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Remote Irrigation Pump Control with Danfoss VLT AQUA Drive and FarmHQ

by | Oct 18, 2024 | Engineering and How-To | 0 comments

In modern irrigation systems, precision and automation are crucial for water conservation and energy efficiency. The Danfoss VLT AQUA Drive FC202 is a powerful tool for controlling irrigation pumps, allowing for automatic speed adjustment to match real-time demand. By integrating this variable frequency drive (VFD) with FarmHQ, you can automate the control of your irrigation system, including pipe fill and pressure management, making your system smarter and more efficient.

This post will walk you through the benefits of integrating the Danfoss VLT AQUA Drive with FarmHQ and provide step-by-step instructions on how to reprogram the drive for automatic pipe fill and pressure control.

Why Choose the Danfoss VLT AQUA Drive for Irrigation Pumps?

The Danfoss VLT AQUA Drive is ideal for water and wastewater applications, making it a great choice for irrigation pump control. Its key features include:

  • Energy savings: The drive adjusts pump speed dynamically, reducing power consumption.
  • Improved pump lifespan: Smooth ramp-ups and slowdowns minimize wear and tear on your equipment.
  • Comprehensive protection: Features like overload protection and dry-run prevention help keep your system safe.
  • Easy maintenance and monitoring: Built-in diagnostics simplify troubleshooting and maintenance.

By using the VLT AQUA Drive, you can significantly improve the efficiency of your irrigation system, reduce water waste, and optimize energy usage.

Integrating FarmHQ with Danfoss VLT AQUA Drive

FarmHQ is an advanced platform designed to automate and monitor your irrigation system. With FarmHQ’s 4-20mA output, you can control the Danfoss VLT AQUA Drive to adjust pump speeds automatically based on real-time irrigation needs. FarmHQ allows you to remotely manage your system, connect multiple devices, and automate processes such as turning pumps on and off, adjusting speeds, and monitoring feedback from sensors.

Key Features of FarmHQ Integration

When connected to FarmHQ, your irrigation system benefits from:

  1. Automatic pump control: FarmHQ can automatically turn the Danfoss VLT AQUA Drive on or off based on the system’s demands.
  2. Dynamic speed adjustments: The 4-20mA output from FarmHQ allows the drive to adjust pump speed in real-time, ensuring efficient water use and energy conservation.
  3. Remote monitoring and diagnostics: FarmHQ provides real-time feedback, helping you monitor pump operation and pressure levels from anywhere.

The combination of FarmHQ and the Danfoss VLT AQUA Drive enables a fully automated and intelligent irrigation system that works seamlessly to optimize performance and reduce costs.

Step-by-Step Instructions for Reprogramming the Danfoss VLT AQUA Drive for Automatic Pipe Fill and Pressure Control with FarmHQ

To ensure that your system works optimally, follow the steps below to configure the Danfoss VLT AQUA Drive FC202 for automatic pipe fill and pressure control using FarmHQ.

Step 1: Wiring the Danfoss VLT AQUA Drive FC202

    • Connect the FarmHQ switch cable to the circuit to complete the circuit.
    • Connect terminal 12 or 13 (24VDC+) to RED (Normally Open) and terminal 18 (run) to BLACK (Common).
    • Wire a 200 psi 4-20mA pressure transducer for pipe fill and pressure monitoring from terminal 12 or 13 (24VDC+) to the transducer, and connect the transducer output to terminal 53 (AI1). This is an additional pressure transducer that is separate from the pressure transducer that the FarmHQ device monitors.
    • Connect the FarmHQ CAN bus – BLUE wire to terminal 54 (AI COM), BLACK wire to 12 or 13 (24VDC+)
    • Set the input switches to “I” (current) for 4-20mA transducers (FarmHQ operates on 4-20mA signals).

Step 2: Programming the Danfoss VLT AQUA Drive

Basic Settings
  1. 00-01 Language: Set to your preferred language.
  2. 00-02 Motor Speed Unit: Set to [1] Hz.
  3. 00-03 Regional Settings: Set to [0] International or [1] North America.
  4. 00-10 Active Set-up: Set to [1] Set-up 1.
  5. 00-11 Programming Set-up: Set to [9] Active Set-up.
Display Settings
  1. 00-20 Display Line 1.1 Small: Set to [1613] frequency.
  2. 00-21 Display Line 1.2 Small: Set to [1614] current.
  3. 00-22 Display Line 1.3 Small: Set to [1617] speed.
  4. 00-23 Display Line 2 Large: Set to [1654] feedback (displays pipe pressure).
  5. 00-24 Display Line 3 Large: Set to [1664] AI 54 (displays FarmHQ 4-20mA input for diagnostics).
Motor Configuration
  1. 01-00 Configuration Mode: Set to [3] Closed Loop.
  2. 01-2x Motor Data: Enter motor-specific data.
  3. 03-03 Maximum Reference: Set to the upper limit of the pressure transducer (e.g., 200 psi).
  4. 03-13 Reference Site: Set to [0] Linked to Hand/Auto.
  5. 03-15 Reference 1 Source: Set to [2] AI 54.
Ramp and Speed Limits
  1. 03-41 Ramp 1 Ramp Up Time: Set to 20 seconds or adjust to your system.
  2. 04-12 Motor Low Speed Limit: Set to 30 Hz (or as low as allowed by the motor manufacturer).
  3. 04-14 Motor High Speed Limit: Set to 50 or 60 Hz, depending on the motor nameplate.
Terminal Programming
  1. 05-10 Terminal 18 Digital Input: Set to [8] Start.
  2. 06-12 Terminal 53 Low Current: Set to [4mA].
  3. 06-13 Terminal 53 High Current: Set to [20mA].
  4. 06-15 Terminal 53 High Ref./Feedb. Value: Set to 200 psi.
  5. 06-16 Terminal 53 Filter Time Constant: Set to 10 seconds for stable readings.
  6. 06-22 Terminal 54 Low Current: Set to 4mA.
  7. 06-23 Terminal 54 High Current: Set to 20mA.
  8. 06-25 Terminal 54 High Ref./Feedb. Value: Set to 150 psi.
Feedback Configuration
  1. 20-00 Feedback 1 Source: Set to [1] AI 53.
  2. 20-12 Reference/Feedback Unit: Set to [170] psi.
Pipe Fill Control
  1. 29-00 Pipe Fill Enable: Set to [1] Enabled.
  2. 29-02 Pipe Fill Speed: Set to 30-40 Hz.
  3. 29-05 Filled Set Point: Set between 30-50 psi based on system needs.

Final Notes on Programming

  • Changing 20-xx parameters may alter other settings like 03-03 Maximum Reference or 06-15 High Ref./Feedb. Value. Go through the programming steps twice to ensure all parameters are set correctly.
  • Fine-tune settings for ramp times, speed limits, and pipe fill speed based on your system’s specific requirements.

Conclusion

By integrating the Danfoss VLT AQUA Drive FC202 with FarmHQ, you gain full control over your irrigation pumps, optimizing water usage and energy efficiency. The automation provided by FarmHQ, combined with the precision of the Danfoss VLT AQUA Drive, ensures your irrigation system operates at peak performance with minimal manual intervention.

This setup not only enhances irrigation efficiency but also helps conserve valuable resources like water and energy, making it an excellent solution for modern farming.