Danfoss FC 300 Guide

Contents
1. How to Read this Design Guide
5
How to Read this Design Guide 5
Approvals 5
Symbols 5
Abbreviations 6
Definitions 6
2. Safety and Conformity 13
Safety Precautions 13
3. Introduction to FC 300 19
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 61
FC 300 Design Guide Contents
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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 91
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
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
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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
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1. How to Read this Design Guide FC 300 Design Guide
4 MG.33.B9.22 - VLT®is a registered Danfoss trademark.
1

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.
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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).
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I
VLT,MAX
The maximum output current.
I
VLT,N
The rated output current supplied by the adjustable frequency drive.
U
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:
f
JOG
The motor frequency when the jog function is activated (via digital terminals).
f
M
The motor frequency.
f
MAX
The maximum motor frequency.
f
MIN
The minimum motor frequency.
f
M,N
The rated motor frequency (nameplate data).
I
M
The motor current.
I
M,N
The rated motor current (nameplate data).
M-TYPE
Size and type of the connected motor (dependencies).
n
M,N
The rated motor speed (nameplate data).
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P
M,N
The rated motor power (nameplate data).
T
M,N
The rated torque (motor).
U
M
The instantaneous motor voltage.
U
M,N
The rated motor voltage (nameplate data).
Break-away torque
η
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).
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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
®
Hiperface
®
is a registered trademark by Stegmann.
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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
in
2
[0.5067 mm
2
].
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
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