Danfoss FC 300 Leitfaden

Contents

1 How to Read this Design Guide

1-1

How to Read this Design Guide 1-1

Symbols 1-1

Abbreviations 1-2

Definitions 1-2

2 Safety and Conformity

2-1

Safety Precautions 2-1

Aggressive Environments 2-5

3 Introduction to AutomationDrive FC 300

3-1

Product Overview 3-1

Control Principle 3-4

AutomationDrive FC 300 Controls 3-4

AutomationDrive FC 301 vs. AutomationDrive FC 302 Control Principle 3-5

Control Structure in VVC

plus

Advanced Vector Control 3-6

Control Structure in Flux Sensorless (AutomationDrive FC 302 only) 3-7

Control Structure in Flux with Motor Feedback 3-8

Internal Current Control in VVC

plus

Mode 3-8

Local (Hand On) and Remote (Auto On) Control 3-8

Reference Limits 3-11

Scaling of Preset References and Bus References 3-11

Scaling of Analog and Pulse References and Feedback 3-12

Dead Band Around Zero 3-12

Speed PID Control 3-15

Process PID Control 3-18

Ziegler Nichols Tuning Method 3-22

EMC Test Results 3-24

PELV - Protective Extra Low Voltage 3-26

Brake Functions in AutomationDrive FC 300 3-28

Mechanical Holding Brake 3-28

Dynamic Braking 3-28

Selection of Brake Resistor 3-28

Control with Brake Function 3-31

Mechanical Brake Control 3-31

Hoist Mechanical Brake 3-32

Safe Stop of AutomationDrive FC 300 3-37

FC 300 Design Guide Contents

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

4 AutomationDrive FC 300 Selection

4-1

Electrical Data - 200–240 V 4-1

Electrical Data - 380–500 V 4-3

Electrical Data - 525–600 V 4-9

Electrical Data - 525–690 V 4-12

General Specifications 4-20

Acoustic Noise 4-26

du/dt Conditions 4-26

Special Conditions 4-31

Automatic Adaptations to Ensure Performance 4-39

5 How to Order

5-1

Drive Configurator 5-1

Ordering Form Type Code 5-2

6 Mechanical Installation - Frame Size A, B and C

6-1

7 Mechanical Installation - Frame size D, E and F

7-1

Pre-installation 7-1

Planning the Installation Site 7-1

Receiving the Adjustable Frequency Drive 7-1

Transportation and Unpacking 7-1

Lifting 7-2

Mechanical Dimensions 7-4

Mechanical Installation 7-11

Terminal Locations - Frame size D 7-13

Terminal Locations - Frame size E 7-15

Terminal Locations - Frame size F 7-19

Cooling and Airflow 7-22

8 Electrical Installation

8-1

Connections Frame Sizes A, B and C 8-1

Connection to Line Power and Grounding 8-2

Motor Connection 8-5

Relay Connection 8-8

Connections - Frame Sizes D, E and F 8-9

Power Connections 8-10

Fuses 8-22

Disconnectors, Circuit Breakers and Contactors 8-28

Contents FC 300 Design Guide

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

Motor Thermal Protection 8-30

Parallel Connection of Motors 8-30

Motor Insulation 8-32

Motor Bearing Currents 8-32

Control Cables and Terminals 8-32

Control Cable Routing 8-34

Control Terminals 8-36

Switches S201, S202, and S801 8-36

Electrical Installation, Control Terminals 8-37

Basic Wiring Example 8-38

Electrical Installation, Control Cables 8-39

Relay Output 8-41

Additional Connections 8-42

How to Connect a PC to the Adjustable Frequency Drive 8-43

The AutomationDrive FC 300 PC software 8-44

Residual Current Device 8-50

Final Set-up and Test 8-51

9 Application Examples

9-1

Encoder Connection 9-2

Encoder Direction 9-2

Closed-loop Drive System 9-3

Programming of Torque Limit and Stop 9-3

Advanced Mechanical Brake Control for Hoisting Applications 9-4

Automatic Motor Adaptation (AMA) 9-5

Smart Logic Control Programming 9-5

SLC Application Example 9-6

MCB 112 PTC Thermistor Card 9-7

Torque Control Open-loop 9-9

10 Options and Accessories

10-1

Mounting of Option Modules in Slot A 10-1

Mounting Option Modules in Slot B 10-1

Mounting of Options in Slot C 10-2

General Purpose Input Output Module MCB 101 10-3

Encoder Option MCB 102 10-6

Resolver Option MCB 103 10-8

Relay Option MCB 105 10-10

24 V Backup Option MCB 107 10-12

FC 300 Design Guide Contents

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

MCB 112 PTC Thermistor Card 10-13

MCB 113 Extended Relay Card 10-15

MCF 106 A/ B in C Option Adaptor 10-16

Brake Resistors 10-18

Remote Mounting Kit for LCP 10-19

IP21/IP 4X/ TYPE 1 Enclosure Kit 10-20

Mounting Bracket for Frame Size A5, B1, B2, C1 and C2 10-22

Sine-wave Filters 10-24

High Power Options 10-24

Frame Size F Panel Options 10-24

11 RS-485 Installation and Set-up

11-1

RS-485 Installation and Set-up 11-1

Network Configuration 11-3

Adjustable frequency drive Protocol Message Framing Structure -

AutomationDrive FC 300 11-4

Examples 11-10

Modbus RTU Overview 11-11

Modbus RTU Message Framing Structure 11-13

How to Access Parameters 11-18

Danfoss FC Control Profile 11-19

12 Index

12-1

Contents FC 300 Design Guide

MG.33.BC.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 AutomationDrive FC 300.

Available literature for AutomationDrive FC 300

-The VLT AutomationDrive Instruction Manual MG.33.AX.YY provides the neccessary information for getting the drive up and running.

-The VLT AutomationDrive High Power Instruction Manual MG.33.UX.YY

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

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

scriptions.

-The VLT AutomationDrive Profibus Instruction Manual MG.33.CX.YY provides the information required for controlling, monitoring and program-

ming the drive via a Profibus serial communication bus.

-The VLT AutomationDrive DeviceNet Instruction Manual MG.33.DX.YY provides the information required for controlling, monitoring and pro-

gramming 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+Documenta-

tion.

1.1.2 Symbols

Symbols used in this guide.

NOTE!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

*Indicates a default setting

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1-1

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

Adjustable Frequency 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

Regenerative terminals Regen

Second s

Synchronous Motor Speed ns

Torque limit TLIM

Volt V

The maximum output current IVLT,MAX

The rated output current supplied by the adjustable frequency drive IVLT,N

1.1.4 Definitions

Adjustable frequency drive:

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 adjustable frequency drive.

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

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Motor:

fJOG

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

Motor frequency. Output from the adjustable frequency drive. Output frequency is related to the shaft speed on motor depending on number of poles

and slip frequency.

fMAX

The maximum output frequency the adjustable frequency drive 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 adjustable frequency drive. 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

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ηVLT

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

An analog signal applied to input 53 or 54. The signal can be either Voltage 0–10 V (FC 301 and FC 302) or -10–+10 V (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, 20 mA) 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 0 V, 0 mA, 4 mA) 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 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 (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 braking energy generated in regenerative braking. This regenerative braking energy 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 adjustable frequency drive functions.

Digital Outputs

The adjustable frequency 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.

1 How to Read this Design Guide FC 300 Design Guide

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

Hiperface®

Hiperface®is a registered trademark by Stegmann.

Initializing

If initialization is carried out (par. 14-22

Operation Mode

), 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 makes up a complete interface for control and programming of the adjustable frequency drive. The control panel is detachable

and can be installed up to 10 ft [3 m] from the adjustable frequency drive, i.e., in a front panel by means of the installation kit option.

NLCP

Numerical Local Control Panel interface for control and programming of adjustable frequency drive. 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-sections. 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 adjustable frequency drive 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

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1-5

Thermistor:

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

THD

Total Harmonic Distortion state the total harmonic contribution.

Trip

A state entered in fault situations, e.g., if the adjustable frequency drive is subject to an overtemperature or when the adjustable frequency drive is

protecting the motor, process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is canceled 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 adjustable frequency drive is protecting itself and requiring physical intervention, e.g., if the adjustable

frequency drive is subject to a short circuit on the output. A locked trip can only be canceled by cutting off line power, removing the cause of the fault,

and reconnecting the adjustable frequency drive. Restart is prevented until the trip state is canceled by activating reset or, in some cases, by being

programmed to reset automatically. Trip may not be used for personal safety.

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 adjustable frequency drive

imposes a load on the line power 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 adjustable frequency drives have built-in DC coils in the DC link to increase the power factor and to reduce the THD on the line power supply.

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1-6

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