MAKING MODERN LIVING POSSIBLE Design Guide VLT® AutomationDrive Contents FC 300 Design Guide Contents 1 How to Read this Design Guide 7 1.1.1 Symbols 7 1.1.2 Abbreviations 7 1.1.3 Definitions 8 2 Safety and Conformity 11 2.1 Safety Precautions 11 3 Introduction to FC 300 15 3.1 Product Overview 15 3.2.1 Control Principle 17 3.2.2 FC 300 Controls 17 3.2.3 FC 301 vs. FC 302 Control Principle 18 3.2.4 Control Structure in VVCplus Advanced Vector Control 19 3.2.5 Control Structure in Flux Sensorless (FC 302 only) 20 3.2.6 Control Structure in Flux with Motor Feedback 21 3.2.7 Internal Current Control in VVCplus Mode 22 3.2.8 Local (Hand On) and Remote (Auto On) Control 22 3.3 Reference Handling 23 3.3.1 Reference Limits 24 3.3.2 Scaling of Preset References and Bus References 25 3.3.3 Scaling of Analog and Pulse References and Feedback 25 3.3.4 Dead Band Around Zero 26 3.4 PID Control 30 3.4.1 Speed PID Control 30 3.4.2 Tuning PID Speed Control 31 3.4.3 Process PID Control 32 3.4.4 Example of Process PID Control 34 3.4.5 Ziegler Nichols Tuning Method 35 3.5 General Aspects of EMC 37 3.5.1 General Aspects of EMC Emissions 37 3.5.2 EMC Test Results 38 3.5.3 Emission Requirements 39 3.5.4 Immunity Requirements 40 3.6.1 PELV - Protective Extra Low Voltage 41 3.8 Brake Functions in FC 300 42 3.8.1 Mechanical Holding Brake 42 3.8.2 Dynamic Braking 43 3.8.3 Selection of Brake Resistor 43 MG.33.BD.02 - VLT® is a registered Danfoss trademark 1 Contents FC 300 Design Guide 3.9.1 Mechanical Brake Control 45 3.9.2 Hoist Mechanical Brake 46 3.9.3 Brake Resistor Cabling 47 3.10 Smart Logic Controller 47 3.11 Extreme Running Conditions 49 3.11.1 Motor Thermal Protection 49 3.12 Safe Stop of FC 300 51 3.12.2 Installation of External Safety Device in Combination with MCB 112 56 3.12.3 Safe Stop Commissioning Test 57 3.13 Certificates 58 4 FC 300 Selection 60 4.1 Electrical Data - 200-240V 60 4.2 Electrical Data - 380-500V 63 4.3 Electrical Data - 525-600V 71 4.4 Electrical Data - 525-690V 74 4.5 General Specifications 85 4.7.1 Acoustic Noise 90 4.8.1 du/dt Conditions 91 4.9 Special Conditions 94 4.9.1 Manual Derating 94 4.6.1.1 Derating for Running at Low Speed 94 4.9.2 Automatic Derating 94 5 How to Order 95 5.1.1 Ordering from Type Code 95 5.1.2 Drive Configurator 95 5.2.1 Ordering Numbers: Options and Accessories 99 5.2.2 Ordering Numbers: Spare Parts 100 5.2.3 Ordering Numbers: Accessory Bags 100 5.2.4 Ordering Numbers: High Power Kits 101 5.2.5 Ordering Numbers: Brake Resistors 10% 101 5.2.6 Ordering Numbers: Brake Resistors 40% 106 5.2.7 Flat Packs 111 5.2.8 Ordering Numbers: Harmonic Filters 113 5.2.9 Ordering Numbers: Sine Wave Filter Modules, 200-500 VAC 115 5.2.10 Ordering Numbers: Sine-Wave Filter Modules, 525-690 VAC 116 5.2.11 Ordering Numbers: du/dt Filters, 380-480/500V AC 116 5.2.12 Ordering Numbers: du/dt Filters, 525-690V AC 116 6 Mechanical Installation - Frame Size A, B and C 117 2 MG.33.BD.02 - VLT® is a registered Danfoss trademark Contents FC 300 Design Guide 6.1.1 Safety Requirements of Mechanical Installation 117 6.1.2 Mechanical Mounting 120 7 Mechanical Installation - Frame size D, E and F 121 7.1 Pre-installation 121 7.1.1 Planning the Installation Site 121 7.1.2 Receiving the Frequency Converter 121 7.1.3 Transportation and Unpacking 121 7.1.4 Lifting 121 7.1.5 Mechanical Dimensions 123 7.1.6 Mechanical Dimensions, 12-Pulse Units 130 7.2 Mechanical Installation 133 7.2.1 Tools Needed 133 7.2.2 General Considerations 133 7.2.3 Terminal Locations - Frame size D 135 7.2.4 Terminal Locations - Frame size E 137 7.2.5 Terminal Locations - Frame size F 142 7.2.6 Terminal Locations, F8-F13 - 12-Pulse 146 7.2.7 Cooling and Airflow 151 7.2.8 Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units 152 7.2.9 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 153 7.2.10 Gland/Conduit Entry, 12-Pulse - IP21 (NEMA 1) and IP54 (NEMA12) 154 7.2.11 IP21 Drip Shield Installation (Frame size D1 and D2 ) 156 8 Electrical Installation 157 8.1 Connections- Frame Sizes A, B and C 157 8.1.1 Removal of Knockouts for Extra Cables 158 8.1.2 Connection to Mains and Earthing 158 8.1.3 Motor Connection 160 8.1.4 Relay Connection 168 8.2 Connections - Frame Sizes D, E and F 169 8.2.1 Torque 169 8.2.2 Power Connections 169 8.2.3 Power Connections 12-Pulse Drives 180 8.2.4 Shielding against Electrical Noise 189 8.2.5 External Fan Supply 189 8.3 Fuses and Circuit Breakers 190 8.3.1 Recommendations 190 8.3.2 CE Compliance 191 8.4 Disconnectors and Contactors 203 8.4.1 Mains Disconnectors 203 MG.33.BD.02 - VLT® is a registered Danfoss trademark 3 Contents FC 300 Design Guide 8.4.4 F-Frame Mains Contactors 205 8.5 Additional Motor Information 206 8.5.1 Motor Cable 206 8.5.2 Motor Thermal Protection 206 8.5.3 Parallel Connection of Motors 206 8.5.5 Motor Bearing Currents 208 8.6 Control Cables and Terminals 209 8.6.1 Access to Control Terminals 209 8.6.2 Control Cable Routing 209 8.6.3 Control Terminals 210 8.6.4 Switches S201, S202, and S801 211 8.6.5 Electrical Installation, Control Terminals 211 8.6.6 Basic Wiring Example 212 8.6.7 Electrical Installation, Control Cables 213 8.6.8 12-Pulse Control Cables 215 8.6.9 Relay Output 218 8.6.10 Brake Resistor Temperature Switch 218 8.7 Additional Connections 218 8.7.1 DC Bus Connection 218 8.7.2 Load Sharing 218 8.7.3 Installation of Brake Cable 219 8.7.4 How to Connect a PC to the Frequency Converter 219 8.7.5 The FC 300 PC Software 219 8.8.1 High Voltage Test 220 8.8.2 Earthing 220 8.8.3 Safety Earth Connection 220 8.9 EMC-correct Installation 220 8.9.1 Electrical Installation - EMC Precautions 220 8.9.2 Use of EMC-Correct Cables 222 8.9.3 Earthing of Screened Control Cables 224 8.9.4 RFI Switch 224 8.10.1 Mains Supply Interference/Harmonics 225 8.10.2 The Effect of Harmonics in a Power Distribution System 225 8.10.3 Harmonic Limitation Standards and Requirements 226 8.10.4 Harmonic Mitigation 226 8.10.5 Harmonic Calculation 226 8.11 Residual Current Device - FC 300 DG 226 8.12 Final Setup and Test 227 9 Application Examples 228 9.1.1 Encoder Connection 233 4 MG.33.BD.02 - VLT® is a registered Danfoss trademark Contents FC 300 Design Guide 9.1.2 Encoder Direction 233 9.1.3 Closed Loop Drive System 233 9.1.4 Programming of Torque Limit and Stop 233 10 Options and Accessories 235 10.1.1 Mounting of Option Modules in Slot A 235 10.1.2 Mounting of Option Modules in Slot B 235 10.1.3 Mounting of Options in Slot C 236 10.2 General Purpose Input Output Module MCB 101 236 10.2.1 Galvanic Isolation in the MCB 101 236 10.2.2 Digital Inputs - Terminal X30/1-4: 238 10.2.3 Analog Inputs - Terminal X30/11, 12: 238 10.2.4 Digital Outputs - Terminal X30/6, 7: 238 10.2.5 Analog Output - Terminal X30/8: 238 10.3 Encoder Option MCB 102 239 10.4 Resolver Option MCB 103 240 10.5 Relay Option MCB 105 241 10.6 24V Back-Up Option MCB 107 243 10.7 MCB 112 PTC Thermistor Card 244 10.8 MCB 113 Extended Relay Card 246 10.9 Brake Resistors 247 10.10 LCP Panel Mounting Kit 247 10.11 IP21/IP 4X/ TYPE 1 Enclosure Kit 248 10.12 Mounting Bracket for Frame Size A5, B1, B2, C1 and C2 251 10.13 Sine-wave Filters 253 10.14 High Power Options 253 10.14.1 Frame Size F Options 253 11 RS-485 Installation and Set-up 255 11.1 Overview 255 11.2 Network Connection 255 11.3 Bus Termination 255 11.4.1 EMC Precautions 256 11.5 Network Configuration 256 11.5.1 FC 300 Frequency Converter Set-up 256 11.6 FC Protocol Message Framing Structure - FC 300 257 11.6.1 Content of a Character (byte) 257 11.6.2 Telegram Structure 257 11.6.3 Length (LGE) 257 11.6.4 Frequency Converter Address (ADR) 257 MG.33.BD.02 - VLT® is a registered Danfoss trademark 5 Contents FC 300 Design Guide 11.6.5 Data Control Byte (BCC) 257 11.6.6 The Data Field 257 11.6.7 The PKE Field 258 11.6.8 Parameter Number (PNU) 259 11.6.9 Index (IND) 259 11.6.10 Parameter Value (PWE) 259 11.6.11 Data Types Supported by FC 300 260 11.6.12 Conversion 260 11.6.13 Process Words (PCD) 261 11.7 Examples 261 11.7.1 Writing a Parameter Value 261 11.7.2 Reading a Parameter Value 261 11.8 Modbus RTU Overview 261 11.8.1 Assumptions 261 11.8.2 What the User Should Already Know 261 11.8.3 Modbus RTU Overview 261 11.8.4 Frequency Converter with Modbus RTU 262 11.9.1 Frequency Converter with Modbus RTU 262 11.10 Modbus RTU Message Framing Structure 262 11.10.1 Frequency Converter with Modbus RTU 262 11.10.2 Modbus RTU Message Structure 262 11.10.3 Start/Stop Field 263 11.10.4 Address Field 263 11.10.5 Function Field 263 11.10.6 Data Field 263 11.10.7 CRC Check Field 263 11.10.8 Coil Register Addressing 264 11.10.9 How to Control the Frequency Converter 266 11.10.10 Function Codes Supported by Modbus RTU 266 11.10.11 Modbus Exception Codes 266 11.11 How to Access Parameters 266 11.11.1 Parameter Handling 266 11.11.2 Storage of Data 266 11.11.3 IND 266 11.11.4 Text Blocks 266 11.11.5 Conversion Factor 267 11.11.6 Parameter Values 267 11.12 Danfoss FC Control Profile 267 Index 275 6 MG.33.BD.02 - VLT® is a registered Danfoss trademark How to Read this Design Gui... FC 300 Design Guide 1 1 1 How to Read this Design Guide This Design Guide will introduce all aspects of your FC 300. * Indicates default setting 1.1.2 Abbreviations Available literature for FC 300 - The VLT AutomationDrive Operating Instructions MG.33.AX.YY provide the neccessary information Alternating current AC for getting the drive up and running. American wire gauge AWG Ampere/AMP A - The VLT AutomationDrive High Power Operating Instructions MG.33.UX.YY Automatic Motor Adaptation AMA Current limit ILIM - The VLT AutomationDrive Design Guide MG. Degrees Celsius °C 33.BX.YY entails all technical information about Direct current DC the drive and customer design and applications. Drive Dependent D-TYPE - The VLT AutomationDrive Programming Guide Electro Magnetic Compatibility EMC MG.33.MX.YY provides information on how to Electronic Thermal Relay ETR programme and includes complete parameter frequency converter FC descriptions. Gram g - The VLT AutomationDrive Profibus Operating Hertz Hz Instructions MG.33.CX.YY provide the information Horsepower hp required for controlling, monitoring and Kilohertz kHz programming the drive via a Profibus fieldbus. Local Control Panel LCP - The VLT AutomationDrive DeviceNet Operating Meter m Instructions MG.33.DX.YY provide the information Millihenry Inductance mH required for controlling, monitoring and Milliampere mA programming the drive via a DeviceNet fieldbus. Millisecond ms X = Revision number Minute min YY = Language code Motion Control Tool MCT Nanofarad nF Danfoss Drives technical literature is also available online Newton Meters Nm at www.danfoss.com/BusinessAreas/DrivesSolutions/ Nominal motor current IM,N Documentations/Technical+Documentation. Nominal motor frequency fM,N Nominal motor power PM,N 1.1.1 Symbols Nominal motor voltage UM,N Parameter par. Symbols used in this guide. Protective Extra Low Voltage PELV Printed Circuit Board PCB NOTE Rated Inverter Output Current IINV Indicates something to be noted by the reader. Revolutions Per Minute RPM Regenerative terminals Regen CAUTION Second sec. Synchronous Motor Speed ns Indicates a potentially hazardous situation which, if not Torque limit TLIM avoided, may result in minor or moderate injury or Volts V equipment damage. The maximum output current IVLT,MAX The rated output current supplied by the IVLT,N WARNING frequency converter Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. MG.33.BD.02 - VLT® is a registered Danfoss trademark 7 How to Read this Design Gui... FC 300 Design Guide 1 1 1.1.3 Definitions Frequency converter: PM,N Coast The rated motor power (nameplate data). The motor shaft is in free mode. No torque on motor. IMAX TM,N The maximum output current. The rated torque (motor). IN The rated output current supplied by the frequency UM The instantaneous motor voltage. converter. UMAX UM,N The maximum output voltage. The rated motor voltage (nameplate data). Input: Control command Break-away torque Start and stop the connected motor by means of LCP and the digital inputs. Torque Functions are divided into two groups. 0 1 Pull-out 78. Functions in group 1 have higher priority than functions in 0 A Z group 2. 75 1 Group 1 Reset, Coasting stop, Reset and Coasting stop, Quick-stop, DC braking, Stop and the "Off" key. Group 2 Start, Pulse start, Reversing, Start reversing, Jog and Freeze output Motor: fJOG The motor frequency when the jog function is activated (via digital terminals). rpm fM Motor frequency. Output from the frequency converter. Output frequency is related to the shaft speed on motor η depending on number of poles and slip frequency. The efficiency of the frequency converter is defined as the ratio between the power output and the power input. fMAX The maximum output frequency the frequency converter Start-disable command applies on its output. The maximum output frequency is A stop command belonging to the group 1 control set in limit par. 4-12, 4-13 and 4-19. commands - see this group. fMIN The minimum motor frequency from frequency converter. Stop command Default 0 Hz. See Control commands. fM,N The rated motor frequency (nameplate data). References: IM Analog Reference The motor current. An analog signal applied to input 53 or 54. The signal can be either Voltage 0-10V (FC 301 and FC 302) or -10 -+10V IM,N (FC 302). Current signal 0-20 mA or 4-20 mA. The rated motor current (nameplate data). Binary Reference nM,N A signal applied to the serial communication port (RS-485 The rated motor speed (nameplate data). term 68 – 69). ns Preset Reference Synchronous motor speed A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references 2×par. 1−23×60 s via the digital terminals. n = s par. 1−39 8 MG.33.BD.02 - VLT® is a registered Danfoss trademark How to Read this Design Gui... FC 300 Design Guide 1 1 Pulse Reference Intermittent Duty Cycle A pulse reference applied to term 29 or 33, selected by An intermittent duty rating refers to a sequence of duty par. 5-13 or 5-15 [32]. Scaling in par. group 5-5*. cycles. Each cycle consists of an on-load and an off-load period. The operation can be either periodic duty or non- RefMAX periodic duty. Determines the relationship between the reference input at 100% full scale value (typically 10V, 20mA) and the LCP resulting reference. The maximum reference value set in The Local Control Panel makes up a complete interface for 3-03 Maximum Reference. control and programming of the frequency converter. The control panel is detachable and can be installed up to 3 RefMIN metres from the frequency converter, i.e. in a front panel Determines the relationship between the reference input by means of the installation kit option. at 0% value (typically 0V, 0mA, 4mA) and the resulting reference. The minimum reference value set in NLCP 3-02 Minimum Reference. Numerical Local Control Panel interface for control and programming of frequency converter. The display is Miscellaneous: numerical and the panel is basically used for display Analog Inputs process values. The NLCP has no storing and copy The analog inputs are used for controlling various function. functions of the frequency converter. There are two types of analog inputs: lsb Current input, 0-20mA and 4-20mA Least significant bit. Voltage input, 0-10V DC (FC 301) msb Voltage input, -10 - +10V DC (FC 302). Most significant bit. Analog Outputs MCM The analog outputs can supply a signal of 0-20mA, Short for Mille Circular Mil, an American measuring unit for 4-20mA. cable cross-section. 1 MCM = 0.5067 mm2. Automatic Motor Adaptation, AMA On-line/Off-line Parameters AMA algorithm determines the electrical parameters for Changes to on-line parameters are activated immediately the connected motor at standstill. after the data value is changed. Changes to off-line Brake Resistor parameters are not activated until you enter [OK] on the The brake resistor is a module capable of absorbing the LCP. brake power generated in regenerative braking. This Process PID regenerative braking power increases the intermediate The PID regulator maintains the desired speed, pressure, circuit voltage and a brake chopper ensures that the temperature, etc. by adjusting the output frequency to power is transmitted to the brake resistor. match the varying load. CT Characteristics PCD Constant torque characteristics used for all applications Process Data such as conveyor belts, displacement pumps and cranes. Pulse Input/Incremental Encoder Digital Inputs An external digital sensor used for feedback information of The digital inputs can be used for controlling various motor speed and direction. Encoders are used for high functions of the frequency converter. speed accuracy feedback and in high dynamic applications. Digital Outputs The encoder connection is either via term 32 and 32 or The frequency converter features two Solid State outputs encoder option MCB 102. that can supply a 24V DC (max. 40mA) signal. RCD DSP Residual Current Device. Digital Signal Processor. Set-up ETR You can save parameter settings in four Set-ups. Change Electronic Thermal Relay is a thermal load calculation between the four parameter Set-ups and edit one Set-up, based on present load and time. Its purpose is to estimate while another Set-up is active. the motor temperature. SFAVM Hiperface® Switching pattern called Stator Flux oriented Asynchronous Hiperface® is a registered trademark by Stegmann. Vector Modulation (14-00 Switching Pattern). Initialising Slip Compensation If initialising is carried out (14-22 Operation Mode), the The frequency converter compensates for the motor slip frequency converter returns to the default setting. by giving the frequency a supplement that follows the MG.33.BD.02 - VLT® is a registered Danfoss trademark 9