Danfoss VLT AutomationDrive FC 300 Guide

Contents
How to Read this Design Guide
5
How to Read this Design Guide 5
Approvals 5
Symbols 6
Abbreviations 6
Definitions 7
Introduction to FC 300
13
Safety Precautions 13
Safety Precautions 13
Disposal Instruction 14
Software Version 15
Control Principle 19
FC 300 Controls 19
FC 301 vs. FC 302 Control Principle 19
Control Structure in VVC
plus
20
Control Structure in Flux Sensorless (FC 302 only) 21
Control Structure in Flux with Motor Feedback 21
Internal Current Control in VVC
plus
Mode 22
Local (Hand On) and Remote (Auto On) Control 22
Reference Handling 24
Scaling of References and Feedback 25
Dead Band Around Zero 27
Speed PID Control 31
The following parameters are relevant for the Speed Control 31
Process PID Control 33
Ziegler Nichols Tuning Method 37
Motor cables to comply with EMC regulations 39
EMC Immunity 40
Earth Leakage Current 42
Selection of Brake Resistor 42
Mechanical Brakecontrol 44
Hoist Mechanical Brake 45
Safe Stop of FC 300 48
Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) 49
Safe Stop Commissioning Test 50
FC 300 Selection
53
Electrical Data 53
General Specifications 59
Efficiency 64
Acoustic Noise 64
Peak Voltage on Motor 65
Purpose of derating 66
Automatic adaptations to ensure performance 69
FC 300 Design Guide
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How to Order
71
Drive Configurator 71
Ordering Form Type Code 71
Ordering Numbers 73
How to Install
79
Mechanical Dimension 79
Mechanical Installation 81
Accessory Bag 81
Electrical Installation 84
Removal of Knockouts for Extra Cables 84
Connection to Mains and Earthing 85
Motor Connection 87
Fuses 89
Access to Control Terminals 91
Control Terminals 91
Electrical Installation, Control Terminals 92
Basic Wiring Example 92
Electrical Installation, Control Cables 93
Motor Cables 95
Switches S201, S202, and S801 96
Final Set-Up and Test 97
Additional Connections 99
Relay Connection 100
Relay Output 101
Parallel Connection of Motors 101
Motor Thermal Protection 102
How to Connect a PC to the FC 300 103
The FC 300 Software Dialog 103
Residual Current Device 108
Application Examples
109
Start/Stop 109
Pulse Start/Stop 109
Potentiometer Reference 110
Encoder Connection 110
Encoder Direction 110
Closed Loop Drive System 111
Programming of Torque Limit and Stop 111
Smart Logic Control Programming 112
Options and Accessories
115
Options and Accessories 115
Mounting of Option Modules in Slot B 115
General Purpose Input Output Module MCB 101 115
Encoder Option MCB 102 117
Resolver Option MCB 103 119
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Relay Option MCB 105 121
24 V Back-Up Option MCB 107 (Option D) 124
IP 21/IP 4X/ TYPE 1 Enclosure Kit 125
Sine-wave Filters 126
RS-485 Installation and Set-up
127
RS-485 Installation and Set-up 127
FC Protocol Overview 130
Network Configuration 130
FC Protocol Message Framing Structure - FC 300 131
Examples 136
Danfoss FC Control Profile 136
Troubleshooting
149
Status messages - FC 300 DG 149
Warnings/Alarm Messages 149
Index
158
FC 300 Design Guide
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®
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FC 300 Design Guide
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®
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How to Read this Design Guide
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 Operating Instructions MG.33.AX.YY provide the neccessary
information for getting the drive up and running.
-The VLT
®
AutomationDrive FC 300 Design Guide MG.33.BX.YY entails all technical information
about the drive and customer design and applications.
-The VLT
®
AutomationDrive FC 300 Programming Guide MG.33.MX.YY provides information on
how to programme and includes complete parameter descriptions.
-The VLT
®
AutomationDrive FC 300 Profibus Operating Instructions MG.33.CX.YY provide the in-
formation required for controlling, monitoring and programming the drive via a Profibus fieldbus.
-The VLT
®
AutomationDrive FC 300 DeviceNet Operating Instructions MG.33.DX.YY provide the
information required for controlling, monitoring and programming the drive via a DeviceNet field-
bus.
X = Revision number
YY = Language code
Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/Drives-
Solutions/Documentations/Technical+Documentation.
Approvals
FC 300 Design Guide
MG.33.B8.02 - VLT
®
is a registered Danfoss trademark 5

Symbols
Symbols used in this guide.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
*Indicates default setting
Abbreviations
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit ILIM
Degrees Celcius °C
Direct current DC
Drive Dependent D-TYPE
Electro Magnetic Compatibility EMC
Electronic Thermal Relay ETR
Frequency Converter FC
Gram g
Hertz Hz
Kilohertz kHz
Local Control Panel LCP
Meter m
Milli Henry 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
Volts V
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Definitions
Drive:
D-TYPE
Size and type of the connected drive (dependencies).
I
VLT,MAX
The maximum output current.
I
VLT,N
The rated output current supplied by the frequency converter.
U
VLT, MAX
The maximum output voltage.
Input:
Control command
You can start and stop the connected motor by
means of 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).
P
M,N
The rated motor power (nameplate data).
T
M,N
The rated torque (motor).
U
M
The instantaneous motor voltage.
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U
M,N
The rated motor voltage (nameplate data).
Break-away torque

VLT
The efficiency of the frequency converter 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).
Ref
MAX
Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA)
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 0V, 0mA, 4mA) 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 frequency converter.
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.
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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 brake power generated in regenerative braking.
This regenerative braking power 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 functions of the frequency converter.
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.
Initialising
If initialising is carried out (par. 14-22), the frequency converter returns to the default setting.
Intermittent Duty C ycle
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 3 metres from the frequency converter,
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 = 0.5067 mm
2
.
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 fre-
quency to match the varying load.
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Pulse Input/Incremental Encoder
An external, digital pulse transmitter used for feeding back information on motor speed. The encoder 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 Set-up, while another Set-up is active.
SFAVM
Switching pattern called Stator Flux oriented Asynchronous Vector Modulation (par. 14-00).
Slip Compensation
The frequency converter compensates for the motor slip by giving the frequency a supplement that fol-
lows 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 SLC. (Parameter group 13-xx).
FC Standard Bus
Includes RS 485 bus with FC protocol or MC protocol. See parameter 8-30.
Thermistor:
A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter
or motor).
Trip
A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or
when the frequency converter is protecting the motor, process or mechanism. Restart is prevented until
the cause of the fault has disappeared and the trip state is cancelled 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 frequency converter is protecting itself and requiring physical
intervention, e.g. if the frequency converter is subject to a short circuit on the output. A locked trip can
only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the frequency
converter. Restart is prevented until the trip state is cancelled 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.
VVC
plus
If compared with standard voltage/frequency ratio control, Voltage Vector Control (VVC
plus
) 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).
Power Factor
The power factor is the relation between I
1
and
I
RMS
.
Power factor =3
xU xI 1 xcos ϕ
3 xU xI
RMS
The power factor for 3-phase control:
=
I 1 xcos ϕ1
I
RMS
=
I
1
I
RMS
since cos ϕ1=1
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