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Danfoss VLT AQUA Design Manual

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®
VLT
AQUA Drive Design Guide
Contents
®
MG.20.N3.02 - VLT
is a registered Danfoss trademark
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  • Page 1: Table Of Contents

    1. How to Read this Design Guide Copyright, Limitation of Liability and Revision Rights Approvals Symbols Abbreviations Definitions 2. Introduction to VLT AQUA Drive CE labelling Air humidity Aggressive Environments Vibration and shock VLT AQUA Controls General aspects of EMC...
  • Page 2 RS-485 Installation and Set-up FC Protocol Overview Network Configuration FC Protocol Message Framing Structure Examples Modbus RTU Overview VLT AQUA with Modbus RTU Modbus RTU Message Framing Structure How to Access Parameters Examples Danfoss FC Control Profile 8. Troubleshooting Fault messages Index ®...

  • Page 3: How To Read This Design Guide

    Danfoss A/S reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former or present users of such revisions or changes.

  • Page 4: Abbreviations

    Revolutions Per Minute Second Torque limit Volts 1.1.5. Definitions Drive: VLT,MAX The maximum output current. VLT,N The rated output current supplied by the frequency converter. VLT, MAX The maximum output voltage. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 5 The efficiency of the frequency converter is defined as the ratio between the power output and the power input. Start-disable command A stop command belonging to the group 1 control commands - see this group. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 6 The digital inputs can be used for controlling various functions of the frequency converter. Digital Outputs The drive features two Solid State outputs that can supply a 24 V DC (max. 40 mA) signal. Digital Signal Processor. Relay Outputs: ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 7 Graphical LCP102 (GLCP) Least significant bit. Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM 0.5067 mm ≡ Most significant bit. NLCP Numerical Local Control Panel LCP101 ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 8 ) 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.N3.02 - VLT is a registered Danfoss trademark...
  • Page 9 In addition, a high power factor indicates that the different harmonic currents are low. The frequency converters' built-in DC coils produce a high power factor, which minimises the imposed load on the mains supply. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 10 ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 11: Introduction To Vlt Aqua Drive

    Installation at High Altitudes By altitudes above 2 km, please contact Danfoss Drives 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 frequency converter is connected to mains.
  • Page 12 2.2. Software Version VLT AQUA Drive Design Guide Software version: 1.05 This Design Guide can be used for all VLT AQUA frequency converters with software version 1.05. The software version number can be seen from parameter 15-43. ® MG.20.N3.02 - VLT...

  • Page 13: Ce Labelling

    Frequency converters must be CE labelled in accordance with the low-voltage directive of January 1, 1997. The directive applies to all electrical equipment and appliances used in the 50 - 1000 V AC and the 75 - 1500 V DC voltage ranges. Danfoss CE-labels in accordance with the directive and issues a declaration of conformity upon request.

  • Page 14: Air Humidity

    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 Drive...

  • Page 15: Vibration And Shock

    ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive Mounting frequency converters in aggressive environments increases the risk of stoppages and considerably reduces the life of the converter. Before installing the frequency converter, check the ambient air for liquids, particles, and gases. This is done by observing existing installations in this environment.
  • Page 16 ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide Illustration 2.2: When using a frequency converter to reduce fan capacity to 60% - more than 50% energy savings may be obtained in typical applications. 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.
  • Page 17 ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive Flow Pressure Power 2.7.4. Example with varying flow over 1 year The example below is calculated on the basis of pump characteristics ob- Energy savings tained from a pump datasheet.
  • Page 18 ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide Distribution Valve regulation Frequency converter 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 11,5 20.148...
  • Page 19 ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive 2.7.6. Better control If a frequency converter is used for controlling the flow or pressure of a system, improved control is obtained. A frequency converter can vary the speed of the fan or pump, thereby obtaining variable control of flow and pressure.

  • Page 20: Vlt Aqua Controls

    ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide 2.8. VLT AQUA Controls 2.8.1. Control Principle A frequency converter rectifies AC voltage from mains into DC voltage, after which this DC voltage is converted into a AC current with a variable amplitude and frequency.
  • Page 21 ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive After pressing the [Auto On] key, the frequency converter goes into Auto mode and follows (as default) the Remote reference. In this mode, it is possible to control the frequency converter via the digital inputs and var- ious serial interfaces (RS-485, USB, or an optional fieldbus).

  • Page 22: Pid

    ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide 2.9. PID 2.9.1. Closed Loop (PID) Controller The drive’s Closed Loop Controller allows the drive to become an integral part of the controlled system. The drive receives a feedback signal from a sensor in the system.
  • Page 23 ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive The following parameters are relevant for a simple PID control application: Parameter Description of function Feedback 1 Source par. 20-00 Select the source for Feedback 1. This is most commonly an analog input, but other sources are also available.
  • Page 24 ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide 2.9.2. Closed Loop Control Relevant Parameters The drive’s Closed Loop Controller is capable of handling more complex applications, such as situations where a conversion function is applied to the feedback signal or situations where multiple feedback signals and/or setpoint references are used.
  • Page 25 ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive 2.9.3. Example of Closed Loop PID Control The following is an example of a Closed Loop Control for a booster pump application: In a water distribution system, the pressure is to be maintained at a constant value. The desired pressure is set between 0 and 10 Bar using a 0-10 volt potentiometer.
  • Page 26 ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide 2.9.4. 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 out- 0-02 put frequency.
  • Page 27 ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive 2.9.5. 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 28 ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide Type of Control Proportional Gain Integral Time Differentiation Time PI-control 0.45 * 0.833 * PID tight control 0.6 * 0.5 * 0.125 * PID some overshoot 0.33 * 0.5 * 0.33 *...
  • Page 29 ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive 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 30 ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide Multi Zone, Single Setpoint Multi Zone Single Setpoint uses two or three feedback sensors but only one setpoint. The feedbacks can be added, subtracted (only feedback 1 and 2) or averaged.

  • Page 31: General Aspects Of Emc

    ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive 2.10. General aspects of EMC 2.10.1. General Aspects of EMC Emissions Electrical interference is usually conducted at frequences in the range 150 kHz to 30 MHz. Airborne interference from the drive system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor.
  • Page 32 ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide 2.10.2. EMC Test Results (Emission, Immunity) The following test results have been obtained using a system with a frequency converter (with options if relevant), a screened control cable, a control box with potentiometer, as well as a motor and motor screened cable.
  • Page 33 ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive VLT AQUA; 200-240 V, 380-480 V Basic standard Burst Surge Radiated electromagnetic field RF common IEC 61000-4-4 IEC 61000-4-5 IEC 61000-4-2 IEC 61000-4-3 mode voltage IEC 61000-4-6 Acceptance criterion Line 2 kV/2 Ω...

  • Page 34: Galvanic Isolation (Pelv)

    The functional galvanic isolation (a and b on drawing) is for the 24 V back-up option and for the RS 485 standard bus interface. Installation at high altitude 380 - 500 V: At altitudes above 3 km, please contact Danfoss Drives regarding PELV. 525 - 690 V: At altitudes above 2 km, please contact Danfoss Drives regarding PELV.

  • Page 35: Control With Brake Function

    (as part of the total cycle time) Danfoss offers brake resistors with duty cycle of 5%, 10% and 40% suitable for use with the FC202 AQUA drive series. If a 10% duty cycle resistor is applied, this is able of absorbing braking power upto 10% of the cycle time with the remaining 90% being used to dissipate heat from the resistor.

  • Page 36: Mechanical Brake Control

    ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide 2.13.2. Control with Brake Function The brake is to limit the voltage in the intermediate circuit when the motor acts as a generator. This occurs, for example, when the load drives the motor and the power accumulates on the DC link.

  • Page 37: Extreme Running Conditions

    ® AQUA Drive Design Guide 2. Introduction to VLT AQUA Drive 2.15. Extreme running conditions Short Circuit (Motor Phase – Phase) The frequency converter is protected against short circuits by means of current measurement in each of the three motor phases or in the DC link. A short circuit between two output phases will cause an overcurrent in the inverter.

  • Page 38: Safe Stop Operation (Optional)

    ® 2. Introduction to VLT AQUA Drive AQUA Drive Design Guide 2.15.2. Safe Stop Operation (optional) The FC 202 can perform the Safety Function “Uncontrolled Stopping by removal of power” (as defined by draft IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).

