Danfoss FC 360 Design guide

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Design Guide

VLT® AutomationDrive FC 360

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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

-20

130BD454.10

Analog input 53

Low reference 0 Hz High reference 20 Hz Low voltage 1 V High voltage 10 V

Ext. source 1

Range:

0.0% (0 Hz)

100.0% (20 Hz)

Ext. reference Range:

0.0% (0 Hz)

20 Hz 10V

Ext. Reference

Absolute 0 Hz 1 V

Reference algorithm

Reference

100.0% (20 Hz)

0.0% (0 Hz)

Range:

Limited to:

0%- +100%

(0 Hz- +20 Hz)

Limited to: -200%- +200%

(-40 Hz- +40 Hz)

Reference is scaled according to min

max reference giving a speed.!!!

Scale to speed

+20 Hz

-20 Hz

Range:

Speed setpoint

Motor control

Range:

-8 Hz +8 Hz

Motor

Digital input 19 Low No reversing

High Reversing

Limits Speed Setpoint according to min max speed.!!!

Motor PID

Dead band

Digital input

General Reference parameters: Reference Range: Min - Max Minimum Reference: 0 Hz (0,0%)

Maximum Reference: 20 Hz (100,0%)

General Motor parameters: Motor speed direction:Both directions Motor speed Low limit: 0 Hz Motor speed high limit: 8 Hz

Product Overview

VLT® AutomationDrive FC 360

Case 1: Positive reference with dead band, digital input to trigger reverse, part I

Illustration 2.22 shows how reference input with limits inside minimum to maximum limits clamps.

Illustration 2.22 Clamping of Reference Input with Limits inside Minimum to Maximum

30 Hz

20 Hz

130BD433.11

-20 Hz

Analog input 53

Low reference 0 Hz High reference 20 Hz Low voltage 1 V High voltage 10 V

Ext. source 1

Range:

0.0% (0 Hz)

150.0% (30 Hz)

Ext. reference Range:

0.0% (0 Hz)

30 Hz 10 V

Ext. Reference

Absolute 0 Hz 1 V

Reference algorithm

Reference

100.0% (20 Hz)

0.0% (0 Hz)

Range:

Limited to:

-100%- +100%

(-20 Hz- +20 Hz)

Limited to: -200%- +200%

(-40 Hz- +40 Hz)

Reference is scaled according to

max reference giving a speed.!!!

Scale to speed

+20 Hz

-20 Hz

Range:

Speed setpoint

Motor

control

Range: –10 Hz +10 Hz

Motor

Digital input 19 Low No reversing

High Reversing

Limits Speed Setpoint according to min max speed.!!!

Motor PID

Dead band

Digital input

General Reference parameters: Reference Range: -Max - Max Minimum Reference: Don't care

Maximum Reference: 20 Hz (100.0%)

General Motor parameters: Motor speed direction: Both directions Motor speed Low limit: 0 Hz Motor speed high limit: 10 Hz

Product Overview Design Guide

Case 2: Positive reference with dead band, digital input to trigger reverse, part II

Illustration 2.23 shows how reference input with limits outside -maximum to +maximum limits clamps to the input low and high limits before adding to external reference, and how the external reference is clamped to -maximum to +maximum by the reference algorithm.

2 2

Illustration 2.23 Clamping of Reference Input with Limits outside -Maximum to +Maximum

Product Overview

VLT® AutomationDrive FC 360

2.5 PID Control

2.5.1 Speed PID Control

Parameter 1-00 Conguration Mode

[0] Speed open loop

[1] Speed closed loop

[2] Torque Not available Not active

[3] Process Not active Not active

Table 2.4 Control Congurations, Active Speed Control

1) Not active indicates that the specic mode is available, but the speed control is not active in that mode.

2) Not available indicates that the specic mode is not available at all.

Parameter Description of function

Parameter 7-00 Speed PID Feedback Source Select from which input the speed PID gets its feedback.

Parameter 7-02 Speed PID Proportional Gain The higher the value, the quicker the control. However, too high a value may lead to

Parameter 7-03 Speed PID Integral Time Eliminates steady state speed error. Lower values mean quicker reaction. However, too low

Parameter 7-04 Speed PID Dierentiation Time Provides a gain proportional to the rate of change of the feedback. A setting of 0 disables

Parameter 7-05 Speed PID Di. Gain Limit If there are quick changes in reference or feedback in a given application, which means

Parameter 7-06 Speed PID Lowpass Filter Time A low-pass lter that dampens oscillations on the feedback signal and improves steady

Parameter 1-01 Motor Control Principle

U/f

Not active

Not available

oscillations.

a value may lead to oscillations.

the dierentiator.

that the error changes swiftly, the dierentiator may soon become too dominant. This is

because it reacts to changes in the error. The quicker the error changes, the stronger the

dierentiator gain is. The dierentiator gain can thus be limited to allow setting of the

reasonable dierentiation time for slow changes and a suitably quick gain for quick

changes.

state performance. However, too long a lter time deteriorates the dynamic performance of

the speed PID control.

Practical settings of parameter 7-06 Speed PID Lowpass Filter Time taken from the number of

pulses per revolution from encoder (PPR):

Encoder PPR Parameter 7-06 Speed PID Lowpass Filter

512 10 ms

1024 5 ms

2048 2 ms

4096 1 ms

VVC

Not active

ACTIVE

Time

Table 2.5 Speed Control Parameters

Example of programming the speed control

In this example, the speed PID control is used to maintain a constant motor speed regardless of the changing load on the motor. The required motor speed is set via a potentiometer connected to terminal 53. The speed range is 0–1500 RPM corresponding to 0–10 V over the potentiometer. A switch connected to terminal 18 controls starting and stopping. The speed PID monitors the actual RPM of the motor by using a 24 V (HTL) incremental encoder as feedback. The feedback sensor is an encoder (1024 pulses per revolution) connected to terminals 32 and 33. The pulse frequency range to terminals 32 and 33 is 4 Hz–32 kHz.

96 97 9998

91 92 93 95

L1 L2L1PEL3

W PEVU

32 33

24 Vdc

130BD372.11

Product Overview Design Guide

2 2

Illustration 2.24 Speed Control Programming

Product Overview

VLT® AutomationDrive FC 360

Follow the steps in Table 2.6 to program the speed control (see explanation of settings in the programming guide)

In Table 2.6, it is assumed that all other parameters and switches remain at their default setting.

Function Parameter number Setting

1) Make sure that the motor runs properly. Do the following:

Set the motor parameters using the data on the

nameplate.

Perform an AMA. Parameter 1-29 Automatic

2) Check that the motor is running and that the encoder is attached properly. Do the following:

Press [Hand On]. Check that the motor is running and note

the rotation direction (referred to as the positive direction).

3) Make sure that the frequency converter limits are set to safe values:

Set acceptable limits for the references. Parameter 3-02 Minimum

Check that the ramp settings are within frequency

converter capabilities and allowed application operating

specications.

Set acceptable limits for the motor speed and frequency. Parameter 4-12 Motor

4) Congure the speed control and select the motor control principle:

Activation of speed control Parameter 1-00 Congu-

Selection of motor control principle Parameter 1-01 Motor

5) Congure and scale the reference to the speed control:

Set up analog input 53 as a reference source. Parameter 3-15 Reference 1

Scale analog input 53 0 Hz (0 V) to 50 Hz (10 V) Parameter group 6-1*

6) Congure the 24 V HTL encoder signal as feedback for the motor control and the speed control:

Set up digital input 32 and 33 as encoder inputs. Parameter 5-14 Terminal

Select terminal 32/33 as speed PID feedback. Parameter 7-00 Speed PID

7) Tune the speed control PID parameters:

Use the tuning guidelines when relevant or tune manually. Parameter group 7-0*

8) Finish:

Save the parameter setting to the LCP for safe-keeping. Parameter 0-50 LCP Copy [1] All to LCP

Parameter group 1-2*

Motor Data

Motor Adaption (AMA)

Set a positive reference.

Reference

Parameter 3-03 Maximum

Reference

Parameter 3-41 Ramp 1

Ramp Up Time

Parameter 3-42 Ramp 1

Ramp Down Time

Speed Low Limit [Hz]

Parameter 4-14 Motor

Speed High Limit [Hz]

Parameter 4-19 Max

Output Frequency

ration Mode

Control Principle

Source

Analog Input 1

32 Digital Input

Parameter 5-15 Terminal

33 Digital Input

Feedback Source

Speed PID Ctrl.

As specied by motor nameplate.

[1] Enable complete AMA

Default setting

0 Hz

50 Hz

60 Hz

[1] Speed closed loop

[1] VVC

Not necessary (default)

[82] Encoder input B

[83] Encoder input A

[1] 24 V Encoder

Table 2.6 Programming Order for Speed PID Control

P 7-30 normal/inverse

PID

P 7-38

*(-1)

Feed forward

Reference Handling

Feedback Handling

% [unit]

% [speed]

Scale to speed

P 4-10 Motor speed direction

To motor control

Process PID

130BA178.10

-100%

100%

-100%

100%

Product Overview Design Guide

2.5.2 Process PID Control

The process PID control can be used to control application parameters that can be measured by a sensor (for example pressure, temperature, ow) and aected by the connected motor through a pump, fan, or other connected devices.

Table 2.7 shows the control congurations in which the process control is possible. Refer to chapter 2.3 Control Structures to see where the speed control is active.

Parameter 1-00 Conguration Mode Parameter 1-01 Motor Control Principle

U/f

VVC

[3] Process Not available Process

Table 2.7 Control Conguration

NOTICE

The process control PID works under the default parameter setting, but tuning the parameters is recommended to optimize the application control performance.

2 2

Illustration 2.25 Process PID Control Diagram

Product Overview

VLT® AutomationDrive FC 360

2.5.3 Process Control Relevant Parameters

Parameter Description of function

Parameter 7-20 Process CL Feedback 1 Resource Select from which source (analog or pulse input) the process PID gets its feedback.

Parameter 7-22 Process CL Feedback 2 Resource Optional: Determine if (and from where) the process PID gets an additional feedback

signal. If an additional feedback source is selected, the 2 feedback signals are added

before being used in the process PID control.

Parameter 7-30 Process PID Normal/ Inverse

Control

Parameter 7-31 Process PID Anti Windup The anti-windup function ensures that when either a frequency limit or a torque limit is

Parameter 7-32 Process PID Start Speed In some applications, reaching the required speed/setpoint can take a long time. In such

Parameter 7-33 Process PID Proportional Gain The higher the value, the quicker the control. However, too large a value may lead to

Parameter 7-34 Process PID Integral Time Eliminates steady state speed error. A lower value means a quicker reaction. However, too

Parameter 7-35 Process PID Dierentiation Time Provides a gain proportional to the rate of feedback change. A setting of 0 disables the

Parameter 7-36 Process PID Di. Gain Limit If there are quick changes in reference or feedback in a given application (which means

Parameter 7-38 Process PID Feed Forward

Factor

Parameter 6-16 Terminal 53 Filter Time

•

Constant (Analog term 53)

Parameter 6-26 Terminal 54 Filter Time

•

Constant (Analog term. 54)

Under [0] Normal operation, the process control responds with an increase of the motor

speed if the feedback is lower than the reference. Under [1] Inverse operation, the process

control responds with a decreasing motor speed instead.

reached, the integrator is set to a gain that corresponds to the actual frequency. This

avoids integrating on an error that cannot be compensated for by a speed change. Press

[0] O to disable this function.

applications, it may be an advantage to set a xed motor speed from the frequency

converter before the process control is activated. Set a xed motor speed by setting a

process PID start value (speed) in parameter 7-32 Process PID Start Speed.

oscillations.

small a value may lead to oscillations.

dierentiator.

that the error changes swiftly), the dierentiator may soon become too dominant. This is

because it reacts to changes in the error. The quicker the error changes, the stronger the

dierentiator gain is. The dierentiator gain can thus be limited to allow setting of the

reasonable dierentiation time for slow changes.

In applications where there is a good (and approximately linear) correlation between the

process reference and the motor speed necessary for obtaining that reference, use the

feed-forward factor to achieve better dynamic performance of the process PID control.

If there are oscillations of the current/voltage feedback signal, use a low-pass lter to

dampen these oscillations.

Example: If the low-pass lter has been set to 0.1 s, the limit speed is 10 RAD/s (the

reciprocal of 0.1 s), corresponding to (10/(2 x π))=1.6 Hz. This means that the lter

dampens all currents/voltages that vary by more than 1.6 oscillations per second. The

control is only carried out on a feedback signal that varies by a frequency (speed) of less

than 1.6 Hz.

The low-pass lter improves steady state performance, but selecting a too long lter time

deteriorates the dynamic performance of the process PID control.

Table 2.8 Process Control Parameters

Temperature

Fan speed

Temperature transmitter

Heat

Heat generating process

Cold air

130BA218.10

100kW

n °CW

Transmitter

96 97 9998

91 92 93 95

L1 L2L1PEL3

W PEVU

130BD373.10

Product Overview Design Guide

2.5.4 Example of Process PID Control

Illustration 2.26 is an example of a process PID control used in a ventilation system:

Illustration 2.26 Process PID Control in a Ventilation System

In a ventilation system, the temperature can be set from -5 to +35 °C (23–95 °F) with a potentiometer of 0–10 V. To keep the set temperature constant, use the process control.

1. Start/stop via the switch connected to terminal

18.

2. Temperature reference via potentiometer (-5 to

+35 °C (23–95 °F), 0–10 V DC) connected to terminal 53.

3. Temperature feedback via transmitter (-10 to

+40 °C (14–104 °F), 4–20 mA) connected to terminal 54.

2 2

The control is inverse, which means that when the temperature increases, the ventilation speed is increased as well to generate more air. When the temperature drops, the speed is reduced. The transmitter used is a temperature sensor with a working range of -10 to +40 °C (14–104 °F), 4–20 mA.

Illustration 2.27 2-wire Transmitter

Product Overview

VLT® AutomationDrive FC 360

Function Parameter

number

Initialize the frequency converter. Parameter 14-2

1) Set motor parameters:

Set the motor parameters according to nameplate

data.

Perform a full AMA. Parameter 1-29

2) Check that motor is running in the correct direction.

When the motor is connected to the frequency converter with straight forward phase order as U-U; V-V; W-W, the motor shaft usually

turns clockwise seen into shaft end.

Press [Hand On]. Check the shaft direction by

applying a manual reference.

If the motor turns opposite of required direction:

1. Change motor direction in

parameter 4-10 Motor Speed Direction.

2. Turn o mains, and wait for DC link to

discharge.

3. Switch 2 of the motor phases.

Set conguration mode. Parameter 1-00

3) Set reference conguration, that is the range for reference handling. Set scaling of analog input in parameter group 6-** Analog In/Out.

Set reference/feedback units.

Set minimum reference (10 °C (50 °F)).

Set maximum reference (80 °C (176 °F)).

If the set value is determined from a preset value

(array parameter), set other reference sources to [0]

No Function.

4) Adjust limits for the frequency converter:

Set ramp times to an appropriate value as 20 s. Parameter 3-41

2 Operation

Mode

Parameter

group 1-2*

Motor Data

Automatic

Motor

Adaption

(AMA)

Parameter 4-10

Motor Speed

Direction

Conguration

Mode

Parameter 3-01

Reference/

Feedback Unit

Parameter 3-02

Minimum

Reference

Parameter 3-03

Maximum

Reference

Parameter 3-10

Preset

Reference

Ramp 1 Ramp

Up Time

Parameter 3-42

Ramp 1 Ramp

Down Time

Setting

[2] Initialisation - perform a power cycling - press reset.

As stated on motor nameplate.

[1] Enable complete AMA.

Select correct motor shaft direction.

[3] Process.

[60] °C Unit shown on display.

-5 °C (23 °F).

35 °C (95 °F).

[0] 35%.

Par . 3 − 10

Ref  = 

Parameter 3-14 Preset Relative Reference to parameter 3-18 Relative

Scaling Reference Resource [0] = No Function.

20 s

 ×  Par . 3 − 03  −  par . 3 − 02  = 24, 5°C

100

Product Overview Design Guide

Function Parameter

number

Set minimum speed limits.

Set motor speed maximum limit.

Set maximum output frequency.

Set parameter 6-19 Terminal 53 mode and parameter 6-29 Terminal 54 mode to voltage or current mode.

5) Scale analog inputs used for reference and feedback:

Set terminal 53 low voltage.

Set terminal 53 high voltage.

Set terminal 54 low feedback value.

Set terminal 54 high feedback value.

Set feedback source.

6) Basic PID settings:

Process PID normal/inverse. Parameter 7-30

Process PID anti wind-up. Parameter 7-31

Process PID start speed. Parameter 7-32

Save parameters to LCP. Parameter 0-50

Parameter 4-12

Motor Speed

Low Limit [Hz]

Parameter 4-14

Motor Speed

High Limit [Hz]

Parameter 4-19

Max Output

Frequency

Parameter 6-10

Terminal 53

Low Voltage

Parameter 6-11

Terminal 53

High Voltage

Parameter 6-24

Terminal 54

Low Ref./Feedb.

Value

Parameter 6-25

Terminal 54

High Ref./

Feedb. Value

Parameter 7-20

Process CL

Feedback 1

Resource

Process PID

Normal/

Inverse Control

Process PID

Anti Windup

Process PID

Start Speed

LCP Copy

Setting

10 Hz

50 Hz

60 Hz

0 V

10 V

-5 °C (23 °F)

35 °C (95 °F)

[2] Analog input 54

[0] Normal

[1] On

300 RPM

[1] All to LCP

2 2

Table 2.9 Example of Process PID Control Set-up

130BA183.10

y(t)

Product Overview

VLT® AutomationDrive FC 360

2.5.5 Process Controller Optimization

1. Select only proportional control, meaning that the integral time is set to the maximum value,

chapter 2.5.5 Programming Order, optimize the proportional gain, the integration time, and the dierentiation time (parameter 7-33 Process PID Proportional Gain,

parameter 7-34 Process PID Integral Time, and parameter 7-35 Process PID Dierentiation Time). In most

processes, complete the following procedure:

1. Start the motor.

2. Set parameter 7-33 Process PID Proportional Gain

After conguring the basic settings as described in

to 0.3 and increase it until the feedback signal again begins to vary continuously. Reduce the

The process operator can do the nal tuning of the control iteratively to yield satisfactory control.

while the dierentiation time is set to 0.

2. Increase the value of the proportional gain until the point of instability is reached (sustained oscillations) and the critical value of gain, Ku, is reached.

3. Measure the period of oscillation to obtain the critical time constant, Pu.

4. Use Table 2.10 to calculate the necessary PID control parameters.

value until the feedback signal has stabilized. Lower the proportional gain by 40–60%.

3. Set parameter 7-34 Process PID Integral Time to 20 s and reduce the value until the feedback signal again begins to vary continuously. Increase the integration time until the feedback signal stabilizes, followed by an increase of 15–50%.

4. Only use parameter 7-35 Process PID

Dierentiation

Time for fast-acting systems (dierentiation time). The typical value is 4 times the set integration time. Use the dierentiator when the setting of the proportional gain and the integration time has been fully optimized. Make sure that the lowpass lter dampens the oscillations on the feedback signal suciently.

Illustration 2.28 Marginally Stable System

NOTICE

If necessary, start/stop can be activated several times to provoke a variation of the feedback signal.

2.5.6 Ziegler Nichols Tuning Method

To tune the PID controls of the frequency converter, Danfoss recommends the Ziegler Nichols tuning method.

Type of

control

PI-control 0.45 x K

PID tight

control

PID some

overshoot

Proportional

gain

0.6 x K

0.33 x K

Integral time Dierentiation

time

0.833 x P

0.5 x P

0.125 x P

0.33 x P

–

NOTICE

Table 2.10 Ziegler Nichols Tuning for Regulator

Do not use the Ziegler Nichols Tuning method in applications that could be damaged by the oscillations created by marginally stable control settings.

The criteria for adjusting the parameters are based on evaluating the system at the limit of stability rather than on taking a step response. Increase the proportional gain until observing continuous oscillations (as measured on the feedback), that is, until the system becomes marginally stable. The corresponding gain (Ku) is called the ultimate gain and is the gain, at which the oscillation is obtained. The period of the oscillation (Pu) (called the ultimate period) is determined as shown in Illustration 2.28 and should be measured when the amplitude of oscillation is small.

175ZA062.12

Product Overview Design Guide

2.6 EMC Emission and Immunity

2.6.1 General Aspects of EMC Emission

Electrical interference is conducted at frequencies in the range 150 kHz to 30 MHz. Airborne interference from the frequency converter system in the range 30 MHz to 1 GHz is generated from the frequency converter, motor cable, and motor. Capacitive currents in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents. Using a shielded motor cable increases the leakage current (see Illustration 2.29) because shielded cables have higher capacitance to ground than unshielded cables. If the leakage current is not mains in the radio frequency range below approximately 5 MHz. Since the leakage current (I1) is carried back to the unit through the shield (I3), there is only a small electro-magnetic eld (I4) from the shielded motor cable.

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

eect and increases the leakage current (I4).

Mount the shield on the enclosure at both ends if a shielded cable is used for the following purposes:

Fieldbus

•

Network

•

Relay

•

Control cable

•

Signal interface

•

Brake

•

ltered, it causes greater interference on the

2 2

In some situations, however, it is necessary to break the shield to avoid current loops.

1 Ground cable

2 Shield

3 AC mains supply

4 Frequency converter

5 Shielded motor cable

6 Motor

Illustration 2.29 EMC Emission

Product Overview

VLT® AutomationDrive FC 360

If placing the shield on a mounting plate for the frequency converter, use a metal mounting plate to convey the shield currents back to the unit. Ensure good electrical contact from the mounting plate through the mounting screws to the frequency converter chassis.

When using unshielded cables, some emission requirements are not complied with, although the immunity requirements are observed.

To reduce the interference level from the entire system (unit and installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside mains, motor, and brake cables. Radio interference higher than 50 MHz (airborne) is especially generated by the control electronics.

2.6.2 EMC Emission Requirements

The test results in Table 2.11 have been obtained using a system with a frequency converter (with the mounting plate), a motor, and shielded motor cables.

Class A Group 2/EN 55011

Industrial environment

Enclosure size and rated power

J1 0.37–2.2 kW (0.5–3.0 hp), 380–480 V – – 25 m (82 ft) Yes

Filter

Table 2.11 EMC Emission (Filter Type: Internal)

1) Frequency range from 150 kHz to 30 MHz is not harmonized between IEC/EN 61800-3 and EN 55011 and not mandatorily included.

J2 3.0–5.5 kW (4.0–7.5 hp), 380–480 V – – 25 m (82 ft) Yes

J3 7.5 kW (10 hp), 380–480 V – – 25 m (82 ft) Yes

J4 11–15 kW (15–20 hp), 380–480 V – – 25 m (82 ft) Yes

J5 18.5–22 kW (25–30 hp), 380–480 V – – 25 m (82 ft) Yes

J1 0.37–2.2 kW (0.5–3.0 hp), 380–480 V 5 m (16.4 ft)

J2 3.0–5.5 kW (4.0–7.5 hp), 380–480 V 5 m (16.4 ft)

J3 7.5 kW (10 hp), 380–480 V 5 m (16.4 ft)

J4 11–15 kW (15–20 hp), 380–480 V 5 m (16.4 ft)

J5 18.5–22 kW (25–30 hp), 380–480 V 5 m (16.4 ft)

J6 30–45 kW (40–60 hp), 380–480 V 25 m (82 ft)

J7 55–75 kW (75–100 hp), 380–480 V 25 m (82 ft)

Category C3/EN/IEC 61800-3

Second environment

Conducted Radiated Conducted Radiated

Yes

Class A Group 1/EN 55011

Industrial environment

Category C2/EN/IEC 61800-3

First environment restricted

– –

2.6.3 EMC Immunity Requirements

The immunity requirements for frequency converters depend on the environment in which they are installed. The requirements for the industrial environment are higher than the requirements for the home and oce environment. All Danfoss frequency converters comply with the requirements for the industrial environment. Therefore they also comply with the lower requirements for home and oce environment with a large safety margin.

To document immunity against burst transient from electrical phenomena, the following immunity tests have been made on a system consisting of:

A frequency converter (with options if relevant).

•

A shielded control cable.

•

A control box with potentiometer, motor cable, and motor.

•

Product Overview Design Guide

The tests were performed in accordance with the following basic standards:

EN 61000-4-2 (IEC 61000-4-2) Electrostatic discharges (ESD): Simulation of electrostatic discharges from human

•

beings.

EN 61000-4-3 (IEC 61000-4-3) Radiated immunity: Amplitude modulated simulation of the eects of radar and

•

radio communication equipment and mobile communications equipment.

EN 61000-4-4 (IEC 61000-4-4) Burst transients: Simulation of interference caused by switching a contactor, relay,

•

or similar devices.

EN 61000-4-5 (IEC 61000-4-5) Surge transients: Simulation of transients caused by, for example, lightning that

•

strikes near installations.

EN 61000-4-6 (IEC 61000-4-6) Conducted immunity: Simulation of the eect from radio-transmission equipment

•

joined by connection cables.

The immunity requirements should follow product standard IEC 61800-3. See Table 2.12 for details.

Voltage range: 380–480 V

Product standard 61800-3

Test

Acceptance criterion B B B A A

Mains cable – – 2 kV CN

Motor cable – – 4 kV CCC – 10 V

Brake cable – – 4 kV CCC – 10 V

Load sharing cable – – 4 kV CCC – 10 V

Relay cable – – 4 kV CCC – 10 V

Control cable – –

Standard/eldbus cable – –

LCP cable – –

Enclosure

ESD Radiated immunity Burst Surge Conducted

immunity

4 kV CD

8 kV AD

2 kV/2 Ω DM

2 kV/12 Ω CM

Length >2 m

(6.6 ft)

1 kV CCC

Length >2 m

(6.6 ft)

1 kV CCC

Length >2 m

(6.6 ft)

1 kV CCC

10 V/m – – –

Unshielded:

1 kV/42 Ω CM

Unshielded:

1 kV/42 Ω CM

– 10 V

10 V

2 2

RMS

Table 2.12 EMC Immunity Requirements

Denition:

CD: Contact discharge

AD: Air discharge

DM: Dierential mode

CM: Common mode

CN: Direct injection through coupling network

CCC: Injection through capacitive coupling clamp

130BD447.11

130BB955.12

Leakage current

Motor cable length

Product Overview

VLT® AutomationDrive FC 360

2.7 Galvanic Isolation

PELV oers protection through extra low voltage.

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

WARNING

Before touching any electrical parts, ensure that other voltage inputs have been disconnected, such as load sharing (linkage of DC intermediate circuit) and the motor connection for kinetic back-up. Wait at least the amount of time indicated in Table 1.2. Failure to follow recommendations could result in death or serious injury.

All control terminals and relay terminals 01-03/04-06 comply with PELV (Protective Extra Low Voltage). This does

2.8 Earth Leakage Current

not apply to grounded Delta leg above 400 V.

Follow national and local codes regarding protective

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

The components that make up the electrical isolation, as shown in Illustration 2.30, also comply with the requirements for higher isolation and the relevant test as described in EN 61800-5-1. The PELV galvanic isolation can be shown in 3 locations (see Illustration 2.30):

grounding of equipment with a leakage current >3.5 mA. Frequency converter technology implies high frequency switching at high power. This generates a leakage current in the ground connection. A fault current in the frequency converter at the output power terminals might contain a DC component, which can charge the lter capacitors and cause a transient ground current. The earth leakage current is made up of several contributions and depends on various system congurations including RFI ltering, shielded motor cables, and frequency converter power.

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

1 Power supply (SMPS) for control cassette

2 Communication between power card and control cassette

3 Customer relays

Illustration 2.30 Galvanic Isolation

Interface between Standard RS485 and I/O circuit (PELV) is functionally isolated.

Illustration 2.31 Inuence of the Cable Length and Power Size

on Leakage Current, Pa>P

130BB956.12

THDv=0%

THDv=5%

Leakage current

130BB958.12

Cable

150 Hz

3rd harmonics

50 Hz

Mains

RCD with low f

cut-

RCD with high f

cut-

Leakage current

Frequency

130BB957.11

Leakage current [mA]

100 Hz

2 kHz

100 kHz

Product Overview Design Guide

The leakage current also depends on the line distortion.

2 2

Illustration 2.33 Main Contributions to Leakage Current

Illustration 2.32 Inuence of Line Distortion on Leakage

Current

NOTICE

High leakage current may cause the RCDs to switch o. To avoid this problem, remove the RFI screw (enclosure sizes J1 to J5) or set parameter 14-50 RFI Filter to [0] O (enclosure sizes J6 and J7) when a lter is being charged.

EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3.5mA. Grounding must be reinforced in 1 of the following ways:

Ground wire (terminal 95) of at least 10 mm2.

•

2 separate ground wires that comply with the

•

dimensioning rules.

See EN/IEC61800-5-1 for further information.

Using RCDs

Where residual current devices (RCDs), also known as earth leakage circuit breakers (ELCBs), are used, comply with the following:

Use RCDs of type B only, which are capable of

•

detecting AC and DC currents.

Use RCDs with an inrush delay to prevent faults

•

caused by transient earth currents.

Dimension RCDs according to the system

•

ration and environmental considerations.

congu-

Illustration 2.34 Inuence of Cut-o Frequency of the RCD on

What is Responded to/Measured

For more details, refer to the RCD Application Note.

Brake Functions

2.9

2.9.1 Mechanical Holding Brake

A mechanical holding brake mounted directly on the motor shaft normally performs static braking.

NOTICE

When the holding brake is included in a safety chain, a frequency converter cannot provide a safe control of a mechanical brake. Include a redundancy circuitry for the brake control in the total installation.

to ta

130BA167.10

Load

Time

Speed

Product Overview

2.9.2 Dynamic Braking

VLT® AutomationDrive FC 360

Resistor brake: A brake IGBT keeps the

•

overvoltage under a certain threshold by directing the brake energy from the motor to the connected brake resistor (parameter 2-10 Brake Function = [1] Resistor brake). Adjust the threshold in parameter 2-14 Brake voltage reduce, with 70 V range.

Dynamic braking is established by:

AC brake: The brake energy is distributed in the

•

motor by changing the loss conditions in the

Illustration 2.35 Typical Braking Cycle

motor. The AC brake function cannot be used in applications with high cycling frequency as this overheats the motor (parameter 2-10 Brake Function = [2] AC brake).

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).

2.9.3 Brake Resistor Selection

To handle higher demands by generatoric braking, a brake resistor is necessary. Using a brake resistor ensures that the heat is absorbed in the brake resistor and not in the

frequency converter. For more information, see the VLT Brake Resistor MCE 101 Design Guide.

Power range

380–480 V

Cycle time (s) 120

Braking duty cycle at 100% torque Continuous

Braking duty cycle at overtorque

(150/160%)

Table 2.13 Braking at High Overload Torque Level

1) For 30–75 kW (40–100 hp) frequency converters, an external brake

resistor is needed to meet the specication in Table 2.13.

Danfoss oers brake resistors with duty cycle of 10% and 40%. If a 10% duty cycle is applied, the brake resistors are

0.37–75 kW (0.5–100

hp)

40%

able to absorb brake power for 10% of the cycle time. The

If the amount of kinetic energy transferred to the resistor in each braking period is not known, the average power

remaining 90% of the cycle time is used for dissipating excess heat.

can be calculated based on the cycle time and braking time. The resistor intermittent duty cycle is an indication of the duty cycle at which the resistor is active. Illustration 2.35 shows a typical braking cycle.

NOTICE

Make sure that the resistor is designed to handle the required braking time.

The intermittent duty cycle for the resistor is calculated as follows:

The maximum allowed load on the brake resistor is stated as a peak power at a given intermittent duty cycle and can

Duty cycle = tb/T .

tb is the braking time in seconds T = cycle time in seconds.

be calculated as:

Brake Resistance Calculation

x0 . 83

dc,br

 Ω = 

peak

where

peak

= P

x Mbr [%] x η

motor

x η

VLT

[W]

As can be seen, the brake resistor depends on the DC-link voltage (Udc).

Size Brake active

dc,br

FC 360

3x380–480 V

770 V 800 V 800 V

Warning

before cut

out

Cut out (trip)

Product Overview Design Guide

The threshold can be adjusted in parameter 2-14 Brake voltage reduce, with 70 V range.

NOTICE

Make sure that the brake resistor can cope with a voltage of 410 V or 820 V.

Danfoss recommends calculating the brake resistance R

rec

according to the formula below. The recommended brake resistance guarantees that the frequency converter is able to brake at the highest braking torque (M

x100x0.83

motor

xM

br( % )

xη

motor



xη

VLT

Ω = 



rec

is typically at 0.80 (≤ 75 kW/100 hp); 0.85 (11–22

motor

) of 160%.

br(%)

kW/15–30 hp). η

is typically at 0.97.

VLT

For FC 360, R

480V : R

rec

480V : R

rec

at 160% braking torque is written as:

rec

= 

396349

397903

 Ω 

motor

 Ω 

motor

1) For frequency converters ≤ 7.5 kW (10 hp) shaft output

2) For frequency converters 11–75 kW (15–100 hp) shaft output

NOTICE

The resistance of the brake resistor should not be higher than the value recommended by Danfoss. If a brake resistor with a higher ohmic value is selected, the 160% braking torque may not be achieved because the frequency converter might cut out for safety reasons. The resistance should be bigger than R

min

NOTICE

If a short circuit in the brake transistor occurs, power dissipation in the brake resistor is only prevented by using a mains switch or contactor to disconnect the mains for the frequency converter. (The contactor can be controlled by the frequency converter).

NOTICE

Do not touch the brake resistor because it can get hot during braking. Place the brake resistor in a secure environment to avoid re risk.

2.9.4 Control with Brake Function

The brake is protected against short-circuiting of the brake resistor, and the brake transistor is monitored to ensure that short-circuiting of the transistor is detected. A relay/ digital output can be used for protecting the brake resistor from overloading caused by a fault in the frequency converter. In addition, the brake enables readout of the momentary power and the mean power for the latest 120 s. The brake can also monitor the power energizing and make sure that it does not exceed a limit selected in parameter 2-12 Brake Power Limit (kW).

NOTICE

Monitoring the brake power is not a safety function. A thermal switch is required to prevent the brake power from exceeding the limit. The brake resistor circuit is not ground leakage protected.

Overvoltage control (OVC) (exclusive brake resistor) can be selected as an alternative brake function in parameter 2-17 Over-voltage Control. This function is active for all units. The function ensures that a trip can be avoided if the DC-link voltage increases. This is done by increasing the output frequency to limit the voltage from the DC link. It is a useful function, for example if the rampdown time is too short to avoid tripping of the frequency converter. In this situation, the ramp-down time is extended.

NOTICE

OVC can be activated when running a PM motor (when

parameter 1-10 Motor Construction is set to [1] PM nonsalient SPM).

2.10 Smart Logic Controller

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. That leads to an associated action as shown in Illustration 2.36.

2 2

. . . . . .

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..

. . . . . .

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 Overview

VLT® AutomationDrive FC 360

Comparators

Comparators are used for comparing continuous variables (for example output frequency, output current, and analog

input) to xed preset values.

Illustration 2.38 Comparators

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.

