Danfoss VLT® AutomationDrive User guide

FC 300 Design Guide

Contents

! How to Read this Design Guide .................................................. 5

" How to Read this Design Guide .................................................................. 5

" Approvals ............................................................................................... 7

" Symbols ................................................................................................. 7

" Abbreviations .......................................................................................... 8

" Definitions ............................................................................................. 8

" Power Factor ......................................................................................... 13

! Introduction to FC 3 0 0 ................................................................. 15

" Software Version ................................................................................... 15

" CE Conformity and Labe lling .................................................................... 15

" What Is Covered .................................................................................... 16

" Danfoss VLT Frequency Converter and CE Labelling .................................... 16

" Compliance with EMC Directive 89/336/EEC ............................................... 17

" Mechanical Build-Up ............................................................................... 17

" Air Humidity .......................................................................................... 18

" Aggressive Environments ........................................................................ 18

" Vibration and Shock ............................................................................... 19

" Control Principle .................................................................................... 19

" FC 300 Controls ..................................................................................... 19

" Control Structure in VVC

plus

..................................................................... 20

" Control Structure in Flux Sensorless ......................................................... 21

" Control Structure in Flux with Motor Feedback ........................................... 22

" Local (Hand On) and Remote (Auto On) Control ......................................... 23

" Reference Handling ................................................................................ 25

" Scaling of References and Feedback ......................................................... 26

" Analog Reference with Dead Band ............................................................ 26

" DigiPot Function .................................................................................... 31

" Automatic Motor Adaptation (AMA) ........................................................... 31

" Control of Mechanical Brake .................................................................... 32

" Speed PID Control ................................................................................ 33

" The following parameters are relevant for the Speed Control ........................ 33

" Process PID Control ............................................................................... 36

" Ziegler Nichols Tuning Method ................................................................. 40

" Internal Current Regulator ...................................................................... 41

" Programming of Torque Limit and Stop .................................................... 41

" Parameter Download .............................................................................. 42

" General Aspects of EMC E missions ............................................................ 42

" EMC Test Results (Emission, Immunity) .................................................... 44

" Required Compliance Levels .................................................................... 45

" EMC Immunity ...................................................................................... 45

" Selection of Brake Resistor ...................................................................... 47

" Control with Brake Function ..................................................................... 48

" Smart Logic Control ............................................................................... 48

" Galvanic Isolation (PELV) ........................................................................ 49

" Earth Leakage Current ............................................................................ 50

" Extreme Running Conditions .................................................................... 50

" Motor Thermal Protection ........................................................................ 51

" Acoustic Noise ....................................................................................... 51

" Safe Stop of FC 302 ............................................................................... 52

" Safe Stop Operation ............................................................................... 52

" General Specifications ............................................................................ 54

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FC 300 Design Guide

! How to Select Your VLT ............................................................... 59

" Peak Voltage on Motor ............................................................................ 59

" Derating for Ambient Temperature ........................................................... 59

" Derating for Air Pressure ......................................................................... 60

" Derating for Running at Low Speed .......................................................... 60

" Derating for Installing Long Motor Cables or Cables with Larger Cross-Section 60

" Temperature-Dependent Switch Frequency ................................................ 61

" Options and Accessories ......................................................................... 61

" Encoder Option MCB 102 ........................................................................ 61

" Relay Option MCB 105 ............................................................................ 64

" 24 V Back-Up Option (Option D) .............................................................. 66

" Brake Resistors ..................................................................................... 66

" Remote mounting Kits for LCP ................................................................. 67

" External 24 V DC Supply ......................................................................... 67

" IP 21/IP 4X/ TYPE 1 Enclosure Kit ............................................................ 67

" LC Filters .............................................................................................. 67

" Ordering Numbers ................................................................................. 68

" Electrical Data ....................................................................................... 72

" Efficiency .............................................................................................. 75

! How to Order .................................................................................... 77

" Drive Configurator ................................................................................. 77

" Ordering Form Type Code ........................................................................ 78

! How to Install .................................................................................. 81

" Mechanical Installation ........................................................................... 81

" Accessory Bag ....................................................................................... 81

