Danfoss vlt aqua User manual

VLT® AQUA Drive
Training Session Hand Outs
www.danfossdrives.com

Danfoss FC Drive LCP Display Layout
Danfoss FC drives have a total of 5 possible variables that can be set up and displayed to
the user. There is also a 3 word status line at the bottom of the display. The status line
tells you what the drive is doing, or being commanded to do.
These displays are very powerful tools for setting up and troubleshooting a system. It is
good practice to set them up when commissioning a drive. They are labeled “Display
Line 1.1 Small (P 0-20), “Display Line 1.2 Small (P 0-21), “Display Line 1.3 Small (P
0-22), Display Line 2 Large (P 0-23) and Display Line 3 Large (P 0-24).
The illustration below shows the layout of the displays. You can display the variables in
several different ways. Refer to the next page for the available display choices.
NOTE: Any variable that is being displayed on the LCP can also be shown as a graph using
Quick Menu “Q6 Loggings”
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These variables can be viewed temporarily using the given “Data Readout” parameters, or
set up on the display permanently in the “Operation / Display” (0-20) menu group
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Status Messages
As stated previously, the bottom line tells you the current status of the drive.
The first (left) word will appear as either “Hand”, “Off” or “Auto”. This indicates what
type of control the drive is set for. Hand means the drive is started locally by the LCP
“Hand On” button, and the speed is controlled by the up and down arrows. Auto means
the drive is setup to be controlled remotely via digital inputs or serial communication.
Off means the drive is not able to run in either mode.
The second (middle) word states where the drives reference comes from. The two
choices are “Local” and “Remote”. “Local” means the reference will be entered with the
LCP arrow keys. “Remote” means that the reference will either come from an external
source feeding an analog input, serial communication or a preset.
The last (right) word describes the state of the frequency converter. The charts on the
following pages give a description of these status words.
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Below are a list of the actual status words (far right on display) and what they mean
Operation Status
AC Brake
AC-Brake was selected in par. 2-10 Brake Function. The motor is slowed down via the active down
ramp and feeds the FC with generative energy. The AC Brake over-magnetizes the motor to achieve
a controlled end of the active ramp.
AMA finish OK
Enable complete or reduced AMA was selected in par. 1-29 Automatic Motor Adaptation (AMA).
The Automatic Motor Adaptation was carried out successfully.
AMA ready
Enable complete or reduced AMA was selected in par. 1-29 Automatic Motor Adaptation (AMA).
The Automatic Motor Adaptation is ready to start. Press [Hand On] on the LCP to start.
AMA running
Enable complete or reduced AMA was selected in par. 1-29 Automatic Motor Adaptation (AMA).
The AMA process is in progress.
Braking
The brake chopper is in operation. Generative energy is absorbed by the Brake resistor.
Braking max.
The brake chopper is in operation. The power limit for the brake resistor defined in par.
2-12 Brake Power Limit (kW) is reached.
Bus Jog 1
PROFIDrive profile was selected in par. 8-10 Control Word Profile. Via serial communication the
Jog 1 function is activated. The Motor is running with par. 8-90 Bus Jog 1 Speed.
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Bus Jog 2
PROFIDrive profile was selected in par. 8-10 Control Word Profile. Via serial communication the Jog 2
function is activated. The Motor is running with par. 8-91 Bus Jog 2 Speed.
Catch up
The output frequency is corrected by the value set in par. 3-12 Catch up/slow Down Value.
1. Catch up is selected as a function for a digital input (parameter group 5-1*). The corresponding
terminal is active.
2. Catch up was activated via serial communication.
Coast
1. Coast inverse has been selected as a function for a digital input (parameter group 5-1*).
The corresponding terminal (e.g. Terminal 27) is not connected to 24 volts.
2. Coast is on 0 on serial communication
Control ready
PROFIDrive profile was selected in par. 8-10 Control Word Profile. The FC needs the second part of
the two-part serial start command (e.g. 0x047F) via serial communication to allow starting. Using an
input terminal is not possible.
Ctrl. Ramp-down
A function with Ctrl. Ramp-down was selected in par. 14-10 Mains Failure. The Mains Voltage is
below the value set in par. 14-11 Mains Voltage at Mains Fault. The FC ramps down the motor
using a controlled ramp-down.
Current High
In par. 4-51 Warning Current High a current limit is set. It is displayed when the output current of the
FC is above this limit.
Current Low
In par. 4-52 Warning Speed Low a current limit is set. The output current of the FC is below this
limit.
DC Hold
The Motor is driven with a permanent DC current, par. 2-00 DC Hold Current. DC hold is selected
in par. 1-80 Function at Stop. A Stop command (e.g. Stop (inverse)) is active.
DC Stop
The Motor is momentarily driven with a DC current, par. 2-01 DC Brake Current, for a specified
time, par. 2-02 DC Braking Time.
1. DC-Brake is activated (OFF) in par. 2-03 DC Brake Cut In Speed [RPM] and a Stop command
(e.g. Stop (inverse)) is active.
2. DC Brake (inverse) is selected as a function for a digital input (parameter group 5-1*).
The corresponding terminal is not active.
3. The DC Brake is activated via serial communication.
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DC Voltage U0
In par. 1-01 Motor Control Principle U/f and in par. 1-80 Function at Stop DC-Voltage U0 is selected.
A Stop command (e.g. Stop (inverse)) is activated. The Voltage selected according to the
par. 1-55 U/f Characteristic - U [0] (U/f-Characteristic – U[V]) is applied to the Motor.
Feedback high
In par. 4-57 Warning Feedback High, an upper Feedback limit is set. The warning is displayed when
the sum of all active feedbacks is below this feedback limit.
Feedback low
In par. 4-56 Warning Feedback Low, a low Feedback limit is set. The warning is displayed when the
sum of all active feedbacks is below this feedback limit.
Flying start
In par. 1-73 Flying Start the Flying start function is activated. The FC is searching for the unknown
shaft speed of the connected motor, within the adjusted speed range. The process was started by
A start command, re-connecting a digital input (parameter group 5-1*) programmed as Coast inverse
or by connecting the Mains.
Freeze output
The remote reference is active and the momentarily given speed is saved.
1. Freeze output was selected as a function for a digital input (Group 5-1*). The corresponding terminal
is active. Speed control is only possible via the terminal functions “Speed up and Speed down”.
Freeze output request
A freeze output command has been given, but the motor will remain stopped until a Run permissive
signal is received via a digital input.
Freeze Ref.
Freeze Ref. was chosen as a function for a digital input (parameter group 5-1*). The corresponding
terminal is controlled. The FC saves the actual reference. Changing the reference is now only
possible via terminal functions Speed up and Speed down.
Jog request
A JOG command has been given, but the motor will be stopped until a Run permissive signal is
received via a digital input.
Jogging
The Motor is running with par. 3-19 Jog Speed [RPM].
1. Jog was selected as function for a digital input (parameter group 5-1*). The corresponding
terminal (e.g. Terminal 29) is active.
2. The Jog function is activated via the serial communication.
3. The Jog function was selected as a reaction for a monitoring function (e.g. No signal).
The monitoring function is active.
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Kinetic back-up
In par. 14-10 Mains Failure a function was set as Kinetic back-up. The Mains Voltage is below the value
set in par. 14-11 Mains Voltage at Mains Fault. The FC is running the motor momentarily
with kinetic energy from the inertia of the load.
Motor check (FC 100/200 only)
In par. 1-80 Function at Stop the function Motor check was selected. A stop command (e.g. Stop
inverse) is active. To ensure, that a Motor is connected to the FC a permanent test current is
applied to the Motor.
Off1
PROFIDrive profile was selected in par. 8-10 Control Word Profile. Via serial communication the
OFF 1 function is activated. The Motor is stopped via the ramp.
Off2
PROFIDrive profile was selected in par. 8-10 Control Word Profile. Via serial communication the
OFF 2 function is activated. The output of the FC is disabled immediately and the motor coasted.
Off3
PROFIDrive profile was selected in par. 8-10 Control Word Profile. Via serial communication the
OFF 3 function is activated. The Motor is stopped via the ramp.
OVC control
Over Voltage Control is activated in par. 2-17 Over-voltage Control. The connected Motor is supplying
the FC with generative energy. The Over Voltage Control is adjusting the U/f ratio, to run
the motor in controlled mode and to prevent the FC from tripping.
PowerUnit Off
Only with drives with installed Option (ext. 24 V supply). The mains supply to the drive is cut off,
but the control card is still supplied with 24 V.
Premagnetise
Pre-magnetisation is selected in par. 1-80 Function at Stop. A stop command (e.g. Stop inverse)
is activated. A suitable constant magnetising current is applied to the Motor.
Protection md
The FC 100/200/300 has detected a critical status (e.g. an over current, over voltage). To avoid
the drive to trip (Alarm) the Protection Mode was activated, which among others reduces the
switching frequency to 4 kHz. If possible, the protection mode ends after approximately 10 s.
Activation of the Protection Mode can be restricted by adjusting the par. 14-26 Trip Delay at
Inverter Fault.
Q-Stop
1. Quick stop inverse was chosen as a function for a digital input (parameter group 5-1*).
The corresponding terminal (e.g. Terminal 27) is not active.
2. The Quick stop function was activated via serial communication.
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Ramping
The motor is accelerating/decelerating using the active Up/Down ramp. The reference, a limit
value or a standstill is not yet reached.
Ref. high
In par. 4-55 Warning Reference High a reference high limit is set. The sum of all active references
is above the reference limit.2
Ref. low
In par. 4-55 Warning Reference High a reference low limit is set. The sum of all active references
is below the reference limit.
Run on ref.
The FC is running in the reference range. The feedback value matches the set reference value.
Run request (FC 100/200 only)
A start command has been given, but the motor will be stopped until a Run permissive signal is
received via digital input.
Running
The Motor is driven by the FC, the ramping phase is done and the motor revolutions are outside
the "On Reference" range. Occurs when one of the motor speed limits (Par. 4-11 / 4-12 / 4-13 or
4-14) is set, but the maximum reference is outside this range.
Sleep Boost (FC 100/200 only)
The boost function in parameter 406Boost setpoint is enabled. This function is only possible in
Closed loop operation.
Sleep Mode (FC 100/200 only)
The energy saving function in parameter 403Sleep mode timer is enabled. This means that at
present the motor has stopped, but that it will restart automatically when required.
Slow down
The output frequency is corrected by the value set in par. 3-12 Catch up/slow Down Value.
1. Slow down was selected as a function for a digital input (parameter group 5-1*). The corresponding
terminal is active.
2. Slow down was activated via serial communication.
Speed high
In par. 4-53 Warning Speed High a value is set. The speed of the motor is above this value.
Speed low
In par. 4-52 Warning Speed Low a value is set. The speed of the motor is below this value.
Standby
[Auto On] The FC starts the motor at a start signal on a digital input (if the parameter is programmed
accordingly) or via serial communication.
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Start delay
In par. 1-71 Start Delay, the delay of the starting time was set. A Start command was activated
and the delay time is still running. The Motor will start after the delay time has expired.
Start fwd/rev
Enable start forward and Enable start reverse were selected as functions for two different digital
inputs (parameter group 5-1*). To start the motor a direction dependent start signal has to be
given and the corresponding terminal has to be active.
Start inhibit
PROFIDrive profile was selected in par. 8-10 Control Word Profile. The start inhibition is active.
The FC needs the first part (e.g. 0x047E) of the two-part start command via serial communication
to allow starting. See also operation status control ready.
Stop
[Off] was pressed on the LCP or Stop inverse was selected as a function for a digital input (Group
5-1*). The corresponding terminal is not active.
Trip
An alarm occurred. It is possible, provided the cause of the alarm is cleared, to reset the alarm
via a Reset signal ([Reset]-Key on the LCP, a control terminal or serial communication).
Trip lock
A serious alarm occurred. It is possible, provided the cause of the alarm was cleared, to reset the
alarm after the mains have been switched off and on again. This can be done via a reset signal
([Reset] on the LCP, a control terminal or serial communication).
Unit/Drive not ready
PROFIDrive profile was selected in par. 8-10 Control Word Profile. A Control word is sent to the
FC via serial communication with Off 1, Off 2 and Off 3 active. Start inhibit is active. To enable
Start, see operation status Start inhibit.
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FC Series VFD Terminals
Power Terminals:
Line: 91, 92 & 93 (L1, L2 & L3)
Motor Connections: 96, 97 & 98 (U, V & W)
Chassis Ground: 95
DC BUS: 88 & 89
Braking Terminals: 81 & 82
Digital Inputs: 18, 19, 27, 29, 32 & 33 Digital Outputs: 27 & 29
Analog Inputs: 53 & 54 Analog Output: 42
Control Power Supplies:
24 volt supply on terminals 12 & 13
10 volt supply on terminal 50
Power supply commons (0V) are terminals 20, 39 & 55
Relays:
Relay 1 = 1, 2 & 3
Relay 2 = 4, 5 & 6
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Danfoss FC Series VFD Reference Handling
There are some distinct differences in the handling and setup of reference signals in the FC series drives
when compared to legacy products. This tutorial will explain how to interpret the reference parameters
and achieve the desired results.
The first step in the setup requires you to setup parameters in the 3-0 parameter group and enter your
desired minimum and maximum references, which can be entered in parameters 3-02 & 3-03. No
matter which reference unit you will be working in, these are the lowest and highest allowable values to
be commanded to the VFD.
Next, you must understand the relevance of parameter 3-04. There are two available choices here,
“Sum” & “External / Preset”
When “Sum” is selected, any terminal programmed as a reference resource, including digital inputs,
analog inputs, preset references or serial bus references will be added together to produce the total
allowable “Maximum Reference” set in parameter 3-03. Each of these different possible reference
resources can be scaled to produce a certain percentage of the maximum.
When “External / Preset” has been selected, the drive will respond to either only preset references, OR
the sum of all the external reference resources as described above. The drive will toggle between the two
through the use of a digital input, as shown below……..
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Now you need to define where your references will come from. This is done in the 3-1 parameter group.
Parameters 3-10, 3-15, 3-16 & 3-17 are all parameters will that allow you set up your reference sources.
If you want to use multiple reference points, then you must define them here. Most applications will
only use one reference terminal rather than multiples. If this is the case then set the single reference
source in 3-15, and program all other resources to “No Operation”. This is good practice because of the
“Sum” function described earlier. If other terminals are programmed as reference resources but not
actually used, any electrical noise that might ride on those terminals will be summed into the equation.
After the reference sources have been defined, the next step is to scale them. The analog inputs are
programmed in parameter group 6. For the example above, analog input 53 must now be scaled. You
will need to set a low and high voltage or current as well as a low and high reference value. See below;
Be aware that if multiple reference sources are chosen, then each can be scaled individually to
contribute the desired portion of your maximum reference. For example, AI 53 = 0-10 V = 0-50 Hz &
AI 54 = 0-10 V = 0-10 Hz. Now AI 53 will command the first 50 Hz and AI 54 will act as a trim for the
last 10 Hz.
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AQUA Drive Quick Startup Sheet
Set Main Menu parameter 0-03 to “North America”
Place a normally closed safety contact between control card terminals 12 &
27 or a jumper wire if a safety interlocks will not be used.
Set up the following Quick Menu Parameters in Q2
• 0-01 Language
• 0-02 Set to Hz
• 1-21 Motor Power
• 1-22 Motor Voltage
• 1-23 Motor Frequency
• 1-24 Motor Current
• 1-25 Motor Speed
• 3-41 Ramp 1 Ramp Up Time
• 3-42 Ramp 1 Ramp Down Time
• 4-11 Motor Speed Low Limit (Hz or RPM)
• 4-13 Motor Speed High Limit (Hz or RPM)
• 1-29 Set to “Enable Complete A.M.A.”Press Hand On to start tuning
• 5-40 Relay Function
Wire the VFD start contact between terminals 12 and 18
Wire the relays for VFD & fault status (P 5-40 sets function of relay)
Wire the speed reference on terminals 53 and 55 (+ on 53, common on 55)
(Remove the LCP and verify that the DIP switch for AI53 is set to the correct position. For
voltage signals it should be left in the default position, to the left. For current reference
signals move it to the right position.)
The drive is ready to run at this point. The parameters listed below may
enhance the setup and can be used if desirable.
-Flying Start P 1-73
-Broken Belt Detection P 22-60 & 22-61
-Speed Bypass Frequencies P 4-6
Parameter 0-50 to “All To LCP” to copy all parameters to the keypad
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VLT Aqua Drive Lab # 1
Introduction
In this lab you will set up a VLT Aqua drive to operate in “Hand Mode”. This is the
simplest form of operation and consists of using the drives LCP to operate the
drive manually. You will use the 12 parameter quick setup menu to set up the
basic parameters required for local control.
Behavioural Objectives
¾Learn how to access the FC-202’s software quick menus
¾Program & understand the 12 “Quick Setup” parameters
¾Run an “AMA” sequence to fine tune the connected motor
¾Start the drive and change it’s speed using the LCP (local control panel)
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Mechanical Setup
xPlug in the demo drives power cord into a 120 volt outlet
xConnect the motor to the drive. Drive terminals 96, 97 & 98 are
used for the motor connections. Also connect the motor ground
wire to the drive chassis.
xPlace a jumper wire between control card terminals 12 & 27.
Software Setup
You will want to start programming the drive from scratch. Performing an
“initialization” will reset all parameters back to the factory default. With power off,
simultaneously hold down the “status, main menu & OK” keys. Apply power and
continue to hold the buttons for at least 5 seconds after you apply power to the
drive. If you were successful, the display will read “Drive initialized [A80]. (setting
parameter 14-22 to “initialize” and cycling power is an alternative method)
After initializing the drive, the first change to be made is parameter # 0-03.
Changing this parameter to “North America” will set any regional parameters to
North American defaults.
Press the “Quick Menus” key, scroll down to Q2 with the arrow and press the
“OK” to enter the “Quick Setup” menu.
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There are 12 parameters in the quick menu. You can use the up and down arrow
keys to scroll through the following parameters. Using the motor nameplate data,
enter parameters 1-20 through 1-25 in ascending order. Set the remaining quick
menu parameters to the values shown in the list.
0-01 - Language
0-02 - Motor Speed Unit (Set to Hz)
1-21 - Motor Power
1-22 - Motor Voltage
1-23 - Motor Frequency
1-24 - Motor Current
1-25 - Motor Nominal Speed
3-41 - Ramp 1 Ramp Up Time - 10s (based on motor nameplate speed)
3-42 - Ramp 1 Ramp Down Time - 10s (based on motor nameplate speed)
4-12 - Motor Speed Low Limit - 20 Hz
4-14 - Motor Speed High Limit - 60 Hz
1-29 - Automatic Motor Adaptation - Choose “Enable complete “AMA” and then
press the “Hand On” key to start the process.
Note that any of these parameters can be accessed through the drives “Main Menu” as
well.
Verifying Operation
Pressing the “Hand On” key starts the drive. The bottom line (status line) of the
display should read “Hand Local Running”. This means that the drive is running,
but not at the commanded reference speed. This is because the drive is being
commanded to run at 0 Hz locally, but the drive will is running at 20 Hz because
of the programmed low speed limit. A different message will appear when the
actual speed matched the commanded speed. The low speed limit (parameter 4-
12) limits the minimum motor speed to protect pumps from running below the
manufacturers minimum recommended speed.
Use the arrow keys to enter a reference of something greater than 20 Hz into the
display. This will be the “local reference” speed that you want the drive to run at.
You should notice that the drive will ramp up to that speed following the
programmed ramp time that you entered in parameter 3-41. Notice the bottom
line of the display while this is happening. It will change from “Ramping” to
“Running on Ref” once it reaches the commanded speed.
Press the “Off” key on the LCP and you should notice the drive ramp down to a
stop following the ramp down time that you set in parameter 3-42. The status line
should now read “Off Local Stop” indicating that the off key was pressed and the
drive is in the “stop” condition.
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VLT AQUA Drive Lab # 2
(Open Loop Speed Control)
Introduction
In this lab you will set up a VLT AQUA drive to simulate a wastewater pumping application.
The drive will be set up in an open loop configuration. In an “open loop” configuration the
reference signal fed into the drive is directly proportional to the speed it will run at. The drive
will receive the control signals by means of a SCADA system. The SCADA system will
provide the VFD with an enable (safety) signal, a start stop command and the 0-10 volt speed
reference. The drive itself will have one relay output programmed to indicate when it is
running. For this lab, you will use the switch box found in your demo case to simulate the
SCADA signals. The instructor will explain how the switch boxes work before you begin the
lab.
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