Danfoss VLT AutomationDrive FC 300 Guide

MAKING MODERN LIVING POSSIBLE
Design Guide, 0.25-75 kW
VLT®AutomationDrive FC 300
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Contents
1 How to Read this Design Guide 7
1.1.1 Symbols 7
1.1.2 Abbreviations 7
1.1.3 Definitions 8
2 Safety and Conformity 11
2.1 Safety Precautions 11
3 Introduction 15
3.1 Product Overview 15
3.2 Controls 16
3.2.1 Control Principle 16
3.2.2 Controls 16
3.2.3 FC 301 vs. FC 302 Control Principle 17
3.2.4 Control Structure in VVCplus 18
3.2.5 Control Structure in Flux Sensorless (FC 302 only) 19
3.2.6 Control Structure in Flux with Motor Feedback 20
3.2.7 Internal Current Control in VVCplus Mode 21
3.2.8 Local (Hand On) and Remote (Auto On) Control 21
3.3 Reference Handling 22
3.3.1 Reference Limits 24
3.3.2 Scaling of Preset References and Bus References 25
3.3.3 Scaling of Analog and Pulse References and Feedback 25
3.3.4 Dead Band Around Zero 26
3.4 PID Control 30
3.4.1 Speed PID Control 30
3.4.2 Tuning PID Speed Control 33
3.4.3 Process PID Control 33
3.4.4 Optimisation of the Process Regulator 36
3.4.5 Ziegler Nichols Tuning Method 36
3.5 General Aspects of EMC 38
3.5.1 EMC Test Results 38
3.5.3 Immunity Requirements 40
3.6 Mains Supply Interference/Harmonics 41
3.6.1 The Effect of Harmonics in a Power Distribution System 41
3.6.2 Harmonic Limitation Standards and Requirements 42
3.6.3 Harmonic Mitigation 43
3.6.4 Harmonic Calculation 43
3.7 Galvanic Isolation (PELV) 43
Contents VLT®AutomationDrive FC 300 Design Guide, 0.25-75 kW
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3.7.1 PELV - Protective Extra Low Voltage 43
3.8 Brake Functions 44
3.8.1 Mechanical Holding Brake 45
3.8.2 Dynamic Braking 45
3.8.3 Selection of Brake Resistor 45
3.8.4 Brake Resistor Cabling 46
3.9 Mechanical brake control 47
3.9.1 Hoist Mechanical Brake 48
3.10 Smart Logic Controller 50
3.11 Extreme Running Conditions 51
3.12 Safe Stop 52
3.12.2 Installation of External Safety Device in Combination with MCB 112 57
3.12.3 Safe Stop Commissioning Test 58
4 FC 300 Selection 59
4.1 Electrical Data - 200-240 V 59
4.2 General Specifications 72
4.2.1 Measured Values for dU/dt Testing 76
4.3 Efficiency 78
4.4 Acoustic noise 78
4.5 dU/dt Conditions 79
4.6 Special Conditions 79
4.6.2 Derating for Ambient Temperature, Frame Size A 79
4.6.3 Derating for Ambient Temperature, Frame Size B 80
4.6.4 Derating for Ambient Temperature, Frame Size C 83
4.6.7 Automatic Derating 86
5 How to Order 87
5.1.1 Ordering from Type Code 87
5.1.2 Drive Configurator 87
5.2.1 Ordering Numbers: Options and Accessories 90
5.2.2 Ordering Numbers: Spare Parts 93
5.2.3 Ordering Numbers: Accessory Bags 93
5.2.4 Ordering Numbers: Brake Resistors FC 301 94
5.2.5 Ordering Numbers: Brake Resistors FC 302 96
5.2.6 Miscellaneous Flat Packs 100
5.2.7 Ordering Numbers: Harmonic Filters 102
5.2.8 Ordering Numbers: Sine Wave Filters 104
5.2.9 Ordering Numbers: dU/dt Filters, 200-690 V AC 106
6 Mechanical Installation - Frame Sizes A, B and C 107
Contents VLT®AutomationDrive FC 300 Design Guide, 0.25-75 kW
2 MG33BE02 - VLT®is a registered Danfoss trademark
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6.1.1 Safety Requirements of Mechanical Installation 107
6.1.2 Mechanical Mounting 110
7 Electrical Installation 112
7.1 Connections- Frame Sizes A, B and C 112
7.1.1 Removal of Knockouts for Extra Cables 113
7.1.2 Connection to Mains and Earthing 113
7.1.3 Motor Connection 115
7.1.4 Relay Connection 121
7.2 Fuses and Circuit Breakers 122
7.2.2 Recommendations 122
7.2.3 CE Compliance 123
7.3 Disconnectors and Contactors 131
7.3.1 Mains Disconnectors 131
7.4 Additional Motor Information 132
7.4.1 Motor Cable 132
7.4.2 Motor Thermal Protection 132
7.4.3 Parallel Connection of Motors 132
7.4.5 Motor Bearing Currents 135
