Johnson Controls VFD66 Series Manual

Product/Technical Bulletin VFD66

Issue Date January 5, 2010

VFD66 Series Condenser Fan Speed Controls

The VFD66 Series Condenser Fan Speed Controls

regulate the speed of three-phase condenser fan

motors in refrigeration and Heating, Ventilating, and

Air Conditioning (HVAC) systems by varying the

frequency and voltage of the power supplied to the

motor.

The VFD66 control accepts an input signal from the

P35 Pressure Transducer, P499 Electronic Pressure

Transducer, System 350

™

controls, or any other

device that provides a 0-5 VDC or 0-10 VDC analog

output signal.

The application-specific design of the VFD66 control

provides a simple interface, which makes the control

easy to understand and operate.

Figure 1: VFD66 Condenser Fan Speed Control

with NEMA 1 Enclosure

Features and Benefits

Isolated Input Circuitry Permits application with 0-5 VDC or 0-10 VDC

controllers, sensors, transducers, and

Johnson Controls System 350 controls

Simultaneous Acceptance

of Two Similar Inputs Allows use on dual refrigeration circuits

cooled by a single fan

Compact Design Provides installation ease and flexibility

Three-Phase, 208/230, or

400/460 VAC Models Handle three-phase motors ranging up to

10.6 amperes at 208/230 VAC or 5.5 amperes

at 400/460 VAC

Few End-User Settings Provide fast and easy installation and setup

Code No. LIT-125467 www.johnsoncontrols.com

Part No. 24-7664-1555, Rev. F

Application

IMPORTANT: The VFD66 Series Condenser Fan

Speed Controls are intended to control equipment

under normal operating conditions. Where failure or

malfunction of a VFD66 control could lead to an

abnormal operating condition that could cause

personal injury or damage to the equipment or other

property, other devices (limit or safety controls), or

systems (alarm or supervisory) intended to warn of

or protect against failure or malfunction of the

VFD66 control must be incorporated into and

maintained as part of the control system.

The VFD66 control accepts input signals from a variety

of pressure transducers, temperature sensors, and

low-voltage controllers to provide continuous response

to changing condenser load conditions.

The VFD66 control allows the system to:

maintain optimum condenser head pressure in low

ambient temperature conditions

eliminate short-cycling in low ambient temperatures or

changing load conditions

match the condenser fan speed to the load on the

condenser, which increases the efficiency of the

refrigeration system. This can reduce electricity cost

and help maintain a constant evaporator temperature.

Terminal

Access

Cover

Terminal

Cover

Screw

Heat

Sink

7-1/2

(190)

(177)

3 conduit openings

7/8-in. (22 mm) actual size

1/2-in. trade size 1/4-in. (6 mm)

mounting screws,

4 places

6-1/4

(159)

4-3/4

(120)

4-5/8

(117)

7-1/4

(184)

Diagnostic

Light-Emitting

Diodes (LEDs)

Figure 2: VFD66 NEMA 1 Enclosure Dimensions

The VFD66 control can also:

stabilize the condenser head pressures, which helps

optimize compressor operation and can reduce wear

and extend compressor life

eliminate the condenser fan short-cycling, which can

reduce motor repair and replacement costs

stabilize evaporator temperatures, which can extend

refrigerated product life and provide more consistent

comfort cooling

Mounting

CAUTION: Risk of Property Damage.

The VFD66 control can generate and dissipate

significant heat. Mount the control on a metal,

concrete, or cinderblock mounting surface. Mounting

the VFD66 control on surfaces made of wood or

other heat-sensitive material may result in damage

to the mounting surface.

Observe the following the guidelines when mounting a

VFD66 control:

Mount the VFD66 control on a vertical surface with the

heat sink fins oriented vertically and the conduit holes

facing down.

Provide a minimum of 4 in. (102 mm) clearance

around the heat sink.

Ensure that output power wiring between the VFD66

control and the motor does not exceed 50 ft (15 m).

Mount the VFD66 control indoors, in a location

protected from explosive vapors, corrosive gas, water,

and dust.

Ambient air temperature and installation altitude affect

the maximum output rating of the VFD66 controls (see

De-Rating the VFD66 Control for

High Temperatures and High Altitudes).

2 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin

Wiring Read this entire section, including the information on

emissions compliance, before wiring the

VFD66 control. Follow these guidelines when wiring

the VFD66 control:

WARNING: Risk of Electric Shock.

Disconnect the power supply before making

electrical connections. The printed circuit board and

its components are at AC line voltage. Contact with

components carrying hazardous voltage can cause

electric shock and may result in personal injury or

death.

•Use copper conductors only.

•Size field wiring based on 75°C.

Accessing the Interior

Remove the terminal access cover (Figure 2) to

access terminal blocks, jumper blocks, and internal

potentiometers (Figure 3).

WARNING: Risk of Electric Shock.

To avoid possible electric shock, wait at least 5

minutes after AC supply power has been

disconnected from the VFD66 control before

servicing the device. The VFD66 Condenser Fan

Speed Control remains electrically charged for a

period of time after power is removed. Failure to wait

until the VFD66 control fully discharges could cause

electric shock, personal injury, or death.

NEMA 1 Enclosure

Follow these steps to remove the terminal cover:

1. Remove the terminal cover screw and push

downward on the ventilation holes.

2. Pull outward on the top of the terminal access

cover.

J7 J8

TB3

1 2 34

TB1

L3 L2 L1

TB2

T1 T2 T3

J5 J6 J2 J3 J4J9

Circuit

Board

(cropped

view)

Conduit

Entry

Bracket

Potentiometers

Jumper

Blocks

for

Adjusting

VFD66

Control

Jumper Blocks for

Input Device Selection

Ground

Connection Terminals

Route wiring from input devices

through this conduit entry hole.

Input

Device

Power

Input

Output

Fan

Motor

CAUTION: Risk of Property Damage.

Do not run low voltage cable in the same conduit or

wiring troughs with high voltage wires. Running low

and high voltage wires in the same conduit or wiring

troughs may damage the equipment or cause

system malfunction.

Figure 3: Jumper Block, Terminal Block, and

Potentiometer Locations

VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin 3

Table 1: Terminal Blocks

Terminal

Block Label Terminal Block Function Electrical Rating Terminal Terminal Function

L1 Line 1 Input

L2 Line 2 Input

TB1 Input Line-Voltage Supply Power

L3 Line 3 Input

T1 Line 1 Output

T2 Line 2 Output

TB2 Output Line-Voltage Power to Fan

Motor

See Technical

Specifications.

T3 Line 3 Output

1 5 VDC power supply

2 First signal input

3 Second signal input1

TB3 Low-voltage Input Signals,

0-5 VDC Power Supply 0-5 VDC or 0-10 VDC

4 Common

1 Switch contact

TB4 Alarm Output for User-Installed

Alarm Device 100 mA at 24 VAC/30 VDC 2 Switch contact

1. See Adjusting the Control Settings.

Wiring Input Devices to a VFD66

Connect the appropriate low-voltage input signal

device to Terminal Block TB3 (Figure 3). See Table 2,

Figure 4, Figure 5, and Figure 6 for additional

information on wiring specific

Johnson Controls/PENN™ input devices to the

VFD66 controls.

Table 2: Wiring Johnson Controls/PENN

Input Devices

Input Device Input Device

Terminal VFD66 Control

TB3 Terminal

1 1

2 2 (or 3)1

P35AG-9200R

Transducer

3 4

V 2 (or 3)1

A350PS-1C or

P352PN Series

Controls C 4

Red 1

White 2 (or 3)1

P499 Series

Transducers

Black 4

1. Use Terminal 3 to connect an optional second

input device to the VFD66 (Figure 5).

TB3

3 4

P35 Transducer

Figure 4: Wiring P35 Transducers to VFD66

Terminal Block 3

White

(Second Output Signal)

Red (5 VDC Supply)

White

(Output Signal)

P499 Transducer

TB3

Black

(Common)

Second P499 Transducer

(Optional)

Red (5 VDC Supply)

Black

(Common)

1 2 3 4

Figure 5: Wiring P499 Transducers to VFD66

Terminal Block 3 (TB3)

4 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin

TB3

VDC

24V

A350P Control

or P352PN Control

Second A350P Control

or P352PN Control

(if used)

2 4

C: Common (-)

V: 0-10 VDC Output

Figure 6: Wiring A350P Controls

or P352PN Controls to

VFD66 Terminal Block 3

Wiring an External Alarm to a VFD66 Control

Some models of the VFD66 controls feature an alarm

output. The Metal Oxide Silicon Field Effect Transistor

(MOSFET) alarm output activates when a permanent

fault condition occurs. See Table 12, Figure 3, and

Figure 7.

Visual

or Audible

External Alarm

Device

Alarm output

is rated for 100 mA

at 30 VDC/24 VAC.

24VAC/30 VDC

VFD66 Control

Terminal Block T 4B

Figure 7: Wiring the Alarm Output

Wiring VFD66 Input and Output Power

Select wire size for field wiring based on a wire

insulation temperature resistance rating of 167°F

(75°C), with a maximum wire size of 12 AWG. Use

only stranded copper wire, rated for at least 600 volts.

Maximum terminal tightening torque for all VFD66

controls electrical terminals is 5 lb·in (0.565 N·m).

Ensure that the motor(s) and VFD66 control are

securely and adequately grounded. Use the two

ground connection terminals on the conduit entry

bracket. (See Figure 3.) Use a ground connection

terminal similar to AMP Part Number 34162 for

16-14 AWG wire size or AMP Part Number 322455 for

12-10 AWG wire size.

Wiring Input Power

CAUTION: Risk of Property Damage.

Ensure that the power source conforms to the

requirements of the equipment. Failure to use a

correct power source may result in permanent

damage to the equipment.

IMPORTANT: Wiring line-voltage input power to the

wrong terminal block will damage the VFD66 control.

Wire input power ONLY to Terminal Block 1 (TB1).

The input line-voltage supply power to L1, L2, and L3

(Terminal Block 1) must be fused. Use fuses sized for

250% of the input current rating of the VFD66 control.

For example, if a VDF66 control is rated at 4 amperes

input current, use a 10-ampere fuse. Do not use fuses

with an extremely fast-opening characteristic (rectifier

fuses).

Wiring Output Power

IMPORTANT: The output phase rotation on TB2 at

T1(U), T2(V), T3(W) is ABC. If the motor rotation is

incorrect, interchange any two motor leads on TB2.

Do not make changes to the input power supply

wiring.

The length of output power wires between the

VFD66 control (TB2) and the motor must not exceed

50 ft (15 m).

Emissions Compliance

If the VFD66 control is used in commercial or

residential applications, FCC and DOC compliance

may require the addition of the items in Table 3 to

reduce electronic noise emissions. Installation of the

parts listed is required for EU Directive Compliance

(CE mark):

•72/23/EEC (Low Voltage Directive)

•89/336/EEC (EMC Directive)

VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin 5

Table 3: Emissions Compliance

Required Item Suggested Model

Axx, Bxx, Dxx,

and Fxx Schaffner® EMV AG

FN 258-7/291

EMI

Filter for

VFD

Types: Cxx and Exx Schaffner EMV AG

FN 258-16/29

Ferrite Core

(Two Required) Fair-Rite® No.

0443167251

Shielded Power Wiring Any 3-conductor, braided,

shielded cable

1. Contact Schaffner and Fair-Rite for local distributors.

TB3 TB1 TB2

1 2 34L1

L2 L3 T1 T2T3

Motor

EMI Filter

Shielded

Wiring

Separate input and output cables. Do not run input cables

alongside output cables. Do not bundle input and output

cables together.

Input

Device(s)

Ferrite Cores

2, 3 or 4 Conductor

Shielded Cables Alarm

Device

Figure 8: CE/FCC/DOC Compliance Wiring

Setup and Adjustments

This section describes how to set up the

VFD66 control. Remove the terminal access cover to

access the jumper blocks and internal potentiometers.

See Accessing the Interior.

Adjusting the Control Settings

WARNING: Risk of Electric Shock.

Disconnect power from the control before making

any adjustments. Do not touch any part of the

printed circuit board while power is applied. Failure

to follow these precautions can result in personal

injury or death.

Control settings are established by positioning

six jumpers and adjusting two potentiometers.

Factory default settings have all the jumpers in the

installed position and the potentiometers set fully

clockwise. (See Table 4, Figure 3 and Figure 9.)

Table 4: Jumper Settings by Function

Jumper

Block Function Jumper

Removed1Jumper

Installed

J3 Mode of

Operation See Selecting an Input Mode.

J4 Acceleration/

Deceleration

Time

5 Seconds 30 Seconds

J5 Internal/

External P1

J6 Internal/

External P2

Do not move the jumpers

from the factory-installed

position unless installing the

External Potentiometer

Replacement Cover.

J7 Input Signal

Type 0-10 VDC 0-5 VDC

J8 Number of

Input Signals

Used

Dual Single

J9 Maximum

Output

Frequency

50 Hz 60 Hz

1. Do not discard jumpers. See Figure 9.

To place a jumper in the removed position, reposition

the jumper so that it is connected to only one pin on

the jumper block. Keep the jumper because it may be

needed in the future. To place a jumper in the installed

position, place the jumper on both pins (Figure 9).

Jumper blocks J2 and J3 establish input modes and

work in conjunction with potentiometers P1 and P2.

See Selecting an Input Mode.

Jumper

Pins

Removed

(positioned

on one pin)

Installed

(positioned

on both pins)

Jumper

Block

Figure 9: Jumper Placement on Pins

Jumper blocks J5 and J6 have jumpers installed on

the two middle pins of each jumper block. These

jumpers activate the internal potentiometers. Moving

the jumpers from the factory-installed position disables

the internal potentiometers.

6 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin

Jumpers on J7 and J8 must be set for the correct input

voltage range and number of input devices. (See

Table 4.) Jumper block J7 sets the voltage range for

the input signal(s). If the jumper on jumper block J7 is

incorrectly set, the control may operate in an

unexpected manner. See Troubleshooting.

Jumper block J8 selects the number of input signals

used. When dual inputs are selected, Terminal 3 of

TB3 (TB3-3) is enabled. The VFD66 control varies the

speed of the fan motor in accordance with the higher

value of the two input signals received. If the jumper

on jumper block J8 is incorrectly set, the control may

operate in an unexpected manner. See

Troubleshooting.

Jumper block J9 selects maximum frequency output of

the control. Remove the jumper for 50 Hz motors,

typically used in Europe. Install the jumper for 60 Hz

motors, typically used in North America. Power to the

VFD66 control must be disconnected and reconnected

before frequency changes take effect.

De-Rating the VFD66 Control for

High Temperatures and High Altitudes

Ambient air temperature and altitude of the installation

affect the maximum output ampere rating of the

VFD66 control. High air temperature makes the heat

sink less effective in dissipating the generated heat.

High altitudes have thinner air than lower altitudes,

which is less effective in dissipating heat. The less

effective the heat sink is, the lower the maximum

output ampere rating of the VFD66 control.

Temperature De-Rating

For temperatures up to 122°F (50°C), the maximum

output ampere rating is unaffected by temperature. At

temperatures between 122°F (50°C) and 140°F

(60°C), the maximum output ampere rating is

decreased. The VFD66 controls are not designed to

operate in temperatures above 140°F (60°C).

See Figure 10 for temperature de-rating for

208/230 VAC models. See Figure 11 for temperature

de-rating for 400/460 VAC models.

mperes

Temperature

10.0

5.0

7.5

2.5

122 F

50 C

140 F

60 C

131 F

55 C

126 F

52 C

136 F

58 C

4.0

10.6

VFD66Axx Type

VFD66Cxx Type

VFD66Exx Type

Figure 10: 208/230 VAC Temperature De-Rating

mperes

Temperature

6.0

3.0

4.5

1.5

122 F

50 C

140 F

60 C

5.5

1.8

3.6

2.2

131 F

55 C

126 F

52 C

136 F

58 C

VFD66Fxx Type

VFD66Dxx Type

VFD66Bxx Type

Figure 11: 400/460 VAC Temperature De-Rating

Altitude De-Rating

See Table 5 for altitude multipliers. Use the following

formula to determine the adjusted rating:

Temperature

De-Rated

Maximum

Output

Amperes

XAltitude

Multiplier =

De-Rated

Maximum

Output

Amperes

VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin 7

8 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin

Table 5: Altitude Multipliers for De-Rating

Altitude Range Altitude Multiplier

0-3300 ft (0-1000 m) 1.0

3300-4300 ft (1000-1305 m) 0.97

4300-5300 ft (1305-1610 m) 0.94

5300-6300 ft (1610-1915 m) 0.91

6300-7300 ft (1915-2220 m) 0.88

7300-8300 ft (2220-2525 m) 0.86

8300-9300 ft (2525-2830 m) 0.83

9300-10300 ft (2830-3135 m) 0.80

10300-11300 ft (3135-3440 m) 0.78

De-Rating Examples

For these examples, the control used is a VFD66Exx

type. See Figure 10, Figure 11, and Table 5.

•If a VFD66Exx type (208/230 VAC) is used and

the temperature is below 122°F (50°C), the VFD66

control may be used for loads up to 10.6 amperes

at any altitude below 3,300 ft (1,000 m).

•If the temperature around the VFD66 control

reaches 140°F (60°C), the rating is different.

According to Figure 10, the VFD66 control is rated

for only 7.5 amperes at 140°F (60°C).

•If the VFD66 control is used in Denver, Colorado

(altitude 5200 ft), the output rating is reduced.

(See Table 5.) When the temperature is less than

122°F (50°C), the VFD66 control is rated for

9.96 amperes, as shown by the equation:

De-Rated Maximum Output Amperes = 10.6 Amperes

x 0.94 = 9.96 Amperes

•If the VFD66 control is used in Denver, Colorado

(altitude 5200 ft), and the ambient temperature

reaches 140°F (60°C), then the VFD66 control is

de-rated to a 7.5-ampere maximum current draw

due to the high ambient temperature and is further

de-rated to 7.05 amperes of current draw because

of high altitude.

De-rated Maximum Output Amperes = 7.5 Amperes x

0.94 = 7.05 Amperes

Commissioning

Table 6: Mode Selections According to Input Device

Input Device Input Type Input Mode J2 Jumper

Position J3 Jumper

Position J7 Jumper

Position1

Any2None2Manual Installed Installed NA

A350P Temperature Standard Installed Removed Removed

P352PN Pressure Standard Installed Removed Removed

P35AG-9200 Pressure Standard Installed Removed Installed

Any 0-5 VDC Devices Any3Standard Installed Removed Installed

Any 0-10 VDC Devices Any3Standard Installed Removed Removed

P499 or Other Electronic

Pressure Transducer Pressure Electronic Pressure

Transducer Removed Removed or

Installed4Removed or Installed4

1. J7 jumper position depends on the input device connected.

2. Setting the input mode to manual ignores any connected input devices.

3. Input type varies with device.

4. Transducer may provide 0-5 VDC or 0-10 VDC signal. A 0-10 VDC transducer must be separately powered. Note that

a non-ratiometric transducer generates more error than ratiometric transducers.

Selecting an Input Mode

See Table 6 for the available input mode options for

the VFD66 control. The factory–set mode is Manual

Input mode.

Manual Input Mode

Manual Input mode allows the user to set a constant

motor speed. This can be used where manual control

is desired or while repairing input signal devices or

obtaining replacements. InManual Input mode, the input

device signals are disregarded. Motor speed is controlled

by adjusting the P1 potentiometer. Potentiometer P2 is

disregarded and adjusting P2 has no effect.

Table 7: Manual Input Mode

J2 Jumper

Position J3 Jumper

Position P1:

Motor Speed P2:

Not

Used

Installed Installed Adjusts constant

speed of motor

(0-100%)

—

Standard Input Mode

Standard Input mode is the most commonly used

mode. The majority of input devices compatible with

the VFD66 controls are used with this mode. The input

device determines the setpoint and proportional band.

Table 8: Standard Input Mode

Jumper

Position

Jumper

Position

P1:

Minimum

Motor

Speed

P2: Motor

Action at

Minimum

Speed

CCW:

Motor idles.

Installed Removed Can be set at

0-50% of

maximum

motor speed. CW: Motor

shuts off.

P1 adjusts the minimum speed of the motor. The

minimum speed is adjustable from 0 to 50% of total

motor speed. Turning P1 Clockwise (CW) increases

minimum speed setting, Counterclockwise (CCW)

decreases minimum speed setting.

P2 determines whether the motor idles at minimum

speed or shuts off at minimum speed. P2 must be set

at full CCW or full CW position; intermediate settings

have no effect.

Figure 12 illustrates three possible motor speed

curves. When P2 is rotated fully CCW, the motor idles

at the minimum speed set by P1 at input values below

the end of the proportional band (Curve A in

Figure 12). When P2 is rotated fully CW, the motor

shuts off at the minimum speed set by P1 when the

input is below the bottom end of the proportional band

(Curve B in Figure 12).

In Curve C, the minimum motor speed (P1) is set at

0% of maximum motor speed and the position of

P2 has no effect.

Pressure or Temperature

RPM

100%

50%

Setpoint

Proportional Band

40%

30%

Minimum

Motor Speed

Setby P1

Idle

Curve B

P2=CW

P1=30%

Curve C

P2=CCW or CW

P1=0%

Curve A

P2=CCW

P1=40%

Figure 12: Standard Input Mode

VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin 9

P2 adjusts the proportional band over which fan motor

speed is controlled.

Electronic Pressure Transducer Input Mode

IMPORTANT: Minimum motor speed and motor

action at minimum speed cannot be set in this mode. Figure 13 illustrates J3, P1, and P2 settings in

Electronic Pressure Transducer Input mode with a

P499 transducer (0-500 psi). If the jumper on J3 is in

the removed position, P1 adjusts the setpoint between

200-350 psi. The fan motor starts when pressure

reaches 200 psi (Setpoint – Proportional Band) and

maximum motor speed (100% RPM) is reached at

250 psi (Setpoint).

The VFD66 controls work with most 0-5 VDC or

0-10 VDC electronic pressure transducers. For best

results, use 0-5 VDC, ratiometric P499 Electronic

Pressure Transducers. Ratiometric transducers vary

the signal voltage from 10-90% of the 5 VDC supply

power as the pressure goes from minimum to

maximum of the transducer rating.

Pressure

RPM

100%

50%

Setpoint

Set by P1 and J3

25–100 psi

(50 psi)

Proportional Band

Setby P2

(200 psi) (250 psi)

Note: Non-ratiometric transducers generate more

error than ratiometric transducers. 0-10 VDC P499

transducers are not ratiometric.

The J7 jumper position sets the input signal voltage

range. Install the J7 jumper when using a 0-5 VDC

transducer. Remove the J7 jumper when using a

0-10 VDC transducer.

Note: Applications using 0-10 VDC transducers

require a separate 15 VDC power supply.

The J3 jumper position establishes the low or high

pressure range of P1 (Table 9). Figure 13: Electronic Pressure Transducer Input

Mode, 0-500 psi P499 Transducer

P1 adjusts the pressure setpoint and establishes the

pressure value at which the VFD66 controls drive the

fan motor at maximum speed.

10 VFD66 Series Condenser Fan Speed Controls Product/Technical Bulletin

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