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FC 300
Instruction Manual
108 pgs2 Mb0
Design Guide
279 pgs9.23 Mb0

Danfoss Electronics FC 300 Design Guide

MAKING MODERN LIVING POSSIBLE
Design Guide
VLT® AutomationDrive
Contents FC 300 Design Guide
Contents
1 How to Read this Design Guide
2 Safety and Conformity
2.1 Safety Precautions
3 Introduction to FC 300
3.1 Product Overview
3.2.1 Control Principle 17
3.2.3 FC 301 vs. FC 302 Control Principle 18
3.2.4 Control Structure in VVC
3.2.6 Control Structure in Flux with Motor Feedback 21
3.2.7 Internal Current Control in VVC
plus
Advanced Vector Control 19
plus
Mode 22
7
11 11
15 15
3.3 Reference Handling
3.3.4 Dead Band Around Zero 26
3.4 PID Control
3.4.2 Tuning PID Speed Control 31
3.4.5 Ziegler Nichols Tuning Method 35
3.5 General Aspects of EMC
3.5.1 General Aspects of EMC Emissions 37
3.5.2 EMC Test Results 38
23
30
37
3.8 Brake Functions in FC 300
3.8.3 Selection of Brake Resistor 43
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42
Contents FC 300 Design Guide
3.9.3 Brake Resistor Cabling 47
3.10 Smart Logic Controller
3.11 Extreme Running Conditions
3.12 Safe Stop of FC 300
3.12.2 Installation of External Safety Device in Combination with MCB 112 56
3.13 Certificates
4 FC 300 Selection
4.1 Electrical Data - 200-240V
4.2 Electrical Data - 380-500V
4.3 Electrical Data - 525-600V
4.4 Electrical Data - 525-690V
4.5 General Specifications
4.8.1 du/dt Conditions 91
4.9 Special Conditions
4.9.1 Manual Derating 94
47 49
51
58
60 60 63 71 74 85
94
5 How to Order
5.2.2 Ordering Numbers: Spare Parts 100
5.2.4 Ordering Numbers: High Power Kits 101
5.2.9 Ordering Numbers: Sine Wave Filter Modules, 200-500 VAC 115
5.2.10 Ordering Numbers: Sine-Wave Filter Modules, 525-690 VAC 116
95
6 Mechanical Installation - Frame Size A, B and C
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117
Contents FC 300 Design Guide
6.1.1 Safety Requirements of Mechanical Installation 117
7 Mechanical Installation - Frame size D, E and F
7.1 Pre-installation
7.1.1 Planning the Installation Site 121
7.1.2 Receiving the Frequency Converter 121
7.2 Mechanical Installation
7.2.3 Terminal Locations - Frame size D 135
7.2.7 Cooling and Airflow 151
7.2.8 Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units 152
121 121
133
7.2.9 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 153
7.2.10 Gland/Conduit Entry, 12-Pulse - IP21 (NEMA 1) and IP54 (NEMA12) 154
8 Electrical Installation
8.1 Connections- Frame Sizes A, B and C
8.1.2 Connection to Mains and Earthing 158
8.2 Connections - Frame Sizes D, E and F
8.2.4 Shielding against Electrical Noise 189
8.3 Fuses and Circuit Breakers
8.3.1 Recommendations 190
157 157
169
190
8.4 Disconnectors and Contactors
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203
Contents FC 300 Design Guide
8.5 Additional Motor Information
8.5.5 Motor Bearing Currents 208
8.6 Control Cables and Terminals
8.6.1 Access to Control Terminals 209
8.6.2 Control Cable Routing 209
8.6.4 Switches S201, S202, and S801 211
8.7 Additional Connections
206
209
218
8.9 EMC-correct Installation
8.9.3 Earthing of Screened Control Cables 224
8.10.2 The Effect of Harmonics in a Power Distribution System 225
220
8.10.5 Harmonic Calculation 226
8.11 Residual Current Device - FC 300 DG
8.12 Final Setup and Test
9 Application Examples
4 MG.33.BD.02 - VLT® is a registered Danfoss trademark
226 227
228
Contents FC 300 Design Guide
10 Options and Accessories
10.1.1 Mounting of Option Modules in Slot A 235
10.1.2 Mounting of Option Modules in Slot B 235
10.1.3 Mounting of Options in Slot C 236
10.2 General Purpose Input Output Module MCB 101
10.2.2 Digital Inputs - Terminal X30/1-4: 238
10.2.3 Analog Inputs - Terminal X30/11, 12: 238
10.2.4 Digital Outputs - Terminal X30/6, 7: 238
10.2.5 Analog Output - Terminal X30/8: 238
10.3 Encoder Option MCB 102
10.4 Resolver Option MCB 103
10.5 Relay Option MCB 105
10.6 24V Back-Up Option MCB 107
10.7 MCB 112 PTC Thermistor Card
10.8 MCB 113 Extended Relay Card
235
236
239 240 241 243 244 246
10.9 Brake Resistors
10.10 LCP Panel Mounting Kit
10.11 IP21/IP 4X/ TYPE 1 Enclosure Kit
10.12 Mounting Bracket for Frame Size A5, B1, B2, C1 and C2
10.13 Sine-wave Filters
10.14 High Power Options
11 RS-485 Installation and Set-up
11.1 Overview
11.2 Network Connection
11.3 Bus Termination
11.4.1 EMC Precautions 256
11.5 Network Configuration
11.6 FC Protocol Message Framing Structure - FC 300
11.6.1 Content of a Character (byte) 257
247 247 248 251 253 253
255 255 255 255
256
257
11.6.4 Frequency Converter Address (ADR) 257
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Contents FC 300 Design Guide
11.6.8 Parameter Number (PNU) 259
11.6.13 Process Words (PCD) 261
11.7 Examples
11.7.1 Writing a Parameter Value 261
11.8 Modbus RTU Overview
11.8.3 Modbus RTU Overview 261
11.8.4 Frequency Converter with Modbus RTU 262
11.9.1 Frequency Converter with Modbus RTU 262
11.10 Modbus RTU Message Framing Structure
261
261
262
11.10.8 Coil Register Addressing 264
11.10.9 How to Control the Frequency Converter 266
11.10.10 Function Codes Supported by Modbus RTU 266
11.11 How to Access Parameters
11.11.5 Conversion Factor 267
11.11.6 Parameter Values 267
11.12 Danfoss FC Control Profile
Index
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266
267
275
How to Read this Design Gui... FC 300 Design Guide
1 How to Read this Design Guide
This Design Guide will introduce all aspects of your FC 300.
Available literature for FC 300
- The VLT AutomationDrive Operating Instructions MG.33.AX.YY provide the neccessary information for getting the drive up and running.
- The VLT AutomationDrive High Power Operating Instructions MG.33.UX.YY
- The VLT AutomationDrive Design Guide MG.
33.BX.YY entails all technical information about the drive and customer design and applications.
- The VLT AutomationDrive Programming Guide MG.33.MX.YY provides information on how to programme and includes complete parameter descriptions.
- The VLT AutomationDrive Profibus Operating Instructions MG.33.CX.YY provide the information required for controlling, monitoring and programming the drive via a Profibus fieldbus.
- The VLT AutomationDrive DeviceNet Operating Instructions MG.33.DX.YY provide the information required for controlling, monitoring and programming the drive via a DeviceNet fieldbus.
X = Revision number YY = Language code
Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/DrivesSolutions/ Documentations/Technical+Documentation.
Symbols
1.1.1
Symbols used in this guide.
NOTE
Indicates something to be noted by the reader.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or equipment damage.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Indicates default setting
*
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 frequency converter FC 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. 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
LIM
°C
M,N
M,N
M,N
M,N
INV
s
LIM
VLT,MAX
I
VLT,N
1 1
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175ZA078.10
Pull-out
rpm
Torque
How to Read this Design Gui... FC 300 Design Guide
11
1.1.3 Definitions
Frequency converter: Coast
P
M,N
The rated motor power (nameplate data).
The motor shaft is in free mode. No torque on motor.
T
I
MAX
The maximum output current. I
N
The rated output current supplied by the frequency converter.
U
MAX
The maximum output voltage.
M,N
The rated torque (motor).
U
M
The instantaneous motor voltage.
U
M,N
The rated motor voltage (nameplate data). Input: Control command
Break-away torque Start and stop the connected motor by means of LCP and
the 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,
Group 2 Start, Pulse start, Reversing, Start reversing, Jog
Quick-stop, DC braking, Stop and the "Off" key.
and Freeze output
Motor: f
JOG
The motor frequency when the jog function is activated (via digital terminals).
f
M
Motor frequency. Output from the frequency converter. Output frequency is related to the shaft speed on motor depending on number of poles and slip frequency.
f
MAX
The maximum output frequency the frequency converter applies on its output. The maximum output frequency is set in limit par. 4-12, 4-13 and 4-19.
f
MIN
The minimum motor frequency from frequency converter. Default 0 Hz.
f
M,N
The rated motor frequency (nameplate data). I
M
The motor current. I
M,N
The rated motor current (nameplate data). n
M,N
The rated motor speed (nameplate data). n
s
Synchronous motor speed
2 ×
par
n
=
s
. 1 − 23 × 60
par
. 1 − 39
s
η
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:
Analog Reference
An analog signal applied to input 53 or 54. The signal can
be either Voltage 0-10V (FC 301 and FC 302) or -10 -+10V
(FC 302). Current signal 0-20 mA or 4-20 mA.
Binary Reference
A signal applied to the serial communication port (RS-485
term 68 – 69).
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.
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How to Read this Design Gui... FC 300 Design Guide
Pulse Reference A pulse reference applied to term 29 or 33, selected by par. 5-13 or 5-15 [32]. Scaling in par. group 5-5*.
Ref
MAX
Determines the relationship between the reference input at 100% full scale value (typically 10V, 20mA) 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 0V, 0mA, 4mA) and the resulting reference. The minimum reference value set in 3-02 Minimum Reference.
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, 0-20mA and 4-20mA Voltage input, 0-10V DC (FC 301) Voltage input, -10 - +10V DC (FC 302).
Analog Outputs The analog outputs can supply a signal of 0-20mA, 4-20mA.
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 24V DC (max. 40mA) 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 non-
periodic 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
metres from the frequency converter, i.e. in a front panel
by means of the installation kit option.
NLCP
Numerical Local Control Panel interface for control and
programming of frequency converter. The display is
numerical and the panel is basically used for display
process values. The NLCP has no storing and copy
function.
lsb
Least significant bit.
msb
Most significant bit.
MCM
Short for Mille Circular Mil, an American measuring unit for
cable cross-section. 1 MCM = 0.5067 mm2.
On-line/Off-line Parameters
Changes to on-line parameters are activated immediately
after the data value is changed. Changes to off-line
parameters are not activated until you enter [OK] on the
LCP.
Process PID
The PID regulator maintains the desired speed, pressure,
temperature, etc. by adjusting the output frequency to
match the varying load.
PCD
Process Data
Pulse Input/Incremental Encoder
An external digital sensor used for feedback information of
motor speed and direction. Encoders are used for high
speed accuracy feedback and in high dynamic applications.
The encoder connection is either via term 32 and 32 or
encoder option MCB 102.
RCD
Residual Current Device.
Set-up
You can 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).
Slip Compensation
The frequency converter compensates for the motor slip
by giving the frequency a supplement that follows the
1 1
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How to Read this Design Gui... FC 300 Design Guide
11
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. (Par. group 13-** Smart
Power Factor
The power factor is the relation between I1 and I
3 x U x
I
cos
ϕ
Power factor
=
3 x U x
1
I
RMS
The power factor for 3-phase control:
RMS
.
Logic Control (SLC). STW
Status Word FC Standard Bus
Includes RS -485 bus with FC protocol or MC protocol. See 8-30 Protocol.
I1 x cos
=
I
RMS
The power factor indicates to which extent the frequency
converter imposes a load on the mains supply.
The lower the power factor, the higher the I
same kW performance.
ϕ1
=
I
RMS
I
1
since cos
ϕ1 = 1
RMS
for the
Thermistor: A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).
THD Total Harmonic Distortion state the total contribution of harmonic.
I
RMS
=
I
+
1
2
I
+
I
+ .. +
5
7
In addition, a high power factor indicates that the different
harmonic currents are low.
All Danfoss frequency converters have built-in DC coils in
the DC link to have a high power factor and to reduce the
THD on the main supply.
2
I
n
2
2
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 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).
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Safety and Conformity FC 300 Design Guide
2 Safety and Conformity
2.1 Safety Precautions
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.
Safety Regulations
1. The mains supply to the frequency converter must be disconnected whenever repair work is to be carried out. Check that the mains supply has been disconnected and that the necessary time has elapsed before removing motor and mains supply plugs.
2. The [OFF] button on the control panel of the frequency converter does not disconnect the mains supply and consequently it 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 3.5mA.
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 ETR trip 1 [4] or data value ETR warning 1 [3].
6. Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains. Check that the mains supply has been disconnected and that the necessary time has elapsed before removing motor and mains plugs.
7. Please note that the frequency converter has more voltage sources than L1, L2 and L3, when load sharing (linking of DC intermediate circuit) or external 24V DC are installed. Check that all voltage sources have been disconnected and that the necessary time has elapsed before commencing repair work.
Warning against unintended start
1. The motor can be brought to a stop by means of digital commands, bus commands, references or
a local stop, while the frequency converter is
2 2
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 or the Safe Stop function must be activated.
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 use of the Safe Stop function or 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 or the Safe Stop function must be activated.
NOTE
When using the Safe Stop function, always follow the instructions in the section Safe Stop of the VLT AutomationDrive Design Guide.
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.
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Safety and Conformity FC 300 Design Guide
WARNING
High Voltage
22
Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains. Also make sure that other voltage inputs have been disconnected, such as external 24V DC, load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back up. Systems where frequency converters are installed must, if necessary, be equipped with additional monitoring and protective devices according to the valid safety regulations, 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.
NOTE
Crane, Lifts and Hoists: The controlling of external brakes must always have a redundant system. The frequency converter can in no circumstances be the primary safety circuit. Comply with relevant standards, e.g. Hoists and cranes: IEC 60204-32 Lifts: EN 81
The DC link capacitors remain charged after power has been disconnected. Be aware that there may be high voltage on the DC link even when the Control Card LEDs are turned off. A red LED is mounted on a circuit board inside the drive to indicate the DC bus voltage. The red LED will stay lit until the DC link is 50 Vdc or lower. 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 Power Waiting Time 380 - 500 V 0.25 - 7.5 kW 4 minutes 11 - 75 kW 15 minutes 90 - 200 kW 20 minutes 250 - 800 kW 40 minutes 525 - 690 V 11-75 kW (frame
size B and C)
37 - 315 kW (frame
size D)
355 - 1000 kW 30 minutes
15 minutes
20 minutes
2.2.1 Disposal Instruction
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.
FC 300
Design Guide
Software version: 6.4x
Protection Mode Once a hardware limit on motor current or dc-link voltage is exceeded the frequency converter will enter “Protection mode”. “Protection mode” means a change of the PWM modulation strategy and a low switching frequency to minimize losses. This continues 10 sec after the last fault and increases the reliability and the robustness of the frequency converter while re-establishing full control of the motor. In hoist applications “Protection mode” is not usable because the frequency converter will usually not be able to leave this mode again and therefore it will extend the time before activating the brake – which is not recommendable. The “Protection mode” can be disabled by setting 14-26 Trip Delay at Inverter Fault to zero which means that the frequency converter will trip immediately if one of the hardware limits is exceeded.
NOTE
It is recommended to disable protection mode in hoisting applications (14-26 Trip Delay at Inverter Fault = 0)
This Design Guide can be used for all FC 300 frequency converters with software version 6.4x. The software version number can be seen from 15-43 Software Version.
2.3.1 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
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Safety and Conformity FC 300 Design Guide
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 - 1000V AC and the 75 - 1500V 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. We offer the filters presented in the specifications and provide other types of assistance to ensure the optimum EMC result.
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
2.3.2
The EU "Guidelines on the Application of Council Directive 2004/108/EC" outline three typical situations of using a frequency converter. See below 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 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.
2.3.3 Danfoss Frequency Converter and CE Labelling
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.
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, Danfoss specifies which our different products comply with.
Danfoss provides other types of assistance that can help you obtain the best EMC result.
2.3.4
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
2 2
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Safety and Conformity FC 300 Design Guide
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
22
Drive systems are complied with, provided that the EMC­correct instructions for installation are followed, see the section EMC Immunity.
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.
A frequency converter contains a large number of mechanical and electronic components. All are to some extent vulnerable to environmental effects.
CAUTION
The frequency converter should not be installed 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 The safe Stop function may only be installed and operated in a control cabinet with degree of protection IP54 or higher (or equivalent environment). This is required to avoid cross faults and short circuits between terminals, connectors, tracks and safety-related circuitry caused by foreign objects.
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.
D and E enclosures have a stainless steel back-channel option to provide additional protection in aggressive environments. Proper ventilation is still required for the internal components of the drive. Contact Danfoss for additional information.
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.
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 IP 54/55. As an extra protection, coated printed circuit boards can be ordered as an option.
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 dust particles around the frequency converter fan. In very dusty environments, use equipment with enclosure rating IP 54/55 or a cabinet for IP 00/IP 20/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.
Such 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. An extra protection in such areas is a coating of the printed circuit boards, which can be ordered as an option.
IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970
•
IEC/EN 60068-2-64: Vibration, broad-band random
•
D and E frames have a stainless steel backchannel option to provide additional protection in aggressive environments. Proper ventilation is still required for the internal components of the drive. Contact factory for additional information.
14 MG.33.BD.02 - VLT® is a registered Danfoss trademark
130BA870.10
130BA809.10
130BA810.10
130BB458.10
130BA811.10
130BA812.10
130BA813.10
130BA826.10
130BA827.10
130BA814.10
130BA815.10
130BA828.10
130BA829.10
Introduction to FC 300 FC 300 Design Guide
3 Introduction to FC 300
3.1 Product Overview
Frame size depends on enclosure type, power range and mains voltage Frame size A1* A2* A3* A4 A5
Enclosure protection
High overload rated power ­160% overload torque Frame size B1 B2 B3 B4
IP 20/21 20/21 20/21 55/66 55/66 NEM A
Chassis/Type 1 Chassis/ Type 1 Chassis/ Type 1 Type 12 Type 12
0.25 – 1.5kW (200-240V)
0.37 – 1.5kW (380-480V)
0.25-3kW (200–240V)
0.37-4.0kW (380-480/ 500V)
3.7kW (200-240V)
5.5-7.5kW (380-480/500V)
0.75-7.5kW (525-600V )
0.25-3kW (200–240V)
0.37-4.0kW (380-480/500V)
0.25-3.7kW (200-240V)
0.37-7.5kW (380-480/500V)
0.75 -7.5kW (525-600V)
3
3
Enclosure protection
High overload rated power ­160% overload torque
Frame size C1 C2 C3 C4
Enclosure protection
High overload rated power ­160% overload torque * A1, A2 and A3 are bookstyle enclosures. All other sizes are compact enclosures.
IP 21/55/66 21/55/66 20 20 NEM A
IP 21/55/66 21/55/66 20 20 NEM A
Type 1/Type 12 Type 1/Type 12 Chassis Chassis
5.5-7.5kW (200-240V) 11-15kW (380-480/500V) 11-15kW (525-600V)
Type 1/Type 12 Type 1/Type 12 Chassis Chassis
15-22kW (200-240V) 30-45kW (380-480/500V) 30-45kW (525-600V)
11kW (200-250V)
18.5-22kW (380-480/500V)
18.5-22kW (525-600V) 11-22kW (525-690V)
30-37kW (200-240V) 55-75kW (380-480/500V) 55-90kW (525-600V) 30-75kW (525-690V)
5.5-7.5kW (200-240V) 11-15kW (380-480/500V) 11-15kW (525-600V)
18.5-22kW (200-240V) 37-45kW (380-480/500V) 37-45kW (525-600V)
11-15kW (200-240V)
18.5-30kW (380-480/500V)
18.5-30kW (525-600V)
30-37kW (200-240V) 55-75kW (380-480/500V) 55-90kW (525-600V)
MG.33.BD.02 - VLT® is a registered Danfoss trademark 15
130BA816.10
130BA817.10
130BA819.10
130BA820.10
130BA818.10
130BA821.10
F3
F1
130BA959.10
F4
F3
130BB092.10
F9
F8
130BB690.10
F11
F10
130BB691.10
F13
F12
130BB692.10
3
Introduction to FC 300 FC 300 Design Guide
Frame size D1 D2 D3 D4
Enclosure protection
High overload rated power - 160% overload torque
Frame size E1 E2 F1/F3 F2/ F4
Enclosure protection
High overload rated power - 160% overload torque
IP 21/54 21/54 00 00 NEMA Type 1/ Type 12 Type 1/ Type 12 Chassis Chassis
90-110kW at 400V (380-/ 500V) 37-132kW at 690V (525-690V)
IP 21/54 00 21/54 21/54 NEMA Type 1/ Type 12 Chassis Type 1/ Type 12 Type 1/ Type 12
250-400kW at 400V (380-/500V) 355-560kW at 690V (525-690V)
132-200kW at 400V (380-/ 500V) 160-315kW at 690V (525-690V)
250-400kW at 400V (380-/500V) 355-560kW at 690V (525-690V)
90-110kW at 400V (380-/500V) 37-132kW at 690V (525-690V)
450 - 630kW at 400V (380 - /500V) 630 - 800kW at 690V (525-690V)
132-200kW at 400V (380-/ 500V) 160-315kW at 690V (525-690V)
710 - 800kW at 400V (380 - / 500V) 900 - 1000kW at 690V (525-690V)
NOTE
The F frames are available with or without options cabinet. The F1 and F2 consist of an inverter cabinet on the right and rectifier cabinet on the left. The F3 and F4 have an additional options cabinet left of the rectifier cabinet. The F3 is an F1 with an additional options cabinet. The F4 is an F2 with an additional options cabinet.
12-Pulse Units Frame size F8 F9 F10 F11 F12 F13 IP NEMA
High overload rated power - 160% overload torque
21, 54
Type 1/Type 12
250 - 400kW (380 - 500V) 355 - 560kW
(525-690V)
21, 54
Type 1/Type 12
250 - 400kW (380 - 500V)
355 - 56kW
(525-690V)
21, 54
Type 1/Type 12
450 - 630kW
(380 - 500V)
630 - 800kW
(525-690V)
21, 54
Type 1/Type 12
450 - 630kW (380 - 500V) 630 - 800kW
(525-690V)
21, 54
Type 1/Type 12
710 - 800kW
(380 - 500V)
900 - 1200kW
(525-690V)
21, 54
Type 1/Type 12
710 - 800kW (380 - 500V)
900 - 1200kW
(525-690V)
NOTE
The F frames are available with or without options cabinet. The F8, F10 and F12 consist of an inverter cabinet on the right and rectifier cabinet on the left. The F9, F11 and F13 have an additional options cabinet left of the rectifier cabinet. The F9 is an F8 with an additional options cabinet. The F11 is an F10 with an additional options cabinet. The F13 is an F12 with an additional options cabinet.
16 MG.33.BD.02 - VLT® is a registered Danfoss trademark
Introduction to FC 300 FC 300 Design Guide
3.2.1 Control Principle
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.
3.2.2 FC 300 Controls
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 open loop control which does not require
•
any feedback from motor (sensorless). 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.
Speed / torque reference: The reference to these controls can either be a single refrence or be the sum of various references including relatively scaled references. The handling of references is explained in detail later in this section.
3
3
Torque control (FC 302 only): 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 par. 1-00, either in VVC+ open loop [4] or Flux control closed loop with motor speed feedback [2]. Torque setting is done by setting an analog, digital or bus controlled reference. The max speed limit factor is set in par. 4-21. 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.
Closed loop in Flux mode with encoder feedback
•
offers superior performance in all four quadrants and at all motor speeds.
Open loop in VVC+ mode. The function is used in
•
mechanical robust applications, but the accuracy is limited. Open loop torque function works basically only in one speed direction. The torque is calculated on basic of current measurement internal in the frequency converter. See Application Example Torque open Loop
MG.33.BD.02 - VLT® is a registered Danfoss trademark 17
M
L2 92
L1 91
L3 93
89(+)
88(-)
R+ 82
R­81
U 96
V 97
W 98
130BA192.12
InrushR inr
Load sharing -
De-saturation protection
Load sharing +
Brake Resistor
Drive Control Board
Inrush
R inr
Load sharing -
Load sharing +
LC Filter ­(5A)
LC Filter + (5A)
Brake Resistor
130BA193.13
M
L2 92
L1 91
L3 93
89(+)
88(-)
R+ 82
R­81
U 96
V 97
W 98
P 14-50
Introduction to FC 300 FC 300 Design Guide
3.2.3 FC 301 vs. FC 302 Control Principle
3
FC 301 is a general purpose frequency converter for variable speed applications. The control principle is based on Voltage Vector Control (VVC
plus
). FC 301 can handle asynchronous motors only. The current sensing principle in FC 301 is based on current measurement in the DC link or motor phase. The ground fault protection on the motor side is solved by a de-saturation circuit in the IGBTs connected to the control board. Short circuit behaviour on FC 301 depends on the current transducer in the positive DC link and the desaturation protection with feedback from the 3 lower IGBT's and the brake.
Illustration 3.1 FC 301
FC 302 is a high performance frequency converter for demanding applications. The frequency converter can handle various kinds of motor control principles such as U/f special motor mode, VVC
plus
or Flux Vector motor control. FC 302 is able to handle Permanent Magnet Synchronous Motors (Brushless servo motors) as well as normal squirrel cage asynchronous motors. Short circuit behaviour on FC 302 depends on the 3 current transducers in the motor phases and the desaturation protection with feedback from the brake.
Illustration 3.2 FC 302
18 MG.33.BD.02 - VLT® is a registered Danfoss trademark
+
_
+
_
Cong. mode
Ref.
Process
P 1-00
High
+f max.
Low
-f max.
P 4-11 Motor speed low limit (RPM)
P 4-12 Motor speed low limit (Hz)
P 4-13 Motor speed high limit (RPM)
P 4-14 Motor speed high limit (Hz)
Motor controller
Ramp
Speed PID
P 7-20 Process feedback 1 source
P 7-22 Process feedback 2 source
P 7-00 Speed PID
feedback source
P 1-00
Cong. mode
P 4-19
Max. output freq.
-f max.
Motor controller
P 4-19 Max. output freq.
+f max.
P 3-**
P 7-0*
130BA055.10
Introduction to FC 300 FC 300 Design Guide
3.2.4
Control Structure in VVC
Control structure in VVC
plus
Advanced Vector Control
plus
open loop and closed loop configurations:
3
3
In the configuration shown in Illustration 3.3, 1-01 Motor Control Principle is set to “VVC
plus
[1]” and 1-00 Configuration Mode is
set to “Speed open loop [0]”. The resulting reference from the reference handling system is received and fed through the ramp limitation and speed limitation before being sent to the motor control. The output of the motor control is then limited by the maximum frequency limit.
If 1-00 Configuration Mode is set to “Speed closed loop [1]” 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*. The resulting reference from the Speed PID control is sent to the motor control limited by the frequency limit.
Select “Process [3]” 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* and 7-3*.
MG.33.BD.02 - VLT® is a registered Danfoss trademark 19
+
_
+
_
130BA053.11
Ref.
Cong. mode
P 1-00
P 7-20 Process feedback 1 source
P 7-22 Process feedback 2 source
Process PID
P 4-11 Motor speed low limit [RPM]
P 4-12 Motor speed low limit [Hz]
P 4-14 Motor speed high limit [Hz]
P 4-13 Motor speed high limit [RPM]
Low
High
Ramp
P 3-**
+f max.
P 4-19 Max. output freq.
Motor controller
-f max.
Speed PID
P 7-0*
3
Introduction to FC 300 FC 300 Design Guide
3.2.5 Control Structure in Flux Sensorless (FC 302 only)
Control structure in Flux sensorless open loop and closed loop configurations.
In the shown configuration,
1-01 Motor Control Principle is set to “Flux sensorless [2]” and 1-00 Configuration Mode is set to
“Speed open loop [0]”. The resulting reference from the reference handling system is fed through the ramp and speed limitations as determined by the parameter settings indicated.
An estimated speed feedback is generated to the Speed PID to control the output frequency. The Speed PID must be set with its P,I, and D parameters (parameter group 7-0*).
Select “Process [3]” in 1-00 Configuration Mode to use the process PID control for closed loop control of i.e. speed or pressure in the controlled application. The Process PID parameters are found in parameter group 7-2* and 7-3*.
20 MG.33.BD.02 - VLT® is a registered Danfoss trademark
130BA054.11
P 3-** P 7-0*P 7-2*
+
_
+
_
P 7-20 Process feedback 1 source P 7-22 Process feedback 2 source
P 4-11 Motor speed low limit (RPM) P 4-12 Motor speed low limit (Hz)
P 4-13 Motor speed high limit (RPM) P 4-14 Motor speed high limit (Hz)
High
Low
Ref.
Process
PID
Speed
PID
Ramp
P 7-00 PID source
Motor controller
-f max.
+f max.
P 4-19 Max. output freq.
P 1-00 Cong. mode
P 1-00 Cong. mode
Torque
Introduction to FC 300 FC 300 Design Guide
3.2.6 Control Structure in Flux with Motor Feedback
Control structure in Flux with motor feedback configuration (only available in FC 302):
In the shown configuration, 1-01 Motor Control Principle is set to “Flux w motor feedb [3]” and 1-00 Configuration Mode is set to “Speed closed loop [1]”.
3
3
The motor control in this configuration relies on a feedback signal from an encoder mounted directly on the motor (set in 1-02 Flux Motor Feedback Source).
Select “Speed closed loop [1]” in 1-00 Configuration Mode to use the resulting reference as an input for the Speed PID control. The Speed PID control parameters are located in parameter group 7-0*.
Select “Torque [2]” in 1-00 Configuration Mode to use the resulting reference directly as a torque reference. Torque control can only be selected in the Flux with motor feedback (1-01 Motor Control Principle) configuration. When this mode has been selected, the reference will use the Nm unit. It requires no torque feedback, since the actual torque is calculated on the basis of the current measurement of the frequency converter.
Select “Process [3]” in 1-00 Configuration Mode to use the process PID control for closed loop control of e.g. speed or a process variable in the controlled application.
MG.33.BD.02 - VLT® is a registered Danfoss trademark 21
130BP046.10
Hand
on
O
Auto
on
Reset
Remote reference
Local reference
Auto mode
Hand mode
Linked to hand/auto
Local
Remote
Reference
130BA245.11
LCP Hand on, o and auto on keys
P 3-13 Reference site
Torque
Speed open/
closed loop
Scale to RPM or Hz
Scale to Nm
Scale to process unit
Process
closed loop
Local
ref.
Local reference
Conguration mode
Local conguration
mode
130BA246.10
P 1-00
P 1-05
Introduction to FC 300 FC 300 Design Guide
3
3.2.7
Internal Current Control in VVC
plus
Mode
The frequency converter features an integral current limit control which is activated when the motor current, and thus the torque, is higher than the torque limits set in
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
3.2.8
On) Control
The frequency converter can be operated manually via the local control panel (LCP) or remotely via analog and digital inputs and serial bus. If allowed in 0-40 [Hand on] Key on
LCP, 0-41 [Off] Key on LCP, 0-42 [Auto on] Key on LCP, and 0-43 [Reset] Key on LCP, it is possible to start and stop the
frequency converter via the LCP using the [Hand ON] and [Off] keys. Alarms can be reset via the [RESET] key. After pressing the [Hand ON] key, the frequency converter goes into Hand mode and follows (as default) the Local reference that can be set using arrow key on the LCP.
After pressing the [Auto On] key, the frequency converter goes into Auto mode and follows (as default) the Remote reference. In this mode, it is possible to control the frequency converter via the digital inputs and various serial interfaces (RS-485, USB, or an optional fieldbus). See more about starting, stopping, changing ramps and parameter set-ups etc. in parameter group 5-1* (digital inputs) or parameter group 8-5* (serial communication).
Hand OnAutoLCP Keys Hand Linked to Hand /
Active Reference and Configuration Mode
The active reference can be either the local reference or the remote reference.
In 3-13 Reference Site the local reference can be permanently selected by selecting Local [2]. To permanently select the remote reference select Remote [1]. By selecting Linked to Hand/Auto [0] (default) the reference site will depend on which mode is active. (Hand Mode or Auto Mode).
Hand -> Off Linked to Hand /
Auto Linked to Hand /
Auto -> Off Linked to Hand /
All keys Local Local All keys Remote Remote
Table 3.1 Conditions for Local/Remote Reference Activation.
1-00 Configuration Mode determines what kind of application control principle (i.e. Speed, Torque or Process Control) is used when the remote reference is active. 1-05 Local Mode Configuration determines the kind of application control principle that is used when the local reference is active. One of them is always active, but both can not be active at the same time.
22 MG.33.BD.02 - VLT® is a registered Danfoss trademark
3-13 Reference Site
Auto
Auto
Auto
Auto
Active Reference Local
Local
Remote
Remote
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 RPM or 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
Conguration mode
P 1-00
P 3-14
±100%
130BA244.11
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
Introduction to FC 300 FC 300 Design Guide
3.3 Reference Handling
Local Reference The local reference is active when the frequency converter is operated with ‘Hand On’ button active. Adjust the reference by up/down and left/right arrows respectively.
Remote Reference The reference handling system for calculating the Remote reference is shown in Illustration 3.3.
3
3
Illustration 3.3 Remote reference
MG.33.BD.02 - VLT® is a registered Danfoss trademark 23
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
3
Introduction to FC 300 FC 300 Design Guide
The Remote Reference is calculated once every scan interval and initially consists of two types of reference inputs:
1. X (the external reference): A sum (see
3-04 Reference Function) of up to four externally selected references, comprising any combination (determined by the setting of 3-15 Reference
Resource 1, 3-16 Reference Resource 2 and 3-17 Reference Resource 3) 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 Resource) in [%].
The two types of reference inputs are combined in the following formula: Remote reference = X + X * Y / 100%. If relative reference is not used par. 3-18 must be set to No function and par. 3-14 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 Programming Guide, MG33MXYY. The scaling of analog references are described in parameter groups 6-1* and 6-2*, and the scaling of digital pulse references are described in parameter group 5-5*. Reference limits and ranges are set in parameter group 3-0*.
Reference Limits
3.3.1
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 below.
The value of 3-02 Minimum Reference can not be set to less than 0, unless1-00 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 3.4.
24 MG.33.BD.02 - VLT® is a registered Danfoss trademark
Illustration 3.4 Sum of all References
(RPM)
Resource output
Resource input
Terminal X low
Terminal X high
Low reference/feedback value
High reference/feedback value
130BA181.10
-1500
-6 8 (V)
1500
-10 10
P1
P2
0
-600
(RPM)
Resource output
Resource input
Terminal X low
Terminal X high
Low reference/feedback value
High reference/feedback value
130BA182.10
-1500
-6 8 (V)
1500
-10 10
P1
P2
0
-600
Introduction to FC 300 FC 300 Design Guide
3.3.2 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.
3
3
3.3.3
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 3.5) are clamped whereas a feedback above or below is not.
Scaling of Analog and Pulse References and Feedback
Illustration 3.5 Scaling of Analog and Pulse References and Feedback
MG.33.BD.02 - VLT® is a registered Danfoss trademark 25
(RPM)
Resource output
Resource input
Quadrant 2
Quadrant 3
Quadrant 1
Quadrant 4
Terminal X low
Terminal X high
Low reference/feedback value
High reference/feedback value
-1 1
130BA179.10
-1500
-6 6
(V)
1500
-10 10
P1P20
(RPM)
Resource output
Resource input
Quadrant 2
Quadrant 3
Quadrant 1
Quadrant 4
Terminal X low
Terminal X high
Low reference/feedback value
High reference/feedback value
-1 1
130BA180.10
-1500
-6 6
(V)
1500
-10 10
P1
P2
0
Introduction to FC 300 FC 300 Design Guide
The endpoints P1 and P2 are defined by the following parameters depending on which analog or pulse input is used
3
Analog 53 S201=OFF
P1 = (Minimum input value, Minimum reference value) Minimum reference value
Minimum input value
P2 = (Maximum input value, Maximum reference value) Maximum reference value
Maximum input value
6-14 Terminal 53 Low Ref./Feedb. Value 6-10 Terminal 53 Low Voltage [V]
6-15 Terminal 53 High Ref./Feedb. Value 6-11 Terminal 53 High Voltage [V]
Analog 53 S201=ON
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]
3.3.4 Dead Band Around Zero
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 above
•
for relevant parameter) or Maximum Reference Value must be zero. In other words; Either P1 or P2 must be on the X-axis in the graph below.
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 inIllustration 3.6.
Analog 54 S202=OFF
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 S202=ON
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]
Thus a reference endpoint of P1 = (0 V, 0 RPM) will not result in any dead band, but a reference endpoint of e.g. P1 = (1V, 0 RPM) will result in a -1V to +1V dead band in this case provided that the end point P2 is placed in either Quadrant 1 or Quadrant 4.
26 MG.33.BD.02 - VLT® is a registered Danfoss trademark
500
1
10
V
V
500
1
10
-500
130BA187.11
+
Analog input 53 Low reference 0 RPM
High reference 500 RPM Low voltage 1V High voltage 10V
Ext. source 1
Range:
0,0% (0 RPM)
100,0% (500 RPM)
100,0% (500 RPM)
Ext. reference
Range: 0,0% (0 RPM)
500 RPM 10V
Ext. Reference
Absolute 0 RPM 1V
Reference algorithm
Reference
100,0% (500 RPM)
0,0% (0 RPM)
Range:
Limited to:
0%- +100%
(0 RPM- +500 RPM)
Limited to: -200%- +200% (-1000 RPM- +1000 RPM)
Reference is scaled
according to min max reference giving a
speed.!!!
Scale to speed
+500 RPM
-500 RPM
Range:
Speed setpoint
Motor
control
Range:
-200 RPM +200 RPM
Motor
Digital input 19
Low No reversing High Reversing
Limits Speed Setpoint according to min max speed.!!!
Motor PID
RPM
RPM
Dead band
Digital input
General Reference parameters: Reference Range: Min - Max Minimum Reference: 0 RPM (0,0%)
Maximum Reference: 500 RPM (100,0%)
General Motor parameters: Motor speed direction:Both directions Motor speed Low limit: 0 RPM Motor speed high limit: 200 RPM
Introduction to FC 300 FC 300 Design Guide
Case 1: Positive Reference with Dead band, Digital input to trigger reverse This Case shows how Reference input with limits inside Min – Max limits clamps.
3
3
MG.33.BD.02 - VLT® is a registered Danfoss trademark 27
+
750
1
10
500
1
10
130BA188.13
-500
V
V
Analog input 53
Low reference 0 RPM High reference 500 RPM Low voltage 1V High voltage 10V
Ext. source 1
Range: 0,0% (0 RPM)
150,0% (750 RPM)
150,0% (750 RPM)
Ext. reference Range: 0,0% (0 RPM)
750 RPM 10V
Ext. Reference
Absolute
0 RPM 1V
Reference algorithm
Reference
100,0% (500 RPM)
0,0% (0 RPM)
Range:
Limited to:
-100%- +100%
(-500 RPM- +500 RPM)
Limited to: -200%- +200%
(-1000 RPM- +1000 RPM)
Reference is scaled according to
max reference giving a speed.!!!
Scale to speed
+500 RPM
-500 RPM
Range:
Speed setpoint
Motor control
Range:
-200 RPM +200 RPM
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: 500 RPM (100,0%)
General Motor parameters: Motor speed direction:Both directions Motor speed Low limit: 0 RPM Motor speed high limit: 200 RPM
3
Introduction to FC 300 FC 300 Design Guide
Case 2: Positive Reference with Dead band, Digital input to trigger reverse. Clamping rules. This Case shows how Reference input with limits outside -Max – +Max limits clamps to the inputs low and high limits before addition to External reference. And how the External reference is clamped to -Max – +Max by the Reference algorithm.
28 MG.33.BD.02 - VLT® is a registered Danfoss trademark
+
500
10
V
130BA189.12
-10
-500
-1
500
-500
-10
1
10
V
Analog input 53
Low reference 0 RPM High reference +500 RPM Low voltage 1V High voltage 10V
Ext. source 1
Range:
-50,0% (-500 RPM) +50,0% (+500 RPM)
+100,0% (+1000 RPM)
Ext. reference
Range:
-100,0% (-1000 RPM)
+500 RPM 10V
Ext. Reference
Absolute
-500 RPM -10V
Reference algorithm
Reference
+100,0% (+1000 RPM)
-100,0% (-1000 RPM)
Range:
Limited to:
-100%- +100% (-1000 RPM-
+1000 RPM)
Limited to:
-200%- +200% (-2000 RPM-
+2000 RPM)
Reference is scaled according to max reference.!!!
Scale to RPM
+1000 RPM
-1000 RPM
Range:
Speed setpoint
Motor control
Motor
Limits Speed to min max motor speed.!!!
Motor PID
RPM
Dead band
General Reference parameters: Reference Range: -Max - +Max Minimum Reference: Don't care
Maximum Reference: 1000 RPM (100,0%)
General Motor parameters: Motor speed direction:Both directions Motor speed Low limit: 0 RPM Motor speed high limit: 1500 RPM
-1V to 1V
RPM
-500 RPM -10V
Ext. Reference
+500 RPM 10V
Absolute
+50,0% (+500 RPM)
-50,0% (-500 RPM)
High reference +500 RPM
Ext. source 2
Low reference -500 RPM
Analog input 54
Range:
High voltage +10V
Low voltage -10V
No Dead band
Introduction to FC 300 FC 300 Design Guide
Case 3: Negative to positive reference with dead band, Sign determines the direction, -Max – +Max
3
3
MG.33.BD.02 - VLT® is a registered Danfoss trademark 29
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