Danfoss FC 300 Guida

Contents

1 How to Read this Design Guide

How to Read this Design Guide 5

Symbols 5

Abbreviations 6

Definitions 6

2 Safety and Conformity

Safety Precautions 11

Aggressive Environments 14

3 Introduction to AutomationDrive FC 300

Product Overview 17

Control Principle 19

AutomationDrive FC 300 Controls 19

AutomationDrive FC 301 vs. AutomationDrive FC 302 Control Principle 20

Control Structure in VVC

plus

Advanced Vector Control 21

Control Structure in Flux Sensorless (AutomationDrive FC 302 only) 22

Control Structure in Flux with Motor Feedback 22

Internal Current Control in VVC

plus

Mode 23

Local (Hand On) and Remote (Auto On) Control 23

Reference Limits 26

Scaling of Preset References and Bus References 26

Scaling of Analog and Pulse References and Feedback 27

Dead Band Around Zero 27

Speed PID Control 30

Process PID Control 33

Ziegler Nichols Tuning Method 37

EMC Test Results 39

PELV - Protective Extra Low Voltage 41

Brake Functions in AutomationDrive FC 300 43

Mechanical Holding Brake 43

Dynamic Braking 43

Selection of Brake Resistor 43

Control with Brake Function 46

Mechanical Brake Control 46

Hoist Mechanical Brake 47

Safe Stop of AutomationDrive FC 300 51

4 AutomationDrive FC 300 Selection

Electrical Data - 200-240 V 59

Electrical Data - 380-500 V 61

FC 300 Design Guide Contents

MG.33.BC.02 - VLT®is a registered Danfoss trademark

Electrical Data - 525-600 V 67

Electrical Data - 525-690 V 70

General Specifications 78

Efficiency 83

Acoustic Noise 84

du/dt Conditions 84

Special Conditions 89

Automatic Adaptations to Ensure Performance 96

5 How to Order

Drive Configurator 97

Ordering Form Type Code 98

6 Mechanical Installation - Frame Size A, B and C

117

7 Mechanical Installation - Frame size D, E and F

121

Pre-installation 121

Planning the Installation Site 121

Receiving the Frequency Converter 121

Transportation and Unpacking 121

Lifting 122

Mechanical Dimensions 124

Mechanical Installation 131

Terminal Locations - Frame size D 133

Terminal Locations - Frame size E 135

Terminal Locations - Frame size F 139

Cooling and Airflow 142

8 Electrical Installation

149

Connections- Frame Sizes A, B and C 149

Connection to Mains and Earthing 150

Motor Connection 153

Relay Connection 156

Connections - Frame Sizes D, E and F 157

Power Connections 157

Fuses 168

Disconnectors, Circuit Breakers and Contactors 173

Motor Thermal Protection 175

Parallel Connection of Motors 175

Motor Insulation 177

Motor Bearing Currents 177

Control Cables and Terminals 178

Contents FC 300 Design Guide

MG.33.BC.02 - VLT®is a registered Danfoss trademark

Control Cable Routing 178

Control Terminals 180

Switches S201, S202, and S801 180

Electrical Installation, Control Terminals 181

Basic Wiring Example 182

Electrical Installation, Control Cables 183

Relay Output 185

Additional Connections 186

How to Connect a PC to the Frequency Converter 187

The AutomationDrive FC 300 PC Software 188

Residual Current Device 193

Final Setup and Test 194

9 Application Examples

197

Encoder Connection 198

Encoder Direction 198

Closed Loop Drive System 199

Programming of Torque Limit and Stop 199

Advanced Mechanical Brake Control for Hoisting Applications 200

Automatic Motor Adaptation (AMA) 201

Smart Logic Control Programming 201

SLC Application Example 202

MCB 112 PTC Termistor Card 203

Torque Control Open Loop 205

10 Options and Accessories

207

Mounting of Option Modules in Slot A 207

Mounting of Option Modules in Slot B 207

Mounting of Options in Slot C 208

General Purpose Input Output Module MCB 101 209

Encoder Option MCB 102 211

Resolver Option MCB 103 213

Relay Option MCB 105 214

24 V Back-Up Option MCB 107 216

MCB 112 PTC Thermistor Card 217

MCB 113 Extended Relay Card 219

MCF 106 A/ B in C Option Adaptor 220

Brake Resistors 222

Remote Mounting Kit for LCP 223

IP21/IP 4X/ TYPE 1 Enclosure Kit 224

Mounting Bracket for Frame Size A5, B1,B2, C1 and C2 226

Sine-wave Filters 227

FC 300 Design Guide Contents

MG.33.BC.02 - VLT®is a registered Danfoss trademark

High Power Options 227

Frame Size F Panel Options 227

11 RS-485 Installation and Set-up

231

RS-485 Installation and Set-up 231

Network Configuration 233

FC Protocol Message Framing Structure - AutomationDrive FC 300 233

Examples 238

Modbus RTU Overview 239

Modbus RTU Message Framing Structure 240

How to Access Parameters 244

Danfoss FC Control Profile 245

Index

255

Contents FC 300 Design Guide

MG.33.BC.02 - VLT®is a registered Danfoss trademark

1 How to Read this Design Guide

1.1.1 How to Read this Design Guide

This Design Guide will introduce all aspects of your AutomationDrive FC 300.

Available literature for AutomationDrive FC 300

-The VLT AutomationDrive Operating Instructions MG.33.AX.YY provide the neccessary information for getting the drive up and running.

-The VLT AutomationDrive High Power Operating Instructions MG.33.UX.YY

-The VLT AutomationDrive Design Guide MG.33.BX.YY entails all technical information about the drive and customer design and applications.

-The VLT AutomationDrive Programming Guide MG.33.MX.YY provides information on how to programme and includes complete parameter

descriptions.

-The VLT AutomationDrive Profibus Operating Instructions MG.33.CX.YY provide the information required for controlling, monitoring and pro-

gramming the drive via a Profibus fieldbus.

-The VLT AutomationDrive DeviceNet Operating Instructions MG.33.DX.YY provide the information required for controlling, monitoring and pro-

gramming the drive via a DeviceNet fieldbus.

X = Revision number

YY = Language code

Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documenta-

tion.

1.1.2 Symbols

Symbols used in this guide.

NB!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

*Indicates default setting

FC 300 Design Guide 1 How to Read this Design Guide

MG.33.BC.02 - VLT®is a registered Danfoss trademark

1.1.3 Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Automatic Motor Adaptation AMA

Current limit ILIM

Degrees Celsius °C

Direct current DC

Drive Dependent D-TYPE

Electro Magnetic Compatibility EMC

Electronic Thermal Relay ETR

Frequency Converter FC

Gram g

Hertz Hz

Kilohertz kHz

Local Control Panel LCP

Meter m

Millihenry Inductance mH

Milliampere mA

Millisecond ms

Minute min

Motion Control Tool MCT

Nanofarad nF

Newton Meters Nm

Nominal motor current IM,N

Nominal motor frequency fM,N

Nominal motor power PM,N

Nominal motor voltage UM,N

Parameter par.

Protective Extra Low Voltage PELV

Printed Circuit Board PCB

Rated Inverter Output Current IINV

Revolutions Per Minute RPM

Regenerative terminals Regen

Second s

Synchronous Motor Speed ns

Torque limit TLIM

Volts V

The maximum output current IVLT,MAX

The rated output current supplied by the frequency converter IVLT,N

1.1.4 Definitions

Frequency converter:

Coast

The motor shaft is in free mode. No torque on motor.

IVLT,MAX

The maximum output current.

IVLT,N

The rated output current supplied by the frequency converter.

UVLT, MAX

The maximum output voltage.

Input:

Control command

Start and stop the connected motor by means of LCP and the digital in-

puts.

Functions are divided into two groups.

Functions in group 1 have higher priority than functions in group 2.

Group 1 Reset, Coasting stop, Reset and Coasting

stop, Quick-stop, DC braking, Stop and the

"Off" key.

Group 2 Start, Pulse start, Reversing, Start reversing,

Jog and Freeze output

Motor:

fJOG

The motor frequency when the jog function is activated (via digital terminals).

1 How to Read this Design Guide FC 300 Design Guide

MG.33.BC.02 - VLT®is a registered Danfoss trademark

Motor frequency. Output from the frequency converter. Output frequency is related to the shaft speed on motor depending on number of poles and slip

frequency.

fMAX

The maximum output frequency the frequency converter applies on its output. The maximum output frequency is set in limit parameters 4-12, 4-13 and

4-19.

fMIN

The minimum motor frequency from frequency converter. Default 0 Hz.

fM,N

The rated motor frequency (nameplate data).

The motor current.

IM,N

The rated motor current (nameplate data).

nM,N

The rated motor speed (nameplate data).

Synchronous motor speed

=2×

par

. 1 −23 × 60

par

. 1 −39

PM,N

The rated motor power (nameplate data).

TM,N

The rated torque (motor).

The instantaneous motor voltage.

UM,N

The rated motor voltage (nameplate data).

Break-away torque

ηVLT

The efficiency of the frequency converter is defined as the ratio between the power output and the power input.

Start-disable command

A stop command belonging to the group 1 control commands - see this group.

FC 300 Design Guide 1 How to Read this Design Guide

MG.33.BC.02 - VLT®is a registered Danfoss trademark

Stop command

See Control commands.

References:

Analog Reference

An analog signal applied to input 53 or 54. The signal can be either Voltage 0-10V (FC 301 and FC 302) or -10 -+10V (FC 302) Current signal 0-20 mA

or 4-20 mA

Binary Reference

A signal applied to the serial communication port (RS 485 term 68 – 69) .

Preset Reference

A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references via the digital terminals.

Pulse Reference

A pulse reference applied to term 29 or 33, selected by par 5-13 or 5-15 [32]. Scaling in par group 5-5*.

RefMAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA) and the resulting reference. The maximum

reference value set in par. 3-03

Maximum Reference

RefMIN

Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4mA) and the resulting reference. The minimum reference value

set in par. 3-02

Minimum Reference

Miscellaneous:

Analog Inputs

The analog inputs are used for controlling various functions of the frequency converter.

There are two types of analog inputs:

Current input, 0-20 mA and 4-20 mA

Voltage input, 0-10 V DC (AutomationDrive FC 301)

Voltage input, -10 - +10 V DC (AutomationDrive FC 302).

Analog Outputs

The analog outputs can supply a signal of 0-20 mA, 4-20 mA.

Automatic Motor Adaptation, AMA

AMA algorithm determines the electrical parameters for the connected motor at standstill.

Brake Resistor

The brake resistor is a module capable of absorbing the brake power generated in regenerative braking. This regenerative braking power increases the

intermediate circuit voltage and a brake chopper ensures that the power is transmitted to the brake resistor.

CT Characteristics

Constant torque characteristics used for all applications such as conveyor belts, displacement pumps and cranes.

Digital Inputs

The digital inputs can be used for controlling various functions of the frequency converter.

Digital Outputs

The frequency converter features two Solid State outputs that can supply a 24 V DC (max. 40 mA) signal.

DSP

Digital Signal Processor.

ETR

Electronic Thermal Relay is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature.

Hiperface®

Hiperface®is a registered trademark by Stegmann.

Initialising

If initialising is carried out (par. 14-22

Operation Mode

), the frequency converter returns to the default setting.

Intermittent Duty Cycle

An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an off-load period. The operation can be either

periodic duty or non-periodic duty.

1 How to Read this Design Guide FC 300 Design Guide

MG.33.BC.02 - VLT®is a registered Danfoss trademark

LCP

The Local Control Panel makes up a complete interface for control and programming of the frequency converter. The control panel is detachable and can

be installed up to 3 metres from the frequency converter, i.e. in a front panel by means of the installation kit option.

NLCP

Numerical Local Control Panel interface for control and programming of frequency converter. The display is numerical and the panel is basically used for

display process values. The NLCP has no storing and copy function.

lsb

Least significant bit.

msb

Most significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM = 0.5067 mm2.

On-line/Off-line Parameters

Changes to on-line parameters are activated immediately after the data value is changed. Changes to off-line parameters are not activated until you enter

[OK] on the LCP.

Process PID

The PID regulator maintains the desired speed, pressure, temperature, etc. by adjusting the output frequency to match the varying load.

PCD

Process Data

Pulse Input/Incremental Encoder

An external digital sensor used for feedback information of motor speed and direction. Encoders are used for high speed accuracy feedback and in high

dynamic applications. The encoder connection is either via term 32 and 32 or encoder option MCB 102.

RCD

Residual Current Device.

Set-up

You can save parameter settings in four Set-ups. Change between the four parameter Set-ups and edit one Set-up, while another Set-up is active.

SFAVM

Switching pattern called Stator Flux oriented Asynchronous Vector Modulation (par. 14-00

Switching Pattern

Slip Compensation

The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor

speed almost constant..

Smart Logic Control (SLC)

The SLC is a sequence of user defined actions executed when the associated user defined events are evaluated as true by the Smart Logic Controller.

(Parameter group 13-xx Smart Logic Control (SLC).

STW

Status Word

FC Standard Bus

Includes RS 485 bus with FC protocol or MC protocol. See par. 8-30

Protocol

Thermistor:

A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).

THD

Total Harmonic Distortion state the total contribution of harmonic.

Trip

A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency converter is protecting the

motor, process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating reset or, in

some cases, by being programmed to reset automatically. Trip may not be used for personal safety.

Trip Locked

A state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention, e.g. if the frequency converter is

subject to a short circuit on the output. A locked trip can only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the

frequency converter. Restart is prevented until the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically.

Trip may not be used for personal safety.

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MG.33.BC.02 - VLT®is a registered Danfoss trademark

VT Characteristics

Variable torque characteristics used for pumps and fans.

VVCplus

If compared with standard voltage/frequency ratio control, Voltage Vector Control (VVCplus) improves the dynamics and the stability, both when the speed

reference is changed and in relation to the load torque.

60° AVM

Switching pattern called 60°Asynchronous Vector Modulation (par. 14-00

Switching Pattern

Power Factor

The power factor is the relation between I1and IRMS.

Power

factor

cos

IRMS

The power factor for 3-phase control:

cos

ϕ1

IRMS

since

cos

ϕ1 = 1

The power factor indicates to which extent the frequency converter im-

poses a load on the mains supply.

The lower the power factor, the higher the IRMS for the same kW per-

formance.

IRMS

2+ .. +

In addition, a high power factor indicates that the different harmonic currents are low.

All Danfoss frequency converters have built-in DC coils in the DC link to have a high power factor and to reduce the THD on the main supply.

1 How to Read this Design Guide FC 300 Design Guide

MG.33.BC.02 - VLT®is a registered Danfoss trademark

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