Danfoss FC 301, FC 302 Design guide
Design Guide
VLT® AutomationDrive FC 301/302
0.25–75 kW
ContentsDesign Guide | VLT® AutomationDrive FC 301/302
Contents
1 Introduction 12
1.1 Purpose of this Design Guide 12
1.2 Trademarks 12
1.3 Additional Resources 12
1.4 Document Version 13
1.5 Conventions 13
2 Safety 14
2.1 Safety 14
2.2 Safety Symbols 14
2.3 Qualified Personnel 14
3 Approvals and Certifications 15
3.1 Regulatory/Compliance Approvals 15
3.2 Typical Product Approvals and Certifications for VLT® Drives 15
3.3 Export Control Regulation 18
3.4 Enclosure Protection Rating 18
4 VLT® Product Family Overview 19
4.1 VLT® Drives 19
4.2 Product Overview of the VLT® AutomationDrive FC 301/302 19
4.3 Power Drive Systems 23
4.3.1 Ecodesign for Power Drive Systems 23
4.3.1.1 Losses in Mains Cabling 25
4.3.1.2 Input Filters: Line Reactors and Harmonic Filters 25
4.3.1.3 Drive, Input Side 26
4.3.1.4 DC Link 27
4.3.1.5 Drive, Output Side 28
4.3.1.6 Motor Cables and Motor 29
5 Product Overview 30
5.1 Overview of Drives Systems 30
5.1.1 Filter Options 30
5.1.1.1 Protection of Motor Insulation 31
5.1.1.2 Reduction of Motor Acoustic Noise 31
5.1.1.3 Reduction of High-frequency Electromagnetic Noise in Motor Cables 31
5.1.1.4 Bearing Currents and Shaft Voltage 31
5.1.2 Supported Motor Types 32
5.1.3 Bearing Currents 33
5.2 Integrated Motion Controller 36
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5.2.1 Positioning, Homing, and Synchronization 36
5.2.1.1 Positioning 36
5.2.1.2 Homing 37
5.2.1.3 Synchronization 37
5.2.1.4 Fieldbus References 38
5.2.2 Control 39
5.2.2.1 Control Loops 39
5.2.2.2 Control and Status Signals 40
5.3 Functional Safety 42
5.3.1 Protection of Personnel and Equipment 42
5.3.2 VLT® Safety Option MCB 150 and MCB 151 42
5.3.3 VLT® Sensorless Safety MCB 159 43
5.3.4 VLT® Safety Option MCB 152 43
5.3.5 Safety Functions 43
5.4 Danfoss VLT® FlexConcept® 45
5.5 Torque Sharing/Droop 46
5.6 Power Limit Function 47
5.7 Service Log 49
5.8 Maintenance Functions 49
6 Product Features 52
6.1 Automated Operational Features 52
6.1.1 Short-circuit Protection 52
6.1.2 Overvoltage Protection 52
6.1.3 Missing Motor Phase Detection 53
6.1.4 Mains Phase Imbalance Detection 53
6.1.5 Switching on the Output 53
6.1.6 Overload Protection 54
6.1.7 Locked Rotor Protection 54
6.1.8 Automatic Derating 54
6.1.8.1 Overview of Automatic Derating 55
6.1.8.2 Sine-wave Filter Fixed Mode 56
6.1.8.3 Overview Table 57
6.1.8.4 High Motor Load 58
6.1.8.5 High Voltage on the DC link 58
6.1.8.6 Low Motor Speed 58
6.1.8.7 High Internal Temperature 59
6.1.8.8 Current 60
6.1.9 Automatic Energy Optimization 60
6.1.10 Automatic Switching Frequency Modulation 61
6.1.11 Automatic Derating for High Switching Frequency 61
6.1.12 Power Fluctuation Performance 61
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6.1.13 Resonance Damping 61
6.1.14 Temperature-controlled Fans 61
6.1.15 EMC Compliance 61
6.1.16 Galvanic Isolation of Control Terminals 62
6.2 Custom Application Features 62
6.2.1 Automatic Motor Adaptation (AMA) 62
6.2.2 Motor Thermal Protection 62
6.2.3 Motor Thermal Protection for Ex-e or Ex-n Motors 63
6.2.4 Mains Dropout 65
6.2.5 Built-in PID Controller 65
6.2.6 Automatic Restart 65
6.2.7 Flying Start 65
6.2.8 Full Torque at Reduced Speed 65
6.2.9 Frequency Bypass 66
6.2.10 Motor Preheat 66
6.2.11 Programmable Set-ups 66
6.2.12 Smart Logic Controller 66
6.2.13 Safe Torque Off 68
6.3 Dynamic Braking Overview 68
6.4 Mechanical Holding Brake Overview 69
6.4.1 Open-loop Mechanical Brake Control 69
6.4.2 Closed-loop Mechanical Brake Control/Hoist Mechanical Brake 70
6.5 Load Sharing Overview 71
6.5.1 Preconditions and Special Conditions 72
6.5.2 Combinations of Enclosure Sizes 73
6.6 Regen Overview 74
7 Options and Accessories Overview 76
7.1 Introduction 76
7.2 VLT® FC Series Options Concept 76
7.3 VLT® Fieldbus Options 77
7.4 VLT® Functional Extensions 78
7.5 VLT® Programmable Controllers 78
7.6 VLT® Power Options 79
7.6.1 VLT® Harmonic Filters 79
7.6.2 VLT® Sine-wave Filters 79
7.6.3 VLT® dU/dt Filters 80
7.6.4 VLT® Common-mode Filters 80
7.6.5 VLT® Brake Resistors 80
7.6.6 VLT® Line Reactors 81
7.7 Kits and Accessories 81
7.7.1 Panel Through Mounting Kits for VLT® FC Series Enclosure Sizes A, B, and C 81
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7.7.2 IP21/NEMA Type 1 Enclosure Kits for VLT® FC Series Enclosure Sizes A, B, and C 82
7.7.3 Mounting Brackets for VLT® FC Series Enclosure Sizes A5, B1, B2, C1, and C2 86
7.7.4 Remote Mounting Kits for LCP 88
7.7.4.1 Remote Mounting Kit for LCP 102 and LCP 103 with Cover for Outdoor Mounting 88
7.7.4.2 Panel Mounting Kit for LCP 102, LCP 101, and LCP 103 89
7.7.5 VLT® Wireless Communication Panel LCP 103 and MyDrive® Connect 91
8 Specifications 92
8.1 Enclosure Size by Power Rating 92
8.2 Electrical Data 94
8.2.1 Mains Supply 3x200–240 V AC, T2 94
8.2.2 Mains Supply 3x380–480 V AC, FC 301 T4 and 3x380–500 V AC, FC 302 T5 97
8.2.3 Mains Supply 3x525–600 V AC, T6 101
8.2.4 Mains Supply 3x525–690 V AC, T7 105
8.2.5 Power Cable Cross-sections 108
8.3 Mains Supply 109
8.4 Motor Output and Motor Data 109
8.4.1 Motor Output (U, V, W) 109
8.4.2 Torque Characteristics 110
8.5 Ambient Conditions 110
8.6 Cable Specifications 111
8.6.1 Cable Lengths and Cross-sections for Control Cables 111
8.7 Control Input/Output and Control Data 111
8.7.1 Digital Inputs 111
8.7.2 STO Terminal 37 111
8.7.3 Analog Inputs 112
8.7.4 Pulse/Encoder Inputs 112
8.7.5 Digital Outputs 113
8.7.6 Analog Output 113
8.7.7 Control Card, 24 V DC Output 114
8.7.8 Control Card, +10 V DC Output 114
8.7.9 Control Card, RS485 Serial Communication 114
8.7.10 Control Card, USB Serial Communication 114
8.7.11 Relay Outputs 114
8.7.12 Control Card Performance 115
8.7.13 Control Characteristics 115
8.8 Connection Tightening Torques 116
8.9 Power Ratings, Weight, and Dimensions 117
9 Mechanical Installation Considerations 122
9.1 Storage 122
9.2 Operating Environment 122
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9.2.1 Gases 122
9.2.2 Dust 123
9.2.3 Outdoor Installation in freezing Temperature Environments 124
9.2.4 Potentially Explosive Atmospheres 125
9.2.5 Vibration and Shock 126
9.2.6 Maintenance 126
9.3 Mounting Configurations 126
9.3.1 Side-by-side Mounting 126
9.3.2 Wall Mounting 128
9.4 Derating 129
9.4.1 Derating for Running at Low Speed 129
9.4.2 Derating for Low Air Pressure 130
9.4.3 Derating for Ambient Temperature and Switching Frequency 131
9.4.3.1 Derating for Ambient Temperature, Enclosure Size A 131
9.4.3.2 Derating for Ambient Temperature, Enclosure Size B 132
9.4.3.3 Derating for Ambient Temperature, Enclosure Size C 137
10 Electrical Installation Considerations 141
10.1 Safety Instructions 141
10.2 Wiring Schematic 143
10.3 Connections 144
10.3.1 Power Connections 144
10.3.2 IT Grid Connection 145
10.3.3 DC Bus Connection 146
10.3.4 Load Sharing Connection 146
10.3.5 Brake Cable Connection 147
10.3.6 Grounding 147
10.3.7 Safety Ground Connection 147
10.4 Cables 147
10.4.1 EMC-correct Cables 147
10.4.2 Preparing Cable Entry Holes 149
10.4.3 Specifications of Entry Holes 149
10.4.3.1 Entry Holes, Enclosure Size A2, IP21 149
10.4.3.2 Entry Holes, Enclosure Size A3, IP21 150
10.4.3.3 Entry Holes, Enclosure Size A4, IP55 150
10.4.3.4 Entry Holes, Enclosure Size A4, IP55 Threaded Gland Holes 151
10.4.3.5 Entry Holes, Enclosure Size A5, IP55 151
10.4.3.6 Entry Holes, Enclosure Size A5, IP55 Threaded Gland Holes 152
10.4.3.7 Entry Holes, Enclosure Size B1, IP21 152
10.4.3.8 Entry Holes, Enclosure Size B1, IP55 153
10.4.3.9 Entry Holes, Enclosure Size B1, IP55 Threaded Gland Holes 153
10.4.3.10 Entry Holes, Enclosure Size B2, IP21 154
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10.4.3.11 Entry Holes, Enclosure Size B2, IP55 155
10.4.3.12 Entry Holes, Enclosure Size B2, IP55 Threaded Gland Holes 155
10.4.3.13 Entry Holes, Enclosure Size B3, IP21 156
10.4.3.14 Entry Holes, Enclosure Size C1, IP21 156
10.4.3.15 Entry Holes, Enclosure Size C2, IP21 157
10.4.4 Tightening Torques for Cover 157
10.5 Control Wiring and Terminals 158
10.5.1 Shielded Control Cables 158
10.5.2 Wiring to Control Terminals 159
10.5.3 Control Terminal Types 160
10.5.4 Terminal Descriptions 161
10.6 Fuses and Circuit Breakers 162
10.6.1 Fuse Recommendations 162
10.6.2 CE Compliance 163
10.6.3 UL Compliance 166
10.7 Relays 168
10.7.1 Overview of Relay Terminals 170
10.8 Disconnects and Contactors 171
10.9 Motor 173
10.9.1 Motor Thermal Protection 174
10.9.2 Parallel Connection of Motors 174
10.9.3 Motor Insulation 175
10.9.4 Motor Bearing Currents 176
10.10 Braking 176
10.10.1 Selection of Brake Resistor 176
10.10.2 Control with Brake Function 179
10.11 Residual Current Device 180
10.12 Leakage Current 180
10.12.1 Using a Residual Current Device (RCD) 182
10.13 Efficiency 183
10.14 Acoustic Noise and Airflow 184
10.15 dU/dt Conditions 185
10.15.1 dU/dt Values, 200–240 V (T2) 186
10.15.1.1 dU/dt Values for P5K5T2, 200–240 V 186
10.15.1.2 dU/dt Values for P7K5T2, 200–240 V 186
10.15.1.3 dU/dt Values for P11KT2, 200–240 V 186
10.15.1.4 dU/dt Values for P15KT2, 200–240 V 187
10.15.1.5 dU/dt Values for P18KT2, 200–240 V 187
10.15.1.6 dU/dt Values for P22KT2, 200–240 V 187
10.15.1.7 dU/dt Values for P30KT2, 200–240 V 187
10.15.1.8 dU/dt Values for P37KT2, 200–240 V 187
10.15.2 dU/dt Values, 380–480 V (T4) 188
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10.15.2.1 dU/dt Values for P1K5T4, 380–480 V 188
10.15.2.2 dU/dt Values for P4K0T4, 380–480 V 188
10.15.2.3 dU/dt Values for P7K5T4, 380–480 V 188
10.15.2.4 dU/dt Values for P11KT4, 380–480 V 188
10.15.2.5 dU/dt Values for P15KT4, 380–400 V 189
10.15.2.6 dU/dt Values for P18KT4, 380–480 V 189
10.15.2.7 dU/dt Values for P22KT4, 380–480 V 189
10.15.2.8 dU/dt Values for P30KT4, 380–480 V 189
10.15.2.9 dU/dt Value for P37KT4, 380–480 V 190
10.15.2.10dU/dt Values for P45KT4, 380–480 V 190
10.15.3 dU/dt Values, 380–500 V (T5) 190
10.15.3.1 dU/dt Values for P55KT5, 380–500 V 190
10.15.3.2 dU/dt Values for P75KT5, 380–500 V 190
10.15.4 dU/dt Values, 600 V (T6) 190
10.15.4.1 dU/dt Values for P15KT6, 600 V 191
10.15.4.2 dU/dt Values for P30KT6, 600 V 191
10.15.4.3 dU/dt Values for P75KT6, 600 V 191
10.15.5 dU/dt Values, 525–690 V (T7) 191
10.15.5.1 dU/dt Values for P7K5T7, 525–690 V 191
10.15.5.2 dU/dt Values for P45KT7, 525–690 V 192
10.16 Electromagnetic Compatibility (EMC) Overview 192
10.16.1 EMC Test Results 192
10.16.2 Emission Requirements 193
10.16.3 Immunity Requirements 194
10.16.4 EMC Compatibility 196
10.17 EMC-compliant Installation 197
10.18 Harmonics Overview 200
10.18.1 Harmonics Analysis 200
10.18.2 Effect of Harmonics in a Power Distribution System 201
10.18.3 IEC Harmonic Standards 202
10.18.4 Harmonic Results (Emission) 203
10.18.5 Harmonic Mitigation 204
10.18.6 Harmonic Calculation 205
10.18.7 Line Reactors 205
11 Basic Operating Principles 206
11.1 Introduction 206
11.2 Drive Controls 206
11.2.1 Control Principle 206
11.2.2 Local (Hand On) and Remote (Auto On) Control 207
11.3 Reference Limits 209
11.4 PID Control 211
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11.4.1 Speed PID Control 211
11.4.2 Tuning PID Speed Control 212
11.4.3 Process PID Control 212
11.4.4 Advanced PID Control 213
11.5 More Operating Principles 213
11.5.1 FC 301 versus FC 302 Control Principle 214
11.5.2 Control Structure in VVC+ 215
11.5.3 Control Structure in Flux Sensorless 216
11.5.4 Control Structure in Flux with Motor Feedback 217
12 How to Order a Drive 218
12.1 Drive Configurator 218
12.1.1 Type Code 218
12.1.2 Language Packages 221
12.2 Order Numbers for Options and Accessories 222
12.2.1 Order Numbers for Options for Slot A 222
12.2.2 Order Numbers for Options for Slot B 222
12.2.3 Order Numbers for Options for Slot C 223
12.2.4 Order Numbers for Options for Slot D 223
12.2.6 Order Numbers for Miscellaneous Hardware 224
12.2.7 Order Numbers for Local Control Panel Options 225
12.2.8 Order Numbers for PC Software 226
12.2.9 Ordering of VLT® Brake Resistors MCE 101 226
12.2.9.1 Order Numbers for Brake Resistors FC 301, T2, Horizontal Braking 10% Duty Cycle 227
12.2.9.2 Order Numbers for Brake Resistors FC 301, T2, Vertical Braking 40% Duty Cycle 228
12.2.9.3 Order Numbers for Brake Resistors FC 301, T2, Flat-pack for Horizontal Conveyors 229
12.2.9.4 Order Numbers for Brake Resistors FC 301, T4, Horizontal Braking 10% Duty Cycle 229
12.2.9.5 Order Numbers for Brake Resistors FC 301, T4, Vertical Braking 40% Duty Cycle 231
12.2.9.6 Order Numbers for Brake Resistors FC 301, T4, Flat-pack for Horizontal Conveyors 232
12.2.9.7 Order Numbers for Brake Resistors FC 302, T2, Horizontal Braking 10% Duty Cycle 232
12.2.9.8 Order Numbers for Brake Resistors FC 302, T2, Vertical Braking 40% Duty Cycle 233
12.2.9.9 Order Numbers for Brake Resistors FC 302, T2, Flat-pack for Horizontal Conveyors 234
12.2.9.10 Order Numbers for Brake Resistors FC 302, T5, Horizontal Braking 10% Duty Cycle 235
12.2.9.11 Order Numbers for Brake Resistors FC 302, T5, Vertical Braking 40% Duty Cycle 236
12.2.9.12 Order Numbers for Brake Resistors FC 302, T5, Flat-pack for Horizontal Conveyors 237
12.2.9.13 Order Numbers for Brake Resistors FC 302, T6, Horizontal Braking 10% Duty Cycle 237
12.2.9.14 Order Numbers for Brake Resistors FC 302, T6, Vertical Braking 40% Duty Cycle 239
12.2.9.15 Order Numbers for Brake Resistors FC 302, T7, Vertical Braking 40% Duty Cycle 240
12.2.10 Order Numbers for Accessory Bags 241
12.2.11 Ordering of Harmonic Filters 241
12.2.11.1 Order Numbers for Harmonic Filters, 380–415 V, 50 Hz 242
12.2.11.2 Order Numbers for Harmonic Filters, 380–415 V, 60 Hz 243
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12.2.11.3 Order Numbers for Harmonic Filters, 440–480 V, 60 Hz 245
12.2.11.4 Order Numbers for Harmonic Filters, 600 V, 60 Hz 246
12.2.11.5 Order Numbers for Harmonic Filters, 500–690 V, 50 Hz 248
12.2.12 Order Numbers for VLT® Sine-wave Filters MCC 101 249
12.2.13 Order Numbers for VLT® dU/dt Filters MCC 102 250
12.2.15 Spare Parts 252
13 Appendix 253
13.1 Symbols and Abbreviations 253
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Design Guide | VLT® AutomationDrive FC 301/302
Introduction
1 Introduction
1.1 Purpose of this Design Guide
This Design Guide is intended for qualified personnel, such as:
• Project and systems engineers.
• Design consultants.
• Application and product specialists.
The Design Guide provides technical information to understand the capabilities of the VLT® AutomationDrive FC 301/FC 302 for
integration into motor control and monitoring systems. Its purpose is to provide design considerations and planning data for
integration of the drive into a system. It caters for selection of drives and options for a diversity of applications and installations.
Reviewing the detailed product information in the design stage enables developing a well-conceived system with optimal
functionality and efficiency.
This manual is targeted at a worldwide audience. Therefore, wherever occurring, both SI and imperial units are shown.
1.2 Trademarks
VLT® is a registered trademark for Danfoss A/S.
1.3 Additional Resources
Various resources are available to understand advanced drive operation, programming, and directives compliance.
• The VLT® AutomationDrive FC 301/302 Operating Guide provides detailed information for the installation and start-up of the
drive.
• The VLT® AutomationDrive FC 301/302 Programming Guide provides greater detail on how to work with parameters. It also
contains application examples.
• The VLT® Condition-based Monitoring Programming Guide provides information on working with condition-based monitoring
parameters on the VLT® FC series AC drives.
• The VLT® Integrated Motion Control Application Guide provides information on working with the Integrated Motion Controller
(IMC) feature. The guide shows application examples, and presents the functionalities while showing required parameter settings
and connections.
• The VLT® Safe Torque Off Operating Guide describes how to use Danfoss VLT® drives in functional safety applications. This
manual is supplied with the drive when the Safe Torque Off option is present.
• The VLT® Brake Resistor MCE 101 Design Guide describes how to select the optimal brake resistor.
• The VLT® Advanced Harmonic Filters AHF 005/AHF 010 Design Guide describes harmonics, various mitigation methods, and
the operation principle of the advanced harmonic filter. This guide also describes how to select the correct advanced harmonics
filter for a particular application.
• The Output Filter Design Guide explains why it is necessary to use output filters for certain applications and how to select the
optimal dU/dt or sine-wave filter.
• Supplemental publications, drawings, EPLAN macros, and manuals are available at
Optional equipment is available that may change some of the information described in these publications. Be sure to follow the
instructions supplied with the options for specific requirements.
www.danfoss.com.
Contact a Danfoss supplier or visit www.danfoss.com for more information.
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1.4 Document Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
The original language of this manual is English.
Table 1: Document Version
Edition Remarks
MG33BGxx New document structure. All chapters updated.
1.5 Conventions
• Numbered lists indicate procedures.
• Bulleted and dashed lists indicate listings of other information where the order of the information is not relevant.
• Bolded text indicates highlighting and section headings.
• Italicized text indicates the following:
- Cross-reference.
- Link.
- Footnote.
- Parameter name.
- Parameter option.
- Parameter group name.
- Alarms/warnings.
• All dimensions in drawings are in metric values (imperial values in brackets).
• An asterisk (*) indicates the default setting of a parameter.
Introduction
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Safety
2 Safety
2.1 Safety
When designing AC drives, some residual dangers cannot be avoided constructively. One example is the discharge time, which is very
important to observe to avoid potential death or serious injury. For the Danfoss VLT® drives, the discharge time is from 4–40 minutes
depending on the drive size.
For further information on safety precautions, refer to the product-specific Operating Guide.
2.2 Safety Symbols
The following symbols are used in this manual:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
2.3 Qualified Personnel
To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store,
assemble, install, program, commission, maintain, and decommission this equipment.
Persons with proven skills:
• Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably
experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.
• Are familiar with the basic regulations concerning health and safety/accident prevention.
• Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in the
Operating Guide.
• Have good knowledge of the generic and specialist standards applicable to the specific application.
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Approvals and Certifications
3 Approvals and Certifications
3.1 Regulatory/Compliance Approvals
This section provides a brief description of the various approvals and certifications that are on Danfoss VLT® drives. Not all approvals
are on all drives.
NOTICE
IMPOSED LIMITATIONS ON THE OUTPUT FREQUENCY
From software version 6.72 onwards, the output frequency of the drive is limited to 590 Hz due to export control regulations.
Software versions 6.xx also limit the maximum output frequency to 590 Hz, but these versions cannot be flashed, that is,
neither downgraded nor upgraded.
3.2 Typical Product Approvals and Certifications for VLT® Drives
The VLT® AutomationDrive product series complies with a wide scope of required standards and directives. Information on the specific
product certifications can be found on the product nameplate.
3.2.1 CE Mark
The drive complies with relevant directives and their related standards for the extended Single Market in the European Economic Area.
Table 2: EU directives applicable to drives
EU Directive Version
Low Voltage Directive 2014/35/EU
EMC Directive 2014/30/EU
Machinery Directive
(1)
ErP Directive 2009/125/EU
ATEX Directive 2014/34/EU
RoHS Directive
Radio Equipment Directive
(2)
(3)
REACH Directive 1907/2006/EC
1
Machinery Directive conformance is only required for drives with an integrated safety function.
2
For China RoHS, contact Danfoss application support to get the certificate.
3
Radio Equipment Directive is only required for interfaces supporting wireless communication.
2014/42/EU
2011/65/EU
2014/53/EU
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Approvals and Certifications
3.2.2 Low Voltage Directive
The aim of the Low Voltage Directive is to protect persons, domestic animals and property against dangers caused by the electrical
equipment, when operating electrical equipment that is installed and maintained correctly, in its intended application. The directive
applies to all electrical equipment in the 50–1000 V AC and the 75–1500 V DC voltage ranges.
3.2.3 EMC Directive
The purpose of the EMC (electromagnetic compatibility) Directive is to reduce electromagnetic interference and enhance immunity of
electrical equipment and installations. The basic protection requirement of the EMC Directive states that devices that generate
electromagnetic interference (EMI), or whose operation could be affected by EMI, must be designed to limit the generation of
electromagnetic interference and shall have a suitable degree of immunity to EMI when properly installed, maintained, and used as
intended. Electrical equipment devices used alone or as part of a system must bear the CE mark. Systems do not require the CE mark,
but must comply with the basic protection requirements of the EMC Directive.
3.2.4 Machinery Directive
The aim of the Machinery Directive is to ensure personal safety and avoid property damage to mechanical equipment used in its
intended application. The Machinery Directive applies to a machine consisting of an aggregate of interconnected components or
devices of which at least 1 is capable of mechanical movement. Drives with an integrated functional safety function must comply with
the Machinery Directive. Drives without a functional safety function do not fall under the Machinery Directive. If a drive is integrated
into a machinery system, Danfoss can provide information on safety aspects relating to the drive. When drives are used in machines
with at least 1 moving part, the machine manufacturer must provide a declaration stating compliance with all relevant statutes and
safety measures.
3.2.5 ErP Directive
The ErP directive is the European Ecodesign Directive for energy-related products. The directive sets ecodesign requirements for
energy-related products, including drives, and aims at reducing the energy consumption and environmental impact of products by
establishing minimum energy-efficiency standards.
3.2.6 ATEX Directive
Illustration 1: ATEX Logo
3.2.7 Radio Equipment Directive
Devices that emit or receive radio waves as part of radio communication are required to comply with the Radio Equipment Directive.
The drive itself does not contain a radio device, and hence compliance to the directive is not relevant. However, user interfaces
containing active radio devices, such as the integrated control panel with wireless communication capabilities, comply with the
directive.
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Approvals and Certifications
3.2.8 UL Listing
3.2.9 CSA/cUL
3.2.10 TÜV
TÜV is a European safety organization which certifies the functional safety of the drive in accordance to EN/IEC 61800-5-2. The TÜV
both tests products and monitors their production to ensure that companies stay compliant with their regulations.
3.2.11 EAC
Illustration 2: EAC Mark
The EAC logo must be both on the product label and on the packaging label. All products used within the EAC area, must be bought at
Danfoss inside the EAC area.
3.2.12 UkrSEPRO
Illustration 3: UkrSEPRO Mark
3.2.13 RCM Mark Compliance
Illustration 4: RCM Mark
3.2.14 Marine Type Approvals
VLT® AutomationDrive drives have several marine type approvals. For a list of the approvals and certifications, see the FC 301/FC 302
product page at www.danfoss.com.
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Design Guide | VLT® AutomationDrive FC 301/302
Approvals and Certifications
3.2.15 Moroccan Conformity Mark
Illustration 5: Morocco CMIM Mark
The drive complies with relevant directives and their related standards for the Morocco market.
3.3 Export Control Regulation
AC drives can be subject to regional and/or national export control regulations. Both the EU and USA have regulations for so-called
dual-use products (products for both military and non-military use), which currently includes AC drives with a capacity to operate 600–
2000 Hz. These products can still be sold, but it requires a set of measures, for example a license, or an end-user statement.
An ECCN number is used to classify all AC drives that are subject to export control regulations. The ECCN number is provided in the
documentation accompanying the AC drive. If the AC drive is re-exported, it is the responsibility of the exporter to ensure compliance
with the relevant export control regulations.
For further information, contact Danfoss Drives Global or the local sales office.
3.4 Enclosure Protection Rating
The VLT® drive series are available in various enclosure protection ratings to accommodate the needs of the application. Enclosure
protection ratings are provided based on 2 international standards:
• UL type validates that the enclosures meet NEMA (National Electrical Manufacturers Association) standards. The construction and
testing requirements for enclosures are provided in NEMA Standards Publication 250-2003 and UL 50, 11th edition.
• IP (Ingress Protection) ratings outlined by the IEC (International Electrotechnical Commission) in the rest of the world. The standard
Danfoss VLT® drive series are available in various enclosure protections to meet the requirements of IP00 (Chassis), IP20 (Protected
chassis), IP21 (NEMA Type 1), or IP54 (NEMA Type 12). In this manual, NEMA Type is written as Type, for example, IP21/Type 1.
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VLT® Product Family Overview
4 VLT® Product Family Overview
4.1 VLT® Drives
Danfoss offers 3 types of AC drives in different-sized enclosures for a wide range of applications, with power ratings from 0.25–1200 kW
(0.34–1350 hp).
Standalone drives (frequency converters)
The Danfoss standalone drives are so robust that they can be mounted outside of cabinets virtually anywhere, even right beside the
motor. Equipped for the toughest of environment, they suit any application.
More uncompromising features:
• Enclosure sizes with protection ratings up to IP54/UL Type 12.
• Full EMC compliance according to international standards.
• Ruggedized and coated PCBs.
• Wide temperature range, operating from -25 to +40 °C (-13 to 104 °F) without derating.
• Motor cable lengths up to 150 m (492 ft) for shielded cables and 300 m (984 ft) for unshielded cables.
Enclosed drives
Danfoss enclosed drives are designed with the installer and operator in mind to save time on installation, commissioning, and
maintenance. The enclosed drives are designed for full access from the front. After opening the cabinet door, all components can be
reached without removing the drive, even when mounted side by side. Several cooling options, including back-channel cooling,
provide optimum adaption to the installation location and application.
More time-saving features:
• An intuitive user interface with an award-winning local control panel (LCP) and common control platform that streamlines start-up
and operating procedures.
• Robust design and advanced controls make Danfoss drives virtually maintenance free.
System modules
The compact design of the system modules makes them easy to fit even in small spaces. Integrated filters, input fuses, options, and
accessories provide extra capabilities and protection without increasing the enclosure size.
More space-saving features:
• Built-in DC-link reactors for harmonic suppression eliminate the need for higher loss external AC line reactors.
• Optional built-in RFI filters are available throughout the power range.
• Regen terminals are available within the standard enclosures (for enclosure sizes D, E, and F).
• In addition to the many valuable features that the Danfoss drives offers as standard, there are several other control, monitoring,
and power options available in pre-engineered factory configurations.
For more details on the enclosure types, the modularity, and the applications, see the product-specific Selection Guides on
www.danfoss.com.
4.2 Product Overview of the VLT® AutomationDrive FC 301/302
The VLT® AutomationDrive FC 301/FC 302 is a drive for controlling
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Design Guide | VLT® AutomationDrive FC 301/302
• Asynchronous AC induction motors,
• Permanent magnet synchronous motors,
• AC induction servomotors, and
• Synchronous reluctance motors (SynRM motors).
As other Danfoss AC drives, the VLT® AutomationDrive is motor independent, meaning that the drive can be connected to any brand of
motor, thus providing great flexibility when designing an installation.
The FC 301/FC 302 is built on a modular concept design and is equipped with a wide range of features enabling optimal process
control and high-quality output. With the many features, the drive meets the requirements of many industrial, chemical, and marine
applications, for example:
• Operating pumps.
• Conveyors.
• Material handling equipment.
• Hoists.
• Steering gear.
• Extruders.
• Palletizers.
In typical installations, the drive forms part of a bigger system and can be supplied with extra equipment, for example brakes, kits, and
various filters.
VLT® Product Family Overview
Adding to the flexibility are the different ways of connectivity, and as the drive supports all leading industry fieldbusses, it is
independent of the fieldbus system being used. The drive can be controlled:
• Directly from the local LCP.
• Local digital I/O or via industrial network connection.
• Wireless via the VLT® Wireless Control Panel LCP 103. The LCP 103 connects to the MyDrive® Connect app and enables control from
a mobile device.
Easy installation and commissioning
The FC 301/FC 302 comes with pluggable and spring-loaded I/O terminals making wiring and installation easy. During commissioning,
the FC 301/FC 302 offers time-saving application-dependent functions, such as:
• Droop for load sharing.
• Integrated brake control for safe operation of hoists.
• Integrated process controller for demand-based pumping.
• Power limit function for limiting the motor power distributed to the motor when required.
Commissioning can be made effectively via the VLT® Motion Control Tool MCT 10, which is a PC tool designed especially for drive
commissioning. The tool contains many features, and it is also possible to create Smart Assisted Start-up wizards, define initial
parameter values, and much more.
To ensure optimal control of the motor, the VLT® AutomationDrive offers a built-in algorithm, automatic motor adaptation (AMA). At
commissioning, program the function via the parameters to fine-tune the drive to match the motor.
Power sizes, voltage ranges, and enclosure protection classes
The VLT® AutomationDrive FC 301/FC 302 is available in many power sizes, voltage ranges, and enclosure protection classes, which
makes it easy to find the perfect drive for a given application.
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Table 3: Voltage Ranges and Power Ranges
VLT® Product Family Overview
Voltage ranges [V] Power ranges [kW (hp)]
3 x 200–240 0.25–37 (0.34–50)
3 x 380–480/500 0.37–800 (0.5–1075)
3 x 525–600 0.75–75 (1.0–100)
3 x 525–690 1.1–1200 (1.5–1600)
Enclosure protection ratings:
• IP20/Chassis
• IP21/Type 1
• IP54/Type 12
• IP55/Type 12
• IP66/Type 4X
Table 4: Enclosures A1–A5: Power Sizes, Voltage Ranges, and Protection Rating
Enclosure A1 A2 A3 A4 A5
Power
[kW]
200–240 V 0.25–1.5 0.25–2.2 3–3.7 0.25–2.2 0.25–3.7
380–480/500V0.37–1.5 0.37–4 5.5–7.5 0.37–4 0.37–7.5
525–600 V – – 0.75–7.5 – 0.75–7.5
525–690 V – – 1.1–7.5 – –
IP 20 20/21 20/21 55/66 55/66
NEMA Chassis Chassis/Type 1 Chassis/Type 1 Type 12/4X Type 12/4X
Table 5: Enclosures B1–B4: Power Sizes, Voltage Ranges, and Protection Rating
Enclosure B1 B2 B3 B4
Power [kW] 200–240 V 5.5–7.5 11 5.5–7.5 11–15
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380–480/500 V 11–15 18.5–22 11–15 18.5–30
525–600 V 11–15 18.5–22 11–15 18.5–30
525–690 V – 11–22 – 11–30
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Design Guide | VLT® AutomationDrive FC 301/302
VLT® Product Family Overview
Enclosure B1 B2 B3 B4
IP 21/55/66 21/55/66 20 55
NEMA Type 1/12/4X Type 1/12/4X Chassis Chassis
Table 6: Enclosures C1–C4/D3h: Power Sizes, Voltage Ranges, and Protection Rating
Enclosure C1 C2 C3 C4
Power
[kW]
200–240 V 5.5–7.5 11 5.5–7.5 11–15 –
380–
11–15 18.5–22 11–15 18.5–30 –
D3h
480/500 V
525–600 V 11–15 18.5–22 11–15 18.5–30 –
525–690 V – 11–22 – 11–30 55–75
IP 21/55/66 21/55/66 20 55 20
NEMA Type 1/12/4X Type 1/12/4X Chassis Chassis Chassis
1
Details, see separate design guide VLT® AutomationDrive FC 302 90–710 kW
(1)
Standalone drives and enclosed drives
Based on the selected protection rating, select either a standalone drive or an enclosed drive.
The standalone drives have a protection rating of at least IP21/Type 1. These drives can be mounted both outside and inside in dusty
and damp environments without any further protection.
The enclosed drives have a protection rating of IP20/Chassis and must be built into cabinets for protection against dust and moisture.
The enclosed drives are not suitable for outdoor installation.
Both standalone drives and enclosed drives come in different enclosure sizes depending on the selected power size, voltage range,
and enclosure protection rating.
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Design Guide | VLT® AutomationDrive FC 301/302
For low-power applications (0.25–75 kW), select between enclosure sizes A, B, C, and D3h.
For high-power applications (90–1200 kW), select between enclosure sizes Dxh, Exh, and F.
For more information about available enclosure sizes, refer to 8.1 Enclosure Size by Power Rating.
Functionalities
The VLT® AutomationDrive offers various customizable functionalities such as:
• Power hardware with varying voltage ratings, current ratings, protection ratings, and EMC performance ratings.
• Control hardware with various control cards with, for example, Integrated Motion Controller for high-precision positioning and
synchronization applications.
• Added functional extensions for extending the functionalities of the drive, for example, easy PLC integration.
• License packages, including condition-based monitoring and other extra software functionalities.
Safety functions
As standard, the drive is delivered with the Safe Torque Off (STO) function, which protects both operators and equipment if a failure
occurs. Furthermore, the built-in STO function is cost-saving as it makes separate safety modules unnecessary. Furthermore, 6 different
safety options are available:
• VLT® Safety PLC Interface MCB 108
• VLT® PTC Thermistor Card MCB 112 (for example, for ATEX applications).
• VLT® Safety Option MCB 150.
• VLT® Safety Option MCB 151.
• VLT® Safety Option MCB 152.
• VLT® Sensorless Safety MCB 159.
VLT® Product Family Overview
Troubleshooting and Maintenance
Troubleshooting and maintenance of the VLT® AutomationDrive FC 301/FC 302 are made easier and more precise with the increased
digitalization.
The sensors in the FC 301/FC 302 record and store real-time information about warnings and alarms. By adding the VLT® Real-time
Clock MCB 117 option, it is even possible to have the stored events time and date stamped.
Regarding maintenance, the FC 301/FC 302 features functions for preventive maintenance and condition-based monitoring.
The preventive maintenance functions are programmed in the drive and can be used to schedule maintenance alerts based on
running time of the drive.
Using the condition-based monitoring functions turns the drive into a sensor that continuously monitors the condition of the motor
and application. Using the DrivePro® services with the drive, the collected data can be shared with maintenance personnel and other
service providers.
4.3 Power Drive Systems
4.3.1 Ecodesign for Power Drive Systems
The Ecodesign Directive is the legislative framework that sets requirements on all energy-related products in the domestic,
commercial, and industrial sectors throughout Europe.
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Mains &
cabling
Transmis-
sion
Load-
Machine
Driven Equipment
Extended Product
Motor System
Vollständiges Antriebsgerät (CDM)
Motor Starter
(Contactor, Softstarter,…)
Motor control equipment = CDM or starter
Feeding
section
Auxiliaries
Basic
Drive
Module
(BDM)
Complete Drive Module (CDM)
Power Drive System (PDS)
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producing current
Relative
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frequency
100 %
50 %
25 %
0 %
0 % 50 % 90 %
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Design Guide | VLT® AutomationDrive FC 301/302
VLT® Product Family Overview
The Ecodesign requirements are only mandatory within the European Union. These requirements are like the legislative requirements
for energy-related products which apply in North America and Australia.
Terms like Complete Drive Module (CDM) and Power Drive Systems (PDS) are used to define the elements in the design. The objective
is to make more efficient and fewer energy consuming designs.
The CDM contains the drive controller as well as auxiliary devices and input components.
Illustration 6: Drive System Design
The efficiency classes IE0 to IE2 of the drive controller as specified in IEC 61800-9-2 (EN 50598-2) refer to the 90/100 operating point, i.e.
90 % motor stator frequency and 100% torque current (see illustration 7).
Illustration 7: Operating Point according to IEC 61800-9-2 (EN 50598)
Since in the future all component manufacturers will disclose their loss data according to this new standard, optimized applications
can be designed with a wide range of different components. The new Standard allows an accurate preliminary calculation of the power
losses, so that the ROI (Return of Investment) can be reliably determined. Up to now the overall efficiency of speed-regulated electric
motors was estimated with the aid of approximate energy consumption calculations.
It is now possible to determine the total losses of a system for the 8 operating points defined in the standard, including the part load
operation, via a simple addition of power losses. Danfoss helps its customers to avoid having to rely on system solution providers, to
ensure that their systems will retain a competitive advantage also in the future.
EC 61800-9-2 (EN 50598-2) shifts the focus from the individual component to the efficiency of the whole drive system. The new
efficiency classes (International Efficiency for Systems, IES)
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Input power
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Mains cabeling Input filters
Drive input
DC link
Drive output Output filters
Motor cables
and motor
Losses
Losses
Losses
Losses
Losses Losses Losses
Design Guide | VLT® AutomationDrive FC 301/302
VLT® Product Family Overview
allow a simple determination of the total losses for a whole drive system (PDS).
Danfoss offers the MyDrive® ecoSmart™ tool, which is available online or as a Smartphone app to assist with the efficiency calculation.
Use MyDrive® ecoSmart™ to:
• Look up part load data as defined in IEC 61800-9-2, for VLT® and VACON® drives
• Calculate efficiency class and part load efficiency for drives and power drive systems
• Create a report documenting part load loss data and IE or IES efficiency class.
For more information, refer to http://ecosmart.danfoss.com.
illustration 8 shows the components in the PDS which contribute to losses in the design. Mains cables and the load machine are not a
part of the PDS, even though their losses can be significant and could be a part of the evaluation of the overall energy efficiency of the
installation.
Illustration 8: Losses in a Power Drive System
4.3.1.1 Losses in Mains Cabling
The cabling from the supply must be considered, as the selection of suitable cables is often a problem, especially when dedicated
feeding transformers are installed. From the impedance of the cables, the energy losses are created in the ohmic part. Calculate the
active power losses for a 3-phase system with a star point groundingas follows:
P
L,mains
= 3 x R x I
2
L1
Because the load, when using drives and motors, also include reactive power and harmonic currents, these parameters also contribute
to losses. The ratio between active and apparent power is normally called the power factor. Having a PDS with a power factor close to 1
result in the lowest losses in the mains. Using filters on the input side of the drive can lower the power factor.
4.3.1.2 Input Filters: Line Reactors and Harmonic Filters
Line reactor
A line reactor is an inductor which is wired in series between a power source and a load. Line reactors, also called input AC reactors, are
typically used in motor drive applications.
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Design Guide | VLT® AutomationDrive FC 301/302
The main function of the line reactor lies into its current limiting characteristics. Line reactors also reduce the main harmonics, limit the
inrush currents, and protect drives and motors. An overall improvement of the true power factor and the quality of the input current
waveform can be achieved.
When to use line reactors
It is important to consider the installation environment for the drives. In some situations, distortion from the grid can damage the drive
and precautions must be taken.
A simple menas of prevention is to ensure a minimum of impedance in front of the drive.
• The installation site has switched power factor correction capacitors.
• The installation site has lightening strikes or voltage spikes.
• The installation site has power interruptions or voltage dips.
VLT® Product Family Overview
Danfoss offers the line reactor program VLT® Line Reactor MCC 103, see
Harmonic filters
The purpose of using harmonic filters is to reduce the distortion on the mains. The distortion is generated by the drives when
switching the voltage to generate a frequency on the output. The harmonics should be limited both seen from energy consumption
perspective and disturbance of other users in the grid.
There are 2 categories of harmonic solutions:
• Passive.
• Active.
Passive solutions consist of capacitors, inductors, or a combination of both in different arrangements. The simplest solution is to add
inductors/reactors of typically 3–5% in front of the drive. This added inductance reduces the number of harmonic currents produced
by the drive. More advanced passive solutions combine capacitors and inductors in trap arrangement specially tuned to eliminate
harmonics starting from, for example, the 5th harmonic.
For more details on the Danfoss passive solutions, refer to VLT® Advanced Harmonic Filters AHF 005/AHF 010 Design Guide.
The active solutions determine the exact current that cancels the harmonics present in the circuit and synthesizes and injects that
current into the system. Thus, the active solution mitigates the real-time harmonic disturbances, which makes these solutions effective
at any load profile.
For more details on the Danfoss active solutions, refer to VLT® Low Harmonic Drive Operating Instructions, and VLT® Advanced Active
Filter AAF 006 Operating Instructions.
Danfoss.com.
4.3.1.3 Drive, Input Side
RFI (radio frequency interference)
Drives generate radio frequency interference (RFI) due to their variable-width current pulses. Drives and motor cables radiate these
components and conduct them into the mains system.
RFI filters are used to reduce this interference on the mains according to IEC 61800-3 in order not to disturb radio services. Maximum
allowed emission depends on the environment where the PDS is used.
The need for reducing the interferences and the losses created by the coils is a trade-off that is hard to influence in the use of drives.
Even though the losses exist, it is important to fulfill the legislation demands for the installation environment.
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RFI filter on IT grid
If the drive is supplied from an isolated mains source (IT mains, floating delta) or TT/TN-S mains with grounded leg (grounded delta),
the RFI filter must be turned off.
In the OFF position, the internal capacitors between the chassis (ground), the input RFI filter, and the DC link are cut off. As the RFI
switch is turned off, the drive is not able to meet optimum EMC performance.
By opening the RFI filter switch, the ground leakage currents are also reduced, but not the high-frequency leakage currents caused by
the switching frequency of the drive. It is important to use isolation monitors that are designed for use with power electronics (IEC
61557-8). For example, Deif type SIMQ, Bender type IRDH 275/375, or similar.
The Danfoss VLT® drives can be ordered with different types of RFI filters. See more details on RFI, the use of RFI filters, and EMC
compliance in 10.16 Electromagnetic Compatibility (EMC) Overview.
Passive diode rectifier input
The use of diode rectifiers on the input side of the drives are the most cost-effective design. The energy flow goes from the mains to
the load and have low losses. On the other hand, diodes create harmonics in the mains when rectifying and thereby create losses.
These harmonics can be reduced by having DC-link coils, which are used in the Danfoss VLT® drives.
An energy flow from the drive back to the grid is not possible with this design as the energy is generated back from the application to
the DC link. Use a DC chopper and a connected resistor to absorb the energy. This reduces the energy efficiency significantly. If more
drives are installed, an improvement can be gained via load sharing by connecting the DC links, see
For information about the use of brake resistors for drives ordered with built-in brake choppers, refer to 10.10.1 Selection of Brake
Resistor and 10.10.2 Control with Brake Function.
VLT® Product Family Overview
10.3.4 Load Sharing Connection.
Active front end
In contrast to the diode rectifier, the active front end can generate excessive energy from the DC link back to the mains. In regenerative
applications, this design provides a significant improvement of the energy efficiency. This technology also has advantages in relation
to harmonics compensation and a more stable DC-link voltage. The design has similar functions on the input as on the output,
controlling IGBTs. There are also losses generated by switching of the IGBTs, which influence the energy efficiency. Due to the extra
IGBTs, this solution can be more expensive and is not used as often as the passive diode rectifier.
4.3.1.4 DC Link
The DC link is a power storage facility for the output section of the drive. There are 2 major components to the DC-link section:
• Capacitors
• Coils
In illustration 9 only 1 capacitor is shown, but it is always a series of capacitors.
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3
+
+
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Design Guide | VLT® AutomationDrive FC 301/302
VLT® Product Family Overview
1 Direct current (AC ripple)
3 Direct current
Illustration 9: Wiring Diagram of the DC Link
2 Rectifier
4 Inverter
With Danfoss VLT® drives, this intermediate section always uses DC coils, also known as DC line reactors or DC chokes. For cost
considerations, most other drive manufacturers do not offer these DC line reactors as standard equipment. Danfoss regards these coils
as essential for 2 main reasons:
• The ability to reduce harmonic noise (interference) by 40%.
• The ability to ride through a temporary loss of power. This allows the drive to avoid numerous unplanned shutdowns.
4.3.1.5 Drive, Output Side
The output side of the drive contains IGBTs used for generating a variable AC voltage with variable frequency. If no filters are used,
overvoltage spikes, due to reflection of the voltage waveform, can be measured on the motor connection. This situation is often linked
with long motor cables used in the installation and can reach values up to twice the level of the DC-link voltage.
From a user perspective, losses on the output side of the drive can be influenced by using a lower switching frequency, but this also
contributes to higher losses in the motor and filters installed. To optimize energy efficiency, a compromise must be found when
selecting the components used, for example, filters, motor type, and others. Often, output filters are used with the purpose of reducing
stress on the insulation.
In the following sections, the aspect of different filter types is discussed in perspective of energy efficiency versus function.
Common-mode filters
Common-mode HF filters are placed between the drive and the motor. They are nanocrystaline cores that mitigate high-frequency
noise in the motor cable (shielded or unshielded) and eliminate bearing currents, and hence Electro Discharge Machining (EDM) or
bearing etching in the motor. Bearing currents caused by drives are also referred to as common-mode currents.
Since the common-mode filters mitigate high frequency, these filters absorb energy and contribute also to losses. Here, the trade-off is
the advantage described compared with the losses.
More information on VLT® Common Mode Filters MCC 105 can be found on www.Danfoss.com.
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dU/dt filters
At the IGBTs on the output switch, the voltage is not a clean sinus curve. It contains fast changes in voltage levels over a very short
time. The use of dU/dt filters increases the raise time of the motor voltage to reduce the stress on the motor insulation. If not avoided,
the problem will typically not show at once, but after some time, the insulation breaks and creates problems.
The switching frequency influences the losses in the dU/dt filters. These losses can be up to 1% of the rated power. Here, the trade-off
is the possible damage of the motor over time compared with the cost of energy losses.
Danfoss offers the VLT® dU/dt Filter MCC 102 as a possible solution. Find more information on www.Danfoss.com.
Sine-wave filters
A more advanced, but also more costly solution, is using sine-wave filters.
The VLT® Sine-Wave Filter MCC 101 is a differential-mode low-pass filter that suppresses the switching frequency component coming
from the drive and smoothes out the phase-to-phase voltage of the drive to become sinusoidal. This reduces the motor insulation
stress and bearing currents. By supplying the motor with a sinusoidal voltage waveform, the switching acoustic noise from the motor is
also eliminated.
For more detailed information, see the VLT® Sine-Wave Filter MCC 101 factsheet.
VLT® Product Family Overview
However, this type of filter also produces a voltage drop and there may be a reduction in the available control bandwidth. This can
sometimes make it impossible to use this filter type. Again, as for the dU/dt filter, losses are linked to the switching frequency.
For more detailed information, see the
VLT® Output Filters Design Guide.
4.3.1.6 Motor Cables and Motor
Motor cables
Motor cables introduce mainly ohmic losses: the longer the cables, the more resistance. In general, when correctly selected, the losses
in cables shorter than 25 m (82 ft) can be neglected. In single-wire cables with individual shielding, current causes losses in the cable
shielding. These losses can be neglected when using 3-wire cables.
Motor
There are many different types of motors that can be operated with a drive. The solution for dealing with losses in motors is therefore
depending on the individual motor type and installation. In standard IEC 61800-9-2:2017 annex D, a discussion on motor load and
losses is found.
A method to evaluate the losses generated in the motor operated with a drive can be found in the standards IEC 60034-2-1 and IEC TS
60034-2-4.
For the drive dealt with in this manual, find more information on supported motor types in 5.1.2 Supported Motor Types.
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Design Guide | VLT® AutomationDrive FC 301/302
Product Overview
5 Product Overview
5.1 Overview of Drives Systems
Danfoss offers drives in different enclosure types for a wide range of applications.
Standalone AC drives
The Danfoss standalone AC drives are so robust that they can be mounted outside of cabinets virtually anywhere, even right beside the
motor. Equipped for the toughest of environment, they suit any application.
More uncompromising features:
• Enclosure sizes with protection ratings up to IP66/UL Type 4X.
• Full EMC compliance according to international standards.
• Ruggedized and coated PCBs.
• Wide temperature range, operating from -25 °C to +50 °C (-13 °F to 122 °F) without derating.
• Motor cable lengths up to 150 m (492 ft) shielded / 300 m (984 ft) unshielded as standard with uncompromised performance.
Enclosed drives
Danfoss drives are designed with the installer and operator in mind to save time on installation, commissioning, and maintenance.
VLT® enclosed drives are designed for full access from the front. After opening the cabinet door, all components can be reached
without removing the drive, even when mounted side by side.
Several cooling options, including back-channel cooling, provide optimum adaption to the installation location and application.
More time-saving features:
• An intuitive user interface with an award-winning local control panel (LCP) and common control platform that streamlines start-up
and operating procedures.
• Robust design and advanced controls make Danfoss drives virtually maintenance-free.
Modules
The compact design of the VLT® high-power drive modules makes them easy to fit even in small spaces. Integrated filters, options, and
accessories provide extra capabilities and protection without increasing the enclosure size.
More space-saving features:
• Built-in DC-link reactors for harmonic suppression eliminate the need for higher loss external AC line reactors.
• Optional built-in RFI filters are available throughout the power range.
• Optional input fuses and load share terminals are available within the standard enclosures.
• In addition to the many valuable features that the Danfoss drives offer as standard, there are several other control, monitoring, and
power options available in pre-engineered factory configurations.
For more details on the enclosure types, the modularity, and the applications, see the product-specific selection guides on
www.danfoss.com.
5.1.1 Filter Options
Filters are often extra components that must be planned for when designing the power drive system. It is important to understand
why and when to use output filters with Danfoss drives.
30 | Danfoss A/S © 2019.10
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