These documents are intended for trained professionals only! These professionals must guarantee personal safety and the prevention of machine damage during any operations. Appropriate safety instructions for other persons have not been provided!
NON-STANDARD DOCUMENTATION
Conversion instructions DANFOSS frequency inverter Conver Conv ersion sion of VLT 5000 to FC302 F C302
D-11-E0-0-07-54 / TD10002771 EN 00 / Update: 11/2009
DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
Copyright
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Copyright
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
Table of Contents 1
2
Preface Pref ace .............................................................................................. ............................................................................................................ .............. 5 1.1
Target group ..........................................................................................5
1.2
Notes......................................................................................................5
1.3
Notations................................................................................................5
Safety...............................................................................................................6 2.1
3
4
General infor in for mati on ............ ................. ........... ............ ........... ........... ............ ........... ........... ............ ........... ........... ............ ........... ....... ..8 8 3.1
Hardware: VLT5000 - terminal-controlled..............................................9
3.2
Hardware: VLT5000 - with bus option ...................................................9
3.3
Software in general: Parameter conversion .......................................... 9
Hardware.......................................................................................................10 4.1
4.2
5
4.1.1
Preparation..............................................................................10
4.1.2
Hardware conversion ..............................................................10
Hardware conversion for bus-controlled devices.................................11 4.2.1
Preparation..............................................................................11
4.2.2
Hardware conversion ..............................................................12
4.2.3
Note about the converter card (MCA114)...............................12
Scenario 1: Backup of the VLT5000 available in the LCP...................14 5.1.1
Possibility No. 1: "By hand".....................................................14
5.1.2
Possibility No. 2: "With MCT10"..............................................14
5.2
Scenario 2: Backup of the VLT5000 available in MCT10 (.ssp)..........15
5.3
Scenario 3: Backup of the VLT5000 available with DOS VLS dialogue16
5.4
5.3.1
1st step: Import .......................................................................16
5.3.2
2nd step: Convert....................................................................16
Scenario 4: Backup of the VLT5000 available in PLC.........................17 5.4.1
General information ................................................................17
5.4.2
Important information ..............................................................17
5.4.3
Procedure................................................................................17
5.4.4
Alternatives also for future backups using PLC (customer request) ...................................................................................17
Soft ware (DeviceNet devi ces) ............ ................. ........... ............ ............ ........... ........... ............ ........... ........... ............18 ......18 6.1
CLX software adjustment for "Message "Message command" ............................ 19
6.2
Scenario 1: Backup of the VLT5000 available in the LCP...................20
6.3
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Hardware conversion for terminal-controlled devices..........................10
Soft ware (Profi bus devi ces) ........... ................. ........... ........... ............ ............ ............ ............ ............ ........... ........... .........13 ...13 5.1
6
Safety notices ........................................................................................6
6.2.1
Possibility No. 1: "By hand".....................................................20
6.2.2
Possibility No. 2: "With MCT10"..............................................20
Scenario 2: Backup in the DeviceNet file (.dnt) ................................... 21
Table of contents
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 7
Ap pendi pen dix x ....................................................................................... ....................................................................................................... ................ 22 7.1
Procedure for dismantling and starting................................................22
7.2
Backup with MCT10 using serial bus (RS485) or Profibus ................. 23 7.2.1
Case 1: Backup Backup using serial bus (RS485): ............................. 23
7.2.2
Case 2: Backup via Profibus:..................................................24
7.3
Software conversion of a VLT5000 to FC302 with MCT10 ................. 25
7.4
Parameter assignment VLT5000 FC302.........................................27 7.4.1
7.5
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Conversion table (parameters) ...............................................27
Hardware "rewiring table" ....................................................................35
Table of contents
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
1
Preface
1.1 Target group This service manual is addressed to the trained professional personnel responsible for the start-up and service of the machines. Carry out the work to be done correctly, in order to guarantee personal safety and to prevent machine damage, as well as to ensure proper functioning of the machine.
1.2 Notes If disassembly, assembly, or start-up are performed by the customer or someone authorised by him to do so, instead of by KRONES' personnel, KRONES shall not be held liable for resultant damage or repairs!
1.3 Notations CAUTION
INFORMATION
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If there is a risk of injury, damage or loss of data, the respective warning will be highlighted with a red bar. Important comments are marked by a grey bar.
1 Preface
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
2
Safety Alw Al w ays rememb rem ember: er: Safet y f ir st ! The safety equipment which KRONES AG has fitted to the machine provides only the basic conditions for preventing accidents. In addition, it is imperative that safety regulations are observed in order to prevent hazards that may arise when servicing the machine. Please observe the generally valid national and international (EU) employment
protection regulations and the safety instructions of the respective customer. Please observe the safety instructions of this manual. In addition, follow the chapter titled "Safety" in the operating manual.
2.1 Safety notices Always follow the safety instructions mentioned below when doing service work.
Nominate a coordinator. Block off the danger zone. Use only tested facilities and equipment (drills, power supply units, etc.). Do not step on the machine or on casings (use elevated work platforms etc.) Only use tested and flawless slings. Call attention to possible hazardous material (e.g. in the machine, or similar). Discuss the behaviour you wish to see in an emergency, before any emergency arises. Pay attention to traffic.
Risk of electric electric sh ock! Prior to working on the electrical system, make sure it has been disconnected from the power supply. Disconnect it from the power supply in the following way:
Danger
Isolate. Lock it to prevent it being turned ON. Check whether the power supply has been disconnected. Earth and short-circuit. Adjacent live components must be covered or safeguarded.
Risk of being crushed by pneumatic and hydraulic hydraulic com ponents
Danger
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Do not do any work on pneumatic or hydraulic components until the machine has been depressurised. There must not be any residual pressure (if required, depressurise the pressure accumulator). If necessary, secure components to prevent uncontrolled movement!
2 Safety
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
Risk of injury due to falling or tripping It is imperative that you keep away from the conveyor systems and conveyed goods.
Danger
When working in the top area of the conveyor system, use only suitable
climbing aids (e.g. stable ladders). Be sure to only cross conveyors using the appropriate stairs.
Risk of injury f rom the high pressure in the system. The media in the system are pressurised. Shut down the pressure and vent the pipelines before you undo any pipelines or
Danger
valves.
The machine must be empty and OFF
Warning
If turning ON the machine cannot be avoided in order to do service work, turn it ON but only as long as is absolutely necessary. When doing so, make absolutely sure that personal hazards and machine damage are prevented. When carrying out service work, attach the "Do not operate the machine!
Service work in progress" sign to the control cabinet / operating panel. Keep unauthorised persons away from the machine during service and
maintenance work. Attach a warning sign to the control cabinet / operating position when carrying
out service work. Whenever the machine does not need to be in operation, turn all the master
switches OFF and secure them in this position with a padlock to prevent unauthorised persons from turning the switches ON.
Dangers during a restart Before restarting the machine and after all maintenance and service work, ensure that:
Danger
the correct parts have all been installed and properly fitted, all the adjustment work is completely finished, no loose items (cloths, tools, etc.) have been left in the machine, removed guard covers and safety equipment have been properly refitted, all safety devices are working properly, all pressure and fluid lines are properly connected and sealed, personal hazards and machine damage are prevented when restarting the
machine.
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2 Safety
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
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General information
In the event of a failure (not a new order / not an upgrade) in the field of frequency converters from the VLT5000 series (Danfoss) which has already been reported, conversion to the FC302 is necessary. A bus option is required if bus-controlled devices are to be replaced. After every failure of a VLT5000, the converter card (MCA114) must be fitted in the FC302 for Profibus devices and the standard DeviceNet bus card for DeviceNet devices. The conversion is described in the chapter entitled 4.2 „Hardware conversion for bus-controlled devices". No devices". No bus option is required or fitted for terminal-controlled devices. The software conversion is described in the chapter entitled 5 „Software (Profibus devices)" and devices)" and the chapter entitled 6 „Software (DeviceNet devices)" in devices)" in a range of scenarios. Note
Caution
FC302 devices with a normal Profibus card (DeviceNet card for DeviceNet devices) must always be planned for new orders and upgrades (not failures) for frequency converters. Please note that no converter card should be fitted in these cases.
These instructions contain details of the measures which are designed to make the conversion work as simple and uniform as possible.
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3 General information
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 Remark: In the event of a hardware conversion, ensure that you know in advance what optional equipment the defective device contains.
Caution
There are two hardware configuration types: Chapter 3.1 3.1 and and chapter 3.2 3.2..
Remark: If you are fitting a bus option you must ensure that the plastic installation frame (on which the LCP display is installed) is replaced.
Caution
The new, higher installation frame is supplied with every bus option.
3.1 Hardware: VLT5000 - terminal-controlled terminal-controlled These devices do not create problems. For replacing a terminal-controlled VLT5000 with an FC302, the only hardware work which is required is that shown in the rewiring table.
3.2 Hardware: VLT5000 - with bus option There are several points to bear in mind for devices with a bus option. The conversion work for these devices is described later for a range of scenarios. (Chapter entitled 5 „Software (Profibus devices)" and devices)" and the chapter entitled 6: „Software (DeviceNet devices)“) devices)“) This description primarily refers to the software conversion which differs in the various scenarios.
3.3 Software in general: Parameter conversion The parameterisation of the FC302 can be carried out by hand using either the LCP or with the MCT10 on the basis of the table (chapter entitled 7.4Parameter assignment VLT5000 FC302 FC302). ). If you have a data backup in MCT10 (.ssp) or DOS program (.mnu), the data record can also be converted and uploaded using the MCT10. (Chapter entitled5.3 entitled 5.3 „Scenario 3: Backup of the VLT5000 available with DOS VLS DOS VLS dialogue“ dialogue“) Special attention must be given to backing up the parameters using the PLC (read/write parameters). (Chapter entitled 5.4 „Scenario 4: Backup of the VLT5000 available in PLC in PLC “)
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3 General information
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
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Hardware
4.1 Hardware conversion for terminal-controlled devices 4.1.1 Preparation The following hardware components may be required for the conversion Item
Descripti on
SAP No.
1
Frequency converter FC302 (always required)
Depending on the rating
2
Display LCP 102 (optional)
0-900-78-399-7
3
Mechanical adapter plate (always required)
Depending on the type, depending on the rating
4
Additional module MCB101 (optional)
0-901-41-057-3 (depending on the application)
5
24 V option for FC302 (always required)
0-900-78-399-8
6
Isolation amplifier (optional)
0-901-72-449-7
Note: The application-specific assignment of the inputs and outputs of the VLT5000 must be borne in mind when it is replaced by the FC302.
Caution
(The FC302 has fewer inputs and outputs than the VLT5000 as standard) If more inputs and outputs are assigned on the VLT5000 than the FC302 has
available, the additional module MCB101 must be fitted in the FC302 to expand the number of inputs and outputs.
Isolation amplifier (optional) If the analogue setpoint selection has been used in the VLT5000, an isolation amplifier must be fitted when replacing it with the FC302.
Caution
For analogue setpoint selection Use an isolation amplifier!
4.1.2 Hardware conversion The FC302 must be mounted on the mechanical adapter plate and the 24 V option card must be fitted in the FC302. If necessary the additional module MCB101 must be fitted to expand the number of inputs and outputs. The FC302 must then be connected using the rewiring table in the appendix (chapter entitled 7.5 "Hardware "rewiring table" "rewiring table""").
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4 Hardware
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 4.2 Hardware conversion for bus-controlled devices 4.2.1 Preparation The following hardware components may be required for the conversion Item
Descripti on
SAP No.
1
Frequency converter FC302 (always required)
Depending on the rating
2
Display LCP 102 (optional)
0-900-78-399-7
3
Profibus converter card (always required) (MCA-114; software version 2.02)
0-901-88-989-7
4
DeviceNet card (130B1102 )
0-900-78-399-6
5
Mechanical adapter plate (always required)
Depending on the type, depending on the rating
6
Additional module MCB101 (optional)
0-901-41-057-3
7
24 V option for FC302 (always required)
0-900-78-399-8
8
Isolation amplifier (optional)
0-901-72-449-7
Note: The application-specific assignment of the inputs and outputs of the VLT5000 must be borne in mind when it is replaced by the FC302.
Caution
(The FC302 has fewer inputs and outputs than the VLT5000 as standard) If more inputs and outputs are assigned on the VLT5000 than the FC302 has
available, the additional module MCB101 must be fitted in the FC302 to expand the number of inputs and outputs.
Isolation amplifier (optional) If the analogue setpoint selection has been used in the VLT5000, an isolation amplifier must be fitted when replacing it with the FC302.
Caution
For analogue setpoint selection Use an isolation amplifier!
Bus opt ion (converter card)
Caution
In the event of a failure by a VLT5000 with the Profibus option, the converter card must always be used in the replacement for the new device FC302). FC302). If the parameters are backed up using the PLC (read/write parameters), the replaced frequency converter must be deleted from the equipment list (DB in the PLC for backing up). For (read/write parameters) via PLC Delete replaced frequency converter
from the equipment list. Bus option (DeviceNet) In the event of a failure of a VLT50000 with a DeviceNet bus option, an FC-302 with a DeviceNet card must be used.
Caution D-11-E0-0 -07-54 / TD10002771 EN 00
The software conversion is described in chapter 4. 4 Hardware
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 4.2.2 Hardware conversion The FC302 must be mounted on the mechanical adapter plate. The 24 V option card and the bus option (converter card or DeviceNet card) must be fitted in the FC302. The address switches must be configured according to the addresses which were previously used. If necessary the additional module MCB101 must be fitted to expand the number of inputs and outputs. The FC302 must then be connected using the rewiring table in the appendix (chapter entitled 7.5 "Hardware "rewiring table" "rewiring table""").
4.2.3 Note about the converter card (MCA114)
In general the Profibus converter card allocates the VLT5000 parameters/data listed in the conversion table to the corresponding FC302 parameters/data. (FC302 firmware version from 5.96; converter card firmware version from 2.02)
Note The converter card only works for the Profibus DP standard and not for Sinec L2 or Siemens DP.
Caution
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The converter card may only be used if the Profibus DP standard is used.
4 Hardware
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
5
Software (Profibus devices) The following software tools and files are required to enable you to complete the software conversion successfully. Item
Descripti on
Functio n
1
MCT10 (Motion Control Tool) from V3.13 (Build 808)
Frequency converter parameterisation
Remark: A distinction is made for the software conversion between four different scenarios. A different procedure is required for each scenario.
Caution Note
Caution
If an FC302 with a converter card is used, the parameters can only be backed up in future with the MCT10 in "Serial" or "USB" mode. Alternatively they can still be backed up using the LCP display. Profibus communication between the MCT10 and FC302 with a converter card
is not possible.
Backing up the parameters after the replacement The various methods for backing up the parameters after the replacement has been completed are described on the following pages.
Caution
However, it is always possible to back up the parameters for the replacement
device (FC302) using the optional LCP display.
Conversion measures If the parameters have not been backed up in the PLC using the acyclical Profibus services (read/write parameters) and there is no other way of backing them up, you should attempt (if it is still possible) to read all the parameters out of the corresponding old frequency converter. If there is a bus option (L2 or Profibus) on the converter, the current parameterisation should be read using the MCT10 if this is still possible. Otherwise all the parameters must be taken from the appropriate backup DBs in the PLC or possibly from the lists in the control enclosure. The parameters taken from these sources must then be converted by hand using the table (chapter entitled 7.4Parameter assignment VLT5000 FC302) and then entered in the FC302. (LCP display or MCT10) Now the old frequency converter must be removed and the new one installed. Disconnect the device from the power supply for this purpose. In addition ensure that you comply with all the safety instructions. (See appendix: (Chapter entitled7.1 entitled 7.1 "Procedure for dismantling and starting") starting")
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5 Software (Profibus devices)
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 5.1 Scenario 1: Backup of the VLT5000 available in the LCP The backup of the VLT50000 has been completed exclusively in the LCP display. In this scenario, backing up the parameters may prove to be difficult. However, there are two different methods of converting the parameters.
5.1.1 Possibility No. 1: "By hand" All the parameters are entered using the table (chapter entitled 7.4Parameter assignment VLT5000 FC302), on the LCP of the FC302 or via the MCT10 in the frequency converter. The parameters of the VLT50000 must be converted from lists in the control enclosure or read out of existing backups and converted "by hand".
5.1.2 Possibility No. 2: "With MCT10" If it is still possible, the parameters of the VLT5000 can be backed up using the MCT10 (Serial or Profibus). if this is no longer possible with the defective converter, the display (with the backup) may alternatively also be connected to a VLT5000 which is still functional. The parameters must then be transferred from the LCP to the converter. The parameters can then be read through the serial port or via the Profibus using the MCT10. When the parameters have been successfully read into the MCT10, the parameter conversion assistant can be used. A description of this is provided in the appendix in the chapter entitled7.3 entitled 7.3 "Software conversion of a VLT5000 to FC302 with FC302 with MCT10" MCT10".
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5 Software (Profibus devices)
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 5.2 Scenario 2: Backup of the VLT5000 available in MCT10 (.ssp) The data record must be converted for the FC302 in the MCT10. The assistant for parameter conversion can be used for the conversion process. A description of this is provided in the appendix in the chapter entitled7.3 entitled 7.3 "Software conversion of a VLT5000 to FC302 with FC302 with MCT10" MCT10".
Note Depending on how the MCT10 communicates with the frequency converter there is a difference in handling the backup process for all the converters in a system.
Caution
After the replacement, the procedure for backing up all the converters via
Profibus is different to the one for backing them up via the serial bus.
A
more detailed description of backing up using the "Serial" or Profibus" method is provided in the appendix in the chapter entitled 7.2 "Backup with MCT10 using serial bus (RS485) or Profibus". Profibus".
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5 Software (Profibus devices)
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 5.3 Scenario 3: Backup of the VLT5000 available with DOS VLS dialogue If the backup of the parameters for the defective VLT50000 is available in the form of an mnu file via "DOS VLS dialogue", proceed as follows.
5.3.1 1st step: Import The data record can be imported into the MCT10 from the file in mnu format.
5.3.2 2nd step: Convert The data record must then be converted from the VLT5000 to the FC302. The assistant for parameter conversion can be used for the conversion process. A description of this is provided in the appendix in the chapter entitled 7.3 "Software conversion of a VLT5000 to FC302 with MCT10". MCT10".
Note Depending on how the MCT10 communicates with the frequency converter there is a difference in handling the backup process for all the converters in a system.
Caution
After the replacement, the procedure for backing up all the converters via
Profibus is different to the one for backing them up via the serial bus.
A
more detailed description of backing up using the "Serial" or Profibus" method is provided in the appendix in the chapter entitled 7.2 "Backup with MCT10 using serial bus (RS485) or Profibus". Profibus".
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5 Software (Profibus devices)
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 5.4 Scenario 4: Backup of the VLT5000 available in PLC 5.4.1 General information The parameters from the VLT5000 are backed up using the PLC (read/write parameters). The parameters are loaded into the PLC using acyclical Profibus services and saved in data blocks.
5.4.2 Important information In principle, the parameters may also be backed up using the FC302 + converter card. However, compatibility tests showed that this creates a great many problems which made the further backup process via the PLC (read/write parameters) very difficult and unreliable.
NOTE
We therefore therefore do not recommend and in fact advise against against backing up the paramete parameters rs v ia the PLC (without adjusting the softw are)!!! are)!!!
Since
in this case the converter card is used anyway, no new projects are required in the PLC. The parameter values are set out in the backup DB in the S7 and should be used for the conversion process.
5.4.3 Procedure The failed converter must be deleted from the equipment list (data block) for the data backup in the PLC. The backup of the FC302 (+ converter card) must in future be carried out separately via the MCT10. (Serial or USB) Note
Caution
If the parameters are backed up using the PLC (read/write parameters), you must note the following after you have replaced the defective VLT5000 with an FC302 (+ converter card): Remove the failed VLT5000 from the equipment list (DB in the PLC) of the
converter you wish to back up and back up the new converter (FC302 + converter card) separately using MCT10. (Serial or USB) Alternatively the backup can be created using the LCP display.
5.4.4 Alternatives also for future backups using PLC (customer request) If as a result of a customer request the parameters should continue to be backed up using the PLC, this should be regarded as an upgrade and charged separately. This results in more work for the software project. In this case the failed converter must be replaced by an FC302 with a conventional Profibus option and planned as completely new and independent in the PLC in the form of an FC302. The software parts for "Read/Write parameters" are to be updated. All the converters (VLT50000 + new/new FC302 with normal Profibus option) must be entered in the equipment list for the backup. This software conversion then enables the backup for all the converters to continue to be carried out using the PLC. This backup can then include the existing VLT5000 devices and the newly planned FC302 devices (with the normal Profibus option).
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5 Software (Profibus devices)
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
6
Software (DeviceNet devices) The following software tools and files are required to enable you to complete the software conversion successfully. Item
Descripti on
Functio n
1
MCT10 (Motion Control Tool) from V3.13 (Build xxx)
Frequency converter parameterisation
RSNetWorx for DeviceNet
Parameter retention for Rockwell (DeviceNet)
2
(Use the current Krones version)
Remark: A distinction is made for the software conversion between two different scenarios. A different procedure is required for each scenario.
Caution
Backing up the parameters after the replacement The various methods for backing up the parameters after the replacement has been completed are described on the following pages.
Caution
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However, it is always possible to back up the parameters for the replacement
device (FC302) using the optional LCP display.
6 Software (DeviceNet devices)
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 6.1 CLX software adjustment for "Message command" Compatibility If terminal 37 on the frequency converter (FC302 with DeviceNet) is jumpered, the old "control" block is compatible with the new frequency converter.
Caution
Jumper terminal 37 for compatibility!
General information Reading the frequency converter parameters is in principle exactly the same for the FC302 as for the VLT5000. However, the parameter numbers have been changed. This means that a software adjustment is essential. Example This example shows how to read the potentiometer value (analogue input). The following parts of the software must be changed for this purpose:
The constants must be changed as follows: Tag name constants ….Instance
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VLT5000 constants
FC302
1
1
….Class
0x69
0x74
….Attribute
0x81
0xA2
6 Software (DeviceNet devices)
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 6.2 Scenario 1: Backup of the VLT5000 available in the LCP The backup of the VLT5000 has been completed exclusively in the LCP display. In this scenario, backing up the parameters may prove to be difficult. However, there are two different methods for converting the parameters.
6.2.1 Possibility No. 1: "By hand" All the parameters are entered using the table (chapter entitled 7.4Parameter assignment VLT5000 FC302) (in the appendix), on the LCP of the FC302 or via the MCT10 in the frequency converter. The parameters of the VLT50000 must be converted from lists in the control enclosure or read out of existing backups and converted "by hand".
6.2.2 Possibility No. 2: "With MCT10" If it is still possible, the parameters of the VLT5000 can be backed up using the MCT10 (serial). if this is no longer possible with the defective converter, the display (with the backup) may alternatively also be connected to a VLT5000 which is still functional. The parameters must then be transferred from the LCP to the converter. The parameters can then be read through the serial port using the MCT10. When the parameters have been successfully read into the MCT10, the parameter conversion assistant can be used. A description of this is provided in the appendix in the chapter entitled7.3 entitled 7.3 "Software conversion of a VLT5000 to FC302 with FC302 with MCT10" MCT10".
INFORMATION After the conversion, the parameters must be transferred into the new FC302 using the MCT10. After the parameter transfer, the parameters in "RS NetWorks" must be read by the converter. (See illustration below). The converter or the controlled must not be restarted between the new parameterisation process and reading back the parameters.
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6 Software (DeviceNet devices)
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 6.3 Scenario 2: Backup in the DeviceNet file (.dnt) If the backup of the parameters is only available in the DeviceNet file, the parameters cannot be converted automatically. The procedure in this case is described in the following steps: Step 1: The DeviceNet file must be evaluated manually. (for example move the entries into an Excel document or in a newly created FC302 in MCT10) Step 2: The parameters must be converted manually to the parameter structure of the FC302. In other words the FC302 must be completely newly planned. The table (chapter entitled 7.4Parameter assignment VLT5000 FC302) can be used for this purpose. Alternatively MCT10 can also be used for the conversion process. Step 3: The new FC302 must be newly created in the "DeviceNet" file (.dnt) using the parameters found in step 2. The frequency converter (FC302 with DeviceNet) must be newly created for this purpose:
"Drag and drop" "Right click"
The parameters which have been converted by hand must be entered in "Properties Parameters".
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6 Software (DeviceNet devices)
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302
7
Appendix
7.1 Procedure for dismantling and starting
Procedure: The five safety rules and the following instructions must be followed for dismantling and starting a frequency converter.
Danger
Note the following description for the procedure.
1.
Observe the 5 safety rules: a) Switch off b) Secure to prevent switching on c) Verify disconnection from the power supply d) Earth. e) Cover or safeguard adjacent components 2. Install the prepared FC-302 FC-302 in the control enclosure 3. Check wiring and enter deviations in the schematic diagram, if necessary 4. Install the new device 5. Connect electrically electrically (observe the terminal assignment in the following list) 6. Re-energise the system 7. Parameterise (either on LCP or via MCT10) 8. Check parameters 3 - 15 to 3 - 17 for correct setting 9. Save set parameters 10. Jog the line 11. Turn on the line
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7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 7.2 Backup with MCT10 using serial bus (RS485) or Profibus 7.2.1 Case 1: Backup using serial bus (RS485): This case applies if all the converters in the system (VLT5000) are connected using the serial bus (RS485) and the backup is created via the PC's serial port in MCT10. First of all the data record from the failed VLT5000 must be converted for the FC302 in the MCT10. Instructions for converting the parameters are provided in the chapter entitled 7.3 "Software conversion of a VLT5000 to FC302 with FC302 with MCT10" MCT10"). After the conversion has been completed, the following settings must be made: The FC302 (with converter card) must also replace the failed VLT5000 on the serial bus. In other words after it has been installed in the control enclosure it must also be connected to the serial bus and must be assigned the address of the failed VLT5000. The communication setting of the converter FC302 must be set to serial in MCT10 on the converted converter. (Right-click on the converted converter Properties Connection: Set "SerialBus" + address of the failed VLT5000)
The backup can then be created as in the past via all the converters on the serial bus (RS485).
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7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 7.2.2 Case 2: Backup via Profibus: This case applies if all the converters in the system are backed up with MCT10 via Profibus.
The replaced "FC302 with converter card" converter cannot be backed up in the future via Profibus. This is no longer possible with the converter card. NOTE: If an FC302 with a converter card is used, the parameters can only be backed up in future with the MCT10 in "Serial" or "USB" mode.
Caution
Profibus communication between the MCT10 and FC302 with a converter card
is not possible.
These converters must be regarded separately in future for the creation of a backup and must be backed up in"Serial" or "USB" mode. (Right-click on the converted converter Properties Connection). The connection must be set to "SerialBus" or "USB 1".
The converted converter can continue to be in the MCT10 backup file of all the drive units. It must be ensured, however, that the backup for the various converters is connected with the planned connection type ("Serial" or "USB"). Only then will this also be backed with (right-click on "Project" "Read from frequency converter") among all the converters. If the separate converter(s) (FC302 with converter card) are not connected, the backup for these converters must be initiated and completed manually at a later time.
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7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 7.3 Software conversion of a VLT5000 to FC302 with MCT10 An existing data record can be converted for the FC-302 using MCT10 with the "Parameter conversion assistant".
After clicking on "Continue", the converter in questrion must be selected from the project. When you click on "Continue" you will go to the next window which must also be closed by clicking on "Continue".
Remark:
Caution
D-11-E0-0-07-54 D-11-E0-0-07-54 / TD10002771 EN 00
In the next dialogue the system will point out that it is not possible to provide a 100% guarantee that all the parameters will be converted correctly for the specific application. The parameters should be checked manually after the conversion.
7 Appendix
25 / 35
DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 If the dialogue is closed by clicking on "Accept", the automatic conversion process will start.
When the progress bar has run to the end, another dialogue will appear. The converted converter can be defined in this dialogue. For this purpose a name must be entered and the rating class, options, voltage range and bus parameters set.
The dialogue must be confirmed by clicking on "OK". The conversion has now been completed and can be ended by clicking on "Finish". The frequency converter is then automatically created in the project.
After this the data record is fed into the FC302 via "USB" or "Serial".
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7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 Note If an FC302 with a converter card is used, the parameters can only be backed up in future with the MCT10 in "Serial" or "USB" mode.
Caution
Profibus communication between the MCT10 and FC302 with a converter card
is not possible.
7.4 Parameter assignment VLT5000
FC302
The "Rewiring list" for the paramters is listed on the following pages. Further
information is provided in the manual for the Profibus converter (MCA114) supplied by Danfoss.
Note: nc = not converted NOTE: Parameters 315 - 317 deserve special attention for the setpoint selection. . They must be enabled or disabled depending on the application and circuit.
Caution NOTE: It may be that parameter 164 (resonance attenuation) will have to be adjusted after the conversion, particularly for VLT5000 synchronous applications.
Caution
Default: 100% to be reduced to 20%
7.4.1 Conversion table (parameters) VLT-5000 (SW 3.7)
Valu es
FC-300 (SW 4.02)
0
D-11-E0-0-07-54 D-11-E0-0-07-54 / TD10002771 EN 00
001
0-01
Language
002
nc
Local/Remote
003
nc
Local setpoint selection
004
0-10
Active set
005
9-70
Programme set
006
nc
Parameter set copy
007
nc
LCP copy
008
nc
Max. value of user-defined
009
0-23
Display line 2
010
0-20
Display line 1.1
011
0-21
Display line 1.2
012
0-22
Display line 1.3
013
nc
Manual/local operation configuration
014
0-41
[Off] LCP button
015
nc
016
nc
017
0-43
[Reset] LCP button 7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 VLT-5000 (SW 3.7)
Valu es
FC-300 (SW 4.02)
018
0-61
Main menu password
019
0-04
Power ON mode (manual)
027
nc
1 100
1-00, 1-01
Control procedure
101
1-03, 1-04, 14-40
Torque characterstic of load
102
1-20
Nominal motor output [kW]
103
1-22
Nominal motor voltage
104
1-23
Rated motor frequency
105
1-24
Nominal motor current
106
1-25
Nominal motor speed
107
1-29
Motor adaptation (AMA)
108
1-30
Stator resistance
109
1-35
Stator reactance
110
1-50
Motor magnetisation at 0 rpm
111
1-52
Min. speed norm. magnetis. [Hz]
113
1-60
Load equalisation low
114
1-61
Load equalisation high
115
1-62
Slip compensation
116
1-63
Slip time constant
117
1-64
Resonance dampening
118
1-65
Time constant dampening
119
nc
120
1-71
Start delay
121
1-72
Start function
122
1-80
Function at stop
123
1-82
ON speed stop funct. [Hz]
124
2-00
DC holding current
125
2-01
DC braking current
126
2-02
DC braking time
127
2-04
DC brake ON [Hz]
128
1-90
Thermal motor protection
129
1-91
External ventilation
130
1-75
Start speed [Hz]
131
nc
Start current
145
nc
2
D-11-E0-0-07-54 D-11-E0-0-07-54 / TD10002771 EN 00
200
4-10
Direction of motor rotation
201
4-12
Min. frequency
202
4-14, 4-19
Max. output frequency
203
3-00
Set-point value range
204
3-02, 6-14, 6-25, 5-52, 5-57
Min. set-point value
205
3-03, 6-15, 6-25, 5-53, 5-58
Max. set-point value
206
3-40, 3-50, 3-82
Ramp type 1 7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 VLT-5000 (SW 3.7)
Valu es
FC-300 (SW 4.02)
207
3-41
Ramp up 1
208
3-42
Ramp down 1
209
3-51
Ramp up 2
210
3-52
Ramp down 2
211
3-80
Ramp jog
212
3-81
Ramp quick stop
213
3-11
Jog speed [Hz]
214
3-04
Set-point value funct.
215
3-10[0]
Fixed set-point value 0
216
3-10[1]
Fixed set-point value 1
217
3-10[2]
Fixed set-point value 2
218
3-10[3]
Fixed set-point value 3
219
3-12
Frequency correction raise/lower
221
4-16
Mom. limit, motor
222
4-17
Mom. limit, general
223
4-50
I min. limit
224
4-51
I max. limit
225
4-52
Min. speed limit
226
4-53
Max. speed limit
227
4-56
Min. act. val. limit
228
4-57
Max. act. val. limit
229
nc
230
4-61[0], 4-63[0]
Frequency Bypass 1
231
4-61[1], 4-63[1]
Frequency Bypass 2
232
4-61[2], 4-63[2]
Frequency Bypass 3
233
4-61[3], 4-63[3]
Frequency Bypass 4
234
4-58
Motor phase monitoring
300
5-16 (MCB 101)
Terminal 16, input
301
5-17 (MCB 101)
Terminal 17, input
302
5-10
Input 18 Digital
303
5-11
Input 19 Digital
304
5-12
Input 27 Digital
305
5-13
Input 29 Digital
306
5-14
Input 32 Digital
307
5-15
Input 33 Digital
308
3-15, 7-00, 1-93, 4-20
Terminal 53 analogue input voltage
309
6-10
Terminal 53 scal. min. voltage
310
6-11
Terminal 53 scal. max. voltage
311
3-16, 4-20, 1-93, 4-21
Terminal 54 analogue input voltage
312
6-20
Terminal 54 scal. min. voltage
313
6-21
Terminal 54 scal. max. voltage
314
3-17, 7-00, 1-93, 4-20
Terminal 60 analogue input voltage
315
6-22
Terminal 60 scal. min. voltage
3
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7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 VLT-5000 (SW 3.7)
Valu es
FC-300 (SW 4.02)
316
6-23
Terminal 60 scal. max. voltage
317
6-00
Signal drop-out time
318
6-01
Signal drop-out function
319
6-50
Terminal 42 analog output
320
5-68
Terminal 42 Output, pulse scaling
321
6-60
Terminal X30/8 analogue output
322
5-68
Terminal 45 Output, pulse scaling
323
5-40[0]
Relay function
324
5-41[x]
ON delay Relay
325
5-42[x]
OFF delay Relay
326
5-40[1]
Relay function
327
5-51
Terminal 29 max. frequency
328
5-58
Terminal 33 max. frequency
329
5-70
Encoder resolution
330
nc
345
4-32
Encoder timeout time
346
4-30
Encoder monitoring function
357
6-51
Terminal 42 min. scaling
358
6-52
Terminal 42 max. scaling
359
6-61
Term. 45, Output min. scale
360
6-62
Term. 45, Output max. scale
361
4-31
Encoder loss threshold
400
2-10, 2-17
Braking function
401
30-81
Braking resistor (ohm)
402
2-12
Braking resistor power (kW)
403
2-13
Braking resistor power monitoring
404
2-15
Braking resistor test
405
14-20
Reset function
406
14-21
Automatic reset time
407
14-10
Power failure function
408
nc
409
14-25
Time delay curr. val.
410
14-26
Switching frequency
411
14-01
Clock frequency
412
nc
413
14-03
414
nc
415
nc
416
3-01
Set-point/actual value unit
417
7-02
Speed controller P amplification
418
7-03
Speed controller integration time
419
7-04
Speed controller D time
420
7-05
Speed controller D amplif./limit
4
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Overmodulation
7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 VLT-5000 (SW 3.7)
Valu es
FC-300 (SW 4.02)
421
7-06
Speed controller low-pass filter time
422
1-55[0]
U0 voltage
423
1-55[1]
U1 voltage
424
1-56[1]
F1 frequency
425
1-55[2]
U2 voltage
426
1-56[2]
F2 frequency
427
1-55[3]
U3 voltage
428
1-56[3]
F3 frequency
429
1-55[4]
U4 voltage
430
1-56[4]
F4 frequency
431
1-55[5]
U5 voltage
432
1-56[5]
F5 frequency
433
7-12
Torque control, open loop proportional gain
434
7-13
437
7-30
PID norm./reverse
438
7-31
PID anti-windup
439
7-32
PID start freq.
440
7-33
PID P amplif.
441
7-34
PID integr. Time
442
7-35
PID diff. Time
443
7-36
PID diff. Adjust.
444
nc
445
1-73
Motor diagnostic circuit
446
14-00
Switching pattern
447
nc
448
nc
449
nc
450
14-11
Power failure voltage
453
7-07
Gear ratio, speed close loop
454
nc
455
nc
457
14-12
483
nc
Torque control, open loop integral time
Mains phases unbalance
5
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500
8-31
Address
501
8-32
FC Baud rate
502
8-50
Motor free-wheeling
503
8-51
Quick stop
504
8-52
DC brake
505
8-53
Start
506
8-54
Direction of rotation
507
8-55
Parameter set selection
508
8-56
Fixed speed selection
509
8-90
Bus jog speed 1
510
8-91
Bus jog speed 2 7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 VLT-5000 (SW 3.7)
Valu es
FC-300 (SW 4.02)
512
8-10
Control word profile
513
nc
Control word timeout time
514
nc
Control word timeout function
515
16-02
Setpoint %
516
16-01
Set-point value [unit]
517
16-52
Actual value [unit]
518
16-13
Frequency
519
nc
520
16-14
Motor current
521
16-22
Torque
522
16-10
Power (kW)
523
16-11
Power (HP)
524
16-12
Motor voltage
525
16-30
DC voltage
526
16-18
Th. Motor Protector
527
16-35
Inverter overload
528
16-60
Digital inputs
529
16-62
Analogue input 53
530
16-64
Analogue input 54
531
16-64
Analogue input 60
532
16-51
Pulse set-point value
533
16-50
External set-point value (%)
534
16-03
Status word
535
16-33
Braking performance/2min
536
16-32
Braking performance/s
537
16-34
Dissipator temperature
538
14-72
Alarm Word
539
16-00
Control word
540
14-73
Warning word
541
14-74
Expanded status word
553
nc
554
nc
557
16-17
558
nc
580
nc
581
nc
582
nc
Speed (rpm)
Defined parameters
6
D-11-E0-0-07-54 D-11-E0-0-07-54 / TD10002771 EN 00
600
15-00
Operating hours
601
15-01
Motor operating hours
602
15-02
Counter kWh
603
15-03
Number power ON
604
15-04
Number overtemperatures
605
15-05
Number overvoltages
606
nc
607
nc
608
nc 7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 VLT-5000 (SW 3.7)
Valu es
FC-300 (SW 4.02)
609
nc
610
nc
611
nc
612
nc
613
nc
614
nc
615
15-30
Fault memory: Fault code
616
15-31
Fault memory: Time
617
15-32
Fault memory: Value
618
15-06
Reset counter kWh
619
15-07
Reset motor operating hours
620
14-22
Mode of operation
621
15-40
FC type
622
15-41
Power section
623
nc
Type order no.
624
nc
Software version
625
nc
LCP version
626
nc
627
nc
628
nc
629
nc
630
nc
631
nc
8 800
nc
801
nc
802
8-02
Minimum station delay
803
8-03
Time out after bus error
804
8-04
Response after bus time out
805
8-14
Function of control word bit 10
806
nc
808
nc
849
8-07
Extended diagnose
9
D-11-E0-0-07-54 D-11-E0-0-07-54 / TD10002771 EN 00
900
nc
901
nc
902
nc
903
nc
904
nc
907
nc
908
nc
909
nc
910
nc
911
nc
913
nc
7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 VLT-5000 (SW 3.7)
D-11-E0-0-07-54 D-11-E0-0-07-54 / TD10002771 EN 00
Valu es
FC-300 (SW 4.02)
914
nc
915
9-15
PCD config write
916
9-16
PCD config read
917
nc
918
9-18
Station address
927
9-27
Parameter edit
928
9-28
Control authority
953
9-53
Warning parameter
964
9-64
Identification
965
9-65
Profile number
967
nc
968
nc
970
9-70
Parameter setup selection
971
9-71
Save data values
980
nc
981
nc
982
nc
990
nc
7 Appendix
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DANFOS DANF OSS S frequency inverter inverter Convers Conversion ion of VLT 5000 to FC F C 302 7.5 Hardware "rewiring table" The following table is to facilitate terminal rewiring. Item
VLT3000
VLT5000
FC -302
Group:
Method of operation
Power connections 01
91 (L1)
02
92 (L2)
03
93 (L3)
04
94 (PU)
96 (U)
06
97 (V)
08
Power
95 (PU)
05 07
Phase 1
95 (PU)
Phase 3 Power connection PE Motor connection U
Motor
98 (W) 95 (PU)
Phase 2
95 (PU)
99 (PU)
09
81 (R-)
10
82 (R+)
11 12
88 (-DC) 89 (+DC)
Motor connection V Motor connection W Motor connection PE
Brake DCOut
Braking resistor Braking resistor + DC-link voltage DC-link voltage +
Control terminals 13
01 (COM)
01 (NC)
01 (COM)
14
02 (NC)
02 (NO)
02 (NO)
15
03 (NO)
03 (COM)
03 (NC)
16 17
04 (COM) 05 (NO)
04 (NO) 05 (COM)
04 (COM) 05 (NO)
18
-/-
-/-
06 (NC)
19
Relay 2
24V auxiliary voltage output
-/-
21
16 (DIN)
22
17 (D IN / Puls)
17 (DIN/OUT )
-/-
23
18 (DIN)
18 (DIN/OUT )
18 (DIN)
24
19 (DIN)
19 (DIN/OUT )
19 (DIN)
26
27 (DIN)
27 (DIN/OUT )
27 (DIN/OUT )
27
29 (DIN)
29 (DIN/OUT )
29 (DIN/OUT )
28
32 (DIN)
32 (DIN/OUT )
32 (DIN)
29
33 (DIN)
33 (DIN/OUT )
30
-/-
35 (0V DC IN)
31
-/-
36 (+24V DC IN)
25
13 (24V) 16 (DIN/OUT )
-/Digital connection
20 (D COM)
Digital mass
-/-
-/-
37 (D IN)
33
38 ( D PE)
-/-
-/-
34
39 (ACOM)
35
42 (AOUT) 45 (AOUT)
38
53 (A IN [U])
53 (AIN [U])
53 (A IN [U],[I])
39
-/-
54 (A IN [U])
54 (A IN [U],[I])
Analog output
-/-
50 (+10V)
40
Digital connection
Analog mass (I)
45 (A OUT)
37
Digital
33 (DIN)
32
41
Voltage-free
12 (24V)
20
36
Relay 1
Analog
Analog input
55 (ACOM) 60 (A IN [I])
60 (A IN [I]) [I])
42
61 (BCOM)
43
68 (+Bus)
44
69 (-Bus)
10V auxiliary voltage
Analog mass (U) -/-
Analog input RS485 mass RS485
RS485 Tx/Rx + RS485 Tx/Rx -
After successful connection of the new frequency inverter, the bus addr ess must be set using the slide switches and on the display. Then, restart the frequency inverter (isolate power) and parameterise with the MCT10 tool or the LCP.
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7 Appendix
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