7.5 Control Cables and Terminals 136
7.5.1 Access to Control Terminals 136
7.5.2 Control Cable Routing 136
7.5.3 Control Terminals 137
7.5.4 Switches S201, S202, and S801 137
7.5.5 Electrical Installation, Control Terminals 138
7.5.6 Basic Wiring Example 138
7.5.7 Electrical Installation, Control Cables 140
7.5.8 Relay Output 141
7.6 Additional Connections 142
7.6.1 DC Bus Connection 142
7.6.2 Load Sharing 142
7.6.3 Installation of Brake Cable 142
7.6.4 How to Connect a PC to the Frequency Converter 142
7.6.5 PC Software 143
7.7 Safety 143
7.7.1 High Voltage Test 143
7.7.2 Earthing 143
7.7.3 Safety Earth Connection 144
7.7.4 Spark Free Installation 144
7.8 EMC-correct Installation 144
7.8.1 Electrical Installation - EMC Precautions 144
Contents VLT®AutomationDrive FC 300 Design Guide, 0.25-75 kW
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7.8.2 Use of EMC-Correct Cables 146
7.8.3 Earthing of Screened Control Cables 146
7.8.4 RFI Switch 147
7.9 Residual Current Device 147
7.10 Final Setup and Test 147
8 Application Examples 149
8.1.1 Closed Loop Drive System 154
8.1.2 Programming of Torque Limit and Stop 154
9 Options and Accessories 156
9.1.1 Mounting of Option Modules in
Slot A 156
9.1.2 Mounting of Option Modules in
Slot B 156
9.1.3 Mounting of Options in Slot C 156
9.2 MCO 305 Programmable Motion Controller 157
9.3 General Purpose Input Output Module MCB 101 161
9.3.1 Galvanic Isolation in the MCB 101 162
9.4 Encoder Option MCB 102 163
9.5 Resolver Option MCB 103 165
9.6 Relay Option MCB 105 167
9.7 24 V Back-Up Option MCB 107 168
9.8 MCB 112 PTC Thermistor Card 169
9.9 MCB 113 Extended Relay Card 171
9.10 Brake Resistors 172
9.11 LCP Panel Mounting Kit 172
9.12 IP21/IP 4X/ TYPE 1 Enclosure Kit 174
9.13 Mounting Bracket for Frame Size A5, B1, B2, C1 and C2 176
9.14 Sine-wave Filters 177
9.15 Safety Option Module MCB 15x 178
10 RS-485 Installation and Set-up 181
10.1 Installation and Set-up 181
10.1.1 Overview 181
10.2 Network Connection 181
10.3 Bus Termination 181
10.4 RS-485 Installation and Set-up 182
10.4.1 EMC Precautions 182
10.5 Network Configuration 182
10.5.1 Frequency Converter Set-up 182
10.6 FC Protocol Message Framing Structure 182
Contents VLT®AutomationDrive FC 300 Design Guide, 0.25-75 kW
4 MG33BE02 - VLT®is a registered Danfoss trademark
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10.6.1 Content of a Character (byte) 182
10.6.2 Telegram Structure 183
10.6.3 Telegram Length (LGE) 183
10.6.4 Frequency Converter Address (ADR) 183
10.6.5 Data Control Byte (BCC) 183
10.6.6 The Data Field 184
10.6.7 The PKE Field 184
10.6.8 Parameter Number (PNU) 185
10.6.9 Index (IND) 185
10.6.10 Parameter Value (PWE) 185
10.6.11 Supported Data Types 186
10.6.12 Conversion 186
10.6.13 Process Words (PCD) 186
10.7 Examples 186
10.7.1 Writing a Parameter Value 186
10.7.2 Reading a Parameter Value 187
10.8 Modbus RTU Overview 187
10.8.1 Assumptions 187
10.8.2 What the User Should Already Know 187
10.8.3 Modbus RTU Overview 187
10.8.4 Frequency Converter with Modbus RTU 188
10.9 Network Configuration 188
10.9.1 Frequency Converter with Modbus RTU 188
10.10 Modbus RTU Message Framing Structure 188
10.10.1 Frequency Converter with Modbus RTU 188
10.10.2 Modbus RTU Message Structure 188
10.10.3 Start/Stop Field 189
10.10.4 Address Field 189
10.10.5 Function Field 189
10.10.6 Data Field 189
10.10.7 CRC Check Field 189
10.10.8 Coil Register Addressing 189
10.10.9 How to Control the Frequency Converter 191
10.10.10 Function Codes Supported by Modbus RTU 191
10.10.11 Modbus Exception Codes 191
10.11 How to Access Parameters 191
10.11.1 Parameter Handling 191
10.11.2 Storage of Data 191
10.11.3 IND 192
10.11.4 Text Blocks 192
Contents VLT®AutomationDrive FC 300 Design Guide, 0.25-75 kW
MG33BE02 - VLT®is a registered Danfoss trademark 5
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10.11.5 Conversion Factor 192
10.11.6 Parameter Values 192
10.12 Danfoss FC Control Profile 192
Index 199
Contents VLT®AutomationDrive FC 300 Design Guide, 0.25-75 kW
6 MG33BE02 - VLT®is a registered Danfoss trademark
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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 Operating Instructions
0.25-75 kW provide the neccessary information
for getting the frequency converter up and
running.
-The VLT®AutomationDrive High Power Operating
Instructions
-The VLT®AutomationDrive High Power Design
Guide 90-1400 kW
-The VLT®AutomationDrive Programming Guide
provides information on how to programme and
includes complete parameter descriptions.
-The VLT®AutomationDrive Profibus Operating
Instructions provide the information required for
controlling, monitoring and programming the
frequency converter via a Profibus fieldbus.
-The VLT®AutomationDrive DeviceNet Operating
Instructions provide the information required for
controlling, monitoring and programming the
frequency converter via a DeviceNet fieldbus.
X = Revision number
YY = Language code
Danfoss Drives technical literature is also available online
at www.danfoss.com/BusinessAreas/DrivesSolutions/
Documentations/Technical+Documentation.
1.1.1 Symbols
The following symbols are used in this manual.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
CAUTION
Indicates a situation that may result in equipment or
property-damage-only accidents.
NOTE
Indicates highlighted information that should be regarded
with attention to avoid mistakes or operate equipment at
less than optimal performance.
1.1.2 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
Frequency converter FC
Gram g
Hertz Hz
Horsepower hp
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
Permanent Magnet motor PM motor
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
Volts V
The maximum output current IVLT,MAX
The rated output current supplied by the
frequency converter
IVLT,N
Table 1.1 Abbreviations
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1.1.3 Definitions
Frequency converter
Coast
The motor shaft is in free mode. No torque on motor.
IMAX
The maximum output current.
IN
The rated output current supplied by the frequency
converter.
UMAX
The maximum output voltage.
Input
Control command
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.
Table 1.2 Function Priorities
Motor
fJOG
The motor frequency when the jog function is activated
(via digital terminals).
fM
Motor frequency. Output from the frequency converter.
Output frequency is related to the shaft speed on motor
depending on number of poles and slip frequency.
fMAX
The maximum output frequency the frequency converter
applies on its output. The maximum output frequency limit
is set in 4-14 Motor Speed High Limit [Hz] (4-13 Motor Speed
High Limit [RPM]) and 4-19 Max Output Frequency.
fMIN
The minimum motor frequency from frequency converter.
The minimum output frequency limit is set in 4-12 Motor
Speed Low Limit [Hz] (4-11 Motor Speed Low Limit [RPM]).
Default 0 Hz.
fM,N
The rated motor frequency (nameplate data).
IM
The motor current.
IM,N
The rated motor current (nameplate data).
nM,N
The rated motor speed (nameplate data).
ns
Synchronous motor speed
ns =2 ×
(par . 1 −23) × 60
par . 1 −39
PM,N
The rated motor power (nameplate data).
TM,N
The rated torque (motor).
UM
The instantaneous motor voltage.
UM,N
The rated motor voltage (nameplate data).
Break-away torque
175ZA078.10
Pull-out
rpm
Torque
Illustration 1.1 Break-away Torque
η
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.
How to Read this Design Gui... VLT®AutomationDrive FC 300 Design Guide, 0.25-75 kW
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