Danfoss VLT Decentral FCD 300 Guide

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Contents
1 The Decentral Concept
5
Introduction 5
Decentral Design Benefits 6
Application Examples 13
Product Design Guide 15
Ordering Form 21
PC Software Tools 22
Accessories 22
Communication 24
Good Installation Practice 27
Servicing the Danfoss Decentral Products 30
2 Introduction to FCD 300 31
Safety 32
High Voltage Warning 32
These Rules Concern your Safety 32
Warning against Unintended Start 32
Technology 33
CE Labelling 35
3 Installation 37
Mechanical Dimensions 37
Mechanical Dimensions, Motor Mounting 37
Mechanical Dimensions, Stand Alone Mounting 37
General Information about Electrical Installation 40
Electronics Purchased without Installation Box 41
EMC-Correct Electrical Installation 43
Earthing of Screened/Armoured Control Cables 44
Diagram 45
RFI Switches J1, J2 45
Electrical Installation - Description of 46
Location of Terminals 46
Mains Connection 47
Pre-Fuses 47
Motor Connection 48
Direction of Motor Rotation 48
Mains and Motor Connection with Service Switch 49
Connection of HAN 10E Motor Plug for T73 49
Parallel Connection of Motors 49
Motor Cables 50
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Motor Thermal Protection 50
Brake Resistor 50
Control of Mechanical Brake 51
Electrical Installation, Control Cables 51
Connection of Sensors to M12 Plugs for T63 and T73 52
Electrical Installation, Control Terminals 52
PC Communication 53
Relay Connection 53
Connection Examples 54
4 Programming 61
LCP Control Unit 61
The LCP 2 Control Unit, Option 61
Parameter Selection 65
Parameter Group 0-** Operation & Display 66
Setup Configuration 67
Parameter Group 1-** Load and Motor 72
DC Braking 75
Parameter Group 2-** References & Limits 79
Handling of References 79
Reference Function 82
Parameter Group 3-** Inputs and Outputs 85
Parameter Group 4-** Special Functions 91
PID Functions 93
Handling of Feedback 94
Serial Communication 98
Control Word According to FC Protocol 103
Status Word According to FC Profile 104
Fast I/O FC-Profile 105
Control Word According to Fieldbus Profile 106
Status Word According to Profidrive Protocol 107
Parameter Group 5-** Serial communication 109
Parameter Group 6-** Technical Functions 115
5 All About FCD 300 119
Brake Resistors 119
Dynamic Braking 119
Internal Brake Resistor 123
Special Conditions 126
Galvanic Isolation (PELV) 126
Earth Leakage Current and RCD Relays 126
Extreme Operating Conditions 127
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dU/dt on Motor 127
Switching on the Input 127
Acoustic Noise 128
Temperature-Dependent Switch Frequency 128
Derating for Air Pressure 129
Derating for Running at Low Speed 129
Motor Cable Lengths 129
Vibration and Shock 129
Air Humidity 129
UL Standard 129
Efficiency 130
Mains Supply Interference/Harmonics 130
Power Factor 131
Emission Test Results according to Generic Standards and PDS Product Standard 131
Immunity Test Result according to Generic Standards, PDS Product Standards and
Basic Standards 131
Aggressive Environments 132
Cleaning 132
Status Messages 134
Warnings/Alarm Messages 134
Warning Words, Extended Status Words and Alarm Words 136
General Technical Data 137
Available Literature 141
Factory Settings 142
Index
146
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1 The Decentral Concept VLT
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1 The Decentral Concept
1.1 Introduction
Danfoss was the world's first company to manufacture and supply frequency converters for infinitely variable speed control of three-phase AC motors.
Until then, AC motors had to operate at the speed determined by the frequency of the main power supply.
Production of frequency converters started in 1968. The first frequency converter was also the first decentralised drive as it was placed next to the motor.
The first frequency converter was totally enclosed and filled with silicone oil for cooling, as semiconductors of that time were very inefficient. The enclosure
design was made for mounting the drive directly in the application next to the motor. Temperature, water, cleaning agents, dust and other environmental
factors were also no problem, even in harsh environments.
Semiconductors improved during the next decades. Air-cooling showed sufficient and oil cooling was abandoned. At the same time use of frequency
converters grew significantly. PLCs gained a footing for advanced application control and it became common practice to install all frequency converters
in one cabinet, rather than several places in the factory.
Continuing improvements in semi-conductors and related technologies - such as fieldbus technology - now again makes it feasible to consider installing
drives close to the motors, achieving the benefits of decentralised installation without the disadvantages from the first oil-filled frequency converters.
Development of automation in industry is based on the ability to send and receive data from the application needed to control the processes. More and
more sensors are installed and more and more data is submitted to the central PLC control. This trend depends on increased use of fieldbus systems.
Industrial sources often claim that up to 30 % of all drive installations will be installed decentrally within the next few years and the trend towards
distributed intelligent control is undisputed as more and more components and applications are developed for decentralised installation.
This book is a general introduction to basic features of decentralised installation philosophies for motor controls and differences from the centralised
concept. It will help you choose the most suitable concept and guide you through the process of selecting the appropriate products.
Finally we have included comprehensive information about the Danfoss decentralised products.
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1.2 Decentral Design Benefits
In the following we will concentrate on describing decentralised installation of frequency converters, referred to here as motor controls.
There are two topologic concepts for the layout of motor control installations in a plant, in the following referred to as “centralised” and “decentralised”
installations. The two typologies are illustrated in the figure.
In a centralised installation:
-motor controls are placed in a central place
In a decentralised installation:
-motor controls are distributed throughout the plant, mounted
on or next to the motor they control
Decentralised does not mean
control cabinet free , but merely that their
enormous size can now be reduced thanks to innovative designs of the
components that will be placed decentralised. There will continue to be
a need for cabinets for power distribution and for overall intelligence, and
there are areas, particularly in the process industry with areas such as
explosion protection, where centralised cabinets continue to be the pre-
ferred solution.
Placing the advanced and reliable electronics needed to ensure a smooth,
responsive and economical operation of the motor next to – or on – the
motor facilitates modularisation and reduces cabling costs and EMC prob-
lems dramatically. Further benefits:
Illustration 1.1: Centralised versus decentralised installa-
tions
• Space-consuming motor control cabinets in long rows of centralised panels are eliminated
• Reduced efforts for building in and wiring long screened motor cables where special attention on EMC terminations is required
• Heat dissipation from power electronics is moved from the panel into the plant
• Standardised machine elements by modularisation reduces design time and time to market
• Commissioning is easier and faster
Decentralised motor control is rapidly gaining ground despite of the advantages of the centralised control concept:
• no need for extra space around the motor or close to the motor
• no control cable wiring into the plant
• independence of plant environment
1.2.1 Direct Cost Savings
Motor controls for decentralised installations must be built to meet the harsh conditions in manufacturing areas - especially such conditions found in the
food and beverage industry, where frequent wash downs are required. This of course increases the cost of the drive. This increase will be more than set
off by savings in expenses for cabinets and cables.
The cable saving potential is considerable, as will be demonstrated by the following example.
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The figure illustrates an installation with motors distributed in a number of rows with several motors in each, as is the situation in for example parallel
bottling or baking lines in the Food and Beverage industry. This example shows the need for power cables from the centrally placed drives to the motors.
Illustration 1.2: Centralised installation
The drives are distributed equidistant with the distance L between each drive and the distance h between each row and also with a distance h from the
centralised power entry/cabinet location to the first row. There are n rows, and N drives in each row.
Illustration 1.3: Decentralised installation
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The Illustration 1.4 shows how the three-phase mains cable can be dis-
tributed with power looping from one motor (drive) to the next. The cable
saving potential is illustrated in Illustration xx. Given a distance of 10 m
between each motor and 20 m between each line, the potential cable
savings as a function of the number of motors and number of lines shows
of the figure.
Illustration 1.4: Cable saving potential in an illustrative in-
stallation
The saving potential in power cable length alone is substantial. The figure only illustrates the potential concerning power cables. Issues like unscreened/
screened cables and cable dimensions also ads to the benefits of decentralised installations.
Real case
Calculations on a specific, typical bottling line with 91 pieces of 1.5 kW motors, taking the cable dimensioning into account, showed the following saving
potential in cables and terminations:
• Cable terminations are reduced from 455 to 352
• EMC cable terminations are reduced from 364 to 182 by using motor controls with integrated service switches
• Power cable length reduced from 6468m to 1180m, a reduction of 5288m, and it is converted from screened cables to standard installation
cables
For details consult the following chapter on
Good installation practice .
1.2.2 Design Savings
End users want to postpone the final decision for new equipment - and to start production as fast as possible once a decision has been made. Payback
time and time to market must be reduced. This squeezes both the design phase and the commissioning phase.
Modularisation can minimise lead-time. Even manufacturers of large production equipment or lines use modularisation to reduce lead-time. Up to 40-50
% on the total time from design to running production can be saved.
The concept of modularisation is known from equipment like PC’s and cars. Modules with well-described functionalities and interfaces are used in these
products. The same concept can be applied to manufacturing, even though specific physical constraints play a role.
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Production equipment is often built from different basic building blocks, each kind employed at several places in the installation. Examples include various
types of conveyor sections and machinery like mixers, scales, fillers, labellers, palletisers, packaging machines etc.
Illustration 1.5: Centralised cabinet
In a truly modular machine, all basic elements are self-confined and need nothing but electricity, water, compressed air or similar to function.
Modularisation therefore requires the distribution of intelligence to the individual sections and modules.
Sure, centralised installations can be modualarised, but then motor controls will be physically separated from the rest of the module.
Fewer cabinets, cooling and cable trays
Further savings will result from smaller cabinets, less cabinet cooling and fewer cable trays. Motor controls generate heat and are often mounted side by
side due to limited space, as illustrated in illustration 1.5. Forced cooling is therefore required to remove the heat.
Less Commissioning
Time spend commissioning at the end-user is significantly reduced using
decentralised solutions - especially when fieldbus communication is com-
bined with decentralised motor controls.
An Australian brewery has installed a line of 96 decentralised drives from
Danfoss connected by DeviceNet. An excessive amount of time was saved
as the commissioning of the variable speed drives was done in a few days.
The brewery estimates a saving exceeding AUD 100,000 compared to
traditional centralised installation.
Illustration 1.6: Decentralised brewery installation
Minimal Need for Additional Fieldbus Cables
Power cable savings are not offset by the additional cost for expensive fieldbus cables. Fieldbus cables will be extended in a decentralised installation,
but since fieldbus cables will be distributed in the plant anyway to connect sensors or remote I/O-stations, the extension will be limited. Decentralised
products from Danfoss can even be used as remote I/O stations to connect sensors to the fieldbus and reduce direct costs even more.
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