  • Page 39: Vlt Aqua Selection

    ® AQUA Drive Design Guide 3. VLT AQUA Selection 3. VLT AQUA Selection 3.1. General Specifications ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 40 ® 3. VLT AQUA Selection AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 41 ® AQUA Drive Design Guide 3. VLT AQUA Selection ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 42 ® 3. VLT AQUA Selection AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 43 ® AQUA Drive Design Guide 3. VLT AQUA Selection ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 44 ® 3. VLT AQUA Selection AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 45 ® AQUA Drive Design Guide 3. VLT AQUA Selection ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 46 ® 3. VLT AQUA Selection AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 47 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 95 deg C.
  • Page 48 ® 3. VLT AQUA Selection AQUA Drive Design Guide Analog inputs: Number of analog inputs Terminal number 53, 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201/switch S202 = OFF (U) Voltage level...
  • Page 49 ® AQUA Drive Design Guide 3. VLT AQUA Selection Digital output: Programmable digital/pulse outputs Terminal number 27, 29 Voltage level at digital/frequency output 0 - 24 V Max. output current (sink or source) 40 mA Max. load at frequency output 1 kΩ...
  • Page 50 ® 3. VLT AQUA Selection AQUA Drive Design Guide Control card, 10 V DC output: Terminal number Output voltage 10.5 V ±0.5 V Max. load 25 mA The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
  • Page 51 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 earth. Use only isolated laptop/PC as connection to the USB connector on VLT AQUA Drive or an isolated USB cable/converter. ®...

  • Page 52: Efficiency

    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 53 ® AQUA Drive Design Guide 3. VLT AQUA Selection The typical values measured at a distance of 1 m from the unit: At reduced fan speed (50%) Enclosure Full fan speed [dBA] [dBA] *** D1+D3 D2+D4 E1/E2 * E1/E2 ** * 315 kW, 380-480 VAC and 355 kW, 525-600 VAC only! ** Remaining E1+E2 power sizes.
  • Page 54 ® 3. VLT AQUA Selection AQUA Drive Design Guide FC 202, P11KT5 Cable Mains Rise time Vpeak dU/dt length [m] voltage [μsec] [kV] [kV/μsec] 400 V 0.22 0.470 1.573 400 V 0.52 0.512 0.846 480 V 0.34 0.580 1.394 480 V 0.36...
  • Page 55 ® AQUA Drive Design Guide 3. VLT AQUA Selection FC 202, P30KT5 Cable Mains Rise time Vpeak dU/dt length [m] voltage [μsec] [kV] [kV/μsec] 400 V 0.216 1.000 3.773 400 V 0.250 1.000 2.000 480 V 0.264 1.150 3.788 480 V 0.400...
  • Page 56 ® 3. VLT AQUA Selection AQUA Drive Design Guide FC 202, P30KT2 Cable Mains Rise time Vpeak dU/dt length [m] voltage [μsec] [kV] [kV/μsec] 240 V 0.194 0.626 2.581 240 V 0.252 0.574 1.822 240 V 0.488 0.538 0.882 FC 202, P30KT2...

  • Page 57: 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 frequency converter at low air pressure (heights), at low speeds, with long motor cables, cables with a large cross section or at high ambient temperature.
  • Page 58 ® 3. VLT AQUA Selection AQUA Drive Design Guide A enclosures 60 AVM - Pulse Width Modulation SFAVM - Stator Frequency Asyncron Vector Modulation Illustration 3.1: Derating of I for different T for en- Illustration 3.2: Derating of I for different T...
  • Page 59 ® AQUA Drive Design Guide 3. VLT AQUA Selection B enclosures 60 AVM - Pulse Width Modulation SFAVM - Stator Frequency Asyncron Vector Modulation Illustration 3.5: Derating of I for different T for en- Illustration 3.6: Derating of I for different T...
  • Page 60 ® 3. VLT AQUA Selection AQUA Drive Design Guide 60 AVM - Pulse Width Modulation, 525 - 600 V (except P315) SFAVM - Stator Frequency Asyncron Vector Modulation Illustration 3.11: Derating of I for different T for en- Illustration 3.12: Derating of I...
  • Page 61 3.5.3. Derating for Low Air Pressure The cooling capability of air is decreased at lower air pressure. At altitudes higher than 2 km, please contact Danfoss Drives regarding PELV. Below 1000 m altitude no derating is necessary but above 1000 m the ambient temperature (T ) or max.

  • Page 62: Mechanical Dimension

    ® 3. VLT AQUA Selection AQUA Drive Design Guide 3.5.5. Derating for Installing Long Motor Cables or Cables with Larger Cross-Section The maximum cable length for this frequency converter is 300 m unscreened and 150 m screened cable. The frequency converter has been designed to work using a motor cable with a rated cross-section. If a cable with a larger cross-section is used, reduce the output current by 5% for every step the cross-section is increased.
  • Page 63 ® AQUA Drive Design Guide 3. VLT AQUA Selection ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 64 ® 3. VLT AQUA Selection AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 65: Options And Accessories

    AQUA Drive Design Guide 3. VLT AQUA Selection 3.7. Options and Accessories Danfoss offers a wide range of options and accessories for the VLT frequency converters. 3.7.1. Mounting of Option Modules in Slot B The power to the frequency converter must be disconnected.
  • Page 66 ® 3. VLT AQUA Selection AQUA Drive Design Guide Galvanic Isolation in the MCB 101 Digital/analog inputs are galvanically isolated from other inputs/outputs on the MCB 101 and in the control card of the drive. Digital/analog outputs in the MCB 101 are galvanically isolated from other inputs/outputs on the MCB 101, but not from these on the control card of the drive.
  • Page 67 ® AQUA Drive Design Guide 3. VLT AQUA Selection 3.7.3. Digital inputs - Terminal X30/1-4 Parameters for set-up: 5-16, 5-17 and 5-18 Number of digital Voltage level Voltage levels Input impedance Max. load inputs 0-24 V DC PNP type: Approx. 5 k ohm ±...
  • Page 68 ® 3. VLT AQUA Selection AQUA Drive Design Guide A2-A3-B3 A5-B1-B2-B4-C1-C2-C3-C4 IMPORTANT! The label MUST be placed on the LCP frame as shown (UL approved). Warning Dual supply How to add the MCB 105 option: • See mounting instructions in the beginning of section Options and Accessories •...
  • Page 69 ® AQUA Drive Design Guide 3. VLT AQUA Selection 3.7.8. 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 control card and any option card installed. This enables full operation of the LCP (including the parameter setting) and fieldbusses without mains supplied to the power section.

  • Page 70: Analog I/O Option Mcb

    ® 3. VLT AQUA Selection AQUA Drive Design Guide 3.7.9. Analog I/O option MCB 109 The Analog I/O card is supposed to be used in e.g. the following cases: • Providing battery back-up of clock function on control card •...
  • Page 71 ® AQUA Drive Design Guide 3. VLT AQUA Selection Analog inputs - terminal X42/1-6 ® Parameter group for read out: 18-3* See also AQUA Drive Programming Guide, MG20OXYY ® Parameter groups for set-up: 26-0*, 26-1*, 26-2* and 26-3* See also...
  • Page 72 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 verity...
  • Page 73 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 74 ® 4. How to Order AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 75: How To Order

    It is possible to design a VLT AQUA frequency converter 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 a to the Danfoss sales office, i.e.:...

  • Page 76: Type Code String

    36-37 XX: Standard software DX: No option D options 38-39 D0: DC back-up Table 4.1: Type code description. The various options are described further in the VLT AQUA Drive Design Guide. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 77: Ordering Numbers

    130B0047 1) Only IP21 / > 11 kW Options can be ordered as factory built-in options, see ordering information. For information on fieldbus and application option combatibility with older software versions, please contact your Danfoss supplier. ® MG.20.N3.02 - VLT...
  • Page 78 144 A 110, 132 130B2333 130B2298 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 ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 79 130B2318 130B2292 1200 A P630 P710 2 kHz 60 Hz 130B2318 130B2292 1200 A par. 14-01 Switching Frequency When using Sine-wave filters, the switching frequency should comply with filter specifications in ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 80 2 kHz 60 Hz 130B2407 130B2394 1500 A 800 kW 1000 kW 2 kHz 60 Hz 130B2407 130B2394 1500 A 1000 kW 1100 kW 2 kHz 60 Hz 130B2410 130B2395 2300 A ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 81: How To Install

    1 + 2 only available in units with brake chopper. Only one relay connector is included for FC 101/202/301 units. For DC link connection (Load sharing) the connector 1 can be ordered separately (Code no 130B1064) An eight pole connector is included in accessory bag for FC 301 without Safe Stop. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 82 The service life of the frequency converter is reduced if derating for ambient temperature is not taken into account. 5.1.4. Field Mounting For field mounting the IP 21/IP 4X top/TYPE 1 kits or IP 54/55 units (planned) are recommended. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 83: Electrical Installation

    Make sure the frequency converter is properly earthed. Connect to earth connection (terminal 95). Use screw from the accessory bag. Place plug connector 91, 92, 93 from the accessory bag onto the terminals labelled MAINS at the bottom of the frequency converter. Connect mains wires to the mains plug connector. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 84 Do not connect 400 V frequency converters with RFI-filters to mains supplies with a voltage between phase and earth of more than 440 V. For IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase and earth. Illustration 5.1: Terminals for mains and earthing. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 85 Illustration 5.2: How to connect to mains and earthing with disconnector (A5 enclosure). 5.2.4. Motor Connection Motor cable must be screened/armoured. If an unscreened/unarmoured cable is used, some EMC requirements are not complied with. EMC specifications For more information, see ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 86 ® 5. How to Install AQUA Drive Design Guide Illustration 5.3: Mounting of decoupling plate. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 87 Avoid mounting with twisted screen ends (pigtails), which will spoil high frequency screening effects. • If it is necessary to split the screen to install a motor isolator or motor relay, the screen must be continued with the lowest possible HF impedance. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 88 Non UL compliance If UL/cUL is not to be complied with, Danfoss recommends using the fuses mentioned in table 5.2, which will ensure compliance with EN50178: In case of malfunction, not following the recommendation may result in unnecessary damage to the frequency converter.
  • Page 89 JKS-150 JJN-125 2028220-125 KLN-R125 A2K-125R KTN-R125 JKS-150 JJN-125 2028220-125 KLN-R125 A2K-125R FWX-150 2028220-150 L25S-150 A25X-150 FWX-200 2028220-200 L25S-200 A25X-200 FWX-250 2028220-250 L25S-250 A25X-250 Table 5.4: UL fuses 200 - 240 V ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 90 L50S fuses from LITTEL FUSE may substitute L50S fuses for 240 V frequency converters. A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V frequency converters. A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V frequency converters. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 91 Illustration 5.4: A1, A2, A3,B3, B4, C3 and C4 enclosures 5.2.9. Control Terminals Drawing reference numbers: 10 pole plug digital I/O. 3 pole plug RS485 Bus. 6 pole analog I/O. USB Connection. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 92 ® 5. How to Install AQUA Drive Design Guide Illustration 5.6: Control terminals (all enclosures) ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 93 Remove the screw driver. 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. 0.4 x 2.5 mm ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 94 Connect terminals 18 and 27 to +24 V (terminal 12/13) Default settings: 18 = Start 27 = stop inverse Illustration 5.8: Terminal 37 available with Safe Stop Function only! ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 95 If this occurs, you may have to break the screen or insert a 100 nF capacitor between screen 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 96 (terminals 68 and 69). See drawing Diagram showing all electrical terminals in section Electrical Installation. Default setting: S201 (A53) = OFF (voltage input) S202 (A54) = OFF (voltage input) S801 (Bus termination) = OFF ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 97: Final Set-Up And Test

    Press the [Hand on] key. A progress bar indicates if the AMA is in progress. Stop the AMA during operation Press the [OFF] key - the frequency converter enters into alarm mode and the display shows that the AMA was terminated by the user. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 98 "Report Value” in the [Alarm Log] shows the last measuring sequence carried out by the AMA, before the frequency converter 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 99: Safe Stop Installation

    (if connected) remains activated. Then reapply 24 V DC to terminal 37. The test step is passed if the motor remains in the coasted state, and the mechanical brake (if connected) remains activated. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 100: Additional Connections

    Illustration 5.12: DC bus connections for enclosure B3. Illustration 5.15: DC bus connections for enclosure C4. Illustration 5.14: DC bus connections for enclosure C3. Please contact Danfoss if you require further information. 5.5.2. Brake Connection Option The connection cable to the brake resistor must be screened/armoured.
  • Page 101 5. How to Install Dynamic brake calls for extra equipment and safety considerations. For further information, please contact Danfoss. Use cable clamps to connect the screen to the metal cabinet of the frequency converter and to the decoupling plate of the brake resistor.
  • Page 102 (A5, B1 and B2 enclosures). (C1 and C2 enclosures). The relay connections are shown in the cut-out with relay plugs (from the Accessory Bag) fitted. Illustration 5.20: Terminals for relay connection ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 103 Relay 1 and relay 2 are programmed in par. 5-40, 5-41, and 5-42. • Terminal 03: normal closed 240 V AC Relay 2 Additional relay outputs by using option module MCB 105. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 104 Provide further motor protection by e.g. thermistors in each motor or individual thermal relays. (Circuit breakers are not suit- able as protection). ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 105: Installation Of Misc. Connections

    The RS485 bus must be terminated by a resistor network at both ends. For this purpose, set switch S801 on the control card for "ON". Switches S201, S202, and S801 For more information, see the paragraph Communication protocol must be set to FC MC par. 8-30. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 106 ® 5. How to Install AQUA Drive Design Guide 5.6.2. How to Connect a PC to the VLT AQUA Drive To control or program the frequency converter from a PC, install the MCT 10 Set-up Software. How to Install >...

  • Page 107: Safety

    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 frequency converters as well as non-Danfoss frequency converters with different additional harmonic reduction devices, such as Danfoss AHF filters and 12-18-pulse rectifiers, can be calculated.

  • Page 108: Emc-Correct Installation

    If the installation is not carried out according to the guideline and if unscreened cables and control wires are used, some emission requirements are not EMC test results complied with, although the immunity requirements are fulfilled. See the paragraph ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 109 5.8.2. Use of EMC-Correct Cables Danfoss recommends braided screened/armoured cables to optimise 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 110 ® 5. How to Install AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 111 Fourier analysis and split up into sine-wave which increases the input current I . A non-sinusoidal current is trans- currents with different frequencies, i.e. different harmonic currents I with 50 Hz as the basic frequency: ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 112: 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 Earth Leakage Current a brief discharge on power-up see section for further information. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 113: Application Examples

    Terminal 27= Stop par. 5-12 [6] Stop inverse Par. 5-10 Digital Input, Terminal 18 Latched start Digital Input, Terminal 27 Stop inverse Par. 5-12 Illustration 6.2: Terminal 37: Available only with Safe Stop Function! ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 114: Potentiometer Reference

    This means that when the SLC starts, it evaluates (and only ) each scan interval. Only when is evaluated TRUE, the SLC executes action [1] and starts evaluating event [2] ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 115 In applications where a PLC is generating a simple sequence the SLC may take over elementary tasks from the main control. SLC is designed to act from event send to or generated in the VLT AQUA Drive . The frequency converter will then perform the pre-programmed action.

  • Page 116: Slc Application Example

    Set Action 2 in par. 13-52 [2] to [29] Select preset 1 Set Action 3 in par. 13-52 [3] to [11] Set Action 4 in par. 13-52 [4] to No Action ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 117 When the variable pump (lead) is connected directly to the drive, the other 2 pumps are controlled by the two built-in relays. When lead pump alternations is enabled, pumps are connected to the built-in relays and the drive is capable of operating 2 pumps. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 118: System Status And Operation

    • Destage at No-Flow ensures that all fixed speed pumps are stopped individually until the no-flow status disappears. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 119: 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. 6.1.12. Fixed Variable Speed Pump Wiring Diagram ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 120: Lead Pump Alternation Wiring Diagram

    The system consists of a submersible pump controlled by a Danfoss VLT AQUA Drive and a pressure transmitter. The transmitter gives a 4-20 mA feedback signal to the VLT AQUA Drive, which keeps a constant pressure by controlling the speed of the pump. To design a drive for a submersible pump application, there are a few important issues to take into consideration.
  • Page 121 It is important that the system is operated with a minimum of wear and tear of the pump and motor. A Danfoss Sine-Wave filter can lower the motor insulation stress and increase lifetime (check actual motor insulation and VLT AQUA Drive du/dt specification). It is recommended to use a filter to reduce the need for service.
  • Page 122 ® 6. Application Examples AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 123: Master/Follower Operation Application

    Application Description The system used as example contains 4 equal sized pumps in a water distribution system. They are each connected to a Danfoss VLT AQUA Drive. A pressure transmitter with an analogue format of 4-20mA is used as feedback and connected to one of the drives named the master drive. The master drive also includes the Danfoss VLT Extended Cascade controller option MCB-101.
  • Page 124 Settings for the master drive only Use the “Closed Loop” Wizard under “Quick Menu_Function Setup”, to easily set up the feedback settings and the PID controller. Set up the master configuration in par. 27-** ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 125 Pumps with priority 2 will only be staged on when there is no priority 1 pumps available. It might be needed to fine adjust the on/off speed to optimise the energy consumption. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 126 ® 7. RS-485 Installation and Set-up AQUA Drive Design Guide ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 127: Installation And Set-Up

    Connect signal wires to terminal 68 (P+) and terminal 69 (N-) on the main control board of the frequency converter. Connect the cable screen to the cable clamps. Screened, twisted-pair cables are recommended in or- der to reduce noise between conductors. Illustration 7.1: Network Terminal Connection ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 128 RS-485 bus. Terminator Switch Factory Setting The factory setting for the dip switch is OFF. 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...

  • Page 129: Fc Protocol Overview

    7. RS-485 Installation and Set-up 7.2. FC Protocol Overview The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss Drives standard fieldbus. It defines an access technique according to the master-slave principle for communications via a serial bus.

  • Page 130: Network Configuration

    ® 7. RS-485 Installation and Set-up AQUA Drive Design Guide 7.3. Network Configuration 7.3.1. VLT AQUA Frequency Converter Set-up Set the following parameters to enable the FC protocol for the VLT AQUA. Parameter Number Parameter name Setting 8-30 Protocol 8-31...
  • Page 131 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.N3.02 - VLT is a registered Danfoss trademark...
  • Page 132 Command cannot be performed text transferred If the command cannot be performed, the slave sends this response: 0111 Command cannot be performed - and issues the following fault report in the parameter value (PWE): ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 133 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 characters high-byte must be “5”. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 134 ® 7. RS-485 Installation and Set-up AQUA Drive Design Guide 7.4.11. Data Types Supported by VLT AQUA Data types Description Integer 16 Integer 32 Unsigned 8 Unsigned 16 Unsigned 32 Text string Byte string Time difference Reserved Bit sequence Unsigned means that there is no operational sign in the telegram.

  • Page 135: Examples

    These operating instructions assume that the installed controller supports the interfaces in this document and that all the requirements stipulated in the controller, as well as the frequency converter, are strictly observed, along with all limitations therein. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 136: Vlt Aqua With Modbus Rtu

    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...
  • Page 137 This tells the master what kind of error occurred, or the reason for the exception. Please also refer to the sections Function Codes Supported by Modbus RTU Exception Codes. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 138 Parameter write control (master to slave) Master to slave Parameter changes are written to the RAM of the frequency con- verter Parameter changes are written to the RAM and EEPROM of the frequency converter. 66-65536 Reserved ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 139 * Used to specify the index number to be used when accessing an indexed parameter. 7.8.9. How to Control 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 140: How To Access Parameters

    The PNU (Parameter Number) is translated from the register address contained in the Modbus read or write message. The parameter number is translated to Modbus as (10 x parameter number) DECIMAL. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 141 Non standard data types are text strings and are 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). ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 142: Examples

    Field Name Example (HEX) Slave Address 01 (frequency converter address) Function 01 (read coils) Byte Count 02 (2 bytes of data) Data (Coils 40-33) Data (Coils 48-41) 06 (STW=0607hex) Error Check (CRC) ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 143 The normal response is an echo of the query, 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) ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 144 01 (frequency converter 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) ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 145 Slave Address Function Byte Count Data HI (Register 40001) Data LO (Register 40001) Data HI (Register 40002) Data LO (Register 40002) Data HI (Register 40003) Data LO (Register 40003) Error Check (CRC) ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 146 Response The normal response is an echo of the query, 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) ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 147 The normal response returns the slave address, function code, starting address, and quantity of registers preset. Field Name Example (HEX) Slave Address Function Starting Address HI Starting Address LO No. of Registers HI No. of registers LO Error Check (CRC) ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 148: Danfoss Fc Control Profile

    ® 7. RS-485 Installation and Set-up AQUA Drive Design Guide 7.11. Danfoss FC Control Profile 7.11.1. Control Word According to FC Profile(Par. 8-10 = FC profile) Bit value = 0 Bit value = 1 Reference value external selection lsb Reference value...
  • Page 149 Control word bit 12 is chosen in par. 5-40 Function relay Bit 13/14, Selection of set-up: Use bits 13 and 14 to choose from the four menu set-ups according to the shown table: . ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 150 Local operation Bus control Out of frequency limit Frequency limit OK No operation In operation Drive OK Stopped, auto start Voltage OK Voltage exceeded Torque OK Torque exceeded Timer OK Timer exceeded ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 151 Bit 15, Timer OK/limit exceeded: Bit 15 = ’0’: The timers for motor thermal protection and thermal protection are not exceeded 100%. Bit 15 = ’1’: One of the timers exceeds 100%. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 152 Negative figures are formatted by means of 2’s complement. The Actual Output frequency (MAV) is scaled in the same way as the bus reference. The reference and MAV are scaled as follows: ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 153: Troubleshooting

    By using the [RESET] control button on the LCP control panel. Via a digital input with the “Reset” function. Via serial communication/optional fieldbus. By resetting automatically using the [Auto Reset] function, which is a default setting for VLT AQUA Drive. see par. 14-20 Reset Mode AQUA Programming Guide After a manual reset using the [RESET] button on the LCP, the [AUTO ON] button must be pressed to restart the motor.
  • Page 154 Option Configuration has Changed Safe Stop Activated Drive Initialised to Default Value Table 8.1: Alarm/Warning code list (X) Dependent on parameter LED indication Warning yellow Alarm flashing red Trip locked yellow and red ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 155: Fault Messages

    The frequency converter is still active. WARNING 6, DC link voltage low: The intermediate circuit voltage (DC) is below the undervoltage limit of the control system. The frequency converter is still active. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 156 There is a discharge from the output phases to earth, either in the cable Too long motor cable between the frequency converter and the motor or in the motor itself. Turn off the frequency converter and remove the earth fault. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 157 The load and speed combination demands a motor voltage higher than ALARM 38, Internal fault: the actual DC link voltage. Contact your local Danfoss supplier. WARNING/ALARM/TRIP 65, Control Card Over Temperature: WARNING 40, Overload of Digital Output Terminal 27 Control card over temperature: The cut-out temperature of the control Check the load connected to terminal 27 or remove short-circuit connec- card is 80°...
  • Page 158 Par 14-23 according to the label on unit. Remember to select ‘Save to EEPROM’ to complete. ALARM 251, New Type Code: The frequency converter has got a new type code. ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

  • Page 159: Index

    Cable Length And Cross-section Cable Lengths And Cross Sections Ce Conformity And Labelling Clockwise Rotation Closed Loop (pid) Controller Coasting Coasting 5, 149 Communication Option Conducted Emission Connection To Mains Control Cables Control Cables ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 160 Example Of Closed Loop Pid Control External 24 V Dc Supply Extreme Running Conditions Fault Messages Fc Profile Final Set-up And Test Freeze Output Function Codes Supported By Modbus Rtu Fuses General Warning ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 161 AQUA Drive Design Guide Index Harmonic Filters High Voltage Test Hold Output Frequency How To Connect A Pc To The Vlt Aqua Drive I/os For Set Point Inputs Installation At High Altitudes Intermediate Circuit 36, 37, 52, 53, 155 Ip 21/ip 4x/ Type 1 Enclosure Kit...
  • Page 162 Screening Of Cables Serial Communication 50, 111 Serial Communication Port Set Speed Limit And Ramp Time Sfavm Side-by-side Installation Sine-wave Filter Sine-wave Filters Smart Logic Control Soft-starter Software Versions Star/delta Starter ® MG.20.N3.02 - VLT is a registered Danfoss trademark...
  • Page 163 Variable Control Of Flow And Pressure Varying Flow Over 1 Year Vibration And Shock Voltage Level Vvcplus Warning Against Unintended Start What Is Ce Conformity And Labelling? What Is Covered Ziegler Nichols Tuning Method ® MG.20.N3.02 - VLT is a registered Danfoss trademark...

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