Danfoss Vlt aqua Guide

Contents

1 How to Read this Design Guide

1-1

Symbols 1-2

Abbreviations 1-3

Definitions 1-3

2 Introduction to the VLT AQUA Drive

2-1

CE labeling 2-3

Vibration and shock 2-6

Control Structures 2-11

General aspects of EMC 2-20

Immunity Requirements 2-24

Galvanic isolation (PELV) 2-25

PELV - Protective Extra Low Voltage 2-25

Ground leakage current 2-26

Control with brake function 2-27

Control with Brake Function 2-28

Mechanical brake control 2-28

Extreme running conditions 2-28

Safe Stop Operation (optional) 2-32

3 VLT AQUA Selection

3-1

General Specifications 3-1

Efficiency 3-19

Special Conditions 3-25

Options and Accessories 3-31

General Description 3-40

High Power Options 3-47

Installation of Duct Cooling Kit in Rittal Enclosures 3-47

Outside Installation/ NEMA 3R Kit for Rittal enclosures 3-49

Installation on Pedestal 3-51

Input Plate Option 3-53

Installation of Line Power Shield for Adjustable Frequency Drives 3-54

Frame size F Panel Options 3-55

4 How to Order

4-1

Ordering form 4-1

Type Code String 4-2

VLT

AQUA Drive Design Guide Contents

MG.20.N5.22 - VLT®is a registered Danfoss trademark

Ordering Numbers 4-6

5 How to Install

5-1

Mechanical Installation 5-1

Pre-installation 5-7

Planning the Installation Site 5-7

Receiving the Adjustable Frequency Drive 5-7

Transportation and Unpacking 5-7

Lifting 5-8

Cooling and Airflow 5-11

Electrical Installation 5-15

Connections - Frame sizes D, E and F 5-32

Power Connections 5-32

Disconnectors, circuit breakers and contactors 5-44

Final Set-Up and Test 5-46

Safe Stop Installation 5-47

Safe Stop Commissioning Test 5-48

Additional Connections 5-49

Installation of misc. connections 5-51

Safety 5-54

EMC-correct Installation 5-54

Residual Current Device 5-58

6 Application Examples

6-1

Potentiometer Reference 6-2

Automatic Motor Adaptation (AMA) 6-2

SLC Application Example 6-4

System Status and Operation 6-6

Cascade Controller Wiring Diagram 6-7

Fixed Variable Speed Pump Wiring Diagram 6-7

Lead Pump Alternation Wiring Diagram 6-8

7 RS-485 Installation and Set-up

7-1

RS-485 Installation and Set-up 7-1

FC Protocol Overview 7-4

Network Configuration 7-5

FC Protocol Message Framing Structure 7-5

Examples 7-12

Modbus RTU Overview 7-13

Contents VLT

AQUA Drive Design Guide

MG.20.N5.22 - VLT®is a registered Danfoss trademark

VLT AQUA with Modbus RTU 7-13

Modbus RTU Message Framing Structure 7-14

How to Access Parameters 7-19

Examples 7-20

Danfoss FC Control Profile 7-25

8 Troubleshooting

8-1

9 Index

9-1

VLT

AQUA Drive Design Guide Contents

MG.20.N5.22 - VLT®is a registered Danfoss trademark

Contents VLT

AQUA Drive Design Guide

MG.20.N5.22 - 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. By accepting and using this manual, the user agrees that the information contained herein

will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication

with Danfoss equipment over a serial communication link. This publication is protected under the copyright laws of Denmark and most other countries.

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

hardware and software environment.

Although Danfoss has tested and reviewed the documentation within this manual, Danfoss 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 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, Danfoss 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.

Danfoss 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.N5.22 - VLT®is a registered Danfoss trademark

1-1

1.1.2 Available Literature for VLT

AQUA DriveFC 200

-VLT®AQUA Drive Instruction Manual MG.20.Mx.yy provides the neccessary information for getting the drive up and running.

-VLT® AQUA Drive High Power Instruction Manual MG.20.Px.yy provides the neccessary information for getting the HP drive up and running.

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

-VLT® AQUA Drive Programming Guide MN.20.Ox.yy provides information on how to program 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

-Output Filters Design Guide MG.90.Nx.yy

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

-Application Note MN20A102: Submersible Pump Application

-Application Note MN20B102: Master/Follower Operation Application

-Application Note MN20F102: Drive Closed-loop and Sleep Mode

-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

Danfoss technical literature is also available online at

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

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 a default setting

1 How to Read this Design Guide VLT

AQUA Drive Design Guide

1-2

MG.20.N5.22 - 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 Adjustable frequency drive

Gram g

Hertz Hz

Kilohertz kHz

Local Control Panel LCP

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

Volt V

1.1.5 Definitions

Drive:

IVLT,MAX

The maximum output current.

IVLT,N

The rated output current supplied by the adjustable frequency drive.

UVLT, MAX

The maximum output voltage.

VLT

AQUA Drive Design Guide 1 How to Read this Design Guide

MG.20.N5.22 - VLT®is a registered Danfoss trademark

1-3

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.

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

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

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).

1 How to Read this Design Guide VLT

AQUA Drive Design Guide

1-4

MG.20.N5.22 - VLT®is a registered Danfoss trademark

ηVLT

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).

RefMAX

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.

RefMIN

Determines the relationship between the reference input at 0% value (typically 0 V, 0 mA, 4 mA) 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 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 power is transmitted to the brake resistor.

CT Characteristics

Constant torque characteristics used for positive displacement pumps and blowers.

VLT

AQUA Drive Design Guide 1 How to Read this Design Guide

MG.20.N5.22 - VLT®is a registered Danfoss trademark

1-5

Digital Inputs

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

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.

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 m] 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 in2(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 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 output frequency to match the varying load.

1 How to Read this Design Guide VLT

AQUA Drive Design Guide

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MG.20.N5.22 - VLT®is a registered Danfoss trademark

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