Danfoss VLT AutomationDrive FC 301, VLT AutomationDrive FC 302 Operating Instructions Manual
MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT® AutomationDrive FC 301/302
0.25-75 kW
www.danfoss.com/drives
Contents
Contents
VLT® AutomationDrive FC 301/302 Operating Instructions
1 Introduction
1.1 Purpose of the Manual
1.2 Additional Resources
1.3 Document and Software Version
1.4 Product Overview
1.5 Enclosure Types and Power Ratings
1.6 Approvals and Certifications
1.7 Disposal Instruction
2 Safety
2.1 Safety Symbols
2.2 Qualified Personnel
2.3 Safety Precautions
3 Mechanical Installation
3.1 Unpacking
3.2 Installation Environments
3.3 Mounting
3
3
3
3
3
6
6
6
7
7
7
7
9
9
9
10
4 Electrical Installation
4.1 Safety Instructions
4.2 EMC Compliant Installation
4.3 Grounding
4.4 Wiring Schematic
4.5 Access
4.6 Motor Connection
4.7 AC Mains Connection
4.8 Control Wiring
4.8.1 Control Terminal Types 16
4.8.2 Wiring to Control Terminals 17
4.8.3 Enabling Motor Operation (Terminal 27) 17
4.8.4 Voltage/Current Input Selection (Switches) 18
4.8.5 Safe Torque Off (STO) 18
4.8.6 Mechanical Brake Control 18
4.8.7 RS-485 Serial Communication 19
4.9 Installation Check List
11
11
11
11
12
14
14
15
15
20
5 Commissioning
5.1 Safety Instructions
5.2 Applying Power
21
21
21
MG33AN02 - Rev. 2013-09-06 1
Contents
VLT® AutomationDrive FC 301/302 Operating Instructions
5.3 Local Control Panel Operation
5.4 Basic Programming
5.4.1 Commissioning with SmartStart 24
5.4.2 Commissioning via [Main Menu] 24
5.4.3 Asynchronous Motor Setup 25
5.4.4 PM Motor Setup in VVC
5.4.5 Automatic Motor Adaptation (AMA) 26
plus
5.5 Checking Motor Rotation
5.6 Checking Encoder Rotation
5.7 Local-control Test
5.8 System Start-up
6 Application Set-up Examples
7 Diagnostics and Troubleshooting
7.1 Maintenance and Service
7.2 Status Messages
7.3 Warning and Alarm Types
21
24
25
26
26
27
27
28
34
34
34
36
7.4 List of Warnings and Alarms
7.5 Troubleshooting
8 Specifications
8.1 Electrical Data
8.1.1 Mains Supply 3x200-240 V AC 47
8.1.2 Mains Supply 3x380-500 V AC 49
8.1.3 Mains Supply 3x525-600 V AC (FC 302 only) 52
8.1.4 Mains Supply 3x525-690 V AC (FC 302 only) 55
8.2 Mains Supply
8.3 Motor Output and Motor Data
8.4 Ambient Conditions
8.5 Cable Specifications
8.6 Control Input/Output and Control Data
8.7 Fuses and Circuit Breakers
8.8 Connection Tightening Torques
8.9 Power Ratings, Weight and Dimensions
37
45
47
47
57
57
58
58
58
62
68
69
9 Appendix
9.1 Symbols, Abbreviations and Conventions
9.2 Parameter Menu Structure
Index
2 MG33AN02 - Rev. 2013-09-06
70
70
70
75
Introduction
1 Introduction
VLT® AutomationDrive FC 301/302 Operating Instructions
1
1
1.1 Purpose of the Manual
These operating instructions provide information for safe
installation and commissioning of the frequency converter.
The operating instructions are intended for use by
qualified personnel.
Read and follow the operating instructions to use the
frequency converter safely and professionally, and pay
particular attention to the safety instructions and general
warnings. Keep these operating instructions available with
the frequency converter at all times.
1.2 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
®
The VLT
•
detail on working with parameters and many
application examples.
The VLT® Design Guide provides detailed
•
information about capabilities and functionality to
design motor control systems.
Instructions for operation with optional
•
equipment.
Supplementary publications and manuals are available
from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical+Documentation.htm
for listings.
Disclosure, duplication and sale of this document, as well
as communication of its content, are prohibited unless
explicitly permitted. Infringement of this prohibition incurs
liability for damages. All rights reserved with regard to
patents, utility patents and registered designs. VLT® is a
registered trademark.
Programming Guide provides greater
1.4
Product Overview
1.4.1 Intended Use
The frequency converter is an electronic motor controller
intended for
regulation of motor speed in response to system
•
feedback or to remote commands from external
controllers. A power drive system consists of the
frequency converter, the motor and equipment
driven by the motor.
system and motor status surveillance.
•
The frequency converter can also be used for motor
protection.
Depending on configuration, the frequency converter can
be used in standalone applications or form part of a larger
appliance or installation.
The frequency converter is allowed for use in residential,
industrial and commercial environments in accordance
with local laws and standards.
NOTICE
In a residential environment this product can cause radio
interference, in which case supplementary mitigation
measures can be required.
Foreseeable misuse
Do not use the frequency converter in applications which
are non-compliant with specified operating conditions and
environments. Ensure compliance with the conditions
specified in 8 Specifications.
1.3
Document and Software Version
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
MG33ANxx Replaces MG33AMxx 6.72
Table 1.1 Document and Software Version
Remarks Software version
MG33AN02 - Rev. 2013-09-06 3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
8
15
16
17
18
130BB492.10
Introduction
VLT® AutomationDrive FC 301/302 Operating Instructions
1
1.4.2 Exploded Views
Illustration 1.1 Exploded View Enclosure Type A, IP20
Local control panel (LCP) 10 Motor output terminals 96 (U), 97 (V), 98 (W)
1
2 RS-485 serial bus connector (+68, -69) 11 Relay 2 (01, 02, 03)
3 Analog I/O connector 12 Relay 1 (04, 05, 06)
4 LCP input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals
5 Analog switches (A53), (A54) 14 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable screen connector 15 USB connector
7 Decoupling plate 16 Serial bus terminal switch
8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply
9 Screened cable grounding clamp and strain relief 18 Cover
Table 1.2 Legend to Illustration 1.1
4 MG33AN02 - Rev. 2013-09-06
1
2
3
4
5
6
7
8
9
10
11
12
13
16
17
18
19
14
15
FAN MOUNTING
QDF-30
DC-
DC+
Remove jumper to activate Safe Stop
Max. 24 Volt !
12
13
18
19 27 29 32
33
20
61
68
39
42
50
53 54
0605 04
0302 01
130BB493.10
Introduction
VLT® AutomationDrive FC 301/302 Operating Instructions
1
1
Illustration 1.2 Exploded View Enclosure Types B and C, IP55 and IP66
Local control panel (LCP) 11 Relay 2 (04, 05, 06)
1
2 Cover 12 Lifting ring
3 RS-485 serial bus connector 13 Mounting slot
4 Digital I/O and 24 V power supply 14 Grounding clamp (PE)
5 Analog I/O connector 15 Cable screen connector
6 Cable screen connector 16 Brake terminal (-81, +82)
7 USB connector 17 Load sharing terminal (DC bus) (-88, +89)
8 Serial bus terminal switch 18 Motor output terminals 96 (U), 97 (V), 98 (W)
9 Analog switches (A53), (A54) 19 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
Table 1.3 Legend to Illustration 1.2
MG33AN02 - Rev. 2013-09-06 5
Introduction
VLT® AutomationDrive FC 301/302 Operating Instructions
1
1.4.3 Block Diagram of the Frequency
Converter
Illustration 1.3 is a block diagram of the frequency
converter's internal components. See Table 1.4 for their
functions.
Illustration 1.3 Frequency Converter Block Diagram
Area Title Functions
3-phase AC mains power
•
1 Mains input
2 Rectifier
3 DC bus
4 DC reactors
5 Capacitor bank
6 Inverter
7 Output to motor
supply to the frequency
converter
The rectifier bridge converts
•
the AC input to DC current to
supply inverter power
Intermediate DC-bus circuit
•
handles the DC current
Filter the intermediate DC
•
circuit voltage
Prove line transient protection
•
Reduce RMS current
•
Raise the power factor
•
reflected back to the line
Reduce harmonics on the AC
•
input
Stores the DC power
•
Provides ride-through
•
protection for short power
losses
Converts the DC into a
•
controlled PWM AC waveform
for a controlled variable
output to the motor
Regulated 3-phase output
•
power to the motor
Area Title Functions
Input power, internal
•
processing, output, and motor
current are monitored to
provide efficient operation
and control
8 Control circuitry
Table 1.4 Legend to Illustration 1.3
User interface and external
•
commands are monitored and
performed
Status output and control can
•
be provided
1.5 Enclosure Types and Power Ratings
For enclosure types and power ratings of the frequency
converters, refer to 8.9 Power Ratings, Weight and
Dimensions.
1.6 Approvals and Certifications
Table 1.5 Approvals and Certifications
More approvals and certifications are available. Contact
local Danfoss partner. The T7 (525-690 V) frequency
converters are not certified for UL.
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the Design
Guide.
For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation in the
Design Guide.
1.7
Disposal Instruction
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Table 1.6 Disposal Instruction
6 MG33AN02 - Rev. 2013-09-06
Safety
VLT® AutomationDrive FC 301/302 Operating Instructions
2 Safety
2.1 Safety Symbols
The following symbols are used in this document.
WARNING
Indicates a potentially hazardous situation which could
result in death or serious injury.
2 2
WARNING
UNINTENDED START!
When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency
converter, motor, and any driven equipment must be in
operational readiness. Failure to be in operational
readiness when the frequency converter is connected to
AC mains could result in death, serious injury, equipment
or property damage.
CAUTION
Indicates a potentially hazardous situation which could
result in minor or moderate injury. It may also be used
to alert against unsafe practices.
NOTICE
Indicates important information, including situations that
may result in damage to equipment or property.
2.2 Qualified Personnel
Correct and reliable transport, storage, installation,
operation and maintenance are required for the troublefree and safe operation of the frequency converter. Only
qualified personnel is allowed to install or operate this
equipment.
Qualified personnel is defined as trained staff, who are
authorised to install, commission, and maintain equipment,
systems and circuits in accordance with pertinent laws and
regulations. Additionally, the personnel must be familiar
with the instructions and safety measures described in this
document.
WARNING
DISCHARGE TIME!
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is
not powered. To avoid electrical hazards, disconnect AC
mains, any permanent magnet type motors, and any
remote DC-link power supplies, including battery
backups, UPS and DC-link connections to other
frequency converters. Wait for the capacitors to
discharge completely before performing any service or
repair work. The amount of waiting time is listed in
Table 2.1. Failure to wait the specified time after power
has been removed before doing service or repair could
result in death or serious injury.
Voltage [V] Minimum waiting time [minutes]
4 7 15
200-240 0.25-3.7 kW 5.5-37 kW
380-500 0.25-7.5 kW 11-75 kW
525-600 0.75-7.5 kW 11-75 kW
525-690 1.5-7.5 kW 11-75 kW
High voltage may be present even when the warning LED
indicator lights are off.
2.3
Safety Precautions
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains input power. Installation, startup, and maintenance must be performed by qualified
personnel only. Failure to perform installation, start-up,
and maintenance by qualified personnel could result in
death or serious injury.
MG33AN02 - Rev. 2013-09-06 7
Table 2.1 Discharge Time
WARNING
LEAKAGE CURRENT HAZARD!
Leakage currents are higher than 3.5 mA. It is the
responsibility of the user or certified electrical installer to
ensure correct grounding of the equipment. Failure to
ground the frequency converter properly could result in
death or serious injury.
Safety
VLT® AutomationDrive FC 301/302 Operating Instructions
WARNING
EQUIPMENT HAZARD!
22
Rotating shafts and electrical equipment can be
hazardous. All electrical work must conform to national
and local electrical codes. Installation, start-up, and
maintenance are performed only by trained and
qualified personnel. Failure to follow these guidelines
could result in death or serious injury.
WARNING
WINDMILLING!
Unintended rotation of permanent magnet motors
causes a risk of personal injury and equipment damage.
Ensure permanent magnet motors are blocked to
prevent unintended rotation.
CAUTION
POTENTIAL HAZARD IN THE EVENT OF
INTERNAL FAILURE!
Risk of personal injury when the frequency converter is
not properly closed. Before applying power, ensure all
safety covers are in place and securely fastened.
8 MG33AN02 - Rev. 2013-09-06
130BD600.10
CHASSIS/ IP20 Tamb.50
C/122 F
V LT
MADE IN DENMARK
R
P/N: 131X3537 S/N: 010122G430
0.37kW/ 0.50HP
IN: 3x200-240V 50/60Hz 2.2A
OUT: 3x0-Vin 0-1000Hz 2.4A
o
CAUTION:
See manual for special condition/mains fuse
voir manual de conditions speclales/fusibles
WARNING:
Stored charge, wait 4 min.
Charge residuelle, attendez 4 min.
* 1 3 1
X
3 5 3 7 0 1 0 1 2 2 G 4 3 0 *
`
Automation Drive
www.danfoss.com
T/C: FC-302PK37T2E20H1BGXXXXSXXXXA6BKC4XXXD0
Listed 76X1 E134261 Ind. Contr. Eq.
o
`
1
2
4
5
6
7
8
9
10
3
Mechanical Installation
VLT® AutomationDrive FC 301/302 Operating Instructions
3 Mechanical Installation
3.1 Unpacking
3.1.1 Items Supplied
Items supplied may vary according to product configuration.
Make sure the items supplied and the
•
information on the nameplate correspond to the
order confirmation.
Check the packaging and the frequency converter
•
visually for damage caused by inappropriate
handling during shipment. File any claim for
damage with the carrier. Retain damaged parts
for clarification.
NOTICE
Do not remove the nameplate from the
frequency converter (loss of warranty).
3.1.2 Storage
Ensure that requirements for storage are fulfilled. Refer to
8.4 Ambient Conditions for further details.
3.2 Installation Environments
NOTICE
In environments with airborne liquids, particles, or
corrosive gases, ensure that the IP/Type rating of the
equipment matches the installation environment. Failure
to meet requirements for ambient conditions can reduce
lifetime of the frequency converter. Ensure that
requirements for air humidity, temperature and altitude
are met.
3 3
Illustration 3.1 Product Nameplate (Example)
1 Type code
2 Order number
3 Serial number
4 Power rating
Input voltage, frequency and current (at low/high
5
voltages)
6
7 Enclosure type and IP rating
8 Maximum ambient temperature
9 Certifications
10 Discharge time (Warning)
Table 3.1 Legend to Illustration 3.1
Output voltage, frequency and current (at low/high
voltages)
Vibration and Shock
The frequency converter complies with requirements for
units mounted on the walls and floors of production
premises, as well as in panels bolted to walls or floors.
For detailed ambient conditions specifications, refer to
8.4 Ambient Conditions.
MG33AN02 - Rev. 2013-09-06 9
a
a
130BD528.10
130BD504.10
Mechanical Installation
3.3 Mounting
NOTICE
Improper mounting can result in
33
overheating and reduced performance.
Cooling
Ensure that top and bottom clearance for air
•
cooling is provided. See Illustration 3.2 for
clearance requirements.
VLT® AutomationDrive FC 301/302 Operating Instructions
Mounting
1. Ensure that the strength of the mounting location
supports the unit weight. The frequency
converter allows side-by-side installation.
2. Locate the unit as near to the motor as possible.
Keep the motor cables as short as possible.
3. Mount the unit vertically on a solid flat surface or
on the optional back plate.
4. Use the slotted mounting holes on the unit for
wall mounting, when provided.
Mounting with back plate and railings
Illustration 3.2 Top and Bottom Cooling Clearance
Enclosure A1-A5 B1-B4 C1, C3 C2, C4
a [mm] 100 200 200 225
Table 3.2 Minimum Airflow Clearance Requirements
Lifting
To determine a safe lifting method, check the
•
weight of the unit, see 8.9 Power Ratings, Weight
and Dimensions.
Ensure that the lifting device is suitable for the
•
task.
If necessary, plan for a hoist, crane, or forklift with
•
the appropriate rating to move the unit.
For lifting, use hoist rings on the unit, when
•
provided.
Illustration 3.3 Proper Mounting with Back Plate
NOTICE
Back plate is required when mounted on railings.
10 MG33AN02 - Rev. 2013-09-06
Electrical Installation
4 Electrical Installation
VLT® AutomationDrive FC 301/302 Operating Instructions
4.1 Safety Instructions
See 2 Safety for general safety instructions.
WARNING
INDUCED VOLTAGE!
Induced voltage from output motor cables that run
together can charge equipment capacitors even with the
equipment turned off and locked out. Failure to run
output motor cables separately or use screened cables
could result in death or serious injury.
CAUTION
DC CURRENT HAZARD!
A DC current in the protective grounding conductor can
be caused by the frequency converters. When a residual
current-operated protective or monitoring device (RCD/
RCM) is used for protection, only an RCD or RCM of Type
B is allowed.
Over-current Protection
Additional protective equipment such as short-
•
circuit protection or motor thermal protection
between frequency converter and motor is
required for applications with multiple motors.
Input fusing is required to provide short-circuit
•
and over-current protection. If not factorysupplied, fuses must be provided by the installer.
See maximum fuse ratings in 8.7 Fuses and Circuit
Breakers.
Wire Type and Ratings
All wiring must comply with local and national
•
regulations regarding cross-section and ambient
temperature requirements.
Power connection wire recommendation:
•
minimum 75 °C rated copper wire.
See 8.1 Electrical Data and 8.5 Cable Specifications for
recommended wire sizes and types.
4.2
EMC Compliant Installation
4.3
Grounding
WARNING
LEAKAGE CURRENT HAZARD!
Leakage currents are higher than 3.5 mA. It is the
responsibility of the user or certified electrical installer to
ensure correct grounding of the equipment. Failure to
ground the frequency converter properly could result in
death or serious injury.
For electrical safety
Ground the frequency converter properly in
•
accordance with applicable standards and
directives.
Use a dedicated ground wire for input power,
•
motor power and control wiring.
Do not ground one frequency converter to
•
another in a “daisy chain” fashion.
Keep the ground wire connections as short as
•
possible.
Follow motor manufacturer wiring requirements.
•
Minimum cable cross-section: 10 mm2 (or 2 rated
•
ground wires terminated separately).
For EMC compliant installation
Establish electrical contact between cable screen
•
and frequency converter enclosure by using
metal cable glands or by using the clamps
provided on the equipment (see Illustration 4.5
and Illustration 4.6).
Use high-strand wire to reduce electrical
•
interference.
Do not use pigtails.
•
NOTICE
POTENTIAL EQUALISATION!
Electrical interference risks disturbing the entire installation, when the ground potential between the
frequency converter and the system is different. To avoid
electrical interference, install equalising cables between
the system components. Recommended cable crosssection: 16 mm2.
4 4
To obtain an EMC compliant installation, follow the
instructions provided in 4.3 Grounding, 4.4 Wiring
Schematic, 4.6 Motor Connection, and 4.8 Control Wiring.
MG33AN02 - Rev. 2013-09-06 11
130BD599.10
3-phase
power
input
DC bus
Switch Mode
Power Supply
Motor
Analog Output
Interface
relay1
relay2
ON=Terminated
OFF=Open
Brake
resistor
91 (L1)
92 (L2)
93 (L3)
PE
88 (-)
89 (+)
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24 V OUT)
13 (+24 V OUT)
37 (D IN)
18 (D IN)
20 (COM D IN)
10 V DC
15 mA 130/200 mA
+ - + -
(U) 96
(V) 97
(W) 98
(PE) 99
(COM A OUT) 39
(A OUT) 42
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0 V
5V
S801
0/4-20 mA
RS-485
RS-485
03
+10 V DC
0/-10 V DC -
+10 V DC
+10 V DC
0/4-20 mA
0/-10 V DC-
240 V AC, 2 A
24 V DC
02
01
05
04
06
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
19 (D IN)
24 V (NPN)
0 V (PNP)
27
24 V
0 V
(D IN/OUT)
0 V (PNP)
24 V (NPN)
(D IN/OUT)
0 V
24 V
29
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
S201
ON
21
S202
ON=0/4-20 mA
OFF=0/-10 V DC +10 V DC
95
P 5-00
21
ON
S801
(R+) 82
(R-) 81
: Chassis
: Ground
**
240 V AC, 2 A
400 V AC, 2 A
*
*
*
Electrical Installation
VLT® AutomationDrive FC 301/302 Operating Instructions
4.4 Wiring Schematic
44
Illustration 4.1 Basic Wiring Schematic
A=Analog, D=Digital
*Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off
Operating Instructions for Danfoss VLT® Frequency Converters. Terminal 37 is not included in FC 301 (except enclosure type
A1). Relay 2 and terminal 29 have no function in FC 301.
**Do not connect cable screen.
12 MG33AN02 - Rev. 2013-09-06
130BD529.10
1
2
3
4
5
6
7
8
PE
U
V
W
9
L1
L2
L3
PE
10
Electrical Installation
VLT® AutomationDrive FC 301/302 Operating Instructions
4 4
Illustration 4.2 EMC-correct Electrical Connection
1
2 Frequency converter 7 Motor, 3-phase and PE (screened)
3 Output contactor 8 Mains, 3-phase and reinforced PE (not screened)
4 Cable clamp 9 Control wiring (screened)
5 Cable insulation (stripped) 10
PLC 6 Cable gland
Potential equalisation min. 16 mm2 (0.025 in)
Table 4.1 Legend to Illustration 4.2
NOTICE
EMC INTERFERENCE!
Use screened cables for motor and control wiring, and separate cables for input power, motor wiring and control
wiring. Failure to isolate power, motor and control cables can result in unintended behaviour or reduced performance.
Minimum 200 mm (7.9 in) clearance between power, motor and control cables.
MG33AN02 - Rev. 2013-09-06 13
130BT248.10
130BT334.10
Electrical Installation
VLT® AutomationDrive FC 301/302 Operating Instructions
4.5 Access
4.6
Remove cover with a screw driver (See
•
Illustration 4.3) or by loosening attaching screws
(See Illustration 4.4).
44
Illustration 4.3 Access to Wiring for IP20 and IP21 Enclosures
Illustration 4.4 Access to Wiring for IP55 and IP66 Enclosures
Motor Connection
WARNING
INDUCED VOLTAGE!
Induced voltage from output motor cables that run
together can charge equipment capacitors even with the
equipment turned off and locked out. Failure to run
output motor cables separately or use screened cables
could result in death or serious injury.
Comply with local and national electrical codes
•
for cable sizes. For maximum wire sizes see
8.1 Electrical Data.
Follow motor manufacturer wiring requirements.
•
Motor wiring knockouts or access panels are
•
provided at the base of IP21 (NEMA1/12) and
higher units.
Do not wire a starting or pole-changing device
•
(e.g. Dahlander motor or slip ring induction
motor) between the frequency converter and the
motor.
Procedure
1. Strip a section of the outer cable insulation.
2. Position the stripped wire under the cable clamp
to establish mechanical fixation and electrical
contact between cable screen and ground.
3. Connect ground wire to the nearest grounding
terminal in accordance with grounding
instructions provided in 4.3 Grounding, see
Illustration 4.5.
4. Connect the 3-phase motor wiring to terminals
96 (U), 97 (V), and 98 (W), see Illustration 4.5.
5. Tighten terminals in accordance with the
information provided in 8.8 Connection Tightening
Torques.
See Table 4.2 before tightening covers.
Enclosure IP55 IP66
A4/A5 2 2
B1/B2 2.2 2.2
C1/C2 2.2 2.2
No screws to tighten for A1/A2/A3/B3/B4/C3/C4.
Table 4.2 Tightening Torques for Covers [Nm]
14 MG33AN02 - Rev. 2013-09-06
130BD531.10
U
V
W
96
97
98
95
130BB920.10
+DC
BR-
B
M A I N S
L1 L2 L3
91 92 93
RELAY 1 RELAY 2
99
- LC -
U V W
MOTOR
99
Electrical Installation
Illustration 4.5 Motor Connection
VLT® AutomationDrive FC 301/302 Operating Instructions
4.7 AC Mains Connection
Size wiring based upon the input current of the
•
frequency converter. For maximum wire sizes see
8.1 Electrical Data.
Comply with local and national electrical codes
•
for cable sizes.
Procedure
1. Connect 3-phase AC input power wiring to
terminals L1, L2, and L3 (see Illustration 4.6).
2. Depending on the configuration of the
equipment, input power is connected to the
mains input terminals or the input disconnect.
3. Ground the cable in accordance with grounding
instructions provided in 4.3 Grounding.
4. When supplied from an isolated mains source (IT
mains or floating delta) or TT/TN-S mains with a
grounded leg (grounded delta), ensure that
14-50 RFI Filter is set to OFF to avoid damage to
the intermediate circuit and to reduce earth
capacity currents in accordance with IEC 61800-3.
4 4
Illustration 4.6 represents mains input, motor, and earth
grounding for basic frequency converters. Actual configurations vary with unit types and optional equipment.
Illustration 4.6 Example of Motor, Mains and Ground Wiring
4.8
Control Wiring
Isolate control wiring from high power
•
components in the frequency converter.
When the frequency converter is connected to a
•
thermistor, ensure that the thermistor control
wiring is screened and reinforced/double
insulated. A 24 V DC supply voltage is
recommended.
MG33AN02 - Rev. 2013-09-06 15
2
3
4
1
130BB921.11
12 13 18 19 27 29 32 33 20 37
39 42 50 53 54 55
61 68 69
130BB931.10
1
2 3
Electrical Installation
VLT® AutomationDrive FC 301/302 Operating Instructions
4.8.1 Control Terminal Types
Terminal description
Default
Illustration 4.7 and Illustration 4.8 show the removable
Terminal Parameter
frequency converter connectors. Terminal functions and
default settings are summarised in Table 4.3 and Table 4.4.
12, 13 - +24 V DC 24 V DC supply
44
18 5-10 [8] Start
19 5-11 [10] Reversing
32 5-14 [0] No
33 5-15 [0] No
Illustration 4.7 Control Terminal Locations
Illustration 4.8 Terminal Numbers
Connector 1 provides 4 programmable digital
•
inputs terminals, 2 additional digital terminals
programmable as either input or output, a 24 V
DC terminal supply voltage, and a common for
optional customer supplied 24 V DC voltage. FC
302 and FC 301 (optional in A1 enclosure) also
provide a digital input for STO (Safe Torque Off)
function.
Connector 2 terminals (+)68 and (-)69 for RS-485
•
serial communication connection
Connector 3 provides 2 analog inputs, one
•
analog output, 10 V DC supply voltage, and
27 5-12 [2] Coast
29 5-13 [14] JOG
20 - Common for digital
37 - Safe Torque
39 -
42 6-50 [0] No
50 - +10 V DC 10 V DC analog
53 6-1* Reference Analog input. For
54 6-2* Feedback
55 -
setting Description
Digital inputs/outputs
operation
operation
inverse
Off (STO)
Analog inputs/outputs
operation
voltage for digital
inputs and external
transducers. Maximum
output current 200
mA (130 mA for FC
301) for all 24 V loads.
Digital inputs.
For digital input or
output. Default setting
is input.
inputs and 0 V
potential for 24 V
supply.
Safe input. Used for
STO.
Common for analog
output
Programmable analog
output. 0-20 mA or
4-20 mA at a
maximum of 500 Ω
supply voltage for
potentiometer or
thermistor. 15 mA
maximum
voltage or current.
Switches A53 and A54
select mA or V.
Common for analog
input
commons for the inputs and output
Connector 4 is a USB port available for use with
•
the MCT 10 Set-up Software
Table 4.3 Terminal Description Digital Inputs/Outputs,
Analog Inputs/Outputs
16 MG33AN02 - Rev. 2013-09-06
130BD546.10
2
1
10 mm
29
27
32
19
18
13
12
33
Electrical Installation
Terminal description
Default
Terminal Parameter
61 -
68 (+) 8-3* RS-485 Interface. A
69 (-) 8-3*
01, 02, 03 5-40 [0]
04, 05, 06 5-40 [1] [0] No
Table 4.4 Terminal Description Serial Communication
Additional terminals:
2 form C relay outputs. Location of the outputs
•
depends on frequency converter configuration.
Terminals located on built-in optional equipment.
•
See the manual provided with the equipment
option.
setting Description
Serial communication
Relays
[0] No
operation
operation
VLT® AutomationDrive FC 301/302 Operating Instructions
Integrated RC-Filter
for cable screen. ONLY
for connecting the
screen in the event of
EMC problems.
control card switch is
provided for
termination resistance.
Form C relay output.
For AC or DC voltage
and resistive or
inductive loads.
Illustration 4.9 Connecting Control Wires
2. Insert the bared control wire into the contact.
3. Remove the screw driver to fasten the control
wire into the contact.
4. Ensure the contact is firmly established and not
loose. Loose control wiring can be the source of
equipment faults or less than optimal operation.
See 8.5 Cable Specifications for control terminal wiring sizes
and 6 Application Set-up Examples for typical control wiring
connections.
Enabling Motor Operation (Terminal
4.8.3
27)
4 4
Wiring to Control Terminals
4.8.2
Control terminal connectors can be unplugged from the
frequency converter for ease of installation, as shown in
Illustration 4.7.
NOTICE
Keep control wires as short as possible and separate
from high power cables to minimise interference.
1. Open the contact by inserting a small screw
driver into the slot above the contact and push
the screw driver slightly upwards.
A jumper wire may be required between terminal 12 (or
13) and terminal 27 for the frequency converter to operate
when using factory default programming values.
Digital input terminal 27 is designed to receive an
•
24 V DC external interlock command. In many
applications, the user wires an external interlock
device to terminal 27.
When no interlock device is used, wire a jumper
•
between control terminal 12 (recommended) or
13 to terminal 27. This provides an internal 24 V
signal on terminal 27.
When the status line at the bottom of the LCP
•
reads AUTO REMOTE COAST, this indicates that
the unit is ready to operate but is missing an
input signal on terminal 27.
When factory installed optional equipment is
•
wired to terminal 27, do not remove that wiring.
NOTICE
The frequency converter cannot operate without a signal
on terminal 27 unless terminal 27 is re-programmed.
MG33AN02 - Rev. 2013-09-06 17
130BD530.10
1
2
N O
VLT
BUSTER.
OFF-ON
A53 A54
U- I U- I
L1 L2 L3
U V W
02 01
A1
A2
130BA902.10
Drive
Output
relay
Command Circuit
220Vac
Mechanical
Brake
Shaft
Motor
Frewheeling
diode
Brake
380Vac
Output
Contactor
Input
Power Circuit
Electrical Installation
VLT® AutomationDrive FC 301/302 Operating Instructions
4.8.4 Voltage/Current Input Selection
4.8.6
Mechanical Brake Control
(Switches)
The analog input terminals 53 and 54 allow setting of
input signal to voltage (0-10 V) or current (0/4-20 mA).
Default parameter settings:
Terminal 53: speed reference signal in open loop
•
44
(see 16-61 Terminal 53 Switch Setting).
Terminal 54: feedback signal in closed loop (see
•
16-63 Terminal 54 Switch Setting).
NOTICE
Disconnect power to the frequency converter
before changing switch positions.
1. Remove the local control panel (see
Illustration 4.10).
2. Remove any optional equipment covering the
switches.
3. Set switches A53 and A54 to select the signal
type. U selects voltage, I selects current.
In hoisting/lowering applications, it is necessary to
control an electro-mechanical brake:
Control the brake using any relay output or
•
digital output (terminal 27 or 29).
Keep the output closed (voltage-free) as long as
•
the frequency converter is unable to keep the
motor at standstill, for example due to the load
being too heavy.
Select [32] Mechanical brake control in parameter
•
group 5-4* Relays for applications with an electromechanical brake.
The brake is released when the motor current
•
exceeds the preset value in 2-20 Release Brake
Current.
The brake is engaged when the output frequency
•
is less than the frequency set in 2-21 Activate
Brake Speed [RPM] or 2-22 Activate Brake Speed
[Hz], and only if the frequency converter carries
out a stop command.
If the frequency converter is in alarm mode or in an overvoltage situation, the mechanical brake immediately closes.
Illustration 4.10 Location of Terminals 53 and 54 Switches
Safe Torque Off (STO)
4.8.5
To run Safe Torque Off, additional wiring for the frequency
converter is required, refer to Safe Torque Off Operating
Instructions for Danfoss VLT® Frequency Converters for
further information.
The frequency converter is not a safety device. It is the
responsibility of the system designer to integrate safety
devices according to relevant national crane/lift
regulations.
Illustration 4.11 Connecting the Mechanical Brake to the
Frequency Converter
18 MG33AN02 - Rev. 2013-09-06
61
68
69
+
130BB489.10
RS-485
Electrical Installation
VLT® AutomationDrive FC 301/302 Operating Instructions
4.8.7 RS-485 Serial Communication
Connect RS-485 serial communication wiring to terminals
(+)68 and (-)69.
Use screened serial communication cable
•
(recommended)
See 4.3 Grounding for proper grounding
•
4 4
Illustration 4.12 Serial Communication Wiring Diagram
For basic serial communication set-up, select the following:
1.
Protocol type in 8-30 Protocol.
2.
Frequency converter address in 8-31 Address.
3.
Baud rate in 8-32 Baud Rate.
2 communication protocols are internal to the
•
frequency converter.
Danfoss FC
Modbus RTU
Functions can be programmed remotely using
•
the protocol software and RS-485 connection or
in parameter group 8-** Communications and
Options
Selecting a specific communication protocol
•
changes various default parameter settings to
match that protocol’s specifications along with
making additional protocol-specific parameters
available
Option cards which install into the frequency
•
converter are available to provide additional
communication protocols. See the option-card
documentation for installation and operation
instructions
MG33AN02 - Rev. 2013-09-06 19
Electrical Installation
VLT® AutomationDrive FC 301/302 Operating Instructions
4.9 Installation Check List
Before completing installation of the unit, inspect the entire installation as detailed in Table 4.5. Check and mark the items
when completed.
Inspect for Description
Auxiliary equipment•Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on the
input power side of the frequency converter or output side to the motor. Ensure that they are ready for
44
Cable routing
Control wiring
Cooling clearance
Ambient conditions•Check that requirements for ambient conditions are met
Fusing and circuit
breakers
Grounding
Input and output
power wiring
Panel interior
Switches
Vibration
full-speed operation
Check function and installation of any sensors used for feedback to the frequency converter
•
Remove any power factor correction caps on motor(s)
•
Adjust any power factor correction caps on the mains side and ensure that they are dampened
•
Ensure that motor wiring and control wiring are separated or screened or in 3 separate metallic conduits
•
for high-frequency interference isolation
Check for broken or damaged wires and loose connections
•
Check that control wiring is isolated from power and motor wiring for noise immunity
•
Check the voltage source of the signals, if necessary
•
The use of screened cable or twisted pair is recommended. Ensure that the shield is terminated correctly
•
Measure that top and bottom clearance is adequate to ensure proper air flow for cooling, see
•
3.3 Mounting
Check for proper fusing or circuit breakers
•
Check that all fuses are inserted firmly and are in operational condition and that all circuit breakers are in
•
the open position
Check for good ground connections that are tight and free of oxidation
•
Grounding to conduit, or mounting the back panel to a metal surface, is not a suitable grounding
•
Check for loose connections
•
Check that motor and mains are in separate conduit or separated screened cables
•
Inspect that the unit interior is free of dirt, metal chips, moisture, and corrosion
•
Check that the unit is mounted on an unpainted, metal surface
•
Ensure that all switch and disconnect settings are in the proper positions
•
Check that the unit is mounted solidly, or that shock mounts are used, as necessary
•
Check for an unusual amount of vibration
•
☑
Table 4.5 Installation Check List
CAUTION
POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE!
Risk of personal injury when the frequency converter is not properly closed. Before applying power, ensure all safety
covers are in place and securely fastened.
20 MG33AN02 - Rev. 2013-09-06
Commissioning
VLT® AutomationDrive FC 301/302 Operating Instructions
5 Commissioning
5.1 Safety Instructions
See 2 Safety for general safety instructions.
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains input power. Installation, startup, and maintenance must be performed by qualified
personnel only. Failure to perform installation, start-up,
and maintenance by qualified personnel could result in
death or serious injury.
Before applying power:
1. Close cover properly.
2. Check that all cable glands are firmly tightened.
3. Ensure that input power to the unit is OFF and
locked out. Do not rely on the frequency
converter disconnect switches for input power
isolation.
4. Verify that there is no voltage on input terminals
L1 (91), L2 (92), and L3 (93), phase-to-phase and
phase-to-ground.
5. Verify that there is no voltage on output
terminals 96 (U), 97 (V), and 98 (W), phase-tophase and phase-to-ground.
6. Confirm continuity of the motor by measuring
ohm values on U-V (96-97), V-W (97-98), and W-U
(98-96).
7. Check for proper grounding of the frequency
converter as well as the motor.
8. Inspect the frequency converter for loose
connections on terminals.
9. Confirm that the supply voltage matches voltage
of frequency converter and motor.
5.2
Applying Power
1. Confirm that the input voltage is balanced within
3%. If not, correct input voltage imbalance before
proceeding. Repeat this procedure after the
voltage correction.
2. Ensure that optional equipment wiring, if present,
matches the installation application.
3. Ensure that all operator devices are in the OFF
position. Panel doors must be closed or cover
mounted.
4. Apply power to the unit. DO NOT start the
frequency converter at this time. For units with a
disconnect switch, turn to the ON position to
apply power to the frequency converter.
NOTICE
If the status line at the bottom of the LCP reads AUTO
REMOTE COASTING or Alarm 60 External Interlock is
displayed, this indicates that the unit is ready to operate
but is missing an input signal on terminal 27. See
4.8.3 Enabling Motor Operation (Terminal 27) for details.
5.3 Local Control Panel Operation
5.3.1 Local Control Panel
The local control panel (LCP) is the combined display and
keypad on the front of the unit.
The LCP has several user functions:
Start, stop, and control speed when in local
•
control
Display operational data, status, warnings and
•
cautions
Programming frequency converter functions
•
Manually reset the frequency converter after a
•
fault when auto-reset is inactive
An optional numeric LCP (NLCP) is also available. The NLCP
operates in a manner similar to the LCP. See the
Programming Guide for details on use of the NLCP.
5 5
WARNING
UNINTENDED START!
When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency
converter, motor, and any driven equipment must be in
operational readiness. Failure to be in operational
readiness when the frequency converter is connected to
AC mains could result in death, serious injury, equipment
or property damage.
MG33AN02 - Rev. 2013-09-06 21
NOTICE
For commissioning via PC, install MCT 10 Set-up
Software. The software is available for download at
www.danfoss.com/BusinessAreas/DrivesSolutions/Softwaredownload (basic version) or for ordering (advanced
version, order number 130B1000).
130BD598.10
Auto
on
Reset
Hand
on
O
Status
Quick
Menu
Main
Menu
Alarm
Log
Back
Cancel
Info
OK
Status
1(1)
36.4 kW
Auto Remote Ramping
0.000
On
Alarm
Warn.
A
7.83 A
799 RPM
B
C
D
53.2 %
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18 19 20 21
Commissioning
VLT® AutomationDrive FC 301/302 Operating Instructions
5.3.2 LCP Layout
B. Display menu keys
Menu keys are used for menu access for parameter set-up,
The LCP is divided into 4 functional groups (see
Illustration 5.1).
A. Display area
B. Display menu keys
C. Navigation keys and indicator lights (LEDs)
D. Operation keys and reset
55
toggling through status display modes during normal
operation, and viewing fault log data.
Key Function
6
Status
7
Quick Menu
8
Main Menu
9
Alarm Log
Table 5.2 Legend to Illustration 5.1, Display Menu Keys
Shows operational information.
Allows access to programming parameters
for initial set-up instructions and many
detailed application instructions.
Allows access to all programming
parameters.
Displays a list of current warnings, the last
10 alarms, and the maintenance log.
C. Navigation keys and indicator lights (LEDs)
Navigation keys are used for programming functions and
moving the display cursor. The navigation keys also
provide speed control in local operation. There are also 3
frequency converter status indicator lights in this area.
Key Function
10
11
12
13
14
Back
Cancel
Info
Navigation
Keys
OK
Reverts to the previous step or list in the
menu structure.
Cancels the last change or command as long
as the display mode has not changed.
Press for a definition of the function being
displayed.
Use the 4 navigation keys to move between
items in the menu.
Use to access parameter groups or to enable
a choice.
Table 5.3 Legend to Illustration 5.1, Navigation Keys
Illustration 5.1 Local Control Panel (LCP)
A. Display area
The display area is activated when the frequency converter
receives power from mains voltage, a DC bus terminal, or
an external 24 V DC supply.
The information displayed on the LCP can be customised
for user application. Select options in the Quick Menu
Q3-13 Display Settings.
Display Parameter number Default setting
1 0-20 Speed [RPM]
2 0-21 Motor Current
3 0-22 Power [kW]
4 0-23 Frequency
5 0-24 Reference [%]
Table 5.1 Legend to Illustration 5.1, Display Area
22 MG33AN02 - Rev. 2013-09-06
Indicator Light Function
15 On Green The ON light activates when the
frequency converter receives
power from mains voltage, a DC
bus terminal, or an external 24 V
supply.
16 Warn Yellow When warning conditions are met,
the yellow WARN light comes on
and text appears in the display
area identifying the problem.
17 Alarm Red A fault condition causes the red
alarm light to flash and an alarm
text is displayed.
Table 5.4 Legend to Illustration 5.1, Indicator Lights (LEDs)
D. Operation keys and reset
Operation keys are located at the bottom of the LCP.
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