VLT® AutomationDrive

Danfoss VLT® AutomationDrive User guide

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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 Labeling .................................................................... 15
" What Is Covered .................................................................................... 16
" Danfoss VLT Adjustable Frequency Drive and CE Labeling ............................ 1 6
" Compliance with EMC Directive 89/336/EEC ............................................... 17
" Mechanical Build-Up ............................................................................... 18
" Air Humidity .......................................................................................... 19
" Aggressive Environments ........................................................................ 19
" Vibration and Shock ............................................................................... 20
" Control Principle .................................................................................... 20
" FC 300 Controls ..................................................................................... 21
" FC 301 vs. FC 302 Control Principle .......................................................... 22
" Control Structure in VVC
plus
..................................................................... 23
" Control Structure in Flux Sensorless ......................................................... 24
" Control Structure in Flux with Motor Feedback ........................................... 25
" Local (Hand on) and Remote (Auto on) Control .......................................... 26
" Reference Handling ................................................................................ 28
" Scaling of References and Feedback ......................................................... 29
" Analog Reference with Dead Band ............................................................ 30
" Speed PID Control ................................................................................ 34
" The following parameters are relevant for the Speed Control ........................ 34
" Process PID Control ............................................................................... 37
" Ziegler Nichols Tuning Method ................................................................. 41
" Internal Current Control ......................................................................... 42
" Parameter Download .............................................................................. 42
" General Aspects of EMC E missions ............................................................ 43
" EMC Test Results (Emission, Immunity) .................................................... 44
" Required Compliance Levels .................................................................... 45
" EMC Immunity ...................................................................................... 45
" Galvanic Isolation (PELV) ........................................................................ 47
" Ground Leakage Current ......................................................................... 47
" Selection of Brake Resistor ...................................................................... 48
" Control with Brake Function ..................................................................... 49
" Control of Mechanical Brake .................................................................... 50
" Smart Logic Controller ............................................................................ 51
" Extreme Running Conditions .................................................................... 52
" Motor Thermal Protection ........................................................................ 53
" Safe Stop of FC 300 ............................................................................... 53
" Safe Stop Operation ............................................................................... 53
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FC 300 Design Guide
! How to Select Your VLT ............................................................... 55
" Electrical Data ....................................................................................... 55
" General Specifications ............................................................................ 58
" Efficiency .............................................................................................. 63
" Acoustic Noise ....................................................................................... 64
" Peak Voltage on Motor ............................................................................ 64
" Derating for Ambient Temperature ........................................................... 65
" Derating for Air Pressure ......................................................................... 65
" Derating for Running at Low Speed .......................................................... 6 5
" Derating for Installing Long Motor Cables or C ables with Larger Cross-Section 66
" Temperature-Dependent Switch Frequency ................................................ 66
" Options and Accessories ......................................................................... 67
" Encoder Option MCB 102 ........................................................................ 67
" Relay Option MCB 105 ............................................................................ 69
" 24 V Back-Up Option (Option D) .............................................................. 71
" Brake Resistors ..................................................................................... 71
" Remote mounting Kit for LCP ................................................................... 72
" IP 21/IP 4X/ TYPE 1 (NEMA 1) Enclosure Kit .............................................. 72
" LC Filters .............................................................................................. 72
! How to Order .................................................................................... 73
" Drive Configurator ................................................................................. 73
" Ordering Form Type Code ........................................................................ 74
" Ordering Numbers ................................................................................. 77
! How to Install .................................................................................. 83
" Mechanical Installation ........................................................................... 83
" Accessory Bag ....................................................................................... 83
" IP 21/Type 1 Enclosure Kit ...................................................................... 84
" Safety Requirements of Mechanical Installation .......................................... 87
" Field Mounting ....................................................................................... 87
" Electrical Installation .............................................................................. 88
" Connection to Mains and Gro unding .......................................................... 88
" Motor connection ................................................................................... 89
" Motor Cables ......................................................................................... 90
" Thermal Motor Protection ....................................................................... 91
" Electrical Installation of Motor Cables ........................................................ 92
" Fuses ................................................................................................... 93
" Access to control terminals ...................................................................... 95
" Electrical Installation, Control Terminals .................................................... 95
" Terminal 10, analog input voltage ............................................................ 96
" Electrical Installation, Control Cables ........................................................ 97
" Switches S201, S202, and S801 .............................................................. 98
" Tightening Torque .................................................................................. 99
" Final Set-Up and Test ............................................................................. 99
" Safe Stop Installation (FC 302 only) ........................................................ 101
" Safe Stop Commissioning Test ................................................................ 102
