Danfoss VLT AutomationDrive FC 301, Operating Instructions Manual

Page 1: ...MAKING MODERN LIVING POSSIBLE Operating Instructions VLT AutomationDrive FC 301 302 0 25 75 kW vlt drives danfoss com...

Page 2: ......

Page 3: ...Instructions 13 4 2 EMC compliant Installation 13 4 3 Grounding 13 4 4 Wiring Schematic 14 4 5 Access 16 4 6 Motor Connection 16 4 7 AC Mains Connection 17 4 8 Control Wiring 17 4 8 1 Control Terminal...

Page 4: ...xamples 31 7 Maintenance Diagnostics and Troubleshooting 37 7 1 Maintenance and Service 37 7 2 Status Messages 37 7 3 Warning and Alarm Types 39 7 4 List of Warnings and Alarms 40 7 5 Troubleshooting...

Page 5: ...9 1 Symbols Abbreviations and Conventions 73 9 2 Parameter Menu Structure 73 Index 79 Contents Operating Instructions MG33AQ02 Danfoss A S 07 2015 All rights reserved 3...

Page 6: ...ted All suggestions for improvement are welcome Table 1 1 shows the manual version and the corresponding software version Edition Remarks Software version MG33AQxx Replaces MG33APxx 7 XX Table 1 1 Man...

Page 7: ...g slot 4 Digital I O and 24 V 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...

Page 8: ...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 Ground termination plate 16 Fieldbus terminal switch 8 Gro...

Page 9: ...icient operation and control User interface and external commands are monitored and performed Status output and control can be provided Illustration 1 3 Frequency Converter Block Diagram 1 4 4 Enclosu...

Page 10: ...l lation start up and maintenance 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 progr...

Page 11: ...y Ensure that only trained and qualified personnel perform installation start up and maintenance Ensure that electrical work conforms to national and local electrical codes Follow the procedures in th...

Page 12: ...cy and current at low high voltages 6 Output voltage frequency and current at low high voltages 7 Enclosure type and IP rating 8 Maximum ambient temperature 9 Certifications 10 Discharge time Warning...

Page 13: ...hoist rings on the unit when provided 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...

Page 14: ...a e f 130BA715 12 Illustration 3 5 Top and Bottom Mounting Holes B4 C3 and C4 Mechanical Installation VLT AutomationDrive FC 301 302 12 Danfoss A S 07 2015 All rights reserved MG33AQ02 3 3...

Page 15: ...able Specifi cations for recommended wire sizes and types 4 2 EMC compliant Installation To obtain an EMC compliant installation follow the instructions provided in chapter 4 3 Grounding chapter 4 4 W...

Page 16: ...P 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 1 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 2 1 S202 ON 0 4 20 mA OFF 0 10 V DC 10...

Page 17: ...e clamp 10 Potential equalisation minimum 16 mm2 0 025 in2 5 Cable insulation stripped 11 Clearance between control cable motor cable and mains cable Minimum 200 mm 7 9 in 6 Cable gland Illustration 4...

Page 18: ...motor cables separately or use screened cables could result in death or serious injury Run output motor cables separately or Use screened cables Comply with local and national electrical codes for cab...

Page 19: ...dance with the grounding instructions provided in chapter 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 ens...

Page 20: ...potential for 24 V supply 37 STO Safe input Analog inputs outputs 39 Common for analog output Terminal description Terminal Parameter Default setting Description 42 6 50 0 No operation Programmable a...

Page 21: ...ck device is used wire a jumper between control terminal 12 recommended or 13 to terminal 27 The jumper provides an internal 24 V signal on terminal 27 When the status line at the bottom of the LCP re...

Page 22: ...nd circuit 220 V AC Mechanical brake Shaft Motor Frewheeling diode Brake 380 V AC Output contactor input power circuit Illustration 4 11 Connecting the Mechanical Brake to the Frequency Converter 4 8...

Page 23: ...ensure proper air flow for cooling see chapter 3 3 Mounting Ambient conditions Check that requirements for ambient conditions are met Fusing and circuit breakers Check for proper fusing or circuit br...

Page 24: ...e installation application 3 Ensure that all operator devices are in the OFF position Panel doors must be closed and covers securely fastened 4 Apply power to the unit Do not start the frequency conve...

Page 25: ...a list of current warnings the last 10 alarms and the maintenance log Table 5 2 Legend to Illustration 5 1 Display Menu Keys C Navigation keys and indicator lights LEDs Navigation keys are used for pr...

Page 26: ...to normal operation 5 3 4 Changing Parameter Settings Access and change parameter settings from the Quick Menu or from the Main Menu The Quick Menu only gives access to a limited number of parameters...

Page 27: ...the on screen instructions to complete the commissioning of the frequency converter Always reactivate SmartStart by selecting Quick Menu Q4 SmartStart For commissioning without use of the SmartStart...

Page 28: ...istance Rfe Application specific adjustment when running VVC VVC is the most robust control mode In most situations it provides optimum performance without further adjustments Run a complete AMA for b...

Page 29: ...l programming and motor data 2 Check if the start function in parameter 1 70 PM Start Mode fits the application requirements Rotor detection This function is the recommended selection for applications...

Page 30: ...pplication specific adjustments Start the motor at nominal speed If the application does not run well check the VVC SynRM settings Table 5 8 provides application specific recommendations Application S...

Page 31: ...default clockwise 4a Verify that the motor turns clockwise 5a Verify that the LCP direction arrow is clockwise When parameter 1 06 Clockwise Direction is set to 1 Inverse counterclockwise 4b Verify th...

Page 32: ...n 2 Apply an external run command 3 Adjust the speed reference throughout the speed range 4 Remove the external run command 5 Check the sound and vibration levels of the motor to ensure that the syste...

Page 33: ...ments Set parameter group 1 2 Motor Data according to the motor D IN 37 is an option Table 6 1 AMA with T27 Connected 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...

Page 34: ...l 53 High Voltage 10 V Parameter 6 14 T erminal 53 Low Ref Feedb Value 0 Hz Parameter 6 15 T erminal 53 High Ref Feedb Value 1500 Hz Default value Notes comments D IN 37 is an option Table 6 5 Speed R...

Page 35: ...ion 130BB805 11 Speed Start 18 Illustration 6 2 Start Stop Command with Safe Stop 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...

Page 36: ...al 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 130BB928 10 Function Setting Parameter 5 11 T...

Page 37: ...ror 100 RPM Parameter 4 32 M otor Feedback Loss Timeout 5 s Parameter 7 00 Sp eed PID Feedback Source 2 MCB 102 Parameter 17 11 R esolution PPR 1024 Parameter 13 00 S L Controller Mode 1 On Parameter...

Page 38: ...ing Parameter 1 71 S tart Delay 0 2 Parameter 1 72 S tart Function 5 VVC FLUX Clockwise Parameter 1 76 S tart Current Im n Parameter 2 20 R elease Brake Current App dependent Parameter 2 21 A ctivate...

Page 39: ...e frequency converter is in Status mode status messages are generated automatically and appear in the bottom line of the display see Illustration 7 1 Status 799RPM 7 83A 36 4kW 0 000 53 2 1 1 Auto Han...

Page 40: ...rameter group 5 1 Digital Inputs The corresponding terminal is active Speed control is only possible via the terminal options 21 Speed up and 22 Speed down Hold ramp is activated via serial communi ca...

Page 41: ...s options for 2 different digital inputs parameter group 5 1 Digital Inputs The motor starts in forward or reverse direction depending on which terminal is activated Stop The frequency converter recei...

Page 42: ...he signal can cause this condition Troubleshooting Check the connections on all the analog mains terminals Control card terminals 53 and 54 for signals terminal 55 common VLT General Purpose I O MCB 1...

Page 43: ...n Running AMA in parameter 1 29 Automatic Motor Adaptation AMA tunes the frequency converter to the motor more accurately and reduces thermal loading WARNING ALARM 11 Motor thermistor overtemp Check w...

Page 44: ...ication to the frequency converter The warning is only active when parameter 8 04 Control Word Timeout Function is NOT set to 0 Off If parameter 8 04 Control Word Timeout Function is set to 5 Stop and...

Page 45: ...r 2 15 Brake Check ALARM 29 Heat Sink temp The maximum temperature of the heat sink is exceeded The temperature fault is not reset until the temperature drops below a defined heat sink temperature The...

Page 46: ...6 Option in slot C1 Hardware incompatible with the control board hardware 5376 6231 Internal fault Contact the Danfoss supplier or Danfoss Service Department Table 7 4 Internal Fault Codes ALARM 39 He...

Page 47: ...restart AMA Repeated restarts can overheat the motor ALARM 58 AMA Internal fault Contact the Danfoss supplier WARNING 59 Current limit The current is higher than the value in parameter 4 18 Current L...

Page 48: ...istor Alarm related to VLT PTC Thermistor Card MCB 112 The PTC is not working ALARM 75 Illegal profile sel Do not write the parameter value while the motor runs Stop the motor before writing the MCO p...

Page 49: ...erter is running for more than 50 s below the permitted minimum frequency parameter 1 98 ATEX ETR interpol points freq ALARM 166 ATEX ETR freq lim alarm The frequency converter has operated for more t...

Page 50: ...settings Check parameter 3 13 Reference Site Set preset reference active in parameter group 3 1 References Check for correct wiring Check scaling of terminals Check reference signal Motor running in...

Page 51: ...ier Motor current imbalance greater than 3 Problem with motor or motor wiring Rotate output motor cables 1 position U to V V to W W to U If imbalanced leg follows the wire the problem is in the motor...

Page 52: ...4 10 6 12 0 17 0 20 0 26 7 Continuous kVA 208 V kVA 0 65 0 86 1 26 1 66 2 38 2 70 3 82 4 50 6 00 Maximum input current Continuous 200 240 V A 1 6 2 2 3 2 4 1 5 9 6 8 9 5 11 3 15 0 Intermittent 200 240...

Page 53: ...NO HO NO HO NO HO NO HO NO Typical shaft output kW 15 18 5 18 5 22 22 30 30 37 37 45 Enclosure protection rating IP20 B4 C3 C3 C4 C4 Enclosure protection rating IP21 IP55 IP66 C1 C1 C1 C2 C2 Output cu...

Page 54: ...9 5 0 6 9 9 0 11 Continuous kVA 460 V kVA 0 9 1 3 1 7 2 4 2 7 3 8 5 0 6 5 8 8 11 6 Maximum input current Continuous 380 440 V A 1 2 1 6 2 2 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermittent 380 440 V A 1 9...

Page 55: ...0 55 Intermittent 60 s overload 380 440 V A 35 2 31 9 46 4 37 4 54 4 44 64 60 5 Continuous 441 500 V A 19 25 25 31 31 36 36 47 Intermittent 60 s overload 441 500 V A 30 4 27 5 40 34 1 49 6 39 6 57 6 5...

Page 56: ...99 90 2 123 106 144 146 200 177 Continuous 441 500 V A 47 59 59 73 73 95 95 118 118 145 Intermittent 60 s overload 441 500 V A 70 5 64 9 88 5 80 3 110 105 143 130 177 160 Additional specifications IP2...

Page 57: ...uous kVA 525 V kVA 1 7 2 5 2 8 3 9 5 0 6 1 9 0 11 0 Continuous kVA 575 V kVA 1 7 2 4 2 7 3 9 4 9 6 1 9 0 11 0 Maximum input current Continuous 525 600 V A 1 7 2 4 2 7 4 1 5 2 5 8 8 6 10 4 Intermittent...

Page 58: ...9 39 49 Intermittent at 550 V A 28 23 33 28 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 IP20 m...

Page 59: ...550 V A 74 65 89 87 118 105 143 137 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 maximum cable cross section for ma...

Page 60: ...NO HO NO HO NO HO NO Typical shaft output at 550 V kW 7 5 11 11 15 15 18 5 18 5 22 Typical shaft output at 690 V kW 11 15 15 18 5 18 5 22 22 30 Enclosure protection rating IP20 B4 B4 B4 B4 Enclosure p...

Page 61: ...cifications Maximum cable cross section for mains and motor mm2 AWG 150 300 MCM Maximum cable cross section for load share and brake mm2 AWG 95 3 0 Maximum cable cross section2 for mains disconnect mm...

Page 62: ...ng on input supply L1 L2 L3 power ups 7 5 kW Maximum 2 times per minute Switching on input supply L1 L2 L3 power ups 11 75 kW Maximum 1 time per minute Switching on input supply L1 L2 L3 power ups 90...

Page 63: ...s Cable lengths and cross sections for control cables1 Maximum motor cable length screened 150 m Maximum motor cable length unscreened 300 m Maximum cross section to control terminals flexible rigid w...

Page 64: ...ely a 30 V or 50 V MOV for quicker response time across the coil Typical contactors can be bought with this diode Analog inputs Number of analog inputs 2 Terminal number 53 54 Modes Voltage or current...

Page 65: ...t frequency output 0 Hz Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Maximum error 0 1 of full scale Resolution of frequency outputs 12 bit 1 Terminal 27 and 29 can...

Page 66: ...240 V AC 0 2 A Maximum terminal load DC 1 1 on 4 5 NO resistive load 80 V DC 2 A Maximum terminal load DC 13 1 on 4 5 NO inductive load 24 V DC 0 1 A Maximum terminal load AC 1 1 on 4 6 NC resistive l...

Page 67: ...e rating With the proper fusing the frequency converter short circuit current rating SCCR is 100000 Arms 8 7 1 CE Compliance 200 240 V Enclosure Power kW Recommended fuse size Recommended maximum fuse...

Page 68: ...5 B1 11 15 gG 40 gG 80 PKZM4 63 63 B2 18 5 22 gG 50 18 5 gG 63 22 gG 100 NZMB1 A100 100 B3 11 15 gG 40 gG 63 PKZM4 50 50 B4 18 5 30 gG 50 18 5 gG 63 22 gG 80 30 gG 125 NZMB1 A100 100 C1 30 45 gG 80 30...

Page 69: ...C2 75 aR 200 75 aR 250 NZMB2 A250 250 C3 37 45 gG 63 37 gG 100 45 gG 150 NZMB2 A200 150 C4 55 75 aR 160 55 aR 200 75 aR 250 NZMB2 A250 250 Table 8 15 525 600 V Enclosure Types A B and C 525 690 V Enc...

Page 70: ...05 R FWX 5 HSJ 6 0 55 1 1 5017906 010 KLN R 10 ATM R 10 A2K 10 R FWX 10 HSJ 10 1 5 5017906 016 KLN R 15 ATM R 15 A2K 15 R FWX 15 HSJ 15 2 2 5017906 020 KLN R 20 ATM R 20 A2K 20 R FWX 20 HSJ 20 3 0 50...

Page 71: ...erraz Shawmut JFerraz Shawmut J Ferraz Shawmut JFHR21 Littel fuse JFHR2 0 37 1 1 5017906 006 KLS R 6 ATM R 6 A6K 6 R FWH 6 HSJ 6 1 5 2 2 5017906 010 KLS R 10 ATM R 10 A6K 10 R FWH 10 HSJ 10 3 5017906...

Page 72: ...0 JKS 80 JJS 80 5014006 080 KLS R 075 A6K 80 R HSJ 80 37 KTS R 100 JKS 100 JJS 100 5014006 100 KLS R 100 A6K 100 R HSJ 100 45 KTS R 125 JKS 125 JJS 125 2028220 125 KLS R 125 A6K 125 R HSJ 125 55 KTS R...

Page 73: ...4006 100 KLS R 100 A6K 100 R HST 100 55 125 A KTS R 125 JKS 125 JJS 125 2028220 125 KLS 150 A6K 125 R HST 125 75 150 A KTS R 150 JKS 150 JJS 150 2028220 150 KLS 175 A6K 150 R HST 150 Table 8 23 525 69...

Page 74: ...ng plate B 75 90 90 130 130 200 242 242 242 165 230 308 370 308 370 250 Width of mounting plate with 1 C option B 130 130 170 170 242 242 242 205 230 308 370 308 370 Width of mounting plate with 2 C o...

Page 75: ...rotection LCP Local control panel MCT Motion control tool ns Synchronous motor speed PM N Nominal motor power PELV Protective extra low voltage PCB Printed circuit board PM Motor Permanent magnet moto...

Page 76: ...rgy 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 Brake Check Condit...

Page 77: ...Feedback 2 Resource 7 3 Process PID Ctrl 7 30 Process PID Normal Inverse Control 7 31 Process PID Anti Windup 7 32 Process PID Start Speed 7 33 Process PID Proportional Gain 7 34 Process PID Integral...

Page 78: ...ning Hours Counter 15 1 Data Log Settings 15 10 Logging Source 15 11 Logging Interval 15 12 Trigger Event 15 13 Logging Mode 15 14 Samples Before Trigger 15 2 Historic Log 15 20 Historic Log Event 15...

Page 79: ...uracy Window for Position Sync 33 14 Relative Slave Velocity Limit 33 15 Marker Number for Master 33 16 Marker Number for Slave 33 17 Master Marker Distance 33 18 Slave Marker Distance 33 19 Master Ma...

Page 80: ...Safe Option Status 2 42 82 Safe Control Word 42 83 Safe Status Word 42 85 Active Safe Func 42 86 Safe Option Info 42 87 Time Until Manual Test 42 88 Supported Customization File Version 42 89 Customiz...

Page 81: ...26 37 39 wiring 13 16 19 21 word time out 42 Control card 64 Convention 73 Cooling 11 Cooling clearance 21 Current limit 49 rating 41 DC current 13 38 Input current 17 Output current 38 41 D DC link...

Page 82: ...20 36 Mechanical installation 10 Menu key 22 23 Menu structure 23 Modbus RTU 20 Motor cable 16 current 23 29 45 data 26 29 41 45 49 output 60 power 13 23 45 protection 4 rotation 29 speed 25 status 4...

Page 83: ...tus mode 37 STO 19 Storage 10 Supply voltage 17 18 22 43 Switch 19 Switching frequency 39 Symbol 73 System feedback 4 T Terminals Input 40 Output terminal 22 Terminal 53 19 Terminal 54 19 47 Tightenin...

Page 84: ...ucts already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the resp...