MAKING MODERN LIVING POSSIBLE
O
Operating Instructions
VLTp Decentral Drive FCD 302
inverter.ru (812) 702-47-50
Operating Instructions Addendum
Mains Supply 3 x 380 - 480VAC
Frequency Converter PK37 PK55 PK75 P1K1 P1K5 P2K2 P3K0
Typical Shaft Output [kW] 0.37 0.55 0.75 1.1 1.5 2.2 3.0
Typical Shaft Output [HP] at 460V 0.5 0.75 1.0 1.5 2.0 3.0 4.0
Output current
Continuous (3 x 380-440V) [A] 1.3 1.8 2.4 3.0 4.1 5.2 7.2
Intermittent (3 x 380-440V) [A] 2.1 2.9 3.8 4.8 6.6 8.3 11.5
Continuous (3 x 441-480V) [A] 1.2 1.6 2.1 3.0 3.4 4.8 6.3
Intermittent (3 x 441-480V) [A] 1.9 2.6 3.4 4.8 5.4 7.7 10.1
Continuous kVA (400V AC) [kVA] 0.9 1.3 1.7 2.1 2.8 3.9 5.0
Continuous kVA (460V AC) [kVA] 0.9 1.3 1.7 2.4 2.7 3.8 5.0
Max. cable size:
(mains, motor, brake)
[mm2/ AWG]
6/10
Max. input current
Continuous (3 x 380-440V) [A] 1.2 1.6 2.2 2.7 3.7 5.0 6.5
Intermittent (3 x 380-440V) [A] 1.9 2.6 3.5 4.3 5.9 8.0 10.4
Continuous (3 x 441-480V) [A] 1.0 1.4 1.9 2.7 3.1 4.3 5.7
Intermittent (3 x 441-480V) [A] 1.6 2.2 3.0 4.3 5.0 6.9 9.1
Recommended fuse size gG-10 gG-16
Recommended Max. fuse gG-25
Recommended circuit breaker (big box) CTI-25M 047b3151
Recommended circuit breaker (small box) CTI-45MB
Power loss at max. load [W] 35 42 46 58 62 88 116
Efficiency 0.93 0.95 0.96 0.96 0.97 0.97 0.97
Weight [kg] ( small box ) 9.8 X
Weight [kg] ( big box ) 13.9
General specifications:
x Fuses;
The unit is suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical Amperes, 480V maximum.
x
Circuit breaker
The unit is suitable for use on a circuit capable of delivering not more than 10,000 RMS symmetrical Amperes, 480V maximum.
x
Delta grounded net is not supporting PELV
x For design of the brake resistor refer to brake resistor manual
inverter.ru (812) 702-47-50
Type of circuit breaker
Small box – CTI45MB external
Big box – CTI25M internal; ordering nr. 047b3151
inverter.ru (812) 702-47-50
C
Contents
1 Introduction
3
1.1.1 Symbols 3
1.1 Safety
3
1.2 Purpose of the Manual
3
1.3 Additional Resources
4
1.4 Product Overview
4
1.5 Internal Frequency Converter Controller Functions
4
1.6 Type Code Description
5
2 Installation
6
2.1 Check List
6
2.2 Exploded View of the FCD 302
7
2.3 Mechanical Installation
8
2.3.1 Recommended Tools and Equipment 8
2.3.2 Mechanical Dimensions 8
2.3.3 Cooling 9
2.3.4 Mounting 9
2.3.4.1 Hygienic Installation 10
2.3.4.2 Cleaning 10
2.3.5 Tightening Torques 11
2.4 Electrical Installation
11
2.4.1 Requirements 12
2.4.2 Location of Terminals 13
2.4.3 Terminal Types 14
2.4.4 Motor Connection 14
2.4.5 Control Wiring 15
2.4.6 AC Mains Input Connection 16
2.4.7 Motor and Mains Connection with Service Switch 16
2.4.8 Brake Resistor 17
2.4.9 Mechanical Brake 17
2.4.10 Connection of Sensors/Actuators on M12 Sockets 17
2.4.11 Earth (Grounding) Requirements 18
2.4.12 Grounding Shielded Control Cables 20
2.4.13 DIP Switches 20
2.4.14 Serial Communication 20
2.4.15 Connection to PC 21
2.4.16 Safe Stop 21
3 Start Up and Functional Testing
24
3.1 Pre-start
24
Contents
VLT
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Decentral Drive FCD 302 Operating Instructions
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3.1.1 Safety Inspection 24
3.1.2 Start Up Check List 24
3.2 Applying Power to the Frequency Converter
25
3.3 Basic Operational Programming
25
3.4 Automatic Motor Adaptation
26
3.5 Local-control Test
26
3.6 System Start Up
27
4 User Interface
28
4.1 Local Control Panel
28
4.1.1 LCP Layout 28
4.1.2 Setting LCP Display Values 29
4.1.3 Display Menu Keys 29
4.1.4 Navigation Keys 30
4.1.5 Operation Keys 30
4.2 Back Up and Copying Parameter Settings
30
4.2.1 Uploading Data to the LCP 31
4.2.2 Downloading Data from the LCP 31
4.3 Restoring Default Settings
31
4.3.1 Recommended Initialisation 31
4.3.2 Manual Initialisation 31
5 Programming
32
5.1 Introduction
32
5.2 Quick Setup
32
5.3 Parameter Lists
35
5.4 Remote Programming with MCT 10 Set-up Software
59
6 Status Indication
60
6.1 Frontal LEDs
60
6.2 Status Display
60
6.3 Status Message Definitions Table
60
7 Troubleshooting
63
8 Specifications
71
8.1 Electrical Data and Wire Sizes
71
8.2 General Specifications
72
Index
76
Contents
VLT
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Decentral Drive FCD 302 Operating Instructions
2 MG.04.F2.02 - VLTp is a registered Danfoss trademark
inverter.ru (812) 702-47-50
1 Introduction
F
FCD 302 Series
Operating instructions
Software version: 6.22
1.1.1 Symbols
The following symbols are used in this manual:
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also
be used to alert against unsafe practices.
CAUTION
Indicates a situation that may result in equipment or
property-damage-only accidents.
NOTE
Indicates highlighted information that should be regarded
with attention to avoid mistakes or operate equipment at
less than optimal performance.
ᅴ
Indicates default setting of parameter.
1.1 Safety
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when connected
to AC mains input power. Installation, start-up and
maintenance should be performed by qualified personnel
only. Failure to perform installation, start-up and
maintenance by qualified personnel could result in death or
serious injury.
WARNING
UNINTENDED START
When the frequency converter is connected to the AC mains,
the motor may be started by means of an external switch, a
serial bus command, an input reference signal, or a cleared
fault condition. Use appropriate cautions to guard against an
unintended start.
WARNING
DISCHARGE TIME
Frequency converters contain DC link capacitors that can
remain charged even when AC mains input power is disconnected. To avoid electrical hazards, remove AC mains input
power from the frequency converter before doing any
service or repair and wait at least 4 minutes.
1.2 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and start up of the frequency converter.
Chapter Pre-installation Planning provides requirements for
installation, wiring, and environmental considerations.
Chapter Installation provides detailed procedures for startup and functional testing. The remaining chapters provide
supplementary details. These include user interface, basic
operational concepts, programming and application
examples, start-up troubleshooting, and equipment specifications.
Optional equipment is available that may change some of
the procedures described. Be sure to see the instructions
supplied with those options for specific requirements.
Introduction
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Decentral Drive FCD 302 Operating Instructions
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1.3 Additional Resources
Other resources are available to understand advanced
frequency controller functions and programming.
•
•
The Programming Guide, MG.04.GX.YY, provides
greater detail in how to work with parameters and
many application examples
•
The Design Guide, MG.04.HX.YY, is intended to
provide detailed capabilities and functionality to
design motor control systems.
•
Training courses both on-line and in person.
•
Phone and on-line help.
•
Installation, set up, and commissioning is also
available by Danfoss trained and approved
installers.
•
Danfoss sales representatives are also trained to
provide customer service and instruction for
applications
Contact your Danfoss supplier or go to www.Danfoss.com for
downloads or additional information.
1.4 Product Overview
A frequency converter is an electronic motor controller that
converts AC mains input into a variable AC waveform output.
The frequency and voltage of the output are regulated to
control the motor speed or torque.
In addition, the frequency converter monitors the system
and motor status, issues warnings or alarms for fault
conditions, starts and stops the motor, optimizes energy
efficiency, provides line harmonics protection, and offers
many more control, monitoring, and efficiency functions.
Operation and monitoring functions are available as status
indications to an outside control system or serial communication network.
The FCD 302 designed for decentral mounting, e.g. in the
food and beverage industry, or for other material handling
applications. With the FCD 302 it is possible to utilize the
cost saving potential by placing the power electronics
decentrally, and thus make the central panels obsolete
saving cost, space and effort for installation and wiring. The
basic design with a plugable electronic part and a flexible
and “spacious” wiring box is extremely service-friendly, and it
is easy to change electronics without the need for unwiring.
The FCD 302 is a part of the VLT
p
frequency converter family,
which means similar functionality, programming, and
operating as the other family members.
1.5 Internal Frequency Converter Controller
Functions
Below is a block diagram of the frequency converter's
internal components. See Table 1.1 for their functions.
Illustration 1.1 Frequency Converter Block Diagram
Area Title Functions
1 Mains input Three-phase AC mains power supply to the
frequency converter.
2 Recifier The rectifier bridge converts the AC input to
DC current for use within the frequency
converter.
3 DC bus The frequency converter's intermediate DC-
bus circuit handles the DC current for internal
routing.
4 DC line
reactors
•
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
5 Capacitor
bank
•
Stores the DC power
•
Provides a regulated DC current supply
•
Provides ride-through protection for short
power losses
6 Inverter The inverter converts the DC into a controlled
PWM AC waveform for a controlled variable
output to the motor.
7 Output to
motor
By controlling the voltage and frequency, the
frequency converter provides regulated motor
control from 0-50/60 Hz at 100% supply
voltage.
8 Control
circuitry
•
Input power, internal processing, output,
and motor current are monitored to
provide efficient operation and control
•
User interface and external commands are
monitored and performed
•
Status output and control can be provided
Table 1.1 Frequency Converter Internal Components
Introduction
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Decentral Drive FCD 302 Operating Instructions
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1.6 Type Code Description
Position 2 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 39 39
F CD302P T 4 H1 XA B XXXXXD
135
130BB797.10
P
Position Description Choices/options
01-03 Product group FCD Decentral Drive
04-06
Frequency
converter series 302 Advanced performance
07-10 Power size PK37 0.37kW/0.5HP
PK55 0.55kW/0.75HP
PK75 0.75kW/1.0HP
P1K1 1.1kW/1.5HP
P1K5 1.5kW/2.0HP
P2K2 2.2kW/3.0HP
P3K0 3.0kW/4.0HP
PXXX
Installation box only
(without power section)
11-12 Phases, Mains
voltage
T Three phase
4 380-480V AC
13-15 Enclosure
B66
Standard Black -
IP66/Type 4X
W66
Standard White -
IP66/Type 4X
W69
Hygienic White -
IP66K/Type 4X
16-17 RFI filter H1 RFI filter class A1/C2
18 Brake X No brake
S
Brake chopper +
mechanical brake Supply
19 Hardware
configuration
1
Complete product, small
enclosure, stand alone
mount
2
Complete product, small
enclosure, motor mount
3
Complete product, large
enclosure, stand alone
mount
X
Drive part, small enclosure
(No installation box)
Y
Drive part, large enclosure
(No installation box)
R
Installation box, small
enclosure, stand alone
mount (No drive part)
S
Installation box, small
enclosure, motor mount
(No drive part)
T
Installation box, large
enclosure, stand alone
mount (No drive part)
Position Description Choices/options
20 Brackets X No brackets
E Flat brackets
F 40mm brackets
21 Threads X No installation box
M Metric threads
22 Switch option X No switch option
E
Service switch on mains
side
F
Service switch on motor
side
23 Display
X
No display connector (No
installation box)
C With Display Connector
24 Sensor plugs X No sensor plugs
E Direct mount 4xM12
F Direct mount 6xM12
25 Motor plug X No motor plug
26 Mains plug X No mains plug
27 Fieldbus plug X No fieldbus plug
28 Reserved X For future use
29-30 A option AX No A option
A0 PROFIBUS DP
AN EtherNet/IP
AL PROFINET
31-32 B option BX No B option
BR Encoder option
BU Resolver option
33-37 Reserved XXXXX For future use
38-39 D option DX No D option
D0 24 V DC back-up input
Not all choices/options are available for each FCD 302
variant. To verify if the appropriate version is available,
please consult the Drive Configurator on the internet: http://
driveconfig.danfoss.com.
NOTE
A and D options for FCD 302 are integrated in the control
card and therefore pluggable options for FC-drives can not
be used here. Future retrofit will require exchange of the
entire control card. B options are pluggable, using the same
concept and parts as for FC-drives.
Introduction
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Decentral Drive FCD 302 Operating Instructions
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2 Installation
2.1 Check List
The packaging contains:
•
•
Accessories bag(s)
•
Documentation
•
The unit
Depending on options fitted there may be one or two bags
and one or more booklets.
•
When unpacking the frequency converter, ensure
that the unit is undamaged and complete
•
Compare model number of unit on the name plate
to what was ordered to verify the proper
equipment.
•
Ensure the mains (power) supply, frequency
converter, and motor are rated for same voltage.
Installation
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Decentral Drive FCD 302 Operating Instructions
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2.2 Exploded View of the FCD 302
130BB711.10
1
4
6
5
9
10
11
7
3
8
2
1 Electronics (drive) part 7 Display connection
2 Fastening screws (4 x, one in each corner) 8 Access to USB port
3 Sealing gasket 9 Service switch-motor side
4 Protection cover 10 Flat mounting brackets
5 Ground connection pin 11 40mm mounting bracket
6 Installation box
Installation
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Decentral Drive FCD 302 Operating Instructions
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2.3 Mechanical Installation
2.3.1 Recommended Tools and Equipment
E
Equipment Size Description
Screwdrivers
Spanner (Hex) 8 For fastening screws/mounting
brackets
Slotted 0.4 x 2.5 For spring loaded power and
control terminals
Slotted/Torx 1.0x5.5/TX20 For cable clamps inside the instal-
lation box
Spanner 19, 24, 28 For blind-plugs
Hammer For knock-out holes (motor mount
version)
Drilling machine For preparing universal adaptor
plate (motor mount version)
2.3.2 Mechanical Dimensions
41
175
349.5
315
ON
WARNING
ALARM
Bus MS NS2NS1
331.5
280
178
6.5
80
80
190
25
Ø13
130BB712.10
200
1
2
3
4
Cable entries, holes sizes (small frame size).
Motor side 1xM20, 1xM25
Control side
2xM20, 9xM16
1)
Mains side 2xM25
1)
Also used for 4xM12/6xM12 sensor/acuator sockets.
Installation
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Decentral Drive FCD 302 Operating Instructions
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2.3.3 Cooling
The FCD 302 has no forced cooling. It relies only on natural
convection for cooling using the cooling fins.
•
•
A minimum of 100mm (4in) top and bottom air
cooling clearance must be provided. See
Illustration 2.1.
•
Derating starts above 40rC (104rF) and 1000m
(3300ft) elevation above sea level. See the
equipment Design Guide for detailed information.
100 (4)
100 (4)
100 (4)
100 (4)
195NA261.10
Illustration 2.1 Top and Bottom Cooling Clearence
2.3.4 Mounting
The FCD 302 consists of two parts: The installation box and
the electronic part. See section 2.2 Exploded View of the FCD
302.
WARNING
Do not switch on the mains before the 4 screws are
tightened
Stand alone mounting
•
The holes on the rear of the installation box are
used to fix mounting brackets
•
Ensure that the strength of the mounting location
can support the unit weight
•
Make sure that the proper mounting screws or
bolts are used
130BB701.10
Illustration 2.2 FCD 302 Stand Alone Mounted with Mounting
Brackets
Motor mounting
•
The larger hole on the rear of the installation box is
used for passing the motor cable
•
Eight knock out points are available around the
hole for the motor cable to fix the frequency
converter on the motor terminal box or adaptor
plate
Installation
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Decentral Drive FCD 302 Operating Instructions
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Universal adaptor plate(175N2115):
1. Prepare the adaptor plate for mounting on the
motor by drilling the fixing holes and the hole for
the cables.
2. Mount the plate on the motor with the normal
terminal box gasket.
3. Knock out the four outer holes on the installation
box for mounting the adaptor plate.
4. Mount the terminal box onto the motor by the 4
sealing screws and the gasket supplied. Use the
supplied star washers for securing PE connection
according to EN 60204. The screws must be
tightened with 5Nm.
130BB798.10
Illustration 2.3 FCD 302 Motor Mounted with an Adaptor Plate
Illustration 2.4 Universal Adaptor Plate
Allowed mounting positions
130BB702.10
2.3.4.1 Hygienic Installation
The FCD 302 is designed according to the EHEDG guidelines,
suitable for installation in environments with high focus on
cleanability.
The FCD 302 must be mounted vertically on a wall or
machine frame, thereby liquids will drain of the enclosure
due to the slightly sloped top and cooling fin design.
For the best possible cleanability of the FCD 302 in the installation, use cable glands especially designed for hygienic
installations, e.g. Rittal HD 2410.110/120/130.
NOTE
Only frequency converters configured as hygienic enclosure
designation, FCD 302 P XXX T4
W69, will carry the EHEDG
certification.
2.3.4.2 Cleaning
The enclosure (IP66/NEMA type 4x indoor) will offer
protection against dirt and water ingress, and is designed
suitable for cleaning as performed in food and beverage
plants with the concentrations of cleaning solvent as
recommended by the manufacturer. High pressure cleaning
in very short distance or long time with hot water may
damage gaskets and labels.
Installation
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Decentral Drive FCD 302 Operating Instructions
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2.3.5 Tightening Torques
For compressing the gasket between the two parts, the screws must be tightened with 2.8-3.0Nm. Tighten the screws in a
cross-over way.
2.4 Electrical Installation
The frequency converter must be wired for operation in the following manner:
•
•
Wire the motor to the frequency converter output terminals.
•
Connect control and serial communication wiring.
•
Wire the AC mains to the frequency converter input terminals.
•
After power has been applied, input and motor power must be checked, and control terminals programmed for
intended functions.
This section provides detailed descriptions of the requirements and procedures to accomplish these tasks. The following
illustration shows a basic electrical connection.
3 phase
power
input
Mechanical
brake
+10Vdc
-10Vdc+10Vdc
0/4-20 mA
-10Vdc+10Vdc
0/4-20 mA
91 (L1)
92 (L2)
93 (L3)
95 (PE)
122(MBR+)
123(MBR-)
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
12 (+24 V OUT)
13 (+24 V OUT)
18 (D IN)
19 (D IN)
20 (COM D IN)
27 (D IN/OUT)
29 (D IN/OUT)
24V
OV
32 (D IN)
33 (D IN)
37 (D IN)
S201
S202
ON/I=0-20mA
OFF/U=0-10V
P 5-00
24V (NPN)
OV (PNP)
24V (NPN)
OV (PNP)
24V (NPN)
OV (PNP)
24V (NPN)
OV (PNP)
24V (NPN)
OV (PNP)
24V (NPN)
OV (PNP)
Switch Mode
Power Supply
10Vdc
15mA
24Vdc
130/500mA
(U) 96
(U) 97
(W) 98
(PE) 99
Motor
Brake
resistor
(R+) 82
(R-) 81
relay1
relay2
03
02
01
06
05
04
240Vac, 2A
240Vac, 2A
400Vac, 2A
Analog Output
0/4-20 mA
(COM A OUT) 39
(A OT) 42
ON=Terminated
OFF=Open
S801
S801
GX
(N RS-485) 69
(P RS-485) 68
5V
RS-485
I
nterface
(COM RS-485) 61
(PNP) = Source
(NPN) = Sink
RS-485
ON
1 2
ON
1 2
ON
1 2
130BB703.10
0V
Illustration 2.5 Electrical Installation
Installation
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2.4.1 Requirements
W
WARNING
EQUIPMENT HAZARD
Rotating shafts and electrical equipment can be hazardous.
All electrical work must conform to national and local
electrical codes. It is strongly recommended that installation,
start-up, and maintenance be performed only by trained and
qualified personnel. Failure to follow these guidelines could
result in death or serious injury.
For your safety, comply with the following requirements:
•
Electronic controls equipment is connected to
hazardous mains voltage. Extreme care should be
taken to protect against electrical hazards when
applying power to the unit.
•
Wear safety glasses whenever working on electric
control or rotating equipment.
•
Run motor cables from multiple frequency
converters separately. Induced voltage from output
motor cables run together can charge equipment
capacitors even with the equipment turned off and
locked out.
Overload and equipment protection
•
An electronically activated function within the
frequency converter provides overload protection
for the motor. Set 1-90 Motor Thermal Protection to
ETR (Electronic Thermal Relay) for warning trip if
desired. It measures motor current and is internally
set based on the value in 1-24 Motor Current. A 1.2 x
FLA (full load amps) service factor is built-in and
maintained. Should the motor current increase
above that value, the overload will calculate the
level of increase to activate timing for the trip
(controller output stop) function. The higher the
current draw, the quicker the trip response. The
overload provides Class 20 motor protection. See
chapter 7 Troubleshooting for details on the trip
function.
•
Because the motor wiring carries high frequency
current, it is important that wiring for mains input
power, motor power, and control are run
separately. Use separated shielded wire or metallic
conduit. Failure to isolate power, motor, and
control wiring could result in less than optimum
equipment performance.
•
When being placed in cable trays, sensitive cables
such as telephone or data cables should not be
placed in the same cable tray as the motor cable. If
signal cables run across power cables, this is done
at an angle of 90r.
Wire type and ratings
•
All wiring must comply with local and national
regulations regarding cross-section and ambient
temperature requirements.
•
The screen must have low RF impedance, which is
achieved by a braided screen of copper, aluminium
or iron.
•
Danfoss recommends that all power connections
be made with a minimum 75rC rated copper wire.
•
See section 8.1 Electrical Data and Wire Sizes for
recommended wire sizes.
Cable glands
It must be assured that appropriate cable glands needed for
the environment are chosen and carefully mounted.
WARNING
Do not plug/unplug the electronic part with mains voltage
switched on.
Installation
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2.4.2 Location of Terminals
81
82
123
122
U/96
V/97
W/98
04 05 06
01 02 03
R
G
V
N
P
B04
B03
B02 B01
B08
B01 B06
B05
B12
B11 B10 B09
12
18 19
27
29 32 33
12
12
12
12
12
12
13
20
20
20
20
20
20 20
20
20
39
50 54
5355
42
37
37
35
36
36
35
66
67 62
6263 63
61 686968
69
L3/93 L1/91
L2/92
130BB704.10
2
1
4
3
5
6
7
8
9
10
11
12
12
12
1 Digital inputs/outputs 7 24V DC back-up input
2 Safe stop, LCP connection, B-option 8 USB port
3 Relay 1 9 Standard bus/RS-485
4 Relay 2 10 Profibus
5 Motor, mechanical brake, brake resistor 11 Ethernet dual port RS-485
6 Mains 12 Protective Earth (PE)
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130BB705.10
Illustration 2.6 Service Switch on Motor Side and Sensor Plugs
2.4.3 Terminal Types
Motor, control, and mains terminals are spring loaded
(CAGE-CLAMP) type.
1. Open the contact by inserting a small screwdriver
into the slot above the contact, as shown in
Illustration 2.7.
2. Insert the stripped wire into the contact.
3. Remove the screwdriver to fasten the wire into the
contact.
4. Ensure the contact is firmly established and not
loose. Loose wiring can result in equipment faults
or injury.
Illustration 2.7 Opening the Terminals
2.4.4 Motor Connection
WARNING
INDUCED VOLTAGE
Run output motor cables from multiple frequency converters
separately. Induced voltage from output motor cables run
together can charge equipment capacitors even with the
equipment turned off and locked out. Failure to run output
motor cables separately could result in death or serious
injury.
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C
CAUTION
WIRING ISOLATION
Run input power, motor wiring and control wiring in three
separate metallic conduits or use separated shielded motor
and control cables for high frequency noise isolation. Failure
to isolate power, motor and control wiring could result in
less than optimum frequency converter and associated
equipment performance.
MOTOR PROTECTION
Protection against motor overload is not included in the
factory setting. If this function is desired, set 1-90 Motor
Thermal Protection to data value ETR trip 1 [4] or data value
ETR warning 1 [3].
•
Connect the motor to terminals 96, 97, 98.
•
Connect earth to PE-terminal.
•
Make sure the screen of the motor cable is properly
earthed at both ends (motor and frequency
converter).
•
For correct dimensioning of cable cross-section see
section 8.1.1 Electrical Data and Wire Sizes.
No.
96 97 98 Motor voltage 0-100 % of mains voltage
U V W 3 wires out of motor
U1 V1 W1
6 wires out of motor
W2 U2 V2
U1 V1 W1 6 wires out of motor, Star connected
U2, V2, W2 to be interconnected separately (optional
terminal block)
PE Earth connection
NOTE
Do not install power factor correction capacitors between
the frequency converter and the motor.
Do not wire a starting or pole-changing device between the
frequency converter and the motor.
Parallel connection of motors
The frequency converter can control several parallelconnected motors. The total current consumption of the
motors must not exceed the rated output current I
M,N
for the
frequency converter.
NOTE
•
Installations with cables connected in a common
joint as in Illustration 2.8, is only recommended for
short cable lengths (max. 10m).
•
When motors are connected in parallel,
1-29 Automatic Motor Adaptation (AMA) cannot be
used.
CAUTION
The electronic thermal relay (ETR) of the frequency converter
cannot be used as motor protection for the individual motor
in systems with parallel-connected motors. Provide further
motor protection by e.g. thermistors in each motor or
individual thermal relays (circuit breakers are not suitable as
protection).
130BB706.10
Illustration 2.8 Parallel Connection of Motors
Problems may arise at start and at low RPM values if motor
sizes are widely different because small motors' relatively
high ohmic resistance in the stator calls for a higher voltage
at start and at low RPM values.
2.4.5 Control Wiring
WARNING
UNINTENDED START
When frequency converter is connected to AC mains input
power, 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.
•
It is recommended that control wiring is rated for
600V.
•
Isolate control wiring from high power
components in the frequency converter.
•
If the frequency converter is connected to a
thermistor, for PELV isolation, control wiring must
be reinforced/double insulated.
•
See section 8.2 General Specifications for control
terminal wiring sizes and maximum loads.
Terminal No. Function
01, 02, 03 Relay1 output. Useable for AC or DC voltage and
resistive or inductive loads.
04, 05, 06 Relay2 output. Useable for AC or DC voltage and
resistive or inductive loads .
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12, 13 24V DC digital supply voltage. Useable for digital
inputs and external transducers. To use the 24V DC
for digital input common, programme 5-00 Digital I/
O Mode for PNP operation.
18, 19, 32, 33 Digital inputs. Selectable for NPN or PNP function in
5-00 Digital I/O Mode. Default is PNP.
27, 29 Digital inputs or outputs. Programmable for either
5-01 Terminal 27 Mode for terminal 27 and
5-02 Terminal 29 Mode for 29 selects input/output
function. Default setting is input.
35 Common (-) for external 24V control back up supply.
Optional.
36 External + 24V control back up supply. Optional.
37 Safe Stop. See Safe Stop installation for details.
20 Common for digital inputs. To use for digital input
common, programme 5-00 Digital I/O Mode for NPN
operation.
39 Common for analog output.
42 Analog output. Programmable for various functions
in parameter group 6-5*. The analog signal is 0 to
20mA or 4 to 20mA at a maximum of 500˖.
50 10V DC analog supply voltage. 15mA maximum
commonly used for a potentiometer or thermistor.
53, 54
Analog input. Selectable for voltage (0s10V) or
current (0- or 4-s20mA). Closed is for current and
open is for voltage. Switches are located on the
frequency converter control card. See 2.4.13 DIP
Switches
55 Common for analog inputs.
61 Common for serial communication (RS-485
interface). See 2.4.12 Grounding Shielded Control
Cables
68 (+), 69 (-) RS-485 interface. When the frequency converter is
connected to an RS-485 serial communication bus, a
switch on control card is provided for termination
resistance. ON for termination and OFF for no
termination.
62 RxD/TxD –P (red cable) for PROFIBUS. See dedicated
literature (MCA 101) for details.
63 RxD/TxD –N (green cable) for PROFIBUS.
66 0V for PROFIBUS.
67 +5V for PROFIBUS.
B01-B12 B-option. See dedicated literature for details.
G, R, V, N, P Connection of LCP.
2.4.6 AC Mains Input Connection
•
•
Size wiring based upon the input current of the
frequency converter. See the maximum wire size in
the Input Current and Wire tables in section Specifi-
cations.
•
Comply with local and national electrical codes for
cable sizes.
•
Connect 3-phase AC input power wiring to
terminals L1, L2, and L3.
•
Depending on the configuration of the equipment,
input power will be connected to the mains input
terminals or the input disconnect.
•
Ground the cable in accordance with grounding
instructions provided in General Earth (Ground)
Requirements.
•
All frequency converters may be used with an
isolated input source as well as with ground
reference power lines. When supplied from an
isolated mains source (IT mains or floating delta) or
TT/TN-S mains with a grounded leg (grounded
delta), set 14-50 RFI Filter to OFF. When off, the
internal RFI filter capacitors between the chassis
and the intermediate circuit are isolated to avoid
damage to the intermediate circuit and to reduce
earth capacity currents in accordance with IEC
61800-3.
No.
91 92 93 Mains voltage 3 x 380-480V
L1 L2 L3
PE Earth connection
2.4.7 Motor and Mains Connection with
Service Switch
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2.4.8 Brake Resistor
No. 81 (optional
function)
82 (optional
function)
Brake resistor
terminals
R- R+
•
•
The connection cable to the brake resistor must be
screened/armoured. Connect the screen to the
metal cabinet of the frequency converter and to
the metal cabinet of the brake resistor by means of
cable clamps.
•
Dimension the cross-section of the brake cable to
match the brake torque.
2.4.9 Mechanical Brake
No. 122 (optional
function)
123 (optional
function)
MBR+ MBR- Mechanical brake
(UDC=0.45 x mains voltage)
max. 0.8 A
In hoisting/lowering applications, it is necessary to be able to
control an electro-mechanical brake:
•
The brake is controlled using the special
mechanical brake control/ supply terminals 122
and 123.
•
Select Mechanical brake control [32] in parameter
group 5-4*, Array [1], Relay 2 for applications with
an electro-mechanical 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 cuts in.
NOTE
Since the Mechanical Brake Control/Supply terminals 122
and 123 are set through parameter group 5-4*, Array [1],
Relay 2, only one relay output (Relay 1) will be available for
free programming.
2.4.10 Connection of Sensors/Actuators on
M12 Sockets
Pin Wire colour Terminal Function
1 Brown 12 +24V
2 White Reserved* Reserved
3 Blue 20 0V
4 Black 18, 19, 32,33 Digital input
Table 2.1 4 x M12 Connection Input
Pin Wire colour Terminal Function
1 Brown Reserved* Reserved
2 White Reserved* Reserved
3 Blue 20 0V
4 Black 02, 05 N.O. (24V)
Table 2.2 2 x M12 Connection Output
NOTE
* Reserved wires for optional used. If not utilised, they can be
cut off.
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
LCP
01
32
18
02
33
19
130BB707.10
Installation
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2.4.11 Earth (Grounding) Requirements
W
WARNING
GROUNDING HAZARD
For operator safety, it is important to ground frequency
converter properly in accordance with national and local
electrical codes as well as instructions contained within these
instructions. Ground currents are higher than 3.5mA. Failure
to ground frequency converter properly could result in death
or serious injury.
NOTE
It is the responsibility of the user or certified electrical
installer to ensure correct grounding (earthing) of the
equipment in accordance with national and local electrical
codes and standards.
•
Proper protective grounding for equipment with
ground currents higher than 3.5mA must be
established, see Leakage Current (3.5mA) following.
•
A dedicated ground wire is required for input
power and motor.
•
Use the clamps provided with on the equipment
for proper ground connections.
•
Use of high-strand wire to reduce electrical noise is
recommended.
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 they are not
loosened, removed, or violated in any way. See
Illustration 2.9.
130BB732.10
Illustration 2.9 PE Connection between the Installation Box and the
Electronic Part
Installation
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G
Grounding shielded cable
Earthing (grounding) clamps are provided for motor and control wiring (see Illustration 2.10).
81
82
123
122
U/96
V/97
W/98
04 05 06
01 02 03
35
36
36
35
66
67 62
6263 63
61 686968
69
L3/93 L1/91
L2/92
130BB731.10
R
G
V
N
P
B04
B03
B02 B01
B08
B01 B06
B05
B12
B11 B10 B09
12
18 19
27
29 32 33
12
12
12
12
12
12
13
20
20
20
20
20
20 20
20
20
39
50 54
5355
42
37
37
Illustration 2.10 Earthing (Grounding) Clamp for Motor and Control Wiring
1. Use a wire stripper to remove the insulation for
proper grounding.
2. Secure the grounding clamp to the stripped
portion of the wire with the screws provided.
3. Secure the grounding wire to the grounding clamp
provided.
Leakage current (3.5mA)
NOTE
Follow national and local codes regarding protective
earthing of equipment with a leakage current > 3.5mA.
The frequency converter technology implies high frequency
switching at high power. This will generate a leakage current
in the earth connection. RFI filtering and screened motor
cables contribute to this phenomenon. According to EN/
IEC61800-5-1 (Power Drive System Product Standard) which
implies special means if the leakage current exceeds 3.5 mA,
earth grounding must be reinforced in one of the following
ways:
•
Earth ground wire of at least 10mm2.
•
Two separate earth ground wires both complying
with the dimensioning rules.
RCD use
A fault current in the frequency converter or at the output
power terminals might contain a DC component, and
charging of the filter capacitors might cause a transient earth
current. Where Residual Current Devices (RCDs), also known
as Earth Leakage Circuit Breakers (ELCBs), are used, the
following must be taken into account:
•
Use RCDs of type B only
•
Use RCDs with an inrush delay
•
Use RCDs of 300mA, if possible
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2.4.12 Grounding Shielded Control Cables
See Illustration 2.11 for details.
A
A. Correct grounding
Secure control and serial communication cables with
grounding clamps provided at both ends to ensure best
possible electrical contact.
B. 50/60Hz ground loops
With very long control cables, ground loops may occur. To
eliminate ground loops, connect one end of the screen to
ground with a 10nF capacitor (keeping leads short).
C. Serial communication
To eliminate low-frequency noise between frequency
converters, connect one end of the screen to terminal 61.
This terminal is connected to ground via an internal RC link.
Use twisted-pair cables to reduce interference between
conductors.
FC
130BB807.10
10nF
FC
69
FC
68
61
FC
a
b
c
PLC etc.
PLC etc.
2.4.13 DIP Switches
•
Analog input terminals 53 and 54 can select for
either voltage (0-10V) or current (0-20mA) input
signals
•
Set switches S201 (terminal 53) and S202 (terminal
54) to select the signal type. ON is for current, OFF
for voltage
•
Terminal 53 default is for a speed reference in open
loop
•
Terminal 54 default is for a feedback signal in
closed loop
130BB708.10
1
2
4
3
5
Illustration 2.11 Location of DIP Switches
1 S201 - terminal 53
2 S202 - terminal 54
3 S801 - standard bus termination
4 Profibus termination
5 Profibus address
NOTE
Switches 4 and 5 are only valid for units fitted with Profibus.
2.4.14 Serial Communication
Connect RS-485 serial communication wiring to terminals
(+)68 and (-)69.
•
Switch S801 (BUS TER.) can be used to enable
termination on the RS-485 port (terminals 68 and
69). See Illustration 2.11 above.
•
Shielded serial communication cable is
recommended
•
See 2.4.12 Grounding Shielded Control Cables for
proper grounding
•
Two communication protocols are internal to the
frequency converter
•
Danfoss FC
•
Modbus RTU
•
For basic serial communication set up, select the
following
•
Protocol type in 8-30 Protocol
•
Frequency converter address in
8-31 Address
•
Baud rate in 8-32 FC Port Baud Rate
•
Functions can be programmed remotely using the
protocol software and RS-485 connection or in
parameter. group 8-** Communications and
Options
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•
•
Selecting a specific communication protocol
changes various default parameter settings to
match that protocol’s specifications along with
making additional protocol-specific parameters
available
•
Control card options are available to provide
additional communication protocols. See the
option-card documentation for installation and
operation instructions
•
PROFIBUS
•
Ethernet/IP
•
PROFINET
2.4.15 Connection to PC
To control the frequency converter from a PC, install the MCT
10 Set-up Software.
The PC is connected via a standard (host/device) USB cable,
or via the RS-485 interface.
130BB709.10
Illustration 2.12 USB Connection
CAUTION
The USB connection is galvanically isolated from the supply
voltage (PELV) and other high-voltage terminals.
The USB connection is
not galvanically isolated from
protection earth. Use only isolated laptop/PC as connection
to the USB connector on frequency converter or an isolated
USB cable/converter.
2.4.16 Safe Stop
The FCD 302 is available with safe stop functionality via
control terminal 37. Safe stop disables the control voltage of
the power semiconductors of the frequency controller
output stage which in turn prevents generating the voltage
required to rotate the motor. When the Safe Stop (T37) is
activated, the frequency converter issues an alarm, trips the
unit, and coasts the motor to a stop. Manual restart is
required. The safe stop function can be used for stopping the
frequency converter in emergency stop situations. In the
normal operating mode when safe stop is not required, use
the frequency converter’s regular stop function instead.
When automatic restart is used – the requirements according
to ISO 12100-2 paragraph 5.3.2.5 must be fulfilled.
Liability Conditions
It is the responsibility of the user to ensure personnel
installing and operating the Safe Stop function:
•
Read and understand the safety regulations
concerning health and safety/accident prevention
•
Understand the generic and safety guidelines given
in this description and the extended description in
the Design Guide
•
Have a good knowledge of the generic and safety
standards applicable to the specific application
User is defined as: integrator, operator, servicing,
maintenance staff.
Protective Measures
•
Safety engineering systems may only be installed
and commissioned by qualified and skilled
personnel
•
The cable between terminal 37 and the external
safety device must be short circuit protected
according to ISO 13849-2 table D.4
•
If any external forces influence the motor axis (e.g.
suspended loads), additional measures (e.g., a
safety holding brake) are required in order to
eliminate hazards
Safe Stop Installation and Set-Up
WARNING
Safe Stop Function!
The safe stop function does NOT isolate mains voltage to the
frequency converter or auxiliary circuits. Perform work on
electrical parts of the frequency converter or the motor only
after isolating the mains voltage supply and waiting the
length of time specified under Safety in this manual. Failure
to isolate the mains voltage supply from the unit and waiting
the time specified could result in death or serious injury.
•
It is not recommended to stop the frequency
converter by using the Safe Torque Off function. If
a running frequency converter is stopped by using
the function, the unit will trip and stop by coasting.
If this is not acceptable, e.g. causes danger, the
frequency converter and machinery must be
stopped using the appropriate stopping mode
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before using this function. Depending on the
application a mechanical brake may be required.
•
•
Concerning synchronous and permanent magnet
motor frequency converters in case of a multiple
IGBT power semiconductor failure: In spite of the
activation of the Safe Torque Off function, the
frequency converter system can produce an
alignment torque which maximally rotates the
motor shaft by 180/p degrees. p denotes the pole
pair number.
•
This function is suitable for performing mechanical
work on the frequency converter system or
affected area of a machine only. It does not provide
electrical safety. This function should not be used
as a control for starting and/or stopping the
frequency converter.
The following requirements have to be meet to perform a
safe installation of the frequency converter:
1. Remove the jumper wire between control
terminals 37 and 12 or 13. Cutting or breaking the
jumper is not sufficient to avoid short-circuiting.
(See jumper in Illustration 2.13.)
2. Connect an external Safety monitoring relay via a
NO safety function (the instruction for the safety
device must be followed) to terminal 37 (safe stop)
and either terminal 12 or 13 (24V DC). The Safety
monitoring relay must comply with Category 3 (EN
954-1) / PL “d” (ISO 13849-1).
04 05 06
01 02 03
R
G
V
N
P
B04
B03 B02 B01
B08
B01 B06 B05
B12
B11 B10 B09
12
12 12
12
12 12 12
12
12
12
12
12
12
13
20
20
20
20
20
20 20
20
20
55
55 53
5355
50
54
42
32
37
37
3329
271918
130BB730.10
Illustration 2.13 Jumper Between Terminal 13 and 37
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