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Danfoss VLT FC 360 Design Manual

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MAKING MODERN LIVING POSSIBLE
Design Guide
®
VLT
AutomationDrive FC 360

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Summary of Contents for Danfoss VLT FC 360

  • Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® AutomationDrive FC 360...

  • Page 3: Table Of Contents

    2.5.4 Example of Process PID Control 2.5.5 Optimisation of the Process Regulator 2.5.6 Ziegler Nichols Tuning Method 2.6 General Aspects of EMC 2.6.1 General Aspects of EMC Emissions 2.6.2 EMC Test Results ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 4 3.4.12 Conversion 3.4.13 Process Words (PCD) 3.5 Examples 3.6 Modbus RTU Overview 3.6.1 Assumptions 3.6.2 What the User Should Already Know 3.6.3 Modbus RTU Overview 3.6.4 Frequency Converter with Modbus RTU ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 5 3.10.5 Preset Single Register (06 HEX) 3.10.6 Preset Multiple Registers (10 HEX) 3.11 Danfoss FC Control Profile 3.11.1 Control Word According to FC Profile (8-10 Protocol = FC profile) 3.11.2 Status Word According to FC Profile (STW) (8-30 Protocol = FC profile) 3.11.3 Bus Speed Reference Value...
  • Page 6 6.2 General Specifications 6.3 Fuse Specifications 6.3.1 Fuses 6.3.2 Recommendations 6.3.3 CE Compliance 6.4 Efficiency 6.5 Acoustic Noise 6.6 dU/dt Conditions 6.7 Special Conditions 6.7.1 Manual Derating 6.7.2 Automatic Derating Index ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 7: Introduction

    AutomationDrive FC 360 Programming Horsepower Guide provides information on how to Kilohertz programme and includes complete parameter Local Control Panel descriptions. Meter Danfoss Drives technical literature is also available online Millihenry Inductance at www.danfoss.com/BusinessAreas/DrivesSolutions/ Milliampere Documentations/Technical+Documentation. Millisecond Minute 1.1.1 Symbols...

  • Page 8: Definitions

    A pulse frequency signal transmitted to the digital inputs Synchronous motor speed (terminal 29 or 33). par . 1 − 23 × 60 s 2 × n s = par . 1 − 39 ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 9: Miscellaneous

    Stegmann. SFAVM Initialising Switching pattern called Stator Flux oriented Asynchronous If initialising is carried out (14-22 Operation Mode), the Vector Modulation (14-00 Switching Pattern). frequency converter returns to the default setting. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 10: Safety Precautions

    Modulation (14-00 Switching Pattern). the necessary time has elapsed before commencing repair work. Power Factor The power factor is the relation between I and I ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 11: Software Version

    The software version number can be seen from 15-43 Software e.g law on mechanical tools, regulations for the prevention Version. of accidents etc. Modifications on the frequency converters by means of the operating software are allowed. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 12: Ce Labelling

    50-1000 V AC and the 75-1500 V DC voltage If he chooses to use only CE labelled ranges. Danfoss CE-labels in accordance with the directive components, he does not have to test the entire and issues a declaration of conformity upon request.

  • Page 13: Air Humidity

    EMC properties of the appliance, system or installation rests NOTE with the installer. As an aid to the installer, Danfoss has prepared EMC installation guidelines for the Power Drive Mounting frequency converters in aggressive environments system.

  • Page 14: Product Overview

    30-45 kW (380-480 V) 55-75 kW (380-480 V) 160% overload torque Table 2.1 Enclosure Types Sizes 11-75 kW also have normal overload: 110% overload Sizes 11-22 kW high overload types: 150% overload ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 15: Electrical Installation

    2) Relay 2 is 2 pole for J1-J3 and 3 pole for J4-J7. Relay 2 of J4-J7 with terminal 4, 5, 6, same NO/NC logic as Relay 1. 3) Dual DC choke in 30-75 kW 4) Switch S801 (bus terminal) can be used to enable termination on the RS-485 port (terminals 68 and 69). ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 16: Control Structures

    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 later in this section. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 17: Control Structure In Vvc Plus

    Select [3] Process in 1-00 Configuration Mode to use the process PID control for closed loop control of e.g. speed or pressure in the controlled application. The Process PID parameters are located in parameter group 7-2* Process Ctrl. Feedb and 7-3* Process PID Ctrl. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 18: Internal Current Control In Vvc Plus Mode

    Off Auto Reset Illustration 2.3 LCP Control Keys Local Reference forces the configuration mode to open loop, independent of the setting of 1-00 Configuration Mode. Local Reference is restored at power-down. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 19: Reference Handling

    No function P 16-02 Analog ref. 200% Ref. in % Pulse ref. -200% Local bus ref. DigiPot No function Analog ref. Pulse ref. Local bus ref. DigiPot Illustration 2.4 Remote Reference ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 20: Reference Limits

    P 3-00 Reference Range= [0] Min to Max references is shown in Illustration 2.5 and Illustration 2.6. Resulting reference P 3-03 Sum of all P 3-02 references Illustration 2.7 Sum of all References ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 21: Scaling Of Preset References And Bus References

    Resource output [Hz] High reference/ feedback value Low reference/ feedback value Resource input Terminal X high Illustration 2.8 Minimum and Maximum Endpoints ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 22 5-51 Term. 29 5-56 Term. 33 High 53 High High Current 54 High High Current High Frequency Frequency [Hz] Voltage [V] [mA] Voltage[V] [mA] [Hz] Table 2.2 P1 and P2 Endpoints ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 23: Dead Band Around Zero

    Quadrant 2 [Hz] or “No unit” High reference/feedback value forward Resource input Low reference/feedback [mA] value Terminal X high Terminal low reverse Quadrant 3 Quadrant 4 Illustration 2.9 Size of Dead Band ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 24 High Reversing Limits Speed Setpoint according to min max speed.!!! Motor PID Range: Motor Motor -8 Hz control +8 Hz Illustration 2.10 Clamping of Reference Input with Limits inside Min to Max ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 25 High Reversing Limits Speed Setpoint according to min max speed.!!! Motor PID Range: Motor Motor -8 Hz control +8 Hz Illustration 2.11 Clamping of Reference Input with Limits outside -Min to +Max ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 26: Pid Control

    Practical settings of parameter 7-06 taken from the number of pulses per revolution on from encoder (PPR): Encoder PPR 7-06 Speed PID Lowpass Filter Time 10 ms 1024 5 ms 2048 2 ms 4096 1 ms Table 2.4 Speed Control Parameters ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 27 33. The pulse frequency range to terminals 32 and 33 is 4 Hz-32 kHz 91 92 93 95 L1 L2 W PE 96 97 24 Vdc Illustration 2.12 Speed Control Programming ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 28 See the guidelines below 8) Finished! Save the parameter setting to the LCP for safe keeping 0-50 LCP Copy [1] All to LCP Table 2.5 Programming Order for Speed PID Control ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 29: Process Pid Control

    % [unit] [unit] [speed] To motor Scale to control speed -100% *(-1) Feedback 100% Handling % [unit] -100% P 7-30 P 4-10 normal/inverse Motor speed direction Illustration 2.13 Process PID Control Diagram ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 30: Process Control Relevant Parameters

    (speed) of less than 1.6 Hz. The low-pass filter improves steady state performance but selecting a too large filter time will deteriorate the dynamic performance of the Process PID Control. Table 2.7 Process Control Parameters ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 31: Example Of Process Pid Control

    Temperature feedback via transmitter (-10 to 40 used is a temperature sensor with a working range of -10 to 40 °C, 4-20 mA. Min./Max. speed 300/1500 RPM. °C, 4-20 mA) connected to terminal 54. ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 32 Process PID Anti Wind-up 7-31 [1] On Process PID start speed 7-32 300 rpm Save parameters to LCP 0-50 [1] All to LCP Table 2.8 Example of Process PID Control Set-up ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 33: Optimisation Of The Process Regulator

    Time To tune the PID controls of the frequency converter, PI-control 0.45 * K 0.833 * P several tuning methods can be used. Danfoss recommends PID tight 0.6 * K 0.5 * P 0.125 * P to use the Ziegler Nichols tuning method.

  • Page 34: General Aspects Of Emc

    To reduce the interference level from the entire system (unit + installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50 MHz (airborne) is especially generated by the control electronics. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 35: Emc Test Results

    3.0-5.5 kW, 380-480 V 25 m 7.5 kW, 380-480 V 25 m 11-15 kW (380-480 V) 25 m 18.5-22 kW (380-480 V) 25 m Table 2.11 EMC Test Results (Emission, Immunity) ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 36: Immunity Requirements

    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.

  • Page 37: Galvanic Isolation (Pelv)

    The earth leakage current is made up of several contri- butions and depends on various system configurations including RFI filtering, screened motor cables, and frequency converter power. ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 38 RCD switch. EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3.5mA. Earth grounding must be reinforced in one of the following ways: ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 39: Brake Functions

    AC brake: The brake energy is distributed in the motor by changing the loss conditions in the Danfoss offers brake resistors with duty cycle of 10% and motor. The AC brake function cannot be used in 40%. If a 10% duty cycle is applied, the brake resistors are applications with high cycling frequency since able to absorb brake power for 10% of the cycle time.
  • Page 40 Check that the brake resistor can cope with a voltage of against overloading in connection with a fault in the 410 V or 820 V - unless Danfoss brake resistors are used. frequency converter. In addition, the brake enables readout of the momentary Danfoss recommends the brake resistance R , i.e.

  • Page 41: Smart Logic Controller

    DC link. A short circuit between two output phases will cause an overcurrent in the inverter. The inverter will be turned off individually when ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 42: Motor Thermal Protection

    The calculated temperature is To protect the application from serious damage VLT visible as a read out parameter in 16-18 Motor Thermal. AutomationDrive offers several dedicated features. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 43: Rs-485 Installation And Set-Up

    69 (N-) on the main control board of the Response Delay receiving a request and transmitting a frequency converter. response. This function is for overcoming Connect the cable screen to the cable clamps. modem turnaround delays. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 44: Emc Precautions

    3.3 Network Configuration The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss standard fieldbus. It defines an access 3.3.1 Frequency Converter Set-up technique according to the master-slave principle for communications via a serial bus.

  • Page 45: Telegram Structure

    Address format 1-126 Bit 7=1 (address format 1-126 active) Bit 0-6=frequency converter address 1-126 Bit 0-6=0 Broadcast The slave returns the address byte unchanged to the master in the response telegram. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 46: The Data Field

    The PKE field contains two subfields: Parameter command and response (AK) and Parameter number (PNU): 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Illustration 3.7 PKE Field ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 47: Parameter Number (Pnu)

    When a slave responds to a parameter request (read command), the present parameter value in the PWE block is transferred and returned to the master. If a parameter ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 48: Data Types Supported By The Frequency Converter

    100. A conversion factor of 0.1 means that the value transferred is multiplied by 0.1. The value 100 is thus E19E 0000 H 0000 H 03E8 perceived as 10.0. high Illustration 3.8 Telegram ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 49: Modbus Rtu Overview

    3.6.1 Assumptions in response, or a time-out occurs. Danfoss assumes that the installed controller supports the interfaces in this document, and strictly observe all requirements and limitations stipulated in the controller and frequency converter.

  • Page 50: Frequency Converter With Modbus Rtu

    A typical message frame is shown in Table 3.14. Start Address Function Data check T1-T2-T3- 8 bits 8 bits N x 8 16 bits T1-T2-T3- bits Table 3.13 Typical Modbus RTU Message Structure ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 51: Start/Stop Field

    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 and 3.8.11 Modbus Exception Codes ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 52 Data not valid Data valid Relay 1 off Relay 1 on Relay 2 off Relay 2 on Set up LSB No reversing Reversing Table 3.15 Frequency Converter Control Word (FC Profile) ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 53 20 bytes space reserved pr parameter in Modbus Map Table 3.17 Adress/Registers Value written in Modbus RTU telegram must be one or less than register number. E.g. Read Modbus Register 1 by writing value 0 in telegram. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 54: How To Control The Frequency Converter

    The PNU (Parameter Number) is translated from the register address contained in the Modbus read or write message. The parameter number is translated to Modbus as (10 x parameter number) DECIMAL. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 55: Storage Of Data

    Coils and registers are addressed explicit with an off-set of 3.10 Examples -1 in Modbus. I.e. Coil 33 is addressed as Coil 32. The following examples illustrate various Modbus RTU commands. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 56: Force/Write Single Coil (05 Hex)

    Starting Address LO 05 (Register address 3029) No. of Points HI No. of Points LO 02 - (3-03 Maximum Reference is 32 bits long, i.e. 2 registers) Error Check (CRC) Table 3.27 Query ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 57: Preset Single Register (06 Hex)

    Write Data LO Table 3.29 Query (Register 4: 1050) Error Check (CRC) Table 3.31 Query Response The normal response returns the slave address, function code, starting address, and quantity of registers preset. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 58: Danfoss Fc Control Profile

    Table 3.32 Response Make a selection in 8-56 Preset Reference Select to define how Bit 00/01 gates with the corresponding function on 3.11 Danfoss FC Control Profile the digital inputs. 3.11.1 Control Word According to FC Profile (8-10 Protocol = FC profile) Bit 02, DC brake Bit 02=’0’...

  • Page 59: Status Word According To Fc Profile (Stw) (8-30 Protocol = Fc Profile)

    Bit 15=’1’: Reversing. In the default setting, reversing is set operation, press [Reset]. to digital in 8-54 Reversing Select. Bit 15 causes reversing only when Serial communication, Logic or Logic and is selected. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 60: Bus Speed Reference Value

    Bit 14=’1’: The torque limit in 4-18 Current Limit is exceeded. Bit 15, Timer OK/limit exceeded Bit 15=’0’: The timers for motor thermal protection and thermal protection are not exceeded 100%. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 61: Application Examples

    * = Default Value * = Default Value A IN Notes/comments: Notes/comments: A OUT 0 ~10 V A OUT Table 4.4 Start/Stop with Reversing and 4 Preset Speeds Table 4.2 Analog Speed Reference (Voltage) ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 62 5 s, the frequency converter continues and the warning disappears. But Relay 1 will still be triggered until pressing [Off/Reset]. Table 4.7 Using SLC to Set a Relay ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 63 S p e e d d o w n ( 3 2 ) Illustration 4.1 Speed Up/Down Illustration for Table 4.8 CAUTION Thermistors must use reinforced or double insulation to meet PELV insulation requirements. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 64: Encoder Connection

    Illustration 4.2 24 V or 10-30 V Encoder Transmission Motor Gearbox Encoder Mech. brake Load Illustration 4.4 Basic Set-up for Closed Loop Speed Control Illustration 4.3 24 V Incremental Encoder. Max. Cable Length 5 ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 65: Type Code And Selection

    Table 5.1 Legend to Illustration 5.1 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 31 32 Illustration 5.2 Typecode String ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 66: Drive Configurator

    FC-360HK37T4E20H2BXCDXXSXXXXAXBX respect to its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide variety of different The meaning of the characters in the string can be located resistors that are specially designed to our frequency in the pages containing the ordering numbers in this converters.

  • Page 67: Ordering Numbers: Brake Resistors 10

    3341 13.3 H37K 11.71 3.206 3359 15.3 H45K 9.58 3.921 3065 H55K 7.80 4.816 3070 H75K 5.68 6.612 3231 Table 5.4 FC 360 - Mains: 380-480 V (T4), 10% Duty Cycle ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 68: Ordering Numbers: Brake Resistors 40

    The frequency of the resonance noise thus corresponds to the switching frequency of the frequency converter. For the FC 360, Danfoss can supply a Sine-wave filter to dampen the acoustic motor noise. The filter reduces the ramp-up time of the voltage, the and the ripple current ΔI to the...

  • Page 69: Specifications

    85 mm /AWG] Estimated power loss at rated max. 331.5 457.7 load [W] Weight enclosure IP20 [kg] 12.3 12.5 97.8% 97.9% Efficiency Table 6.2 Mains Supply 3x380-480 V AC - Heavy Duty ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 70 Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for ( 4) Measured using 5 m screened motor cables at rated load and rated frequency. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 71: General Specifications

    > 19 V DC Voltage level, logic '1' NPN < 14 V DC Maximum voltage on input 28 V DC Pulse frequency range 4 Hz-32 kHz (Duty cycle) Min. pulse width 4.5 ms ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 72 68 (P,TX+, RX+), 69 (N,TX-, RX-) Terminal number 61 Common for terminals 68 and 69 The RS-485 serial communication circuit is functionally seated from other central circuits and galvanically isolated from the supply voltage (PELV). ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 73 Ambient temperature (at 60 AVM switching mode) max. 55 °C - with derating max. 50 °C - at full continuous output current with some power size max. 45 °C - at full continuous output current ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 74 Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high. • The frequency converter is protected against earth faults on motor terminals U, V, W. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 75: Fuse Specifications

    6.3 Fuse Specifications 6.3.1 Fuses Fuses or circuit breakers are mandatory to comply with IEC 60364. Danfoss recommend using a selection of the It is recommended to use fuses and/or circuit breakers on following. the supply side as protection in case of component break- down inside the frequency converter (first fault).

  • Page 76: Efficiency

    Peak voltage on the motor terminals is caused by the switching of the IGBTs. The FC 360 complies with the demands of IEC 60034-25 regarding motors designed to be ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 77: Special Conditions

    23.0 23.0 0.456 1.51 2.65 31.0 26.0 0.236 1.14 3.87 18.5 37.0 37.0 0.408 1.33 2.61 42.5 40.0 Table 6.10 FC 360, 15 kW T4 Table 6.12 Derating at 380 V ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 78: Automatic Derating

    Low motor speed As a response to a critical level, the frequency converter adjusts the switching frequency. For low motor speed, the frequency converter can also force the PWM pattern to SFAVM. ® MG06B202 - VLT is a registered Danfoss trademark...

  • Page 79: Index

    Disposal Instruction................9 Machinery Directive (2006/42/EC)..........10 Drive Configurator................64 Mains Drop-out....................40 Supply..................... 8 Supply (L1, L2, L3)................69 Earth Leakage Current................ 35 Supply 3 X 380-480 V AC............... 67 ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 80 What Is Covered..................10 Rated Motor Speed................6 RCD....................... 7 Read Holding Registers (03 HEX)............ 54 Reference Limits..................18 Relay Outputs..................71 Reset......................72 Rise Time....................74 RS-485 RS-485....................41 Installation And Set-up..............41 ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 81 ® Index AutomationDrive FC 360 Design Guide ® MG06B202 - VLT is a registered Danfoss trademark...
  • Page 82 130R0499 MG06B202 Rev. 2013-03-06 *MG06B202*...

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