" Additional Connections .......................................................................... 103
" Load sharing ........................................................................................ 103
" Installation of Load Sharing .................................................................... 103
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" Brake Connection Option ....................................................................... 103
" Relay connection .................................................................................. 104
" Relay Output ........................................................................................ 105
" Parallel Connection of Motors .................................................................. 105
" Direction of Motor Rotation ..................................................................... 106
" Installation of Brake Cable ..................................................................... 106
" Bus Connection .................................................................................... 107
" How to Connect a PC to the FC 300 ......................................................... 107
" The FC 300 Software Dialog ................................................................... 107
" High Voltage Test .................................................................................. 108
" Safety Grounding .................................................................................. 108
" Electrical Installation - EMC P recautions ................................................... 108
" Use of EMC-Correct Cables ..................................................................... 110
" Grounding of Shielded/Armored Control Cables ......................................... 111
" Mains Supply Interference/Harmonics ...................................................... 112
" Residual Current Device ......................................................................... 113
! Application E xam p les .................................................................. 115
" Start/Stop ........................................................................................... 115
" Pulse start/stop .................................................................................... 115
" Potentiometer Reference ........................................................................ 116
" Encoder Connection .............................................................................. 116
" Encoder Direction ................................................................................. 117
" Closed Loop Drive System ...................................................................... 117
" Programming of Torque Limit and Stop ................................................... 118
" Automatic Motor Adaptation (AMA) .......................................................... 118
" Smart Logic Control ............................................................................. 120
! How to Program ............................................................................. 123
" The Graphical and Numerical FC 300 Local ............................................... 123
" How to Program on the Graphical Local Control Panel ................................. 123
" Quick Transfer of Parameter Settings ....................................................... 127
" Display Mode ....................................................................................... 128
" Display Mode - Selection of Read-Outs ..................................................... 128
" Parameter Set-Up ................................................................................. 129
" Quick Menu Key Functions ...................................................................... 129
" Main Menu Mode ................................................................................... 130
" Parameter Selection .............................................................................. 131
" Changing Data ..................................................................................... 131
" Changing a Text Value ........................................................................... 131
" Changing a Group of Numeric Data Values ................................................ 132
" Infinitely Variable Change of Numeric Data Value ...................................... 132
" Changing of Data Value, Step-by-Step ..................................................... 133
" Read-out and Programming of Indexed Parameters ................................... 133
" How to Program on the Numerical Local Control Panel ................................ 134
" Local Control Keys ................................................................................ 135
" Initialization to Default Settings .............................................................. 137
" Parameter Selection - FC 300 ................................................................. 138
" Parameters: Operation and Display ......................................................... 139
" Parameters: Load and Motor .................................................................. 148
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" Parameters: Brakes .............................................................................. 159
" Parameters: Reference/Ramps ............................................................... 162
" Parameters: Limits/Warnings ................................................................. 171
" Parameters: Digital In/Out ..................................................................... 174
" Parameters: Analog In/Out .................................................................... 183
" Parameters: Controllers ......................................................................... 187
" Parameters: Communications and Options ............................................... 190
" Parameters: Profibus ............................................................................ 194
" Parameters: DeviceNet CAN Fieldbus ....................................................... 200
" Parameters: Smart logic control ............................................................. 203
" Parameters: Special functions ................................................................ 213
" Parameters: Drive information ................................................................ 217
" Parameters: Data readouts .................................................................... 222
" Parameters: Motor Feedb.Option ............................................................ 227
" Parameter lists ..................................................................................... 228
" Protocols ............................................................................................. 243
" Telegram Traffic .................................................................................... 243
" Telegram Structure ............................................................................... 243
" Data Character (byte) ........................................................................... 245
" Process Words ...................................................................................... 250
" Control Word According to FC Profile (CTW) .............................................. 251
" Status Word According to FC Profile (STW) ............................................... 254
" Control Word according to PROFIdrive Profile (CTW ) .................................. 256
" Status Word According to PROFIdrive Profile (STW) ................................... 259
" Serial Communication Reference ............................................................. 261
" Present Output Frequency ...................................................................... 262
" Example 1: For Controlling the D rive and Reading Parameters .................... 26 2
" Example 2: Only for Controlling the Drive ................................................ 263
" Read Parameter Description Elements ...................................................... 263
" Additional Text ..................................................................................... 269
! Troubleshooting ............................................................................. 271
" Warnings/Alarm Messages ..................................................................... 271
! Index .................................................................................................. 279
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FC 300 Design Guide
How to Read this Design Guide
" How to Read this Design Guide
This Design Guide will introduce all aspects of your FC 3
00.
Chapter 1, How to Read this Design Guide,
introduces the design guide and provides
information about the ap provals, symbols,
and
abbreviations used in this manual.
Page divider for How to Read this Design Guide.
Chapter 2, Introduction to FC 300,provides
information about a
vailable features and instr uctions
on how to handle the FC 300 correctly.
Page divider for Introduction to FC 300.
Chapter 3, How to Select Your VLT, how to select
the right FC 300 model for the application.
Page divider for How to Select Your VLT.
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FC 300 Design Guide
How to Read this Design Guide
Chapter 4, How to O rde r, supplies the information
needed for ordering the FC 300.
Page divider for How to Order.
Chapter 5, How to Install, provides information
about the mechanical and electrical installation.
Page divider for How to Install
Chapter 6, Application Examples,shows
some typica l applications.
Page divider for Application Examples
Chapter 7, How to Program, information
on how to operate and program the FC 300
via the Local Control Panel.
Page divider for Ho w to Program.
Chapter 8, Troubleshooting, g uidance in solving
problems that may occur when using FC 300.
Page divider for Troubleshooting.
Available literature for FC 300
- The VLT
®
AutomationDrive FC 300 Instruction Manual MG.33.AX.YY provides the nece ssary
information for getting the drive up and running.
- The VLT
®
AutomationDrive FC 300 Design Guide MG.33.BX.YY entails all technical info rm a tion
about the drive and customer design and applications .
- The VLT
®
AutomationDrive FC 300 Profibus Instruction Manual MG.33.CX.YY provides the information
required for controlling, m onitoring , and programming the drive via a Profibus se rial communication bus.
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FC 300 Design Guide
How to Read this Design Guide
- The VLT
®
AutomationDrive FC 300 DeviceNet Instruction Manual MG.33.DX.YY provides the information
required for controlling, monitoring, and p rogramming the drive via a DeviceNet serial communication bus.
Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAr-
eas/DrivesSolutions/Documentations/Technical+Documentation.
" Approvals
" Symbols
Symbols used in this D
esign Guide.
NOTE
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
Indicates default setting
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How to Read this Design Guide
" Abbreviations
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit I
LIM
Degrees Celsius °C
Direct current DC
Drive Dependent D-TYPE
Electronic Thermistor Relay ETR
Adjustable Frequency Drive AFD
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 meter Nm
Nominal motor current I
M,N
Nominal motor frequency f
M,N
Nominal motor power 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
Volt V
" Definitions
Drive:
D
-TYPE
Size a nd type of the connected drive (dependencies).
I
VLT,MAX
The maximum output current.
I
VLT,N
The rated output current supplied by the adjustable frequency drive.
U
VLT, MAX
The maximum output voltage.
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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, Reverse, Start
reverse, Jog and Freeze output
Motor:
f
JOG
The motor frequency when the jog function is activated (via digital terminals).
f
M
The m otor frequency.
f
MAX
The maximum motor frequency.
f
MIN
The minimum motor frequency.
f
M,N
The rated motor frequency (nam ep late data).
I
M
The motor 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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Break-away torque
η
VLT
The efficiency of the adjustable frequency drive is define d as the ratio betw een
the power output and the power input.
S
tart-disabl e command
A stop command belonging to the grou
p 1 control commands - see this group.
S
top comman d
See Control commands.
References:
A
nalog Reference
A signal transmitted to the analo
g 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 refe rence range. Selection
of eight preset references v ia the digital terminals.
P
ulse Reference
A pulse frequency signal transm
itted to the dig ital inputs (terminal 29 or 3 3).
R
ef
MAX
Determines the relationship between the reference 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 relationshi
p between the reference input at 0% value (typically 0V, 0mA, 4mA) and
the resulting reference. The m inimum reference value set in par. 3-02.
Miscellaneous:
A
nalog Input s
The analog inputs are used for controlling various functions of the adjus table frequency drive.
There ar
e two types of analog inputs:
Current input, 0-20 mA and 4-20 mA
Voltage input, 0-10 V DC (FC 301)
Voltage in
put, -10 - +10 V DC (FC 30 2).
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How to Read this Design Guide
Analog Outp uts
The analog o utputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal.
A
utomatic Motor Adaptation, AMA
AMA algorithm determines the electric al parameters for the connected motor at standstill.
B
rake Resistor
The brake resistor is a module capable of absorbing the braking energy generated in regene rative
braking. This regenerative braking energy increases the intermedia te circuit voltage and a brake
chopper ensures that the e nergy is transmitted to the brake resistor.
C
T Characteristics
Constant torque characteristics used for all applications such as co nveyor belts ,
displacement pumps, and cranes.
D
igital Inputs
The digital inp uts can be used for controlling various functions of the adjustable frequency drive.
D
igital Outputs
The drive features two solid state outputs that can supply a 24 V DC (max. 40 mA) signal.
D
SP
DigitalSignalProcessor.
Relay Outputs:
TheFC301drivefeaturesoneprogrammableRelayOutput.
TheFC302drivefeaturestwoprogrammableRelayOutputs.
E
TR
Electronic Thermal Relay is a thermal load calc ulation based on pr esent load and tim e.
Its p u rpose is to estimate the motor temperature.
H
iperface
®
Hiperface
®
is a registered trademark of Ste gm ann.
I
nitializing
If initializing i s carried out (par. 14-22), the adjustable frequency drive returns to the default setting.
I
ntermittent D uty Cycle
An interm ittent duty rating refers to a sequence of duty cycles. Each cycle consis ts of an on-load a nd
an off-load period. The operation can be either periodic dut
yornon-periodicduty.
L
CP
The Local Control Panel (LCP) makes up a complete interface for control and p rogramming of the FC
300 Series. The control panel is d etacha ble and can be installed up to 9.8 ft (3 meters) from the
adjustable frequency drive, i.e. in a front panel by m
eans of the installation kit option.
l
sb
Least significant bit.
M
CM
Short for Mille Circular Mil, an American measuring unit for c able cross-section.
1MCM≡ 0.00079 in.
2
(0.5067 mm
2
).
m
sb
Most significant bit.
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FC 300 Design Guide
How to Read this Design Guide
Online/Offline Parameters
Changes to online pa rameters are activated immediately after the data value is changed. Changes
to offline 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/ Incremen tal Encoder
An exte rnal, digita l pulse transmitter used for feeding back information on motor speed. The encoder
is used in applications where grea t accuracy in speed control is required.
R
CD
Residual Current De v ice.
S
et-up
You can save p arameter sett ings 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 oriente d A synchronous V ector M odulation (par. 14-00).
S
lip Compensation
The ad justable frequency drive compensates for the motor slip by giving the freq uency a supplement
that follows the measured motor load keeping the motor speed almost const
ant..
S
mart Logic Control (SLC)
The SLC is a sequence of user-defined actions executed when the associated user-defined
events are evaluated as true by the SLC.
T
hermistor:
A temperature-dependent resistor placed where the temperatur
eistobemonitored
(adjustable frequency drive or motor).
T
rip
A state entered in fault situations, e.g. if the adjustable frequency d rive is subject to an over-temperature or
when the adjustable frequency drive is p rotec ting the motor, p
rocess, or mechanism. Restart is prevented
until the cause of the fault has d isappeared and the trip state is cancelled b y activating reset o r, in some
cases, b y being programmed to reset automatically. Trip m ay not be used for perso nal safety.
T
rip-Locked
A state entered in fault situations when the adjustabl
e frequency drive is prote cting itself and requiring
physical intervention, e.g. if the adjustab le frequency drive is subject to a short circuit on the output. A
locked trip can only be cancelled by cutting off AC line, removing the cause of the fault, and reconnecting the
adjustable frequency drive. Restart is preve
nted until the trip s tate is cancelled by activating reset or, in
some cases, by being programmed to reset automatically. Trip may not be used for personal safety.
V
T Characteristics
Variable torque characteristics used for pumps and fans.
V
VC
plus
Compared with standard voltage/frequenc
y ratio control, Voltage Vecto r Control (VVC
plus
)improvesthe
dynamics a n d the stability, both when the speed reference is changed and in relation to the load torque.
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FC 300 Design Guide
How to Read this Design Guide
60° AVM
Switching pattern called 60° A synchronous V ector M odulation (par. 14-00).
" Power Factor
The power factor is the relation between I
1
and I
RMS
.
The power factor for 3-phase control:
The power factor indicates to what extent
theadjustablefrequencydriveimposesa
load on the mains supply.
The lower the power factor, the higher the I
RMS
for the same HP/kW performance.
In addition, a high power factor indicates that the different harmonic currents are low.
The FC 300 adjustable frequency drives’ built-in DC coils produce a high power factor,
which minim izes the imposed load on the mai ns supply.
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FC 300 Design Guide
How to Read this Design Guide
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FC 300 Design Guide
Introduction to FC 300
130BA140.11
FC 300
Design Guide
Software version: 2.5x
This Design Guide can be used for all FC 300 adjustable
frequency drives (AFD) with software version 2.5x.
The software version number can be seen from parameter
15-43.
" CE Conformity and Labeling
What is CE Conformity and Labeling?
The purpose of CE labeling is to avoid technical trade obstacles within EFTA 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.
Adjustable fre quency drives are re gulate d by three EU directives:
The machinery directive (98/37/EEC)
All machines with critical moving parts are covered by the machinery directive of J anuary 1, 1995. Since an
adjustable frequency drive is largely electrical, it does not fall under the machinery directive. However, if
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FC 300 Design Guide
Introduction to FC 300
an adjustable frequency drive is supplied for use in a machine, we provide information on safety aspects
relating to the adjustable frequency drive. We do this by means of a manufacturer’s de claration.
The low-voltage directive (73/23/EEC)
Adjustable frequency drives must be CE-labeled in accordance 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. Danfoss 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 electrom agnetic compatibility. The presence of electromagnetic compatibility means that the
mutual interference between different components/appliances does not affect the way the appliances work.
The EMC directive came into e ffect January 1, 1996. Danfoss CE-labels in accordance with the directive and
issues a declaration of conformity upon request. To carry out EMC-correct installation, see the instructions in
this Design Guide. In addition, w e specify which standards our prod u cts c omply with. We offer the f
ilters
presented in the specifications and provide other types of assistance to ensure the op timum EMC result.
The adjustable frequency d rive is most ofte n use 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 re spons ibility for
the final EMC properties of the appliance, system, or installation lies with th
einstaller.
" What Is Covered
The EU "Guidelines on the Application of Council Directive 89/336 /EEC" outline three typical situations
of using an adjustable frequency drive. See following for EMC coverage and
CE labeling.
1. The adjustable frequen cy drive is sold direc tly to the en d consu
mer. The adjustable frequency drive is
for example sold to a DIY market. The end consumer is a layman. He installs the adjustable frequency
drive himself for use with a hobby machine, a kitche n appl iance, etc. Fo r such appli cations, the
adjustable frequency drive must be CE-labeled in accordanc
e with the EMC directive.
2. The adjustable frequency drive is sold for installation in a p lant. The plant is built up by p rofessi onals of the
trade. It could be a production plant or a heating/ventilation pla nt de signed and installed by profes sionals
of the trade. Neither the adjustable frequency driv
e nor the finished p lant must be CE-labeled under the
EMC d irective. How ever, the unit must comply with the b asic EMC requirements of the directive. This is
ensured by using components, appliances, and systems that are CE-labeled under the EMC directive.
3. Theadjustablefrequencydriveissoldaspartofac
ompletesystem. Thesystemisbeingmarketed
as complete and could be e.g. an air conditioning system. ThecompletesystemmustbeCE-labeled
in accordance with the EMC directive. The manufacturer can ensure CE labeling under the EMC
directive either by using CE-labeled comp
onents or by testing the EMC of the system. If it chooses
to use only CE-labeled components, it does not have to test the entire system.
" Danfoss VLT Adjustable Frequency
Drive and CE L abeling
CE labeling is a positive feature when used for its original purpose, i.e. to facilitate trade within the EU and EFTA.
However, CE labeling may cover many d ifferent specifications. Thus, you must check
what a given CE label specifically covers.
The covered specificatio ns can be very different and a CE label may therefore give the installer a false sense
of security when using an adj
ustable frequency drive as a component in a system or a n appliance.
Danfoss CE labels the adjust
able frequency drives in accordance with the l ow-voltage dire ctive.
This means that if the adjustable frequency drive is inst alled correctly, we guarantee compliance
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FC 300 Design Guide
Introduction to FC 300
with the low-voltage directive. Danfoss issues a d ecla ration of conformity that confirms our
CE labeling in accordance with the low-voltage directive.
The CE label also applie s to the EMC directive p rovided that the instructions for EMC-correct inst allation and
filtering are followed. On this basis, a declaration of conformity in accordance with the EMC directive is issued.
The Design Guid e offers detailed instructions for installation to ensure EMC-correct installation.
Furthermore, Danfoss specifies which our diffe rent produ cts com pl y with.
Danfoss gladly provides other types of assistance that can help you obtain the best EMC result.
" Compliance with EMC Directive 89/336/EEC
As mentioned, the adjustable fre quency drive is mostly used by p rofessionals of the trade as a complex
component forming part of a larger appliance, system, or installation. It must be noted t
hat the
responsibility for the final EMC properties of the appliance, system, or installation lies with the installer.
As an aid to the installer, Danfoss has pre pare d EMC installation guidelines for the Power Drive System.
The standards and test levels state d for Power Drive Systems are compli
ed with, provided that the
EMC-correct instructions for installation are followed, see section Electrical Installation.
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FC 300 Design Guide
Introduction to FC 300
" Mechanical Build-Up
Illustration of the mechanical build-up of FC 300. The exact unit dimensions are listed in the chapter How to Install.
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Introduction to FC 300
A Cold plate technology
The adjustable frequ ency drive is bu ilt upon a very stable aluminum base integrated with the back
panel. This provides high mechanical stability, efficient cooling, and the possibility of cold plate
operation. The cold plate serves as a flat cooling surface on the adjustable frequency drive, where a
majority of the heat dissipates from the electronics to an external cooling surface.
B DC coil
The built-in DC coil ensures low harmonic disturbance of the power supply according to IEC-1000-3-2.
C Air-guiding shield
The shield allows cold air to pass by the electronics only. The plastic air guide shield is enclosed in
the package and is easily snapped in place. If the adjustable frequen cy drive is to operate as a
cold plate drive, the air-guiding shield is inserted in the cooling channel through the bottom of the
drive if it is snapped onto the fan. Thus, the amount of heat transferred t o the surroundings via the
cooling air from the fan is reduced.
D Removable fan
Like most of the elements, the fan can easily be removed for cleaning and remounted.
E Safe Stop (FC 302 only)
The adjustable frequen cy drive comes standard prepared for installations with the safe stop
functionality for stop category 0 (EN 60204-1) with safety category 3 (EN 954-1). This feature
prevents the drive from starting unintent ionally.
F Control terminals
Spring-loaded cage clamps and screwl ess terminals contribu te to relia bility and faci litate easy
commissioning and service.
G Options
Options for bus communication, I/O extension, etc. can be delivered extra or ordered built-in (and
tested togethe r with the drive) from the factory. Options mounted under the LCP are referred to as
option Slot A (top) and option Slot B (bottom). Option C is mounted on the side of the drive, while
option D is mounted underneath the control cable decoupling plate.
H Local Control Panel
The LCP 102 has a graphical us er interface. Choose between 27 built-in languages (including Chinese)
or have it customized with your own languages and phrases.
Additionally a simple version, LCP 101, is available with an a lpha-num eric display. The complete
programming of FC 301 and FC 302 can be handled by both LCPs.
J Hot-pluggable 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 with the MCT-10 set-up software.
" Air Humidity
The adjustable fre quency drive has b ee n designed to meet the IEC/EN 60068 -2-3 standard,
EN 50178 pkt. 9.4.2.2 at 122 °
F(50°C).
" Aggressive Environments
An adjustable frequency drive contains a large number of mechanical and electronic components.
All are to some extent vul
nerable to environmental effects.
19
MG.33.B4.22 - VLT is a registered Danfoss trademark
FC 300 Design Guide
Introduction to FC 300
The adjust able frequenc y drive should not be installed in environments with airborne
liquids,particles,orgasescapableofaffecting and damaging the electronic components.
Failure t o take the necessary p rotective measure s increases the risk of stoppages,
thus reducing the life of the adjustable frequency drive.
L
iquids can be carried through the air and condense in the adjustable frequency drive and m ay
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 printed circuit boards can be ordered as an option.
Airborne P
articles such as dust may cause mechanical, electrical, or thermal f ailure in the adjustable
frequency drive. A typical indicator of excessive levels of airborne particles is dust particles
around the adjustable frequency drive fan. In very dusty envir o nments, use equip ment wi
th
enclosure 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 sulfur, nitrogen, and chlorine
compounds w ill cause chemical processes on the adjustable frequency drive components.
Such chemical reactions will rapidly affect and damage the electronic components. In
such environments, mount the eq uipment in a cab inet with fre sh air ven
tilation, keeping
aggressive gases away from the adjustable freque nc y drive.
An extra protectio n in such areas is a coating of the printed circuit boards, which can be ordered as an option.
NOTE
Mounting adjustable frequency drives in aggressive e nvi
ronments increases the risk of
stoppages and considerably red uces the life of the drive.
Before installing the adjustable frequency drive, check the ambient air for liquids, particles, and gases .
This is d one by observing existing installa tions in this environment. Typ ical indicators of harmful
airborne liquids are water or oil on metal parts, or c o
rrosion of metal parts.
Excessive dust particle levels are often found
on installation cabinets and existing electrical installations. One
indicator of aggressive airborne gases is blackening of copper rails and cable ends on existing installations.
" Vibration and Shock
The adjustabl e frequency drive has been
tested according to a procedu
re based on
the shown standards:
The adjustable frequency drive com plies w ith
requirements that exist for units mounted on the
wallsandfloorsofproduc
tion premises, as well
as in panels bolted to walls or floors.
IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970
IEC/EN 60068-2-64: Vibration, broad-band
random
" Control Principle
An adjust able frequency drive rectifi es AC voltage from line into DC voltage, after which this DC
voltage is converted into an AC current with a variable am pl itude and frequency.
The motor is supplied with variable voltage / curre nt and frequency, which enables infinitely variable speed
control of three-phased, standard AC motors and permanent magnet synchronous motors.
20
MG.33.B4.22 - VLT is a registered Danfoss trademark
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