Danfoss FC 111 Design guide

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Design Guide

VLT® Flow Drive FC 111

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VLT® Flow Drive FC 111

Design Guide

Introduction 10

1.1

Purpose of this Design Guide 10

Additional Resources 10

1.2

Other Resources 10

1.2.1

1.2.2

MCT 10 Set-up Software Support 10

1.3

Document and Software Version 10

1.4

Regulatory Compliance 10

1.4.1

Introduction 10

1.4.2

CE Mark 10

Safety 12

Safety Symbols 12

2.1

Qualified Personnel 12

2.2

Contents

Safety Precautions 12

2.3

Product Overview 14

3.1

Advantages 14

3.1.1

Why Use a Drive for Controlling Fans and Pumps? 14

3.1.1.1

3.1.1.2

3.1.1.3

3.1.1.4

3.1.1.5

3.1.1.6

3.1.1.7

3.1.1.8

3.1.1.9

3.1.2

Application Examples 20

3.1.2.1

3.1.2.2

The Clear Advantage - Energy Savings 14

Example of Energy Savings 15

Comparison of Energy Savings 15

Example with Varying Flow over 1 Year 17

Better Control 18

Star/Delta Starter or Soft Starter not Required 18

Using a Drive Saves Money 18

Traditional Fan System without a Drive 19

Fan System Controlled by Drives 20

Variable Air Volume 20

Constant Air Volume 21

3.1.2.3

3.1.2.4

3.1.2.5

3.1.2.6

3.1.3

Check Valve Monitoring 26

3.1.4

Dry Pump Detection 26

3.1.5

End of Curve Detection 26

Cooling Tower Fan 22

Condenser Pumps 23

Primary Pumps 24

Secondary Pumps 25

VLT® Flow Drive FC 111

Design Guide

3.1.6

3.2

Control Structures 26

3.2.1

3.2.2

3.2.3

3.2.4

3.2.5

3.2.6

3.2.7

3.2.8

3.2.9

3.3

Ambient Running Conditions 30

3.3.1

3.3.2

Contents

Time-based Functions 26

Introduction 26

Control Structure Open Loop 27

PM/EC+ Motor Control 27

Local (Hand On) and Remote (Auto On) Control 27

Control Structure Closed Loop 28

Feedback Conversion 28

Reference Handling 28

Tuning the Drive Closed-loop 29

Adjusting the Manual PI 29

Air Humidity 30

Acoustic Noise or Vibration 30

3.3.2.1

3.3.2.2

3.3.3

Aggressive Environments 31

3.4

General Aspects of EMC 31

3.4.1

Overview of EMC Emissions 31

3.4.2

Emission Requirements 32

3.4.3

EMC Emission Test Results 33

3.4.4

Harmonics Emission 34

3.4.4.1

3.4.4.2

3.4.5

Harmonics Emission Requirements 34

3.4.6

Harmonics Test Results (Emission) 36

3.4.7

Immunity Requirements 37

3.5

Galvanic Isolation (PELV) 37

3.6

Ground Leakage Current 38

3.6.1

Using a Residual Current Device (RCD) 40

Acoustic Noise 30

Vibration and Shock 31

Harmonics Emission Requirements 34

Harmonics Test Results (Emission) 35

3.7

Extreme Running Conditions 41

3.7.1

Introduction 41

3.7.2

Motor Thermal Protection (ETR) 42

3.7.3

Thermistor Inputs 42

3.7.3.1

3.7.3.2

Example with Digital Input and 10 V Power Supply 43

Example with Analog Input and 10 V Power Supply 43

VLT® Flow Drive FC 111

Design Guide

Selection and Ordering 45

Type Code 45

4.1

4.2

Options and Accessories 46

Local Control Panel (LCP) 46

4.2.1

4.2.2

IP21 Enclosure Kit 46

4.2.3

Decoupling Plate 48

4.3

Ordering Numbers 49

4.3.1

Options and Accessories 49

4.3.2

Harmonic Filters 50

4.3.3

External RFI Filter 51

Mechanical Installation Considerations 53

5.1

Power Ratings, Weights, and Dimensions 53

5.2

Mechanical Installation H1-H8 55

5.2.1

Side-by-side Installation 55

Contents

5.3

Mechanical Installation H13-H14 56

5.3.1

Tools Needed 56

5.3.2

Installation and Cooling Requirements 56

5.3.3

Lifting the Drive 57

5.3.4

Wall Mounting the Drive 58

5.3.5

Creating Cable Openings 59

5.3.6

Back-channel Cooling 59

5.4

Derating 60

5.4.1

Manual Derating and Automatic Derating 60

5.4.2

Derating for Low-speed Operation 60

5.4.3

Derating for Low Air Pressure and High Altitudes 60

5.4.4

Derating for Ambient Temperature and Switching Frequency 60

Electrical Installation Considerations 63

6.1

Safety Instructions 63

6.2

Electrical Wiring 64

6.3

EMC-compliant Electrical Installation 64

6.4

Relays and Terminals 66

6.4.1

Relays and Terminals on Enclosure Sizes H1–H5 66

6.4.2

Relays and Terminals on Enclosure Size H6 67

6.4.3

Relays and Terminals on Enclosure Size H7 67

6.4.4

Relays and Terminals on Enclosure Size H8 68

6.4.5

Relays and Terminals on Enclosure Size H13–H14 69

6.5

View of Control Shelf 69

VLT® Flow Drive FC 111

Design Guide

6.6

Fastener Tightening Torques 70

6.7

IT Mains 71

6.8

Mains and Motor Connection 72

6.8.1

6.8.2

6.8.3

6.8.4

6.9

Fuses and Circuit Breakers 73

6.9.1

6.9.2

6.9.3

6.9.4

6.9.5

6.10

Control Terminals 75

Contents

Introduction 72

Connecting to the Ground 72

Connecting the Motor 73

Connecting the AC Mains 73

Branch Circuit Protection 73

Short-circuit Protection 73

Overcurrent Protection 74

CE Compliance 74

Recommendation of Fuses and Circuit Breakers 74

6.11

Efficiency 76

6.11.1

Efficiency of the Drive 76

6.11.2

Efficiency of the Motor 77

6.11.3

Efficiency of the System 77

6.12

dU/dt Conditions 77

6.12.1

dU/dt Overview 77

6.12.2

dU/dt Test Results for H1–H8 77

6.12.3

High-power Range 80

6.12.4

dU/dt Test Results for H13–H14 80

Programming 81

7.1

Local Control Panel (LCP) 81

7.2

Menus 82

7.2.1

Status Menu 82

7.2.2

Quick Menu 82

7.2.2.1

7.2.2.2

Quick Menu Introduction 82

Setup Wizard Introduction 83

7.2.2.3

7.2.2.4

7.2.2.5

7.2.2.6

7.2.2.7

7.2.2.8

7.2.3

Main Menu 98

Setup Wizard for Open-loop Applications 84

Setup Wizard for Closed-loop Applications 89

Motor Setup 94

Changes Made Function 97

Changing Parameter Settings 98

Accessing All Parameters via the Main Menu 98

VLT® Flow Drive FC 111

Design Guide

7.3

Quick Transfer of Parameter Settings between Multiple Drives 98

7.3.1

Transferring Data from the Drive to the LCP 98

7.3.2

Transferring Data from the LCP to the Drive 98

7.4

Readout and Programming of Indexed Parameters 99

7.5

Initialization to Default Settings 99

7.5.1

Recommended Initialization 99

7.5.2

Two-finger Initialization 99

RS485 Installation and Set-up 101

8.1

RS485 101

8.1.1

Overview 101

8.1.2

Connecting the Drive to the RS485 Network 102

8.1.3

Hardware Set-up 102

8.1.4

Parameter Settings for Modbus Communication 103

8.1.5

EMC Precautions 103

Contents

8.2

FC Protocol 104

8.2.1

Overview 104

8.2.2

FC with Modbus RTU 104

8.3

Network Configuration 105

8.4

FC Protocol Message Framing Structure 105

8.4.1

Content of a Character (byte) 105

8.4.2

Telegram Structure 105

8.4.3

Telegram Length (LGE) 105

8.4.4

Drive Address (ADR) 106

8.4.5

Data Control Byte (BCC) 106

8.4.6

The Data Field 106

8.4.7

The PKE Field 107

8.4.8

Parameter Number (PNU) 108

8.4.9

Index (IND) 108

8.4.10

Parameter Value (PWE) 108

8.4.11

Data Types Supported by the Drive 109

8.4.12

Conversion 109

8.4.13

Process Words (PCD) 110

8.5

Examples 110

8.5.1

Writing a Parameter Value 110

8.5.2

Reading a Parameter Value 110

8.6

Modbus RTU 111

8.6.1

Prerequisite Knowledge 111

VLT® Flow Drive FC 111

Design Guide

8.6.2

8.6.3

8.7

Network Configuration 112

8.8

Modbus RTU Message Framing Structure 112

8.8.1

8.8.2

8.8.3

8.8.4

8.8.5

8.8.6

8.8.7

8.8.8

Contents

Modbus RTU Overview 111

Drive with Modbus RTU 111

Modbus RTU Message Byte Format 112

Modbus RTU Telegram Structure 113

Start/Stop Field 113

Address Field 113

Function Field 113

Data Field 113

CRC Check Field 113

Coil Register Addressing 114

8.8.8.1

8.8.8.2

Introduction 114

Coil Register 114

8.8.8.3

8.8.8.4

8.8.8.5

8.8.9

Access via PCD Write/read 116

8.8.10

How to Control the Drive 117

8.8.10.1

8.8.10.2

8.8.10.3

8.9

How to Access Parameters 118

8.9.1

Parameter Handling 118

8.9.2

Storage of Data 118

8.9.3

IND (Index) 119

8.9.4

Text Blocks 119

8.9.5

Conversion Factor 119

8.9.6

Parameter Values 119

8.10

Examples 119

Drive Control Word (FC Profile) 114

Drive Status Word (FC Profile) 115

Address/Registers 115

Introduction 117

Function Codes Supported by Modbus RTU 117

Modbus Exception Codes 118

8.10.1

Introduction 119

8.10.2

Read Coil Status (01 hex) 119

8.10.3

Force/Write Single Coil (05 hex) 120

8.10.4

Force/Write Multiple Coils (0F hex) 121

8.10.5

Read Holding Registers (03 hex) 122

8.10.6

Preset Single Register (06 hex) 122

8.10.7

Preset Multiple Registers (10 hex) 123

8.10.8

Read/Write Multiple Registers (17 hex) 124

VLT® Flow Drive FC 111

Design Guide

8.11

Danfoss FC Control Profile 125

8.11.1

Control Word According to FC Profile (8-10 Protocol = FC Profile) 125

8.11.2

Explanation of Each Control Bit 126

8.11.3

Status Word According to FC Profile (STW) 128

8.11.4

Explanation of Each Status Bit 128

8.11.5

Bus Speed Reference Value 130

General Specifications 131

9.1

Mains Supply 131

9.1.1

3x380–480 V AC 131

9.2

General Technical Data 133

9.2.1

Protection and Features 133

9.2.2

Mains Supply 133

9.2.3

Motor Output (U, V, W) 133

9.2.4

Cable Length and Cross-section 134

Contents

9.2.5

Digital Inputs 134

9.2.6

Analog Inputs 134

9.2.7

Analog Outputs 135

9.2.8

Digital Output 135

9.2.9

RS485 Serial Communication 135

9.2.10

24 V DC Output 135

9.2.11

Relay Output 135

9.2.12

10 V DC Output 136

9.2.13

Ambient Conditions (H1–H8) 136

9.2.14

Ambient Conditions (H13–H14) 137

Appendix 138

10.1

Abbreviations 138

10.2

Definitions 139

10.2.1

AC Drive 139

10.2.2

Input 139

10.2.3

Motor 139

10.2.4

References 141

10.2.5

Miscellaneous 141

Edition

Remarks

Software version

AJ363928382091, version 0101

First edition.

65.00

VLT® Flow Drive FC 111

Design Guide

Introduction

1 Introduction

1.1 Purpose of this Design Guide

This Design Guide is intended for qualified personnel, such as:

•

Project and systems engineers.

•

Design consultants.

•

Application and product specialists.

The Design Guide provides technical information to understand the capabilities of the VLT® Flow Drive FC 111 for integration into motor control and monitoring systems. Its purpose is to provide design considerations and planning data for integration of the drive into a system. It caters for selection of drives 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 efficiency.

This manual is targeted at a worldwide audience. Therefore, wherever occurring, both SI and imperial units are shown. VLT® is a registered trademark for Danfoss A/S.

1.2 Additional Resources

1.2.1 Other Resources

Other resources are available to understand advanced drive functions and programming.

•

VLT® Flow Drive FC 111 Operating Guide provides basic information on mechanical dimensions, installation, and programming.

•

VLT® Flow Drive FC 111 Programming Guide provides information on how to program, and includes complete parameter descriptions.

•

Danfoss VLT® Energy Box software. Select PC Software Download at

VLT® Energy Box software allows energy consumption comparisons of HVAC fans and pumps driven by Danfoss drives and alternative methods of flow control. Use this tool to accurately project the costs, savings, and payback of using Danfoss drives on HVAC fans, pumps, and cooling towers.

Supplementary publications and manuals are available from Danfoss website www.danfoss.com.

www.danfoss.com.

1.2.2 MCT 10 Set-up Software Support

Download the software from the service and support section on www.danfoss.com. During the installation process of the software, enter access code 81462700 to activate the VLT® Flow Drive FC 111 functionality. A

license key is not required for using the VLT® Flow Drive FC 111 functionality. The latest software does not always contain the latest updates for drives. Contact the local sales office for the latest drive updates (in

the form of *.OSS files).

1.3 Document and Software Version

This guide is regularly reviewed and updated. All suggestions for improvement are welcome. The original language of this manual is English.

Table 1: Document and Software Version

1.4 Regulatory Compliance

1.4.1 Introduction

AC drives are designed in compliance with the directives described in this section.

1.4.2 CE Mark

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 drives are listed in the following table.

EU directive

Version

Low Voltage Directive

2014/35/EU

EMC Directive

2014/30/EU

ErP Directive

VLT® Flow Drive FC 111

Design Guide

Introduction

N O T I C E

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

N O T I C E

Drives with an integrated safety function must comply with the machinery directive.

Table 2: EU Directives Applicable to Drives

Declarations of conformity are available on request.

1.4.2.1 Low Voltage Directive

The aim of the Low Voltage Directive is to protect persons, domestic animals and property against dangers caused by the electrical equipment, when operating electrical equipment that is installed and maintained correctly, in its intended application. The directive applies to all electrical equipment in the 50–1000 V AC and the 75–1500 V DC voltage ranges.

1.4.2.2 EMC Directive

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 states that devices that generate electromagnetic interference (EMI), or whose operation could be affected by EMI, must be designed to limit the generation of electromagnetic interference and shall 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.

1.4.2.3 ErP Directive

The ErP Directive is the European Ecodesign Directive for energy-related products. The directive sets ecodesign requirements for energy-related products, including drives, and aims at reducing the energy consumption and environmental impact of products by establishing minimum energy-efficiency standards.

VLT® Flow Drive FC 111

Design Guide

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

D A N G E R

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

N O T I C E

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

Safety

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

•

Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

•

Are familiar with the basic regulations concerning health and safety/accident prevention.

•

Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in the Operating Guide.

•

Have good knowledge of the generic and specialist standards applicable to the specific application.

2.3 Safety Precautions

W A R N I N G

HAZARDOUS VOLTAGE

AC drives contain hazardous voltage when connected to the AC mains or connected on the DC terminals. Failure to perform

installation, start-up, and maintenance by skilled personnel can result in death or serious injury.

Only skilled personnel must perform installation, start-up, and maintenance.

W A R N I N G

UNINTENDED START

When the drive 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. Start the motor with an external

switch, a fieldbus command, an input reference signal from the local control panel (LCP), via remote operation using MCT 10

software, or after a cleared fault condition.

Disconnect the drive from the mains.

Press [Off/Reset] on the LCP before programming parameters.

Ensure that the drive is fully wired and assembled when it is connected to AC mains, DC supply, or load sharing.

Voltage [V]

Power range [kW (hp)]

Minimum waiting time (minutes)

3x400

0.37–7.5 (0.5–10)

3x400

11–90 (15–125)

3x400

110–315 (150–450)

VLT® Flow Drive FC 111

Design Guide

Safety

W A R N I N G

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be

present even when the warning indicator lights are off.

Failure to wait the specified time after power has been removed before performing service or repair work could result in death or

serious injury.

Stop the motor.

Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and

DC-link connections to other drives.

Wait for the capacitors to discharge fully. The minimum waiting time is specified in the table Discharge time and is also visible

on the nameplate on the top of the drive.

Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors

are fully discharged.

Table 3: Discharge Time

W A R N I N G

LEAKAGE CURRENT HAZARD

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

Ensure that the minimum size of the ground conductor complies with the local safety regulations for high touch current

equipment.

W A R N I N G

EQUIPMENT HAZARD

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

Ensure that only trained and qualified personnel perform installation, start-up, and maintenance.

Ensure that electrical work conforms to national and local electrical codes.

Follow the procedures in this manual.

C A U T I O N

INTERNAL FAILURE HAZARD

An internal failure in the drive can result in serious injury when the drive is not properly closed.

Ensure that all safety covers are in place and securely fastened before applying power.

e30ba780.11

SYSTEM CURVE

FAN CURVE

PRESSURE%

100

120

60 80 100 120 140 160 180

VOLUME%

120

100

80 100 120 140 160 180

120

100

60 80 100 120 140 160 180

Volume %

INPUT POWER % PRESSURE %

SYSTEM CURVE

FAN CURVE

e30ba781.11

ENERGY CONSUMED

VLT® Flow Drive FC 111

Design Guide

Product Overview

3 Product Overview

3.1 Advantages

3.1.1 Why Use a Drive for Controlling Fans and Pumps?

A drive takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further information, see 3.1.1.2 Example of Energy Savings.

3.1.1.1 The Clear Advantage - Energy Savings

The clear advantage of using a drive for controlling the speed of fans or pumps lies in the electricity savings. When comparing with alternative control systems and technologies, a drive is the optimum energy control system for controlling

fan and pump systems.

Illustration 1: Fan Curves (A, B, and C) for Reduced Fan Volumes

Illustration 2: Energy Savings with Drive Solution

100%

50%

25%

12,5%

50% 100%

80%

e75ha208.10

P o w er ~n

P r essur e ~n

Fl o w ~n

Q = Flow

P = Power

Q1 = Rated flow

P1 = Rated power

Q2 = Reduced flow

P2 = Reduced power

H = Pressure

n = Speed control

H1 = Rated pressure

n1 = Rated speed

H2 = Reduced pressure

n2 = Reduced speed

VLT® Flow Drive FC 111

Design Guide

Product Overview

When using a drive to reduce fan capacity to 60% - more than 50% energy savings may be obtained in typical applications.

3.1.1.2 Example of Energy Savings

As shown in the following illustration, the flow is controlled by changing the RPM. By reducing the speed by only 20% from the rated speed, the flow is also reduced by 20%. This is because the flow is directly proportional to the RPM. The consumption of electricity, however, is reduced by 50%.

If the system in question only needs to be able to supply a flow that corresponds to 100% a few days in a year, while the average is below 80% of the rated flow for the remainder of the year, the amount of energy saved is even more than 50%.

The following illustration describes the dependence of flow, pressure, and power consumption on RPM.

Illustration 3: Laws of Proportionally

Flow:

Pressure:

Power:

Table 4: The Laws of Proportionality

 = 

3.1.1.3 Comparison of Energy Savings

The Danfoss drive solution offers major savings compared with traditional energy saving solutions such as discharge damper solution and inlet guide vanes (IGV) solution. This is because the drive is able to control fan speed according to thermal load on the system, and the drive has a built-in facility that enables the drive to function as a building management system, BMS.

The illustration in 3.1.1.2 Example of Energy Savings shows typical energy savings obtainable with 3 well-known solutions when fan volume is reduced to 60%. As the graph shows, more than 50% energy savings can be achieved in typical applications.

e30ba782.10

Discharge damper

Less energy savings

Maximum energy savings

IGV5Costlier installation

e30ba779.12

0 60 0 60 0 60

100

Discharge Damper Solution

IGV Solution

VLT Solution

Energy consumed

Input power %

Volume %

VLT® Flow Drive FC 111

Design Guide

Product Overview

Illustration 4: The 3 Common Energy Saving Systems

Illustration 5: Energy Savings

Discharge dampers reduce power consumption. Inlet guide vanes offer a 40% reduction, but are expensive to install. The Danfoss drive solution reduces energy consumption with more than 50% and is easy to install. It also reduces noise, mechanical stress, and wear-and-tear, and extends the life span of the entire application.

500

[h]

1000

1500

2000

200100

300

[m3 /h]

400

e75ha210.11

e75ha209.11

100

200 300 400

(m w g)

750r pm

1050r pm

1350r pm

1650r pm

(kW

)

200

100

300 ( m 3 /h )

( m

/h )

400

750r

1050r pm

1350r pm

1650r pm

shaf

m3/h

Distribution

Valve regulation

Drive control

Hours

Power

Consumption

Power

Consumption

A1 - B

kWh

A1 - C

kWh

VLT® Flow Drive FC 111

Design Guide

Product Overview

3.1.1.4 Example with Varying Flow over 1 Year

This example is calculated based on pump characteristics obtained from a pump datasheet. The result obtained shows energy savings of more than 50% at the given flow distribution over a year. The payback period depends on the price per kWh and the price of drive. In this example, it is less than a year when compared with valves and constant speed.

Energy savings

= P

shaft

shaft output

Illustration 6: Flow Distribution over 1 Year

Illustration 7: Energy

Table 5: Result

3505438

42.5

18.615

42.5

18.615

300151314

38.5

50.589

29.0

38.106

250201752

35.0

61.320

18.5

32.412

200201752

31.5

55.188

11.5

20.148

150201752

28.0

49.056

6.5

11.388

100201752

23.0

40.296

3.5

6.132

100

8760–275.064

–

26.801

F ull load

% F ull load cur r en t

& speed

500

100

12,5 25 37,5 50H z

200

300

400

600

700

800

e75ha227.10

VLT® Flow Drive FC 111

Star/delta starter

Soft starter

Start directly on mains

VLT® Flow Drive FC 111

Design Guide

Product Overview

3.1.1.5 Better Control

If a drive is used for controlling the flow or pressure of a system, improved control is obtained. A drive can vary the speed of the fan or pump, obtaining variable control of flow and pressure. Furthermore, a drive can quickly

adapt the speed of the fan or pump to new flow or pressure conditions in the system. Simple control of process (flow, level, or pressure) utilizing the built-in PI control.

3.1.1.6 Star/Delta Starter or Soft Starter not Required

When larger 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. Such motor starters are not required if a drive is used.

As shown in the following illustration, a drive does not consume more than rated current.

Illustration 8: Start-up Current

3.1.1.7 Using a Drive Saves Money

The example in 3.1.1.8 Traditional Fan System without a Drive and 3.1.1.9 Fan System Controlled by Drives shows that a drive replaces other equipment. It is possible to calculate the cost of installing the 2 different systems. In the example, the 2 systems can be established at roughly the same price.

Use the VLT® Energy Box software that is introduced in chapter Additional Resources to calculate the cost savings that can be achieved by using a drive.

- +

x6 x6

e75ha205.12

Valve position

Starter

Fuses

supply

P.F.C

Flow

3-Port valve

Bypass

Return

Control

Supply air

V.A.V outlets

Duct

P.F.C

Mains

Fuses

Starter

Bypass

supply

Return

valve

3-Port

Flow

Control

Valve position

Starter

Power Factor Correction

Mains

IGV

Mechanical linkage and vanes

Fan

Motor or actuator

Main B.M.S

Local D.D.C. control

Sensors PT

Pressure control signal 0/10V

Temperature control signal 0/10V

Control

Mains

Cooling section Heating section

Fan sectionInlet guide vane

Pump Pump

D.D.C.

Direct digital control

E.M.S.

Energy management system

V.A.V.

Variable air volume

Sensor P

Pressure

Sensor T

Temperature

VLT® Flow Drive FC 111

Design Guide

3.1.1.8 Traditional Fan System without a Drive

Product Overview

Illustration 9: Traditional Fan System without a Drive

e75ha206.11

Pump

Flow

Return

Supply air

V.A.V outlets

Duct

Mains

Pump

Return

Flow

Mains

Fan

Main B.M.S

Local D.D.C. control

Sensors

Mains

Cooling section

Heating section

Fan section

Pressure control 0-10V or 0/4-20mA

Control temperature 0-10V or 0/4-20mA

VLT

- +

VLT

x3 x3

D.D.C.

Direct digital control

E.M.S.

Energy management system

V.A.V.

Variable air volume

Sensor P

Pressure

Sensor T

Temperature

VLT® Flow Drive FC 111

Design Guide

3.1.1.9 Fan System Controlled by Drives

Product Overview

Illustration 10: Fan System Controlled by Drives

3.1.2 Application Examples

The following sections give typical examples of applications.

3.1.2.1 Variable Air Volume

VAV or variable air volume systems, control both the ventilation and temperature to satisfy the requirements of a building. Central VAV systems are considered to be the most energy efficient method to air condition buildings. By designing central systems instead of distributed systems, a greater efficiency can be obtained.

The efficiency comes from utilizing larger fans and larger chillers which have much higher efficiencies than small motors and distributed air-cooled chillers. Savings are also seen from the decreased maintenance requirements.

The VLT Solution

While dampers and IGVs work to maintain a constant pressure in the ductwork, a drive solution saves much more energy and reduces the complexity of the installation. Instead of creating an artificial pressure drop or causing a decrease in fan efficiency, the drive decreases the speed of the fan to provide the flow and pressure required by the system.

Centrifugal devices such as fans behave according to the centrifugal laws. This means that the fans decrease the pressure and flow they produce as their speed is reduced. Their power consumption is thereby significantly reduced. The PI controller of the drive can be used to eliminate the need for additional controllers.

ooling c oil

Hea ting c oil

ilt

P r essur e sig nal

Supply fan

V A V bo x es

Fl o w

P r essur e tr ansmitt er

R etur n fan

e30bb455.10

Drive

VLT® Flow Drive FC 111

Design Guide

Illustration 11: Variable Air Volume

Product Overview

3.1.2.2 Constant Air Volume

CAV, or constant air volume systems, are central ventilation systems usually used to supply large common zones with the minimum amounts of fresh tempered air. They preceded VAV systems and are therefore found in older multi-zoned commercial buildings as well. These systems preheat amounts of fresh air utilizing air handling units (AHUs) with a heating coil, and many are also used to air condition buildings and have a cooling coil. Fan coil units are frequently used to assist in the heating and cooling requirements in the individual zones.

The VLT Solution

With a drive, significant energy savings can be obtained while maintaining decent control of the building. Temperature sensors or CO2 sensors can be used as feedback signals to drives. Whether controlling temperature, air quality, or both, a CAV system can be controlled to operate based on actual building conditions. As the number of people in the controlled area decreases, the need for fresh air decreases. The CO2 sensor detects lower levels and decreases the supply fans speed. The return fan modulates to maintain a static pressure setpoint or fixed difference between the supply and return airflows.

With temperature control, especially used in air conditioning systems, as the outside temperature varies as well as the number of people in the controlled zone changes, different cooling requirements exist. As the temperature decreases below the setpoint, the supply fan can decrease its speed. The return fan modulates to maintain a static pressure setpoint. By decreasing the air flow, energy used to heat or cool the fresh air is also reduced, adding further savings.

Several features of the Danfoss dedicated drive can be utilized to improve the performance of the CAV system. One concern of controlling a ventilation system is poor air quality. The programmable minimum frequency can be set to maintain a minimum amount of supply air regardless of the feedback or reference signal. The drive also includes a PI controller, which allows monitoring both temperature and air quality. Even if the temperature requirement is fulfilled, the drive maintains enough supply air to satisfy the air quality sensor. The controller is capable of monitoring and comparing 2 feedback signals to control the return fan by maintaining a fixed differential airflow between the supply and return ducts as well.

P r essur e sig nal

C ooling c oil

Hea ting c oil

F ilt er

P r essur e tr ansmitt er

Supply fan

R etur n fan

T emper a tur e sig nal

T emper a tur e tr ansmitt er

e30bb451.10

Drive

VLT® Flow Drive FC 111

Design Guide

Illustration 12: Constant Air Volume

Product Overview

3.1.2.3 Cooling Tower Fan

Cooling tower fans cool condenser-water in water-cooled chiller systems. Water-cooled chillers provide the most efficient means of creating chilled water. They are as much as 20% more efficient than air cooled chillers. Depending on climate, cooling towers are often the most energy efficient method of cooling the condenser-water from chillers.

They cool the condenser water by evaporation. The condenser water is sprayed into the cooling tower until the cooling towers fill to increase its surface area. The tower fan blows air through the fill and sprayed water to aid in the evaporation. Evaporation removes energy from the water dropping its temperature. The cooled water collects in the cooling towers basin where it is pumped back into the chillers condenser and the cycle is repeated.

The VLT Solution

With a drive, the cooling towers fans can be controlled to the required speed to maintain the condenser-water temperature. The drives can also be used to turn the fan on and off as needed.

Several features of the Danfoss dedicated drive can be utilized to improve the performance of cooling tower fans applications. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes small. Also, when utilizing a gearbox to frequency control the tower fan, a minimum speed of 40–50% is required.

The customer programmable minimum frequency setting is available to maintain this minimum frequency even as the feedback or speed reference calls for lower speeds.

Also as a standard feature, the drive can be programmed to enter a sleep mode and stop the fan until a higher speed is required. Additionally, some cooling tower fans have undesirable frequencies that may cause vibrations. These frequencies can easily be avoided by programming the bypass frequency ranges in the drive.

W a t er I nlet

W a t er Outlet

CHILLER

T emper a tur e S ensor

BASIN

C onderser W a t er pump

Supply

e30bb453.10

Drive

VLT® Flow Drive FC 111

Design Guide

Product Overview

Illustration 13: Cooling Tower Fan

3.1.2.4 Condenser Pumps

Condenser water pumps are primarily used to circulate water through the condenser section of water cooled chillers and their associated cooling tower. The condenser water absorbs the heat from the chiller's condenser section and releases it into the atmosphere in the cooling tower. These systems are used to provide the most efficient means of creating chilled water, they are as much as 20% more efficient than air cooled chillers.

The VLT Solution

Drives can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump impeller.

Using a drive instead of a throttling valve simply saves the energy that would have been absorbed by the valve. This can amount to savings of 15–20% or more. Trimming the pump impeller is irreversible, thus if the conditions change and higher flow is required the impeller must be replaced.

Wa t e

nlet

t e

Outlet

BASIN

lo w or pr essur

e sensor

C ondenser W a t er pump

T hr ottling v alv e

Supply

CHILLER

e30bb452.10

Drive

VLT® Flow Drive FC 111

Design Guide

Product Overview

Illustration 14: Condenser Pumps

3.1.2.5 Primary Pumps

Primary pumps in a primary/secondary pumping system can be used to maintain a constant flow through devices that encounter operation or control difficulties when exposed to variable flow. The primary/secondary pumping technique decouples the primary production loop from the secondary distribution loop. This allows devices such as chillers to obtain constant design flow and operate properly while allowing the rest of the system to vary in flow.

As the evaporator flow rate decreases in a chiller, the chilled water begins to become overchilled. As this happens, the chiller attempts to decrease its cooling capacity. If the flow rate drops far enough, or too quickly, the chiller cannot shed its load sufficiently and the chiller’s safety trips the chiller requiring a manual reset. This situation is common in large installations especially when 2 or more chillers in parallel are installed if primary/ secondary pumping is not utilized.

The VLT Solution

Depending on the size of the system and the size of the primary loop, the energy consumption of the primary loop can become substantial.

A drive can be added to the primary system to replace the throttling valve and/or trimming of the impellers, leading to reduced operating expenses. 2 control methods are common:

Flow meter

Because the desired flow rate is known and is constant, a flow meter installed at the discharge of each chiller, can be used to control the pump directly. Using the built-in PI controller, the drive always maintains the appropriate flow rate, even compensating for the changing resistance in the primary piping loop as chillers and their pumps are staged on and off.

Local speed determination

The operator simply decreases the output frequency until the design flow rate is achieved. Using a drive to decrease the pump speed is very similar to trimming the pump impeller, except it does not require any labor, and

the pump efficiency remains higher. The balancing contractor simply decreases the speed of the pump until the proper flow rate is achieved and leaves the speed fixed. The pump operates at this speed any time the chiller is staged on. Because the primary loop does not have control valves or other devices that can cause the system curve to change, and the variance due to staging pumps and chillers on and off is usually small, this fixed speed remains appropriate. If the flow rate needs to be increased later in the system’s life, the drive can simply increase the pump speed instead of requiring a new pump impeller.

CHILLER

wmet er

F lo wmet er

F F

e30bb456.10

Drive

VLT® Flow Drive FC 111

Design Guide

Product Overview

Illustration 15: Primary Pumps

3.1.2.6 Secondary Pumps

Secondary pumps in a primary/secondary chilled water pumping system distribute the chilled water to the loads from the primary production loop. The primary/secondary pumping system is used to hydronically de-couple 1 piping loop from another. In this case, the primary pump is used to maintain a constant flow through the chillers while allowing the secondary pumps to vary in flow, increase control and save energy.

If the primary/secondary concept is not used in the design of a variable volume system when the flow rate drops far enough or too quickly, the chiller cannot shed its load properly. The chiller’s low evaporator temperature safety then trips the chiller requiring a manual reset. This situation is common in large installations especially when 2 or more chillers in parallel are installed.

The VLT Solution

While the primary-secondary system with 2-way valves improves energy savings and eases system control problems, the true energy savings and control potential is realized by adding drives.

With the proper sensor location, the addition of drives allows the pumps to vary their speed to follow the system curve instead of the pump curve. This results in the elimination of wasted energy and eliminates most of the overpressurization that 2-way valves can be subjected to.

As the monitored loads are reached, the 2-way valves close down. This increases the differential pressure measured across the load and the 2-way valve. As this differential pressure starts to rise, the pump is slowed to maintain the control head also called setpoint value. This setpoint value is calculated by summing the pressure drop of the load and the 2-way valve together under design conditions.

N O T I C E

When running multiple pumps in parallel, they must run at the same speed to maximize energy savings, either with individual

dedicated drives or 1 drive running multiple pumps in parallel.

CHILLER

e30bb454.10

Drive

VLT® Flow Drive FC 111

Design Guide

Product Overview

Illustration 16: Secondary Pumps

3.1.3 Check Valve Monitoring

In the pump application system, a damaged check valve is hard to detect, which therefore causes low efficiency of the whole system. VLT® Flow Drive FC 111 has the ability to monitor the status of check valves in the system. After enabling the check valve monitoring function via setting the parameter 22-04 Check Valve Monitor to [1] Enabled, once a damaged check valve is detected, the drive trips warning 159, Check Valve Failure.

3.1.4 Dry Pump Detection

In the pump application system, the drive monitors the operation status of the system to detect whether there is water on pump's suction side. If the pump runs at maximum speed and consumes little power, then it can be assumed that there is no water on the pump's suction side. Via setting the parameter 22-26 Dry Pump Function to warning or alarm, once the dry pump condition is detected, the drive trips warning/alarm 93, dry pump.

3.1.5 End of Curve Detection

In the pump application system, the drive monitors the operation status of the system to detect whether the pressure side of pump is subject to a major leakage. If the pump runs at maximum speed for a defined time period, but the pressure is below the set point, then it can be considered to reflect the end of curve situation. Via setting the parameter 22-50 End of Curve Function to warning or alarm, once the end of curve condition is detected, the drive trips warning/alarm 94, end of curve.

3.1.6 Time-based Functions

In some application scenarios, there are requirements to control the motor running for a specific time, in a specific direction and a specific speed within a specific time interval. For example, checking the motor status in fire mode or exercising pumps, fans, and compressors.

For detailed parameter settings, refer to the parameter group 23-** Time-based Functions in the drive's Programming Guide.

3.2 Control Structures

3.2.1 Introduction

There are two control modes for the drive:

Open loop.

•

Closed loop.

•

Select [0] Open loop or [1] Closed loop in parameter 1-00 Configuration Mode.

100%

-100%

100%

A ut o mode

Hand mode

L ocal

P 4-10 M ot or speed dir ec tion

P 4-14 M ot or speed high limit [H z]

P 4-12 M ot or speed lo w limit [H z]

Reference handling Remote reference

Local reference scaled to Hz

LCP Hand on, off and auto on keys

Remote

Reference

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

Ramp

To motor control

e30bb892.11

Hand

e30bb893.11

Off Auto

Reset

VLT® Flow Drive FC 111

Design Guide

Product Overview

3.2.2 Control Structure Open Loop

Illustration 17: Open-loop Structure

In the configuration shown in the above illustration, parameter 1-00 Configuration Mode is set to [0] Open loop. The resulting reference from the reference handling system or the local reference is received and fed through the ramp limitation and speed limitation before being sent to the motor control. The output from the motor control is then limited by the maximum frequency limit.

3.2.3 PM/EC+ Motor Control

The Danfoss EC+ concept provides the possibility for using high-efficient PM motors (permanent magnet motors) in IEC standard enclosure sizes operated by Danfoss drives.

The commissioning procedure is comparable to the existing one for asynchronous (induction) motors by utilizing the Danfoss VVC PM control strategy.

Customer advantages:

•

Free choice of motor technology (permanent magnet or induction motor).

•

Installation and operation as know on induction motors.

•

Manufacturer independent when selecting system components (for example, motors).

•

Best system efficiency by selecting best components.

•

Possible retrofit of existing installations.

•

Power range: 0.37–90 kW (0.5–121 hp) (400 V) for induction motors and 0.37–22 kW (0.5–30 hp) (400 V) for PM motors.

Current limitations for PM motors:

•

Currently only supported up to 22 kW (30 hp).

•

LC filters are not supported with PM motors.

•

Kinetic back-up algorithm is not supported with PM motors.

•

Support only complete AMA of the stator resistance Rs in the system.

•

No stall detection (supported from software version 62.80).

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

The drive can be operated manually via the local control panel (LCP) or remotely via analog/digital inputs or serial bus. If allowed in parameter 0-40 [Hand on] Key on LCP, parameter 0-44 [Off/Reset] Key on LCP, and parameter 0-42 [Auto on] Key on LCP, it is possible to start and stop the drive via LCP by pressing [Hand On] and [Off/Reset]. Alarms can be reset via the [Off/Reset] key.

Illustration 18: LCP Keys

Local reference forces the configuration mode to open loop, independent on the setting of parameter 1-00 Configuration Mode.

7-30 PI

Nor mal/I n v erse

C on tr ol

F eedback

P 4-10

M ot or speed

dir ec tion

T o mot or c on tr ol

e30bb894.11

100%

-100%

100%

*[-1]

Reference

Scale to speed

e30bb895.10

Ref. signal

Desired flow

FB conversion

Ref.

Flow

FB signal

Flow

P 20-01

VLT® Flow Drive FC 111

Design Guide

Product Overview

Local reference is restored at power-down.

3.2.5 Control Structure Closed Loop

The internal controller allows the drive to become a part of the controlled system. The drive receives a feedback signal from a sensor in the system. It then 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.

For example, consider a compressor application where the speed of the compressor is to be controlled to ensure a constant suction pressure in an evaporator. The suction pressure value is supplied to the drive as the setpoint reference. A pressure sensor measures the actual suction pressure in the evaporator and supplies the data to the drive as a feedback signal. If the feedback signal is greater than the setpoint reference, the drive speeds up the compressor to reduce the pressure. In a similar way, if the suction pressure is lower than the setpoint reference, the drive automatically slows down the compressor to increase the pressure.

Illustration 19: Control Structure Closed Loop

While the default values for the closed-loop controller of the drive often provide satisfactory performance, the control of the system can often be optimized by adjusting parameters.

3.2.6 Feedback Conversion

In some applications, it may be useful to convert the feedback signal. One example of this is using a pressure signal to provide flow feedback. Since the square root of pressure is proportional to flow, the square root of the pressure signal yields a value proportional to the flow. See the following illustration.

Illustration 20: Feedback Signal Conversion

3.2.7 Reference Handling

Details for open-loop and closed-loop operation.

Speed open loop

mode

Input command:

freeze reference

Process control

Scale to Hz

Scale to process unit

Remote reference/ setpoint

±200% Feedback handling

Remote reference in %

maxRefPCT

minRefPct

min-max ref

Freeze reference & increase/ decrease reference

±100%

Input commands:

Speed up/speed down

±200%

Relative reference = X+X*Y/100

±200%

External reference in %

±200%

Parameter choise: Reference resource 1,2,3

±100%

Preset reference

Input command: preset ref bit0, bit1, bit2

Relative scalling reference

Intern resource

Preset relative reference

±100%

Preset reference 0 ±100%

Preset reference 1 ±100%

Preset reference 2 ±100% Preset reference 3 ±100% Preset reference 4 ±100% Preset reference 5 ±100%

Preset reference 6 ±100% Preset reference 7 ±100%

External resource 1 No function

Analog reference ±200 %

Local bus reference ±200 % Pulse input reference ±200 %

Pulse input reference ±200 %

External resource 2

No function Analog reference ±200 %

Local bus reference ±200 %

External resource 3 No function

Analog reference ±200 %

Local bus reference ±200 %

e30be842.10

VLT® Flow Drive FC 111

Design Guide

Product Overview

Illustration 21: Block Diagram Showing Remote Reference

The remote reference consists of:

•

Preset references.

•

External references (analog inputs and serial communication bus references).

•

The preset relative reference.

•

Feedback-controlled setpoint.

Up to 8 preset references can be programmed in the drive. The active preset reference can be selected using digital inputs or the serial communications bus. The reference can also be supplied externally, most commonly from an analog input. This external source is selected by 1 of the 3 reference source parameters (parameter 3-15 Reference 1 Source, parameter 3-16 Reference 2 Source, and parameter 3-17 Reference 3 Source). All reference resources and the bus reference are added to produce the total external reference. The external reference, the preset reference, or the sum of the 2 can be selected to be the active reference. Finally, this reference can by be scaled using parameter 3-14 Preset Relative Reference.

The scaled reference is calculated as follows:

Reference = X  +  X × 

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

If Y, parameter 3-14 Preset Relative Reference, is set to 0%, the reference is not affected by the scaling.

3.2.8 Tuning the Drive Closed-loop

Once the drive's closed-loop controller has been set up, test the performance of the controller. Often, its performance may be acceptable using the default values of parameter 20-93 PI Proportional Gain and parameter 20-94 PI Integral Time. However, sometimes it may be helpful to optimize these parameter values to provide faster system response while still controlling speed overshoot.

3.2.9 Adjusting the Manual PI

Procedure

Start the motor.

100

Enclosure size

Level [dBA]

(1)

43.6H250.2H353.8H464H563.7H671.5H767.5 (75 kW (100 hp) 71.5 dB)

73.5

H1373H14

VLT® Flow Drive FC 111

Design Guide

Set parameter 20-93 PI Proportional Gain to 0.3 and increase it until the feedback signal begins to oscillate. If necessary, start and stop the drive or make step changes in the setpoint reference to attempt to cause oscillation.

Reduce the PI proportional gain until the feedback signal stabilizes.

Reduce the proportional gain by 40–60%.

Set parameter 20-94 PI Integral Time to 20 s and reduce it until the feedback signal begins to oscillate. If necessary, start and stop the drive or make step changes in the setpoint reference to attempt to cause oscillation.

Increase the PI integral time until the feedback signal stabilizes.

Increase the integral time by 15–50%.

Product Overview

3.3 Ambient Running Conditions

3.3.1 Air Humidity

The drive has been designed to meet the IEC/EN 60068-2-3 standard, EN 50178 9.4.2.2 at 50 °C (122 °F).

3.3.2 Acoustic Noise or Vibration

If the motor or the equipment driven by the motor - for example, a fan - makes noise or vibrations at certain frequencies, configure the following parameters or parameter groups to reduce or eliminate the noise or vibrations:

•

Parameter group 4-6* Speed Bypass.

•

Set parameter 14-03 Overmodulation to [0] Off.

•

Switching pattern and switching frequency parameter group 14-0* Inverter Switching.

•

Parameter 1-64 Resonance Dampening.

3.3.2.1 Acoustic Noise

The acoustic noise from the drive comes from 3 sources:

DC-link coils.

•

Integral fan.

•

RFI filter choke.

•

Table 6: Typical Values Measured at a Distance of 1 m (3.28 ft) from the Unit

The values are measured under the background of 35 dBA noise and the fan running with full speed.

VLT® Flow Drive FC 111

Design Guide

Product Overview

3.3.2.2 Vibration and Shock

The drive has been tested according to the following standards:

•

IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970

•

IEC/EN 60068-2-64: Vibration, broad-band random

The drive complies with the requirements that exist for units mounted on the walls and floors of production premises, and in panels bolted to walls or floors.

3.3.3 Aggressive Environments

A drive contains many mechanical and electronic components. All are to some extent vulnerable to environmental effects.

C A U T I O N

INSTALLATION ENVIRONMENTS

Failure to take necessary protective measures increases the risk of stoppages, potentially causing equipment damage and per-

sonnel injury.

Do not install the drive in environments with airborne liquids, particles, or gases that may affect or damage the electronic

components.

Liquids can be carried through the air and condense in the drive and may cause corrosion of components and metal parts. Steam, oil, and salt water may cause corrosion of components and metal parts. As an extra protection, coated printed circuit boards can be ordered as an option (standard on some power sizes).

Airborne particles such as dust may cause mechanical, electrical, or thermal failure in the drive. A typical indicator of excessive levels of airborne particles is dust particles around the drive fan. In dusty environments, use a cabinet for IP20/TYPE 1 equipment.

In environments with high temperatures and humidity, corrosive gases such as sulphur, nitrogen, and chlorine compounds cause chemical processes on the drive components.

Such chemical reactions rapidly affect and damage the electronic components. In such environments, mount the equipment in a cabinet with fresh air ventilation, keeping aggressive gases away from the drive. An extra protection in such areas is a coating of the printed circuit boards, which can be ordered as an option.

Before installing the drive, check the ambient air for liquids, particles, and gases. This is done by observing existing installations in this environment. Typical indicators of harmful airborne liquids are water or oil on metal parts, or corrosion of metal parts.

Excessive dust particle levels are often found on installation cabinets and existing electrical installations. One indicator of aggressive airborne gases is blackening of copper rails and cable ends on existing installations.

3.4 General Aspects of EMC

3.4.1 Overview of EMC Emissions

Drives (and other electrical devices) generate electronic or magnetic fields that may interfere with their environment. The electromagnetic compatibility (EMC) of these effects depends on the power and the harmonic characteristics of the devices.

Uncontrolled interaction between electrical devices in a system can degrade compatibility and impair reliable operation. Interference may take the form of mains harmonics distortion, electrostatic discharges, rapid voltage fluctuations, or high-frequency interference. Electrical devices generate interference along with being affected by interference from other generated sources.

Electrical interference usually occur at frequencies in the range 150 kHz to 30 MHz. Airborne interference from the drive system in the range 30 MHz to 1 GHz is generated from the inverter, the 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 the following illustration.

The use of a shielded motor cable increases the leakage current (see the following illustration) because shielded cables have higher capacitance to ground than unshielded cables. If the leakage current is not filtered, it causes greater 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 shield (I3), there is only a small electromagnetic field (I4) from the shielded motor cable according to the following illustration.

1 2

e75za062.12

Ground wire

Shield

AC mains supply

Drive5Shielded motor cable

Motor

EN/IEC 61800-3 Category

Definition

Equivalent emission class in EN 55011

Drives installed in the first environment (home and office) with a supply voltage less than 1000 V.

Class B

Drives installed in the first environment (home and office) with a supply voltage less than 1000 V, which are neither plug-in nor movable and are intended to be installed and commissioned by a professional.

Class A Group 1 C3

Drives installed in the second environment (industrial) with a supply voltage lower than 1000 V.

Class A Group 2

Drives 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.

No limit line. Make an EMC plan.

VLT® Flow Drive FC 111

Design Guide

Illustration 22: Generation of Leakage Currents

Product Overview

The shield reduces the radiated interference, but increases the low-frequency interference on the mains. Connect the motor cable shield to the drive enclosure and on the motor enclosure. This is best done by using integrated shield clamps to avoid twisted shield ends (pigtails). Pigtails increase the shield impedance at higher frequencies, which reduces the shield effect and increases the leakage current (I4).

If a shielded cable is used for relay, control cable, signal interface, and brake, mount the shield on the enclosure at both ends. In some situations, however, it is necessary to break the shield to avoid current loops.

If the shield is to be placed on a mounting plate for the drive, the mounting plate must be made of metal, to convey the shield currents back to the unit. Moreover, ensure good electrical contact from the mounting plate through the mounting screws to the drive chassis.

When using unshielded 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 as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50 MHz (airborne) is especially generated by the control electronics.

3.4.2 Emission Requirements

The EMC product standard for drives defines 4 categories (C1, C2, C3, and C4) with specified requirements for emission and immunity. The following table states the definition of the 4 categories and the equivalent classification from EN 55011.

Table 7: Correlation between IEC 61800-3 and EN 55011

Environment

Generic emission standard

Equivalent emission class in EN 55011

First environment (home and office)

EN/IEC 61000-6-3 Emission standard for residential, commercial and light industrial environments.

Class B

Second environment (industrial environment)

EN/IEC 61000-6-4 Emission standard for industrial environments.

Class A Group 1

RFI filter type

Conduct emission. Maximum shielded cable length [m (ft)]

Radiated emission Industrial environment

EN 55011

Class A Group 2

Industrial environment

Class A Group 1

Industrial environment

Class B

Housing, trades and light industries

Class A Group 1

Industrial environment

Class B

Housing, trades and light industries

EN/IEC 61800-3

Category C3

Second environment industrial

Category C2

First environment home and office

Category C1

First environment home and office

Category C2

First environment home and office

Category C1

First environment home and office

Without external filter

With external filter

Without external filter

With external filter

Without external filter

With external filter

Without external filter

With external filter

Without external filter

With external filter

H4 RFI filter (EN55011 A1, EN/IEC61800-3 C2)

0.37–22 kW (0.5–30 hp) 3x380–480 V IP20

––25 (82)

50 (164)

–

20 (66)

Yes

Yes–No

H2 RFI filter (EN 55011 A2, EN/IEC 61800-3 C3)

30–90 kW (40–125 hp) 3x380– 480 V IP20

25 (82)

–––––No–No–

H3 RFI filter (EN55011 A1/B, EN/IEC 61800-3 C2/C1)

30–90 kW (40–125 hp) 3x380– 480 V IP20

––50 (164)

–

20 (66)

–

Yes–No

–

VLT® Flow Drive FC 111

Design Guide

When the generic (conducted) emission standards are used, the drives are required to comply with the limits in the following table.

Table 8: Correlation between Generic Emission Standards and EN 55011

Product Overview

3.4.3 EMC Emission Test Results

The following test results have been obtained using a system with a drive, a shielded control cable, a control box with potentiometer, and a shielded motor cable.

Table 9: EMC Emission Test Results, H1–H8

RFI filter type

Conduct emission. Maximum shielded cable length [m (ft)]

Radiated emission

EN 55011

Class B Housing, trades and light industries

Class A Group 1 Industrial environment

Class A Group 2 Industrial environment

Class B Housing, trades and light industries

Class A Group 1 Industrial environment

Class A Group 2 Industrial environment

EN/IEC 61800-3

Category C1

First environment home and office

Category C2

First environment home and office

Category C3

Second environment industrial

Category C1

First environment home and office

Category C2

First environment home and office

Category C3

First environment home and office

H2 RFI filter (EN 55011 A2, EN/IEC 61800-3 C3)

110–315 kW (150– 450 hp) 3x380–480 V IP20

NoNo150 m (492 ft)

NoNoYes

I1I5I

Hz50250

350

e75ha034.10

VLT® Flow Drive FC 111

Design Guide

Table 10: EMC Emission Test Results, H13–H14

Product Overview

3.4.4 Harmonics Emission

A drive takes up a non-sinusoidal current from mains, which increases the input current I formed with a Fourier analysis and split into sine-wave currents with different frequencies, that is, different harmonic currents I with 50 Hz basic frequency:

. A non-sinusoidal current is trans-

RMS

Table 11: Harmonic Currents

The harmonics do not affect the power consumption directly, but increase the heat losses in the installation (transformer, cables). So, in plants with a high percentage of rectifier load, maintain harmonic currents at a low level to avoid overload of the transformer and high temperature in the cables.

Illustration 23: DC-link Coils

N O T I C E

Some of the harmonic currents might disturb communication equipment connected to the same transformer or cause resonance

with power factor correction batteries.

To ensure low harmonic currents, the drive is equipped with DC-link coils as standard. This normally reduces the input current I by 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 total voltage distortion THDv is calculated based on the individual voltage harmonics using this formula:

RMS

THD% = U

 + U

 + ... + U

(UN% of U)

3.4.4.1 Harmonics Emission Requirements

Equipment is connected to the public supply network.

Options

Definition

IEC/EN 61000-3-2 Class A for 3-phase balanced equipment (for professional equipment only up to 1 kW (1.3 hp) total power).

IEC/EN 61000-3-12 Equipment 16–75 A and professional equipment as from 1 kW (1.3 hp) up to 16 A phase current.

Individual harmonic current In/I1 (%)

I5I7I11I

Actual 6.0–10 kW (8.0–15 hp), IP20, 200 V (typical)

32.6

16.6

8.0

6.0

Limit for R

sce

≥120

402515

Harmonic current distortion factor (%)

THDi

PWHD

Actual 6.0–10 kW (8.0–15 hp), 200 V (typical)

41.4

Limit for R

sce

≥120

Individual harmonic current In/I1 (%)

I5I7I11I

Actual 6.0–22 kW (8.0–30 hp), IP20, 380–480 V (typical)

36.7

20.8

7.6

6.4

Limit for R

sce

≥120

402515

Harmonic current distortion factor (%)

THDi

PWHD

Actual 6.0–22 kW (8.0–30 hp), 380–480 V (typical)

44.4

40.8

Limit for R

sce

≥120

Individual harmonic current In/I1 (%)

I5I7I11I

Actual 30 kW (40 hp), IP20, 380–480 V (typical)

36.7

13.8

6.9

4.2

Limit for R

sce

≥120

402515

Harmonic current distortion factor (%)

THDi

PWHD

Actual 30 kW (40 hp), 380–480 V (typical)

40.6

28.8

VLT® Flow Drive FC 111

Design Guide

Table 12: Connected Equipment

Product Overview

3.4.4.2 Harmonics Test Results (Emission)

Power sizes up to 10 kW (15 hp) [200–240 V AC] comply with IEC/EN 61000-3-12, Table 4. Power sizes up to 30 kW (40 hp) [380– 480 V AC] comply with IEC/EN 61000-3-2 Class A and IEC/EN 61000-3-12, Table 4.

Table 13: Harmonic Current 6.0–10 kW (8.0–15 hp), 200 V

Table 14: Harmonic Current 6.0–22 kW (8.0–30 hp), 380–480 V

Table 15: Harmonic Current 30 kW (40 hp), 380–480 V

Limit for R

sce

≥120

Options

Definition

IEC/EN 61000-3-2 Class A for 3-phase balanced equipment (for professional equipment only up to 1 kW (1.3 hp) total power).

IEC/EN 61000-3-12 Equipment 16–75 A and professional equipment as from 1 kW (1.3 hp) up to 16 A phase current.

Individual harmonic current In/I1 (%)

I5I7I11I

Actual 0.37–22 kW (0.5–30 hp), IP20, 380-480 V (typical)

36.7

20.8

7.6

6.4

Limit for R

sce

≥120

402515

Harmonic current distortion factor (%)

THDi

PWHD

Actual 0.37–22 kW (0.5–30 hp), 380-480 V (typical)

44.4

40.8

Limit for R

sce

≥120

Individual harmonic current In/I1 (%)

I5I7I11I

Actual 30–90 kW (40–120 hp), IP20, 380-480 V (typical)

36.7

13.8

6.9

4.2

Limit for R

sce

≥120

402515

Harmonic current distortion factor (%)

VLT® Flow Drive FC 111

Design Guide

Product Overview

If the short-circuit power of the supply Ssc is greater than or equal to:

SSC= 3 × R

at the interface point between the user’s supply and the public system (R

SCE

 × U

mains

 × I

 =  3 × 120 × 400 × I

equ

sce

The installer or user of the equipment is responsible for ensuring that the equipment is connected only to a supply with a shortcircuit power Ssc greater than or equal to what is specified above. If necessary, consult with the distribution network operator. Other power sizes can be connected to the public supply network by consultation with the distribution network operator.

Compliance with various system level guidelines: The harmonic current data in Table 13 to Table 15 are given in accordance with IEC/EN 61000-3-12 with reference to the Power Drive Systems product standard. They may be used as the basis for calculation of the harmonic currents' influence on the power supply system and for the documentation of compliance with relevant regional guidelines: IEEE 519 -1992; G5/4.

If there is a need for further reduction of harmonic currents, passive or active filters in front of the drives can be installed. Consult Danfoss for further information.

3.4.5 Harmonics Emission Requirements

Equipment is connected to the public supply network.

Table 16: Connected Equipment

3.4.6 Harmonics Test Results (Emission)

Power sizes up to PK75 in T4 complies with IEC/EN 61000-3-2 Class A. Power sizes from P1K1 and up to P90K in T4 complies with IEC/EN 61000-3-12, Table 4.

Table 17: Harmonic Current 0.37–22 kW (0.5–30 hp), 380-480 V

Table 18: Harmonic Current 30–90 kW (40–120 hp), 380-480 V

THDi

PWHD

Actual 30–90 kW (40–120 hp), 380-480 V (typical)

40.6

28.8

Limit for R

sce

≥120

SMPS

e30bb896.10

Supply (SMPS)

Optocouplers, communication between AOC and BOC3Custom relays

Control card terminals

VLT® Flow Drive FC 111

Design Guide

Product Overview

Provided that the short-circuit power of the supply Ssc is greater than or equal to:

SSC= 3 × R

at the interface point between the user’s supply and the public system (R

SCE

 × U

mains

 × I

 =  3 × 120 × 400 × I

equ

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 Ssc greater than or equal to specified above. Other power sizes can be connected to the public supply network by consultation with the distribution network operator.

Compliance with various system level guidelines: The harmonic current data in the tables above are given in accordance with IEC/EN 61000-3-12 with reference to the Power Drive Systems product standard. They may be used as the basis for calculation of the harmonic currents' influence on the power supply system and for the documentation of compliance with relevant regional guidelines: IEEE 519 -1992; G5/4.

3.4.7 Immunity Requirements

The immunity requirements for drives depend on the environment in which they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss drives comply with the requirements for the industrial environment and therefore comply also with the lower requirements for home and office environment with a large safety margin.

3.5 Galvanic Isolation (PELV)

PELV offers protection through extra low voltage. Protection against electric shock is ensured when the electrical supply is of the PELV type and the installation is made as described in local/national regulations on PELV supplies.

All control terminals and relay terminals 01-03/04-06 comply with PELV (protective extra low voltage) (does not apply to grounded delta leg above 440 V).

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

The components that make up the electrical isolation, as described, also comply with the requirements for higher isolation and the relevant test as described in EN 61800-5-1. The PELV galvanic isolation can be shown in the following illustrations.

To maintain PELV, all connections made to the control terminals must be PELV, for example, thermistors must be reinforced/double insulated.

Illustration 24: Galvanic Isolation 0.37–22 kW (0.5–30 hp)

e30bb901.10

Supply (SMPS) including signal isolation of UDC, indicating the intermediate current voltage

Gate drive that runs the IGBTs (trigger transformers/ optocouplers)

Current transducers

Internal soft-charge, RFI, and temperature measurement circuits

Custom relays

Control card terminals

e30bx514.10

37 6

Current transducers

Galvanic isolation for the RS485 standard bus interface3Gate drive for the IGBTs

Supply (SMPS) including signal isolation of V DC, indicating the intermediate current voltage

Galvanic isolation for the 24 V back-up option

Opto-coupler, brake module (optional)

Internal inrush, RFI, and temperature measurement circuits

Customer relays

VLT® Flow Drive FC 111

Design Guide

Illustration 25: Galvanic Isolation 30–90 kW (40–120 hp)

Product Overview

Illustration 26: Galvanic Isolation 110–315 kW (150–450 hp)

The functional galvanic isolation (see Illustration 24) is for the RS485 standard bus interface.

C A U T I O N

INSTALLATION AT HIGH ALTITUDE

At altitudes above 2000 m (6500 ft), contact Danfoss regarding PELV.

3.6 Ground Leakage Current

Follow national and local codes regarding protective earthing of equipment where leakage current exceeds 3.5 mA. Drive 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 configurations, including:

e30bb955.12

Motor cable length

Leakage current

e30bb956.12

THDv=0%

THDv=5%

Leakage current

VLT® Flow Drive FC 111

Design Guide

•

RFI filtering.

•

Motor cable length.

•

Motor cable shielding.

•

Drive power.

Product Overview

Illustration 27: Influence of the Cable Length and Power Size on Leakage Current, Power Size a > Power Size B

The leakage current also depends on the line distortion.

Illustration 28: Influence of Line Distortion on Leakage Current

If the leakage current exceeds 3.5 mA, compliance with EN/IEC 61800-5-1 (power drive system product standard) requires special care.

Reinforce grounding with the following protective earth connection requirements:

e30bb958.12

Leakage current

Frequency

3rd harmonics

Mains Cable

RCD with low f

cut-off

RCD with high f

cut-off

50 Hz

150 Hz

VLT® Flow Drive FC 111

Design Guide

•

Ground wire (terminal 95) of at least 10 mm2 (8 AWG) cross-section.

•

2 separate ground wires both complying with the dimensioning rules.

Product Overview

See EN/IEC 61800-5-1 and IEC EN 62477-1 for further information.

W A R N I N G

DISCHARGE TIME

Touching the electrical parts, even after the equipment has been disconnected from mains, could be fatal.

Make sure that other voltage inputs have been disconnected, such as load sharing (linkage of DC-link), and the motor con-

nection for kinetic back-up.

Before touching any electrical parts, wait at least the amount of time indicated in the safety chapter. Shorter time is allowed

only if indicated on the nameplate for the specific unit.

W A R N I N G

LEAKAGE CURRENT HAZARD

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

Ensure the correct grounding of the equipment by a certified electrical installer.

3.6.1 Using a Residual Current Device (RCD)

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, which are capable of detecting AC and DC currents.

•

Use RCDs with an inrush delay to prevent faults caused by transient ground currents.

•

Dimension RCDs according to the system configuration 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 29: Mains Contributions to Leakage Current

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

e30bb957.12

Leakage current [mA]

100 Hz

2 kHz

100 kHz

VLT® Flow Drive FC 111

Design Guide

Product Overview

Illustration 30: Influence of Cut-off Frequency of the RCD on what is Responded to/Measured

For more details, refer to the RCD Application Note.

RESIDUAL CURRENT DEVICE PROTECTION

This product can cause a DC current in the protective conductor. Where a residual current device (RCD) is used for protection in

case of direct or indirect contact, only an RCD of Type B is allowed on the supply side of this product. Otherwise, apply another

protective measure, such as separation from the environment by double or reinforced insulation, or isolation from the supply

system by a transformer. See also application note Protection against Electrical Hazards.

3.7 Extreme Running Conditions

3.7.1 Introduction

Short circuit (motor phase-phase)

Current measurement in each of the 3 motor phases or in the DC-link, protects the drive against short circuits. A short circuit between 2 output phases causes an overcurrent in the inverter. The inverter is turned off individually when the short circuit current exceeds the allowed value (alarm 16, Trip Lock).

For information about protecting the drive against a short circuit at the load sharing and brake outputs, see chapter Fuses and Circuit Breakers.

Switching on the output

Switching on the output between the motor and the drive is allowed. The drive is not damaged in any way by switching on the output. However, fault messages may appear.

Motor-generated overvoltage

The voltage in the DC link is increased when the motor acts as a generator. This occurs in following cases:

•

The control unit may attempt to correct the ramp if parameter 2-17 Over-voltage Control is enabled. The drive turns off to protect the transistors and the DC-link capacitors when a certain voltage level is reached.

W A R N I N G

Protective grounding of the drive and the use of RCDs must always follow national and local regulations.

The load drives the motor (at constant output frequency from the drive), that is the load generates energy.

During deceleration (ramp-down) if the inertia moment is high, the friction is low, and the rampdown time is too short for the energy to be dissipated as a loss in the drive, the motor, and the installation.

Incorrect slip compensation setting (parameter 1-62 Slip Compensation) may cause higher DC-link voltage.

1.21.0 1.4

100

1.81.6 2.0

2000

500

200

400 300

1000

600

t [s]

e75za052.13

M,N

(parameter 1-24)

OUT

= 2 x f

M,N

(parameter 1-23)

OUT

= 1 x f

M,N

OUT

= 0.2 x f

M,N

VLT® Flow Drive FC 111

Design Guide

Product Overview

Mains drop-out

During a mains dropout, the drive keeps running until the DC-link voltage drops below the minimum stop level, which is typically 15% below the drive's lowest rated supply voltage. The mains voltage before the drop-out and the motor load determines how long it takes for the drive to coast.

3.7.2 Motor Thermal Protection (ETR)

Danfoss uses ETR to protect the motor from being overheated. It is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in the following illustration.

Illustration 31: Motor Thermal Protection Characteristic

The X-axis shows the ratio between I

motor

and I

nominal. The Y-axis shows the time in seconds before the ETR cuts off and trips

motor

the drive. The curves show the characteristic nominal speed at twice the nominal speed and at 0.2x the nominal speed. It is clear that at lower speed the ETR cuts off 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.

3.7.3 Thermistor Inputs

The thermistor cutout value is >3 kΩ. Integrate a thermistor (PTC sensor) in the motor for winding protection. Motor protection can be implemented using a range of techniques:

•

PTC sensor in motor windings.

•

Mechanical thermal switch (Klixon type).

•

Electronic thermal relay (ETR).

1330

550

250

-20°C

e75ha183.10

4000

3000

(W)

nominel

nominel -5°C

nominel + 5°C

[°C ]

OFF

<800 Ω >2.9 κΩ

12 20 55

27 29 42 45 50 53 54

DIGI IN

C OMM. GND

+24V

0/4-20mA A OUT / DIG OUT 0/4-20mA A OUT / DIG OUT

C OM A IN

C OM DIG IN

10V/20mA IN

10V OUT

BUS

TER.

OFF

e30bb898.10

VLT® Flow Drive FC 111

Design Guide

Illustration 32: Trip due to High Motor Temperature

Product Overview

3.7.3.1 Example with Digital Input and 10 V Power Supply

The drive trips when the motor temperature is too high. Parameter set-up:

•

Set parameter 1-90 Motor Thermal Protection to [2] Thermistor Trip.

•

Set parameter 1-93 Thermistor Source to [6] Digital Input 29.

Illustration 33: Digital Input/10 V Power Supply

3.7.3.2 Example with Analog Input and 10 V Power Supply

The drive trips when the motor temperature is too high. Parameter set-up:

12 20 55

27 29 42 45 50 53 54

DIGI IN

C OMM. GND

+24V

0/4-20mA A OUT / DIG OUT 0/4-20mA A OUT / DIG OUT

C OM A IN

C OM DIG IN

10V/20mA IN

10V OUT

BUS

TER.

OFF

e30bb897.10

<3.0 k

>2.9k Ω

OFF

Input

Supply voltage [V]

Threshold cutout values [Ω]

Digital

<800⇒2.9 k

Analog

<800⇒2.9 k

VLT® Flow Drive FC 111

Design Guide

•

Set parameter 1-90 Motor Thermal Protection to [2] Thermistor Trip.

•

Set parameter 1-93 Thermistor Source to [1] Analog Input 53.

N O T I C E

Do not set Analog Input 54 as reference source.

Product Overview

Illustration 34: Analog Input/10 V Power Supply

Table 19: Supply Voltage

Make sure that the selected supply voltage follows the specification of the used thermistor element.

ETR is activated in parameter 1-90 Motor Thermal Protection.

N O T I C E

F C - P

X S A B C X X X X

1 2 3 4 5 6 7 8 9

11 12 13

15 16 17

19 20 30 22 21 23 27 25 24 26 28 29 31 37 36 35 34 33 32 38

1 D 1

X X X

Description

Position

Possible choice

Product group & FC series

1–6

FC 111

Power rating

7–10

0.37–315 kW (0.5–450 hp) (PK37-P315)

Number of phases

3 phases (T)

Mains voltage

11–12

T4: 380-480 V AC

Enclosure

13–15

E20: IP20/chassis P20: IP20/chassis with back plate

RFI filter

16–17

H1: RFI filter class A1/B H2: RFI filter class A2 H3: RFI filter class A1/B (reduced cable length) H4: RFI filter class A1

Brake

X: No brake chopper included

Display

A: Alpha numeric local control panel X: No local control panel

Coating PCB

X: No coated PCB C: Coated PCB

Mains option

X: No mains option

Adaptation

X: No adaptation

Adaptation

X: No adaptation

Software release

24–27

SXXXX: Latest release - standard software

Software language

X: Standard

A options

29–30

AX: No A options

B options

31–32

BX: No B options

C0 options MCO

33–34

CX: No C options

C1 options

X: No C1 options

C option software

36–37

XX: No options

VLT® Flow Drive FC 111

Design Guide

Selection and Ordering

4 Selection and Ordering

4.1 Type Code

A type code defines a specific configuration of the drive. Use the following illustration to create a type code string for the desired configuration.

Illustration 35: Type Code

Table 20: Type Code Description

D options

38–39

DX: No D0 options

Ordering number

Description

132B0200

LCP 31

132B9221

LCP 32

Enclosure

Front-mounted

Maximum cable length to unit

3 m (10 ft)

Communication standard

RS485

VLT® Flow Drive FC 111

Design Guide

4.2 Options and Accessories

4.2.1 Local Control Panel (LCP)

Table 21: Ordering Number of LCP

Table 22: Technical Data of LCP

Selection and Ordering

4.2.2 IP21 Enclosure Kit

IP21 is an optional enclosure element available for IP20 units. If the enclosure kit is used, an IP20 unit is upgraded to comply with enclosure IP21.

e30bb902.12

VLT® Flow Drive FC 111

Design Guide

Selection and Ordering

Illustration 36: H1–H5

e30bb903.10

Frame

IP class

3x380-480 V [kW (hp)]

Height [mm (in)] A

Width [mm (in)] B

Depth [mm (in)] C

IP21 kit ordering number

IP20

0.37–1.5 (0.5–2.0)

293 (11.5)

81 (3.2)

173 (6.8)

132B0212

IP20

2.2-4.0 (3.0–5.4)

322 (12.7)

96 (3.8)

195 (7.7)

132B0213

IP20

5.5-7.5 (7.4–10)

346 (13.6)

106 (4.2)

210 (8.3)

132B0214

IP20

11–15 (15–20)

374 (14.7)

141 (5.6)

245 (9.6)

132B0215

IP20

18.5–22 (25–30)

418 (16.5)

161 (6.3)

260 (10.2)

132B0216

IP20

30–45 (40–60)

663 (26.1)

260 (10.2)

242 (9.5)

132B0217

IP20

55–75 (74–100)

807 (31.8)

329 (13.0)

335 (13.2)

132B0218

IP20

90 (120)

943 (37.1)

390 (15.3)

335 (13.2)

132B0219

VLT® Flow Drive FC 111

Design Guide

Selection and Ordering

Illustration 37: Dimensions

Table 23: Enclosure Kit Specifications

4.2.3 Decoupling Plate

Use the decoupling plate for EMC-correct installation. The following illustration shows the decoupling plate on an H3 enclosure.

e30bb793.11

Frame

IP class

3x380–480 V

Decoupling plate ordering numbers

IP20

0.37–1.5 (0.5–2.0)

132B0202

IP20

2.2–4.0 (3.0–5.4)

132B0202

IP20

5.5–7.5 (7.5–10)

132B0204

IP20

11–15 (15–20)

132B0205

IP20

18.5–22 (25–30)

132B0205

IP20

30 (40)

132B0207

IP20

37–45 (50–60)

132B0242

IP20

55 (75)

132B0208

IP20

75 (100)

132B0243

IP20

90 (125)

132B0209

Enclo-

sure

size

Mains

volt-

age

H1 [kW

(hp)]

H2 [kW

(hp)]

H3 [kW

(hp)]

H4 [kW

(hp)]

H5 [kW

(hp)]

H6 [kW (hp)]

H7 [kW (hp)]

H8 [kW

(hp)]

VLT® Flow Drive FC 111

Design Guide

Selection and Ordering

Illustration 38: Decoupling Plate

Table 24: Decoupling Plate Specifications

4.3 Ordering Numbers

4.3.1 Options and Accessories

Table 25: Options and Accessories

T4 (380– 480 V AC)

0.37–1.5

(0.5–2.0)

2.2–4.0

(3.0–5.4)

5.5–7.5

(7.5–10)

11–15

(15–20)

18.5–22 (25–30)

30 (40)

37–45

(50–60)

55 (75)

75 (100)

90 (125)

Description

LCP

(1)

132B0200

LCP panel mounting kit including 3 m (9.8 ft) cable

132B0201

Decoupling plate

132B0202

132B0204

132B0205

132B0207

132B0242

132B0208

132B0243

132B0209

IP21 option

132B0212

132B0213

132B0214

132B0215

132B0216

132B0217

132B0218

132B0219

3x380–480 V 50 Hz

Power [kW (hp)]

Drive input current continuous [A]

Default switching frequency [kHz]

THDi level [%]

Order number filter IP00

Code number filter IP20

22 (30)

41.544

130B1397

130B1239

30 (40)

5743

130B1398

130B1240

37 (50)

7043

130B1442

130B1247

45 (60)

8433

130B1442

130B1247

55 (74)

10335

130B1444

130B1249

75 (100)

14034

130B1445

130B1250

90 (120)

17634

130B1445

130B1250

3x380–480 V 50 Hz

Power [kW (hp)]

Drive input current continuous [A]

Default switching frequency [kHz]

THDi level [%]

Order number filter IP00

Code number filter IP20

22 (30)

41.546

130B1274

130B1111

30 (40)

5746

130B1275

130B1176

37 (50)

7049

130B1291

130B1201

VLT® Flow Drive FC 111

Design Guide

Selection and Ordering

For IP20 units, LCP is ordered separately.

4.3.2 Harmonic Filters

Table 26: AHF Filters (5% Current Distortion)

Table 27: AHF Filters (10% Current Distortion)

45 (60)

8439

130B1291

130B1201

55 (74)

10339

130B1292

130B1204

75 (100)

14038

130B1294

130B1213

90 (120)

17638

130B1294

130B1213

3x440–480 V 60 Hz

Power [kW (hp)]

Drive input current Continuous [A]

Default switching frequency [kHz]

THDi level [%]

Order number filter IP00

Code number filter IP20

22 (30)

34.643

130B1792

130B1757

30 (40)

4943

130B1793

130B1758

37 (50)

6143

130B1794

130B1759

45 (60)

7334

130B1795

130B1760

55 (74)

8934

130B1796

130B1761

75 (100)

12135

130B1797

130B1762

90 (120)

14335

130B1798

130B1763

3x440–480 V 60 Hz

Power [kW (hp)]

Drive input current continuous [A]

Default switching frequency [kHz]

THDi level [%]

Order number filter IP00

Code number filter IP20

22 (30)

34.646

130B1775

130B1487

30 (40)

4948

130B1776

130B1488

37 (50)

6147

130B1777

130B1491

45 (60)

7339

130B1778

130B1492

55 (74)

8938

130B1779

130B1493

75 (100)

12139

130B1780

130B1494

90 (120)

143310

130B1781

130B1495

Power [kW (hp)] Size 380– 480 V

TypeABCDEFGHIJKL1

Torque [Nm (inlb)]

Weight [kg (lb)]

Ordering Number

VLT® Flow Drive FC 111

Design Guide

Table 28: AHF Filters (5% Current Distortion)

Selection and Ordering

Table 29: AHF Filters (10% Current Distortion)

4.3.3 External RFI Filter

With external filters listed in the following table, the maximum shielded cable length of 50 m (164 ft) according to EN/IEC 61800-3 C2 (EN 55011 A1), or 20 m (65.6 ft) according to EN/IEC 61800-3 C1(EN 55011 B) can be achieved.

Table 30: RFI Filters - Details

0.37–

2.2 (0.5–

3.0)

FN3258-7-45

1904070

160

180204.5110.6M520310.7–0.8 (6.2–

7.1)

0.5 (1.1)

132B0244

3.0–7.5 (4.0–10)

FN3258-16-45

2504570

220

235254.5110.6M522.5310.7–0.8 (6.2–

7.1)

0.8 (1.8)

132B0245

11–15 (15–20)

FN3258-30-47

2705085

240

255305.4110.6M525401.9–2.2 (16.8–

19.5)

1.2 (2.6)

132B0246

18.5–22 (25–30)

FN3258-42-47

3105085

280

295305.4110.6M525401.9–2.2 (16.8–

19.5)

1.4 (3.1)

132B0247

e30bc247.10

VLT® Flow Drive FC 111

Design Guide

Selection and Ordering

Illustration 39: RFI Filter - Dimensions

e30bf984.10

Enclosure Size

H1H2H3

IP class

IP20

Power [kW (hp)]

3x380–480 V

0.37–1.5 (0.5–2.0)

2.2–4.0 (3.0–5.0)

5.5–7.5 (7.5–10)

11–15 (15–20)

Height [mm (in)]

195 (7.7)

227 (8.9)

255 (10.0)

296 (11.7)

(1)

273 (10.7)

303 (11.9)

329 (13.0)

359 (14.1)

183 (7.2)

212 (8.3)

240 (9.4)

275 (10.8)

Width [mm (in)]

75 (3.0)

90 (3.5)

100 (3.9)

135 (5.3)

56 (2.2)

65 (2.6)

74 (2.9)

105 (4.1)

Depth [mm (in)]

168 (6.6)

190 (7.5)

206 (8.1)

241 (9.5)

Mounting hole [mm (in)]

9 (0.35)

11 (0.43)

12.6 (0.50)

4.5 (0.18)

5.5 (0.22)

7 (0.28)

5.3 (0.21)

7.4 (0.29)

8.1 (0.32)

8.4 (0.33)

Maximum weight kg (lb)

2.1 (4.6)

3.4 (7.5)

4.5 (9.9)

7.9 (17.4)

Enclosure Size

H5H6H7

IP class

IP20

Power [kW (hp)]

3x380–480 V

18.5–22 (25–30)

30–45 (40–60)

55–75 (70–100)

90 (125)

Height [mm (in)]

334 (13.1)

518 (20.4)

550 (21.7)

660 (26)

(1)

402 (15.8)

595 (23.4)/635 (25), 45 kW

630 (24.8)/690 (27.2), 75 kW

800 (31.5)

VLT® Flow Drive FC 111

Design Guide

5 Mechanical Installation Considerations

5.1 Power Ratings, Weights, and Dimensions

Illustration 40: Dimensions, Enclosure Sizes H1–H8

Mechanical Installation

Considerations

Table 31: Power Ratings, Weights, and Dimensions, Enclosure Sizes H1–H4

Including decoupling plate.

Table 32: Power Ratings, Weights, and Dimensions H6–H8

Enclosure Size

H5H6H7

H8a314 (12.4)

495 (19.5)

521 (20.5)

631 (24.8)

Width [mm (in)]

150 (5.9)

239 (9.4)

313 (12.3)

375 (14.8)

120 (4.7)

200 (7.9)

270 (10.6)

330 (13)

Depth [mm (in)]

255 (10)

242 (9.5)

335 (13.2)

Mounting hole [mm (in)]

12.6 (0.50)

–––e7 (0.28)

8.5 (0.33)

15 (0.6)

17 (0.67)

Maximum weight kg (lb)

9.5 (20.9)

24.5 (54)

36 (79)

51 (112)

e30bu775.10

b D

(1) (2)

(3)

Front view

Side view

Back view

VLT® Flow Drive FC 111

Design Guide

Including decoupling plate.

Mechanical Installation

Considerations

Illustration 41: Dimensions, Enclosure Sizes H13–H14

Enclosure Size

H13

H14

IP class

IP20

Power [kW (hp)]

3x380–480 V

110–160 (150–250)

200–315 (300–450)

Height [mm (in)]

889 (35.0)

1096 (43.1)

(1)

909 (35.8)

1122 (44.2)

844 (33.2)

1051 (41.4)

Width [mm (in)]

250 (9.8)

350 (13.8)

180 (7.1)

280 (11.0)

200 (7.9)

271 (10.7)

Depth [mm (in)]

375 (14.8)

Mounting hole [mm (in)]

11 (0.4)

Center of gravity [mm (in)]

128 (5.0)

176 (6.9)

495 (19.5)

611 (24.1)

148 (5.8)

Maximum weight kg (lb)

98 (216)

164 (362)

Power [kW (hp)]

Clearance above/below [mm (in)]

Size

IP class

3x380–480 V

IP20

0.37–1.5 (0.5–2.0)

100 (4)

IP20

2.2–4.0 (3.0–5.4)

100 (4)

IP20

5.5–7.5 (7.5–10)

100 (4)

IP20

11–15 (15–20)

100 (4)

IP20

18.5–22 (25–30)

100 (4)

IP20

30–45 (40–60)

200 (7.9)

IP20

55–75 (70–100)

200 (7.9)

IP20

90 (125)

225 (8.9)

VLT® Flow Drive FC 111

Design Guide

Table 33: Power Ratings, Weights, and Dimensions H13–H14

Mechanical Installation

Considerations

Including decoupling plate.

The dimensions are only for the physical units.

5.2 Mechanical Installation H1-H8

5.2.1 Side-by-side Installation

The drive can be mounted side by side but requires the clearance above and below for cooling.

Table 34: Clearance Required for Cooling

VLT® Flow Drive FC 111

Design Guide

N O T I C E

With IP21 option kit mounted, a distance of 50 mm (2 in) between the units is required.

5.3 Mechanical Installation H13-H14

5.3.1 Tools Needed

Receiving/unloading

•

I-beam and hooks rated to lift the weight of the drive. Refer to 5.1 Power Ratings, Weights, and Dimensions.

•

Crane or other lifting aid to place the unit into position.

Installation

•

Drill with a 12 mm (1/2 in) drill bit.

•

Tape measurer.

•

Phillips and flat bladed screwdrivers.

•

Wrench with 7–17 mm metric sockets.

•

Wrench extensions.

•

T25 and T50 Torx drives.

•

Sheet metal punch and/or pliers for cable entry plate.

Mechanical Installation

Considerations

5.3.2 Installation and Cooling Requirements

N O T I C E

OVERHEATING

Improper mounting can result in overheating and reduced performance.

Install the drive according to the installation and cooling requirements.

Installation requirements

•

Ensure drive stability by mounting the drive vertically to a solid flat surface.

•

Ensure that the strength of the mounting location supports the drive weight. Ensure that the mounting location allows access to open the enclosure door. Refer to 5.1 Power Ratings, Weights, and Dimensions.

•

Ensure that there is enough space around the drive for cooling airflow.

•

Place the drive as near to the motor as possible. Keep the motor cables as short as possible. See 9.2.4 Cable Length and Cross-

section.

•

Ensure that the location allows for cable entry at the bottom of the drive.

Cooling and airflow requirements

•

Ensure that top and bottom clearance for air cooling is provided. Clearance requirement: 225 mm (9 in).

•

Consider derating for temperatures starting between 45 °C (113 °F) and 50 °C (122 °F) and elevation 1000 m (3300 ft) above sea level. See chapter Derating for detailed information.

The drive uses back-channel cooling to circulate the heat sink cooling air. The cooling duct carries approximately 90% of the heat out of the back channel of the drive. Redirect the back-channel air from the panel or room by using:

•

Duct cooling. Back-channel cooling kits are available to direct the air away from the panel when an IP20/chassis drive is installed in a Rittal enclosure. Use of a kit reduces the heat in the panel and smaller door fans can be specified on the enclosure.

•

Cooling out the back (top and base covers). The back-channel cooling air can be ventilated out of the room so that the heat from the back channel is not dissipated into the control room.

N O T I C E

One or more door fans are required on the enclosure to remove heat not contained in the back channel of the drive. The fans also

remove any additional losses generated by other components inside the drive.

Enclosure size

Door fan/top fan

Heat sink fan

H13

102 m3/hr (60 CFM)

420 m3/hr (250 CFM)

H14

204 m3/hr (120 CFM)

840 m3/hr (500 CFM)

e30bg512.11

65° min

VLT® Flow Drive FC 111

Mechanical Installation

Design Guide

Ensure that the fans supply adequate airflow over the heat sink. To select the appropriate number of fans, calculate the total required airflow. The flow rate is shown in the following table.

Table 35: Airflow

Considerations

5.3.3 Lifting the Drive

W A R N I N G

HEAVY LOAD

Unbalanced loads can fall or tip over. Failure to take proper lifting precautions increases risk of death, serious injury, or equip-

ment damage.

Move the unit using a hoist, crane, forklift, or other lifting device with the appropriate weight rating. See 5.1 Power Ratings,

Weights, and Dimensions for the weight of the drive.

Failure to locate the center of gravity and correctly position the load can cause unexpected shifting during lifting and trans-

port. For measurements and center of gravity, see 5.1 Power Ratings, Weights, and Dimensions.

The angle from the top of the drive module to the lifting cables affects the maximum load force on the cable. This angle

must be 65° or greater. Refer to the following illustration. Attach and dimension the lifting cables properly.

Never walk under suspended loads.

To guard against injury, wear personal protective equipment such as gloves, safety glasses, and safety shoes.

Always lift the drive using the dedicated eye bolts at the top of the drive. See the following illustration.

Illustration 42: Lifting the Drive

e30bg288.10

Top mounting holes

Lower fastener slots

VLT® Flow Drive FC 111

Mechanical Installation

Design Guide

Considerations

5.3.4 Wall Mounting the Drive

H13 and H14 are chassis drives intended to be mounted on a wall or on a mounting plate within an enclosure. To wall mount the drive, use the following steps.

Procedure

Fasten 2 M10 bolts in the wall to align with the fastener slots at the bottom of drive.

Slide the lower fastener slots in the drive over the M10 bolts.

Tip the drive against the wall, and secure the top with 2 M10 bolts in the mounting holes.

Example

Illustration 43: Drive-to-wall Mounting Holes

e30bf662.10

Plastic tabs

Tabs removed for cable access

e30bg823.10

225 mm (8.9 in)

VLT® Flow Drive FC 111

Mechanical Installation

Design Guide

Considerations

5.3.5 Creating Cable Openings

After installing the drive, create cable openings in the gland plate to accommodate the mains and motor cables. The gland plate is required to maintain the drive protection rating.

Procedure

Punch out plastic tabs to accommodate the cables.

Illustration 44: Cable Openings in Plastic Gland Plate

5.3.6 Back-channel Cooling

A unique back-channel duct passes cooling air over the heat sinks with minimal air passing through the electronics area. There is an IP54/Type 12 seal between the back-channel cooling duct and the electronics area of the VLT® drive. This back-channel cooling allows 90% of the heat losses to be exhausted directly outside the enclosure. This design improves reliability and prolongs component life by dramatically reducing interior temperatures and contamination of the electronic components. Different back-channel cooling kits are available to redirect the airflow based on individual needs.

5.3.6.1 Airflow for H13 & H14 Enclosures

Illustration 45: Standard Airflow Configuration for Enclosures H13 and H14

VLT® Flow Drive FC 111

Mechanical Installation

Design Guide

Considerations

5.4 Derating

5.4.1 Manual Derating and Automatic Derating

Derating is a method used to reduce output current to avoid tripping the drive when high temperatures are reached within the enclosure. If certain extreme operating conditions are expected, a higher-powered drive can be selected to eliminate the need for derating. This is called manual derating. Otherwise, the drive automatically derates the output current to eliminate the excessive heat generated by extreme conditions.

Manual derating

When the following conditions are present, Danfoss recommends selecting a drive 1 power size higher (for example P132 instead of P110):

•

Low-speed – continuous operation at low RPM in constant torque applications.

•

Low air pressure – operating at altitudes above 1000 m (3281 ft).

•

High ambient temperature – operating at ambient temperatures of 10 °C (50 °F).

•

High switching frequency.

•

Long motor cables.

•

Cables with a large cross-section.

Automatic derating

If the following operating conditions are found, the drive automatically changes switching frequency or switching pattern (PWM to SFAVM) to reduce excessive heat within the enclosure:

•

High temperature on the control card or heat sink.

•

High motor load or low motor speed.

•

High DC-link voltage.

5.4.2 Derating for Low-speed Operation

When a motor is connected to a drive, it is necessary to ensure that the cooling of the motor is adequate. The level of cooling required depends on the following:

•

Load on the motor.

•

Operating speed.

•

Length of operating time.

Constant torque applications (CT mode)

In a constant torque application, a motor may overheat at low speeds because the fan within the motor is providing less cooling air. Therefore, if the motor is to be run continuously at an RPM value lower than half of the rated value, the motor must be supplied

with extra air cooling. If extra air cooling is not available, use a motor designed for low RPM/constant torque applications, or select a larger motor to reduce the load level.

Variable (quadratic) torque applications (VT)

In variable torque applications where the torque is proportional to the square of the speed and the power is proportional to the cube of the speed, there is no need for extra cooling or derating of the motor. Common variable torque applications are centrifugal pumps and fans.

5.4.3 Derating for Low Air Pressure and High Altitudes

The cooling capability of air is decreased at low air pressure. For altitudes above 2000 m (6562 ft), contact Danfoss regarding PELV. Below 1000 m (3281 ft) altitude, derating is not necessary. For altitudes above 1000 m (3281 ft), decrease the ambient temperature or the maximum output current. Decrease the output by 1% per 100 m (328 ft) altitude above 1000 m (3281 ft) or reduce the maximum ambient cooling air temperature by 1 °C (1.8 °F) per 200 m (656 ft).

5.4.4 Derating for Ambient Temperature and Switching Frequency

Ensure that the ambient temperature measured over 24 hours is at least 5 °C (9 °F) lower than the maximum ambient temperature that is specified for the drive. If the drive is operated at a high ambient temperature, decrease the constant output current.

N O T I C E

FACTORY DERATING

Danfoss drives have already derated for operational temperature (55 °C (131 °F) T

and 50 °C (122 °F) T

AMB,MAX

AMB,AVG

e30bc218.11

fsw[kHz]

20 10

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

Iout[%]

165

40 C 104 F

。。

45 C 113 F

。。

50 C 122 F

。。

0.37–1.5 kW (0.5–2.0 hp), 400 V, Enclosure Size H1, IP20

e30bc220.11

fsw[kHz]

20 10

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

out[%]

165

40 C 104 F

。。

45 C 113 F

。。

50 C 122 F

。。

2.2–4.0 kW (3.0–5.4 hp), 400 V, Enclosure Size H2, IP20

e30bc222.11

fsw[kHz]

20 10

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110 %

out[%]

165

40 C 104 F

。。

45 C 113 F

。。

50 C 122 F

。。

5.5–7.5 kW (7.4–10 hp), 400 V, Enclosure Size H3, IP20

e30bc224.10

fsw[kHz]

20 10

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

out[%]

40 C 104 F

。。

45 C 113 F

。。

50 C 122 F

。。

11–15 kW (15–20 hp), 400 V, Enclosure Size H4, IP20

e30bc226.10

fsw[kHz]

20 10

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

out[%]

40 C 104 F

。。

50 C 122 F

。。

45 C 113 F

。。

18.5–22 kW (25–30 hp), 400 V, Enclosure Size H5, IP20

e30bc228.10

Iout [%]

fsw [

kHz

]

20%

2 4 6 8 10 12

40%

60%

80%

100%

110%

40 C 104 F

。。

50 C 122 F

。。

45 C 113 F

。。

30–37 kW (40–50 hp), 400 V, Enclosure Size H6, IP20

VLT® Flow Drive FC 111

Mechanical Installation

Design Guide

Use the following graphs to determine if the output current must be derated based on switching frequency and ambient temperature. When referring to the graphs, I

indicates the percentage of rated output current, and fsw indicates the switching frequency.

out

Considerations

e30bc229.10

40 C 104 F

。。

50 C 122 F

。。

45 C 113 F

。。

Iout [%]

fsw [kHz]

20%

2 4 6 8 10 12

40%

60%

80%

100%

110%

45 kW (60 hp), 400 V, Enclosure Size H6, IP20

e30bc232.10

Iout [%]

fsw [kHz]

20%

2 4 6 8 10 12

40%

60%

80%

100%

110%

40 C 104 F

。。

50 C 122 F

。。

45 C 113 F

。。

55–75 kW (74–100 hp), 400 V, Enclosure Size H7, IP20

e30bc235.10

Iout [%]

fsw [ kHz]

20 %

2 4 6 8 10 12

40 %

60 %

80 %

100 %

110 %

40 C 104 F

。。

50 C 122 F

。。

45 C 113 F

。。

90 kW (120 hp), 400 V, Enclosure Size H8, IP20

e30bx474.11

100

110

2 3 4 5 6 7 8 90

Iout [%]

fsw

[kHz]

45 ˚C (113 ˚F) 50 ˚C (122 ˚F)

55 ˚C (131 ˚F)

110–315 kW (150–450 hp), 400 V, Enclosure Size H13–H14, IP20, Switching Pattern 60 AVM

e30bx476.11

Iout [%]

fsw

[kHz]

100

110

2 4

40 ˚C (104 ˚F) 45 ˚C (113 ˚F)

50 ˚C (122 ˚F) 55 ˚C (131 ˚F)

110–315 kW (150–450 hp), 400 V, Enclosure Size H13–H14, IP20, Switching Pattern SFAVM

VLT® Flow Drive FC 111

Design Guide

Mechanical Installation

Considerations

VLT® Flow Drive FC 111

Electrical Installation

Design Guide

Considerations

6 Electrical Installation Considerations

6.1 Safety Instructions

See chapter Safety for general safety instructions.

W A R N I N G

INDUCED VOLTAGE

Induced voltage from output motor cables from different drives that are run together can charge equipment capacitors even

with the equipment turned off and locked out. Failure to run output motor cables separately or use shielded cables could result

in death or serious injury.

Run output motor cables separately or use shielded cables.

Simultaneously lock out all the drives.

W A R N I N G

SHOCK HAZARD

The drive can cause a DC current in the ground conductor and thus result in death or serious injury. Failure to follow the recom-

mendation means that the residual current-operated protective device (RCD) cannot provide the intended protection.

When a residual current-operated protective device (RCD) is used for protection against electrical shock, only an RCD of Type

B is allowed on the supply side.

Overcurrent protection

•

Additional protective equipment such as short-circuit protection or motor thermal protection between drive and motor is required for applications with multiple motors.

•

Input fusing is required to provide short circuit and overcurrent protection. If fuses are not factory-supplied, the installer must provide them. See maximum fuse ratings in chapter Fuses and Circuit Breakers.

Wire type and ratings

•

All wiring must comply with local and national regulations regarding cross-section and ambient temperature requirements.

•

Power connection wire recommendation: Minimum 75 °C (167 °F) rated copper wire.

See 9.2.4 Cable Length and Cross-section for recommended wire sizes and types.

L1 L2 L3

3-phase power input

+10 V DC

0-10 V DC-

50 (+10 V OUT)

54 (A IN)

53 (A IN)

55 (COM A IN/OUT)

0/4-20 mA

42 0/4-20 mA A OUT / D OUT

45 0/4-20 mA A OUT / D OUT

18 (D IN)

19 (D IN)

27 (D IN/OUT)

29 (D IN/OUT)

12 (+24 V OUT)

24 V (NPN)

20 (COM D IN)

O V (PNP)

24 V (NPN) O V (PNP)

Bus ter.

RS485 Interface

RS485

(N RS485) 69

(P RS485) 68

(Com RS485 ) 61

(PNP)-Source (NPN)-Sink

ON=Terminated

OFF=Unterminated

1 2

240 V AC 3 A

Not present on all power sizes

Do not connect shield to 61

relay 1

relay 2

UDC+

UDC-

Motor

U V

e30bd467.12

240 V AC 3 A

VLT® Flow Drive FC 111

Design Guide

6.2 Electrical Wiring

Electrical Installation

Considerations

Illustration 46: Basic Wiring Schematic Drawing

N O T I C E

There is no access to UDC- and UDC+ on the following units:

IP20, 380–480 V, 30–315 kW (40–450 hp)

6.3 EMC-compliant Electrical Installation

To ensure EMC-correct electrical installation, observe the following:

•

Use only shielded/armored motor cables and shielded/armored control cables.

•

Ground the shield at both ends.

•

Avoid installation with twisted shield ends (pigtails), because it reduces the shielding effect at high frequencies. Use the cable clamps provided.

•

Ensure the same potential between the drive and the ground potential of PLC.

•

Use star washers and galvanically conductive installation plates.

Com.

Warn.

Alarm

Hand

Reset

Auto

Status Quick

Main Menu

Minimum 16 mm

equalizing cable

Control cables

All cable entries in

one side of the panel

Grounding rail

Cable insulation stripped

Output contactor

Motor cable

Motor, 3 phases and

PLC

Panel

Mains-supply

Minimum 200 mm (7.87 in) between control cable, mains cable, and between mains motor cable

PLC

protective earth

Reinforced protective earth

e30bb761.13

(6 AWG)

VLT® Flow Drive FC 111

Design Guide

Electrical Installation

Considerations

Illustration 47: EMC-compliant Installation

e30bb634.10

-DC

+DC

AINS

Mains

Ground

Motor

Relays

VLT® Flow Drive FC 111

Design Guide

6.4 Relays and Terminals

6.4.1 Relays and Terminals on Enclosure Sizes H1–H5

Electrical Installation

Considerations

Illustration 48: Enclosure Sizes H1–H5 IP20, 380–480 V, 0.37–22 kW (0.5–30 hp)

L1 91 / L2 92 / L3 93

U 96 /

V 97 /

W 98

03 02 01

06 05 04

e30bb762.11

Mains

Motor

Ground

Relays

e30bb763.10

VLT® Flow Drive FC 111

Design Guide

6.4.2 Relays and Terminals on Enclosure Size H6

Electrical Installation

Considerations

Illustration 49: Enclosure Size H6 IP20, 380–480 V, 30–45 kW (40–60 hp)

6.4.3 Relays and Terminals on Enclosure Size H7

Illustration 50: Enclosure Size H7 IP20, 380–480 V, 55–75 kW (70–100 hp)

Mains

Relays

Ground

Motor

91 L1

e30bb764.10

Mains

Relays

Ground

Motor

VLT® Flow Drive FC 111

Design Guide

6.4.4 Relays and Terminals on Enclosure Size H8

Electrical Installation

Considerations

Illustration 51: Enclosure Size H8 IP20, 380–480 V, 90 kW (125 hp)

e30bu777 .10

Mains

Motor

Ground

VLT® Flow Drive FC 111

Design Guide

6.4.5 Relays and Terminals on Enclosure Size H13–H14

Electrical Installation

Considerations

Illustration 52: Enclosure Size H13–H14 IP20, 380–480 V, 110–315 kW (150–450 hp)

See 6.5 View of Control Shelf for the relay terminals of H13–H14 drives.

6.5 View of Control Shelf

The control shelf of H13-H14 drives holds the keypad, known as the local control panel or LCP. The control shelf also includes the control terminals, relays, and various connectors.

e30bu776.10

LCP connector

RS485 termination switch

RS485 fieldbus connector

Analog I/O connector

Digital I/O and 24 V supply

Relay 1 on power card

Relay 2 on power card

Power [kW (hp)]

Torque [Nm (in-lb)]

Enclosure size

IP class

3x380–480 V

Mains

Motor

DC connection

Control terminals

Ground

Relay

IP20

0.37–1.5 (0.5–2.0)

0.8 (7)

0.5 (4)

0.8 (7)

0.5 (4)

IP20

2.2–4.0 (3.0–5.4)

0.8 (7)

0.5 (4)

0.8 (7)

0.5 (4)

IP20

5.5–7.5 (7.5–10)

0.8 (7)

0.5 (4)

0.8 (7)

0.5 (4)

IP20

11–15 (15–20)

1.2 (11)

0.5 (4)

0.8 (7)

0.5 (4)

IP20

18.5–22 (25–30)

1.2 (11)

0.5 (4)

0.8 (7)

0.5 (4)

IP20

30–45 (40–60)

4.5 (40)

–

0.5 (4)

3 (27)

0.5 (4)

VLT® Flow Drive FC 111

Design Guide

Electrical Installation

Considerations

Illustration 53: View of Control Shelf in H13–H14

6.6 Fastener Tightening Torques

Apply the correct torque when tightening fasteners in the locations that are listed in the following tables. Too low or too high torque when fastening an electrical connection results in a bad electrical connection. To ensure correct torque, use a torque wrench.

Table 36: Tightening Torques for Enclosure Sizes H1–H8, 3x380–480 V

Power [kW (hp)]

Torque [Nm (in-lb)]

IP20

55 (70)

10 (89)

–

0.5 (4)

3 (27)

0.5 (4)

IP20

75 (100)

14 (124)

–

0.5 (4)

3 (27)

0.5 (4)

IP20

90 (125)

24 (212)

(1)

24 (212)

(1)

–

0.5 (4)

3 (27)

0.5 (4)

Location

Bolt size

Torque [Nm (in-lb)]

Mains terminals

M10/M12

19 (168)/37 (335)

Motor terminals

M10/M12

19 (168)/37 (335)

Ground terminals

M8/M10

9.6 (84)/19.1 (169)

Relay terminals

–

0.5 (4)

Door/panel cover

2.3 (20)

Gland plate

2.3 (20)

e30bb612.10

EMC screw

VLT® Flow Drive FC 111

Design Guide

Cable dimensions >95 mm2.

Table 37: Tightening Torques for Enclosure Sizes H13–H14, 3x380–480 V

Electrical Installation

Considerations

6.7 IT Mains

C A U T I O N

IT MAINS

Installation on isolated mains source, that is, IT mains.

Ensure that the supply voltage does not exceed 440 V (3x380–480 V units) when connected to mains.

For 380–480 V, IP20, 0.37–22 kW (0.5–30 hp) units, open the RFI switch by removing the screw on the side of the drive when at IT grid.

Illustration 54: IP20, 0.37–22 kW (0.5–30 hp), 380–480 V

If reinserted, use only M3x12 screw.

For 380–480 V, 30–90 kW (40–125 hp) units, set parameter 14-50 RFI Filter to [0] Off when operating in IT mains. For 380–480 V, 110–315 kW (150–450 hp) units, if the drive is supplied from an isolated mains source (IT mains, floating delta, or

grounded delta) or TT/TN-S mains with grounded leg, the RFI switch is recommended to be turned off via parameter 14-50 RFI Filter

N O T I C E

VLT® Flow Drive FC 111

Electrical Installation

Design Guide

on the drive and parameter 14-50 RFI Filter on the filter. For more detail, see IEC 364-3. In the [Off] position, the filter capacitors between the chassis and the DC link are cut off to avoid damage to the DC link and to reduce the ground capacity currents, according to IEC 61800-3.

If optimum EMC performance is needed, or parallel motors are connected, or the motor cable length is above 25 m (82 ft), Danfoss recommends setting parameter 14-50 RFI Filter to [On]. It is important to use isolation monitors that are rated for use together with power electronics (IEC 61557-8).

Considerations

6.8 Mains and Motor Connection

6.8.1 Introduction

The drive is designed to operate all standard 3-phase asynchronous motors.

Use a shielded/armored motor cable to comply with EMC emission specifications and connect this cable to both the decoupling

• plate and the motor.

Keep the motor cable as short as possible to reduce the noise level and leakage currents.

•

For further details on mounting the decoupling plate, see the Decoupling Plate Mounting Instructions.

Also see EMC-Correct Installation in the

•

6.3 EMC-compliant Electrical Installation.

6.8.2 Connecting to the Ground

W A R N I N G

LEAKAGE CURRENT HAZARD

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

Ensure that the minimum size of the ground conductor complies with the local safety regulations for high touch current

equipment.

For electrical safety:

•

Ground the drive in accordance with applicable standards and directives.

•

Use a dedicated ground wire for input power, motor power, and control wiring.

•

Do not ground 1 drive to another in a daisy chain fashion.

•

Keep the ground wire connections as short as possible.

•

Follow motor manufacturer wiring requirements.

•

Minimum cable cross-section: 10 mm2 (8 AWG) Cu or 16 mm2 (6 AWG) Al (or 2 rated ground wires terminated separately).

•

Tighten the terminals in accordance with the information provided in 6.6 Fastener Tightening Torques.

For EMC-compliant installation

•

Establish electrical contact between the cable shield and the drive enclosure by using metal cable glands or by using the clamps provided on the equipment.

•

Reduce burst transient by using high-strand wire.

•

Do not use twisted shield ends (pigtails).

N O T I C E

POTENTIAL EQUALIZATION

There is a risk of burst transient when the ground potential between the drive and the control system is different.

Install equalizing cables between the system components. Recommended cable cross-section: 16 mm2 (6 AWG).

VLT® Flow Drive FC 111

Electrical Installation

Design Guide

Considerations

6.8.3 Connecting the Motor

W A R N I N G

INDUCED VOLTAGE

Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned

off and locked out/tagged out. Failure to run output motor cables separately or to use shielded cables could result in death or

serious injury.

Run output motor cables separately or use shielded cables.

Simultaneously lock out/tag out all the drives.

•

Comply with local and national electrical codes for cable sizes. For maximum wire sizes, see 9.2.4 Cable Length and Cross-sec-

tion.

•

Follow motor manufacturer wiring requirements.

•

Motor wiring knockouts or access panels are provided at the base of IP21 (NEMA1/12) and higher units.

•

Do not wire a starting or pole-changing device (for example, Dahlander motor or slip ring asynchronous motor) between the drive and the motor.

Procedure

Strip a section of the outer cable insulation.

Position the stripped wire under the cable clamp, establishing mechanical fixation and electrical contact between the cable shield and ground.

Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions provided in

6.8.2 Connecting to the Ground.

Connect the 3-phase motor wiring to terminals U, V, and W.

Tighten the terminals in accordance with the information provided in 6.6 Fastener Tightening Torques.

6.8.4 Connecting the AC Mains

•

Size the wiring according to the input current of the drive. For maximum wire sizes, see 9.1.1 3x380–480 V AC.

•

Comply with local and national electrical codes for cable sizes.

Procedure

Strip a section of the outer cable insulation.

Position the stripped wire under the cable clamp, establishing mechanical fixation and electrical contact between the cable shield and ground.

Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions provided in

6.8.2 Connecting to the Ground.

For H1-H8 drives, connect the 3-phase AC input power wiring to terminals L1, L2, and L3.

For H13-H14 drives, connect the 3-phase AC input power wiring to terminals R, S, and T.

When supplied from an isolated mains source (IT mains or floating delta) or TT/TN-S mains with a grounded leg (grounded delta), ensure that parameter 14-50 RFI Filter is set to [0] Off to avoid damage to the DC link and to reduce ground capacity currents.

Tighten the terminals in accordance with the information provided in 6.6 Fastener Tightening Torques.

6.9 Fuses and Circuit Breakers

6.9.1 Branch Circuit Protection

To prevent fire hazards, protect the branch circuits in an installation, switch gear, machines, and so on, against short circuits and overcurrent. Follow national and local regulations.

6.9.2 Short-circuit Protection

Danfoss recommends using the fuses and circuit breakers listed in this chapter to protect service personnel or other equipment in case of an internal failure in the unit or a short circuit on the DC link. The drive provides full short-circuit protection in case of a short circuit on the motor.

3x380–480 V IP20 kW (hp)

Circuit breaker

Maximum fuse

0.37 (0.5)

–

gG-10

0.75 (1.0)

–

gG-10

1.5 (2.0)

–

gG-10

2.2 (3.0)

–

gG-16

3.0 (4.0)

–

gG-16

4.0 (5.4)

–

gG-16

5.5 (7.5)

–

gG-25

7.5 (10)

–

gG-25

11 (15)

–

gG-50

15 (20)

–

gG-50

18.5 (25)

–

gG-65

22 (30)

–

gG-65

30 (40)

Moeller NZMB1- A125

gG-80

37 (50)

Moeller NZMB1- A125

gG-100

45 (60)

Moeller NZMB1- A125

gG-125

55 (70)

Moeller NZMB1- A200

gG-150

75 (100)

Moeller NZMB1- A200

gG-200

90 (125)

Moeller NZMB2- A250

gG-250

110 (150)

–

aR-315

132 (175)

–

aR-350

160 (250)

–

aR-400

200 (300)

–

aR-500

250 (350)

–

aR-630

VLT® Flow Drive FC 111

Electrical Installation

Design Guide

Considerations

6.9.3 Overcurrent Protection

Provide overload protection to avoid overheating of the cables in the installation. Overcurrent protection must always be carried out according to local and national regulations. Design circuit breakers and fuses for protection in a circuit capable of supplying a maximum of 100000 A

(symmetrical), 480 V maximum.

rms

6.9.4 CE Compliance

To ensure compliance with IEC 61800-5-1, use the circuit breakers or fuses listed in this chapter. Circuit breakers must be designed for protection in a circuit capable of supplying a maximum of 10000 A

(symmetrical), 480 V maximum.

rms

6.9.5 Recommendation of Fuses and Circuit Breakers

N O T I C E

In the event of malfunction, failure to follow the protection recommendation may result in damage to the drive.

Table 38: Fuses and Circuit Breakers

315 (450)

–

aR-800

Model

Fuse Options

Bussman

Littelfuse

Bussman

Siba

Ferraz-Shawmut

Ferraz-Shawmut(Europe)

P110

170M2619

LA50QS300-4

L50S-300

FWH-300A

20 189 20.315

A50QS300-4

6,9URD31D08A0315

P132

170M2620

LA50QS350-4

L50S-350

FWH-350A

20 189 20.350

A50QS350-4

6,9URD31D08A0350

P160

170M2621

LA50QS400-4

L50S-400

FWH-400A

20 189 20.400

A50QS400-4

6,9URD31D08A0400

P200

170M4015

LA50QS500-4

L50S-500

FWH-500A

20 189 20.550

A50QS500-4

6,9URD31D08A0550

P250

170M4016

LA50QS600-4

L50S-600

FWH-600A

20 189 20.630

A50QS600-4

6,9URD31D08A0630

P315

170M4017

LA50QS800-4

L50S-800

FWH-800A

20 189 20.800

A50QS800-4

6,9URD32D08A0800

e30bd331.11

VLT® Flow Drive FC 111

Electrical Installation

Design Guide

Table 39: H13–H14 Power/semiconductor Fuse Options, 380–480 V

Considerations

6.10 Control Terminals

Remove the terminal cover (H1-H8) or the cradle cover (H13-H14) to access the control terminals.

H1-H8

Use a flat-edged screwdriver to push down the lock lever of the terminal cover under the LCP, then remove the terminal cover as shown in Illustration 55.

Illustration 55: Removing the Terminal Cover

H13-H14

Press the tips of the cradle cover inwards as shown in Illustration 56, and then lift the cradle cover up.

e30bu793.10

e30bf892.10

12 20 55

181927 29 42 54

45 50 53

DIGI IN

61 68 69

COMM. GND

+24 V

GND

10 V OUT

10 V/20 mA IN

0/4-20 mA A OUT/DIG OUT

BUS TER.

OFF ON

DIGI IN

0/4-20 mA A OUT/DIG OUT

10 V/20 mA IN

VLT® Flow Drive FC 111

Electrical Installation

Design Guide

Illustration 56: Removing the Cradle Cover

All the drive control terminals are shown in Illustration 57. Applying start (terminal 18), connection between terminals 12-27, and an analog reference (terminal 53 or 54, and 55) make the drive run.

The digital input mode of terminal 18, 19, and 27 is set in parameter 5-00 Digital Input Mode (PNP is default value). Digital input 29 mode is set in parameter 5-03 Digital Input 29 Mode (PNP is default value).

Considerations

Illustration 57: Control Terminals

6.11 Efficiency

6.11.1 Efficiency of the Drive

The load on the drive has little effect on its efficiency. In general, the efficiency is the same at the rated motor frequency f rule also applies even if the motor supplies 100% of the rated shaft torque or only 75%, for example if there is part loads.

This also means that the efficiency of the drive does not change even if other U/f characteristics are selected. However, the U/f characteristics influence the efficiency of the motor. The efficiency declines a little when the switching frequency is set to a value above the default value. If the mains voltage is 480 V,

or if the motor cable is longer than 30 m (98.4 ft), the efficiency is also slightly reduced. Calculate the efficiency of the drive (η

illustration by the specific efficiency factor listed in the specification tables.

) at different loads based on the following illustration. Multiply the factor in the following

VLT

M,N

. This

e30bb252.11

1.0

0.99

0.98

0.97

0.96

0.95

0.93

0.92 0%

50% 100% 200%

0.94

1.01

150%

% Speed

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

Relative Efficiency

Cable length [m (ft)]

AC line voltage [V]

Rise time [μsec]

peak

[kV]

dU/dt [kV/μsec]

400 V 0.37 kW (0.5 hp)

5 (16)

400

0.160

0.808

4.050

25 (82)

400

0.240

1.026

3.420

VLT® Flow Drive FC 111

Electrical Installation

Design Guide

Illustration 58: Typical Efficiency Curves

Considerations

6.11.2 Efficiency of the Motor

The efficiency of a motor (η with mains operation. The efficiency of the motor depends on the type of motor.

In the range of 75–100% of the rated torque, the efficiency of the motor is practically constant, both when controlled by the drive and when running directly on mains.

In small motors, the influence from the U/f characteristic on efficiency is marginal. However, in motors from 11 kW (15 hp) and up, the advantages are significant.

In general, the switching frequency does not affect the efficiency of small motors. Motors from 11 kW (15 hp) and up have their efficiency improved 1–2% because the sine shape of the motor current is almost perfect at high switching frequency.

) connected to the drive depends on the magnetizing level. In general, the efficiency is as good as

MOTOR

6.11.3 Efficiency of the System

To calculate the system efficiency (η

= η

SYSTEM

VLT

x η

MOTOR

), the efficiency of the drive (η

SYSTEM

) is multiplied by the efficiency of the motor (η

VLT

MOTOR

6.12 dU/dt Conditions

6.12.1 dU/dt Overview

N O T I C E

To avoid the premature aging of motors that are not designed to be used with drives, such as those motors without phase insula-

tion paper or other insulation reinforcement, Danfoss strongly recommends a dU/dt filter or a sine-wave filter fitted on the out-

put of the drive. For further information about dU/dt and sine-wave filters, see the Output Filters Design Guide.

When a transistor in the inverter bridge switches, the voltage across the motor increases by a dU/dt ratio depending on the motor cable (type, cross-section, length shielded or unshielded) and the inductance.

The natural induction causes an overshoot U in the intermediate circuit. The rise time and the peak voltage U phase coil insulation are affected if the peak voltage is too high. Motor cable length affects the rise time and peak voltage. If the motor cable is short (a few meters), the rise time and peak voltage are lower. If the motor cable is long (100 m (328 ft)), the rise time and peak voltage are higher.

Peak voltage on the motor terminals is caused by the switching of the IGBTs. The drive complies with the demands of IEC 60034-25:2007 edition 2.0 regarding motors designed to be controlled by drives. The drive also complies with IEC 60034-17:2006 edition 4 regarding Norm motors controlled by drives.

in the motor voltage before it stabilizes itself at a level depending on the voltage

PEAK

affect the service life of the motor. In particular, motors without

PEAK

6.12.2 dU/dt Test Results for H1–H8

Table 40: dU/dt Test Results for H1–H8

Cable length [m (ft)]

AC line voltage [V]

Rise time [μsec]

peak

[kV]

dU/dt [kV/μsec]

50 (164)

400

0.340

1.056

2.517

400 V 0.75 kW (1.0 hp)

5 (16)

400

0.160

0.808

4.050

25 (82)

400

0.240

1.026

3.420

50 (164)

400

0.340

1.056

2.517

400 V 1.5 kW (2.0 hp)

5 (16)

400

0.160

0.808

4.050

25 (82)

400

0.240

1.026

3.420

50 (164)

400

0.340

1.056

2.517

400 V 2.2 kW (3.0 hp)

5 (16)

400

0.190

0.760

3.200

25 (82)

400

0.293

1.026

2.801

50 (164)

400

0.422

1.040

1.971

400 V 3.0 kW (4.0 hp)

5 (16)

400

0.190

0.760

3.200

25 (82)

400

0.293

1.026

2.801

50 (164)

400

0.422

1.040

1.971

400 V 4.0 kW (5.4 hp)

5 (16)

400

0.190

0.760

3.200

25 (82)

400

0.293

1.026

2.801

50 (164)

400

0.422

1.040

1.971

400 V 5.5 kW (7.4 hp)

5 (16)

400

0.168

0.81

3.857

25 (82)

400

0.239

1.026

3.434

50 (164)

400

0.328

1.05

2.560

400 V 7.5 kW (10 hp)

5 (16)

400

0.168

0.81

3.857

25 (82)

400

0.239

1.026

3.434

50 (164)

400

0.328

1.05

2.560

400 V 11 kW (15 hp)

5 (16)

400

0.116

0.69

4.871

25 (82)

400

0.204

0.985

3.799

50 (164)

400

0.316

1.01

2.563

400 V 15 kW (20 hp)

5 (16)

400

0.139

0.864

4.955

50 (82)

400

0.338

1.008

2.365

400 V 18.5 kW (25 hp)

5 (16)

400

0.132

0.88

5.220

25 (82)

400

0.172

1.026

4.772

50 (164)

400

0.222

1.00

3.603

400 V 22 kW (30 hp)

5 (16)

400

0.132

0.88

5.220

25 (82)

400

0.172

1.026

4.772

VLT® Flow Drive FC 111

Design Guide

Electrical Installation

Considerations

Cable length [m (ft)]

AC line voltage [V]

Rise time [μsec]

peak

[kV]

dU/dt [kV/μsec]

50 (164)

400

0.222

1.00

3.603

400 V 30 kW (40 hp)

10 (33)

400

0.376

0.92

1.957

50 (164)

400

0.536

0.97

1.448

100 (328)

400

0.696

0.95

1.092

150 (492)

400

0.8

0.965

10 (33)

480

0.384

1.2

2.5

50 (164)

480

0.632

1.18

1.494

100 (328)

480

0.712

1.2

1.348

150 (492)

480

0.832

1.17

1.125

10 (33)

500

0.408

1.24

2.431

50 (164)

500

0.592

1.29

1.743

100 (328)

500

0.656

1.28

1.561

150 (492)

500

0.84

1.26

1.2

400 V 37 kW (50 hp)

10 (33)

400

0.276

0.928

2.69

50 (164)

400

0.432

1.02

1.889

10 (33)

480

0.272

1.17

3.441

50 (164)

480

0.384

1.21

2.521

10 (33)

500

0.288

1.2

3.333

50 (164)

500

0.384

1.27

2.646

400 V 45 kW (60 hp)

10 (33)

400

0.3

0.936

2.496

50 (164)

400

0.44

0.924

1.68

100 (328)

400

0.56

0.92

1.314

150 (492)

400

0.8

0.92

10 (33)

480

0.3

1.19

3.173

50 (164)

480

0.4

1.15

2.3

100 (328)

480

0.48

1.14

1.9

150 (492)

480

0.72

1.14

1.267

10 (33)

500

0.3

1.22

3.253

50 (164)

500

0.38

1.2

2.526

100 (328)

500

0.56

1.16

1.657

150 (492)

500

0.74

1.16

1.254

400 V 55 kW (74 hp)

10 (33) 400

0.46

1.12

1.948

VLT® Flow Drive FC 111

Design Guide

Electrical Installation

Considerations

Cable length [m (ft)]

AC line voltage [V]

Rise time [μsec]

peak

[kV]

dU/dt [kV/μsec]

480

0.468

1.3

2.222

400 V 75 kW (100 hp)

10 (33)

400

0.502

1.048

1.673

480

0.52

1.212

1.869

500

0.51

1.272

1.992

400 V 90 kW (120 hp)

10 (33)

400

0.402

1.108

2.155

400

0.408

1.288

2.529

400

0.424

1.368

2.585

Power size [kW (hp)]

Cable [m (ft)]

Mains voltage [V]

Rise time [μs]

Peak voltage [V]

dU/dt [V/μs]

90–160 (125–250)

30 (98)

500

0.71

1180

1339

150 (492)

500

0.76

1423

1497

300 (984)

500

0.91

1557

1370

200–315 (300–450)

30 (98)

500

1.10

1116

815

150 (492)

500

2.53

1028

321

300 (984)

500

1.29

835

517

Power size [kW (hp)]

Cable [m (ft)]

Mains voltage [V]

Rise time [μs]

Peak voltage [V]

dU/dt [V/μs]

90–160 (125–250)

30 (98)

500–––150 (492)

500

0.66

1418

1725

300 (984)

500

0.96

1530

1277

200–315 (300–450)

30 (98)

500–––150 (492)

500

0.56

1261

1820

300 (984)

500

0.78

1278

1295

VLT® Flow Drive FC 111

Electrical Installation

Design Guide

Considerations

6.12.3 High-power Range

The power sizes in the tables in 6.12.4 dU/dt Test Results for H13–H14 at the appropriate mains voltages comply with the requirements of IEC 60034-17:2006 edition 4 regarding normal motors controlled by drives, IEC 60034-25:2007 edition 2.0 regarding motors designed to be controlled by drives, and NEMA MG 1-1998 Part 31.4.4.2 for inverter-fed motors. The power sizes in the tables in

6.12.4 dU/dt Test Results for H13–H14 do not comply with NEMA MG 1-1998 Part 30.2.2.8 for general purpose motors.

6.12.4 dU/dt Test Results for H13–H14

Table 41: IEC dU/dt Test Results for H13–H14 with Unshielded Cables and No Output Filter, 380–480 V

Table 42: IEC dU/dt Test Results for H13–H14 with Shielded Cables and No Output Filter, 380–480 V

e30bu792.10

Com.

1-20 Motor Power [5] 0.37kW - 0.5HP Setup 1

13 14 15

Status

Main Menu

Quick Menu

Hand

Off

Reset

Auto

Alarm

Warn.

13 14 15

LCP 32 LCP 31

Parameter number and name.

Parameter value.

The setup number shows the active setup and the edit setup. For LCP 32, the setup number only shows in Status menu, the number outside brackets is active setup, and the number inside

brackets is edit setup. For example, 1(2) means 1 is the active setup, and 2 is the edit setup. For LCP 31, if the same setup acts as both active and edit setup, only that setup number is shown (factory setting). When the

active and the edit setup differ, both numbers are shown in the display (setup 12). The number flashing indicates the edit setup.

Motor direction is shown to the bottom left of the display – indicated by a small arrow pointing either clockwise or counterclockwise.

The triangle indicates if the LCP is in Status, Quick Menu, or Main Menu.

VLT® Flow Drive FC 111

Design Guide

7 Programming

7.1 Local Control Panel (LCP)

The LCP is divided into 4 functional sections.

•

A. Display

•

B. Menu key

•

C. Navigation keys and indicator lights

•

D. Operation keys and indicator lights

Programming

Illustration 59: Local Control Panel (LCP)

A. Display

The LCD-display is illuminated with 2 alphanumeric lines. All data is shown on the LCP. The Table 43 describes the information that can be read from the display.

Table 43: Legend to Section A, Illustration 3

B. Menu key

Press [Menu] to select among Status, Quick Menu, or Main Menu.

Com. (yellow indicator): Flashes during bus communication.

On (green indicator): Shows the power on status.

Warn. (yellow indicator): Indicates a warning.

Alarm (red indicator): Indicates an alarm.

[Back]: For moving to the previous step or layer in the navigation structure.

Up arrow key, down arrow key, and right arrow key: For navigating among parameter groups and parameters, and within parameters. They can also be used for setting local reference.

[OK]: For selecting a parameter and for accepting changes to parameter settings.

[Hand On]: Starts the motor and enables control of the drive via the LCP.

N O T I C E

[2] Coast inverse is the default option for parameter 5-12 Terminal 27 Digital Input. If there is no 24 V supply to terminal 27,

[Hand On] does not start the motor. Connect terminal 12 to terminal 27.

[Off/Reset]: Stops the compressor (Off). If in alarm mode, the alarm is reset.

[Auto On]: The drive is controlled either via control terminals or serial communication.

VLT® Flow Drive FC 111

Design Guide

C. Navigation keys and indicator lights

Table 44: Legend to Section C, Illustration 3

D. Operation keys and indicator lights

Table 45: Legend to Section D, Illustration 3

Programming

7.2 Menus

7.2.1 Status Menu

In the Status menu, the selection options are:

•

Motor frequency [Hz], parameter 16-13 Frequency.

•

Motor current [A], parameter 16-14 Motor current.

•

Motor speed reference in percentage [%], parameter 16-02 Reference [%].

•

Feedback, parameter 16-52 Feedback [Unit].

•

Motor power parameter 16-10 Power [kW] for kW, parameter 16-11 Power [hp] for hp. If parameter 0-03 Regional Settings is set to [1] North America, motor power is shown in hp instead of kW.

•

Custom readout, parameter 16-09 Custom Readout.

•

Motor Speed [RPM], parameter 16-17 Speed [RPM].

7.2.2 Quick Menu

7.2.2.1 Quick Menu Introduction

Use the Quick Menu to program the most common functions. The Quick Menu consists of:

Wizard for open-loop applications.

•

Wizard for closed-loop applications.

•

Motor set-up.

•

Changes made.

•

+24 V (OUT)

DIG IN DIG IN

COM DIG IN

A OUT / D OUT A OUT / D OUT

18 19

27 29

50 53 54

01 02 03

04 05 06

0–10 V

Start

+10 V (OUT) A IN A IN

COM IN/OUT

Reference

e30bb674.11

VLT® Flow Drive FC 111

Design Guide

Programming

7.2.2.2 Setup Wizard Introduction

The built-in wizard menu guides the installer through the setup of the drive in a clear and structured manner for open-loop and closed-loop applications, and for quick motor settings.

Illustration 60: Drive Wiring

The wizard can always be accessed again through the quick menu. Press [OK] to start the wizard. Press [Back] to return to the status view.

Power kW/50 H z

Motor Power

Motor Voltage

Motor Frequency

Motor Current

Motor nominal speed

Select Regional Settings

... the Wizard starts

200-240V/50Hz/Delta

Grid Type

Asynchronous motor

Asynchronous

Motor Type

Motor current

Motor nominal speed

Motor Cont. Rated Torque

Stator resistance

Motor poles

Back EMF at 1000 rpm

Motor type = IPM

Motor type = SPM

d-axis Inductance Sat. (LdSat)

[0]

3.8

3000

RPM

5.4

0.65

Ohms

Start Mode

Rotor Detection

[0]

Position Detection Gain

Off

100

Locked Rotor Detection

[0]

Locked Rotor Detection Time[s]

0.10

q-axis Inductance (Lq)

1.10

400

Max Output Frequency

Motor Cable Length

4.66

1420

RPM

[0]

PM motor

Set Motor Speed low Limit

Set Motor Speed high Limit

Set Ramp 1 ramp-up time

Set Ramp 1 ramp-down Time

Active Flying start ?

Disable

Set T53 low Voltage

Set T53 high Voltage

Set T53 Low Current

Set T53 High Current

Voltage

AMA Failed

Automatic Motor Adaption

Auto Motor Adapt OK Press OK

Select Function of Relay 2 No function

Off

Select Function of Relay 1 [0] No function

Set Max Reference

Set Min Reference

AMA running

-----

Do AMA

(Do not AMA)

AMA OK

[0]

Select T53 Mode

Current

Motor type = Asynchronous

Motor type = PM motor

0000

0050

0010

[0]

04.66

13.30

0050

0220

0000

0050

The next screen is the Wizard screen.

Power-up Screen

e30bu808.10

q-axis Inductance Sat. (LqSat)

Current at Min Inductance for d-axis

100

Current at Min Inductance for q-axis

100

d-axis Inductance (Lq)

... the Wizard starts

1 (1)

0.0 Hz

0.000 kW

Auto On

0-**: FC-xxx Wizard 1-**: Closed Loop Set 2-**: Motor Setup

VLT® Flow Drive FC 111

Design Guide

7.2.2.3 Setup Wizard for Open-loop Applications

Programming

Illustration 61: Setup Wizard for Open-loop Applications

•

Parameter

Option

Default

Usage

Parameter 0-03 Regional Settings

[0] International [1] US

[0] International

–

Parameter 0-06 GridType

[10] 380–440 V/50 Hz/IT-grid [11] 380–440 V/50 Hz/Delta [12] 380–440 V/50 Hz [20] 440–480 V/50 Hz/IT-grid [21] 440–480 V/50 Hz/Delta [22] 440–480 V/50 Hz [110] 380–440 V/60 Hz/IT-grid [111] 380–440 V/60 Hz/Delta [112] 380–440 V/60 Hz [120] 440–480 V/60 Hz/IT-grid [121] 440–480 V/60 Hz/Delta [122] 440–480 V/60 Hz

Size related

Select the operating mode for restart after reconnection of the drive to mains voltage after power down.

N O T I C E

Compared to 380–440 V groups, when selecting 440–

480 V groups, the rated current decreases accordingly.

Parameter 1-10 Motor Construction

*[0] Asynchron [1] PM, non-salient SPM [3] PM, salient IPM

[0] Asynchron

Setting the parameter value might change these parameters:

Parameter 1-01 Motor Control Principle.

Parameter 1-03 Torque Characteristics.

Parameter 1-08 Motor Control Bandwidth.

Parameter 1-14 Damping Gain.

Parameter 1-15 Low Speed Filter Time Const.

Parameter 1-16 High Speed Filter Time Const.

Parameter 1-17 Voltage Filter Time Const.

Parameter 1-20 Motor Power.

Parameter 1-22 Motor Voltage.

Parameter 1-23 Motor Frequency.

Parameter 1-24 Motor Current.

Parameter 1-25 Motor Nominal Speed.

Parameter 1-26 Motor Cont. Rated Torque.

Parameter 1-30 Stator Resistance (Rs).

Parameter 1-33 Stator Leakage Reactance (X1).

Parameter 1-35 Main Reactance (Xh).

Parameter 1-37 d-axis Inductance (Ld).

Parameter 1-38 q-axis Inductance (Lq).

Parameter 1-39 Motor Poles.

Parameter 1-40 Back EMF at 1000 RPM.

Parameter 1-44 d-axis Inductance Sat. (LdSat).

Parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-46 Position Detection Gain.

Parameter 1-48 Current at Min Inductance for d-axis.

Parameter 1-49 Current at Min Inductance for q-axis.

Parameter 1-66 Min. Current at Low Speed.

VLT® Flow Drive FC 111

Design Guide

Table 46: Setup Wizard for Open-loop Applications

Programming

•

Parameter

Option

Default

Usage

Parameter 1-70 PM Start Mode.

Parameter 1-72 Start Function.

Parameter 1-73 Flying Start.

Parameter 1-80 Function at Stop.

Parameter 1-82 Min Speed for Function at Stop [Hz].

Parameter 1-90 Motor Thermal Protection.

Parameter 2-00 DC Hold/Motor Preheat Current.

Parameter 2-01 DC Brake Current.

Parameter 2-02 DC Braking Time.

Parameter 2-04 DC Brake Cut In Speed.

Parameter 2-10 Brake Function.

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

Parameter 4-19 Max Output Frequency.

Parameter 4-58 Missing Motor Phase Function.

Parameter 14-65 Speed Derate Dead Time Compensation.

Parameter 1-20 Motor Power

0.18–110 kW/0.25–150 hp

Size related

Enter the motor power from the nameplate data.

Parameter 1-22 Motor Voltage

50–1000 V

Size related

Enter the motor voltage from the nameplate data.

Parameter 1-23 Motor Frequency

20–400 Hz

Size related

Enter the motor frequency from the nameplate data.

Parameter 1-24 Motor Current

0.01–1000.00 A

Size related

Enter the motor current from the nameplate data.

Parameter 1-25 Motor Nominal Speed

50–9999 RPM

Size related

Enter the motor nominal speed from the nameplate data.

Parameter 1-26 Motor Cont. Rated Torque

0.1–1000.0 Nm

Size related

This parameter is available when parameter 1-10 Motor Con- struction is set to options that enable permanent motor mode.

N O T I C E

Changing this parameter affects the settings of other pa-

rameters.

Parameter 1-29 Automatic Motor Adaption (AMA)

See parameter 1-29 Automatic Motor Adaption (AMA).

Off

Performing an AMA optimizes motor performance.

Parameter 1-30 Stator Resistance (Rs)

0.000–99.990 Ω

Size related

Set the stator resistance value.

Parameter 1-37 d-axis Inductance (Ld)

0.000–1000.000 mH

Size related

Enter the value of the d-axis inductance. Obtain the value from the permanent magnet motor datasheet.

VLT® Flow Drive FC 111

Design Guide

Programming

Parameter

Option

Default

Usage

Parameter 1-38 q-axis Inductance (Lq)

0.000–1000.000 mH

Size related

Enter the value of the q-axis inductance.

Parameter 1-39 Motor Poles

2–100

Enter the number of motor poles.

Parameter 1-40 Back EMF at 1000 RPM

10–9000 V

Size related

Line-line RMS back EMF voltage at 1000 RPM.

Parameter 1-42 Motor Cable Length

0–100 m

50 m

Enter the motor cable length.

Parameter 1-44 d-axis Inductance Sat. (LdSat)

0.000–1000.000 mH

Size related

This parameter corresponds to the inductance saturation of Ld. Ideally, this parameter has the same value as parameter 1-37 d-axis Inductance (Ld). However, if the motor supplier provides an induction curve, enter the induction value, which is 200% of the nominal current.

Parameter 1-45 q-axis Inductance Sat. (LqSat)

0.000–1000.000 mH

Size related

This parameter corresponds to the inductance saturation of Lq. Ideally, this parameter has the same value as parameter 1-38 q-axis Inductance (Lq). However, if the motor supplier provides an induction curve, enter the induction value, which is 200% of the nominal current.

Parameter 1-46 Position Detection Gain

20–200%

100%

Adjusts the height of the test pulse during position detection at start.

Parameter 1-48 Current at Min Inductance for d-axis

20–200%

100%

Enter the inductance saturation point.

Parameter 1-49 Current at Min Inductance for q-axis

20–200%

100%

This parameter specifies the saturation curve of the d- and qinductance values. From 20–100% of this parameter, the inductances are linearly approximated due to parameter 1-37

d-axis Inductance (Ld), parameter 1-38 q-axis Inductance (Lq), parameter 1-44 d-axis Inductance Sat. (LdSat), and parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-70 PM Start Mode

[0] Rotor Detection [1] Parking [3] Rotor Last Position

[1] Parking

Select the PM motor start mode.

Parameter 1-73 Flying Start

[0] Disabled [1] Enabled

[0] Disabled

Select [1] Enabled to enable the drive to catch a motor spinning due to mains drop-out. Select [0] Disabled if this function is not required. When this parameter is set to [1] Ena-

bled, parameter 1-71 Start Delay and parameter 1-72 Start Function are not functional. Parameter 1-73 Flying Start is ac-

tive in VVC+ mode only.

Parameter 3-02 Minimum Reference

-4999.000–4999.000

The minimum reference is the lowest value obtainable by summing all references.

Parameter 3-03 Maximum Reference

-4999.000–4999.000

The maximum reference is the lowest obtainable by summing all references.

VLT® Flow Drive FC 111

Design Guide

Programming

Parameter

Option

Default

Usage

Parameter 3-41 Ramp 1 Ramp Up Time

0.01–3600.00 s

Size related

If asynchronous motor is selected, the ramp-up time is from 0 to rated parameter 1-23 Motor Frequency. If PM motor is selected, the ramp-up time is from 0 to parameter 1-25 Motor

Nominal Speed.

Parameter 3-42 Ramp 1 Ramp Down Time

0.01–3600.00 s

Size related

For asynchronous motors, the ramp-down time is from rated parameter 1-23 Motor Frequency to 0. For PM motors, the ramp-down time is from parameter 1-25 Motor Nominal

Speed to 0.

Parameter 4-12 Motor Speed Low Limit [Hz]

0.0–400.0 Hz

0 Hz

Enter the minimum limit for low speed.

Parameter 4-14 Motor Speed High Limit [Hz]

0.0–400.0 Hz

100 Hz

Enter the maximum limit for high speed.

Parameter 4-19 Max Output Frequency

0.0–400.0 Hz

100 Hz

Enter the maximum output frequency value. If parameter 4-19 Max Output Frequency is set lower than parameter 4-14 Motor Speed High Limit [Hz], parameter 4-14 Motor Speed High Limit [Hz] is set equal to parameter 4-19 Max Output Frequency automatically.

Parameter 5-40 Function Relay

See parameter 5-40 Function Relay.

[9] Alarm

Select the function to control output relay 1.

Parameter 5-40 Function Relay

See parameter 5-40 Function Relay.

[5] Drive running

Select the function to control output relay 2.

Parameter 6-10 Terminal 53 Low Voltage

0.00–10.00 V

0.07 V

Enter the voltage that corresponds to the low reference value.

Parameter 6-11 Terminal 53 High Voltage

0.00–10.00 V

10 V

Enter the voltage that corresponds to the high reference value.

Parameter 6-12 Terminal 53 Low Current

0.00–20.00 mA

4 mA

Enter the current that corresponds to the low reference value.

Parameter 6-13 Terminal 53 High Current

0.00–20.00 mA

20 mA

Enter the current that corresponds to the high reference value.

Parameter 6-19 Terminal 53 mode

[0] Current [1] Voltage

[1] Voltage

Select if terminal 53 is used for current or voltage input.

Parameter 30-22 Locked Rotor Detection

[0] Off [1] On

[0] Off

–

Parameter 30-23 Locked Rotor Detection Time [s]

0.05–1 s

0.10 s

–

VLT® Flow Drive FC 111

Design Guide

Programming

6-29 Terminal 54 Mode

[1]

Voltage

6-25 T54 high Feedback

0050

20-94 PI integral time

0020.00

Current

Voltage

This dialog is forced to be set to [1] Analog input 54

20-00 Feedback 1 source

[1]

Analog input 54

3-10 Preset reference [0]

0.00

3-03 Max Reference

50.00

3-02 Min Reference

0.00

Asynchronous motor

1-73 Flying Start

[0]

1-22 Motor Voltage

400

1-24 Motor Current

04.66

1-25 Motor nominal speed

1420

RPM

3-41 Ramp 1 ramp-up time

0010

3-42 Ramp1 ramp-down time

0010

0-06 Grid Type

4-12 Motor speed low limit

0016

4-14 Motor speed high limit

0050

e30bc402.15

1-20 Motor Power

1.10

1-23 Motor Frequency

6-22 T54 Low Current

6-24 T54 low Feedback

0016

6-23 T54 high Current

13.30

6-25 T54 high Feedback

0050

0.01

20-81 PI Normal/Inverse Control

[0]

Normal

20-83 PI Normal/Inverse Control

0050

20-93 PI Proportional Gain

00.50

1-29 Automatic Motor Adaption

[0]

Off

6-20 T54 low Voltage

0050

6-24 T54 low Feedback

0016

6-21 T54 high Voltage

0220

6-26

T54 Filter time const.

1-00 Configuration Mode

[3]

Closed Loop

0-03 Regional Settings

[0]

Power kW/50 Hz

3-16 Reference Source 2

[0]

No Operation

1-10 Motor Type

[0]

Asynchronous

[0]

200-240V/50Hz/Delta

1-30 Stator Resistance

0.65

Ohms

1-25 Motor Nominal Speed

3000

RPM

1-24 Motor Current

3.8

1-26 Motor Cont. Rated Torque

5.4

1-38 q-axis inductance(Lq)

4-19 Max Ouput Frequency

0065

1-40 Back EMF at 1000 RPM

PM motor

1-39 Motor Poles

04.66

Motor type = Asynchronous

Motor type = PM motor

Motor type = IPM

Motor type = SPM

1-44 d-axis Inductance Sat. (LdSat)

(1-70) Start Mode

Rotor Detection

[0]

1-46 Position Detection Gain

Off

100

30-22 Locked Rotor Detection

[0]

30-23 Locked Rotor Detection Time[s]

0.10

1-42 Motor Cable Length

(1-45) q-axis Inductance Sat. (LqSat)

(1-48) Current at Min Inductanc e for d-axis

100

1-49 Current at Min Inductanc e for q-axis

100

1-37 d-axis inductance(Lq)

... the Wizard starts

VLT® Flow Drive FC 111

Design Guide

7.2.2.4 Setup Wizard for Closed-loop Applications

Programming

Illustration 62: Setup Wizard for Closed-loop Applications

•

Parameter

Range

Default

Usage

Parameter 0-03 Regional Settings

[0] International [1] US

[0] International

–

Parameter 0-06 GridType

Size selected

Select the operating mode for restart after reconnection of the drive to mains voltage after power down.

Parameter 1-00 Configuration Mode

[0] Open loop [3] Closed loop

[0] Open loop

Select [3] Closed loop.

Parameter 1-10 Motor Construction

*[0] Asynchron [1] PM, non-salient SPM [3] PM, salient IPM

[0] Asynchron

Setting the parameter value might change these parameters:

Parameter 1-01 Motor Control Principle.

Parameter 1-03 Torque Characteristics.

Parameter 1-08 Motor Control Bandwidth.

Parameter 1-14 Damping Gain.

Parameter 1-15 Low Speed Filter Time Const.

Parameter 1-16 High Speed Filter Time Const.

Parameter 1-17 Voltage Filter Time Const.

Parameter 1-20 Motor Power.

Parameter 1-22 Motor Voltage.

Parameter 1-23 Motor Frequency.

Parameter 1-24 Motor Current.

Parameter 1-25 Motor Nominal Speed.

Parameter 1-26 Motor Cont. Rated Torque.

Parameter 1-30 Stator Resistance (Rs).

Parameter 1-33 Stator Leakage Reactance (X1).

Parameter 1-35 Main Reactance (Xh).

Parameter 1-37 d-axis Inductance (Ld).

Parameter 1-38 q-axis Inductance (Lq).

Parameter 1-39 Motor Poles.

Parameter 1-40 Back EMF at 1000 RPM.

Parameter 1-44 d-axis Inductance Sat. (LdSat).

Parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-46 Position Detection Gain.

VLT® Flow Drive FC 111

Design Guide

Table 47: Setup Wizard for Closed-loop Applications

Programming

•

Parameter

Range

Default

Usage

Parameter 1-48 Current at Min Inductance for d-axis.

Parameter 1-49 Current at Min Inductance for q-axis.

Parameter 1-66 Min. Current at Low Speed.

Parameter 1-70 PM Start Mode.

Parameter 1-72 Start Function.

Parameter 1-73 Flying Start.

Parameter 1-80 Function at Stop.

Parameter 1-82 Min Speed for Function at Stop [Hz].

Parameter 1-90 Motor Thermal Protection.

Parameter 2-00 DC Hold/Motor Preheat Current.

Parameter 2-01 DC Brake Current.

Parameter 2-02 DC Braking Time.

Parameter 2-04 DC Brake Cut In Speed.

Parameter 2-10 Brake Function.

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

Parameter 4-19 Max Output Frequency.

Parameter 4-58 Missing Motor Phase Function.

Parameter 14-65 Speed Derate Dead Time Compensation.

Parameter 1-20 Motor Power

0.18–110 kW/0.25–150 hp

Size related

Enter the motor power from the nameplate data.

Parameter 1-22 Motor Voltage

50–1000 V

Size related

Enter the motor voltage from the nameplate data.

Parameter 1-23 Motor Frequency

20–400 Hz

Size related

Enter the motor frequency from the nameplate data.

Parameter 1-24 Motor Current

0.01–1000.00 A

Size related

Enter the motor current from the nameplate data.

Parameter 1-25 Motor Nominal Speed

50–60000 RPM

Size related

Enter the motor nominal speed from the nameplate data.

Parameter 1-26 Motor Cont. Rated Torque

0.1–10000.0 Nm

Size related

This parameter is available when parameter 1-10 Motor Con- struction is set to options that enable permanent motor mode.

N O T I C E

Changing this parameter affects the settings of other pa-

rameters.

Parameter 1-29 Automatic Motor Adaption (AMA)

–

Off

Performing an AMA optimizes motor performance.

Parameter 1-30 Stator Resistance (Rs)

0.000–9999.000 Ω

Size related

Set the stator resistance value.

VLT® Flow Drive FC 111

Design Guide

Programming

Parameter

Range

Default

Usage

Parameter 1-37 d-axis Inductance (Ld)

0.000–1000.000 mH

Size related

Enter the value of the d-axis inductance. Obtain the value from the permanent magnet motor datasheet.

Parameter 1-38 q-axis Inductance (Lq)

0.000–1000.000 mH

Size related

Enter the value of the q-axis inductance.

Parameter 1-39 Motor Poles

2–100

Enter the number of motor poles.

Parameter 1-40 Back EMF at 1000 RPM

10–9000 V

Size related

Line-line RMS back EMF voltage at 1000 RPM.

Parameter 1-42 Motor Cable Length

0–100 m

50 m

Enter the motor cable length.

Parameter 1-44 d-axis Inductance Sat. (LdSat)

0.000–1000.000 mH

Size related

Parameter 1-45 q-axis Inductance Sat. (LqSat)

0.000–1000.000 mH

Size related

Parameter 1-46 Position Detection Gain

20–200%

100%

Adjusts the height of the test pulse during position detection at start.

Parameter 1-48 Current at Min Inductance for d-axis

20–200%

100%

Enter the inductance saturation point.

Parameter 1-49 Current at Min Inductance for q-axis

20–200%

100%

This parameter specifies the saturation curve of the d- and qinductance values. From 20–100% of this parameter, the inductances are linearly approximated due to parameter 1-37

d-axis Inductance (Ld), parameter 1-38 q-axis Inductance (Lq), parameter 1-44 d-axis Inductance Sat. (LdSat), and parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-70 PM Start Mode

[0] Rotor Detection [1] Parking [3] Rotor Last Position

[1] Parking

Select the PM motor start mode.

Parameter 1-73 Flying Start

[0] Disabled [1] Enabled

[0] Disabled

Select [1] Enabled to enable the drive to catch a spinning motor in, for example, fan applications. When PM is selected, this parameter is enabled.

Parameter 3-02 Minimum Reference

-4999.000–4999.000

The minimum reference is the lowest value obtainable by summing all references.

VLT® Flow Drive FC 111

Design Guide

Programming

Parameter

Range

Default

Usage

Parameter 3-03 Maximum Reference

-4999.000–4999.000

The maximum reference is the highest value obtainable by summing all references.

Parameter 3-10 Preset Reference

-100–100%

Enter the setpoint.

Parameter 3-41 Ramp 1 Ramp Up Time

0.05–3600.0 s

Size related

Ramp-up time from 0 to rated parameter 1-23 Motor Frequen-

cy for asynchronous motors. Ramp-up time from 0 to parameter 1-25 Motor Nominal Speed for PM motors.

Parameter 3-42 Ramp 1 Ramp Down Time

0.05–3600.0 s

Size related

Ramp-down time from rated parameter 1-23 Motor Frequency to 0 for asynchronous motors. Ramp-down time from param-

eter 1-25 Motor Nominal Speed to 0 for PM motors.

Parameter 4-12 Motor Speed Low Limit [Hz]

0.0–400.0 Hz

0.0 Hz

Enter the minimum limit for low speed.

Parameter 4-14 Motor Speed High Limit [Hz]

0.0–400.0 Hz

100 Hz

Enter the minimum limit for high speed.

Parameter 4-19 Max Output Frequency

0.0–400.0 Hz

100 Hz

Parameter 6-20 Terminal 54 Low Voltage

0.00–10.00 V

0.07 V

Enter the voltage that corresponds to the low reference value.

Parameter 6-21 Terminal 54 High Voltage

0.00–10.00 V

10.00 V

Enter the voltage that corresponds to the high reference value.

Parameter 6-22 Terminal 54 Low Current

0.00–20.00 mA

4.00 mA

Enter the current that corresponds to the low reference value.

Parameter 6-23 Terminal 54 High Current

0.00–20.00 mA

20.00 mA

Enter the current that corresponds to the high reference value.

Parameter 6-24 Terminal 54 Low Ref./Feedb. Value

-4999–4999

Enter the feedback value that corresponds to the voltage or current set in parameter 6-20 Terminal 54 Low Voltage/param-

eter 6-22 Terminal 54 Low Current.

Parameter 6-25 Terminal 54 High Ref./ Feedb. Value

-4999–4999

Enter the feedback value that corresponds to the voltage or current set in parameter 6-21 Terminal 54 High Voltage/pa-

rameter 6-23 Terminal 54 High Current.

Parameter 6-26 Terminal 54 Filter Time Constant

0.00–10.00 s

0.01

Enter the filter time constant.

VLT® Flow Drive FC 111

Design Guide

Programming

Parameter

Range

Default

Usage

Parameter 6-29 Terminal 54 mode

[0] Current [1] Voltage

[1] Voltage

Select if terminal 54 is used for current or voltage input.

Parameter 20-81 PI Normal/Inverse Control

[0] Normal [1] Inverse

[0] Normal

Select [0] Normal to set the process control to increase the output speed when the process error is positive. Select [1] In-

verse to reduce the output speed.

Parameter 20-83 PI Start Speed [Hz]

0–200 Hz

0 Hz

Enter the motor speed to be attained as a start signal for commencement of PI control.

Parameter 20-93 PI Proportional Gain

0.00–10.00

0.01

Enter the process controller proportional gain. Quick control is obtained at high amplification. However, if amplification is too high, the process may become unstable.

Parameter 20-94 PI Integral Time

0.1–999.0 s

999.0 s

Enter the process controller integral time. Obtain quick control through a short integral time, though if the integral time is too short, the process becomes unstable. An excessively long integral time disables the integral action.

Parameter 30-22 Locked Rotor Detection

[0] Off [1] On

[0] Off

–

Parameter 30-23 Locked Rotor Detection Time [s]

0.05–1.00 s

0.10 s

–

Parameter

Range

Default

Usage

Parameter 0-03 Regional Settings

[0] International [1] US

[0] International

–

Parameter 0-06 GridType

Size selected

Select the operating mode for restart after reconnection of the drive to mains voltage after power down.

Parameter 1-10 Motor Construction

*[0] Asynchron [1] PM, non-salient SPM [3] PM, salient IPM

[0] Asynchron

Setting the parameter value might change these parameters:

VLT® Flow Drive FC 111

Design Guide

Programming

7.2.2.5 Motor Setup

The motor setup wizard guides users through the needed motor parameters.

Table 48: Motor Setup Wizard Settings

•

Parameter

Range

Default

Usage

Parameter 1-01 Motor Control Principle.

Parameter 1-03 Torque Characteristics.

Parameter 1-08 Motor Control Bandwidth.

Parameter 1-14 Damping Gain.

Parameter 1-15 Low Speed Filter Time Const.

Parameter 1-16 High Speed Filter Time Const.

Parameter 1-17 Voltage Filter Time Const.

Parameter 1-20 Motor Power.

Parameter 1-22 Motor Voltage.

Parameter 1-23 Motor Frequency.

Parameter 1-24 Motor Current.

Parameter 1-25 Motor Nominal Speed.

Parameter 1-26 Motor Cont. Rated Torque.

Parameter 1-30 Stator Resistance (Rs).

Parameter 1-33 Stator Leakage Reactance (X1).

Parameter 1-35 Main Reactance (Xh).

Parameter 1-37 d-axis Inductance (Ld).

Parameter 1-38 q-axis Inductance (Lq).

Parameter 1-39 Motor Poles.

Parameter 1-40 Back EMF at 1000 RPM.

Parameter 1-44 d-axis Inductance Sat. (LdSat).

Parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-46 Position Detection Gain.

Parameter 1-48 Current at Min Inductance for d-axis.

Parameter 1-49 Current at Min Inductance for q-axis.

Parameter 1-66 Min. Current at Low Speed.

Parameter 1-70 PM Start Mode.

Parameter 1-72 Start Function.

Parameter 1-73 Flying Start.

Parameter 1-80 Function at Stop.

Parameter 1-82 Min Speed for Function at Stop [Hz].

Parameter 1-90 Motor Thermal Protection.

Parameter 2-00 DC Hold/Motor Preheat Current.

Parameter 2-01 DC Brake Current.

Parameter 2-02 DC Braking Time.

Parameter 2-04 DC Brake Cut In Speed.

Parameter 2-10 Brake Function.

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

Parameter 4-19 Max Output Frequency.

Parameter 4-58 Missing Motor Phase Function.

Parameter 14-65 Speed Derate Dead Time Compensation.

VLT® Flow Drive FC 111

Design Guide

Programming

Parameter

Range

Default

Usage

Parameter 1-20 Motor Power

0.18–110 kW/0.25–150 hp

Size related

Enter the motor power from the nameplate data.

Parameter 1-22 Motor Voltage

50–1000 V

Size related

Enter the motor voltage from the nameplate data.

Parameter 1-23 Motor Frequency

20–400 Hz

Size related

Enter the motor frequency from the nameplate data.

Parameter 1-24 Motor Current

0.01–10000.00 A

Size related

Enter the motor current from the nameplate data.

Parameter 1-25 Motor Nominal Speed

50–9999 RPM

Size related

Enter the motor nominal speed from the nameplate data.

Parameter 1-26 Motor Cont. Rated Torque

0.1–1000.0 Nm

Size related

This parameter is available when parameter 1-10 Motor Con- struction is set to options that enable permanent motor mode.

N O T I C E

Changing this parameter affects the settings of other pa-

rameters.

Parameter 1-30 Stator Resistance (Rs)

0–99.990 Ω

Size related

Set the stator resistance value.

Parameter 1-37 d-axis Inductance (Ld)

0.000–1000.000 mH

Size related

Enter the value of the d-axis inductance. Obtain the value from the permanent magnet motor datasheet.

Parameter 1-38 q-axis Inductance (Lq)

0.000–1000.000 mH

Size related

Enter the value of the q-axis inductance.

Parameter 1-39 Motor Poles

2–100

Enter the number of motor poles.

Parameter 1-40 Back EMF at 1000 RPM

10–9000 V

Size related

Line-line RMS back EMF voltage at 1000 RPM.

Parameter 1-42 Motor Cable Length

0–100 m

50 m

Enter the motor cable length.

Parameter 1-44 d-axis Inductance Sat. (LdSat)

0.000–1000.000 mH

Size related

Parameter 1-45 q-axis Inductance Sat. (LqSat)

0.000–1000.000 mH

Size related

VLT® Flow Drive FC 111

Design Guide

Programming

Parameter

Range

Default

Usage

Parameter 1-46 Position Detection Gain

20–200%

100%

Adjusts the height of the test pulse during position detection at start.

Parameter 1-48 Current at Min Inductance for d-axis

20–200%

100%

Enter the inductance saturation point.

Parameter 1-49 Current at Min Inductance for q-axis

20–200%

100%

This parameter specifies the saturation curve of the d- and qinductance values. From 20–100% of this parameter, the inductances are linearly approximated due to parameter 1-37

d-axis Inductance (Ld), parameter 1-38 q-axis Inductance (Lq), parameter 1-44 d-axis Inductance Sat. (LdSat), and parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-70 PM Start Mode

[0] Rotor Detection [1] Parking [3] Rotor Last Position

[1] Parking

Select the PM motor start mode.

Parameter 1-73 Flying Start

[0] Disabled [1] Enabled

[0] Disabled

Select [1] Enabled to enable the drive to catch a spinning motor.

Parameter 3-41 Ramp 1 Ramp Up Time

0.05–3600.0 s

Size related

Ramp-up time from 0 to rated parameter 1-23 Motor Frequen-

cy.

Parameter 3-42 Ramp 1 Ramp Down Time

0.05–3600.0 s

Size related

Ramp-down time from rated parameter 1-23 Motor Frequency to 0.

Parameter 4-12 Motor Speed Low Limit [Hz]

0.0–400.0 Hz

0.0 Hz

Enter the minimum limit for low speed.

Parameter 4-14 Motor Speed High Limit [Hz]

0.0–400.0 Hz

100.0 Hz

Enter the maximum limit for high speed.

Parameter 4-19 Max Output Frequency

0.0–400.0 Hz

100.0 Hz

Parameter 30-22 Locked Rotor Detection

[0] Off [1] On

[0] Off

–

Parameter 30-23 Locked Rotor Detection Time [s]

0.05–1.00 s

0.10 s

–

VLT® Flow Drive FC 111

Design Guide

Programming

7.2.2.6 Changes Made Function

The changes made function lists all parameters changed from default settings.

VLT® Flow Drive FC 111

Design Guide

•

The list shows only parameters that have been changed in the current edit setup.

•

Parameters that have been reset to default values are not listed.

•

The message Empty indicates that no parameters have been changed.

7.2.2.7 Changing Parameter Settings

Procedure

To enter the Quick Menu, press the [Menu] key until the indicator in the display is placed above Quick Menu.

Press [▵] [▿] to select the wizard, closed-loop setup, motor setup, or changes made.

Press [OK].

Press [▵] [▿] to browse through the parameters in the Quick Menu.

Press [OK] to select a parameter.

Press [▵] [▿] to change the value of a parameter setting.

Press [OK] to accept the change.

Press either [Back] twice to enter Status, or press [Menu] once to enter the Main Menu.

7.2.2.8 Accessing All Parameters via the Main Menu

Procedure

Press the [Menu] key until the indicator in the display is placed above Main Menu.

Press [▵] [▿] to browse through the parameter groups.

Press [OK] to select a parameter group.

Press [▵] [▿] to browse through the parameters in the specific group.

Press [OK] to select the parameter.

Press [▵] [▿] to set/change the parameter value.

Press [OK] to accept the change.

Programming

7.2.3 Main Menu

Press [Menu] to access the main menu and program all parameters. The main menu parameters can be accessed readily unless a password has been created via parameter 0-60 Main Menu Password.

For most applications, it is not necessary to access the main menu parameters. The quick menu provides the simplest and quickest access to the typical required parameters.

7.3 Quick Transfer of Parameter Settings between Multiple Drives

When the set-up of a drive is completed, store the data in the LCP. Then connect the LCP to another drive and copy the parameter settings to the new drive.

7.3.1 Transferring Data from the Drive to the LCP

Procedure

Go to parameter 0-50 LCP Copy. Press [OK].

Select [1] All to LCP. Press [OK].

7.3.2 Transferring Data from the LCP to the Drive

Procedure

Go to parameter 0-50 LCP Copy. Press [OK].

Select [2] All from LCP. Press [OK].

VLT® Flow Drive FC 111

Design Guide

7.4 Readout and Programming of Indexed Parameters

Procedure

Select the parameter and press [OK].

Press [▵]/[▿] to scroll through the indexed values.

To change the parameter value, select the indexed value and press [OK].

Change the value by pressing [▵]/[▿].

Press [OK] or [Cancel] to accept or abort the new setting.

Press [Back] to leave the parameter.

7.5 Initialization to Default Settings

There are 2 ways to initialize the drive to the default settings.

•

Recommended initialization

•

Two-finger initialization

Initialization of parameters is confirmed by alarm 80, Drive initialised in the display after the power cycle.

7.5.1 Recommended Initialization

Procedure

Select parameter 14-22 Operation Mode. Press [OK].

Select [2] Initialisation and press [OK]. Power off the drive and wait until the display turns off.

Reconnect the mains supply. The drive is now reset, except for the following parameters.

Programming

•

Parameter 1-06 Clockwise Direction

•

Parameter 8-30 Protocol

•

Parameter 8-31 Address

•

Parameter 8-32 Baud Rate

•

Parameter 8-33 Parity / Stop Bits

•

Parameter 8-35 Minimum Response Delay

•

Parameter 8-36 Maximum Response Delay

•

Parameter 8-37 Maximum Inter-char delay

•

Parameter 8-70 BACnet Device Instance

•

Parameter 8-72 MS/TP Max Masters

•

Parameter 8-73 MS/TP Max Info Frames

•

Parameter 8-74 "I am" Service

•

Parameter 8-75 Intialisation Password

•

Parameter 15-00 Operating hours to parameter 15-05 Over Volt's

•

Parameter 15-03 Power Up's

•

Parameter 15-04 Over Temp's

•

Parameter 15-05 Over Volt's

•

Parameter 15-30 Alarm Log: Error Code

•

Parameter group 15-4* Drive identification

•

Parameter 18-10 FireMode Log:Event

7.5.2 Two-finger Initialization

Procedure

Power off the drive.

VLT® Flow Drive FC 111

Design Guide

Press [OK] and [Menu].

Power up the drive while still pressing the keys for 10 s.

The drive is now reset, except for the following parameters.

•

Programming

Parameter 1-06 Clockwise Direction

Parameter 15-00 Operating hours

Parameter 15-03 Power Up's

Parameter 15-04 Over Temp's

Parameter 15-05 Over Volt's

Parameter group 15-4* Drive identification

Parameter 18-10 FireMode Log:Event

Danfoss FC 111 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

1 Introduction

1.1 Purpose of this Design Guide

1.2 Additional Resources

1.2.1 Other Resources

1.2.2 MCT 10 Set-up Software Support

1.3 Document and Software Version

1.4 Regulatory Compliance

1.4.1 Introduction

1.4.2 CE Mark

2 Safety

2.1 Safety Symbols

2.2 Qualified Personnel

2.3 Safety Precautions

3 Product Overview

3.1 Advantages

3.1.1 Why Use a Drive for Controlling Fans and Pumps?

3.1.1.1 The Clear Advantage - Energy Savings

3.1.1.2 Example of Energy Savings

3.1.1.3 Comparison of Energy Savings

3.1.1.4 Example with Varying Flow over 1 Year

3.1.1.5 Better Control

3.1.1.6 Star/Delta Starter or Soft Starter not Required

3.1.1.7 Using a Drive Saves Money

3.1.1.8 Traditional Fan System without a Drive

3.1.1.9 Fan System Controlled by Drives

3.1.2 Application Examples

3.1.2.1 Variable Air Volume

3.1.2.2 Constant Air Volume

3.1.2.3 Cooling Tower Fan

3.1.2.4 Condenser Pumps

3.1.2.5 Primary Pumps

3.1.2.6 Secondary Pumps

3.1.3 Check Valve Monitoring

3.1.4 Dry Pump Detection

3.1.5 End of Curve Detection

3.1.6 Time-based Functions

3.2 Control Structures

3.2.1 Introduction

3.2.2 Control Structure Open Loop

3.2.3 PM/EC+ Motor Control

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

3.2.5 Control Structure Closed Loop

3.2.6 Feedback Conversion

3.2.7 Reference Handling

3.2.8 Tuning the Drive Closed-loop

3.2.9 Adjusting the Manual PI

3.3 Ambient Running Conditions

3.3.1 Air Humidity

3.3.2 Acoustic Noise or Vibration

3.3.2.1 Acoustic Noise

3.3.2.2 Vibration and Shock

3.3.3 Aggressive Environments

3.4 General Aspects of EMC

3.4.1 Overview of EMC Emissions

3.4.2 Emission Requirements

3.4.3 EMC Emission Test Results

3.4.4 Harmonics Emission

3.4.4.1 Harmonics Emission Requirements

3.4.4.2 Harmonics Test Results (Emission)

3.4.5 Harmonics Emission Requirements

3.4.6 Harmonics Test Results (Emission)

3.4.7 Immunity Requirements

3.5 Galvanic Isolation (PELV)

3.6 Ground Leakage Current

3.6.1 Using a Residual Current Device (RCD)

3.7 Extreme Running Conditions

3.7.1 Introduction

3.7.2 Motor Thermal Protection (ETR)

3.7.3 Thermistor Inputs

3.7.3.1 Example with Digital Input and 10 V Power Supply

3.7.3.2 Example with Analog Input and 10 V Power Supply

4 Selection and Ordering

4.1 Type Code

4.2 Options and Accessories

4.2.1 Local Control Panel (LCP)