danfoss vlt aqua drive fc202

The New VLT® AQUA Drive FC202

Confidential / Property of

Danfoss Drives A/S

9 August, 2008

Name/department

The new VLT® AQUA Drive Sets new benchmarks in water and waste water business

Danfoss Drives A/S

9 August, 2008

Name/department

The new VLT® Aqua Drive is 1:1 compatible withVLT® 8000...

All you have in VLT® 8000 you will have in VLT® Aqua Drive…and even more.

Award-winning user friendliness

Compatibility

Danfoss Drives A/S

9 August, 2008

Name/department

Supply and power range

200 – 240Vac, 0,25 – 45kW200 – 240Vac, 2,2 – 22kW, 1Ø - 3Ø

380 – 480Vac, 0,37 – 90kW380 – 480Vac, 7,5 – 37kW, 1Ø - 3Ø

380 – 480Vac, 110 – 1000kW

525 – 600Vac, 0,75 – 90kW

525 – 690Vac, 11 – 1,2MW

One drive for full voltage range

Lower need for training, less confuse

Danfoss Drives A/S

9 August, 2008

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Flexible mechanical design

Common mechanicalconcept

•Backwards compatible with footprint of VLT 2800 + VLT 8000

Flexible mounting•Horizontal•Vertical•True side-by-side

Global labelling•CE marked according to:•C-tick approval•UL and cUL approvals

Danfoss Drives A/S

9 August, 2008

Name/department

Flexible mounting

Quick and easy replacement of old drives

Less installation time

Danfoss Drives A/S

9 August, 2008

Name/department

True side by side mounting saves space and time

Less panel space – Less cost

Compact design

Danfoss Drives A/S

9 August, 2008

Name/department

The smallest IP20

Saves considerablySpace in panels

Danfoss Drives A/S

9 August, 2008

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The smallest IP20

Footprint:- up to 57 % smaller

Volume- up to 60 % smaller

Former width

New width,

FP 54%VL 60%

FP 15%VL 11%

FP 54%VL 60%

Danfoss Drives A/S

9 August, 2008

Name/department

VLT AQUA Drive - High Power

Integrated options

• Disconnect switch

• Fast acting fuses

• Built in filters comply withEN61000-6-4 and EN61000-3

• Class A2 filter as standard • Optional class A1 (150 m cable)

• Also available as field installable kits for later upgrade

Danfoss Drives A/S

9 August, 2008

Name/department

Innovative Cooling

• Separate cooling path for power components

• Removes 85% of losses using drive main fan

• Main airflow away from control electronics

• Separate cooling for control components

• IP54 seal between power and control cooling air

• Reduced air volume inside the enclosure

• Less contaminants enter the enclosure

• Small door fans

Back Channel Cooling

Details

Internal inlet air

Back channel exhaust air

Back channel inlet air

Internal exhaust air

Danfoss Drives A/S

9 August, 2008

Name/department

Innovative cooling by design

Upper exhaust

Back exhaust

Back inlet

Bottom inlet

Heat sink fan

Heat sink

IP54 Seal

§ Two cooling possibilities

§ Back cooling –Air ducted in and out the back

§ Duct work cooling –Air ducted in the bottom, out the top

§ 85% of the cooling air volume never enters the controls area

§ Separate path makes heat sink cleaning easy

§ Pre-engineered, thermally tested cooling kits available for IP00 enclosuresDetails

Danfoss Drives A/S

9 August, 2008

Name/department

IP00 enclosure with back channel kits

IP54 Seal

Internal inlet air

Back channel

inlet air

Internal inlet air

Back channel inlet air

Danfoss Drives A/S

9 August, 2008

Name/department

Designed for maximum uptime and long life

• High ambient temp

• High IP-rating

• Robust housing

• Maintenance free

The reliable VLT® AQUA Drive

Danfoss Drives A/S

9 August, 2008

Name/department

Value of high ambient temp, IPand robust housing

Panel builder:

•Less need for panel cooling•Increased lifetime•Stabile and reliable system•Possible mounting outside panel

End user:

•Reduced installation cost.•Increased drive lifetime.•Usable in harsh environments•Reliable system

Danfoss Drives A/S

9 August, 2008

Name/department

VLT® Aqua Drive cooling system

Fan controlled by internal temperature

Energy savedLess acoustic noise

Minimum ambient air passes the electronic components in IP20 and no in IP21/55

Optimizes the lifetime

Cold Plate option

Heat sink outside the panelLess need for panel cooling

Picture shows IP20 unit

Danfoss Drives A/S

9 August, 2008

Name/department

Conformal Coated PCB’s

For harsh environments

Water applications: Chlorine etc.

Wastewater applications:Hydrogen sulphide, Amonium etc.

Protects against pollution, moisture, and dust

Increase drive lifetime

Danfoss Drives A/S

9 August, 2008

Name/department

Large variety of options

• Only pay for what you need

• Flexible specification

• Reduced total installed system costs

• Easy Mounting – plug and play

Danfoss Drives A/S

9 August, 2008

Name/department

• Relay option

+ 3 relay outputs

Danfoss Drives A/S

9 August, 2008

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• Relay option

• General purpose I/O

+ 3 digital inputs

+ 2 digital outputs

+ 2 analogue inputs

+ 1 analogue output

Danfoss Drives A/S

9 August, 2008

Name/department

• Relay option

• Aqua I/O option

+ 3 PT/NI 1000

analogue input

+ 3 analogue output

Danfoss Drives A/S

9 August, 2008

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• Relay option

• Aqua I/O option

• Fieldbusses– Modbus RTU (Standard)– Profibus– Device net– Ethernet (April 2007)– Modbus TCP (late 2007)

Danfoss Drives A/S

9 August, 2008

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• Relay option

• Aqua I/O option

• Fieldbusses

• Cascade control– Extended 5 relays– Advanced 8 relays

Danfoss Drives A/S

9 August, 2008

Name/department

• Relay option

• Aqua I/O option

• Fieldbusses

• Cascade control

Danfoss Drives A/S

9 August, 2008

Name/department

• Relay option

• Aqua I/O option

• Fieldbusses

• Cascade control

• Real Time Clock with24V backup

Danfoss Drives A/S

9 August, 2008

Name/department

Value of a large variety of options?

Panel builder:

• Only pay for the needed• Easy to upgrade a system• Flexibility in project planning• Saves cost

End user:,

• Only pay for the needed• Easy retrofit• Saves money

Danfoss Drives A/S

9 August, 2008

Name/department

Customized units assembled and tested in the factory

• Reliability

• Quick and low costinstallation

Tested – ready for operation

Danfoss Drives A/S

9 August, 2008

Name/department

Option of 2 Displays

(graphical and numerical)

“Blind cover” available

• Award winning graphical display

• Easy navigation and troubleshooting

• Quick learning

Same user interfaces for whole range

Danfoss Drives A/S

9 August, 2008

Name/department

Value of only one user interface for the whole range?

Panel builder:

• No need for display in all drives

• Easy commissioning• Saves time and money• Possible cost optimized user

interface.

End user:

• Very easy commissioning

• Saves time and money.

The new VLT® AQUA Drive

Excellent electronic performance

Danfoss Drives A/S

9 August, 2008

Name/department

3 levels filtering available, complies IEC 61800-3

Screened Cable length up to 150m and 300m unscreened

Flexibility to meet different requirements

Eliminates interference with other installed equipment

Best built-in EMC performance

Danfoss Drives A/S

9 August, 2008

Name/department

Value of the EMC performance?

Panel builder:

Onboard filter saves:• panel space• cost of an external filter• time for mounting of

external filter

End user:

• Lower installation cost • Compliance with EMC norms• Easy replacement

3 Different RFI filters: ScreenedH1 Class A1/A2 150mH1 Class B 50mH2 Class A2 Up to 25m (Size depended)H3 Class A1 (reduced) 50mH3 Class B (reduced) Up to 20m (Size depended)

Unscreened up to 300m

Danfoss Drives A/S

9 August, 2008

Name/department

Up to 150 m screened motor cable / 300 m unscreened

Flexibility in project planning

No need for external filters

Saves space and money

Danfoss Drives A/S

9 August, 2008

Name/department

DC-coils are built-in standard

• Reduced installation cost

• Smaller transformer and cables

Optimum harmonic performance

Danfoss Drives A/S

9 August, 2008

Name/department

Value of the Harmonic performance?

Panel builder:

• Total Harmonic Distortion (THiD) current lower than 48%

• No need for external input filter

• Saves space, time and money

End user:

• Lower installation cost• Lower kVar Penalty• Lower need for power Factor

correction• Less cooling

Use less energy

Danfoss Drives A/S

9 August, 2008

Name/department

Energy optimization

Voltage

Automatic EnergyOptimization (AEO)

• Better system efficiency

• Optimize energy savings

• Quicker Start-up

• Optimizes motor

magnetization voltage based

on load dynamics

• Can be used both in VT and

CT torque mode

Danfoss Drives A/S

9 August, 2008

Name/department

Value of Automatic EnergyOptimization (AEO)

Only one parameter that saves a significant amount of energy

Decrease the payback time

Danfoss Drives A/S

9 August, 2008

Name/department

Energy optimization

Automatic Motor Adaptation (AMA)

• Optimizes motor performance

• Higher system efficiency

• Simple and optimum commissioning

Danfoss Drives A/S

9 August, 2008

Name/department

Value of Automatic Motor Adaption (AMA)?

• Easy to fit the drive to the motor.

• Ensure optimized motor performance.

• Saves cost because of lower commissioning time

• Compensate for voltage drop because of long motor cables for submersible pumps.

• Submersible pump motors are often differencing from standard motor data.

AMA compensate for this.

Danfoss Drives A/S

9 August, 2008

Name/department

Energy optimization

Voltage Vector Control

(VVCplus)

• Full voltage at full speed

• No motor derating

• No overheat at full load

• Improved dynamic and stability

Danfoss Drives A/S

9 August, 2008

Name/department

Value of VVCPlus

Panel builder:

• Full motor power at rated speed - No need for motor derating

• Cost optimized drive and motor system

• Minimize drive internal energy consumption

• Reduces the need for panel cooling

End user:

• Optimized motor performance

• Dynamic, stabile and reliable system

• Minimize drive internal energy consumption

• 60° PWM compensate for weak supply grids. Up to 115% mains voltage

Danfoss Drives A/S

9 August, 2008

Name/department

Energy monitoring

Built-in energy measurement tool

• Helps user to track record of the system

• Identifies energy improvement possibilities within water systems

Danfoss Drives A/S

9 August, 2008

Name/department

Value of energy monitoring?

Panel builder:

• Easy process optimization.

End user:

• Easy to control and optimize the system.

• Easy to track energy consumption

• Easy to compare the actual conditions with the estimated.

Protects applications and motors

Danfoss Drives A/S

9 August, 2008

Name/department

Effective motor and drive protection

• No extra heating due to switching pattern

• Electronic Thermal Relay function (ETR)

• Direct thermistorconnection

• Current limit protection

• Motor DC brake function at stand still. (Motor preheat)

• Switching on output

• Low du/dt and Upeak

Danfoss Drives A/S

9 August, 2008

Name/department

Effective system protection

Automated skip frequencies

Preventive maintenance

• Reduces system stress

• Reducescommissioning time

• Easy to avoid system resonance

• Quick setup of the frequency bands

Water operation Child’s play

Danfoss Drives A/S

9 August, 2008

Name/department

• Quick setup menu

• AQUA application menu

• AQUA function menu

• Personal menu can be customised

• Very easy and quick commissioning

AQUA specific menus

Menu Structure

Quick Menu

Quick Setup

Function Setup

Closed loop Settings

My PersonalMenu

Analogreference

Changes Made

Danfoss Drives A/S

9 August, 2008

Name/department

Spin Motor/ Prove System

Main menuQuick menu Alarm logStatus

My Personal Menu

Changes Made

Loggings

General settingsGeneral

settings

Open loop settingsOpen loop

settings

Closed loop settingsClosed loop

settings

Application settingsApplication

settings

Digital ReferenceAnalog Reference

Clock settings LCP Display settingsAnalogue outputsRelays

Fan functionsPump functions

Quick Setup

Function Setup

Feedback SettingsPID Settings

Danfoss Drives A/S

9 August, 2008

Name/department

Protects personal and main menus

• Allows controlled access to drive settings

• Reliable water and waste water systems

2-level password

Danfoss Drives A/S

9 August, 2008

Name/department

Provides access to ”Onboard Manual”

Available “on-site”

• No need for a printed manual

• It’s ”always there”

Info key

Danfoss Drives A/S

9 August, 2008

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Up to 5 variables…• User-defined Display

• Display values with units (kPa, Bar, mmHq, kWh and…)

Programmable display

Danfoss Drives A/S

9 August, 2008

Name/department

Graphical display

• Simple monitoring of logged data

• Graphs and bars

• Multiple font size

• Icons

• International letters, numbers and signs

Danfoss Drives A/S

9 August, 2008

Name/department

Display features

Alarm messages/log:Full text messagesCustomised texts

Customised display:Text and valuesEasy and improved

monitoring/fault findingGraphical data log

Undo-function:Resets latest change

Hand-Off-Auto on keypad

Danfoss Drives A/S

9 August, 2008

Name/department

Plug and play connection of a PC

Easy use of• VLT® Set-up Software

MCT 10

• VLT® Energy Box

Saves time and money

USB port

Danfoss Drives A/S

9 August, 2008

Name/department

Drive communicates with other devices

Standard RS-485• MODBUS RTU

• Danfoss FC

Optional• Profibus

• DeviceNet

• Ethernet

• Modbus TCP

Danfoss Drives A/S

9 August, 2008

Name/department

Clear text message

• Many languages are available in the display and documentation

• Chinese, Mandarin, Cyril, Greek etc. characters

Drive communicates with operator

Installation is Child's play

Danfoss Drives A/S

9 August, 2008

Name/department

Power terminals

Standard cable-glands

Pluggable terminals(up to 7,5kW)

Screwed terminals(11 – 90kW)

• Easy cable access

• No need for EMC glands

• Saves money

Danfoss Drives A/S

9 August, 2008

Name/department

• No need for extra switch

• Easy installation

• Reduced installation time and cost

Optional mains disconnect switch

Danfoss Drives A/S

9 August, 2008

Name/department

• Spring loaded connections

• Pluggable terminals– Quick installation– Reliable system– Vibration proof

– loop connection

Control terminals

Built-in Intelligence

Danfoss Drives A/S

9 August, 2008

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Advanced process control

4 x PID controllers• 1 controller for the drive

• 3 controllers for other process equipment

• Eliminates need for secondary controllers

• Provides flexibility for SCADA

• Can be used for Chemical feed pumps, valve control, Aeration with diff. levels

Danfoss Drives A/S

9 August, 2008

Name/department

Auto tuning of all PI-s

• Easy system commissioning

• Makes PID control simple

• Saves installation and labour cost

Danfoss Drives A/S

9 August, 2008

Name/department

PI Auto Tune

33,7 Hz 1035 rpmPID tuning ! 1(2)

Auto Remote Running

Step 1 of 4

1. PI Auto Tune enabled.

2. Monitors the feedback.

3. Manuel adjust the speed to approximately set point is reached.

4. Press OK

5. Drive runs in closed loop

Example

3 acceptable curve periodsStabilize with fixed speed Drive runs in closed loop

Danfoss Drives A/S

9 August, 2008

Name/department

Feedback

Scope from MCT10 software

Danfoss Drives A/S

9 August, 2008

Name/department

3-zone feedback

• Increased control flexibility

• Improves system by using the average of feedbacks

Danfoss Drives A/S

9 August, 2008

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Real Time Clock

20 actions can be triggered• Eliminates need

for external timers

• Increased flexibility

Danfoss Drives A/S

9 August, 2008

Name/department

Preventive Maintenance

20 actions items can be scheduled

• Helps planned system maintenance

• More reliable water and waste water system

Danfoss Drives A/S

9 August, 2008

Name/department

Smart Logic Controller

Offers a wide range of PLC functions

Automated sequence actions can be programmed

• No need for external controllers

• Saves cost

Example

Danfoss Drives A/S

9 August, 2008

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Smart Logic Controller

Less thanStart pump

OperationPump

Shut off

Pressure Setpoint

ComparePipe

pressure

ConditionControl off

Start command

Stop command

Danfoss Drives A/S

9 August, 2008

Name/department

• Catch motor in both directions

• Maintains pressure in case of short voltagedrop-out

Prevent damage and trip if for instance a Check Valve is defect.

Flying start

Defect Check valve

VLT® AQUA Drive

Dedicated pump features

Danfoss Drives A/S

9 August, 2008

Name/department

End of curve monitoring in case of a leakage

•Provides warning or an alarm

•Extends life time of pump

•Shut down of Pump

•Prevent damaging of the pump

Pump dedicated functions

Danfoss Drives A/S

9 August, 2008

Name/department

Cascade Controller built-in as standard

• Staging / destaging

• Possible alternation

• Pump Cycling

• Pump Interlocking

Efficient Pump operation

Danfoss Drives A/S

9 August, 2008

Name/department

Cascade Controller

Basic Standard Cascade2 relaysAlternation of 2 pumps (1 relay/pump)

Extended Cascade – B option

2 + 3 relaysAlternation of 2 pumpsUnequal sized pumpsMaster / slave

Advanced Cascade – C option

8 relaysAlternation of 4 pumpsUnequal sized pumpsMaster / slave

Danfoss Drives A/S

9 August, 2008

Name/department

Cascade CTL and setpoint

Danfoss Drives A/S

9 August, 2008

Name/department

Master/Slave control mode

• Master Drive contains the cascade CTL

• Slave units are standard drives

• All motors operate at the same frequency when in use

• Maximum performance

• Maximum energy saving

Danfoss Drives A/S

9 August, 2008

Name/department

Dry pump detection

No-flow/low-flow monitoring

• Based on Speed and power

• Semi Automatic setup

• Avoid dry-running and pump overheat

• Prevent damaging of the pump

• Saves energy

• Less cost for sensors

Danfoss Drives A/S

9 August, 2008

Name/department

Sleep Mode

• Based on low flow

• Boost function

• Internal or external signal to enter sleep mode

• Maximizes energy savings

• Reduces wear on equipment

Danfoss Drives A/S

9 August, 2008

Name/department

Initial / Final Ramp

• Independent ramp from zero to minimum freq

• User programmable time period

• Protects bearings and other equipment

• Reduces maintenance

Danfoss Drives A/S

9 August, 2008

Name/department

Check Valve ramp time

• Used when ramping down from min. speed.

• Slow ramp rate at ramping down from min. speed

• Protect check valves

• Prevent water hammering

Danfoss Drives A/S

9 August, 2008

Name/department

Pipe fill mode-For vertical and horizontal pipe

systems

• Eliminates Water Hammer

Programmable fill rate in units/second

• Normal ramp from fill pressure to operating pressure

• Increase system performance

• Prevent water hammeringPipe Fill Example

Danfoss Drives A/S

9 August, 2008

Name/department

Pipe Fill, vertical pipes

PID ramp the pressure at a user specifiedrate units/sec.

Danfoss Drives A/S

9 August, 2008

Name/department

Pipe Fill, horizontal pipes

Constant speed for a settime.

Danfoss Drives A/S

9 August, 2008

Name/department

Flow compensation at setpoint

• Simplifies sensor installation

• Mount the pressure sensor close to the pump

• Easy installation

• Reliable system

• Saves money

• Saves energy

Danfoss Drives A/S

9 August, 2008

Name/department

Automatic Flow compensation

1. Program the system curve

2. Closed loop PID decrease the speed depending on pressure

3. Flow compensation decrease the setpoint

• Flow resistance decreases with reduced flow

• Saves significantly amount of energy

Danfoss Drives A/S

9 August, 2008

Name/department

1. Program the system curve

2. Closed loop PID decrease the speed depending on pressure

3. Flow compensation decrease the set point

• Also useable with Cascade CTL.

• Saves significantly amount of energy

Automatic Flow compensation

Flow comp. and cascade CTL

VLT® AQUA Drive

VLT Software

Danfoss Drives A/S

9 August, 2008

Name/department

VLT® Set-up Software MCT 10

Planned:

- Profi-Safe option SW.

- Wizards Framework Builder - Remote access.

- Alarm collection.

Free of charge

- Project files (max 4)- Scope & Graph (max 2)- View Alarm history

More functionality: - Full Scope & graph- Alarm history in saved

projects. - Option configuration- MCO305

Easy to use on/off-line commissioning tool

Danfoss Drives A/S

9 August, 2008

Name/department

Cascade CTL configuration tool

Cascade CTLconfiguration tool

•Set up feedback

•Set up Setpoint

Danfoss Drives A/S

9 August, 2008

Name/department

Cascade CTL configuration tool

•Set up cascade

Danfoss Drives A/S

9 August, 2008

Name/department

• PC tool to calculate Return on Investment, Payback Time

• Communicate and withdraw energy data from the Drive

• Easy way to follow up yourenergy bill

VLT® Energy Box

Danfoss Drives A/S

9 August, 2008

Name/department

VLT®Energy Box

PC tool to calculate Return on Investment, Payback Time

Danfoss Drives A/S

9 August, 2008

Name/department

VLT®Energy Box

Generated Reports:

Danfoss Drives A/S

9 August, 2008

Name/department

VLT®Energy Box

Generated Reports for documentation

Danfoss Drives A/S

9 August, 2008

Name/department

Local Service – Globally

Dedicated Water and Waste Water sales organisation world-wide with skilled specialists

• Spare parts

• Hotline support

• Preventative service

• Service around-the-clock

• Global service network

danfoss vlt aqua drive fc202

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