Illustration 2.36 Associated Action

Events and actions are each numbered and linked in pairs (states). This means that when event [0] is fullled (attains the value true), action [0] is executed. After this, the conditions of event [1] are evaluated and if evaluated true, action [1] is executed, and so on. 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 evaluates event [0] (and only event [0]) each scan interval. Only when event [0] is evaluated true, the SLC executes action [0] and starts evaluating event [1]. 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 2.37 shows an example with 3 event/actions:

Illustration 2.39 Logic Rules

2.11 Extreme Running Conditions

Short circuit (motor phase-to-phase)

The frequency converter is protected against short circuits by current measurement in each of the 3 motor phases or in the DC link. A short circuit between 2 output phases causes an overcurrent in the frequency converter. The frequency converter is turned o individually when the short-circuit current exceeds the permitted value (alarm 16, Trip lock).

Switching on the output

Switching on the output between the motor and the frequency converter is fully allowed and does not damage the frequency converter. However, fault messages may appear.

Illustration 2.37 Sequence with 3 Events/Actions

1.21.0 1.4

100

1.81.6 2.0

2000

500

200

400 300

1000

600

t [s]

175ZA052.12

OUT

= 2 x f

M,N

OUT

= 0.2 x f

M,N

OUT

= 1 x f

M,N

(par. 1-23)

IMN(par. 1-24)

Product Overview Design Guide

Motor-generated overvoltage

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

The load drives the motor (at constant output

•

frequency from the frequency converter).

If the inertia moment is high during deceleration

•

(ramp-down), the friction is low and the rampdown time is too short for the energy to be dissipated as a loss in the frequency converter, the motor, and the installation.

Incorrect slip compensation setting may cause

•

higher DC-link voltage.

The control unit may attempt to correct the ramp if possible (parameter 2-17 Over-voltage Control). The frequency converter turns o to protect the transistors and the DC link capacitors when a certain voltage level is reached. To select the method used for controlling the DC-link voltage level, see parameter 2-10 Brake Function and parameter 2-17 Over-voltage Control.

Mains drop-out

During a mains drop-out, the frequency converter keeps running until the DC-link voltage drops below the minimum stop level, which is 320 V. The mains voltage before the drop-out and the motor load determines how long it takes for the inverter to coast.

Minimum speed limit

Parameter 4-12 Motor Speed Low Limit [Hz] sets the minimum output speed that the drive can provide.

Maximum speed limit

Parameter 4-14 Motor Speed High Limit [Hz] or parameter 4-19 Max Output Frequency sets the maximum

output speed that the drive can provide.

ETR (electronic thermal relay)

The drive ETR function measures the actual current, speed, and time to calculate motor temperature. The function also protects the motor from being overheated (warning or trip). An external thermistor input is also available. ETR is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in Illustration 2.40.

2 2

Static overload in VVC+ mode

When the frequency converter is overloaded, the torque limit in parameter 4-16 Torque Limit Motor Mode/ parameter 4-17 Torque Limit Generator Mode is reached, the

Illustration 2.40 ETR

control unit reduces the output frequency to reduce the load. If the overload is excessive, a current may occur that makes the frequency converter cut out after approximately 5–10 s.

Operation within the torque limit is limited in time (0–60 s) in parameter 14-25 Trip Delay at Torque Limit.

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

motor

and I

cooling of the motor. In that way, the motor is protected

2.11.1 Motor Thermal Protection

from being overheated even at low speed. The ETR feature

calculates the motor temperature based on actual current To protect the application from serious damage, the drive oers several dedicated features.

and speed. The calculated temperature is visible as a

readout parameter in parameter 16-18 Motor Thermal.

Torque limit

The torque limit protects the motor from being overloaded independent of the speed. Torque limit is controlled in

parameter 4-16 Torque Limit Motor Mode and parameter 4-17 Torque Limit Generator Mode. Parameter 14-25 Trip Delay at Torque Limit controls the time

before the torque limit warning trips.

Current limit

Parameter 4-18 Current Limit controls the current limit, and parameter 14-24 Trip Delay at Current Limit controls the

time before the current limit warning trips.

motor

130BC435.13

CHASSIS/IP20

MADE BY DANFOSS IN CHINA

Danfoss A/S 6430 Nordborg Denmark

T/C: FC-360HK37T4E20H2BXCDXXSXXXXAXBX

P/N: 134F2970 S/N: 691950A240

0.37 kW 0.5HP High Overload

IN: 3x380-480V 50/60Hz 1.24/0.99A

OUT: 3x0-Vin 0-500Hz 1.2/1.1A(Tamb. 45 C)

CAUTION:

SEE MANUAL

WARNING:

AND LOADSHARING BEFORE SERVICE

STORED CHARGE DO NOT TOUCH UNTIL 4 MIN. AFTER DISCONNECTION RISK OF ELECTRIC SHOCK-DUAL SUPPLY DISCONNECT MAINS

V LT

Automation Drive www.danfoss.com

130BC437.11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

F C - 3 6 0 H T 4 E 2 0 H 1 X X C D X X S X X X X A X B X

Q B

LAA

H 2

Type Code and Selection

3 Type Code and Selection

VLT® AutomationDrive FC 360

3.1 Ordering

Conrm that the equipment matches the requirements and ordering information by checking power size, voltage data, and overload data on the nameplate of the frequency converter.

1–6: Product Name

7: Overload

8–10: Power size

H: Heavy duty

Q: Normal duty

0.37–75 kW (0.5–100 hp). For example:

K37: 0.37 kW2) (0.5 hp)

1K1: 1.1 kW (1.5 hp)

11 K: 11 kW (15 hp)

11–12: Voltage class T4: 380–480 V 3 phases

13–15: IP class E20: IP20

16–17: RFI

H1: C2 Class

H2: C3 Class

18: Brake chopper

X: No

B: Built-in

19: LCP X: No

20: PCB coating C: 3C3

21: Mains terminals D: Load sharing

29–30: Embedded

eldbus

AX: No

A0: PROFIBUS

AL: PROFINET

31–32: Option B BX: No option

Table 3.1 Type Code: Selection of Dierent Features and Options

For options and accessories, refer to the section Options and

Accessories in the VLT® AutomationDrive FC 360 Design Guide.

1) Only 11–75 kW (15–100 hp) for normal duty variants. PROFIBUS

1 Type code

2 Ordering number

3 Specications

and PROFINET are unavailable for normal duty.

2) For all power sizes, see chapter 4.1.1 Mains Supply 3x380–480 V

AC.

3) H1 RFI lter is available for 0.37–22 kW (0.5–30 hp).

Illustration 3.1 Nameplates 1 and 2

4) 0.37–22 kW (0.5–30 hp) with built-in brake chopper. 30–75 kW

(40–100 hp) with external brake chopper only.

Illustration 3.2 Type Code String

Type Code and Selection Design Guide

3.2 Ordering Numbers: Options, Accessories, and Spare Parts

Description Ordering

numbers

VLT® Control Panel LCP 21

LCP remote mounting kit with 3 m cable

Blind cover, FC 360

Graphical LCP adapter 132B0281

VLT® Control Panel LCP 102

VLT® Encoder Input MCB 102, FC 360

VLT® Resolver Input MCB 103, FC 360

Terminal cover for MCB, J1, FC 360 132B0263

Terminal cover for MCB, J2, FC 360 132B0265

Terminal cover for MCB, J3, FC 360 132B0266

Terminal cover for MCB, J4, FC 360 132B0267

Terminal cover for MCB, J5, FC 360 132B0268

Decoupling plate mounting kit, J1 132B0258

Decoupling plate mounting kit, J2, J3 132B0259

Decoupling plate mounting kit, J4, J5 132B0260

Decoupling plate mounting kit, J6 132B0284

Decoupling plate mounting kit, J7 132B0285

LCP remote mounting cable, 3 m (10 ft) 132B0132

VLT® Control Panel LCP 21 - RJ45 Converter Kit

Table 3.2 Ordering Numbers for Options and Accessories

1) 2 kinds of packages, 6 pieces or 72 pieces.

2) 2 pieces in 1 package.

132B0254

132B0102

132B0262

130B1107

132B0282

132B0283

132B0254

Description Ordering

numbers

Standard control cassette 132B0255

Control cassette (with PROFIBUS) 132B0256

Control cassette (with PROFINET) 132B0257

Fan 50x15 IP21 for J1 0.37–1.5 kW (0.5–2 hp) 132B0275

Fan 50x20 IP21 for J1 2.2 kW (3 hp) 132B0276

Fan 60x20 IP21 for J2 132B0277

Fan 70x20 IP21 for J3 132B0278

Fan 92x38 IP21 for J4 132B0279

Fan 120x38 IP21 for J5 132B0280

Fan 92x38 IP21 for J6 132B0295

Fan 120x38 IP21 for J7 132B0313

Relay & RS485 header for J1–J5 132B0264

Power control card, 30 kW (40 hp) 132B0287

Power control card, 37 kW (50 hp) 132B0290

Power control card, 45 kW (60 hp) 132B0291

RFI auxiliary card, J6 132B0292

Rectier module, 30–37 kW (40–50 hp) 132B0293

Rectier module, 45 kW (60 hp) 132B0294

Front cover, J6 132B0296

Mains terminal, J6 132B0297

Motor terminal, J6 132B0298

DC bus terminal, J6 132B0299

Power control card supply cable, J6 132B0300

Fan extension cable, J6 132B0301

Isolation RFI foil, J6 132B0302

Cradle for power card & bus bar, J6 132B0303

Power control card, 55 kW (75 hp) 132B0305

Power control card, 75 kW (100 hp) 132B0306

Power card, J7 132B0307

RFI auxiliary card, J7 132B0308

Rectier module, J7 132B0309

IGBT module with gate drive cable, J7 132B0310

DC capacitor, 55 kW (75 hp) 132B0311

DC capacitor, 75 kW (100 hp) 132B0312

Front cover, J7 132B0314

Mains, motor terminal, 55 kW (75 hp) 132B0315

DC bus terminal, 55 kW (75 hp) 132B0316

Mains, motor, DC bus terminal, 75 kW (100 hp) 132B0317

Temperature sensing cable, J7 132B0318

Power control card supply cable, J7 132B0319

Fan extension cable, J7 132B0320

Isolation RFI foil, J7 132B0321

Isolation inrush foil, J7 132B0322

3 3

Table 3.3 Ordering Numbers for Spare Parts

Type Code and Selection

VLT® AutomationDrive FC 360

3.3 Ordering Numbers: Brake Resistors

Danfoss oers a wide variety of dierent resistors that are specially designed for our frequency converters. See chapter 2.9.4 Control with Brake Function for the dimensioning of brake resistors. This section lists the ordering numbers for the brake resistors.

3.3.1 Ordering Numbers: Brake Resistors 10%

FC 360 P

T4 [kW]

HK37 0.37 890 1041.98 989 0.030 3000 120 1.5 0.3 139

HK55 0.55 593 693.79 659 0.045 3001 120 1.5 0.4 131

HK75 0.75 434 508.78 483 0.061 3002 120 1.5 0.4 129

H1K1 1.1 288 338.05 321 0.092 3004 120 1.5 0.5 132

H1K5 1.5 208 244.41 232 0.128 3007 120 1.5 0.8 145

H2K2 2.2 139 163.95 155 0.190 3008 120 1.5 0.9 131

H3K0 3 100 118.86 112 0.262 3300 120 1.5 1.3 131

H4K0 4 74 87.93 83 0.354 3335 120 1.5 1.9 128

H5K5 5.5 54 63.33 60 0.492 3336 120 1.5 2.5 127

H7K5 7.5 38 46.05 43 0.677 3337 120 1.5 3.3 132

H11K 11 27 32.99 31 0.945 3338 120 1.5 5.2 130

H15K 15 19 24.02 22 1.297 3339 120 1.5 6.7 129

H18K 18.5 16 19.36 18 1.610 3340 120 1.5 8.3 132

H22K 22 16 18.00 17 1.923 3357 120 1.5 10.1 128

H30K 30 11 14.6 13 2.6 3341 120 2.5 13.3 150

H37K 37 9 11.7 11 3.2 3359 120 2.5 15.3 150

H45K 45 8 9.6 9 3.9 3065 120 10 20 150

H55K 55 6 7.8 7 4.8 3070 120 10 26 150

H75K 75 4 5.7 5 6.6 3231 120 10 36 150

m (HO)

min

[Ω] [Ω] [Ω]

br. nom

rec

br avg

[kW] 175Uxxxx [s]

Code no. Period Cable

cross-

section

[mm2]

Thermal

relay

[A] [%]

Maximu

m brake

torque

with R

rec

Table 3.4 FC 360 - Mains: 380–480 V (T4), 10% Duty Cycle

1) All cabling must comply with national and local regulations on cable cross-sections and ambient temperature.

Type Code and Selection Design Guide

3.3.2 Ordering Numbers: Brake Resistors 40%

FC 360 P

T4 [kW]

HK37 0.37 890 1041.98 989 0.127 3101 120 1.5 0.4 139

HK55 0.55 593 693.79 659 0.191 3308 120 1.5 0.5 131

HK75 0.75 434 508.78 483 0.260 3309 120 1.5 0.7 129

H1K1 1.1 288 338.05 321 0.391 3310 120 1.5 1 132

H1K5 1.5 208 244.41 232 0.541 3311 120 1.5 1.4 145

H2K2 2.2 139 163.95 155 0.807 3312 120 1.5 2.1 131

H3K0 3 100 118.86 112 1.113 3313 120 1.5 2.7 131

H4K0 4 74 87.93 83 1.504 3314 120 1.5 3.7 128

H5K5 5.5 54 63.33 60 2.088 3315 120 1.5 5 127

H7K5 7.5 38 46.05 43 2.872 3316 120 1.5 7.1 132

H11K 11 27 32.99 31 4.226 3236 120 2.5 11.5 130

H15K 15 19 24.02 22 5.804 3237 120 2.5 14.7 129

H18K 18.5 16 19.36 18 7.201 3238 120 4 19 132

H22K 22 16 18.00 17 8.604 3203 120 4 23 128

H30K 30 11 14.6 13 11.5 3206 120 10 32 150

H37K 37 9 11.7 11 14.3 3210 120 10 38 150

H45K 45 8 9.6 9 17.5 3213 120 16 47 150

H55K 55 6 7.8 7 21.5 3216 120 25 61 150

H75K 75 4 5.7 5 29.6 3219 120 35 81 150

m (HO)

min

[Ω] [Ω] [Ω]

br. nom

rec

br avg

[kW] 175Uxxxx [s]

Code no. Period Cable

cross-

section

[mm2]

Thermal

relay

Maximum

brake

torque

with R

[A] [%]

rec

3 3

Table 3.5 FC 360 - Mains: 380–480 V (T4), 40% Duty Cycle

1) All cabling must comply with national and local regulations on cable cross-sections and ambient temperature.

Specications

4 Specications

4.1 Mains Supply 3x380–480 V AC

VLT® AutomationDrive FC 360

Frequency converter typical shaft

output [kW (hp)]

Enclosure protection rating IP20 J1 J1 J1 J1 J1 J1 J2 J2 J2 J3

Output current

Shaft output [kW] 0.37 0.55 0.75 1.1 1.5 2.2 3 4 5.5 7.5

Continuous (3x380–440 V) [A] 1.2 1.7 2.2 3 3.7 5.3 7.2 9 12 15.5

Continuous (3x441–480 V) [A] 1.1 1.6 2.1 2.8 3.4 4.8 6.3 8.2 11 14

Intermittent (60 s overload) [A] 1.9 2.7 3.5 4.8 5.9 8.5 11.5 14.4 19.2 24.8

Continuous kVA (400 V AC) [kVA] 0.84 1.18 1.53 2.08 2.57 3.68 4.99 6.24 8.32 10.74

Continuous kVA (480 V AC) [kVA] 0.9 1.3 1.7 2.5 2.8 4.0 5.2 6.8 9.1 11.6

Maximum input current

Continuous (3x380–440 V) [A] 1.2 1.6 2.1 2.6 3.5 4.7 6.3 8.3 11.2 15.1

Continuous (3x441–480 V) [A] 1.0 1.2 1.8 2.0 2.9 3.9 4.3 6.8 9.4 12.6

Intermittent (60 s overload) [A] 1.9 2.6 3.4 4.2 5.6 7.5 10.1 13.3 17.9 24.2

Additional specications

Maximum cable cross-section (mains,

motor, brake, and load sharing) [mm

(AWG)]

Estimated power loss at rated

maximum load [W]

Weight [kg (lb)], enclosure protection

rating IP20

Eciency [%]

HK37

0.37

(0.5)

20.88 25.16 30.01 40.01 52.91 73.97 94.81 115.5 157.54 192.83

2.3 (5.1) 2.3 (5.1)

96.2 97.0 97.2 97.4 97.4 97.6 97.5 97.6 97.7 98.0

HK55

0.55

(0.75)

HK75

0.75

(5.1)

H1K1

1.1

(1)

2.3

(1.5)

2.3 (5.1) 2.3 (5.1) 2.5 (5.5) 3.6 (7.9) 3.6 (7.9) 3.6 (7.9) 4.1 (9.0)

H1K5

1.5

(2)

4 (12)

H2K2

2.2

(3)

H3K0

(4)

H4K0

(5.5)

H5K5

5.5

(7.5)

H7K5

7.5

(10)

Table 4.1 Mains Supply 3x380–480 V AC - Heavy Duty

Specications Design Guide

Frequency converter typical

shaft output [kW (hp)]

Enclosure protection rating

IP20

Output current

Continuous (3x380–440 V) [A] 23 31 37 42.5 61 73 90 106 147

Continuous (3x441–480 V) [A] 21 27 34 40 52 65 77 96 124

Intermittent (60 s overload) [A] 34.5 46.5 55.5 63.8 91.5 109.5 135 159 220.5

Continuous kVA (400 V AC)

[kVA]

Continuous kVA (480 V AC)

[kVA]

Maximum input current

Continuous (3x380–440 V) [A] 22.1 29.9 35.2 41.5 57 70.3 84.2 102.9 140.3

Continuous (3x441–480 V) [A] 18.4 24.7 29.3 34.6 49.3 60.8 72.7 88.8 121.1

Intermittent (60 s overload) [A] 33.2 44.9 52.8 62.3 85.5 105.5 126.3 154.4 210.5

Additional specications

Maximum cable size (mains,

motor, brake) [mm2 (AWG)]

Estimated power loss at rated

maximum load [W]

Weight [kg (lb)], enclosure

protection rating IP20

Eciency [%]3)

H11K

(15)

J4 J4 J5 J5 J6 J6 J6 J7 J7

15.94 21.48 25.64 29.45 42.3 50.6 62.4 73.4 101.8

17.5 22.4 28.3 33.3 43.2 54.0 64.0 79.8 103.1

289.53 393.36 402.83 467.52 630 848 1175 1250 1507

9.4 (20.7) 9.5 (20.9)

97.8 97.8 98.1 97.9 98.1 98.0 97.7 98.0 98.2

H15K

(20)

H18K

18.5

(25)

16 (6) 50 (1/0) 95 (3/0)

12.3

(27.1)

H22K

(30)

12.5

(27.6)

H30K

(40)

22.4

(49.4)

H37K

(50)

22.5

(49.6)

H45K

(60)

22.6 (49.8) 37.3 (82.2) 38.7 (85.3)

H55K

(75)

H75K

(100)

4 4

Table 4.2 Mains Supply 3x380–480 V AC - Heavy Duty

Specications

VLT® AutomationDrive FC 360

Frequency converter typical

shaft output [kW (hp)]

Enclosure protection rating

IP20

Output current

Continuous (3x380–440 V)

[A]

Continuous (3x441–480 V)

[A]

Intermittent (60 s overload)

[A]

Continuous kVA (400 V AC)

[kVA]

Continuous kVA (480 V AC)

[kVA]

Maximum input current

Continuous (3x380–440 V)

[A]

Continuous (3x441–480 V)

[A]

Intermittent (60 s overload)

[A]

Additional specications

Maximum cable size (mains,

motor, brake) [mm2 (AWG)]

Estimated power loss at

rated maximum load [W]

Weight [kg (lb)], enclosure

protection rating IP20

Eciency [%]3)

Q11K

(15)

J4 J4 J5 J5 J6 J6 J6 J7 J7

23 31 37 42.5 61 73 90 106 147

21 27 34 40 52 65 77 96 124

25.3 34.1 40.7 46.8 67.1 80.3 99 116.6 161.7

15.94 21.48 25.64 29.45 42.3 50.6 62.4 73.4 101.8

17.5 22.4 28.3 33.3 43.2 54.0 64.0 79.8 103.1

22.1 29.9 35.2 41.5 57 70.3 84.2 102.9 140.3

18.4 24.7 29.3 34.6 49.3 60.8 72.7 88.8 121.1

24.3 32.9 38.7 45.7 62.7 77.3 92.6 113.2 154.3

289.53 393.36 402.83 467.52 630 848 1175 1250 1507

9.4 (20.7) 9.5 (20.9) 12.3 (27.1) 12.5 (27.6) 22.4 (49.4)

97.8 97.8 98.1 97.9 98.1 98.0 97.7 98.0 98.2

Q15K

(20)

Q18K

18.5

(25)

16 (6) 50 (1/0) 95 (3/0)

Q22K

(30)

Q30K

(40)

Q37K

(50)

22.5

(49.6)

Q45K

(60)

22.6

(49.8)

Q55K

(75)

37.3

(82.2)

Q75K

(100)

38.7 (85.3)

Table 4.3 Mains Supply 3x380–480 V AC - Normal Duty

1) Heavy duty=150–160% current during 60 s, Normal duty=110% current during 60 s.

2) The typical power loss is at nominal load conditions and expected to be within ±15% (tolerance relates to variety in voltage and cable

conditions).

Values are based on a typical motor eciency (IE2/IE3 border line). Motors with lower eciency add to the power loss in the frequency converter

and motors with high eciency reduce power loss.

Applies to dimensioning of frequency converter cooling. If the switching frequency is higher than the default setting, the power losses may rise.

LCP and typical control card power consumptions are included. Further options and customer load may add up to 30 W to the losses (though

typically only 4 W extra for a fully loaded control card, eldbus, or options for slot B).

For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyeciency.

3) Measured using 5 m shielded motor cables at rated load and rated frequency for enclosure sizes J1–J5, and using 33 m shielded motor cables

at rated load and rated frequency for enclosure sizes J6 and J7. For energy eciency class, see the Ambient Conditions section in

chapter 4 Specications. For part load losses, see www.danfoss.com/vltenergyeciency.

Specications Design Guide

4.2 General Specications

Mains supply (L1, L2, L3) Supply terminals L1, L2, L3

Supply voltage 380–480 V: -15% (-25%)1) to +10%

1) The frequency converter can run at -25% input voltage with reduced performance. The maximum output power of the frequency converter is 75% if input voltage is -25%, and 85% if input voltage is -15%. Full torque cannot be expected at mains voltage lower than 10% below the lowest rated supply voltage of the frequency converter.

Supply frequency 50/60 Hz ±5% Maximum imbalance temporary between mains phases 3.0% of rated supply voltage True power factor (λ) ≥0.9 nominal at rated load Displacement power factor (cos ϕ) Near unity (>0.98) Switching on input supply L1, L2, L3 (power-ups) ≤7.5 kW (10 hp) Maximum 2 times/minute Switching on input supply L1, L2, L3 (power-ups) 11–75 kW (15–100 hp) Maximum 1 time/minute

The unit is suitable for use on a circuit capable of delivering less than 5000 RMS symmetrical Amperes, 480 V maximum.

Motor output (U, V, W) Output voltage 0–100% of supply voltage Output frequency in U/f mode (for AM motor) 0–500 Hz

Output frequency in VVC+ mode (for AM motor) 0–200 Hz

Output frequency in VVC+ mode (for PM motor) 0–400 Hz Switching on output Unlimited Ramp time 0.01–3600 s

4 4

Torque characteristics

Starting torque (high overload)

Maximum 160% for 60 s

Overload torque (high overload) Maximum 160% for 60 s

Starting torque (normal overload) Maximum 110% for 60 s

Overload torque (normal overload) Maximum 110% for 60 s

1)2)

Starting current Maximum 200% for 1 s

Torque rise time in VVC+ (independent of fsw) Maximum 50 ms

1) Percentage relates to the nominal torque. It is 150% for 11–75 kW (15–100 hp) frequency converters.

2) Once every 10 minutes.

Cable lengths and cross-sections

Maximum motor cable length, shielded 50 m (164 ft) Maximum motor cable length, unshielded 0.37–22 kW (0.5–30 hp): 75 m (246 ft), 30–75 kW (40–100 hp): 100 m (328 ft)

Maximum cross-section to control terminals, exible/rigid wire 2.5 mm2/14 AWG

Minimum cross-section to control terminals 0.55 mm2/30 AWG

1) For power cables, see Table 4.1 to Table 4.3.

Digital inputs Programmable digital inputs 7

Terminal number 18, 19, 271), 291), 31, 32, 33 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic 0 PNP < 5 V DC Voltage level, logic 1 PNP > 10 V DC Voltage level, logic 0 NPN > 19 V DC Voltage level, logic 1 NPN < 14 V DC Maximum voltage on input 28 V DC Pulse frequency range 4 Hz–32 kHz (Duty cycle) minimum pulse width 4.5 ms

Mains

Functional isolation

PELV isolation

Motor

DC Bus

High voltage

Control

+24 V

RS-485

130BD310.10

Specications

VLT® AutomationDrive FC 360

Input resistance, R

Approximately 4 kΩ

1) Terminals 27 and 29 can also be programmed as output.

Analog inputs Number of analog inputs 2 Terminal number 53, 54 Modes Voltage or current Mode select Software Voltage level 0–10 V

Input resistance, R

Approximately 10 kΩ

Maximum voltage -15 to +20 V Current level 0/4 to 20 mA (scaleable) Input resistance, R

Approximately 200 Ω

Maximum current 30 mA Resolution for analog inputs 11 bit Accuracy of analog inputs Maximum error 0.5% of full scale Bandwidth 100 Hz

The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Illustration 4.1 Analog Inputs

NOTICE

HIGH ALTITUDE

For installation at altitudes above 2000 m (6562 ft), contact Danfoss hotline regarding PELV.

Pulse inputs Programmable pulse inputs 2 Terminal number pulse 29, 33 Maximum frequency at terminal 29, 33 32 kHz (push-pull driven) Maximum frequency at terminal 29, 33 5 kHz (open collector) Minimum frequency at terminal 29, 33 4 Hz Voltage level See the section on digital input Maximum voltage on input 28 V DC Input resistance, R

Pulse input accuracy Maximum error: 0.1% of full scale

Analog outputs Number of programmable analog outputs 2 Terminal number 45, 42 Current range at analog output 0/4–20 mA Maximum resistor load to common at analog output 500 Ω Accuracy on analog output Maximum error: 0.8% of full scale Resolution on analog output 10 bit

The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Approximately 4 kΩ

Specications Design Guide

Control card, RS485 serial communication Terminal number 68 (P,TX+, RX+), 69 (N,TX-, RX-) Terminal number 61 Common for terminals 68 and 69

The RS485 serial communication circuit is galvanically isolated from the supply voltage (PELV).

Digital outputs Programmable digital/pulse outputs 2

Terminal number 27, 29 Voltage level at digital/frequency output 0–24 V Maximum output current (sink or source) 40 mA Maximum load at frequency output 1 kΩ Maximum capacitive load at frequency output 10 nF Minimum output frequency at frequency output 4 Hz Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Maximum error: 0.1% of full scale Resolution of frequency output 10 bit

1) Terminal 27 and 29 can also be programmed as input.

The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control card, 24 V DC output Terminal number 12 Maximum load 100 mA

The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs.

4 4

Relay outputs Programmable relay outputs 2 Relay 01 and 02 01–03 (NC), 01–02 (NO), 04–06 (NC), 04–05 (NO)

Maximum terminal load (AC-1)1) on 01–02/04–05 (NO) (Resistive load) 250 V AC, 3 A

Maximum terminal load (AC-15)1) on 01–02/04–05 (NO) (Inductive load @ cosφ 0.4) 250 V AC, 0.2 A

Maximum terminal load (DC-1)1) on 01–02/04–05 (NO) (Resistive load) 30 V DC, 2 A

Maximum terminal load (DC-13)1) on 01–02/04–05 (NO) (Inductive load) 24 V DC, 0.1 A

Maximum terminal load (AC-1)1) on 01–03/04–06 (NC) (Resistive load) 250 V AC, 3 A

Maximum terminal load (AC-15)1)on 01–03/04–06 (NC) (Inductive load @ cosφ 0.4) 250 V AC, 0.2 A

Maximum terminal load (DC-1)1) on 01–03/04–06 (NC) (Resistive load) 30 V DC, 2 A Minimum terminal load on 01–03 (NC), 01–02 (NO) 24 V DC 10 mA, 24 V AC 20 mA

1) IEC 60947 t 4 and 5. The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation. The relays can be used on dierent loads (resistive load or inductive load) with dierent life cycles. The life cycle depends on the conguration of the specic load.

Control card, +10 V DC output Terminal number 50 Output voltage 10.5 V ±0.5 V Maximum load 15 mA

The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control characteristics Resolution of output frequency at 0–500 Hz ±0.003 Hz System response time (terminals 18, 19, 27, 29, 32, and 33) ≤2 ms Speed control range (open loop) 1:100 of synchronous speed Speed accuracy (open loop) ±0.5% of nominal speed Speed accuracy (closed loop) ±0.1% of nominal speed

All control characteristics are based on a 4-pole asynchronous motor.

Specications

Ambient conditions Enclosure sizes J1–J7 IP20 Vibration test, all enclosure sizes 1.0 g Relative humidity 5–95% (IEC 721-3-3); Class 3K3 (non-condensing) during operation Aggressive environment (IEC 60068-2-43) H2S test Class Kd Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature (at 60 AVM switching mode)

- with derating Maximum 55 °C (131 °F)

- at full continuous output current with some power size Maximum 50 °C (122 °F)

- at full continuous output current Maximum 45 °C (113 °F) Minimum ambient temperature during full-scale operation 0 °C (32 °F) Minimum ambient temperature at reduced performance -10 °C (14 °F) Temperature during storage/transport -25 to +65/70 °C (-13 to +149/158 °F) Maximum altitude above sea level without derating 1000 m (3281 ft) Maximum altitude above sea level with derating 3000 m (9843 ft)

EMC standards, emission

EMC standards, immunity

Energy eciency class

1) Refer to chapter 4.7 Special Conditions for:

Derating for high ambient temperature.

•

Derating for high altitude.

•

2) To prevent control card overtemperature on PROFIBUS and PROFINET variants of VLT® AutomationDrive FC 360, avoid full digital/analog I/O load at ambient temperature higher than 45 °C (113 °F).

3) Determined according to EN 50598-2 at:

Rated load.

•

90% rated frequency.

•

Switching frequency factory setting.

•

Switching pattern factory setting.

•

VLT® AutomationDrive FC 360

1)2)

EN 61800-3, EN 61000-3-2, EN 61000-3-3, EN 61000-3-11,

EN 61000-3-12, EN 61000-6-3/4, EN 55011, IEC 61800-3

EN 61800-3, EN 61000-6-1/2, EN 61000-4-2,

EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6

IE2

Control card performance Scan interval 1 ms

Protection and features

Electronic thermal motor protection against overload.

•

Temperature monitoring of the heat sink ensures that the frequency converter trips when the temperature reaches

•

a predened level. An overload temperature cannot be reset until the temperature of the heat sink is below the temperature limit.

The frequency converter is protected against short circuits on motor terminals U, V, W.

•

If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load and

•

parameter setting).

Monitoring of the intermediate circuit voltage ensures that the frequency converter trips when the intermediate

•

circuit voltage is too low or too high.

The frequency converter is protected against ground faults on motor terminals U, V, W.

•

Specications Design Guide

4.3 Fuses

Use fuses and/or circuit breakers on the supply side to protect service personnel and equipment from injuries and damage if there is component breakdown inside the frequency converter (rst fault).

Branch circuit protection

Protect all branch circuits in an installation, switchgear, and machines against short circuit and overcurrent according to national/international regulations.

NOTICE

The recommendations do not cover branch circuit protection for UL.

Table 4.4 lists the recommended fuses that have been tested.

WARNING

PERSONAL INJURY AND EQUIPMENT DAMAGE RISK Malfunction or failing to follow the recommendations may result in personal risk and damage to the frequency converter and other equipment.

Select fuses according to recommendations.

•

Possible damage can be limited to be inside the frequency converter.

Enclosure

size

J3 7.5 (10) gG-32

J4 11–15 (15–20) gG-50

Table 4.4 CE Fuse, 380–480 V, Enclosure Sizes J1–J7

Power [kW (hp)] CE compliance fuse

0.37–1.1 (0.5–1.5)

gG-101.5 (2)

2.2 (3)

3.0 (4)

gG-254.0 (5.5)

5.5 (7.5)

18.5 (25)

22 (30)

30 (40)

45 (60)

55 (75)

75 (100)

gG-80

gG-12537 (50)

aR-250

4 4

NOTICE

Using fuses or circuit breakers is mandatory to ensure compliance with IEC 60364 for CE.

Danfoss recommends using the fuses in Table 4.4 on a circuit capable of delivering 100000 A 380–480 V depending on the frequency converter voltage rating. With the proper fusing, the frequency converter short circuit current rating (SCCR) is 100000 A

(symmetrical),

rms

1.0

0.99

0.98

0.97

0.96

0.95

0.93

0.92 0% 50% 100% 200%

0.94

Relative Eciency

130BB252.11

1.01

150%

% Speed

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

Specications

VLT® AutomationDrive FC 360

4.4 Eciency

Eciency of the system (η

SYSTEM

)

To calculate the system eciency, the eciency of the

Eciency of the frequency converter (η

The load on the frequency converter has little eect on its eciency. In general, the eciency is the same at the

rated motor frequency f

, even if the motor supplies

M,N

100% of the rated shaft torque or only 75%, i.e. in case of part loads.

This also means that the eciency of the frequency

converter does not change even if other U/f characteristics are selected. However, the U/f characteristics inuence the eciency of the motor.

The eciency declines a little when the switching frequency is set to a value above the default value. The

VLT

)

frequency converter (η the motor (η

= η

SYSTEM

VLT

MOTOR

x η

MOTOR

) is multiplied by the eciency of

VLT

4.5 Acoustic Noise

The acoustic noise from the frequency converter comes from 3 sources:

DC intermediate circuit coils.

•

Integral fan.

•

RFI lter choke.

•

The typical values measured at a distance of 1 m (3.3 ft) from the unit are:

eciency is also slightly reduced if the mains voltage is 480 V, or if the motor cable is longer than 30 m.

Frequency converter eciency calculation

Calculate the eciency of the frequency converter at dierent loads based on Illustration 4.2. The factor in this

graph must be multiplied with the specic eciency factor listed in the specication tables:

Enclosure size

J1 (0.37–2.2 kW/0.5–

3.0 hp)

J2 (3.0–5.5 kW/4.0–

7.5 hp)

J3 (7.5 kW/10 hp)

J4 (11–15 kW/15–20

hp)

J5 (18.5–22 kW/25–30

hp)

J6 (30–45 kW/40–60

hp)

J7 (55–75 kW/75–100

hp)

50% fan speed

[dBA]

N.A.

52 66

57.5 63

56 71

63 72

Full fan speed

[dBA]

Illustration 4.2 Typical Eciency Curves

Eciency

of the motor (η

MOTOR

The eciency of a motor connected to the frequency converter depends on the magnetizing level. In general, the eciency is just as good as with mains operation. The eciency of the motor depends on the type of motor.

In the range of 75–100% of the rated torque, the eciency of the motor is practically constant, both when it is controlled by the frequency converter and when it runs directly on mains.

In small motors, the inuence from the U/f characteristic on eciency is marginal. However, in motors from 11 kW (15 hp) and up, the advantages are signicant.

In general, the switching frequency does not aect the eciency of small motors. Motors from 11 kW (15 hp) and up achieve eciency improvements of 1–2% because the sine shape of the motor current is almost perfect at high switching frequency.

Table 4.5 Typical Measured Values

1) For J1–J3, the fan speed is xed.

dU/dt Conditions

4.6

)

When a transistor in the frequency converter bridge switches, the voltage across the motor increases by a dU/dt ratio depending on the following factors:

The motor cable type.

•

The cross-section of the motor cable.

•

The length of the motor cable.

•

Whether the motor cable is shielded or not.

•

Inductance.

•

The natural induction causes an overshoot U

PEAK

in the motor voltage before it stabilizes itself at a level depending on the voltage in the intermediate circuit. The rise time and the peak voltage U

aect the service life

PEAK

of the motor. If the peak voltage is too high, motors without phase coil insulation are aected. The longer the motor cable, the higher the rise time and peak voltage.

Specications Design Guide

Peak voltage on the motor terminals is caused by the switching of the IGBTs. The FC 360 complies with IEC 60034-25 regarding motors designed to be controlled by frequency converters. The FC 360 also complies with IEC 60034-17 regarding Norm motors controlled by frequency converters. The following dU/dt data are measured at the motor terminal side:

Cable

length

[m (ft)]

5 (16.4) 400 0.164 0.98 5.4

50 (164) 400 0.292 1.04 2.81

5 (16.4) 480 0.168 1.09 5.27

50 (164) 480 0.32 1.23 3.08

Table 4.6 dU/dt Data for FC 360, 2.2 kW (3.0 hp)

Cable

length

[m (ft)]

5 (16.4) 400 0.18 0.86 3.84

50 (164) 400 0.376 0.96 2.08

5 (16.4) 480 0.196 0.97 3.98

50 (164) 480 0.38 1.19 2.5

Table 4.7 dU/dt Data for FC 360, 5.5 kW (7.5 hp)

Mains

voltage

[V]

Mains

voltage

[V]

Rise time

[μsec]

Rise time

[μsec]

[kV]

PEAK

dU/dt

[kV/μsec]

dU/dt

[kV/μsec]

Cable

length

[m (ft)]

Mains

voltage

[V]

Rise time

[μsec]

PEAK

[kV]

dU/dt

[kV/μsec]

5 (16.4) 400 0.272 0.947 2.79

50 (164) 400 0.344 1.03 2.4

5 (16.4) 480 0.316 1.01 2.56

50 (164) 480 0.368 1.2 2.61

Table 4.10 dU/dt Data for FC 360, 22 kW (30 hp)

Cable

length

[m (ft)]

Mains

voltage

[V]

Rise time

[μsec]

PEAK

[kV]

dU/dt

[kV/μsec]

5 (16.4) 400 0.212 0.81 3.08

53 (174) 400 0.294 0.94 2.56

5 (16.4) 480 0.228 0.95 3.37

53 (174) 480 0.274 1.11 3.24

Table 4.11 dU/dt Data for FC 360, 37 kW (50 hp)

Cable

length

[m (ft)]

Mains

voltage

[V]

Rise time

[μsec]

PEAK

[kV]

dU/dt

[kV/μsec]

5 (16.4) 400 0.14 0.64 3.60

50 (164) 400 0.548 0.95 1.37

5 (16.4) 480 0.146 0.70 3.86

50 (164) 480 0.54 1.13 1.68

Table 4.12 dU/dt Data for FC 360, 45 kW (60 hp)

4 4

Cable

length

[m (ft)]

Mains

voltage

[V]

Rise time

[μsec]

PEAK

[kV]

dU/dt

[kV/μsec]

5 (16.4) 400 0.166 0.992 4.85

50 (164) 400 0.372 1.08 2.33

5 (16.4) 480 0.168 1.1 5.2

50 (164) 480 0.352 1.25 2.85

Table 4.8 dU/dt Data for FC 360, 7.5 kW (10 hp)

Cable

length

[m (ft)]

Mains

voltage

[V]

Rise time

[μsec]

PEAK

[kV]

dU/dt

[kV/μsec]

5 (16.4) 400 0.224 0.99 3.54

50 (164) 400 0.392 1.07 2.19

5 (16.4) 480 0.236 1.14 3.87

50 (164) 480 0.408 1.33 2.61

Table 4.9 dU/dt Data for FC 360, 15 kW (20 hp)

Cable

length

[m (ft)]

Mains

voltage

[V]

Rise time

[μsec]

PEAK

[kV]

dU/dt

[kV/μsec]

5 (16.4) 400 0.206 0.91 3.52

54 (177) 400 0.616 1.03 1.34

5 (16.4) 480 0.212 1.06 3.99

54 (177) 480 0.62 1.23 1.59

Table 4.13 dU/dt Data for FC 360, 55 kW (75 hp)

Cable

length

[m (ft)]

Mains

voltage

[V]

Rise time

[μsec]

PEAK

[kV]

dU/dt

[kV/μsec]

5 (16.4) 400 0.232 0.81 2.82

50 (164) 400 0.484 1.03 1.70

5 (16.4) 480 0.176 1.06 4.77

50 (164) 480 0.392 1.19 2.45

Table 4.14 dU/dt Data for FC 360, 75 kW (100 hp)

0 2 4 6 8 10 12 14 16

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Switching Frequency [kHz]

Output Current

45C

50C

55C

130BG247.10

(1)

(2)

0 2 4 6 8 10 12 14 16

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Switching Frequency [kHz]

Output Current

45C

50C

55C

130BG248.10

(1)

(2)

0 2 4 6 8 10 12 14 16

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Switching Frequency [kHz]

Output Current

45C

50C

55C

130BG249.10

(1)

(2)

Specications

VLT® AutomationDrive FC 360

4.7 Special Conditions

Under some special conditions, where the operation of the frequency converter is challenged, consider derating. In some conditions, derating must be done manually. In other conditions, the frequency converter automatically performs a degree of derating when necessary. Derating is done to ensure the performance at critical stages where the alternative could be a trip.

4.7.1 Manual Derating

Manual derating must be considered for:

Air pressure – for installation at altitudes above

•

1000 m (3281 ft).

Motor speed – at continuous operation at low

•

RPM in constant torque applications.

Ambient temperature – above 45 °C (113 °F), for

•

some types above 50 °C (122 °F), for details, see

Illustration 4.3 to Illustration 4.9, Table 4.15 and Table 4.16.

(1) Output current

(2) Switching frequency [kHz]

Illustration 4.4 J2 Derating Curve

(1) Output current

(2) Switching frequency [kHz]

Illustration 4.3 J1 Derating Curve

(1) Output current

(2) Switching frequency [kHz]

Illustration 4.5 J3 Derating Curve

0 2 4 6 8 10 12 14 16

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Switching Frequency [kHz]

Output Current

45C

50C

55C

130BG250.10

(1)

(2)

0 2 4 6 8 10 12 14 16

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Switching Frequency [kHz]

Output Current

45C

50C

55C

130BG251.10

(1)

(2)

0 2 4 6 8 10 12

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Switching Frequency [kHz]

Output Current

45C

50C

55C

130BG252.10

(1)

(2)

110%

0 2 4 6 8 10 12

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Switching Frequency [kHz]

Output Current

45C

50C

55C

130BG253.10

(1)

(2)

110%

Specications Design Guide

4 4

(1) Output current

(2) Switching frequency [kHz]

Illustration 4.6 J4 Derating Curve

(1) Output current

(2) Switching frequency [kHz]

Illustration 4.7 J5 Derating Curve

(1) Output current

(2) Switching frequency [kHz]

Illustration 4.8 J6 Derating Curve

(1) Output current

(2) Switching frequency [kHz]

Illustration 4.9 J7 Derating Curve

Specications

VLT® AutomationDrive FC 360

Enclosure size Power size

[kW (hp)]

0.37 (0.5) 1.2 1.2

0.55 (0.75) 1.7 1.7

J3 7.5 (10) 15.5 13.1

Table 4.15 Derating at 380 V

0.75 (1.0) 2.2 2.2

1.1 (1.5) 3.0 3.0

1.5 (2.0) 3.7 3.0

2.2 (3.0) 5.3 4.1

3 (4) 7.2 7.2

4 (5.5) 9.0 9.0

5.5 (7.5) 12.0 10.2

11 (15) 23.0 23.0

15 (20) 31.0 26.0

18.5 (25) 37.0 37.0

22 (30) 42.5 40.0

30 (40) 61 61

37 (50) 73 73

45 (60) 90 77

55 (75) 106 106

75 (100) 147 125

Maximum output

current at 45 °C

Maximum output

current at 50 °C

4.7.2 Automatic Derating

The frequency converter constantly checks for critical levels:

Critical high temperature on the control card or

•

heat sink.

High motor load.

•

Low motor speed.

•

Protection signals (overvoltage/undervoltage,

•

overcurrent, ground fault, and short circuit) are triggered.

As a response to a critical level, the frequency converter adjusts the switching frequency.

Enclosure size Power size

[kW]

0.37 (0.5) 1.1 1.1

0.55 (0.75) 1.6 1.6

J3 7.5 (10) 14.0 11.9

Table 4.16 Derating at 480 V

0.75 (1.0) 2.1 2.1

1.1 (1.5) 3.0 2.8

1.5 (2.0) 3.4 2.8

2.2 (3.0) 4.8 3.8

3 (4) 6.3 6.3

4 (5.5) 8.2 8.2

5.5 (7.5) 11.0 9.4

11 (15) 21.0 21.0

15 (20) 27.0 22.6

18.5 (25) 34.0 34.0

22 (30) 40.0 37.7

30 (40) 52 52

37 (50) 65 65

45 (60) 77 76

55 (75) 96 96

75 (100) 124 117

Maximum output

current at 45 °C

Maximum output

current at 50 °C

B b

130BC449.10

130BA648.12

Specications Design Guide

4.8 Enclosure Sizes, Power Ratings, and Dimensions

Enclosure size J1 J2 J3 J4 J5 J6 J7

Power size

[kW (hp)]

Dimensions

[mm (in)]

Weight

[kg (lb)]

Mounting holes [mm

(in)]

3-phase

380–480 V

Height A 210 (8.3) 272.5 (10.7) 272.5 (10.7)

Width B 75 (3.0) 90 (3.5) 115 (4.5) 133 (5.2) 150 (5.9) 233 (9.2) 308 (12.1)

Depth C 168 (6.6) 168 (6.6) 168 (6.6) 245 (9.6) 245 (9.6) 241 (9.5) 323 (12.7)

Depth C with

option B

IP20

a 198 (7.8) 260 (10.2) 260 (10.2)

b 60 (2.4) 70 (2.8) 90 (3.5) 105 (4.1) 120 (4.7) 200 (7.87) 270 (10.63)

c 5 (0.2) 6.4 (0.25) 6.5 (0.26) 8 (0.32) 7.8 (0.31) 140 (5.5) 204 (8.0)

d 9 (0.35) 11 (0.43) 11 (0.43) 12.4 (0.49) 12.6 (0.5) 8.5 (0.33) 8.5 (0.33)

e 4.5 (0.18) 5.5 (0.22) 5.5 (0.22) 6.8 (0.27) 7 (0.28) 8.5 (0.33) 8.5 (0.33)

f 7.3 (0.29) 8.1 (0.32) 9.2 (0.36) 11 (0.43) 11.2 (0.44) 8.5 (0.33) 8.5 (0.33)

0.37–2.2

(0.5–3.0)

173 (6.8) 173 (6.8) 173 (6.8) 250 (9.8) 250 (9.8) 241 (9.5) 323 (12.7)

0.37–1.5 kW/

0.5–2.0 hp:

2.3 (5.1)

2.2 kW/3.0

hp:

2.5 (5.5)

3.0–5.5

(4.0–7.5)

3.6 (7.9) 4.1 (9.0)

7.5 (10)

11–15

(15–20)

317.5

(12.5)

11 kW/15

hp:

9.4 (20.7)

15 kW/20

hp:

9.5 (20.9)

297.5

(11.7)

18.5–22

(25–30)

410 (16.1) 515 (20.3) 550 (21.7)

18.5 kW/25

hp:

12.3 (27.1)

22 kW/30

hp:

12.5 (27.6)

390 (15.4) 495 (19.49) 521 (20.5)

30–45

(40–60)

30 kW/40

hp:

22.4 (49.4)

37 kW/50

hp:

22.5 (49.6)

45 kW/60

hp:

22.6 (49.8)

55–75

(75–100)

55 kW/75

hp:

37.3 (82.2)

75 kW/100

hp:

38.7 (85.3)

4 4

Table 4.17 Enclosure Sizes, Power Ratings, and Dimensions

Illustration 4.10 Dimensions

Illustration 4.11 Top and Bottom Mounting Holes J1–J5

130BG254.10

Specications

VLT® AutomationDrive FC 360

Illustration 4.12 Top and Bottom Mounting Holes J6–J7

drop cable

RS485 Installation and Set-... Design Guide

5 RS485 Installation and Set-up

5.1 Introduction

5.1.1 Overview

RS485 is a 2-wire bus interface compatible with multi-drop network topology. The nodes can be connected as a bus, or via drop cables from a common trunk line. A total of 32 nodes can be connected to 1 network segment. Repeaters divide network segments, see Illustration 5.1.

5 5

Illustration 5.1 RS485 Bus Interface

NOTICE

Each repeater functions as a node within the segment in which it is installed. Each node connected within a given network must have a unique node address across all segments.

Terminate each segment at both ends, using either the termination switch (S801) of the frequency converters or a biased termination resistor network. Always use shielded twisted pair (STP) cable for bus cabling and follow good common installation practice.

Low-impedance ground connection of the shield at every node is important, including at high frequencies. Thus, connect a large surface of the shield to ground, for example with a cable clamp or a conductive cable gland. Sometimes, it is necessary to apply potential-equalizing cables to maintain the same ground potential throughout the network, particularly in installations with long cables.

To prevent impedance mismatch, use the same type of cable throughout the entire network. When connecting a motor to the frequency converter, always use shielded motor cable.

Cable Shielded twisted pair (STP)

Impedance [Ω]

Cable length [m

(ft)]

Table 5.1 Cable Specications

120

Maximum 1200 (3937) (including drop lines).

Maximum 500 (1640) station-to-station.

61 68 69

COMM. GND

130BB795.10

RS485 Installation and Set-...

VLT® AutomationDrive FC 360

5.1.2 Network Connection

5.1.4 Parameter Settings for Modbus

Communication

Connect the frequency converter to the RS485 network as follows (see also Illustration 5.2):

1. Connect signal wires to terminal 68 (P+) and terminal 69 (N-) on the main control board of the frequency converter.

2. Connect the cable shield to the cable clamps.

NOTICE

To reduce noise between conductors, use shielded, twisted-pair cables.

Parameter Function

Parameter 8-30 Prot

ocol

Parameter 8-31 Add

ress

Select the application protocol to run for

the RS485 interface.

Set the node address.

NOTICE

The address range depends on the protocol selected in parameter 8-30 Protocol.

Illustration 5.2 Network Connection

5.1.3 Hardware Set-up

To terminate the RS485 bus, use the terminator switch on the main control board of the frequency converter.

The factory setting for the switch is OFF.

Parameter 8-32 Bau

d Rate

Parameter 8-33 Pari

ty / Stop Bits

Parameter 8-35 Min

imum Response

Delay

Parameter 8-36 Ma

ximum Response

Delay

Parameter 8-37 Ma

ximum Inter-char

delay

Set the baud rate.

NOTICE

The default baud rate depends on the protocol selected in parameter 8-30 Protocol.

Set the parity and number of stop bits.

NOTICE

The default selection depends on the protocol selected in parameter 8-30 Protocol.

Specify a minimum delay time between

receiving a request and transmitting a

response. This function is for overcoming

modem turnaround delays.

Specify a maximum delay time between

transmitting a request and receiving a

response.

If transmission is interrupted, specify a

maximum delay time between 2 received

bytes to ensure timeout.

NOTICE

The default selection depends on the protocol selected in parameter 8-30 Protocol.

Table 5.2 Modbus Communication Parameter Settings

RS485 Installation and Set-... Design Guide

5.1.5 EMC Precautions

To achieve interference-free operation of the RS485 network, Danfoss recommends the following EMC precautions.

NOTICE

Observe relevant national and local regulations, for example regarding protective earth connection. To avoid coupling of high-frequency noise between the cables, keep the RS485 communication cable away from motor and brake resistor cables. Normally, a distance of 200 mm (8 in) is sucient. Maintain the greatest possible distance between the cables, especially where cables run in parallel over long distances. When crossing is unavoidable, the RS485 cable must cross motor and brake resistor cables at an angle of 90°.

5.2 FC Protocol

5.2.1 Overview

The FC protocol, also referred to as FC bus or standard bus, is the Danfoss standard eldbus. It denes an access technique according to the master/slave principle for communications via a eldbus. One master and a maximum of 126 slaves can be connected to the bus. The master selects the individual slaves via an address character in the telegram. A slave itself can never transmit without rst being requested to do so, and direct telegram transfer between the individual slaves is not possible. Communications occur in the halfduplex mode. The master function cannot be transferred to another node (single-master system).

The physical layer is RS485, thus utilizing the RS485 port built into the frequency converter. The FC protocol supports

dierent telegram formats:

A short format of 8 bytes for process data.

•

A long format of 16 bytes that also includes a

•

parameter channel.

A format used for texts.

•

5.2.2 FC with Modbus RTU

The FC protocol provides access to the control word and bus reference of the frequency converter.

The control word allows the Modbus master to control several important functions of the frequency converter:

Start.

•

Stop of the frequency converter in various ways:

•

- Coast stop.

- Quick stop.

- DC brake stop.

- Normal (ramp) stop.

Reset after a fault trip.

•

Run at various preset speeds.

•

Run in reverse.

•

Change of the active set-up.

•

Control of the 2 relays built into the frequency

•

converter.

The bus reference is commonly used for speed control. It is also possible to access the parameters, read their values, and where possible, write values to them. Accessing the parameters oers a range of control options, including controlling the setpoint of the frequency converter when its internal PI controller is used.

Network Conguration

5.3

To enable the FC protocol for the frequency converter, set the following parameters.

Parameter Setting

Parameter 8-30 Protocol FC

Parameter 8-31 Address 1–126

Parameter 8-32 Baud Rate 2400–115200

Parameter 8-33 Parity / Stop Bits

Table 5.3 Parameters to Enable the Protocol

Even parity, 1 stop bit

(default)

5 5

0 1 32 4 5 6 7

195NA036.10

Start bit

Even Stop Parity bit

STX LGE ADR D ATA BCC

195NA099.10

ADRLGESTX PCD1 PCD2 BCC

130BA269.10

PKE INDADRLGESTX PCD1 PCD2 BCC

130BA271.10

PWE

high

PWE

low

PKE IND

130BA270.10

ADRLGESTX PCD1 PCD2 BCCCh1 Ch2 Chn

RS485 Installation and Set-...

VLT® AutomationDrive FC 360

5.4 FC Protocol Message Framing Structure

5.4.1 Content of a Character (byte)

Each character transferred begins with a start bit. Then 8 data bits are transferred, corresponding to a byte. Each character is secured via a parity bit. This bit is set at 1 when it reaches parity. Parity is when there is an equal number of 1s in the 8 data bits and the parity bit in total.

5.4.4 Frequency Converter Address (ADR)

Address format 1–126

Bit 7 = 1 (address format 1–126 active).

•

Bit 0–6 = frequency converter address 1–126.

•

Bit 0–6 = 0 broadcast.

•

The slave returns the address byte unchanged to the master in the response telegram.

A stop bit completes a character, consisting of 11 bits in all.

5.4.5 Data Control Byte (BCC)

The checksum is calculated as an XOR-function. Before the rst byte in the telegram is received, the calculated checksum is 0.

Illustration 5.3 Content of a Character

5.4.6 The Data Field

5.4.2 Telegram Structure

Each telegram has the following structure:

Start character (STX) = 02 hex.

•

A byte denoting the telegram length (LGE).

•

A byte denoting the frequency converter address

•

(ADR).

Several data bytes (variable, depending on the type of telegram) follow.

A data control byte (BCC) completes the telegram.

The structure of data blocks depends on the type of telegram. There are 3 telegram types, and the type applies for both control telegrams (master⇒slave) and response telegrams (slave⇒master).

The 3 types of telegram are:

Process block (PCD)

The PCD is made up of a data block of 4 bytes (2 words) and contains:

Control word and reference value (from master to

•

slave).

Status word and present output frequency (from

•

slave to master).

Illustration 5.4 Telegram Structure

5.4.3 Telegram Length (LGE)

The telegram length is the number of data bytes plus the address byte ADR and the data control byte BCC.

4 data bytes LGE=4+1+1=6 bytes

12 data bytes LGE=12+1+1=14 bytes

Telegrams containing texts

Table 5.4 Length of Telegrams

1) 10 represents the

on the length of the text).

xed characters, while n is variable (depending

101)+n bytes

Illustration 5.5 Process Block

Parameter block

The parameter block is used to transfer parameters between master and slave. The data block is made up of 12 bytes (6 words) and also contains the process block.

Illustration 5.6 Parameter Block

Text block

The text block is used to read or write texts via the data block.

Illustration 5.7 Text Block

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

130BB918.10

PKE IND

PWE

high

PWE

low

AK PNU

Parameter

commands

and replies

Parameter

number

RS485 Installation and Set-... Design Guide

5.4.7 The PKE Field

The PKE eld contains 2 subelds:

•

Illustration 5.8 PKE Field

Bits 12–15 transfer parameter commands from master to slave and return processed slave responses to the master.

Bit number Parameter command

15 14 13 12

0 0 0 0 No command.

0 0 0 1 Read parameter value.

0 0 1 0 Write parameter value in RAM (word).

0 0 1 1

1 1 0 1

1 1 1 0

1 1 1 1 Read text.

Table 5.5 Parameter Commands

Bit number Response

15 14 13 12

0 0 0 0 No response.

0 0 0 1 Parameter value transferred (word).

0 0 1 0

0 1 1 1 Command cannot be performed.

1 1 1 1 Text transferred.

Table 5.6 Response

If the command cannot be performed, the slave sends 0111 Command cannot be performed response and issues the following fault reports in Table 5.7.

Parameter command and response (AK).

Parameter number (PNU).

Parameter commands master⇒slave

Write parameter value in RAM (double

word).

Write parameter value in RAM and

EEPROM (double word).

Write parameter value in RAM and

EEPROM (word).

Response slave⇒master

Parameter value transferred (double

word).

Fault code FC specication

0 Illegal parameter number.

1 Parameter cannot be changed.

2 Upper or lower limit is exceeded.

3 Subindex is corrupted.

4 No array.

5 Wrong data type.

6 Not used.

7 Not used.

9 Description element is not available.

11 No parameter write access.

15 No text available.

17 Not applicable while running.

18 Other errors.

100 –

>100 –

130 No bus access for this parameter.

131 Write to factory set-up is not possible.

132 No LCP access.

252 Unknown viewer.

253 Request is not supported.

254 Unknown attribute.

255 No error.

Table 5.7 Slave Report

5.4.8 Parameter Number (PNU)

Bits 0–11 transfer parameter numbers. The function of the relevant parameter is dened in the parameter description

in the VLT® AutomationDrive FC 360 Programming Guide.

5.4.9 Index (IND)

The index is used with the parameter number to read/ write access parameters with an index, for example, parameter 15-30 Alarm Log: Error Code. The index consists of 2 bytes: a low byte and a high byte.

Only the low byte is used as an index.

5.4.10 Parameter Value (PWE)

The parameter value block consists of 2 words (4 bytes), and the value depends on the dened command (AK). The master prompts for a parameter value when the PWE block contains no value. To change a parameter value (write), write the new value in the PWE block and send from the master to the slave.

When a slave responds to a parameter request (read command), the present parameter value in the PWE block is transferred and returned to the master. If a parameter contains several data options, for example

5 5

E19E H

PKE IND PWE

high

PWE

low

0000 H 0000 H 03E8 H

130BA092.10

RS485 Installation and Set-...

VLT® AutomationDrive FC 360

parameter 0-01 Language, select the data value by entering the value in the PWE block. Serial communication is only capable of reading parameters containing data type 9 (text string).

Parameter 15-40 FC Type to parameter 15-53 Power Card Serial Number contain data type 9.

For example, read the unit size and mains voltage range in parameter 15-40 FC Type. When a text string is transferred (read), the length of the telegram is variable, and the texts are of dierent lengths. The telegram length is dened in the 2nd byte of the telegram (LGE). When using text

transfer, the index character indicates whether it is a read or a write command.

To read a text via the PWE block, set the parameter command (AK) to F hex. The index character high-byte

Conversion index Conversion factor

74 3600

2 100

1 10

0 1

-1 0.1

-2 0.01

-3 0.001

-4 0.0001

-5 0.00001

Table 5.9 Conversion

5.4.13 Process Words (PCD)

The block of process words is divided into 2 blocks of 16 bits, which always occur in the dened sequence.

must be 4.

PCD 1 PCD 2

5.4.11 Data Types Supported by the Frequency Converter

Control telegram (master⇒slave control word)

Control telegram (slave⇒master) status word

Reference value

Present output

frequency

Unsigned means that there is no operational sign in the telegram.

Table 5.10 Process Words (PCD)

Data types Description

3 Integer 16

4 Integer 32

5 Unsigned 8

6 Unsigned 16

7 Unsigned 32

9 Text string

Table 5.8 Data Types

5.4.12 Conversion

The programming guide contains the descriptions of attributes of each parameter. Parameter values are transferred as whole numbers only. Conversion factors are used to transfer decimals.

Parameter 4-12 Motor Speed Low Limit [Hz] has a conversion factor of 0.1. To preset the minimum frequency to 10 Hz, transfer the value 100. A conversion factor of 0.1 means that the value transferred is multiplied by 0.1. The value 100 is thus perceived as 10.0.

Examples

5.5

5.5.1 Writing a Parameter Value

Change parameter 4-14 Motor Speed High Limit [Hz] to 100 Hz. Write the data in EEPROM.

PKE = E19E hex - Write single word in parameter 4-14 Motor Speed High Limit [Hz]:

IND = 0000 hex.

•

PWEHIGH = 0000 hex.

•

PWELOW = 03E8 hex.

•

Data value 1000, corresponding to 100 Hz, see chapter 5.4.12 Conversion.

The telegram looks like Illustration 5.9.

Illustration 5.9 Telegram

119E H

PKE

IND

PWE

high

PWE

low

0000 H 0000 H 03E8 H

130BA093.10

1155 H

PKE IND PWE

high

PWE

low

0000 H 0000 H 0000 H

130BA094.10

130BA267.10

1155 H

PKE

IND

0000 H 0000 H 03E8 H

PWE

high

PWE

low

RS485 Installation and Set-... Design Guide

NOTICE

Parameter 4-14 Motor Speed High Limit [Hz] is a single

word, and the parameter command for write in EEPROM is E. Parameter 4-14 Motor Speed High Limit [Hz] is 19E in hexadecimal.

The response from the slave to the master is shown in Illustration 5.10.

Illustration 5.10 Response from Master

5.5.2 Reading a Parameter Value

Read the value in parameter 3-41 Ramp 1 Ramp Up Time.

PKE = 1155 hex - Read parameter value in parameter 3-41 Ramp 1 Ramp Up Time:

IND = 0000 hex.

•

PWE

•

PWE

•

Illustration 5.11 Telegram

If the value in parameter 3-41 Ramp 1 Ramp Up Time is 10 s, the response from the slave to the master is shown in Illustration 5.12.

Illustration 5.12 Response

3E8 hex corresponds to 1000 decimal. The conversion index for parameter 3-41 Ramp 1 Ramp Up Time is -2, that is, 0.01.

Parameter 3-41 Ramp 1 Ramp Up Time is of the type Unsigned 32.

= 0000 hex.

HIGH

= 0000 hex.

LOW

Modbus RTU

5.6

5.6.1 Prerequisite Knowledge

Danfoss assumes that the installed controller supports the interfaces in this manual and strictly observes all requirements and limitations stipulated in the controller and frequency converter.

The built-in Modbus RTU (remote terminal unit) is designed to communicate with any controller that supports the interfaces dened in this manual. It is assumed that the user has full knowledge of the capabilities and limitations of the controller.

5.6.2 Overview

Regardless of the type of physical communication networks, this section describes the process that a controller uses to request access to another device. This process includes how the Modbus RTU responds to requests from another device, and how errors are detected and reported. It also establishes a common format for the layout and contents of telegram elds.

During communications over a Modbus RTU network, the protocol:

Determines how each controller learns its device

•

address.

Recognizes a telegram addressed to it.

•

Determines which actions to take.

•

Extracts any data or other information contained

•

in the telegram.

If a reply is required, the controller constructs the reply telegram and sends it. Controllers communicate using a master/slave technique in which only the master can initiate transactions (called queries). Slaves respond by supplying the requested data to the master, or by acting as requested in the query. The master can address individual slaves, or initiate a broadcast telegram to all slaves. Slaves return a response to queries that are addressed to them individually. No responses are returned to broadcast queries from the master.

The Modbus RTU protocol establishes the format for the master query by providing the following information:

The device (or broadcast) address.

•

A function code dening the requested action.

•

Any data to be sent.

•

An error-checking eld.

•

The response telegram of the slave device is also constructed using Modbus protocol. It contains elds conrming the action taken, any data to be returned, and

5 5

RS485 Installation and Set-...

VLT® AutomationDrive FC 360

an error-checking eld. If an error occurs in receipt of the telegram, or if the slave is unable to perform the requested action, the slave constructs and sends an error message. Alternatively, a timeout occurs.

5.6.3 Frequency Converter with Modbus

RTU

The frequency converter communicates in Modbus RTU format over the built-in RS485 interface. Modbus RTU provides access to the control word and bus reference of the frequency converter.

The control word allows the Modbus master to control several important functions of the frequency converter:

Start.

•

Various stops:

•

- Coast stop.

- Quick stop.

- DC brake stop.

- Normal (ramp) stop.

Reset after a fault trip.

•

Run at various preset speeds.

•

Run in reverse.

•

Change the active set-up.

•

Control built-in relay of the frequency converter.

•

The bus reference is commonly used for speed control. It is also possible to access the parameters, read their values, and, where possible, write values to them. Accessing the parameters controlling the setpoint of the frequency converter when its internal PI controller is used.

5.7

To enable Modbus RTU on the frequency converter, set the following parameters:

Parameter 8-30 Protocol Modbus RTU

Parameter 8-31 Address 1–247

Parameter 8-32 Baud Rate 2400–115200

Parameter 8-33 Parity / Stop Bits

Table 5.11 Network Conguration

oers a range of control options, including

Network Conguration

Parameter Setting

Even parity, 1 stop bit

(default)

Modbus RTU Message Framing

5.8 Structure

5.8.1 Introduction

The controllers are set up to communicate on the Modbus network using RTU (remote terminal unit) mode, with each byte in a telegram containing 2 4-bit hexadecimal characters. The format for each byte is shown in Table 5.12.

Start

bit

Table 5.12 Format for Each Byte

Coding system 8-bit binary, hexadecimal 0–9, A–F.

Bits per byte

Error check eld Cyclic redundancy check (CRC).

Table 5.13 Byte Details

Data byte Stop/

parity

2 hexadecimal characters contained in each

8-bit eld of the telegram.

1 start bit.

•

8 data bits, least signicant bit sent rst.

•

1 bit for even/odd parity; no bit for no

•

parity.

1 stop bit if parity is used; 2 bits if no

•

parity.

Stop

5.8.2 Modbus RTU Telegram Structure

The transmitting device places a Modbus RTU telegram into a frame with a known beginning and ending point. This allows receiving devices to begin at the start of the telegram, read the address portion, determine which device is addressed (or all devices, if the telegram is broadcast), and to recognize when the telegram is completed. Partial telegrams are detected and errors set as a result. Characters for transmission must be in hexadecimal 00–FF format in each eld. The frequency converter continuously monitors the network bus, also during silent intervals. When the rst eld (the address eld) is received, each frequency converter or device decodes it to determine which device is being addressed. Modbus RTU telegrams addressed to 0 are broadcast telegrams. No response is permitted for broadcast telegrams. A typical telegram frame is shown in Table 5.14.

Start Address Function Data

T1-T2-T3-

8 bits 8 bits N x 8 bits 16 bits

CRC

check

End

T1-T2-T3-

Table 5.14 Typical Modbus RTU Telegram Structure

RS485 Installation and Set-... Design Guide

5.8.3 Start/Stop Field

Telegrams start with a silent period of at least 3.5 character intervals. The silent period is implemented as a multiple of character intervals at the selected network baud rate (shown as Start T1-T2-T3-T4). The rst eld to be transmitted is the device address. Following the last transmitted character, a similar period of at least 3.5 character intervals marks the end of the telegram. A new telegram can begin after this period.

Transmit the entire telegram frame as a continuous stream. If a silent period of more than 1.5 character intervals occurs before completion of the frame, the receiving device

ushes the incomplete telegram and assumes that the next byte is the address eld of a new telegram. Similarly, if a new telegram begins before 3.5 character intervals after a previous telegram, the receiving device considers it a continuation of the previous telegram. This behavior causes a timeout (no response from the slave), since the value in the nal CRC eld is not valid for the combined telegrams.

5.8.4 Address Field

The address eld of a telegram frame contains 8 bits. Valid slave device addresses are in the range of 0–247 decimal. The individual slave devices are assigned addresses in the range of 1–247. 0 is reserved for broadcast mode, which all slaves recognize. A master addresses a slave by placing the slave address in the address eld of the telegram. When the slave sends its response, it places its own address in this address eld to let the master know which slave is responding.

5.8.6 Data Field

The data eld is constructed using sets of 2 hexadecimal digits, in the range of 00–FF hexadecimal. These digits are made up of 1 RTU character. The data eld of telegrams sent from a master to a slave device contains additional information which the slave must use to perform accordingly.

The information can include items such as:

Coil or register addresses.

•

The quantity of items to be handled.

•

The count of actual data bytes in the

•

eld.

5.8.7 CRC Check Field

Telegrams include an error-checking eld, operating based on a cyclic redundancy check (CRC) method. The CRC eld checks the contents of the entire telegram. It is applied regardless of any parity check method used for the individual characters of the telegram. The transmitting device calculates the CRC value and appends the CRC as the last eld in the telegram. The receiving device recalculates a CRC during receipt of the telegram and compares the calculated value to the actual value received in the CRC eld. 2 unequal values result in bus timeout. The error-checking eld contains a 16-bit binary value implemented as 2 8-bit bytes. After the implementation, the low-order byte of the eld is appended rst, followed by the high-order byte. The CRC high-order byte is the last byte sent in the telegram.

5.8.8 Coil Register Addressing

5 5

5.8.5 Function Field

The function eld of a telegram frame contains 8 bits. Valid codes are in the range of 1–FF. Function elds are used to send telegrams between master and slave. When a telegram is sent from a master to a slave device, the function code eld tells the slave what kind of action to perform. When the slave responds to the master, it uses the function code eld to indicate either a normal (errorfree) response, or that some kind of error occurred (called an exception response).

For a normal response, the slave simply echoes the original function code. For an exception response, the slave returns a code that is equivalent to the original function code with its most places a unique code into the data eld of the response telegram. This code tells the master what kind of error occurred, or the reason for the exception. Also refer to

chapter 5.8.10 Function Codes Supported by Modbus RTU and chapter 5.8.11 Modbus Exception Codes.

signicant bit set to logic 1. In addition, the slave

In Modbus, all data is organized in coils and holding registers. Coils hold a single bit, whereas holding registers hold a 2 byte word (that is 16 bits). All data addresses in Modbus telegrams are referenced to 0. The rst occurrence of a data item is addressed as item number 0. For example: The coil known as coil 1 in a programmable controller is addressed as coil 0000 in the data address eld of a Modbus telegram. Coil 127 decimal is addressed as coil 007Ehex (126 decimal). Holding register 40001 is addressed as register 0000 in the data address eld of the telegram. The function code eld already species a holding register operation. Therefore, the 4XXXX reference is implicit. Holding register 40108 is addressed as register 006Bhex (107 decimal).

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VLT® AutomationDrive FC 360

Coil

number

1–16 Frequency converter control word

17–32 Frequency converter speed or

33–48 Frequency converter status word

49–64 Open-loop mode: Frequency

66–65536 Reserved. –

Table 5.15 Coil Register

Coil 0 1

01 Preset reference lsb

02 Preset reference msb

03 DC brake No DC brake

04 Coast stop No coast stop

05 Quick stop No quick stop

06 Freeze frequency No freeze frequency

07 Ramp stop Start

08 No reset Reset

09 No jog Jog

10 Ramp 1 Ramp 2

11 Data not valid Data valid

12 Relay 1 o Relay 1 on

13 Relay 2 o Relay 2 on

14 Set up lsb

15 –

16 No reversing Reversing

Description Signal

direction

Master to slave

(see Table 5.16).

Master to slave

setpoint reference range 0x0–

0xFFFF (-200% ... ~200%).

Slave to master

(see Table 5.17).

converter output frequency.

Closed-loop mode: Frequency

converter feedback signal.

Parameter write control (master to

slave).

0 = Parameter changes are written

to the RAM of the frequency

converter.

1 = Parameter changes are written

to the RAM and EEPROM of the

frequency converter.

Slave to master

Master to slave

Coil 0 1

33 Control not ready Control ready

34 Frequency converter not

ready

35 Coast stop Safety closed

36 No alarm Alarm

37 Not used Not used

38 Not used Not used

39 Not used Not used

40 No warning Warning

41 Not at reference At reference

42 Hand mode Auto mode

43 Out of frequency range In frequency range

44 Stopped Running

45 Not used Not used

46 No voltage warning Voltage warning

47 Not in current limit Current limit

48 No thermal warning Thermal warning

Table 5.17 Frequency Converter Status Word (FC Prole)

Frequency converter ready

Table 5.16 Frequency Converter Control Word (FC Prole)

RS485 Installation and Set-... Design Guide

Bus

address

0 1 40001 Reserved

1 2 40002 Reserved

2 3 40003 Reserved

3 4 40004 Free – –

4 5 40005 Free – –

5 6 40006 Modbus conguration Read/Write TCP only. Reserved for Modbus TCP

6 7 40007 Last fault code Read only Fault code received from parameter database, refer to

7 8 40008 Last error register Read only Address of register with which last error occurred, refer

8 9 40009 Index pointer Read/Write Subindex of parameter to be accessed. Refer to WHAT

9 10 40010 Parameter 0-01 Language Dependent on

19 20 40020 Parameter 0-02 Motor Speed

29 30 40030 Parameter 0-03 Regional

Bus

PLC

Content Access Description

Reserved for legacy frequency converters VLT® 5000 and

VLT® 2800.

Reserved for legacy frequency converters VLT® 5000 and

VLT® 2800.

Reserved for legacy frequency converters VLT® 5000 and

VLT® 2800.

(parameter 12-28 Store Data Values and

parameter 12-29 Store Always - stored in, for example,

EEPROM).

WHAT 38295 for details.

to WHAT 38296 for details.

38297 for details.

Parameter 0-01 Language (Modbus register = 10

parameter number)

20 bytes space reserved for parameter in Modbus map.

Parameter 0-02 Motor Speed Unit

20 bytes space reserved for parameter in Modbus map.

Parameter 0-03 Regional Settings

20 bytes space reserved for parameter in Modbus map.

Unit

Settings

–

parameter

access

Dependent on

parameter

access

Dependent on

parameter

access

5 5

Table 5.18 Address/Registers

1) Value written in the Modbus RTU telegram must be 1 or less than the register number. For example, Read Modbus Register 1 by writing value 0

in the telegram.

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VLT® AutomationDrive FC 360

5.8.9 How to Control the Frequency

5.8.11 Modbus Exception Codes

Converter

For a full explanation of the structure of an exception code This section describes codes which can be used in the function and data elds of a Modbus RTU telegram.

5.8.10 Function Codes Supported by

Modbus RTU

Modbus RTU supports use of the following function codes in the function eld of a telegram:

Function Function code (hex)

Read coils 1

Read holding registers 3

Write single coil 5

Write single register 6

Write multiple coils F

Write multiple registers 10

Get comm. event counter B

Report slave ID 11

Table 5.19 Function Codes

Function Function

code

Diagnostics 8 1 Restart communication.

Table 5.20 Function Codes

Subfunction

code

2 Return diagnostic

10 Clear counters and

11 Return bus message

12 Return bus communi-

13 Return slave error count.

14 Return slave message

Subfunction

diagnostic register.

count.

cation error count.

count.

response, refer to chapter 5.8.5 Function Field.

Code Name Meaning

The function code received in the query is

not an allowable action for the server (or

slave). This may be because the function

code is only applicable to newer devices

Table 5.21 Modbus Exception Codes

Illegal

function

Illegal data

address

Illegal data

value

Slave device

failure

and was not implemented in the unit

selected. It could also indicate that the

server (or slave) is in the wrong state to

process a request of this type, for example

because it is not congured and is being

asked to return register values.

The data address received in the query is

not an allowable address for the server (or

slave). More specically, the combination

of reference number and transfer length is

invalid. For a controller with 100 registers,

a request with oset 96 and length 4

succeeds, while a request with oset 96

and length 5 generates exception 02.

A value contained in the query data eld

is not an allowable value for server (or

slave). This indicates a fault in the

structure of the remainder of a complex

request, such as that the implied length is

incorrect. It does NOT mean that a data

item submitted for storage in a register

has a value outside the expectation of the

application program, since the Modbus

protocol is unaware of the signicance of

any value of any register.

An unrecoverable error occurred while the

server (or slave) was attempting to

perform the requested action.

RS485 Installation and Set-... Design Guide

5.9 How to Access Parameters

5.9.1 Parameter Handling

The PNU (parameter number) is translated from the register address contained in the Modbus read or write message. The parameter number is translated to Modbus as (10 x parameter number) decimal. Example: Reading parameter 3-12 Catch up/slow Down Value (16 bit): The holding register 3120 holds the parameters’ values. A value of 1352 (decimal) means that the parameter is set to

12.52%.

Reading parameter 3-14 Preset Relative Reference (32 bit): The holding registers 3410 and 3411 hold the parameters’ values. A value of 11300 (decimal) means that the parameter is set to 1113.00.

For information on the parameters, size, and conversion index, see the programming guide.

5.9.2 Storage of Data

The coil 65 decimal determines whether data written to the frequency converter is stored in EEPROM and RAM (coil 65 = 1), or only in RAM (coil 65 = 0).

5.9.3 IND (Index)

Some parameters in the frequency converter are array parameters, for example parameter 3-10 Preset Reference. Since the Modbus does not support arrays in the holding registers, the frequency converter has reserved the holding register 9 as pointer to the array. Before reading or writing an array parameter, set the holding register 9. Setting holding register to the value of 2 causes all following read/ write to array parameters to be to the index 2.

5.9.4 Text Blocks

Parameters stored as text strings are accessed in the same way as the other parameters. The maximum text block size is 20 characters. If a read request for a parameter is for more characters than the parameter stores, the response is truncated. If the read request for a parameter is for fewer characters than the parameter stores, the response is space

lled.

5.9.6 Parameter Values

Standard data types

Standard data types are int 16, int 32, uint 8, uint 16, and

uint 32. They are stored as 4x registers (40001–4FFFF). The

parameters are read using function 03 hex read holding

registers. Parameters are written using the function 6 hex

preset single register for 1 register (16 bits), and the

function 10 hex preset multiple registers for 2 registers (32

bits). Readable sizes range from 1 register (16 bits) up to

10 registers (20 characters).

Non-standard data types

Non-standard data types are text strings and are stored as

4x registers (40001–4FFFF). The parameters are read using

function 03 hex read holding registers and written using

function 10 hex preset multiple registers. Readable sizes

range from 1 register (2 characters) up to 10 registers (20

characters).

5.10 Examples

The following examples show various Modbus RTU

commands.

5.10.1 Read Coil Status (01 hex)

Description

This function reads the ON/OFF status of discrete outputs

(coils) in the frequency converter. Broadcast is never

supported for reads.

Query

The query telegram species the starting coil and quantity

of coils to be read. Coil addresses start at 0, that is, coil 33

is addressed as 32.

Example of a request to read coils 33–48 (status word)

from slave device 01.

Field name Example (hex)

Slave address 01 (frequency converter address)

Function 01 (read coils)

Starting address HI 00

Starting address LO 20 (32 decimals) coil 33

Number of points HI 00

Number of points LO 10 (16 decimals)

Error check (CRC) –

Table 5.22 Query

5 5

5.9.5 Conversion Factor

A parameter value can only be transferred as a whole number. To transfer decimals, use a conversion factor.

Response

The coil status in the response telegram is packed as 1 coil

per bit of the data

OFF. The lsb of the 1st data byte contains the coil

addressed in the query. The other coils follow toward the

high-order end of this byte, and from low order to high

order in subsequent bytes.

eld. Status is indicated as: 1 = ON; 0 =

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VLT® AutomationDrive FC 360

If the returned coil quantity is not a multiple of 8, the remaining bits in the nal data byte are padded with values 0 (toward the high-order end of the byte). The byte

Response

The normal response is an echo of the query, returned

after the coil state has been forced. count eld species the number of complete bytes of data.

Field name Example (hex)

Slave address 01 (frequency converter address)

Function 01 (read coils)

Byte count 02 (2 bytes of data)

Data (coils 40–33) 07

Data (coils 48–41) 06 (STW = 0607hex)

Error check (CRC) –

Slave address 01

Function 05

Force data HI FF

Force data LO 00

Quantity of coils HI 00

Quantity of coils LO 01

Error check (CRC) –

Table 5.23 Response

NOTICE

Coils and registers are addressed explicitly with an oset of -1 in Modbus.

For example, coil 33 is addressed as coil 32.

5.10.2 Force/Write Single Coil (05 hex)

Description

This function forces the coil to either ON or OFF. When broadcast, the function forces the same coil references in all attached slaves.

Query

The query telegram species the coil 65 (parameter write control) to be forced. Coil addresses start at 0, that is, coil 65 is addressed as 64. Force data = 00 00 hex (OFF) or FF 00 hex (ON).

Field name Example (hex)

Slave address 01 (frequency converter address)

Function 05 (write single coil)

Coil address HI 00

Coil address LO 40 (64 decimal) Coil 65

Force data HI FF

Force data LO 00 (FF 00 = ON)

Error check (CRC) –

Table 5.24 Query

Table 5.25 Response

5.10.3 Force/Write Multiple Coils (0F hex)

Description

This function forces each coil in a sequence of coils to

either on or o. When broadcasting, the function forces

the same coil references in all attached slaves.

Query

The query telegram species the coils 17–32 (speed

setpoint) to be forced.

NOTICE

Coil addresses start at 0, that is, coil 17 is addressed as

16.

Field name Example (hex)

Slave address 01 (frequency converter address)

Function 0F (write multiple coils)

Coil address HI 00

Coil address LO 10 (coil address 17)

Quantity of coils HI 00

Quantity of coils LO 10 (16 coils)

Byte count 02

Force data HI

(Coils 8–1)

Force data LO

(Coils 16–9)

Error check (CRC) –

00 (reference = 2000 hex)

Table 5.26 Query

RS485 Installation and Set-... Design Guide

Response

The normal response returns the slave address, function code, starting address, and quantity of coils forced.

Field name Example (hex)

Slave address 01 (frequency converter address)

Function 0F (write multiple coils)

Coil address HI 00

Coil address LO 10 (coil address 17)

Quantity of coils HI 00

Quantity of coils LO 10 (16 coils)

Error check (CRC) –

Table 5.27 Response

5.10.4 Read Holding Registers (03 hex)

Description

This function reads the contents of holding registers in the slave.

Query

The query telegram species the starting register and quantity of registers to be read. Register addresses start at 0, that is, registers 1–4 are addressed as 0–3.

Example: Read parameter 3-03 Maximum Reference, register

03030.

Field name Example (hex)

Slave address 01

Function 03 (Read holding registers)

Starting address HI 0B (Register address 3029)

Starting address LO D5 (Register address 3029)

Number of points HI 00

02 – (parameter 3-03 Maximum

Number of points LO

Error check (CRC) –

Table 5.28 Query

Response

The register data in the response telegram is packed as 2 bytes per register, with the binary contents right justied within each byte. For each register, the 1st byte contains the high-order bits, and the 2nd contains the low-order bits.

Example: hex 000088B8 = 35.000 = 35 Hz.

Reference is 32 bits long, that is, 2

registers)

Field name Example (hex)

Slave address 01

Function 03

Byte count 04

Data HI (register 3030) 00

Data LO (register 3030) 16

Data HI (register 3031) E3

Data LO (register 3031) 60

Error check (CRC) –

Table 5.29 Response

5.10.5 Preset Single Register (06 hex)

Description

This function presets a value into a single holding register.

Query

The query telegram species the register reference to be

preset. Register addresses start at 0, that is, register 1 is

addressed as 0.

Example: Write to parameter 1-00 Conguration Mode,

Field name Example (hex)

Slave address 01

Function 06

Preset data HI 00

Preset data LO 01

Error check (CRC) –

Table 5.30 Query

Response

The normal response is an echo of the query, returned

after the register contents have been passed.

Field name Example (hex)

Slave address 01

Function 06

Preset data HI 00

Preset data LO 01

Error check (CRC) –

Table 5.31 Response

5 5

Speed ref.CTW

Master-follower

130BA274.11

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Bit no.:

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VLT® AutomationDrive FC 360

5.10.6 Preset Multiple Registers (10 hex)

Description

This function presets values into a sequence of holding

Danfoss FC Control Prole

5.11

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

registers.

Query

The query telegram species the register references to be preset. Register addresses start at 0, that is, register 1 is addressed as 0. Example of a request to preset 2 registers (set parameter 1-24 Motor Current to 738 (7.38 A)):

Slave address 01

Function 10

Starting address HI 04

Starting address LO 07

Number of registers HI 00

Number of registers LO 02

Byte count 04

Write data HI (Register 4: 1049) 00

Write data LO (Register 4: 1049) 00

Write data HI (Register 4: 1050) 02

Write data LO (Register 4: 1050) E2

Error check (CRC) –

Table 5.32 Query

Field name Example (hex)

Response

The normal response returns the slave address, function code, starting address, and quantity of registers preset.

Field name Example (hex)

Slave address 01

Function 10

Starting address HI 04

Starting address LO 19

Number of registers HI 00

Number of registers LO 02

Error check (CRC) –

Illustration 5.13 Control Word According to FC Prole

Bit Bit value = 0 Bit value = 1

00 Reference value External selection lsb

01 Reference value External selection msb

02 DC brake Ramp

03 Coasting No coasting

04 Quick stop Ramp

Hold output

frequency

06 Ramp stop Start

07 No function Reset

08 No function Jog

09 Ramp 1 Ramp 2

10 Data invalid Data valid

11 Relay 01 open Relay 01 active

12 Relay 02 open Relay 02 active

13 Parameter set-up Selection lsb

15 No function Reverse

Table 5.34 Control Word According to FC Prole

Use ramp

Explanation of the control bits Bits 00/01

Bits 00 and 01 are used to select among the 4 reference values, which are preprogrammed in parameter 3-10 Preset Reference according to Table 5.35.

Table 5.33 Response

Programmed

reference

value

1 Parameter 3-10 Preset Reference [0] 0 0

2 Parameter 3-10 Preset Reference [1] 0 1

3 Parameter 3-10 Preset Reference [2] 1 0

4 Parameter 3-10 Preset Reference [3] 1 1

Table 5.35 Control Bits

Parameter

Bit01Bit

RS485 Installation and Set-... Design Guide

NOTICE

In parameter 8-56 Preset Reference Select, dene how bit 00/01 gates with the corresponding function on the digital inputs.

Bit 02, DC brake

Bit 02 = 0: Leads to DC braking and stop. Set braking current and duration in parameter 2-01 DC Brake Current and parameter 2-02 DC Braking Time. Bit 02 = 1: Leads to ramping.

Bit 03, Coasting

Bit 03 = 0: The frequency converter immediately releases the motor (the output transistors are shut o), and it coasts to a standstill. Bit 03 = 1: If the other starting conditions are met, the frequency converter starts the motor.

In parameter 8-50 Coasting Select, dene how bit 03 gates with the corresponding function on a digital input.

Bit 04, Quick stop

Bit 04 = 0: Makes the motor speed ramp down to stop (set in parameter 3-81 Quick Stop Ramp Time).

Bit 05, Hold output frequency

Bit 05 = 0: The present output frequency (in Hz) freezes. Change the frozen output frequency only with the digital inputs programmed to [21] Speed up and [22] Speed down (parameter 5-10 Terminal 18 Digital Input to parameter 5-13 Terminal 29 Digital Input).

NOTICE

If freeze output is active, the frequency converter can only be stopped in 1 of the following ways:

Bit 03 coast stop.

•

Bit 02 DC brake.

•

Digital input programmed to [5] DC brake

•

inverse, [2] Coast inverse, or [3] Coast and reset inv (parameter 5-10 Terminal 18 Digital Input to parameter 5-13 Terminal 29 Digital Input).

Bit 06, Ramp stop/start

Bit 06 = 0: Causes a stop and makes the motor speed ramp down to stop via the selected ramp-down parameter. Bit 06 = 1: If the other starting conditions are met, bit 06 allows the frequency converter to start the motor.

In parameter 8-53 Start Select, dene how bit 06 ramp stop/ start gates with the corresponding function on a digital input.

Bit 07, Reset

Bit 07 = 0: No reset. Bit 07 = 1: Resets a trip. Reset is activated on the leading signal edge, that is, when changing from logic 0 to logic 1.

Bit 08, Jog

Bit 08 = 1: Parameter 3-11 Jog Speed [Hz] determines the output frequency.

Bit 09, Selection of ramp 1/2

Bit 09 = 0: Ramp 1 is active (parameter 3-41 Ramp 1 Ramp Up Time to parameter 3-42 Ramp 1 Ramp Down Time).

Bit 09 = 1: Ramp 2 (parameter 3-51 Ramp 2 Ramp Up Time to parameter 3-52 Ramp 2 Ramp Down Time) is active.

Bit 10, Data not valid/Data valid

Tell the frequency converter whether to use or ignore the control word. Bit 10 = 0: The control word is ignored. Bit 10 = 1: The control word is used. This function is relevant because the telegram always contains the control word, regardless of the telegram type. If the control word is not needed when updating or reading parameter, turn it

o.

Bit 11, Relay 01

Bit 11 = 0: Relay not activated. Bit 11 = 1: Relay 01 activated if [36] Control word bit 11 is selected in parameter 5-40 Function Relay.

Bit 12, Relay 02

Bit 12 = 0: Relay 02 is not activated. Bit 12 = 1: Relay 02 is activated if [37] Control word bit 12 is selected in parameter 5-40 Function Relay.

Bit 13, Set-up selection

Use bit 13 to select from the 2 menu set-ups according to Table 5.36.

Set-up Bit 13

1 0

2 1

Table 5.36 Menu Set-ups

The function is only possible when [9] Multi set-ups is selected in parameter 0-10 Active Set-up.

To dene how bit 13 gates with the corresponding function on the digital inputs, use parameter 8-55 Set-up Select.

Bit 15 Reverse

Bit 15 = 0: No reversing. Bit 15 = 1: Reversing. In the default setting, reversing is set to digital in parameter 8-54 Reversing Select. Bit 15 causes reversing only when serial communication, [2] Logic OR or [3] Logic AND is selected.

5 5

Output frequencySTW

Bit

Slave-master

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

130BA273.12

RS485 Installation and Set-...

VLT® AutomationDrive FC 360

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

Bit 04, No error/error (no trip)

Bit 04=0: The frequency converter is not in fault mode. Bit 04=1: The frequency converter shows an error but does

Set parameter 8-30 Protocol to [0] FC.

not trip.

Bit 05, Not used

Bit 05 is not used in the status word.

Bit 06, No error/triplock

Bit 06=0: The frequency converter is not in fault mode. Bit 06=1: The frequency converter is tripped and locked.

Bit 07, No warning/warning

Illustration 5.14 Status Word

Bit 07=0: There are no warnings. Bit 07=1: A warning has occurred.

Bit 08, Speed reference/speed=reference

Bit Bit=0 Bit=1

00 Control not ready Control ready

01 Frequency converter not

ready

02 Coasting Enable

03 No error Trip

04 No error Error (no trip)

05 Reserved –

06 No error Triplock

07 No warning Warning

09 Local operation Bus control

10 Out of frequency limit Frequency limit OK

11 No operation In operation

12 Frequency converter OK Stopped, auto start

13 Voltage OK Voltage exceeded

14 Torque OK Torque exceeded

15 Timer OK Timer exceeded

Speed≠reference

Frequency converter ready

Speed=reference

Bit 08=0: The motor runs, but the present speed is dierent from the preset speed reference. It might happen when the speed ramps up/down during start/stop. Bit 08=1: The motor speed matches the preset speed reference.

Bit 09, Local operation/bus control

Bit 09=0: [O/Reset] is activated on the control unit or [2] Local in parameter 3-13 Reference Site is selected. It is not

possible to control the frequency converter via serial communication. Bit 09=1: It is possible to control the frequency converter via the eldbus/serial communication.

Bit 10, Out of frequency limit

Bit 10=0: The output frequency has reached the value in

parameter 4-12 Motor Speed Low Limit [Hz] or parameter 4-14 Motor Speed High Limit [Hz].

Bit 10=1: The output frequency is within the dened limits.

Bit 11, No operation/in operation

Bit 11=0: The motor is not running.

Table 5.37 Status Word According to FC Prole

Bit 11=1: The frequency converter has a start signal without coast.

Explanation of the status bits

Bit 12, Frequency converter OK/stopped, auto start

Bit 00, Control not ready/ready

Bit 00=0: The frequency converter trips. Bit 00=1: The frequency converter controls are ready but the power component does not necessarily receive any supply (if there is 24 V external supply to controls).

Bit 01, Frequency converter ready

Bit 01=0: The frequency converter is not ready.

Bit 01=1: The frequency converter is ready for operation, but the coasting command is active via the digital inputs or via serial communication.

Bit 02, Coast stop

Bit 02=0: The frequency converter releases the motor. Bit 02=1: The frequency converter starts the motor with a start command.

Bit 03, No error/trip

Bit 03=0: The frequency converter is not in fault mode. Bit 03=1: The frequency converter trips. To re-establish

Bit 12=0: There is no temporary overtemperature on the frequency converter. Bit 12=1: The frequency converter stops because of overtemperature, but the unit does not trip and resumes operation once the overtemperature normalizes.

Bit 13, Voltage OK/limit exceeded

Bit 13=0: There are no voltage warnings. Bit 13=1: The DC voltage in the frequency converter’s DC link is too low or too high.

Bit 14, Torque OK/limit exceeded

Bit 14=0: The motor current is lower than the current limit selected in parameter 4-18 Current Limit. Bit 14=1: The current limit in parameter 4-18 Current Limit is exceeded.

Bit 15, Timer OK/limit exceeded

Bit 15=0: The timers for motor thermal protection and thermal protection are not exceeded 100%. Bit 15=1: 1 of the timers exceed 100%.

operation, press [Reset].

Actual output frequency

STW

Follower-slave

Speed referenceCTW

Master-slave

16bit

130BA276.11

Reverse Forward

Par.3-00 set to

(1) -max- +max

Max reference Max reference

Par.3-00 set to

(0) min-max

Max reference

Forward

Min reference

100%

(4000hex)

-100%

(C000hex)

(0hex)

Par.3-03 0 Par.3-03

Par.3-03

(4000hex)(0hex)

0% 100%

Par.3-02

130BA277.10

RS485 Installation and Set-... Design Guide

5.11.3 Bus Speed Reference Value

Speed reference value is transmitted to the frequency converter in a relative value in %. The value is transmitted in the form of a 16-bit word. The integer value 16384 (4000 hex) corresponds to 100%. Negative gures are formatted using 2’s complement. The actual output frequency (MAV) is scaled in the same way as the bus reference.

Illustration 5.15 Actual Output Frequency (MAV)

The reference and MAV are scaled as follows:

5 5

Illustration 5.16 Reference and MAV

130BF817.10

+24 V

D IN

+10 V

A IN

COM

A OUT

D IN

+24 V

D IN

+10 V

A IN

COM

A OUT

0 ~10 V

130BF818.10

D IN

130BF819.10

+24 V

D IN

+10 V

A IN

COM

A OUT

4 - 20mA

D IN

Application Examples

6 Application Examples

VLT® AutomationDrive FC 360

6.1 Introduction

The examples in this section are intended as a quick reference for common applications.

Parameter settings are the regional default values

•

unless otherwise indicated (selected in parameter 0-03 Regional Settings).

Parameters associated with the terminals and

•

their settings are shown next to the drawings.

Required switch settings for analog terminals 53

•

or 54 are also shown.

6.1.1 AMA

Parameters

Function Setting

Parameter 1-29 A

utomatic Motor

Adaptation

(AMA)

Parameter 5-12 T

erminal 27

Digital Input

*=Default value

Notes/comments: Set

parameter group 1-2* Motor

Data according to motor

specications.

NOTICE

If terminals 12 and 27 are not connected, set

parameter 5-12 Terminal 27 Digital Input to [0] No operation.

Table 6.1 AMA with T27 Connected

[1] Enable

complete

AMA

*[2] Coast

inverse

6.1.2 Speed

Parameters

Function Setting

Parameter 6-10 T

erminal 53 Low

Voltage

Parameter 6-11 T

erminal 53 High

Voltage

Parameter 6-14 T

erminal 53 Low

Ref./Feedb. Value

Parameter 6-15 T

erminal 53 High

Ref./Feedb. Value

Parameter 6-19 T

erminal 53 mode

*=Default value

Notes/comments:

Table 6.2 Analog Speed Reference (Voltage)

Parameters

Function Setting

Parameter 6-22 T

erminal 54 Low

Current

Parameter 6-23 T

erminal 54 High

Current

Parameter 6-24 T

erminal 54 Low

Ref./Feedb. Value

Parameter 6-25 T

erminal 54 High

Ref./Feedb. Value

Parameter 6-29 T

erminal 54 mode

*=Default value

Notes/comments:

Table 6.3 Analog Speed Reference (Current)

*0.07 V

*10 V

50 Hz

*[1] Voltage

*4 mA

*20 mA

50 Hz

[0] Current

130BF820.10

+24 V

D IN

+10 V

A IN

COM

A OUT

≈ 5kΩ

D IN

+24 V

D IN

+10

A IN

COM

A OUT

130BF821.10

D IN

130BB840.12

Speed

Reference

Start (18)

Freeze ref (27)

Speed up (29)

Speed down (32)

130BF822.10

+24 V

D IN

+10 V

A IN

COM

A OUT

D IN

Application Examples Design Guide

Parameters

Function Setting

Parameter 6-10 T

erminal 53 Low

Voltage

Parameter 6-11 T

erminal 53 High

Voltage

Parameter 6-14 T

erminal 53 Low

Ref./Feedb. Value

Parameter 6-15 T

erminal 53 High

Ref./Feedb. Value

Parameter 6-19 T

erminal 53 mode

*=Default value

Notes/comments:

Table 6.4 Speed Reference (Using a Manual Potentiometer)

Parameters

Function Setting

Parameter 5-10 T

erminal 18

Digital Input

Parameter 5-12 T

erminal 27

Digital Input

Parameter 5-13 T

erminal 29

Digital Input

Parameter 5-14 T

erminal 32

Digital Input

*=Default value

Notes/comments:

*0.07 V

*10 V

50 Hz

*[1] Voltage

*[8] Start

[19] Freeze

Reference

[21] Speed Up

[22] Speed

Down

Illustration 6.1 Speed Up/Speed Down

6.1.3 Start/Stop

Parameters

Parameter 5-10 Ter

minal 18 Digital

Input

Parameter 5-11 Ter

minal 19 Digital

Input

Parameter 5-12 Ter

minal 27 Digital

Input

Parameter 5-14 Ter

minal 32 Digital

Input

Parameter 5-15 Ter

minal 33 Digital

Input

Parameter 3-10 Pre

set Reference

Preset ref. 0

Preset ref. 1

Preset ref. 2

Preset ref. 3

*=Default value

Notes/comments:

Function Setting

*[8] Start

*[10]

Reversing

[0] No

operation

[16] Preset

ref bit 0

[17] Preset

ref bit 1

25%

50%

75%

100%

Table 6.5 Speed Up/Speed Down

Table 6.6 Start/Stop with Reversing and 4 Preset Speeds

130BF823.10

+24 V

D IN

+10 V

A IN

COM

A OUT

D IN

130BF824.10

+24 V

D IN

+10 V

A IN

COM

A OUT

D IN

+24 V

D IN

+10

A IN

COM

A OUT

315053

Application Examples

VLT® AutomationDrive FC 360

6.1.4 External Alarm Reset

Parameters

Function Setting

Parameters

Function Setting

Parameter 5-11 T

erminal 19

[1] Reset

Digital Input

*=Default value

Notes/comments:

Parameter 4-30

Motor Feedback

Loss Function

Parameter 4-31

Motor Feedback

Speed Error

Parameter 4-32

Motor Feedback

[1] Warning

100

5 s

Loss Timeout

Parameter 7-00 S

peed PID

[2] MCB 102

Feedback Source

Parameter 17-11

Resolution (PPR)

1024*

Parameter 13-00

SL Controller

[1] On

Mode

Table 6.7 External Alarm Reset

6.1.5 Motor Thermistor

Parameter 13-01

Start Event

Parameter 13-02

Stop Event

Parameter 13-10

Comparator

Operand

[19] Warning

[44] Reset

key

[21] Warning

no.

Parameter 13-11

NOTICE

To meet PELV insulation requirements, use reinforced or double insulation on the thermistors.

Parameters

Function Setting

Parameter 1-90

Motor Thermal

Protection

Parameter 1-93 T

hermistor Source

Parameter 6-19 T

erminal 53 mode

[2] Thermistor

trip

[1] Analog

input 53

*[1] Voltage

Comparator

Operator

Parameter 13-12

Comparator

Value

Parameter 13-51

SL Controller

Event

Parameter 13-52

SL Controller

Action

Parameter 5-40 F

unction Relay

*=Default value

[1] ≈*

[22]

Comparator 0

[32] Set

digital out A

low

[80] SL digital

output A

Notes/comments:

* = Default value

Notes/comments:

If only a warning is needed, set

parameter 1-90 Motor Thermal

Protection to [1] Thermistor

warning.

Table 6.8 Motor Thermistor

Table 6.9 Using SLC to Set a Relay

If the limit in the feedback

monitor is exceeded, warning

90 feedback monitor is issued.

The SLC monitors warning 90

feedback monitor. If warning 90

feedback monitor becomes true,

relay 1 is triggered.

External equipment could

indicate that service is required.

If the feedback error goes

below the limit again within 5

s, the frequency converter

continues and the warning

disappears. But relay 1 persists

until [O/Reset] is pressed.

130BD366.12

+24 V DC

GND

12 18 322719 29 33 20

130BA646.10

CCW

Motor

Gearbox

Load

Transmission

Encoder Mech. brake

Brake resistor

130BA120.10

Application Examples Design Guide

6.1.6 Encoder Connection

The purpose of this guideline is to ease the set-up of encoder connection to the frequency converter. Before setting up the encoder, the basic settings for a closed-loop speed control system are shown.

6.1.7 Encoder Direction

The order in which the pulses enter the frequency converter determines the direction of the encoder. Clockwise direction means that channel A is 90 electrical degrees before channel B. Counterclockwise direction means that channel B is 90 electrical degrees before A. The direction is determined by looking into the shaft end.

6.1.8 Closed-loop Drive System

A drive system usually consists of more elements such as:

Motor.

•

Brake (gearbox, mechanical brake).

•

Frequency converter.

•

Encoder as feedback system.

•

Brake resistor for dynamic brake.

•

Transmission.

•

Load.

•

Applications demanding mechanical brake control usually need a brake resistor.

Illustration 6.2 24 V or 10–30 V Encoder

Illustration 6.3 24 V Incremental Encoder, Maximum Cable

Length 5 m (16.4 ft)

Illustration 6.4 Basic Set-up for Closed-loop Speed Control

Index

VLT® AutomationDrive FC 360

Index

Abbreviation....................................................................................... 0

Acoustic noise........................................................................................ 60

AMA.............................................................................................................. 8

AMA with T27 connected.................................................................. 86

Ambient condition............................................................................... 58

Analog feedback................................................................................... 26

Analog output....................................................................................... 56

Analog reference.................................................................................. 26

Automatic motor adaptation.............................................................. 8

Brake

power...................................................................................................... 8

resistor.................................................................................................... 8

Brake function........................................................................................ 45

Brake power............................................................................................ 45

Brake resistor................................................................................... 44, 50

Branch circuit protection................................................................... 59

Break-away torque.................................................................................. 7

Bus reference.......................................................................................... 26

Cable length........................................................................................... 55

Catch up/slow down........................................................................... 25

CE mark.................................................................................................... 11

Coast............................................................................................................ 6

Coasting............................................................................................ 83, 84

Coil............................................................................................................. 79

Control

Characteristic..................................................................................... 57

wiring................................................................................................... 16

word...................................................................................................... 82

Control cable.......................................................................................... 19

Control card

+10 V DC output............................................................................... 57

Performance...................................................................................... 58

RS485 serial communication....................................................... 57

Control structures

Open loop........................................................................................... 23

Control wiring........................................................................................ 16

Cross-section.......................................................................................... 55

Data type, supported.......................................................................... 72

DC brake.................................................................................................. 83

Dead band............................................................................................... 27

Dead band around 0........................................................................... 27

Derating................................................................................................... 58

Digital output......................................................................................... 57

Directive, EMC........................................................................................ 11

Directive, Low Voltage........................................................................ 11

Directive, Machinery............................................................................ 11

Discharge time...................................................................................... 10

Disposal instruction............................................................................. 11

Eciency.................................................................................................. 60

Electrical noise....................................................................................... 16

Electronic thermal relay........................................................................ 8

Danfoss FC 360 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual