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MAKING MODERN LIVING POSSIBLE Design Guide VLT® AutomationDrive FC 360 www.danf

MAKING MODERN LIVING POSSIBLE Design Guide VLT® AutomationDrive FC 360 www.danfoss.com/drives Contents 1 Introduction 5 1.1 How to Read This Design Guide 5 1.1.1 Symbols 5 1.1.2 Abbreviations 5 1.2 Definitions 6 1.2.1 Frequency Converter 6 1.2.2 Input 6 1.2.3 Motor 6 1.2.4 References 6 1.2.5 Miscellaneous 7 1.3 Safety Precautions 8 1.4 Disposal Instruction 9 1.5 Document and Software Version 9 1.6 Approvals and Certifications 10 1.6.1 CE Mark 10 1.6.2 Low Voltage Directive 10 1.6.3 EMC Directive 10 2 Product Overview 11 2.1 Enclosure Size Overview 11 2.2 Electrical Installation 12 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 Modes 18 2.3.3 FC 360 Control Principle 19 2.3.4 Control Structure in VVC+ 20 2.3.5 Internal Current Control in VVC+ Mode 21 2.3.6 Local (Hand On) and Remote (Auto On) Control 21 2.4 Reference Handling 22 2.4.1 Reference Limits 23 2.4.2 Scaling of Preset References and Bus References 24 2.4.3 Scaling of Analog and Pulse References and Feedback 24 2.4.4 Dead Band Around Zero 26 2.5 PID Control 29 2.5.1 Speed PID Control 29 Contents Design Guide MG06B402 Danfoss A/S © 09/2014 All rights reserved. 1 2.5.2 Process PID Control 32 2.5.3 Process Control Relevant Parameters 33 2.5.4 Example of Process PID Control 34 2.5.5 Optimisation of the Process Regulator 36 2.5.6 Ziegler Nichols Tuning Method 36 2.6 EMC Emission and Immunity 37 2.6.1 General Aspects of EMC Emission 37 2.6.2 EMC Emission Requirements 38 2.6.3 EMC Immunity Requirements 38 2.7 Galvanic Isolation 40 2.8 Earth Leakage Current 40 2.9 Brake Functions 41 2.9.1 Mechanical Holding Brake 41 2.9.2 Dynamic Braking 42 2.9.3 Brake Resistor Selection 42 2.10 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 Ordering Numbers: Brake Resistors 10% 48 3.3.2 Ordering Numbers: Brake Resistors 40% 49 4 Specifications 50 4.1 Power-dependent Specifications 50 4.2 General Specifications 52 4.3 Fuses 56 4.3.1 Introduction 56 4.3.2 CE Compliance 56 4.4 Efficiency 57 4.5 Acoustic Noise 57 4.6 dU/dt Conditions 57 4.7 Special Conditions 59 4.7.1 Manual Derating 59 4.7.2 Automatic Derating 59 5 RS485 Installation and Set-up 60 5.1 Introduction 60 5.1.1 Overview 60 Contents Design Guide 2 Danfoss A/S © 09/2014 All rights reserved. MG06B402 5.1.2 Network Connection 61 5.1.3 Hardware Set-up 61 5.1.4 Parameter Settings for Modbus Communication 61 5.1.5 EMC Precautions 61 5.2 FC Protocol 61 5.3 Network Configuration 62 5.4 FC Protocol Message Framing Structure 62 5.4.1 Content of a Character (byte) 62 5.4.2 Telegram Structure 62 5.4.3 Telegram Length (LGE) 62 5.4.4 Frequency Converter Address (ADR) 63 5.4.5 Data Control Byte (BCC) 63 5.4.6 The Data Field 63 5.4.7 The PKE Field 63 5.4.8 Parameter Number (PNU) 64 5.4.9 Index (IND) 64 5.4.10 Parameter Value (PWE) 64 5.4.11 Data Types Supported by the 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 66 5.7 Network Configuration 66 5.8 Modbus RTU Message Framing Structure 67 5.8.1 Introduction 67 5.8.2 Modbus RTU Message Structure 67 5.8.3 Start/Stop Field 67 5.8.4 Address Field 67 5.8.5 Function Field 67 5.8.6 Data Field 68 5.8.7 CRC Check Field 68 5.8.8 Coil Register Addressing 68 5.8.9 How to Control the Frequency Converter 70 5.8.10 Function Codes Supported by Modbus RTU 70 5.8.11 Modbus Exception Codes 70 5.9 How to Access Parameters 70 5.9.1 Parameter Handling 70 Contents Design Guide MG06B402 Danfoss A/S © 09/2014 All rights reserved. 3 5.9.2 Storage of Data 71 5.10 Examples 71 5.10.1 Read Coil Status (01 hex) 71 5.10.2 Force/Write Single Coil (05 hex) 72 5.10.3 Force/Write Multiple Coils (0F hex) 72 5.10.4 Read Holding Registers (03 hex) 72 5.10.5 Preset Single Register (06 hex) 73 5.10.6 Preset Multiple 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 profile) 75 5.11.3 Bus Speed Reference Value 77 6 Application Examples 78 6.1 Introduction 78 6.1.1 Encoder Connection 81 6.1.2 Encoder Direction 81 6.1.3 Closed Loop Drive System 81 Index 82 Contents Design Guide 4 Danfoss A/S © 09/2014 All rights reserved. MG06B402 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 ILIM 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 IM,N Nominal motor frequency fM,N Nominal motor power PM,N Nominal motor voltage UM,N Permanent magnet motor PM motor Protective extra low voltage PELV Printed circuit board PCB Rated inverter output current IINV Revolutions per minute RPM Regenerative terminals Regen Second s Synchronous motor speed ns Torque limit TLIM Volts V Maximum output current IVLT,MAX Rated output current supplied by the frequency converter IVLT,N Introduction Design Guide MG06B402 Danfoss A/S © 09/2014 All rights reserved. 5 1 1 1.2 Definitions 1.2.1 Frequency Converter Coast The motor shaft is in free mode. No torque on the motor. IVLT, MAX Maximum output current. IVLT,N Rated output current supplied by the frequency converter. UVLT,MAX Maximum output voltage. 1.2.2 Input Control commands Start and stop the connected motor with LCP and digital inputs. Functions are divided into 2 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 [OFF]. Group 2 Start, pulse start, reversing, start reversing, jog, and freeze output. Table 1.1 Function Groups 1.2.3 Motor Motor running Torque generated on the output shaft and speed from 0 RPM to maximum speed on the motor. fJOG Motor frequency when the jog function is activated (via digital terminals). fM Motor frequency. fMAX Maximum motor frequency. fMIN Minimum motor 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. 1−23×60 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 motor voltage. UM,N Rated motor voltage (nameplate data). Breakaway torque 175ZA078.10 Pull-out rpm Torque Illustration 1.1 Breakaway Torque ηVLT The efficiency of the frequency converter is defined as the ratio between the power output and the power input. Start-disable command A stop command belonging to the group 1 control commands. See chapter 1.2.2 Input for more details. Stop command A stop command belonging to the group 1 control commands. See chapter 1.2.2 Input for more details. 1.2.4 References Analog reference A signal transmitted to the analog inputs 53 or 54, can be voltage or current. Binary reference A signal transmitted to the serial communication port. Introduction Design Guide 6 Danfoss A/S © 09/2014 All rights reserved. MG06B402 1 1 Preset reference A defined preset reference to be set from -100% to +100% of the reference range. Selection of 8 preset references via the digital terminals. Pulse reference A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33). RefMAX Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20 mA) and the resulting reference. The maximum reference value is set in 3-03 Maximum Reference. RefMIN Determines the relationship between the reference input at 0% value (typically 0 V, 0 mA, 4 mA) and the resulting reference. The minimum reference value is set in 3-02 Minimum Reference. 1.2.5 Miscellaneous Analog inputs The analog inputs are used for controlling various uploads/Ingenierie_Lourd/ design-guide-fc360.pdf