Danfoss VLT Condition-based Monitoring Programming guide

Programming Guide

VLT® Condition-based Monitoring

VLT® FC Series

vlt-drives.danfoss.com

VLT® Condition-based Monitoring

Programming Guide

Before you begin 5

1.1

Introduction to the Programming Guide 5

Reading the parameter table 5

1.2

Introduction to Condition-based monitoring 7

2.1

System Requirements and Compatibility 7

2.2

Ordering Condition-based Monitoring in drives 9

2.2.1

Ordering Condition-based monitoring License From Factory 9

2.2.2

Ordering Condition-based Monitoring in Existing VLT Drive Using MCT-10 9

2.2.3

Enabling Condition-based Monitoring Features 11

2.3

Overview on Condition-based Monitoring 11

2.4

Condition-based Monitoring Workow 12

2.4.1

Step 1: Baseline Conguration 12

Contents

2.4.2

Step 2: Sensor Conguration (Optional) 13

2.4.3

Step 3: Threshold Calculation 13

2.4.4

Step 4: Alarms and Warnings 13

Examples of Condition-based Monitoring Functions 15

3.1

Example 1: Motor Stator Winding Monitoring 15

3.2

Example 2: Load Envelope 15

3.3

Example 3: Vibration Monitoring 16

Commissioning of Condition-based Monitoring 17

4.1

Commissioning Overview 17

4.2

Commissioning using MCT-10 Condition-based Monitoring Plug-in 17

4.3

Recommended Parameter Set-up using LCP or MCT-10 22

4.4

Threshold Conguration Guidelines 24

Fieldbus Integration for Condition-based Monitoring 25

5.1

Fieldbus Integration - Options and Parameters 25

Parameter Descriptions 29

6.1

Parameter Group 45 -** Condition-based Monitoring 29

6.2

Parameter Group 46-** CBM Monitoring Conguration 39

6.3

Parameter Group 47 -** CBM Baseline Data 45

Appendix 49

7.1

Motor Stator Windings 49

7.1.1

Alarm 510, Motor Stator Winding Alarm 49

VLT® Condition-based Monitoring

Programming Guide

7.1.2

Warning 510, Motor Stator Winding Warning 1 49

7.1.3

Warning 500, Motor Stator Winding Warning 2 49

7.2

Vibration Monitoring 49

7.2.1

Alarm 512, Vibration Monitoring Alarm 49

7.2.2

Warning 512, Vibration Monitoring Warning 1 49

7.2.3

Warning 502, Vibration Monitoring Warning 2 49

7.3

Load Envelope 49

7.3.1

Alarm 511, Load Envelope Alarm 49

7.3.2

Warning 511, Load Envelope Warning 1 50

7.3.3

Warning 501, Load Envelope Warning 2 50

Contents

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VLT® Condition-based Monitoring

Programming Guide

Before you begin

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/Documen-

tation 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.

Illustration 1: Parameter Table

1 indicates the value set in factory.

2 indicates whether the parameter type is option or range.

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.

Conversion index

Conversion factor

100175

3600000

36007060671/6061000000

100000

10000

1000210011001-10.1-20.01-30.001

-4

0.0001

-5

0.00001

-6

0.000001

Data type

Description

Type2Integer 8

Int83Integer 16

Int164Integer 32

Int325Unsigned 8

Uint8

Unsigned 16

Uint16

Unsigned 32

Uint32

Visible string

VisStr

Normalized value 2 bytes

N235Bit sequence of 16 boolean variables

V254Time dierence w/o date

TimD

VLT® Condition-based Monitoring

Programming Guide

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

Before you begin

Table 2: Data type

VLT® Product

Minimum Software Compatibility Version

VLT® HVAC Drive FC 102

5.70

VLT® Refrigeration Drive FC 103

2.70

VLT® AQUA Drive FC 202

3.80

VLT® Automation Drive FC 302

8.60

VLT® Motion Control Tool MCT 10

5.11

Control card version

Compatibility

Identication of control card version

MKII

Yes

White USB

MKINoBlack USB

Control mode

Compatibility

VVC+

Yes

U/fNoFluxNoMotor type

Compatibility

Asynchronous

Yes

PM, non salient SPM

(1)

PM, salient IPM

(1)

SynRM

PMaSynRM

Filter name

Compatibility

Description

VLT® dU/dt Filter MCC 102

Yes

Baseline needs to be run with the lter. When the lter is installed later, make sure a new baseline is generated.

VLT® Sine-Wave Filter MCC 101

Yes

VLT® All-Mode Filter MCC 201

Yes

VLT® Condition-based Monitoring

Introduction to Condition-based

Programming Guide

monitoring

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-requirements.

VLT® Products and Software compatibility for Condition-based monitoring

Control card compatibility for Condition-based monitoring

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 acti-

vate license code.

Stator Winding Monitoring Compatibilities

Ongoing implementation

Filters for stator winding monitoring function

Table 3: Compatible Filters for stator winding function

Option type

Number of AI

Name of AI on the board

VLT® General Purpose I/O MCB 101

30/11, 30/12

VLT® Analog I/O MCB109

42/1, 42/3, 42/5

VLT® Sensor Input MCB 114

48/2

VLT(R) Programmable I/O MCB 115

X49/7+8, X49/9+10, X49/11+12

Option name

Status of Condition-based monitoring support

Slot

FC 102

FC 103

FC 202

FC 302

FCD 302

Modbus RTU

Yes

RS485

xxxxx

BACNet MS/TP

RS485

x----

Metasys N2

Yes

RS485

x----

VLT® Probus DP MCA 101

Yes, with basic PDC value exchange.

AxxxxxVLT® Devicenet MCA 104

Yes, with basic PDC value exchange.

Ax-xx-VLT® CANOpen MCA 105

Yes, with basic PDC value exchange.

A---x

AK-LonWorks MCA 107 for ADAP-Kool

NoA-x---

LonWorks MCA 108

NoAxx---

VLT® BACNet MCA 109

NoAx----

VLT® Pronet MCA 120

Yes, with basic PDC value exchange.

Axxxx

x VLT® Ethernet/IP MCA 121

YesAx-xxx

VLT® Modbus TCP MCA 122

YesAx-xxx

VLT® POWERLINK MCA 123

NoA---xx

VLT® EtherCAT MCA 124

YesA---xx

VLT® BACNet/IP MCA 125

YesAx----

VLT® Condition-based Monitoring

Introduction to Condition-based

Programming Guide

Sensor Congurations 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, congure the following options to extend the analog inputs.

Table 4: Options and Analog Input Congurations

Fieldbus support in Condition-based Monitoring

Table 5: Fieldbus and Product Compatibility for Condition-based Monitoring

monitoring

In the above table:

•

x indicates the VLT® product supports the eldbus protocol.

•

- indicates the VLT® product does not support the eldbus protocol.

Parameter number and name

License enabled from factory

License activated by customer (retrot)

Parameter 15-44 Ordered Typecode String

LX1X

SXXX

Parameter 15-45 Actual Typecode String

LX1X

Parameter 50-00 License Installed

CBM

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VLT® Condition-based Monitoring

Introduction to Condition-based

Programming Guide

For more information on eldbus 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

monitoring

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-** reect the acceptance of license code. These parameters are visible in LCP, MCT-10 or eld bus when license code is activated. For further information on specic 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.

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 congurator.

Procedure

Go to Danfoss Drives Congurator.

Click the symbol corresponding to Software Release to open software release selections.

Select LX1X Condition Based Monitoring CBM.

2.2.2 Ordering Condition-based Monitoring in Existing VLT Drive Using MCT-10

For retrot, 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:

Go to parameter group 50-** License group.

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VLT® Condition-based Monitoring

Programming Guide

Stop polling. Press the button as shown in the gure.

Introduction to Condition-based

monitoring

Illustration 2: Stop Polling

Go to parameter 50-01 License Code using the LCP or MCT-10.

Enter the license code in parameter 50-01 License Code, instead of 0000-0000-0000-0000.

After entering the license code using the LCP, parameter 50-01 License Code shows the following information.

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Name

Value

Description

45-00.0

Function

[1] Warning

Set the value for enabling stator monitoring.

45-00.1

Function

[1] Warning

Set the value for enabling load envelope.

45-00.2

Function

[1] Warning

Set the option for enabling vibration monitoring sensor 1.

45-00.3

Function

[0] O

Set the option for enabling vibration monitoring sensor 2.

VLT® Condition-based Monitoring

Introduction to Condition-based

Programming Guide

When the license is accepted by the drive, the LCP displays as shown below.

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.



monitoring

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

Go to Parameter Group 45 -** Condition-based Monitoring.

Set the values to raise warnings for condition-based monitoring features, as described in the table.

N O T I C E

Make sure to congure 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 param-

eter 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.

Benets of installing the condition-based monitoring rmware 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

AC drive is installed and commissioned

Baseline Configuration

Threshold Calculation

Monitoring

Initiate Baseline (Measurement)

Sensor Configuration (optional)

Baseline Configuration

Initiate Baseline (Measurement)

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duration from few minutes upto 6 months

VLT® Condition-based Monitoring

Introduction to Condition-based

Programming Guide

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.

monitoring

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 Workow

Before starting the commissioning of condition-based monitoring, make sure that the system is congured (installed and commissioned) for normal operation of the drive.

Depending on the user's requirement, commissioning condition-based monitoring allows the possibility to congure 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.

Illustration 3: Condition-based Monitoring Workow Overview

2.4.1 Step 1: Baseline Conguration

Baseline conguration 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 congure baseline:

•

Baseline Run: The drive takes control of the motor speed and creates a certain congurable speed prole 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-specied 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 congured into the drive.This method is relevant when the baseline values are dened using prior experience and the values are congured in the drive.

As illustrated in the graph below, a baseline consists of 20 speed points which are captured based on the user-dened minimum and maximum observation interval.

Speed point x 20

Value depending on feature

(vibration, load envelope, stator winding)

Observation area

Minimum

Frequency Maximum

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Parameter ID and name

Example Values

Parameter 6-12 Terminal 53 Low Current

4 mA

Parameter 6-13 High Current

20 mA

VLT® Condition-based Monitoring

Introduction to Condition-based

Programming Guide

monitoring

N O T I C E

For new installations, ISO 20816 recommends a wear-in period before taking a baseline measurement.

2.4.2 Step 2: Sensor Conguration (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 congure the correct scaling using parameters in Parameter Group 6-1* Analog Input 1.

For example when terminal AI53 is used, congure the following:

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

Dening or setting the threshold values

In this step, the thresholds are dened. There are 3 methods of threshold calculation.

•

Absolute: This is the common method when the equipment values are already known. The threshold has a xed value irrespec- tive 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.

•

Oset: 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-dened oset is considered in the threshold conguration. 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 dene 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). Notication

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). Notica- tion 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.

Threshold

Time

No Faults

Warning Stage 1 Fault

Warning Stage 2 Fault

Critical Fault

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VLT® Condition-based Monitoring

Introduction to Condition-based

Programming Guide

Illustration 4: Alarm and Warning Stages

For more information, see 7.1 Motor Stator Windings, 7.2 Vibration Monitoring, and 7.3 Load Envelope.

monitoring

Current spectrum

Voltage spectrum

Machine status

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Current (A)

Frequency (Hz)

Upper threshold

Lower threshold

Baseline

-0.5

0.5

1.5

0 10 20 30 40 50

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VLT® Condition-based Monitoring

Examples of Condition-based

Programming Guide

Monitoring Functions

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.

Illustration 5: Example of Motor Stator Winding Monitoring

3.2 Example 2: Load Envelope

The function monitors torque and speed prole of the application which is measured during the baseline measurement. The threshold conguration 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.

Illustration 6: Load Envelope Example

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VLT® Condition-based Monitoring

Examples of Condition-based

Programming Guide

Monitoring Functions

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.

Illustration 7: Vibration Monitoring Example

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Danfoss VLT Condition-based Monitoring Programming guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Before you begin