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The New VLT® AQUA Drive FC202
2
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
3
Confidential / Property of
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
4
Confidential / Property of
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
5
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
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
6
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Flexible mounting
Quick and easy replacement of old drives
Less installation time
7
Confidential / Property of
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
8
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
The smallest IP20
Saves considerablySpace in panels
9
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
The smallest IP20
Footprint:- up to 57 % smaller
Volume- up to 60 % smaller
Former width
New
IP20
hei
ght
New width,
B5
FP 54%VL 60%
New
IP21
Hei
ght
FP 15%VL 11%
FP 54%VL 60%
Form
er IP
21 H
eigh
t
10
Confidential / Property of
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
11
Confidential / Property of
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
12
Confidential / Property of
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
13
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
IP00 enclosure with back channel kits
IP54 Seal
Internal inlet air
Back channel exhaust air
Back channel
inlet air
Internal exhaust air
Internal inlet air
Back channel exhaust air
Back channel inlet air
Internal exhaust air
14
Confidential / Property of
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
Value
15
Confidential / Property of
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
16
Confidential / Property of
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
17
Confidential / Property of
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
18
Confidential / Property of
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
19
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Large variety of options
• Relay option
+ 3 relay outputs
20
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Large variety of options
• Relay option
• General purpose I/O
+ 3 digital inputs
+ 2 digital outputs
+ 2 analogue inputs
+ 1 analogue output
21
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Large variety of options
• Relay option
• General purpose I/O
• Aqua I/O option
+ 3 PT/NI 1000
analogue input
+ 3 analogue output
22
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Large variety of options
• Relay option
• General purpose I/O
• Aqua I/O option
• Fieldbusses– Modbus RTU (Standard)– Profibus– Device net– Ethernet (April 2007)– Modbus TCP (late 2007)
23
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Large variety of options
• Relay option
• General purpose I/O
• Aqua I/O option
• Fieldbusses
• Cascade control– Extended 5 relays– Advanced 8 relays
24
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Large variety of options
• Relay option
• General purpose I/O
• Aqua I/O option
• Fieldbusses
• Cascade control
25
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Large variety of options
• Relay option
• General purpose I/O
• Aqua I/O option
• Fieldbusses
• Cascade control
• Real Time Clock with24V backup
Value
26
Confidential / Property of
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
27
Confidential / Property of
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
28
Confidential / Property of
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
Value
29
Confidential / Property of
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
31
Confidential / Property of
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
Value
32
Confidential / Property of
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
33
Confidential / Property of
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
34
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
DC-coils are built-in standard
• Reduced installation cost
• Smaller transformer and cables
Value
Optimum harmonic performance
35
Confidential / Property of
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
The new VLT® AQUA Drive
Use less energy
37
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Energy optimization
Voltage
Speed
Value
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
38
Confidential / Property of
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
39
Confidential / Property of
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
Value
40
Confidential / Property of
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.
41
Confidential / Property of
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
Value
42
Confidential / Property of
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
43
Confidential / Property of
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
Value
44
Confidential / Property of
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.
The new VLT® AQUA Drive
Protects applications and motors
46
Confidential / Property of
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
47
Confidential / Property of
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
The new VLT® AQUA Drive
Water operation Child’s play
49
Confidential / Property of
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
50
Confidential / Property of
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
1/1
51
Confidential / Property of
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
52
Confidential / Property of
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
53
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Up to 5 variables…• User-defined Display
• Display values with units (kPa, Bar, mmHq, kWh and…)
Programmable display
54
Confidential / Property of
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
55
Confidential / Property of
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
56
Confidential / Property of
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
57
Confidential / Property of
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
58
Confidential / Property of
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
The new VLT® AQUA Drive
Installation is Child's play
60
Confidential / Property of
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
61
Confidential / Property of
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
62
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
• Spring loaded connections
• Pluggable terminals– Quick installation– Reliable system– Vibration proof
– loop connection
Control terminals
The new VLT® AQUA Drive
Built-in Intelligence
64
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
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
65
Confidential / Property of
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
Advanced process control
66
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
PI Auto Tune
33,7 Hz 1035 rpmPID tuning ! 1(2)
1.6 A
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
67
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Speed
Feedback
Scope from MCT10 software
68
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
3-zone feedback
• Increased control flexibility
• Improves system by using the average of feedbacks
Advanced process control
69
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Real Time Clock
20 actions can be triggered• Eliminates need
for external timers
• Increased flexibility
70
Confidential / Property of
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
71
Confidential / Property of
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
72
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Smart Logic Controller
Less thanStart pump
OperationPump
Shut off
Pressure Setpoint
ComparePipe
pressure
ConditionControl off
Start command
Stop command
73
Confidential / Property of
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
75
Confidential / Property of
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
76
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Pump dedicated functions
Cascade Controller built-in as standard
• Staging / destaging
• Possible alternation
• Pump Cycling
• Pump Interlocking
Efficient Pump operation
77
Confidential / Property of
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
78
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Cascade CTL and setpoint
79
Confidential / Property of
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
80
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Pump dedicated functions
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
81
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Pump dedicated functions
Sleep Mode
• Based on low flow
• Boost function
• Internal or external signal to enter sleep mode
• Maximizes energy savings
• Reduces wear on equipment
82
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Pump dedicated functions
Initial / Final Ramp
• Independent ramp from zero to minimum freq
• User programmable time period
• Protects bearings and other equipment
• Reduces maintenance
83
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Pump dedicated functions
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
84
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Pump dedicated functions
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
85
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Pipe Fill, vertical pipes
Time
PID ramp the pressure at a user specifiedrate units/sec.
86
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Pipe Fill, horizontal pipes
Constant speed for a settime.
87
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Pump dedicated functions
Flow compensation at setpoint
• Simplifies sensor installation
• Mount the pressure sensor close to the pump
• Easy installation
• Reliable system
• Saves money
• Saves energy
88
Confidential / Property of
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
89
Confidential / Property of
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
91
Confidential / Property of
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
2/2
92
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Cascade CTL configuration tool
Cascade CTLconfiguration tool
•Set up feedback
•Set up Setpoint
93
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
Cascade CTL configuration tool
•Set up cascade
94
Confidential / Property of
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
1/2
VLT® Energy Box
95
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
VLT®Energy Box
PC tool to calculate Return on Investment, Payback Time
96
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
VLT®Energy Box
Generated Reports:
97
Confidential / Property of
Danfoss Drives A/S
9 August, 2008
Name/department
VLT®Energy Box
Generated Reports for documentation
98
Confidential / Property of
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