confidential / property of danfoss drives a/s 2004-10-18 dd-smt/dej 1 drives division vlt ®...

Confidential / Property of Danfoss Drives A/S

2004-10-18

DD-SMT/DEJ 1Drives Division

VLTVLT®® AutomationDrive FC302 AutomationDrive FC302PM MotorsPM Motors

Configuration procedureConfiguration procedure

By: Dennis Jakobsen

Contributers:Nicolas Trolle

Mogens Allan JensenHans Jørgen Nørgaard.

Johan Kirkebæk.


2004-10-18


Configuration by example.

• This document describes how to configure the AutomationDrive FC302 running a PM motor.

• The FC302 is using the B-Option encoder module MCB102.

• This model is used in our training lab.

PREREQUISITES.

• A PM motor from AEG Lafert is used as and all settings shown are based on the model no. B5602P3H2BRS0000.

• Specifications:Motor brushless size 56, stall torque 02 Nm, 8 Poles, 3000 Rpm, 400 V, with Sin/Cos Encoder from Stegmann, HIPERFACE® protocol.SRS 1024 PPR and brake. Shaft diameter 14mm.


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AEG Lafert PM Motor example.

• Settings in the cross sections are those we must insert into the drive.


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Selection of frequency converter.

• Select your FC302 according to the nominal current of the chosen PM motor.

• PM motor solutions often require a high starting current because of high acceleration or inertia.

• If our solution requires more than 160% for one minute go one step up in size of your FC302.

• In our example we selected a 0,55 KW FC302at 3 x 380 - 500V.

• It has a continuous output current of 1,8 Amps.

• Our motor has a rated current of 1,08 Amps.

• We have no special requirements as it is for training purposes only.


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Stator resistance Rs and d-axis inductance Ld.

• P 1-30 Stator resistance Rs and P 1-37 d-axis inductance Ld.

Typical ways of specifying Rs and Ld dependent on motor type.

Rs and LdRs and Ld

asynchronous motors Permanent magnet motors

• For PM motors divide Rs and Ld by 2 if technical specifications defines “Line – Line”.

• AutomationDrive requires “Line – Common” value.


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Drive configuration – Necessary steps.

Basic motor data configuration.Basic motor data configuration.

Advanced motor data configuration.Advanced motor data configuration.

Encoder configuration.Encoder configuration.

0° Motor angle adjustment. 0° Motor angle adjustment. STEP 5STEP 5

Angle offset adjustment. Angle offset adjustment. STEP 6STEP 6

STEP 3STEP 3

STEP 2STEP 2

STEP 1STEP 1 Configura

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Drive tuningDrive tuningSTEP 7STEP 7

Test run your motor.Test run your motor.STEP 4STEP 4


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Step 1 – Basic motor data configuration 1.

Set motor construction.Set motor construction.

Set control principle.Set control principle.

STEP 1.4STEP 1.4

Set motor feedback source.Set motor feedback source.STEP 1.5STEP 1.5

STEP 1.3STEP 1.3

STEP 1.2STEP 1.2

Set max. Hz and motor speedSet max. Hz and motor speedSTEP 1.8STEP 1.8

Set nominal motor current.Set nominal motor current.STEP 1.6STEP 1.6

Set motor speed.Set motor speed.STEP 1.7STEP 1.7

Perform an initializationof the drive.

Perform an initializationof the drive.STEP 1.1STEP 1.1 [P 14-22] (toggle power)[P 14-22] (toggle power)

[P 1-10] = [1]PM, non salient SPM[P 1-10] = [1]PM, non salient SPM

[P 1-01] = [3]Flux with motor feedback[P 1-01] = [3]Flux with motor feedback

Set configuration mode.Set configuration mode. [P 1-00] = [1]Speed closed loop[P 1-00] = [1]Speed closed loop

[P 1-02] = [1]MCB102[P 1-02] = [1]MCB102

[P 4-19] = 400Hz, [P 4-13] = 6000 RPM[P 4-19] = 400Hz, [P 4-13] = 6000 RPM

[P 1-24] = 1,08 Amps[P 1-24] = 1,08 Amps

[P 1-25] = 3000 RPM[P 1-25] = 3000 RPM


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Step 2 – Advanced motor data configuration.

Set stator resistance.Set stator resistance.

Set d-axis inductance.Set d-axis inductance.

Set motor poles.Set motor poles.STEP 2.4STEP 2.4

Set B-EMF.Set B-EMF.STEP 2.5STEP 2.5

STEP 2.3STEP 2.3

STEP 2.2STEP 2.2

Set rated torque.Set rated torque.STEP 2.1STEP 2.1

rpmSpeed

BEMFBEMF

n

n 1000

Set max current limit.Set max current limit.STEP 2.6STEP 2.6 [P 4-18] = 4,81 /1,08 * 100 = 445 %[P 4-18] = 4,81 /1,08 * 100 = 445 %

[P 1-26] = 1,60 Nm[P 1-26] = 1,60 Nm

[P 1-40] = 89,33 V [P 1-40] = 89,33 V

[P 1-30] = 13,5 / 2 Ohm[P 1-30] = 13,5 / 2 Ohm

[P 1-37] = 22,8 / 2 mH[P 1-37] = 22,8 / 2 mH

[P 1-38] = 8[P 1-38] = 8

Motor data configuration is now finished.Please note that you can NOT use AMA !

Motor data configuration is now finished.Please note that you can NOT use AMA !

100% max nI

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B-EMF calculator.

1. From the motor data technical sheet, input your B-EMF value and at which speed it is defined.

2. The FC302 needs the B-EMF to be input at 1000 RPM.3. Press calculate and you will get the B-EMF value to insert into

your drive.


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Step 3 – Encoder configuration.

Set resolution (PPR).Set resolution (PPR).

Set protocol selection.Set protocol selection.

Set resolution (Positions/Rev).Set resolution (Positions/Rev).STEP 3.4STEP 3.4

STEP 3.3STEP 3.3

STEP 3.2STEP 3.2

Set signal type.Set signal type.STEP 3.1STEP 3.1 [P 17-10] = [2]Sinusodial 1 Vpp [P 17-10] = [2]Sinusodial 1 Vpp

[P 17-11] = 1024[P 17-11] = 1024

[P 17-20] = [1]HIPERFACE[P 17-20] = [1]HIPERFACE

[P 17-21] = 32768[P 17-21] = 32768

MOTOR IS READY TO RUN.MOTOR IS READY TO RUN.


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Drive configuration – Additional steps.

Basic motor data configuration.Basic motor data configuration.

Advanced motor data configuration.Advanced motor data configuration.

Encoder configuration.Encoder configuration.

0° Motor angle adjustment. 0° Motor angle adjustment. STEP 5STEP 5

Angle offset adjustment. Angle offset adjustment. STEP 6STEP 6

STEP 3STEP 3

STEP 2STEP 2

STEP 1STEP 1 Configura

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Test run your motor.Test run your motor.STEP 4STEP 4


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Step 5 – 0° motor angle adjustment 1.

Verify that the motor angle (on display line 1) shows zero.Verify that the motor angle (on display line 1) shows zero.

Set Start delay, [P 1-71] to 10 sec. Set Start delay, [P 1-71] to 10 sec.

Set Start Function, [P 1-72] to DC-holdSet Start Function, [P 1-72] to DC-holdSTEP 5.5STEP 5.5

STEP 5.4STEP 5.4

STEP 5.3STEP 5.3

The encoder must be disconnected. This can be done by setting Motor Feedback Source, [P 1-02] to 24 V encoder.

(There is no 24V encoder connected).

The encoder must be disconnected. This can be done by setting Motor Feedback Source, [P 1-02] to 24 V encoder.

(There is no 24V encoder connected).STEP 5.1STEP 5.1

If the motor doesn't run, the Position of the motor encoder must be calibrated. The SinCos encoder delivers an absolute position (motor angle), and it is very important

that the position feedback is zero when a DC at angle zero is send to the motor. Otherwise it is not possible to run the permanent magnet motor.

If the motor doesn't run, the Position of the motor encoder must be calibrated. The SinCos encoder delivers an absolute position (motor angle), and it is very important

that the position feedback is zero when a DC at angle zero is send to the motor. Otherwise it is not possible to run the permanent magnet motor.

Select motor angleon display line 1.

Select motor angleon display line 1.STEP 5.2STEP 5.2 [P 0-21 or 22] = [1620] Motor angle[P 0-21 or 22] = [1620] Motor angle


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Step 5 – 0° motor angle adjustment 2.

Verify that the Motor moves a little, and then stands still. There is a small chance that the motor is at position zero, and does not move. In that

case stop and move the motor shaft a little and repeat from step 5.5.

Verify that the Motor moves a little, and then stands still. There is a small chance that the motor is at position zero, and does not move. In that

case stop and move the motor shaft a little and repeat from step 5.5.

Stop the motor. (Within 10 sec.)Stop the motor. (Within 10 sec.)

Start again, and verify that the motor does not move.Start again, and verify that the motor does not move.STEP 5.8STEP 5.8

STEP 5.7STEP 5.7

STEP 5.6STEP 5.6

Look at the motor shaft, and start the motor.Look at the motor shaft, and start the motor.STEP 5.5STEP 5.5

In the next, it is important to stop the motor before the start function ends. (10 sec.)In the next, it is important to stop the motor before the start function ends. (10 sec.)

The Motor is now set at position zero. (do not move the motor)The Motor is now set at position zero. (do not move the motor)STEP 5.9STEP 5.9


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Step 6 – Offset adjustment.

Set Start delay, [P 1-71] to Zero. (disabling start function) Set Start delay, [P 1-71] to Zero. (disabling start function)

Look at motor angle on display line 1. (0-65535 equals 0-2PI)Look at motor angle on display line 1. (0-65535 equals 0-2PI)STEP 6.3STEP 6.3

STEP 6.2STEP 6.2

Set Motor Feedback Source, [P 1-02] to [1]MCB102Set Motor Feedback Source, [P 1-02] to [1]MCB102STEP 6.1STEP 6.1

The Motor is now set at position zero. It is important that you do not move the motor.The Motor is now set at position zero. It is important that you do not move the motor.

Adjust Motor Angle Offset, [P 1-41] until the motor angle displays zero.- If Motor angle >= 32268 at beginning, then adjust [P 1-41] positive- If Motor angle < 32768 at beginning, then adjust [P 1-41] negative

Adjust Motor Angle Offset, [P 1-41] until the motor angle displays zero.- If Motor angle >= 32268 at beginning, then adjust [P 1-41] positive- If Motor angle < 32768 at beginning, then adjust [P 1-41] negative

STEP 6.4STEP 6.4

DO NOT START THE MOTOR YET !DO NOT START THE MOTOR YET !

MOTOR IS READY TO RUN.MOTOR IS READY TO RUN.


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Step 7 - Tuning the application.

Set torque limits [P 4-14] and [P 4-15] to protect your application.Set torque limits [P 4-14] and [P 4-15] to protect your application.

Fine tuning the application can be……Fine tuning the application can be……

Reduce ramp times [P 3-41] and [P 3-42] etc. to optimize the dynamics of your system. If set to minimum the motor will accelerate along the torque limit.

(beware of over voltage if no brake resistor is attached)

Reduce ramp times [P 3-41] and [P 3-42] etc. to optimize the dynamics of your system. If set to minimum the motor will accelerate along the torque limit.

(beware of over voltage if no brake resistor is attached)

Adjust PID Speed Gain [P 7-02], Integral time [P 7-03] to optimize the dynamics of your system.

Adjust PID Speed Gain [P 7-02], Integral time [P 7-03] to optimize the dynamics of your system.

Reduce Speed PID Lowpass filter time [P 7-06] to optimize the dynamics of your system. (5 mS for 1024 PPR. Less if more pulses)

Reduce Speed PID Lowpass filter time [P 7-06] to optimize the dynamics of your system. (5 mS for 1024 PPR. Less if more pulses)

Adjust min. reference RPM [P 3-02] and max. reference RPM [P 3-03].Adjust min. reference RPM [P 3-02] and max. reference RPM [P 3-03].

Adjust max. output frequency [P 4-19]. In this example nominal RPM=3000 equals 200 Hz. Max RPM=6000 RPM equals 400 Hz

Adjust max. output frequency [P 4-19]. In this example nominal RPM=3000 equals 200 Hz. Max RPM=6000 RPM equals 400 Hz

Switch frequency must be 10 x Max. Hz.Switch frequency must be 10 x Max. Hz.


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Trouble shooting.• It is important that all wires from encoder to encoder

option is correct mounted.- Cosine connects to A(8) and An(6)- Sine Connect to B(7) and Bn(5)

• If it is not possible to run the motor, then two of the motor wires may be twisted. Direction can be changed in parameter P 17-60, “Encoder positive direction”. (Only for incremental encoders)

• Do you have mechanical brake, and is it released?

• If the angle adjustment is wrong. a high current is typically drawn by the motor.

• Currents above max. peak motor current can damage the permanent magnets.

• To high motor temperatures can damage the permanent magnets. Use PTC,KTY, Klixon sensors/relays.

confidential / property of danfoss drives a/s 2004-10-18 dd-smt/dej 1 drives division vlt ®...

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