Page 1 Contents Contents 1 How to Read this Design Guide Copyright, Limitation of Liability and Revision Rights Symbols Abbreviations Definitions 2 Introduction to the VLT AQUA Drive CE labeling Vibration and shock Control Structures 2-11 General aspects of EMC 2-20 Immunity Requirements...
Page 2: Table Of Contents
Fixed Variable Speed Pump Wiring Diagram Lead Pump Alternation Wiring Diagram 7 RS-485 Installation and Set-up RS-485 Installation and Set-up FC Protocol Overview Network Configuration FC Protocol Message Framing Structure Examples 7-12 Modbus RTU Overview 7-13 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 3 ® AQUA Drive Design Guide Contents VLT AQUA with Modbus RTU 7-13 Modbus RTU Message Framing Structure 7-14 How to Access Parameters 7-19 Examples 7-20 Danfoss FC Control Profile 7-25 8 Troubleshooting 9 Index ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 4 ® Contents AQUA Drive Design Guide ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 5: How To Read This Design Guide
Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former or present users of such revisions or changes.
Page 6: Symbols
Instruction MI.38.Bx.yy: Installation Instruction for Mounting Brackets Enclosure type A5, B1, B2, C1 and C2 IP21, IP55 or IP66 Instruction MI.90.Lx.yy: Analog I/O Option MCB109 Instruction MI.33.Hx.yy: Panel through mount kit x = Revision number yy = Language code Danfoss technical literature is also available online at www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm 1.1.3 Symbols Symbols used in this guide. NOTE! Indicates something to be noted by the reader.
Page 7: Abbreviations
Synchronous Motor Speed Torque limit Volt 1.1.5 Definitions Drive: VLT,MAX The maximum output current. VLT,N The rated output current supplied by the adjustable frequency drive. VLT, MAX The maximum output voltage. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 8 The rated motor current (nameplate data). The rated motor speed (nameplate data). The rated motor power (nameplate data). The rated torque (motor). The instantaneous motor voltage. The rated motor voltage (nameplate data). ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 9 The brake resistor is a module capable of absorbing the braking energy generated in regenerative braking. This regenerative braking energy increases the intermediate circuit voltage and a brake chopper ensures that the power is transmitted to the brake resistor. CT Characteristics Constant torque characteristics used for positive displacement pumps and blowers. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 10 Changes to on-line parameters are activated immediately after the data value is changed. Changes to offline parameters are not activated until you enter [OK] on the LCP. PID Controller The PID controller maintains the desired speed, pressure, temperature, etc., by adjusting the output frequency to match the varying load. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 11 ) 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). ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 12 In addition, a high power factor indicates that the different harmonic currents are low. The built-in DC coils in the adjustable frequency drive produce a high power factor, which minimizes the imposed load on the line power supply. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 13: Introduction To The Vlt Aqua Drive
Installation at High Altitudes At altitudes higher than 6,600 feet [2 km], please contact Danfoss regarding PELV. 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 adjustable frequency drive is connected to line power.
Page 14 ® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide 2.1.2 Caution The adjustable frequency drive DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard, disconnect the adjustable frequency drive from line power before carrying out maintenance. Wait at least as follows before...
Page 15: Ce Labeling
Adjustable frequency drives must be CE-labeled in accordance with the Low-voltage Directive of January 1, 1997. The directive applies to all electrical equipment and appliances used in the 50–1,000 V AC and the 75 –1,500 V DC voltage ranges. Danfoss CE labels in accordance with the directive and issues a declaration of conformity upon request.
Page 16 Danfoss CE labels the adjustable frequency drives in accordance with the low-voltage directive. This means that if the adjustable frequency drive is installed correctly, we guarantee compliance with the low-voltage directive. Danfoss issues a declaration of conformity that confirms our CE labeling in accordance with the low-voltage directive.
Page 17 It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer. As an aid to the installer, Danfoss has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for power EMC Immunity drive systems are complied with, provided that the EMC-correct instructions for installation are followed;...
Page 18: Vibration And Shock
® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide 2.6 Vibration and shock The adjustable frequency drive has been tested according to the procedure based on the shown standards: The adjustable frequency drive complies with requirements that exist for units mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors.
Page 19 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive 2.7.3 Example of Energy Savings As can be seen from the figure (the laws of proportionality), the flow is controlled by changing the RPM. By reducing the rated speed by only 20%, the flow is also reduced by 20%.
Page 20 ® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide Energy savings shaft shaft output Flow distribution over 1 year ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 21 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive Distribution Valve regulation Adjustable frequency drive control Hours Power Consumption Power Consumption 42.5 18.615 42.5 18.615 1314 38.5 50.589 29.0 38.106 1752 35.0 61.320 18.5 32.412 1752 31.5 55.188...
Page 22 ® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide 2.7.7 Star/delta starter or soft-starter not required When larger motors are started, it is necessary in many countries to use equipment that limits the start-up current. In more traditional systems, a star/ delta starter or soft-starter is widely used.
Page 23: Control Structures
® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive 2.8 Control Structures 2.8.1 Control Principle Figure 2.3: Control structures. The adjustable frequency drive is a high performance unit for demanding applications. It can handle various kinds of motor control principles such as U/ f special motor mode and VVC plus and can handle normal squirrel cage asynchronous motors.
Page 24 ® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide 2.8.3 Local (Hand On) and Remote (Auto On) Control The adjustable frequency drive can be operated manually via the local control panel (LCP) or remotely via analog/digital inputs or serial bus.
Page 25 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive NOTE! While the default values for the drive’s closed-loop controller will often provide satisfactory performance, the control of the system can often be optimized by adjusting some of the closed-loop controller’s parameters. It is also possible to autotune the PI constants.
Page 26 ® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide Multi Setpoint Min Multi Setpoint Maximum [13] is selected, the setpoint/feedback pair with the largest difference controls the speed of the drive. [14] Multi Setpoint Min attempts to keep all zones at or below their respective setpoints, while [13] attempts to keep all zones at or above their respective setpoints.
Page 27 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive 2.8.7 Reference Handling Details for Open-loop and Closed-loop Operation A block diagram of how the drive produces the Remote Reference is shown below:. 2-15 ® MG.20.N5.22 - VLT...
Page 28 ® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide The Remote Reference is comprised of: • Preset references. • External references (analog inputs, pulse frequency inputs, digital potentiometer inputs and serial communication bus references). • The preset relative reference.
Page 29 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive 1. Start/Stop via switch connected between terminals 12 (+24 V) and 18. 2. Pressure reference via a potentiometer (0–10 Bar, 0–10 V) connected to terminals 50 (+10 V), 53 (input) and 55 (common).
Page 30 ® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide 2.8.9 Programming Order Function Par. no. Setting 1) Make sure the motor runs properly. Do the following: Set the drive to control the motor based on drive output fre- 0-02 quency.
Page 31 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive 2.8.10 Tuning the Drive Closed-loop Controller Once the drive’s closed-loop controller has been set up, the performance of the controller should be tested. In many cases, its performance may be acceptable using the default values of PID Proportional Gain (par.
Page 32: General Aspects Of Emc
® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide 2.9 General aspects of EMC 2.9.1 General Aspects of EMC Emissions Electrical interference is usually conducted at frequencies in the range of 150 kHz to 30 MHz. Airborne interference from the drive system in the range of 30 MHz to 1 GHz is generated from the inverter, motor cable and motor.
Page 33 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive 2.9.2 Emission Requirements According to the EMC product standard for adjustable speed adjustable frequency drives EN/IEC61800-3:2004, the EMC requirements depend on the intended use of the adjustable frequency drive. Four categories are defined in the EMC product standard. The definitions of the four categories together...
Page 34 ® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide 2.9.3 EMC Test Results (Emission) The following test results were obtained using a system with an adjustable frequency drive (with options, if relevant), a shielded control cable, a control box with potentiometer, as well as a motor and motor-shielded cable.
Page 35 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive NOTE! Some of the harmonic currents might disturb communication equipment connected to the same transformer or cause resonance in connection with power-factor correction batteries. NOTE! To ensure low harmonic currents, the adjustable frequency drive is standard-equipped with intermediate circuit coils. This normally reduces the input current I by 40%.
Page 36: Immunity Requirements
The immunity requirements for adjustable frequency drives depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss adjustable frequency drives comply with the requirements for the industrial environment and consequently comply also with the lower requirements for home and office environment with a large safety margin.
Page 37: Galvanic Isolation (Pelv)
® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive See following EMC immunity form. Voltage range: 200–240 V, 380–480 V Basic standard Burst Surge Radiated electromagnetic field RF common IEC 61000-4-4 IEC 61000-4-5 IEC 61000-4-3 mode voltage...
Page 38: Ground Leakage Current
Installation at high altitude: 380–500 V, enclosure A, B and C: At altitudes above 6,500 ft [2 km], please contact Danfoss regarding PELV. 380–500 V, enclosure D, E and F: At altitudes above 10,000 ft [3 km], please contact Danfoss regarding PELV.
Page 39: Control With Brake Function
(as part of the total cycle time) Danfoss offers brake resistors with a duty cycle of 5%, 10% and 40%, which are all suitable for use with the FC202 AQUA drive series. If a 10% duty cycle resistor is applied, it is capable of absorbing braking energy up to 10% of the cycle time, with the remaining 90% being used to dissipate heat from the resistor.
Page 40: Control With Brake Function
® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide 2.13.2 Control with Brake Function The brake is protected against short-circuiting of the brake resistor, and the brake transistor is monitored to ensure that short-circuiting of the transistor is detected.
Page 41 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive High Temperature High ambient temperature may overheat the adjustable frequency drive. Line Drop-out During a line drop-out, the adjustable frequency drive keeps running until the intermediate circuit voltage drops below the minimum stop level, which is typically 15% below the adjustable frequency drive's lowest rated supply voltage.
Page 42 AQUA Drive Design Guide 2.15.1 Motor Thermal Protection This is the way Danfoss is protecting the motor from being overheated. It is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in the following figure: Figure 2.6: The X-axis show the ratio between I...
Page 43 ® AQUA Drive Design Guide 2 Introduction to the VLT AQUA Drive Using a digital input and 10 V as power supply: Example: The adjustable frequency drive trips when the motor temper- ature is too high. Parameter set-up: Set par. 1-90...
Page 44: Safe Stop Operation (Optional)
® 2 Introduction to the VLT AQUA Drive AQUA Drive Design Guide NOTE! ETR is activated in par. and is controlled in par. 4-16 Torque Limit Motor Mode . The time before the torque limit warning trips the adjustable frequency Trip Delay at Torque Limit drive is set in par.
Page 45: Vlt Aqua Selection
® AQUA Drive Design Guide 3 VLT AQUA Selection 3 VLT AQUA Selection 3.1 General Specifications ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 46 ® 3 VLT AQUA Selection AQUA Drive Design Guide ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 47 ® AQUA Drive Design Guide 3 VLT AQUA Selection ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 48 ® 3 VLT AQUA Selection AQUA Drive Design Guide ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 49 ® AQUA Drive Design Guide 3 VLT AQUA Selection ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 50 ® 3 VLT AQUA Selection AQUA Drive Design Guide ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 51 ® AQUA Drive Design Guide 3 VLT AQUA Selection ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 52 ® 3 VLT AQUA Selection AQUA Drive Design Guide ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 53 ® AQUA Drive Design Guide 3 VLT AQUA Selection ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 54 ® 3 VLT AQUA Selection AQUA Drive Design Guide 3-10 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 55 ® AQUA Drive Design Guide 3 VLT AQUA Selection 3-11 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 56 ® 3 VLT AQUA Selection AQUA Drive Design Guide 3-12 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 57 ® AQUA Drive Design Guide 3 VLT AQUA Selection 3-13 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 58 5°C]. An overload temperature cannot be reset until the temperature of the heatsink is below 158°F ± 9°F [70°C ± 5°C] (Guideline - these temperatures may vary for different power sizes, enclosures etc.). VLT AQUA Drive has an auto derating function to avoid it's heatsink reaching 203°F [95°C].
Page 59 3 VLT AQUA Selection Cable lengths and cross-sections: Max. motor cable length, shielded/armored VLT AQUA Drive: 492 ft [150 m] Max. motor cable length, unshielded/unarmored VLT AQUA Drive: 984 ft [300 m] Max. cross-section to motor, line power, load sharing and brake * Maximum cross-section to control terminals, rigid wire 0.0023 in...
Page 60 ® 3 VLT AQUA Selection AQUA Drive Design Guide Digital inputs: Programmable digital inputs 4 (6) Terminal number 18, 19, 27 , 29 , 32, 33, Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic'0' PNP < 5 V DC Voltage level, logic'1' PNP >...
Page 61 ® AQUA Drive Design Guide 3 VLT AQUA Selection Max. terminal load (DC-1) on 4-5 (NO) (Resistive load) 80 V DC, 2 A Max. terminal load (DC-13) on 4-5 (NO) (Inductive load) 24 V DC, 0.1A Max. terminal load (AC-1)
Page 62 The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is not galvanically isolated from protection ground. Only use an isolated laptop/PC as the connection to the USB connector on an VLT AQUA Drive or an isolated USB cable/drive. 3-18 ®...
Page 63: Efficiency
2%. This is because the sine shape of the motor current is almost perfect at high switching frequency. Efficiency of the system (η SYSTEM To calculate the system efficiency, the efficiency of VLT AQUA (η ) is multiplied by the efficiency of the motor (η MOTOR η...
Page 64 ® 3 VLT AQUA Selection AQUA Drive Design Guide 3.3 Acoustic noise The acoustic noise from the adjustable frequency drive comes from three sources: DC intermediate circuit coils. Integrated fan. RFI filter choke. Typical values are measured at a distance of 3.28 ft. [1 m] from the unit:...
Page 65 ® AQUA Drive Design Guide 3 VLT AQUA Selection Rise time increases/decreases proportionally with cable length. = DC-link voltage x 1.9 PEAK (DC-link voltage = AC line voltage x 1.35). U PEAK 0.8 × Risetime Data are measured according to IEC 60034-17.
Page 66 ® 3 VLT AQUA Selection AQUA Drive Design Guide FC 202, P37KT2 Cable length [m] AC line voltage [V] Rise time [μsec] Vpeak [kV] dU/dt [kV/μsec] 0.300 0.598 1.594 0.536 0.566 0.844 0.776 0.546 0.562 FC 202, P45KT2 Cable length [m] AC line voltage [V] Rise time [μsec]...
Page 67 ® AQUA Drive Design Guide 3 VLT AQUA Selection FC 202, P22KT4 Cable length [m] AC line voltage [V] Rise time [μsec] Vpeak [kV] dU/dt [kV/μsec] 0.312 2.846 0.556 1.250 1.798 0.608 1.230 1.618 FC 202, P30KT4 Cable length [m] AC line voltage [V] Rise time [μsec]...
Page 68 ® 3 VLT AQUA Selection AQUA Drive Design Guide FC 202, P315 - P1M0, T4 Cable length [m] AC line voltage [V] Rise time [μsec] Vpeak [kV] dU/dt [kV/μsec] 0.71 1.165 1.389 0.61 0.942 1.233 FC 202, P110 - P400, T7...
Page 69: Special Conditions
® AQUA Drive Design Guide 3 VLT AQUA Selection 3.5 Special Conditions 3.5.1 Purpose of derating Derating must be taken into account when using the adjustable frequency drive at low air pressure (high elevations), at low speeds, with long motor cables, cables with a large cross-section or at high ambient temperature.
Page 70 ® 3 VLT AQUA Selection AQUA Drive Design Guide B enclosures 60 AVM - Pulse Width Modulation SFAVM - Stator Frequency Asyncron Vector Modulation Figure 3.6: Derating of I for different T for enclo- AMB, MAX Figure 3.5: Derating of I...
Page 71 ® AQUA Drive Design Guide 3 VLT AQUA Selection 60 AVM - Pulse Width Modulation, 525–690 V (except P400) SFAVM - Stator Frequency Asyncron Vector Modulation Figure 3.12: Derating of I for different T for en- Figure 3.11: Derating of I...
Page 72 ® 3 VLT AQUA Selection AQUA Drive Design Guide 60 AVM - Pulse Width Modulation, 525–690 V SFAVM - Stator Frequency Asyncron Vector Modulation Figure 3.17: Derating of I for different T for en- Figure 3.18: Derating of I for different T...
Page 73 ® AQUA Drive Design Guide 3 VLT AQUA Selection Derating of output current versus altitude at T for frame sizes D, E and F. AMB, MAX 3.5.4 Derating for Running at Low Speed When a motor is connected to an adjustable frequency drive, it is necessary to check that the cooling of the motor is adequate.
Page 74 ® 3 VLT AQUA Selection AQUA Drive Design Guide Maximum Load for a Standard Motor at 104°F [40°C] driven by an adjustable frequency drive type VLT FCxxx Legend: ─ ─ ─ ─Typical torque at VT load ─•─•─•─Max torque with forced cooling ‒‒‒‒‒Max torque Note 1) Oversyncronous speed operation will result in the available motor torque decreasing inversely proportional to the increase in speed.
Page 75: Options And Accessories
AQUA Drive Design Guide 3 VLT AQUA Selection 3.6 Options and Accessories Danfoss offers a wide range of options and accessories for adjustable frequency drives. 3.6.1 Mounting Option Modules in Slot B The power to the adjustable frequency drive must be disconnected.
Page 76 3.6.2 General Purpose Input Output Module MCB 101 MCB 101 is used for extension of the number of digital and analog inputs and outputs of the VLT AQUA Drive. Contents: the MCB 101 must be inserted into slot B in the VLT AQUA Drive.
Page 77 ® AQUA Drive Design Guide 3 VLT AQUA Selection 3.6.3 Digital inputs - Terminal X30/1-4 Parameters for set-up: 5-16, 5-17 and 5-18 Number of digital Voltage level Voltage levels Tolerance Max. Input impedance inputs 0–24 V DC PNP type: ± 28 V continuous Approx.
Page 78 ® 3 VLT AQUA Selection AQUA Drive Design Guide 3.6.7 Relay Option MCB 105 The MCB 105 option includes 3 pieces of SPDT contacts and must be fitted into option slot B. Electrical Data: Max terminal load (AC-1) (Resistive load)
Page 79: Index
® AQUA Drive Design Guide 3 VLT AQUA Selection Warning Dual supply How to add the MCB 105 option: • See the mounting instructions at the beginning of the section Options and Accessories. • The power to the live part connections on relay terminals must be disconnected.
Page 80 ® 3 VLT AQUA Selection AQUA Drive Design Guide Do not combine low voltage parts and PELV systems. 3.6.8 24 V Back-up Option MCB 107 (Option D) External 24 V DC Supply An external 24 V DC supply can be installed for low-voltage supply to the the LCP (including the parameter setting) and serial communication bus- control card and any option card installed.
Page 81 ® AQUA Drive Design Guide 3 VLT AQUA Selection Figure 3.21: Connection to 24 V back-up supplier (A2-A3). Figure 3.22: Connection to 24 V back-up supplier (A5-C2). 3.6.9 Analog I/O option MCB 109OPCAIO Analog I/O Option Module The analog I/O card is supposed to be used in e.g., the following cases: •...
Page 82 ® 3 VLT AQUA Selection AQUA Drive Design Guide Figure 3.23: Principle diagram for analog I/O mounted in the adjustable frequency drive. Analog I/O configuration 3 x analog inputs, capable of handling following: • 0–10 VDC • 0–20 mA (voltage input 0–10 V) by mounting a 510Ω resistor across terminals (see NB!) •...
Page 83 ® AQUA Drive Design Guide 3 VLT AQUA Selection 3 x analog inputs Operating range Resolution Accuracy Sampling Max load Impedance Used as -58°–+302°F [-50°– 11 bits -58°F [-50°C] 3 Hz temperature +150°C] ±1 Kelvin sensor input 302°F [+150°C] ±2 Kelvin 0.2% of full...
Page 84: General Description
When using cascade controllers, the individual pumps are automatically turned on (staged) and turned off (de-staged) as needed in order to satisfy the required system output for flow or pressure. The speed of the pumps connected to VLT AQUA Drives is also controlled to provide a continuous range of system output.
Page 85 ® AQUA Drive Design Guide 3 VLT AQUA Selection Each pump, variable speed or fixed-speed, is controlled by a relay in the master drive. The adjustable frequency drive with the cascade controller option card installed has five relays available for controlling pumps. Two (2) relays are standard in the adjustable frequency drive and additional three relays are found on the option card MCO 101 or 8 relays and 7 digital inputs on option card MCO 102.
Page 86 Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected in respect to its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide variety of different resistors that are specially designed to our adjustable frequency drives.
Page 87 ® AQUA Drive Design Guide 3 VLT AQUA Selection 3.6.14 Remote Mounting Kit for The local control panel can be moved to the front of a cabinet by using Technical data the remote built-in kit. The enclosure is the IP65. The fastening screws...
Page 88 If the enclosure kit is used, an IP 20 unit is upgraded to comply with enclosure IP 21/ 4X top/TYPE 1. The IP 4X top can be applied to all standard IP 20 VLT AQUA variants. A – Top cover B –...
Page 89 DC coil but if additional reduction is needed, Danfoss offers two types of passive filters. The Danfoss AHF 005 and AHF 010 are advanced harmonic filters, not to be compared with traditional harmonic trap filters. The Danfoss harmonic filters have been specially designed to match the Danfoss adjustable frequency drives.
Page 90 ® 3 VLT AQUA Selection AQUA Drive Design Guide 3.6.17 Output Filters The high speed switching of the adjustable frequency drive produces some secondary effects, which influence the motor and the enclosed environment. These side effects are addressed by two different filter types, the du/dt and the sine-wave filter.
Page 91: High Power Options
® AQUA Drive Design Guide 3 VLT AQUA Selection 3.7 High Power Options 3.7.1 Installation of Duct Cooling Kit in Rittal Enclosures This section deals with the installation of IP00 / chassis enclosed adjustable frequency drives with duct work cooling kits in Rittal enclosures. In addition to the enclosure an 8 in [200 mm] base/plinth is required.
Page 92 ® 3 VLT AQUA Selection AQUA Drive Design Guide NOTE! A door fan or fans are required on the Rittal cabinet to remove the losses not contained in the backchannel of the drive. The minimum door fan airflow required at the drive maximum ambient for the D3 and D4 is 391 m^3/h (230 cfm). The minimum door fan airflow required at the drive maximum ambient for the E2 is 782 m^3/h (460 cfm).
Page 93: Outside Installation/ Nema 3R Kit For Rittal Enclosures
® AQUA Drive Design Guide 3 VLT AQUA Selection Figure 3.30: E Frame Derating vs. Pressure Change (Small Fan), P250T5 and P355T7-P400T7 Drive air flow: 650 cfm (1105 m3/h) Figure 3.31: E Frame Derating vs. Pressure Change (Large Fan), P315T5-P400T5 and P500T7-P560T7 Drive air flow: 850 cfm (1445 m3/h) 3.7.2 Outside Installation/ NEMA 3R Kit for Rittal enclosures...
Page 94 ® 3 VLT AQUA Selection AQUA Drive Design Guide that provides a degree of protection against rain and ice. The NEMA-4 enclosure is an outdoor enclosure that provides a greater degree of protection against weather and hosed water. The minimum enclosure depth is 19.7 in [500 mm] 23.6 in [600 mm] for E2 frame) and the kit is designed for a 23.6 in [600 mm] 31.5 in [800 mm] for E2 frame) wide enclosure.
Page 95: Installation On Pedestal
® AQUA Drive Design Guide 3 VLT AQUA Selection 3.7.3 Installation on Pedestal This section describes the installation of a pedestal unit available for the adjustable frequency drives frames D1 and D2. This is an 8 in [200 mm] high pedestal that allows these frames to be floor mounted. The front of the pedestal has openings for input air to the power components.
Page 96 ® 3 VLT AQUA Selection AQUA Drive Design Guide 3.7.4 Floor Mounting - Pedestal Installation IP21 (NEMA1) and IP54 (NEMA12) Install the pedestal on the floor. Fixing holes are to be drilled according to this figure: Figure 3.34: Drill master for fixing holes in floor.
Page 97: Input Plate Option
® AQUA Drive Design Guide 3 VLT AQUA Selection 3.7.5 Input Plate Option This section is for the field installation of input option kits available for adjustable frequency drives in all D and E frames. Do not attempt to remove RFI filters from input plates. Damage may occur to RFI filters if they are removed from the input plate.
Page 98: Installation Of Line Power Shield For Adjustable Frequency Drives
® 3 VLT AQUA Selection AQUA Drive Design Guide Cautions The adjustable frequency drive contains dangerous voltages when connected to line voltage. The adjustable frequency drive contains dangerous voltages when connected to line voltage. Electrical parts on the adjustable frequency drive may contain dangerous voltages even after line power has been discon- nected.
Page 99: Frame Size F Panel Options
® AQUA Drive Design Guide 3 VLT AQUA Selection 3.7.7 Frame size F Panel Options Space Heaters and Thermostat Mounted on the cabinet interior of frame size F adjustable frequency drives, space heaters controlled via automatic thermostat help control humidity inside the enclosure, extending the lifetime of drive components in damp environments.
Page 100 ® 3 VLT AQUA Selection AQUA Drive Design Guide Manual Motor Starters Provide 3-phase power for electric blowers often required for larger motors. Power for the starters is provided from the load side of any supplied contactor, circuit breaker, or disconnect switch. Power is fused before each motor starter, and is off when the incoming power to the drive is off. Up to two starters are allowed (one if a 30 A, fuse-protected circuit is ordered).
Page 101: How To Order
It is possible to design a VLT AQUA adjustable frequency drive according to the application requirements by using the ordering number system. For the VLT AQUA, you can order standard drives and drives with integral options by sending a type code string describing the product to the Danfoss sales office, for example.:...
Page 102: Type Code String
Brake T: Safe Stop U: Safe + brake G: Graphical Local Control Panel (GLCP) Display N: Numeric Local Control Panel (NLCP) X: No Local Control Panel Table 4.1: Type code description. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 103 C option software 36-37 XX: Standard software DX: No option D options 38-39 D0: DC backup The various options are described further on in this Design Guide. Table 4.2: Type code description. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 104 8: Line Power Disconnect + Loadsharing X: Standard cable entries Cable entries O: European metric thread in cable entries Reserved Software release 24-27 Current software version Software language Table 4.3: Type code description. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 105 5: MCO 102 Advanced Cascade Control C option software 36-37 XX: Standard software D options 38-39 DX: No option D0: DC backup The various options are described further in this Design Guide. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 106: Ordering Numbers
Panel mounting kit for all LCPs including fasteners and gasket - without ca- 130B1170 LCP kit Panel mounting kit for all LCPs including fasteners, 26 ft [8 m] cable, con- 130B1129 nectors and gasket for IP55/66 enclosures ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 107 Mounting kit for frame size B3 (2.36 in [60 mm] for C0 + C1 option) 130B1414 Option for Slot C MCO 102 Advanced Cascade Control 130B1154 130B1254 Option for Slot D MCB 107 24 V DC back-up 130B1108 130B1208 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 108 1) Only IP 21 / > 14.75 HP [11 kW] Options can be ordered as factory built-in options, see ordering information. For information on serial communication bus and application option compatibility with older software versions, please contact your Danfoss supplier. ®...
Page 109 324 A 130B2470 130B2482 P160 370 A 130B2471 130B2483 P200 506 A 130B2468 130B2480 P250 + 130B2469 + 130B2481 578 A 2x 130B2469 2x 130B2481 P315 648 A 2x130B2470 2x130B2482 P355 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 110 217 A 175G6653 175G6665 P160 289 A 175G6654 175G6666 P200 324 A 175G6655 175G6667 P250 370 A 2x175G6653 2x175G6665 P315 - P400 578 A 2X 175G6654 2X 175G6666 P500 - P560 4-10 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 111 130B2333 130B2298 P90K - P110 180 A 130B2334 130B2299 P132 217 A 130B2335 130B2300 P160 289 A 130B2331+2333 130B2301 P200 324 A 130B2333+2334 130B2302 P250 370 A 130B2334+2335 130B2304 P315 4-11 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 112 1200 A P630 P710 2 kHz 60 Hz 130B2318 130B2292 1200 A NOTE! Switching Frequency When using sine-wave filters, the switching frequency should comply with filter specifications in par. 14-01 4-12 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 113 130B2325 130B2345 130B2326 130B2346 130B2327 130B2347 130B2329 130B2348 130B2241 130B2270 130B2242 130B2271 130B2337 130B2381 130B2338 130B2382 130B2339 130B2383 1000 1320 130B2340 130B2384 1200 Table 4.4: Line power supply 3x525–690 V 4-13 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 114 1075 hp [800 kW] 1350 hp [1000 kW] 2 kHz 60 Hz 130B2407 130B2394 1500 A 1350 hp [1000 kW] 1475 hp [1100 kW] 2 kHz 60 Hz 130B2410 130B2395 2300 A 4-14 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 115 130B2416 130B2425 130B2417 130B2426 130B2418 130B2427 130B2419 130B2428 130B2420 130B2429 130B2235 130B2238 130B2236 130B2239 130B2280 130B2274 130B2421 130B2430 1350 130B2422 130B2431 1000 1200 Table 4.5: Line power supply 3x525–690 V 4-15 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 116 ® 4 How to Order AQUA Drive Design Guide 4.2.7 Ordering Numbers: Brake Resistors NOTE! When/where two resistors are listed in the tables - order two resistors. 4-16 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 117 110 (110) P250 1963 110 (110) P315 1963 98 (110) P355 (110) P400 (110) P450 (110) P500 (100) P560 (89) P630 (79) P710 (70) P800 (62) P1M0 1000 1.2 (50) 4-17 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 118 ® 4 How to Order AQUA Drive Design Guide 4-18 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 119: How To Install
® AQUA Drive Design Guide 5 How to Install 5 How to Install 5.1 Mechanical Installation Page intentionally left blank! ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 120 ® 5 How to Install AQUA Drive Design Guide ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 121 ® AQUA Drive Design Guide 5 How to Install ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 122 ® 5 How to Install AQUA Drive Design Guide ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 123 ® AQUA Drive Design Guide 5 How to Install ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 124 The service life of the adjustable frequency drive is reduced if derating for ambient temperature is not taken into account. 5.1.5 Field Mounting For field mounting the IP 21/IP 4X top/TYPE 1 kits or IP 54/55 units are recommended. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 125: Pre-Installation
NOTE! Mechanical The card box cover contains a drilling master for the mounting holes in the D frames. For the E size, please refer to section Dimensions later in this chapter. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 126: Lifting
Maximum diameter for bar is 1 in [25 cm]. The angle from the top of the drive to the lifting cable should be 60 degrees or greater. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 127 The plinth is required to allow airflow to the drive to provide proper cooling. The Unit SizesF6 frames should be positioned on top of the plinth in the final installation location. The angle from the top of the drive to the lifting cable should be 60 degrees or greater. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 128 NOTE! All cable lugs/shoes must mount within the width of the terminal bus bar. 5-10 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 129: Cooling And Airflow
Cables are connected through the gland plate from the bottom. Remove the plate, and plan where to place the entry for the glands or conduits. Prepare holes in the marked area on the drawing. 5-11 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 130 Figure 5.11: Example of proper installation of the gland plate. Frame size D1 + D2 Frame size E1 Cable entries viewed from the bottom of the adjustable frequency drive - 1) Line power side 2) Motor side 5-12 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 131 Frame size F1 Frame size F2 Frame size F3 Frame size F4 F1-F4: Cable entries viewed from the bottom of the adjustable frequency drive - 1) Place conduits in marked areas 5-13 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 132 • Remove the two front screws. • Insert the drip shield and replace the screws. • Torque the screws to 5.6 Nm (50 in-lbs). Figure 5.13: Install the drip shield. 5-14 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 133: Electrical Installation
The cable entry must be supported around the knockout you intend to remove. The knockout can now be removed with a strong mandrel and a hammer. Remove burrs from the hole. Mount cable entry on adjustable frequency drive. 5-15 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 134 440 V. For IT line power and delta ground (grounded leg), AC line voltage may exceed 440 V between phase and ground. Figure 5.14: Terminals for line power and grounding. 5-16 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 135 ® AQUA Drive Design Guide 5 How to Install Figure 5.15: How to connect to the line power supply and grounding with disconnector (A5 enclosure). 5-17 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 136 In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply (such as a ad- justable frequency drive), fit a sine-wave filter on the output of the adjustable frequency drive. 5-18 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 137 The adjustable frequency drive has been tested with a given length of cable and a given cross-section of that cable. If the cross-section is increased, the cable capacitance - and thus the leakage current - may increase, thereby requiring that the cable length is reduced accordingly. 5-19 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 138 Short circuit protection: The adjustable frequency drive must be protected against short circuit in order to prevent electrical or fire hazard. Danfoss recommends using the fuses mentioned in tables 5.3 and 5.4 to protect service personnel or other equipment in case of an internal failure in the unit. The adjustable frequency drive provides full short circuit protection in case of a short circuit in the motor output.
Page 139 1) Max. fuses - see national/international regulations to select an appropriate fuse size. Danfoss PN Bussmann Ferraz Siba 20220 170M4017 6.9URD31D08A0700 20 610 32.700 20221 170M6013 6.9URD33D08A0900 20 630 32.900 Table 5.5: Additional Fuses for Non-UL Applications, E enclosures, 380-480 V 5-21 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 140 A6KR fuses from FERRAZ SHAWMUT may substitute for A2KR for 240 V adjustable frequency drives. A50X fuses from FERRAZ SHAWMUT may substitute for A25X for 240 V adjustable frequency drives. 5-22 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 141 L50S fuses from LITTEL FUSE may substitute for L50S fuses for 240 V adjustable frequency drives. A6KR fuses from FERRAZ SHAWMUT may substitute for A2KR for 240 V adjustable frequency drives. 5-23 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 142 *170M fuses from Bussmann shown use the -/80 visual indicator; -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for external use **Any minimum 500 V UL listed fuse with associated current rating may be used to meet UL requirements. 5-24 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 143 Suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical amperes, 500/600/690 Volts maximum when protected by the above fuses. 5-25 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 144 Figure 5.17: Frame sizes A1, A2, A3,B3, B4, C3 and C4 5.3.9 Control Terminals Drawing reference numbers: 10-pole plug, digital I/O. 3-pole plug, RS-485 bus. 6-pole, analog I/O. USB Connection. Figure 5.19: Control terminals (all enclosures) 5-26 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 145 Remove the screwdriver. The cable is now mounted to the ter- minal. To remove the cable from the terminal: Insert a screw driver in the square hole. Pull out the cable. Max. 0.015 x 0.1 in. [0.4 x 2.5 mm] 5-27 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 146 Connect terminals 18 and 27 to +24 V (terminal 12/13) Default settings: 18 = Start 27 = stop inverse Figure 5.21: Terminal 37 available with Safe Stop Function only! 5-28 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 147 Again the electronics used puts a limitation on the cable length. NOTE! Noise is always a factor to be reckoned with. 5.3.13 Electrical Installation, Control Cables Figure 5.22: Terminal 37: Safe Stop input available with Safe Stop Function only! 5-29 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 148 If this occurs, you may have to break the shield or insert a 100 nF capacitor between shield and chassis. The digital and analog in- and outputs must be connected separately to the VLT AQUA Drive common inputs (terminal 20, 55, 39) to avoid ground currents from both groups to affect other groups.
Page 149 Default setting: S201 (A53) = OFF (voltage input) S202 (A54) = OFF (voltage input) S801 (Bus termination) = OFF NOTE! It is recommended to only change switch position at power off. 5-31 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 150: Connections - Frame Sizes D, E And F
When adjustable frequency drives are used together with sine-wave filters to reduce the acoustic noise from a motor, the switching frequency must be Switching Frequency set according to the instructions in par. 14-01 5-32 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 151 In motors without phase insulation paper or other in- sulation reinforcement suitable for operation with volt- age supply (such as a adjustable frequency drive), fit a sine-wave filter on the output of the adjustable fre- quency drive. 5-33 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 152 AUX Relay Brake Temp Switch SMPS Fuse (see fuse tables for part number) AUX Fan Line Fan Fuse (see fuse tables for part number) Line power ground Load sharing Motor 5-34 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 153 AUX Relay Brake Temp Switch SMPS Fuse (see fuse tables for part number) AUX Fan Line Fan Fuse (see fuse tables for part number) Line power ground Load sharing Motor 5-35 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 154 Figure 5.27: Position of ground terminals IP00, frame sizes Figure 5.28: Position of ground terminals IP21 (NEMA type 1) and IP54 (NEMA type 12) NOTE! D2 and D4 shown as examples. D1 and D3 are equivalent. 5-36 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 155 Figure 5.29: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) frame size E1 Figure 5.30: Compact IP 00 (Chassis) with disconnect, fuse and RFI filter, frame size E2 5-37 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 156 SMPS Fuse (see fuse tables for part number) Fan Fuse (see fuse tables for part number) Line AUX Fan Line power ground Brake Motor Figure 5.31: Position of ground terminals IP00, frame sizes E 5-38 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 157 Manual Motor Controller fuses (3 or 6 pieces). See fuse tables for part numbers Line Line Fuses, F1 and F2 frame (3 pieces). See fuse tables for part numbers 30 Amp Fuse Protected Power fuses 5-39 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 158 NAMUR Fuse. See fuse tables for part numbers AUX Fan Fan Fuses. See fuse tables for part numbers 101 102 103 SMPS Fuses. See fuse tables for part numbers Brake 5-40 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 159 NAMUR Fuse. See fuse tables for part numbers AUX Fan Fan Fuses. See fuse tables for part numbers 101 102 103 SMPS Fuses. See fuse tables for part numbers Brake 5-41 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 160 See fuse tables for part numbers Contactor Relay Coil (230 V AC). N/C and N/O Aux Contacts Circuit Breaker Shunt Trip Control Terminals (230 V AC or 230 V DC) 5-42 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 161 AC line (jumpers between 100-102 and 101-103). If an external supply is needed, the jumpers are removed and the supply is connected to terminals 100 and 101. A 5 Amp fuse should be used for protection. In UL applications, this should be a LittleFuse KLK-5 or equivalent. 5-43 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 162: Disconnectors, Circuit Breakers And Contactors
P710-P800 380–500 V & P900-P1M0 525–690 V Merlin Gerin NRK36000S20AAYP* * Drive SCCR rating maybe less than 100 kA when this option is added. See the drive label for SCCR rating. 5-44 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 163 P710-P800 380–500 V & P1M0 525–690 V Eaton XTCEC14P22B* * Drive SCCR rating maybe less than 100 kA when this option is added. See the drive label for SCCR rating. 5-45 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 164: Final Set-Up And Test
Choose between complete or reduced AMA. If an LC filter is mounted, run only the reduced AMA, or remove the LC filter during the AMA procedure. Press the [OK] key. The display shows “Press [Hand on] to start”. Press the [Hand on] key. A progress bar indicates if the AMA is in progress. 5-46 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 165: Safe Stop Installation
"Report Value” in the [Alarm Log] shows the last measuring sequence carried out by the AMA before the adjustable frequency drive entered alarm mode. This number along with the description of the alarm will assist you in troubleshooting. If you contact Danfoss Service, make sure to mention number and alarm description.
Page 166: Safe Stop Commissioning Test
Then send reset signal (via Bus, Digital I/O or [Reset] key). The test step is passed if the motor becomes operational again. The commissioning test is passed if all four test steps are passed. 5-48 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 167: Additional Connections
Provide further motor protection with, for ex- ample, thermistors in each motor or individual thermal relays (circuit breakers are not a suitable means of protection). 5-49 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 168 ® 5 How to Install AQUA Drive Design Guide 5-50 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 169: Installation Of Misc. Connections
The RS-485 bus must be terminated by a resistor network at both ends. For this purpose, set switch S801 on the control card to "ON". Switches S201, S202, and S801 For more information, see the paragraph NOTE! Protocol Communication protocol must be set to FC MC 8-30 5-51 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 170 5 How to Install AQUA Drive Design Guide 5.9.2 How to Connect a PC to the VLT AQUA Drive To control or program the adjustable frequency drive from a PC, install the MCT 10 Set-up software. How to Install >...
Page 171 MCT 31 The MCT 31 harmonic calculation PC tool enables easy estimation of the harmonic distortion in a given application. Both the harmonic distortion of Danfoss adjustable frequency drives as well as non-Danfoss adjustable frequency drives with different additional harmonic reduction devices, such as Danfoss AHF filters and 12-18-pulse rectifiers, can be calculated.
Page 172: Safety
Use low impedance cable clamps or EMC cable connectors instead. • Avoid using unshielded/unarmored motor or control cables inside cabinets housing the drive(s), whenever this can be avoided. Leave the shield as close to the connectors as possible. 5-54 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 173 See the paragraph Figure 5.39: EMC-compliant electrical installation of an adjustable frequency drive in a cabinet. Figure 5.40: Electrical connection diagram. 5-55 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 174 5.11.2 Use of EMC-Compliant Cables Danfoss recommends braided shielded/armored cables to optimize EMC immunity of the control cables and the EMC emission from the motor cables. The ability of a cable to reduce the in and outgoing radiation of electric noise depends on the transfer impedance (Z ).
Page 175 61. This terminal is grounded via an internal RC link. Use twis- ted-pair cables to reduce the differential mode interference be- tween the conductors. 5-57 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 176: Residual Current Device
If RCD relays are used, you must observe local regulations. Relays must be suitable for protection of 3-phase equipment with a bridge rectifier and for Ground Leakage Current a brief discharge on power-up see section for further information. 5-58 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 177: Application Examples
Terminal 27= Stop par. 5-12 [6] Digital Input, Terminal 18 Latched start Par. 5-10 Par. 5-12 Digital Input, Terminal 27 Stop inverse Figure 6.2: Terminal 37: Available only with Safe Stop Func- tion! ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 178: Potentiometer Reference
[2] action [2] is executed. After this, the conditions of will be evaluated and, if evaluated TRUE, will be executed and so on. Events and actions are placed in array parameters. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 179 In applications where a PLC generates a simple sequence, the SLC may take over elementary tasks from the main control. SLC is designed to act from event send to, or it is generated in the VLT AQUA Drive. The adjustable frequency drive will then perform the pre-programmed action.
Page 180: Slc Application Example
[2] to [29] SL Controller Action Select preset 1 Set Action 3 in par. 13-52 [3] to [11] SL Controller Action No Action Set Action 4 in par. 13-52 [4] to ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 181 The alternation of the lead pump can take place at a command signal or at staging (adding another pump). ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 182: System Status And Operation
• De-staging at No-Flow ensures that all fixed speed pumps are stopped individually until the no-flow status disappears. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 183: Cascade Controller Wiring Diagram
The wiring diagram shows an example with the built-in BASIC cascade controller with one variable speed pump (lead) and two fixed speed pumps, a 4– 20 mA transmitter and system safety interlock. 6.1.11 Fixed Variable Speed Pump Wiring Diagram ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 184: Lead Pump Alternation Wiring Diagram
Auxiliary break contact on K1 prevents K3 from cutting in. • RELAY 2 controls contactor K4 for on/off control of the fixed speed pump. • At alternation, both relays de-energize, and RELAY 2 will be energized as the first relay. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 185 Ramps up (if stopped by a normal stop com- De-staging (if running) mand) or stays in operation if already running. Ramps down Cut out Auto On Starts and stops according to commands sent via Staging/De-staging terminals or serial bus. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 186 ® 6 Application Examples AQUA Drive Design Guide 6-10 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 187: Installation And Set-Up
To prevent impedance mismatch, always use the same type of cable throughout the entire network. When connecting a motor to the adjustable frequency drive, always use shielded motor cable. Cable: Shielded twisted pair (STP) Impedance: 120 Ohm Cable length: Max. 3,396 ft [1,200 m] (including drop lines) Max. 1,640 ft [500 m] station-to-station ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 188 Figure 7.1: Network Terminal Connection Figure 7.2: Control card terminals 7.1.3 VLT AQUA Hardware Set-up Use the terminator dip switch on the main control board of the adjustable frequency drive to terminate the RS-485 bus.
Page 189 ® AQUA Drive Design Guide 7 RS-485 Installation and Set-up 7.1.4 VLT AQUA Parameter Settings for Modbus Communication The following parameters apply to the RS-485 interface (FC-port): Parameter Number Parameter name Function 8-30 Protocol Select the application protocol to run on the RS-485 interface...
Page 190: Fc Protocol Overview
7.2 FC Protocol Overview The adjustable frequency protocol, also referred to as adjustable frequency bus or standard bus, is the Danfoss standard serial communication bus. It defines an access technique according to the master-slave principle for communications via a serial bus.
Page 191: Network Configuration
® AQUA Drive Design Guide 7 RS-485 Installation and Set-up 7.3 Network Configuration 7.3.1 VLT AQUA Adjustable Frequency Drive Set-up Set the following parameters to enable the FC protocol for the VLT AQUA. Parameter Number Parameter name Setting 8-30 Protocol...
Page 192 The slave returns the address byte unchanged to the master in the response telegram. 7.4.5 Data Control Byte (BCC) The checksum is calculated as an XOR-function. Before the first byte in the telegram is received, the calculated checksum is 0. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 193 The parameter block is used to transfer parameters between master and slave. The data block is made up of 12 bytes (6 words) and also contains the process block. Text block: The text block is used to read or write texts via the data block. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 194 Write parameter value in RAM and EEPROM (word) Read/write text Response slave ⇒master Bit no. Response No response Parameter value transferred (word) Parameter value transferred (double word) Command cannot be performed text transferred ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 195 The message length is defined in the second byte of the message, LGE. When using text transfer, the index character indicates whether it is a read or a write command. ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 196 Some parameters contain text that can be written to via the serial bus. To write a text via the PWE block, set the parameter command (AK) to ’F’ Hex. The index character's high-byte must be "5". 7.4.11 Data Types Supported by VLT AQUA Data types...
Page 197 The block of process words is divided into two blocks of 16 bits, which always occur in the defined sequence. PCD 1 PCD 2 Control message (master⇒slave control word) Reference value Control message (slave ⇒master) Status word Present output frequency 7-11 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 198: Examples
NOTE! Ramp 1 Ramp Up Time 3E8 Hex corresponds to 1000 decimal. The conversion index for par. 3-41 is -2, i.e., 0.01. Par. 3-41 is of the type Unsigned 32 7-12 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 199: Modbus Rtu Overview
7.7 Network Configuration 7.7.1 VLT AQUA with Modbus RTU To enable modbus RTU on the VLT AQUA, set the following parameters: Parameter Number Parameter name Setting...
Page 200: Modbus Rtu Message Framing Structure
This will cause a time-out (no response from the slave), since the value in the final CRC field will not be valid for the combined messages. 7-14 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 201 Holding register 40001 is addressed as register 0000 in the data address field of the message. The function code field already specifies a ‘holding register’ operation. Therefore, the ‘4XXXX’ reference is implicit. Holding register 40108 is addressed as register 006BHEX (107 decimal). 7-15 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 202 Voltage warning No reversing Reversing Not in current limit Current limit Adjustable frequency drive control word (FC profile) No thermal warning Thermal warning Adjustable frequency drive status word (FC profile) 7-16 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 203 * Used to specify the index number to be used when accessing an indexed parameter. 7.8.9 How to Control the VLT AQUA This section describes codes which can be used in the function and data fields of a Modbus RTU message. For a complete description of all the message fields, please refer to the section Modbus RTU Message Framing Structure.
Page 204 Invalid message length Invalid data length or value Invalid function code There is no bus access to the parameter called Data change is not possible because factory set-up is selected 7-18 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 205: How To Access Parameters
Non standard data types are text strings stored as 4x registers (40001–4FFFF). The parameters are read using function 03HEX "Read Holding Registers" and written using function 10HEX "Preset Multiple Registers." Readable sizes range from 1 register (2 characters) up to 10 registers (20 characters). 7-19 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 206: Examples
Data (Coils 48-41) 06 (STW=0607hex) Error Check (CRC) NOTE! Coils and registers are addressed explicit with an off-set of -1 in Modbus. For example, Coil 33 is addressed as Coil 32. 7-20 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 207 The normal response is an echo of the query, which is returned after the coil state has been forced. Field Name Example (HEX) Slave Address Function Force Data HI Force Data LO Quantity of Coils HI Quantity of Coils LO Error Check (CRC) 7-21 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 208 01 (adjustable frequency drive address) Function 0F (write multiple coils) Coil Address HI Coil Address LO 10 (coil address 17) Quantity of Coils HI Quantity of Coils LO 10 (16 coils) Error Check (CRC) 7-22 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 209 Example: Hex 0016E360 = 1.500.000 = 1500 RPM. Field Name Example (HEX) Slave Address Function Byte Count Data HI (Register 3030) Data LO (Register 3030) Data HI (Register 3031) Data LO (Register 3031) Error Check (CRC) 7-23 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 210 Response: the normal response is an echo of the query, which is returned after the register contents have been passed. Field Name Example (HEX) Slave Address Function Register Address HI Register Address LO Preset Data HI Preset Data LO Error Check (CRC) 7-24 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 211: Danfoss Fc Control Profile
® AQUA Drive Design Guide 7 RS-485 Installation and Set-up 7.11 Danfoss FC Control Profile Control Pro- 7.11.1 Control Word According to Adjustable Frequency Drive Profile(par. 8-10 file = Adjustable Frequency profile) Bit value = 0 Bit value = 1...
Page 212 Bit 09 = "0": Ramp 1 is active (par. 3-41 to par. 3-42 ). Bit 09 = "1": Ramp 2 (par. 3-51 Up Time to par. 3-52 Ramp 2 Ramp Down Time ) is active. 7-26 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 213 Bit 15 = ’0’: No reversing. Bit 15 = ’1’: Reversing. In the default setting, reversing is set to digital in par. 8-54 . Bit 15 causes reversing only when Ser. communication, Logic or or Logic and is selected. 7-27 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 214 Bit 04, No error/error (no trip): Bit 04 = ’0’: The adjustable frequency drive is not in fault mode. Bit 04 = “1”: The adjustable frequency drive shows an error but does not trip. 7-28 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 215 All bits in the STW are set to ’0’ if the connection between the Interbus option and the adjustable frequency drive is lost, or if an internal communication problem has occurred. 7-29 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 216 100%. Negative figures are formatted by means of 2’s com- plement. The Actual Output frequency (MAV) is scaled in the same way as the bus reference. The reference and MAV are scaled as follows: 7-30 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 217 Via a digital input with the “Reset” function. Via serial communication/optional serial communication bus. Reset Mode By resetting automatically using the [Auto Reset] function, which is a default setting for VLT AQUA Drive. See par. 14-20 AQUA Drive Programming Guide NOTE! After a manual reset using the [RESET] button on the LCP, the [AUTO ON] or [HAND ON] button must be pressed to restart the motor.
Page 218 AMA low I AMA motor too big AMA motor too small AMA parameter out of range AMA interrupted by user AMA timeout AMA internal fault Current limit Table 8.1: Alarm/Warning code list ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 219 A trip lock situation can only be reset by power cycling. LED indication Warning yellow Alarm flashing red Trip locked yellow and red ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 220 The alarm words, warning words and extended status words can be read out via serial bus or optional serial communication bus for diagnosis. See also Alarm Word Warning Word Ext. Status Word par. 16-90 , par. 16-92 and par. 16-94 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 221 3-33 Analog Voltage Inputs - Terminal X30/10-12 3-33 Automatic Adaptations To Ensure Performance 3-30 Automatic Motor Adaptation Automatic Motor Adaptation (ama) 5-46 Available Literature For Vlt® Aqua Drive Back Cooling 5-11 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 222 Control Terminals 5-26 Control Word 7-25 Cooling 3-29 Cooling 5-11 Copyright, Limitation Of Liability And Revision Rights Cos Φ Compensation Data Types Supported By Vlt Aqua 7-10 Database Error Codes 7-18 Dc Brake 7-26 Dc Link Connector Decoupling Plate 5-18 Definitions...
Page 223 Freeze Output Function Codes Supported By Modbus Rtu 7-18 Fuse Tables 5-24 Fuses 5-20 Fusing 5-32 General Aspects Of Emc Emissions 2-20 General Aspects Of Harmonics Emission 2-22 General Considerations 5-10 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 224 2-23 Harmonics Test Results (emission) 2-24 High Voltage Test 5-54 Hold Output Frequency 7-26 How To Connect A Pc To The Vlt Aqua Drive 5-52 I/os For Setpoint Inputs 3-37 Iec Emergency Stop With Pilz Safety Relay 3-55 Immunity Requirements...
Page 225 Ordering Numbers: Du/dt Filters, 380–480 Vac 4-14 Ordering Numbers: Harmonic Filters Ordering Numbers: Options And Accessories Ordering Numbers: Sine Wave Filter Modules, 200–500 V Ac 4-12 Output Filters 3-46 Output Performance (u, V, W) 3-14 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 226 Residual Current Device 2-26, 5-58 Rise Time 3-20 Rs-485 Rs-485 Bus Connection 5-51 Safe Stop Commissioning Test 5-48 Safe Stop Installation 5-47 Safe Stop Operation (optional) 2-32 Safety Ground Connection 5-54 Safety Note ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 227 Usb Cable Usb Connection 5-26 Use Of Emc-compliant Cables 5-56 Variable (quadratic) Torque Applications (vt) 3-29 Variable Control Of Flow And Pressure Variable Speed Pumps. 3-40 Varying Flow Over 1 Year ® MG.20.N5.22 - VLT is a registered Danfoss trademark...
Page 228 ® Index AQUA Drive Design Guide Vibration And Shock Voltage Level 3-16 Vvcplus Warning Against Unintended Start What Is Ce Conformity And Labeling? What Is Covered Wire Access 5-10 ® MG.20.N5.22 - VLT is a registered Danfoss trademark...

Danfoss vlt aqua Design Manual

8 Troubleshooting

Index

How to Install

Application Examples

Installation and Set-Up

Quick Links

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