Rosewood STP ST42 Manual

Queensland Urban Utilities
Rosewood Sewage Treatment Plant
Contract No. I112-025
A084 OM Manual.docx Revision A 25-Mar-13 Page 1
QUEENSLAND URBAN UTILITIES
Rosewood Sewage Treatment Plant
Stage 2a
A084 OPERATIONS & MAINTENANCE MANUAL
CONTRACT No. I112-025
Rosewood STP ST42 General (Operation and Maintenance Manual - Part 4:
Section 6.3 Manufacturers Manuals 6.3.33 Danfoss VLT Aquadrive 8000) Vendor Manual
QP Id: VM207
Active: 03/09/2013
Page 1 of 208

Queensland Urban Utilities
Rosewood Sewage Treatment Plant
Contract No. I112-025
A084 OM Manual.docx Revision A 25-Mar-13 Page 2
Table of Contents
Volume 1. INTRODUCTION, SYSTEM OVERVIEW, FUNCTIONAL SPEC, DESIGN 5
1.1 INTRODUCTION & SYSTEM OVERVIEW 5
1.2 LOCATION DETAILS & MAP 5
1.3DESCRIPTION OF EQUIPMENT & PROCESS 6
1.3.1 INLET WORKS 6
1.3.2 FLOW SPLITTER 6
1.3.3 SBR – SEQUENCING BATCH REACTOR 7
1.3.4 RETURN ACTIVATED SLUDGE (RAS) PUMP STATION 7
1.3.5 CHLORINE CONTACT TANK 8
1.3.6 WASTE ACTIVATED SLUDGE (WAS) PUMP STATION 8
1.3.7 SLUDGE THICKENER 8
1.3.8 CHLORINE STORAGE AND DOSING AREA 8
1.3.9 POLYELECTROLYTE STORAGE AND DOSING AREA 9
1.4 OPERATIONAL MODES 9
Volume 2. PROPRIETARY EQUIPMENT MANUALS, MAINTENANCE SERVICE, DATA
SHEETS 10
2.1 PROPRIETARY EQUIPMENT MANUALS 10
2.1.1 POLYMER DOSING SKID (GRUNDFOS) 10
2.1.2 SODIUM HYPOCHLORITE DOSING SKID (GRUNDFOS) 10
2.1.3 SCREEN EXTRACTOR (CST WASTEWATER SOLUTIONS) 10
2.1.4 LD300 LINEAR DECANTER (PROWATER) 10
2.1.5 MECHANICAL EQUIPMENT 10
2.1.6 ELECTRICAL EQUIPMENT 11
2.2 OPERATIONAL PROCEDURES 12
2.2.1 INLET WORKS 12
2.2.2 FLOW SPLITTER 12
2.2.3 SEQUENCING BATCH REACTOR (SBR) 13
2.2.4 RETURN ACTIVATED SLUDGE (RAS) PUMP STATION 15
2.2.5 CHLORINE CONTACT TANK (CCT) 15
2.2.6 WASTE ACTIVATED SLUDGE (WAS) PUMP STATION AND SLUDGE
THICKENER 16
2.2.7 CHLORINE STORAGE AND DOSING AREA 18
2.2.8 POLYELECTROLYTE STORAGE AND DOSING AREA 18
2.3 FAULT PROTECTION & RECTIFICATION 20
2.3.1 INLET WORKS 20
2.3.2 FLOW SPLITTER 20
2.3.3 SEQUENCING BATCH REACTOR (SBR) 21
2.3.4 RETURN ACTIVATED SLUDGE (RAS) PUMP STATION 22
2.3.5 CHLORINE CONTACT TANK (CCT) 22
Rosewood STP ST42 General (Operation and Maintenance Manual - Part 4:
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Queensland Urban Utilities
Rosewood Sewage Treatment Plant
Contract No. I112-025
A084 OM Manual.docx Revision A 25-Mar-13 Page 3
2.3.6 WASTE ACTIVATED SLUDGE (WAS) PUMP STATION AND SLUDGE
THICKENER 22
2.3.7 CHLORINE STORAGE AND DOSING AREA 23
2.3.8 POLYELECTROLYTE STORAGE AND DOSING AREA 23
2.4 START-UP & SHUT-DOWN PROCEDURES 24
2.5 ISOLATION & RESTORATION PROCEDURES 24
2.6 MAINTENANCE SCHEDULE 24
2.7 lIST OF SUB-CONTRACTORS & PROPRIETARY EQUIPMENT 37
2.8 RECOMMENDED SPARE PARTS & SPECIAL TOOLS 38
2.9 LIST OF MANUFACTURER & SUPPLIER DETAILS 41
Volume 3. DRAWINGS, DRAWING REGISTER, UNDERGROUND CABLE ROUTING
DETAILS 43
3.1 DRAWINGS REGISTER 43
3.2 ‘AS-CONSTRUCTED’ DRAWINGS 43
3.3 UNDERGROUND CABLE ROUTING DETAILS 43
Volume 4. INSTALLATION, PRE-COMMISSIONING, COMMISSIONING, SYSTEM
TESTING, TRAINING, METHOD STATEMENTS, Q.A. 144
4.1 COMMISSIONING PLAN 144
4.2 SITE ACCEPTANCE TESTING DOCUMENTATION 707
Volume 5. DESIGN REPORTS, APPROPRIATE RECORDS & APPENDICES 1079
5.1 DESIGN DETAILS 1079
5.2 DESIGN CRITERIA 1079
5.3 PROCESS DESIGN DESCRIPTION 1079
Volume 6. APPENDICES 1080
6.1 APPENDIX A - LOT REGISTER 1080
6.2 NOT USED 1086
6.3 APPENDIX C – MANUFACTURER O&M MANUALS 1087
Rosewood STP ST42 General (Operation and Maintenance Manual - Part 4:
Section 6.3 Manufacturers Manuals 6.3.33 Danfoss VLT Aquadrive 8000) Vendor Manual
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Queensland Urban Utilities
Rosewood Sewage Treatment Plant
Contract No. I112-025
A084 OM Manual.docx Revision A 25-Mar-13 Page 4
Revisions
Revision No.
Details
Date
Completed By
A
Draft
25/10/12
Daniel Hassed
B
Second Draft
25/01/13
Daniel Hassed
1.0
Finalised Manual
25/03/13
Daniel Hassed
Rosewood STP ST42 General (Operation and Maintenance Manual - Part 4:
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Q-Pulse Id
Manual Section
Link
TMS308
Operation and Maintenance Manual - Part 1: Sections 1.1 - 4.1
TMS308
TMS309
Operation and Maintenance Manual - Part 2: Section 4.2
TMS309
TMS310
Operation and Maintenance Manual - Part 3: Sections 5.1 - 6.2
TMS310
VM175
Manufacturers Manuals - Part 4: 6.3.1 Grundfos Sodium Hypochlorite
Dosing System
VM175
VM176
Manufacturers Manuals - Part 4: 6.3.2 Grundfos Polymer Dosing System
VM176
VM177
Manufacturers Manuals - Part 4: 6.3.3 CST Wastewater Screen Extractor
VM177
VM178
Manufacturers Manuals - Part 4: 6.3.4 LD300 Linear Decanter
VM178
VM179
Manufacturers Manuals - Part 4: 6.3.5 Amarex KRT Submersible Pump
VM179
VM180
Manufacturers Manuals - Part 4: 6.3.6 DW Vox Submersible Pump
VM180
VM181
Manufacturers Manuals - Part 4: 6.3.7 Sewatec Volute Casing Pump
VM181
VM182
Manufacturers Manuals - Part 4: 6.3.8 CST Rotary Drum Thickener
VM182
VM183
Manufacturers Manuals - Part 4: 6.3.9 Liquitek AquaDDM Mixer
VM183
VM184
Manufacturers Manuals - Part 4: 6.3.10 Liquitek FSS Aqua-Jet Aerators
VM184
VM185
Manufacturers Manuals - Part 4: 6.3.11 Tyco Class 16 FL-FL Gate Valve
VM185
VM186
Manufacturers Manuals - Part 4: 6.3.12 Dobbie Dico Reflux Valve
VM186
VM187
Manufacturers Manuals - Part 4: 6.3.13 Tyco Ball-Centric Valve
VM187
VM188
Manufacturers Manuals - Part 4: 6.3.14 Rotork IQT Actuator
VM188
VM189
Manufacturers Manuals - Part 4: 6.3.15 Grundfos AQC-D2 Measuring Cell
VM189
VM190
Manufacturers Manuals - Part 4: 6.3.16 Davey Sump Pump
VM190
VM191
Manufacturers Manuals - Part 4: 6.3.17 Amarex KRT Dry Installation Pump
VM191
VM192
Manufacturers Manuals - Part 4: 6.3.18Watts Series 009 RPZ Assembly
VM192
VM193
Manufacturers Manuals - Part 4: 6.3.19 Enware Emergency Shower
VM193
VM194
Manufacturers Manuals - Part 4: 6.3.20 ABB Electromagnetic Flowmeter
VM194
VM195
Manufacturers Manuals - Part 4: 6.3.21 Vegason 61 Level Transmitter
VM195
VM196
Manufacturers Manuals - Part 4: 6.3.22 Vegason 62 Level Transmitter
VM196
VM197
Manufacturers Manuals - Part 4: 6.3.23 COS61D Dissolved O2 Sensor
VM197
VM198
Manufacturers Manuals - Part 4: 6.3.24 FTS20 Level Switch
VM198
VM199
Manufacturers Manuals - Part 4: 6.3.25 Proline Promag 50W
Electromagnetic Flowmeter
VM199
VM200
Manufacturers Manuals - Part 4: 6.3.26 Turbimax CUS51D Turbidity Sensor
VM200
VM201
Manufacturers Manuals - Part 4: 6.3.27 Liquiline CM442 Multichannel
Controller
VM201
VM202
Manufacturers Manuals - Part 4: 6.3.28 Orbisint CPS12D ORP Sensor
VM202
VM203
Manufacturers Manuals - Part 4: 6.3.29 Grundfos Conex DIA-1 Controller
VM203
VM204
Manufacturers Manuals - Part 4: 6.3.30 Chloromax CCS142D Chlorine
Analyser
VM204
VM205
Manufacturers Manuals - Part 4: 6.3.31 Danfoss VLT Aquadrive FC200
VM205
VM206
Manufacturers Manuals - Part 4: 6.3.32 Danfoss VLT Soft Starter MCD500
VM206
VM207
Manufacturers Manuals - Part 4: 6.3.33 Danfoss VLT Aquadrive 8000
VM207
VM208
Manufacturers Manuals - Part 4: 6.3.34 Davey SS Vertical Multistage Pump
VM208
Rosewood STP ST42 General (Operation and Maintenance Manual - Part 4:
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Queensland Urban Utilities
Rosewood Sewage Treatment Plant
Contract No. I112-025
A084 OM Manual.docx Revision A 25 JAN 12 Page 82
6.3.33 Danfoss VLT Aquadrive 8000
Rosewood STP ST42 General (Operation and Maintenance Manual - Part 4:
Section 6.3 Manufacturers Manuals 6.3.33 Danfoss VLT Aquadrive 8000) Vendor Manual
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VLT®8000 AQUA
■Contents
Introduction ......................................................................................................... 4
Software version ...................................................................................................... 4
Definitions ................................................................................................................ 5
Safety regulations .................................................................................................... 7
Warning against unintended start ............................................................................. 7
Introduction to Instruction Manual ............................................................................ 9
Control principle ..................................................................................................... 10
AEO - Automatic Energy Optimization ................................................................... 11
Example of application - Constant pressure regulation in water supply system ..... 12
PC software and serial communication .................................................................. 13
PC Software tools .................................................................................................. 13
Serial communication options ................................................................................ 13
Profibus .................................................................................................................. 13
LON - Local Operating Network ............................................................................ 14
DeviceNet .............................................................................................................. 14
Modbus RTU ......................................................................................................... 14
Cascade Controller Option ..................................................................................... 17
Unpacking and ordering an AFD ............................................................................ 24
Type code ordering number string ........................................................................ 24
TYPE CODE Table/Ordering form .......................................................................... 27
Installation ......................................................................................................... 28
General technical data ........................................................................................... 28
Technical data, line supply 3 x 200 - 240 V ........................................................... 33
Technical data, line supply 3 x 380 - 480 V ......................................................... 35
Technical data, line supply 3 x 525 - 600 V ........................................................... 40
Fuses ..................................................................................................................... 43
Mechanical dimensions .......................................................................................... 45
Mechanical installation ........................................................................................... 49
IP 00 VLT 8450-8600 380-480 V .......................................................................... 51
General information about electrical installation ...................................................... 52
High voltage warning ............................................................................................. 52
Grounding .............................................................................................................. 52
Cables .................................................................................................................... 52
Shielded/armored cables ....................................................................................... 52
Extra protection with regard to indirect contact ...................................................... 53
RFI switch .............................................................................................................. 53
High voltage test .................................................................................................... 56
Heat emission from VLT 8000 AQUA ..................................................................... 56
EMC-correct electrical installation .......................................................................... 56
Earthing/Grounding of shielded/armored control cables ......................................... 59
Electrical installation, enclosures ............................................................................ 60
Use of EMC-correct cables .................................................................................... 68
Tightening torque and screw sizes ......................................................................... 69
Line connection ..................................................................................................... 70
Motor connection ................................................................................................... 70
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VLT®8000 AQUA
DC bus connection ................................................................................................ 72
High-voltage relay .................................................................................................. 72
Electrical installation, control cables ....................................................................... 72
Switches 1-4 .......................................................................................................... 73
Connection example VLT 8000 AQUA ................................................................... 75
Control unit LCP .................................................................................................... 78
Control keys for parameter setup ........................................................................... 78
Indicator lamps ...................................................................................................... 79
Local control .......................................................................................................... 79
Display mode ......................................................................................................... 80
Navigation between display modes ........................................................................ 81
Changing data ....................................................................................................... 83
Manual initialization ................................................................................................. 83
Quick Menu ........................................................................................................... 84
Programming .................................................................................................... 86
Operation and Display 001-017 ............................................................................. 86
The Setup configuration ......................................................................................... 86
Setup of user-defined readout ............................................................................... 87
Load and motor 100-124 ...................................................................................... 93
Configuration .......................................................................................................... 93
Motor power factor (Cos ø) .................................................................................... 99
References and limits 200-228 ............................................................................ 102
Reference handling .............................................................................................. 102
Reference type ..................................................................................................... 106
Initial ramp parameter 229 ................................................................................... 110
Fill Mode .............................................................................................................. 111
Fill Rate parameter 230 ........................................................................................ 111
Filled Setpoint parameter 231 .............................................................................. 112
Inputs and outputs 300-328 ................................................................................ 113
Analog inputs ....................................................................................................... 116
Analog/digital outputs ........................................................................................... 120
Relay outputs ....................................................................................................... 123
Application functions 400-434 ............................................................................. 127
Sleep mode ......................................................................................................... 128
PID for process control ........................................................................................ 133
PID overview ........................................................................................................ 135
Feedback handling ............................................................................................... 135
Serial communication for FC protocol .................................................................. 142
Protocols .............................................................................................................. 142
Telegram communication ..................................................................................... 142
Telegram build-up under FC protocol .................................................................. 143
Data character (byte) ............................................................................................ 144
Process word ....................................................................................................... 148
Control word as per FC protocol ......................................................................... 149
Status word as per FC protocol ........................................................................... 150
Serial communication 500-556 ............................................................................ 153
Warning words 1+2 and Alarm word ................................................................... 161
Service functions 600-631 ................................................................................... 163
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VLT®8000 AQUA
Electrical installation of the relay card ................................................................... 168
All about VLT 8000 AQUA ......................................................................... 170
Status messages .................................................................................................. 170
List of warnings and alarms ................................................................................. 172
Special conditions ................................................................................................ 177
Aggressive environments ...................................................................................... 177
Calculation of resulting reference ......................................................................... 178
Extreme running conditions .................................................................................. 180
Peak voltage on motor ......................................................................................... 180
Derating for ambient temperature ........................................................................ 182
Switching on the input ......................................................................................... 182
Efficiency .............................................................................................................. 184
Line supply interference/harmonics ...................................................................... 184
CE labelling .......................................................................................................... 186
EMC test results (Emission, Immunity) .................................................................. 187
EMC Immunity .................................................................................................... 189
Factory settings .................................................................................................... 191
Index .................................................................................................................... 200
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VLT®8000 AQUA
176FA145.13
VLT 8000 AQUA
Instruction Manual
Software version: 1.5x
This Instruction Manual can be used for all VLT 8000 AQUA,
AFDs (Adjustable Frequency Drives) with software version
1.5x.
The software version number can be seen from parameter 624
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VLT®8000 AQUA
Introduction
■Definitions
Definitions are given in alphabetical order.
AEO:
Automatic Energy Optimization – function that
dynamically adjusts the voltage supplied to a
variable torque load to optimize motor power
factor and motor efficiency.
AFD:
Adjustable Frequency Drive; also known as VFDs,
(Variable Frequency Drives).
Analog inputs:
The analog inputs can be used for controlling
various functions of the AFD. There are two
types of analog inputs:
Current input, 0-20 mA
Voltage input, 0-10 V DC.
Analog reference:
A signal transmitted to input 53, 54 or 60.
Can be voltage or current.
Analog outputs:
There are two analog outputs, which are able to
supply a signal of 0-20 mA, 4-20 mA or a digital signal.
Automatic motor adjustment, AMA:
Automatic motor adjustment algorithm, which
determines the electrical parameters for the
connected motor, at standstill.
AWG:
Means American Wire Gauge.
Control command:
By means of the control unit and the digital inputs,
it is possible to start and stop the connected
motor. Functions are divided into two groups,
with the following priorities:
Group 1 Reset, Coasting stop, Reset and
Coasting stop, DC braking, Stop
and the [OFF/ STOP] key.
Group 2 Start, Pulse start, Reversing, Start
reversing, Jog and Freeze output
Group 1 functions are called Start-disable commands.
The difference between group 1 and group 2 is that
in group 1 all stop signals must be cancelled for the
motor to start. The motor can then be started by
means of a single start signal in group 2.
A stop command given as a group 1 command
results in the display indication STOP. A missing
stop command given as a group 2 command results
in the display indication STAND BY.
CT:
Constant torque: used for e.g. heavy, solid
sludge pumps and centrifuges.
Digital inputs:
The digital inputs can be used for controlling
various functions of the AFD.
Digital outputs:
There are four digital outputs, two of which activate
a relay switch. The outputs are able to supply a 24
V DC signal at a maximum load or 24mA.
fJOG
TheoutputfrequencyfromtheAFDtransmittedto
the motor when the jog function is activated (via
digital terminals or serial communication).
fM
The output frequency from the AFD transmitted
to the motor.
fM,N
The rated motor frequency (nameplate data).
fMAX
Maximum output frequency transmitted to the motor.
fMIN
Minimum output frequency transmitted to the motor.
IM
The current transmitted to the motor.
IM,N
The rated motor current (nameplate data).
Initializing:
If Initializing is carried out (see parameter 620 Operating
mode), the AFD returns to the factory setting.
IVLT,MAX
The maximum output current.
IVLT,N
The rated output current supplied by the AFD.
LCP:
The control panel, which makes up a complete interface
for control and programming of VLT 8000 AQUA.
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VLT®8000 AQUA
The control panel is detachable and may, as
an alternative, be installed up to 10 feet away
from the AFD, i.e. in a front panel, by means
of the installation kit option.
LSB:
Least significant bit.
Used in serial communication.
MCM:
Stands for Mille Circular Mil, an American measuring
unit for cable cross-section.
MSB:
Most significant bit.
Used in serial communication.
nM,N
The rated motor speed (nameplate data).
ηVLT
The efficiency of the AFD is defined as the ratio
between the power output and the power input.
On-line/off-line parameters:
On-line parameters are activated immediately after the
data value is changed. Off-line parameters are not
activated until OK has been entered on the control unit.
PCB: Printed circuit board.
PELV: Protective extra low voltage.
PID:
The PID regulator maintains the desired speed
(pressure, temperature, etc.) by adjusting the output
frequency to match the varying load.
PM,N
The rated power delivered by the motor
(nameplate data).
Preset reference:
A permanently defined reference, which can be
set from -100% to +100% of the reference range.
There are four preset references, which can be
selected via the digital terminals.
RefMAX
The maximum value which the reference
signal may have. Set in parameter 205
Maximum reference, RefMAX.
RefMIN
The smallest value which the reference signal may have.
Set in parameter 204 Minimum reference, RefMIN.
Setup:
There are four Setups, in which it is possible to
save parameter settings. It is possible to change
between the four parameter Setups.
Start-disable command:
A stop command that belongs to group 1 of the
control commands - see this group.
Stop command:
See Control commands.
Thermistor:
A temperature-dependent resistor placed where the
temperature is to be monitored (AFD or motor).
Trip:
A state which occurs in different situations, e.g.
if the AFD is subjected to an overtemperature.
A trip can be cancelled by pressing reset or,
in some cases, automatically.
Trip locked:
A state which occurs in different situations, e.g.
if the AFD is subject to an overtemperature. A
locked trip can be cancelled by removing line power,
then reapplying it and starting the.
U/F:
Voltage to frequency ratio that is supplied to the motor.
UM
The voltage transmitted to the motor.
UM,
The rated motor voltage (nameplate data).
UVLT, MAX
The maximum output voltage.
VFD:
See AFD.
VT characteristics:
Variable torque characteristics, used for
centrifugal pumps and fans.
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VLT®8000 AQUA
Introduction
The voltage of the adjustable frequency
drive is dangerous whenever the equipment
is connected to line. Incorrect installation
of the motor or the AFD may cause damage to the
equipment, serious personal injury or death.
Consequently, the instructions in this manual,
as well as national and local rules and safety
regulations, must be complied with.
■Safety regulations
1. The AFD must be disconnected from the line
if repair work is to be carried out.
Check that the line supply has been disconnected
and that the necessary time has passed before
removing motor and line plugs.
2. The [OFF/STOP] key on the control panel of the
AFD does not disconnect the equipment from line
and is thus not to be used as a safety switch.
3. Correct protective earthing/grounding of the
equipment must be established, the user must be
protected against supply voltage, and the motor
must be protected against overload in accordance
with the National Electrical Code and local codes.
4. The ground leakage currents are higher than 3.5mA.
5. Protection against motor overload is not included
in the factory setting. If this function is required,
set parameter 117, Motor thermal protection,to
data value ETR trip or data value ETR warning.
Note: The function is initialised at 1.0 x rated motor
current and rated motor frequency (see parameter
117, Motor thermal protection).InUL/cUL
applications ETR provides Class 20, over-load
protection in accordance with the NEC ®.
6. Do not remove the plugs for the motor and
line supply while the AFD is connected to line.
Check that the line supply has been disconnected
and that the necessary time has passed before
removing motor and line plugs.
7. Please note that the AFD has more voltage inputs
than L1, L2, L3 when the DC-bus terminals
or AUX 24 V option are used.
Check that all voltage inputs have been
disconnected and that the necessary time has
passed before repair work is commenced.
■Warning against unintended start
1. The motor can be brought to a stop by means
of digital commands, bus commands, references
or a local stop, while the AFD is connected to
line. If personal safety considerations make it
necessary to ensure that no unintended start
occurs, these stop functions are not sufficient.
2. While parameters are being changed, the motor
may start. Consequently, the stop key [OFF/
STOP] must always be activated, following
which data can be modified.
3. A stopped motor may start if a fault occurs in
the electronics of the AFD, or if a temporary
overload or a fault in the supply line or the
motor connection ceases.
176FA159.13
Warning:
Touching the electrical parts may be fatal - even after the equipment has
been disconnected from line.
VLT 8006-8062, 200-240 V: wait at least 15 minutes
VLT 8006-8072, 380-480 V: wait at least 15 minutes
VLT 8102-8352, 380-480 V: wait at least 20 minutes
VLT 8450-8600, 380-480 V: wait at least 15 minutes
VLT 8002-8006, 525-600 V: wait at least 4 minutes
VLT 8008-8027, 525-600 V: wait at least 15 minutes
VLT 8032-8072, 525-600 V: wait at least 30 minutes
VLT 8052-8402, 525-690 V: wait at least 20 minutes
■Use on isolated line
See section RFI Switch regarding use on isolated line.
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Page 13 of 208

VLT®8000 AQUA
It is the responsibility of the user or the
person installing the VLT to provide proper
earthing/grounding, as well as motor
overload and branch circuit protection according to
local codes such as the Nation Electrical Code (NEC).
NOTE
Electrostatic Precaution; Electrostatic discharge
(ESD). Many electronic components are
sensitive to static electricity. Voltages so low
that they cannot be felt, seen or heard, can reduce
the life, affect performance, or completely destroy
sensitive electronic components. When performing
service, proper ESD equipment should be used to
prevent possible damage from occurring.
The Adjustable Frequency Drive contains
dangerous voltages when connected
to line voltage. After disconnecting
from the line wait at least
15 minutes for VLT 8006-8062, 200-240 V
15 minutes for VLT 8006-8072, 380-480 V
20 minutes for VLT 8102-8352, 380-480 V
15 minutes for VLT 8450-8600, 380-480 V
4 minutes for VLT 8002-8006, 525-600 V
15 minutes for VLT 8008-8027, 525-600 V
30 minutes for VLT 8032-8300, 525-600 V
before touching any electrical components. Also
make sure that other voltage inputs have been
disconnected, such as external 24 VDC and
load-sharing (linkage of DC intermediate circuit). Only
a competent electrician should carry out the electrical
installation. Improper installation of the motor or the
VLT may cause equipment failure, serious injury or
death. Follow this manual and National Electrical
Codes (NEC) and local safety codes.
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VLT®8000 AQUA
Introduction
■Introduction to Instruction Manual
This Instruction Manual is divided into four sections
with information about VLT 8000 AQUA.
Introduction to AQUA: This section tells you the advantages you can obtain by using a VLT
8000 AQUA - such as Automatic Energy Optimization, Constant
Torque or Variable Torque and other AQUA relevant functions.
This section also contains examples of applications as well as
information about Danfoss.
Installation: This section tells you how to carry out a mechanically correct
installation of the VLT 8000 AQUA.
Furthermore, a list is given of line and motor connections, together with
a description of the control card terminals.
Programming: This section describes the control unit and the software parameters
for the VLT 8000 AQUA. Also included is a guide to the Quick Setup
menu, which allows you to get started on your application very quickly.
All about VLT 8000 AQUA: This section gives information about status, warning and error
messages from the VLT 8000 AQUA. Additionally, information is given
on technical data, ser-vice, factory settings and special conditions.
NOTE
Indicates something to be noted by the reader.
Indicates a general warning
Indicates a high-voltage warning
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VLT®8000 AQUA
■Control principle
An AFD rectifies AC voltage from line into DC voltage,
after which this DC voltage is converted into a AC
current with a variable amplitude and frequency.
The motor is thus supplied with variable voltage and
frequency, which enables infinitely variable speed
control of three-phased, standard AC motors.
1. Line voltage
3 x 200 - 240 V AC, 50 / 60 Hz.
3 x 380 - 480 V AC, 50 / 60 Hz.
3 x 525 - 600 V AC, 50 / 60 Hz.
2. Rectifier
A three-phase rectifier bridge that rectifies AC
current into DC current.
3. Intermediate circuit
DC voltage = 1.35 x line voltage [V].
4. Intermediate circuit coils
Even out the intermediate circuit voltage and reduce
the harmonic current feedback to the line supply.
5. Intermediate circuit capacitors
Even out the intermediate circuit voltage.
6. Inverter
Converts DC voltage into variable AC voltage
with a variable frequency.
7. Motor voltage
Variable AC voltage, 0-100% of line supply voltage.
8. Control card
This is where to find the computer that controls
the inverter which generates the pulse pattern by
which the DC voltage is converted into variable
AC voltage with a variable frequency.
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Rosewood STP ST42 General (Operation and Maintenance Manual - Part 4:
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VLT®8000 AQUA
Introduction
■AEO - Automatic Energy Optimization
AEO is intended for use on Variable Torque single
motor applications. Normally, the U/f characteristics
have to be set on the basis of the expected load at
different frequencies. However, knowing the load
at a given frequency in an installation is often a
problem. This problem can be solved by using a
VLT 8000 AQUA with its integral Automatic Energy
Optimization (AEO), which ensures optimum energy
utilization. All VLT 8000 AQUA units feature this
function as a factory setting, i.e. it is not necessary to
adjust the AFD U/f ratio in order to obtain maximum
energy savings. In other AFDs, the given load and
voltage/frequency ratio (U/f) must be assessed to
carry out correct setting of the AFD.
Using Automatic Energy Optimization (AEO), you
no longer need to calculate or assess the system
characteristics of the installation, since Danfoss VLT
8000 AQUA units guarantee optimum, load-dependent
energy consumption by the motor at all times.
The figure on the right illustrates the working
range of the AEO function, within which energy
optimization is enabled.
If the AEO function has been selected in parameter
101, Torque characteristics, this function will be
constantly active. If there is a major deviation from the
optimum U/f ratio, the AFD will quickly adjust itself.
Advantages of the AEO function
•Automatic energy optimization
•Compensation if an oversize motor is used
•AEO matches operations to daily or
seasonal fluctuations
•Energy savings in a constant volume system
•Compensation in the oversynchronous
working range
•Reduces acoustic motor noise
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VLT®8000 AQUA
■Example of application - Constant pressure
regulation in water supply system
The demand for water from waterworks varies considerably during the course of a day. In the night,
practically no water is used, while in the morning and in the evening the consumption is high. In order to
maintain a suitable pressure in the water supply lines in relation to the current demand, the water supply
pumps are equipped with speed control. The use of AFD’s enables the energy consumed by the pumps to
be kept at a minimum, while optimizing the water supply to consumers.
A VLT 8000 AQUA with its integral PID controller ensures simple and quick installation. For example, an
IP54/NEMA 12 unit can be mounted close to the pump on the wall and the existing line cables can be used
as line supply to the AFD. A Pressure transmitter (e.g. Danfoss MBS 33 or MBS 3000) can be fitted a
few meters (feet) from the joint outlet point from the waterworks to obtain closed loop regulation. Danfoss
MBS 33 and MBS 3000 is a two-wire transmitter (4-20 mA) that can be powered directly from a VLT 8000
AQUA. The required setpoint (e.g. 5 bar) can be set locally in parameter 418 Setpoint 1.
Assume:
Transmitter is scaled 0-10 Bar, minimum flow
is achieved at 30 Hz. An increase in motor
speed increases the pressure.
Set the following parameters:
Par. 100 Configuration Closed loop [1]
Par. 201 Minimum Output Frequency 30 Hz
Par. 202 Maximum Output Frequency 50 Hz (or 60 Hz)
Par. 204 Minimum Reference 0 Bar
Par. 205 Maximum Reference 10 Bar
Par. 302 Terminal 18 Digital inputs Start [1]
Par. 314 Terminal 60, analog input current Feedback signal [2]
Par. 315 Terminal 60, min. scaling 4 mA
Par. 316 Terminal 60, max. scaling 20 mA
Par. 403 Sleep mode timer 10 sec.
Par. 404 Sleep frequency 15 Hz
Par. 405 Wake-up frequency 20 Hz
Par. 406 Boost setpoint 125%
Par. 413 Minimum Feedback 0 Bar
Par. 414 Maximum Feedback 10 Bar
Par. 415 Process units Bar [16]
Par. 418 Setpoint 1 5 bar
Par. 420 PID control action Normal
Par. 423 PID Proportional gain 0.3*
Par. 424 PID Integral time 30 sec.*
* The PID tuning parameters depend on the actual system dynamics.
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VLT®8000 AQUA
Introduction
■PC software and serial communication
Danfoss offers various options for serial
communication. Using serial communication,
it is possible to monitor, program, and control
one or several adjustable frequency drives from
a centrally located computer.
All VLT 8000 AQUA units have an RS-485 port as
standard with a choice of two protocols. The protocols
selectable in parameter 500 protocols are:
•FC Protocol
•Modbus RTU
A bus option card allows higher transmission speed
than RS-485. In addition, a higher number of units
can be linked to the bus and alternative transmission
media can be used. Danfoss offers the following
option cards for communication:
•Profibus
•LonWorks
•DeviceNet
Information on the installation of various options is
not included in this Instruction Manual.
Using the RS-485 port enables communication,
e.g. with a PC. A Windows TM program, called
MCT 10, is available for this purpose. It can
be used to monitor, program, and control one
or several VLT 8000 AQUA units.
■PC Software tools
PC Software - MCT 10
All drives are equipped with a serial communication
port. WeprovideaPCtoolforcommunication
between PC and adjustable frequency drive, VLT
Motion Control Tool MCT 10 Set-up Software.
MCT 10 Set-up Software
MCT 10 has been designed as an easy-to-use
interactive tool for setting parameters in our
adjustable frequency drives.
The MCT 10 Set-up Software will be useful for:
•Planning a communication network off-line.
MCT 10 contains a complete adjustable
frequency drive database
•Commissioning adjustable frequency drives on line
•Saving settings for all adjustable frequency drives
•Replacing a drive in a network
•Expanding an existing network
•Future developed drives will be supported
MCT10Set-upSoftwaresupportProfibusDP-V1via
a Master class 2 connection. It makes it possible to
on-line read/write parameters in a adjustable frequency
drive via the Profibus network. This will eliminate the
need for an extra communication network.
The MCT 10 Set-up Software Modules
The following modules are included in the
software package:
MCT 10 Set-up Software
Setting parameters
Copy to and from adjustable
frequency drives
Documentation and print out of
parameter settings incl. diagrams
SyncPos
Creating SyncPos program
Ordering number:
Please order your CD containing MCT 10 Set-up
Software using code number 130B1000.
■Serial communication options
The increasing need for information in building
management systems makes it necessary to collect or
visualize many different types of process data.
Important process data can help the system technician
in the day-to-day monitoring of the system, which
means that a negative development, e. g. an increase
in energy consumption, can be rectified in time.
The substantial amount of data in large buildings
may generate a need for a higher transmission
speed than 9600 baud.
■Profibus
Profibus is a serial communication system with FMS
and DP, which can be used for linking automation
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VLT®8000 AQUA
units, such as sensors and actuators, to the controls
by means of a two-conductor cable.
Profibus FMS is used if major communication
tasks are to be solved at cell- and system-level
by means of large volumes of data.
Profibus DP is an extremely fast communication
protocol, made specially for communication between
the automation system and various units.
VLT 8000 AQUA only supports DP.
■LON - Local Operating Network
LonWorks is an intelligent serial communication system
which improves the possibility of decentralizing control,
as communication is enabled between individual
units in the same system (Peer-to-Peer).
This means that there is no need for a large main
station for handling all the signals of the system
(Master-Slave). Signals are sent directly to the unit
that needs them via a common network medium.
This makes communication much more flexible and
the central building state control and monitoring
system can be changed into a dedicated building
state monitoring system whose task is to ensure that
everything is running as planned. If the potential
of LonWorks is fully utilized, sensors will also be
connected to the bus, which means that a sensor signal
can quickly be moved to another controller. If room
dividers are mobile, this is a particularly useful feature.
■DeviceNet
DeviceNet is a digital, multi-drop network, based
on the CAN protocol, that connects and serves
as a communication network between industrial
controllers and I/O devices.
Each device and/or controller is a node on the
network. DeviceNet is a producer-consumer
network that supports multiple communication
hierarchies and message prioritization.
DeviceNet systems can be configured to operate in a
master-slave or a distributed control architecture using
peer-to-peer communication. This system offers a
single point of connection for configuration and control
by supporting both I/O and explicit messaging.
DeviceNet also has the feature of having power
on the network. This allows devices with limited
power requirements to be powered directly from
the network via the 5-conductor cable.
■Modbus RTU
MODBUS RTU (Remote Terminal Unit) Protocol is
a messaging structure developed by Modicon in
1979, used to establish master-slave/client-server
communication between intelligent devices.
MODBUS is used to monitor and program
devices; to communicate intelligent devices
with sensors and instruments; to monitor field
devices using PCs and HMIs.
MODBUS is often applied in gas and oil
applications, but applications in building,
infrastructure, transportation, and energy are
also making use of its benefits.
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