Danfoss VLT Condition-based Monitoring Programming guide
Programming Guide
VLT® Condition-based Monitoring
VLT® FC Series
vlt-drives.danfoss.com 
VLT® Condition-based Monitoring |
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Programming Guide |
Contents |
Contents
1 |
Before you begin |
5 |
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1.1 |
Introduction to the Programming Guide |
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1.2 |
Reading the parameter table |
5 |
2 |
Introduction to Condition-based monitoring |
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2.1 |
System Requirements and Compatibility |
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2.2 |
Ordering Condition-based Monitoring in drives |
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2.2.1 Ordering Condition-based monitoring License From Factory |
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2.2.2 Ordering Condition-based Monitoring in Existing VLT Drive Using MCT-10 |
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2.2.3 Enabling Condition-based Monitoring Features |
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2.3 |
Overview on Condition-based Monitoring |
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2.4 |
Condition-based Monitoring Workflow |
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2.4.1 Step 1: Baseline Configuration |
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2.4.2 Step 2: Sensor Configuration (Optional) |
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2.4.3 Step 3: Threshold Calculation |
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2.4.4 Step 4: Alarms and Warnings |
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3 |
Examples of Condition-based Monitoring Functions |
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3.1 |
Example 1: Motor Stator Winding Monitoring |
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3.2 |
Example 2: Load Envelope |
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3.3 |
Example 3: Vibration Monitoring |
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4 |
Commissioning of Condition-based Monitoring |
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4.1 |
Commissioning Overview |
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4.2 |
Commissioning using MCT-10 Condition-based Monitoring Plug-in |
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4.3 |
Recommended Parameter Set-up using LCP or MCT-10 |
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4.4 |
Threshold Configuration Guidelines |
24 |
5 |
Fieldbus Integration for Condition-based Monitoring |
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5.1 |
Fieldbus Integration - Options and Parameters |
25 |
6 |
Parameter Descriptions |
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6.1 |
Parameter Group 45 -** Condition-based Monitoring |
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6.2 |
Parameter Group 46-** CBM Monitoring Configuration |
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6.3 |
Parameter Group 47 -** CBM Baseline Data |
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7 |
Appendix |
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7.1 |
Motor Stator Windings |
49 |
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7.1.1 Alarm 510, Motor Stator Winding Alarm |
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Danfoss A/S © 2020.10 |
AU310741645108en-000201/130R0901 | 3 |
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VLT® Condition-based Monitoring |
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Programming Guide |
Contents |
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7.1.2 Warning 510, Motor Stator Winding Warning 1 |
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7.1.3 Warning 500, Motor Stator Winding Warning 2 |
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7.2 |
Vibration Monitoring |
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7.2.1 Alarm 512, Vibration Monitoring Alarm |
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7.2.2 Warning 512, Vibration Monitoring Warning 1 |
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7.2.3 Warning 502, Vibration Monitoring Warning 2 |
49 |
7.3 |
Load Envelope |
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7.3.1 Alarm 511, Load Envelope Alarm |
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7.3.2 Warning 511, Load Envelope Warning 1 |
50 |
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7.3.3 Warning 501, Load Envelope Warning 2 |
50 |
4 | Danfoss A/S © 2020.10 |
AU310741645108en-000201/130R0901 |
VLT® Condition-based Monitoring
Programming Guide |
Before you begin |
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1 Before you begin
1.1 Introduction to the Programming Guide
Introduction
This chapter describes the purpose of the programming guide, intended audience, disclaimer, safety conventions and additional resources.
Purpose of this Programming Guide
This programming guide provides information on working with Condition-based monitoring parameters on the VLT® FC series.
It provides an overview of parameters and value ranges for operating the drive. Installation and operating instructions are not in scope of this programming guide.
Intended Audience
The intended audience of the programming guide is trained personnel, automation engineers and programmers with experience in operating with parameters and basic knowledge of Danfoss AC drives.
Safety Symbols
The following symbols are used in this manual:
D A N G E R 
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
W A R N I N G 
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
C A U T I O N 
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
N O T I C E
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
Additional Resources
Additional resources are available to help you understand related information.
Technical documentation for various product options is available via the Danfoss home page in the Service and Support/Documentation section.
1.2 Reading the parameter table
This programming guide includes parameter and options tables. These descriptions explain how to read the parameter and options tables.
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6 |
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Illustration 1: Parameter Table
1 indicates the value set in factory.
2 indicates whether the parameter type is option or range.
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3 indicates the manner of parameter set-ups. All setups means that the parameter can be set individually in each of the 4 setups. For example, 1 single parameter can have 4 di„erent data values. 1 setup indicates that the data value is the same in all setups.
4 refers to the conversion index. Parameter values are transferred as whole numbers only. Conversion factors are therefore used to transfer decimals. If a value is transferred as 100 and a conversion index of -1, the real value is 10.0.
5 indicates the di„erent data types for the parameters.
Danfoss A/S © 2020.10 |
AU310741645108en-000201 / 130R0901 | 5 |
VLT® Condition-based Monitoring |
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Programming Guide |
Before you begin |
6 indicates whether the parameter value can be changed while the frequency converter is in operation. False indicates that the frequency converter must be stopped before a change can be made.
Table 1: Conversion Table
Conversion index |
Conversion factor |
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100 |
1 |
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75 |
3600000 |
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74 |
3600 |
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70 |
60 |
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67 |
1/60 |
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6 |
1000000 |
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5 |
100000 |
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4 |
10000 |
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3 |
1000 |
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2 |
100 |
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1 |
10 |
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0 |
1 |
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-1 |
0.1 |
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-2 |
0.01 |
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-3 |
0.001 |
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-4 |
0.0001 |
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-5 |
0.00001 |
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-6 |
0.000001 |
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Table 2: Data type
Data type |
Description |
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Type |
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2 |
Integer 8 |
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Int8 |
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3 |
Integer 16 |
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Int16 |
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4 |
Integer 32 |
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Int32 |
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5 |
Unsigned 8 |
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Uint8 |
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6 |
Unsigned 16 |
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Uint16 |
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7 |
Unsigned 32 |
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Uint32 |
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9 |
Visible string |
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VisStr |
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33 |
Normalized value 2 bytes |
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N2 |
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35 |
Bit sequence of 16 boolean variables |
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V2 |
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54 |
Time di„erence w/o date |
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TimD |
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6 | Danfoss A/S © 2020.10 |
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AU310741645108en-000201 / 130R0901 |
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VLT® Condition-based Monitoring |
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Programming Guide |
Introduction to Condition-based |
monitoring |
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2 Introduction to Condition-based monitoring
2.1 System Requirements and Compatibility
In order to enable Condition-based monitoring and e„ectively function, verify the following software compatibilty and system-re- quirements.
VLT® Products and Software compatibility for Condition-based monitoring
VLT® Product |
Minimum Software Compatibility Version |
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VLT® HVAC Drive FC 102 |
5.70 |
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VLT® Refrigeration Drive FC 103 |
2.70 |
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VLT® AQUA Drive FC 202 |
3.80 |
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VLT® Automation Drive FC 302 |
8.60 |
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VLT® Motion Control Tool MCT 10 |
5.11 |
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Control card compatibility for Condition-based monitoring
Control card version |
Compatibility |
Identification of control card version |
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MKII |
Yes |
White USB |
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MKI |
No |
Black USB |
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MKII control card is required to enable license code functions.
Contact local Danfoss Sales partner to determine the possibility of upgrading VLT® product with new control card, inorder to activate license code.
Stator Winding Monitoring Compatibilities
Control mode |
Compatibility |
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VVC+ |
Yes |
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U/f |
No |
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Flux |
No |
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Motor type |
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Compatibility |
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Asynchronous |
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Yes |
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PM, non salient SPM(1) |
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No |
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PM, salient IPM(1) |
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No |
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SynRM |
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No |
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PMaSynRM |
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No |
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1 Ongoing implementation |
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Filters for stator winding monitoring function |
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Table 3: Compatible Filters for stator winding function |
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Filter name |
Compatibility |
Description |
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VLT® dU/dt Filter MCC 102 |
Yes |
Baseline needs to be run with the filter. |
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When the filter is installed later, make sure a new baseline is generated. |
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VLT® Sine-Wave Filter MCC 101 |
Yes |
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VLT® All-Mode Filter MCC 201 |
Yes |
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Danfoss A/S © 2020.10 |
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AU310741645108en-000201 / 130R0901 | 7 |
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VLT® Condition-based Monitoring |
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Programming Guide |
Introduction to Condition-based |
monitoring |
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Sensor Configurations and Additional Analog Inputs
Condition-based programming use external sensors to obtain data. These external sensors are connected to AC Drive via Analog Inputs (AI).
By default, the software enables the use of 2 sensors which is used for vibration monitoring in 2 directions. The software also allows the addition of more sensors. Contact your local sales o†ce for more information.
To facilitate the addition of more sensors or when embedded analog inputs are used, configure the following options to extend the analog inputs.
Table 4: Options and Analog Input Configurations
Option type |
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Number of AI |
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Name of AI on the board |
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VLT® General Purpose I/O MCB 101 |
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2 |
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30/11, 30/12 |
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VLT® Analog I/O MCB109 |
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3 |
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42/1, 42/3, 42/5 |
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VLT® Sensor Input MCB 114 |
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1 |
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48/2 |
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VLT(R) Programmable I/O MCB 115 |
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3 |
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X49/7+8, X49/9+10, X49/11+12 |
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Fieldbus support in Condition-based Monitoring |
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Table 5: Fieldbus and Product Compatibility for Condition-based Monitoring |
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Option name |
Status of Condition-based |
Slot |
FC 102 |
FC 103 |
FC 202 |
FC 302 |
FCD 302 |
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monitoring support |
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Modbus RTU |
Yes |
RS485 |
x |
x |
x |
x |
x |
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BACNet MS/TP |
No |
RS485 |
x |
- |
- |
- |
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Metasys N2 |
Yes |
RS485 |
x |
- |
- |
- |
- |
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VLT® Profibus DP MCA 101 |
Yes, with basic PDC value ex- |
A |
x |
x |
x |
x |
x |
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change. |
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VLT® Devicenet MCA 104 |
Yes, with basic PDC value ex- |
A |
x |
- |
x |
x |
- |
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change. |
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VLT® CANOpen MCA 105 |
Yes, with basic PDC value ex- |
A |
- |
- |
- |
x |
- |
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change. |
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AK-LonWorks MCA 107 for ADAP-Kool |
No |
A |
- |
x |
- |
- |
- |
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LonWorks MCA 108 |
No |
A |
x |
x |
- |
- |
- |
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VLT® BACNet MCA 109 |
No |
A |
x |
- |
- |
- |
- |
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VLT® Profinet MCA 120 |
Yes, with basic PDC value ex- |
A |
x |
x |
x |
x |
x |
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change. |
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VLT® Ethernet/IP MCA 121 |
Yes |
A |
x |
- |
x |
x |
x |
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VLT® Modbus TCP MCA 122 |
Yes |
A |
x |
- |
x |
x |
x |
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VLT® POWERLINK MCA 123 |
No |
A |
- |
- |
- |
x |
x |
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VLT® EtherCAT MCA 124 |
Yes |
A |
- |
- |
- |
x |
x |
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VLT® BACNet/IP MCA 125 |
Yes |
A |
x |
- |
- |
- |
- |
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In the above table:
•x indicates the VLT® product supports the fieldbus protocol.
•- indicates the VLT® product does not support the fieldbus protocol.
