Danfoss FC 103 Design guide

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MAKING MODERN LIVING POSSIBLE

Design Guide

VLT® Refrigeration Drive FC 103

1.1–90 kW

vlt-drives.danfoss.com

Contents Design Guide

Contents

1 Introduction

1.1 Purpose of the Design Guide

1.2 Organisation

1.3 Additional Resources

1.4 Abbreviations, Symbols and Conventions

1.5 Safety Symbols

1.6 Denitions

1.7 Document and Software Version

1.8 Approvals and Certications

1.8.1 CE Mark 10

1.8.1.1 Low Voltage Directive 10

1.8.1.2 EMC Directive 10

1.8.1.3 Machinery Directive 11

1.8.1.4 ErP Directive 11

1.8.2 C-tick Compliance 11

1.8.3 UL Compliance 11

1.8.4 Marine Compliance (ADN) 11

1.8.5 Export Control Regulations 12

1.9 Safety

1.9.1 General Safety Principles 12

2 Product Overview

2.1 Introduction

2.2 Description of Operation

2.3 Sequence of Operation

2.3.1 Rectier Section 18

2.3.2 Intermediate Section 18

2.3.3 Inverter Section 18

2.4 Control Structures

2.4.1 Control Structure Open Loop 19

2.4.2 Control Structure Closed Loop 19

2.4.3 Local (Hand On) and Remote (Auto On) Control 20

2.4.4 Reference Handling 21

2.4.5 Feedback Handling 23

2.5 Automated Operational Functions

2.5.1 Short-circuit Protection 24

2.5.2 Overvoltage Protection 24

2.5.3 Missing Motor Phase Detection 24

2.5.4 Mains Phase Imbalance Detection 25

Contents

VLT® Refrigeration Drive FC 103

2.5.5 Switching on the Output 25

2.5.6 Overload Protection 25

2.5.7 Automatic Derating 25

2.5.8 Automatic Energy Optimisation 25

2.5.9 Automatic Switching Frequency Modulation 25

2.5.10 Automatic Derating for High Switching Frequency 26

2.5.11 Automatic Derating for Overtemperature 26

2.5.12 Auto Ramping 26

2.5.13 Current Limit Circuit 26

2.5.14 Power Fluctuation Performance 26

2.5.15 Motor Soft Start 26

2.5.16 Resonance Damping 26

2.5.17 Temperature-controlled Fans 26

2.5.18 EMC Compliance 26

2.5.19 Current Measurement on All Three Motor Phases 27

2.5.20 Galvanic Isolation of Control Terminals 27

2.6 Custom Application Functions

2.6.1 Automatic Motor Adaptation 27

2.6.2 Motor Thermal Protection 27

2.6.3 Mains Drop-out 27

2.6.4 Built-in PID Controllers 28

2.6.5 Automatic Restart 28

2.6.6 Flying Start 28

2.6.7 Full Torque at Reduced Speed 28

2.6.8 Frequency Bypass 28

2.6.9 Motor Preheat 28

2.6.10 Four Programmable Set-ups 29

2.6.11 DC Braking 29

2.6.12 Sleep Mode 29

2.6.13 Run Permissive 29

2.6.14 Smart Logic Control (SLC) 29

2.6.15 Safe Torque O Function 30

2.7 Fault, Warning and Alarm Functions

2.7.1 Operation at Overtemperature 31

2.7.2 High and Low Reference Warning 31

2.7.3 High and Low Feedback Warning 31

2.7.4 Phase Imbalance or Phase Loss 31

2.7.5 High Frequency Warning 31

2.7.6 Low Frequency Warning 31

2.7.7 High Current Warning 31

Contents Design Guide

2.7.8 Low Current Warning 31

2.7.9 No Load/Broken Belt Warning 31

2.7.10 Lost Serial Interface 32

2.8 User Interfaces and Programming

2.8.1 Local Control Panel 32

2.8.2 PC Software 33

2.8.2.1 MCT 10 Set-up Software 33

2.8.2.2 VLT® Harmonics Calculation Software MCT 31 33

2.8.2.3 Harmonic Calculation Software (HCS) 33

2.9 Maintenance

2.9.1 Storage 34

3 System Integration

3.1 Ambient Operating Conditions

3.1.1 Humidity 35

3.1.2 Temperature 36

3.1.3 Cooling 36

3.1.4 Motor-generated Overvoltage 37

3.1.5 Acoustic Noise 37

3.1.6 Vibration and Shock 37

3.1.7 Aggressive Atmospheres 37

3.1.8 IP Rating Denitions 38

3.1.9 Radio Frequency Interference 39

3.1.10 PELV and Galvanic Isolation Compliance 39

3.2 EMC, Harmonics, and Ground Leakage Protection

3.2.1 General Aspects of EMC Emissions 40

3.2.2 EMC Test Results (Emission) 42

3.2.3 Emission Requirements 43

3.2.4 Immunity Requirements 43

3.2.5 Motor Insulation 44

3.2.6 Motor Bearing Currents 44

3.2.7 Harmonics 45

3.2.8 Ground Leakage Current 47

3.3 Energy Eciency

3.3.1 IE and IES Classes 50

3.3.2 Power Loss Data and Eciency Data 50

3.3.3 Losses and Eciency of a Motor 51

3.3.4 Losses and Eciency of a Power Drive System 51

3.4 Mains Integration

3.4.1 Mains Congurations and EMC Eects 51

Contents

VLT® Refrigeration Drive FC 103

3.4.2 Low-frequency Mains Interference 52

3.4.3 Analysing Mains Interference 53

3.4.4 Options for Reducing Mains Interference 53

3.4.5 Radio Frequency Interference 53

3.4.6 Classication of the Operating Site 53

3.4.7 Use with Isolated Input Source 54

3.4.8 Power Factor Correction 54

3.4.9 Input Power Delay 54

3.4.10 Mains Transients 54

3.4.11 Operation with a Standby Generator 54

3.5 Motor Integration

3.5.1 Motor Selection Considerations 55

3.5.2 Sine-wave and dU/dt Filters 55

3.5.3 Proper Motor Grounding 55

3.5.4 Motor Cables 55

3.5.5 Motor Cable Shielding 56

3.5.6 Connection of Multiple Motors 56

3.5.7 Motor Thermal Protection 57

3.5.8 Output Contactor 58

3.5.9 Energy Eciency 58

3.6 Additional Inputs and Outputs

3.6.1 Wiring Schematic 59

3.6.2 Relay Connections 60

3.6.3 EMC-compliant Electrical Connection 61

3.7 Mechanical Planning

3.7.1 Clearance 62

3.7.2 Wall Mounting 63

3.7.3 Access 63

3.8 Options and Accessories

3.8.1 Communication Options 66

3.8.2 Input/Output, Feedback, and Safety Options 66

3.8.3 Sine-wave Filters 66

3.8.4 dU/dt Filters 66

3.8.5 Harmonic Filters 66

3.8.6 IP21/NEMA Type 1 Enclosure Kit 67

3.8.7 Common-mode Filters 69

3.8.8 Remote Mounting Kit for LCP 69

3.8.9 Mounting Bracket for Enclosure Sizes A5, B1, B2, C1, and C2 70

3.9 Serial Interface RS485

3.9.1 Overview 71

Contents Design Guide

3.9.2 Network Connection 72

3.9.3 RS485 Bus Termination 72

3.9.4 EMC Precautions 73

3.9.5 FC Protocol Overview 73

3.9.6 Network Conguration 73

3.9.7 FC Protocol Message Framing Structure 73

3.9.8 FC Protocol Examples 77

3.9.9 Modbus RTU Protocol 78

3.9.10 Modbus RTU Message Framing Structure 79

3.9.11 Access to Parameters 82

3.9.12 FC Drive Control Prole 83

3.10 System Design Checklist

4 Application Examples

4.1 Application Examples

4.2 Selected Application Features

4.2.1 SmartStart 91

4.2.2 Start/Stop 92

4.2.3 Pulse Start/Stop 92

4.2.4 Potentiometer Reference 93

4.3 Application Set-up Examples

5 Special Conditions

5.1 Derating

5.2 Manual Derating

5.3 Derating for Long Motor Cables or Cables with Larger Cross-section

5.4 Derating for Ambient Temperature

6 Type Code and Selection

100

104

6.1 Ordering

6.1.1 Introduction 104

6.1.2 Type Code 104

6.2 Options, Accessories, and Spare Parts

6.2.1 Ordering Numbers: Options and Accessories 105

6.2.2 Ordering Numbers: Harmonic Filters 107

6.2.3 Ordering Numbers: Sine-wave Filter Modules, 200–480 V AC 107

6.2.4 Ordering Numbers: Sine-wave Filter Modules, 525-600/690 V AC 108

6.2.5 Harmonic Filters 109

6.2.6 Sine-wave Filters 111

6.2.7 dU/dt Filters 113

6.2.8 Common Mode Filters 114

104

105

Contents

VLT® Refrigeration Drive FC 103

7 Specications

7.1 Electrical Data

7.1.1 Mains Supply 3x200–240 V AC 115

7.1.2 Mains Supply 3x380–480 V AC 117

7.1.3 Mains Supply 3x525–600 V AC 119

7.2 Mains Supply

7.3 Motor Output and Motor Data

7.4 Ambient Conditions

7.5 Cable Specications

7.6 Control Input/Output and Control Data

7.7 Connection Tightening Torque

7.8 Fuses and Circuit Breakers

7.9 Power Ratings, Weight, and Dimensions

7.10 dU/dt Testing

7.11 Acoustic Noise Ratings

7.12 Selected Options

7.12.1 VLT® General Purpose I/O Module MCB 101 135

115

121

122

123

126

127

132

133

135

7.12.2 VLT® Relay Card MCB 105 136

7.12.3 VLT® Extended Relay Card MCB 113 138

8 Appendix - Selected Drawings

8.1 Mains Connection Drawings

8.2 Motor Connection Drawings

8.3 Relay Terminal Drawings

8.4 Cable Entry Holes

Index

140

143

145

146

151

Introduction Design Guide

1 Introduction

1.1 Purpose of the Design Guide

This design guide for VLT® Refrigeration Drive FC 103 frequency converters is intended for:

Project and systems engineers.

•

Design consultants.

•

Application and product specialists.

•

The design guide provides technical information to understand the capabilities of the frequency converter for integration into motor control and monitoring systems.

The purpose of the design guide is to provide design considerations and planning data for integration of the frequency converter into a system. The design guide caters for selection of frequency converters and options for a diversity of applications and installations.

Reviewing the detailed product information in the design stage enables developing a well-conceived system with optimal functionality and

VLT® is a registered trademark.

Organisation

1.2

Chapter 1 Introduction: The general purpose of the design guide and compliance with international directives.

Chapter 2 Product Overview: The internal structure and functionality of the frequency converter and operational features.

Chapter 3 System Integration: Environmental conditions; EMC, harmonics, and ground leakage; mains input; motors and motor connections; other connections; mechanical planning; and descriptions of options and accessories available.

Chapter 4 Application Examples: Samples of product applications and guidelines for use.

eciency.

Chapter 8 Appendix - Selected Drawings: A compilation of graphics illustrating:

Mains and motor connections

•

Relay terminals

•

Cable entries

•

1.3 Additional Resources

Resources available to understand advanced operation of the frequency converter, programming, and directives compliance:

The VLT® Refrigeration Drive FC 103 Operating

•

Instructions (referenced as operating instructions in this manual) provide detailed information for the installation and start-up of the frequency converter.

The VLT® Refrigeration Drive FC 103 Design Guide

•

provides information required for design and planning for integration of the frequency converter into a system.

The VLT

•

Guide (referenced as programming guide in this manual) provides greater detail about how to work with parameters and many application examples.

The VLT® Safe Torque O Operating Instructions

•

describe how to use Danfoss frequency converters in functional safety applications. This manual is supplied with the frequency converter when the STO option is present.

Supplemental publications and manuals are available for download from vlt-drives.danfoss.com/Products/Detail/

Technical-Documents.

Refrigeration Drive FC 103 Programming

NOTICE

Optional equipment is available that may change some of the information described in these publications. Be sure to see the instructions supplied with the options for specic requirements.

1 1

Chapter 5 Special Conditions: Details on unusual operational environments.

Chapter 6 Type Code and Selection: Procedures for ordering equipment and options to meet the intended use of the system.

Chapter 7

table and graphics format.

Specications: A compilation of technical data in

Contact a Danfoss supplier or visit www.danfoss.com for more information.

Introduction

VLT® Refrigeration Drive FC 103

1.4 Abbreviations, Symbols and Conventions

60° AVM 60° asynchronous vector modulation

A Ampere/AMP

AC Alternating current

AD Air discharge

AEO Automatic energy optimisation

AI Analog input

AMA Automatic motor adaptation

AWG American wire gauge

°C

CD Constant discharge

CDM Complete drive module: the frequency converter,

CM Common mode

CT Constant torque

DC Direct current

DI Digital input

DM Dierential mode

D-TYPE Drive dependent

EMC Electromagnetic compatibility

EMF Electromotive force

ETR Electronic thermal relay

JOG

MAX

MIN

M,N

FC Frequency converter

g Gramme

Hiperface®Hiperface® is a registered trademark by Stegmann

HO High overload

hp Horse power

HTL HTL encoder (10–30 V) pulses - High-voltage

Hz Hertz

INV

LIM

M,N

VLT,MAX

VLT,N

kHz Kilohertz

LCP Local control panel

lsb Least signicant bit

m Meter

Degrees celsius

feeding section and auxiliaries

Motor frequency when jog function is activated.

Motor frequency

Maximum output frequency, the frequency

converter applies on its output.

Minimum motor frequency from the frequency

converter

Nominal motor frequency

transistor logic

Rated inverter output current

Current limit

Nominal motor current

Maximum output current

Rated output current supplied by the frequency

converter

ms Millisecond

msb Most signicant bit

VLT

Eciency of the frequency converter dened as

ratio between power output and power input.

nF Capacitance in nano Farad

NLCP Numerical local control panel

Nm Newton meter

NO Normal overload

Online/

Oine

Synchronous motor speed

Changes to online parameters are activated

immediately after the data value is changed.

Parameters

br,cont.

Rated power of the brake resistor (average power

during continuous braking).

PCB Printed circuit board

PCD Process data

PDS Power drive system: a CDM and a motor

PELV Protective extra low voltage

Frequency converter nominal output power as

high overload (HO).

M,N

Nominal motor power

PM motor Permanent magnet motor

Process PID PID (Proportional Integrated Dierential) regulator

that maintains the speed, pressure, temperature,

and so on.

br,nom

Nominal resistor value that ensures a brake power

on the motor shaft of 150/160% for 1 minute

RCD Residual current device

Regen Regenerative terminals

min

Minimum permissible brake resistor value by

frequency converter

RMS Root mean square

RPM Revolutions per minute

rec

Recommended brake resistor resistance of

Danfoss brake resistors

s Second

SFAVM Stator ux-oriented asynchronous vector

modulation

STW Status word

SMPS Switch mode power supply

THD Total harmonic distortion

LIM

Torque limit

TTL TTL encoder (5 V) pulses - transistor transistor

logic

M,N

Nominal motor voltage

V Volts

VT Variable torque

VVC+

Voltage vector control plus

Table 1.1 Abbreviations

mA Milliampere

MCM Mille circular mil

MCT Motion control tool

mH Inductance in milli Henry

mm Millimeter

Introduction Design Guide

Conventions

Numbered lists indicate procedures. Bullet lists indicate other information and description of illustrations. Italicised text indicates:

Cross reference.

•

Link.

•

Footnote.

•

Parameter name, parameter group name,

•

parameter option.

All dimensions are in mm (inch). * indicates a default setting of a parameter.

1.5 Safety Symbols

The following symbols are used in this manual:

WARNING

Indicates a potentially hazardous situation that could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could result in minor or moderate injury. It can also be used to alert against unsafe practices.

NOTICE

Indicates important information, including situations that can result in damage to equipment or property.

1.6 Denitions

Coast

The motor shaft is in free mode. No torque on the motor.

CT characteristics

Constant torque characteristics used for all applications such as:

Conveyor belts.

•

Displacement pumps.

•

Cranes.

•

Initialising

If initialising is carried out (parameter 14-22 Operation Mode), the frequency converter returns to the default

setting.

Intermittent duty cycle

An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an period. The operation can be either periodic duty or nonperiodic duty.

o-load

Power factor

The true power factor (lambda) considers all the harmonics. The true power factor is always smaller than the power factor (cosphi) that only considers the 1st harmonics of current and voltage.

cosϕ = 

Cosphi is also known as displacement power factor.

Both lambda and cosphi are stated for Danfoss VLT frequency converters in chapter 7.2 Mains Supply.

The power factor indicates to which extent the frequency converter imposes a load on the mains supply. The lower the power factor, the higher the I same kW performance.

In addition, a high power factor indicates that the harmonic currents are low. All Danfoss frequency converters have built-in DC coils in the DC link. The coils ensure a high power factor and reduce the THDi on the main supply.

Set-up

Save parameter settings in 4 set-ups. Change between the 4 parameter set-ups and edit 1 set-up while another set-up is active.

Slip compensation

The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load, keeping the motor speed almost constant.

Smart logic control (SLC)

The SLC is a sequence of when the associated user-dened events are evaluated as true by the SLC. (Parameter group 13-** Smart Logic).

FC standard bus

Includes RS485 bus with FC protocol or MC protocol. See parameter 8-30 Protocol.

Thermistor

A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).

Trip

A state entered in fault situations, such as when the frequency converter is subject to an overtemperature or when it protects the motor, process, or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled. Cancel the trip state by:

Do not use trip for personal safety.

P kW

P kVA

Activating reset, or

•

Programming the frequency converter to reset

•

automatically

UλxIλxcosϕ

 = 

UλxIλ

for the

RMS

user-dened actions executed

1 1

Introduction

VLT® Refrigeration Drive FC 103

Trip lock

A state entered in fault situations when the frequency converter is protecting itself and requires physical intervention, for example if the frequency converter is subject to a short circuit on the output. A locked trip can only be cancelled by cutting o mains, removing the cause of the fault, and reconnecting the frequency converter. Restart is prevented until the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically. Do not use trip for personal safety.

VT characteristics

Variable torque characteristics for pumps and fans.

1.7 Document and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome.

Table 1.2 shows the document version and the corresponding software version.

Edition Remarks Software version

MG16G2xx Replaces MG16G1xx 1.4x

Table 1.2 Document and Software Version

Approvals and Certications

1.8

Frequency converters are designed in compliance with the directives described in this section.

NOTICE

Frequency converters with an integrated safety function must comply with the machinery directive.

EU Directive Version

Low Voltage Directive 2014/35/EU

EMC Directive 2014/30/EU

Machinery Directive

ErP Directive 2009/125/EC

ATEX Directive 2014/34/EU

RoHS Directive 2002/95/EC

Table 1.3 EU Directives Applicable to Frequency Converters

1) Machinery Directive conformance is only required for frequency

converters with an integrated safety function.

Declarations of conformity are available on request.

1.8.1.1 Low Voltage Directive

The Low Voltage Directive applies to all electrical equipment in the 50–1000 V AC and the 75–1600 V DC voltage ranges.

The aim of the directive is to ensure personal safety and avoid property damage, when operating electrical equipment that is installed, maintained, and used as intended.

2014/32/EU

1.8.1.2 EMC Directive

For more information on approvals and certicates, go to the download area at vlt-marine.danfoss.com/support/type- approval-certicates/.

1.8.1 CE Mark

Illustration 1.1 CE

The CE mark (Communauté Européenne) indicates that the product manufacturer conforms to all applicable EU directives. The EU directives applicable to the design and manufacture of frequency converters are listed in Table 1.3.

The purpose of the EMC (electromagnetic compatibility) Directive is to reduce electromagnetic interference and enhance immunity of electrical equipment and installations. The basic protection requirement of the EMC Directive is that devices that generate electromagnetic interference (EMI), or whose operation could be aected by EMI, must be designed to limit the generation of electromagnetic interference. The devices must have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

Electrical equipment devices used alone or as part of a system must bear the CE mark. Systems do not require the CE mark, but must comply with the basic protection requirements of the EMC Directive.

NOTICE

The CE mark does not regulate the quality of the product. Technical specications cannot be deduced from the CE mark.

Introduction Design Guide

1.8.1.3 Machinery Directive

The aim of the Machinery Directive is to ensure personal safety and avoid property damage for mechanical equipment used in its intended application. The Machinery Directive applies to a machine consisting of an aggregate of interconnected components or devices of which at least 1 is capable of mechanical movement.

Frequency converters with an integrated safety function must comply with the Machinery Directive. Frequency converters without a safety function do not fall under the Machinery Directive. If a frequency converter is integrated into a machinery system, Danfoss can provide information on safety aspects relating to the frequency converter.

When frequency converters are used in machines with at least 1 moving part, the machine manufacturer must provide a declaration stating compliance with all relevant statutes and safety measures.

1.8.1.4 ErP Directive

The ErP Directive is the European Ecodesign Directive for energy-related products. The directive sets ecodesign requirements for energy-related products, including frequency converters. The aim of the directive is to increase energy eciency and the level of protection of the environment, while increasing the security of the energy supply. Environmental impact of energy-related products includes energy consumption throughout the entire product life cycle.

1.8.2 C-tick Compliance

Illustration 1.2 C-tick

1.8.3 UL Compliance

UL Listed

Illustration 1.3 UL

NOTICE

525–690 V frequency converters are not certied for UL.

The frequency converter complies with UL 508C thermal memory retention requirements. For more information, refer to chapter 2.6.2 Motor Thermal Protection.

1.8.4 Marine Compliance (ADN)

Units with ingress protection rating IP55 (NEMA 12) or higher prevent spark formation, and are classied as limited explosion risk electrical apparatus in accordance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN).

For units with ingress protection rating IP20/Chassis, IP21/ NEMA 1, or IP54, prevent risk of spark formation as follows:

Do not install a mains switch.

•

Ensure that parameter 14-50 RFI Filter is set to [1]

•

On.

Remove all relay plugs marked RELAY. See

•

Illustration 1.4.

Check which relay options are installed, if any.

•

The only permitted relay option is VLT® Extended Relay Card MCB 113.

Go to vlt-marine.danfoss.com/support/type-approval-certif- icates/ for additional marine approvals information.

1 1

The C-tick label indicates compliance with the applicable technical standards for Electromagnetic Compatibility (EMC). C-tick compliance is required for placing electrical and electronic devices on the market in Australia and New Zealand.

The C-tick regulatory is about conducted and radiated emission. For frequency converters, apply the emission limits specied in EN/IEC 61800-3.

A declaration of conformity can be provided on request.

130BD832.10

Introduction

VLT® Refrigeration Drive FC 103

1.9

Safety

1.9.1 General Safety Principles

If handled improperly, frequency converters have the potential for fatal injury as they contain high-voltage components. Only operate the equipment. Do not attempt repair work without rst removing power from the frequency converter and waiting the designated amount of time for stored electrical energy to dissipate.

Strict adherence to safety precautions and notices is mandatory for safe operation of the frequency converter.

Correct and reliable transport, storage, installation, operation, and maintenance are required for the troublefree and safe operation of the frequency converter. Only qualied personnel are allowed to install and operate this equipment.

Qualied personnel are dened as trained sta, who are authorised to install, commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Additionally, the qualied personnel must be familiar with the instructions and safety measures described in these operating instructions.

1, 2 Relay plugs

qualied personnel should install and

WARNING

Illustration 1.4 Location of Relay Plugs

Manufacturer declaration is available on request.

1.8.5 Export Control Regulations

Frequency converters can be subject to regional and/or national export control regulations.

HIGH VOLTAGE

Frequency converters contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation, start-up, and maintenance by qualied personnel can result in death or serious injury.

Only qualied personnel must perform instal-

•

lation, start-up, and maintenance.

The frequency converters that are subject to export control regulations are classied by an ECCN number.

The ECCN number is provided in the documents accompanying the frequency converter.

In case of re-export, it is the responsibility of the exporter to ensure compliance with the relevant export control regulations.

Introduction Design Guide

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains, DC supply, or load sharing, the motor may start at any time. Unintended start during programming, service, or repair work can result in death, serious injury, or property damage. The motor can start via an external switch, a eldbus command, an input reference signal from the LCP, or after a cleared fault condition. To prevent unintended motor start:

Disconnect the frequency converter from the

•

mains.

Press [O/Reset] on the LCP before

•

programming parameters.

Completely wire and assemble the frequency

•

converter, motor, and any driven equipment before connecting the frequency converter to AC mains, DC supply, or load sharing.

WARNING

DISCHARGE TIME

The frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not powered. High voltage may be present even when the warning LED indicator lights are o. Failure to wait the specied time after power has been removed before performing service or repair work, could result in death or serious injury.

1. Stop the motor.

2. Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and DC-link connections to other frequency converters.

3. Wait for the capacitors to discharge fully, before performing any service or repair work. The duration of waiting time is specied in Table 1.4.

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground frequency converter properly can result in death or serious injury.

Ensure the correct grounding of the equipment

•

by a certied electrical installer.

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

Ensure that only trained and qualied personnel

•

perform installation, start-up, and maintenance.

Ensure that electrical work conforms to national

•

and local electrical codes.

Follow the procedures in this manual.

•

WARNING

UNINTENDED MOTOR ROTATION WINDMILLING

Unintended rotation of permanent magnet motors creates voltage and can charge the unit, resulting in death, serious injury, or equipment damage.

Ensure that permanent magnet motors are

•

blocked to prevent unintended rotation.

CAUTION

INTERNAL FAILURE HAZARD

An internal failure in the frequency converter can result in serious injury, when the frequency converter is not properly closed.

Ensure that all safety covers are in place and

•

securely fastened before applying power.

1 1

Voltage [V] Minimum waiting time (minutes)

4 15

200–240 1.1–3.7 kW 5.5–45 kW

380–480 1.1–7.5 kW 11–90 kW

525–600 1.1–7.5 kW 11–90 kW

Table 1.4 Discharge Time

130BD889.10

0 100 200 300 400

(mwg)

1350rpm

1650rpm

(kW)

200100 300

(

m3 /h

)

(

m3 /h

)

400

1350rpm

1650rpm

shaft

Product Overview

VLT® Refrigeration Drive FC 103

2 Product Overview

2.1 Introduction

2.1.2 Energy Savings

This chapter provides an overview of the frequency converter’s primary assemblies and circuitry. It describes the internal electrical and signal processing functions. A description of the internal control structure is also included.

Also described are automated and optional frequency converter functions available for designing robust operating systems with sophisticated control and status reporting performance.

2.1.1 Product Dedication to Refrigeration Applications

The VLT® Refrigeration Drive FC 103 is designed for refrigeration applications. The integrated application wizard guides the user through the commissioning process. The range of standard and optional features includes:

Multi-zone cascade control

•

Neutral zone control.

•

Floating condensing temperature control.

•

Oil return management.

•

Multi-feedback evaporator control.

•

Cascade control.

•

Dry-run detection.

•

End of curve detection.

•

Motor alternation.

•

STO.

•

Sleep mode.

•

Password protection.

•

Overload protection.

•

Smart logic control.

•

Minimum speed monitor.

•

Free programmable texts for information,

•

warnings, and alerts.

When comparing with alternative control systems and technologies, a frequency converter is the optimum energy control system for controlling fan and pump systems.

By using a frequency converter to control the ow, a pump speed reduction of 20% leads to energy savings of about 50% in typical applications. Illustration 2.1 shows an example of the achievable energy reduction.

1 Energy saving

Illustration 2.1 Example: Energy Saving

100%

50%

25%

12,5%

50% 100%

80%

175HA208.10

Power ~n

Pressure ~n

Flow ~n

500

[h]

1000

1500

2000

200100 300

/h]

400

175HA210.11

Product Overview Design Guide

2.1.3 Example of Energy Savings

As shown in Illustration 2.2, the ow is controlled by changing the pump speed, measured in RPM. By reducing the speed only 20% from the rated speed, the ow is also reduced by 20%. The ow is directly proportional to the speed. The consumption of electricity is reduced by up to 50%. If the system only has to supply a ow that corresponds to 100% a few days in a year, while the average is below 80% of the rated ow for the remainder of the year, the energy savings are even greater than 50%.

Illustration 2.2 describes the dependence of and power consumption on pump speed in RPM for centrifugal pumps.

ow, pressure,

2.1.4 Example with Varying Flow over 1 Year

This example is calculated based on pump characteristics obtained from a pump datasheet, shown in Illustration 2.4.

The result obtained shows energy savings in excess of 50% at the given ow distribution over a year, see Illustration 2.3. The payback period depends on the price of electricity and the price of the frequency converter. In this example, payback is less than a year, when compared with valves and constant speed.

2 2

t [h] Duration of ow. See also Table 2.2.

Flowrate

Illustration 2.2 Anity Laws for Centrifugal Pumps

Flow: 

Pressure: 

Power:

 = 

Q [m3/h]

Illustration 2.3 Flow Distribution over 1 Year (Duration versus

Flowrate)

Assuming an equal eciency in the speed range.

Q=Flow P=Power

Q1=Flow 1 P1=Power 1

Q2=Reduced ow P2=Reduced power

H=Pressure n=Speed regulation

H1=Pressure 1 n1=Speed 1

H2=Reduced pressure n2=Reduced speed

Table 2.1 Anity Laws

175HA209.11

0 100 200 300 400

(mwg)

750rpm

1050rpm

1350rpm

1650rpm

(kW)

200100 300

(

m3 /h

)

(

m3 /h

)

400

750rpm

1050rpm

1350rpm

1650rpm

shaft

Full load

% Full-load current

& speed

500

100

0 12,5 25 37,5 50Hz

200

300

400

600

700

800

175HA227.10

Product Overview

VLT® Refrigeration Drive FC 103

2.1.5 Improved Control

or pressure of a system. Use a frequency converter to vary the speed of the compressor, fan, or pump, obtaining variable control of ow and pressure. Furthermore, a frequency converter can quickly adapt the speed of the compressor, fan, or pump to new ow or pressure conditions in the system. Obtain simple control of process (ow, level, or pressure) utilising the built-in PI control.

2.1.6 Star/Delta Starter or Soft Starter

When large motors are started, it is necessary in many countries to use equipment that limits the start-up current. In more traditional systems, a star/delta starter or soft starter is widely used. If a frequency converter is used, such motor starters are not required.

As illustrated in Illustration 2.5, a frequency converter does not consume more than rated current.

Use a frequency converter to improve control of the ow

Illustration 2.4 Energy Consumption at Dierent Speeds

Flow

Distribution Valve regulation Frequency

rate

% Duration Power Consump-

[m3/h]

[h] [kW] [kWh] [kW] [kWh]

350 5 438

42.5

300 15 1314 38.5 50.589 29.0 38.106

250 20 1752 35.0 61.320 18.5 32.412

200 20 1752 31.5 55.188 11.5 20.148

150 20 1752 28.0 49.056 6.5 11.388

100 20 1752

1008760 – 275.064 – 26.801

23.0

Table 2.2 Result

1) Power reading at point A1.

2) Power reading at point B1.

3) Power reading at point C1.

tion

18.615

40.296

Power Consump-

42.5

3.5

converter

control

18.615

tion

6.132

VLT® Refrigeration Drive FC 103

2 Star/delta starter

3 Soft starter

4 Start directly on mains

Illustration 2.5 Start-up Current

Product Overview Design Guide

2.2 Description of Operation

The frequency converter supplies a regulated amount of mains AC power to the motor to control its speed. The frequency converter supplies variable frequency and voltage to the motor.

The frequency converter is divided into 4 main modules:

Rectier

•

Intermediate DC bus circuit

•

Inverter

•

Control and regulation

•

Illustration 2.6 is a block diagram of the internal components of the frequency converter.

Area Title Functions

Input power, internal processing,

•

output, and motor current are

monitored to provide ecient

operation and control.

User interface and external

8 Control circuitry

Illustration 2.6 Frequency Converter Block Diagram

•

commands are monitored and

performed.

Status output and control can be

•

provided.

2 2

Area Title Functions

3-phase AC mains supply to the

1 Mains input

2 Rectier

3 DC bus

4 DC reactors

5 Capacitor bank

6 Inverter

7 Output to motor

•

frequency converter.

The rectier bridge converts the

•

AC input to DC current to supply

inverter power.

Intermediate DC bus circuit

•

handles the DC current.

Filter the intermediate DC circuit

•

voltage.

Prove mains transient protection.

•

Reduce RMS current.

•

Raise the power factor reected

•

back to the line.

Reduce harmonics on the AC

•

input.

Stores the DC power.

•

Provides ride-through protection

•

for short power losses.

Converts the DC into a controlled

•

PWM AC waveform for a

controlled variable output to the

motor.

Regulated 3-phase output power

•

to the motor.

Inrush

R inr

Load sharing -

Load sharing +

LC Filter (5A)

LC Filter + (5A)

Brake Resistor

130BA193.14

L2 92

L1 91

L3 93

89(+)

88(-)

R+ 82

R81

U 96

V 97

W 98

P 14-50 R Filter

Product Overview

VLT® Refrigeration Drive FC 103

2.2.1 Control Structure Principle

speed control of 3-phased, standard asynchronous motors and non-salient PM motors.

The frequency converter recties AC voltage from

•

mains into DC voltage.

The DC voltage is converted into an AC current

•

with a variable amplitude and frequency.

The frequency converter manages various motor control principles such as U/f special motor mode and VVC+. Shortcircuit behaviour of the frequency converter depends on the 3 current transducers in the motor phases.

The frequency converter supplies the motor with variable voltage/current and frequency, which enables variable

Illustration 2.7 Frequency Converter Structure

2.3 Sequence of Operation

2.3.1 Rectier Section

When power is applied to the frequency converter, it enters through the mains terminals (L1, L2, and L3). Depending on the unit

conguration, the power moves on

to the disconnect and/or RFI lter option.

2.3.2 Intermediate Section

Following the rectier section, voltage passes to the intermediate section. A lter circuit consisting of the DC bus inductor and the DC bus capacitor bank smoothes the rectied voltage.

The DC bus inductor provides series impedance to changing current. This aids the ltering process while reducing harmonic distortion to the input AC current waveform normally inherent in rectier circuits.

2.3.3 Inverter Section

In the inverter section, once a run command and speed reference are present, the IGBTs begin switching to create the output waveform. This waveform, as generated by the Danfoss VVC+ PWM principle at the control card, provides optimal performance and minimal losses in the motor.

130BB153.10

100%

-100%

100%

P 3-13 Reference site

Local reference scaled to RPM or Hz

Auto mode

Hand mode

LCP Hand on, o and auto on keys

Linked to hand/auto

Local

Remote

Reference

Ramp

P 4-10 Motor speed direction

To motor control

Reference handling Remote reference

P 4-13 Motor speed high limit [RPM]

P 4-14 Motor speed high limit [Hz]

P 4-11 Motor speed low limit [RPM]

P 4-12 Motor speed low limit [Hz]

P 3-4* Ramp 1 P 3-5* Ramp 2

P 20-81

PID Normal/Inverse

Control

PID

Ref. Handling

Feedback Handling

Scale to speed

P 4-10

Motor speed

direction

To motor control

(Illustration)

130BA359.12



100%

-100%

100%

*[-1]

Product Overview Design Guide

2.4 Control Structures

2.4.1 Control Structure Open Loop

When operating in open-loop mode, the frequency converter responds to input commands manually via the LCP keys or remotely via the analog/digital inputs or serial bus.

In the conguration shown in Illustration 2.8, the frequency converter operates in open-loop mode. It receives input

from either the LCP (Hand mode) or via a remote signal (Auto mode). The signal (speed reference) is received and conditioned with the following:

Programmed minimum and maximum motor

•

speed limits (in RPM and Hz).

Ramp-up and ramp-down times.

•

Motor rotation direction.

•

The reference is then passed on to control the motor.

2 2

Illustration 2.8 Block Diagram of Open-loop Mode

2.4.2 Control Structure Closed Loop

frequency converter can provide status and alarm messages, along with many other programmable options,

In closed-loop mode, an internal PID controller allows the frequency converter to process system reference and

for external system monitoring while operating independently in closed loop.

feedback signals to act as an independent control unit. The

Illustration 2.9 Block Diagram of Closed-loop Controller

For example, consider a pump application in which the speed of a pump is controlled so that the static pressure in a pipe is constant (see Illustration 2.9). The frequency converter receives a feedback signal from a sensor in the system. It compares this feedback to a setpoint reference value and determines the error, if any, between these 2

signals. It then adjusts the speed of the motor to correct this error.

The static pressure setpoint is the reference signal to the frequency converter. A static pressure sensor measures the actual static pressure in the pipe and provides this

Remote reference

Local reference

Auto mode

Hand mode

Linked to hand/auto

Local

Remote

Reference

130BA245.11

LCP Hand on, o and auto on keys

P 3-13 Reference site

130BD893.10

open loop

Scale to

RPM or

Scale to

closed loop

unit

closed loop

Local

ref.

Local

reference

Conguration

mode

P 1-00

Product Overview

VLT® Refrigeration Drive FC 103

information to the frequency converter as a feedback signal. If the feedback signal exceeds the setpoint reference, the frequency converter ramps down to reduce

the pressure. Similarly, if the pipe pressure is lower than the setpoint reference, the frequency converter ramps up to increase the pump pressure.

While the default values for the frequency converter in closed loop often provide satisfactory performance, system control can often be optimised by tuning the PID parameters. Auto tuning is provided for this optimisation.

Other programmable features include:

Inverse regulation - motor speed increases when

•

a feedback signal is high. This is useful in compressor applications, where speed needs to be increased if the pressure/temperarure is too high.

Start-up frequency - lets the system quickly reach

•

an operating status before the PID controller takes over.

Built-in lowpass lter - reduces feedback signal

•

noise.

2.4.3 Local (Hand On) and Remote (Auto On) Control

Operate the frequency converter manually via the LCP, or remotely via analog and digital inputs, and serial bus.

Active reference and conguration mode

The active reference is either a local reference or a remote reference. Remote reference is the default setting.

To use the local reference, congure in Hand

•

mode. To enable Hand mode, adapt parameter settings in parameter group 0–4* LCP Keypad. For more information, refer to the programming guide.

To use the remote reference, congure in Auto

•

mode, which is the default mode. In Auto mode, it is possible to control the frequency converter via the digital inputs and various serial interfaces (RS485, USB, or an optional eldbus).

Illustration 2.10 shows the conguration mode

•

resulting from active reference selection, either local or remote.

Illustration 2.11 shows manual conguration mode

•

for local reference.

Illustration 2.10 Active Reference

Illustration 2.11 Manual Conguration Mode

Application control principle

Either the remote reference or the local reference is active at any time. Both cannot be active simultaneously. Set the application control principle (that is, open loop or closed loop) in parameter 1-00 Conguration Mode, as shown in Table 2.3. When the local reference is active, set the application control principle in parameter 1-05 Local Mode Congu- ration. Set the reference site in parameter 3-13 Reference Site, as shown in Table 2.3.

For more information, refer to the programming guide.

Product Overview Design Guide

[Hand On]

[Auto On]

LCP Keys

Hand Linked to Hand/Auto Local

Hand⇒O

Auto Linked to Hand/Auto Remote

Auto⇒O

All keys Local Local

All keys Remote Remote

Table 2.3 Local and Remote Reference Congurations

Parameter 3-13 Reference

Site

Linked to Hand/Auto Local

Linked to Hand/Auto Remote

Active Reference

2.4.4 Reference Handling

Reference handling is applicable in both open- and closedloop operation.

Internal and external references

Up to 8 internal preset references can be programmed into the frequency converter. The active internal preset reference can be selected externally through digital control inputs or the serial communications bus.

External references can also be supplied to the frequency converter, most commonly through an analog control input. All reference sources and the bus reference are added to produce the total external reference. As active reference select one of the following:

The external reference

•

The preset reference

•

The setpoint

•

The sum of all the above 3

•

The active reference can be scaled.

The scaled reference is calculated as follows:

Reference = X + X × 

Where X is the external reference, the preset reference, or the sum of these references, and Y is parameter 3-14 Preset Relative Reference in [%].

If Y, parameter 3-14 Preset Relative Reference, is set to 0%, the scaling does not aect the reference.

Remote reference

A remote reference is comprised of the following (see Illustration 2.12):

Preset references

•

External references:

•

- Analog inputs

- Pulse frequency inputs

- Digital potentiometer inputs

- Serial communication bus references

A preset relative reference

•

A feedback controlled setpoint

•

100

2 2

Preset relative ref.

Preset ref.Ref. 1 source

Ext. closed loop outputs

No function

Analog inputs

Frequency inputs

No function

Freeze ref.

Speed up/ speed down

ref.

Remote

Ref. in %

[1]

[2]

[3]

[4]

[5]

[6]

[7]

Open loop

Freeze ref. & increase/ decrease ref.

Scale to RPM,Hz

or %

Scale to

Closed loop unit

Relative X+X*Y /100

DigiPot

max ref.

min ref.

[0]

o

Conguration mode

Closed loop

Input command:

Ref. function

Ref. Preset

Input command:

Preset ref. bit0, bit1, bit2

External reference in %

Bus reference

Open loop

From Feedback Handling

Setpoint

Conguration mode

Input command:

Digipot ref.

Increase

Decrease

Clear

DigiPot

Closed loop

Ref. 2 sourceRef. 3 source

Analog inputs

Frequency inputs

Analog inputs

Frequency inputs

Ext. closed loop outputs

P 3-10P 3-15P 3-16P 3-17

P 1-00

P 3-14

±100%

130BA357.12

P 3-04

±200%

P 1-00

±200%

0/1



Product Overview

VLT® Refrigeration Drive FC 103

Illustration 2.12 Remote Reference Handling

Setpoint 1

P 20-21

Setpoint 2

P 20-22

Setpoint 3

P 20-23

Feedback 1 Source

P 20-00

Feedback 2 Source

P 20-03

Feedback 3 Source

P 20-06

Feedback conv. P 20-01

Feedback conv. P 20-04

Feedback conv. P 20-07

Feedback 1

Feedback 2

Feedback 3

Feedback

Feedback Function

P 20-20

Multi setpoint min. Multi setpoint max.

Feedback 1 only Feedback 2 only Feedback 3 only Sum (1+2+3) Dierence (1-2) Average (1+2+3) Minimum (1|2|3) Maximum (1|2|3)

Setpoint to Reference Handling

130BA354.12

Product Overview Design Guide

2.4.5 Feedback Handling

Feedback handling can be congured to work with applications requiring advanced control, such as multiple setpoints and multiple types of feedback (see Illustration 2.13. 3 types of control are common:

Single zone, single setpoint

This control type is a basic feedback Setpoint 1 is added to any other reference (if any) and the feedback signal is selected.

Multi-zone, single setpoint

This control type uses 2 or 3 feedback sensors but only 1 setpoint. The feedback can be added, subtracted, or averaged. In addition, the maximum or minimum value can be used. Setpoint 1 is used exclusively in this congu-

ration.

conguration.

Multi-zone, setpoint/feedback

The setpoint/feedback pair with the largest dierence controls the speed of the frequency converter. The maximum attempts to keep all zones at or below their respective setpoints, while minimum attempts to keep all zones at or above their respective setpoints.

Example

A 2-zone, 2-setpoint application. Zone 1 setpoint is 15 bar, and the feedback is 5.5 bar. Zone 2 setpoint is 4.4 bar, and the feedback is 4.6 bar. If maximum is selected, the zone 2 setpoint and feedback are sent to the PID controller, since it has the smaller dierence (feedback is higher than setpoint, resulting in a negative dierence). If minimum is selected, the zone 1 setpoint and feedback is sent to the PID controller, since it has the larger dierence (feedback is lower than setpoint, resulting in a positive dierence).

2 2

Illustration 2.13 Block Diagram of Feedback Signal Processing

PID

130BA358.11

Ref. signal

Desired

ow

P 20-07

FB conversion

Ref.

Flow

FB signal

Flow

P 20-04

P 20-01

Product Overview

VLT® Refrigeration Drive FC 103

Feedback conversion

In some applications, it is useful to convert the feedback signal. One example is using a pressure signal to provide

ow feedback. Since the square root of pressure is proportional to ow, the square root of the pressure signal yields a value proportional to the ow, see Illustration 2.14.

Illustration 2.14 Feedback Conversion

2.5 Automated Operational Functions

Automated operational features are active as soon as the frequency converter is operating. Most of them require no programming or set-up. Understanding that these features are present can optimise a system design and possibly avoid introducing redundant components or functionality.

For details of any set-up required, in particular motor parameters, refer to the programming guide.

The frequency converter has a range of built-in protection functions to protect itself and the motor when it runs.

2.5.1 Short-circuit Protection

2.5.2 Overvoltage Protection

Motor-generated overvoltage

When the motor acts as a generator, the voltage in the DC link increases. This behaviour occurs in the following cases:

The load drives the motor (at constant output

•

frequency from the frequency converter), for example, the load generates energy.

During deceleration (ramp down) with high

•

inertia moment, low friction, and a too short ramp-down time for the energy to be dissipated as a loss in the frequency converter, the motor, and the installation.

Incorrect slip compensation setting may cause

•

higher DC-link voltage.

Back EMF from PM motor operation. If coasted at

•

high RPM, the PM motor back EMF may potentially exceed the maximum voltage tolerance of the frequency converter and cause damage. To prevent this situation, the value of parameter 4-19 Max Output Frequency is automatically limited via an internal calculation based on the value of parameter 1-40 Back EMF at 1000

RPM, parameter 1-25 Motor Nominal Speed, and parameter 1-39 Motor Poles.

NOTICE

To avoid motor overspeeding (for example due to excessive windmilling eects or uncontrolled water ow), equip the frequency converter with a brake resistor.

Handle the overvoltage by either using a brake function (parameter 2-10 Brake Function) or using overvoltage control (parameter 2-17 Over-voltage Control).

Motor (phase-phase)

The frequency converter is protected against short circuits on the motor side by current measurement in each of the motor phases or in the DC link. A short circuit between 2 output phases causes an overcurrent in the inverter. The inverter is turned o when the short-circuit current exceeds the permitted value (Alarm 16, Trip Lock).

Mains side

A frequency converter that works correctly limits the current it can draw from the supply. Use fuses and/or circuit breakers on the supply side as protection in case of component break-down inside the frequency converter (rst fault). See chapter 7.8 Fuses and Circuit Breakers for more information.

NOTICE

To ensure compliance with IEC 60364 for CE or NEC 2009 for UL, it is mandatory to use fuses and/or circuit breakers.

Overvoltage control (OVC)

OVC reduces the risk of the frequency converter tripping due to an overvoltage on the DC-link. This is managed by automatically extending the ramp-down time.

NOTICE

OVC can be activated for PM motors (PM VVC+).

2.5.3 Missing Motor Phase Detection

The missing motor phase function (parameter 4-58 Missing Motor Phase Function) is enabled by default to avoid motor damage in the case that a motor phase is missing. The default setting is 1000 ms, but it can be adjusted for a faster detection.

Product Overview Design Guide

2.5.4 Mains Phase Imbalance Detection

Operation under severe mains imbalance conditions reduces the lifetime of the motor. If the motor is operated continuously near nominal load, conditions are considered severe. The default setting trips the frequency converter in case of mains imbalance (parameter 14-12 Function at Mains Imbalance).

2.5.5 Switching on the Output

Adding a switch to the output between the motor and the frequency converter is permitted. Fault messages may appear. To catch a spinning motor, enable ying start.

2.5.6 Overload Protection

Torque limit

The torque limit feature protects the motor against overload, independent of the speed. Torque limit is controlled in parameter 4-16 Torque Limit Motor Mode or parameter 4-17 Torque Limit Generator Mode, and the time before the torque limit warning trips is controlled in parameter 14-25 Trip Delay at Torque Limit.

Current limit

The current limit is controlled in parameter 4-18 Current Limit.

Speed limit

Dene lower and upper limits for the operating speed range using 1 or more of the following parameters:

Parameter 4-11 Motor Speed Low Limit [RPM].

•

Parameter 4-12 Motor Speed Low Limit [Hz] and

•

parameter 4-13 Motor Speed High Limit [RPM].

Parameter 4-14 Motor Speed High Limit [Hz].

•

For example, the operating speed range can be dened as between 30 and 50/60 Hz. Parameter 4-19 Max Output Frequency limits the maximum output speed the frequency converter can provide.

ETR

ETR is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in Illustration 2.15.

Voltage limit

When a certain hard-coded voltage level is reached, the frequency converter turns o to protect the transistors and the DC link capacitors.

Overtemperature

The frequency converter has built-in temperature sensors and reacts immediately to critical values via hard-coded limits.

2.5.7 Automatic Derating

The frequency converter constantly checks for critical levels:

High temperature on the control card or heat sink

•

High motor load

•

High DC-link voltage

•

Low motor speed

•

As a response to a critical level, the frequency converter adjusts the switching frequency. For high internal temperatures and low motor speed, the frequency converters can also force the PWM pattern to SFAVM.

NOTICE

The automatic derating is dierent when

parameter 14-55 Output Filter is set to [2] Sine-Wave Filter Fixed.

2.5.8 Automatic Energy Optimisation

Automatic energy optimisation (AEO) directs the frequency converter to monitor the load on the motor continuously and adjust the output voltage to maximise eciency. Under light load, the voltage is reduced and the motor current is minimised. The motor benets from:

Increased eciency.

•

Reduced heating.

•

Quieter operation.

•

There is no need to select a V/Hz curve because the frequency converter automatically adjusts motor voltage.

2.5.9 Automatic Switching Frequency Modulation

The frequency converter generates short electrical pulses to form an AC wave pattern. The switching frequency is the rate of these pulses. A low switching frequency (slow pulsing rate) causes audible noise in the motor, making a higher switching frequency preferable. A high switching frequency, however, generates heat in the frequency converter which can limit the amount of current available to the motor.

Automatic switching frequency modulation regulates these conditions automatically to provide the highest switching frequency without overheating the frequency converter. By providing a regulated high switching frequency, it quiets motor operating noise at slow speeds, when audible noise control is critical, and produces full output power to the motor when required.

2 2

Product Overview

VLT® Refrigeration Drive FC 103

2.5.10 Automatic Derating for High

2.5.14 Power Fluctuation Performance

Switching Frequency

The frequency converter is designed for continuous, fullload operation at switching frequencies between 3.0 and

4.5 kHz (this frequency range depends on power size). A switching frequency exceeding the maximum permissible range generates increased heat in the frequency converter and requires the output current to be derated.

An automatic feature of the frequency converter is loaddependent switching frequency control. This feature allows the motor to the load allow.

benet from as high a switching frequency as

2.5.11 Automatic Derating for

The frequency converter withstands mains uctuations such as:

Transients.

•

Momentary drop-outs.

•

Short voltage drops.

•

Surges.

•

The frequency converter automatically compensates for input voltages ±10% from the nominal to provide full rated motor voltage and torque. With auto restart selected, the frequency converter automatically powers up after a voltage trip. With synchronises to motor rotation before start.

ying start, the frequency converter

Overtemperature

Automatic overtemperature derating works to prevent tripping the frequency converter at high temperature. Internal temperature sensors measure conditions to protect the power components from overheating. The frequency converter can automatically reduce the switching frequency to maintain the operating temperature within safe limits. After reducing the switching frequency, the frequency converter can also reduce the output frequency and current by as much as 30% to avoid an overtemperature trip.

2.5.15 Motor Soft Start

The frequency converter supplies the right amount of current to the motor to overcome load inertia and bring the motor up to speed. This avoids full mains voltage being applied to a stationary or slow-turning motor, which generates high current and heat. This inherent soft start feature reduces thermal load and mechanical stress, extends motor life, and provides quieter system operation.

2.5.16 Resonance Damping

2.5.12 Auto Ramping

A motor trying to accelerate a load too quickly for the current available can cause the frequency converter to trip. The same is true for too quick a deceleration. Auto ramping protects against these situations by extending the motor ramping rate (acceleration or deceleration) to match the available current.

2.5.13 Current Limit Circuit

When a load exceeds the current capability of the frequency converter normal operation (from an undersized frequency converter or motor), current limit reduces the output frequency to ramp down the motor and reduce the load. An adjustable timer is available to limit operation in this condition for 60 s or less. The factory default limit is 110% of the rated motor current to minimise overcurrent stress.

Eliminate high frequency motor resonance noise through resonance damping. Automatic or manually selected frequency damping is available.

2.5.17 Temperature-controlled Fans

Sensors in the frequency converter control the temperature of the internal cooling fans. Often, the cooling fans do not run during low load operation, or when in sleep mode or standby. This reduces noise, increases eciency, and extends the operating life of the fan.

2.5.18 EMC Compliance

Electromagnetic interference (EMI) or radio frequency interference (RFI, in case of radio frequency) is disturbance that can aect an electrical circuit due to electromagnetic induction or radiation from an external source. The frequency converter is designed to comply with the EMC product standard for frequency converters IEC 61800-3 as well as the European standard EN 55011. To comply with the emission levels in EN 55011, screen and terminate the motor cable properly terminated. For more information regarding EMC performance, see chapter 3.2.2 EMC Test Results (Emission).

1.21.0 1.4

100

1.81.6 2.0

2000

500

200

400 300

1000

600

t [s]

175ZA052.12

OUT

= 2 x f

M,N

OUT

= 0.2 x f

M,N

OUT

= 1 x f

M,N

(par. 1-23)

IMN(par. 1-24)

Product Overview Design Guide

2.5.19 Current Measurement on All Three Motor Phases

Output current to the motor is continuously measured on all 3 phases to protect the frequency converter and motor against short circuits, ground faults, and phase loss. Output ground faults are instantly detected. If a motor phase is lost, the frequency converter stops immediately and reports which phase is missing.

2.5.20 Galvanic Isolation of Control Terminals

All control terminals and output relay terminals are galvanically isolated from mains power. This means the controller circuitry is completely protected from the input current. The output relay terminals require their own grounding. This isolation meets the stringent protective extra-low voltage (PELV) requirements for isolation.

The components that make up the galvanic isolation are:

Power supply, including signal isolation.

•

Gate drive for the IGBTs, trigger transformers, and

•

optocouplers.

The output current Hall eect transducers.

•

2.6.2 Motor Thermal Protection

Motor thermal protection can be provided in 3 ways:

Via direct temperature sensing via the PTC sensor

•

in the motor windings and connected on a standard AI or DI.

Mechanical thermal switch (Klixon type) on a DI.

•

Via the built-in electronic thermal relay (ETR) for

•

asynchronous motors.

ETR calculates motor temperature by measuring current, frequency, and operating time. The frequency converter shows the thermal load on the motor in percentage and can issue a warning at a programmable overload setpoint. Programmable options at the overload allow the frequency converter to stop the motor, reduce output, or ignore the condition. Even at low speeds, the frequency converter meets I2t Class 20 electronic motor overload standards.

2 2

Custom Application Functions

2.6

Custom application functions are the most common features programmed in the frequency converter for enhanced system performance. They require minimum programming or set-up. Understanding that these functions are available can optimise the system design and possibly avoid introducing redundant components or functionality. See the programming guide for instructions on activating these functions.

2.6.1 Automatic Motor Adaptation

Automatic motor adaptation (AMA) is an automated test procedure used to measure the electrical characteristics of the motor. AMA provides an accurate electronic model of the motor. It allows the frequency converter to calculate optimal performance and eciency with the motor. Running the AMA procedure also maximises the automatic energy optimisation feature of the frequency converter. AMA is performed without the motor rotating and without uncoupling the load from the motor.

Illustration 2.15 ETR Characteristics

The X-axis in Illustration 2.15 shows the ratio between I and I before the ETR cuts o and trips the frequency converter. The curves show the characteristic nominal speed, at twice the nominal speed and at 0.2 x the nominal speed. At lower speed, the ETR cuts o at lower heat due to less cooling of the motor. In that way, the motor is protected from being overheated even at low speed. The ETR feature calculates the motor temperature based on actual current and speed. The calculated temperature is visible as a readout parameter in parameter 16-18 Motor Thermal.

nominal. The Y-axis shows the time in seconds

motor

2.6.3 Mains Drop-out

During a mains drop-out, the frequency converter keeps running until the DC-link voltage drops below the minimum stop level. The minimum stop level is typically 15% below the lowest rated supply voltage. The mains

motor

Product Overview

VLT® Refrigeration Drive FC 103

voltage before the drop-out and the motor load determines how long it takes for the frequency converter to coast.

Congure the frequency converter(parameter 14-10 Mains Failure) to dierent types of behaviour during mains drop-

out,

Trip lock once the DC link is exhausted.

•

Coast with ying start whenever mains return

•

(parameter 1-73 Flying Start).

Kinetic back-up.

•

Controlled ramp down.

•

Flying start

This selection makes it possible to catch a motor that spins freely due to a mains drop-out. This option is relevant for centrifuges and fans.

Kinetic back-up

This selection ensures that the frequency converter runs as long as there is energy in the system. For short mains drop-out, the operation is restored after mains return, without bringing the application to a stop or losing control at any time. Several variants of kinetic back-up can be selected.

Congure the behaviour of the frequency converter at mains drop-out, in parameter 14-10 Mains Failure and parameter 1-73 Flying Start.

NOTICE

Coast is recommended for compressors as the inertia is too small for ying start in most situations.

2.6.5 Automatic Restart

The frequency converter can be programmed to restart the motor automatically after a minor trip, such as momentary power loss or uctuation. This feature eliminates the need for manual resetting and enhances automated operation for remotely controlled systems. The number of restart attempts as well as the duration between attempts can be limited.

2.6.6 Flying Start

Flying start allows the frequency converter to synchronise with an operating motor rotating at up to full speed, in either direction. This prevents trips due to overcurrent draw. It minimises mechanical stress to the system since the motor receives no abrupt change in speed when the frequency converter starts.

2.6.7 Full Torque at Reduced Speed

The frequency converter follows a variable V/Hz curve to provide full motor torque even at reduced speeds. Full output torque can coincide with the maximum designed operating speed of the motor. This diers from variable torque frequency converters and constant torque frequency converters. Variable torque frequency converters provide reduced motor torque at low speed. Constant torque frequency converters provide excess voltage, heat, and motor noise at less than full speed.

2.6.8 Frequency Bypass

2.6.4 Built-in PID Controllers

The 4 built-in proportional, integral, derivative (PID) controllers eliminate the need for auxiliary control devices.

One of the PID controllers maintains constant control of closed-loop systems where regulated pressure, ow, temperature, or other system requirements are maintained. The frequency converter can provide self-reliant control of the motor speed in response to feedback signals from remote sensors. The frequency converter accommodates 2 feedback signals from 2 dierent devices. This feature allows regulating a system with dierent feedback requirements. The frequency converter makes control decisions by comparing the 2 signals to optimise system performance.

Use the 3 additional and independent controllers for controlling other process equipment, such as chemical feed pumps, valve control, or for aeration with

dierent levels.

In some applications, the system may have operational speeds that create a mechanical resonance. This can generate excessive noise and possibly damage mechanical components in the system. The frequency converter has 4 programmable bypass-frequency bandwidths. These allow the motor to step over speeds that induce system resonance.

2.6.9 Motor Preheat

To preheat a motor in a cold or damp environment, a small amount of DC current can be trickled continuously into the motor to protect it from condensation and cold starts. This can eliminate the need for a space heater.

. . . . . .

Par. 13-11 Comparator Operator

Par. 13-43 Logic Rule Operator 2

Par. 13-51 SL Controller Event

Par. 13-52 SL Controller Action

130BB671.13

Coast Start timer Set Do X low Select set-up 2 . . .

Running Warning Torque limit Digital input X 30/2 . . .

= TRUE longer than..

. . . . . .

130BA062.14

State 1 13-51.0 13-52.0

State 2 13-51.1 13-52.1

Start event P13-01

State 3 13-51.2 13-52.2

State 4 13-51.3 13-52.3

Stop event P13-02

Product Overview Design Guide

2.6.10 Four Programmable Set-ups

The frequency converter has 4 set-ups that can be independently programmed. Using multi-setup, it is possible to switch between independently programmed functions activated by digital inputs or a serial command. Independent set-ups are used, for example, to change references, or for day/night or summer/winter operation, or to control multiple motors. The LCP shows the active setup.

Set-up data can be copied from frequency converter to frequency converter by downloading the information from the removable LCP.

2.6.11 DC Braking

Some applications may require braking a motor to slow or stopping it. Applying DC current to the motor brakes the motor and eliminates the need for a separate motor brake. DC brake can be set to activate at a predetermined frequency or after receiving a signal. The rate of braking can also be programmed.

2.6.12 Sleep Mode

Sleep mode automatically stops the motor when demand is low for a specied time. When the system demand increases, the frequency converter restarts the motor. Sleep mode provides energy savings and reduces motor wear. Unlike a setback clock, the frequency converter is always available to run when the preset wake-up demand is reached.

2.6.13 Run Permissive

The frequency converter can wait for a remote system ready signal before starting. When this feature is active, the frequency converter remains stopped until receiving permission to start. Run permissive ensures that the system or auxiliary equipment is in the proper state before the frequency converter is allowed to start the motor.

2.6.14 Smart Logic Control (SLC)

Smart logic control (SLC) is a sequence of user-dened actions (see parameter 13-52 SL Controller Action [x]) executed by the SLC when the associated user-dened event (see parameter 13-51 SL Controller Event [x]) is evaluated as TRUE by the SLC. The condition for an event can be a particular status or that the output from a logic rule or a comparator operand becomes TRUE. That leads to an associated action as shown in Illustration 2.16.

Illustration 2.16 SLC Event and Action

Events and actions are each numbered and linked in pairs (states). This means that when event [0] is fullled (attains the value TRUE), action [0] is executed. After this, the conditions of event [1] is evaluated and if evaluated TRUE, action [1] is executed and so on. Only one event is evaluated at any time. If an event is evaluated as FALSE, nothing happens (in the SLC) during the current scan interval and no other events are evaluated. This means that when the SLC starts, it evaluates event [0] (and only event [0]) each scan interval. Only when event [0] is evaluated TRUE, the SLC executes action [0] and starts evaluating event [1]. It is possible to programme from 1 to 20 events and actions. When the last event/action has been executed, the sequence starts over again from event [0]/action [0]. Illustration 2.17 shows an example with 4 event/actions:

Illustration 2.17 Order of Execution when 4 Events/Actions are

Programmed

2 2

Par. 13-11 Comparator Operator

TRUE longer than.

. . .

Par. 13-10 Comparator Operand

Par. 13-12 Comparator Value

130BB672.10

. . . . . .

Par. 13-43 Logic Rule Operator 2

Par. 13-41 Logic Rule Operator 1

Par. 13-40 Logic Rule Boolean 1

Par. 13-42 Logic Rule Boolean 2

Par. 13-44 Logic Rule Boolean 3

130BB673.10

Product Overview

VLT® Refrigeration Drive FC 103

Comparators

Comparators are used for comparing continuous variables (output frequency, output current, analog input, and so on)

to xed preset values.

Illustration 2.18 Comparators

Logic rules

Combine up to 3 boolean inputs (TRUE/FALSE inputs) from timers, comparators, digital inputs, status bits, and events using the logical operators AND, OR, and NOT.

Illustration 2.19 Logic Rules

The logic rules, timers, and comparators are also available for use outside of the SLC sequence.

For an example of SLC, refer to chapter 4.3 Application Set- up Examples.

2.6.15 Safe Torque O Function

The frequency converter is available with Safe Torque O (STO) functionality via control terminal 37. STO disables the control voltage of the power semiconductors of the frequency converter output stage. This in turn prevents generating the voltage required to rotate the motor. When the STO (terminal 37) is activated, the frequency converter issues an alarm, trips the unit, and coasts the motor to a stop. Manual restart is required. The STO function can be used as an emergency stop for the frequency converter. In the normal operating mode when STO is not required, use the regular stop function. When using automatic restart, ensure the requirements of ISO 12100-2 paragraph 5.3.2.5 are fullled.

Liability conditions

It is the responsibility of the user to ensure personnel installing and operating the STO function:

Read and understand the safety regulations

•

concerning health, safety, and accident prevention.

Have a good knowledge of the generic and safety

•

standards applicable to the specic application.

A user is dened as:

Integrator.

•

Operator.

•

Service technician.

•

Maintenance technician.

•

Standards

Use of STO on terminal 37 requires that the user fullls all provisions for safety including relevant laws, regulations, and guidelines. The optional STO function complies with the following standards:

EN 954-1: 1996 Category 3

•

IEC 60204-1: 2005 category 0 – uncontrolled stop

•

IEC 61508: 1998 SIL2

•

IEC 61800-5-2: 2007 – STO function

•

IEC 62061: 2005 SIL CL2

•

ISO 13849-1: 2006 Category 3 PL d

•

ISO 14118: 2000 (EN 1037) – prevention of

•

unexpected start-up

The listed information and instructions are not sucient for a proper and safe use of the STO functionality. For full

information about STO, refer to the VLT® Safe Torque O Operating Instructions.

Protective measures

Qualied and skilled personnel are required for

•

installation and commissioning of safety engineering systems.

Install the unit in an IP54 enclosure or in an

•

equivalent environment. In special applications, a higher IP degree is required.

The cable between terminal 37 and the external

•

safety device must be short circuit protected according to ISO 13849-2 table D.4.

When external forces inuence the motor axis (for

•

example, suspended loads), to eliminate potential hazards, additional measures are required (for example, a safety holding brake).

Product Overview Design Guide

2.7 Fault, Warning and Alarm Functions

The frequency converter monitors many aspects of system operation including mains conditions, motor load, and performance, as well as frequency converter status. An alarm or warning does not necessarily indicate a problem with the frequency converter itself. It may be a condition outside of the frequency converter that is being monitored for performance limits. The frequency converter has various pre-programmed fault, warning, and alarm responses. Select additional alarm and warning features to enhance or modify system performance.

This section describes common alarm and warning features. Understanding that these features are available can optimise a system design and possibly avoid introducing redundant components or functionality.

2.7.1 Operation at Overtemperature

By default, the frequency converter issues an alarm and trip at overtemperature. If Autoderate and Warning is selected, the frequency converter warns of the condition but continues to run and attempt to cool itself by rst reducing its switching frequency. Then, if necessary, it reduces the output frequency.

capacitors. Other options are to issue a warning and reduce output current to 30% of full current or to issue a warning and continue normal operation. Operating a unit connected to an imbalanced line may be desirable until the imbalance is corrected.

2.7.5 High Frequency Warning

When staging on additional equipment such as compressors or cooling fans, the frequency converter can warn when the motor speed is high. A specic high frequency setting can be entered into the frequency converter. If the output exceeds the set warning frequency, the unit shows a high frequency warning. A digital output from the frequency converter can signal external devices to stage on.

2.7.6 Low Frequency Warning

When staging o equipment, the frequency converter can warn when the motor speed is low. A specic low frequency setting can be selected for warning and to stage o external devices. The unit does not issue a low frequency warning when it stops nor after start-up until after the operating frequency has been reached.

2 2

Autoderating does not replace the user settings for derating for ambient temperature (see chapter 5.4 Derating for Ambient Temperature).

2.7.2 High and Low Reference Warning

In open-loop operation, the reference signal directly determines the speed of the frequency converter. The display shows a ashing reference high or low warning when the programmed maximum or minimum is reached.

2.7.3 High and Low Feedback Warning

In closed-loop operation, the frequency converter monitors the selected high and low feedback values. The display shows a ashing high or ashing low warning when appropriate. The frequency converter can also monitor feedback signals in open-loop operation. While the signals do not aect the operation of the frequency converter in open loop, they can be useful for system status indication locally or via serial communication. The frequency converter handles 39 dierent units of measure.

2.7.4 Phase Imbalance or Phase Loss

2.7.7 High Current Warning

This function is similar to high frequency warning, except a high current setting is used to issue a warning and stage on additional equipment. The function is not active when stopped or at start-up until the set operating current has been reached.

2.7.8 Low Current Warning

This function is similar to low frequency warning (see chapter 2.7.6 Low Frequency Warning), except a low current setting is used to issue a warning and stage o equipment. The function is not active when stopped or at start-up until the set operating current has been reached.

2.7.9 No Load/Broken Belt Warning

This feature can be used for monitoring a no-load condition, for example a V-belt. After a low current limit has been stored in the frequency converter, if loss of the load is detected, the frequency converter can be programmed to issue an alarm and trip or to continue operation and issue a warning.

Excessive ripple current in the DC bus indicates either a mains phase imbalance or a phase loss. When a power phase to the frequency converter is lost, the default action is to issue an alarm and trip the unit to protect the DC bus

130BP066.10

1107 RPM

0 -

Operation/Display

1 -

Load/Motor

2 -

Brakes

3 -

Reference / Ramps

3.84 A 1 (1)

Main Menu

Auto

Reset

Hand

Oﬀ

Status

Quick Menu

Main

Alarm

Log

Back

Cancel

Info

Status

1(1)

1234rpm 10,4A 43,5Hz

Run OK

43,5Hz

Alarm

Warn.

130BB465.10

Product Overview

VLT® Refrigeration Drive FC 103

2.7.10 Lost Serial Interface

The frequency converter can detect loss of serial communication. A time delay of up to 99 s is selectable to avoid a response due to interruptions on the serial communications bus. When the delay is exceeded, options available include for the unit to:

Maintain its last speed.

•

Go to maximum speed.

•

Go to a preset speed.

•

Stop and issue a warning.

•

2.8 User Interfaces and Programming

The frequency converter uses parameters for programming its application functions. Parameters provide a description of a function and a menu of options to either select from or for entering numeric values. A sample programming menu is shown in Illustration 2.20.

part number 130B1000. A user’s manual provides detailed operation instructions. See also chapter 2.8.2 PC Software.

Programming control terminals

Each control terminal has specied functions it is

•

capable of performing.

Parameters associated with the terminal enable

•

the function selections.

For proper frequency converter functioning using

•

control terminals, the terminals must be:

- Wired properly.

- Programmed for the intended function.

2.8.1 Local Control Panel

The local control panel (LCP) is a graphic display on the front of the unit, which provides the user interface through push-button controls and shows status messages, warnings and alarms, programming parameters, and more. A numeric display is also available with limited display options. Illustration 2.21 shows the LCP.

Illustration 2.20 Sample Programming Menu

Local user interface

For local programming, parameters are accessible by pressing either [Quick Menu] or [Main Menu] on the LCP.

The Quick Menu is intended for initial start-up and motor characteristics. The Main Menu accesses all parameters and allows for advanced applications programming.

Remote user interface

For remote programming, Danfoss oers a software program for developing, storing, and transferring programming information. MCT 10 Set-up Software allows the user to connect a PC to the frequency converter and perform live programming rather than using the LCP keypad. Or programming can be done o-line and downloaded to the unit. The entire frequency converter prole can be loaded onto the PC for back-up storage or analysis. A USB connector and RS485 terminal are available for connecting to the frequency converter.

MCT 10 Set-up Software is available for free download at www.VLT-software.com. A CD is also available by requesting

Illustration 2.21 Local Control Panel

130BT308.10

Product Overview Design Guide

2.8.2 PC Software

The PC is connected via a standard (host/device) USB cable, or via the RS485 interface.

USB is a serial bus utilising 4 screened wires with ground pin 4 connected to the screen in the PC USB port. By connecting the PC to a frequency converter through the USB cable, there is a potential risk of damaging the PC USB host controller. All standard PCs are manufactured without galvanic isolation in the USB port. Any ground potential dierence caused by not following the recommendations described in the operating instructions, can damage the USB host controller through the screen of the USB cable. When connecting the PC to a frequency converter through a USB cable, use a USB isolator with galvanic isolation to protect the PC USB host controller from ground potential

dierences.

Do not use a PC power cable with a ground plug when the PC is connected to the frequency converter through a USB cable. It reduces the ground potential dierence, but does not eliminate all potential dierences due to the ground and screen connected in the PC USB port.

Example 1: Data storage in PC via MCT 10 Set-up Software

1. Connect a PC to the unit via USB or via the RS485 interface.

2. Open MCT 10 Set-up Software.

3. Select the USB port or the RS485 interface.

4. Select copy.

5. Select the project section.

6. Select paste.

7. Select save as.

All parameters are now stored.

Example 2: Data transfer from PC to frequency converter via MCT 10 Set-up Software

1. Connect a PC to the unit via USB port or via the RS485 interface.

2. Open MCT 10 Set-up Software.

3. Select Open – stored les are shown.

4. Open the appropriate le.

5. Select Write to drive.

All parameters are now transferred to the frequency converter.

A separate manual for MCT 10 Set-up Software is available. Download the software and the manual from

www.danfoss.com/BusinessAreas/DrivesSolutions/Softwaredownload/.

2 2

Illustration 2.22 USB Connection

2.8.2.1 MCT 10 Set-up Software

The MCT 10 Set-up Software is designed for commissioning and servicing the frequency converter including guided programming of pack controller, real time clock, smart logic controller, and preventive maintenance. This software provides easy control of details as well as a general overview of systems, large, or small. The tool

handles all frequency converter series, VLT® Advanced

Active Filters AAF 006 and VLT® Soft Starter-related data.

2.8.2.2

VLT® Harmonics Calculation Software MCT 31

The MCT 31 Harmonic Calculation PC tool enables easy estimation of the harmonic distortion in a given application. Both the harmonic distortion of Danfoss frequency converters as well as non-Danfoss frequency converters with additional harmonic reduction devices,

such as Danfoss VLT® Advanced Harmonic Filters AHF 005/AHF 010 lters and 12–18 pulse rectiers, can be calculated.

MCT 31 can also be downloaded from www.danfoss.com/ BusinessAreas/DrivesSolutions/Softwaredownload/.

2.8.2.3 Harmonic Calculation Software (HCS)

HCS is an advanced version of the harmonic calculation tool. The calculated results are compared to relevant norms and can be printed afterwards.

For more information, see www.danfoss-hcs.com/

Default.asp?LEVEL=START

Product Overview

VLT® Refrigeration Drive FC 103

2.9 Maintenance

Danfoss frequency converter models up to 90 kW are

maintenance-free. High-power frequency converters (rated at 110 kW or higher) have built-in lter mats, which require periodic cleaning by the operator, depending on the exposure to dust and contaminants. Maintenance intervals for the cooling fans (approximately 3 years) and capacitors (approximately 5 years) are recommended in most environments.

2.9.1 Storage

Like all electronic equipment, frequency converters must be stored in a dry location. Periodic forming (capacitor charging) is not necessary during storage.

It is recommended to keep the equipment sealed in its packaging until installation.

System Integration Design Guide

3 System Integration

This chapter describes the considerations necessary to integrate the frequency converter into a system design. The chapter is divided into these sections:

Chapter 3.1 Ambient Operating Conditions

•

Ambient operating conditions for the frequency converter including:

- Environment.

- Enclosures.

- Temperature.

- Derating.

- Other considerations.

Chapter 3.2 EMC, Harmonics, and Ground Leakage

•

Protection

Input (regeneration) from the frequency converter to the power grid including:

- Power.

- Harmonics.

- Monitoring.

- Other considerations.

Chapter 3.4 Mains Integration

•

Input into the frequency converter from the mains side including:

- Power.

- Harmonics.

- Monitoring.

- Cabling.

- Fusing.

- Other considerations.

Chapter 3.5 Motor Integration

•

Output from the frequency converter to the motor including:

- Motor types.

- Load.

- Monitoring.

- Cabling.

- Other considerations.

Chapter 3.6 Additional Inputs and Outputs,

•

chapter 3.7 Mechanical Planning

Integration of the frequency converter input and output for optimal system design including:

- Frequency converter/motor matching.

- System characteristics.

- Other considerations.

A comprehensive system design anticipates potential problem areas while implementing the most eective combination of frequency converter features. The information that follows provides guidelines for planning and specifying a motor-control system incorporating frequency converters.

Operational features provide a range of .design concepts, from simple motor speed control to a fully integrated automation system with for example:

Handling of feedback.

•

Operational status reporting.

•

Automated fault responses.

•

Remote programming.

•

A complete design concept includes detailed of needs and use.

Frequency converter types

•

Motors

•

Mains requirements

•

Control structure and programming

•

Serial communication

•

Equipment size, shape, weight

•

Power and control cabling requirements; type and

•

length

Fuses

•

Auxiliary equipment

•

Transportation and storage

•

See chapter 3.10 System Design Checklist for a practical guide for selection and design.

Understanding features and strategy options can optimise a system design and possibly avoid introducing redundant components or functionality.

Ambient Operating Conditions

3.1

specication

3.1.1 Humidity

Although the frequency converter can operate properly at high humidity (up to 95% relative humidity), avoid condensation. There is a specic risk of condensation when the frequency converter is colder than moist ambient air. Moisture in the air can also condense on the electronic components and cause short circuits. Condensation occurs in units without power. Install a cabinet heater when

3 3

System Integration

VLT® Refrigeration Drive FC 103

condensation is possible due to ambient conditions. Avoid installation in areas subject to frost.

Alternatively, operating the frequency converter in standby mode (with the unit connected to the mains) reduces

the risk of condensation. Ensure that the power dissipation is sucient to keep the frequency converter circuitry free of moisture.

3.1.2 Temperature

Minimum and maximum ambient temperature limits are specied for all frequency converters. Avoiding extreme ambient temperatures prolongs the life of the equipment and maximises overall system reliability. Follow the recommendations listed for maximum performance and equipment longevity.

Although the frequency converter can operate at

•

temperatures down to -10 °C, proper operation at rated load is only guaranteed at 0 °C or higher.

Do not exceed the maximum temperature limit.

•

The lifetime of electronic components decreases

•

by 50% for every 10 °C when operated above the design temperature.

Even devices with IP54, IP55, or IP66 protection

•

ratings must adhere to the specied ambient temperature ranges.

Extra air conditioning of the enclosure or instal-

•

lation site may be required.

3.1.3 Cooling

Frequency converters dissipate power in the form of heat. The following recommendations are necessary for eective cooling of the units.

Maximum air temperature to enter enclosure

•

must never exceed 40 °C (104 °F).

Day/night average temperature must not exceed

•

35 °C (95 °F).

Mount the unit to allow free cooling airow

•

through the cooling ns. See chapter 3.7.1 Clearance for correct mounting clearances.

Provide minimum front and rear clearance

•

requirements for cooling airow. See the operating instructions for proper installation requirements.

3.1.3.1 Fans

The frequency converter has built-in fans to ensure optimum cooling. The main fan forces the air ow along the cooling ns on the heat sink, ensuring cooling of the internal air. Some power sizes have a small secondary fan close to the control card, ensuring that the internal air is circulated to avoid hot spots.

The internal temperature in the frequency converter controls the main fan. The speed gradually increases along with temperature, reducing noise and energy consumption when the need is low, and ensuring maximum cooling when the need is there. The fan control can be adapted via parameter 14-52 Fan Control to accommodate any application, also to protect against negative eects of cooling in cold climates. In case of overtemperature inside the frequency converter, it derates the switching frequency and pattern. See chapter 5.1 Derating for more info.

3.1.3.2 Calculation of Airow Required for Cooling the Frequency Converter

The airow required to cool a frequency converter, or multiple frequency converters in 1 enclosure, can be calculated as follows:

1. Determine the power loss at maximum output for all frequency converters from data tables in chapter 7 Specications.

2. Add power loss values of all frequency converters that can operate at same time. The calculated sum is the heat Q to be transferred. Multiply the result with the factor f, read from Table 3.1. For example, f = 3.1 m3 x K/Wh at sea level.

3. Determine the highest temperature of the air entering the enclosure. Subtract this temperature from the required temperature inside the enclosure, for example 45 °C (113 °F).

4. Divide the total from step 2 by the total from step 3.

The calculation is expressed by the formula:

f xQ

V =

Ti − T A

where

airow in m3/h

V = f = factor in m3 x K/Wh Q = heat to be transferred in W Ti = temperature inside the enclosure in °C TA = ambient temperature in °C f = cp x ρ (specic heat of air x density of air)

System Integration Design Guide

NOTICE

Specic heat of air (cp) and density of air (ρ) are not constants, but depend on temperature, humidity, and atmospheric pressure. Therefore, they depend on the altitude above sea level.

Table 3.1 shows typical values of the factor f, calculated for

dierent altitudes.

Altitude

[m] [kJ/kgK]

500 0.9348 1.167 3.3

1000 0.9250 1.112 3.5

1500 0.8954 1.058 3.8

2000 0.8728 1.006 4.1

2500 0.8551 0.9568 4.4

3000 0.8302 0.9091 4.8

3500 0.8065 0.8633 5.2

Table 3.1 Factor f, Calculated for Dierent Altitudes

Example

What is the airow required to cool 2 frequency converters (heat losses 295 W and 1430 W) running simultaneously, mounted in an enclosure with an ambient temperature peak of 37 °C?

•

If the = 0.589 CFM.

For the example above, 711.6 m3/h = 418.85 CFM.

3.1.4 Motor-generated Overvoltage

The DC voltage in the DC link (DC bus) increases when the motor acts as a generator. This situation can occur in 2 ways:

•

The frequency converter cannot regenerate energy back to the input. Therefore, it limits the energy accepted from the motor when set to enable autoramping. If the overvoltage

Specic heat of aircpDensity of airρFactor

[kg/m3] [m3⋅K/Wh]

0 0.9480 1.225 3.1

The sum of the heat losses of both frequency converters is 1725 W.

Multiplying 1725 W by 3.3 m3 x K/Wh gives 5693 m x K/h.

Subtracting 37 °C from 45 °C gives 8 °C (=8 K).

