Danfoss VLT Decentral FCD 300 Guide

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Contents

1 The Decentral Concept

Introduction 5

Decentral Design Benefits 6

Application Examples 13

Product Design Guide 15

Ordering Form 21

PC Software Tools 22

Accessories 22

Communication 24

Good Installation Practice 27

Servicing the Danfoss Decentral Products 30

2 Introduction to FCD 300

Safety 32

High Voltage Warning 32

These Rules Concern your Safety 32

Warning against Unintended Start 32

Technology 33

CE Labelling 35

3 Installation

Mechanical Dimensions 37

Mechanical Dimensions, Motor Mounting 37

Mechanical Dimensions, Stand Alone Mounting 37

General Information about Electrical Installation 40

Electronics Purchased without Installation Box 41

EMC-Correct Electrical Installation 43

Earthing of Screened/Armoured Control Cables 44

Diagram 45

RFI Switches J1, J2 45

Electrical Installation - Description of 46

Location of Terminals 46

Mains Connection 47

Pre-Fuses 47

Motor Connection 48

Direction of Motor Rotation 48

Mains and Motor Connection with Service Switch 49

Connection of HAN 10E Motor Plug for T73 49

Parallel Connection of Motors 49

Motor Cables 50

VLT

Decentral FCD 300 Design Guide Contents

MG.90.S1.02 - VLT®is a registered Danfoss trademark

Motor Thermal Protection 50

Brake Resistor 50

Control of Mechanical Brake 51

Electrical Installation, Control Cables 51

Connection of Sensors to M12 Plugs for T63 and T73 52

Electrical Installation, Control Terminals 52

PC Communication 53

Relay Connection 53

Connection Examples 54

4 Programming

LCP Control Unit 61

The LCP 2 Control Unit, Option 61

Parameter Selection 65

Parameter Group 0-** Operation & Display 66

Setup Configuration 67

Parameter Group 1-** Load and Motor 72

DC Braking 75

Parameter Group 2-** References & Limits 79

Handling of References 79

Reference Function 82

Parameter Group 3-** Inputs and Outputs 85

Parameter Group 4-** Special Functions 91

PID Functions 93

Handling of Feedback 94

Serial Communication 98

Control Word According to FC Protocol 103

Status Word According to FC Profile 104

Fast I/O FC-Profile 105

Control Word According to Fieldbus Profile 106

Status Word According to Profidrive Protocol 107

Parameter Group 5-** Serial communication 109

Parameter Group 6-** Technical Functions 115

5 All About FCD 300

119

Brake Resistors 119

Dynamic Braking 119

Internal Brake Resistor 123

Special Conditions 126

Galvanic Isolation (PELV) 126

Earth Leakage Current and RCD Relays 126

Extreme Operating Conditions 127

Contents VLT

Decentral FCD 300 Design Guide

MG.90.S1.02 - VLT®is a registered Danfoss trademark

dU/dt on Motor 127

Switching on the Input 127

Acoustic Noise 128

Temperature-Dependent Switch Frequency 128

Derating for Air Pressure 129

Derating for Running at Low Speed 129

Motor Cable Lengths 129

Vibration and Shock 129

Air Humidity 129

UL Standard 129

Efficiency 130

Mains Supply Interference/Harmonics 130

Power Factor 131

Emission Test Results according to Generic Standards and PDS Product Standard 131

Immunity Test Result according to Generic Standards, PDS Product Standards and

Basic Standards 131

Aggressive Environments 132

Cleaning 132

Status Messages 134

Warnings/Alarm Messages 134

Warning Words, Extended Status Words and Alarm Words 136

General Technical Data 137

Available Literature 141

Factory Settings 142

Index

146

VLT

Decentral FCD 300 Design Guide Contents

MG.90.S1.02 - VLT®is a registered Danfoss trademark

1 The Decentral Concept VLT

Decentral FCD 300 Design Guide

MG.90.S1.02 - VLT®is a registered Danfoss trademark

1 The Decentral Concept

1.1 Introduction

Danfoss was the world's first company to manufacture and supply frequency converters for infinitely variable speed control of three-phase AC motors.

Until then, AC motors had to operate at the speed determined by the frequency of the main power supply.

Production of frequency converters started in 1968. The first frequency converter was also the first decentralised drive as it was placed next to the motor.

The first frequency converter was totally enclosed and filled with silicone oil for cooling, as semiconductors of that time were very inefficient. The enclosure

design was made for mounting the drive directly in the application next to the motor. Temperature, water, cleaning agents, dust and other environmental

factors were also no problem, even in harsh environments.

Semiconductors improved during the next decades. Air-cooling showed sufficient and oil cooling was abandoned. At the same time use of frequency

converters grew significantly. PLCs gained a footing for advanced application control and it became common practice to install all frequency converters

in one cabinet, rather than several places in the factory.

Continuing improvements in semi-conductors and related technologies - such as fieldbus technology - now again makes it feasible to consider installing

drives close to the motors, achieving the benefits of decentralised installation without the disadvantages from the first oil-filled frequency converters.

Development of automation in industry is based on the ability to send and receive data from the application needed to control the processes. More and

more sensors are installed and more and more data is submitted to the central PLC control. This trend depends on increased use of fieldbus systems.

Industrial sources often claim that up to 30 % of all drive installations will be installed decentrally within the next few years and the trend towards

distributed intelligent control is undisputed as more and more components and applications are developed for decentralised installation.

This book is a general introduction to basic features of decentralised installation philosophies for motor controls and differences from the centralised

concept. It will help you choose the most suitable concept and guide you through the process of selecting the appropriate products.

Finally we have included comprehensive information about the Danfoss decentralised products.

VLT

Decentral FCD 300 Design Guide 1 The Decentral Concept

MG.90.S1.02 - VLT®is a registered Danfoss trademark

1.2 Decentral Design Benefits

In the following we will concentrate on describing decentralised installation of frequency converters, referred to here as motor controls.

There are two topologic concepts for the layout of motor control installations in a plant, in the following referred to as “centralised” and “decentralised”

installations. The two typologies are illustrated in the figure.

In a centralised installation:

-motor controls are placed in a central place

In a decentralised installation:

-motor controls are distributed throughout the plant, mounted

on or next to the motor they control

Decentralised does not mean

control cabinet free

, but merely that their

enormous size can now be reduced thanks to innovative designs of the

components that will be placed decentralised. There will continue to be

a need for cabinets for power distribution and for overall intelligence, and

there are areas, particularly in the process industry with areas such as

explosion protection, where centralised cabinets continue to be the pre-

ferred solution.

Placing the advanced and reliable electronics needed to ensure a smooth,

responsive and economical operation of the motor next to – or on – the

motor facilitates modularisation and reduces cabling costs and EMC prob-

lems dramatically. Further benefits:

Illustration 1.1: Centralised versus decentralised installa-

tions

• Space-consuming motor control cabinets in long rows of centralised panels are eliminated

• Reduced efforts for building in and wiring long screened motor cables where special attention on EMC terminations is required

• Heat dissipation from power electronics is moved from the panel into the plant

• Standardised machine elements by modularisation reduces design time and time to market

• Commissioning is easier and faster

Decentralised motor control is rapidly gaining ground despite of the advantages of the centralised control concept:

• no need for extra space around the motor or close to the motor

• no control cable wiring into the plant

• independence of plant environment

1.2.1 Direct Cost Savings

Motor controls for decentralised installations must be built to meet the harsh conditions in manufacturing areas - especially such conditions found in the

food and beverage industry, where frequent wash downs are required. This of course increases the cost of the drive. This increase will be more than set

off by savings in expenses for cabinets and cables.

The cable saving potential is considerable, as will be demonstrated by the following example.

1 The Decentral Concept VLT

Decentral FCD 300 Design Guide

MG.90.S1.02 - VLT®is a registered Danfoss trademark

The figure illustrates an installation with motors distributed in a number of rows with several motors in each, as is the situation in for example parallel

bottling or baking lines in the Food and Beverage industry. This example shows the need for power cables from the centrally placed drives to the motors.

Illustration 1.2: Centralised installation

The drives are distributed equidistant with the distance L between each drive and the distance h between each row and also with a distance h from the

centralised power entry/cabinet location to the first row. There are n rows, and N drives in each row.

Illustration 1.3: Decentralised installation

VLT

Decentral FCD 300 Design Guide 1 The Decentral Concept

MG.90.S1.02 - VLT®is a registered Danfoss trademark

The Illustration 1.4 shows how the three-phase mains cable can be dis-

tributed with power looping from one motor (drive) to the next. The cable

saving potential is illustrated in Illustration xx. Given a distance of 10 m

between each motor and 20 m between each line, the potential cable

savings as a function of the number of motors and number of lines shows

of the figure.

Illustration 1.4: Cable saving potential in an illustrative in-

stallation

The saving potential in power cable length alone is substantial. The figure only illustrates the potential concerning power cables. Issues like unscreened/

screened cables and cable dimensions also ads to the benefits of decentralised installations.

Real case

Calculations on a specific, typical bottling line with 91 pieces of 1.5 kW motors, taking the cable dimensioning into account, showed the following saving

potential in cables and terminations:

• Cable terminations are reduced from 455 to 352

• EMC cable terminations are reduced from 364 to 182 by using motor controls with integrated service switches

• Power cable length reduced from 6468m to 1180m, a reduction of 5288m, and it is converted from screened cables to standard installation

cables

For details consult the following chapter on

Good installation practice

1.2.2 Design Savings

End users want to postpone the final decision for new equipment - and to start production as fast as possible once a decision has been made. Payback

time and time to market must be reduced. This squeezes both the design phase and the commissioning phase.

Modularisation can minimise lead-time. Even manufacturers of large production equipment or lines use modularisation to reduce lead-time. Up to 40-50

% on the total time from design to running production can be saved.

The concept of modularisation is known from equipment like PC’s and cars. Modules with well-described functionalities and interfaces are used in these

products. The same concept can be applied to manufacturing, even though specific physical constraints play a role.

1 The Decentral Concept VLT

Decentral FCD 300 Design Guide

MG.90.S1.02 - VLT®is a registered Danfoss trademark

Production equipment is often built from different basic building blocks, each kind employed at several places in the installation. Examples include various

types of conveyor sections and machinery like mixers, scales, fillers, labellers, palletisers, packaging machines etc.

Illustration 1.5: Centralised cabinet

In a truly modular machine, all basic elements are self-confined and need nothing but electricity, water, compressed air or similar to function.

Modularisation therefore requires the distribution of intelligence to the individual sections and modules.

Sure, centralised installations can be modualarised, but then motor controls will be physically separated from the rest of the module.

Fewer cabinets, cooling and cable trays

Further savings will result from smaller cabinets, less cabinet cooling and fewer cable trays. Motor controls generate heat and are often mounted side by

side due to limited space, as illustrated in illustration 1.5. Forced cooling is therefore required to remove the heat.

Less Commissioning

Time spend commissioning at the end-user is significantly reduced using

decentralised solutions - especially when fieldbus communication is com-

bined with decentralised motor controls.

An Australian brewery has installed a line of 96 decentralised drives from

Danfoss connected by DeviceNet. An excessive amount of time was saved

as the commissioning of the variable speed drives was done in a few days.

The brewery estimates a saving exceeding AUD 100,000 compared to

traditional centralised installation.

Illustration 1.6: Decentralised brewery installation

Minimal Need for Additional Fieldbus Cables

Power cable savings are not offset by the additional cost for expensive fieldbus cables. Fieldbus cables will be extended in a decentralised installation,

but since fieldbus cables will be distributed in the plant anyway to connect sensors or remote I/O-stations, the extension will be limited. Decentralised

products from Danfoss can even be used as remote I/O stations to connect sensors to the fieldbus and reduce direct costs even more.

VLT

Decentral FCD 300 Design Guide 1 The Decentral Concept

MG.90.S1.02 - VLT®is a registered Danfoss trademark

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