VLT FC 300, Instruction Manual

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

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Page 3: ... remain charged even when the adjustable frequency drive is not powered To avoid electrical hazards disconnect AC line power any permanent magnet type motors and any remote DC link power supplies including battery backups UPS and DC link connections to other adjustable frequency drives Wait for the capacitors to fully discharge before performing any service or repair work The wait time required is...

Page 4: ...e output frequency of the adjustable frequency drive is limited to 590 Hz Software versions 6x xx also limit the maximum output frequency to 590 Hz but these versions cannot be flashed i e neither downgraded nor upgraded Safety VLT AutomationDrive Instruction Manual MG33AM22 VLT is a registered Danfoss trademark ...

Page 5: ...age Current 3 5 mA 3 6 2 4 2 2 Grounding Using Shielded Cable 3 6 2 4 3 Motor Connection 3 6 2 4 4 AC Line Input Connection 3 7 2 4 5 Control Wiring 3 7 2 4 5 1 Access 3 7 2 4 5 2 Control Terminal Types 3 8 2 4 5 3 Wiring to Control Terminals 3 9 2 4 5 4 Using Shielded Control Cables 3 10 2 4 5 5 Control Terminal Functions 3 10 2 4 5 6 Jumper Terminals 12 and 27 3 10 2 4 5 7 Terminal 53 and 54 Swi...

Page 6: ...gs 5 3 4 2 1 Uploading Data to the LCP 5 4 4 2 2 Downloading Data from the LCP 5 4 4 3 Restoring Default Settings 5 4 4 3 1 Recommended Initialization 5 4 4 3 2 Manual Initialization 5 4 5 About Adjustable Frequency Drive Programming 6 1 5 1 Introduction 6 1 5 2 Programming Example 6 1 5 3 Control Terminal Programming Examples 6 2 5 4 International North American Default Parameter Settings 6 3 5 5...

Page 7: ...2 9 Basic Troubleshooting 10 1 9 1 Start Up and Operation 10 1 10 Specifications 11 1 10 1 Power dependent Specifications 11 1 10 2 General Technical Data 11 14 10 3 Fuse Specifications 11 19 10 3 2 Recommendations 11 19 10 3 3 CE Compliance 11 19 10 4 Connection Tightening Torques 11 28 12 Index 12 1 Contents VLT AutomationDrive Instruction Manual MG33AM22 VLT is a registered Danfoss trademark ...

Page 8: ...Contents VLT AutomationDrive Instruction Manual MG33AM22 VLT is a registered Danfoss trademark ...

Page 9: ...1 82 and load sharing 88 89 terminals 5 Analog switches A53 A54 14 Line power input terminals 91 L1 92 L2 93 L3 6 Cable strain relief PE ground 15 USB connector 7 Decoupling plate 16 Serial bus terminal switch 8 Grounding clamp PE 17 Digital I O and 24 V power supply 9 Shielded cable grounding clamp and strain relief 18 Control cable cover plate Table 1 1 Legend to Figure 1 1 Introduction VLT Auto...

Page 10: ... 96 U 97 V 98 W 9 Analog switches A53 A54 19 Line power input terminals 91 L1 92 L2 93 L3 10 Relay 1 01 02 03 Table 1 2 Legend to Figure 1 2 1 1 Purpose of the Manual This manual is intended to provide detailed information for the installation and startup of the adjustable frequency drive provides requirements for mechanical and electrical installation including input motor control and serial comm...

Page 11: ...e is an electronic motor controller that converts AC line power input into a variable AC waveform output The frequency and voltage of the output are regulated to control the motor speed or torque The adjustable frequency drive can vary the speed of the motor in response to system feedback such as position sensors on a conveyor belt The adjustable frequency drive can also regulate the motor by resp...

Page 12: ...t 5 Capacitor 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 Output to motor Regulated three phase output power to the motor 8 Control circuitry Input power internal processing output and motor current are monitored to provide efficient operation and contro...

Page 13: ...40 50 380 480 0 5 2 0 0 5 5 0 7 5 10 0 5 5 0 0 5 10 15 20 25 30 40 60 75 100 50 60 75 100 525 600 N A N A 1 0 10 N A 1 0 10 15 20 25 30 40 60 75 125 50 60 75 125 525 690 N A N A 1 5 10 N A N A N A 15 30 N A 40 100 50 60 N A Table 1 4 Frame Sizes and Power Ratings Introduction VLT AutomationDrive Instruction Manual MG33AM22 VLT is a registered Danfoss trademark 1 5 1 1 ...

Page 14: ...Introduction VLT AutomationDrive Instruction Manual 1 6 MG33AM22 VLT is a registered Danfoss trademark 1 1 ...

