Danfoss VLT AutomationDrive 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
Disposal Instruction 14
3. Introduction to FC 300 19
Product Overview 19
Control Principle 21
FC 300 Controls 21
FC 301 vs. FC 302 Control Principle 21
Control Structure in VVCplus 22
Control Structure in Flux Sensorless (FC 302 only) 23
Control Structure in Flux with Motor Feedback 23
Internal Current Control in VVCplus Mode 24
Local (Hand On) and Remote (Auto On) Control 24
Reference Handling 26
Scaling of References and Feedback 27
Dead Band Around Zero 28
Speed PID Control 31
Process PID Control 34
Ziegler Nichols Tuning Method 38
EMC Immunity 41
Earth Leakage Current 43
Selection of Brake Resistor 43
Mechanical Brakecontrol 46
Hoist Mechanical Brake 47
Safe Stop of FC 300 50
Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) 52
Safe Stop Commissioning Test 53
4. FC 300 Selection 55
Electrical Data 55
General Specifications 69
Efficiency 73
FC 300 Design Guide Contents
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Acoustic Noise 74
du/dt conditions 75
Purpose of derating 75
Automatic adaptations to ensure performance 82
5. How to Order 83
Drive Configurator 83
Ordering Form Type Code 83
6. How to Install 93
Mechanical Dimension 93
Mechanical Installation 97
Accessory Bag 97
Electrical Installation 100
Removal of Knockouts for Extra Cables 101
Connection to Mains and Earthing 101
Motor Connection 103
Fuses 105
Access to Control Terminals 108
Control Terminals 108
Electrical Installation, Control Terminals 108
Basic Wiring Example 110
Electrical Installation, Control Cables 111
Motor Cables 112
Switches S201, S202, and S801 113
Additional Connections 117
Relay Connection 118
Relay Output 118
Parallel Connection of Motors 118
Motor Thermal Protection 120
Motor Thermal Protection 120
How to Connect a PC to the FC 300 121
The FC 300 PC Software 121
Residual Current Device 126
7. Application Examples 127
Start/Stop 127
Pulse Start/Stop 127
Potentiometer Reference 128
Encoder Connection 129
Encoder Direction 129
Contents FC 300 Design Guide
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Closed Loop Drive System 129
Programming of Torque Limit and Stop 129
Smart Logic Control Programming 131
8. Options and Accessories 133
Mounting of Option Modules in Slot A 133
Mounting of Option Modules in Slot B 133
General Purpose Input Output Module MCB 101 133
Encoder Option MCB 102 136
Resolver Option MCB 103 138
Relay Option MCB 105 140
24 V Back-Up Option MCB 107 (Option D) 142
MCB 112 VLT
®
PTC Thermistor Card 143
IP 21/IP 4X/ TYPE 1 Enclosure Kit 146
Sine-wave Filters 147
9. RS-485 Installation and Set-up 149
RS-485 Installation and Set-up 149
Network Configuration 151
FC Protocol Message Framing Structure - FC 300 151
Examples 157
Danfoss FC Control Profile 158
10. Troubleshooting 169
Warnings/Alarm Messages 169
Index
178
FC 300 Design Guide Contents
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1. How to Read this Design Guide FC 300 Design Guide
4 MG.33.B9.02 - 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 Operating Instructions MG.33.AX.YY provide the nec-
cessary information for getting the drive up and running.
-The VLT
®
AutomationDrive FC 300 Design Guide MG.33.BX.YY entails all technical in-
formation about the drive and customer design and applications.
-The VLT
®
AutomationDrive FC 300 Programming Guide MG.33.MX.YY provides informa-
tion on how to programme and includes complete parameter descriptions.
-The VLT
®
AutomationDrive FC 300 Profibus Operating Instructions MG.33.CX.YY provide
the information required for controlling, monitoring and programming the drive via a
Profibus fieldbus.
-The VLT
®
AutomationDrive FC 300 DeviceNet Operating Instructions MG.33.DX.YY pro-
vide the information required for controlling, monitoring and programming the drive 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.
1.1.2. Approvals
1.1.3. Symbols
Symbols used in this guide.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
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1

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
Volts V
1.1.5. 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
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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.
U
M,N
The rated motor voltage (nameplate data).
Break-away torque
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η
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.
Automatic Motor Adaptation, AMA
AMA algorithm determines the electrical parameters for the connected motor at standstill.
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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 out-
put frequency 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 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 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 follows 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 pre-
vented 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 re-
connecting 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.
VVCplus
If compared with standard voltage/frequency ratio control, Voltage Vector Control (VVC
plus
) im-
proves 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).
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