Built-on speed controller for GMPM plug fan with permanent magnet motor
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1 Air Comfort air comfort Centriflow 3D Plug fan GMPM Built-on speed controller» Installation and Operation Built-on speed controller for GMPM plug fan with permanent magnet motor Content Page 1. Introduction Features Installation Control signal El. conn. of speed controller power supply Electrical connection of control signals Electrical connection of Modbus cable Modbus termination Electrical connection of hand terminal Operation Control via 0-10 V Control via hand terminal Control via potentiometer Control via Modbus Fire mode function Automatic restart following alarm Relay output Alarm reset Switching frequency LED indicatons Modbus Supported Modbus commands Prohibition of use Safety features Service and maintenance Alarm Disposal and environmental protection Limitation of use CE marking Approvals Technical data Troubleshooting Pictures... 10
2 2 Installation and Operation 1. Introduction This speed controller is used with permanent magnet synchronous motors (PM). Speed can be controlled with 0-10 V DC signal, potentiometer, Modbus RTU or hand terminal. Main voltage requirement is 3-phase 400 V AC. Speed controller is equipped with EMC filter. Speed controller is mounted to the fan motor base frame so that the cooling ribs are in the air flow. Surplus heat is removed by active ventilation. The electronics are unaffected by the heat, cold, moisture, dust and vibration as they are mounted into a sturdy aluminium enclosure. IO-box acts as an interface to the speed controller. Analogue/digital signals, RS-485 Modbus RTU and hand terminal are connected to the IO-box that is mounted on the left hand side of the fan. If the fan service side is on the right hand side of the fan, IO-box can easily be moved to the other side. IO-box is fastened with three screws. There is a flexible flat cable between the speed controller and the IO-box. Speed controller is delivered with a preconnected 3.5 m long supply voltage cable. It can be connected to the isolator or junction box. 2. Features As standard, speed controller has the following built-on features Modbus RTU 0-10 V analogue input for controlling speed Control via external hand terminal Indication relay for alarm or running Flying start Alarms for overload, over-voltage and under-voltage Motor protector with built-on current limiter Short-circuit protected inputs and outputs Digital input for Start/stop Digital input for Fire mode operation Digital input for Alarm reset Built-on EMC filter 3. Installation 3.1 Mechanical installation Speed controller and IO-box are factory mounted to the fan motor base frame. If IO-box is moved to the other side of the fan Open IO-box lid Remove three screws Move IO-box to the other side of the fan Secure that flat cable has free space and is not too short Fasten IO-box with three screws to pre drilled holes To prevent IO-box from being deformed, screws must not be tightened to more than 1.5 Nm of torque. 3.2 Electrical connection of speed controller power supply Speed controller is delivered with a 3.5 m long supply voltage cable. It is connected to the speed controller mains voltage terminals. Other end of the cable can be connected to the isolator or junction box. Supply cable need not to be screened. Leakage Current (>3,5 ma) EN/IEC (Power Drive System Product Standard) requires special care if the leakage current exceeds 3,5 ma. Earth grounding must be reinforced in one of the following ways: Earth ground wire of at least 10mm 2 Two separate earth ground wires both complying with the dimensioning rules Isolation switch All speed controllers may be used with an isolated input source as well as with ground reference power lines. 3.3 Electrical connection of control signals Control cables must be led into the IO-box through the cable glands. The glands are equipped with rubber seals in which a suitable hole must be cut to ensure that the seal grips the cable tightly, thus maintaining the IP54 enclosure rating. If a 0-10 V DC control signal from an external controller is used, the cable must be connected to IO-box terminals 13 (0-10V) and 14 (GND). Speed controller controls speed linearly between 0% and 100% V +/- 2%) taking account of the set ramp-up / ramp-down times and the control range limits defined by the settings for min. and max. revolutions.
3 Installation and Operation 3 If a potentiometer is to be used for speed control, it must be connected to IO-box terminals 13 (0-10V), 14 (GND) and 15 (+10V). Speed controller controls speed linearly between 0% and 100% V +/- 2%) taking account of the set ramp-up / ramp-down times and the control range limits defined by the settings for min. and max. revolutions. The Start / Stop signal, which must come from a potential-free switch, must be connected to IO-box terminals 7 (Start/Stop) and 8 (GND) The Fire mode signal, which must be potential free signal, must be connected to IO-box terminals 9 (Fire mode) and 10 (GND). The Fire mode function is described in the Operation section. The alarm reset signal, which must be potential-free digital signal, must be connected to IO-box terminals 11 (Alarm reset) and 12 (GND). The Alarm reset function is described in the Operation section. Speed controller is equipped with a relay output signal. The function of this relay, alarm or running indication, can be selected from SW1 rotation switch. Signal is potential free (NC). It is connected to the terminals 16 and 17. The function of this relay is described in the Operation section. VOLTAGE LEVEL?? 3.4 Electrical connection of Modbus cable If Modbus RTU is connected by using RJ12 connectors, the Modbus cable must be of MPFK6S or similar flat cable type to which RJ12 connectors have been fitted by using a special tool. The Modbus cable must be led into the IO-box through the gland, which has a split rubber seal, and connected to IO-box connector D. Secure the Modbus cable by using the strain relief clamp located beside the cable gland. Modbus communication can also be established by connecting other type of standard cable connecting and looping the Modbus cable to other units using IO-box spring clip terminals. The Modbus connection terminals on IO-box are marked 1 (A), 2 (B), 3 (GND) while loop terminals are marked 4 (A), 5 (B), 6 (GND). 3.5 Modbus termination Where speed controller is incorporated in a Modbus network, it is necessary to terminate the external Modbus at both ends. Speed controller is equipped with termination resistor and a jumper which can be used to activate or deactivate this Modbus termination. The jumper is located beside terminal no. 1. The termination resistance is 100Ω and the factory setting is OFF. 3.6 Electrical connection of hand terminal The Modbus cable from the hand terminal must be led into IO-box through the gland, which has a split rubber seal, and connected to the IO-box connector C. For further instruction, please read the section Hand terminal. Secure the Modbus cable by using the strain relief clamp located beside the cable gland. 4. Operation Speed controller can be controlled via: 0-10V DC 9.5 V +/-2%. Local hand terminal PAN-07-0 Potentiometer Modbus RTU 4.1 Control via 0-10V Speed controller can be controlled by external input signals. Before speed controller can be started, it must be given a start/ stop signal. It is given by short-circuiting terminals 7(START) and 8 (GND). Speed is controlled by connecting the control signal (0-10V DC) to terminals 13 (Speed IN) and 14 (Speed GND). Speed is controlled linearly between 0% and 100% taking account of the control range of the control range limits defined by the settings for min. and max. revolutions. These are set by means of hand terminal. 100% speed is defined in the IO-box as an input voltage 9.5 V on Speed IN (terminal 13). To control speed controller with a 0-10 V DC signal, Control = 0-10 V DC must be selected in the Start up/control menu of the hand terminal (this is the factory setting). External stop from hand terminal has higher priority than start from hand terminal. The fire mode function must be disabled by short-circuiting the Fire Mode input on terminals 9 (FIRE) and 10 (GND). If the fire mode function is not disabled, speed controller will control the fan without any alarms or safety functions being activated (see Fire Mode section). Speed controller is supplied with Fire Mode function disabled, i.e. with a factory-fitted bridge between terminals 9 (FIRE) and 10 (GND). This bridge must be removed if a fire mode signal is to be received from, for example, an automatic fire alarm (AFA) system Control via hand terminal The hand terminal must be connected to the IO-box by using the RJ12 connector marked C. To control speed controller with the hand terminal, Control = HTERM must be selected in the Start up/control menu of the hand terminal Control via potentiometer Speed controller can be controlled by a potentiometer, which must be connected to the terminals 13 (IN), 14 (GND) and 15 (10 V DC). The potentiometer must have a resistance of min 4Ω k (recommended) and max 47 kω. See also Control with 0-10VDC section Control via Modbus See chapter 5. Modbus in this instruction.
4 4 Installation and Operation 4.5 Fire mode function In fire mode, speed controller runs an emergency control program without alarm monitoring. The internal overheating protection in speed controller is, for example, disabled and the motor is not stopped if communication is lost. Among other things, the function can be used in connection with smoke extraction from burning building. An extraction fan will, for example, be able to continue removing smoke from the building for as long as possible when fire mode is enabled. The fan will thus continue to operate despite faults and other alarms from the fan itself or from speed con troller. Speed is controlled to the actual setting, which comes from an external 0-10 V signal, potentiometer or Modbus Master controller. Speed controller can continue to operate for at least one hour, even with overheated speed controller and fan motor. In fire mode, priority is given to keeping speed controller running regardless of which alarms are active. The fire mode function is enabled by removing the bridge between terminals 9 (FIRE) and 10 (GND). Note: If temperature inside the speed controller exceeds 75 C, the power supply to the hand terminal is disconnected. Consequently, the hand terminal cannot be used at temperatures above 75 C. 4.6 Automatic restart following alarm Speed controller will automatically attempt to restart after an alarm situation, e.g. over or under voltage. Automatic restart is attempted three times at most. If the third attempt is unsuccessful, speed controller remains in alarm state and the alarm must be reset before restarting is possible. See also 4.8 Alarm reset. 4.7 Relay output Speed controller is equipped with a relay output. The function of this relay can be selected from rotary selector SW1 located in the IO-box: SW1 = 1: Alarm relay SW1 = 3 Running indication relay The alarm relay is activated if an alarm situation occurs in the speed controller or is detected in the motor or the fan. The alarm signal must be connected to terminals 16 (C) and 17 (NC) and relay is closed if the unit is powered down or there are active alarms. The running indication relay is activated if the fan is running. 4.9 Switching frequency Motor switching frequency (Switch Mode) can be set to the following values by using the hand terminal. 0 = Auto 1 = Low = 4 khz 2 = High = 8 khz Although raising switching frequency reduces audible noise from the motor, it also increases energy loss within the speed controller. In position 0 = Auto, the speed controller automatically changes switching frequency. When increasing speed, the speed con troller changes from high to low when speed exceeds 70% of nominal maximum speed. When reducing speed, the speed controller changes from low to high when speed drops below 60% of the nominal maximum speed. In position 1 = Low = 4 khz, speed controller uses always low switching frequency during operation. In position 2 = High = 8 khz, speed controller uses always high switching frequency during operation Led indications IO-box is equipped with two LEDs, which are located under the cover and are therefore not visible with the cover closed. The green LED lights constantly when control is via A/D signals. The green LED flashes during Modbus control, indicating communication on external Modbus. The green LED also flashes when the unit is controlled via hand terminal. The red LED lights if at least one alarm is active. Expect when fire alarm mode is active. Warning! The speed controller housing can be very hot. Warning! Sped controller cannot be repaired on site. Never attempt to repair a defective unit. Contact your supplier to obtain a replacement. Note! Additional technical data are available on request from your supplier. 4.8 Alarm reset Speed controller is equipped with a digital input for resetting alarms. The alarm output is reset by short-circuiting terminals 11 (ALARM) and 12 (GND). The alarm output can also be reset via Modbus command or by disconnecting speed controller from the power supply for more than 60 seconds.
