Danfoss VLT AutomationDrive FC 302 Operating Instructions Manual
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Danfoss VLT AutomationDrive FC 302 Operating Instructions Manual

90–1200 kw
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See also: Programming Manual , Operating Instructions Manual
MAKING MODERN LIVING POSSIBLE
Operating Instructions
®
VLT
AutomationDrive FC 302
90–1200 kW
www.danfoss.com/drives

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Summary of Contents for Danfoss VLT AutomationDrive FC 302

  • Page 1 MAKING MODERN LIVING POSSIBLE Operating Instructions ® AutomationDrive FC 302 90–1200 kW www.danfoss.com/drives...

  • Page 3: Table Of Contents

    ® Contents Automation Drive FC 300 Operating Instructions Contents 1 Introduction 1.1 How to Read these Operating Instructions 1.1.1 Approvals 2 Safety Instructions and General Warning 2.1 Safety Regulations 2.1.1 Disposal Instruction 2.1.2 Caution 2.1.3 Software Version 2.1.4 High Voltage 2.1.5 Safety Instructions 2.1.6 General Warning 2.1.7 Before Commencing Repair Work...
  • Page 4 ® Contents Automation Drive FC 300 Operating Instructions 3.3.5 Outside Installation/NEMA 3R Kit for Rittal Enclosures 3.3.6 Outside Installation/NEMA 3R Kit of Industrial Enclosures 3.3.7 Installation of IP00 to IP20 Kits 3.3.8 Installation of IP00s D3, D4, & E2 Cable Clamp Bracket 3.3.9 Installation on Pedestal 3.3.10 Installation of Mains Shield for Frequency Converters 3.3.11 Installation of Input Plate Options...
  • Page 5 ® Contents Automation Drive FC 300 Operating Instructions 3.8 Additional Connections 3.8.1 Mechanical Brake Control 3.8.2 Parallel Connection of Motors 3.8.3 Motor Thermal Protection 4 How to Programme 4.1 The Graphical and Numerical LCP 4.1.1 How to Programme on the Numerical Local Control Panel 4.1.2 Initial Commissioning 4.2 Quick Setup 4.3 Parameter Menu Structure...

  • Page 6: Introduction

    1.1 How to Read these Operating controlling, monitoring and programming the frequency converter via a DeviceNet fieldbus. Instructions Danfoss technical literature is also available online at The frequency converter is designed to provide high shaft www.danfoss.com/drives. performance on electrical motors. Read this manual carefully for proper use.
  • Page 7 Introduction ® Automation Drive FC 300 Operating Instructions Conventions Meter Numbered lists indicate procedures. Milliampere Bullet lists indicate other information and description of Mille Circular Mil illustrations. Motion Control Tool Italicised text indicates Millihenry Inductance • Minute cross reference Millisecond •...

  • Page 8: Safety Instructions And General Warning

    WARNING WARNING Installation in high altitudes The frequency converter DC link capacitors remain 380-500 V: At altitudes above 3,000 m, contact Danfoss charged after power has been disconnected. To avoid regarding PELV. electrical shock hazard, disconnect the frequency 525-690 V: At altitudes above 2,000 m, contact Danfoss converter from the mains before carrying out regarding PELV.

  • Page 9: General Warning

    When using the frequency converter: wait at least 40 converter is required, refer to Safe Torque Off Operating minutes. ® Instructions for Danfoss VLT Frequency Converters for Shorter time is allowed only if indicated on the further information. nameplate for the specific unit.

  • Page 10: How To Install

    How to Install ® Automation Drive FC 300 Operating Instructions 3 How to Install 3.1 Pre-installation 3.1.1 Planning the Installation Site CAUTION Before performing the installation it is important to plan the installation of the frequency converter. Neglecting Illustration 3.1 Recommended Lifting Method, Enclosure Types this may result in extra work during and after instal- D and E lation.
  • Page 11 How to Install ® Automation Drive FC 300 Operating Instructions Illustration 3.3 Recommended Lifting Method, Enclosure Type Illustration 3.6 Recommended lifting method, Enclosure Type F2 (460 V, 1000 to 1200 HP, 575/690 V, 1250 to 1350 HP) Illustration 3.4 Recommended Lifting Method, Enclosure Type F3 (460 V, 600 to 900 HP, 575/690 V, 900 to 1150 HP) Illustration 3.7 Recommended lifting method, Enclosure Type F9/F10...
  • Page 12 How to Install ® Automation Drive FC 300 Operating Instructions Illustration 3.8 Recommended lifting method, Enclosure Type F11/F12/F13/F14 NOTICE The plinth is provided in the same packaging as the frequency converter but is not attached to enclosure types F1-F4 during shipment. The plinth is required to allow airflow to the frequency converter to provide proper cooling.

