Danfoss FC 202 Design guide

Design Guide

VLT® Micro Drive FC 51

vlt-drives.danfoss.com

Contents	Design Guide

Contents

1 Introduction	5
1.1 Available Literature	5
1.2 Manual and Software Version	5
1.3 Abbreviations	5
1.4 De€nitions	6
1.5 Power Factor	8
2 Safety and Conformity	9
2.1 Safety	9
2.2 Disposal Instruction	10
2.3 Approvals	10
2.4 CE Labeling	10
2.6 Aggressive Environments	11
2.7 Vibration and Shock	12
2.8 Advantages	12
3 Product Overview	18
3.1 Control Structures	18
3.1.1 Control Structure Open Loop	18
3.1.2 Local (Hand On) and Remote (Auto On) Control	18
3.1.3 Control Structure Closed Loop	18
3.1.4 Reference Handling	20
3.2 General Aspects of EMC	21
3.2.1 General Aspects of EMC Emissions	21
3.2.2 Emission Requirements	22
3.2.3 EMC Test Results (Emission)	22
3.2.4 Harmonics Emission Requirements	23
3.2.5 Immunity Requirements	23
3.3 Galvanic Isolation (PELV)	23
3.4 Ground Leakage Current	24
3.5 Extreme Running Conditions	24
3.5.1 Motor Thermal Protection	24
4 Selection	26
4.1 Options and Accessories	26
4.1.1 Local Control Panel (LCP)	26
4.1.2 Remote Mounting Kit for LCP	26
4.1.3 FC 51 Remote Mounting Kit Mounting Instruction	26
4.1.4 IP21/TYPE 1 Enclosure Kit	28
4.1.5 Type 1 (NEMA)	28

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Contents

VLT® Micro Drive FC 51

4.1.6 Decoupling Plate	28
4.1.7 FC 51 Type 1 Kit Mounting Instruction for M1, M2 and M3	29
4.1.8 FC 51 Type 1 Kit Mounting Instruction for M4 and M5	29
4.1.9 FC 51 IP21 Kit Mounting Instruction	30
4.1.10 FC 51 Decoupling Plate Mounting Instruction for M1 and M2	31
4.1.11 FC 51 Decoupling Plate Mounting Instruction for M3	31
4.1.12 FC 51 Decoupling Plate Mounting Instruction for M4 and M5	32
4.1.13 FC 51 DIN Rail Kit Mounting Instruction	33
4.1.14 Line Filter MCC 107 Installation Instructions	33
4.1.15 Mounting	34
4.1.16 Wiring	34
4.1.17 Dimensions	35
4.2 Special Conditions	36
4.2.1 Purpose of Derating	36
4.2.2 Derating for Ambient Temperature	36
4.2.3 Derating for Low Air Pressure	37
4.2.4 Automatic Adaptations to Ensure Performance	37
4.2.5 Derating for Running at Low Speed	37

5 How to Order	38
5.1 Drive Con€gurator	38
5.2 FC Identi€cation	38
5.3 Type Code	39
5.4 Ordering Numbers	40
5.5 Options	40
6 How to Install	42
6.1 Before Starting	42
6.2 Side-by-Side Installation	42
6.3 Before Commencing Repair Work	42
6.4 Mechanical Dimensions	42
6.5 Electrical Installation in General	43
6.6 Fuses	44
6.7 Mains Connection	45
6.8 Motor Connection	45
6.9 Use of EMC-Correct Cables	48
6.10 Grounding of Shielded/Armored Control Cables	49
6.11 Residual Current Device	49
6.12 Electrical Overview	50
6.12.1 Power Circuit - Overview	50
6.13 Electrical Installation and Control Cables	51

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MG02K402

Contents	Design Guide

6.14 Control Terminals	51
6.14.1 Access to Control Terminals	51
6.14.2 Connecting to Control Terminals	52
6.15 Switches	52
6.16 Final Set-Up and Test	52
6.17 Parallel Connection of Motors	54
6.18 Motor Installation	55
6.19 Installation of Misc. Connections	55
6.20 Safety	56
6.20.1 High-voltage Test	56
6.20.2 Safety Ground Connection	56

7 Programming	57
7.1 How to Programme	57
7.1.2 Programming with the LCP 11 or LCP 12	57
7.2 Status Menu	58
7.3 Quick Menu	59
7.4 Quick Menu Parameters	59
7.5 Main Menu	63
7.6 Quick Transfer of Parameter Settings between Multiple Frequency Converters	63
7.7 Readout and Programming of Indexed Parameters	63
7.8 Initialize the Frequency Converter to Default Settings in two Ways	63
8 RS485 Installation and Set-up	65
8.1 RS485 Installation and Set-up	65
8.1.1 Overview	65
8.1.2 Network Connection	65
8.1.3 Frequency Converter Hardware Set-up	65
8.1.4 EMC Precautions	66
8.2 FC Protocol Overview	66
8.3 Network Con€guration	67
8.4 FC Protocol Message Framing Structure	67
8.4.1 Content of a Character (byte)	67
8.4.2 Telegram Structure	67
8.4.3 Telegram Length (LGE)	68
8.4.4 Frequency Converter Address (ADR)	68
8.4.5 Data Control Byte (BCC)	68
8.4.6 The Data Field	68
8.4.7 The PKE Field	69
8.4.8 Parameter Number (PNU)	70
8.4.9 Index (IND)	70

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Contents

VLT® Micro Drive FC 51

8.4.10 Parameter Value (PWE)	70
8.4.11 Data Types Supported by the Frequency Converter	70
8.4.12 Conversion	70
8.4.13 Process Words (PCD)	70
8.5 Examples	71
8.6 Modbus RTU Overview	71
8.6.1 Prerequisite Knowledge	71
8.6.2 What the User Should Already Know	71
8.6.3 Overview	71
8.6.4 Frequency Converter with Modbus RTU	72
8.7 Network Con€guration	72
8.8 Modbus RTU Message Framing Structure	72
8.8.1 Introduction	72
8.8.2 Modbus RTU Telegram Structure	73
8.8.3 Start/Stop Field	73
8.8.4 Address Field	73
8.8.6 Data Field	73
8.8.7 CRC Check Field	73
8.8.8 Coil Register Addressing	74
8.8.9 How to Control the Frequency Converter	75
8.8.10 Function Codes Supported by Modbus RTU	75
8.8.11 Modbus Exception Codes	76
8.9 How to Access Parameters	76
8.9.1 Parameter Handling	76
8.9.2 Storage of Data	76
8.10 Examples	77
8.10.1 Read Coil Status (01 hex)	77
8.10.2 Force/Write Single Coil (05 hex)	77
8.10.3 Force/Write Multiple Coils (0F hex)	78
8.10.4 Read Holding Registers (03 hex)	78
8.10.5 Preset Single Register (06 hex)	79
8.10.6 Preset Multiple Registers (10 hex)	79
8.11 FC Drive Control Pro€le	80
8.11.1 Control Word According to FC Pro€le	80
8.11.2 Status Word According to FC Pro€le (STW)	81
8.11.3 Bus Speed Reference Value	83
9 Speci€cations	84
Index	91

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MG02K402

Introduction Design Guide

1 Introduction	1	1

1.1 Available Literature

This design guide contains the basic information necessary for installing and running the frequency converter.

Danfoss technical literature is available in print from local Danfoss Sales Offices or online at: www.vlt- drives.danfoss.com/support/technical-documentation/

•VLT® Micro Drive FC 51 Quick Guide

•VLT® Micro Drive FC 51 Programming Guide

•VLT® Micro Drive FC 51 LCP Mounting Instruction

•VLT® Micro Drive FC 51 De-coupling Plate Mounting Instruction

•VLT® Micro Drive FC 51 Remote Mounting Kit Mounting Instruction

•VLT® Micro Drive FC 51 DIN Rail Kit Mounting Instruction

•VLT® Micro Drive FC 51 IP21 Kit Mounting Instruction

•VLT® Micro Drive FC 51 Nema1 Kit Mounting Instruction

•VLT® Micro Drive FC 51 Line Filter MCC 107 Installation Instruction

1.2Manual and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. Table 1.1 shows the manual version and the corresponding software version.

Edition	Remarks	Software version
MG02K4XX	Miscellaneous minor	3.1X
	updates.

Table 1.1 Manual and Software Version

1.3 Abbreviations

°C	Degrees celsius
A	Ampere/AMP
AC	Alternating current
AMT	Automatic motor tuning
AWG	American wire gauge
DC	Direct current
EMC	Electro magnetic compatibility
ETR	Electronic thermal relay
FC	Frequency converter
fM,N	Nominal motor frequency
g	Gram
Hz	Hertz
IINV	Rated inverter output current
ILIM	Current limit
IM,N	Nominal motor current
IVLT,MAX	The maximum output current
IVLT,N	The rated output current supplied by the
	frequency converter
kHz	Kilohertz
LCP	Local control panel
m	Meter
mA	Milliampere
MCT	Motion control tool
mH	Millihenry inductance
min	Minute
ms	Millisecond
nF	Nanofarad
Nm	Newton meters
ns	Synchronous motor speed
PM,N	Nominal motor power
PCB	Printed circuit board
PELV	Protective extra low voltage
RPM	Revolutions per minute
Regen	Regenerative terminals
s	Second
TLIM	Torque limit
UM,N	Nominal motor voltage
V	Volt

Table 1.2 Abbreviations

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Introduction

VLT® Micro Drive FC 51

1 1 1.4 De€nitions

1.4.1 Frequency Converter

IVLT,MAX

The maximum output current.

IVLT N

The rated output current supplied by the frequency converter.

UVLT,MAX

The maximum output voltage.

1.4.2 Input

Control command

The connected motor can be started and stopped with LCP and the digital inputs.

Functions are divided into 2 groups.

Functions in group 1 have higher priority than functions in group 2.

Break-away torque

Torque

Pull-out	<![if ! IE]> <![endif]>175ZA078.10

rpm

Illustration 1.1 Break-away Torque

ηVLT

The efficiency of the frequency converter is de€ned as the ratio between the power output and the power input.

Group 1 Reset, coast stop, reset and coast stop, quick stop, DC brake, stop, and the [Off] key.

Group 2 Start, pulse start, reversing, start reversing, jog, and freeze output.

Table 1.3 Function Groups

Start-disable command

A stop command belonging to the group 1 control commands, see Table 1.3.

Stop command

See Table 1.3.

1.4.3 Motor

fJOG

The motor frequency when the jog function is activated (via digital terminals).

fM

The motor frequency.

fMAX

The maximum motor frequency.

fMIN

The minimum motor frequency.

fM,N

The rated motor frequency (nameplate data).

IM

The motor current.

IM,N

1.4.4 References

Analog reference

A signal transmitted to the analog inputs 53 or 54, can be voltage or current.

Bus reference

A signal transmitted to the serial communication port (FC port).

Preset reference

A de€ned preset reference to be set from -100% to +100% of the reference range. Selection of 8 preset references via the digital terminals.

RefMAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20 mA) and the resulting reference. The maximum reference value set in parameter 3-03 Maximum Reference.

The rated motor current (nameplate data).

nM,N

The nominal motor speed (nameplate data).

PM,N

The rated motor power (nameplate data).

UM

The instant motor voltage.

UM,N

The rated motor voltage (nameplate data).

RefMIN

Determines the relationship between the reference input at 0% value (typically 0 V, 0 mA, 4 mA) and the resulting reference. The minimum reference value set in

parameter 3-02 Minimum Reference.

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MG02K402

Introduction	Design Guide

1.4.5 Miscellaneous

Analog inputs

The analog inputs are used for controlling various functions of the frequency converter.

There are 2 types of analog inputs:

•Current input, 0–20 mA and 4–20 mA

•Voltage input, 0–10 V DC.

Analog outputs

The analog outputs can supply a signal of 0–20 mA, 4–20 mA, or a digital signal.

Automatic Motor Tuning, AMT

AMT algorithm determines the electrical parameters for the connected motor at standstill.

Brake resistor

The brake resistor is a module capable of absorbing the brake power generated in regenerative braking. This regenerative brake power increases the DC-link voltage, and a brake chopper ensures that the power is transmitted to the brake resistor.

CT characteristics

Constant torque characteristics used for all applications such as conveyor belts, displacement pumps, and cranes.

Digital inputs

The digital inputs can be used for controlling various functions of the frequency converter.

Relay outputs

The frequency converter features 2 programmable relay outputs.

ETR

Electronic thermal relay is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature.

Initializing

If initializing is carried out (parameter 14-22 Operation Mode), the programmable parameters of the frequency converter return to their default settings.

Initializing parameter 14-22 Operation Mode does not initialize communication parameters.

Intermittent duty cycle

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

LCP

The local control panel makes up a complete interface for control and programming of the frequency converter. The control panel is detachable and can be installed up to 3 m from the frequency converter, that is, in a front panel with the installation kit option.

lsb

Least signi€cant bit.

MCM

1 1

Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM ≡ 0.5067 mm2.

msb

Most signi€cant bit.

On-line/Oƒ-line parameters

Changes to on-line parameters are activated immediately after the data value is changed. To activate changes to offline parameters, press [OK].

PI controller

The PI controller maintains the speed, pressure, temperature, and so on, by adjusting the output frequency to match the varying load.

RCD

Residual current device.

Set-up

Save parameter settings in 2 set-ups. Change between the 2 parameter set-ups and edit 1 set-up, while another setup is active.

Slip compensation

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

Smart logic control (SLC)

The SLC is a sequence of user-de€ned actions executed when the associated user-de€ned events are evaluated as true by the SLC.

Thermistor

A temperature-dependent resistor.

STW

Status word.

FC standard bus

Includes RS485 bus with FC protocol.

Trip

A state entered in fault situations, for example, if the frequency converter is subject to an overtemperature or when the frequency converter is protecting the motor, process, or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is canceled by activating reset or, sometimes, by being programmed to reset automatically. Do not use trip for personal safety.

Trip lock

A state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention, for example, if the frequency converter is subject to a short circuit on the output. A trip lock can only be canceled by cutting off mains, removing the cause of the fault, and reconnecting the frequency converter. Restart is prevented until the trip state is canceled by activating reset or, sometimes, by being programmed to reset automatically. Trip lock may not be used for personal safety.

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			Introduction	VLT® Micro Drive FC 51
1	1		VT characteristics
			Variable torque characteristics used for pumps and fans.

VVC+

If compared with standard voltage/frequency ratio control, voltage vector control (VVC+) improves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque.

1.5 Power Factor

The power factor is the relation between I1 and IRMS.

Power factor	=	3 ×	U	×	I	1 ×		COS	ϕ
		3 ×		U	×		IRMS

The power factor for 3-phase control:

Power factor	=	I	1	×	cos	ϕ1 =		I	1	since cos	ϕ1 = 1
				IRMS				IRMS

The power factor indicates to which extent the frequency converter imposes a load on the supply.

The lower the power factor, the higher the IRMS for the same kW performance.

IRMS = I21 + I25 + I27 + . . + I2n

In addition, a high-power factor indicates that the different harmonic currents are low.

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MG02K402

Safety and Conformity	Design Guide

2 Safety and Conformity

2.1 Safety

The following symbols are used in this manual:

WARNING

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

CAUTION

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

NOTICE

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

2.1.1 Safety Precautions

2 2

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains, DC supply, or load sharing, the motor may start at any time. Unintended start during programming, service, or repair work can result in death, serious injury, or property damage. The motor can start with an external switch, a €eldbus command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up Software, or after a cleared fault condition.

To prevent unintended motor start:

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

•Disconnect the frequency converter from the mains.

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

WARNING

HIGH VOLTAGE

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

•Only quali€ed personnel must perform installation, start-up, and maintenance.

WARNING

DISCHARGE TIME

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

•Stop the motor.

•Disconnect AC mains and remote DC-link power supplies, including battery back-ups, UPS, and DC-link connections to other frequency converters.

•Disconnect or lock PM motor.

•Wait for the capacitors to discharge fully. The minimum duration of waiting time is speci€ed in Table 2.1.

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

Size	Minimum waiting time (minutes)
M1, M2, and M3	4
M4 and M5	15

Table 2.1 Discharge Time

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Safety and Conformity

VLT® Micro Drive FC 51

WARNING

LEAKAGE CURRENT HAZARD

2 2 Leakage currents exceed 3.5 mA. Failure to ground the frequency converter properly can result in death or serious injury.

•Ensure the correct grounding of the equipment by a certi€ed electrical installer.

WARNING

EQUIPMENT HAZARD

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

•Ensure that only trained and quali€ed personnel perform installation, start-up, and maintenance.

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

•Follow the procedures in this guide.

WARNING

UNINTENDED MOTOR ROTATION WINDMILLING

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

•Ensure that permanent magnet motors are blocked to prevent unintended rotation.

CAUTION

INTERNAL FAILURE HAZARD

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

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

2.2Disposal Instruction

Equipment containing electrical components cannot be disposed of together with domestic waste.

It must be separately collected with electrical and electronic waste according to local and currently valid legislation.

The frequency converter complies with UL 508C thermal memory retention requirements. For more information refer to chapter 3.5.1 Motor Thermal Protection.

2.4 CE Labeling

2.4.1 CE Conformity and Labeling

What is CE conformity and labeling?

The purpose of CE labelling is to avoid technical trade obstacles within EFTA and the EU. The EU has introduced the CE label as a simple way of showing whether a product complies with the relevant EU directives. The CE label says nothing about the speci€cations or quality of the product. Frequency converters are regulated by 3 EU directives:

The Machinery Directive (98/37/EEC)

All machines with critical moving parts are covered by the machinery directive of January 1, 1995. Since a frequency converter is largely electrical, it does not fall under the machinery directive. However, if a frequency converter is supplied for use in a machine, Danfoss provides information on safety aspects relating to the frequency converter. Danfoss does this with a manufacturer's declaration.

The Low Voltage Directive (73/23/EEC)

Frequency converters must be CE labeled in accordance with the Low Voltage Directive of January 1, 1997. The directive applies to all electrical equipment and appliances used in the 50–1000 V AC and the 75–1500 V DC voltage ranges. Danfoss CE-labels in accordance with the directive and issues a declaration of conformity on request.

The EMC Directive (2004/108/EC)

EMC is short for electromagnetic compatibility. The presence of electromagnetic compatibility means that the mutual interference between different components/ appliances does not affect the way the appliances work. The EMC directive came into effect January 1, 1996. Danfoss CE-labels in accordance with the directive and issues a declaration of conformity after request. To carry out EMC-correct installation, see the instructions in this design guide. In addition, Danfoss speci€es which standards our products comply with. Danfoss offers the €lters presented in the speci€cations and provide other types of assistance to ensure the optimum EMC result.

The frequency converter is most often used by professionals of the trade as a complex component forming part of a larger appliance, system, or installation. Note that the responsibility for the €nal EMC properties of the appliance, system or installation rests with the installer.

2.3 Approvals

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MG02K402

Safety and Conformity	Design Guide

2.4.2 What is Covered

The EU Guidelines on the Application of Council Directive 89/336/EEC outline 3 typical situations of using a frequency converter. See chapter 2.4.3 Danfoss Frequency Converter and CE Labelling for EMC coverage and CE labelling.

•The frequency converter is sold directly to the end-consumer. The frequency converter is for example sold to a DIY market. The end-consumer is a layman. The end-consumer installs the frequency converter himself for use with a hobby machine, a kitchen appliance, and so on. For such applications, the frequency converter must be CE labeled in accordance with the EMC directive.

•The frequency converter is sold for installation in a plant. The plant is built up by professionals of the trade. It could be a production plant or a heating/ventilation plant designed and installed by professionals of the trade. Neither the frequency converter nor the €nished plant has to be CE labeled under the EMC directive. However, the unit must comply with the basic EMC requirements of the directive. This is ensured by using components, appliances, and systems that are CE labeled under the EMC directive.

•The frequency converter is sold as part of a complete system. The system is being marketed as complete and could for example, be an airconditioning system. The complete system must be CE labeled in accordance with the EMC directive. The manufacturer can ensure CE labelling under the EMC directive either by using CE labeled components or by testing the EMC of the system. It is not necessary to test the entire system if only CE labeled components are selected.

2.4.3Danfoss Frequency Converter and CE Labelling

CE labelling is a positive feature when used for its original purpose, that is, to facilitate trade within the EU and EFTA.

However, CE labelling may cover many different speci€- cations. Check what a given CE label speci€cally covers.

The covered speci€cations can be different and a CE label may therefore give the installer a false feeling of security when using a frequency converter as a component in a system or an appliance.

Danfoss CE labels the frequency converters in accordance with the Low Voltage Directive. This means that if the frequency converter is installed correctly, Danfoss

guarantees compliance with the Low Voltage Directive. Danfoss issues a declaration of conformity that con€rms

our CE labelling in accordance with the Low Voltage 2 2 Directive.

The CE label also applies to the EMC directive if the instructions for EMC-correct installation and €ltering are followed. On this basis, a declaration of conformity in accordance with the EMC directive is issued.

The design guide offers detailed instructions for installation to ensure EMC-correct installation. Furthermore, Danfoss speci€es which our different products comply with.

Danfoss provides other types of assistance that can help to obtain the best EMC result.

2.4.4Compliance with EMC Directive

2004/108/EC

As mentioned, the frequency converter is mostly used by professionals of the trade as a complex component forming part of a larger appliance, system, or installation. Note that the responsibility for the €nal EMC properties of the appliance, system, or installation rests with the installer. As an aid to the installer, Danfoss has prepared EMC installation guidelines for the power drive system. If the EMCcorrect instructions for installation are followed, the standards and test levels stated for power drive systems are complied with.

2.5 Air Humidity

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

2.6 Aggressive Environments

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

CAUTION

Do not install the frequency converter in environments with airborne liquids, particles, or gases that may aƒect or damage the electronic components. Failure to take necessary protective measures increases the risk of stoppages, potentially causing equipment damage and personnel injury.

Liquids can be carried through the air and condense in the frequency converter and may cause corrosion of components and metal parts. Steam, oil, and salt water may cause corrosion of components and metal parts. In such environments, use equipment with enclosure rating

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Safety and Conformity

VLT® Micro Drive FC 51

IP54. As an extra protection, coated printed circuit boards can be ordered as an option (standard on some power

2 2 sizes).

Airborne particles such as dust may cause mechanical, electrical, or thermal failure in the frequency converter. A typical indicator of excessive levels of airborne particles is dust particles around the frequency converter fan. In dusty environments, use equipment with enclosure rating IP54 or a cabinet for IP20/TYPE 1 equipment.

2.8 Advantages

2.8.1Why use a Frequency Converter for Controlling Fans and Pumps?

A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further information, see chapter 2.8.3 Example of Energy Savings.

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

An extra protection in such areas is a coating of the printed circuit boards, which can be ordered as an option.

Before installing the frequency converter, 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.

2.8.2 The Clear Advantage - Energy Savings

The clear advantage of using a frequency converter for controlling the speed of fans or pumps lies in the electricity savings.

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

	120																						<![if ! IE]> <![endif]>130BA780.11
												A
	100
<![if ! IE]> <![endif]>%																		SYSTEM CURVE
	80
<![if ! IE]> <![endif]>PRESSURE											B								FAN CURVE
	60
	40
									C
	20
	0
			20		40		60		80		100			120				140		160	180
									VOLUME %

Illustration 2.1 Fan Curves (A, B, and C) for Reduced Fan Volumes

2.7 Vibration and Shock

The frequency converter has been tested according to the procedure based on the shown standards, Table 2.2.

The frequency converter complies with requirements that exist for units mounted on the walls and †oors of production premises, and in panels bolted to walls or †oors.

