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Danfoss VLT® 6000 HVAC User guide

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VLT
®
6000 HVAC Series
■ Contents
Introduction to HVAC
...................................................................................... 4
Software version ....................................................................................................... 4
Safety regulations ..................................................................................................... 5
Warning against unintended start ............................................................................. 5
Introduction to the Design Guide .............................................................................. 6
Available literature ..................................................................................................... 8
Why use a frequency converter for controlling fans and pumps? .............................. 8
The clear advantage - energy savings ...................................................................... 8
Example with varying flow over 1 year .................................................................... 10
Better regulation ..................................................................................................... 11
Frequency converters generate less noise .............................................................. 11
Simpler installation when using a frequency converter ............................................ 11
V-belts no longer required ...................................................................................... 11
Regulating dampers and valves no longer required ................................................. 11
Cos ϕ compensation .............................................................................................. 11
Star/delta starter or soft-starter not required ........................................................... 11
Cost of using frequency converter not higher ......................................................... 11
Control principle ..................................................................................................... 13
CE labelling ............................................................................................................ 14
Application examples ............................................................................................. 14
Variable Air Volume ................................................................................................. 15
The new standard .................................................................................................. 15
Constant Air Volume ............................................................................................... 16
The new standard .................................................................................................. 16
Cooling Tower Fan ................................................................................................. 17
The new standard .................................................................................................. 17
Condenser pumps ................................................................................................. 18
The new standard .................................................................................................. 18
Primary pumps ....................................................................................................... 19
The new standard .................................................................................................. 19
Secondary pumps .................................................................................................. 20
The new standard .................................................................................................. 20
Choice of frequency converter ................................................................................ 21
Unpacking and ordering a VLT frequency converter ................................................ 25
Type code ordering number string ......................................................................... 25
Ordering form ......................................................................................................... 28
PC software and serial communication ................................................................... 29
PC Software tools .................................................................................................. 29
Fieldbus options ..................................................................................................... 29
Profibus .................................................................................................................. 29
LON - Local Operating Network ............................................................................. 30
DeviceNet .............................................................................................................. 30
Modbus RTU .......................................................................................................... 30
Installation ......................................................................................................... 39
General technical data ............................................................................................ 39
Technical data, mains supply 3 x 200-240V ............................................................ 43
Technical data, mains supply 3 x 380-460V ............................................................ 45
Technical data, mains supply 3 x 525-600 V ........................................................... 50
Fuses ..................................................................................................................... 53
Mechanical dimensions .......................................................................................... 55
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VLT
®
6000 HVAC Series
Mechanical installation ............................................................................................ 59
IP 00 VLT 6400-6550 380-460 V ............................................................................ 61
General information about electrical installation ...................................................... 62
High voltage warning .............................................................................................. 62
Earthing .................................................................................................................. 62
Cables .................................................................................................................... 62
Screened/armoured cables .................................................................................... 62
Extra protection with regard to indirect contact ....................................................... 62
RFI switch .............................................................................................................. 63
High voltage test .................................................................................................... 64
Heat emission from VLT 6000 HVAC ...................................................................... 65
Ventilation of integrated VLT 6000 HVAC ................................................................ 65
EMC correct electrical installation ........................................................................... 65
Use of EMC-correct cables .................................................................................... 68
Electrical installation - earthing of control cables ..................................................... 69
Electrical installation, enclosures ............................................................................. 70
Tightening-up torque and screw sizes .................................................................... 78
Mains connection ................................................................................................... 78
Motor connection ................................................................................................... 78
Direction of motor rotation ...................................................................................... 79
Motor cables .......................................................................................................... 79
Motor thermal protection ........................................................................................ 80
Earth connection .................................................................................................... 80
Installation of 24 Volt external DC supply ................................................................ 80
DC bus connection ................................................................................................ 80
High-voltage relay ................................................................................................... 80
Control card ........................................................................................................... 80
Electrical installation, control cables ........................................................................ 81
Switches 1-4 .......................................................................................................... 82
Bus connection ...................................................................................................... 82
Connection examples, VLT 6000 HVAC .................................................................. 83
Programming .................................................................................................... 85
Control unit LCP ..................................................................................................... 85
Control keys for parameter setup ........................................................................... 85
Indicator lamps ....................................................................................................... 86
