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 8
1.1 Purpose of the Design Guide 8
1.2 Additional Resources 8
1.3 Abbreviations, Symbols and Conventions 8
1.4 Definitions 9
1.5 Document and Software Version 10
1.6 Regulatory Compliance 10
1.6.1 CE Mark 10
1.6.1.1 Low Voltage Directive 10
1.6.1.2 EMC Directive 10
1.6.1.3 Machinery Directive 11
1.6.2 UL Compliance 11
1.6.3 C-tick Compliance 11
1.6.4 Marine Compliance 11
1.7 Disposal Instruction 11
1.8 Safety 11
2 Safety 12
2.1 Safety Symbols 12
2.2 Qualified Personnel 12
2.3 Safety Precautions 12
3 Basic Operating Principles 14
3.1 General 14
3.2 Description of Operation 14
3.3 Sequence of Operation 14
3.3.1 Rectifier Section 14
3.3.2 Intermediate Section 14
3.3.3 Inverter Section 14
3.3.4 Brake Option 14
3.3.5 Load Sharing 15
3.4 Control Interface 15
3.5 Wiring Schematic 16
3.6 Controls 18
3.6.1 Control Principle 18
3.6.2 FC 301 vs. FC 302 Control Principle 19
3.6.3 Control Structure in VVC+20
3.6.4 Control Structure in Flux Sensorless (FC 302 only) 21
3.6.5 Control Structure in Flux with Motor Feedback (FC 302 only) 22
Contents VLT®AutomationDrive FC 301/FC 302 Design Guide, 0.25-75 kW
MG33BF02 - Rev. 2013-12-20 1

3.6.6 PID 23
3.6.6.1 Speed PID Control 23
3.6.6.2 Tuning PID Speed Control 25
3.6.6.3 Process PID Control 26
3.6.6.4 Advanced PID Control 27
3.6.7 Internal Current Control in VVC+Mode 27
3.6.8 Local (Hand On) and Remote (Auto On) Control 27
3.7 Reference Handling 28
3.7.1 References 28
3.7.2 Reference Limits 30
3.7.3 Scaling of Preset References and Bus References 31
3.7.4 Scaling of Analog and Pulse References and Feedback 31
3.7.5 Dead Band Around Zero 31
4 Product Features 36
4.1 Automated Operational Features 36
4.1.1 Short Circuit Protection 36
4.1.2 Overvoltage Protection 36
4.1.3 Missing Motor Phase Detection 37
4.1.4 Mains Phase Imbalance Detection 37
4.1.5 Switching on the Output 37
4.1.6 Overload Protection 37
4.1.7 Locked Rotor Protection 37
4.1.8 Automatic Derating 37
4.1.9 Automatic Energy Optimisation 37
4.1.10 Automatic Switching Frequency Modulation 37
4.1.11 Automatic Derating for High Carrier Frequency 38
4.1.12 Power Fluctuation Performance 38
4.1.13 Resonance Damping 38
4.1.14 Temperature-controlled Fans 38
4.1.15 EMC Compliance 38
4.1.16 Galvanic Isolation of Control Terminals 38
4.2 Custom Application Features 38
4.2.1 Automatic Motor Adaptation 38
4.2.2 Motor Thermal Protection 39
4.2.3 Mains Drop-out 39
4.2.4 Built-in PID Controller 39
4.2.5 Automatic Restart 40
4.2.6 Flying Start 40
4.2.7 Full Torque at Reduced Speed 40
4.2.8 Frequency Bypass 40
Contents VLT®AutomationDrive FC 301/FC 302 Design Guide, 0.25-75 kW
2 MG33BF02 - Rev. 2013-12-20

4.2.9 Motor Preheat 40
4.2.10 4 Programmable Set-ups 40
4.2.11 Dynamic Braking 40
4.2.12 Open Loop Mechanical Brake Control 40
4.2.13 Closed Loop Mechancial Brake Control/Hoist Mechanical Brake 41
4.2.14 Smart Logic Control (SLC) 43
4.2.15 Safe Torque Off 43
4.3 Danfoss VLT®FlexConcept®44
5 System Integration 45
5.1 Ambient Operating Conditions 45
5.1.1 Humidity 45
5.1.2 Temperature 45
5.1.3 Temperature and Cooling 45
5.1.4 Manual Derating 45
5.1.4.1 Derating for Running at Low Speed 46
5.1.4.2 Derating for Low Air Pressure 46
5.1.5 Acoustic Noise 47
5.1.6 Vibration and Shock 47
5.1.7 Aggressive Atmospheres 47
5.1.7.1 Gases 47
5.1.7.2 Dust Exposure 47
5.1.7.3 Potentially Explosive Atmospheres 48
5.1.8 Maintenance 48
5.1.9 Storage 48
5.2 General Aspects of EMC 49
5.2.1 EMC Test Results 50
5.2.2 Emission Requirements 51
5.2.3 Immunity Requirements 51
5.2.4 Motor Insulation 52
5.2.5 Motor Bearing Currents 52
5.3 Mains Supply Interference/Harmonics 53
5.3.1 The Effect of Harmonics in a Power Distribution System 53
5.3.2 Harmonic Limitation Standards and Requirements 54
5.3.3 Harmonic Mitigation 54
5.3.4 Harmonic Calculation 54
5.4 Galvanic Isolation (PELV) 54
5.4.1 PELV - Protective Extra Low Voltage 54
5.5 Brake Functions 55
5.5.1 Selection of Brake Resistor 55
Contents VLT®AutomationDrive FC 301/FC 302 Design Guide, 0.25-75 kW
MG33BF02 - Rev. 2013-12-20 3

6 Product Specifications 58
6.1 Electrical Data 58
6.1.1 Mains Supply 200-240 V 58
6.1.2 Mains Supply 380-500 V 60
6.1.3 Mains Supply 525-600 V (FC 302 only) 63
6.1.4 Mains Supply 525-690 V (FC 302 only) 66
6.2 General Specifications 68
6.2.1 Mains Supply 68
6.2.2 Motor Output and Motor Data 68
6.2.3 Ambient Conditions 69
6.2.4 Cable Specifications 69
6.2.5 Control Input/Output and Control Data 69
6.2.6 Derating for Ambient Temperature 73
6.2.6.1 Derating for Ambient Temperature, Enclosure Type A 73
6.2.6.2 Derating for Ambient Temperature, Enclosure Types B 73
6.2.6.3 Derating for Ambient Temperature, Enclosure Types C 76
6.2.7 Measured Values for dU/dt Testing 78
6.2.8 Efficiency 81
6.2.9 Acoustic Noise 81
7 How to Order 82
7.1 Drive Configurator 82
7.1.1 Type Code 82
7.1.2 Language 84
7.2 Ordering Numbers 85
7.2.1 Options and Accessories 85
7.2.2 Spare Parts 87
7.2.3 Accessory Bags 87
7.2.4 VLT AutomationDrive FC 301 88
7.2.5 Brake Resistors for FC 302 92
7.2.6 Other Flat Pack Brake Resistors 99
7.2.7 Harmonic Filters 101
7.2.8 Sine-Wave Filters 103
7.2.9 dU/dt Filters 105
8 Mechanical Installation 107
8.1 Safety 107
8.2 Mechanical Dimensions 108
8.2.1 Mechanical Mounting 110
8.2.1.1 Clearance 110
Contents VLT®AutomationDrive FC 301/FC 302 Design Guide, 0.25-75 kW
4 MG33BF02 - Rev. 2013-12-20

8.2.1.2 Wall Mounting 110
9 Electrical Installation 112
9.1 Safety 112
9.2 Cables 113
9.2.1 Tightening Torque 113
9.2.2 Entry Holes 114
9.2.3 Tightening of the Cover after Connections are Made 118
9.3 Mains Connection 118
9.3.1 Fuses and Circuit Breakers 122
9.3.1.1 Fuses 122
9.3.1.2 Recommendations 123
9.3.1.3 CE Compliance 123
9.3.1.4 UL Compliance 126
9.4 Motor Connection 132
9.5 Earth Leakage Current Protection 134
9.6 Additional Connections 136
9.6.1 Relay 136
9.6.2 Disconnectors and Contactors 138
9.6.3 Load Sharing 138
9.6.4 Brake Resistor 138
9.6.5 PC Software 139
9.6.5.1 MCT 10 139
9.6.5.2 MCT 31 139
9.6.5.3 Harmonic Calculation Software (HCS) 139
9.7 Additional Motor Information 140
9.7.1 Motor Cable 140
9.7.2 Connection of Multiple Motors 140
9.8 Safety 142
9.8.1 High Voltage Test 142
9.8.2 EMC Grounding 142
9.8.3 ADN-compliant Installation 142
10 Application Examples 144
10.1 Commonly Used Applications 144
10.1.1 Closed Loop Drive System 149
10.1.2 Programming of Torque Limit and Stop 149
10.1.3 Programming of Speed Control 150
11 Options and Accessories 152
11.1 Communication Options 152
Contents VLT®AutomationDrive FC 301/FC 302 Design Guide, 0.25-75 kW
MG33BF02 - Rev. 2013-12-20 5

11.2 I/O, Feed-back and Safety Options 152
11.2.1 VLT®General Purpose I/O Module MCB 101 152
11.2.2 VLT®Encoder Option MCB 102 154
11.2.3 VLT®Resolver Option MCB 103 155
11.2.4 VLT®Relay Card MCB 105 157
11.2.5 VLT®Safe PLC Interface Option MCB 108 160
11.2.6 VLT®PTC Thermistor Card MCB 112 161
11.2.7 VLT®Extended Relay Card MCB 113 162
11.2.8 VLT®Sensor Input Option MCB 114 163
11.2.9 VLT®Safe Option MCB 15x 165
11.2.10 VLT®C Option Adapter MCF 106 168
11.3 Motion Control Options 168
11.4 Accessories 170
11.4.1 Brake Resistors 170
11.4.2 Sine-wave Filters 170
11.4.3 dU/dt Filters 170
11.4.4 Common Mode Filters 170
11.4.5 Harmonic Filters 170
11.4.6 IP21/Type 1 Enclosure Kit 170
11.4.7 Remote Mounting Kit for LCP 173
11.4.8 Mounting Bracket for Enclosure Types A5, B1, B2, C1 and C2 174
12 RS-485 Installation and Set-up 176
12.1 Installation and Set-up 176
12.1.1 Overview 176
12.2 Network Connection 177
12.3 Bus Termination 177
12.4 RS-485 Installation and Set-up 177
12.5 FC Protocol Overview 177
12.6 Network Configuration 178
12.7 FC Protocol Message Framing Structure 178
12.7.1 Content of a Character (byte) 178
12.7.2 Telegram Structure 178
12.7.3 Telegram Length (LGE) 178
12.7.4 Frequency Converter Address (ADR) 178
12.7.5 Data Control Byte (BCC) 178
12.7.6 The Data Field 179
12.7.7 The PKE Field 180
12.7.8 Parameter Number (PNU) 180
12.7.9 Index (IND) 180
Contents VLT®AutomationDrive FC 301/FC 302 Design Guide, 0.25-75 kW
6 MG33BF02 - Rev. 2013-12-20

12.7.10 Parameter Value (PWE) 180
12.7.11 Supported Data Types 181
12.7.12 Conversion 181
12.7.13 Process Words (PCD) 181
12.8 Examples 181
12.8.1 Writing a Parameter Value 181
12.8.2 Reading a Parameter Value 182
12.9 Modbus RTU Overview 182
12.9.1 Assumptions 182
12.9.2 What the User Should Already Know 182
12.9.3 Modbus RTU Overview 182
12.9.4 Frequency Converter with Modbus RTU 183
12.10 Network Configuration 183
12.11 Modbus RTU Message Framing Structure 183
12.11.1 Frequency Converter with Modbus RTU 183
12.11.2 Modbus RTU Message Structure 183
12.11.3 Start/Stop Field 184
12.11.4 Address Field 184
12.11.5 Function Field 184
12.11.6 Data Field 184
12.11.7 CRC Check Field 184
12.11.8 Coil Register Addressing 184
12.11.9 How to Control the Frequency Converter 186
12.11.10 Function Codes Supported by Modbus RTU 186
12.11.11 Modbus Exception Codes 186
12.12 How to Access Parameters 186
12.12.1 Parameter Handling 186
12.12.2 Storage of Data 187
12.12.3 IND (Index) 187
12.12.4 Text Blocks 187
12.12.5 Conversion Factor 187
12.12.6 Parameter Values 187
12.13 Danfoss FC Control Profile 187
12.13.1 Control Word According to FC Profile (8-10 Control Profile = FC profile) 187
12.13.2 Status Word According to FC Profile (STW) (8-10 Control Profile = FC profile) 189
12.13.3 Bus Speed Reference Value 190
12.13.4 Control Word according to PROFIdrive Profile (CTW) 190
12.13.5 Status Word according to PROFIdrive Profile (STW) 192
Index 194
Contents VLT®AutomationDrive FC 301/FC 302 Design Guide, 0.25-75 kW
MG33BF02 - Rev. 2013-12-20 7

1 Introduction
1.1 Purpose of the Design Guide
The Design Guide provides information required for
integration of the frequency converter in a diversity of
applications.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced
frequency converter operation, programming, and
directives compliance.
•The Operating Instructions provide detailed
information for the installation and start up of
the frequency converter.
•The Programming Guide provides greater detail in
how to work with parameters and many
application examples.
•The VLT
®
Safe Torque Off Operating Instructions
describe how to use Danfoss frequency
converters in functional safety applications.
•Supplemental publications and manuals are
available from Danfoss. See danfoss.com/Product/
Literature/Technical+Documentation.htm for
listings.
•Optional equipment is available that may change
some of the information described in these
publications. Be sure to see the instructions
supplied with the options for specific
requirements.
Contact a Danfoss supplier or go to www.danfoss.com for
additional information.
1.3 Abbreviations, Symbols and
Conventions
Conventions
Numbered lists indicate procedures.
Bullet lists indicate other information and description of
illustrations.
Italicised text indicates
•cross reference
•link
•footnote
•parameter name, parameter group name,
parameter option
60°AVM 60°Asynchronous Vector Modulation
A Ampere/AMP
AC Alternating current
AD Air discharge
AI Analog Input
AMA Automatic Motor Adaptation
AWG American wire gauge
°CDegrees Celsius
CD Contant discharge
CM Common mode
CT Constand Torque
DC Direct current
DI Digital Input
DM Differential mode
D-TYPE Drive Dependent
EMC Electro Magnetic Compatibility
ETR Electronic Thermal Relay
fJOG Motor frequency when jog function is
activated
fMMotor frequency
fMAX The maximum output frequency the frequency
converter applies on its output
fMIN The minimum motor frequency from
frequency converter
fM,N Nominal motor frequency
FC Frequency converter
g Gram
Hiperface®Hiperface®is a registered trademark by
Stegmann
hp Horsepower
HTL HTL encoder (10-30 V) pulses - High-voltage
Transistor Logic
Hz Hertz
IINV Rated Inverter Output Current
ILIM Current limit
IM,N Nominal motor current
IVLT,MAX The maximum output current
IVLT,N The rated output current supplied by the
frequency converter
kHz Kilohertz
LCP Local Control Panel
lsb Least significant bit
m Meter
mA Milliampere
MCM Mille Circular Mil
MCT Motion Control Tool
mH Millihenry Inductance
min Minute
ms Millisecond
msb Most significant bit
Introduction VLT®AutomationDrive FC 301/FC 302 Design Guide, 0.25-75 kW
8 MG33BF02 - Rev. 2013-12-20
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