Dividing 5693 m x K/h by 8 K gives: 711.6 m3h.

airow is required in CFM, use the conversion 1 m3/h

The load drives the motor when the frequency converter is operated at a constant output frequency. This is referred to as an overhauling load.

During deceleration, if the inertia of the load is high and the deceleration time of the frequency converter is set to a short value.

occurs during deceleration, the frequency converter attempts to do this by automatically lengthening the ramp-down time. If this is unsuccessful, or if the load drives the motor when operating at a constant frequency, the frequency converter shuts down and shows a fault when reaching a critical DC bus voltage level.

3.1.5 Acoustic Noise

Acoustic noise from the frequency converter comes from 3 sources:

DC-link (intermediate circuit) coils

•

RFI lter choke

•

Internal fans

•

See Table 7.40 for acoustic noise ratings.

3.1.6 Vibration and Shock

The frequency converter is tested according to a procedure based on the IEC 68-2-6/34/35 and 36. These tests subject the unit to 0.7 g forces, over the range of 18–1000 Hz randomly, in 3 directions, for 2 hours. All Danfoss frequency converters comply with requirements that correspond to these conditions when the unit is wall- or oor-mounted, as well as when mounted within panels, or bolted to walls or oors.

3.1.7 Aggressive Atmospheres

3.1.7.1 Gases

Aggressive gases, such as hydrogen sulphide, chlorine, or ammonia can damage frequency converter electrical and mechanical components. Contamination of the cooling air can also cause the gradual decomposition of PCB tracks and door seals. Aggressive contaminants are often present in sewage treatment plants or swimming pools. A clear sign of an aggressive atmosphere is corroded copper.

In aggressive atmospheres, restricted IP enclosures are recommended along with conformal-coated circuit boards. See Table 3.2 for conformal-coating values.

NOTICE

The frequency converter comes standard with class 3C2 coating of circuit boards. On request, class 3C3 coating is available.

3 3

System Integration

VLT® Refrigeration Drive FC 103

Class

3C1 3C2 3C3

Gas type Unit

Sea salt n/a None Salt mist Salt mist

Sulphur

oxides

Hydrogen

sulphide

Chlorine mg/

Hydrogen

chloride

Hydrogen

uoride

Ammonia mg/

Ozone mg/

Nitrogen mg/

Table 3.2 Conformal-coating Class Ratings

1) Maximum values are transient peak values not to exceed 30

minutes per day.

mg/

Average

value

0.1 0.3 1.0 5.0 10

0.01 0.1 0.5 3.0 10

0.01 0.1 0.03 0.3 1.0

0.01 0.1 0.5 1.0 5.0

0.003 0.01 0.03 0.1 3.0

0.3 1.0 3.0 10 35

0.01 0.05 0.1 0.1 0.3

0.1 0.5 1.0 3.0 9.0

Maximum

value

Average

value

Maximum

value

3.1.7.2 Dust Exposure

Installation of frequency converters in environments with high dust exposure is often unavoidable. Dust aects wallor frame-mounted units with IP55 or IP66 protection ratings, and also cabinet-mounted devices with IP21 or IP20 protection ratings. Consider the 3 aspects described in this section when frequency converters are installed in such environments.

Reduced cooling

Dust forms deposits on the surface of the device and inside on circuit boards and the electronic components. These deposits act as insulation layers and hamper heat transfer to the ambient air, reducing the cooling capacity. The components become warmer, which causes accelerated aging of the electronic components, and the service life of the unit decreases. Dust deposits on the heat sink in the back of the unit also decrease the service life of the unit.

Cooling fans

The airow for cooling the unit is produced by cooling fans, mostly located on the back of the device. The fan rotors have small bearings into which dust can penetrate

Filters

High-power frequency converters are equipped with cooling f,ans that expel hot air from the interior of the device. Above a certain size, these fans are tted with lter mats. These lters can become quickly clogged when used in dusty environments. Preventive measures are necessary under these conditions.

Periodic maintenance

Under the conditions described above, it is recommended to clean the frequency converter during periodic maintenance. Remove dust from the heat sink and fans, and clean the lter mats.

3.1.8 IP Rating Denitions

First digit

Second

digit

First letter

Extra letter

Against penetration by

solid foreign objects

0 (not protected) (not protected)

≥50 mm diameter

2 12.5 mm diameter Finger

3 2.5 mm diameter Tool

≥1.0 mm diameter

5 Dust protected Wire

6 Dust-tight Wire

Against water

penetration with

harmful eect

0 (not protected) –

1 Drops falling vertically –

2 Drops at 15° angle –

3 Spraying water –

4 Splashing water –

5 Water jets –

6 Powerful water jets –

7 Temporary immersion –

8 Long-term immersion –

More information

specically for

A Back of hand

B Finger

C Tool

D Wire

More information

specically for

H High-voltage device –

M Device moving during

water test

S Device stationary during

water test

W Weather conditions –

Against access to

hazardous parts by

Back of hand

Wire

–

and act as an abrasive. Dust in the bearings leads to bearing damage and fan failure.

Table 3.3 IEC 60529 Denitions for IP Ratings

System Integration Design Guide

3.1.8.1 Cabinet Options and Ratings

Danfoss frequency converters are available with 3 dierent protection ratings:

IP00 or IP20 for cabinet installation.

•

IP54 or IP55 for local mounting.

•

IP66 for critical ambient conditions, such as

•

extremely high (air) humidity or high concentrations of dust or aggressive gases.

3.1.9 Radio Frequency Interference

The main objective in practice is to obtain systems that operate constantly without radio frequency interference between components. To achieve a high level of immunity, use frequency converters with high-quality RFI lters.

Use Category C1 lters specied in the EN 61800-3 which conform to the Class B limits of the general standard EN

55011.

Place warning notices on the frequency converter if RFI lters do not correspond to Category C1 (Category C2 or lower). The responsibility for proper labelling rests with the operator.

In practice, there are 2 approaches to RFI lters:

Built in to the equipment

•

- Built-in lters take up space in the

cabinet but eliminate extra costs for tting, wiring, and material. However, the most important advantage is the perfect EMC conformance and cabling of integrated lters.

External options

•

- Optional external RFI lters that are

installed on the input of the frequency converter cause a voltage drop. In practice, this means that the full mains voltage is not present at the frequency converter input and a higher-rated frequency converter may be necessary. The maximum length of the motor cable for compliance with EMC limits ranges from 1–50 m. Costs are incurred for material, cabling, and assembly. EMC conformance is not tested.

NOTICE

VLT® Refrigeration Drive FC 103 units are supplied as standard with built-in RFI lters conforming to category C1 (EN 61800-3) for use with 400 V mains systems and power ratings up to 90 kW or category C2 for power ratings of 110–630 kW. FC 103 units conform to C1 with screened motor cables up to 50 m or C2 with screened motor cables up to 150 m. Refer to Table 3.4 for details.

3.1.10 PELV and Galvanic Isolation Compliance

Ensure the protection against electric shock, when the electrical supply is of the protective extra-low voltage (PELV) type, and the installation complies with local and national PELV regulations.

To maintain PELV at the control terminals, all connections must be PELV, such as thermistors being reinforced/double insulated. All Danfoss frequency converter control and relay terminals comply with PELV (excluding grounded Delta leg above 400 V).

Galvanic (ensured) isolation is obtained by requirements for higher isolation and by providing the relevant creepage/clearance distances. These requirements are described in the EN 61800-5-1 standard.

Electrical isolation is provided as shown in Illustration 3.1. The components described comply with both PELV and the galvanic isolation requirements.

fullling

3 3

NOTICE

To ensure interference-free operation of the frequency converter/motor system, always use a category C1 RFI

lter.

130BA056.10

1325 4

System Integration

1 Power supply (SMPS) including signal isolation of V DC,

indicating the intermediate current voltage

2 Gate drive for the IGBTs

3 Current transducers

4 Opto-coupler, brake module

5 Internal inrush, RFI, and temperature measurement circuits

6 Custom relays

a Galvanic isolation for the 24 V back-up option

b Galvanic isolation for the RS485 standard bus interface

Illustration 3.1 Galvanic Isolation

Installation at high altitude

WARNING

OVERVOLTAGEInstallations exceeding high altitude

limits may not comply with PELV requirements. The isolation between components and critical parts could be insucient. There is a risk for overvoltage. To reduce the risk for overvoltage, use external protective devices or galvanic isolation.

For installations at high altitude, contact Danfoss regarding PELV compliance.

380–500 V (enclosures A, B, and C): Above 2000

•

m (6500 ft)

380–500 V (enclosures D, E, and F): Above 3000 m

•

(9800 ft)

525–690 V: Above 2000 m (6500 ft)

•

EMC, Harmonics, and Ground Leakage

3.2 Protection

3.2.1 General Aspects of EMC Emissions

VLT® Refrigeration Drive FC 103

Uncontrolled interaction between electrical devices in a system can degrade compatibility and impair reliable operation. Interference may take the form of:

•

Electrical devices generate interference and are aected by interference from other generated sources.

Electrical interference usually occurs at frequencies in the range 150 kHz to 30 MHz. Airborne interference from the frequency converter system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor. Capacitive currents in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents, as shown in Illustration 3.2. The use of a screened motor cable increases the leakage current (see Illustration 3.2) because screened cables have higher capacitance to ground than unscreened cables. If the leakage current is not interference on the mains in the radio frequency range below approximately 5 MHz. Since the leakage current (I1) is carried back to the unit through the screen (I3), there is only a small electro-magnetic eld (I4) from the screened motor cable, see Illustration 3.2.

The screen reduces the radiated interference, but increases the low-frequency interference on the mains. Connect the motor cable screen to the frequency converter enclosure as well as on the motor enclosure. The connection is best done by using integrated screen clamps to avoid twisted screen ends (pigtails). Pigtails increase the screen impedance at higher frequencies, which reduces the screen eect and increases the leakage current (I4). If a screened cable is used for relay, control cable, signal interface, and brake, mount the screen on the enclosure at both ends. In some situations, however, it is necessary to break the screen to avoid current loops.

If placing the screen on a mounting plate for the frequency converter, use a mounting plate of metal to convey the screen currents back to the unit. Moreover, ensure good electrical contact from the mounting plate through the mounting screws to the frequency converter enclosure.

Mains harmonics distortion.

Electrostatic discharges.

Rapid voltage uctuations.

High-frequency interference.

ltered, it causes greater

Frequency converters (and other electrical devices) generate electronic or magnetic elds that may interfere with their environment. The electromagnetic compatibility (EMC) of these eects depends on the power and the harmonic characteristics of the devices.

When using unscreened cables, some emission requirements are not complied with, although most immunity requirements are observed.

To reduce the interference level from the entire system (unit+installation), make motor and brake cables as short

175ZA062.12

System Integration Design Guide

as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Especially the

control electronics generate radio interference higher than 50 MHz (airborne).

1 Ground wire 3 AC mains supply 5 Screened motor cable

2 Screen 4 Frequency converter 6 Motor

Illustration 3.2 Generation of Leakage Currents

3 3

System Integration

VLT® Refrigeration Drive FC 103

3.2.2 EMC Test Results (Emission)

The following test results have been obtained using a system with a frequency converter (with options if relevant), a screened control cable, a control box with potentiometer, as well as a motor and motor screened cable.

RFI lter type Conducted emission Radiated emission

Cable length [m] Cable length [m]

Standards

and

requirements

EN/IEC 61800-3 Category C1

1.1–22 kW 220–240 V 50 150 150 No Yes N/A

1.1–45 kW 200–240 V 50 150 150 No Yes Yes

1.1–90 kW 380–480 V 50 150 150 No Yes Yes

H2/H5

1.1–22 kW 220–240 V No No 25 No No N/A

1.1–3.7 kW 200–240 V No No 5 No No No

5.5–45 kW 200–240 V No No 25 No No No

1.1–7.5 kW 380–480 V No No 5 No No No

11–90 kW 380–480 V No No 25 No No No

1.1–90 kW 525–600 V No No No No No No

EN 55011 Class B

Housing, trades,

and light

industries

First environ-

ment Home

and oce

Class A Group

Industrial

environ-

ment

Category C2

First environ-

ment Home

and oce

Class A Group 2

Industrial

environ-

ment

Category C3

Second environ-

ment Industrial

Class B

Housing, trades,

and light

industries

Category C1

First

environment

Home and

oce

Class A Group

Industrial

environment

Category C2

First

environment

Home and

oce

Class A Group

Industrial

environment

Category C3

Second

environment

Industrial

Table 3.4 EMC Test Results (Emission)

HX, H1 or H2 is

HX – No EMC lters built in the frequency converter (600 V units only).

H1 – Integrated EMC lter. Full Class A1/B.

H2 – No additional EMC lter. Full Class A2.

H5 – Marine versions. Full same emissions levels as H2 versions.

dened in the type code pos. 16–17 for EMC lters.

System Integration Design Guide

3.2.3 Emission Requirements

The EMC product standard for frequency converters denes 4 categories (C1, C2, C3, and C4) with specied requirements for emission and immunity. Table 3.5 states the denition of the 4 categories and the equivalent classication from EN 55011.

Equivalent

Category Denition

C1 Frequency converters installed in

the rst environment (home and

oce) with a supply voltage less

than 1000 V.

C2 Frequency converters installed in

the rst environment (home and

oce) with a supply voltage less

than 1000 V, which are not plug-in

and not movable, and must be

installed and commissioned by a

professional.

C3 Frequency converters installed in

the second environment (industrial)

with a supply voltage lower than

1000 V.

C4 Frequency converters installed in

the second environment with a

supply voltage equal to or above

1000 V or rated current equal to or

above 400 A or intended for use in

complex systems.

Table 3.5 Correlation between IEC 61800-3 and EN 55011

When the generic (conducted) emission standards are used, the frequency converters are required to comply with the limits in Table 3.6.

emission class

in EN 55011

Class B

Class A Group 1

Class A Group 2

No limit line.

Make an EMC

plan.

3.2.4 Immunity Requirements

The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and oce environment. All Danfoss frequency converters comply with the requirements for the industrial environment. Therefore, the frequency converters also comply with the lower requirements for home and oce environment with a large safety margin.

To document immunity against electrical interference, the following immunity tests have been made in accordance with following basic standards:

EN 61000-4-2 (IEC 61000-4-2): Electrostatic

•

discharges (ESD): Simulation of electrostatic discharges from human beings.

EN 61000-4-3 (IEC 61000-4-3): Incoming electro-

•

magnetic eld radiation, amplitude modulated simulation of the eects of radar and radio communication equipment as well as mobile communications equipment.

EN 61000-4-4 (IEC 61000-4-4): Burst transients:

•

Simulation of interference brought about by switching a contactor, relay, or similar devices.

EN 61000-4-5 (IEC 61000-4-5): Surge transients:

•

Simulation of transients brought about for example by lightning that strikes near installations.

EN 61000-4-6 (IEC 61000-4-6): RF common

•

mode: Simulation of the eect from radiotransmission equipment joined by connection cables.

See Table 3.7.

3 3

Environment

First

environment

(home and

oce)

Second

environment

(industrial

environment)

Table 3.6 Correlation between Generic Emission Standards and

EN 55011

Generic emission

standard

EN/IEC 61000-6-3 Emission

standard for residential,

commercial, and light

industrial environments.

EN/IEC 61000-6-4 Emission

standard for industrial

environments.

Equivalent

emission class in

EN 55011

Class B

Class A Group 1

System Integration

VLT® Refrigeration Drive FC 103

Basic standard

IEC 61000-4-42)

Acceptance criterion B B B A A

Voltage range: 200–240 V, 380–500 V, 525–600 V, 525–690 V

Line

Motor

Control wires

Standard bus 2 kV CM

Relay wires 2 kV CM

Application and Fieldbus

options

LCP cable

External 24 V DC

Enclosure

Table 3.7 EMC Immunity Form

1) Injection on cable screen.

2) Values typically obtained by testing.

Burst

IEC 61000-4-5

4 kV CM

2 kV CM

2 V CM

— —

0.5 kV/2 Ω DM

4 kV/12 Ω CM

1 kV/12 Ω CM

3.2.5 Motor Insulation

Surge

2 kV/2 Ω DM

4 kV/2 Ω

2 kV/2 Ω

ESD

IEC

61000-4-2

— — 10 V

8 kV AD

6 kV CD

Radiated electromagnetic

eld

IEC 61000-4-3

10 V/m —

3.2.6 Motor Bearing Currents

RF common

mode voltage

IEC 61000-4-6

RMS

Modern motors for use with frequency converters have a high degree of insulation to account for new generation high-eciency IGBTs with high dU/dt. For retrot in old motors, conrm the motor insulation or mitigate with dU/dt lter or, if necessary, a sine-wave lter.

For motor cable lengths ≤ the maximum cable length listed in chapter 7 Specications, the motor insulation ratings listed in Table 3.8 are recommended. If a motor has lower insulation rating, use a dU/dt or sine-wave lter.

Nominal mains voltage [V] Motor insulation [V]

UN≤420

420 V< UN≤ 500 Reinforced ULL=1600

500 V< UN≤ 600 Reinforced ULL=1800

600 V< UN≤ 690 Reinforced ULL=2000

Table 3.8 Motor Insulation

Standard ULL=1300

To minimise bearing and shaft currents, ground the following to the driven machine:

Frequency converter

•

Motor

•

Driven machine

•

Standard mitigation strategies

1. Use an insulated bearing.

2. Apply rigorous installation procedures:

2a Ensure that the motor and motor load

are aligned.

2b Strictly follow the EMC Installation

guideline.

2c Reinforce the PE so the high frequency

impedance is lower in the PE than the input power leads.

2d Provide a good high-frequency

connection between the motor and the frequency converter, for instance, by screened cable which has a 360° connection in the motor and the frequency converter.

2e Make sure that the impedance from

frequency converter to building ground is lower that the grounding impedance

175HA034.10

System Integration Design Guide

of the machine. This can be dicult for pumps.

2f Make a direct ground connection

between the motor and motor load (for example pump).

3. Lower the IGBT switching frequency.

4. Modify the inverter waveform, 60° AVM vs. SFAVM.

5. Install a shaft grounding system or use an isolating coupling.

6. Apply conductive lubrication.

7. Use minimum speed settings if possible.

8. Try to ensure that the mains voltage is balanced to ground. This can be dicult for IT, TT, TN-CS, or Grounded leg systems.

9. Use a dU/dt or sine-wave lter.

3.2.7 Harmonics

Electrical devices with diode rectiers, such as

Fluorescent lights

•

Computers

•

Copiers

•

Fax machines

•

Various laboratory equipment, and

•

Telecommunications systems

•

can add harmonic distortion to a mains supply. Frequency converters use a diode bridge input, which can also contribute to harmonic distortion.

The frequency converter does not draw current uniformly from the power line. This non-sinusoidal current has components that are multiples of the fundamental current frequency. These components are referred to as harmonics. It is important to control the total harmonic distortion on the mains supply. Although the harmonic currents do not directly

aect electrical energy consumption, they generate heat in wiring and transformers. This heat generation can aect other devices on the same power line.

3.2.7.1 Harmonic Analysis

Various characteristics of a building’s electrical system determine the exact harmonic contribution of the frequency converter to the THD of a facility and its ability to meet IEEE standards. Generalisations about the harmonic contribution of frequency converters on a specic facility is dicult. When necessary, perform an analysis of the system harmonics to determine equipment

eects.

A frequency converter takes up a non-sinusoidal current from mains, which increases the input current I

RMS

. A nonsinusoidal current is transformed with a Fourier series analysis and split up into sine-wave currents with dierent frequencies, that is, dierent harmonic currents IN with 50 Hz or 60 Hz as the fundamental frequency.

The harmonics do not aect the power consumption directly, but increase the heat losses in the installation (transformer, inductors, cables). So, in power plants with a high percentage of rectier load, keep harmonic currents at a low level to avoid overload of the transformer, inductors, and cables.

Abbreviation Description

n Harmonic order

Table 3.9 Harmonics-related Abbreviations

Fundamental

current (I1)

Current I

Frequency

[Hz]

Table 3.10 Transformed Non-sinusoidal Current

Current Harmonic current

Input current 1.0 0.9 0.4 0.2 < 0.1

Table 3.11 Harmonic Currents Compared to the RMS Input

Current

Illustration 3.3 DC-link Coils

Fundamental frequency

Fundamental current

Fundamental voltage

Harmonic currents

Harmonic voltage

Harmonic current (In)

RMSI1

50 250 350 550

11-49

NOTICE

Some of the harmonic currents can disturb communication equipment connected to the same transformer or cause resonance with power factor correction capacitors.

To ensure low harmonic currents, the frequency converter is equipped with passive lters. DC-coils reduce the total harmonic distortion (THD) to 40%.

The voltage distortion on the mains supply voltage depends on the size of the harmonic currents multiplied by the mains impedance for the frequency in question. The

3 3

System Integration

VLT® Refrigeration Drive FC 103

total voltage distortion (THD) is calculated based on the individual voltage harmonics using this formula:

 + U

THD =

3.2.7.2 Harmonics Emission Requirements

 + ... + U

Equipment connected to the public supply network

Option Denition

1 IEC/EN 61000-3-2 Class A for 3-phase balanced

equipment (for professional equipment only up to 1

kW total power).

2 IEC/EN 61000-3-12 Equipment 16–75 A and profes-

sional equipment as from 1 kW up to 16 A phase

current.

Table 3.12 Harmonics Emission Standards

currents have on the supply system and for the documentation of compliance with relevant regional guidelines: IEEE 519 -1992; G5/4.

3.2.7.4 Eect of Harmonics in a Power

Distribution System

In Illustration 3.4, a transformer is connected on the primary side to a point of common coupling PCC1, on the medium voltage supply. The transformer has an impedance Z

and feeds a number of loads. The point of common

xfr

coupling where all loads are connected together is PCC2. Each load is connected through cables that have an impedance Z1, Z2, Z3.

3.2.7.3 Harmonics Test Results (Emission)

Power sizes up to PK75 in T2 and T4 comply with IEC/EN 61000-3-2 Class A. Power sizes from P1K1 and up to P18K in T2 and up to P90K in T4 comply with IEC/EN 61000-3-12, Table 4. Power sizes P110–P450 in T4 also compy with IEC/EN 61000-3-12 even though not required because currents are above 75 A.

Table 3.13 describes that the short-circuit power of the supply Ssc at the interface point between the user’s supply and the public system (R

= 3 × R

Actual (typical) 40 20 10 8

Limit for

sce

Actual (typical) 46 45

Limit for

sce

Table 3.13 Harmonics Test Results (Emission)

≥120

 × U

mains

 × I

SCE

It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S greater than or equal to that To connect other power sizes to the public supply network, consult the distribution network operator.

Compliance with various system level guidelines: The harmonic current data in Table 3.13 are provided in accordance with IEC/EN61000-3-12 with reference to the power drive systems product standard. They may be used as the basis for calculation of the inuence harmonic

) is greater than or equal to:

sce

 =  3 × 120 × 400 × I

equ

Individual harmonic current In/I1 (%)

40 25 15 10

Harmonic current distortion factor (%)

THD PWHD

48 46

equ

specied in the equation.

Illustration 3.4 Small Distribution System

Harmonic currents drawn by non-linear loads cause distortion of the voltage because of the voltage drop on the impedances of the distribution system. Higher impedances result in higher levels of voltage distortion.

Current distortion relates to apparatus performance and it relates to the individual load. Voltage distortion relates to system performance. It is not possible to determine the voltage distortion in the PCC knowing only the load’s harmonic performance. To predict the distortion in the PCC, the conguration of the distribution system and relevant impedances must be known.

A commonly used term for describing the impedance of a grid is the short-circuit ratio R

the ratio between the short circuit apparent power of the supply at the PCC (Ssc) and the rated apparent power of the load (S

sce

where

equ

Ssc=

equ

supply

and S

equ

. This ratio is dened as

sce

= U × I

equ

Non-linear

Current Voltage

System

Impedance

Disturbance to

other users

Contribution to

system losses

130BB541.10

System Integration Design Guide

The negative eect of harmonics is 2-fold

Harmonic currents contribute to system losses (in

•

cabling, transformer).

Harmonic voltage distortion causes disturbance

•

to other loads and increase losses in other loads.

Illustration 3.5 Negative Eects of Harmonics

3.2.7.5 Harmonic Limitation Standards and Requirements

The requirements for harmonic limitation can be:

Application-specic requirements.

•

Standards that must be observed.

•

The application-specic requirements are related to a specic installation where there are technical reasons for

limiting the harmonics.

Example

If 1 of the motors is connected directly online and the other is supplied through a frequency converter, a 250 kVA transformer with 2 110 kW motors connected is sucient. If both motors are frequency converter supplied, however, the transformer is undersized. Using more means of harmonic reduction within the installation or selecting low harmonic drive variants makes it possible for both motors to run with frequency converters.

There are various harmonic mitigation standards, regulations, and recommendations. Dierent standards apply in dierent geographical areas and industries. The following standards are the most common:

IEC61000-3-2

•

IEC61000-3-12

•

IEC61000-3-4

•

IEEE 519

•

G5/4

•

See the VLT® Advanced Harmonic Filter AHF 005/AHF 010 Design Guide for specic details on each standard.

In Europe, the maximum THDv is 8% if the plant is connected via the public grid. If the plant has its own

transformer, the limit is 10% THDv. The VLT® Refrigeration Drive FC 103 is designed to withstand 10% THDv.

3.2.7.6 Harmonic Mitigation

In cases where extra harmonic suppression is required, Danfoss oers a wide range of mitigation equipment. These are:

12-pulse drives.

•

AHF lters.

•

Low harmonic drives.

•

Active lters.

•

The choice of the right solution depends on several factors:

The grid (background distortion, mains

•

unbalance, resonance, and type of supply (transformer/generator).

Application (load prole, number of loads, and

•

load size).

Local/national requirements/regulations (IEEE 519,

•

IEC, G5/4, and so on).

Total cost of ownership (initial cost, eciency,

•

maintenance, and so on).

Always consider harmonic mitigation if the transformer load has a non-linear contribution of 40% or more.

Danfoss oers tools for calculation of harmonics, see chapter 2.8.2 PC Software.

3.2.8 Ground Leakage Current

Follow national and local codes regarding protective earthing of equipment where leakage current exceeds 3.5 mA. Frequency converter technology implies high frequency switching at high power. This generates a leakage current in the ground connection. The ground leakage current is made up of several contributions and depends on various system congurations, including:

RFI ltering.

•

Motor cable length.

•

Motor cable screening.

•

Frequency converter power.

•

3 3

130BB955.12

Leakage current

Motor cable length

130BB956.12

THDv=0%

THDv=5%

Leakage current

130BB958.12

Cable

150 Hz

3rd harmonics

50 Hz

Mains

RCD with low f

cut-

RCD with high f

cut-

Leakage current

Frequency

130BB957.11

Leakage current [mA]

100 Hz

2 kHz

100 kHz

System Integration

VLT® Refrigeration Drive FC 103

Using RCDs

Where residual current devices (RCDs), also known as earth leakage circuit breakers (ELCBs), are used, comply with the following:

Use RCDs of type B only as they can detect AC

•

and DC currents.

Use RCDs with a delay to prevent faults due to

•

transient ground currents.

Dimension RCDs according to the system congu-

•

ration and environmental considerations.

The leakage current includes several frequencies originating from both the mains frequency and the switching frequency. Whether the switching frequency is detected depends on the type of RCD used.

Illustration 3.6 Motor cable length and power size inuence

on leakage current. Power size a > power size b

The leakage current also depends on the line distortion.

Illustration 3.7 Line Distortion Inuences Leakage Current

If the leakage current exceeds 3.5 mA, compliance with EN/IEC61800-5-1 (power drive system product standard) requires special care. Reinforce grounding with the following protective ground connection requirements:

Ground wire (terminal 95) of at least 10 mm

•

cross-section.

2 separate ground wires both complying with the

•

dimensioning rules.

See EN/IEC61800-5-1 and EN 50178 for further information.

Illustration 3.8 Main Contributions to Leakage Current

The amount of leakage current detected by the RCD depends on the cut-o frequency of the RCD.

Illustration 3.9 Inuence of the RCD Cut-o Frequency on

Leakage Current

130BD934.10

PDS

CDM

MCS

4 5

System Integration Design Guide

3.3 Energy Eciency

The standard EN 50598 Ecodesign for power drive systems, motor starters, power electronics and their driven applications provides guidelines for assessing the energy eciency of frequency converters.

The standard provides a neutral method for determining

eciency classes and power losses at full load and at part load.

The standard allows combination of any motor with any frequency converter.

3 3

1 Mains and mains cabling EP Extended product

2 Feeding section MS Motor system

3 Auxiliaries PDS Power drive system

4 Basic drive module (BDM) CDM Complete drive module

5 Auxiliaries DE Driven equipment

6 Motor MCS Motor control system (CDM or starter)

7 Transmission S Motor starter

8 Load machine – –

Illustration 3.10 Power Drive System (PDS) and Complete Drive Module (CDM)

100

f [%]

100

L [%]

130BD932.10

System Integration

VLT® Refrigeration Drive FC 103

3.3.1 IE and IES Classes

Complete drive modules

According to the standard EN 50598-2, the complete drive module (CDM) comprises the frequency converter, its

feeding section, and its auxiliaries.

Energy eciency classes for the CDM:

IE0 = below state of the art.

•

IE1 = state of the art.

•

IE2 = above state of the art.

•

Danfoss frequency converters full energy eciency class IE2. The energy eciency class is dened at the nominal point of the CDM.

Power drive systems

A power drive system (PDS) consists of a complete drive module (CDM) and a motor.

Energy eciency classes for the PDS:

IES0 = Below state of the art.

•

IES1 = State of the art.

•

IES2 = Above state of the art.

•

Depending on the motor

Danfoss VLT® frequency converter typically full energy eciency class IES2.

The energy eciency class is dened at the nominal point of the PDS and can be calculated based on the CDM and the motor losses.

eciency, motors driven by a

3.3.2 Power Loss Data and Eciency Data

The power loss and the eciency of a frequency converter depend on conguration and auxiliary equipment. Danfoss provides conguration-specic power loss and eciency data at the operating points shown in Illustration 3.11. The frequency and load dene an operating point.

Illustration 3.11 Frequency Converter Operating Points

According to EN 50598-2, Load (L) [%] versus Frequency

(f) [%]

The power loss data are provided in % of rated apparent output power, and are determined according to EN 50598-2. When the power loss data are determined, the frequency converter uses the factory settings except for the motor data which is required to run the motor.

Refer to loss and eciency data of the frequency converter at the operating points specied in Illustration 3.11.

Use the VLT® ecoSmart application to calculate IE and IES

eciency classes. The application is available at vlt- ecosmart.danfoss.com.

Example of available data

The following example shows power loss and eciency data for a frequency converter with the following characteristics:

Illustration 3.12 and Illustration 3.13 show the power loss and eciency curves. The speed is proportional to the frequency.

www.danfoss.com/vltenergyeciency for the power

Power rating 55 kW, rated voltage at 400 V.

•

Rated apparent power, Sr, 67.8 kVA.

•

Rated output power, P

•

Rated eciency, ηr, 98.3%.

•

, 59.2 kW.

CDM

130BD930.10

1.80

1.60

1.40

1.20

1.00

0.80

0.60

0.40

0.20

0.00 0 10 20 30 40 50 60 70 80 90 100

N [%]

L,CDM

(freq,load)

[%]

130BD931.10

N [%]

0 20 40 60 80 100

100.00

98.00

96.00

94.00

92.00

90.00

CDM (freq,load)

[%]

1 2

130BE107.10

0 2 4 6 8 10

[kHz]

[%]

System Integration Design Guide

1 100% load

2 50% load

3 25% load

Illustration 3.12 Frequency converter power loss data.

CDM relative losses (P

(n) [% of nominal speed].

) [%] versus speed

L, CDM

Switching frequency

The switching frequency inuences magnetisation losses in the motor and switching losses in the frequency converter, as shown in Illustration 3.14.

3 3

1 Motor and frequency converter

2 Motor only

3 Frequency converter only

1 100% load

2 50% load

3 25% load

Illustration 3.13 Frequency converter eciency data.

CDM eciency (η

(n) [% of nominal speed].

CDM(freq, load)

) [%] versus speed

Interpolation of power loss

Determine the power loss at an arbitrary operating point using 2-dimensional interpolation.

3.3.3 Losses and Eciency of a Motor

The eciency of a motor running at 50–100% of the nominal motor speed and at 75–100% of the nominal torque is practically constant. This is valid both when the frequency converter controls the motor, or when the motor runs directly on mains.

The eciency depends on the type of motor and the level of magnetisation.

For more information about motor types, refer to the motor technology brochure at www.vlt-drives.danfoss.com.

Illustration 3.14 Losses [%] versus Switching Frequency [kHz]

NOTICE

A frequency converter produces extra harmonic losses in the motor. These losses decrease when switching frequency increases.

3.3.4 Losses and Eciency of a Power Drive System

To estimate the power losses at dierent operating points for a power drive system, sum the power losses at the operating point for each system component:

Frequency converter.

•

Motor.

•

Auxiliary equipment.

•

Mains Integration

3.4

3.4.1 Mains Congurations and EMC Eects

There are several types of AC mains systems for supplying power to frequency converters. Each aects the EMC characteristics of the system. The 5-wire TN-S systems are regarded as best for EMC, while the isolated IT system is the least desirable.

System Integration

VLT® Refrigeration Drive FC 103

System

type

TN Mains

Systems

TN-S A 5-wire system with separate neutral (N) and

TN-C A 4-wire system with a common neutral and

TT Mains

Systems

IT Mains

System

Table 3.14 AC Mains System Types

3.4.2 Low-frequency Mains Interference

Description

There are 2 types of TN mains distribution systems:

TN-S and TN-C.

protective earth (PE) conductors. It provides the

best EMC properties and avoids transmitting

interference.

protective earth (PE) conductor throughout the

system. The combined neutral and protective earth

conductor results in poor EMC characteristics.

A 4-wire system with a grounded neutral conductor

and individual grounding of the frequency

converter units. It has good EMC characteristics

when grounded properly.

An isolated 4-wire system with the neutral

conductor either not grounded or grounded via an

impedance.

Standard Denition

EN 61000-2-2, EN

61000-2-4, EN 50160

EN 61000-3-2,

61000-3-12

EN 50178 Monitors electronic equipment for use in

Table 3.15 EN Design Standards for Mains Power Quality

Denes the mains voltage limits to

observe in public and industrial power

grids.

Regulates mains interference generated

by connected devices.

power installations.

3.4.2.3 Interference-free Frequency

Converters

Every frequency converter generates mains interference. Present standards only dene frequency ranges up to 2 kHz. Some frequency converters shift the mains interference in the region above 2 kHz, which the standard does not address, and labels them as interference-free. Limits for this region are currently being studied. Frequency converters do not shift mains interference.

3.4.2.4 How Mains Interference Occurs

3.4.2.1 Non-sinusoidal Mains Supply

The mains voltage is rarely a uniform sinusoidal voltage with constant amplitude and frequency. This is partly due to loads that draw non-sinusoidal currents from the mains or have non-linear characteristics, such as:

Computers.

•

Television sets.

•

Switching power supplies.

•

Energy-ecient lamps.

•

Frequency converters.

•

Deviations are unavoidable and permissible within certain limits.

3.4.2.2 EMC Directives Compliance

In most of Europe, the basis for the objective assessment of the quality of mains power is the Electromagnetic Compatibility of Devices Act (EMVG). Compliance with this regulation ensures that all devices and networks connected to electrical distribution systems full their intended purpose without generating problems.

Mains interference distortion of the sinusoidal waveform caused by the pulsating input currents is referred to as harmonics. Derived from Fourier analysis, it is assessed up to 2.5 kHz, corresponding to the 50th harmonic of the mains frequency.

The input rectiers of frequency converters generate this typical form of harmonic interference on the mains. When frequency converters are connected to 50 Hz mains systems, the 3rd harmonic (150 Hz), 5th harmonic (250 Hz) or 7th harmonic (350 Hz) show the strongest eects. The overall harmonic content is called the total harmonic distortion (THD).

3.4.2.5 Eects of Mains Interference

Harmonics and voltage uctuations are 2 forms of lowfrequency mains interference. They have a dierent appearance at their origin than at any other point in the mains system when a load is connected. So, a range of inuences must be determined collectively when assessing the eects of mains interference. These inuences include the mains feed, structure, and loads.

Undervoltage warnings and higher functional losses can occur as a result of mains interference.

Undervoltage warnings

Incorrect voltage measurements due to distortion

•

of the sinusoidal mains voltage.

Cause incorrect power measurements because

•

only RMS-true measuring takes harmonic content into account.

System Integration Design Guide

Higher losses

Harmonics reduce the active power, apparent

•

power, and reactive power.

Distort electrical loads resulting in audible

•

interference in other devices, or, in worst case, even destruction.

Shorten the lifetime of devices as a result of

•

heating.

NOTICE

Excessive harmonic content puts a load on power factor correction equipment and may even cause its destruction. For this reason, provide chokes for power factor correction equipment when excessive harmonic content is present.

3.4.3 Analysing Mains Interference

To avoid impairment of mains power quality, various methods are available for analysing systems or devices that generate harmonic currents. Mains analysis programs, such as harmonic calculation software (HCS), analyse system designs for harmonics. Specic countermeasures can be tested beforehand and ensure subsequent system compatibility.

For analysing mains systems, go tohttp://www.danfoss- hcs.com/Default.asp?LEVEL=START for software download.

3.4.5 Radio Frequency Interference

Frequency converters generate radio frequency interference (RFI) due to their variable-width current pulses. Frequency converters and motor cables radiate these components and conduct them into the mains system.

RFI

lters are used to reduce this interference on the mains. They provide noise immunity to protect devices against high-frequency conducted interference. They also reduce interference emitted to the mains cable or radiation from the mains cable. The lters are intended to limit interference to a specied level. Built-in lters are often standard equipment rated for specic immunity.

NOTICE

All VLT® Refrigeration Drive FC 103 frequency converters are equipped with integrated mains interference chokes as standard.

3.4.6 Classication of the Operating Site

Knowing the requirements for the environment the frequency converter is intended to operate in is the most important factor regarding EMC compliance.

3.4.6.1 Environment 1/Class B: Residential

3 3

NOTICE

Danfoss has a high level of EMC expertise and provides EMC analyses with detailed evaluation or mains calculations to customers in addition to training courses, seminars, and workshops.

3.4.4 Options for Reducing Mains Interference

Generally speaking, mains interference from frequency converters is reduced by limiting the amplitude of pulsed currents. This reduction improves the power factor λ (lambda).

Several methods are recommended to avoid mains harmonics:

Input chokes or DC-link chokes in the frequency

•

converters.

Passive lters.

•

Active lters.

•

Slim DC links.

•

Active front end and low harmonic drives.

•

Rectiers with 12, 18, or 24 pulses per cycle.

•

Operating sites connected to the public low-voltage power grid, including light industrial areas, are classied as Environment 1/Class B. They do not have their own high voltage or medium-voltage distribution transformers for a separate mains system. The environment classications apply both inside and outside buildings. Some general examples are:

Business areas.

•

Residential buildings.

•

Restaurants.

•

Car parks.

•

Entertainment facilities.

•

3.4.6.2 Environment 2/Class A: Industrial

Industrial environments are not connected to the public power grid. Instead, they have their own high voltage or medium-voltage distribution transformers. The environment classications apply both inside and outside the buildings.

They are dened as industrial and are characterised by specic electromagnetic conditions:

System Integration

VLT® Refrigeration Drive FC 103

The presence of scientic, medical, or industrial

•

devices.

Switching of large inductive and capacitive loads.

•

The occurrence of strong magnetic elds (for

•

example, due to high currents).

3.4.6.3 Special Environments

In areas with medium-voltage transformers clearly demarcated from other areas, the user decides which type of environment to classify their facility. The user is responsible for ensuring the electromagnetic compatibility necessary to enable the trouble-free operation of all devices within specied conditions. Some examples of special environments are:

Shopping centres.

•

Supermarkets.

•

Filling stations.

•

Oce buildings.

•

Warehouses.

•

phase-correction equipment rises because frequency converters generate harmonics. The load and heat factor on the capacitors increases as the number of harmonic generators increases. As a result, t chokes in the power factor correction equipment. The chokes also prevent resonance between load inductances and the capacitance. Frequency converters with cos φ <1 also require chokes in the power factor correction equipment. Also consider the higher reactive power level for cable dimensions.

3.4.9 Input Power Delay

To ensure that the input surge suppression circuitry performs correctly, observe a time delay between successive applications of input power.

Table 3.16 shows the minimum time that must be allowed between applications of input power.

Input voltage [V] 380 415 460 600

Waiting time [s] 48 65 83 133

Table 3.16 Input Power Delay

3.4.6.4 Warning Labels

When a frequency converter does not conform to Category C1, provide a warning notice. This is the responsibility of the user. Interference elimination is based on classes A1, A2, and B in EN 55011. The user is ultimately responsible for the appropriate classication of devices and the cost of remedying EMC problems.

3.4.7 Use with Isolated Input Source

Most utility power in the United States is referenced to ground. Although not in common use in the United States, the input power may be an isolated source. All Danfoss frequency converters may be used with isolated input source as well as with ground reference power lines.

3.4.8 Power Factor Correction

Power factor correction equipment serves to reduce the phase shift (φ) between the voltage and the current to move the power factor closer to unity (cos φ). This is necessary when many inductive loads, such as motors or lamp ballasts, are used in an electrical distribution system. Frequency converters with an isolated DC link do not draw any reactive power from the mains system or generate any phase power factor correction shifts. They have a cos φ of approximately 1.

For this reason, speed-controlled motors do not have to take into account when dimensioning power factor correction equipment. However, the current drawn by the

3.4.10 Mains Transients

Transients are brief voltage peaks in the range of a few thousand volts. They can occur in all types of power distribution systems, including industrial and residential environments.

Lightning strikes are a common cause of transients. However, they are also caused by switching large loads on

o, or switching other mains transients equipment,

line or such as power factor correction equipment. Transients can also be caused by short circuits, tripping of circuit breakers in power distribution systems, and inductive coupling between parallel cables.

EN 61000-4-1 standard describes the forms of these transients and how much energy they contain. There are various ways to limit the harmful eects from transients. Gas-lled surge arresters and spark gaps provide rst-level protection against high-energy transients. For second-level protection, most electronic devices, including frequency converters, use voltage-dependent resistors (varistors) to attenuate transients.

3.4.11 Operation with a Standby Generator

Use back-up power systems, when the continued operation is necessary in the event of mains failure. They are also used in parallel with the public power grid to achieve higher mains power. This is common practice for combined heat and power units, taking advantage of the high

System Integration Design Guide

eciency achieved with this form of energy conversion. When a generator provides back-up power, the mains impedance is usually higher than when power is taken from the public grid. This causes the total harmonic distortion to increase. With proper design, generators can operate in a system containing devices that induce harmonics.

When designing a system, consider the use of a stand-by generator.

When the system is switched from mains

•

operation to generator, the harmonic load usually increases.

Designers must calculate or measure the increase

•

in the harmonic load to ensure that the power quality conforms to regulations to prevent harmonic problems and equipment failure.

Avoid asymmetric loading of the generator since

•

it causes increased losses and may increase total harmonic distortion.

A 5/6 stagger of the generator winding

•

attenuates the 5th and 7th harmonics, but it allows the 3rd harmonic to increase. A 2/3 stagger reduces the 3rd harmonic.

When possible, the operator should disconnect

•

power factor correction equipment because it causes resonance in the system.

Chokes or active absorption

•

resistive loads operated in parallel can attenuate harmonics.

Capacitive loads operated in parallel create extra

•

load due to unpredictable resonance eects.

A more precise analysis is possible using mains analysis software, such as HCS. For analysing mains systems, go to http://www.danfoss-hcs.com/Default.asp?LEVEL=START for software download.

lters as well as

Motor Integration

3.5

3.5.1 Motor Selection Considerations

The frequency converter can induce electrical stress on a motor. Therefore, consider the following motor when matching motor with frequency converter:

Insulation stress

•

Bearing stress

•

Thermal stress

•

eects on the

3.5.2 Sine-wave and dU/dt Filters

Output lters provide benets to some motors to reduce electrical stress and allow for longer cable length. Output options include sine-wave lters (also called LC lters) and dU/dt lters. The dU/dt lters reduce the sharp rise rate of the pulse. Sine-wave lters smooth the voltage pulses to convert them into a nearly sinusoidal output voltage. With some frequency converters, sine-wave lters comply with EN 61800-3 RFI category C2 for unshielded motor cables, see chapter 3.8.3 Sine-wave Filters.

For more information on sine-wave and dU/dt options, refer to chapter 6.2.6 Sine-wave Filters, chapter 3.8.3 Sine-wave Filters and chapter 6.2.7 dU/dt Filters.

For more information on sine-wave and dU/dt lter ordering numbers, refer to chapter 3.8.3 Sine-wave Filters, and chapter 6.2.7 dU/dt Filters.

lter

3.5.3 Proper Motor Grounding

Proper grounding of the motor is imperative for personal safety and to meet EMC electrical requirements for low voltage equipment. Proper grounding is necessary for the eective use of shielding and lters. Design details must be veried for proper EMC implementation.

3 3

When operating with harmonic-inducing devices, the maximum loads based on trouble-free facility operation are shown in the harmonic limits table.

Harmonic limits

B2 and B6

•

generator load.

B6 rectier with choke⇒maximum 20–35% of

•

rated generator load, depending on the composition.

Controlled B6 rectier⇒maximum 10% of rated

•

generator load.

rectiers⇒maximum 20% of rated

3.5.4 Motor Cables

Motor cable recommendations and specications are provided in chapter 7.5 Cable Specications.

All types of 3-phase asynchronous standard motors can be used with a frequency converter unit. The factory setting is for clockwise rotation with the frequency converter output connected as follows.

175HA036.11

96 97 98

Motor

96 97 98

Motor

130BD774.10

System Integration

VLT® Refrigeration Drive FC 103

3.5.6 Connection of Multiple Motors

NOTICE

Problems may arise at start and at low RPM values if motor sizes are widely dierent because small motors'

Illustration 3.15 Terminal Connection for Clockwise and

Counterclockwise Rotation

Change the direction of rotation by switching 2 phases in the motor cable or by changing the setting of parameter 4-10 Motor Speed Direction.

3.5.5 Motor Cable Shielding

Frequency converters generate steep-edged pulses on their outputs. These pulses contain high-frequency components (extending into the gigahertz range), which cause undesirable radiation from the motor cable. Screened motor cables reduce this radiation.

relatively high ohmic resistance in the stator calls for a higher voltage at start and at low RPM values.

The frequency converter can control several parallelconnected motors. When using parallel motor connection, observe the following:

VCC+ -mode may be used in some applications.

•

The total current consumption of the motors

•

must not exceed the rated output current I

INV

for

the frequency converter.

Do not use common joint connection for long

•

cable lengths, see Illustration 3.17.

The total motor cable length specied in

•

Table 3.4, is valid as long as the parallel cables are kept short (less than 10 m each), see Illustration 3.19 and Illustration 3.20.

Consider voltage drop across the motor cable, see

•

Illustration 3.20.

For long parallel cables, use an LC lter, see

•

Illustration 3.20.

For long cables without parallel connection, see

•

Illustration 3.21.

NOTICE

When motors are connected in parallel, set parameter 1-01 Motor Control Principle to [0] U/f.

The purposes of shielding are to:

The screen captures the high frequency components and conducts them back to the interference source, in this case the frequency converter. Screened motor cables also provide immunity to interference from nearby external sources.

Even good shielding does not fully eliminate the radiation. System components located in radiation environments must operate without degradation.

Reduce the magnitude of radiated interference.

•

Improve the interference immunity of individual

•

devices.

Illustration 3.16 Common Joint Connection for Short Cable

Lengths

130BD775.10

130BD776.10

130BD777.10

130BD778.10

130BD779.10

System Integration Design Guide

Illustration 3.17 Common Joint Connection for Long Cable

Lengths

3 3

Illustration 3.20 LC Filter for Long Parallel Cables

Illustration 3.18 Parallel Cables without Load

Illustration 3.19 Parallel Cables with Load

Illustration 3.21 Long Cables in Series Connection

Refer to Table 7.7 for information about cable lengths for multiple parallel motor connections.

3.5.7 Motor Thermal Protection

The frequency converter provides motor thermal protection in several ways:

Torque limit protects the motor from overload

•

independent of the speed.

Minimum speed limits the minimum operating

•

speed range, for instance between 30 and 50/60 Hz.

Maximum speed limits the maximum output

•

speed.

Input is available for an external thermistor.

•

Electronic thermal relay (ETR) for asynchronous

•

motors simulates a bi-metal relay based on

1.21.0 1.4

100

1.81.6 2.0

2000

500

200

400 300

1000

600

t [s]

175ZA052.12

OUT

= 2 x f

M,N

OUT

= 0.2 x f

M,N

OUT

= 1 x f

M,N

(par. 1-23)

IMN(par. 1-24)

1.0

0.99

0.98

0.97

0.96

0.95

0.93

0.92 0% 50% 100% 200%

0.94

Relative Eciency

130BB252.11

1.01

150%

% Speed

100% load 75% load 50% load 25% load

System Integration

VLT® Refrigeration Drive FC 103

internal measurements. The ETR measures actual current, speed, and time to calculate motor temperature and protect the motor from being overheated by issuing a warning or cutting power to the motor. The characteristics of the ETR are shown in Illustration 3.22.

Illustration 3.22 Electronic Thermal Relay Characteristics

The X-axis shows the ratio between I nominal. The Y-axis shows the time in seconds before the ETR cuts o and trips. The curves show the characteristic nominal speed at twice the nominal speed and at 0.2 x the nominal speed. At lower speed, the ETR cuts o at lower heat due to less cooling of the motor. In that way, the motor is protected from overheating even at low speed. The ETR feature calculates the motor temperature based on actual current and speed.

3.5.8 Output Contactor

Although not generally a recommended practice, operating an output contactor between the motor and the frequency converter does not damage the frequency converter. Closing a previously opened output contactor may connect a running frequency converter to a stopped motor. This may cause the frequency converter to trip and show a fault.

3.5.9 Energy Eciency

Eciency of the frequency converter

The load on the frequency converter has little eect on its eciency.

This also means that the frequency converter eciency does not change when other U/f characteristics are selected. However, the U/f characteristics do inuence the eciency of the motor.

The eciency declines a little when the switching frequency is set to a value above 5 kHz. The eciency is

motor

and I

motor

also slightly reduced when the motor cable is longer than 30 m.

Eciency calculation

Calculate the eciency of the frequency converter at dierent loads based on Illustration 3.23. Multiply the factor in this graph with the specic eciency factor listed in

chapter 7.1 Electrical Data.

Illustration 3.23 Typical Eciency Curves

Example: Assume a 55 kW, 380–480 V AC frequency converter with 25% load at 50% speed. The graph is showing 0.97 rated eciency for a 55 kW frequency converter is 0.98. The actual eciency is then: 0.97 x

0.98=0.95.

Motor eciency

The eciency of a motor connected to the frequency converter depends on magnetising level. The eciency of the motor depends on the type of motor.

In the range of 75–100% of the rated torque, the

•

eciency of the motor is practically constant, both when controlled by the frequency converter and when running directly on mains.

The inuence from the U/f characteristic on small

•

motors is marginal. However, in motors from 11 kW and up, the eciency advantage is signicant.

The switching frequency does not aect the

•

eciency of small motors. Motors from 11 kW and up have their eciency improved 1–2%. This is because the sine-shape of the motor current is almost perfect at high switching frequency.

System eciency

To calculate the system eciency, multiply the eciency of the frequency converter by the eciency of the motor.

91 (L1) 92 (L2) 93 (L3)

88 (-) 89 (+)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

0/4–20 mA

12 (+24 V OUT)

13 (+24 V OUT)

18 (D IN)

20 (COM D IN)

15 mA 200 mA

(U) 96

(V) 97 (W) 98 (PE) 99

(COM A OUT) 39

(A OUT) 42

0/4–20 mA

0–10 V DC

+10 V DC

0-10 V DC

0/4–20 mA

240 V AC, 2 A

24 V DC

240 V AC, 2 A

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

19 (D IN)

24 V (NPN) 0 V (PNP)

24 V

0 V

(D IN/OUT)

0 V (PNP)

24 V (NPN)

(D IN/OUT)

0 V

24 V

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

33 (D IN)

32 (D IN)

1 2

S201

S202

ON=0–20 mA OFF=0–10 V

400 V AC, 2 A

P 5-00

(R+) 82

(R-) 81

37 (D IN)

+ - + -

130BA544.13

(P RS485) 68

(N RS485) 69

(COM RS485) 61

5 V

S801

RS485

S801

3-phase power

input

DC bus

Switch mode power supply

Motor

Analog output

Interface

Relay1

Relay2

ON=Terminated OFF=Open

Brake resistor

(NPN) = Sink

(PNP) = Source

System Integration Design Guide

3.6 Additional Inputs and Outputs

3.6.1 Wiring Schematic

When wired and properly programmed, the control terminals provide:

Feedback, reference, and other input signals to the frequency converter.

•

Output status and fault conditions from the frequency converter.

•

Relays to operate auxiliary equipment.

•

A serial communication interface.

•

24 V common.

•

Control terminals are programmable for various functions by selecting parameter options through the local control panel (LCP) on the front of the unit or through external sources. Most control wiring is customer-supplied, unless specied in the factory order.

3 3

Illustration 3.24 Basic Wiring Schematic

A=Analog, D=Digital

*Terminal 37 (optional) is used for STO. For STO installation instructions, refer to the VLT® Frequency Converters - Safe Torque O Operating Instructions. **Do not connect cable screen.

Relay1

Relay2

240 V AC, 2 A

400 V AC, 2 A

130BA047.11

System Integration

VLT® Refrigeration Drive FC 103

3.6.2 Relay Connections

For more information about relay options, refer to chapter 3.8 Options and Accessories.

Relay

1 1 Common

2 4 Common

1 01–02 Make (normally open)

2 04–05 Make (normally open)

Illustration 3.25 Relay Outputs 1 and 2, Maximum Voltages

Terminal

Description

2 Normally open

Maximum 240 V

3 Normally closed

Maximum 240 V

5 Normally closed

Maximum 240 V

6 Normally closed

Maximum 240 V

01–03 Break (normally closed)

04–06 Break (normally closed)

1) To add more relay outputs, install VLT® Relay Option

Module MCB 105 or VLT® Relay Option Module MCB 113.

