Danfoss VLT Aqua Drive Fc202

The New VLT® AQUA Drive FC202
The new VLT® AQUA Drive

Sets new benchmarks in water and
waste water business
Confidential / Property of 9 August, 2008
Danfoss Drives A/S Name/department

2
Compatibility
The new VLT® Aqua Drive

is 1:1 compatible with
VLT® 8000...
All you have in

VLT® 8000
you will have in
VLT® Aqua Drive
…and even more.
Award-winning user
friendliness

3
Supply and power range
One drive for full

voltage range
Lower need for
training, less confuse
200 – 240Vac, 0,25 – 45kW

200 – 240Vac, 2,2 – 22kW, 1Ø - 3Ø
380 – 480Vac, 0,37 – 90kW

380 – 480Vac, 7,5 – 37kW, 1Ø - 3Ø
380 – 480Vac, 110 – 1000kW

525 – 600Vac, 0,75 – 90kW
525 – 690Vac, 11 – 1,2MW

4
Flexible mechanical design
Common mechanical
concept
•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

5
Flexible mounting
Quick and easy

replacement of old
drives
Less installation time

6
Compact design
True side by side

mounting saves
space and time
Less panel space

– Less cost

7
The smallest IP20
Saves considerably
Space in panels

8
The smallest IP20
Footprint:
- up to 57 % smaller Former width
New width,
Volume B5
New IP20 height

- up to 60 % smaller
New IP21 Height

Former IP21 Height
FP54%
FP 54%
VL60%
VL 60%
FP 15%
VL 11%

9
VLT AQUA Drive - High Power
Integrated options
• Disconnect switch
• Fast acting fuses
• Built in filters comply with

EN61000-6-4 and EN61000-3
• Class A2 filter as standard
• Optional class A1 (150 m cable)
• Also available as field installable

kits for later upgrade

10
Innovative Cooling Back channel
exhaust air
Back Channel Cooling
Internal
• Separate cooling path for power components exhaust air
• 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 Internal
inlet air
Details Back channel

inlet air

11
Innovative cooling by design
§ Two cooling possibilities

Upper exhaust
§ Back cooling –
Air ducted in and out the back
Heat sink Back exhaust § Duct work cooling –
Air ducted in the bottom, out the top
Heat sink fan
§ 85% of the cooling air volume
never enters the controls area
IP54 Seal
§ Separate path makes heat sink
cleaning easy
Back inlet
Bottom § Pre-engineered, thermally tested

inlet cooling kits available
Details for IP00 enclosures

12
IP00 enclosure with back channel kits
Back channel
exhaust air
Internal Internal
exhaust air exhaust air
Back channel
exhaust air
IP54 Seal
Internal Internal
inlet air inlet air
Back channel
Back channel inlet air
inlet air

13
The reliable VLT® AQUA Drive
Designed for maximum

uptime and long life
• High ambient temp
• High IP-rating
• Robust housing
• Maintenance free
Value

14
Value of high ambient temp, IP
and robust housing
Panel builder: End user:
•Less need for panel cooling •Reduced installation cost.

•Increased lifetime •Increased drive lifetime.
•Stabile and reliable system •Usable in harsh environments
•Possible mounting outside panel •Reliable system

15
VLT® Aqua Drive cooling system
Fan controlled by
internal temperature
Energy saved
Less 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 panel
Less need for panel cooling
Picture shows IP20 unit

16
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

17
Large variety of options
• Only pay for

what you need
• Flexible specification
• Reduced total installed
system costs
• Easy Mounting
– plug and play

18
• Relay option
+ 3 relay outputs

19
• Relay option
• General purpose I/O
+ 3 digital inputs
+ 2 digital outputs
+ 2 analogue inputs
+ 1 analogue output

20
• Relay option
• Aqua I/O option
+ 3 PT/NI 1000
analogue input
+ 3 analogue output

21
• Relay option
• Aqua I/O option
• Fieldbusses
– Modbus RTU (Standard)
– Profibus
– Device net
– Ethernet (April 2007)
– Modbus TCP (late 2007)

22
• Relay option
• Aqua I/O option
• Fieldbusses
• Cascade control
– Extended 5 relays
– Advanced 8 relays

23
• Relay option
• Aqua I/O option
• Fieldbusses
• Cascade control

24
• Relay option
• Aqua I/O option
• Fieldbusses
• Cascade control
• Real Time Clock with
24V backup
Value

25
Value of a large variety of options?

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

26
Tested – ready for operation
Customized units
assembled and
tested in the factory
• Reliability
• Quick and low cost
installation

27
Same user interfaces for whole range
Option of 2 Displays
(graphical and numerical)
“Blind cover” available
• Award winning
graphical display
• Easy navigation and
troubleshooting
• Quick learning
Value

28
Value of only one user interface
for the whole range?
• No need for display • Very easy
in all drives commissioning
• Easy commissioning • Saves time and money.
• Saves time and money
• Possible cost optimized user
interface.

29
Excellent electronic performance

Best built-in EMC performance
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
Value

31
Value of the EMC performance?

Onboard filter saves:
• panel space • Lower installation cost
• cost of an external filter • Compliance with EMC norms
• time for mounting of • Easy replacement
external filter
3 Different RFI filters: Screened
H1 Class A1/A2 150m
H1 Class B 50m
H2 Class A2 Up to 25m (Size depended)
H3 Class A1 (reduced) 50m
H3 Class B (reduced) Up to 20m (Size depended)
Unscreened up to 300m

32
Up to 150 m screened motor cable / 300 m
unscreened
Flexibility in
project planning
No need for
external filters
Saves space and money

33
Optimum harmonic performance
DC-coils are
built-in standard
• Reduced installation cost
• Smaller transformer
and cables
Value

34
Value of the Harmonic performance?

• Total Harmonic Distortion • Lower installation cost
(THiD) current • Lower kVar Penalty
lower than 48% • Lower need for power Factor
correction
• No need for • Less cooling
external input filter
• Saves space, time
and money

35
Use less energy

Energy optimization
Automatic Energy
Optimization (AEO)
Voltage
• Better system efficiency
• Optimize energy savings
• Quicker Start-up
• Optimizes motor
magnetization voltage based
on load dynamics
• Can be used both in VT and Speed
CT torque mode
Value Confidential / Property of 9 August, 2008

37
Value of Automatic Energy
Optimization (AEO)
Only one parameter that
saves a significant
amount of energy
Decrease the payback time

38
Energy optimization
Automatic Motor
Adaptation (AMA)
• Optimizes motor
performance
• Higher system efficiency
• Simple and optimum
commissioning
Value

39
Value of Automatic Motor
Adaption (AMA)?
• Easy to fit the drive to the • Compensate for voltage drop

motor. because of long motor cables
• Ensure optimized motor for submersible pumps.
performance. • Submersible pump motors are
• Saves cost because of lower often differencing from
commissioning time standard motor data.
AMA compensate for this.

40
Energy optimization
Voltage Vector Control

(VVCplus)
• Full voltage at full speed

• No motor derating
• No overheat at full load
• Improved dynamic and stability
Value

41
Value of VVCPlus
• Full motor power at rated • Optimized motor

speed - No need for motor performance
derating • Dynamic, stabile and
• Cost optimized drive and reliable system
motor system • Minimize drive internal
• Minimize drive internal energy consumption
energy consumption • 60° PWM compensate for
• Reduces the need for panel weak supply grids. Up to
cooling 115% mains voltage

42
Energy monitoring
Built-in energy
measurement tool
• Helps user to track

record of the system
• Identifies energy
improvement
possibilities within
water systems
Value

43
Value of energy monitoring?
• Easy process optimization. • Easy to control and

optimize the system.
• Easy to track energy
consumption
• Easy to compare the
actual conditions with the
estimated.

44
Protects applications and motors

Effective motor and drive protection
• No extra heating due to

switching pattern
• Electronic Thermal Relay
function (ETR)
• Direct thermistor
connection
• Current limit protection
• Motor DC brake function at
stand still. (Motor preheat)
• Switching on output
• Low du/dt and Upeak

46
Effective system protection
Automated
skip frequencies
Preventive maintenance
• Reduces system stress
• Reduces
commissioning time
• Easy to avoid
system resonance
• Quick setup of the
frequency bands

47
Water operation Child’s play

AQUA specific menus
• Quick setup menu

• AQUA application menu Quick Menu
• AQUA function menu My Personal

Menu
• Personal menu
can be customised Quick Setup
• Very easy and quick Function Setup
commissioning Changes Made
Analog
reference
Closed loop
Settings
Menu Structure

49
Status Quick menu Main menu Alarm log
Spin Motor/ Prove

System
My Personal Menu
Quick Setup
General
General Clock settings
Function Setup settings LCP Display settings
settings
Analogue outputs
Relays
Changes Made Openloop
loop
Open Digital Reference
settings
settings Analog Reference
Loggings
Closedloop
loop
Closed Feedback Settings
settings
settings PID Settings
Application Fan functions

Application
settings Pump functions
settings
1/1

50
2-level password
Protects personal and

main menus
• Allows controlled access

to drive settings
• Reliable water and
waste water systems

51
Info key
Provides access to
”Onboard Manual”
Available “on-site”
• No need for
a printed manual
• It’s ”always there”

52
Programmable display
Up to 5 variables…
• User-defined Display
• Display values with units
(kPa, Bar, mmHq, kWh and…)

53
Graphical display
• Simple monitoring of
logged data
• Graphs and bars
• Multiple font size
• Icons
• International letters,
numbers and signs

54
Display features
Alarm messages/log:
Full text messages
Customised texts
Customised display:
Text and values
Easy and improved
monitoring/fault finding
Graphical data log
Undo-function:
Resets latest change
Hand-Off-Auto on keypad

55
USB port
Plug and play

connection of a PC
Easy use of
• VLT® Set-up Software
MCT 10
• VLT® Energy Box
Saves time and money

56
Drive communicates with other devices
Standard RS-485
• MODBUS RTU
• Danfoss FC
Optional
• Profibus
• DeviceNet
• Ethernet
• Modbus TCP

57
Drive communicates with operator
Clear text message
• Many languages are

available in the display
and documentation
• Chinese, Mandarin, Cyril,

Greek etc. characters

58
Installation is Child's play

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

60
Optional mains disconnect switch
• No need for extra

switch
• Easy installation
• Reduced installation
time and cost

61
Control terminals
• Spring loaded
connections
• Pluggable terminals
– Quick installation
– Reliable system
– Vibration proof
– loop connection

62
Built-in Intelligence
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

64
Auto tuning of all PI-s

• Easy system
commissioning
• Makes PID control simple
• Saves installation and
labour cost

65
PI Auto Tune
1. PI Auto Tune enabled.

2. Monitors the feedback.
3. Manuel adjust the speed to
approximately set point is
reached.
4. Press OK
PID tuning ! 1(2)
5. Drive runs in closed loop 33,7 Hz 1035 rpm 1.6 A
Step 1 of 4
Auto Remote Running
Stabilize with fixed speed 3 acceptable curve periods Drive runs in closed loop
Example

66
Scope from MCT10 software
Speed
Feedback

67
3-zone feedback
• Increased control
flexibility
• Improves system by
using the average of
feedbacks

68
Real Time Clock
20 actions can
be triggered
• Eliminates need
for external timers
• Increased flexibility

69
Preventive Maintenance
20 actions items
can be scheduled
• Helps planned
system maintenance
• More reliable water and
waste water system

70
Smart Logic Controller
Offers a wide range of

PLC functions
Automated sequence
actions can be
programmed
• No need for
external controllers
• Saves cost
Example

71
Smart Logic Controller
Start command
Condition
Control off
Pump
Operation
Shut off
Stop command
Less than
Start pump Pressure
Setpoint
Pipe
Compare pressure

72
Flying start
• Catch motor
in both directions
• Maintains pressure in
case of short voltage
drop-out
Prevent damage and trip if for

instance a Check Valve is defect.
Defect Check valve

73
VLT® AQUA Drive
Dedicated pump features

Pump dedicated functions
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

75
Cascade Controller
built-in as standard
• Staging / destaging
• Possible alternation
• Pump Cycling
• Pump Interlocking
Efficient Pump operation

76
Cascade Controller
Basic Standard Cascade

2 relays
Alternation of 2 pumps (1 relay/pump)
Extended Cascade – B option
2 + 3 relays
Alternation of 2 pumps
Unequal sized pumps
Master / slave
Advanced Cascade – C option

8 relays
Alternation of 4 pumps
Unequal sized pumps
Master / slave

77
Cascade CTL and setpoint

78
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

79
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

80
Sleep Mode
• Based on low flow
• Boost function
• Internal or external
signal to enter sleep
mode
• Maximizes energy
savings
• Reduces wear on
equipment

81
Initial / Final Ramp

• Independent ramp from
zero to minimum freq
• User programmable time
period
• Protects bearings and

other equipment
• Reduces maintenance

82
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

83
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 hammering
Pipe Fill Example

84
Pipe Fill, vertical pipes
PID ramp the

pressure at a user specified
rate units/sec.
Time

85
Pipe Fill, horizontal pipes
Constant speed for a set

time.

86
Flow compensation
at setpoint
• Simplifies sensor
installation
• Mount the pressure sensor
close to the pump
• Easy installation
• Reliable system
• Saves money
• Saves energy

87
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

88
Automatic Flow compensation
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
Flow comp. and cascade CTL

89
VLT® AQUA Drive
VLT Software
VLT® Set-up Software MCT 10
Easy to use on/off-line commissioning tool

Planned:
- Profi-Safe option SW.
- Wizards Framework Builder
- Remote access.
- Alarm collection.
More functionality:
- Full Scope & graph
- Alarm history in saved
Free of charge projects.
- Option configuration
- Project files (max 4) - MCO305
- Scope & Graph (max 2)
- View Alarm history
2/2

91
Cascade CTL configuration tool
•Set up feedback
•Set up Setpoint
Cascade CTL
configuration tool

92
Cascade CTL configuration tool
•Set up cascade

93
VLT® Energy Box
• PC tool to calculate Return on

Investment, Payback Time
• Communicate and withdraw
energy data from the Drive
• Easy way to follow up your
energy bill
1/2

94
VLT®Energy Box
PC tool to
calculate
Return on
Investment,
Payback Time

95
VLT®Energy Box
Generated
Reports:

96
VLT®Energy Box
Generated Reports for documentation

97
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

98

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The New VLT® AQUA Drive FC202

The new VLT® AQUA Drive

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

The new VLT® Aqua Drive

All you have in

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

One drive for full

200 – 240Vac, 0,25 – 45kW

380 – 480Vac, 0,37 – 90kW

380 – 480Vac, 110 – 1000kW

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Quick and easy

Less installation time

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

True side by side

Less panel space

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

New IP20 height

New IP21 Height

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

• Fast acting fuses

• Built in filters comply with

• Also available as field installable

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Details Back channel

Danfoss Drives A/S Name/department

§ Two cooling possibilities

Bottom § Pre-engineered, thermally tested

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Danfoss Drives A/S Name/department

Designed for maximum

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Panel builder: End user:

•Less need for panel cooling •Reduced installation cost.

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Minimum ambient air passes

Cold Plate option

Danfoss Drives A/S Name/department

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

• Only pay for

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Confidential / Property of 9 August, 2008

Danfoss Drives A/S Name/department

Confidential / Property of 9 August, 2008