Danfoss FC 300, Operating Instructions Manual

Page 1: ...MAKING MODERN LIVING POSSIBLE Operating Instructions VLT AutomationDrive FC 300 0 25 75 kW...

Page 2: ......

Page 3: ...lies including battery backups UPS and DC link connections to other frequency converters Wait for the capacitors to fully discharge before performing any service or repair work The amount of wait time...

Page 4: ...Safety VLT AutomationDrive Operating Instructions MG33AM02 VLT is a registered Danfoss trademark...

Page 5: ...2 2 Grounding Using Shielded Cable 14 2 4 3 Motor Connection 14 2 4 4 AC Mains Connection 15 2 4 5 Control Wiring 15 2 4 5 1 Access 15 2 4 5 2 Control Terminal Types 16 2 4 5 3 Wiring to Control Term...

Page 6: ...the LCP 34 4 3 Restoring Default Settings 34 4 3 1 Recommended Initialisation 34 4 3 2 Manual Initialisation 34 5 About Frequency Converter Programming 35 5 1 Introduction 35 5 2 Programming Example 3...

Page 7: ...Up and Operation 61 10 Specifications 64 10 1 Power dependent Specifications 64 10 2 General Technical Data 77 10 3 Fuse Specifications 82 10 3 2 Recommendations 82 10 3 3 CE Compliance 82 10 4 Conne...

Page 8: ...1 82 and load sharing 88 89 terminals 5 Analog switches A53 A54 14 Mains input terminals 91 L1 92 L2 93 L3 6 Cable strain relief PE ground 15 USB connector 7 Decoupling plate 16 Serial bus terminal sw...

Page 9: ...nting slot 4 Digital I O and 24 V power supply 14 Grounding clamp PE 5 Analog I O connector 15 Cable strain relief PE ground 6 Cable strain relief PE ground 16 Brake terminal 81 82 7 USB connector 17...

Page 10: ...pplied with those options for specific requirements Contact the local Danfoss supplier or visit the Danfoss website http www danfoss com BusinessAreas DrivesSolutions Documentations Technical Document...

Page 11: ...citor bank Stores the DC power Provides ride through protection for short power losses 6 Inverter Converts the DC into a controlled PWM AC waveform for a controlled variable output to the motor 7 Outp...

Page 12: ...80 480 0 37 1 5 0 37 4 0 5 5 7 5 0 37 4 0 0 37 7 5 11 15 18 5 22 30 45 55 75 37 45 55 75 525 600 N A N A 0 75 7 5 N A 0 75 7 5 11 15 18 5 22 30 45 55 90 37 45 55 90 525 690 N A N A 1 1 7 5 N A N A N A...

Page 13: ...tions according to European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways ADN_2011 refer to VLT AutomationDrive FC 300 Design Guide 2 2 Frequency Converter and Mot...

Page 14: ...ng location will support the unit weight Mount the unit to a solid flat surface or to the optional back plate to provide cooling airflow see Illustration 2 2 and Illustration 2 3 Improper mounting can...

Page 15: ...IN 10Vdc 15mA 130 200mA 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 0V 5V S801 0 4 20 mA RS 485 RS 485 03 10Vdc 0 10Vdc 10Vdc 10Vdc 0 4 20 mA 0 10Vdc 240Vac 2A 24V...

Page 16: ...quency converter 7 Motor 3 phase and PE 3 Output contactor Generally not recommended 8 Mains 3 phase and reinforced PE 4 Earth grounding rail PE 9 Control wiring 5 Cable insulation stripped 10 Equalis...

Page 17: ...un separately Use metallic conduit or separated shielded wire Failure to isolate power motor and control wiring could result in less than optimum equipment performance All frequency converters must be...

Page 18: ...Ds of type B only which are capable of detecting AC and DC currents Use RCDs with an inrush delay to prevent faults due to transient earth currents Dimension RCDs according to the system configu ratio...

Page 19: ...er 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 0 Off When off the internal RFI filter capac...

Page 20: ...ts that are in various locations depending upon the frequency converter configuration and size Some options available for ordering with the unit may provide additional terminals See the manual provide...

Page 21: ...Loose control wiring can be the source of equipment faults or less than optimal operation See 10 1 Power dependent Specifications for control terminal wiring sizes See 6 Application Examples for typic...

Page 22: ...perate 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 de...

Page 23: ...tage situation the mechanical brake immediately cuts in In the vertical movement the key point is that the load must be held stopped controlled raised lowered in a safe mode during the entire operatio...

Page 24: ...y removing the voltage at Terminal 37 of the Safe Inverter By connecting the Safe Inverter to external safety devices providing a safe delay an installation for a safe Stop Category 1 can be obtained...

Page 25: ...personnel are required for installation and commissioning of safety engineering systems The unit must be installed in an IP54 cabinet or in an equivalent environment In special applications a higher...

Page 26: ...mains via an additional contactor 1 Activate the Safe Stop function by removing the 24 V DC voltage supply to the terminal 37 2 After activation of Safe Stop that is after the response time the freque...

Page 27: ...Send Reset signal via Bus Digital I O or Reset key The test step is passed if the motor remains in the Safe Stop state and the mechanical brake if connected remains activated 1 3 Reapply 24 V DC to te...

Page 28: ...erter disconnect switches for input power isolation 2 Verify that there is no voltage on input terminals L1 91 L2 92 and L3 93 phase to phase and phase to ground 3 Verify that there is no voltage on o...

Page 29: ...considerations Check for proper installation regarding electromagnetic compatibility Environmental consider ations See equipment label for the maximum ambient operating temperature limits Humidity lev...

Page 30: ...or being operated and the minimum and maximum motor speeds Parameter settings recommended are intended for start up and checkout purposes Application settings may vary See 4 1 Local Control Panel for...

Page 31: ...e Site Linked to Hand Auto Local Remote 3 4 Asynchronous Motor Setup Enter the motor data in parameters 1 20 1 21 to 1 25 The information can be found on the motor nameplate 1 1 20 Motor Power kW or 1...

Page 32: ...Settings Low inertia applications ILoad IMotor 5 1 17 Voltage filter time const to be increased by factor 5 to 10 1 14 Damping Gain should be reduced 1 66 Min Current at Low Speed should be reduced 10...

Page 33: ...is set to 1 Inverse counter clockwise 4b Verify that the motor turns counter clockwise 5b Verify that the LCP direction arrow is counter clockwise 3 8 Check Encoder Rotation Check encoder rotation onl...

Page 34: ...ered correctly Increase the ramp down time in 3 42 Ramp 1 Ramp Down Time Enable overvoltage control in 2 17 Over voltage Control See 8 4 Warning and Alarm Definitions for resetting the frequency conve...

Page 35: ...n use of the NLCP NOTE The display contrast can be adjusted by pressing Status and key 4 1 1 LCP Layout The LCP is divided into four functional groups see Illustration 4 1 Auto on Reset Hand on Off St...

Page 36: ...ick Menu Main Menu Alarm Log Illustration 4 4 Menu Keys Key Function Status Press to show operational information In Auto mode press and hold to toggle between status read out displays Press repeatedl...

Page 37: ...on keys are found at the bottom of the LCP 130BP046 10 Hand on Off Auto on Reset Illustration 4 6 Operation Keys Key Function Hand On Starts the frequency converter in local control Use the navigation...

Page 38: ...the frequency converter Initialisation can be through 14 22 Operation Mode or manually Initialisation using 14 22 Operation Mode does not change frequency converter data such as operating hours serial...

Page 39: ...0 10 V DC 6 60 Hz Select the following parameters using the navigation keys to scroll to the titles and press OK after each action 1 3 15 Reference Resource 1 5 1 130BB848 10 3 15 Reference Resource 1...

Page 40: ...V control signal connected to frequency converter terminal 53 the system is now ready for operation NOTE When the procedure is complete the scroll bar is at the bottom Illustration 5 8 shows the wirin...

Page 41: ...60 Hz 4 19 Max Output Frequency 132 Hz 120 Hz 4 53 Warning Speed High 1500 RPM 1800 RPM 5 12 Terminal 27 Digital Input Coast inverse External interlock 5 40 Function Relay No operation No alarm 6 15 T...

Page 42: ...the frequency converter to operate properly System details may include such things as input and output signal types programming terminals minimum and maximum signal ranges custom displays automatic re...

Page 43: ...Time 2 1 Brake Energy Funct 2 10 Brake Function 2 11 Brake Resistor ohm 2 12 Brake Power Limit kW 2 13 Brake Power Monitoring 2 15 Brake Check 2 16 AC brake Max Current 2 17 Over voltage Control 2 18...

Page 44: ...Output Pos Clamp 7 43 Process PID Gain Scale at Min Ref 7 44 Process PID Gain Scale at Max Ref 7 45 Process PID Feed Fwd Resource 7 46 Process PID Feed Fwd Normal Inv Ctrl 7 48 PCD Feed Forward 7 49...

Page 45: ...d 15 61 Option SW Version 15 62 Option Ordering No 15 63 Option Serial No 15 70 Option in Slot A 15 71 Slot A Option SW Version 15 72 Option in Slot B 15 73 Slot B Option SW Version 15 74 Option in Sl...

Page 46: ...Digital Input 33 59 Terminal X57 10 Digital Input 33 60 Terminal X59 1 and X59 2 Mode 33 61 Terminal X59 1 Digital Input 33 62 Terminal X59 2 Digital Input 33 63 Terminal X59 1 Digital Output 33 64 T...

Page 47: ...off line and simply downloaded to the frequency converter Or the entire frequency converter profile can be loaded onto the PC for back up storage or analysis The USB connector or RS 485 terminal is av...

Page 48: ...complete AMA 5 12 Terminal 27 Digital Input 2 Coast inverse Default Value Notes comments Parameter group 1 2 Motor Data must be set according to motor Table 6 1 AMA with T27 Connected Parameters FC 2...

Page 49: ...Safe Stop Alarm Default Value Notes comments If 5 12 Terminal 27 Digital Input is set to 0 No operation a jumper wire to terminal 27 is not needed Table 6 5 Start Stop Command with Safe Stop 130BB805...

Page 50: ...e Notes comments Table 6 8 External Alarm Reset Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 A53 U I 5k 1...

Page 51: ...and baud rate in the above mentioned parameters Table 6 11 RS 485 Network Connection Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32...

Page 52: ...ent may then indicate that service may be required If the feedback error goes below the limit again within 5 s then the frequency converter continues and the warning disappears But Relay 1 will still...

Page 53: ...d or the serial communi cation Hand on The frequency converter can be controlled by the navigation keys on the LCP Stop commands reset reversing DC brake and other signals applied to the control termi...

Page 54: ...p and speed down Jog request A jog command has been given but the motor will be stopped until a run permissive signal is received via a digital input Jogging The motor is running as programmed in 3 19...

Page 55: ...rt after the start delay time expires Start fwd rev Start forward and start reverse were selected as functions for two different digital inputs parameter group 5 1 Digital Inputs The motor will start...

Page 56: ...ied the frequency converter can be reset It will then be ready to start operation again A trip can be reset in any of 4 ways Press Reset on the LCP Digital reset input command Serial communication res...

Page 57: ...k voltage high The intermediate circuit voltage DC is higher than the high voltage warning limit The limit is dependent on the frequency converter voltage rating The unit is still active WARNING 6 DC...

Page 58: ...h sensor wiring WARNING ALARM 12 Torque limit The torque has exceeded the value in 4 16 Torque Limit Motor Mode or the value in 4 17 Torque Limit Generator Mode 14 25 Trip Delay at Torque Limit can ch...

Page 59: ...resistor is calculated as a mean value over the last 120 s of run time The calculation is based on the intermediate circuit voltage and the brake resistance value set in 2 16 AC brake Max Current The...

Page 60: ...command is on progress 517 Write command is under time out 518 Failure in the EEPROM 519 Missing or invalid barcode data in EEPROM 783 Parameter value outside of min max limits 1024 1279 A centelegra...

Page 61: ...4 V DC with the MCB 107 option only the 24 V and 5 V supplies are monitored When powered with three phase mains voltage all three supplies are monitored WARNING 47 24 V supply low The 24 V DC is measu...

Page 62: ...nd a reset signal via Bus Digital I O or by pressing the reset key ALARM 69 Power card temperature The temperature sensor on the power card is either too hot or too cold Troubleshooting Check the oper...

Page 63: ...ier module 6 right rectifier module in F14 frame size ALARM 245 Heatsink sensor This alarm is only for F Frame frequency converters It is equivalent to Alarm 39 The report value in the alarm log indic...

Page 64: ...n F10 or F11 frame sizes 2 second frequency converter from the left inverter module in F14 frame size 3 right inverter module in F12 or F13 frame sizes 3 third from the left intverter module in F14 fr...

Page 65: ...perly Wrong LCP LCP from VLT 2800 or 5000 6000 8000 FCD or FCM Use only LCP 101 P N 130B1124 or LCP 102 P N 130B1107 Wrong contrast setting Press Status to adjust the contrast Display LCP is defective...

Page 66: ...Check that 4 10 Motor Speed Direction is programmed correctly Program correct settings Active reversing signal Check if a reversing command is programmed for the terminal in parameter group 5 1 Digita...

Page 67: ...one position A to B B to C C to A If imbalanced leg follows the wire it is a power problem Check mains power supply Problem with the frequency converter unit Rotate input power leads into the frequen...

Page 68: ...rmittent 3x200 240 V A 2 6 3 5 5 1 6 6 9 4 10 9 15 2 18 1 24 0 Additional specifications IP20 IP21 max cable cross section5 mains motor brake and load sharing mm2 AWG 2 4 4 4 12 12 12 min 0 2 24 IP55...

Page 69: ...0 8 44 8 46 2 67 2 59 4 Additional specifications IP21 max cable cross section5 mains brake load sharing mm2 AWG 2 16 10 16 6 8 6 16 10 16 6 8 6 35 2 IP21 max cable cross section5 motor mm2 AWG 2 10 1...

Page 70: ...636 Weight enclosure IP21 IP55 IP66 kg 45 45 45 65 65 Efficiency4 0 96 0 97 0 97 0 97 0 97 Table 10 3 Mains Supply 3x200 240 V AC For fuse ratings see 10 3 1 Fuses 1 High overload 160 torque during 60...

Page 71: ...1 6 2 2 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermittent 3x380 440 V A 1 9 2 6 3 5 4 3 5 9 8 0 10 4 14 4 18 7 23 0 Continuous 3x441 500 V A 1 0 1 4 1 9 2 7 3 1 4 3 5 7 7 4 9 9 13 0 Intermittent 3x441 500 V...

Page 72: ...4 44 64 60 5 Continuous 3x441 500 V A 19 25 25 31 31 36 36 47 Intermittent 60 s overload 3x441 500 V A 30 4 27 5 40 34 1 49 6 39 6 57 6 51 7 Additional specifications IP21 IP55 IP66 max cable cross se...

Page 73: ...1 95 4 0 95 4 0 IP21 IP55 IP66 max cable cross section5 mains motor mm2 AWG 2 50 1 50 1 50 1 150 300 MCM 150 300MCM IP21 IP55 IP66 max cable cross section5 brake load sharing mm2 AWG 2 50 1 50 1 50 1...

Page 74: ...1 9 0 11 0 Intermittent 3x551 600 V A 2 7 3 8 4 3 6 2 7 8 9 8 14 4 17 6 Continuous kVA 525 V AC kVA 1 7 2 5 2 8 3 9 5 0 6 1 9 0 11 0 Continuous kVA 575 V AC kVA 1 7 2 4 2 7 3 9 4 9 6 1 9 0 11 0 Max i...

Page 75: ...8 41 36 52 43 59 54 Continuous at 575 V A 16 20 20 24 24 31 31 37 37 47 Intermittent at 575 V A 26 22 32 27 39 34 50 41 56 52 Additional specifications IP21 IP55 IP66 max cable cross section5 mains br...

Page 76: ...3 137 Continuous at 575 V A 47 56 56 75 75 91 91 119 Intermittent at 575 V A 70 62 85 83 113 100 137 131 Additional specifications IP20 max cable cross section5 mains and motor 50 1 150 300 MCM IP20 m...

Page 77: ...ut current Continuous 3x525 550 V A 1 9 2 4 3 5 4 4 5 5 8 10 Intermittent 3x525 550 V A 3 0 3 9 5 6 7 1 8 8 13 16 Continuous kVA 3x551 690 V A 1 4 2 0 2 9 4 0 4 9 6 7 9 Intermittent kVA 3x551 690 V A...

Page 78: ...Continuous KVA at 575 V KVA 12 9 17 9 17 9 21 9 21 9 26 9 26 9 33 9 Continuous KVA at 690 V KVA 15 5 21 5 21 5 26 3 26 3 32 3 32 3 40 6 Max input current Continuous 3x525 690 V A 15 19 5 19 5 24 24 29...

Page 79: ...0 Continuous KVA at 575 V KVA 33 9 40 8 40 8 51 8 51 8 61 7 61 7 82 7 82 7 99 6 Continuous KVA at 690 V KVA 40 6 49 0 49 0 62 1 62 1 74 1 74 1 99 2 99 2 119 5 Max input current Continuous at 550 V A...

Page 80: ...FC 302 only For fuse ratings see 10 3 1 Fuses 1 High overload 160 torque during 60 s Normal overload 110 torque during 60 s 2 American Wire Gauge 3 Measured using 5 m screened motor cables at rated lo...

Page 81: ...e unit is suitable for use on a circuit capable of delivering not more than 100 000 RMS symmetrical Amperes 240 500 600 690 V maximum Motor output U V W Output voltage 0 100 of supply voltage Output f...

Page 82: ...off This can be done by using a freewheel diode or alternatively a 30 or 50 V MOV for quicker response time across the coil Typical contactors can be bought with this diode Analog inputs Number of ana...

Page 83: ...al 27 and 29 can also be programmed as input The digital output is galvanically isolated from the supply voltage PELV and other high voltage terminals Analog output Number of programmable analog outpu...

Page 84: ...AC 20 mA Environment according to EN 60664 1 overvoltage category III pollution degree 2 1 IEC 60947 part 4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforce...

Page 85: ...itions in the Design Guide Minimum ambient temperature during full scale operation 0 C Minimum ambient temperature at reduced performance 10 C Temperature during storage transport 25 to 65 70 C Maximu...

Page 86: ...ing tables list the recommended rated current Recommended fuses are of the type gG for small to medium power sizes For larger powers aR fuses are recommended For Circuit Breakers Moeller types have be...

Page 87: ...R 160 22 NZMB2 A200 150 C4 30 37 aR 160 30 aR 200 37 aR 200 30 aR 250 37 NZMB2 A250 250 A4 0 25 2 2 gG 10 0 25 1 5 gG 16 2 2 gG 32 PKZM0 25 25 A5 0 25 3 7 gG 10 0 25 1 5 gG 16 2 2 3 gG 20 3 7 gG 32 PK...

Page 88: ...gG 160 45 gG 150 37 gG 160 45 NZMB2 A200 150 C4 55 75 aR 200 55 aR 250 75 aR 250 NZMB2 A250 250 A4 0 37 4 gG 10 0 37 3 gG 16 4 gG 32 PKZM0 25 25 A5 0 37 7 5 gG 10 0 37 3 gG 16 4 7 5 gG 32 PKZM0 25 25...

Page 89: ...NZMB1 A100 100 C1 37 55 gG 63 37 gG 100 45 aR 160 55 gG 160 37 45 aR 250 55 NZMB2 A200 160 C2 75 aR 200 75 aR 250 NZMB2 A250 250 Table 10 16 525 600 V Frame Sizes A B and C Enclosure size Power kW Rec...

Page 90: ...K R 30 LP CC 30 5 5 KTN R 50 KS 50 JJN 50 7 5 KTN R 60 JKS 60 JJN 60 11 KTN R 80 JKS 80 JJN 80 15 18 5 KTN R 125 JKS 125 JJN 125 22 KTN R 150 JKS 150 JJN 150 30 KTN R 200 JKS 200 JJN 200 37 KTN R 250...

Page 91: ...HAWMUT may substitute A25X for 240 V frequency converters Recommended max fuse Power kW Bussmann Type RK1 Bussmann Type J Bussmann Type T Bussmann Type CC Bussmann Type CC Bussmann Type CC 0 37 1 1 KT...

Page 92: ...028220 160 KLS R 150 A6K 150 R 55 2028220 200 KLS R 200 A6K 200 R 75 2028220 250 KLS R 250 A6K 250 R Table 10 22 380 500 V Frame Sizes A B and C Recommended max fuse Power kW Bussmann JFHR2 Ferraz Sha...

Page 93: ...ype RK1 Ferraz Shawmut Type RK1 Ferraz Shawmut J 0 75 1 1 5017906 005 KLS R 005 A6K 5 R HSJ 6 1 5 2 2 5017906 010 KLS R 010 A6K 10 R HSJ 10 3 5017906 016 KLS R 015 A6K 15 R HSJ 15 4 5017906 020 KLS R...

Page 94: ...Power kW Max prefuse Bussmann E52273 RK1 JDDZ Bussmann E4273 J JDDZ Bussmann E4273 T JDDZ SIBA E180276 RK1 JDDZ LittelFuse E81895 RK1 JDDZ Ferraz Shawmut E163267 E2137 RK1 JDDZ Ferraz Shawmut E2137 J...

Page 95: ...1 8 1 5 1 5 3 0 6 B2 11 18 22 18 22 11 22 4 5 4 5 4 5 4 5 3 7 3 7 3 7 3 7 3 3 0 6 0 6 B3 5 5 7 5 11 15 11 15 1 8 1 8 1 8 1 8 3 0 6 B4 11 15 18 30 18 30 4 5 4 5 4 5 4 5 3 0 6 C1 15 22 30 45 30 45 10 1...

Page 96: ...mance 80 Card 10 V DC Output 79 Card 24V DC Output 79 Card RS 485 Serial Communication 79 Card USB Serial Communication 80 Characteristics 80 Signal 35 36 49 System 6 Terminals 11 26 33 49 36 17 Wire...

Page 97: ...Start 30 Local control Test 30 M Main Menu 32 35 32 Mains Mains 13 Supply 64 70 71 72 Supply L1 L2 L3 77 Voltage 32 33 49 Manual Initialisation 34 MCT 10 Set up Software Set up Software 43 Mechanical...

Page 98: ...lication Set up SAS 26 Specifications 6 10 20 64 Speed Reference 18 30 36 49 44 Start Up 6 34 35 24 61 Status Messages 49 Mode 49 Stop Command 49 Supply Voltage 15 16 24 56 Switching Frequency 49 Symb...

Page 99: ...Index VLT AutomationDrive Operating Instructions MG33AM02 VLT is a registered Danfoss trademark 95...

Page 100: ...www danfoss com drives MG33AM02 130R0300 MG33AM02 Rev 2012 11 02...