8 | Danfoss A/S © 2020.10 |
AU310741645108en-000201 / 130R0901 |
VLT® Condition-based Monitoring |
|
Programming Guide |
Introduction to Condition-based |
monitoring |
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For more information on fieldbus integration with condition-based monitoring, see 5 Fieldbus Integration for Condition-based Monitoring
For more information on the slots, see the VLT® product design guide
2.2 Ordering Condition-based Monitoring in drives
Condition-based monitoring can be activated from the factory when ordering a new drive. The user can also activate conditionbased monitoring on existing VLT product using a license code.
When a license code is activated, parameters in parameter groups 45-**, 46-**, and 47-** reflect the acceptance of license code. These parameters are visible in LCP, MCT-10 or field bus when license code is activated. For further information on specific license codes for each VLT product, refer to Selection Guide.
Identifying License code information
Using the parameter group 15, the user can identify license code information.
Parameter number and name |
License enabled from factory |
License activated by customer (retrofit) |
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Parameter 15-44 Ordered Typecode String |
LX1X |
SXXX |
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Parameter 15-45 Actual Typecode String |
LX1X |
LX1X |
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Parameter 50-00 License Installed |
CBM |
CBM |
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2.2.1 Ordering Condition-based monitoring License From Factory
For the license code to be activated from the factory,the information has to be entered during product selection in the configurator.
Procedure
1.Go to Danfoss Drives Configurator.
2.Click the symbol corresponding to Software Release to open software release selections.
e30bi288.10
3.Select LX1X Condition Based Monitoring CBM.
2.2.2 Ordering Condition-based Monitoring in Existing VLT Drive Using MCT-10
For retrofit, licenses can be ordered from the regional sales o†ce. See Product Compatibility.
N O T I C E
License codes are unique to a single drive. The license code cannot be used on multiple drives.
The license code comprises of 16 alphanumeric characters in the format (XXXX-XXXX-XXXX-XXXX).
Procedure After receiving the license code, perform the following steps:
1.Go to parameter group 50-** License group.
Danfoss A/S © 2020.10 |
AU310741645108en-000201 / 130R0901 | 9 |
VLT® Condition-based Monitoring |
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Programming Guide |
Introduction to Condition-based |
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monitoring |
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<![if ! IE]> <![endif]>e30bi438.10 |
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2.Stop polling. Press the button as shown in the figure.
<![if ! IE]><![endif]>e30bi439.10
Illustration 2: Stop Polling
3.Go to parameter 50-01 License Code using the LCP or MCT-10.
4.Enter the license code in parameter 50-01 License Code, instead of 0000-0000-0000-0000.
<![if ! IE]><![endif]>e30bi440.10
After entering the license code using the LCP, parameter 50-01 License Code shows the following information.
<![if ! IE]><![endif]>
e30bi287.10
10 | Danfoss A/S © 2020.10 |
AU310741645108en-000201 / 130R0901 |
VLT® Condition-based Monitoring |
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Programming Guide |
Introduction to Condition-based |
monitoring |
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When the license is accepted by the drive, the LCP displays as shown below.
<![if ! IE]><![endif]>
e30bi286.10
5.Restart the drive and MCT-10 to activate the features.
The parameter groups 45, 46, and 47 are now available in LCP and in MCT-10.
2.2.3 Enabling Condition-based Monitoring Features
In this recommendation, the scenario considered is to enable condition-based monitoring, when one sensor is installed on the drive.
Procedure
1.Go to Parameter Group 45 -** Condition-based Monitoring.
2.Set the values to raise warnings for condition-based monitoring features, as described in the table.
ID |
Name |
Value |
Description |
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45-00.0 |
Function |
[1] Warning |
Set the value for enabling stator monitoring. |
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45-00.1 |
Function |
[1] Warning |
Set the value for enabling load envelope. |
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45-00.2 |
Function |
[1] Warning |
Set the option for enabling vibration monitoring sensor 1. |
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45-00.3 |
Function |
[0] O„ |
Set the option for enabling vibration monitoring sensor 2. |
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N O T I C E
Make sure to configure parameter 45-00 Function inorder to generate [1] Warnings or [2] Warnings & Alarms, for proper functioning of condition-based monitoring features.
- The recommendation is to set [1] Warnings in parameter 45-00 Function. Setting [2] Warnings & Alarms in the parameter can cause the AC drive to trip, as alarms stops the drive.
2.3 Overview on Condition-based Monitoring
Condition-based monitoring in Danfoss VLT® drives enables to regularly check the condition and performance of the machine when the drive is in service, and detects potential mechanical, motor, or application failures before the occurrence of an actual failure.
Benefits of installing the condition-based monitoring firmware are as follows:
•Reduces unexpected downtime
•Eliminates unexpected halts in production
•Optimizes maintenance
•Reduction of spare part stock inventory
•Optimizes production processes
Condition-based monitoring functions
Following are the 3 functions introduced in Condition-based monitoring. All the functions can be enabled at the same time for monitoring the drive.
•Motor stator winding monitoring: For this type of monitoring capability, an additional equipment is not required. The motor current signature (inter-turn short circuit or unbalance in motor winding) is detected in drive. Damages caused by motor stator
Danfoss A/S © 2020.10 |
AU310741645108en-000201 / 130R0901 | 11 |
VLT® Condition-based Monitoring |
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Programming Guide |
Introduction to Condition-based |
monitoring |
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winding isolation occurs over a period of time. When more winding turns are impacted, the overcurrent protection is activated due to extensive heating and stops the motor
•Load envelope: For this type of monitoring capability, an additional equipment is not required. Mechanical load of an application is monitored by comparing current load curve with expected load curve based on data gathered during commissioning. During monitoring, overload and under-load deviations, which occur in applications, are detected.
•Vibration monitoring: For this type of monitoring capability, the installation of vibration sensor(s) is required. Speed related vibration (RMS) monitoring via external vibration sensor, detecting early signs of motor misalignments.
N O T I C E
ISO10816 standard provides guidance for evaluating vibration severity for machines operating within 10–200 Hz of frequency range. The standard shall be complied with before commissioning of vibration monitoring function.
2.4 Condition-based Monitoring Workflow
Before starting the commissioning of condition-based monitoring, make sure that the system is configured (installed and commissioned) for normal operation of the drive.
Depending on the user's requirement, commissioning condition-based monitoring allows the possibility to configure thresholds before or after initiating the baseline measurement. The process of obtaining baseline measurements after initiation takes upto 6 months.
The following illustration depicts the two ways to commission condition-based monitoring in a drive.
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Baseline |
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Sensor |
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Initiate Baseline |
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Threshold |
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Configuration |
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Monitoring |
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Configuration |
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(Measurement) |
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Calculation |
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(optional) |
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and commissioned |
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B |
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Baseline |
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Sensor |
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Threshold |
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Initiate Baseline |
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Monitoring |
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Illustration 3: Condition-based Monitoring Workflow Overview
2.4.1 Step 1: Baseline Configuration
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Baseline configuration is the 1st step and essential when commissioning a drive for condition-based monitoring. A baseline signature is required to determine any deterioration in the stator winding, load operating point, or vibration level of the application. The baseline is recorded for each of the activated condition-based monitoring functions.
Following are the di„erent ways to configure baseline:
•Baseline Run: The drive takes control of the motor speed and creates a certain configurable speed profile and measures the relevant signals. Depending on the load conditions, it is not always possible to execute the baseline run when the load does not allow.
•Online Baseline: In this method, the baseline is created by the drive without interrupting the operation of the drive and application. For the user-specified period of time, the relevant signals are gathered by the drive. This method provides a better representation of normal variation in the application.
•Manual Baseline: In this method, the baseline values are manually configured into the drive.This method is relevant when the baseline values are defined using prior experience and the values are configured in the drive.
As illustrated in the graph below, a baseline consists of 20 speed points which are captured based on the user-defined minimum and maximum observation interval.
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Programming Guide
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Introduction to Condition-based monitoring
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For new installations, ISO 20816 recommends a wear-in period before taking a baseline measurement.
2.4.2 Step 2: Sensor Configuration (Optional)
Vibration monitoring requires installation of an external vibration transmitter. The sensor is connected via analog input using for example terminal 53 or terminal 54. When using these terminals make sure to scale correctly. For AI53 S201 to ON = mA and for AI54 switch S202 to ON = mA.
Make sure to configure the correct scaling using parameters in Parameter Group 6-1* Analog Input 1. For example when terminal AI53 is used, configure the following:
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Parameter 6-12 Terminal 53 Low Current |
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If these terminals are in use for other equipment, it is possible to extend the analog input with extension options. For information on extension options, see the Selection Guide.
2.4.3 Step 3: Threshold Calculation
Defining or setting the threshold values
In this step, the thresholds are defined. There are 3 methods of threshold calculation.
•Absolute: This is the common method when the equipment values are already known. The threshold has a fixed value irrespective of the measured baseline value. For example, when the operator knows the absolute limit for the equipment, an absolute value is set for the alarm threshold. In case of vibration monitoring, the limit values described in standards such as ISO 10816/20816 can be used for the alarm threshold as an absolute value.
•Offset: This method of setting threshold values requires understanding of the application and baseline values. The threshold depends on the baseline value to which a user-defined o„set is considered in the threshold configuration. Setting a very low or high value leading to false positives is a risk when using this method. False settings can cause irresponsive monitoring, even in the case of faults.
•Factor: This method is easier to use when compared to o„set, because it does not require in-depth application knowledge. The threshold depends on the baseline value which is multiplied by a factor. For example, the threshold value may be 150% of the baseline. Setting a very high threshold is a risk when using this method of threshold calculation.
2.4.4 Step 4: Alarms and Warnings
In condition-based monitoring, for each feature, the user can define activation stages for warnings and alarms. The interpretation of alarm and warning color codes are as follows:
Green: No alarms are indicated. Condition-based monitoring operations continue.
Yellow: First indication of warning-stage 1 alarm is visible. Stage 1 warning fault are also shown as Stage 1 Warning (S1). Notification to users to plan for maintenance operations. In this stage, condition-based monitoring operations continue.
Orange: Clear indication of warning-stage 2 alarm is visible. Stage 2 warning fault are also shown as Stage 2 Warning (S2). Notification to users to act as soon as possible before the fault becomes critical.
Red: A critical alarm has occurred and condition-based monitoring operations has stopped.
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Illustration 4: Alarm and Warning Stages
For more information, see 7.1 Motor Stator Windings, 7.2 Vibration Monitoring, and 7.3 Load Envelope.
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3 Examples of Condition-based Monitoring Functions
3.1 Example 1: Motor Stator Winding Monitoring
The AC drive provides variable magnitude of voltage and frequency to the stator terminal of connected 3-phase induction motors. During healthy conditions of the motor with good stator winding insulation between inter-turn, the electrical signature shows consistency on the measurement. The electrical signature repeats the baseline value for repeated measurement.
However, in case of weakened insulation or inter-turn short circuit condition, the electrical signatures deviate from its original baseline values. The function withstands false positive in case of AC mains unbalance.
Current spectrum
Voltage spectrum
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Machine status
Illustration 5: Example of Motor Stator Winding Monitoring
3.2 Example 2: Load Envelope
The function monitors torque and speed profile of the application which is measured during the baseline measurement. The threshold configuration works similar to the other functions. Condition-based monitoring can detect underload and overload situations. Hence, there are 2 warning stages for high side (overload scenario) and 2 warning stages for underload scenario.
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Illustration 6: Load Envelope Example
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3.3 Example 3: Vibration Monitoring
The standard ISO 10816/20816 is the recommendation for vibration monitoring. The advantage, VLT® condition-based monitoring provides, is the speed reference to the vibration level instead of an absolute level. The absolute level can mislead in lower levels of the speed reference.
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Illustration 7: Vibration Monitoring Example
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