Danfoss vlt aqua Guide

Contents
1. How to Read this Design Guide
3
Copyright, Limitation of Liability and Revision Rights 3
Approvals 4
Symbols 4
Abbreviations 5
Definitions 5
2. Introduction to the VLT AQUA Drive 11
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 43
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 77
Ordering form 77
VLT
®
AQUA Drive Design Guide Contents
MG.20.N2.22 - VLT®is a registered Danfoss trademark. 1

Type Code String 78
Ordering Numbers 79
5. How to Install 83
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
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
2 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
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AQUA Drive Design Guide 1. How to Read this Design Guide
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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
4 MG.20.N2.22 - VLT®is a registered Danfoss trademark.
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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:
I
VLT,MAX
The maximum output current.
I
VLT,N
The rated output current supplied by the adjustable frequency drive.
U
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
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Motor:
f
JOG
The motor frequency when the jog function is activated (via digital terminals).
f
M
The motor frequency.
f
MAX
The maximum motor frequency.
f
MIN
The minimum motor frequency.
f
M,N
The rated motor frequency (nameplate data).
I
M
The motor current.
I
M,N
The rated motor current (nameplate data).
n
M,N
The rated motor speed (nameplate data).
P
M,N
The rated motor power (nameplate data).
T
M,N
The rated torque (motor).
U
M
The instantaneous motor voltage.
U
M,N
The rated motor voltage (nameplate data).
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AQUA Drive Design Guide
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η
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.
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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.
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AQUA Drive Design Guide
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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.
2
(0.5067 mm
2
).
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.
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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
1
and I
RMS
.
Power factor =
3× U × I
1× COS ϕ
3× U × IRMS
The power factor for 3-phase control:
=
I
1×
cos ϕ1
IRMS
=
I
1
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
I
RMS
for the same kW performance.
IRMS = I
2
1+
I
2
5+
I
2
7+..+
I
2
n
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.
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®
AQUA Drive Design Guide
10 MG.20.N2.22 - VLT®is a registered Danfoss trademark.
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