Immunity Requirements 29

2.10 Galvanic isolation (PELV) 31

2.10.1 PELV - Protective Extra Low Voltage 31

2.11 Earth Leakage Current 32

2.12 Extreme Running Conditions 33

3 Drive Selection

3.1 Options and Accessories 36

4 How to Order

4.1 Ordering Form 51

4.1.1 Drive Configurator 51

4.1.2 Type Code String 51

4.2 Ordering Numbers 53

4.2.4 Ordering Numbers: dU/dt Filters 55

5 How to Install

5.1 Mechanical Installation 56

5.1.2 Mechanical Dimensions 57

5.1.5 Lifting 61

5.1.6 Safety Requirements of Mechanical Installation 61

Contents VLT

Refrigeration Drive Design Guide

MG16G102 - VLT

is a registered Danfoss trademark 1

5.2 Electrical Installation 62

5.2.2 Electrical Installation and Control Cables 63

5.2.5 Removal of Knockouts for Extra Cables 65

5.2.7 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 66

5.3 Final Set-Up and Test 71

5.4 Additional Connections 73

5.4.2 External Fan Supply 73

5.5 Installation of Misc. Connections 75

5.6 Safety 77

5.6.1 High Voltage Test 77

5.6.2 Safety Earth Connection 77

5.7 EMC-correct Installation 77

5.7.1 Electrical Installation - EMC Precautions 77

5.7.2 Use of EMC-Correct Cables 79

6 Application Examples

6.1.1 Start/Stop 82

6.1.2 Pulse Start/Stop 82

6.1.3 Potentiometer Reference 83

6.1.4 Automatic Motor Adaptation (AMA) 83

6.1.5 Smart Logic Control 83

6.1.6 Smart Logic Control Programming 83

6.1.7 SLC Application Example 84

7 RS-485 Installation and Set-up

7.1 RS-485 Installation and Set-up 86

7.1.1 Overview 86

7.1.5 EMC Precautions 87

7.2 FC Protocol Overview 87

7.3 FC Protocol Message Framing Structure 88

7.3.1 Content of a Character (byte) 88

7.3.2 Telegram Structure 88

7.3.3 Telegram Length (LGE) 88

7.3.4 Frequency Converter Address (ADR) 88

7.3.5 Data Control Byte (BCC) 88

7.3.6 The Data Field 89

7.3.7 The PKE Field 89

7.3.9 Index (IND) 90

7.3.10 Parameter Value (PWE) 90

7.3.12 Conversion 91

7.3.13 Process Words (PCD) 91

Contents VLT

Refrigeration Drive Design Guide

2 MG16G102 - VLT

is a registered Danfoss trademark

7.4 Examples 91

7.4.1 Writing a Parameter Value 91

7.4.2 Reading a Parameter Value 92

7.5 Modbus RTU Overview 92

7.5.1 Assumptions 92

7.5.2 What the User Should Already Know 92

7.5.3 Modbus RTU Overview 92

7.5.4 Frequency Converter with Modbus RTU 93

7.5.5 Frequency Converter with Modbus RTU 93

7.6 Modbus RTU Message Framing Structure 93

7.6.1 Frequency Converter with Modbus RTU 93

7.6.2 Modbus RTU Message Structure 93

7.6.3 Start/Stop Field 94

7.6.4 Address Field 94

7.6.5 Function Field 94

7.6.6 Data Field 94

7.6.7 CRC Check Field 94

7.6.8 Coil Register Addressing 94

7.6.9 How to Control the Frequency Converter 97

7.6.10 Function Codes Supported by Modbus RTU 97

7.6.11 Modbus Exception Codes 97

7.7 How to Access Parameters 97

7.7.1 Parameter Handling 97

7.7.2 Storage of Data 97

7.7.3 IND 98

7.7.4 Text Blocks 98

7.7.5 Conversion Factor 98

7.7.6 Parameter Values 98

7.8 Examples 98

7.8.2 Force/Write Single Coil (05 HEX) 98

7.8.3 Force/Write Multiple Coils (0F HEX) 99

7.8.4 Read Holding Registers (03 HEX) 99

7.8.5 Preset Single Register (06 HEX) 100

7.8.6 Preset Multiple Registers (10 HEX) 100

7.9 FC Control Profile 101

8 General Specifications and Troubleshooting

105

8.1 General Specifications 105

8.2 Efficiency 117

8.5 Special Conditions 122

8.6 Alarm and Status Messages 123

Contents VLT

Refrigeration Drive Design Guide

MG16G102 - VLT

is a registered Danfoss trademark 3

8.6.1 Alarm Words 127

8.6.2 Warning Words 128

8.6.3 Extended Status Words 129

8.6.4 Warning/Alarm List 130

Index

133

Contents VLT