For more information about relays, refer to

chapter 7 Specications and chapter 8.3 Relay Terminal Drawings.

130BD529.12

L1 L2 L3

System Integration Design Guide

3.6.3 EMC-compliant Electrical Connection

3 3

1 PLC 7 Motor, 3-phase, and PE (screened)

2 Frequency converter 8 Mains, 3-phase, and reinforced PE (not screened)

3 Output contactor 9 Control wiring (screened)

4 Cable clamp 10

5 Cable insulation (stripped)

6 Cable gland

Potential equalisation minIMUM 16 mm2 (0.025 in)

Clearance between control cable, motor cable, and mains cable:

Minimum 200 mm

Illustration 3.26 EMC-compliant Electrical Connection

130BD389.11

B3 B3

130BA419.10

System Integration

VLT® Refrigeration Drive FC 103

For more information about EMC, see chapter 2.5.18 EMC Compliance and chapter 3.2 EMC, Harmonics, and Ground Leakage Protection.

NOTICE

EMC INTERFERENCE

Use screened cables for motor and control wiring, and separate cables for input power, motor wiring, and control wiring. Failure to isolate power, motor, and control cables can result in unintended behaviour or reduced performance. Minimum 200 mm (7.9 in) clearance between power, motor, and control cables is required.

3.7 Mechanical Planning

3.7.1 Clearance

Side-by-side installation is suitable for all enclosure sizes, except when an IP21/IP4X/TYPE 1 enclosure kit is used (see chapter 3.8 Options and Accessories).

Horizontal clearance, IP20

IP20 A and B enclosure sizes can be arranged side-by-side with no clearance. However, the correct mounting order is important. Illustration 3.27 shows how to mount correctly.

NOTE

For A2 and A3, ensure a clearance between the frequency converters of minimum 40 mm.

Horizontal clearance, IP21 enclosure kit

When the IP21 enclosure kit is used on enclosure sizes A2 or A3, ensure a clearance between the frequency converters of minimum 50 mm.

Vertical clearance

For optimal cooling conditions, ensure vertical clearance for free air passage above and below the frequency converter. See Illustration 3.28.

Enclosure

size

Illustration 3.27 Correct Side-by-side Mounting with no

Clearance

a [mm] 100 200 225

b [mm] 100 200 225

Illustration 3.28 Vertical Clearance

A2/A3/A4/

A5/B1

B2/B3/B4/

C1/C3

C2/C4

130BA219.11

130BA392.11

System Integration Design Guide

3.7.2 Wall Mounting

When mounting on a at wall, no back plate is required.

When mounting on an uneven wall, use a backplate to ensure sucient cooling air over the heat sink. Use the backplate with enclosures A4, A5, B1, B2, C1, and C2 only.

1 Backplate

Illustration 3.29 Mounting with Backplate

For frequency converters with protection rating IP66, use a bre or nylon washer to protect the epoxy coating.

1 Backplate

2 Frequency converter with IP66 enclosure

3 Backplate

4 Fibre washer

Illustration 3.30 Mounting with Backplate for Protection Rating

IP66

3.7.3 Access

To plan accessibility for cabling before mounting, refer to the drawings in chapter 8.1 Mains Connection Drawings and chapter 8.2 Motor Connection Drawings.

3.8 Options and Accessories

Options

For ordering numbers, see chapter 6 Type Code and Selection

Mains shielding

Lexan® shielding mounted in front of incoming

•

power terminals and input plate to protect from contact when the enclosure door is open.

RFI lters

Frequency converter feature integrated Class A2

•

RFI lters as standard. If more levels of RFI/EMC protection are required, they can be obtained using optional Class A1 RFI lters, which provide suppression of radio frequency interference and electromagnetic radiation in accordance with EN

55011.

Residual current device (RCD)

Uses the core balance method to monitor ground fault currents in grounded and high-resistance grounded systems (TN and TT systems in IEC terminology). There is a pre-warning (50% of main alarm setpoint) and a main alarm setpoint. Associated with each setpoint is an SPDT alarm relay for external use, which requires an external window-type current transformer (supplied and installed by the customer).

Integrated into the frequency converter’s safe

•

torque o circuit.

IEC 60755 Type B device monitors pulsed DC, and

•

pure DC ground fault currents.

LED bar graph indicator of the ground fault

•

current level from 10–100% of the setpoint.

Fault memory.

•

TEST/RESET key.

•

Insulation resistance monitor (IRM)

Monitors the insulation resistance in ungrounded systems (IT systems in IEC terminology) between the system phase conductors and ground. There is an ohmic pre-warning and a main alarm setpoint for the insulation level. Associated with each setpoint is an SPDT alarm relay for external use.

NOTICE

Only 1 insulation resistance monitor can be connected to each ungrounded (IT) system.

Integrated into the frequency converter’s safe

•

torque o circuit.

LCD display of insulation resistance.

•

Fault memory.

•

3 3

System Integration

VLT® Refrigeration Drive FC 103

INFO, TEST, and RESET keys.

•

Fuses

Fuses are recommended for fast-acting current-

•

overload protection of the frequency converter. Fuse protection limits frequency converter

Disconnect

Circuit breakers

Contactors

Manual motor starters

Provide 3-phase power for electric cooling blowers often required for larger motors. Power for the starters is provided from the load side of any supplied contactor, circuit breaker, or disconnect switch and from the input side of the Class 1 RFI lter (optional). Power is fused before each motor starter, and is o when the incoming power to the frequency converter is o. Up to 2 starters are allowed (1 if a 30 A, fuse-protected circuit is ordered). Motor starters are integrated into the frequency converter’s Safe Torque O circuit.

Unit features include:

30 A, fuse-protected terminals

damage and minimises service time in the event of a failure. Fuses are required to meet marine

certication.

A door-mounted handle allows for the manual

•

operation of a power disconnect switch to enable and disable power to the frequency converter, increasing safety during servicing. The disconnect is interlocked with the enclosure doors to prevent them from being opened while power is still applied.

A circuit breaker can be remotely tripped but

•

must be manually reset. Circuit breakers are interlocked with the enclosure doors to prevent them from being opened while power is still applied. When a circuit breaker is ordered as an option, fuses are also included for fast-acting current overload protection of the frequency converter.

An electrically controlled contactor switch allows

•

for the remote enabling and disabling of power to the frequency converter. If the IEC emergency stop option is ordered, the Pilz Safety monitors an auxiliary contact on the contactor.

Operation switch (on/o).

•

Short circuit and overload protection with test

•

function.

Manual reset function.

•

3-phase power matching incoming mains voltage

•

for powering auxiliary customer equipment.

Not available if 2 manual motor starters are

•

selected.

24 V DC supply

External temperature monitoring

Serial communications

VLT® PROFIBUS DP-V1 MCA 101

VLT® LonWorks for ADAP-KOOL® MCA 107

Terminals are o when the incoming power to

•

the frequency converter is o.

Power for the fuse-protected terminals is

•

provided from the load side of any supplied contactor, circuit breaker, or disconnect switch, and from the input side of the Class 1 RFI lter (optional).

5 A, 120 W, 24 V DC.

•

Protected against output overcurrent, overload,

•

short circuits, and overtemperature.

For powering customer-supplied accessory

•

devices such as sensors, PLC I/O, contactors, temperature probes, indicator lights, and/or other electronic hardware.

Diagnostics include a dry DC-ok contact, a green

•

DC-ok LED, and a red overload LED.

Designed for monitoring temperatures of external

•

system components, such as the motor windings and/or bearings. Includes 8 universal input modules plus 2 dedicated thermistor input modules. All 10 modules are integrated into the STO circuit and can be monitored via a eldbus network (requires the purchase of a separate module/bus coupler). Order an STO brake option to select external temperature monitoring.

PROFIBUS DP-V1 gives wide compatibility, a high

•

level of availability, support for all major PLC vendors, and compatibility with future versions.

Fast, ecient communication, transparent instal-

•

lation, advanced diagnosis, and parameterisation and auto-conguration of process data via GSD

le.

Acyclic parameterisation using PROFIBUS DP-V1,

•

PROFIdrive, or Danfoss FC prole state machines, PROFIBUS DP-V1, master class 1 and 2.

Ordering numbers:

•

- 130B1100 uncoated.

- 130B1200 coated (Class G3/ISA

S71.04-1985).

Continuous exchange of messages between a

•

number of processors.

Enables direct communication between individual

•

network devices.

System Integration Design Guide

VLT® PROFINET MCA 120

The PROFINET option oers connectivity to PROFINETbased networks via the PROFINET protocol. The option is able to handle a single connection with an actual packet interval down to 1 ms in both directions.

Built-in web server for remote diagnosis and

•

reading out of basic frequency converter parameters.

If certain warnings or alarms occur, or have

•

cleared again, an e-mail notication can be congured for sending an e-mail message to 1 or

several receivers.

TCP/IP for easy access to frequency converter

•

conguration data from MCT 10 Set-up Software.

FTP (File Transfer Protocol) le upload and

•

download.

Support of DCP (discovery and conguration

•

protocol).

More options

VLT® General Purpose I/O MCB 101

The I/O option inputs and outputs.

•

VLT® Relay Option MCB 105

Enables extending relay functions with 3 extra relay outputs.

•

oers an extended number of control

3 digital inputs 0–24 V: Logic 0<5 V; Logic 1>10 V.

2 analog inputs 0–10 V: Resolution 10 bit plus sign.

2 digital outputs NPN/PNP push-pull.

1 analog output 0/4–20 mA.

Spring-loaded connection.

Separate parameter settings.

Ordering numbers:

- 130B1125 uncoated.

- 130B1212 coated (Class G3/ISA

S71.04-1985).

Maximum terminal load: AC-1 resistive load: 240 V AC, 2 A, AC-15 .

Inductive load @cos ф 0.4: 240 V AC, 0.2 A, DC-1.

Resistive load: 24 V DC, 1 A, DC-13 .

Inductive load: @cos ф 0.4: 24 V DC, 0.1 A.

Minimum terminal load: DC 5 V: 10 mA.

Maximum switch rate at rated load/minimum load: 6 min-1/20 s-1.

Ordering numbers:

- 130B1110 uncoated.

- 130B1210 coated (Class G3/ISA

S71.04-1985).

Analog I/O Option MCB 109

VLT

This analog input/output option is easily tted in the frequency converter for upgrading to advanced performance and control using the additional inputs/ outputs. This option also upgrades the frequency converter with a battery back-up supply for the clock built into the frequency converter. This provides stable use of all frequency converter clock functions as timed actions.

3 analog inputs, each congurable as both

•

voltage and temperature input.

Connection of 0–10 V analog signals as well as

•

PT1000 and NI1000 temperature inputs.

3 analog outputs each congurable as 0–10 V

•

outputs.

Included back-up supply for the standard clock

•

function in the frequency converter. The back-up battery typically lasts for 10 years, depending on the environment.

Ordering numbers:

•

- 130B1143 uncoated

- 130B1243 coated (Class G3/ISA

S71.04-1985)

VLT® Extended Relay Card MCB 113

The Extended Relay Card MCB 113 adds inputs/outputs to the frequency converter for increased

7 digital inputs.

•

2 analog outputs.

•

4 SPDT relays.

•

Meets NAMUR recommendations.

•

Galvanic isolation capability.

•

Ordering numbers:

•

- 130B1164 uncoated.

- 130B1264 coated.

VLT® 24 V DC Supply Option MCB 107

The option is used to connect an external DC supply to keep the control section and any installed option active when mains power is down.

Input voltage range: 24 V DC ±15% (maximum 37

•

V in 10 s).

Maximum input current: 2.2 A.

•

Maximum cable length: 75 m.

•

Input capacitance load: <10 uF.

•

Power-up delay: <0.6 s.

•

Easy to install in frequency converters in existing

•

machines.

Keeps the control board and options active

•

during power cuts.

exibility.

3 3

System Integration

VLT® Refrigeration Drive FC 103

Keeps eldbusses active during power cuts.

•

Ordering numbers:

•

- 130B1108 uncoated.

- 130B1208 coated (Class G3/ISA

S71.04-1985).

3.8.4 dU/dt Filters

Danfoss supplies dU/dt lters which are dierential-mode, low-pass lters that reduce motor terminal phase-to-phase peak voltages and reduce the rise time to a level that lowers the stress on the insulation at the motor windings. This is especially an issue with short motor cables.

3.8.1 Communication Options

VLT® PROFIBUS DP-V1 MCA 101

•

VLT® AK-LonWorks MCA 107

•

VLT® PROFINET MCA 120

•

For further information, refer to chapter 7

Specications.

3.8.2 Input/Output, Feedback, and Safety Options

VLT® General Purpose I/O Module MCB 101

•

VLT® Relay Card MCB 105

•

VLT® Extended Relay Card MCB 113

•

For further information, refer to chapter 7 Specications.

Compared to sine-wave Filters), the dU/dt lters have a cut-o frequency above the switching frequency.

3.8.5 Harmonic Filters

The VLT® Advanced Harmonic Filter AHF 005 and AHF 010 are advanced harmonic lters, not to be compared with traditional harmonic trap lters. The Danfoss harmonic lters have been specially designed to match the Danfoss frequency converters.

Connecting the Danfoss harmonic lters AHF 005 or AHF 010 in front of a Danfoss frequency converter reduces the total harmonic current distortion generated back to the mains to 5% and 10%.

lters (see chapter 3.8.3 Sine-wave

3.8.3 Sine-wave Filters

When a frequency converter controls a motor, resonance noise is heard from the motor. This noise, which is the result of the motor design, occurs every time an inverter switch in the frequency converter is activated. The frequency of the resonance noise thus corresponds to the switching frequency of the frequency converter.

Danfoss supplies a sine-wave lter to dampen the acoustic motor noise.

The lter reduces the ramp-up time of the voltage, the peak load voltage U motor, which means that current and voltage become almost sinusoidal. So, the acoustic motor noise is reduced to a minimum.

The ripple current in the sine-wave lter coils also causes some noise. Solve the problem by integrating the lter in a cabinet or similar.

, and the ripple current ΔI to the

PEAK

130BT323.10

130BT324.10

System Integration Design Guide

3.8.6 IP21/NEMA Type 1 Enclosure Kit

IP20/IP4X top/NEMA TYPE 1 is an optional enclosure element available for IP20 compact units. If the enclosure kit is used, an IP20 unit is upgraded to comply with enclosure IP21/4X top/TYPE 1.

The IP4X top can be applied to all standard IP20 FC 103 variants.

3 3

Illustration 3.31 Enclosure Size A2

A Top cover

B Brim

C Base part

D Base cover

E Screw(s)

Illustration 3.32 Enclosure Size A3

1. Place the top cover as shown. If an A or B option is used, t the brim to cover the top inlet.

2. Place the base part C at the bottom of the frequency converter.

3. Use the clamps from the accessory bag to fasten the cables correctly.

Holes for cable glands:

Size A2: 2x M25 and 3xM32.

•

Size A3: 3xM25 and 3xM32.

•

130BT620.12

130BT621.12

System Integration

VLT® Refrigeration Drive FC 103

Enclosure type

Height A

[mm]

Width B

[mm]

Depth C

[mm]

A2 372 90 205

A3 372 130 205

B3 475 165 249

B4 670 255 246

C3 755 329 337

C4 950 391 337

Table 3.17 Dimensions

1) If option A/B is used, the depth increases (see chapter 7.9 Power

Ratings, Weight, and Dimensions for details)

Illustration 3.34 Enclosure Sizes B4, C3, and C4

A Top cover

B Brim

Illustration 3.33 Enclosure Size B3

C Base part

D Base cover

E Screw(s)

F Fan cover

G Top clip

Table 3.18 Legend to Illustration 3.33 and Illustration 3.34

PE U V W

130BD839.10

130BA138.10

System Integration Design Guide

When option module A and/or option module B is/are used, t the brim (B) to the top cover (A).

NOTICE

Side-by-side installation is not possible when using the

IP21/IP4X/TYPE 1 Enclosure Kit

3.8.7 Common-mode Filters

High-frequency common-mode cores (HF-CM cores) reduce electromagnetic interference and eliminate bearing damage by electrical discharge. They are special nanocrystalline magnetic cores, which have superior ltering performance compared to regular ferrite cores. The HF-CM core acts like a common-mode inductor between phases and ground.

Installed around the 3 motor phases (U, V, W ), the common mode lters reduce high-frequency commonmode currents. As a result, high-frequency electromagnetic interference from the motor cable is reduced.

The number of cores required depends on motor cable length and frequency converter voltage. Each kit consists of 2 cores. To determine the number of cores required, refer to Table 3.19.

3 3

Illustration 3.35 HF-CM Core with Motor Phases

3.8.8 Remote Mounting Kit for LCP

The LCP can be moved to the front of an enclosure by using the remote built-in kit. Tighten the fastening screws with a torque of maximum 1 Nm.

The LCP enclosure is rated IP66.

Cable length

[m] A and B C D

50 2 4 2 2 4

100 4 4 2 4 4

150 4 6 4 4 4

300 4 6 4 4 6

Table 3.19 Number of Cores

1) Where longer cables are required, stack more HF-CM cores.

Enclosure size

T2/T4 T7 T2/T4 T7 T7

Install the HF-CM cores by passing the 3 motor phase cables (U, V, W) through each core, as shown in Illustration 3.35.

Enclosure IP66 front

Maximum cable length between LCP and unit 3 m

Communication standard RS485

Table 3.20 Technical Data

Illustration 3.36 LCP Kit with Graphical LCP, Fasteners, 3 m

Cable, and Gasket

Ordering Number 130B1113

130BA200.10

Max R2(0.08)

Panel cut out

Min 72(2.8)

130BA139.11

129,5± 0.5 mm

64,5± 0.5 mm (2.54± 0.04 in)

(5.1± 0.04 in)

130BA844.10

130BA845.10

System Integration

VLT® Refrigeration Drive FC 103

3.8.9 Mounting Bracket for Enclosure Sizes A5, B1, B2, C1, and C2

Illustration 3.37 LCP Kit with Numerical LCP, Fasteners, and

Gasket

Ordering Number 130B1114

Illustration 3.39 Lower Bracket

Illustration 3.38 Dimensions of LCP Kit

Illustration 3.40 Upper Bracket

See dimensions in Table 3.21.

Enclosure Size IP A [mm] B [mm] Ordering number

A5 55/66 480 495 130B1080

B1 21/55/66 535 550 130B1081

B2 21/55/66 705 720 130B1082

B3 21/55/66 730 745 130B1083

B4 21/55/66 820 835 130B1084

Table 3.21 Details of Mounting Brackets

System Integration Design Guide

3.9 Serial Interface RS485

3.9.1 Overview

RS485 is a 2-wire bus interface compatible with multi-drop network topology. Nodes can be connected as a bus, or via drop cables from a common trunk line. A total of 32 nodes can be connected to 1 network segment. Repeaters divide network segments, see Illustration 3.41.

NOTICE

Each repeater functions as a node within the segment in which it is installed. Each node connected within a given network must have a unique node address across all segments.

Terminate each segment at both ends, using either the termination switch (S801) of the frequency converters or a biassed termination resistor network. Always use screened twisted pair (STP) cable for bus cabling, and follow good common installation practice.

Low-impedance ground connection of the screen at every node is important, including at high frequencies. Thus, connect a large surface of the screen to ground, for example, with a cable clamp or a conductive cable gland. It may be necessary to apply potential-equalising cables to maintain the same ground potential throughout the network, particularly in installations with long cables. To prevent impedance mismatch, always use the same type of cable throughout the entire network. When connecting a motor to the frequency converter, always use screened motor cable.

Cable Screened twisted pair (STP)

Impedance [Ω]

Cable length

[m]

Table 3.22 Cable Specications

120

Maximum 1200 (including drop lines)

Maximum 500 station-to-station

3 3

Illustration 3.41 RS485 Bus Interface

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

R1R2

61 68 69

RS-485

130BB685.10

130BA060.11

68 69 68 69 68 69

RS 485

RS 232 USB

130BB021.10

12 13 18 19 27 29 32

33 20 37

Remove jumper to enable Safe Stop

61 68 69 39 42 50 53 54 55

System Integration

VLT® Refrigeration Drive FC 103

Parameters

3.9.2 Network Connection

Function Setting

Parameter 8-30 P

rotocol FC*

Parameter 8-31 A

ddress

Parameter 8-32 B

9600*

One or more frequency converters can be connected to a control (or master) using the RS485 standardised interface. Terminal 68 is connected to the P signal (TX+, RX+), while terminal 69 is connected to the N signal (TX-, RX-). See drawings in chapter 3.6.1 Wiring Schematic.

aud Rate

* = Default value

Notes/comments:

If more than 1 frequency converter is connected to a master, use parallel connections.

Select protocol, address, and

baud rate in the above

mentioned parameters.

D IN 37 is an option.

Illustration 3.42 Parallel Connections

Table 3.23 RS485 Network Connection

To avoid potential equalising currents in the screen, wire according to Illustration 3.24.

Illustration 3.43 Control Card Terminals

3.9.3 RS485 Bus Termination

Terminate RS485 bus with a resistor network at both ends. For this purpose, set switch S801 on the control card to ON.

Set the communication protocol to parameter 8-30 Protocol.

Fieldbus cable

90° crossing

130BE039.11

Minimum 200 mm (8 in)

0 1 32 4 5 6 7

195NA036.10

Start bit

Even Stop Parity bit

System Integration Design Guide

3.9.4 EMC Precautions

The following EMC precautions are recommended to achieve interference-free operation of the RS485 network.

Observe relevant national and local regulations, for example regarding protective earth connection. Keep the RS485 communication cable away from motor and brake resistor cables to avoid coupling of high frequency noise from one cable to another. Normally, a distance of 200 mm (8 inches) is sucient, but keeping the greatest possible distance between the cables is recommended, especially where cables run in parallel over long distances. When crossing is unavoidable, the RS485 cable must cross motor cables at an angle of 90°.

The physical layer is RS485, thus utilising the RS485 port built into the frequency converter. The FC protocol supports dierent telegram formats:

A short format of 8 bytes for process data.

•

A long format of 16 bytes that also includes a

•

parameter channel.

A format used for texts.

•

3.9.6 Network Conguration

To enable the FC protocol for the frequency converter, set the following parameters:

Parameter number Setting

Parameter 8-30 Protocol FC

Parameter 8-31 Address 1–126

Parameter 8-32 Baud Rate 2400–115200

Parameter 8-33 Parity / Stop Bits Even parity, 1 stop bit (default)

Table 3.24 FC Protocol Parameters

3.9.7 FC Protocol Message Framing Structure

3 3

Illustration 3.44 Cable Routing

3.9.5 FC Protocol Overview

The FC protocol, also referred to as FC bus or standard bus, is the Danfoss standard eldbus. It denes an access technique according to the master/slave principle for communications via a eldbus. 1 master and a maximum of 126 slaves can be connected to the bus. The master selects the individual slaves via an address character in the telegram. A slave itself can never transmit without rst being requested to do so, and direct message transfer between the individual slaves is not possible. Communications occur in the half-duplex mode. The master function cannot be transferred to another node (single-master system).

3.9.7.1 Content of a Character (byte)

Each character transferred begins with a start bit. Then 8 data bits are transferred, corresponding to a byte. Each character is secured via a parity bit. This bit is set at 1 when it reaches parity. Parity is when there is an equal number of 1s in the 8 data bits and the parity bit in total. A stop bit completes a character, thus consisting of 11 bits in all.

Illustration 3.45 Content of a Character

STX LGE ADR DATA BCC

195NA099.10

System Integration

VLT® Refrigeration Drive FC 103

3.9.7.2 Telegram Structure

Each telegram has the following structure:

Start character (STX)=02 hex.

•

A byte denoting the telegram length (LGE).

•

A number of data bytes (variable, depending on the type of telegram) follows.

A data control byte (BCC) completes the telegram.

Illustration 3.46 Telegram Structure

A byte denoting the frequency converter address

•

(ADR).

3.9.7.5 Data Control Byte (BCC)

The checksum is calculated as an XOR-function. Before the rst byte in the telegram is received, the calculated checksum is 0.

3.9.7.3 Telegram Length (LGE)

The telegram length is the number of data bytes plus the address byte ADR and the data control byte BCC.

4 data bytes LGE=4+1+1=6 bytes

12 data bytes LGE=12+1+1=14 bytes

Telegrams containing texts

101)+n bytes

Table 3.25 Length of Telegrams

1) 10 represents the xed characters, while n is variable (depending

on the length of the text).

3.9.7.4 Frequency Converter Address (ADR)

2 dierent address formats are used. The address range of the frequency converter is either 1– 31 or 1–126.

Address format 1–31

•

- Bit 7=0 (address format 1–31 active).

- Bit 6 is not used.

- Bit 5=1: Broadcast, address bits (0–4) are

not used.

- Bit 5=0: No Broadcast.

- Bit 0–4=frequency converter address 1–

31.

Address format 1–126

•

- Bit 7=1 (address format 1–126 active).

- Bit 0–6=frequency converter address 1–

126.

- Bit 0–6 =0 Broadcast.

The slave returns the address byte unchanged to the master in the response telegram.

ADRLGESTX PCD1 PCD2 BCC

130BA269.10

PKE INDADRLGESTX PCD1 PCD2 BCC

130BA271.10

PWE

high

PWE

low

PKE IND

130BA270.10

ADRLGESTX PCD1 PCD2 BCCCh1 Ch2 Chn

System Integration Design Guide

3.9.7.6 The Data Field

The structure of data blocks depends on the type of telegram. There are 3 telegram types, and the type applies for both control telegrams (master⇒slave) and response telegrams (slave⇒master).

The 3 types of telegram are:

Process block (PCD)

The PCD is made up of a data block of 4 bytes (2 words) and contains:

Control word and reference value (from master to slave).

•

Status word and present output frequency (from slave to master).

•

Illustration 3.47 Process Block

Parameter block

The parameter block is used to transfer parameters between master and slave. The data block is made up of 12 bytes (6 words) and also contains the process block.

3 3

Illustration 3.48 Parameter Block

Text block

The text block is used to read or write texts via the data block.

Illustration 3.49 Text Block

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

130BA268.11

PKE IND

PWE

high

PWE

low

AK PNU

Parameter

commands

and replies

Parameter

number

System Integration

VLT® Refrigeration Drive FC 103

3.9.7.7 The PKE Field

The PKE eld contains 2 subelds:

Parameter command and response AK.

•

Parameter number PNU.

•

Illustration 3.50 PKE Field

Bits numbers 12–15 transfer parameter commands from master to slave and return processed slave responses to the master.

Bit number Parameter command

15 14 13 12

0 0 0 0 No command.

0 0 0 1 Read parameter value.

0 0 1 0 Write parameter value in RAM (word).

0 0 1 1 Write parameter value in RAM (double

word).

1 1 0 1 Write parameter value in RAM and

EEPROM (double word).

1 1 1 0 Write parameter value in RAM and

EEPROM (word).

1 1 1 1 Read/write text.

Table 3.26 Parameter Commands Master⇒Slave

Bit number Response

15 14 13 12

0 0 0 0 No response.

0 0 0 1 Parameter value transferred (word).

0 0 1 0 Parameter value transferred (double

word).

0 1 1 1 Command cannot be performed.

1 1 1 1 text transferred.

Table 3.27 Response Slave⇒Master

If the command cannot be performed, the slave sends this response:

0111 Command cannot be performed

- and issues a fault report (see Table 3.28) in the parameter value (PWE):

PWE low

(hex)

11 Data change in the dened parameter is not

82 There is no bus access to the dened parameter.

83 Data change is not possible because factory set-up

Table 3.28 Parameter Value Fault Report

Fault report

0 The parameter number used does not exit.

1 There is no write access to the dened parameter.

2 Data value exceeds the parameter's limits.

3 The sub index used does not exit.

4 The parameter is not the array type.

5 The data type does not match the dened

parameter.

possible in the frequency converter's present

mode. Certain parameters can only be changed

when the motor is turned o.

is selected

3.9.7.8 Parameter Number (PNU)

Bits number 0–11 transfer parameter numbers. The function of the relevant parameter is dened in the parameter description in the programming guide.

3.9.7.9 Index (IND)

The index is used together with the parameter number to read/write-access parameters with an index, for example, parameter 15-30 Alarm Log: Error Code. The index consists of 2 bytes, a low byte and a high byte.

Only the low byte is used as an index.

3.9.7.10 Parameter Value (PWE)

The parameter value block consists of 2 words (4 bytes), and the value depends on the dened command (AK). The master prompts for a parameter value when the PWE block contains no value. To change a parameter value (write), write the new value in the PWE block and send it from the master to the slave.

When a slave responds to a parameter request (read command), the present parameter value in the PWE block is transferred and returned to the master. If a parameter does not contain a numerical value, but several data options, for example parameter 0-01 Language where [0] is English, and [4] is Danish, select the data value by entering the value in the PWE block. Serial communication is only capable of reading parameters containing data type 9 (text string).

Parameter 15-40 FC Type to parameter 15-53 Power Card Serial Number contain data type 9.

For example, read the unit size and mains voltage range in parameter 15-40 FC Type. When a text string is transferred (read), the length of the telegram is variable, and the texts

PWE

high

PWE

low

Read text

Write text

130BA275.10

PKE IND

Fx xx 04 00

Fx xx 05 00

E19E H

PKE IND PWE

high

PWE

low

0000 H 0000 H 03E8 H

130BA092.10

119E H

PKE

IND

PWE

high

PWE

low

0000 H 0000 H 03E8 H

130BA093.10

System Integration Design Guide

are of dierent lengths. The telegram length is dened in the second byte of the telegram, LGE. When using text transfer, the index character indicates whether it is a read or a write command.

To read a text via the PWE block, set the parameter command (AK) to F hex. The index character high-byte must be 4.

Some parameters contain text that can be written to via the eldbus. To write a text via the PWE block, set the parameter command (AK) to F hex. The index characters high-byte must be 5.

Illustration 3.51 Text via PWE Block

3.9.7.11 Supported Data Types

Unsigned means that there is no operational sign in the telegram.

Data types Description

3 Integer 16

4 Integer 32

5 Unsigned 8

6 Unsigned 16

7 Unsigned 32

9 Text string

10 Byte string

13 Time dierence

33 Reserved

35 Bit sequence

Table 3.29 Supported Data Types

3.9.7.13 Process Words (PCD)

The block of process words is divided into 2 blocks of 16 bits, which always occur in the dened sequence.

PCD 1 PCD 2

Control telegram (master⇒slave control word)

Control telegram (slave⇒master status word)

Table 3.30 Process Words (PCD)

Reference value

Present output

frequency

3.9.8 FC Protocol Examples

3.9.8.1 Writing a Parameter Value

Change parameter 4-14 Motor Speed High Limit [Hz] to 100 Hz. Write the data in EEPROM.

PKE=E19E hex - Write single word in parameter 4-14 Motor Speed High Limit [Hz]. IND=0000 hex PWEHIGH=0000 hex PWELOW=03E8 hex - Data value 1000, corresponding to 100 Hz, see chapter 3.9.7.12 Conversion.

The telegram looks like this:

Illustration 3.52 Write Data in EEPROM

NOTICE

Parameter 4-14 Motor Speed High Limit [Hz] is a single

word, and the parameter command for write in EEPROM is E. Parameter number 4-14 is 19E in hexadecimal.

3 3

3.9.7.12 Conversion

The various attributes of each parameter are shown in factory setting. Parameter values are transferred as whole numbers only. Conversion factors are therefore used to transfer decimals.

Parameter 4-12 Motor Speed Low Limit [Hz] has a conversion factor of 0.1. To preset the minimum frequency to 10 Hz, transfer the value 100. A conversion factor of 0.1 means that the value transferred is multiplied by 0.1. The value 100 is therefore read as 10.0.

Examples: 0 s⇒conversion index 0

0.00 s⇒conversion index -2 0 ms⇒conversion index -3

0.00 ms⇒conversion index -5

The response from the slave to the master is:

Illustration 3.53 Response from Slave

3.9.8.2 Reading a Parameter Value

Read the value in parameter 3-41 Ramp 1 Ramp Up Time.

PKE=1155 hex - Read parameter value in parameter 3-41 Ramp 1 Ramp Up Time. IND=0000 hex PWEHIGH=0000 hex PWELOW=0000 hex

1155 H

PKE IND PWE

high

PWE

low

0000 H 0000 H 0000 H

130BA094.10

130BA267.10

1155 H

PKE

IND

0000 H 0000 H 03E8 H

PWE

high

PWE

low

System Integration

Illustration 3.54 Parameter Value

If the value in parameter 3-41 Ramp 1 Ramp Up Time is 10 s, the response from the slave to the master is

Illustration 3.55 Response from Slave

3E8 hex corresponds to 1000 decimal. The conversion index for yparameter 3-41 Ramp 1 Ramp Up Time is -2, that is, 0.01.

Parameter 3-41 Ramp 1 Ramp Up Time is of the type Unsigned 32.

3.9.9 Modbus RTU Protocol

VLT® Refrigeration Drive FC 103

Controllers communicate using a master/slave technique in which only the master can initiate transactions (called queries). Slaves respond by supplying the requested data to the master, or by taking the action requested in the query. The master can address individual slaves, or initiate a broadcast message to all slaves. Slaves return a response to queries that are addressed to them individually. No responses are returned to broadcast queries from the master. The Modbus RTU protocol establishes the format for the master’s query by providing:

•

The slave’s response message is also constructed using Modbus protocol. It contains elds conrming the action taken, any data to be returned, and an error-checking eld. If an error occurs in receipt of the message, or if the slave is unable to perform the requested action, the slave returns an error message. Alternatively, a timeout occurs.

The device (or broadcast) address.

A function code dening the requested action.

Any data to be sent.

An error-checking eld.

3.9.9.1 Assumptions

Danfoss assumes that the installed controller supports the interfaces in this manual, and strictly observes all requirements and limitations stipulated in the controller and frequency converter.

The built-in Modbus RTU (Remote Terminal Unit) is designed to communicate with any controller that supports the interfaces dened in this manual. It is assumed that the user has full knowledge of the capabilities and limitations of the controller.

3.9.9.2 Modbus RTU Overview

Regardless of the type of physical communication networks, the Modbus RTU overview describes the process a controller uses to request access to another device. This process includes how the Modbus RTU responds to requests from another device, and how errors are detected and reported. It also establishes a common format for the layout and contents of message elds. During communications over a Modbus RTU network, the protocol:

Determines how each controller learns its device

•

address.

Recognises a message addressed to it.

•

Determines which actions to take.

•

Extracts any data or other information contained

•

in the message.

If a reply is required, the controller constructs the reply message and sends it.

3.9.9.3 Frequency Converter with Modbus

RTU

The frequency converter communicates in Modbus RTU format over the built-in RS485 interface. Modbus RTU provides access to the control word and bus reference of the frequency converter.

The control word allows the Modbus master to control several important functions of the frequency converter:

Start

•

Stop of the frequency converter in various ways:

•

- Coast stop

- Quick stop

- DC brake stop

- Normal (ramp) stop

Reset after a fault trip

•

Run at various preset speeds

•

Run in reverse

•

Change the active set-up

•

Control the frequency converter’s built-in relay

•

The bus reference is commonly used for speed control. It is also possible to access the parameters, read their values, and, where possible, write values to them. This permits a range of control options, including controlling the setpoint of the frequency converter when its internal PI controller is used.

System Integration Design Guide

3.9.9.4 Network Conguration

To enable Modbus RTU on the frequency converter, set the following parameters:

Parameter Setting

Parameter 8-30 Protocol Modbus RTU

Parameter 8-31 Address 1–247

Parameter 8-32 Baud Rate 2400–115200

Parameter 8-33 Parity / Stop Bits Even parity, 1 stop bit (default)

Table 3.31 Modbus RTU Parameters

3.9.10 Modbus RTU Message Framing Structure

3.9.10.1 Frequency Converter with Modbus

RTU

The controllers are set up to communicate on the Modbus network using RTU mode, with each byte in a message containing 2 4-bit hexadecimal characters. The format for each byte is shown in Table 3.32.

Start

bit

Table 3.32 Format for Each Byte

Data byte Stop/

parity

Stop

Start Address Function Data CRC

check

T1-T2-T3-T48 bits 8 bits N x 8 bits 16 bits T1-T2-T3-

Table 3.33 Typical Modbus RTU Message Structure

End

3.9.10.3 Start/Stop Field

Messages start with a silent period of at least 3.5 character intervals. This is implemented as a multiple of character intervals at the selected network baud rate (shown as Start T1-T2-T3-T4). The rst eld to be transmitted is the device address. Following the last transmitted character, a similar period of at least 3.5 character intervals marks the end of the message. A new message can begin after this period. The entire message frame must be transmitted as a continuous stream. If a silent period of more than 1.5 character intervals occurs before completion of the frame, the receiving device ushes the incomplete message and assumes that the next byte is the address eld of a new message. Similarly, if a new message begins before 3.5 character intervals after a previous message, the receiving device considers it a continuation of the previous message. This causes a timeout (no response from the slave), since the value in the nal CRC eld is not valid for the combined messages.

3 3

Coding system 8–bit binary, hexadecimal 0–9, A–F.

2 hexadecimal characters contained in each

8-bit eld of the message.

Bits per byte 1 start bit.

8 data bits, least signicant bit sent rst;

1 bit for even/odd parity; no bit for no

parity.

1 stop bit if parity is used; 2 bits if no

parity.

Error check eld Cyclic redundancy check (CRC).

3.9.10.2 Modbus RTU Message Structure

The transmitting device places a Modbus RTU message into a frame with a known beginning and ending point. This allows receiving devices to begin at the start of the message, read the address portion, determine which device is addressed (or all devices, if the message is broadcast), and to recognise when the message is completed. Partial messages are detected and errors set as a result. Characters for transmission must be in hexadecimal 00 to FF format in each eld. The frequency converter continuously monitors the network bus, also during silent intervals. When the rst eld (the address eld) is received, each frequency converter or device decodes it to determine which device is being addressed. Modbus RTU messages addressed to zero are broadcast messages. No response is permitted for broadcast messages. A typical message frame is shown in Table 3.33.

3.9.10.4 Address Field

The address eld of a message frame contains 8 bits. Valid slave device addresses are in the range of 0–247 decimal. The individual slave devices are assigned addresses in the range of 1–247. (0 is reserved for broadcast mode, which all slaves recognise.) A master addresses a slave by placing the slave address in the address eld of the message. When the slave sends its response, it places its own address in this address eld to let the master know which slave is responding.

3.9.10.5 Function Field

The function eld of a message frame contains 8 bits. Valid codes are in the range of 1–FF. Function elds are used to send messages between master and slave. When a message is sent from a master to a slave device, the function code eld tells the slave what action to perform. When the slave responds to the master, it uses the function code eld to indicate either a normal (error-free) response, or that an error occurred (called an exception response). For a normal response, the slave simply echoes the original function code. For an exception response, the slave returns a code that is equivalent to the original function code with its most signicant bit set to logic 1. In addition, the slave places a unique code into the data eld of the response message. This tells the master what error occurred, or the reason for the exception. Also refer to

System Integration

VLT® Refrigeration Drive FC 103

chapter 3.9.10.10 Function Codes Supported by Modbus RTU

and chapter 3.9.10.11 Modbus Exception Codes.

3.9.10.6 Data Field

The data eld is constructed using sets of 2 hexadecimal digits, in the range of 00–FF hexadecimal. These are made

Coil

number

1–16 Frequency converter control word. Master to slave

17–32 Frequency converter speed or

33–48 Frequency converter status word (see

up of 1 RTU character. The data eld of messages sent from a master to a slave device contains extra information,

49–64 Open-loop mode: Frequency

which the slave must use to act as dened by the function code. This can include items such as coil or register addresses, the quantity of items to be handled, and the count of actual data bytes in the eld.

65 Parameter write control (master to

3.9.10.7 CRC Check Field

Messages include an error-checking eld, operating based on a cyclic redundancy check (CRC) method. The CRC eld checks the contents of the entire message. It is applied regardless of any parity check method used for the individual characters of the message. The transmitting device calculates the CRC value and appends the CRC as the last eld in the message. The receiving device recalculates a CRC during receipt of the message and compares the calculated value to the actual value received in the CRC eld. If the 2 values are unequal, a bus timeout occurs. The error-checking eld contains a 16-bit binary value implemented as 2 8-bit bytes. When this is done, the low-order byte of the eld is appended rst, followed by the high-order byte. The CRC high-order byte is the last byte sent in the message.

3.9.10.8 Coil Register Addressing

In Modbus, all data is organised in coils and holding registers. Coils hold a single bit, whereas holding registers hold a 2-byte word (16 bits). All data addresses in Modbus messages are referenced to zero. The rst occurrence of a data item is addressed as item number 0. For example: The coil known as coil 1 in a programmable controller is addressed as the data address eld of a Modbus message.

Coil 127 decimal is addressed as coil 007EHEX (126 decimal). Holding register 40001 is addressed as register 0000 in the

data address eld of the message. The function code eld

66–

65536

Table 3.34 Coil Descriptions

Coil 0 1

01 Preset reference lsb

02 Preset reference msb

03 DC brake No DC brake

04 Coast stop No coast stop

05 Quick stop No quick stop

06 Freeze freq. No freeze freq.

07 Ramp stop Start

08 No reset Reset

09 No jog Jog

10 Ramp 1 Ramp 2

11 Data not valid Data valid

12 Relay 1 o Relay 1 on

13 Relay 2 o Relay 2 on

14 Set up lsb

15 Set up msb

16 No reversing Reversing

Table 3.35 Frequency Converter Control Word (FC Prole)

Description Signal

direction

Master to slave

setpoint reference range 0x0–0xFFFF

(-200% ... ~200%).

Slave to master

Table 3.36).

Slave to master

converter output frequency.

Closed-loop mode: Frequency

converter feedback signal.

Master to slave

slave).

0=Parameter changes are written to

the RAM of the frequency

converter.

1=Parameter changes are written to

the RAM and EEPROM of the

frequency converter.

Reserved.

already species a holding register operation. Therefore, the 4XXXX reference is implicit. Holding register 40108 is addressed as register 006BHEX (107 decimal).

System Integration Design Guide

Coil 0 1

33 Control not ready Control ready

34 Frequency converter not

ready

35 Coasting stop Safety closed

36 No alarm Alarm

37 Not used Not used

38 Not used Not used

39 Not used Not used

40 No warning Warning

41 Not at reference At reference

42 Hand mode Auto mode

43 Out of frequency range In frequency range

44 Stopped Running

45 Not used Not used

46 No voltage warning Voltage warning

47 Not in current limit Current limit

48 No thermal warning Thermal warning

Table 3.36 Frequency Converter Status Word (FC Prole)

number

00001–00006 Reserved

00007 Last error code from an FC data object interface

00008 Reserved

00009

00010–00990 000 parameter group (parameters 0-01 through

01000–01990 100 parameter group (parameters 1-00 through

02000–02990 200 parameter group (parameters 2-00 through

03000–03990 300 parameter group (parameters 3-00 through

04000–04990 400 parameter group (parameters 4-00 through

... ...

49000–49990 4900 parameter group (parameters 49-00 through

50000 Input data: Frequency converter control word

50010 Input data: Bus reference register (REF).

... ...

50200 Output data: Frequency converter status word

50210 Output data: Frequency converter main actual

Description

Parameter index

0-99)

1-99)

2-99)

3-99)

4-99)

49-99)

value register (MAV).

Frequency converter ready

3.9.10.9 How to Control the Frequency Converter

Codes available for use in the function and data elds of a Modbus RTU message are listed in

chapter 3.9.10.10 Function Codes Supported by Modbus RTU

and chapter 3.9.10.11 Modbus Exception Codes.

3.9.10.10 Function Codes Supported by

Modbus RTU

Modbus RTU supports use of the function codes (see Table 3.38) in the function eld of a message.

Function Function code (hex)

Read coils 1

Read holding registers 3

Write single coil 5

Write single register 6

Write multiple coils F

Write multiple registers 10

Get communication event counter B

Report slave ID 11

Table 3.38 Function Codes

Function Function

code

Diagnostics 8 1 Restart communication

Table 3.39 Function Codes and Subfunction Codes

Subfunction

code

2 Return diagnostic register

10 Clear counters and

11 Return bus message

12 Return bus communi-

13 Return slave error count

14 Return slave message

Subfunction

diagnostic register

count

cation error count

count

3 3

Table 3.37 Holding Registers

1) Used to specify the index number to be used when accessing an

indexed parameter.

System Integration

VLT® Refrigeration Drive FC 103

3.9.10.11 Modbus Exception Codes

For information on the parameters, size, and converting index, consult the programming guide.

For a full explanation of the structure of an exception code response, refer to chapter 3.9.10.5 Function Field.

Code Name Meaning

1 Illegal

function

2 Illegal data

address

3 Illegal data

value

4 Slave device

failure

The function code received in the query is

not an allowable action for the server (or

slave). This may be because the function

code is only applicable to newer devices,

and was not implemented in the unit

selected. It could also indicate that the

server (or slave) is in the wrong state to

process a request of this type, for example

because it is not congured and is being

asked to return register values.

The data address received in the query is

not an allowable address for the server (or

slave). More specically, the combination

of reference number and transfer length is

invalid. For a controller with 100 registers,

a request with oset 96 and length 4

would succeed, a request with oset 96

and length 5 generates exception 02.

A value contained in the query data eld

is not an allowable value for the server (or

slave). This indicates a fault in the

structure of the remainder of a complex

request, such as that the implied length is

incorrect. It specically does NOT mean

that a data item submitted for storage in

a register has a value outside the

expectation of the application program,

since the Modbus protocol is unaware of

the signicance of any particular value of

any particular register.

An unrecoverable error occurred while the

server (or slave) was attempting to

perform the requested action.

3.9.11.2 Storage of Data

The coil 65 decimal determines whether data written to the frequency converter is stored in EEPROM and RAM (coil 65=1) or only in RAM (coil 65=0).

3.9.11.3 IND (Index)

Some parameters in the frequency converter are array parameters, for example parameter 3-10 Preset Reference. Since the Modbus does not support arrays in the holding registers, the frequency converter has reserved the holding register 9 as pointer to the array. Before reading or writing an array parameter, set the holding register 9. Setting the holding register to the value of 2 causes all following read/ write to array parameters to be to the index 2.

3.9.11.4 Text Blocks

Parameters stored as text strings are accessed in the same way as the other parameters. The maximum text block size is 20 characters. If a read request for a parameter is for more characters than the parameter stores, the response is truncated. If the read request for a parameter is for fewer characters than the parameter stores, the response is space

lled.

3.9.11.5 Conversion Factor

Since a parameter value can only be transferred as a whole number, a conversion factor must be used to transfer decimals.

3.9.11.6 Parameter Values

Table 3.40 Modbus Exception Codes

Standard data types

Standard data types are int 16, int 32, uint 8, uint 16, and

3.9.11 Access to Parameters

uint 32. They are stored as 4x registers (40001–4FFFF). The parameters are read using function 03 hex Read Holding

3.9.11.1 Parameter Handling

Registers. Parameters are written using the function 6 hex Preset Single Register for 1 register (16 bits), and the

The PNU (parameter number) is translated from the register address contained in the Modbus read or write message. The parameter number is translated to Modbus as (10 x parameter number) decimal. Example: Reading parameter 3-12 Catch up/slow Down Value (16 bit): The holding register 3120 holds the parameters value. A value of 1352 (Decimal), means that the parameter is set to

12.52%

Reading parameter 3-14 Preset Relative Reference (32 bit): The holding registers 3410 & 3411 holds the parameter’s

function 10 hex Preset Multiple Registers for 2 registers (32 bits). Readable sizes range from 1 register (16 bits) up to 10 registers (20 characters).

Non-standard data types

Non-standard data types are text strings and are stored as 4x registers (40001–4FFFF). The parameters are read using function 03 hex Read Holding Registers and written using function 10 hex Preset Multiple Registers. Readable sizes range from 1 register (2 characters) up to 10 registers (20

characters). value. A value of 11300 (decimal), means that the parameter is set to 1113.00.

Speed ref.CTW

Master-follower

130BA274.11

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Bit no.:

System Integration Design Guide

3.9.12 FC Drive Control Prole

3.9.12.1 Control Word According to FC

Prole (parameter 8-10 Control Prole=FC prole)

Illustration 3.56 Control Word

Bit Bit value=0 Bit value=1

00 Reference value External selection lsb

01 Reference value External selection msb

02 DC brake Ramp

03 Coasting No coasting

04 Quick stop Ramp

05 Hold output frequency Use ramp

06 Ramp stop Start

07 No function Reset

08 No function Jog

09 Ramp 1 Ramp 2

10 Data invalid Data valid

11 No function Relay 01 active

12 No function Relay 02 active

13 Parameter set-up Selection lsb

14 Parameter set-up Selection msb

15 No function Reverse

Table 3.41 Control Word Bits

Explanation of the Control Bits

Bits 00/01

Bits 00 and 01 are used to select between the 4 reference values, which are pre-programmed in parameter 3-10 Preset Reference according to Table 3.42.

Programmed

reference value

1 Parameter 3-10

2 Parameter 3-10

3 Parameter 3-10

4 Parameter 3-10

Parameter Bit 01 Bit 00

0 0

Preset Reference

[0]

0 1

Preset Reference

[1]

1 0

Preset Reference

[2]

1 1

Preset Reference

[3]

NOTICE

Make a selection in parameter 8-56 Preset Reference Select

to dene how bit 00/01 gates with the corresponding

function on the digital inputs.

Bit 02, DC brake

Bit 02=0 leads to DC braking and stop. Set braking current

and duration in parameter 2-01 DC Brake Current and

parameter 2-02 DC Braking Time.

Bit 02=1 leads to ramping.

Bit 03, Coasting

Bit 03=0: The frequency converter immediately releases the

motor (the output transistors are shut o) and it coasts to

a standstill.

Bit 03=1: If the other starting conditions are met, the

frequency converter starts the motor.

Make a selection in parameter 8-50 Coasting Select to

dene how bit 03 gates with the corresponding function

on a digital input.

Bit 04, Quick stop

Bit 04=0: Makes the motor speed ramp down to stop (set

in parameter 3-81 Quick Stop Ramp Time).

Bit 05, Hold output frequency

Bit 05=0: The present output frequency (in Hz) freezes.

Change the frozen output frequency only with the digital

inputs (parameter 5-10 Terminal 18 Digital Input to

parameter 5-15 Terminal 33 Digital Input) programmed to

Speed up and Slow down.

NOTICE

If freeze output is active, stop the frequency converter

by the following:

Bit 03 Coasting stop.

•

Bit 02 DC braking.

•

Digital input (parameter 5-10 Terminal 18 Digital

•

Input to parameter 5-15 Terminal 33 Digital Input) programmed to DC braking, Coasting stop, or Reset and coasting stop.

Bit 06, Ramp stop/start

Bit 06=0: Causes a stop and makes the motor speed ramp

down to stop via the selected ramp down parameter.

Bit 06=1: If the other starting conditions are met, allow the

frequency converter to start the motor.

Make a selection in parameter 8-53 Start Select to dene

how bit 06 Ramp stop/start gates with the corresponding

function on a digital input.

Bit 07, Reset

Bit 07=0: No reset.

Bit 07=1: Resets a trip. Reset is activated on the signal’s

leading edge, for example, when changing from logic 0 to

logic 1.

3 3

Table 3.42 Reference Values

Output freq.STW

Bit no.:

Follower-master

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

130BA273.11

System Integration

VLT® Refrigeration Drive FC 103

Bit 08, Jog

Bit 08=1: Parameter 3-19 Jog Speed [RPM] determines the output frequency.

Bit 09, Selection of ramp 1/2

3.9.12.2 Status Word According to FC Prole (STW) (parameter 8-10 Control Prole=FC

prole)

Bit 09=0: Ramp 1 is active (parameter 3-41 Ramp 1 Ramp

Up Time to parameter 3-42 Ramp 1 Ramp Down Time). Bit 09=1: Ramp 2 (parameter 3-51 Ramp 2 Ramp Up Time to parameter 3-52 Ramp 2 Ramp Down Time) is active.

Bit 10, Data not valid/Data valid

Tells the frequency converter whether to use or ignore the control word. Bit 10=0: The control word is ignored.

Illustration 3.57 Status Word

Bit 10=1: The control word is used. This function is relevant because the telegram always contains the control word, regardless of the telegram type. Turn o the control word if it should not be used when updating or reading parameters.

Bit 11, Relay 01

Bit 11=0: Relay not activated. Bit 11=1: Relay 01 activated if [36] Control word bit 11 is selected in parameter 5-40 Function Relay.

Bit 12, Relay 04

Bit 12=0: Relay 04 is not activated. Bit 12=1: Relay 04 is activated if [37] Control word bit 12 is selected in parameter 5-40 Function Relay.

Bit 13/14, Selection of set-up

Use bits 13 and 14 to select from the 4 menu set-ups according to Table 3.43.

Set-up Bit 14 Bit 13

1 0 0

2 0 1

3 1 0

4 1 1

Table 3.43 Specication of Menu Set-ups

Bit Bit=0 Bit=1

00 Control not ready Control ready

01 Drive not ready Drive ready

02 Coasting Enable

03 No error Trip

04 No error Error (no trip)

05 Reserved -

06 No error Trip lock

07 No warning Warning

08 Speed ≠ reference Speed = reference

09 Local operation Bus control

10 Out of frequency limit Frequency limit OK

11 No operation In operation

12 Drive OK Stopped, auto start

13 Voltage OK Voltage exceeded

14 Torque OK Torque exceeded

15 Timer OK Timer exceeded

Table 3.44 Status Word Bits

Explanation of the status bits

Bit 00, Control not ready/ready

Bit 00=0: The frequency converter trips. The function is only possible when [9] Multi Set-ups is selected in parameter 0-10 Active Set-up.

Make a selection in parameter 8-55 Set-up Select to dene how bit 13/14 gates with the corresponding function on the digital inputs.

Bit 15 Reverse

Bit 15=0: No reversing. Bit 15=1: Reversing. In the default setting, reversing is set to digital in parameter 8-54 Reversing Select. Bit 15 causes reversing only when [1] Bus, [2] Logic AND or [3] Logic OR is selected.

Bit 00=1: The frequency converter controls are ready but

the power component does not necessarily receive any

power supply (in case of 24 V external supply to controls).

Bit 01, Drive ready

Bit 01=1: The frequency converter is ready for operation

but the coasting command is active via the digital inputs

or via serial communication.

Bit 02, Coasting stop

Bit 02=0: The frequency converter releases the motor.

Bit 02=1: The frequency converter starts the motor with a

start command.

Bit 03, No error/trip

Bit 03=0: The frequency converter is not in fault mode.

Bit 03=1: The frequency converter trips. To re-establish

operation, enter [Reset].

Actual output freq.

STW

Follower-master

Speed ref.CTW

Master-follower

16bit

130BA276.11

Reverse Forward

Par.3-00 set to

(1) -max- +max

Max reference Max reference

Par.3-00 set to

(0) min-max

Max reference

Forward

Min reference

100%

(4000hex)

-100%

(C000hex)

(0hex)

Par.3-03 0 Par.3-03

Par.3-03

(4000hex)(0hex)

0% 100%

Par.3-02

130BA277.10

System Integration Design Guide

Bit 04, No error/error (no trip)

Bit 04=0: The frequency converter is not in fault mode. Bit 04=1: The frequency converter shows an error but does not trip.

Bit 05, Not used

Bit 05 is not used in the status word.

Bit 06, No error/triplock

Bit 15, Timer OK/limit exceeded

Bit 15=0: The timers for motor thermal protection and

thermal protection are not exceeded 100%.

Bit 15=1: One of the timers exceeds 100%.

If the connection between the InterBus option and the

frequency converter is lost, or an internal communication

problem has occurred, all bits in the STW are set to 0.

Bit 06=0: The frequency converter is not in fault mode. Bit 06=1: The frequency converter is tripped and locked.

Bit 07, No warning/warning

Bit 07=0: There are no warnings. Bit 07=1: A warning has occurred.

Bit 08, Speed≠reference/speed=reference

Bit 08=0: The motor is running, but the present speed is dierent from the preset speed reference. It might, for example, be the case when the speed ramps up/down

3.9.12.3 Bus Speed Reference Value

Speed reference value is transmitted to the frequency

converter in a relative value in %. The value is transmitted

in the form of a 16-bit word; in integers (0–32767) the

value 16384 (4000 hex) corresponds to 100%. Negative

gures are formatted with 2’s complement. The actual

output frequency (MAV) is scaled in the same way as the

bus reference. during start/stop.

Bit 08=1: The motor speed matches the preset speed reference.

Bit 09, Local operation/bus control

Bit 09=0: [Stop/Reset] is activated on the control unit or [2] Local control in parameter 3-13 Reference Site is selected.

Control via serial communication is not possible. Bit 09=1 It is possible to control the frequency converter via the eldbus/serial communication.

Illustration 3.58 Actual Output Frequency (MAV)

Bit 10, Out of frequency limit

Bit 10=0: The output frequency has reached the value in parameter 4-11 Motor Speed Low Limit [RPM] or

The reference and MAV are scaled as follows:

parameter 4-13 Motor Speed High Limit [RPM]. Bit 10=1: The output frequency is within the dened limits.

Bit 11, No operation/in operation

Bit 11=0: The motor is not running. Bit 11=1: The frequency converter has a start signal or the output frequency is greater than 0 Hz.

Bit 12, Drive OK/stopped, auto start

Bit 12=0: There is no temporary overtemperature on the inverter. Bit 12=1: The inverter stops because of overtemperature, but the unit does not trip and resumes operation once the overtemperature stops.

Illustration 3.59 Reference and MAV

Bit 13, Voltage OK/limit exceeded

Bit 13=0: There are no voltage warnings. Bit 13=1: The DC voltage in the frequency converter’s DC link is too low or too high.

Bit 14, Torque OK/limit exceeded

Bit 14=0: The motor current is lower than the torque limit selected in parameter 4-18 Current Limit. Bit 14=1: The torque limit in parameter 4-18 Current Limit is exceeded.

3 3

System Integration

VLT® Refrigeration Drive FC 103

3.9.12.4 Control Word according to

PROFIdrive Prole (CTW)

The control word is used to send commands from a master (for example a PC) to a slave.

Bit Bit=0 Bit=1

00 O 1 On 1

01 O 2 On 2

02 O 3 On 3

03 Coasting No coasting

04 Quick stop Ramp

05 Hold frequency output Use ramp

06 Ramp stop Start

07 No function Reset

08 Jog 1 O Jog 1 On

09 Jog 2 O Jog 2 On

10 Data invalid Data valid

11 No function Slow down

12 No function Catch up

13 Parameter set-up Selection lsb

14 Parameter set-up Selection msb

15 No function Reverse

Table 3.45 Control Word Bits

Explanation of the control bits

Bit 00, OFF 1/ON 1

Normal ramp stops using the ramp times of the actual selected ramp. Bit 00=0 leads to the stop and activation of the output relay 1 or 2 if the output frequency is 0 Hz, and if [31]

Relay 123 has been selected in parameter 5-40 Function Relay.

When bit 0=1, the frequency converter is in State 1: Switching on inhibited.

Bit 01, O 2/On 2

Coasting stop If the output frequency is 0 Hz, and if [31] Relay 123 has been selected in parameter 5-40 Function Relay, when bit 01=0, a coasting stop and activation of the output relay 1 or 2 occurs.

Bit 02, O 3/On 3

Quick stop using the ramp time of parameter 3-81 Quick Stop Ramp Time. If the output frequency is 0 Hz and if [31] Relay 123 has been selected in parameter 5-40 Function Relay, when bit 02=0, a quick stop and activation of the

output relay 1 or 2 occurs. When bit 02=1, the frequency converter is in State 1: Switching on inhibited.

Bit 03, Coasting/No coasting

Coasting stop bit 03=0 leads to a stop. If the other start conditions are satised, when bit 03=1, the frequency converter can start.

NOTICE

The selection in parameter 8-50 Coasting Select

determines how bit 03 is linked with the corresponding

function of the digital inputs.

Bit 04, Quick stop/Ramp

Quick stop using the ramp time of parameter 3-81 Quick

Stop Ramp Time.

When bit 04=0, a quick stop occurs.

If the other start conditions are fullled when bit 04=1, the

frequency converter can start.

NOTICE

The selection in parameter 8-51 Quick Stop Select

determines how bit 04 is linked with the corresponding

function of the digital inputs.

Bit 05, Hold frequency output/Use ramp

When bit 05=0, the present output frequency is being

maintained even if the reference value is modied.

When bit 05=1, the frequency converter can perform its

regulating function again; operation occurs according to

the respective reference value.

Bit 06, Ramp stop/Start

Normal ramp stop using the ramp times of the actual

ramp as selected. In addition, activation of the output relay

01 or 04 if the output frequency is 0 Hz and if [31] Relay

123 has been selected in parameter 5-40 Function Relay.

Bit 06=0 leads to a stop.

If the other start conditions are

frequency converter can start.

fullled when bit 06=1, the

NOTICE

The selection in parameter 8-53 Start Select determines

how bit 06 is linked with the corresponding function of

the digital inputs.

Bit 07, No function/Reset

Reset after switching o.

Acknowledges event in fault buer.

When bit 07=0, no reset occurs.

When there is a slope change of bit 07 to 1, a reset occurs

after switching o.

Bit 08, Jog 1 O/On

Activation of the pre-programmed speed in

parameter 8-90 Bus Jog 1 Speed. JOG 1 is only possible if bit

04=0 and bit 00–03=1.

Bit 09, Jog 2 O/On

Activation of the pre-programmed speed in

parameter 8-91 Bus Jog 2 Speed. Jog 2 is only possible if bit

04=0 and bit 00–03=1.

System Integration Design Guide

Bit 10, Data invalid/valid

Is used to tell the frequency converter whether to use or ignore the control word. Bit 10=0 causes the control word to be ignored. Bit 10=1 causes the control word to be used. This function is relevant because the control word is always contained in the telegram, regardless of which type of telegram is used. If it should not be used for updating or reading parameters, it is possible to turn o the control word.

Bit 11, No function/Slow down

Is used to reduce the speed reference value by the amount given in parameter 3-12 Catch up/slow Down Value. When bit 11=0, no modication of the reference value occurs. When bit 11=1, the reference value is reduced.

Bit 12, No function/catch up

Is used to increase the speed reference value by the amount given in parameter 3-12 Catch up/slow Down Value. When bit 12=0, no modication of the reference value occurs. When bit 12=1, the reference value is increased. If both slowing down and accelerating are activated (bit 11 and 12=1), slowing down has priority, that is, the speed reference value is reduced.

Bits 13/14, Set-up selection

Bits 13 and 14 are used to select between the 4 parameter set-ups according to Table 3.46.

The function is only possible if [9] Multi Set-up has been selected in parameter 0-10 Active Set-up. The selection in parameter 8-55 Set-up Select determines how bits 13 and 14 are linked with the corresponding function of the digital inputs. Changing set-up while running is only possible if the set-ups have been linked in parameter 0-12 This Set-up Linked to.

Set-up Bit 13 Bit 14

1 0 0

2 1 0

3 0 1

4 1 1

Table 3.46 Set-up Selection

Bit 15, No function/reverse

Bit 15=0 causes no reversing. Bit 15=1 causes reversing.

NOTICE

In the factory settings, reversing is set to [0] Digital input in parameter 8-54 Reversing Select.

NOTICE

Bit 15 causes reversing only when [1] Bus, [2] Logic AND or [3] Logic OR is selected in parameter 8-54 Reversing Select.

3.9.12.5 Status Word according to PROFIdrive Prole (STW)

The status word is used to notify a master (for example a PC) about the status of a slave.

Bit Bit=0 Bit=1

00 Control not ready Control ready

01 Drive not ready Drive ready

02 Coasting Enable

03 No error Trip

04 O 2 On 2

05 O 3 On 3

06 Start possible Start not possible

07 No warning Warning

09 Local operation Bus control

10 Out of frequency limit Frequency limit OK

11 No operation In operation

12 Drive OK Stopped, auto start

13 Voltage OK Voltage exceeded

14 Torque OK Torque exceeded

15 Timer OK Timer exceeded

Table 3.47 Status Word Bits

Explanation of the status bits Bit 00, Control not ready/ready

When bit 00=0, bit 00, 01, or 02 of the control word is 0 (OFF 1, OFF 2, or OFF 3) – or the frequency converter is switched When bit 00=1, the frequency converter control is ready, but there is not necessarily power supply to the unit present (in the event of 24 V external supply of the control system).

Bit 01, Drive not ready/ready

Same signicance as bit 00, however, there is a supply of the power unit. The frequency converter is ready when it receives the necessary start signals.

Bit 02, Coasting/Enable

When bit 02=0, bit 00, 01, or 02 of the control word is 0 (O 1, O 2, or O 3 or coasting) – or the frequency converter is switched o (trip). When bit 02=1, bit 00, 01, or 02 of the control word is 1; the frequency converter has not tripped.

Bit 03, No error/Trip

When bit 03=0, no error condition of the frequency converter exists. When bit 03=1, the frequency converter has tripped and requires a reset signal before it can start.

Bit 04, On 2/O 2

When bit 01 of the control word is 0, then bit 04=0. When bit 01 of the control word is 1, then bit 04=1.

Bit 05, On 3/O 3

When bit 02 of the control word is 0, then bit 05=0. When bit 02 of the control word is 1, then bit 05=1.

Speed≠reference

o (trip).

Speed=reference

3 3

System Integration

VLT® Refrigeration Drive FC 103

Bit 06, Start possible/Start not possible

If [1] PROFIdrive has been selected in parameter 8-10 Control Prole, bit 06 is 1 after a switch-o

acknowledgement, after activation of O2 or O3, and after switching on the mains voltage, Start not possible is reset, with bit 00 of the control word is set to 0, and bits

01, 02, and 10 are set to 1.

Bit 07, No warning/Warning

Bit 07=0 means that there are no warnings. Bit 07=1 means that a warning has occurred.

Bit 08, Speed≠reference/Speed=reference

When bit 08=0, the current speed of the motor deviates from the set speed reference value. This may occur, for example, when the speed is being changed during start/ stop through ramp up/down. When bit 08=1, the current speed of the motor corresponds to the set speed reference value.

Bit 09, Local operation/Bus control

Bit 09=0 indicates that the frequency converter has been stopped with [Stop] on the LCP, or that [0] Linked to Hand/

Auto or [2] Local has been selected in parameter 3-13 Reference Site.

When bit 09=1, the frequency converter can be controlled through the serial interface.

Bit 10, Out of frequency limit/Frequency limit OK

When bit 10=0, the output frequency is outside the limits set in parameter 4-52 Warning Speed Low and parameter 4-53 Warning Speed High. When bit 10=1, the output frequency is within the indicated limits.

Bit 11, No operation/Operation

When bit 11=0, the motor does not turn. When bit 11=1, the frequency converter has a start signal, or the output frequency is higher than 0 Hz.

Bit 12, Drive OK/Stopped, auto start

When bit 12=0, there is no temporary overloading of the inverter. When bit 12=1, the inverter has stopped due to overloading. However, the frequency converter has not switched o (trip) and starts again after the overloading has ended.

Bit 13, Voltage OK/Voltage exceeded

When bit 13=0, the voltage limits of the frequency converter are not exceeded. When bit 13=1, the direct voltage in the DC link of the frequency converter is too low or too high.

Bit 14, Torque OK/Torque exceeded

When bit 14=0, the motor torque is below the limit selected in parameter 4-16 Torque Limit Motor Mode and parameter 4-17 Torque Limit Generator Mode. When bit 14=1, the limit selected in parameter 4-16 Torque

Limit Motor Mode or parameter 4-17 Torque Limit Generator Mode is exceeded.

Bit 15, Timer OK/Timer exceeded

When bit 15=0, the timers for the thermal motor protection and thermal frequency converter protection have not exceeded 100%. When bit 15=1, 1 of the timers has exceeded 100%.

System Integration Design Guide

3.10 System Design Checklist

Table 3.48 provides a checklist for integrating a frequency converter into a motor control system. The list is intended as a reminder of the general categories and options necessary for specifying the system requirements.

Category Details Notes

FC Model

Power

Volts

Current

Physical

Dimensions

Weight

Ambient operating conditions

Temperature

Altitude

Humidity

Air quality/dust

Derating requirements

Enclosure size

Input

Cables

Type

Length

Fuses

Type

Size

Rating

Options

Connectors

Contacts

Filters

Output

Cables

Type

Length

Fuses

Type

Size

Rating

Options

Filters

Control

Wiring

Type

Length

Terminal connections

Communication

Protocol

Connection

Wiring

Options

Connectors

☑

3 3

System Integration

VLT® Refrigeration Drive FC 103

Category Details Notes

Contacts

Filters

Motor

Type

Rating

Voltage

Options

Special tools and equipment

Moving and storage

Mounting

Connection of mains

Table 3.48 System Design Checklist

☑

Application Examples Design Guide

4 Application Examples

4.1 Application Examples

The VLT® Refrigeration Drive FC 103 is designed for refrigeration applications. The wide range of standard and optional features includes optimised SmartStart:

Motor alternation

•

The motor alternation functionality is suitable for applications (for example fan or pump applications) with 2 motors sharing 1 frequency converter.

NOTICE

Do not use the motor alternation with compressors.

Pack control

•

Basic pack control is built in as standard with a capacity of up to 3 compressors. Pack control provides speed control of a single compressor in a compressor pack. For control of up to 6

compressors, use the VLT® Extended Relay Card MCB 113.

Floating condensing temperature control

•

Saves money by monitoring the outdoor temperature and allowing the condensing temperature to be as low as possible, which reduces fan speed and energy consumption.

Oil return management

•

Oil return management improves reliability and lifetime of the compressor and ensures proper lubrication, by monitoring the variable speed compressor. If it has been running for a certain time, it picks up speed to return oil to the oil reservoir

Low and high pressure monitoring

•

Saves money by reducing the need for onsite resets. The frequency converter monitors the pressure in the system, and if pressure reaches a level close to the level that engages the shutdown valve, the frequency converter makes a safe shutdown, and restart shortly after.

STO

•

STO enables Safe Torque O (coast) when a critical situation occur.

Sleep mode

•

The sleep mode feature saves energy by stopping the pump when there is no demand.

Real time clock.

•

Smart logic control (SLC)

•

SLC comprises programming of a sequence consisting of events and actions. SLC oers a wide range of PLC functions using comparators, logic rules, and timers.

Selected Application Features

4.2

4.2.1 SmartStart

For setting up the frequency converter in the most ecient and logical way, the text and language used in the frequency converter make complete sense to the engineers and installers in the eld of refrigeration. To make the installation even more ecient, the built-in Setup wizard menu guides the user through the set-up of the frequency converter in a clear and structured manner.

The following applications are supported:

Multi-compressor control.

•

Multi-condenser fan, cooling tower/evaporative

•

condensing.

Single fan and pump.

•

Pump system.

•

The feature is activated at the factory reset, or from the quick menu. When activating the wizard, the frequency converter asks for the information needed to run the application.

rst power-up, after a

4 4

12 13 18 37

130BA155.12

322719 29 33 20

P 5-12 [0]

P 5-10 [8]

Start/Stop

+24V

Speed

Safe Stop

Start/Stop [18]

12 13 18 37

130BA156.12

322719 29 33 20

P 5 - 12 [6]

P 5 - 10[9]

+24V

Speed

Start Stop inverse Safe Stop

Start (18)

Start (27)

Application Examples

VLT® Refrigeration Drive FC 103

4.2.2 Start/Stop

Terminal 18 = Start/stop parameter 5-10 Terminal 18 Digital Input [8] Start. Terminal 27 = No operation parameter 5-12 Terminal 27

Digital Input [0] No operation (Default [2] coast inverse).

Parameter 5-10 Terminal 18 Digital Input = [8] Start

(default).

4.2.3 Pulse Start/Stop

Terminal 18 = Start/stop parameter 5-10 Terminal 18 Digital Input [9] Latched start. Terminal 27= Stop parameter 5-12 Terminal 27 Digital Input

[6] Stop inverse.

Parameter 5-10 Terminal 18 Digital Input = [9] Latched start.

Parameter 5-12 Terminal 27 Digital Input = [2] Coast inverse (default).

Parameter 5-12 Terminal 27 Digital Input = [6] Stop inverse.

Illustration 4.1 Terminal 37: Available only with Safe Torque

O (STO) Function

Illustration 4.2 Terminal 37: Available Only with STO Function

130BA287.10

555039 42 53 54

Speed RPM P 6-15

1 kW

+10V/30mA

Ref. voltage P 6-11 10V

Application Examples Design Guide

4.2.4 Potentiometer Reference

Voltage reference via a potentiometer.

Parameter 3-15 Reference 1 Source [1] = Analog Input 53

Parameter 6-10 Terminal 53 Low Voltage = 0 V

Parameter 6-11 Terminal 53 High Voltage = 10 V

Parameter 6-14 Terminal 53 Low Ref./Feedb. Value =

0 RPM

Parameter 6-15 Terminal 53 High Ref./Feedb. Value

= 1.500 RPM

Switch S201 = OFF (U)

Illustration 4.3 Voltage Reference via a Potentiometer

4.3 Application Set-up Examples

The examples in this section are intended as a quick reference for common applications.

4 4

Parameter settings are the regional default values unless otherwise indicated (selected in parameter 0-03 Regional

•

Settings).

Parameters associated with the terminals and their settings are shown next to the drawings.

•

Required switch settings for analog terminals A53 or A54 are also shown.

•

NOTICE

When using the optional STO feature, a jumper wire may be required between terminal 12 (or 13) and terminal 37 for the frequency converter to operate with factory default programming values.

SLC application example

One sequence 1:

1. Start.

2. Ramp up.

3. Run at reference speed 2 s.

4. Ramp down.

5. Hold shaft until stop.

2 sec

Max. ref. P 3-03

2 sec

Preset ref.(0) P 3-10(0)

State 1

State 3State 2

Preset ref.(1) P 3-10(1)

Term 18

P 5-10(start)

130BA157.11

Application Examples

VLT® Refrigeration Drive FC 103

Illustration 4.4 Ramp Up/Ramp Down

Set the ramping times in parameter 3-41 Ramp 1 Ramp Up Time and parameter 3-42 Ramp 1 Ramp Down Time to the desired times.

ramp

 = 

acc

 × n

 par . 1 − 25

norm

ref  RPM

Set terminal 27 to [0] No Operation (parameter 5-12 Terminal 27 Digital Input) Set preset reference 0 to rst preset speed (parameter 3-10 Preset Reference [0]) in percentage of maximum reference speed (parameter 3-03 Maximum Reference). Example: 60% Set preset reference 1 to the second preset speed (parameter 3-10 Preset Reference [1] Example: 0% (zero). Set the timer 0 for constant running speed in parameter 13-20 SL Controller Timer [0]. Example: 2 s

Set Event 1 in parameter 13-51 SL Controller Event [1] to [1] True. Set Event 2 in parameter 13-51 SL Controller Event [2] to [4] On Reference. Set Event 3 in parameter 13-51 SL Controller Event [3] to [30] Time Out 0. Set Event 4 in parameter 13-51 SL Controller Event [4] to [0] False.

Set Action 1 in parameter 13-52 SL Controller Action [1] to [10] Select preset 0. Set Action 2 in parameter 13-52 SL Controller Action [2] to [29] Start Timer 0. Set Action 3 in parameter 13-52 SL Controller Action [3] to [11] Select preset 1. Set Action 4 in parameter 13-52 SL Controller Action [4] to [1] No Action.

Set the in parameter 13-00 SL Controller Mode to ON.

Start/stop command is applied on terminal 18. If the stop signal is applied, the frequency converter ramps down and goes into free mode.

Event 1 True (1)

Action 1 Select Preset (10)

Start

command

State 0

Stop

command

Event 4 False (0)

Action 4 No Action (1)

State 2

State 1

Event 2 On Reference (4)

Action 2 Start Timer (29)

Event 3 Time Out (30)

Action 3 Select Preset ref. (11)

130BA148.12

4-20 mA

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

U - I

130BB675.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A54

U - I

0 - 10V

130BB676.10

Application Examples Design Guide

4 4

Illustration 4.5 SLC Application Example

4.3.1 Feedback

Parameters

Function Setting

Parameter 6-22 Terminal

4 mA*

54 Low Current

Parameter 6-23 Terminal

54 High Current

Parameter 6-24 Terminal

mA*

54 Low Ref./Feedb.

Value

Parameter 6-25 Terminal

54 High Ref./Feedb.

Value

* = Default value

50*

Notes/comments:

D IN 37 is an option.

Parameters

Function Setting

Parameter 6-20 Ter

minal 54 Low

Voltage

Parameter 6-21 Ter

minal 54 High

Voltage

Parameter 6-24 Ter

minal 54 Low Ref./

Feedb. Value

Parameter 6-25 Ter

minal 54 High Ref./

Feedb. Value

* = Default value

Notes/comments:

D IN 37 is an option.

0.07 V*

10 V*

50*

Table 4.1 Analog Current Feedback Transducer

Table 4.2 Analog Voltage Feedback Transducer (3-wire)

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A54

U - I

0 - 10V

130BB677.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

-10 - +10V

130BB926.10

130BB927.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

4 - 20mA

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

≈ 5kΩ

130BB683.10

Application Examples

VLT® Refrigeration Drive FC 103

Parameters

Function Setting

Parameter 6-20 Ter

0.07 V*

minal 54 Low

Voltage

Parameter 6-21 Ter

10 V*

minal 54 High

Voltage

minal 54 Low Ref./

Parameter 6-24 Ter

Feedb. Value

Parameter 6-25 Ter

50*

minal 54 High Ref./

Feedb. Value

* = Default value

Notes/comments:

D IN 37 is an option.

Table 4.3 Analog Voltage Feedback Transducer (4-wire)

Table 4.5 Analog Speed Reference (Current)

Parameters

Function Setting

Parameter 6-12 Ter

minal 53 Low

Current

Parameter 6-13 Ter

minal 53 High

Current

Parameter 6-14 Ter

minal 53 Low Ref./

Feedb. Value

Parameter 6-15 Ter

minal 53 High Ref./

Feedb. Value

* = Default value

Notes/comments:

D IN 37 is an option.

4 mA*

20 mA*

0 Hz

50 Hz

4.3.2 Speed

Parameters

Function Setting

Parameters

Function Setting

Parameter 6-10 Ter

0.07 V*

minal 53 Low

Voltage

Parameter 6-11 Ter

10 V*

minal 53 High

Voltage

Parameter 6-14 Ter

0 Hz

minal 53 Low Ref./

Feedb. Value

Parameter 6-15 Ter

50 Hz

minal 53 High Ref./

Feedb. Value

* = Default value

Notes/comments:

D IN 37 is an option.

Table 4.6 Speed Reference (using a Manual Potentiometer)

Parameter 6-10 Ter

minal 53 Low

Voltage

Parameter 6-11 Ter

minal 53 High

Voltage

Parameter 6-14 Ter

minal 53 Low Ref./

Feedb. Value

Parameter 6-15 Ter

minal 53 High Ref./

Feedb. Value

* = Default value

Notes/comments:

D IN 37 is an option.

0.07 V*

10 V*

0 Hz

50 Hz

Table 4.4 Analog Speed Reference (Voltage)

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BB680.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

R1R2

130BB681.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

R1R2

130BB684.10

Application Examples Design Guide

4.3.3 Run/Stop

Parameters

Function Setting

Parameter 5-10 T

[8] Start*

erminal 18

Digital Input

Parameter 5-12 T

erminal 27

[7] External

interlock

Digital Input

* = Default value

Notes/comments:

D IN 37 is an option.

Parameters

Function Setting

Parameter 5-10 T

[8] Start*

erminal 18

Digital Input

Parameter 5-11 T

erminal 19

[52] Run

Permissive

Digital Input

Parameter 5-12 T

erminal 27

[7] External

interlock

Digital Input

Parameter 5-40 F

unction Relay

[167] Start

command

act.

* = Default value

Notes/comments:

D IN 37 is an option.

4 4

Table 4.7 Run/Stop Command with External Interlock

Parameters

Function Setting

Parameter 5-10 T

[8] Start*

Table 4.9 Run Permissive

erminal 18

Digital Input

Parameter 5-12 T

erminal 27

[7] External

interlock

Digital Input

* = Default value

Notes/comments:

If parameter 5-12 Terminal 27

Table 4.8 Run/Stop Command without External Interlock

Digital Input is set to [0] no

operation, a jumper wire to

terminal 27 is not needed.

D IN 37 is an option.

130BB686.12

VLT

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

A53

U - I

D IN

Application Examples

VLT® Refrigeration Drive FC 103

4.3.4 Motor Thermistor

WARNING

THERMISTOR INSULATION

Risk of personal injury or equipment damage.

Use only thermistors with reinforced or double

•

insulation to meet PELV insulation

requirements.

Parameters

Function Setting

Parameter 1-90

Motor Thermal

Protection

Parameter 1-93 T

hermistor Source

* = Default Value

Notes/comments:

If only a warning is required,

set parameter 1-90 Motor

Thermal Protection to [1]

Thermistor warning.

D IN 37 is an option.

[2] Thermistor

trip

[1] Analog

input 53

Table 4.10 Motor Thermistor

Danfoss FC 103 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual