Danfoss VLT FC 360, VLT AutomationDrive FC 360 Design Manual
MAKING MODERN LIVING POSSIBLE
Design Guide
VLT® AutomationDrive FC 360
Contents
Contents
VLT® AutomationDrive FC 360 Design Guide
1 Introduction
1.1 How to Read This Design Guide
1.1.1 Symbols 5
1.1.2 Abbreviations 5
1.2 Definitions
1.2.1 Frequency Converter 6
1.2.2 Input 6
1.2.3 Motor 6
1.2.4 References 6
1.2.5 Miscellaneous 7
1.3 Safety Precautions
1.4 Software Version
1.5 CE Labelling
1.6 Air Humidity
2 Product Overview
2.1 Enclosure Type Overview
2.2 Electrical Installation
5
5
6
8
9
10
11
12
12
13
2.3 Control Structures
2.3.1 Control Principle 14
2.3.2 FC 360 Controls 14
2.3.3 Control Structure in VVC
2.3.4 Internal Current Control in VVC
2.3.5 Local (Hand On) and Remote (Auto On) Control 16
plus
plus
Mode 16
2.4 Reference Handling
2.4.1 Reference Limits 18
2.4.2 Scaling of Preset References and Bus References 19
2.4.3 Scaling of Analog and Pulse References and Feedback 19
2.4.4 Dead Band Around Zero 21
2.5 PID Control
2.5.1 Speed PID Control 24
2.5.2 Process PID Control 27
2.5.3 Process Control Relevant Parameters 28
2.5.4 Example of Process PID Control 29
2.5.5 Optimisation of the Process Regulator 31
14
15
17
24
2.5.6 Ziegler Nichols Tuning Method 31
2.6 General Aspects of EMC
2.6.1 General Aspects of EMC Emissions 32
2.6.2 EMC Test Results 33
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Contents
VLT® AutomationDrive FC 360 Design Guide
2.6.3 Immunity Requirements 34
2.7 Galvanic Isolation (PELV)
2.7.1 PELV - Protective Extra Low Voltage 35
2.8 Earth Leakage Current
2.9 Brake Functions
2.9.1 Mechanical Holding Brake 37
2.9.2 Dynamic Braking 37
2.9.3 Selection of Brake Resistor 37
2.10 Smart Logic Controller
2.11 Extreme Running Conditions
2.11.1 Motor Thermal Protection 40
3 RS-485 Installation and Set-up
3.1 Introduction
3.1.1 Overview 41
3.1.2 Network Connection 41
3.1.3 Frequency Converter Hardware Set-up 41
3.1.4 Frequency Converter Parameter Settings for Modbus Communication 41
3.1.5 EMC Precautions 42
35
35
37
39
39
41
41
3.2 FC Protocol Overview
3.3 Network Configuration
3.4 FC Protocol Message Framing Structure
3.4.1 Content of a Character (byte) 42
3.4.2 Telegram Structure 43
3.4.3 Telegram Length (LGE) 43
3.4.4 Frequency Converter Address (ADR) 43
3.4.5 Data Control Byte (BCC) 43
3.4.6 The Data Field 44
3.4.7 The PKE Field 44
3.4.8 Parameter Number (PNU) 45
3.4.9 Index (IND) 45
3.4.10 Parameter Value (PWE) 45
3.4.11 Data Types Supported by the Frequency Converter 46
3.4.12 Conversion 46
3.4.13 Process Words (PCD) 46
3.5 Examples
42
42
42
46
3.6 Modbus RTU Overview
3.6.1 Assumptions 47
3.6.2 What the User Should Already Know 47
3.6.3 Modbus RTU Overview 47
3.6.4 Frequency Converter with Modbus RTU 48
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Contents
VLT® AutomationDrive FC 360 Design Guide
3.7 Network Configuration
3.8 Modbus RTU Message Framing Structure
3.8.1 Frequency Converter with Modbus RTU 48
3.8.2 Modbus RTU Message Structure 48
3.8.3 Start/Stop Field 49
3.8.4 Address Field 49
3.8.5 Function Field 49
3.8.6 Data Field 49
3.8.7 CRC Check Field 49
3.8.8 Coil Register Addressing 49
3.8.9 How to Control the Frequency Converter 52
3.8.10 Function Codes Supported by Modbus RTU 52
3.8.11 Modbus Exception Codes 52
3.9 How to Access Parameters
3.9.1 Parameter Handling 52
3.9.2 Storage of Data 53
3.9.3 IND 53
48
48
52
3.9.4 Text Blocks 53
3.9.5 Conversion Factor 53
3.9.6 Parameter Values 53
3.10 Examples
3.10.1 Read Coil Status (01 HEX) 53
3.10.2 Force/Write Single Coil (05 HEX) 54
3.10.3 Force/Write Multiple Coils (0F HEX) 54
3.10.4 Read Holding Registers (03 HEX) 54
3.10.5 Preset Single Register (06 HEX) 55
3.10.6 Preset Multiple Registers (10 HEX) 55
3.11 Danfoss FC Control Profile
3.11.1 Control Word According to FC Profile (8-10 Protocol = FC profile) 56
3.11.2 Status Word According to FC Profile (STW) (8-30 Protocol = FC profile) 57
3.11.3 Bus Speed Reference Value 58
4 Application Examples
4.1 Introduction
4.1.1 Encoder Connection 62
53
56
59
59
4.1.2 Encoder Direction 62
4.1.3 Closed Loop Drive System 62
5 Type Code and Selection
5.1 Ordering from FC 360 Series
5.1.1 Drive Configurator 64
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63
Contents
VLT® AutomationDrive FC 360 Design Guide
5.2 Options and Accessories
5.3 Brake Resistors
5.3.1 Ordering Numbers: Brake Resistors 10% 65
5.3.2 Ordering Numbers: Brake Resistors 40% 66
5.4 Sine-wave Filters
6 Specifications
6.1 Power-dependent Specifications
6.1.1 Mains Supply 3 x 380-480 V AC 67
6.2 General Specifications
6.3 Fuse Specifications
6.3.1 Fuses 73
6.3.2 Recommendations 73
6.3.3 CE Compliance 73
6.4 Efficiency
6.5 Acoustic Noise
6.6 dU/dt Conditions
6.7 Special Conditions
64
64
66
67
67
69
73
74
74
74
75
Index
6.7.1 Manual Derating 75
6.7.2 Automatic Derating 76
77
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Introduction
VLT® AutomationDrive FC 360 Design Guide
1 Introduction
1.1 How to Read This Design Guide
This Design Guide will introduce all aspects of the
frequency converter.
Available literature
-
The VLT® AutomationDrive FC 360 Quick Guide
provides the necessary information for getting
the drive up and running.
-
The VLT® AutomationDrive FC 360 Design Guide
entails all technical information about the drive
and customer design and applications.
-
The VLT® AutomationDrive FC 360 Programming
Guide provides information on how to
programme and includes complete parameter
descriptions.
Danfoss Drives technical literature is also available online
at www.danfoss.com/BusinessAreas/DrivesSolutions/
Documentations/Technical+Documentation.
Symbols
1.1.1
The following symbols are used in this manual.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
CAUTION
Indicates a situation that may result in equipment or
property-damage-only accidents.
NOTE
Indicates highlighted information that should be regarded
with attention to avoid mistakes or operate equipment at
less than optimal performance.
1.1.2
Abbreviations
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit I
Degrees Celsius
Direct current DC
Drive Dependent D-TYPE
Electro Magnetic Compatibility EMC
Electronic Thermal Relay ETR
Gram g
Hertz Hz
Horsepower hp
Kilohertz kHz
Local Control Panel LCP
Meter m
Millihenry Inductance mH
Milliampere mA
Millisecond ms
Minute min
Motion Control Tool MCT
Nanofarad nF
Newton Meters Nm
Nominal motor current I
Nominal motor frequency f
Nominal motor power P
Nominal motor voltage U
Parameter par.
Permanent Magnet motor PM motor
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Rated Inverter Output Current I
Revolutions Per Minute RPM
Regenerative terminals Regen
Second sec.
Synchronous Motor Speed n
Torque limit T
Volts V
The maximum output current I
The rated output current supplied by the
frequency converter
Table 1.1 Abbreviations
LIM
°C
M,N
M,N
M,N
M,N
INV
s
LIM
VLT,MAX
I
VLT,N
1 1
* Indicates default setting
MG06B202 - VLT® is a registered Danfoss trademark 5
175ZA078.10
Pull-out
rpm
Torque
Introduction
VLT® AutomationDrive FC 360 Design Guide
11
1.2 Definitions
1.2.1 Frequency Converter
I
VLT, MAX
Maximum output current.
I
VLT,N
Rated output current supplied by the frequency converter.
U
VLT,MAX
n
slip
Motor slip.
P
M,N
Rated motor power (nameplate data in kW or HP).
T
M,N
Rated torque (motor).
U
M
Instantaneous motor voltage.
U
M,N
Rated motor voltage (nameplate data).
Maximum output voltage.
Input
1.2.2
Control command
Start and stop the connected motor by means of LCP and
digital inputs.
Functions are divided into two groups.
Functions in group 1 have higher priority than functions in
group 2.
Group 1 Reset, Coasting stop, Reset and Coasting stop,
Quick-stop, DC braking, Stop and the [OFF] key.
Group 2 Start, Pulse start, Reversing, Start reversing, Jog
and Freeze output
Illustration 1.1 Break-away Torque
1.2.3 Motor
Motor Running
Torque generated on output shaft and speed from zero
rpm to max. speed on motor.
f
JOG
Motor frequency when the jog function is activated (via
digital terminals).
f
M
Motor frequency.
f
MAX
Maximum motor frequency.
f
MIN
Minimum motor frequency.
f
M,N
Rated motor frequency (nameplate data).
I
M
Motor current (actual).
I
M,N
Rated motor current (nameplate data).
n
M,N
Rated motor speed (nameplate data).
n
s
Synchronous motor speed
2 ×
par
n
=
s
. 1 − 23 × 60
par
. 1 − 39
s
Break-away torque
η
VLT
The efficiency of the frequency converter is defined as the
ratio between the power output and the power input.
Start-disable command
A stop command belonging to the group 1 control
commands - see this group.
Stop command
See Control commands.
References
1.2.4
Analog Reference
A signal transmitted to the analog inputs 53 or 54, can be
voltage or current.
Binary Reference
A signal transmitted to the serial communication port.
Preset Reference
A defined preset reference to be set from -100% to +100%
of the reference range. Selection of eight preset references
via the digital terminals.
Pulse Reference
A pulse frequency signal transmitted to the digital inputs
(terminal 29 or 33).
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Introduction
VLT® AutomationDrive FC 360 Design Guide
Ref
MAX
Determines the relationship between the reference input
at 100% full scale value (typically 10 V, 20 mA) and the
resulting reference. The maximum reference value set in
3-03 Maximum Reference.
Ref
MIN
Determines the relationship between the reference input
at 0% value (typically 0 V, 0 mA, 4 mA) and the resulting
reference. The minimum reference value set in
3-02 Minimum Reference.
1.2.5 Miscellaneous
Analog Inputs
The analog inputs are used for controlling various
functions of the frequency converter.
There are two types of analog inputs:
Current input, 0-20 mA and 4-20 mA
Voltage input, -10 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 braking power increases the intermediate
circuit 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 two Solid State outputs
that can supply a 24 V DC (max. 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.
Initialising
If initialising is carried out (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 off-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
from the frequency converter, i.e. in a front panel with the
installation kit option.
NLCP
Numerical Local Control Pandel interface for control and
programming of the frequency converter. The display is
numerical and the panel is used to display process values.
The NLCP has no storing and copy functions.
lsb
Least significant bit.
msb
Most significant bit.
MCM
Short for Mille Circular Mil, an American measuring unit for
cable cross-section. 1 MCM = 0.5067mm2.
On-line/Off-line Parameters
Changes to on-line parameters are activated immediately
after the data value is changed. Press [OK] to activate
changes to off-line parameters.
Process PID
The PID control maintains the desired speed, pressure,
temperature, etc. by adjusting the output frequency to
match the varying load.
PCD
Process Control Data
Power Cycle
Switch off 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 four Set-ups. Change between
the four parameter Set-ups and edit one Set-up, while
another Set-up is active.
SFAVM
Switching pattern called Stator Flux oriented Asynchronous
Vector Modulation (14-00 Switching Pattern).
1 1
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Introduction
11
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.
Smart Logic Control (SLC)
The SLC is a sequence of user defined actions executed
when the associated user defined events are evaluated as
true by the Smart Logic Controller. (Parameter group 13-**
Smart Logic Control (SLC).
STW
Status Word
FC Standard Bus
Includes RS-485 bus with FC protocol or MC protocol. See
8-30 Protocol.
VLT® AutomationDrive FC 360 Design Guide
Power factor
=
3 x U x
3 x U x
The power factor for 3-phase control:
=
I1 x cos
I
RMS
ϕ1
=
I
RMS
I
1
The power factor indicates to which extent the frequency
converter imposes a load on the mains supply.
The lower the power factor, the higher the I
same kW performance.
2
2
I
=
I
RMS
+
1
2
I
+
I
5
7
In addition, a high power factor indicates that the different
harmonic currents are low.
The frequency converters' built-in DC coils produce a high
power factor, which minimizes the imposed load on the
mains supply.
I
cos
1
I
RMS
since cos
+ .. +
ϕ
ϕ1 = 1
2
I
n
RMS
for the
THD
Total Harmonic Distortion states the total contribution of
1.3 Safety Precautions
harmonic.
Thermistor
A temperature-dependent resistor placed where the
temperature is to be monitored (frequency converter or
motor).
Trip
A state entered in fault situations, e.g. if the frequency
converter is subject to an over-temperature or when the
frequency converter is protecting the motor, process or
WARNING
The voltage of the frequency converter is dangerous
whenever connected to mains. Incorrect installation of the
motor, frequency converter or fieldbus may cause death,
serious personal injury or damage to the equipment.
Consequently, the instructions in this manual, as well as
national and local rules and safety regulations, must be
complied with.
mechanism. Restart is prevented until the cause of the
fault has disappeared and the trip state is cancelled by
activating reset or, in some cases, by being programmed
to reset automatically. Trip may not be used for personal
safety.
Trip Locked
A state entered in fault situations when the frequency
converter is protecting itself and requiring physical
intervention, e.g. if the frequency converter is subject to a
short circuit on the output. A locked trip can only be
cancelled by cutting off mains, removing the cause of the
fault, and reconnecting the frequency converter. Restart is
prevented until the trip state is cancelled by activating
reset or, in some cases, by being programmed to reset
automatically. Trip may not be used for personal safety.
VT Characteristics
Variable torque characteristics used for pumps and fans.
plus
VVC
If compared with standard voltage/frequency ratio control,
Voltage Vector Control (VVC
plus
) improves the dynamics
and the stability, both when the speed reference is
changed and in relation to the load torque.
60° AVM
Switching pattern called 60° Asynchronous Vector
Modulation (14-00 Switching Pattern).
Power Factor
The power factor is the relation between I1 and I
RMS
.
Safety Regulations
1. Always disconnect mains supply to the frequency
converter before carrying out repair work. Check
that the mains supply has been disconnected and
observe the discharge time stated in Table 1.3
before removing motor and mains supply.
2. [Off/Reset] on the LCP does not disconnect the
mains supply and must NOT be used as a safety
switch.
3. The equipment must be properly earthed, the
user must be protected against supply voltage
and the motor must be protected against
overload in accordance with applicable national
and local regulations.
4. The earth leakage current exceeds 3.5 mA.
5. Protection against motor overload is not included
in the factory setting. If this function is desired,
set 1-90 Motor Thermal Protection to data value [4]
ETR trip 1 or data value [3] ETR warning 1.
6. The frequency converter has more voltage
sources than L1, L2 and L3, when load sharing
(linking of DC intermediate circuit). Check that all
voltage sources have been disconnected and that
the necessary time has elapsed before
commencing repair work.
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Introduction
VLT® AutomationDrive FC 360 Design Guide
Warning against unintended start
1. The motor can be stopped with digital
commands, bus commands, references or a local
stop, while the frequency converter is connected
to mains. If personal safety considerations (e.g.
risk of personal injury caused by contact with
moving machine parts following an unintentional
start) make it necessary to ensure that no
unintended start occurs, these stop functions are
not sufficient. In such cases the mains supply
must be disconnected.
2. The motor may start while setting the
parameters. If this means that personal safety
may be compromised (e.g. personal injury caused
by contact with moving machine parts), motor
starting must be prevented, for instance by
secure disconnection of the motor connection.
3. A motor that has been stopped with the mains
supply connected, may start if faults occur in the
electronics of the frequency converter, through
temporary overload or if a fault in the power
supply grid or motor connection is remedied. If
unintended start must be prevented for personal
safety reasons (e.g. risk of injury caused by
contact with moving machine parts), the normal
stop functions of the frequency converter are not
sufficient. In such cases the mains supply must be
disconnected.
4. Control signals from, or internally within, the
frequency converter may in rare cases be
activated in error, be delayed or fail to occur
entirely. When used in situations where safety is
critical, e.g. when controlling the electromagnetic
brake function of a hoist application, these
control signals must not be relied on exclusively.
WARNING
High Voltage
Touching the electrical parts may be fatal - even after the
equipment has been disconnected from mains.
Make sure that all voltage inputs have been disconnected,
including load sharing (linkage of DC intermediate circuit),
as well as 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,
e.g law on mechanical tools, regulations for the prevention
of accidents etc. Modifications on the frequency converters
by means of the operating software are allowed.
NOTE
Hazardous situations shall be identified 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, e.g. law on
mechanical tools, regulations for the prevention of
accidents.
WARNING
The DC link capacitors remain charged after power has
been disconnected. Be aware that there may be high
voltage on the DC link. To avoid electrical shock hazard,
disconnect the frequency converter from mains before
carrying out maintenance. When using a PM-motor, make
sure it is disconnected. Before doing service on the
frequency converter wait at least the amount of time
indicated below:
Voltage
[V]
380-480 0.37-7.5 kW 11-75 kW
Table 1.2 Discharge Time
Disposal Instruction
1.3.1
1.4 Software Version
This Design Guide can be used for all FC 360 frequency
converters with software version 1.0x.
The software version number can be seen from 15-43 Software
Version.
Minimum waiting time [minutes]
4 15
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.
Design Guide
Software version: 1.0x
1 1
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Introduction
VLT® AutomationDrive FC 360 Design Guide
11
1.5 CE Labelling
1.5.1 CE Conformity and Labelling
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, we provide information on safety
aspects relating to the frequency converter.
What is CE Conformity and Labelling?
The purpose of CE labelling 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 specifications or quality of
the product. Frequency converters are regulated by two EU
directives:
The low-voltage directive (2006/95/EC)
Frequency converters must be CE labelled in accordance
with the low-voltage directive of January 1, 1997. The
directive applies to all electrical equipment and appliances
used in the 50-1000 V AC and the 75-1500 V DC voltage
ranges. Danfoss CE-labels in accordance with the directive
and issues a declaration of conformity upon request.
The EMC directive (2004/108/EC)
EMC is short for electromagnetic compatibility. The
presence of electromagnetic compatibility means that the
mutual interference between different components/
appliances does not affect the way the appliances work.
The EMC directive came into effect January 1, 1996.
Danfoss CE-labels in accordance with the directive and
issues a declaration of conformity upon request. To carry
out EMC-correct installation, see the instructions in this
Design Guide. In addition, we specify which standards our
products comply with.
1.5.3
CE labelling is a positive feature when used for its original
purpose, i.e. to facilitate trade within the EU and EFTA.
However, CE labelling may cover many different specifications. Thus, you have to check what a given CE label
specifically covers.
frequency converter must be CE labelled in
accordance with the EMC directive.
2. 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. Neither the
frequency converter nor the finished plant has to
be CE labelled 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 labelled under the EMC directive.
3. The frequency converter is sold as part of a
complete system. The system is being marketed
as complete and could e.g. be an air-conditioning
system. The complete system must be CE labelled
in accordance with the EMC directive. The
manufacturer can ensure CE labelling under the
EMC directive either by using CE labelled
components or by testing the EMC of the system.
If he chooses to use only CE labelled
components, he does not have to test the entire
system.
Danfoss Frequency Converter and CE
Labelling
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. It must be
noted that the responsibility for the final EMC properties of
the appliance, system or installation rests with the installer.
What Is Covered
1.5.2
The EU "Guidelines on the Application of Council Directive
2004/108/EC" outline three typical situations of using a
frequency converter. See the following for EMC coverage
and CE labelling.
1. The frequency converter is sold directly to the
end-consumer. The frequency converter is for
example sold to a DIY market. The end-consumer
is a layman. He installs the frequency converter
himself for use with a hobby machine, a kitchen
appliance, etc. For such applications, the
10 MG06B202 - VLT® is a registered Danfoss trademark
The covered specifications can be very different and a CE
label may therefore give the installer a false feeling 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, we guarantee
compliance with the low-voltage directive. Danfoss issues a
declaration of conformity that confirms our CE labelling in
accordance with the low-voltage directive.
The CE label also applies to the EMC directive provided
that the instructions for EMC-correct installation and
filtering are followed. On this basis, a declaration of
conformity in accordance with the EMC directive is issued.
The Design Guide offers detailed instructions for installation to ensure EMC-correct installation. Furthermore,
Introduction
VLT® AutomationDrive FC 360 Design Guide
Danfoss specifies which our different products comply
with.
Danfoss provides other types of assistance that can help
you obtain the best EMC result.
1.5.4 Compliance with EMC Directive
2004/108/EC
As mentioned, the frequency converter is mostly used by
professionals of the trade as a complex component
forming part of a larger appliance, system, or installation. It
must be noted that the responsibility for the final 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, provided that the EMCcorrect instructions for installation are followed, see
2.6.3 Immunity Requirements.
1.6 Air Humidity
The frequency converter has been designed to meet the
IEC/EN 60068-2-3 standard, EN 50178 pkt. 9.4.2.2 at 50 °C.
Aggressive Environments
1.6.1
A frequency converter contains a large number of
mechanical and electronic components. All are to some
extent vulnerable to environmental effects.
dust particles around the frequency converter fan. In very
dusty environments, use equipment with enclosure rating
IP54/55 or a cabinet for IP00/IP20/TYPE 1 equipment.
In environments with high temperatures and humidity,
corrosive gases such as sulphur, nitrogen, and chlorine
compounds will cause chemical processes on the
frequency converter components.
Chemical reactions will rapidly affect and damage the
electronic components. In such environments, mount the
equipment in a cabinet with fresh air ventilation, keeping
aggressive gases away from the frequency converter.
As an extra protection all printed circuit boards are coated
NOTE
Mounting frequency converters in aggressive environments
increases the risk of stoppages and considerably reduces
the life of the converter.
Before installing the frequency converter, check the
ambient air for liquids, particles, and gases. This is done by
observing existing installations in this environment. Typical
indicators of harmful airborne liquids are water or oil on
metal parts, or corrosion of metal parts.
Excessive dust particle levels are often found on installation cabinets and existing electrical installations. One
indicator of aggressive airborne gases is blackening of
copper rails and cable ends on existing installations.
Vibration and Shock
1.6.2
1 1
CAUTION
Frequency converters in environments with airborne
liquids, particles, or gases capable of affecting and
damaging the electronic components. Failure to take the
necessary protective measures increases the risk of
stoppages, thus reducing the life of the frequency
converter.
Degree of protection as per IEC 60529
Liquids can be carried through the air and condense in the
frequency converter and may cause corrosion of
components and metal parts. Steam, oil, and salt water
may cause corrosion of components and metal parts. In
such environments, use equipment with enclosure rating
IP54/55. As an extra protection, all printed circuit boards
are coated.
Airborne particles such as dust may cause mechanical,
electrical, or thermal failure in the frequency converter. A
typical indicator of excessive levels of airborne particles is
The frequency converter has been tested according to the
procedure based on the shown standards:
The frequency converter complies with requirements that
exist for units mounted on the walls and floors of
production premises, as well as in panels bolted to walls or
floors.
IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970
•
IEC/EN 60068-2-64: Vibration, broad-band random
•
MG06B202 - VLT® is a registered Danfoss trademark 11
130BA870.10
130BA809.10
130BA810.10
130BA810.10
130BA810.10
130BA826.10
130BA826.10
Product Overview
VLT® AutomationDrive FC 360 Design Guide
2 Product Overview
22
2.1 Enclosure Type Overview
Frame size depends on power range.
Frame size J1 J2 J3 J4
Enclosure
protection
High overload
rated power 160% overload
1)
torque
Frame size J5 J6 J7
Enclosure
protection
High overload
rated power 160% overload
torque
Table 2.1 Enclosure Types
1)
Sizes 11-75 kW also have normal overload: 110% overload
Sizes 11-22 kW high overload types: 150% overload
0.37-2.2 kW (380-480 V) 3.0-5.5 kW (380-480 V) 7.5 kW (380-480 V) 11-15 kW (380-480 V)
18.5-22 kW (380-480 V) 30-45 kW (380-480 V) 55-75 kW (380-480 V)
IP20 IP20 IP20 IP20
IP20 IP20 IP20
12 MG06B202 - VLT® is a registered Danfoss trademark
130BC438.12
3 Phase
power
input
Switch Mode
Power Supply
Motor
Analog Output
Interface
(PNP) = Source
(NPN) = Sink
ON=Terminated
OFF=Open
Brake
resistor
91 (L1)
92 (L2)
93 (L3)
PE
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24 V OUT)
31 (D IN)
18 (D IN)
20 (COM D IN)
10 V DC
15 mA 100 mA
+ - + -
(U) 96
(V) 97
(W) 98
(PE) 99
(A OUT) 45
(A OUT) 42
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V
5V
S801
0/4-20 mA
RS-485
RS-485
03
+10 V DC
0/4-20 mA
0-10 V DC
24 V DC
02
01
05
04
240 V AC, 2 A
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
19 (D IN)
24 V (NPN)
0 V (PNP)
27
24 V
0 V
(D IN/OUT)
0 V (PNP)
24 V (NPN)
(D IN/OUT)
0 V
24 V
29
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
33 (D IN)
32 (D IN)
95
P 5-00
21
ON
(+UDC) 82
(BR) 81
24 V (NPN)
0 V (PNP)
0-10 V DC
(-UDC) 88
RFI
3)
0 V
240 V AC, 2 A
Relay 1
1)
Relay 2 2)
4)
06
Product Overview
2.2 Electrical Installation
VLT® AutomationDrive FC 360 Design Guide
2 2
Illustration 2.1 Basic Wiring Schematic Drawing
A=Analog, D=Digital
1) Built-in brake chopper available from 0.37-22 kW
2) Relay 2 is 2 pole for J1-J3 and 3 pole for J4-J7. Relay 2 of J4-J7 with terminal 4, 5, 6, same NO/NC logic as Relay 1.
3) Dual DC choke in 30-75 kW
4) Switch S801 (bus terminal) can be used to enable termination on the RS-485 port (terminals 68 and 69).
MG06B202 - VLT® is a registered Danfoss trademark 13
Product Overview
VLT® AutomationDrive FC 360 Design Guide
2.3 Control Structures
2.3.1 Control Principle
22
A frequency converter rectifies AC voltage from mains into
DC voltage, after which this DC voltage is converted into a
AC current with a variable amplitude and frequency.
The motor is supplied with variable voltage/current and
frequency, which enables infinitely variable speed control
of three-phased, standard AC motors and permanent
magnet synchronous motors.
FC 360 Controls
2.3.2
The frequency converter is capable of controlling either
the speed or the torque on the motor shaft. Setting
1-00 Configuration Mode determines the type of control.
Speed control
There are two types of speed control:
Speed closed loop PID control requires a speed
•
feedback to an input. A properly optimised speed
closed loop control will have higher accuracy
than a speed open loop control.
Selects which input to use as speed PID feedback in
7-00 Speed PID Feedback Source.
Torque control
The torque control function is used in applications where
the torque on motor output shaft is controlling the
application as tension control. Torque control can be
selected in 1-00 Configuration Mode. Torque setting is done
by setting an analog, digital or bus controlled reference.
When running torque control it is recommended to make
a full AMA procedure as the correct motor data are of high
importance for optimal performance.
Open loop in VVC
•
in mechanical robust applications, but the
accuracy is limited. Open loop torque function
works for two directions. The torque is calculated
on basic of current measurement internal in the
frequency converter. See Application Example
Torque open Loop
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 later in this section.
plus
mode. The function is used
14 MG06B202 - VLT® is a registered Danfoss trademark
+
_
+
_
S
S
Cong. mode
Ref.
Process
P 1-00
High
+f max.
Low
-f max.
P 4-12
Motor speed
low limit (Hz)
P 4-14
Motor speed
high limit (Hz)
Motor
controller
Ramp
Speed
PID
P 7-20 Process feedback
1 source
P 7-22 Process feedback
2 source
P 7-00 Speed PID
feedback source
P 1-00
Cong. mode
P 4-19
Max. output freq.
-f max.
Motor
controller
P 4-19
Max. output freq.
+f max.
P 3-**
P 7-0*
130BD371.10
Product Overview
VLT® AutomationDrive FC 360 Design Guide
2.3.3
Control Structure in VVC
Illustration 2.2 Control Structure in VVC
In the configuration shown in Illustration 2.2, 1-01 Motor Control Principle is set to [1] VVC
plus
plus
Open Loop and Closed Loop Configurations
plus
and 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.
2 2
If 1-00 Configuration Mode is set to [1] Speed closed loop the resulting reference will be passed from the ramp limitation and
speed limitation into a speed PID control. The Speed PID control parameters are located 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 1-00 Configuration Mode to use the process PID control for closed loop control of e.g. speed or pressure
in the controlled application. The Process PID parameters are located in parameter group 7-2* Process Ctrl. Feedb and 7-3*
Process PID Ctrl.
MG06B202 - VLT® is a registered Danfoss trademark 15
Hand
On
Off
Reset
Auto
On
130BB893.10
Product Overview
VLT® AutomationDrive FC 360 Design Guide
2.3.4
Internal Current Control in VVC
plus
Mode
22
The frequency converter features an integral current limit
control which is activated when the motor current, and
thus the torque, is higher than the torque limits set in
4-16 Torque Limit Motor Mode, 4-17 Torque Limit Generator
Mode and 4-18 Current Limit.
When the frequency converter is at the current limit during
motor operation or regenerative operation, the frequency
converter will try to get below the preset torque limits as
quickly as possible without losing control of the motor.
Local (Hand On) and Remote (Auto
2.3.5
On) Control
Operate the frequency converter manually via the local
control panel (LCP) or remotely via analog/digital inputs or
serial bus.
Start and stop the frequency converter pressing the [Hand
On] and [Off/Reset] keys on the LCP. Setup required:
0-40 [Hand on] Key on LCP,
0-44 [Off/Reset] Key on LCP, and
0-42 [Auto on] Key on LCP.
Reset alarms via the [Off/Reset] key or via a digital input,
when the terminal is programmed to "Reset".
Illustration 2.3 LCP Control Keys
Local Reference forces the configuration mode to open
loop, independent of the setting of 1-00 Configuration
Mode.
Local Reference is restored at power-down.
16 MG06B202 - VLT® is a registered Danfoss trademark
No function
Analog ref.
Pulse ref.
Local bus ref.
Preset relative ref.
Preset ref.
Local bus ref.
No function
Analog ref.
Pulse ref.
Analog ref.
Pulse ref.
Local bus ref.
No function
Local bus ref.
Pulse ref.
No function
Analog ref.
Input command:
Catch up/ slow down
Catchup Slowdown
value
Freeze ref./Freeze output
Speed up/ speed down
ref.
Remote
Ref. in %
-max ref./
+max ref.
Scale to
Hz
Scale to
Nm
Scale to
process
unit
Relative
X+X*Y
/100
DigiPot
DigiPot
DigiPot
max ref.
min ref.
DigiPot
D1
P 5-1x(15)
Preset '1'
External '0'
Process
Torque
Speed
open/closed loop
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(0)
(0)
(1)
Relative scaling ref.
P 3-18
Ref.resource 1
P 3-15
Ref. resource 2
P 3-16
Ref. resource 3
P 3-17
200%
-200%
Y
X
-100%
100%
%
%
Ref./feedback range
P 3-00
Conguration mode
P 1-00
P 3-14
±100%
130BD374.10
P 16-01
P 16-02
P 3-12
P 5-1x(21)/P 5-1x(22)
P 5-1x(28)/P 5-1x(29)
P 5-1x(19)/P 5-1x(20)
P 3-04
Freeze ref.
&
increase/
decrease
ref.
Catch up/
slow
down
P 3-10
Product Overview
VLT® AutomationDrive FC 360 Design Guide
2.4 Reference Handling
Local reference
The local reference is active when the frequency converter is operated with [Hand On] active. Adjust the reference by
[▲]/[▼] and [◄/[►].
Remote reference
The reference handling system for calculating the Remote reference is shown in Illustration 2.4.
2 2
Illustration 2.4 Remote Reference
MG06B202 - VLT® is a registered Danfoss trademark 17
Resulting reference
Sum of all
references
Forward
Reverse
P 3-00 Reference Range= [0] Min-Max
130BA184.10
-P 3-03
P 3-03
P 3-02
-P 3-02
P 3-00 Reference Range =[1]-Max-Max
Resulting reference
Sum of all
references
-P 3-03
P 3-03
130BA185.10
130BA186.11
P 3-03
P 3-02
Sum of all
references
P 3-00 Reference Range= [0] Min to Max
Resulting reference
Product Overview
VLT® AutomationDrive FC 360 Design Guide
The remote reference is calculated once every scan
interval and initially consists of two types of reference
inputs:
22
1. X (the external reference): A sum (see
3-04 Reference Function) of up to 4 externally
selected references, comprising any combination
(determined by the setting of 3-15 Reference 1
Source, 3-16 Reference 2 Source and 3-17 Reference
3 Source) of a fixed preset reference (3-10 Preset
Reference), variable analog references, variable
digital pulse references, and various serial bus
references in whatever unit the frequency
converter is controlled ([Hz], [RPM], [Nm] etc.).
2. Y- (the relative reference): A sum of one fixed
preset reference (3-14 Preset Relative Reference)
and one variable analog reference (3-18 Relative
Scaling Reference Source) in [%].
Illustration 2.5 Sum of all References
The two types of reference inputs are combined in the
following formula: Remote reference = X + X * Y / 100%. If
relative reference is not used, set 3-18 Relative Scaling
Reference Source to [0] No function and 3-14 Preset Relative
Reference to 0%. The catch up/slow down function and the
freeze reference function can both be activated by digital
inputs on the frequency converter. The functions and
parameters are described in the VLT® AutomationDrive FC
360 Programming Guide.
The scaling of analog references are described in
parameter groups 6-1* Analog Input 53 and 6-2* Analog
Input 54, and the scaling of digital pulse references are
described in parameter group 5-5* Pulse Input.
Reference limits and ranges are set in parameter group
3-0* Reference Limits.
Illustration 2.6 Sum of all References
Reference Limits
2.4.1
3-00 Reference Range, 3-02 Minimum Reference and
3-03 Maximum Reference together define the allowed range
of the sum of all references. The sum of all references are
clamped when necessary. The relation between the
resulting reference (after clamping) and the sum of all
references is shown in Illustration 2.5 and Illustration 2.6.
18 MG06B202 - VLT® is a registered Danfoss trademark
The value of 3-02 Minimum Reference cannot be set to less
than 0, unless 1-00 Configuration Mode is set to [3] Process.
In that case, the following relations between the resulting
reference (after clamping) and the sum of all references is
as shown in Illustration 2.7.
Illustration 2.7 Sum of all References
Resource output
[Hz]
Resource input
Terminal X
high
High reference/
feedback value
130BD431.10
8
[V]
50
10
P1
P2
10
Low reference/
feedback value
Product Overview
VLT® AutomationDrive FC 360 Design Guide
2.4.2 Scaling of Preset References and Bus
References
Preset references are scaled according to the following
rules:
When 3-00 Reference Range: [0] Min - Max 0%
•
reference equals 0 [unit] where unit can be any
unit e.g. rpm, m/s, bar etc. 100% reference equals
the Max (abs (3-03 Maximum Reference), abs
(3-02 Minimum Reference).
When 3-00 Reference Range: [1] -Max - +Max 0%
•
reference equals 0 [unit] -100% reference equals Max Reference 100% reference equals Max
Reference.
Bus references are scaled according to the following rules:
When 3-00 Reference Range: [0] Min - Max. To
•
obtain max resolution on the bus reference the
scaling on the bus is: 0% reference equals Min
Reference and 100% reference equals Max
reference.
When 3-00 Reference Range: [1] -Max - +Max
•
-100% reference equals -Max Reference 100%
reference equals Max Reference.
Scaling of Analog and Pulse
2.4.3
References and Feedback
2 2
References and feedback are scaled from analog and pulse
inputs in the same way. The only difference is that a
reference above or below the specified minimum and
maximum “endpoints” (P1 and P2 in Illustration 2.8) are
clamped whereas a feedback above or below is not.
Illustration 2.8 Minimum and Maximum Endpoints
MG06B202 - VLT® is a registered Danfoss trademark 19
Product Overview
VLT® AutomationDrive FC 360 Design Guide
The endpoints P1 and P2 are defined by the following parameters depending on choice of input.
22
voltage
mode
P1 = (Minimum input value, Minimum reference value)
Minimum reference value 6-14 Terminal
53 Low Ref./
Feedb. Value
Minimum input value 6-10 Terminal
53 Low
Voltage [V]
P2 = (Maximum input value, Maximum reference value)
Maximum reference value 6-15 Terminal
53 High Ref./
Feedb. Value
Maximum input value 6-11 Terminal
53 High
Voltage [V]
Table 2.2 P1 and P2 Endpoints
Input Analog 53
Analog 53
current mode
6-14 Terminal 53
Low Ref./Feedb.
Value
6-12 Terminal 53
Low Current
[mA]
6-15 Terminal 53
High Ref./Feedb.
Value
6-13 Terminal 53
High Current
[mA]
Analog 54
voltage
mode
6-24 Terminal
54 Low Ref./
Feedb. Value
6-20 Terminal
54 Low
Voltage [V]
6-25 Terminal
54 High Ref./
Feedb. Value
6-21 Terminal
54 High
Voltage[V]
Analog 54
current mode
6-24 Terminal 54
Low Ref./Feedb.
Value
6-22 Terminal 54
Low Current
[mA]
6-25 Terminal 54
High Ref./Feedb.
Value
6-23 Terminal 54
High Current
[mA]
Pulse Input 29 Pulse Input 33
5-52 Term. 29
Low Ref./Feedb.
Value
5-50 Term. 29
Low Frequency
[Hz]
5-53 Term. 29
High Ref./
Feedb. Value
5-51 Term. 29
High Frequency
[Hz]
5-57 Term. 33 Low
Ref./Feedb. Value
5-55 Term. 33 Low
Frequency [Hz]
5-58 Term. 33 High
Ref./Feedb. Value
5-56 Term. 33 High
Frequency [Hz]
20 MG06B202 - VLT® is a registered Danfoss trademark
Resource output
[Hz] or “No unit”
Resource input
[mA]
Quadrant 2
Quadrant 3
Quadrant 1
Quadrant 4
Terminal X high
Low reference/feedback
value
High reference/feedback
value
1
-50
165020
P1
P2
0
130BD446.10
forward
reverse
Terminal low
Product Overview
2.4.4 Dead Band Around Zero
VLT® AutomationDrive FC 360 Design Guide
In some cases the reference (in rare cases also the
feedback) should have a dead band around zero (i.e. to
make sure the machine is stopped when the reference is
“near zero”).
To make the dead band active and to set the amount of
dead band, the following settings must be done:
Either minimum reference value (see Table 2.2 for
•
relevant parameter) or maximum reference value
must be zero. In other words; Either P1 or P2
must be on the X-axis in Illustration 2.9.
And both points defining the scaling graph are in
•
the same quadrant.
The size of the Dead Band is defined by either P1 or P2 as
shown in Illustration 2.9.
2 2
Illustration 2.9 Size of Dead Band
MG06B202 - VLT® is a registered Danfoss trademark 21
20
1
10
V
V
20
1
10
-20
130BD454.10
+
Analog input 53
Low reference 0 Hz
High reference 20 Hz
Low voltage 1 V
High voltage 10 V
Ext. source 1
Range:
0.0% (0 Hz)
100.0% (20 Hz)
100.0% (20 Hz)
Ext. reference
Range:
0.0% (0 Hz)
20 Hz 10V
Ext. Reference
Absolute
0 Hz 1 V
Reference
algorithm
Reference
100.0% (20 Hz)
0.0% (0 Hz)
Range:
Limited to:
0%- +100%
(0 Hz- +20 Hz)
Limited to: -200%- +200%
(-40 Hz- +40 Hz)
Reference is scaled
according to min
max reference giving a
speed.!!!
Scale to
speed
+20 Hz
-20 Hz
Range:
Speed
setpoint
Motor
control
Range:
-8 Hz
+8 Hz
Motor
Digital input 19
Low No reversing
High Reversing
Limits Speed Setpoint
according to min max speed.!!!
Motor PID
Hz
Hz
Dead band
Digital input
General Reference
parameters:
Reference Range: Min - Max
Minimum Reference: 0 Hz (0,0%)
Maximum Reference: 20 Hz (100,0%)
General Motor
parameters:
Motor speed direction:Both directions
Motor speed Low limit: 0 Hz
Motor speed high limit: 8 Hz
Product Overview
VLT® AutomationDrive FC 360 Design Guide
Case 1: Positive reference with dead band, digital input to trigger reverse
Illustration 2.10 shows how reference input with limits inside Min to Max limits clamps.
22
Illustration 2.10 Clamping of Reference Input with Limits inside Min to Max
22 MG06B202 - VLT® is a registered Danfoss trademark
+
30 Hz
1
10
20 Hz
1
10
130BD433.10
-20 Hz
V
V
Analog input 53
Low reference 0 Hz
High reference 20 Hz
Low voltage 1 V
High voltage 10 V
Ext. source 1
Range:
0.0% (0 Hz)
150.0% (30 Hz)
150.0% (30 Hz)
Ext. reference
Range:
0.0% (0 Hz)
30 Hz 10 V
Ext. Reference
Absolute
0 Hz 1 V
Reference
algorithm
Reference
100.0% (20 Hz)
0.0% (0 Hz)
Range:
Limited to:
-100%- +100%
(-20 Hz- +20 Hz)
Limited to: -200%- +200%
(-40 Hz- +40 Hz)
Reference is scaled
according to
max reference giving a
speed.!!!
Scale to
speed
+20 Hz
-20 Hz
Range:
Speed
setpoint
Motor
control
Range:
-8 Hz
+8 Hz
Motor
Digital input 19
Low No reversing
High Reversing
Limits Speed Setpoint
according to min max speed.!!!
Motor PID
Dead band
Digital input
General Reference
parameters:
Reference Range: -Max - Max
Minimum Reference: Don't care
Maximum Reference: 20 Hz (100.0%)
General Motor
parameters:
Motor speed direction: Both directions
Motor speed Low limit: 0 Hz
Motor speed high limit: 10 Hz
Product Overview
VLT® AutomationDrive FC 360 Design Guide
Case 2: Positive reference with dead band, digital input to trigger reverse. Clamping rules.
Illustration 2.11 shows how reference input with limits outside -Max to +Max limits clamps to the inputs low and high limits
before addition to external reference. And how the external reference is clamped to -Max to +Max by the Reference
algorithm.
2 2
Illustration 2.11 Clamping of Reference Input with Limits outside -Min to +Max
MG06B202 - VLT® is a registered Danfoss trademark 23
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