Danfoss VLT FC 360, Design Manual

Page 1: ...MAKING MODERN LIVING POSSIBLE Design Guide VLT AutomationDrive FC 360...

Page 2: ......

Page 3: ...nt Control in VVCplus Mode 16 2 3 5 Local Hand On and Remote Auto On Control 16 2 4 Reference Handling 17 2 4 1 Reference Limits 18 2 4 2 Scaling of Preset References and Bus References 19 2 4 3 Scali...

Page 4: ...utions 42 3 2 FC Protocol Overview 42 3 3 Network Configuration 42 3 4 FC Protocol Message Framing Structure 42 3 4 1 Content of a Character byte 42 3 4 2 Telegram Structure 43 3 4 3 Telegram Length L...

Page 5: ...53 3 10 Examples 53 3 10 1 Read Coil Status 01 HEX 53 3 10 2 Force Write Single Coil 05 HEX 54 3 10 3 Force Write Multiple Coils 0F HEX 54 3 10 4 Read Holding Registers 03 HEX 54 3 10 5 Preset Single...

Page 6: ...tions 67 6 1 1 Mains Supply 3 x 380 480 V AC 67 6 2 General Specifications 69 6 3 Fuse Specifications 73 6 3 1 Fuses 73 6 3 2 Recommendations 73 6 3 3 CE Compliance 73 6 4 Efficiency 74 6 5 Acoustic N...

Page 7: ...ent or property damage only accidents NOTE Indicates highlighted information that should be regarded with attention to avoid mistakes or operate equipment at less than optimal performance Indicates de...

Page 8: ...Rated motor speed nameplate data ns Synchronous motor speed ns 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 Instantaneous moto...

Page 9: ...n 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...

Page 10: ...Vector Modulation 14 00 Switching Pattern Power Factor The power factor is the relation between I1 and IRMS Power factor 3 x U x I1 cos 3 x U x IRMS The power factor for 3 phase control I1 x cos 1 IRM...

Page 11: ...ll voltage inputs have been disconnected including load sharing linkage of DC intermediate circuit as well as motor connection for kinetic back up Systems where frequency converters are installed must...

Page 12: ...installs the frequency converter himself for use with a hobby machine a kitchen appliance etc For such applications the frequency converter must be CE labelled in accordance with the EMC directive 2...

Page 13: ...rborne particles such as dust may cause mechanical electrical or thermal failure in the frequency converter A typical indicator of excessive levels of airborne particles is dust particles around the f...

Page 14: ...80 V 7 5 kW 380 480 V 11 15 kW 380 480 V Frame size J5 J6 J7 130BA810 10 130BA826 10 130BA826 10 Enclosure protection IP20 IP20 IP20 High overload rated power 160 overload torque 18 5 22 kW 380 480 V...

Page 15: ...9 D IN 24 V NPN 0 V PNP 27 24 V 0 V D IN OUT 0 V PNP 24 V NPN D IN OUT 0 V 24 V 29 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 82 BR 81 24 V NPN 0 V PNP 0 10 V DC UDC 88 RFI...

Page 16: ...Source Torque control The torque control function is used in applications where the torque on motor output shaft is controlling the application as tension control Torque control can be selected in 1 0...

Page 17: ...ed 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...

Page 18: ...e 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 the Hand...

Page 19: ...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 5 1x 15 Prese...

Page 20: ...es are described in parameter groups 6 1 Analog Input 53 and 6 2 Analog Input 54 and the scaling of digital pulse references are described in parameter group 5 5 Pulse Input Reference limits and range...

Page 21: ...s is 0 reference equals Min Reference and 100 reference equals Max reference When 3 00 Reference Range 1 Max Max 100 reference equals Max Reference 100 reference equals Max Reference 2 4 3 Scaling of...

Page 22: ...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 reference v...

Page 23: ...In other words Either P1 or P2 must be on the X axis in Illustration 2 9 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...

Page 24: ...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 No reversing High...

Page 25: ...gorithm 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 20 Hz Rang...

Page 26: ...ain proportional to the rate of change of the feedback A setting of zero disables the differentiator 7 05 Speed PID Diff Gain Limit If there are quick changes in reference or feedback in a given appli...

Page 27: ...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 c...

Page 28: ...table limits for the motor speed and frequency 4 12 Motor Speed Low Limit Hz 4 14 Motor Speed High Limit Hz 4 19 Max Output Frequency 0 Hz 50 Hz 60 Hz 4 Configure the Speed Control and select the Moto...

Page 29: ...Control Principle U f VVCplus 3 Process N A Process Table 2 6 Control Configuration NOTE The Process Control PID will work under the default parameter setting but tuning the parameters is highly recom...

Page 30: ...ss PID Differentiation Time Provides a gain proportional to the rate of change of the feedback A setting of zero disables the differentiator 7 36 Process PID Diff Gain Limit If there are quick changes...

Page 31: ...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...

Page 32: ...erence 80 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 Pa...

Page 33: ...to use the Ziegler Nichols tuning method NOTE Do not use the Ziegler Nichols Tuning method in applications that could be damaged by the oscillations created by marginally stable control settings The c...

Page 34: ...t higher frequencies which reduces the screen effect and increases the leakage current I4 If a screened cable is used for fieldbus relay control cable signal interface and brake the screen must be mou...

Page 35: ...rements EN 55011 Class A Group 2 Industrial environment Class A Group 1 Industrial environment EN IEC 61800 3 Category C3 Second environment Industrial Category C2 First environment Home and office J1...

Page 36: ...communication equipment as well as 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 devic...

Page 37: ...0BD447 10 1 3 2 a M Illustration 2 18 Galvanic Isolation 1 Power supply SMPS for control cassette 2 Communication between power card and control cassette 3 Customer relays 4 RS 485 standard bus interf...

Page 38: ...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 U...

Page 39: ...e 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 infor...

Page 40: ...ains switch or contactor to disconnect the mains for the frequency converter The contactor can be controlled by the frequency converter NOTE Do not touch the brake resistor as it can get very hot whil...

Page 41: ...the SLC execute action 0 and start evaluating event 1 It is possible to programme from 1 to 20 events and actions When the last event action has been executed the sequence starts over again from event...

Page 42: ...25 Trip Delay at Torque Limit 2 11 1 Motor Thermal Protection To protect the application from serious damage VLT AutomationDrive offers several dedicated features Torque limit The Torque limit feature...

Page 43: ...length m Max 1200 including drop lines Max 500 station to station Table 3 1 Cable 3 1 2 Network Connection Connect the frequency converter to the RS 485 network as follows see also Illustration 3 1 1...

Page 44: ...yer is RS 485 thus utilizing the RS 485 port built into the frequency converter The FC protocol supports different telegram formats A short format of 8 bytes for process data A long format of 16 bytes...

Page 45: ...a bytes plus the address byte ADR and the data control byte BCC 4 data bytes LGE 4 1 1 6 bytes 12 data bytes LGE 12 1 1 14 bytes Telegramscontaining texts 101 n bytes Table 3 4 Length of Telegrams 1 T...

Page 46: ...arameters between master and slave The data block is made up of 12 bytes 6 words and also contains the process block PKE IND ADR LGE STX PCD1 PCD2 BCC 130BA271 10 PWEhigh PWElow Illustration 3 5 Param...

Page 47: ...write access 15 No text available 17 Not while Running 18 Other error 100 100 130 No bus access for this parameter 131 Write to factory set up not possible 132 No LCP access 252 Unknown viewer 253 Req...

Page 48: ...Parameter values are transferred as whole numbers only Conversion factors are therefore used to transfer decimals 4 12 Motor Speed Low Limit Hz has a conversion factor of 0 1 To preset the minimum fre...

Page 49: ...o request access to another device This process includes how the Modbus RTU responds to requests from another device and how errors are detected and reported It also establishes a common format for th...

Page 50: ...racters The format for each byte is shown in Table 3 12 Start bit Data byte Stop parity Stop Table 3 12 Format for Each Byte Coding System 8 bit binary hexadecimal 0 9 A F 2 hexadecimal characters con...

Page 51: ...unique code into the data field of the response message This tells the master what kind of error occurred or the reason for the exception Also refer to 3 8 10 Function Codes Supported by Modbus RTU a...

Page 52: ...stop 05 Quick stop No quick stop 06 Freeze freq No freeze freq 07 Ramp stop Start 08 No reset Reset 09 No jog Jog 10 Ramp 1 Ramp 2 11 Data not valid Data valid 12 Relay 1 off Relay 1 on 13 Relay 2 of...

Page 53: ...WHAT 38296 for details 8 9 40009 Index pointer Read Write Sub index of parameter to be accessed Refer to WHAT 38297 for details 9 10 40010 FC par 0 01 Dependent on parameter access Parameter 0 01 Mod...

Page 54: ...the wrong state to process a request of this type for example because it is not configured and is being asked to return register values 2 Illegal data address The data address received in the query i...

Page 55: ...izes range from 1 register 2 characters up to 10 registers 20 characters 3 10 Examples The following examples illustrate various Modbus RTU commands 3 10 1 Read Coil Status 01 HEX Description This fun...

Page 56: ...y converter address Function 0F write multiple coils Coil Address HI 00 Coil Address LO 10 coil address 17 Quantity of Coils HI 00 Quantity of Coils LO 10 16 coils Byte Count 02 Force Data HI Coils 8...

Page 57: ...3 29 Query Response The normal response is an echo of the query returned after the register contents have been passed Field Name Example HEX Slave Address 01 Function 06 Register Address HI 03 Registe...

Page 58: ...with the corresponding function on the digital inputs Bit 02 DC brake Bit 02 0 leads to DC braking and stop Set braking current and duration in 2 01 DC Brake Current and 2 02 DC Braking Time Bit 02 1...

Page 59: ...verse Bit 15 0 No reversing Bit 15 1 Reversing In the default setting reversing is set to digital in 8 54 Reversing Select Bit 15 causes reversing only when Serial communication Logic or Logic and is...

Page 60: ...o temporary over temperature on the inverter Bit 12 1 The inverter stops because of over temperature but the unit does not trip and resumes operation once the over temperature stops Bit 13 Voltage OK...

Page 61: ...comments Table 4 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 20mA FC A OUT...

Page 62: ...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 PPR 1024 13 00 SL Controller Mode 1...

Page 63: ...peed Up Down Illustration for Table 4 8 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...

Page 64: ...Clockwise 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 determined by looking into the...

Page 65: ...oduct Name 7 Overload H Heavy Duty Q Normal Duty1 8 10 Power Size 0 37 75 kW e g K37 0 37 kW2 1K1 1 1 kW 11K 11 kW etc 11 12 Voltage Class T4 380 480 V three phases 13 15 IP Class E20 IP20 16 17 RFI H...

Page 66: ...541 VLT Numeric LCP IP55 panel mounting 132B01022 VLT Blind Cover for FC 360 132B02621 Standard Control Cassette 132B0255 VLT Decoupling for frame size J1 132B0258 VLT Decoupling for frame sizes J2 J3...

Page 67: ...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 3336 120 1 5 2 5 127 H7K5 7 5 38 46 05 43 0 677 3337 120 1 5 3 3 132 H11K 11 27 32 99 31 0 945 3338 120 1 5 5 2 130...

Page 68: ...38 146 H45K 45 8 9 58 9 17 540 3213 120 16 47 150 H55K 55 6 7 80 7 21 543 3216 120 25 61 150 H75K 75 4 5 68 5 29 581 3219 120 35 81 150 Table 5 5 FC 360 Mains 380 480 V T4 40 Duty Cycle 5 4 Sine wave...

Page 69: ...haring mm2 AWG 2 4 mm2 Estimated power loss at rated max load W 3 52 4 113 9 150 8 Weight enclosure IP20 2 3 2 3 2 3 2 3 2 3 2 5 3 6 3 6 3 6 4 1 Efficiency 4 97 6 97 9 98 0 Table 6 1 Mains Supply 3 x...

Page 70: ...0 current during 60 s 2 American Wire Gauge 3 The typical power loss is at nominal load conditions and expected to be within 15 tolerence relates to variety in voltage and cable conditions Values are...

Page 71: ...oltage Output frequency 0 37 75 kW 0 500 Hz Output frequency in VVCplus Mode 0 200 Hz Switching on output Unlimited Ramp times 0 01 3600 s Torque characteristics Starting torque constant torque maximu...

Page 72: ...pen collector Min frequency at terminal 29 33 4 Hz Voltage level see section on Digital input Maximum voltage on input 28 V DC Input resistance Ri approx 4 k Pulse input accuracy 0 1 1 kHz Max error 0...

Page 73: ...sistive load 250 V AC 3 A Max terminal load AC 15 1 on 01 03 04 06 NC Inductive load cos 0 4 250 V AC 0 2 A Max terminal load DC 1 1 on 01 03 04 06 NC Resistive load 30 V DC 2 A Min terminal load on 0...

Page 74: ...mperature reaches a predefined level An overload temperature cannot be reset until the temperature of the heatsink is below the temperature limit For details of these limits and level refer to the VLT...

Page 75: ...akers which have been tested If fuses circuit breakers according to recommendations are chosen possible damages on the frequency converter will mainly be limited to damages inside the unit 6 3 3 CE Co...

Page 76: ...is marginal However in motors from 11 kW and up the advantages are significant In general the switching frequency does not affect the efficiency of small motors Motors from 11 kW and up have their eff...

Page 77: ...W T4 Cable length m Mains voltage V Rise time sec Upeak kV dU dt kV sec 5 400 0 98 2 8 50 400 1 04 2 4 5 480 1 09 2 6 50 480 1 23 2 6 Table 6 11 FC 360 22 kW T4 6 7 Special Conditions Under some speci...

Page 78: ...3 Derating at 480 V 6 7 2 Automatic Derating The frequency converter constantly checks for critical levels Critical high temperature on the control card or heatsink High motor load Low motor speed As...

Page 79: ...ruction 9 Drive Configurator 64 E Earth Leakage Current 35 Efficiency 74 EMC EMC 72 Directive 2004 108 EC 10 Directive 2004 108 EC 11 Precautions 42 Test Results 33 Extreme Running Conditions 39 F FC...

Page 80: ...rence Limits 18 Relay Outputs 71 Reset 72 Rise Time 74 RS 485 RS 485 41 Installation And Set up 41 S Safety Precautions 8 Scaling Of Analog And Pulse References And Feedback 19 Of Preset References An...

Page 81: ...Index VLT AutomationDrive FC 360 Design Guide MG06B202 VLT is a registered Danfoss trademark 79...

Page 82: ...www danfoss com drives MG06B202 130R0499 MG06B202 Rev 2013 03 06...