1. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 1 Drives Division VLT ® AutomationDrive FC302 PM Motors Configuration procedure By: Dennis Jakobsen Contributers: Nicolas Trolle Mogens Allan Jensen Hans Jørgen Nørgaard. Johan Kirkebæk.

2. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 2 Drives Division 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.

3. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 3 Drives Division AEG Lafert PM Motor example. Settings in the cross sections are those we must insert into the drive.

4. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 4 Drives Division 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 FC302 at 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.

5. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 5 Drives Division Stator resistance R s and d-axis inductance L d. P 1-30 Stator resistance R s and P 1-37 d-axis inductance L d. Typical ways of specifying R s and L d dependent on motor type. For PM motors divide R s and L d by 2 if technical specifications defines “Line – Line”. AutomationDrive requires “Line – Common” value.

6. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 6 Drives Division Drive configuration – Necessary steps. Basic motor data configuration. Advanced motor data configuration. Encoder configuration. 0° Motor angle adjustment. STEP 5 Angle offset adjustment. STEP 6 STEP 3 STEP 2 STEP 1 Configuration Adjustment Drive tuning STEP 7 Test run your motor. STEP 4

7. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 7 Drives Division Step 1 – Basic motor data configuration 1. Set motor construction. Set control principle. STEP 1.4 Set motor feedback source. STEP 1.5 STEP 1.3 STEP 1.2 Set max. Hz and motor speed STEP 1.8 Set nominal motor current. STEP 1.6 Set motor speed. STEP 1.7 Perform an initialization of the drive. STEP 1.1 [P 14-22] (toggle power) [P 1-10] = [1]PM, non salient SPM [P 1-01] = [3]Flux with motor feedback Set configuration mode. [P 1-00] = [1]Speed closed loop [P 1-02] = [1]MCB102 [P 4-19] = 400Hz, [P 4-13] = 6000 RPM [P 1-24] = 1,08 Amps [P 1-25] = 3000 RPM

8. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 8 Drives Division Step 2 – Advanced motor data configuration. Set stator resistance. Set d-axis inductance. Set motor poles. STEP 2.4 Set B-EMF. STEP 2.5 STEP 2.3 STEP 2.2 Set rated torque. STEP 2.1 Set max current limit. STEP 2.6 [P 4-18] = 4,81 /1,08 * 100 = 445 % [P 1-26] = 1,60 Nm [P 1-40] = 89,33 V [P 1-30] = 13,5 / 2 Ohm [P 1-37] = 22,8 / 2 mH [P 1-38] = 8 Motor data configuration is now finished. Please note that you can NOT use AMA !

9. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 9 Drives Division 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.

10. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 10 Drives Division Step 3 – Encoder configuration. Set resolution (PPR). Set protocol selection. Set resolution (Positions/Rev). STEP 3.4 STEP 3.3 STEP 3.2 Set signal type. STEP 3.1 [P 17-10] = [2]Sinusodial 1 Vpp [P 17-11] = 1024 [P 17-20] = [1]HIPERFACE [P 17-21] = 32768 MOTOR IS READY TO RUN.

11. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 11 Drives Division Drive configuration – Additional steps. Basic motor data configuration. Advanced motor data configuration. Encoder configuration. 0° Motor angle adjustment. STEP 5 Angle offset adjustment. STEP 6 STEP 3 STEP 2 STEP 1 Configuration Adjustment Drive tuning STEP 7 Test run your motor. STEP 4

12. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 12 Drives Division Step 5 – 0° motor angle adjustment 1. Verify that the motor angle (on display line 1) shows zero. Set Start delay, [P 1-71] to 10 sec. Set Start Function, [P 1-72] to DC-hold STEP 5.5 STEP 5.4 STEP 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). STEP 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. Select motor angle on display line 1. STEP 5.2 [P 0-21 or 22] = [1620] Motor angle

13. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 13 Drives Division 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. Stop the motor. (Within 10 sec.) Start again, and verify that the motor does not move. STEP 5.8 STEP 5.7 STEP 5.6 Look at the motor shaft, and start the motor. STEP 5.5 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) STEP 5.9

14. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 14 Drives Division Step 6 – Offset adjustment. Set Start delay, [P 1-71] to Zero. (disabling start function) Look at motor angle on display line 1. (0-65535 equals 0-2PI) STEP 6.3 STEP 6.2 Set Motor Feedback Source, [P 1-02] to [1]MCB102 STEP 6.1 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 6.4 DO NOT START THE MOTOR YET ! MOTOR IS READY TO RUN.

15. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 15 Drives Division Step 7 - Tuning the application. Set torque limits [P 4-14] and [P 4-15] to protect your application. 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. 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 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.

16. Confidential / Property of Danfoss Drives A/S 2004-10-18 DD-SMT/DEJ 16 Drives Division 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.