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

" 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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FC 300 Design Guide

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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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 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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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 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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MG.33.B4.02 - VLT is a registered Danfoss trademark

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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Danfoss VLT® AutomationDrive User guide

Danfoss VLT® AutomationDrive User guide

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