Danfoss FCD 300, DMS 300 Design guide
Design Guide
Decentral Solutions
FCD 300
DMS 300
■ Contents
Decentral Solutions - Design Guide
The decentral concept
Introduction .............................................................................................................. 5
Decentral Design Benefits ........................................................................................ 6
Application Examples ............................................................................................. 13
Product Design Guide ............................................................................................ 19
Ordering form - DMS 300 ...................................................................................... 23
Ordering form - FCD 300 ....................................................................................... 26
PC Software tools .................................................................................................. 27
Accessories for DMS 300 and FCD 300 ................................................................ 27
Communication ...................................................................................................... 30
Good Installation Practice ...................................................................................... 32
Servicing the Danfoss Decentral Products ............................................................. 34
................................................................................... 5
Introduction, DMS 300 .................................................................................. 35
Operating instructions ............................................................................................ 36
Symbols used in this manual .................................................................................. 36
General warning ..................................................................................................... 36
Safety regulations .................................................................................................. 36
Warning against unintended start ........................................................................... 36
Avoiding DMS damage .......................................................................................... 36
Mechanical details, DMS 300 .................................................................... 37
Description ............................................................................................................ 37
General layout ....................................................................................................... 37
Construction ......................................................................................................... 37
Tools required ....................................................................................................... 37
Wall mounting ....................................................................................................... 37
Motor mounting .................................................................................................... 38
Ventilation ............................................................................................................. 38
Electrical connections, DMS 300 ............................................................ 39
Power Wiring ......................................................................................................... 39
Power factor correction .......................................................................................... 39
Control Wiring ........................................................................................................ 39
Motor thermistors ................................................................................................... 40
Serial communication ............................................................................................. 40
Earthing .................................................................................................................. 40
High voltage warning ............................................................................................. 40
Galvanic isolation (PELV) ........................................................................................ 40
Electrical Schematic .............................................................................................. 41
SettingupDMS300 ....................................................................................... 42
Adjustment/ Settings .............................................................................................. 42
Start/ stop profile setting ........................................................................................ 42
Start/ stop profile setting table: .............................................................................. 42
Trip Class selection: ............................................................................................... 43
Trip Class selection table: ...................................................................................... 43
Full Load Current setting: ....................................................................................... 44
FLC setting table: ................................................................................................... 44
Completing the installation: .................................................................................... 44
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Decentral Solutions - Design Guide
Operation details, DMS 300 ....................................................................... 45
Operation ............................................................................................................... 45
Powering-up the DMS ........................................................................................... 45
Starting the motor: ................................................................................................. 45
Brake Release ........................................................................................................ 45
Operation with AS-i Interface ................................................................................ 45
Description of AS-i profiles used with DMS .......................................................... 45
Fault Procedure .................................................................................................... 47
Reading the "Alarm" LED ...................................................................................... 47
Specification and order codes, DMS 300 ........................................... 48
General Technical Data ......................................................................................... 48
Current Ratings (AC53a ratings) ............................................................................ 48
Ordering type code ................................................................................................ 49
Certifications .......................................................................................................... 49
Fuses ..................................................................................................................... 50
Special variants: ..................................................................................................... 50
Motor connection ................................................................................................... 50
Details of Profibus Connectivity .............................................................................. 52
Profibus DP Slave 6 E/DC 24 V, 4 A/DC 24 V/1A ................................................. 52
Table of bits in control and status word ................................................................. 52
Profibus connector PCB 4 x M12 .......................................................................... 53
Profibus address setting: DIP switch SW3 ............................................................. 53
Introduction to FCD 300 .............................................................................. 54
Software version .................................................................................................... 54
High voltage warning ............................................................................................. 55
These rules concern your safety ............................................................................. 55
Warning against unintended start ........................................................................... 55
Technology ............................................................................................................ 56
CE labelling ........................................................................................................... 58
Installation, FCD 300 ..................................................................................... 60
Mechanical dimensions .......................................................................................... 60
Mechanical dimensions, FCD, motor mounting ...................................................... 60
Mechanical dimensions, stand alone mounting ...................................................... 60
Mechanical installation ........................................................................................... 61
General information about electrical installation .................................................... 63
Electronics purchased without installation box ....................................................... 63
EMC-correct electrical installation .......................................................................... 64
Earthing of screened/armoured control cables ....................................................... 66
Diagram ................................................................................................................. 67
RFI switches J1, J2 ................................................................................................ 67
Location of terminals .............................................................................................. 68
Mains connection ................................................................................................... 70
Pre-fuses ................................................................................................................ 70
Motor connection ................................................................................................... 70
Direction of motor rotation ..................................................................................... 70
Mains and motor connection with service switch ................................................... 70
Connection of HAN 10E motor plug for T73 .......................................................... 70
Parallel connection of motors ................................................................................. 71
Motor cables .......................................................................................................... 71
Motor thermal protection ....................................................................................... 71
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Decentral Solutions - Design Guide
Brake resistor ......................................................................................................... 71
Control of mechanical brake .................................................................................. 72
Electrical installation, control cables ....................................................................... 73
Connection of sensors to M12 plugs for T53, T63, T73 ........................................ 74
Electrical installation, control terminals ................................................................... 75
PC communication ................................................................................................ 75
Relay connection ................................................................................................... 75
Connection examples ............................................................................................ 76
Programming, FCD 300 ............................................................................... 80
The LCP 2 control unit, option ............................................................................... 80
Parameter selection ............................................................................................... 83
Operation & Display ............................................................................................... 85
Setup configuration ................................................................................................ 85
Load and Motor ..................................................................................................... 93
DC Braking ............................................................................................................ 97
Motortype, par, 147 - FCD 300 ........................................................................... 102
References & Limits ............................................................................................. 103
Handling of references ......................................................................................... 103
Reference function ............................................................................................... 107
Inputs and outputs ............................................................................................... 111
Special functions .................................................................................................. 120
PID functions ....................................................................................................... 122
Handling of feedback ........................................................................................... 124
Serial communication for FCD 300 ...................................................................... 131
Control Word according to FC protocol ............................................................... 135
Status Word according to FC Profile .................................................................... 137
Fast I/O FC-profile ............................................................................................... 138
Control word according to Fieldbus Profile .......................................................... 138
Status word according to Profidrive protocol ....................................................... 139
Serial communication ........................................................................................... 142
Technical functions .............................................................................................. 150
All About FCD 300 ........................................................................................ 155
Dynamic braking .................................................................................................. 155
Internal Brake Resistor .......................................................................................... 159
Special conditions ................................................................................................ 161
Galvanic isolation (PELV) ...................................................................................... 161
Earth leakage current and RCD relays ................................................................. 162
Extreme operating conditions ............................................................................... 162
dU/dt on motor .................................................................................................... 163
Switching on the input ......................................................................................... 163
Acoustic noise ...................................................................................................... 163
Temperature-dependent switch frequency ........................................................... 164
Derating for air pressure ...................................................................................... 164
Derating for running at low speed ........................................................................ 164
Motor cable lengths ............................................................................................. 164
Vibration and shock ............................................................................................. 164
Air humidity .......................................................................................................... 165
UL Standard ........................................................................................................ 165
Efficiency .............................................................................................................. 165
Mains supply interference/harmonics ................................................................... 165
Power factor ........................................................................................................ 166
Emission test results according to generic standards and PDS product standard 167
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Decentral Solutions - Design Guide
Immunity test result according to Generic standards, PDS product standards and basic
standards ............................................................................................................. 167
Aggressive environments ...................................................................................... 169
Cleaning ............................................................................................................... 169
Status messages .................................................................................................. 171
Warnings/alarm messages ................................................................................... 171
Warning words, extended status words and alarm words ................................... 174
General technical data ......................................................................................... 175
Technical data, mains supply 3 x 380 - 480 V ..................................................... 180
Available literature ................................................................................................. 181
Supplied with the unit ........................................................................................... 181
Factory Settings ................................................................................................... 182
Index .................................................................................................................... 189
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Decentral Solutions - Design Guide
■Introduction
Danfoss was the world’s first company to manufacture
and supply frequency converters for infinitely variable
speed control of three-phase AC motors. Until then,
AC motors had to operate at the speed determined
by the frequency of the main power supply.
Production of frequency converters started in 1968.
The first frequency converter was also the first
decentralised drive as it was placed next to the motor.
The first frequency converter was totally enclosed and
filled with silicone oil for cooling, as semiconductors
of that time were very inefficient. The enclosure
design was made for mounting the drive directly in
the application next to the motor. Temperature, water,
cleaning agents, dust and other environmental factors
were also no problem, even in harsh environments.
Semiconductors improved during the next decades.
Air-cooling showed sufficient and oil cooling was
abandoned. At the same time use of frequency
converters grew significantly. PLCs gained a footing
for advanced application control and it became
common practice to install all frequency converters in
one cabinet, rather than several places in the factory.
Finally we have included comprehensive information
about the Danfoss decentralised products.
concept
The decentral
Continuing improvements in semi-conductors and
related technologies - such as fieldbus technology
- now again makes it feasible to consider installing
drives close to the motors, achieving the benefits of
decentralised installation without the disadvantages
from the first oil-filled frequency converters.
Development of automation in industry is based on the
ability to send and receive data from the application
needed to control the processes. More and more
sensors are installed and more and more data is
submitted to the central PLC control. This trend
depends on increased use of fieldbus systems.
Industrial sources often claim that up to 30 % of
all drive installations will be installed decentrally
within the next few years and the trend towards
distributed intelligent control is undisputed as
more and more components and applications are
developed for decentralised installation.
This book is a general introduction to basic features
of decentralised installation philosophies for motor
controls and differences from the centralised
concept. It will help you choose the most suitable
concept and guide you through the process of
selecting the appropriate products.
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■Decentralised design benefits
In the following we will concentrate on describing
decentralised installation of frequency converters and
motor starters, referred to here as motor controls.
There are two topologic concepts for the layout
of motor control installations in a plant, in
the following referred to as "centralised" and
"decentralised" installations. The two typologies
are illustrated in the figure.
In a centralised installation:
- motor controls are placed in a central place
In a decentralised installation:
- motor controls are distributed throughout the plant,
mounted on or next to the motor they control
Decentral Solutions - Design Guide
Placing the advanced and reliable electronics needed
to ensure a smooth, responsive and economical
operation of the motor next to – or on – the motor
facilitates modularisation and reduces cabling costs
and EMC problems dramatically. Further benefits:
• Space-consuming motor control cabinets in long
rows of centralised panels are eliminated
• Reduced efforts for building in and wiring long
screened motor cables where special attention
on EMC terminations is required
• Heat dissipation from power electronics is moved
from the panel into the plant
• Standardised machine elements by modularisation
reduces design time and time to market
• Commissioning is easier and faster
Decentralised does not mean "control cabinet
free", but merely that their enormous size can now
be reduced thanks to innovative designs of the
components that will be placed decentralised. There
will continue to be a need for cabinets for power
distribution and for overall intelligence, and there
are areas, particularly in the process industry with
areas such as explosion protection, where centralised
cabinets continue to be the preferred solution.
Decentralised motor control is rapidly gaining
ground despite of the advantages of the
centralised control concept:
• no need for extra space around the motor
or close to the motor
• no control cable wiring into the plant
• independence of plant environment
■Direct cost savings
Motor controls for decentralised installations must be
built to meet the harsh conditions in manufacturing
areas - especially such conditions found in the food
and beverage industry, where frequent wash downs
are required. This of course increases the cost of
thedrive. Thisincreasewillbemorethansetoffby
savings in expenses for cabinets and cables.
The cable saving potential is considerable, as will
be demonstrated by the following example.
The figure illustrates an installation with motors
distributed in a number of rows with several motors in
each, as is the situation in for example parallel bottling
or baking lines in the Food and Beverage industry.
This example shows the need for power cables from
the centrally placed drives to the motors.
Centralised versus decentralised installations
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Decentral Solutions - Design Guide
concept
The decentral
Centralised installation
The drives are distributed equidistant with the distance
L between each drive and the distance h between
each row and also with a distance h from the
centralised power entry/cabinet location to the first
row. There are n rows, and N drives in each row.
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Decentral Solutions - Design Guide
Decentralised cabling
The figure illustrates how the three-phase mains
cable can be distributed with power looping from one
motor (drive) to the next. The cable saving potential
is illustrated in figure 4. Given a distance of 10m
between each motor and 20m between each line, the
potential cable savings as a function of the number of
motors and number of lines shows of the figure.
Cable saving potential in an illustrative installation
The saving potential in power cable length alone
is substantial. The figure only illustrates the
potential concerning power cables. Issues like
unscreened/screened cables and cable dimensions
also ads to the benefits of decentralised installations.
Real case
Calculations on a specific, typical bottling line with
91 pieces of 1.5 kW motors, taking the cable
dimensioning into account, showed the following
saving potential in cables and terminations:
• Cable terminations are reduced from 455 to 352
• EMC cable terminations are reduced from
364 to 182 by using motor controls with
integrated service switches
• Power cable length reduced from 6468m to
1180m, a reduction of 5288m, and it is converted
from screened cables to standard installation cables
For details consult the following chapter on
Good installation practice.
■Minimal need for additional fieldbus cables
Power cable savings are not offset by the additional
cost for expensive fieldbus cables. Fieldbus cables
will be extended in a decentralised installation, but
since fieldbus cables will be distributed in the plant
anyway to connect sensors or remote I/O-stations,
the extension will be limited. Decentralised products
from Danfoss can even be used as remote I/O
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Decentral Solutions - Design Guide
stations to connect sensors to the fieldbus and
reduce direct costs even more.
Fewer cabinets, cooling and cabletrays
Further savings will result from smaller cabinets, less
cabinet cooling and fewer cable trays. Motor controls
generate heat and are often mounted side by side due
to limited space, as illustrated in Figure 6. Forced
cooling is therefore required to remove the heat.
Less Commissioning
Time spend commissioning at the end-user is
significantly reduced using decentralised solutions especially when fieldbus communication is combined
with decentralised motor controls.
The concept of modularisation is known from
equipment like PC’s and cars. Modules with
well-described functionalities and interfaces are
used in these products. The same concept can
be applied to manufacturing, even though specific
physical constraints play a role.
Production equipment is often built from different basic
building blocks, each kind employed at several places
in the installation. Examples include various types of
conveyor sections and machinery like mixers, scales,
fillers, labellers, palletisers, packaging machines etc.
concept
The decentral
Decentralised brewery installation
An Australian brewery has installed a line of 96
decentralised drives from Danfoss connected by
DeviceNet. An excessive amount of time was saved
as the commissioning of the variable speed drives
was done in a few days. The brewery estimates
a saving exceeding AUD 100,000 compared to
traditional centralised installation.
■Design savings
End users want to postpone the final decision for new
equipment - and to start production as fast as possible
once a decision has been made. Payback time and
time to market must be reduced. This squeezes both
the design phase and the commissioning phase.
Modularisation can minimise lead-time. Even
manufacturers of large production equipment or
lines use modularisation to reduce lead-time. Up
to 40-50 % on the total time from design to
running production can be saved.
Centralised cabinet
In a truly modular machine, all basic elements are
self-confined and need nothing but electricity, water,
compressed air or similar to function.
Modularisation therefore requires the distribution of
intelligence to the individual sections and modules.
Sure, centralised installations can be modualarised,
but then motor controls will be physically separated
from the rest of the module.
■Ready-installed intelligence
The function of machinery and applications is typically
tested at the suppliers. Machines are built, tested,
calibrated and taken apart for transportation.
The process of rebuilding the application at the
production site is considerably simplified by shipping
it in modules with built-in motor controls, as rewiring
and testing is time consuming and calls for skilled
personnel. Using ready-installed, decentralised
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Decentral Solutions - Design Guide
installations reduces both time and risk as wiring for
motor, control and sensors are already in place and
maintained during transportation. The need for highly
skilled experts is reduced and local labour can do a
larger part of the installation. The commissioning costs
and OEM resources on-site will be reduced.
■Improved EMC
Electrical noise emitted is proportional to cable
length. The very short - or eliminated - cable
between motor control and motor in decentralised
installations therefore reduces emitted electrical noise.
In decentralised installations, the machine builder
normally mounts cables between motor controls and
motors in the machine leaving only power cables
and fieldbus cables with no EMC emission to be
installed at the production site. The risk of electrical
noise from motor controls to disturb other electrical
equipment caused by a faulty installation will diminish
and you avoid time-consuming fault finding in the
commissioning phase, where time frame is tight.
■Adapts to standard and special motors
Danfoss’ decentralised motor controls, FCD 300 and
DMS 300, are designed to control standard AC
asynchronous motors. Their flexibility allows them
also to adapt to special motor types. An example
is the AMT feature (Automatic Motor Tuning) in the
FCD 300. Combining Danfoss frequency converters
to Danfoss geared motors makes it even easier
as they fit mechanically and the motor data are
already stored in the FCD 300 memory. Combined
motor-drives are provided pre-assembled directly
from Danfoss removing the need for mechanical
fitting between motor and control.
motoraresimilarorlessthanthelossesinamotor
connected to mains. Thermal losses are minimised
and overheat is prevented. At the same time, the
VVC principle ensures nominal torque at nominal
speed and eliminates bearing currents.
Slim DC-links
It takes two steps to convert the frequency to vary
the speed of an AC motor: A rectifier and an inverter.
As the rectifier itself produces a rippled DC voltage,
a capacitor is often introduced to smoothen the
voltage supplied to the inverter. A link between
rectifier and inverter with only a small capacitor to
even out the voltage is called a "slim DC link". With a
slim DC link, the inverter will not be able to provide
quite the same voltage amplitude as supplied by the
mains supply, leading to lower efficiency. A special
pulse-width-modulation can be used to compensate
the ripple from a slim DC link. In this case the output
voltage for the motor still does not reach the rated
supply voltage value leading to an over-consumption
of motor current up to 10% and this will increase
the motor heating. Low efficiency and need of an
oversized motor is the result. As torque decreases with
the square of voltage the application will be exceeding
sensible to load-changes and speed sensors might be
required. At start, only nominal torque is available.
Danfoss geared motor with FCD 300
■Minimum thermal losses
Danfoss frequency converters feature the unique
VVC switch principle to generate motor voltages.
Due to the VVC principle, power losses in the
10
Principle of a frequency converter using
a DC link coil
The Danfoss option is to add coils to the DC link
inalldrivesasshowninthefigure. Thiswaya
high DC link voltage with a very low voltage ripple
is obtained and the electric strength of the drive
with regard to line transients is improved.
Further advantages are the prolonged lifetime of the
capacitors, reduced harmonic disturbance of the net
supply and presence of 150-160% start torque.
Numerous manufacturers of frequency inverters
use slim DC links leading to bad efficiency rates
– even if users due to the activity of for instance
the CEMEP now tend to use high efficiency
motors - meeting at least EFF2.
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Decentral Solutions - Design Guide
Danfoss’ aim is to provide high efficiency drives that
also improve the efficiency of the motors. There
should be no need of expensive over-dimensioning
and inefficient operation.
■Environmental considerations
Drives – both centrally-mounted and distributed in the
plant - are exposed to the environment. As motor
controls handle high voltages and currents at the
same time they must be protected from dust and
humidity so that they do not fail or break down. Both
manufacturers and installers must take account of this
and Danfoss Drives have designed the decentralised
products with a deep concern in both aspects.
Decentralised motor controls must also meet
increasing demands in respect of hygiene levels in
pharmaceutical industries and in food- and beverage
production in particular, where drives are exposed to
cleaning agents for extensive periods of time, high
pressure hosing and the like. The exterior of the
decentralised motor controls must be designed in such
a way as to achieve this. Complicated heat sinks as
illustrated in the figure must be avoided as it is difficult
to clean and not resistant to common cleaning agents.
challenge by designing a range of aseptic geared
motors. These motors have no fans and only smooth
surfaces. An IP65 enclosure class is standard as is
the special CORO coating resistant to acid, alkali
and cleaning agents used in for instance food and
beverage industry. See the photo of an example
of the aseptic geared motor series.
concept
The decentral
Aseptic Danfoss geared motor
Danfoss decentralised drives are designed to meet
the requirements as shown in Figure 9. There
are no hard-to-clean places, blind plugs have no
notches or indentations and two-layer robust surface
treatment - tested to withstand commonly used
cleaning agents - protects the housing.
Non-cleaning friendly pin fin heat sink versus
the easy to clean Danfoss solution
All corners are rounded to prevent dust sticking, and
the distance between ribs allows high-pressure air
cleaning, hosing and easy cleaning with a brush.
These concerns are more or less irrelevant if not
applied to all elements and standard AC motors
are normally designed without these concerns in
mind – stressed by integrated fans and cooling
ribs both difficult to clean. Danfoss has met the
Electrical contact can cause galvanic corrosion under
wet or humid conditions. This can occur between
housing (Aluminium) and screws (stainless steel). One
possible consequence is that screws become stuck
and therefore impossible to unfasten in a maintenance
situation. Galvanic corrosion will not be found on
Danfoss decentralised products, as the housings
are fully coated and nylon washers underneath
the screws protects the coating. The complete
coating and the unique gasket design prevent pitting
corrosion, which can occur under gaskets.
Tightly enclosed equipment is susceptible to water
build-up inside the enclosure. This is especially
the case where equipment is exposed to ambient
temperature differences under wet conditions. As a
decreasing ambient temperature lowers the surface
temperature inside the enclosure, water vapour
tendstocondensate. Atthesametimepressure
inside the enclosure will drop and cause humid
air from the outside to penetrate non-hermetic
polymer gasket materials and cable glands. When
the enclosure heats up again, only the vaporised
water will escape, leaving more and more condensed
water inside the enclosure. This can lead to water
build-up inside the enclosure and eventually cause
malfunction. The phenomenon is illustrated in the
figure, with a cyclic temperature fluctuation.
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Decentral Solutions - Design Guide
The pumping effect in tight enclosures
Build-up of water inside enclosures can be prevented
bymembranesthatpreventsfluidstopenetrate
but allows for vapour to pass, as known from
fabrics used for outdoor clothing. A special
cable gland with this kind of material is offered
by Danfoss to eliminate this problem. The cable
glandshouldbeusedinapplicationsexposed
to frequent temperature fluctuations and humid
environments as in equipment used only during
daytimewheretheinsidetemperaturetendstofall
to the ambient temperature during the night.
■Installation flexibility
Danfoss decentralised solutions offers exceptional
installation flexibility. Flexibility is supported
by a number of benefits:
• Mountable on Danfoss geared motors
• Decentralised panel mounting possible
• Handheld control panels
• PC software for configuring and logging
• Single or double sided installation
• Service switch optional
• Brake chopper and resistor optional
• External 24 V backup supply optional
• M12 connections for external sensors optional
• Han 10E motor connector optional
• Fieldbus support (Profibus DP V1, DeviceNet,
As-Interface)
• Compatibility with standard mains systems
(TN, TT, IT, delta grounded)
For further details see the chapter on The
decentralised product range.
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Decentral Solutions - Design Guide
■Application Examples
Danfoss has completed a wide range of applications
in many different industries. This has given us a
valuable experience that has influenced the latest
■Beverage - Bottling line
development of our decentralised products. In
the following we provide illustrative examples of
actual installations using Danfoss decentralised
products, and the benefit and value these provide
for the customer in these installations.
concept
The decentral
FCD 300 on bottling conveyor
Benefits:
• Reduced switchboard space as all drives
aremountedinthefield
• Reduced cabling as several drives can be
supplied from same circuit
• Ease of commissioning over the fieldbus as the
protocol allows for transfer of complete parameters.
Once one drive is set up, its basic program can
be copied to any other decentralised drive
• The FCD motor performance is markedly
superior to all other types
MG.90.F3.02 - VLT is a registered Danfoss trademark
• The FCD can be retrofitted to existing motors
of nearly any brand or type
• The aseptic IP 66 enclosure is ideal for
damp bottling hall conditions
• All in one box: e.g. service switch, Profibus
and power looping
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■Beverage - Packaging machine
Decentral Solutions - Design Guide
Decentral motor controls integrated in packaging machine
Benefits:
• Distributing motor controls in the application
releases space fo
the switchboard
• The number of drives in an application can be
increased with
• IP66 enclosure, easy to clean and resistant
to strong cleaning liquids
• Same flexibili
motor controls. Decentralised motor controls
can be adapted for all standard AC motors,
and feature
numbers on connectors
• Profibus integrated
r other purposes in
out extending the switchboard
ty as with centrally mounted
same user interface and same
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■Food - Cocoa powder plant
Decentral Solutions - Design Guide
concept
The decentral
Old solution: Motor control - panel mounted decentrally
New Solution: Genuine decentralised motor control
Benefits:
• Easy to expand plant capacity
• No need for switchboard
• Visible LED for status
• Service switch integrated in the unit
• High enclosure rating IP66
• Low cost installation
• Less space needed for the new solution
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■Food conveyor
Decentral Solutions - Design Guide
Efficient space utilisation in the food industry with decentralised motor controls from Danfoss
Benefits:
• The number of drives in an application can be
raised without extending the switchboard
• IP66 enclosure, easy to clean and resistant
to strong cleaning liquids
• Dirt-repelling surface and design prevents dirt
and product remains on the drive
• Motor or wall mount units available
• Same flexibility as with centrally mounted motor
controls. Decentralised motor controls adapt to all
16
standard AC motors, features same user interface
and same numbering on connectors
• Profibus integrated
• Connectors for fast service integrated in
the installation box
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Decentral Solutions - Design Guide
■Automotive Industry - Hoists and conveyors Benefits:
• Simple installation
• AS-i or Profibus control optional
• Sensor input available within the physical
size of the unit
• Separate 24V supply for sensors and bus
• Brake supply and control build in
• Easy pluggable remote control panel
• Connectors for looping (T-connector) integrated
in the installation box
• Low installation and component costs
• No additional and expensive EMC
connectors needed
• Compact and space saving
• Easy to install and commission
• Input for motor thermistor monitoring
concept
The decentral
Decentral installation in the automotive industry
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■Retrofit in existing applications
Decentral Solutions - Design Guide
Retrofitting on existing application with speed control
Benefits:
• No need for a big control cabinet thanks to
the decentralised motor controls.
• No expensive wiring: All motors use existing
power cables, pipes and local switches
ll motor controls can be controlled from the
• A
existing centralised cabinet via Profibus
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MG.90.F3.02 - VLT is a registered Danfoss trademark
■The decentralised product range
The Danfoss decentralised concept covers
motor controls ranging from motor starters/soft
starters to frequency converters.
Motor starters and soft starters (DMS 300) make
start and stop of your application smoother and
smarter than ordinary DOL (Direct On Line) operation
but do not affect operation further.
Frequency converters (FCD 300) are used
for following requirements:
• Adjustable speed
• Precise speed
• Defined speed ramps at start or/and stop
• Shorter stop times (braking)
Danfoss decentralised motor controls range from
0.18kWto3kW(connectstoupto4kWand
5 HP motors). This chapter lists several optional
features and accessories available.
Decentral Solutions - Design Guide
2. Mounted directly on the motor ("motor-mounted")
• Fair choice of motor brands
• No need for screened motor cable
3. "Pre-mounted" on Danfoss Bauer
geared motors
concept
The decentral
■Flexible installation options
Danfoss decentralised motor controls FCD 300 and
DMS 300 series can be adapted for mounting using
the following options - each offering specific benefits:
1. Stand alone close to the motor ("wall-mounted")
• Free choice of motor brand
• Easy retrofitting to existing motor
• Easy interfacing to motor (short cable)
• Easy access for diagnosis and optimal serviceability
• A fixed combination of motor and electronics
supplied by one supplier
• Easy mounting, only one unit
• No need for screened motor cable
• Clear responsibility regarding the complete solution
Astheelectronicpartsarecommon-samefunction
of terminals, similar operation and similar parts
and spare parts for all drives - you are free to
mix the three mounting concepts.
MG.90.F3.02 - VLT is a registered Danfoss trademark
19
■Configuring a product
The decentralised motor controls DMS 300
and FCD 300 series are configured with a type
code string (see also Ordering):
Decentral Solutions - Design Guide
■24 V external supply
Back up of control supply with 24 V DC is available
in EX and EB versions of FCD 300.
DMS 330 P T4 P66 XX D0 Fxx Txx C0
FCD 3xx P T4 P66 R1 XX Dx Fxx Txx C0
Mains voltage
DMS 300/FCD 300 are available for connection
to mains voltage 3 phase 380-480 V.
Choice of motor starter
The motor starter DMS 300 covers the whole power
range from 0.18-3 kW in one unit.
Choice of frequency converter
The frequency converter must be chosen on the
basis of the present motor current at maximum
loading of the unit. The frequency converter’srated
output current I
must be equal to or greater
INV.
than the required motor current.
Typical shaft output
P
INV.
Type [kW] [HP]
303 0.37 0.50
305 0.55 0.75
307 0.75 1.0
311 1.1 1.5
315 1.5 2.0
322 2.2 3.0
330 3.0 4.0
335** 3.3 5.0*
* at mains/motor voltage 3 x 460 - 480 V
** t
max. 35° C
amb
■Enclosure
DMS 300 / FCD 300 units are protected against
water and dust as standard.
See also the section entitled Technical data
for further details.
■Brake
FCD 300 is available with or without an integral
brake module. See also the section entitled Brake
resistors for ordering a brake resistor.
EB version including mechanical brake control/supply.
NB!:
DMS 300 always needs 24 V external
control supply.
■RFI filter
FCD 300 has an integral 1A RFI-filter. The integral
1A RFI filter complies with EMC standards EN
55011-1A. See the sections Cable lengths and
Cross section for further details.
■Harmonic filter
The harmonic currents do not affect power
consumption directly, but they increase the heat losses
in the installation (transformer, cables). That is why in
a system with a relatively high percentage of rectifier
load it is important to keep the harmonic currents at
a low level so as to avoid a transformer overload and
high cable temperature. For the purpose of ensuring
low harmonic currents, the FCD 300 units are fitted
with coils in their intermediate circuit as standard. This
reduces the input current I
by typically 40 %.
RMS
■Display unit
On the FCD 300 unit there are 5 indicator lamps for
voltage (ON), warning, alarm, status and bus.
In addition, a plug for connecting an LCP control
panel is available as an option. The LCP control
panel can be installed up to 3 metres away from
the frequency converter, e.g. on a front panel,
by means of a mounting kit.
Alldisplaysofdataareviaa4-linealpha-numerical
display, which in normal operation is able to show
4 operating data items and 3 operation modes
continuously. During programming, all the information
required for quick, efficient parameter Setup of the
frequency converter is displayed. As a supplement
to the display, the LCP has three indicator lamps
for voltage (ON), warning (WARNING) and alarm
(ALARM). Most of the frequency converter’s parameter
Setups can be changed immediately via the LCP
control panel. See also the section entitled The
LCP control unit in the Design Guide.
20
MG.90.F3.02 - VLT is a registered Danfoss trademark
Desired features are selected by specifying the
corresponding fields in the string (xx). The choices and detailed explanation - shown in the two tables.
Short form explanations of a feature are u
For technical details and data, see Technical data.
■Installation box variants
Connections on right side
Gland holes for all c
ight side only (seen from motor drive end). This
r
version is useful where cable inlet is required from
one direction only (only FCD 300 series).
Connections on two sides
Gland holes for c
sides allowing for cable inlet from both directions.
able inlets are machined on the
able inlets are machined on both
nderlined.
Decentral Solutions - Design Guide
concept
The decentral
Both m
(selected variants).
P
mains power supply between drives (4 mm
The bottom section contains Cage Clamp connectors
and looping facilities for power and fieldbus cables well
protected against dust, hosing and cleaning agents.
(Not in DMS 300 ST and SB versions).
S
motor drive end). A lockable switch integrated in the
enclosure – disconnecting the motor or drive.
4s
drive end). Looping through of 2 X 24 V external supply.
Pluggable connection of remote I/O such as
sensors and external supply of these.
M
from motor drive end) wired according to DESINA
standard (see electrical installation).
D
of the local control panel for operating and
programming. Can also be used for PC connection.
Only available for FCD 300.
etric thread and NPT thread is available
luggable connection and the possibility of looping
2
line).
ervice switch mounted on the right side (seen from
ensor plugs, M12 on the right side (seen from motor
otor plug, HARTING 10 E on the right side (seen
isplay connector for external pluggable connection
MG.90.F3.02 - VLT is a registered Danfoss trademark
21
Decentral Solutions - Design Guide
■DMS 300 Decentralised electronic Motor Starter
DMS 300 - Combinations o f versions
Installation features
Mounting Motor Wall Motor Wall Motor Wall Wall Wall
Pluggable - X
Service switch - - - - X X - -
Sensor plugs - - - - - - 4XM12 4XM12
Motor plug - - - - - - - Harting 10E
Ordering codes DMS 330 P T4 P66 XX D0 Fxx Txx C0
Metric thread
(NPT thread)
Functional features
Basic functions
(see below)
+ Brake control SB
+ Current monitoring EX
+ Current monitoring
+ Brake control
+ Current monitoring
+ Brake control +
Reversing
Communication
No bus F00 -
AS-interface - F70 -
Profibus - F12* F12
T10 T50 T12
(T16)*
ST
-
T52
(T56)*
T22
(T26)*
EB
ER
-
T62
(T66)*
T53 T73
- = not available * contact Danfoss sales org for availability
Basic functions
Electronic start/stop of a motor
Soft start/stop
Extended functionality
eversing for bi-directional
R
B
rake control and supply of electromechanical brake
urrent monitoring for electronic motor protection
C
operation of the motor
22
MG.90.F3.02 - VLT is a registered Danfoss trademark
■Ordering form - DMS 300
Decentral Solutions - Design Guide
concept
The decentral
MG.90.F3.02 - VLT is a registered Danfoss trademark
23
Decentral Solutions - Design Guide
■FCD 300 Decentralised Frequency Converter
FCD 300: Combinations of version s
Installation features
Mounting Motor Wall Motor Wall Motor Wall Wall Wall
Cable inlets Right side Double sided
Service switch - - - - X X X -
Sensor plugs - - - - - - 4XM12 4XM12
Motor plug - - - - - - - Harting 10E
ATEX 22
Metric thread
(NPT thread)
Display connector Not available
Functional features
Basic functions
(see below)
+ 24 ext. back up EX
+ 24 ext. back up
+ Dynamic brake +
Brake control
Communication
AS-interface F70
Profibus 3 MB F10
Profibus12 MB F12
DeviceNet F30
*
RS 485 F00
X X X X - - - -
Ordering co des FCD 3xx P T4 P66 R1 XX Dx Fxx Txx C0
T11
(-)
only D0
T51
(-)
T12
(T16)
T52
(T56)
DC DC
ST
EB
T22
(T26)
T62
(T66)
T63
(-)
included
T73
(-)
DC included
* ATEX 22: Approved for use in dusty environments according to the ATEX directive (ATmosphère EXplosive)
Basic functions
Adjustable motor speed
Defined speed ramps - up and down
Features and operation concepts similar
to other VLT series
Electronic motor protection and rev
ersing
are always included
Extended functionality
4 V external back up of control and communication
2
rake control and supply of elect
B
ynamic braking (brake resistor is optional
D
romechanical brake
see brake resistors)
24
MG.90.F3.02 - VLT is a registered Danfoss trademark
Decentral Solutions - Design Guide
The below explanations refer to the ordering form.
P
ower sizes (positions 1-6):
0,37 kW – 3,3 kW (See power size selection table)
A
pplication range (position 7):
• P-process
M
ains voltage (positions 8-9):
• T4 - 380-480 V three phase supply voltage
E
nclosure (positions 10-12):
The enclosure offers protection against dusty,
wet, and aggressive environment
• P66 - Protected IP66 enclosure (exceptions
see Installation box T00, T73)
ardware variant (positions 13-14):
H
• ST - Standard hardware
• EX - 24 V external supply for backup of control card
• EB - 24 V external supply for backup of control
card, control and supply of mechanical brake
and an additional brake chopper
FI filter (positions 15-16):
R
• R1 - Compliance with class A1 filter
nstallation box (positions 22-24):
I
• T00 - No Installation box
• T11 - Installation box, motor mount, metric
thread, only right side
• T12 - Installation box, motor mount, metric
thread, double side
• T16 - Installation box, motor mount, NPT
thread, double side
• T22 - Installation box, motor mount, metric
thread, double side, service switch
• T26 - Installation box, motor mount, NPT
thread, double side, service switch
• T51 - Installation box, wall mount, metric
thread, only right side
• T52 - Installation box, wall mount, metric
thread, double side
• T56 - Installation box, wall mount, NPT
thread, double side
• T62 - Installation box, wall mount, metric
thread, double side, service switch
• T66 - Installation box, wall mount, NPT thread,
double side, service switch
• T63 - Installation box, wall mount, metric thread,
double side, service switch, sensor plugs
• T73 - Installation box, wall mount, metric thread,
double side, motor plug, sensor plugs, Viton gasket
concept
The decentral
D
isplay unit (LCP) (positions 17-18):
Connection possibility for display and keypad
• D0 - No pluggable display connector in the unit
• DC - Display connector plug mounted (not available
with "only right side" installation box variants)
ieldbus option card (positions 19-21):
F
A wide selection of high performance fieldbus
options is available (integrated)
• F00 - No fieldbus option built in
• F10 - Profibus DP V0/V1 3 Mbaud
• F12-ProfibusDPV0/V112Mbaud
• F30 - DeviceNet
• F70 - AS-interface
oating (positions 25-26):
C
The IP66 enclosure offers protection of the drive
against aggressive environments, which practically
eliminates the need for coated printed circuit boards.
• C0 - Non coated boards
MG.90.F3.02 - VLT is a registered Danfoss trademark
25
■Ordering form - FCD 300
Decentral Solutions - Design Guide
26
MG.90.F3.02 - VLT is a registered Danfoss trademark
Decentral Solutions - Design Guide
■PC Software tools
PC Software - MCT 10
All drives are equipped with a serial communication
port. We provide a PC tool for communication
between PC and frequency converter, VLT Motion
Control Tool MCT 10 Set-up Software.
MCT 10 Set-up Software
MCT 10 has been designed as an easy to
use interactive tool for setting parameters in
our frequency converters.
The MCT 10 Set-up Software will be useful for:
• Planning a communication network off-line. MCT 10
contains a complete frequency converter database
• Commissioning frequency converters on line
• Saving settings for all frequency converters
• Replacing a drive in a network
• Expandinganexistingnetwork
• Future developed drives will be supported
MCT10Set-upSoftwaresupportProfibusDP-V1via
a Master class 2 connection. It makes it possible to
on line read/write parameters in a frequency converter
via the Profibus network. This will eliminate the
need for an extra communication network.
The MCT 10 Set-up Software Modules
The following modules are included in the
software package:
MCT10Set-upSoftware
Setting parameters
Copy to and from frequency converters
Documentation and print out of parameter
settings incl. diagrams
SyncPos
Creating SyncPos programme
Ordering number:
Please order your CD containing MCT 10 Set-up
Software using code number 130B10
00.
concept
The decentral
■Accessories for DMS 300 and FCD 300
Type Description Ordering no.
LCP2 control unit FCD LCP2 for programming the frequency converter 175N0131
Cable for LCP2 control unit FCD Cable from LCP2 to frequency converter 175N0162
LCP2 remote-mounting kit FCD Kit for remote-mounting of LCP2 (incl. 3 m cable, excl.
LCP2)
LOP (Local Operation Pad) FCD LOP can be used for setting the reference
and start/stop via the control terminals
Motor adaption plate DMS/FCD Plate for adapting to non Danfoss Bauer motors 175N2115
Membrane DMS/FCD Membrane for preventing condensation 175N2116
Plug kit for LCP2 FCD Plug for LCP2 for mounting in the terminal bo
Motor star terminal DMS/FCD Terminal for interconnection of motor wires (star point) 175N2119
Installation kit FCD Installation kit for mounting in panels 175N2207
M 12 plug FCD E.g. for DeviceNet 175N2279
Viton Gasket FCD 303-315 Painting shop compatible 175N2431
Viton Gasket FCD 322-335 Painting shop compatible 175N2450
Data Cable FCD For PC communication 175N2491
PCB Terminal FCD Terminal for 24 V distribution 175N2550
PE ext. terminal DMS/FCD Stainless steel 175N2703
PE external terminal DMS/FCD Nickel plated brass 175N2704
Motor mounting adaptor 175N2115
Aluminium plate with holes drilled to fit the FCD/DMS
display LCP2 (code DC). The connector can be ordered
separately (Not for single sided installation boxes).
x.
175N0160
175N0128
175N2118
box. Must be fitted locally for the actual motor.
LCP2 keyboard/Display 175N0131 (for
LCP2 connection 175N2118 (for the FCD
300 series)
The installation box can be mounted with or without
the FCD 300 series)
Alfanumeric display for programming the
frequency converter.
a sealed connector (IP66) to connect the common
MG.90.F3.02 - VLT is a registered Danfoss trademark
27
Decentral Solutions - Design Guide
Cable for LCP2 175N0162 (for the FCD 300 series)
Preconfectioned cable to be used between
frequency converter and LCP2.
Data cable for PC communication 175N2491
(for the FCD 300 series)
connects a converter (e.g. USB) to the
LCP2 connector.
5 pole M12 plug for AS-interface 175N2281
The plug, M12, can be mounted into the gland
holes of the installation box.
Viton Gasket for FCD 303-315 175N2431
With this gasket the FCD can be used in painting
shops in e.g. the automotive industry.
Remote mounting kit for LCP2 175N0160
(for the FCD 300 series)
Kit for permanent mounting of the LCP2
in an enclosure.
Venting membrane 175N2116
Membrane preventing water build-up due to
condensation inside enclosures.
Star point terminal 175N2119
Six wires must be either star- or delta-connected
to supply an AC motor. Delta connection is
possible in the standard motor terminal. Star
connection requires a separate terminal.
5 pole M12 plug for e.g. DeviceNet 175N2279
(for the FCD 300 series)
The plug, micro type, M12 can be mounted into the
gland holes of the installation box. The plug can also be
used for other purposes such as connection of sensors.
2m drop cable for DeviceNet 195N3113
(for the FCD 300 series)
The cable can be mounted inside the terminal
box, and connects to the DeviceNet trunk line
via a micro connector (M12).
Viton Gasket for FCD 322-335 175N2450
With this gasket the FCD can be used in painting
shops in e.g. the automotive industry.
■Brake resistors (only for FCD 300)
Internally mountable brake resistors for low duty cycle
braking. The resistors are self-protecting.
Type FCD P motor kW Rmin R Duty cycle approx. % Code no.
303 0.37 520 1720 5 175N2154
305 0.55 405 1720 3 175N2154
307 0.75 331 1720 2 175N2154
311 1.1 243 350 1.5 175N2117
315 1.5 197 350 1 175N2117
322 2.2 140 350 1 175N2117
330 3.0 104 350 0.7 175N2117
335 3.3 104 350 0.5 175N2117
28
Single pulse braking approx. 0,6 kJ each 1-2 minutes.
Internal brake resistors cannot be mounted in
FCD 303-315 with service switch.
MG.90.F3.02 - VLT is a registered Danfoss trademark
Flatpack brake resistors IP 65
Decentral Solutions - Design Guide
Type P
303 (400 V) 0.37 520 830 / 100 W 20 1000 2397
305 (400 V) 0.55 405 830 / 100 W 20 1000 2397
307 (400 V) 0.75 331 620 / 100 W 14 1001 2396
311 (400 V) 1.10 243 430 / 100 W 8 1002 2395
315 (400 V) 1.50 197 310 / 200 W 16 0984 2400
322 (400 V) 2.20 140 210 / 200 W 9 0987 2399
330 (400 V) 3.00 104 150 / 200 W 5.5 0989 2398
335 (400 V) 3.30 104 150 / 200 W 5.5 0989 2398
motor
[kW]
R
MIN
[ ]
Size [ ]/[W]
per item
Duty cycle % 2wires
Order no.
175Uxxxx
Screened cable
Order no.
175Nxxxx
Mounting bracket for brake resistors
Type Order no.
175Nxxxx
303-315 2402
322-335 2401
Coiled wire brake resistors Duty-cycle 40%
VLT type Intermit-
tent braking period
time
[seconds]
303 (400 V) 120 0,37 520 830 0,45 0,7 1976 1,5*
305 (400 V) 120 0,55 405 830 0,45 0,7 1976 1,5*
307 (400 V) 120 0,75 331 620 0,32 0,7 1910 1,5*
311 (400 V) 120 1,1 243 430 0,85 1,4 1911 1,5*
315 (400 V) 120 1,5 197 330 0,85 1,6 1912 1,5*
322 (400 V) 120 2,2 140 220 1,00 2,1 1913 1,5*
330 (400 V) 120 3,0 104 150 1,35 3,0 1914 1,5*
335 (400 V) 120 3,3 104 150 1,35 3,0 1914 1,5*
P
motor
[kW]
R
[ ]
min
R
[ ]
rec
P
b, max
[kW]
Therm.re-
lay
[Amp]
Code
number
175Uxxxx
Cable
cross
section
[mm
concept
The decentral
2
]
*Always observe national and local regulations
P
motor
R
min
R
rec
P
b, max
Therm. relay : Brake current setting of thermal relay
Code number : Order numbers for Danfoss brake resistors
Cable cross section : Recommended m
See dimensions of Coiled wire brake resistors in instructions MI.90.FX.YY
:RatedmotorsizeforVLTtype
: Minimum permissible brake resistor
: Recommended brake resistor (Danfoss)
: Brake resistor rated power as stated by supplier
inimum value based upon PVC insulated cober cable, 30 degree Celsius
ambient temperature with normal heat dissipation
Externally mounted brake resistors in general
No use of aggressive cleaning solvents. Cleaning
solvents must be pH neutral.
See Dynamic braking for dimensioning of
brake resistors.
MG.90.F3.02 - VLT is a registered Danfoss trademark
29
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