Danfoss FC 302 Operating guide

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

vlt-drives.danfoss.com

Contents Operating Instructions

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Product Overview

1.3.1 Intended Use 5

1.3.2 Working Principle 6

1.3.3 Exploded View Drawings 7

1.4 Enclosure Sizes and Power Ratings

1.5 Approvals and Certications

1.5.1 Approvals 15

1.5.2 Compliance with ADN 15

1.6 Harmonics Overview

1.6.1 Harmonics 15

1.6.2 Harmonic Analysis 15

1.6.3 Eect of Harmonics in a Power Distribution System 16

1.6.4 IEC Harmonic Standards 17

1.6.5 IEEE Harmonic Standards 18

5
5
5
5

15
15

15

2 Safety

2.1 Safety

2.2 Qualied Personnel

2.3 Safety Precautions

3 Mechanical Installation

3.1 Installation Site Checklist

3.2 Unpacking

3.2.1 Items Supplied 22

3.3 Mounting

3.3.1 Cooling and Airow 23

3.3.2 Lifting 24

3.3.3 Cable Entry and Anchoring 26

3.3.4 Terminal Locations for Enclosure Size D1n/D2n 30

3.3.5 Terminal Locations for Enclosure Size E9 32

3.3.6 Terminal Locations for Enclsoure Size F18 33

3.3.7 Torque 35

20
20
20
20

21
21
22

23

4 Electrical Installation

4.1 Safety Instructions

4.2 Electromagnetic Compatability (EMC)

4.2.1 EMC Interference 37

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Contents

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

4.3 Power Connections

4.4 Grounding

4.5 Input Options

4.5.1 Extra Protection (RCD) 39

4.5.2 RFI Switch 39

4.5.3 Screened Cables 39

4.6 Motor Connection

4.6.1 Motor Cable 39

4.6.2 Brake Cable 40

4.6.3 Motor Insulation 40

4.6.4 Motor Bearing Currents 41

4.7 AC Mains Connection

4.7.1 Mains Connection 41

4.7.2 External Fan Supply 41

4.7.3 Power and Control Wiring for Unscreened Cables 42

4.7.4 Mains Disconnects 42

4.7.5 F-FrameCircuit Breakers 43

38
38
39

39

41

4.7.6 F-Frame Mains Contactors 43

4.8 Control Wiring

4.8.1 Control Cable Routing 43

4.8.2 Access to Control Terminals 45

4.8.3 Electrical Installation, Control Terminals 45

4.8.4 Electrical Installation, Control Cables 47

4.8.5 Safe Torque O (STO) 49

4.9 Additional Connections

4.9.1 Serial Communication 49

4.9.2 Mechanical Brake Control 49

4.9.3 Parallel Connection of Motors 50

4.9.4 Motor Thermal Protection 50

4.9.5 Voltage/Current Input Selection (Switches) 50

4.10 Final Set-up and Test

4.11 F-frame Options

5 Commissioning

5.1 Safety Instructions

43

49

51
52

54
54

5.2 Applying Power

5.3 Local Control Panel Operation

5.3.1 Local Control Panel 56

5.3.2 LCP Layout 56

5.3.3 Parameter Settings 57

5.3.4 Uploading/Downloading Data to/from the LCP 58

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56

Contents Operating Instructions

5.3.5 Changing Parameter Settings 58

5.3.6 Restoring Default Settings 58

5.4 Basic Operational Programming

5.4.1 VLT® Low Harmonic Drive Programming 59

5.4.2 Commissioning with SmartStart 59

5.4.3 Commissioning via [Main Menu] 59

5.4.4 Asynchronous Motor Set-up 60

5.4.5 Permanent Magnet Motor Set-up 60

5.4.6 Automatic Energy Optimisation (AEO) 61

5.4.7 Automatic Motor Adaptation (AMA) 62

5.5 Checking Motor Rotation

5.6 Local Control Test

5.7 System Start-up

6 Application Examples

6.1 Introduction

6.2 Application Examples

7 Diagnostics and Troubleshooting

7.1 Status Messages

59

62
62
62

63
63
63

68
68

7.2 Warning and Alarm Types

7.2.1 Warnings 68

7.2.2 Alarm Trip 68

7.2.3 Alarm Trip-lock 68

7.3 Warnings and Alarm Denitions - Frequency Converter

7.4 Warnings and Alarm Denitions - Active Filter

7.5 Troubleshooting

8 Specications

8.1 Power-Dependent Specications

8.1.1 Mains Supply 3x380–480 V AC 85

8.1.2 Derating for Temperature 88

8.2 Mechanical Dimensions

8.3 General Technical Data

8.4 Fuses

8.4.1 Non-UL Compliance 99

8.4.2 Fuse Tables 99

8.4.3 Supplementary Fuses 100

68

68
77
82

85
85

90
93
98

8.5 General Torque Tightening Values

9 Appendix A - Parameters

9.1 Description of Parameters

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Contents

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

9.2 Frequency Converter Parameter Lists

9.3 Active Filter Parameter Lists

10 Appendix B

10.1 Abbreviations and Conventions

Index

102
108

115
115

116

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Introduction Operating Instructions

1 Introduction

1

1

1.1 Purpose of the Manual

The purpose of this manual is to provide information for
the installation and operation of a VLT® AutomationDrive

FC 302 Low Harmonic Drive. The manual includes relevant
safety information for installation and operation.

Chapter 1 Introduction, chapter 2 Safety,
chapter 3 Mechanical Installation, and chapter 4 Electrical
Installation introduce the unit functions and cover proper

mechanical and electrical installation procedures. There are
chapters on start-up and commissioning, applications and
basic troubleshooting. Chapter 8 Specications provides a
quick reference for ratings and dimensions, as well as other
operating specications. This manual provides a basic
knowledge of the unit and explains set-up and basic
operation.

VLT® is a registered trademark.

1.2 Additional Resources

Other resources are available to understand advanced
functions and programming.

The VLT® AutomationDrive FC 302 Programming

•

Guide provides greater detail on working with
parameters and many application examples.

®

The VLT

•

provides detailed capabilities and functionality to
design motor control systems.

Supplemental publications and manuals are

•

available from Danfoss.
See vlt-drives.danfoss.com/Support/Technical-
Documentation/ for listings.

Optional equipment may change some of the

•

procedures described. Reference the instructions
supplied with those options for specic
requirements. Contact the local Danfoss supplier
or visit the Danfoss website: vlt-

drives.danfoss.com/Support/Technical­Documentation/ for downloads or additional

information.

The VLT

•

Instructions provide additional information about
the lter portion of the low harmonic drive.

AutomationDrive FC 302 Design Guide

®

Active Filter AAF 006 Operating

1.3

Product Overview

1.3.1 Intended Use

A frequency converter is an electronic motor controller
that converts AC mains input into a variable AC waveform
output. The frequency and voltage of the output are
regulated to control the motor speed or torque. The
frequency converter can vary the speed of the motor in
response to system feedback, such as with position sensors
on a conveyor belt. The frequency converter can also
regulate the motor by responding to remote commands
from external controllers.

The frequency converter:

Monitors the system and motor status.

•

Issues warnings or alarms for fault conditions.

•

Starts and stops the motor.

•

Optimises energy eciency.

•

Operation and monitoring functions are available as status
indications to an outside control system or serial communi­cation network.

A low harmonic drive (LHD) is a single unit that combines
the frequency converter with an advanced active lter
(AAF) for harmonic mitigation. The frequency converter
and lter are packaged together in an integrated system,
but each functions independently. In this manual, there are
separate specications for the frequency converter and the
lter. Since the frequency converter and lter are in the
same enclosure, the unit is transported, installed, and
operated as a single entity.

MG37A302 Danfoss A/S © Rev. 04/2015 All rights reserved. 5

Mains
380 to

500 VAC

Optional

RFI

Optional

Fuses

Optional

Manual

Disconnect

HI Reactor

L

m

L

m

L

m

L

ac

L

ac

L

ac

AC
Contactor

Relay 12

Control & AUX

Feedback

Soft-Charge

Resistor

Converter Side

Filter

Power Stage

AF Current
Sensors

Capacitor

Current Sensors

VLT Drive

Main’s

3

3

3

CTs

L

c

L

c

L

c

CefC

ef

C

ef

R

ef

R

ef

R

ef

I

r

I

s

I

t

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Introduction

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

1

1.3.2 Working Principle

The low harmonic drive is a high-power frequency converter with an integrated active lter. An active lter is a device that
actively monitors harmonic distortion levels and injects compensative harmonic current onto the line to cancel the
harmonics.

Illustration 1.1 Basic Layout for the Low Harmonic Drive

Low harmonic drives are designed to draw an ideal sinusoidal current waveform from the supply grid with a power factor of

1. Where traditional non-linear load draws pulse-shaped currents, the low harmonic drive compensates that via the parallel
lter path, lowering the stress on the supply grid. The low harmonic drive meets the highest harmonic standards with a
THDi less than 5% at full load for <3% pre-distortion on a 3% unbalanced 3-phase grid.

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Introduction

1.3.3 Exploded View Drawings

Operating Instructions

1

1

1 Local control panel (LCP) 5 Input/output terminal assembly
2 Control card assembly 6 Capacitor bank assembly
3 Power card assembly 7 D1/D2 assembly
4 Terminal cover sheet 8 EOC assembly

Illustration 1.2 Enclosure Size D1n/D2n, Frequency Converter Enclosure

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Introduction

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

1 Local control panel (LCP) 13 Mains fuses
2 Active lter card (AFC) 14 Mains disconnect
3 Metal oxide varistor (MOV) 15 Mains terminals
4 Soft charge resistors 16 Heat sink fan
5 AC capacitors discharge board 17 DC capacitor bank
6 Mains contactor 18 Current transformer
7 LC inductor 19 RFI dierential mode lter
8 AC capicators 20 RFI common mode lter
9 Mains bus bar to frequency converter input 21 HI inductor
10 IGBT fuses 22 Power card
11 RFI lter 23 Gate drive card
12 Fuses

Illustration 1.3 Enclosure Size D1n/D2n, Filter Enclosure

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Operating Instructions

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1 Control card 14 SCR and diode
2 Control input terminals 15 Fan inductor (not on all units)
3 Local control panel (LCP) 16 Soft charge resistor assembly
4 Control card C option 17 IGBT output bus bar
5 Mounting bracket 18 Fan assembly
6 Power card mounting plate 19 Output motor terminals
7 Power card 20 Current sensor
8 IGBT gate drive card 21 Mains AC power input terminals
9 Upper capacitor bank assembly 22 Input terminal mounting plate
10 Soft charge fuses 23 AC input bus bar
11 DC inductor 24 Soft charge card
12 Fan transformer 25 Lower capacitor bank assembly
13 IGBT module

Illustration 1.4 Enclosure Size E9, Frequency Converter Enclosure

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Introduction

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

1

1 Local control panel (LCP) 12 AC capacitor current transducers
2 Active lter card (AFC) 13 Heat sink fan
3 Mains contactors 14 Mains terminals
4 Soft charge resistors 15 Mains disconnect
5 RFI dierential mode lter 16 Mains fuses
6 RFI common mode lter 17 LC inductor
7 Current transformer (CT) 18 HI inductor
8 Mains bus bars to drive output 19 Power card
9 AC capacitors 20 Control card
10 RFI 21 LCP cradle
11 Lower DC capacitor bank

Illustration 1.5 Enclosure Size E9, Filter Enclosure

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Introduction Operating Instructions

1

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1 Contactor 4 Circuit breaker or disconnect (if purchased)
2 RFI lter 5 AC mains/line fuses (if purchased)
3 Mains AC power input terminals 6 Mains disconnect

Illustration 1.6 Enclosure Size F18, Input Options Cabinet

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Introduction

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

1 Local control panel (LCP) 10 Mains bus bars to frequency converter input
2 Active lter card (AFC) 11 Heat sink fans
3 Soft charge resistors 12 Mains terminals (R/L1, S/L2, T/L3) from options cabinet
4 Metal oxide varistor (MOV) 13 RFI dierential mode lter
5 AC capacitors discharge board 14 RFI common mode lter
6 LC inductor 15 Mains contactor
7 HI inductor 16 Power card
8 Mixing fan 17 Control card
9 IGBT fuses 18 LCP cradle

Illustration 1.7 Enclosure Size F18, Filter Cabinet

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Introduction Operating Instructions

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1 Rectier module 8 Module heat sink fan
2 DC bus bar 9 Fan door cover
3 SMPS fuse 10 SMPS fuse
4 (Optional) back AC fuse mounting bracket 11 Power card
5 (Optional) middle AC fuse mounting bracket 12 Panel connectors
6 (Optional) front AC fuse mounting bracket 13 Control card
7 Module lifting eye bolts (mounted on a vertical strut)

Illustration 1.8 Enclosure Size F18, Rectier Cabinet

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Introduction

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

1 Fan transformer 9 Fan door cover
2 DC-link inductor 10 Module heat sink fan
3 Top cover plate 11 Inverter module
4 MDCIC board 12 Panel connectors
5 Control card 13 DC fuse
6 SMPS fuse and fan fuse 14 Mounting bracket
7 Motor output bus bar 15 (+) DC bus bar
8 Brake output bus bar 16 (-) DC bus bar

Illustration 1.9 Enclosure Size F18, Inverter Cabinet

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Introduction Operating Instructions

1.4 Enclosure Sizes and Power Ratings

Enclosure size D1n D2n E9 F18

Enclosure protection

Frequency converter
dimensions
[mm/inch]

Frequency converter

weights
[kg/lbs]

Table 1.1 Mechanical Dimensions, Enclosure Sizes D, E, and F

IP 21/54 21/54 21/54 21/54
NEMA Type 1/Type 12 Type 1/Type 12 Type 1/Type 12 Type 1/Type 12
Height 1740/68.5 1740/68.5 2000.7/78.77 2278.4/89.70
Width 915/36.02 1020/40.16 1200/47.24 2792/109.92
Depth 380/14.96 380/14.96 493.5/19.43 605.8/23.85
Maximum
weight
Shipping weight 416/917 476/1050 840/1851 2345/5171

353/777 413/910 676/1490 1900/4189

1.5 Approvals and Certications

Harmonic Analysis

1.6.2

1

1

1.5.1 Approvals

Table 1.2 Compliance Marks: CE, UL, and C-Tick

1.5.2 Compliance with ADN

For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation in the
Design Guide.

1.6 Harmonics Overview

1.6.1 Harmonics

Non-linear loads such as found with 6-pulse frequency
converters do not draw current uniformly from the power
line. This non-sinusoidal current has components which are
multiples of the fundamental current frequency. These
components are referred to as harmonics. It is important to
control the total harmonic distortion on the mains supply.
Although the harmonic currents do not directly aect
electrical energy consumption, they generate heat in
wiring and transformers and can impact other devices on
the same power line.

Since harmonics increase heat losses, it is important to
design systems with harmonics in mind to prevent
overloading the transformer, inductors, and wiring.

When necessary, perform an analysis of the system
harmonics to determine equipment eects.

A non-sinusoidal current is transformed with a Fourier
series analysis into sine-wave currents at dierent
frequencies, that is, dierent harmonic currents IN with 50
Hz or 60 Hz as the fundamental frequency.

Abbreviation Description

f

1

I

1

U

1

I

n

U

n

n Harmonic order

Table 1.3 Harmonics-related Abbreviations

Fundamental

Current I
Frequency
[Hz]

Table 1.4 Fundamental and Harmonic Currents

Current Harmonic current

I
Input current 1.0 0.9 0.5 0.2 < 0.1

Fundamental frequency (50 Hz or 60 Hz)
Current at the fundamental frequency
Voltage at the fundamental frequency
Current at the nth harmonic frequency
Voltage at the nth harmonic frequency

Harmonic current (In)

current (I1)

RMSI1

I

5

1

50 250 350 550

I

7

I

I

5

7

I

11-49

I

11

Table 1.5 Harmonic Currents Compared to the RMS Input
Current

The voltage distortion on the mains supply voltage
depends on the size of the harmonic currents multiplied

MG37A302 Danfoss A/S © Rev. 04/2015 All rights reserved. 15

Introduction

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

1

by the mains impedance for the frequency in question. The
total voltage distortion (THDi) is calculated based on the
individual voltage harmonics using this formula:

THDi =

U25 + U27 + ... + U2n

U

1.6.3 Eect of Harmonics in a Power
Distribution System

In Illustration 1.10, a transformer is connected on the
primary side to a point of common coupling PCC1, on the
medium voltage supply. The transformer has an impedance
Z

and feeds a number of loads. The point of common

xfr

coupling where all loads are connected is PCC2. Each load
is connected through cables that have an impedance Z1,
Z2, Z3.

PCC, the conguration of the distribution system and
relevant impedances must be known.

A commonly used term for describing the impedance of a
grid is the short-circuit ratio R

. R

is dened as the ratio

sce

sce

between the short circuit apparent power of the supply at
the PCC (Ssc) and the rated apparent power of the load
(S

).

equ

S

sce

sc

=

S

equ

2

U

Z

supply

and S

=

sc

equ

= U × I

equ

R

where S

Negative eects of harmonics

Harmonic currents contribute to system losses (in

•

cabling, and transformer).
Harmonic voltage distortion causes disturbance

•

to other loads and increases losses in other loads.

PCC Point of common coupling
MV Medium voltage
LV Low voltage
Z

xfr

Z

#

Illustration 1.10 Small Distribution System

Transformer impedance
Modeling resistance and inductance in the
wiring

Harmonic currents drawn by non-linear loads cause
distortion of the voltage because of the voltage drop on
the impedances of the distribution system. Higher
impedances result in higher levels of voltage distortion.

Current distortion relates to apparatus performance and it
relates to the individual load. Voltage distortion relates to
system performance. It is not possible to determine the
voltage distortion in the PCC knowing only the harmonic
performance of the load. To predict the distortion in the

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Introduction

Operating Instructions

1.6.4 IEC Harmonic Standards

The mains voltage is rarely a uniform sinusoidal voltage with constant amplitude and frequency because loads that draw
non-sinusoidal currents from the mains have non-linear characteristics.

Harmonics and voltage uctuations are 2 forms of low-frequency mains interference. They have a dierent appearance at
their origin than at any other point in the mains system when a load is connected. So, a range of inuences must be
determined collectively when assessing the eects of mains interference. These inuences include the mains feed, structure,
and loads.

Mains interference can cause the following:

Undervoltage warnings

Incorrect voltage measurements due to distortion of the sinusoidal mains voltage.

•

Cause incorrect power measurements because only RMS-true measuring takes harmonic content into account.

•

Higher functional losses

Harmonics reduce the active power, apparent power, and reactive power.

•

Distort electrical loads resulting in audible interference in other devices, or in worst case, even destruction.

•

Shorten the lifetime of devices as a result of heating.

•

1

1

In most of Europe, the basis for the objective assessment of the quality of mains power is the Electromagnetic Compatibility
of Devices Act (EMVG). Compliance with these regulations ensures that all devices and networks connected to electrical
distribution systems

Standard Denition

EN 61000-2-2, EN 61000-2-4, EN 50160 Dene the mains voltage limits required for public and industrial power grids.
EN 61000-3-2, 61000-3-12 Regulate mains interference generated by connected devices in lower current products.
EN 50178 Monitors electronic equipment for use in power installations.

Table 1.6 EN Design Standards for Mains Power Quality

There are 2 European standards that address harmonics in the frequency range from 0 Hz to 9 kHz:

EN 61000-2-2 (Compatibility Levels for Low-Frequency Conducted Disturbances and Signalling in Public Low-Voltage Power
Supply Systems) states the requirements for compatibility levels for PCC (point of common coupling) of low-voltage AC
systems on a public supply network. Limits are specied only for harmonic voltage and total harmonic distortion of the
voltage. EN 61000-2-2 does not dene limits for harmonic currents. In situations where the total harmonic distortion
THD(V)=8%, PCC limits are identical to those limits specied in the EN 61000-2-4 Class 2.

EN 61000-2-4 (Compatibility Levels for Low-Frequency Conducted Disturbances and Signalling in Industrial Plants) states the
requirements for compatibility levels in industrial and private networks. The standard further denes the following 3 classes
of electromagnetic environments:

Class 1 relates to compatibility levels that are less than the public supply network, which

•

sensitive to disturbances (lab equipment, some automation equipment, and certain protection devices).
Class 2 relates to compatibility levels that are equal to the public supply network. The class applies to PCCs on the

•

public supply network and to IPCs (internal points of coupling) on industrial or other private supply networks. Any
equipment designed for operation on a public supply network is allowed in this class.

Class 3 relates to compatibility levels greater than the public supply network. This class applies only to IPCs in

•

industrial environments. Use this class where the following equipment is found:

full their intended purpose without generating problems.

aects equipment

MG37A302 Danfoss A/S © Rev. 04/2015 All rights reserved. 17

Introduction

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

1

Large converters.

-

Welding machines.

-

Large motors starting frequently.

-

Loads that change quickly.

-

Typically, a class cannot be dened ahead of time without taking into account the intended equipment and processes to be
used in the environment. VLT® AutomationDrive FC 302 Low Harmonic Drive observes the limits of Class 3 under typical

supply system conditions (RSC>10 or

Harmonic order (h) Class 1 (Vh%) Class 2 (Vh%) Class 3 (Vh%)

5 3 6 8

7 3 5 7
11 3 3.5 5
13 3 3 4.5
17 2 2 4

17˂h≤49 2.27 x (17/h) – 0.27 2.27 x (17/h) – 0.27 4.5 x (17/h) – 0.5

Table 1.7 Compatibility Levels for Harmonics

Class 1 Class 2 Class 3
THD(V)

Table 1.8 Compatibility Levels for the Total Harmonic Voltage Distortion THD(V)

Vk Line

<10%).

5% 8% 10%

IEEE Harmonic Standards

1.6.5

The IEEE 519 standard (Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems)
provides specic limits for harmonic voltages and currents for individual components within the supply network. The
standard also provides limits for the sum of all loads at the point of common coupling (PCC).

To determine permissible harmonic voltage levels, IEEE 519 uses a ratio between the supply short-circuit current and the
maximum current of the individual load. For permissible harmonic voltage levels for individual loads, see Table 1.9. For
permissible levels for all loads connected to the PCC, see Table 1.10.

ISC/IL (R

10 2.5–3% Weak grid
20 2.0–2.5% 1–2 large loads
50 1.0–1.5% A few high-output loads
100 0.5–1% 5–20 medium-output loads
1000 0.05–0.1% Strong grid

Table 1.9 Permissible Voltage THD at the PCC for Each Individual Load

Voltage at the PCC Permissible individual harmonic voltages Permissible THD(V)

V

Line

Table 1.10 Permissible Voltage THD at the PCC for all Loads

) Permissible individual harmonic voltages Typical areas

SCE

≤69 kV 3% 5%

Limit harmonic currents to

specied levels, as shown in Table 1.11. IEEE 519 utilises a ratio between the supply short-circuit

current and the maximum current consumption at the PCC, averaged over 15 minutes or 30 minutes. In certain instances
when dealing with harmonic limits containing low harmonic numbers, the IEEE 519 limits are lower than the 61000-2-4
limits. Low harmonic drives observe the total harmonic distortion as dened in IEEE 519 for all R
harmonic current fullls table 10–3 in IEEE 519 for R

18 Danfoss A/S © Rev. 04/2015 All rights reserved. MG37A302

sce

≥20.

. Each individual

sce

Introduction Operating Instructions

ISC/IL (R

<20 4% 2.0% 1.5% 0.6% 0.3% 5%
20<50 7% 3.5% 2.5% 1.0% 0.5% 8%
50<100 10% 4.5% 4.0% 1.5% 0.7% 12%
100<1000 12% 5.5% 5.0% 2.0% 1.0% 15%
>1000 15% 7.0% 6.0% 2.5% 1.4% 20%

Table 1.11 Permissible Harmonic Currents at the PCC

The VLT® AutomationDrive FC 302 Low Harmonic Drive complies with the following standards:

) h<11 11≤h<17 17≤h<23 23≤h<35 35≤h Total demand

SCE

IEC61000-2-4

•

IEC61000-3-4

•

IEEE 519

•

G5/4

•

distortion TDD

1

1

MG37A302 Danfoss A/S © Rev. 04/2015 All rights reserved. 19

2

Safety

2 Safety

2.1 Safety

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

2.3

Safety Precautions

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation which could
result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which could
result in minor or moderate injury. It may also be used
to alert against unsafe practices.

NOTICE

Indicates important information, including situations that
may result in damage to equipment or property.

2.2 Qualied Personnel

Correct and reliable transport, storage, installation,
operation and maintenance are required for the safe
operation of the frequency converter. Only qualied
personnel are allowed to install or operate this equipment.

Qualied personnel is dened as trained sta, who are
authorised to install, commission, and maintain equipment,
systems and circuits in accordance with pertinent laws and
regulations. Additionally, qualied personnel are familiar
with the instructions and safety measures described in this
document.

WARNING

HIGH VOLTAGE

Frequency converters contain high voltage when
connected to AC mains input power. Qualied personnel
only should perform installation, start up, and
maintenance. Failure to perform installation, start up,
and maintenance by qualied personnel could result in
death or serious injury.

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency
converter, motor, and any driven equipment must be in
operational readiness. Failure to be in operational
readiness when the frequency converter is connected to
AC mains could result in death, serious injury,
equipment, or property damage.

WARNING

DISCHARGE TIME

Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is
not powered. To avoid electrical hazards, disconnect AC
mains, any permanent magnet type motors, and any
remote DC-link power supplies, including battery back­ups, UPS, and DC-link connections to other frequency
converters. Wait for the capacitors to fully discharge
before performing any service or repair work. The
amount of wait time is listed in the Discharge Time table.
Failure to wait the specied time after power has been
removed before doing service or repair could result in
death or serious injury.

Voltage [V] Power range [kW] Minimum waiting time

(minutes)

380–500

Table 2.1 Discharge Times

20 Danfoss A/S © Rev. 04/2015 All rights reserved. MG37A302

132–200 kW 20
250–630 kW 40

Mechanical Installation Operating Instructions

3 Mechanical Installation

3.1 Installation Site Checklist

3.1.1 Planning the Installation Site

CAUTION

It is important to plan the installation of the frequency
converter. Neglecting to plan may result in extra work
during and after installation.

Select the best possible operation site by considering
the following:

Ambient operating temperature.

•

Installation method.

•

How to cool the unit.

•

Position of the frequency converter.

•

Cable routing.

•

Ensure that the power source supplies the correct

•

voltage and necessary current.
Ensure that the motor current rating is within the

•

maximum current from the frequency converter.
If the frequency converter is without built-in

•

fuses, ensure that the external fuses are rated
correctly.

Motor size and frequency converter

-

power must match for proper overload
protection.

If frequency converter rating is less than

-

that of the motor, full motor output is
impossible.

3 3

Equipment Pre-Installation Checklist

3.1.2

Before unpacking the frequency converter,

•

examine the packaging for signs of damage. If
the unit is damaged, refuse delivery, and
immediately contact the shipping company to
claim the damage.

Before unpacking the frequency converter, locate

•

it as close as possible to the
Compare the model number on the nameplate to

•

what was ordered to verify the proper
equipment.

Ensure that each of the following are rated for

•

the same voltage:

Mains (power)

-

Frequency converter

-

Motor

-

Ensure that the output current rating is equal to

•

or greater than the motor full load current for
peak motor performance.

nal installation site.

MG37A302 Danfoss A/S © Rev. 04/2015 All rights reserved. 21

130BD600.10

CHASSIS/ IP20 Tamb.50

C/122 F

V LT

MADE IN DENMARK

R

P/N: 131X3537 S/N: 010122G430

0.37kW/ 0.50HP

IN: 3x200-240V 50/60Hz 2.2A

OUT: 3x0-Vin 0-1000Hz 2.4A

o

CAUTION:
See manual for special condition/mains fuse

voir manual de conditions speclales/fusibles

WARNING:
Stored charge, wait 4 min.
Charge residuelle, attendez 4 min.

* 1 3 1

X

3 5 3 7 0 1 0 1 2 2 G 4 3 0 *

`

Automation Drive
www.danfoss.com

T/C: FC-302PK37T2E20H1BGXXXXSXXXXA6BKC4XXXD0

Listed 76X1 E134261 Ind. Contr. Eq.

o

`

1

2

4

5

6

7

8

9

10

3

Mechanical Installation

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

3.2 Unpacking

3.2.1 Items Supplied

Items supplied may vary according to product congu-

ration.

33

Make sure that the items supplied and the

•

information on the nameplate correspond to the
order conrmation.

Check the packaging and the frequency converter

•

visually for damage caused by inappropriate
handling during shipment. File any claim for
damage with the carrier. Retain damaged parts
for clarication.

1 Type code
2 Order number
3 Serial number
4 Power rating

Input voltage, frequency and current (at low/high

5

voltages)
Output voltage, frequency and current (at low/high

6

voltages)
7 Enclosure type and IP rating
8 Maximum ambient temperature
9 Certications

10 Discharge time (Warning)

Illustration 3.1 Product Nameplate (Example)

NOTICE

Do not remove the nameplate from the frequency
converter (loss of warranty).

22 Danfoss A/S © Rev. 04/2015 All rights reserved. MG37A302

Mechanical Installation Operating Instructions

3.3 Mounting

3.3.1 Cooling and Airow

Cooling

Obtain cooling by taking air in through the plinth in the front and out of the top, in and out the back of the unit, or by
combining the cooling possibilities.

Back cooling

The backchannel air can also be ventilated in and out the back. This
from outside the facility and return the heat losses outside the facility thus reducing air-conditioning requirements.

Airow

Secure the necessary airow over the heat sink. The ow rate is shown in Table 3.1.

oers a solution where the backchannel could take air

3 3

Enclosure protection Enclosure size

D1n

D2n

IP21/NEMA 1

IP54/NEMA 12

Table 3.1 Heat Sink Air Flow

E9

F18

NOTICE

For the frequency converter section, the fan runs for the
following reasons:

AMA.

•

DC hold.

•

Pre-mag.

•

DC brake.

•

60% of nominal current is exceeded.

•

Specic heat sink temperature exceeded (power

•

size dependent).
Specic power card ambient temperature

•

exceeded (power size dependent).
Specic control card ambient temperature

•

exceeded.

Once the fan is started, it runs for minimum 10 minutes.

Door fan/top fan airow
Total airow of multiple fans

3 door fans, 442 m3/h
2+1=2x170+102

3 door fan, 544 m3/h
2+1=2x170+204

4 door fans, 680 m3/h (400 cfm)
(2+2, 4x170=680)

6 door fans, 3150 m3/h (1854
cfm)
(6x525=3150)

Heat sink fan
Total airow for multiple fans

2 heat sink fans, 1185 m3/h
(1+1=765+544)

2 heat sink fans, 1605 m3/h
(1+1=765+840)

2 heat sink fans, 2675 m3/h
(1574 cfm)
(1+1, 1230+1445=2675)

5 heat sink fans, 4485 m3/h
(2639 cfm)
2+1+2, ((2x765)+(3x985)=4485)

NOTICE

For the active lter, the fan runs for the following
reasons:

Active lter running.

•

Active lter not running, but mains current

•

exceeding the limit (power size dependent).
Specic heat sink temperature exceeded (power

•

size dependent).
Specic power card ambient temperature

•

exceeded (power size dependent).
Specic control card ambient temperature

•

exceeded.

Once the fan is started, it runs for minimum 10 minutes.

External ducts

If additional duct work is added externally to the Rittal
cabinet, calculate the pressure drop in the ducting. Use
Illustration 3.2, Illustration 3.3, and Illustration 3.4 to derate
the frequency converter according to the pressure drop.

MG37A302 Danfoss A/S © Rev. 04/2015 All rights reserved. 23

90

80

70

60

50

40

30

20

10

0

0 0.5 4.9 13 27.3 45.9 66 89.3 115.7 147

(%)

(Pa)

Pressure Increase

Drive Derating

130BB007.10

90

80

70

60

50

40

30

20

10

0

(%)

Drive Derating

0 0.2 0.6 2.2 5.8 11.4 18.1 30.8 152.8 210.8

(Pa)

Pressure Change

130BB011.10

69.5

90

80

70

60

50

40

30

20

10

0

(%)

Drive Derating

0 25 50 75 100 125 150 175 225

130BB190.10

200

Pressure Change

1

130BE111.10

130BC170.10

Lifting Holes

Mechanical Installation

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

Lifting

3.3.2

Lift the frequency converter using the dedicated lifting
eyes. For all D-frames, use a bar to avoid bending the
lifting holes of the frequency converter.

33

Illustration 3.2 D-Enclosure Derating vs. Pressure Change
Frequency Converter Air Flow: 450 cfm (765 m3/h)

1 Lifting holes

Illustration 3.5 Recommended Lifting Method, Enclosure Size
D1n/D2n

Illustration 3.3 E-Enclosure Derating vs. Pressure Change
Frequency Converter Air Flow: 850 cfm (1445 m3/h)

Illustration 3.4 F-Enclosure Derating vs. Pressure Change
Frequency Converter Air Flow: 580 cfm (985 m3/h)

24 Danfoss A/S © Rev. 04/2015 All rights reserved. MG37A302

Illustration 3.6 Recommended Lifting Method, Enclosure Size
E9

WARNING

The lifting bar must be able to handle the weight of the
frequency converter. See chapter 8.2 Mechanical
Dimensions for the weight of the dierent enclosure
sizes. Maximum diameter for bar is 2.5 cm (1 inch). The
angle from the top of the frequency converter to the
lifting cable should be 60° or greater.

1

2

130BD574.10

Mechanical Installation Operating Instructions

1 Lifting holes for the lter
2 Lifting holes for the frequency converter

Illustration 3.7 Recommended Lifting Method, Enclosure Size
F18

3 3

NOTICE

A spreader bar is also an acceptable way to lift the F­frame.

NOTICE

The F18 pedestal is packaged separately and included in
the shipment. Mount the frequency converter on the
pedestal in its nal location. The pedestal allows proper
airow and cooling.

MG37A302 Danfoss A/S © Rev. 04/2015 All rights reserved. 25

64.5
[2.5]

20.0
[0.8]

40.0
[1.6]

560.0
[22.0]

327.4
[12.9]

289.4
[11.4]

227.8
[9.0]

246.0
[9.7]

350.0
[13.8]

397.3
[15.6]

240.0
[9.4]

220.0
[8.7]

235.0
[9.3]

42.3
[1.7]

8X 14.0
[0.6]

8X 25.0
[1.0]

1

130BE112.10

Mechanical Installation

VLT® AutomationDrive FC 302 Low Harmonic Drive
132-630 kW

3.3.3 Cable Entry and Anchoring

Cables enter the unit through gland plate openings in the bottom. Illustration 3.8, Illustration 3.9, Illustration 3.10, and
Illustration 3.11 show gland entry locations and detailed views of anchoring hole dimensions.

33

Bottom View, D1n/D2n

1 Cable entry locations

Illustration 3.8 Cable Entry Diagram, Enclsoure Size D1n

26 Danfoss A/S © Rev. 04/2015 All rights reserved. MG37A302