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Danfoss VLT AQUA Drive Design Manual

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AQUA Drive Design Guide
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  • Page 1: Table Of Contents

    Contents 1. How to Read this Design Guide Copyright, Limitation of Liability and Revision Rights Approvals Symbols Abbreviations Definitions 2. Introduction to the VLT AQUA Drive Disposal Instructions CE labeling Air humidity Aggressive Environments Vibration and shock VLT AQUA Controls...
  • Page 2 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 Index MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • 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: Approvals

    AQUA Drive Design Guide 1.1.2. Approvals 1.1.3. Symbols Symbols used in this guide. NOTE Indicates something to be noted by the reader. Indicates a general warning. Indicates a high-voltage warning. Indicates default setting MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 5: Abbreviations

    "Off" key. Functions are divided into two groups. Group 2 Start, Pulse start, Reversing, Start reversing, Functions in group 1 have higher priority than Jog and Freeze output functions in group 2. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 6 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.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 7 20 mA) and the resulting reference. The maximum reference value set in par. 3-03. Determines the relationship between the reference input at 0% value (typically 0V, 0 mA, 4 mA) and the resulting reference. The minimum reference value set in par. 3-02. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 8 An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an off-load period. The operation can be either periodic duty or non-periodic duty. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 9 Smart Logic Control (SLC) The SLC is a sequence of user-defined actions executed when the associated user-defined events are evaluated as true by the SLC. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 10 In addition, a high power factor indicates that the different harmonic currents are low. The adjustable frequency drive's built-in DC coils produce a high power factor, which minimizes the imposed load on the line power supply. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 11: Introduction To The Vlt Aqua Drive

    Make sure that all voltage inputs have been disconnected and that the necessary time has passed before commencing repair work. Installation at High Altitudes At altitudes higher than 6,600 feet [2 km], please contact Danfoss Drives regarding PELV. Warning against Unintended Start 1.

  • Page 12: Disposal Instructions

    2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide quency drive, or if a temporary overload or a fault in the supply line or the motor connection ceases. Warning: Touching the electrical parts may be fatal - even after the equipment has been dis- connected from line power.

  • Page 13: Ce Labeling

    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 uses CE labels in accordance with the directive and will issue a declaration of conformity upon request.
  • Page 14 The Design Guide offers detailed instructions for installation to ensure EMC-correct installation. Furthermore, Danfoss specifies which our different products comply with. Danfoss gladly provides other types of assistance that can help you obtain the best EMC result. MG.20.N2.22 - VLT ®...

  • Page 15: Air Humidity

    EMC properties of the appliance, system or installation rests with the installer. To assist the installer, Danfoss has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for power drive systems are complied with, provided that the EMC-correct instructions for installation are followed;...

  • Page 16: Vibration And Shock

    2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide NOTE Mounting adjustable frequency drives in aggressive environments increases the risk of stoppages and considerably reduces the life of the drive. Before installing the adjustable frequency drive, check the ambient air for liquids, particles and gases.
  • Page 17 ® AQUA Drive Design Guide 2. Introduction to the VLT AQUA Drive If the system in question only needs to be able to supply a flow corresponding to 100% a few days each year, while the average is below 80% of the rated flow for the remainder of the year, the amount of energy saved is even greater than 50%.
  • Page 18 2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide Pump characteristics Energy savings shaft shaft output Flow distribution over 1 year Distribution Valve regulation Adjustable frequency drive control Hours Power Consumption Power Consumption 42,5 18.615 42,5 18.615...
  • Page 19 ® AQUA Drive Design Guide 2. Introduction to the VLT AQUA Drive 2.7.6. Cos φ compensation Generally speaking, an adjustable frequency drive with a cos φ of 1 provides power factor cor- rection for the cos φ of the motor, which means that there is no need to make allowance for the cos φ...

  • Page 20: Vlt Aqua Controls

    2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide 2.8. VLT AQUA Controls 2.8.1. Control Principle An adjustable frequency drive rectifies AC voltage from line into DC voltage, after which DC voltage is converted into an AC current with a variable amplitude and frequency.
  • Page 21 ® AQUA Drive Design Guide 2. Introduction to the VLT AQUA Drive After pressing the [Auto On] key, the adjust- able frequency drive goes into auto mode and follows (as default) the remote reference. In this mode, it is possible to control the adjust- able frequency drive via the digital inputs and 130BP046.10...

  • Page 22: Pid

    2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide Reference Handling - Local Reference 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. It then compares this feedback to a setpoint reference value and determines the error, if any, between these two signals.
  • Page 23 ® AQUA Drive Design Guide 2. Introduction to the 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 the 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 sit- uations where a conversion function is applied to the feedback signal, or where multiple feedback signals and/or setpoint references are used.
  • Page 25 ® AQUA Drive Design Guide 2. Introduction to the 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 the 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 0-02 drive output frequency.
  • Page 27 ® AQUA Drive Design Guide 2. Introduction to the VLT AQUA Drive 2.9.6. Manual PID Adjustment Start the motor Set par. 20-93 (PID Proportional Gain) to 0.3 and increase it until the feedback signal begins to oscillate. If necessary, start and stop the drive, or make step changes in the setpoint reference to attempt to cause oscillation.
  • Page 28 2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide NOTE: P should be measured when the amplitude of oscillation is relatively small. The output must not saturate (i.e., the maximum or minimum feedback signal must not be reached during the test).
  • Page 29 ® AQUA Drive Design Guide 2. Introduction to the VLT AQUA Drive 2.9.8. Reference Handling A block diagram of how the drive produces the remote reference is shown below. The Remote Reference is comprised of: • Preset references. • External references (analog inputs, pulse frequency inputs, digital potentiometer inputs and serial communication bus references).
  • Page 30 2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide input is programmed to increase the reference, while another digital input is programmed to de- crease the reference. A third digital input can be used to reset the digipot reference. All reference resources and the bus reference are added to produce the total external reference.
  • Page 31 ® AQUA Drive Design Guide 2. Introduction to the VLT AQUA Drive Multi-zone, Multi-setpoint applies an individual setpoint reference to each feedback. The drive’s closed-loop controller choo- Multi-setpoint ses one pair to control the drive based on the user’s selection in par. 20-20. If [14] is selected, the setpoint/feedback pair with the smallest difference controls the speed of the drive.

  • Page 32: General Aspects Of Emc

    2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide 2.10. General aspects of EMC 2.10.1. 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 In order to reduce the interference level from the entire system (unit + installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables.
  • Page 34 2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide 2.10.4. EMC Immunity In order to document immunity against interference from electrical phenomena, the following immunity tests have been performed on a system consisting of an adjustable frequency drive (with options, if relevant), a shielded control cable and a control box with potentiometer, motor cable and motor.

  • Page 35: Galvanic Isolation (Pelv)

    The functional galvanic isolation (a and b in drawing) is for the 24 V backup option and for the RS-485 standard bus interface. At altitudes higher than 6,600 feet [2 km], please contact Danfoss Drives regarding PELV. MG.20.N2.22 - VLT ®...

  • Page 36: Ground Leakage Current

    2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide 2.12. Ground leakage current Warning: Touching the electrical parts may be fatal - even after the equipment has been dis- connected from line power. Also make sure that other voltage inputs have been disconnected, such as load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic backup.
  • Page 37 2. Introduction to the VLT AQUA Drive 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 38: Mechanical Brake Control

    2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide NOTE Monitoring the braking energy is not a safety function; a thermal switch is required for that purpose. The brake resistor circuit is not protected against ground leakage.
  • Page 39 ® AQUA Drive Design Guide 2. Introduction to the VLT AQUA Drive The control unit may attempt to correct the ramp if possible (par. 2-17 Overvoltage Control The inverter turns off to protect the transistors and the intermediate circuit capacitors when a certain voltage level is reached.

  • Page 40: Safe Stop Operation

    2. Introduction to the VLT AQUA Drive ® AQUA Drive Design Guide 2.15.1. Motor Thermal Protection The motor temperature is calculated on the basis of motor current, output frequency, and time How to Program or thermistor. See par. 1-90 in the chapter 2.15.2.
  • Page 41 ® AQUA Drive Design Guide 2. Introduction to the VLT AQUA Drive NOTE The safe stop function of the FC 202 can be used for asynchronous and synchronous motors. It may happen that two faults occur in the adjustable frequency drive's power semiconductor.
  • Page 42 3. VLT AQUA Selection ® AQUA Drive Design Guide MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 43: Vlt Aqua Selection

    A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 44 A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 45 A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 46 A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 47: Line Supply 3 X 380-480 V Ac

    A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 48 A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 49 A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 50 A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5%). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 51 158°C ± 9°C [70°C ± 5°C] (Guideline - these temperatures may vary for different power sizes, enclosures, etc.). The VLT AQUA Drive has an auto-derating function to prevent its heatsink from reaching 203°F [95°C].
  • Page 52 AQUA Drive Design Guide 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 * 0.0023 in.
  • Page 53 Max. frequency at terminal, 29, 33 5 kHz (open collector) Min. frequency at terminal 29, 33 4 Hz Voltage level see section on Digital input Maximum voltage on input 28 V DC MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 54 : ≤ 2 ms Speed control range (open-loop) 1:100 of synchronous speed Speed accuracy (open-loop) 30-4000 rpm: Maximum error of ±8 rpm All control characteristics are based on a 4-pole asynchronous motor MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 55: Efficiency

    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. Use only isolated laptop/PC as connection to the USB connector on VLT AQUA Drive or an isolated USB cable/drive. 3.2. Efficiency Efficiency of VLT AQUA (η...
  • Page 56 Integrated fan. RFI filter choke. Typical values are measured at a distance of 3.28 ft. [1 m] from the unit: At reduced fan speed (50%) Encapsulation Full fan speed [dBA] [dBA] MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 57 AC line 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 0.598 1.328 MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 58 AC line 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 1.225 1.750 MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 59 2.096 400 V 0.496 1.000 1.612 400 V 0.752 0.980 1.070 480 V 0.256 1.230 3.847 480 V 0.328 1.200 2.957 480 V 0.456 1.200 2.127 480 V 0.960 1.150 1.052 MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 60: Special Conditions

    If the adjustable frequency drive is operated at high ambient temperatures, the continuous output current should be decreased. The derating depends on the switching pattern, which can be set to 60 PWM or SFAVM in pa- rameter 14-00. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 61 3.6: Derating of I for different T for en- AMB, MAX closure B, using 60 PWM in normal torque mode closure B, using SFAVM in normal torque mode (110% over-torque) (110% over-torque) MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 62 The cooling capability of air is decreased at a lower air pressure. At altitudes higher than 6,600 feet [2 km], please contact Danfoss Drives regarding PELV. At an altitude lower than 3,280 ft [1,000 m], no derating is necessary; but at an altitude higher than 3,280 ft [1,000 m], the ambient temperature (T ) or max.

  • Page 63: Automatic Adaptations To Ensure Performance

    The capability to automatically reduce the output current extends the acceptable operating conditions even further. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 64: Mechanical Dimension

    0.35 in [9 mm] 0.35 in [9 mm] 0.35 in [9 mm] 0.35 in [9 mm] 0.35 in [9 mm] 11.7 lbs [5.3 15.4 lbs [7.0 29.8/31.3 lbs Max weight 10.8 lbs [4.9 kg] 14.6 lbs [6.6 kg] [13.5/14.2 kg] MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 65: Options And Accessories

    134.5 lbs [61 kg] 3.7. Options and Accessories Danfoss offers a wide range of options and accessories for the VLT adjustable frequency drives. 3.7.1. Mounting Option Modules in Slot B The power to the adjustable frequency drive must be disconnected.
  • Page 66 MCB 101 is used for extension of the number of digital and analog inputs and outputs of the VLT AQUA Drive. Contents: MCB 101 must be fitted into slot B in the VLT AQUA Drive. • MCB 101 option module •...
  • Page 67 If digital inputs 7, 8 or 9 are to be switched using the internal 24 V power supply (terminal 9), the connection between terminal 1 and 5 illustrated in the drawing has to be established. 3.10: Principle Diagram MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 68 3.7.6. Analog outputs - Terminal X30/5+8 Parameters for set-up: 6-6* and 16-77 Number of analog outputs Output signal level Tolerance Max. load 0/4 - 20 mA ± 0.1 mA < 500 ohm MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 69 • Select the relay functions in par. 5-40 [6-8], 5-41 [6-8] and 5-42 [6-8]. NB (Index [6] is relay 7, index [7] is relay 8, and index [8] is relay 9) MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 70 Average input current for the adjustable frequency drive 0.9 A Max. cable length 246 ft [75 m] Input capacitance load < 10 uF Power-up delay < 0.6 s The inputs are protected. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 71: Analog I/O Option Mcb

    Management System with inputs for sensors and outputs for operating dampers and valve switches. • Support Extended PID controllers with I/Os for set point inputs, transmitter/sensor in- puts and outputs for switches. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 72 E96: Closest standard value is 523Ω, creating an input of 498.2Ω and 9.964 V. Analog inputs - terminal X42/1-6 ® Parameter group for read out: 18-3* See also AQUA Drive Programming Guide, MG20OXYY MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 73 Real-time clock (RTC) with back-up The data format of RTC includes year, month, date, hour, minutes and weekday. Accuracy of clock is better than ± 20 ppm at 77° F [25° C]. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 74 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 of different resistors that are specially designed for our How to order drives.
  • Page 75 C at the bottom of the drive and use the clamps from the accessory bag to correctly fasten the cables. Holes for cable glands: Size A2: 2x M25 and 3xM32 Size A3: 3xM25 and 3xM32 MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 76 Sine-wave filters enable use of longer motor cables in applications where the motor is installed far from the drive. The length is unfortunately limited because the filter does not reduce leakage currents in the cables. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 77: How To Order

    The drive configurator will automatically generate an eight-digit sales number to be delivered to your local sales office. Furthermore, you can establish a project list with several products and send it to a Danfoss sales representative.

  • Page 78: Type Code String

    C option software 36-37 XX: Standard software D options 38-39 DX: No option D0: DC backup 4.1: Type code description. The various options are described further in the VLT AQUA Drive Design Guide. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 79: Ordering Numbers

    130B0046 Accessory bag C2 Accessory bag, frame size C2 130B0047 1) Only IP 21 / > 14.75 HP [11 kW] Options can be ordered as factory built-in options; see ordering information. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 80 4. How to Order ® AQUA Drive Design Guide For information on serial communication bus and application option compatibility with older soft- ware versions, please contact your Danfoss supplier. 4.2.2. Ordering Numbers: Harmonic Filters Harmonic filters are used to reduce line harmonics. •...
  • Page 81 130B2318 130B2292 1200 A P630 P710 2 kHz 60 Hz 130B2318 130B2292 1200 A NOTE When using sine-wave filters, the switching frequency should comply with filter Switching Frequency specifications in par. 14-01 MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 82 130B2394 1500 A 1070 hp [800 1340 hp [1000 2 kHz 60 Hz 130B2407 130B2394 1500 A 1340 hp [1000 1475 hp [1100 2 kHz 60 Hz 130B2410 130B2395 2300 A MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 83: How To Install

    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 the FC 101/202/301 without Safe Stop. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 84 The service life of the adjustable frequency drive 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.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 85: Electrical Installation

    The plug connector for power can be removed. Make sure the adjustable frequency drive is properly grounded. Connect to ground con- nection (terminal 95). Use the screw from the accessory bag. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 86 5.4: How to connect to the line supply and grounding (C1 and C2 enclosure). NOTE Make sure that the line voltage corresponds to the line voltage of the adjustable frequency drive nameplate. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 87 5.7: Mounting of decoupling plate Attach the motor cable to terminals 96 (U), 97 (V), 98 (W). Connect to ground connection (terminal 99) on decoupling plate with screws from the accessory bag. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 88 In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply (such as an adjustable frequency drive), fit a sine- wave filter on the output of the adjustable frequency drive. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 89 Aluminum conductors are not recommended. Terminals can accept aluminum conductors, but the conductor surface has to be clean, oxidation must be removed, and the area must be sealed by neutral acid-free Vaseline grease before the conductor is connected. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 90 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 4.3 and 4.4 in order to protect service personnel and 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 91 A2K-80R 18K5 KTN-R125 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 5.3: UL fuses 200-240 V MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 92: Access To Control Terminals

    All terminals to the control cables are located underneath the terminal cover on the front of the adjustable frequency drive. Remove the terminal cover using a screwdriver (see illustration). 5.13: A5, B1, B2, C1 and C2 enclosures 5.12: A1, A2 and A3 enclosures MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 93: Electrical Installation, Control Terminals

    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] MG.20.N2.22 - 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 5.15: Terminal 37 available with Safe Stop Func- tion only! MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 95 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 96 69). Diagram showing all electrical See drawing terminals in section Electrical Installation. Default setting: S201 (A53) = OFF (voltage input) S202 (A54) = OFF (voltage input) S801 (Bus termination) = OFF MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 97: Final Set-Up And Test

    Choose between complete or reduced AMA. If an LC filter is mounted, run only the re- duced AMA, or remove the LC filter during the AMA procedure. Press the [OK] key. The display shows “Press [Hand on] to start.” MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 98 Service, make sure to mention both the number and the alarm description. NOTE Unsuccessful AMA is often caused by incorrectly registered motor nameplate data or a difference between the motor power size and the VLT AQUA Drive power size that is too great. Step 4. Set speed limit and ramp time...

  • Page 99: Safe Stop Installation

    The circuit interruption is caused by an opening door contact. The illustration also shows how to connect a non-safety-related hardware coast. 5.18: Illustration of the essential aspects of an installation to achieve a stopping category 0 (EN 60204-1) with safety cat. 3 (EN 954-1). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 100: Safe Stop Commissioning Test

    The DC bus terminal is used for DC back-up, with the intermediate circuit being supplied from an external source. Terminal numbers: 88, 89 Please contact Danfoss if you require further information. 5.5.2. Brake Connection Option The connection cable to the brake resistor 81 82 Brake resistor must be shielded/armored.
  • Page 101 01 - 03 break (normally closed) 04 - 05 make (normally open) 04 - 06 break (normally closed) Terminals for relay connection Terminals for relay connection (A2 and A3 enclosures). (A5, B1 and B2 enclosures). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 102 • Terminal 06: normal closed 240 V AC Relay 1 and relay 2 are programmed in par. 5-40, 5-41, and 5-42. Additional relay outputs by using option mod- ule MCB 105. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 103 Terminal 96 connected to U-phase Terminal 97 connected to V-phase Terminal 98 connected to W-phase Thedirection of motor rotation is changed by switching two motor phases. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 104: Installation Of Misc. Connections

    NOTE Communication protocol must be set to FC MC par. 8-30. 5.6.2. 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 soft- ware.
  • Page 105 MCT 10 Set-up Software support Profibus DP-V1 via a Master class 2 connection. This makes it possible to access on-line read/write parameters in an adjustable frequency drive via the Profibus network. This will eliminate the need for an extra communication network. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 106 Copy to and from adjustable frequency drives Documentation and print-out of parameter settings incl. diagrams Ext. User Interface Preventive Maintenance Schedule Clock settings Timed Action Programming Smart Logic Controller Set-up Cascade Control Config. Tool MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 107: Safety

    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 108: Emc-Correct Installation

    If the installation is not carried out according to the guidelines, and if non-shielded cables and control wires are used, some emission requirements will not be fulfilled, although the immunity EMC test results requirements will be. See the paragraph MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 109 5.20: EMC-compliant electrical installation of an IP 20 adjustable frequency drive. 5.8.2. 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 110 Twisted copper wire or armored steel wire cable. 1 Single-layer braided copper wire with varying percentage shield cov- erage. This is the typical Danfoss reference cable.1 Double-layer braided copper wire.1 Twin layer of braided copper wire with a magnetic, shielded/armored intermediate layer.1...
  • Page 111 Fourier analysis and split up into sine-wave currents with different frequencies, i.e., dif- ferent harmonic currents I with 50 Hz as the basic frequency: MG.20.N2.22 - 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 a brief discharge on power-up see section Ground Leakage Current for further information. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 113: Application Examples

    Terminal 27= Stop par. 5-12 [6] Digital Input, Terminal 18 Par. 5-10 Latched start Digital Input, Terminal 27 Par. 5-12 Stop inverse 6.2: Terminal 37: Available only with Safe Stop Function! MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 114 AMA, it is imperative that the application does not force the motor shaft to run, which is known to happen with windmilling in ventilation systems, for example. This disturbs the AMA function. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 115 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 116 Set Action 2 in par. 13-52 [2] to [29] Select preset 1 Set Action 3 in par. 13-52 [3] to [11] No Action Set Action 4 in par. 13-52 [4] to MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 117 (lead) is connected directly to the drive, the other 2 pumps are controlled by the two built- in relays. When lead pump alternations are enabled, pumps are connected to the built-in relays and the drive is capable of operating 2 pumps. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 118 If the lead pump has been running at minimum frequency (fmin) for a programmed amount of time with a fixed speed pump running, the lead pump contributes little to the system. When the MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 119 • De-staging at No-Flow ensures that all fixed speed pumps are stopped individually until the no-flow status disappears. 6.1.11. Fixed Variable Speed Pump Wiring Diagram MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 120 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. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 121 De-staging (if running) mal stop command) or stays in operation if already running. Ramps down Cut out Auto On Starts and stops according to Staging/De-staging commands sent via terminals or serial bus. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 122 7. RS-485 Installation and Set-up ® AQUA Drive Design Guide MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 123: Installation And Set-Up

    Connect signal wires to terminal 68 (P+) and terminal 69 (N-) on the main control board of the adjustable frequency drive. Connect the cable shield to the cable clamps. NOTE Shielded, twisted-pair cables are recommended in order to reduce noise between conductors. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 124 Use the terminator dip switch on the main control board of the adjustable frequency drive to terminate the RS-485 bus. Terminator Switch Factory Setting NOTE The factory setting for the dip switch is OFF. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 125 When crossing is unavoidable, the RS-485 cable must cross motor and brake resistor cables at an angle of 90 degrees. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 126: Fc Protocol Overview

    AQUA Drive Design Guide 7.2. FC Protocol Overview The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss Drives standard serial communication bus. It defines an access technique according to the master-slave principle for communications via a serial bus.

  • Page 127: Network Configuration

    (LGE) and a byte denoting the adjustable frequency drive address (ADR). A number of data bytes (variable, depending on the type of telegram) follows. The telegram is completed by a data control byte (BCC). MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 128 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.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 129 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.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 130 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.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 131 For example, read the unit size and line voltage range in par. 15-40 . When a text string is transferred (read), the length of the telegram is variable, and the texts are of different lengths. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 132 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. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 133: Examples

    Note: Parameter 4-14 is a single word, and the parameter command for write in EEPROM is “E”. Parameter number 414 is 19E in hexa- decimal. The response from the slave to the master will MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 134 If the value in par. 3-41 is 10 s, the response from the slave to the master will be: NOTE 3E8 Hex corresponds to 1000 decimal. The conversion index for par. 3-41 is -2, i.e., 0.01. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 135: Modbus Rtu Overview

    If an error occurs in receipt of the message, or if the slave is unable to perform the requested action, the slave will construct an error message and send it in response, or a timeout will occur. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 136: Vlt Aqua With Modbus Rtu

    Modbus RTU messages addressed to zero are broadcast messages. No response is permitted for broadcast messages. A typical message frame is shown below. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 137 This can include items such as coil or register addresses, the quantity of items to be handled and the count of actual data bytes in the field. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 138 Master to slave Parameter changes are written to the RAM of the adjustable frequency drive. Parameter changes are written to the RAM and EEPROM of the adjustable fre- quency drive. 66-65536 Reserved MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 139 Output data: Adjustable frequency drive status word register (STW). 50210 Output data: Adjustable frequency drive main actual value register (MAV). * Used to specify the index number to be used when accessing an indexed parameter. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 140 In the event of an error, the following exception codes may appear in the data field of a response message. For a full explanation of the structure of an exception (i.e., error) response, please refer Modbus RTU Message Framing Structure, Function Field. to the section MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 141: How To Access Parameters

    20 characters. If a read request for a parameter is for more characters than the parameter stores, the response is truncated. If the read request for a parameter is fewer characters than the parameter stores, the response is space-filled. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 142: Examples

    01 (adjustable frequency drive address) Function 01 (read coils) Starting Address HI Starting Address LO 20 (32 decimals) No. of Points HI No. of Points LO 10 (16 decimals) Error Check (CRC) MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 143 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) MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 144 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) MG.20.N2.22 - 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.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 146 Response: the normal response is an echo of the query, which is returned after the register con- tents 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.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 147 The normal response returns the slave address, function code, starting address and quantity of preset registers. 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.N2.22 - 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...
  • Page 149 Bit 07, Reset: Bit 07 = ’0’: No reset. Bit 07 = ’1’: Resets a trip. Reset is activated on the leading edge of the signal, i.e., when changing from logic ’0’ to logic ’1’. Bit 08, Jog: Bit 08 = ’1’: The output frequency is determined by par. 3-19 Jog Speed MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 150 Reversing Select . Bit 15 causes reversing only when Ser. communication, Logic or or Logic and is selected. 7.11.2. Status Word According to FC Profile (STW) (Par. 8-10 = FC profile) MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 151 Bit 06 = ’0’: The adjustable frequency drive is not in fault mode. Bit 06 = “1”: The adjustable frequency drive is tripped and locked. Bit 07, No warning/warning: Bit 07 = ’0’: There are no warnings. Bit 07 = ’1’: A warning has occurred. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 152 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. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 153 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.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 154 8. Troubleshooting ® AQUA Drive Design Guide MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 155: Troubleshooting

    Via serial communication/optional serial communication bus. For automatically resetting using the [Auto Reset] function, which is a default setting for Reset Mode VLT AQUA Drive, see par. 14-20 VLT AQUA Programming Guide NOTE After a manual reset using the [RESET] button on the LCP, the [AUTO ON] button must be pressed to restart the motor.
  • Page 156 Output Frequency at Maximum Limit Voltage Limit Control Board Overtemperature Heatsink Temperature Low Option Configuration Has Changed Safe Stop Activated Drive Initialized to Default Value 8.1: Alarm/Warning code list (X) Dependent on parameter MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 157 6-22, respectively. the 10 V supply is overloaded. Max. 15 mA or minimum 590 Ω. WARNING/ALARM 3 No motor: No motor has been connected to the output of the adjustable frequency drive. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 158 100% in par. 1-90. The fault is that the motor has been overloaded by more than nominal current for too long. Check that the motor par. 1-24 is set correctly. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 159 There is a short-circuit in the motor or on the Turn off the adjustable frequency drive and motor terminals. remove the brake resistor. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 160 WARNING/ALARM 29 ALARM 38 Drive overtemperature: Internal fault: If the enclosure is IP 20 or IP 21/TYPE 1, the Contact your local Danfoss supplier. cut-out temperature of the heat-sink is 203 F [95 C +5 C]. The temperature fault WARNING 47...
  • Page 161 The actual motor current has not exceeded the “release brake” current within the “Start delay” time window. WARNING 64 Voltage Limit: The load and speed combinations demand a motor voltage higher than the actual DC link voltage. MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

  • Page 162: Index

    Cable Clamps Cable Length And Cross-section Cable Lengths And Cross-sections Ce Conformity And Labeling Clockwise Rotation Closed-loop (pid) Controller Coasting Coasting 5, 149 Communication Option Conducted Emission Connection To Line Power MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 163 Example Of Closed-loop Pid Control External 24 V Dc Supply Extreme Running Conditions Fc Profile Final Set-up And Test Freeze Output Fuses Galvanic Isolation (pelv) General Warning Ground Connection Ground Leakage Current MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 164 Grounding Grounding Of Shielded/armored Control Cables 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 37, 38, 56, 57, 158...
  • Page 165 Removal Of Knockouts For Extra Cables Residual Current Device 36, 112 Rise Time Rs-485 Rs-485 Bus Connection Safety Ground Connection Safety Note Safety Regulations Save Drive Settings Serial Communication 55, 111 Serial Communication Port MG.20.N2.22 - VLT ® is a registered Danfoss trademark.
  • Page 166 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 Labeling? What Is Covered Ziegler Nichols Tuning Method MG.20.N2.22 - VLT ® is a registered Danfoss trademark.

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