Danfoss vlt fcd 302 Guide

ENGINEERING TOMORROW
Design Guide
VLT®Decentral Drive FCD 302
vlt-drives.danfoss.com

Contents
1 Introduction 6
1.1 How to Read the Design Guide 6
1.1.1 Additional Resources 6
1.2 Document and Software Version 6
1.3 Denitions 6
1.3.1 Frequency Converter 6
1.3.2 Input 7
1.3.3 Motor 7
1.3.4 References 7
1.3.5 Miscellaneous 8
1.4 Safety Precautions 10
1.5 CE Labeling 11
1.5.1 Conformity 11
1.5.2 What Is Covered? 11
1.6 Compliance with EMC Directive 2004/1087EC 12
1.7 Approvals 12
1.8 Disposal 12
2 Product Overview and Functions 13
2.1 Galvanic Isolation (PELV) 13
2.1.1 PELV - Protective Extra Low Voltage 13
2.1.2 Ground Leakage Current 14
2.2 Control 14
2.2.1 Control Principle 15
2.2.2 Internal Current Control in VVC+Mode 16
2.3 Control Structures 16
2.3.1 Control Structure in VVC+Advanced Vector Control 16
2.3.2 Control Structure in Flux Sensorless 17
2.3.3 Control Structure in Flux with Motor Feedback 17
2.3.4 Local [Hand On] and Remote [Auto On] Control 18
2.3.5 Programming of Torque Limit and Stop 19
2.4 PID Control 20
2.4.1 Speed PID Control 20
2.4.2 Parameters Relevant for Speed Control 20
2.4.3 Tuning PID Speed Control 22
2.4.4 Process PID Control 23
2.4.5 Process Control Relevant Parameters 24
2.4.6 Example of Process PID Control 25
2.4.7 Programming Order 26
Contents Design Guide
MG04H302 Danfoss A/S © 05/2018 All rights reserved. 1

2.4.8 Process Controller Optimization 27
2.4.9 Ziegler Nichols Tuning Method 28
2.5 Control Cables and Terminals 28
2.5.1 Control Cable Routing 28
2.5.2 DIP Switches 29
2.5.3 Basic Wiring Example 29
2.5.4 Electrical Installation, Control Cables 30
2.5.5 Relay Output 31
2.6 Handling of Reference 32
2.6.1 Reference Limits 33
2.6.2 Scaling of Preset References and Bus References 34
2.6.3 Scaling of Analog and Pulse References and Feedback 34
2.6.4 Dead Band Around Zero 35
2.7 Brake Functions 38
2.7.1 Mechanical Brake 38
2.7.1.1 Mechanical Brake Selection Guide and Electrical Circuit Description 39
2.7.1.2 Mechanical Brake Control 40
2.7.1.3 Mechanical Brake Cabling 42
2.7.1.4 Hoist Mechanical Brake 42
2.7.2 Dynamic Brake 42
2.7.2.1 Brake Resistors 42
2.7.2.2 Selection of Brake Resistor 42
2.7.2.3 Brake Resistors 10 W 43
2.7.2.4 Brake Resistor 40% 43
2.7.2.5 Control with Brake Function 44
2.7.2.6 Brake Resistor Cabling 44
2.8 Safe Torque O 44
2.9 EMC 44
2.9.1 General Aspects of EMC Emissions 44
2.9.2 Emission Requirements 46
2.9.3 Immunity Requirements 47
2.9.4 EMC 48
2.9.4.1 EMC-correct Installation 48
2.9.4.2 Use of EMC-correct Cables 50
2.9.4.3 Grounding of Shielded Control Cables 51
2.9.4.4 RFI Switch 52
2.9.5 Mains Supply Interference/Harmonics 52
2.9.5.1 Eect of Harmonics in a Power Distribution System 53
2.9.5.2 Harmonic Limitation Standards and Requirements 53
2.9.5.3 Harmonic Mitigation 53
Contents VLT®Decentral Drive FCD 302
2 Danfoss A/S © 05/2018 All rights reserved. MG04H302

2.9.5.4 Harmonic Calculation 54
2.9.6 Residual Current Device 54
2.9.7 EMC Test Results 54
3 System Integration 55
3.1 Ambient Conditions 55
3.1.1 Air Humidity 55
3.1.2 Aggressive Environments 55
3.1.3 Vibration and Shock 55
3.1.4 Acoustic Noise 55
3.2 Mounting Positions 55
3.2.1 Mounting Positions for Hygienic Installation 56
3.3 Electrical Input: Mains-side Dynamics 57
3.3.1 Connections 57
3.3.1.1 Cables General 57
3.3.1.2 Connection to Mains and Grounding 57
3.3.1.3 Relay Connection 57
3.3.2 Fuses and Circuit Breakers 58
3.3.2.1 Fuses 58
3.3.2.2 Recommendations 58
3.3.2.3 CE Compliance 58
3.3.2.4 UL Compliance 58
3.4 Electrical Output: Motor-side Dynamics 58
3.4.1 Motor Connection 58
3.4.2 Mains Disconnectors 60
3.4.3 Additional Motor Information 60
3.4.3.1 Motor Cable 60
3.4.3.2 Motor Thermal Protection 60
3.4.3.3 Parallel Connection of Motors 61
3.4.3.4 Motor Insulation 61
3.4.3.5 Motor Bearing Currents 61
3.4.4 Extreme Running Conditions 61
3.4.4.1 Motor Thermal Protection 62
3.5 Final Test and Set-up 63
3.5.1 High-voltage Test 63
3.5.2 Grounding 63
3.5.3 Safety Grounding Connection 63
3.5.4 Final Set-up Check 64
4 Application Examples 65
4.1 Overview 65
Contents Design Guide
MG04H302 Danfoss A/S © 05/2018 All rights reserved. 3

4.2 AMA 65
4.2.1 AMA with T27 Connected 65
4.2.2 AMA without T27 Connected 65
4.3 Analog Speed Reference 65
4.3.1 Voltage Analog Speed Reference 65
4.3.2 Current Analog Speed Reference 66
4.3.3 Speed Reference (Using a Manual Potentiometer) 66
4.3.4 Speed Up/Speed Down 66
4.4 Start/Stop Applications 67
4.4.1 Start/Stop Command with Safe Torque O 67
4.4.2 Pulse Start/Stop 67
4.4.3 Start/Stop with Reversing and 4 Preset Speeds 68
4.5 Bus and Relay Connection 68
4.5.1 External Alarm Reset 68
4.5.2 RS485 Network Connection 69
4.5.3 Motor Thermistor 69
4.5.4 Using SLC to Set a Relay 70
4.6 Brake Application 70
4.6.1 Mechanical Brake Control 70
4.6.2 Hoist Mechanical Brake 71
4.7 Encoder 73
4.7.1 Encoder Direction 73
4.8 Closed-loop Drive System 73
4.9 Smart Logic Control 74
5 Special Conditions 76
5.1 Manual Derating 76
5.1.1 Derating for Low Air Pressure 76
5.1.2 Derating for Running at Low Speed 76
5.1.3 Ambient Temperature 77
5.1.3.1 Power Size 0.37–0.75 kW 77
5.1.3.2 Power Size 1.1–1.5 kW 77
5.1.3.3 Power Size 2.2–3.0 kW 78
5.2 Automatic Derating 78
5.2.1 Sine-Wave Filter Fixed Mode 80
5.2.2 Overview Table 81
5.2.3 High Motor Load 81
5.2.4 High Voltage on the DC link 82
5.2.5 Low Motor Speed 82
5.2.6 High Internal 82
5.2.7 Current 83
Contents VLT®Decentral Drive FCD 302
4 Danfoss A/S © 05/2018 All rights reserved. MG04H302

5.3 Derating for Running at Low Speed 83
6 Type Code and Selection Guide 84
6.1 Type Code Description 84
6.2 Ordering Numbers 85
6.2.1 Ordering Numbers: Accessories 85
6.2.2 Ordering Numbers: Spare Parts 86
6.3 Options and Accessories 87
6.3.1 Fieldbus Options 87
6.3.2 VLT®Encoder Input MCB 102 87
6.3.3 VLT®Resolver Input MCB 103 88
7 Specications 91
7.1 Mechanical Dimensions 91
7.2 Electrical Data and Wire Sizes 92
7.2.1 Overview 92
7.2.2 UL/cUL Approved Pre-fuses 93
7.2.3 VLT®Decentral Drive FCD 302 DC Voltage Levels 93
7.3 General Specications 94
7.4 Eciency 99
7.5 dU/dt Conditions 99
Index 101
Contents Design Guide
MG04H302 Danfoss A/S © 05/2018 All rights reserved. 5

1 Introduction
1.1 How to Read the Design Guide
The design guide provides information required for
integration of the frequency converter in a diversity of
applications.
1.1.1 Additional Resources
•VLT
®
Decentral Drive FCD 302 Operating Guide, for
information required to install and commission
the frequency converter.
•VLT
®
AutomationDrive FC 301/302 Programming
Guide, for information about how to program the
unit, including complete parameter descriptions.
•Modbus RTU Operating Instructions, for the
information required for controlling, monitoring,
and programming the frequency converter via
the built-in Modbus eldbus.
•VLT
®
PROFIBUS Converter MCA 114 Operating
Instructions, VLT
®
EtherNet/IP MCA 121 Installation
Guide, and VLT
®
PROFINET MCA 120 Installation
Guide, for information required for controlling,
monitoring, and programming the frequency
converter via a eldbus.
•VLT
®
Encoder Option MCB 102 Installation
Instructions.
•VLT
®
AutomationDrive FC 300, Resolver Option MCB
103 Installation Instructions.
•VLT
®
AutomationDrive FC 300, Safe PLC Interface
Option MCB 108 Installation Instructions.
•VLT
®
Brake Resistor MCE 101 Design Guide.
•VLT
®
Frequency Converters Safe Torque O
Operating Guide.
•Approvals.
Technical literature and approvals are available online at
www.danfoss.com/en/search/?lter=type%3Adocumentation
%2Csegment%3Adds.
The following symbols are used in this manual:
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.
The following conventions are used in this manual:
•Numbered lists indicate procedures.
•Bullet lists indicate other information and
description of illustrations.
•Italicized text indicates:
-Cross-reference.
-Link.
-Footnote.
-Parameter name.
-Parameter group name.
-Parameter option.
•All dimensions in drawings are in mm (inch).
1.2 Document and Software Version
This manual is regularly reviewed and updated. All
suggestions for improvement are welcome. Table 1.1 shows
the document version and the corresponding software
version.
Edition Remarks Software version
MG04H3xx EMC-correct Installation has been
updated.
7.5x
Table 1.1 Document and Software Version
1.3 Denitions
1.3.1 Frequency Converter
IVLT,MAX
Maximum output current.
IVLT,N
Rated output current supplied by the frequency converter.
UVLT,MAX
Maximum output voltage.
Introduction VLT®Decentral Drive FCD 302
6 Danfoss A/S © 05/2018 All rights reserved. MG04H302
11

1.3.2 Input
Control command
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, coast stop, reset and coast stop, quick stop,
DC brake, stop, the [OFF] key.
Group 2 Start, pulse start, reversing, start reversing, jog,
freeze output.
Table 1.2 Function Groups
1.3.3 Motor
Motor running
Torque generated on output shaft and speed from 0 RPM
to maximum speed on 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
Nominal 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
Instant motor voltage.
UM,N
Rated motor voltage (nameplate data).
Break-away torque
175ZA078.10
Pull-out
RPM
Torque
Illustration 1.1 Break-away Torque
ηVLT
The eciency of the frequency converter is dened as the
ratio between the power output and the power input.
Start-disable command
A stop command belonging to Group 1 control commands
- see Table 1.2.
Stop command
A stop command belonging to Group 1 control commands
- see Table 1.2.
1.3.4 References
Analog reference
A signal transmitted to the analog inputs 53 or 54 (voltage
or current).
Binary reference
A signal transmitted to the serial communication port.
Preset reference
A dened 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
parameter 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
parameter 3-02 Minimum Reference.
Introduction Design Guide
MG04H302 Danfoss A/S © 05/2018 All rights reserved. 7
11

1.3.5 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, -10 V DC 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 brake power increases the DC-link 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.
Hiperface®
Hiperface®is a registered trademark by Stegmann.
Initializing
If initializing is carried out (parameter 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 o-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
(10 ft) from the frequency converter, that is, in a front
panel with the installation kit option.
lsb
Least signicant bit.
msb
Most signicant bit.
MCM
Short for mille circular mil, an American measuring unit for
cable cross-section. 1 MCM=0.5067 mm2.
Online/oine parameters
Changes to online parameters are activated immediately
after the data value is changed. Press [OK] to activate
changes to o-line parameters.
Process PID
The PID control maintains the required speed, pressure,
temperature, and so on, by adjusting the output frequency
to match the varying load.
PCD
Process control data.
Power cycle
Switch o the mains until display (LCP) is dark, then turn
power on again.
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 4 set-ups. Change between the
4 parameter set-ups and edit 1 set-up, while another set-
up is active.
SFAVM
Switching pattern called stator ux-oriented asynchronous
vector modulation (parameter 14-00 Switching Pattern).
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.
SLC
The SLC (smart logic control) is a sequence of user-dened
actions executed when the associated user-dened events
are evaluated as true by the SLC. (See chapter 4.9.1 Smart
Logic Controller).
STW
Status word.
FC standard bus
Includes RS485 bus with FC protocol or MC protocol. See
parameter 8-30 Protocol.
THD
Total harmonic distortion states the total contribution of
harmonic.
Introduction VLT®Decentral Drive FCD 302
8 Danfoss A/S © 05/2018 All rights reserved. MG04H302
11