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 4
Definitions 5
2. Introduction to VLT AQUA Drive 11
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 43
General Specifications 43
Efficiency 57
Special Conditions 63
Options and Accessories 68
General Description 77
4. How to Order 83
Ordering form 83
Type Code String 84
Ordering Numbers 85
5. How to Install 93
Mechanical Installation 93
Electrical Installation 99
Final Set-Up and Test 116
Final Set-Up and Test 116
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AQUA Drive Design Guide Contents
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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
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AQUA Drive Design Guide
2 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.
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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
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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).
fM
The motor frequency.
fMAX
The maximum motor frequency.
fMIN
The minimum motor frequency.
fM,N
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The rated motor frequency (nameplate data).
IM
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).
UM
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).
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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.
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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..
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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 × 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 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 = 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 frequency converters' built-in DC coils produce a high power factor, which minimises the imposed load on the mains supply.
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2. Introduction to VLT AQUA Drive VLT
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