Page 15: ...allations 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 Adjustable Frequency Drive and Motor Pre installation Checklist Compare the model number of unit on the nameplate to what was ordered to verify the proper equipment Ensure each of the following are rated for the same voltag...

Page 16: ...at the strength of the mounting location will support the unit weight Mount the unit onto a solid flat surface or onto the optional backplate to provide cooling airflow see Figure 2 2 and Figure 2 3 Improper mounting can result in overheating and reduced performance Use the slotted mounting holes on the unit for wall mounting when provided 130BA219 10 A Figure 2 2 Proper Mounting with Backplate It...

Page 17: ...UT 53 A IN 54 A IN 55 COM A IN 0 4 20 mA 12 24V OUT 13 24V OUT 37 D IN 18 D IN 20 COM D 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 24Vdc 02 01 05 04 06 240Vac 2A 24V NPN 0V PNP 0V PNP 24V NPN 19 D IN 24V NPN 0V PNP 27 24V 0V D IN OUT 0V PNP 24V N...

Page 18: ...C 6 Min 200 mm 7 9 in between control cables motor and line power 2 Adjustable frequency drive 7 Motor 3 phase and PE 3 Output contactor Generally not recommended 8 Line power 3 phase and reinforced PE 4 Grounding rail PE 9 Control wiring 5 Cable insulation stripped 10 Equalizing min 16 mm2 0 025 in2 Table 2 2 Legend to Figure 2 5 Installation VLT AutomationDrive Instruction Manual 2 4 MG33AM22 VL...

Page 19: ...ms for details on the trip function Because the motor wiring carries high frequency current it is important that wiring for line power motor power and control is run 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 adjustable frequency drives must be provided with short circuit a...

Page 20: ... separate ground wires both complying with the dimensioning rules See EN 60364 5 54 543 7 for further information Using RCDs Where residual current devices RCDs also known as ground leakage circuit breakers GLCBs are used comply with the following Use RCDs 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 ground curren...

Page 21: ...uctions provided in 2 4 2 Grounding Requirements All adjustable frequency drives may be used with an isolated input source as well as with ground reference power lines When supplied from an isolated line power source IT line power or floating delta or TT TN S line power with a grounded leg grounded delta set 14 50 RFI 1 to 0 Off When off the internal RFI filter capacitors between the chassis and t...

Page 22: ...input for STO Safe Torque Off function Connector 2 terminals 68 and 69 are for an RS 485 serial communications connection Connector 3 provides two analog inputs one analog output 10 V DC supply voltage and commons for the inputs and output Connector 4 is a USB port available for use with the MCT 10 Set up Software Also provided are two Form C relay outputs that are in various locations depending u...

Page 23: ...switch is provided for termination resistance 69 8 3 Relays Terminal description Terminal Parameter Default setting Description 01 02 03 5 40 0 0 No operation Form C relay output Usable for AC or DC voltage and resistive or inductive loads 04 05 06 5 40 1 0 No operation Table 2 5 Terminal Description Serial Communication 2 4 5 3 Wiring to Control Terminals Control terminal connectors can be unplug...

Page 24: ...ction to terminal 61 can be omitted PE FC PE FC 130BB924 12 PE PE 69 69 68 68 1 2 10 mm Figure 2 17 Twisted pair Cables without Terminal 61 1 Min 0 025 in2 16 mm2 2 Equalizing cable Table 2 8 Legend to Figure 2 17 2 4 5 5 Control Terminal Functions Adjustable frequency drive functions are commanded by receiving control input signals Each terminal must be programmed for the function it will be supp...

Page 25: ...inal 53 Switch Setting Terminal 54 default is for a feedback signal in closed loop set in 16 63 Terminal 54 Switch Setting 130BT310 10 1 2 N O VLT BUS TER OFF ON A53 A54 U I U I Figure 2 18 Location of Terminals 53 and 54 Switches and Bus Termination Switch 2 4 5 8 Mechanical Brake Control In hoisting lowering applications it is necessary to be able to control an electro mechanical brake Control t...

Page 26: ...on Wiring Diagram For basic serial communication set up select the following 1 Protocol type in 8 30 Protocol 2 Adjustable frequency drive address in 8 31 Address 3 Baud rate in 8 32 Baud Rate Two communication protocols are internal to the adjustable frequency drive Follow the motor manufacturer wiring requirements Danfoss FC Modbus RTU Functions can be programmed remotely using the protocol soft...

Page 27: ...ata for EN IEC 61508 low demand PFDavg for one year proof test 1E 10 PFDavg for three year proof test 1E 10 PFDavg for five year proof test 1E 10 No maintenance of the STO functionality is needed Security measures have to be taken by the user e g installation in a closed cabinet that is only accessible for skilled personnel SISTEMA Data Functional safety data is available via a data library for us...

Page 28: ...AC line voltage supply and waiting the length of time specified in Table 1 1 Failure to isolate the AC line voltage supply from the unit and waiting the time specified could result in death or serious injury It is not recommended to stop the adjustable frequency drive by using the Safe Torque Off function If a running adjustable frequency drive is stopped by using the function the unit trips and s...

Page 29: ... by an internal fault in accordance with Cat 3 PL d acc EN ISO 13849 1 and SIL 2 acc EN 62061 After activation of Safe Stop the display shows the text Safe Stop activated The associated help text says Safe Stop has been activated This means that the Safe Stop has been activated or that normal operation has not been resumed yet after Safe Stop activation NOTE The requirements of Cat 3 PL d ISO 1384...

Page 30: ...sed if the motor remains in the coasted state and the mechanical brake if connected remains activated 1 4 Send Reset signal via bus digital I O or Reset key The test step is passed when the motor becomes operational again The commissioning test is passed if all four test steps 1 1 1 2 1 3 and 1 4 are passed Case 2 Automatic Restart of Safe Stop is wanted and allowed that is Safe Stop only where 5 ...

Page 31: ... drive 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 output terminals 96 U 97 V and 98 W phase to phase and phase to ground 4 Confirm continuity of the motor by measuring ohm values on U V 96 97 V W 97 98 and W U 98 96 5 Check for proper grounding of th...

Page 32: ...ensure proper airflow for cooling EMC considerations Check for proper installation regarding electromagnetic compatibility Environmental consider ations See equipment label for the maximum ambient operating temperature limits Humidity levels must be 5 95 non condensing Fusing and circuit breakers Check for proper fusing or circuit breakers Check that all fuses are inserted firmly and in operationa...

Page 33: ...quency drives require basic operational programming before running Basic operational programming requires entering motor nameplate data for the motor being operated and the minimum and maximum motor speeds The recommended parameter settings are intended for start up and checkout purposes Application settings may vary See 4 1 Local Control Panel for detailed instructions on entering data through th...

Page 34: ...3 4 Q2 Quick Set up 8 Select language and press OK 130BT772 10 Q2 0 0 Hz 0 00kW 1 1 Motor Setup 1 21 Motor Power kW 4 0 kW Figure 3 5 Select Language 9 A jumper wire should be in place between control terminals 12 and 27 If this is the case leave 5 12 Terminal 27 Digital Input at factory default Otherwise select No Operation For adjustable frequency drives with an optional bypass no jumper wire is...

Page 35: ...e Value This parameter gives back EMF across stator terminal of PM Motor at 1 000 RPM mechanical speed specifically It is defined between line to line and expressed in RMS Value In case the PM Motor specifications provides this value related to another motor speed the voltage must be recalculated for 1 000 RPM Table 3 2 Note concerning back EMF Back EMF is the voltage generated by a PM motor when ...

Page 36: ...Verify that the LCP direction arrow is clockwise When 1 06 Clockwise Direction 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 only if encoder feedback is used Check encoder rotation in default open loop control 1 Verify that the encoder connection is...

Page 37: ...red 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 adjustable frequency drive after a trip NOTE 3 1 Pre start through 3 9 Local Control Test in this chapter conclude the procedures for applying power to the adjustable frequency drive basic programming set up and func...

Page 38: ...Start up and Functional Tes VLT AutomationDrive Instruction Manual 3 8 MG33AM22 VLT is a registered Danfoss trademark 3 3 ...

Page 39: ...Guide for details on 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 Figure 4 1 Auto on Reset Hand on Off Status Quick Menu Main Menu Alarm Log C a n c e l Info Status 1 1 1234rpm B a c k OK 43 5Hz Run OK 43 5Hz On Alarm Warn 130BC362 10 a b c d 1 0 A Figure 4 1 LCP a Display area b Display men...

Page 40: ...Quick Menu Main Menu Alarm Log Figure 4 4 Menu Keys Key Function Status Press to show operational information In Auto mode press and hold to toggle between status readout displays Press repeatedly to scroll through each status display Press and hold Status plus or to adjust the display brightness The symbol in the upper right corner of the display shows the direction of motor rotation and which se...

Page 41: ...d at the bottom of the LCP 130BP046 10 Hand on Off Auto on Reset Figure 4 6 Operation Keys Key Function Hand On Starts the adjustable frequency drive in local control Use the navigation keys to control adjustable frequency drive speed An external stop signal by control input or serial communication overrides the local hand on Off Stops the motor but does not remove power to the adjustable frequenc...

Page 42: ...alization of the adjustable frequency drive Initialization can be through 14 22 Operation Mode or manually Initialization using 14 22 Operation Mode does not change adjustable frequency drive data such as operating hours serial communication selections personal menu settings fault log alarm log and other monitoring functions Using 14 22 Operation Mode is generally recommended Manual initialization...

Page 43: ...l to the input signal 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 Analog input 53 14 7 0 00A 1 1 References Figure 5 1 3 15 Reference Resource 1 2 3 02 Minimum Reference Set minimum internal adjustable frequency drive reference to 0 Hz This se...

Page 44: ...xternal device providing a 0 10 V control signal connected to adjustable frequency drive terminal 53 the system is now ready for operation NOTE When the procedure is complete the scroll bar is at the bottom Figure 5 8 shows the wiring connections used to enable this set up 53 55 6 1 A53 U I 130BB482 10 0 10V Figure 5 8 Wiring Example for External Device Providing 0 10 V Control Signal adjustable f...

Page 45: ...tput Frequency 132 Hz 120 Hz 4 53 Warning Speed High 1 500 RPM 1 800 RPM 5 12 Terminal 27 Digital Input Coast inverse External interlock 5 40 Function Relay No operation No alarm 6 15 Terminal 53 High Ref Feedb Value 50 60 6 50 Terminal 42 Output No operation Speed 4 20 mA 14 20 Reset Mode Manual reset Infinite auto reset Table 5 1 International North American Default Parameter Settings Note 1 1 2...

Page 46: ...the adjustable frequency drive 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 restart and other features See the LCP display to view detailed parameter programming and setting options Press Info in any menu location to view additional details for that function Press and ho...

Page 47: ...e Cut in Speed RPM 2 04 DC Brake Cut in Speed Hz 2 05 Maximum Reference 2 06 Parking Current 2 07 Parking 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 Brake Check Condition 2 19 Over voltage Gain 2 2 Mechanical Brake 2 20 Release Brake Current 2...

Page 48: ...Time 7 36 Process PID Differentiation Gain Limit 7 38 Process PID Feed Forward Factor 7 39 On Reference Bandwidth 7 4 Adv Process PID I 7 40 Process PID I part Reset 7 41 Process PID Output Neg Clamp 7 42 Process PID 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 Fe...

Page 49: ...15 49 SW ID Control Card 15 50 SW ID Power Card 15 51 Adj Freq Dr Serial No 15 53 Power Card Serial Number 15 58 Smart Setup Filename 15 59 CSIV Filename 15 6 Option Ident 15 60 Option Mounted 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 Slot C0 15 ...

Page 50: ...ut 33 55 Terminal X57 6 Digital Input 33 56 Terminal X57 7 Digital Input 33 57 Terminal X57 8 Digital Input 33 58 Terminal X57 9 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 Terminal X59 2 Digital Output 33 65 Terminal X59 3 Digital Output 33 66 T...

Page 51: ... done off line and simply downloaded to the adjustable frequency drive Or the entire adjustable frequency drive profile can be loaded onto the PC for backup storage or analysis The USB connector or RS 485 terminal is available for connecting to the adjustable frequency drive MCT 10 Set up Software is available for free download at www VLT software com A CD is also available by requesting part numb...

Page 52: ...About Adjustable Frequency VLT AutomationDrive Instruction Manual 5 10 MG33AM22 VLT is a registered Danfoss trademark 5 5 ...

Page 53: ...nable 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 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 130BB930 10 Function Setting 1 29 Automatic Motor Adaptation AMA 1 Ena...

Page 54: ...fe Stop 1 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 11 Speed Start 18 Figure 6 1 Start Stop 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 37 50 53 54 55 4...

Page 55: ...t Value 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 5kΩ 130BB683 10 Function Setting 6 10 Terminal 53 Low Voltage 0 07 V 6 11 Terminal 53 High Voltage 10 V 6 14 Terminal 53 Low Ref Feedb Value 0 RPM 6 15 Terminal 53 High Ref Feedb Value 1 500 RPM Def...

Page 56: ...nd 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 33 37 50 53 54 55 42 39 A53 U I 130BB686 11 Function Setting 1 90 Motor Thermal Protection 2 Thermistor trip 1 93 Thermistor Source 1 Analog input 53 Default Value Notes comments If only a warning is ...

Page 57: ...y then indicate that service may be required If the feedback error goes below the limit again within 5 sec then the adjustable frequency drive continues and the warning disappears But Relay 1 will still be triggered until Reset on the LCP Table 6 13 Using SLC to Set a Relay 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 R1 R2 12 13 18 19 20 27 29 32 33 ...

Page 58: ...Application Examples VLT AutomationDrive Instruction Manual 6 6 MG33AM22 VLT is a registered Danfoss trademark 6 6 ...

Page 59: ...ol terminals and or the serial communication Hand on The adjustable frequency drive can be controlled by the navigation keys on the LCP Stop commands reset reversing DC brake and other signals applied to the control terminals can override local control Table 7 1 Operation Mode Remote The speed reference is given from external signals serial communication or internal preset references Local The adj...

Page 60: ...ce was chosen as a function for a digital input parameter group 5 1 Digital Inputs The corresponding terminal is active The adjustable frequency drive saves the actual reference Changing the reference is now only possible via terminal functions speed up and slow 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 Jogg...

Page 61: ...dby In Auto On Auto mode the adjustable frequency drive will start the motor with a start signal from a digital input or serial communication Start delay In 1 71 Start Delay a delay starting time was set A start command is activated and the motor will start after the start delay time expires Start fwd rev Start forward and start reverse were selected as functions for two different digital inputs p...

Page 62: ...Status Messages VLT AutomationDrive Instruction Manual 7 4 MG33AM22 VLT is a registered Danfoss trademark 7 7 ...

Page 63: ... condition is remedied the adjustable frequency drive can be reset It will then be ready to start operation again A trip can be reset in any of four ways Press Reset on the LCP Digital reset input command Serial communication reset input command Auto reset An alarm that causes the adjustable frequency drive to trip lock requires that input power is cycled The motor will coast to a stop The adjusta...

Page 64: ...re programmed at 14 12 Function at Mains Imbalance Troubleshooting Check the supply voltage and supply currents to the adjustable frequency drive WARNING 5 DC link voltage high The intermediate circuit voltage DC is higher than the high voltage warning limit The limit is dependent on the adjustable frequency drive voltage rating The unit is still active WARNING 6 DC link voltage low The intermedia...

Page 65: ...mistor is connected correctly between either terminal 18 or 19 digital input PNP only and terminal 50 If a KTY sensor is used check for correct connection between terminals 54 and 55 If using a thermal switch or thermistor check that the programming if 1 93 Thermistor Resource matches sensor wiring If using a KTY sensor check the programming of 1 95 KTY Sensor Type 1 96 KTY Thermistor Resource and...

Page 66: ...ARNING 24 External fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning can be disabled in 14 53 Fan Monitor 0 Disabled Troubleshooting Check fan resistance Check soft charge fuses WARNING 25 Brake resistor short circuit The brake resistor is monitored during operation If a short circuit occurs the brake function is disabled a...

Page 67: ...the communication option card is not working WARNING ALARM 36 Mains Failure This warning alarm is only active if the supply voltage to the adjustable frequency drive is lost and 14 10 Mains Failure is NOT set to 0 No Function Check the fuses to the adjustable frequency drive and line power supply to the unit ALARM 38 Internal fault When an internal fault occurs a code number defined in Table 8 2 i...

Page 68: ...slot C0 Hardware incompatible with control board hardware 5126 Option in slot C1 Hardware incompatible with control board hardware 5376 6231 Out of memory Table 8 2 Internal Fault Code Numbers ALARM 39 Heatsink sensor No feedback from the heatsink temperature sensor The signal from the IGBT thermal sensor is not available on the power card The problem could be on the power card on the gate drive c...

Page 69: ...or setting in 4 31 Motor Feedback Speed Error and the allowed time the error occur setting in 4 32 Motor Feedback Loss Timeout During a commissioning procedure the function may be effective WARNING 62 Output frequency at maximum limit The output frequency is higher than the value set in 4 19 Max Output Frequency ALARM 64 Voltage Limit The load and speed combination demands a motor voltage higher t...

Page 70: ...unit to clear the alarm ALARM 81 CSIV corrupt CSIV file has syntax errors ALARM 82 CSIV par err CSIV failed to init a parameter ALARM 85 Dang fail PB Profibus Profisafe Error WARNING ALARM 104 Mixing fan fault The fan monitor checks that the fan is spinning at power up or whenever the mixing fan is turned on If the fan is not operating then the fault is annunciated The mixing fan fault can be conf...

Page 71: ...report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F12 or F3 frame sizes 2 right inverter module in F10 or F11 frame sizes 2 second adjustable frequency drive from the left inverter module in F14 frame size 3 right inverter module in F12 or F13 frame sizes 3 third from the left inverter module in F14 frame size 4 f...

Page 72: ...Warnings and Alarms VLT AutomationDrive Instruction Manual 8 10 MG33AM22 VLT is a registered Danfoss trademark 8 8 ...

Page 73: ...erly 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 Test using a different LCP Replace the faulty LCP or connection cable Internal voltage supply fault or SMPS is defective Contact supplier Intermittent display Overloaded power supply SMPS due to impro...

Page 74: ...mit 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 Digital inputs Deactivate reversing signal Wrong motor phase connection See 3 7 Check Motor Rotation in this manual Motor is not reaching maximum speed Frequency limits set wrong Check output limits in4...

Page 75: ...sition A to B B to C C to A If imbalanced leg follows the wire it is a power problem Check line power supply Problem with the adjustable frequency drive unit Rotate input power leads into the adjustable frequency drive one position A to B B to C C to A If imbalance leg stays on same input terminal it is a problem with the unit Contact supplier Motor current imbalance greater than 3 Problem with mo...

Page 76: ...Basic Troubleshooting VLT AutomationDrive Instruction Manual 9 4 MG33AM22 VLT is a registered Danfoss trademark 9 9 ...

Page 77: ...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 line power motor brake and load sharing mm2 AWG 2 4 4 4 12 12 12 min 0 2 24 IP55 IP66 max cable cross section5 line power motor brake and load sharing mm2 AWG 4 4 4 12 12 12 Max cable cross section5 with disconnect 6 4 4 10 12 12 Estimated power loss at rated max load W 4 21 29 42 54 63 82 116 155 ...

Page 78: ... 8 46 2 67 2 59 4 Additional specifications IP21 max cable cross section5 line power brake load sharing AWG mm2 2 16 10 16 6 8 6 16 10 16 6 8 6 35 2 IP21 max cable cross section5 motor AWG mm2 2 10 10 8 8 10 10 8 8 35 25 25 2 4 4 IP20 max cable cross section5 line power brake motor and load sharing 10 10 8 8 10 10 8 8 35 2 Max cable cross section with disconnect AWG mm2 2 16 10 10 6 8 8 Estimated ...

Page 79: ...ted max load W 4 624 737 740 845 874 1140 1143 1353 1400 1636 Weight enclosure IP21 IP55 IP66 lbs kg 99 21 45 99 21 45 99 21 45 143 3 65 143 3 65 Efficiency4 0 96 0 97 0 97 0 97 0 97 Table 10 3 Line Power Supply 3x200 240 V AC 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 16 5 ft 5 m shielded m...

Page 80: ... 8 11 6 Max input current Continuous 3x380 440 V A 1 2 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 A 1 6 2 2 3 0 4 3 5 0 6 9 9 1 11 8 15 8 20 8 Additional specifications IP20 IP21 max cable cross section5 line power motor brake and load sharing...

Page 81: ...ous 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 section5 line power brake load sharing mm2 AWG 2 16 10 16 6 8 6 16 10 16 6 8 6 35 2 35 2 IP21 IP55 IP66 max cable cross section5 motor mm2 AWG 2 10 10 8 8 10 10 8 8 35 25 25 2 4 4 35 25 25 2 4 4 IP20 max cable cross sectio...

Page 82: ...section5 line power and motor 35 2 50 1 50 1 150 300 MCM 150 300 MCM IP20 max cable cross section5 brake and load sharing 35 2 50 1 50 1 95 4 0 95 4 0 IP21 IP55 IP66 max cable cross section5 line power motor mm2 AWG 2 50 1 50 1 50 1 150 300 MCM 300MCM 150 IP21 IP55 IP66 max cable cross section5 brake load sharing mm2 AWG 2 50 1 50 1 50 1 95 3 0 95 3 0 Max cable size with line power disconnect AWG ...

Page 83: ...ermittent 3x525 550 V A 2 9 4 2 4 6 6 6 8 3 10 2 15 2 18 4 Continuous 3x551 600 V A 1 7 2 4 2 7 3 9 4 9 6 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 input current Continuous 3x525 600 V A 1 7 2 4 2 7 4 1 5 2 5 8 8 6 10 4 Intermittent 3x525 600 V...

Page 84: ...tinuous 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 line power brake load sharing mm2 AWG 2 16 10 10 6 8 8 16 10 10 6 8 8 35 2 35 2 50 1 IP21 IP55 IP66 max cable cross section5 motor mm2 AWG 2 10 10 8 8 10 10 8 8 35 25 25 2 4 4 35 25 25 2 4 4 50 1 IP20 max cable cross section5 line ...

Page 85: ... 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 line power and motor 50 1 150 300 MCM IP20 max cable cross section5 brake and load sharing 50 1 95 4 0 IP21 IP55 IP66 max cable cross section5 line power motor mm2 AWG 2 50 1 150 300 MCM IP21 IP55 IP66 max cable cross section5 brake load sharing mm2 AWG 2 50...

Page 86: ...nuous 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 2 3 3 2 4 6 6 5 7 9 10 8 14 4 Additional specifications IP20 max cable cross section5 line power motor brake and load sharing mm2 AWG 0 2 4 24 12 Estimated power loss at rated max load W 4 44 60 88 120 160 220 300 We...

Page 87: ... 26 7 26 7 34 3 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 29 36 Intermittent 60 s overload 3x525 690 V A 23 2 21 5 31 2 26 4 38 4 31 9 46 4 39 6 Additional specifications Max cable cross section line power load share and brake AWG mm2 35 2 M...

Page 88: ... 61 9 61 9 82 9 82 9 100 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 36 49 49 59 59 71 71 87 87 99 Continuous at 575 V A 54 53 9 72 64 9 87 78 1 105 95 7 129 108 9 Additional specifications Max cable cross section line power and motor AWG mm2 15...

Page 89: ...Protected Chassis 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 16 5 ft 5 m shielded motor cables at rated load and rated frequency 4 The typical power loss is at nominal load conditions and expected to be within 15 tolerance relates to variety in voltage and cable conditions Values...

Page 90: ...according to EN60664 1 overvoltage category III pollution degree 2 The 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 frequency 0 33 10 hp 0 25 75 kW FC 301 0 2 590 Hz FC 302 0 590 Hz Output frequency 125 1 350 hp 90 1 000 kW 0 5901 Hz Output frequen...

Page 91: ...eturn way for the current from the coil when turning it 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 analog inputs 2 Terminal number 53 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201 switch S202 OFF U V...

Page 92: ...frequency at frequency output 32 kHz Accuracy of frequency output Max error 0 1 of full scale Resolution of frequency outputs 12 bit 1 Terminal 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 outputs 1 Terminal number 42 Current range at analog output 0 4 ...

Page 93: ...1 on 4 6 NC resistive load 240 V AC 2A Max terminal load AC 15 1 on 4 6 NC inductive load cosφ 0 4 240 V AC 0 2 A Max terminal load DC 1 1 on 4 6 NC resistive load 50 V DC 2A Max terminal load DC 13 1 on 4 6 NC inductive load 24 V DC 0 1A Min terminal load on 1 3 NC 1 2 NO 4 6 NC 4 5 NO 24 V DC 10 mA 24 V AC 20 mA Environment according to EN 60664 1 overvoltage category III pollution degree 2 1 IE...

Page 94: ...m 113 F 45 C 1 Only for 3 7 kW 5 HP 200 240 V 7 5 kW 10 HP 400 480 500 V 2 As enclosure kit for 3 7 kW 5 HP 200 240 V 7 5 kW 10 HP 400 480 500 V 3 Derating for high ambient temperature see special conditions in the Design Guide Minimum ambient temperature during full scale operation 32 F 0 C Minimum ambient temperature at reduced performance 14 F 10 C Temperature during storage transport 13 to 149...

Page 95: ...owing 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 been tested to have a recommendation Other types of circuit breakers may be used provided they limit the energy into the adjustable frequency drive to a level equal to or lower than the Moeller types ...

Page 96: ...50 30 37 aR 160 30 aR 200 37 aR 200 30 aR 250 37 NZMB2 A250 250 A4 0 34 3 0 25 2 2 gG 10 0 34 2 0 25 1 5 gG 16 3 2 2 gG 32 PKZM0 25 25 A5 0 34 5 0 25 3 7 gG 10 0 34 2 0 25 1 5 gG 16 3 4 2 2 3 gG 20 5 3 7 gG 32 PKZM0 25 25 B1 7 5 10 5 5 7 5 gG 25 7 5 5 5 gG 32 10 7 5 gG 80 PKZM4 63 63 B2 15 11 gG 50 gG 100 NZMB1 A100 100 C1 20 30 15 22 gG 63 20 15 gG 80 25 18 5 gG 100 30 22 gG 160 20 25 15 18 5 aR ...

Page 97: ...7 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 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 C1 30 45 gG 80 30 gG 100 37 gG 160 45 gG 160 NZMB2 A200 160 C2 55 75 aR 200 55 aR 250 75 aR 250 NZMB2 A250 250 T...

Page 98: ...ZMB1 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 Recommended fuse size Recommended Max fuse Recommended circuit breaker Moeller Max trip level A A3 1 1 1 5 3 2 2 3 5 4 5 5 7 5 gG 6 gG 6 gG 6 gG 10 gG 10 gG 16 gG 16 gG 25 gG 25 gG 25 gG 25 gG 25 gG 25 gG...

Page 99: ... 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 JKS 250 JJN 250 Table 10 18 200 240 V Frame Sizes A B and C Recommended max fuse Power kW SIBA Type RK1 Littel fuse Type RK1 Ferraz Shawmut Type CC Ferraz Shawmut Type RK13 0 25 0 37 5017906 005 KLN R ...

Page 100: ...from FERRAZ SHAWMUT may substitute for A25X for 240 V adjustable frequency drives 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 KTS R 6 JKS 6 JJS 6 FNQ R 6 KTK R 6 LP CC 6 1 5 2 2 KTS R 10 JKS 10 JJS 10 FNQ R 10 KTK R 10 LP CC 10 3 KTS R 15 JKS 15 JJS 15 FNQ R 15 KTK R 15 LP CC 15 4 KTS R 20 JKS 20 JJS 20...

Page 101: ... 2028220 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 Shawmut J Ferraz Shawmut JFHR21 Littel fuse JFHR2 0 37 1 1 FWH 6 HSJ 6 1 5 2 2 FWH 10 HSJ 10 3 FWH 15 HSJ 15 4 FWH 20 HSJ 20 5 5 FWH 25 HSJ 25 7 5 FWH 30 HSJ 30 11 FWH 40 HSJ 40 15 FWH 50 HSJ 50 18 FWH...

Page 102: ... Type 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 020 A6K 20 R HSJ 20 5 5 5017906 025 KLS R 025 A6K 25 R HSJ 25 7 5 5017906 030 KLS R 030 A6K 30 R HSJ 30 11 5014006 040 KLS R 035 A6K 35 R HSJ 35 15 5014006 050 KLS R 045 A6K 45 R HSJ 45 18 5014006 0...

Page 103: ...e 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 HSJ 11 30 A KTS R 30 JKS 30 JKJS 30 5017906 030 KLS R 030 A6K 30 R HST 30 15 18 5 45 A KTS R 45 JKS 45 JJS 45 5014006 050 KLS R 045 A6K 45 R HST 45 22 60 A KTS R 60 JKS 60 JJS 60 5014006 063 KLS R 0...

Page 104: ...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 7 5 10 5 5 7 5 15 20 11 15 15 20 11 15 1 8 1 8 1 8 1 8 3 0 6 B4 15 20 11 15 25 40 18 30 25 40 18 30 4 5 4 5 4 5 4 5 3 0 6 C1 20 30 15 22 40 60 30 45 40 60 30 45 10 10 10 10 3 0 6 C2 40 50 30 37 7 5 10 5 5 7 5 75 100 55 75 40 100 30 75 14 241 14 241 14 14 3 0 6 C3 25 30 18 22 50 60 37 45 50 60 37 45 50 75 45 55 10 10 10 10 3 0 6 C4...

Page 105: ... Control Cables 2 10 Card 8 2 Card Performance 10 17 Card 10 V DC Output 10 16 Card 24V DC Output 10 16 Card RS 485 Serial Communication 10 17 Card USB Serial Communication 10 17 Characteristics 10 17 Signal 5 1 5 2 7 1 System 1 3 Terminals 2 3 7 1 5 2 2 9 Wire 2 9 Wiring 2 5 2 6 2 9 3 2 2 7 Cooling Cooling 2 1 Clearance 3 2 Copying Parameter Settings 4 3 Current Limit 3 7 Rating 2 1 8 3 D Danfoss...

Page 106: ...ontrol 4 1 4 3 7 1 Control Panel 4 1 Control Test 3 7 Mode 3 7 Operation 4 1 Start 3 7 M Main Menu 4 2 5 1 4 2 Manual Initialization 4 4 MCT 10 Set up Software Set up Software 5 9 Mechanical Brake Control 2 11 Menu Keys 4 1 4 2 Structure 4 3 5 4 Modbus RTU 2 12 Motor Cables 2 1 2 5 2 6 Current 1 4 3 5 8 7 4 2 Data 3 3 3 4 3 7 8 3 8 7 3 6 Output 10 14 Power 2 3 2 5 2 6 8 7 Protection 2 5 Rotation 3...

Page 107: ...ntrol Cables 2 10 Wire 2 5 Short Circuit 8 4 Smart Application Set up SAS 3 3 Specifications 1 2 2 12 10 1 Speed Reference 2 11 3 7 5 2 7 1 Start Up 9 1 Startup 1 2 Start up 4 4 5 1 3 0 Status Messages 7 1 Mode 7 1 Stop Command 7 1 Supply Voltage 2 7 2 8 3 1 8 5 Switching Frequency 7 1 Symbols 0 iii System Feedback 1 3 Monitoring 8 1 Start up 3 7 T Technical Data 10 14 Temperature Limits 3 2 Termi...

Page 108: ...W Warning And Alarm Definitions 8 2 And Alarm Displays 8 1 And Alarm Types 8 1 Wire Sizes 2 5 2 6 Index VLT AutomationDrive Instruction Manual 12 4 MG33AM22 VLT is a registered Danfoss trademark ...

Page 109: ...Index VLT AutomationDrive Instruction Manual MG33AM22 VLT is a registered Danfoss trademark 12 5 ...

Page 110: ...www danfoss com drives MG33AM22 130R0300 MG33AM22 Rev 2013 03 12 ...