Danfoss FC 302 Design guide

ENGINEERING TOMORROW

Design Guide

VLT® AutomationDrive FC 302 315–1200 kW

vlt-drives.danfoss.com

Contents Design Guide

Contents

1 Introduction

1.1 Purpose of the Design Guide

1.2 Additional Resources

1.3 Document and Software Version

1.4 Conventions

2 Safety

2.1 Safety Symbols

2.2 Qualied Personnel

2.3 Safety Precautions

3 Approvals and Certications

3.1 Regulatory/Compliance Approvals

3.2 Enclosure Protection Ratings

4 Product Overview

4.1 VLT® High-power Drives

4.2 Enclosure Size by Power Rating

4.3 Overview of Enclosures, 380–500 V

4.4 Overview of Enclosures, 525–690 V

4.5 Kit Availability

5 Product Features

5.1 Automated Operational Features

5.2 Custom Application Features

5.3 Dynamic Braking Overview

5.4 Mechanical Holding Brake Overview

5.5 Load Share Overview

5.6 Regen Overview

6 Options and Accessories Overview

6.1 Fieldbus Devices

6.2 Functional Extensions

6.3 Motion Control and Relay Cards

6.4 Brake Resistors

6.5 Sine-wave Filters

6.6 dU/dt Filters

6.7 Common-mode Filters

6.8 Harmonic Filters

6.9 Enclosure Built-in Options

6.10 High-power Kits

Contents

VLT® AutomationDrive FC 302 315–1200 kW

7 Specications

7.1 Electrical Data, 380–500 V

7.2 Electrical Data, 525–690 V

7.3 Mains Supply

7.4 Motor Output and Motor Data

7.5 Ambient Conditions

7.6 Cable Specications

7.7 Control Input/Output and Control Data

7.8 Enclosure Weights

7.9 Airow for Enclosures E1–E2 and F1–F13

8 Exterior and Terminal Dimensions

8.1 E1 Exterior and Terminal Dimensions

8.2 E2 Exterior and Terminal Dimensions

8.3 F1 Exterior and Terminal Dimensions

8.4 F2 Exterior and Terminal Dimensions

8.5 F3 Exterior and Terminal Dimensions

8.6 F4 Exterior and Terminal Dimensions

100

8.7 F8 Exterior and Terminal Dimensions

8.8 F9 Exterior and Terminal Dimensions

8.9 F10 Exterior and Terminal Dimensions

8.10 F11 Exterior and Terminal Dimensions

8.11 F12 Exterior and Terminal Dimensions

8.12 F13 Exterior and Terminal Dimensions

9 Mechanical Installation Considerations

9.1 Storage

9.2 Lifting the Unit

9.3 Operating Environment

9.4 Mounting Congurations

9.5 Cooling

9.6 Derating

10 Electrical Installation Considerations

10.1 Safety Instructions

10.2 Wiring Schematic

111

115

121

127

135

141

149

150

151

152

153

156

157

10.3 Connections

10.4 Control Wiring and Terminals

10.5 Fuses and Circuit Breakers

10.6 Disconnects and Contactors

10.7 Motor

158

162

169

173

174

Contents Design Guide

10.8 Braking

10.9 Residual Current Devices (RCD) and Insulation Resistance Monitor (IRM)

10.10 Leakage Current

10.11 IT Grid

10.12 Eciency

10.13 Acoustic Noise

10.14 dU/dt Conditions

10.15 Electromagnetic Compatibility (EMC) Overview

10.16 EMC-compliant Installation

10.17 Harmonics Overview

11 Basic Operating Principles of a Drive

11.1 Description of Operation

11.2 Drive Controls

12 Application Examples

12.1 Programming a Closed-loop Drive System

12.2 Wiring Congurations for Automatic Motor Adaptation (AMA)

177

179

180

181

182

186

189

192

201

12.3 Wiring Congurations for Analog Speed Reference

12.4 Wiring Congurations for Start/Stop

12.5 Wiring Conguration for an External Alarm Reset

12.6 Wiring Conguration for Speed Reference Using a Manual Potentiometer

12.7 Wiring Conguration for Speed Up/Speed Down

12.8 Wiring Conguration for RS485 Network Connection

12.9 Wiring Conguration for a Motor Thermistor

12.10 Wiring Conguration for a Relay Set-up with Smart Logic Control

12.11 Wiring Conguration for Mechanical Brake Control

12.12 Wiring Conguration for the Encoder

12.13 Wiring Conguration for Torque and Stop Limit

13 How to Order a Drive

13.1 Drive Congurator

13.2 Ordering Numbers for Options/Kits

13.3 Ordering Numbers for Filters and Brake Resistors

13.4 Spare Parts

202

204

205

206

207

208

209

213

216

14 Appendix

14.1 Abbreviations and Symbols

14.2 Denitions

14.3 RS485 Installation and Set-up

14.4 RS485: FC Protocol Overview

14.5 RS485: FC Protocol Telegram Structure

217

218

219

220

Contents

VLT® AutomationDrive FC 302 315–1200 kW

14.6 RS485: FC Protocol Parameter Examples

14.7 RS485: Modbus RTU Overview

14.8 RS485: Modbus RTU Telegram Structure

14.9 RS485: Modbus RTU Message Function Codes

14.10 RS485: Modbus RTU Parameters

14.11 RS485: FC Control Prole

Index

225

226

229

230

237

Introduction Design Guide

1 Introduction

1.1 Purpose of the Design Guide

This design guide is intended for:

Project and systems engineers.

•

Design consultants.

•

Application and product specialists.

•

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

VLT® is a registered trademark.

1.2 Additional Resources

Other resources are available to understand advanced drive operation, programming, and directives compliance.

The operating guide provides detailed information

•

for the installation and start-up of the drive.

The programming guide provides greater detail on

•

how to work with parameters and includes many application examples.

The VLT

•

describes how to use Danfoss drives in functional safety applications. This manual is supplied with the drive when the Safe Torque O option is present.

The VLT® Brake Resistor MCE 101 Design Guide

•

describes how to select the optimal brake resistor.

Safe Torque O Operating Guide

Document and Software Version

1.3

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

Edition Remarks Software

version

MG34S3xx Removed D1h–D8h content and

implemented new structure.

Table 1.1 Document and Software Version

8.03

1.4 Conventions

Numbered lists indicate procedures.

•

Bullet lists indicate other information and

•

description of illustrations.

Italicized text indicates:

•

- Cross-reference.

- Link.

- Footnote.

- Parameter name, parameter group

name, parameter option.

All dimensions in drawings are in mm (in).

