Danfoss Vlt aqua Guide

Contents

1. How to Read this Design Guide

Approvals 4

Symbols 4

Abbreviations 4

Definitions 5

2. Introduction to VLT AQUA Drive

CE labelling 12

Air humidity 15

Aggressive Environments 15

Vibration and shock 15

VLT AQUA Controls 20

PID 22

General aspects of EMC 31

Immunity Requirements 34

Galvanic isolation (PELV) 35

PELV - Protective Extra Low Voltage 35

Earth leakage current 36

Control with brake function 37

Mechanical brake control 38

Extreme running conditions 38

Safe Stop Operation (optional) 41

3. VLT AQUA Selection

General Specifications 43

Efficiency 57

Special Conditions 63

Options and Accessories 68

General Description 77

4. How to Order

Ordering form 83

Type Code String 84

Ordering Numbers 85

5. How to Install

Mechanical Installation 93

Electrical Installation 99

Final Set-Up and Test 116

VLT

AQUA Drive Design Guide Contents

MG.20.N4.02 - VLT®is a registered Danfoss trademark

Safe Stop Installation 117

Safe Stop Commissioning Test 118

Additional Connections 118

DC bus connection 118

Brake Connection Option 119

Relay Connection 120

Installation of misc. connections 124

Safety 126

EMC-correct Installation 127

Residual Current Device 131

6. Application Examples

133

Potentiometer Reference 134

Automatic Motor Adaptation (AMA) 134

SLC Application Example 135

System Status and Operation 138

Cascade Controller Wiring Diagram 138

Fixed Variable Speed Pump Wiring Diagram 139

Lead Pump Alternation Wiring Diagram 140

Submersible Pump Application 142

Master/Follower Operation Application 143

7. RS-485 Installation and Set-up

147

RS-485 Installation and Set-up 147

FC Protocol Overview 149

Network Configuration 150

FC Protocol Message Framing Structure 150

Examples 155

Modbus RTU Overview 156

VLT AQUA with Modbus RTU 156

Modbus RTU Message Framing Structure 156

How to Access Parameters 161

Examples 162

Danfoss FC Control Profile 168

8. Troubleshooting

173

Index

177

Contents VLT

AQUA Drive Design Guide

MG.20.N4.02 - 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 . By accepting and using this manual the user agrees that the information contained herein will be

used solely for operating equipment from or equipment from other vendors provided that such equipment is intended for communication with equipment

over a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries.

does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical, hardware

or software environment.

Although has tested and reviewed the documentation within this manual, 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 be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information

contained in this manual, even if advised of the possibility of such damages. In particular, is not responsible for any costs, including but not limited to

those incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these,

or any claims by third parties.

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.

VLT

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

MG.20.N4.02 - VLT®is a registered Danfoss trademark

1.1.2. Available Literature for VLT AQUA Drive

-VLT® AQUA Drive Operating Instructions MG.20.Mx.yy provide the neccessary information for getting the drive up and running.

-VLT® AQUA Drive Design Guide MG.20.Nx.yy entails all technical information about the drive and customer design and applications.

-VLT® AQUA Drive Programming Guide MN.20.Ox.yy provides information on how to programme and includes complete parameter descriptions.

-VLT® AQUA Drive FC 200 Profibus MG.33.Cx.yy

-VLT® AQUA Drive FC 200 DeviceNet MG.33.Dx.yy

-VLT® AQUA Drive FC 200 Cascade Controller MI.38.Cx.yy

-Application Note MN20B102: Master/Follower Operation Application

-Application Note MN20A102: Submersible Pump Application

-Instruction MI.38.Bx.yy: Installation Instruction for Mounting Brackets Enclosure type A5, B1, B2, C1 and C2 IP21, IP55 or IP66

-Instruction MI.90.Lx.yy: Analog I/O Option MCB109

-Instruction MI.33.Hx.yy: Panel through mount kit

x = Revision number

yy = Language code

technical literature is also available online at

www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm

1.1.3. Approvals

1.1.4. Symbols

Symbols used in this guide.

NB!

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.N4.02 - VLT®is a registered Danfoss trademark

1.1.5. 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

Meter m

Millihenry 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

Regenerative terminals Regen

Second s

Synchronous Motor Speed ns

Torque limit TLIM

Volts V

1.1.6. Definitions

Drive:

IVLT,MAX

The maximum output current.

IVLT,N

The rated output current supplied by the frequency converter.

UVLT, MAX

The maximum output voltage.

Input:

Control command

You can start and stop the connected motor by means

of LCP and the digital inputs.

Functions are divided into two groups.

Functions in group 1 have higher priority than functions

in group 2.

Grou

p 1

Reset, Coasting stop, Reset and Coasting stop,

Quick-stop, DC braking, Stop and the "Off" key.

Grou

p 2

Start, Pulse start, Reversing, Start reversing, Jog

and Freeze output

Motor:

fJOG

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

The motor frequency.

fMAX

The maximum motor frequency.

fMIN

The minimum motor frequency.

fM,N

VLT

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

MG.20.N4.02 - VLT®is a registered Danfoss trademark

The rated motor frequency (nameplate data).

The motor current.

IM,N

The rated motor current (nameplate data).

nM,N

The rated motor speed (nameplate data).

PM,N

The rated motor power (nameplate data).

TM,N

The rated torque (motor).

The instantaneous motor voltage.

UM,N

The rated motor voltage (nameplate data).

ηVLT

The efficiency of the frequency converter is defined as the ratio between the power output and the power input.

Start-disable command

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

Stop command

See Control commands.

References:

Analog Reference

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

Bus Reference

A signal transmitted to the serial communication port (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).

1. How to Read this Design Guide VLT

AQUA Drive Design Guide

MG.20.N4.02 - VLT®is a registered Danfoss trademark

RefMAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA) and the resulting reference. The maximum

reference value set in par. 3-03.

RefMIN

Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4mA) and the resulting reference. The minimum reference value

set in par. 3-02.

Miscellaneous:

Analog Inputs

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

There are two types of analog inputs:

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

Voltage input, 0-10 V DC.

Analog Outputs

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

Automatic Motor Adaptation, AMA

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

Brake Resistor

The brake resistor is a module capable of absorbing the brake power generated in regenerative braking. This regenerative braking power increases the

intermediate circuit voltage and a brake chopper ensures that the power 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 frequency converter.

Digital Outputs

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

DSP

Digital Signal Processor.

VLT

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

MG.20.N4.02 - VLT®is a registered Danfoss trademark

Relay Outputs:

The frequency converter 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)

Initialising

If initialising is carried out (par. 14-22), the programmable parameters of the frequency converter return to their default settings.

Intermittent Duty Cycle

An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an off-load period. The operation can be either

periodic duty or none-periodic duty.

LCP

The Local Control Panel (LCP) makes up a complete interface for control and programming of the frequency converter. The control panel is detachable

and can be installed up to 3 metres from the frequency converter, i.e. in a front panel by means of the installation kit option.

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 ≡0.5067 mm2.

msb

Most significant bit.

NLCP

Numerical Local Control Panel LCP101

On-line/Off-line Parameters

Changes to on-line parameters are activated immediately after the data value is changed. Changes to off-line parameters are not activated until you enter

[OK] on the LCP.

PID Controller

The PID controller maintains the desired speed, pressure, temperature, etc. by adjusting the output frequency to match the varying load.

RCD

Residual Current Device.

Set-up

You can save parameter settings in four Set-ups. Change between the four parameter Set-ups and edit one Set-up, while another Set-up is active.

SFAVM

Switching pattern called S tator F lux oriented A synchronous V ector M odulation (par. 14-00).

Slip Compensation

The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor

speed almost constant..

1. How to Read this Design Guide VLT

AQUA Drive Design Guide

MG.20.N4.02 - VLT®is a registered Danfoss trademark

Smart Logic Control (SLC)

The SLC is a sequence of user defined actions executed when the associated user defined events are evaluated as true by the SLC.

Thermistor:

A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).

Trip

A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency converter is protecting the

motor, process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating reset or, in

some cases, by being programmed to reset automatically. Trip may not be used for personal safety.

Trip Locked

A state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention, e.g. if the frequency converter is

subject to a short circuit on the output. A locked trip can only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the

frequency converter. Restart is prevented until the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically.

Trip locked may not be used for personal safety.

VT Characteristics

Variable torque characteristics used for pumps and fans.

VVCplus

If compared with standard voltage/frequency ratio control, Voltage Vector Control (VVCplus) improves the dynamics and the stability, both when the speed

reference is changed and in relation to the load torque.

60° AVM

Switching pattern called 60°A synchronous V ector M odulation (par. 14-00).

1.1.7. Power Factor

The power factor is the relation between I1and IRMS.

Power

factor

3 ×

1 ×

COS

3 ×

IRMS

The power factor for 3-phase control:

1×

cos

ϕ1

IRMS

since

cos

ϕ1=1

The power factor indicates to which extent the frequency converter im-

poses a load on the mains supply.

The lower the power factor, the higher the IRMS for the same kW per-

formance.

IRMS

7+ . . +

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

The frequency converters' built-in DC coils produce a high power factor, which minimises the imposed load on the mains supply.

VLT

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

MG.20.N4.02 - VLT®is a registered Danfoss trademark

2. Introduction to VLT AQUA Drive VLT

AQUA Drive Design Guide

MG.20.N4.02 - VLT®is a registered Danfoss trademark

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