Danfoss VLT FCD 311 Leitfaden

VLT®FCD Series

■Contents

Introduction to FCD 300 ................................................................................ 3

Software version ...................................................................................................... 3

General warning ...................................................................................................... 4

These rules concern your safety ............................................................................. 4

Warning against unintended start ........................................................................... 4

Technology ............................................................................................................... 5

CE labelling ............................................................................................................ 7

Order form ............................................................................................................... 8

Ordering numbers for FCD 300, 380-480 V .......................................................... 10

Order form ............................................................................................................. 14

PC software and serial communication ................................................................. 15

Accessories for FCD 300 ...................................................................................... 16

The LCP 2 control unit, option .............................................................................. 23

Parameter selection ............................................................................................... 27

Installation .......................................................................................................... 29

Mechanical measurements .................................................................................... 29

Mechanical dimensions, motor mounting .............................................................. 29

Mechanical dimensions, stand alone mounting .................................................... 29

Mechanical installation ........................................................................................... 30

General information about electrical installation ................................................... 32

EMC-correct electrical installation ......................................................................... 34

Earthing of screened/armoured control cables ..................................................... 36

Diagram ................................................................................................................. 37

Electrical installation .............................................................................................. 38

Mains connection ................................................................................................... 39

Pre-fuses ................................................................................................................ 39

Motor connection ................................................................................................... 39

Direction of motor rotation ..................................................................................... 39

Parallel connection of motors ................................................................................ 39

Motor cables .......................................................................................................... 40

Motor thermal protection ....................................................................................... 40

Brake connection ................................................................................................... 40

Earth connection .................................................................................................... 41

Control of mechanical brake .................................................................................. 41

Electrical installation, control cables ...................................................................... 42

Elektrical installation, control terminals ................................................................. 43

VLT Software Dialog .............................................................................................. 43

Relay connection ................................................................................................... 43

Connection examples ............................................................................................ 44

Programming ..................................................................................................... 48

Operation & Display ............................................................................................... 48

Setup conﬁguration ................................................................................................ 48

Load and Motor ..................................................................................................... 56

DC Braking ............................................................................................................ 60

References & Limits .............................................................................................. 65

Handling of references .......................................................................................... 66

Reference function ................................................................................................. 69

Inputs and outputs ................................................................................................. 74

Special functions .................................................................................................... 83

PID functions ......................................................................................................... 85

MG.04.A1.02 - VLT is a registered Danfoss trade mark 1

VLT®FCD Series

Handling of feedback ............................................................................................. 87

Serial communication for FCD 300 ....................................................................... 94

Control Word according toFC protocol ................................................................ 100

Status Word according toFC Proﬁle .................................................................... 101

Control word according to Fieldbus Proﬁle ......................................................... 103

Status word according to proﬁdrive protocol ....................................................... 104

Serial communication .......................................................................................... 106

Technical functions .............................................................................................. 113

All about FCD 300 ......................................................................................... 118

Special conditions ................................................................................................ 118

Galvanic isolation (PELV) .................................................................................... 118

Earth leakage current and RCD relays ............................................................... 118

Extreme operating conditions .............................................................................. 118

dU/dt on motor ..................................................................................................... 119

Switching on the input ......................................................................................... 119

Acoustic noise ...................................................................................................... 119

Temperature-dependent switch frequency ........................................................... 119

Derating for air pressure ...................................................................................... 120

Derating for running at low speed ....................................................................... 120

Motor cable lengths ............................................................................................. 120

Vibration and shock ............................................................................................. 120

Air humidity .......................................................................................................... 120

UL Standard ......................................................................................................... 120

Efﬁciency .............................................................................................................. 120

Mains supply interference/harmonics .................................................................. 121

Power factor ......................................................................................................... 121

Generic EMC standards / product standards ...................................................... 122

EMC emission ...................................................................................................... 122

EMC Immunity ..................................................................................................... 122

Status messages ................................................................................................. 125

Warnings/alarm messages .................................................................................. 125

Warning words, extended status words and Alarmwords ................................... 129

General technical data ......................................................................................... 130

Technical data, mains supply 3 x 380 - 480 V .................................................... 134

Available literature ............................................................................................... 135

Supplied with the unit .......................................................................................... 135

Factory Settings ................................................................................................... 136

MG.04.A1.02 - VLT is a registered Danfoss trade mark

VLT®FCD Series

195NA193.10

FCD 300 Series

Design guide

Software version: 1.0x

This design guide can be used for all FCD 300 Series fre-

quency converters with software version 1.0x.

The software version number can be seen from parameter

640 Software version no.

NB!:

This symbol indicates

something that should be noted by the reader.

Indicates a general warning.

This sym-

bol indicates a warning of high voltage.

MG.04.A1.02 - VLT is a registered Danfoss trade mark 3

Introduction to FCD 300

VLT®FCD Series

■General warning

The voltage of the frequency converter is

dangerous whenever the converter is con-

nected to mains. Incorrect ﬁtting of the

motor or frequency converter may cause damage to

the equipment, serious injury or death. Conse-

quently, it is essential to comply with the instructions

in this manual as well as local and national rules and

safety regulations

■These rules concern your safety

1. The frequency converter must be disconnected

from the mains if repair work is to be carried out.

Check that the mains supply has been discon-

nected and that the prescribed time has passed

before removing the inverter part from the instal-

lation.

2. The [STOP/RESET] key on the optional control

panel does not disconnect the equipment from

mains and is thus not to be used as a safety

switch.

3. The unit must be properly connected to the earth,

the user must be protected against the supply

voltage and the motor must be protected against

overloading pursuant to prevailing national and lo-

cal regulations.

4. The earth leakage currents are higher than 3.5

mA.

5. Protection against motor overload is not included

in the factory setting. If this function is required,

set parameter 128 Motor thermal protection to

data value ETR trip or data value ETR warning.

For the North American market: The ETR func-

tions provide overload protection of the motor,

class 20, in accordance with NEC.

■Warning against unintended start

1. The motor can be brought to a stop by means of

digital commands, bus commands, references or

a local stop, while the frequency converter is con-

nected to mains. If personal safety considerations

make it necessary to ensure that no unintended

start occurs, these stop functions are not sufﬁ-

cient.

2. While parameters are being changed, the motor

may start. Consequently, the stop key [STOP/RE-

SET] on the optional control panel must always be

activated, following which data can be modiﬁed.

3. A motor that has been stopped may start if faults

occur in the electronics of the frequency con-

verter, or if a temporary overload or a fault in the

supply mains or the motor connection ceases.

195NA194.10

Warning:

It can be extremely dangerous to touch the electrical parts

even when the AC line supply has been disconnected.

For FCD 300: wait at least 4 minutes.

MG.04.A1.02 - VLT is a registered Danfoss trade mark

VLT®FCD Series

■Technology

■Control principle

A frequency converter rectiﬁes AC voltage from the

mains supply into DC voltage, following which it

changes this voltage to an AC voltage with variable

amplitude and frequency.

The motor thus receives a variable voltage and fre-

quency, which enables inﬁnitely variable speed

control of three-phase, standard AC motors.

1. Mains voltage

3 x 380 - 480 V AC, 50 / 60 Hz.

2. Rectiﬁer

Three-phase rectiﬁer bridge which rectiﬁes AC volt-

age into DC voltage.

3. Intermediate circuit

DC voltage



√2 x mains voltage [V].

4. Intermediate circuit coils

Evens out the intermediate circuit current and limits

the load on mains and components (mains trans-

former, cables, fuses and contactors).

5. Intermediate circuit capacitor

Evens out the intermediate circuit voltage.

6. Inverter

Converts DC voltage into a variable AC voltage with

a variable frequency.

7. Motor voltage

Variable AC voltage depending on supply voltage.

Variable frequency: 0.2 - 132 / 1 - 1000 Hz.

8. Control card

Here is the computer that controls the inverter which

generates the pulse pattern by which the DC voltage

is converted into variable AC voltage with a variable

frequency.

■The decentral concept

The FCD 300 Adjustable speed drive is designed for

decentral mounting, e.g. in the food and beverage

industry, in the automotive industry, or for other ma-

terial handling applications.

With the FCD 300 it is possible to utilize the cost

saving potential by placing the power electronics de-

centrally, and thus make the central panels obsolete

saving cost, space and effort for installation and

wiring.

The unit is ﬂexible in its mounting options for as well

stand alone mounting and motor mounting. It is also

possible to have the unit pre-mounted on a Danfoss

Bauer geared motor (3 in one solution). The basic

design with a plugable electronic part and a ﬂexible

and “spacious”wiring box is extremely service-

friendly and easy to change electronics without the

need for unwiring.

The FCD 300 is a part of the VLT frequency con-

verter family, which means similar funcionality,

programming, and operating as the other family

members.

■Cleaning

The enclosure (IP66/NEMA type 4x indoor) will offer

protection against dirt and water ingress, and is de-

signed suitable for cleaning as performed in food and

beverage plants with the concentrations of cleaning

solvent as recommended by the manufacturer. High

pressure cleaning in very short distance or long time

with hot water may damage gaskets and lables.

■FCD 300 control principle

A frequency converter is an electronic unit which is

able to inﬁnitely variably control the rpm of an AC

motor. The frequency converter governs the motor

speed by converting the regular voltage and fre-

quency from mains, e.g. 400 V / 50 Hz, into variable

magnitudes. Today the frequency converter con-

trolled AC motor is a natural part of all types of

automated plants.

The FCD 300 Series has an inverter control system

called VVC (Voltage Vector Control). VVC controls

an induction motor by energizing with a variable fre-

quency and a voltage suitable for it. If the motor load

changes, so does its energizing and speed. That is

why the motor current is measured on an ongoing

MG.04.A1.02 - VLT is a registered Danfoss trade mark 5

Introduction to FCD 300

VLT®FCD Series

basis, and a motor model is used to calculate the

actual voltage requirement and slip of the motor.

■Programmable inputs and outputs in four Setups

In the FCD 300 Series it is possible to program the

different control inputs and signal outputs and to se-

lect four different user-deﬁned Setups for most

parameters. It is easy for the user to program the re-

quired functions on the control panel or via serial

communication.

■Mains protection

The FCD 300 Series is protected against the tran-

sients that may occur on the mains, such as

coupling with a phase compensation system or tran-

sients from fuses blown or when lightening strikes.

Rated motor voltage and full torque can be main-

tained down to approx. 10% undervoltage in the

mains supply.

As all 400 V units in the FCD 300 Series have inter-

mediate circuit coils, there is only a low amount of

harmonic mains supply interference. This gives a

good power factor (lower peak current), which re-

duces the load on the mains installation.

■Frequency converter protection

The current measurement in the intermediate circuit

constitutes perfect protection of the FCD 300 Series

in case there is a short-circuit or an earth fault on

the motor connection.

Constant monitoring of the intermediate circuit cur-

rent allows switching on the motor output, e.g. by

means of a contactor.

Efﬁcient monitoring of the mains supply means that

the unit will stop in the case of a phase drop-out (if

the load exceeds approx. 50%). In this way, the in-

verter and the capacitors in the intermediate circuit

are not overloaded, which would dramatically reduce

the service life of the frequency converter.

The FCD 300 Series offers temperature protection

as standard. If there is a thermal overload, this func-

tion cuts out the inverter.

■Reliable galvanic isolation

In the FCD 300 all digital inputs/outputs, analogue

inputs/outputs and the terminals for serial communi-

cation are supplied from or in connection with

circuits that comply with PELV requirements. PELV

is also complied with in relation to relay terminals at

max. 250 V, so that they can be connected to the

mains potential.

See section Galvanic Isolation (PELV) for further de-

tails.

■Advanced motor protection

The FCD 300 Series has integral electronic motor

protection.

The frequency converter calculates the motor tem-

perature on the basis of current, frequency and time.

As opposed to traditional, bimetallic protection, elec-

tronic protection takes account of reduced cooling at

low frequencies because of reduced fan speed (mo-

tors with internal fan). This function cannot protect

the individual motors when motors are connected in

parallel. Thermal motor protection can be compared

to a protective motor switch, CTI.

To give the motor maximum protection against over-

heating when it is covered or blocked, or if the fan

should fail, you can install a thermistor and connect it

to the frequency converter’s thermistor input (Digital

input), see parameter 128 Thermal motor protection.

NB!:

This function cannot protect the individual

motors in the case of motors linked in parallel.

MG.04.A1.02 - VLT is a registered Danfoss trade mark

VLT®FCD Series

■CE labelling

What is CE labelling?

The purpose of CE labelling is to avoid technical ob-

stacles to trade within EFTA and the EU. The EU has

introduced the CE label as a simple way of showing

whether a product complies with the relevant EU di-

rectives. The CE label says nothing about the

speciﬁcations or quality of the product. Frequency

converters are regulated by three EU directives:

The machinery directive (98/37/EEC)

All machines with critical moving parts are covered

by the machinery directive, which came into force on

1 January 1995. Since a frequency converter is

largely electrical, it does not fall under the machinery

directive. However, if a frequency converter is sup-

plied for use in a machine, we provide information on

safety aspects relating to the frequency converter.

We do this by means of a manufacturer’s declaration.

The low-voltage directive (73/23/EEC)

Frequency converters must be CE labelled in accor-

dance with the low-voltage directive, which came

into force on 1 January 1997. The directive applies

to all electrical equipment and appliances used in

the 50 - 1000 Volt AC and the 75 - 1500 Volt DC

voltage ranges. Danfoss CE labels in accordance

with the directive and issues a declaration of confor-

mity upon request.

The EMC directive (89/336/EEC)

EMC is short for electromagnetic compatibility. The

presence of electromagnetic compatibility means

that the mutual interference between different com-

ponents/appliances is so small that the functioning of

the appliances is not affected.

The EMC directive came into force on 1 January

1996. Danfoss CE labels in accordance with the di-

rective and issues a declaration of conformity upon

request. In order that EMC-correct installation can

be carried out, this manual gives detailed instruc-

tions for installation. In addition, we specify the

standards which our different products comply with.

We offer the ﬁlters that can be seen from the speciﬁ-

cations and provide other types of assistance to

ensure the optimum EMC result.

In the great majority of cases, the frequency con-

verter is used by professionals of the trade as a

complex component forming part of a larger appli-

ance, system or installation. It must be noted that the

responsibility for the ﬁnal EMC properties of the ap-

pliance, system or installation rests with the installer.

MG.04.A1.02 - VLT is a registered Danfoss trade mark 7

Introduction to FCD 300

VLT®FCD Series

■Order form

This section makes it easier for you to specify and

order an FCD 300.

Choice of frequency converter

The frequency converter must be chosen on the ba-

sis of the present motor current at maximum loading

of the unit. The frequency converter’s rated output

current IINV. must be equal to or greater than the re-

quired motor current.

Mains voltage

FCD 300 is available for mains voltage range: 380-

480 V.

The frequency converter is connected to a mains

voltage of:

- 3 x 380 - 480 V three-phase AC voltage

3 x 380 - 480 Volt mains voltage

Typical shaft output

PINV.

Max. constant output current

IINV.

Max. constant output power

at 400 V SINV.

Type [kW] [HP] [A] [kVA]

303 0.37 0.50 1.4 1.0

305 0.55 0.75 1.8 1.2

307 0.75 1.0 2.2 1.5

311 1.1 1.5 3.0 2.0

315 1.5 2.0 3.7 2.6

322 2.2 3.0 5.2 3.6

330 3.0 4.0 7.0 4.8

■Enclosure

All FCD 300 units are supplied with IP 66, NEMA 4x

(Indoor) enclosure as standard.

■Brake

FCD 300 is available with or without an integral

brake module. See also the section entitled Brake

resistors for ordering a brake resistor.

Including mechanical brake control/supply.

■24 V external supply

Back up of control supply with 24 V DC is available

as optional function.

■RFI ﬁlter

FCD 300 has an integral 1A RFI-ﬁlter. The integral

1A RFI ﬁlter complies with EMC standards EN

55011-1A. See the sections Cable lengths and

Cross section for further details.

■Harmonic ﬁlter

The harmonic currents do not affect power con-

sumption directly, but they increase the heat losses

in the installation (transformer, cables). That is why

in a system with a relatively high percentage of recti-

ﬁer load it is important to keep the harmonic currents

at a low level so as to avoid a transformer overload

and high cable temperature. For the purpose of en-

suring low harmonic currents, the units are ﬁtted with

coils in their intermediate circuit as standard. This

reduces the input current IRMS by typically 40 %.

■Display unit

On the FCD 300 unit there are 5 indicator lamps for

voltage (ON), warning, alarm, status and bus.

In addition, an LCP control panel to be connected

via a plug to the frequency converter is available as

an option. The LCP control panel can be installed

up to 3 metres away from the frequency converter,

e.g. on a front panel, by means of a mounting kit.

All displays of data are via a 4-line alpha-numerical

display, which in normal operation is able to show 4

operating data items and 3 operation modes continu-

MG.04.A1.02 - VLT is a registered Danfoss trade mark

VLT®FCD Series

ously. During programming, all the information

required for quick, efﬁcient parameter Setup of the

frequency converter is displayed. As a supplement

to the display, the LCP has three indicator lamps for

voltage (ON), warning (WARNING) and alarm

(ALARM). Most of the frequency converter’s parame-

ter Setups can be changed immediately via the LCP

control panel. See also the section entitled The LCP

control unit in the Design Guide.

■Fieldbus protocols

Danfoss frequency converters are able to fulﬁll many

different functions in a process control system. The

frequency converter can be integrated directly in an

overall surveillance system, which will allow detailed

process data to be transferred via serial communica-

tion.

The protocols listed below are based on an RS 485

bus system with a maximum transmission speed of

9600 baud. The following telegram proﬁles are sup-

ported as standard:

- FC protocol, which is a proﬁle adapted to Dan-

foss.

- Proﬁdrive protocol, which supports the proﬁdrive

proﬁle

See Serial communication for FCD 300 for further

details of telegram proﬁles.

■Fieldbus option

The increasing information requirements in industry

make it necessary to collect or visualize many differ-

ent process data. Important process data help the

system technician with the daily monitoring of the

system. The large amounts of data involved in major

systems make a higher transmission speed than

9600 baud desirable.

Proﬁbus is a ﬁeldbus system, which can be used for

linking automation devices such as sensors and

actuators with the controls by means of a two-

conductor cable.

Proﬁbus DP is a very fast communication protocol,

made specially for communication between the au-

tomation system and various types of equipment.

Danfoss FCD 300 can be supplied with the Proﬁbus ®

DP in a 3 mbit and a 12 mbit version. Units with

Proﬁbus protocol can either be controlled by FC pro-

tocol or Proﬁdrive protocol.

Proﬁbus is a registered trade mark.

MG.04.A1.02 - VLT is a registered Danfoss trade mark 9

Introduction to FCD 300

VLT®FCD Series

■Ordering numbers for FCD 300, 380-480 V

0.37

For motor mounting

FCD 303 3 x 380-480 V

Unit Fieldbus Ordering no.

ST* - 175N1698

ST - 175N1699

ST Proﬁbus DP 3 MB 175N1700

ST Proﬁbus DP 12 MB 175N1701

ST AS(i)** 175N1702

EX - 175N1703

EX Proﬁbus DP 3 MB 175N1704

EX Proﬁbus DP 12 MB 175N1705

EX AS(i)** 175N1706

EB - 175N1707

EB Proﬁbus DP 3 MB 175N1708

EB Proﬁbus DP 12 MB 175N1709

EB AS(i)** 175N1710

0.55

For motor mounting

FCD 305 3 x 380-480 V

Unit Fieldbus Ordering no.

ST* - 175N1750

ST - 175N1751

ST Proﬁbus DP 3 MB 175N1752

ST Proﬁbus DP 12 MB 175N1753

ST AS(i)** 175N1754

EX - 175N1755

EX Proﬁbus DP 3 MB 175N1756

EX Proﬁbus DP 12 MB 175N1757

EX AS(i)** 175N1758

EB - 175N1759

EB Proﬁbus DP 3 MB 175N1760

EB Proﬁbus DP 12 MB 175N1761

EB AS(i)** 175N1762

0.37

For stand alone mounting

FCD 303 3 x 380-480 V

Unit Fieldbus Ordering no.

ST* - 175N1711

ST - 175N1712

ST Proﬁbus DP 3 MB 175N1713

ST Proﬁbus DP 12 MB 175N1714

ST AS(i)** 175N1715

EX - 175N1716

EX Proﬁbus DP 3 MB 175N1717

EX Proﬁbus DP 12 MB 175N1718

EX AS(i)** 175N1719

EB - 175N1720

EB Proﬁbus DP 3 MB 175N1721

EB Proﬁbus DP 12 MB 175N1722

EB AS(i)** 175N1723

0.55

For stand alone mounting

FCD 305 3 x 380-480 V

Unit Fieldbus Ordering no.

ST* - 175N1763

ST - 175N1764

ST Proﬁbus DP 3 MB 175N1765

ST Proﬁbus DP 12 MB 175N1766

ST AS(i)** 175N1767

EX - 175N1768

EX Proﬁbus DP 3 MB 175N1769

EX Proﬁbus DP 12 MB 175N1770

EX AS(i)** 175N1771

EB - 175N1772

EB Proﬁbus DP 3 MB 175N1773

EB Proﬁbus DP 12 MB 175N1774

EB AS(i)** 175N1775

ST: Standard unit.

EX: Unit with 24 V external supply.

EB: Unit with 24 V external supply and brake.

*: Only cable entries on the right side.

**: For availability , contact Danfoss.

MG.04.A1.02 - VLT is a registered Danfoss trade mark

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