ENGINEERING TOMORROW
Design Guide
VLT® Decentral Drive FCD 302
www.DanfossDrives.com
Contents |
Design Guide |
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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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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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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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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 |
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1 |
1 |
Introduction |
VLT® Decentral Drive FCD 302 |
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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 |
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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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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 |
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23 × 60 |
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par. 1 |
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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 |
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Pull-out |
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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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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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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.
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U x I cos |
Power factor |
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3 x x U x1IRMSϕ |
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3 |
The power factor for 3-phase control:
Power factor |
= |
I |
1 |
x cos |
ϕ1 |
= |
I |
1 |
since cos |
ϕ1 = 1 |
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RMS |
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I |
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IRMS |
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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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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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Design Guide |
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Voltage [V] |
Minimum waiting time (minutes) |
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4 |
7 |
15 |
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200–240 |
0.25–3.7 kW |
– |
5.5–37 kW |
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(0.34–5 hp) |
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(7.5–50 hp) |
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380–500 |
0.25–7.5 kW |
– |
11–75 kW |
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(0.34–10 hp) |
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(15–100 hp) |
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525–600 |
0.75–7.5 kW |
– |
11–75 kW |
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(1–10 hp) |
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(15–100 hp) |
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525–690 |
– |
1.5–7.5 kW |
11–75 kW |
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(2–10 hp) |
(15–100 hp) |
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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.
MG04H322 |
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11 |
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VLT® Decentral Drive FCD 302 |
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1.7 Approvals |
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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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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.
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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
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Mechanical brake. |
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Functional galvanic isolation for the 24 V back-up option |
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Functional galvanic isolation for the 24 V back-up option |
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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
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grounding of equipment with a leakage current >3.5 mA. |
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switching at high power. This generates a leakage current |
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When a €lter is used, turn off parameter 14-50 RFI Filter |
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when charging the €lter, to avoid that a high leakage |
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current makes the RCD switch. |
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requires special care if the leakage current exceeds 3.5 mA. |
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Grounding must be reinforced in 1 of the following ways: |
Figure 2.4 In†uence of Cut-off Frequency of the RCD |
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•Ground wire (terminal 95) of at least 10 mm2
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(7 AWG). This requires a PE adapter (available as |
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A frequency converter recti€es AC voltage from mains into |
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DC voltage. This DC voltage is converted into an AC |
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Using RCDs |
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ground leakage circuit breakers (CLCBs), are used, comply |
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synchronous motors. |
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Use RCDs of type B, which are capable of |
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detecting AC and DC currents. |
The VLT® Decentral Drive FCD 302 frequency converter is |
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Use RCDs with an inrush delay to prevent faults |
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due to transient ground currents. |
converters, especially on conveyor applications, for |
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•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 |
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around a facility such as bottling plants, food preparation, |
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lations, there may be dozens, perhaps hundreds, of |
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frequency converters, working together but spread over a |
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large physical area. In these cases, cabling costs alone |
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outweigh the cost of the individual frequency converters |
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and it makes sense to get the control closer to the motors. |
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The frequency converter can control either the speed or |
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the torque on the motor shaft. |
14 |
Danfoss A/S © 05/2018 All rights reserved. |
MG04H322 |
Product Overview and Functi... |
Design Guide |
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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 |
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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 |
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Figure 2.5 Control Principle
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15 |
Product Overview and Functi... VLT® Decentral Drive FCD 302
2 |
2 |
2.2.2 |
Internal Current Control in VVC+ Mode |
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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
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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 |
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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.
16 |
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MG04H322 |
Product Overview and Functi... |
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
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P 7-22 Process feedback 2 source
Figure 2.7 Control Structure in Flux Sensorless
P 4-13 Motor speed |
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<![if ! IE]><![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.
MG04H322 |
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17 |
Product Overview and Functi... |
VLT® Decentral Drive FCD 302 |
2 |
2 |
2.3.3 Control Structure in Flux with Motor Feedback |
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P 1-00 |
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Figure 2.8 Control Structure in Flux with Motor Feedback
<![endif]>130BA054.11
P 4-19
Max. output freq.
+f max.
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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.
18 |
Danfoss A/S © 05/2018 All rights reserved. |
MG04H322 |
Product Overview and Functi... |
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.
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Figure 2.9 LCP Keys
Active reference and con€guration mode |
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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).
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and (Auto On) |
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Figure 2.10 Local Handling of Reference
Figure 2.11 Remote Handling of Reference
MG04H322 |
Danfoss A/S © 05/2018 All rights reserved. |
19 |
Product Overview and Functi... |
VLT® Decentral Drive FCD 302 |
2 |
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LCP keys |
Parameter 3-13 Reference Site |
Active reference |
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Hand |
Linked to Hand/Auto |
Local |
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Hand O‚ |
Linked to Hand/Auto |
Local |
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Auto |
Linked to Hand/Auto |
Remote |
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Auto O‚ |
Linked to Hand/Auto |
Remote |
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All keys |
Local |
Local |
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All keys |
Remote |
Remote |
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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 |
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I max |
0.1 Amp |
<![if ! IE]> <![endif]>130BC997.10 |
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Item |
Description |
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1 |
External 24 V DC |
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2 |
Mechanical brake connection |
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3 |
Relay 1 |
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Figure 2.12 Mechanical Brake Control
20 |
Danfoss A/S © 05/2018 All rights reserved. |
MG04H322 |
Product Overview and Functi... Design Guide
2.4 PID Control |
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2.4.1 Speed PID Control |
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Parameter 1-00 Configu- |
Parameter 1-01 Motor Control Principle |
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ration Mode |
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U/f |
VVC+ |
Flux sensorless |
Flux w/ encoder feedback |
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[0] Speed open loop |
Not active1) |
Not active1) |
Active |
– |
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[1] Speed closed loop |
– |
Active |
– |
Active |
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[2] Torque |
– |
– |
– |
Not active1) |
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[3] Process |
– |
Not active1) |
Active |
Active |
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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 |
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Parameter 7-00 Speed PID Feedback Source |
Select from which input the speed PID should get its feedback. |
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Parameter 30-83 Speed PID Proportional Gain |
The higher the value - the quicker the control. However, too high value may lead to |
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oscillations. |
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Parameter 7-03 Speed PID Integral Time |
Eliminates steady state speed error. Lower value means quick reaction. However, too low |
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value may lead to oscillations. |
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Parameter 7-04 Speed PID Differentiation Time |
Provides a gain proportional to the rate of change of the feedback. A setting of 0 disables |
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the di‚erentiator. |
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Parameter 7-05 Speed PID Diff. Gain Limit |
If there are quick changes in reference or feedback in a given application, which means |
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that the error changes swiftly, the di‚erentiator may soon become too dominant. This is |
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because it reacts to changes in the error. The quicker the error changes, the stronger the |
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di‚erentiator gain is. The di‚erentiator gain can thus be limited to allow setting of the |
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reasonable di‚erentiation time for slow changes and a suitably quick gain for quick |
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changes. |
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Parameter 7-06 Speed PID Lowpass Filter Time |
A low-pass €lter that dampens oscillations on the feedback signal and improves steady |
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state performance. However, too large €lter time deteriorates the dynamic performance of |
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the speed PID control. |
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Practical settings of parameter 7-06 Speed PID Lowpass Filter Time taken from the number of |
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pulses per revolution from encoder (PPR): |
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Encoder PPR |
Parameter 7-06 Speed PID Lowpass Filter Time |
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512 |
10 ms |
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1024 |
5 ms |
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2048 |
2 ms |
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4096 |
1 ms |
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Table 2.3 Parameters Relevant for Speed Control
MG04H322 |
Danfoss A/S © 05/2018 All rights reserved. |
21 |
Product Overview and Functi... |
VLT® Decentral Drive FCD 302 |
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
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92 |
93 |
95 |
12 |
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L2 |
L3 |
PE |
18 |
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50 |
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53 |
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55 |
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39 |
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V |
W |
PE |
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32 |
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96 |
97 |
98 |
99 |
33 |
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24 Vdc |
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3 |
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Figure 2.13 Example - Speed Control Connections
<![endif]>130BA174.10
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 |
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1) Make sure that the motor runs properly. Do the following: |
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Set the motor parameters using nameplate data. |
Parameter group 1-2* |
As speci€ed on motor nameplate. |
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Motor Data |
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Perform an automatic motor adaptation. |
Parameter 1-29 Auto |
[1] Enable complete AMA. |
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matic Motor |
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Adaptation (AMA) |
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2) Check that the motor is running and that the encoder is attached properly. Do the following: |
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Press the [Hand On] LCP key. Check that the motor is |
– |
Set a positive reference. |
running and note in which direction it is turning |
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(referred to as the positive direction). |
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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 |
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value in parameter 16-20 Motor Angle is increasing or |
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decreasing. |
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22 |
Danfoss A/S © 05/2018 All rights reserved. |
MG04H322 |
Product Overview and Functi... |
Design Guide |
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Function |
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Parameter |
Setting |
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2 |
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2 |
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If parameter 16-20 Motor Angle is decreasing, then |
Parameter 5-71 Term |
[1] Counterclockwise (if parameter 16-20 Motor Angle is |
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change the encoder direction in parameter 5-71 Term |
32/33 Encoder |
decreasing). |
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32/33 Encoder Direction. |
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Direction |
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3) Make sure that the frequency converter limits are set to safe values. |
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Set acceptable limits for the references. |
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Parameter 3-02 Minim |
0 RPM (default). |
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um Reference |
1500 RPM (default). |
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Parameter 3-03 Maxi |
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mum Reference |
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Check that the ramp settings are within frequency |
Parameter 3-41 Ramp |
Default setting. |
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converter capabilities and allowed application operating |
1 Ramp-up Time |
Default setting. |
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speci€cations. |
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Parameter 3-42 Ramp |
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1 Ramp-down Time |
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Set acceptable limits for the motor speed and frequency. |
Parameter 4-11 Motor |
0 RPM (default). |
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Speed Low Limit |
1500 RPM (default). |
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[RPM] |
60 Hz (default 132 Hz). |
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Parameter 4-13 Motor |
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Speed High Limit |
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[RPM] |
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Parameter 4-19 Max |
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Output Frequency |
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4) Con€gure the speed control and select the motor control principle. |
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Activation of speed control. |
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Parameter 1-00 Config |
[1] Speed closed loop. |
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uration Mode |
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Selection of motor control principle. |
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Parameter 1-01 Motor |
[3] Flux w motor feedb. |
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Control Principle |
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5) Con€gure and scale the reference to the speed control. |
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Set up analog input 53 as a reference source. |
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Parameter 3-15 Refere |
Not necessary (default). |
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nce Resource 1 |
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Scale analog input 53 from 0 RPM (0 V) to 1500 RPM |
Parameter group 6-1* |
Not necessary (default). |
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(10 V). |
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Analog Input 1 |
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6) Con€gure the 24 V HTL encoder signal as feedback for the motor control and the speed control. |
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Set up digital input 32 and 33 as encoder inputs. |
Parameter 5-14 Termi |
[0] No operation (default). |
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nal 32 Digital Input |
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Parameter 5-15 Termi |
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nal 33 Digital Input |
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Select terminal 32/33 as motor feedback. |
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Parameter 1-02 Flux |
Not necessary (default). |
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Motor Feedback |
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Source |
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Select terminal 32/33 as speed PID feedback. |
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Parameter 7-00 Speed |
Not necessary (default). |
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PID Feedback Source |
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7) Tune the speed control PID parameters. |
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Use the tuning guidelines when relevant or tune |
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Parameter group 7-0* |
See the guidelines in chapter 2.4.3 Tuning PID Speed |
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manually. |
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Speed PID Ctrl. |
Control. |
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8) Finished. |
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Save the parameter setting to the LCP for safe keeping. |
Parameter 0-50 LCP |
[1] All to LCP. |
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Copy |
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Table 2.4 Speed Control Settings |
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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 |
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2 2 |
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The following tuning guidelines are relevant when using 1 |
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of the flux motor control principles in applications where |
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the load is mainly inertial (with a low amount of friction). |
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The value of parameter 30-83 Speed PID Proportional Gain |
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depends on the combined inertia of the motor and load, |
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and the selected bandwidth can be calculated using the |
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following formula: |
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Par |
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x par |
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inertia kgm |
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Total. 7 02 = |
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. 1 25 x Bandwidth |
rad |
/ |
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Par |
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NOTICE!. 1 |
20 |
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9550 |
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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 |
= |
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0 . 01 |
4 |
x Encoder Resolution x Par |
. 7 06 |
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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 |
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Configuration |
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U/f |
VVC+ |
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Flux |
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Flux with |
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sensorles |
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encoder |
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s |
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feedback |
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[3] Process |
– |
Process |
Process |
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Process & |
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& speed |
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speed |
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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.
24 |
Danfoss A/S © 05/2018 All rights reserved. |
MG04H322 |
Product Overview and Functi... |
Design Guide |
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2 2
Figure 2.14 Process PID Control Diagram
MG04H322 |
Danfoss A/S © 05/2018 All rights reserved. |
25 |
Product Overview and Functi... VLT® Decentral Drive FCD 302
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2.4.5 Process Control Relevant Parameters |
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2 |
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Parameter |
Description of function |
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Parameter 7-20 Process CL Feedback 1 Resource |
Select from which source (that is, analog or pulse input) the process PID should get its |
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feedback. |
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Parameter 7-22 Process CL Feedback 2 Resource |
Optional: Determine if (and from where) the process PID should get an additional |
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feedback signal. If an additional feedback source is selected, the 2 feedback signals are |
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added before being used in the process PID control. |
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Parameter 7-30 Process PID Normal/Inverse |
Under [0] Normal operation, the process control responds with an increase of the motor |
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Control |
speed if the feedback is getting lower than the reference. In the same situation, but under |
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[1] Inverse operation, the process control responds with a decreasing motor speed instead. |
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Parameter 7-31 Process PID Anti Windup |
The anti-wind-up function ensures that when either a frequency limit or a torque limit is |
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reached, the integrator is set to a gain that corresponds to the actual frequency. This |
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avoids integrating on an error that cannot in any case be compensated for with a speed |
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change. This function can be disabled by selecting [0] Off. |
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Parameter 7-32 Process PID Controller Start |
In some applications, reaching the required speed/set point can take long time. In such |
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Value |
applications, it might be an advantage to set a €xed motor speed from the frequency |
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converter before the process control is activated. This is done by setting a process PID |
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start value (speed) in parameter 7-32 Process PID Controller Start Value. |
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Parameter 7-33 Process PID Proportional Gain |
The higher the value - the quicker the control. However, too large value may lead to |
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oscillations. |
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Parameter 7-34 Process PID Integral Time |
Eliminates steady state speed error. Lower value means quick reaction. However, too small |
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value may lead to oscillations. |
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Parameter 7-35 Process PID Differentiation Time |
Provides a gain proportional to the rate of change of the feedback. A setting of 0 disables |
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the di‚erentiator. |
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Parameter 7-36 Process PID Differentiation Gain |
If there are quick changes in reference or feedback in a given application - which means |
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Limit |
that the error changes swiftly - the di‚erentiator may soon become too dominant. This is |
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because it reacts to changes in the error. The quicker the error changes, the stronger the |
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di‚erentiator gain is. The di‚erentiator gain can thus be limited to allow setting of the |
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reasonable di‚erentiation time for slow changes. |
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Parameter 7-38 Process PID Feed Forward |
In applications where there is a good (and approximately linear) correlation between the |
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Factor |
process reference and the motor speed necessary for obtaining that reference, the feed |
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forward factor can be used to achieve better dynamic performance of the process PID |
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control. |
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Parameter 5-54 Pulse Filter Time Constant #29 |
If there are oscillations of the current/voltage feedback signal, these can be dampened |
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(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 |
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Time Constant #33 (Pulse term. 33), |
the feedback signal. |
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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 |
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Constant (Analog term 53), |
reciprocal of 0.1 s), corresponding to (10/(2 x π))=1.6 Hz. This means that all currents/ |
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parameter 6-26 Terminal 54 Filter Time |
voltages that vary by more than 1.6 oscillations per second are dampened by the €lter. |
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Constant (Analog term. 54) |
The control is only carried out on a feedback signal that varies by a frequency (speed) of |
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less than 1.6 Hz. |
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The low-pass €lter improves steady state performance but selecting a too large €lter time |
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deteriorates the dynamic performance of the process PID control. |
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Table 2.6 Parameters are Relevant for the Process Control
26 |
Danfoss A/S © 05/2018 All rights reserved. |
MG04H322 |
Product Overview and Functi... |
Design Guide |
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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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Description |
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Cold air |
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Heat generating process |
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Temperature transmitter |
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Temperature |
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Fan speed |
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Heat |
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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
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2.4.7 Programming Order |
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Function |
Parameter |
Setting |
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Initialize the frequency converter. |
Parameter 14-22 |
[2] Initialization - make a power-cycle - press reset. |
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Operation Mode |
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1) Set motor parameters. |
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Set the motor parameters according to nameplate |
Parameter group |
As stated on motor nameplate. |
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data. |
1-2* Motor Data |
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Perform a full AMA. |
Parameter 1-29 Au |
[1] Enable complete AMA. |
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tomatic Motor |
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Adaptation (AMA) |
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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. |
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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. |
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nfiguration Mode |
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Set local mode con€guration |
Parameter 1-05 |
Lo |
[0] Speed Open Loop. |
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cal Mode Configu- |
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ration |
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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.
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• Set reference/feedback units. |
Parameter 3-01 Re |
[60] °C Unit shown on display. |
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• Set minimum reference (10 °C (50 °F)). |
ference/Feedback |
-5 °C. |
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• Set maximum reference (80 °C (176 °F)). |
Unit |
35 °C. |
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Parameter 3-02 Mi |
[0] 35%. |
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If set value is determined from a preset value |
nimum Reference |
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= |
100 |
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× |
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. 3 03 |
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. 3 02 |
= 24, 5° |
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no function. |
aximum Reference |
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(array parameter), set other reference sources to |
Parameter 3-03 M |
Ref |
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Par . 3 10 |
0 |
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Par |
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par |
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C |
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Parameter 3-14 Preset Relative Reference to parameter 3-18 Relative |
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Parameter 3-10 Pr |
Scaling Reference Resource, [0] = No function |
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eset Reference |
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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 |
Danfoss A/S © 05/2018 All rights reserved. |
MG04H322 |