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 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
" FC 301 vs. FC 302 Control Principle .......................................................... 20
" Control Structure in VVC
plus
..................................................................... 21
" Control Structure in Flux Sensorless (FC 302 only) ..................................... 2 2
" Control Structure in Flux with Motor Feedback ........................................... 23
" Local (Hand On) and Remote (Auto On) Control ......................................... 24
" Reference Handling ................................................................................ 26
" Scaling of References and Feedback ......................................................... 27
" Analog Reference with Dead Band ............................................................ 27
" Speed PID Control ................................................................................ 32
" The following parameters are relevant for the Speed Control ........................ 32
" Process PID Control ............................................................................... 35
" Ziegler Nichols Tuning Method ................................................................. 39
" Internal Current Control ......................................................................... 40
" Parameter Download .............................................................................. 40
" General Aspects of EMC E missions ............................................................ 40
" EMC Test Results (Emission, Immunity) .................................................... 42
" Required Compliance Levels .................................................................... 43
" EMC Immunity ...................................................................................... 43
" Galvanic Isolation (PELV) ........................................................................ 45
" Earth Leakage Current ............................................................................ 45
" Selection of Brake Resistor ...................................................................... 46
" Control with Brake Function ..................................................................... 47
" Control of Mechanical Brake .................................................................... 48
" Smart Logic Control ............................................................................... 49
" Extreme Running Conditions .................................................................... 49
" Motor Thermal Protection ........................................................................ 50
" Safe Stop Operation (FC 302 Only) ........................................................... 50
" Safe Stop Operation (FC 302 only) ........................................................... 50
! How to Select Your VLT ............................................................... 53
" Electrical Data ....................................................................................... 53
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FC 300 Design Guide
" General Specifications ............................................................................ 56
" Efficiency .............................................................................................. 61
" Acoustic Noise ....................................................................................... 62
" Peak Voltage on Motor ............................................................................ 62
" Derating for Ambient Temperature ........................................................... 63
" Derating for Low Air Pressure .................................................................. 63
" Derating for Running at Low Speed .......................................................... 63
" Derating for Installing Long Motor Cables or C ables with Larger Cross-Section 64
" Temperature-Dependent Switch Frequency ................................................ 64
" Options and Accessories ......................................................................... 65
" Encoder Option MCB 102 ........................................................................ 65
" Relay Option MCB 105 ............................................................................ 67
" 24 V Back-Up Option MCB 107 (Option D) ................................................. 6 9
" Brake Resistors ..................................................................................... 70
" Remote mounting Kit for LCP ................................................................... 70
" IP 21/IP 4X/ TYPE 1 Enclosure Kit ............................................................ 70
" LC Filters .............................................................................................. 70
! How to Order .................................................................................... 71
" Drive Configurator ................................................................................. 71
" Ordering Form Type Code ........................................................................ 72
" Ordering Numbers ................................................................................. 75
! 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 .............................................................................. 85
" Connection to Mains and Earthing ............................................................ 85
" Motor Connection ................................................................................... 86
" Motor Cables ......................................................................................... 87
" Thermal Motor Protection ....................................................................... 88
" Electrical Installation of Motor Cables ........................................................ 89
" Fuses ................................................................................................... 90
" Access to Control Terminals ..................................................................... 92
" Electrical Installation, Control Terminals .................................................... 92
" Control Terminals ................................................................................... 93
" Electrical Installation, Control Cables ........................................................ 94
" Switches S201, S202, and S801 .............................................................. 95
" Tightening Torque .................................................................................. 95
" Final Set-Up and Test ............................................................................. 96
" Safe Stop Installation (FC 302 only) ......................................................... 98
" Safe Stop Commissioning Test ................................................................. 99
" Additional Connections .......................................................................... 100
" Load Sharing ........................................................................................ 100
" Installation of Loadsharing ..................................................................... 100
" Brake Connection Option ....................................................................... 100
" Relay Connection .................................................................................. 101
" Relay Output ........................................................................................ 102
" Parallel Connection of Motors .................................................................. 102
" Direction of Motor Rotation ..................................................................... 103
" Motor Thermal Protection ....................................................................... 103
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FC 300 Design Guide
" Installation of Brake Cable ..................................................................... 103
" RS 485 Bus Connection .......................................................................... 103
" How to Connect a PC to the FC 300 ......................................................... 104
" The FC 300 Software Dialog ................................................................... 104
" High Voltage Test .................................................................................. 105
" Safety Earthing .................................................................................... 105
" Electrical Installation - EMC P recautions ................................................... 105
" Use of EMC-Correct Cables ..................................................................... 107
" Earthing of Screened/Armoured Control Cables ......................................... 108
" Mains Supply Interference/Harmonics ...................................................... 109
" Residual Current Device ......................................................................... 109
! Application E xam p les .................................................................. 111
" Start/Stop ........................................................................................... 111
" Pulse Start/Stop ................................................................................... 111
" Potentiometer Reference ........................................................................ 112
" Encoder Connection .............................................................................. 112
" Encoder Direction ................................................................................. 113
" Closed Loop Drive System ...................................................................... 113
" Programming of Torque Limit and Stop ................................................... 114
" Automatic Motor Adaptation (AMA) .......................................................... 114
" Smart Logic Control Programming ........................................................... 116
! How to Programme ....................................................................... 119
" The Graphical and Numerical FC 300 Local ............................................... 119
" How to Programme on the Graphical Local Control Panel ............................ 119
" Quick Transfer of Parameter Settings ....................................................... 122
" Display Mode ....................................................................................... 124
" Display Mode - Selection of Read-Outs ..................................................... 124
" Parameter Set-Up ................................................................................. 125
" Quick Menu Key Functions ...................................................................... 125
" Main Menu Mode ................................................................................... 126
" Parameter Selection .............................................................................. 127
" Changing Data ..................................................................................... 127
" Changing a Text Value ........................................................................... 127
" Changing a Group of Numeric Data Values ................................................ 128
" Infinitely Variable Change of Numeric Data Value ...................................... 128
" Changing of Data Value, Step-by-Step ..................................................... 129
" Read-out and Programming of Indexed Parameters ................................... 129
" How to Programme on the Numerical Local Control Panel ............................ 130
" Local Control Keys ................................................................................ 131
" Initialisation to Default Settings .............................................................. 132
" Parameter Selection - FC 300 ................................................................. 133
" Parameters: Operation and Display ......................................................... 134
" Parameters: Load and Motor .................................................................. 141
" Parameters: Brakes .............................................................................. 151
" Parameters: Reference/Ramps ............................................................... 154
" Parameters: Limits/Warnings ................................................................. 162
" Parameters: Digital In/Out ..................................................................... 165
" Parameters: Analog In/Out .................................................................... 174
" Parameters: Controllers ......................................................................... 177
" Parameters: Communications and Options ............................................... 180
" Parameters: Profibus ............................................................................ 184
" Parameters: DeviceNet CAN Fieldbus ....................................................... 190
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FC 300 Design Guide
" Parameters: Smart Logic Control ............................................................ 194
" Parameters: Special Functions ................................................................ 204
" Parameters: Drive Information ............................................................... 208
" Parameters: Data Read-outs .................................................................. 213
" Parameters: EncoderInput ..................................................................... 218
" Parameter Lists .................................................................................... 219
" Protocols ............................................................................................. 236
" Telegram Traffic .................................................................................... 236
" Telegram Structure ............................................................................... 236
" Data Character (byte) ........................................................................... 238
" Process Words ...................................................................................... 243
" Control Word According to FC Profile (CTW) .............................................. 243
" Status Word According to FC Profile (STW) ............................................... 246
" Control Word according to PROFIdrive Profile (CTW ) .................................. 248
" Status Word According to PROFIdrive Profile (STW) ................................... 251
" Serial Communication Reference ............................................................. 253
" Present Output Frequency ...................................................................... 254
" Example 1: For Controlling the D rive and Reading Parameters .................... 25 4
" Example 2: Only for Controlling the Drive ................................................ 255
" Read Parameter Description Elements ...................................................... 255
" Additional Text ..................................................................................... 260
! Troubleshooting ............................................................................. 261
" Warnings/Alarm Messages ..................................................................... 261
! Index .................................................................................................. 269
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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, an
d
abbreviations used in this manual.
Page divider for How to Read this Design Guide.
Chapter 2, Introduction to FC 300,provides
information about ava
ilable features and instructions
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 Programme, information
on how to operate and programme the F C
300 via the Loca l Control Panel.
Page divider for How to Programme.
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 Operating Instructions MG.33.A X.YY provide the
neccessary information for getting the drive up a nd 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 Operating Instructions MG.33.CX.YY provide the information
required for controlling , mo nitoring and programming the drive via a Profibus fieldbus.
- The VLT
®
AutomationDrive FC 300 De viceNet Operating Instructions MG.33.DX.YY provide th e information
required for controlling, monitoring and pro gramming the drive via a DeviceNet fieldbus.
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FC 300 Design Guide
How to Read this Design Guide
Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAr-
eas/DrivesSolutions/Documentations/Technical+Documentation.
" Approvals
" Symbols
SymbolsusedinthisDesignGuide.
NB!:
Indicates som
ething 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 c urre 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 Dependen t M-TYPE
Nanofarad nF
Newton Meters Nm
Nominal m otor current I
M,N
Nominal motor frequency f
M,N
Nominal motor power P
M,N
Nominal m otor 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 connected 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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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 motor frequency when the jog function is activated (via digital terminals).
f
M
The motor frequency.
f
MAX
The maximum mo tor frequency.
f
MIN
The minimum motor frequency.
f
M,N
The rated motor frequency (nam ep late data).
I
M
The motor cu rrent.
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 (nam eplate data).
P
M,N
The rated motor power (nam ep late 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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How to Read this Design Guide
Break-away torque
η
VLT
The efficiency of the frequency converter is defined as the ratio between the pow er 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 C ontrol comma n ds.
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 preset references v ia the digital 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 reference input at 100% f ull scale value (typically 10 V, 20m A)
and the resulting reference. The maximum reference value set in par. 3-03.
R
ef
MIN
Determines the relationship between the refere n ce 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 and 4-20 mA
Voltage input, 0-10 V DC (FC 301)
Voltage input, -10 - +10 V DC (FC 302).
A
nalog Outputs
The analog o u
tputs can supply a s ignal of 0-20 mA, 4-20 mA, or a dig ital signal.
A
utomatic M
otor Adaptation, A MA
AMA algorithm determines the electric al parameters for the connected motor at standstill.
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FC 300 Design Guide
How to Read this Design Guide
Brake Resistor
The brake resistor is a module capable of absorbing the brake power generated in regenerative
braking. This regenerative braking power increases the intermediate 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 c onveyor belts ,
displacement pumps and cranes.
D
igital Inputs
The digital inputs can be used for controlling various functions of the frequency converter.
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 registere d 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 interm ittent duty rating refers to a sequence of duty cycles. Each c
ycle consists of an on-load and
an off-load period. The operation can be either periodic duty or none-periodic duty.
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 detachable and can be installed up t
o 3 m etre s from the frequency
converter, i.e. in a front panel by means of the installation kit option.
l
sb
Least significant bit.
M
CM
Short for M ille Circular Mil, an American m easuri n g un
it for cable cross-section. 1 MCM ≡ 0.5067 mm
2
.
m
sb
Most significant bit.
O
n-line/Off-line Parameters
Changes to on-line parameters are activated immediately after the data value is changed. Changes
to off-line parameters are not activated until yo
uenter[OK]ontheLCP.
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.
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FC 300 Design Guide
How to Read this Design Guide
Pulse Input/Incre mental 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 Device.
S
et-up
You can save parameter settings in f our Set-ups. Change betwe en 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 frequency converter compensates for the motor slip by giving the frequency a supplement that
follows the measured moto r load keeping the motor speed almost constant..
S
mart Logic 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 (freque ncy converter or motor).
T
rip
A state entered in fault situat ions, e.g. if the frequency converter is subject to an over-temperature or
when the freq uency converter is protecting t he motor, process or m echanism. Restart is prevented until
the cause of the fault has disappeared and the trip state is cancelled by ac
tivating reset or, in some cases,
by being programmed to reset automatically. Trip may not be used for personal safety.
T
rip Locked
A state entered in fault situations when the frequency converter is protecting itself and requiring p hysical
intervention, e.g. if the frequency converter is subject to a s
hort circuit on the output. A locked trip can
only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the frequency
converter. Restart is pre vented until the trip state is can celled by ac tivating rese t or, in some cases, by
beingprogrammedtoresetautomatically. Tripmaynotbeus
ed 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 and the stability, both when the speed refer
ence is changed and in re lation to the load torque.
6
0° AVM
Switching pattern called 60° A synchronous V ector M odulation (par. 14-00).
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FC 300 Design Guide
How to Read this Design Guide
" 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 w hich extent
the frequency converter impose s 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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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 frequency
converters with software version 2.5x.
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. T he
EU has introduced the CE label as a simple way of showing whether a product complies with
the relevant EU dire ctives. 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 machinery directive of January 1, 1995. S ince
a frequen cy converter is largely electrical, it does not fall unde r the mac hinery directive. H owever, 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 m a nufact ur er’s decla ration.
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. 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, we specify which standards our products comply with. We offer the filters
presented in the specifications and provide other types of assistance to ensure the op timum EMC result.
The frequency converter is mos t ofte n us ed by professionals of the trade as a complex component
forming part of a larger appliance, system or installation. It must be noted that the re spons ibility for
the final EMC properti es of the appliance, system or installation rests with the installer.
" What Is Covered
The EU "Guidelines on the Application of Council Directive 89/336 /EEC" outline three typical situations
of using a frequency converter. See be low for EM C coverage and CE labelling.
1. The frequency converter is sold directly to the end-consumer. The frequen
cy converter is for exam p le
sold to a DIY market. The end-consumer is a layman. He installs the frequency converter himself
for use w ith a hobb y machine, a kitche n appliance, etc. For such applications, the frequency
converter must be CE labelled in accordance with the EMC directive.
2. The frequency 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 profes sionals
of the trade. Neither the fre quency converter nor the finish
ed pla n t has to be CE labelled under the EMC
directive. However, the unit m ust comply with the basic E MC requirements of the directive. This is
ensured b y using components, appliances, and systems that are CE labelled under the EMC dir ective.
3. The frequency converter is sold as part of a complete
system. The system is being marketed as
complete and could e.g. b e an air-conditioning system. The complete system must be CE labelled
in accordance with the EMC directive. The manufacture r can ensure CE labelling under the EMC
directive either by using CE labelled component
s or by testing the E MC of the system . If he choose s
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 original purpose, i.e. to facilitate trade within the EU and EFTA.
However, CE labe lling may cover many different specifications. Thus, you have to check
what a given CE label specifically covers.
The covered specifications can be very different and a CE label m ay therefore give the installer a false
feeling of security when using a
frequency converter as a c omponent in a system or an appliance.
Danfoss CE labels the frequenc
y converters in accordance with the low-voltage dire ctive. This means that if
the frequency converter is installed cor rectly, we guarantee comp liance 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 applie s to the EMC directive p rovided that the instructions for EMC-correct inst allation and
filtering are followed. O
n this basis, a declaration of conformity in accord ance with the EMC d irec tive is issued.
The Design Guide offe rs d
etailed instructions for installation to ensure EM C-correct instal lation.
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 best EMC result.
" 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 noted that the
responsibility for the final EMC properties of the appliance, system or installation rests with the installe r.
As an aid to the installer, Danfoss has pre pare d EMC installation guide lines for the Power Drive System.
The standards and test levels stated for Power Drive Systems are com pl ied with, provided that the
EMC-correct instructions for installation are followed, see section Electrical Installation.
" Mechanical Build-Up
Illustration of the mecha nical 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 frequ en cy converter is built upon a very stable aluminium base integrated with the back pan el.
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 fre quen cy converter, where a majority of the heat
losses 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 screen
The screen allows cold air to pass by the electronics only. The plastic air guide screen is enclosed in
the package and is easily s nap ped in place. If the frequency converter is to operate as a cold plate
drive, the air guiding screen is inserted in the cooling cha nne l through the bottom of the drive if it
is snapped unto t he fan. Thus, the amount of heat transferred t o the surroundings via the cooling
air from the fa n is reduced.
D Removable fan
Like most of the elements , the fan can easily be remove d for easy cleaning and remounted .
E Safe Stop (FC 302 only)
The frequ ency converter co mes standa r d 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 unintended.
F Control terminals
Spring-loaded cage c lamps, screw less terminals, add to reliability and facilitate 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 t he factory. Options moun ted 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 user-interface. Choose between 27 built-in langua ges (including Chinese)
or have it customised with your own languages and phrases.
Additionally a simple version, LCP 101, is available with an alpha- num eric display. A complete
programming of FC 301 and 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 with the MCT-10 set-up software.
" Air Humidity
The frequency converter has b een designed to meet the IEC/EN 60068-2-3 stan-
dard, EN 50178 pkt. 9.4.2.2 at 50°
C.
" Aggressive Environments
A f re quency converter contains a large number of mechanical and electronic components. All
are to some extent vulnerab
le to environmental effects.
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MG.33.B4.02 - 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 necess ary 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 freque ncy 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, coate d printet circuit boads can be orded a s 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 particles 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 0 0/IP 20/TYPE 1 equipmen t.
In environments with high temperatures and humidity,
corrosive gases such as sulphur, nitrogen, and
chlorine compounds will cause chemical processes on the 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 opt ion.
NB!:
Mounting frequency converters in aggressive environments increas
es the risk of stoppages
and considerably reduces the life of the converter.
Before installing the frequency converter, 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 m etal parts, or corrosion of metal parts.
Excessive dust particle levels are often found on installation cabinets and existing electri cal installations. One
indicator of aggressive airborne gases is blackening of copp er rails and cable ends on existing installations.
" Vibration and Shock
The fre quency converter has been tested accord ing
to a procedure based on the shown standards:
The frequency converter complies w ith requirements
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 / curre nt and frequency, which enables 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.
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MG.33.B4.02 - VLT is a registered Danfoss trademark
FC 300 Design Guide
Introduction to FC 300
Speed control:
There are two types of speed control:
• Speed open loop control which does not require any feedback (sensorless).
• Speed closed loop contro l in the form of a PID control that requires a sp eed feedback to an input. A
properly optimised speed closed loop control will have higher accuracy than a speed open loop control.
Selects which input to use as speed PID feedback in par. 7-00 .
T
orque control (FC 302 only):
To rque 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 P rinciple ).
• Flux sensorless offers superior performance in all four quadrants at motor frequencies above 10 Hz.
• Flux with encoder feedback offers superior perform a nc e in all four quadrants and at all m otor speeds.
The "Flux with encoder feedb" mode requires that an encoder speed feedback signal
is present. Select which input to use in par. 1-02.
S
peed / torque reference:
The reference to these controls can either be a single refrence or be the sum of various refe rence s including
relatively scaled refere n ces. The hand ling of references is explained in detail later in this section.
" FC 301 vs. FC 302 Control Principle
FC 301 is a general purpose frequency converter for variable speed applic
ations. The control
principle is based on space Voltage Vector Control (VVC
plus
).
FC 301 can handle asynchronous motors only.
The current sensing principle in FC 301 is based on sum current mea
surement in the DC link. The ground
fault protection on the motor side is solved by a de-saturation circuit in the IGBTs.
FC 302 is a high performance freq
uency converter for demanding applications. The
frequency converter can handle various kinds of motor control p rinciples such as U/f special
motormode,VVCplusorFluxVectormotorcontrol.
FC 302 is able to handle Perma
nent Magnet Synchronous Motors (Brushless servo motors)
as well as normal squirrel cage asynchronous motors.
The current sensing principle in FC 302 is actually sensing the current in each motor phase. The advantage
of having a current transduc
er in each phase is to have full ground failure protection.
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MG.33.B4.02 - VLT is a registered Danfoss trademark
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