Danfoss FC 302 Operating guide

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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

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

4 Electrical Installation

4.1 Safety Instructions

4.2 Electromagnetic Compatability (EMC)

4.2.1 EMC Interference 37

36 36 37

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

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

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

56 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

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 77 82

85 85

90 93 98

8.5 General Torque Tightening Values

9 Appendix A - Parameters

9.1 Description of Parameters

101

102 102

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

Introduction Operating Instructions

1 Introduction

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.

Mains 380 to

500 VAC

Optional

RFI

Optional

Fuses

Optional

Manual

Disconnect

HI Reactor

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

CTs

CefC

130BB406.11

Introduction

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

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.

130BE136.10

Introduction

1.3.3 Exploded View Drawings

Operating Instructions

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

130BE110.10

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

130BX168.10

Introduction

Operating Instructions

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

130BD572.11

Introduction

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

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

130BX334.11

Introduction Operating Instructions

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

130BD573.10

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

130BX331.11

Introduction Operating Instructions

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

130BX330.11

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

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

1.5.1 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

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

50 250 350 550

11-49

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

Introduction

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

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

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

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

equ

sce

equ

supply

and S

equ

= U × I

equ

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

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

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.

•

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

Introduction

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

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)

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

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

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

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.

130BD600.10

CHASSIS/ IP20 Tamb.50

C/122 F

V LT

MADE IN DENMARK

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

0.37kW/ 0.50HP

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

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

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

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.

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.

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

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

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).

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

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.

0 0.5 4.9 13 27.3 45.9 66 89.3 115.7 147

(%)

(Pa)

Pressure Increase

Drive Derating

130BB007.10

(%)

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

(%)

Drive Derating

0 25 50 75 100 125 150 175 225

130BB190.10

200

Pressure Change

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.

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)

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.

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.

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]

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.

Bottom View, D1n/D2n

1 Cable entry locations

Illustration 3.8 Cable Entry Diagram, Enclsoure Size D1n

130BE113.10

64.5 [2.5]

560.0 [22.0]

422.4 [16.6]

384.8 [15.1]

18.6 [0.7]

27.5

[1.1]

227.8 [9.0]

220.0 [8.7]

235.0 [9.3]

40.4 [1.6]

8X 25.0 [1.0]

8X 14.0 [0.6]

330.0 [13.0]

470.4 [18.5]

390.0 [15.4]

246.0 [9.7]

Mechanical Installation Operating Instructions

3 3

1 Cable entry locations

Illustration 3.9 Cable Entry Diagram, Enclsoure Size D2n

130BC586.10

Mechanical Installation

Bottom view, enclosure size E9

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

1 Cable entry locations

Illustration 3.10 Cable Entry Diagram, E9

130BC587.10

Mechanical Installation

Bottom view, F18

Operating Instructions

3 3

1 Mains cable entry 4 Motor cable entry 2 Option enclosure 5 Inverter enclosure 3 Filter enclosure 6 Rectier enclosure

Illustration 3.11 Cable Entry Diagram, F18

784.6 [30.9]

78.3 [3.1]

245.8 [9.7]

39.2 [1.5]

267.4 [10.5]

266.2 [10.5]

204.0 [8.0]

259.7

[10.2]

695.9

[27.4]

83.5 [3.3]

167.0 [6.6]

88.0

[3.5]

476.0 [18.7]

483.0 [19.0]

1080.5 [42.5]

29.0 [1.1]

121.3 [4.8]

MAINS INPUT TERMINALS

MOTOR OUTPUT TERMINALS

130BE114.10

Mechanical Installation

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

3.3.4 Terminal Locations for Enclosure Size D1n/D2n

Illustration 3.12 Terminal Locations, Enclosure Size D1n

845.7 [33.3]

108.0 [4.3]

257.6 [10.1]

268.9

[10.6]

1005.1 [39.6]

486.8 [19.2]

167.0 [6.6]

786.7 [31.0]

259.7

[10.2]

204.0 [8.0]

88.0 [3.5]

266.2 [10.5]

83.5 [3.3]

121.8 [4.8]

54.0 [2.1]

29.0 [1.1]

476.0 [18.7]

MOTOR OUTPUT TERMINALS

MAINS INPUT TERMINALS

130BE115.10

Mechanical Installation Operating Instructions

3 3

Illustration 3.13 Terminal Locations, Enclosure Size D2n

Allow for bend radius of heavy power cables.

NOTICE

All D-frames are available with standard input terminals, fuse, or disconnect switch.

130BC604.10

383 [15.1]

518.0 [20.4]

90.0 [3.5]

153.8 [6.1]

517.5 [20.4]

225.0 [8.9]

112.5 [4]

900.0 [35.4]

368.3 [14.5]

323.3 [12.7]

180.0 [7.1]

90.0 [3.5]

168.7 [6.6]

MAINS INPUT TERMINAL

MOTOR OUTPUT TERMINAL

104[4.1]

35[1.4]

10[0.4] 0[0.0]

0[0.0]

40[1.6]

78[3.1]

0[0.0]

26[1.0]

176FA271.10

Mechanical Installation

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

3.3.5 Terminal Locations for Enclosure Size E9

Illustration 3.14 Terminal Locations, Enclsoure Size E9

Allow for bend radius of heavy power cables.

NOTICE

All E-frames are available with standard input terminals, fuse, or disconnect switch.

Illustration 3.15 Close-up Terminal Diagrams

1 2 3

0.0[0.00]

76.4[3.01]

128.4[5.05]

119.0[4.69]

171.0[6.73]

294.6[11.60]

344.0[13.54]

3639[14.33]

438.9[17.28]

75.3[2.96]

150.3[5.92]

154.0[6.06]

219.6[18.65]

0.0[0.00]

244.4[9.62]

244.4[1.75]

939.0[36.97]

1031.4[40.61]

0.0[0.00]

134.6[5.30]

130BA851.12

0.0[1.75]

Mechanical Installation

Operating Instructions

3.3.6 Terminal Locations for Enclsoure Size F18

Consider the position of the terminals when designing the cable access.

F-frame units have 4 interlocked cabinets:

Input options cabinet (not optional for LHD)

•

Filter cabinet

•

Rectier cabinet

•

Inverter cabinet

•

See chapter 1.3.3 Exploded View Drawings for exploded views of each cabinet. Mains inputs are located in the input option cabinet, which conducts power to the rectier via interconnecting bus bars. Output from the unit is from the inverter cabinet. No connection terminals are located in the rectier cabinet. Interconnecting bus bars are not shown.

3 3

1 Right side cut-away 3 Left side cut-away 2 Front view 4 Ground bar

Illustration 3.16 Input Option Cabinet, Enclosure Size F18 - Fuses Only

The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right.

0.0 [0.00]

134.6 [5.30]

104.3 [4.11]

0.0 [0.00]

179.3 [7.06]

219.6 [8.65]

294.6 [11.60]

334.8 [13.18]

409.8 [16.14]

436.9 [17.20]

0.0 [0.00]

532.9 [20.98]

0.0 [0.00]

44.4 [1.75]

244.4 [9.62]

154.0 [6.06]

344.0 [13.54]

234

130BA852.11

Mechanical Installation

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

500 kW1)(mm [in.]) 560–710 kW1)(mm [in.])

1 Ground bar 2 34.9 [1.4] 46.3 [1.8] 3 86.9 [3.4] 98.3 [3.9] 4 122.2 [4.8] 119 [4.7] 5 174.2 [6.9] 171 [6.7]

1) Disconnect location and related dimensions vary with kilowatt rating.

Illustration 3.17 Input Option Cabinet with Circuit Breaker, Enclosure Size F18

The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right.

130BA849.13

.0 [.0]

54.4[2.1]

169.4 [6.7]

284.4 [11.2]

407.3 [16.0]

522.3 [20.6]

637.3 [25.1]

287.4 [11.3]

253.1 [10.0]

.0 [.0]

339.4 [13.4]

287.4 [11.3]

.0 [.0]

339.4 [13.4]

308.3 [12.1]

465.6 [18.3]

198.1[7.8]

234.1 [9.2]

282.1 [11.1]

318.1 [12.5]

551.0 [21.7]

587.0 [23.1]

635.0 [25.0]

671.0 [26.4]

44.40 [1.75]

244.40 [9.62]

204.1 [8.0]

497.1

[19.6]

572.1

[22.5]

180.3 [7.1]

129.1 [5.1]

Mechanical Installation Operating Instructions

3 3

1 Front view 2 Left side view 3 Right side view

Illustration 3.18 Inverter Cabinet, Enclosure Size F18

The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right.

Torque

3.3.7

Correct torque is imperative for all electrical connections. The correct values are listed in Table 3.2. Incorrect torque results in a bad electrical connection. Use a torque wrench to ensure correct torque.

Enclosure size

Terminal Torque [Nm] (in-

Mains Motor

Regen Brake Mains Motor Regen

Brake

lbs)

19–40 (168–354)

8.5–20.5 (75–181)

19–40 (168–354)

8.5–20.5 (75–181)

Bolt size

M10

Enclosure size

Table 3.2 Torque for Terminals

Terminal Torque [Nm] (in-

Mains Motor

Brake

Regen

lbs)

19–40 (168–354)

8.5–20.5 (75–181)

Bolt size

M10

Electrical Installation

4 Electrical Installation

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

4.1 Safety Instructions

See chapter 2 Safety for general safety instructions.

WARNING

INDUCED VOLTAGE

Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned o and locked out. Failure to run output motor cables separately or use screened cables could result in death or serious injury.

Run output motor cables separately, or

•

Use screened cables.

•

CAUTION

SHOCK HAZARD

The frequency converter can cause a DC current in the PE conductor. Failure to follow the recommendation means that the RCD may not provide the intended protection.

When a residual current-operated protective

•

device (RCD) is used for protection against electrical shock, only an RCD of Type B is permitted on the supply side.

Overcurrent protection

Extra protective equipment, such as short-circuit

•

protection or motor thermal protection between frequency converter and motor, is required for applications with multiple motors.

Input fusing is required to provide short-circuit

•

and overcurrent protection. If not factorysupplied, the installer must provide fuses. See maximum fuse ratings in chapter 8.4 Fuses.

Wire type and ratings

All wiring must comply with local and national

•

regulations regarding cross-section and ambient temperature requirements.

Power connection wire recommendation:

•

Minimum 75 °C rated copper wire.

See and chapter 8.3 General Technical Data for recommended wire sizes and types.

3 2

6 3

130BC644.10

Electrical Installation Operating Instructions

4.2 Electromagnetic Compatability (EMC)

To obtain an EMC-compliant installation, follow the instructions provided in chapter 4.4 Grounding,

chapter 4.3 Power Connections, chapter 4.6 Motor Connection, and chapter 4.8 Control Wiring.

4.2.1 EMC Interference

4 4

1 Customer control termination points–options A and B 6 Motor output cable, 3-phase and PE (not screened) 2 Screened control wiring 7 Cable gland 3 Cable clamp 8 Clearance, minimum 200 mm 4 Customer control input 9 Mains input cable, 3-phase and reinforce PE (not screened) 5

Potential equialisation wire [minimum 16 mm2]

Illustration 4.1 EMC-correct Installation

10 Low harmonic drive (LHD)

NOTICE

EMC Interference Use screened cables for motor and control wiring. Separate the LHD mains input cable, motor cable, and control wiring. Minimum 200 mm (7.9 in) clearance between power, motor, and control cables is required. Maximise this clearance to minimise EMC emissions. This reduces the risk of interference between the LHD and other electronic devices.

3 Phase

power

input

130BA026.10

91 (L1)

92 (L2)

93 (L3)

95 PE

175ZA114.11

96 97 98

Motor

Electrical Installation

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

4.3 Power Connections

Make the screen connections with the largest possible surface area (cable clamp). Use the installation devices

NOTICE

Cables, general information All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. UL applications require 75 °C copper conductors. For non-UL applications, 75 and 90 °C copper conductors are thermally acceptable.

The power cable connections are located as shown in Illustration 4.2. Dimension cable cross-section in accordance

within the frequency converter.

Cable-length and cross-section

The frequency converter has been EMC-tested with a given cable length. To reduce the noise level and leakage currents, keep the motor cable as short as possible.

Switching frequency

When frequency converters are used with sine-wave lters to reduce the acoustic noise from a motor, set the switching frequency according to parameter 14-01 Switching Frequency.

with the current ratings and local legislation. See

Termi

chapter 8.3.1 Cable lengths and cross-sections for details.

For protection of the frequency converter, use the recommended fuses if there are no built-in fuses. Fuse recommendations are provided in chapter 8.4 Fuses. Ensure that proper fusing is made according to local regulation.

If included, the mains connection is

tted to the mains

switch.

96 97 98 99

nal

numb

Motor voltage 0–100% of mains

U V W

U1 V1 W1

W2 U2 V2 6 wires out of motor

U1 V1 W1

voltage.

3 wires out of motor Delta-connected

Star-connected U2, V2, W2

U2, V2, and W2 to be interconnected

separately.

NOTICE

To comply with EMC emission specications, screened/ armoured cables are recommended. If an unscreened/ unarmoured cable is used, see chapter 4.7.3 Power and Control Wiring for Unscreened Cables.

See chapter 8 Specications for correct dimensioning of motor cable cross-section and length.

Screening of cables

Avoid installation with twisted screen ends (pigtails). They spoil the screening eect at higher frequencies. If breaking the screen is necessary to install a motor isolator or contactor, continue the screen at the lowest possible HF impedance.

Connect the motor cable screen to both the de-coupling plate of the frequency converter and to the metal housing of the motor.

Illustration 4.2 Power Cable Connections

Table 4.1 Terminal Connections

1) Protective earth connection

Illustration 4.3 Y and Delta Terminal Congurations

4.4 Grounding

WARNING

GROUNDING HAZARD!

For operator safety, it is important to ground the frequency converter properly in accordance with national and local electrical codes as well as instructions contained within this document. Do not use conduit connected to the frequency converter as a replacement for proper grounding. Ground currents are higher than

3.5 mA. Failure to ground the frequency converter properly could result in death or serious injury.

Electrical Installation

Operating Instructions

NOTICE

It is the responsibility of the user or certied electrical installer to ensure correct grounding of the equipment in accordance with national and local electrical codes and standards.

Follow all local and national electrical codes to

•

ground electrical equipment properly. Establish proper protective earthing for

•

equipment with ground currents higher than 3.5 mA, see chapter 4.4.1 Leakage Current (>3.5 mA).

A dedicated ground wire is required for input

•

power, motor power, and control wiring. Use the clamps provided with the equipment for

•

proper ground connections. Do not ground one frequency converter to

•

another in a “daisy chain” fashion. Keep the ground wire connections as short as

•

possible. Using high-strand wire to reduce electrical noise

•

is recommended. Follow motor manufacturer wiring requirements.

•

Leakage Current (>3.5 mA)

4.4.1

Follow national and local codes regarding protective earthing of equipment with a leakage current >3.5 mA. Frequency converter technology implies high frequency switching at high power. This generates a leakage current in the ground connection. A fault current in the frequency converter at the output power terminals might contain a DC component, which can charge the lter capacitors and cause a transient ground current. The earth leakage current depends on various system congurations including RFI ltering, screened motor cables, and frequency converter power.

In the case of a ground fault, a DC component develops in the fault current.

If using ELCB relays, observe local regulations. Relays must be suitable for protection of 3-phase equipment with a bridge rectier and for a brief discharge on power-up.

4.5.2 RFI Switch

Mains supply isolated from ground

If the frequency converter is supplied from an isolated mains source or TT/TN-S mains with grounded leg, turn o the RFI switch via parameter 14-50 RFI Filter on both frequency converter and the lter. For further reference, see IEC 364-3. When optimum EMC performance is needed, parallel motors are connected, or the motor cable length is above 25 m, set parameter 14-50 RFI Filter to [ON]. In OFF, the internal RFI capacitors (lter capacitors) between the enclosure and the DC link are cut o to avoid damage to the intermediate circuit and reduce ground capacity currents (IEC 61800-3). Refer to the application note VLT on IT mains. It is important to use isolation monitors that work together with power electronics (IEC 61557-8).

Screened Cables

4.5.3

It is important to connect screened cables properly to ensure high EMC immunity and low emissions.

Connection can be made using either cable glands or clamps:

EMC cable glands: Generally available cable

•

glands can be used to ensure an optimum EMC connection.

EMC cable clamp: Clamps allowing easy

•

connection are supplied with the unit.

4.6

Motor Connection

4 4

EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3.5 mA. Grounding must be reinforced in 1 of the following ways:

Ground wire of at least 10 mm2.

•

2 separate ground wires both complying with the

•

dimensioning rules.

See EN 60364-5-54 § 543.7 for further information.

4.5

Input Options

4.5.1 Extra Protection (RCD)

ELCB relays, multiple protective grounding, or standard grounding provide extra protection, if local safety regulations are followed.

4.6.1 Motor Cable

Connect the motor to terminals U/T1/96, V/T2/97, W/T3/98, on the far right of the unit. Ground to terminal 99. All types of 3-phase asynchronous standard motors can be used with a frequency converter. The factory setting is for clockwise rotation with the frequency converter output connected as follows:

Terminal number Function

96, 97, 98 Mains U/T1, V/T2, W/T3 99 Ground

Table 4.2 Terminal Functions

175HA036.11

96 97 98

Motor

96 97 98

Motor

Electrical Installation

Terminal U/T1/96 connected to U-phase.

•

Terminal V/T2/97 connected to V-phase.

•

Terminal W/T3/98 connected to W-phase.

•

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

The direction of rotation can be changed by switching 2 phases in the motor cable or by changing the setting of parameter 4-10 Motor Speed Direction.

NOTICE

If a retrot application requires an unequal number of wires per phase, consult the factory or use the top/ bottom entry side cabinet option instruction.

4.6.2 Brake Cable

Motor rotation check can be performed via

parameter 1-28 Motor Rotation Check and following the

Frequency converters with factory installed brake chopper option.

steps shown in the display.

(Only standard with letter B in position 18 in the type code).

The connection cable to the brake resistor must be screened and the maximum length from frequency converter to the DC bar is limited to 25 m.

Terminal number Function

81, 82 Brake resistor terminals

Table 4.3 Terminal Functions

The connection cable to the brake resistor must be screened. Connect the screen with cable clamps to the conductive back plate of the frequency converter and the metal cabinet of the brake resistor. Size the brake cable cross-section to match the brake torque.

WARNING

Note that voltages up to 790 V DC, depending on the supply voltage, are possible on the terminals.

Illustration 4.4 Motor Rotation Check

F-frame requirements

Use motor phase cables in quantities of 2, resulting in 2, 4, 6, or 8 to obtain an equal number of wires on both inverter module terminals. The cables are required to be equal length within 10% between the inverter module terminals and the recommended common point is the motor terminals.

Output junction box requirements

The length, minimum 2.5 m, and quantity of cables must be equal from each inverter module to the common terminal in the junction box.

F-frame requirements

Connect the brake resistors to the brake terminals in each inverter module.

Motor Insulation

4.6.3

For motor cable lengths ≤ the maximum cable length, the motor insulation ratings listed in Table 4.4 are recommended. The peak voltage can be twice the DC-link voltage or 2.8 times mains voltage, due to transmission line eects in the motor cable. If a motor has lower insulation rating, use a dU/dt or sine wave lter.

rst common point of a phase. The

Nominal mains voltage Motor insulation

UN≤420 V 420 V<UN≤500 V Reinforced ULL=1600 V

Table 4.4 Recommended Motor Insulation Ratings

Standard ULL=1300 V

Electrical Installation

Operating Instructions

4.6.4 Motor Bearing Currents

Motors with a rating of 110 kW or higher combined with frequency converters are best with NDE (non-drive end) insulated bearings to eliminate circulating bearing currents caused by motor size. To minimise DE (drive end) bearing and shaft currents, proper grounding is required for:

The frequency converter.

•

The motor.

•

Motor-driven machine.

•

Motor to the driven machine.

•

Although failure due to bearing currents is infrequent, use the following strategies to reduce the likelihood:

Use an insulated bearing.

•

Apply rigorous installation procedures.

•

Ensure that the motor and load motor are

•

aligned. Strictly follow the EMC Installation guideline.

•

Reinforce the PE so the high frequency

•

impedance is lower in the PE than the input power leads.

Provide a good high frequency connection

•

between the motor and the frequency converter. Ensure that the impedance from frequency

•

converter to building ground is lower than the grounding impedance of the machine. Make a direct ground connection between the motor and load motor.

Apply conductive lubrication.

•

Balance the line voltage to ground.

•

Use an insulated bearing as recommended by the

•

motor manufacturer.

NOTICE

Motors from reputable manufacturers typically have insulated bearings as standard in motors of this size.

If necessary, and after consultation with Danfoss:

Lower the IGBT switching frequency.

•

Modify the inverter waveform, 60° AVM vs.

•

SFAVM. Install a shaft grounding system or use an

•

isolating coupling between motor and load. Use minimum speed settings if possible.

•

Use a dU/dt or sine-wave lter.

•

4.7

AC Mains Connection

4.7.1 Mains Connection

Connect mains to terminals 91, 92, and 93 on the far left of the unit. Ground is connected to the terminal on the right of terminal 93.

Terminal number

91, 92, 93 Mains R/L1, S/L2, T/L3 94 Ground

Table 4.5 Terminal Functions

Ensure sucient current supply to the frequency converter.

If the unit is without built-in fuses, ensure that the appropriate fuses have the correct current rating.

External Fan Supply

4.7.2

Function

NOTICE

Applicable for E and F enclosures only.

If the frequency converter is supplied by DC, or the fan must run independently of the supply, use an external supply. Make the connection on the power card.

Terminal number

100, 101 Auxiliary supply S, T 102, 103 Internal supply S, T

Table 4.6 Terminal Functions

The connector on the power card provides the connection of line voltage for the cooling fans. The fans are connected from the factory to be supplied from a common AC line (jumpers between 100–102 and 101–103). If external supply is needed, remove the jumpers and connect the supply to terminals 100 and 101. Protect with a 5 A fuse. In UL applications, use a LittelFuse KLK-5 or equivalent.

Function

4 4

Motor

Line Power

Stop

Start

Speed

Control

130BX370.10

Electrical Installation

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

4.7.3 Power and Control Wiring for Unscreened Cables

WARNING

INDUCED VOLTAGE Induced voltage from coupled output motor cables charges equipment capacitors even with the equipment turned o and locked out. Run motor cables from

multiple frequency converters separately. Failure to run output cables separately could result in death or serious injury.

CAUTION

COMPROMISED PERFORMANCE The frequency converter runs less eciently if wiring is not isolated properly. To isolate high frequency noise, place the following in separate metallic conduits:

Power wiring

•

Motor wiring

•

Control wiring

•

Failure to isolate these connections could result in less than optimum controller and associated equipment performance.

Because the power wiring carries high-frequency electrical pulses, it is important to run input power and motor power in separate conduit. If incoming power wiring is in the same conduit as motor wiring, these pulses can couple electrical noise back onto the power grid. Isolate control wiring from high-voltage power wiring. See Illustration 4.5. When screened/armoured cable is not used, at least 3 separate conduits are connected to the panel options cabinet.

Mains Disconnects

4.7.4

Enclosure size Power and voltage Type

D 132–200 kW 380–500 V OT400U12-9 or ABB OETL-NF400A E 250 kW 380–500 V ABB OETL-NF600A E 315–400 kW 380–500 V ABB OETL-NF800A F 450 kW 380–500 V Merlin Gerin NPJF36000S12AAYP F 500–630 kW 380–500 V Merlin Gerin NRK36000S20AAYP

Table 4.7 Recommended Mains Disconnects

Illustration 4.5 Example of Proper Electrical Installation Using Conduit

130BE138.10

Electrical Installation Operating Instructions

4.7.5 F-FrameCircuit Breakers

Enclosure size Power and voltage Type

F 450 kW 380–500 V Merlin Gerin NPJF36120U31AABSCYP F 500–630 kW 380–500 V Merlin Gerin NRJF36200U31AABSCYP

Table 4.8 Recommended Circuit Breakers

4.7.6 F-Frame Mains Contactors

Enclosure size Power and voltage Type

F 450–500kW 380–500 V Eaton XTCE650N22A F 560–630kW380–500 V Eaton XTCEC14P22B

Table 4.9 Recommended Contactors

4.8 Control Wiring

4.8.1 Control Cable Routing

Tie down all control wires to the designated control cable routing as shown in Illustration 4.6, Illustration 4.7, Illustration 4.8, and Illustration 4.9. Remember to connect the shields in a proper way to ensure optimum electrical immunity.

4 4

Fieldbus connection

Connections are made to the relevant options on the control card. For details, see the relevant instruction. The cable must either be entered through the access point in the top or be placed in the provided path inside the frequency converter and tied down with other control wires (see Illustration 4.6, Illustration 4.7, and Illustration 4.8).

eldbus

Illustration 4.6 Control Card Wiring Path for Enclosure Size D1n

130BE137.10

Electrical Installation

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

Illustration 4.7 Control Card Wiring Path for Enclosure Size D2n

Illustration 4.8 Control Card Wiring Path for Enclosure Size E9

130BB187.10

130BA150.10

9 - 10 mm

(0.37 in)

130BT312.10

Electrical Installation

Operating Instructions

Access to Control Terminals

4.8.2

All terminals for the control cables are located beneath the LCP (both lter and frequency converter LCPs). They are accessed by opening the door of the unit.

4.8.3 Electrical Installation, Control Terminals

1 Routing path for the control card wiring inside the frequency

converter enclosure.

To connect the cable to the terminal:

1. Strip insulation by about 9–10 mm.

Illustration 4.10 Length to Strip the Insulation

2. Insert a screwdriver (maximum 0.4 x 2.5 mm) in the square hole.

3. Insert the cable in the adjacent circular hole.

4 4

Illustration 4.9 Control Card Wiring Path for Enclosure Size F18

Illustration 4.11 Inserting the Cable in the Terminal Block

4. Remove the screwdriver. The cable is now mounted in the terminal.

To remove the cable from the terminal:

1. Insert a screwdriver (maximum 0.4 x 2.5 mm) in the square hole.

2. Pull out the cable.

130BT311.10

130BT306.10

Electrical Installation

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

Illustration 4.13 Control Terminal Locations

Illustration 4.12 Removing the Screwdriver after Cable Insertion

HI inductor Temperature feed back

(NC)

91 (L1) 92 (L2) 93 (L3)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

0/4-20 mA

12 (+24 V OUT)

13 (+24 V OUT)

18 (D IN)

20 (COM D IN)

15 mA

200 mA

(U) 96

(V) 97 (W) 98 (PE) 99

(COM A OUT) 39

(A OUT) 42

0/4-20 mA

+10 VDC

0 VDC - 10 VDC

0/4-20 mA

24 VDC

240 VAC, 2A

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

19 (D IN)

24 V (NPN) 0 V (PNP)

24 V

0 V

(D IN/OUT)

0 V (PNP)

24 V (NPN)

(D IN/OUT)

0 V

24 V

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

33 (D IN)

32 (D IN)

1 2 1 2

1 2

A53 U-I (S201)

A54 U-I (S202)

ON=0-20 mA OFF=0-10 V

400 VAC, 2A

P 5-00

(R+) 82

(R-) 81

+ - + -

(P RS-485) 68

(N RS-485) 69

(COM RS-485) 61

0 V

5 V

S801

RS-485

S801/Bus Term. OFF-ON

3 Phase power

After HI inductor

Switch Mode

Power Supply

Motor

Analog Output

Interface

Relay1

Relay2

ON=Terminated OFF=Open

Brake resistor

(NPN) = Sink

(PNP) = Source

240 VAC, 2A

400 VAC, 2A (E & F frame only)

0 VDC - 10 VDC

10 VDC

37 (D IN) - option

130BE195.10

Electrical Installation Operating Instructions

4.8.4 Electrical Installation, Control Cables

4 4

Illustration 4.14 Terminal Diagram for the Frequency Converter Side

Switch Mode

Power Supply

Analog Output

Interface

relay1

relay2

(PNP) = Source

(NPN) = Sink

ON=Terminated OFF=Open

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

0/4-20 mA

12 (+24V OUT)

13 (+24V OUT)

18 (D IN)

20 (COM D IN)

10Vdc 15mA 130/200mA

+ - + -

(COM A OUT) 39

(A OUT) 42

(P RS-485) 68

(N RS-485) 69

(COM RS-485) 61

S801

0/4-20 mA

RS-485

+10Vdc

-10Vdc -

+10Vdc

0/4-20 mA

-10Vdc -

240Vac, 2A

24Vdc

240Vac, 2A

24V (NPN) 0V (PNP)

0V (PNP)

24V (NPN)

19 (D IN)

24V (NPN) 0V (PNP)

24V

(D IN/OUT)

0V (PNP)

24V (NPN)

(D IN/OUT)

24V

24V (NPN) 0V (PNP)

0V (PNP)

24V (NPN)

33 (D IN)

32 (D IN)

1 2

S201

S202

ON/I=0-20mA OFF/U=0-10V

400Vac, 2A

P 5-00

S801

Optional

RFI

Optional

Fuses

Optional

Manual

Disconnect

HI Reactor

Contactor

Relay 12

Control &

AUX

Feedback

Soft-Charge

Resistor

Converter Side

Filter

Power Stage

AF Current Sensors

Capacitor

Current Sensors

VLT Drive

Main’s

CTs

CefCefC

RefRefR

91 (L1)

92 (L2)

93 (L3)

Mains 380 to

500 VAC

130BE196.10

Electrical Installation

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

Illustration 4.15 Terminal Diagram for the Filter Side

Electrical Installation Operating Instructions

4.8.5 Safe Torque O (STO)

To run STO, additional wiring for the frequency converter is required. Refer to VLT® Frequency Converters Safe Torque O

Operating Instructions for further information.

4.9 Additional Connections

4.9.1 Serial Communication

RS485 is a 2-wire bus interface compatible with multi-drop network topology, that is nodes can be connected as a bus, or via drop cables from a common trunk line. A total of 32 nodes can be connected to 1 network segment. Repeaters divide networks.

NOTICE

Each repeater functions as a node within the segment in which it is installed. Each node connected within a given network must have a unique node address across all segments.

Terminate each segment at both ends, using either the termination switch (S801) of the frequency converters or a biased termination resistor network. Always use screened twisted pair (STP) cable for bus cabling, and always follow good common installation practice. Low-impedance ground connection of the screen at every node is important, including at high frequencies. Thus, connect a large surface of the screen to ground, for example with a cable clamp or a conductive cable gland. It may be necessary to apply potential-equalizing cables to maintain the same ground potential throughout the network, particularly in installations with long cables. To prevent impedance mismatch, always use the same type of cable throughout the entire network. When connecting a motor to the frequency converters, always use screened motor cable.

4.9.2

Mechanical Brake Control

In hoisting/lowering applications, it is necessary to be able to control an electro-mechanical brake:

Control the brake using any relay output or

•

digital output (terminal 27 or 29). Keep the output closed (voltage-free) as long as

•

the frequency converter is unable to support the motor, due to the load being too heavy, for example.

Select [32] Mechanical brake control in parameter

•

group 5-4* Relays for applications with an electromechanical brake.

The brake is released when the motor current

•

exceeds the preset value in parameter 2-20 Release Brake Current.

The brake engages when the output frequency is

•

less than the frequency set in

parameter 2-21 Activate Brake Speed [RPM] or parameter 2-22 Activate Brake Speed [Hz], only if

the frequency converter completes a stop command.

If the frequency converter is in alarm mode or in an overvoltage situation, the mechanical brake immediately cuts in.

4 4

Cable Impedance Cable length [m]

Table 4.10 Cable Recommendations

Screened twisted pair (STP) 120 Ω Maximum 1200 (including drop lines)

Maximum 500 station-to-station

130BA170.11

LC lter

Electrical Installation

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

4.9.3 Parallel Connection of Motors

The frequency converter can control several parallelconnected motors. The total current consumption of the motors must not exceed the rated output current I the frequency converter.

M,N

for

NOTICE

Installations with cables connected in a common joint as in Illustration 4.16 are only recommended for short cable lengths.

NOTICE

When motors are connected in parallel, parameter 1-29 Automatic Motor Adaptation (AMA) cannot be used.

NOTICE

The electronic thermal relay (ETR) of the frequency converter cannot be used as motor protection for the individual motor in systems with parallel-connected motors. Provide further motor protection with thermistors in each motor or individual thermal relays. Circuit breakers are not suitable as protection.

Problems are possible at start and at low RPM values if motor sizes vary widely. The relatively high ohmic resistance in the stator of small motors calls for a higher voltage at start and at low RPM values.

4.9.4 Motor Thermal Protection

The electronic thermal relay in the frequency converter has received UL-approval for single motor protection, when

parameter 1-90 Motor Thermal Protection is set for [4] ETR Trip 1 and parameter 1-24 Motor Current is set to the rated

motor current (see motor nameplate).

For the North American market: The ETR functions provide class 20 motor overload protection in accordance with NEC.

For motor thermal protection, it is also possible to use the VLT® PTC Thermistor Card MCB 112. This card provides

ATEX

certication to protect motors in explosion hazardous

areas, Zone 1/21 and Zone 2/22. When

parameter 1-90 Motor Thermal Protection is set to [20] ATEX ETR and MCB 112 are combined, it is possible to control an

Ex-e motor in explosion hazardous areas. Consult the Programming Guide for details on how to set up the frequency converter for safe operation of Ex-e motors.

Illustration 4.16 Installations with Cables Connected in a Common Joint

Voltage/Current Input Selection

4.9.5 (Switches)

The analog mains terminals 53 and 54 allow setting of input signal to voltage (0–10 V) or current (0/4–20 mA). See Illustration 4.14 and Illustration 4.15 for the location of the control terminals within the low harmonic drive.

Default parameter settings:

Terminal 53: Speed reference signal in open loop

•

(see parameter 16-61 Terminal 53 Switch Setting). Terminal 54: Feedback signal in closed loop (see

•

parameter 16-63 Terminal 54 Switch Setting).

NOTICE

REMOVE POWER

Remove power to the low harmonic drive before changing switch positions.

Remove the LCP (see Illustration 4.17).

2. Remove any optional equipment covering the switches.

3. Set switches A53 and A54 to select the signal type. U selects voltage, I selects current.

130BE063.10

N O

3~ MOTOR NR. 1827421 2003

S/E005A9

1,5 KW

n 31,5 /min. 400 Y V

n 1400 /min. 50 Hz

COS  0,80 3,6 A

1,7L

B IP 65 H1/1A

BAUER D-7 3734 ESLINGEN

130BT307.10

Electrical Installation

1 Bus termination switch 2 A54 switch 3 A53 switch

Operating Instructions

4 4

Illustration 4.17 Bus Termination Switch, A53, and A54 Switch Locations

4.10

Final Set-up and Test

Before operating the frequency converter, perform a nal test of the installation:

1. Locate the motor name plate to nd out whether the motor is star- (Y) or delta- connected (Δ).

2. Enter the motor name plate data in the parameter list. Access the list by pressing the [Quick Menu] key and selecting Q2 Quick Set-up. See Table 4.11.

Table 4.11 Quick Set-up Parameters

Parameter 1-20 Motor Power [kW ] Parameter 1-21 Motor Power [HP] Parameter 1-22 Motor Voltage Parameter 1-23 Motor Frequency Parameter 1-24 Motor Current Parameter 1-25 Motor Nominal Speed

Illustration 4.18 Motor Name Plate

3. Perform an automatic motor adaptation (AMA) to ensure optimum performance.

3a Connect terminal 27 to terminal 12 or

set parameter 5-12 Terminal 27 Digital Input to [0] No operation.

3b Activate the AMA in

parameter 1-29 Automatic Motor Adaptation (AMA).

3c Select either complete or reduced AMA.

If an LC

lter is mounted, run only the reduced AMA, or remove the LC lter during the AMA procedure.

Press [OK]. The display shows Press [Hand On] to start.

3e Press [Hand On]. A progress bar

indicates whether the AMA is in progress.

3f Press

[O] - the frequency converter enters alarm mode and the display shows that the user terminated AMA.

Electrical Installation

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

Stop the AMA during operation Successful AMA

The display shows Press [OK] to nish AMA.

•

Press [OK] to exit the AMA state.

•

Unsuccessful AMA

The frequency converter enters into alarm mode.

•

A description of the alarm can be found in chapter 7 Diagnostics and Troubleshooting.

Report value in the alarm log shows the last

•

measuring sequence carried out by the AMA before the frequency converter entered alarm mode. This number, along with the description of the alarm, helps with troubleshooting. Mention the number and alarm description when contacting Danfoss service personnel.

Unsuccessful AMA is the result of incorrectly registered motor nameplate data or too large a the motor power size and the frequency converter power size.

Set up the desired limits for speed and ramp time

Minimum reference

Maximum reference

Table 4.12 Reference Parameters

Motor speed low limit

Motor speed high limit

Table 4.13 Speed Limits

Ramp-up time 1 [s]

Ramp-down time 1 [s]

Table 4.14 Ramp Times

4.11

F-frame Options

Space heaters and thermostat

There are space heaters mounted on the cabinet interior of F-frame frequency converters. These heaters are controlled by an automatic thermostat and help control humidity inside the enclosure. The thermostat default settings turn on the heaters at 10 °C (50 °F) and turn them o at 15.6 °C (60 °F).

dierence between

Parameter 3-02 Minimum Reference Parameter 3-03 Maximum Reference

Parameter 4-11 Motor Speed Low Limit [RPM] or parameter 4-12 Motor Speed Low Limit [Hz] Parameter 4-13 Motor Speed High Limit [RPM] or parameter 4-14 Motor Speed High Limit [Hz]

Parameter 3-41 Ramp 1 Ramp Up Time Parameter 3-42 Ramp 1 Ramp Down Time

Cabinet light with power outlet

A light mounted on the cabinet interior of F-frame frequency converters increases visibility during servicing and maintenance. The housing includes a power outlet for temporarily powering tools or other devices, available in 2 voltages:

230 V, 50 Hz, 2.5 A, CE/ENEC

•

120 V, 60 Hz, 5 A, UL/cUL

•

Transformer tap set-up

If the cabinet light, outlet, and/or the space heaters, and thermostat are installed, transformer T1 requires its taps to be set to the proper input voltage. A 380–480/500 V frequency converter is initially set to the 525 V tap to ensure that no overvoltage of secondary equipment occurs if the tap is not changed before applying power. See Table 4.15 to set the proper tap at terminal T1 located in the rectier cabinet.

Input voltage range [V] Tap to select [V]

380–440 400 441–500 460

Table 4.15 Transformer Tap Set-up

NAMUR terminals

NAMUR is an international association of automation technology users in the process industries, primarily chemical and pharmaceutical industries in Germany. Selecting this option, provides terminals organised and labeled to the frequency converters input and output terminals. This

requires VLT® PTC Thermistor Card MCB 112 and VLT Extended Relay Card MCB 113.

RCD (residual current device)

Uses the core balance method to monitor ground fault currents in grounded and high-resistance grounded systems (TN and TT systems in IEC terminology). There is a pre-warning (50% of main alarm set-point) and a main alarm set-point. Associated with each set-point is an SPDT alarm relay for external use. Requires an external windowtype current transformer (supplied and installed by the customer).

•

Insulation resistance monitor (IRM)

Monitors the insulation resistance in ungrounded systems (IT systems in IEC terminology) between the system phase conductors and ground. There is an ohmic pre-warning and a main alarm setpoint for the insulation level. An SPDT

specications of the NAMUR standard for

Integrated into the frequency converter safe torque o circuit.

IEC 60755 Type B device monitors AC, pulsed DC, and pure DC ground fault currents.

LED bar graph indicator of the ground fault current level from 10–100% of the setpoint.

Fault memory. TEST/RESET key.

Electrical Installation Operating Instructions

alarm relay for external use is associated with each setpoint.

NOTICE

Only 1 insulation resistance monitor can be connected to each ungrounded (IT) system.

Integrated into the frequency converter Safe

•

Torque

O circuit.

LCD display of the ohmic value of the insulation

•

resistance. Fault memory.

•

INFO, TEST, and RESET keys.

•

IEC emergency stop with Pilz safety relay

Includes a redundant 4-wire emergency-stop push button mounted on the front of the enclosure and a Pilz relay that monitors it in conjunction with the frequency converter STO (Safe Torque O) circuit and the mains contactor located in the options cabinet.

Manual motor starters

Provide 3-phase power for electric blowers often required for larger motors. Power for the starters is provided from the load side of any supplied contactor, circuit breaker, or disconnect switch. Power is fused before each motor starter, and is o when the incoming power to the frequency converters is o. Up to 2 starters are allowed (1 if a 30 A, fuse-protected circuit is ordered), and are integrated into the frequency converter STO circuit. Unit features include:

Operation switch (on/o).

•

Short-circuit and overload protection with test

•

function. Manual reset function.

•

30 A, fuse-protected terminals

3-phase power matching incoming mains voltage

•

for powering auxiliary customer equipment. Not available if 2 manual motor starters are

•

selected. Terminals are

•

the frequency converter is o. Power for the fused protected terminals is

•

provided from the load side of any supplied contactor, circuit breaker, or disconnect switch.

In applications where the motor is used as a brake, energy is generated in the motor and sent back into the frequency converter. If the energy cannot be transported back to the motor, it increases the voltage in the frequency converter DC line. In applications with frequent braking and/or high inertia loads, this increase may lead to an overvoltage trip in the frequency converter and shut down. Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor

o when the incoming power to

nally a

is selected based on its ohmic value, its power dissipation rate, and its physical size. Danfoss oers a wide variety of dierent resistors that are specically designed for Danfoss frequency converters.

4 4

Commissioning

5 Commissioning

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

5.1 Safety Instructions

See chapter 2 Safety for general safety instructions.

WARNING

HIGH VOLTAGE

Frequency converters contain high voltage when

connected to AC mains input power. Failure to perform installation, start-up, and maintenance by qualied personnel could result in death or serious injury.

Installation, start-up, and maintenance must be

•

performed by qualied personnel only.

Before applying power:

1. Close the cover properly.

2. Check that all cable glands are rmly tightened.

3. Ensure that input power to the unit is OFF and locked out. Do not rely on the frequency

Pre-start

5.1.1

converter disconnect switches for input power isolation.

4. Verify that there is no voltage on input terminals L1 (91), L2 (92), and L3 (93), phase-to-phase, and phase-to-ground.

5. Verify that there is no voltage on output terminals 96 (U), 97 (V), and 98 (W), phase-tophase, and phase-to-ground.

Conrm continuity of the motor by measuring Ω values on U-V (96-97), V-W (97-98), and W-U (98-96).

7. Check for proper grounding of the frequency converter as well as the motor.

8. Inspect the frequency converter for loose connections on the terminals.

9. Conrm that the supply voltage matches the voltage of the frequency converter and the motor.

CAUTION

Before applying power to the unit, inspect the entire installation as detailed in Table 5.1. Check mark those items when completed.

Inspect for Description

Auxiliary equipment

Cable routing

Control wiring

Cooling clearance

EMC considerations

Environmental considerations

Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers on the input

•

power side of the frequency converter or output side to the motor. Ensure that they are ready for full speed operation.

Check function and installation of any sensors used for feedback to the frequency converter.

•

Remove power factor correction capacitors on motors, if present.

•

Use separate metallic conduits for each of the following:

•

Check for broken or damaged wires and loose connections.

•

Check that control wiring is isolated from power and motor wiring for noise immunity.

•

Check the voltage source of the signals.

•

Use screened or twisted pair cable. Ensure that the screen is terminated correctly.

•

Measure that top and bottom clearance is adequate to ensure proper air ow for cooling.

•

Check for proper installation regarding electromagnetic compatibility.

•

See equipment label for the maximum ambient operating temperature limits.

•

Humidity levels must be 5–95%, non-condensing.

•

☑

Input power

Motor wiring

Control wiring

Commissioning Operating Instructions

Inspect for Description

Fusing and circuit breakers

Grounding

Input and output power wiring

Panel interior

Switches

Vibration

Table 5.1 Start-up Checklist

Check for proper fusing or circuit breakers.

•

Check that all fuses are inserted rmly and in operational condition, and that all circuit breakers are

•

in the open position.

The unit requires a ground wire from its enclosure to the building ground.

•

Check for good ground connections that are tight and free of oxidation.

•

Grounding to conduit or mounting the back panel to a metal surface is not sucient.

•

Check for loose connections.

•

Check that motor and mains are in separate conduit or separated screened cables.

•

Inspect that the unit interior is free of debris and corrosion.

•

Ensure that all switch and disconnect settings are in the proper positions.

•

Check that the unit is mounted solidly or that shock mounts are used as necessary.

•

Check for an unusual amount of vibration.

•

☑

5 5

130BD512.10

Auto

Reset

Hand

O

Status

Quick Menu

Main

Alarm

Log

Back

Cancel

Info

Status

1(1)

0.00 kW

O Remote Stop

0.0Hz

Alarm

Warn.

0.00 A

0.0 %

2605 kWh

18 19 20 21

Commissioning

5.2 Applying Power

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

Programme frequency converter and active lter

•

functions.

WARNING

HIGH VOLTAGE!

Frequency converters contain high voltage when connected to AC mains. Installation, start-up, and maintenance should be performed by qualied personnel only. Failure to comply could result in death or serious injury.

NOTICE

For commissioning via PC, install the MCT 10 Set-up Software. The software is available for download (basic version) or for ordering (advanced version, order number 130B1000). For more information and downloads, see

Manually reset the frequency converter or active

•

lter after a fault when auto-reset is inactive.

www.danfoss.com/BusinessAreas/DrivesSolutions/Software

UNINTENDED START!

When the frequency converter is connected to AC mains,

WARNING

+MCT10/MCT10+Downloads.htm.

5.3.2 LCP Layout

the motor may start at any time. The frequency converter, motor, and any driven equipment must be in operational readiness. Failure to comply could result in

The LCP is divided into 4 functional groups (see Illustration 5.1).

death, serious injury, equipment, or property damage.

A. Display area

1. Conrm that the input voltage is balanced within 3%. If not, correct input voltage imbalance before proceeding.

2. Ensure that optional equipment wiring, if present,

B. Display menu keys C. Navigation keys and indicator lights (LEDs) D. Operation keys and reset

matches the installation application.

3. Ensure that all operator devices are o. Panel doors should be closed or cover mounted.

4. Apply power to the unit. Do not start the frequency converter at this time. For units with a disconnect switch, turn the switch on to apply power.

NOTICE

If the status line at the bottom of the LCP reads AUTO REMOTE COASTING or Alarm 60 External Interlock is displayed, the unit is ready to operate but is missing an input signal on terminal 27.

5.3 Local Control Panel Operation

5.3.1 Local Control Panel

The local control panel (LCP) is the combined display and keypad on the front of the unit. The low harmonic drive includes 2 LCPs: 1 to control the frequency converter side and 1 to control the lter side.

The LCP has several functions:

Control speed of frequency converter when in

•

local mode. Start and stop in local mode.

•

Display operational data, status, warnings, and

•

alarms.

Illustration 5.1 Local Control Panel (LCP)

A. Display area

The display area is activated when the frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V DC supply.

Commissioning

Operating Instructions

The information displayed on the LCP can be customised for user application. Select options in the Quick Menu Q3-13 Display Settings.

Callout Display Parameter number Default setting

1 1.1 0-20 Reference % 2 1.2 0-21 Motor current 3 1.3 0-22 Power [kW] 4 2 0-23 Frequency 5 3 0-24 kWh counter

Table 5.2 Legend to Illustration 5.1, Display Area (Frequency Converter Side)

B. Display menu keys

Menu keys are used for menu access for parameter set-up, toggling through status display modes during normal operation, and viewing fault log data.

Callout Key Function

6 Status Shows operational information. 7 Quick Menu Allows access to programming

parameters for initial set-up instructions and many detailed application instructions.

8 Main Menu Allows access to all programming

parameters.

9 Alarm Log Displays a list of current warnings, the

last 10 alarms, and the maintenance log.

Table 5.3 Legend to

Illustration 5.1, Display Menu Keys

C. Navigation keys and indicator lights (LEDs)

Navigation keys are used for programming functions and moving the display cursor. The navigation keys also provide speed control in local (hand) operation. There are also 3 frequency converter status indicator lights in this area.

Callout Indicator Light Function

15 ON Green The ON light activates when the

frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V supply.

16 WARN Yellow When a warning is issued, the

yellow WARN light comes on and text appears in the display area identifying the problem.

17 ALARM Red A fault condition causes the red

alarm light to ash and an alarm text is displayed.

Table 5.5 Legend to Illustration 5.1, Indicator Lights (LEDs)

D. Operation keys and reset

Operation keys are located at the bottom of the LCP.

Callout Key Function

18 Hand On Starts the frequency converter in local

control.

An external stop signal by control

•

input or serial communication overrides the local hand on.

19 O Stops the operation but does not remove

power to the frequency converter.

20 Auto On Puts the system in remote operational

mode.

Responds to an external start

•

command by control terminals or serial communication.

21 Reset Resets the frequency converter or active

lter manually after a fault has been cleared.

Table 5.6 Legend to

Illustration 5.1, Operation Keys and Reset

5 5

Callout Key Function

10 Back Reverts to the previous step or list in the

menu structure.

11 Cancel Cancels the last change or command as

long as the display mode has not changed.

12 Info Press for a denition of the function being

displayed.

13 Navigation

14 OK Press to access parameter groups or to

Table 5.4 Legend to Illustration 5.1, Navigation Keys

Press to move between items in the menu.

keys

enable an option.

NOTICE

The display contrast can be adjusted by pressing [Status] and [▲]/[▼] keys.

5.3.3 Parameter Settings

Establishing the correct programming for applications often requires setting functions in several related parameters.

Programming data are stored internally in the frequency converter.

For back-up, upload data into the LCP memory.

•

To download data to another frequency

•

converter, connect the LCP to that unit and download the stored settings.

Restoring factory default settings does not

•

change data stored in the LCP memory.

Commissioning

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

5.3.4 Uploading/Downloading Data to/from

5.3.6

Restoring Default Settings

the LCP

NOTICE

1. Press [O] to stop operation before uploading or downloading data.

Press [Main Menu] parameter 0-50 LCP Copy and press [OK].

Select [1] All to LCP to upload data to the LCP or select [2] All from LCP to download data from the LCP.

4. Press [OK]. A progress bar shows the uploading or

5.3.5

Parameter settings can be accessed and changed from the Quick Menu or from the Main Menu. The Quick Menu only gives access to a limited number of parameters.

View changes

Quick Menu Q5 - Changes Made lists all parameters changed from default settings.

downloading progress.

5. Press [Hand On] or [Auto On] to return to normal operation.

Changing Parameter Settings

1. Press [Quick Menu] or [Main Menu] on the LCP.

Press [▲] [▼] to browse through the parameter groups, press [OK] to select a parameter group.

Press [▲] [▼] to browse through the parameters, press [OK] to select a parameter.

Press [▲] [▼] to change the value of a parameter setting.

Press [◄] [►] to shift digit when a decimal parameter is in the editing state.

6. Press [OK] to accept the change.

Press either [Back] twice to enter Status, or press [Main Menu] once to enter the Main Menu.

The list only shows parameters, which have been

•

changed in the current edit set-up. Parameters, which have been reset to default

•

values, are not listed. The message Empty indicates that no parameters

•

have been changed.

Risk of losing programming and monitoring records by restoration of default settings. To provide a back-up, upload data to the LCP before initialisation.

Restoring the default parameter settings is done by initialisation of the frequency converter. Initialisation is carried out through parameter 14-22 Operation Mode (recommended) or manually.

Initialisation using parameter 14-22 Operation

•

Mode does not reset frequency converter settings, such as operating hours, serial communication selections, personal menu settings, fault log, alarm log, and other monitoring functions.

Manual initialisation erases all motor,

•

programming, localisation, and monitoring data, and restores factory default settings.

Recommended initialisation procedure, via

parameter 14-22 Operation Mode

1. Press [Main Menu] twice to access parameters.

Scroll to parameter 14-22 Operation Mode and press [OK].

Scroll to [2] Initialisation and press [OK].

4. Remove power to the unit and wait for the display to turn o.

5. Apply power to the unit.

Default parameter settings are restored during start-up. This may take slightly longer than normal.

6. Alarm 80 is displayed.

7. Press [Reset] to return to operation mode.

Manual initialisation procedure

1. Remove power to the unit and wait for the display to turn o.

2. Press and hold [Status], [Main Menu], and [OK] at the same time while applying power to the unit (approximately 5 s or until audible click and fan starts).

Factory default parameter settings are restored during start-up. This may take slightly longer than normal.

Manual initialisation does not reset the following frequency converter information:

Parameter 15-00 Operating hours

•

Parameter 15-03 Power Up's

•

Parameter 15-04 Over Temp's

•

Parameter 15-05 Over Volt's

•

130BP066.10

1107 RPM

0 -

Operation/Display

1 -

Load/Motor

2 -

Brakes

3 -

Reference / Ramps

3.84 A 1 (1)

Main Menu

Operation / Display

0.0%

0-0

Basic Settings

0-1

Set-up Operations

0-2

LCP Display

0-3

LCP Custom Readout

0.00A 1(1)

130BP087.10

0-0

Basic Settings

0.0%

0-03 Regional Settings

[0] International

0.00A 1(1)

130BP088.10

Commissioning

Operating Instructions

5.4 Basic Operational Programming

5.4.1

VLT® Low Harmonic Drive Programming

The low harmonic drive includes 2 LCPs: 1 to control the frequency converter side and 1 to control the lter side. Because of this unique design, the detailed parameter information for the product is found in 2 places.

Detailed programming information for the frequency converter portion can be found in the relevant programming guide. Detailed programming information for

the

lter can be found in the VLT® Active Filter AAF 006

Operating Instructions.

The remaining sections in this chapter apply to the frequency converter side. The active lter of the low harmonic drives is pre-congured for optimal performance and must only be turned on by pressing its [Hand On] key after the frequency converter side is commissioned.

Illustration 5.2 Main Menu

3. Press the navigation keys to scroll to parameter group 0-0* Basic Settings and press [OK].

5 5

Commissioning with SmartStart

5.4.2

The SmartStart wizard enables fast conguration of basic motor and application parameters.

SmartStart starts automatically at rst power-up

•

or after initialisation of the frequency converter. Follow the on-screen instructions to complete the

•

commissioning of the frequency converter. Always reactivate SmartStart by selecting Quick Menu Q4 - SmartStart.

For commissioning without use of the SmartStart

•

wizard, refer to chapter 5.4.3 Commissioning via [Main Menu] or the programming guide.

Illustration 5.3 Operation/Display

4. Press the navigation keys to scroll to parameter 0-03 Regional Settings and press [OK].

NOTICE

Motor data is required for the SmartStart set-up. The required data is normally available on the motor nameplate.

5.4.3 Commissioning via [Main Menu]

Recommended parameter settings are intended for startup and check-out purposes. Application settings may vary.

Enter data with power ON, but before operating the frequency converter.

1. Press [Main Menu] on the LCP.

2. Press the navigation keys to scroll to parameter

group 0-** Operation/Display and press [OK].

Illustration 5.4 Basic Settings

Press the navigation keys to select [0] Interna- tional or [1] North America as appropriate and press [OK]. (This changes the default settings for a number of basic parameters).

6. Press [Main Menu] on the LCP.

7. Press the navigation keys to scroll to parameter 0-01 Language.

8. Select the language and press [OK].

9. If a jumper wire is in place between control terminals 12 and 27, leave parameter 5-12 Terminal 27 Digital Input at factory default. Otherwise, select No Operation in parameter 5-12 Terminal 27 Digital Input.

Commissioning

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

10. Make the application-specic settings in the following parameters:

10a

Parameter 3-02 Minimum Reference.

10b

Parameter 3-03 Maximum Reference.

10c

Parameter 3-41 Ramp 1 Ramp Up Time.

10d

Parameter 3-42 Ramp 1 Ramp Down Time.

10e

Parameter 3-13 Reference Site. Linked to Hand/Auto Local Remote.

5.4.4 Asynchronous Motor Set-up

Enter the following motor data. The information can be found on the motor nameplate.

Parameter 1-20 Motor Power [kW] or parameter 1-21 Motor Power [HP].

Parameter 1-22 Motor Voltage.

Parameter 1-23 Motor Frequency.

Parameter 1-24 Motor Current.

Parameter 1-25 Motor Nominal Speed.

When running in

ux mode, or for optimum performance in VVC+ mode, extra motor data is required to set up the following parameters. The data can be found in the motor datasheet (this data is typically not available on the motor nameplate). Run a complete AMA using

parameter 1-29 Automatic Motor Adaptation (AMA) [1] Enable Complete AMA or enter the parameters manually. Parameter 1-36 Iron Loss Resistance (Rfe) is always entered

manually.

Parameter 1-30 Stator Resistance (Rs).

Parameter 1-31 Rotor Resistance (Rr).

Parameter 1-33 Stator Leakage Reactance (X1).

Parameter 1-34 Rotor Leakage Reactance (X2).

Parameter 1-35 Main Reactance (Xh).

Parameter 1-36 Iron Loss Resistance (Rfe).

Application Settings

Low-inertia applications Keep calculated values. High-inertia applications

High load at low speed

No-load application

Flux sensorless only

Table 5.7 Recommendations for Flux Applications

Permanent Magnet Motor Set-up

5.4.5

Parameter 1-66 Min. Current at Low Speed.

Increase current to a value between default and maximum depending on the application. Set ramp times matching the application. Too fast ramp up causes an overcurrent or overtorque. Too fast ramp down causes an overvoltage trip.

Parameter 1-66 Min. Current at Low Speed.

Increase current to a value between default and maximum depending on the application. Adjust parameter 1-18 Min. Current at No Load to achieve smoother motor operation by reducing torque ripple and vibration. Adjust parameter 1-53 Model Shift Frequency. Example 1: If the motor oscillates at 5 Hz and dynamics performance is required at 15 Hz, set

parameter 1-53 Model Shift Frequency

to 10 Hz. Example 2: If the application involves dynamic load changes at low speed, reduce parameter 1-53 Model Shift Frequency. Observe the motor behaviour to make sure that the model shift frequency is not reduced too much. Symptoms of inappropriate model shift frequency are motor oscillations or frequency converter tripping.

Application-specic adjustment when running VVC

VVC+ is the most robust control mode. In most situations, it provides optimum performance without further

NOTICE

Only use permanent magnet (PM) motor with fans and pumps.

adjustments. Run a complete AMA for best performance.

Application-specic adjustment when running Flux

Flux mode is the preferred control mode for optimum shaft performance in dynamic applications. Perform an AMA since this control mode requires precise motor data. Depending on the application, further adjustments may be required.

Initial programming steps

1. Activate PM motor operation in

parameter 1-10 Motor Construction, select [1] PM, non-salient SPM.

Set parameter 0-02 Motor Speed Unit to [0] RPM.

See Table 5.7 for application-related recommendations.

Commissioning

Operating Instructions

Programming motor data

After selecting PM motor in parameter 1-10 Motor Construction, the PM motor-related parameters in

parameter groups 1-2* Motor Data, 1-3* Adv. Motor Data, and 1-4* are active. Find the necessary data on the motor nameplate and in the motor data sheet. Program the following parameters in the listed order:

Parameter 1-24 Motor Current.

Parameter 1-26 Motor Cont. Rated Torque.

Parameter 1-25 Motor Nominal Speed.

Parameter 1-39 Motor Poles.

Parameter 1-30 Stator Resistance (Rs). Enter line to common stator winding resistance (Rs). If only line-line data are available, divide the line-line value with 2 to achieve the line to common (starpoint) value. It is also possible to measure the value with an ohmmeter, which takes the resistance of the cable into account. Divide the measured value by 2 and enter the result.

Parameter 1-37 d-axis Inductance (Ld). Enter line to common direct axis inductance of the PM motor. If only line-line data are available, divide the lineline value with 2 to achieve the line-common (starpoint) value. It is also possible to measure the value with an inductancemeter, which takes the inductance of the cable into account. Divide the measured value by 2 and enter the result.

Parameter 1-40 Back EMF at 1000 RPM

Enter line-line back EMF of PM Motor at 1000 RPM mechanical speed (RMS value). Back EMF is the voltage generated by a PM motor when no frequency converter is connected and the shaft is turned externally. Back EMF is normally specied for nominal motor speed or for 1000 RPM measured between 2 lines. If the value is not available for a motor speed of 1000 RPM, calculate the correct value as follows: If back EMF is for example 320 V at 1800 RPM, it can be calculated at 1000 RPM as follows: Back EMF = (Voltage/RPM)x1000 = (320/1800)x1000 = 178. Program this value for parameter 1-40 Back EMF at 1000 RPM.

Test motor operation

1. Start the motor at low speed (100–200 RPM). If the motor does not turn, check installation, general programming, and motor data.

Check if start function in parameter 1-70 PM Start

ts the application requirements.

Mode

Rotor detection

This function is the recommended choice for applications where the motor starts from standstill, for example pumps or conveyors. On some motors, a sound is heard when the impulse is sent out. This does not harm the motor.

Parking

This function is the recommended choice for applications where the motor is rotating at slow speed for example windmilling in fan applications. Parameter 2-06 Parking Current and parameter 2-07 Parking Time can be adjusted. Increase the factory setting of these parameters for applications with high inertia.

Start the motor at nominal speed. If the application does not run well, check the VVC+ PM settings. Table 5.7 shows recommendations in dierent applications.

Application Settings

Low-inertia applications I

Load/IMotor

Low-inertia applications 50>I High-inertia applications I

Load/IMotor

High load at low speed <30% (rated speed)

Load/IMotor

Table 5.8 Recommendations in Dierent Applications

> 50

Increase parameter 1-17 Voltage lter time const. by factor 5–10 Reduce parameter 1-14 Damping Gain. Reduce parameter 1-66 Min. Current at Low Speed (<100%). Keep the calculated values.

Increase parameter 1-14 Damping

Gain, parameter 1-15 Low Speed Filter Time Const., and parameter 1-16 High Speed Filter Time Const.. Increase parameter 1-17 Voltage lter time const.. Increase parameter 1-66 Min. Current at Low Speed (>100% for a

prolonged time can overheat the motor).

If the motor starts oscillating at a certain speed, increase parameter 1-14 Damping Gain. Increase the value in small steps. Depending on the motor, a good value for this parameter can be 10% or 100% higher than the default value.

Starting torque can be adjusted in parameter 1-66 Min. Current at Low Speed. 100% provides nominal torque as starting torque.

5.4.6

Automatic Energy Optimisation (AEO)

NOTICE

AEO is not relevant for permanent magnet motors.

AEO is a procedure which minimises voltage to the motor, thereby reducing energy consumption, heat, and noise.

5 5

Commissioning

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

To activate AEO, set parameter 1-03 Torque Characteristics to [2] Auto Energy Optim. CT or [3] Auto Energy Optim. VT.

5.4.7 Automatic Motor Adaptation (AMA)

AMA is a procedure which optimises compatibility between the frequency converter and the motor.

The frequency converter builds a mathematical

•

model of the motor for regulating output motor current. The procedure also tests the input phase

To run AMA

5.5

balance of electrical power. It compares the motor characteristics with the entered nameplate data.

The motor shaft does not turn and no harm is

•

done to the motor while running the AMA. Some motors may be unable to run the complete

•

version of the test. In that case, select [2] Enable reduced AMA.

If an output

•

select [2] Enable reduced AMA. If warnings or alarms occur, see

•

chapter 7 Diagnostics and Troubleshooting. Run this procedure on a cold motor for best

•

results.

1. Press [Main Menu] to access parameters.

Scroll to parameter group 1-** Load and Motor and press [OK].

Scroll to parameter group 1-2* Motor Data and press [OK].

Scroll to parameter 1-29 Automatic Motor Adaptation (AMA) and press [OK].

Select [1] Enable complete AMA and press [OK].

6. Follow the on-screen instructions.

7. The test runs automatically and indicates when it is complete.

8. The advanced motor data is entered in parameter group 1-3* Adv. Motor Data.

lter is connected to the motor,

Checking Motor Rotation

NOTICE

Risk of damage to pumps/compressors caused by motor running in wrong direction. Before running the frequency converter, check the motor rotation.

1. Press [Main Menu].

Scroll to parameter 1-28 Motor Rotation Check and press [OK].

Scroll to [1] Enable.

The following text appears: Note! Motor may run in wrong direction.

4. Press [OK].

5. Follow the on-screen instructions.

NOTICE

To change the direction of rotation, remove power to the frequency converter and wait for power to discharge. Reverse the connection of any 2 of the 3 motor wires on the motor or frequency converter side of the connection.

5.6 Local Control Test

1. Press [Hand On] to provide a local start command to the frequency converter.

2. Accelerate the frequency converter by pressing [▲] to full speed. Moving the cursor left of the

decimal point provides quicker input changes.

3. Note any acceleration problems.

4. Press [O]. Note any deceleration problems.

In the event of acceleration or deceleration problems, see chapter 7.5 Troubleshooting. See chapter 7.3 Warnings and

Denitions - Frequency Converter for resetting the

Alarm

frequency converter after a trip.

5.7

System Start-up

The procedure in this section requires wiring and application programming to be completed. The following procedure is recommended after application set-up is completed.

1. Press [Auto On].

2. Apply an external run command.

3. Adjust the speed reference throughout the speed range.

4. Remove the external run command.

5. Check the sound and vibration levels of the motor to ensure that the system is working as intended.

If warnings or alarms occur, see chapter 7.3 Warnings and

Denitions - Frequency Converter or

Alarm chapter 7.4 Warnings and Alarm Denitions - Active Filter.

The motor runs briey at 5 Hz or the minimum frequency set in parameter 4-12 Motor Speed Low Limit [Hz].

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB929.10

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB930.10

Application Examples

6 Application Examples

Operating Instructions

6.1 Introduction

The examples in this section are intended as a quick reference for common applications.

Parameter settings are the regional default values

•

unless otherwise indicated (selected in parameter 0-03 Regional Settings).

Parameters associated with the terminals and

•

their settings are shown next to the drawings. Required switch settings for analog terminals A53

•

or A54 are also shown.

NOTICE

When using the optional STO feature, a jumper wire may be required between terminal 12 (or 13) and terminal 37 for the frequency converter to operate with factory default programming values.

NOTICE

The following examples refer only to the frequency converter control card (right LCP), not the lter.

6.2 Application Examples

CAUTION

Thermistors must use reinforced or double insulation to meet PELV insulation requirements.

Parameter 1-29 A utomatic Motor Adaptation (AMA) Parameter 5-12 T erminal 27 Digital Input

*=Default value Notes/comments: Parameter group 1–2* Motor Data must be set according to motor

Table 6.1 AMA with T27 Connected

Parameter 1-29 A utomatic Motor Adaptation (AMA) Parameter 5-12 T erminal 27 Digital Input

*=Default value Notes/comments: Parameter group 1–2* Motor Data must be set according to motor

Parameters

Function Setting

[1] Enable complete AMA

[2]* Coast inverse

6 6

Parameters

Function Setting

[1] Enable complete AMA

[0] No operation

Table 6.2 AMA without T27 Connected

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

-10 - +10V

130BB926.10

130BB927.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

4 - 20mA

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BB802.10

130BB805.11

Speed

Start (18)

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB803.10

Application Examples

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

Parameters

Function Setting

Parameter 6-10 T

0.07 V*

erminal 53 Low Voltage Parameter 6-11 T

10 V*

erminal 53 High Voltage Parameter 6-14 T

0 RPM

erminal 53 Low Ref./Feedb. Value Parameter 6-15 T

1500 RPM

erminal 53 High Ref./Feedb. Value

*=Default value

Notes/comments:

Parameters

Function Setting

Parameter 5-10 T

[8] Start*

erminal 18 Digital Input Parameter 5-12 T erminal 27

[0] No operation

Digital Input Parameter 5-19 T erminal 37 Safe

[1] Safe Stop Alarm

Stop

*=Default value

Notes/comments:

If parameter 5-12 Terminal 27 Digital Input is set to [0] No operation, a jumper wire to

terminal 27 is not needed.

Table 6.5 Start/Stop Command with Safe Torque O

Table 6.3 Analog Speed Reference (Voltage)

Parameters

Function Setting

Parameter 6-12 T

4 mA*

erminal 53 Low Current Parameter 6-13 T erminal 53 High

20 mA*

Illustration 6.1 Start/Stop with Safe Torque O

Current

0 RPM

1500 RPM

Table 6.6 Pulse Start/Stop

Parameters

Function Setting

Parameter 5-10 T erminal 18

[9] Latched Start

Digital Input Parameter 5-12 T erminal 27

[6] Stop Inverse

Digital Input

*=Default value

Notes/comments:

If parameter 5-12 Terminal 27 Digital Input is set to [0] No operation, a jumper wire to

terminal 27 is not needed.

Table 6.4 Analog Speed Reference (Current)

Parameter 6-14 T erminal 53 Low Ref./Feedb. Value Parameter 6-15 T erminal 53 High Ref./Feedb. Value

*=Default value

Notes/comments:

Speed

130BB806.10

Latched Start (18)

Stop Inverse (27)

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB934.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BB928.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

≈ 5kΩ

130BB683.10

Application Examples

Operating Instructions

Parameters

Function Setting

Parameter 5-11 T

[1] Reset

erminal 19 Digital Input

*=Default value

Notes/comments:

Illustration 6.2 Latched Start/Stop Inverse

Parameters

Function Setting

Parameter 5-10 Ter

[8] Start

minal 18 Digital Input Parameter 5-11 Ter minal 19 Digital Input

Parameter 5-12 Ter minal 27 Digital Input Parameter 5-14 Ter minal 32 Digital Input Parameter 5-15 Ter minal 33 Digital Input Parameter 3-10 Pre set Reference

Preset ref. 0 Preset ref. 1 Preset ref. 2

Table 6.7 Start/Stop with Reversing and 4 Preset Speeds

Preset ref. 3 *=Default value

Notes/comments:

[10] Reversing*

[0] No operation

[16] Preset ref bit 0

[17] Preset ref bit 1

25% 50% 75% 100%

Table 6.8 External Alarm Reset

Parameters

Function Setting

Parameter 6-10 T

0.07 V*

erminal 53 Low Voltage Parameter 6-11 T

10 V*

erminal 53 High Voltage Parameter 6-14 T

0 RPM

erminal 53 Low Ref./Feedb. Value Parameter 6-15 T

1500 RPM

erminal 53 High Ref./Feedb. Value

*=Default value

Notes/comments:

Table 6.9 Speed Reference (using a Manual Potentiometer)

6 6

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB804.10

Start ( 18)

Freeze ref ( 27)

Speed up (29 )

Speed down ( 32)

Speed

Reference

130BB840.11

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

R1R2

61 68 69

RS-485

130BB685.10

130BB686.12

VLT

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

A53

U - I

D IN

Application Examples

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

Parameters

Function Setting

Parameter 5-10 T

[8] Start*

erminal 18 Digital Input Parameter 5-12 T erminal 27

[19] Freeze Reference

Digital Input Parameter 5-13 T erminal 29

[21] Speed Up

Digital Input Parameter 5-14 T erminal 32

[22] Speed Down

Parameters

Function Setting

Parameter 8-30 P rotocol Parameter 8-31 A

FC* 1*

ddress Parameter 8-32 B

9600*

aud Rate

*=Default value

Notes/comments:

Select protocol, address, and Baud rate in the abovementioned parameters.

Digital Input

*=Default value

Notes/comments:

Table 6.10 Speed Up/Down

Table 6.11 RS485 Network Connection

Parameters

Function Setting

Illustration 6.3 Speed Up/Down

Table 6.12 Motor Thermistor

Parameter 1-90 Motor Thermal Protection Parameter 1-93 T hermistor Source

*=Default value

Notes/comments:

If only a warning is desired, set

parameter 1-90 Motor Thermal Protection to [1] Thermistor warning.

[2] Thermistor trip [1] Analog input 53

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

R1R2

130BB839.10

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

R1R2

130BB841.10

Start ( 18)

Start

reversing (19)

Relay output

Speed

Time

Current

1-71

2-21

1-76

Open

Closed

130BB842.10

Application Examples Operating Instructions

Parameters

Function Setting

Parameter 4-30

[1] Warning

Motor Feedback Loss Function Parameter 4-31

100 RPM

Motor Feedback Speed Error Parameter 4-32

5 s

Motor Feedback Loss Timeout Parameter 7-00 S

[2] MCB 102

peed PID Feedback Source Parameter 17-11

1024*

Resolution (PPR) Parameter 13-00

[1] On

SL Controller Mode Parameter 13-01

[19] Warning

Start Event Parameter 13-02 Stop Event Parameter 13-10 Comparator

[44] Reset key [21] Warning no.

Operand Parameter 13-11

[1] ≈*

Comparator Operator Parameter 13-12

Comparator Value Parameter 13-51 SL Controller

[22] Comparator 0

Event Parameter 13-52 SL Controller Action Parameter 5-40 F unction Relay

[32] Set digital out A low [80] SL digital output A

*=Default value

Notes/comments:

If the limit in the feedback monitor is exceeded, Warning 90 is issued. The SLC monitors the warning and in the case that it becomes TRUE, relay 1 is triggered. External equipment may indicate that service is required. If the feedback error goes below the limit again within 5 s, the frequency converter continues and the warning disappears. But relay 1 is still triggered until pressing [Reset] on the LCP.

Parameters

Function Setting

Parameter 1-00 C onguration

Mode Parameter 1-01

[0] Speed open loop

[1] VVC

Motor Control Principle Parameter 5-40 F unction Relay Parameter 5-10 T

[32] Mech. brake ctrl. [8] Start*

erminal 18 Digital Input Parameter 5-11 T erminal 19

[11] Start reversing

Digital Input Parameter 1-71 S

0.2

tart Delay Parameter 1-72 S tart Function

[5] VVC+/ FLUX Clockwise

Parameter 1-76 S

m,n

tart Current Parameter 2-20 R elease Brake

App. dependent

Current Parameter 2-21 A ctivate Brake Speed [RPM]

Half of nominal slip of the motor

*=Default value

Notes/comments:

Table 6.14 Mechanical Brake Control (Open Loop)

Illustration 6.4 Mechanical Brake Control (Open Loop)

6 6

Table 6.13 Using SLC to Set a Relay

Status

799RPM 7.83A 36.4kW

0.000

53.2%

1(1)

Auto Hand O

Remote Local

Ramping Stop Running Jogging . . . Stand by

130BB037.11

1 2 3

Diagnostics and Troubleshoo...

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

7 Diagnostics and Troubleshooting

7.1 Status Messages

7.2.2

Alarm Trip

When the frequency converter is in Status mode, status messages are generated automatically and appear in the bottom line of the display (see Illustration 7.1). Refer to the

VLT® AutomationDrive FC 302 Programming Guide for detailed descriptions of the displayed status messages.

1 Operation mode 2 Reference site 3 Operation status

Illustration 7.1 Status Display

7.2 Warning and Alarm Types

The frequency converter monitors the condition of its input power, output, and motor factors, as well as other system performance indicators. A warning or alarm does not necessarily indicate a problem internally the frequency converter. In many cases, it indicates failure conditions from:

Input voltage.

•

Motor load.

•

Motor temperature.

•

External signals.

•

Other areas monitored by internal logic.

•

Investigate as indicated in the alarm or warning.

7.2.1

Warnings

A warning is issued when an alarm condition is impending or when an abnormal operating condition is present and may result in the frequency converter issuing an alarm. A warning clears by itself when the abnormal condition is removed.

An alarm is issued when the frequency converter is tripped, that is, the frequency converter suspends operation to prevent frequency converter or system damage. The motor coasts to a stop, if the alarm trip is on the frequency converter side. The frequency converter logic continues to operate and monitors the frequency converter status. After the fault condition is remedied, reset the frequency converter. It is then ready to start operation again.

A trip can be reset in any of 4 ways:

Press [Reset] on the LCP.

•

Digital reset input command.

•

Serial communication reset input command.

•

Auto reset.

•

Alarm Trip-lock

7.2.3

An alarm that causes the frequency converter to trip-lock requires that input power is cycled. If the alarm trip is on the frequency converter side, the motor coasts to a stop. The frequency converter logic continues to operate and monitors the frequency converter status. Remove input power to the frequency converter and correct the cause of the fault, then restore power. This action puts the frequency converter into a trip condition as described in chapter 7.2.2 Alarm Trip and may be reset in any of the 4 ways.

7.3

Warnings and Alarm Denitions Frequency Converter

The following warning/alarm information denes each warning/alarm condition, provides the probable cause for the condition, and details a remedy or troubleshooting procedure.

WARNING 1, 10 Volts low

The control card voltage is <10 V from terminal 50. Remove some of the load from terminal 50, as the 10 V supply is overloaded. Maximum 15 mA or minimum 590 Ω.

A short circuit in a connected potentiometer or incorrect wiring of the potentiometer can cause this condition.

Troubleshooting

Remove the wiring from terminal 50. If the

•

warning clears, the problem is with the wiring. If the warning does not clear, replace the control card.

Diagnostics and Troubleshoo...

Operating Instructions

WARNING/ALARM 2, Live zero error

This warning or alarm only appears if programmed in parameter 6-01 Live Zero Timeout Function. The signal on 1 of the analog inputs is less than 50% of the minimum value programmed for that input. Broken wiring or a faulty device sending the signal can cause this condition.

Troubleshooting

Check the connections on all the analog mains

•

terminals.

Control card terminals 53 and 54 for

signals, terminal 55 common. MCB 101 terminals 11 and 12 for signals,

terminal 10 common. MCB 109 terminals 1, 3, and 5 for

signals, terminals 2, 4, and 6 common.

Check that the frequency converter programming

•

and switch settings match the analog signal type. Perform an input terminal signal test.

•

WARNING/ALARM 3, No motor

No motor has been connected to the output of the frequency converter.

WARNING/ALARM 4, Mains phase loss

A phase is missing on the supply side, or the mains voltage imbalance is too high. This message also appears for a fault in the input Options are programmed in parameter 14-12 Function at Mains Imbalance.

Troubleshooting

Check the supply voltage and supply currents to

•

the frequency converter.

WARNING 5, DC link voltage high

The DC-link voltage (DC) is higher than the high-voltage warning limit. The limit depends on the frequency converter voltage rating. The unit is still active.

WARNING 6, DC link voltage low

The DC-link voltage (DC) is lower than the low-voltage warning limit. The limit depends on the frequency converter voltage rating. The unit is still active.

WARNING/ALARM 7, DC overvoltage

If the DC-link voltage exceeds the limit, the frequency converter trips after a time.

Troubleshooting

Connect a brake resistor.

•

Extend the ramp time.

•

Change the ramp type.

•

Activate the functions in parameter 2-10 Brake

•

Function. Increase parameter 14-26 Trip Delay at Inverter

•

Fault.

rectier on the frequency converter.

If the alarm/warning occurs during a power sag,

•

use kinetic back-up (parameter 14-10 Mains Failure).

WARNING/ALARM 8, DC under voltage

If the DC-link voltage drops below the undervoltage limit, the frequency converter checks if a 24 V DC back-up supply is connected. If no 24 V DC back-up supply is connected, the frequency converter trips after a xed time delay. The time delay varies with unit size.

Troubleshooting

Check that the supply voltage matches the

•

frequency converter voltage. Perform an input voltage test.

•

Perform a soft charge circuit test.

•

WARNING/ALARM 9, Inverter overload

The frequency converter has run with more than 100% overload for too long and is about to cut-out. The counter for electronic thermal inverter protection issues a warning at 98% and trips at 100%, while giving an alarm. The frequency converter cannot be reset until the counter is below 90%.

Troubleshooting

Compare the output current shown on the LCP

•

with the frequency converter rated current. Compare the output current shown on the LCP

•

with the measured motor current. Display the thermal frequency converter load on

•

the LCP and monitor the value. When running above the frequency converter continuous current rating, the counter increases. When running below the frequency converter continuous current rating, the counter decreases.

WARNING/ALARM 10, Motor overload temperature

According to the electronic thermal protection (ETR), the motor is too hot. Select whether the frequency converter issues a warning or an alarm when the counter reaches 100% in parameter 1-90 Motor Thermal Protection. The fault occurs when the motor runs with more than 100% overload for too long.

Troubleshooting

Check for motor overheating.

•

Check if the motor is mechanically overloaded.

•

Check that the motor current set in

•

parameter 1-24 Motor Current is correct. Ensure that the motor data in parameters 1–20 to

•

1–25 are set correctly. If an external fan is in use, check that it is

•

selected in parameter 1-91 Motor External Fan. Running AMA in parameter 1-29 Automatic Motor

•

Adaptation (AMA) tunes the frequency converter to the motor more accurately and reduces thermal loading.

7 7

Diagnostics and Troubleshoo...

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

WARNING/ALARM 11, Motor thermistor overtemp

The thermistor may be disconnected. Select whether the frequency converter issues a warning or an alarm in parameter 1-90 Motor Thermal Protection.

Troubleshooting

Check for motor overheating.

•

Check if the motor is mechanically overloaded.

•

Check that the thermistor is connected correctly

•

between either terminal 53 or 54 (analog voltage input) and terminal 50 (+10 V supply). Also check that the terminal switch for 53 or 54 is set for voltage. Check that parameter 1-93 Thermistor Resource is set to terminal 53 or 54.

When using digital inputs 18 or 19, check that

•

the thermistor is connected correctly between either terminal 18 or 19 (digital input PNP only) and terminal 50.

WARNING/ALARM 12, Torque limit

The torque has exceeded the value in

parameter 4-16 Torque Limit Motor Mode or the value in parameter 4-17 Torque Limit Generator Mode. Parameter 14-25 Trip Delay at Torque Limit can change this

warning from a warning-only condition to a warning followed by an alarm.

Troubleshooting

WARNING/ALARM 13, Over current

The inverter peak current limit (approximately 200% of the rated current) is exceeded. The warning lasts approximately

1.5 s, then the frequency converter trips and issues an alarm. Shock loading or quick acceleration with high-inertia loads can cause this fault. If the acceleration during rampup is quick, the fault can also appear after kinetic back-up. If extended mechanical brake control is selected, a trip can be reset externally.

If a KTY sensor is used, check for correct

•

connection between terminals 54 and 55 If using a thermal switch or thermistor, check that

•

the programming of parameter 1-93 Thermistor Resource matches sensor wiring.

If using a KTY Sensor, check the programming of

•

parameter 1-95 KTY Sensor Type, parameter 1-96 KTY Thermistor Resource and parameter 1-97 KTY Threshold level match sensor

wiring.

If the motor torque limit is exceeded during

•

ramp-up, extend the ramp-up time. If the generator torque limit is exceeded during

•

ramp-down, extend the ramp-down time. If torque limit occurs while running, increase the

•

torque limit. Make sure that the system can operate safely at a higher torque.

Check the application for excessive current draw

•

on the motor.

Troubleshooting

Remove the power and check if the motor shaft

•

can be turned. Check that the motor size matches the frequency

•

converter. Check that the motor data is correct in

•

parameters 1–20 to 1–25.

ALARM 14, Earth (ground) fault

There is current from the output phases to ground, either in the cable between the frequency converter and the motor, or in the motor itself.

Troubleshooting

Remove the power to the frequency converter

•

and repair the ground fault. Check for ground faults in the motor by

•

measuring the resistance to the ground of the motor cables and the motor with a megohmmeter.

Perform a current sensor test.

•

ALARM 15, Hardware mismatch

tted option is not operational with the present control

board hardware or software. Record the value of the following parameters and contact

Danfoss:

Parameter 15-40 FC Type.

•

Parameter 15-41 Power Section.

•

Parameter 15-42 Voltage.

•

Parameter 15-43 Software Version.

•

Parameter 15-45 Actual Typecode String.

•

Parameter 15-49 SW ID Control Card.

•

Parameter 15-50 SW ID Power Card.

•

Parameter 15-60 Option Mounted.

•

Parameter 15-61 Option SW Version (for each

•

option slot).

ALARM 16, Short circuit

There is short-circuiting in the motor or motor wiring.

Troubleshooting

Remove the power to the frequency converter

•

and repair the short circuit.

WARNING/ALARM 17, Control word timeout

There is no communication with the frequency converter. The warning is only active when parameter 8-04 Control Word Timeout Function is not set to [0] If parameter 8-04 Control Word Timeout Function is set to [2] Stop and [26] Trip, a warning appears and the frequency converter ramps down until it trips and then displays an alarm.

O.

Diagnostics and Troubleshoo...

Operating Instructions

Troubleshooting

Check the connections on the serial communi-

•

cation cable. Increase parameter 8-03 Control Word Timeout

•

Time

Check the operation of the communication

•

equipment. Verify a proper installation based on EMC

•

requirements.

WARNING/ALARM 22, Hoist mechanical brake

Report value shows what kind it is. 0 = The torque reference was not reached before timeout (parameter 2-27 Torque Ramp Up Time). 1 = Expected brake feedback not received before timeout (parameter 2-23 Activate Brake Delay, parameter 2-25 Brake Release Time).

WARNING 23, Internal fan fault

The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ([0] Disabled).

Troubleshooting

Check the fan resistance.

•

Check the soft charge fuses.

•

WARNING 24, External fan fault

The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ([0] Disabled).

Troubleshooting

Check the fan resistance.

•

Check the soft charge fuses.

•

WARNING 25, Brake resistor short circuit

The brake resistor is monitored during operation. If a short circuit occurs, the brake function is disabled and the warning appears. The frequency converter is still operational, but without the brake function.

Troubleshooting

Remove the power to the frequency converter

•

and replace the brake resistor (see parameter 2-15 Brake Check).

WARNING/ALARM 26, Brake resistor power limit

The power transmitted to the brake resistor is calculated as a mean value over the last 120 s of run time. The calculation is based on the intermediate circuit voltage and the brake resistance value set in parameter 2-16 AC brake Max. Current. The warning is active when the dissipated braking is >90% of the brake resistance power. If [2] Trip is selected in parameter 2-13 Brake Power Monitoring, the frequency converter trips when the dissipated braking power reaches 100%.

WARNING

If the brake transistor is short-circuited, there is a risk of substantial power being transmitted to the brake resistor.

WARNING/ALARM 27, Brake chopper fault

This alarm/warning could occur if the brake resistor overheats. Terminals 104 and 106 are available as brake resistors Klixon inputs.

NOTICE

This signal feedback is used by LHD to monitor the temperature of the HI inductor. This fault indicates that Klixon opened on the HI inductor at the active lter side.

WARNING/ALARM 28, Brake check failed

The brake resistor is not connected or not working. Check parameter 2-15 Brake Check.

ALARM 29, Heat Sink temp

The maximum temperature of the heat sink has been exceeded. The temperature fault resets when the temperature falls below a dened heat sink temperature. The trip and reset points vary based on the frequency converter power size.

Troubleshooting

Check for the following conditions.

Ambient temperature too high.

•

Motor cables too long.

•

Incorrect airow clearance above and below the

•

frequency converter. Blocked airow around the frequency converter.

•

Damaged heat sink fan.

•

Dirty heat sink.

•

For D, E, and F enclosures, this alarm is based on the temperature measured by the heat sink sensor mounted inside the IGBT modules. For the F enclosures, the thermal sensor in the rectier module can also cause this alarm.

Troubleshooting

Check the fan resistance.

•

Check the soft charge fuses.

•

Check the IGBT thermal sensor.

•

ALARM 30, Motor phase U missing

Motor phase U between the frequency converter and the motor is missing.

Troubleshooting

Remove the power from the frequency converter

•

and check motor phase U.

ALARM 31, Motor phase V missing

Motor phase V between the frequency converter and the motor is missing.

7 7

Diagnostics and Troubleshoo...

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

Troubleshooting

Remove the power from the frequency converter

•

and check motor phase V.

ALARM 32, Motor phase W missing

Motor phase W between the frequency converter and the motor is missing.

Troubleshooting

Remove the power from the frequency converter

•

and check motor phase W.

ALARM 33, Inrush fault

Too many power-ups have occurred within a short time period.

Troubleshooting

Let the unit cool to operating temperature.

•

WARNING/ALARM 34, Fieldbus communication fault

The

eldbus on the communication option card is not

working.

WARNING/ALARM 36, Mains failure

This warning/alarm is only active if the supply voltage to the frequency converter is lost and parameter 14-10 Mains Failure is not set to option [0] No Function. Check the fuses to the frequency converter and mains supply to the unit.

ALARM 38, Internal fault

When an internal fault occurs, a code number

dened in

Table 7.1 is displayed.

Troubleshooting

Cycle the power.

•

Check that the option is properly installed.

•

Check for loose or missing wiring.

•

It may be necessary to contact Danfoss Service or the supplier. Note the code number for further troubleshooting directions.

Number Text

0 The serial port cannot be initialised. Contact your

Danfoss supplier or Danfoss Service.

256–258 The power EEPROM data is defective or too old.

512 The control board EEPROM data is defective or too

old. 513 Communication time-out reading EEPROM data 514 Communication time-out reading EEPROM data 515 Application-oriented control cannot recognise the

EEPROM data. 516 Cannot write to the EEPROM because a write

command is in progress. 517 The write command is under time-out. 518 Failure in the EEPROM. 519 Missing or invalid barcode data in EEPROM. 783 Parameter value outside of minimum/maximum

limits.

1024–1279 A CAN telegram could not be sent.

1281 Digital signal processor ash time-out.

Number Text

1282 Power micro software version mismatch. 1283 Power EEPROM data version mismatch. 1284 Cannot read digital signal processor software

version. 1299 The option software in slot A is too old. 1300 The option software in slot B is too old. 1301 The option software in slot C0 is too old. 1302 The option software in slot C1 is too old. 1315 The option software in slot A is not supported (not

allowed). 1316 The option software in slot B is not supported (not

allowed). 1317 The option software in slot C0 is not supported

(not allowed). 1318 The option software in slot C1 is not supported

(not allowed). 1379 Option A did not respond when calculating the

platform version 1380 Option B did not respond when calculating the

platform version. 1381 Option C0 did not respond when calculating the

platform version. 1382 Option C1 did not respond when calculating the

platform version. 1536 An exception in the application-oriented control is

registered. The debug information is written on

the LCP. 1792 DSP Watch Dog is active. Debugging of power part

data, motor-oriented control data not transferred

correctly. 2049 Power data restarted.

2064–2072 H081x: Option in slot x has restarted. 2080–2088 H082x: Option in slot x has issued a power-up

wait.

2096–2104 H983x: Option in slot x has issued a legal power-

up wait. 2304 Could not read any data from the power EEPROM. 2305 Missing software version from the power unit. 2314 Missing power unit data from the power unit. 2315 Missing software version from the power unit. 2316 Missing lo_statepage from the power unit. 2324 The power card conguration is determined to be

incorrect at power-up. 2325 A power card has stopped communicating while

mains power is applied. 2326 The power card conguration is determined to be

incorrect after the delay for power cards to

registered as present. 2330 The power size information between the power

cards does not match. 2561 No communication from DSP to ATACD.

Diagnostics and Troubleshoo...

Operating Instructions

Number Text

2562 No communication from ATACD to DSP (state

running). 2816 Stack overow control board module 2817 Scheduler slow tasks 2818 Fast tasks 2819 Parameter thread 2820 LCP stack overow 2821 Serial port overow 2822 USB port overow 2836 cfListMempool is too small.

3072–5122 The parameter value is outside its limits.

5123 Option in slot A: Hardware incompatible with the

control board hardware. 5124 Option in slot B: Hardware incompatible with the

control board hardware. 5125 Option in slot C0: Hardware incompatible with the

control board hardware. 5126 Option in slot C1: Hardware incompatible with the

control board hardware.

5376–6231 Out of memory

Table 7.1 Internal Fault, Code Numbers

ALARM 39, Heat sink sensor

No feedback from the heat sink temperature sensor. The signal from the IGBT thermal sensor is not available on

the power card. The problem could be on the power card, on the gate drive card, or the ribbon cable between the power card and gate drive card.

WARNING 40, Overload of digital output terminal 27

Check the load connected to terminal 27 or remove the short circuit connection. Check parameter 5-00 Digital I/O Mode and parameter 5-01 Terminal 27 Mode.

WARNING 41, Overload of digital output terminal 29

Check the load connected to terminal 29 or remove the short circuit connection. Check parameter 5-00 Digital I/O Mode and parameter 5-02 Terminal 29 Mode.

WARNING 42, Overload of digital output on X30/6 or overload of digital output on X30/7

For X30/6, check the load connected to X30/6 or remove the short circuit connection. Check parameter 5-32 Term X30/6 Digi Out (MCB 101).

For X30/7, check the load connected to X30/7 or remove the short-circuit connection. Check parameter 5-33 Term X30/7 Digi Out (MCB 101).

ALARM 45, Earth fault 2

Ground fault.

Troubleshooting

Check for proper grounding and loose

•

connections. Check for proper wire size.

•

Check the motor cables for short circuits or

•

leakage currents.

ALARM 46, Power card supply

The supply on the power card is out of range. There are 3 power supplies generated by the switch mode

power supply (SMPS) on the power card: 24 V, 5 V, and ±18 V. When powered with 24 V DC with the MCB 107 option, only the 24 V and 5 V supplies are monitored. When powered with 3-phase mains voltage, all 3 supplies are monitored.

WARNING 47, 24 V supply low

The supply on the power card is out of range. There are 3 supplies generated by the switch mode supply

(SMPS) on the power card:

24 V.

•

5 V.

•

±18 V.

•

Troubleshooting

Check for a defective power card.

•

WARNING 48, 1.8 V supply low

The 1.8 V DC supply used on the control card is outside of the allowable limits. The supply is measured on the control card. Check for a defective control card. If an option card is present, check for overvoltage.

WARNING 49, Speed limit

When the speed is outside of the specied range in

parameter 4-11 Motor Speed Low Limit [RPM] and parameter 4-13 Motor Speed High Limit [RPM], the frequency

converter shows a warning. When the speed is below the specied limit in parameter 1-86 Trip Speed Low [RPM] (except when starting or stopping), the frequency converter trips.

ALARM 50, AMA calibration failed

Contact the Danfoss supplier or Danfoss Service.

ALARM 51, AMA check U

The settings for motor voltage, motor current, and motor power are wrong. Check the settings in parameters 1–20 to 1–25.

ALARM 52, AMA low I

The motor current is too low. Check the settings in parameter 4-18 Current Limit.

ALARM 53, AMA motor too big

The motor is too big for the AMA to operate.

ALARM 54, AMA motor too small

The motor is too small for the AMA to operate.

ALARM 55, AMA parameter out of range

The parameter values of the motor are outside of the acceptable range. AMA cannot run.

ALARM 56, AMA interrupted by user

The user has interrupted AMA.

nom

and I

nom

7 7

Diagnostics and Troubleshoo...

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

ALARM 57, AMA internal fault

Continue to restart the AMA, until the AMA is carried out.

NOTICE

Repeated runs may heat the motor to a level where the resistance Rs and Rr are increased. In most cases, however, this behaviour is not critical.

ALARM 58, AMA Internal fault

Contact the Danfoss supplier.

WARNING 59, Current limit

The current is higher than the value in

parameter 4-18 Current Limit. Ensure that motor data in parameters 1–20 to 1–25 are set correctly. Increase the

current limit if necessary. Ensure that the system can operate safely at a higher limit.

WARNING 60, External interlock

External interlock has been activated. To resume normal operation, apply 24 V DC to the terminal programmed for external interlock and reset the frequency converter (via serial communication, digital I/O, or by pressing [Reset]).

WARNING/ALARM 61, Tracking error

An error has occurred between the calculated motor speed and the speed measurement from the feedback device. The function warning/alarm/disable is set in parameter 4-30 Motor Feedback Loss Function. Accepted error setting in parameter 4-31 Motor Feedback Speed Error and the allowed time the error occur setting in parameter 4-32 Motor Feedback Loss Timeout. During a commissioning procedure, the function could be

WARNING 62, Output frequency at maximum limit

The output frequency is higher than the value set in parameter 4-19 Max Output Frequency.

ALARM 63, Mechanical brake low

The actual motor current has not exceeded the release brake current within the start delay time window.

ALARM 64, Voltage Limit

The load and speed combination demands a motor voltage higher than the actual DC-link voltage.

WARNING/ALARM 65, Control card over temperature

The cut-out temperature of the control card is 80 °C.

Troubleshooting

Check that the ambient operating temperature is

•

within the limits. Check for clogged lters.

•

Check the fan operation.

•

Check the control card.

•

WARNING 66, Heat sink temperature low

The frequency converter is too cold to operate. This warning is based on the temperature sensor in the IGBT module.

eective.

Increase the ambient temperature of the unit. Also, a trickle amount of current can be supplied to the frequency converter whenever the motor is stopped by setting

parameter 2-00 DC Hold/Preheat Current at 5% and parameter 1-80 Function at Stop.

Troubleshooting

The heat sink temperature measured as 0 °C could indicate that the temperature sensor is defective, causing the fan speed to increase to the maximum. This warning results if the sensor wire between the IGBT and the gate drive card is disconnected. Also, check the IGBT thermal sensor.

ALARM 67, Option module conguration has changed

1 or more options have either been added or removed since the last power-down. Check that the conguration change is intentional and reset the unit.

ALARM 68, Safe Stop activated

STO has been activated. To resume normal operation, apply 24 V DC to terminal 37, then send a reset signal (via bus, digital I/O, or by pressing [Reset].

ALARM 69, Power card temperature

The temperature sensor on the power card is either too hot or too cold.

Troubleshooting

Check the operation of the door fans.

•

Check that the lters for the door fans are not

•

blocked. Check that the gland plate is properly installed

•

on IP21/IP54 (NEMA 1/12) frequency converters.

ALARM 70, Illegal FC conguration

The control card and power card are incompatible. To check compatibility, contact the Danfoss supplier with the type code of the unit from the nameplate and the part numbers of the cards.

ALARM 71, PTC 1 Safe Torque O

STO has been activated from the VLT® PTC Thermistor Card MCB 112 (motor too warm). Normal operation can resume

when the VLT® PTC Thermistor Card MCB 112 applies 24 V DC to terminal 37 (when the motor temperature is

acceptable ) and when the digital input from the VLT® PTC Thermistor Card MCB 112 is deactivated. When that happens, a reset signal is be sent (via Bus, Digital I/O, or by pressing [Reset]).

NOTICE

If automatic restart is enabled, the motor could start when the fault is cleared.

ALARM 72, Dangerous failure

STO with trip lock. Unexpected signal levels on safe stop and digital input from the VLT® PTC Thermistor Card MCB

112.

WARNING 73, Safe Stop auto restart

Safe Torque O activated. With automatic restart enabled, the motor can start when the fault is cleared.

Diagnostics and Troubleshoo...

Operating Instructions

WARNING 76, Power unit setup

The required number of power units does not match the detected number of active power units.

Troubleshooting

When replacing an F-frame module, this warning occurs, if the power-specic data in the module power card does not match the rest of the frequency converter. Conrm that the spare part and its power card are the correct part number.

WARNING 77, Reduced power mode

The frequency converter is operating in reduced power mode (less than the allowed number of inverter sections). This warning is generated on power cycle when the frequency converter is set to run with fewer inverters and remains on.

ALARM 79, Illegal power section

The scaling card has an incorrect part number or is not installed. The MK102 connector on the power card could not be installed.

ALARM 80, Drive initialised to default value

Parameter settings are initialised to default settings after a manual reset. To clear the alarm, reset the unit.

ALARM 81, CSIV corrupt

CSIV le has syntax errors.

ALARM 82, CSIV parameter error

CSIV failed to initialise a parameter.

ALARM 85, Dang fail PB

PROFIBUS/PROFIsafe error.

WARNING/ALARM 104, Mixing fan fault

The fan is not operating. The fan monitor checks that the fan is spinning at power-up or whenever the mixing fan is turned on. The mixing-fan fault can be congured as a warning or an alarm trip in parameter 14-53 Fan Monitor.

Troubleshooting

Cycle power to the frequency converter to

•

determine if the warning/alarm returns.

ALARM 243, Brake IGBT

This alarm is only for enclosure size F frequency converters. It is equivalent to Alarm 27. The report value in the alarm log indicates which power module generated the alarm:

1 = Left most inverter module. 2 = Middle inverter module in enclosure sizes F12

or F13. 2 = Right inverter module in enclosure sizes F10

or F11. 2 = Second frequency converter from the left

inverter module in enclosure size F14. 3 = Right inverter module in enclosure sizes F12

or F13. 3 = Third from the left intverter module in

enclosure size F14 or F15.

conguration

4 = Far right inverter module in enclosure size F14.

5 = Rectier module. 6 = Right rectier module in enclosure size F14 or

F15.

ALARM 244, Heat Sink temperature

This alarm is only for enclosure type F frequency converters. It is equivalent to Alarm 29. The report value in the alarm log indicates which power module generated the alarm:

1 = Left most inverter module. 2 = Middle inverter module in enclosure size F12

or F13. 2 = Right inverter module in enclosure size F10 or

F11. 2 = Second frequency converter from the left

inverter module in enclosure size F14 or F15. 3 = Rght inverter module in enclosure sizes F12

or F13. 3 = Tird from the left intverter module in

enclosure size F14 or F15. 4 = Far right inverter module in enclosure sizes

F14 or F15. 5 = Rectier module. 6 = Right rectier module in enclosure sizes F14

or F15.

ALARM 245, Heat Sink sensor

This alarm is only for enclosure size F frequency converters. It is equivalent to Alarm 39. The report value in the alarm log indicates which power module generated the alarm:

1 = Left most inverter module. 2 = Middle inverter module in enclosure sizes F12

or F13. 2 = Right inverter module in enclosure sizes F10

or F11. 2 = Second frequency converter from the left

inverter module in enclosure size F14 or F15. 3 = Right inverter module in enclosure sizes F12

or F13. 3 = Third from the left inverter module in

enclosure size F14 or F15. 4 = Far right inverter module in enclosure size

F14 or F15. 5 = Rectier module. 6 = Right rectier module in enclosure size F14 or

F15.

The 12-pulse frequency converter may generate this warning/alarm when one of the disconnects or circuit breakers is opened while the unit is on.

7 7

Diagnostics and Troubleshoo...

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

ALARM 246, Power card supply

This alarm is only for enclosure size F frequency converters. It is equivalent to Alarm 46. The report value in the alarm log indicates which power module generated the alarm:

1 = Left most inverter module. 2 = Middle inverter module in enclosure sizes F12

or F13. 2 = Right inverter module in enclosure sizes F10

or F11. 2 = Second frequency converter from the left

inverter module in enclosure size F14 or F15. 3 = Right inverter module in enclosure sizes F12

or F13. 3 = Third from the left inverter module in

enclosure size F14 or F15.

ALARM 247, Power card temperature

This alarm is only for enclosure size F frequency converters. It is equivalent to Alarm 69. The report value in the alarm log indicates which power module generated the alarm:

4 = Far right inverter module in enclosure size F14 or F15.

5 = Rectier module. 6 = Right rectier module in enclosure size F14 or

F15.

1 = Left most inverter module. 2 = Middle inverter module in enclosure sizes F12

or F13. 2 = Right inverter module in enclosure sizes F10

or F11. 2 = Second frequency converter from the left

inverter module in enclosure size F14 or F15. 3 = Right inverter module in enclosure sizes F12

or F13. 3 = Third from the left inverter module in

enclosure size F14 or F15. 4 = Far right inverter module in enclosure size

F14 or F15. 5 = Rectier module. 6 = Right rectier module in enclosure size F14 or

F15.

ALARM 248, Illegal power section

This alarm is only for enclosure size F frequency converters. It is equivalent to Alarm 79. The report value in the alarm log indicates which power module generated the alarm:

1 = Left most inverter module. 2 = Middle inverter module in enclosure sizes F12

or F13. 2 = Right inverter module in enclosure sizes F10

or F11. 2 = Second frequency converter from the left

inverter module in enclosure size F14 or F15. 3 = Right inverter module in enclosure sizes F12

or F13. 3 = Third from the left inverter module in

enclosure sizes F14 or F15. 4 = Far right inverter module in enclosure sizes

F14 or F15. 5 = Rectier module. 6 = Right rectier module in enclosure size F14 or

F15.

WARNING 250, New spare part

A component in the frequency converter has been replaced.

Troubleshooting

Reset the frequency converter for normal

•

operation.

WARNING 251, New typecode

The power card or other components have been replaced and the type code has been changed.

Troubleshooting

Reset to remove the warning and resume normal

•

operation.

conguration

Diagnostics and Troubleshoo... Operating Instructions

7.4 Warnings and Alarm Denitions - Active Filter

NOTICE

After a manual reset pressing [Reset], press [Auto On] or [Hand On] to restart the unit.

Number Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference

1 10 Volts low X 2 Live zero error (X) (X) 6-01 4 Mains phase loss X 5 DC link voltage high X 6 DC link voltage low X 7 DC over voltage X X 8 DC under voltage X X 13 Over current X X X 14 Earth fault X X X 15 Hardware mismatch X X 16 Short circuit X X 17 Control word timeout (X) (X) 8-04 23 Internal fan fault X 24 External fan fault X 14-53 29 Heatsink temp X X X 33 Inrush fault X X 34 Fieldbus fault X X 35 Option fault X X 38 Internal fault 39 Heatsink sensor X X 40 Overload of digital output terminal 27 (X) 5-00, 5-01 41 Overload of digital output terminal 29 (X) 5-00, 5-02 46 Pwr. card supply X X 47 24 V supply low X X X 48 1.8 V supply low X X 65 Control board over-temperature X X X 66 Heat sink temperature low X 67 Option conguration has changed X 68 Safe torque o activated X 69 Pwr. card temp X X 70 Illegal FC conguration X 72 Dangerous failure X 73 Safe torque o auto restart 76 Power unit setup X 79 Illegal PS cong X X 80 Unit initialised to default value X 250 New spare part X 251 New type code X X 300 Mains cont. fault X 301 SC cont. fault X 302 Cap. over current X X 303 Cap. earth fault X X 304 DC over current X X 305 Mains freq. limit X 306 Compensation Limit 308 Resistor temp X X 309 Mains earth fault X X

7 7

Diagnostics and Troubleshoo...

Number Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference

311 Switch. freq. limit X 312 CT range X 314 Auto CT interrupt X 315 Auto CT error X 316 CT location error X 317 CT polarity error X 318 CT ratio error X

Table 7.2 Alarm/Warning Code List

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

A trip is the action when an alarm has appeared. The trip disables the active lter and can be reset by pressing [Reset] or resetting via a digital input (parameter group 5-1* Digital Inputs [1] Reset). The original event that caused an alarm cannot damage the active lter or cause dangerous conditions. A trip lock is an action when an alarm occurs, which may cause damage to active lter or connected parts. A trip lock situation can only be reset by a power cycling.

Warning Yellow

Alarm Flashing red

Table 7.3 LED Indicator Lights

Trip locked Yellow and red

Diagnostics and Troubleshoo... Operating Instructions

Alarm word and extended status word Bit Hex Dec Alarm word Warning word Extended status word

0 00000001 1 Mains cont. fault Reserved Reserved 1 00000002 2 Heat sink temp Heat sink temp Auto CT running 2 00000004 4 Ground fault Ground fault Reserved 3 00000008 8 Ctrl.card temp Ctrl.card temp Reserved 4 00000010 16 Ctrl. word TO Ctrl. word TO Reserved 5 00000020 32 Over current Over current Reserved 6 00000040 64 SC cont. fault Reserved Reserved 7 00000080 128 Cap. over current Cap. over current Reserved 8 00000100 256 Cap. earth fault Cap. earth fault Reserved 9 00000200 512 Inverter overld. Inverter overld. Reserved 10 00000400 1024 DC under volt DC under volt Reserved 11 00000800 2048 DC over volt DC over volt Reserved 12 00001000 4096 Short circuit DC voltage low Reserved 13 00002000 8192 Inrush fault DC voltage high Reserved 14 00004000 16384 Mains ph. loss Mains ph. loss Reserved 15 00008000 32768 Auto CT error Reserved Reserved 16 00010000 65536 Reserved Reserved Reserved 17 00020000 131072 Internal fault 10 V low Password Time Lock 18 00040000 262144 DC over current DC over current Password Protection 19 00080000 524288 Resistor temp Resistor temp Reserved 20 00100000 1048576 Mains earth fault Mains earth fault Reserved 21 00200000 2097152 Switch. freq. limit Reserved Reserved 22 00400000 4194304 Fieldbus fault Fieldbus fault Reserved 23 00800000 8388608 24 V supply low 24 V supply low Reserved 24 01000000 16777216 CT range Reserved Reserved 25 02000000 33554432 1.8 V supply low Reserved Reserved 26 04000000 67108864 Reserved Low temp Reserved 27 08000000 134217728 Auto CT interrupt Reserved Reserved 28 10000000 268435456 Option change Reserved Reserved 29 20000000 536870912 Unit initialised Unit initialised Reserved 30 40000000 1073741824 Safe torque o Safe torque o Reserved 31 80000000 2147483648 Mains freq. limit Extended status word Reserved

7 7

Table 7.4 Description of Alarm Word, Warning Word, and Extended Status Word

The alarm words, warning words, and extended status words can be read out via serial bus or optional eldbus for diagnosis. See also parameter 16-90 Alarm Word, parameter 16-92 Warning Word, and parameter 16-94 Ext. Status Word. Reserved means that the bit is not guaranteed to be any particular value. Reserved bits should not be used for any purpose.

Diagnostics and Troubleshoo...

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

7.4.1 Fault Messages for Active Filter

WARNING 1, 10 volts low

The control card voltage is below 10 V from terminal 50. Remove some of the load from terminal 50, as the 10 V supply is overloaded. Maximum 15 mA or minimum 590 Ω.

WARNING/ALARM 2, Live zero error

The signal on terminal 53 or 54 is less than 50% of the value set in:

Parameter 6-10 Terminal 53 Low Voltage.

•

Parameter 6-12 Terminal 53 Low Current.

•

Parameter 6-20 Terminal 54 Low Voltage.

•

Parameter 6-22 Terminal 54 Low Current.

•

WARNING 4, Mains phase loss

A phase is missing on the supply side, or the mains

voltage imbalance is too high.

WARNING 5, DC-link voltage high

The DC-link voltage (DC) is higher than the high-voltage warning limit. The unit is still active.

WARNING 6, DC-link voltage low

The DC-link voltage (DC) is below the low-voltage warning limit. The unit is still active.

WARNING/ALARM 7, DC overvoltage

If the DC-link voltage exceeds the limit, the unit trips.

WARNING/ALARM 8, DC under voltage

If the DC-link voltage (DC) drops below the undervoltage limit, the lter checks if a 24 V back-up supply is connected. If not, the lter trips. Check that the mains voltage matches the nameplate specication.

WARNING/ALARM 13, Overcurrent

The unit current limit has been exceeded.

ALARM 14, Ground fault

The sum current of the IGBT CTs does not equal 0. Check if the resistance of any phase-to-ground has a low value. Check both before and after mains contactor. Ensure that IGBT current transducers, connection cables, and connectors are OK.

ALARM 15, Incomp. Hardware

A mounted option is incompatible with the present control card SW/HW.

ALARM 16, Short circuit

There is a short circuit in the output. Turn correct the error.

WARNING/ALARM 17, Control word time-out

There is no communication to the unit. The warning is only active when parameter 8-04 Control Word Timeout Function is not set to Possible correction: Increase parameter 8-03 Control Word

Timeout Time. Change parameter 8-04 Control Word Timeout Function

o the unit and

o.

WARNING 23, Internal fan fault

Internal fans have failed due to defect hardware or fans not mounted.

WARNING 24, External fan fault

External fans have failed due to defective hardware or fans not mounted.

ALARM 29, Heat sink temp

The maximum temperature of the heat sink has been exceeded. The temperature fault is not reset until the temperature drops below a dened heat sink temperature.

ALARM 33, Inrush fault

Check whether a 24 V external DC supply has been connected.

WARNING/ALARM 34, Fieldbus communication fault

The eldbus on the communication option card is not working.

WARNING/ALARM 35, Option fault:

Contact Danfoss or supplier.

ALARM 38, Internal fault

Contact Danfoss or supplier.

ALARM 39, Heat sink sensor

No feedback from the heat sink temperature sensor.

WARNING 40, Overload of digital output terminal 27

Check the load connected to terminal 27 or remove short circuit connection.

WARNING 41, Overload of digital output terminal 29

Check the load connected to terminal 29 or remove short circuit connection.

ALARM 46, Power card supply

The supply on the power card is out of range.

WARNING 47, 24 V supply low

Contact Danfoss or supplier.

WARNING 48, 1.8 V supply low

Contact Danfoss or supplier.

WARNING/ALARM/TRIP 65, Control card overtemperature

Control card overtemperature: The cut-out temperature of the control card is 80 °C.

WARNING 66, Heat sink temperature low

This warning is based on the temperature sensor in the IGBT module.

Troubleshooting

The heat sink temperature measured as 0 °C could indicate that the temperature sensor is defective, causing the fan speed to increase to the maximum. If the sensor wire between the IGBT and the gate drive card is disconnected, this warning would result. Also, check the IGBT thermal sensor.

ALARM 67, Option module

One or more options have either been added or removed since the last power-down.

conguration has changed

Diagnostics and Troubleshoo...

Operating Instructions

ALARM 68, Safe Torque O (STO) activated

Safe Torque O (STO) has been activated. To resume normal operation, apply 24 V DC to terminal 37, then send a reset signal (via bus, digital I/O, or by pressing [Reset]. See parameter 5-19 Terminal 37 Safe Stop.

ALARM 69, Power card temperature

The temperature sensor on the power card is either too hot or too cold.

ALARM 70, Illegal FC Conguration

Actual combination of control board and power board is illegal.

ALARM 79, Illegal power section

The scaling card is the incorrect part number or not installed. Also MK102 connector on the power card could not be installed.

ALARM 80, Unit initialised to default value

Parameter settings are initialised to default settings after a manual reset.

ALARM 247, Power card temperature

Power card overtemperature. A report value indicates the source of the alarm (from left): 1–4 inverter.

rectier.

5–8

ALARM 250, New spare part

The power or switch mode supply has been exchanged. Restore the lter type code in the EEPROM. Select the correct type code in parameter 14-23 Typecode Setting according to the label on the unit. Remember to select Save to EEPROM to complete.

ALARM 251, New type code

The lter has a new type code.

ALARM 300, Mains cont. fault

The feedback from the mains contactor did not match the expected value within the allowed time frame. Contact Danfoss or supplier.

ALARM 301, SC cont. fault

The feedback from the soft charge contactor did not match the expected value within the allowed time frame. Contact Danfoss or supplier.

ALARM 302, Cap. overcurrent

Excessive current was detected through the AC capacitors. Contact Danfoss or supplier.

conguration

ALARM 303, Cap. ground fault

A ground fault was detected through the AC capacitor currents. Contact Danfoss or supplier.

ALARM 304, DC overcurrent

Excessive current through the DC-link capacitor bank was detected. Contact Danfoss or supplier.

ALARM 305, Mains freq. limit

The mains frequency was outside the limits. Verify that the mains frequency is within product specication.

ALARM 306, Compensation limit

The needed compensation current exceeds unit capability. The unit runs at full compensation.

ALARM 308, Resistor temp

Excessive resistor heat sink temperature detected.

ALARM 309, Mains ground fault

A ground fault was detected in the mains currents. Check the mains for shorts and leakage current.

ALARM 310, RTDC buer full

Contact Danfoss or supplier.

ALARM 311, Switch. freq. limit

The average switching frequency of the unit exceeded the limit. Verify that parameter 300-10 Active Filter Nominal Voltage and parameter 300-22 CT Nominal Voltage are set correctly. If so, contact Danfoss or supplier.

ALARM 312, CT range

Current transformer measurement limitation was detected. Verify that the CTs used are an appropriate ratio.

ALARM 314, Auto CT interrupt

Auto CT detection has been interrupted.

ALARM 315, Auto CT error

An error was detected while performing auto CT detection. Contact Danfoss or supplier.

WARNING 316, CT location error

The auto CT function could not determine the correct locations of the CTs.

WARNING 317, CT polarity error

The auto CT function could not determine the correct polarity of the CTs.

WARNING 318, CT ratio error

The auto CT function could not determine the correct primary rating of the CTs.

7 7

Diagnostics and Troubleshoo...

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

7.5 Troubleshooting

Symptom Possible cause Test Solution

Missing input power. Missing or open fuses, or circuit breaker tripped.

No power to the LCP. Check the LCP cable for proper

Shortcut on control voltage (terminal 12 or 50) or at control

Display dark/no function

Intermittent display

Motor not running

Motor running in wrong direction

terminals. Wrong LCP (LCP from VLT® 2800

or 5000/6000/8000/ FCD or FCM). Wrong contrast setting.

Display (LCP) is defective. Test using a dierent LCP. Replace the faulty LCP or

Internal voltage supply fault or SMPS is defective. Overloaded power supply (SMPS) due to improper control wiring or a fault within the frequency converter.

Service switch open or missing motor connection.

No mains power with 24 V DC option card.

LCP Stop. Check if [O] has been pressed. Press [Auto On] or [Hand On]

Missing start signal (Standby).

Motor coast signal active (Coasting).

Wrong reference signal source. Check reference signal: Local,

Motor rotation limit.

Active reversing signal. Check if a reversing command is

Wrong motor phase connection.

See Table 5.1. See Open fuses and Tripped circuit breaker in this table for possible causes.

connection or damage. Check the 24 V control voltage supply for terminals 12/13 to 20–39 or 10 V supply for terminals 50–55. Use only LCP 101 (P/N 130B1124)

Contact supplier.

To rule out a problem in the control wiring, disconnect all control wiring by removing the terminal blocks.

Check if the motor is connected and the connection is not interrupted (by a service switch or other device). If the display is functioning but no output, check that mains power is applied to the frequency converter.

Check parameter 5-10 Terminal 18 Digital Input for correct setting for terminal 18 (use default setting). Check 5-12 Coast inv. for correct setting for terminal 27 (use default setting).

remote or bus reference? Preset reference active? Terminal connection correct? Scaling of terminals correct? Reference signal available?

Check that parameter 4-10 Motor Speed Direction is programmed correctly.

programmed for the terminal in parameter group 5-1* Digital inputs.

Check the input power source. Follow the recommendations provided.

Replace the faulty LCP or connection cable. Wire the terminals properly.

or LCP 102 (P/N 130B1107). Press [Status] + [▲]/[▼] to adjust

the contrast

connection cable.

If the display stays lit, then the problem is in the control wiring. Check the wiring for shorts or incorrect connections. If the display continues to cut out, follow the procedure for display dark. Connect the motor and check the service switch.

Apply mains power to run the unit.

(depending on operation mode) to run the motor. Apply a valid start signal to start the motor.

Apply 24 V on terminal 27 or program this terminal to no operation. Program correct settings. Check parameter 3-13 Reference Site. Set preset reference active in parameter group 3-1* References. Check for correct wiring. Check scaling of terminals. Check reference signal. Program correct settings.

Deactivate reversing signal.

See chapter 4.6.1 Motor Cable.

Diagnostics and Troubleshoo... Operating Instructions

Symptom Possible cause Test Solution

Frequency limits set wrong. Check output limits in:

Parameter 4-13 Motor Speed

•

High Limit [RPM].

Parameter 4-14 Motor Speed

•

High Limit [Hz].

Motor is not reaching maximum speed

Motor speed unstable

Motor runs rough

Motor does not brake

Open power fuses or circuit breaker trip

Mains current imbalance greater than 3%

Motor current imbalance greater than 3%

Reference input signal not scaled correctly.

Possible incorrect parameter settings.

Possible overmagnetisation. Check for incorrect motor settings

Possible incorrect settings in the brake parameters. Possible too short ramp down times. Phase-to-phase shortcircuit. Motor or panel has a short phase-

Motor overload. Motor is overloaded for the

Loose connections. Perform pre-startup check for loose

Problem with mains power (See

Alarm 4 Mains phase loss

description). Problem with the frequency converter.

Problem with motor or motor wiring.

Problem with the frequency converters.

Parameter 4-19 Max Output

•

Frequency.

Check reference input signal scaling in 6-0* Analog I/O Mode and parameter group 3-1* References. Reference limits in parameter group 3-0* Reference Limit. Check the settings of all motor parameters, including all motor compensation settings. For closedloop operation, check PID settings.

in all motor parameters.

Check brake parameters. Check ramp time settings.

to-phase. Check motor and panel phase for shortcircuits.

application.

connections. Rotate input power leads into the frequency converter 1 position: A to B, B to C, C to A. Rotate input power leads into the frequency converter 1 position: A to B, B to C, C to A. Rotate output motor leads 1 position: U to V, V to W, W to U.

Rotate output motor leads 1 position: U to V, V to W, W to U.

Program correct limits.

Program correct settings.

Check settings in parameter group 1-6* Load Depen. Setting. For closed-loop operation, check settings in parameter group 20-0* Feedback. Check motor settings in parameter groups 1-2* Motor Data, 1-3* Adv

Motor Data, and 1-5* Load Indep. Setting. Check parameter group 2-0* DC Brake and 3-0* Reference Limits.

Eliminate any shortcircuits detected.

Perform start-up test and verify that the motor current is within specications. If motor current is exceeding nameplate full load current, motor may run only with reduced load. Review the speci- cations for the application. Tighten loose connections.

If imbalanced leg follows the wire, it is a power problem. Check mains power supply. If imbalance leg stays on same input terminal, it is a problem with the unit. Contact the supplier. If imbalanced leg follows the wire, the problem is in the motor or motor wiring. Check motor and motor wiring. If imbalance leg stays on same output terminal, it is a problem with the unit. Contact the supplier.

7 7

Diagnostics and Troubleshoo...

Symptom Possible cause Test Solution

Acoustic noise or vibration (for example a fan blade is making noise or vibrations at certain frequencies)

Table 7.5 Troubleshooting

Resonances, for example in the motor/fan system.

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

Bypass critical frequencies by using parameters in parameter group 4-6* Speed Bypass. Turn o overmodulation in parameter 14-03 Overmodulation. Change switching pattern and frequency in parameter group 14-0* Inverter Switching. Increase resonance dampening in

parameter 1-64 Resonance Dampening.

Check if noise and/or vibration have been reduced to an acceptable limit.

130BA230.10

130BA229.10

Specications

Operating Instructions

8 Specications

8.1 Power-Dependent Specications

8.1.1 Mains Supply 3x380–480 V AC

Mains supply 3x380–480 V AC

N132 N160 N200

High/normal load* HO NO HO NO HO NO

Typical shaft output at 400 V [kW] Typical shaft output at 460 V [HP] Typical shaft output at 480 V [kW] Enclosure protection rating IP21 Enclosure protection rating IP54

Output current

Continuous (at 400 V) [A] Intermittent (60 s overload) (at 400 V) [A] Continuous (at 460/480 V) [A] Intermittent (60 s overload) (at 460/480 V) [A] Continuous KVA (at 400 V) [KVA] Continuous KVA (at 460 V) [KVA] Continuous KVA (at 480 V) [KVA]

Maximum input current

Continuous (at 400 V) [A] Continuous (at 460/480 V) [A] Maximum cable size, mains motor, brake, and load share [mm2 (AWG2))] Maximum external mains

fuses [A] Total LHD loss 400 V AC [kW] Total back channel loss 400 V AC [kW] Total lter loss 400 V AC [kW] Total LHD loss 460 V AC [kW] Total back channel loss 460 V AC [kW] Total lter loss 460 V AC [kW] Weight, enclosure protection rating IP21, IP54 [kg]

Eciency

* High overload = 150% current for 60 s, normal overload = 110% current for 60 s.

Acoustic noise 85 dBa Output frequency 0–590 Hz Heat sink overtemperature trip Power card ambient trip 85 °C

132 160 160 200 200 250

200 250 250 300 300 350

160 200 200 250 250 315

D1n D2n D2n

260 315 315 395 395 480

390 347 473 435 593 528

240 302 302 361 361 443

360 332 453 397 542 487

180 218 218 274 274 333

191 241 241 288 288 353

208 262 262 313 313 384

251 304 304 381 381 463

231 291 291 348 348 427

Motor, brake and load

share: 2x95 (2x3/0)

Mains: 2x185 (2x350)

400 550 630

7428 8725 8048 9831 9753 11371

6302 7554 6877 8580 8503 10020

4505 4954 4954 5714 5714 6234

7490 8906 7875 9046 8937 10626

5974 7343 6274 7374 7338 8948

3604 4063 3751 4187 4146 4822

352 413 413

105 °C 105 °C 105 °C

2x185

(2x350 mcm)

0.96

2x185

(2x350 mcm)

8 8

Table 8.1 D-frame Ratings

130BA230.10

130BA229.10

Specications

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

Mains supply 3x380–480 VAC

P250 P315 P355 P400

High/ normal load* HO NO HO NO HO NO HO NO

Typical shaft output at 400 V [kW] Typical shaft output at 460 V [HP] Typical shaft output at 480 V [kW] Enclosure protection rating IP21 Enclosure protection rating IP54

250 315 315 355 355 400 400 450

350 450 450 500 500 600 550 600

315 355 355 400 400 500 500 530

E9 E9 E9 E9

Output current

Continuous (at 400 V) [A]

480 600 600 658 658 745 695 800

Intermittent (60 s overload)

720 660 900 724 987 820 1043 880 (at 400 V) [A] Continuous (at 460/480 V) [A]

443 540 540 590 590 678 678 730 Intermittent (60 s

overload)

665 594 810 649 885 746 1017 803 (at 460/480 V) [A] Continuous KVA (at 400 V) [KVA]

Continuous KVA (at 460 V) [KVA] Continuous KVA (at 480 V) [KVA]

333 416 416 456 456 516 482 554

353 430 430 470 470 540 540 582

384 468 468 511 511 587 587 632

Maximum input current

Continuous (at 400 V) [A] Continuous (at 460/480 V) [A] Maximum cable size, mains, motor, and load share [mm2 (AWG2))] Maximum cable size, brake [mm2 (AWG2)) Maximum external mains

472 590 590 647 647 733 684 787

436 531 531 580 580 667 667 718

4x240

(4x500 mcm)

2x185

(2x350 mcm)

4x240

(4x500 mcm)

2x185

(2x350 mcm)

4x240

(4x500 mcm)

2x185

(2x350 mcm)

4x240

(4x500 mcm)

2x185

(2x350 mcm)

700 900 900 900

11587 14051 14140 15320 15286 17180 16036 18447

9011 11301 10563 11648 11650 13396 12348 14570

6528 7346 7346 7788 7788 8503 8060 8974

10962 12936 13124 14083 13998 15852 15847 16962

8432 10277 9636 10522 10466 12184 12186 13214

6316 7066 7006 7359 7326 8033 8033 8435

Weight, enclosure protection

596 623 646 646

rating IP21, IP54 [kg]

Eciency

0.96 Acoustic noise 72 dBa Output frequency 0–600 Hz Heat sink overtem-

perature trip

105 °C

Power card ambient trip 85 °C

* High overload = 160% current for 60 s, normal overload = 110% current for 60 s.

Table 8.2 E-frame Ratings

130BA230.10

130BA229.10

Specications

Operating Instructions

Mains supply 3x380–480 V AC

P450 P500 P560 P630

High/ normal load* HO NO HO NO HO NO HO NO

Typical shaft output at 400 V [kW] Typical shaft output at 460 V [HP] Typical shaft output at 480 V [kW] Enclosure protection rating IP21, 54

450 500 500 560 560 630 630 710

600 650 650 750 750 900 900 1000

530 560 560 630 630 710 710 800

F18 F18 F18 F18

Output current

Continuous (at 400 V) [A] 800 880 880 990 990 1120 1120 1260 Intermittent (60 s overload) (at 400 V) [A] Continuous (at 460/480 V) [A] Intermittent (60 s overload) (at 460/480 V) [A] Continuous KVA (at 400 V) [KVA] Continuous KVA (at 460 V) [KVA] Continuous KVA (at 480 V) [KVA]

1200 968 1320 1089 1485 1232 1680 1386

730 780 780 890 890 1050 1050 1160

1095 858 1170 979 1335 1155 1575 1276

554 610 610 686 686 776 776 873

582 621 621 709 709 837 837 924

632 675 675 771 771 909 909 1005

Maximum input current

Continuous (at 400 V ) [A]

779 857 857 964 964 1090 1090 1227

Continuous (at 460/ 480 V) [A] 711 759 759 867 867 1022 1022 1129 Maximum cable size, motor [mm2 (AWG2))]

8x150

(8x300 mcm)

8 8

Maximum cable size, mains F1/F2 [mm2 (AWG2))]

Maximum cable size, mains F3/F4 [mm2 (AWG2))] Maximum cable size, loadsharing [mm2 (AWG2))] Maximum cable size, brake [mm2 (AWG2)) Maximum external mains fuses

[A] Total LHD loss 400 V AC [kW] Total back channel loss 400 V AC [kW] Total lter loss 400 V AC [kW] Total LHD loss 460 V AC [kW] Total back channel loss 460 V AC [kW] Total lter loss 460 V AC [kW]

20077 21909 21851 24592 23320 26640 26559 30519

16242 17767 17714 19984 18965 21728 21654 24936

11047 11747 11705 12771 12670 14128 14068 15845

18855 19896 19842 22353 21260 25030 25015 27989

15260 16131 16083 18175 17286 20428 20417 22897

10643 11020 10983 11929 11846 13435 13434 14776

1600 2000

Maximum panel options losses 400 Weight, enclosure protection ratings IP21, IP54 [kg] Weight frequency converter section [kg] Weight lter section [kg] 1005

Eciency

Acoustic noise 69 dBa Output frequency 0–600 Hz Heat sink overtemperature trip 105 °C

* High overload = 160% current for 60 s, normal overload = 110% current for 60 s.

Power card ambient trip 85 °C

8x240

(8x500 mcm)

8x456

(8x900 mcm)

4x120

(4x250 mcm)

4x185

(4x350 mcm)

2009

1004

0.96

Table 8.3 F-frame Ratings

130BX473.10

Iout [%]

fsw [kHz]

100

110

2 3 4 5 6 7 8

50 C

55 C

130BX474.10

100

110

2 3 4 5 6 7 8 90

50 C

55 C

45 C

Iout [%]

fsw

[kHz]

130BX475.10

Iout [%]

fsw

[kHz]

100

110

2 4 6

50 C

55 C

45 C

31 5

130BX476.10

Iout [%]

fsw

[kHz]

100

110

2 4

50 C

55 C

45 C

40 C

Specications

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

1) For type of fuse see chapter 8.4.1 Fuses.

2) American Wire Gauge.

3) Measured using 5 m screened motor cables at rated load and rated frequency.

4) The typical power loss is at nominal load conditions and expected to be within ±15% (tolerence relates to variety in voltage and cable conditions). Values are based on a typical motor eciency (e2/e3 border line). Motors with lower eciency also add to the power loss in the frequency converter and opposite. If the switching frequency is increased compared to the default setting, the power losses may rise signicantly. LCP and typical control card power consumptions are included. Further options and customer load may add up to 30 W to the losses (though typical only 4 W extra for a fully loaded control card, or options for slot A or slot B, each). Although measurements are made with state-of-the-art equipment, some measurement inaccuracy must be allowed for (±5%).

Derating for Temperature

8.1.2

The frequency converter automatically derates the switching frequency, switching type, or output current under certain load or ambient conditions as described in the following. Illustration 8.1 to Illustration 8.8 show the derating curve for SFAWM and 60 AVM switching modes.

Illustration 8.3 Derating Enclosure Size D, N132 to N200 380– 480 V (T5) High overload 150%, SFAVM

Illustration 8.1 Derating Enclosure Size D, N132 to N200 380– 480 V (T5) High overload 150%, 60 AVM

Illustration 8.4 Derating Enclosure Size D, N132 to N200 380– 480 V (T5) Normal Overload 110%, SFAVM

Illustration 8.2 Derating Enclosure Size D, N132 to N200 380– 480 V (T5) Normal Overload 110%, 60 AVM

130BX477.10

100

110

2 3 4 5 6 7

50 C

55 C

Iout [%]

fsw

[kHz]

130BX478.10

Iout [%]

fsw

[kHz]

100

110

2 3 4 5 6 7

50 C

55 C

45 C

130BX479.10

Iout [%]

fsw

[kHz]

100

110

2 3 4 5

50 C

55 C

45 C

130BX480.10

Iout [%]

fsw

[kHz]

100

110

2 3 4 5

50 C 55 C

45 C

40 C

Specications Operating Instructions

Illustration 8.5 Derating Enclosure Sizes E and F, P250 to P630 380–480 V (T5) High overload 150%, 60 AVM

Illustration 8.8 Derating Enclosure Sizes E and F, P250 to P630 380–480 V (T5) Normal Overload 110%, SFAVM

Illustration 8.6 Derating Enclosure Sizes E and F, P250 to P630 380–480 V (T5) Normal Overload 110%, 60 AVM

Illustration 8.7 Derating Enclosure Sizes E and F, P250 to P630 380–480 V (T5) High overload 150%, SFAVM

8 8

576,8 [22.7]

1915,91 [75.4]

1781,7 [70.1]

1698,3 [66.9]

1755,5 [69.1]

411,0 [16.2]

115,5 [4.5]

139,0 [5.5]

443,0 [17.4]

611,0 [24.1]

663,5 [26.1]

843,5 [33.2]

1568,3 [61.7]

807,3 [31.8]

677,3 [26.7]

929.2 [36.6]

377,8 [14.9]

130BE140.10

251,0 [9.9]

221,0 [8.7]

301,9

[11.9] 369,0 [14.5]

664,4 [26.2]

864,4 [34.0]

Specications

8.2 Mechanical Dimensions

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

Illustration 8.9 Enclosure Size D1n

576,8 [22.7]

92,88 [3.7]

89,7 [3.5]

59 [2.3]

4,52 [0.2]

32,52 [1.3]

184,52 [7.3]

336,52 [13.2]

364,52

[14.4]

461,92 [18.2]

1024,2 [40.3]

377,8 [14.9]

117,4 [4.6]

184,5

[7.3] 369 [14.5]

534,5

[21] 641,17 [25.2]

747,83

[29.4] 854,5 [33.6]

1914,7 [75.4]

1781,4 [70.1]

1562,4 [61.5]

1504 [59.2]

470,92 [18.5]

130 [5.1]

160 [6.3]

251,89 [9.9]

130BE139.10

Specications Operating Instructions

Illustration 8.10 Enclosure Size D2n

8 8

2000.7 [78.8]

184.5 [7.3]

369.0 [14.5]

553.5 [21.8]

600.0 [23.6]

784.5 [30.9]

969.0 [38.2]

1153.5 [45.4]

160.0 [6.3]

248.0

[9.8]

725.0 [28.5]

1043.0 [41.1]

160.0 [6.3]

493.5 [19.4]

1200.0 [47.2]

130BC171.10

2078.4

2278.4

130BC174.11

2792.0 [110]

605.8 [24]

Specications

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

Illustration 8.11 Enclosure Size E9

Illustration 8.12 Enclosure Size F18, Front and Side View

Specications

Operating Instructions

8.3 General Technical Data

Mains supply (L1, L2, L3) Supply voltage 380–480 V +5%

Mains voltage low/mains drop-out: During low mains voltage or mains drop-out, the frequency converter continues until the intermediate circuit voltage drops below the minimum stop level, corresponding to 15% below the lowest rated supply voltage. Power-up and full torque cannot be expected at mains voltage lower than 10% below the lowest rated supply voltage.

Supply frequency 50/60 Hz ±5% Maximum imbalance temporary between mains phases 3.0% of rated supply voltage True power factor (λ) >0.98 nominal at rated load Displacement power factor (cosφ) near unity (>0.98) THDi <5% Switching on input supply L1, L2, L3 (power-ups) maximum once/2 minutes Environment according to EN60664-1 overvoltage category III/pollution degree 2

The unit is suitable for use on a circuit capable of delivering not more than 100000 RMS symmetrical Amperes, 480/690 V maximum.

Motor output (U, V, W) Output voltage 0–100% of supply voltage Output frequency 0–590 Hz Switching on output Unlimited Ramp times 0.01–3600 s

1) Voltage and power dependent

8 8

Torque characteristics Starting torque (constant torque) maximum 150% for 60 s Starting torque maximum 180% up to 0.5 s Overload torque (constant torque) maximum 150% for 60 s

1) Percentage relates to nominal torque of the unit.

Cable lengths and cross-sections Maximum motor cable length, screened/armoured 150 m Maximum motor cable length, unscreened/unarmoured 300 m Maximum cross-section to motor, mains, load sharing, and brake

Maximum cross-section to control terminals, rigid wire 1.5 mm2/16 AWG (2 x 0.75 mm2) Maximum cross-section to control terminals, exible cable 1 mm2/18 AWG Maximum cross-section to control terminals, cable with enclosed core 0.5 mm2/20 AWG Minimum cross-section to control terminals 0.25 mm

1) See chapter 8.1.1 Mains Supply 3x380–480 V AC for more information

Digital inputs Programmable digital inputs 4 (6) on frequency converter and 2 (4) on active lter Terminal number 18, 19, 271), 291), 32, and 33 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic 0 PNP <5 V DC Voltage level, logic 1 PNP >10 V DC Voltage level, logic 0 NPN >19 V DC Voltage level, logic 1 NPN <14 V DC Maximum voltage on input 28 V DC Input resistance, R

approximately 4 kΩ

All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

1) Terminals 27 and 29 can also be programmed as output.

Mains

Functional isolation

PELV isolation

Motor

DC-Bus

High voltage

Control

+24V

RS485

130BA117.10

Specications

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

Analog inputs Number of analog inputs 2 on frequency converter Terminal number 53 and 54 Modes Voltage or current Mode select Switch S201 and switch S202, Switch A53 and A54 Voltage mode Switch S201/switch S202 = OFF (U), Switch A53 and A54 Voltage level 0–10 V (scaleable) Input resistance, R

approximately 10 kΩ Maximum voltage ± 20 V Current mode Switch S201/switch S202 = ON (I), switch A53 and A54 Current level 0/4 to 20 mA (scaleable) Input resistance, R

approximately 200 Ω Maximum current 30 mA Resolution for analog inputs 10 bit (+ sign) Accuracy of analog inputs Maximum error 0.5% of full scale Bandwidth 100 Hz (D-frame), 200 Hz

The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Illustration 8.13 PELV Isolation of Analog Inputs

Pulse inputs Programmable pulse inputs 2 on frequency converter Terminal number pulse 29 and 33 Maximum frequency at terminal, 29 and 33 110 kHz (push-pull driven) Maximum frequency at terminal, 29 and 33 5 kHz (open collector) Minimum frequency at terminal 29 and 33 4 Hz Voltage level see chapter 8.3.1 Digital inputs Maximum voltage on input 28 V DC Input resistance, R

Pulse input accuracy (0.1–1 kHz) Maximum error: 0.1% of full scale

Analog output Number of programmable analog outputs 1 on both frequency converter and active lter Terminal number 42 Current range at analog output 0/4–20 mA Maximum resistor load to common at analog output 500 Ω Accuracy on analog output Maximum error: 0.8% of full scale Resolution on analog output 8 bit

The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

approximately 4 kΩ

Control card, RS485 serial communication Terminal number 68 (P,TX+, RX+) and 69 (N,TX-, RX-) Terminal number 61 Common for terminals 68 and 69

The RS485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage (PELV).

Specications

Digital output Programmable digital/pulse outputs 2 on both frequency converter and active lter Terminal number 27 and 29 Voltage level at digital/frequency output 0–24 V Maximum output current (sink or source) 40 mA Maximum load at frequency output 1 kΩ Maximum capacitive load at frequency output 10 nF Minimum output frequency at frequency output 0 Hz Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Maximum error: 0.1% of full scale Resolution of frequency outputs 12 bit

1) Terminals 27 and 29 can also be programmed as input.

The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control card, 24 V DC output Terminal number 13 Output voltage 24 V (+1, -3 v) Maximum load 200 mA

The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs.

Relay outputs Programmable relay outputs 2 on frequency converter only

Relay 01 Terminal number (D-frame)

Maximum terminal load (AC-1)1) on 1–2 (NO) (Resistive load) Maximum terminal load (AC-15)1) on 1–2 (NO) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 1–2 (NO) (Resistive load) 80 V DC, 2 A Maximum terminal load (DC-13)1) on 1–2 (NO) (Inductive load) 24 V DC, 0.1 A Maximum terminal load (AC-1)1) on 1–3 (NC) (Resistive load) 240 V AC, 2 A Maximum terminal load (AC-15)1) on 1–3 (NC) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 1–3 (NC) (Resistive load) 50 V DC, 2 A Maximum terminal load (DC-13)1) on 1–3 (NC) (Inductive load) 24 V DC, 0.1 A Minimum terminal load on 1–3 (NC), 1–2 (NO) 24 V DC 10 mA, 24 V AC 2 mA Environment according to EN 60664-1 overvoltage category III/pollution degree 2

Relay 01 terminal number (E-frame and F-frame)

Maximum terminal load (AC-1)1) on 1–3 (NC), 1–2 (NO) (resistive load) 240 V AC, 2A Maximum terminal load (AC-15)1) (inductive load @ cosφ 0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 1–2 (NO), 1–3 (NC) (resistive load) 60 V DC, 1 A Maximum terminal load (DC-13)1) (inductive load) 24 V DC, 0.1 A

Relay 02 terminal number

Maximum. terminal load (AC-1)1) on 4–5 (NO) (resistive load) Maximum terminal load (AC-15)1) on 4–5 (NO) (inductive load @ cosφ 0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 4–5 (NO) (resistive load) 80 V DC, 2 A Maximum terminal load (DC-13)1) on 4–5 (NO) (inductive load) 24 V DC, 0.1 A Maximum terminal load (AC-1)1) on 4–6 (NC) (resistive load) 240 V AC, 2 A Maximum terminal load (AC-15)1) on 4–6 (NC) (inductive load @ cosφ 0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 4–6 (NC) (resistive load) 50 V DC, 2 A Maximum terminal load (DC-13)1) on 4–6 (NC) (inductive load) 24 V DC, 0.1 A Minimum terminal load on 1–3 (NC), 1–2 (NO), 4–6 (NC), 4–5 (NO) 24 V DC 10 mA, 24 V AC 20 mA Environment according to EN 60664-1 overvoltage category III/pollution degree 2

1) IEC 60947 parts 4 and 5. The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).

2) Overvoltage Category II.

3) UL applications 300 V AC 2 A.

Operating Instructions

2)3)

1–3 (break), 1–2 (make)

400 V AC, 2 A

1–3 (break), 1–2 (make)

4–6 (break), 4–5 (make)

400 V AC, 2 A

8 8

Specications

Control characteristics Resolution of output frequency at 0–1000 Hz ±0.003 Hz System response time (terminals 18, 19, 27, 29, 32, and 33) ≤2 ms Speed control range (open loop) 1:100 of synchronous speed Speed accuracy (open loop) 30–4000 RPM: Maximum error of ±8 RPM

All control characteristics are based on a 4-pole asynchronous motor.

Surroundings Enclosure protection rating, enclosure sizes D and E IP21, IP54 Enclosure protection rating, enclosure size F IP21, IP54 Vibration test 0.7 g Relative humidity 5–95% (IEC 721-3-3; Class 3K3 (non-condensing) during operation Aggressive environment (IEC 60068-2-43) H2S test Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature (at 60 AVM switching mode)

- with derating maximum 55 °C

- with full output power, typical IE2 motors (see chapter 8.1.2 Derating for Temperature maximum 50 °C

- at full continuous FC output current maximum 45 °C Minimum ambient temperature during full-scale operation 0 °C Minimum ambient temperature at reduced performance - 10 °C

Temperature during storage/transport -25 to +65/70 °C Maximum altitude above sea level without derating 1000 m Maximum altitude above sea level with derating 3000 m

For more information on derating, consult the design guide.

EMC standards, emission EN 61800-3, EN 61000-6-3/4, EN 55011, IEC 61800-3

EMC standards, immunity

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

class kD

EN 61800-3, EN 61000-6-1/2,

EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6

Control card performance Scan interval 1 ms

Control card, USB serial communication USB standard 1.1 (full speed) USB plug USB type B device plug

NOTICE

Connection to PC is carried out via a standard host/device USB cable. The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is not galvanically isolated from protective earth. Use only an isolated laptop/PC as connection to the USB connector on the frequency converter or an isolated USB cable/converter.

Protection and features:

Electronic thermal motor protection against overload.

•

Temperature monitoring of the heat sink ensures that the frequency converter trips if the temperature reaches a

•

predened level. An overload temperature cannot be reset until the temperature of the heat sink is below the allowed values.

The frequency converter is protected against short circuits on motor terminals U, V, W.

•

If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load).

•

Monitoring of the DC-link voltage ensures that the frequency converter trips if the intermediate circuit voltage is

•

too low or too high. The frequency converter is protected against ground faults on motor terminals U, V, W.

•

Danfoss FC 302 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual