Danfoss VLT AutomationDrive FC 360 Guide

MAKING MODERN LIVING POSSIBLE
Design Guide
VLT®AutomationDrive FC 360
www.danfoss.com/drives

Contents
1 Introduction 5
1.1 How to Read This Design Guide 5
1.1.1 Symbols 5
1.1.2 Abbreviations 5
1.2 Definitions 6
1.2.1 Frequency Converter 6
1.2.2 Input 6
1.2.3 Motor 6
1.2.4 References 6
1.2.5 Miscellaneous 7
1.3 Safety Precautions 8
1.4 Disposal Instruction 9
1.5 Document and Software Version 9
1.6 Approvals and Certifications 10
1.6.1 CE Mark 10
1.6.2 Low Voltage Directive 10
1.6.3 EMC Directive 10
2 Product Overview 11
2.1 Enclosure Size Overview 11
2.2 Electrical Installation 12
2.2.1 General Requirements 14
2.2.2 Grounding Requirements 14
2.2.3 Mains, Motor, and Ground Connections 15
2.2.4 Control Wiring 16
2.3 Control Structures 18
2.3.1 Control Principle 18
2.3.2 Control Modes 18
2.3.3 FC 360 Control Principle 19
2.3.4 Control Structure in VVC+20
2.3.5 Internal Current Control in VVC+Mode 21
2.3.6 Local (Hand On) and Remote (Auto On) Control 21
2.4 Reference Handling 22
2.4.1 Reference Limits 23
2.4.2 Scaling of Preset References and Bus References 24
2.4.3 Scaling of Analog and Pulse References and Feedback 24
2.4.4 Dead Band Around Zero 26
2.5 PID Control 29
2.5.1 Speed PID Control 29
Contents Design Guide
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2.5.2 Process PID Control 32
2.5.3 Process Control Relevant Parameters 33
2.5.4 Example of Process PID Control 34
2.5.5 Optimisation of the Process Regulator 36
2.5.6 Ziegler Nichols Tuning Method 36
2.6 EMC Emission and Immunity 37
2.6.1 General Aspects of EMC Emission 37
2.6.2 EMC Emission Requirements 38
2.6.3 EMC Immunity Requirements 38
2.7 Galvanic Isolation 40
2.8 Earth Leakage Current 40
2.9 Brake Functions 41
2.9.1 Mechanical Holding Brake 41
2.9.2 Dynamic Braking 42
2.9.3 Brake Resistor Selection 42
2.10 Smart Logic Controller 44
2.11 Extreme Running Conditions 44
3 Type Code and Selection 46
3.1 Ordering 46
3.2 Ordering Numbers: Options and Accessories 47
3.3 Ordering Numbers: Brake Resistors 48
3.3.1 Ordering Numbers: Brake Resistors 10% 48
3.3.2 Ordering Numbers: Brake Resistors 40% 49
4 Specifications 50
4.1 Power-dependent Specifications 50
4.2 General Specifications 52
4.3 Fuses 56
4.3.1 Introduction 56
4.3.2 CE Compliance 56
4.4 Efficiency 57
4.5 Acoustic Noise 57
4.6 dU/dt Conditions 57
4.7 Special Conditions 59
4.7.1 Manual Derating 59
4.7.2 Automatic Derating 59
5 RS485 Installation and Set-up 60
5.1 Introduction 60
5.1.1 Overview 60
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5.1.2 Network Connection 61
5.1.3 Hardware Set-up 61
5.1.4 Parameter Settings for Modbus Communication 61
5.1.5 EMC Precautions 61
5.2 FC Protocol 61
5.3 Network Configuration 62
5.4 FC Protocol Message Framing Structure 62
5.4.1 Content of a Character (byte) 62
5.4.2 Telegram Structure 62
5.4.3 Telegram Length (LGE) 62
5.4.4 Frequency Converter Address (ADR) 63
5.4.5 Data Control Byte (BCC) 63
5.4.6 The Data Field 63
5.4.7 The PKE Field 63
5.4.8 Parameter Number (PNU) 64
5.4.9 Index (IND) 64
5.4.10 Parameter Value (PWE) 64
5.4.11 Data Types Supported by the Frequency Converter 64
5.4.12 Conversion 64
5.4.13 Process Words (PCD) 65
5.5 Examples 65
5.6 Modbus RTU 66
5.6.1 Prerequisite Knowledge 66
5.6.2 Overview 66
5.6.3 Frequency Converter with Modbus RTU 66
5.7 Network Configuration 66
5.8 Modbus RTU Message Framing Structure 67
5.8.1 Introduction 67
5.8.2 Modbus RTU Message Structure 67
5.8.3 Start/Stop Field 67
5.8.4 Address Field 67
5.8.5 Function Field 67
5.8.6 Data Field 68
5.8.7 CRC Check Field 68
5.8.8 Coil Register Addressing 68
5.8.9 How to Control the Frequency Converter 70
5.8.10 Function Codes Supported by Modbus RTU 70
5.8.11 Modbus Exception Codes 70
5.9 How to Access Parameters 70
5.9.1 Parameter Handling 70
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5.9.2 Storage of Data 71
5.10 Examples 71
5.10.1 Read Coil Status (01 hex) 71
5.10.2 Force/Write Single Coil (05 hex) 72
5.10.3 Force/Write Multiple Coils (0F hex) 72
5.10.4 Read Holding Registers (03 hex) 72
5.10.5 Preset Single Register (06 hex) 73
5.10.6 Preset Multiple Registers (10 hex) 73
5.11 Danfoss FC Control Profile 74
5.11.1 Control Word According to FC Profile (8-10 Protocol = FC profile) 74
5.11.2 Status Word According to FC Profile (STW) (8-30 Protocol = FC profile) 75
5.11.3 Bus Speed Reference Value 77
6 Application Examples 78
6.1 Introduction 78
6.1.1 Encoder Connection 81
6.1.2 Encoder Direction 81
6.1.3 Closed Loop Drive System 81
Index 82
Contents Design Guide
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1 Introduction
1.1 How to Read This Design Guide
This design guide provides information on how to select,
commission, and order a frequency converter. It provides
information about mechanical and electrical installation.
The design guide is intended for use by qualified
personnel.
Read and follow the design guide to use the frequency
converter safely and professionally, and pay particular
attention to the safety instructions and general warnings.
VLT®is a registered trademark.
•VLT
®
AutomationDrive FC 360 Quick Guide provides
the necessary information for getting the
frequency converter up and running.
•VLT
®
AutomationDrive FC 360 Programming Guide
provides information on how to programme and
includes complete parameter descriptions.
FC 360 technical literature is also available online at
www.danfoss.com/fc360.
1.1.1 Symbols
The following symbols are used in this document:
WARNING
Indicates a potentially hazardous situation that could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that could
result in minor or moderate injury. It may also be used
to alert against unsafe practices.
NOTICE
Indicates important information, including situations that
may result in damage to equipment or property.
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
Electromagnetic compatibility EMC
Electronic thermal relay ETR
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 meter 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
Maximum output current IVLT,MAX
Rated output current supplied by the
frequency converter
IVLT,N
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1.2 Definitions
1.2.1 Frequency Converter
Coast
The motor shaft is in free mode. No torque on the motor.
IVLT, MAX
Maximum output current.
IVLT,N
Rated output current supplied by the frequency converter.
UVLT,MAX
Maximum output voltage.
1.2.2 Input
Control commands
Start and stop the connected motor with LCP and digital
inputs.
Functions are divided into 2 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 [OFF].
Group 2 Start, pulse start, reversing, start reversing, jog,
and freeze output.
Table 1.1 Function Groups
1.2.3 Motor
Motor running
Torque generated on the output shaft and speed from
0 RPM to maximum speed on the motor.
fJOG
Motor frequency when the jog function is activated (via
digital terminals).
fM
Motor frequency.
fMAX
Maximum motor frequency.
fMIN
Minimum motor frequency.
fM,N
Rated motor frequency (nameplate data).
IM
Motor current (actual).
IM,N
Rated motor current (nameplate data).
nM,N
Rated motor speed (nameplate data).
ns
Synchronous motor speed
ns =2×
par . 1−23×60 s
par . 1−39
nslip
Motor slip.
PM,N
Rated motor power (nameplate data in kW or hp).
TM,N
Rated torque (motor).
UM
Instantaneous motor voltage.
UM,N
Rated motor voltage (nameplate data).
Breakaway torque
175ZA078.10
Pull-out
rpm
Torque
Illustration 1.1 Breakaway Torque
ηVLT
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 chapter 1.2.2 Input for more details.
Stop command
A stop command belonging to the group 1 control
commands. See chapter 1.2.2 Input for more details.
1.2.4 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.
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Preset reference
A defined preset reference to be set from -100% to +100%
of the reference range. Selection of 8 preset references via
the digital terminals.
Pulse reference
A pulse frequency signal transmitted to the digital inputs
(terminal 29 or 33).
RefMAX
Determines the relationship between the reference input
at 100% full scale value (typically 10 V, 20 mA) and the
resulting reference. The maximum reference value is set in
3-03 Maximum Reference.
RefMIN
Determines the relationship between the reference input
at 0% value (typically 0 V, 0 mA, 4 mA) and the resulting
reference. The minimum reference value is set in
3-02 Minimum Reference.
1.2.5 Miscellaneous
Analog inputs
The analog inputs are used for controlling various
functions of the frequency converter.
There are 2 types of analog inputs:
•Current input, 0–20 mA and 4–20 mA
•Voltage input, 0 to +10 V DC
Analog outputs
The analog outputs can supply a signal of 0–20 mA, 4–20
mA.
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 frequency converter features 2 solid-state outputs that
can supply a 24 V DC (maximum 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.
FC standard bus
Includes RS485 bus with FC protocol or MC protocol. See
8-30 Protocol.
Initialising
If initialising is carried out (14-22 Operation Mode), the
frequency converter returns to the default setting.
Intermittent duty cycle
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 makes up a complete interface for
control and programming of the frequency converter. The
control panel is detachable and can be installed up to 3 m
from the frequency converter, i.e. in a front panel with the
installation kit option.
NLCP
The numerical local control panel interface for control and
programming of the frequency converter. The display is
numerical and the panel is used to display process values.
The NLCP has storing and copy functions.
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 mm2.
On-line/Off-line parameters
Changes to on-line parameters are activated immediately
after the data value is changed. Press [OK] to activate
changes to off-line parameters.
Process PID
The PID control maintains the desired speed, pressure,
temperature, etc. by adjusting the output frequency to
match the varying load.
PCD
Process control data
Power cycle
Switch off the mains until display (LCP) is dark, then turn
power on again.
Power factor
The power factor is the relation between I1and IRMS.
Power factor = 3
x U x I
1
cos ϕ1
3 x U x IRMS
For FC 360 frequency converters, cosϕ 1=1, therefore:
Power factor =
I 1 x cos ϕ1
IRMS
=
I
1
IRMS
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The power factor indicates to which extent the frequency
converter imposes a load on the mains supply.
The lower the power factor, the higher the IRMS for the
same kW performance.
IRMS
=
I
1
2 +
I
5
2 +
I
7
2 + .. +
In
2
In addition, a high power factor indicates that the different
harmonic currents are low.
The built-in DC coils produce a high power factor
minimising the imposed load on the mains supply.
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
Save parameter settings in 2 set-ups. Change between the
2 parameter set-ups and edit 1 set-up while another set-up
is active.
SFAVM
Acronym describing the switching pattern Stator Flux
oriented Asynchronous Vector Modulation.
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 smart logic controller (parameter group 13-**
Smart Logic Control).
STW
Status word.
THD
Total harmonic distortion states the total contribution of
harmonic distortion.
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 overtemperature or when it 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. Do not
use trip 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. Do not use trip locked for personal safety.
VT characteristics
Variable torque characteristics used for pumps and fans.
VVC+
If compared with standard voltage/frequency ratio control,
Voltage Vector Control (VVC+) improves the dynamics and
stability, both when the speed reference is changed and in
relation to the load torque.
60°AVM
Refers to the switching pattern 60
° Asynchronous Vector
Modulation.
1.3 Safety Precautions
WARNING
The voltage of the frequency converter is dangerous
whenever connected to mains. Incorrect installation of
the motor, frequency converter or fieldbus may cause
death, serious personal injury or damage to the
equipment. Consequently, the instructions in this
manual, as well as national and local rules and safety
regulations, must be complied with.
Safety Regulations
1. Always disconnect mains supply to the frequency
converter before carrying out repair work. Check
that the mains supply has been disconnected and
observe the discharge time stated in Table 1.2
before removing motor and mains supply.
2. [Off/Reset] on the LCP does not disconnect the
mains supply and must not be used as a safety
switch.
3. Ground the equipment properly, protect the user
against supply voltage, and protect the motor
against overload in accordance with applicable
national and local regulations.
4. Protection against motor overload is not included
in the factory setting. If this function is desired,
set 1-90 Motor Thermal Protection to [4] ETR trip 1
or [3] ETR warning 1.
5. The frequency converter has more voltage
sources than L1, L2 and L3, when load sharing
(linking of DC intermediate circuit). Check that all
voltage sources have been disconnected and that
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the necessary time has elapsed before
commencing repair work.
Warning against unintended start
1. The motor can be stopped with digital
commands, bus commands, references or a local
stop, while the frequency converter is connected
to mains. If personal safety considerations (e.g.
risk of personal injury caused by contact with
moving parts following an unintentional start)
make it necessary to ensure that no unintended
start occurs, these stop functions are not
sufficient. In such cases, disconnect the mains
supply.
2. The motor may start while setting the
parameters. If this means that personal safety
may be compromised, motor starting must be
prevented, for instance by secure disconnection
of the motor connection.
3. A motor that has been stopped with the mains
supply connected, may start if faults occur in the
electronics of the frequency converter, through
temporary overload or if a fault in the power
supply grid or motor connection is remedied. If
unintended start must be prevented for personal
safety reasons, the normal stop functions of the
frequency converter are not sufficient. In such
cases, disconnect the mains supply.
4. In rare cases, control signals from, or internally
within, the frequency converter may be activated
in error, be delayed, or fail to occur entirely.
When used in situations where safety is critical,
e.g. when controlling the electromagnetic brake
function of a hoist application, do not rely on
these control signals exclusively.
WARNING
High Voltage
Touching the electrical parts may be fatal–even after the
equipment has been disconnected from mains.
Make sure that all voltage inputs have been discon-
nected, including load sharing (linkage of DC
intermediate circuit), as well as motor connection for
kinetic back up.
Systems where frequency converters are installed must,
if necessary, be equipped with additional monitoring
and protective devices according to valid safety
regulations, such as laws on mechanical tools,
regulations for the prevention of accidents, etc. Modifi-
cations to the frequency converters via the operating
software are allowed.
NOTICE
Hazardous situations shall be identified by the machine
builder/integrator responsible for considering necessary
preventive means. Additional monitoring and protective
devices may be included, always according to valid
national safety regulations, such as laws on mechanical
tools and regulations for the prevention of accidents.
WARNING
DISCHARGE TIME
The frequency converter contains DC-link capacitors,
which can remain charged even when the frequency
converter is not powered. Failure to wait the specified
time after power has been removed before performing
service or repair work, could result in death or serious
injury.
1. Stop the motor.
2. Disconnect AC mains, permanent magnet type
motors, and remote DC-link power supplies,
including battery back-ups, UPS, and DC-link
connections to other frequency converters.
3. Wait for the capacitors to discharge fully, before
performing any service or repair work. The
duration of waiting time is specified in
Table 1.2.
Voltage [V] Minimum waiting time (minutes)
4 15
380–480 0.37–7.5 kW 11–75 kW
High voltage may be present even when the warning LEDs are
off.
Table 1.2 Discharge Time
1.4 Disposal Instruction
Equipment containing electrical
components may not be disposed of
together with domestic waste.
It must be collected separately with
electrical and electronic waste according
to local and currently valid legislation.
1.5 Document and Software Version
This manual is regularly reviewed and updated. All
suggestions for improvement are welcome.
Edition Remarks Software version
MG06B4xx Replaces MG06B3xx 1.4x
Introduction Design Guide
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1.6 Approvals and Certifications
Frequency converters are designed in compliance with the
directives described in this section.
For more information on approvals and certificates, go to
the download area at www.danfoss.com/fc360.
1.6.1 CE Mark
The CE mark (Communauté européenne) indicates that the
product manufacturer conforms to all applicable EU
directives. The EU directives applicable to the design and
manufacture of frequency converters are the directive low-
voltage, the EMC directive, and (for units with an
integrated safety function) the machinery directive.
The CE mark is intended to eliminate technical barriers to
free trade between the EC and EFTA states inside the ECU.
The CE mark does not regulate the quality of the product.
Technical specifications cannot be deduced from the CE
mark.
1.6.2 Low Voltage Directive
Frequency converters are classified as electronic
components and must be CE labelled in accordance with
the low-voltage directive. The directive applies to all
electrical equipment in the 50–1000 V AC and the 75–1600
V DC voltage ranges.
The directive mandates that the equipment design must
ensure the safety and health of people and livestock and
the preservation of material by ensuring the equipment is
properly installed, maintained, and used as intended.
Danfoss CE labels comply with the low-voltage directive
and Danfoss will provide a declaration of conformity upon
request.
1.6.3 EMC Directive
Electromagnetic compatibility (EMC) means that electro-
magnetic interference between pieces of equipment does
not hinder their performance. The basic protection
requirement of the EMC Directive 2004/108/EC states that
devices that generate electromagnetic interference (EMI) or
whose operation could be affected by EMI must be
designed to limit the generation of electromagnetic
interference and shall have a suitable degree of immunity
to EMI when properly installed, maintained, and used as
intended.
A frequency converter can be used as stand-alone device
or as part of a more complex installation. Devices in either
of these cases must bear the CE mark. Systems must not
be CE marked but must comply with the basic protection
requirements of the EMC directive.
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2 Product Overview
2.1 Enclosure Size Overview
Enclosure size depends on power range.
Enclosure size J1 J2 J3 J4
130BA870.10
130BA809.10
130BA810.10
130BA810.10
Enclosure
protection IP20 IP20 IP20 IP20
High overload
rated power -
maximum
160%
overload1)
0.37–2.2 kW (380–480 V) 3.0–5.5 kW (380–480 V) 7.5 kW (380–480 V) 11–15 kW (380–480 V)
Enclosure size J5 J6 J7
130BA810.10
130BA826.10
130BA826.10
Enclosure
protection IP20 IP20 IP20
High overload
rated power -
maximum
160%
overload1)
18.5–22 kW (380–480 V) 30–45 kW (380–480 V) 55–75 kW (380–480 V)
Table 2.1 Enclosure Sizes
1) Sizes 11–75 kW normal overload type: 110% overload 1 minute
Sizes 0.37–7.5 kW high overload type: 160% overload 1 minute
Sizes 11–22 kW high overload type: 150% overload 1 minute
Sizes 30–75 kW high overload type: 150% overload 1 minute
Product Overview Design Guide
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22

2.2 Electrical Installation
This section describes how to wire the frequency converter.
130BC438.15
3 Phase
power
input
Switch Mode
Power Supply
Motor
Analog Output
Interface
(PNP) = Source
(NPN) = Sink
ON=Terminated
OFF=Open
Brake
resistor
91 (L1)
92 (L2)
93 (L3)
PE
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24 V OUT)
31 (D IN)
18 (D IN)
20 (COM D IN)
10 V DC
15 mA 100 mA
+ - + -
(U) 96
(V) 97
(W) 98
(PE) 99
(A OUT) 45
(A OUT) 42
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V
5V
S801
0/4-20 mA
RS-485
RS-485
03
+10 V DC
0/4-20 mA
0-10 V DC
24 V DC
02
01
05
04
240 V AC, 3 A
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
19 (D IN)
24 V (NPN)
0 V (PNP)
27 (D IN/OUT)
24 V
0 V
0 V (PNP)
24 V (NPN)
0 V
24 V
29 (D IN/OUT)
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
33 (D IN)
32 (D IN)
95
P 5-00
21
ON
(+UDC) 89
(BR) 81 5)
24 V (NPN)
0 V (PNP)
0-10 V DC
(-UDC) 88
RFI
3)
0 V
240 V AC, 3 A
Relay 1
1)
Relay 2 2)
4)
06
Illustration 2.1 Basic Wiring Schematic Drawing
A=Analog, D=Digital
1) Built-in brake chopper available from 0.37–22 kW
2) Relay 2 is 2-pole for J1–J3 and 3-pole for J4–J7. Relay 2 of J4–J7 with terminals 4, 5 and 6 has the same NO/NC logic as Relay
1. Relays are pluggable in J1–J5, and fixed in J6–J7.
3) Single DC choke in 0.37–22 kW (J1–J5); Dual DC choke in 30–75 kW (J6–J7).
4) Switch S801 (bus terminal) can be used to enable termination on the RS485 port (terminals 68 and 69).
5) No BR for 30–75 kW (J6–J7).
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130BD391.11
1
2
3
4
5
6
78
910
Reset Auto
On
Hand
On
OK
Back
Menu
Status Quick
Menu
Main
Menu
PE
U
V
W
L1
L2
L3
PE
1 PLC 6 Minimum 200 mm (7.9 inch) between control cables, motor and mains
2 Frequency converter 7 Motor, 3-phase and PE
3 Output contactor (generally not
recommended)
8 Mains, 3-phase and reinforced PE
4 Grounding rail (PE) 9 Control wiring
5 Cable shielding (stripped) 10 Equalising minimum 16 mm2(6 AWG)
Illustration 2.2 Typical Electrical Connection
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2.2.1 General Requirements
WARNING
EQUIPMENT HAZARD!
Rotating shafts and electrical equipment can be
hazardous. It is important to protect against electrical
hazards when applying power to the unit. All electrical
work must conform to national and local electrical codes
and installation, start up, and maintenance should only
be performed by trained and qualified personnel. Failure
to follow these guidelines could result in death or
serious injury.
CAUTION
WIRING ISOLATION!
Run input power, motor wiring and control wiring in 3
separate metallic conduits or use separated shielded
cable for high frequency noise isolation. Failure to isolate
power, motor and control wiring could result in less than
optimum frequency converter and associated equipment
performance.
Run motor cables from multiple frequency converters
separately. Induced voltage from output motor cables
run together can charge equipment capacitors even with
the equipment turned off and locked out.
•An electronically activated function within the
frequency converter provides overload protection
for the motor. The overload provides Class 20
motor protection.
Wire Type and Ratings
•All wiring must comply with local and national
regulations regarding cross-section and ambient
temperature requirements.
•Danfoss recommends that all power connections
be made with a minimum 75 °C rated copper
wire.
•See chapter 4 Specifications for recommended
wire sizes.
2.2.2 Grounding Requirements
WARNING
GROUNDING HAZARD!
For operator safety, a certified electrical installer should
ground the frequency converter in accordance with
national and local electrical codes as well as instructions
contained within this document. Ground currents are
higher than 3.5 mA. Failure to ground the frequency
converter properly could result in death or serious injury.
•Establish proper protective grounding for
equipment with ground currents higher than 3.5
mA must be established. See chapter 2.8 Earth
Leakage Current for details.
•A dedicated ground wire is required for input
power, motor power, and control wiring.
•Use the clamps provided with the equipment for
proper ground connections.
•Do not ground 1 frequency converter to another
in a “daisy chain” fashion (see Illustration 2.3).
•Keep the ground wire connections as short as
possible.
•Use high-strand wire to reduce electrical noise.
•Follow motor manufacturer wiring requirements.
130BC500.10
FC 1
FC 1
FC 2
FC 2
FC 3
FC 3
PE
PE
Illustration 2.3 Grounding Principle
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2.2.3 Mains, Motor, and Ground
Connections
WARNING
INDUCED VOLTAGE!
Run output motor cables from multiple frequency
converters separately. Induced voltage from output
motor cables run together can charge equipment
capacitors even when the equipment is turned off and
locked out. Failure to run output motor cables separately
could result in death or serious injury.
Grouding clamps are provided for motor wiring (see
Illustration 2.4).
•Do not install power factor correction capacitors
between the frequency converter and the motor
•Do not wire a starting or pole-changing device
between the frequency converter and the motor
•Follow motor manufacturer wiring requirements
•All frequency converters may be used with an
isolated input source as well as with ground
reference power lines. When supplied from an
isolated mains source (IT mains or floating delta)
or TT/TN-S mains with a grounded leg (grounded
delta), set 14-50 RFI Filter to OFF (enclosure sizes
J6–J7) or remove the RFI screw (enclosure sizes
J1–J5). When off, the internal RFI filter capacitors
between the chassis and the intermediate circuit
are isolated to avoid damage to the intermediate
circuit and reduce earth capacity currents in
accordance with IEC 61800-3.
•Do not install a switch between the frequency
converter and the motor in IT mains.
130BC501.10
01 02 03 04 05
Illustration 2.4 Mains, Motor and Ground Connections for
Enclosure Sizes J1–J5
130BD648.11
Illustration 2.5 Mains, Motor, and Ground Connections for
Enclosure Size J7
Illustration 2.4 displays mains input, motor, and grounding
for enclosure sizes J1–J5. Illustration 2.5 displays mains
input, motor, and grounding for enclosure size J7. Actual
configurations vary with unit types and optional
equipment.
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2.2.4 Control Wiring
Access
•Remove the cover plate with a screwdriver. See
Illustration 2.6.
130BC504.10
Illustration 2.6 Control Wiring Access for Enclosure Sizes J1–J7
Control Terminal Types
Illustration 2.7 shows the frequency converter control
terminals. Terminal functions and default settings are
summarised in Table 2.2.
42 45
12
18 19 27 29 31 32 33 20 50 53 54 55
130BC505.12
Illustration 2.7 Control Terminal Locations
See chapter 4.2 General Specifications for terminal ratings
details.
Terminal Parameter Default
setting Description
Digital I/O, Pulse I/O, Encoder
12 – +24 V DC
24 V DC supply
voltage.
Maximum
output current is
100 mA for all
24 V loads.
18 5-10 Terminal 18
Digital Input [8] Start
Digital inputs.
19 5-11 Terminal 19
Digital Input
[10]
Reversing
31 5-16 Terminal 31
Digital Input
[0] No
operation Digital input
32 5-14 Terminal 32
Digital Input
[0] No
operation
Digital input, 24
V encoder.
Terminal 33 can
be used for
pulse input.
33 5-15 Terminal 33
Digital Input
[0] No
operation
27
5-12 Terminal 27
Digital Input
5-30 Terminal 27
Digital Output
DI [2] Coast
inverse
DO [0] No
operation
Selectable for
either digital
input, digital
output or pulse
output. Default
setting is digital
input.
Terminal 29 can
be used for
pulse input.
29
5-13 Terminal 29
Digital Input
5-31 Terminal 29
Digital Output
DI [14] Jog
DO [0] No
operation
20 –
Common for
digital inputs
and 0 V
potential for 24
V supply.
Analog inputs/outputs
42 6-91 Terminal 42
Analog Output
[0] No
operation
Programmable
analog output.
The analog
signal is 0–20
mA or 4–20 mA
at a maximum
of 500 Ω. Can
also be
configured as
digital outputs
45 6-71 Terminal 45
Analog Output
[0] No
operation
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Terminal Parameter Default
setting Description
50 – +10 V DC
10 V DC analog
supply voltage.
15 mA
maximum
commonly used
for potenti-
ometer or
thermistor.
53 6-1* parameter
group Reference Analog input.
Selectable for
voltage or
current.
54 6-2* parameter
group Feedback
55 – Common for
analog input
Serial communication
61 –
Integrated RC-
Filter for cable
screen. ONLY for
connecting the
screen when
experiencing
EMC problems.
68 (+) 8-3* parameter
group
RS485 interface.
A control card
switch is
provided for
termination
resistance.
69 (-) 8-3* parameter
group
Relays
01, 02, 03 5-40 [0] [0] No
operation
Form C relay
output. These
relays are in
various locations
depending upon
the frequency
converter config-
uration and size.
Usable for AC or
DC voltage and
resistive or
inductive loads.
RO2 in J1–J3
enclosure is 2-
pole, only
terminals 04 and
05 are available
04, 05, 06 5-40 [1] [0] No
operation
Table 2.2 Terminal Descriptions
Control terminal functions
Frequency converter functions are commanded by
receiving control input signals.
•Programme each terminal for the function it
supports in the parameters associated with that
terminal.
•Confirm that the control terminal is programmed
for the correct function. See chapter Local Control
Panel and Programming in the quick guide for
details on accessing parameters and
programming.
•The default terminal programming initiates
frequency converter functioning in a typical
operational mode.
Using screened control cables
The preferred method in most cases is to secure control
and serial communication cables with screening clamps
provided at both ends to ensure the best possible high
frequency cable contact.
If the ground potential between the frequency converter
and the PLC is different, electric noise may occur that
disturbs the entire system. Solve this problem by fitting an
equalising cable as close as possible to the control cable.
Minimum cable cross section: 16 mm2(6 AWG).
1
2
PE
FC
PE
PLC
130BB922.12
PE PE
<10 mm
1Minimum 16 mm2(6 AWG)
2 Equalising cable
Illustration 2.8 Screening Clamps at Both Ends
50/60 Hz ground loops
With very long control cables, ground loops may occur. To
eliminate ground loops, connect one end of the screen-to-
ground with a 100 nF capacitor (keeping leads short).
100nF
FC
PE PE
PLC
<10 mm
130BB609.12
Illustration 2.9 Connection with a 100 nF Capacitor
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Avoid EMC noise on serial communication
This terminal is connected to ground via an internal RC
link. Use twisted-pair cables to reduce interference
between conductors. The recommended method is shown
in Illustration 2.10.
PE
FC
PE
FC
130BB923.12
PE PE
69
68
61
69
68
61
1
2
<10 mm
1Minimum 16 mm2(6 AWG)
2 Equalising cable
Illustration 2.10 Twisted-pair Cables
Alternatively, the connection to terminal 61 can be
omitted.
PE
FC
PE
FC
130BB924.12
PE PE
69
69
68
68
1
2
<10 mm
1Minimum 16 mm2(6 AWG)
2 Equalising cable
Illustration 2.11 Twisted-pair Cables without Terminal 61
2.3 Control Structures
2.3.1 Control Principle
A frequency converter rectifies AC voltage from mains into
DC voltage, after which this DC voltage is converted into
an AC current with a variable amplitude and frequency.
The motor is supplied with variable voltage/current and
frequency, enabling infinitely variable speed control of 3-
phased, standard AC motors and permanent magnet
synchronous motors.
2.3.2 Control Modes
The frequency converter is capable of controlling either
the speed or the torque on the motor shaft. Setting
1-00 Configuration Mode determines the type of control.
Speed control
There are 2 types of speed control:
•Speed open loop control, which does not require
any feedback from the motor (sensorless).
•Speed closed loop PID control, which requires a
speed feedback to an input. A properly optimised
speed closed loop control has higher accuracy
than a speed open loop control.
Select which input to use as speed PID feedback in
7-00 Speed PID Feedback Source.
Torque control
The torque control function is used in applications where
the torque on motor output shaft is controlling the
application as tension control. Torque control can be
selected in 1-00 Configuration Mode. Torque setting is done
by setting an analog, digital, or bus controlled reference.
When running torque control, it is recommended to run a
full AMA procedure, because correct motor data is
important in achieving optimal performance.
•Closed loop in VVC+mode. This function is used
in applications with low to medium dynamic
variation of shaft, and offers excellent
performance in all 4 quadrants and at all motor
speeds. The speed feedback signal is mandatory.
It is recommended to use MCB102 option card.
Ensure the encoder resolution is at least 1024
PPR, and the shield cable of the encoder is well
grounded, because the accuracy of the speed
feedback signal is important. Tune 7-06 Speed PID
Lowpass Filter Time to get the best speed
feedback signal.
•Open loop in VVC+mode. The function is used in
mechanically robust applications, but the
accuracy is limited. Open loop torque function
works for 2 directions. The torque is calculated on
the basis of the internal current measurement in
the frequency converter.
Speed/torque reference
The reference to these controls can be either a single
reference or the sum of various references including
relatively scaled references. Reference handling is
explained in detail in chapter 2.4 Reference Handling.
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