Refrigeration Drive Design Guide

4 MG16G102 - VLT

is a registered Danfoss trademark

1 How to Read this Design Guide

1.1.1 Software Version and Approvals: VLT

Refrigeration Drive FC 103

VLT

Refrigeration Drive FC 103

Software version: 1.0x

This manual can be used for all VLT

Refrigeration Drive FC 103

frequency converters with software version 1.0x.

The software version number can be seen from 15-43 Software

Version.

Table 1.1

1.1.2 Approvals & Certificates

The latest certificates and approvals are available on the

Internet, see

http://www.danfoss.com/BusinessAreas/DrivesSolutions/

Documentations/DDapprovalscertificate.htm

1.1.3 Legal Information

This publication contains information proprietary to

Danfoss. By accepting and using this manual the user

agrees that the information contained herein is used solely

for operating equipment from Danfoss or equipment from

other vendors if such equipment is intended for communi-

cation with Danfoss equipment over a serial

communication link. This publication is protected under

the Copyright laws of Denmark and most other countries.

Danfoss does not warrant that a software program

produced according to the guidelines provided in this

manual will function properly in every physical, hardware

or software environment.

Although Danfoss has tested and reviewed the documen-

tation within this manual, Danfoss makes no warranty or

representation, neither expressed nor implied, with respect

to this documentation, including its quality, performance,

or fitness for a particular purpose.

In no event shall Danfoss be liable for direct, indirect,

special, incidental, or consequential damages arising out of

the use, or the inability to use information contained in

this manual, even if advised of the possibility of such

damages. In particular, Danfoss is not responsible for any

costs, including but not limited to those incurred as a

result of lost profits or revenue, loss or damage of

equipment, loss of computer programs, loss of data, the

costs to substitute these, or any claims by third parties.

Danfoss reserves the right to revise this publication at any

time and to make changes to its contents without prior

notice or any obligation to notify former or present users

of such revisions or changes.

1.1.4 Available literature for VLT

Refrigeration Drive FC 103

-VLT

Refrigeration Drive Operating Instructions

1.1-90 kW, MG16E provide the necessary

information for getting the frequency converter

up and running.

-VLT

Refrigeration Drive Operating Instructions

110-250 kW, MG16F

-VLT

Refrigeration Drive Design Guide, MG16G

entails all technical information about the

frequency converter and customer design and

applications.

-VLT

Refrigeration Drive Programming Guide,

MG16H provides information on how to

programme and includes complete parameter

descriptions.

Danfoss technical literature is available in print from local

Danfoss Sales Offices or online at:

http://www.danfoss.com/BusinessAreas/DrivesSolutions/

Documentations/Technical+Documentation.htm

1.1.5 Symbols

The following symbols are used in this manual.

WARNING

Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. It may

also be used to alert against unsafe practices.

CAUTION

Indicates a situation that may result in equipment or

property-damage-only accidents.

How to Read this Design Gui... VLT

Refrigeration Drive Design Guide

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NOTE

Indicates highlighted information that should be regarded

with attention to avoid mistakes or operate equipment at

less than optimal performance.

Indicates default setting

Table 1.2

1.1.6 Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Automatic Motor Adaptation AMA

Current limit I

LIM

Degrees Celsius

Direct current DC

Drive Dependent D-TYPE

Electro Magnetic Compatibility EMC

Electronic Thermal Relay ETR

Frequency converter FC

Gram g

Hertz Hz

Horsepower hp

Kilohertz kHz

Local Control Panel LCP

Meter m

Millihenry Inductance mH

Milliampere mA

Millisecond ms

Minute min

Motion Control Tool MCT

Nanofarad nF

Newton Meters Nm

Nominal motor current I

M,N

Nominal motor frequency f

M,N

Nominal motor power P

M,N

Nominal motor voltage U

M,N

Permanent Magnet motor PM motor

Protective Extra Low Voltage PELV

Printed Circuit Board PCB

Rated Inverter Output Current I

INV

Revolutions Per Minute RPM

Regenerative terminals Regen

Second s

Synchronous Motor Speed n

Torque limit T

LIM

Volts V

The maximum output current I

VLT,MAX

The rated output current supplied by the

frequency converter

VLT,N

Table 1.3

1.1.7 Definitions

Drive:

DRIVE,MAX

The maximum output current.

DRIVE,N

The rated output current supplied by the frequency

converter.

DRIVE, MAX

The maximum output voltage.

Input:

Control command

Start and stop the

connected motor with the

LCP or the digital inputs.

Functions are divided into

two groups.

Functions in group 1 have

higher priority than

functions in group 2.

Group

Reset, Coasting stop, Reset

and Coasting stop, Quick-

stop, DC braking, Stop and

the "Off" key.

Group

Start, Pulse start, Reversing,

Start reversing, Jog and

Freeze output

Table 1.4

Motor:

JOG

The motor frequency when the jog function is activated

(via digital terminals).

The motor frequency.

MAX

The maximum motor frequency.

MIN

The minimum motor frequency.

M,N

The rated motor frequency (nameplate data).

The motor current.

M,N

The rated motor current (nameplate data).

M,N

The rated motor speed (nameplate data).

How to Read this Design Gui... VLT

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M,N

The rated motor power (nameplate data).

M,N

The rated torque (motor).

The instantaneous motor voltage.

M,N

The rated motor voltage (nameplate data).

Break-away torque

Illustration 1.1

DRIVE

The efficiency of the frequency converter is defined as the

ratio between the power output and the power input.

Start-disable command

A stop command belonging to the group 1 control

commands - see this group.

Stop command

See Control commands.

References:

Analog Reference

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

voltage or current.

Bus Reference

A signal transmitted to the serial communication port

(drive port).

Preset Reference

A defined preset reference to be set from -100% to +100%

of the reference range. Selection of eight preset references

via the digital terminals.

Pulse Reference

A pulse frequency signal transmitted to the digital inputs

(terminal 29 or 33).

Ref

MAX

Determines the relationship between the reference input

at 100% full scale value (typically 10 V, 20mA) and the

resulting reference. The maximum reference value set in

3-03 Maximum Reference.

Ref

MIN

Determines the relationship between the reference input

at 0% value (typically 0V, 0mA, 4mA) and the resulting

reference. The minimum reference value set in

3-02 Minimum Reference

Miscellaneous:

Analog Inputs

The analog inputs are used for controlling various

functions of the frequency converter.

There are two types of analog inputs:

Current input, 0-20 mA and 4-20 mA

Voltage input, 0-10 V DC.

Analog Outputs

The analog outputs can supply a signal of 0-20 mA, 4-20

mA, or a digital signal.

Automatic Motor Adaptation, AMA

AMA algorithm determines the electrical parameters for

the connected motor at standstill.

CT Characteristics

Constant torque characteristics used for screw and scroll

refrigeration compressors.

Digital Inputs

The digital inputs can be used for controlling various

functions of the frequency converter.

How to Read this Design Gui... VLT

Refrigeration Drive Design Guide

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Digital Outputs

The frequency converter features two Solid State outputs

that can supply a 24 V DC (max. 40 mA) signal.

DSP

Digital Signal Processor.

Relay Outputs:

The frequency converter features two programmable Relay

Outputs.

ETR

Electronic Thermal Relay is a thermal load calculation

based on present load and time. Its purpose is to estimate

the motor temperature.

Initialising

If initialising is carried out (14-22 Operation Mode), the

programmable parameters of the frequency converter

return to their default settings.

Intermittent Duty Cycle

An intermittent duty rating refers to a sequence of duty

cycles. Each cycle consists of an on-load and an off-load

period. The operation can be either periodic duty or none-

periodic duty.

LCP

The Local Control Panel (LCP)keypad makes up a complete

interface for control and programming of the frequency

converter. The control panelkeypad is detachable and can

be installed up to 3 metres from the frequency converter,

i.e. in a front panel by means of the installation kit option.

lsb

Least significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for

cable cross-section. 1 MCM ≡0.5067 mm

msb

Most significant bit.

On-line/Off-line Parameters

Changes to on-line parameters are activated immediately

after the data value is changed. Changes to off-line

parameters are not activated until you enter [OK] on the

LCP.

PID Controller

The PID controller maintains the desired speed, pressure,

temperature, etc. by adjusting the output frequency to

match the varying load.

RCD

Residual Current Device.

Set-up

You can save parameter settings in four Set-ups. Change

between the four parameter Set-ups and edit one Set-up,

while another Set-up is active.

SFAVM

Switching pattern called Stator Flux oriented Asynchronous

V ector M odulation (14-00 Switching Pattern).

Slip Compensation

The frequency converter compensates for the motor slip

by giving the frequency a supplement that follows the

measured motor load keeping the motor speed almost

constant.

Smart Logic Control (SLC)

The SLC is a sequence of user defined actions executed

when the associated user defined events are evaluated as

true by the SLC.

Thermistor:

A temperature-dependent resistor placed where the

temperature is to be monitored (frequency converter or

motor).

Trip

A state entered in fault situations, e.g. if the frequency

converter is subject to an over-temperature or when the

frequency converter is protecting the motor, process or

mechanism. Restart is prevented until the cause of the

fault has disappeared and the trip state is cancelled by

activating reset or, in some cases, by being programmed

to reset automatically. Trip may not be used for personal

safety.

Trip Locked

A state entered in fault situations when the frequency

converter is protecting itself and requiring physical

intervention, e.g. if the frequency converter is subject to a

short circuit on the output. A locked trip can only be

cancelled by cutting off mains, removing the cause of the

How to Read this Design Gui... VLT

Refrigeration Drive Design Guide

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fault, and reconnecting the frequency converter. Restart is

prevented until the trip state is cancelled by activating

reset or, in some cases, by being programmed to reset

automatically. Trip locked may not be used for personal

safety.

VT Characteristics

Variable torque characteristics used for pumps and fans.

VVC

plus

If compared with standard voltage/frequency ratio control,

Voltage Vector Control (VVC

plus

) improves the dynamics

and the stability, both when the speed reference is

changed and in relation to the load torque.

60 °AVM

Switching pattern called 60°Asynchronous Vector

Modulation (See 14-00 Switching Pattern).

1.1.8 Power Factor

The power factor is the relation between I

and I

RMS

Power

factor

3 ×

1 ×

COS

3 ×

IRMS

The power factor for 3-phase control:

1×

cos

ϕ1

IRMS

since

cos

ϕ1=1

The power factor indicates to which extent the frequency

converter imposes a load on the mains supply.

The lower the power factor, the higher the I

RMS

for the

same kW performance.

IRMS

2+ .. +

In addition, a high power factor indicates that the different

harmonic currents are low.

The frequency converters' built-in DC coils produce a high

power factor, which minimizes the imposed load on the

mains supply.

How to Read this Design Gui... VLT

Refrigeration Drive Design Guide

MG16G102 - VLT

is a registered Danfoss trademark 9

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