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Danfoss vlt fcd 302 Design Manual Download Page 69

Abbrev. Ref.

Description

PL

EN ISO
13849-1

Discrete level used to specify the ability
of safety-related parts of control systems
to perform a safety function under
foreseeable conditions. Levels a-e.

SFF

IEC 61508

Safe Failure Fraction [%]; Percentage
part of safe failures and dangerous
detected failures of a safety function or
a subsystem related to all failures.

SIL

IEC 61508

Safety Integrity Level

STO

EN
61800-5-2

Safe Torque Off

SS1

EN 61800
-5-2

Safe Stop 1

Table 4.27 Abbreviations Related to Functional Safety

The PFDavg value (Probability of Failure on Demand)
Failure probability in the event of a request of the safety
function.

4.9.1.1 Terminal 37 Safe Stop Function

The frequency converter is available with safe stop
functionality via control terminal 37. Safe stop disables the
control voltage of the power semiconductors of the
frequency converter output stage. This in turn prevents
generating the voltage required to rotate the motor. When
the Safe Stop (T37) is activated, the frequency converter
issues an alarm, trips the unit, and coasts the motor to a
stop. Manual restart is required. The safe stop function can
be used as an emergency stop for the frequency converter.
In the normal operating mode when safe stop is not
required, use the regular stop function instead. When
automatic restart is used, ensure the requirements of ISO
12100-2 paragraph 5.3.2.5 are fulfilled.

Liability Conditions
It is the responsibility of the user to ensure personnel
installing and operating the safe stop function:

•

Read and understand the safety regulations
concerning health and safety/accident prevention

•

Understand the generic and safety guidelines
given in this description and the extended
description in this manual

•

Have a good knowledge of the generic and safety
standards applicable to the specific application

User is defined as: integrator, operator, service technician,
maintenance technician.

Standards
Use of safe stop on terminal 37 requires that the user
satisfies all provisions for safety including relevant laws,
regulations and guidelines. The optional safe stop function
complies with the following standards.

•

EN 954-1: 1996 Category 3

•

IEC 60204-1: 2005 category 0 – uncontrolled stop

•

IEC 61508: 1998 SIL2

•

IEC 61800-5-2: 2007 – safe torque off (STO)
function

•

IEC 62061: 2005 SIL CL2

•

ISO 13849-1: 2006 Category 3 PL d

•

ISO 14118: 2000 (EN 1037) – prevention of
unexpected startup

The information and instructions of the instruction manual
are not sufficient for a proper and safe use of the safe stop
functionality. The related information and instructions of
the relevant 

Design Guide

 must be followed.

Protective Measures

•

Qualified and skilled personnel are required for
installation and commissioning of safety
engineering systems

•

The unit must be installed in an IP54 cabinet or
in an equivalent environment. In special
applications a higher IP degree is required

•

The cable between terminal 37 and the external
safety device must be short circuit protected
according to ISO 13849-2 table D.4

•

When external forces influence the motor axis (for
example, suspended loads), to eliminate potential
hazards additional measures are required (for
example, a safety holding brake)

Safe Stop Installation and Set-Up

WARNING

SAFE STOP FUNCTION!

The safe stop function does NOT isolate mains voltage to
the frequency converter or auxiliary circuits. Perform work
on electrical parts of the frequency converter or the motor
only after isolating the mains voltage supply and waiting
the length of time specified under Safety in this manual.
Failure to isolate the mains voltage supply from the unit
and waiting the time specified could result in death or
serious injury.

•

It is not recommended to stop the frequency
converter by using the Safe Torque Off function.
If a running frequency converter is stopped by
using the function, the unit trips and stops by
coasting. If unacceptable or dangerous, use
another stopping mode to stop the frequency
converter and machinery, before using this
function. Depending on the application a
mechanical brake can be required.

•

For synchronous and permanent magnet motor
frequency converters, in a multiple IGBT power
semiconductor failure: In spite of the activation of

Application Examples

VLT

® 

Decentral Drive FCD 302

68

MG04H102 - VLT

®

 is a registered Danfoss trademark

4

4

Summary of Contents for vlt fcd 302

Page 1: ...MAKING MODERN LIVING POSSIBLE Design Guide VLT Decentral Drive FCD 302 ...

