Danfoss Electronics FC322 Design Guide

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT® Automation VT Drive FC 322

Automation VT Drive FC322 Design Guide Contents

Contents

1 How to Read this Design Guide

Symbols 6

Abbreviations 7

Definitions 7

2 Introduction to VLT Automation VT Drive

CE labelling 17

Vibration and shock 19

Control Structures 24

General aspects of EMC 34

Immunity Requirements 38

Galvanic isolation (PELV) 39

PELV - Protective Extra Low Voltage 39

Earth leakage current 40

Control with Brake Function 41

Control with Brake Function 42

Mechanical Brake Control 42

Extreme Running Conditions 42

Safe Stop Operation (Optional) 47

3 VLT Automation VT Drive Selection

General Specifications 49

Efficiency 65

Special Conditions 72

Options and Accessories 77

General Description 89

High Power Options 95

Installation of Duct Cooling Kit in Rittal Enclosures 95

Outside Installation/ NEMA 3R Kit for Rittal Enclosures 98

Installation on Pedestal 99

Input Plate Option 102

Installation of Mains Shield for Frequency Converters 103

Frame size F Panel Options 104

4 How to Order

Ordering Form 107

Type Code String 108

107

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Contents Automation VT Drive FC322 Design Guide

Ordering Numbers 111

5 How to Install

Mechanical Installation 125

Pre-installation 131

Planning the Installation Site 131

Receiving the Frequency Converter

Transportation and Unpacking 131

Lifting 132

Cooling and Airflow 136

Electrical Installation 140

Connections - Frame sizes D, E and F 156

Power Connections 156

Disconnectors, Circuit Breakers and Contactors 170

Final Set-Up and Test 171

Safe Stop Installation 173

Safe Stop Commissioning Test 174

Additional Connections 176

Installation of Misc. Connections 179

Safety 181

EMC-correct Installation 182

Residual Current Device 186

125

131

6 Application Examples

Potentiometer Reference 188

Automatic Motor Adaptation (AMA) 188

SLC Application Example 189

System Status and Operation 192

Cascade Controller Wiring Diagram

Fixed Variable Speed Pump Wiring Diagram 194

Lead Pump Alternation Wiring Diagram 194

7 RS-485 Installation and Set-up

RS-485 Installation and Set-up 197

FC Protocol Overview 199

Network Configuration 201

FC Protocol Message Framing Structure 201

Examples 209

Modbus RTU Overview 210

187

193

197

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Automation VT Drive FC322 Design Guide Contents

VLT Automation VT Drive with Modbus RTU 210

Modbus RTU Message Framing Structure 211

How to Access Parameters 216

Examples 217

Danfoss FC Control Profile 222

8 Troubleshooting

231

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1 How to Read this Design Guide Automation VT Drive FC322 Design Guide

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Automation VT Drive FC322 Design Guide 1 How to Read this Design Guide

1 How to Read this Design Guide

1.1.1 Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to Danfoss. By accepting and using this manual the user agrees that the information contained herein

will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication

with Danfoss equipment over a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries.

Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical,

hardware or software environment.

Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or representation, neither expressed nor

implied, with respect to this documentation, including its quality, performance, or fitness for a particular purpose.

In no event shall Danfoss be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information

contained in this manual, even if advised of the possibility of such damages. In particular, Danfoss is not responsible for any costs, including but not

limited to those incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute

these, or any claims by third parties.

Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former

or present users of such revisions or changes.

1.1.2

Available Literature for VLT

Automation VT Drive FC322

- Output Filters Design Guide MG.90.Nx.yy

- Application Note MN20A102: Submersible Pump Application

- Application Note MN20B102: Master/Follower Operation Application

- Application Note MN20F102: Drive Closed Loop and Sleep Mode

- Instruction MI.38.Bx.yy: Installation Instruction for Mounting Brackets Enclosure type A5, B1, B2, C1 and C2 IP21, IP55 or IP66

- Instruction MI.90.Lx.yy: Analog I/O Option MCB109

- Instruction MI.33.Hx.yy: Panel through mount kit

x = Revision number

yy = Language code

Danfoss technical literature is also available online at

www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm

Automation VT Drive FC322 Instruction Manual MG.20.Ux.yy provide the neccessary information for getting the drive up and running.

VLT

Automation VT Drive FC322 High Power Instruction Manual MG.20.Vx.yy provide the neccessary information for getting the HP drive up

VLT

and running.

VLT

Automation VT Drive FC322 Design Guide MG.20.Xx.yy entails all technical information about the drive and customer design and appli-

cations.

VLT

Automation VT Drive FC322 Programming Guide MN.20.Wx.yy provides information on how to programme and includes complete pa-

rameter descriptions.

VLT

Automation VT Drive FC322 Profibus MG.33.Cx.yy

Automation VT Drive FC322 DeviceNet MG.33.Dx.yy

VLT

Automation VT Drive FC322 Cascade Controller MI.38.Cx.yy

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1 How to Read this Design Guide Automation VT Drive FC322 Design Guide

1.1.3 Symbols

Symbols used in this guide.

NB!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

 Indicates default setting

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1.1.4 Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Automatic Motor Adaptation AMA

Current limit I

Degrees Celsius °C

Direct current DC

Drive Dependent D-TYPE

Electro Magnetic Compatibility EMC

Electronic Thermal Relay ETR

Drive FC

Gram g

Hertz Hz

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 s

Synchronous Motor Speed n

Torque limit T

Volts V

VLT,MAX

VLT,N

LIM

M,N

INV

LIM

The maximum output current

The rated output current supplied by the frequency converter

1.1.5 Definitions

Drive:

VLT,MAX

The maximum output current.

VLT,N

The rated output current supplied by the frequency converter.

VLT, MAX

The maximum output voltage.

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1 How to Read this Design Guide Automation VT Drive FC322 Design Guide

Input:

Control command You can 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.

Motor:

JOG

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

The motor frequency.

MAX

The maximum motor frequency.

MIN

The minimum motor frequency.

M,N

The rated motor frequency (nameplate data).

The motor current.

M,N

The rated motor current (nameplate data).

M,N

The rated motor speed (nameplate data).

M,N

The rated motor power (nameplate data).

M,N

The rated torque (motor).

The instantaneous motor voltage.

M,N

The rated motor voltage (nameplate data).

Group 1 Reset, Coasting stop, Reset and Coasting stop, Quick-

stop, DC braking, Stop and the "Off" key.

Group 2 Start, Pulse start, Reversing, Start reversing, Jog and

Freeze output

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Automation VT Drive FC322 Design Guide 1 How to Read this Design Guide



VLT

The efficiency of the frequency converter is defined as the ratio between the power output and the power input.

Start-disable command

A stop command belonging to the group 1 control commands - see this group.

Stop command

See Control commands.

References:

Analog Reference

A signal transmitted to the analog inputs 53 or 54, can be voltage or current.

Bus Reference

A signal transmitted to the serial communication port (FC port).

Preset Reference

A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references via the digital terminals.

Pulse Reference

A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33).

Ref

MAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA) and the resulting reference. The maximum

reference value set in par. 3-03.

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 par. 3-02.

Miscellaneous:

Analog Inputs

The analog inputs are used for controlling various functions of the frequency converter.

There are two types of analog inputs:

Current input, 0-20 mA and 4-20 mA

Voltage input, 0-10 V DC.

Analog Outputs

The analog outputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal.

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 positive displacement pumps and blowers.

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Digital Inputs

The digital inputs can be used for controlling various functions of the frequency converter.

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Digital Outputs

The drive features two Solid State outputs that can supply a 24 V DC (max. 40 mA) signal.

DSP

Digital Signal Processor.

Relay Outputs:

The frequency converter drive features two programmable Relay Outputs.

ETR

Electronic Thermal Relay is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature.

GLCP:

Graphical Local Control Panel (LCP102)

Initialising

If initialising is carried out (par. 14-22), the programmable parameters of the frequency converter return to their default set tings.

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 none-periodic duty.

LCP

The Local Control Panel (LCP) 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.

The Local Control Panel is available in two versions:

- Numerical LCP101 (NLCP)

- Graphical LCP102 (GLCP)

lsb

Least significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM ิ 0.5067 mm

msb

Most significant bit.

NLCP

Numerical Local Control Panel LCP101

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.

PID Controller

The PID controller maintains the desired speed, pressure, temperature, etc. by adjusting the output frequency to match the varying load.

RCD

Residual Current Device.

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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.

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SFAVM

Switching pattern called

S tator F lux oriented A synchronous V ector M odulation (par. 14-00).

Slip Compensation

The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor

speed almost constant..

Smart Logic Control (SLC)

The SLC is a sequence of user defined actions executed when the associated user defined events are evaluated as true by the SLC.

Thermistor:

A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).

Trip

A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency converter is protecting the

motor, process or 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 locked 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

reference is changed and in relation to the load torque.

plus

) improves the dynamics and the stability, both when the speed

60° AVM

Switching pattern called 60°

A synchronous V ector M odulation (par. 14-00).

1.1.6 Power Factor

The power factor is the relation between I1 and I

The power factor for 3-phase control:

The power factor indicates to which extent the frequency converter im-

poses a load on the mains supply.

The lower the power factor, the higher the I

formance.

In addition, a high power factor indicates that the different harmonic currents are low.

The frequency converters' built-in DC coils produce a high power factor, which minimizes the imposed load on the mains supply.

RMS

for the same kW per-

RMS

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Power factor

cos

RMS

1

3 × U ×

RMS

+ . . +

1 ×

since cos

COS

RMS

1=1



2 Introduction to VLT Automation VT Drive Automation VT Drive FC322 Design Guide

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2 Introduction to VLT Automation VT Drive

2.1 Safety

2.1.1 Safety Note

The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor, frequency

converter or fieldbus may cause damage to the equipment, serious personal injury or death. Consequently, the instructions in this

manual, as well as national and local rules and safety regulations, must be complied with.

Safety Regulations

1. The frequency converter must be disconnected from mains if repair work is to be carried out. Check that the mains supply has been disconnected and

that the necessary time has passed before removing motor and mains plugs.

2. The [STOP/RESET] key on the control panel of the frequency converter does not disconnect the equipment from mains and is thu s not to be used as

a safety switch.

3. Correct protective earthing of the equipment must be established, 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 currents are higher than 3.5 mA.

5. Protection against motor overload is set by par. 1-90

value) or data value [ETR warning]. Note: The function is initialised at 1.16 x rated motor current and rated motor frequency. For the North American

market: The ETR functions provide class 20 motor overload protection in accordance with NEC.

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 passed before removing motor and mains plugs.

7. Please note that the frequency converter has more voltage inputs than L1, L2 and L3, when load sharing (linking of DC intermediate circuit) and external

24 V DC have been installed. Check that all voltage inputs have been disconnected and that the necessary time has passed before commencing repair

work.

Installation at High Altitudes

Motor Thermal Protection

. If this function is desired, set par. 1-90 to data value [ETR trip] (default

By altitudes above 2 km, please contact Danfoss regarding PELV.

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

connected to mains. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not sufficient.

2. While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] must always be activated; following which data

can be modified. 3. A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a temporary overload or

a fault in the supply mains or the motor connection ceases.

Warning:

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 24 V DC, load sharing (linkage of DC intermediate circuit), as well as

the motor connection for kinetic back up.

VLTp Automation VT Drive FC322 Instruction Manual MG.20.UX.YY

Refer to

MG.20.X1.22 - VLTp is a registered Danfoss trademark

for further safety guidelines.

2 Introduction to VLT Automation VT Drive Automation VT Drive FC322 Design Guide

2.1.2 Caution

The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard,

disconnect the frequency converter from the mains before carrying out maintenance. Wait at least as follows before doing service on

the frequency converter:

Voltage (V) Min. Waiting Time (Minutes)

4 15 20 30 40

200 - 240 0.25 - 3.7 kW 5.5 - 45 kW

380 - 480 0.37 - 7.5 kW 11 - 90 kW 110 - 250 kW 315 - 1000 kW

525-600 0.75 kW - 7.5 kW 11 - 90 kW 315 - 1200 kW

525-690 11 - 90 kW 45 - 400 kW 450 - 1200 kW

Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

2.1.3 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 cur-

rently valid legislation.

2.2 Software Version

2.2.1 Software Version and Approvals

VLT Automation VT Drive FC322

Software version: 1.7x

This manual can be used with all VLT Automation VT Drive FC322 frequency converters with software version 1.7x.

The software version number can be found in parameter 15-43.

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2.3 CE labelling

2.3.1 CE Conformity and Labelling

What is CE Conformity and Labelling?

The purpose of CE labelling is to avoid technical trade obstacles within EFTA and the EU. The EU has introduced the CE label as a simple way of showing

whether a product complies with the relevant EU directives. The CE label says nothing about the specifications or quality of the product. Frequency

converters are regulated by three EU directives:

The machinery directive (98/37/EEC)

All machines with critical moving parts are covered by the machinery directive of January 1, 1995. Since a frequency converter is largely electrical, it does

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. We do this by means of a manufacturer's declaration.

The low-voltage directive (73/23/EEC)

Frequency converters must be CE labelled in accordance with the low-voltage directive of January 1, 1997. The directive applies to all electrical equipment

and appliances used in the 50 - 1000 V AC and the 75 - 1500 V DC voltage ranges. Danfoss CE-labels in accordance with the directive and issues a

declaration of conformity upon request.

The EMC directive (89/336/EEC)

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.

2.3.2 What Is Covered

The EU "

Guidelines on the Application of Council Directive 89/336/EEC

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.

" outline three typical situations of using a frequency converter. See below for EMC

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2 Introduction to VLT Automation VT Drive Automation VT Drive FC322 Design Guide

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 prod-

ucts comply with.

Danfoss gladly provides other types of assistance that can help you obtain the best EMC result.

2.3.4 Compliance with EMC Directive 89/336/EEC

As mentioned, the frequency converter is mostly used by professionals of the trade as a complex component forming part of a larger appliance, system,

or installation. It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer. As an

aid to the installer, Danfoss has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for Power Drive

systems are complied with, provided that the EMC-correct instructions for installation are followed, see the section

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.

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.

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.

Particles such as dust may cause mechanical, electrical, or thermal failure in the frequency converter. A typical indicator of excessive levels of

Airborne

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,

on the frequency converter components.

corrosive gases such as sulphur, nitrogen, and chlorine compounds will cause chemical processes

EMC Immunity

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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.

NB!

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.

NB!

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.

2.4 Vibration and shock

The frequency converter has been tested according to the procedure based on the shown standards:

The frequency converter complies with requirements that exist for units mounted on the walls and floors of production premises, as well as in panels

bolted to walls or floors.

IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970

IEC/EN 60068-2-64: Vibration, broad-band random

2.5 Advantages

2.7.1 Why use a Frequency Converter for Controlling Fans and Pumps?

A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further

information see the text

The Laws of Proportionality

2.7.2 The Clear Advantage - Energy Savings

The very clear advantage of using a frequency converter for controlling the speed of fans or pumps lies in the electricity savings.

When comparing with alternative control systems and technologies, a frequency converter is the optimum energy control system for controlling fan and

pump systems.

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2 Introduction to VLT Automation VT Drive Automation VT Drive FC322 Design Guide

Illustration 2.1: The graph is showing fan curves (A, B and

C) for reduced fan volumes.

Illustration 2.2: When using a frequency converter to reduce

fan capacity to 60% - more than 50% energy savings may

be obtained in typical applications.

2.7.3 Example of Energy Savings

As can be seen from the figure (the laws of proportional ity), the flow is controlled by changing t he RPM. By reducing the speed only 20% from the rated

speed, the flow is also reduced by 20%. This is because the flow is directly proportional to the RPM. The consumption of electricity, however, is reduced

by 50%.

If the system in question only needs to be able to supply a flow that corresponds to 100% a few days in a year, while the average is below 80% of the

rated flow for the remainder of the year, the amount of energy saved is even more than 50%.

The laws of proportionality

The figure below describes the dependence of flow, pressure and power consumption on RPM.

Q = Flow P = Power

Q1 = Rated flow P1 = Rated power

= Reduced flow P2 = Reduced power

H = Pressure n = Speed regulation

H1 = Rated pressure n1 = Rated speed

= Reduced pressure n2 = Reduced speed

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Automation VT Drive FC322 Design Guide 2 Introduction to VLT Automation VT Drive

Flow

Pressure

(

)

2.7.4 Example with Varying Flow over 1 Year

The example below is calculated on the basis of pump characteristics ob-

tained from a pump datasheet.

The result obtained shows energy savings in excess of 50% at the given

flow distribution over a year. The pay back period depends on the price

per kwh and price of frequency converter. In this example it is less than

a year when compared with valves and constant speed.

Power

Energy savings

shaft=Pshaft output

Flow distribution over 1 year

(

)

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Distribution Valve regulation Frequency converter control

% Hours Power Consumption Power Consumption

350 5 438 42,5 18.615 42,5 18.615

300 15 1314 38,5 50.589 29,0 38.106

250 20 1752 35,0 61.320 18,5 32.412

200 20 1752 31,5 55.188 11,5 20.148

150 20 1752 28,0 49.056 6,5 11.388

100 20 1752 23,0 40.296 3,5 6.132

 100 8760 275.064 26.801

- B

kWh A1 - C

kWh

2.7.5 Better Control

If a frequency converter is used for controlling the flow or pressure of a system, improved control is obtained.

A frequency converter can vary the speed of the fan or pump, thereby obtaining variable control of flow and pressure.

Furthermore, a frequency converter can quickly adapt the speed of the fan or pump to new flow or pressure conditions in the system.

Simple control of process (Flow, Level or Pressure) utilizing the built in PID control.

2.7.6 Cos  Compensation

Generally speaking, a frequency converter with a cos  of 1 provides power factor correction for the cos  of the motor, which means that there is no

need to make allowance for the cos  of the motor when sizing the power factor correction unit.

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2.7.7 Star/delta Starter or Soft-starter not required

When larger motors are started, it is necessary in many countries to use equipment that limits the start-up current. In more tr aditional systems, a star/

delta starter or soft-starter is widely used. Such motor starters are not required if a frequency converter is used.

As illustrated in the figure below, a frequency converter does not consume more than rated current.

1 = VLT Automation VT Drive

2 = Star/delta starter

3 = Soft-starter

4 = Start directly on mains

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2.6 Control Structures

2.8.1 Control Principle

Illustration 2.3: Control structures.

The frequency converter is a high performance unit for demanding applications. It can handle various kinds of motor control principles such as U/f special

motor mode and VVC plus and can handle normal squirrel cage asynchronous motors.

Short circuit behavior on this FC depends on the 3 current transducers in the motor phases.

par. 1-00 Configuration Mode

is to be used

it can be selected if open or closed lo op

2.8.2 Control Structure Open Loop

Illustration 2.4: Open Loop structure.

In the configuration shown in the illustration above,

handling system or the local reference is received and fed through the ramp limitation and speed limitation before being sent to the motor control.

The output from the motor control is then limited by the maximum frequency limit.

par. 1-00 Configuration Mode

is set to Open loop [0]. The resulting reference from the reference

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2.8.3 Local (Hand On) and Remote (Auto On) Control

The frequency converter can be operated manually via the local control panel (LCP) or remotely via analog/digital inputs or serial bus.

If allowed in par. 0-40

to start and stop the frequency converter byLCP 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 set by using the LCP arrow keys up [Ÿ] and down

[ź].

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 var-

ious serial interfaces (RS-485, USB, or an optional fieldbus). See more

about starting, stopping, changing ramps and parameter set-ups etc. in

par. group 5-1* (digital inputs) or par. group 8-5* (serial communica-

tion).

[Hand on] Key on LCP

, par. 0-41

[Off] Key on LCP

, par. 0-42

[Auto on] Key on LCP

, and par. 0-43

[Reset] Key on LCP

130BP046.1

, it is possible

Hand Off

Auto

LCP Keys

Hand Linked to Hand / Auto Local

Hand -> Off Linked to Hand / Auto Local

Auto Linked to Hand / Auto Remote

Auto -> Off Linked to Hand / Auto Remote

All keys Local Local

All keys Remote Remote

The table shows under which conditions either the Local Reference or the Remote Reference is active. One of them is always active, but both can not be

active at the same time.

NB!

Local Reference will be restored at power-down.

par. 1-00

Configuration Mode

is active (see table above for the conditions).

determines what kind of application control principle (i.e. Open Loop or Closed loop) is used when the Remote reference

Reference Site

par. 3-13

Reference Site

Active Reference

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2.8.4 Control Structure Closed Loop

The closed loop controller allows the drive to become an integral part of the controlled system. The drive receives a feedback signal from a sensor in the

system. It then compares this feedback to a set-point reference value and determines the error, if any, between these two signals. It then adjusts the

speed of the motor to correct this error.

For example, consider a pump application where the speed of a pump is to be controlled so that the static pressure in a pipe is constant. The desired

static pressure value is supplied to the drive as the set-point reference. A static pressure sensor measures the actual static pressure in the pipe and

supplies this to the drive as a feedback signal. If the feedback signal is greater than the set-point reference, the drive will slow down to reduce the

pressure. In a similar way, if the pipe pressure is lower than the set-point reference, the drive will automatically speed up to increase the pressure provided

by the pump.

NB!

While the default values for the drive’s Closed Loop controller will often provide satisfactory performance, the control of the system

can often be optimized by adjusting some of the Closed Loop controller’s parameters. It is also possible to autotune the PI constants.

The figure is a block diagram of the drive’s Closed Loop controller. The details of the Reference Handling block and Feedback Handling block are described

in their respective sections below.

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2.8.5 Feedback Handling

A block diagram of how the drive processes the feedback signal is shown below.

Feedback handling can be configured to work with applications requiring advanced control, such as multiple setpoints and multiple feedbacks. Three

types of control are common.

Single Zone, Single Setpoint

Single Zone Single Setpoint is a basic configuration. Setpoint 1 is added to any other reference (if any, see Reference Handling) and the feedback signal

is selected using par. 20-20.

Multi Zone, Single Setpoint

Multi Zone Single Setpoint uses two or three feedback sensors but only one setpoint. The feedbacks can be added, subtracted (only feedback 1 and 2)

or averaged. In addition, the maximum or minimum value may be used. Setpoint 1 is used exclusively in this configuration.

Multi Setpoint Min

attempts to keep all zones at or below their respective setpoints, while

setpoints.

Example:

A two zone two setpoint application Zone 1 setpoint is 15 bar and the feedback is 5.5 bar. Zone 2 setpoint is 4.4 bar and the feedback is 4.6 bar. If

Setpoint Max

setpoint, resulting in a negative difference). If

has the larger difference (feedback is lower than setpoint, resulting in a positive difference).

[13] is selected, the setpoint/feedback pair with the largest difference controls the speed of the drive.

Multi Setpoint Min

[14] is selected, Zone 1’s setpoint and feedback are sent to the PID controller, since this has the smaller difference (feedbac k i s higher th an

Multi Setpoint Min

[13] is selected, Zone 2’s setpoint and feedback is sent to the PID controller, since this

[13] attempts to keep all zones at or above their respective

Multi Setpoint Maximum

[14]

Multi

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2.8.6 Feedback Conversion

In some applications it may be useful to convert the feedback signal. One example of this is using a pressure signal to provide flow feedback. Since the

square root of pressure is proportional to flow, the square root of the pressure signal yields a value proportional to the flow. This is shown below.

2.8.7 Reference Handling

Details for Open Loop and Closed Loop operation.

A block diagram of how the drive produces the Remote Reference is shown below:.

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