Danfoss VLT Decentral Drive FCD 302 Guide

ENGINEERING TOMORROW
Design Guide
VLT® Decentral Drive FCD 302
vlt-drives.danfoss.com
Contents
Design Guide
Contents
1 Introduction
6
1.1 How to Read the Design Guide
1.1.1 Additional Resources
6
1.2 Document and Software Version
6
1.3 Definitions
6
1.3.1 Frequency Converter
6
1.3.2 Input
7
1.3.3 Motor
7
1.3.4 References
7
1.3.5 Miscellaneous
8
1.4 Safety Precautions
10
1.5 CE Labeling
11
1.5.1 Conformity
11
1.5.2 What Is Covered?
11
1.6 Compliance with EMC Directive 2004/1087EC
12
1.7 Approvals
12
1.8 Disposal
12
2 Product Overview and Functions
2.1 Galvanic Isolation (PELV)
13
13
2.1.1 PELV - Protective Extra Low Voltage
13
2.1.2 Ground Leakage Current
14
2.2 Control
14
2.2.1 Control Principle
15
2.2.2 Internal Current Control in VVC+ Mode
16
2.3 Control Structures
16
2.3.1 Control Structure in VVC+ Advanced Vector Control
16
2.3.2 Control Structure in Flux Sensorless
17
2.3.3 Control Structure in Flux with Motor Feedback
17
2.3.4 Local [Hand On] and Remote [Auto On] Control
18
2.3.5 Programming of Torque Limit and Stop
19
2.4 PID Control
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20
2.4.1 Speed PID Control
20
2.4.2 Parameters Relevant for Speed Control
20
2.4.3 Tuning PID Speed Control
22
2.4.4 Process PID Control
23
2.4.5 Process Control Relevant Parameters
24
2.4.6 Example of Process PID Control
25
2.4.7 Programming Order
26
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VLT® Decentral Drive FCD 302
Contents
2.4.8 Process Controller Optimization
27
2.4.9 Ziegler Nichols Tuning Method
28
2.5 Control Cables and Terminals
28
2.5.1 Control Cable Routing
28
2.5.2 DIP Switches
29
2.5.3 Basic Wiring Example
29
2.5.4 Electrical Installation, Control Cables
30
2.5.5 Relay Output
31
2.6 Handling of Reference
2.6.1 Reference Limits
33
2.6.2 Scaling of Preset References and Bus References
34
2.6.3 Scaling of Analog and Pulse References and Feedback
34
2.6.4 Dead Band Around Zero
35
2.7 Brake Functions
2
32
38
2.7.1 Mechanical Brake
38
2.7.1.1 Mechanical Brake Selection Guide and Electrical Circuit Description
39
2.7.1.2 Mechanical Brake Control
40
2.7.1.3 Mechanical Brake Cabling
42
2.7.1.4 Hoist Mechanical Brake
42
2.7.2 Dynamic Brake
42
2.7.2.1 Brake Resistors
42
2.7.2.2 Selection of Brake Resistor
42
2.7.2.3 Brake Resistors 10 W
43
2.7.2.4 Brake Resistor 40%
43
2.7.2.5 Control with Brake Function
44
2.7.2.6 Brake Resistor Cabling
44
2.8 Safe Torque Off
44
2.9 EMC
44
2.9.1 General Aspects of EMC Emissions
44
2.9.2 Emission Requirements
46
2.9.3 Immunity Requirements
47
2.9.4 EMC
48
2.9.4.1 EMC-correct Installation
48
2.9.4.2 Use of EMC-correct Cables
50
2.9.4.3 Grounding of Shielded Control Cables
51
2.9.4.4 RFI Switch
52
2.9.5 Mains Supply Interference/Harmonics
52
2.9.5.1 Effect of Harmonics in a Power Distribution System
53
2.9.5.2 Harmonic Limitation Standards and Requirements
53
2.9.5.3 Harmonic Mitigation
53
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MG04H302
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Design Guide
2.9.5.4 Harmonic Calculation
54
2.9.6 Residual Current Device
54
2.9.7 EMC Test Results
54
3 System Integration
55
3.1 Ambient Conditions
55
3.1.1 Air Humidity
55
3.1.2 Aggressive Environments
55
3.1.3 Vibration and Shock
55
3.1.4 Acoustic Noise
55
3.2 Mounting Positions
55
3.2.1 Mounting Positions for Hygienic Installation
3.3 Electrical Input: Mains-side Dynamics
57
3.3.1 Connections
57
3.3.1.1 Cables General
57
3.3.1.2 Connection to Mains and Grounding
57
3.3.1.3 Relay Connection
57
3.3.2 Fuses and Circuit Breakers
58
3.3.2.1 Fuses
58
3.3.2.2 Recommendations
58
3.3.2.3 CE Compliance
58
3.3.2.4 UL Compliance
58
3.4 Electrical Output: Motor-side Dynamics
58
3.4.1 Motor Connection
58
3.4.2 Mains Disconnectors
60
3.4.3 Additional Motor Information
60
3.4.3.1 Motor Cable
60
3.4.3.2 Motor Thermal Protection
60
3.4.3.3 Parallel Connection of Motors
61
3.4.3.4 Motor Insulation
61
3.4.3.5 Motor Bearing Currents
61
3.4.4 Extreme Running Conditions
61
3.4.4.1 Motor Thermal Protection
62
3.5 Final Test and Set-up
63
3.5.1 High-voltage Test
63
3.5.2 Grounding
63
3.5.3 Safety Grounding Connection
63
3.5.4 Final Set-up Check
64
4 Application Examples
65
4.1 Overview
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65
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VLT® Decentral Drive FCD 302
Contents
4.2 AMA
65
4.2.1 AMA with T27 Connected
65
4.2.2 AMA without T27 Connected
65
4.3 Analog Speed Reference
4.3.1 Voltage Analog Speed Reference
65
4.3.2 Current Analog Speed Reference
66
4.3.3 Speed Reference (Using a Manual Potentiometer)
66
4.3.4 Speed Up/Speed Down
66
4.4 Start/Stop Applications
67
4.4.1 Start/Stop Command with Safe Torque Off
67
4.4.2 Pulse Start/Stop
67
4.4.3 Start/Stop with Reversing and 4 Preset Speeds
68
4.5 Bus and Relay Connection
68
4.5.1 External Alarm Reset
68
4.5.2 RS485 Network Connection
69
4.5.3 Motor Thermistor
69
4.5.4 Using SLC to Set a Relay
70
4.6 Brake Application
70
4.6.1 Mechanical Brake Control
70
4.6.2 Hoist Mechanical Brake
71
4.7 Encoder
73
4.7.1 Encoder Direction
73
4.8 Closed-loop Drive System
73
4.9 Smart Logic Control
74
5 Special Conditions
5.1 Manual Derating
76
76
5.1.1 Derating for Low Air Pressure
76
5.1.2 Derating for Running at Low Speed
76
5.1.3 Ambient Temperature
77
5.1.3.1 Power Size 0.37–0.75 kW
77
5.1.3.2 Power Size 1.1–1.5 kW
77
5.1.3.3 Power Size 2.2–3.0 kW
78
5.2 Automatic Derating
4
65
78
5.2.1 Sine-Wave Filter Fixed Mode
80
5.2.2 Overview Table
81
5.2.3 High Motor Load
81
5.2.4 High Voltage on the DC link
82
5.2.5 Low Motor Speed
82
5.2.6 High Internal
82
5.2.7 Current
83
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Contents
Design Guide
5.3 Derating for Running at Low Speed
6 Type Code and Selection Guide
84
6.1 Type Code Description
84
6.2 Ordering Numbers
85
6.2.1 Ordering Numbers: Accessories
85
6.2.2 Ordering Numbers: Spare Parts
86
6.3 Options and Accessories
87
6.3.1 Fieldbus Options
87
6.3.2 VLT® Encoder Input MCB 102
87
6.3.3
VLT®
Resolver Input MCB 103
7 Specifications
88
91
7.1 Mechanical Dimensions
91
7.2 Electrical Data and Wire Sizes
92
7.2.1 Overview
92
7.2.2 UL/cUL Approved Pre-fuses
93
7.2.3 VLT® Decentral Drive FCD 302 DC Voltage Levels
93
7.3 General Specifications
94
7.4 Efficiency
99
7.5 dU/dt Conditions
99
Index
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101
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1 1
Introduction
VLT® Decentral Drive FCD 302
1 Introduction
1.1 How to Read the Design Guide
CAUTION
The design guide provides information required for
integration of the frequency converter in a diversity of
applications.
Indicates a potentially hazardous situation that could
result in minor or moderate injury. It may also be used
to alert against unsafe practices.
1.1.1 Additional Resources
NOTICE
•
VLT® Decentral Drive FCD 302 Operating Guide, for
information required to install and commission
the frequency converter.
•
VLT® AutomationDrive FC 301/302 Programming
Guide, for information about how to program the
unit, including complete parameter descriptions.
•
Modbus RTU Operating Instructions, for the
information required for controlling, monitoring,
and programming the frequency converter via
the built-in Modbus fieldbus.
•
VLT® PROFIBUS Converter MCA 114 Operating
Instructions, VLT® EtherNet/IP MCA 121 Installation
Guide, and VLT® PROFINET MCA 120 Installation
Guide, for information required for controlling,
monitoring, and programming the frequency
converter via a fieldbus.
•
VLT® Encoder Option MCB 102 Installation
Instructions.
•
VLT® AutomationDrive FC 300, Resolver Option MCB
103 Installation Instructions.
•
VLT® AutomationDrive FC 300, Safe PLC Interface
Option MCB 108 Installation Instructions.
•
•
VLT® Brake Resistor MCE 101 Design Guide.
•
VLT® Frequency Converters Safe Torque Off
Operating Guide.
The following conventions are used in this manual:
• Numbered lists indicate procedures.
•
Bullet lists indicate other information and
description of illustrations.
•
Italicized text indicates:
•
-
Cross-reference.
-
Link.
-
Footnote.
-
Parameter name.
-
Parameter group name.
-
Parameter option.
All dimensions in drawings are in mm (inch).
1.2 Document and Software Version
This manual is regularly reviewed and updated. All
suggestions for improvement are welcome. Table 1.1 shows
the document version and the corresponding software
version.
Edition
Remarks
MG04H3xx EMC-correct Installation has been
updated.
Software version
7.5x
Table 1.1 Document and Software Version
Approvals.
Technical literature and approvals are available online at
www.danfoss.com/en/search/?filter=type%3Adocumentation
%2Csegment%3Adds.
The following symbols are used in this manual:
WARNING
Indicates a potentially hazardous situation that could
result in death or serious injury.
6
Indicates important information, including situations that
may result in damage to equipment or property.
1.3 Definitions
1.3.1 Frequency Converter
IVLT,MAX
Maximum output current.
IVLT,N
Rated output current supplied by the frequency converter.
UVLT,MAX
Maximum output voltage.
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Introduction
Design Guide
1.3.2 Input
1 1
Break-away torque
175ZA078.10
Torque
Control command
Start and stop the connected motor with LCP and digital
inputs.
Functions are divided into 2 groups.
Pull-out
Functions in group 1 have higher priority than functions in
group 2.
Group 1
Reset, coast stop, reset and coast stop, quick stop,
DC brake, stop, the [OFF] key.
Group 2
Start, pulse start, reversing, start reversing, jog,
freeze output.
Table 1.2 Function Groups
RPM
Illustration 1.1 Break-away Torque
1.3.3 Motor
Motor running
Torque generated on output shaft and speed from 0 RPM
to maximum speed on motor.
ηVLT
The efficiency of the frequency converter is defined as the
ratio between the power output and the power input.
fJOG
Motor frequency when the jog function is activated (via
digital terminals).
Start-disable command
A stop command belonging to Group 1 control commands
- see Table 1.2.
fM
Motor frequency.
Stop command
A stop command belonging to Group 1 control commands
- see Table 1.2.
fMAX
Maximum motor frequency.
1.3.4 References
fMIN
Minimum motor frequency.
Analog reference
A signal transmitted to the analog inputs 53 or 54 (voltage
or current).
fM,N
Rated motor frequency (nameplate data).
IM
Motor current (actual).
Binary reference
A signal transmitted to the serial communication port.
IM,N
Rated motor current (nameplate data).
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.
nM,N
Nominal motor speed (nameplate data).
ns
Synchronous motor speed.
ns =
Pulse reference
A pulse frequency signal transmitted to the digital inputs
(terminal 29 or 33).
2 × par . 1 − 23 × 60 s
par . 1 − 39
nslip
Motor slip.
PM,N
Rated motor power (nameplate data in kW or hp).
TM,N
Rated torque (motor).
UM
Instant motor voltage.
UM,N
Rated motor voltage (nameplate data).
MG04H302
RefMAX
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 is set in
parameter 3-03 Maximum Reference.
RefMIN
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 is set in
parameter 3-02 Minimum Reference.
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7
1 1
Introduction
VLT® Decentral Drive FCD 302
1.3.5 Miscellaneous
lsb
Least significant bit.
Analog inputs
The analog inputs are used for controlling various
functions of the frequency converter.
There are 2 types of analog inputs:
Current input, 0–20 mA, and 4–20 mA
Voltage input, -10 V DC to +10 V DC.
msb
Most significant bit.
Analog outputs
The analog outputs can supply a signal of 0–20 mA, 4–
20 mA.
Online/offline parameters
Changes to online parameters are activated immediately
after the data value is changed. Press [OK] to activate
changes to off-line parameters.
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 brake power increases the DC-link voltage
and a brake chopper ensures that the power is transmitted
to the brake resistor.
CT characteristics
Constant torque characteristics used for all applications
such as conveyor belts, displacement pumps, and cranes.
Digital inputs
The digital inputs can be used for controlling various
functions of the frequency converter.
Digital outputs
The frequency converter features 2 solid-state outputs that
can supply a 24 V DC (maximum 40 mA) signal.
DSP
Digital signal processor.
ETR
Electronic thermal relay is a thermal load calculation based
on present load and time. Its purpose is to estimate the
motor temperature.
Hiperface®
Hiperface® is a registered trademark by Stegmann.
Initializing
If initializing is carried out (parameter 14-22 Operation
Mode), the frequency converter returns to the default
setting.
Intermittent duty cycle
An intermittent duty rating refers to a sequence of duty
cycles. Each cycle consists of an on-load and an off-load
period. The operation can be either periodic duty or nonperiodic duty.
LCP
The local control panel makes up a complete interface for
control and programming of the frequency converter. The
control panel is detachable and can be installed up to 3 m
(10 ft) from the frequency converter, that is, in a front
panel with the installation kit option.
8
MCM
Short for mille circular mil, an American measuring unit for
cable cross-section. 1 MCM=0.5067 mm2.
Process PID
The PID control maintains the required speed, pressure,
temperature, and so on, by adjusting the output frequency
to match the varying load.
PCD
Process control data.
Power cycle
Switch off the mains until display (LCP) is dark, then turn
power on again.
Pulse input/incremental encoder
An external, digital pulse transmitter used for feeding back
information on motor speed. The encoder is used in
applications where great accuracy in speed control is
required.
RCD
Residual current device.
Set-up
Save parameter settings in 4 set-ups. Change between the
4 parameter set-ups and edit 1 set-up, while another setup is active.
SFAVM
Switching pattern called stator flux-oriented asynchronous
vector modulation (parameter 14-00 Switching Pattern).
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.
SLC
The SLC (smart logic control) is a sequence of user-defined
actions executed when the associated user-defined events
are evaluated as true by the SLC. (See chapter 4.9.1 Smart
Logic Controller).
STW
Status word.
FC standard bus
Includes RS485 bus with FC protocol or MC protocol. See
parameter 8-30 Protocol.
THD
Total harmonic distortion states the total contribution of
harmonic.
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Introduction
Design Guide
Thermistor
A temperature-dependent resistor placed on the frequency
converter or the motor.
Trip
A state entered in fault situations, for example if the
frequency converter is subject to an overtemperature or
when the frequency converter is protecting the motor,
process, or mechanism. The frequency converter prevents a
restart until the cause of the fault has disappeared. To
cancel the trip state, restart the frequency converter. Do
not use the trip state for personal safety.
Trip lock
The frequency converter enters this state in fault situations
to protect itself. The frequency converter requires physical
intervention, for example when there is a short circuit on
the output. A trip lock can only be canceled by disconnecting 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,
sometimes, by being programmed to reset automatically.
Do not use the trip lock state for personal safety.
1 1
Commanded position
The actual position reference calculated by the profile
generator. The frequency converter uses the commanded
position as setpoint for position PI.
Actual position
The actual position from an encoder, or a value that the
motor control calculates in open loop. The frequency
converter uses the actual position as feedback for position
PI.
Position error
Position error is the difference between the actual position
and the commanded position. The position error is the
input for the position PI controller.
Position unit
The physical unit for position values.
VT characteristics
Variable torque characteristics used for pumps and fans.
VVC+
If compared with standard voltage/frequency ratio control,
voltage vector control (VVC+) improves the dynamics and
the stability, both when the speed reference is changed
and in relation to the load torque.
60° AVM
60° asynchronous vector modulation
(parameter 14-00 Switching Pattern).
Power factor
The power factor is the relation between I1 and IRMS.
Power factor =
3 x U x I1 cosϕ
3 x U x IRMS
The power factor for 3-phase control:
Power factor =
I1
I1 x cosϕ1
=
since cosϕ1 = 1
IRMS
IRMS
The power factor indicates to which extent the frequency
converter imposes a load on the mains supply.
The lower the power factor, the higher the IRMS for the
same kW performance.
IRMS =
I21 + I25 + I27 + .. + I2n
In addition, a high-power factor indicates that the different
harmonic currents are low.
The DC coils in the frequency converters produce a highpower factor, which minimizes the imposed load on the
mains supply.
Target position
The final target position specified by positioning
commands. The profile generator uses this position to
calculate the speed profile.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
9
1 1
Introduction
VLT® Decentral Drive FCD 302
1.4 Safety Precautions
WARNING
The voltage of the frequency converter is dangerous
whenever connected to mains. Correct planning of the
installation of the motor, frequency converter, and
fieldbus are necessary. Follow the instructions in this
manual, and the national and local rules and safety
regulations. Failure to follow design recommendations
could result in death, serious personal injury, or damage
to the equipment once in operation.
NOTICE
Disable protection mode in hoisting applications
(parameter 14-26 Trip Delay at Inverter Fault=0).
WARNING
HIGH VOLTAGE
Touching the electrical parts may be fatal - even after
the equipment has been disconnected from mains.
In planning, ensure that other voltage inputs can be
disconnected, such as external 24 V DC, load sharing
(linkage of DC intermediate circuit), and the motor
connection for kinetic back-up.
Systems where frequency converters are installed must, if
necessary, be equipped with additional monitoring and
protective devices according to the valid safety
regulations, for example law on mechanical tools,
regulations for the prevention of accidents, and so on.
Modifications on the frequency converters by means of
the operating software are allowed.
Failure to follow design recommendations, could result in
death or serious injury once the equipment is in
operation.
NOTICE
Hazardous situations have to be identified by the
machine builder/integrator who is responsible for taking
necessary preventive means into consideration.
Additional monitoring and protective devices may be
included, always according to valid national safety
regulations, for example, law on mechanical tools,
regulations for the prevention of accidents.
NOTICE
Crane, lifts, and hoists:
The controlling of external brakes must always be
designed with a redundant system. The frequency
converter can in no circumstances be the primary safety
circuit. Comply with relevant standards, for example.
Hoists and cranes: IEC 60204-32
Lifts: EN 81
Protection mode
Once a hardware limit on motor current or DC-link voltage
is exceeded, the frequency converter enters protection
mode. Protection mode means a change of the PWM
modulation strategy and a low switching frequency to
minimize losses. This continues 10 s after the last fault and
10
increases the reliability and the robustness of the
frequency converter while re-establishing full control of the
motor.
In hoist applications, protection mode is not usable
because the frequency converter is usually unable to leave
this mode again and therefore it extends the time before
activating the brake – which is not recommended.
The protection mode can be disabled by setting
parameter 14-26 Trip Delay at Inverter Fault to 0 which
means that the frequency converter trips immediately if 1
of the hardware limits is exceeded.
WARNING
DISCHARGE TIME
The frequency converter contains DC-link capacitors,
which can remain charged even when the frequency
converter is not powered. High voltage can be present
even when the warning LED indicator lights are off.
Failure to wait the specified time after power has been
removed before performing service or repair work can
result in death or serious injury.
•
•
Stop the motor.
•
•
Disconnect or lock PM motor.
•
Disconnect AC mains and remote DC-link power
supplies, including battery back-ups, UPS, and
DC-link connections to other frequency
converters.
Wait for the capacitors to discharge fully. The
minimum waiting time is specified in Table 1.3
and is also visible on the product label on top
of the frequency converter.
Before performing any service or repair work,
use an appropriate voltage measuring device to
make sure that the capacitors are fully
discharged.
Voltage [V]
Minimum waiting time (minutes)
4
7
15
200–240
0.25–3.7 kW
(0.34–5 hp)
–
5.5–37 kW
(7.5–50 hp)
380–500
0.25–7.5 kW
(0.34–10 hp)
–
11–75 kW
(15–100 hp)
525–600
0.75–7.5 kW
(1–10 hp)
–
11–75 kW
(15–100 hp)
525–690
–
1.5–7.5 kW
(2–10 hp)
11–75 kW
(15–100 hp)
Table 1.3 Discharge Time
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Introduction
Design Guide
1.5 CE Labeling
CE labeling is a positive feature when used for its original
purpose, that is, to facilitate trade within the EU and EFTA.
However, CE labeling may cover many different specifications. Check what a given CE label specifically covers.
The specifications can vary greatly. A CE label may
therefore give the installer a false sense 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, compliance with
the Low Voltage Directive is achieved. Danfoss issues a
declaration of conformity that confirms CE labeling in
accordance with the Low Voltage Directive.
The CE label also applies to the EMC directive, if 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.
Electrical equipment devices used alone or as part of a
system must bear the CE mark. Systems do not require the
CE mark, but must comply with the basic protection
requirements of the EMC Directive.
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.
1.5.2 What Is Covered?
The EU EMC Directive 2014/30/EU outline 3 typical
situations of using a frequency converter. See below for
EMC coverage and CE labeling.
•
The frequency converter is sold directly to the
end user. The frequency converter is for example
sold to a do-it-yourself market. The end user is a
layman, installing the frequency converter for use
with a hobby machine, a kitchen appliance, and
so on. For such applications, the frequency
converter must be CE labeled in accordance with
the EMC directive.
•
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. The frequency
converter and the finished plant do not have 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
using components, appliances, and systems that
are CE labeled under the EMC directive.
•
The frequency converter is sold as part of a
complete system. The system is marketed as
complete, for example an air-conditioning 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 used, it is
unnecessary to test the entire system.
1.5.1 Conformity
The Machinery Directive (2006/42/EC)
Frequency converters do not fall under the machinery
directive. However, if a frequency converter is supplied for
use in a machine, Danfoss provides information on safety
aspects relating to the frequency converter.
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 2 EU
directives:
The Low Voltage Directive (2014/35/EU)
Frequency converters must be CE-labeled in accordance
with the Low Voltage Directive of January 1, 2014. The Low
Voltage Directive applies to all electrical equipment in the
50–1000 V AC and the 75–1500 V DC voltage ranges.
The aim of the directive is to ensure personal safety and
avoid property damage when operating electrical
equipment that is installed, maintained, and used as
intended.
MG04H302
1 1
The EMC Directive (2014/30/EU)
The purpose of the EMC (electromagnetic compatibility)
Directive is to reduce electromagnetic interference and
enhance immunity of electrical equipment and installations. The basic protection requirement of the EMC
Directive is that devices that generate electromagnetic
interference (EMI), or whose operation could be affected
by EMI, must be designed to limit the generation of
electromagnetic interference. The devices must have a
suitable degree of immunity to EMI when properly
installed, maintained, and used as intended.
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11
1 1
VLT® Decentral Drive FCD 302
Introduction
1.6 Compliance with EMC Directive
2004/1087EC
The frequency converter is mostly used by professionals of
the trade as a complex component forming part of a larger
appliance, system, or installation.
NOTICE
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, see chapter 2.9.4 EMC.
1.7 Approvals
Table 1.4 FCD 302 Approvals
The frequency converter complies with UL 508C thermal
memory retention requirements. For more information,
refer to chapter 3.4.3.2 Motor Thermal Protection.
1.8 Disposal
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.
Table 1.5 Disposal Instruction
12
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MG04H302
Product Overview and Functi...
Design Guide
130BC963.10
2 Product Overview and Functions
2 2
The components that make up the electrical isolation, as
described in Illustration 2.3, 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 6 locations
(see Illustration 2.3).
130BC968.11
To maintain PELV, all connections made to the control
terminals must be PELV, for example, thermistor must be
reinforced/double insulated.
3
Illustration 2.1 Small Unit
M
130BC964.10
7
6
5
4
1
8
Illustration 2.2 Large Unit
2
9
1
Power supply (SMPS) including signal isolation of UDC,
indicating the voltage of intermediate DC Link circuit.
2
Gate drive that runs the IGBTs (trigger transformers/optocouplers).
3
Current transducers.
4
Opto-coupler, brake module.
5
Internal inrush, RFI, and temperature measurement circuits.
6
Custom relays.
7
Mechanical brake.
2.1 Galvanic Isolation (PELV)
8
Functional galvanic isolation for the 24 V back-up option
and for the RS485 standard bus interface.
2.1.1 PELV - Protective Extra Low Voltage
9
Functional galvanic isolation for the 24 V back-up option
and for the RS485 standard bus interface.
PELV offers protection by way of extra low voltage.
Protection against electric shock is ensured when the
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), except for
grounded delta leg above 400 V.
Illustration 2.3 Galvanic Isolation
NOTICE
Installation at high altitude:
380–500 V: At altitudes above 2000 m (6561 ft), contact
Danfoss regarding PELV.
Galvanic (ensured) isolation is obtained by fulfilling
requirements for higher isolation and by providing the
relevant creepage/clearance distances. These requirements
are described in the EN 61800-5-1 standard.
MG04H302
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13
VLT® Decentral Drive FCD 302
2.1.2 Ground Leakage Current
130BB957.11
2 2
Product Overview and Functi...
Leakage current [mA]
Follow national and local codes regarding protective
grounding of equipment with a leakage current >3.5 mA.
Frequency converter technology implies high frequency
switching at high power. This generates a leakage current
in the ground connection. A fault current in the frequency
converter at the output power terminals might contain a
DC component which can charge the filter capacitors and
cause a transient ground current.
100 Hz
2 kHz
100 kHz
The leakage current also depends on the line distortion.
NOTICE
When a filter is used, turn off parameter 14-50 RFI Filter
when charging the filter, to avoid that a high leakage
current makes the RCD switch.
EN/IEC61800-5-1 (power drive system product standard)
requires special care if the leakage current exceeds 3.5 mA.
Grounding must be reinforced in 1 of the following ways:
•
Ground wire (terminal 95) of at least 10 mm2
(7 AWG). This requires a PE adapter (available as
an option).
•
Two separate ground wires both complying with
the dimensioning rules.
See EN/IEC61800-5-1 and EN 50178 for further information.
Using RCDs
Where residual current devices (RCDs), also known as
ground leakage circuit breakers (CLCBs), are used, comply
with the following:
• Use RCDs of type B, which are capable of
detecting AC and DC currents.
•
Use RCDs with an inrush delay to prevent faults
due to transient ground currents.
•
Dimension RCDs according to the system configuration and environmental considerations.
Illustration 2.4 Influence of Cut-off Frequency of the RCD
See also RCD Application Note.
2.2 Control
A frequency converter rectifies AC voltage from mains into
DC voltage. This DC voltage is converted into an AC
current with a variable amplitude and frequency.
The motor is supplied with variable voltage, current, and
frequency, which enables infinitely variable speed control
of 3-phased, standard AC motors and permanent magnet
synchronous motors.
The VLT® Decentral Drive FCD 302 frequency converter is
designed for installations of multiple smaller frequency
converters, especially on conveyor applications, for
example, in the food and beverage industries and materials
handling. In installations where multiple motors are spread
around a facility such as bottling plants, food preparation,
packaging plants, and airport baggage handling installations, there may be dozens, perhaps hundreds, of
frequency converters, working together but spread over a
large physical area. In these cases, cabling costs alone
outweigh the cost of the individual frequency converters
and it makes sense to get the control closer to the motors.
The frequency converter can control either the speed or
the torque on the motor shaft.
14
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MG04H302
Product Overview and Functi...
Design Guide
Speed control
Two types of speed control:
• Speed open-loop control, which does not require
any feedback from the motor (sensorless).
•
Speed closed-loop PID control, which requires a
speed feedback to an input. A properly optimized
speed closed-loop control is more accurate than a
speed open-loop control.
Torque control
The torque control function is used in applications where
the torque on motor output shaft controls the application
as tension control.
•
Closed loop in flux mode with encoder feedback
comprises motor control based on feedback
signals from the system. It improves performance
in all 4 quadrants and at all motor speeds.
•
Open loop in VVC+ mode. The function is used in
mechanical robust applications, but the accuracy
is limited. Open-loop torque function works only
in 1 speed direction. The torque is calculated on
basis of current measurement internal in the
frequency converter. See application example
chapter 2.3.1 Control Structure in VVC+ Advanced
Vector Control.
Speed/torque reference
The reference to these controls can either be a single
reference or be the sum of various references including
relatively scaled references. The handling of references is
explained in detail in chapter 2.6 Handling of Reference.
2.2.1 Control Principle
L1 91
R+
82
L2 92
R81
Brake
Resistor
130BC965.10
The frequency converter is compatible with various motor control principles such as U/f special motor mode, VVC+, or flux
vector motor control.
In addition, the frequency converter is operable with permanent magnet synchronous motors (brushless servo motors) and
normal squirrel lift cabin asynchronous motors.
The short circuit behavior depends on the 3 current transducers in the motor phases and the desaturation protection with
feedback from the brake.
U 96
L3 93
V 97
R inr
Inrush
W 98
M
P 14-50
Illustration 2.5 Control Principle
MG04H302
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15
2 2
VLT® Decentral Drive FCD 302
2.2.2 Internal Current Control in VVC+ Mode
The frequency converter features an integral current limit control which is activated when the motor current, and thus the
torque, is higher than the torque limits set in parameter 4-16 Torque Limit Motor Mode, parameter 4-17 Torque Limit Generator
Mode, and parameter 4-18 Current Limit.
When the frequency converter is at the current limit during motor operation or regenerative operation, it reduces torque to
below the preset torque limits as quickly as possible without losing control of the motor.
2.3 Control Structures
2.3.1 Control Structure in VVC+ Advanced Vector Control
P 1-00
Config. mode
P 4-13
Motor speed
high limit (RPM)
High
Ref.
P 4-19
Max. output freq.
P 1-00
Config. mode
P 4-14
Motor speed
high limit (Hz)
+f max.
Motor
controller
P 3-**
Ramp
+

Process
_
P 7-20 Process feedback
1 source
P 7-22 Process feedback
2 source
Low
P 4-11
Motor speed
low limit (RPM)
P 4-12
Motor speed
low limit (Hz)
130BA055.10
2 2
Product Overview and Functi...
-f max.
P 4-19
Max. output freq.
P 7-0*
+
Speed
PID

_
+f max.
Motor
controller
-f max.
P 7-00 Speed PID
feedback source
Illustration 2.6 Control Structure in VVC+ Open-loop and Closed-loop Configurations
In the configuration shown in Illustration 2.6, parameter 1-01 Motor Control Principle is set to [1] VVC+ and
parameter 1-00 Configuration Mode is set to [0] Speed open loop. The resulting reference from the reference handling system
is received and fed through the ramp limitation and speed limitation before being sent to the motor control. The output of
the motor control is then limited by the maximum frequency limit.
If parameter 1-00 Configuration Mode is set to [1] Speed closed loop, the resulting reference passes from the ramp limitation
and speed limitation into a speed PID control. The speed PID control parameters are in the parameter group 7-0* Speed PID
Ctrl. The resulting reference from the speed PID control is sent to the motor control limited by the frequency limit.
Select [3] Process in parameter 1-00 Configuration Mode to use the process PID control for closed-loop control of, for example,
speed or pressure in the controlled application. The process PID parameters are in parameter group 7-2* Process Ctrl. Feedb
and parameter group 7-3* Process PID Ctrl.
16
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MG04H302
Product Overview and Functi...
Design Guide
2.3.2 Control Structure in Flux Sensorless
2 2
Control structure in flux sensorless open-loop and closed-loop configurations.
P 4-13 Motor speed
high limit [RPM]
P 4-19
Max. output
freq.
P 4-14 Motor speed
high limit [Hz]
High
P 7-0*
P 3-**
Ref.
+
Ramp
Speed
PID

_
+f max.
Motor
controller
-f max.
Low
+
Process
PID

_
130BA053.11
P 1-00
Config. mode
P 4-11 Motor speed
low limit [RPM]
P 4-12 Motor speed
low limit [Hz]
P 7-20 Process feedback
1 source
P 7-22 Process feedback
2 source
Illustration 2.7 Control Structure in Flux Sensorless
In the configuration shown, parameter 1-01 Motor Control Principle is set to [2] Flux Sensorless and parameter 1-00 Configuration Mode is set to [0] Speed open loop. The resulting reference from the reference handling system is fed through the
ramp and speed limitations as determined by the parameter settings indicated.
An estimated speed feedback is generated to the speed PID to control the output frequency.
The speed PID must be set with its P, I, and D parameters (parameter group 7-0* Speed PID Ctrl.).
Select [3] Process in parameter 1-00 Configuration Mode to use the process PID control for closed-loop control of speed or
pressure in the controlled application. The process PID parameters are in parameter group 7-2* Process Ctrl. Feedb. and
parameter group7-3* Process PID Ctrl.
2.3.3 Control Structure in Flux with Motor Feedback
130BA054.11
P 1-00
Config. mode
P 1-00
Config. mode
Torque
P 4-13 Motor speed
high limit (RPM)
P 4-14 Motor speed
high limit (Hz)
P 7-2*
Ref.
+
_
High
Process
PID
P 4-19
Max. output
freq.
P 3-**
Ramp
P 7-0*
+
_
Speed
PID
Low
P 7-20 Process feedback
1 source
P 7-22 Process feedback
2 source
P 4-11 Motor speed
low limit (RPM)
P 4-12 Motor speed
low limit (Hz)
+f max.
Motor
controller
-f max.
P 7-00
PID source
Illustration 2.8 Control Structure in Flux with Motor Feedback
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
17
In the configuration shown, parameter 1-01 Motor Control Principle is set to [3] Flux w motor feedb and parameter 1-00 Configuration Mode is set to [1] Speed closed loop.
The motor control in this configuration relies on a feedback signal from an encoder mounted directly on the motor (set in
parameter 1-02 Flux Motor Feedback Source).
Select [1] Speed closed loop in parameter 1-00 Configuration Mode to use the resulting reference as an input for the speed
PID control. The speed PID control parameters are located in parameter group 7-0* Speed PID Ctrl.
Select [2] Torque in parameter 1-00 Configuration Mode to use the resulting reference directly as a torque reference. Torque
control can only be selected in the [3] Flux with motor feedback (parameter 1-01 Motor Control Principle) configuration. When
this mode has been selected, the reference uses the Nm unit. It requires no torque feedback, since the actual torque is
calculated based on the current measurement of the frequency converter.
Select [3] Process in parameter 1-00 Configuration Mode to use the process PID control for closed-loop control of a process
variable (for example, speed) in the controlled application.
2.3.4 Local [Hand On] and Remote [Auto On] Control
After pressing the [Auto On] key, the frequency converter
goes into auto-on mode and follows (as default) the
remote reference. In this mode, it is possible to control the
frequency converter via the digital inputs and various serial
interfaces (RS485, USB, or an optional fieldbus). See more
about starting, stopping, changing ramps, parameter setups, and so on, in parameter group 5-1* Digital Inputs or
parameter group 8-5* Digital/Bus.
Hand
on
Off
Auto
on
Reset
Active reference and configuration mode
The active reference can be either the local reference or
the remote reference.
In parameter 3-13 Reference Site, the local reference can be
permanently selected by selecting [2] Local.
For permanent setting of the remote reference, select [1]
Remote. By selecting [0] Linked to Hand/Auto (default), the
reference site links to the active mode (hand-on mode or
auto-on Mode).
130BA245.12
The frequency converter can be operated manually via the
local control panel (LCP) or remotely via analog and digital
inputs and fieldbus. If allowed in parameter 0-40 [Hand on]
Key on LCP, parameter 0-41 [Off] Key on LCP,
parameter 0-42 [Auto on] Key on LCP, and
parameter 0-43 [Reset] Key on LCP, it is possible to start and
stop the frequency converter via the LCP using the [Hand
On] and [Off] keys. Alarms can be reset via the [Reset] key.
After pressing the [Hand On] key, the frequency converter
goes into hand-on mode and follows (as default) the local
reference that can be set using the navigation keys on the
LCP.
130BP046.10
2 2
VLT® Decentral Drive FCD 302
Product Overview and Functi...
Remote
reference
Remote
(Auto On)
Linked to hand/auto
Reference
(Hand On)
Local
Local
reference
LCP keys:
(Hand On), (Off ),
and (Auto On)
P 3-13 Reference Site
Illustration 2.10 Local Handling of Reference
Illustration 2.9 LCP Keys
18
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MG04H302
P 1-00
Configuration
mode
130BA246.10
P 1-05
Local
configuration
mode
Design Guide
Speed open/
closed loop
Scale to
RPM or
Hz
Local
reference
Torque
Local
ref.
Scale to
Nm
parameter 5-02 Terminal 29 Mode to [1] Output and [27]
Torque limit & stop.
Description
If a stop command is active via terminal 18, and the
frequency converter is not at the torque limit, the motor
ramps down to 0 Hz.
If the frequency converter is at the torque limit and a stop
command is activated, parameter 5-31 Terminal 29 Digital
Output (programmed to [27] torque limit and stop) is
activated. The signal to terminal 27 changes from logic 1
to logic 0, and the motor starts to coast. The coast ensures
that the hoist stops even if the frequency converter itself
cannot handle the required torque (that is, due to
excessive overload).
Scale to
process
unit
Process
closed loop
Illustration 2.11 Remote Handling of Reference
LCP keys
Parameter 3-13 Reference Site Active reference
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
•
Start/stop via terminal 18
Parameter 5-10 Terminal 18 Digital Input [8] Start
•
Quick stop via terminal 27
Parameter 5-12 Terminal 27 Digital Input [2] Coast
Stop, inverse
•
Terminal 29 output
Parameter 5-02 Terminal 29 Mode [1] Terminal 29
Mode Output
Parameter 5-31 Terminal 29 Digital Output [27]
Torque Limit & Stop
•
[0] Relay output (relay 1)
Parameter 5-40 Function Relay [32] Mechanical
Brake Control
1
Table 2.1 Conditions for Local/Remote Handling of Reference
+
P 5-40 [0] [32]
01 02
03
2.3.5 Programming of Torque Limit and
Stop
MG04H302
I max 0.1 Amp
-
24 VDC
Parameter 1-00 Configuration Mode determines what type
of application control principle (that is, speed, torque, or
process control) is used when the remote reference is
active. Parameter 1-05 Local Mode Configuration determines
the type of application control principle that is used when
the local reference is active. One of them is always active,
but both cannot be active at the same time.
In applications with an external electro-mechanical brake,
such as hoisting applications, it is possible to stop the
frequency converter via a standard stop command and
simultaneously activate the external electro-mechanical
brake.
The example given below, illustrates the programming of
the frequency converter connections.
The external brake can be connected to relay 1 or 2.
Program parameter 5-01 Terminal 27 Mode to [2] Coast,
inverse or [3] Coast and Reset, inverse, and program
130BC997.10
Product Overview and Functi...
2
Item
Description
1
External 24 V DC
2
Mechanical brake connection
3
Relay 1
3
Illustration 2.12 Mechanical Brake Control
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19
2 2
2 2
Product Overview and Functi...
VLT® Decentral Drive FCD 302
2.4 PID Control
2.4.1 Speed PID Control
Parameter 1-00 Configuration Mode
Parameter 1-01 Motor Control Principle
U/f
VVC+
Flux sensorless
Flux w/ encoder feedback
[0] Speed open loop
Not
Active
–
[1] Speed closed loop
–
Active
–
Active
[2] Torque
–
–
–
Not active1)
[3] Process
–
Active
Active
active1)
Not
Not
active1)
active1)
Table 2.2 Control Configurations where the Speed Control is Active
1) “Not active” means that the specific mode is available, but the speed control is not active in that mode.
NOTICE
The speed PID control works under the default parameter setting, but tuning the parameters is highly recommended to
optimize the motor control performance. The 2 flux motor control principles are particularly dependent on proper
tuning to yield their full potential.
2.4.2 Parameters Relevant for Speed Control
Parameter
Description of function
Parameter 7-00 Speed PID Feedback Source
Select from which input the speed PID should get its feedback.
Parameter 30-83 Speed PID Proportional Gain
The higher the value - the quicker the control. However, too high value may lead to
oscillations.
Parameter 7-03 Speed PID Integral Time
Eliminates steady state speed error. Lower value means quick reaction. However, too low
value may lead to oscillations.
Parameter 7-04 Speed PID Differentiation Time Provides a gain proportional to the rate of change of the feedback. A setting of 0 disables
the differentiator.
Parameter 7-05 Speed PID Diff. Gain Limit
If there are quick changes in reference or feedback in a given application, which means
that the error changes swiftly, the differentiator may soon become too dominant. This is
because it reacts to changes in the error. The quicker the error changes, the stronger the
differentiator gain is. The differentiator gain can thus be limited to allow setting of the
reasonable differentiation time for slow changes and a suitably quick gain for quick
changes.
Parameter 7-06 Speed PID Lowpass Filter Time
A low-pass filter that dampens oscillations on the feedback signal and improves steady
state performance. However, too large filter time deteriorates the dynamic performance of
the speed PID control.
Practical settings of parameter 7-06 Speed PID Lowpass Filter Time taken from the number of
pulses per revolution from encoder (PPR):
Encoder PPR
Parameter 7-06 Speed PID Lowpass Filter Time
512
10 ms
1024
5 ms
2048
2 ms
4096
1 ms
Table 2.3 Parameters Relevant for Speed Control
20
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MG04H302
Product Overview and Functi...
Design Guide
Example of how to program the speed control
In this case, the speed PID control is used to maintain a constant motor speed regardless of the changing load on the
motor. The required motor speed is set via a potentiometer connected to terminal 53. The speed range is 0–1500 RPM
corresponding to 0–10 V over the potentiometer. Starting and stopping is controlled by a switch connected to terminal 18.
The speed PID monitors the actual RPM of the motor by using a 24 V (HTL) incremental encoder as feedback. The feedback
sensor is an encoder (1024 pulses per revolution) connected to terminals 32 and 33.
130BA174.10
L1
L2
L3
N
PE
F1
12
91 92 93 95
37
L1 L2 L3 PE
U
18
50
53
55
39
20
32
33
V W PE
96 97 98 99
M
3
24 Vdc
Illustration 2.13 Example - Speed Control Connections
The following must be programmed in the order shown (see explanation of settings in the VLT® AutomationDrive FC
301/FC 302 Programming Guide)
In the list, it is assumed that all other parameters and switches remain at their default setting.
Function
Parameter
Setting
1) Make sure that the motor runs properly. Do the following:
Set the motor parameters using nameplate data.
Parameter group 1-2* As specified on motor nameplate.
Motor Data
Perform an automatic motor adaptation.
Parameter 1-29 Auto
matic Motor
Adaptation (AMA)
[1] Enable complete AMA.
2) Check that the motor is running and that the encoder is attached properly. Do the following:
Press the [Hand On] LCP key. Check that the motor is
running and note in which direction it is turning
(referred to as the positive direction).
–
Set a positive reference.
Go to parameter 16-20 Motor Angle. Turn the motor
slowly in the positive direction. It must be turned so
slowly (only a few RPM) that it can be determined if the
value in parameter 16-20 Motor Angle is increasing or
decreasing.
Parameter 16-20 Moto (Read-only parameter) Note: An increasing value
r Angle
overflows at 65535 and starts again at 0.
If parameter 16-20 Motor Angle is decreasing, then
change the encoder direction in parameter 5-71 Term
32/33 Encoder Direction.
Parameter 5-71 Term
32/33 Encoder
Direction
[1] Counterclockwise (if parameter 16-20 Motor Angle is
decreasing).
3) Make sure that the frequency converter limits are set to safe values.
MG04H302
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VLT® Decentral Drive FCD 302
Product Overview and Functi...
Function
Parameter
Set acceptable limits for the references.
Parameter 3-02 Minim 0 RPM (default).
um Reference
1500 RPM (default).
Parameter 3-03 Maxi
mum Reference
Check that the ramp settings are within frequency
converter capabilities and allowed application operating
specifications.
Parameter 3-41 Ramp Default setting.
1 Ramp up Time
Default setting.
Parameter 3-42 Ramp
1 Ramp Down Time
2 2
Setting
Set acceptable limits for the motor speed and frequency. Parameter 4-11 Motor 0 RPM (default).
Speed Low Limit
1500 RPM (default).
[RPM]
60 Hz (default 132 Hz).
Parameter 4-13 Motor
Speed High Limit
[RPM]
Parameter 4-19 Max
Output Frequency
4) Configure the speed control and select the motor control principle.
Activation of speed control.
Parameter 1-00 Config [1] Speed closed loop.
uration Mode
Selection of motor control principle.
Parameter 1-01 Motor [3] Flux w motor feedb.
Control Principle
5) Configure and scale the reference to the speed control.
Set up analog input 53 as a reference source.
Parameter 3-15 Refere Not necessary (default).
nce Resource 1
Scale analog input 53 from 0 RPM (0 V) to 1500 RPM
(10 V).
Parameter group 6-1* Not necessary (default).
Analog Input 1
6) Configure the 24 V HTL encoder signal as feedback for the motor control and the speed control.
Set up digital input 32 and 33 as encoder inputs.
Parameter 5-14 Termi
nal 32 Digital Input
Parameter 5-15 Termi
nal 33 Digital Input
[0] No operation (default).
Select terminal 32/33 as motor feedback.
Parameter 1-02 Flux
Motor Feedback
Source
Not necessary (default).
Select terminal 32/33 as speed PID feedback.
Parameter 7-00 Speed Not necessary (default).
PID Feedback Source
7) Tune the speed control PID parameters.
Use the tuning guidelines when relevant or tune
manually.
Parameter group 7-0* See the guidelines in chapter 2.4.3 Tuning PID Speed
Speed PID Ctrl.
Control.
8) Finished.
Save the parameter setting to the LCP for safe keeping.
Parameter 0-50 LCP
Copy
[1] All to LCP.
Table 2.4 Speed Control Settings
2.4.3 Tuning PID Speed Control
The following tuning guidelines are relevant when using 1
of the flux motor control principles in applications where
the load is mainly inertial (with a low amount of friction).
The value of parameter 30-83 Speed PID Proportional Gain
depends on the combined inertia of the motor and load,
and the selected bandwidth can be calculated using the
following formula:
22
Par . 7 − 02 =
Total inertia kgm2 x par . 1 − 25
x Bandwidth rad/s
Par . 1 − 20 x 9550
NOTICE
Parameter 1-20 Motor Power [kW] is the motor power in
[kW] (that is, enter 4 kW instead of 4000 W in the
formula).
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Product Overview and Functi...
Design Guide
2.4.4 Process PID Control
A practical value for the bandwidth is 20 rad/s. Check the
result of the Parameter 30-83 Speed PID Proportional Gain
calculation against the following formula (not required
when using high-resolution feedback such as a SinCos
feedback):
The process PID Control can be used to control application
parameters that can be measured by a sensor (that is,
pressure, temperature, flow) and be affected by the
connected motor through a pump, fan, or otherwise.
Par . 7 − 02MAX =
Table 2.5 shows the control configurations where the
process control is possible. When a flux vector motor
control principle is used, take care also to tune the speed
control PID parameters. To see where the speed control is
active, refer to chapter 2.3 Control Structures.
0 . 01 x 4 x Encoder Resolution x Par . 7 − 06
2xπ
x Max torque ripple %
A good start value for parameter 7-06 Speed PID Lowpass
Filter Time is 5 ms (lower encoder resolution calls for a
higher filter value). Typically, a maximum torque ripple of
3% is acceptable. For incremental encoders, the encoder
resolution is found in either parameter 5-70 Term 32/33
Pulses per Revolution (24 V HTL on standard frequency
converter) or parameter 17-11 Resolution (PPR) (5 V TTL on
VLT® Encoder Input MCB 102 option).
Parameter 1-00 Parameter 1-01 Motor Control Principle
Configuration
U/f
Flux
Flux with
VVC+
Mode
sensorles encoder
s
feedback
[3] Process
–
Process
Process
& speed
Process &
speed
Table 2.5 Process PID Control Settings
Generally, the practical maximum limit of
parameter 30-83 Speed PID Proportional Gain is determined
by the encoder resolution and the feedback filter time. But
other factors in the application might limit the
parameter 30-83 Speed PID Proportional Gain to a lower
value.
NOTICE
The process PID control works under the default
parameter setting, but tuning the parameters is highly
recommended to optimize the application control
performance. The 2 flux motor control principles are
specially dependent on proper speed control PID tuning
(before tuning the process control PID) to yield their full
potential.
To minimize the overshoot, parameter 7-03 Speed PID
Integral Time could be set to approximately 2.5 s (varies
with the application).
Parameter 7-04 Speed PID Differentiation Time should be set
to 0 until everything else is tuned. If necessary, finish the
tuning by experimenting with small increments of this
setting.
130BA178.10
Process PID
P 7-38
Feed forward
Reference
Handling
Feedback
Handling
100%
+
% [unit]
0%
%
[unit]
_
PID
%
[speed]
0%
Scale to
speed
To motor
control
-100%
*(-1)
100%
% [unit]
P 7-30
normal/inverse
-100%
P 4-10
Motor speed
direction
Illustration 2.14 Process PID Control Diagram
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
23
2 2
2 2
Product Overview and Functi...
VLT® Decentral Drive FCD 302
2.4.5 Process Control Relevant Parameters
Parameter
Description of function
Parameter 7-20 Process CL Feedback 1 Resource Select from which source (that is, analog or pulse input) the process PID should get its
feedback.
Parameter 7-22 Process CL Feedback 2 Resource Optional: Determine if (and from where) the process PID should get an additional
feedback signal. If an additional feedback source is selected, the 2 feedback signals are
added before being used in the process PID control.
Parameter 7-30 Process PID Normal/ Inverse
Control
Under [0] Normal operation, the process control responds with an increase of the motor
speed if the feedback is getting lower than the reference. In the same situation, but under
[1] Inverse operation, the process control responds with a decreasing motor speed instead.
Parameter 7-31 Process PID Anti Windup
The anti-wind-up function ensures that when either a frequency limit or a torque limit is
reached, the integrator is set to a gain that corresponds to the actual frequency. This
avoids integrating on an error that cannot in any case be compensated for with a speed
change. This function can be disabled by selecting [0] Off.
Parameter 7-32 Process PID Start Speed
In some applications, reaching the required speed/set point can take long time. In such
applications, it might be an advantage to set a fixed motor speed from the frequency
converter before the process control is activated. This is done by setting a process PID
start value (speed) in parameter 7-32 Process PID Start Speed.
Parameter 7-33 Process PID Proportional Gain
The higher the value - the quicker the control. However, too large value may lead to
oscillations.
Parameter 7-34 Process PID Integral Time
Eliminates steady state speed error. Lower value means quick reaction. However, too small
value may lead to oscillations.
Parameter 7-35 Process PID Differentiation Time Provides a gain proportional to the rate of change of the feedback. A setting of 0 disables
the differentiator.
Parameter 7-36 Process PID Diff. Gain Limit
If there are quick changes in reference or feedback in a given application - which means
that the error changes swiftly - the differentiator may soon become too dominant. This is
because it reacts to changes in the error. The quicker the error changes, the stronger the
differentiator gain is. The differentiator gain can thus be limited to allow setting of the
reasonable differentiation time for slow changes.
Parameter 7-38 Process PID Feed Forward
Factor
In applications where there is a good (and approximately linear) correlation between the
process reference and the motor speed necessary for obtaining that reference, the feed
forward factor can be used to achieve better dynamic performance of the process PID
control.
Parameter 5-54 Pulse Filter Time Constant #29
(Pulse term. 29), parameter 5-59 Pulse Filter
Time Constant #33 (Pulse term. 33),
parameter 6-16 Terminal 53 Filter Time
Constant (Analog term 53),
parameter 6-26 Terminal 54 Filter Time
Constant (Analog term. 54)
If there are oscillations of the current/voltage feedback signal, these can be dampened
with a low-pass filter. This time constant shows the speed limit of the ripples occurring on
the feedback signal.
Example: If the low-pass filter has been set to 0.1 s, the limit speed is 10 RAD/s (the
reciprocal of 0.1 s), corresponding to (10/(2 x π))=1.6 Hz. This means that all currents/
voltages that vary by more than 1.6 oscillations per second are dampened by the filter.
The control is only carried out on a feedback signal that varies by a frequency (speed) of
less than 1.6 Hz.
The low-pass filter improves steady state performance but selecting a too large filter time
deteriorates the dynamic performance of the process PID control.
Table 2.6 Parameters are Relevant for the Process Control
24
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Product Overview and Functi...
Design Guide
L1
L2
PE
130BA175.12
Illustration 2.15 is an example of a process PID control used
in a ventilation system.
130BC966.10
2.4.6 Example of Process PID Control
L3
N
1
100kW
ON
Bus MS
WARNING
ALARM
NS1
NS2
F1
2
91 92 93 95
12
37
L1 L2 L3 PE
W n °C
3
V W PE
5 kΩ
54
5
4
6
U
18
50
53
55
96 97 98 99
Item
Description
1
Cold air
2
Heat generating process
3
Temperature transmitter
4
Temperature
5
Fan speed
6
Heat
Transmitter
M
3
Illustration 2.16 Two-wire Transmitter
Illustration 2.15 Process PID Control in Ventilation System
In a ventilation system, the temperature is to be settable
from -5 to +35 °C (23–95 °F) with a potentiometer of 0–
10 V. The task of the process control is to maintain
temperature at a constant preset level.
1.
Start/stop via a switch connected to terminal 18.
2.
Temperature reference via potentiometer (-5 to
35 °C (23–95 °F), 0–10 V DC) connected to
terminal 53.
3.
Temperature feedback via transmitter (-10 to
40 °C (14–104 °F), 4–20 mA) connected to
terminal 54. Switch S202 set to ON (current
input).
The control is of the inverse type, which means that when
the temperature increases, the ventilation speed is
increased as well, to generate more air. When the
temperature drops, the speed is reduced. The transmitter
used is a temperature sensor with a working range of -10
to +40 °C (14–104 °F), 4–20 mA. Minimum/maximum
speed 300/1500 RPM.
MG04H302
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25
2 2
2 2
VLT® Decentral Drive FCD 302
Product Overview and Functi...
2.4.7 Programming Order
Function
Parameter
Setting
Initialize the frequency converter.
Parameter 14-22
Operation Mode
[2] Initialization - make a power-cycle - press reset.
Set the motor parameters according to nameplate
data.
Parameter group
1-2* Motor Data
As stated on motor nameplate.
Perform a full AMA.
Parameter 1-29 Au [1] Enable complete AMA.
tomatic Motor
Adaptation (AMA)
1) Set motor parameters.
2) Check that motor is running in the right direction.
When the motor is connected to the frequency converter with straight forward phase order as U - U; V- V; W - W, the motor shaft usually
turns clockwise seen into shaft end.
Press [Hand On] LCP key. Check shaft direction by applying a manual reference.
Parameter 4-10 M Select correct motor shaft direction.
otor Speed
Direction
If the motor turns opposite of the required
direction:
1. Change motor direction in
parameter 4-10 Motor Speed Direction.
2. Turn off mains - wait for DC link to discharge switch 2 of the motor phases.
Set configuration mode.
Parameter 1-00 Co [3] Process.
nfiguration Mode
Set local mode configuration
Parameter 1-05 Lo [0] Speed Open Loop.
cal Mode Configuration
3) Set reference configuration, that is, the range for handling of reference. Set scaling of analog input in parameter group 6-** Analog
In/Out.
•
•
•
Set reference/feedback units.
Set minimum reference (10 °C (50 °F)).
Set maximum reference (80 °C (176 °F)).
If set value is determined from a preset value
(array parameter), set other reference sources to
no function.
Parameter 3-01 Re
ference/Feedback
Unit
Parameter 3-02 Mi
nimum Reference
Parameter 3-03 M
aximum Reference
Parameter 3-10 Pr
eset Reference
[60] °C Unit shown on display.
-5 °C.
35 °C.
[0] 35%.
Par . 3 − 10 0
× Par . 3 − 03 − par . 3 − 02 = 24, 5° C
100
Parameter 3-14 Preset Relative Reference to parameter 3-18 Relative
Scaling Reference Resource, [0] = No function
Ref =
4) Adjust limits for the frequency converter:
Set ramp times to an appropriate value as 20 s.
Parameter 3-41 Ra 20 s.
mp 1 Ramp up
20 s.
Time
Parameter 3-42 Ra
mp 1 Ramp Down
Time
•
•
•
Parameter 4-11 M 300 RPM.
otor Speed Low
1500 RPM.
Limit [RPM]
60 Hz.
Parameter 4-13 M
otor Speed High
Limit [RPM]
Parameter 4-19 M
ax Output
Frequency
26
Set minimum speed limits.
Set motor speed maximum limit.
Set maximum output frequency.
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Product Overview and Functi...
Design Guide
Function
Parameter
Setting
Set S201 or S202 to wanted analog input function (Voltage (V) or milliamps (I))
NOTICE
2 2
Switches are sensitive - Make a power-cycle keeping the default setting of V.
5) Scale analog inputs used for reference and feedback.
•
•
•
•
•
Set terminal 53 low voltage.
Set terminal 53 high voltage.
Set terminal 54 low feedback value.
Set terminal 54 high feedback value.
Set feedback source.
Parameter 6-10 Te
rminal 53 Low
Voltage
Parameter 6-11 Te
rminal 53 High
Voltage
Parameter 6-24 Te
rminal 54 Low
Ref./Feedb. Value
Parameter 6-25 Te
rminal 54 High
Ref./Feedb. Value
Parameter 7-20 Pr
ocess CL Feedback
1 Resource
0 V.
10 V.
-5 °C.
35 °C.
[2] Analog input 54.
6) Basic PID settings.
Process PID normal/inverse.
Parameter 7-30 Pr [0] Normal.
ocess PID Normal/
Inverse Control
Process PID anti-wind-up.
Parameter 7-31 Pr [1] On.
ocess PID Anti
Windup
Process PID start speed.
Parameter 7-32 Pr 300 RPM.
ocess PID Start
Speed
Save parameters to LCP.
Parameter 0-50 LC [1] All to LCP.
P Copy
Table 2.7 Example of Process PID Control Set-up
2.4.8 Process Controller Optimization
The basic settings have now been made. All that needs to
be done is to optimize the proportional gain, the
integration time, and the differentiation time
(parameter 7-33 Process PID Proportional Gain,
parameter 7-34 Process PID Integral Time,
parameter 7-35 Process PID Differentiation Time). In most
processes, this can be done by following these guidelines:
1.
Start the motor.
2.
Set parameter 7-33 Process PID Proportional Gain
to 0.3 and increase it until the feedback signal
again begins to vary continuously. Then reduce
the value until the feedback signal has stabilized.
Now lower the proportional gain by 40–60%.
3.
the integration time until the feedback signal
stabilizes, followed by an increase of 15–50%.
4.
Only use parameter 7-35 Process PID Differentiation
Time for very fast-acting systems only (differentiation time). The typical value is 4 times the set
integration time. The differentiator should only be
used when the setting of the proportional gain
and the integration time has been fully
optimized. Make sure that oscillations on the
feedback signal are sufficiently dampened by the
lowpass filter on the feedback signal.
NOTICE
If necessary, start/stop can be activated several times to
provoke a variation of the feedback signal.
Set parameter 7-34 Process PID Integral Time to
20 s and reduce the value until the feedback
signal again begins to vary continuously. Increase
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
27
VLT® Decentral Drive FCD 302
2.4.9 Ziegler Nichols Tuning Method
Type of
control
Proportional
gain
To tune the PID controls of the frequency converter,
Danfoss recommends the Ziegler Nichols tuning method.
PI-control
0.45 x Ku
0.833 x Pu
PID tight
control
0.6 x Ku
0.5 x Pu
0.125 x Pu
NOTICE
PID some
overshoot
0.33 x Ku
0.5 x Pu
0.33 x Pu
Do not use the Ziegler Nichols Tuning method in
applications that could be damaged by the oscillations
created by marginally stable control settings.
Differentiation
time
–
Table 2.8 Ziegler Nichols Tuning for Regulator
The criteria for adjusting the parameters are based on
evaluating the system at the limit of stability rather than
on taking a step response. Increase the proportional gain
until observing continuous oscillations (as measured on
the feedback), that is, until the system becomes marginally
stable. The corresponding gain (Ku) is called the ultimate
gain and is the gain, at which the oscillation is obtained.
The period of the oscillation (Pu) (called the ultimate
period) is determined as shown in Illustration 2.17 and
should be measured when the amplitude of oscillation is
small.
1.
Integral time
Select only proportional control, meaning that
the integral time is set to the maximum value,
while the differentiation time is set to 0.
2.5 Control Cables and Terminals
2.5.1 Control Cable Routing
A 24 V DC external supply can be used as low voltage
supply to the control card and any option cards installed.
This enables full operation of the LCP (including parameter
setting) without connection to mains.
NOTICE
A warning of low voltage is given when 24 V DC has
been connected; however, there is no tripping.
WARNING
2.
Increase the value of the proportional gain until
the point of instability is reached (sustained
oscillations) and the critical value of gain, Ku, is
reached.
3.
Measure the period of oscillation to obtain the
critical time constant, Pu.
4.
Use Table 2.8 to calculate the necessary PID
control parameters.
ELECTRICAL SHOCK HAZARD
Without galvanic isolation (type PELV), the control
terminals impose an electrical shock hazard. Failure to
follow the recommendations, may lead to death or
serious injury.
•
Use 24 V DC supply of type PELV to ensure
correct galvanic isolation (type PELV).
The process operator can do the final tuning of the control
iteratively to yield satisfactory control.
y(t)
130BA183.10
2 2
Product Overview and Functi...
t
Pu
Illustration 2.17 Marginally Stable System
28
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Design Guide
2.5.2 DIP Switches
Safe
torque off
2.5.3 Basic Wiring Example
20
B07
B08
B12
37
20
12
B03
B04
20
G
20
B01
B02
B05
B06
B09
B10
B11
20
P
20
N
20
V
37
20
13
Default settings:
27 = [2] Coast inverse parameter 5-10 Terminal 18 Digital
Input
37 = Safe Torque Off inverse
R
Connect terminals 27 and 37 to +24 V terminals 12 and 13,
as shown in Illustration 2.18.
130BC985.10
Product Overview and Functi...
20
55
42
18
19
27
29
32
33
50
54
12
12
12
12
12
12
55
53
Coast inverse
Speed
Coast inverse (27)
Illustration 2.18 Basic Wiring Example
MG04H302
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29
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VLT® Decentral Drive FCD 302
Product Overview and Functi...
2.5.4 Electrical Installation, Control Cables
3-phase
power
input
Mechanical
brake
+10 V DC
Switch mode
power supply
24 V DC
10 V DC
600 mA
15 mA
122(MBR+)
123(MBR-)
50 (+10 V OUT)
(R+) 82
Motor
Brake
resistor
(R-) 81
S201
ON
53 (A IN)
S202
Relay1
ON/I=0-20mA
OFF/U=0-10V
03
ON
54 (A IN)
1 2
-10 V DC+10 V DC
0/4-20 mA
(U) 96
(U) 97
(W) 98
(PE) 99
1 2
-10 V DC+10 V DC
0/4-20 mA
91 (L1)
92 (L2)
93 (L3)
95 (PE)
130BC384.10
2 2
02
55 (COM A IN)
Relay2
12 (+24 V OUT)
01
06
13 (+24 V OUT)
P 5-00
05
18 (D IN)
24 V (NPN)
0 V (PNP)
19 (D IN)
24 V (NPN)
0 V (PNP)
(COM A OUT) 39
20 (COM D IN)
S801
ON
1 2
24 V (NPN)
0 V (PNP)
240 V AC, 2A
400 V AC, 2A
04
(A OT) 42
0V
27 (D IN/OUT)
240 V AC, 2A
Analog output
0/4–20 mA
ON=Terminated
OFF=Open
5V
29 (D IN/OUT)
24V
24 V (NPN)
0 V (PNP)
GX
S801
OV
32 (D IN)
24 V (NPN)
0 V (PNP)
33 (D IN)
24 V (NPN)
0 V (PNP)
RS485
Interface
(N RS485) 69
RS485
(P RS485) 68
(COM RS485) 61
GX
(PNP) = Source
(NPN) = Sink
37 (D IN)
VCXA
67
GND1
62
PROFIBUS
interface
63
RS485
66
GND1
Illustration 2.19 Electrical Terminals without Options
A = analog, D = digital
Terminal 37 is used for Safe Torque Off.
Relay 2 has no function when the frequency converter has mechanical brake output.
30
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Product Overview and Functi...
Design Guide
Long control cables and analog signals may in rare cases
result in 50/60 Hz ground loops due to noise from mains
supply cables. If this occurs, it may be necessary to break
the shield or insert a 100 nF capacitor between shield and
chassis. Connect the digital and analog inputs and outputs
separately to the common inputs (terminal 20, 55, 39) to
avoid ground currents from both groups affecting other
groups. For example, switching on the digital input may
disturb the analog input signal.
130BC987.10
Safe
torque off
2.5.5 Relay Output
The relay output with the terminals 01, 02, 03 and 04, 05,
06 has a capacity of maximum 240 V AC, 2 A. Minimum
24 V DC, 10 mA, or 24 V AC, 100 mA can be used for
indicating status and warnings. The 2 relays are physically
located on the installation card. These are programmable
through parameter group 5-4* Relays. The relays are Form C,
meaning each has 1 normally open contact and 1 normally
closed contact on a single throw. The contacts of each
relay are rated for a maximum load of 240 V AC at 2 amps.
Relay 1
•
•
•
Terminal 01: Common
Terminal 02: Normal open 240 V AC
Terminal 03: Normal closed 240 V AC
R
G
V
12
N
20
P
20
B04
B08
B03
B07
B02
B06
B01
B05
Relay 2
B09
B10
B11
B12
37
37
20
13
20
20
20
20
20
20
55
42
18
19
27
29
32
33
50
54
12
12
12
12
12
12
55
53
•
•
•
Terminal 05: Normal open 240 V AC
Terminal 06: Normal closed 240 V AC
Relay 1 and relay 2 are programmed in
parameter 5-40 Function Relay, parameter 5-41 On Delay,
Relay, and parameter 5-42 Off Delay, Relay.
130BC998.10
PNP (Source)
Digital input wiring
Terminal 04: Common
Safe
torque off
20
20
N
V
20
12
G
20
13
55
42
18
19
27
29
32
33
50
54
12
12
12
12
12
12
55
53
B
GND
B09
B10
B11
B12
37
37
20
A
B05
B06
B07
B08
20
20
+24V
B01
B02
B03
B04
P
20
R
20
13
20
37
37
B12
G
12
20
20
B08 B07 B06
B05
R
V
N
P
B04 B03
B01
B11
B10 B09
B02
NPN (Sink)
Digital input wiring
/Z
/A
B
+5V
/B
GND
Illustration 2.20 Input Polarity of Control Terminals
Z
A
Illustration 2.21 Relay Connection
NOTICE
To comply with EMC emission specifications, shielded/
armored cables are recommended. If an unshielded/
unarmored cable is used, see chapter 2.9.7 EMC Test
Results for more information.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
31
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VLT® Decentral Drive FCD 302
2.6 Handling of Reference
Local reference
The local reference is active when the frequency converter is operated with [Hand On] key active. Adjust the reference by
[▲]/[▼] and [◄]/[►] arrows, respectively.
130BA244.11
Relative scaling ref.
P 3-18
Remote reference
The reference handling system for calculating the remote reference is shown in Illustration 2.22.
No function
Analog ref.
Pulse ref.
Local bus ref.
DigiPot
P 3-14
Preset relative ref.
P 3-00
Ref./feedback range
(0)
P 1-00
Configuration mode
(1)
(2)
P 5-1x(19)/P 5-1x(20)
P 3-10
Preset ref.
(3)
Speed
open/closed loop
Freeze ref./Freeze output
(4)
(5)
(7)
Scale to
RPM or
Hz
-max ref./
+max ref.
100%
P 5-1x(28)/P 5-1x(29)
Input command:
Catch up/ slow down
(6)
-100%
Y
P 3-04
(0)
Ref.resource 1
P 3-15
No function
Analog ref.
Pulse ref.
D1
P 5-1x(15)
Preset '1'
External '0'
Ref. resource 2
P 3-16
(1)
X
Relative
X+X*Y
/100
P 3-12
Catchup Slowdown
value
Local bus ref.
Scale to
Nm
P 16-01
Remote
ref.
max ref.
%
Process
%
min ref.
Scale to
process
unit
Freeze ref.
&
increase/
decrease
ref.
DigiPot
Analog ref.
Torque
Catch up/
slow
down
±100%
P 5-1x(21)/P 5-1x(22)
Speed up/ speed down
No function
200%
P 16-02
Ref. in %
Pulse ref.
Local bus ref.
-200%
DigiPot
Ref. resource 3
No function
P 3-17
2 2
Product Overview and Functi...
Analog ref.
Pulse ref.
Local bus ref.
DigiPot
Illustration 2.22 Remote Reference
32
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Design Guide
•
Y (the relative reference): A sum of 1 fixed preset
reference (parameter 3-14 Preset Relative Reference)
and 1 variable analog reference
(parameter 3-18 Relative Scaling Reference
Resource) in [%].
The 2 types of reference inputs are combined in the
following formula: Remote reference=X+X*Y/100%. If
relative reference is not used, set parameter 3-18 Relative
Scaling Reference Resource to [0] No function and
parameter 3-14 Preset Relative Reference to 0%. The catch
up/slow down function and the freeze reference function can
both be activated by digital inputs on the frequency
converter. The functions and parameters are described in
the VLT® AutomationDrive FC 301/FC 302 Programming
Guide.
The scalings of analog references are described in
parameter groups 6-1* Analog Input 1 and 6-2* Analog Input
2, and the scaling of digital pulse references are described
in parameter group 5-5* Pulse Input.
Reference limits and ranges are set in parameter group 3-0*
Reference Limits.
2.6.1 Reference Limits
Parameter 3-00 Reference Range, parameter 3-02 Minimum
Reference, and parameter 3-03 Maximum Reference together
define the allowed range of the sum of all references. The
sum of all references is clamped when necessary. The
relation between the resulting reference (after clamping) is
shown in Illustration 2.23/Illustration 2.24 and the sum of all
references is shown in Illustration 2.25.
130BA184.10
P 3-00 Reference Range= [0] Min-Max
Resulting reference
2 2
P 3-03
Forward
P 3-02
Sum of all
references
-P 3-02
Reverse
-P 3-03
Illustration 2.23 Reference Range=[0] Min-Max
130BA185.10
The remote reference is calculated once in every scan
interval and initially consists of 2 types of reference
inputs:
• X (the external reference): A sum (see
parameter 3-04 Reference Function) of up to 4
externally selected references. These comprise any
combination (determined by the setting of
parameter 3-15 Reference Resource 1,
parameter 3-16 Reference Resource 2, and
parameter 3-17 Reference Resource 3) of a fixed
preset reference (parameter 3-10 Preset Reference),
variable analog references, variable digital pulse
references, and various fieldbus references in the
unit, which controls the frequency converter ([Hz],
[RPM], [Nm] and so on).
P 3-00 Reference Range =[1]-Max-Max
Resulting reference
P 3-03
Sum of all
references
-P 3-03
Illustration 2.24 Reference Range=[1] -Max-Max
The value of parameter 3-02 Minimum Reference cannot be
set to less than 0, unless parameter 1-00 Configuration
Mode is set to [3] Process. In that case, the following
relations between the resulting reference (after clamping)
and the sum of all references is as shown in
Illustration 2.25.
130BA186.11
Product Overview and Functi...
P 3-00 Reference Range= [0] Min to Max
Resulting reference
P 3-03
P 3-02
Sum of all
references
Illustration 2.25 Sum of all References
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
33
2.6.2 Scaling of Preset References and Bus References
Preset references are scaled according to the following
rules:
• When parameter 3-00 Reference Range is set to [0]
Min-Max : 0% reference equals 0 [unit] where unit
can be any unit, for example RPM, m/s, bar, and
so on. 100% reference equals the maximum (abs
(parameter 3-03 Maximum Reference), abs
(parameter 3-02 Minimum Reference)).
•
When parameter 3-00 Reference Range: [1] -Max to
+Max 0% reference equals 0 [unit] -100%
reference equals -Maximum reference 100%
reference equals maximum reference.
Bus references are scaled according to the following
rules:
• When parameter 3-00 Reference Range: [0] Min to
Max. To obtain maximum resolution on the bus
reference the scaling on the bus is: 0% reference
equals minimum reference and 100% reference
equals maximum reference.
•
When parameter 3-00 Reference Range: [1] -Max to
+Max -100% reference equals maximum reference
100% reference equals max reference.
References and feedback are scaled from analog and pulse
inputs in the same way. The only difference is that a
reference above or below the specified minimum and
maximum endpoints (P1 and P2 in Illustration 2.26) are
clamped whereas a feedback above or below is not.
Resource output
(RPM)
High reference/feedback
value
P2
1500
Resource output
(RPM)
High reference/feedback
value
-10
0
-6
0
-10
-6
P1
Resource
input
8
10
Terminal X
high
-600
P2
1500
Terminal X low
P1
Terminal X low
130BA182.10
2.6.3 Scaling of Analog and Pulse References and Feedback
130BA181.10
2 2
VLT® Decentral Drive FCD 302
Product Overview and Functi...
Resource
input
8
10
Terminal X
high
-600
(V)
Low reference/feedback value
-1500
(V)
Illustration 2.27 Scaling of Reference Output
Low reference/feedback value
The endpoints P1 and P2 are defined by the parameters in
Table 2.9, depending on which analog or pulse input is
used.
-1500
Illustration 2.26 Scaling of Analog and Pulse References and
Feedback
34
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Product Overview and Functi...
Analog 53
S201=OFF
Design Guide
Analog 53
S201=ON
Analog 54
S202=OFF
Analog 54
S202=ON
Pulse input 29
Pulse input 33
P1=(Minimum input value, minimum reference value)
Minimum reference value
Parameter 6-14 Parameter 6-14 T Parameter 6-24 Parameter 6-24 T Parameter 5-52 Parameter 5-57 Term.
Terminal 53
erminal 53 Low
Terminal 54
erminal 54 Low
Term. 29 Low
33 Low Ref./Feedb.
Low Ref./Feedb. Ref./Feedb. Value Low Ref./Feedb. Ref./Feedb. Value Ref./Feedb. Value Value
Value
Value
Minimum input value
Parameter 6-10 Parameter 6-12 T Parameter 6-20 Parameter 6-22 T Parameter 5-50
Terminal 53
erminal 53 Low
Terminal 54
erminal 54 Low
Term. 29 Low
Low Voltage
Current [mA]
Low Voltage
Current [mA]
Frequency [Hz]
[V]
[V]
Parameter 5-55 Term.
33 Low Frequency
[Hz]
P2=(Maximum input value, maximum reference value)
Maximum reference value
Parameter 6-15 Parameter 6-15 T Parameter 6-25 Parameter 6-25 T Parameter 5-53 Parameter 5-58 Term.
Terminal 53
erminal 53 High
Terminal 54
erminal 54 High Term. 29 High
33 High Ref./Feedb.
High Ref./
Ref./Feedb. Value High Ref./
Ref./Feedb. Value Ref./Feedb. Value Value
Feedb. Value
Feedb. Value
Maximum input value
Parameter 6-11 Parameter 6-13 T Parameter 6-21 Parameter 6-23 T Parameter 5-51
Terminal 53
erminal 53 High
Terminal 54
erminal 54 High Term. 29 High
High Voltage
Current [mA]
High
Current[mA]
Frequency [Hz]
[V]
Voltage[V]
Parameter 5-56 Term.
33 High Frequency
[Hz]
2.6.4 Dead Band Around Zero
Quadrant 2
Resource output
Quadrant 1
(RPM)
Sometimes the reference (in rare cases also the feedback)
should have a dead band around zero (that is, to make
sure that the machine is stopped when the reference is
near 0).
To make the dead band active and to set the amount of
dead band, the following settings must be done:
• Either minimum reference value (see Table 2.9 for
relevant parameter) or maximum reference value
must be 0. In other words, either P1 or P2 must
be on the X-axis in Illustration 2.28.
•
High reference/feedback
value
Low reference/feedback
value
-10
-6
And both points defining the scaling graph are in
the same quadrant.
The size of the dead band is defined by either P1 or P2 as
shown in Illustration 2.28.
MG04H302
P2
1500
0
-1
P1
1
Terminal X
low
130BA179.10
Table 2.9 Input and Reference Endpoint Values
Resource
input
6
10 (V)
Terminal X
high
-1500
Quadrant 3
Quadrant 4
Illustration 2.28 Dead Band
Danfoss A/S © 05/2018 All rights reserved.
35
2 2
Quadrant 2
Resource output
(RPM)
2 2
Quadrant 1
1500
High reference/feedback
value
-6
Terminal X
low
If endpoint 2 is placed in either quadrant 1 or quadrant 4,
a reference endpoint of, for example, P1=(1 V, 0 RPM)
results in a -1 V to +1 V dead band.
Low reference/feedback
value
P1
-10
130BA180.10
VLT® Decentral Drive FCD 302
Product Overview and Functi...
Resource
input
P2 0
-1
Terminal X
high
1
6
(V)
10
-1500
Quadrant 3
Quadrant 4
Illustration 2.29 Reverse Dead Band
General reference
parameters:
Reference range: Min - Max
Minimum reference: 0 RPM (0,0%)
Maximum reference: 500 RPM (100,0%)
Ext. Reference
Absolute
0 RPM 1 V
500 RPM 10 V
Analog input 53
Low reference 0 RPM
High reference 500 RPM
Low voltage 1 V
High voltage 10 V
Ext. source 1
Range:
0,0% (0 RPM)
100,0% (500 RPM)
500
+
General motor
parameters:
Motor speed direction: Both directions
Motor speed Low limit: 0 RPM
Motor speed high limit: 200 RPM
Limited to: -200%- +200%
(-1000 RPM- +1000 RPM)
Ext. reference
Range:
0,0% (0 RPM)
100,0% (500 RPM)
Reference
algorithm
Limited to:
0%- +100%
(0 RPM- +500 RPM)
Reference range:
Reference is scaled
according to min max
reference giving a speed
0,0% (0 RPM)
100,0% (500 RPM)
Dead band
RPM
Scale to
speed
1
10
500
RPM
V
1
Speed setpoint
range:
Digital input
130BA187.12
Case 1: Positive reference with dead band, digital input to trigger reverse
This case shows how reference input with limits inside minimum to maximum limits clamps.
Digital input 19
Low No reversing
High Reversing
-500 RPM
+500 RPM
10
V
-500
Limits speed setpoint
according to min max speed
Motor PID
Motor
control
Range:
-200 RPM
+200 RPM
Motor
Illustration 2.30 Example 1 - Positive Reference
36
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Product Overview and Functi...
Design Guide
General reference
parameters:
Reference range: -Max - Max
Minimum reference: Not relevant
Maximum Reference: 500 RPM (100,0%)
Ext. Reference
Absolute
0 RPM 1 V
750 RPM 10 V
Analog input 53
Low reference 0 RPM
High reference 500 RPM
Low voltage 1 V
High voltage 10 V
Ext. source 1
range:
0,0% (0 RPM)
150,0% (750 RPM)
+
General motor
parameters:
Motor speed direction: Both directions
Motor speed Low limit: 0 RPM
Motor speed high limit: 200 RPM
Limited to: -200%- +200%
(-1000 RPM- +1000 RPM)
Ext. reference range:
0,0% (0 RPM)
150,0% (750 RPM)
Reference is scaled
according to max
reference giving a speed
Reference
algorithm
130BA188.13
Case 2: Positive reference with dead band, digital input to trigger reverse. Clamping rules.
This case shows how reference input with limits outside -maximum to +maximum limits clamps to the inputs low and high
limits before addition to external reference. The case also shows how the external reference is clamped to -maximum to
+maximum by the reference algorithm.
Limited to:
-100%- +100%
(-500 RPM- +500 RPM)
Reference range:
0,0% (0 RPM)
100,0% (500 RPM)
Dead band
750
Scale to
speed
1
Digital input
10
500
V
1
Speed
setpoint
range:
-500 RPM
+500 RPM
Digital input 19
Low No reversing
High Reversing
10
V
-500
Limits speed setpoint
according to min max speed
Motor PID
Motor
control
Range:
-200 RPM
+200 RPM
Motor
Illustration 2.31 Example 2 - Positive Reference
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
37
2 2
VLT® Decentral Drive FCD 302
Product Overview and Functi...
General reference
parameters:
Reference range: -Max - +Max
Minimum reference: Not relevant
Maximum reference: 1000 RPM (100,0%)
2 2
Ext. reference
absolute
-500 RPM -10 V
+500 RPM 10 V
Dead band
-1 V to 1 V
Analog input 53
Low reference 0 RPM
High reference +500 RPM
Low voltage 1 V
High voltage 10 V
+
500
Ext. source 1
range:
-50,0% (-500 RPM)
+50,0% (+500 RPM)
-10
RPM
-1
-500
Ext. reference
absolute
-500 RPM -10 V
+500 RPM 10 V
Ext. source 2
range:
-50,0% (-500 RPM)
+50,0% (+500 RPM)
500
Reference
algorithm
Ext. reference
range:
-100,0% (-1000 RPM)
+100,0% (+1000 RPM)
Reference
range:
-100,0% (-1000 RPM)
+100,0% (+1000 RPM)
Limited to:
-200%- +200%
(-2000 RPM+2000 RPM)
V
10
1
Analog input 54
Low reference -500 RPM
High reference +500 RPM
Low voltage -10 V
High voltage +10 V
General motor
parameters:
Motor speed direction: Both directions
Motor speed low limit: 0 RPM
Motor speed high limit: 1500 RPM
Limited to:
-100%- +100%
(-1000 RPM+1000 RPM)
RPM
Scale to
RPM
Reference is scaled
according to max
reference
-10
10
130BA189.13
Case 3: Negative to positive reference with dead band, sign determines the direction, -maximum to +maximum
Speed setpoint
range:
-1000 RPM
+1000 RPM
V
Limits speed to min max
motor speed
-500
No dead
band
Motor PID
Motor
control
Motor
Illustration 2.32 Example 3 - Positive to Negative Reference
2.7 Brake Functions
Brake function is applied for braking the load on the
motor shaft, either as dynamic brake or static braking.
2.7.1 Mechanical Brake
A mechanical holding brake mounted directly on the
motor shaft normally performs static braking. In some
applications (usually synchronous permanent motors), the
static holding torque holds the motor shaft. The holding
brake is either controlled by a PLC, directly by a relay, or a
digital output from the frequency converter.
NOTICE
A frequency converter cannot provide Safe Torque Off
control of a mechanical brake. A redundancy circuitry for
the brake control must be included in the installation.
38
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Design Guide
2.7.1.1 Mechanical Brake Selection Guide
and Electrical Circuit Description
VLT® Decentral Drive FCD 302 can be configured with or
without a brake (see position 18 in Illustration 6.1).
If the inverter part is configured with brake, relay 1 can be
configured for various applications, while relay 2 should be
reserved only for the mechanical brake. Relay 2 is mounted
inside the installation box, but in this configuration state it
is not active.
The mechanical brake coil can be powered by a low
voltage (of 24 V DC) or from mains line AC voltage.
If the mechanical brake is a 24 V DC type, 1 of the 2
custom relays, relay 1, or a functional relay 2, can be used
within the electrical specification (voltage, current, and so
on) or with external relays. If the frequency converter is
configured without brake, the internal electrical control
signal for relay 2 is active.
If the brake is powered by mains supply, or a mains
rectified DC voltage, it is recommended to order the FCD
302 with a mechanical brake. In this case, all the parameter
settings for relay 2 now control the internal solid-state
switch which gives the output voltage at the MBR+ and
MBR- terminals. In some motors, this mechanical brake can
be of AC-type or DC-type. If the unit is AC-type, the
mechanical brake has an internal diode D and the internal
MOV, as described in the electrical diagram in
Illustration 2.33.
2
1
3
130BD547.11
Product Overview and Functi...
I Lm
MBR +
L3
D
MOV
VMBR
V L3-L2
MOV
L
MBR MOV
4
L2
5
6
1
Inverter part
2
MBR+ terminal 122
3
Mechanical brake coil
4
MBR- terminal 123
5
Solid state switch
6
Galvanic isolated control circuit
Illustration 2.33 Electrical Diagram of Mechanical Brake
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
39
2 2
The supply voltage is derived from the mains voltage
between phases L2 and L3, which is passed through a
single pulse diode rectification.
The output voltage of solid-state supply is not a constant
value, but rather a pulsed voltage with an average level
direct dependent on the mains voltage, as shown in
Illustration 2.34:
VMBR
VMBR
Average Output Voltage (Vdc)
260
240
520; 234
220
500; 225
480; 216
200
440;198
180
160
140
120
130BD200.10
VLT® Decentral Drive FCD 302
130BD199.10
2 2
Product Overview and Functi...
400; 180
380; 171
340; 153
320; 144
300; 135
100
300
350
400
450
500
550
Input Mains Line Voltage (Vrms)
Illustration 2.35 Average Output Voltage
It is possible to supply the mechanical brake in the motor
with both DC and AC voltage. The output voltage is
rectified by the internal diode inside the mechanical brake
unit circuit. The average voltage applied to the brake coil
remains at the same value.
VL1-L2
ILm
2.7.1.2 Mechanical Brake Control
VMBR
Mechanical brake voltage
ILm
Instant line voltage
Illustration 2.34 Instant Voltage VMBR with its average level of
VMBR
This rectified voltage is applied to the mechanical brake
inductor, with the smoothed current shape ILm.
The voltage shown in Illustration 2.33 has the amplitude of
the line voltage and an average voltage level calculated as:
VMBR(DC) = 0.45 x VAC
Examples:
VAC = 400 Vrms ⇒ VMBR = 180 VDC.
VAC = 480 Vrms ⇒ VMBR = 216 VDC.
The average level of output voltage is directly determined
by the amplitude of the line voltage measured between
phases L1 and L2.
NOTICE
For hoisting applications, it is necessary to be able to
control an electro-magnetic brake. For controlling the
brake, a relay output (relay 1 or relay 2/solid state brake)
or a programmed digital output (terminal 27 or 29) is
required. Normally, this output must be closed for as long
as the frequency converter is unable to hold the motor, for
example, because of excess load. For applications with an
electro-magnetic brake, select [32] mechanical brake control
in 1 of the following parameters:
•
•
•
Parameter 5-40 Function Relay (Array parameter),
Parameter 5-30 Terminal 27 Digital Output, or
Parameter 5-31 Terminal 29 Digital Output
When [32] mechanical brake control is selected, the
mechanical brake relay stays closed during start until the
output current is above a preset level. Select the preset
level in parameter 2-20 Release Brake Current. During stop,
the mechanical brake closes when the speed is below the
level selected in parameter 2-21 Activate Brake Speed [RPM].
When the frequency converter is brought into an alarm
condition (that is, an overvoltage situation), or during Safe
Torque Off, the mechanical brake immediately cuts in.
Maximum nominal voltage = 480 AC.
40
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Design Guide
130BC970.10
Product Overview and Functi...
Start
term.18
1=on
0=off
Par 1-71
Start delay time
Par 2-21
Activate brake
speed
Shaft speed
Par 1-74
Start speed
Output current
Pre-magnetizing
current or
DC hold current
Par 1-76 Start current/
Par 2-00 DC hold current
Par 2-23
Brake delay time
Par 2-20
Release brake current
Reaction time EMK brake
Relay 01or
Relay 02/solid
state brake
on
off
Mechanical brake
locked
Mechanical brake
free
Time
Illustration 2.36 Mechanical Brake Control for Hoisting Applications
In hoisting/lowering applications, it must be possible to
control an electromechanical brake.
Step-by-step description
• To control the mechanical brake, use any relay
output, digital output (terminal 27 or 29), or
solid-state brake voltage output (terminals 122–
123). Use a suitable contactor when required.
•
Ensure that the output is switched off as long as
the frequency converter is unable to drive the
motor. For example, due to the load being too
heavy, or when the motor is not yet mounted.
•
Select [32] mechanical brake control in parameter
group 5-4* Relays (or in parameter group 5-3*
Digital Outputs) before connecting the mechanical
brake.
•
The brake is released when the motor current
exceeds the preset value in
parameter 2-20 Release Brake Current.
•
The brake is engaged when the output frequency
is lower than a preset limit. Set the limit in
parameter 2-21 Activate Brake Speed [RPM] or
parameter 2-22 Activate Brake Speed [Hz] and only
if the frequency converter carries out a stop
command.
MG04H302
NOTICE
Recommendation: For vertical lifting or hoisting
applications, ensure that the load can be stopped in an
emergency or a malfunction of a single part such as a
contactor.
When the frequency converter enters alarm mode or an
overvoltage situation, the mechanical brake cuts in.
NOTICE
For hoisting applications, make sure that the torque limit
settings do not exceed the current limit. Set torque limits
in parameter 4-16 Torque Limit Motor Mode and
parameter 4-17 Torque Limit Generator Mode. Set current
limit in parameter 4-18 Current Limit.
Recommendation: Set parameter 14-25 Trip Delay at
Torque Limit to [0], parameter 14-26 Trip Delay at Inverter
Fault to [0], and parameter 14-10 Mains Failure to [3]
Coasting.
Danfoss A/S © 05/2018 All rights reserved.
41
2 2
2.7.1.3 Mechanical Brake Cabling
2.7.2.2 Selection of Brake Resistor
EMC (twisted cables/shielding)
To reduce the electrical noise from the wires between the
mechanical brake and the frequency converter, the wires
must be twisted.
For enhanced EMC performance, use a metal shield.
To handle higher demands by generatoric braking, a brake
resistor is necessary. Using a brake resistor ensures that the
energy is absorbed in the brake resistor and not in the
frequency converter. For more information, see the VLT®
Brake Resistor MCE 101 Design Guide.
Twisted-pair cables, containing both the motor and brake
cables, can be used.
If the amount of kinetic energy transferred to the resistor
in each braking period is not known, the average power
can be calculated based on the cycle time and braking
time also called intermittent duty cycle. The resistor
intermittent duty cycle is an indication of the duty cycle at
which the resistor is active. Illustration 2.37 shows a typical
braking cycle.
2.7.1.4 Hoist Mechanical Brake
For an example of advanced mechanical brake control for
hoisting applications, see chapter 4 Application Examples.
2.7.2 Dynamic Brake
Motor suppliers often use S5 when stating the allowed
load, which is an expression of intermittent duty cycle.
Dynamic brake established by:
• Resistor brake: A brake IGBT keeps the
overvoltage under a certain threshold by
directing the brake energy from the motor to the
connected brake resistor (parameter 2-10 Brake
Function = [1] Resistor Brake).
•
•
NOTICE
AC brake: The brake energy is distributed in the
motor by changing the loss conditions in the
motor. The AC brake function cannot be used in
applications with high cycling frequency since
this overheats the motor (parameter 2-10 Brake
Function = [2] AC Brake).
DC brake: An overmodulated DC current added to
the AC current works as an eddy current brake
(parameter 2-02 DC Braking Time ≠ 0 s).
The intermittent duty cycle for the resistor is calculated as
follows:
Duty cycle=tb/T
T=cycle time in s.
tb is the braking time in s (of the cycle time).
Load
Speed
ta
2.7.2.1 Brake Resistors
tc
tb
to
ta
tc
tb
to
ta
T
In certain applications, break down of kinetic energy is
required. In this frequency converter, the energy is not fed
back to the grid. Instead, the kinetic energy must be
transformed to heat, and this is achieved by braking using
a brake resistor.
In applications where the motor is used as a brake, energy
is generated in the motor and sent back into the
frequency converter. If the energy cannot be transported
back to the motor, it increases the voltage in the frequency
converter DC-line. In applications with frequent braking
and/or high inertia loads, this increase may lead to an
overvoltage trip in the frequency converter and finally a
shutdown. Brake resistors are used to dissipate the excess
energy resulting from the regenerative braking. The resistor
is selected in respect to its ohmic value, its power
dissipation rate, and its physical size. Danfoss brake
resistors are available in several types, for internal or
external installation to the frequency converter. Code
numbers can be found in chapter 6.2.1 Ordering Numbers:
Accessories.
42
130BA167.10
2 2
VLT® Decentral Drive FCD 302
Product Overview and Functi...
Time
Illustration 2.37 Dynamic Brake Cycle Time
Cycle time [s]
Braking duty
cycle at
100% torque
Braking duty
cycle at over
torque
(150/160%)
120
Continuous
40%
3x380–480 V
PK37–P3K0
Table 2.10 Braking at High Overload Torque Level
Brake resistors have a duty cycle of 5%, 10%, and 40%. If a
10% duty cycle is applied, the brake resistors are able to
absorb brake power for 10% of the cycle time. The
remaining 90% of the cycle time is used on dissipating
excess heat.
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Product Overview and Functi...
Design Guide
NOTICE
NOTICE
Ensure that the resistor is designed to handle the
required braking time.
Do not touch the brake resistor as it can get very hot
while/after braking. The brake resistor must be placed in
a secure environment to avoid fire risk.
The maximum allowed load on the brake resistor is stated
as a peak power at a given intermittent duty cycle and can
be calculated as:
Rbr Ω =
U 2dc
Ppeak
where
Ppeak=Pmotor x Mbr [%] x ηmotor x ηVLT[W]
The brake resistance depends on the DC-link voltage (Udc).
The brake function is settled in 4 areas of mains.
Size
Brake active
Warning
before cutout
Cutout (trip)
FCD 302
3x380–480 V
778 V
810 V
820 V
For frequency converters equipped with the dynamic brake
option, 1 brake IGBT along with terminals 81 (R-) and 82 (R
+) is included in each inverter module for connecting a
brake resistor(s).
An internal 10 W brake resistor can be mounted in the
installation box (bottom part). This optional resistor is
suitable for applications where braking IGBT is only active
for very short duty cycles, for example to avoid warning
and trip events.
For internal brake resistor use:
Brake resistor 1750 Ω 10 W/ For mounting inside installation
100%
box, below motor terminals.
Table 2.11 Brake Limit Values
Brake resistor 350 Ω 10 W/
100%
NOTICE
Check that the brake resistor can cope with a voltage of
820 V - unless brake resistors are used.
Danfoss recommends that the brake resistance Rrec
guarantees that the frequency converter is able to brake at
the highest brake power (Mbr(%)) of 160%. The formula can
be written as:
Rrec Ω =
2.7.2.3 Brake Resistors 10 W
U 2dc x 100
Pmotor x Mbr ( % ) xηVLT x ηmotor
ηmotor is typically at 0.90
ηVLT is typically at 0.98
Table 2.12 Brake Resistors 10 W
2.7.2.4 Brake Resistor 40%
Placing the brake resistor externally has the advantages of
selecting the resistor based on application need,
dissipating the energy outside of the control panel, and
protecting the frequency converter from overheating if the
brake resistor is overloaded.
Number
For 480 V frequency converters, Rrec at 160% brake power
is written as:
375300
480V : Rrec =
Ω
Pmotor
NOTICE
The resistance in the the brake resistor circuit should not
exceed the limits recommended by Danfoss. If a brake
resistor with a higher ohmic value is selected, the 160%
brake power may not be achieved because there is a risk
that the frequency converter cuts out for safety reasons.
For mounting inside installation
box, below motor terminals.
Function
81 (optional function)
R-
82 (optional function)
R+
Brake resistor terminals
Table 2.13 Brake Resistors 40%
•
The connection cable to the brake resistor must
be shielded/armored. Connect the shield to the
metal cabinet of the frequency converter and to
the metal cabinet of the brake resistor with cable
clamps.
•
Dimension the cross-section of the brake cable to
match the brake torque.
NOTICE
If a short circuit in the brake transistor occurs, power
dissipation in the brake resistor is only prevented by
using a mains switch or contactor to disconnect the
mains for the frequency converter (The contactor can be
controlled by the frequency converter).
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
43
2 2
2 2
Product Overview and Functi...
VLT® Decentral Drive FCD 302
2.7.2.5 Control with Brake Function
The brake is protected against short-circuiting of the brake
resistor, and the brake transistor is monitored to ensure
that short-circuiting of the transistor is detected. A relay/
digital output can be used for protecting the brake resistor
against overloading in connection with a fault in the
frequency converter.
In addition, the brake makes it possible to readout the
momentary power and the mean power for the latest
120 s. The brake can also monitor the energizing power
and make sure that it does not exceed a limit selected in
parameter 2-12 Brake Power Limit (kW). In
parameter 2-13 Brake Power Monitoring, select the function
to carry out when the power transmitted to the brake
resistor exceeds the limit set in parameter 2-12 Brake Power
Limit (kW).
NOTICE
Monitoring the brake power is not a safety function; a
thermal switch is required for that purpose. The brake
resistor circuit is not ground leakage protected.
Overvoltage control (OVC) (exclusive brake resistor) can be
selected as an alternative brake function in
parameter 2-17 Over-voltage Control. This function is active
for all units. The function ensures that a trip can be
avoided if the DC-link voltage increases. This is done by
increasing the output frequency to limit the voltage from
the DC link. It is a very useful function to avoid
unnecessary tripping of the frequency converter, for
example when the ramp-down time is too short. In this
situation, the ramp-down time is extended.
NOTICE
OVC cannot be activated when running a PM motor
(when parameter 1-10 Motor Construction is set to [1] PM
non-salient SPM).
2.7.2.6 Brake Resistor Cabling
For enhanced EMC performance, use a metal shield.
2.8 Safe Torque Off
To run STO, additional wiring for the frequency converter is
required. Refer to VLT® Frequency Converters Safe Torque Off
Operating Guide for further information.
2.9 EMC
2.9.1 General Aspects of EMC Emissions
Burst transient is usually conducted at frequencies in the
range 150 kHz to 30 MHz. Airborne interference from the
frequency converter system in the range 30 MHz to 1 GHz
is generated from the inverter, motor cable, and the motor.
Capacitive currents in the motor cable coupled with a high
dU/dt from the motor voltage generate leakage currents.
The use of a shielded motor cable increases the leakage
current (see Illustration 2.38) because shielded cables have
higher capacitance to ground than unshielded 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 shield (I3), there is
only a small electro-magnetic field (I4) from the shielded
motor cable.
The shield reduces the radiated interference but increases
the low-frequency interference on the mains. Connect the
motor cable shield to the frequency converter and motor
enclosures. Use integrated shield clamps to avoid twisted
shield ends (pigtails). Twisted shield ends increase the
shield impedance at higher frequencies, which reduces the
shield effect and increases the leakage current (I4).
When a shielded cable is used for fieldbus relay, control
cable, signal interface, or brake, ensure that the shield is
mounted on the enclosure at both ends. In some
situations, however, it is necessary to break the shield to
avoid current loops.
EMC (twisted cable/shielding)
To reduce the electrical noise from the wires between the
brake resistor and the frequency converter, the wires must
be twisted.
44
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Design Guide
CS
z
L1
z
L2
V
z
L3
W
z PE
PE
CS
U
I1
I2
I3
CS
1
2
CS
CS
I4
3
1
Ground wire
2
Shield
3
AC mains supply
4
Frequency converter
5
Shielded motor cable
6
Motor
175ZA062.12
Product Overview and Functi...
CS
I4
5
4
6
Illustration 2.38 Example - Leakage Current
Mounting plates, when used, must be constructed of metal
to ensure that the shield currents are conveyed back to the
unit. Ensure good electrical contact from the mounting
plate through the mounting screws to the chassis of the
frequency converter.
When unshielded cables are used, some emission
requirements are not fulfilled. However, the immunity
requirements are observed.
To reduce the interference level from the entire system
(unit+installation), keep motor and brake cables as short as
possible. Avoid placing cables with a sensitive signal level
alongside motor and brake cables. Radio interference
frequency above 50 MHz (airborne) is generated by the
control electronics in particular.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
45
2 2
2 2
VLT® Decentral Drive FCD 302
Product Overview and Functi...
2.9.2 Emission Requirements
According to the EMC product standard for adjustable speed frequency converters EN/IEC 61800-3:2004 the EMC
requirements depend on the intended use of the frequency converter. Four categories are defined in the EMC product
standard. The definitions of the 4 categories together with the requirements for mains supply voltage conducted emissions
are given in Table 2.14.
Conducted emission requirement
according to the limits given in EN
55011
Category
Definition
C1
Frequency converters installed in the 1st environment (home and office) with a
supply voltage less than 1000 V.
Class B
C2
Frequency converters installed in the 1st environment (home and 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.
Class A Group 1
C3
Frequency converters installed in the 2nd environment (industrial) with a supply
voltage lower than 1000 V.
Class A Group 2
C4
Frequency converters installed in the 2nd environment with a supply voltage equal
to or above 1000 V or rated current equal to or above 400 A or intended for use in
complex systems.
No limit line.
An EMC plan should be made.
Table 2.14 Emission Requirements
When the generic emission standards are used, the frequency converters are required to comply with the limits in Table 2.15.
Conducted emission requirement
according to the limits given in EN
55011
Environment
Generic standard
First environment
(home and office)
EN/IEC 61000-6-3 Emission standard for residential, commercial,
and light industrial environments.
Class B
Second environment
(Industrial environment)
EN/IEC 61000-6-4 Emission standard for industrial environments.
Class A Group 1
Table 2.15 Emission Limit Classes
46
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MG04H302
Product Overview and Functi...
Design Guide
2.9.3 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.
To document immunity against burst transient from
electrical phenomena, the following immunity tests have
been made on a system consisting of a frequency
converter (with options if relevant), a shielded control
cable, and a control box with potentiometer, motor cable,
and motor.
:
The tests were performed in accordance with the following
basic standards
•
EN 61000-4-2 (IEC 61000-4-2): Electrostatic
discharges (ESD): Simulation of electrostatic
discharges from human beings.
•
EN 61000-4-3 (IEC 61000-4-3): Incoming electromagnetic field radiation, amplitude modulated
simulation of the effects of radar and radio
communication equipment and mobile communications equipment.
•
EN 61000-4-4 (IEC 61000-4-4): Burst transients:
Simulation of interference brought about by
switching a contactor, relay, or similar devices.
•
EN 61000-4-5 (IEC 61000-4-5): Surge transients:
Simulation of transients brought about for
example, by lightning that strikes near installations.
•
EN 61000-4-6 (IEC 61000-4-6): RF common
mode: Simulation of the effect from radiotransmission equipment joined by connection
cables.
See Table 2.16.
Voltage range: 200–240 V, 380–480 V
Basic standard
Acceptance criterion
Burst
IEC 61000-4-4
B
Surge
IEC 61000-4-5
ESD
IEC
61000-4-2
Radiated electromagnetic
field
IEC 61000-4-3
RF common
mode voltage
IEC 61000-4-6
B
B
A
A
—
—
10 VRMS
2 kV/2 Ω DM
Line
4 kV CM
Motor
4 kV CM
4 kV/2 Ω1)
—
—
10 VRMS
Brake
4 kV CM
4 kV/2
Ω1)
—
—
10 VRMS
Load sharing
4 kV CM
4 kV/2 Ω1)
—
—
10 VRMS
Control wires
2 kV CM
2 kV/2 Ω1)
—
—
10 VRMS
Standard bus
2 kV CM
2 kV/2 Ω1)
—
—
10 VRMS
Relay wires
2 kV CM
2 kV/2 Ω1)
—
—
10 VRMS
Application and fieldbus
options
2 kV CM
2 kV/2 Ω1)
—
—
10 VRMS
LCP cable
2 kV CM
2 kV/2 Ω1)
—
—
10 VRMS
2 V CM
0.5 kV/2 Ω DM
1 kV/12 Ω CM
—
—
10 VRMS
—
—
8 kV AD
6 kV CD
10 V/m
—
External 24 V DC
Enclosure
4kV/12 Ω CM
Table 2.16 EMC Immunity
1) Injection on cable shield
AD: Air Discharge
CD: Contact Discharge
CM: Common Mode
DM: Differential Mode
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
47
2 2
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VLT® Decentral Drive FCD 302
Product Overview and Functi...
2.9.4 EMC
2.9.4.1 EMC-correct Installation
The following is a guideline to good engineering practice
when installing frequency converters. Follow these
guidelines to comply with EN 61800-3 First environment. If
the installation is in EN 61800-3 Second environment, for
example industrial networks, or in an installation with its
own transformer. Deviation from these guidelines is
allowed but not recommended. See also chapter 1.5.1 CE
Labeling, chapter 2.9.1 General Aspects of EMC Emissions,
and chapter 2.9.7 EMC Test Results.
Good engineering practice to ensure EMC-correct
electrical installation:
• Use only braided shielded/armored motor cables
and braided shielded/armored control cables. The
shield should provide a minimum coverage of
80%. The shield material must be metal, not
limited to but typically copper, aluminum, steel,
or lead. There are no special requirements for the
mains cable.
•
48
Installations using rigid metal conduits are not
required to use shielded cable, but the motor
cable must be installed in conduit separate from
the control and mains cables. Full connection of
the conduit from the frequency converter to the
motor is required. The EMC performance of
flexible conduits varies a lot and information from
the manufacturer must be obtained.
•
Connect the shield/armor/conduit to ground at
both ends for motor cables and for control
cables. Sometimes, it is not possible to connect
the shield in both ends. If so, connect the shield
at the frequency converter.
•
Avoid terminating the shield/armor with twisted
ends (pigtails). It increases the high frequency
impedance of the shield, which reduces its
effectiveness at high frequencies. Use low
impedance cable clamps or EMC cable glands
instead.
•
Avoid using unshielded/unarmored motor or
control cables inside cabinets housing the
frequency converter(s), whenever this can be
avoided.
Leave the shield as close to the connectors as possible.
Illustration 2.39 shows an example of an EMC-correct
electrical installation of the VLT® Decentral Drive FCD 302.
The frequency converter is connected to a PLC, which is
installed in a separate cabinet. Other ways of doing the
installation may have just as good an EMC performance,
provided the above guidelines are followed.
If the installation is not carried out according to the
guidelines, and if unshielded cables and control wires are
used, then certain emission requirements are not fulfilled,
although the immunity requirements are fulfilled. See
chapter 2.9.7 EMC Test Results.
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Design Guide
130BC989.10
Product Overview and Functi...
PLC etc.
Output contactor etc.
PLC
Earthing rail
Cable insulation stripped
Min. 16 mm2
Equalizing cable
Control cables
Mains-supply
L1
Min. 200mm
between control cables,
motor cable and
mains cable
Motor cable
L2
L3
PE
Motor, 3 phases and
Reinforced protective earth
Protective earth
Illustration 2.39 EMC-correct Electrical Installation of a Frequency Converter
A minimum distance of 200 mm (7.87 in) is required
between the fieldbus cable and the motor cable and also
between fieldbus cable and the mains cable. If this cannot
be achieved, use the optional PE grounding plug on the
underside of the VLT® Decentral Drive FCD 302.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
49
2 2
130BA175.12
L1
L2
L3
N
PE
F1
91 92 93 95
12
37
L1 L2 L3 PE
U
V W PE
96 97 98 99
18
50
53
55
5 kΩ
Equalizing cable
As the shield of the communication cable needs to be
connected to ground by each drive/device, there is a risk
of having current in the communication cable. This might
lead to communication problems as the equalizing current
can interfere with the communication. To reduce currents
in the shield of the communication cable, always apply a
short grounding cable between units that are connected
to the same communication cable. Danfoss recommend
using minimum 16 mm2 (6 AWG) equalizing cable and
install the equalizing cable parallel with the communication cable.
For good equalizing between VLT® Decentral Drive FCD 302
in a decentral installation, use the external equalizing
terminal from Danfoss (ordering number 130B5833).
54
Transmitter
2.9.4.2 Use of EMC-correct Cables
Danfoss recommends braided shielded/armored cables to
optimize EMC immunity of the control cables and emission
from the motor cables.
M
3
Illustration 2.40 Connection of Mains Diagram
Electrical safety ground connections
To obtain the electrical safety, always connect the safety
ground on the dedicated connections inside the VLT®
Decentral Drive FCD 302 installation box. See
Illustration 2.41.
130BG474.10
2 2
VLT® Decentral Drive FCD 302
Product Overview and Functi...
The ability of a cable to reduce the in- and outgoing
radiation of electric noise depends on the transfer
impedance (ZT). The shield of a cable is normally designed
to reduce the transfer of electric noise; however, a shield
with a lower transfer impedance (ZT) value is more
effective than a shield with a higher transfer impedance
(ZT).
Transfer impedance (ZT) is rarely stated by cable manufacturers but it is often possible to estimate transfer
impedance (ZT) by assessing the physical design of the
cable.
Transfer impedance (ZT) can be assessed based on the
following factors:
• The conductibility of the shield material.
•
The contact resistance between the individual
shield conductors.
•
The shield coverage, that is, the physical area of
the cable covered by the shield - often stated as
a percentage value.
•
Shield type, that is, braided or twisted pattern.
Illustration 2.41 Electrical Safety Ground Connections
50
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
a
104
b
FC
PLC
PE
PE
2
10³
The lower the Z the better the cable shielding performance
c
10²
10¹
d
1
10ˉ¹
e
10ˉ²
f
10ˉ³
0,01
PE <10 mm
PE
0,1
1
10
100 MHz
g
2 2
1
1
Minimum 16 mm2 (6 AWG)
2
Equalizing cable
Illustration 2.43 Shielding of Control Cables
50/60 Hz ground loops
With very long control cables, ground loops may occur. To
eliminate ground loops, connect 1 end of the shield-toground with a 100 nF capacitor (keeping leads short).
PLC
PE
130BB609.12
Transfer impedance, Z
t
mΩ/m
105
130BB922.12
Design Guide
175ZA166.13
Product Overview and Functi...
FC
PE
100nF
<10 mm
Illustration 2.44 Shielding for 50/60 Hz Ground Loops
Aluminum-clad with copper wire
b.
Twisted copper wire or armored steel wire cable
c.
Single-layer braided copper wire with varying percentage
shield coverage. This is the typical reference cable
d.
Double-layer braided copper wire
e.
Twin layer of braided copper wire with a magnetic,
shielded/armored intermediate layer
f.
Cable that runs in copper tube or steel tube
g.
Lead cable with 1.1 mm (0.04 inch) wall thickness
Avoid EMC noise on serial communication
This terminal is connected to ground via an internal RC
link. Use twisted-pair cables to reduce interference
between conductors. The recommended method is shown
in Illustration 2.45.
Illustration 2.42 Transfer Impedance
69
68
61
PE
PE
2.9.4.3 Grounding of Shielded Control
Cables
Correct shielding
The preferred method usually is to secure control cables
and cables with shielding clamps provided at both ends to
ensure best possible high frequency cable contact.
If the ground potential between the frequency converter
and the PLC is different, electric noise may occur that
disturbs the entire system. Solve this problem by fitting an
equalizing cable next to the control cable. Minimum cable
cross-section: 16 mm2 (6 AWG).
MG04H302
FC
FC
69
68
61
PE <10 mm
PE
2
130BB923.12
a.
1
1
Minimum 16 mm2 (6 AWG)
2
Equalizing cable
Illustration 2.45 Shielding for EMC Noise Reduction, Serial
Communication
Danfoss A/S © 05/2018 All rights reserved.
51
VLT® Decentral Drive FCD 302
Product Overview and Functi...
The harmonics do not affect the power consumption
directly but increase the heat losses in the installation
(transformer, cables). Therefore, in plants with a high
percentage of rectifier load, maintain harmonic currents at
a low level to avoid overload of the transformer and high
temperature in the cables.
FC
FC
69
68
68
69
PE
PE
PE <10 mm
PE
175HA034.10
2 2
130BB924.12
Alternatively, the connection to terminal 61 can be
omitted:
1
2
1
Minimum 16 mm2 (6 AWG)
2
Equalizing cable
Illustration 2.47 DC-link Coils
Illustration 2.46 Shielding for EMC Noise Reduction, Serial
Communication, without Terminal 61
2.9.4.4 RFI Switch
Mains supply isolated from ground
When the frequency converter is supplied from an isolated
mains source (IT mains, floating delta, and grounded delta)
or TT/TN-S mains with grounded leg, set the RFI switch to
[Off] via parameter 14-50 RFI Filter on the frequency
converter.
Otherwise, set parameter 14-50 RFI Filter to [On].
For further information, refer to:
•
•
IEC 364-3.
Application note VLT® on IT mains. It is important
to use isolation monitors that are capable for use
together with power electronics (IEC 61557-8).
2.9.5 Mains Supply Interference/Harmonics
NOTICE
Some of the harmonic currents might disturb communication equipment connected to the same transformer or
cause resonance in connection with power factor
correction batteries.
Input current
IRMS
1.0
I1
0.9
I5
0.4
I7
0.2
I11-49
<0.1
Table 2.18 Harmonic Currents Compared to
the RMS Input Current
To ensure low harmonic currents, the frequency converter
is equipped with DC-link coils as standard. DC coils reduce
the total harmonic distortion (THD) to 40%.
A frequency converter takes up a non-sinusoidal current
from mains, which increases the input current IRMS. A nonsinusoidal current is transformed with a Fourier analysis
and split up into sine-wave currents with different
frequencies, that is, different harmonic currents IN with
50 Hz as the basic frequency:
Harmonic currents
Hz
I1
I5
I7
50 Hz
250 Hz
350 Hz
Table 2.17 Harmonic Currents
52
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MG04H302
Design Guide
2.9.5.1 Effect of Harmonics in a Power
Distribution System
In Illustration 2.48, a transformer is connected on the
primary side to a point of common coupling PCC1 on the
medium voltage supply. The transformer has an impedance
Zxfr and feeds a number of loads. The point of common
coupling where all loads are connected together is PCC2.
Each load is connected through cables that have an
impedance Z1, Z2, Z3.
The negative effect of harmonics is twofold
• Harmonic currents contribute to system losses (in
cabling, transformer).
•
Harmonic voltage distortion causes disturbance
to other loads and increase losses in other loads.
130BB541.10
Product Overview and Functi...
Non-linear
Current
System
Impedance
Contribution to
system losses
Voltage
Disturbance to
other users
Illustration 2.49 Negative Effects of Harmonics
2.9.5.2 Harmonic Limitation Standards and
Requirements
The requirements for harmonic limitation can be:
• Application-specific requirements.
•
The application-specific requirements are related to a
specific installation where there are technical reasons for
limiting the harmonics.
Illustration 2.48 Small Distribution System
Harmonic currents drawn by non-linear loads cause
distortion of the voltage because of the voltage drop on
the impedances of the distribution system. Higher
impedances result in higher levels of voltage distortion.
Current distortion relates to apparatus performance and it
relates to the individual load. Voltage distortion relates to
system performance. It is not possible to determine the
voltage distortion in the PCC knowing only the load’s
harmonic performance. To predict the distortion in the
PCC, the configuration of the distribution system and
relevant impedances must be known.
A commonly used term for describing the impedance of a
grid is the short circuit ratio Rsce, defined as the ratio
between the short circuit apparent power of the supply at
the PCC (Ssc) and the rated apparent power of the load
(Sequ).
Sce
Rsce =
Sequ
where S sc =
U2
Z supply
Standards that must be observed.
Example: A 250 kVA transformer with 2 110 kW motors
connected is sufficient if 1 of the motors is connected
directly online and the other is supplied through a
frequency converter. However, the transformer is
undersized if a frequency converter supplies both motors.
Using extra means of harmonic reduction within the installation or selecting low harmonic frequency converter
variants makes it possible for both motors to run with
frequency converters.
There are various harmonic mitigation standards,
regulations, and recommendations. Different standards
apply in different geographical areas and industries. The
following standards are the most common:
•
•
•
•
•
IEC61000-3-2
IEC61000-3-12
IEC61000-3-4
IEEE 519
G5/4
See the VLT® Advanced Harmonic Filter AHF 005 & AHF 010
Design Guide for specific details on each standard.
and Sequ = U × Iequ
2.9.5.3 Harmonic Mitigation
In cases where extra harmonic suppression is required,
Danfoss offers a wide range of mitigation equipment.
These are:
MG04H302
•
•
VLT® 12-pulse frequency converters.
VLT® AHF filters.
Danfoss A/S © 05/2018 All rights reserved.
53
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VLT® Decentral Drive FCD 302
Product Overview and Functi...
•
•
VLT® Low Harmonic Drives.
VLT® Advanced Active Filters.
The selection of the right solution depends on several
factors:
• The grid (background distortion, mains
unbalance, resonance, and type of supply
(transformer/generator))
•
•
Local/national requirements/regulations (IEEE 519,
IEC, G5/4, and so on)
•
Total cost of ownership (initial cost, efficiency,
maintenance, and so on)
Application (load profile, number of loads, and
load size)
2.9.5.4 Harmonic Calculation
Determining the degree of voltage pollution on the grid and needed precaution is done with the Danfoss VLT® Harmonic
Calculation MCT 31 software. The free tool MCT 31 can be downloaded from www.danfoss.com. The software is built with a
focus on user-friendliness and limited to involve only system parameters that are normally accessible.
2.9.6 Residual Current Device
Use RCD relays, multiple protective earthing, or grounding as extra protection to comply with local safety regulations.
If a ground fault appears, a DC content may develop in the faulty current.
If RCD relays are used, local regulations must be observed. Relays must be suitable for protection of 3-phase equipment
with a bridge rectifier and for a brief discharge on power-up using RCDs.
2.9.7 EMC Test Results
The following test results have been obtained using a system with a frequency converter (with options if relevant), a
shielded control cable, a control box with potentiometer, a motor, and motor shielded cable.
RFI filter type
Standards and
requirements
Conducted emission
EN 55011
Class B
Housing, trades,
and light
industries
EN/IEC 61800-3
Category C1
First
environment
Home and
office
Class A Group 1
Radiated emission
Class A Group 2
Class B
Class A Group 1
Industrial
environment
Industrial
environment
Housing, trades,
and light
industries
Industrial
environment
Category C2
Category C3
Category C1
Category C2
First environment Second environment First environment
Home and office
Industrial
Home and office
First
environment
Home and office
H1
FCD 302
0.37–3 kW
(0.5–4 hp)
No
10 m (32.8 ft)
10 m (32.8 ft)
No
Yes
Table 2.19 EMC Test Results (Emission, Immunity)
54
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
System Integration
Design Guide
3 System Integration
3.1.3 Vibration and Shock
3.1 Ambient Conditions
3.1.1 Air Humidity
The frequency converter has been tested according to the
procedure based on the shown standards:
The frequency converter meets the IEC/EN 60068-2-3
standard, EN 50178 section 9.4.2.2 at 50 °C (122 °F).
3.1.2 Aggressive Environments
A frequency converter contains many mechanical and
electronic components. All are to some extent vulnerable
to environmental effects.
NOTICE
The frequency converter should not be installed in
environments with airborne liquids, particles, or gases
capable of affecting and damaging the electronic
components. Failure to take the necessary protective
measures increases the risk of stoppages, thus reducing
the life of the frequency converter.
Degree of protection as per IEC 60529
In environments with high temperatures and humidity,
corrosive gases such as sulphur, nitrogen, and chlorine
compounds cause chemical processes on the frequency
converter components.
Such chemical reactions 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.
The frequency converter complies with requirements that
exist for units mounted on the walls and floors of
production premises, and in panels bolted to walls or
floors.
•
•
IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970
IEC/EN 60068-2-64: Vibration, broad-band random
3.1.4 Acoustic Noise
The acoustic noise from the frequency converter comes
from these sources:
• DC intermediate circuit coils.
•
RFI filter choke.
VLT® Decentral Drive FCD 302 has no significant audible
noise. Refer to chapter 7 Specifications for acoustic noise
data.
3.2 Mounting Positions
The VLT® Decentral Drive FCD 302 consists of 2 parts:
• The installation box
•
The electronic part
Standalone mounting
• The holes on the rear of the installation box are
used to fix mounting brackets.
NOTICE
•
Mounting frequency converters in aggressive
environments increases the risk of stoppages and considerably reduces the life of the frequency converter.
Ensure that the strength of the mounting location
can support the unit weight.
•
Make sure that the proper mounting screws or
bolts are used.
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.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
55
3 3
VLT® Decentral Drive FCD 302
130BB701.10
System Integration
3 3
3.2.1 Mounting Positions for Hygienic
Installation
The VLT® Decentral Drive FCD 302 is designed according to
the EHEDG guidelines, suitable for installation in
environments with high focus on ease of cleaning.
Mount the FCD 302 vertically on a wall or machine frame,
to ensure that liquids drain off the enclosure. Orient the
unit so the cable glands are located at the base.
Use cable glands designed to meet hygienic application
requirements, for example Rittal HD 2410.110/120/130.
Hygienic-purpose cable glands ensure optimal ease of
cleaning the installation.
NOTICE
130BC383.10
Illustration 3.1 FCD 302 Stand-alone Mounted with Mounting
Brackets
Only frequency converters configured as hygienic
enclosure designation, FCD 302 P XXX T4 W69, have the
EHEDG certification.
130BC382.10
Allowed mounting positions
Illustration 3.3 Allowed Mounting Positions for Hygienic
Applications
Illustration 3.2 Allowed Mounting Positions for Standard
Applications
56
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
System Integration
Design Guide
3.3 Electrical Input: Mains-side Dynamics
3.3.1 Connections
3.3.1.1 Cables General
3 3
NOTICE
Cables general
All cabling must comply with national and local
regulations on cable cross-sections and ambient
temperature. Copper (75 °C (175 °F)) conductors are
recommended.
3.3.1.2 Connection to Mains and
Grounding
For installation instructions and location of terminals, refer
to VLT® Decentral Drive FCD 302 Operating Guide.
130BC286.10
Connection of mains
2
1
L1
1 L1
T1 2
L2
3 L2
T2 4
L3
5 L3
T3 6
PE
33 NO
NO 34
L1
91
L2
92
L3
93
12
41 NC
NC 42
27
U
96
V
97
W
98
Illustration 3.6 Motor and Connection of Mains with Service
Switch
For both small and large units, the service switch is
optional. The switch is shown mounted on the motor side.
Alternatively, the switch can be on the mains side, or
omitted.
For the large unit, the circuit breaker is optional. The large
unit can be configured with either service switch or circuit
breaker, not both. Illustration 3.6 is not configurable in
practice, but shows the respective positions of components
only.
1 Looping terminals
2 Circuit breaker
Illustration 3.4 Large Unit only: Circuit Breaker and Mains
Disconnect
Usually, the power cables for mains are unshielded cables.
130BC287.10
3.3.1.3 Relay Connection
1
L1
L2
L3
PE
1
2
3
4
5
6
7
8
L1
91
L2
92
L3
93
12
U
96
V
97
W
98
To set relay output, see parameter group 5-4* Relays.
Number
Description
01-02
Make (normally open)
U
01-03
Break (normally closed)
V
04-05
Make (normally open)
W
04-06
Break (normally closed)
Table 3.1 Relay Settings
27
For location of relay terminals, refer to VLT® Decentral Drive
FCD 302 Operating Guide.
1 Looping terminals
Illustration 3.5 Large Unit only: Service Switch at Mains with
Looping Terminals
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
57
3 3
VLT® Decentral Drive FCD 302
System Integration
3.3.2 Fuses and Circuit Breakers
3.3.2.3 CE Compliance
3.3.2.1 Fuses
Use of fuses or circuit breakers is mandatory to comply
with IEC 60364.
Danfoss recommends fuse size up to gG-25. This fuse size
is suitable for use on a circuit capable of delivering
100000 Arms (symmetrical), 480 V. With the proper fusing,
the frequency converter short-circuit current rating (SCCR)
is 100000 Arms.
Fuses and/or circuit breakers are recommended protection
on the supply side, if a component break-down inside the
frequency converter (first fault) occurs.
NOTICE
Using fuses and/or circuit breakers is mandatory in order
to ensure compliance with IEC 60364 for CE or NEC 2009
for UL.
NOTICE
Personnel and property must be protected against the
consequence of component break-down internally in the
frequency converter.
3.3.2.4 UL Compliance
Fuses or circuit breakers are mandatory to comply with
NEC 2009. To meet UL/cUL requirements, use the pre-fuses
in Table 7.2, and comply with the conditions listed in
chapter 7.2 Electrical Data and Wire Sizes.
The current and voltage ratings are also valid for UL.
3.4 Electrical Output: Motor-side Dynamics
Branch circuit protection
To protect the installation against electrical and fire hazard,
all branch circuits in an installation, switchgear, machines,
and so on, must be protected against short circuit and
overcurrent according to national/international regulations.
NOTICE
NOTICE
To comply with EMC emission specifications, shielded/
armored cables are recommended.
The recommendations given do not cover branch circuit
protection for UL.
Short-circuit protection
Danfoss recommends using the fuses/circuit breakers
mentioned below to protect service personnel and
property in case of component break-down in the
frequency converter.
3.3.2.2 Recommendations
CAUTION
In the event of malfunction, failure to follow the
recommendation may result in personnel risk and
damage to the frequency converter and other
equipment.
The following sections list the recommended rated current.
Danfoss recommends fuse type gG and Danfoss CB
(Danfoss - CTI-25M) circuit breakers. Other types of circuit
breakers may be used if they limit the energy into the
frequency converter to a level equal to or lower than the
Danfoss CB types.
Follow the recommendations for fuses and circuit breakers
to ensure that any damage to the frequency converter is
internal only.
3.4.1 Motor Connection
See chapter 7.3 General Specifications for correct
dimensioning of motor cable cross-section and length.
Shielding of cables
Avoid installation with twisted shield ends (pigtails). They
spoil the shielding effect at higher frequencies. If it is
necessary to break the shield to install a motor isolator or
motor contactor, the shield must be continued at the
lowest possible HF impedance.
Connect the motor cable shield to both the decoupling
plate of the frequency converter and to the metal housing
of the motor.
Make the shield connections with the largest possible
surface area (cable clamp). This is done by using the
supplied installation devices in the frequency converter.
If it is necessary to split the shield to install a motor
isolator or motor relay, the shield must be continued with
the lowest possible HF impedance.
Cable length and cross-section
The frequency converter has been tested with a given
length of cable and a given cross-section of that cable. If
the cross-section is increased, the cable capacitance - and
thus the leakage current - may increase, and the cable
length must be reduced correspondingly. Keep the motor
cable as short as possible to reduce the noise level and
leakage currents.
For further information, see Application Note Fuses and
Circuit Breakers.
58
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Design Guide
All types of 3-phase asynchronous standard motors can be
connected to the frequency converter. Normally, small
motors are star-connected (230/400 V, Y). Large motors are
normally delta-connected (400/690 V, Δ). Refer to the
motor nameplate for correct connection mode and
voltage.
For installation of mains and motor cables, refer to VLT®
Decentral Drive FCD 302 Operating Guide.
Termi 96 97
nal
numb
er
U
98
Motor
U2
V2
W2
Motor
U2
U1
V1
W1
U1
V2
175ZA114.11
System Integration
W2
V1
W1
3 3
FC
FC
96
99
97
98
96
97
98
Illustration 3.7 Star - Delta Grounding Connections
V
W PE1) Motor voltage 0–100% of mains
voltage.
3 wires out of motor.
U1 V1 W1
W2 U2
V2
PE1)
Delta-connected.
6 wires out of motor.
U1 V1 W1 PE1) Star-connected U2, V2, W2.
U2, V2, and W2 to be interconnected
separately.
NOTICE
In motors without phase insulation paper or other
insulation reinforcement suitable for operation with
voltage supply (such as a frequency converter), fit a sinewave filter on the output of the frequency converter.
The VLT® Decentral Drive FCD 302 is also available as a real
NPT version in 2 different variants.
Table 3.2 Motor Connection Terminals
2
1
7
2
6
6
2
2
3
2
2
2
3
2
4
4
130BC981.10
1) Protective earth connection
5
Metric
NPT 1 for USA
NPT 2 for USA
1
Brake M20
1/2” NPT
1/2” NPT
2
8xM16
8xM16
3/8” NPT (except ground plug, which is
M16)
3
2xM20
2xM20
1/2” NPT
4
Mains cables M25
3/4” NPT
3/4” NPT
5
M20
M20
1/2” NPT
6
24 V M20
1/2” NPT
1/2” NPT
7
Motor M25
3/4” NPT
3/4” NPT
Illustration 3.8 Cable Entry Holes - Large Unit
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
59
VLT® Decentral Drive FCD 302
System Integration
3.4.2 Mains Disconnectors
3 3
•
Built-in circuit breaker on the mains side (large
unit only)
Terminal U/T1/96 connected to U-phase.
Terminal V/T2/97 connected to V-phase.
Terminal W/T3/98 connected to W-phase.
Motor
U2
Specify the requirement when ordering.
V2
W2
U1
V1
W1
96
97
98
Motor
U2
V2
W2
U1
V1
W1
96
97
98
130BC986.10
Illustration 3.9 and Illustration 3.10 show examples of
configuration for the large unit.
175HA036.11
•
•
•
The frequency converter is available with optional
• Service switch on mains side or motor side
or
FC
130BC983.10
Illustration 3.9 Location of Service Switch, Mains Side, Large
Unit (IP66/Type 4X indoor)
FC
Illustration 3.11 Motor Connection - Direction of Rotation
Illustration 3.10 Location of Circuit Breaker, Mains Side, Large
Unit
3.4.3 Additional Motor Information
3.4.3.1 Motor Cable
The motor must be connected to terminals U/T1/96, V/
T2/97, W/T3/98. Ground to terminal 99. All types of 3phase asynchronous standard motors can be used with a
frequency converter unit. The factory setting is for
clockwise rotation with the frequency converter output
connected as shown in Table 3.3:
Terminal number
Function
96, 97, 98, 99
Mains U/T1, V/T2, W/T3
Ground
The direction of rotation can be changed by switching 2
phases in the motor cable or by changing the setting of
parameter 4-10 Motor Speed Direction.
Motor rotation check can be performed using
parameter 1-28 Motor Rotation Check and following the
steps shown in the display.
3.4.3.2 Motor Thermal Protection
The electronic thermal relay in the frequency converter has
received UL approval for single motor overload protection,
when parameter 1-90 Motor Thermal Protection is set for
ETR Trip and parameter 1-24 Motor Current is set to the
rated motor current (see motor nameplate).
Table 3.3 Motor Connection - Factory Setting
60
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
System Integration
Design Guide
3.4.3.3 Parallel Connection of Motors
3.4.3.5 Motor Bearing Currents
The frequency converter can control several parallelconnected motors. When using parallel motor connection,
observe the following:
• Recommended to run applications with parallel
motors in U/F mode parameter 1-01 Motor Control
Principle [0]. Set the U/F graph in
parameter 1-55 U/f Characteristic - U and
parameter 1-56 U/f Characteristic - F.
To minimize DE (Drive End) bearing and shaft currents
proper grounding of the frequency converter, motor,
driven machine, and motor to the driven machine is
required.
•
•
3 3
Standard mitigation strategies
1.
Use an insulated bearing.
2.
Apply rigorous installation procedures:
VVC+ mode may be used in some applications.
2a
The total current consumption of the motors
must not exceed the rated output current IINV for
the frequency converter.
Ensure that the motor and load motor
are aligned.
2b
Strictly follow the EMC Installation
guideline.
•
If motor sizes are widely different in winding
resistance, starting problems may occur due to
too low motor voltage at low speed.
2c
Reinforce the PE so the high frequency
impedance is lower in the PE than the
input power leads.
•
The electronic thermal relay (ETR) of the
frequency inverter cannot be used as motor
overload protection for the individual motor.
Provide further motor overload protection with
for example thermistors in each motor winding or
individual thermal relays. Circuit breakers are not
suitable as protection device.
2d
Provide a good high frequency
connection between the motor and the
frequency converter, for instance via a
shielded cable which has a 360°
connection in the motor and the
frequency converter.
2e
Make sure that the impedance from the
frequency converter to the building
ground is lower than the grounding
impedance of the machine. This can be
difficult for pumps.
2f
Make a direct ground connection
between the motor and load motor.
NOTICE
Installations with cables connected in a common joint as
shown in the first example in the picture is only
recommended for short cable lengths.
NOTICE
When motors are connected in parallel,
parameter 1-02 Flux Motor Feedback Source cannot be
used, and parameter 1-01 Motor Control Principle must be
set to Special motor characteristics (U/f).
The total motor cable length specified in chapter 7 Specifications, is valid as long as the parallel cables are kept short
(less than 10 m (32.8 ft) each).
3.4.3.4 Motor Insulation
For motor cable lengths ≤ the maximum cable length
listed in chapter 7.3 General Specifications, the following
motor insulation ratings are recommended because the
peak voltage can be up to twice the DC-link voltage, 2.8
times the mains voltage, due to transmission line effects in
the motor cable. If a motor has lower insulation rating, it is
recommended to use a dU/dt or sine-wave filter.
Nominal mains voltage
Motor insulation
UN≤420 V
Standard ULL=1300 V
420 V<UN≤500 V
Reinforced ULL=1600 V
3.
Lower the IGBT switching frequency.
4.
Modify the inverter waveform, 60° AVM vs.
SFAVM.
5.
Install a shaft grounding system or use an
isolating coupling.
6.
Apply conductive lubrication.
7.
Use minimum speed settings if possible.
8.
Try to ensure that the mains voltage is balanced
to ground. This can be difficult for IT, TT, TN-CS,
or grounded leg systems.
9.
Use a dU/dt or sinus filter.
3.4.4 Extreme Running Conditions
Short circuit (motor phase – phase)
The frequency converter is protected against short circuits
with current measurement in each of the 3 motor phases
or in the DC link. A short circuit between 2 output phases
causes an overcurrent in the inverter. The inverter is turned
off individually when the short-circuit current exceeds the
allowed value (Alarm 16, Trip Lock).
Table 3.4 Mains Voltage and Motor Insulation
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
61
3 3
System Integration
VLT® Decentral Drive FCD 302
To protect the frequency converter 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
frequency converter is fully allowed. No damage to the
frequency converter can occur by switching on the output.
However, fault messages can appear.
Motor-generated overvoltage
The voltage in the DC link is increased when the motor
acts as a generator, in the 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 inertia
moment 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 can cause
higher DC-link voltage.
•
Back EMF from PM motor operation. When
coasted at high RPM, the PM motor back EMF can
potentially exceed the maximum voltage
tolerance of the frequency converter and cause
damage. The frequency converter is designed to
prevent the occurrence of back EMF: The value of
parameter 4-19 Max Output Frequency is automatically limited based on an internal calculation
based on the value of parameter 1-40 Back EMF at
1000 RPM, parameter 1-25 Motor Nominal Speed,
and parameter 1-39 Motor Poles.
When motor overspeed is possible (for example,
due to excessive windmilling effects), then a
brake resistor is recommended.
NOTICE
The frequency converter must be equipped with a break
chopper.
When possible, the control unit may attempt to correct the
ramp (parameter 2-17 Over-voltage Control).
The inverter turns off when a certain voltage level is
reached, to protect the transistors and the DC link
capacitors.
See parameter 2-10 Brake Function and parameter 2-17 Overvoltage Control to select the method used for controlling
the DC-link voltage level.
NOTICE
OVC cannot be activated when running a PM motor, that
is, for parameter 1-10 Motor Construction set to [1] PM
non-salient SPM.
62
Mains drop-out
During mains drop-out, the frequency converter keeps
running until the DC-link voltage drops below the
minimum stop level. The minimum stop level is typically
15% below the lowest rated supply voltage of the
frequency converter. The mains voltage before the dropout, combined with the motor load, determines how long
it takes for the inverter to coast.
Static overload in VVC+ mode
When the frequency converter is overloaded, the controls
reduce the output frequency to reduce the load. Overload
is defined as reaching the torque limit set in
parameter 4-16 Torque Limit Motor Mode/
parameter 4-17 Torque Limit Generator Mode.
For extreme overload, a current acts to ensure the
frequency converter cuts out after approximately 5–
10 seconds.
Operation within the torque limit is limited in time (0–
60 seconds) in parameter 14-25 Trip Delay at Torque Limit.
3.4.4.1 Motor Thermal Protection
To protect the application from serious damage, the
frequency converter offers several dedicated features:
Torque limit
The torque limit feature protects the motor from being
overloaded independent of the speed. Select torque limit
settings in parameter 4-16 Torque Limit Motor Mode and/or
parameter 4-17 Torque Limit Generator Mode. Set the time
to trip for the torque limit warning in parameter 14-25 Trip
Delay at Torque Limit.
Current limit
Set the current limit in parameter 4-18 Current Limit. Set the
time before the current limit warning trips in
parameter 14-24 Trip Delay at Current Limit.
Minimum speed limit
Parameter 4-11 Motor Speed Low Limit [RPM] or
parameter 4-12 Motor Speed Low Limit [Hz] limit the
operating speed range to for instance between 30 and
50/60 Hz. Maximum speed limit: Parameter 4-13 Motor
Speed High Limit [RPM] or parameter 4-19 Max Output
Frequency limit the maximum output speed the frequency
converter can provide.
ETR (electronic thermal relay)
The ETR function measures actual current, speed, and time
to calculate motor temperature and protect the motor
from being overheated (warning or trip). An external
thermistor input is also available. ETR is an electronic
feature that simulates a bimetal relay based on internal
measurements. The characteristic is shown in
Illustration 3.12.
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Design Guide
175ZA052.12
System Integration
t [s]
2000
1000
600
500
400
300
200
fOUT = 1 x f M,N(par. 1-23)
100
60
50
40
30
20
10
fOUT = 2 x f M,N
fOUT = 0.2 x f M,N
1.0 1.2 1.4 1.6 1.8 2.0
IM
IMN(par. 1-24)
Illustration 3.12 ETR Functions
In Illustration 3.12 the X-axis shows the ratio between Imotor
and Imotor 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 overheating even at low speed. The ETR feature
calculates the motor temperature based on actual current
and speed. The calculated temperature is visible as a
readout parameter in parameter 16-18 Motor Thermal in the
frequency converter.
3.5 Final Test and Set-up
The following basic issues need to be considered when
installing a frequency converter to obtain electromagnetic compatibility (EMC).
• Safety grounding: Note that the frequency
converter has a high leakage current and must be
grounded appropriately for safety reasons. Apply
local safety regulations.
•
High frequency grounding: Keep the ground wire
connections as short as possible.
Connect the different ground systems at the lowest
possible conductor impedance. The lowest possible
conductor impedance is obtained by keeping the
conductor as short as possible and by using the greatest
possible surface area.
The metal cabinets of the different devices are mounted
on the cabinet rear plate using the lowest possible HF
impedance. This avoids having different HF voltages for the
individual devices and avoids the risk of radio interference
currents running in connection cables that may be used
between the devices. The radio interference has been
reduced.
To obtain a low HF impedance, use the fastening bolts of
the devices as HF connection to the rear plate. It is
necessary to remove insulating paint or similar from the
fastening points.
3.5.3 Safety Grounding Connection
The frequency converter has a high leakage current and
must be grounded appropriately for safety reasons
according to IEC 61800-5-1.
3.5.1 High-voltage Test
Carry out a high-voltage test by short-circuiting terminals
U, V, W, L1, L2, and L3. Energize maximum 2.15 kV DC for
380–500 V frequency converters for 1 s between this short
circuit and the chassis.
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
frequency converter properly can result in death or
serious injury.
The limits for the high-voltage test are:
• LVD (CE) = 1500 V AC = 2150 V DC
•
3.5.2 Grounding
UL = (2 x 500) + 1000 = 2000 V AC = 2850 V DC
WARNING
•
Ensure the correct grounding of the equipment
by a certified electrical installer.
HIGH LEAKAGE CURRENT
When running high-voltage tests of the entire installation, leakage currents can be high. Failure to follow
recommendations could result in death or serious injury.
•
Interrupt the mains and motor connection if the
leakage currents are too high.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
63
3 3
3.5.4 Final Set-up Check
2.
Follow these steps to check the set-up and ensure that the
frequency converter is running.
Check the motor nameplate data in this
parameter list.
To access this list, press the [Quick Menu] key on
the LCP and select “Q2 Quick Set-up”.
2a
Parameter 1-20 Motor Power [kW].
Parameter 1-21 Motor Power [HP].
NOTICE
2b
Parameter 1-22 Motor Voltage.
The motor is either star- (Y) or delta- connected (Δ). This
information is located on the motor nameplate data.
2c
Parameter 1-23 Motor Frequency.
2d
Parameter 1-24 Motor Current.
2e
Parameter 1-25 Motor Nominal Speed.
Locate the motor nameplate.
Barcode
178uxxxxxxxxxxb011
Type OGDHK231K131402L09R1S11P1A9010H1Bxx
MLT 140-65 Nm nLT 0..370 rpm
INmax 7,2 A t amb 40 °C
2,9 L Optileb GT220
i 8,12
KTY 84-130
P3
fmax 250 Hz
130BD002.10
1.
3.
Select OGD motor data.
3a
155 °C (F)
IP 69K
28 kg
4.
Made in Germany
Illustration 3.13 Location of Motor Nameplate
Type
4a
Parameter 3-02 Minimum Reference.
4b
Parameter 3-03 Maximum Reference.
4c
Parameter 4-11 Motor Speed Low Limit
[RPM] or parameter 4-12 Motor Speed
Low Limit [Hz].
4d
Parameter 4-13 Motor Speed High Limit
[RPM] or parameter 4-14 Motor Speed
High Limit [Hz].
4e
Parameter 3-41 Ramp 1 Ramp up Time.
4f
Parameter 3-42 Ramp 1 Ramp Down
Time.
Barcode
178uxxxxxxxxxxb011
OGDHK214K13140L06XXS31P3A9010H1BXX
M HST/n =280/180..131 Nm
I N/max 5.5/9.0 A
n max =212 rpm
t amb 40 °C
3.1 L Optileb GT220
i 14.13
KTY 84-130
P3
f max
250 Hz
150 °C (F)
IP 69K
Set 1-11 Motor Model to 'Danfoss OGD
LA10'.
Set speed limit and ramp times.
Set up the desired limits for speed and ramp
time:
130BB851.15
3 3
VLT® Decentral Drive FCD 302
System Integration
24 kg
Made in Germany
Illustration 3.14 Nameplate
64
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Application Examples
Design Guide
4 Application Examples
4.2.2 AMA without T27 Connected
The examples in this section are intended as a quick
reference for common applications.
Parameters
130BB930.10
4.1 Overview
FC
Function
Setting
Parameter 1-29 A [1] Enable
utomatic Motor complete
Adaptation
AMA
(AMA)
+24 V
12
Parameter settings are the regional default values
unless otherwise indicated (selected in
parameter 0-03 Regional Settings).
+24 V
13
D IN
18
D IN
19
•
COM
20
Parameters associated with the terminals and
their settings are shown next to the drawings.
D IN
27
D IN
29
•
D IN
32
Where switch settings for analog terminals A53 or
A54 are required, these are also shown.
D IN
33
Parameter 5-12 T [0] No
erminal 27
operation
Digital Input
D IN
37
*=Default value
+10 V
A IN
50
A IN
54
COM
55
A OUT
42
COM
39
NOTICE
A jumper wire may be required between terminal 12 (or
13) and terminal 27 for the frequency converter to
operate when using factory default programming values.
Refer to VLT® Frequency Converters Safe Torque Off
Operating Instructions for further information
4.2 AMA
4.3 Analog Speed Reference
+24 V
12
+24 V
13
D IN
18
D IN
19
COM
20
D IN
27
D IN
29
D IN
32
D IN
D IN
130BB929.10
Parameters
Function
53
Table 4.2 AMA without T27 Connected
4.2.1 AMA with T27 Connected
FC
Setting
4.3.1 Voltage Analog Speed Reference
Parameter 1-29 A [1] Enable
utomatic Motor complete
Adaptation
AMA
(AMA)
Parameters
FC
+10 V
A IN
50
33
Parameter 5-12 T [2]* Coast
erminal 27
inverse
Digital Input
37
*=Default value
A IN
54
Notes/comments: Parameter
group 1-2* Motor Data must be
set according to motor.
COM
55
A OUT
42
COM
39
+10 V
A IN
50
A IN
54
COM
55
A OUT
42
COM
39
53
4 4
Notes/comments: Parameter
group 1-2* Motor Data must be
set according to motor.
e30bb926.11
•
53
U-I
A53
Function
Setting
Parameter 6-10 T 0.07 V*
erminal 53 Low
Voltage
Parameter 6-11 T 10 V*
erminal 53 High
Voltage
+
0 – 10 V
Parameter 6-14 T 0 RPM
erminal 53 Low
Ref./Feedb. Value
Parameter 6-15 T 1500 RPM
erminal 53 High
Ref./Feedb. Value
*=Default value
Notes/comments:
Table 4.1 AMA with T27 Connected
Table 4.3 Voltage Analog Speed Reference
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
65
VLT® Decentral Drive FCD 302
Application Examples
4.3.2 Current Analog Speed Reference
4.3.3 Speed Reference (Using a Manual
Potentiometer)
FC
4 4
+10 V
A IN
50
A IN
54
COM
55
A OUT
42
COM
39
53
U-I
A53
Parameters
Setting
Parameter 6-12 T 4 mA*
erminal 53 Low
Current
FC
Parameter 6-13 T 20 mA*
erminal 53 High
Current
+
-
Function
4 - 20mA
e30bb683.11
e30bb927.11
Parameters
Parameter 6-14 T 0 RPM
erminal 53 Low
Ref./Feedb. Value
Parameter 6-15 T 1500 RPM
erminal 53 High
Ref./Feedb. Value
+10 V
A IN
50
A IN
54
COM
55
A OUT
42
COM
39
53
≈ 5kΩ
Function
Setting
Parameter 6-10 T 0.07 V*
erminal 53 Low
Voltage
Parameter 6-11 T 10 V*
erminal 53 High
Voltage
Parameter 6-14 T 0 RPM
erminal 53 Low
Ref./Feedb. Value
U-I
*=Default value
Parameter 6-15 T 1500 RPM
erminal 53 High
Ref./Feedb. Value
Notes/comments:
*=Default value
A53
Notes/comments:
Table 4.4 Current Analog Speed Reference
Reference
130BB840.12
Table 4.5 Speed Reference (Using a Manual Potentiometer)
Speed
4.3.4 Speed Up/Speed Down
Parameters
Start (18)
Speed up (29)
Speed down (32)
Illustration 4.1 Speed Up/Speed Down
FC
+24 V
12
+24 V
13
D IN
18
D IN
19
COM
20
D IN
27
D IN
29
D IN
32
D IN
33
D IN
37
Setting
Parameter 5-10 T [8] Start*
erminal 18
Digital Input
Parameter 5-12 T [19] Freeze
erminal 27
Reference
Digital Input
e30bb804.12
Freeze ref (27)
Function
Parameter 5-13 T [21] Speed Up
erminal 29
Digital Input
Parameter 5-14 T [22] Speed
erminal 32
Down
Digital Input
*=Default value
Notes/comments:
Table 4.6 Speed Up/Speed Down
66
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Application Examples
Design Guide
4.4.2 Pulse Start/Stop
4.4 Start/Stop Applications
4.4.1 Start/Stop Command with Safe
Torque Off
Parameters
+24 V
13
D IN
18
Parameter 5-10 T [8] Start*
erminal 18
Digital Input
D IN
13
19
COM
20
D IN
27
D IN
29
Parameter 5-12 T [6] Stop
erminal 27
Inverse
Digital Input
D IN
18
D IN
19
COM
20
D IN
27
Parameter 5-12 T [0] No
erminal 27
operation
Digital Input
D IN
32
D IN
33
*=Default value
D IN
29
D IN
37
D IN
32
D IN
33
D IN
37
+10 V
50
A IN
53
A IN
+10
50
54
COM
A IN
53
55
A OUT
A IN
54
42
COM
COM
55
39
A OUT
42
COM
39
Setting
Parameter 5-19 T [1] Safe Stop
erminal 37 Safe Alarm
Stop
*=Default value
Notes/comments:
If parameter 5-12 Terminal 27
Digital Input is set to [0] No
operation, a jumper wire to
terminal 27 is not needed.
Table 4.7 Start/Stop Command with Safe Torque Off
Notes/comments:
If parameter 5-12 Terminal 27
Digital Input is set to [0] No
operation, a jumper wire to
terminal 27 is not needed.
Table 4.8 Pulse Start/Stop
130BB805.12
Speed
4 4
Speed
130BB806.10
+24 V
Function
130BB803.10
12
130BB802.10
+24 V
Setting
Parameter 5-10 T [9] Latched
erminal 18
Start
Digital Input
12
Parameters
FC
Function
FC
+24 V
Start/Stop (18)
Illustration 4.2 Start/Stop Command with Safe Torque Off
Latched Start (18)
Stop Inverse (27)
Illustration 4.3 Pulse Start/Stop
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
67
VLT® Decentral Drive FCD 302
Application Examples
4.4.3 Start/Stop with Reversing and 4
Preset Speeds
4.5 Bus and Relay Connection
4.5.1 External Alarm Reset
Parameters
Function
12
+24 V
13
D IN
18
D IN
19
COM
20
D IN
27
D IN
29
D IN
32
D IN
33
+10 V
A IN
50
A IN
54
COM
55
A OUT
42
COM
39
Parameter 5-10 Ter [8] Start
minal 18 Digital
Input
53
Function
FC
12
+24 V
13
D IN
18
D IN
19
COM
20
*=Default value
D IN
27
Notes/comments:
D IN
29
Parameter 5-12 Ter [0] No
minal 27 Digital
operation
Input
D IN
32
D IN
33
D IN
37
Parameter 5-14 Ter [16] Preset
minal 32 Digital
ref bit 0
Input
+10 V
A IN
50
A IN
54
COM
Parameter 5-15 Ter [17] Preset
minal 33 Digital
ref bit 1
Input
55
A OUT
42
COM
39
53
Parameter 3-10 Pre
set Reference
Preset
Preset
Preset
Preset
ref.
ref.
ref.
ref.
0
1
2
3
25%
50%
75%
100%
Setting
Parameter 5-11 T [1] Reset
erminal 19
Digital Input
+24 V
Parameter 5-11 Ter [10]
minal 19 Digital
Reversing*
Input
130BB934.11
4 4
+24 V
Parameters
Setting
130BB928.11
FC
Table 4.10 External Alarm Reset
*=Default value
Notes/comments:
Table 4.9 Start/Stop with Reversing and 4 Preset Speeds
68
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Application Examples
Design Guide
4.5.2 RS485 Network Connection
4.5.3 Motor Thermistor
130BB685.10
Parameters
FC
12
+24 V
13
D IN
18
D IN
19
COM
20
D IN
27
D IN
29
D IN
32
D IN
33
D IN
37
Setting
Parameter 8-30 P [0] FC*
rotocol
NOTICE
Thermistors must use reinforced or double insulation to
meet insulation requirements.
Parameter 8-31 A 1*
ddress
Parameters
Function
VLT
+24 V
12
*=Default value
+24 V
13
D IN
18
D IN
19
COM
20
D IN
27
Parameter 1-93 T [1] Analog
hermistor Source input 53
D IN
29
D IN
32
*=Default value
Notes/comments:
Select protocol, address, and
baud rate in the above
mentioned parameters.
+10 V
A IN
50
A IN
54
COM
55
D IN
33
A OUT
42
D IN
37
COM
39
+10 V
A IN
50
A IN
54
03
COM
55
A OUT
42
04
COM
39
53
R2
R1
01
02
RS-485
61
68
69
+
U-I
A53
[2] Thermistor
trip
Notes/comments:
If only a warning is desired,
parameter 1-90 Motor Thermal
Protection should be set to [1]
Thermistor warning.
-
Table 4.11 RS485 Network Connection
MG04H302
Parameter 1-90
Motor Thermal
Protection
53
05
06
Setting
Parameter 8-32 B 9600*
aud Rate
130BB686.12
+24 V
Function
Table 4.12 Motor Thermistor
Danfoss A/S © 05/2018 All rights reserved.
69
4 4
VLT® Decentral Drive FCD 302
Application Examples
4.5.4 Using SLC to Set a Relay
*=Default value
Notes/comments:
If the limit in the feedback
monitor is exceeded, warning
90 Feedback Mon. is issued. The
SLC monitors warning 90 and if
the warning becomes true,
relay 1 is triggered.
External equipment may then
indicate that service may be
required. If the feedback error
goes below the limit again
within 5 s, the frequency
converter continues and the
warning disappears. But relay 1
is still triggered until pressing
[Reset] on the LCP.
4 4
12
+24 V
13
D IN
18
D IN
19
COM
20
D IN
27
D IN
29
D IN
32
D IN
33
D IN
37
+10 V
A IN
50
A IN
54
COM
55
A OUT
42
COM
39
53
R1
01
02
03
R2
04
05
06
Function
Setting
Parameter 4-30
Motor Feedback
Loss Function
[1] Warning
Parameter 4-31
Motor Feedback
Speed Error
100 RPM
Parameter 4-32
Motor Feedback
Loss Timeout
5s
Parameter 7-00 S [2] MCB 102
peed PID
Feedback Source
Parameter 17-11
Resolution (PPR)
1024*
Parameter 13-00
SL Controller
Mode
[1] On
Parameter 13-01
Start Event
[19] Warning
Parameter 13-02
Stop Event
[44] Reset key
Parameter 13-10
Comparator
Operand
[21] Warning
no.
Parameter 13-11
Comparator
Operator
[1] ≈*
Table 4.14 Using Smart Logic Controller to Set a Relay
4.6 Brake Application
Parameter 13-12
Comparator
Value
90
Parameter 13-51
SL Controller
Event
[22]
Comparator 0
Parameter 13-52
SL Controller
Action
[32] Set
digital out A
low
Parameter 5-40 F [80] SL digital
unction Relay
output A
4.6.1 Mechanical Brake Control
Parameters
FC
+24 V
12
+24 V
13
D IN
18
D IN
19
COM
20
D IN
27
D IN
29
D IN
32
D IN
33
D IN
37
+10 V
A IN
50
A IN
54
COM
55
A OUT
42
COM
39
53
01
R1
Table 4.13 Using Smart Logic Controller to Set a Relay
02
03
R2
04
130BB841.10
FC
+24 V
130BB839.10
Parameters
Function
Setting
Parameter 5-40 F [32] Mech.
unction Relay
brake ctrl
Parameter 5-10 T [8] Start*
erminal 18
Digital Input
Parameter 5-11 T [11] Start
erminal 19
reversing
Digital Input
Parameter 1-71 S 0.2
tart Delay
Parameter 1-72 S [5] VVC+/
tart Function
FLUX
Clockwise
Parameter 1-76 S Im,n
tart Current
Parameter 2-20 R Application
elease Brake
dependent
Current
Parameter 2-21 A Half of
ctivate Brake
nominal slip
Speed [RPM]
of the motor
05
*=Default value
06
Notes/comments:
Table 4.15 Mechanical Brake Control
70
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Design Guide
130BB842.10
Application Examples
1-76
Current
Speed
1-71
Time
2-21 1-71
2-21
Start (18)
4 4
Start
reversing (19)
Relay output
Open
Closed
Illustration 4.4 Mechanical Brake Control
4.6.2 Hoist Mechanical Brake
The VLT® Decentral Drive FCD 302 features a mechanical brake control designed for hoisting applications. The hoist
mechanical brake is activated via option [6] Hoist Mech. Brake Rel in parameter 1-72 Start Function. The main difference
compared to the regular mechanical brake control, where a relay function monitoring the output current is used, is that the
hoist mechanical brake function has direct control over the brake relay. This means that instead of setting a current for
release of the brake, the torque is applied against the closed brake before release is defined. Because the torque is defined
directly, the set-up is more straightforward for hoisting applications.
Set parameter 2-28 Gain Boost Factor to obtain a quicker control when releasing the brake. The hoist mechanical brake
strategy is based on a 3-step sequence, where motor control and brake release are synchronized to obtain the smoothest
possible brake release.
3-step sequence
1.
Pre-magnetize the motor
To ensure that there is a hold on the motor and to verify that it is mounted correctly, the motor is first premagnetized.
2.
Apply torque against the closed brake
When the load is held by the mechanical brake, its size cannot be determined, only its direction. The moment the
brake opens, the load must be taken over by the motor. To facilitate the takeover, a user-defined torque, set in
parameter 2-26 Torque Ref, is applied in hoisting direction. This is used to restore the speed controller that finally
takes over the load. To reduce wear on the gearbox due to backlash, the torque is acceled.
3.
Release brake
When the torque reaches the value set in parameter 2-26 Torque Ref, the brake is released. The value set in
parameter 2-25 Brake Release Time determines the delay before the load is released. To react as quickly as possible
on the load-step that follows brake release, increase the proportional gain to boost the speed PID control.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
71
4 4
VLT® Decentral Drive FCD 302
130BA642.12
Application Examples
Motor
Speed
Torque Ramp Brake Release
Up Time
Time
p. 2-27
p. 2-25
Ramp 1 Up
P. 3-41
Ramp 1 Down
P. 3-42
Stop Delay Activate Brake Torque Ramp
P. 2-24
Delay
Down Time
P. 2-23
p. 2-29
Torque Ref. p. 2-26
W22
Active
Torque
Ref.
A22
Active
A22
Active
W22
Active
Brake
Relay
Mech Brake
Feedback
High Contact no.1
E.g. DI32 [70] Mech. Brake Feedback
Low
High
Contact no.2
Low OPTIONAL
E.g. DI33 [71] Mech. Brake Feedback
Mech Brake
Position
Open
Closed
Gain Boost. p. 2-28
Gain Boost or
Postion Control
Illustration 4.5 Brake Release Sequence for Hoist Mechanical Brake Control
I) Activate Brake Delay: The frequency converter starts again from the mechanical brake engaged position.
II) Stop delay: When the time between successive starts is shorter than the setting in parameter 2-24 Stop Delay, the frequency
converter starts without applying the mechanical brake (for example, reversing).
Both relays 1 and 2 can be used to control the brake.
72
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Application Examples
Design Guide
4.7.1 Encoder Direction
The purpose of this guideline is to ease the set-up of
encoder connection to the frequency converter. Before
setting up the encoder, the basic settings for a closed-loop
speed control system is shown.
The direction of the encoder is determined by which order
the pulses are entering the frequency converter.
• Clockwise direction means channel A is 90
electrical degrees before channel B.
20
20
20
20
20
20
55
42
130BC995.10
4.7 Encoder
•
Counterclockwise direction means channel B is 90
electrical degrees before A.
The direction is determined by looking into the shaft end.
18
19
27
29
32
33
50
54
4.8 Closed-loop Drive System
12
12
12
12
12
12
55
53
A closed-loop drive system usually comprises elements
such as:
• Motor.
GND
•
•
•
•
•
1
Additional equipment:
-
Gearbox
-
Mechanical Brake
Frequency converter.
Encoder as feedback system.
Brake resistor for dynamic brake.
Transmission.
Load.
Applications demanding mechanical brake control usually
needs a brake resistor.
Illustration 4.6 Encoder Connection to the Frequency
Converter
ON
CW
A
WARNING
ALARM
NS1
NS2
130BA646.10
Bus MS
130BC996.10
B
A
+24V
•
6
B
5
1
CCW
2
3
4
7
A
B
Illustration 4.7 24 V Incremental Encoder with Maximum Cable
Length 5 m (16.4 ft)
Item
Description
1
Encoder
2
Mechanical brake
3
Motor
4
Gearbox
5
Transmission
6
Brake resistor
7
Load
Illustration 4.8 Basic Set-up for Closed-loop Speed Control
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
73
4 4
VLT® Decentral Drive FCD 302
4.9 Smart Logic Control
Smart logic control (SLC) is essentially a sequence of userdefined actions (see parameter 13-52 SL Controller Action
[x]) executed by the SLC when the associated user-defined
event (see parameter 13-51 SL Controller Event [x]) is
evaluated as true by the SLC.
The condition for an event can be a particular status or
that the output from a logic rule or a comparator operand
becomes true. This leads to an associated action as
illustrated in Illustration 4.9.
Running
Warning
Torque limit
Digital input X 30/2
...
Par. 13-52
SL Controller Action
Coast
Start timer
Set Do X low
Select set-up 2
...
State 2
13-51.1
13-52.1
Stop
event P13-02
Stop
event P13-02
State 4
13-51.3
13-52.3
State 3
13-51.2
13-52.2
Stop
event P13-02
Illustration 4.10 Example - Internal Current Control
Comparators
Comparators are used for comparing continuous variables
(that is, output frequency, output current, analog input,
and so forth) to fixed preset values.
Par. 13-43
Logic Rule Operator 2
Par. 13-11
Comparator Operator
130BB672.10
Par. 13-51
SL Controller Event
State 1
13-51.0
13-52.0
130BA062.14
Start
event P13-01
130BB671.13
Par. 13-10
Comparator Operand
=
TRUE longer than.
Par. 13-12
Comparator Value
...
...
...
...
Par. 13-11
Comparator Operator
Illustration 4.11 Comparators
=
TRUE longer than..
...
...
Illustration 4.9 Current Control Status/Event and Action
Events and actions are each numbered and linked together
in pairs (states). This means that when event [0] is fulfilled
(attains the value true), action [0] is executed. After this,
the conditions of event [1] is evaluated and if evaluated
true, action [1] is executed, and so on. Only 1 event is
evaluated at any time. If an event is evaluated as false,
nothing happens (in the SLC) during the current scan
interval and no other events are evaluated. This means
that when the SLC starts, it evaluates event [0] (and only
event [0]) each scan interval. Only when event [0] is
evaluated true, the SLC executes action [0] and starts
evaluating event. It is possible to program from 1 to 20
events and actions.
When the last event/action has been executed, the
sequence starts over again from event [0]/action [0].
Illustration 4.10 shows an example with 3 event/actions.
74
Logic rules
Combine up to 3 boolean inputs (true/false inputs) from
timers, comparators, digital inputs, status bits, and events
using the logical operators AND, OR, and NOT.
Par. 13-40
Logic Rule Boolean 1
Par. 13-42
Logic Rule Boolean 2
Par. 13-41
Logic Rule Operator 1
...
...
Par. 13-43
Logic Rule Operator 2
130BB673.10
4 4
Application Examples
...
...
Par. 13-44
Logic Rule Boolean 3
Illustration 4.12 Logic Rules
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Application Examples
Design Guide
Application example
*=Default value
Notes/comments:
If the limit in the feedback
monitor is exceeded, warning
90 Feedback Mon. is issued. The
SLC monitors warning 90 and if
the warning becomes true,
relay 1 is triggered.
External equipment may then
indicate that service may be
required. If the feedback error
goes below the limit again
within 5 s, the frequency
converter continues and the
warning disappears. But relay 1
is still triggered until pressing
[Reset] on the LCP.
FC
+24 V
12
+24 V
13
D IN
18
D IN
19
COM
20
D IN
27
D IN
29
D IN
32
D IN
33
D IN
37
+10 V
A IN
50
A IN
54
COM
55
A OUT
42
COM
39
53
R1
01
02
03
R2
04
05
06
130BB839.10
Parameters
Function
Setting
Parameter 4-30
Motor Feedback
Loss Function
[1] Warning
Parameter 4-31
Motor Feedback
Speed Error
100 RPM
Parameter 4-32
Motor Feedback
Loss Timeout
5s
Parameter 7-00 S [2] MCB 102
peed PID
Feedback Source
Parameter 17-11
Resolution (PPR)
1024*
Parameter 13-00
SL Controller
Mode
[1] On
Parameter 13-01
Start Event
[19] Warning
Parameter 13-02
Stop Event
[44] Reset key
Parameter 13-10
Comparator
Operand
[21] Warning
no.
Parameter 13-11
Comparator
Operator
[1] ≈*
Parameter 13-12
Comparator
Value
90
Parameter 13-51
SL Controller
Event
[22]
Comparator 0
Parameter 13-52
SL Controller
Action
[32] Set
digital out A
low
Table 4.17 Using SLC to Set a Relay
Parameter 5-40 F [80] SL digital
unction Relay
output A
Table 4.16 Using SLC to Set a Relay
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
75
4 4
5 Special Conditions
Under some special conditions, where the operation of the
frequency converter is challenged, consider derating. In
some conditions, derating must be done manually.
In other conditions, the frequency converter automatically
performs a degree of derating when necessary. This is
done to ensure the performance at critical stages where
the alternative could be a trip.
5.1 Manual Derating
Manual derating must be considered for:
• Air pressure – relevant for installation at altitudes
above 1000 m (3280 ft)
•
Motor speed – at continuous operation at low
RPM in constant torque applications
•
Ambient temperature – relevant for ambient
temperatures above 40 °C (104 °F)
Contact Danfoss for the application note for tables and
elaboration. Only the case of running at low motor speeds
is elaborated here.
5.1.1 Derating for Low Air Pressure
The cooling capability of air is decreased at lower air
pressure.
Below 1000 m (3280 ft) altitude no derating is necessary.
But above 1000 m (3280 ft) the ambient temperature
(TAMB) or maximum output current (Iout) should be derated
in accordance with the diagram in Illustration 5.1.
D T AMB, MAX (K)
at 100% Iout
FCD
enclosure
Max.Iout (%)
at TAMB, MAX
100%
0K
91%
-5 K
82%
-9 K
1000
3280
2000
6561
3000
9842
An alternative is to lower the ambient temperature at high
altitudes and by that ensuring 100% output current at high
altitudes. As an example of how to read the graph, the
situation at 2000 m (6561 ft) is elaborated for a 3 kW
(4 hp) frequency converter with TAMB, MAX = 40 °C (104 °F).
At a temperature of 36 °C (96.8 °F) (TAMB, MAX - 3.3 K), 91%
of the rated output current is available. At a temperature
of 41.7 °C (107 °F), 100% of the rated output current is
available.
5.1.2 Derating for Running at Low Speed
When a motor is connected to a frequency converter, it is
necessary to check that the cooling of the motor is
adequate.
The level of heating depends on the load on the motor,
and the operating speed and time.
130BD549.11
5 5
VLT® Decentral Drive FCD 302
Special Conditions
Constant torque applications (CT mode)
A problem may occur at low RPM values in constant
torque applications. In a constant torque application, a
motor may overheat at low speed due to less cooling air
from the motor integral fan.
Therefore, if the motor is to be run continuously at an RPM
value lower than half of the rated value, the motor must
be supplied with extra air-cooling (or a motor designed for
this type of operation may be used).
An alternative is to reduce the load level of the motor by
selecting a larger motor. However, the design of the
frequency converter puts a limit to the motor size.
Variable (quadratic) torque applications (VT)
In VT applications such as centrifugal pumps and fans,
where the torque is proportional to the square of the
speed and the power is proportional to the cube of the
speed, there is no need for extra cooling or derating of the
motor.
Altitude (m)
Altitude (ft)
Illustration 5.1 Derating of output current versus altitude at
TAMB, MAX for VLT® Decentral Drive FCD 302. At altitudes above
2000 m (6561 ft), contact Danfoss regarding PELV.
76
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Special Conditions
Design Guide
5.1.3 Ambient Temperature
5.1.3.2 Power Size 1.1–1.5 kW
Graphs are presented individually for 60° AVM and SFAVM.
60° AVM only switches 2/3 of the time whereas SFAVM
switches throughout the whole period. The maximum
switching frequency is 16 kHz for 60° AVM and 10 kHz for
SFAVM. The discrete switching frequencies are presented in
Table 5.1.
60° AVM - Pulse width modulation
130BD208.10
I out (%)
110%
100%
80%
40 0 C
45 0 C
50 0 C
60%
Switchin
g
pattern
Discrete switching frequencies
40%
60° AVM
2 2.5
3
3.
5
4
5
6
7
8
10 12 14 16
SFAVM
2 2.5
3
3.
5
4
5
6
7
8
10
0
–
–
–
5 5
20%
0
2
4
6
8
10
12
14
16
fsw
(kHz)
Illustration 5.4 Derating of Iout for different TAMB, MAX for FCD
302 1.1–1.5 kW, using 60° AVM
Table 5.1 Discrete Switching Frequencies
5.1.3.1 Power Size 0.37–0.75 kW
SFAVM - Stator frequency asynchron vector modulation
60° AVM - Pulse width modulation
130BD210.10
I out (%)
110%
100%
80%
40 0 C
45 0 C
50 0 C
60%
110%
100%
80%
40 0 C
45 0 C
50 0 C
60%
40%
20%
40%
0
20%
0
130BD209.10
I out (%)
0
2
4
6
8
10
12
14
16
fsw
(kHz)
0
2
4
6
8
10
12
14
16
fsw
(kHz)
Illustration 5.5 Derating of Iout for different TAMB, MAX for FCD
302 1.1–1.5 kW, using SFAVM
Illustration 5.2 Derating of Iout for different TAMB, MAX for FCD
302 0.37–0.55–0.75 kW, using 60° AVM
SFAVM - Stator frequency asynchron vector modulation
130BD211.10
I out (%)
110%
100%
80%
40 0 C
45 0 C
50 0 C
60%
40%
20%
0
0
2
4
6
8
10
12
14
16
fsw
(kHz)
Illustration 5.3 Derating of Iout for different TAMB, MAX for FCD
302 0.37–0.55–0.75 kW, using SFAVM
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
77
VLT® Decentral Drive FCD 302
Special Conditions
5.1.3.3 Power Size 2.2–3.0 kW
SFAVM - Stator frequency asynchron vector modulation
60° AVM - Pulse width modulation
130BD206.10
I out (%)
110%
100%
80%
40 0 C
45 0 C
50 0 C
60%
80%
40 0 C
45 0 C
50 0 C
60%
40%
0
20%
0
110%
100%
20%
40%
5 5
130BD207.10
I out (%)
0
2
4
6
8
10
12
14
16
fsw
(kHz)
0
2
4
6
8
10
12
14
16
fsw
(kHz)
Illustration 5.7 Derating of Iout for different TAMB, MAX for FCD
302 2.2–3.0 kW, using SFAVM
Illustration 5.6 Derating of Iout for different TAMB, MAX for FCD
302 2.2–3.0 kW, using 60° AVM
5.2 Automatic Derating
The frequency converter constantly checks for critical levels:
• Critical high temperature on the control card or heat sink
•
•
•
High motor load
High DC-link voltage
Low motor speed
As a response to a critical level, the frequency converter adjusts the switching frequency. For critical high internal temperatures and low motor speed, the frequency converter can also force the PWM pattern to SFAVM.
NOTICE
The automatic derating is different when parameter 14-55 Output Filter is set to [2] Sine-Wave Filter Fixed.
The automatic derating is made up of contributions from separate functions that evaluate the need. Their interrelationship is
illustrated in Illustration 5.9.
78
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Special Conditions
Design Guide
NOTICE
CTRL/
Modulation
Limit
fSW
(load)
fSW, ref
fSW
( fm )
fSW
(UDC)
fSW (T)
130BD550.10
In sine-wave filter fixed mode, the structure is different. See chapter 5.2.1 Sine-Wave Filter Fixed Mode.
Ramp
fSW, ref
fSW, ref
Protection
flag
PWM
PWM (T)
fSW Setting
from LCP
PWM (f )
fs w (I load)
CTRL/
modulation
limit
fs w(fm)
fs w(UDC)
fsw
fskH
[ ]
w z
fsw
16 kHz @ 60PWM
10 kHz @ SFAVM
Requested f
10 kHz @ 60PWM
7 kHz @ SFAVM
f s w, ref
70%
160%
Im
fs w, I
UDC,TRIP
UDC, START DERATING
f s w, UDC
UDC
s f
,1
wm
f
fs w (T)
TAMB
SF AV
M only
sw
High warning
Low warning
f
fsm
,4
w
f s w, fs
sf sf
wm wm
f , 2,f , 3
3.9 4
9.9
130BB971.10
Illustration 5.8 Automatic Derating Function Block
1
0
fs w, TAS
fsw
1 fm otH
[ ]
5 or z
f s w, DSP
τ2
τ1
fs w setting
from LCP
Ramp
Protection flag
(drop to fs w,min
immediately)
PWM
PWM(T)
TAMB
TPWM SWITCH
60PWM
SFAVM
PWM(fs )
PWM
fs
SFAVM
optional
60PWM
fmotor[Hz]
10Hz-15Hz
80%-86% of
fmotor,nom
Illustration 5.9 Interrelationship Between the Automatic Derating Contributions
The switching frequency is first derated due to motor current, followed by DC-link voltage, motor frequency, and then
temperature. If multiple deratings occur on the same iteration, the resulting switching frequency would be the same as
though only the most significant derating occurred by itself (the deratings are not cumulative). Each of these functions is
presented in the following sections.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
79
5 5
VLT® Decentral Drive FCD 302
Special Conditions
5.2.1 Sine-Wave Filter Fixed Mode
130BB972.11
If the frequency converter is running with a fixed frequency sine-wave filter, the switching frequency is not derated due to
motor current or DC-link voltage. The switching frequency is still derated due to motor frequency and temperature; however
the order of these 2 operations is reversed. It should be noted that, in this situation, the function for derating based on
motor frequency does nothing unless the frequency converter’s LC_Low_Speed_Derate_Enable PUD parameter is set to true.
Also, the function for derating due to temperature is slightly different. In sine filter fixed mode, a different protection mode
switching frequency is sent to the DSP.
1[ms] task time of microcontroller
5 5
1[ms] DSP task
fm limit
Fsw, DSP
fsw, fm
Ramp
fsw, TAS
TAS limit
fsw, ref
Control /
Modulation
limit
Protection flag
( drop to fswmin
immediately )
Fsw, LCP
LCP
setting
fsw, max
SFAVM or 60 PWM
fsw, min
Illustration 5.10 The Switching Frequency Limiting Algorithm when the Frequency Converter is Operating with a Fixed Frequency
Sine-wave Filter
80
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Special Conditions
Design Guide
5.2.2 Overview Table
PWM - Functions that adjust the switching
pattern
Iload ↑
No automatic derating
fsw – Functions that derate the switching frequency
130BB973.10
Background for derating
fsw
16 kHz @ 60 PWM
10 kHz @ SFAVM
10 kHz @ 60 PWM
7 kHz @ SFAVM
70%
No automatic derating
fsw
Requested f
sw
PWM
optional
60 PWM
fsw [kHz]
SFAVM only
fsw,fm4
fmotor [Hz]
10Hz-15Hz 80%-86% of
fmotor,nom
f sw,fm2, f sw,fm3
f sw,fm1
3.9
130BC142.10
T↑
TAMB
TPWM SWITCH
4
9.9
10
15
130BB976.10
SFAVM
UDC
130BB975.10
130BC143.10
UDC,TRIP
UDC, START DERATING
fs
5 5
130BB974.10
Udc ↑
Im
160 %
TAMB
High warning
Low warning
fsw
60 PWM
SFAVM
τ1
τ2
Table 5.2 Overview - Derating
5.2.3 High Motor Load
The switching frequency is automatically adjusted
according to the motor current.
When a certain percentage of the nominal HO motor load
is reached, the switching frequency is derated. This
percentage is individual for each enclosure size and a value
that is coded in the EEPROM along with the other points
that limit the derating.
130BB977.10
fsw [kHz]
In EEPROM, the limits depend on the modulation mode. In
60° AVM, f1 and f2 are higher than for SFAVM. I1 and I2 are
independent of modulation mode.
f1
f2
I1
I2 Iout [%]
Illustration 5.11 Derating of Switching Frequency According to
Motor Load. f1, f2, I1, and I2 are Coded in EEPROM.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
81
VLT® Decentral Drive FCD 302
5.2.4 High Voltage on the DC link
The switching frequency is automatically adjusted
according to the voltage on the DC link.
When the DC link reaches a certain magnitude, the
switching frequency is derated. The points that limit the
derating are individual for each enclosure size and are
coded in the EEPROM.
f1
5 5
fsw [kHz]
130BB978.10
fsw [kHz]
frequency can be reduced to lower the peak temperature
and thereby the temperature variations.
For VT-applications, the load current is relatively small for
small stator frequencies and the temperature variations are
thus not as large as for the CT-applications. For this reason,
also the load current is considered.
SFAVM only
fsw,fm4
U2 Udc [V]
Illustration 5.12 Derating of Switching Frequency According to
Voltage on the DC link. f1, f2, U1, and U2 are Coded in
EEPROM.
In EEPROM the limits depend on the modulation mode. In
60° AVM, f1 and f2 are higher than for SFAVM. U1 and U2
are independent of the modulation mode.
optional
60PWM
130BB979.10
The option of PWM strategy depends on the stator
frequency. To prevent that the same IGBT is conducting for
too long (thermal consideration), fm, switch1 is specified as
the minimum stator frequency for 60° PWM, whereas fm,
switch2 is specified as the maximum stator frequency for
SFAVM to protect the frequency converter. 60° PWM helps
to reduce the inverter loss above fm, switch1 as the switch
loss is reduced by 1/3 by changing from SFAVM to
60° AVM.
SFAVM
KIs 1*Inom,ho <= I s < KIs2*Inom,ho
I s >= KIs2*I nom,ho
f sw,fm1
fm1 fm2
fm3
fm4
fm5 (fm, switch 1)
fm [HZ]
Illustration 5.14 Switching Frequency (fsw) Variation for
Different Stator Frequencies (fm)
The points that limit the derating are individual for each
enclosure size and are coded in the EEPROM.
NOTICE
5.2.5 Low Motor Speed
PWM
I s < KIs1*Inom,ho
f sw,fm3
f sw,fm2,
f2
U1
130BB980.10
Special Conditions
The VLT® Decentral Drive FCD 302 never derates the
current automatically. Automatic derating refers to
adaptation of the switching frequency and pattern.
For VT-applications, the load current is considered before
derating the switching frequency at low motor speed.
5.2.6 High Internal
The switching frequency is derated based on both control
card- and heat sink temperature. This function may
sometimes be referred to as the temperature adaptive
switching frequency function (TAS).
fm[Hz]
fm,switch1
fm,switch2
Illustration 5.13 Reducing Inverter Loss
The shape of the average temperature is constant
regardless of the stator frequency. The peak temperature,
however, follows the shape of the output power for small
stator frequencies and goes towards the average
temperature for increasing stator frequency. This results in
higher temperature variations for small stator frequencies.
This means that the expected lifetime of the component
decreases for small stator frequencies if no compensation
is used. Therefore, for low values of the stator frequency
where the temperature variations are large, the switching
82
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Special Conditions
Design Guide
NOTICE
5.3 Derating for Running at Low Speed
T [ºC]
TasTRefHigh
TasTRefNormal
TasTHys
Δt
Δt
fsw [kHz]
fswMax
fswMin
Δt
PWM
60 PWM
Time
Illustration 5.15 Switching Frequency Derating due to High
Temperature
NOTICE
dt is 10 s when the control card is too hot but 0 s when
the heat sink is too hot (more critical).
The high warning can only be violated for a certain time
before the frequency converter trips.
When a motor is connected to a frequency converter, it is
necessary to check that the cooling of the motor is
adequate.
The level of heating depends on the load on the motor,
the operating speed, and time.
Constant torque applications (CT mode)
A problem may occur at low RPM values in constant
torque applications. In constant torque applications, a
motor may overheat at low speeds due to less cooling air
from the motor integral fan. Therefore, if the motor is to
be run continuously at an RPM value lower than half of the
rated value, the motor must be supplied with extra aircooling (or a motor designed for this type of operation
may be used). An alternative is to reduce the load level of
the motor by selecting a larger motor. However, the design
of the frequency converter puts a limit to the motor size.
Variable (quadratic) torque applications (VT)
In VT applications such as centrifugal pumps and fans, the
torque is proportional to the square of the speed and the
power is proportional to the cube of the speed. In these
applications, there is no need for extra cooling or derating
of the motor. In Illustration 5.16, the typical VT curve is
below the maximum torque with derating and maximum
torque with forced cooling at all speeds.
120
100
5.2.7 Current
1)
130BA893.10
130BB981.10
Illustration 5.15 shows 1 temperature affecting the
derating. In fact there are 2 limiting temperatures:
Control card temperature and heat sink temperature.
Both have their own set of control temperatures.
The final derating function is a derating of the output
current due to high temperatures. This calculation takes
place after the calculations for derating the switching
frequency. This results in an attempt to lower the temperatures by first lowering the switching frequency, and then
lowering the output current. Current derating is only
performed if the unit is programmed to derate in overtemperature situations. If the user has selected a trip function
for overtemperature situations, the current derate factor is
not lowered.
T%
80
60
40
20
0
0
10
20
30
40
50
v%
60
70
80
Item
Description
‒‒‒‒‒‒‒‒
Maximum torque
────
Typical torque at VT load
90
100 110
Illustration 5.16 VT Applications - Maximum Load for a
Standard Motor at 40 °C (104 °F)
NOTICE
Oversynchronous speed operation results in decrease of
the available motor torque, inversely proportional to the
increase in speed. Consider this during the design phase
to avoid motor overload.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
83
5 5
VLT® Decentral Drive FCD 302
Type Code and Selection Gui...
6 Type Code and Selection Guide
Position
1 2 3 4 5 6 7
F C D 3 0 2 P
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 39 39
T 4
H 1
X A
B
X X X X X D
Position
Description
Choices/options
01–03
Product group
FCD
Decentral Drive
04–06
Frequency converter series
302
Advanced performance
PK37
0.37 kW/0.5 hp
PK55
0.55 kW/0.75 hp
PK75
0.75 kW/1.0 hp
P1K1
1.1 kW/1.5 hp
P1K5
1.5 kW/2.0 hp
P2K2
2.2 kW/3.0 hp
P3K0
3.0 kW/4.0 hp (large unit only)
6 6
07–10
11–12
13–15
16–17
18
19
20
21
22
23
24
84
Power size
Phases, mains voltage
Enclosure
RFI filter
Brake
Hardware configuration
Brackets
Threads
Switch option
Display
Sensor plugs
PXXX
Installation box only (without power section)
T
3-phase
4
380–480 V AC
B66
Standard Black IP66/Type 4X
W66
Standard White IP66/Type 4X
W69
Hygienic White IP66K/Type 4X
H1
RFI filter class A1/C2
X
No brake
S
Brake chopper + mechanical brake supply
1
Complete product, small unit, standalone mount
3
Complete product, large unit, standalone mount
X
Drive part, small unit (no installation box)
Y
Drive part, large unit (no installation box)
R
Installation box, small unit, standalone mount (no drive part)
T
Installation box, large unit, standalone mount (no drive part)
X
No brackets
E
Flat brackets
F
40 mm brackets
X
No installation box
M
Metric threads
X
No switch option
E
Service switch on mains input
F
Service switch on motor output
L
Circuit breaker & mains disconnect, looping terminals (large unit only)
K
Service switch on mains input with extra looping terminals (large unit only)
X
No display connector (No installation box)
C
With display connector
X
No sensor plugs
E
Direct mount 4xM12: 4 digital inputs
F
Direct mount 6xM12: 4 digital inputs, 2 relay outputs
Danfoss A/S © 05/2018 All rights reserved.
130BB797.10
6.1 Type Code Description
MG04H302
Type Code and Selection Gui...
Design Guide
Position
Description
Choices/options
25
Motor plug
X
No motor plug
26
Mains plug
X
No mains plug
X
No fieldbus plug
E
M12 Ethernet
P
M12 PROFIBUS
X
For future use
27
28
29–30
31–32
Fieldbus plug
Reserved
A option
B option
33–37
Reserved
38–39
D option
AX
No A option
A0
PROFIBUS DP
AN
EtherNet/IP
AL
PROFINET
BX
No B option
BR
Encoder option
BU
Resolver option
BZ
Safety PLC Interface
XXXXX
For future use
DX
No D option
D0
24 V DC back-up input
6 6
Illustration 6.1 Type Code Description
Not all choices/options are available for each VLT® Decentral Drive FCD 302 variant. To verify if the appropriate version is
available, consult the Drive Configurator on the Internet: vltconfig.danfoss.com/ .
NOTICE
A and D options for FCD 302 are integrated into the control card. Do not use pluggable options for frequency
converters. Future retrofit requires exchange of the entire control card. B options are pluggable, using the same concept
as for frequency converters.
6.2 Ordering Numbers
6.2.1 Ordering Numbers: Accessories
Accessories
Description
Ordering number
Mounting brackets extended
40 mm brackets
130B5771
Mounting brackets
Flat brackets
130B5772
LCP cable
Preconfectioned cable to be used between inverter and LCP
130B5776
Brake resistor 1750 Ω 10 W/100%
For mounting inside installation box below motor terminals
130B5778
Brake resistor 350 Ω 10 W/100%
For mounting inside installation box below motor terminals
130B5780
VLT® Control Panel LCP 102
Graphical LCP for programming and readout
130B1078
Venting membrane, goretex
Preventing condensation inside enclosure
175N2116
Stainless chassis kit, M16
Stainless Steel
130B5833
Table 6.1 Ordering Numbers: Accessories
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
85
6 6
VLT® Decentral Drive FCD 302
Type Code and Selection Gui...
6.2.2 Ordering Numbers: Spare Parts
Spare parts
Description
Ordering number
Protection cover
Plastic protection cover for inverter part
130B5770
Gasket
Gasket between installation box and inverter part
130B5773
Accessory bag
Spare cable clamps and screws for shield termination
130B5774
Service switch
Spare switch for mains or motor disconnect
130B5775
LCP plug
Spare plug for mounting in installation box
130B5777
Main termination board
For mounting in installation box
130B5779
M12 sensor plugs
Set of two M12 sensor plugs for mounting in cable gland hole
130B5411
Control card
Control card with 24 V back-up
130B5783
Control card PROFIBUS
Control card PROFIBUS with 24 V back-up
130B5781
Control card Ethernet
Control card Ethernet with 24 V back-up
130B5788
Control card PROFINET
Control card PROFINET with 24 V back-up
130B5794
Table 6.2 Ordering Numbers: Spare Parts
The packaging contains:
• Accessories bag, supplied only with order of
installation box. Contents:
•
-
2 cable clamps
-
Bracket for motor/loads cables
-
Elevation bracket for cable clamp
-
Screw 4 mm x 20 mm
-
Thread forming 3.5 mm x 8 mm
Documentation
Depending on options fitted, the box contains 1 or 2 bags
and 1 or more booklets.
86
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Type Code and Selection Gui...
Design Guide
•
•
6.3 Options and Accessories
Danfoss offers a wide range of options and accessories for
the frequency converter.
•
•
Select the fieldbus option when ordering the frequency
converter. All fieldbus options are included on the control
card. No separate A option is available.
To change the fieldbus option later, change out the control
card. The following control cards with different fieldbus
options are available. All control cards have 24 V back-up
as standard.
Ordering number
Control card PROFIBUS
130B5781
Control card Ethernet
130B5788
Control card PROFINET
130B5794
Permanent magnet motor.
Supported encoder types:
• Incremental encoder: 5 V TTL type, RS422,
maximum frequency: 410 kHz
6.3.1 Fieldbus Options
Item
Flux vector torque control.
Incremental encoder: 1Vpp, sine-cosine
Hiperface® Encoder: Absolute and Sine-Cosine
(Stegmann/SICK)
•
EnDat encoder: Absolute and Sine-Cosine
(Heidenhain) Supports version 2.1
•
•
SSI encoder: Absolute
Encoder monitor: The 4 encoder channels (A, B, Z,
and D) are monitored, open, and short circuit can
be detected. There is a green LED for each
channel which lights up when the channel is OK.
NOTICE
The LEDs are not visible when mounted in a VLT®
Decentral Drive FCD 302 frequency converter. Reaction in
case of an encoder error can be selected in
parameter 17-61 Feedback Signal Monitoring: [0] Disabled,
[1] Warning, or [2] Trip.
Table 6.3 Control Cards with Fieldbus Options
6.3.2 VLT® Encoder Input MCB 102
The encoder module can be used as feedback source for
closed-loop flux control (parameter 1-02 Flux Motor
Feedback Source) and closed-loop speed control
(parameter 7-00 Speed PID Feedback Source). Configure the
encoder option in parameter group 17-** Position Feedback.
The encoder option kit contains:
• Encoder Option MCB 102
•
Cable to connect customer terminals to control
card
The encoder option MCB 102 is used for:
• VVC+ closed-loop.
•
Flux vector speed control.
Connector
Designation
X31
Incremental
SinCos Encoder EnDat Encoder
Encoder (refer HIPERFACE®
to Graphic A) (refer to Graphic
B)
SSI Encoder
Description
1
NC
–
–
24 V1)
24 V output (21–25 V, Imax:125 mA)
2
NC
8 VCC
–
–
8 V output (7–12 V, Imax: 200 mA)
3
5 VCC
–
5 VCC
5
4
GND
–
GND
GND
5
A input
+COS
+COS
–
A input
6
A inv input
REFCOS
REFCOS
–
A inv input
7
B input
+SIN
+SIN
–
B input
8
B inv input
REFSIN
REFSIN
–
B inv input
9
Z input
+Data RS485
Clock out
Clock out
Z input OR +Data RS485
10
Z inv input
-Data RS485
Clock out inv.
Clock out inv.
Z input OR -Data RS485
11
NC
NC
Data in
Data in
Future use
12
NC
NC
Data in inv.
Data in inv.
Future use
–
–
–
–
Maximum 5 V on X31.5–12
V1)
5 V output (5 V ±5%, Imax: 200 mA)
GND
Table 6.4 Encoder Option MCB 102 Connection Terminals
1) Supply for encoder: See data on encoder.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
87
6 6
130BC998.10
B
GND
A
+24V
6 6
13
20
37
37
B12
G
12
20
20
B08 B07 B06
R
V
N
P
B11
B04 B03
13
20
37
37
B12
B10
B09
G
12
20
20
B08 B07 B06
B05
R
V
N
P
B04
B02
B01
B11
B03
-RS485
7-12V
-cos
+sin
-sin
GND
B10 B09
B05
B02
Item
Description
1
HIPERFACE® encoder
B01
130BC999.10
VLT® Decentral Drive FCD 302
Type Code and Selection Gui...
1
+RS485
+cos
Illustration 6.4 Connections for HIPERFACE® Encoder - 2
Z
A
/Z
/A
B
+5V
/B
GND
6.3.3 VLT® Resolver Input MCB 103
Illustration 6.2 Connections for 5 V Incremental Encoder
The MCB 103 is used for interfacing resolver motor
feedback to the frequency converter. Resolvers are used
basically as motor feedback device for permanent magnet
brushless synchronous motors.
Data +RS 485 (gray)
Data -RS 485 (green)
5
6
7
8
9
10
130BA164.10
REFSIN (brown)
4
+SIN (white)
3
REFCOS (black)
2
+COS (pink)
1
GND (blue)
Us 7-12V (red)
Maximum cable length 10 m (32.8 ft)
11
12
The resolver option kit comprises:
• MCB 103 Resolver Option.
•
Cable to connect customer terminals to control
card.
Find the relevant parameters in parameter group 17-5*
Resolver Interface.
MCB 103 supports a various number of resolver types.
Resolver poles
Parameter 17-50 Poles: 2 *2
Resolver input
voltage
Parameter 17-51 Input Voltage: 2.0–8.0 Vrms
*7.0 Vrms
Resolver input
frequency
Parameter 17-52 Input Frequency: 2–15 kHz
*10.0 kHz
Transformation ratio Parameter 17-53 Transformation Ratio: 0.1–
1.1 *0.5
Secondary input
voltage
Maximum 4 Vrms
Secondary load
Approximately 10 kΩ
Table 6.5 Resolver Option MCB 103 Specifications
Illustration 6.3 Connections for HIPERFACE® Encoder - 1
88
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
13
20
37
37
B12
B10
B09
G
12
20
20
B08 B07 B06
B05
R
V
N
P
B04
B02
B01
B11
B03
130BT102.10
Design Guide
130BD001.10
Type Code and Selection Gui...
B01 REF+
B02 REFB03 Cos+
B04 CosB05 Sin+
B06 Sin-
LED 1 REF OK
LED 2 COS OK
LED 3 SIN OK
LED NA
R1
Rotor
S1
R2
REF+
REFCOS+
COSSIN+
SIN-
S3
Resolver
stator
S4
6 6
R1
R2
S1
S3
S2
S4
Illustration 6.6 Resolver Signals
S2
Motor
Illustration 6.5 Connections for Resolver Option MCB 103
NOTICE
The Resolver Option MCB 103 can only be used with
rotor-supplied resolver types. Stator-supplied resolvers
cannot be used.
NOTICE
LED indicators are not visible at the resolver option.
LED indicators
• LED 1 is on when the reference signal is OK to
resolver.
•
LED 2 is on when the cosine signal is OK from
resolver.
•
LED 3 is on when the sine signal is OK from
resolver.
Set-up example
In this example, a permanent magnet (PM) motor is used
with resolver as speed feedback. A PM motor must usually
operate in flux mode.
Wiring
The maximum cable length is 150 m (492 ft) when a
twisted pair type of cable is used.
NOTICE
Shield and separate the resolver cables from the motor
cables.
NOTICE
The shield of the resolver cable must be correctly
connected to the decoupling plate and connected to
chassis (ground) on the motor side.
NOTICE
Always use shielded motor cables and brake chopper
cables.
The LEDs are active when parameter 17-61 Feedback Signal
Monitoring is set to [1] Warning or [2] Trip.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
89
6 6
Type Code and Selection Gui...
VLT® Decentral Drive FCD 302
Parameter 1-00 Configuration Mode
[1] Speed closed loop
Parameter 1-01 Motor Control Principle
[3] Flux with feedback
Parameter 1-10 Motor Construction
[1] PM, non-salient SPM
Parameter 1-24 Motor Current
Nameplate
Parameter 1-25 Motor Nominal Speed
Nameplate
Parameter 1-26 Motor Cont. Rated Torque
Nameplate
AMA is not possible on PM motors
Parameter 1-30 Stator Resistance (Rs)
Motor datasheet
Parameter 30-80 d-axis Inductance (Ld)
Motor datasheet (mH)
Parameter 1-39 Motor Poles
Motor datasheet
Parameter 1-40 Back EMF at 1000 RPM
Motor datasheet
Parameter 1-41 Motor Angle Offset
Motor datasheet (usually 0)
Parameter 17-50 Poles
Resolver datasheet
Parameter 17-51 Input Voltage
Resolver datasheet
Parameter 17-52 Input Frequency
Resolver datasheet
Parameter 17-53 Transformation Ratio
Resolver datasheet
Parameter 17-59 Resolver Interface
[1] Enabled
Table 6.6 Parameters to Adjust
6.3.4 VLT® 24 V DC Supply MCB 107
24 V DC external supply
A 24 V DC external supply can be installed for low voltage supply to the control card and any option card installed. This
enables full operation of the LCP (including the parameter setting) without connection to mains.
24 V DC external supply specification
Input voltage range
Maximum input current
Average input current
Maximum cable length
Input capacitance load
Power-up delay
The inputs are protected.
24 V DC ±15% (maximum 37 V in 10 s)
2.2 A
0.9 A
75 m
<10 uF
<0.6 s
Terminal numbers
• Terminal 35: - 24 V DC external supply.
•
90
Terminal 36: + 24 V DC external supply.
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Specifications
Design Guide
7.1 Mechanical Dimensions
431.5 mm (16.98 in)
6.5 mm
(0.25 in)
32 mm
(1.25 in)
190 mm (7.48 in)
80 mm
(3.14 in)
80 mm
(3.14 in)
25 mm
(0.98 in)
178 mm (7 in)
Ø13 mm
(0,51 in)
415 mm (16.33 in)
7 7
4
1
3
2
186 mm (7.32 in)
190 mm (7.48 in)
80 mm
(3.14 in)
25 mm
(0.98 in)
178 mm (7 in)
315 mm (12.4 in)
175 mm (6.88 in)
41 mm
(1.61 in)
Ø13 mm
(0,51 in)
80 mm
(3.14 in)
6.5 mm
(0.25 in)
280 mm (11.02 in)
380 mm (14.96 in)
130BB712.10
331.5 mm (13.05 in)
130BC381.10
7 Specifications
449.5 mm (17.69 in)
ON
WARNING
ALARM
NS1
NS2
200 mm (7.87 in)
Bus MS
201 mm (7.91 in)
349.5 mm (13.75 in)
Illustration 7.1 Small Unit
Motor side
1xM20, 1xM25
Control side
2xM20, 9xM161)
Mains side
2xM25
1)
Also used for 4xM12/6xM12 sensor/actuator sockets.
Illustration 7.2 Large Unit
MG04H302
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91
VLT® Decentral Drive FCD 302
Specifications
7.2 Electrical Data and Wire Sizes
7.2.1 Overview
Mains supply 3x380–480 V AC
Frequency converter
PK37
PK55
PK75
P1K1
P1K5
P2K2
P3K0
Rated shaft output [kW]
0.37
0.55
0.75
1.1
1.5
2.2
3.0
Rated shaft output [hp]
0.5
0.75
1.0
1.5
2.0
3.0
4.0
Continuous (3x380–440 V) [A]
1.2
1.6
2.2
2.7
3.7
5.0
6.5
Intermittent (3x380–440 V) [A]
1.9
2.6
3.5
4.3
5.9
8.0
10.4
Continuous (3x441–480 V) [A]
1.0
1.4
1.9
2.7
3.1
4.3
5.7
Intermittent (3x441–480 V) [A]
1.6
2.2
3.0
4.3
5.0
6.9
9.1
Maximum input current
Recommended maximum fuse size
(non-UL)
gG-25
Built-in circuit breaker (large unit)
CTI-25M Danfoss part number: 047B3151
Recommended circuit breaker
Danfoss CTI-25M (small and large
unit) part number:
ON
Bus MS
WARNING
ALARM
NS1
NS2
130BB800.10
7 7
0.37, 0.55 kW
Danfoss part number: 047B3148
0.75, 1.1 kW
Danfoss part number: 047B3149
1.5 kW, 2.2 kW, and 3 kW
Danfoss part number: 047B3151
Recommended circuit breaker
Danfoss CTI-45MB1) (small unit) part
number:
0.55, 0.75 kW
Danfoss part number: 047B3160
1.1 kW
Danfoss part number: 047B3161
1.5 kW
Danfoss part number: 047B3162
2.2 kW
Danfoss part number: 047B3163
Power loss at maximum load [W]2)
Efficiency3)
35
42
46
58
62
88
116
0.93
0.95
0.96
0.96
0.97
0.97
0.97
Weight, small unit [kg]
9.8 (21.6 lb)
Weight, large unit [kg]
–
13.9 (30.6 lb)
ON
Bus MS
WARNING
ALARM
NS1
NS2
130BB799.10
Output current
Continuous (3x380–440 V) [A]
1.3
1.8
2.4
3.0
4.1
5.2
7.2
Intermittent (3x380–440 V) [A]
2.1
2.9
3.8
4.8
6.6
8.3
11.5
Continuous (3x441–480 V) [A]
1.2
1.6
2.1
3.0
3.4
4.8
6.3
Intermittent (3x441–480 V) [A]
1.9
2.6
3.4
4.8
5.4
7.7
10.1
Continuous kVA (400 V AC) [kVA]
0.9
1.3
1.7
2.1
2.8
3.9
5.0
Continuous kVA (460 V AC) [kVA]
0.9
1.3
1.7
2.4
2.7
3.8
5.0
Maximum cable size:
(Mains, motor, brake)
[mm2/AWG]
Solid cable 6/10
Flexible cable 4/12
Table 7.1 VLT® Decentral Drive FCD 302 Shaft Output, Output Current, and Input Current
1) Type CTI-45MB circuit breakers are not available for 3 kW (4 hp) units.
2) Applies for dimensioning of frequency converter cooling. If the switching frequency is higher than the default setting, the power losses may
increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to
drives.danfoss.com/knowledge-center/energy-efficiency-directive/#/.
3) Efficiency measured at nominal current. For energy efficiency class, see chapter 7.3 General Specifications. For part load losses, see
drives.danfoss.com/knowledge-center/energy-efficiency-directive/#/.
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MG04H302
Specifications
Design Guide
7.2.2 UL/cUL Approved Pre-fuses
•
American wire gauge. Maximum cable crosssection is the largest cable cross-section that can
be attached to the terminals. Always observe
national and local regulations.
•
Type gG pre-fuses must be used. To maintain UL/
cUL, use pre-fuses of these types (see Table 7.2).
•
Measured using a 10 m (32.8 ft) shielded/armored
motor cable with a rated load and rated
frequency.
Fuses
The unit is suitable for use on a circuit capable of
delivering not more than 100000 RMS symmetrical
Amperes, 500 V maximum.
Circuit breaker
The unit is suitable for use on a circuit capable of
delivering not more than 10000 RMS symmetrical Amperes,
500 V maximum.
Recommended maximum pre-fuse size 25 A
Brand
Fuse type UL File
number
Bussmann
FWH-1)
Bussmann
KTS-R1)
E4273
RK1/JDDZ
Bussmann
JKS-1)
E4273
J/JDDZ
Bussmann
JJS-1)
E4273
T/JDDZ
Bussmann
FNQ-R-1)
E4273
CC/JDDZ
Bussmann
KTK-R-1)
E4273
CC/JDDZ
Bussmann
LP-CC-1)
E4273
SIBA
5017906-1) E180276
Littelfuse
KLS-R1)
Ferraz Shawmut
ATM-R1)
E2137
CC/JDDZ
Ferraz Shawmut A6K-R1)
E2137
RK1/JDDZ
Ferraz Shawmut HSJ1)
E2137
J/HSJ
E91958
E81895
UL Category (CCN
code)
JFHR2
7 7
CC/JDDZ
RK1/JDDZ
RK1/JDDZ
Table 7.2 VLT® Decentral Drive FCD 302 Pre-fuses Meeting
UL/cUL Requirements
1) 5 A (0.37 kW/0.5 hp), 7 A (0.55 kW/0.37 hp), 9 A (0.75 kW/1 hp),
12 A (1.1 kW/1.5 hp), 15 A (1.5 kW/2 hp), 20 A (2.2 kW/3 hp), 25 A
(3 kW/4 hp)
7.2.3 VLT® Decentral Drive FCD 302 DC
Voltage Levels
DC voltage level
Inverter undervoltage disable
380–480 V units (V DC)
373
Undervoltage warning
410
Inverter undervoltage re-enable
(warning reset)
398
Overvoltage warning (without
brake)
778
Dynamic brake turn on
778
Inverter overvoltage re-enable
(warning reset)
795
Overvoltage warning (with brake)
810
Overvoltage trip
820
Table 7.3 FCD 302 DC Voltage Level
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7 7
VLT® Decentral Drive FCD 302
Specifications
7.3 General Specifications
Mains supply (L1, L2, L3)1)
Supply voltage
Supply frequency
Maximum imbalance temporary between mains phases
True power factor (λ)
Displacement power factor (cos ϕ)
Switching on input supply L1, L2, L3 (power-ups)
380–480 V ±10%2)
50/60 Hz ± 5%
3.0% of rated supply voltage
≥ 0.9 nominal at rated load
Near unity (> 0.98)
Maximum 2 times/minute
1) The unit is suitable for use on a circuit capable of delivering not more than 100000 RMS symmetrical Amperes, 480 V
maximum.
2) Mains voltage low/mains drop-out:
During low mains voltage or a mains drop-out, the frequency converter continues until the DC-link voltage drops below the
minimum stop level, which corresponds typically to 15% below the frequency converter's lowest rated supply voltage. Power-up
and full torque cannot be expected at mains voltage lower than 10% below the frequency converter's lowest rated supply
voltage.
Motor output (U, V, W)
Output voltage
Output frequency
Output frequency in flux mode
Switching on output
Ramp times
0–100% of supply voltage
0–590 Hz
0–300 Hz
Unlimited
0.01–3600 s
Torque characteristics
Starting torque (constant torque)
Starting torque
Overload torque (constant torque)
Starting torque (variable torque)
Overload torque (variable torque)
Maximum 160% for 60
Maximum 180% up to 0.5
Maximum 160% for 60
Maximum 110% for 60
Maximum 110% for 60
s1)
s1)
s1)
s1)
s1)
1) Percentage relates to the nominal torque.
Cable lengths and cross-sections for control cables1)
Maximum motor cable length, shielded
Maximum motor cable length, unshielded, without fulfilling emission specification
Maximum cross-section to control terminals, flexible/ rigid wire without cable end sleeves
Maximum cross-section to control terminals, flexible wire with cable end sleeves
Maximum cross-section to control terminals, flexible wire with cable end sleeves with collar
Minimum cross-section to control terminals
1.5
1.5
1.5
0.25
10 m (32.8 ft)
10 m (32.8 ft)
mm2/16 AWG
mm2/16 AWG
mm2/16 AWG
mm2/24 AWG
1) Power cables, see tables in chapter 7.2 Electrical Data and Wire Sizes.
Protection and features
•
•
94
Electronic motor thermal protection against overload.
Temperature monitoring of the heat sink ensures that the frequency converter trips if the temperature reaches a
predefined level.
•
•
•
The frequency converter is protected against short circuits on motor terminals U, V, W.
•
The frequency converter constantly checks for critical levels of internal temperature, load current, high voltage on
the DC link, and low motor speeds. As a response to a critical level, the frequency converter can adjust the
switching frequency and/or change the switching pattern to ensure the performance of the frequency converter.
If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load).
Monitoring of the DC-link voltage ensures that the frequency converter trips if the DC-link voltage is too low or
too high.
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Specifications
Design Guide
Digital inputs
Programmable digital inputs
Terminal number
Logic
Voltage level
Voltage level, logic 0 PNP
Voltage level, logic 1 PNP
Voltage level, logic 0 NPN2)
Voltage level, logic 1 NPN2)
Maximum voltage on input
Pulse frequency range
(Duty cycle) Minimum pulse width
Input resistance, Ri
4 (6)1)
18, 19,
32, 33
PNP or NPN
0–24 V DC
<5 V DC
>10 V DC
>19 V DC
<14 V DC
28 V DC
0–110 kHz
4.5 ms
Approximately 4 kΩ
271),
291),
All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
1) Terminals 27 and 29 can also be programmed as output.
Safe Torque Off terminal 37 (terminal 37 is fixed PNP logic)
Voltage level
Voltage level, logic 0 PNP
Voltage level, logic 1 PNP
Nominal input current at 24 V
Nominal input current at 20 V
Input capacitance
Analog inputs
Number of analog inputs
Terminal number
Modes
Mode select
Voltage mode
Voltage level
Input resistance, Ri
Maximum voltage
Current mode
Current level
Input resistance, Ri
Maximum current
Resolution for analog inputs
Accuracy of analog inputs
Bandwidth
0–24 V DC
<4 V DC
20 V DC
50 mA rms
60 mA rms
400 nF
2
53, 54
Voltage or current
Switch S201 and switch S202
Switch S201/switch S202=OFF (U)
-10 V to +10 V (scaleable)
Approximately 10 kΩ
±20 V
Switch S201/switch S202=ON (I)
0/4–20 mA (scaleable)
Approximately 200Ω
30 mA
10 bit (+ sign)
Maximum error 0.5% of full scale
100 Hz
The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
MG04H302
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95
7 7
7 7
2
3
4
+24V
18
130BD007.10
VLT® Decentral Drive FCD 302
Specifications
5
6
37
1
RS485
Item
Description
1
Functional isolation
2
Control
3
PELV isolation
4
Mains
5
High voltage
6
Motor
Illustration 7.3 Analog Inputs
Pulse/encoder inputs
Programmable pulse/encoder inputs
Terminal number pulse/encoder
Maximum frequency at terminal 29, 32, 33
Maximum frequency at terminal 29, 32, 33
Minimum frequency at terminal 29, 32, 33
Voltage level
Maximum voltage on input
Input resistance, Ri
Pulse input accuracy (0.1–1 kHz)
Encoder input accuracy (1–110 kHz)
2/1
29, 331)/322), 332)
110 kHz (Push-pull driven)
5 kHz (open collector)
4 Hz
See Digital Inputs in this section
28 V DC
Approximately 4 kΩ
Maximum error: 0.1% of full scale
Maximum error: 0.05% of full scale
The pulse and encoder inputs (terminals 29, 32, 33) are galvanically isolated from the supply voltage (PELV) and other highvoltage terminals.
1) Pulse inputs are 29 and 33
2) Encoder inputs: 32=A, and 33=B
Analog output
Number of programmable analog outputs
Terminal number
Current range at analog output
Maximum load GND - analog output less than
Accuracy on analog output
Resolution on analog output
1
42
0/4 to 20 mA
500 Ω
Maximum error: 0.5% of full scale
12 bit
The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
96
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MG04H302
Specifications
Design Guide
Control card, RS485 serial communication
Terminal number
Terminal number 61
68 (P, TX+, RX+), 69 (N, TX-, RX-)
Common for terminals 68 and 69
The RS485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the
supply voltage (PELV).
Digital output
Programmable digital/pulse outputs
Terminal number
Voltage level at digital/frequency output
Maximum output current (sink or source)
Maximum load at frequency output
Maximum capacitive load at frequency output
Minimum output frequency at frequency output
Maximum output frequency at frequency output
Accuracy of frequency output
Resolution of frequency outputs
2
27, 291)
0–24 V
40 mA
1 kΩ
10 nF
0 Hz
32 kHz
Maximum error: 0.1% of full scale
12 bit
1) Terminal 27 and 29 can also be programmed as input.
7 7
The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
Control card, 24 V DC output
Terminal number
Output voltage
Maximum load
12, 13
24 V +1, -3 V
600 mA
The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same ground potential as the analog and
digital inputs and outputs.
Relay outputs
Programmable relay outputs
Relay 01 terminal number
Maximum terminal load (AC-1)1) on 1-3 (NC), 1-2 (NO) (Resistive load)
Maximum terminal load (AC-15)1) (Inductive load @ cosφ 0.4)
Maximum terminal load (DC-1)1) on 1-2 (NO), 1-3 (NC) (Resistive load)
Maximum terminal load (DC-13)1) (Inductive load)
Relay 02 terminal number
Maximum terminal load (AC-1)1) on 4-5 (NO) (Resistive load)2)3) Overvoltage cat. II
Maximum terminal load (AC-15)1) on 4-5 (NO) (Inductive load @ cosφ 0.4)
Maximum terminal load (DC-1)1) on 4-5 (NO) (Resistive load)
Maximum terminal load (DC-13)1) on 4-5 (NO) (Inductive load)
Maximum terminal load (AC-1)1) on 4-6 (NC) (Resistive load)
Maximum terminal load (AC-15)1) (Inductive load @ cosφ 0.4)
Maximum terminal load (DC-1)1) on 4-6 (NO), 4-5 (NC) (Resistive load)
Maximum terminal load (DC-13)1) (Inductive load)
Minimum terminal load on 1-3 (NC), 1-2 (NO), 4-6 (NC), 4-5 (NO)
2
1-3 (break), 1-2 (make)
240 V AC, 2A
240 V AC, 0.2 A
48 V DC, 1 A
24 V DC, 0.1 A
4-6 (break), 4-5 (make)
240 V AC, 2 A
240 V AC, 0.2 A
80 V DC, 2 A
24 V DC, 0.1 A
240 V AC, 2 A
240 V AC, 0.2 A
48 V DC, 1 A
24 V DC, 0.1 A
24 V DC 10 mA, 24 V AC 20 mA
1) IEC 60947 part 4 and 5
The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).
2) Overvoltage Category II
3) UL applications 300 V AC 2A
Control card, 10 V DC output
Terminal number
Output voltage
Maximum load
±50
10.5 V ±0.5 V
15 mA
The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
97
7 7
VLT® Decentral Drive FCD 302
Specifications
Control characteristics
Resolution of output frequency at 0–590 Hz
Repeat accuracy of precise start/stop (terminals 18, 19)
System response time (terminals 18, 19, 27, 29, 32, 33)
Speed control range (open loop)
Speed control range (closed loop)
Speed accuracy (open loop)
Speed accuracy (closed loop), depending on resolution of feedback device
Torque control accuracy (speed feedback)
±0.003 Hz
≤±0.1 ms
≤2 ms
1:100 of synchronous speed
1:1000 of synchronous speed
30–4000 RPM: error ±8 RPM
0–6000 RPM: error ±0.15 RPM
Maximum error ±5% of rated torque
All control characteristics are based on a 4-pole asynchronous motor.
Control card performance
Scan interval
1 ms
Surroundings
Enclosure rating
IP66/Type 4X (indoor)
Vibration test for units with no circuit breaker
1.7 g RMS
Mounts unit with integrated circuit breaker on a level, vibration-proof, and torsionally rigid support structure
Maximum relative humidity
5–95% (IEC 60 721-3-3; Class 3K3 (non-condensing) during operation
Ambient temperature
Maximum 40 °C (75 °F) (24-hour average maximum 35 °C (95 °F))
Temperature during storage/transport
-25 to +65/70 °C (-13 to +149/158 °F)
Derating for high ambient temperature
Minimum ambient temperature during full-scale operation
Minimum ambient temperature at reduced performance
Maximum altitude above sea level
Energy efficiency class1)
0 °C (32 °F)
-10 °C (14 °F)
1000 m (3280.8 ft)
IE2
Derating for high altitude
1) Determined according to EN 50598-2 at:
• Rated load.
•
•
•
90% rated frequency.
Switching frequency factory setting.
Switching pattern factory setting.
Control card, USB serial communication
USB standard
USB plug
1.1 (Full speed)
USB type B plug
Connection to PC is carried out via a standard host/device USB cable.
The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.
The USB ground connection is not galvanically isolated from protection ground. Use only an isolated laptop as PC connection to
the USB connector on the frequency converter.
98
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MG04H302
Specifications
Design Guide
7.4 Efficiency
Efficiency of the frequency converter (nVLT)
The load on the frequency converter has little effect on its
efficiency. In general, the efficiency is the same at the
rated motor frequency fM,N, even if the motor supplies
100% of the rated shaft torque or only 75%, that is, if there
is part loads.
This also means that the efficiency of the frequency
converter does not change even if other U/f characteristics
are selected. However, the U/f characteristics influence the
efficiency of the motor.
The efficiency declines a little when the switching
frequency is set to a value of above 5 kHz. The efficiency is
also slightly reduced if the mains voltage is 480 V.
Efficiency calculation
Calculate the efficiency of the frequency converter at
different loads based on the following graph. The factor in
this graph must be multiply by the specific efficiency factor
listed in Table 7.1:
130BD198.10
Relative Efficiency
1,02
1
0,98
0,96
100% Load
75% Load
50% Load
25% Load
0,94
0,92
0,9
0%
50%
100%
150%
% Speed
200%
Illustration 7.4 Typical Efficiency Curves
Efficiency of the system (ηSYSTEM)
To calculate the system efficiency, the efficiency of the
frequency converter (ηVLT) is multiplied by the efficiency of
the motor (ηMOTOR):
ηSYSTEM = ηVLT x ηMOTOR.
7.5 dU/dt Conditions
NOTICE
380–690 V
To avoid premature aging of motors (without phase
insulation paper or other insulation reinforcement) not
designed for operation of the frequency converter,
Danfoss strongly recommend fitting a dU/dt filter or a
sine-wave filter on the output of the frequency
converter. For further information about dU/dt and sinewave filters, see the Output Filters Design Guide.
7 7
When a transistor in the inverter bridge switches, the
voltage across the motor increases by a dU/dt ratio
depending on:
• The motor cable (type, cross-section, length,
shielded, or unshielded)
•
Inductance
The natural induction causes an overshoot UPEAK in the
motor voltage before it stabilizes itself at a level
depending on the voltage in the DC link. The rise time and
the peak voltage UPEAK affect the service life of the motor.
If the peak voltage is too high, especially motors without
phase coil insulation are affected. When the motor cable is
short (a few meters), the rise time and peak voltage are
lower.
Example: Assume a 3.0 kW, 380–480 V AC at 75% load at
50% speed. The graph is showing 0.99 - the rated
efficiency for a 3.0 kW, FCD 302 is 0.97. The actual
efficiency is then: 0.99x0.97=0.96.
Efficiency of the motor (ηMOTOR )
The efficiency of a motor connected to the frequency
converter depends on magnetising level. In general, the
efficiency is just as good as with mains operation. The
efficiency of the motor depends on the type of motor.
In the range of 75–100% of the rated torque, the efficiency
of the motor is practically constant, both when it is
controlled by the frequency converter and when it runs
directly on mains.
In small motors, the influence from the U/f characteristic
on efficiency is marginal.
In general, the switching frequency does not affect the
efficiency of small motors. Motors with low internal
impedance (for example, PM motors with a very highpower factor) require relatively high switching frequency to
maintain the sine shape of the current. The resulting
increase in switching losses can decrease the efficiency of
the frequency converter.
MG04H302
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99
7 7
VLT® Decentral Drive FCD 302
Specifications
Peak voltage on the motor terminals is caused by the
switching of the IGBTs. The frequency converter complies
with the demands of IEC 60034-25 regarding motors
designed to be controlled by frequency converters. The
frequency converter also complies with IEC 60034-17
regarding Norm motors controlled by frequency converters
The measured values from the laboratory tests are detailed
in Table 7.4, Table 7.5, Table 7.6, Table 7.7, and Table 7.8:
Inverter measurements FCD 302: P0K37T4 & FCD 302:
P0K55T4
Motor cable length
[m] (ft)
Mains voltage Rise time Upeak dU/dt
[Vrms]
[kV] [V/µs]
[µs]
10 (32.8 ft)
480
0.25
0.662 2118.40
Table 7.4 FCD 302: P0K37T4 & FCD 302: P0K55T4
Inverter measurements FCD 302: P0K75T4
Motor cable length
[m] (ft)
Mains voltage Rise time Upeak dU/dt
[Vrms]
[kV] [V/µs]
[µs]
10 (32.8 ft)
480
0.22
0.66
2118.40
Table 7.5 FCD 302: P0K75T4
Inverter measurements FCD 302: P1K1T4 & FCD 302:
P1K5T4
Motor cable length
[m] (ft)
Mains voltage
[Vrms]
Rise time
[µs]
Upeak dU/dt
[kV] [V/µs]
10 (32.8 ft)
480
0.22
0.66
2400
Table 7.6 FCD 302: P1K1T4 & FCD 302: P1K5T4
Inverter measurements FCD 302: P2K2T4
Motor cable length
[m] (ft)
Mains voltage Rise time Upeak dU/dt
[Vrms]
[kV] [V/µs]
[µs]
10 (32.8 ft)
480
0.142
0.685 3859.15
Table 7.7 FCD 302: P2K2T4
Inverter measurements FCD 302: P3K0T4
Control Structure in
Motor cable length
[m] (ft)
Mains
voltage
[Vrms]
Rise time Upeak dU/dt
[kV] [V/µs]
[µs]
10 (32.8 ft)
480
0.202
0.68 2693.07
Table 7.8 FCD 302: P3K0T4
100
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Index
Design Guide
Index
Acoustic noise........................................................................................ 55
Derating
Automatic derating.........................................................................
for low air pressure..........................................................................
for running at low speed...............................................................
Manual derating...............................................................................
Aggressive environments.................................................................. 55
Digital input............................................................................................ 95
Air humidity............................................................................................ 55
Digital output......................................................................................... 97
AMA with T27 connected.................................................................. 65
Directives
EMC Directive.................................................................................... 11
Low Voltage Directive.................................................................... 11
A
AMA without T27 connected........................................................... 65
78
76
76
76
Analog
input..................................................................................................... 95
output.................................................................................................. 96
Discharge time...................................................................................... 10
B
E
Brake
function............................................................................................... 44
power............................................................................................... 8, 44
selection.............................................................................................. 39
Hoist mechanical brake................................................................. 42
Mechanical brake............................................................................. 38
Mechanical brake control.............................................................. 40
Efficiency........................................................................................... 92, 99
Branch circuit protection................................................................... 58
Break-away torque.................................................................................. 7
C
Cable lengths......................................................................................... 94
Catch up/slow down........................................................................... 32
CE conformity and labeling.............................................................. 11
Coast............................................................................................................ 7
Compliance
CE mark................................................................................................ 11
Disposal.................................................................................................... 12
Electrical data......................................................................................... 92
Electrical terminals............................................................................... 30
EMC
directive (2014/30/EU)............................................................ 11, 12
emissions............................................................................................ 44
test results.......................................................................................... 54
EMC-correct cables.......................................................................... 50
Emission
Conducted emission....................................................................... 54
requirements..................................................................................... 46
Radiated emission........................................................................... 54
Energy efficiency class........................................................................ 98
External alarm reset............................................................................. 68
F
Flux............................................................................................................ 17
Constant torque applications (CT mode)..................................... 76
Flux sensorless control structure.................................................... 17
Control
cable routing.....................................................................................
cables...................................................................................................
characteristics...................................................................................
structures............................................................................................
Freeze output........................................................................................... 7
28
30
98
16
Freeze reference.................................................................................... 32
G
Control card
Control card....................................................................................... 85
Control card performance............................................................ 98
Control card, 24 V DC output....................................................... 97
DC Output, 10 V................................................................................ 97
RS485.................................................................................................... 97
Serial communication.................................................................... 97
USB serial communication............................................................ 98
Galvanic isolation (PELV).................................................................... 13
Cooling..................................................................................................... 76
Hygienic installation............................................................................ 56
Cross-sections........................................................................................ 94
Ground leakage current..................................................................... 14
H
Harmonic calculation.......................................................................... 54
Hoist mechanical brake...................................................................... 71
I
D
Immunity requirements..................................................................... 47
DC output, 10 V..................................................................................... 97
Input
Analog input................................................................................. 7, 95
Digital input....................................................................................... 95
Pulse/encoder input....................................................................... 96
Dead band............................................................................................... 35
Installation.............................................................................................. 55
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
101
Index
VLT® Decentral Drive FCD 302
Installation, hygienic........................................................................... 56
Protection................................................................................................ 13
Intermediate circuit............................................................... 55, 61, 99
Protection and features...................................................................... 94
Protection mode................................................................................... 10
J
Jog................................................................................................................ 7
R
RCD............................................................................................................... 8
L
Reference limits..................................................................................... 33
LCP.................................................................................................... 7, 8, 18
Relay output.................................................................................... 31, 97
Leakage current.................................................................................... 63
Remote [Auto On] control................................................................. 18
Local [Hand On] control..................................................................... 18
Residual current device...................................................................... 54
Low Voltage Directive (2014/35/EU).............................................. 11
Rise time.................................................................................................. 99
M
RS485
RS485.................................................................................................... 97
network connection........................................................................ 69
Machinery Directive (2006/42/EC)................................................. 11
Mains
IT mains................................................................................................ 52
disconnectors.................................................................................... 60
drop-out.............................................................................................. 61
supply (L1, L2, L3)............................................................................. 94
supply interference......................................................................... 52
Mains supply............................................................................................. 9
Mechanical dimensions...................................................................... 91
Moment of inertia................................................................................ 61
Motor
feedback.............................................................................................. 17
nameplate........................................................................................... 64
output.................................................................................................. 94
phases.................................................................................................. 61
speed, rated.......................................................................................... 7
speed, synchronous........................................................................... 7
thermal protection.......................................................................... 62
voltage................................................................................................. 99
Motor-generated overvoltage.................................................... 61
Mounting................................................................................................. 55
S
Safe Torque Off...................................................................................... 44
Safety precautions............................................................................... 10
Scaling
Analog references............................................................................ 34
Bus references................................................................................... 34
Feedback............................................................................................. 34
Preset references.............................................................................. 34
Pulse references................................................................................ 34
Serial communication
RS485.................................................................................................... 97
Serial communication......................................................... 7, 97, 98
Shielded/armored cables.................................................................. 58
Short circuit (motor phase – phase).............................................. 62
Short-circuit ratio.................................................................................. 53
Smart logic controller......................................................................... 70
Speed PID................................................................................................ 14
Speed PID control................................................................................. 20
N
Speed reference.................................................................................... 65
Nameplate data..................................................................................... 64
Static overload in VVC+ mode......................................................... 61
STO............................................................................................................. 44
O
Surroundings......................................................................................... 98
Output
Analog output................................................................................... 96
Digital output.................................................................................... 97
Switching on the output.................................................................... 61
Output performance (U, V, W)......................................................... 94
T
Thermal protection.............................................................................. 12
Thermistor.......................................................................................... 9, 69
P
PELV........................................................................................................... 69
Torque
characteristics................................................................................... 94
PELV - Protective Extra Low Voltage.............................................. 13
Torque control....................................................................................... 14
Point of common coupling............................................................... 53
Process PID control.............................................................................. 23
V
Programming
Stop....................................................................................................... 19
Torque limit........................................................................................ 19
Variable (quadratic) torque applications (VT)............................ 76
102
Vibration and shock............................................................................. 55
Danfoss A/S © 05/2018 All rights reserved.
MG04H302
Index
Design Guide
Voltage level........................................................................................... 95
VVC+............................................................................................................ 9
VVC+ advanced vector control........................................................ 16
W
Wiring example..................................................................................... 29
MG04H302
Danfoss A/S © 05/2018 All rights reserved.
103
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MG04H302
*MG04H302*
05/2018