5 Installation and Operation 5 5. Modbus The default speed controller Modbus address is 54 and the default baud rate is 38.4 kbps with 1 start bit, 8 data bits, 2 stop bits and no parity. To control speed controller via external Modbus, HTERM must be selected in the Control menu of the hand terminal. Modbus address and baud rate can be changed from the hand terminal by using the following procedure: With the encoder (figure) set to 0, the required parameters can be set to the required values with the hand terminal. Once the new settings have been made, turn the encoder to position 1 (Alarm relay) or 3 (Running indication relay). See chapter 4.7 Relay output. The hand terminal will not work if the baud rate is changed from the default value of 38.4 kbps and the hand terminal is disconnected from connector C. The changed settings will then apply. Once speed controller has been connected to Modbus with valid communication, the 0-10V signal and Start/Stop input are ignored Supported Modbus commands Coil stat bits Available Modbus commands 0x01: Read / 0x05: Write single Coil (NOTE: ON => output value 0xFF00) / 0x0F: Write multiple Coils. Register Function Range Active state Comment 1 Motor ON/OFF = ON For speed controller 2 Reset Alarms = Reset For IO-box and speed controller 3 Fire Mode = Active For speed controller 4 Control = Modbus, 1 = 0-10 V For IO-box Input stat bits Available Modbus commands 0x02: Read Register Function Range Active state Comment 1 V LO Alarm = Alarm Alarm in speed controller 2 V HI Alarm = Alarm Alarm in speed controller 3 I HI Alarm = Alarm Alarm in speed controller 4 Temp Alarm = Alarm Alarm in speed controller 5 Phase Error = Error Alarm in speed controller 6 Rotor Blocked = Blocked Alarm in speed controller 7 I HI Limit = Limit Alarm in speed controller 9 I Ripple = Irip high Alarm in speed controller 10 EEPROM Error = Error Alarm in speed controller 11 Internal Stop = Stop Motor stopped 15 Communication Error = Error Comm. Error with speed controller 18 External Stop = Stop External signal on speed controller 19 External Fire Mode = Fire mode External signal on speed controller
6 6 Installation and Operation Holding registers Available Modbus commands 0x03: Read / 0x06: Write Single / 0x10: Write Multiple Register Function Range Resolution Unit Comment 1 Setpoint / PrcSet % For speed controller 2 Min. RPM X - Y 1 RPM For speed controller 3 Max. RPM X - Y 1 RPM For speed controller 4 UpRampTime Sec. For speed controller 5 DownRampTime Sec. For speed controller 11 0 Auto For speed controller SwitchMode 1 4 khz For speed controller 2 8 khz For speed controller 17 Modbus ID For IO-box bps For IO-box bps For IO-box bps For IO-box CommRate* bps For IO-box bps For IO-box bps For IO-box 19 0 None For IO-box Parity* 1 Odd For IO-box 2 Even For IO-box 20 0 INVALID For IO-box Stop Bits* 1 1 For IO-box 2 2 For IO-box * Alternative communication settings when the encoder is in position 1 or 3 Input registers Available Modbus commands 0x04: Read Register Function Range Resolution Unit Comment 1 Speed contr. Type ? 1 - For IO-box 2 IO-box SW version 100 -? Of IO-box 4 PRCOUNT % Of speed controller 5 RPMOUT RPM Of speed controller 6 INTERN TEMP C Of speed controller 7 V IN V Of speed controller 8 I OUT ma Of speed controller 9 POWER IN W Of speed controller 10 I RIPPLE ma Of speed controller 11 OPERATION MINUTES min Of speed controller 12 OPERATION DAYS day Of speed controller 13 V RIPPLE V Of speed controller 14 CONFIG FILE VARIANT AA - ZZ 2 ASCII CHAR - Of speed controller 15 CONFIG FILE VARIANT Of speed controller 16 EXTERN SET V External input on IO-box 20 SPEED CONTR. SW VERS Of speed controller 21 BOOT SW VERSION Of speed controller
7 Installation and Operation 7 6. Prohibition of use It is hereby declared that the product must not be taken into use until the machine/system in which it is to be incorporated has in its entirety been declared to be in conformity with all relevant requirements of the Machine Directive 98/37/EEC and any applicable national regulations. The product must not be energised until the entire installation complies with ALL relevant EU directives. The product carries the manufacturer s warranty if installed in accordance with these installation instructions and applicable installation regulations. If the product has been damaged in any way, e.g. during transport, it must be inspected and repaired by authorised personnel before connected to the power supply. 6.1 Safety features Speed controller is protected against phase-to-phase shotcircuiting and built in current limitation to protect the motor. It is the responsibility of the electrician installing the unit to ensure the proper earthing and any other protection required by applicable local regulations and standards. Residual current devices (RDC), multiple protective earthing or standard earthing can be used as additional precautions, provided they comply with local safety regulations. Earth leakage currents are higher than 3,5 ma. The unit therefore requires fixed permanent installation and reinforced protective earthing. Note! When earth fault occur, the fault current may contain DC component. If RDCs are used, they must therefore be capable of detaching such current and must be installed in accordance with applicable local and international regulations. 6.2 Service and maintenance Cooling ribs must be clean to ensure sufficient cooling. Please contact your supplier if faults arise. To locate faults in the use, see Troubleshooting section. 6.3 Alarm The alarm relay built into IO-box is of normally closed (NC) type, and is marked Alarm relay on the unit. The alarm relay is closed when the unit is powered down and open during problem-free conditions. The alarm relay closes in alarm situations, causing speed controller to shut down and the alarm led to light up. If the alarm situation passes, the alarm is automatically reset and speed controller restarted. Speed controller will automatically attempt to restart. If maximum number of restarts (three) is exceeded, the alarm must be reset. When speed is controlled via Modbus, the alarm is reset by pulsing CoilStatBit, address 1 = 1. When speed is controlled via 0-10V DC and digital signals, the alarm is reset by short-circuiting Alarm reset and GND. The alarm is automatically reset if power is disconnected for longer than 60 seconds. 6.4 Disposal and environmental protection Help protect the environment by disposing of the packaging and redundant products in a responsible manner Product disposal Products marked with this symbol must not be disposed of along with household refuse but must be delivered to a waste collection centre in accordance with current local regulations Applied standards EN Adjustable speed electrical power drive systems. Part 2: electrical requirements. EN General electromagnetic compatibility 6.5 Limitation of use The product may only be used if the complete installation complies with applicable directives and local statutory regulations. The product carries a manufacturer s warranty if installed in accordance with these instructions and applicable regulations. If the product has been damaged in any way, e.g. during transport, it must be inspected and checked by authorised personnel before being taken into use and connected to the power supply. 6.6 CE Marking The product is manufactured in accordance with Council Directive 92/31/EEC on electromagnetic compatibility (and subsequent amendments) and Council Directive 73/23/EEC on electrical equipment designed for use within certain voltage limits. 6.7 Approvals EMC EN LVD EN PRODUCT STANDARD EN PARTS 2 & 3 PRODUCT APPROVAL CE
8 8 Installation and Operation 7. TECHNICAL DATA SPEED CONTROLLER TECHNICAL DATA Description Unit Speed Controller size 1.6 kw 2.4 kw 4.0 kw 6.5 kw POWER SUPPLY Voltage V 3x400 V AC 50/60 Hz -10%/+15% Nominal motor power (on shaft) kw 1.6 kw 2.4 kw 4.0 kw 6.5 kw Power consumption at max. Load A 3 x 3 A 3 x 4.5 A 3 x 7.5 A 3 x 12 A Power factor cosφ at max. Load > 0.9 MOTOR OUTPUT Efficiency % Up to 97 Max output voltage V 360 V AC Max. Output current A 3 x 4.5 A 3 x 7 A 3 x 11.5 A 3 x 16 A PROTECTION Max. Fuse A 16 Motor output Short-circuit protected between phases Motor Protected by current due to demagnetisation and power loss in motor Inputs Transient protected by VDR ENVIROMENTAL SPECIFICATIONS Operating temperature C -40 C to +40 C Starting temperature C -40 C to +50 C Storage temperature C -40 C to +70 C Enclosure rating IP 54 Enclosure material Aluminium Humidity % rh 10-95% rh, non-condensing Surface Corrosion resistant EN/ISO :1998 Category C4 INTERFACES Digital communication 2 x Modbus via RJ12 connectors plus 2 terminals for max. 1,5 mm2 Digital input Start/stop with internal Pull up / Fire mode / Alarm reset Analogue input 1 x 0-10 VDC at 20 kω VDC +/-2% Alarm or running indication Relay 1 x potential-free relay (NC) 24 V AC / 24V DC / 1 A FUNCTIONS Technology Sinusoidal back-emf signal controlled via field oriental control Flying start Yes, <30% of max. Speed Min. ramp-up time sec Max. ramp-up time sec Alarm Yes Running indication Yes, alternative with Alarm Alarm reset Via digital input, Modbus or powering down more than 60 seconds Fan stop The braking function will stop the fan as quickly as possible. The braking time will depend on the inertia of the fan. Service data log Operating hours, alarms, loads, software version, max. Temp, max. Motor voltage, max. Motor current, max ripple voltage, max. Ripple current Software updating Yes, via serial interface Motor parameters Programmable by supplier Fire mode Nominal power for 1 hour at 70 C APPROVALS EMC EN LVD EN Product standard EN Parts 2 & 3 RoHS Directive Yes Product approvals CE
9 Installation and Operation 9 8. Troubleshooting Opening speed controller Before speed controller is opened, mains voltage must have been disconnected for at least 2 minutes. Otherwise the unit may contain residual current capable of causing serious injury. Troubleshooting when speed is controlled by external (A/D) signals Symptom Cause Action Motor inoperative Motor is noisier than acceptable Speed controller cuts out. *) Note: remember reset alarms by shortcircuiting terminals 11 (ALARM) and 12 (GND). The alarm can also be reset by disconnecting the power supply to the speed controller and reconnecting it after approx. 60 seconds. No supply voltage Poor electrical connections No operating signal No 0-10 V DC control signal The motor has been stopped by the built-on motor protector 3 times because of overload or other alarm. Defective speed controller Overloaded motor Switching frequency too low At least 2 phases shortcircuited on motor terminals. Check voltage 400 V in speed controller terminals L1, L2 and L3 Check connectors and other electrical connections Short-circuit speed controller terminals 7 (START) and 8 (GND) Check that 0-10 V DC signal is connected correctly to speed controller terminals 13 (IN) and 14 (GND) With potentiometer control : Check that the potentiometer s 0-10 VDC control signal is connected correctly to speed controller terminals 13 (IN), 14 (GND) and 15 (10 VDC). The potentiometer must have internal resistance at least 4 kω. Reset the alarm by short-circuiting speed controller terminals 11 (ALARM) and 12 (GND). The alarm can also be reset by disconnecting the power supply to the speed controller and reconnecting it after approx. 60 seconds Replace speed controller Replace motor Increase switching frequency. 0 = Auto (factory setting), 1 = Low = 4 khz, 2 = High = 8 khz. Raising the switching frequency increases energy losses in speed controller. Switching frequency can be changed using the hand terminal. Remove short-circuit on motor terminals *) Defective motor Replace the motor *) Overloaded motor Relieve motor overload *) Troubleshooting when speed is controlled by modbus Symptom Cause Action No supply voltage Check voltage 400V in speed controller terminals L1, L2 and L3 Poor electrical connections Check connectors and other electrical connections No operating signal Coil stat Bits Register 1: Motor Start/stop (1 = On) 0-1 No speed set point Holding registers; Register 1: PrcSet ( %) Motor inoperative The motor has been stopped by the built-on motor protector 3 times because of overload or other alarm. Coil stat Bits Register 2: Reset (1 = Reset / pulse) 0-1. The alarm can also be reset by disconnecting the power supply to the speed controller and reconnecting it after approx. 60 seconds Defective speed controller Replace speed controller Overloaded motor Replace motor Motor is noisier than acceptable Switching frequency too low Holding registers; Register 11: SwitchMode Increase switching frequency. 0 = Auto (factory setting), 1 = Low = 4 khz, 2 = High = 8 khz. Raising the switching frequency increases energy losses in speed controller. Speed controller cuts out. *) Note: remember reset alarms by setting Coil stat Bits Register 2: 1 = Reset (1 = Reset/Pulse) 0-1. The alarm can also be reset by disconnecting the power supply to the speed controller and reconnecting it after approx. 60 seconds. At least 2 phases shortcircuited on motor terminals Remove short-circuit on motor terminals *) Defective motor Replace the motor *) Overloaded motor Relieve motor overload *)
10 10 Installation and Operation 9. Pictures Picture Eleectric power connection. BR-0982B07a BR-0990-A06a Picture IO-box connection.
11 Installation and Operation Pictures, cont. BR-0990-A10a Picture Connecting Hand terminal. BR-0990-A09a BR-0990-A04a Picture Encoder. Picture Connecting potentiometer. BR-0990-A12b Picture Modbus termination.
12 FWG-OEM Fans Installation & Operation-GB GB Copyright 2015 Fläkt Woods Group Centriflow 3D 9757GB A history of innovation and reliability Fläkt Woods is a global leader in air management. We specialize in the design and manufacturing of a wide range of air climate and air movement solutions. Our product brands such as SEMCO, eq, eq PRIME, Econet, Veloduct, Optivent, Econovent and Cleanvent are well-known and trusted by customers all over the world to deliver Air Comfort and Fire Safety. We are constantly aiming to provide systems that precisely deliver required function and performance, as well as maximum energy efficiency. Manufacturer: Fläkt Woods Oy Kalevantie 39, FI Turku, Finland Tel info@flaktwoods.com
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