  • Page 13: Mechanical Dimensions

    How to Install ® Automation Drive FC 300 Operating Instructions 3.1.5 Mechanical Dimensions MG33U402 - Rev. 2013-12-16...
  • Page 14 How to Install ® Automation Drive FC 300 Operating Instructions MG33U402 - Rev. 2013-12-16...
  • Page 15 How to Install ® Automation Drive FC 300 Operating Instructions MG33U402 - Rev. 2013-12-16...
  • Page 16 How to Install ® Automation Drive FC 300 Operating Instructions MG33U402 - Rev. 2013-12-16...
  • Page 17 How to Install ® Automation Drive FC 300 Operating Instructions MG33U402 - Rev. 2013-12-16...
  • Page 18 How to Install ® Automation Drive FC 300 Operating Instructions MG33U402 - Rev. 2013-12-16...
  • Page 19 How to Install ® Automation Drive FC 300 Operating Instructions Frame size 90-110 kW 132-200 kW 90-110 kW 132-200 kW (380-500 V) (380-500 V) (380-500 V) (380-500 V) 37-132 kW 160-315 kW 37-132 kW 160-315 kW (525-690 V) (525-690 V) (525-690 V) (525-690 V) NEMA...

  • Page 20: Rated Power

    How to Install ® Automation Drive FC 300 Operating Instructions 3.1.6 Rated Power Frame size Enclosure 21/54 21/54 protection NEMA Type 1/Type 12 Type 1/Type 12 Chassis Chassis 90-110 kW at 400 V 132-200 kW at 400 V 90-110 kW at 400 V 132-200 kW at 400 V High overload rated (380-500 V)

  • Page 21: Mechanical Installation

    How to Install ® Automation Drive FC 300 Operating Instructions 3.2 Mechanical Installation Preparation of the mechanical installation of the frequency converter must be done carefully to ensure a proper result and to avoid additional work during installation. Start taking a close look at the mechanical drawings at the end (15.7) of this instruction to become familiar with the space demands.

  • Page 22: Terminal Locations - Enclosure Type D

    How to Install ® Automation Drive FC 300 Operating Instructions 2x579 (22.8) (22.8) (24.6) Illustration 3.14 Space in Front of IP21/IP54 Rated Enclosure Type F4 3.2.3 Terminal Locations - Enclosure Type D Consider the following terminal positions when designing for cables access. R/12 91 S/L2 92 T/L3 93...
  • Page 23 How to Install ® Automation Drive FC 300 Operating Instructions R/L1 S/L2 T/L3 U/T1 96 V/T2 97 W/T398 (0,) (0,) (0,) Illustration 3.16 Position of Power Connections with Disconnect Switch, Enclosure Types D1 and D2 Be aware that the power cables are heavy and hard to bend. Consider the optimum position of the frequency converter for ensuring easy installation of the cables.
  • Page 24 How to Install ® Automation Drive FC 300 Operating Instructions NOTICE All D enclosures are available with standard input terminals or disconnect switch. All terminal dimensions can be found in Table 3.5. IP21 (NEMA 1)/IP54 (NEMA 12) IP00/Chassis 277 (10.9) 379 (14.9) 119 (4.7) 122 (4.8)

  • Page 25: Terminal Locations - E Enclosures

    How to Install ® Automation Drive FC 300 Operating Instructions 3.2.4 Terminal Locations - E Enclosures Terminal Locations - E1 Take the following position of the terminals into consideration when designing the cable access. 492[19.4] 323[12.7] 0[0.0] 195[7.7] Illustration 3.17 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions MG33U402 - Rev.
  • Page 26 How to Install ® Automation Drive FC 300 Operating Instructions 19 Nm [14 FTa 453[17.8] 0[0.0] Illustration 3.18 IP21 (NEMA type 1) and IP54 (NEMA type 12) Enclosure Power Connection Positions (Detail B) MG33U402 - Rev. 2013-12-16...
  • Page 27 How to Install ® Automation Drive FC 300 Operating Instructions Illustration 3.19 IP21 (NEMA type 1) and IP54 (NEMA type 12) Enclosure Power Connection Position of Disconnect Switch Enclosure Unit type Dimensions [mm]/(inch) types IP54/IP21 UL AND NEMA1/NEMA12 250/315 kW (400 V) AND 355/450-500/630 396 (15.6) 267 (10.5) 332 (13.1)
  • Page 28 How to Install ® Automation Drive FC 300 Operating Instructions Terminal locations - enclosure type E2 Take the following position of the terminals into consideration when designing the cable access. FASTENER TORQUE M8 9.6 Nm (7 FT-LB) FASTENER TORQUE M8 9.6 Nm (7 FT-LB) R/L1 91 S/L2 92 T/L3 93...
  • Page 29 How to Install ® Automation Drive FC 300 Operating Instructions Illustration 3.22 IP00 Enclosure Power Connections Positions of Disconnect Switch NOTICE The power cables are heavy and difficult to bend. Consider the optimum position of the frequency converter for ensuring easy installation of the cables. Each terminal allows use of up to 4 cables with cable lugs or use of standard box lug.

  • Page 30: Terminal Locations - Frame Size F

    How to Install ® Automation Drive FC 300 Operating Instructions NOTICE Power connections can be made to positions A or B Enclosure Unit type Dimensions [mm]/(inch) type IPOO/CHASSIS 250/315 kW (400 V) AND 355/450-500/630 396 (15.6) 268 (10.6) 333 (13.1) 398 (15.7) 221 (8.7) KW (690 V)
  • Page 31 How to Install ® Automation Drive FC 300 Operating Instructions DC ‘-’ 1739.1 805.0 765.0 1694.1 DC ‘+’ 1654.1 710.0 Illustration 3.25 Terminal Locations - Regen Terminals - F1 and Terminal locations - Frame size F2 and F4 308.3 [12.14] 253.1 [9.96] FASTENER TORQUE: MIO 19 Nm (14 FT -LB) FASTENER TORQUE: MIO 19 Nm (14 FT -LB)
  • Page 32 How to Install ® Automation Drive FC 300 Operating Instructions DC ‘-’ 1739.1 1203.2 1163.2 1694.1 DC ‘+’ 1654.1 1098.1 Illustration 3.27 Terminal Locations - Regen Terminals - F2 and Terminal locations - Rectifier (F1, F2, F3 and F4) CH22 CH22 CH22 CH22...
  • Page 33 How to Install ® Automation Drive FC 300 Operating Instructions Terminal locations - Options Cabinet (F3 and F4) 1031.4[40.61] 939.0[36.97] 134.6[5.30] 0.0[0.00] 0.0[1.75] 244.4[1.75] 244.4[9.62] Illustration 3.29 Terminal locations - Options Cabinet (Left side, front and right side view). The gland plate is 42 mm below .0 level. 1) Earth ground bar Terminal locations - Options Cabinet with circuit breaker/ molded case switch (F3 and F4) 532.9 [20.98]...

  • Page 34: Cooling And Airflow

    How to Install ® Automation Drive FC 300 Operating Instructions Power size 450 kW (480 V), 630-710 kW 34.9 86.9 122.2 174.2 (690 V) 500-800 kW (480 V), 46.3 98.3 119.0 171.0 800-1000 kW (690 V) Table 3.8 Dimension for Terminal 3.2.6 Cooling and Airflow and return the heat loses outside the facility thus reducing air-conditioning requirements.
  • Page 35 How to Install ® Automation Drive FC 300 Operating Instructions NOTICE The fan runs for the following reasons: • • DC Hold • Pre-Mag • DC Brake • 60% of nominal current is exceeded • Specific heatsink temperature exceeded (power size dependent).

  • Page 36: Installation On The Wall - Ip21 (Nema 1) And Ip54 (Nema 12) Units

    How to Install ® Automation Drive FC 300 Operating Instructions 3.2.7 Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units This only applies to enclosure types D1 and D2. It must be considered where to install the unit. Take the relevant points into consideration before selecting the final installation site: •...
  • Page 37 How to Install ® Automation Drive FC 300 Operating Instructions 655.9 25.825 994.3 [39.146] 37.7 460.0 [1.485] [18.110] 62.5 216.5 199.5 [8.524] [7.854] 535.0 202.8 [21.063] 281.8 258.2 130.0 [11.096] [10.167] 533.0 35.5 [20.984] [1.398] 36.2 594.8 98.6 [1.425] [23.417] 1727.8 [68.024] Illustration 3.38 Enclosure Type E1...

  • Page 38: Ip21 Drip Shield Installation (Enclosure Types D1 And D2)

    How to Install ® Automation Drive FC 300 Operating Instructions 3.2.9 IP21 Drip Shield Installation (Enclosure Types D1 and D2) To comply with the IP21 rating, a separate drip shield is to be installed as explained below: • Remove the 2 front screws •...

  • Page 39: Installation Of Top-Only Duct Cooling Kit

    How to Install ® Automation Drive FC 300 Operating Instructions 3.3.2 Installation of Top-only Duct Cooling supported along the mid-section of the panel. These duct work kits do not support the “in frame” mounting of the panel (see Rittal TS8 catalogue for details). The duct work cooling kits listed in Table 3.10 are suitable for use only This description is for the installation of the top section with IP00/Chassis frequency converters in Rittal TS8 IP 20...

  • Page 40: Installation Of Top And Bottom Covers

    How to Install ® Automation Drive FC 300 Operating Instructions additional losses generated from other If the frequency converter is the only heat components installed inside the enclosure. The generating component in the enclosure, the total required airflow must be calculated so that minimum airflow required at an ambient temperature of 45 °C for the D3 and D4 frame the appropriate fans can be selected.

  • Page 41: Outside Installation/Nema 3R Kit Of Industrial Enclosures

    How to Install ® Automation Drive FC 300 Operating Instructions enclosure that provides a greater degree of protection Note: The current rating of D3 and D4 frame frequency against weather and hosed water. converters are de-rated by 3% when installed in a NEMA- The minimum enclosure depth is 500 mm (600 mm for 3R enclosure.

  • Page 42: Installation Of Mains Shield For Frequency Converters

    How to Install ® Automation Drive FC 300 Operating Instructions the frequency converter via the door fan and to maintain the IP21/NEMA 1 or IP54/NEMA 12 degrees of enclosure protections. Illustration 3.47 Mounting of Frequency Converter to Pedestal NOTICE See the Pedestal Kit Instruction Manual, for further information.

  • Page 43: Installation Of D Or E Loadshare Option

    How to Install ® Automation Drive FC 300 Operating Instructions NOTICE Where RFI filters are available, there are 2 different type of RFI filters depending on the input plate combination and the RFI filters interchangeable. Field installable kits in certain cases are the same for all voltages. 380-480 V Fuses Disconnect Fuses...
  • Page 44 How to Install ® Automation Drive FC 300 Operating Instructions • Transformer Tap Setup Integrated into the frequency converter’s safe- If the cabinet light & outlet and/or the space heaters & stop circuit thermostat are installed Transformer T1 requires it taps to •...

  • Page 45: Electrical Installation

    How to Install ® Automation Drive FC 300 Operating Instructions External Temperature Monitoring Designed for monitoring temperatures of external system components, such as the motor windings and/or bearings. 3 Phase 91 (L1) Includes five universal input modules. The modules are power integrated into the frequency converter’s safe-stop circuit 92 (L2)
  • Page 46 How to Install ® Automation Drive FC 300 Operating Instructions Term. 96 97 98 99 W PE Motor voltage 0-100% of mains voltage. 3 wires out of motor U1 V1 W1 Delta-connected U2 V2 6 wires out of motor U1 V1 W1 PE Star-connected U2, V2, W2 U2, V2 and W2 to be intercon- nected separately.
  • Page 47 How to Install ® Automation Drive FC 300 Operating Instructions Illustration 3.50 Compact IP21 (NEMA 1) and IP54 (NEMA 12), Illustration 3.51 Compact IP21 (NEMA 1) and IP54 (NEMA 12) Enclosure Type D1 with Disconnect, Fuse and RFI Filter, Enclosure Type D2 AUX Relay Brake Temp Switch...
  • Page 48 How to Install ® Automation Drive FC 300 Operating Instructions Illustration 3.52 Compact IP00 (Chassis), Enclosure Type D3 Illustration 3.53 Compact IP00 (Chassis) with Disconnect, Fuse and RFI Filter, Enclosure Type D4 AUX Relay Load sharing Fan Fuse (see fuse tables for part number) Mains ground Motor...
  • Page 49 How to Install ® Automation Drive FC 300 Operating Instructions EARTH TERMINALS Illustration 3.54 Position of Earth Terminals IP00, Enclosure Type D EARTH TERMINALS Illustration 3.55 Position of Earth Terminals IP21 (NEMA type 1) and IP54 (NEMA type 12) NOTICE D2 and D4 shown as examples.
  • Page 50 How to Install ® Automation Drive FC 300 Operating Instructions Illustration 3.56 Compact IP21 (NEMA 1) and IP54 (NEMA 12) Enclosure Type E1 Illustration 3.57 Compact IP00 (Chassis) with Disconnect, Fuse and RFI Filter, Enclosure Type E2 AUX Relay Load sharing Temp Switch SMPS Fuse (see fuse tables for part number) Fan Fuse (see fuse tables for part number)
  • Page 51 How to Install ® Automation Drive FC 300 Operating Instructions Earth Terminals Illustration 3.58 Position of Earth Terminals IP00, Enclosure Type E MG33U402 - Rev. 2013-12-16...
  • Page 52 How to Install ® Automation Drive FC 300 Operating Instructions FUSE ONNECT CH22 CH22 CH22 CH22 CH22 CH22 CTI25MB CTI25MB FASTENER TORQUE: M10 19Nm (14 FT -LB) FASTENER TORQUE: M10 19Nm (14 FT -LB) +DC 89 +DC 89 24 V DC, 5 A Loadsharing T1 Output Taps Temp Switch...
  • Page 53 How to Install ® Automation Drive FC 300 Operating Instructions 4, 8, 9 External Temperature Monitoring Motor AUX Relay NAMUR NAMUR Fuse. See fuse tables for part numbers AUX Fan Fan Fuses. See fuse tables for part numbers 101 102 103 SMPS Fuses.
  • Page 54 How to Install ® Automation Drive FC 300 Operating Instructions 4, 8, 9 FASTENER TORQUE: M10 19 Nm (14 FT-LB) FASTENER TORQUE: M10 19 Nm (14 FT-LB) FASTENER TORQUE: M10 19 Nm (14 FT-LB) U/T1 96 V/T2 97 W/T3 98 U/T1 96 V/T2 97 W/T3 98...
  • Page 55 How to Install ® Automation Drive FC 300 Operating Instructions Pilz Relay Terminal Safety Relay Coil Fuse with PILZ Relay RCD or IRM Terminal See fuse tables for part numbers Mains Line Fuses, F3 and F4 (3 pieces) See fuse tables for part numbers Contactor Relay Coil (230 VAC).

  • Page 56: Grounding

    How to Install ® Automation Drive FC 300 Operating Instructions 3.5.2 Grounding In OFF, the internal RFI capacities (filter capacitors) between the chassis and the intermediate circuit are cut off to avoid damage to the intermediate circuit and to The following basic issues need to be considered when reduce the earth capacity currents (according to IEC installing a frequency converter, so as to obtain electro- 61800-3).

  • Page 57: Shielded Cables

    The direction of rotation can be changed by switching 2 phases in the motor cable or by changing the setting of 4-10 Motor Speed Danfoss recommends to use shielded cables between the Direction. LCL filter and the AFE unit. Unshielded cables can be Motor rotation check can be performed using 1-28 Motor between transformer and LCL filter input side.

  • Page 58: Brake Cable For Frequency Converters With Factory Installed Brake Chopper Option

    How to Install ® Automation Drive FC 300 Operating Instructions 3.5.8 Brake Cable for Frequency Converters 3.5.10 Shielding against Electrical Noise with Factory Installed Brake Chopper Option Before mounting the mains power cable, mount the EMC metal cover to ensure best EMC performance. (Only standard with letter B in position 18 of typecode).

  • Page 59: External Fan Supply

    Automation Drive FC 300 Operating Instructions 3.5.12 External Fan Supply Non UL compliance If UL/cUL is not to be complied with, Danfoss recommends using the following fuses, which ensure compliance with In case the frequency converter is supplied by DC or if the...
  • Page 60 How to Install ® Automation Drive FC 300 Operating Instructions UL compliance Enclosure FC 300 power Recommended Recommended Recommended circuit Max trip level fuse size max. fuse breaker Size [kW] Moeller 0.25-1.5 gG-10 gG-25 PKZM0-16 0.25-2.2 gG-10 (0.25-1.5) gG-25 PKZM0-25 gG-16 (2.2) 3.0-3.7 gG-16 (3)
  • Page 61 How to Install ® Automation Drive FC 300 Operating Instructions Enclosure FC 300 power Recommended Recommended Recommended circuit Max trip level fuse size Max. fuse breaker Size [kW] Moeller 0.37-1.5 gG-10 gG-25 PKZM0-16 0.37-4.0 gG-10 (0.37-3) gG-25 PKZM0-25 gG-16 (4) 5.5-7.5 gG-16 gG-32...
  • Page 62 How to Install ® Automation Drive FC 300 Operating Instructions Enclosure FC 300 power Recommended Recommended Recommended circuit Max trip level fuse size Max. fuse breaker Size [kW] Moeller 0-75-4.0 gG-10 gG-25 PKZM0-25 5.5-7.5 gG-10 (5.5) gG-32 PKZM0-25 gG-16 (7.5) 11-15 gG-25 (11) gG-63...
  • Page 63 How to Install ® Automation Drive FC 300 Operating Instructions Enclosure Power [kW] Recommended Recommended Recommended circuit Max trip level [A] fuse size Max. fuse breaker Moeller 1.1-7.5 gG-6 (3) gG-25 gG-10 (2) gG-16 (2) 22-30 gG-25 (11) gG-63 gG-32 (15) gG-32 (18) gG-40 (22) 75-90...
  • Page 64 Automation Drive FC 300 Operating Instructions UL Compliance Fuses or circuit breakers are mandatory to comply with NEC 2009. Danfoss recommends 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, or 480 V, or 500 V, or 600 V depending on the frequency converter voltage rating.
  • Page 65 How to Install ® Automation Drive FC 300 Operating Instructions Recommended max. fuse FC 300 Ferraz- Ferraz- Bussmann Littel fuse Power Shawmut Shawmut [kW] JFHR2 Type JFHR2 JFHR2 0.25-0.37 FWX-5 HSJ-6 0.55-1.1 FWX-10 HSJ-10 FWX-15 HSJ-15 FWX-20 HSJ-20 FWX-25 HSJ-25 FWX-30 HSJ-30 FWX-50...
  • Page 66 How to Install ® Automation Drive FC 300 Operating Instructions Recommended max. fuse FC 302 Ferraz- Ferraz- SIBA Littel fuse Power Shawmut Shawmut [kW] Type RK1 Type RK1 Type CC Type RK1 0.37-1.1 5017906-006 KLS-R-6 ATM-R-6 A6K-6-R 1.5-2.2 5017906-010 KLS-R-10 ATM-R-10 A6K-10-R 5017906-016...
  • Page 67 How to Install ® Automation Drive FC 300 Operating Instructions Recommended max. fuse FC 302 Bussmann Ferraz- Shawmut Ferraz- Shawmut Littel fuse Power [kW] JFHR2 JFHR2 JFHR2 0.37-1.1 FWH-6 HSJ-6 1.5-2.2 FWH-10 HSJ-10 FWH-15 HSJ-15 FWH-20 HSJ-20 FWH-25 HSJ-25 FWH-30 HSJ-30 FWH-40 HSJ-40...
  • Page 68 How to Install ® Automation Drive FC 300 Operating Instructions Recommended max. fuse FC 302 Ferraz- Ferraz- SIBA Littel fuse Power Shawmut Shawmut [kW] Type RK1 Type RK1 Type RK1 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 5017906-016 KLS-R-015 A6K-15-R...
  • Page 69 How to Install ® Automation Drive FC 300 Operating Instructions Recommended max. fuse Power Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann [kW] Type RK1 Type J Type T Type CC Type CC Type CC KTS-R-5 JKS-5 JJS-6 FNQ-R-5 KTK-R-5 LP-CC-5 1.5-2.2 KTS-R-10 JKS-10 JJS-10...
  • Page 70 How to Install ® Automation Drive FC 300 Operating Instructions Size/Type Bussmann PN* Rating Alternative Fuses 2.5-4.0 A Fuse P450-P800, 380-500 V LPJ-6 SP or SPI 6 A, 600V Any listed Class J Dual Element, Time Delay, 6 A P630-P1M2, 525-690 V LPJ-10 SP or SPI 10 A, 600V Any listed Class J Dual...

  • Page 71: Mains Disconnectors - Frame Size D, E And F

    How to Install ® Automation Drive FC 300 Operating Instructions 3.5.14 Mains Disconnectors - Frame Size D, E and F Frame size Power Type 380-500 V D1/D3 P90K-P110 ABB OT200U12-91 D2/D4 P132-P200 ABB OT400U12-91 E1/E2 P250 ABB OT600U03 E1/E2 P315-P400 ABB OT800U03 P450 Merlin Gerin NPJF36000S12AAYP...

  • Page 72: Motor Insulation

    How to Install ® Automation Drive FC 300 Operating Instructions 3.5.17 Motor Insulation Install a shaft grounding system or use an isolating coupling For motor cable lengths ≤ the maximum cable length Apply conductive lubrication listed in , the recommended motor insulation ratings are in Use minimum speed settings if possible Table 3.50.
  • Page 73 How to Install ® Automation Drive FC 300 Operating Instructions Illustration 3.67 Top Connection for Fieldbus. Illustration 3.65 Control Card Wiring Path for the D3. Control Card Wiring for the D1, D2, D4, E1 and E2 use the same Path Illustration 3.68 Illustration 3.66 Control Card Wiring Path for the F1/F3.

  • Page 74: Access To Control Terminals

    How to Install ® Automation Drive FC 300 Operating Instructions Installation of 24 V external DC Supply Torque: 0.5 - 0.6 Nm (5 in-lbs) Screw size: M3 Function 35 (-), 36 (+) 24 V external DC supply Table 3.52 Terminals for 24 V External DC Supply 24 V DC external supply can be used as low-voltage supply to the control card and any option cards installed.

  • Page 75: Electrical Installation, Control Cables

    *Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off ® Operating Instructions for Danfoss VLT Frequency Converters. Terminal 37 is not included in FC 301 (except enclosure type A1).
  • Page 76 How to Install ® Automation Drive FC 300 Operating Instructions CUSTOMER SUPPLIED 24V RET. CONTROL CARD PIN 20 REGEN (TERMINAL JUMPERED TOGETHER) TERMINALS CUSTOMER SUPPLIED 24V CUSTOMER SUPPLIED (TERMINAL JUMPERED TOGETHER) MCB 113 PIN X46/1 MCB 113 PIN X46/3 MCB 113 PIN X46/5 MCB 113 PIN X46/7 MCB 113 PIN X46/9 PILZ...

  • Page 77: Switches S201, S202, And S801

    How to Install ® Automation Drive FC 300 Operating Instructions NOTICE Very long control cables and analog signals may in rare cases and depending on installation result in 50/60 Hz Control cables must be screened/armoured. ground loops due to noise from mains supply cables. If this occurs, it may be necessary to break the screen or insert a 100 nF capacitor between screen and chassis.

  • Page 78: Connection Examples

    How to Install ® Automation Drive FC 300 Operating Instructions NOTICE When changing the function of S201, S202 or S801 be careful not to use force for the switch over. It is recommended to remove the LCP fixture (cradle) when operating the switches.

  • Page 79: Final Set-Up And Test

    How to Install ® Automation Drive FC 300 Operating Instructions 3.6.4 Potentiometer Reference Voltage reference via a potentiometer Reference Source 1 = [1] Analog input 53 (default) Terminal 53, Low Voltage = 0 V Terminal 53, High Voltage = 10 V Terminal 53, Low Ref./Feedback = 0 RPM Terminal 53, High Ref./Feedback = 1500 RPM Switch S201 = OFF (U)

  • Page 80: Additional Connections

    This number along with the description of motors must not exceed the rated output current I the alarm assists in troubleshooting. If contacting the frequency converter. Danfoss for service, make sure to mention number and alarm description. NOTICE Unsuccessful AMA is often caused by incorrectly...

  • Page 81: Motor Thermal Protection

    How to Install ® Automation Drive FC 300 Operating Instructions NOTICE 3.8.3 Motor Thermal Protection Installations with cables connected in a common joint as The electronic thermal relay in the frequency converter has in Illustration 3.85, is only recommended for short cable received UL-approval for single motor protection, when lengths.

  • Page 82: How To Programme

    How to Programme ® Automation Drive FC 300 Operating Instructions 4 How to Programme 4.1 The Graphical and Numerical LCP The easiest programming of the frequency converter is performed by the graphical LCP (LCP 102). Consult the frequency converter Design Guide, when using the Numeric Local Control Panel (LCP 101).

  • Page 83: How To Programme On The Numerical Local Control Panel

    How to Programme ® Automation Drive FC 300 Operating Instructions 4.1.1 How to Programme on the Numerical Local Control Panel The following instructions are valid for the numerical LCP (LCP 101): The control panel is divided into 4 functional groups: Numerical display.

  • Page 84: Initial Commissioning

    How to Programme ® Automation Drive FC 300 Operating Instructions 4.1.2 Initial Commissioning The easiest way of carrying out the initial commissioning is by pressing [Quick Menu] and following the quick set-up procedure using LCP 102 (read Table 4.1 from left to right). The example applies to open loop applications. Press Quick Q2 Quick Menu...

  • Page 85: Quick Setup

    How to Programme ® Automation Drive FC 300 Operating Instructions Another easy way of commissioning the frequency 0-01 Language converter is by using the Smart Application Setup (SAS), Option: Function: which can also be found under the Quick Menu. Follow [22] English US Part of Language package 4 the indications on the successive screens for setting up the...
  • Page 86 How to Programme ® Automation Drive FC 300 Operating Instructions 1-23 Motor Frequency 1-29 Automatic Motor Adaptation (AMA) Range: Function: Option: Function: Size [20 - Min - Max motor frequency: 20-1000 Hz. , the rotor leakage reactance X and the main reactance X related 1000...

  • Page 87: Parameter Menu Structure

    How to Programme ® Automation Drive FC 300 Operating Instructions 4.3 Parameter Menu Structure 3-02 Minimum Reference Range: Function: for [1] Speed closed loop, RPM; for [2] Torque, Nm. • The unit selected in 3-01 Reference/Feedback Unit. 3-03 Maximum Reference Range: Function: Size...
  • Page 88 How to Programme ® Automation Drive FC 300 Operating Instructions MG33U402 - Rev. 2013-12-16...
  • Page 89 How to Programme ® Automation Drive FC 300 Operating Instructions MG33U402 - Rev. 2013-12-16...
  • Page 90 How to Programme ® Automation Drive FC 300 Operating Instructions MG33U402 - Rev. 2013-12-16...
  • Page 91 How to Programme ® Automation Drive FC 300 Operating Instructions MG33U402 - Rev. 2013-12-16...

  • Page 92: General Specifications

    General Specifications ® Automation Drive FC 300 Operating Instructions 5 General Specifications Mains supply (L1, L2, L3): Supply voltage 380-500 V ±10% Supply voltage 525-690 V ±10% Mains voltage low/mains drop-out: During low mains voltage or a mains drop-out, the frequency converters continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the drive's lowest rated supply voltage.
  • Page 93 General Specifications ® Automation Drive FC 300 Operating Instructions Safe stop Terminal 37 (Terminal 37 is fixed PNP logic) Voltage level 0 - 24 V DC Voltage level, logic'0' PNP < 4 V DC Voltage level, logic'1' PNP >20 V DC Nominal input current at 24 V 50 mA rms Nominal input current at 20 V...
  • Page 94 General Specifications ® Automation Drive FC 300 Operating Instructions Pulse/encoder inputs Programmable pulse/encoder inputs Terminal number pulse/encoder , 33 / 32 , 33 Max. frequency at terminal 29, 32, 33 110 kHz (Push-pull driven) Max. frequency at terminal 29, 32, 33 5 kHz (open collector) Min.
  • Page 95 General Specifications ® Automation Drive FC 300 Operating Instructions Control card, USB serial communication: USB standard 1.1 (Full speed) USB plug USB type B plug Connection to PC is carried out via a standard host/device USB cable. The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB ground connection is not galvanically isolated from protection earth.
  • Page 96 General Specifications ® Automation Drive FC 300 Operating Instructions Surroundings Enclosure, frame size D and E IP 00/ Chassis, IP 21/ Type 1, IP 54/ Type 12 Enclosure, frame size F IP 21/ Type 1, IP 54/ Type 12 Vibration test 0.7 g Max.
  • Page 97 General Specifications ® Automation Drive FC 300 Operating Instructions Mains Supply 3 x 380 - 500 V AC FC 302 P90K P110 P132 P160 P200 High/ Normal Load* Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [hp] Typical Shaft output at 500 V [kW] Enclosure IP21...
  • Page 98 General Specifications ® Automation Drive FC 300 Operating Instructions Mains Supply 3 x 380 - 500 V AC FC 302 P250 P315 P355 P400 High/ Normal Load* Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [hp] Typical Shaft output at 500 V [kW]...
  • Page 99 General Specifications ® Automation Drive FC 300 Operating Instructions Mains Supply 3 x 380 - 500 V AC FC 302 P450 P500 P560 P630 P710 P800 High/ Normal Load* Typical Shaft output at 400 V [kW] 1000 Typical Shaft output at 460 V [hp] 1000 1000 1200...
  • Page 100 General Specifications ® Automation Drive FC 300 Operating Instructions Mains Supply 525-690 V AC FC 302 P37K P45K P55K P75K P90K High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [hp] Typical Shaft output at 690 V [kW] Enclosure IP21 Enclosure IP54...
  • Page 101 General Specifications ® Automation Drive FC 300 Operating Instructions Mains Supply 525-690 V AC FC 302 P110 P132 P160 P200 High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [hp] Typical Shaft output at 690 V [kW] Enclosure IP21 Enclosure IP54...
  • Page 102 General Specifications ® Automation Drive FC 300 Operating Instructions Mains Supply 525-690 V AC FC 302 P250 P315 P355 High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [hp] Typical Shaft output at 690 V [kW] Enclosure IP21 Enclosure IP54 Enclosure IP00...
  • Page 103 General Specifications ® Automation Drive FC 300 Operating Instructions Mains Supply 525-690 V AC FC 302 P400 P500 P560 High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [hp] Typical Shaft output at 690 V [kW] Enclosure IP21 Enclosure IP54 Enclosure IP00...
  • Page 104 General Specifications ® Automation Drive FC 300 Operating Instructions Mains Supply 525-690 V AC FC 302 P630 P710 P800 High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [hp] 1050 Typical Shaft output at 690 V [kW] Enclosure IP21, 54 without/ with options F1/ F3 F1/ F3...
  • Page 105 General Specifications ® Automation Drive FC 300 Operating Instructions Mains Supply 525-690 V AC FC 302 P900 P1M0 P1M2 High/ Normal Load* Typical Shaft output at 550 V [kW] 1000 1000 1100 Typical Shaft output at 575 V [hp] 1050 1150 1150 1350...
  • Page 106 General Specifications ® Automation Drive FC 300 Operating Instructions 1) For type of fuse see chapter 3.5.13 Fuses. 2) American Wire Gauge. 3) Measured using 5 m screened motor cables at rated load and rated frequency. 4) The typical power loss is at nominal load conditions and expected to be within +/-15% (tolerence relates to variety in voltage and cable conditions).

  • Page 107: Warnings And Alarms

    Warnings and Alarms ® Automation Drive FC 300 Operating Instructions 6 Warnings and Alarms 6.1 Status Messages If an alarm cannot be reset, the reason may be that its cause has not been rectified, or the alarm is trip-locked 6.1.1 Warnings/Alarm Messages (see also Table 6.1).
  • Page 108 Warnings and Alarms ® Automation Drive FC 300 Operating Instructions Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference Earth Fault Hardware mismatch Short Circuit Control word time-out 8-04 Control Word Timeout Function Start Failed 1-77 Compressor Start Max Speed [RPM] and 1-79 Compressor Start Max Time to Trip Temp.
  • Page 109 Warnings and Alarms ® Automation Drive FC 300 Operating Instructions Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference AMA time-out AMA internal fault Current limit External Interlock Feedback Error 4-30 Motor Feedback Loss Function Output Frequency at Maximum Limit Mechanical Brake Low 2-20 Release Brake Current Voltage Limit...

  • Page 110: Earth Fault

    Warnings and Alarms ® Automation Drive FC 300 Operating Instructions or connected parts. A Trip Lock situation can only be reset LED indication by a power cycling. Warning yellow Alarm flashing red Trip locked yellow and red Table 6.2 Alarm Word Alarm Word 2 Warning Word Warning...

  • Page 111: Mains Failure

    Warnings and Alarms ® Automation Drive FC 300 Operating Instructions Alarm Word Alarm Word 2 Warning Word Warning Extended Word 2 Status Word 00020000 131072 Internal Fault (A38) KTY error 10V Low (W1) KTY Warn Password Timelock number of allowed password trials exceeded - timelock active...
  • Page 112 Warnings and Alarms ® Automation Drive FC 300 Operating Instructions The warning/alarm information below defines each WARNING/ALARM 7, DC overvoltage warning/alarm condition, provides the probable cause for If the intermediate circuit voltage exceeds the limit, the the condition, and details a remedy or troubleshooting frequency converter trips after a time.
  • Page 113 54 and 55 • Record the value of the following parameters and contact If using a thermal switch or thermistor, check that the Danfoss supplier: the programming if 1-93 Thermistor Resource • matches sensor wiring 15-40 FC Type •...
  • Page 114 Warnings and Alarms ® Automation Drive FC 300 Operating Instructions WARNING If 8-04 Control Word Timeout Function is set to Stop and Trip, a warning appears and the frequency converter ramps There is a risk of substantial power being transmitted to down until it trips then displays an alarm.
  • Page 115 H081x: option in slot x has restarted. 2080-2088 H082x: option in slot x has issued a powerup-wait. Contact the Danfoss supplier or service department if 2096-2104 H983x: option in slot x has issued a legal required. Note the code number for further trouble- powerup-wait.

  • Page 116: Heatsink Sensor

    5126 Option in slot C1: Hardware incompatible with ALARM 50, AMA calibration failed control board hardware. Contact the Danfoss supplier or Danfoss Service 5376-6231 Out of memory. Department. ALARM 51, AMA check U and I Table 6.4 Code Numbers for Internal Faults...
  • Page 117 Warnings and Alarms ® Automation Drive FC 300 Operating Instructions WARNING 61, Tracking error ALARM 70, Illegal FC configuration An error has been detected between the calculated motor The control card and power card are incompatible. Contact speed and the speed measurement from the feedback the supplier with the type code of the unit from the device.
  • Page 118 Warnings and Alarms ® Automation Drive FC 300 Operating Instructions ALARM 243, Brake IGBT ALARM 247, Power card temperature This alarm is only for F Frame frequency converters. It is This alarm is only for F Frame frequency converter. It is equivalent to Alarm 27.

  • Page 119: Index

    ® Index Automation Drive FC 300 Operating Instructions Index Digital input....................111 Inputs:....................90 Output....................92 Abbreviations..................5 Disposal..................... 6 Access to Control Terminals............72 Drip Shield Installation..............36 Airflow...................... 32 Duct cooling....................32 Alarm work cooling kits................36 log....................... 116 Messages..................
  • Page 120 ® Index Automation Drive FC 300 Operating Instructions LCP......................80 Protection and Features..............94 LEDs....................80, 81 Pulse Start/Stop................... 76 Lifting......................8 Pulse/Encoder Inputs................ 92 Load Sharing..................56 Local Control Panel................81 Rated Power..................18 RCD (Residual Current Device)............42 Main reactance..................
  • Page 121 ® Index Automation Drive FC 300 Operating Instructions Unintended Start................... 7 Unpacking....................8 Voltage imbalance..................110 level....................... 90 reference via a potentiometer............ 77 VVCplus...................... 5 Warnings....................105 Wire access..................... 19 MG33U402 - Rev. 2013-12-16...
  • Page 122 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies.

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