Danfoss FC 300 Leitfaden

Contents

1. How to Read this Design Guide

How to Read this Design Guide 5

Approvals 5

Symbols 5

Abbreviations 6

Definitions 6

2. Safety and Conformity

Safety Precautions 13

3. Introduction to FC 300

Product Overview 19

Control Principle 21

FC 300 Controls 21

FC 301 vs. FC 302 Control Principle 22

Control Structure in VVCplus 23

Control Structure in Flux Sensorless (FC 302 only) 24

Control Structure in Flux with Motor Feedback 24

Internal Current Control in VVCplus Mode 25

Local (Hand On) and Remote (Auto On) Control 25

Reference Handling 28

Scaling of References and Feedback 29

Dead Band Around Zero 29

Speed PID Control 32

Process PID Control 35

Ziegler Nichols Tuning Method 40

EMC Immunity 44

Ground Leakage Current 46

Selection of Brake Resistor 46

Mechanical Brakecontrol 49

Hoist Mechanical Brake 51

Smart Logic Control 52

Safe Stop of the FC 300 54

Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) 56

Safe Stop Commissioning Test 57

4. FC 300 Selection

FC 300 Design Guide Contents

MG.33.B9.22 - VLT®is a registered Danfoss trademark.

Electrical Data 61

General Specifications 75

Efficiency 81

Acoustic Noise 81

du/dt conditions 82

Automatic adaptations to ensure performance 90

5. How to Order

Drive Configurator 91

Ordering Form Type Code 91

6. How to Install

101

Mechanical Dimension 101

Mechanical Installation 105

Electrical Installation 108

Connection to Line Power and Grounding 110

Motor Connection 111

Fuses 116

Control Terminals 121

Electrical Installation, Control Terminals 121

Basic Wiring Example 124

Electrical Installation, Control Cables 124

Motor Cables 125

Switches S201, S202, and S801 126

Additional Connections 130

Relay Connection 131

Relay Output 132

Parallel Connection of Motors 132

Motor Thermal Protection 133

How to Connect a PC to the FC 300 135

The FC 300 PC Software 136

Residual Current Device 142

7. Application Examples

143

Start/Stop 143

Pulse Start/Stop 143

Potentiometer Reference 144

Contents FC 300 Design Guide

MG.33.B9.22 - VLT®is a registered Danfoss trademark.

Encoder Connection 145

Encoder Direction 145

Closed-loop Drive System 145

Programming of Torque Limit and Stop 146

Automatic Motor Adaptation (AMA) 146

Smart Logic Control Programming 147

SLC Application Example 147

8. Options and Accessories

149

Mounting of Option Modules in Slot A 149

Mounting Option Modules in Slot B 149

General Purpose Input Output Module MCB 101 150

Encoder Option MCB 102 152

Resolver Option MCB 103 155

Relay Option MCB 105 157

24 V Backup Option MCB 107 (Option D) 159

MCB 112 VLT

PTC Thermistor Card 160

IP 21/IP 4X/ TYPE 1 Enclosure Kit 163

Sine-wave Filters 164

9. RS-485 Installation and Set-up

165

RS-485 Installation and Set-up 165

Network Configuration 167

FC Protocol Message Framing Structure - FC 300 168

Examples 173

Danfoss FC Control Profile 174

10. Troubleshooting

187

Warnings/Alarm Messages 187

Index

196

FC 300 Design Guide Contents

MG.33.B9.22 - VLT®is a registered Danfoss trademark.

1. How to Read this Design Guide FC 300 Design Guide

MG.33.B9.22 - 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 FC 300.

Available literature for FC 300

-The VLT

AutomationDrive FC 300 Instruction Manual MG.33.AX.YY provides the nec-

essary information for getting the drive up and running.

-The VLT

AutomationDrive FC 300 Design Guide MG.33.BX.YY contains all the technical

information about the drive, customer design and applications.

-The VLT

AutomationDrive FC 300 Programming Guide MG.33.MX.YY provides informa-

tion on how to program and includes complete parameter descriptions.

-The VLT

AutomationDrive FC 300 Profibus Instruction Manual MG.33.CX.YY provides

all the information required for controlling, monitoring and programming the drive via a

Profibus serial communication bus.

-The VLT

AutomationDrive FC 300 DeviceNet Instruction Manual MG.33.DX.YY provides

the information required for controlling, monitoring and programming the drive via a

DeviceNet serial communication bus.

X = Revision number

YY = Language code

Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/

DrivesSolutions/Documentations/Technical+Documentation.

1.1.2. Approvals

1.1.3. Symbols

Symbols used in this guide.

NOTE

Indicates something to be noted by the reader.

FC 300 Design Guide 1. How to Read this Design Guide

MG.33.B9.22 - VLT®is a registered Danfoss trademark.

Indicates a general warning.

Indicates a high-voltage warning.

*Indicates default setting

1.1.4. 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

drive 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

Second s

Torque limit TLIM

Volt V

1.1.5. Definitions

Drive:

D-TYPE

Size and type of the connected drive (dependencies).

1. How to Read this Design Guide FC 300 Design Guide

MG.33.B9.22 - VLT®is a registered Danfoss trademark.

VLT,MAX

The maximum output current.

VLT,N

The rated output current supplied by the adjustable frequency drive.

VLT, MAX

The maximum output voltage.

Input:

Control command

You can start and stop the connected motor

using the LCP and the digital inputs.

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:

JOG

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

The motor frequency.

MAX

The maximum motor frequency.

MIN

The minimum motor frequency.

M,N

The rated motor frequency (nameplate data).

The motor current.

M,N

The rated motor current (nameplate data).

M-TYPE

Size and type of the connected motor (dependencies).

M,N

The rated motor speed (nameplate data).

FC 300 Design Guide 1. How to Read this Design Guide

MG.33.B9.22 - VLT®is a registered Danfoss trademark.

M,N

The rated motor power (nameplate data).

M,N

The rated torque (motor).

The instantaneous motor voltage.

M,N

The rated motor voltage (nameplate data).

Break-away torque

VLT

The efficiency of the adjustable frequency drive 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.

Stop command

See Control commands.

References:

Analog Reference

A signal transmitted to the analog inputs 53 or 54 can be voltage or current.

Binary Reference

A signal transmitted to the serial communication port.

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 frequency signal transmitted to the digital inputs (terminal 29 or 33).

1. How to Read this Design Guide FC 300 Design Guide

MG.33.B9.22 - VLT®is a registered Danfoss trademark.

Ref

MAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V,

20 mA) and the resulting reference. The maximum reference value set in par. 3-03.

Ref

MIN

Determines the relationship between the reference input at 0% value (typically 0 V, 0 mA, 4 mA)

and the resulting reference. The minimum reference value set in par. 3-02.

Miscellaneous:

Analog Inputs

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

There are two types of analog inputs:

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

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

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

Analog Outputs

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

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 braking energy generated in regenerative

braking. This regenerative braking energy increases the intermediate circuit voltage, while a brake

chopper ensures that the energy 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 adjustable frequency drive.

Digital Outputs

The drive 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

is a registered trademark by Stegmann.

FC 300 Design Guide 1. How to Read this Design Guide

MG.33.B9.22 - VLT®is a registered Danfoss trademark.

Initializing

If initializing is carried out (par. 14-22), the adjustable frequency drive 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.

LCP

The Local Control Panel (LCP) makes up a complete interface for control and programming of the

FC 300 Series. The control panel is detachable and can be installed up to 9.8 ft (3 meters) from

the adjustable frequency drive, i.e. in a front panel by means of the installation kit option.

lsb

Least significant bit.

msb

Most significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM = 0.00079

[0.5067 mm

Online/Offline Parameters

Changes to online parameters are activated immediately after the data value is changed. Changes

to offline 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 out-

put frequency to match the varying load.

Pulse Input/Incremental Encoder

An external, digital pulse transmitter used for feeding back information on motor speed. The en-

coder is used in applications where great accuracy in speed control is required.

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 while another set-up is active.

SFAVM

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

Slip Compensation

The adjustable frequency drive compensates for the motor slip by giving the frequency a supple-

ment that follows the measured motor load, thus keeping the motor speed almost constant.

1. How to Read this Design Guide FC 300 Design Guide

MG.33.B9.22 - VLT®is a registered Danfoss trademark.

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