Danfoss VLT AutomationDrive FC 301 Guide

MAKING MODERN LIVING POSSIBLE
Design Guide
VLT®AutomationDrive FC 301/302
0.25–75 kW
www.danfoss.com/drives

Contents
1 Introduction 9
1.1 Purpose of the Design Guide 9
1.2 Additional Resources 9
1.3 Abbreviations, Symbols and Conventions 9
1.4 Definitions 10
1.5 Document and Software Version 11
1.6 Regulatory Compliance 11
1.6.1 CE Mark 11
1.6.1.1 Low Voltage Directive 11
1.6.1.2 EMC Directive 12
1.6.1.3 Machinery Directive 12
1.6.2 UL Compliance 12
1.6.3 C-tick Compliance 12
1.6.4 Marine Compliance 12
1.7 Disposal Instruction 12
1.8 Safety 12
2 Safety 13
2.1 Safety Symbols 13
2.2 Qualified Personnel 13
2.3 Safety Precautions 13
3 Basic Operating Principles 15
3.1 General 15
3.2 Description of Operation 15
3.3 Sequence of Operation 15
3.3.1 Rectifier Section 15
3.3.2 Intermediate Section 15
3.3.3 Inverter Section 15
3.3.4 Brake Option 16
3.3.5 Load Sharing 16
3.4 Control Interface 16
3.5 Wiring Schematic 17
3.6 Controls 19
3.6.1 Control Principle 19
3.6.2 FC 301 vs. FC 302 Control Principle 20
3.6.3 Control Structure in VVCplus 21
3.6.4 Control Structure in Flux Sensorless (FC 302 only) 22
Contents Design Guide
MG33BF22 Rev. 2014-04-04 All rights reserved.

3.6.5 Control Structure in Flux with Motor Feedback (FC 302 only) 23
3.6.6 PID 24
3.6.6.1 Speed PID Control 24
3.6.6.2 Tuning PID speed control 27
3.6.6.3 Process PID Control 27
3.6.6.4 Advanced PID Control 29
3.6.7 Internal Current Control in VVCplus Mode 29
3.6.8 Local (Hand On) and Remote (Auto On) Control 29
3.7 Reference Handling 31
3.7.1 References 31
3.7.2 Reference Limits 33
3.7.3 Scaling of Preset References and Bus References 34
3.7.4 Scaling of Analog and Pulse References and Feedback 34
3.7.5 Dead Band Around Zero 35
4 Product Features 39
4.1 Automated Operational Features 39
4.1.1 Short Circuit Protection 39
4.1.2 Overvoltage Protection 39
4.1.3 Missing Motor Phase Detection 40
4.1.4 Line Phase Imbalance Detection 40
4.1.5 Switching on the Output 40
4.1.6 Overload Protection 40
4.1.7 Locked Rotor Protection 40
4.1.8 Automatic Derating 41
4.1.9 Automatic Energy Optimization 41
4.1.10 Automatic Switching Frequency Modulation 41
4.1.11 Automatic Derating for High Carrier Frequency 41
4.1.12 Power Fluctuation Performance 41
4.1.13 Resonance Damping 41
4.1.14 Temperature-controlled Fans 41
4.1.15 EMC Compliance 42
4.1.16 Galvanic Isolation of Control Terminals 42
4.2 Custom Application Features 42
4.2.1 Automatic Motor Adaptation 42
4.2.2 Motor Thermal Protection 42
4.2.3 Line Drop-out 43
4.2.4 Built-in PID Controller 43
Contents Design Guide
Rev. 2014-04-04 All rights reserved. MG33BF22

4.2.5 Automatic Restart 43
4.2.6 Flying Start 43
4.2.7 Full Torque at Reduced Speed 43
4.2.8 Frequency Bypass 44
4.2.9 Motor Preheat 44
4.2.10 Four Programmable Set-ups 44
4.2.11 Dynamic Braking 44
4.2.12 Open-loop Mechanical Brake Control 45
4.2.13 Closed-loop Mechanical Brake Control/Hoist Mechanical Brake 46
4.2.14 Smart Logic Control (SLC) 47
4.2.15 Safe Torque Off 48
4.3 Danfoss VLT®FlexConcept®48
5 System Integration 49
5.1 Ambient Operating Conditions 49
5.1.1 Humidity 49
5.1.2 Temperature 49
5.1.3 Temperature and Cooling 49
5.1.4 Manual Derating 50
5.1.4.1 Derating for Running at Low Speed 50
5.1.4.2 Derating for Low Air Pressure 50
5.1.5 Acoustic Noise 51
5.1.6 Vibration and Shock 51
5.1.7 Aggressive Atmospheres 51
5.1.7.1 Gases 51
5.1.7.2 Dust Exposure 52
5.1.7.3 Potentially Explosive Atmospheres 52
5.1.8 Maintenance 53
5.1.9 Storage 53
5.2 General Aspects of EMC 53
5.2.1 EMC Test Results 54
5.2.2 Emission Requirements 56
5.2.3 Immunity Requirements 57
5.2.4 Motor Insulation 58
5.2.5 Motor Bearing Currents 58
5.3 Line Power Supply Interference/Harmonics 59
5.3.1 The Effect of Harmonics in a Power Distribution System 59
5.3.2 Harmonic Limitation Standards and Requirements 60
5.3.3 Harmonic Mitigation 60
Contents Design Guide
MG33BF22 Rev. 2014-04-04 All rights reserved.

5.3.4 Harmonic Calculation 60
5.4 Galvanic Isolation (PELV) 61
5.4.1 PELV - Protective Extra Low Voltage 61
5.5 Brake Functions 61
5.5.1 Selection of Brake Resistor 61
6 Product Specifications 64
6.1 Electrical Data 64
6.1.1 Line Power Supply 200–240 V 64
6.1.2 Line Power Supply 380–500 V 66
6.1.3 Line Power Supply 525–600 V (FC 302 only) 69
6.1.4 Line Power Supply 525–690 V (FC 302 only) 72
6.2 General Specifications 75
6.2.1 Line Power Supply 75
6.2.2 Motor Output and Motor Data 75
6.2.3 Ambient Conditions 76
6.2.4 Cable Specifications 76
6.2.5 Control Input/Output and Control Data 77
6.2.6 Derating for Ambient Temperature 81
6.2.6.1 Derating for Ambient Temperature, Enclosure Type A 81
6.2.6.2 Derating for Ambient Temperature, Enclosure Types B 81
6.2.6.3 Derating for Ambient Temperature, Enclosure Types C 84
6.2.7 Measured Values for dU/dt Testing 87
6.2.8 Efficiency 90
6.2.9 Acoustic Noise 90
7 How to Order 91
7.1 Drive Configurator 91
7.1.1 Type Code 91
7.1.2 Language 94
7.2 Ordering Numbers 95
7.2.1 Options and Accessories 95
7.2.2 Spare Parts 97
7.2.3 Accessory Bags 97
7.2.4 VLT AutomationDrive FC 301 98
7.2.5 Brake Resistors for FC 302 102
7.2.6 Other Flat Pack Brake Resistors 109
7.2.7 Harmonic Filters 111
7.2.8 Sine-Wave Filters 113
Contents Design Guide
Rev. 2014-04-04 All rights reserved. MG33BF22

7.2.9 dU/dt Filters 115
8 Mechanical Installation 117
8.1 Safety 117
8.2 Mechanical Dimensions 118
8.2.1 Mechanical Mounting 121
8.2.1.1 Clearance 121
8.2.1.2 Wall Mounting 121
9 Electrical Installation 123
9.1 Safety 123
9.2 Cables 124
9.2.1 Tightening Torque 124
9.2.2 Entry Holes 125
9.2.3 Tightening of the Cover after Connections are Made 129
9.3 AC line input connections 129
9.3.1 Fuses and Circuit Breakers 133
9.3.1.1 Fuses 133
9.3.1.2 Recommendations 133
9.3.1.3 CE Compliance 134
9.3.1.4 UL Compliance 137
9.4 Motor Connection 142
9.5 Ground Leakage Current Protection 144
9.6 Additional Connections 146
9.6.1 Relay 146
9.6.2 Disconnectors and Contactors 147
9.6.3 Load Sharing 148
9.6.4 Brake Resistor 148
9.6.5 PC Software 148
9.6.5.1 MCT 10 149
9.6.5.2 MCT 31 149
9.6.5.3 Harmonic Calculation Software (HCS) 149
9.7 Additional Motor Information 150
9.7.1 Motor Cable 150
9.7.2 Connection of Multiple Motors 150
9.8 Safety 153
9.8.1 High Voltage Test 153
9.8.2 EMC Grounding 153
10 Application Examples 154
Contents Design Guide
MG33BF22 Rev. 2014-04-04 All rights reserved.

10.1 Commonly Used Applications 154
10.1.1 Closed-loop Drive System 159
10.1.2 Programming of Torque Limit and Stop 159
10.1.3 Programming of Speed Control 160
11 Options and Accessories 162
11.1 Communication Options 162
11.2 I/O, Feedback and Safety Options 162
11.2.1 VLT®General Purpose I/O Module MCB 101 162
11.2.2 VLT®Encoder Option MCB 102 164
11.2.3 VLT®Resolver Option MCB 103 166
11.2.4 VLT®Relay Card MCB 105 168
11.2.5 VLT®Safe PLC Interface Option MCB 108 170
11.2.6 VLT®PTC Thermistor Card MCB 112 172
11.2.7 VLT®Extended Relay Card MCB 113 173
11.2.8 VLT®Sensor Input Option MCB 114 175
11.2.9 VLT®Safe Option MCB 15x 176
11.2.10 VLT®C Option Adapter MCF 106 180
11.3 Motion Control Options 180
11.4 Accessories 182
11.4.1 Brake Resistors 182
11.4.2 Sine-wave Filters 182
11.4.3 dU/dt Filters 182
11.4.4 Common Mode Filters 182
11.4.5 Harmonic Filters 182
11.4.6 IP21/Type 1 Enclosure Kit 183
11.4.7 Remote Mounting Kit for LCP 185
11.4.8 Mounting Bracket for Enclosure Types A5, B1, B2, C1 and C2 186
12 RS-485 Installation and Set-up 188
12.1 Installation and Set-up 188
12.1.1 Overview 188
12.2 Network Connection 189
12.3 Bus Termination 189
12.4 RS-485 Installation and Set-up 189
12.5 FC Protocol Overview 190
12.6 Network Configuration 190
12.7 FC Protocol Message Framing Structure 190
Contents Design Guide
Rev. 2014-04-04 All rights reserved. MG33BF22

12.7.1 Content of a Character (byte) 190
12.7.2 Message Structure 190
12.7.3 Message Length (LGE) 191
12.7.4 Adjustable Frequency Drive Address (ADR) 191
12.7.5 Data Control Byte (BCC) 191
12.7.6 The Data Field 192
12.7.7 The PKE Field 193
12.7.8 Parameter Number (PNU) 193
12.7.9 Index (IND) 193
12.7.10 Parameter Value (PWE) 194
12.7.11 Supported Data Types 194
12.7.12 Conversion 194
12.7.13 Process Words (PCD) 195
12.8 Examples 195
12.8.1 Writing a Parameter Value 195
12.8.2 Reading a Parameter Value 195
12.9 Modbus RTU Overview 196
12.9.1 Assumptions 196
12.9.2 What the User Should Already Know 196
12.9.3 Modbus RTU Overview 196
12.9.4 Adjustable Frequency Drive with Modbus RTU 196
12.10 Network Configuration 197
12.11 Modbus RTU Message Framing Structure 197
12.11.1 Adjustable Frequency Drive with Modbus RTU 197
12.11.2 Modbus RTU Message Structure 197
12.11.3 Start/Stop Field 197
12.11.4 Address Field 198
12.11.5 Function Field 198
12.11.6 Data Field 198
12.11.7 CRC Check Field 198
12.11.8 Coil Register Addressing 198
12.11.9 How to Control the Adjustable Frequency Drive 200
12.11.10 Function Codes Supported by Modbus RTU 200
12.11.11 Modbus Exception Codes 200
12.12 How to Access Parameters 201
12.12.1 Parameter Handling 201
12.12.2 Storage of Data 201
12.12.3 IND (Index) 201
Contents Design Guide
MG33BF22 Rev. 2014-04-04 All rights reserved.

12.12.4 Text Blocks 201
12.12.5 Conversion Factor 201
12.12.6 Parameter Values 201
12.13 Danfoss FC Control Profile 202
12.13.1 Control Word According to FC Profile (8-10 Control Profile = FC profile) 202
12.13.2 Status Word According to FC Profile (STW) (8-10 Control Profile = FC
profile) 203
12.13.3 Bus Speed Reference Value 204
12.13.4 Control Word according to PROFIdrive Profile (CTW) 205
12.13.5 Status Word according to PROFIdrive Profile (STW) 206
Index 208
Contents Design Guide
Rev. 2014-04-04 All rights reserved. MG33BF22