Danfoss Vlt aqua Guide

Contents

1. How to Read this Design Guide

Approvals 4

Symbols 4

Abbreviations 5

Definitions 5

2. Introduction to the VLT AQUA Drive

Disposal Instructions 12

CE labeling 13

Air humidity 15

Aggressive Environments 15

Vibration and shock 16

VLT AQUA Controls 20

PID 22

General aspects of EMC 32

Galvanic isolation (PELV) 35

Ground leakage current 36

Control with brake function 36

Mechanical brake control 38

Extreme running conditions 38

Safe Stop Operation 40

3. VLT AQUA Selection

General Specifications 43

Line Supply 3 x 200-240 V AC 43

Line Supply 3 x 380-480 V AC 47

Efficiency 55

Special Conditions 60

Purpose of derating 60

Automatic adaptations to ensure performance 63

Mechanical Dimension 64

Options and Accessories 65

Analog I/O option MCB 109 71

4. How to Order

Ordering form 77

VLT

AQUA Drive Design Guide Contents

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

Type Code String 78

Ordering Numbers 79

5. How to Install

Mechanical Installation 83

Accessory Bag 83

Electrical Installation 85

Removal of Knockouts for Extra Cables 85

Access to Control Terminals 92

Electrical Installation, Control Terminals 93

Final Set-Up and Test 97

Safe Stop Installation 99

Safe Stop Commissioning Test 100

Additional Connections 100

Installation of misc. connections 104

Safety 107

EMC-correct Installation 108

Residual Current Device 112

6. Application Examples

113

7. RS-485 Installation and Set-up

123

RS-485 Installation and Set-up 123

FC Protocol Overview 126

Network Configuration 127

FC Protocol Message Framing Structure 127

Examples 133

Modbus RTU Overview 135

VLT AQUA with Modbus RTU 136

Modbus RTU Message Framing Structure 136

How to Access Parameters 141

Examples 142

Danfoss FC Control Profile 148

8. Troubleshooting

155

Index

162

Contents VLT

AQUA Drive Design Guide

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

1. How to Read this Design Guide

1.1.1. Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to Danfoss A/S. By accepting and using this

manual, the user agrees that the information contained herein will be used solely for operating

equipment from Danfoss A/S or equipment from other vendors, provided that such equipment is

intended for communication with Danfoss equipment over a serial communication link. This pub-

lication is protected under the copyright laws of Denmark and most other countries.

Danfoss A/S does not guarantee that a software program produced according to the guidelines

provided in this manual will function properly in every physical, hardware or software environment.

Although Danfoss A/S has tested and reviewed the documentation within this manual,

Danfoss A/S makes no warranty or representation, neither expressed nor implied, with respect to

this documentation, including its quality, performance or fitness for a particular purpose.

In no event shall Danfoss A/S be liable for direct, indirect, special, incidental or consequential

damages arising from the use or the inability to use information contained in this manual, even if

advised of the possibility of such damages. In particular, Danfoss A/S is not responsible for any

costs, including, but not limited to, those incurred as a result of lost profits or revenue, loss of or

damages to equipment, loss of computer programs, loss of data, the costs to substitute these, or

any claims by third parties.

Danfoss A/S reserves the right to revise this publication at any time and to make changes to its

contents without prior notice or any obligation to notify former or present users of such revisions

or changes.

This design guide will introduce all aspects of your VLT AQUA Drive.

Available literature for the VLT AQUA

Drive

-The Instruction Manual MG.20.MX.YY provides the necessary information for getting the

drive up and running.

-Drive Design Guide MG.20.NX.YY contains all the technical information about the drive,

customer design and applications.

-Programming Guide MG.20.0X.YY provides information on how to program and includes

complete parameter descriptions.

X = Revision number

YY = Language code

Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/

DrivesSolutions/Documentations/Technical+Documentation.

VLT

AQUA Drive Design Guide 1. How to Read this Design Guide

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

1.1.2. Approvals

1.1.3. Symbols

Symbols used in this guide.

NOTE

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

*Indicates default setting

1. How to Read this Design Guide VLT

AQUA Drive Design Guide

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

1.1.4. Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Automatic Motor Adaptation AMA

Current limit ILIM

Degrees Celsius °C

Direct current DC

Drive Dependent D-TYPE

Electro Magnetic Compatibility EMC

Electronic Thermal Relay ETR

drive FC

Gram g

Hertz Hz

Kilohertz kHz

Local Control Panel LCP

Meter m

Milli Henry Inductance mH

Milliampere mA

Millisecond ms

Minute min

Motion Control Tool MCT

Nanofarad nF

Newton Meters Nm

Nominal motor current IM,N

Nominal motor frequency fM,N

Nominal motor power PM,N

Nominal motor voltage UM,N

Parameter par.

Protective Extra Low Voltage PELV

Printed Circuit Board PCB

Rated Inverter Output Current IINV

Revolutions Per Minute RPM

Second s

Torque limit TLIM

Volt V

1.1.5. Definitions

Drive:

VLT,MAX

The maximum output current.

VLT,N

The rated output current supplied by the adjustable frequency drive.

VLT, MAX

The maximum output voltage.

Input:

Control command

You can start and stop the connected motor using

the LCP and the digital inputs.

Functions are divided into two groups.

Functions in group 1 have higher priority than

functions in group 2.

Group 1 Reset, Coasting stop, Reset and Coasting

stop, Quick stop, DC braking, Stop and the

"Off" key.

Group 2 Start, Pulse start, Reversing, Start reversing,

Jog and Freeze output

VLT

AQUA Drive Design Guide 1. How to Read this Design Guide

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

Motor:

JOG

The motor frequency when the jog function is activated (via digital terminals).

The motor frequency.

MAX

The maximum motor frequency.

MIN

The minimum motor frequency.

M,N

The rated motor frequency (nameplate data).

The motor current.

M,N

The rated motor current (nameplate data).

M,N

The rated motor speed (nameplate data).

M,N

The rated motor power (nameplate data).

M,N

The rated torque (motor).

The instantaneous motor voltage.

M,N

The rated motor voltage (nameplate data).

1. How to Read this Design Guide VLT

AQUA Drive Design Guide

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

VLT

The efficiency of the adjustable frequency drive is defined as the ratio between the power output

and the power input.

Start-disable command

A stop command belonging to the group 1 control commands - see this group.

Stop command

See Control commands.

References:

Analog Reference

A signal transmitted to the analog inputs 53 or 54 can be voltage or current.

Bus Reference

A signal transmitted to the serial communication port (FC port).

Preset Reference

A defined preset reference to be set from -100% to +100% of the reference range. Selection of

eight preset references via the digital terminals.

Pulse Reference

A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33).

Ref

MAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V,

20 mA) and the resulting reference. The maximum reference value set in par. 3-03.

Ref

MIN

Determines the relationship between the reference input at 0% value (typically 0V, 0 mA, 4 mA)

and the resulting reference. The minimum reference value set in par. 3-02.

VLT

AQUA Drive Design Guide 1. How to Read this Design Guide

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

Miscellaneous:

Analog Inputs

The analog inputs are used for controlling various functions of the adjustable frequency drive.

There are two types of analog inputs:

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

Voltage input, 0-10 V DC.

Analog Outputs

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

Automatic Motor Adaptation, AMA

AMA algorithm determines the electrical parameters for the connected motor at standstill.

Brake Resistor

The brake resistor is a module capable of absorbing the braking energy generated in regenerative

braking. This regenerative braking energy increases the intermediate circuit voltage, and a brake

chopper ensures that the energy is transmitted to the brake resistor.

CT Characteristics

Constant torque characteristics used for positive displacement pumps and blowers.

Digital Inputs

The digital inputs can be used for controlling various functions of the adjustable frequency drive.

Digital Outputs

The drive features two solid state outputs that can supply a 24 V DC (max. 40 mA) signal.

DSP

Digital Signal Processor.

Relay Outputs:

The adjustable frequency drive features two programmable relay outputs.

ETR

Electronic Thermal Relay is a thermal load calculation based on present load and time. Its purpose

is to estimate the motor temperature.

GLCP:

Graphical Local Control Panel (LCP102)

Initializing

If initializing is carried out (par. 14-22), the programmable parameters of the adjustable frequency

drive return to their default settings.

Intermittent Duty Cycle

An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load

and an off-load period. The operation can be either periodic duty or non-periodic duty.

1. How to Read this Design Guide VLT

AQUA Drive Design Guide

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

LCP

The Local Control Panel (LCP) makes up a complete interface for control and programming of the

adjustable frequency drive. The control panel is detachable and can be installed up to 9.8 ft (3

meters) from the adjustable frequency drive, i.e. in a front panel by means of the installation kit

option.

The local control panel is available in two versions:

-Numerical LCP101 (NLCP)

-Graphical LCP102 (GLCP)

lsb

Least significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM 0.00079≡

in.

(0.5067 mm

msb

Most significant bit.

NLCP

Numerical Local Control Panel LCP101

Online/Offline Parameters

Changes to online parameters are activated immediately after the data value is changed. Changes

to offline parameters are not activated until you enter [OK] on the LCP.

PID Controller

The PID controller maintains the desired speed, pressure, temperature, etc. by adjusting the out-

put frequency to match the varying load.

RCD

Residual Current Device.

Set-up

You can save parameter settings in four set-ups. Change between the four parameter set-ups and

edit one set-up while another set-up is active.

SFAVM

Switching pattern called Stator Flux oriented Asynchronous Vector Modulation (par. 14-00).

Slip Compensation

The adjustable frequency drive compensates for the motor slip by giving the frequency a supple-

ment that follows the measured motor load, thus keeping the motor speed almost constant.

Smart Logic Control (SLC)

The SLC is a sequence of user-defined actions executed when the associated user-defined events

are evaluated as true by the SLC.

VLT

AQUA Drive Design Guide 1. How to Read this Design Guide

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

Thermistor:

A temperature-dependent resistor placed where the temperature is to be monitored (adjustable

frequency drive or motor).

Trip

A state entered in fault situations, such as when the adjustable frequency drive is subject to an

overtemperature, or when the adjustable frequency drive is protecting the motor, process or

mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is

cancelled by activating reset or, in some cases, by being programmed to reset automatically. Trip

may not be used for personal safety.

Trip-Locked

A state entered in fault situations when the adjustable frequency drive is protecting itself and

requires physical intervention, such as when it is subject to a short circuit on the output. A locked

trip can only be cancelled by cutting off AC line power, removing the cause of the fault, and

reconnecting the adjustable frequency drive . Restart is prevented until the trip state is cancelled

by activating reset or, in some cases, by being programmed to reset automatically. The trip-lock

function may not be used as a personal safety measure.

VT Characteristics

Variable torque characteristics used for pumps and fans.

VVCplus

Compared with standard voltage/frequency ratio control, Voltage Vector Control (VVC

plus

) im-

proves the dynamics and the stability, both when the speed reference is changed and in relation

to the load torque.

60° AVM

Switching pattern called 60° Asynchronous Vector Modulation (par. 14-00).

1.1.6. Power Factor

The power factor is the relation between I

and I

RMS

Power factor

3×

1×

COS

3×

IRMS

The power factor for 3-phase control:

1×

cos

ϕ1

IRMS

since cos

ϕ1=1

The power factor indicates to which extent the

adjustable frequency drive imposes a load on

the line supply.

The lower the power factor, the higher the

RMS

for the same kW performance.

IRMS

7+..+

In addition, a high power factor indicates that the different harmonic currents are low.

The adjustable frequency drive's built-in DC coils produce a high power factor, which minimizes

the imposed load on the line power supply.

1. How to Read this Design Guide VLT

AQUA Drive Design Guide

MG.20.N2.22 - VLT®is a registered Danfoss trademark.

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