Danfoss FCD 302 Design guide

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ENGINEERING TOMORROW

Design Guide

VLT® Decentral Drive FCD 302

www.DanfossDrives.com

Contents Design Guide

Contents

1 Introduction

1.1 How to Read the Design Guide

1.1.1 Additional Resources 6

1.2 Document and Software Version

1.3 Denitions

1.3.1 Frequency Converter 6

1.3.2 Input 7

1.3.3 Motor 7

1.3.4 References 7

1.3.5 Miscellaneous 8

1.4 Safety Precautions

1.5 CE Labeling

1.5.1 Conformity 11

1.5.2 What Is Covered? 12

1.6 Compliance with EMC Directive 2004/1087EC

1.7 Approvals

1.8 Disposal

2 Product Overview and Functions

2.1 Galvanic Isolation (PELV)

2.1.1 PELV - Protective Extra Low Voltage 13

2.1.2 Ground Leakage Current 14

2.2 Control

2.2.1 Control Principle 15

2.2.2 Internal Current Control in VVC+ Mode 16

2.3 Control Structures

2.3.1 Control Structure in VVC+ Advanced Vector Control 16

2.3.2 Control Structure in Flux Sensorless 17

2.3.3 Control Structure in Flux with Motor Feedback 18

2.3.4 Local [Hand On] and Remote [Auto On] Control 19

2.3.5 Programming of Torque Limit and Stop 20

2.4 PID Control

2.4.1 Speed PID Control 21

2.4.2 Parameters Relevant for Speed Control 21

2.4.3 Tuning PID Speed Control 24

2.4.4 Process PID Control 24

2.4.5 Process Control Relevant Parameters 26

Contents

VLT® Decentral Drive FCD 302

2.4.6 Example of Process PID Control 27

2.4.7 Programming Order 28

2.4.8 Process Controller Optimization 30

2.4.9 Ziegler Nichols Tuning Method 30

2.5 Control Cables and Terminals

2.5.1 Control Cable Routing 31

2.5.2 DIP Switches 31

2.5.3 Basic Wiring Example 31

2.5.4 Electrical Installation, Control Cables 32

2.5.5 Relay Output 33

2.6 Handling of Reference

2.6.1 Reference Limits 35

2.6.2 Scaling of Preset References and Bus References 36

2.6.3 Scaling of Analog and Pulse References and Feedback 36

2.6.4 Dead Band Around Zero 37

2.7 Brake Functions

2.7.1 Mechanical Brake 41

2.7.1.1 Mechanical Brake Selection Guide and Electrical Circuit Description 42

2.7.1.2 Mechanical Brake Control 43

2.7.1.3 Mechanical Brake Cabling 45

2.7.1.4 Hoist Mechanical Brake 45

2.7.2 Dynamic Brake 45

2.7.2.1 Brake Resistors 45

2.7.2.2 Selection of Brake Resistor 45

2.7.2.3 Brake Resistors 10 W 46

2.7.2.4 Brake Resistor 40% 46

2.7.2.5 Control with Brake Function 47

2.7.2.6 Brake Resistor Cabling 47

2.8 Safe Torque O

2.9 EMC

2.9.1 General Aspects of EMC Emissions 47

2.9.2 Emission Requirements 49

2.9.3 Immunity Requirements 50

2.9.4 EMC 51

2.9.4.1 EMC-correct Installation 51

2.9.4.2 Use of EMC-correct Cables 53

2.9.4.3 Grounding of Shielded Control Cables 54

2.9.4.4 RFI Switch 55

Contents Design Guide

2.9.5 Mains Supply Interference/Harmonics 55

2.9.5.1 Eect of Harmonics in a Power Distribution System 56

2.9.5.2 Harmonic Limitation Standards and Requirements 56

2.9.5.3 Harmonic Mitigation 57

2.9.5.4 Harmonic Calculation 57

2.9.6 Residual Current Device 57

2.9.7 EMC Test Results 57

3 System Integration

3.1 Ambient Conditions

3.1.1 Air Humidity 58

3.1.2 Aggressive Environments 58

3.1.3 Vibration and Shock 58

3.1.4 Acoustic Noise 58

3.2 Mounting Positions

3.2.1 Mounting Positions for Hygienic Installation 59

3.3 Electrical Input: Mains-side Dynamics

3.3.1 Connections 60

3.3.1.1 Cables General 60

3.3.1.2 Connection to Mains and Grounding 60

3.3.1.3 Relay Connection 61

3.3.2 Fuses and Circuit Breakers 61

3.3.2.1 Fuses 61

3.3.2.2 Recommendations 61

3.3.2.3 CE Compliance 61

3.3.2.4 UL Compliance 61

3.4 Electrical Output: Motor-side Dynamics

3.4.1 Motor Connection 61

3.4.2 Mains Disconnectors 64

3.4.3 Additional Motor Information 64

3.4.3.1 Motor Cable 64

3.4.3.2 Motor Thermal Protection 64

3.4.3.3 Parallel Connection of Motors 65

3.4.3.4 Motor Insulation 65

3.4.3.5 Motor Bearing Currents 65

3.4.4 Extreme Running Conditions 66

3.4.4.1 Motor Thermal Protection 66

3.5 Final Test and Set-up

3.5.1 High-voltage Test 67

Contents

VLT® Decentral Drive FCD 302

3.5.2 Grounding 67

3.5.3 Safety Grounding Connection 67

3.5.4 Final Set-up Check 68

4 Application Examples

4.1 Overview

4.2 AMA

4.2.1 AMA with T27 Connected 69

4.2.2 AMA without T27 Connected 69

4.3 Analog Speed Reference

4.3.1 Voltage Analog Speed Reference 69

4.3.2 Current Analog Speed Reference 70

4.3.3 Speed Reference (Using a Manual Potentiometer) 70

4.3.4 Speed Up/Speed Down 70

4.4 Start/Stop Applications

4.4.1 Start/Stop Command with Safe Torque O 71

4.4.2 Pulse Start/Stop 71

4.4.3 Start/Stop with Reversing and 4 Preset Speeds 72

4.5 Bus and Relay Connection

4.5.1 External Alarm Reset 72

4.5.2 RS485 Network Connection 73

4.5.3 Motor Thermistor 73

4.5.4 Using SLC to Set a Relay 74

4.6 Brake Application

4.6.1 Mechanical Brake Control 74

4.6.2 Hoist Mechanical Brake 75

4.7 Encoder

4.7.1 Encoder Direction 77

4.8 Closed-loop Drive System

4.9 Smart Logic Control

5 Special Conditions

5.1 Manual Derating

5.1.1 Derating for Low Air Pressure 81

5.1.2 Derating for Running at Low Speed 81

5.1.3 Ambient Temperature 82

5.1.3.1 Power Size 0.37–0.75 kW 82

5.1.3.2 Power Size 1.1–1.5 kW 82

5.1.3.3 Power Size 2.2–3.0 kW 83

Contents Design Guide

5.2 Automatic Derating

5.2.1 Sine-Wave Filter Fixed Mode 85

5.2.2 Overview Table 86

5.2.3 High Motor Load 86

5.2.4 High Voltage on the DC link 87

5.2.5 Low Motor Speed 87

5.2.6 High Internal 87

5.2.7 Current 88

5.3 Derating for Running at Low Speed

6 Type Code and Selection Guide

6.1 Type Code Description

6.2 Ordering Numbers

6.2.1 Ordering Numbers: Accessories 90

6.2.2 Ordering Numbers: Spare Parts 91

6.3 Options and Accessories

6.3.1 Fieldbus Options 92

6.3.2 VLT® Encoder Input MCB 102 92

6.3.3 VLT® Resolver Input MCB 103 94

7 Specications

7.1 Mechanical Dimensions

7.2 Electrical Data and Wire Sizes

7.2.1 Overview 98

7.2.2 UL/cUL Approved Pre-fuses 99

7.2.3 VLT® Decentral Drive FCD 302 DC Voltage Levels 99

7.3 General Specications

7.4 Eciency

7.5 dU/dt Conditions

Index

100

105

107

Introduction

VLT® Decentral Drive FCD 302

1 Introduction

1.1 How to Read the Design Guide

The design guide provides information required for integration of the frequency converter in a diversity of applications.

1.1.1 Additional Resources

Decentral Drive FCD 302 Operating Guide, for

VLT

•

information required to install and commission the frequency converter.

VLT® AutomationDrive FC 301/302 Programming

•

Guide, for information about how to program the unit, including complete parameter descriptions.

Modbus RTU Operating Instructions, for the

•

information required for controlling, monitoring, and programming the frequency converter via the built-in Modbus eldbus.

VLT® PROFIBUS Converter MCA 114 Operating

•

Instructions, VLT

Guide, and VLT® PROFINET MCA 120 Installation Guide, for information required for controlling,

monitoring, and programming the frequency converter via a eldbus.

VLT® Encoder Option MCB 102 Installation

•

Instructions.

VLT

•

Technical literature and approvals are available online at

www.danfoss.com/en/search/?lter=type%3Adocumentation %2Csegment%3Adds.

The following symbols are used in this manual:

AutomationDrive FC 300, Resolver Option MCB

103 Installation Instructions.

VLT® AutomationDrive FC 300, Safe PLC Interface Option MCB 108 Installation Instructions.

VLT® Brake Resistor MCE 101 Design Guide.

VLT® Frequency Converters Safe Torque O Operating Guide.

Approvals.

EtherNet/IP MCA 121 Installation

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).

•

Document and Software Version

1.2

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

Edition Remarks Software version

MG04H3xx EMC-correct Installation has been

updated.

Table 1.1 Document and Software Version

Denitions

1.3

1.3.1 Frequency Converter

VLT,MAX

Maximum output current.

VLT,N

Rated output current supplied by the frequency converter.

VLT,MAX

Maximum output voltage.

7.5x

175ZA078.10

Pull-out

RPM

Torque

Introduction Design Guide

1.3.2 Input

Control command

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

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

Group 1 Reset, coast stop, reset and coast stop, quick stop,

DC brake, stop, the [OFF] key.

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

freeze output.

Table 1.2 Function Groups

1.3.3 Motor

M,N

Rated motor voltage (nameplate data).

Break-away torque

1 1

Motor running

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

JOG

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

Motor frequency.

MAX

Maximum motor frequency.

MIN

Minimum motor frequency.

M,N

Rated motor frequency (nameplate data).

Motor current (actual).

M,N

Rated motor current (nameplate data).

M,N

Nominal motor speed (nameplate data).

Synchronous motor speed.

2 × par . 1 − 23 × 60s

ns=

slip

par . 1 − 39

Motor slip.

M,N

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

M,N

Rated torque (motor).

Instant motor voltage.

Figure 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 stop command belonging to Group 1 control commands

- see Table 1.2.

Stop command

A stop command belonging to Group 1 control commands

- see Table 1.2.

1.3.4 References

Analog reference

A signal transmitted to the analog inputs 53 or 54 (voltage or current).

Binary reference

A signal transmitted to 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.

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.

Introduction

VLT® Decentral Drive FCD 302

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.

1.3.5 Miscellaneous

Analog inputs

The analog inputs are used for controlling various functions of the frequency converter. There are 2 types of analog inputs: Current input, 0–20 mA, and 4–20 mA Voltage input, -10 V DC to +10 V DC.

Analog outputs

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

Automatic motor adaptation, AMA

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.

DSP

Digital signal processor.

ETR

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

Hiperface

Hiperface® is a registered trademark by Stegmann.

Initializing

If initializing is carried out (parameter 14-22 Operation Mode), 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 control panel is detachable and can be installed up to 3 m (10 ft) from the frequency converter, that is, in a front panel with the installation kit option.

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.

Online/oine parameters

Changes to online parameters are activated immediately after the data value is changed. Press [OK] to activate changes to o-line parameters.

Process PID

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

PCD

Process control data.

Power cycle

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

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.

RCD

Residual current device.

Set-up

Save parameter settings in 4 set-ups. Change between the 4 parameter set-ups and edit 1 set-up, while another setup is active.

SFAVM

Switching pattern called stator ux-oriented asynchronous vector modulation (parameter 14-00 Switching Pattern).

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.

Introduction Design Guide

1 1

SLC

The SLC (smart logic control) is a sequence of user-dened actions executed when the associated user-dened events are evaluated as true by the SLC. (See chapter 4.9.1 Smart Logic Controller).

STW

Status word.

FC standard bus

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

THD

Total harmonic distortion states the total contribution of harmonic.

Thermistor

A temperature-dependent resistor placed on the frequency converter or the motor.

Trip

A state entered in fault situations, for example if the frequency converter is subject to an overtemperature or when the frequency converter is protecting the motor, process, or mechanism. The frequency converter prevents a restart until the cause of the fault has disappeared. To cancel the trip state, restart the frequency converter. Do not use the trip state for personal safety.

Trip lock

The frequency converter enters this state in fault situations to protect itself. The frequency converter requires physical intervention, for example when there is a short circuit on the output. A trip lock can only be canceled by disconnecting 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 the trip lock state 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 the stability, both when the speed reference is changed and in relation to the load torque.

60° AVM

60° asynchronous vector modulation (parameter 14-00 Switching Pattern).

Power factor

The power factor is the relation between I1 and I

Power factor = 

3xUxI1cosϕ

3xUxI

RMS

The power factor for 3-phase control:

Power factor = 

I1xcosϕ1

RMS

 = 

sincecosϕ1 = 1

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.

I

RMS

= 

 + I

 + I

 + .. + I

In addition, a high-power factor indicates that the dierent harmonic currents are low. The DC coils in the frequency converters produce a highpower factor, which minimizes the imposed load on the mains supply.

Target position

The nal target position specied by positioning commands. The prole generator uses this position to calculate the speed prole.

Commanded position

The actual position reference calculated by the prole generator. The frequency converter uses the commanded position as setpoint for position PI.

Actual position

The actual position from an encoder, or a value that the motor control calculates in open loop. The frequency converter uses the actual position as feedback for position PI.

Position error

Position error is the dierence between the actual position and the commanded position. The position error is the input for the position PI controller.

Position unit

The physical unit for position values.

Introduction

VLT® Decentral Drive FCD 302

1.4 Safety Precautions

WARNING

The voltage of the frequency converter is dangerous whenever connected to mains. Correct planning of the installation of the motor, frequency converter, and eldbus are necessary. Follow the instructions in this manual, and the national and local rules and safety regulations. Failure to follow design recommendations could result in death, serious personal injury, or damage to the equipment once in operation.

WARNING

HIGH VOLTAGE

Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains. In planning, ensure that other voltage inputs can be disconnected, such as external 24 V DC, load sharing (linkage of DC intermediate circuit), and the 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 the valid safety regulations, for example law on mechanical tools, regulations for the prevention of accidents, and so on. Modications on the frequency converters by means of the operating software are allowed. Failure to follow design recommendations, could result in death or serious injury once the equipment is in operation.

NOTICE!

Hazardous situations have to be identied by the machine builder/integrator who is responsible for taking necessary preventive means into consideration. Additional monitoring and protective devices may be included, always according to valid national safety regulations, for example, law on mechanical tools, regulations for the prevention of accidents.

NOTICE!

Crane, lifts, and hoists: The controlling of external brakes must always be designed with a redundant system. The frequency converter can in no circumstances be the primary safety circuit. Comply with relevant standards, for example. Hoists and cranes: IEC 60204-32 Lifts: EN 81

Protection mode

Once a hardware limit on motor current or DC-link voltage is exceeded, the frequency converter enters protection mode. Protection mode means a change of the PWM modulation strategy and a low switching frequency to minimize losses. This continues 10 s after the last fault and increases the reliability and the robustness of the frequency converter while re-establishing full control of the motor. In hoist applications, protection mode is not usable because the frequency converter is usually unable to leave this mode again and therefore it extends the time before activating the brake – which is not recommended. The protection mode can be disabled by setting parameter 14-26 Trip Delay at Inverter Fault to 0 which means that the frequency converter trips immediately if 1 of the hardware limits is exceeded.

NOTICE!

Disable protection mode in hoisting applications (parameter 14-26 Trip Delay at Inverter Fault=0).

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 1.3 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.

Introduction Design Guide

1 1

Voltage [V] Minimum waiting time (minutes)

4 7 15

200–240 0.25–3.7 kW

(0.34–5 hp)

380–500 0.25–7.5 kW

(0.34–10 hp)

525–600 0.75–7.5 kW

(1–10 hp)

525–690 – 1.5–7.5 kW

Table 1.3 Discharge Time

– 5.5–37 kW

(7.5–50 hp)

– 11–75 kW

(15–100 hp)

– 11–75 kW

(15–100 hp)

(2–10 hp)

(15–100 hp)

11–75 kW

1.5 CE Labeling

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

However, CE labeling may cover many cations. Check what a given CE label specically covers.

The specications can vary greatly. A CE label may therefore give the installer a false sense of security when using a frequency converter as a component in a system or an appliance.

Danfoss CE labels the frequency converters in accordance with the Low Voltage Directive. This means that if the frequency converter is installed correctly, compliance with the Low Voltage Directive is achieved. Danfoss issues a declaration of conformity that conrms CE labeling in accordance with the Low Voltage Directive.

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

dierent speci-

ltering are

What is CE conformity and labeling?

The purpose of CE labeling is to avoid technical trade obstacles within EFTA and the EU. The EU has introduced the CE label as a simple way of showing whether a product complies with the relevant EU directives. The CE label says nothing about the specications or quality of the product. Frequency converters are regulated by 2 EU directives:

The Low Voltage Directive (2014/35/EU)

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

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

The EMC Directive (2014/30/EU)

The purpose of the EMC (electromagnetic compatibility) Directive is to reduce electromagnetic interference and enhance immunity of electrical equipment and installations. The basic protection requirement of the EMC Directive is that devices that generate electromagnetic interference (EMI), or whose operation could be aected by EMI, must be designed to limit the generation of electromagnetic interference. The devices must have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

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

The frequency converter is most often used by professionals of the trade as a complex component forming part of a larger appliance, system, or installation.

The design guide oers detailed instructions for installation to ensure EMC-correct installation.

1.5.1 Conformity

The Machinery Directive (2006/42/EC)

Frequency converters do not fall under the machinery directive. However, if a frequency converter is supplied for use in a machine, Danfoss provides information on safety aspects relating to the frequency converter.

Introduction

VLT® Decentral Drive FCD 302

1.5.2 What Is Covered?

The EU EMC Directive 2014/30/EU outline 3 typical situations of using a frequency converter. See below for EMC coverage and CE labeling.

The frequency converter is sold directly to the

•

end user. The frequency converter is for example sold to a do-it-yourself market. The end user is a layman, installing the frequency converter for use with a hobby machine, a kitchen appliance, and so on. For such applications, the frequency converter must be CE labeled in accordance with the EMC directive.

The frequency converter is sold for installation in

•

a plant. The plant is built up by professionals of the trade. It could be a production plant or a heating/ventilation plant designed and installed by professionals of the trade. The frequency converter and the nished plant do not have to be CE labeled under the EMC directive. However, the unit must comply with the basic EMC requirements of the directive. This is ensured by using components, appliances, and systems that are CE labeled under the EMC directive.

The frequency converter is sold as part of a

•

complete system. The system is marketed as complete, for example an air-conditioning system. The complete system must be CE labeled in accordance with the EMC directive. The manufacturer can ensure CE labeling under the EMC directive either by using CE labeled components or by testing the EMC of the system. If only CE labeled components are used, it is unnecessary to test the entire system.

Approvals

1.7

Table 1.4 FCD 302 Approvals

The frequency converter complies with UL 508C thermal memory retention requirements. For more information, refer to chapter 3.4.3.2 Motor Thermal Protection.

1.8 Disposal

Equipment containing electrical

components may not be disposed of

together with domestic waste.

It must be separately collected with

electrical and electronic waste according

to local and currently valid legislation.

Table 1.5 Disposal Instruction

Compliance with EMC Directive

1.6 2004/1087EC

The frequency converter is mostly used by professionals of the trade as a complex component forming part of a larger appliance, system, or installation.

NOTICE!

The responsibility for the nal EMC properties of the appliance, system, or installation rests with the installer.

As an aid to the installer, Danfoss has prepared EMC installation guidelines for the power drive system. The standards and test levels stated for power drive systems are complied with, if the EMC-correct instructions for installation are followed, see chapter 2.9.4 EMC.

130BC963.10

130BC964.10

130BC968.11

1325 4

Product Overview and Functi... Design Guide

2 Product Overview and Functions

Figure 2.1 Small Unit

2 2

relevant creepage/clearance distances. These requirements are described in the EN 61800-5-1 standard.

The components that make up the electrical isolation, as described in Figure 2.3, 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 6 locations (see Figure 2.3).

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

1 Power supply (SMPS) including signal isolation of UDC,

indicating the voltage of intermediate DC Link circuit.

2 Gate drive that runs the IGBTs (trigger transformers/opto-

Figure 2.2 Large Unit

2.1 Galvanic Isolation (PELV)

2.1.1 PELV - Protective Extra Low Voltage

PELV oers protection by way of extra low voltage. Protection against electric shock is ensured when the electrical supply is of the PELV type and the installation is

couplers).

3 Current transducers.

4 Opto-coupler, brake module.

5 Internal inrush, RFI, and temperature measurement circuits.

6 Custom relays.

7 Mechanical brake.

8 Functional galvanic isolation for the 24 V back-up option

and for the RS485 standard bus interface.

9 Functional galvanic isolation for the 24 V back-up option

and for the RS485 standard bus interface.

made as described in local/national regulations on PELV supplies.

Figure 2.3 Galvanic Isolation

All control terminals and relay terminals 01–03/04–06 comply with PELV (protective extra low voltage), except for grounded delta leg above 400 V.

Galvanic (ensured) isolation is obtained by fullling

NOTICE!

Installation at high altitude: 380–500 V: At altitudes above 2000 m (6561 ft), contact Danfoss regarding PELV.

requirements for higher isolation and by providing the

130BB957.11

Leakage current [mA]

100 Hz

2 kHz

100 kHz

Product Overview and Functi...

VLT® Decentral Drive FCD 302

2.1.2 Ground Leakage Current

Follow national and local codes regarding protective 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 leakage current also depends on the line distortion.

NOTICE!

When a lter is used, turn o parameter 14-50 RFI Filter when charging the lter, to avoid that a high leakage current makes the RCD switch.

EN/IEC61800-5-1 (power drive system product standard) requires special care if the leakage current exceeds 3.5 mA. Grounding must be reinforced in 1 of the following ways:

Figure 2.4 Inuence of Cut-o Frequency of the RCD

Ground wire (terminal 95) of at least 10 mm

•

(7 AWG). This requires a PE adapter (available as an option).

Two separate ground wires both complying with

•

the dimensioning rules.

See EN/IEC61800-5-1 and EN 50178 for further information.

Using RCDs

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

Use RCDs of type B, which are capable of

•

detecting AC and DC currents.

Use RCDs with an inrush delay to prevent faults

•

due to transient ground currents.

Dimension RCDs according to the system

•

ration and environmental considerations.

congu-

See also RCD Application Note.

Control

2.2

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

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

The VLT® Decentral Drive FCD 302 frequency converter is designed for installations of multiple smaller frequency converters, especially on conveyor applications, for example, in the food and beverage industries and materials handling. In installations where multiple motors are spread around a facility such as bottling plants, food preparation, packaging plants, and airport baggage handling installations, there may be dozens, perhaps hundreds, of frequency converters, working together but spread over a large physical area. In these cases, cabling costs alone outweigh the cost of the individual frequency converters and it makes sense to get the control closer to the motors.

The frequency converter can control either the speed or the torque on the motor shaft.

R+ 82

R81

Brake Resistor

U 96

V 97

W 98

InrushR inr

P 14-50

L1 91

L2 92

L3 93

130BC965.10

Product Overview and Functi... Design Guide

Speed control

Two 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 speed closed-loop control is more accurate than a speed open-loop control.

Torque control

The torque control function is used in applications where the torque on motor output shaft controls the application as tension control.

Closed loop in ux mode with encoder feedback

•

comprises motor control based on feedback signals from the system. It improves performance in all 4 quadrants and at all motor speeds.

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

•

mechanical robust applications, but the accuracy is limited. Open-loop torque function works only

in 1 speed direction. The torque is calculated on basis of current measurement internal in the frequency converter. See application example

chapter 2.3.1 Control Structure in VVC+ Advanced Vector Control.

Speed/torque reference

The reference to these controls can either be a single reference or be the sum of various references including relatively scaled references. The handling of references is explained in detail in chapter 2.6 Handling of Reference.

2 2

2.2.1 Control Principle

The frequency converter is compatible with various motor control principles such as U/f special motor mode, VVC+, or ux vector motor control. In addition, the frequency converter is operable with permanent magnet synchronous motors (brushless servo motors) and normal squirrel lift cabin asynchronous motors. The short circuit behavior depends on the 3 current transducers in the motor phases and the desaturation protection with feedback from the brake.

Figure 2.5 Control Principle



Cong. mode

Ref.

Process

P 1-00

High

+f max.

Low

-f max.

P 4-11 Motor speed low limit (RPM)

P 4-12 Motor speed low limit (Hz)

P 4-13 Motor speed high limit (RPM)

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*

130BA055.10

Product Overview and Functi...

2.2.2

Internal Current Control in VVC+ Mode

VLT® Decentral Drive FCD 302

The frequency converter features an integral current limit control which 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, it reduces torque to below the preset torque limits as quickly as possible without losing control of the motor.

2.3 Control Structures

2.3.1

Control Structure in VVC+ Advanced Vector Control

Figure 2.6 Control Structure in VVC+ Open-loop and Closed-loop Congurations

In the conguration shown in Figure 2.6, parameter 1-01 Motor Control Principle is set to [1] VVC+ and parameter 1-00 Congu- ration 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 and speed limitation into a speed PID control. The speed PID control parameters are in the 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, for example, speed or pressure in the controlled application. The process PID parameters are in parameter group 7-2* Process Ctrl. Feedb and parameter group 7-3* Process PID Ctrl.

Conguration Mode is set to [1] Speed closed loop, the resulting reference passes from the ramp limitation



130BA053.11

Ref.

Cong. mode

P 1-00

P 7-20 Process feedback 1 source

P 7-22 Process feedback 2 source

Process PID

P 4-11 Motor speed low limit [RPM]

P 4-12 Motor speed low limit [Hz]

P 4-14 Motor speed high limit [Hz]

P 4-13 Motor speed high limit [RPM]

Low

High

Ramp

P 3-**

+f max.

P 4-19 Max. output freq.

Motor

controller

-f max.

Speed PID

P 7-0*

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2.3.2 Control Structure in Flux Sensorless

Control structure in ux sensorless open-loop and closed-loop congurations.

2 2

Figure 2.7 Control Structure in Flux Sensorless

In the conguration shown, parameter 1-01 Motor Control Principle is set to [2] Flux Sensorless and parameter 1-00 Congu- ration Mode is set to [0] Speed open loop. The resulting reference from the reference handling system is fed through the

ramp and speed limitations as determined by the parameter settings indicated.

An estimated speed feedback is generated to the speed PID to control the output frequency. The speed PID must be set with its P, I, and D parameters (parameter group 7-0* Speed PID Ctrl.).

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 group 7-2* Process Ctrl. Feedb. and parameter group7-3* Process PID Ctrl.

130BA054.11

P 3-** P 7-0*P 7-2*

P 7-20 Process feedback 1 source P 7-22 Process feedback 2 source

P 4-11 Motor speed low limit (RPM) P 4-12 Motor speed low limit (Hz)

P 4-13 Motor speed high limit (RPM) P 4-14 Motor speed high limit (Hz)

High

Low

Ref.

Process

PID

Speed

PID

Ramp

P 7-00 PID source

Motor controller

-f max.

+f max.

P 4-19 Max. output freq.

P 1-00 Cong. mode

Torque

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VLT® Decentral Drive FCD 302

2.3.3 Control Structure in Flux with Motor Feedback

Figure 2.8 Control Structure in Flux with Motor Feedback

In the conguration shown, parameter 1-01 Motor Control Principle is set to [3] Flux w motor feedb and parameter 1-00 Cong- uration Mode is set to [1] Speed closed loop.

The motor control in this conguration relies on a feedback signal from an encoder mounted directly on the motor (set in parameter 1-02 Flux Motor Feedback Source).

Select [1] Speed closed loop in parameter 1-00 Conguration Mode to use the resulting reference as an input for the speed PID control. The speed PID control parameters are located in parameter group 7-0* Speed PID Ctrl.

Select [2] Torque in parameter 1-00 Conguration Mode to use the resulting reference directly as a torque reference. Torque control can only be selected in the [3] Flux with motor feedback (parameter 1-01 Motor Control Principle) conguration. When this mode has been selected, the reference uses the Nm unit. It requires no torque feedback, since the actual torque is calculated based on the current measurement of the frequency converter.

Select [3] Process in parameter 1-00

Conguration Mode to use the process PID control for closed-loop control of a process

variable (for example, speed) in the controlled application.

130BP046.10

Hand

O

Auto

Reset

Remote reference

Local reference

(Auto On)

(Hand On)

Linked to hand/auto

Local

Remote

Reference

130BA245.12

LCP keys: (Hand On), (O), and (Auto On)

P 3-13 Reference Site

Product Overview and Functi... Design Guide

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

The frequency converter can be operated manually via the local control panel (LCP) or remotely via analog and digital inputs and eldbus. If allowed in parameter 0-40 [Hand on]

Key on LCP, parameter 0-41 [O] Key on LCP, parameter 0-42 [Auto on] Key on LCP, and parameter 0-43 [Reset] Key on LCP, it is possible to start and

stop the frequency converter via the LCP using the [Hand On] and [O] keys. Alarms can be reset via the [Reset] key. After pressing the [Hand On] key, the frequency converter goes into hand-on mode and follows (as default) the local reference that can be set using the navigation keys on the LCP.

After pressing the [Auto On] key, the frequency converter goes into auto-on mode and follows (as default) the remote reference. In this mode, it is possible to control the frequency converter via the digital inputs and various serial interfaces (RS485, USB, or an optional about starting, stopping, changing ramps, parameter setups, and so on, in parameter group 5-1* Digital Inputs or parameter group 8-5* Digital/Bus.

eldbus). See more

Active reference and conguration mode

The active reference can be either the local reference or the remote reference.

In parameter 3-13 Reference Site, the local reference can be permanently selected by selecting [2] Local. For permanent setting of the remote reference, select [1] Remote. By selecting [0] Linked to Hand/Auto (default), the reference site links to the active mode (hand-on mode or auto-on Mode).

Figure 2.10 Local Handling of Reference

2 2

Figure 2.9 LCP Keys

Figure 2.11 Remote Handling of Reference

130BC997.10

P 5-40 [0] [32]

01 02 03

24 VDC

I max

0.1 Amp

2 3

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VLT® Decentral Drive FCD 302

LCP keys Parameter 3-13 Reference Site Active reference

Hand Linked to Hand/Auto Local

Hand⇒O

Auto Linked to Hand/Auto Remote

Auto⇒O Linked to Hand/Auto Remote

All keys Local Local

All keys Remote Remote

Table 2.1 Conditions for Local/Remote Handling of Reference

Parameter 1-00

Linked to Hand/Auto Local

Conguration Mode determines what type

Parameter 5-02 Terminal 29 Mode [1] Terminal 29 Mode Output Parameter 5-31 Terminal 29 digital Output [27] Torque Limit & Stop

[0] Relay output (relay 1)

•

Parameter 5-40 Function Relay [32] Mechanical Brake Control

of application control principle (that is, speed, torque, or process control) is used when the remote reference is active. Parameter 1-05 Local Mode Conguration determines the type of application control principle that is used when the local reference is active. One of them is always active, but both cannot be active at the same time.

2.3.5 Programming of Torque Limit and Stop

In applications with an external electro-mechanical brake, such as hoisting applications, it is possible to stop the frequency converter via a standard stop command and simultaneously activate the external electro-mechanical brake. The example given below, illustrates the programming of the frequency converter connections. The external brake can be connected to relay 1 or 2. Program parameter 5-01 Terminal 27 Mode to [2] Coast,

inverse or [3] Coast and Reset, inverse, and program parameter 5-02 Terminal 29 Mode to [1] Output and [27] Torque limit & stop.

Item Description

1 External 24 V DC

2 Mechanical brake connection

3 Relay 1

Figure 2.12 Mechanical Brake Control

Description

If a stop command is active via terminal 18, and the frequency converter is not at the torque limit, the motor ramps down to 0 Hz. If the frequency converter is at the torque limit and a stop command is activated, parameter 5-31 Terminal 29 digital Output (programmed to [27] torque limit and stop) is activated. The signal to terminal 27 changes from logic 1 to logic 0, and the motor starts to coast. The coast ensures that the hoist stops even if the frequency converter itself cannot handle the required torque (that is, due to excessive overload).

Start/stop via terminal 18

•

Parameter 5-10 Terminal 18 Digital Input [8] Start

Quick stop via terminal 27

Parameter 5-12 Terminal 27 Digital Input [2] Coast Stop, inverse

Terminal 29 output

Product Overview and Functi... Design Guide

2.4 PID Control

2.4.1 Speed PID Control

2 2

Parameter 1-00 Congu-

ration Mode

[0] Speed open loop

[1] Speed closed loop – Active – Active

[2] Torque – – –

[3] Process –

Table 2.2 Control Congurations where the Speed Control is Active

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

Parameter 1-01 Motor Control Principle

U/f

Not active

VVC

Not active

Flux sensorless Flux w/ encoder feedback

Active –

Not active

Active Active

NOTICE!

The speed PID control works under the default parameter setting, but tuning the parameters is highly recommended to optimize the motor control performance. The 2 ux motor control principles are particularly dependent on proper tuning to yield their full potential.

2.4.2 Parameters Relevant for Speed Control

Parameter Description of function

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

Parameter 30-83 Speed PID Proportional Gain The higher the value - the quicker the control. However, too high value may lead to

oscillations.

Parameter 7-03 Speed PID Integral Time Eliminates steady state speed error. Lower value means quick reaction. However, too low

value may lead to oscillations.

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

the dierentiator.

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

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.

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

state performance. However, too large 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 Time

512 10 ms

1024 5 ms

2048 2 ms

4096 1 ms

Table 2.3 Parameters Relevant for Speed Control

96 97 9998

91 92 93 95

L1 L2L1PEL3

W PEVU

20 32 33

24 Vdc

130BA174.10

Product Overview and Functi...

VLT® Decentral Drive FCD 302

Example of how to program the speed control

In this case, 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. Starting and stopping is controlled by a switch connected to terminal 18. 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.

Figure 2.13 Example - Speed Control Connections

The following must be programmed in the order shown (see explanation of settings in the 301/FC 302 Programming Guide)

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

Function Parameter Setting

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

Set the motor parameters using nameplate data. Parameter group 1-2*

Motor Data

Perform an automatic motor adaptation. Parameter 1-29 Auto

matic Motor

Adaptation (AMA)

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

Press the [Hand On] LCP key. Check that the motor is

– Set a positive reference.

running and note in which direction it is turning

(referred to as the positive direction).

Go to parameter 16-20 Motor Angle. Turn the motor

slowly in the positive direction. It must be turned so

slowly (only a few RPM) that it can be determined if the

value in parameter 16-20 Motor Angle is increasing or

decreasing.

Parameter 16-20 Moto

r Angle

As specied on motor nameplate.

[1] Enable complete AMA.

(Read-only parameter) Note: An increasing value

overows at 65535 and starts again at 0.

VLT® AutomationDrive FC

Product Overview and Functi... Design Guide

Function Parameter Setting

If parameter 16-20 Motor Angle is decreasing, then

change the encoder direction in parameter 5-71 Term

32/33 Encoder Direction.

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

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

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 4-11 Motor

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

Activation of speed control. Parameter 1-00 Cong

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 Refere

Scale analog input 53 from 0 RPM (0 V ) to 1500 RPM

(10 V).

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 Termi

Select terminal 32/33 as motor feedback. Parameter 1-02 Flux

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

7) Tune the speed control PID parameters.

Use the tuning guidelines when relevant or tune

manually.

8) Finished.

Save the parameter setting to the LCP for safe keeping. Parameter 0-50 LCP

Parameter 5-71 Term

32/33 Encoder

Direction

um Reference

Parameter 3-03 Maxi

mum Reference

Parameter 3-41 Ramp

1 Ramp-up Time

Parameter 3-42 Ramp

1 Ramp-down Time

Speed Low Limit

[RPM]

Parameter 4-13 Motor

Speed High Limit

[RPM]

Parameter 4-19 Max

Output Frequency

uration Mode

Control Principle

nce Resource 1

Parameter group 6-1*

Analog Input 1

nal 32 Digital Input

Parameter 5-15 Termi

nal 33 Digital Input

Motor Feedback

Source

PID Feedback Source

Parameter group 7-0*

Speed PID Ctrl.

Copy

[1] Counterclockwise (if parameter 16-20 Motor Angle is

decreasing).

0 RPM (default).

1500 RPM (default).

Default setting.

0 RPM (default).

1500 RPM (default).

60 Hz (default 132 Hz).

[1] Speed closed loop.

[3] Flux w motor feedb.

Not necessary (default).

[0] No operation (default).

Not necessary (default).

See the guidelines in chapter 2.4.3 Tuning PID Speed

Control.

[1] All to LCP.

2 2

Table 2.4 Speed Control Settings

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VLT® Decentral Drive FCD 302

2.4.3 Tuning PID Speed Control

The following tuning guidelines are relevant when using 1 of the ux motor control principles in applications where the load is mainly inertial (with a low amount of friction).

The value of parameter 30-83 Speed PID Proportional Gain depends on the combined inertia of the motor and load, and the selected bandwidth can be calculated using the following formula:

Par . 7 − 02 =

Totalinertia k gm2xpar . 1 − 25



Par . 1 − 20x 9550

xBandwidth

NOTICE!

Parameter 1-20 Motor Power [kW] is the motor power in

[kW] (that is, enter 4 kW instead of 4000 W in the formula).

A practical value for the bandwidth is 20 rad/s. Check the result of the Parameter 30-83 Speed PID Proportional Gain calculation against the following formula (not required when using high-resolution feedback such as a SinCos feedback):

rad/ s

other factors in the application might limit the parameter 30-83 Speed PID Proportional Gain to a lower value.

To minimize the overshoot, parameter 7-03 Speed PID Integral Time could be set to approximately 2.5 s (varies with the application).

Parameter 7-04 Speed PID

to 0 until everything else is tuned. If necessary, nish the tuning by experimenting with small increments of this setting.

Dierentiation Time should be set

2.4.4 Process PID Control

The process PID Control can be used to control application parameters that can be measured by a sensor (that is, pressure, temperature, ow) and be aected by the connected motor through a pump, fan, or otherwise.

Table 2.5 shows the control congurations where the process control is possible. When a ux vector motor control principle is used, take care also to tune the speed control PID parameters. To see where the speed control is active, refer to chapter 2.3 Control Structures.

Par . 7 − 02

0 . 01x4xEncoderResolutionxPar . 7 − 06



xMaxtorqueripple %

A good start value for parameter 7-06 Speed PID Lowpass Filter Time is 5 ms (lower encoder resolution calls for a

higher lter value). Typically, a maximum torque ripple of 3% is acceptable. For incremental encoders, the encoder resolution is found in either parameter 5-70 Term 32/33 Pulses per Revolution (24 V HTL on standard frequency converter) or parameter 17-11 Resolution (PPR) (5 V TTL on

VLT® Encoder Input MCB 102 option).

Generally, the practical maximum limit of parameter 30-83 Speed PID Proportional Gain is determined by the encoder resolution and the feedback lter time. But

MAX

2xπ



Parameter 1-00

Conguration

Mode

[3] Process – Process Process

Table 2.5 Process PID Control Settings

Parameter 1-01 Motor Control Principle

U/f

VVC

Flux

sensorles

& speed

Flux with

encoder

feedback

Process &

speed

NOTICE!

The process PID control works under the default parameter setting, but tuning the parameters is highly recommended to optimize the application control performance. The 2 ux motor control principles are specially dependent on proper speed control PID tuning (before tuning the process control PID) to yield their full potential.

Product Overview and Functi... Design Guide

Figure 2.14 Process PID Control Diagram

2 2

Product Overview and Functi...

VLT® Decentral Drive FCD 302

2.4.5 Process Control Relevant Parameters

Parameter Description of function

Parameter 7-20 Process CL Feedback 1 Resource Select from which source (that is, analog or pulse input) the process PID should get its

feedback.

Parameter 7-22 Process CL Feedback 2 Resource Optional: Determine if (and from where) the process PID should get 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-wind-up function ensures that when either a frequency limit or a torque limit is

Parameter 7-32 Process PID Controller Start

Value

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

Parameter 7-34 Process PID Integral Time Eliminates steady state speed error. Lower value means quick reaction. However, too small

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

Parameter 7-36 Process PID Dierentiation Gain

Limit

Parameter 7-38 Process PID Feed Forward

Factor

Parameter 5-54 Pulse Filter Time Constant #29

(Pulse term. 29), parameter 5-59 Pulse Filter

Time Constant #33 (Pulse term. 33),

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 getting lower than the reference. In the same situation, but 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 in any case be compensated for with a speed

change. This function can be disabled by selecting [0] O.

In some applications, reaching the required speed/set point can take long time. In such

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

converter before the process control is activated. This is done by setting a process PID

start value (speed) in parameter 7-32 Process PID Controller Start Value.

oscillations.

value may lead to oscillations.

the dierentiator.

If there are quick changes in reference or feedback in a given application - which means

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, the feed

forward factor can be used to achieve better dynamic performance of the process PID

control.

If there are oscillations of the current/voltage feedback signal, these can be dampened

with a low-pass lter. This time constant shows the speed limit of the ripples occurring on

the feedback signal.

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 all currents/

voltages that vary by more than 1.6 oscillations per second are dampened by the lter.

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 large lter time

deteriorates the dynamic performance of the process PID control.

Table 2.6 Parameters are Relevant for the Process Control

130BC966.10

100kW

n °CW

WARNING

ALARM

Bus MS NS2NS1

Product Overview and Functi... Design Guide

2.4.6 Example of Process PID Control

Figure 2.15 is an example of a process PID control used in a ventilation system.

Item Description

1 Cold air

2 Heat generating process

3 Temperature transmitter

4 Temperature

5 Fan speed

6 Heat

2 2

Figure 2.16 Two-wire Transmitter

Figure 2.15 Process PID Control in Ventilation System

1. Start/stop via a switch connected to terminal 18.

In a ventilation system, the temperature is to be settable from -5 to +35 °C (23–95 °F) with a potentiometer of 0– 10 V. The task of the process control is to maintain temperature at a constant preset level.

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

The control is of the inverse type, which means that when the temperature increases, the ventilation speed is

terminal 54. Switch S202 set to ON (current input).

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. Minimum/maximum speed 300/1500 RPM.

Product Overview and Functi...

VLT® Decentral Drive FCD 302

2.4.7 Programming Order

Function Parameter Setting

Initialize the frequency converter. Parameter 14-22

Operation Mode

1) Set motor parameters.

Set the motor parameters according to nameplate

data.

Perform a full AMA. Parameter 1-29 Au

2) Check that motor is running in the right 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] LCP key. Check shaft direction by applying a manual reference.

If the motor turns opposite of the required

direction:

1. Change motor direction in

parameter 4-10 Motor Speed Direction.

2. Turn o mains - wait for DC link to discharge -

switch 2 of the motor phases.

Set conguration mode. Parameter 1-00 Co

Set local mode conguration Parameter 1-05 Lo

3) Set reference conguration, that is, the range for handling of reference. 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 set value is determined from a preset value

(array parameter), set other reference sources to

no function.

4) Adjust limits for the frequency converter:

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

Parameter group

1-2* Motor Data

tomatic Motor

Adaptation (AMA)

Parameter 4-10 M

otor Speed

Direction

nguration Mode

cal Mode Congu-

ration

Parameter 3-01 Re

ference/Feedback

Unit

Parameter 3-02 Mi

nimum Reference

Parameter 3-03 M

aximum Reference

Parameter 3-10 Pr

eset Reference

mp 1 Ramp-up

Time

Parameter 3-42 Ra

mp 1 Ramp- down

Time

[2] Initialization - make a power-cycle - press reset.

As stated on motor nameplate.

[1] Enable complete AMA.

Select correct motor shaft direction.

[3] Process.

[0] Speed Open Loop.

[60] °C Unit shown on display.

-5 °C.

35 °C.

[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.

100

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

Product Overview and Functi... Design Guide

Function Parameter Setting

Set minimum speed limits.

•

Set motor speed maximum limit.

•

Set maximum output frequency.

•

Set S201 or S202 to wanted analog input function (Voltage (V) or milliamps (I))

Parameter 4-11 M

otor Speed Low

Limit [RPM]

Parameter 4-13 M

otor Speed High

Limit [RPM]

Parameter 4-19 M

ax Output

Frequency

300 RPM.

1500 RPM.

60 Hz.

NOTICE!

Switches are sensitive - Make a power-cycle keeping the default setting of V.

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 Pr

Process PID anti-wind-up. Parameter 7-31 Pr

Process PID start speed. Parameter 7-32 Pr

Save parameters to LCP. Parameter 0-50 LC

Parameter 6-10 Te

rminal 53 Low

Voltage

Parameter 6-11 Te

rminal 53 High

Voltage

Parameter 6-24 Te

rminal 54 Low

Ref./Feedb. Value

Parameter 6-25 Te

rminal 54 High

Ref./Feedb. Value

Parameter 7-20 Pr

ocess CL Feedback

1 Resource

ocess PID Normal/

Inverse Control

ocess PID Anti

Windup

ocess PID

Controller Start

Value

P Copy

0 V.

10 V.

-5 °C.

35 °C.

[2] Analog input 54.

[0] Normal.

[1] On.

300 RPM.

[1] All to LCP.

2 2

Table 2.7 Example of Process PID Control Set-up

130BA183.10

y(t)

Product Overview and Functi...

VLT® Decentral Drive FCD 302

2.4.8 Process Controller Optimization

2.4.9 Ziegler Nichols Tuning Method

The basic settings have now been made. All that needs to be done is to 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, parameter 7-35 Process PID Dierentiation Time). In most

processes, this can be done by following these guidelines:

1. Start the motor.

2. Set parameter 7-33 Process PID Proportional Gain to 0.3 and increase it until the feedback signal again begins to vary continuously. Then reduce the value until the feedback signal has stabilized. Now 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

Time for very fast-acting systems only (dieren- tiation time). The typical value is 4 times the set

integration time. The dierentiator should only be used when the setting of the proportional gain and the integration time has been fully optimized. Make sure that oscillations on the feedback signal are suciently dampened by the lowpass lter on the feedback signal.

Dierentiation

NOTICE!

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

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

NOTICE!

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 Figure 2.17 and should be measured when the amplitude of oscillation is small.

1. Select only proportional control, meaning that the integral time is set to the maximum value, 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 2.8 to calculate the necessary PID control parameters.

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

Figure 2.17 Marginally Stable System

Speed

Coast inverse (27)

Coast inverse

Safe

torque off

130BC985.10

NVR B03B04P B02 B01

2012G B07B0820 B06 B05

372013 B11B1237 B10 B09

1212

121212 55 53

271918

3229 50 54

202020 202020 55 42

Product Overview and Functi... Design Guide

Type of

control

PI-control 0.45 x K

PID tight

control

PID some

overshoot

Table 2.8 Ziegler Nichols Tuning for Regulator

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

–

2.5 Control Cables and Terminals

2.5.1 Control Cable Routing

A 24 V DC external supply can be used as low voltage supply to the control card and any option cards installed. This enables full operation of the LCP (including parameter setting) without connection to mains.

NOTICE!

A warning of low voltage is given when 24 V DC has been connected; however, there is no tripping.

Default settings: 27 = [2] Coast inverse parameter 5-10 Terminal 18 Digital

Input

37 = Safe Torque O inverse

2 2

WARNING

ELECTRICAL SHOCK HAZARD

Without galvanic isolation (type PELV), the control terminals impose an electrical shock hazard. Failure to follow the recommendations, may lead to death or serious injury.

Use 24 V DC supply of type PELV to ensure

•

correct galvanic isolation (type PELV).

2.5.2 DIP Switches

2.5.3 Basic Wiring Example

Connect terminals 27 and 37 to +24 V terminals 12 and 13, as shown in Figure 2.18.

Figure 2.18 Basic Wiring Example

130BC384.10

3-phase power input

Mechanical brake

+10 V DC

-10 V DC+10 V DC 0/4-20 mA

91 (L1) 92 (L2) 93 (L3) 95 (PE)

122(MBR+)

123(MBR-)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

12 (+24 V OUT)

13 (+24 V OUT)

18 (D IN)

19 (D IN)

20 (COM D IN)

27 (D IN/OUT)

29 (D IN/OUT)

24V

32 (D IN)

33 (D IN)

37 (D IN)

S201

S202

ON/I=0-20mA OFF/U=0-10V

P 5-00

24 V (NPN) 0 V (PNP)

Switch mode

power supply

10 V DC

15 mA

24 V DC 600 mA

(U) 96

(U) 97 (W) 98 (PE) 99

Motor

Brake resistor

(R+) 82

(R-) 81

Relay1

Relay2

240 V AC, 2A

400 V AC, 2A

Analog output 0/4–20 mA

(COM A OUT) 39

(A OT) 42

ON=Terminated OFF=Open

S801

(N RS485) 69

(P RS485) 68

RS485 Interface

(COM RS485) 61

(PNP) = Source (NPN) = Sink

RS485

1 2

0 V

VCXA

PROFIBUS interface

GND1

RS485

Product Overview and Functi...

VLT® Decentral Drive FCD 302

2.5.4 Electrical Installation, Control Cables

Figure 2.19 Electrical Terminals without Options

A = analog, D = digital Terminal 37 is used for Safe Torque O. Relay 2 has no function when the frequency converter has mechanical brake output.

130BC987.10

Safe

torque off

Safe

torque off

PNP (Source) Digital input wiring

NPN (Sink) Digital input wiring

NVR B03B04P B02 B01

2012G B07B0820 B06 B05

372013 B11B1237 B10 B09

1212

121212 55 53

271918 333229 50 54

202020 202020 55 42

NVR B03B04P B02 B01

2012G B07B0820 B06 B05

372013 B11B1237 B10 B09

1212

121212 55 53

271918

3229 50 54

202020 202020 55 42

+5V

GND

+24V

GND

130BC998.10

Product Overview and Functi... Design Guide

Long control cables and analog signals may in rare cases result in 50/60 Hz ground loops due to noise from mains supply cables. If this occurs, it may be necessary to break the shield or insert a 100 nF capacitor between shield and chassis. Connect the digital and analog inputs and outputs separately to the common inputs (terminal 20, 55, 39) to avoid ground currents from both groups aecting other groups. For example, switching on the digital input may disturb the analog input signal.

2.5.5 Relay Output

The relay output with the terminals 01, 02, 03 and 04, 05, 06 has a capacity of maximum 240 V AC, 2 A. Minimum 24 V DC, 10 mA, or 24 V AC, 100 mA can be used for indicating status and warnings. The 2 relays are physically located on the installation card. These are programmable through parameter group 5-4* Relays. The relays are Form C, meaning each has 1 normally open contact and 1 normally closed contact on a single throw. The contacts of each relay are rated for a maximum load of 240 V AC at 2 amps.

Relay 1

Terminal 01: Common

•

Terminal 02: Normal open 240 V AC

•

Terminal 03: Normal closed 240 V AC

•

Relay 2

Terminal 04: Common

•

Terminal 05: Normal open 240 V AC

•

Terminal 06: Normal closed 240 V AC

•

Relay 1 and relay 2 are programmed in

parameter 5-40 Function Relay, parameter 5-41 On Delay, Relay, and parameter 5-42

O Delay, Relay.

2 2

Figure 2.20 Input Polarity of Control Terminals

NOTICE!

To comply with EMC emission specications, shielded/ armored cables are recommended. If an unshielded/ unarmored cable is used, see chapter 2.9.7 EMC Test Results for more information.

Figure 2.21 Relay Connection

Product Overview and Functi...

VLT® Decentral Drive FCD 302

2.6 Handling of Reference

Local reference

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

Remote reference

The reference handling system for calculating the remote reference is shown in Figure 2.22.

Figure 2.22 Remote Reference

Product Overview and Functi... Design Guide

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

X (the external reference): A sum (see

•

parameter 3-04 Reference Function) of up to 4 externally selected references. These comprise any combination (determined by the setting of

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

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

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 catch up/slow down function and the freeze reference function can

both be activated by digital inputs on the frequency converter. The functions and parameters are described in

the VLT® AutomationDrive FC 301/FC 302 Programming Guide. The scalings of analog references are described in

parameter groups 6-1* Analog Input 1 and 6-2* Analog Input 2, and the scaling of digital pulse references are described

in parameter group 5-5* Pulse Input. Reference limits and ranges are set in parameter group 3-0* Reference Limits.

2 2

Figure 2.23 Reference Range=[0] Min-Max

Figure 2.24 Reference Range=[1] -Max-Max

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 is as shown in Figure 2.25.

2.6.1 Reference Limits

Parameter 3-00 Reference Range, parameter 3-02 Minimum Reference, and parameter 3-03 Maximum Reference together

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) is shown in Figure 2.23/Figure 2.24 and the sum of all references is shown in Figure 2.25.

Figure 2.25 Sum of all References

(RPM)

Resource output

Resource input

Terminal X low

Terminal X high

Low reference/feedback value

High reference/feedback value

130BA181.10

-1500

-6 8 (V)

1500

-10 10

-600

(RPM)

Resource output

Resource input

Terminal X low

Terminal X high

Low reference/feedback value

High reference/feedback value

130BA182.10

-1500

-6 8 (V)

1500

-10 10

-600

Product Overview and Functi...

VLT® Decentral Drive FCD 302

2.6.2 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, bar, and so on. 100% reference equals the maximum (abs (parameter 3-03 Maximum Reference), abs (parameter 3-02 Minimum Reference)).

When parameter 3-00 Reference Range: [1] -Max to

•

+Max 0% reference equals 0 [unit] -100% reference equals -Maximum reference 100% reference equals maximum reference.

2.6.3 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 Figure 2.26) are clamped whereas a feedback above or below is not.

Bus references are scaled according to the following rules:

When parameter 3-00 Reference Range: [0] Min to

•

Max. To obtain maximum resolution on the bus reference the scaling on the bus is: 0% reference equals minimum reference and 100% reference equals maximum reference.

When parameter 3-00 Reference Range: [1] -Max to

•

+Max -100% reference equals maximum reference 100% reference equals max reference.

Figure 2.26 Scaling of Analog and Pulse References and

Feedback

Figure 2.27 Scaling of Reference Output

The endpoints P1 and P2 are dened by the parameters in Table 2.9, depending on which analog or pulse input is used.

(RPM)

Resource output

Resource input

Quadrant 2

Quadrant 3

Quadrant 1

Quadrant 4

Terminal X low

Terminal X high

Low reference/feedback value

High reference/feedback value

-1 1

130BA179.10

-1500

-6 6

(V)

1500

-10 10

Product Overview and Functi... Design Guide

Analog 53

S201=OFF

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 2.9 Input and Reference Endpoint Values

Analog 53

S201=ON

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]

2.6.4 Dead Band Around Zero

Analog 54

S202=OFF

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

S202=ON

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 zero (that is, to make sure 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, the following settings must be done:

The size of the dead band is dened by either P1 or P2 as shown in Figure 2.28.

Either minimum reference value (see Table 2.9 for

•

relevant parameter) or maximum reference value must be 0. In other words, either P1 or P2 must be on the X-axis in Figure 2.28.

And both points

•

dening the scaling graph are in

the same quadrant.

Figure 2.28 Dead Band

(RPM)

Resource output

Resource input

Quadrant 2

Quadrant 3

Quadrant 1

Quadrant 4

Terminal X low

Terminal X high

Low reference/feedback value

High reference/feedback value

-1 1

130BA180.10

-1500

-6 6

(V)

1500

-10 10

Product Overview and Functi...

VLT® Decentral Drive FCD 302

Figure 2.29 Reverse Dead Band

If endpoint 2 is placed in either quadrant 1 or quadrant 4, a reference endpoint of, for example, P1=(1 V, 0 RPM) results in a -1 V to +1 V dead band.

Product Overview and Functi... Design Guide

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

This case shows how reference input with limits inside minimum to maximum limits clamps.

2 2

Figure 2.30 Example 1 - Positive Reference

Product Overview and Functi...

Case 2: Positive reference with dead band, digital input to trigger reverse. Clamping rules.

This case shows how reference input with limits outside -maximum to +maximum limits clamps to the inputs low and high limits before addition to external reference. The case also shows how the external reference is clamped to -maximum to +maximum by the reference algorithm.

VLT® Decentral Drive FCD 302

Figure 2.31 Example 2 - Positive Reference

Product Overview and Functi... Design Guide

Case 3: Negative to positive reference with dead band, sign determines the direction, -maximum to +maximum

2 2

Figure 2.32 Example 3 - Positive to Negative Reference

Brake Functions

2.7

Brake function is applied for braking the load on the motor shaft, either as dynamic brake or static braking.

NOTICE!

A frequency converter cannot provide Safe Torque O control of a mechanical brake. A redundancy circuitry for the brake control must be included in the installation.

2.7.1 Mechanical Brake

A mechanical holding brake mounted directly on the motor shaft normally performs static braking. In some applications (usually synchronous permanent motors), the static holding torque holds the motor shaft. The holding brake is either controlled by a PLC, directly by a relay, or a digital output from the frequency converter.

MOV

L 3

MBR +

MBR -

MBR

L3-L2

130BD547.11

MOV

Product Overview and Functi...

VLT® Decentral Drive FCD 302

2.7.1.1 Mechanical Brake Selection Guide

and Electrical Circuit Description

within the electrical specication (voltage, current, and so on) or with external relays. If the frequency converter is congured without brake, the internal electrical control

VLT® Decentral Drive FCD 302 can be congured with or without a brake (see position 18 in Figure 6.1). If the inverter part is congured with brake, relay 1 can be congured for various applications, while relay 2 should be reserved only for the mechanical brake. Relay 2 is mounted inside the installation box, but in this conguration state it is not active. The mechanical brake coil can be powered by a low voltage (of 24 V DC) or from mains line AC voltage. If the mechanical brake is a 24 V DC type, 1 of the 2

signal for relay 2 is active. If the brake is powered by mains supply, or a mains rectied DC voltage, it is recommended to order the FCD 302 with a mechanical brake. In this case, all the parameter settings for relay 2 now control the internal solid-state switch which gives the output voltage at the MBR+ and MBR- terminals. In some motors, this mechanical brake can be of AC-type or DC-type. If the unit is AC-type, the mechanical brake has an internal diode D and the internal MOV, as described in the electrical diagram in Figure 2.33.

custom relays, relay 1, or a functional relay 2, can be used

1 Inverter part

2 MBR+ terminal 122

3 Mechanical brake coil

4 MBR- terminal 123

5 Solid state switch

6 Galvanic isolated control circuit

Figure 2.33 Electrical Diagram of Mechanical Brake

VMBR

VL1-L2

VMBR

ILm

130BD199.10

300; 135

320; 144

340; 153

380; 171

400; 180

440;198

480; 216

500; 225

520; 234

100

120

140

160

180

200

220

240

260

300 350 400 450 500 550

Average Outpu t Voltage (Vdc)

Input Mains Line Voltage (Vrms)

130BD200.10

Product Overview and Functi... Design Guide

The supply voltage is derived from the mains voltage between phases L2 and L3, which is passed through a single pulse diode rectication.

The output voltage of solid-state supply is not a constant value, but rather a pulsed voltage with an average level direct dependent on the mains voltage, as shown in Figure 2.34:

2 2

Figure 2.35 Average Output Voltage

It is possible to supply the mechanical brake in the motor with both DC and AC voltage. The output voltage is rectied by the internal diode inside the mechanical brake unit circuit. The average voltage applied to the brake coil remains at the same value.

ILm Instant line voltage

Mechanical brake voltage

MBR

Figure 2.34 Instant Voltage V

with its average level of V

MBR

This rectied voltage is applied to the mechanical brake inductor, with the smoothed current shape ILm.

The voltage shown in Figure 2.33 has the amplitude of the line voltage and an average voltage level calculated as:

= 0.45 x V

MBR(DC)

Examples: VAC = 400 V VAC = 480 V

rms

⇒ V ⇒ V

= 180 VDC.

MBR

= 216 VDC.

MBR

The average level of output voltage is directly determined by the amplitude of the line voltage measured between phases L1 and L2.

NOTICE!

Maximum nominal voltage = 480 AC.

2.7.1.2 Mechanical Brake Control

For hoisting applications, it is necessary to be able to control an electro-magnetic brake. For controlling the brake, a relay output (relay 1 or relay 2/solid state brake) or a programmed digital output (terminal 27 or 29) is required. Normally, this output must be closed for as long as the frequency converter is unable to hold the motor, for example, because of excess load. For applications with an electro-magnetic brake, select [32] mechanical brake control in 1 of the following parameters:

Parameter 5-40 Function Relay (Array parameter),

•

Parameter 5-30 Terminal 27 Digital Output, or

•

Parameter 5-31 Terminal 29 digital Output

•

When [32] mechanical brake control is selected, the mechanical brake relay stays closed during start until the output current is above a preset level. Select the preset level in parameter 2-20 Release Brake Current. During stop, the mechanical brake closes when the speed is below the level selected in parameter 2-21 Activate Brake Speed [RPM]. When the frequency converter is brought into an alarm condition (that is, an overvoltage situation), or during Safe Torque O, the mechanical brake immediately cuts in.

130BC970.10

Start term.18

1=on

Shaft speed

Start delay time

Brake delay time

Time

Output current

Relay 01or Relay 02/solid state brake

Pre-magnetizing

current or

DC hold current

Reaction time EMK brake

Par 2-20 Release brake current

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

Par 1-74 Start speed

Par 2-21

Activate brake

speed

Mechanical brake locked

Mechanical brake

free

Par 1-71

Par 2-23

o

0=o

Product Overview and Functi...

VLT® Decentral Drive FCD 302

Figure 2.36 Mechanical Brake Control for Hoisting Applications

In hoisting/lowering applications, it must be possible to control an electromechanical brake.

Step-by-step description

To control the mechanical brake, use any relay

•

output, digital output (terminal 27 or 29), or solid-state brake voltage output (terminals 122–

123). Use a suitable contactor when required.

Ensure that the output is switched o as long as

•

the frequency converter is unable to drive the motor. For example, due to the load being too heavy, or when the motor is not yet mounted.

Select [32] mechanical brake control in parameter

•

group 5-4* Relays (or in parameter group 5-3* Digital Outputs) before connecting the mechanical

brake.

The brake is released when the motor current

•

exceeds the preset value in parameter 2-20 Release Brake Current.

The brake is engaged when the output frequency

•

is lower than a preset limit. Set the limit in

NOTICE!

Recommendation: For vertical lifting or hoisting applications, ensure that the load can be stopped in an emergency or a malfunction of a single part such as a contactor. When the frequency converter enters alarm mode or an overvoltage situation, the mechanical brake cuts in.

NOTICE!

For hoisting applications, make sure that the torque limit settings do not exceed the current limit. Set torque limits in parameter 4-16 Torque Limit Motor Mode and parameter 4-17 Torque Limit Generator Mode. Set current limit in parameter 4-18 Current Limit. Recommendation: Set parameter 14-25 Trip Delay at

Torque Limit to [0], parameter 14-26 Trip Delay at Inverter Fault to [0], and parameter 14-10 Line Failure to [3] Coasting.

if the frequency converter carries out a stop command.

parameter 2-21 Activate Brake Speed [RPM] or parameter 2-22 Activate Brake Speed [Hz] and only

to ta

130BA167.10

Charge

Temps

Vitesse

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2.7.1.3 Mechanical Brake Cabling

EMC (twisted cables/shielding)

To reduce the electrical noise from the wires between the mechanical brake and the frequency converter, the wires must be twisted. For enhanced EMC performance, use a metal shield.

Twisted-pair cables, containing both the motor and brake cables, can be used.

2.7.1.4 Hoist Mechanical Brake

For an example of advanced mechanical brake control for hoisting applications, see chapter 4 Application Examples.

2.7.2 Dynamic Brake

Dynamic brake established by:

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).

AC brake: The brake energy is distributed in the

•

motor by changing the loss conditions in the motor. The AC brake function cannot be used in applications with high cycling frequency since 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).

numbers can be found in chapter 6.2.1 Ordering Numbers: Accessories.

2.7.2.2 Selection of Brake Resistor

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

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

If the amount of kinetic energy transferred to the resistor in each braking period is not known, the average power can be calculated based on the cycle time and braking time also called intermittent duty cycle. The resistor intermittent duty cycle is an indication of the duty cycle at which the resistor is active. Figure 2.37 shows a typical braking cycle.

NOTICE!

Motor suppliers often use S5 when stating the allowed load, which is an expression of intermittent duty cycle.

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

Duty cycle=tb/T

T=cycle time in s. tb is the braking time in s (of the cycle time).

2 2

2.7.2.1 Brake Resistors

In certain applications, break down of kinetic energy is required. In this frequency converter, the energy is not fed back to the grid. Instead, the kinetic energy must be transformed to heat, and this is achieved by braking using a brake resistor.

In applications where the motor is used as a brake, energy is generated in the motor and sent back into the frequency converter. If the energy cannot be transported back to the motor, it increases the voltage in the frequency converter DC-line. In applications with frequent braking and/or high inertia loads, this increase may lead to an overvoltage trip in the frequency converter and nally a shutdown. Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected in respect to its ohmic value, its power dissipation rate, and its physical size. Danfoss brake resistors are available in several types, for internal or external installation to the frequency converter. Code

Figure 2.37 Dynamic Brake Cycle Time

Braking duty

Cycle time [s]

3x380–480 V

PK37–P3K0 120 Continuous 40%

Table 2.10 Braking at High Overload Torque Level

cycle at

100% torque

Braking duty

cycle at over

(150/160%)

torque

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VLT® Decentral Drive FCD 302

Brake resistors have a duty cycle of 5%, 10%, and 40%. If a

10% duty cycle is applied, the brake resistors are able to absorb brake power for 10% of the cycle time. The remaining 90% of the cycle time is used on dissipating excess heat.

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).

Ensure that the resistor is designed to handle the required braking time.

NOTICE!

Do not touch the brake resistor as it can get very hot

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

while/after braking. The brake resistor must be placed in a secure environment to avoid re risk.

be calculated as:

Rbr Ω = 

peak

where

peak=Pmotor

x Mbr [%] x η

motor

x η

VLT

[W]

The brake resistance depends on the DC-link voltage (Udc). The brake function is settled in 4 areas of mains.

2.7.2.3 Brake Resistors 10 W

For frequency converters equipped with the dynamic brake option, 1 brake IGBT along with terminals 81 (R-) and 82 (R +) is included in each inverter module for connecting a brake resistor(s). An internal 10 W brake resistor can be mounted in the installation box (bottom part). This optional resistor is

Size Brake active Warning

before cutout

FCD 302

3x380–480 V

Table 2.11 Brake Limit Values

778 V 810 V 820 V

NOTICE!

Check that the brake resistor can cope with a voltage of

Cutout (trip)

suitable for applications where braking IGBT is only active for very short duty cycles, for example to avoid warning and trip events.

For internal brake resistor use:

Brake resistor 1750 Ω 10 W/

100%

Brake resistor 350 Ω 10 W/

100%

For mounting inside installation

box, below motor terminals.

For mounting inside installation

box, below motor terminals.

820 V - unless brake resistors are used.

Table 2.12 Brake Resistors 10 W

Danfoss recommends that the brake resistance R guarantees that the frequency converter is able to brake at the highest brake power (M

) of 160%. The formula can

br(%)

be written as:

x100

 Ω = 

η η

rec

motor

VLT

motor

is typically at 0.90

is typically at 0.98

For 480 V frequency converters, R

xM

br( % )

xη

VLT



xη

motor

at 160% brake power

rec

is written as:

480

V: R

rec

375300

= 

motor

 Ω 

rec

2.7.2.4 Brake Resistor 40%

Placing the brake resistor externally has the advantages of selecting the resistor based on application need, dissipating the energy outside of the control panel, and protecting the frequency converter from overheating if the brake resistor is overloaded.

Number Function

81 (optional function) R- Brake resistor terminals

82 (optional function) R+

Table 2.13 Brake Resistors 40%

NOTICE!

The connection cable to the brake resistor must

The resistance in the the brake resistor circuit should not exceed the limits recommended by Danfoss. If a brake resistor with a higher ohmic value is selected, the 160% brake power may not be achieved because there is a risk that the frequency converter cuts out for safety reasons.

•

be shielded/armored. Connect the shield to the metal cabinet of the frequency converter and to the metal cabinet of the brake resistor with cable clamps.

Dimension the cross-section of the brake cable to

•

match the brake torque.

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2.7.2.5 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 against overloading in connection with a fault in the frequency converter. In addition, the brake makes it possible to readout the momentary power and the mean power for the latest 120 s. The brake can also monitor the energizing power and make sure that it does not exceed a limit selected in

parameter 2-12 Brake Power Limit (kW). In parameter 2-13 Brake Power Monitoring, select the function

to carry out when the power transmitted to the brake resistor exceeds the limit set in parameter 2-12 Brake Power Limit (kW).

NOTICE!

Monitoring the brake power is not a safety function; a thermal switch is required for that purpose. 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 very useful function to avoid unnecessary tripping of the frequency converter, for example when the ramp-down time is too short. In this situation, the ramp-down time is extended.

NOTICE!

OVC cannot be activated when running a PM motor (when parameter 1-10 Motor Construction is set to [1] PM non-salient SPM).

2.7.2.6 Brake Resistor Cabling

For enhanced EMC performance, use a metal shield.

2.8 Safe Torque O

To run STO, additional wiring for the frequency converter is

required. Refer to VLT® Frequency Converters Safe Torque O Operating Guide for further information.

2.9 EMC

2.9.1 General Aspects of EMC Emissions

Burst transient is usually 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 inverter, motor cable, and the motor. Capacitive currents in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents. The use of a shielded motor cable increases the leakage current (see Figure 2.38) because shielded cables have higher capacitance to ground than unshielded cables. If the leakage current is not ltered, it causes greater interference on the mains in the radio frequency range below approximately 5 MHz. Since the leakage current (I1) is carried back to the unit through the shield (I3), there is 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 and motor enclosures. Use integrated shield clamps to avoid twisted shield ends (pigtails). Twisted shield ends increase the shield impedance at higher frequencies, which reduces the shield eect and increases the leakage current (I4). When a shielded cable is used for eldbus relay, control cable, signal interface, or brake, ensure that the shield is mounted on the enclosure at both ends. In some situations, however, it is necessary to break the shield to avoid current loops.

2 2

EMC (twisted cable/shielding)

To reduce the electrical noise from the wires between the brake resistor and the frequency converter, the wires must be twisted.

175ZA062.12

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VLT® Decentral Drive FCD 302

1 Ground wire

2 Shield

3 AC mains supply

4 Frequency converter

5 Shielded motor cable

6 Motor

Figure 2.38 Example - Leakage Current

Mounting plates, when used, must be constructed of metal to ensure that the shield currents are conveyed back to the unit. Ensure good electrical contact from the mounting plate through the mounting screws to the chassis of the frequency converter.

When unshielded cables are used, some emission requirements are not fullled. However, the immunity requirements are observed.

To reduce the interference level from the entire system (unit+installation), keep motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference frequency above 50 MHz (airborne) is generated by the control electronics in particular.

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2.9.2 Emission Requirements

According to the EMC product standard for adjustable speed frequency converters EN/IEC 61800-3:2004 the EMC requirements depend on the intended use of the frequency converter. Four categories are dened in the EMC product standard. The denitions of the 4 categories together with the requirements for mains supply voltage conducted emissions are given in Table 2.14.

Conducted emission requirement

Category Denition

C1 Frequency converters installed in the 1st environment (home and oce) with a

supply voltage less than 1000 V.

C2 Frequency converters installed in the 1st environment (home and oce) with a

supply voltage less than 1000 V, which are neither plug-in nor movable and are

intended to be installed and commissioned by a professional.

C3 Frequency converters installed in the 2nd environment (industrial) with a supply

voltage lower than 1000 V.

C4 Frequency converters installed in the 2nd environment with a supply voltage equal

to or above 1000 V or rated current equal to or above 400 A or intended for use in

complex systems.

according to the limits given in EN

55011

Class B

Class A Group 1

Class A Group 2

No limit line.

An EMC plan should be made.

2 2

Table 2.14 Emission Requirements

When the generic emission standards are used, the frequency converters are required to comply with the limits in Table 2.15.

Conducted emission requirement

Environment Generic standard

First environment

(home and oce)

Second environment

(Industrial environment)

Table 2.15 Emission Limit Classes

EN/IEC 61000-6-3 Emission standard for residential, commercial,

and light industrial environments.

EN/IEC 61000-6-4 Emission standard for industrial environments. Class A Group 1

according to the limits given in EN

55011

Class B

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2.9.3 Immunity Requirements

The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and oce environment. All Danfoss frequency converters comply with the requirements for the industrial environment and consequently comply also 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, and a control box with potentiometer, motor cable, and motor. :

The tests were performed in accordance with the following basic standards

See Table 2.16.

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): Incoming electro-

•

magnetic eld radiation, 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 brought about by switching a contactor, relay, or similar devices.

EN 61000-4-5 (IEC 61000-4-5): Surge transients:

•

Simulation of transients brought about for example, by lightning that strikes near installations.

EN 61000-4-6 (IEC 61000-4-6): RF common

•

mode: Simulation of the eect from radiotransmission equipment joined by connection cables.

Voltage range: 200–240 V, 380–480 V

Basic standard

Acceptance criterion B B B A A

Line 4 kV CM

Motor 4 kV CM

Brake 4 kV CM

Load sharing 4 kV CM

Control wires 2 kV CM

Standard bus 2 kV CM

Relay wires 2 kV CM

Application and eldbus

options

LCP cable 2 kV CM

External 24 V DC 2 V CM

Enclosure — —

Table 2.16 EMC Immunity

1) Injection on cable shield

AD: Air Discharge

CD: Contact Discharge

CM: Common Mode

DM: Dierential Mode

Burst

IEC 61000-4-4

2 kV CM

Surge

IEC 61000-4-5

2 kV/2 Ω DM

4kV/12 Ω CM

4 kV/2 Ω

2 kV/2 Ω

0.5 kV/2 Ω DM

1 kV/12 Ω CM

ESD

IEC

61000-4-2

— — 10 V

8 kV AD

6 kV CD

Radiated electromagnetic

eld

IEC 61000-4-3

10 V/m —

RF common

mode voltage

IEC 61000-4-6

RMS

Product Overview and Functi... Design Guide

2.9.4 EMC

2.9.4.1 EMC-correct Installation

The following is a guideline to good engineering practice when installing frequency converters. Follow these guidelines to comply with EN 61800-3 First environment. If the installation is in EN 61800-3 Second environment, for example industrial networks, or in an installation with its own transformer. Deviation from these guidelines is allowed but not recommended. See also chapter 1.5.1 CE Labeling, chapter 2.9.1 General Aspects of EMC Emissions, and chapter 2.9.7 EMC Test Results.

Good engineering practice to ensure EMC-correct electrical installation:

Use only braided shielded/armored motor cables

•

and braided shielded/armored control cables. The shield should provide a minimum coverage of 80%. The shield material must be metal, not limited to but typically copper, aluminum, steel, or lead. There are no special requirements for the mains cable.

Installations using rigid metal conduits are not

•

required to use shielded cable, but the motor cable must be installed in conduit separate from the control and mains cables. Full connection of the conduit from the frequency converter to the motor is required. The EMC performance of exible conduits varies a lot and information from the manufacturer must be obtained.

Connect the shield/armor/conduit to ground at

•

both ends for motor cables and for control cables. Sometimes, it is not possible to connect the shield in both ends. If so, connect the shield at the frequency converter.

Avoid terminating the shield/armor with twisted

•

ends (pigtails). It increases the high frequency impedance of the shield, which reduces its eectiveness at high frequencies. Use low impedance cable clamps or EMC cable glands instead.

Avoid using unshielded/unarmored motor or

•

control cables inside cabinets housing the frequency converter(s), whenever this can be avoided.

Leave the shield as close to the connectors as possible.

Figure 2.39 shows an example of an EMC-correct electrical

installation of the VLT® Decentral Drive FCD 302. The frequency converter is connected to a PLC, which is installed in a separate cabinet. Other ways of doing the installation may have just as good an EMC performance, provided the above guidelines are followed.

If the installation is not carried out according to the guidelines, and if unshielded cables and control wires are used, then certain emission requirements are not although the immunity requirements are fullled. See chapter 2.9.7 EMC Test Results.

fullled,

2 2

130BC989.10

L2 L3

Min. 16 mm

Equalizing cable

Control cables

Earthing rail

Cable insulation stripped

Output contactor etc.

Min. 200mm between control cables, motor cable and

Motor cable

Motor, 3 phases and

PLC etc.

Mains-supply

mains cable

PLC

Protective earth

Reinforced protective earth

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Figure 2.39 EMC-correct Electrical Installation of a Frequency Converter

A minimum distance of 200 mm (7.87 in) is required between the eldbus cable and the motor cable and also between eldbus cable and the mains cable. If this cannot be achieved, use the optional PE grounding plug on the

underside of the VLT® Decentral Drive FCD 302.

130BG474.10

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Figure 2.40 Connection of Mains Diagram

Electrical safety ground connections

To obtain the electrical safety, always connect the safety

ground on the dedicated connections inside the VLT Decentral Drive FCD 302 installation box. See Figure 2.41.

Equalizing cable

As the shield of the communication cable needs to be connected to ground by each drive/device, there is a risk of having current in the communication cable. This might lead to communication problems as the equalizing current can interfere with the communication. To reduce currents in the shield of the communication cable, always apply a short grounding cable between units that are connected to the same communication cable. Danfoss recommend using minimum 16 mm2 (6 AWG) equalizing cable and install the equalizing cable parallel with the communication cable.

For good equalizing between VLT in a decentral installation, use the external equalizing terminal from Danfoss (ordering number 130B5833).

Decentral Drive FCD 302

2.9.4.2 Use of EMC-correct Cables

Danfoss recommends braided shielded/armored cables to optimize EMC immunity of the control cables and emission from the motor cables.

The ability of a cable to reduce the in- and outgoing radiation of electric noise depends on the transfer impedance (ZT). The shield of a cable is normally designed to reduce the transfer of electric noise; however, a shield with a lower transfer impedance (ZT) value is more eective than a shield with a higher transfer impedance (ZT).

Transfer impedance (ZT) is rarely stated by cable manufacturers but it is often possible to estimate transfer impedance (ZT) by assessing the physical design of the cable.

Transfer impedance (ZT) can be assessed based on the following factors:

The conductibility of the shield material.

•

The contact resistance between the individual

•

shield conductors.

The shield coverage, that is, the physical area of

•

the cable covered by the shield - often stated as a percentage value.

Shield type, that is, braided or twisted pattern.

•

2 2

Figure 2.41 Electrical Safety Ground Connections

PLC

130BB922.12

PE PE

<10 mm

100nF

PLC

<10 mm

130BB609.12

130BB923.12

PE PE

69 68 61

<10 mm

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VLT® Decentral Drive FCD 302

Minimum 16 mm2 (6 AWG)

2 Equalizing cable

Figure 2.43 Shielding of Control Cables

50/60 Hz ground loops

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

a. Aluminum-clad with copper wire

b. Twisted copper wire or armored steel wire cable

c. Single-layer braided copper wire with varying percentage

shield coverage. This is the typical reference cable

d. Double-layer braided copper wire

e. Twin layer of braided copper wire with a magnetic,

shielded/armored intermediate layer

f. Cable that runs in copper tube or steel tube

g. Lead cable with 1.1 mm (0.04 inch) wall thickness

Figure 2.42 Transfer Impedance

2.9.4.3 Grounding of Shielded Control Cables

Correct shielding

The preferred method usually is to secure control cables and cables with shielding clamps provided at both ends to ensure 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 next to the control cable. Minimum cable cross-section: 16 mm2 (6 AWG).

Figure 2.44 Shielding for 50/60 Hz Ground Loops

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 Figure 2.45.

Minimum 16 mm2 (6 AWG)

2 Equalizing cable

Figure 2.45 Shielding for EMC Noise Reduction, Serial

Communication

130BB924.12

PE PE

<10 mm

175HA034.10

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Alternatively, the connection to terminal 61 can be omitted:

Minimum 16 mm2 (6 AWG)

2 Equalizing cable

Figure 2.46 Shielding for EMC Noise Reduction, Serial

Communication, without Terminal 61

2.9.4.4 RFI Switch

Mains supply isolated from ground

When the frequency converter is supplied from an isolated mains source (IT mains,

oating delta, and grounded delta) or TT/TN-S mains with grounded leg, set the RFI switch to [O] via parameter 14-50 RFI 1 on the frequency converter. Otherwise, set parameter 14-50 RFI 1 to [On]. For further information, refer to:

IEC 364-3.

•

Application note VLT® on IT mains. It is important

•

to use isolation monitors that are capable for use together with power electronics (IEC 61557-8).

2.9.5 Mains Supply Interference/Harmonics

A frequency converter takes up a non-sinusoidal current from mains, which increases the input current I sinusoidal current is transformed with a Fourier analysis and split up into sine-wave currents with dierent frequencies, that is, dierent harmonic currents IN with 50 Hz as the basic frequency:

RMS

. A non-

The harmonics do not aect the power consumption directly but increase the heat losses in the installation (transformer, cables). Therefore, in plants with a high percentage of rectier load, maintain harmonic currents at a low level to avoid overload of the transformer and high temperature in the cables.

Figure 2.47 DC-link Coils

NOTICE!

Some of the harmonic currents might disturb communication equipment connected to the same transformer or cause resonance in connection with power factor correction batteries.

Input current

RMS

11-49

Table 2.18 Harmonic Currents Compared to

the RMS Input Current

To ensure low harmonic currents, the frequency converter is equipped with DC-link coils as standard. DC coils reduce the total harmonic distortion (THD) to 40%.

1.0

0.9

0.4

0.2

<0.1

2 2

Harmonic currents I

Hz 50 Hz 250 Hz 350 Hz

Table 2.17 Harmonic Currents

Non-linear

Current Voltage

System

Impedance

Disturbance to

other users

Contribution to

system losses

130BB541.10

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2.9.5.1 Eect of Harmonics in a Power Distribution System

In Figure 2.48, a transformer is connected on the primary side to a point of common coupling PCC1 on the medium voltage supply. The transformer has an impedance Z feeds a number of loads. The point of common coupling where all loads are connected together is PCC2. Each load is connected through cables that have an impedance Z1, Z2, Z3.

Figure 2.48 Small Distribution System

Harmonic currents drawn by non-linear loads cause distortion of the voltage because of the voltage drop on the impedances of the distribution system. Higher impedances result in higher levels of voltage distortion.

Current distortion relates to apparatus performance and it relates to the individual load. Voltage distortion relates to system performance. It is not possible to determine the voltage distortion in the PCC knowing only the load’s harmonic performance. To predict the distortion in the PCC, the conguration of the distribution system and relevant impedances must be known.

A commonly used term for describing the impedance of a grid is the short circuit ratio R between the short circuit apparent power of the supply at the PCC (Ssc) and the rated apparent power of the load (S

equ

sce

equ

Ssc=

supply

and

where

, dened as the ratio

sce

= U × I

equ

xfr

and

The negative eect of harmonics is twofold

Harmonic currents contribute to system losses (in

•

cabling, transformer).

Harmonic voltage distortion causes disturbance

•

to other loads and increase losses in other loads.

Figure 2.49 Negative Eects of Harmonics

2.9.5.2 Harmonic Limitation Standards and Requirements

The requirements for harmonic limitation can be:

Application-specic requirements.

•

Standards that must be observed.

•

The application-specic requirements are related to a specic installation where there are technical reasons for

limiting the harmonics.

Example: A 250 kVA transformer with 2 110 kW motors connected is sucient if 1 of the motors is connected directly online and the other is supplied through a frequency converter. However, the transformer is undersized if a frequency converter supplies both motors. Using extra means of harmonic reduction within the installation or selecting low harmonic frequency converter variants makes it possible for both motors to run with frequency converters.

There are various harmonic mitigation standards, regulations, and recommendations. Dierent standards apply in dierent geographical areas and industries. The following standards are the most common:

IEC61000-3-2

•

IEC61000-3-12

•

IEC61000-3-4

•

IEEE 519

•

G5/4

•

See the VLT® Advanced Harmonic Filter AHF 005 & AHF 010 Design Guide for specic details on each standard.

Product Overview and Functi... Design Guide

2.9.5.3 Harmonic Mitigation

In cases where extra harmonic suppression is required, Danfoss oers a wide range of mitigation equipment. These are:

VLT® 12-pulse frequency converters.

•

VLT® AHF lters.

•

VLT® Low Harmonic Drives.

•

VLT® Advanced Active Filters.

•

The selection of the right solution depends on several factors:

The grid (background distortion, mains

•

unbalance, resonance, and type of supply (transformer/generator))

Application (load prole, number of loads, and

•

load size)

Local/national requirements/regulations (IEEE 519,

•

IEC, G5/4, and so on)

Total cost of ownership (initial cost, eciency,

•

maintenance, and so on)

2.9.5.4 Harmonic Calculation

Determining the degree of voltage pollution on the grid and needed precaution is done with the Danfoss VLT® Harmonic Calculation MCT 31 software. The free tool MCT 31 can be downloaded from www.danfoss.com. The software is built with a focus on user-friendliness and limited to involve only system parameters that are normally accessible.

2.9.6 Residual Current Device

2 2

Use RCD relays, multiple protective earthing, or grounding as extra protection to comply with local safety regulations. If a ground fault appears, a DC content may develop in the faulty current. If RCD relays are used, local regulations must be observed. Relays must be suitable for protection of 3-phase equipment with a bridge rectier and for a brief discharge on power-up using RCDs.

2.9.7 EMC Test Results

The following test results have been obtained using a system with a frequency converter (with options if relevant), a shielded control cable, a control box with potentiometer, a motor, and motor shielded cable.

RFI lter type Conducted emission Radiated emission

Standards and

requirements

FCD 302

EN 55011 Class B Class A Group 1 Class A Group 2 Class B Class A Group 1

Housing, trades,

and light

industries

EN/IEC 61800-3 Category C1 Category C2 Category C3 Category C1 Category C2

First

environment

Home and

oce

0.37–3 kW

(0.5–4 hp)

No 10 m (32.8 ft) 10 m (32.8 ft) No Yes

Industrial

environment

First environment

Home and oce

Industrial

environment

Second environment

Industrial

Housing, trades,

and light

industries

First environment

Home and oce

Industrial

environment

First

environment

Home and oce

Table 2.19 EMC Test Results (Emission, Immunity)

System Integration

3 System Integration

VLT® Decentral Drive FCD 302

3.1 Ambient Conditions

3.1.1 Air Humidity

The frequency converter meets the IEC/EN 60068-2-3 standard, EN 50178 section 9.4.2.2 at 50 °C (122 °F).

3.1.2 Aggressive Environments

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

NOTICE!

The frequency converter should not be installed in environments with airborne liquids, particles, or gases capable of aecting and damaging the electronic components. Failure to take the necessary protective measures increases the risk of stoppages, thus reducing the life of the frequency converter.

Degree of protection as per IEC 60529

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

Such chemical reactions rapidly aect and damage the electronic components. In such environments, mount the equipment in a cabinet with fresh air ventilation, keeping aggressive gases away from the frequency converter. An extra protection in such areas is a coating of the printed circuit boards, which can be ordered as an option.

NOTICE!

Mounting frequency converters in aggressive environments increases the risk of stoppages and considerably reduces the life of the frequency converter.

3.1.3 Vibration and Shock

The frequency converter has been tested according to the procedure based on the shown standards:

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

oors.

IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970

•

IEC/EN 60068-2-64: Vibration, broad-band random

•

3.1.4 Acoustic Noise

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

DC intermediate circuit coils.

•

RFI lter choke.

•

VLT® Decentral Drive FCD 302 has no signicant audible noise. Refer to chapter 7 Specications for acoustic noise data.

Mounting Positions

3.2

The VLT® Decentral Drive FCD 302 consists of 2 parts:

The installation box

•

The electronic part

•

Standalone mounting

The holes on the rear of the installation box are

•

used to x mounting brackets.

Ensure that the strength of the mounting location

•

can support the unit weight.

Make sure that the proper mounting screws or

•

bolts are used.

Before installing the frequency converter, check the ambient air for liquids, particles, and gases. This is done by observing existing installations in this environment. Typical indicators of harmful airborne liquids are water or oil on metal parts, or corrosion of metal parts.

Excessive dust particle levels are often found on installation cabinets and existing electrical installations. One indicator of aggressive airborne gases is blackening of copper rails and cable ends on existing installations.

130BB701.10

130BC382.10

130BC383.10

System Integration Design Guide

Figure 3.1 FCD 302 Stand-alone Mounted with Mounting

Brackets

3.2.1 Mounting Positions for Hygienic Installation

The VLT® Decentral Drive FCD 302 is designed according to the EHEDG guidelines, suitable for installation in environments with high focus on ease of cleaning.

Mount the FCD 302 vertically on a wall or machine frame, to ensure that liquids drain o the enclosure. Orient the unit so the cable glands are located at the base.

Use cable glands designed to meet hygienic application requirements, for example Rittal HD 2410.110/120/130. Hygienic-purpose cable glands ensure optimal ease of cleaning the installation.

NOTICE!

Only frequency converters congured as hygienic enclosure designation, FCD 302 P XXX T4 W69, have the EHEDG certication.

3 3

Allowed mounting positions

Figure 3.3 Allowed Mounting Positions for Hygienic

Applications

Figure 3.2 Allowed Mounting Positions for Standard

Applications

130BC286.10

U 96 V 97 W 98

L1 91 L2 92 L3 93

1 2

U 96 V 97 W 98

L1 91 L2 92 L3 93

1 2

3 4

7 8

130BC287.10

System Integration

VLT® Decentral Drive FCD 302

3.3 Electrical Input: Mains-side Dynamics

3.3.1 Connections

3.3.1.1 Cables General

NOTICE!

Cables general All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper (75 °C (175 °F)) conductors are recommended.

1 Looping terminals

3.3.1.2 Connection to Mains and Grounding

For installation instructions and location of terminals, refer

Decentral Drive FCD 302 Operating Guide.

to VLT

Connection of mains

Figure 3.5 Large Unit only: Service Switch at Mains with

Looping Terminals

1 Looping terminals

2 Circuit breaker

Figure 3.4 Large Unit only: Circuit Breaker and Mains

Disconnect

Figure 3.6 Motor and Connection of Mains with Service Switch

For both small and large units, the service switch is optional. The switch is shown mounted on the motor side. Alternatively, the switch can be on the mains side, or omitted.

For the large unit, the circuit breaker is optional. The large

unit can be congured with either service switch or circuit breaker, not both. Figure 3.6 is not congurable in practice, but shows the respective positions of components only.

Usually, the power cables for mains are unshielded cables.

System Integration Design Guide

3.3.1.3 Relay Connection

To set relay output, see parameter group 5-4* Relays.

Number Description

01-02 Make (normally open)

01-03 Break (normally closed)

04-05 Make (normally open)

04-06 Break (normally closed)

Table 3.1 Relay Settings

For location of relay terminals, refer to VLT® Decentral Drive FCD 302 Operating Guide.

3.3.2 Fuses and Circuit Breakers

3.3.2.1 Fuses

Fuses and/or circuit breakers are recommended protection on the supply side, if a component break-down inside the frequency converter (rst fault) occurs.

NOTICE!

Using fuses and/or circuit breakers is mandatory in order to ensure compliance with IEC 60364 for CE or NEC 2009 for UL.

NOTICE!

Personnel and property must be protected against the consequence of component break-down internally in the frequency converter.

3.3.2.2 Recommendations

CAUTION

In the event of malfunction, failure to follow the recommendation may result in personnel risk and damage to the frequency converter and other equipment.

The following sections list the recommended rated current. Danfoss recommends fuse type gG and Danfoss CB (Danfoss - CTI-25M) circuit breakers. Other types of circuit breakers may be used if they limit the energy into the frequency converter to a level equal to or lower than the Danfoss CB types.

Follow the recommendations for fuses and circuit breakers to ensure that any damage to the frequency converter is internal only.

For further information, see Application Note Fuses and Circuit Breakers.

3.3.2.3 CE Compliance

Use of fuses or circuit breakers is mandatory to comply with IEC 60364. Danfoss recommends fuse size up to gG-25. This fuse size is suitable for use on a circuit capable of delivering 100000 A the frequency converter short-circuit current rating (SCCR) is 100000 A

3.3.2.4 UL Compliance

(symmetrical), 480 V. With the proper fusing,

rms

3 3

Branch circuit protection

To protect the installation against electrical and re hazard, all branch circuits in an installation, switchgear, machines, and so on, must be protected against short circuit and overcurrent according to national/international regulations.

NOTICE!

The recommendations given do not cover branch circuit protection for UL.

Fuses or circuit breakers are mandatory to comply with NEC 2009. To meet UL/cUL requirements, use the pre-fuses in Table 7.2, and comply with the conditions listed in chapter 7.2 Electrical Data and Wire Sizes.

The current and voltage ratings are also valid for UL.

Electrical Output: Motor-side Dynamics

3.4

3.4.1 Motor Connection

Short-circuit protection

Danfoss recommends using the fuses/circuit breakers mentioned below to protect service personnel and property in case of component break-down in the frequency converter.

NOTICE!

To comply with EMC emission specications, shielded/ armored cables are recommended.

See chapter 7.3 General Specications for correct dimensioning of motor cable cross-section and length.

175ZA114.11

96 97 98

Motor

System Integration

VLT® Decentral Drive FCD 302

Shielding of cables

Avoid installation with twisted shield ends (pigtails). They spoil the shielding eect at higher frequencies. If it is necessary to break the shield to install a motor isolator or

motor contactor, the shield must be continued at the lowest possible HF impedance. Connect the motor cable shield to both the decoupling plate of the frequency converter and to the metal housing of the motor. Make the shield connections with the largest possible surface area (cable clamp). This is done by using the supplied installation devices in the frequency converter. If it is necessary to split the shield to install a motor

Figure 3.7 Star - Delta Grounding Connections

isolator or motor relay, the shield must be continued with the lowest possible HF impedance.

NOTICE!

Cable length and cross-section

The frequency converter has been tested with a given length of cable and a given cross-section of that cable. If the cross-section is increased, the cable capacitance - and thus the leakage current - may increase, and the cable length must be reduced correspondingly. Keep the motor cable as short as possible to reduce the noise level and leakage currents.

All types of 3-phase asynchronous standard motors can be connected to the frequency converter. Normally, small motors are star-connected (230/400 V, Y). Large motors are normally delta-connected (400/690 V, Δ). Refer to the motor nameplate for correct connection mode and voltage.

For installation of mains and motor cables, refer to VLT

Decentral Drive FCD 302 Operating Guide.

In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply (such as a frequency converter), t a sinewave lter on the output of the frequency converter.

Termi

96 97 98 99

nal

numb

U V W

Motor voltage 0–100% of mains

voltage.

3 wires out of motor.

U1 V1 W1

W2 U2 V2 6 wires out of motor.

U1 V1 W1

Delta-connected.

Star-connected U2, V2, W2.

U2, V2, and W2 to be interconnected

separately.

Table 3.2 Motor Connection Terminals

1) Protective earth connection

130BC981.10

2 2 22332

2226

System Integration Design Guide

The VLT® Decentral Drive FCD 302 is also available as a real NPT version in 2 dierent variants.

Metric NPT 1 for USA NPT 2 for USA

1 Brake M20 1/2” NPT 1/2” NPT

2 8xM16 8xM16 3/8” NPT (except ground plug, which is

M16)

3 2xM20 2xM20 1/2” NPT

4 Mains cables M25 3/4” NPT 3/4” NPT

5 M20 M20 1/2” NPT

6 24 V M20 1/2” NPT 1/2” NPT

7 Motor M25 3/4” NPT 3/4” NPT

3 3

Figure 3.8 Cable Entry Holes - Large Unit

130BC986.10

130BC983.10

175HA036.11

96 97 98

Motor

96 97 98

Motor

System Integration

3.4.2 Mains Disconnectors

VLT® Decentral Drive FCD 302

The frequency converter is available with optional

Service switch on mains side or motor side

•

Built-in circuit breaker on the mains side (large

•

Terminal U/T1/96 connected to U-phase.

•

Terminal V/T2/97 connected to V-phase.

•

Terminal W/T3/98 connected to W-phase.

•

unit only)

Specify the requirement when ordering.

Figure 3.9 and Figure 3.10 show examples of conguration for the large unit.

Figure 3.9 Location of Service Switch, Mains Side, Large Unit

(IP66/Type 4X indoor)

Figure 3.10 Location of Circuit Breaker, Mains Side, Large Unit

3.4.3 Additional Motor Information

3.4.3.1 Motor Cable

The motor must be connected to terminals U/T1/96, V/ T2/97, W/T3/98. Ground to terminal 99. All types of 3phase asynchronous standard motors can be used with a frequency converter unit. The factory setting is for clockwise rotation with the frequency converter output connected as shown in Table 3.3:

Terminal number Function

96, 97, 98, 99 Mains U/T1, V/T2, W/T3

Table 3.3 Motor Connection - Factory Setting

Figure 3.11 Motor Connection - Direction of Rotation

The direction of rotation can be changed by switching 2 phases in the motor cable or by changing the setting of parameter 4-10 Motor Speed Direction.

Motor rotation check can be performed using parameter 1-28 Motor Rotation Check and following the steps shown in the display.

3.4.3.2 Motor Thermal Protection

The electronic thermal relay in the frequency converter has received UL approval for single motor overload protection, when parameter 1-90 Motor Thermal Protection is set for

Ground

ETR Trip and parameter 1-24 Motor Current is set to the rated motor current (see motor nameplate).

System Integration Design Guide

3.4.3.3 Parallel Connection of Motors

The frequency converter can control several parallelconnected motors. When using parallel motor connection, observe the following:

Recommended to run applications with parallel

•

motors in U/F mode parameter 1-01 Motor Control Principle [0]. Set the U/F graph in parameter 1-55 U/f Characteristic - U and parameter 1-56 U/f Characteristic - F.

VVC+ mode may be used in some applications.

•

The total current consumption of the motors

•

must not exceed the rated output current I the frequency converter.

If motor sizes are widely dierent in winding

•

resistance, starting problems may occur due to too low motor voltage at low speed.

The electronic thermal relay (ETR) of the

•

frequency inverter cannot be used as motor overload protection for the individual motor. Provide further motor overload protection with for example thermistors in each motor winding or individual thermal relays. Circuit breakers are not suitable as protection device.

INV

for

NOTICE!

Installations with cables connected in a common joint as shown in the rst example in the picture is only recommended for short cable lengths.

NOTICE!

When motors are connected in parallel, parameter 1-02 Flux Motor Feedback Source cannot be used, and parameter 1-01 Motor Control Principle must be set to Special motor characteristics (U/f ).

The total motor cable length specied in chapter 7 Speci- cations, is valid as long as the parallel cables are kept short

(less than 10 m (32.8 ft) each).

3.4.3.4 Motor Insulation

For motor cable lengths ≤ the maximum cable length listed in chapter 7.3 General Specications, the following motor insulation ratings are recommended because the peak voltage can be up to twice the DC-link voltage, 2.8 times the mains voltage, due to transmission line eects in the motor cable. If a motor has lower insulation rating, it is recommended to use a dU/dt or sine-wave lter.

Nominal mains voltage Motor insulation

UN≤420 V

420 V<UN≤500 V Reinforced ULL=1600 V

Table 3.4 Mains Voltage and Motor Insulation

Standard ULL=1300 V

3.4.3.5 Motor Bearing Currents

To minimize DE (Drive End) bearing and shaft currents proper grounding of the frequency converter, motor, driven machine, and motor to the driven machine is required.

Standard mitigation strategies

1. Use an insulated bearing.

2. Apply rigorous installation procedures:

2a Ensure that the motor and load motor

are aligned.

2b Strictly follow the EMC Installation

guideline.

2c Reinforce the PE so the high frequency

impedance is lower in the PE than the input power leads.

2d Provide a good high frequency

connection between the motor and the frequency converter, for instance via a shielded cable which has a 360° connection in the motor and the frequency converter.

2e Make sure that the impedance from the

frequency converter to the building ground is lower than the grounding impedance of the machine. This can be dicult for pumps.

2f Make a direct ground connection

between the motor and load motor.

3. Lower the IGBT switching frequency.

Modify the inverter waveform, 60° AVM vs. SFAVM.

5. Install a shaft grounding system or use an isolating coupling.

6. Apply conductive lubrication.

7. Use minimum speed settings if possible.

8. Try to ensure that the mains voltage is balanced to ground. This can be dicult for IT, TT, TN-CS, or grounded leg systems.

9. Use a dU/dt or sinus lter.

3 3

System Integration

VLT® Decentral Drive FCD 302

3.4.4 Extreme Running Conditions

Short circuit (motor phase – phase)

The frequency converter is protected against short circuits

with 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 inverter. The inverter is turned o individually when the short-circuit current exceeds the allowed value (Alarm 16, Trip Lock). To protect the frequency converter against a short circuit at the load sharing and brake outputs, see the design guidelines.

Switching on the output

Switching on the output between the motor and the frequency converter is fully allowed. No damage to the frequency converter can occur by switching on the output. However, fault messages can appear.

Motor-generated overvoltage

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

The load drives the motor (at constant output

•

frequency from the frequency converter), that is, the load generates energy.

During deceleration (ramp-down), if the inertia

•

moment is high, the friction is low, and the rampdown time is too short for the energy to be dissipated as a loss in the frequency converter, the motor, and the installation.

Incorrect slip compensation setting can cause

•

higher DC-link voltage.

Back EMF from PM motor operation. When

•

coasted at high RPM, the PM motor back EMF can potentially exceed the maximum voltage tolerance of the frequency converter and cause damage. The frequency converter is designed to prevent the occurrence of back EMF: The value of parameter 4-19 Max Output Frequency is automatically limited based on an internal calculation based on the value of parameter 1-40 Back EMF at 1000 RPM, parameter 1-25 Motor Nominal Speed, and parameter 1-39 Motor Poles. When motor overspeed is possible (for example, due to excessive windmilling eects), then a brake resistor is recommended.

NOTICE!

The frequency converter must be equipped with a break chopper.

When possible, the control unit may attempt to correct the ramp (parameter 2-17 Over-voltage Control).

The inverter turns o when a certain voltage level is reached, to protect the transistors and the DC link capacitors. See parameter 2-10 Brake Function and parameter 2-17 Over- voltage Control to select the method used for controlling the DC-link voltage level.

NOTICE!

OVC cannot be activated when running a PM motor, that is, for parameter 1-10 Motor Construction set to [1] PM non-salient SPM.

Mains drop-out

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

Static overload in VVC+ mode

When the frequency converter is overloaded, the controls reduce the output frequency to reduce the load. Overload is dened as reaching the torque limit set in

parameter 4-16 Torque Limit Motor Mode/ parameter 4-17 Torque Limit Generator Mode.

For extreme overload, a current acts to ensure the frequency converter cuts out after approximately 5– 10 seconds.

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

3.4.4.1 Motor Thermal Protection

To protect the application from serious damage, the frequency converter oers several dedicated features:

Torque limit

The torque limit feature protects the motor from being overloaded independent of the speed. Select torque limit settings in parameter 4-16 Torque Limit Motor Mode and/or parameter 4-17 Torque Limit Generator Mode. Set the time to trip for the torque limit warning in parameter 14-25 Trip Delay at Torque Limit.

Current limit

Set the current limit in parameter 4-18 Current Limit. Set the time before the current limit warning trips in parameter 14-24 Trip Delay at Current Limit.

Minimum speed limit

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

operating speed range to for instance between 30 and 50/60 Hz. Maximum speed limit: Parameter 4-13 Motor

1.21.0 1.4

100

1.81.6 2.0

2000

500

200

400 300

1000

600

t [s]

175ZA052.11

fOUT = 0.2 x f M,N

fOUT = 2 x f M,N

fOUT = 1 x f M,N

IMN

System Integration Design Guide

Speed High Limit [RPM] or parameter 4-19 Max Output Frequency limit the maximum output speed the frequency

converter can provide.

ETR (electronic thermal relay)

The ETR function measures actual current, speed, and time to calculate motor temperature and protect 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 Figure 3.12.

Figure 3.12 ETR Functions

In Figure 3.12 the X-axis shows the ratio between I I

nominal. The Y-axis shows the time in seconds before

motor

the ETR cut of and trips the frequency converter. The curves show the characteristic nominal speed, at twice the nominal speed and at 0.2 x the nominal speed. At lower speed the ETR cuts o at lower heat due to less cooling of the motor. In that way, the motor is protected from overheating even at low speed. The ETR feature calculates the motor temperature based on actual current and speed. The calculated temperature is visible as a readout parameter in parameter 16-18 Motor Thermal in the frequency converter.

Final Test and Set-up

3.5

motor

and

WARNING

HIGH LEAKAGE CURRENT

When running high-voltage tests of the entire installation, leakage currents can be high. Failure to follow recommendations could result in death or serious injury.

Interrupt the mains and motor connection if the

•

leakage currents are too high.

3.5.2 Grounding

The following basic issues need to be considered when installing a frequency converter to obtain electromagnetic compatibility (EMC).

Safety grounding: Note that the frequency

•

converter has a high leakage current and must be grounded appropriately for safety reasons. Apply local safety regulations.

High frequency grounding: Keep the ground wire

•

connections as short as possible.

Connect the dierent ground systems at the lowest possible conductor impedance. The lowest possible conductor impedance is obtained by keeping the conductor as short as possible and by using the greatest possible surface area. The metal cabinets of the dierent devices are mounted on the cabinet rear plate using the lowest possible HF impedance. This avoids having dierent HF voltages for the individual devices and avoids the risk of radio interference currents running in connection cables that may be used between the devices. The radio interference has been reduced. To obtain a low HF impedance, use the fastening bolts of the devices as HF connection to the rear plate. It is necessary to remove insulating paint or similar from the fastening points.

3.5.3 Safety Grounding Connection

The frequency converter has a high leakage current and must be grounded appropriately for safety reasons according to IEC 61800-5-1.

3 3

3.5.1 High-voltage Test

Carry out a high-voltage test by short-circuiting terminals U, V, W, L1, L2, and L3. Energize maximum 2.15 kV DC for 380–500 V frequency converters for 1 s between this short circuit and the chassis.

The limits for the high-voltage test are:

LVD (CE) = 1500 V AC = 2150 V DC

•

UL = (2 x 500) + 1000 = 2000 V AC = 2850 V DC

•

WARNING

LEAKAGE CURRENT HAZARD

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

Ensure the correct grounding of the equipment

•

by a certied electrical installer.

130BD002.10

Nmax

7,2 A

0..370 rpm

max

250 Hz

amb

40 °C KTY 84-130

28 kgP3

IP 69K

155 °C (F)

178uxxxxxxxxxxb011

i 8,12

Type OGDHK231K131402L09R1S11P1A9010H1Bxx

Barcode

Made in Germany

140-65 Nm

2,9 L Optileb GT220

130BB851.15

N/max

5.5/9.0 A

max

=212 rpm

max

250 Hz

amb

40 °C

KTY 84-130

24 kg P3

IP 69K

150 °C (F)

178uxxxxxxxxxxb011

i 14.13

Type

OGDHK214K13140L06XXS31P3A9010H1BXX

Barcode

Made in Germany

HST/n

=280/180..131 Nm

3.1 L Optileb GT220

System Integration

VLT® Decentral Drive FCD 302

3.5.4 Final Set-up Check

2. Check the motor nameplate data in this parameter list.

Follow these steps to check the set-up and ensure that the frequency converter is running.

1. Locate the motor nameplate.

NOTICE!

The motor is either star- (Y) or delta- connected (Δ). This information is located on the motor nameplate data.

To access this list, press the [Quick Menu] key on the LCP and select “Q2 Quick Set-up”.

2a Parameter 1-20 Motor Power [kW].

Parameter 1-21 Motor Power [HP].

2b Parameter 1-22 Motor Voltage.

2c Parameter 1-23 Motor Frequency.

2d Parameter 1-24 Motor Current.

2e Parameter 1-25 Motor Nominal Speed.

3. Select OGD motor data.

3a Set 1-11 Motor Model to 'Danfoss OGD

LA10'.

4. Set speed limit and ramp times.

Figure 3.13 Location of Motor Nameplate

Set up the desired limits for speed and ramp time:

4a Parameter 3-02 Minimum Reference.

4b Parameter 3-03 Maximum Reference.

4c Parameter 4-11 Motor Speed Low Limit

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

4d Parameter 4-13 Motor Speed High Limit

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

4e Parameter 3-41 Ramp 1 Ramp-up Time.

4f Parameter 3-42 Ramp 1 Ramp-down Time.

Figure 3.14 Nameplate

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB929.10

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB930.10

+10

A IN

COM

A OUT

COM

A53

U - I

0 – 10 V

e30bb926.11

Application Examples Design Guide

4 Application Examples

4.1 Overview

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.

Where switch settings for analog terminals A53 or

•

A54 are required, these are also shown.

NOTICE!

A jumper wire may be required between terminal 12 (or

4.2.2 AMA without T27 Connected

Parameters

Function Setting

Parameter 1-29 A

utomatic Motor

Adaptation

(AMA)

Parameter 5-12 T

erminal 27

Digital Input

*=Default value

Notes/comments: Parameter

group 1-2* Motor Data must be

set according to motor.

[1] Enable

4 4

complete

AMA

[0] No

operation

13) and terminal 27 for the frequency converter to operate when using factory default programming values.

Refer to VLT® Frequency Converters Safe Torque O Operating Instructions for further information

4.2 AMA

Table 4.2 AMA without T27 Connected

4.2.1 AMA with T27 Connected Analog Speed Reference

4.3

Parameters

Function Setting

Parameter 1-29 A

utomatic Motor

Adaptation

[1] Enable

complete

AMA

(AMA)

Parameter 5-12 T

erminal 27

[2]* Coast

inverse

Digital Input

*=Default value

Notes/comments: Parameter

group 1-2* Motor Data must be

set according to motor.

Table 4.1 AMA with T27 Connected

4.3.1 Voltage Analog Speed Reference

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

*=Default value

Notes/comments:

Table 4.3 Voltage Analog Speed Reference

0.07 V*

10 V*

0 RPM

1500 RPM

+10

A IN

COM

A OUT

COM

e30bb927.11

A53

U - I

4 - 20mA

130BB840.12

Speed

Reference

Start (18)

Freeze ref (27)

Speed up (29)

Speed down (32)

+10

A IN

COM

A OUT

COM

A53

U - I

≈ 5kΩ

e30bb683.11

+24 V

D IN

COM

D IN

e30bb804.12

Application Examples

VLT® Decentral Drive FCD 302

4.3.2 Current Analog Speed Reference

4.3.3 Speed Reference (Using a Manual Potentiometer)

Parameters

Function Setting

Parameter 6-12 T

4 mA*

erminal 53 Low

Current

Parameter 6-13 T

20 mA*

erminal 53 High

Current

Parameter 6-14 T

0 RPM

erminal 53 Low

Ref./Feedb. Value

Parameter 6-15 T

1500 RPM

erminal 53 High

Ref./Feedb. Value

*=Default value

Notes/comments:

Table 4.4 Current Analog Speed Reference

Table 4.5 Speed Reference (Using a Manual Potentiometer)

Parameters

Function Setting

Parameter 6-10 T

0.07 V*

erminal 53 Low

Voltage

Parameter 6-11 T

10 V*

erminal 53 High

Voltage

Parameter 6-14 T

0 RPM

erminal 53 Low

Ref./Feedb. Value

Parameter 6-15 T

1500 RPM

erminal 53 High

Ref./Feedb. Value

*=Default value

Notes/comments:

Figure 4.1 Speed Up/Speed Down

4.3.4 Speed Up/Speed Down

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:

Table 4.6 Speed Up/Speed Down

[8] Start*

[19] Freeze

Reference

[21] Speed Up

[22] Speed

Down

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BB802.10

130BB805.12

Speed

Start/Stop (18)

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB803.10

Speed

130BB806.10

Latched Start (18)

Stop Inverse (27)

Application Examples Design Guide

4.4 Start/Stop Applications

4.4.1 Start/Stop Command with Safe Torque O

Parameters

Function Setting

Parameter 5-10 T

erminal 18

Digital Input

Parameter 5-12 T

erminal 27

Digital Input

Parameter 5-19 T

erminal 37 Safe

Stop

*=Default value

Notes/comments:

If parameter 5-12 Terminal 27

Digital Input is set to [0] No

operation, a jumper wire to

terminal 27 is not needed.

Table 4.7 Start/Stop Command with Safe Torque O

[8] Start*

[0] No

operation

[1] Safe Stop

Alarm

4.4.2 Pulse Start/Stop

Parameters

Table 4.8 Pulse Start/Stop

Function Setting

Parameter 5-10 T

erminal 18

[9] Latched

Start

Digital Input

Parameter 5-12 T

erminal 27

[6] Stop

Inverse

Digital Input

*=Default value

Notes/comments:

If parameter 5-12 Terminal 27

Digital Input is set to [0] No

operation, a jumper wire to

terminal 27 is not needed.

4 4

Figure 4.2 Start/Stop Command with Safe Torque O

Figure 4.3 Pulse Start/Stop

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB934.11

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BB928.11

Application Examples

VLT® Decentral Drive FCD 302

4.4.3 Start/Stop with Reversing and 4

Bus and Relay Connection

4.5

Preset Speeds

4.5.1 External Alarm Reset

Parameters

Function Setting

Parameter 5-10 Ter

[8] Start

minal 18 Digital

Input

Parameter 5-11 Ter

minal 19 Digital

[10]

Reversing*

Input

Parameter 5-12 Ter

minal 27 Digital

[0] No

operation

Input

Parameter 5-14 Ter

minal 32 Digital

[16] Preset

ref bit 0

Input

Parameter 5-15 Ter

minal 33 Digital

[17] Preset

ref bit 1

Input

Parameter 3-10 Pre

set Reference

Preset ref. 0

Preset ref. 1

Preset ref. 2

Preset ref. 3

25%

50%

75%

100%

Table 4.10 External Alarm Reset

*=Default value

Notes/comments:

Parameters

Function Setting

Parameter 5-11 T

[1] Reset

erminal 19

Digital Input

*=Default value

Notes/comments:

Table 4.9 Start/Stop with Reversing and 4 Preset Speeds

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

R1R2

61 68 69

RS-485

130BB685.10

130BB686.12

VLT

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

A53

U - I

D IN

Application Examples Design Guide

4.5.2 RS485 Network Connection

Parameters

Function Setting

Parameter 8-30 P

rotocol

Parameter 8-31 A

ddress

Parameter 8-32 B

aud Rate

*=Default value

Notes/comments:

Select protocol, address, and

baud rate in the above

mentioned parameters.

[0] FC*

9600*

4.5.3 Motor Thermistor

NOTICE!

Thermistors must use reinforced or double insulation to meet insulation requirements.

Parameters

Function Setting

Parameter 1-90

Motor Thermal

Protection

Parameter 1-93 T

hermistor Source

*=Default value

Notes/comments:

If only a warning is desired,

parameter 1-90 Motor Thermal

Protection should be set to [1]

Thermistor warning.

[2] Thermistor

trip

[1] Analog

input 53

4 4

Table 4.11 RS485 Network Connection

Table 4.12 Motor Thermistor

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

R1R2

130BB839.10

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

R1R2

130BB841.10

Application Examples

VLT® Decentral Drive FCD 302

4.5.4 Using SLC to Set a Relay

*=Default value

Notes/comments:

Parameters

Function Setting

Parameter 4-30

[1] Warning

Motor Feedback

Loss Function

Parameter 4-31

100 RPM

Motor Feedback

Speed Error

Parameter 4-32

5 s

Motor Feedback

Loss Timeout

Parameter 7-00 S

[2] MCB 102

peed PID

Feedback Source

Parameter 17-11

Resolution (PPR)

Parameter 13-00

SL Controller

1024*

Table 4.14 Using Smart Logic Controller to Set a Relay

[1] On

4.6 Brake Application

If the limit in the feedback

monitor is exceeded, warning

90 Feedback Mon. is issued. The

SLC monitors warning 90 and if

the warning becomes true,

relay 1 is triggered.

External equipment may then

indicate that service may be

required. If the feedback error

goes below the limit again

within 5 s, the frequency

converter continues and the

warning disappears. But relay 1

is still triggered until pressing

[Reset] on the LCP.

Mode

Parameter 13-01

[19] Warning

4.6.1 Mechanical Brake Control

Start Event

Parameter 13-02

Stop Event

Parameter 13-10

Comparator

Operand

Parameter 13-11

Comparator

Operator

Parameter 13-12

Comparator

Value

Parameter 13-51

Table 4.13 Using Smart Logic Controller to Set a Relay

SL Controller

Event

Parameter 13-52

SL Controller

Action

Parameter 5-40 F

unction Relay

[44] Reset key

[21] Warning

no.

[1] ≈*

[22]

Comparator 0

[32] Set

digital out A

low

[80] SL digital

output A

Parameter 5-40 F

unction Relay

Parameter 5-10 T

erminal 18

Digital Input

Parameter 5-11 T

erminal 19

Digital Input

Parameter 1-71 S

tart Delay

Parameter 1-72 S

tart Function

Parameter 1-76 S

tart Current

Parameter 2-20 R

elease Brake

Current

Parameter 2-21 A

ctivate Brake

Speed [RPM]

*=Default value

Notes/comments:

Table 4.15 Mechanical Brake Control

Parameters

Function Setting

[32] Mech.

brake ctrl

[8] Start*

[11] Start

reversing

0.2

[5] VVC+/

FLUX

Clockwise

m,n

Application

dependent

Half of

nominal slip

of the motor

Start ( 18)

Start

reversing (19)

Relay output

Speed

Time

Current

1-71

2-21

1-76

Open

Closed

130BB842.10

Application Examples Design Guide

Figure 4.4 Mechanical Brake Control

4.6.2 Hoist Mechanical Brake

The VLT® Decentral Drive FCD 302 features a mechanical brake control designed for hoisting applications. The hoist mechanical brake is activated via option [6] Hoist Mech. Brake Rel in parameter 1-72 Start Function. The main dierence compared to the regular mechanical brake control, where a relay function monitoring the output current is used, is that the hoist mechanical brake function has direct control over the brake relay. This means that instead of setting a current for release of the brake, the torque is applied against the closed brake before release is dened. Because the torque is dened directly, the set-up is more straightforward for hoisting applications. Set parameter 2-28 Gain Boost Factor to obtain a quicker control when releasing the brake. The hoist mechanical brake strategy is based on a 3-step sequence, where motor control and brake release are synchronized to obtain the smoothest possible brake release.

4 4

3-step sequence

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

2. Apply torque against the closed brake When the load is held by the mechanical brake, its size cannot be determined, only its direction. The moment the brake opens, the load must be taken over by the motor. To facilitate the takeover, a user-dened torque, set in parameter 2-26 Torque Ref, is applied in hoisting direction. This is used to restore the speed controller that nally takes over the load. To reduce wear on the gearbox due to backlash, the torque is acceled.

3. Release brake When the torque reaches the value set in parameter 2-26 Torque Ref, the brake is released. The value set in parameter 2-25 Brake Release Time determines the delay before the load is released. To react as quickly as possible on the load-step that follows brake release, increase the proportional gain to boost the speed PID control.

Mech.Brake

GainBoost

Relay

Torqueref.

MotorSpeed

Premag Torque Ramp

Time p. 2-27

Torque Ref. 2-26

Gain Boost Factor p. 2-28

Brake Release Time p. 2-25

Ramp 1 upp. 3-41 Ramp 1 downp. 3-42 Stop

Delay p. 2-24

Activate Brake Delay p. 2-23

1 2 3

130BA642.12

Application Examples

VLT® Decentral Drive FCD 302

Figure 4.5 Brake Release Sequence for Hoist Mechanical Brake Control

I) Activate Brake Delay: The frequency converter starts again from the mechanical brake engaged position.

II) Stop delay: When the time between successive starts is shorter than the setting in parameter 2-24 Stop Delay, the frequency

converter starts without applying the mechanical brake (for example, reversing).

Both relays 1 and 2 can be used to control the brake.

121212 121212 55 53

271918 333229 50 54

202020 202020 55 42

+24V

GND

130BC995.10

130BA646.10

CCW

Application Examples Design Guide

4.7 Encoder

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 is shown.

Figure 4.6 Encoder Connection to the Frequency Converter

4.7.1 Encoder Direction

The direction of the encoder is determined by which order the pulses are entering the frequency converter.

Clockwise direction means channel A is 90

•

electrical degrees before channel B.

Counterclockwise direction means channel B is 90

•

electrical degrees before A.

The direction is determined by looking into the shaft end.

4.8 Closed-loop Drive System

A closed-loop drive system usually comprises elements such as:

Motor.

•

Additional equipment:

•

- Gearbox

- Mechanical Brake

Frequency converter.

•

Encoder as feedback system.

•

Brake resistor for dynamic brake.

•

Transmission.

•

Load.

•

Applications demanding mechanical brake control usually needs a brake resistor.

4 4

Figure 4.7 24 V Incremental Encoder with Maximum Cable

Length 5 m (16.4 ft)

130BC996.10

3 4

WARNING

ALARM

Bus MS NS2NS1

1 2

Application Examples

VLT® Decentral Drive FCD 302

Item Description

1 Encoder

2 Mechanical brake

3 Motor

4 Gearbox

5 Transmission

6 Brake resistor

7 Load

Figure 4.8 Basic Set-up for Closed-loop Speed Control

. . . . . .

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..

. . . . . .

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

Application Examples Design Guide

4.9 Smart Logic Control

Smart logic control (SLC) is essentially 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. This leads to an associated action as illustrated in Figure 4.9.

4 4

Figure 4.10 Example - Internal Current Control

Comparators

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

Events and actions are each numbered and linked together 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] is 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. This means that 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. It is possible to program from 1 to 20 events and actions. When the last event/action has been executed, the sequence starts over again from event [0]/action [0]. Figure 4.10 shows an example with 3 event/actions.

Figure 4.9 Current Control Status/Event and Action

Figure 4.11 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.

Figure 4.12 Logic Rules

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

R1R2

130BB839.10

Application Examples

VLT® Decentral Drive FCD 302

Application example

*=Default value

Notes/comments:

Parameters

Function Setting

Parameter 4-30

[1] Warning

Motor Feedback

Loss Function

Parameter 4-31

Motor Feedback

100 RPM

Speed Error

Parameter 4-32

5 s

Motor Feedback

Loss Timeout

Parameter 7-00 S

[2] MCB 102

peed PID

Feedback Source

Parameter 17-11

1024*

If the limit in the feedback

monitor is exceeded, warning

90 Feedback Mon. is issued. The

SLC monitors warning 90 and if

the warning becomes true,

relay 1 is triggered.

External equipment may then

indicate that service may be

required. If the feedback error

goes below the limit again

within 5 s, the frequency

converter continues and the

warning disappears. But relay 1

is still triggered until pressing

[Reset] on the LCP.

Resolution (PPR)

Parameter 13-00

[1] On

Table 4.17 Using SLC to Set a Relay

SL Controller

Mode

Parameter 13-01

[19] Warning

Start Event

Parameter 13-02

[44] Reset key

Stop Event

Parameter 13-10

Comparator

[21] Warning

no.

Operand

Parameter 13-11

[1] ≈*

Comparator

Operator

Parameter 13-12

Comparator

Value

Parameter 13-51

SL Controller

Table 4.16 Using SLC to Set a Relay

Event

Parameter 13-52

SL Controller

Action

Parameter 5-40 F

unction Relay

[22]

Comparator 0

[32] Set

digital out A

low

[80] SL digital

output A

130BD549.11

Max.I

out

(%)

at T

AMB, MAX

Altitude (m)

FCD

enclosure

at 100% I

out

100%

91%

82%

0 K

-5 K

-9 K

1000 2000 3000

AMB, MAX

(K)

3280 6561 9842 Altitude (ft)

Special Conditions Design Guide

5 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. This is done to ensure the performance at critical stages where the alternative could be a trip.

5.1 Manual Derating

Manual derating must be considered for:

Air pressure – relevant for installation at altitudes

•

above 1000 m (3280 ft)

Motor speed – at continuous operation at low

•

RPM in constant torque applications

Ambient temperature – relevant for ambient

•

temperatures above 40 °C (104 °F)

Contact Danfoss for the application note for tables and elaboration. Only the case of running at low motor speeds is elaborated here.

5.1.1 Derating for Low Air Pressure

The cooling capability of air is decreased at lower air pressure.

Below 1000 m (3280 ft) altitude no derating is necessary. But above 1000 m (3280 ft) the ambient temperature (T

) or maximum output current (I

AMB

in accordance with the diagram in Figure 5.1.

) should be derated

out

An alternative is to lower the ambient temperature at high altitudes and by that ensuring 100% output current at high altitudes. As an example of how to read the graph, the situation at 2000 m (6561 ft) is elaborated for a 3 kW (4 hp) frequency converter with T At a temperature of 36 °C (96.8 °F) (T

= 40 °C (104 °F).

AMB, MAX

- 3.3 K), 91%

of the rated output current is available. At a temperature of 41.7 °C (107 °F), 100% of the rated output current is available.

5.1.2 Derating for Running at Low Speed

When a motor is connected to a frequency converter, it is necessary to check that the cooling of the motor is adequate. The level of heating depends on the load on the motor, and the operating speed and time.

Constant torque applications (CT mode)

A problem may occur at low RPM values in constant torque applications. In a constant torque application, a motor may overheat at low speed due to less cooling air from the motor integral fan. Therefore, if the motor is to be run continuously at an RPM value lower than half of the rated value, the motor must be supplied with extra air-cooling (or a motor designed for this type of operation may be used).

An alternative is to reduce the load level of the motor by selecting a larger motor. However, the design of the frequency converter puts a limit to the motor size.

Variable (quadratic) torque applications (VT)

In VT applications such as centrifugal pumps and fans, where the torque is proportional to the square of the speed and the power is proportional to the cube of the speed, there is no need for extra cooling or derating of the motor.

5 5

AMB,

Figure 5.1 Derating of output current versus altitude at T

for VLT® Decentral Drive FCD 302. At altitudes above

MAX

2000 m (6561 ft), contact Danfoss regarding PELV.

110%

100%

60%

80%

40%

20%

2 4 6 8 10

12 14

I (%)

out

(kHz)

40 C

45 C

50 C

130BD210.10

110%

100%

60%

80%

40%

20%

2 4 6 8 10

12 14

I (%)

out

(kHz)

40 C

45 C

50 C

130BD211.10

110%

100%

60%

80%

40%

20%

2 4 6 8 10

12 14

I (%)

out

(kHz)

40 C

45 C

50 C

130BD208.10

110%

100%

60%

80%

40%

20%

2 4 6 8 10

12 14

I (%)

out

(kHz)

40 C

45 C

50 C

130BD209.10

Special Conditions

VLT® Decentral Drive FCD 302

5.1.3 Ambient Temperature

Graphs are presented individually for 60° AVM and SFAVM.

5.1.3.2 Power Size 1.1–1.5 kW

60° AVM - Pulse width modulation

60° AVM only switches 2/3 of the time whereas SFAVM switches throughout the whole period. The maximum switching frequency is 16 kHz for 60° AVM and 10 kHz for SFAVM. The discrete switching frequencies are presented in Table 5.1.

Switchin

pattern

60° AVM

2 2.5 3 3.54 5 6 7 8 10 12 14 16

SFAVM 2 2.5 3 3.54 5 6 7 8 10 – – –

Table 5.1 Discrete Switching Frequencies

5.1.3.1 Power Size 0.37–0.75 kW

Discrete switching frequencies

Figure 5.4 Derating of I

for dierent T

out

AMB, MAX

for FCD 302

1.1–1.5 kW, using 60° AVM

SFAVM - Stator frequency asynchron vector modulation

60° AVM - Pulse width modulation

Figure 5.2 Derating of I

for dierent T

out

AMB, MAX

for FCD 302

0.37–0.55–0.75 kW, using 60° AVM

SFAVM - Stator frequency asynchron vector modulation

Figure 5.3 Derating of I

0.37–0.55–0.75 kW, using SFAVM

for dierent T

out

AMB, MAX

for FCD 302

Figure 5.5 Derating of I

1.1–1.5 kW, using SFAVM

for dierent T

out

AMB, MAX

for FCD 302

110%

100%

60%

80%

40%

20%

2 4 6 8 10

12 14

I (%)

out

(kHz)

40 C

45 C

50 C

130BD206.10

110%

100%

60%

80%

40%

20%

2 4 6 8 10

12 14

I (%)

out

(kHz)

40 C

45 C

50 C

130BD207.10

Special Conditions Design Guide

5.1.3.3 Power Size 2.2–3.0 kW

60° AVM - Pulse width modulation

Figure 5.6 Derating of I

2.2–3.0 kW, using 60° AVM

for dierent T

out

AMB, MAX

for FCD 302

5.2 Automatic Derating

The frequency converter constantly checks for critical levels:

Critical high temperature on the control card or heat sink

•

High motor load

•

High DC-link voltage

•

Low motor speed

•

SFAVM - Stator frequency asynchron vector modulation

Figure 5.7 Derating of I

2.2–3.0 kW, using SFAVM

for dierent T

out

AMB, MAX

for FCD 302

5 5

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

NOTICE!

The automatic derating is dierent when parameter 14-55 Output Filter is set to [2] Sine-Wave Filter Fixed.

The automatic derating is made up of contributions from separate functions that evaluate the need. Their interrelationship is illustrated in Figure 5.9.

CTRL/ Modulation Limit

Setting

from LCP

SW, ref

(load)

(UDC)

( fm )

(T)

Ramp

PWM

PWM (T)

PWM (f)

Protection

ag

SW, ref

130BD550.10

70%

160%

16 kHz @ 60PWM 10 kHz @ SFAVM

10 kHz @ 60PWM 7 kHz @ SFAVM

CTRL/

modulation

limi t

setting

from LCP

sw, ref

sw, I

sw, UD C

fmot

[

H z

]

fs w

[

]

1 0

SF AV

M only

1 5

3.9 4 9.9

s w

, f

f m

s w

f m

s w

DC,TRIP

Requested f

DC, START DERATING

PWM

fmotor[Hz]

SFAVM

60PWM

optional

80%-86% of fmotor,nom

10Hz-15Hz

AMB

PWM SWITCH

60PWM

SFAVM

AMB

High warning

Low warning

sw, fs

sw , TAS

Ramp

sw, DSP

fsw(I

load

) fsw(UDC)

fsw(fm)

fsw(T)

PWM(T)

PWM(fs)

PWM

130BB971.10

Protection flag (drop to f

sw,min

immediately)

Special Conditions

VLT® Decentral Drive FCD 302

NOTICE!

In sine-wave lter xed mode, the structure is dierent. See chapter 5.2.1 Sine-Wave Filter Fixed Mode.

Figure 5.8 Automatic Derating Function Block

Figure 5.9 Interrelationship Between the Automatic Derating Contributions

The switching frequency is rst derated due to motor current, followed by DC-link voltage, motor frequency, and then temperature. If multiple deratings occur on the same iteration, the resulting switching frequency would be the same as though only the most signicant derating occurred by itself (the deratings are not cumulative). Each of these functions is presented in the following sections.

TAS limit

fm limit

LCP

setting

Control/

Modulation

limi t

Ramp

Protection ag

( drop to fswmin

immediately )

Fsw, DSP

SFAVM 60 PWM

fsw, ref

fsw, TAS

fsw, fm

1[ms] DSP task

1[ms] task time of microcontroller

Fsw, LCP

fsw, max

fsw, minor

130BB972.11

Special Conditions Design Guide

5.2.1 Sine-Wave Filter Fixed Mode

If the frequency converter is running with a xed frequency sine-wave lter, the switching frequency is not derated due to motor current or DC-link voltage. The switching frequency is still derated due to motor frequency and temperature; however the order of these 2 operations is reversed. It should be noted that, in this situation, the function for derating based on motor frequency does nothing unless the frequency converter’s LC_Low_Speed_Derate_Enable PUD parameter is set to true. Also, the function for derating due to temperature is slightly dierent. In sine lter xed mode, a dierent protection mode switching frequency is sent to the DSP.

5 5

Figure 5.10 The Switching Frequency Limiting Algorithm when the Frequency Converter is Operating with a Fixed Frequency Sine-

wave Filter

70%

160%

16 kHz @ 60 PWM 10 kHz @ SFAVM

10 kHz @ 60PWM 7 kHz @ SFAVM

130BB973.10

DC,TRIP

Requested f

DC, START DERATING

130BB974.10

PWM

fmotor[Hz]

SFAVM

60 PWM

optional

80%-86% of

fmotor, nom

10Hz-15Hz

130BC143.10

fsw [kHz]

SFAVM only

153.9 4 9.9

sw,fm2

, f

sw,fm3

sw,fm4

sw,fm1

130BB975.10

AMB

PWM SWITCH

60PWM

SFAVM

130BC142.10

AMB

High warning

Low warning

130BB976.10

fsw [kHz]

Iout [%]

130BB977.10

Special Conditions

5.2.2 Overview Table

VLT® Decentral Drive FCD 302

Background for derating PWM - Functions that adjust the switching

fsw – Functions that derate the switching frequency

pattern

↑

load

Udc ↑

No automatic derating

T ↑

Table 5.2 Overview - Derating

5.2.3 High Motor Load

The switching frequency is automatically adjusted according to the motor current. When a certain percentage of the nominal HO motor load is reached, the switching frequency is derated. This percentage is individual for each enclosure size and a value that is coded in the EEPROM along with the other points that limit the derating.

Figure 5.11 Derating of Switching Frequency According to

Motor Load. f1, f2, I1, and I2 are Coded in EEPROM.

In EEPROM, the limits depend on the modulation mode. In 60° AVM, f1 and f2 are higher than for SFAVM. I1 and I2 are independent of modulation mode.

fsw [kHz]

Udc [V ]

130BB978.10

PWM

fm[Hz]

SFAVM

60PWM

optional

fm,switch2fm,switch1

130BB979.10

fm [HZ]

fsw [kHz]

fm4

SFAVM only

fm5 (fm, switch 1)fm1 fm2 fm3

sw,fm2

sw,fm3

sw,fm 4

sw,fm1

Is< K

Is1*Inom ,ho

Is1*Inom,ho

<= Is< K

Is2*Inom,ho

Is>= K

Is2*Inom,ho

130BB980.10

Special Conditions Design Guide

5.2.4 High Voltage on the DC link

The switching frequency is automatically adjusted according to the voltage on the DC link. When the DC link reaches a certain magnitude, the switching frequency is derated. The points that limit the derating are individual for each enclosure size and are coded in the EEPROM.

Figure 5.12 Derating of Switching Frequency According to

Voltage on the DC link. f1, f2, U1, and U2 are Coded in

EEPROM.

In EEPROM the limits depend on the modulation mode. In 60° AVM, f1 and f2 are higher than for SFAVM. U1 and U2 are independent of the modulation mode.

5.2.5 Low Motor Speed

is used. Therefore, for low values of the stator frequency where the temperature variations are large, the switching frequency can be reduced to lower the peak temperature and thereby the temperature variations. For VT-applications, the load current is relatively small for small stator frequencies and the temperature variations are thus not as large as for the CT-applications. For this reason, also the load current is considered.

5 5

Figure 5.14 Switching Frequency (fsw) Variation for Dierent

Stator Frequencies (fm)

The points that limit the derating are individual for each enclosure size and are coded in the EEPROM.

The option of PWM strategy depends on the stator frequency. To prevent that the same IGBT is conducting for too long (thermal consideration), fm, switch1 is specied as the minimum stator frequency for 60° PWM, whereas fm,

NOTICE!

The VLT® Decentral Drive FCD 302 never derates the current automatically. Automatic derating refers to adaptation of the switching frequency and pattern.

switch2 is specied as the maximum stator frequency for SFAVM to protect the frequency converter. 60° PWM helps to reduce the inverter loss above f

m, switch1

as the switch

For VT-applications, the load current is considered before derating the switching frequency at low motor speed.

loss is reduced by 1/3 by changing from SFAVM to 60° AVM.

5.2.6 High Internal

The switching frequency is derated based on both control card- and heat sink temperature. This function may sometimes be referred to as the temperature adaptive switching frequency function (TAS).

Figure 5.13 Reducing Inverter Loss

The shape of the average temperature is constant regardless of the stator frequency. The peak temperature, however, follows the shape of the output power for small stator frequencies and goes towards the average temperature for increasing stator frequency. This results in higher temperature variations for small stator frequencies. This means that the expected lifetime of the component decreases for small stator frequencies if no compensation

TasTRefHigh

TasTRefNormal

TasTHys

fswMax

fswMin

T [ºC]

fsw [kHz]

Time

Δt

130BB981.10

Δt

PWM

60 PWM

10 20 30 40 50 60 70 80 90 100 110

100

120

v %

T %

1) 130BA893.10

Special Conditions

NOTICE!

Figure 5.15 shows 1 temperature aecting the derating.

In fact there are 2 limiting temperatures: Control card temperature and heat sink temperature. Both have their own set of control temperatures.

VLT® Decentral Drive FCD 302

Derating for Running at Low Speed

5.3

When a motor is connected to a frequency converter, it is necessary to check that the cooling of the motor is adequate. The level of heating depends on the load on the motor, the operating speed, and time.

Constant torque applications (CT mode)

A problem may occur at low RPM values in constant

torque applications. In constant torque applications, a motor may overheat at low speeds due to less cooling air from the motor integral fan. Therefore, if the motor is to be run continuously at an RPM value lower than half of the rated value, the motor must be supplied with extra aircooling (or a motor designed for this type of operation may be used). An alternative is to reduce the load level of the motor by selecting a larger motor. However, the design

Figure 5.15 Switching Frequency Derating due to High

Temperature

of the frequency converter puts a limit to the motor size.

Variable (quadratic) torque applications (VT)

In VT applications such as centrifugal pumps and fans, the torque is proportional to the square of the speed and the

NOTICE!

dt is 10 s when the control card is too hot but 0 s when the heat sink is too hot (more critical).

power is proportional to the cube of the speed. In these applications, there is no need for extra cooling or derating of the motor. In Figure 5.16, the typical VT curve is below the maximum torque with derating and maximum torque

The high warning can only be violated for a certain time

with forced cooling at all speeds.

before the frequency converter trips.

5.2.7 Current

The nal derating function is a derating of the output current due to high temperatures. This calculation takes place after the calculations for derating the switching frequency. This results in an attempt to lower the temperatures by rst lowering the switching frequency, and then lowering the output current. Current derating is only performed if the unit is programmed to derate in overtemperature situations. If the user has selected a trip function for overtemperature situations, the current derate factor is not lowered.

Item Description

‒‒‒‒‒‒‒‒ Maximum torque

─ ─ ─ ─ Typical torque at VT load

Figure 5.16 VT Applications - Maximum Load for a Standard

Motor at 40 °C (104 °F)

NOTICE!

Oversynchronous speed operation results in decrease of the available motor torque, inversely proportional to the increase in speed. Consider this during the design phase to avoid motor overload.

Position 2 4 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 33 34 35 36 37 39 39

F C D 3 0 2 P T 4 H 1 X A B X X X X X D

1 3 5

130BB797.10

Type Code and Selection Gui... Design Guide

6 Type Code and Selection Guide

6.1 Type Code Description

Position Description Choices/options

01–03 Product group FCD Decentral Drive

04–06 Frequency converter series 302 Advanced performance

PK37 0.37 kW/0.5 hp

PK55 0.55 kW/0.75 hp

PK75 0.75 kW/1.0 hp

07–10 Power size

11–12 Phases, mains voltage

13–15 Enclosure

16–17 RFI lter H1 RFI lter class A1/C2

18 Brake

19 Hardware conguration

20 Brackets

21 Threads

22 Switch option

23 Display

P1K1 1.1 kW/1.5 hp

P1K5 1.5 kW/2.0 hp

P2K2 2.2 kW/3.0 hp

P3K0 3.0 kW/4.0 hp (large unit only)

PXXX Installation box only (without power section)

T 3-phase

4 380–480 V AC

B66

W66

W69

X No brake

S Brake chopper + mechanical brake supply

1 Complete product, small unit, standalone mount

3 Complete product, large unit, standalone mount

X Drive part, small unit (no installation box)

Y Drive part, large unit (no installation box)

R Installation box, small unit, standalone mount (no drive part)

T Installation box, large unit, standalone mount (no drive part)

X No brackets

E Flat brackets

F 40 mm brackets

X No installation box

M Metric threads

X No switch option

E Service switch on mains input

F Service switch on motor output

L Circuit breaker & mains disconnect, looping terminals (large unit only)

K Service switch on mains input with extra looping terminals (large unit only)

X No display connector (No installation box)

C With display connector

Standard Black -

IP66/Type 4X

Standard White -

IP66/Type 4X

Hygienic White -

IP66K/Type 4X

Type Code and Selection Gui...

Position Description Choices/options

24 Sensor plugs

25 Motor plug X No motor plug

26 Mains plug X No mains plug

27 Fieldbus plug

28 Reserved X For future use

29–30 A option

31–32 B option

33–37 Reserved XXXXX For future use

38–39 D option

VLT® Decentral Drive FCD 302

X No sensor plugs

E Direct mount 4xM12: 4 digital inputs

F Direct mount 6xM12: 4 digital inputs, 2 relay outputs

X No eldbus plug

E M12 Ethernet

P M12 PROFIBUS

AX No A option

A0 PROFIBUS DP

AN EtherNet/IP

AL PROFINET

BX No B option

BR Encoder option

BU Resolver option

BZ Safety PLC Interface

DX No D option

D0 24 V DC back-up input

Figure 6.1 Type Code Description

Not all choices/options are available for each VLT® Decentral Drive FCD 302 variant. To verify if the appropriate version is available, consult the Drive Congurator on the Internet: vltcong.danfoss.com/ .

NOTICE!

A and D options for FCD 302 are integrated into the control card. Do not use pluggable options for frequency converters. Future retrot requires exchange of the entire control card. B options are pluggable, using the same concept as for frequency converters.

6.2 Ordering Numbers

6.2.1 Ordering Numbers: Accessories

Accessories Description Ordering number

Mounting brackets extended 40 mm brackets 130B5771

Mounting brackets Flat brackets 130B5772

LCP cable Preconfectioned cable to be used between inverter and LCP 130B5776

Brake resistor 1750 Ω 10 W/100%

Brake resistor 350 Ω 10 W/100%

VLT® Control Panel LCP 102

Venting membrane, goretex Preventing condensation inside enclosure 175N2116

Stainless chassis kit, M16 Stainless Steel 130B5833

For mounting inside installation box below motor terminals 130B5778

For mounting inside installation box below motor terminals 130B5780

Graphical LCP for programming and readout 130B1078

Table 6.1 Ordering Numbers: Accessories

Type Code and Selection Gui... Design Guide

6.2.2 Ordering Numbers: Spare Parts

Spare parts Description Ordering number

Protection cover Plastic protection cover for inverter part 130B5770

Gasket Gasket between installation box and inverter part 130B5773

Accessory bag Spare cable clamps and screws for shield termination 130B5774

Service switch Spare switch for mains or motor disconnect 130B5775

LCP plug Spare plug for mounting in installation box 130B5777

Main termination board For mounting in installation box 130B5779

M12 sensor plugs Set of two M12 sensor plugs for mounting in cable gland hole 130B5411

Control card Control card with 24 V back-up 130B5783

Control card PROFIBUS Control card PROFIBUS with 24 V back-up 130B5781

Control card Ethernet Control card Ethernet with 24 V back-up 130B5788

Control card PROFINET Control card PROFINET with 24 V back-up 130B5794

Table 6.2 Ordering Numbers: Spare Parts

The packaging contains:

Accessories bag, supplied only with order of

•

installation box. Contents:

- 2 cable clamps

- Bracket for motor/loads cables

- Elevation bracket for cable clamp

- Screw 4 mm x 20 mm

- Thread forming 3.5 mm x 8 mm

Documentation

•

Depending on options tted, the box contains 1 or 2 bags and 1 or more booklets.

Type Code and Selection Gui...

VLT® Decentral Drive FCD 302

6.3 Options and Accessories

Danfoss oers a wide range of options and accessories for the frequency converter.

6.3.1 Fieldbus Options

Select the eldbus option when ordering the frequency converter. All eldbus options are included on the control card. No separate A option is available. To change the eldbus option later, change out the control card. The following control cards with dierent eldbus options are available. All control cards have 24 V back-up as standard.

Item Ordering number

Control card PROFIBUS 130B5781

Control card Ethernet 130B5788

Control card PROFINET 130B5794

Table 6.3 Control Cards with Fieldbus Options

6.3.2

VLT® Encoder Input MCB 102

The encoder module can be used as feedback source for closed-loop ux control (parameter 1-02 Flux Motor Feedback Source) and closed-loop speed control (parameter 7-00 Speed PID Feedback Source). Congure the encoder option in parameter group 17-** Position Feedback.

Flux vector torque control.

•

Permanent magnet motor.

•

Supported encoder types:

Incremental encoder: 5 V TTL type, RS422,

•

maximum frequency: 410 kHz

Incremental encoder: 1Vpp, sine-cosine

•

Hiperface® Encoder: Absolute and Sine-Cosine

•

(Stegmann/SICK)

EnDat encoder: Absolute and Sine-Cosine

•

(Heidenhain) Supports version 2.1

SSI encoder: Absolute

•

Encoder monitor: The 4 encoder channels (A, B, Z,

•

and D) are monitored, open, and short circuit can be detected. There is a green LED for each channel which lights up when the channel is OK.

NOTICE!

The LEDs are not visible when mounted in a VLT Decentral Drive FCD 302 frequency converter. Reaction in

case of an encoder error can be selected in

parameter 17-61 Feedback Signal Monitoring: [0] Disabled, [1] Warning, or [2] Trip.

The encoder option kit contains:

Encoder Option MCB 102

•

Cable to connect customer terminals to control

•

card

The encoder option MCB 102 is used for:

VVC+ closed-loop.

•

Flux vector speed control.

•

+5V

GND

+24V

GND

130BC998.10

Us 7-12V (red)

GND (blue)

+COS (pink)

REFCOS (black)

+SIN (white)

REFSIN (brown)

Data +RS 485 (gray)

Data -RS 485 (green)

1 2 3 12754 6 8 9 10 11

130BA164.10

Type Code and Selection Gui... Design Guide

Connector

Designation

X31

Incremental

Encoder (refer

to Graphic A)

SinCos Encoder

HIPERFACE

(refer to Graphic

EnDat Encoder SSI Encoder Description

1 NC – –

2 NC 8 VCC – – 8 V output (7–12 V, I

3 5 VCC – 5 VCC

24 V

5 V

24 V output (21–25 V, I

max

5 V output (5 V ±5%, I

4 GND – GND GND GND

5 A input +COS +COS – A input

6 A inv input REFCOS REFCOS – A inv input

7 B input +SIN +SIN – B input

8 B inv input REFSIN REFSIN – B inv input

9 Z input +Data RS485 Clock out Clock out Z input OR +Data RS485

10 Z inv input -Data RS485 Clock out inv. Clock out inv. Z input OR -Data RS485

11 NC NC Data in Data in Future use

12 NC NC Data in inv. Data in inv. Future use

Maximum 5 V on X31.5–12 – – – –

Table 6.4 Encoder Option MCB 102 Connection Terminals

1) Supply for encoder: See data on encoder.

:125 mA)

max

: 200 mA)

max

Figure 6.2 Connections for 5 V Incremental Encoder

Maximum cable length 10 m (32.8 ft)

Figure 6.3 Connections for HIPERFACE® Encoder - 1

+RS485 +cos

-RS485

+sin

-sin

GND

7-12V

-cos

130BC999.10

130BD001.10

Resolver stator

Rotor

REF+ REFCOS+ COS-

SIN+ SIN-

LED 1 REF OK LED 2 COS OK LED 3 SIN OK LED NA

R1 R2 S1

Motor

37201

B11

B12

B05

B03

B01 REF+

B06 Sin-

B05 Sin+

B04 Cos-

B03 Cos+

B02 REF-

Type Code and Selection Gui...

VLT® Decentral Drive FCD 302

HIPERFACE® encoder

Figure 6.4 Connections for HIPERFACE® Encoder - 2

Item Description

6.3.3

VLT® Resolver Input MCB 103

The MCB 103 is used for interfacing resolver motor feedback to the frequency converter. Resolvers are used basically as motor feedback device for permanent magnet brushless synchronous motors.

Figure 6.5 Connections for Resolver Option MCB 103

The resolver option kit comprises:

MCB 103 Resolver Option.

•

Cable to connect customer terminals to control

•

card.

Find the relevant parameters in parameter group 17-5* Resolver Interface.

MCB 103 supports a various number of resolver types.

Resolver poles Parameter 17-50 Poles: 2 *2

Resolver input

voltage

Resolver input

frequency

Transformation ratio Parameter 17-53 Transformation Ratio: 0.1–

Secondary input

voltage

Secondary load

Parameter 17-51 Input Voltage: 2.0–8.0 V

*7.0 V

rms

Parameter 17-52 Input Frequency: 2–15 kHz

*10.0 kHz

1.1 *0.5

Maximum 4 V

Approximately 10 kΩ

Table 6.5 Resolver Option MCB 103 Specications

rms

NOTICE!

The Resolver Option MCB 103 can only be used with rotor-supplied resolver types. Stator-supplied resolvers cannot be used.

NOTICE!

LED indicators are not visible at the resolver option.

LED indicators

LED 1 is on when the reference signal is OK to

•

resolver.

LED 2 is on when the cosine signal is OK from

•

resolver.

LED 3 is on when the sine signal is OK from

•

resolver.

130BT102.10

Type Code and Selection Gui... Design Guide

The LEDs are active when parameter 17-61 Feedback Signal Monitoring is set to [1] Warning or [2] Trip.

Figure 6.6 Resolver Signals

Set-up example

In this example, a permanent magnet (PM) motor is used with resolver as speed feedback. A PM motor must usually operate in ux mode.

Wiring

The maximum cable length is 150 m (492 ft) when a twisted pair type of cable is used.

NOTICE!

Shield and separate the resolver cables from the motor cables.

NOTICE!

The shield of the resolver cable must be correctly connected to the decoupling plate and connected to chassis (ground) on the motor side.

NOTICE!

Always use shielded motor cables and brake chopper cables.

Parameter 1-00 Conguration Mode [1] Speed closed loop

Parameter 1-01 Motor Control Principle [3] Flux with feedback

Parameter 1-10 Motor Construction [1] PM, non-salient SPM

Parameter 1-24 Motor Current Nameplate

Parameter 1-25 Motor Nominal Speed Nameplate

Parameter 1-26 Motor Cont. Rated Torque Nameplate

AMA is not possible on PM motors

Parameter 1-30 Stator Resistance (Rs) Motor datasheet

Parameter 30-80 d-axis Inductance (Ld) Motor datasheet (mH)

Parameter 1-39 Motor Poles Motor datasheet

Parameter 1-40 Back EMF at 1000 RPM Motor datasheet

Parameter 1-41 Motor Angle Oset Motor datasheet (usually 0)

Parameter 17-50 Poles Resolver datasheet

Parameter 17-51 Input Voltage Resolver datasheet

Parameter 17-52 Input Frequency Resolver datasheet

Parameter 17-53 Transformation Ratio Resolver datasheet

Parameter 17-59 Resolver Interface [1] Enabled

Table 6.6 Parameters to Adjust

Type Code and Selection Gui...

6.3.4

VLT® 24 V DC Supply MCB 107

24 V DC external supply

A 24 V DC external supply can be installed for low voltage supply to the control card and any option card installed. This enables full operation of the LCP (including the parameter setting) without connection to mains.

VLT® Decentral Drive FCD 302

24 V DC external supply Input voltage range 24 V DC ±15% (maximum 37 V in 10 s) Maximum input current 2.2 A Average input current 0.9 A Maximum cable length 75 m Input capacitance load <10 uF Power-up delay <0.6 s The inputs are protected.

Terminal numbers

Terminal 35: - 24 V DC external supply.

•

Terminal 36: + 24 V DC external supply.

•

specication

41 mm (1.61 in)

175 mm (6.88 in)

349.5 mm (13.75 in)

315 mm (12.4 in)

WARNING

ALARM

Bus MS NS2NS1

331.5 mm (13.05 in)

280 mm (11.02 in)

178 mm (7 in)

6.5 mm (0.25 in)

80 mm

(3.14 in)

190 mm (7.48 in)

25 mm

(0.98 in)

Ø13 mm (0,51 in)

130BB712.10

200 mm (7.87 in)

80 mm

(3.14 in)

130BC381.10

431.5 mm (16.98 in)

380 mm (14.96 in)

178 mm (7 in)

201 mm (7.91 in)

32 mm (1.25 in)

415 mm (16.33 in)

186 mm (7.32 in)

449.5 mm (17.69 in)

6.5 mm (0.25 in)

190 mm (7.48 in)

80 mm

(3.14 in)

80 mm

(3.14 in)

Ø13 mm (0,51 in)

25 mm

(0.98 in)

Specications Design Guide

7 Specications

7.1 Mechanical Dimensions

7 7

Figure 7.1 Small Unit

Motor side 1xM20, 1xM25

Control side

2xM20, 9xM16

Mains side 2xM25

Also used for 4xM12/6xM12 sensor/actuator sockets.

Figure 7.2 Large Unit

WARNING

ALARM

Bus MS NS2NS1

130BB800.10

WARNING

ALARM

Bus MS NS2NS1

130BB799.10

Specications

VLT® Decentral Drive FCD 302

7.2 Electrical Data and Wire Sizes

7.2.1 Overview

Mains supply 3x380–480 V AC

Frequency converter PK37 PK55 PK75 P1K1 P1K5 P2K2 P3K0

Rated shaft output [kW ] 0.37 0.55 0.75 1.1 1.5 2.2 3.0

Rated shaft output [hp] 0.5 0.75 1.0 1.5 2.0 3.0 4.0

Maximum input current

Continuous (3x380–440 V) [A] 1.2 1.6 2.2 2.7 3.7 5.0 6.5

Intermittent (3x380–440 V) [A] 1.9 2.6 3.5 4.3 5.9 8.0 10.4

Continuous (3x441–480 V) [A] 1.0 1.4 1.9 2.7 3.1 4.3 5.7

Intermittent (3x441–480 V) [A] 1.6 2.2 3.0 4.3 5.0 6.9 9.1

Recommended maximum fuse size

(non-UL) gG-25

Output current

Built-in circuit breaker (large unit) CTI-25M Danfoss part number: 047B3151

Recommended circuit breaker

Danfoss CTI-25M (small and large

unit) part number:

0.37, 0.55 kW Danfoss part number: 047B3148

0.75, 1.1 kW Danfoss part number: 047B3149

1.5 kW, 2.2 kW, and 3 kW Danfoss part number: 047B3151

Recommended circuit breaker

Danfoss CTI-45MB1) (small unit) part

number:

0.55, 0.75 kW Danfoss part number: 047B3160

1.1 kW Danfoss part number: 047B3161

1.5 kW Danfoss part number: 047B3162

2.2 kW Danfoss part number: 047B3163

Power loss at maximum load [W]

Eciency

35 42 46 58 62 88 116

0.93 0.95 0.96 0.96 0.97 0.97 0.97

Weight, small unit [kg] 9.8 (21.6 lb) –

Weight, large unit [kg] 13.9 (30.6 lb)

Continuous (3x380–440 V) [A] 1.3 1.8 2.4 3.0 4.1 5.2 7.2

Intermittent (3x380–440 V) [A] 2.1 2.9 3.8 4.8 6.6 8.3 11.5

Continuous (3x441–480 V) [A] 1.2 1.6 2.1 3.0 3.4 4.8 6.3

Intermittent (3x441–480 V) [A] 1.9 2.6 3.4 4.8 5.4 7.7 10.1

Continuous kVA (400 V AC) [kVA] 0.9 1.3 1.7 2.1 2.8 3.9 5.0

Continuous kVA (460 V AC) [kVA] 0.9 1.3 1.7 2.4 2.7 3.8 5.0

Maximum cable size:

(Mains, motor, brake) [mm2/AWG]

Solid cable 6/10

Flexible cable 4/12

Table 7.1 VLT® Decentral Drive FCD 302 Shaft Output, Output Current, and Input Current

1) Type CTI-45MB circuit breakers are not available for 3 kW (4 hp) units.

2) Applies for dimensioning of frequency converter cooling. If the switching frequency is higher than the default setting, the power losses may

increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to

drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

Eciency measured at nominal current. For energy eciency class, see chapter 7.3 General Specications. For part load losses, see

drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

Danfoss FCD 302 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual