Danfoss VLT AQUA Drive Series Design Manual Download

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Variable speed pump (lead)

Fixed speed pumps

Hand On

Ramps up (if stopped by a normal stop com-
mand) or stays in operation if already running

Destaging (if running)

Off

Ramps down

Cut out

Auto On

Starts and stops according to commands via ter-
minals or serial bus

Staging/Destaging

VLT

AQUA Drive Design Guide

6 Application Examples

MG.20.N5.02 - VLT

is a registered Danfoss trademark

167

Summary of Contents for VLT AQUA Drive Series

Page 1: ...l 34 Extreme running conditions 34 Safe Stop Operation optional 37 3 VLT AQUA Selection 39 General Specifications 39 Efficiency 54 Special Conditions 60 Options and Accessories 65 General Description...

Page 2: ...Current Device 158 6 Application Examples 159 Potentiometer Reference 160 Automatic Motor Adaptation AMA 160 SLC Application Example 161 System Status and Operation 164 Cascade Controller Wiring Diag...

Page 3: ...8 Troubleshooting 195 Index 198 VLT AQUA Drive Design Guide Contents MG 20 N5 02 VLT is a registered Danfoss trademark 3...

Page 4: ...1 How to Read this Design Guide VLT AQUA Drive Design Guide 4 MG 20 N5 02 VLT is a registered Danfoss trademark 1...

Page 5: ...foss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former or present users of such revisions or changes...

Page 6: ...H Milliampere mA Millisecond ms Minute min Motion Control Tool MCT Nanofarad nF Newton Meters Nm Nominal motor current IM N Nominal motor frequency fM N Nominal motor power PM N Nominal motor voltage...

Page 7: ...ulse start Reversing Start reversing Jog and Freeze output Motor fJOG The motor frequency when the jog function is activated via digital terminals fM The motor frequency fMAX The maximum motor frequen...

Page 8: ...typically 0V 0mA 4mA and the resulting reference The minimum reference value set in par 3 02 Miscellaneous Analog Inputs The analog inputs are used for controlling various functions of the frequency...

Page 9: ...es from the frequency converter i e in a front panel by means of the installation kit option The Local Control Panel is available in two versions Numerical LCP101 NLCP Graphical LCP102 GLCP lsb Least...

Page 10: ...emoving the cause of the fault and reconnecting the frequency converter Restart is prevented until the trip state is cancelled by activating reset or in some cases by being programmed to reset automat...

Page 11: ...equency converter is connected to mains Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs 7 Please note that the frequency...

Page 12: ...00 kW Be aware that there may be high voltage on the DC link even when the LEDs are turned off 2 1 3 Disposal Instruction Equipment containing electrical components may not be disposed of together wit...

Page 13: ...ted that the responsibility for the final EMC properties of the appliance system or installation rests with the installer 2 3 2 What Is Covered The EU Guidelines on the Application of Council Directiv...

Page 14: ...e necessary protective measures increases the risk of stoppages thus reducing the life of the frequency converter Liquids can be carried through the air and condense in the frequency converter and may...

Page 15: ...ns and Pumps A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps For further information see the text The Laws...

Page 16: ...nd power consumption on RPM Q Flow P Power Q1 Rated flow P1 Rated power Q2 Reduced flow P2 Reduced power H Pressure n Speed regulation H1 Rated pressure n1 Rated speed H2 Reduced pressure n2 Reduced s...

Page 17: ...ency converter can vary the speed of the fan or pump thereby obtaining variable control of flow and pressure Furthermore a frequency converter can quickly adapt the speed of the fan or pump to new flo...

Page 18: ...lta starter or soft starter is widely used Such motor starters are not required if a frequency converter is used As illustrated in the figure below a frequency converter does not consume more than rat...

Page 19: ...Open Loop Illustration 2 4 Open Loop structure In the configuration shown in the illustration above par 1 00 Configuration Mode is set to Open loop 0 The resulting reference from the reference handli...

Page 20: ...is always active but both can not be active at the same time NB Local Reference will be restored at power down par 1 00 Configuration Mode determines what kind of application control principle i e Op...

Page 21: ...ndling can be configured to work with applications requiring advanced control such as multiple setpoints and multiple feedbacks Three types of control are common Single Zone Single Setpoint Single Zon...

Page 22: ...roller since this has the smaller difference feedback is higher than setpoint resulting in a negative difference If Multi Setpoint Min 13 is selected Zone 2 s setpoint and feedback is sent to the PID...

Page 23: ...for Open Loop and Closed Loop operation A block diagram of how the drive produces the Remote Reference is shown below VLT AQUA Drive Design Guide 2 Introduction to VLT AQUA Drive MG 20 N5 02 VLT is a...

Page 24: ...ence resources and the bus reference are added to produce the total External Reference The External Reference the Preset Reference or the sum of the two can be selected to be the active reference Fina...

Page 25: ...ec Depends on motor load size Also active in Hand mode Prohibit the motor from reversing if necessary 4 10 Clockwise 0 Set acceptable limits for the motor speed 4 12 4 14 4 19 10 Hz Motor min speed 50...

Page 26: ...par 6 16 6 26 5 54 or 5 59 as required 2 9 General aspects of EMC 2 9 1 General Aspects of EMC Emissions Electrical interference is usually conducted at frequences in the range 150 kHz to 30 MHz Airb...

Page 27: ...are used some emission requirements are not complied with although the immunity requirements are ob served In order to reduce the interference level from the entire system unit installation make motor...

Page 28: ...e installed and commissioned by a professional Class A Group 1 C3 frequency converters installed in the second environment industrial with a supply volt age lower than 1000 V Class A Group 2 C4 freque...

Page 29: ...o 0 75 90 kW 525 600 V T6 150 No No No No 11 90 kW 525 690 V T7 Yes No No No No 45 1200 kW 525 690 V T7 150 No No No No H3 0 25 45 kW 200 240 V T2 75 50 10 Yes No 0 37 90 kW 380 480 V T4 75 50 10 Yes...

Page 30: ...EN 61000 3 2 Class A Power sizes from P1K1 and up to P18K in T2 and up to P90K in T4 complies with IEC EN 61000 3 12 Power sizes P110 P450 in T4 also complies with IEC EN 61000 3 12 even though not r...

Page 31: ...Standard bus 2 kV CM 2 kV 2 1 10 VRMS Relay wires 2 kV CM 2 kV 2 1 10 VRMS Application and Fieldbus op tions 2 kV CM 2 kV 2 1 10 VRMS LCP cable 2 kV CM 2 kV 2 1 10 VRMS External 24 V DC 2 kV CM 0 5 kV...

Page 32: ...he amount of time indicated in the Safety Precautions section Shorter time is allowed only if indicated on the nameplate for the specific unit Leakage Current The earth leakage current from the freque...

Page 33: ...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 For further selection advice please contact Danfoss NB If a shor...

Page 34: ...converter in any way by switching on the output However fault messages may appear Motor generated Overvoltage The voltage in the intermediate circuit is increased when the motor acts as a generator T...

Page 35: ...ver heated even at low speed The ETR feature is calculating the motor temperature based on actual current and speed The calculated temperature is visible as a read out parameter in par 16 18 Motor The...

Page 36: ...ecification of the used thermistor element Summary With the Torque limit feature the motor is protected for being overloaded independent of the speed With the ETR the motor is protected for being over...

Page 37: ...ot provide electrical safety NB The Safe Stop function of FC 202 can be used for asynchronous and synchronous motors It may happen that two faults occur in the frequency converter s power semiconducto...

Page 38: ...3 VLT AQUA Selection VLT AQUA Drive Design Guide 38 MG 20 N5 02 VLT is a registered Danfoss trademark 3...

Page 39: ...3 VLT AQUA Selection 3 1 General Specifications VLT AQUA Drive Design Guide 3 VLT AQUA Selection MG 20 N5 02 VLT is a registered Danfoss trademark 39 3...

Page 40: ...00 6 40 12 27 18 30 Max cable size mains motor brake mm 2 AWG 2 0 2 4 4 10 10 7 35 2 50 1 0 95 4 0 Max input current Continuous 1 x 200 240 V A 12 5 15 20 5 24 32 46 59 111 172 Intermittent 1 x 200 2...

Page 41: ...70 3 82 4 50 6 00 Max cable size mains motor brake mm 2 AWG 2 0 2 4 mm 2 4 10 AWG Max input current Continuous 3 x 200 240 V A 1 6 2 2 3 2 4 1 5 9 6 8 9 5 11 3 15 0 Intermittent 3 x 200 240 V A 1 7 2...

Page 42: ...Continuous kVA 208 V AC kVA 8 7 11 1 16 6 21 4 26 9 31 7 41 4 51 5 61 2 Max cable size mains motor brake mm 2 AWG 2 10 7 35 2 50 1 0 95 4 0 120 250 MCM Max input current Continuous 3 x 200 240 V A 22...

Page 43: ...ontinuous kVA 460 V AC kVA 11 6 16 7 27 1 51 8 Max cable size mains motor brake mm 2 AWG 2 10 7 35 2 50 1 0 120 4 0 Max input current Continuous 1 x 380 440 V A 33 48 78 151 Intermittent 1 x 380 440 V...

Page 44: ...60 V AC kVA 0 9 1 3 1 7 2 4 2 7 3 8 5 0 6 5 8 8 11 6 Max cable size mains motor brake mm 2 AWG 2 4 10 Max input current Continuous 3 x 380 440 V A 1 2 1 6 2 2 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermitten...

Page 45: ...22 2 26 30 5 42 3 50 6 62 4 73 4 102 123 Continuous kVA 460 V AC kVA 16 7 21 5 27 1 31 9 41 4 51 8 63 7 83 7 104 128 Max cable size mains motor brake mm 2 AWG 2 10 7 35 2 50 1 0 120 4 0 120 4 0 Max in...

Page 46: ...441 480V A 183 231 291 348 427 531 667 718 759 867 1022 1129 1344 1490 Max pre fuses 1 A 300 350 400 500 630 700 900 900 1600 1600 2000 2000 2500 2500 Environment Estimated power loss at 400 VAC at r...

Page 47: ...AC kVA 1 7 2 5 2 8 3 9 5 0 6 1 9 0 11 0 18 1 21 9 26 7 34 3 41 51 4 61 9 82 9 100 130 5 Continuous kVA 575 V AC kVA 1 7 2 4 2 7 3 9 4 9 6 1 9 0 11 0 17 9 21 9 26 9 33 9 40 8 51 8 61 7 82 7 99 6 130 5...

Page 48: ...100 Continuous kVA 575 V AC kVA 12 9 17 9 21 9 26 9 33 8 40 8 51 8 61 7 82 7 99 6 Continuous kVA 690 V AC kVA 15 5 21 5 26 3 32 3 40 6 49 62 1 74 1 99 2 119 5 Max cable size mains motor brake mm 2 AW...

Page 49: ...ontinuous 3 x 690 V A 58 77 87 109 128 155 197 240 296 352 400 434 482 549 607 711 828 920 1032 1227 Max mains pre fuses 1 A 125 160 200 200 250 315 350 350 400 500 550 700 700 900 900 2000 2000 2000...

Page 50: ...ment Power Factor cos near unity 0 98 Switching on input supply L1 L2 L3 power ups enclosure type A maximum 2 times min Switching on input supply L1 L2 L3 power ups enclosure type B C maximum 1 time m...

Page 51: ...urrent range at analog output 0 4 20 mA Max resistor load to common at analog output 500 Accuracy on analog output Max error 0 8 of full scale Resolution on analog output 8 bit The analog output is ga...

Page 52: ...make Max terminal load AC 1 1 on 1 3 NC 1 2 NO Resistive load 240 V AC 2 A Max terminal load AC 15 1 Inductive load cos 0 4 240 V AC 0 2 A Max terminal load DC 1 1 on 1 2 NO 1 3 NC Resistive load 60 V...

Page 53: ...re Max 50 C Derating for high ambient temperature see section on special conditions Minimum ambient temperature during full scale operation 0 C Minimum ambient temperature at reduced performance 10 C...

Page 54: ...tors the influence from the U f characteristic on efficiency is marginal However in motors from 11 kW and up the advantages are significant In general the switching frequency does not affect the effic...

Page 55: ...uch as a frequency converter fit a sine wave filter on the output of the frequency converter To obtain approximate values for cable lengths and voltages not mentioned below use the following rules of...

Page 56: ...th m Mains voltage V Rise time sec Vpeak kV dU dt kV sec 30 240 0 300 0 598 1 594 100 240 0 536 0 566 0 844 150 240 0 776 0 546 0 562 FC 202 P45KT2 Cable length m Mains voltage V Rise time sec Vpeak k...

Page 57: ...tage V Rise time sec Vpeak kV dU dt kV sec 36 480 0 396 1 210 2 444 100 480 0 844 1 230 1 165 150 480 0 696 1 160 1 333 FC 202 P22KT4 Cable length m Mains voltage V Rise time sec Vpeak kV dU dt kV sec...

Page 58: ...523 FC 202 P90KT4 Cable length m Mains voltage V Rise time sec Vpeak kV dU dt kV sec 5 480 0 371 1 170 2 523 High Power Range FC 202 P110 P250 T4 Cable length m Mains voltage V Rise time sec Vpeak kV...

Page 59: ...ltage V Rise time sec Vpeak kV dU dt kV sec 30 690 0 57 1 611 2 261 30 575 0 25 2 510 30 690 1 1 13 1 629 1 150 1 With Danfoss dU dt filter VLT AQUA Drive Design Guide 3 VLT AQUA Selection MG 20 N5 02...

Page 60: ...h can be set to 60 AVM or SFAVM in parameter 14 00 A enclosures 60 AVM Pulse Width Modulation Illustration 3 1 Derating of Iout for different TAMB MAX for enclosure A using 60 AVM SFAVM Stator Frequen...

Page 61: ...MAX for enclosure C using 60 AVM in Normal torque mode 110 over torque SFAVM Stator Frequency Asyncron Vector Modulation Illustration 3 8 Derating of Iout for different TAMB MAX for enclosure C using...

Page 62: ...ing 60 AVM in Normal torque mode 110 over torque Note P400 only SFAVM Stator Frequency Asyncron Vector Modulation Illustration 3 14 Derating of Iout for different TAMB MAX for enclosure D at 690 V usi...

Page 63: ...e ambient temperature TAMB or max output current Iout should be derated in accordance with the shown diagram Illustration 3 19 Derating of output current versus altitude at TAMB MAX for frame sizes A...

Page 64: ...e motor by choosing a larger motor However the design of the frequency converter puts a limit to the motor size Variable Quadratic torque applications VT In VT applications such as centrifugal pumps a...

Page 65: ...extends the acceptable operating conditions even further 3 6 Options and Accessories Danfoss offers a wide range of options and accessories for the frequency converters 3 6 1 Mounting of Option Modul...

Page 66: ...al 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 inpu...

Page 67: ...Illustration 3 20 Principle Diagram VLT AQUA Drive Design Guide 3 VLT AQUA Selection MG 20 N5 02 VLT is a registered Danfoss trademark 67 3...

Page 68: ...r set up 6 3 6 4 and 16 76 Number of analog voltage inputs Standardized input signal Tolerance Resolution Max Input impedance 2 0 10 V DC 20 V continuously 10 bits Approx 5 K ohm 3 6 5 Digital outputs...

Page 69: ...terminal load DC 5 V 10 mA Max switching rate at rated load min load 6 min 1 20 sec 1 1 IEC 947 part 4 and 5 When the relay option kit is ordered separately the kit includes Relay Module MCB 105 Exte...

Page 70: ...erminals must be disconnected Do not mix live parts high voltage with control signals PELV Select the relay functions in par 5 40 Function Relay 6 8 par 5 41 On Delay Relay 6 8 and par 5 42 Off Delay...

Page 71: ...put capacitance load 10 uF Power up delay 0 6 s The inputs are protected Terminal numbers Terminal 35 external 24 V DC supply Terminal 36 external 24 V DC supply Follow these steps 1 Remove the LCP or...

Page 72: ...selection available on control card e g for multi zone control with three pressure transmitters Turning frequency converter into de central I O block supporting Building Management System with inputs...

Page 73: ...x Analog Outputs supplying 0 10 VDC NB Please note the values available within the different standard groups of resistors E12 Closest standard value is 470 creating an input of 449 9 and 8 997V E24 Cl...

Page 74: ...oup for read out and write 18 3 See also Programming Guide Parameter groups for set up 26 4 26 5 and 26 6 See also Programming Guide 3 x Analog outputs Output signal level Resolution Linearity Max loa...

Page 75: ...ontroller is designed for pumping applications and this document describes the cascade controller for this application it is also possible to use the Cascade Controllers for any application requiring...

Page 76: ...the set of pumps controlled by the cascade controller 3 6 12 Extended Cascade Control MCO 101 The MCO 101 option includes 3 pieces of change over contacts and can be fitted into option slot B Electri...

Page 77: ...ertia loads this increase may lead to an over voltage trip in the converter and finally a shut down Brake resistors are used to dissipate the excess energy resulting from the regenerative braking The...

Page 78: ...ordering number is 130B1129 3 6 15 IP 21 IP 4X TYPE 1 Enclosure Kit IP 20 IP 4X top TYPE 1 is an optional enclosure element available for IP 20 Compact units enclosure size A2 A3 up to 7 5 kW If the...

Page 79: ...he cables Holes for cable glands Size A2 2x M25 and 3xM32 Size A3 3xM25 and 3xM32 A2 Enclosure A3 Enclosure Dimensions Enclosure type Height mm A Width mm B Depth mm C A2 372 90 205 A3 372 130 205 B3...

Page 80: ...es premature aging and worst of all erratic operation The majority of harmonics are reduced by the built in DC coil but if additional reduction is needed Danfoss offers two types of passive filters Th...

Page 81: ...tion Besides the features of the du dt filter the sine wave filter also reduces insulation stress and bearing currents in the motor thus leading to prolonged motor lifetime and longer periods between...

Page 82: ...provided to cool the inside of the Rittal enclosure Ordering Information Rittal TS 8 Enclosure Frame D3 Kit Part No Frame D4Kit Part No Frame E2 Part No 1800 mm 176F1824 176F1823 Not possible 2000 mm...

Page 83: ...s for the installation of NEMA 3R kits available for the frequency converter frames D3 D4 and E2 These kits are designed and tested to be used with IP00 Chassis versions of these frames in Rittal TS8...

Page 84: ...Frame size D3 176F4600 Frame size D4 176F4601 Frame size E2 176F1852 Kit contents Ductwork components Mounting hardware 16 mm M5 torx screws for top vent cover 10 mm M5 for attaching drive mounting pl...

Page 85: ...or E1 frame Required Tools Socket wrench with 7 17 mm sockets T30 Torx Driver Torques M6 4 0 Nm 35 in lbs M8 9 8 Nm 85 in lbs M10 19 6 Nm 170 in lbs Kit Contents Pedestal parts Instruction manual Illu...

Page 86: ...ustration Illustration 3 36 Mounting of drive to pedestal NB Please see the Pedestal Kit Instruction Manual 175R5642 for further information 3 7 5 Input Plate Option This section is for the field inst...

Page 87: ...ins disconnect Cautions Frequency converter contains dangerous voltages when connected to line voltage No disassembly should be attempted with power applied Electrical parts of the frequency converter...

Page 88: ...e below to set the proper tap at terminal T1 located in the rectifier cabinet For location in the drive see illustration of rectifier in the Power Connections section Input Voltage Range Tap to Select...

Page 89: ...g auxiliary customer equipment Not available if two manual motor starters are selected Terminals are off when the incoming power to the drive is off Power for the fused protected terminals will be pro...

Page 90: ...certification A third thermistor input can be provided by the PTC Thermistor Option Card MCB 112 if necessary 3 VLT AQUA Selection VLT AQUA Drive Design Guide 90 MG 20 N5 02 VLT is a registered Danfos...

Page 91: ...ove a Profibus LON works option and a General purpose I O option is included in the drive Ordering numbers for VLT AQUA Drive standard variants can also be located in the chapter How to Select Your VL...

Page 92: ...brake Display 19 G Graphical Local Control Panel GLCP N Numeric Local Control Panel NLCP X No Local Control Panel Coating PCB 20 X No coated PCB C Coated PCB Mains option 21 D Loadsharing X No Mains...

Page 93: ...o Local Control Panel D frames IP00 and IP 21 only Coating PCB 20 C Coated PCB X No coated PCB D frames 380 480 500 V only Mains option 21 X No mains option 3 Mains disconnect and Fuse 5 Mains disconn...

Page 94: ...with NAMUR terminals and class A2 RFI filter1 2 HP IRM with NAMUR terminals and class A1 RFI filter1 2 3 Brake 18 B Brake IGBT mounted X No brake IGBT R Regeneration terminals M IEC Emergency stop pus...

Page 95: ...C2 IP21 IP55 NEMA 12 130B3911 Backplate A5 IP66 NEMA 4x 130B3242 Backplate B1 IP66 NEMA 4x 130B3434 Backplate B2 IP66 NEMA 4x 130B3465 Backplate C1 IP66 NEMA 4x 130B3468 Backplate C2 IP66 NEMA 4x 130B...

Page 96: ...y bag frame size C1 130B0046 Accessory bag C2 Accessory bag frame size C2 130B0047 Accessory bag C3 Accessory bag frame size C3 130B0981 Accessory bag C4 Accessory bag frame size C4 130B0982 Small Acc...

Page 97: ...6642 P250 578 A 500 2x 175G6621 2x 175G6643 P315 P355 659 A 550 600 175G6690 175G6621 175G6693 175G6643 P400 Matching the frequency converter and filter is pre calculated based on 400V 480V and on a t...

Page 98: ...2448 130B2413 38 A P11K P22K P22K 4 kHz 60 Hz 130B2307 130B2281 48 A P15K P30K P30K 3 kHz 60 Hz 130B2308 130B2282 62 A P18K P37K P37K 3 kHz 60 Hz 130B2309 130B2283 75 A P22K P45K P55K 3 kHz 60 Hz 130B...

Page 99: ...2448 130B2413 38 A P11K P22K P22K 4 kHz 60 Hz 130B2307 130B2281 48 A P15K P30K P30K 3 kHz 60 Hz 130B2308 130B2282 62 A P18K P37K P37K 3 kHz 60 Hz 130B2309 130B2283 75 A P22K P45K P55K 3 kHz 60 Hz 130B...

Page 100: ...B2324 130B2344 45 55 55 75 115 2 130B2325 130B2345 75 90 90 110 165 2 130B2326 130B2346 110 132 150 160 260 2 130B2327 130B2347 180 200 220 250 303 2 130B2329 130B2348 260 315 430 1 5 130B2241 130B227...

Page 101: ...Hz 130B2400 130B2389 182 A 110 kW 132 kW 3 kHz 60 Hz 130B2401 130B2390 280 A 132 kW 160 kW 3 kHz 60 Hz 130B2401 130B2390 280 A 160 kW 200 kW 3 kHz 60 Hz 130B2402 130B2391 400 A 200 kW 250 kW 3 kHz 60...

Page 102: ...2418 130B2427 110 132 150 160 260 3 130B2419 130B2428 180 200 220 250 310 3 130B2420 130B2429 260 315 430 3 130B2235 130B2238 300 400 375 500 530 2 130B2236 130B2239 450 560 630 2 130B2280 130B2274 48...

Page 103: ...0 26 1920 120 150 100 14 1005 110 110 P1K1 1 1 130 152 145 0 065 1820 120 145 0 26 1920 120 150 200 27 0989 110 110 P1K5 1 5 81 110 90 0 095 1821 120 90 0 43 1921 120 100 100 10 1006 110 110 P1K5 1 5...

Page 104: ...9 161 150 0 43 1844 120 150 3 7 1944 120 300 200 7 2X0985 110 110 P5K5 5 5 62 5 115 110 0 6 1845 120 110 4 7 1945 120 120 200 6 2X0990 110 110 P7K5 7 5 45 3 83 7 80 0 85 1846 120 80 6 1 1946 120 82 2...

Page 105: ...77 2122 600 110 110 P110 110 8 8 10 7 7 3 153 2123 600 7 3 93 2123 600 110 110 P132 132 6 6 8 9 4 7 185 2124 600 4 7 113 2124 600 110 110 P160 160 6 6 7 3 4 7 224 2125 600 4 7 137 2125 600 110 110 P2...

Page 106: ...5 How to Install VLT AQUA Drive Design Guide 106 MG 20 N5 02 VLT is a registered Danfoss trademark 5...

Page 107: ...5 How to Install 5 1 Mechanical Installation Page intentionally left blank VLT AQUA Drive Design Guide 5 How to Install MG 20 N5 02 VLT is a registered Danfoss trademark 107 5...

Page 108: ...bottom mounting holes Illustration 5 2 Top and bottom mounting holes B4 C3 C4 only Accessory bags containing necessary brackets screws and connectors are included with the drives upon delivery All mea...

Page 109: ...h mm Enclosure B 90 90 130 130 242 242 242 165 231 308 370 308 370 With one C option B 130 130 170 170 242 242 242 205 231 308 370 308 370 Back plate B 90 90 130 130 242 242 242 165 231 308 370 308 37...

Page 110: ...ttom mount ing hole Lifting eye and mounting holes Lifting eye IP21 54 IP21 54 Enclosure F1 Enclosure F2 All measurements in mm Base plate mount Enclosure F3 Enclosure F4 5 How to Install VLT AQUA Dri...

Page 111: ...2281 2281 Width Back plate B 420 420 408 408 600 585 1400 1800 2000 2400 Depth C 380 380 375 375 494 494 607 607 607 607 Dimensions brackets mm inch Centre hole to edge a 22 0 9 22 0 9 22 0 9 22 0 9...

Page 112: ...injury especially when installing large units The frequency converter is cooled by means of air circulation To protect the unit from overheating it must be ensured that the ambient temperature does n...

Page 113: ...s without built in fuses ensure that the external fuses are rated correctly 5 2 2 Receiving the Frequency Converter When receiving the frequency converter please make sure that the packaging is intact...

Page 114: ...4 Recommended lifting method frame sizes D and E NB The lifting bar must be able to handle the weight of the frequency converter See Mechanical Dimensions for the weight of the different frame sizes...

Page 115: ...ched to F1 F4 frames during shipment The plinth is required to allow airflow to the drive to provide proper cooling The F frames should be positioned on top of the plinth in the final installation loc...

Page 116: ...t of the unit must be considered to enable opening of the door of the panel Illustration 5 9 Space in front of IP21 IP54 enclosure type frame size D1 and D2 Illustration 5 10 Space in front of IP21 IP...

Page 117: ...inimum doorfan s airflow required at the drive maximum ambient for the E2 is 782 m 3 h 460 cfm If the ambient is below maximum or if additional components heat loses are added within the enclosure a c...

Page 118: ...te is not mounted the frequency converter may trip on Alarm 69 Pwr Card Temp Illustration 5 11 Example of proper installation of the gland plate Frame size D1 D2 Frame size E1 Cable entries viewed fro...

Page 119: ...ame size F3 Frame size F4 F1 F4 Cable entries viewed from the bottom of the frequency converter 1 Place conduits in marked areas VLT AQUA Drive Design Guide 5 How to Install MG 20 N5 02 VLT is a regis...

Page 120: ...ted before the frequency converter is placed on the pedestal 5 2 9 IP21 Drip Shield Installation frame size D1 and D2 To comply with the IP21 rating a separate drip shield is to be installed as explai...

Page 121: ...0 6 D2 D4 160 250 160 315 19 19 9 6 9 6 19 0 6 E1 E2 315 450 355 560 19 19 9 6 9 6 19 0 6 Enclosure 200 240 V 380 480 V 525 690 V Mains Motor DC Con nection Brake Regen Relay F1 F2 F3 F4 500 1000 710...

Page 122: ...itted to the main switch if this is included NB Check that mains voltage corresponds to the mains voltage of the frequency converter name plate IT Mains Do not connect 400 V frequency converters with...

Page 123: ...Motor cable must be screened armoured If an unscreened unarmoured cable is used some EMC requirements are not complied with For more information see EMC specifications Illustration 5 16 Mounting of d...

Page 124: ...to reduce the noise level and leakage currents Connect the motor cable screen to both the de coupling plate of the frequency converter and to the metal cabinet of the motor Make the screen connection...

Page 125: ...ium surface will oxidize again 5 3 7 Fuses NB All fuses mentioned are max fuse sizes Branch circuit protection In order to protect the installation against electrical and fire hazard all branch circui...

Page 126: ...2 700 20221 170M6013 6 9URD33D08A0900 20 630 32 900 Table 5 5 Additional Fuses for Non UL Applications E enclosures 380 480 V UL Compliance VLT AQUA Bussmann Bussmann Bussmann SIBA Littel fuse Ferraz...

Page 127: ...N 50 5012406 050 KLN R50 A2K 50R 7K5 KTN R50 JKS 60 JJN 60 5012406 050 KLN R60 A2K 50R 11K KTN R60 JKS 60 JJN 60 5014006 063 KLN R60 A2K 60R A2K 60R 15K KTN R80 JKS 80 JJN 80 5014006 080 KLN R80 A2K 8...

Page 128: ...M4017 700 A 700 V 6 9URD31D08A0700 20 610 32 700 P315 170M6013 900 A 700 V 6 9URD33D08A0900 20 630 32 900 P355 170M6013 900 A 700 V 6 9URD33D08A0900 20 630 32 900 P400 170M6013 900 A 700 V 6 9URD33D08...

Page 129: ...0 170M6013 900 A 700 V 6 9URD33D08A0900 20 630 32 900 Table 5 17 Frame size E 525 690 V Size Type Bussmann PN Rating Siba Internal Bussmann Option P630 170M7081 1600 A 700 V 20 695 32 1600 170M7082 P7...

Page 130: ...ug digital I O 2 3 pole plug RS485 Bus 3 6 pole analog I O 4 USB Connection Illustration 5 19 Control terminals all enclosures 5 3 10 Control Cable Terminals To mount the cable to the terminal 1 Strip...

Page 131: ...0 4 x 2 5 mm 1 2 3 Illustration 5 20 Assembling of IP21 IP55 NEMA TYPE 12 housing with mains disconnector VLT AQUA Drive Design Guide 5 How to Install MG 20 N5 02 VLT is a registered Danfoss trademark...

Page 132: ...fre quency converter 2 Connect terminals 18 and 27 to 24 V terminal 12 13 Default settings 18 Start 27 stop inverse Illustration 5 21 Terminal 37 available with Safe Stop Func tion only 5 How to Inst...

Page 133: ...to be reckoned with 5 3 13 Electrical Installation Control Cables Illustration 5 22 Terminal 37 Safe Stop input available with Safe Stop Function only Very long control cables and analog signals may i...

Page 134: ...l Cables for the correct termination of control cables 5 3 14 Switches S201 S202 and S801 Switches S201 A53 and S202 A54 are used to select a current 0 20 mA or a voltage 0 to 10 V configuration of th...

Page 135: ...fica tions in the Design Guide See section General Specifications for correct dimensioning of motor cable cross section and length Screening of cables Avoid installation with twisted screen ends pigta...

Page 136: ...t phase insulation paper or other in sulation reinforcement suitable for operation with volt age supply such as a frequency converter fit a Sine wave filter on the output of the frequency converter Il...

Page 137: ...93 8 Fan Fuse see fuse tables for part number L1 L2 L3 9 Mains ground 4 Load sharing 10 Motor DC DC U V W 88 89 96 97 98 T1 T2 T3 Illustration 5 25 Compact IP 00 Chassis frame size D3 Illustration 5 2...

Page 138: ...or part number L1 L2 L3 9 Mains ground 4 Load sharing 10 Motor DC DC U V W 88 89 96 97 98 T1 T2 T3 Illustration 5 27 Position of earth terminals IP00 frame sizes D Illustration 5 28 Position of earth...

Page 139: ...ring 01 02 03 DC DC 04 05 06 88 89 2 Temp Switch 6 SMPS Fuse see fuse tables for part number 106 104 105 7 Fan Fuse see fuse tables for part number 3 Line 8 AUX Fan R S T 100 101 102 103 91 92 93 L1 L...

Page 140: ...31 Position of earth terminals IP00 frame sizes E Illustration 5 32 Rectifier Cabinet frame size F1 F2 F3 and F4 5 How to Install VLT AQUA Drive Design Guide 140 MG 20 N5 02 VLT is a registered Danfo...

Page 141: ...and F2 frame 3 pieces See fuse tables for part numbers R S T 10 30 Amp Fuse Protected Power fuses L1 L2 L3 Illustration 5 33 Inverter Cabinet frame size F1 and F3 1 External Temperature Monitoring 6...

Page 142: ...97 98 04 05 06 T1 T2 T3 3 NAMUR 7 NAMUR Fuse See fuse tables for part numbers 4 AUX Fan 8 Fan Fuses See fuse tables for part numbers 100 101 102 103 9 SMPS Fuses See fuse tables for part numbers L1 L...

Page 143: ...rs 91 92 93 6 Contactor Relay Coil 230 VAC N C and N O Aux Contacts L1 L2 L3 7 Circuit Breaker Shunt Trip Control Terminals 230 VAC or 230 VDC 5 4 2 Shielding against Electrical Noise Before mounting...

Page 144: ...S T The connector located on the power card provides the connection of line voltage for the cooling fans The fans are connected from factory to be supplied form a common AC line jumpers between 100 10...

Page 145: ...Naimer KG250 T303 5 5 2 Mains disconnectors frame size D E and F Frame size Power Voltage Type D1 D3 P90K P110 380 500V P90K P132 525 690V ABB OETL NF200A D2 D4 P132 P200 380 500V P160 P315 525 690V...

Page 146: ...on XTCE820N22A F4 P710 P800 380 500V P1M0 525 690V Eaton XTCEC14P22B Drive SCCR rating maybe less than 100 kA when this option is added See the drive label for SCCR rating 5 6 Final Set Up and Test To...

Page 147: ...tion 1 Press the OFF key the frequency converter enters into alarm mode and the display shows that the AMA was terminated by the user Successful AMA 1 The display shows Press OK to finish AMA 2 Press...

Page 148: ...FC 202 must be removed Cutting or breaking the jumper is not sufficient Remove it entirely to avoid short circuiting See jump er on illustration 2 Connect terminal 37 to 24 V DC by a short circuit pr...

Page 149: ...The test step is passed if the motor remains in the Safe Stop state and the mechanical brake if connected remains activated 3 Then reapply 24 V DC to terminal 37 The test step is passed if the motor...

Page 150: ...5 How to Install VLT AQUA Drive Design Guide 150 MG 20 N5 02 VLT is a registered Danfoss trademark 5...

Page 151: ...if motor sizes are widely different because small motors relatively high ohmic resistance in the stator calls for a higher voltage at start and at low RPM values The electronic thermal relay ETR of t...

Page 152: ...name plate 5 9 Installation of misc connections 5 9 1 RS 485 Bus Connection One or more frequency converters can be connected to a control or master using the RS485 standardized interface Terminal 68...

Page 153: ...MCT 10 Set up Software MCT 10 Set up Software MCT 10 has been designed as an easy to use interactive tool for setting parameters in our frequency converters The MCT 10 Set up Software will be useful f...

Page 154: ...COM Business Area Motion Controls 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 freq...

Page 155: ...ol and mains cables Full connection of the conduit from the drive to the motor is required The EMC performance of flexible conduits varies a lot and information from the manufacturer must be obtained...

Page 156: ...MC correct electrical installation of a frequency converter in cabinet Illustration 5 40 Electrical connection diagram 5 How to Install VLT AQUA Drive Design Guide 156 MG 20 N5 02 VLT is a registered...

Page 157: ...he cable Transfer impedance ZT can be assessed on the basis of the following factors The conductibility of the screen material The contact resistance between the individual screen conductors The scree...

Page 158: ...16 mm 2 d For 50 60 Hz earth loops If very long control cables are used 50 60 Hz earth loops may occur Solve this problem by connecting one end of the screen to earth via a 100nF capacitor keeping lea...

Page 159: ...lt Illustration 6 1 Terminal 37 Available only with Safe Stop Function 6 1 2 Pulse Start Stop Terminal 18 start stop par 5 10 9 Latched start Terminal 27 Stop par 5 12 6 Stop inverse Par 5 10 Digital...

Page 160: ...a reduced AMA test with a Sine wave filter installed Avoid carrying out a complete AMA with a Sine wave filter If an overall setting is required remove the Sine wave filter while running a total AMA A...

Page 161: ...requency converter will then perform the pre programmed action 6 1 6 SLC Application Example One sequence 1 Start ramp up run at reference speed 2 sec ramp down and hold shaft until stop Set the rampi...

Page 162: ...verter will ramp down and go into free mode 6 1 7 BASIC Cascade Controller The BASIC Cascade Controller is used for pump applications where a certain pressure head or level needs to be maintained over...

Page 163: ...city is determined as lead pump plus fixed speed pumps capacities Bandwidth Management In cascade control systems to avoid frequent switching of fixed speed pumps the desired system pressure is kept w...

Page 164: ...or each pump and the cascade controller is displayed on the Local Control Panel Information displayed includes Pumps Status is a read out of the status for the relays assigned to each pump The display...

Page 165: ...6 1 11 Fixed Variable Speed Pump Wiring Diagram VLT AQUA Drive Design Guide 6 Application Examples MG 20 N5 02 VLT is a registered Danfoss trademark 165 6...

Page 166: ...equency converter via K1 Auxiliary break contact on K1 prevents K3 to cut in RELAY 2 controls contactor K4 for on off control of the fixed speed pump At alternation both relays de energizes and now RE...

Page 167: ...mand or stays in operation if already running Destaging if running Off Ramps down Cut out Auto On Starts and stops according to commands via ter minals or serial bus Staging Destaging VLT AQUA Drive...

Page 168: ...7 RS 485 Installation and Set up VLT AQUA Drive Design Guide 168 MG 20 N5 02 VLT is a registered Danfoss trademark 7...

Page 169: ...surface of the screen to ground for example by means of a cable clamp or a conductive cable gland It may be necessary to apply potential equalizing cables to maintain the same ground potential through...

Page 170: ...can be used for overcoming modem turnaround delays 8 36 Max response delay Specify a maximum delay time between transmitting a request and receiving a response 8 37 Max inter char delay Specify a max...

Page 171: ...data and a long format of 16 bytes that also includes a parameter channel A third telegram format is used for texts 7 2 1 VLT AQUA with Modbus RTU The FC protocol provides access to the Control Word a...

Page 172: ...bit thus consisting of 11 bits in all 7 4 2 Telegram Structure Each telegram begins with a start character STX 02 Hex followed by a byte denoting the telegram length LGE and a byte denoting the frequ...

Page 173: ...ore the first byte in the telegram is received the Calculated Checksum is 0 7 4 6 The Data Field The structure of data blocks depends on the type of telegram There are three telegram types and the typ...

Page 174: ...0 0 0 1 Read parameter value 0 0 1 0 Write parameter value in RAM word 0 0 1 1 Write parameter value in RAM double word 1 1 0 1 Write parameter value in RAM and EEprom double word 1 1 1 0 Write param...

Page 175: ...consists of 2 words 4 bytes and the value depends on the defined command AK The master prompts for a parameter value when the PWE block contains no value To change a parameter value write write the n...

Page 176: ...ly Conversion factors are therefore used to transfer decimals par 4 12 Motor Speed Low Limit Hz has a conversion factor of 0 1 To preset the minimum frequency to 10 Hz transfer the value 100 A convers...

Page 177: ...er number 4 14 is 19E in hexadecimal The response from the slave to the master will be 7 5 2 Reading a parameter value Read the value in par 3 41 Ramp 1 Ramp Up Time PKE 1155 Hex Read parameter value...

Page 178: ...respond by supplying the requested data to the master or by taking the action requested in the query The master can address individual slaves or can initiate a broadcast message to all slaves Slaves...

Page 179: ...than 1 5 character intervals occurs before completion of the frame the receiving device flushes the incomplete message and assumes that the next byte will be the address field of a new message Similar...

Page 180: ...Coil Register Addressing In Modbus all data are organized in coils and holding registers Coils hold a single bit whereas holding registers hold a 2 byte word i e 16 bits All data addresses in Modbus...

Page 181: ...mber Description 00001 00006 Reserved 00007 Last error code from an FC data object interface 00008 Reserved 00009 Parameter index 00010 00990 000 parameter group parameters 001 through 099 01000 01990...

Page 182: ...sponse message For a full explanation of the structure of an exception i e error response please refer to the section Modbus RTU Message Framing Structure Function Field Error Code in data field decim...

Page 183: ...tes for each parameter can be seen in the section on factory settings Since a parameter value can only be transferred as a whole number a conversion factor must be used to transfer decimals Please ref...

Page 184: ...e The coil status in the response message is packed as one coil per bit of the data field Status is indicated as 1 ON 0 OFF The LSB of the first data byte contains the coil addressed in the query The...

Page 185: ...d Name Example HEX Slave Address 01 frequency converter address Function 05 write single coil Coil Address HI 00 Coil Address LO 40 64 decimal Coil 65 Force Data HI FF Force Data LO 00 FF 00 ON Error...

Page 186: ...00 Coil Address LO 10 coil address 17 Quantity of Coils HI 00 Quantity of Coils LO 10 16 coils Byte Count 02 Force Data HI Coils 8 1 20 Force Data LO Coils 10 9 00 ref 2000hex Error Check CRC Respons...

Page 187: ...ss 3029 No of Points HI 00 No of Points LO 02 Par 3 03 is 32 bits long i e 2 registers Error Check CRC Response The register data in the response message are packed as two bytes per register with the...

Page 188: ...tion 06 Register Address HI 03 Register address 999 Register Address LO E7 Register address 999 Preset Data HI 00 Preset Data LO 01 Error Check CRC Response Response The normal response is an echo of...

Page 189: ...f the Control Bits Bits 00 01 Bits 00 and 01 are used to choose between the four reference values which are pre programmed in par 3 10 Preset Reference according to the following table Programmed ref...

Page 190: ...ther starting conditions are met NB Make a selection in par 8 53 Start Select to define how Bit 06 Ramp stop start gates with the corresponding function on a digital input Bit 07 Reset Bit 07 0 No res...

Page 191: ...y limit Frequency limit OK 11 No operation In operation 12 Drive OK Stopped auto start 13 Voltage OK Voltage exceeded 14 Torque OK Torque exceeded 15 Timer OK Timer exceeded Explanation of the Status...

Page 192: ...y is within the defined limits Bit 11 No operation in operation Bit 11 0 The motor is not running Bit 11 1 The frequency converter has a start signal or the output frequency is greater than 0 Hz Bit 1...

Page 193: ...t word in integers 0 32767 the value 16384 4000 Hex corresponds to 100 Negative figures are formatted by means of 2 s complement The Actual Output frequency MAV is scaled in the same way as the bus re...

Page 194: ...8 Troubleshooting VLT AQUA Drive Design Guide 194 MG 20 N5 02 VLT is a registered Danfoss trademark 8...

Page 195: ...r If an alarm cannot be reset the reason may be that its cause has not been rectified or the alarm is trip locked see also table on following page Alarms that are trip locked offer additional protecti...

Page 196: ...t Terminal 27 X 5 00 5 01 41 Overload of Digital Output Terminal 29 X 5 00 5 02 42 Overload of Digital Output On X30 6 X 5 32 42 Overload of Digital Output On X30 7 X 5 33 46 Pwr card supply X X 47 24...

Page 197: ...r Th Over Output Current High 8 00000100 256 Motor ETR Over Motor ETR Over Output Current Low 9 00000200 512 Inverter Overld Inverter Overld Output Freq High 10 00000400 1024 DC under Volt DC under Vo...

Page 198: ...vironments 14 Air Humidity 14 Airflow 117 Alarm warning Code List 196 Alarms And Warnings 195 Aluminium Conductors 125 Ama 160 Analog I o Option Mcb 109 72 Analog I o Selection 72 Analog Inputs 8 Anal...

Page 199: ...d 24 V Dc Output 52 Control Card Rs 485 Serial Communication 50 Control Card Usb Serial Communication 53 Control Characteristics 52 Control Structure Closed Loop 20 Control Structure Open Loop 19 Cont...

Page 200: ...V Dc Supply 71 External Fan Supply 144 External Temperature Monitoring 89 Extreme Running Conditions 34 F Fan A2 96 Fan A3 96 Fan A5 96 Fan B1 96 Fan B2 96 Fan B3 96 Fan B4 96 Fan C1 96 Fan C2 96 Fan...

Page 201: ...Enclosure Kit 78 Ip 21 type 1 Enclosure Kit 78 Ip21 type 1 Kit 95 J Jog 7 Jog 190 K Kit Contents 82 L Laws Of Proportionality 16 Lcp 7 9 19 Lcp 101 95 Lcp Cable 95 Lcp Kit 95 Lead Pump Alternation Wi...

Page 202: ...rdering 82 Ordering Numbers 91 Ordering Numbers Brake Resistors 102 Ordering Numbers Du dt Filters 380 480 Vac 101 Ordering Numbers Harmonic Filters 96 Ordering Numbers Options And Accessories 95 Orde...

Page 203: ...Commissioning Test 149 Safe Stop Installation 148 Safe Stop Operation optional 37 Safety Earth Connection 155 Safety Note 11 Safety Regulations 11 Safety Requirements Of Mechanical Installation 112 S...

Page 204: ...d Loop Controller 26 Type Code String 92 Type Code String High Power 93 U Ul Fuses 200 240 V 127 Unpacking 113 Unsuccessful Ama 147 Usb Cable 95 Usb Connection 130 Use Of Emc correct Cables 157 V Vari...

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