Local control .......................................................................................................... 86
Display mode ......................................................................................................... 87
Navigation between display modes ........................................................................ 89
Changing data ........................................................................................................ 90
Manual initialisation ................................................................................................. 90
Quick Menu ............................................................................................................ 91
Operation and Display 001-017 .............................................................................. 93
The Setup configuration ......................................................................................... 93
Setup of user-defined readout ................................................................................ 94
Load and Motor 100-117 ..................................................................................... 100
Configuration ........................................................................................................ 100
Motor power factor (Cos ø) .................................................................................. 106
Reference handling ............................................................................................... 108
Reference type ..................................................................................................... 111
Inputs and outputs 300-328 ................................................................................. 116
Analogue inputs ................................................................................................... 119
Analog/digital outputs ........................................................................................... 122
Relay outputs ...................................................................................................... 125
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Application functions 400-427 .............................................................................. 128
Sleep mode .......................................................................................................... 129
PID for process control ......................................................................................... 133
PID overview ........................................................................................................ 136
Feedback handling ............................................................................................... 136
Serial communication for FC protocol ................................................................... 141
Protocols .............................................................................................................. 141
Telegram communication ..................................................................................... 141
Telegram build-up under FC protocol ................................................................... 142
Data character (byte) ............................................................................................ 143
Process word ....................................................................................................... 147
Control word according to FC protocol ................................................................. 147
Status word as per FC protocol ............................................................................ 148
Serial communication reference ............................................................................ 149
Present output frequency ..................................................................................... 150
Serial communication 500 - 556 ........................................................................... 151
Extended status word, warning word, and alarm word ......................................... 158
Service functions 600-631 .................................................................................... 161
Electrical installation of the relay card .................................................................... 166
All about VLT 6000 HVAC .......................................................................... 167
Status messages .................................................................................................. 167
List of warnings and alarms .................................................................................. 169
Aggressive environments ...................................................................................... 174
Calculation of resulting reference .......................................................................... 174
Galvanic isolation (PELV) ....................................................................................... 175
Earth leakage current ........................................................................................... 175
Extreme running conditions .................................................................................. 176
Peak voltage on motor ......................................................................................... 177
Switching on the input .......................................................................................... 177
Acoustic noise ...................................................................................................... 178
Derating for ambient temperature ......................................................................... 178
Derating for air pressure ....................................................................................... 179
Derating for running at low speed ......................................................................... 179
Derating for long motor cables or cables with larger cross-section ....................... 179
Derating for high switching frequency ................................................................... 179
Vibration and shock .............................................................................................. 180
Air humidity ......................................................................................................... 180
Efficiency ............................................................................................................. 181
Mains supply interference/harmonics .................................................................... 182
Power factor ........................................................................................................ 182
EMC test results (Emission, Immunity) .................................................................. 184
EMC Immunity ..................................................................................................... 185
Definitions ........................................................................................................... 187
Parameter overview and factory settings .............................................................. 189
Index .................................................................................................................... 196
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VLT
®
6000 HVAC Series
■Software version
175ZA692.12
VLT 6000 HVAC
Design Guide
Software version: 2.6x
This Design Guide can be used for all VLT 6000 HVAC
frequency converters with software version 2.6x.
The software version number can be seen from parameter
624.
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VLT
®
6000 HVAC Series
Introduction to
HVAC
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.
■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 n
ot disconnect
the equipment from mains and is thus n
ot to
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.
5. Protection against motor overload is included in
the factory setting. Parameter 117, Motor thermal
protection default value is ETR trip 1.
N
ote: The function is initialised at 1.0 x rated
motor current and rated motor frequency (see
parameter 117, Motor thermal protection).
6. Do n
ot 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.
7. Reliable galvanic isolation (PELV) is not 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
withbasicgalvanicisolation.
8. Please note that the frequency converter has
more voltage inputs than L1, L2 and L3, when
the DC-bus terminals are used.
Check that a
ll voltage inputs have been
disconnected and that the necessary time has
passed before repair work is commenced.
■Warning against unintended start
1. The motor can be brought to a stop by
means 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, t
hese
stop functions are not sufficient.
2. While parameters are being changed, the
motor may start. Consequently, t
he stop key
[OFF/STOP] must always be activated, following
which data can be modified.
3. A motor that has been stopped may start if 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.
175HA490.11
Warning:
Touching the electrical parts may be fatal - even after the equipment
has been disconnected from mains.
Using VLT
6002 - 6005, 200-240 V: Wait at least 4 minutes
Using VLT
6006 - 6062, 200-240 V: Wait at least 15 minutes
Using VLT
6002 - 6005, 380-460 V: Wait at least 4 minutes
Using VLT
6006 - 6072, 380-460 V: Wait at least 15 minutes
Using VLT 6102 - 6352, 380-460 V: Wait at least 20 minutes
Using VLT 6400 - 6550, 380-460 V: Wait at least 15 minutes
Using VLT
6002 - 6006, 525-600 V: Wait at least 4 minutes
Using VLT
6008 - 6027, 525-600 V: Wait at least 15 minutes
Using VLT
6032 - 6275, 525-600 V: Wait at least 30 minutes
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VLT
®
6000 HVAC Series
■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 Instruc tions and a Quick Setup Guide.
See the section Other Literature.
Operating Instructions: 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
thatyoucaneasilyfittheVLT6000HVACintoyourapplication.
Quick Setup Guide: Helps you get your VLT 6000 HVAC installed and commissioned quickly.
Design Guide: 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 hasexamplesofthemostcommon
types of HVAC applications. In addition, the Design Guide has all information
relating to Serial Communication.
This Design Guide is split in four sections that have information about VLT 6000 HVAC.
Introduction to HVAC: 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.
There are also examples of applications and information is given about Danfoss
and CE-labelling.
The specification section deals with the requirements relating to bei
ng allowed
to 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.
The section ends with an Ordering Guide that makes it easier for y
ou to specify
and order a VLT 6000 HVAC.
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VLT
®
6000 HVAC Series
Introduction to
HVAC
■Introduction to the Design Guide
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
VLT6000HVAC.ThereisalsoaguidetotheQuickSetupmenu,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 indicat
essomethingtobe
noted by the reader.
This symbol indicates a general warning.
This symbol indicates a high-voltage
warning.
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VLT
®
6000 HVAC Series
■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.dan-
foss.com for information about new literature.
Supplied with the unit:
Operating instructions ....................................................................................................................... MG.60.AX.YY
Quick Setup ...................................................................................................................................... MG.60.CX.YY
Communication with VLT 6000 HVAC:
Software Dialog ................................................................................................................................ MG.50.EX.YY
Profibus Manual ................................................................................................................................ MG.10.LX.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
LC-filter ............................................................................................................................................... MI.56.DX.51
IP20 terminal cover ............................................................................................................................. MI.56.CX.51
RCD instructions ................................................................................................................................. MI.66.AX.YY
Relay card instructions ........................................................................................................................ MI.66.BX.YY
Various literature for VLT 6000 HVAC:
Operating Instructions ....................................................................................................................... MG.60.AX.YY
Data sheet ........................................................................................................................................ MD.60.AX.YY
Installation Guide .............................................................................................................................. MG.56.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.
The graph below describes the laws of proportionality.
The graph shows that flow and pressure can be
regulated by changing the rpm figure.
■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 to be obtained.
When comparing with alternative regulating systems
and technologies, a frequency converter is the
optimum energy control system for regulating
fan and pump systems.
■Exampleofenergysavings
As can be seen from the figure (the laws of
proportionality), the flow is regulated by changing
the rpm figure. By reducing the speed only 20%
from the rated speed, the flow is also reduced by
20%.Thisisbecausetheflowisdirectlyproportional
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VLT
®
6000 HVAC Series
Introduction to
HVAC
to the rpm figure. 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
This figure describes the dependence of flow, pres-
sure and power consumption on the rpm figure.
Q=Flow P=Power
Q
1
=Ratedflow P
1
=Ratedpower
Q
2
= Reducing flow P
2
=Reducingpower
H = Pressure n = Speed regulation
H
1
= Rated pressure n
1
= Rated speed
H
2
= Reducing pressure n
2
= Reducing speed
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VLT
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■Example with varying flow over 1 year
The example below is calculated on the basis of pump
characteristics obtained from a pump datasheet.
(45 kW). The same examples of calculations can be
used in the case of fan characteristics.
The result obtained is savings in excees of 50% at the
given flow distribution over a year, corresponding
to 8,760 hours.
Typically, the example calculated below results in a
pay-back period of one year - depending on the price
per kWh and the price of the frequency converter.
Pump characteristics
Energy savings
This figure compares flow regulation via valves and
without speed control with flow regulation via a
frequency converter.
P
shaft
=P
shaft output
Flow distribution over 1 year
m3/t Distribution Valve regulation Frequency converter control
% Hours Power Consumption Power Consumption
A
1
-B
1
kWh A
1
-C
1
kWh
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 10,0 17.520
150 20 1752 28,0 49.056 6,5 11.388
100 20 1752 23,0 40.296 3,5 6.132
100 8760 275.064 124.173
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VLT
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6000 HVAC Series
Introduction to
HVAC
■Better regulation
If a frequency converter is used for regulating the
flow or pressure of a system, improved regulation is
obtained which can be adjusted very precisely.
A frequency converter can vary the speed of the
fan or pump infinitely, thereby obtaining infinitely
variable control of flow and pressure.
Furthermore, a frequency converter can quickly
regulate the speed of the fan or pump, so as to adapt it
to new flow or pressure conditions in the system.
More traditional, mechanical flow or pressure regulating
systems tend to provide slow, inaccurate regulation if
compared with that of the frequency converter.
■Frequency converters generate less noise
If the speed of a fan is changed, the sound level
changes, too. If the rpm figure is reduced by
50% from the rated rpm value, the sound level
will go down by approx. 16 dB(A).
The formula is:
■Simpler installation when using a fre-
quency converter
A frequency converter can replace a traditional
regulating system, in which mechanical dampers and
valves are used for regulating 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 regulating 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 V-belts 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 regulated by means
of the frequency converter, no regulating dampers
and valves are required in the system.
■Cos ϕ compensation
Generally speaking, a frequency converter with a cos
of 1 provides power factor correction for the cos ϕ
of the motor, which means that there is no need to
makeallowanceforthecosϕ 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 start-up
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=VLT6000HVAC
2 = Star/delta starter
3=Soft-starter
4 = Start directly on mains
■Cost of using frequency converter not higher
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 page, the two systems can
be established at roughly the same price.
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VLT
®
6000 HVAC Series
■Without a frequency converter
Thefigureshowsafansystemmadeinthetraditionalway. D.D.C. = DirectDigitalControl
E.M.S. = Energy Management
System
V.A.V. = Variable Air Volume
Sensor P = Pressure
Sensor T = Temperature
■With a frequency converter
T
he figure shows a fan system controlled by VLT 6000 HVAC frequency converters.
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VLT
®
6000 HVAC Series
Introduction to
HVAC
■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.
The motor is thus supplied with variable voltage and
frequency, which enables infinitely variable speed
control of three-phased, standard AC motors.
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 mai
ns supply.
5
. Intermediate circuit capacitors
Even out the intermediate circuit voltage.
6
. Inverter
Converts DC voltage into variable AC voltage
withavariablefrequency.
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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VLT
®
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’sdeclaration.
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
orinstallation.Itmustbenotedthattheresponsibility
for the final EMC properties of the appliance, system
or installation rests with the installer.
NOTE: 525-600 V units 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.
Ask for The Drive to...Improving Variable Air Volume Vent ilation systems MN.60.A1.02
Ask for The Drive to...Improving Constant Air Volume Ve ntilation systems MN.60.B1.02
Ask for The Drive to...Improving fan control o n cooling towers MN.60.C1.02
Ask for The Drive to...Improving condenser water pumping systems MN.60.F1.02
Ask for The D rive to...Improve your primary p um ping in primay/secondar y pumping systems MN.60.D1.02
Ask for The Drive to...Improve your secondary pumping in primay/secondary pum ping systems MN.60.E1.02
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VLT
®
6000 HVAC Series
Introduction to
HVAC
■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 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
Flow
Flow
Cooling coil
Heating coil
D1
D2
D3
Filter
Pressure
transmitter
Supply fan
Return fan
T
3
3
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VLT
®
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.
Pressure
signal
Cooling coil
Heating coil
D1
D2
D3
Filter
Pressure
transmitter
Supply fan
Return fan
Temperature
signal
Temperature
transmitter
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Introduction to
HVAC
■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 tempera-ture. The cooled water collects in the
cooling towers basin where it is pumped back into the
chillers con-denser 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.
The customer programmable minimum frequency
set-ting 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.
Water Inlet
Water Outlet
CHILLER
Temperature
Sensor
BASIN
Conderser
Water pump
Supply
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■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 chillers condenser section and releases it into
the atmosphere in the cooling tower. These systems
areusedtoprovidethemostefficientmeansof
creating chilled water, they are as much as 20%
more efficient than air cooled chillers.
■The new standard
Frequency converters can be added to condenser
water pumps instead of balancing the pumps with a
throttling valve, to control the water temperature instead
of tower fans, or to control the water temperature
in addition to controlling the tower fans.
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. Frequency converters are used
to control the water temperature instead of controlling
the cooling tower fans when it is more convenient to
access the pumps than the tower fans. Pump control
is used in conjunction with fan control to control the
water temperature in free cooling applications or when
the cooling towers are significantly oversized. In some
circumstances the environment itself causes the water
to become too cool even when the fan is off. The
frequency converter controlled pump maintains the
appropriate temperature by increasing or decreasing
the discharge pressure and flow rate. The decreased
pressure at the spray nozzle in the cooling tower
decreases the surface area of the water exposed to the
air. Cooling is decreases and the design temperature
can be maintained in periods of low loads.
Water Inlet
Water Outlet
CHILLER
BASIN
Conderser
Water pump
Supply
Temperature
sensor
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Introduction to
HVAC
■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. Thisallowsdevicessuchaschillerstoobtain
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 new standard
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
can be 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.
The other method is local speed determination. The
operator simple decreases the output frequency
until the design flow rate is achieved.
Using a frequency converter to decrease the pumps
speed is very similar to trimming the pumps impeller,
exceptitdoesn’t require any labor and the pumps
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
pumps speed instead of requiring a new pump impeller.
CHILLER
F
CHILLER
F
Flowmeter
Flowmeter
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■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
theflowratedropsfarenoughortooquickly,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 new standard
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 the
two-way valves can be subjected too.
As the monitored loads are satisfied, the loads 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 setpoint 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 drive
running multiple pumps in parallel.
CHILLER
CHILLER
∆P
3
3
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