" IP 21/Type 1 Enclosure Kit ...................................................................... 81

" Safety Requirements of Mechanical Installation .......................................... 84

" Field Mounting ....................................................................................... 84

" Electrical Installation .............................................................................. 84

" Connection to Mains and Earthing ............................................................ 84

" Motor Connection ................................................................................... 86

" Motor Cables ......................................................................................... 87

" Thermal Motor Protection ....................................................................... 88

" Electrical Installation of Motor Cables ........................................................ 88

" Fuses ................................................................................................... 89

" Access to Control Terminals ..................................................................... 91

" Electrical Installation, Control Terminals .................................................... 91

" Control Terminals ................................................................................... 92

" Electrical Installation, Control Cables ........................................................ 93

" Switches S201, S202, and S801 .............................................................. 94

" Tightening Torque .................................................................................. 94

" Final Set-Up and Test ............................................................................. 95

" Safe Stop Installation ............................................................................. 97

" Safe Stop Commissioning Test ................................................................. 98

" Additional Connections ........................................................................... 99

" Load Sharing ......................................................................................... 99

" Installation of Loadsharing ...................................................................... 99

" Brake Connection Option ........................................................................ 99

" Relay Connection .................................................................................. 100

" Relay Output ........................................................................................ 101

" Control of Mechanical Brake ................................................................... 101

" Parallel Connection of Motors .................................................................. 102

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FC 300 Design Guide

" Direction of Motor Rotation ..................................................................... 102

" Motor Thermal Protection ....................................................................... 102

" Installation of Brake Cable ..................................................................... 103

" Bus Connection .................................................................................... 103

" How to Connect a PC to the FC 300 ......................................................... 104

" The FC 300 Software Dialogue ................................................................ 104

" High Voltage Test .................................................................................. 105

" Safety Earthing .................................................................................... 105

" Electrical Installation - EMC Precautions ................................................... 105

" Use of EMC-Correct Cables ..................................................................... 106

" Earthing of Screened/Armoured Control Cables ......................................... 108

" Mains Supply Interference/Harmonics ...................................................... 109

" Residual Current Device ......................................................................... 109

! Application E xam p les .................................................................. 111

" Encoder Connection .............................................................................. 111

" Encoder Direction ................................................................................. 112

" Closed Loop Drive System ...................................................................... 112

" Smart Logic Control

Programming 01 ................................................................................... 113

! How to Programme ....................................................................... 117

" The FC 300 Local Control Panel ............................................................... 117

" How to Programme on the Local Control Panel .......................................... 117

" Quick Transfer of Parameter Settings ....................................................... 119

" Control Panel - Display .......................................................................... 120

" Control Panel - LEDs .............................................................................. 120

" Control Panel - Control Keys ................................................................... 120

" Control Key Functions ............................................................................ 121

" Local Control Key Functions .................................................................... 122

" Display Mode ....................................................................................... 123

" Display Mode - Selection of Read-Outs ..................................................... 123

" Parameter Set-Up ................................................................................. 124

" Quick Menu Key Functions ...................................................................... 124

" Main Menu Mode ................................................................................... 125

" Parameter Selection .............................................................................. 125

" Changing Data ..................................................................................... 126

" Changing a Text Value ........................................................................... 126

" Changing a Group of Numeric Data Values ................................................ 126

" Infinitely Variable Change of Numeric Data Value ...................................... 127

" Changing of Data Value, Step-by-Step ..................................................... 127

" Read-out and Programming of Indexed Parameters ................................... 127

" Initialisation to Default Settings .............................................................. 127

" Start/Stop ........................................................................................... 128

" Pulse Start/Stop ................................................................................... 128

" Potentiometer Reference ........................................................................ 129

" Setting up FC 302 ................................................................................. 129

" Quick Menu Parameters ........................................................................ 130

" Parameters: Operation and Display ......................................................... 131

" Parameters: Load and Motor .................................................................. 137

" Parameters: Brakes .............................................................................. 147

" Parameters: Reference/Ramps ............................................................... 150

" Parameters: Limits/Warnings ................................................................. 158

" Parameters: Digital In/Out ..................................................................... 161

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FC 300 Design Guide

" Parameters: Analog In/Out .................................................................... 170

" Parameters: Controllers ......................................................................... 173

" Parameters: Communications and Options ............................................... 176

" Parameters: Profibus ............................................................................ 180

" Parameters: DeviceNet CAN Fieldbus ....................................................... 186

" Parameters: Smart Logic Control ............................................................ 190

" Parameters: Special Functions ................................................................ 200

" Parameters: Drive Information ............................................................... 204

" Parameters: Data Read-outs .................................................................. 209

" Parameters: EncoderInput ..................................................................... 214

" Parameter Lists .................................................................................... 215

" Protocols ............................................................................................. 232

" Telegram Traffic .................................................................................... 232

" Telegram Structure ............................................................................... 232

" Data Character (byte) ........................................................................... 234

" Process Words ...................................................................................... 239

" Control Word According to FC Profile (CTW) .............................................. 239

" Status Word According to FC Profile (STW) ............................................... 242

" Control Word according to PROFIdrive Profile (CTW ) .................................. 244

" Status Word According to PROFIdrive Profile (STW) ................................... 247

" Serial Communication Reference ............................................................. 249

" Present Output Frequency ...................................................................... 250

" Example 1: For Controlling the D rive and Reading Parameters .................... 25 0

" Example 2: Only for Controlling t he Drive ................................................ 25 1

" Read Parameter Description Elements ...................................................... 251

" Additional Text ..................................................................................... 256

! Troubleshooting ............................................................................. 257

" Warnings/Alarm Messages ..................................................................... 257

! Index .................................................................................................. 263

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FC 300 Design Guide

How to Read this D esign Guide

" How to Read this Design Guide

This Design Guide will introduce all aspect s of your FC 300

.

Chapter 1, How to Read this Design Guide,

introduces the design guide and informs you

about the approvals, symbols, and abbreviati

ons

used in this manual.

Page divider for How to Read this Design Guide.

Chapter 2, Introduction to FC 300,informs

you about available fe

atures and instructions on

how to handle the FC 300 correctly.

Page divider for Introduction to FC 300.

Chapter 3, How to Select Your VLT,showsyou

how to select the right FC 300 model for your plant.

Page divider for How to S elect Your VLT.

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FC 300 Design Guide

How to Read this Design Guide

Chapter 4, How to Order, supp lies the information

needed for ordering your FC 300.

Page divider for How to Order.

Chapter 5, How t o Install , guides you through

mechanical and elec trical installation.

Page divider for How to Install

Chapter 6, How to Programme,showsyou

how to op erate and programme the FC 300

via the Local Control Panel.

Page divider for How to Programme.

Chapter 7, Troubleshooting, assists you in solving

problems that may occur when using FC 300.

Page divider for Troubleshooting.

Available literature for FC 300

- The VLT

®

AutomationDrive FC 300 Operating Instructions MG.33.AX.YY provide the

neccessary information for getting the drive up a nd running.

- The VLT

®

AutomationDrive FC 300 De sign Guide M G.33.BX.YY entails all technical information

about the drive and customer design and applications.

- The VLT

®

AutomationDrive FC 30 0 Profibus Operating Instructions MG.33.CX.YY provide the information

required for controlling, monitoring and programming the drive via a Profibus fieldbus.

- The VLT

®

AutomationDrive FC 300 DeviceNet Operating Instructions MG.33.DX.YY provide th e information

required for controlling, m onitoring and programming the drive via a DeviceNet fieldbus.

Danfoss Drives technical literature is also available online at ww w.danfoss.com/drives.

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FC 300 Design Guide

How to Read this Design Guide

" Approvals

" Symbols

SymbolsusedinthisDesignGuide.

NB!:

Indicates something to be no ted by the reader.

Indicates a general warning.

Indicates a hig h -voltage warning.

Indicates default setting

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FC 300 Design Guide

How to Read this Design Guide

" Abbreviations

Alternating curre nt AC

American wire gauge AWG

Ampere/AMP A

Autom atic Motor Adaptation AMA

Current limit I

LIM

Degrees celcius °C

Direct current DC

Drive Dependent D-TYPE

Electronic Thermistor Relay ETR

Frequency Converter FC

Gram g

Hertz Hz

Kilohertz kHz

Local Control Panel LCP

Meter m

Milliampere mA

Millisecond ms

Minute min

Motion Control Tool MCT

Motor Type Dependent M-TYPE

Nanofarad nF

Newton Meters Nm

Nominal motor current I

M,N

Nominal motor frequency f

M,N

Nominal motor pow e r P

M,N

Nominal motor voltage U

M,N

Parameter par.

Rated Inverter Output Current I

INV

Revolutions Per Minute RPM

Second s

Torque limit T

LIM

Volts V

" Definitions

Drive:

D

-TYPE

Size a nd type of the connec ted drive (dependencies ) .

I

VLT,MAX

The maximum output current.

I

VLT,N

The rated output current supplied by the frequency converter.

U

VLT MAX

The maximum output voltage.

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FC 300 Design Guide

How to Read this Design Guide

Input:

C

ontrol command

You can start and stop the connected motor by

means of LCP and the digital inputs.

Functions are divided into two 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 the "Off" key.

Group 2 Start, Pulse start, Reversing,

Start reversing, Jog and Freeze

output

Motor:

f

JOG

The m otor frequency when the jog function is activated (via digital terminals).

f

M

The motor frequency.

f

MAX

The maximum motor fre quenc y.

f

MIN

The minimum motor frequency.

f

M,N

The rated m otor frequency (nameplate data).

I

M

The mo tor current.

I

M,N

The rated motor current (nameplate data).

M

-TYPE

Size and type of the connected motor (dependencies).

n

M,N

The rated motor speed (nameplate data).

P

M,N

The rated motor power (nameplate data).

T

M,N

The rated torque (motor).

U

M

The instantaneous motor voltage.

U

M,N

The rated motor voltage (nameplate data).

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FC 300 Design Guide

How to Read this Design Guide

Break-away torque

η

VLT

The efficiency of the frequency converter is defined as the ratio between the power output and the power input.

S

tart-disabl e command

A stop command belonging to the group 1 control commands - see this group.

S

top command

See Control comma nds.

References:

A

nalog Reference

A signal transmitted to the analog inputs 53 or 54, can be voltage or current.

B

inary Reference

A signal transmitted to the serial communication port.

P

reset Reference

A defined preset reference to be set from

-100% to +100% of the reference range. S ele ction

of eight prese t references via the digit al terminals.

P

ulse Reference

A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33).

R

ef

MAX

Determines the relationship betwe

en the refere n ce input at 100% full scale value (typically 10 V, 20mA)

and the resulting reference. The maximum reference value set in par. 3-03.

R

ef

MIN

Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4m A) and

the resulting reference. The

minimum reference value set in par. 3-02.

Miscellaneous:

A

nalog In

puts

The analog inputs are used for controlling various functions of the frequency converter.

There are two types of analog inputs:

Current inp

ut, 0-20 mA

Voltage input, 0 -10 V DC.

A

nalog Outpu ts

The analog outputs ca n supply a signal of 0-20 m A, 4-20 mA, or a digital signal.

A

utomatic Motor Ada p tation, AMA

AMA algorit

hm determines the electrical parameters for the connected motor at standstill.

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FC 300 Design Guide

How to Read this Design Guide

Brake Resisto r

The brake resistor is a module capable of absorbing the brake power generated in regenerative

braking. This regenerative braking pow er increases the inte rm ediate circuit voltage and a brake

chopper ensur es that the power is transmitted to the brake resistor.

C

T Characteristics

Constant torque characteristics used for all applications such as conveyor belts and cranes.

D

igital Inputs

The digital inputs can b e used for cont rolling various functions of the frequency converter.

D

igital Outputs

The dri ve featyres two Solid State o utp u ts that can supply a 24 V DC (max. 40 mA) signal.

D

SP

DigitalSignalProcessor.

Relay Outputs:

The drive features two p rogrammable Relay Outputs.

E

TR

Electronic Thermal Relay is a thermal load calculation based on present load and time.

Its p u rpose is to estimate the motor temperature.

H

iperface

®

Hiperface

®

is a registered trademark by Stegmann.

I

nitialising

If initialising is carried out (par. 14-22), the frequency converter returns

to the default setting.

I

ntermittent Duty Cycle

An intermittent duty rating refers to a seque nce of duty cycles. Each cycle consists of an on-load a nd

an off-load peri od. The operation can be eithe r periodic duty or none-periodic duty.

L

CP

The Local Control Panel (LCP) makes up a complete interface for contr

ol and programming of the FC

300 Series. The control panel is detachable and can be installed up to 3 metres from the freq u ency

converter, i.e. in a front panel by means of the installation kit o ption.

l

sb

Least significant bit.

M

CM

Short for M ille C ircular Mil, an American measuring unit for cable cross-se ction. 1 MCM ≡ 0.5067 mm

2

.

m

sb

Most significant bit.

O

n-line/Off-line Parameters

Changes to on-line parameters are activated immediate

ly after the data value is changed. Changes

to off-line parameters are not activated until you enter [ OK] on the LCP.

P

rocess PID

The PI D regula tor mainta ins the desired speed, pressure, temperature, etc. by adjusting

the output frequency to match the varying load.

P

ulse Input/Incremental Encoder

An external, digital pulse transmitter used for fe eding back information on motor speed. The encoder

is used in applications where grea t accuracy in speed control is required.

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FC 300 Design Guide

How to Read this Design Guide

RCD

Residual Current Device.

S

et-up

You can save parameter settings in four Set-ups. C hange between the four parameter

Set-ups and edit one Set-up, while another Set-up is active.

S

FAVM

Switching pattern called S tator F lux oriented A synchronous V ector M odulation (pa r. 14-00).

S

lip Compensation

The frequency converter compensates for the motor slip by giving t h e frequency a

supplement that follows the measured motor load.

S

mart Logi c Control (SLC)

The SLC is a sequence of user defined actions executed when the associa ted user defined

events are evaluated as true by the SLC.

T

hermistor:

A temperature-dependent resistor placed where the temperature is to be moni-

tored (frequency converter or motor).

T

rip

A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature. Restart

is prevented until the cause of the fault has disapp eare d and the trip state is cancelle

dbyactivatingresetor,

in s ome cases, by being programmed to reset automatically. Trip may not be used for personal safety.

T

rip Locked

A state en tere d in fault situations requiring physical intervention, e.g. if the f requency converter is subject to a

short circuit on the output. A locked trip can be cancelled by cutting off m

ains, removing the cause of the fault,

and rec onnecting the frequency converter. Restart is prevented until the trip sta te is cancelle d by activating

reset o r, in some cases, by being programmed to re set automatically. Trip may not be used for personal safety.

V

T Characteristics

Variable torque characteristics used for pumps and fans.

V

VC

plus

If compared with standard voltage/frequency ratio control, Voltage Vector Control (VVC

plus

)improvesthe

dynamics a n d the stability, both when the speed reference is changed and in relation to the loa d torque.

6

0° AVM

Switching patt ern called 60° A synchronous V ector M odu

lation (p ar. 14-00 ).

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FC 300 Design Guide

How to Read this Design Guide

" Power F actor

The power factor is the relation between I

1

and I

RMS

.

The power factor for 3-phase control:

The power factor indicates to w hich extent

the frequency converter imposes a load

on the mains supply.

The lower the power factor, the higher the I

RMS

for the same kW performance.

In addition, a high power factor indicates that the different harmonic currents are low.

The FC 300 frequency converters’ built-in DC coils produce a high power factor, which

minimises the imposed load on the mains supply.

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FC 300 Design Guide

How to Read this Design Guide

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MG.33.B3.02 - VLT is a registered Danfoss trademark

FC 300 Design Guide

Introduction to FC 300

130BA140.10

FC 300

Design Guide

Software version: 2.0x

This Design Guide can be used for all FC 300 frequency

converters with software version 2.0x.

The software version number can be seen from parameter

15-43.

" CE Conformity and Labelling

What is CE Conformity and Labelling?

The purpose of CE labelling is to avoid technica l trade obstacles within E FTA and the EU. The

EU has introduced the CE label as a simple way of showing whether a product complies with

the relevant EU directives. The CE label says nothing about the specifications or quality of the

product. Frequency converters are regulated by three EU directives:

The machinery directive (98/37/EEC)

All machines with critical moving parts are covered by the m achinery directive of January 1, 1995. Since

a freque n cy converter is largely electrical, it does n ot fall under the machinery directive. However, if a

frequency converter is supplied for use in a machine, we provide information on safety aspects relating

to the frequency converter. We do this by means of a manufacturer’s declaration.

The low-voltage directive (73/23/EEC)

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FC 300 Design Guide

Introduction to FC 300

Frequency converters must be CE labelled in accord ance with the low-voltage directive of

January 1, 1997. The dire ctive applies to all electrical equipment and appliances used in the

50 - 1000 V AC and the 75 - 1500 V DC voltage ranges. Da nfoss CE-labels in accordance with

the directive and issues a d eclaration of conformity upon request.

The EMC directive (89/336/EEC)

EMC is short for electromagnetic compatib ility. The presence of electromagne tic compatibility means that the

mutual interference between different com p onents/appliances does not affect the way the appliances work.

The EMC directive came into effect January 1, 1996. Danfoss CE-labels in accordance with the directive and

issues a declaration of conformity upon request. To c arry out EMC-correct installation, see the instructions in

this Design Guid e. In addition, we specify which standards our products c omply with. We offer the filters

presented in the specifications and provide other typ es of assistance to ensure the op timum EMC result.

The frequency converter is most often used by professionals of the trade a s a complex component

forming part of a larger appliance, system or installation. It m ust be noted that the responsibility for

the final EMC properties of the app liance, system or installation rests with the installer.

" What Is Covered

The EU "Guideline s on the Ap plication of Council Directive 8 9/336/EEC" outline three typical situations

of using a frequency converte r. See below for EMC coverage and CE labelling .

1. The frequency converter is sold directly to the end-consumer. The frequen

cy converter is for example

sold t o a DIY market. The end-consume r is a layman. He installs the frequency converter himself

for use with a hobby machine, a kitche n appliance, etc. For such ap plic ations, the frequency

converter must be CE labelled in accordance with the EMC directive.

2. The frequen cy converter is sold for installation in a plant. The plant is built up by professionals of the

trade. It could be a production plant or a heating/ventilation pla nt de signed and installed by professionals

of the trade. Neithe r the f re quency converter nor the finish

ed pla n t has to be CE labelled under the EMC

directive. However, the unit must comply with the b asic EMC requirements of the directive. This is

ensured b y using components, appliances, and systems that are CE labelled under the E MC directive.

3. The frequency converter is sold as part of a complete

system. The system is being m arketed as

complete and could e.g. be an air-conditioning system. The complete system must be CE lab elled

in accordance with the E MC directive. The manufacturer can ensure CE labelling under the EMC

directive either by using CE labelled component

s or by testing the EMC of the syst em . If he chooses

to use only CE labelled components, he does not have to test the entire system.

" Danfoss VLT Frequency Converter

and CE Labelling

CE labelling is a positive feature when used for its orig inal purpose, i.e. to facilitate trade within the E U and EF TA.

However, CE labelling m ay cover many different specifications. Thus, you have to che ck

what a given CE label specifically covers.

The covered specifications can be very diffe rent and a CE labe l may therefore give the installer a false

feeling of security when using a

frequency converter as a component in a system or an appliance.

Danfoss CE labels the frequenc

y converters in accordance with the low-voltage directive. This means that if

the frequency converter is installed correctly, we guarantee compliance with the low-voltage directive. Danfoss

issues a d eclaration of conformity that confirms our CE labelling in accordance with the low-voltage directive.

The CE label also ap plie s to the EM C directive provided that the instructions for EMC -correct installation and

filtering are followed. O

n this basis, a decla ration of conformity in accordance with the EMC directive is issued.

The Design Guide offers d

etailed instructions for installation to ensure EMC-correct installation.

Furthermore, Danfoss specifies which our diffe rent produ cts com pl y with.

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FC 300 Design Guide

Introduction to FC 300

Danfoss gladly provides other types of assistance that can help you obtain the bes t EMC r esult.

" Compliance with EMC Directive 89/336/EEC

As mentioned, the frequency converter is mostly u se d by professionals of the trade as a complex

component forming part of a larger appliance, system, or installation. It must be n oted that the

responsibility for the final EMC properties of the appliance, system or installation res ts with the installer.

As an aid to the installer, Danfoss has prepare d EMC installat ion guidelines for the Power Drive System.

The standards and test levels stated for Power Drive Systems are complied with, provided that the

EMC-correct instructions for installation are followed, see s ection Electrical Installation.

" Mechanical Build-Up

Illustration of the mechanical build-up of FC 300. The exact unit dimensions are listed in chapter How to Install.

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FC 300 Design Guide

Introduction to FC 300

A Cold plate technology

The frequen cy converter is built upon a very stable aluminium base integrated with the back panel.

This provides h igh m echanical stability, efficient cooling and the possibility of cold plate operation. The

cold plate serves as a flat cooling surface on the frequency converter, where a m ajority of the heat

losses dissipates from the electronics to an external cooling surface.

B DC coil

The b uilt-in DC coil ensures low harmonic disturbance of the power supply according to IEC-1000-3-2.

C Air guiding screen

The screen allows cold air to pass by the electronics only. The plastic air guide screen is enclosed in

the package and is e asily snapped in place. If the frequency converter is to operate as a cold plate

drive, the air guiding screen is ins erted in the cooling channel through the bottom of the drive if it

is sn apped unto the fan. Thus, the am oun t of heat transferred to the surrou ndings via the cooling

air from the fan is reduced.

D Snap off the fan

Like most of th e elements, the fan can eas ily be r e moved for easy cleaning and r emounted .

E Safe Stop

The frequency co nverter comes standard with the safe stop functionality for stop category 0 (EN

60204-1) with safety category 3 (EN 954-1) installations. This feature prevents the drive from

starting unintended.

F Control signals

Spring -loaded cage clamps add to reliability and facilitate e asy commissio ning and service.

G Options

Options for bus communication, I/O extension etc. can be delivered or ordered built-in from the

factory. Options m ounted under the LCP is referred to as option Slot A (top) and option Slot B

(bottom). Option C (see under K Free programmable option is mounted on the side of the drive, while

option D is mounted underneath the control cable decoupling clamps.

H Local Control Panel

The LCP 102 has a graphical user-interface. Choose between six built-in languages (including Chinese)

or have it customised with your own languages and phrases. Two of the languages can be changed

by the user.

Additionally a simple version, LCP 101, is available with an alpha- n umeric display. A complete

programming of FC 302 can be handled by both LCP’s.

J Hot plugable LCP

The LCP can be plugged in or out during operation. Settings are easily transferred via the control panel

from one drive to another or from a PC w ith the MCT-10 set-up s oftware.

" Air Humidity

The frequency converter has been designed to meet the IEC/EN 60068-2-3 stan-

dard, EN 50178 pkt. 9.4.2.2 at 50 °

C.

" Aggressive Environments

A frequency converter contains a large number of mechanical and electronic components. All

are to some extent vulnerab

le to environmental effects.

18

MG.33.B3.02 - VLT is a registered Danfoss trademark

FC 300 Design Guide

Introduction to FC 300

The frequency converter should not be installed in environments with airb o rne

liquids, particles, or gases capable of affecting and damaging the electronic

components. Failure to take the necessary protective mea sures increases the risk

of stoppages, thus reducing the life of the frequency converter.

L

iquids can be carried through the air and condense in the frequency converter and may cause

corrosion of components and metal parts. Steam, oil, and salt water may cause corrosion of

components and metal parts. In such environments, use equipment with enclosure rating IP 55. As

an extra protection, coated printet circuit b oads can be orded as an option.

Airborne P

articles such as dust may cause me chanical, electrical, or thermal failure in the

frequency converter. A typical indicator of excessive levels of airborne pa rticles is dust p articles

around the frequency converter fan. In very dusty environments, use equipment with enclos

ure

rating IP 55 or a cabinet for IP 00/IP 20/TYPE 1 equipment.

In environments with high temperatures and humidity,

corrosive gases such as sulphur, nitrogen, and

chlorine comp ounds will cause chemical processes on t he frequency converter components.

Such chemical reactions will rapidly affect and damage the electronic components. In

such environments, mount the equipment in a cabinet with fresh air venti

lation, keeping

aggressive gases away from the frequency converter.

An extra protection in such areas is a coating of the printed circuit boards, which can be ordered as an option.

NB!:

Mounting frequency converters in aggressive environments increas

es the risk of stoppages

and considerably reduces the life of the converter.

Before insta lling the frequency converter, check the am bient air for l iquid s, particles, and gases.

This is done b y observing existing installations in this environment. Typical indicators of harmful

airborne liquids are water or oil on metal parts, or corrosion of metal parts.

Excessive dust particle levels are often found on installation cabine ts and existing electrical insta llations. One

indicator of aggressive airborne gases is blackening of copper rails and c able ends on existing installations.

" Vibration and Shock

The fre quency converter has been tested according

to a procedure based on the shown standards:

The frequency converter com plies with r eq uirements

that exist for units mounted on the walls and

floors of production premises, as well as in

panels bo lted to walls or floors.

IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970

IEC/EN 60068-2-64: Vibration, broad-band

random

" Control Principle

Afrequency

converter rectifies AC voltage from mains into DC voltage, after which this DC voltage

is converted into a AC current with a variable amplitude and frequency.

The motor is supplied with variable voltage / current and f re quency, which e n ables infinitely variable speed

control of three-phased, standard AC motors and permanent magnet synchronous motors.

" FC 300 Controls

The frequency converter is capable of controlling either the speed or the torque on the motor

shaft. Setting par. 1-00 determines the type of control.

19

MG.33.B3.02 - VLT is a registered Danfoss trademark

FC 300 Design Guide

Introduction to FC 300

Speed control:

There are two types of s peed control:

• Speed open loop control which does not require any feedback.

• Speed closed loop control in the form of a PID control that re quire s a speed feedback t o an input. A

properly optimised speed closed loop control w ill have hig h er accuracy than a s peed open loop control.

Selects which terminal to use as speed PID feedback in par. 7-00.

T

orque con trol:

Torque co ntrol is part of the motor control and correct settings of motor parameters are very

important. The accuracy and settling time o f the torque control are determine d from Flux

with motor feedback (par. 1-01 Motor Control Principle).

• Flux sensorless offers superior performance in all four quadrants at motor frequencies above 10 Hz.

• Flux with encode r feedback offers superior performance in all four quadrants and at all motor speeds.

The "Flux with encoder feedb" m ode requires that an encod er speed feedback signal is

present. Select which terminal to use in par. 1-02.

S

peed / torque reference:

The reference to these control s can either be a single refre nce or be the sum of various references including

relatively scaled references. The handling of references is explained in detail later in this section.

" Control Structure in VVC

plus

Control structure in VVC

plus

open loop and closed loop configurations:

In the configuration shown in

the illustration above, par. 1-01 Motor Control Principle is set to “VVC

plus

[1]” and par. 1-00 is set to “S pe ed open loop [0]”. The resulting refere n ce from the reference handling

system is received and fed through the ramp limitation and speed limitation before being sent to the motor

control. The out put of th

e m otor control is then limited by the maxim um freq uency lim it.

If par. 1-00 is set to “Sp

eed closed loop [1]” the resulting reference will be passed from the ramp limitation and

speed limitation into a speed PID control. The Sp eed PID control parameters are located in the par. group 7-0*.

The resulting reference from the Speed PID control is sent to the motor control limited by the frequency limi t.

20

MG.33.B3.02 - VLT is a registered Danfoss trademark

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Danfoss VLT® AutomationDrive User guide

Danfoss VLT® AutomationDrive User guide

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