Danfoss FCD 302 Design guide
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 Denitions
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
6
6
6
6
10
11
12
12
12
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
13
13
14
16
21
2.4.4 Process PID Control 24
2.4.5 Process Control Relevant Parameters 26
MG04H322 Danfoss A/S © 05/2018 All rights reserved.
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
31
34
41
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
47
47
Danfoss A/S © 05/2018 All rights reserved. MG04H322
Contents Design Guide
2.9.5 Mains Supply Interference/Harmonics 55
2.9.5.1 Eect 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
58
58
58
60
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
MG04H322 Danfoss A/S © 05/2018 All rights reserved.
61
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
69
69
69
69
71
72
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
74
77
77
79
81
81
Danfoss A/S © 05/2018 All rights reserved. MG04H322
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
83
88
89
89
90
92
6.3.3 VLT® Resolver Input MCB 103 94
7 Specications
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 Specications
7.4 Eciency
7.5 dU/dt Conditions
Index
97
97
98
100
105
105
107
MG04H322 Danfoss A/S © 05/2018 All rights reserved.
Introduction
VLT® Decentral Drive FCD 302
11
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
Denitions
1.3
1.3.1 Frequency Converter
I
VLT,MAX
Maximum output current.
I
VLT,N
Rated output current supplied by the frequency converter.
U
VLT,MAX
Maximum output voltage.
7.5x
6 Danfoss A/S © 05/2018 All rights reserved. MG04H322
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
U
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.
f
JOG
Motor frequency when the jog function is activated (via
digital terminals).
f
M
Motor frequency.
f
MAX
Maximum motor frequency.
f
MIN
Minimum motor frequency.
f
M,N
Rated motor frequency (nameplate data).
I
M
Motor current (actual).
I
M,N
Rated motor current (nameplate data).
n
M,N
Nominal motor speed (nameplate data).
n
s
Synchronous motor speed.
2 × par . 1 − 23 × 60s
ns=
n
slip
par . 1 − 39
Motor slip.
P
M,N
Rated motor power (nameplate data in kW or hp).
T
M,N
Rated torque (motor).
U
M
Instant motor voltage.
Figure 1.1 Break-away Torque
η
VLT
The eciency of the frequency converter is dened 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 dened 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.
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 7
Introduction
VLT® Decentral Drive FCD 302
11
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 signicant bit.
msb
Most signicant bit.
MCM
Short for mille circular mil, an American measuring unit for
cable cross-section. 1 MCM=0.5067 mm2.
Online/oine 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.
8 Danfoss A/S © 05/2018 All rights reserved. MG04H322
Introduction Design Guide
1 1
SLC
The SLC (smart logic control) is a sequence of user-dened
actions executed when the associated user-dened 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 =
3xUxI1cosϕ
3xUxI
RMS
RMS
.
The power factor for 3-phase control:
Power factor =
I1xcosϕ1
I
RMS
=
I
1
sincecosϕ1 = 1
I
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
1
5
+ I
2
+ .. + I
7
2
n
2
2
In addition, a high-power factor indicates that the dierent
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 specied by positioning
commands. The prole generator uses this position to
calculate the speed prole.
Commanded position
The actual position reference calculated by the prole
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 dierence 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.
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 9
Introduction
VLT® Decentral Drive FCD 302
11
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.
Modications 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 identied 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 specied 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 specied 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.
10 Danfoss A/S © 05/2018 All rights reserved. MG04H322
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 specically covers.
The specications 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 conrms 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.
dierent 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 specications 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 aected
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 oers 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.
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 11
Introduction
VLT® Decentral Drive FCD 302
11
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.
12 Danfoss A/S © 05/2018 All rights reserved. MG04H322
130BC963.10
130BC964.10
130BC968.11
1325 4
6
9
8
M
7
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 oers 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 fullling
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
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 13
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
22
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 Inuence 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.
2
congu-
See also RCD Application Note.
Control
2.2
A frequency converter recties 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 innitely 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.
14 Danfoss A/S © 05/2018 All rights reserved. MG04H322
R+
82
R81
Brake
Resistor
U 96
V 97
W 98
InrushR inr
P 14-50
L1 91
L2 92
L3 93
M
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
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 15
+
_
+
_
Cong. 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
Cong. 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
22
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 Congurations
In the conguration shown in Figure 2.6, parameter 1-01 Motor Control Principle is set to [1] VVC+ and parameter 1-00 Congu-
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 Conguration 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.
16 Danfoss A/S © 05/2018 All rights reserved. MG04H322
Conguration Mode is set to [1] Speed closed loop, the resulting reference passes from the ramp limitation
+
_
+
_
130BA053.11
Ref.
Cong. 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*
Product Overview and Functi... Design Guide
2.3.2 Control Structure in Flux Sensorless
Control structure in ux sensorless open-loop and closed-loop congurations.
2 2
Figure 2.7 Control Structure in Flux Sensorless
In the conguration shown, parameter 1-01 Motor Control Principle is set to [2] Flux Sensorless and parameter 1-00 Congu-
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 Conguration 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.
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 17
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
Cong. mode
P 1-00
Cong. mode
Torque
Product Overview and Functi...
VLT® Decentral Drive FCD 302
2.3.3 Control Structure in Flux with Motor Feedback
22
Figure 2.8 Control Structure in Flux with Motor Feedback
In the conguration shown, parameter 1-01 Motor Control Principle is set to [3] Flux w motor feedb and parameter 1-00 Cong-
uration Mode is set to [1] Speed closed loop.
The motor control in this conguration 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 Conguration 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 Conguration 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) conguration. 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
Conguration Mode to use the process PID control for closed-loop control of a process
variable (for example, speed) in the controlled application.
18 Danfoss A/S © 05/2018 All rights reserved. MG04H322
130BP046.10
Hand
on
O
Auto
on
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 conguration 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
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 19
130BC997.10
P 5-40 [0] [32]
-
+
01 02 03
24 VDC
I max
0.1 Amp
2 3
1
Product Overview and Functi...
VLT® Decentral Drive FCD 302
LCP keys Parameter 3-13 Reference Site Active reference
22
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
Conguration 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 Conguration 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
•
•
•
20 Danfoss A/S © 05/2018 All rights reserved. MG04H322
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 Congu-
ration Mode
[0] Speed open loop
[1] Speed closed loop – Active – Active
[2] Torque – – –
[3] Process –
Table 2.2 Control Congurations where the Speed Control is Active
1) “Not active” means that the specic mode is available, but the speed control is not active in that mode.
Parameter 1-01 Motor Control Principle
U/f
Not active
1)
+
VVC
Not active
Not active
Flux sensorless Flux w/ encoder feedback
1)
1)
Active –
Not active
Active Active
1)
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 Dierentiation Time Provides a gain proportional to the rate of change of the feedback. A setting of 0 disables
the dierentiator.
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 dierentiator may soon become too dominant. This is
because it reacts to changes in the error. The quicker the error changes, the stronger the
dierentiator gain is. The dierentiator gain can thus be limited to allow setting of the
reasonable dierentiation 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
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 21
M
3
96 97 9998
91 92 93 95
50
12
L1 L2L1PEL3
W PEVU
F1
L2
L3
N
PE
18
53
37
55
20
32
33
39
24 Vdc
130BA174.10
Product Overview and Functi...
VLT® Decentral Drive FCD 302
Example of how to program the speed control
22
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 specied on motor nameplate.
[1] Enable complete AMA.
(Read-only parameter) Note: An increasing value
overows at 65535 and starts again at 0.
VLT® AutomationDrive FC
22 Danfoss A/S © 05/2018 All rights reserved. MG04H322
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
specications.
Set acceptable limits for the motor speed and frequency. Parameter 4-11 Motor
4) Congure the speed control and select the motor control principle.
Activation of speed control. Parameter 1-00 Cong
Selection of motor control principle. Parameter 1-01 Motor
5) Congure 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) Congure 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.
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).
Not necessary (default).
[0] No operation (default).
Not necessary (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
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 23
Product Overview and Functi...
VLT® Decentral Drive FCD 302
2.4.3 Tuning PID Speed Control
22
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 =
Totalinertia k gm2xpar . 1 − 25
Par . 1 − 20x 9550
xBandwidth
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.
Dierentiation 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 aected by the
connected motor through a pump, fan, or otherwise.
Table 2.5 shows the control congurations 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 . 01x4xEncoderResolutionxPar . 7 − 06
xMaxtorqueripple %
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
=
2xπ
Parameter 1-00
Conguration
Mode
[3] Process – Process Process
Table 2.5 Process PID Control Settings
Parameter 1-01 Motor Control Principle
U/f
VVC
+
Flux
sensorles
s
& 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.
24 Danfoss A/S © 05/2018 All rights reserved. MG04H322
Product Overview and Functi... Design Guide
Figure 2.14 Process PID Control Diagram
2 2
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 25
Product Overview and Functi...
VLT® Decentral Drive FCD 302
2.4.5 Process Control Relevant Parameters
22
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 Dierentiation Time Provides a gain proportional to the rate of change of the feedback. A setting of 0 disables
Parameter 7-36 Process PID Dierentiation 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 dierentiator.
If there are quick changes in reference or feedback in a given application - which means
that the error changes swiftly - the dierentiator may soon become too dominant. This is
because it reacts to changes in the error. The quicker the error changes, the stronger the
dierentiator gain is. The dierentiator gain can thus be limited to allow setting of the
reasonable dierentiation 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
26 Danfoss A/S © 05/2018 All rights reserved. MG04H322
130BC966.10
5
6
1
100kW
n °CW
2
3
4
ON
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.
MG04H322 Danfoss A/S © 05/2018 All rights reserved. 27
Product Overview and Functi...
VLT® Decentral Drive FCD 302
2.4.7 Programming Order
22
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 conguration mode. Parameter 1-00 Co
Set local mode conguration Parameter 1-05 Lo
3) Set reference conguration, 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
nguration Mode
cal Mode Congu-
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.
20 s.
100
0
× Par . 3 − 03 − par . 3 − 02 = 24, 5°C
28 Danfoss A/S © 05/2018 All rights reserved. MG04H322
Loading...