AC Drive Training

Drive Internal
Components
 Topics

• AC Drive Components
• Danfoss Drives
• MCT10 Software
• Local Control Panel
 Safety Notes
DRIVES CONTAIN LIVE VOLTAGES AFTER
DISCONNECTION FROM MAINS.
WAIT AT LEAST 40 MIN. BEFORE MAINTENANCE.

BEFORE MAINTENANCE, CHECK ALL

CONDUCTING PARTS FOR AC AND DC VOLTAGE
BETWEEN EACH OTHER AND TO GROUND.

PRESS AN EMERGENCY STOP TO PREVENT

DRIVES BEING RESTARTED

WEAR EAR AND EYE PROTECTION REQUIRED

 Danfoss FC302 –
Internal Components

• Exploded view
of a typical
D-Frame drive
Danfoss FC302 Connections
 Danfoss FC302 Bit Switches
• Switches S201 (A53)
and S202 (A54) are
used to select a current
(0-20 mA) or a voltage
(-10 to +10V)
configuration of the
analog input terminals
53 and 54.
• Switch S801 (BUS
TER.) can be used to
enable termination on
the RS-485 port
(terminals 68 and 69).
Danfoss FC302 LCP Panel
 Danfoss FC302 Control Card
• Logic Control – microprocessor
which supervises and controls all
drive functions.
• PROMs – contain parameters for
programmable options.
• EEPROM - data storage including
during power down.
• PWM IC – pulse width modulation
waveform for Power card.
• Control Terminals –
programmable function I/O,
analog and digital.
• Serial Link communications.
 Danfoss FC302 Power Card
• Low level logic – high level power signal
isolation
• Monitoring DC bus voltage, line voltage, output
current etc.
• Gate drive firing signals.
• Scaling of current / voltage feedback signals.
• Fault processing for output short circuit and
ground fault conditions.
• Switch mode power supplies.
Danfoss FC302 Power Card
Danfoss FC302 LCP, Control
Card and Power Card
 Danfoss FC302 Gate Driver Card
• Isolation /
buffering of
gate drive
signals to
IGBTs.
 Danfoss FC302 - IGBT
• IGBT – Insulated Gate Bipolar Transistor
• Similar to Thyristor in construction but
IGBT can switch off at any time. Not just
at 0A like Thyristor.
IGBT
Collector

Gate

Emitter
 Danfoss FC302 – Pulse Width
Modulation (PWM)

• PWM is a power electronics technique

for arbitrary voltage waveform
generation.
DC Link + Voltage

Imaginary 0V

DC Link - Voltage
 PWM Duty Cycle
• The duty cycle of
PWM determines
the average voltage
of the output. t

• D=t/T T

• Vout_avg = Vin x D Vin

Vout_avg
 IGBT Switching
DC +

DC +

Vout
DC -

DC -
 Danfoss FC302 - IGBT
• The IGBT’s provide an output of variable voltage
and frequency, required for a constant torque
with increasing speed.
• There are 6 IGBT’s in the output inverter of the
drive, 2 per phase.
• The drive produces a high switching voltage
often in excess of 1000V, and due to this high
switching it is not possible to see motor voltage
with a standard multi meter. This also has an
effect on motor windings which have to be
insulated to 3000V.
 Encoder Connection
• Extra Option Card
MCB102 required.
• 5V TTL Encoder
used for resistance
to noise.
 Encoder Direction
• Two pairs of pulses
are created when
the encoder is
turned.
• A and B pulses are
90° apart.
• To change the
encoder direction A
and B pulse wires
can be switched with
each other.
 Motor Direction

• Motor Direction can be changed by

switching two phases.
 Danfoss Control
• UF control - In this control there is no field weakening,
no feedback and no current regulation. A voltage and
frequency is applied to the motor with reference from the
joystick.
• VVC+ - This is a sophisticated form of Uf control,
branded by Danfoss. It constantly adjusts the voltage/
frequency curve to keep stator current low.
• Open-loop Flux - See below without feedback.
• Closed-loop Flux Vector Control - In this method, 2
windings are created from 1 stator winding. Separates
stator current required for rotating magnetic flux and
current required for torque. With this method the AC
drive is getting very close to the control of a DC drive.
 RS485 Communication
Hoist Travel Travel Trolley
Danfoss Danfoss Danfoss Danfoss
FC FC FC FC
Addr - 1 Addr - 2 Addr - 3 Addr - 4

S801 S801 S801 S801

68 69 68 69 68 69 68 69

• Each drive has its own address number on the

bus – Parameter 831
• Each drive should be set to 115,200 Baud –
parameter 832
• End of line resistor, S801, is set to off on all
drives except last drive.
 RS485 Communication

• Dipswitches on the
RS232/RS485
converter should be
set as shown in the
drawing.
 Information
• The Danfoss Manuals are an invaluable
source of information.
– FC300 Service Manual
• Information about hardware fault finding and repair
– FC300 Programming Guide
• Information about all parameters
– FC300 Operating Manual
• Information about alarms, warnings and trouble-
shooting
End