Danfoss VLT DMS 300, VLT FCD 300 User Manual
■ Contents
Decentral Solutions
The decentral concept
Introduction .............................................................................................................. 5
Decentral Design Benefits ........................................................................................ 6
Application Examples ............................................................................................. 13
Product Design Guide ............................................................................................ 21
Ordering form - DMS 300 ....................................................................................... 25
Ordering form - FCD 300 ........................................................................................ 28
PC Software tools .................................................................................................. 29
Accessories for DMS 300 and FCD 300 ................................................................. 29
Communication ...................................................................................................... 33
Good Installation Practice ....................................................................................... 36
Servicing the Danfoss Decentral Products .............................................................. 40
................................................................................... 5
Introduction, DMS 300 .................................................................................. 41
Operating instructions ............................................................................................ 42
Symbols used in this manual .................................................................................. 42
General warning ..................................................................................................... 42
Safety regulations ................................................................................................... 42
Warning against unintended start ........................................................................... 42
Avoiding DMS damage ........................................................................................... 42
Mechanical details, DMS 300 .................................................................... 43
Description ............................................................................................................ 43
General layout ....................................................................................................... 43
Construction ......................................................................................................... 43
Tools required ........................................................................................................ 43
Wall mounting ....................................................................................................... 43
Motor mounting ..................................................................................................... 43
Ventilation .............................................................................................................. 44
Electrical connections, DMS 300 ............................................................ 45
Power Wiring .......................................................................................................... 45
Power factor correction .......................................................................................... 45
Control Wiring ........................................................................................................ 45
Motor thermistors ................................................................................................... 47
Serial communication ............................................................................................. 47
Grounding .............................................................................................................. 47
High voltage warning .............................................................................................. 47
Galvonic isolation (PELV) ........................................................................................ 47
Electrical Schematic .............................................................................................. 48
SettingupDMS300 ....................................................................................... 49
Adjustment/ Settings .............................................................................................. 49
Start/ stop profile setting ........................................................................................ 49
Start/ stop profile setting table: ............................................................................... 50
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Decentral Solutions
Trip Class selection: ................................................................................................ 51
Trip Class selection table : ...................................................................................... 51
Full Load Current setting: ...................................................................................... 51
FLC setting table : .................................................................................................. 51
Completing the installation: .................................................................................... 52
Operation details, DMS 300 ....................................................................... 53
Operation ............................................................................................................... 53
Powering-up the DMS ............................................................................................ 53
Starting the motor: ................................................................................................. 53
Brake Release ........................................................................................................ 53
Operation with AS-i Interface ................................................................................. 53
Description of AS-i profiles used with DMS ............................................................ 53
Fault Procedure ..................................................................................................... 55
Reading the "Alarm" LED ...................................................................................... 55
Specification and order codes, DMS 300 ........................................... 56
General Technical Data .......................................................................................... 56
Current Ratings (AC53a ratings) ............................................................................. 56
Ordering type code ................................................................................................ 57
Certifications .......................................................................................................... 57
Fuses ..................................................................................................................... 57
Special variants: ..................................................................................................... 58
Motor connection ................................................................................................... 58
Details of Profibus Connectivity .............................................................................. 59
Profibus DP Slave 6 E/DC 24 V, 4 A/DC 24 V/1A ................................................... 59
Table of bits in control and status word .................................................................. 60
Profibus connector PCB 4 x M12 ........................................................................... 60
Profibus address setting: DIP switch SW3 .............................................................. 61
Introduction to FCD 300 .............................................................................. 62
Software version ..................................................................................................... 62
High voltage warning .............................................................................................. 63
These rules concern your safety ............................................................................. 63
Warning against unintended start ........................................................................... 63
Technology ............................................................................................................. 64
CE labeling ............................................................................................................. 67
Installation, FCD 300 ..................................................................................... 69
Mechanical dimensions .......................................................................................... 69
Mechanical dimensions, FCD, motor mounting ...................................................... 69
Mechanical dimensions, stand-alone mounting ...................................................... 69
Mechanical Installation ........................................................................................... 70
General information about electrical installation ..................................................... 73
Electronics purchased without installation box ........................................................ 73
EMC-correct electrical installation ........................................................................... 75
Grounding of shielded/armoured control cables ..................................................... 77
Diagram ................................................................................................................. 78
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RFI switches J1, J2 ................................................................................................ 78
Location of terminals .............................................................................................. 79
Electrical connection .............................................................................................. 82
Pre-fuses ................................................................................................................ 82
Motor connection ................................................................................................... 82
Direction of motor rotation ...................................................................................... 82
AC lines and motor connection with service switch ................................................ 82
Connection of HAN 10E motor plug for T73 ........................................................... 83
Parallel connection of motors ................................................................................. 83
Motor cables .......................................................................................................... 83
Motor thermal protection ........................................................................................ 84
Brake resistor ......................................................................................................... 84
Control of mechanical brake ................................................................................... 84
Electrical installation, control cables ........................................................................ 85
Connection of sensors to M12 plugs for T73 .......................................................... 86
Electrical installation, control terminals .................................................................... 87
PC communication ................................................................................................. 87
Relay connection .................................................................................................... 87
Connection examples ............................................................................................. 88
Programming, FCD 300 ............................................................................... 93
The LCP 2 control unit, option ................................................................................ 93
Parameter selection ................................................................................................ 97
Operation & Display ................................................................................................ 99
Setup configuration ................................................................................................ 99
Load and Motor ................................................................................................... 108
DC Braking .......................................................................................................... 113
Motortype, par, 147 - FCD 300 ............................................................................ 117
References & Limits .............................................................................................. 118
Handling of references .......................................................................................... 118
Reference function ............................................................................................... 122
Inputs and outputs ............................................................................................... 127
Special functions .................................................................................................. 137
PID functions ........................................................................................................ 139
Handling of feedback ........................................................................................... 141
Serial communication for FCD 300 ....................................................................... 149
Control Word according to FC protocol ................................................................ 154
Status Word according to FC Profile ..................................................................... 156
Control word according to Fieldbus Profile ........................................................... 157
Status word according to Profidrive protocol ........................................................ 158
Serial communication ........................................................................................... 161
Technical functions ............................................................................................... 169
All About FCD 300 ........................................................................................ 173
Dynamic braking .................................................................................................. 173
Internal Brake Resistor ......................................................................................... 177
Special conditions ................................................................................................ 179
Galvonic isolation (PELV) ...................................................................................... 179
Ground leakage current and RCD relays ............................................................... 180
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Extreme operating conditions ............................................................................... 180
dU/dt on motor .................................................................................................... 180
Switching on the input .......................................................................................... 181
Acoustic noise ...................................................................................................... 181
Temperature-dependent switch frequency ............................................................ 182
Derating for air pressure ....................................................................................... 182
Derating for running at low speed ......................................................................... 182
Motor cable lengths .............................................................................................. 182
Vibration and shock .............................................................................................. 182
Air humidity .......................................................................................................... 183
UL Standard ......................................................................................................... 183
Efficiency .............................................................................................................. 183
Electrical supply interference/harmonics ............................................................... 183
Power factor ........................................................................................................ 184
Emission test results according to generic standards and PDS product standard . 185
Immunity test result according to Generic standards, PDS product standards and basic
standards ............................................................................................................. 185
Aggressive environments ...................................................................................... 187
Cleaning ............................................................................................................... 187
Status messages .................................................................................................. 189
Warnings/alarm messages ................................................................................... 189
Warning words, extended status words and alarm words ..................................... 192
General technical data .......................................................................................... 194
Technical data, line supply 3 x 380 - 480V ............................................................ 199
Available literature ................................................................................................. 200
Supplied with the unit ........................................................................................... 200
Factory Settings ................................................................................................... 201
Index .................................................................................................................... 209
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Decentral Solutions
■Introduction
Danfosswastheworld’s first company to manufacture
and supply variable frequency drives for infinitely variable
speed control of three-phase AC motors. Until then,
AC motors had to operate at the speed determined
by the frequency of the electrical power supply.
Production of variable frequency drives started in 1968.
The first variable frequency drive was also the first
decentralized drive as it was placed next to the motor.
The first variable frequency drive was totally enclosed
and filled with silicone oil for cooling, as semiconductors
of that time were very inefficient. The enclosure
design was made for mounting the drive directly in the
application next to the motor. Temperature, water,
cleaning agents, dust and other environmental factors
were also no problem, even in harsh environments.
Semiconductors improved during the next decades.
Air-cooling showed sufficient and oil cooling was
abandoned. At the same time use of variable frequency
drives grew significantly. PLCs gained a footing for
advanced application control and it became common
practice to install all variable frequency drives in one
cabinet, rather than several places in the factory.
concept and guide you through the process of
selecting the appropriate products.
Finally we have included comprehensive information
about the Danfoss decentralized products.
concept
The decentral
Continuing improvements in semi-conductors and
related technologies - such as fieldbus technolog
- now again makes it feasible to consider installing
drives close to the motors, achieving the benefits of
decentralized installation without
from the first oil-filled variable frequency drives.
Development of automation in industry is based on the
ability to send and receive data from the application
needed to control the processes. More and more
sensors are installed and more and more data is
submitted to the central PLC control. This trend
depends on increased use of fieldbus systems.
Industrial sources often clai
all drive installations will be installed decentrally
within the next few years and the trend towards
distributed intellig
more and more components and applications are
developed for decentralized installation.
This book is a general introduction to basic features
of decentralized installation philosophies for motor
controls and differences from the centralized
concept. It will help you choose the most suitable
ent control is undisputed as
the disadvantages
mthatupto30%of
y
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■Decentralized design benefits
In the following we will concentrate on describing
decentralized installation of adjustable frequency drives
and motor starters, referred to here as motor controls.
There are two topologic concepts for the layout of motor
control installations in a plant, in the following referred
to as "centralized" and "decentralized" installations.
The two typologies are illustrated in the figure.
In a centralized installation:
- motor controls are placed in a central place
In a decentralized installation:
- motor controls are distributed throughout the plant,
mounted on or next to the motor they control
Decentralized does not mean "control cabinet free", but
merely that their enormous size can now be reduced
thanks to innovative designs of the components that
will be placed decentralized. There will continue
to be a need for cabinets for power distribution
and for overall intelligence, and there are areas,
particularly in the process industry with areas such
as explosion protection, where centralized cabinets
continue to be the preferred solution.
Decentral Solutions
Centralized versus decentralized installations
Placing the advanced and reliable electronics needed
to ensure a smooth, responsive and economical
operation of the motor next to - or on - the motor
facilitates modularization and reduces cabling costs
and EMC problems dramatically. Further benefits:
• Space-consuming motor control cabinets in long
rows of centralized panels are eliminated
• Reduced efforts for building in and wiring long
screened motor cables where special attention
on EMC terminations is required
• Heat dissipation from power electronics is moved
from the panel into the plant
• Standardized machine elements by modularization
reduces design time and time to market
• Commissioning is easier and faster
Decentralized motor control is rapidly gaining
ground despite of the advantages of the
centralized control concept:
• no need for extra space around the motor
or close to the motor
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Decentral Solutions
• no control cable wiring into the plant
• independence of plant environment
■Direct cost savings
Motor controls for decentralized installations must be
built to meet the harsh conditions in manufacturing
areas - especially such conditions found in the food
and beverage industry, where frequent wash downs
are required. This of course increases the cost of
the drive. This increase will be more than offset by
savings in expenses for cabinets and cables.
The cable saving potential is considerable, as will be
demonstrated by the following example.
The figure illustrates an installation with motors
distributed in a number of rows with several motors in
each, as is the situation in for example parallel bottling
or baking lines in the Food and Beverage industry.
This example shows the need for power cables from
the centrally placed drives to the motors.
concept
The decentral
Centralized installation
The drives are distributed equidistant with the distance
L between each drive and the distance h between each
row and also with a distance h from the centralized
power entry/cabinet location to the first row. There
are n rows, and N drives in each row.
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Decentral Solutions
Decentralized cabling
The figure illustrates how the three-phase power
cable can be distributed with power looping from one
motor (drive) to the next. The cable saving potential is
illustrated in figure 4. Given a distance of 33 ft (10m)
between each motor and 66ft (20m) between each line,
the potential cable savings as a function of the number
of motors and number of lines shows of the figure.
Cable saving potential in an illustrative installation
The saving potential in power cable length alone
is substantial. The figure only illustrates the
potential concerning power cables. Issues like
unshielded/shielded cables and cable dimensions also
adds to the benefits of decentralized installations.
Real case
Calculations on a specific, typical bottling line with 91
pieces of 1.5 HP (1.5 kW) motors, taking the cable
dimensioning into account, showed the following
saving potential in cables and terminations:
• Cable terminations are reduced from 455 to 352
• EMC cable terminations are reduced from
364 to 182 by using motor controls with
integrated service switches
• Power cable length reduced from 21,220 ft
(6468m) to 3870ft (1180m), a reduction of 17,350ft
(5288m), and it is converted from shielded cables
to standard installation cables
For details consult the following chapter on
Good installation practice.
■Minimal need for additional fieldbus cables
Power cable savings are not offset by the additional
cost for expensive fieldbus cables. Fieldbus cables
will be extended in a decentralized installation, but
since fieldbus cables will be distributed in the plant
anyway to connect sensors or remote I/O-stations,
the extension will be limited. Decentralized products
from Danfoss can even be used as remote I/O
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Decentral Solutions
stations to connect sensors to the fieldbus and
reduce direct costs even more.
Fewer cabinets, cooling and cabletrays
Further savings will result from smaller cabinets, less
cabinet cooling and fewer cable trays. Motor controls
generate heat and are often mounted side by side
due to limited space, as illustrated in Figure 6. Forced
cooling is therefore required to remove the heat.
Less Commissioning
Time spent commissioning at the end-user is
significantly reduced using decentralized solutions especially when fieldbus communication is combined
with decentralized motor controls.
Up to 40-50 % on the total time from design to
running production can be saved.
The concept of modularization is known from
equipment like PC’s and cars. Modules with
well-described functionalities and interfaces are
used in these products. The same concept can
be applied to manufacturing, even though specific
physical constraints play a role.
Production equipment is often built from different basic
building blocks, each kind employed at several places
in the installation. Examples include various types of
conveyor sections and machinery like mixers, scales,
fillers, labellers, palletizers, packaging machines etc.
concept
The decentral
Decentralized brewery installation
An Australian brewery has installed a line of 96
decentralized drives from Danfoss connected by
DeviceNet. An excessive amount of time was saved
as the commissioning of the v ariable speed drives
was done in a few days. The brewery estimates
a saving exceeding AUD 100,000 compared to
traditional centralized installation.
■Design savings
End users want to postpone the final decision for new
equipment - and to start production as fast as possible
once a decision has been made. Payback time and
time to market must be reduced. This squeezes both
the design phase and the commissioning phase.
Modularization can minimize lead-time. Even
manufacturers of large production equipment
or lines use modularization to reduce lead-time.
MG.90.F2.22 - VLT is a registered Danfoss trademark
Centralized cabinet
In a truly modular machine, all basic elements are
self-confined and need nothing but electricity, water,
compressed air or similar to function.
Modularization therefore requires the distribution of
intelligence to the individual sections and modules.
Sure, centralized installations can be modularized,
but then motor controls will be physically separated
from the rest of the module.
■Ready-installed intelligence
The function of machinery and applications is typically
tested at the suppliers. Machines are built, tested,
calibrated and taken apart for transportation.
The process of rebuilding the application at the
production site is considerably simplified by shipping
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it in modules with built-in motor controls, as rewiring
and testing is time consuming and calls for skilled
personnel. Using ready-installed, decentralized
installations reduces both time and risk as wiring for
motor, control and sensors are already in place and
maintained during transportation. The need for highly
skilled experts is reduced and local labour can do a
larger part of the installation. The commissioning costs
and OEM resources on-site will be reduced.
■Improved EMC
Electrical noise emitted is proportional to cable
length. The very short - or eliminated - cable
between motor control and motor in decentralized
installations therefore reduces emitted electrical noise.
In decentralized installations, the machine builder
normally mounts cables between motor controls and
motors in the machine leaving only power cables
and fieldbus cables with no EMC emission to be
installed at the production site. The risk of electrical
noise from motor controls to disturb other electrical
equipment caused by a faulty installation will diminish
and you avoid time-consuming fault finding in the
commissioning phase, where time frame is tight.
■Adapts to standard and special motors
Danfoss’ decentralized motor controls, FCD 300
and DMS 300, are designed to control standard AC
asynchronous motors. Their flexibility allows them
also to adapt to special motor types. An example
istheAMTfeature(AutomaticMotorTu
FCD 300. Combining Danfoss adjustable frequency
drives to Danfoss geared motors makes it even
easier as they fit mechanically and
already stored in the FCD 300 memory. Combined
motor-drives are provided pre-assembled directly
from Danfoss removing the need f
fitting between motor and control.
ning) in the
the motor data are
or mechanical
Decentral Solutions
Danfoss geared motor with FCD 300
■Minimum thermal losses
Danfoss adjustable frequency drives feature the
unique VVC switch principle to generate motor
voltages. Due to the VVC principle, power losses
in the motor are similar or less than the losses in a
motor connected to line. Thermal losses are minimized
and overheating is prevented. At the same time, the
VVC principle ensures nominal torque at nominal
speed and eliminates bearing currents.
Slim DC-links
It takes two steps to convert the frequency to
vary the speed of an AC motor: A rectifier and an
inverter. As the rectifier itself produces a rippled DC
voltage, a capacitor is often introduced to smooth
the voltage supplied to the inverter. A link between
rectifier and inverter with only a small capacitor to
even out the voltage is called a "slim DC link". With
a slim DC link, the inverter will not be able to provide
quitethesamevoltageamplitudeassuppliedby
the line supply, leading to lower efficiency. A special
pulse-width-modulation can be used to compensate
theripplefromaslimDClink.Inthiscasetheoutput
voltage for the motor still does not reach the rated
supply voltage value leading to an over-consumption
of motor current up to 10% and this will increase the
motor heating. Low efficiency and need of an oversized
motor is the result. As torque decreases with the
square of voltage the application will be exceedingly
sensitive to load-changes and speed sensors might be
required. At start, only nominal torque is available.
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Principle of a adjustable frequency drive
using a DC link coil
The Danfoss option is to add coils to the DC link in
all drives as shown in the figure. This way a high
DC link voltage with a very low voltage ripple is
obtained and the electric strength of the drive with
regard to line transients is improved.
Further advantages are the prolonged lifetime of the
capacitors, reduced harmonic disturbance of the net
supply and presence of 150-160% start torque.
Decentral Solutions
Danfoss decentralized drives are designed to meet
the requirements as shown in Figure 9. There
are no hard-to-clean places, blind plugs have no
notches or indentations and two-layer robust surface
treatment - tested to withstand commonly used
cleaning agents - protects the housing.
concept
The decentral
Non-cleaning friendly pin fin heat sink versus
the easy to clean Danfoss solution
Numerous manufacturers of frequency inverters
use slim DC links leading to bad efficiency rates
- even if users due to the activity of for instance
the CEMEP now tend to use high efficiency
motors - meeting at least EFF2.
Danfoss’ aim is to provide high efficiency drives that
also improve the efficiency of the motors. There
should be no need for expensive over-dimensioning
and inefficient operation.
■Environmental considerations
Drives - both centrally-mounted and distributed in the
plant - are exposed to the environment. As motor
controls handle high voltages and currents at the
same time they must be protected from dust and
humidity so that they do not fail or break down. Both
manufacturers and installers must take account of this
and Danfoss Drives have designed the decentralized
products with a deep concern in both aspects.
Decentralized motor controls must also meet increasing
demands in respect of hygiene levels in pharmaceutical
industries and in food- and beverage production
in particular, where drives are exposed to cleaning
agents for extensive periods of time, high pressure
hosing and the like. The exterior of the decentralized
motor controls must be designed in such a way as
to achieve this. Complicated heat sinks as illustrated
in the figure must be avoided as it is difficult to clean
and not resistant to common cleaning agents.
All corners are rounded to prevent dust sticking, and
the distance between ribs allows high-pressure air
cleaning, hosing and easy cleaning with a brush.
These concerns are more or less irrelevant if not applied
to all elements and standard AC motors are normally
designed without these concerns in mind - stressed by
integrated fans and cooling ribs both difficult to clean.
Danfoss has met the challenge by designing a range
of aseptic geared motors. These motors have no fans
and only smooth surfaces. An IP65 enclosure class is
standard as is the special CORO coating resistant to
acid, alkali and cleaning agents used in for instance
food and beverage industry. See the photo of an
example of the aseptic geared motor series.
Aseptic Danfoss geared motor
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Electrical contact can cause galvanic corrosion under
wet or humid conditions. This can occur between
housing (Aluminium) and screws (stainless steel). One
possible consequence is that screws become stuck
and therefore impossible to unfasten in a maintenance
situation. Galvanic corrosion will not be found on
Danfoss decentralized products, as the housings
are fully coated and nylon washers underneath
the screws protects the coating. The complete
coating and the unique gasket design prevent pitting
corrosion, which can occur under gaskets.
Tightly enclosed equipment is susceptible to water
build-up inside the enclosure. This is especially the case
where equipment is exposed to ambient temperature
differences under wet conditions. As a decreasing
ambient temperature lowers the surface temperature
inside the enclosure, water vapor tends to condensate.
At the same time pressure inside the enclosure will
drop and cause humid air from the outside to penetrate
non-hermetic polymer gasket materials and cable
glands. When the enclosure heats up again, only the
vaporized water will escape, leaving more and more
condensed water inside the enclosure. This can lead
to water build-up inside the enclosure and eventually
cause malfunction. The phenomenon is illustr
the figure, with a cyclic temperature fluctuation.
ated in
Decentral Solutions
material is offered by Danfoss to eliminate this problem.
The cable gland should be used in applications
exposed to frequent temperature fluctuations and
humid environments as in equipment used only during
daytimewheretheinsidetemperaturetendstofallto
the ambient temperature during the night.
■Installation flexibility
Danfoss decentralized solutions offers exceptional
installation flexibility. Flexibility is supported
by a number of benefits:
• Mountable on Danfoss geared motors
• Decentralized panel mounting possible
• Handheld control panels
• PC software for configuring and logging
• Single or double-sided installation
• Service switch optional
• Brake chopper and resistor optional
• External 24 V backup supply optional
• M12 connections for external sensors optional
• Han 10E motor connector optional
• Fieldbus support (Profibus DP V1, DeviceNet,
As-Interface)
• Compatibility with standard AC supply systems
(TN, TT, IT, delta grounded)
For further details see the chapter on The
decentralized product range.
The pumping effect in tight enclosures
Build-up of water inside enclosures can be prevented
by membranes that prevents fluids to penetrate but
allows for vapor to pass, as known from fabrics used for
outdoor clothing. A special cable gland with this kind of
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Decentral Solutions
■Application Examples
Danfoss has completed a wide range of applications
in many different industries. This has given us a
valuable experience that has influenced the latest
■Beverage - Bottling line
development of our decentralized products. In
the following we provide illustrative examples of
actual installations using Danfoss decentralized
products, and the benefit and value these provide
for the customer in these installations.
concept
The decentral
FCD 300 on bottling conveyor
Benefits:
• Reduced switchboard space as all drives
are mounted in the field
• Reduced cabling as several drives can be
supplied from same circuit
• Ease of commissioning over the fieldbus as the
protocol allows for transfer of complete parameters.
MG.90.F2.22 - VLT is a registered Danfoss trademark
Once one drive is set up, its basic program can
be copied to any other decentralized drive
• The FCD motor performance is markedly
superior to all other types
• The FCD can be retrofitted to existing motors
of nearly any brand or type
• The aseptic IP 66 enclosure is ideal for damp
bottling hall conditions
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• All in one box: e.g. service switch, Profibus
and power looping
Decentral Solutions
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■Beverage - Packaging machine
Decentral Solutions
concept
The decentral
Decentral motor controls integrated in packaging machine
Benefits:
• Distributing motor controls in the application releases
space for other purposes in the switchboard
• The number of drives in an application can be
increased without extending the switchboard
• IP66 enclosure, easy to clean and resistant
to strong cleaning liquids
• Same flexibility as with centrally mounted
motor controls. Decentralized motor controls
can be adapted for all standard AC motors,
and feature same user interface and same
numbers on connectors
• Profibus integrated
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■Food - Cocoa powder plant
Old solution: Motor control - panel mounted decentrally
Decentral Solutions
New Solution: Genuine decentralized motor control
Benefits:
• Easy to expand plant capacity
• No need for switchboard
• Visible LED for status
• Service switch integrated in the unit
• High enclosure rating IP66
• Low cost installation
• Less space needed for the new solution
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■Food conveyor
Decentral Solutions
concept
The decentral
Efficient space utilisation in the food industry with decentralized motor controls from Danfoss
Benefits:
• The number of drives in an application can be
raised without extending the switchboard
• IP66 enclosure, easy to clean and resistant
to strong cleaning liquids
MG.90.F2.22 - VLT is a registered Danfoss trademark
• Dirt-repelling surface and design prevents dirt
and product remains on the drive
• Motor or wall mount units available
• Same flexibility as with centrally mounted motor
controls. Decentralized motor controls adapt to all
17
standard AC motors, features same user interface
and same numbering on connectors
• Profibus integrated
• Connectors for fast service integrated in
the installation box
Decentral Solutions
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■Automotive Industry - Hoists and conveyors Benefits:
• Simple installation
• AS-i or Profibus control optional
• Sensor input available within the physical
size of the unit
• Separate 24V supply for sensors and bus
• Brake supply and control build in
• Easy pluggable remote control panel
• Connectors for looping (T-connector) integrated
in the installation box
• Low installation and component costs
• No additional and expensive EMC
connectors needed
• Compact and space saving
• Easy to install and commission
• Input for motor thermistor monitoring
Decentral Solutions
concept
The decentral
Decentral installation in the automotive industry
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■Retrofit in existing applications
Decentral Solutions
Retrofitting on existing application with speed control
Benefits:
• No need for a big control cabinet thanks to
the decentralized motor controls.
• No expensive wiring: All motors use existing
power cables, pipes and local switches
• All motor controls can be controlled from the
existing centralized cabinet via Profibus
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■The decentralized product range
The Danfoss decentralized concept covers motor
controls ranging from motor starters/soft starters
to variable frequency drives.
Motor starters and soft starters (DMS 300) make
start and stop of your application smoother and
smarter than ordinary DOL (Direct On Line) operation
but do not affect operation further.
Variable frequency drives (FCD 300) are used
for following requirements:
• Adjustable speed
• Precise speed
• Defined speed ramps at start or/and stop
• Shorter stop times (braking)
Danfoss decentralized motor controls range from
0.24HP(0.18kW)to4HP(3kW)(connectstoup
to 5 HP (4 kW) motors). This chapter lists several
optional features and accessories available.
Decentral Solutions
2. Mounted directly on the motor ("motor-mounted")
• Fair choice of motor brands
• No need for shielded motor cable
3. "Pre-mounted" on Danfoss Bauer
geared motors
concept
The decentral
■Flexible installation options
Danfoss decentralized motor controls FCD 300 and
DMS 300 series can be adapted for mounting using
the following options - each offering specific benefits:
1. Stand alone close to the motor ("wall-mounted")
• Free choice of motor brand
• Easy retrofitting to existing motor
• Easy interfacing to motor (short cable)
• Easy access for diagnosis and optimal serviceability
• A fixed combination of motor and electronics
supplied by one supplier
• Easy mounting, only one unit
• No need for shielded motor cable
• Clear responsibility regarding the complete solution
As the electronic parts are common - same function
of terminals, similar operation and similar parts
and spare parts for all drives - you are free to
mixthethreemountingconcepts.
MG.90.F2.22 - VLT is a registered Danfoss trademark
21
Decentral Solutions
■Configuring a product
The decentralized motor controls DMS 300 and
FCD300seriesareconfiguredwithatypecode
string (see also Ordering):
DMS 330 P T4 P66 XX D0 Fxx Txx C0
FCD 3xx P T4 P66 R1 XX Dx Fxx Txx C0
Electrical voltage
DMS 300/FCD 300 are available for connection to
electrical voltage 3 phase 380-480 V.
Choice of motor starter
The motor starter DMS 300 covers the whole power
range from 0.18-3 HP (kW) in one unit.
Choice of adjustable frequency drive
Theadjustablefrequencydrivemustbechosenon
the basis of the present motor current at maximum
loading of the unit. The adjustable frequency drive’s
rated output current I
must be equal to or greater
INV.
than the required motor current.
Typical shaft output
P
INV.
Type [kW] [HP] [HP]
303 0.37 0.50
305 0.55 0.75
307 0.75 1.0
311 1.1 1.5
315 1.5 2.0
322 2.2 3.0
330 3.0 4.0
335** 3.3 5.0*
* at power/motor voltage 3 x 460 - 480 V
** t
max. 95º F (35° C)
amb
■Enclosure
DMS 300 / FCD 300 units are protected against
water and dust as standard.
See also th
e section entitled Technical data
for further details.
■Brake
FCD 300 is available with or without an integral
brake m
odule. See also the section entitled Brake
resistors for ordering a brake resistor.
EB version including mechanical brake control/supply.
■24 V external supply
Back up of control supply with 24 V DC is
available in EX and EB versions.
■RFI filter
FCD 300 has an integral 1A RFI-filter. The integral
1A RFI filter complies with EMC standards EN
55011-1A. See the sections Cable lengths and
Cross section for further details.
■Harmonic filter
The harmonic currents do not affect power
consumption directly, but they increase the heat losses
in the installation (transformer, cables). That is why in
a system with a relatively high percentage of rectifier
load it is important to keep the harmonic currents at
alowlevelsoastoavoidatransformeroverloadand
high cable temperature. For the purpose of ensuring
low harmonic currents, the FCD 300 units are fitted
with coils in their intermediate circuit as standard. This
reduces the input current I
by typically 40 %.
RMS
■Display unit
OntheFCD300unitthereare5LEDsforvoltage
(ON), warning, alarm, status and bus.
In addition, a plug for connecting an LCP control panel
is available as an option. The LCP control panel can be
installed up to 9 feet away from the variable frequency
drive, e.g. on a front panel, by means of a mounting kit.
All displays of data are via a 4-line alpha-numerical
display, which in normal operation is able to show
4 operating data items and 3 operation modes
continuously. During programming, all the information
required for quick, efficient parameter Setup of the
variable frequency drive is displayed. As a supplement
to the display, the LCP has three LEDs for voltage
(ON), warning (WARNING) and alarm (ALARM).
Most of the variable frequency drive’s parameter
Setups can be changed immediately via the LCP
control panel. See also the section entitled The
LCP control unit in the Design Guide.
Desired features are selected by specifying the
corresponding fields in the string (xx). The choices -
22
MG.90.F2.22 - VLT is a registered Danfoss trademark
and detailed explanation - shown in the two tables.
Short form explanations of a feature are u
For technical details and data, see Technical data.
■Installation box variants
Connections on right side
Gland holes for all c
ight side only (seen from motor drive end). This
r
version is useful where cable inlet is required from
one direction only (only FCD 300 series).
able inlets are machined on the
nderlined.
Decentral Solutions
Connections on two sides
Gland holes for c
allowing for cable inlet from both directions.
Both m
(selected variants).
P
looping AC line power supply between drives
(0.15 in
The bottom section contains Cage Clamp connectors
and looping facilities for power and fieldbus cables well
protected against dust, hosing and cleaning agents.
S
motor drive end). A lockable switch integrated in the
enclosure - disconnecting the motor or drive.
4s
drive end). Looping through of 2 X 24 V external supply.
Pluggable connection of remote I/O such as sens
and external supply of these.
M
from motor drive end) wired according to DESINA
standard (see electrical installation).
etric thread and NPT thread is available
luggable connection and the possibility of
2
line or 4 mm2line).
ervice switch mounted on the right side (seen from
ensor plugs, M12 on the right side (seen from motor
otor plug, HARTING 10 E on the right side (seen
able inlets are machined on both sides
ors
concept
The decentral
D
isplay connector for external pluggable
of the local control panel for operating and
programming. Can also be used for PC connection.
Only available for FCD 300.
MG.90.F2.22 - VLT is a registered Danfoss trademark
connection
23
Decentral Solutions
■DMS 300 Decentralized electronic Motor Starter
DMS 300 - Combinations of versions
Installation features
Mounting Motor Wall Motor Wall Motor Wall Wall Wall
Pluggable - X
Service switch - - - - X X - -
Sensor plugs - - - - - - 4XM12 4XM12
Motor plug - - - - - - - Harting
Ordering codes DMS330PT4P66XX D0 Fxx Txx C0
Metric thread
(NPT thread)
Functional features
Basic functions
(see below)
+ Brake control SB
+ Current
monitoring
+ Current
monitoring +
Brake control
+ Current
monitoring +
Brake control
+Reverse
Communication
No bus F00 -
AS-interface - F70 -
Profibus - F12* F12
T10 T50 T12
(T16)*
ST
-
T52
(T56)*
T22
(T26)*
-
EX
EB
ER
T62
(T66)*
T53 T73
10E
- = not available * contact Danfoss sales org for availability
Basic functions
Electronic start/stop of a motor
Soft start/stop
Extended functionality
everse for bi-directional operation of the motor
R
rake control and supply of electromechanical brake
B
C
urrent monitoring for electronic motor protection
24
MG.90.F2.22 - VLT is a registered Danfoss trademark
■Ordering form - DMS 300
Decentral Solutions
concept
The decentral
MG.90.F2.22 - VLT is a registered Danfoss trademark
25
Decentral Solutions
■FCD 300 Decentralized Adjustable Frequency Drive
FCD 300: Combinations of versions
Installation features
Mounting Motor Wall Motor Wall Motor Wall Wall Wall
Cable inlets Right side Double sided
Service switch - - - - X X X -
Sensor plugs - - - - - - 4XM12 4XM12
Motor plug - - - - - - - Harting
ATEX 22
Metric thread
(NPT thread)
Display
connector
Functional features
Basic functions
(see below)
+24ext.backup EX
+24ext.backup
+ Dynamic brake
+ Brake control
Communication
RS 485 F00
AS-interface F70
Profibus 3 MB F10
Profibus12 MB F12
DeviceNet F30
*
X X X X - - - -
Ordering codes FCD 3xx P T4 P66 R1 XX DxFxx Txx C0
T11
(-)
Not available
only D0
T51
(-)
T12
(T16)
T52
(T56)
T22
(T26)
T62
(T66)
DC DC
T63
(-)
includedDCincluded
ST
EB
10E
T73
(-)
* ATEX 22: Approved for use in dusty environments according to the ATEX directive (ATmosphère EXplosive)
Basic functions
Adjustable motor speed
Defined speed ramps - up and down
Features and operation concepts similar to
other VLT series
Electronic motor protection and reverse are
always included
Extended functionality
2
4 V external back up of control and communication
rake control and supply of electromechanical brake
B
ynamic braking (brake resistor is optional
D
see brake resistors)
26
MG.90.F2.22 - VLT is a registered Danfoss trademark
The below explanations refer to the ordering form.
P
ower sizes (positions 1-6):
0,37 HP (kW) - 3,3 HP (kW) (See power
size selection table)
A
pplication range (position 7):
• P-process
E
lectrical voltage (positions 8-9):
• T4 - 380-480 V three phase supply voltage
E
nclosure (positions 10-12):
The enclosure offers protection against dusty,
wet, and aggressive environment
• P66 - Protected IP66 enclosure
ardware variant (positions 13-14):
H
• ST - Standard hardware
• EX - 24 V external supply for backup of control card
• EB - 24 V external supply for backup of control
card, control and supply of mechanical brake
and an additional brake chopper
R
FI filter (positions 15-16):
• R1 - Compliance with class A1 filter
Decentral Solutions
nstallation box (positions 22-24):
I
• T00 - No Installation box
• T11 - Installation box, motor mount, metric
thread, only right side
• T12 - Installation box, motor mount, metric
thread, double side
• T16 - Installation box, motor mount, NPT
thread, double side
• T22 - Installation box, motor mount, metric
thread, double side, service switch
• T26 - Installation box, motor mount, NPT thread,
double side, service switch
• T51 - Installation box, wall mount, metric
thread, only right side
• T52 - Installation box, wall mount, metric
thread, double side
• T56 - Installation box, wall mount, NPT
thread, double side
• T62 - Installation box, wall mount, metric thread,
double side, service switch
• T66 - Installation box, wall mount, NPT thread,
double side, service switch
• T63 - Installation box, wall mount, metric thread,
double side, service switch, sensor plugs
• T73 - Installation box, wall mount, metric thread,
double side, motor plug, sensor plugs, Viton gasket
concept
The decentral
D
isplay unit (LCP) (positions 17-18):
Connection possibility for display and keypad
• D0 - No pluggable display connector in the unit
• DC - Display connector plug mounted (not available
with "only right side" installation box variants)
F
ieldbus option card (positions 19-21):
A wide selection of high performance fieldbus
options is available (integrated)
• F00 - No fieldbus option built in
• F10 - Profibus DP V0/V1 3 Mbaud
• F12-ProfibusDPV0/V112Mbaud
• F30 - DeviceNet
• F70 - AS-interface
C
oating (positions 25-26):
The IP66 enclosure offers protection of the drive against
aggressive environments, which practically eliminates
the need for coated printed circuit boards.
• C0 - Non-coated boards
MG.90.F2.22 - VLT is a registered Danfoss trademark
27
■Ordering form - FCD 300
Decentral Solutions
28
MG.90.F2.22 - VLT is a registered Danfoss trademark
Decentral Solutions
■PC Software tools
PC Software - MCT 10
All drives are equipped with a serial communication
port. We provide a PC tool for communication
between PC and adjustable frequency drive, VLT
Motion Control Tool MCT 10 Set-up Software.
MCT10Set-upSoftware
MCT 10 has been designed as an easy-to-use
interactive tool for setting parameters in our
adjustable frequency drives.
The MCT 10 Set-up Software will be useful for:
• Planning a communication network off-line.
MCT10containsacompleteadjustable
frequency drive database
• Commissioning adjustable frequency drives on line
• Saving settings for all adjustable frequency drives
• Replacing a drive in a network
• Expanding an existing network
• Future developed drives will be supported
MCT 10 Set-up Software support Profibus DP-V1 via
a Master class 2 connection. It makes it possible to
on-line read/write parameters in a adjustable frequency
driveviatheProfibusnetwork. Thiswilleliminatethe
need for an extra communication network.
The MCT 10 Set-up Software Modules
The following modules are included in the
software package:
MCT10Set-upSoftware
Setting parameters
Copy to and from adjustable frequency
drives
Documentation and print out of
parameter settings incl. diagrams
SyncPos
Creating SyncPos program
Ordering number:
Please order your CD containing MCT 10 Set-up
Software using code number 130B1000.
concept
The decentral
■Accessories for DMS 300 and FCD 300
Type Description Ordering no.
LCP2 control unit FCD LCP2 for programming the adjustable frequency
175N0131
drive
Cable for LCP2 control
FCD Cable from LCP2 to adjustable frequency drive 175N0162
unit
LCP2 remote-mounting
kit
LOP (Local Operation
Pad)
FCD Kit for remote-mounting of LCP2 (incl. 39 in.
cable, excl. LCP2)
FCD LOP can be used for setting the reference
and start/stop via the control terminals
175N0160
175N0128
Motor adaption plate DMS/FCD Plate for adapting to non Danfoss Bauer motors 175N2115
Membrane DMS/FCD Membrane for preventing condensation 175N2116
Plug kit for LCP2 FCD Plug for LCP2 for mounting in the terminal box. 175N2118
Motor star terminal DMS/FCD Terminal for interconnection of motor wires (star
175N2119
point)
Installation kit FCD Installation kit for mounting in panels 175N2207
M 12 plug FCD E.g. for DeviceNet 175N2279
Viton Gasket FCD 303-315 Painting shop compatible 175N2431
Viton Gasket FCD 322-335 Painting shop compatible 175N2450
Data Cable FCD For PC communication 175N2491
Motor mounting adaptor 175N2115
Aluminium plate with holes drilled to fit the FCD/DMS
box. Must be fitted locally for the actual motor.
LCP2 connection 175N2118 (for the FCD
300 series)
MG.90.F2.22 - VLT is a registered Danfoss trademark
29
The installation box can be mounted with or without
a sealed connector (IP66) to connect the common
display LCP2 (code DC). The connector can be ordered
separately (Not for single sided installation boxes).
LCP2 keyboard/Display 175N0131 (for
the FCD 300 series)
Alphanumeric display for programming the
adjustable frequency drive.
Cable for LCP2 175N0162 (for the FCD 300 series)
Preconfectioned cable to be used between adjustable
frequency drive and LCP2.
Data cable for PC communication 175N2491
(for the FCD 300 series)
connects a drive (e.g. USB) to the LCP2 connector.
Remote mounting kit for LCP2 175N0160
(for the FCD 300 series)
Kit for permanent mounting of the LCP2 in an enclosure.
Decentral Solutions
5 pole M12 plug for AS-interface 175N2281
The plug, M12, can be mounted into the gland
holes of the installation box.
Viton Gasket for FCD 303-315 175N2431
With this gasket the FCD can be used in painting
shops in e.g. the automotive industry.
Viton Gasket for FCD 322-335 175N2450
With this gasket the FCD can be used in painting
shops in e.g. the automotive industry.
■Ordering numbers for brake resistors
Internally mountable brake resistors for low duty cycle
braking (1-3%). The resistors are self-protecting.
Internal brake resistors cannot be mounted in
FCD 303-315 with service switch.
Venting membrane 175N2116
Membrane preventing water build-up due to
condensation inside enclosures.
Star point terminal 175N2119
Six wires must be either star- or delta-connected to
supply an AC motor. Delta connection is possible
in the standard motor terminal. Star connection
requires a separate terminal.
5 pole M12 plug for e.g. DeviceNet 175N2279
(for the FCD 300 series)
The plug, micro type, M12 can be mounted into the
gland holes of the installation box. The plug can also be
used for other purposes such as connection of sensors.
6.5ft (2m) drop cable for DeviceNet 195N3113
(for the FCD 300 series)
The cable can be mounted inside the terminal
box, and connects to the DeviceNet trunk line
via a micro connector (M12).
Type Description Ordering no.
Internal brake resistor FCD 303-307 Brake resistor for mounting inside the terminal
175N2154
box
Internal brake resistor FCD 311-335 Brake resistor for mounting inside the terminal
175N2117
box
30
MG.90.F2.22 - VLT is a registered Danfoss trademark
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