Danfoss VLT AutomationDrive FC 360 Design Manual Download Page 7 | Manualshive

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1 Introduction

1.1 How to Read This Design Guide

This design guide provides information on how to select,
commission, and order a frequency converter. It provides
information about mechanical and electrical installation.

The design guide is intended for use by qualified
personnel.

Read and follow the design guide to use the frequency
converter safely and professionally, and pay particular
attention to the safety instructions and general warnings.

VLT

®

is a registered trademark.

•

VLT

®

AutomationDrive FC 360 Quick Guide

provides

the necessary information for getting the
frequency converter up and running.

•

VLT

®

AutomationDrive FC 360 Programming Guide

provides information on how to programme and
includes complete parameter descriptions.

FC 360 technical literature is also available online at

www.danfoss.com/fc360

.

1.1.1 Symbols

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation that could
result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could
result in minor or moderate injury. It may also be used
to alert against unsafe practices.

NOTICE

Indicates important information, including situations that
may result in damage to equipment or property.

1.1.2 Abbreviations

Alternating current

AC

American wire gauge

AWG

Ampere/AMP

A

Automatic motor adaptation

AMA

Current limit

I

LIM

Degrees Celsius

°

C

Direct current

DC

Drive dependent

D-TYPE

Electromagnetic compatibility

EMC

Electronic thermal relay

ETR

Gram

g

Hertz

Hz

Horsepower

hp

Kilohertz

kHz

Local control panel

LCP

Meter

m

Millihenry inductance

mH

Milliampere

mA

Millisecond

ms

Minute

min

Motion control tool

MCT

Nanofarad

nF

Newton meter

Nm

Nominal motor current

I

M,N

Nominal motor frequency

f

M,N

Nominal motor power

P

M,N

Nominal motor voltage

U

M,N

Permanent magnet motor

PM motor

Protective extra low voltage

PELV

Printed circuit board

PCB

Rated inverter output current

I

INV

Revolutions per minute

RPM

Regenerative terminals

Regen

Second

s

Synchronous motor speed

n

s

Torque limit

T

LIM

Volts

V

Maximum output current

I

VLT,MAX

Rated output current supplied by the
frequency converter

I

VLT,N

Introduction

Design Guide

MG06B402

Danfoss A/S © 09/2014 All rights reserved.

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Summary of Contents for VLT AutomationDrive FC 360

Page 1: ...MAKING MODERN LIVING POSSIBLE Design Guide VLT AutomationDrive FC 360 www danfoss com drives...

Page 2: ......

Page 3: ...2 2 2 1 General Requirements 14 2 2 2 Grounding Requirements 14 2 2 3 Mains Motor and Ground Connections 15 2 2 4 Control Wiring 16 2 3 Control Structures 18 2 3 1 Control Principle 18 2 3 2 Control M...

Page 4: ...Smart Logic Controller 44 2 11 Extreme Running Conditions 44 3 Type Code and Selection 46 3 1 Ordering 46 3 2 Ordering Numbers Options and Accessories 47 3 3 Ordering Numbers Brake Resistors 48 3 3 1...

Page 5: ...Frequency Converter 64 5 4 12 Conversion 64 5 4 13 Process Words PCD 65 5 5 Examples 65 5 6 Modbus RTU 66 5 6 1 Prerequisite Knowledge 66 5 6 2 Overview 66 5 6 3 Frequency Converter with Modbus RTU 6...

Page 6: ...iple Registers 10 hex 73 5 11 Danfoss FC Control Profile 74 5 11 1 Control Word According to FC Profile 8 10 Protocol FC profile 74 5 11 2 Status Word According to FC Profile STW 8 30 Protocol FC prof...

Page 7: ...rdous situation that could result in minor or moderate injury It may also be used to alert against unsafe practices NOTICE Indicates important information including situations that may result in damag...

Page 8: ...otor frequency fM N Rated motor frequency nameplate data IM Motor current actual IM N Rated motor current nameplate data nM N Rated motor speed nameplate data ns Synchronous motor speed ns 2 par 1 23...

Page 9: ...processor ETR Electronic thermal relay is a thermal load calculation based on present load and time Its purpose is to estimate the motor temperature FC standard bus Includes RS485 bus with FC protoco...

Page 10: ...s protecting itself and requiring physical intervention e g if the frequency converter is subject to a short circuit on the output A locked trip can only be cancelled by cutting off mains removing the...

Page 11: ...requency converters are installed must if necessary be equipped with additional monitoring and protective devices according to valid safety regulations such as laws on mechanical tools regulations for...

Page 12: ...75 1600 V DC voltage ranges The directive mandates that the equipment design must ensure the safety and health of people and livestock and the preservation of material by ensuring the equipment is pr...

Page 13: ...size J5 J6 J7 130BA810 10 130BA826 10 130BA826 10 Enclosure protection IP20 IP20 IP20 High overload rated power maximum 160 overload1 18 5 22 kW 380 480 V 30 45 kW 380 480 V 55 75 kW 380 480 V Table...

Page 14: ...7 D IN OUT 24 V 0 V 0 V PNP 24 V NPN 0 V 24 V 29 D IN OUT 24 V NPN 0 V PNP 0 V PNP 24 V NPN 33 D IN 32 D IN 95 P 5 00 2 1 ON UDC 89 BR 81 5 24 V NPN 0 V PNP 0 10 V DC UDC 88 RFI 3 0 V 240 V AC 3 A Rel...

Page 15: ...motor and mains 2 Frequency converter 7 Motor 3 phase and PE 3 Output contactor generally not recommended 8 Mains 3 phase and reinforced PE 4 Grounding rail PE 9 Control wiring 5 Cable shielding stri...

Page 16: ...with local and national regulations regarding cross section and ambient temperature requirements Danfoss recommends that all power connections be made with a minimum 75 C rated copper wire See chapte...

Page 17: ...lated mains source IT mains or floating delta or TT TN S mains with a grounded leg grounded delta set 14 50 RFI Filter to OFF enclosure sizes J6 J7 or remove the RFI screw enclosure sizes J1 J5 When o...

Page 18: ...1 5 16 Terminal 31 Digital Input 0 No operation Digital input 32 5 14 Terminal 32 Digital Input 0 No operation Digital input 24 V encoder Terminal 33 can be used for pulse input 33 5 15 Terminal 33 Di...

Page 19: ...terminal Confirm that the control terminal is programmed for the correct function See chapter Local Control Panel and Programming in the quick guide for details on accessing parameters and programmin...

Page 20: ...ed open loop control Select which input to use as speed PID feedback in 7 00 Speed PID Feedback Source Torque control The torque control function is used in applications where the torque on motor outp...

Page 21: ...3 M U 96 V 97 W 98 RFI switch Inrush R 82 Load sharing 88 R 81 Brake resistor Load sharing 89 Illustration 2 12 Control Diagram for FC 360 0 37 22 kW 30 75 kW FC 360 30 75 kW frequency converters can...

Page 22: ...stem is received and fed through the ramp limitation and speed limitation before being sent to the motor control The output of the motor control is then limited by the maximum frequency limit If 1 00...

Page 23: ...and Remote Auto On Control Operate the frequency converter manually via the local control panel LCP or remotely via analog digital inputs or serial bus Start and stop the frequency converter pressing...

Page 24: ...ue Freeze ref Freeze output Speed up speed down ref Remote Ref in max ref max ref Scale to Hz Scale to Nm Scale to process unit Relative X X Y 100 DigiPot DigiPot DigiPot max ref min ref DigiPot D1 P...

Page 25: ...Programming Guide The scaling of analog references is described in parameter groups 6 1 Analog Input 53 and 6 2 Analog Input 54 and the scaling of digital pulse references is described in parameter gr...

Page 26: ...he following rules When 3 00 Reference Range is set to 0 Min Max 0 reference equals minimum reference and 100 reference equals maximum reference When 3 00 Reference Range is set to 1 Max Max 100 refer...

Page 27: ...Low Current mA 6 20 Terminal 54 Low Voltage V 6 22 Terminal 54 Low Current mA 5 50 Term 29 Low Frequency Hz 5 55 Term 33 Low Frequency Hz P2 Maximum input value Maximum reference value Maximum refere...

Page 28: ...ther words either P1 or P2 must be on the X axis in Illustration 2 21 Ensure that both points defining the scaling graph are in the same quadrant The size of the dead band is defined by either P1 or P...

Page 29: ...ited to 200 200 40 Hz 40 Hz Reference is scaled according to min max reference giving a speed Scale to speed 20 Hz 20 Hz Range Speed setpoint Motor control Range 8 Hz 8 Hz Motor Digital input 19 Low N...

Page 30: ...eference algorithm Reference 100 0 20 Hz 0 0 0 Hz Range Limited to 100 100 20 Hz 20 Hz Limited to 200 200 40 Hz 40 Hz Reference is scaled according to max reference giving a speed Scale to speed 20 Hz...

Page 31: ...ntiation Time Provides a gain proportional to the rate of change of the feedback A setting of 0 disables the differentiator 7 05 Speed PID Diff Gain Limit If there are quick changes in reference or fe...

Page 32: ...s 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 1 024 pulses...

Page 33: ...lt setting Set acceptable limits for the motor speed and frequency 4 12 Motor Speed Low Limit Hz 0 Hz 4 14 Motor Speed High Limit Hz 50 Hz 4 19 Max Output Frequency 60 Hz 4 Configure the speed control...

Page 34: ...guration Mode 1 01 Motor Control Principle U f VVC 3 Process Not Available Process Table 2 7 Control Configuration NOTICE The process control PID works under the default parameter setting but tuning t...

Page 35: ...ntiation Time Provides a gain proportional to the rate of change of the feedback A setting of 0 disables the differentiator 7 36 Process PID Diff Gain Limit If there are quick changes in reference or...

Page 36: ...ture 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 t...

Page 37: ...nce 10 C Set maximum reference 80 C If the set value is determined from a preset value array parameter set other reference sources to No Function 3 01 3 02 3 03 3 10 60 C Unit shown on display 5 C 35...

Page 38: ...ols tuning method NOTICE Do not use the Ziegler Nichols Tuning method in applications that could be damaged by the oscillations created by marginally stable control settings The criteria for adjusting...

Page 39: ...l electro magnetic field I4 from the screened motor cable The screen reduces the radiated interference but increases the low frequency interference on the mains Connect the motor cable screen to the f...

Page 40: ...Emission Requirements 2 6 3 EMC Immunity Requirements The immunity requirements for frequency converters depend on the environment in which they are installed The requirements for the industrial envir...

Page 41: ...le 4 kV CCC 10 VRMS Relay cable 4 kV CCC 10 VRMS Control cable length 2m 1 kV CCC Unshielded 1 kV 42 CM 10 VRMS Standard fieldbus cable length 2m 1 kV CCC Unshielded 1 kV 42 CM 10 VRMS LCP cable lengt...

Page 42: ...ette 3 Customer relays Illustration 2 30 Galvanic Isolation Interface between Standard RS485 and I O circuit PELV is functionally isolated WARNING Before touching any electrical parts ensure that othe...

Page 43: ...e B only which are capable of detecting AC and DC currents Use RCDs with an inrush delay to prevent faults caused by transient earth currents Dimension RCDs according to the system configu ration and...

Page 44: ...esistor is active Illustration 2 35 shows a typical braking cycle The intermittent duty cycle for the resistor is calculated as follows Duty cycle tb T tb is the braking time in seconds T cycle time i...

Page 45: ...hot during braking Place the brake resistor in a secure environment to avoid fire risk 2 9 4 Control with Brake Function The brake is protected against short circuiting of the brake resistor and the...

Page 46: ...ts and actions When the last event action has been executed the sequence starts over again from event 0 action 0 Illustration 2 37 shows an example with 3 event actions 130BA062 14 State 1 13 51 0 13...

Page 47: ...ation from serious damage VLT AutomationDrive FC 360 offers several dedicated features Torque limit The torque limit protects the motor from being overloaded independent of the speed Torque limit is c...

Page 48: ...5 kW e g K37 0 37 kW2 1K1 1 1 kW 11K 11 kW etc 11 12 Voltage Class T4 380 480 V 3 phases 13 15 IP Class E20 IP20 16 17 RFI H2 C3 Class 18 Brake chopper X No B Built in3 19 LCP X No 20 PCB Coating C 3C...

Page 49: ...0 132B0263 VLT terminal cover for MCB J2 FC 360 132B0265 VLT terminal cover for MCB J3 FC 360 132B0266 VLT terminal cover for MCB J4 FC 360 132B0267 VLT terminal cover for MCB J5 FC 360 132B0268 VLT d...

Page 50: ...128 3007 120 1 5 0 8 145 H2K2 2 2 139 163 95 155 0 190 3008 120 1 5 0 9 131 H3K0 3 100 118 86 112 0 262 3300 120 1 5 1 3 131 H4K0 4 74 87 93 83 0 354 3335 120 1 5 1 9 128 H5K5 5 5 54 63 33 60 0 492 3...

Page 51: ...1 504 3314 120 1 5 3 7 128 H5K5 5 5 54 63 33 60 2 088 3315 120 1 5 5 127 H7K5 7 5 38 46 05 43 2 872 3316 120 1 5 7 1 132 H11K 11 27 32 99 31 4 226 3236 120 2 5 11 5 130 H15K 15 19 24 02 22 5 804 3237...

Page 52: ...3 2 5 3 6 3 6 3 6 4 1 Efficiency 3 96 2 97 0 97 2 97 4 97 4 97 6 97 5 97 6 97 7 98 0 Table 4 1 Mains Supply 3x380 480 V AC Heavy Duty1 Frequency converter typical shaft output kW H11K 11 H15K 15 H18K...

Page 53: ...uty 150 160 current during 60 s Normal duty 110 current during 60 s 2 The typical power loss is at nominal load conditions and expected to be within 15 tolerence relates to variety in voltage and cabl...

Page 54: ...que maximum 160 for 60 s1 Overload torque constant torque maximum 160 for 60 s1 Starting torque variable torque maximum 110 for 60 s1 Overload torque variable torque maximum 110 for 60 s Starting curr...

Page 55: ...at terminal 29 33 5 kHz open collector Minimum frequency at terminal 29 33 4 Hz Voltage level see section on digital input Maximum voltage on input 28 V DC Input resistance Ri approximately 4 k Pulse...

Page 56: ...Inductive load cos 0 4 250 V AC 0 2 A Maximum terminal load DC 1 1 on 01 02 04 05 NO Resistive load 30 V DC 2 A Maximum terminal load DC 13 1 on 01 02 04 05 NO Inductive load 24 V DC 0 1 A Maximum ter...

Page 57: ...N 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 Energy efficiency class1 IE2 1 Determined according to EN50598 2 at Rated load 90 rated frequency Switching frequency factory setting Sw...

Page 58: ...requency converter WARNING Malfunction or failing to follow the recommendations may result in personal risk and damage to the frequency converter and other equipment 4 3 2 CE Compliance NOTICE Using f...

Page 59: ...witching frequency does not affect the efficiency of small motors Motors from 11 kW and up have their efficiency improved 1 2 because the sine shape of the motor current is almost perfect at high swit...

Page 60: ...gth m Mains voltage V Rise time sec UPEAK kV dU dt kV sec 5 400 0 272 0 947 2 79 50 400 0 344 1 03 2 4 5 480 0 316 1 01 2 56 50 480 0 368 1 2 2 61 Table 4 10 dU dt Data for FC 360 22 kW Cable length m...

Page 61: ...0 2 2 5 3 4 1 J2 3 7 2 7 2 4 9 0 9 0 5 5 12 0 10 2 J3 7 5 15 5 13 1 J4 11 23 0 23 0 15 31 0 26 0 J5 18 5 37 0 37 0 22 42 5 40 0 J6 30 61 61 37 73 73 45 90 77 J7 55 106 106 75 147 125 Table 4 15 Derat...

Page 62: ...k Always use screened twisted pair STP cable for bus cabling and follow good common installation practice Low impedance ground connection of the screen at every node is important including at high fre...

Page 63: ...ransmission is interrupted specify a maximum delay time between 2 received bytes to ensure time out NOTICE The default selection depends on the protocol selected in 8 30 Protocol Table 5 2 Modbus Comm...

Page 64: ...Parity Stop Bits Even parity 1 stop bit default Table 5 3 Parameters to Enable the Protocol 5 4 FC Protocol Message Framing Structure 5 4 1 Content of a Character byte Each character transferred begi...

Page 65: ...2 BCC 130BA271 10 PWEhigh PWElow Illustration 5 6 Parameter Block Text block The text block is used to read or write texts via the data block PKE IND 130BA270 10 ADR LGE STX PCD1 PCD2 BCC Ch1 Ch2 Chn...

Page 66: ...r request read command the present parameter value in the PWE block is transferred and returned to the master If a parameter contains several data options e g 0 01 Language select the data value by en...

Page 67: ...4 Motor Speed High Limit Hz is a single word and the parameter command for write in EEPROM is E 4 14 Motor Speed High Limit Hz is 19E in hexadecimal The response from the slave to the master is shown...

Page 68: ...m the master The Modbus RTU protocol establishes the format for the master s query by providing the following information The device or broadcast address A function code defining the requested action...

Page 69: ...d of at least 3 5 character intervals marks the end of the message A new message can begin after this period The entire message frame must be transmitted as a continuous stream If a silent period of m...

Page 70: ...ferenced to 0 The first occurrence of a data item is addressed as item number 0 For example The coil known as coil 1 in a programmable controller is addressed as coil 0000 in the data address field of...

Page 71: ...dbus configu ration Read Write TCP only Reserved for Modbus TCP p12 28 and 12 29 stored in Eeprom etc 6 7 40007 Last error code Read only Error code recieved from parameter database refer to WHAT 3829...

Page 72: ...gured and is being asked to return register values 2 Illegal data address The data address received in the query is not an allowable address for the server or slave More specifically the combination o...

Page 73: ...its Readable sizes range from 1 register 16 bits up to 10 registers 20 characters Non standard data types Non standard data types are text strings and are stored as 4x registers 40001 4FFFF The parame...

Page 74: ...2 speed set point to be forced Field name Example hex Slave address 01 frequency converter address Function 0F write multiple coils Coil address HI 00 Coil address LO 10 coil address 17 Quantity of co...

Page 75: ...gister contents have been passed Field name Example hex Slave address 01 Function 06 Register address HI 03 Register address LO E7 Preset data HI 00 Preset data LO 01 Error check CRC Table 5 31 Respon...

Page 76: ...nverter immediately releases the motor the output transistors are shut off and it coasts to a standstill Bit 03 1 The frequency converter starts the motor if the other starting conditions are met Make...

Page 77: ...or 3 Logic AND is selected 5 11 2 Status Word According to FC Profile STW 8 30 Protocol FC profile Output freq STW Bit no Follower master 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 130BA273 11 Illustration...

Page 78: ...Bit 10 Out of frequency limit Bit 10 0 The output frequency has reached the value in 4 12 Motor Speed Low Limit Hz or 4 14 Motor Speed High Limit Hz Bit 10 1 The output frequency is within the define...

Page 79: ...us reference Actual output freq STW Follower master Speed ref CTW Master follower 16bit 130BA276 11 Illustration 5 15 Actual Output Frequency MAV The reference and MAV are scaled as follows Reverse Fo...

Page 80: ...t value Notes comments Table 6 2 Analog Speed Reference Voltage Parameters 130BD065 11 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT 12 18 19 20 27 29 32 33 31 50 53 54 55 42 4...

Page 81: ...A OUT Function Setting 4 30 Motor Feedback Loss Function 1 Warning 4 31 Motor Feedback Speed Error 100 4 32 Motor Feedback Loss Timeout 5 s 7 00 Speed PID Feedback Source 2 MCB 102 17 11 Resolution P...

Page 82: ...B840 11 Illustration 6 1 Speed Up Down CAUTION Thermistors must use reinforced or double insulation to meet PELV insulation requirements Parameters 130BD070 11 24 V D IN D IN D IN COM D IN D IN D IN D...

Page 83: ...ockwise direction means channel A is 90 electrical degrees before channel B Counter Clockwise direction means channel B is 90 electrical degrees before A The direction is determined by looking into th...

Page 84: ...C brake 74 Dead band 26 Dead band around 0 26 Derating 55 Digital input 52 Digital output 54 Directive EMC 10 Directive low voltage 10 Directive machinery 10 Discharge time 9 Disposal instruction 9 E...

Page 85: ...uipment 15 Output current 54 Overload protection 14 P Parameter number PNU 64 PELV 54 80 PELV protective extra low voltage 40 Power connection 14 Power cycle 7 Power factor 7 15 Preset reference 24 Pr...

Page 86: ...length LGE 62 Terminal programming 17 Thermistor 8 80 Torque characteristic 52 Torque control 18 Trip 8 Trip function 14 V Voltage level 52 VVC 8 20 W Wire size 14 Index Design Guide 84 Danfoss A S 0...

Page 87: ...Index Design Guide MG06B402 Danfoss A S 09 2014 All rights reserved 85...

Page 88: ...ies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property...

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