Danfoss FC 360 Design guide

ENGINEERING TOMORROW

Design Guide

VLT® AutomationDrive FC 360

vlt-drives.danfoss.com

Contents Design Guide

Contents

1 Introduction

1.1 How to Read This Design Guide

1.2 Denitions

1.3 Safety Precautions

1.4 Disposal Instruction

1.5 Document and Software Version

1.6 Approvals and Certications

2 Product Overview

2.1 Enclosure Size Overview

2.2 Electrical Installation

2.2.1 Grounding Requirements 16

2.2.2 Control Wiring 18

2.3 Control Structures

2.3.1 Control Principle 20

2.3.2 Control Modes 20

2.3.3 FC 360 Control Principle 21

2.3.4 Control Structure in VVC

2.3.5 Internal Current Control in VVC+ Mode 23

2.3.6 Local [Hand On] and Remote [Auto On] Control 23

2.4 Reference Handling

2.4.1 Reference Limits 25

2.4.2 Scaling of Preset References and Bus References 26

2.4.3 Scaling of Analog and Pulse References and Feedback 26

2.4.4 Dead Band Around Zero 27

2.5 PID Control

2.5.1 Speed PID Control 30

2.5.2 Process PID Control 33

2.5.3 Process Control Relevant Parameters 34

2.5.4 Example of Process PID Control 35

2.5.5 Process Controller Optimization 38

2.5.6 Ziegler Nichols Tuning Method 38

2.6 EMC Emission and Immunity

2.6.1 General Aspects of EMC Emission 39

2.6.2 EMC Emission Requirements 40

2.6.3 EMC Immunity Requirements 40

2.7 Galvanic Isolation

2.8 Earth Leakage Current

2.9 Brake Functions

Contents

VLT® AutomationDrive FC 360

2.9.1 Mechanical Holding Brake 43

2.9.2 Dynamic Braking 44

2.9.3 Brake Resistor Selection 44

2.10 Smart Logic Controller

2.11 Extreme Running Conditions

3 Type Code and Selection

3.1 Ordering

3.2 Ordering Numbers: Options, Accessories, and Spare Parts

3.3 Ordering Numbers: Brake Resistors

3.3.1 Ordering Numbers: Brake Resistors 10% 50

3.3.2 Ordering Numbers: Brake Resistors 40% 51

4 Specications

4.1 Mains Supply 3x380–480 V AC

4.2 General Specications

4.3 Fuses

4.4 Eciency

4.5 Acoustic Noise

4.6 dU/dt Conditions

4.7 Special Conditions

4.7.1 Manual Derating 62

4.7.2 Automatic Derating 64

4.8 Enclosure Sizes, Power Ratings, and Dimensions

5 RS485 Installation and Set-up

5.1 Introduction

5.1.1 Overview 67

5.1.2 Network Connection 68

5.1.3 Hardware Set-up 68

5.1.4 Parameter Settings for Modbus Communication 68

5.1.5 EMC Precautions 69

5.2 FC Protocol

5.2.1 Overview 69

5.2.2 FC with Modbus RTU 69

5.3 Network Conguration

5.4 FC Protocol Message Framing Structure

5.4.1 Content of a Character (byte) 70

5.4.2 Telegram Structure 70

5.4.3 Telegram Length (LGE) 70

5.4.4 Frequency Converter Address (ADR) 70

Contents Design Guide

5.4.5 Data Control Byte (BCC) 70

5.4.6 The Data Field 70

5.4.7 The PKE Field 71

5.4.8 Parameter Number (PNU) 71

5.4.9 Index (IND) 71

5.4.10 Parameter Value (PWE) 71

5.4.11 Data Types Supported by the Frequency Converter 72

5.4.12 Conversion 72

5.4.13 Process Words (PCD) 72

5.5 Examples

5.5.1 Writing a Parameter Value 72

5.5.2 Reading a Parameter Value 73

5.6 Modbus RTU

5.6.1 Prerequisite Knowledge 73

5.6.2 Overview 73

5.6.3 Frequency Converter with Modbus RTU 74

5.7 Network Conguration

5.8 Modbus RTU Message Framing Structure

5.8.1 Introduction 74

5.8.2 Modbus RTU Telegram Structure 74

5.8.3 Start/Stop Field 75

5.8.4 Address Field 75

5.8.5 Function Field 75

5.8.6 Data Field 75

5.8.7 CRC Check Field 75

5.8.8 Coil Register Addressing 75

5.8.9 How to Control the Frequency Converter 78

5.8.10 Function Codes Supported by Modbus RTU 78

5.8.11 Modbus Exception Codes 78

5.9 How to Access Parameters

5.9.1 Parameter Handling 79

5.9.2 Storage of Data 79

5.9.3 IND (Index) 79

5.9.4 Text Blocks 79

5.9.5 Conversion Factor 79

5.9.6 Parameter Values 79

5.10 Examples

5.10.1 Read Coil Status (01 hex) 79

5.10.2 Force/Write Single Coil (05 hex) 80

5.10.3 Force/Write Multiple Coils (0F hex) 80

Contents

VLT® AutomationDrive FC 360

5.10.4 Read Holding Registers (03 hex) 81

5.10.5 Preset Single Register (06 hex) 81

5.10.6 Preset Multiple Registers (10 hex) 82

5.11 Danfoss FC Control Prole

5.11.1 Control Word According to FC Prole (8-10 Protocol = FC Prole) 82

5.11.2 Status Word According to FC Prole (STW) 84

5.11.3 Bus Speed Reference Value 85

6 Application Examples

6.1 Introduction

Index

Introduction Design Guide

1 Introduction

1.1 How to Read This Design Guide

This design guide provides information on how to select, commission, and order a frequency converter. It provides information about mechanical and electrical installation.

The design guide is intended for use by personnel.

Read and follow the design guide to use the frequency converter safely and professionally, and pay particular attention to the safety instructions and general warnings.

VLT® is a registered trademark.

VLT® AutomationDrive FC 360 Quick Guide provides

•

the necessary information for getting the frequency converter up and running.

VLT® AutomationDrive FC 360 Programming Guide

•

provides information on how to program and includes complete parameter descriptions.

FC 360 technical literature is also available online at www.danfoss.com/fc360.

qualied

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 may also be used to alert against unsafe practices.

NOTICE

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

The following conventions are used in this manual:

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 (inch).

•

1 1

Introduction

VLT® AutomationDrive FC 360

1.1.1 Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Automatic motor adaptation AMA

Current limit I

Degrees Celsius

Direct current DC

Drive dependent D-TYPE

Electromagnetic compatibility EMC

Electronic thermal relay ETR

Gram g

Hertz Hz

Horsepower hp

Kilohertz kHz

Local control panel LCP

Meter m

Millihenry inductance mH

Milliampere mA

Millisecond ms

Minute min

Motion control tool MCT

Nanofarad nF

Newton meter Nm

Nominal motor current I

Nominal motor frequency f

Nominal motor power P

Nominal motor voltage U

Permanent magnet motor PM motor

Protective extra low voltage PELV

Printed circuit board PCB

Rated inverter output current I

Revolutions per minute RPM

Regenerative terminals Regen

Second s

Synchronous motor speed n

Torque limit T

Volts V

Maximum output current I

Rated output current supplied by the

frequency converter

LIM

°C

M,N

INV

LIM

VLT,MAX

VLT,N

1.2 Denitions

1.2.1 Frequency Converter

Coast

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

VLT,MAX

Maximum output current.

VLT,N

Rated output current supplied by the frequency converter.

VLT,MAX

Maximum output voltage.

1.2.2 Input

Control commands

Start and stop the connected motor with the LCP and digital inputs. Functions are divided into 2 groups.

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

Group 1 Precise stop, coast stop, precise stop and coast

stop, quick stop, DC braking, stop, and [OFF].

Group 2 Start, pulse start, start reversing, jog, freeze

output, and [Hand On].

Table 1.1 Function Groups

175ZA078.10

Pull-out

RPM

Torque

Introduction Design Guide

1.2.3 Motor

Motor running

Torque generated on the output shaft and speed from 0 RPM to maximum speed on the motor.

JOG

Motor frequency when the jog function is activated (via digital terminals or bus).

Motor frequency.

MAX

Maximum motor frequency.

MIN

Minimum motor frequency.

M,N

Rated motor frequency (nameplate data).

Motor current (actual).

M,N

Nominal motor current (nameplate data).

M,N

Nominal motor speed (nameplate data).

Synchronous motor speed.

2 × Parameter 1−23 × 60s

ns=

slip

Motor slip.

M,N

Rated motor power (nameplate data in kW or hp).

M,N

Rated torque (motor).

Instantaneous motor voltage.

M,N

Rated motor voltage (nameplate data).

Parameter 1−39

Break-away torque

Illustration 1.1 Break-away Torque

VLT

The eciency of the frequency converter is dened as the ratio between the power output and the power input.

Start-disable command

A start-disable command belonging to the control commands in group 1. See Table 1.1 for more details.

Stop command

A stop command belonging to the control commands in group 1. See Table 1.1 for more details.

1.2.4 References

Analog reference

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

Binary reference

A signal transmitted via the serial communication 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. Selection of 4 preset references via the bus.

Pulse reference

A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33).

Ref

MAX

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 is set in parameter 3-03 Maximum Reference.

Ref

MIN

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 is set in parameter 3-02 Minimum Reference.

1 1

Introduction

VLT® AutomationDrive FC 360

1.2.5 Miscellaneous

GLCP

The graphic local control panel (LCP 102) interface for

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 or 4– 20 mA.

Automatic motor adaptation, AMA

The AMA 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.

Digital outputs

The frequency converter features 2 solid-state outputs that can supply a 24 V DC (maximum 40 mA) signal.

ETR

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

FC standard bus

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

Initializing

If initializing is carried out (parameter 14-22 Operation Mode or

2-nger reset), the frequency converter returns to the

default setting.

Intermittent duty cycle

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

LCP

The local control panel makes up a complete interface for control and programming of the frequency converter. The LCP is detachable. With the installation kit option, the LCP can be installed up to 3 m (9.8 ft) from the frequency converter in a front panel.

control and programming of the frequency converter. The display is graphic and the panel is used to show process values. The GLCP has storing and copy functions.

NLCP

The numerical local control panel (LCP 21) interface for control and programming of the frequency converter. The display is numerical and the panel is used to show process values. The NLCP has storing and copy functions.

lsb

Least signicant bit.

msb

Most signicant bit.

MCM

Short for mille circular mil, an American measuring unit for cable cross-section. 1 MCM = 0.5067 mm2.

On-line/o-line parameters

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

Process PID

The PID control maintains speed, pressure, and temperature by adjusting the output frequency to match the varying load.

PCD

Process control data.

Power cycle

Switch o the mains until the display (LCP) is dark, then turn power on again.

Power factor

The power factor is the relation between I1 and I

Power factor = 

3xUxI1cosϕ1

3xUxI

RMS

For VLT® AutomationDrive FC 360 frequency converters,

cosϕ

1 = 1, therefore:

Power factor = 

I1xcosϕ1

RMS

 = 

RMS



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

RMS

for the

same kW performance.



RMS

=  I

 + I

 + I

 + .. + I

In addition, a high power factor indicates that the dierent harmonic currents are low. The built-in DC coils produce a high power factor, minimizing the imposed load on the mains supply.

Pulse input/incremental encoder

An external, digital pulse transmitter used for feeding back information on motor speed. The encoder is used in applications where great accuracy in speed control is required.

Introduction Design Guide

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 set-up is active.

SFAVM

Acronym describing the switching pattern stator uxoriented asynchronous vector modulation.

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 smart logic controller evaluates the associated

user-dened events as true (parameter group 13-** Smart Logic Control).

STW

Status word.

THD

Total harmonic distortion states the total contribution of harmonic distortion.

Thermistor

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

Trip

A state entered in fault situations, for example if the frequency converter is subject to overvoltage or when it 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

Trip lock is a state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention., An example causing a trip lock is the frequency converter being subject to a short circuit on the output. A locked trip can only be canceled by cutting o 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. Do not use trip lock for personal safety.

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 stability, both when the speed reference is changed and in relation to the load torque.

60° AVM

Refers to the switching pattern 60° asynchronous vector modulation.

1.3 Safety Precautions

WARNING

The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor, frequency converter or eldbus may cause death, serious personal injury or damage to the equipment. Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.

Safety Regulations

1. Always disconnect mains supply to the frequency converter before carrying out repair work. Check that the mains supply has been disconnected and observe the discharge time stated in Table 1.2 before removing motor and mains supply.

2. [O/Reset] on the LCP does not disconnect the mains supply and must not be used as a safety switch.

3. Ground the equipment properly, protect the user against supply voltage, and protect the motor against overload in accordance with applicable national and local regulations.

4. Protection against motor overload is not included in the factory setting. If this function is desired, set parameter 1-90 Motor Thermal Protection to [4] ETR trip 1 or [3] ETR warning 1.

5. The frequency converter has more voltage sources than L1, L2 and L3, when load sharing (linking of DC intermediate circuit). Check that all voltage sources have been disconnected and that the necessary time has elapsed before commencing repair work.

1 1

Introduction

VLT® AutomationDrive FC 360

Warning against unintended start

1. The motor can be stopped with digital commands, bus commands, references or a local stop, while the frequency converter is connected to mains. If personal safety considerations (e.g. risk of personal injury caused by contact with moving parts following an unintentional start) make it necessary to ensure that no unintended start occurs, these stop functions are not sucient. In such cases, disconnect the mains supply.

2. The motor may start while setting the parameters. If this means that personal safety may be compromised, motor starting must be prevented, for instance by secure disconnection of the motor connection.

3. A motor that has been stopped with the mains supply connected, may start if faults occur in the electronics of the frequency converter, through temporary overload or if a fault in the power supply grid or motor connection is remedied. If unintended start must be prevented for personal safety reasons, the normal stop functions of the frequency converter are not sucient. In such cases, disconnect the mains supply.

4. In rare cases, control signals from, or internally within, the frequency converter may be activated in error, be delayed, or fail to occur entirely. When used in situations where safety is critical, e.g. when controlling the electromagnetic brake function of a hoist application, do not rely on these control signals exclusively.

NOTICE

Hazardous situations shall be identied by the machine builder/integrator responsible for considering necessary preventive means. Additional monitoring and protective devices may be included, always according to valid national safety regulations, such as laws on mechanical tools and regulations for the prevention of accidents.

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 o. 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 waiting time is specied in Table 1.2 and is also visible on the product label on top of the frequency converter.

Before performing any service or repair work,

•

use an appropriate voltage measuring device to make sure that the capacitors are fully discharged.

WARNING

HIGH VOLTAGE

Touching the electrical parts may be fatal even after the equipment has been disconnected from mains. Make sure that all voltage inputs have been disconnected, including load sharing (linkage of DC intermediate circuit), as well as motor connection for kinetic back up. Systems where frequency converters are installed must, if necessary, be equipped with additional monitoring and protective devices according to valid safety regulations, such as laws on mechanical tools, regulations for the prevention of accidents, etc. Modications to the frequency converters via the operating software are allowed.

Voltage

[V]

380–480

Table 1.2 Discharge Time

Power range

[kW (hp)]

0.37–7.5 kW

(0.5–10 hp)

11–75 kW

(15–100 hp)

Minimum waiting

time

(minutes)

Introduction Design Guide

1.4 Disposal Instruction

Equipment containing electrical

components may not be disposed of

together with domestic waste.

It must be collected separately with

electrical and electronic waste according

to local and currently valid legislation.

1.5 Document and Software Version

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

Edition Remarks Software version

MG06B5xx Update due to new

hardware and software

release.

1.8x

1.6 Approvals and Certications

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

For more information on approvals and the download area at www.danfoss.com/fc360.

certicates, go to

1.6.1 CE Mark

The CE mark (Conformité Européenne) indicates that the product manufacturer conforms to all applicable EU directives.

The EU directives applicable to the design and manufacture of drives are:

The Low Voltage Directive.

•

The EMC Directive.

•

The Machinery Directive (for units with an

•

integrated safety function).

The CE mark is intended to eliminate technical barriers to free trade between the EC and EFTA states inside the ECU. The CE mark does not regulate the quality of the product. Technical specications cannot be deduced from the CE mark.

1.6.2 Low Voltage Directive

Drives are classied as electronic components and must be CE-labeled in accordance with the Low Voltage Directive. The directive applies to all electrical equipment in the 50– 1000 V AC and the 75–1500 V DC voltage ranges.

The directive mandates that the equipment design must ensure the safety and health of people and livestock, and the preservation of material by ensuring the equipment is properly installed, maintained, and used as intended. Danfoss CE labels comply with the Low Voltage Directive, and Danfoss provides a declaration of conformity upon request.

1.6.3 EMC Directive

Electromagnetic compatibility (EMC) means that electromagnetic interference between pieces of equipment does not hinder their performance. The basic protection requirement of the EMC Directive 2014/30/EU states that devices that generate electromagnetic interference (EMI) or whose operation could be aected by EMI must be designed to limit the generation of electromagnetic interference and shall have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

A drive can be used as stand-alone device or as part of a more complex installation. Devices in either of these cases must bear the CE mark. Systems must not be CE-marked but must comply with the basic protection requirements of the EMC directive.

1 1

130BA870.10

130BA809.10

130BA810.10

130BA826.10

Product Overview

VLT® AutomationDrive FC 360

2 Product Overview

2.1 Enclosure Size Overview

Enclosure size depends on power range.

Enclosure size J1 J2 J3 J4

Enclosure

protection

High overload

rated power -

maximum

160%

overload

Enclosure size J5 J6 J7

Enclosure

protection

High overload

rated power -

maximum

160%

overload

IP20 IP20 IP20 IP20

0.37–2.2 kW/0.5–3 hp

(380–480 V)

IP20 IP20 IP20

18.5–22 kW/25–30 hp

(380–480 V)

3.0–5.5 kW/4.0–7.5 hp

(380–480 V)

30–45 kW/40–60 hp

(380–480 V)

7.5 kW/10 hp (380–480 V)

55–75 kW/75–100 hp

(380–480 V)

11–15 kW/15–20 hp

(380–480 V)

Table 2.1 Enclosure Sizes

1) Sizes 11–75 kW (15–100 hp) normal overload type: 110% overload 1 minute.

Sizes 0.37–7.5 kW (0.5–10 hp) high overload type: 160% overload 1 minute.

Sizes 11–22 kW (15–30 hp) high overload type: 150% overload 1 minute.

Sizes 30–75 kW (40–100 hp) high overload type: 150% overload 1 minute.

130BC438.19

3 phase power input

Switch mode

power supply

Motor

Interface

(PNP) = Source (NPN) = Sink

ON=Terminated OFF=Open

Brake resistor

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

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN/OUT)

0/4-20 mA

12 (+24 V OUT)

33 (D IN)

18 (D IN)

20 (COM D IN)

10 V DC 15 mA 100 mA

+ - + -

(U) 96 (V) 97

(W) 98

(PE) 99

(P RS485) 68

(N RS485) 69

(COM RS485) 61

S801

RS485

+10 V DC

0/4-20 mA

0-10 V DC

24 V DC

250 V AC, 3 A

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

19 (D IN)

24 V (NPN) 0 V (PNP)

27 (D IN/OUT)

24 V

0 V

0 V (PNP)

24 V (NPN)

0 V

24 V

29 (D IN/OUT)

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

32 (D IN)

31 (D IN)

P 5-00

(+UDC) 89

(BR) 81 5)

24 V (NPN) 0 V (PNP)

0-10 V DC

(-UDC) 88

RFI

0 V

250 V AC, 3 A

Relay 1

Relay 2 2)

42 (A OUT)

45 (A OUT)

Analog output 0/4-20 mA

Product Overview Design Guide

2.2 Electrical Installation

This section describes how to wire the frequency converter.

2 2

Illustration 2.1 Basic Wiring Schematic Drawing

A=Analog, D=Digital

1) Built-in brake chopper available from J1–J5.

2) Relay 2 is 2-pole for J1–J3 and 3-pole for J4–J7. Relay 2 of J4–J7 with terminals 4, 5, and 6 has same NO/NC logic as relay 1. Relays are pluggable in J1–J5 and xed in J6–J7.

Product Overview

3) Single DC choke in J1–J5; dual DC choke in J6–J7.

4) Switch S801 (bus terminal) can be used to enable termination on the RS485 port (terminals 68 and 69).

5) No BR for J6–J7.

VLT® AutomationDrive FC 360

e30bf228.11

L1 L2 L3

Product Overview Design Guide

2 2

1 PLC 10 Mains cable (unshielded)

Minimum 16 mm2 (6 AWG) equalizing cable

3 Control cables 12 Cable insulation stripped

4 Minimum 200 mm (7.87 in) between control cables, motor

cables, and mains cables.

5 Mains supply 14 Brake resistor

6 Bare (unpainted) surface 15 Metal box

7 Star washers 16 Connection to motor

8 Brake cable (shielded) 17 Motor

9 Motor cable (shielded) 18 EMC cable gland

Illustration 2.2 Typical Electrical Connection

11 Output contactor, and more.

13 Common ground busbar. Follow local and national

requirements for cabinet grounding.

130BC500.10

FC 1

FC 2

FC 3

Product Overview

VLT® AutomationDrive FC 360

WARNING

2.2.1 Grounding Requirements

EQUIPMENT HAZARD

Rotating shafts and electrical equipment can be hazardous. It is important to protect against electrical hazards when applying power to the unit. All electrical work must conform to national and local electrical codes. Installation, start up, and maintenance must be performed only by trained and qualied personnel. Failure to follow these guidelines could result in death or serious injury.

WARNING

WIRING ISOLATION

Run input power, motor wiring, and control wiring in 3 separate metallic conduits, or use separated shielded cables for high-frequency noise isolation. Failure to isolate power, motor, and control wiring could result in less than optimum frequency converter and associated equipment performance. Run motor cables from multiple frequency converters separately. Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned o and locked out. Failure to run output motor cables separately or use shielded cables could result in death or serious injury.

Run output motor cables separately.

•

Use shielded cables.

•

Lock out all frequency converters simultaneously.

•

Wire type and ratings

All wiring must comply with local and national

•

regulations regarding cross-section and ambient temperature requirements.

Danfoss recommends that all power connections

•

are made with a minimum 75 °C (167 °F) rated copper wire.

See chapter 4 Specications for recommended

•

wire sizes.

WARNING

GROUNDING HAZARD!

For operator safety, a certied electrical installer should ground the frequency converter in accordance with national and local electrical codes as well as instructions contained within this manual. Ground currents are higher than 3.5 mA. Failure to ground the frequency converter properly could result in death or serious injury.

Establish proper protective grounding for

•

equipment with ground currents higher than 3.5 mA. See chapter 2.8 Earth Leakage Current for details.

A dedicated ground wire is required for input

•

power, motor power, and control wiring.

Use the clamps provided with the equipment for

•

proper ground connections.

Do not ground 1 frequency converter to another

•

in a “daisy chain” fashion (see Illustration 2.3).

Keep the ground wire connections as short as

•

possible.

Use high-strand wire to reduce electrical noise.

•

Follow motor manufacturer wiring requirements.

•

Illustration 2.3 Grounding Principle

130BC501.10

02 03

130BD648.11

Product Overview Design Guide

WARNING

INDUCED VOLTAGE

Run output motor cables from multiple frequency converters separately. Induced voltage from output motor cables run together can charge equipment capacitors even when the equipment is turned o and locked out. Failure to run output motor cables separately could result in death or serious injury.

Grounding clamps are provided for motor wiring (see Illustration 2.4).

Do not install power factor correction capacitors

•

between the frequency converter and the motor.

Do not wire a starting or pole-changing device

•

between the frequency converter and the motor.

Follow motor manufacturer wiring requirements.

•

All frequency converters must be used with an

•

isolated input source and with ground reference power lines. When supplied from an isolated mains source (IT mains or oating delta) or TT/TN-S mains with a grounded leg (grounded delta), set parameter 14-50 RFI Filter to OFF (enclosure sizes J6–J7) or remove the RFI screw (enclosure sizes J1–J5). When o, the internal RFI lter capacitors between the chassis and the intermediate circuit are isolated to avoid damage to the intermediate circuit and reduce ground capacity currents in accordance with IEC 61800-3.

Do not install a switch between the frequency

•

converter and the motor in IT mains.

2 2

Illustration 2.4 Mains, Motor, and Ground Connections for

Enclosure Sizes J1–J5 (Taking J2 as an Example)

Illustration 2.5 Mains, Motor, and Ground Connections for

Enclosure Sizes J6–J7 (Taking J7 as an Example)

Illustration 2.4 shows mains input, motor, and grounding for enclosure sizes J1–J5. Illustration 2.5 shows mains input, motor, and grounding for enclosure sizes J6–J7. Actual congurations vary with unit types and optional equipment.

130BC504.11

42 45

130BC505.12

Product Overview

VLT® AutomationDrive FC 360

2.2.2 Control Wiring

Access

•

Remove the cover plate with a screwdriver. See

Terminal Parameter

Digital I/O, Pulse I/O, Encoder

Illustration 2.6.

12 – +24 V DC

Default

setting

Description

24 V DC supply

voltage.

Maximum

output current is

100 mA for all

24 V loads.

Parameter 5-10 Ter

minal 18 Digital

Input

Parameter 5-11 Ter

minal 19 Digital

Input

Parameter 5-16 Ter

minal 31 Digital

Input

Parameter 5-14 Ter

minal 32 Digital

Input

Parameter 5-15 Ter

minal 33 Digital

Input

[8] Start

[10]

Reversing

[0] No

operation

[0] No

operation

[0] No

operation

Digital inputs.

Digital input

Digital input, 24

V encoder.

Terminal 33 can

be used for

pulse input.

Parameter 5-12 Ter

Illustration 2.6 Control Wiring Access for Enclosure Sizes J1–J7

Control Terminal Types

Illustration 2.7 shows the frequency converter control terminals. Terminal functions and default settings are summarized in Table 2.2.

minal 27 Digital

Input

Parameter 5-30 Ter

minal 27 Digital

Output

Parameter 5-13 Ter

minal 29 Digital

Input

Parameter 5-31 Ter

minal 29 Digital

DI [2] Coast

inverse

DO [0] No

operation

DI [14] Jog

DO [0] No

operation

Selectable for

either digital

input, digital

output or pulse

output. Default

setting is digital

input.

Terminal 29 can

be used for

pulse input.

Output

Common for

digital inputs

20 –

and 0 V

potential for 24

V supply.

Analog inputs/outputs

Parameter 6-91 Ter

minal 42 Analog

Output

[0] No

operation

Programmable

analog output.

The analog

signal is 0–20

mA or 4–20 mA

Parameter 6-71 Ter

minal 45 Analog

Output

[0] No

operation

at a maximum of

500 Ω. Can also

be congured as

digital outputs

Illustration 2.7 Control Terminal Locations

See chapter 4.2 General Specications for terminal ratings details.

PLC

130BB922.12

PE PE

<10 mm

100nF

PLC

<10 mm

130BB609.12

Product Overview Design Guide

Terminal Parameter

50 – +10 V DC

55 –

61 –

68 (+)

69 (-)

01, 02, 03 5-40 [0]

04, 05, 06 5-40 [1]

6-1* parameter

group

6-2* parameter

group

Serial communication

8-3* parameter

group

8-3* parameter

group

Relays

Default

setting

Reference

Feedback

[0] No

operation

[0] No

operation

Description

10 V DC analog

supply voltage.

15 mA maximum

commonly used

for potenti-

ometer or

thermistor.

Analog input.

Selectable for

voltage or

current.

Common for

analog input

Integrated RC

Filter for shield.

ONLY for

connecting the

screen when

experiencing

EMC problems.

RS485 interface.

A control card

switch is

provided for

termination

resistance.

Form C relay

output. These

relays are in

various locations

depending upon

the frequency

converter cong-

uration and size.

Usable for AC or

DC voltage and

resistive or

inductive loads.

RO2 in J1–J3

enclosure is 2-

pole, only

terminals 04 and

05 are available

Control terminal functions

Frequency converter functions are commanded by receiving control input signals.

Program each terminal for the function it

•

supports in the parameters associated with that terminal.

Conrm that the control terminal is programmed

•

for the correct function. See chapter Local Control Panel and Programming in the quick guide for

details on accessing parameters and programming.

The default terminal programming initiates

•

frequency converter functioning in a typical operational mode.

Using shielded control cables

The preferred method in most cases is to secure control and serial communication cables with shielding clamps provided at both ends to ensure the best possible high frequency cable contact. If the ground potential between the frequency converter and the PLC is dierent, electric noise may occur that disturbs the entire system. Solve this problem by tting an equalizing cable as close as possible to the control cable. Minimum cable cross section: 16 mm2 (6 AWG).

Minimum 16 mm2 (6 AWG)

2 Equalizing cable

Illustration 2.8 Shielding Clamps at Both Ends

50/60 Hz ground loops

With very long control cables, ground loops may occur. To eliminate ground loops, connect 1 end of the screen-toground with a 100 nF capacitor (keeping leads short).

Illustration 2.9 Connection with a 100 nF Capacitor

2 2

Table 2.2 Terminal Descriptions

Avoid EMC noise on serial communication

This terminal is connected to ground via an internal RC link. Use twisted-pair cables to reduce interference between conductors. The recommended method is shown in Illustration 2.10.

130BB923.12

PE PE

69 68 61

<10 mm

130BB924.12

PE PE

<10 mm

Product Overview

VLT® AutomationDrive FC 360

Speed control

There are 2 types of speed control:

Speed open-loop control, which does not require

•

any feedback from the motor (sensorless).

Speed closed-loop PID control, which requires a

•

speed feedback to an input. A properly optimized

Minimum 16 mm2 (6 AWG)

2 Equalizing cable

speed-closed loop control has higher accuracy than a speed open-loop control.

Select which input to use as speed PID feedback in

Illustration 2.10 Twisted-pair Cables

parameter 7-00 Speed PID Feedback Source.

Torque control

The torque control function is used in applications where

Alternatively, the connection to terminal 61 can be omitted.

the torque on motor output shaft is controlling the application as tension control. Torque control can be selected in parameter 1-00 Conguration Mode. Torque setting is done by setting an analog, digital, or bus controlled reference. When running torque control, it is recommended to run a full AMA procedure, because correct motor data is important in achieving optimal performance.

Minimum 16 mm2 (6 AWG)

2 Equalizing cable

Illustration 2.11 Twisted-pair Cables without Terminal 61

2.3 Control Structures

2.3.1 Control Principle

A frequency converter recties AC voltage from mains into DC voltage. Then the DC voltage is converted into an AC current with a variable amplitude and frequency.

The motor is supplied with variable voltage/current and frequency, enabling innitely variable speed control of 3phased standard AC motors and permanent magnet synchronous motors.

2.3.2 Control Modes

The frequency converter is capable of controlling either the speed or the torque on the motor shaft. Setting parameter 1-00 Conguration Mode determines the type of control.

Closed loop in VVC+ mode. This function is used

•

in applications with low to medium dynamic variation of shaft, and oers excellent performance in all 4 quadrants and at all motor speeds. The speed feedback signal is mandatory. It is recommended to use MCB102 option card. Ensure the encoder resolution is at least 1024 PPR, and the shield cable of the encoder is well grounded, because the accuracy of the speed feedback signal is important. Tune parameter 7-06 Speed PID Lowpass Filter Time to get the best speed feedback signal.

Open loop in VVC+ mode. The function is used in

•

mechanically robust applications, but the accuracy is limited. Open-loop torque function works for 2 directions. The torque is calculated on the basis of the internal current measurement in the frequency converter.

Speed/torque reference

The reference to these controls can be either a single reference or the sum of various references including relatively scaled references. Reference handling is explained in detail in chapter 2.4 Reference Handling.

130BD974.10

L2 92

L1 91

L3 93

U 96

V 97

W 98

RFI switch

Inrush

R+ 82

Load sharing -

88(-)

R81

Brake resistor

Load sharing +

89(+)

Load sharing -

Load sharing +

L2 92

L1 91

L3 93

89(+)

88(-)

Inrush

R inr

U 96

V 97

W 98

P 14-50

130BD975.10

Product Overview Design Guide

2.3.3 FC 360 Control Principle

VLT® AutomationDrive FC 360 is a general-purpose frequency converter for variable speed applications. The control principle is based on Voltage Vector Control+.

0.37–22 kW (0.5–30 hp)

FC 360 0.37–22 kW (0.5–30 hp) frequency converters can handle asynchronous motors and permanent magnet synchronous motors up to 22 kW.

The current-sensing principle in FC 360 0.37–22 kW (0.5–30 hp) frequency converters is based on the current measurement by a resistor in the DC link. The ground fault protection and short-circuit behavior are handled by the same resistor.

2 2

Illustration 2.12 Control Diagram for FC 360 0.37–22 kW (0.5–30 hp)

30–75 kW (40–100 hp)

FC 360 30–75 kW (40–100 hp) frequency converters can handle asynchronous motors only.

The current-sensing principle in FC 360 30–75 kW (40–100 hp) frequency converters is based on the current measurement in the motor phases.

The ground fault protection and short-circuit behavior on FC 360 30–75 kW (40–100 hp) frequency converters are handled by the 3 current transducers in the motor phases.

Illustration 2.13 Control Diagram for FC 360 30–75 kW (40–100 hp)

Cong. mode

Ref.

Process

P 1-00

High

+f max.

Low

-f max.

P 4-12 Motor speed low limit (Hz)

P 4-14 Motor speed high limit (Hz)

Motor controller

Ramp

Speed PID

P 7-20 Process feedback 1 source

P 7-22 Process feedback 2 source

P 7-00 Speed PID

feedback source

P 1-00

Cong. mode

P 4-19 Max. output freq.

-f max.

Motor controller

P 4-19 Max. output freq.

+f max.

P 3-**

P 7-0*

130BD371.10

Product Overview

VLT® AutomationDrive FC 360

2.3.4

Control Structure in VVC

Illustration 2.14 Control Structure in VVC+ Open-loop Congurations and Closed-loop Congurations

In the conguration shown in Illustration 2.14, parameter 1-01 Motor Control Principle is set to [1] VVC+ and parameter 1-00 Conguration Mode is set to [0] Speed open loop. The resulting reference from the reference handling system

is received and fed through the ramp limitation and speed limitation before being sent to the motor control. The output of the motor control is then limited by the maximum frequency limit.

If parameter 1-00 Conguration Mode is set to [1] Speed closed loop, the resulting reference is passed from the ramp limitation and speed limitation into a speed PID control. The speed PID control parameters are in parameter group 7-0* Speed PID Ctrl. The resulting reference from the speed PID control is sent to the motor control limited by the frequency limit.

Select [3] Process in parameter 1-00 Conguration Mode to use the process PID control for closed-loop control of speed or pressure in the controlled application. The process PID parameters are in parameter groups 7-2* Process Ctrl. Feedb and 7-3* Process PID Ctrl.

e30bp046.12

Hand

Oﬀ

Auto

Reset

Product Overview Design Guide

2.3.5

Internal Current Control in VVC

Mode

The frequency converter features an integral current limit control. This feature is activated when the motor current, and thus the torque, is higher than the torque limits set in

parameter 4-16 Torque Limit Motor Mode, parameter 4-17 Torque Limit Generator Mode, and parameter 4-18 Current Limit.

When the frequency converter is at the current limit during motor operation or regenerative operation, the frequency converter tries to get below the preset torque limits as quickly as possible without losing control of the motor.

2.3.6 Local [Hand On] and Remote [Auto On] Control

Operate the frequency converter manually via the local control panel (LCP) or remotely via analog/digital inputs or eldbus.

Start and stop the frequency converter pressing the [Hand On] and [O/Reset] keys on the LCP. Set-up is required:

Parameter 0-40 [Hand on] Key on LCP.

•

Parameter 0-44 [O/Reset] Key on LCP.

•

Parameter 0-42 [Auto on] Key on LCP.

•

Reset alarms via the [O/Reset] key or via a digital input, when the terminal is programmed to Reset.

2 2

Illustration 2.15 LCP Control Keys

Local reference forces the conguration mode to open loop, independent of the setting in parameter 1-00 Congu- ration Mode.

Local reference is restored at power-down.

No function

Analog ref.

Pulse ref.

Local bus ref.

Preset relative ref.

Preset ref.

Local bus ref.

No function

Analog ref.

Pulse ref.

Analog ref.

Pulse ref.

Local bus ref.

No function

Local bus ref.

Pulse ref.

No function

Analog ref.

Input command: Catch up/ slow down

Catchup Slowdown

value

Freeze ref./Freeze output

Speed up/ speed down

ref.

Remote

Ref. in %

-max ref./ +max ref.

Scale to Hz

Scale to Nm

Scale to process unit

Relative X+X*Y /100

DigiPot

max ref.

min ref.

DigiPot

D1 P 5-1x(15) Preset '1' External '0'

Process

Torque

Speed open/closed loop

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(0)

(1)

Relative scaling ref.

P 3-18

Ref.resource 1

P 3-15

Ref. resource 2

P 3-16

Ref. resource 3

P 3-17

200%

-200%

-100%

100%

Ref./feedback range

P 3-00

Conguration mode

P 1-00

P 3-14

±100%

130BD374.10

P 16-01

P 16-02

P 3-12

P 5-1x(21)/P 5-1x(22)

P 5-1x(28)/P 5-1x(29)

P 5-1x(19)/P 5-1x(20)

P 3-04

Freeze ref. & increase/ decrease ref.

Catch up/ slow down

P 3-10

Product Overview

VLT® AutomationDrive FC 360

2.4 Reference Handling

Local reference

The local reference is active when the frequency converter is operated with [Hand On] active. Adjust the reference by [▲]/[▼] and [◄/[►].

Remote reference

The reference handling system for calculating the remote reference is shown in Illustration 2.16.

Illustration 2.16 Remote Reference

Resulting reference

Sum of all

references

Forward

Reverse

P 3-00 Reference Range= [0] Min-Max

130BA184.10

-P 3-03

P 3-03

P 3-02

-P 3-02

P 3-00 Reference Range =[1]-Max-Max

Resulting reference

Sum of all references

-P 3-03

P 3-03

130BA185.10

Product Overview Design Guide

The remote reference is calculated once in every scan interval and initially consists of 2 types of reference inputs:

1. X (the external reference): A sum (see parameter 3-04 Reference Function) of up to 4 externally selected references, comprising any combination (determined by the setting of

parameter 3-15 Reference 1 Source, parameter 3-16 Reference 2 Source, and parameter 3-17 Reference 3 Source) of a xed

preset reference (parameter 3-10 Preset Reference), variable analog references, variable digital pulse references, and various eldbus references in any unit the frequency converter is monitoring ([Hz], [RPM], [Nm], and so on).

2. Y (the relative reference): A sum of 1 xed preset reference (parameter 3-14 Preset Relative Reference) and 1 variable analog reference (parameter 3-18 Relative Scaling Reference Resource) in [%].

The 2 types of reference inputs are combined in the following formula: Remote reference=X+X*Y/100%. If relative reference is not used, set parameter 3-18 Relative

Scaling Reference Resource to [0] No function and parameter 3-14 Preset Relative Reference to 0%. The digital

inputs on the frequency converter can activate both the catch up/slow down function and the freeze reference function. The functions and parameters are described in

the VLT® AutomationDrive FC 360 Programming Guide. The scaling of analog references is described in parameter groups 6-1* Analog Input 53 and 6-2* Analog Input 54, and the scaling of digital pulse references is described in parameter group 5-5* Pulse Input. Reference limits and ranges are set in parameter group 3-0* Reference Limits.

2 2

Illustration 2.17 Sum of All References When Reference Range

is Set to 0

Illustration 2.18 Sum of All References When Reference Range

is Set to 1

2.4.1 Reference Limits

Parameter 3-00 Reference Range, parameter 3-02 Minimum Reference, and parameter 3-03 Maximum Reference dene

the allowed range of the sum of all references. The sum of all references is clamped when necessary. The relation between the resulting reference (after clamping) and the sum of all references are shown in Illustration 2.17 and Illustration 2.18.

The value of parameter 3-02 Minimum Reference cannot be set to less than 0, unless parameter 1-00 Conguration Mode is set to [3] Process. In that case, the following relations between the resulting reference (after clamping) and the sum of all references are as shown in Illustration 2.19.

130BA186.11

P 3-03

P 3-02

Sum of all references

P 3-00 Reference Range= [0] Min to Max

Resulting reference

Resource output [Hz]

Resource input

Terminal X high

High reference/ feedback value

130BD431.10

[V]

Low reference/ feedback value

Product Overview

VLT® AutomationDrive FC 360

2.4.3 Scaling of Analog and Pulse References and Feedback

References and feedback are scaled from analog and pulse inputs in the same way. The only dierence is that a reference above or below the specied minimum and maximum endpoints (P1 and P2 in Illustration 2.20) are clamped while a feedback above or below is not.

Illustration 2.19 Sum of All References When Minimum

Reference is Set to a Minus Value

2.4.2 Scaling of Preset References and Bus References

Preset references are scaled according to the following rules:

When parameter 3-00 Reference Range is set to [0]

•

Min–Max, 0% reference equals 0 [unit] where unit can be any unit, for example RPM, m/s, and bar. 100% reference equals the maximum (absolute value of parameter 3-03 Maximum Reference, absolute value of parameter 3-02 Minimum Reference).

When parameter 3-00 Reference Range is set to [1]

•

-Max–+Max, 0% reference equals 0 [unit], and 100% reference equals maximum reference.

Bus references are scaled according to the following rules:

When parameter 3-00 Reference Range is set to [0]

•

Min–Max, 0% reference equals minimum reference and 100% reference equals maximum reference.

When parameter 3-00 Reference Range is set to [1]

•

-Max–+Max, -100% reference equals -maximum reference, and 100% reference equals maximum reference.

Illustration 2.20 Minimum and Maximum Endpoints

Resource output [Hz] or “No unit”

Resource input [mA]

Quadrant 2

Quadrant 3

Quadrant 1

Quadrant 4

Terminal X high

Low reference/feedback value

High reference/feedback value

-50

165020

130BD446.10

forward

reverse

Terminal low

Product Overview Design Guide

The endpoints P1 and P2 are dened in Table 2.3 depending on choice of input.

Input Analog 53

voltage mode

P1=(Minimum input value, Minimum reference value)

Minimum reference value Parameter 6-14

Terminal 53

Low Ref./Feedb.

Value

Minimum input value Parameter 6-10

Terminal 53

Low Voltage

[V]

P2=(Maximum input value, Maximum reference value)

Maximum reference value Parameter 6-15

Terminal 53

High Ref./

Feedb. Value

Maximum input value Parameter 6-11

Terminal 53

High Voltage

[V]

Table 2.3 P1 and P2 Endpoints

Analog 53

current mode

Parameter 6-14 T

erminal 53 Low

Ref./Feedb. Value

Parameter 6-12 T

erminal 53 Low

Current [mA]

Parameter 6-15 T

erminal 53 High

Ref./Feedb. Value

Parameter 6-13 T

erminal 53 High

Current [mA]

2.4.4 Dead Band Around Zero

Analog 54

voltage mode

Parameter 6-24

Terminal 54

Low Ref./Feedb.

Value

Parameter 6-20

Terminal 54

Low Voltage

[V]

Parameter 6-25

Terminal 54

High Ref./

Feedb. Value

Parameter 6-21

Terminal 54

High

Voltage[V]

Analog 54

current mode

Parameter 6-24 T

erminal 54 Low

Ref./Feedb. Value

Parameter 6-22 T

erminal 54 Low

Current [mA]

Parameter 6-25 T

erminal 54 High

Ref./Feedb. Value

Parameter 6-23 T

erminal 54 High

Current [mA]

Pulse input 29 Pulse input 33

Parameter 5-52

Term. 29 Low

Ref./Feedb. Value

Parameter 5-50

Term. 29 Low

Frequency [Hz]

Parameter 5-53

Term. 29 High

Ref./Feedb. Value

Parameter 5-51

Term. 29 High

Frequency [Hz]

Parameter 5-57 Term.

33 Low Ref./Feedb.

Value

Parameter 5-55 Term.

33 Low Frequency

[Hz]

Parameter 5-58 Term.

33 High Ref./Feedb.

Value

Parameter 5-56 Term.

33 High Frequency

[Hz]

2 2

Sometimes, the reference (in rare cases also the feedback) should have a dead band around 0 to ensure that the machine is stopped when the reference is near 0.

To make the dead band active and to set the amount of dead band, do the following:

P1 or P2 denes the size of the dead band as shown in Illustration 2.21.

Set either the minimum reference value (see

•

Table 2.3 for relevant parameter) or maximum reference value at 0. In other words, either P1 or P2 must be on the X-axis in Illustration 2.21.

Ensure that both points dening the scaling

•

graph are in the same quadrant.

Illustration 2.21 Size of Dead Band

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Danfoss FC 360 Design guide

Specifications and Main Features

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