IEC/EN 60068-2-6	Vibration (sinusoidal) - 1970
IEC/EN 60068-2-64	Vibration, broad-band random

Table 2.2 Standards

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MG02K402

Safety and Conformity	Design Guide

	120									<![if ! IE]> <![endif]>130BA781.11				<![if ! IE]> <![endif]>175HA208.10
						A					100%				2	2
	100
	80							SYSTEM CURVE			80%
<![if ! IE]> <![endif]>%						B			FAN CURVE
<![if ! IE]> <![endif]>PRESSURE	60
	40
					C							Flow ~n
	20										50%
													Pressure~n 2
	0	20	40	60	80	100	120	140	160	180
					Volume %						25%
											12,5%		Power ~n3
	120													n
												50%	80%	100%

100

Illustration 2.3 Laws of Proportionally

<![if ! IE]> <![endif]>%

80

<![if ! IE]> <![endif]>INPUTPOWER

40

:

2

=

2

60

Q

n

Flow

Q1

H1

n1

n1

ENERGY

Pressure

:

H

=

n

2

20

2

2

CONSUMED

Power

P

n

3

P1

n1

0

:

2 =

2

20 40 60 80 100 120 140 160 180

Volume %

Q=Flow

P=Power

Illustration 2.2 Energy Savings with Frequency Converter

Q1=Rated †ow

P1=Rated power

Solution

Q2=Reduced †ow

P2=Reduced power

H=Pressure

n=Speed control

H1=Rated pressure

n1=Rated speed

When using a frequency converter to reduce fan capacity

H2=Reduced pressure

n2=Reduced speed

to 60% - more than 50% energy savings may be obtained

Table 2.3 The Laws of Proportionality

in typical applications.

2.8.3 Example of Energy Savings

As shown in Illustration 2.3, the †ow is controlled by changing the RPM. By reducing the speed by only 20% from the rated speed, the †ow is also reduced by 20%. This is because the †ow 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 †ow that corresponds to 100% a few days in a year, while the average is below 80% of the rated †ow for the remainder of the year, the amount of energy saved is even more than 50%.

Illustration 2.3 describes the dependence of †ow, pressure, and power consumption on RPM.

2.8.4 Comparison of Energy Savings

The Danfoss frequency converter 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 frequency converter is able to control fan speed according to thermal load on the system, and the frequency converter has a built-in facility that enables the frequency converter to function as a building management system, BMS.

Illustration 2.3 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.

MG02K402

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13

2 2

Safety and Conformity

VLT® Micro Drive FC 51

<![if ! IE]>

<![endif]>130BA782.10

Discharge damper

Less energy savings

Maximum energy savings

IGV

Costlier installation

Illustration 2.4 The 3 Common Energy Saving Systems

2.8.5Example 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 more than 50% at the given †ow distribution over a year. The payback period depends on the price per kWh and the price of frequency converter. In this example, it is less than a year when compared with valves and constant speed.

Energy savings

Pshaft=Pshaft output

[h] t								<![if ! IE]> <![endif]>175HA210.11
2000
1500

1000

500

						Q
100	200	300	400
					[m3 /h]

Illustration 2.6 Flow Distribution over 1 Year

	100		Discharge Damper Solution						<![if ! IE]> <![endif]>130BA779.12
<![if ! IE]> <![endif]>%	80				IGV Solution
	60
			<![if ! IE]> <![endif]>Energyconsumed
<![if ! IE]> <![endif]>Inputpower
					<![if ! IE]> <![endif]>consumedEnergy			<![if ! IE]> <![endif]>consumed
	40							VLT Solution
	20
								<![if ! IE]> <![endif]>Energy
	0
	0		60	0	60		0	60

Volume %

Illustration 2.5 Energy Savings

Discharge dampers reduce power consumption. Inlet guide vanes offer a 40% reduction, but are expensive to install. The Danfoss frequency converter 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.

14

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MG02K402

Safety and Conformity				Design Guide
(mwg)	Hs			<![if ! IE]> <![endif]>175HA209.11
60
50
		B
40
30
20				A 1650rpm
				1350rpm

10								C				1050rpm
									750rpm
		0			100				200				300				400			(m3 /h)
(kW)			Pshaft
60
50
																A1
40																1650rpm
30
20								B1					1350rpm
10						C1				1050rpm
								750rpm
		0			100				200				300				400			(m3 /h)
Illustration 2.7 Energy
m3/			Distri-					Valve regulation						Frequency converter
h			bution													control
		%		Hours				Power		Consump-						Power	Consump-
												tion							tion
								A1 - B1				kWh				A1 - C1			kWh
350		5		438		42.5				18.615				42.5			18.615
300		15		1314		38.5				50.589				29.0			38.106
250		20		1752		35.0				61.320				18.5			32.412
200		20		1752		31.5				55.188				11.5			20.148
150		20		1752		28.0				49.056				6.5			11.388
100		20		1752		23.0				40.296				3.5			6.132
Σ		100		8760						275.064							26.801

Table 2.4 Result

2.8.6 Better Control

If a frequency converter is used for controlling the †ow or pressure of a system, improved control is obtained.

A frequency converter can vary the speed of the fan or pump, obtaining variable control of †ow and pressure. Furthermore, a frequency converter can quickly adapt the speed of the fan or pump to new †ow or pressure conditions in the system.

Simple control of process (†ow, level, or pressure) utilizing the built-in PI control.

2.8.7 Star/Delta Starter or Soft Starter not

2 2

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 frequency converter is used.

As illustrated in Illustration 2.8, a frequency converter does not consume more than rated current.

	800														<![if ! IE]> <![endif]>175HA227.10
	700
	600										4
<![if ! IE]> <![endif]>current	500
	400
<![if ! IE]> <![endif]>-load	300										3
<![if ! IE]> <![endif]>% Full
	200
											2
	100							1
	0
	0				12,5			25			37,5			50Hz

Full load & speed

1VLT® Micro Drive

2Star/delta starter

3Soft starter

4Start directly on mains

Illustration 2.8 Current

2.8.8Using a Frequency Converter Saves Money

The example in chapter 2.8.9 Without a Frequency Converter shows that a frequency converter 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 1.1 Available Literature to calculate the cost savings that can be achieved by using a frequency converter.

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15

Safety and Conformity

VLT® Micro Drive FC 51

2

2.8.9 Without a Frequency Converter

2

Cooling section

Heating section

Inlet guide vane

Fan section

<![if ! IE]> <![endif]>175HA205.12

-

+

M

Supply

Fan

air

V.A.V

Sensors

outlets

PT

Return

Flow

Return

Flow

Control

Control

3-Port

3-Port

valve

Valve

valve

Valve

Mechanical

Bypass

posi-

Bypass

posi-

linkage

tion

tion

and vanes

x6

IGV

M

Pump

M

Pump

Motor

Duct

or

x6

x6

actuator

Local

Main

D.D.C.

B.M.S

Starter

Starter

Starter

control

Control

Fuses

Fuses

Temperature

LV

LV

control

Pressure

signal

supply

supply

Power

0/10V

P.F.C

P.F.C

control

Factor

signal

Correction

0/10V

Mains

Mains

Mains

D.D.C.	Direct digital control
E.M.S.	Energy management system
V.A.V.	Variable air volume
Sensor P	Pressure
Sensor T	Temperature

Illustration 2.9 Traditional Fan System

16

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MG02K402

Safety and Conformity

Design Guide

2.8.10 With a Frequency Converter

Cooling section

Heating section

Fan section

						Supply
					Fan	air
-			+				V.A.V
					M	Sensors
							outlets
						PT
Return	Flow	Return	Flow
					x3
M	Pump		M	Pump		Duct
	x3			x3
						Local	Main
VLT			VLT		VLT	D.D.C.
							B.M.S
					Pressure	control
					control
					0-10V
					or
					0/4-20mA
		Control		Control
				temperature
		temperature
				0-10V
		0-10V
				or
		or
				0/4-20mA
		0/4-20mA	Mains		Mains
Mains

D.D.C.	Direct digital control
E.M.S.	Energy management system
V.A.V.	Variable air volume
Sensor P	Pressure
Sensor T	Temperature

Illustration 2.10 Fan System Controlled by Frequency Converters

<![if ! IE]>

<![endif]>175HA206.11

2 2

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17

Product Overview VLT® Micro Drive FC 51

3 Product Overview

3.1 Control Structures

3	3	Select the con€guration mode in parameter 1-00 Configuration Mode.

3.1.1 Control Structure Open Loop

Reference handling Remote reference

Auto mode

Hand mode

Local reference scaled to Hz

LCP Hand on, o and auto on keys

P 4-14 Motor speed

high limit [Hz]

Remote

Reference

Local

P 4-12 Motor speed low limit [Hz]

P 3-4* Ramp 1

P 3-5* Ramp 2

Ramp

100%	<![if ! IE]> <![endif]>130BB892.10
0%	To motor
	control

100%
-100%				P 4-10
				Motor speed
				direction

Illustration 3.1 Open-loop Structure

In the con€guration shown in Illustration 3.1,

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.

3.1.2Local (Hand On) and Remote (Auto On) Control

The frequency converter can be operated manually via the local control panel (LCP) or remotely via analog/digital inputs or €eldbus. 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 frequency converter by pressing the [Hand On] and [Off/Reset] keys. Alarms can be reset via the [Off/ Reset] key. After pressing the [Hand On] key, the frequency converter goes into hand mode and follows (by default) the local reference set using the LCP potentiometer (LCP 12) or [▲]/[▼] (LCP 11). The potentiometer can be disabled using parameter 6-80 LCP Potmeter Enable. If the potentiometer is disabled, use the navigation keys for adjusting reference.

After pressing the [Auto On] key, the frequency converter goes into auto mode and follows (by default) the remote reference. In this mode, it is possible to control the

frequency converter via the digital inputs and RS485. See more about starting, stopping, changing ramps and parameter set-ups, and so on, in parameter group 5-1* Digital Inputs or parameter group 8-5* Serial Communication.

Hand	O	Auto	<![if ! IE]> <![endif]>130BB893.10
On	Reset	On

Illustration 3.2 LCP Control Keys

Local reference forces the con€guration mode to open loop, independent on the setting of 1-00 Configuration Mode.

Local reference is restored at power-down.

3.1.3 Control Structure Closed Loop

The internal controller allows the frequency converter to become a part of the controlled system. The frequency converter 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.

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Product Overview

Design Guide

For example, consider a pump application where the speed of a pump is to be controlled so that the static pressure in a pipe is constant. The static pressure value is supplied to the frequency converter as the setpoint reference. A static pressure sensor measures the actual static pressure in the pipe and supplies this data to the frequency converter as a feedback signal. If the feedback signal is greater than the

Reference	+	S
	_	PI

*[-1]

Feedback

7-30 PI

Normal/Inverse

Control

Illustration 3.3 Control Structure Closed Loop

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

setpoint reference, the frequency converter slows the pump down to reduce the pressure. In a similar way, if the pipe pressure is lower than the setpoint reference, the frequency converter automatically speeds the pump up to increase the pressure provided by the pump.

3 3

100%

0%

100%
-100%	P 4-10
	Motor speed
	direction

<![if ! IE]>

<![endif]>130BB894.11

Scale to		To motor
speed		control

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Product Overview

VLT® Micro Drive FC 51

3.1.4 Reference Handling

Details for open-loop and closed-loop operation.

Intern resource

Relative scalling reference

3

3

Preset relative reference

±100%

Input command:

Preset reference 0 ±100%

preset ref bit0, bit1, bit2

Preset reference 1 ±100%

Preset reference 2 ±100%

Preset reference 3 ±100%

Preset reference 4 ±100%

Preset reference

Preset reference 5 ±100%

Preset reference 6 ±100%

±100%

Preset reference 7 ±100%

Y

Relative

Extern resource 1

reference

Parameter choise:

+

X

=

No function

X+X*Y/100

Reference resource 1,2,3

±200%

Analog reference

±200 %

Local bus reference ±200 %

LCP potmeter 0~100 %

+

±200%

Extern resource 2 No function Analog reference

±200 %

Local bus reference

	±200 %	External reference in %
	LCP potmeter 0~100 %

Extern resource 3

No function

Analog reference

±200 %

Local bus reference ±200 % LCP potmeter 0~100 %

Illustration 3.4 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 frequency converter. 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

<![if ! IE]>

<![endif]>130BB900.13

		Speed open
	Con guration	loop
Input command:		Scale to
	mode
		Hz
freeze reference

			Remote
		maxRefPCT	reference/
			setpoint
	±200%	minRefPct
			Process
		min-max ref
	±100%		control

	Freeze
	reference &
	increase/
	decrease
	reference		Scale to
			process
Input commands:			unit
Speed up/speed down

±200% Feedback handling

Remote reference in %

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 ×	Y
	100

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.

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Product Overview	Design Guide

3.2 General Aspects of EMC

3.2.1 General Aspects of EMC Emissions

Frequency converters (and other electrical devices) generate electronic or magnetic €elds 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 †uctuations, or high frequency interference. Electrical devices generate interference along with being affected by interference from other generated sources.

Electrical interference usually occurs at frequencies in the range 150 kHz to 30 MHz. Airborne interference from the frequency converter system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor. Capacitive currents in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents, as shown in Illustration 3.5.

The use of a shielded motor cable increases the leakage current (see Illustration 3.5) because shielded cables have higher capacitance to ground than unshielded cables. If the leakage current is not €ltered, 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, in principle, only a small electro-magnetic €eld (I4) from the shielded motor cable according to Illustration 3.5.

The shield reduces the radiated interference, but increases the low-frequency interference on the mains. Connect the motor cable shield to the frequency converter enclosure and to the motor enclosure. Use the integrated shield

clamps to avoid twisted-pair ends (pigtails). Pigtails 3 3 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, it is necessary to break the shield to avoid current loops.

When placing the shield on a mounting plate for the frequency converter, ensure that the mounting plate is made of metal, to convey the shield currents back to the unit. Ensure good electrical contact from the mounting plate through the mounting screws to the frequency converter 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 cables and brake cables. The control electronics generate radio interference at frequencies higher than 50 MHz (airborne).

z	L1	CS	U			CS	<![if ! IE]> <![endif]>175ZA062.12
z	L2		V	I1
z	L3		W
z PE	PE		I2	CS	1
			I3		2
		CS			CS	CS
			I4		I4
3		4			5		6

1	Ground wire	3	AC mains supply	5	Shielded motor cable
2	Shield	4	Frequency converter	6	Motor

Illustration 3.5 Generation of Leakage Currents

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Product Overview

VLT® Micro Drive FC 51

3.2.2 Emission Requirements

The EMC product standard for frequency converters de€nes 4 categories (C1, C2, C3, and C4) with speci€ed requirements for emission and immunity. Table 3.1 states

3 3 the de€nition of the 4 categories and the equivalent classi- €cation from EN 55011.

		Equivalent
Category	De€nition	emission class
		in EN 55011
C1	Frequency converters installed in	Class B
	the €rst environment (home and
	office) with a supply voltage less
	than 1000 V.
C2	Frequency converters installed in	Class A Group 1
	the €rst environment (home and
	office) with a supply voltage less
	than 1000 V, which are not plug-in
	and not movable, and must be
	installed and commissioned by a
	professional.
C3	Frequency converters installed in	Class A Group 2
	the second environment (industrial)
	with a supply voltage lower than
	1000 V.

3.2.3 EMC Test Results (Emission)

		Equivalent
Category	De€nition	emission class
		in EN 55011
C4	Frequency converters installed in	No limit line.
	the second environment with a	Make an EMC
	supply voltage equal to or above	plan.
	1000 V, or rated current equal to or
	above 400 A, or intended for use in
	complex systems.

Table 3.1 Correlation between IEC 61800-3 and EN 55011

When the generic (conducted) emission standards are used, the frequency converters are required to comply with the limits in Table 3.2.

		Generic emission	Equivalent
	Environment		emission class in
		standard
			EN 55011
	First	EN/IEC 61000-6-3 Emission	Class B
	environment	standard for residential,
	(home and	commercial, and light
	office)	industrial environments.
	Second	EN/IEC 61000-6-4 Emission	Class A Group 1
	environment	standard for industrial
	(industrial	environments.
	environment)

Table 3.2 Correlation between Generic Emission Standards and EN 55011

FC type	Conducted emission. Maximum shielded cable length [m]							Radiated emission
		Industrial environment			Housing, trades, and			Industrial environment
					light industries
	EN 55011 Class A2		EN 55011 Class A1		EN 55011 Class B		EN 55011 Class A2		EN 55011 Class A1
	Without	With	Without	With	Without	With	Without	With	Without	With
	external	external	external	external	external	external	external	external	external	external
	€lter	€lter	€lter	€lter	€lter	€lter	€lter	€lter	€lter	€lter
≤2.2 kW.
Single-	25	–	15	50	5	15	Yes	–	No	Yes
phase, 230 V
≤7.5 kW. Up
to 500 V AC,	25	–	15	50	–	15	Yes	–	No	Yes
3-phase
11–22 kW.
Up to 500 V	25	–	15	50	–	15	Yes	–	No	Yes
AC, 3-phase

Table 3.3 EMC Test Result

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Product Overview	Design Guide

3.2.4 Harmonics Emission Requirements

Equipment connected to the public supply network

NOTICE

Without a power option, the frequency converter may not comply with harmonics emission requirements.

Options De€nition

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

2IEC/EN 61000-3-12 Equipment 16 A-75 A and professional equipment as from 1 kW up to 16 A phase current.

0.25–22 kW (0.34–30 hp)

SMPS

M

<![if ! IE]> <![endif]>130BB896.10

3 3

1

2

3

a

Table 3.4 Harmonics Emission Requirements

3.2.5 Immunity Requirements

The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss frequency converters 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.

3.3 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 ful€lling requirements for higher isolation and by providing the relevant creapage/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 Illustration 3.7.

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

1	Supply (SMPS)
2	Optocouplers, communication between AOC and BOC
3	Custom relays
a	Control card terminals

Illustration 3.6 Galvanic Isolation

30–90 kW (40–120 hp)					<![if ! IE]> <![endif]>130BB901.10
			3
				M
5	4	1	2

a

1	Supply (SMPS) including signal isolation of UDC, indicating
	the intermediate current voltage
2	Gate drive that runs the IGBTs (trigger transformers/opto-
	couplers)
3	Current transducers
4	Internal soft-charge, RFI, and temperature measurement
	circuits
5	Custom relays
a	Control card terminals

Illustration 3.7 Galvanic Isolation

The functional galvanic isolation (see Illustration 3.6) is for the RS485 standard bus interface.

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Product Overview

VLT® Micro Drive FC 51

CAUTION

INSTALLATION AT HIGH ALTITUDE

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

3	3		3.4	Ground Leakage Current
			WARNING
			DISCHARGE TIME
			Touching the electrical parts could be fatal - even after
			the equipment has been disconnected from mains.
			Also make sure that other voltage inputs have been
			disconnected, such as load sharing (linkage of DC
			intermediate circuit), and the motor connection for
			kinetic back-up.
			Before touching any electrical parts, wait at least the
			amount of time indicated in Table 2.1.
			Shorter time is allowed only if indicated on the
			nameplate for the speci€c unit.
			WARNING
			LEAKAGE CURRENT HAZARD
			Leakage currents exceed 3.5 mA. Failure to ground the
			frequency converter properly can result in death or
			serious injury.
			•	Ensure the correct grounding of the equipment
				by a certi€ed electrical installer.

WARNING

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.

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

3.5 Extreme Running Conditions

For information about protecting the frequency converter against a short circuit at the load sharing and brake outputs, see chapter 6.6 Fuses.

Switching on the output

Switching on the output between the motor and the frequency converter is fully permitted. The frequency converter 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 load drives the motor (at constant output frequency from the frequency converter), 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 frequency converter, the motor, and the installation.

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

The control unit may attempt to correct the ramp if parameter 2-17 Over-voltage Control is enabled.

The frequency converter turns off to protect the transistors and the DC link capacitors when a certain voltage level is reached.

Mains drop-out

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

3.5.1 Motor Thermal Protection

Motor thermal protection can be provided in 2 ways.

Using a motor thermistor, via 1 of the following:

•Thermistor input on a standard AI.

•VLT® Sensor Input MCB 114.

•VLT® PTC Thermistor Card MCB 112.

Short circuit (motor phase-phase)

Current measurement in each of the 3 motor phases or in the DC-link, protects the frequency converter 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).

The frequency converter monitors motor temperature as the speed and load vary to detect overheating conditions.

The other method calculates motor temperature by measuring current, frequency, and operating time. The frequency converter shows the thermal load on the motor in percentage and can issue a warning at a programmable

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Danfoss A/S © 01/2016 All rights reserved.

MG02K402

Product Overview	Design Guide
overload setpoint. Programmable options at the overload
allow the frequency converter to stop the motor, reduce
output, or ignore the condition. Even at low speeds, the
frequency converter meets I2t Class 20 electronic motor
overload standards.
This method is called electronic thermal relay (ETR).		3	3

t [s]

2000

1000

600

500

400

300

200

100

60

50

40

30

20

10

1.0 1.2 1.4 1.6 1.8

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fOUT = 1 x f M,N(par. 1-23) fOUT = 2 x f M,N

fOUT = 0.2 x f M,N

IM

2.0 IMN(par. 1-24)

Illustration 3.8 ETR Characteristics

The X-axis shows the ratio between Imotor and Imotor nominal. The Y axis shows the time in s before the ETR cut of and trips the frequency converter. The curves show the characteristic nominal speed, at twice the nominal speed and at 0.2 x the nominal speed.

At lower speed, the ETR cuts 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 is calculating the motor temperature based on actual current and speed. The calculated temperature is visible as a readout parameter in parameter 16-18 Motor Thermal in the product-speci€c Programming Guide.

A special version of the ETR is also available for EX-e motors in ATEX areas. This function makes it possible to enter a speci€c curve to protect the Ex-e motor. The Programming Guide takes the user through the set-up.

MG02K402

Danfoss A/S © 01/2016 All rights reserved.

25

Selection

VLT® Micro Drive FC 51

4 Selection

4.1 Options and Accessories

4.1.1 Local Control Panel (LCP)

For detailed information on programming, see VLT® Micro

4 4 Drive FC 51 Programming Guide.

NOTICE

The frequency converter can also be programmed from a PC via RS485 port by installing the MCT 10 Set-up Software.

This software can either be ordered using code number 130B1000 or downloaded from the Danfoss website: www.danfoss.com/BusinessAreas/DrivesSolutions/softwaredownload

Operation keys

A yellow indicator light above the operation keys indicates the active key.

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

[Oƒ/Reset]: Stops the motor (off). If in alarm mode, the alarm is reset.

[Auto On]: The frequency converter is controlled either via control terminals or serial communication. [Potentiometer] (LCP 12): The potentiometer works in 2 ways:

In auto mode the potentiometer acts as an extra programmable analog input.

In hand-on mode, the potentiometer controls local reference.

Illustration 4.1 Description of LCP Keys and Display

Press [Menu] to select one of the following menus:

Status

For readouts only.

Quick Menu

For access to Quick Menus 1 and 2.

Main Menu

For access to all parameters.

Navigation keys

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

[▲] [▼]: For maneuvering between parameter groups, parameters and within parameters.

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

4.1.2 Remote Mounting Kit for LCP

The LCP can be moved to the front of a cabinet by using the remote built-in kit. The enclosure is IP55.

Enclosure	IP55 front
Maximum cable length between LCP and
unit	3 m
Communication standard:	RS485
Ordering number	132B0102

Table 4.1 Technical Data

4.1.3FC 51 Remote Mounting Kit Mounting Instruction

Step 1

Fit the gasket on the LCP in the frequency converter.

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Illustration 4.2 Fit Gasket on LCP

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Danfoss A/S © 01/2016 All rights reserved.

MG02K402

Selection

Design Guide

Step 2

Place the LCP on the panel - see dimensions of the hole in

Illustration 4.3.

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Illustration 4.5 Place the Bracket on LCP

4xR 1.5±0.5	1

Illustration 4.3 Dimensions of Hole

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2

3

Illustration 4.4 Panel, Gasket, and LCP

Step 3

Place the bracket on the back of the LCP, then slide down. Tighten screws and connect the cable to the LCP.

NOTICE

Use the provided thread cutting screws to fasten the connector to the LCP. Tightening torque: 1.3 Nm (11.5 inlb).

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Illustration 4.6 Tighten Screws and Connect Cable to LCP

Step 4

Connect the cable to the frequency converter.

NOTICE

Use the provided thread cutting screws to fasten connector to the frequency converter. Tightening torque: 1.3 Nm (11.5 in-lb).

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Illustration 4.7 Connect Cable to the Frequency Converter

4 4

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