•

An asterisk (*) indicates a default setting of a

•

parameter.

1 1

The VLT® Advanced Harmonic Filters AHF 005/AHF

•

010 Design Guide describes harmonics, various mitigation methods, and the operating principle of the advanced harmonics lter. This guide also describes how to select the correct advanced harmonics lter for a particular application.

The Output Filters Design Guide explains why it is

•

necessary to use output lters for certain applications, and how to select the optimal dU/dt or sine-wave lter.

Optional equipment is available that can change

•

some of the information described in these publications. For specic requirements, see the instructions supplied with the options.

Supplementary publications and manuals are available from Danfoss. See drives.danfoss.com/downloads/portal/#/ for listings.

Safety

VLT® AutomationDrive FC 302 315–1200 kW

2 Safety

2.1 Safety Symbols

The following symbols are used in this guide:

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.

2.2 Qualied Personnel

Only qualied personnel are allowed to install or operate this equipment.

WARNING

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 LED indicator lights are o. Failure to wait 40 minutes after power has been removed before performing service or repair work can result in death or serious injury.

1. Stop the motor.

2. Disconnect AC mains and remote DC-link supplies, including battery back-ups, UPS, and DC-link connections to other drives.

3. Disconnect or lock motor.

4. Wait 40 minutes for the capacitors to discharge fully.

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

Qualied personnel are dened as trained sta, who are authorized to install, commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Also, the personnel must be familiar with the instructions and safety measures described in this manual.

Safety Precautions

2.3

WARNING

HIGH VOLTAGE

Drives contain high voltage when connected to AC mains input, DC supply, load sharing, or permanent motors. Failure to use qualied personnel to install, start up, and maintain the drive can result in death or serious injury.

Only qualied personnel must install, start up,

•

and maintain the drive.

WARNING

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 certied electrical installer.

WARNING

FIRE HAZARD

Brake resistors get hot during and after braking. Failure to place the brake resistor in a secure area can result in property damage and/or serious injury.

Ensure that the brake resistor is placed in a

•

secure environment to avoid re risk.

Do not touch the brake resistor during or after

•

braking to avoid serious burns.

NOTICE

MAINS SHIELD SAFETY OPTION

A mains shield option is available for enclosures with a protection rating of IP21/IP54 (Type 1/Type 12). The mains shield is a cover installed inside the enclosure to protect against the accidental touch of the power terminals, according to BGV A2, VBG 4.

2.3.1 ADN-compliant Installation

To prevent spark formation in accordance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), take precautions for drives with protection rating of IP00 (Chassis), IP20 (Chassis), IP21 (Type 1), or IP54 (Type 12).

e30bd832.10

Safety Design Guide

Do not install a mains switch.

•

Ensure that parameter 14-50 RFI Filter is set to

•

[1] On.

Remove all relay plugs marked RELAY. See

•

Illustration 2.1.

Check which relay options are installed, if any.

•

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

2 2

1, 2 Relay plugs

Illustration 2.1 Location of Relay Plugs

Approvals and

Certication...

VLT® AutomationDrive FC 302 315–1200 kW

3 Approvals and Certications

This section provides a brief description of the various approvals and certications that are found on Danfoss

drives. Not all approvals are found on all drives.

3.1 Regulatory/Compliance Approvals

NOTICE

IMPOSED LIMITATIONS ON THE OUTPUT FREQUENCY

From software version 6.72 onwards, the output frequency of the drive is limited to 590 Hz due to export control regulations. Software versions 6.xx also limit the maximum output frequency to 590 Hz, but these versions cannot be ashed, that is, neither downgraded nor upgraded.

3.1.1.1 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 Table 3.1.

NOTICE

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

EU Directive Version

Low Voltage Directive 2014/35/EU EMC Directive 2014/30/EU

Machinery Directive ErP Directive 2009/125/EC ATEX Directive 2014/34/EU RoHS Directive 2002/95/EC

Table 3.1 EU Directives Applicable to Drives

1) Machinery Directive conformance is only required for drives with

an integrated safety function.

2014/32/EU

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

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 is that devices that generate electromagnetic interference (EMI), or whose operation can be aected by EMI, must be designed to limit the generation of electromagnetic interference. The devices must have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

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

Machinery Directive

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

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

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

3.1.1.2 ErP Directive

NOTICE

Drives with an integrated safety function, such as Safe Torque O (STO), must comply with the Machinery Directive.

Declarations of conformity are available on request.

Low Voltage Directive

Drives must be CE-labeled in accordance with the Low Voltage Directive of January 1, 2014. The Low Voltage Directive applies to all electrical equipment in the 50– 1000 V AC and the 75–1500 V DC voltage ranges.

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

Approvals and Certication... Design Guide

3.1.1.3 UL Listing

The Underwriters Laboratory (UL) mark certies the safety of products and their environmental claims based on standardized testing. Drives of voltage T7 (525–690 V) are UL-certied for only 525–600 V.

3.1.1.4 CSA/cUL

The CSA/cUL approval is for AC drives of voltage rated at 600 V or lower. The standard ensures that, when the drive is installed according to the provided operating/installation guide, the equipment meets the UL standards for electrical and thermal safety. This mark certies that the product performs to all required engineering specications and testing. A certicate of compliance is provided on request.

3.1.1.5 EAC

The EurAsian Conformity (EAC) mark indicates that the product conforms to all requirements and technical regulations applicable to the product per the EurAsian Customs Union, which is composed of the member states of the EurAsian Economic Union.

The EAC logo must be both on the product label and on the packaging label. All products used within the EAC area, must be bought at Danfoss inside the EAC area.

3.1.1.9 Marine

In order for ships and oil/gas platforms to receive a regulatory license and insurance, 1 or more marine certi-

cation societies must certify these applications. Up to 12 dierent marine classication societies have certied

Danfoss drive series.

To view or print marine approvals and certicates, go to the download area at drives.danfoss.com/industries/marine- and-oshore/marine-type-approvals/#/.

3.1.2 Export Control Regulations

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

An ECCN number is used to classify all drives that are subject to export control regulations. The ECCN number is provided in the documents accompanying the drive.

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

3 3

3.1.1.6 UKrSEPRO

UKrSEPRO certicate ensures quality and safety of both products and services, in addition to manufacturing stability according to Ukrainian regulatory standards. The UkrSepro certicate is a required document to clear customs for any products coming into and out of the territory of Ukraine.

3.1.1.7 TÜV

TÜV SÜD is a European safety organization which certies the functional safety of the drive in accordance to EN/IEC 61800-5-2. The TÜV SÜD both tests products and monitors their production to ensure that companies stay compliant with their regulations.

3.1.1.8 RCM

The Regulatory Compliance Mark (RCM) indicates compliance with telecommunications and EMC/radiocommunications equipment per the Australian Communications and Media Authorities EMC labeling notice. RCM is now a single compliance mark covering both the A-Tick and the C-Tick compliance marks. RCM compliance is required for placing electrical and electronic devices on the market in Australia and New Zealand.

Approvals and Certication...

VLT® AutomationDrive FC 302 315–1200 kW

3.2 Enclosure Protection Ratings

The VLT® drive series are available in various enclosure protection to accommodate the needs of the application. Enclosure protection ratings are provided based on 2 international standards:

UL type validates that the enclosures meet NEMA (National Electrical Manufacturers Association) standards. The

•

construction and testing requirements for enclosures are provided in NEMA Standards Publication 250-2003 and UL

Standard Danfoss VLT® drive series are available in various enclosure protections to meet the requirements of IP00 (Chassis), IP20 (Protected chassis) or IP21 (UL Type 1), or IP54 (UL Type 12). In this manual, UL Type is written as Type. For example, IP21/Type 1.

UL type standard

Type 1 – Enclosures constructed for indoor use to provide a degree of protection to personnel against incidental contact with the enclosed units and to provide a degree of protection against falling dirt.

Type 12 – General-purpose enclosures are intended for use indoors to protect the enclosed units against the following:

50, Eleventh Edition.

IP (Ingress Protection) ratings outlined by IEC (International Electrotechnical Commission) in the rest of the world.

•

Fibers

•

Lint

•

Dust and dirt

•

Light splashing

•

Seepage

•

Dripping and external condensation of noncorrosive liquids

•

There can be no holes through the enclosure and no conduit knockouts or conduit openings, except when used with oilresistant gaskets to mount oil-tight or dust-tight mechanisms. Doors are also provided with oil-resistant gaskets. In addition, enclosures for combination controllers have hinged doors, which swing horizontally and require a tool to open.

IP standard

Table 3.2 provides a cross-reference between the 2 standards. Table 3.3 demonstrates how to read the IP number and then

denes the levels of protection. The drives meet the requirements of both.

NEMA and UL IP

Chassis IP00 Protected chassis IP20 Type 1 IP21 Type 12 IP54

Table 3.2 NEMA and IP Number Cross-reference

Approvals and Certication... Design Guide

1st digit 2nd digit

0 – No protection. 1 – Protected to 50 mm (2.0 in). No hands would be able to get into the enclosure. 2 – Protected to 12.5 mm (0.5 in). No ngers would be able to get into the enclosure. 3 – Protected to 2.5 mm (0.1 in). No tools would be able to get into the enclosure. 4 – Protected to 1.0 mm (0.04 in). No wires would be able to get into the enclosure. 5 – Protected against dust – limited entry. 6 – Protected totally against dust. – 0 No protection. – 1 Protected from vertical dripping water. – 2 – 3 – 4 Protected from splashing water. – 5 Protected from water jets. – 6 Protected from strong water jets. – 7 Protected from temporary immersion. – 8 Protected from permanent immersion.

Table 3.3 IP Number Breakdown

Level of protection

Protected from dripping water at 15° angle. Protected from water at 60° angle.

3 3

Product Overview

VLT® AutomationDrive FC 302 315–1200 kW

4 Product Overview

4.1

VLT® High-power Drives

The Danfoss VLT Each VLT® drive is congurable, compatible, and eciency-optimized for all standard motor types, which avoids the

restrictions of motor-drive package deals. These drives come in 2 front-end congurations: 6-pulse and 12-pulse.

drives described in this manual are available as free-standing, wall-mounted, or cabinet-mounted units.

Benets of VLT® 6-pulse drives

Available in various enclosure sizes and protection ratings.

•

98% eciency reduces operating costs.

•

Unique back-channel cooling design reduces the need for more cooling equipment, resulting in lower installation

•

and recurring costs.

Lower power consumption for control room cooling equipment.

•

Reduced ownership costs.

•

Consistent user interface across the entire range of Danfoss drives.

•

Application-oriented start-up wizards.

•

Multi-language user interface.

•

Benets of VLT® 12-pulse drives

The VLT® 12-pulse is a high eciency AC drive that provides harmonic reduction without adding capacitive or inductive components, which often require network analysis to avoid potential system resonance problems. The 12-pulse is built with

the same modular design as the popular 6-pulse VLT® drive. For more harmonic reduction methods, see the VLT® Advanced Harmonic Filter AHF 005/AHF 010 Design Guide.

The 12-pulse drives provide the same benets as the 6-pulse drives in addition to being:

Robust and highly stable in all network and operating conditions.

•

Ideal for applications where stepping down from medium voltage is required or where isolation from the grid is

•

needed.

Excellent input transient immunity.

•

Enclosure Size by Power Rating

4.2

Available enclosures

250 350 – F8–F9 315 450 E1–E2 F8–F9 355 500 E1–E2 F8–F9 400 550 E1–E2 F8–F9 450 600 F1–F3 F10–F11 500 650 F1–F3 F10–F11 560 750 F1–F3 F10–F11 630 900 F1–F3 F10–F11 710 1000 F2–F4 F12–F13 800 1200 F2–F4 F12–F13

6-pulse 12-pulse

kW1)Hp

355 400 E1–E2 F8–F9 400 400 E1–E2 F8–F9 500 500 E1–E2 F8–F9 560 600 E1–E2 F8–F9 630 650 F1–F3 F10–F11 710 750 F1–F3 F10–F11 800 950 F1–F3 F10–F11

900 1050 F2–F4 F12–F13 1000 1150 F2–F4 F12–F13 1200 1350 F2–F4 F12–F13

Available enclosures

6-pulse 12-pulse

Table 4.1 Enclosure Power Ratings, 380–500 V

1) All power ratings are taken at high overload.

Output is measured at 400 V (kW) and 460 V (hp).

Table 4.2 Enclosure Power Ratings, 525–690 V

1) All power ratings are taken at high overload.

Output is measured at 690 V (kW) and 575 V (hp).

Product Overview Design Guide

4.3 Overview of Enclosures, 380–500 V

Enclosure size E1 E2

Power rating

Output at 400 V (kW) 315–400 315–400 Output at 460 V (hp) 450–550 450–550

Front-end conguration

6-pulse S S 12-pulse – –

Protection rating

IP IP21/54 IP00 UL type Type 1/12 Chassis

Hardware options

Stainless steel back channel – O Mains shielding O – Space heater and thermostat – – Cabinet light with power outlet – – RFI lter (Class A1) O O NAMUR terminals – – Insulation resistance monitor (IRM) – – Residual current monitor (RCM) – – Brake chopper (IGBTs) O O Safe Torque O S S Regen terminals O O Common motor terminals – – Emergency stop with Pilz safety relay – – Safe Torque O with Pilz safety relay – – No LCP – – Graphical LCP S S Numerical LCP O O Fuses O O Load share terminals O O Fuses + load share terminals O O Disconnect O O Circuit breakers – – Contactors – – Manual motor starters – – 30 A, fuse-protected terminals – – 24 V DC supply (SMPS, 5 A) O O External temperature monitoring – –

Dimensions

Height, mm (in) 2000 (78.8) 1547 (60.9) Width, mm (in) 600 (23.6) 585 (23.0) Depth, mm (in) 494 (19.4) 498 (19.5) Weight, kg (lb) 270–313 (595–690) 234–277 (516–611)

4 4

Table 4.3 E1–E2 Drives, 380–500 V

1) All power ratings are taken at high overload. Output is measured at 400 V (kW) and 460 V (hp).

2) If the enclosure is congured with load share or regen terminals, the protection rating is IP00, otherwise the protection rating is IP20.

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

Product Overview

Enclosure size F1 F2 F3 F4

Power rating

Output at 400 V (kW) 315–400 450–500 315–400 450–500 Output at 460 V (hp) 450–550 600–650 450–550 600–650

Front-end conguration

6-pulse S S S S 12-pulse – – – –

Protection rating

IP IP21/54 IP21/54 IP21/54 IP21/54 UL type Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Stainless steel back channel O O O O Mains shielding – – – – Space heater and thermostat O O O O Cabinet light with power outlet O O O O RFI lter (Class A1) – – O O NAMUR terminals O O O O Insulation resistance monitor (IRM) – – O O Residual current monitor (RCM) – – O O Brake chopper (IGBTs) O O O O Safe Torque O S S S S Regen terminals O O O O Common motor terminals O O O O Emergency stop with Pilz safety relay – – O O Safe Torque O with Pilz safety relay O O O O No LCP – – – – Graphical LCP S S S S Numerical LCP – – – – Fuses O O O O Load share terminals O O O O Fuses + load share terminals O O O O Disconnect – – O O Circuit breakers – – O O Contactors – – O O Manual motor starters O O O O 30 A, fuse-protected terminals O O O O 24 V DC supply (SMPS, 5 A) O O O O External temperature monitoring O O O O

Dimensions

Height, mm (in) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) Width, mm (in) 1400 (55.1) 1800 (70.9) 2000 (78.7) 2400 (94.5) Depth, mm (in) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) Weight, kg (lb) 1017 (2242.1) 1260 (2777.9) 1318 (2905.7) 1561 (3441.5)

VLT® AutomationDrive FC 302 315–1200 kW

Table 4.4 F1–F4 Drives, 380–500 V

1) All power ratings are taken at high overload. Output is measured at 400 V (kW) and 460 V (hp).

2) If the enclosure is

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

congured with load share or regen terminals, the protection rating is IP00, otherwise the protection rating is IP20.

Product Overview Design Guide

Enclosure size F8 F9 F10 F11 F12 F13

Power rating

Output at 400 V (kW) 90–132 160–250 450–630 450–630 710–800 710–800 Output at 460 V (hp) 125–200 250–350 600–900 600–900 1000–1200 1000–1200

Front-end conguration

6-pulse – – – – – – 12-pulse S S S S S S

Protection rating

IP IP21/54 IP21/54 IP21/54 IP21/54 IP21/54 IP21/54 NEMA Type 1/12 Type 1/12 Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Stainless steel back channel – – – – – – Mains shielding – – – – – – Space heater and thermostat – – O O O O Cabinet light with power outlet RFI lter (Class A1) – O – – O O NAMUR terminals O O O O O O Insulation resistance monitor (IRM) Residual current monitor (RCM) Brake chopper (IGBTs) O O O O O O Safe Torque O S S S S S S Regen terminals – – – – – – Common motor terminals – – O O O O Emergency stop with Pilz safety relay Safe Torque O with Pilz safety relay No LCP – – – – – – Graphical LCP S S S S S S Numerical LCP – – – – – – Fuses O O O O O O Load share terminals – – – – – – Fuses + load share terminals – – – – – – Disconnect – O O O O O Circuit breakers – – – – – – Contactors – – – – – – Manual motor starters – – O O O O 30 A, fuse-protected terminals – – O O O O 24 V DC supply (SMPS, 5 A) O O O O O O External temperature monitoring

Dimensions

Height, mm (in) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) Width, mm (in) 800 (31.5) 1400 (55.2) 1600 (63.0) 2400 (94.5) 2000 (78.7) 2800 (110.2) Depth, mm (in) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) Weight, kg (lb) 447 (985.5) 669 (1474.9) 893 (1968.8) 1116 (2460.4) 1037 (2286.4) 1259 (2775.7)

– – O O O O

– O – – O O

– – – – – –

O O O O O O

– – O O O O

4 4

Table 4.5 F8–F13 Drives, 380–500 V

1) All power ratings are taken at high overload. Output is measured at 400 V (kW) and 460 V (hp).

2) S = standard, O = optional, and a dash indicates that the option is unavailable.

Product Overview

VLT® AutomationDrive FC 302 315–1200 kW

4.4 Overview of Enclosures, 525–690 V

Enclosure size E1 E2

Power rating

Output at 690 V (kW) 355–560 355–560 Output at 575 V (hp) 400–600 400–600

Front-end conguration

6-pulse S S

12-pulse – –

Protection rating

IP IP21/54 IP00 UL type Type 1/12 Chassis

Hardware options

Dimensions

Height, mm (in) 2000 (78.8) 1547 (60.9) Width, mm (in) 600 (23.6) 585 (23.0) Depth, mm (in) 494 (19.4) 498 (19.5) Weight, kg (lb) 263–313 (580–690) 221–277 (487–611)

Table 4.6 E1–E2 Drives, 525–690 V

1) All power ratings are taken at high overload. Output is measured at 690 V (kW) and 575 V (hp).

2) If the enclosure is congured with load share or regen terminals, the protection rating is IP00, otherwise the protection rating is IP20.

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

Product Overview Design Guide

Enclosure size F1 F2 F3 F4

Power rating

Output at 690 V (kW) 630–800 900–1200 630–800 900–1200 Output at 575 V (hp) 650–950 1050–1350 650–950 1050–1350

Front-end conguration

6-pulse S S S S 12-pulse – – – –

Protection rating

IP IP21/54 IP21/54 IP21/54 IP21/54 UL type Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Dimensions

4 4

Table 4.7 F1–F4 Drives, 525–690 V

1) All power ratings are taken at high overload. Output is measured at 690 V (kW) and 575 V (hp).

2) If the enclosure is

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

congured with load share or regen terminals, the protection rating is IP00, otherwise the protection rating is IP20.

Product Overview

Enclosure size F8 F9 F10 F11 F12 F13

Power rating

Output at 690 V (kW) 355–560 355–560 630–800 630–800 900–1200 900–1200 Output at 575 V (hp) 400–600 400–600 650–950 650–950 1050–1350 1050–1350

Front-end conguration

6-pulse – – – – – – 12-pulse S S S S S S

Protection rating

IP IP21/54 IP21/54 IP21/54 IP21/54 IP21/54 IP21/54 NEMA Type 1/12 Type 1/12 Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Dimensions

Height, mm (in) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8) Width, mm (in) 800 (31.5) 1400 (55.1) 1600 (63.0) 2400 (94.5) 2000 (78.7) 2800 (110.2) Depth, mm (in) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9) Weight, kg (lb) 447 (985.5) 669 (1474.9) 893 (1968.8) 1116 (2460.4) 1037 (2286.4) 1259 (2775.7)

– – O O O O

– O – – O O

– – – – – –

O O O O O O

– – O O O O

VLT® AutomationDrive FC 302 315–1200 kW

Table 4.8 F8–F13 Drives, 525–690 V

1) All power ratings are taken at high overload. Output is measured at 690 V (kW) and 575 V (hp).

2) S = standard, O = optional, and a dash indicates that the option is unavailable.

Product Overview Design Guide

4.5 Kit Availability

Kit description

USB in door O – O O O O O O O O O O LCP, numerical O O O O O O O O O O O O

LCP, graphical LCP cable, 3 m (9 ft) O O O O O O O O O O O O Mounting kit for numerical LCP (LCP, fasteners, gasket, and cable) Mounting kit for graphical LCP (LCP, fasteners, gasket, and cable) Mounting kit for all LCPs (fasteners, gasket, and cable) Top entry for motor cables – – O O O O O O O O O O Top entry for mains cables – – O O O O O O O O O O Top entry for mains cables with disconnect – – – – O O – – – – – – Top entry for eldbus cables – O – – – – – – – – – – Common motor terminals – – O O O O – – – – – – NEMA 3R enclosure – O – – – – – – – – – – Pedestal O O – – – – – – – – – – Input options plate O O – – – – – – – – – – IP20 conversion – O – – – – – – – – – – Out top (only) cooling – O – – – – – – – – – – Back-channel cooling (in-back/out-back) O O O O O O O O O O O O Back-channel cooling (in-bottom/out-top) – O – – – – – – – – – –

E1 E2 F1 F2 F3 F4 F8 F9 F10 F11 F12 F13

O O O O O O O O O O O O

4 4

Table 4.9 Available Kits for Enclosures E1–E2, F1–F4, and F8–F13

1) S = standard, O = optional, and a dash indicates that the kit is unavailable for that enclosure. For kit descriptions and part numbers, see

chapter 13.2 Ordering Numbers for Options/Kits.

2) The graphical LCP comes standard with enclosures E1–E2, F1–F4, and F8–F13. If more than 1 graphical LCP is required, the kit is available for

purchase.

Product Features

VLT® AutomationDrive FC 302 315–1200 kW

5 Product Features

Incorrect slip compensation setting causing

5.1 Automated Operational Features

Automated operational features are active when the drive is operating. Most of them require no programming or setup. The drive has a range of built-in protection functions to protect itself and the motor when it runs.

For details of any set-up required, in particular motor

parameters, refer to the programming guide.

5.1.1 Short-circuit Protection

Motor (phase-to-phase)

The drive is protected against short circuits on the motor side by current measurement in each of the 3 motor phases. A short circuit between 2 output phases causes an overcurrent in the inverter. The inverter is turned o when the short circuit current exceeds the allowed value (Alarm 16, Trip Lock).

Mains side

A drive that works correctly limits the current it can draw from the supply. Still, it is recommended to use fuses and/or circuit breakers on the supply side as protection if there is component break-down inside the drive (1st fault). Mains side fuses are mandatory for UL compliance.

NOTICE

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

Brake resistor

The drive is protected from a short circuit in the brake resistor.

Load sharing

To protect the DC bus against short circuits and the drives from overload, install DC fuses in series with the load sharing terminals of all connected units.

5.1.2 Overvoltage Protection

•

higher DC-link voltage.

Back EMF from PM motor operation. If coasted at

•

high RPM, the PM motor back EMF can potentially exceed the maximum voltage tolerance of the drive and cause damage. To help prevent this situation, the value of parameter 4-19 Max Output Frequency is automatically limited based on an internal calculation based on the value of parameter 1-40 Back EMF at 1000 RPM, parameter 1-25 Motor Nominal Speed, and parameter 1-39 Motor Poles.

NOTICE

To avoid motor overspeeds (for example, due to excessive windmilling eects), equip the drive with a brake resistor.

The overvoltage can be handled either using a brake function (parameter 2-10 Brake Function) and/or using overvoltage control (parameter 2-17 Over-voltage Control).

Brake functions

Connect a brake resistor for dissipation of surplus brake energy. Connecting a brake resistor allows a higher DC-link voltage during braking.

AC brake is an alternative to improving braking without using a brake resistor. This function controls an overmagnetization of the motor when the motor is acting as a generator. Increasing the electrical losses in the motor allows the OVC function to increase the braking torque without exceeding the overvoltage limit.

NOTICE

AC brake is not as eective as dynamic braking with a resistor.

Overvoltage control (OVC)

By automatically extending the ramp-down time, OVC reduces the risk of the drive tripping due to an overvoltage on the DC-link.

Motor-generated overvoltage

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

The load rotates 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 throughout the drive system.

NOTICE

OVC can be activated for a PM motor with all control core, PM VVC+, Flux OL, and Flux CL for PM Motors.

NOTICE

Do not enable OVC in hoisting applications.

Product Features Design Guide

5.1.3 Missing Motor Phase Detection

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

5.1.4 Supply Voltage Imbalance Detection

Operation under severe supply voltage imbalance reduces the lifetime of the motor and drive. If the motor is operated continuously near nominal load, conditions are considered severe. The default setting trips the drive if there is supply voltage imbalance (parameter 14-12 Function at Mains Imbalance).

5.1.5 Switching on the Output

Adding a switch to the output between the motor and the drive is allowed, however fault messages can appear. Danfoss does not recommend using this feature for 525– 690 V drives connected to an IT mains network.

5.1.6 Overload Protection

Torque limit

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

Current limit

The current limit is controlled in parameter 4-18 Current Limit, and the time before the drive trips is controlled in parameter 14-24 Trip Delay at Current Limit.

Speed limit

Minimum speed limit: Parameter 4-11 Motor Speed Low Limit [RPM] or parameter 4-12 Motor Speed Low Limit [Hz]

limit the minimum operating speed range of the drive. Maximum speed limit: Parameter 4-13 Motor Speed High Limit [RPM] or parameter 4-19 Max Output Frequency limit the maximum output speed the drive can provide.

Electronic thermal relay (ETR)

ETR is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in Illustration 5.1.

Voltage limit

The inverter turns o to protect the transistors and the DC link capacitors when a certain hard-coded voltage level is reached.

Overtemperature

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

5.1.7 Locked Rotor Protection

There can be situations when the rotor is locked due to excessive load or other factors. The locked rotor cannot produce enough cooling, which in turn can overheat the motor winding. The drive is able to detect the locked rotor situation with open-loop PM ux control and PM VVC control (parameter 30-22 Locked Rotor Protection).

5.1.8 Automatic Derating

The drive constantly checks for the following critical levels:

High temperature on the control card or heat

•

sink.

High motor load.

•

High DC-link voltage.

•

Low motor speed.

•

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

NOTICE

The automatic derating is dierent when

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

5.1.9 Automatic Energy Optimization

Automatic energy optimization (AEO) directs the drive to monitor the load on the motor continuously and adjust the output voltage to maximize eciency. Under light load, the voltage is reduced and the motor current is minimized. The motor benets from:

Increased eciency.

•

Reduced heating.

•

Quieter operation.

•

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

5.1.10 Automatic Switching Frequency Modulation

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

Automatic switching frequency modulation regulates these conditions automatically to provide the highest switching

5 5

Product Features

VLT® AutomationDrive FC 302 315–1200 kW

frequency without overheating the drive. By providing a regulated high switching frequency, it quiets motor operating noise at slow speeds, when audible noise control is critical, and produces full output power to the motor when required.

5.1.11 Automatic Derating for High

radiation from an external source. The drive is designed to comply with the EMC product standard for drives IEC 61800-3 and the European standard EN 55011. Motor cables must be shielded and properly terminated to comply with the emission levels in EN 55011. For more information regarding EMC performance, see chapter 10.15.1 EMC Test Results.

Switching Frequency

5.1.16 Galvanic Isolation of Control

The drive is designed for continuous, full-load operation at switching frequencies between 1.5–2 kHz for 380–500 V,

and 1–1.5 kHz for 525–690 V. The frequency range depends on power size and voltage rating. A switching frequency exceeding the maximum allowed range generates increased heat in the drive and requires the output current to be derated.

An automatic feature of the drive is load-dependent switching frequency control. This feature allows the motor to benet from as high a switching frequency as the load allows.

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

The components that make up the galvanic isolation are:

5.1.12 Power Fluctuation Performance

The drive withstands mains uctuations such as:

Transients.

•

Momentary drop-outs.

•

Short voltage drops.

•

Surges.

•

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

5.1.13 Resonance Damping

Resonance damping eliminates the high-frequency motor resonance noise. Automatic or manually selected frequency damping is available.

5.2

Custom application functions are the most common features programmed in the drive for enhanced system performance. They require minimum programming or setup. See the programming guide for instructions on activating these functions.

5.2.1 Automatic Motor Adaptation

Automatic motor adaptation (AMA) is an automated test procedure used to measure the electrical characteristics of the motor. AMA provides an accurate electronic model of the motor, allowing the drive to calculate optimal performance and eciency. Running the AMA procedure also maximizes the automatic energy optimization feature of the drive. AMA is performed without the motor rotating and without uncoupling the load from the motor.

Terminals

Supply, including signal isolation.

•

Gatedrive for the IGBTs, trigger transformers, and

•

optocouplers.

The output current Hall

•

eect transducers.

Custom Application Features

5.1.14 Temperature-controlled Fans

5.2.2 Built-in PID Controller

Sensors in the drive regulate the operation of the internal cooling fans. Often, the cooling fans do not run during low load operation, or when in sleep mode or standby. These sensors reduce noise, increase eciency, and extend the operating life of the fan.

The built-in proportional, integral, derivative (PID) controller eliminates the need for auxiliary control devices. The PID controller maintains constant control of closedloop systems where regulated pressure, ow, temperature, or other system requirements must be maintained.

5.1.15 EMC Compliance

dierent

Electromagnetic interference (EMI) and radio frequency interference (RFI) are disturbances that can aect an electrical circuit due to electromagnetic induction or

The drive can use 2 feedback signals from 2 devices, allowing the system to be regulated with dierent feedback requirements. The drive makes control decisions

1.21.0 1.4

100

1.81.6 2.0

2000

500

200

400 300

1000

600

t [s]

175ZA052.12

OUT

= 2 x f

M,N

OUT

= 0.2 x f

M,N

OUT

= 1 x f

M,N

(par. 1-23)

IMN(par. 1-24)

Product Features Design Guide

by comparing the 2 signals to optimize system performance.

5.2.3 Motor Thermal Protection

Motor thermal protection can be provided via:

Direct temperature sensing using a

•

- PTC- or KTY sensor in the motor

windings and connected on a standard AI or DI.

- PT100 or PT1000 in the motor windings and motor bearings, connected on VLT

Sensor Input Card MCB 114.

PTC Thermistor input on VLT® PTC Thermistor Card MCB 112 (ATEX approved).

Mechanical thermal switch (Klixon type) on a DI.

•

Built-in electronic thermal relay (ETR).

•

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

and speed. The calculated temperature is visible as a readout parameter in parameter 16-18 Motor Thermal. 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. See the programming guide for set-up instructions.

5.2.4 Motor Thermal Protection for Ex-e Motors

The drive is equipped with an ATEX ETR thermal

monitoring function for operation of Ex-e motors according to EN-60079-7. When combined with an ATEX approved

PTC monitoring device such as the VLT® PTC Thermistor Card MCB 112 option or an external device, the installation does not require an individual approval from an approbated organization.

The ATEX ETR thermal monitoring function enables use of an Ex-e motor instead of a more expensive, larger, and heavier Ex-d motor. The function ensures that the drive limits motor current to prevent overheating.

Requirements related to the Ex-e motor

Ensure that the Ex-e motor is approved for

•

operation in hazardous zones (ATEX zone 1/21, ATEX zone 2/22) with drives. The motor must be certied for the specic hazardous zone.

Install the Ex-e motor in zone 1/21 or 2/22 of the

•

hazardous zone, according to motor approval.

5 5

NOTICE

Install the drive outside the hazardous zone.

Ensure that the Ex-e motor is equipped with an

•

ATEX-approved motor overload protection device. This device monitors the temperature in the motor windings. If there is a critical temperature level or a malfunction, the device switches o the motor.

The VLT® PTC Thermistor Card MCB 112 option provides ATEX-approved monitoring of motor temperature. It is a

Illustration 5.1 ETR Characteristics

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

motor

and I

motor

Sine-wave lter is required when

•

prerequisite that the drive is equipped with 3–6 PTC thermistors in series according to DIN 44081 or 44082.

- Alternatively, an external ATEX-approved PTC protection device can be used.

- Long cables (voltage peaks) or increased mains voltage produce voltages

130BD888.10

CONVERTER SUPPLY VALID FOR 380 - 415V FWP 50Hz 3 ~ Motor

MIN. SWITCHING FREQ. FOR PWM CONV. 3kHz l = 1.5XI

M,N

tOL = 10s tCOOL = 10min

MIN. FREQ. 5Hz MAX. FREQ. 85 Hz

PWM-CONTROL

f [Hz]

Ix/I

M,N

PTC °C DIN 44081/-82

Manufacture xx

EN 60079-0 EN 60079-7

СЄ 1180 Ex-e ll T3

5 15 25 50 85

0.4 0.8 1.0 1.0 0.95

xЗ

2 3 4

Product Features

VLT® AutomationDrive FC 302 315–1200 kW

exceeding the maximum allowable voltage at motor terminals.

- Minimum switching frequency of the drive does not meet the requirement stated by the motor manufacturer. The minimum switching frequency of the drive is shown as the default value in parameter 14-01 Switching Frequency.

Compatibility of motor and drive

For motors certied according to EN-60079-7, a data list including limits and rules is supplied by the motor

manufacturer as a data sheet, or on the motor nameplate. During planning, installation, commissioning, operation, and service, follow the limits and rules supplied by the manufacturer for:

Minimum switching frequency.

•

Maximum current.

•

Minimum motor frequency.

•

Maximum motor frequency.

•

Illustration 5.2 shows where the requirements are indicated on the motor nameplate.

1 Minimum switching frequency 2 Maximum current 3 Minimum motor frequency 4 Maximum motor frequency

When matching drive and motor, Danfoss species the following extra requirements to ensure adequate motor

Illustration 5.2 Motor Nameplate showing Drive Requirements

thermal protection:

Do not exceed the maximum allowed ratio

•

between drive size and motor size. The typical value is I

Consider all voltage drops from drive to motor. If

•

the motor runs with lower voltage than listed in the U/f characteristics, current can increase, triggering an alarm.

VLT, n

≤2xI

m,n

For further information, see the application example in chapter 12 Application Examples.

5.2.5 Mains Drop-out

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

The drive can be congured (parameter 14-10 Mains Failure) to dierent types of behavior during mains drop-out:

Trip lock once the DC link is exhausted.

•

Coast with ying start whenever mains return

•

(parameter 1-73 Flying Start).

Kinetic back-up.

•

Controlled ramp down.

•

Flying start

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

Kinetic back-up

This selection ensures that the drive runs as long as there is energy in the system. For short mains drop-out, the operation is restored after mains return, without bringing

. . . . . .

Par. 13-11 Comparator Operator

Par. 13-43 Logic Rule Operator 2

Par. 13-51 SL Controller Event

Par. 13-52 SL Controller Action

130BB671.13

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

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

= TRUE longer than..

. . . . . .

Product Features Design Guide

the application to a stop or losing control at any time. Several variants of kinetic back-up can be selected.

Congure the behavior of the drive at mains drop-out, in

parameter 14-10 Mains Failure and parameter 1-73 Flying Start.

5.2.6 Automatic Restart

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

5.2.7 Full Torque at Reduced Speed

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

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

5.2.11 Smart Logic Control (SLC)

Smart logic control (SLC) is a sequence of user-dened actions (see parameter 13-52 SL Controller Action [x]) executed by the SLC when the associated user-dened event (see parameter 13-51 SL Controller Event [x]) is evaluated as TRUE by the SLC. The condition for an event can be a particular status, or that the output from a logic rule or a comparator operand becomes TRUE. The condition leads to an associated action as shown in Illustration 5.3.

5 5

5.2.8 Frequency Bypass

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

5.2.9 Motor Preheat

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

5.2.10 Programmable Set-ups

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

Illustration 5.3 SLC Event and Action

Events and actions are each numbered and linked in pairs (states), which means that when event [0] is fullled (attains the value TRUE), action [0] is executed. After the 1 action is executed, the conditions of the next event are evaluated. If this event is evaluated as true, then the corresponding action is executed. Only 1 event is evaluated at any time. If an event is evaluated as false, nothing happens in the SLC during the current scan interval and no other events are evaluated. When the SLC starts, it only evaluates event [0] during each scan interval. Only when event [0] is evaluated as true, the SLC executes action [0] and starts evaluating the next event. It is possible to program 1–20 events and actions. When the last event/action has been executed, the sequence starts over again from event [0]/action [0]. Illustration 5.4 shows an example with 4 event/actions:

130BA062.14

State 1 13-51.0 13-52.0

State 2 13-51.1 13-52.1

Start event P13-01

State 3 13-51.2 13-52.2

State 4 13-51.3 13-52.3

Stop event P13-02

Par. 13-11 Comparator Operator

TRUE longer than.

. . .

Par. 13-10 Comparator Operand

Par. 13-12 Comparator Value

130BB672.10

. . . . . .

Par. 13-43 Logic Rule Operator 2

Par. 13-41 Logic Rule Operator 1

Par. 13-40 Logic Rule Boolean 1

Par. 13-42 Logic Rule Boolean 2

Par. 13-44 Logic Rule Boolean 3

130BB673.10

Product Features

VLT® AutomationDrive FC 302 315–1200 kW

Liability conditions

The customer is responsible for ensuring that personnel know how to install and operate the safe torque o function by:

Reading and understanding the safety regulations

•

concerning health, safety, and accident prevention.

Understanding the generic and safety guidelines

•

provided in the Safe Torque O Operating Guide.

Having a good knowledge of the generic and

•

safety standards for the specic application.

Illustration 5.4 Order of Execution when 4 Events/Actions are

Programmed

5.3 Dynamic Braking Overview

Dynamic braking slows the motor using 1 of the following methods:

Comparators

Comparators are used for comparing continuous variables (output frequency, output current, analog input, and so on) to xed preset values.

AC brake

•

The brake energy is distributed in the motor by changing the loss conditions in the motor (parameter 2-10 Brake Function = [2]). The AC brake function cannot be used in applications with high cycling frequency since this situation overheats the motor.

DC brake

•

An overmodulated DC current added to the AC current works as an eddy current brake (parameter 2-02 DC Braking Time ≠ 0 s).

Illustration 5.5 Comparators

Resistor brake

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A brake IGBT keeps the overvoltage under a certain threshold by directing the brake energy

Logic rules

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

from the motor to the connected brake resistor (parameter 2-10 Brake Function = [1]). For more

information on selecting a brake resistor, see VLT Brake Resistor MCE 101 Design Guide.

For drives equipped with the brake option, a brake IGBT along with terminals 81(R-) and 82(R+) are included for connecting an external brake resistor.

The function of the brake IGBT is to limit the voltage in the DC link whenever the maximum voltage limit is exceeded. It limits the voltage by switching the externally mounted resistor across the DC bus to remove excess DC voltage

Illustration 5.6 Logic Rules

present on the bus capacitors.

External brake resistor placement has the advantages of

5.2.12 Safe Torque O

selecting the resistor based on application need, dissipating the energy outside of the control panel, and

The Safe Torque O (STO) function is used to stop the drive in emergency stop situations.

For more information about Safe Torque O, including installation and commissioning, refer to the Safe Torque O Operating Guide.

protecting the drive from overheating if the brake resistor is overloaded.

The brake IGBT gate signal originates on the control card and is delivered to the brake IGBT via the power card and gatedrive card. Also, the power and control cards monitor the brake IGBT for a short circuit. The power card also monitors the brake resistor for overloads.

Product Features Design Guide

5.4 Mechanical Holding Brake Overview

A mechanical holding brake is an external piece of equipment mounted directly on the motor shaft that performs static braking. Static braking is when a brake is used to clamp down on the motor after the load has been stopped. A holding brake is either controlled by a PLC or directly by a digital output from the drive.

NOTICE

A drive cannot provide a safe control of a mechanical brake. A redundancy circuitry for the brake control must be included in the installation.

5.4.1 Mechanical Brake Using Open-loop Control

For hoisting applications, typically it is necessary to control an electromagnetic brake. A relay output (relay 1 or relay 2) or a programmed digital output (terminal 27 or 29) is required. Normally, this output must be closed for as long as the drive is unable to hold the motor. In parameter 5-40 Function Relay (array parameter), parameter 5-30 Terminal 27 Digital Output, or parameter 5-31 Terminal 29 Digital Output, select [32] mechanical brake control for applications with an electromagnetic brake.

When [32] mechanical brake control is selected, the mechanical brake relay remains closed during start until the output current is above the level selected in parameter 2-20 Release Brake Current. During stop, the mechanical brake closes when the speed is below the level selected in parameter 2-21 Activate Brake Speed [RPM]. If the drive is brought into an alarm condition, such as an overvoltage situation, the mechanical brake immediately cuts in. The mechanical brake also cuts in during safe torque o.

Consider the following when using the electromagnetic brake:

Use any relay output or digital output (terminal 27 or 29). If necessary, use a contactor.

•

Ensure that the output is switched

•

being too heavy or the motor not being mounted.

Before connecting the mechanical brake, select [32] Mechanical brake control in parameter group 5-4* Relays (or in

•

parameter group 5-3* Digital Outputs).

The brake is released when the motor current exceeds the preset value in parameter 2-20 Release Brake Current.

•

The brake is engaged when the output frequency is less than the frequency set in parameter 2-21 Activate Brake

•

Speed [RPM] or parameter 2-22 Activate Brake Speed [Hz] and only if the drive carries out a stop command.

o as long as the drive is unable to rotate the motor. Examples include the load

5 5

NOTICE

For vertical lifting or hoisting applications, ensure that the load can be stopped if there is an emergency or a malfunction. If the drive is in alarm mode or in an overvoltage situation, the mechanical brake cuts in.

For hoisting applications, make sure that the torque limits in parameter 4-16 Torque Limit Motor Mode and parameter 4-17 Torque Limit Generator Mode are set lower than the current limit in parameter 4-18 Current Limit. It is also recommended to set parameter 14-25 Trip Delay at Torque Limit to 0, parameter 14-26 Trip Delay at Inverter Fault to 0, and parameter 14-10 Mains Failure to [3] Coasting.

Start

term.18

1=on

0=o

Shaft speed

Start delay time

o

Brake delay time

Time

Output current

Relay 01

Pre-magnetizing current or DC hold current

Reaction time EMK brake

Par 2-20 Release brake current

Par 1-76 Start current/ Par 2-00 DC hold current

Par 1-74 Start speed

Par 2-21

Activate brake

speed

Mechanical brake locked

Mechanical brake free

Par 1-71

Par 2-23

130BA074.12

Product Features

VLT® AutomationDrive FC 302 315–1200 kW

Illustration 5.7 Mechanical Brake Control in Open Loop

5.4.2 Mechanical Brake Using Closed-loop Control

The VLT® AutomationDrive FC 302 features a mechanical brake control designed for hoisting applications and supports the following functions:

2 channels for mechanical brake feedback, oering protection against unintended behavior resulting from a broken

•

cable.

Monitoring the mechanical brake feedback throughout the complete cycle. Monitoring helps protect the

•

mechanical brake - especially if more drives are connected to the same shaft.

No ramp up until feedback conrms that the mechanical brake is open.

•

Improved load control at stop.

•

The transition when motor takes over the load from the brake can be congured.

•

Parameter 1-72 Start Function [6] Hoist Mech. Brake Rel activates the hoist mechanical brake. The main dierence compared to the regular mechanical brake control is that the hoist mechanical brake function has direct control over the brake relay. Instead of setting a current to release the brake, the torque applied against the closed brake before release is dened. Because the torque is dened directly, the set-up is more straightforward for hoisting applications.

The hoist mechanical brake strategy is based on the following 3-step sequence, where motor control and brake release are synchronized to obtain the smoothest possible brake release.

1. Pre-magnetize the motor. To ensure that there is a hold on the motor and to verify that it is mounted correctly, the motor is magnetized.

2. Apply torque against the closed brake.

rst pre-

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Danfoss FC 302 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual