Danfoss VLT AutomationDrive FC 300 Guide

MAKING MODERN LIVING POSSIBLE
Design Guide
VLT®AutomationDrive FC 300
90–1200 kW
www.danfoss.com/drives

Contents
1 How to Read this Design Guide 9
1.1 How to Read This Design Guide - FC 300 9
1.2 Available Literature 9
1.3 Approvals 10
1.4 Symbols 10
1.5 Abbreviations 10
1.6 Definitions 11
1.7 Power Factor 14
2 Safety and Conformity 15
2.1 Safety Precautions 15
2.2 Caution 15
2.3 CE Labeling 15
2.4 Enclosure Types 17
2.5 Aggressive Environments 18
3 Product Introduction 19
3.1 Product Overview 19
3.2 Controls 21
3.2.1 Control Principle 22
3.2.2 Control Structure in VVCplus Advanced Vector Control 26
3.2.3 Control Structure in Flux Sensorless 27
3.2.4 Control Structure in Flux with Motor Feedback 27
3.2.5 Internal Current Control in VVCplus Mode 28
3.2.6 Control Local [Hand On] and Remote [Auto On] Control 28
3.3 Reference Handling 30
3.3.1 Reference Limits 31
3.3.2 Scaling of Preset References and Bus References 32
3.3.3 Scaling of Analog and Pulse References and Feedback 32
3.3.4 Dead Band around Zero 33
3.4 PID Control 37
3.4.1 Speed PID Control 37
3.4.2 Speed PID Control Parameters 37
3.4.3 Example of How to Program the Speed Control 38
3.4.4 Speed PID Control Programming Order 38
3.4.5 Tuning Speed PID Control 40
3.4.6 Process PID Control 41
3.4.7 Process PID Control Parameters 42
Contents Design Guide
MG34S222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

3.4.8 Example of Process PID Control 43
3.4.9 Process PID Control Programming Order 44
3.4.10 Optimization of the process regulator 45
3.4.11 Ziegler Nichols Tuning Method 45
3.5 General Aspects of EMC 46
3.5.1 General Aspects of EMC Emissions 46
3.5.2 EMC Test Results 48
3.5.3 Emission Requirements 49
3.5.4 Immunity Requirements 50
3.6 Galvanic Isolation (PELV) 51
3.7 Ground Leakage Current 51
3.8 Brake Functions 52
3.8.1 Mechanical Holding Brake 52
3.8.2 Dynamic Braking 53
3.8.3 Selection of Brake Resistor 53
3.9 Mechanical Brake Control 56
3.9.1 Hoist Mechanical Brake 57
3.10 Smart Logic Controller 59
3.11 Extreme Running Conditions 60
3.12 Safe Stop 62
3.12.1 Safe Torque Off Operation 62
3.12.2 Safe Torque Off Operation (FC 302 only) 62
3.12.3 Liability Conditions 62
3.12.4 Additional Information 62
3.12.5 Installation of External Safety Device in Combination with MCB 112 63
4 Selection 64
4.1 Electrical Data, 380–500 V 64
4.2 Electrical Data, 525–690 V 69
4.2.1 Electrical Data, 525–690 V AC, 12-Pulse 75
4.3 General Specifications 78
4.4 Efficiency 84
4.5 Acoustic Noise 84
4.6 dU/dt Conditions 85
4.7 Special Conditions 86
4.7.1 Manual Derating 86
4.7.2 Derating for Ambient Temperature 87
4.7.3 Automatic Derating 89
Contents Design Guide
Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG34S222

5 How to Order 90
5.1 Ordering Form 90
5.1.1 Type Code 90
5.1.2 Drive Configurator 91
5.2 Ordering Numbers 95
5.2.1 Options and Accessories 95
5.2.2 Brake Resistors 96
5.2.3 Advanced Harmonic Filters 98
5.2.4 Sine-Wave Filter Modules, 380–690 V AC 105
5.2.5 dU/dt Filters 107
6 Mechanical Installation 109
6.1 Pre-installation 109
6.1.1 Receiving the Adjustable Frequency Drive 109
6.1.2 Transportation and Unpacking 109
6.1.3 Lifting 110
6.1.4 Mechanical Dimensions 112
6.1.5 Mechanical Dimensions, 12-Pulse Units 125
6.2 Mechanical Installation 131
6.2.1 Tools Needed 131
6.2.2 General Considerations 131
6.2.3 Terminal Locations - Frame Size D 133
6.2.4 Terminal Locations - Frame Size E 146
6.2.5 Terminal Locations - Frame Size F 153
6.2.6 Terminal Locations - Frame Size F, 12-Pulse 158
6.2.7 Connector/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 164
6.2.8 Connector/Conduit Entry, 12-Pulse - IP21 (NEMA 1) and IP54 (NEMA12) 169
6.2.9 Cooling and Airflow 173
6.2.10 Wall/Panel Mount Installation 175
6.2.11 Pedestal Installation of D-frames 175
6.2.12 Pedestal Installation of E-frames 177
6.2.13 Pedestal Installation of F-frames 178
7 Electrical Installation 179
7.1 Connections 179
7.1.1 Torque Settings 179
7.1.2 Power Connections 180
7.1.3 Power Connections 12-Pulse Adjustable Frequency Drives 205
7.1.4 12-Pulse Transformer Selection Guidelines 207
Contents Design Guide
MG34S222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

7.1.5 Shielding against Electrical Noise 208
7.1.6 External Fan Power Supply 208
7.2 Fuses and Circuit Breakers 208
7.2.1 Fuses 208
7.2.2 D-frame Short Circuit Current Rating (SCCR) 209
7.2.3 Recommendations 209
7.2.4 Power/Semiconductor Fuse Size 210
7.2.5 Power/Semiconductor Fuse Options 211
7.2.6 Supplementary Fuses 213
7.2.7 High Power Fuses 12-Pulse 215
7.2.8 Supplementary Fuses - High Power 216
7.3 Disconnectors and Contactors 217
7.3.1 Line Power Disconnects - Frame Sizes E and F 217
7.3.2 Line Power Disconnects, 12-Pulse 218
7.3.3 Line Power Contactors 218
7.4 Additional Motor Information 219
7.4.1 Motor Cable 219
7.4.2 Parallel Connection of Motors 220
7.4.3 Motor Insulation 222
7.4.4 Motor Bearing Currents 222
7.5 Control Cables and Terminals 222
7.5.1 Access to Control Terminals 222
7.5.2 Control Cable Routing 222
7.5.3 Control Terminals 224
7.5.4 Switches S201 (A53), S202 (A54), and S801 224
7.5.5 Installing Control Terminals 225
7.5.6 Basic Wiring Example 225
7.5.7 Installing Control Cables 226
7.5.8 12-Pulse Control Cables 229
7.5.9 Relay Output D Frame 231
7.5.10 Relay Output E & F-Frame 231
7.5.11 Brake Resistor Temperature Switch 232
7.6 Additional Connections 232
7.6.1 DC Bus Connection 232
7.6.2 Load Sharing 232
7.6.3 Installation of Brake Cable 232
7.6.4 How to Connect a PC to the Adjustable Frequency Drive 233
7.6.5 PC Software 233
Contents Design Guide
Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG34S222

7.7 Safety 234
7.7.1 High Voltage Test 234
7.7.2 Grounding 234
7.7.3 Safety Ground Connection 234
7.8 EMC-compatible Installation 234
7.8.1 Electrical Installation - EMC Precautions 234
7.8.2 Use of EMC-Compatible Cables 236
7.8.3 Grounding of Shielded Control Cables 236
7.8.4 RFI Switch 237
7.9 Line Power Supply Interference/Harmonics 238
7.9.1 The Effect of Harmonics in a Power Distribution System 238
7.9.2 Harmonic Limitation Standards and Requirements 239
7.9.3 Harmonic Mitigation 239
7.9.4 Harmonic Calculation 239
7.10 Residual Current Device 239
7.11 Final Set-up and Test 240
8 Application Examples 241
8.1 Automatic Motor Adaptation (AMA) 241
8.2 Analog Speed Reference 241
8.3 Start/Stop 242
8.4 External Alarm Reset 243
8.5 Speed Reference with Manual Potentiometer 243
8.6 Speed Up/Slow 244
8.7 RS-485 Network Connection 244
8.8 Motor Thermistor 245
8.9 Relay Set-up with Smart Logic Control 245
8.10 Mechanical Brake Control 246
8.11 Encoder Connection 246
8.12 Encoder Direction 247
8.13 Closed-loop Drive System 247
8.14 Stop and Torque Limit 247
9 Options and Accessories 249
9.1.1 Slot A 249
9.1.2 Slot B 249
9.1.3 Slot C 249
9.2 General Purpose Input Output Module MCB 101 250
9.2.1 Galvanic Isolation in the MCB 101 250
Contents Design Guide
MG34S222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

9.2.2 Digital Inputs - Terminal X30/1-4 251
9.2.3 Analog Inputs - Terminal X30/11, 12 251
9.2.4 Digital Outputs - Terminal X30/6, 7 251
9.2.5 Analog Output - Terminal X30/8 252
9.3 Encoder Option MCB 102 252
9.4 Resolver Option MCB 103 254
9.5 Relay Option MCB 105 256
9.6 24 V Backup Option MCB 107 258
9.7 PTC Thermistor Card MCB 112 259
9.8 MCB 113 Extended Relay Card 261
9.9 Brake Resistors 263
9.10 LCP Panel Mounting Kit 263
9.11 Sine-wave Filters 264
9.12 High Power Options 264
9.12.1 Frame Size D Options 264
9.12.1.1 Load Share Terminals 264
9.12.1.2 Regeneration Terminals 264
9.12.1.3 Anti-condensation Heater 264
9.12.1.4 Brake Chopper 264
9.12.1.5 Line Power Shield 264
9.12.1.6 Ruggedized Printed Circuit Boards 264
9.12.1.7 Heatsink Access Panel 265
9.12.1.8 Line Power Disconnect 265
9.12.1.9 Contactor 265
9.12.1.10 Circuit Breaker 265
9.12.2 Frame Size F Options 265
10 RS-485 Installation and Set-up 267
10.1 Overview 267
10.2 Network Connection 267
10.3 Bus Termination 268
10.4 RS-485 Installation and Set-up 268
10.4.1 EMC Precautions 268
10.5 FC Protocol Overview 268
10.6 Network Configuration 268
10.6.1 Adjustable Frequency Drive Set-up 268
10.7 FC Protocol Message Framing Structure 269
10.7.1 Content of a Character (Byte) 269
Contents Design Guide
Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG34S222

10.7.2 Message Structure 269
10.7.3 Message Length (LGE) 269
10.7.4 Adjustable Frequency Drive Address (ADR) 269
10.7.5 Data Control Byte (BCC) 269
10.7.6 The Data Field 270
10.7.7 The PKE Field 271
10.7.8 Parameter Number (PNU) 271
10.7.9 Index (IND) 271
10.7.10 Parameter Value (PWE) 272
10.7.11 Data Types Supported 272
10.7.12 Conversion 272
10.7.13 Process Words (PCD) 273
10.8 Examples 273
10.8.1 Writing a Parameter Value 273
10.8.2 Reading a Parameter Value 273
10.9 Modbus RTU Overview 274
10.9.1 Assumptions 274
10.9.2 Prerequisite Knowledge 274
10.9.3 Modbus RTU Overview 274
10.9.4 Adjustable Frequency Drive with Modbus RTU 274
10.10 Network Configuration 275
10.10.1 Adjustable Frequency Drive with Modbus RTU 275
10.11 Modbus RTU Message Framing Structure 275
10.11.1 Adjustable Frequency Drive with Modbus RTU 275
10.11.2 Modbus RTU Message Structure 275
10.11.3 Start/Stop Field 275
10.11.4 Address Field 276
10.11.5 Function Field 276
10.11.6 Data Field 276
10.11.7 CRC Check Field 276
10.11.8 Coil Register Addressing 277
10.11.9 How to Control the Adjustable Frequency Drive 278
10.11.10 Function Codes Supported by Modbus RTU 279
10.11.11 Modbus Exception Codes 279
10.12 How to Access Parameters 280
10.12.1 Parameter Handling 280
10.12.2 Storage of Data 280
10.12.3 IND 280
Contents Design Guide
MG34S222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

10.12.4 Text Blocks 280
10.12.5 Conversion Factor 280
10.12.6 Parameter Values 280
10.13 FC Control Profile 280
10.13.1 Control Word According to FC Profile 280
10.13.2 Status Word According to FC Profile 282
10.13.3 Bus Speed Reference Value 284
Index 288
Contents Design Guide
Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG34S222