Danfoss FCD 302 Design guide

ENGINEERING TOMORROW

Design Guide

VLT® Decentral Drive FCD 302

www.DanfossDrives.com

Contents	Design Guide

Contents

1 Introduction	6
1.1 How to Read the Design Guide	6
1.1.1 Additional Resources	6
1.2 Document and Software Version	6
1.3 De€nitions	6
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	10
1.5 CE Labeling	11
1.5.1 Conformity	11
1.5.2 What Is Covered?	12
1.6 Compliance with EMC Directive 2004/1087EC	12
1.7 Approvals	12
1.8 Disposal	12
2 Product Overview and Functions	13
2.1 Galvanic Isolation (PELV)	13
2.1.1 PELV - Protective Extra Low Voltage	13
2.1.2 Ground Leakage Current	14
2.2 Control	14
2.2.1 Control Principle	15
2.2.2 Internal Current Control in VVC+ Mode	16
2.3 Control Structures	16
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	21
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

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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	31
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	34
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	41
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‚	47
2.9 EMC	47
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

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MG04H322

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	58
3.1 Ambient Conditions	58
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	58
3.2.1 Mounting Positions for Hygienic Installation	59
3.3 Electrical Input: Mains-side Dynamics	60
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	61
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	67
3.5.1 High-voltage Test	67

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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	69
4.1 Overview	69
4.2 AMA	69
4.2.1 AMA with T27 Connected	69
4.2.2 AMA without T27 Connected	69
4.3 Analog Speed Reference	69
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	71
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	72
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	74
4.6.1 Mechanical Brake Control	74
4.6.2 Hoist Mechanical Brake	75
4.7 Encoder	77
4.7.1 Encoder Direction	77
4.8 Closed-loop Drive System	77
4.9 Smart Logic Control	79
5 Special Conditions	81
5.1 Manual Derating	81
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

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MG04H322

Contents	Design Guide

5.2 Automatic Derating	83
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	88

6 Type Code and Selection Guide	89
6.1 Type Code Description	89
6.2 Ordering Numbers	90
6.2.1 Ordering Numbers: Accessories	90
6.2.2 Ordering Numbers: Spare Parts	91
6.3 Options and Accessories	92
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	97
7.1 Mechanical Dimensions	97
7.2 Electrical Data and Wire Sizes	98
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	100
7.4 Efficiency	105
7.5 dU/dt Conditions	105
Index	107

MG04H322

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1	1	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.

CAUTION

Indicates a potentially hazardous situation that could result in minor or moderate injury. It may also be used to alert against unsafe practices.

1.1.1 Additional Resources

•VLT® Decentral Drive FCD 302 Operating Guide, for 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® EtherNet/IP MCA 121 Installation 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® 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 Off Operating Guide.

•Approvals.

Technical literature and approvals are available online at www.danfoss.com/en/search/?filter=type%3Adocumentation %2Csegment%3Adds.

The following symbols are used in this manual:

WARNING

Indicates a potentially hazardous situation that could result in death or serious injury.

NOTICE!

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

The following conventions are used in this manual:

•Numbered lists indicate procedures.

•Bullet lists indicate other information and description of illustrations.

•Italicized text indicates:

-Cross-reference.

-Link.

-Footnote.

-Parameter name.

-Parameter group name.

-Parameter option.

•All dimensions in drawings are in mm (inch).

1.2Document and Software Version

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	7.5x
	updated.

Table 1.1 Document and Software Version

1.3De€nitions

1.3.1Frequency Converter

IVLT,MAX

Maximum output current.

IVLT,N

Rated output current supplied by the frequency converter.

UVLT,MAX

Maximum output voltage.

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MG04H322

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

Motor running

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

fJOG

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

fM

Motor frequency.

fMAX

Maximum motor frequency.

fMIN

Minimum motor frequency.

fM,N

Rated motor frequency (nameplate data).

IM

Motor current (actual).

IM,N

Rated motor current (nameplate data).

nM,N

Nominal motor speed (nameplate data).

ns

Synchronous motor speed.

ns		2 ×	par	23 × 60	s
	=		par. 1
			. 1	39

nslip

Motor slip.

PM,N

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

TM,N

Rated torque (motor).

UM

Instant motor voltage.

1 1

UM,N

Rated motor voltage (nameplate data).

Break-away torque

Torque			<![if ! IE]> <![endif]>175ZA078.10
		Pull-out

RPM

Figure 1.1 Break-away Torque

ηVLT

The efficiency 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).

RefMAX

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.

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				Introduction	VLT® Decentral Drive FCD 302
1		1

RefMIN

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/offline 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 flux-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.

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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 IRMS.

		U x I cos
Power factor	=	3 x x U x1IRMSϕ
		3

The power factor for 3-phase control:

Power factor	=	I	1	x cos		ϕ1	=	I	1	since cos	ϕ1 = 1
					RMS
				I				IRMS

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 IRMS for the same kW performance.

IRMS = I21 + I25 + I27 + .. + I2n

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.

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				Introduction	VLT® Decentral Drive FCD 302
1		1

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 off. 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.

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MG04H322

Introduction	Design Guide
			1		1

Voltage [V]	Minimum waiting time (minutes)
	4	7	15
200–240	0.25–3.7 kW	–	5.5–37 kW
	(0.34–5 hp)		(7.5–50 hp)
380–500	0.25–7.5 kW	–	11–75 kW
	(0.34–10 hp)		(15–100 hp)
525–600	0.75–7.5 kW	–	11–75 kW
	(1–10 hp)		(15–100 hp)
525–690	–	1.5–7.5 kW	11–75 kW
		(2–10 hp)	(15–100 hp)

Table 1.3 Discharge Time

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 di‚erent speci€- 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 €ltering are followed. On this basis, a declaration of conformity in accordance with the EMC directive is issued.

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.

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.

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				Introduction	VLT® Decentral Drive FCD 302
1		1
				1.5.2 What Is Covered?	1.7 Approvals

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.

1.6Compliance with EMC Directive 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.

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

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MG04H322

Product Overview and Functi...

Design Guide

2 Product Overview and Functions

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Figure 2.1 Small Unit

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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.

				3	<![if ! IE]> <![endif]>130BC968.11
					M
7	5	4	1	2
6
			8	9

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

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 requirements for higher isolation and by providing the

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-
	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.

Figure 2.3 Galvanic Isolation

NOTICE!

Installation at high altitude:

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

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Product Overview and Functi... VLT® Decentral Drive FCD 302

2.1.2 Ground Leakage Current

<![if ! IE]> <![endif]>130BB957.11

2

2

Leakage current [mA]

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

100 Hz

in the ground connection. A fault current in the frequency

converter at the output power terminals might contain a

2 kHz

DC component which can charge the €lter capacitors and

100 kHz

cause a transient ground current.

The leakage current also depends on the line distortion.

NOTICE!

When a €lter is used, turn off 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-off Frequency of the RCD

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

		(7 AWG). This requires a PE adapter (available as	See also RCD Application Note.
		an option).	2.2 Control
	•	Two separate ground wires both complying with
			A frequency converter recti€es AC voltage from mains into
		the dimensioning rules.
	See EN/IEC61800-5-1 and EN 50178 for further information.		DC voltage. This DC voltage is converted into an AC
			current with a variable amplitude and frequency.
	Using RCDs		The motor is supplied with variable voltage, current, and
	Where residual current devices (RCDs), also known as
			frequency, which enables in€nitely variable speed control
	ground leakage circuit breakers (CLCBs), are used, comply
			of 3-phased, standard AC motors and permanent magnet
	with the following:
			synchronous motors.
	•	Use RCDs of type B, which are capable of
		detecting AC and DC currents.	The VLT® Decentral Drive FCD 302 frequency converter is
	•	Use RCDs with an inrush delay to prevent faults
			designed for installations of multiple smaller frequency
		due to transient ground currents.	converters, especially on conveyor applications, for

•Dimension RCDs according to the system con€guexample, in the food and beverage industries and materials

ration and environmental considerations.	handling. In installations where multiple motors are spread
	around a facility such as bottling plants, food preparation,
	packaging plants, and airport baggage handling instal-
	lations, 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.

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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 flux 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

2

2

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.

2.2.1 Control Principle

The frequency converter is compatible with various motor control principles such as U/f special motor mode, VVC+, or flux 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.

L1 91

L2 92

L3 93

R inr	Inrush
P 14-50

R+	Brake
82	Resistor

	R-
	81
	U 96
	V 97	M
	W 98

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Figure 2.5 Control Principle

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2	2	2.2.2	Internal Current Control in VVC+ Mode

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

P 4-13 Motor speed

high limit (RPM)

P 1-00

P 4-14 Con g. mode Motor speed

high limit (Hz) High

Ref.

+									Low
							P 4-11
			Process				Motor speed
_							low limit (RPM)

P 4-12 Motor speed

P 7-20 Process feedback low limit (Hz) 1 source

P 7-22 Process feedback 2 source

Con g. mode	+f max.	<![if ! IE]> <![endif]>130BA055.10
	P 4-19

Max. output freq.

P 1-00

P 3-**	Motor
	controller
Ramp	-f max.
		P 4-19
		Max. output freq.
	P 7-0*	+f max.
+	Speed	Motor
	PID	controller
_
		-f max.
	P 7-00 Speed PID

feedback source

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 Configuration 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 Configuration Mode is set to [1] Speed closed loop, the resulting reference passes from the ramp limitation 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 Configuration 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.

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Design Guide

2.3.2 Control Structure in Flux Sensorless

Control structure in flux sensorless open-loop and closed-loop con€gurations.

P 1-00

Con g. mode

	Ref.
	+	Process
		PID
	_

P 7-20 Process feedback 1 source

P 7-22 Process feedback 2 source

Figure 2.7 Control Structure in Flux Sensorless

P 4-13 Motor speed
high limit [RPM]	P 4-19
P 4-14 Motor speed	Max. output
high limit [Hz]	freq.

High	P 3-**			P 7-0*	+f max.
	Ramp	+		Speed	Motor
				PID	controller
			_
					-f max.
Low
P 4-11 Motor speed
low limit [RPM]
P 4-12 Motor speed
low limit [Hz]

2 2

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<![endif]>130BA053.11

In the con€guration shown, parameter 1-01 Motor Control Principle is set to [2] Flux Sensorless and parameter 1-00 Configuration 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 Configuration 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.

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2	2	2.3.3 Control Structure in Flux with Motor Feedback

			P 1-00					P 1-00
								Con g. mode
			Con g. mode
							Torque
			P 4-13 Motor speed
			high limit (RPM)
			P 4-14 Motor speed
			high limit (Hz)
		P 7-2*	High	P 3-**			P 7-0*
Ref.	+	Process		Ramp	+		Speed	Motor
		PID					PID	controller
	_					_
			Low
P 7-20 Process feedback			P 4-11 Motor speed				P 7-00
							PID source
1 source			low limit (RPM)
P 7-22 Process feedback			P 4-12 Motor speed
2 source			low limit (Hz)

Figure 2.8 Control Structure in Flux with Motor Feedback

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P 4-19

Max. output freq.

+f max.

-f max.

In the con€guration shown, parameter 1-01 Motor Control Principle is set to [3] Flux w motor feedb and parameter 1-00 Configuration 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 Configuration 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 Configuration 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 Configuration Mode to use the process PID control for closed-loop control of a process variable (for example, speed) in the controlled application.

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Design Guide

2.3.4Local [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 [Off] 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 €eldbus). See more about starting, stopping, changing ramps, parameter setups, and so on, in parameter group 5-1* Digital Inputs or parameter group 8-5* Digital/Bus.

on		on		<![if ! IE]> <![endif]>130BP046.10
Hand	O	Auto	Reset

Figure 2.9 LCP Keys

Active reference and con€guration mode	2 2
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).

Remote									<![if ! IE]> <![endif]>130BA245.12
reference						Remote
	(Auto On)
					Linked to hand/auto				Reference

(Hand On)

Local

Local reference

	LCP keys:	P 3-13 Reference Site
	(Hand On), (O ),
	and (Auto On)

Figure 2.10 Local Handling of Reference

Figure 2.11 Remote Handling of Reference

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2		2		LCP keys	Parameter 3-13 Reference Site	Active reference
				Hand	Linked to Hand/Auto	Local
				Hand O‚	Linked to Hand/Auto	Local
				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 Configuration Mode determines what type of application control principle (that is, speed, torque, or process control) is used when the remote reference is active. Parameter 1-05 Local Mode Configuration 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.

2.3.5Programming 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.

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

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

1	-	I max	0.1 Amp	<![if ! IE]> <![endif]>130BC997.10
24 VDC
	+
			P 5-40 [0] [32]
			<![if ! IE]> <![endif]>01
			<![if ! IE]> <![endif]>02
			<![if ! IE]> <![endif]>03
	2		3
Item	Description
1	External 24 V DC
2	Mechanical brake connection
3	Relay 1

Figure 2.12 Mechanical Brake Control

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2.4 PID Control						2		2
2.4.1 Speed PID Control
Parameter 1-00 Configu-	Parameter 1-01 Motor Control Principle
ration Mode
	U/f	VVC+	Flux sensorless	Flux w/ encoder feedback
[0] Speed open loop	Not active1)	Not active1)	Active	–
[1] Speed closed loop	–	Active	–	Active
[2] Torque	–	–	–	Not active1)
[3] Process	–	Not active1)	Active	Active

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

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

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 Differentiation 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 Diff. 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

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Example of how to program the speed control

2 2 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.

L1

L2

L3

N

PE

F1

	91	92	93	95	12
					37
	L1	L2	L3	PE	18
					50
					53
					55
					39
	U	V	W	PE	20
					32
	96	97	98	99	33
		M			24 Vdc
		3

Figure 2.13 Example - Speed Control Connections

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The following must be programmed in the order shown (see explanation of settings in the VLT® AutomationDrive FC

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*	As speci€ed on motor nameplate.
	Motor Data
Perform an automatic motor adaptation.	Parameter 1-29 Auto	[1] Enable complete AMA.
	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	Parameter 16-20 Moto	(Read-only parameter) Note: An increasing value
slowly in the positive direction. It must be turned so	r Angle	overflows at 65535 and starts again at 0.
slowly (only a few RPM) that it can be determined if the
value in parameter 16-20 Motor Angle is increasing or
decreasing.

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Function		Parameter	Setting		2		2
If parameter 16-20 Motor Angle is decreasing, then		Parameter 5-71 Term	[1] Counterclockwise (if parameter 16-20 Motor Angle is
change the encoder direction in parameter 5-71 Term		32/33 Encoder	decreasing).
32/33 Encoder Direction.		Direction
3) Make sure that the frequency converter limits are set to safe values.
Set acceptable limits for the references.		Parameter 3-02 Minim	0 RPM (default).
		um Reference	1500 RPM (default).
		Parameter 3-03 Maxi
		mum Reference
Check that the ramp settings are within frequency		Parameter 3-41 Ramp	Default setting.
converter capabilities and allowed application operating		1 Ramp-up Time	Default setting.
speci€cations.		Parameter 3-42 Ramp
		1 Ramp-down Time
Set acceptable limits for the motor speed and frequency.		Parameter 4-11 Motor	0 RPM (default).
		Speed Low Limit	1500 RPM (default).
		[RPM]	60 Hz (default 132 Hz).
		Parameter 4-13 Motor
		Speed High Limit
		[RPM]
		Parameter 4-19 Max
		Output Frequency
4) Con€gure the speed control and select the motor control principle.
Activation of speed control.		Parameter 1-00 Config	[1] Speed closed loop.
		uration Mode
Selection of motor control principle.		Parameter 1-01 Motor	[3] Flux w motor feedb.
		Control Principle
5) Con€gure and scale the reference to the speed control.
Set up analog input 53 as a reference source.		Parameter 3-15 Refere	Not necessary (default).
		nce Resource 1
Scale analog input 53 from 0 RPM (0 V) to 1500 RPM		Parameter group 6-1*	Not necessary (default).
(10 V).		Analog Input 1
6) Con€gure the 24 V HTL encoder signal as feedback for the motor control and the speed control.
Set up digital input 32 and 33 as encoder inputs.		Parameter 5-14 Termi	[0] No operation (default).
		nal 32 Digital Input
		Parameter 5-15 Termi
		nal 33 Digital Input
Select terminal 32/33 as motor feedback.		Parameter 1-02 Flux	Not necessary (default).
		Motor Feedback
		Source
Select terminal 32/33 as speed PID feedback.		Parameter 7-00 Speed	Not necessary (default).
		PID Feedback Source
7) Tune the speed control PID parameters.
Use the tuning guidelines when relevant or tune		Parameter group 7-0*	See the guidelines in chapter 2.4.3 Tuning PID Speed
manually.		Speed PID Ctrl.	Control.
8) Finished.
Save the parameter setting to the LCP for safe keeping.		Parameter 0-50 LCP	[1] All to LCP.
		Copy
Table 2.4 Speed Control Settings

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2.4.3 Tuning PID Speed Control
2 2
The following tuning guidelines are relevant when using 1
of the flux 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			x par
inertia kgm
Total. 7 02 =		2 x			. 1 25 x Bandwidth	rad	/	s
Par
NOTICE!. 1	20			9550

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):

Par	. 7x	02		MAX	=
0 . 01		4	x Encoder Resolution x Par			. 7 06
					2 x π

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

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 Differentiation Time should be set to 0 until everything else is tuned. If necessary, €nish the tuning by experimenting with small increments of this setting.

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, flow) 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 flux 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.

Parameter 1-00	Parameter 1-01		Motor Control Principle
Configuration
	U/f	VVC+		Flux		Flux with
Mode				sensorles		encoder
				s		feedback
[3] Process	–	Process		Process		Process &
				& speed		speed

Table 2.5 Process PID Control Settings

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.

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2 2

Figure 2.14 Process PID Control Diagram

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Product Overview and Functi... VLT® Decentral Drive FCD 302

				2.4.5 Process Control Relevant Parameters
2		2
				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	Under [0] Normal operation, the process control responds with an increase of the motor
				Control	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.
				Parameter 7-31 Process PID Anti Windup	The anti-wind-up function ensures that when either a frequency limit or a torque limit is
					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] Off.
				Parameter 7-32 Process PID Controller Start	In some applications, reaching the required speed/set point can take long time. In such
				Value	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.
				Parameter 7-33 Process PID Proportional Gain	The higher the value - the quicker the control. However, too large value may lead to
					oscillations.
				Parameter 7-34 Process PID Integral Time	Eliminates steady state speed error. Lower value means quick reaction. However, too small
					value may lead to oscillations.
				Parameter 7-35 Process PID Differentiation Time	Provides a gain proportional to the rate of change of the feedback. A setting of 0 disables
					the di‚erentiator.
				Parameter 7-36 Process PID Differentiation Gain	If there are quick changes in reference or feedback in a given application - which means
				Limit	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.
				Parameter 7-38 Process PID Feed Forward	In applications where there is a good (and approximately linear) correlation between the
				Factor	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.
				Parameter 5-54 Pulse Filter Time Constant #29	If there are oscillations of the current/voltage feedback signal, these can be dampened
				(Pulse term. 29), parameter 5-59 Pulse Filter	with a low-pass €lter. This time constant shows the speed limit of the ripples occurring on
				Time Constant #33 (Pulse term. 33),	the feedback signal.
				parameter 6-16 Terminal 53 Filter Time	Example: If the low-pass €lter has been set to 0.1 s, the limit speed is 10 RAD/s (the
				Constant (Analog term 53),	reciprocal of 0.1 s), corresponding to (10/(2 x π))=1.6 Hz. This means that all currents/
				parameter 6-26 Terminal 54 Filter Time	voltages that vary by more than 1.6 oscillations per second are dampened by the €lter.
				Constant (Analog term. 54)	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

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MG04H322

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.

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Item				Description
1				Cold air
2				Heat generating process
3				Temperature transmitter
4				Temperature
5				Fan speed
6				Heat

Figure 2.15 Process PID Control in Ventilation System

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.

The control is of the inverse type, which means that when the temperature increases, the ventilation speed is increased as well, to generate more air. When the temperature drops, the speed is reduced. The transmitter used is a temperature sensor with a working range of -10 to +40 °C (14–104 °F), 4–20 mA. Minimum/maximum speed 300/1500 RPM.

2 2

Figure 2.16 Two-wire Transmitter

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

2.Temperature reference via potentiometer (-5 to 35 °C (23–95 °F), 0–10 V DC) connected to terminal 53.

3.Temperature feedback via transmitter (-10 to 40 °C (14–104 °F), 4–20 mA) connected to terminal 54. Switch S202 set to ON (current input).

MG04H322

Danfoss A/S © 05/2018 All rights reserved.

27

Product Overview and Functi... VLT® Decentral Drive FCD 302

				2.4.7 Programming Order
2		2
				Function	Parameter	Setting
				Initialize the frequency converter.	Parameter 14-22	[2] Initialization - make a power-cycle - press reset.
					Operation Mode
				1) Set motor parameters.
				Set the motor parameters according to nameplate	Parameter group	As stated on motor nameplate.
				data.	1-2* Motor Data
				Perform a full AMA.	Parameter 1-29 Au	[1] Enable complete AMA.
					tomatic Motor
					Adaptation (AMA)

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	Parameter 4-10 M Select correct motor shaft direction.
direction:	otor Speed
1. Change motor direction in	Direction
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	[3] Process.
	nfiguration Mode
Set local mode con€guration	Parameter 1-05	Lo	[0] Speed Open Loop.
	cal Mode Configu-
	ration

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.

Parameter 3-01 Re

[60] °C Unit shown on display.

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

ference/Feedback

-5 °C.

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

Unit

35 °C.

Parameter 3-02 Mi

[0] 35%.

If set value is determined from a preset value

nimum Reference

=

100

×

. 3 03

. 3 02

= 24, 5°

no function.

aximum Reference

(array parameter), set other reference sources to

Parameter 3-03 M

Ref

Par . 3 10

0

Par

par

C

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

Parameter 3-10 Pr

Scaling Reference Resource, [0] = No function

eset Reference

4) Adjust limits for the frequency converter:

Set ramp times to an appropriate value as 20 s.

Parameter 3-41 Ra 20 s. mp 1 Ramp-up 20 s. Time

Parameter 3-42 Ra mp 1 Ramp-down Time

28

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MG04H322