Danfoss Electronics FC 51 Design Guide

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT® Micro Drive FC 51

Contents

VLT® Micro Drive FC 51 Design Guide

1 Introduction

1.1 Available Literature

1.2 Document and Software Version

1.3 Abbreviations

1.4 Definitions

1.5 Power Factor

2 Safety and Conformity

2.1 Safety

2.2 Disposal Instruction

2.3 Approvals

2.4 CE Labeling

2.5 Aggressive Environments

2.6 Vibration and Shock

2.7 Advantages

3 Product Overview

3.1 Control Structures

5 5 5 5 6 8

9 10 10 10 11 12 12

18 18

3.1.1 Control Structure Open Loop 18

3.1.2 Local (Hand On) and Remote (Auto On) Control 18

3.1.3 Control Structure Closed Loop 19

3.1.4 Reference Handling 20

3.2 General Aspects of EMC

3.2.1 Emission Requirements 22

3.3 Galvanic Isolation (PELV)

3.4 Earth Leakage Current

3.5 Extreme Running Conditions

3.5.1 Motor Thermal Protection 25

4 Selection

4.1 Options and Accessories

4.1.1 Local Control Panel (LCP) 26

4.1.2 Remote Mounting Kit for LCP 26

4.1.3 FC 51 LCP Mounting Instruction 27

4.1.4 FC 51 Remote Mounting Kit Mounting Instruction 27

4.1.5 IP21/TYPE 1 Enclosure Kit 29

23 24 24

26 26

4.1.6 Type 1 (NEMA) 29

4.1.7 De-Coupling 29

4.1.8 FC 51 Type 1 Kit Mounting Instruction for M1, M2 and M3 30

4.1.9 FC 51 Type 1 Kit Mounting Instruction for M4 and M5 30

MG02K302 - Rev. 2013-12-03 1

Contents

VLT® Micro Drive FC 51 Design Guide

4.1.10 FC 51 IP21 Kit Mounting Instruction 31

4.1.11 FC 51 De-coupling Plate Mounting Instruction for M1 and M2 32

4.1.12 FC 51 De-coupling Plate Mounting Instruction for M3 32

4.1.13 FC 51 De-coupling Plate Mounting Instruction for M4 and M5 33

4.1.14 FC 51 DIN Rail Kit Mounting Instruction 34

4.1.15 Line Filter MCC 107 Installation Instructions 34

4.1.16 Mounting 35

4.1.17 Wiring 35

4.1.18 Dimensions 36

4.2 Special Conditions

4.2.1 Purpose of Derating 37

4.2.2 Derating for Ambient Temperature 37

4.2.3 Derating for Low Air Pressure 38

4.2.4 Automatic Adaptations to Ensure Performance 38

4.2.5 Derating for Running at Low Speed 38

5 How to Order

5.1 Drive Configurator

5.2 FC Identification

5.3 Type Code

5.4 Ordering Numbers

5.5 Options

6 How to Install

6.1 Before Starting

6.2 Side-by-Side Installation

6.3 Before Commencing Repair Work

39 39 39 40 41 41

43 43 43 43

6.4 Mechanical Dimensions

6.5 Electrical Installation in General

6.6 Fuses

6.7 Mains Connection

6.8 Motor Connection

6.9 Use of EMC-Correct Cables

6.10 Earthing of Screened/Armoured Control Cables

6.11 Residual Current Device

6.12 Electrical Overview

6.12.1 Power Circuit - Overview 51

6.13 Electrical Installation and Control Cables

6.14 Control Terminals

6.14.1 Access to Control Terminals 52

6.14.2 Connecting to Control Terminals 53

2 MG02K302 - Rev. 2013-12-03

44 44 45 46 46 49 50 50 51

52 52

Contents

VLT® Micro Drive FC 51 Design Guide

6.15 Switches

6.16 Final Set-Up and Test

6.17 Parallel Connection of Motors

6.18 Motor Installation

6.19 Installation of Misc. Connections

6.20 Safety

6.20.1 High Voltage Test 57

6.20.2 Safety Earth Connection 57

7 Programming

7.1 How to Programme

7.1.1 Programming with MCT 10 Set-up Software 58

7.1.2 Programming with the LCP 11 or LCP 12 58

7.2 Status Menu

7.3 Quick Menu

7.4 Quick Menu Parameters

7.5 Main Menu

7.6 Quick Transfer of Parameter Settings between Multiple Frequency Converters

53 53 55 56 56 57

58 58

59 59 60 63 63

7.7 Read-out and Programming of Indexed Parameters

7.8 Initialise the Frequency Converter to Default Settings in two Ways

8 RS-485 Installation and Set-up

8.1 RS-485 Installation and Set-up

8.1.1 Overview 65

8.1.2 Network Connection 65

8.1.3 Frequency Converter Hardware Set-up 65

8.1.4 EMC Precautions 66

8.2 FC Protocol Overview

8.3 Network Configuration

8.4 FC Protocol Message Framing Structure

8.4.1 Content of a Character (byte) 67

8.4.2 Telegram Structure 67

8.4.3 Telegram Length (LGE) 67

8.4.4 Frequency Converter Address (ADR) 68

8.4.5 Data Control Byte (BCC) 68

8.4.6 The Data Field 68

63 64

65 65

66 67 67

8.4.7 The PKE Field 69

8.4.8 Parameter Number (PNU) 69

8.4.9 Index (IND) 69

8.4.10 Parameter Value (PWE) 69

8.4.11 Data Types Supported by the Frequency Converter 70

MG02K302 - Rev. 2013-12-03 3

Contents

VLT® Micro Drive FC 51 Design Guide

8.4.12 Conversion 70

8.5 Examples

8.6 Modbus RTU Overview

8.6.1 Assumptions 71

8.6.2 What the User Should Already Know 71

8.6.3 Modbus RTU Overview 71

8.6.4 Frequency Converter with Modbus RTU 72

8.7 Network Configuration

8.8 Modbus RTU Message Framing Structure

8.8.1 Frequency Converter with Modbus RTU 72

8.8.2 Modbus RTU Message Structure 72

8.8.3 Start/Stop Field 73

8.8.4 Address Field 73

8.8.6 Data Field 73

8.8.7 CRC Check Field 73

8.8.8 Coil Register Addressing 73

8.8.9 How to Control the Frequency Converter 75

8.8.10 Function Codes Supported by Modbus RTU 75

70 71

72 72

8.8.11 Modbus Exception Codes 76

8.9 How to Access Parameters

8.9.1 Parameter Handling 76

8.9.2 Storage of Data 76

8.9.3 IND (Index) 76

8.9.4 Text Blocks 76

8.9.6 Parameter Values 76

8.10 Examples

8.10.1 Read Coil Status (01 hex) 77

8.10.2 Force/Write Single Coil (05 hex) 77

8.10.3 Force/Write Multiple Coils (0F hex) 78

8.10.4 Read Holding Registers (03 hex) 78

8.10.5 Preset Single Register (06 hex) 78

8.10.6 Preset Multiple Registers (10 hex) 79

8.11 FC Drive Control Profile

8.11.1 Control Word According to FC Profile (8-10 Protocol = FC profile) 79

8.11.2 Status Word According to FC Profile (STW) (8-30 Protocol = FC profile) 81

8.11.3 Bus Speed Reference Value 82

9 Specifications

Index

4 MG02K302 - Rev. 2013-12-03

Introduction

VLT® Micro Drive FC 51 Design Guide

1 Introduction

1.1 Available Literature

NOTICE

This design guide contains the basic information necessary converter.

Danfoss technical literature is available in print from local Danfoss

BusinessAreas/DrivesSolutions/Documentations

1.2 Document and Software Version

This manual is regularly reviewed and updated. All suggestions the document version and the corresponding software version.

Edition Remarks Software Version

MG02K3XX Replaces MG02K2XX 3.1X

Table 1.1 Document and Software Version

for installing and running the frequency

Sales Offices or online at: www.danfoss.com/

VLT Micro Drive FC 51 Quick Guide, MG02B

•

VLT Micro Drive FC 51 Programming Guide, MG02C

•

FC 51 LCP Mounting Instruction, MI02A

•

FC 51 De-coupling Plate Mounting Instruction,

•

MI02B FC 51 Remote Mounting Kit Mounting Instruction,

•

MI02C FC 51 DIN Rail Kit Mounting Instruction, MI02D

•

FC 51 IP21 Kit Mounting Instruction, MI02E

•

FC 51 Nema1 Kit Mounting Instruction, MI02F

•

FC 51 Line Filter MCC 107 Installation Instruction,

•

MI02U

for improvement are welcome. Table 1.1 shows

1.3 Abbreviations

°C A Ampere/AMP AC Alternating current AMT Automatic Motor Tuning AWG American wire gauge DC Direct current EMC Electro Magnetic Compatibility ETR Electronic Thermal Relay FC Frequency Converter f

M,N

g Gram Hz Hertz I

INV

LIM

M,N

VLT,MAX

VLT,N

kHz Kilohertz LCP Local Control Panel m Meter mA Milliampere MCT Motion Control Tool mH Millihenry Inductance min Minute ms Millisecond nF Nanofarad Nm Newton Meters n

M,N

PCB Printed Circuit Board PELV Protective Extra Low Voltage RPM Revolutions Per Minute Regen Regenerative terminals s Second T

LIM

M,N

V Volts

Degrees Celsius

Nominal motor frequency

Rated Inverter Output Current Current limit Nominal motor current The maximum output current The rated output current supplied by the frequency

Synchronous Motor Speed Nominal motor power

Torque limit Nominal motor voltage

converter

1 1

Table 1.2 Abbreviations

MG02K302 - Rev. 2013-12-03 5

175ZA078.10

Pull-out

rpm

Torque

Introduction

VLT® Micro Drive FC 51 Design Guide

1.4 Definitions

Break-away torque

1.4.1 Frequency Converter

VLT,MAX

maximum output current.

The

VLT,N

The rated output current supplied by the frequency converter.

VLT, MAX

The maximum output voltage.

1.4.2 Input

Control command

connected motor can be started and stopped with LCP

The and the digital inputs. Functions are divided into 2 groups. Functions in group 1 have higher priority than functions in group 2.

Group 1 Reset, Coasting stop, Reset and Coasting stop,

Quick-stop, DC braking, Stop and the [Off] key.

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

Freeze output

and

Table 1.3 Function Groups

Illustration 1.1 Break-away Torque

VLT

efficiency of the frequency converter is defined as the

The ratio between the power output and the power input.

Start-disable command

A stop command belonging to the group 1 control commands, see Table 1.3.

Stop command

See Control commands.

1.4.3 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).

The instantaneous motor voltage.

M,N

The rated motor voltage (nameplate data).

1.4.4 References

Analog Reference

signal transmitted to the analog inputs 53 or 54, can be

A 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 8 preset references via the digital terminals.

Ref

MAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20 mA) and the resulting reference. The maximum reference value set in 3-03 Maximum Reference.

Ref

MIN

Determines the relationship between the reference input at 0% value (typically 0 V, 0 mA, 4 mA) and the resulting reference. The minimum reference value set in

3-02 Minimum Reference

6 MG02K302 - Rev. 2013-12-03

Introduction

VLT® Micro Drive FC 51 Design Guide

1.4.5 Miscellaneous

Analog Inputs

analog inputs are used for controlling various

The functions of the frequency converter. There are 2 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 Tuning, AMT

AMT 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.

Relay Outputs

The frequency converter 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.

Initialising

If initialising is carried out (14-22 Operation Mode), the programmable parameters of the frequency converter return to their default settings. Initialising 14-22 Operation Mode does not initialise communication parameters.

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 noneperiodic duty.

LCP

The Local Control Panel makes up a complete interface for control and programming of the frequency converter. The control panel is detachable and can be installed up to 3 m from the frequency converter, that is, in a front panel with the installation kit option.

lsb

Least significant bit.

MCM

for Mille Circular Mil, an American measuring unit for

Short cable cross-section. 1 MCM ≡ 0.5067 mm2.

msb

Most significant bit.

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 pressing [OK].

PI Controller

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

RCD

Residual Current Device.

Set-up

Save parameter settings in 2 set-ups. Change between the 2 parameter set-ups and edit one set-up, while another set-up is active.

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).

STW

Status Word.

FC Standard Bus

Includes RS 485 bus with FC protocol. See 8-30 Protocol.

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 canceled by activating reset or, in some cases, by being programmed to reset automatically. Trip may not be used for personal safety.

1 1

MG02K302 - Rev. 2013-12-03 7

Introduction

VLT® Micro Drive FC 51 Design Guide

Trip Locked

state entered in fault situations when the frequency

A converter is protecting itself and requiring physical intervention, for example, if the frequency converter is subject to a short circuit on the output. A locked trip can only be canceled by cutting off mains, removing the cause of the fault, and reconnecting the frequency converter. Restart is prevented until the trip state is canceled by activating reset or, 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

plus

) improves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque.

1.5 Power Factor

The power factor is the relation between I1

× U ×

1 ×

COS

Power factor

3 ×

RMS

The power factor for 3-phase control:

and I

RMS

cos

ϕ1

since cos

RMS

ϕ1 =1

The power factor indicates to which extent the frequency converter The lower the power factor, the higher the I

imposes a load on the mains supply.

RMS

for the

same kW performance.

RMS

+ . . +

In addition, a high-power factor indicates that the different harmonic

currents are low.

8 MG02K302 - Rev. 2013-12-03

Safety and Conformity

VLT® Micro Drive FC 51 Design Guide

2 Safety and Conformity

2.1 Safety

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation which could

in death or serious injury.

result

CAUTION

Indicates a potentially hazardous situation which could

in minor or moderate injury. It may also be used

result to alert against unsafe practices.

NOTICE

Indicates important information, including situations that may

result in damage to equipment or property.

WARNING

DISCHARGE TIME

The

frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not powered. Failure to wait the specified time after power has been removed before performing service or repair work, could result in death or serious injury.

1. Stop motor.

2. Disconnect AC mains, permanent magnet type motors, and remote DC-link power supplies, including battery back-ups, UPS, and DC-link connections to other frequency converters.

3. Wait for the capacitors to discharge fully, before performing any service or repair work. The duration of waiting time is specified in Table 2.1.

2 2

2.1.1 Safety Precautions

WARNING

HIGH VOLTAGE

Frequency connected to AC mains input power. Failure to perform installation, start-up, and maintenance by qualified personnel could result in death or serious injury.

converters contain high voltage when

Installation, start-up, and maintenance must be

•

performed by qualified personnel only.

WARNING

UNINTENDED START

When

the frequency converter is connected to AC mains, the motor may start at any time, causing risk of death, serious injury, equipment, or property damage. The motor can start by means of an external switch, a serial bus command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 software, or after a cleared fault condition.

Disconnect the frequency converter from mains

•

whenever personal safety considerations make it necessary to avoid unintended motor start.

Press [Off/Reset] on the LCP, before

•

programming parameters. The frequency converter, motor, and any driven

•

equipment must be in operational readiness when the frequency converter is connected to AC mains.

Size Minimum waiting time (min)

M1, M2 and M3 4

M4 and M5 15

Table 2.1 Discharge Time

WARNING

LEAKAGE CURRENT HAZARD

Leakage frequency converter properly could result in death or serious injury.

currents exceed 3.5 mA. Failure to ground the

Ensure correct grounding of the equipment by

•

a certified electrical installer.

WARNING

EQUIPMENT HAZARD

Contact can result in death or serious injury.

with rotating shafts and electrical equipment

Ensure that only trained and qualified

•

personnel perform installation, start up, and maintenance.

Ensure that electrical work conforms to national

•

and local electrical codes. Follow the procedures in this manual.

•

MG02K302 - Rev. 2013-12-03 9

Safety and Conformity

VLT® Micro Drive FC 51 Design Guide

CAUTION

WINDMILLING

Unintended causes risk of personal injury and equipment damage.

•

rotation of permanent magnet motors

Ensure that permanent magnet motors are blocked to prevent unintended rotation.

CAUTION

POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE

of personal injury when the frequency converter is

Risk not properly closed.

Before applying power, ensure all safety covers

•

are in place and securely fastened.

2.2 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.

2.3 Approvals

information on safety aspects relating to the frequency converter. declaration.

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

Frequency converters must be CE labeled 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, Danfoss specifies which standards our products comply with. Danfoss offers 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. Not that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer.

Danfoss do this by means of a manufacturer's

Table 2.2 Approvals

The

frequency converter complies with UL508C thermal

memory retention requirements. For more information refer to chapter 3.5.1 Motor Thermal Protection.

2.4 CE Labeling

2.4.1 CE Conformity and Labeling

What is CE Conformity and Labeling?

The

purpose of CE labeling is to avoid technical trade obstacles within EFTA and the EU. The EU has introduced the CE label as a simple way of showing whether a product complies with the relevant EU directives. The CE label says nothing about the specifications or quality of the product. Frequency converters are regulated by 3 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, Danfoss provides

2.4.2 What is Covered

The EU "Guidelines on the Application of Council Directive 89/336/EEC" outline three typical situations of using a frequency converter. See chapter 2.4.3 Danfoss Frequency Converter and CE Labeling for EMC coverage and CE labeling.

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 labeled 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 labeled under the EMC directive. However, the unit must comply with the basic EMC requirements of the directive. This is ensured by

10 MG02K302 - Rev. 2013-12-03

Safety and Conformity

VLT® Micro Drive FC 51 Design Guide

using components, appliances, and systems that

CE labeled under the EMC directive.

are

3. The frequency converter is sold as part of a complete system. The system is being marketed as complete and could for example, be an airconditioning system. The complete system must be CE labeled in accordance with the EMC directive. The manufacturer can ensure CE labeling under the EMC directive either by using CE labeled components or by testing the EMC of the system. If only CE labeled components are chosen, the entire system does not have to be tested.

2.4.3 Danfoss Frequency Converter and CE Labeling

CE labeling is a positive feature when used for its original purpose,

However, CE labeling may cover many different specifications. 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, Danfoss guarantees compliance with the low-voltage directive. Danfoss issues a declaration of conformity that confirms our CE labeling 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.

that is, to facilitate trade within the EU and EFTA.

2.4.4 Compliance with EMC Directive 89/336/EEC

As mentioned, the frequency converter is mostly used by professionals forming part of a larger appliance, system, or installation. Not 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, if the EMC-correct instructions for installation are followed.

The frequency converter has been designed to meet the IEC/EN 60068-2-3 standard, EN 50178 9.4.2.2 at 50 °C.

of the trade as a complex component

2.5 Aggressive Environments

A frequency converter contains many mechanical and electronic to environmental effects.

components. All are to some extent vulnerable

CAUTION

The frequency converter should not be installed in environments 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 components and metal parts. Steam, oil, and salt water may cause corrosion of components and metal parts. In such environments, use equipment with enclosure rating IP54. As an extra protection, coated printed circuit boards can be ordered as an option. (Standard on some power sizes.)

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 dusty environments, use equipment with enclosure rating IP54 or a cabinet for IP20/TYPE 1 equipment.

with airborne liquids, particles, or gases

converter and may cause corrosion of

2 2

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

MG02K302 - Rev. 2013-12-03 11

In environments with high temperatures and humidity, corrosive gases such as sulphur, nitrogen, and chlorine compounds causes chemical processes on the frequency converter components.

Such chemical reactions rapidly affects and damages the electronic components. In such environments, mount the equipment in a cabinet with fresh air ventilation, keeping aggressive gases away from the frequency converter.

SYSTEM CURVE

FAN CURVE

PRESSURE%

130BA780.10

100

120

20 40 60 80 100 120 140 160 180

VOLUME%

120

100

20 40 60 80 100 120 140 160 180

120

100

0 20 40 60 80 100 120 140 160 180

Voume %

INPUT POWER % PRESSURE %

SYSTEM CURVE

FAN CURVE

130BA781.10

ENERGY CONSUMED

Safety and Conformity

VLT® Micro Drive FC 51 Design Guide

An extra protection in such areas is a coating of the

circuit boards, which can be ordered as an option.

printed

2.7.2 The Clear Advantage - Energy Savings

The clear advantage of using a frequency converter for

NOTICE

Mounting frequency converters in aggressive environments

increases the risk of stoppages and consid-

erably reduces the life of the frequency converter.

controlling 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.

the speed of fans or pumps lies in the

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.

2.6 Vibration and Shock

The frequency converter has been tested according to the procedure

based on the shown standards, Table 2.3

Vibration and shock

Illustration 2.1 Fan Curves (A, B, and C) for Reduced Fan Volumes

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

Table 2.3 Standards

2.7 Advantages

2.7.1 Why use a Frequency Converter for

Controlling

A frequency converter takes advantage of the fact that centrifugal tionality for such fans and pumps. For further information see chapter 2.7.3 Example of Energy Savings.

fans and pumps follow the laws of propor-

Fans and Pumps?

12 MG02K302 - Rev. 2013-12-03

Illustration 2.2 When using a frequency converter to reduce

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

fan obtained in typical applications.

100%

50%

25%

12,5%

50% 100%

80%

175HA208.10

Power ~n

Pressure ~n

Flow ~n

130BA782.10

Discharge damper

Less energy savings

IGV

Costlier installation

Maximum energy savings

130BA779.11

0 60 0 60 0 60

100

Discharge Damper Solution

IGV Solution

VLT Solution

Energy consumed

Input power %

Volume %

Safety and Conformity

VLT® Micro Drive FC 51 Design Guide

2.7.3 Example of Energy Savings

As shown in Illustration changing the 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%.

Illustration 2.3 describes the dependence of flow, pressure and power consumption on RPM.

2.3, the flow is controlled by

Illustration 2.5

shows typical energy savings obtainable with 3 well-known solutions when fan volume is reduced to i.e. 60%. As the graph shows, more than 50% energy savings can be achieved in typical applications.

2 2

Illustration 2.3 Laws of Proportionally

H H

Flow

Pressure

Power

Q=Flow P=Power Q1=Rated

flow P1=Rated power Q2=Reduced flow P2=Reduced power H=Pressure n=Speed regulation H1=Rated H2=Reduced

pressure n1=Rated speed

pressure n2=Reduced speed

Table 2.4 The Laws of Proportionality

2.7.4 Comparison of Energy Savings

The Danfoss frequency converter solution offers major savings

compared with traditional energy saving solutions. This is because the frequency converter is able to control fan speed according to thermal load on the system and the fact that the frequency converter has a built-in facility that enables the frequency converter to function as a Building Management System, BMS.

Illustration 2.4 The 3 Common Energy Saving Systems

Illustration 2.5 Energy Savings

Discharge dampers reduce power consumption. Inlet Guide

offer a 40% reduction, but are expensive to install.

Vans The Danfoss frequency converter solution reduces energy consumption with more than 50% and is easy to install.

MG02K302 - Rev. 2013-12-03 13

175HA209.11

0 100 200 300 400

(mwg)

750rpm

1050rpm

1350rpm

1650rpm

(kW)

200100 300

(

m3 /h

)

(

m3 /h

)

400

750rpm

1050rpm

1350rpm

1650rpm

shaft

Safety and Conformity

VLT® Micro Drive FC 51 Design Guide

2.7.5 Example with Varying Flow over 1

Year

This example is calculated based on pump characteristics obtained

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.

Energy savings

shaft=Pshaft output

Illustration 2.6 Flow Distribution over 1 Year

Illustration 2.7 Energy

Distri-

m3/

bution

% Hours Power Consump-

Valve regulation Frequency converter

control

Power Consump-

- B

tion

kWh A1 - C

tion

kWh

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

Table 2.5 Result

14 MG02K302 - Rev. 2013-12-03

Full load

% Full load current

& speed

500

100

0 12,5 25 37,5 50Hz

200

300

400

600

700

800

175HA227.10

Safety and Conformity

VLT® Micro Drive FC 51 Design Guide

2.7.6 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, 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) utilising the built-in PI control.

2.7.7 Star/Delta Starter or Soft-starter not

Required

When larger motors are started, it is necessary in many countries In more traditional systems, a star/delta starter or softstarter is widely used. Such motor starters are not required if a frequency converter is used.

As illustrated in Illustration 2.8, a frequency converter does not consume more than rated current.

to use equipment that limits the start-up current.

2.7.8 Using a Frequency Converter Saves Money

Example chapter that a lot of equipment is not required when a frequency converter is used. It is possible to calculate the cost of installing the 2 different systems. In the example, the 2 systems can be established at roughly the same price.

2.7.9 Without a Frequency Converter shows

2 2

1 2 Star/delta starter 3 Soft-starter 4 Start directly on mains

Illustration 2.8 Current

VLT®

Micro Drive

MG02K302 - Rev. 2013-12-03 15

- +

x6 x6

175HA205.12

Valve position

Starter

Fuses

supply

P.F.C

Flow

3-Port valve

Bypass

Return

Control

Supply air

V.A.V

outlets

Duct

P.F.C

Mains

Fuses

Starter

Bypass

supply

Return

valve

3-Port

Flow

Control

Valve position

Starter

Power Factor Correction

Mains

IGV

Mechanical linkage and vanes

Fan

Motor or actuator

Main B.M.S

Local D.D.C. control

Sensors PT

Pressure control signal 0/10V

Temperature control signal 0/10V

Control

Mains

Cooling section Heating section

Fan sectionInlet guide vane

Pump Pump

Safety and Conformity

VLT® Micro Drive FC 51 Design Guide

2.7.9 Without a Frequency Converter

D.D.C. Direct Digital Control E.M.S. Energy Management system V.A.V. Variable Air Volume Sensor P Pressure Sensor T Temperature

Table 2.6 Abbreviations used in Illustration 2.9

Illustration 2.9 Traditional Fan System

16 MG02K302 - Rev. 2013-12-03

175HA206.11

Pump

Flow

Return

Supply air

V.A.V outlets

Duct

Mains

Pump

Return

Flow

Mains

Fan

Main B.M.S

Local D.D.C. control

Sensors

Mains

Cooling section Heating section

Fan section

Pressure control 0-10V or 0/4-20mA

Control temperature 0-10V or 0/4-20mA

VLT

- +

VLT

x3 x3

Safety and Conformity

2.7.10 With a Frequency Converter

D.D.C. Direct Digital Control E.M.S. Energy Management system V.A.V. Variable Air Volume Sensor P Pressure Sensor T Temperature

VLT® Micro Drive FC 51 Design Guide

2 2

Table 2.7 Abbreviations used in Illustration

2.10

Illustration 2.10 Fan System Controlled by Frequency Converters

MG02K302 - Rev. 2013-12-03 17

130BB892.10

100%

-100%

100%

Local reference scaled to Hz

Auto mode

Hand mode

LCP Hand on, oﬀ and auto on keys

Local

Remote

Reference

Ramp

P 4-10 Motor speed direction

To motor control

Reference handling Remote reference

P 4-14 Motor speed high limit [Hz]

P 4-12 Motor speed low limit [Hz]

P 3-4* Ramp 1 P 3-5* Ramp 2

Hand On

Oﬀ Reset

Auto On

130BB893.10

Product Overview

3 Product Overview

3.1 Control Structures

VLT® Micro Drive FC 51 Design Guide

Select open loop or closed loop in 1-00

Configuration Mode.

3.1.1 Control Structure Open Loop

Illustration 3.1 Open Loop Structure

In the configuration shown in Illustration 3.1, 1-00 Configuration Mode is set to [0] Open loop. The resulting reference

from the reference 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.

After pressing the [Auto On] key, the frequency converter

into auto mode and follows (as default) the remote

goes reference. In this mode, it is possible to control the frequency converter via the digital inputs and RS-485. 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.

3.1.2 Local (Hand On) and Remote (Auto Control

On)

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 0-40 [Hand on] Key on

LCP, 0-44 [Off/Reset] Key on LCP, and 0-42 [Auto on] Key on LCP, it is possible to start and stop the frequency converter

by LCP pressing the [Hand On] and [Off/Reset] keys. Alarms can be reset via the [Off/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 potentiometer (LCP 12) or [▲]/[▼] (LCP 11). The potentiometer can be disabled by parameter 6-80 LCP Potmeter Enable. If the potentiometer is disabled, use the navigation keys for adjusting reference.

18 MG02K302 - Rev. 2013-12-03

Illustration 3.2 LCP Control Keys

Local reference forces the configuration mode to open

independent on the setting of 1-00 Configuration

loop, Mode.

Local reference is restored at power-down.

7-30 PI

Normal/Inverse

Control

Reference

Feedback

Scale to speed

P 4-10

Motor speed

direction

To motor control

130BB894.11

100%

-100%

100%

*[-1]

Product Overview

VLT® Micro Drive FC 51 Design Guide

3.1.3 Control Structure Closed Loop

The internal controller allows the frequency converter to become an integral part of the controlled system. The frequency converter value and determines the error, if any, between these 2 signals. It then adjusts the speed of the motor to correct this error.

receives a feedback signal from a sensor in the system. It then compares this feedback to a set-point reference

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 frequency converter as the set-point reference. A static pressure sensor measures the actual static pressure in the pipe and supplies this to the frequency converter as a feedback signal. If the feedback signal is greater than the set-point reference, the frequency converter slows down to reduce the pressure. In a similar way, if the pipe pressure is lower than the set-point reference, the frequency converter automatically speed up to increase the pressure provided by the pump.

Illustration 3.3 Control Structure Closed Loop

While the default values for the frequency converter’s closed loop controller often provides satisfactory performance, the control

of the system can often be optimised by adjusting some of the closed loop controller’s parameters.

3 3

MG02K302 - Rev. 2013-12-03 19

Speed open loop

Conﬁguration mode

Input command:

freeze reference

Process control

Scale to Hz

Scale to process unit

Remote reference/ setpoint

±200%

Feedback handling

Remote reference in %

maxRefPCT

minRefPct

min-max ref

Freeze reference & increase/ decrease reference

±100%

Input commands:

Speed up/speed down

±200%

Relative reference = X+X*Y/100

±200%

External reference in %

±200%

Parameter choise: Reference resource 1,2,3

±100%

Preset reference

Input command: preset ref bit0, bit1, bit2

Relative scalling reference

Intern resource

Preset relative reference

±100%

Preset reference 0 ±100% Preset reference 1 ±100%

Preset reference 2 ±100% Preset reference 3 ±100% Preset reference 4 ±100% Preset reference 5 ±100%

Preset reference 6 ±100%

Preset reference 7 ±100%

Extern resource 1

No function

Analog reference ±200 %

Local bus reference ±200 % LCP potmeter 0~100 %

Extern resource 2

No function

Analog reference ±200 %

Local bus reference ±200 % LCP potmeter 0~100 %

Extern resource 3

No function

Analog reference ±200 %

Local bus reference ±200 % LCP potmeter 0~100 %

130BB900.13

Product Overview

VLT® Micro Drive FC 51 Design Guide

3.1.4 Reference Handling

Details for open loop and closed loop operation.

Illustration 3.4 Block Diagram Showing Remote Reference

The remote reference is comprised of:

references

Preset

•

Up to 8 preset references can be programmed in the frequency converter. The active preset reference can be selected using

External references (analog inputs and serial communication bus references)

•

The preset relative reference

•

Feedback controlled setpoint

•

digital inputs or the serial communications bus. The reference can also be supplied externally, most commonly from an analog input. This external source is selected by one of the 3 Reference Source parameters (3-15 Reference 1 Source, 3-16 Reference 2 Source and 3-17 Reference 3 Source). All reference resources and the bus reference are added to produce the total external reference. The external reference, the preset reference or the sum of the 2 can be selected to be the active reference. Finally, this reference can by be scaled using 3-14 Preset Relative Reference.

20 MG02K302 - Rev. 2013-12-03

175ZA062.12

Product Overview

VLT® Micro Drive FC 51 Design Guide

The scaled reference is calculated as follows:

Reference

= X + X ×

100

Where X is the external reference, the preset reference or the sum of these and Y is 3-14 Preset Relative Reference in [%].

If Y, 3-14 Preset Relative Reference, is set to 0%, the reference is not affected by the scaling.

3.2 General Aspects of EMC

Electrical interference is usually conducted at frequencies in the range 150 kHz to 30 MHz. Airborne interference from the frequency As shown in Illustration 3.5, capacitance in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents. The use of a screened motor cable increases the leakage current (see Illustration 3.5) because screened cables have higher capacitance to ground than unscreened cables. If the leakage current is not filtered, it causes greater interference on the mains in the radio frequency range below approximately 5 MHz. Since the leakage current (I1) is carried back to the unit through the screen (I3), there is in principle only a small electro-magnetic field (I4) from the screened motor cable according to Illustration 3.5.

The screen reduces the radiated interference, but increases the low-frequency interference on the mains. Connect the motor cable screen to the frequency converter enclosure as well as on the motor enclosure. This is best done by using integrated screen clamps so as to avoid twisted screen ends (pigtails). Pigtails increase the screen impedance at higher frequencies, which reduces the screen effect and increases the leakage current (I4). If a screened cable is used for relay, control cable, signal interface and brake, mount the screen on the enclosure at both ends. In some situations, however, it is necessary to break the screen to avoid current loops.

converter system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor.

3 3

1 Ground wire 4 Frequency converter 2 Screen 5 Screened motor cable 3 AC mains supply 6 Motor

Illustration 3.5 Situation that Generates Leakage Currents

If the screen is to be placed on a mounting plate for the frequency converter, the mounting plate must be made of metal,

convey the screen currents back to the unit. Moreover, ensure good electrical contact from the mounting plate through

to the mounting screws to the frequency converter chassis.

When unscreened cables are used, some emission requirements are not complied with, although most immunity requirements are observed.

MG02K302 - Rev. 2013-12-03 21

Product Overview

VLT® Micro Drive FC 51 Design Guide

To reduce the interference level from the entire system (unit+installation), make motor and brake cables as short as possible.

Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than

50 MHz (airborne) is especially generated by the control electronics.

3.2.1 Emission Requirements

The EMC product standard for frequency converters defines

4 categories (C1, C2, C3 and C4) with specified

requirements for emission and immunity. Table 3.1 states the definition of the 4 categories and the equivalent classification from EN 55011.

Equivalent

Category Definition

emission

in EN

class 55011

C1 Frequency converters installed in

first environment (home and

the office) with a supply voltage less than 1000 V.

C2 Frequency converters installed in

first environment (home and

the office) with a supply voltage less than 1000 V, which are neither plug-in nor movable and are intended to be installed and commissioned by a professional.

C3 Frequency converters installed in

second environment

the (industrial) with a supply voltage lower than 1000 V.

C4 Frequency converters installed in

second environment with a

the supply voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems.

Class B

Class A Group 1

Class A Group 2

No limit line. An EMC plan should be made.

When the generic (conducted) emission standards are used,

the frequency converters are required to comply

with the limits in Table 3.2.

Environment

First environment

and

(home office) Second environment (industrial environment)

Table 3.2 Correlation between Generic Emission Standards and

55011

Generic emission standard

EN/IEC 61000-6-3 Emission standard for residential, commercial and light industrial environments. EN/IEC 61000-6-4 Emission standard environments.

for industrial

Equivalent emission

class

in EN 55011

Class B

Class A Group 1

Table 3.1 Correlation between IEC 61800-3 and EN 55011

22 MG02K302 - Rev. 2013-12-03

Product Overview

VLT® Micro Drive FC 51 Design Guide

3.2.2 EMC Test Results (Emission)

Drive type Conducted emission. Maximum shielded cable length [m] Radiated emission

Housing, trades and

light

industries

Without external

filter

With

external

filter

Without external

filter

Industrial environment

With

external

filter

Without external

filter

≤2.2 kW. Single

230 V

phase, ≤7.5 kW. Up

500 V AC,

to 3 phase 11 kW to 22

Up to

kW. 500 V AC, 3 phase

Table 3.3 EMC Test Result

EN 55011 Class A2 EN 55011 Class A1 EN 55011 Class B EN 55011 Class A2 EN 55011 Class A1

Without

external

filter

25 - 15 50 5 15 Yes - No Yes

25 - 15 50 - 15 Yes - No Yes

Industrial environment

With

external

filter

Without external

filter

With

external

filter

With

external

filter

3 3

3.2.3 Harmonics Emission Requirements

Equipment connected to the public supply network

WARNING

Cannot comply, only with power option

Options Definition

1 IEC/EN 61000-3-2 Class A for 3-phase balanced

equipment kW total power).

2 IEC/EN 61000-3-12 Equipment 16 A-75 A and profes-

sional current.

Table 3.4 Harmonics Emission Requirements

3.2.4 Immunity Requirements

The immunity requirements for frequency converters depend

on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss frequency converters comply with the requirements for the industrial environment and consequently comply also with the lower requirements for home and office environment with a large safety margin.

(for professional equipment only up to 1

equipment as from 1 kW up to 16 A phase

3.3 Galvanic Isolation (PELV)

3.3.1 PELV - Protective Extra Low Voltage

PELV offers protection by way of extra low voltage. Protection electrical supply is of the PELV type and the installation is made as described in local/national regulations on PELV supplies.

All control terminals and relay terminals 01-03/04-06 comply with PELV (Protective Extra Low Voltage) (Does not apply to grounded Delta leg above 440 V).

Galvanic (ensured) isolation is obtained by fulfilling requirements for higher isolation and by providing the relevant creapage/clearance distances. These requirements are described in the EN 61800-5-1 standard.

The components that make up the electrical isolation, as described, also comply with the requirements for higher isolation and the relevant test as described in EN 61800-5-1. The PELV galvanic isolation can be shown in Illustration 3.7.

against electric shock is ensured when the

To maintain PELV all connections made to the control terminals must be PELV, e.g. thermistor must be reinforced/double insulated.

MG02K302 - Rev. 2013-12-03 23

SMPS

130BB896.10

130BB901.10

1324

Product Overview

VLT® Micro Drive FC 51 Design Guide

0.25-22 kW

3.4 Earth Leakage Current

WARNING

DISCHARGE TIME

Touching

the equipment has been disconnected from mains. Also make sure that other voltage inputs have been disconnected, such as load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up. Before touching any electrical parts, wait at least the amount of time indicated in Table 2.1. Shorter time is allowed only if indicated on the

1 Power supply (SMPS) 2 Optocouplers, communication between AOC and BOC 3 Custom relays a Control card terminals

nameplate for the specific unit.

NOTICE

Leakage Current

Illustration 3.6 Galvanic Isolation

The exceeds 3.5 mA. To ensure that the ground cable has a good mechanical connection to the ground connection,

30-90 kW

the cable cross section must be at least 10 mm2 Cu or 16 mm2 Al or 2 rated earth wires terminated separately. Residual Current Device protection RCD This product can cause a DC current in the protective conductor. Where a residual current device (RCD) is used for protection in case of direct or indirect contact, only an RCD of Type B is allowed on the supply side of this product. Otherwise, another protective measure shall be applied, such as separation from the environment by double or reinforced insulation, or isolation from the supply system by a transformer. See also Application Note Protection against Electrical Hazards, MN90G. Protective earthing of the frequency converter and the

1 Power supply (SMPS) incl. signal isolation of UDC, indicating

the

intermediate current voltage

2 Gate drive that runs the IGBTs (trigger transformers/opto-

couplers) 3 Current transducers 4 Internal soft-charge, RFI and temperature measurement

circuits 5 Custom relays a Control card terminals

use of RCDs must always follow national and local regulations.

3.5 Extreme Running Conditions

Short circuit (motor phase – phase)

Current the DC-link, protects the frequency converter against short circuts. A short circuit between 2 output phases causes an overcurrent in the inverter. The inverter is turned off

Illustration 3.7 Galvanic Isolation

individually when the short circuit current exceeds the permitted value (Alarm 16 Trip Lock). For information about protecting the frequency converter

The functional galvanic isolation (see Illustration the RS-485 standard bus interface.

3.6) is for

against a short circuit at the load sharing and brake outputs, see the design guidelines.

Switching on the output

Switching on the output between the motor and the

CAUTION

Installation at high altitude: At

altitudes above 2,000 m, contact Danfoss regarding

PELV.

frequency converter is fully permitted. The frequency converter is not damaged in any way by switching on the output. However, fault messages may appear.

the electrical parts could be fatal - even after

earth leakage current from the frequency converter

measurement in each of the 3 motor phases or in

24 MG02K302 - Rev. 2013-12-03

1.21.0 1.4

100

1.81.6 2.0

2000

500

200

400 300

1000

600

t [s]

175ZA052.12

OUT

= 2 x f

M,N

OUT

= 0.2 x f

M,N

OUT

= 1 x f

M,N

(par. 1-23)

IMN(par. 1-24)

Product Overview

VLT® Micro Drive FC 51 Design Guide

Motor-generated over-voltage

voltage in the intermediate circuit is increased when

The the motor acts as a generator. This occurs in following cases:

The load drives the motor (at constant output

•

frequency from the frequency converter), that is the load generates energy.

During deceleration ("ramp-down") if the moment

•

of inertia is high, the friction is low and the rampdown time is too short for the energy to be dissipated as a loss in the frequency converter, the motor and the installation.

Incorrect slip compensation setting (1-62 Slip

•

Compensation) may cause higher DC link voltage.

The control unit may attempt to correct the ramp if possible (2-17 Over-voltage Control.) The inverter turns off to protect the transistors and the intermediate circuit capacitors when a certain voltage level is reached.

Mains drop-out

During a mains drop-out, the frequency converter keeps running until the intermediate circuit voltage drops below the minimum stop level, which is typically 15% below the frequency converter's lowest rated supply voltage. The mains voltage before the drop-out and the motor load determines how long it takes for the frequency converter to coast.

3.5.1 Motor Thermal Protection

Motor thermal protection can be provided in 2 ways.

Illustration 3.8 ETR Characteristics

The

X-axis shows the ratio between I

motor

and I

motor

nominal. The Y- axis shows the time in seconds before the ETR cut of and trips the frequency converter. The curves show the characteristic nominal speed, at twice the nominal speed and at 0,2 x the nominal speed. At lower speed, the ETR cuts off at lower heat due to less cooling of the motor. In that way, the motor is protected from being over heated even at low speed. The ETR feature is calculating the motor temperature based on actual current and speed. The calculated temperature is visible as a read out parameter in 16-18 Motor Thermal in the product specific Programming Guide. A special version of the ETR is also available for EX-e motors in ATEX areas. This function makes it possible to enter a specific curve to protect the Ex-e motor. The Programming Guide takes the user through the set-up.

3 3

method uses a motor thermistor, via one of the

One following

Thermistor input on a standard AI

•

Sensor input MCB 114

•

PTC Thermistor input MCB 112

•

The frequency converter monitors motor temperature as the speed and load vary to detect overheating conditions.

The other method calculates motor temperature by measuring current, frequency, and operating time. The converter displays the thermal load on the motor in percentage and can issue a warning at a programmable overload setpoint. Programmable options at the overload allow the frequency converter to stop the motor, reduce output, or ignore the condition. Even at low speeds, the frequency converter meets I2t Class 20 electronic motor overload standards. This method is called Electronic Thermal Relay (ETR).

MG02K302 - Rev. 2013-12-03 25

Selection

4 Selection

4.1 Options and Accessories

VLT® Micro Drive FC 51 Design Guide

4.1.1 Local Control Panel (LCP)

For detailed information on programming, see VLT

Drive FC 51Programming Guide.

Micro

NOTICE

The frequency converter can also be programmed from a PC

via RS-485 com-port by installing the MCT 10 Set-up Software. This software can either be ordered using code number 130B1000 or downloaded from the DanfossWeb site:

www.danfoss.com/BusinessAreas/DrivesSolutions/softwaredownload

Navigation Keys: [Back]:

For moving to the previous step or layer in the

navigation structure. [▲] [▼]: For maneuvering between parameter groups,

parameters and within parameters. [OK]: For selecting a parameter and for accepting changes to parameter settings.

Operation Keys:

A yellow light above the operation keys indicates the active key. [Hand On]: Starts the motor and enables control of the frequency converter via the LCP. [Off/Reset]: Stops the motor (off). If in alarm mode the alarm is reset. [Auto On]: The frequency converter is controlled either via control terminals or serial communication. [Potentiometer] (LCP 12): The potentiometer works in 2 ways depending on the mode in which the frequency converter is running. In Auto Mode the potentiometer acts as an extra programmable analog input. In Hand on Mode the potentiometer controls local reference.

Illustration 4.1 Description of LCP Keys and Display

Press [Menu] to select one of the following menus:

Status:

For

readouts only.

Quick Menu:

For access to Quick Menus 1 and 2.

Main Menu:

For access to all parameters.

4.1.2 Remote Mounting Kit for LCP

The LCP can be moved to the front of a cabinet by using

remote built-in kit. The enclosure is IP55.

the

Enclosure IP55 front

Max. cable length between LCP and unit: 3 m Communication std: RS-485 Ordering no. 132B0102

Table 4.1 Technical Data

26 MG02K302 - Rev. 2013-12-03

130BA526.10

62.3±0.2

82.8±0.2

4xR 1.5±0.5

130BA568.10

130BA527.10

Selection

VLT® Micro Drive FC 51 Design Guide

4.1.3 FC 51 LCP Mounting Instruction

Step 1

the bottom of the LCP in the frequency converter.

Place

Illustration 4.2 Place the LCP in the Frequency Converter

Step 2

the top of the LCP into the frequency converter.

Push

4.1.4 FC 51 Remote Mounting Kit Mounting Instruction

Step 1

Fit

gasket on LCP in the frequency converter.

Illustration 4.4 Fit Gasket on LCP

Step 2

LCP on panel - see dimensions of hole on drawing.

Place

4 4

Illustration 4.3 Push the Top of the LCP into Place

Illustration 4.5 Dimensions of Hole

Illustration 4.6 Panel, Gasket and LCP

MG02K302 - Rev. 2013-12-03 27

+ 65 hidden pages