Danfoss FC 103 Design guide

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

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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.

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Danfoss FC 103 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual