This operating guide provides information for safe installation and commissioning of the frequency converter.
The operating guide is intended for use by
personnel.
Read and follow the instructions to use the frequency
converter safely and professionally, and pay particular
attention to the safety instructions and general warnings.
Always keep this operating guide available with the
frequency converter.
VLT® is a registered trademark.
1.2 Additional Resources
Supplementary publications and manuals are available.
The VLT® AutomationDrive FC 301/302
•
Programming Guide provides greater detail on
working with parameters and many application
examples.
The VLT® Decentral Drive FCD 302 Design Guide
•
provides detailed information about capabilities
and functionality to design motor control
systems.
Instructions for operation with optional
•
equipment.
See www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/VLT+Technical+Documentation.htm.
Document and Software Version
1.3
qualied
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
overload protection.
Depending on the conguration, the frequency converter
can be used in standalone applications or form part of a
larger appliance or installation.
The VLT® Decentral Drive FCD 302 is designed for decentral
mounting, for example, in the food and beverage industry,
or for other material handling applications. With the FCD
302, it is possible to reduce costs by placing the power
electronics decentrally. Central panels are then rendered
obsolete, saving cost, space, and eort for installation and
wiring. The basic design is service-friendly, with a
pluggable electronic part, and a
wiring box. It is easy to change electronics without the
need for rewiring.
The FCD 302 is designed according to the EHEDG
guidelines, suitable for installation in environments with
high focus on ease of cleaning.
exible and “spacious”
NOTICE
Only frequency converters congured as hygienic
enclosure designation, FCD 302 P XXX T4 W69, have the
EHEDG certication.
11
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.
EditionRemarksSoftware version
MG04F5xxSTO functionality has been
updated.
Table 1.1 Document and Software Version
Product Overview
1.4
7.5X
1.4.1 Intended Use
The frequency converter is an electronic motor controller
intended for:
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 specied operating conditions and
environments. Ensure compliance with the conditions
specied in chapter 7 Specications.
130BC379.10
3
1
4
6
5
9
10
7
2
8
Introduction
VLT® Decentral Drive FCD 302
11
1.4.2 Exploded Views
1Inverter part6Installation box
2Fastening screws (4 x, 1 in each corner)7Display connection
3Sealing gasket8Access to USB port
4Inverter part plastic cover9Service switch-motor side (alternatively, switch located on
Illustration 1.3 is a block diagram of the internal
components of the frequency converter.
AreaTitleFunctions
1Mains input
2Rectier
3DC bus
4DC reactors
5Capacitor bank
6Inverter
7Output to motor
3-phase AC mains supply to the
frequency converter.
The rectier 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.
Provide mains transient
•
protection.
Reduce RMS current.
•
Raise the power factor
•
reected back to the line.
Reduce harmonics on the AC
•
input.
Stores the DC power.
•
Provides ride-through
•
protection for short power
losses.
The inverter 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.
AreaTitleFunctions
Input power, internal
•
processing, output, and motor
current are monitored to
provide ecient operation
and control.
8Control circuitry
Illustration 1.3 Frequency Converter Block Diagram
User interface and external
•
commands are monitored and
performed.
Status output and control can
•
be provided.
1.5 Approvals and Certications
Table 1.2 Approvals and Certications
More approvals and certications are available. Contact the
local Danfoss partner. Frequency converters of enclosure
size T7 (525–690 V) are UL certied for only 525–600 V.
The frequency converter complies with UL 508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the
product-specicdesign guide.
For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation in the
product-specic design guide.
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 Qualied Personnel
WARNING
UNINTENDED START
When the frequency converter is connected to AC mains,
DC supply, or load sharing, the motor may start at any
time. Unintended start during programming, service, or
repair work can result in death, serious injury, or
property damage. The motor can start via an external
switch, a eldbus command, an input reference signal
from the LCP, or after a cleared fault condition.
To prevent unintended motor start:
Disconnect the frequency converter from the
•
mains.
Press [O/Reset] on the LCP before
•
programming parameters.
Completely wire and assemble the frequency
•
converter, motor, and any driven equipment
before connecting the frequency converter to
AC mains, DC supply, or load sharing.
Correct and reliable transport, storage, installation,
operation, and maintenance are required for the troublefree and safe operation of the frequency converter. Only
qualied personnel are allowed to install and operate this
equipment.
Qualied personnel are dened as trained sta, who are
authorized to install, commission, and maintain equipment,
systems, and circuits in accordance with pertinent laws and
regulations. Also, the qualied personnel must be familiar
with the instructions and safety measures described in this
manual.
Safety Precautions
2.3
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when
connected to AC mains input, DC supply, or load sharing.
Failure to perform installation, start-up, and maintenance
by qualied personnel can result in death or serious
injury.
Only qualied personnel must perform instal-
•
lation, start-up, and maintenance.
WARNING
DISCHARGE TIME
The frequency converter contains DC-link capacitors,
which can remain charged even when the frequency
converter is not powered. High voltage can be present
even when the warning indicator lights are o. Failure to
wait the specied time after power has been removed
before performing service or repair work could result in
death or serious injury.
1.Stop the motor.
2.Disconnect AC mains, permanent magnet type
motors, and remote DC-link supplies, including
battery back-ups, UPS, and DC-link connections
to other frequency converters.
3.Wait for the capacitors to discharge fully before
performing any service or repair work. The
discharge time is specied in Table 2.1.
Do not remove the nameplate from the frequency
converter (loss of warranty).
3.2 Mounting
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
the lifetime of the frequency converter. Ensure that
requirements for air humidity, temperature, and altitude
are met.
Vibration and shock
The frequency converter complies with requirements for
units mounted on the walls and oors of production
premises, and in panels bolted to walls or oors.
For detailed ambient conditions specications, refer to
chapter 7.4 Ambient Conditions.
41 mm
(1.61 in)
175 mm (6.88 in)
349.5 mm (13.75 in)
315 mm (12.4 in)
ON
WARNING
ALARM
Bus MSNS2NS1
331.5 mm (13.05 in)
280 mm (11.02 in)
178 mm (7 in)
6.5 mm
(0.25 in)
80 mm
(3.14 in)
190 mm (7.48 in)
25 mm
(0.98 in)
Ø13 mm
(0,51 in)
130BB712.10
200 mm (7.87 in)
1
2
3
4
80 mm
(3.14 in)
130BC381.10
431.5 mm (16.98 in)
380 mm (14.96 in)
178 mm (7 in)
201 mm (7.91 in)
32 mm
(1.25 in)
415 mm (16.33 in)
186 mm (7.32 in)
449.5 mm (17.69 in)
6.5 mm
(0.25 in)
190 mm (7.48 in)
80 mm
(3.14 in)
80 mm
(3.14 in)
Ø13 mm
(0,51 in)
25 mm
(0.98 in)
Mechanical InstallationOperating Guide
3.2.1 Recommended Tools and Equipment
EquipmentSizeDescription
Screwdrivers––
Socket (hex)8For fastening inverter
screws/mounting of
brackets
Slotted0.4x2.5For spring loaded power
and control terminals
Slotted/torx1.0x5.5/TX20For cable clamps inside
the installation box
Spanner19, 24, 28For blind-plugs
LCP, ordering
–Local control panel
number 130B1078
LCP cable,
ordering number
–Connection cable for
local control panel
130B5776
Table 3.1 Recommended Tools and Equipment
3.2.2 Mechanical Dimensions
33
Illustration 3.2 Cable Entries and Hole Sizes (Small Unit)
Illustration 3.3 Cable Entries and Hole Sizes (Large Unit)
Motor side1xM20, 1xM25
Control side
2xM20, 9xM16
1)
Mains side2xM25
Table 3.2 Mechanical Dimensions
1) Also used for 4xM12/6xM12 sensor/acuator sockets.
3.2.3 Mounting
The VLT® Decentral Drive FCD 302 consists of 2 parts:
Do not apply power to the unit at this stage, as this
33
could result in death or serious injury.
CAUTION
DAMAGE OR PERSONAL INJURY
Failure to tighten the 4 mounting screws can result in
personal injury or material damage.
Ensure that the strength of the mounting
•
location can support the unit weight.
Prerequisites:
Use the holes on the rear of the installation box
•
to x the mounting brackets.
Use proper mounting screws or bolts.
•
For hygienic versions, use cable glands designed
•
to meet hygienic application requirements, for
example Rittal HD 2410.110/120/130.
1.
Illustration 3.4 Allowed Mounting Positions - Standard
Applications
Mount the VLT® Decentral Drive FCD 302
vertically on a wall or machine frame. For
hygienic versions, ensure that liquids drain
enclosure and orient the unit so the cable glands
are located at the base.
o the
Illustration 3.6 FCD 302 Standalone Mounted with Mounting
See chapter 2 Safety for general safety instructions.
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run
together can charge equipment capacitors, even with the
equipment turned o and locked out. Failure to run
output motor cables separately or use shielded cables
could result in death or serious injury.
Run output motor cables separately, or
•
Use shielded cables.
•
CAUTION
SHOCK HAZARD
The frequency converter can cause a DC current in the
PE conductor. Failure to follow the recommendation
below means that the RCD may not provide the
intended protection.
When a residual current-operated protective
•
device (RCD) is used for protection against
electrical shock, only an RCD of Type B is
allowed on the supply side.
Overcurrent 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 overcurrent protection. If not factorysupplied, the installer must provide the fuses. See
UL/cUL approved pre-fuses in chapter 7.7 Fusesand 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 (167 °F) rated copper wire.
See chapter 7.1 Electrical Data and chapter 7.5 Cable Speci-cations for recommended wire sizes and types.
EMC-compliant Installation
4.2
To obtain an EMC-compliant installation, follow the
instructions provided in chapter 4.3 Grounding,
chapter 4.4 Wiring Schematic, chapter 4.7 Motor Connection,
and chapter 4.10 Control Wiring.
4.3 Grounding
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
frequency converter properly could result in death or
serious injury.
Ensure the correct grounding of the equipment
•
by a certied electrical installer.
For electrical safety
Ground the frequency converter 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 (7 AWG)
•
(or 2 rated ground wires terminated separately).
For EMC-compliant installation
Establish electrical contact between the cable
•
shield and the frequency converter enclosure by
using metal cable glands or by using the clamps
provided on the equipment.
Risk of burst transient, when the ground potential
between the frequency converter and the control system
is dierent. Install equalizing cables between the system
components. Recommended cable cross-section: 16 mm
(5 AWG).
2
44
CAUTION
PE CONNECTION
The metal pins in the corners of the electronic part and
the holes on the corner of the installation box are
essential for the protective earth connection. Make sure
that they are not loosened, removed, or violated in any
way. Tightening torque requirement is 3 Nm. (26 in-lb).
See Illustration 4.1.
Grounding shielded cable
Grounding clamps are provided for motor and control wiring (see Illustration 4.2).
Illustration 4.1 PE Connection between the Installation Box
and the Electronic Part
NOTICE
The external grounding terminal is available as an
accessory (part no: 130B5833).
Illustration 4.2 Grounding for Motor and Control Wiring (Small Unit)
Illustration 4.5 Large Unit only: Circuit Breaker and Mains
Disconnect
44
1 Looping terminals
Illustration 4.6 Large Unit only: Service Switch at Mains with
Looping Terminals
NOTICE
EMC INTERFERENCE
Use shielded 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 behavior or
reduced performance. Minimum clearance requirement
between power, motor, and control cables is 200 mm
(7.9 in).