Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® AutomationDrive FC 301/302 0.25–75 kW www.danfoss.com/drives...
Page 3: Table Of Contents
Contents Design Guide Contents 1 Introduction 1.1 Purpose of the Design Guide 1.2 Additional Resources 1.3 Abbreviations, Symbols and Conventions 1.4 Definitions 1.5 Document and Software Version 1.6 Regulatory Compliance 1.6.1 CE Mark 1.6.1.1 Low Voltage Directive 1.6.1.2 EMC Directive 1.6.1.3 Machinery Directive 1.6.2 UL Compliance 1.6.3 C-tick Compliance...
Page 4 Contents Design Guide 3.6.5 Control Structure in Flux with Motor Feedback (FC 302 only) 3.6.6 PID 3.6.6.1 Speed PID Control 3.6.6.2 Tuning PID speed control 3.6.6.3 Process PID Control 3.6.6.4 Advanced PID Control plus 3.6.7 Internal Current Control in VVC Mode 3.6.8 Local (Hand On) and Remote (Auto On) Control 3.7 Reference Handling...
Page 5 4.2.12 Open-loop Mechanical Brake Control 4.2.13 Closed-loop Mechanical Brake Control/Hoist Mechanical Brake 4.2.14 Smart Logic Control (SLC) 4.2.15 Safe Torque Off ® ® 4.3 Danfoss VLT FlexConcept 5 System Integration 5.1 Ambient Operating Conditions 5.1.1 Humidity 5.1.2 Temperature 5.1.3 Temperature and Cooling 5.1.4 Manual Derating...
Page 6 Contents Design Guide 5.3.4 Harmonic Calculation 5.4 Galvanic Isolation (PELV) 5.4.1 PELV - Protective Extra Low Voltage 5.5 Brake Functions 5.5.1 Selection of Brake Resistor 6 Product Specifications 6.1 Electrical Data 6.1.1 Line Power Supply 200–240 V 6.1.2 Line Power Supply 380–500 V 6.1.3 Line Power Supply 525–600 V (FC 302 only) 6.1.4 Line Power Supply 525–690 V (FC 302 only) 6.2 General Specifications...
Page 7 Contents Design Guide 7.2.9 dU/dt Filters 8 Mechanical Installation 8.1 Safety 8.2 Mechanical Dimensions 8.2.1 Mechanical Mounting 8.2.1.1 Clearance 8.2.1.2 Wall Mounting 9 Electrical Installation 9.1 Safety 9.2 Cables 9.2.1 Tightening Torque 9.2.2 Entry Holes 9.2.3 Tightening of the Cover after Connections are Made 9.3 AC line input connections 9.3.1 Fuses and Circuit Breakers 9.3.1.1 Fuses...
Page 8 Contents Design Guide 10.1 Commonly Used Applications 10.1.1 Closed-loop Drive System 10.1.2 Programming of Torque Limit and Stop 10.1.3 Programming of Speed Control 11 Options and Accessories 11.1 Communication Options 11.2 I/O, Feedback and Safety Options ® 11.2.1 VLT General Purpose I/O Module MCB 101 ®...
Page 9 Contents Design Guide 12.7.1 Content of a Character (byte) 12.7.2 Message Structure 12.7.3 Message Length (LGE) 12.7.4 Adjustable Frequency Drive Address (ADR) 12.7.5 Data Control Byte (BCC) 12.7.6 The Data Field 12.7.7 The PKE Field 12.7.8 Parameter Number (PNU) 12.7.9 Index (IND) 12.7.10 Parameter Value (PWE) 12.7.11 Supported Data Types 12.7.12 Conversion...
Page 10 12.12.4 Text Blocks 12.12.5 Conversion Factor 12.12.6 Parameter Values 12.13 Danfoss FC Control Profile 12.13.1 Control Word According to FC Profile (8-10 Control Profile = FC profile) 12.13.2 Status Word According to FC Profile (STW) (8-10 Control Profile = FC profile) 12.13.3 Bus Speed Reference Value...
Page 11: Introduction
Stegmann supplied with the options for specific Horsepower requirements. HTL encoder (10–30 V) pulses - High-voltage Transistor Logic Contact a Danfoss supplier or go to www.danfoss.com for Hertz additional information. Rated Inverter Output Current 1.3 Abbreviations, Symbols and Current limit...
Page 12: Definitions
Introduction Design Guide The following symbols are used in this document: Minute Millisecond WARNING Most significant bit η Efficiency of the adjustable frequency drive Indicates a potentially hazardous situation which could defined as ratio between power output and result in death or serious injury. power input Nanofarad CAUTION...
Page 13: Document And Software Version
The power factor indicates to which extent the adjustable long as the equipment is properly installed, maintained, frequency drive imposes a load on the line power supply. and used as intended. Danfoss CE labels comply with the The lower the power factor, the higher the I for the low-voltage directive and provide a declaration of same kW performance.
Page 14: Emc Directive
Danfoss CE labels amount of time for stored electrical energy to dissipate. comply with the machinery directive for adjustable...
Page 15: Safety
Safety Design Guide 2 Safety 2.1 Safety Symbols 2.3 Safety Precautions WARNING The following symbols are used in this document: HIGH VOLTAGE WARNING Adjustable frequency drives contain high voltage when Indicates a potentially hazardous situation which could connected to AC line power. Failure to perform instal- result in death or serious injury.
Page 16 Safety Design Guide WARNING WARNING DISCHARGE TIME EQUIPMENT HAZARD The adjustable frequency drive contains DC link Contact with rotating shafts and electrical equipment capacitors which can remain charged even when the can result in death or serious injury. adjustable frequency drive is not powered. Failure to •...
Page 17: Basic Operating Principles
In the inverter section, once a run command and speed reference are present, the IGBTs begin switching to create the output waveform. This waveform, as generated by the plus Danfoss VVC PWM principle at the control card, provides optimal performance and minimal losses in the motor.
Page 18: Brake Option
Again such a configuration should not limit is exceeded. It does this by switching the externally be attempted with out first consulting Danfoss application mounted resistor across the DC bus to remove excess DC engineering.
Page 19: Wiring Schematic
*Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off ® Instruction Manual for Danfoss VLT Adjustable Frequency Drives. Terminal 37 is not included in FC 301 (except enclosure type A1).
Page 20 Basic Operating Principles Design Guide Motor, 3--phase and PE (shielded) Adjustable frequency drive Line power, 3--phase and reinforced PE (non-shielded) Output contactor Control wiring (shielded) Cable clamp Potential equalization min. 16 mm (0.025 in Cable insulation (stripped) Clearance between control cable, motor cable and line cable: Min.
Page 21: Controls
Basic Operating Principles Design Guide NOTICE! Torque control The torque control function is used in applications where EMC INTERFERENCE the torque on motor output shaft is controlling the Run cables for input power, motor wiring and control application as tension control. Torque control can be wiring in three separate metallic conduits.
Page 22: Fc 301 Vs. Fc 302 Control Principle
Basic Operating Principles Design Guide 3.6.2 FC 301 vs. FC 302 Control Principle FC 301 is a general purpose adjustable frequency drive for variable speed applications. The control principle is based on plus Voltage Vector Control (VVC FC 301 can handle both asynchronous and PM motors. The current sensing principle in FC 301 is based on current measurement in the DC link or motor phase.
Page 23: Control Structure In Vvc Plus
Basic Operating Principles Design Guide 3.6.3 Control Structure in VVC plus P 4-13 Motor speed P 4-19 high limit (RPM) Max. output freq. P 1-00 P 1-00 P 4-14 Con g. mode Con g. mode Motor speed +f max. high limit (Hz) Motor P 3-** High...
Page 24: Control Structure In Flux Sensorless (Fc 302 Only)
Basic Operating Principles Design Guide 3.6.4 Control Structure in Flux Sensorless (FC 302 only) P 1-00 Con g. mode P 4-13 Motor speed high limit [RPM] P 4-19 P 4-14 Motor speed Max. output high limit [Hz] freq. High P 3-** P 7-0* +f max.
Page 25: Control Structure In Flux With Motor Feedback (Fc 302 Only)
Basic Operating Principles Design Guide 3.6.5 Control Structure in Flux with Motor Feedback (FC 302 only) P 1-00 P 1-00 Con g. mode Con g. mode Torque P 4-13 Motor speed P 4-19 high limit (RPM) Max. output P 4-14 Motor speed freq.
Page 26: Pid
Basic Operating Principles Design Guide 3.6.6 PID 3.6.6.1 Speed PID Control Speed PID Control maintains a constant motor speed regardless of the changing load on the motor. 1-01 Motor Control Principle 1-00 Configuration Mode Flux Sensorless Flux w/ enc. feedb plus [0] Speed open-loop ACTIVE...
Page 27 Basic Operating Principles Design Guide Parameter Description of function 7-00 Speed PID Feedback Source Select from which input the speed PID should get its feedback. 7-02 Speed PID Proportional Gain The higher the value, the quicker the control. However, too high value may lead to oscillations.
Page 28 Basic Operating Principles Design Guide Function Parameter Setting Set acceptable limits for the references. 3-02 Minimum 0 RPM (default) Reference 1500 RPM (default) 3-03 Maximum Reference Check that the ramp settings are within adjustable 3-41 Ramp 1 default setting frequency drive capabilities and the allowed application Ramp-up Time default setting operating specifications.
Page 29: Tuning Pid Speed Control
Basic Operating Principles Design Guide 3.6.6.2 Tuning PID speed control 3.6.6.3 Process PID Control The following tuning guidelines are relevant when using Use the Process PID Control to control application one of the Flux motor control principles in applications parameters that can be measured by a sensor (i.e., where the load is mainly inertial (with a low amount of pressure, temperature, flow) and be affected by the friction).
Page 30 Basic Operating Principles Design Guide Figure 3.9 Process PID Control Diagram Table 3.5 sums up the characteristics that can be set up for the process control. Parameter Description of function 7-20 Process CL Feedback 1 Resource Select from which source (i.e., analog or pulse input) the Process PID should receive its feedback 7-22 Process CL Feedback 2 Resource Optional: Determine if (and from where) the process PID should get an additional...
Page 31: Advanced Pid Control
Basic Operating Principles Design Guide Parameter Description of function 5-54 Pulse Filter Time Constant #29 (Pulse If there are oscillations of the current/voltage feedback signal, these can be dampened by term. 29), means of a low-pass filter. This time constant represents the speed limit of the ripples 5-59 Pulse Filter Time Constant #33 (Pulse occurring on the feedback signal.
Page 32 Basic Operating Principles Design Guide Active Reference and Configuration Mode The active reference can be either the local reference or the remote reference. In 3-13 Reference Site, the local reference can be permanently selected by selecting [2] Local. To permanently select the remote reference, select [1] Remote.
Page 33: Reference Handling
Basic Operating Principles Design Guide 3.7 Reference Handling 3.7.1 References Analog Reference An analog signal applied to input 53 or 54. The signal can be either voltage 0–10 V (FC 301 and FC 302) or -10 to +10 V (FC 302). Current signal 0–20 mA or 4–20 mA. Binary Reference A signal applied to the serial communication port (RS-485 terminals 68–69).
Page 35: Reference Limits
Basic Operating Principles Design Guide 3.7.2 Reference Limits The remote reference is calculated once every scan interval and initially consists of two types of reference 3-00 Reference Range, 3-02 Minimum Reference and inputs: 3-03 Maximum Reference define the allowed range of the X (the actual reference): A sum (see sum of all references.
Page 36: Scaling Of Preset References And Bus References
Basic Operating Principles Design Guide 3.7.4 Scaling of Analog and Pulse The value of 3-02 Minimum Reference cannot be set to less References and Feedback than 0 unless 1-00 Configuration Mode is set to [3] Process. In that case, the following relations between the resulting reference (after clamping) and the sum of all references is References and feedback are scaled from analog and pulse shown in Figure 3.16.
Page 37: Dead Band Around Zero
Basic Operating Principles Design Guide 3.7.5 Dead Band Around Zero Quadrant 2 Resource output Quadrant 1 (RPM) In some cases, the reference (in rare cases also the 1500 feedback) should have a dead band around zero (i.e., to Low reference/feedback make sure the machine is stopped when the reference is value “near zero”).
Page 38 Basic Operating Principles Design Guide Figure 3.21 shows how reference input with limits inside Min – Max limits clamps. Figure 3.21 Positive Reference with Dead Band, Digital input to Trigger Reverse Rev. 2014-04-04 All rights reserved. MG33BF22...
Page 39 Basic Operating Principles Design Guide Figure 3.22 shows how reference input with limits outside -Max to +Max limits clamps to the inputs low and high limits before being added to actual reference. Figure 3.22 also shows how the actual reference is clamped to -Max to +Max by the reference algorithm.
Page 41: Product Features
Product Features Design Guide 4 Product Features 4.1.2 Overvoltage Protection 4.1 Automated Operational Features These features are active as soon as the adjustable Motor-generated overvoltage frequency drive is operating. They require no programming The voltage in the intermediate circuit is increased when or set-up.
Page 42: Missing Motor Phase Detection
Product Features Design Guide NOTICE! 4.1.6 Overload Protection AC brake is not as effective as dynamic breaking with a Torque Limit resistor. The torque limit feature protects the motor against overload, independent of the speed. Torque limit is OverVoltage Control (OVC) controlled in 4-16 Torque Limit Motor Mode and or OVC reduces the risk of the adjustable frequency drive 4-17 Torque Limit Generator Mode and the time before the...
Page 43: Automatic Derating
Product Features Design Guide 4.1.8 Automatic Derating Automatic switching frequency modulation regulates these conditions automatically to provide the highest carrier frequency without overheating the adjustable frequency The adjustable frequency drive constantly checks for drive. By providing a regulated high carrier frequency, it critical levels: quiets motor operating noise at slow speeds when audible noise control is critical, and produces full output power to...
Page 44: Emc Compliance
Product Features Design Guide 4.1.15 EMC Compliance 4.2.2 Motor Thermal Protection Electromagnetic interference (EMI) or radio frequency Motor thermal protection can be provided in three ways: interference (RFI, in case of radio frequency) is disturbance • which can affect an electrical circuit due to electro- Via direct temperature sensing via one of the magnetic induction or radiation from an external source.
Page 45: Line Drop-Out
Product Features Design Guide 4.2.4 Built-in PID Controller The X-axis shows the ratio between I and I motor motor nominal. The Y-axis shows the time in seconds before the ETR cuts off and trips the adjustable frequency drive. The The built-in proportional, integral, derivative (PID) curves show the characteristic nominal speed, at twice the controller is available, eliminating the need for auxiliary nominal speed and at 0.2 x the nominal speed.
Page 46: Frequency Bypass
Product Features Design Guide 4.2.8 Frequency Bypass In some applications, the system may have operational speeds that create a mechanical resonance. This can generate excessive noise and possibly damage mechanical components in the system. The adjustable frequency drive has four programmable bypass-frequency bandwidths. These allow the motor to step over speeds which induce system resonance.
Page 47: Open-Loop Mechanical Brake Control
Product Features Design Guide 4.2.12 Open-loop Mechanical Brake Control Parameters for controlling operation of an electro-magnetic (mechanical) brake, typically required in hoisting applications. To control a mechanical brake, a relay output (relay 01 or relay 02) or a programmed digital output (terminal 27 or 29) is required.
Page 48: Closed-Loop Mechanical Brake Control/Hoist Mechanical Brake
Product Features Design Guide 4.2.13 Closed-loop Mechanical Brake Control/Hoist Mechanical Brake The hoist mechanical break control supports the following functions: • Two channels for mechanical brake feedback to offer further protection against unintended behavior resulting from broken cable. • Monitoring of mechanical brake feedback throughout the complete cycle. This helps protect the mechanical brake - especially if more adjustable frequency drives are connected to the same shaft.
Page 49: Smart Logic Control (Slc)
Product Features Design Guide 4.2.14 Smart Logic Control (SLC) When the last event/action has been executed, the sequence starts over again from event [0]/action [0]. Figure 4.5 shows an example with four event/actions: Smart Logic Control (SLC) is a sequence of user-defined actions (see 13-52 SL Controller Action [x]) executed by the SLC when the associated user-defined event (see 13-51 SL Controller Event [x]) is evaluated as TRUE by the SLC.
Page 50: Safe Torque Off
1-11 Motor Model, and the recommended parameters are set automatically. ® For further information, refer to the VLT AutomationDrive ® FC 301/FC 302 Programming Guide, the VLT OneGearDrive Selection Guide, and www.danfoss.com/BusinessAreas/Drives- Solutions/VLTFlexConcept/ Rev. 2014-04-04 All rights reserved. MG33BF22...
Page 51: System Integration
System Integration Design Guide 5 System Integration 5.1.3 Temperature and Cooling 5.1 Ambient Operating Conditions 5.1.1 Humidity The adjustable frequency drives have built-in fans to ensure optimum cooling. The main fan forces the air flow Although the adjustable frequency drive can operate along the cooling fins on the heatsink, ensuring a cooling properly at high humidity (up to 95% relative humidity), of the internal air.
Page 52: Manual Derating
A, B and C. At altitudes above Ambient Temperature. AMB, MAX 6,600 ft [2,000 m], contact Danfoss regarding PELV. 5.1.4.1 Derating for Running at Low Speed An alternative is to lower the ambient temperature at high When a motor is connected to an adjustable frequency...
Page 53: Acoustic Noise
The adjustable frequency drive tested according to a procedure based on the IEC 68-2-6/34/35 and 36. These tests subject the unit to 0.7 g forces, over the range of 18 to 1,000 Hz random, in three directions for two hours. All Danfoss adjustable frequency drives comply with requirements that correspond to these conditions when the unit is wall or floor mounted, as well as when mounted within panels bolted to walls or floors.
Page 54: Dust Exposure
System Integration Design Guide • 5.1.7.2 Dust Exposure e classification consists of preventing any occurrence of a spark. The FC 302 with firmware version V6.3x or higher is equipped with an Installation of adjustable frequency drives in environments "ATEX ETR thermal monitoring" function for with high dust exposure is often unavoidable.
Page 55: Maintenance
Design Guide 5.1.8 Maintenance Danfoss adjustable frequency drive models up to 90 kW are maintenance free. High power adjustable frequency drives (rated at 110 kW or higher) have built-in filter mats which require periodic cleaning by the operator, depending on the exposure to dust and contaminants.
Page 56: Emc Test Results
System Integration Design Guide Ground wire Adjustable frequency drive Shield Shielded motor cable AC line power supply Motor Figure 5.3 Situation that Generates Leakage Currents If the shield is to be placed on a mounting plate for the adjustable frequency drive, the mounting plate must be made of metal, to convey the shield currents back to the unit.
Page 57 T5, 30–60 hp [22–45 kW] and T7, 30–100 hp [22–75 kW] comply with class A group 1 with 25 m motor cable. Some restrictions for the instal- lation apply (contact Danfoss for details). Hx, H1, H2, H3, H4 or H5 is defined in the type code pos. 16-17 for EMC filters, see Table 7.1.
Page 58: Emission Requirements
System Integration Design Guide 5.2.2 Emission Requirements The EMC product standard for adjustable frequency drives defines four categories (C1, C2, C3 and C4) with specified requirements for emission and immunity. Table 5.3 states the definition of the four categories and the equivalent classifi- cation from EN 55011.
Page 59: Immunity Requirements
All Danfoss adjustable frequency drives comply with the requirements for the industrial environment and consequently comply also with the lower requirements for home and office environment with a large safety margin.
Page 60: Motor Insulation
System Integration Design Guide 5.2.4 Motor Insulation Standard Mitigation Strategies Use an insulated bearing. Modern design of motors for use with adjustable Apply rigorous installation procedures frequency drives have a high degree of insulation to Ensure the motor and load motor are account for new generation high-efficiency IGBTs with high aligned.
Page 61: Line Power Supply Interference/Harmonics
System Integration Design Guide 5.3.1 The Effect of Harmonics in a Power 5.3 Line Power Supply Interference/ Distribution System Harmonics An adjustable frequency drive takes up a non-sinusoidal In Figure 5.5, a transformer is connected on the primary current from the line power, which increases the input side to a point of common coupling PCC1, on the medium current I .
Page 62: Harmonic Limitation Standards And Requirements
5.3.3 Harmonic Mitigation In cases where additional harmonic suppression is Contribution to Disturbance to system losses other users required, Danfoss offers a wide range of mitigation equipment. These are: Figure 5.6 Negative Effects of Harmonics • 12-pulse drives • 5.3.2 Harmonic Limitation Standards and...
Page 63: Galvanic Isolation (Pelv)
Protection against electric shock is ensured when the Installation at high altitude: electrical supply is of the PELV type and the installation is At altitudes above 6,600 ft [2,000 m], contact Danfoss made as described in local/national regulations on PELV regarding PELV.
Page 64 Check that the brake resistor can cope with a voltage of 650 hp [500 kW] at 130% braking torque/750 hp [560 kW] at 115% 410 V, 820 V, 850 V, 975 V or 1130 V - unless Danfoss braking torque brake resistors are used.
Page 65 The resistor brake circuit resistance selected should not In addition, the brake enables reading out the momentary be higher than that recommended by Danfoss. If a brake power and the mean power for the latest 120 s. The brake resistor with a higher ohmic value is selected, the 160%...
Page 66: Product Specifications
Product Specifications Design Guide 6 Product Specifications 6.1 Electrical Data 6.1.1 Line Power Supply 200–240 V Type Designation PK25 PK37 PK55 PK75 P1K1 P1K5 P2K2 P3K0 P3K7 Typical Shaft Output [kW] 0.25 0.37 0.55 0.75 Enclosure IP20 (FC 301 only) Enclosure IP20/IP21 Enclosure IP55, IP66 A4/A5...
Page 67 Product Specifications Design Guide Type Designation P5K5 P7K5 P11K High/Normal Overload Typical Shaft Output [kW] Enclosure IP20 Enclosure IP21, IP55, IP66 Output current Continuous (200–240 V) [A] 24.2 30.8 30.8 46.2 46.2 59.4 Intermittent (60 s overload) (200–240 V) [A] 38.7 33.9 49.3...
Page 68: Line Power Supply 380-500
Product Specifications Design Guide 6.1.2 Line Power Supply 380–500 V Type Designation PK37 PK55 PK75 P1K1 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 Typical Shaft Output [kW] 0.37 0.55 0.75 Enclosure IP20 (FC 301 only) Enclosure IP20/IP21 Enclosure IP55, IP66 A4/A5 A4/A5 A4/A5 A4/A5...
Page 69 Product Specifications Design Guide Type Designation P11K P15K P18K P22K High/Normal Overload Typical Shaft output [kW] 18.5 18.5 22.0 22.0 30.0 Enclosure IP20 Enclosure IP21 Enclosure IP55, IP66 Output current Continuous (380–440 V) [A] 37.5 37.5 Intermittent (60 s overload) (380–440 V) [A] 38.4 35.2 51.2...
Page 70 Product Specifications Design Guide Type Designation P30K P37K P45K P55K P75K High/Normal Overload Typical Shaft output [kW] Enclosure IP21 Enclosure IP20 Enclosure IP55, IP66 Output current Continuous (380–440 V) [A] Intermittent (60 s overload) 91.5 80.3 (380–440 V) [A] Continuous (441–500 V) [A] Intermittent (60 s overload) 71.5 97.5...
Page 71: Line Power Supply 525-600 V (Fc 302 Only)
Product Specifications Design Guide 6.1.3 Line Power Supply 525–600 V (FC 302 only) Type Designation PK75 P1K1 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 Typical Shaft Output [kW] 0.75 Enclosure IP20, IP21 Enclosure IP55 Output current Continuous (525–550 V) [A] 11.5 Intermittent (525–550 V) [A] 10.2 15.2...
Page 72 Product Specifications Design Guide Type Designation P11K P15K P18K P22K P30K High/Normal Overload Typical Shaft Output [kW] 18.5 18.5 Enclosure IP20 Enclosure IP21, IP55, IP66 Output current Continuous (525–550 V) [A] Intermittent (525–550 V) [A] Continuous (551–600 V) [A] Intermittent (551–600 V) [A] Continuous kVA (550 V) [kVA] 18.1 21.9...
Page 73 Product Specifications Design Guide Type Designation P37K P45K P55K P75K High/Normal Overload Typical Shaft Output [kW] Enclosure IP20 Enclosure IP21, IP55, IP66 Output current Continuous (525–550 V) [A] Intermittent (525–550 V) [A] Continuous (551–600 V) [A] Intermittent (551–600 V) [A] Continuous kVA (550 V) [kVA] 51.4 61.9...
Page 74: Line Power Supply 525-690 V (Fc 302 Only)
Product Specifications Design Guide 6.1.4 Line Power Supply 525–690 V (FC 302 only) Type Designation P1K1 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 High/Normal Overload HO/NO HO/NO HO/NO HO/NO HO/NO HO/NO HO/NO Typical Shaft output (kW) Enclosure IP20 Output current Continuous (525–550 V) [A] 11.0 Intermittent (525–550 V) [A] 14.4...
Page 75 Product Specifications Design Guide Type Designation P11K P15K P18K P22K High/Normal Overload Typical Shaft output at 550 V [kW] 18.5 18.5 Typical Shaft output at 690 V [kW] 18.5 18.5 Enclosure IP20 Enclosure IP21, IP55 Output current Continuous (525–550 V) [A] 14.0 19.0 19.0...
Page 76 Product Specifications Design Guide Type Designation P30K P37K P45K P55K P75K High/Normal Overload Typical Shaft output at 550 V hp [kW] Typical Shaft output at 690 V [kW] Enclosure IP20 Enclosure IP21, IP55 Output current Continuous (525–550 V) [A] 36.0 43.0 43.0 54.0...
Page 77: General Specifications
Product Specifications Design Guide 6.2 General Specifications 6.2.1 Line Power Supply Line power supply Supply Terminals (6-pulse) L1, L2, L3 200–240 V ±10% Supply voltage FC 301: 380–480 V/FC 302: 380–500 V ±10% Supply voltage FC 302: 525–600 V ±10% Supply voltage FC 302: 525–690 V ±10% Supply voltage...
Page 78: Ambient Conditions
Product Specifications Design Guide 6.2.3 Ambient Conditions Environment Enclosure IP20/Chassis, IP21/Type 1, IP55/ Type 12, IP66/ Type 4X Vibration test 1.0 g Max. THVD Max. relative humidity 5%–93% (IEC 721-3-3; Class 3K3 (non-condensing) during operation Aggressive environment (IEC 60068-2-43) H S test class Kd Ambient temperature...
Page 79: Control Input/Output And Control Data
Product Specifications Design Guide 6.2.5 Control Input/Output and Control Data 6.2.5.1 Digital Inputs Digital inputs Programmable digital inputs FC 301: 4 (5) /FC 302: 4 (6) Terminal number 18, 19, 27 , 29 , 32, 33 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic'0' PNP...
Page 80 Product Specifications Design Guide Analog inputs Number of analog inputs Terminal number 53, 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201/switch S202 = OFF (U) Voltage level -10 to +10 V (scaleable) Input resistance, R approx.
Page 81 Product Specifications Design Guide Digital output Programmable digital/pulse outputs Terminal number 27, 29 Voltage level at digital/frequency output 0–24 V Max. output current (sink or source) 40 mA Max. load at frequency output 1 kΩ Max. capacitive load at frequency output 10 nF Minimum output frequency at frequency output 0 Hz...
Page 82 Product Specifications Design Guide Relay outputs Programmable relay outputs FC 301 all kW: 1/FC 302 all kW: 2 Relay 01 Terminal number 1-3 (break), 1-2 (make) Max. terminal load (AC-1) on 1-3 (NC), 1-2 (NO) (Resistive load) 240 V AC, 2 A Max.
Page 83: Derating For Ambient Temperature
Product Specifications Design Guide SFAVM 6.2.6 Derating for Ambient Temperature 110% 100% 6.2.6.1 Derating for Ambient Temperature, Enclosure Type A A1-A3 45°C, A4-A5 40°C A1-A3 50°C, A4-A5 45°C A1-A3 55°C, A4-A5 50°C 60° AVM - Pulse Width Modulation I out (%) f sw (kHz) 110% 100%...
Page 84 Product Specifications Design Guide 110% 100% 110% B3 & B4 100% 45°C 50°C 45 C 55°C 50 C (kHz) (kHz) Figure 6.11 Derating of I for different T AMB, MAX Enclosure Types B1 and B2, using SFAVM in Normal overload mode (110% overtorque) Figure 6.8 Derating of I for different T AMB, MAX...
Page 85 Product Specifications Design Guide Enclosures B, T6 SFAVM - Stator Frequency Asyncron Vector Modulation 60° AVM - Pulse Width Modulation 110% 100% B1 & B2 110% 100% B1 & B2 45 C 45 C 50 C 50 C (kHz) (kHz) Figure 6.16 Output current derating with switching Figure 6.14 Output current derating with switching frequency and ambient temperature for 600 V adjustable...
Page 86: Derating For Ambient Temperature, Enclosure Types C
Product Specifications Design Guide 6.2.6.3 Derating for Ambient Temperature, Enclosures B, T7 Enclosure Types C Enclosures B2 and B4, 525–690 V 60° AVM - Pulse Width Modulation Enclosures C, T2, T4 and T5 all options 60° AVM - Pulse Width Modulation 30.6 110% 27.2...
Page 87 Product Specifications Design Guide 110% 110% 100% 100% C3 & C4 C3 & C4 45 C 45 C 50 C 50 C 55 C (kHz) (kHz) Figure 6.23 Derating of I for different T Figure 6.26 Derating of I for different T AMB, MAX AMB, MAX enclosure types C3 and C4, using 60°...
Page 88 Product Specifications Design Guide Enclosure Types C, T6 SFAVM - Stator Frequency Asyncron Vector Modulation 60° AVM - Pulse Width Modulation 110% 100% C1 & C2 110% 100% C1 & C2 45 C 45 C 50 C 50 C (kHz) (kHz) Figure 6.30 Output current derating with switching Figure 6.28 Output current derating with switching...
Page 89: Measured Values For Du/Dt Testing
Product Specifications Design Guide 6.2.7 Measured Values for dU/dt Testing Enclosure Type C, T7 60° AVM - Pulse Width Modulation I out (A) To avoid damage to motors without phase insulation all options paper or other insulation reinforcement designed for operation of the adjustable frequency drive, it is strongly recommend to install a dU/dt filter or LC filter on the 28.9...
Page 90 Product Specifications Design Guide 380–500 V (T4) Cable AC line length voltage Rise time Upeak dU/dt Cable AC line [μs] [kV] [kV/μs] Rise time dU/dt length voltage Upeak 0.556 0.650 0.935 [μs] [kV] [kV/μs] 0.592 0.594 0.802 0.640 0.690 0.862 0.708 0.587 0.663...
Page 91 Product Specifications Design Guide 600 V (T6) Cable AC line length voltage Rise time Upeak dU/dt Cable AC line [μs] [kV] [kV/μs] Rise time dU/dt length voltage Upeak 0.288 3.083 [μs] [kV] [kV/μs] 0.492 1.230 2.000 0.304 1.560 4.105 0.468 1.190 2.034 0.300...
Page 92: Efficiency
Product Specifications Design Guide • 6.2.8 Efficiency The influence from the U/f characteristic on small motors is marginal. However, in motors from 15 hp [11 kW] and up, the efficiency advantage is Efficiency of the adjustable frequency drive significant. The load on the adjustable frequency drive has little effect •...
Page 93: How To Order
The Drive Configurator automatically generates an 8-digit sales number to be delivered to the local sales office. Furthermore, it is possible to establish a project list with several products and send it to a Danfoss sales representative. The Drive Configurator can be found on the global Internet site: www.danfoss.com/drives.
Page 94 How to Order Design Guide Description Possible choices RFI filter 16-17 Hx: No EMC filters built in the adjustable frequency drive (600 V units only) H1: Integrated EMC filter. Fulfill EN 55011 Class A1/B and EN/IEC 61800-3 Category 1/2 H2: No additional EMC filter. Fulfill EN 55011 Class A2 and EN/IEC 61800-3 Category 3 H3 - Integrated EMC filter.
Page 95 How to Order Design Guide Description Possible choices A options 29-30 AX: No A option A0: MCA 101 Profibus DP V1 (standard) A4: MCA 104 DeviceNet (standard) A6: CANOpen MCA 105 (standard) AN: MCA 121 Ethernet IP AL: MCA 120 ProfiNet AQ: MCA 122 Modbus TCP AT: MCA 113 Profibus Drive VLT 3000 AU: MCA 114 Profibus Drive VLT 5000...
Page 96: Language
How to Order Design Guide 7.1.2 Language Adjustable Frequency Drives are automatically delivered with a language package relevant to the region from which it is ordered. Four regional language packages cover the following languages: Language Language Language Language package 1 package 2 package 3 package 4...
Page 97: Ordering Numbers
How to Order Design Guide 7.2 Ordering Numbers 7.2.1 Options and Accessories Description Ordering no. Uncoated Coated Miscellaneous hardware ® 130B1028 Panel through kit enclosure type A5 ® 130B1046 Panel through kit enclosure type B1 ® 130B1047 Panel through kit enclosure type B2 ®...
Page 98 LCP Mounting Kit, w/ no LCP ® 130B1129 LCP Mounting Kit Blind Cover IP55/66, 8 m ® 130B1078 Control Panel LCP 102, graphical ® 130B1077 Blindcover, w/ Danfoss logo, IP55/66 Options for slot A ® 130B1100 130B1200 Profibus DP V1 MCA 101 ® 130B1102 130B1202 DeviceNet MCA 104 ®...
Page 99: Spare Parts
Options can be ordered as factory built-in options, see ordering information, chapter 7.1 Drive Configurator. Table 7.4 Ordering Numbers for Options and Accessories 7.2.2 Spare Parts Consult the VLT shop or the configurator for spare parts available for your specification, VLTShop.danfoss.com. 7.2.3 Accessory Bags Type Description Ordering no.
Page 100: Vlt Automationdrive Fc
How to Order Design Guide 7.2.4 VLT AutomationDrive FC 301 T2, Horizontal Braking 10% Duty Cycle FC 301 Horizontal braking 10% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont.
Page 101 How to Order Design Guide FC 301 Vertical braking 40% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω] [kW] Wire IP54 terminal...
Page 102 How to Order Design Guide FC 301 Horizontal braking 10% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω] [kW] Wire IP54 terminal...
Page 103 How to Order Design Guide FC 301 Vertical braking 40% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω] [kW] Wire IP54 terminal...
Page 104: Brake Resistors For Fc
How to Order Design Guide 7.2.5 Brake Resistors for FC 302 FC 302 Horizontal braking 10% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω]...
Page 105 How to Order Design Guide FC 302 Vertical braking 40% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω] [kW] Wire IP54 terminal...
Page 106 How to Order Design Guide FC 302 Horizontal braking 10% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω] [kW] Wire IP54 terminal...
Page 107 How to Order Design Guide FC 302 Vertical braking 40% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω] [kW] Wire IP54 terminal...
Page 108 How to Order Design Guide FC 302 Horizontal braking 10% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω] [kW] Wire IP54 terminal...
Page 109 How to Order Design Guide FC 302 Vertical braking 40% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω] [kW] Wire IP54 terminal...
Page 110 How to Order Design Guide FC 302 Vertical braking 40% duty cycle Brake resistor data Installation Adjustable frequency drive data Danfoss part number Cable Thermo cross- Line Screw Screw Bolt br.cont. relay br.nom section power [Ω] [kW] Wire IP54 terminal...
Page 111: Other Flat Pack Brake Resistors
How to Order Design Guide 7.2.6 Other Flat Pack Brake Resistors Flat pack IP65 for horizontal conveyors FC 301 per item Duty cycle Ordering no. br, nom (hp [kW]) 175Uxxxx [Ω] [Ω] [Ω//W] PK25 0.37 [0.25] 430/100 1002 PK37 0.5 [0.37] 330/100 or 310/200 27 or 55 1003 or 0984...
Page 112 How to Order Design Guide Flat pack IP65 for horizontal conveyors FC 301 per item Duty cycle Ordering no. br. nom (hp [kW]) [Ω] [Ω] [Ω/W] 175Uxxxx PK37 0.37 1121 830/100 1000 PK55 0.75 [0.55] 830/100 1000 PK75 1 [0.75] 620/100 or 620/200 14 or 27 1001 or 0982...
Page 113: Harmonic Filters
How to Order Design Guide 7.2.7 Harmonic Filters Harmonic filters are used to reduce line harmonics. • AHF 010: 10% current distortion • AHF 005: 5% current distortion Cooling and ventilation IP20: Cooled by natural convection or with built-in fans. IP00: Additional forced cooling is required. Secure sufficient airflow through the filter during installation to prevent overheating of the filter.
Page 114 How to Order Design Guide Filter current rating Power and current Typical Ordering no. AHF 005 Ordering no. AHF 010 ratings motor 60 Hz [kW] (hp [kW]) IP00 IP20 IP00 IP20 PK37-P4K0 1–7.4 4 [3] 130B1787 130B1752 130B1770 130B1482 P5K5-P7K5 9.9+13 10 [7.5] 130B1788...
Page 115: Sine-Wave Filters
How to Order Design Guide 7.2.8 Sine-Wave Filters Switching Adjustable frequency drive power and current ratings Filter current rating Ordering no. frequency 200–240 V 380–440 V 441–500 V 50 Hz 60 Hz 100 Hz IP00 IP20/23 [kHz] [kW]) [kW]) [kW]) [0.37] [0.37] 0.34...
Page 116 How to Order Design Guide Switching Adjustable frequency drive power and current ratings Filter current rating Ordering no. frequency 525–600 V 690 V 525–550 V 50 Hz 60 Hz 100 Hz IP00 IP20/23 (hp [kW]) [kW]) [kW]) 1 [0.75] 1.5 [1.1] 1.5 [1.1] 2 [1.5] 130B7335...
Page 118 How to Order Design Guide Parameter Setting 14-01 Switching Frequency Higher operating switching frequency than specified by the individual filter is not recommended. 14-55 Output Filter [0] No Filter 14-56 Capacitance Output Filter Not used 14-57 Inductance Output Filter Not used Table 7.30 Parameter Settings for dU/dt Filter Operation Rev.
Page 119 Mechanical Installation Design Guide 8 Mechanical Installation 8.1 Safety See chapter 2 Safety for general safety instructions. WARNING Pay attention to the requirements that apply to integration and the field mounting kit. Observe the information in the list to avoid serious injury or equipment damage, especially when installing large units.
Page 120 Mechanical Installation Design Guide 8.2 Mechanical Dimensions Enclosure Type Power 200–240 V 0.25–1.5 0.25–2.2 3–3.7 0.25–2.2 0.25–3.7 5.5–7.5 5.5–7.5 11–15 [kW] 380–480/ 0.37–1.5 0.37–4.0 5.5–7.5 0.37–4 0.37–7.5 11–15 18.5–22 11–15 18.5–30 500 V 525–600 V 0.75–7.5 0.75–7.5 11–15 18.5–22 11–15 18.5–30 525–690 V 1.1–7.5...
Page 121 Mechanical Installation Design Guide Enclosure Type Power 200–240 V 0.25–1.5 0.25–2.2 3–3.7 0.25–2.2 0.25–3.7 5.5–7.5 5.5–7.5 11–15 [kW] 380–480/ 0.37–1.5 0.37–4.0 5.5–7.5 0.37–4 0.37–7.5 11–15 18.5–22 11–15 18.5–30 500 V 525–600 V 0.75–7.5 0.75–7.5 11–15 18.5–22 11–15 18.5–30 525–690 V 1.1–7.5 11–22 11–30...
Page 122 Mechanical Installation Design Guide Enclosure Type Power 200–240 V 15–22 30–37 18.5–22 30–37 [kW] 380–480/500 V 30–45 55–75 37–45 55–75 525–600 V 30–45 55–90 37–45 55–90 525–690 V 30–75 37–45 55–75 Figures 21/55/66 21/55/66 NEMA Type 1/12/4X Type 1/12/4X Chassis Chassis Chassis Height (in [mm])
Page 123 Mechanical Installation Design Guide 8.2.1 Mechanical Mounting 8.2.1.1 Clearance All enclosure types allow side-by-side installation except when an IP21/IP4X/TYPE 1 enclosure kit is used (see chapter 11 Options and Accessories). Side-by-side mounting IP20 A and B enclosure types can be arranged side-by-side with no clearance required between them, but the mounting order is important.
Page 124 Mechanical Installation Design Guide NOTICE! The backplate is relevant for A4, A5, B1, B2, C1 and C2 only. Backplate Backplate Figure 8.3 Mounting on a non-solid backwall requires a IP66 adjustable frequency drive backplate Base plate Fiber washer For adjustable frequency drives with IP66, take extra care Figure 8.4 Mounting on a Non-solid Back Wall to maintain the corrosive-resistant surface.
Page 125 Electrical Installation Design Guide 9 Electrical Installation 9.1 Safety For electrical safety • Ground the adjustable frequency drive in See chapter 2 Safety for general safety instructions. accordance with applicable standards and WARNING directives. • Use a dedicated ground wire for input power, INDUCED VOLTAGE motor power and control wiring.
Page 126 Electrical Installation Design Guide 9.2 Cables NOTICE! Cables General All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper (167 °F [75 °C]) conductors are recommended. Aluminum Conductors Terminals can accept aluminum conductors, but the conductor surface must be clean, and the oxidation must be removed and sealed by neutral acid-free Vaseline grease before the conductor is connected.
Page 127 Electrical Installation Design Guide 9.2.2 Entry Holes Remove the cable entry from the adjustable frequency drive (this prevents foreign parts from falling into the adjustable frequency drive when removing knockouts). Cable entry has to be supported around the knockout to be removed. The knockout can now be removed with a strong mandrel and a hammer.
Page 128 Electrical Installation Design Guide Hole number and recommended use Nearest metric Hole number and recommended use Nearest metric 1) Line power 1) Line power 2) Motor 2) Motor 3) Brake/load sharing 3) Brake/load sharing 4) Control cable 1.12 in [28.4 mm] 5) Control cable 4) Control cable 5) Control cable...
Page 129 Electrical Installation Design Guide Hole number Dimensions Hole number Dimensions Nearest metric recommended UL [in] [mm] Nearest metric recommended UL [in] [mm] 1) Line power 34.7 2) Motor 34.7 1) Line power 1 1/4 44.2 3) Brake/load 34.7 2) Motor 1 1/4 44.2 sharing...
Page 130 Electrical Installation Design Guide Hole number and recommended use Nearest metric Hole number Dimensions 1) Line power Nearest metric recommended 2) Motor UL [in] [mm] 3) Brake/load sharing 1) Line power 63.3 4) Control cable 2) Motor 63.3 5) Control cable 3) Brake/load 1 1/2 50.2...
Page 131 Electrical Installation Design Guide NOTICE! 9.2.3 Tightening of the Cover after Connections are Made Exceeding 480 V RMS RISK OF DAMAGE TO THE ADJUSTABLE Enclosure FREQUENCY DRIVE WITH RFI FILTER INSTALLED Type IP20 IP21 IP55 IP66 When installed on a delta-grounded grid or an IT grid (including ground fault condition), line input voltage in the range of 380–500 V (T4,T5) must not exceed 480 V RMS between line power and ground.
Page 132 Electrical Installation Design Guide Figure 9.17 Support Plate Figure 9.19 Mounting Line Power Plug and Tightening Wires Figure 9.20 Tighten Support Bracket Figure 9.18 Tightening the Ground Cable Rev. 2014-04-04 All rights reserved. MG33BF22...
Page 133 Electrical Installation Design Guide AC line input connector enclosures A4/A5 Figure 9.21 Connecting to Line Power and Grounding without Disconnector Figure 9.23 AC Line Input Connection Enclosures B1 and B2 Figure 9.22 Connecting to Line Power and Grounding with Disconnector adjustable frequency driveWhen disconnector is used (enclosures A4/A5), mount the PE on the left side of the adjustable frequency drive.
Page 134 Electrical Installation Design Guide Figure 9.25 AC Line Input Connection Enclosure B4 Figure 9.26 AC Line Input Connection Enclosures C1 and C2 (IP21/NEMA Type 1 and IP55/66/NEMA Type 12). Rev. 2014-04-04 All rights reserved. MG33BF22...
Page 135 The recommendations given do not cover branch circuit Figure 9.27 AC Line Input Connection Enclosures C3 (IP20). protection for UL. Short-circuit protection Danfoss recommends using the fuses/circuit breakers mentioned below to protect service personnel and property in case of component breakdown in the adjustable frequency drive.
Page 136 Design Guide 9.3.1.3 CE Compliance Fuses or circuit breakers are mandatory to comply with IEC 60364. Danfoss recommend using a selection of the following. The fuses below are suitable for use on a circuit capable of delivering 100,000 A (symmetrical), 240 V, 500 V, 600 V, or 690 V depending on the adjustable frequency drive voltage rating.
Page 137 Electrical Installation Design Guide Enclosure Power (hp [kW]) Recommended Recommended Recommended circuit Max trip level [A] fuse size max. fuse breaker Moeller 0.37–1.5 gG-10 gG-25 PKZM0-10 0.37–4.0 gG-10 (0.37–3) gG-25 PKZM0-16 gG-16 (4) 7.5–10 [5.5–7.5] gG-16 gG-32 PKZM0-25 0.5–4 [0.37–4] gG-10 (0.37–3) gG-32 PKZM0-25...
Page 138 Electrical Installation Design Guide Enclosure Power (hp [kW]) Recommended Recommended Recommended circuit Max trip level [A] fuse size max. fuse breaker Moeller 1–5 [0.75–4.0] gG-10 gG-25 PKZM0-16 7.5–10 [5.5–7.5] gG-10 (5.5) gG-32 PKZM0-25 gG-16 (7.5) 1–10 [0.75–7.5] gG-10 (0.75–5.5) gG-32 PKZM0-25 gG-16 (7.5) 15–24 [11–18]...
Page 139 With the proper fusing, the adjustable frequency drive Short Circuit Current Rating (SCCR) is 100,000 A Fuses or circuit breakers are mandatory to comply with NEC 2009. Danfoss recommends using a selection of the following: Recommended max. fuse...
Page 140 Electrical Installation Design Guide Recommended max. fuse Ferraz- Bussmann Power Littelfuse Ferraz- Shawmut [kW] Type JFHR2 JFHR2 Shawmut J JFHR2 0.34–0.5 FWX-5 HSJ-6 [0.25–0.37] 0.75–1.5 FWX-10 HSJ-10 [0.55–1.1] 2 [1.5] FWX-15 HSJ-15 3 [2.2] FWX-20 HSJ-20 4 [3.0] FWX-25 HSJ-25 5 [3.7] FWX-30 HSJ-30...
Page 141 Electrical Installation Design Guide Recommended max. fuse Ferraz- Ferraz- Power SIBA Littelfuse Shawmut Shawmut [kW] Type RK1 Type RK1 Type CC Type RK1 0.5–1.5 5017906-006 KLS-R-6 ATM-R-6 A6K-6-R [0.37–1.1] 2–3 5017906-010 KLS-R-10 ATM-R-10 A6K-10-R [1.5–2.2] 4 [3] 5017906-016 KLS-R-15 ATM-R-15 A6K-15-R 5 [4] 5017906-020...
Page 142 Electrical Installation Design Guide Recommended max. fuse Power Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann [kW] Type RK1 Type J Type T Type CC Type CC Type CC 1–1.5 KTS-R-5 JKS-5 JJS-6 FNQ-R-5 KTK-R-5 LP-CC-5 [0.75–1.1] 2–3 KTS-R-10 JKS-10 JJS-10 FNQ-R-10 KTK-R-10 LP-CC-10 [1.5–2.2]...
Page 143 Electrical Installation Design Guide Recommended max. fuse Power Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann [kW] Type RK1 Type J Type T Type CC Type CC Type CC (hp [kW]) 1.5 [1.1] KTS-R-5 JKS-5 JJS-6 FNQ-R-5 KTK-R-5 LP-CC-5 2–3 KTS-R-10 JKS-10 JJS-10 FNQ-R-10 KTK-R-10...
Page 144 Electrical Installation Design Guide NOTICE! 9.4 Motor Connection In motors without phase insulation paper or other WARNING insulation reinforcement suitable for operation with voltage supply (such as an adjustable frequency drive), INDUCED VOLTAGE fit a sine-wave filter on the output of the adjustable Induced voltage from output motor cables that run frequency drive.
Page 145 Electrical Installation Design Guide Insert plug connectors 96 (U), 97 (V), 98 (W) (up to 10 hp [7.5 kW]) and motor cable to terminals labeled MOTOR. Fasten shielded cable to the decoupling plate with screws and washers from the accessory bag. All types of three-phase asynchronous standard motors can be connected to the adjustable frequency drive.
Page 146 Electrical Installation Design Guide Figure 9.35 Motor Connection Enclosures C1 and C2 (IP21/ NEMA Type 1 and IP55/66/NEMA Type 12) Figure 9.33 Motor Connection for Enclosure B3 Figure 9.36 Motor Connection for Enclosures C3 and C4 9.5 Ground Leakage Current Protection Follow national and local codes regarding protective grounding of equipment with a leakage current >...
Page 147 Electrical Installation Design Guide See EN/IEC61800-5-1 and EN50178 for further information. Leakage current 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 as they are capable of detecting AC and DC currents •...
Page 148 Electrical Installation Design Guide Leakage current [mA] 100 Hz 2 kHz 100 kHz Figure 9.41 Relay Outputs 1 and 2 To set the relay output, see parameter group 5-4* Relays. 01-02 make (normally open) 01-03 break (normally closed) 04-05 make (normally open) 04-06 break (normally closed) Figure 9.40 The Influence of the Cut-off Frequency of the RCD...
Page 149 Electrical Installation Design Guide 9.6.2 Disconnectors and Contactors Assembling of IP55/NEMA Type 12 (enclosure type A5) with line power disconnector. Line power switch is placed on left side on enclosure types B1, B2, C1 and C2. Line power switch on A5 enclosures is placed on right side.
Page 150 Electrical Installation Design Guide 9.6.4 Brake Resistor The connection cable to the brake resistor must be shielded and the max. length from adjustable frequency drive to the DC bar is limited to 82 feet [25 m]. Connect the shield by means of cable clamps to the conductive backplate on the adjustable frequency drive and to the metal cabinet of the brake resistor.
Page 151 Figure 9.48 USB Connection adjustable frequency drives with additional harmonic reduction devices, such as Danfoss AHF filters and 12–18- pulse rectifiers, can be calculated. 9.6.5.1 MCT 10 MCT 31 can also be downloaded from www.danfoss.com/ BusinessAreas/DrivesSolutions/Softwaredownload/.
Page 152 Electrical Installation Design Guide 9.7.2 Connection of Multiple Motors 9.7 Additional Motor Information 9.7.1 Motor Cable NOTICE! Problems may arise at start and at low RPM values if All types of three-phase asynchronous standard motors can motor sizes are widely different because small motors' be used with an adjustable frequency drive unit.
Page 153 Electrical Installation Design Guide Figure 9.50 Common Joint Connection for Short Cable Lengths Figure 9.53 Parallel Cables with Load Figure 9.51 Common Joint Connection for Long Cable Lengths Figure 9.54 LC Filter for Long Parallel Cables Figure 9.52 Parallel Cables without Load MG33BF22 Rev.
Page 154 Electrical Installation Design Guide Figure 9.55 Long Cables in Series Connection Enclosure types Power Size (hp Voltage [V] 1 cable (ft [m]) 2 cables (ft [m]) 3 cables (ft [m]) 4 cables (ft [m]) [kW]) 0.5–1 500 [150] 145 [45] 26 [8] 20 [6] A1, A2, A4, A5...
Page 155 Electrical Installation Design Guide 9.8 Safety 9.8.1 High Voltage Test Carry out a high voltage test by short-circuiting terminals U, V, W, L and L . Energize maximum 2.15 kV DC for 380–500 V adjustable frequency drives and 2.525 kV DC for 525–690 V adjustable frequency drives for one second between this short-circuit and the chassis.
Page 156 Application Examples Design Guide 10 Application Examples 10.1 Commonly Used Applications Parameters Function Setting The examples in this section are intended as a quick 1-29 Automatic [1] Enable +24 V reference for common applications. Motor complete +24 V Adaptation D IN •...
Page 157 Application Examples Design Guide Parameters Speed Function Setting 6-12 Terminal 53 4 mA* +24 V Low Current +24 V D IN 6-13 Terminal 53 20 mA* D IN High Current 6-14 Terminal 53 0 RPM Start (18) D IN Low Ref./Feedb. Figure 10.1 Start/Stop with Safe Torque Off D IN Value...
Page 158 Application Examples Design Guide Parameters Parameters Function Setting Function Setting 5-10 Terminal 18 [8] Start 6-10 Terminal 53 0.07 V* +24 V +24 V Digital Input Low Voltage +24 V +24 V 5-11 Terminal 19 [10] 6-11 Terminal 53 10 V* D IN D IN Digital Input...
Page 159 Application Examples Design Guide Parameters Function Setting 1-90 Motor +24 V S p e e d Thermal Thermistor +24 V R e f e r e n c e Protection trip D IN 1-93 Thermistor [1] Analog D IN Source input 53 S t a r t ( 1 8 ) D IN...
Page 160 Application Examples Design Guide Parameters Parameters Function Setting Function Setting 4-30 Motor [1] Warning 1-00 Configu- [0] Speed +24 V +24 V Feedback Loss ration Mode open-loop +24 V +24 V Function 1-01 Motor [1] VVC plus D IN D IN 4-31 Motor 100 RPM Control Principle...
Page 161 Application Examples Design Guide 10.1.1 Closed-loop Drive System 10.1.2 Programming of Torque Limit and Stop An adjustable frequency drive system consist usually of more elements such as In applications with an external electro-mechanical brake, • Motor such as hoisting applications, it is possible to stop the adjustable frequency drive via a 'standard' stop command •...
Page 162 Application Examples Design Guide 10.1.3 Programming of Speed Control The required motor speed is set via a potentiometer connected to terminal 53. The speed range is 0 to 1,500 RPM corresponding to 0 to 10 V over the potenti- ometer. Starting and stopping is controlled by a switch connected to terminal 18.
Page 163 Application Examples Design Guide Application Example Parameters Function Setting 7-00 Speed PID [2] MCB 102 +24 V Feedback Source +24 V 17-11 Resolution 1024* D IN D IN (PPR) 13-00 SL [1] On D IN Controller Mode D IN 13-01 Start [19] Warning D IN Event...
Page 164 Options and Accessories Design Guide 11 Options and Accessories 11.2.1.1 Galvanic Isolation in MCB 101 11.1 Communication Options • ® PROFIBUS DP V1 MCA 101 Digital/analog inputs are galvanically isolated from other • inputs/outputs on the MCB 101 and in the control card of ®...
Page 165 Options and Accessories Design Guide Digital input - terminal X30/1-4 Number of digital inputs Terminal number X30.2, X30.3, X30.4 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic'0' PNP (GND = 0 V) < 5 V DC Voltage level, logic'1' PNP (GND = 0 V) >...
Page 166 Options and Accessories Design Guide NOTICE! 11.2.2 VLT ® Encoder Option MCB 102 The LEDs are only visible when removing the LCP. Reaction in case of an encoder error can be selected in The encoder module can be used as feedback source for 17-61 Feedback Signal Monitoring: [0] Disabled, [1] closed-loop flux control (1-02 Flux Motor Feedback Source) Warning or [2] Trip.
Page 167 Options and Accessories Design Guide Connector Incremental SinCos Encoder EnDat Encoder SSI Encoder Description Designation Encoder (refer to ® Hiperface Figure 11.3) (refer to Figure 11.4) 24 V* 24 V output (21–25 V, I :125 mA) 8 VCC 8 V Output (7–12 V, I : 200 mA) 5 VCC 5 VCC...
Page 168 Options and Accessories Design Guide Resolver Poles 17-50 Poles: 2 *2 Resolver Input 17-51 Input Voltage: 2.0–8.0 V *7.0 V Voltage Resolver Input 17-52 Input Frequency: 2–15 kHz Frequency *10.0 kHz Transformation ratio 17-53 Transformation Ratio: 0.1–1.1 *0.5 Secondary input Max 4 Vrms voltage Secondary load...
Page 169 Options and Accessories Design Guide Figure 11.7 Permanent Magnet (PM) Motor with Resolver as Speed Feedback Set-up example In this example, a permanent magnet (PM) motor is used with resolver as speed feedback. A PM motor must usually operate in flux mode. Wiring The max cable length is 500 ft [150 m] when a twisted-pair cable is used.
Page 170 Options and Accessories Design Guide 1-00 Configuration Mode [1] Speed closed-loop 1-01 Motor Control Principle [3] Flux with feedback 1-10 Motor Construction [1] PM, non-salient SPM 1-24 Motor Current Nameplate 1-25 Motor Nominal Speed Nameplate 1-26 Motor Cont. Rated Torque Nameplate AMA is not possible on PM motors 1-30 Stator Resistance (Rs)
Page 171 Options and Accessories Design Guide How to add the Relay Card MCB 105 Option: Disconnect power to the adjustable frequency drive. Disconnect power to the live part connections on relay terminals. Remove the LCP, the terminal cover and the LCP fixture from the adjustable frequency drive.
Page 172 Options and Accessories Design Guide ® 11.2.5 VLT Safe PLC Interface Option MCB The Safe PLC Interface Option MCB 108 is designed to be built-in between the Safe dual pole (plus/minus) on the Safe PLC and the Safe Stop input on FC 302. The Safe PLC interface allows the safe output on the Safe PLC to maintain the test pulses on the plus and minus output without impacting the sensor signal to safe stop T37.
Page 173 Options and Accessories Design Guide Input voltage (DC) 18–28 V DC Typical current input (DC) 60 mA Max. current input (DC) 110 mA DC Max. current inrush (DC) 500 mA DC Output voltage (DC) 20 V DC@Vin = 24 V Turn on delay 1 ms Turn off delay...
Page 174 Options and Accessories Design Guide ® 11.2.6 VLT PTC Thermistor Card MCB 112 ATEX Certification with FC 102, FC 202 and FC 302 The MCB 112 has been certified for ATEX, which means that the adjustable frequency drive with the MCB 112 can The MCB 112 option makes it possible to monitor the be used with motors in potentially explosive atmospheres.
Page 175 Options and Accessories Design Guide Electrical Data Resistor connection PTC compliant with DIN 44081 and DIN 44082. Number 1..6 resistors in series 3.3 Ω..3.65 Ω..3.85 Ω Shut-off value 1.7 Ω..1.8 Ω... 1.95 Ω Reset value ± 6 °C Trigger tolerance <...
Page 176 Options and Accessories Design Guide 13 14 X45/ X48/ X46/ Figure 11.17 Electrical Connections of MCB 113 ® MCB 113 can be connected to an external 24 V on X58/ to ensure galvanical isolation between the VLT AutomationDrive and the option card. If galvanical isolation is not needed, the option card can be supplied through internal 24 V from the adjustable frequency drive.
Page 177 Typical motors, designed with temperature sensors to protect bearings from being overloaded, are fitted with 3 PT100/1000 temperature sensors; one in front, one in the backend bearing, and one in the motor windings. The Danfoss Option MCB 114 supports 2- or 3-wire sensors with individual temperature limits for under/over temperature. An auto detection of sensor type PT100 or PT1000 takes place at power-up.
Page 178 ® The MCB 15x is built into a VLT AutomationDrive FC 302 and requires a signal from a sensor unit. A safe drive system from Danfoss consists of the following • ® Adjustable frequency drive, VLT AutomationDrive FC 302 •...
Page 179 Options and Accessories Design Guide The MCB 15x The safety control system • • activates safety functions activates the safety functions via inputs on the MCB 15x • monitors safe motion sequences • evaluates signals from safety devices, such as •...
Page 180 Options and Accessories Design Guide Technical Specifications MCB 150/MCB 151 Power consumption 2 W (equivalent power consumption related to VDD) Current consumption VCC (5 V) < 200 mA Current consumption VDD (24 V) < 30 mA (< 25 mA for MCB 150) Digital inputs Number of digital inputs 4 (2 x 2-channel Digital Safety Input)
Page 181 Options and Accessories Design Guide HTL encoder input (MCB 151) Number of encoder inputs 2 (2 x single ended inputs A; B) Encoder types HTL incremental encoders; HTL Proximity sensor Logic input Input voltage range 0 to 24 V DC Input voltage, logic '0' <...
Page 182 Options and Accessories Design Guide ® 11.2.10 VLT C Option Adapter MCF 106 The C Option Adapter MCF 106 makes it possible to add an additional B option to the adjustable frequency drive. One A and one B option can be installed in the standard A and B slots of the control card and up to two B options can be installed in the C Option Adapter.
Page 183 Options and Accessories Design Guide Terminal Overview Terminal number Descriptive Name Digital outputs Digital Output/Input Terminal number Descriptive Name Encoder 2 Digital Output/Input (Feedback) Digital Output +24 V Supply Digital Output +8 V Supply Digital Output +5 V Supply Digital Output Digital Output Digital Output A not...
Page 184 (between phases and ground). its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide variety of different resistors that Installed around the three motor phases (U, V, W), the are specially designed to our adjustable frequency drives.
Page 185 Options and Accessories Design Guide 11.4.6 IP21/Type 1 Enclosure Kit IP20/IP4X top/TYPE 1 is an optional enclosure element available for IP20 compact units. If the enclosure kit is used, an IP20 unit is upgraded to comply with enclosure IP21/4X top/TYPE 1. The IP4X top can be applied to all standard IP20 FC 300 variants.
Page 186 Options and Accessories Design Guide Height A Width B Depth C* Enclosure type (in [mm]) (in [mm]) (in [mm]) 14.65 [372] 3.54 [90] 8.07 [205] 14.65 [372] 5.12 [130] 8.07 [205] 18.70 [475] 6.50 [165] 9.8 [249] 26.38 [670] 10.04 [255] 9.69 [246] 29.72 [755] 12.95 [329]...
Page 187 Options and Accessories Design Guide NOTICE! Side-by-side installation is not possible when using the IP21/IP4X/TYPE 1 Enclosure Kit. 11.4.7 Remote Mounting Kit for LCP The LCP can be moved to the front of a cabinet by using the remote built-in kit. The enclosure is the IP66. The fastening screws must be tightened with a torque of max.
Page 188 Options and Accessories Design Guide Step 2 Figure 11.30 LCP Kit with Graphical LCP, Fasteners, 10 ft [3 m] Cable and Gasket, for US only Figure 11.32 Upper Bracket 11.4.8 Mounting Bracket for Enclosure Types A5, B1, B2, C1 and C2 Measure distance A or B, and position the upper bracket, Step 1 but do not tighten it.
Page 189 Options and Accessories Design Guide Step 3 Step 4 Figure 11.34 Tightening of Screws Figure 11.33 Positioning Now tighten the screws. For extra security, drill and mount screws in all holes. Place the adjustable frequency drive in the lower bracket, and lift the upper one.
Page 190 RS-485 Installation and Set... Design Guide 12 RS-485 Installation and Set-up 12.1 Installation and Set-up 12.1.1 Overview RS-485 is a two-wire bus interface compatible with multi-drop network topology, that is, nodes can be connected as a bus, or via drop cables from a common trunk line. A total of 32 nodes can be connected to one network segment. Repeaters divide network segments, see Figure 12.1.
Page 191 RS-485 Installation and Set... Design Guide 12.2 Network Connection 12.3 Bus Termination One or more adjustable frequency drives can be connected The RS-485 bus must be terminated by a resistor network to a control (or master) using the RS-485 standardized at both ends.
Page 192 12.7 FC Protocol Message Framing Structure The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss standard serial communication bus. It 12.7.1 Content of a Character (byte) defines an access technique according to the master- follower principle for communications via a serial bus.
Page 193 RS-485 Installation and Set... Design Guide 12.7.3 Message Length (LGE) The message length is the number of data bytes plus the address byte ADR and the data control byte BCC. 4 data bytes LGE=4+1+1=6 bytes 12 data bytes LGE=12+1+1=14 bytes Messagescontaining texts +n bytes Table 12.3 Length of Messages...
Page 194 RS-485 Installation and Set... Design Guide 12.7.6 The Data Field The structure of data blocks depends on the type of message. There are three message types, and the type applies for both control messages (master⇒follower) and response messages (follower⇒master). The three types of message are: Process block (PCD) The PCD is made up of a data block of four bytes (two words) and contains: •...
Page 195 RS-485 Installation and Set... Design Guide 12.7.7 The PKE Field If the command cannot be performed, the follower sends this response: 0111 Command cannot be performed The PKE field contains two subfields: Parameter command - and issues the following fault report in the parameter and response AK, and parameter number PNU: value (PWE): high...
Page 196 RS-485 Installation and Set... Design Guide 12.7.10 Parameter Value (PWE) 12.7.11 Supported Data Types The parameter value block consists of two words (four Unsigned means that there is no operational sign in the bytes), and the value depends on the defined command message.
Page 197 RS-485 Installation and Set... Design Guide The message looks like this: Conversion index Conversion factor E19E 0000 H 0000 H 03E8 high 1000000 Figure 12.12 Write Data in EEPROM 100000 10000 1000 NOTICE! 4-14 Motor Speed High Limit [Hz] is a single word, and the parameter command for write in EEPROM is “E”.
Page 198 No responses are returned to broadcast queries from the master. The Modbus RTU protocol Danfoss assumes that the installed controller supports the establishes the format for the master’s query by providing interfaces in this document, and strictly observes all...
Page 199 RS-485 Installation and Set... Design Guide 12.11.2 Modbus RTU Message Structure 12.10 Network Configuration To enable Modbus RTU on the adjustable frequency drive, The transmitting device places a Modbus RTU message set the following parameters into a frame with a known beginning and ending point. This allows receiving devices to begin at the start of the Parameter Setting...
Page 200 RS-485 Installation and Set... Design Guide 12.11.4 Address Field 12.11.7 CRC Check Field The address field of a message frame contains 8 bits. Valid Messages include an error-checking field, operating based follower device addresses are in the range of 0–247 on a Cyclical Redundancy Check (CRC) method.
Page 201 RS-485 Installation and Set... Design Guide Coil number Description Signal direction 1-16 Adjustable frequency drive control word Master to follower 17-32 Adjustable frequency driver speed or setpoint reference Range 0x0–0xFFFF Master to follower (-200% ... ~200%) 33-48 Adjustable frequency drive status word (see Table 12.15) Follower to master 49-64 Open-loop mode: Adjustable frequency drive output frequency closed-loop...
Page 202 RS-485 Installation and Set... Design Guide 12.11.10 Function Codes Supported by Register Description Modbus RTU number 00001-00006 Reserved Modbus RTU supports use of the following function codes 00007 Last error code from an FC data object interface in the function field of a message. 00008 Reserved 00009...
Page 203 RS-485 Installation and Set... Design Guide 12.12.3 IND (Index) Code Name Meaning Illegal data The data address received in the query is address not an allowable address for the server Some parameters in the adjustable frequency drive are (or follower). More specifically, the array parameters, e.g., 3-10 Preset Reference.
Page 204 RS-485 Installation and Set... Design Guide NOTICE! 12.13 Danfoss FC Control Profile Make a selection in 8-56 Preset Reference Select to define 12.13.1 Control Word According to FC how Bit 00/01 gates with the corresponding function on Profile (8-10 Control Profile = FC the digital inputs.
Page 205 RS-485 Installation and Set... Design Guide 12.13.2 Status Word According to FC Bit 08, Jog Profile (STW) (8-10 Control Profile = Bit 08 = ’1’: The output frequency is determined by FC profile) 3-19 Jog Speed [RPM]. Bit 09, Selection of ramp 1/2 Follower-master Bit 09 = "0": Ramp 1 is active (3-41 Ramp 1 Ramp-up Time to 3-42 Ramp 1 Ramp-down Time).
Page 206 RS-485 Installation and Set... Design Guide Bit 03, No error/trip Bit 14, Torque OK/limit exceeded Bit 03 =’0’: The adjustable frequency drive is not in fault Bit 14 = ’0’: The motor current is lower than the torque mode. Bit 03 = ’1’: The adjustable frequency drive trips. To limit selected in 4-18 Current Limit.
Page 207 RS-485 Installation and Set... Design Guide NOTICE! 12.13.4 Control Word according to PROFIdrive Profile (CTW) The selection in 8-50 Coasting Select determines how bit 03 is linked with the corresponding function of the The control word is used to send commands from a master digital inputs.
Page 208 RS-485 Installation and Set... Design Guide 12.13.5 Status Word according to Bit 10, Data invalid/valid PROFIdrive Profile (STW) Is used to tell the adjustable frequency drive whether the control word is to be used or ignored. Bit 10=“0” causes the control word to be ignored, The status word is used to notify a master (for example, a Bit 10=“1”...
Page 209 RS-485 Installation and Set... Design Guide Bit 03, No error/Trip Bit 12, Drive OK/Stopped, autostart When bit 03="0", no error condition of the adjustable When bit 12="0", there is no temporary overloading of the frequency drive exists. inverter. When bit 03="1", the adjustable frequency drive has When bit 12="1", the inverter has stopped due to tripped and requires a reset signal before it can start.
Page 210 Index Design Guide Index Cooling....................50, 52 Cooling conditions................121 Abbreviations................... 9 DC brake....................202 Accessory bags..................97 DC bus connection................148 Acoustic noise................. 51, 90 DC link....................20, 61 Airflow...................... 52 Dead band....................35 AMA with T27 connected..............154 Decoupling plate................
Page 211 Index Design Guide Flux..................... 22, 23 MCT 31....................149 Freeze reference................... 33 Mechanical brake................. 45 Front cover tightening torque..........119, 120 Mechanical brake control..............158 Function code..................200 Mechanical dimensions............0 , 119 Fuse......................133 Mechanical mounting..............121 Message length (LGE)............... 191 Modbus exception code..............
Page 212 Index Design Guide Profibus....................96 Speed PID.................. 19, 21, 24 Programming of Torque Limit and Stop........159 Speed reference................ 154, 156 Protection....................61 Start/stop command................. 155 Protocol overview................190 Status word................. 203, 206 Pulse start/stop................... 155 Switching on the output..............40 Pulse width modulation..............
Page 214 Danfoss shall not be responsible for any errors in catalogs, brochures or other printed material. Danfoss reserves the right to alter its products at any time without notice, provided that alterations to products already on order shall not require material changes in specifications previously agreed upon by Danfoss and the Purchaser. All trademarks in this material are property of the respective companies.

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