Page 2: ...2 EMC Test Results 14 2 2 3 Emission Requirements 15 2 2 4 Immunity Requirements 15 2 3 Reference Handling 17 2 3 1 Reference Limits 18 2 3 2 Scaling of Preset References and Bus References 19 2 3 3 Scaling of Analog and Pulse References and Feedback 19 2 3 4 Dead Band Around Zero 20 2 5 Galvanic Isolation PELV 24 2 5 1 PELV Protective Extra Low Voltage 24 2 6 Mechanical Brake 25 2 6 1 Hoist Mecha...

Page 3: ...Thermal Protection 33 3 3 3 3 Parallel Connection of Motors 33 3 3 3 4 Motor Insulation 33 3 3 3 5 Motor Bearing Currents 34 3 3 4 Extreme Running Conditions 34 3 3 4 1 Motor Thermal Protection 35 3 4 Drive Options Selections 35 3 4 1 Control Cables and Terminals 35 3 4 1 1 Control Cable Routing 35 3 4 1 2 DIP Switches 36 3 4 1 3 Basic Wiring Example 36 3 4 1 4 Electrical Installation Control Cabl...

Page 4: ...4 Application Examples 47 4 1 Encoder Connection 51 4 2 Encoder Direction 52 4 3 Closed Loop Drive System 52 4 4 PID Control 52 4 4 1 Speed PID Control 53 4 4 2 The Following Parameters are relevant for the Speed Control 53 4 4 3 Tuning PID Speed Control 55 4 4 4 Process PID Control 55 4 4 6 Example of Process PID Control 57 4 4 8 Ziegler Nichols Tuning Method 60 4 4 9 Example of Process PID Contr...

Page 5: ... Spare Parts 76 5 3 Options and Accessories 77 5 3 1 Fieldbus Options 77 5 3 2 Encoder Option MCB 102 77 5 3 3 Resolver Option MCB 103 78 6 Specifications 81 6 1 Mechanical Dimensions 81 6 2 Electrical Data and Wire Sizes 82 6 3 General Specifications 84 6 4 Efficiency 88 6 5 1 Acoustic Noise 88 6 6 1 dU dt Conditions 88 Index 89 Contents VLT Decentral Drive FCD 302 4 MG04H102 VLT is a registered ...

Page 6: ...utput current IN The rated output current supplied by the frequency converter UMAX The maximum output voltage Input Control command Start and stop the connected motor using the LCP and the digital inputs Functions are divided into two groups Functions in group 1 have higher priority than functions in group 2 Group 1 Reset Coasting stop Reset and Coasting stop Quick stop DC braking Stop and the Off...

Page 7: ...tage input 10 to 10 V DC Analog Outputs The analog outputs can supply a signal of 0 20 mA or 4 20 mA Automatic Motor Adaptation AMA The AMA algorithm determines the electrical parameters for the connected motor at standstill Brake Resistor The brake resistor is a module capable of absorbing the brake power generated in regenerative braking This regenerative braking power increases the intermediate...

Page 8: ...ed frequency converter or motor THD Total Harmonic Distortion state the total contribution of harmonic Trip A state entered in fault situations e g if the frequency converter is subject to an over temperature or when the frequency converter is protecting the motor process or mechanism Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating re...

Page 9: ...lations e g law on mechanical tools regulations for the prevention of accidents etc Modifications on the frequency converters by means of the operating software are allowed Failure to follow design recommendations could result in death or serious injury once the equipment is operation NOTE Hazardous situations shall be identified by the machine builder integrator who is responsible for taking nece...

Page 10: ...n 1 4 2 What Is Covered The EU Guidelines on the Application of Council Directive 2004 108 EC outline three typical situations of using a frequency converter See below for EMC coverage and CE labelling 1 The frequency converter is sold directly to the end 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 ...

Page 11: ... or installation NOTE 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 instal lation guidelines for the Power Drive system The standards and test levels stated for Power Drive systems are complied with provided that the EMC correct instructions for installation are followed see 3 4 4...

Page 12: ...ontrol which requires a speed feedback to an input A properly optimised 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 is controlling the application as tension control Closed loop in Flux mode with encoder feedback comprises motor control based on feedback signals f...

Page 13: ...E 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 That leads to an associated Action as illustrated in Illustration 2 4 Par 13 43 Comparator Operator Par 13 43 Logic Rule Operator 2 Par 13 51 SL Controller Event Par 13 51 SL Controller Action 130BB671 10 Coast Start timer Set Do X low Select set up 2 Running...

Page 14: ...0BB673 10 Illustration 2 7 Logic Rules Application Example Parameters FC 24 V 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 COM R1 R2 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 01 02 03 04 05 06 130BB839 10 Function Setting 4 30 Motor Feedback Loss Function 1 Warning 4 31 Motor Feedback Speed Error 100 RPM 4 32 Motor Feedback Loss Timeout 5 s 7 00 Speed PID Feedback Sou...

Page 15: ...ncreases the leakage current I4 When a screened cable is used for fieldbus relay control cable signal interface or brake ensure the screen is mounted on the enclosure at both ends In some situations however it will be necessary to break the screen to avoid current loops Earth Plane LINE FREQUENCY MOTOR CABLE SCREENED MOTOR CONVERTER Earth wire Screen z z z L1 L2 L3 PE U V W PE 175ZA062 11 C S I 2 ...

Page 16: ... 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 second environment industrial with a supply voltage lower than 1000 V Class A Group 2 C4 Frequency converters installed in the second environment with a supply voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use ...

Page 17: ...bout e g by lightning that strikes near installations EN 61000 4 6 IEC 61000 4 6 RF Common mode Simulation of the effect from radio transmission equipment joined by connection cables See Table 2 5 Voltage range 200 240 V 380 480 V Basic standard Burst IEC 61000 4 4 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 Acceptance cri...

Page 18: ... value Freeze ref Freeze output Speed up speed down ref Remote Ref in max ref max ref Scale to RPM or Hz Scale to Nm Scale to process unit Relative X X Y 100 DigiPot DigiPot DigiPot max ref min ref DigiPot D1 P 5 1x 15 Preset 1 External 0 Process Torque Speed open closed loop 1 2 3 4 5 6 7 0 0 1 Relative scaling ref P 3 18 Ref resource 1 P 3 15 Ref resource 2 P 3 16 Ref resource 3 P 3 17 200 200 Y...

Page 19: ... are described in parameter groups 6 1 and 6 2 and the scaling of digital pulse references are described in parameter group 5 5 Reference limits and ranges are set in parameter group 3 0 2 3 1 Reference Limits 3 00 Reference Range 3 02 Minimum Reference and 3 03 Maximum Reference together define the allowed range of the sum of all references The sum of all references are clamped when necessary The...

Page 20: ...nce 2 3 3 Scaling of Analog and Pulse References and Feedback 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 13 are clamped whereas a feedback above or below is not RPM Resource output Resource input Terminal X low Terminal X high Low refer...

Page 21: ...re cases also the feedback should have a dead band around zero i e to make sure the machine is stopped when the reference is near zero To make the dead band active and to set the amount of dead band the following settings must be done Either Minimum Reference Value see Table 2 6 for relevant parameter or Maximum Reference Value must be zero In other words Either P1 or P2 must be on the X axis in t...

Page 22: ...ed to 200 200 1000 RPM 1000 RPM Reference is scaled according to min max reference giving a speed Scale to speed 500 RPM 500 RPM Range Speed setpoint Motor control Range 200 RPM 200 RPM Motor Digital input 19 Low No reversing High Reversing Limits Speed Setpoint according to min max speed Motor PID RPM RPM Dead band Digital input General Reference parameters Reference Range Min Max Minimum Referen...

Page 23: ...ce algorithm Reference 100 0 500 RPM 0 0 0 RPM Range Limited to 100 100 500 RPM 500 RPM Limited to 200 200 1000 RPM 1000 RPM Reference is scaled according to max reference giving a speed Scale to speed 500 RPM 500 RPM Range Speed setpoint Motor control Range 200 RPM 200 RPM Motor Digital input 19 Low No reversing High Reversing Limits Speed Setpoint according to min max speed Motor PID Dead band D...

Page 24: ...x reference Scale to RPM 1000 RPM 1000 RPM Range Speed setpoint Motor control Motor Limits Speed to min max motor speed Motor PID RPM Dead band General Reference parameters Reference Range Max Max Minimum Reference Don t care Maximum Reference 1000 RPM 100 0 General Motor parameters Motor speed direction Both directions Motor speed Low limit 0 RPM Motor speed high limit 1500 RPM 1V to 1V RPM 500 R...

Page 25: ... current exceeds 3 5 mA Earth grounding must be reinforced in one of the following ways Earth ground wire terminal 95 of at least 10 mm2 Two separate earth ground wires both complying with the dimensioning rules See EN IEC61800 5 1 and EN50178 for further information Using RCDs Where residual current devices RCDs also known as earth leakage circuit breakers ELCBs are used comply with the following...

Page 26: ...itudes above 3 km contact Danfoss regarding PELV WARNING Touching the electrical parts could be fatal even after the equipment has been disconnected from mains Also make sure that other voltage inputs have been disconnected such as load sharing linkage of DC intermediate circuit as well as the motor connection for kinetic back up Before touching any electrical parts wait at least the amount of tim...

Page 27: ... 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 25 shows a typical braking cycle NOTE Motor suppliers often use S5 when stating the permissible load which is an expression of intermittent duty cycle The intermittent duty cycle for the resistor is calculated...

Page 28: ...nt to avoid fire risk D F size frequency converters contain more than one brake chopper Consequently use one brake resistor per brake chopper for those frame sizes 2 7 4 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 us...

Page 29: ...pplications 3 1 1 1 Hygienic Installation The 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 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 requireme...

Page 30: ...s refer to FCD 302 Operating Instructions MG04F Mains connection 130BC286 10 U 96 V 97 W 98 L1 L2 L3 L1 91 L2 92 L3 93 12 27 T1 T2 T3 NO NC NO NC L2 L3 PE L1 41 33 5 3 1 2 4 6 34 42 1 2 Illustration 3 4 Large Unit only Circuit Breaker and Mains Disconnect 1 Looping terminals 2 Circuit breaker Table 3 1 Legend L1 L2 L3 PE U 96 V 97 W 98 L1 91 L2 92 L3 93 12 27 U V W 1 2 3 4 5 6 7 8 1 130BC287 10 Il...

Page 31: ... the consequence of component break down internally in the frequency converter Branch Circuit Protection In order to protect the installation against electrical and fire hazard all branch circuits in an installation switch gear machines etc must be protected against short circuit and over current according to national international regulations NOTE The recommendations given do not cover Branch cir...

Page 32: ...e clamp This is done by using the supplied installation devices in the frequency converter If it is necessary to split the screen to install a motor isolator or motor relay the screen 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...

Page 33: ...M25 5 M20 6 24 V M20 7 Motor M25 Table 3 5 Legend 3 3 2 Mains Disconnectors The frequency converter is available with optional service switch on mains side or motor side built in circuit breaker on the mains side large unit only Specify the requirement when ordering Illustration 3 9 and Illustration 3 10 show examples of configuration for the large unit 130BC986 10 Illustration 3 9 Location of Ser...

Page 34: ... applications with parallel motors in U F mode 1 01 Motor Control Principle 0 Set the U F graph in 1 55 U f Characteristic U and 1 56 U f Characteristic F VCC mode may be used in some applications The total current consumption of the motors must not exceed the rated output current IINV for the frequency converter If motor sizes are widely different in winding resistance starting problems may arise...

Page 35: ...uses an overcurrent in the inverter The inverter is turned off individually when the short circuit current exceeds the permitted value Alarm 16 Trip Lock 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 permitted No damage ...

Page 36: ...urrent Limit Min Speed Limit 4 11 Motor Speed Low Limit RPM or 4 12 Motor Speed Low Limit Hz limit the operating speed range to for instance between 30 and 50 60 Hz Max Speed Limit 4 13 Motor Speed High Limit RPM or 4 19 Max Output Frequency limit the max output speed the drive can provide ETR Electronic Thermal relay The ETR function measures actual current speed and time to calculate motor tempe...

Page 37: ... Location of DIP Switches 1 S201 terminal 53 2 S202 terminal 54 3 S801 standard bus termination 4 Profibus termination 5 Fieldbus address Table 3 9 Legend NOTE Switches 4 and 5 are only valid for units fitted with fieldbus options 3 4 1 3 Basic Wiring Example Connect terminals 27 and 37 to 24 V terminals 12 and 13 as shown in Illustration 3 13 Default settings 27 Coast inverse 5 10 Terminal 18 Dig...

Page 38: ...ce COM RS 485 61 PNP Source NPN Sink RS 485 ON 1 2 ON 1 2 ON 1 2 0V VCXA Profibus interface GND1 GND1 RS485 66 63 62 67 GX Illustration 3 14 Electrical Terminals without Options A analog D digital Terminal 37 is used for Safe Stop Relay 2 has no function when the frequency converter has mechanical brake output Very long control cables and analogue signals may in rare cases result in 50 60 Hz earth...

Page 39: ...rmal closed 240 V AC Relay 2 Terminal 04 common Terminal 05 normal open 240 V AC Terminal 06 normal closed 240 V AC Relay 1 and relay 2 are programmed in 5 40 Function Relay 5 41 On Delay Relay and 5 42 Off Delay Relay 37 20 13 B11 B12 37 B10 B09 20 12 G B07 B08 20 B06 B05 N V R B03 B04 P B02 B01 Z A Z B 5V B GND A A 24V B GND 130BC998 10 Illustration 3 16 Relay Connection 3 4 2 Brake Resistors In...

Page 40: ...eratures above 50 C Contact Danfoss for the application note for tables and elaboration Only the case of running at low motor speeds is elaborated here 3 4 3 2 Automatic Derating The drive constantly checks for critical levels Critical high temperature on the control card or heatsink High motor load High DC link voltage Low motor speed As a response to a critical level the frequency converter adju...

Page 41: ... cable but the motor cable must be installed in conduit separate from the control and mains cables Full connection of the conduit from the drive to the motor is required The EMC performance of flexible conduits varies a lot and information from the manufacturer must be obtained Connect the screen armour conduit to earth at both ends for motor cables as well as for control cables In some cases it i...

Page 42: ...00mm between con trol cables motor cable and Motor cable Motor 3 phases and PLC etc Mains supply mains cable PLC Protective earth Reinforced protective earth Illustration 3 18 EMC correct Electrical Installation of a Frequency Converter System Integration VLT Decentral Drive FCD 302 MG04H102 VLT is a registered Danfoss trademark 41 3 3 ...

Page 43: ... 100nF FC PE PE PLC 130BB609 11 Illustration 3 21 Screening for 50 60 Hz Ground Loops Avoid EMC noise on serial communication This terminal is connected to earth via an internal RC link Use twisted pair cables to reduce interference between conductors The recommended method is shown in Illustration 3 22 PE FC PE FC 130BB923 11 PE PE 69 68 61 69 68 61 1 2 Illustration 3 22 Screening for EMC Noise R...

Page 44: ...tortion THD to 40 3 4 5 2 Effect of Harmonics in a Power Distribution System In Illustration 3 25 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 a...

Page 45: ...esonance and type of supply transformer generator Application load profile number of loads and load size Local national requirements regulations IEEE519 IEC G5 4 etc Total cost of ownership initial cost efficiency maintenance etc 3 4 5 5 Harmonic Calculation Determining the degree of voltage pollution on the grid and needed precaution is done with the Danfoss MCT31 calculation software From www da...

Page 46: ...erter is running follow these steps Step 1 Locate the motor name plate NOTE The motor is either star Y or delta connected Δ This information is located on the motor name plate data 130BD002 10 INmax 7 2 A nLT 0 370 rpm fmax250 Hz tamb 40 C KTY 84 130 28 kg P3 IP 69K 155 C F 178uxxxxxxxxxxb011 i 8 12 Type OGDHK231K131402L09R1S11P1A9010H1Bxx Barcode Made in Germany MLT 140 65 Nm 2 9 L Optileb GT220 ...

Page 47: ...ctions 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 NOTE Mounting frequency converters in aggressive environments increases the risk of stoppa...

Page 48: ...l 27 Digital Input 2 Coast inverse Default Value Notes comments Parameter group 1 2 must be set according to motor Table 4 1 AMA with T27 Connected Parameters FC 24 V 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 COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 130BB930 10 Function Setting 1 29 Automatic Motor Adaptation AMA 1 Enable complete AMA 5 12 Terminal 27 Digital ...

Page 49: ...fe Stop 1 Safe Stop Alarm Default Value Notes comments If 5 12 Terminal 27 Digital Input is set to 0 No operation a jumper wire to terminal 27 is not needed Table 4 5 Start Stop Command with Safe Stop 130BB805 10 Speed Start 18 Illustration 4 1 Start Stop Command with Safe Stop Parameters FC 24 V 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 COM 12 13 18 19 20 27 29 32 33 37...

Page 50: ...ult Value Notes comments Table 4 8 External Alarm Reset Parameters FC 24 V 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 COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 A53 U I 5kΩ 130BB683 10 Function Setting 6 10 Terminal 53 Low Voltage 0 07 V 6 11 Terminal 53 High Voltage 10 V 6 14 Terminal 53 Low Ref Feedb Value 0 RPM 6 15 Terminal 53 High Ref Feedb Value 1500 RPM De...

Page 51: ...meters Table 4 11 RS 485 Network Connection CAUTION Thermistors must use reinforced or double insulation to meet PELV insulation requirements Parameters FC 24 V 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 COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 A53 U I 130BB686 11 Function Setting 1 90 Motor Thermal Protection 2 Thermistor trip 1 93 Thermistor Source 1 Analog i...

Page 52: ...in within 5 then the drive continues and the warning disappears But Relay 1 will still be triggered until Reset on the LCP Table 4 13 Using SLC to Set a Relay Parameters FC 24 V 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 COM R1 R2 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 01 02 03 04 05 06 130BB841 10 Function Setting 5 40 Function Relay 32 Mech brake ctrl 5 10 Term...

Page 53: ...haft end 4 3 Closed Loop Drive System A closed loop drive system usually comprises elements such as Motor Add Gearbox Mechanical Brake Frequency converter Encoder as feed back system Brake resistor for dynamic braking Transmission Load Applications demanding mechanical brake control will usually need a brake resistor 130BC996 10 3 4 7 5 6 ON WARNING ALARM Bus MS NS2 NS1 1 2 Illustration 4 7 Basic ...

Page 54: ...it 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 ch...

Page 55: ...o slowly only a few RPM that it can be determined if the value in 16 20 Motor Angle is increasing or decreasing 16 20 Motor Angle N A read only parameter Note An increasing value overflows at 65535 and starts again at 0 If 16 20 Motor Angle is decreasing then change the encoder direction in 5 71 Term 32 33 Encoder Direction 5 71 Term 32 33 Encoder Direction 1 Counter clockwise if 16 20 Motor Angle...

Page 56: ...lue for the Bandwith is 20 rad s Check the result of the 30 83 Speed PID Proportional Gain calculation against the following formula not required if you are using a high resolution feedback such as a SinCos feedback Par 7 02 MAX 0 01 x 4 x Encoder Resolution x Par 7 06 2 x π x Max torque ripple A good start value for 7 06 Speed PID Lowpass Filter Time is 5 ms lower encoder resolution calls for a h...

Page 57: ... control performance The two Flux motor control principles are specially dependant on proper Speed Control PID tuning prior to tuning the Process Control PID to yield their full potential P 7 30 normal inverse PID P 7 38 1 Feed forward Ref Handling Feedback Handling unit unit unit speed Scale to speed P 4 10 Motor speed direction To motor control Process PID 130BA178 10 _ 0 100 100 0 100 100 Illus...

Page 58: ... of change of the feedback A setting of zero disables the differentiator 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 diff...

Page 59: ...tilation speed is increased as well so as 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 4 20 mA Min Max speed 300 1500 RPM Transmitter 96 97 99 98 91 92 93 95 50 12 L1 L2 L1 PE L3 W PE V U F1 L2 L3 N PE 130BA175 12 18 53 37 55 54 M 3 5 kΩ Illustration 4 11 Two wire Transmitter 1 Start Stop via sw...

Page 60: ... C If 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 C 0 35 Ref Par 3 10 0 100 Par 3 03 par 3 02 24 5 C 3 14 Preset Relative Reference to 3 18 Relative Scaling Reference Resource 0 No Function 4 Adjust limits for the frequency converter Set ramp times to an appropriate value as 20 s 3 41 3...

Page 61: ...ls tuning method NOTE The method described must not be used on applications that could be damaged by the oscillations created by marginally stable control settings The criteria for adjusting the parameters are based on evaluating the system at the limit of stability rather than on taking a step response The proportional gain is increased until continuous oscillations are observed as measured on th...

Page 62: ... level The control is of the inverse type which means that when the temperature increases the ventilation speed is increased as well so as 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 4 20 mA Min Max speed 300 1500 RPM Transmitter 96 97 99 98 91 92 93 95 50 12 L1 L2 L1 PE L3 W PE V U F1 L2 L3 N ...

Page 63: ... handling system is received and fed through the ramp limitation and speed limitation before being sent to the motor control The output of the motor control is then limited by the maximum frequency limit If 1 00 Configuration Mode is set to 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 ...

Page 64: ...nd in parameter group 7 2 and 7 3 4 5 3 Control Structure in Flux with Motor Feedback 130BA054 11 P 3 P 7 0 P 7 2 _ _ P 7 20 Process feedback 1 source P 7 22 Process feedback 2 source P 4 11 Motor speed low limit RPM P 4 12 Motor speed low limit Hz P 4 13 Motor speed high limit RPM P 4 14 Motor speed high limit Hz High Low Ref Process PID Speed PID Ramp P 7 00 PID source Motor controller f max f m...

Page 65: ...faces RS 485 USB or an optional fieldbus See more about starting stopping changing ramps and parameter set ups and so on in parameter group 5 1 digital inputs or parameter group 8 5 serial communication 130BP046 10 Hand on Off Auto on Reset Illustration 4 18 LCP Keys Active Reference and Configuration Mode The active reference can be either the local reference or the remote reference In 3 13 Refer...

Page 66: ...top 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 terminal 29 Output programmed to Torque limit and stop 27 is activated The signal to terminal 27 changes from logic 1 to logic 0 and the motor starts to coast thereby ensuring that the hoist stops...

Page 67: ... an over voltage situation or during safe stop the mechanical brake immediately cuts in Illustration 4 22 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 term...

Page 68: ...t magnet motors WARNING After installation of Safe Stop STO a commissioning test must be performed A passed commissioning test is mandatory after first installation and after each change to the safety installation Safe Stop Technical Data The following values are associated to the different types of safety levels Reaction time for T37 Typical reaction time 10 ms Reaction time delay between de ener...

Page 69: ...idelines The optional safe stop function complies with the following standards EN 954 1 1996 Category 3 IEC 60204 1 2005 category 0 uncontrolled stop IEC 61508 1998 SIL2 IEC 61800 5 2 2007 safe torque off STO function IEC 62061 2005 SIL CL2 ISO 13849 1 2006 Category 3 PL d ISO 14118 2000 EN 1037 prevention of unexpected startup The information and instructions of the instruction manual are not suf...

Page 70: ...eve a Stopping Category 0 EN 60204 1 with Safety Cat 3 EN 954 1 PL d ISO 13849 1 or SIL 2 EN 62061 1 Frequency converter 2 Reset button 3 Safety relay cat 3 PL d or SIL2 4 Emergency stop button 5 Short circuit protected cable if not inside installation IP54 cabinet Table 4 28 Legend Safe Stop Commissioning Test After installation and before first operation perform a commissioning test of the insta...

Page 71: ...ncy converter If the frequency converter is not stopped after the safe delay time the activation of STO will coast the frequency converter NOTE When using the SS1 function the brake ramp of the frequency converter is not monitored with respect to safety 130BC973 10 18 37 4 1 2 12 3 Illustration 4 26 SS1 Example 1 Frequency converter 2 Reset key 3 Safety relay 4 Emergency stop Table 4 30 Legend Exa...

Page 72: ... 1 1 3 4 5 2 37 20 37 20 Illustration 4 28 Paralleling of Multiple Drives Example 1 Frequency converter 2 24 V DC 3 Reset key 4 Safety relay 5 Emergency stop Table 4 32 Legend WARNING Safe Stop activation that is removal of 24 V DC voltage supply to terminal 37 does not provide electrical safety The Safe Stop function itself is therefore not sufficient to implement the Emergency Off function as de...

Page 73: ...allation or application using Safe Stop Perform the test again after each modification of the installation or application involving the Safe Stop NOTE A passed commissioning test is mandatory after first instal lation and after each change to the safety installation The commissioning test select one of cases 1 or 2 as applicable Case 1 Restart prevention for Safe Stop is required that is Safe Stop...

Page 74: ...ynchronous or permanent magnet motors a residual rotation can result from the faults The rotation can be calculated to Angle 360 Number of Poles The application using synchronous or permanent magnet motors must take this residual rotation into consideration and ensure that it does not pose a safety risk This situation is not relevant for asynchronous motors Application Examples VLT Decentral Drive...

Page 75: ...allation box R Installation box small unit stand alone mount No drive part T Installation box large unit stand alone mount No drive part 20 Brackets X No brackets E Flat brackets F 40 mm brackets Position Description Choices options 21 Threads X No installation box M Metric threads 22 Switch option X No switch option E Service switch on mains input F Service switch on motor output H Circuit breake...

Page 76: ...CXXXXXA0BXXXXXXDX The meaning of the characters in the string can be located in the pages containing the ordering numbers in this chapter In the example above a Profibus DP V1 and a 24 V back up option is included in the drive From the Internet based Drive Configurator configure the right drive for the right application and generate the type code string The Drive Configurator will automatically ge...

Page 77: ...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...

Page 78: ...lute 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 NOTE The LEDS are not visible when mounted in an FCD302 frequency converter Reaction in case of an encoder error can be selected in 17 61 Feedbac...

Page 79: ... 103 The MCB 103 Resolver Option 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 The resolver option kit comprises MCB 103 Resolver Option Cable to connect customer terminals to control card Selection of parameters 17 5x resolver Interface MCB 103 Resolver Option suppo...

Page 80: ...gnal is OK from resolver LED 3 is on when Sinus signal is OK from resolver The LEDs are active when 17 61 Feedback Signal Monitoring is set to Warning or Trip 130BT102 10 Illustration 5 6 Resolver Signals 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 max cable length is 150 m when a twisted...

Page 81: ...ansformation Ratio Resolver data sheet 17 59 Resolver Interface 1 Enabled Table 5 8 Adjust following Parameters 5 3 4 24 V Back Up Option MCB 107 External 24 V DC Supply An external 24 V DC 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 External 24 V ...

Page 82: ...0 25 Ø13 130BB712 10 200 1 2 3 4 Illustration 6 1 Small Unit Illustration 6 2 Large Unit Motor side 1xM20 1xM25 Control side 2xM20 9xM161 Mains side 2xM25 Table 6 1 Legend 1 Also used for 4xM12 6xM12 sensor actuator sockets Specifications VLT Decentral Drive FCD 302 MG04H102 VLT is a registered Danfoss trademark 81 6 6 ...

Page 83: ...inuous 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 Max cable size mains motor brake mm2 AWG solid cable 6 10 flexible cable 4 12 Table 6 2 FCD 302 Shaft Output Output Current and Input Current To meet UL cULrequirements use the following pre fuses 1 American Wire Gauge Max Cable cross section is the largest cable cross section that can be at...

Page 84: ...95 Overvoltage warning with brake 810 Overvoltage trip 820 Table 6 4 FCD 302 DC Voltage Level Fuses The unit is suitable for use on a circuit capable of delivering not more than 100 000 RMS symmetrical Amperes 500 V maximum Circuit breaker The unit is suitable for use on a circuit capable of delivering not more than 10 000 RMS symmetrical Amperes 500 V maximum Specifications VLT Decentral Drive FC...

Page 85: ... sections for control cables1 Max motor cable length screened 10 m Max motor cable length unscreened without fulfilling emission specification 10 m Maximum cross section to control terminals flexible rigid wire without cable end sleeves 1 5 mm2 16 AWG Maximum cross section to control terminals flexible wire with cable end sleeves 1 5 mm2 16 AWG Maximum cross section to control terminals flexible w...

Page 86: ...c 0 PNP 4 V DC Voltage level logic 1 PNP 20 V DC Nominal input current at 24 V 50 mA rms Nominal input current at 20 V 60 mA rms Input capacitance 400 nF Analog inputs Number of analog inputs 2 Terminal number 53 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201 switch S202 OFF U Voltage level 10 to 10 V scaleable Input resistance Ri approx 10 kΩ Max volt...

Page 87: ...ammable analog outputs 1 Terminal number 42 Current range at analog output 0 4 to 20 mA Max load GND analog output less than 500 Ω Accuracy on analog output Max error 0 5 of full scale Resolution on analog output 12 bit The analogue output is galvanically isolated from the supply voltage PELV and other high voltage terminals Control card RS 485 serial communication Terminal number 68 P TX RX 69 N ...

Page 88: ... DC 13 1 Inductive load 24 V DC 0 1 A Min terminal load on 1 3 NC 1 2 NO 4 6 NC 4 5 NO 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 50 Output voltage 10 5 V 0 5 V Max load 15 mA The 10 V DC...

Page 89: ...rongly recommend to fit a dU dt filter or a Sine Wave filter on the output of the frequency converter For further information about du dt and Sine Wave filters see the Output Filters Design Guide 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 screened or unscreened inductance The natur...

Page 90: ... DeviceNet 5 Digital Inputs 85 Output 86 Disposal Instruction 10 Drive Configurator 75 E Earth Leakage Current 24 Efficiency 88 Electro 65 EMC Directive 2004 108 EC 9 Directive 2004 108 EC 10 Test Results 15 Emission Requirements 15 External 24 V DC Supply 80 F Flux 62 63 Freeze Output 5 Reference 17 G General Aspects Of EMC Emissions 14 H Hoist Mechanical Brake 25 I Immunity Requirements 15 Inter...

Page 91: ...eed 5 RCD 5 Reference Limits 18 Relay Outputs 87 Residual Current Device 44 Rise Time 88 S Safety Precautions 8 Scaling Of Analog And Pulse References And Feedback 19 Of Preset References And Bus References 19 Screened armoured 31 Serial Communication 88 Short Circuit Motor Phase Phase 34 Circuit Ratio 43 Speed PID 11 62 PID Control 53 Reference 47 Static Overload In VVCplus Mode 34 Surroundings 8...

Page 92: ...www danfoss com drives MG04H102 130R0320 MG04H102 Rev 2012 05 08 ...

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