Danfoss FC 302 Design guide

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ENGINEERING TOMORROW

Design Guide

VLT® AutomationDrive FC 302

90–710 kW, Enclosure Sizes D and E

vlt-drives.danfoss.com

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Contents Design Guide

Contents

1 Introduction

1.1 Purpose of the Design Guide

1.2 Additional Resources

1.3 Document and Software Version

1.4 Conventions

2 Safety

2.1 Safety Symbols

2.2 Qualied Personnel

2.3 Safety Precautions

3 Approvals and Certications

3.1 Regulatory/Compliance Approvals

3.2 Enclosure Protection Ratings

4 Product Overview

4.1 VLT® High-power Drives

4.2 Enclosure Size by Power Rating

4.3 Overview of Enclosures, 380–500 V

4.4 Overview of Enclosures, 525–690 V

4.5 Kit Availability

5 Product Features

5.1 Automated Operational Features

5.2 Custom Application Features

5.3 Dynamic Braking Overview

5.4 Mechanical Holding Brake Overview

5.5 Load Share Overview

5.6 Regen Overview

5.7 Back-channel Cooling Overview

6 Options and Accessories Overview

6.1 Fieldbus Devices

6.2 Functional Extensions

6.3 Motion Control and Relay Cards

6.4 Brake Resistors

6.5 Sine-wave Filters

6.6 dU/dt Filters

6.7 Common-mode Filters

6.8 Harmonic Filters

6.9 High-power Kits

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Contents VLT® AutomationDrive FC 302

7 Specications

7.1 Electrical Data, 380–500 V

7.2 Electrical Data, 525–690 V

7.3 Mains Supply

7.4 Motor Output and Motor Data

7.5 Ambient Conditions

7.6 Cable Specications

7.7 Control Input/Output and Control Data

7.8 Enclosure Weights

8 Exterior and Terminal Dimensions

8.1 D1h Exterior and Terminal Dimensions

8.2 D2h Exterior and Terminal Dimensions

8.3 D3h Exterior and Terminal Dimensions

8.4 D4h Exterior and Terminal Dimensions

8.5 D5h Exterior and Terminal Dimensions

8.6 D6h Exterior and Terminal Dimensions

8.7 D7h Exterior and Terminal Dimensions

8.8 D8h Exterior and Terminal Dimensions

8.9 E1h Exterior and Terminal Dimensions

8.10 E2h Exterior and Terminal Dimensions

8.11 E3h Exterior and Terminal Dimensions

8.12 E4h Exterior and Terminal Dimensions

9 Mechanical Installation Considerations

9.1 Storage

9.2 Lifting the Unit

9.3 Operating Environment

9.4 Mounting Congurations

9.5 Cooling

9.6 Derating

10 Electrical Installation Considerations

10.1 Safety Instructions

10.2 Wiring Schematic

10.3 Connections

101

112

118

124

131

138

139

140

144

145

146

10.4 Control Wiring and Terminals

10.5 Fuses and Circuit Breakers

10.6 Motor

10.7 Braking

10.8 Residual Current Devices (RCD) and Insulation Resistance Monitor (IRM)

148

151

153

155

158

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Contents Design Guide

10.9 Leakage Current

10.10 IT Mains

10.11 Eciency

10.12 Acoustic Noise

10.13 dU/dt Conditions

10.14 Electromagnetic Compatibility (EMC) Overview

10.15 EMC-compliant Installation

10.16 Harmonics Overview

11 Basic Operating Principles of a Drive

11.1 Description of Operation

11.2 Drive Controls

12 Application Examples

12.1 Programming a Closed-loop Drive System

12.2 Wiring Congurations for Automatic Motor Adaptation (AMA)

12.3 Wiring Congurations for Analog Speed Reference

12.4 Wiring Congurations for Start/Stop

158

159

160

166

169

172

175

184

185

12.5 Wiring Conguration for an External Alarm Reset

12.6 Wiring Conguration for Speed Reference Using a Manual Potentiometer

12.7 Wiring Conguration for Speed Up/Speed Down

12.8 Wiring Conguration for RS485 Network Connection

12.9 Wiring Conguration for a Motor Thermistor

12.10 Wiring Conguration for a Relay Set-up with Smart Logic Control

12.11 Wiring Conguration for Mechanical Brake Control

12.12 Wiring Conguration for the Encoder

12.13 Wire Conguration for Torque and Stop Limit

13 How to Order a Drive

13.1 Drive Congurator

13.2 Ordering Numbers for Options and Accessories

13.3 Ordering Numbers for Filters and Brake Resistors

13.4 Spare Parts

14 Appendix

14.1 Abbreviations and Symbols

187

188

189

190

192

196

200

201

14.2 Denitions

Index

202

203

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Introduction VLT® AutomationDrive FC 302

1 Introduction

1.1 Purpose of the Design Guide

This design guide is intended for:

Project and systems engineers.

•

Design consultants.

•

Application and product specialists.

•

The design guide provides technical information to understand the capabilities of the drive for integration into motor control and monitoring systems.

VLT® is a registered trademark.

Document and Software Version

1.3

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. Table 1.1 shows the document version and the corresponding software version.

Edition Remarks Software version

MG38C2xx Added D1h–D8h content 8.03

Table 1.1 Document and Software Version

1.4 Conventions

1.2 Additional Resources

Numbered lists indicate procedures.

Other resources are available to understand advanced drive operation, programming, and directives compliance.

The operating guide provides detailed information

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for the installation and start-up of the drive.

The programming guide provides greater detail on

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how to work with parameters and includes many application examples.

The VLT

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Guide describes how to use Danfoss drives in functional safety applications. This manual is supplied with the drive when the Safe Torque O option is present.

The VLT® Brake Resistor MCE 101 Design Guide

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describes how to select the optimal brake resistor.

FC Series - Safe Torque O Operating

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Bullet lists indicate other information and

•

description of illustrations.

Italicized text indicates:

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- Cross-reference.

- Link.

- Footnote.

- Parameter name, parameter group

name, parameter option.

All dimensions in drawings are in mm (in).

•

An asterisk (*) indicates a default setting of a

•

parameter.

The VLT® Advanced Harmonic Filters AHF 005/AHF

•

010 Design Guide describes harmonics, various mitigation methods, and the operating principle of the advanced harmonics lter. This guide also describes how to select the correct advanced harmonics lter for a particular application.

The Output Filters Design Guide explains why it is

•

necessary to use output lters for certain applications, and how to select the optimal dU/dt or sine-wave lter.

Optional equipment is available that can change

•

some of the information described in these publications. For specic requirements, see the instructions supplied with the options.

Supplementary publications and manuals are available from Danfoss. See drives.danfoss.com/downloads/portal/#/ for listings.

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Safety Design Guide

2 Safety

2.1 Safety Symbols

The following symbols are used in this guide:

WARNING

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

CAUTION

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

NOTICE

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

2.2 Qualied Personnel

Only qualied personnel are allowed to install or operate this equipment.

2 2

WARNING

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be present even when the warning LED indicator lights are o. Failure to wait for the specied amount of time listed in Table 2.1 after power has been removed before performing service or repair work can result in death or serious injury.

1. Stop the motor.

2. Disconnect AC mains and remote DC-link supplies, including battery back-ups, UPS, and DC-link connections to other drives.

3. Disconnect or lock motor.

4. Wait for the capacitors to discharge fully. Refer to Table 2.1.

5. Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors are fully discharged.

Qualied personnel are dened as trained sta, who are authorized to install, commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Also, the personnel must be familiar with the instructions and safety measures described in this manual.

Safety Precautions

2.3

WARNING

HIGH VOLTAGE

Drives contain high voltage when connected to AC mains input, DC supply, load sharing, or permanent motors. Failure to use qualied personnel to install, start up, and maintain the drive can result in death or serious injury.

Only qualied personnel must install, start up,

•

and maintain the drive.

Voltage Power rating

(normal overload)

380–500 90–250 kW

125–350 hp

380–500 315–500 kW

450–650 hp

525–690 55–315 kW

60–350 hp

525–690 355–710 kW

400–750 hp

Table 2.1 Discharge Time for Enclosures D1h–D8h and E1h–E4h

Enclosure Minutes to disharge

D1h–D8h 20

E1h–E4h 40

D1h–D8h 20

E1h–E4h 40

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.

Ensure the correct grounding of the equipment

•

by a certied electrical installer.

NOTICE

MAINS SHIELD SAFETY OPTION

A mains shield option is available for enclosures with a protection rating of IP21/IP54 (Type 1/Type 12). The mains shield is a cover installed inside the enclosure to protect against the accidental touch of the power terminals, according to BGV A2, VBG 4.

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e30bd832.10

Safety VLT® AutomationDrive FC 302

2.3.1 ADN-compliant Installation

To prevent spark formation in accordance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), take precautions for drives with protection rating of IP00 (Chassis), IP20 (Chassis), IP21 (Type 1), or IP54 (Type 12).

Do not install a mains switch.

•

Ensure that parameter 14-50 RFI Filter is set to

•

[1] On.

Remove all relay plugs marked RELAY. See

•

Illustration 2.1.

Check which relay options are installed, if any.

•

The only allowed relay option is VLT® Extended Relay Card MCB 113.

1, 2 Relay plugs

Illustration 2.1 Location of Relay Plugs

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Approvals and Certication... Design Guide

3 Approvals and Certications

This section provides a brief description of the various approvals and certications that are found on Danfoss drives. Not all approvals are found on all drives.

3.1 Regulatory/Compliance Approvals

NOTICE

IMPOSED LIMITATIONS ON THE OUTPUT FREQUENCY

From software version 6.72 onwards, the output frequency of the drive is limited to 590 Hz due to export control regulations. Software versions 6.xx also limit the maximum output frequency to 590 Hz, but these versions cannot be ashed, that is, neither downgraded nor upgraded.

3.1.1.1 CE Mark

The CE mark (Communauté Européenne) indicates that the product manufacturer conforms to all applicable EU directives. The EU directives applicable to the design and manufacture of drives are listed in Table 3.1.

NOTICE

The CE mark does not regulate the quality of the product. Technical specications cannot be deduced from the CE mark.

EU Directive Version

Low Voltage Directive 2014/35/EU EMC Directive 2014/30/EU

Machinery Directive ErP Directive 2009/125/EC ATEX Directive 2014/34/EU RoHS Directive 2002/95/EC

Table 3.1 EU Directives Applicable to Drives

1) Machinery Directive conformance is only required for drives with

an integrated safety function.

2014/32/EU

The aim of the directive is to ensure personal safety and avoid property damage when operating electrical equipment that is installed, maintained, and used as intended.

EMC Directive

The purpose of the EMC (electromagnetic compatibility) Directive is to reduce electromagnetic interference and enhance immunity of electrical equipment and installations. The basic protection requirement of the EMC Directive is that devices that generate electromagnetic interference (EMI), or whose operation can be aected by EMI, must be designed to limit the generation of electromagnetic interference. The devices must have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

Electrical equipment devices used alone or as part of a system must bear the CE mark. Systems do not require the CE mark, but must comply with the basic protection requirements of the EMC Directive.

Machinery Directive

The aim of the Machinery Directive is to ensure personal safety and avoid property damage to mechanical equipment used in its intended application. The Machinery Directive applies to a machine consisting of an aggregate of interconnected components or devices of which at least 1 is capable of mechanical movement.

Drives with an integrated safety function must comply with the Machinery Directive. Drives without a safety function do not fall under the Machinery Directive. If a drive is integrated into a machinery system, Danfoss can provide information on safety aspects relating to the drive.

When drives are used in machines with at least 1 moving part, the machine manufacturer must provide a declaration stating compliance with all relevant statutes and safety measures.

3.1.1.2 ErP Directive

3 3

NOTICE

Drives with an integrated safety function, such as Safe Torque O (STO), must comply with the Machinery Directive.

Declarations of conformity are available on request.

Low Voltage Directive

Drives must be CE-labeled in accordance with the Low Voltage Directive of January 1, 2014. The Low Voltage Directive applies to all electrical equipment in the 50– 1000 V AC and the 75–1500 V DC voltage ranges.

The ErP Directive is the European Ecodesign Directive for energy-related products, including drives. The aim of the directive is to increase energy eciency and the level of protection of the environment, while increasing the security of the energy supply. Environmental impact of energy-related products includes energy consumption throughout the entire product life cycle.

3.1.1.3 UL Listing

The Underwriters Laboratory (UL) mark certies the safety of products and their environmental claims based on standardized testing. Drives of voltage T7 (525–690 V) are

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Approvals and Certication... VLT® AutomationDrive FC 302

UL-certied for only 525–600 V. The drive complies with UL 61800-5-1 thermal memory retention requirements. For more information, refer to chapter 10.6.1 Motor Thermal Protection.

3.1.1.4 CSA/cUL

The CSA/cUL approval is for AC drives of voltage rated at 600 V or lower. The standard ensures that, when the drive is installed according to the provided operating/installation guide, the equipment meets the UL standards for electrical and thermal safety. This mark certies that the product performs to all required engineering specications and testing. A certicate of compliance is provided on request.

3.1.1.9 Marine

In order for ships and oil/gas platforms to receive a regulatory license and insurance, 1 or more marine certi-

cation societies must certify these applications. Up to 12 dierent marine classication societies have certied

Danfoss drive series.

To view or print marine approvals and certicates, go to the download area at drives.danfoss.com/industries/marine- and-oshore/marine-type-approvals/#/.

3.1.2 Export Control Regulations

Drives can be subject to regional and/or national export control regulations.

3.1.1.5 EAC

The EurAsian Conformity (EAC) mark indicates that the product conforms to all requirements and technical regulations applicable to the product per the EurAsian Customs Union, which is composed of the member states of the EurAsian Economic Union.

The EAC logo must be both on the product label and on the packaging label. All products used within the EAC area, must be bought at Danfoss inside the EAC area.

An ECCN number is used to classify all drives that are subject to export control regulations. The ECCN number is provided in the documents accompanying the drive.

In case of re-export, it is the responsibility of the exporter to ensure compliance with the relevant export control regulations.

3.1.1.6 UKrSEPRO

UKrSEPRO certicate ensures quality and safety of both products and services, in addition to manufacturing stability according to Ukrainian regulatory standards. The UkrSepro certicate is a required document to clear customs for any products coming into and out of the territory of Ukraine.

3.1.1.7 TÜV

TÜV SÜD is a European safety organization which certies the functional safety of the drive in accordance to EN/IEC 61800-5-2. The TÜV SÜD both tests products and monitors their production to ensure that companies stay compliant with their regulations.

3.1.1.8 RCM

The Regulatory Compliance Mark (RCM) indicates compliance with telecommunications and EMC/radiocommunications equipment per the Australian Communications and Media Authorities EMC labeling notice. RCM is now a single compliance mark covering both the A-Tick and the C-Tick compliance marks. RCM compliance is required for placing electrical and electronic devices on the market in Australia and New Zealand.

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Approvals and Certication... Design Guide

3.2 Enclosure Protection Ratings

The VLT® drive series are available in various enclosure protection to accommodate the needs of the application. Enclosure protection ratings are provided based on 2 international standards:

UL type validates that the enclosures meet NEMA (National Electrical Manufacturers Association) standards. The

•

construction and testing requirements for enclosures are provided in NEMA Standards Publication 250-2003 and UL 50, Eleventh Edition.

IP (Ingress Protection) ratings outlined by IEC (International Electrotechnical Commission) in the rest of the world.

•

Standard Danfoss VLT® drive series are available in various enclosure protections to meet the requirements of IP00 (Chassis), IP20 (Protected chassis) or IP21 (UL Type 1), or IP54 (UL Type 12). In this manual, UL Type is written as Type. For example, IP21/Type 1.

UL type standard

Type 1 – Enclosures constructed for indoor use to provide a degree of protection to personnel against incidental contact with the enclosed units and to provide a degree of protection against falling dirt.

Type 12 – General-purpose enclosures are intended for use indoors to protect the enclosed units against the following:

Fibers

•

Lint

•

Dust and dirt

•

Light splashing

•

Seepage

•

Dripping and external condensation of noncorrosive liquids

•

3 3

There can be no holes through the enclosure and no conduit knockouts or conduit openings, except when used with oilresistant gaskets to mount oil-tight or dust-tight mechanisms. Doors are also provided with oil-resistant gaskets. In addition, enclosures for combination controllers have hinged doors, which swing horizontally and require a tool to open.

IP standard

Table 3.2 provides a cross-reference between the 2 standards. Table 3.3 demonstrates how to read the IP number and then

denes the levels of protection. The drives meet the requirements of both.

NEMA and UL IP

Chassis IP00 Protected chassis IP20 Type 1 IP21 Type 12 IP54

Table 3.2 NEMA and IP Number Cross-reference

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Approvals and Certication... VLT® AutomationDrive FC 302

1st digit 2nd digit

0 – No protection. 1 – Protected to 50 mm (2.0 in). No hands would be able to get into the enclosure. 2 – Protected to 12.5 mm (0.5 in). No ngers would be able to get into the enclosure. 3 – Protected to 2.5 mm (0.1 in). No tools would be able to get into the enclosure.

4 – Protected to 1.0 mm (0.04 in). No wires would be able to get into the enclosure. 5 – Protected against dust – limited entry. 6 – Protected totally against dust. – 0 No protection. – 1 Protected from vertical dripping water. – 2 – 3 – 4 Protected from splashing water. – 5 Protected from water jets. – 6 Protected from strong water jets. – 7 Protected from temporary immersion. – 8 Protected from permanent immersion.

Table 3.3 IP Number Breakdown

Level of protection

Protected from dripping water at 15° angle. Protected from water at 60° angle.

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Product Overview Design Guide

4 Product Overview

4.1

VLT® High-power Drives

The Danfoss VLT® drives described in this manual are available as free-standing, wall-mounted, or cabinet-mounted units. Each VLT® drive is congurable, compatible, and eciency-optimized for all standard motor types, which avoids the

restrictions of motor-drive package deals.

Benets of VLT® Drives

Available in various enclosure sizes and protection ratings.

•

98% eciency reduces operating costs.

•

Unique back-channel cooling design reduces the need for more cooling equipment, resulting in lower installation

•

and recurring costs.

Lower power consumption for control room cooling equipment.

•

Reduced ownership costs.

•

Consistent user interface across the entire range of Danfoss drives.

•

Application-oriented start-up wizards.

•

Multi-language user interface.

•

4 4

4.2 Enclosure Size by Power Rating

kW1)Hp

90 125 D1h/D3h/D5h/D6h 110 150 D1h/D3h/D5h/D6h 132 200 D1h/D3h/D5h/D6h 160 250 D2h/D4h/D7h/D8h 200 300 D2h/D4h/D7h/D8h 250 350 D2h/D4h/D7h/D8h 315 450 E1h/E3h 355 500 E1h/E3h 400 550 E1h/E3h 450 600 E2h/E4h 500 650 E2h/E4h

Table 4.1 Enclosure Power Ratings, 380–500 V

1) All power ratings are taken at high overload.

Output is measured at 400 V (kW) and 460 V (hp).

Available enclosures

kW1)Hp

55 60 D1h/D3h/D5h/D6h 75 75 D1h/D3h/D5h/D6h

90 100 D1h/D3h/D5h/D6h 110 125 D1h/D3h/D5h/D6h 132 150 D1h/D3h/D5h/D6h 160 200 D2h/D4h/D7h/D8h 200 250 D2h/D4h/D7h/D8h 250 300 D2h/D4h/D7h/D8h 315 350 D2h/D4h/D7h/D8h 355 400 E1h/E3h 400 400 E1h/E3h 500 500 E1h/E3h 560 600 E1h/E3h 630 650 E2h/E4h 710 750 E2h/E4h

Table 4.2 Enclosure Power Ratings, 525–690 V

1) All power ratings are taken at high overload.

Output is measured at 690 V (kW) and 575 V (hp).

Available enclosures

Page 14

Product Overview VLT® AutomationDrive FC 302

4.3 Overview of Enclosures, 380–500 V

Enclosure size D1h D2h D3h D4h D5h D6h D7h D8h

Power rating

Output at 400 V (kW) 90–132 160–250 90–132 160–250 90–132 90–132 160–250 160–250 Output at 460 V (hp) 125–200 250–350 125–200 250–350 125–200 125–200 250–350 250–350

Protection rating

IP IP21/54 IP21/54 IP20 IP20 IP21/54 IP21/54 IP21/54 IP21/54

NEMA Type 1/12 Type 1/12 Type Chassis Type Chassis Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Stainless steel back channel Mains shielding O O – – O O O O Space heater O O – – O O O O RFI lter (Class A1) O O O O O O O O Safe torque o S S S S S S S S No LCP O O O O O O O O Numerical LCP O O O O O O O O Graphical LCP O O O O O O O O Fuses O O O O O O O O

Heat sink access Brake chopper – – O O O O O O Regeneration terminals – – O O O O O O Loadshare terminals – – O O – – – – Fuses + loadshare – – O O – – – – Disconnect – – – – – O – O Circuit breakers – – – – – O – O Contactors – – – – – O – O 24 V DC supply O O O O O O O O

Dimensions

Height, mm (in) 901 (35.5) 1107 (43.6) 909 (35.8)

Width, mm (in) 325 (12.8) 325 (12.8) 250 (9.8) 375 (14.8) 325 (12.8) 325 (12.8) 420 (16.5) 420 (16.5) Depth, mm (in) 379 (14.9) 379 (14.9) 375 (14.8) 375 (14.8) 381 (15.0) 381 (15.0) 386 (15.2) 406 (16.0) Weight, kg (lb) 62 (137) 125 (276) 62 (137)

O O O O O O O O

1004 (39.5)

108 (238)

1027 (40.4)

125 (276)

179 (395)

1324 (52.1) 1663 (65.5) 1978 (77.9) 2284 (89.9)

99 (218) 128 (282) 185 (408) 232 (512)

Table 4.3 D1h–D8h Drives, 380–500 V

1) All power ratings are taken at high overload. Output is measured at 400 V (kW) and 460 V (hp).

2) S = standard, O = optional, and a dash indicates that the option is unavailable.

3) Heat sink access is not available with stainless steel back-channel option.

4) With optional load share and regen terminals.

Page 15

Product Overview Design Guide

Enclosure size E1h E2h E3h E4h

Power rating

Output at 400 V (kW) 315–400 450–500 315–400 450–500 Output at 460 V (hp) 450–550 600–650 450–550 600–650

Protection rating

IP IP21/54 IP21/54 UL type Type 1/12 Type 1/12 Chassis Chassis

Hardware options

Stainless steel back channel O O O O Mains shielding O O – – Space heater O O – – RFI lter (Class A1) O O O O Safe torque o S S S S No LCP O O O O Graphical LCP O O O O Fuses S S O O Heat sink access O O O O Brake chopper O O O O Regen terminals O O O O Load share terminals – – O O Fuses + load share – – O O Disconnect O O – – Circuit breakers – – – – Contactors – – – – 24 V DC supply (SMPS, 5 A) – – – –

Dimensions

Height, mm (in) 2043 (80.4) 2043 (80.4) 1578 (62.1) 1578 (62.1) Width, mm (in) 602 (23.7) 698 (27.5) 506 (19.9) 604 (23.9) Depth, mm (in) 513 (20.2) 513 (20.2) 482 (19.0) 482 (19.0) Weight, kg (lb) 295 (650) 318 (700) 272 (600) 295 (650)

IP20

4 4

Table 4.4 E1h–E4h Drives, 380–500 V

1) All power ratings are taken at high overload. Output is measured at 400 V (kW) and 460 V (hp).

2) If the enclosure is congured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20.

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

Page 16

Product Overview VLT® AutomationDrive FC 302

4.4 Overview of Enclosures, 525–690 V

Enclosure size D1h D2h D3h D4h D5h D6h D7h D8h

Power rating

Output at 690 V (kW) 55–132 160–315 55–132 160–315 55–132 55–132 160–315 160–315 Output at 575 V (hp) 60–150 200–350 60–150 200–350 60–150 60–150 200–350 200–350

Protection rating

IP IP21/54 IP21/54 IP20 IP20 IP21/54 IP21/54 IP21/54 IP21/54

NEMA Type 1/12 Type 1/12 Type Chassis Type Chassis Type 1/12 Type 1/12 Type 1/12 Type 1/12

Hardware options

Stainless steel backchannel Mains shielding O O O O O O O O Space heater O O O O O O O O Safe torque o S S S S S S S S No LCP O O O O O O O O Numerical LCP O O O O O O O O Graphical LCP O O O O O O O O Fuses O O O O O O O O

Heat sink access Brake chopper – – O O O O O XO Regeneration terminals – – O O – – – – Loadshare terminals – – O O O O O O Fuses + loadshare – – O O – – – – Disconnect – – – – O O O O Circuit breakers – – – – – O – O Contactors – – – – – O – O 24 V DC supply O O O O O O O O

Dimensions

Height, mm (in) 901 (35.5) 1107 (43.6) 909 (35.8)

– – O O – – – –

O O O O O O O O

1004 (39.5)

108 (238)

1027 (40.4)

125 (276)

179 (395)

1324 (52.1) 1663 (65.5) 1978 (77.9) 2284 (89.9)

99 (218) 128 (282) 185 (408) 232 (512)

Table 4.5 D1h–D8h Drives, 525–690 V

1) All power ratings are taken at high overload. Output is measured at 690 V (kW) and 575 V (hp).

2) S = standard, O = optional, and a dash indicates that the option is unavailable.

3) Heat sink access is not available with stainless steel back-channel option.

4) With optional load share and regen terminals.

Page 17

Product Overview Design Guide

Enclosure size E1h E2h E3h E4h

Power rating

Output at 690 V (kW) 355–560 630–710 355–560 630–710 Output at 575 V (hp) 400–600 650–750 400–600 650–750

Protection rating

IP IP21/54 IP21/54 UL type Type 1/12 Type 1/12 Chassis Chassis

Hardware options

Stainless steel back channel O O O O Mains shielding O O – – Space heater O O – – RFI lter (Class A1) – – – – Safe torque o S S S S No LCP O O O O Graphical LCP O O O O Fuses S S O O Heat sink access O O O O Brake chopper O O O O Regen terminals O O O O Load share terminals – – O O Fuses + load share – – O O Disconnect O O – – Circuit breakers – – – – Contactors – – – – 24 V DC supply (SMPS, 5 A) – – – –

Dimensions

IP20

4 4

Table 4.6 E1h–E4h Drives, 525–690 V

1) All power ratings are taken at high overload. Output is measured at 690 V (kW) and 575 V (hp).

2) If the enclosure is congured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20.

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

Page 18

Product Overview VLT® AutomationDrive FC 302

4.5 Kit Availability

Kit description

NEMA 3R outdoor weather shield O O – – – – – – – – – – NEMA 3R protection for in-back/out-back cooling kit USB in door O O O O O O O O S S – – LCP, numerical O O O O O O O O O O O O

LCP, graphical LCP cable, 3 m (9 ft) O O O O O O O O O O O O Mounting kit for numerical LCP (LCP, fasteners, gasket, and cable) Mounting kit for graphical LCP (LCP, fasteners, gasket, and cable) Mounting kit for all LCPs (fasteners, gasket, and cable) Mains shield – – – – – – – – O O – – Grounding bar – – – – – – – – O O – – Input plate option O O O O O O O O – – – – Terminal blocks O O O O O O O O O O O O Top entry for eldbus cables O O O O O O O O O O O O Pedestal O O – – O O O O S S – – In bottom/out-top cooling – – O O – – – – – – O O In bottom/out-back cooling O O O O – – – – – – O O In back/out-top cooling – – – – – – – – – – O O In back/out-back cooling O O O O O O O O O O O O Out top (only) cooling – – O O – – – – – – – –

D1h D2h D3h D4h D5h D6h D7h D8h E1h E2h E3h E4h

– – O O – – – – – – – –

O O O O O O O O O O O O

Table 4.7 Available Kits for Enclosures D1h–D8h and E1h–E4h

1) S = standard, O = optional, and a dash indicates that the kit is unavailable for that enclosure. For kit descriptions and part numbers, see

chapter 13.2.6 Ordering Numbers for D1h–D8h Kits and chapter 13.2.7 Ordering Numbers for E1h–E4h Kits.

2) The graphical LCP comes standard with enclosures D1h–D8h and E1h–E4h. If more than 1 graphical LCP is required, the kit is available for

purchase.

Page 19

Product Features Design Guide

5 Product Features

5.1 Automated Operational Features

Automated operational features are active when the drive is operating. Most of them require no programming or setup. The drive has a range of built-in protection functions to protect itself and the motor when it runs.

For details of any set-up required, in particular motor parameters, refer to the programming guide.

5.1.1 Short-circuit Protection

Motor (phase-to-phase)

The drive is protected against short circuits on the motor side by current measurement in each of the 3 motor phases. A short circuit between 2 output phases causes an overcurrent in the inverter. The inverter is turned o when the short circuit current exceeds the allowed value (Alarm 16, Trip Lock).

Mains side

A drive that works correctly limits the current it can draw from the supply. Still, it is recommended to use fuses and/or circuit breakers on the supply side as protection if there is component break-down inside the drive (1st fault). Mains side fuses are mandatory for UL compliance.

NOTICE

To ensure compliance with IEC 60364 for CE or NEC 2009 for UL, it is mandatory to use fuses and/or circuit breakers.

Brake resistor

The drive is protected from a short circuit in the brake resistor.

Load sharing

To protect the DC bus against short circuits and the drives from overload, install DC fuses in series with the load sharing terminals of all connected units.

5.1.2 Overvoltage Protection

Incorrect slip compensation setting causing

•

higher DC-link voltage.

Back EMF from PM motor operation. If coasted at

•

high RPM, the PM motor back EMF can potentially exceed the maximum voltage tolerance of the drive and cause damage. To help prevent this situation, the value of parameter 4-19 Max Output Frequency is automatically limited based on an internal calculation based on the value of parameter 1-40 Back EMF at 1000 RPM, parameter 1-25 Motor Nominal Speed, and parameter 1-39 Motor Poles.

NOTICE

To avoid motor overspeeds (for example, due to excessive windmilling eects), equip the drive with a brake resistor.

The overvoltage can be handled either using a brake function (parameter 2-10 Brake Function) and/or using overvoltage control (parameter 2-17 Over-voltage Control).

Brake functions

Connect a brake resistor for dissipation of surplus brake energy. Connecting a brake resistor allows a higher DC-link voltage during braking.

AC brake is an alternative to improving braking without using a brake resistor. This function controls an overmagnetization of the motor when the motor is acting as a generator. Increasing the electrical losses in the motor allows the OVC function to increase the braking torque without exceeding the overvoltage limit.

NOTICE

AC brake is not as eective as dynamic braking with a resistor.

Overvoltage control (OVC)

By automatically extending the ramp-down time, OVC reduces the risk of the drive tripping due to an overvoltage on the DC-link.

5 5

Motor-generated overvoltage

The voltage in the DC link is increased when the motor acts as a generator. This situation occurs in following cases:

The load rotates the motor at constant output

•

frequency from the drive, that is, the load generates energy.

During deceleration (ramp-down) if the inertia

•

moment is high, the friction is low, and the rampdown time is too short for the energy to be dissipated as a loss throughout the drive system.

NOTICE

OVC can be activated for a PM motor with all control core, PM VVC+, Flux OL, and Flux CL for PM Motors.

NOTICE

Do not enable OVC in hoisting applications.

Page 20

Product Features VLT® AutomationDrive FC 302

5.1.3 Missing Motor Phase Detection

The missing motor phase function (parameter 4-58 Missing Motor Phase Function) is enabled by default to avoid motor damage if a motor phase is missing. The default setting is 1000 ms, but it can be adjusted for faster detection.

5.1.4 Supply Voltage Imbalance Detection

Operation under severe supply voltage imbalance reduces the lifetime of the motor and drive. If the motor is

operated continuously near nominal load, conditions are considered severe. The default setting trips the drive if there is supply voltage imbalance (parameter 14-12 Response to Mains Imbalance).

5.1.5 Switching on the Output

Adding a switch to the output between the motor and the drive is allowed, however fault messages can appear. Danfoss does not recommend using this feature for 525– 690 V drives connected to an IT mains network.

5.1.6 Overload Protection

Torque limit

The torque limit feature protects the motor against overload, independent of the speed. Torque limit is controlled in parameter 4-16 Torque Limit Motor Mode and parameter 4-17 Torque Limit Generator Mode. The time before the torque limit warning trips is controlled in parameter 14-25 Trip Delay at Torque Limit.

Current limit

The current limit is controlled in parameter 4-18 Current Limit, and the time before the drive trips is controlled in parameter 14-24 Trip Delay at Current Limit.

Speed limit

Minimum speed limit: Parameter 4-11 Motor Speed Low Limit [RPM] or parameter 4-12 Motor Speed Low Limit [Hz]

limit the minimum operating speed range of the drive. Maximum speed limit: Parameter 4-13 Motor Speed High Limit [RPM] or parameter 4-19 Max Output Frequency limit the maximum output speed the drive can provide.

Electronic thermal relay (ETR)

ETR is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in Illustration 5.1.

Voltage limit

The inverter turns o to protect the transistors and the DC link capacitors when a certain hard-coded voltage level is reached.

Overtemperature

The drive has built-in temperature sensors and reacts immediately to critical values via hard-coded limits.

5.1.7 Locked Rotor Protection

There can be situations when the rotor is locked due to excessive load or other factors. The locked rotor cannot produce enough cooling, which in turn can overheat the motor winding. The drive is able to detect the locked rotor situation with open-loop PM ux control and PM VVC control (parameter 30-22 Locked Rotor Protection).

5.1.8 Automatic Derating

The drive constantly checks for the following critical levels:

High temperature on the control card or heat

•

sink.

High motor load.

•

High DC-link voltage.

•

Low motor speed.

•

As a response to a critical level, the drive adjusts the switching frequency. For high internal temperatures and low motor speed, the drive can also force the PWM pattern to SFAVM.

NOTICE

The automatic derating is dierent when

parameter 14-55 Output Filter is set to [2] Sine-Wave Filter Fixed.

5.1.9 Automatic Energy Optimization

Automatic energy optimization (AEO) directs the drive to monitor the load on the motor continuously and adjust the output voltage to maximize eciency. Under light load, the voltage is reduced and the motor current is minimized. The motor benets from:

Increased eciency.

•

Reduced heating.

•

Quieter operation.

•

There is no need to select a V/Hz curve because the drive automatically adjusts motor voltage.

5.1.10 Automatic Switching Frequency Modulation

The drive generates short electrical pulses to form an AC wave pattern. The switching frequency is the rate of these pulses. A low switching frequency (slow pulsing rate) causes audible noise in the motor, making a higher switching frequency preferable. A high switching frequency, however, generates heat in the drive that can limit the amount of current available to the motor.

Automatic switching frequency modulation regulates these conditions automatically to provide the highest switching

Page 21

Product Features Design Guide

frequency without overheating the drive. By providing a regulated high switching frequency, it quiets motor operating noise at slow speeds, when audible noise control is critical, and produces full output power to the motor when required.

5.1.11 Automatic Derating for High Switching Frequency

The drive is designed for continuous, full-load operation at switching frequencies between 1.5–2 kHz for 380–500 V, and 1–1.5 kHz for 525–690 V. The frequency range depends on power size and voltage rating. A switching frequency exceeding the maximum allowed range generates increased heat in the drive and requires the output current to be derated.

An automatic feature of the drive is load-dependent switching frequency control. This feature allows the motor to benet from as high a switching frequency as the load allows.

5.1.12 Power Fluctuation Performance

The drive withstands mains uctuations such as:

Transients.

•

Momentary drop-outs.

•

Short voltage drops.

•

Surges.

•

The drive automatically compensates for input voltages ±10% from the nominal to provide full rated motor voltage and torque. With auto restart selected, the drive automatically powers up after a voltage trip. With ying start, the drive synchronizes to motor rotation before start.

5.1.13 Resonance Damping

Resonance damping eliminates the high-frequency motor resonance noise. Automatic or manually selected frequency damping is available.

5.1.14 Temperature-controlled Fans

Sensors in the drive regulate the operation of the internal cooling fans. Often, the cooling fans do not run during low load operation, or when in sleep mode or standby. These sensors reduce noise, increase eciency, and extend the operating life of the fan.

5.1.15 EMC Compliance

Electromagnetic interference (EMI) and radio frequency interference (RFI) are disturbances that can aect an electrical circuit due to electromagnetic induction or

radiation from an external source. The drive is designed to comply with the EMC product standard for drives IEC 61800-3 and the European standard EN 55011. Motor cables must be shielded and properly terminated to comply with the emission levels in EN 55011. For more information regarding EMC performance, see chapter 10.14.1 EMC Test Results.

5.1.16 Galvanic Isolation of Control Terminals

All control terminals and output relay terminals are galvanically isolated from mains power, which completely protects the controller circuitry from the input current. The output relay terminals require their own grounding. This isolation meets the stringent protective extra-low voltage (PELV) requirements for isolation.

The components that make up the galvanic isolation are:

Supply, including signal isolation.

•

Gatedrive for the IGBTs, trigger transformers, and

•

optocouplers.

The output current Hall

•

Custom Application Features

5.2

Custom application functions are the most common features programmed in the drive for enhanced system performance. They require minimum programming or setup. See the programming guide for instructions on activating these functions.

eect transducers.

5.2.1 Automatic Motor Adaptation

Automatic motor adaptation (AMA) is an automated test procedure used to measure the electrical characteristics of the motor. AMA provides an accurate electronic model of the motor, allowing the drive to calculate optimal performance and eciency. Running the AMA procedure also maximizes the automatic energy optimization feature of the drive. AMA is performed without the motor rotating and without uncoupling the load from the motor.

5.2.2 Built-in PID Controller

The built-in proportional, integral, derivative (PID) controller eliminates the need for auxiliary control devices. The PID controller maintains constant control of closedloop systems where regulated pressure, ow, temperature, or other system requirements must be maintained.

The drive can use 2 feedback signals from 2 devices, allowing the system to be regulated with dierent feedback requirements. The drive makes control decisions

dierent

5 5

Page 22

1.21.0 1.4

100

1.81.6 2.0

2000

500

200

400 300

1000

600

t [s]

175ZA052.12

OUT

= 2 x f

M,N

OUT

= 0.2 x f

M,N

OUT

= 1 x f

M,N

(par. 1-23)

IMN(par. 1-24)

Product Features VLT® AutomationDrive FC 302

by comparing the 2 signals to optimize system performance.

5.2.3 Motor Thermal Protection

Motor thermal protection can be provided via:

Direct temperature sensing using a

•

- PTC- or KTY sensor in the motor

windings and connected on a standard AI or DI.

- PT100 or PT1000 in the motor windings

Mechanical thermal switch (Klixon type) on a DI.

•

Built-in electronic thermal relay (ETR).

•

ETR calculates motor temperature by measuring current, frequency, and operating time. The drive shows the thermal load on the motor in percentage and can issue a warning at a programmable overload setpoint. Programmable options at the overload allow the drive to stop the motor, reduce output, or ignore the condition. Even at low speeds, the drive meets I2t Class 20 electronic motor overload standards.

and motor bearings, connected on VLT Sensor Input Card MCB 114.

PTC Thermistor input on VLT® PTC Thermistor Card MCB 112 (ATEX approved).

and speed. The calculated temperature is visible as a readout parameter in parameter 16-18 Motor Thermal. A special version of the ETR is also available for EX-e motors in ATEX areas. This function makes it possible to enter a specic curve to protect the Ex-e motor. See the programming guide for set-up instructions.

5.2.4 Motor Thermal Protection for Ex-e

Motors

The drive is equipped with an ATEX ETR thermal monitoring function for operation of Ex-e motors according to EN-60079-7. When combined with an ATEX approved

PTC monitoring device such as the VLT® PTC Thermistor Card MCB 112 option or an external device, the installation does not require an individual approval from an approbated organization.

The ATEX ETR thermal monitoring function enables use of an Ex-e motor instead of a more expensive, larger, and heavier Ex-d motor. The function ensures that the drive limits motor current to prevent overheating.

Requirements related to the Ex-e motor

Ensure that the Ex-e motor is approved for

•

operation in hazardous zones (ATEX zone 1/21, ATEX zone 2/22) with drives. The motor must be certied for the specic hazardous zone.

Install the Ex-e motor in zone 1/21 or 2/22 of the

•

hazardous zone, according to motor approval.

NOTICE

Install the drive outside the hazardous zone.

Ensure that the Ex-e motor is equipped with an

•

ATEX-approved motor overload protection device. This device monitors the temperature in the motor windings. If there is a critical temperature level or a malfunction, the device switches o the motor.

The VLT® PTC Thermistor Card MCB 112 option provides ATEX-approved monitoring of motor temperature. It is a

Illustration 5.1 ETR Characteristics

The X-axis shows the ratio between I nominal. The Y-axis shows the time in seconds before the ETR cuts o and trips the drive. The curves show the characteristic nominal speed, at twice the nominal speed and at 0.2 x the nominal speed. At lower speed, the ETR cuts o at lower heat due to less cooling of the motor. In that way, the motor is protected from being overheated even at low speed. The ETR feature calculates the motor temperature based on actual current

motor

and I

motor

Sine-wave lter is required when

•

prerequisite that the drive is equipped with 3–6 PTC thermistors in series according to DIN 44081 or 44082.

- Alternatively, an external ATEX-approved PTC protection device can be used.

- Long cables (voltage peaks) or increased mains voltage produce voltages

Page 23

130BD888.10

CONVERTER SUPPLY VALID FOR 380 - 415V FWP 50Hz 3 ~ Motor

MIN. SWITCHING FREQ. FOR PWM CONV. 3kHz l = 1.5XI

M,N

tOL = 10s tCOOL = 10min

MIN. FREQ. 5Hz MAX. FREQ. 85 Hz

PWM-CONTROL

f [Hz]

Ix/I

M,N

PTC °C DIN 44081/-82

Manufacture xx

EN 60079-0 EN 60079-7

СЄ 1180 Ex-e ll T3

5 15 25 50 85

0.4 0.8 1.0 1.0 0.95

xЗ

2 3 4

Product Features Design Guide

exceeding the maximum allowable voltage at motor terminals.

- Minimum switching frequency of the drive does not meet the requirement stated by the motor manufacturer. The minimum switching frequency of the drive is shown as the default value in parameter 14-01 Switching Frequency.

Compatibility of motor and drive

For motors certied according to EN-60079-7, a data list including limits and rules is supplied by the motor manufacturer as a data sheet, or on the motor nameplate. During planning, installation, commissioning, operation, and service, follow the limits and rules supplied by the manufacturer for:

Minimum switching frequency.

•

Maximum current.

•

Minimum motor frequency.

•

Maximum motor frequency.

•

Illustration 5.2 shows where the requirements are indicated on the motor nameplate.

When matching drive and motor, Danfoss species the following extra requirements to ensure adequate motor thermal protection:

Do not exceed the maximum allowed ratio

•

between drive size and motor size. The typical value is I

Consider all voltage drops from drive to motor. If

•

VLT, n

≤2xI

m,n

the motor runs with lower voltage than listed in the U/f characteristics, current can increase, triggering an alarm.

5 5

1 Minimum switching frequency 2 Maximum current 3 Minimum motor frequency 4 Maximum motor frequency

Illustration 5.2 Motor Nameplate showing Drive Requirements

For further information, see the application example in chapter 12 Application Examples.

5.2.5 Mains Drop-out

During a mains drop-out, the drive keeps running until the DC-link voltage drops below the minimum stop level. The minimum stop level is typically 15% below the lowest rated supply voltage. The mains voltage before the dropout and the motor load determines how long it takes for the drive to coast.

The drive can be congured (parameter 14-10 Mains Failure) to dierent types of behavior during mains drop-out:

Trip lock once the DC link is exhausted.

•

Coast with ying start whenever mains return

•

(parameter 1-73 Flying Start).

Kinetic back-up.

•

Controlled ramp down.

•

Flying start

This selection makes it possible to catch a motor that is spinning freely due to a mains drop-out. This option is relevant for centrifuges and fans.

Kinetic back-up

This selection ensures that the drive runs as long as there is energy in the system. For short mains drop-out, the operation is restored after mains return, without bringing

Page 24

. . . . . .

Par. 13-11 Comparator Operator

Par. 13-43 Logic Rule Operator 2

Par. 13-51 SL Controller Event

Par. 13-52 SL Controller Action

130BB671.13

Coast Start timer Set Do X low Select set-up 2 . . .

Running Warning Torque limit Digital input X 30/2 . . .

= TRUE longer than..

. . . . . .

Product Features VLT® AutomationDrive FC 302

the application to a stop or losing control at any time. Several variants of kinetic back-up can be selected.

Set-up data can be copied from drive to drive by downloading the information from the removable LCP.

Congure the behavior of the drive at mains drop-out in parameter 14-10 Mains Failure and parameter 1-73 Flying

5.2.11 Smart Logic Control (SLC)

Start.

Smart logic control (SLC) is a sequence of user-dened

5.2.6 Automatic Restart

actions (see parameter 13-52 SL Controller Action [x]) executed by the SLC when the associated user-dened

The drive can be programmed to restart the motor automatically after a minor trip, such as momentary power loss or uctuation. This feature eliminates the need for

manual resetting, and enhances automated operation for remotely controlled systems. The number of restart attempts and the duration between attempts can be

event (see parameter 13-51 SL Controller Event [x]) is evaluated as TRUE by the SLC. The condition for an event can be a particular status, or that the output from a logic rule or a comparator operand becomes TRUE. The condition leads to an associated action as shown in Illustration 5.3.

limited.

5.2.7 Full Torque at Reduced Speed

The drive follows a variable V/Hz curve to provide full motor torque even at reduced speeds. Full output torque can coincide with the maximum designed operating speed of the motor. This drive diers from variable torque drives and constant torque drives. Variable torque drives provide reduced motor torque at low speed. Constant torque drives provide excess voltage, heat, and motor noise at less than full speed.

5.2.8 Frequency Bypass

In some applications, the system can have operational speeds that create a mechanical resonance. This mechanical resonance can generate excessive noise and possibly damage mechanical components in the system. The drive has 4 programmable bypass-frequency bandwidths. The bandwidths allow the motor to step over speeds that induce system resonance.

5.2.9 Motor Preheat

To preheat a motor in a cold or damp environment, a small amount of DC current can be trickled continuously into the motor to protect it from condensation and cold starts. This function can eliminate the need for a space heater.

5.2.10 Programmable Set-ups

The drive has 4 set-ups that can be independently programmed. Using multi-setup, it is possible to switch between independently programmed functions activated by digital inputs or a serial command. Independent set-ups are used, for example, to change references, or for day/ night or summer/winter operation, or to control multiple motors. The LCP shows the active set-up.

Illustration 5.3 SLC Event and Action

Events and actions are each numbered and linked in pairs (states), which means that when event [0] is fullled (attains the value TRUE), action [0] is executed. After the 1 action is executed, the conditions of the next event are evaluated. If this event is evaluated as true, then the corresponding action is executed. Only 1 event is evaluated at any time. If an event is evaluated as false, nothing happens in the SLC during the current scan interval and no other events are evaluated. When the SLC starts, it only evaluates event [0] during each scan interval. Only when event [0] is evaluated as true, the SLC executes action [0] and starts evaluating the next event. It is possible to program 1–20 events and actions.

Page 25

130BA062.14

State 1 13-51.0 13-52.0

State 2 13-51.1 13-52.1

Start event P13-01

State 3 13-51.2 13-52.2

State 4 13-51.3 13-52.3

Stop event P13-02

Par. 13-11 Comparator Operator

TRUE longer than.

. . .

Par. 13-10 Comparator Operand

Par. 13-12 Comparator Value

130BB672.10

. . . . . .

Par. 13-43 Logic Rule Operator 2

Par. 13-41 Logic Rule Operator 1

Par. 13-40 Logic Rule Boolean 1

Par. 13-42 Logic Rule Boolean 2

Par. 13-44 Logic Rule Boolean 3

130BB673.10

Product Features Design Guide

When the last event/action has been executed, the sequence starts over again from event [0]/action [0]. Illustration 5.4 shows an example with 4 event/actions:

Illustration 5.4 Order of Execution when 4 Events/Actions are

Programmed

Comparators

Comparators are used for comparing continuous variables (output frequency, output current, analog input, and so on) to xed preset values.

Illustration 5.5 Comparators

Logic rules

Combine up to 3 boolean inputs (TRUE/FALSE inputs) from timers, comparators, digital inputs, status bits, and events using the logical operators AND, OR, and NOT.

For more information about Safe Torque O, including installation and commissioning, refer to the Safe Torque O Operating Guide.

Liability conditions

The customer is responsible for ensuring that personnel know how to install and operate the safe torque o function by:

Reading and understanding the safety regulations

•

concerning health, safety, and accident prevention.

Understanding the generic and safety guidelines

•

provided in the Safe Torque O Operating Guide.

Having a good knowledge of the generic and

•

safety standards for the specic application.

5.3 Dynamic Braking Overview

Dynamic braking slows the motor using 1 of the following methods:

AC brake

•

The brake energy is distributed in the motor by changing the loss conditions in the motor (parameter 2-10 Brake Function = [2]). The AC brake function cannot be used in applications with high cycling frequency since this situation overheats the motor.

DC brake

•

An overmodulated DC current added to the AC current works as an eddy current brake (parameter 2-02 DC Braking Time ≠ 0 s).

Resistor brake

•

A brake IGBT keeps the overvoltage under a certain threshold by directing the brake energy from the motor to the connected brake resistor (parameter 2-10 Brake Function = [1]). For more

information on selecting a brake resistor, see VLT Brake Resistor MCE 101 Design Guide.

For drives equipped with the brake option, a brake IGBT along with terminals 81(R-) and 82(R+) are included for connecting an external brake resistor.

5 5

The function of the brake IGBT is to limit the voltage in the DC link whenever the maximum voltage limit is exceeded. It limits the voltage by switching the externally mounted resistor across the DC bus to remove excess DC voltage

Illustration 5.6 Logic Rules

present on the bus capacitors.

External brake resistor placement has the advantages of

5.2.12 Safe Torque O

The Safe Torque O (STO) function is used to stop the drive in emergency stop situations.

selecting the resistor based on application need, dissipating the energy outside of the control panel, and protecting the drive from overheating if the brake resistor is overloaded.

Page 26

Product Features VLT® AutomationDrive FC 302

The brake IGBT gate signal originates on the control card and is delivered to the brake IGBT via the power card and gatedrive card. Also, the power and control cards monitor the brake IGBT for a short circuit. The power card also monitors the brake resistor for overloads.

5.4 Mechanical Holding Brake Overview

A mechanical holding brake is an external piece of equipment mounted directly on the motor shaft that performs static braking. Static braking is when a brake is used to clamp down on the motor after the load has been stopped. A holding brake is either controlled by a PLC or directly by a digital output from the drive.

NOTICE

A drive cannot provide a safe control of a mechanical brake. A redundancy circuitry for the brake control must be

included in the installation.

5.4.1 Mechanical Brake Using Open-loop Control

For hoisting applications, typically it is necessary to control an electromagnetic brake. A relay output (relay 1 or relay 2) or a programmed digital output (terminal 27 or 29) is required. Normally, this output must be closed for as long as the drive is unable to hold the motor. In parameter 5-40 Function Relay (array parameter), parameter 5-30 Terminal 27 Digital Output, or parameter 5-31 Terminal 29 Digital Output, select [32] mechanical brake control for applications with an electromagnetic brake.

When [32] mechanical brake control is selected, the mechanical brake relay remains closed during start until the output current is above the level selected in parameter 2-20 Release Brake Current. During stop, the mechanical brake closes when the speed is below the level selected in parameter 2-21 Activate Brake Speed [RPM]. If the drive is brought into an alarm condition, such as an overvoltage situation, the mechanical brake immediately cuts in. The mechanical brake also cuts in during safe torque o.

Consider the following when using the electromagnetic brake:

Use any relay output or digital output (terminal 27 or 29). If necessary, use a contactor.

•

Ensure that the output is switched

•

being too heavy or the motor not being mounted.

Before connecting the mechanical brake, select [32] Mechanical brake control in parameter group 5-4* Relays (or in

•

parameter group 5-3* Digital Outputs).

The brake is released when the motor current exceeds the preset value in parameter 2-20 Release Brake Current.

•

The brake is engaged 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] and only if the drive carries out a stop command.

o as long as the drive is unable to rotate the motor. Examples include the load

NOTICE

For vertical lifting or hoisting applications, ensure that the load can be stopped if there is an emergency or a malfunction. If the drive is in alarm mode or in an overvoltage situation, the mechanical brake cuts in.

For hoisting applications, make sure that the torque limits in parameter 4-16 Torque Limit Motor Mode and parameter 4-17 Torque Limit Generator Mode are set lower than the current limit in parameter 4-18 Current Limit. It is also recommended to set parameter 14-25 Trip Delay at Torque Limit to 0, parameter 14-26 Trip Delay at Inverter Fault to 0, and parameter 14-10 Mains Failure to [3] Coasting.

Page 27

Start

term.18

1=on

0=o

Shaft speed

Start delay time

o

Brake delay time

Time

Output current

Relay 01

Pre-magnetizing current or DC hold current

Reaction time EMK brake

Par 2-20 Release brake current

Par 1-76 Start current/ Par 2-00 DC hold current

Par 1-74 Start speed

Par 2-21

Activate brake

speed

Mechanical brake locked

Mechanical brake free

Par 1-71

Par 2-23

130BA074.12

Product Features Design Guide

5 5

Illustration 5.7 Mechanical Brake Control in Open Loop

5.4.2 Mechanical Brake Using Closed-loop Control

The VLT® AutomationDrive FC 302 features a mechanical brake control designed for hoisting applications and supports the following functions:

2 channels for mechanical brake feedback, oering protection against unintended behavior resulting from a broken

•

cable.

Monitoring the mechanical brake feedback throughout the complete cycle. Monitoring helps protect the

•

mechanical brake - especially if more drives are connected to the same shaft.

No ramp up until feedback conrms that the mechanical brake is open.

•

Improved load control at stop.

•

The transition when motor takes over the load from the brake can be congured.

•

Parameter 1-72 Start Function [6] Hoist Mech. Brake Rel activates the hoist mechanical brake. The main dierence compared to the regular mechanical brake control is that the hoist mechanical brake function has direct control over the brake relay. Instead of setting a current to release the brake, the torque applied against the closed brake before release is dened. Because the torque is dened directly, the set-up is more straightforward for hoisting applications.

The hoist mechanical brake strategy is based on the following 3-step sequence, where motor control and brake release are synchronized to obtain the smoothest possible brake release.

1. Pre-magnetize the motor. To ensure that there is a hold on the motor and to verify that it is mounted correctly, the motor is magnetized.

2. Apply torque against the closed brake.

rst pre-

Page 28

130BA642.12

A22 Active

W22 Active

A22 Active

High

Low

High

Low

Open

Closed

Motor Speed

Torque Ref.

Brake Relay

Mech Brake Feedback

Gain Boost or Postion Control

Mech Brake Position

Activate Brake

Delay

P. 2-23

Torque Ramp

Down Time

p. 2-29

Stop Delay

P. 2-24

Ramp 1 Down

P. 3-42

Ramp 1 Up

P. 3-41

Brake Release

Time

p. 2-25

Torque Ramp

Up Time

p. 2-27

Contact no.2 OPTIONAL E.g. DI33 [71] Mech. Brake Feedback

Contact no.1 E.g. DI32 [70] Mech. Brake Feedback

Gain Boost. p. 2-28

Torque Ref. p. 2-26

Product Features VLT® AutomationDrive FC 302

When the load is held by the mechanical brake, its size cannot be determined, only its direction. The moment the brake opens, the motor must take over the load. To facilitate the takeover, a user-dened torque (parameter 2-26 Torque Ref) is applied in the hoisting direction. This process is used to initialize the speed controller that nally takes over the load. To reduce wear on the gearbox due to backlash, the torque is ramped up.

3. Release the brake. When the torque reaches the value set in parameter 2-26 Torque Ref, the brake is released. The value set in parameter 2-25 Brake Release Time determines the delay before the load is released. To react as quickly as possible on the load-step that follows after brake release, the speed-PID control can be boosted by increasing the proportional gain.

Illustration 5.8 Brake Release Sequence for Hoist Mechanical Brake Control

Parameter 2-26 Torque Ref to parameter 2-33 Speed PID Start Lowpass Filter Time are only available for the hoist mechanical brake control (ux with motor feedback). Parameter 2-30 Position P Start Proportional Gain to parameter 2-33 Speed PID Start

Lowpass Filter Time can be set up for smooth transition change from speed control to position control during parameter 2-25 Brake Release Time - the time when the load is transferred from the mechanical brake to the drive. Parameter 2-30 Position P Start Proportional Gain to parameter 2-33 Speed PID Start Lowpass Filter Time are activated when parameter 2-28 Gain Boost Factor is set to 0. See Illustration 5.8 for more information.

NOTICE

For an example of advanced mechanical brake control for hoisting applications, see chapter 12 Application Examples.

Page 29

130BF758.10

380 V

2x aR-1000 A 2x aR-1500 A

3x 1.2%

315 kW 500 kW

3x 1.2%

3x Class L-800 A

3x Class L-1200 A

Common mains disconnect switch

Mains connecting point for additional drives in the load sharing application

DC connecting point for additional drives in the load sharing application

91 92 93

96 97 98

82 81 82 81

Product Features Design Guide

5.5 Load Share Overview

Load share is a feature that allows the connection of DC circuits of several drives, creating a multiple-drive system to run 1 mechanical load. Load share provides the following benets:

Energy savings

A motor running in regenerative mode can supply drives that are running in motoring mode.

Reduced need for spare parts

Usually, only 1 brake resistor is needed for the entire drive system instead of 1 brake resistor for per drive.

Power back-up

If there is mains failure, all linked drives can be supplied through the DC link from a back-up. The application can continue running or go though a controlled shutdown process.

Preconditions

The following preconditions must be met before load sharing is considered:

The drive must be equipped with load sharing terminals.

•

Product series must be the same. Use only VLT® AutomationDrive FC 302 drives with other VLT® AutomationDrive

•

FC 302 drives.

Drives must be placed physically close to one another to allow the wiring between them to be no longer than

•

25 m (82 ft).

Drives must have the same voltage rating.

•

When adding a brake resistor in a load sharing conguration, all drives must be equipped with a brake chopper.

•

Fuses must be added to load share terminals.

•

5 5

For a diagram of a load share application in which best practices are applied, see Illustration 5.9.

Illustration 5.9 Diagram of a Load Share Application Where Best Practices are Applied

Page 30

Product Features VLT® AutomationDrive FC 302

Load sharing

Units with the built-in load sharing option contain terminals (+) 89 DC and (–) 88 DC. Within the drive, these terminals connect to the DC bus in front of the DC-link reactor and bus capacitors.

The load sharing terminals can connect in 2 dierent congurations.

Terminals tie the DC-bus circuits of multiple drives together. This conguration allows a unit that is in a

•

regenerative mode to share its excess bus voltage with another unit that is running a motor. Load sharing in this manner can reduce the need for external dynamic brake resistors, while also saving energy. The number of units that can be connected in this way is innite, as long as each unit has the same voltage rating. In addition, depending on the size and number of units, it may be necessary to install DC reactors and DC fuses in the DC-link connections, and AC reactors on the mains. Attempting such a conguration requires specic considerations.

The drive is powered exclusively from a DC source. This conguration requires:

•

- A DC source.

- A means to soft charge the DC bus at power-up.

5.6 Regen Overview

Regen typically occurs in applications with continuous braking such as cranes/hoists, downhill conveyors, and centrifuges where energy is pulled out of a decelerated motor.

The excess energy is removed from the drive using 1 of the following options:

Brake chopper allows the excess energy to be dissipated in the form of heat within the brake resistor coils.

•

Regen terminals allow a third-party regen unit to be connected to the drive, allowing the excess energy to be

•

returned to the power grid.

Returning excess energy back to the power grid is the most ecient use of regenerated energy in applications using continuous braking.

Page 31

130BG068.10

225 mm (8.9 in)

130BG069.10

225 mm (8.9 in)

Product Features Design Guide

5.7 Back-channel Cooling Overview

A unique back-channel duct passes cooling air over the heat sinks with minimal air passing through the electronics area. There is an IP54/Type 12 seal between the back-channel cooling duct and the electronics area of the VLT® drive. This back-

channel cooling allows 90% of the heat losses to be exhausted directly outside the enclosure. This design improves reliability and prolongs component life by dramatically reducing interior temperatures and contamination of the electronic components. Dierent back-channel cooling kits are available to redirect the airow based on individual needs.

5.7.1 Airow for D1h–D8h Enclosures

5 5

Illustration 5.10 Standard Airow Conguration for Enclosures D1h/D2h (Left), D3h/D4h (Center), and D5h–D8h (Right).

Illustration 5.11 Optional Airow Conguration Using Back-channel Cooling Kits for Enclosures D1h–D8h.

(Left) In-bottom/out-back cooling kit for enclosures D1h/D2h.

(Center) In-bottom/out-top cooling kit for enclosures D3h/D4h.

(Right) In-back/out-back cooling kit for enclosures D5–D8h.

Page 32

225 mm (8.9 in)

130BF699.10

225 mm (8.9 in)

130BF700.10

Product Features VLT® AutomationDrive FC 302

5.7.2 Airow for E1h–E4h Enclosures

Illustration 5.12 Standard Airow Conguration for E1h/E2h (Left) and E3h/E4h (Right)

Illustration 5.13 Optional Airow Conguration Through the Back Wall for E1h/E2h (Left) and E3h/E4h (Right)

Page 33

Options and Accessories Ove... Design Guide

6 Options and Accessories Overview

6.1 Fieldbus Devices

This section describes the eldbus devices that are available with the VLT® AutomationDrive FC 302 series.

Using a eldbus device reduces system cost, delivers faster and more ecient communication, and provides an easier user interface. For ordering numbers, refer to chapter 13.2 Ordering Numbers for Options and Accessories.

6.1.1

VLT® PROFIBUS DP-V1 MCA 101

The VLT® PROFIBUS DP-V1 MCA 101 provides:

Wide compatibility, a high level of availability,

•

support for all major PLC vendors, and compatibility with future versions.

Fast, ecient communication, transparent instal-

•

lation, advanced diagnosis, and parameterization and auto-conguration of process data via a GSD

le.

Acyclic parameterization using PROFIBUS DP-V1,

•

PROFIdrive, or Danfoss FC prole state machines.

6.1.2

VLT® DeviceNet MCA 104

The VLT® DeviceNet MCA 104 provides:

Support of the ODVA AC drive prole supported

•

via I/O instance 20/70 and 21/71 secures compatibility to existing systems.

Benets from ODVA’s strong conformance testing

•

policies that ensure products are interoperable.

6.1.3

VLT® CAN Open MCA 105

The MCA 105 option provides:

Standardized handling.

•

Interoperability.

•

Low cost.

•

This option is fully equipped with both high-priority access to control the drive (PDO communication) and to access all parameters through acyclic data (SDO communication).

For interoperability, the option uses the DSP 402 AC drive

prole.

6.1.4

VLT® PROFIBUS Converter MCA 113

The MCA 113 option is a special version of the PROFIBUS options that emulates the VLT® 3000 commands in the VLT® AutomationDrive FC 302.

The VLT® 3000 can be replaced by the VLT AutomationDrive FC 302, or an existing system can be expanded without costly change of the PLC program. For upgrade to a be removed and replaced with a new option. The MCA 113 option secures the investment without losing exibility.

6.1.5

The MCA 114 option is a special version of the PROFIBUS options that emulates the VLT® 5000 commands in the VLT® AutomationDrive FC 302. This option supports DP-V1.

The VLT® 5000 can be replaced by the VLT AutomationDrive FC 302, or an existing system can be expanded without costly change of the PLC program. For upgrade to a be removed and replaced with a new option. The MCA 114 option secures the investment without losing exibility.

6.1.6

The VLT® PROFINET MCA 120 combines the highest performance with the highest degree of openness. The option is designed so that many of the features from the

VLT® PROFIBUS MCA 101 can be reused, minimizing user eort to migrate PROFINET and securing the investment in a PLC program.

•

dierent eldbus, the installed converter can

VLT® PROFIBUS Converter MCA 114

dierent eldbus, the installed converter can

VLT® PROFINET MCA 120

Same PPO types as the VLT® PROFIBUS DP V1 MCA 101 for easy migration to PROFINET.

Built-in web server for remote diagnosis and reading out of basic drive parameters.

Supports MRP.

Supports DP-V1. Diagnostic allows easy, fast, and standardized handling of warning and fault information into the PLC, improving bandwidth in the system.

Supports PROFIsafe when combined with VLT Safety Option MCB 152.

Implementation in accordance with Conformance Class B.

Page 34

Options and Accessories Ove... VLT® AutomationDrive FC 302

6.1.7

VLT® EtherNet/IP MCA 121

Ethernet is the future standard for communication at the factory oor. The VLT® EtherNet/IP MCA 121 is based on

the newest technology available for industrial use and handles even the most demanding requirements. EtherNet/IP™ extends standard commercial Ethernet to the Common Industrial Protocol (CIP™) – the same upper-layer protocol and object model found in DeviceNet.

This option

•

6.1.8

oers advanced features such as: Built-in, high-performance switch enabling linetopology, which eliminates the need for external switches.

DLR Ring (from October 2015).

Advanced switch and diagnosis functions.

Built-in web server.

E-mail client for service notication.

Unicast and Multicast communication.

VLT® Modbus TCP MCA 122

6.1.10

The MCA 124 option oers connectivity to EtherCAT® based networks via the EtherCAT Protocol.

The option handles the EtherCAT line communication in full speed, and connection towards the drive with an interval down to 4 ms in both directions, allowing the MCA 124 to participate in networks ranging from low performance up to servo applications.

VLT® EtherCAT MCA 124

EoE Ethernet over EtherCAT support.

•

HTTP (hypertext transfer protocol) for diagnosis

•

via built-in web server.

CoE (CAN over Ethernet) for access to drive

•

parameters.

SMTP (simple mail transfer protocol) for e-mail

•

notication.

TCP/IP for easy access to drive conguration data

•

from MCT 10.

6.2 Functional Extensions

The VLT® Modbus TCP MCA 122 connects to Modbus TCPbased networks. It handles connection intervals down to 5 ms in both directions, positioning it among the fastest performing Modbus TCP devices in the market. For master redundancy, it features hot swapping between 2 masters.

Other features include:

Built-in web-server for remote diagnosis and

•

reading out basic drive parameters.

Email notication that can be congured to send

•

an email message to 1 or more recipients when certain alarms or warnings occur, or when they are cleared.

Dual master PLC connection for redundancy.

•

6.1.9

VLT® POWERLINK MCA 123

The MCA 123 option represents the 2nd generation of eldbus. The high bit rate of industrial Ethernet can now be used to make the full power of IT technologies used in the automation world available for the factory world.

eldbus option provides high performance, real-time,

This and time synchronization features. Due to its CANopenbased communication models, network management, and device description model, it oers a fast communication network and the following features:

Dynamic motion control applications.

•

Material handling.

•

Synchronization and positioning applications.

•

This section describes the functional extension options that are available with the VLT® AutomationDrive FC 302 series.

For ordering numbers, refer to chapter 13.2 Ordering Numbers for Options and Accessories.

6.2.1

VLT® General Purpose I/O Module MCB 101

The VLT® General Purpose I/O Module MCB 101 oers an extended number of control inputs and outputs:

3 digital inputs 0–24 V: Logic 0 < 5 V; Logic 1 >

•

10 V.

2 analog inputs 0–10 V: Resolution 10 bits plus

•

sign.

2 digital outputs NPN/PNP push-pull.

•

1 analog output 0/4–20 mA.

•

Spring-loaded connection.

•

6.2.2

VLT® Encoder Input MCB 102

The MCB 102 option oers the possibility to connect various types of incremental and absolute encoders. The connected encoder can be used for closed-loop speed control and closed-loop ux motor control.

The following encoder types are supported:

5 V TTL (RS 422)

•

1VPP SinCos

•

SSI

•

Page 35

Options and Accessories Ove... Design Guide

HIPERFACE

•

EnDat

•

6.2.3

VLT® Resolver Option MCB 103

The MCB 103 option enables connection of a resolver to provide speed feedback from the motor.

Primary voltage: 2–8 V

•

Primary frequency: 2.0–15 kHz

•

Primary maximum current: 50 mA rms

•

Secondary input voltage: 4 V

•

Spring-loaded connection

•

6.2.4

VLT® Relay Card MCB 105

The VLT® Relay Card MCB 105 extends relay functions with 3 more relay outputs.

Protects control cable connection.

•

Spring-loaded control wire connection.

•

Maximum switch rate (rated load/minimum load)

6 minutes-1/20 s-1.

Maximum terminal load

AC-1 resistive load: 240 V AC, 2 A.

6.2.5

VLT® Safe PLC Interface Option

rms

MCB 108

The MCB 108 option provides a safety input based on a single-pole 24 V DC input. For most applications, this input provides a way to implement safety in a cost-eective way.

For applications that work with more advanced products like Safety PLC and light curtains, the fail-safe PLC interface enables the connection of a 2-wire safety link. The PLC Interface allows the fail-safe PLC to interrupt on the plus or the minus link without interfering with the sense signal of the fail-safe PLC.

6.2.6

VLT® PTC Thermistor Card MCB 112

The MCB 112 option provides extra motor monitoring compared to the built-in ETR function and thermistor terminal.

Protects the motor from overheating.

•

ATEX-approved for use with Ex-d and Ex-e motors

•

(EX-e only FC 302).

Uses Safe Torque O function, which is approved

•

in accordance with SIL 2 IEC 61508.

6.2.7

VLT® Sensor Input Option MCB 114

The VLT® Sensor Input Option MCB 114 protects the motor from being overheated by monitoring the temperature of motor bearings and windings.

3 self-detecting sensor inputs for 2 or 3-wire

•

PT100/PT1000 sensors.

1 extra analog input 4–20 mA.

•

6.2.8

VLT® Safety Option MCB 150 and MCB 151

MCB 150 and MCB 151 options expand the Safe Torque functions, which are integrated in a standard VLT

AutomationDrive FC 302. Use the Safe Stop 1 (SS1) function to perform a controlled stop before removing torque. Use the Safety-Limited Speed (SLS) function to monitor whether a specied speed is exceeded.

These options can be used up to PL d according to ISO 13849-1 and SIL 2 according to IEC 61508.

Extra standard-compliant safety functions.

•

Replacement of external safety equipment.

•

Reduced space requirements.

•

2 safe programmable inputs.

•

1 safe output (for T37).

•

Easier machine certication.

•

Drive can be powered continuously.

•

Safe LCP copy.

•

Dynamic commissioning report.

•

TTL (MCB 150) or HTL (MCB 151) encoder as

•

speed feedback.

6.2.9

VLT® Safety Option MCB 152

The MCB 152 option activates Safe Torque O via the PROFIsafe eldbus with VLT® PROFINET MCA 120 eldbus

option. It improves exibility by connecting safety devices within a plant.

The safety functions of the MCB 152 are implemented according to EN IEC 61800-5-2. The MCB 152 supports PROFIsafe functionality to activate integrated safety

functions of the VLT® AutomationDrive FC 302 from any PROFIsafe host, up to Safety Integrity Level SIL 2 according to EN IEC 61508 and EN IEC 62061, and Performance Level PL d, Category 3 according to EN ISO 13849-1.

PROFIsafe device (with MCA 120).

•

Replacement of external safety equipment.

•

O

Page 36

Options and Accessories Ove... VLT® AutomationDrive FC 302

2 safe programmable inputs.

•

Safe LCP copy.

•

Dynamic commissioning report.

•

6.3 Motion Control and Relay Cards

This section describes the motion control and relay card options that are available with the VLT® AutomationDrive

FC 302 series. For ordering numbers, refer to chapter 13.2 Ordering Numbers for Options and Accessories.

6.3.1

VLT® Motion Control Option MCO 305

The MCO 305 option is an integrated programmable motion controller that adds extra functionality for VLT

AutomationDrive FC 302.

The MCO 305 option oers easy-to-use motion functions combined with programmability – an ideal solution for positioning and synchronizing applications.

Synchronization (electronic shaft), positioning,

•

and electronic cam control.

2 separate interfaces supporting both incremental

•

and absolute encoders.

1 encoder output (virtual master function).

•

10 digital inputs.

•

8 digital outputs.

•

Supports CANopen motion bus, encoders, and I/O

•

modules.

Sends and receives data via

•

(requires eldbus option).

PC software tools for debugging and commis-

•

sioning: Program and cam editor.

Structured programming language with both

•

cyclic and event-driven execution.

6.3.2

VLT® Synchronizing Controller

eldbus interface

MCO 350

Control via I/Os or eldbus.

•

Home function.

•

Conguration and readout of status and data via

•

the LCP.

6.3.3

VLT® Positioning Controller MCO 351

The MCO 351 option oers a host of user-friendly benets for positioning applications in many industries.

Relative positioning.

•

Absolute positioning.

•

Touch-probe positioning.

•

End-limit handling (software and hardware).

•

Control via I/Os or eldbus.

•

Mechanical brake handling (programmable hold

•

delay).

Error handling.

•

Jog speed/manual operation.

•

Marker-related positioning.

•

Home function.

•

Conguration and readout of status and data via

•

the LCP.

6.3.4

VLT® Extended Relay Card MCB 113

The VLT® Extended Relay Card MCB 113 adds inputs/ outputs for increased exibility.

7 digital inputs.

•

2 analog outputs.

•

4 SPDT relays.

•

Meets NAMUR recommendations.

•

Galvanic isolation capability.

•

Brake Resistors

6.4

The MCO 350 option for VLT® AutomationDrive FC 302 expands the functional properties of the AC drive in synchronizing applications and replaces traditional mechanical solutions.

Speed synchronizing.

•

Position (angle) synchronizing with or without

•

marker correction.

On-line adjustable gear ratio.

•

On-line adjustable position (angle) oset.

•

Encoder output with virtual master function for

•

synchronization of multiple slaves.

In applications where the motor is used as a brake, energy is generated in the motor and sent back into the drive. If the energy cannot be transported back to the motor, it increases the voltage in the drive DC line. In applications with frequent braking and/or high inertia loads, this increase can lead to an overvoltage trip in the drive and, nally, a shutdown. Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor 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 specially designed to Danfoss drives. For ordering numbers and more information on how to dimension brake resistors, refer to

the VLT® Brake Resistor MCE 101 Design Guide.

Page 37

Options and Accessories Ove... Design Guide

6.5 Sine-wave Filters

When a drive controls a motor, resonance noise is heard from the motor. This noise, which is the result of the motor design, occurs every time an inverter switch in the drive is activated. The frequency of the resonance noise thus corresponds to the switching frequency of the drive.

Danfoss supplies a sine-wave motor noise. The lter reduces the ramp-up time of the voltage, the peak load voltage (U current (ΔI) to the motor, which means that current and voltage become almost sinusoidal. The acoustic motor noise is reduced to a minimum.

The ripple current in the sine-wave some noise. Solve the problem by integrating the lter in a cabinet or enclosure.

For ordering numbers and more information on sine-wave

lters, refer to the Output Filters Design Guide.

lter to dampen the acoustic

), and the ripple

PEAK

lter coils also causes

6.6 dU/dt Filters

Danfoss supplies dU/dt lters which are dierential mode, low-pass lters that reduce motor terminal phase-to-phase peak voltages and reduce the rise time to a level that lowers the stress on the insulation at the motor windings. This is a typical issue with set-ups using short motor cables.

Harmonic Filters

6.8

The VLT® Advanced Harmonic Filters AHF 005 & AHF 010 should not be compared with traditional harmonic trap lters. The Danfoss harmonic lters have been specially designed to match the Danfoss drives.

By connecting the AHF 005 or AHF 010 in front of a Danfoss drive, the total harmonic current distortion generated back to the mains is reduced to 5% and 10%.

For ordering numbers and more information on how to dimension brake resistors, refer to the VLT® Advanced

Harmonic Filters AHF 005/AHF 010 Design Guide.

6.9 High-power Kits

High-power kits, such as back-wall cooling, space heater, mains shield, are available. See chapter 13.2 Ordering Numbers for Options and Accessories for a brief description and ordering numbers for all available kits.

Compared to sine-wave lters, the dU/dt lters have a cuto frequency above the switching frequency.

For ordering numbers and more information on dU/dt lters, refer to the Output Filters Design Guide.

Common-mode Filters

6.7

High-frequency common-mode cores (HF-CM cores) reduce electromagnetic interference and eliminate bearing damage by electrical discharge. They are special nanocrystalline magnetic cores that have superior ltering performance compared to regular ferrite cores. The HF-CM core acts like a common-mode inductor between phases and ground.

Installed around the 3 motor phases (U, V, W), the common mode lters reduce high-frequency commonmode currents. As a result, high-frequency electromagnetic interference from the motor cable is reduced.

For ordering numbers refer to the Output Filters Design Guide.

Page 38

Specications VLT® AutomationDrive FC 302

7 Specications

7.1 Electrical Data, 380–500 V

VLT® AutomationDrive FC 302

High/normal overload HO NO HO NO HO NO

(High overload=150% current during 60 s, normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 90 110 110 132 132 160 Typical shaft output at 460 V [hp] 125 150 150 200 200 250 Typical shaft output at 500 V [kW] 110 132 132 160 160 200

Enclosure size D1h/D3h/D5h/D6h

Output current (3-phase)

Continuous (at 400 V) [A] 177 212 212 260 260 315 Intermittent (60 s overload) (at 400 V)[A] 266 233 318 286 390 347 Continuous (at 460/500 V) [A] 160 190 190 240 240 302

Intermittent (60 s overload) (at 460/500 V) [kVA] 240 209 285 264 360 332 Continuous kVA (at 400 V) [kVA] 123 147 147 180 180 218 Continuous kVA (at 460 V) [kVA] 127 151 151 191 191 241 Continuous kVA (at 500 V) [kVA] 139 165 165 208 208 262

Maximum input current

Continuous (at 400 V) [A] 171 204 204 251 251 304 Continuous (at 460/500 V) [A] 154 183 183 231 231 291

Maximum number and size of cables per phase

- Mains, motor, brake, and load share [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)]

2), 3)

N90K N110 N132

2x95 (2x3/0) 2x95 (2x3/0) 2x95 (2x3/0)

315 350 400

2031 2559 2289 2954 2923 3770

1828 2261 2051 2724 2089 3628

0.98 0.98 0.98

110 (230) 110 (230) 110 (230)

75 (167) 75 (167) 75 (167)

Table 7.1 Electrical Data for Enclosures D1h/D3h/D5h/D6h, Mains Supply 3x380–500 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.11 Eciency. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 39

Specications Design Guide

VLT® AutomationDrive FC 302

High/normal overload HO NO HO NO HO NO

(High overload=150% current during 60 s, normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 160 200 200 250 250 315 Typical shaft output at 460 V [hp] 250 300 300 350 350 450 Typical shaft output at 500 V [kW] 200 250 250 315 315 355

Enclosure size D2h/D4h/D7h/D8h

Output current (3-phase)

Continuous (at 400 V) [A] 315 395 395 480 480 588 Intermittent (60 s overload) (at 400 V)[A] 473 435 593 528 720 647 Continuous (at 460/500 V) [A] 302 361 361 443 443 535 Intermittent (60 s overload) (at 460/500 V) [kVA] 453 397 542 487 665 589 Continuous kVA (at 400 V) [kVA] 218 274 274 333 333 407 Continuous kVA (at 460 V) [kVA] 241 288 288 353 353 426 Continuous kVA (at 500 V) [kVA] 262 313 313 384 384 463

Maximum input current

Continuous (at 400 V) [A] 304 381 381 463 463 567 Continuous (at 460/500 V) [A] 291 348 348 427 427 516

Maximum number and size of cables per phase

- Mains, motor, brake, and load share [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)]

2), 3)

N160 N200 N250

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

550 630 800

3093 4116 4039 5137 5005 6674

2872 3569 3575 4566 4458 5714

0.98 0.98 0.98

110 (230) 110 (230) 110 (230)

80 (176) 80 (176)

80 (176)

7 7

Table 7.2 Electrical Data for Enclosures D2h/D4h/D7h/D8h, Mains Supply 3x380–500 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.11 Eciency. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 40

Specications VLT® AutomationDrive FC 302

VLT® AutomationDrive FC 302

High/normal overload HO NO HO NO HO NO

(High overload=150% current during 60 s, normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 315 355 355 400 400 450 Typical shaft output at 460 V [hp] 450 500 500 600 550 600 Typical shaft output at 500 V [kW] 355 400 400 500 500 530

Enclosure size E1h/E3h E1h/E3h E1h/E3h

Output current (3-phase)

Continuous (at 400 V) [A] 600 658 658 745 695 800 Intermittent (60 s overload) (at 400 V) [A] 900 724 987 820 1043 880 Continuous (at 460/500 V) [A] 540 590 590 678 678 730 Intermittent (60 s overload) (at 460/500 V) [A] 810 649 885 746 1017 803 Continuous kVA (at 400 V) [kVA] 416 456 456 516 482 554 Continuous kVA (at 460 V) [kVA] 430 470 470 540 540 582 Continuous kVA (at 500 V) [kVA] 468 511 511 587 587 632

Maximum input current

Continuous (at 400 V) [A] 578 634 634 718 670 771 Continuous (at 460/500 V) [A] 520 569 569 653 653 704

Maximum number and size of cables per phase (E1h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)]

- Brake or regen [mm2 (AWG)]

Maximum number and size of cables per phase (E3h)

- Mains and motor [mm2 (AWG)]

- Brake [mm2 (AWG)]

- Load share or regen [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)] Power card overtemperature trip [°C (°F)] Fan power card overtemperature trip [°C (°F)] Active in-rush card overtemperature trip [°C (°F)]

2), 3)

N315 N355 N400

5x240 (5x500 mcm) 5x240 (5x500 mcm) 5x240 (5x500 mcm)

4x240 (4x500 mcm) 4x240 (4x500 mcm) 4x240 (4x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm) 4x185 (4x350 mcm)

800 800 800

6178 6928 6851 8036 7297 8783

5322 5910 5846 6933 7240 7969

0.98 0.98 0.98

110 (230) 110 (230) 110 (230)

80 (176) 80 (176) 80 (176) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185)

Table 7.3 Electrical Data for Enclosures E1h/E3h, Mains Supply 3x380–500 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.11 Eciency. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 41

Specications Design Guide

VLT® AutomationDrive FC 302

High/normal overload HO NO HO NO

(High overload=150% current during 60 s, normal overload=110% current during 60 s) Typical shaft output at 400 V [kW] 450 500 500 560 Typical shaft output at 460 V [hp] 600 650 650 750 Typical shaft output at 500 V [kW] 530 560 560 630

Enclosure size E2h/E4h E2h/E4h

Output current (3-phase)

Continuous (at 400 V) [A] 800 880 880 990 Intermittent (60 s overload) (at 400 V) [A] 1200 968 1320 1089 Continuous (at 460/500 V) [A] 730 780 780 890 Intermittent (60 s overload) (at 460/500 V) [A] 1095 858 1170 979 Continuous kVA (at 400 V) [kVA] 554 610 610 686 Continuous kVA (at 460 V) [kVA] 582 621 621 709 Continuous kVA (at 500 V) [kVA] 632 675 675 771

Maximum input current

Continuous (at 400 V) [A] 771 848 848 954 Continuous (at 460/500 V) [A] 704 752 752 858

Maximum number and size of cables per phase (E2h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)]

- Brake or regen [mm2 (AWG)]

Maximum number and size of cables per phase (E4h)

- Mains and motor [mm2 (AWG)]

- Brake [mm2 (AWG)]

- Load share or regen [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)] Power card overtemperature trip [°C (°F)] Fan power card overtemperature trip [°C (°F)] Active in-rush card overtemperature trip [°C (°F)]

2), 3)

N450 N500

6x240 (6x500 mcm) 6x240 (6x500 mcm)

5x240 (5x500 mcm) 5x240 (5x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm)

1200 1200

8352 9473 9449 11102

7182 7809 7771 9236

0.98 0.98

110 (230) 100 (212)

80 (176) 80 (176) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185)

7 7

Table 7.4 Electrical Data for Enclosures E2h/E4h, Mains Supply 3x380–500 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.11 Eciency. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 42

Specications VLT® AutomationDrive FC 302

7.2 Electrical Data, 525–690 V

VLT® AutomationDrive FC 302

High/normal overload HO NO HO NO HO NO HO NO HO NO (High overload=150% current during 60 s, normal overload=110% current during 60 s) Typical shaft output at 525 V [kW] 45 55 55 75 75 90 90 110 110 132 Typical shaft output at 575 V [hp] 60 75 75 100 100 125 125 150 150 200 Typical shaft output at 690 V [kW] 55 75 75 90 90 110 110 132 132 160

Enclosure size D1h/D3h/D5h/D6h

Output current (3-phase)

Continuous (at 525 V) [A] 76 90 90 113 113 137 137 162 162 201 Intermittent (60 s overload) (at 525 V) [A] Continuous (at 575/690 V) [A] 73 86 86 108 108 131 131 155 155 192 Intermittent (60 s overload)

(at 575/690 V) [A] Continuous kVA (at 525 V) [kVA] 69 82 82 103 103 125 125 147 147 183 Continuous kVA (at 575 V) [kVA] 73 86 86 108 108 131 131 154 154 191 Continuous kVA (at 690 V) [kVA] 87 103 103 129 129 157 157 185 185 230

Maximum input current

Continuous (at 525 V) [A] 74 87 87 109 109 132 132 156 156 193 Continuous (at 575/690 V) 70 83 83 104 104 126 126 149 149 185

Maximum number and size of cables per phase

- Mains, motor, brake, and load share [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 575 V [W]

Estimated power loss at 690 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 0–590 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)]

2), 3)

N55K N75K N90K N110 N132

114 99 135 124 170 151 206 178 243 221

110 95 129 119 162 144 197 171 233 211

2x95 (2x3/0) 2x95 (2x3/0) 2x95 (2x3/0) 2x95 (2x3/0) 2x95 (2x3/0)

160 315 315 315 315

1098 1162 1162 1428 1430 1740 1742 2101 2080 2649

1057 1204 1205 1477 1480 1798 1800 2167 2159 2740

0.98 0.98 0.98 0.98 0.98

110 (230) 110 (230) 110 (230) 110 (230) 110 (230)

75 (167) 75 (167) 75 (167) 75 (167) 75 (167)

Table 7.5 Electrical Data for Enclosures D1h/D3h/D5h/D6h, Mains Supply 3x525–690 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.11 Eciency. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 43

Specications Design Guide

VLT® AutomationDrive FC 302

High/normal overload HO NO HO NO HO NO HO NO (High overload=150% current during 60 s, normal overload=110% current during 60 s) Typical Shaft output at 525 V [kW] 132 160 160 200 200 250 250 315 Typical Shaft output at 575 V [hp] 200 250 250 300 300 350 350 400 Typical Shaft output at 690 V [kW] 160 200 200 250 250 315 315 400

Enclosure size D2h/D4h/D7h/D8h

Output current (3-phase)

Continuous (at 525 V) [A] 201 253 253 303 303 360 360 418 Intermittent (60 s overload) (at 525 V)[A] 301 278 380 333 455 396 540 460 Continuous (at 575/690 V) [A] 192 242 242 290 290 344 344 400 Intermittent (60 s overload) (at 575/690 V) [A] 288 266 363 319 435 378 516 440 Continuous kVA (at 525 V) [kVA] 183 230 230 276 276 327 327 380 Continuous kVA (at 575 V) [kVA] 191 241 241 289 289 343 343 398 Continuous kVA (at 575/690 V) [kVA] 229 289 289 347 347 411 411 478

Maximum input current

Continuous (at 525 V) [A] 193 244 244 292 292 347 347 403 Continuous (at 575/690 V) 185 233 233 279 279 332 332 385

Maximum number and size of cables per phase

- Mains, motor, brake, and load share [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 575 V [W]

Estimated power loss at 690 V [W]

Eciency

Output frequency [Hz] 0–590 0–590 0–590 0–590 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)]

2), 3)

N160 N200 N250 N315

2x185 (2x350) 2x185 (2x350) 2x185 (2x350) 2x185 (2x350)

550 550 550 550

2361 3074 3012 3723 3642 4465 4146 5028

2446 3175 3123 3851 3771 4614 4258 5155

0.98 0.98 0.98 0.98

110 (230) 110 (230) 110 (230) 110 (230)

80 (176) 80 (176) 80 (176) 80 (176)

7 7

Table 7.6 Electrical Data for Enclosures D2h/D4h/D7h/D8h, Mains Supply 3x525–690 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.11 Eciency. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 44

Specications VLT® AutomationDrive FC 302

VLT® AutomationDrive FC 302

High/normal overload HO NO HO NO HO NO

(High overload=150% current during 60 s, normal overload=110% current during 60 s) Typical shaft output at 525 V [kW] 315 355 355 400 400 450 Typical shaft output at 575 V [hp] 400 450 400 500 500 600 Typical shaft output at 690 V [kW] 355 450 400 500 500 560

Enclosure size E1h/E3h E1h/E3h E1h/E3h

Output current (3-phase)

Continuous (at 525 V) [A] 395 470 429 523 523 596 Intermittent (60 s overload) (at 525 V) [A] 593 517 644 575 785 656 Continuous (at 575/690 V) [A] 380 450 410 500 500 570 Intermittent (60 s overload) (at 575/690 V) [A] 570 495 615 550 750 627 Continuous kVA (at 525 V) [kVA] 376 448 409 498 498 568 Continuous kVA (at 575 V) [kVA] 378 448 408 498 498 568 Continuous kVA (at 690 V) [kVA] 454 538 490 598 598 681

Maximum input current

Continuous (at 525 V) [A] 381 453 413 504 504 574 Continuous (at 575/690 V) [A] 366 434 395 482 482 549

Maximum number and size of cables per phase (E1h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)]

- Brake or regen [mm2 (AWG)]

Maximum number and size of cables per phase (E3h)

- Mains and motor [mm2 (AWG)]

- Brake [mm2 (AWG)]

- Load share or regen [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]

Estimated power loss at 690 V [W]

Eciency

Output frequency [Hz] 0–500 0–500 0–500 Heat sink overtemperature trip [°C (°F)] Control card overtemperature trip [°C (°F)] Power card overtemperature trip [°C (°F)] Fan power card overtemperature trip [°C (°F)] Active in-rush card overtemperature trip [°C (°F)]

2), 3)

N355 N400 N500

5x240 (5x500 mcm) 5x240 (5x500 mcm) 5x240 (5x500 mcm)

4x240 (4x500 mcm) 4x240 (4x500 mcm) 4x240 (4x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm) 4x185 (4x350 mcm)

800 800 800

4989 6062 5419 6879 6833 8076

4920 5939 5332 6715 6678 7852

0.98 0.98 0.98

110 (230) 110 (230) 110 (230)

80 (176) 80 (176) 80 (176) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185)

Table 7.7 Electrical Data for Enclosures E1h/E3h, Mains Supply 3x525–690 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.11 Eciency. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 45

Specications Design Guide

VLT® AutomationDrive FC 302

High/normal overload HO NO HO NO HO NO

(High overload=150% current during 60 s, normal overload=110% current during 60 s) Typical shaft output at 525 V [kW] 450 500 500 560 560 670 Typical shaft output at 575 V [hp] 600 650 650 750 750 950 Typical shaft output at 690 V [kW] 560 630 630 710 710 800

Enclosure size E2h/E4h E2h/E4h E2h/E4h

Output current (3-phase)

Continuous (at 525 V) [A] 596 630 659 763 763 889 Intermittent (60 s overload) (at 525 V) [A] 894 693 989 839 1145 978 Continuous (at 575/690 V) [A] 570 630 630 730 730 850 Intermittent (60 s overload) (at 575/690 V) [A] 855 693 945 803 1095 935 Continuous kVA (at 525 V) [kVA] 568 600 628 727 727 847 Continuous kVA (at 575 V) [kVA] 568 627 627 727 727 847 Continuous kVA (at 690 V) [kVA] 681 753 753 872 872 1016

Maximum input current

Continuous (at 525 V) [A] 574 607 635 735 735 857 Continuous (at 575/690 V) [A] 549 607 607 704 704 819

Maximum number and size of cables per phase (E2h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)]

- Brake or regen [mm2 (AWG)]

Maximum number and size of cables per phase (E4h)

- Mains and motor [mm2 (AWG)]

- Brake [mm2 (AWG)]

- Load share or regen [mm2 (AWG)]

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]

Estimated power loss at 690 V [W]

Eciency

2), 3)

N560 N630 N710

6x240 (6x500 mcm) 6x240 (6x500 mcm) 6x240 (6x500 mcm)

5x240 (5x500 mcm) 5x240 (5x500 mcm) 5x240 (5x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm) 4x185 (4x350 mcm)

800 1200 1200

8069 9208 8543 10346 10319 12723

7848 8921 8363 10066 10060 12321

0.98 0.98 0.98

110 (230) 110 (230) 110 (230)

80 (176) 80 (176) 80 (176) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185) 85 (185)

7 7

Table 7.8 Electrical Data for Enclosures E1h–E4h, Mains Supply 3x525–690 V AC

1) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

2) Typical power loss is at normal conditions and expected to be within

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-

eciency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for

slots A and B each add only 4 W.

3) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 10.11 Eciency. For part load losses, see drives.danfoss.com/knowledge-center/energy-eciency-directive/#/.

15% (tolerance relates to variety in voltage and cable conditions). These

Page 46

Specications VLT® AutomationDrive FC 302

7.3 Mains Supply

Mains supply (L1, L2, L3) Supply voltage 380–500 V ±10%, 525–690 V ±10%

Mains voltage low/mains voltage drop-out: During low mains voltage or a mains drop-out, the drive continues until the DC-link voltage drops below the minimum stop level, which corresponds typically to 15% below the lowest rated supply voltage of the drive. Power-up and full torque cannot be expected at mains voltage lower than 10% below the lowest rated supply voltage of the drive.

Supply frequency 50/60 Hz ±5% Maximum imbalance temporary between mains phases 3.0% of rated supply voltage True power factor (λ) ≥0.9 nominal at rated load Displacement power factor (cos Φ) near unity (>0.98) Switching on input supply L1, L2, L3 (power ups) Maximum 1 time/2 minute Environment according to EN60664-1 Overvoltage category III/pollution degree 2

The drive is suitable for use on a circuit capable of delivering up to 100 kA short circuit current rating (SCCR) at 480/600 V.

1) Calculations based on UL/IEC61800-3.

7.4 Motor Output and Motor Data

Motor output (U, V, W) Output voltage 0–100% of supply voltage Output frequency 0–590 Hz Output frequency in ux mode 0–300 Hz Switching on output Unlimited Ramp times 0.01–3600 s

1) Dependent on voltage and power.

Torque characteristics Starting torque (constant torque) Maximum 150% for 60 s Overload torque (constant torque) Maximum 150% for 60 s

1) Percentage relates to the nominal current of the drive.

2) Once every 10 minutes.

1), 2)

7.5 Ambient Conditions

Environment D1h/D2h/D5h/D6h/D7h/D8h/E1h/E2h enclosure IP21/Type 1, IP54/Type 12 D3h/D4h/E3h/E4h enclosure IP20/Chassis Vibration test (standard/ruggedized) 0.7 g/1.0 g Relative humidity 5%–95% (IEC 721-3-3; Class 3K3 (non-condensing) during operation) Aggressive environment (IEC 60068-2-43) H2S test Class Kd Aggressive gases (IEC 60721-3-3) Class 3C3 Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature (at SFAVM switching mode)

- with derating Maximum 55 °C (131 °F)

- with full output power of typical EFF2 motors (up to 90% output current) Maximum 50 °C (122 °F)

- at full continuous FC output current Maximum 45 °C (113 °F) Minimum ambient temperature during full-scale operation 0 °C (32 °F) Minimum ambient temperature at reduced performance -10 °C (14 °F) Temperature during storage/transport -25 to +65/70 °C (13 to 149/158 °F) Maximum altitude above sea level without derating 1000 m (3281 ft) Maximum altitude above sea level with derating 3000 m (9842 ft)

1) For more information on derating, see chapter 9.6 Derating.

Page 47

Specications Design Guide

EMC standards, Emission EN 61800-3 EMC standards, Immunity EN 61800-3 Energy eciency class

1) Determined according to EN 50598-2 at:

Rated load.

•

90% rated frequency.

•

Switching frequency factory setting.

•

Switching pattern factory setting.

•

IE2

7.6 Cable Specications

Cable lengths and cross-sections for control cables Maximum motor cable length, shielded 150 m (492 ft) Maximum motor cable length, unshielded 300 m (984 ft) Maximum cross-section to motor, mains, load sharing, and brake See chapter 7 Specications Maximum cross-section to control terminals, rigid wire 1.5 mm2/16 AWG (2x0.75 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 mm2/23 AWG

1) For power cables, see electrical data in chapter 7.1 Electrical Data, 380–500 V and chapter 7.2 Electrical Data, 525–690 V.

7 7

7.7 Control Input/Output and Control Data

Digital inputs Programmable digital inputs 4 (6) Terminal number 18, 19, 271), 291), 32, 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

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 outputs.

Analog inputs Number of analog inputs 2 Terminal number 53, 54 Modes Voltage or current Mode select Switches A53 and A54 Voltage mode Switch A53/A54=(U) Voltage level -10 V to +10 V (scaleable) Input resistance, R Maximum voltage ±20 V Current mode Switch A53/A54=(I) Current level 0/4 to 20 mA (scaleable) Input resistance, R 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

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

Approximately 4 kΩ

Approximately 10 kΩ

Approximately 200 Ω

Page 48

Mains

Functional isolation

PELV isolation

Motor

DC-bus

High voltage

Control

+24 V

RS485

130BA117.10

Specications VLT® AutomationDrive FC 302

Illustration 7.1 PELV Isolation

Pulse inputs Programmable pulse inputs 2 Terminal number pulse 29, 33 Maximum frequency at terminal 29, 33 (push-pull driven) 110 kHz Maximum frequency at terminal 29, 33 (open collector) 5 kHz

Minimum frequency at terminal 29, 33 4 Hz Voltage level See Digital Inputs in chapter 7.7 Control Input/Output and Control Data Maximum voltage on input 28 V DC Input resistance, R

Approximately 4 kΩ

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

Analog output Number of programmable analog outputs 1 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.

Control card, RS485 serial communication Terminal number 68 (P, TX+, RX+), 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).

Digital output Programmable digital/pulse outputs 2 Terminal number 27, 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 inputs.

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

Page 49

Specications Design Guide

Control card, 24 V DC output Terminal number 12, 13 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 Maximum cross-section to relay terminals 2.5 mm2 (12 AWG) Minimum cross-section to relay terminals 0.2 mm2 (30 AWG) Length of stripped wire 8 mm (0.3 in) Relay 01 terminal number 1–3 (break), 1–2 (make) 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 02 terminal number 4–6 (break), 4–5 (make) 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 4–6 (NC), 4–5 (NO) 24 V DC 10 mA, 24 V AC 2 mA Environment according to EN 60664-1 Overvoltage category III/pollution degree 2

The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).

1) IEC 60947 part 4 and 5.

2) Overvoltage Category II.

3) UL applications 300 V AC 2 A.

2), 3)

400 V AC, 2 A

7 7

Control card, +10 V DC output Terminal number 50 Output voltage 10.5 V ±0.5 V Maximum load 25 mA

The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control characteristics Resolution of output frequency at 0–1000 Hz ±0.003 Hz System response time (terminals 18, 19, 27, 29, 32, 33) ≤2 m/s 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.

Page 50

Specications VLT® AutomationDrive FC 302

Control card performance Scan interval 5 M/S

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 ground. Use only isolated laptop/PC as connection to the USB connector on the drive or an isolated USB cable/converter.

7.8 Enclosure Weights

Enclosure 380–480/500 V 525–690 V

D1h 62 (137) 62 (137) D2h 125 (276) 125 (276)

D3h 62 (137)

108 (238)

D4h 125 (276)

179 (395) D5h 99 (218) 99 (218) D6h 128 (282) 128 (282) D7h 185 (408) 185 (408) D8h 232 (512) 232 (512)

62 (137)

108 (238)

125 (276)

179 (395)

Table 7.9 Enclosure D1h–D8h Weights, kg (lb)

1) With optional load share and regen terminals.

Enclosure 380–480/500 V 525–690 V

E1h 295 (650) 295 (650) E2h 318 (700) 318 (700) E3h 272 (600) 272 (600) E4h 295 (650) 295 (650)

Table 7.10 Enclosure E1h–E4h Weights, kg (lb)

Page 51

130BE982.10

667 (26.3)

500 (19.7)

164 (6.5)

99 (3.9)

Exterior and Terminal Dimen... Design Guide

8 Exterior and Terminal Dimensions

8.1 D1h Exterior and Terminal Dimensions

8.1.1 D1h Exterior Dimensions

8 8

Illustration 8.1 Front View of D1h

Page 52

378 (14.9)

82 (3.2)

148 (5.8)

20 (0.8)

844 (33.2)

561 (22.1)

18 (0.7)

130BF797.10

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.2 Side View of D1h

Page 53

200 (7.9)

246 (9.7)

893 (35.2)

656 (25.8)

200 (7.9)

844 (33.2)

130 (5.1)

180 (7.1)

325 (12.8)

123 (4.8)

78 (3.1)

63 (2.5)

11 (0.4)

20 (0.8)

9 (0.3)

24 (0.9)

33 (1.3)

25 (1.0)

11 (0.4)

130BF798.10

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.3 Back View of D1h

Page 54

130BF669.10

404 (15.9)

298 (11.7)

105

130BF607.10

205 (8.1)

138 (5.4)

274 (10.8)

27 (1.0)

137 (5.4)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.4 Door Clearance for D1h

1 Mains side 2 Motor side

Illustration 8.5 Gland Plate Dimensions for D1h

Page 55

88 (3.5)

0.0

200 (7.9)

130BF342.10

0.0

94 (3.7)

293 (11.5)

263 (10.4)

33 (1.3)

62 (2.4)

101 (4.0)

140 (5.5)

163 (6.4)

185 (7.3)

224 (8.8)

Exterior and Terminal Dimen... Design Guide

8.1.2 D1h Terminal Dimensions

8 8

1 Mains terminals 3 Motor terminals 2 Ground terminals – –

Illustration 8.6 D1h Terminal Dimensions (Front View)

Page 56

130BF343.10

244 (9.6)

272 (10.7)

0.0

1 2

M10

32 (1.3)

13 (0.5)

32 (1.3)

13 (0.5)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

1 Mains terminals 2 Motor terminals

Illustration 8.7 D1h Terminal Dimensions(Side Views)

Page 57

130BF321.10

96 (3.8)

211 (8.3)

602 (23.7)

871 (34.3)

Exterior and Terminal Dimen... Design Guide

8.2 D2h Exterior and Terminal Dimensions

8.2.1 D2h Exterior Dimensions

Illustration 8.8 Front View of D2h

8 8

Page 58

130BF799.10

1050 (41.3)

718 (28.3)

148 (5.8)

18 (0.7)

378 (14.9)

142 (5.6)

20 (0.8)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.9 Side View of D2h

Page 59

1099 (43.3)

1051 (41.4)

107 (4.2)

320 (12.6)

213 (8.4)

857 (33.7)

130 (5.1)

420 (16.5)

346 (13.6)

280 (11.0)

271 (10.7)

9 (0.3)

20 (0.8)

11 (0.4)

75 (2.9)

24 (0.9)

11 (0.4)

33 (1.3)

130BF800.10

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.10 Back View of D2h

Page 60

395 (15.6)

523 (20.6)

105

130BF670.10

130BF608.10

27 (1.0)

185 (7.3)

369 (14.5)

196 (7.7)

145 (5.7)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.11 Door Clearance for D2h

1 Mains side 2 Motor side

Illustration 8.12 Gland Plate Dimensions for D2h

Page 61

130BF345.10

143 (5.6)

168 (6.6)

331 (13.0)

211 (8.3)

168 (6.6)

143 (5.6)

42 (1.6)

68 (2.7)

126 (5.0)

184 (7.2)

246 (9.7)

300 (11.8)

354 (13.9)

378 (14.9)

0.0

Exterior and Terminal Dimen... Design Guide

8.2.2 D2h Terminal Dimensions

1 Mains terminals 3 Motor terminals 2 Ground terminals – –

Illustration 8.13 D2h Terminal Dimensions (Front View)

8 8

Page 62

130BF346.10

0.0

1 2

255 (10.0)

284 (11.2)

M10

15 (0.6)

38 (1.5)

19 (0.8)

15 (0.6)

18 (0.7)

35 (1.4)

M10

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

1 Mains terminals 2 Motor terminals

Illustration 8.14 D2h Terminal Dimensions (Side Views)

Page 63

130BF322.10

61 (2.4)

128 (5.0)

495 (19.5)

660 (26.0)

Exterior and Terminal Dimen... Design Guide

8.3 D3h Exterior and Terminal Dimensions

8.3.1 D3h Exterior Dimensions

8 8

Illustration 8.15 Front View of D3h

Page 64

148 (5.8)

20 (0.8)

130BF801.10

844 (33.2)

39 (1.5)

375 (14.8)

82 (3.2)

18 (0.7)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.16 Side View of D3h

Page 65

656 (25.8)

200 (7.9)

130 (5.1)

889 (35.0)

909 (35.8)

844 (33.2)

78 (3.1)

123 (4.8)

250 (9.8)

180 (7.1)

33 (1.3)

11 (0.4)

25 (1.0)

11 (0.4)

20 (0.8)

9 (0.3)

24 (0.9)

25 (1.0)

M10

130BF802.10

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.17 Back View of D3h

Page 66

130BF341.10

83 (3.3)

0.0

188 (7.4)

22 (0.9)

62 (2.4)

101 (4.0)

145 (5.7)

184 (7.2)

223 (8.8)

152 (6.0)

217 (8.5)

292 (11.5)

0.0

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

8.3.2 D3h Terminal Dimensions

1 Mains terminals 3 Motor terminals 2 Brake terminals 4 Ground terminals

Illustration 8.18 D3h Terminal Dimensions (Front View)

Page 67

M10

13 (0.5)

32 (1.3)

59 (2.3)

12 (0.5)

10 (0.4)

38 (1.5)

M10

244 (9.6)

290 (11.4)

272 (10.7)

130BF344.10

0.0

M10

13 (0.5)

32 (1.3)

145 (5.7)

182 (7.2)

3X M8x18

Exterior and Terminal Dimen... Design Guide

8 8

1 and 6 Bottom brake/regen terminals 3 and 5 Mains terminals 2 and 7 Motor terminals 4 Ground terminals

Illustration 8.19 D3h Terminal Dimensions (Side Views)

Page 68

130BF323.10

176 (6.9)

611 (24.1)

59 (2.3)

868 (34.2)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

8.4 D4h Exterior and Terminal Dimensions

8.4.1 D4h Enclosure Dimensions

Illustration 8.20 Front View of D4h

Page 69

130BF803.10

20 (0.8)

148 (5.8)

18 (0.7)

1050 (41.3)

39 (1.5)

375 (14.8)

142 (5.6)

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.21 Side Dimensions for D4h

Page 70

130BF804.10

857 (33.7)

320 (12.6)

280 (11.0)

350 (13.8)

107 (4.2)

213 (8.4)

1122 (44.2)

1096 (43.1)

1051 (41.4)

271 (10.7)

130 (5.1)

25 (1.0)

33 (1.3)

11 (0.4)

40 (1.6)

11 (0.4)

9 (0.3)

20 (0.8)

24 (0.9)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.22 Back Dimensions for D4h

Page 71

33 (1.3)

91 (3.6)

149 (5.8)

211 (8.3)

265 (10.4)

319 (12.6)

200 (7.9)

319 (12.6)

376 (14.8)

293 (11.5)

237 (9.3)

130BF347.10

0.0

o.o

Exterior and Terminal Dimen... Design Guide

8.4.2 D4h Terminal Dimensions

1 Mains terminals 3 Motor terminals 2 Brake terminals 4 Ground terminals

8 8

Illustration 8.23 D4h Terminal Dimensions (Front View)

Page 72

91 (3.6)

13 (0.5)

200 (7.9)

259 (10.2)

3X M10X20

M10

19 (0.8)

38 (1.5)

255 (10.0)

306 (12.1)

284 (11.2)

130BF348.10

0.0

M10

22 (0.9)

35 (1.4)

15 (0.6)

18 (0.7)

M10

16 (0.6)

32 (1.3)

19 (0.7)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

1 and 6 Brake/regeneration terminals 3 and 5 Mains terminals 2 and 7 Motor terminals 4 Ground terminals

Illustration 8.24 D4h Terminal Dimensions(Side Views)

Page 73

149 (5.9)

733 (28.9)

1107 (43.6)

130BF324.10

Exterior and Terminal Dimen... Design Guide

8.5 D5h Exterior and Terminal Dimensions

8.5.1 D5h Exterior Dimensions

8 8

Illustration 8.25 Front View of D5h

Page 74

130BF805.10

161 (6.3)

23 (0.9)

115 (4.5)

381 (15.0)

1277 (50.3)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.26 Side View of D5h

Page 75

130BF806.10

1276 (50.2)

64 (2.5)

M10

325 (12.8)

306 (12.1)

276 (10.9)

180 (7.1)

130 (5.1)

123 (4.8)

78 (3.1)

200 (7.9)

1324 (52.1)

1111 (43.7)

130 (5.1)

123 (4.8)

78 (3.1

200 (7.9)

220 (8.7)

25 (1)

4X 11 (0.4)

63 (2.5)

15 (0.6)

11 (0.4)

24 (0.9)

20 (0.8)

9 (0.3)

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.27 Back View of D5h

Page 76

130BF828.10

433 (17.0)

670 (26.4)

218 (8.6)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.28 Heat Sink Access Dimensions for D5h

Page 77

130BF669.10

404 (15.9)

298 (11.7)

105

111 (4.4)

224 (8.8)

242 (9.5)

121 (4.8)

43 (1.7)

1 2

130BF609.10

Exterior and Terminal Dimen... Design Guide

Illustration 8.29 Door Clearance for D5h

8 8

1 Mains side 2 Motor side

Illustration 8.30 Gland Plate Dimensions for D5h

Page 78

130BF349.10

0.0

45 (1.8)

46 (1.8)

99 (3.9)

153 (6.0)

146 (5.8)

182 (7.2)

193 (7.6)

249 (9.8)

221 (8.7)

260 (10.2)

118 (4.6)

148 (5.8)

90 (3.6)

196 (7.7)

227 (9.0)

221 (8.7)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

8.5.2 D5h Terminal Dimensions

1 Mains terminals 3 Brake terminals 2 Ground terminals 4 Motor terminals

Illustration 8.31 D5h Terminal Dimensions with Disconnect Option (Front View)

Page 79

0.0

113 (4.4)

206 (8.1)

130BF350.10

Exterior and Terminal Dimen... Design Guide

1 Mains terminals 3 Motor terminals 2 Brake terminals – –

Illustration 8.32 D5h Terminal Dimensions with Disconnect Option (Side Views)

8 8

Page 80

130BF351.10

0.0

33 (1.3)

0.0

62 (2.4)

101 (4.0)

140 (5.5)

163 (6.4)

185 (7.3)

191 (7.5)

224 (8.8)

256 (10.1)

263 (10.4)

293 (11.5)

511 (20.1)

517 (20.4)

623 (24.5)

727 (28.6)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

1 Mains terminals 3 Motor terminals 2 Brake terminals 4 Ground terminals

Illustration 8.33 D5h Terminal Dimensions with Brake Option (Front View)

Page 81

130BF352.10

246 (9.7)

293 (11.5)

274 (10.8)

0.0

Exterior and Terminal Dimen... Design Guide

1 Mains terminals 3 Motor terminals 2 Brake terminals – –

Illustration 8.34 D5h Terminal Dimensionswith Brake Option (Side Views)

8 8

Page 82

159 (6.3)

130BF325.10

909 (35.8)

1447 (57.0)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

8.6 D6h Exterior and Terminal Dimensions

8.6.1 D6h Exterior Dimensions

Illustration 8.35 Front View of D6h

Page 83

130BF807.10

1617 (63.7)

181 (7.1)

23 (0.9)

115 (4.5)

381 (15.0)

Exterior and Terminal Dimen... Design Guide

Illustration 8.36 Side View of D6h

8 8

Page 84

M10

25 (1)

4X 11 (0.4)

63 (2.5)

15 (0.6)

130BF808.10

325 (12.8)

306 (12.1)

276 (10.9)

180 (7.1)

130 (5.1)

1452 (57.2)

200 (7.9)

559 (22.0)

130 (5.1)

200 (7.9)

78 (3.1)

123 (4.8)

1615 (63.6)

1663 (65.5)

200 (7.9)

78 (3.1)

123 (4.8)

24 (0.9)

20 (0.8)

9 (0.1)

64 (3.0)

11 (0.4)

M10

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.37 Back View of D6h

Page 85

130BF829.10

433 (17.0)

1009 (39.7)

218 (8.6)

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.38 Heat Sink Access Dimensions for D6h

Page 86

130BF669.10

404 (15.9)

298 (11.7)

105

111 (4.4)

224 (8.8)

242 (9.5)

121 (4.8)

43 (1.7)

1 2

130BF609.10

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.39 Door Clearance for D6h

1 Mains side 2 Motor side

Illustration 8.40 Gland Plate Dimensions for D6h

Page 87

130BF353.10

0.0

96 (3.8)

195 (7.7)

227 (8.9)

123 (4.8)

153 (6.0)

458 (18.0)

0.0

46 (1.8)

50 (2.0)

99 (3.9)

147 (5.8)

182 (7.2)

193 (7.6)

221 (8.7)

249 (9.8)

260 (10.2)

146 (5.8)

Exterior and Terminal Dimen... Design Guide

8.6.2 D6h Terminal Dimensions

1 Mains terminals 4 Brake terminals 2 Ground terminals 5 Motor terminals 3 TB6 terminal block for contactor – –

Illustration 8.41 D6h Terminal Dimensions with Contactor Option (Front View)

8 8

Page 88

130BF534.10

0.0

286 (11.2)

113 (4.4)

206 (8.1)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

1 Mains terminals 3 Motor terminals 2 Brake terminals – –

Illustration 8.42 D6h Terminal Dimensions with Contactor Option (Side Views)

Page 89

130BF355.10

99 (3.9)

153 (6.0)

0.0

225 (8.9)

45 (1.8)

0.0

Exterior and Terminal Dimen... Design Guide

8 8

1 Mains terminals 4 Brake terminals 2 Ground terminals 5 Motor terminals 3 TB6 terminal block for contactor – –

Illustration 8.43 D6h Terminal Dimensions with Contactor and Disconnect Options (Front View)

Page 90

130BF356.10

0.0

286 (11.2)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

1 Brake terminals 3 Motor terminals 2 Mains terminals – –

Illustration 8.44 D6h Terminal Dimensions with Contactor and Disconnect Options (Side Views)

Page 91

130BF357.10

467 (18.4)

0.0

52 (2.1)

0.0

99 (3.9)

145 (5.7)

Exterior and Terminal Dimen... Design Guide

8 8

1 Mains terminals 3 Brake terminals 2 Ground terminals 4 Motor terminals

Illustration 8.45 D6h Terminal Dimensions with Circuit Breaker Option (Front View)

Page 92

130BF358.10

163 (6.4)

0.0

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

1 Mains terminals 3 Motor terminals 2 Brake terminals – –

Illustration 8.46 D6h Terminal Dimensions with Circuit Breaker Option (Side Views)

Page 93

130BF326.10

209 (8.2)

1282 (50.5)

1754 (69.1)

Exterior and Terminal Dimen... Design Guide

8.7 D7h Exterior and Terminal Dimensions

8.7.1 D7h Exterior Dimensions

8 8

Illustration 8.47 Front View of D7h

Page 94

25 (1.0)

130BF809.10

23 (0.9)

156 (6.2)

386 (15.2)

161 (6.3)

193 (76.0)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.48 Side View of D7h

Page 95

235 (9.3)

71 (2.8)

130 (5.1)

4X 11 (0.4)

130BF810.10

420 (16.5)

411 (16.2)

374 (14.7)

280 (11.0)

25 (1.0)

14 (0.6)

1760 (69.3)

130 (5.1)

70 (2.8)

385 (15.2)

25 (1.0)

M10

668 (26.3)

107 (4.2)

213 (8.4)

320 (12.6)

978 (77.9)

1953 (76.9)

107 (4.2)

213 (8.4)

320 (12.6)

23 (0.9)

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.49 Back View of D7h

Page 96

316 (12.4)

130BF830.10

591 (23.3)

1168 (46.0)

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.50 Heat Sink Access Dimensions for D7h

Page 97

2X 11 (0.4)

130BF832.10

1731 (68.1)

23 (0.9)

468 (18.4)

271 (10.7)

1537 (60.5)

Exterior and Terminal Dimen... Design Guide

8 8

Illustration 8.51 Wall Mount Dimensions for D7h

Page 98

395 (15.6)

523 (20.6)

105

130BF670.10

130BF610.10

222 (8.7)

115 (4.5)

337 (13.3)

169 (6.6)

43 (1.7)

-A-

1 2

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

Illustration 8.52 Door Clearance for D7h

1 Mains side 2 Motor side

Illustration 8.53 Gland Plate Dimensions for D7h

Page 99

130BF359.10

0.0

372 (14.7)

412 (16.2)

395 (15.6)

515 (20.3)

66 (2.6)

95 (3.7)

131 (5.1)

151 (5.9)

195 (7.7)

238 (9.4)

292 (11.5)

346 (13.6)

49 (1.9)

198 (7.8)

368 (14.5)

545 (21.4)

Exterior and Terminal Dimen... Design Guide

8.7.2 D7h Terminal Dimensions

8 8

1 Mains terminals 3 Motor terminals 2 Brake terminals 4 Ground terminals

Illustration 8.54 D7h Terminal Dimensions with Disconnect Option (Front View)

Page 100

0.0

130BF360.10

119 (4.7)

276 (10.9)

1 2

Exterior and Terminal Dimen... VLT® AutomationDrive FC 302

1 Mains terminals 3 Motor terminals 2 Brake terminals – –

Illustration 8.55 D7h Terminal Dimensions with Disconnect Option (Side Views)

Danfoss FC 302 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual