Danfoss FC 301 Operating Manual

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Programming manual (722 pages)

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ENGINEERING TOMORROW

Operating Guide

VLT

AutomationDrive FC 301/302

0.25–75 kW

vlt-drives.danfoss.com

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Summary of Contents for Danfoss FC 301

Page 1 ENGINEERING TOMORROW Operating Guide ® AutomationDrive FC 301/302 0.25–75 kW vlt-drives.danfoss.com...
Page 3: Table Of Contents
5.2 Local Control Panel Operation 5.3 System Set-up 6 Basic I/O Configuration 7 Maintenance, Diagnostics, and Troubleshooting 7.1 Maintenance and Service 7.2 Warning and Alarm Types 7.3 List of Warnings and Alarms MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 4 8.6 Control Input/Output and Control Data 8.7 Fuses and Circuit Breakers 8.8 Connection Tightening Torques 8.9 Power Ratings, Weight, and Dimensions 9 Appendix 9.1 Symbols, Abbreviations, and Conventions 9.2 Parameter Menu Structure Index Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 5: Introduction
This manual is regularly reviewed and updated. All The output frequency of the frequency converter is suggestions for improvement are welcome. Table 1.1 shows limited to 590 Hz. the manual version and the corresponding software For demands exceeding 590 Hz, contact Danfoss. version. Edition Remarks Software version MG33ATxx Error correction.
Page 6 DIP switch for A53 and A54 Mains input terminals 91 (L1), 92 (L2), 93 (L3) Relay 1 (01, 02, 03) LCP connector Illustration 1.1 Exploded View Enclosure Size A, IP20 (left), and Enclosure Size C, IP55/IP66 (right) Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 7: Type Approvals And Certifications
Protection in the product-specific design guide. For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), refer to the section ADN-compliant Installation in the product-specific design guide. MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 8: Safety
• discharged. Before performing any service or repair work, use an appropriate voltage measuring device to make sure that there is no remaining voltage on the frequency converter. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 9 An internal failure in the frequency converter can result in serious injury when the frequency converter is not properly closed. • Ensure that all safety covers are in place and securely fastened before applying power. MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 10: Mechanical Installation
Output voltage, frequency, and current (at low/high voltages) Enclosure size and IP rating Maximum ambient temperature Certifications Discharge time (Warning) Illustration 3.1 Product Nameplate (Example) NOTICE Do not remove the nameplate from the frequency converter (loss of warranty). Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 11 If necessary, plan for a hoist, crane, or forklift with the appropriate rating to move the unit. • For lifting, use hoist rings on the unit, when provided. Illustration 3.3 Proper Mounting with Mounting Plate MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 12: Electrical Installation
• Power connection wire recommendation: Minimum 75 °C (167 °F) rated copper wire. See chapter 8.1 Electrical Data and chapter 8.5 Cable Specifi- cations for recommended wire sizes and types. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 13 Risk of burst transient when the ground potential between the frequency converter and the control system is different. Install equalizing cables between the system components. Recommended cable cross-section: 16 mm (6 AWG). MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 14: Wiring Schematic
1) Terminal 37 (optional) is used for Safe Torque Off (STO). For installation instructions, refer to the VLT Safe Torque Off Operating Guide. For FC 301, terminal 37 is only included in enclosure size A1. Relay 2 and terminal 29 have no function in FC 301.
Page 15 Mains supply. Brake resistor. Bare (unpainted) surface. Metal box. Star washers. Connection to motor. Brake cable (shielded). Motor. Motor cable (shielded). EMC cable gland. Illustration 4.3 Example of Proper EMC Installation MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 16: Motor Connection
96 (U), 97 (V), and 98 (W), see Illustration 4.4. Tighten the terminals in accordance with the information provided in chapter 8.8 Connection Tightening Torques. Illustration 4.5 Example of Motor, Mains, and Ground Wiring Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 17: Ac Mains Connection
• Select [32] Mechanical brake control in parameter group 5-4* Relays for applications with an electro- mechanical brake. MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 18: Installation Check List
POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE Risk of personal injury if the frequency converter is not properly closed. • Before applying power, ensure that all safety covers are in place and securely fastened. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 19: Commissioning
Inspect the frequency converter for loose connections on the terminals. Confirm that the supply voltage matches the voltage of the frequency converter and the motor. MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 20: Local Control Panel Operation
16 Main Menu Allows access to all programming parameters. 17 Alarm Log Shows a list of current warnings, the last 10 alarms, and the maintenance log. Illustration 5.1 Graphic Local Control Panel (GLCP) Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 21: System Set-Up
Parameter 1-23 Motor Frequency Parameter 1-24 Motor Current Parameter 1-25 Motor Nominal Speed Parameter 1-26 Motor Cont. Rated Torque Parameter 1-39 Motor Poles Table 5.1 Basic Parameters to be checked before AMA MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 22: Basic I/O Configuration
6.1.1 Motor Thermistor U - I CAUTION THERMISTOR INSULATION Risk of personal injury or equipment damage. • Table 6.1 Motor Thermistor Use only thermistors with reinforced or double insulation to meet PELV insulation requirements. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 23 *=Default Value Notes/comments: – Table 6.2 Mechanical Brake Control 1-76 Current Speed Time 1-71 2-21 1-71 2-21 Start (18) Start reversing (19) Relay output Open Closed Illustration 6.1 Mechanical Brake Control MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 24: Maintenance, Diagnostics, And Troubleshooting
Illustration 7.1 Alarm Example Alarms An alarm indicates a fault that requires immediate attention. The fault always triggers a trip or a trip lock. Reset the system after an alarm. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 25: List Of Warnings And Alarms
Perform an input voltage test. ® signals, terminal 55 common. VLT General • Perform a soft charge circuit test. Purpose I/O MCB 101 terminals 11 and 12 for ® signals, terminal 10 common. VLT Analog I/O MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 26 Check whether the thermistor is disconnected. Select converter. whether the frequency converter issues a warning or an • alarm in parameter 1-90 Motor Thermal Protection. Check that the motor data is correct in parameters 1-20 to 1-25. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 27 There is short-circuiting in the motor or motor wiring. timeout (parameter 2-23 Activate Brake Delay, Troubleshooting parameter 2-25 Brake Release Time). • Remove the power to the frequency converter and repair the short circuit. MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 28 Cycle power to the frequency converter and check that the fan operates briefly at start-up. • Check for proper fan operation. Use parameter group 43-**Unit Readouts to show the speed of each fan. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 29 Troubleshooting • Remove the power from the frequency converter and check motor phase V. ALARM 32, Motor phase W missing Motor phase W between the frequency converter and the motor is missing. MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 30 ® Maintenance, Diagnostics, a... AutomationDrive FC 301/302 It may be necessary to contact the Danfoss supplier or The signal from the IGBT thermal sensor is not available on service department. Note the code number for further the power card. The problem could be on the power card,...
Page 31 Set the tolerable feedback loss time in ALARM 50, AMA calibration failed parameter 4-32 Motor Feedback Loss Timeout. Contact the Danfoss supplier or Danfoss Service WARNING 62, Output frequency at maximum limit Department. If the output frequency reaches the value set in...
Page 32 The control card and power card are incompatible. To • Adjust the tracking error band in check compatibility, contact the Danfoss supplier with the parameter 4-35 Tracking Error and type code from the unit nameplate and the part numbers parameter 4-37 Tracking Error Ramping.
Page 33 (in a period of 600 s) below the allowed minimum frequency (parameter 1-98 ATEX ETR interpol. points freq.). WARNING 250, New spare part A component in the drive system has been replaced. MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 34: Specifications
Typical shaft output [kW/(hp)], high overload (0.34) (0.5) (0.75) (1.0) (1.5) (2.0) (3.0) (4.0) (5.0) Enclosure protection rating IP20 (FC 301 only) – – – Enclosure protection rating IP20, IP21 Enclosure protection rating IP55, IP66 A4/A5 A4/A5 A4/A5 A4/A5 A4/A5...
Page 35 (3/0, 2/0, 2/0) ] ([AWG]) MCM, 4/0) Estimated power loss at rated maximum load 1140 1143 1353 1400 1636 Efficiency 0.96 0.97 0.97 0.97 0.97 Table 8.3 Mains Supply 200–240 V, P15K–P37K MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 36: Mains Supply 380-500
] ([AWG]) Estimated power loss at rated maximum load 0.93 0.95 0.96 0.96 0.97 0.97 0.97 0.97 0.97 0.97 Efficiency Table 8.4 Mains Supply 380–500 V (FC 302), 380–480 V (FC 301), PK37–P7K5 Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 37 16, 10, 10 (6, 8, 8) disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load Efficiency 0.98 0.98 0.98 0.98 Table 8.5 Mains Supply 380–500 V (FC 302), 380–480 V (FC 301), P11K–P22K MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 38 Estimated power loss 1083 1022 1384 1232 1474 at rated maximum load [W] 0.98 0.98 0.98 0.98 0.99 Efficiency Table 8.6 Mains Supply 380–500 V (FC 302), 380–480 V (FC 301), P30K–P75K Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 39: Mains Supply 525-600 V (Fc 302 Only)
6, 4, 4 (10,12,12) ] ([AWG]) Estimated power loss at rated maximum load Efficiency 0.97 0.97 0.97 0.97 0.97 0.97 0.97 0.97 Table 8.7 Mains Supply 525–600 V (FC 302 only), PK75–P7K5 MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 40 (6, 8, 8) (1, 2, 2) disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.98 0.98 0.98 0.98 0.98 Table 8.8 Mains Supply 525–600 V (FC 302 only), P11K–P30K Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 41 LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-efficiency-directive/#/ 4) Efficiency measured at nominal current. For energy efficiency class, see chapter 8.4 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-efficiency-directive/#/. 5) Cable cross-section is regarded for copper cables. MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 42: Mains Supply 525-690 V (Fc 302 Only)
6, 4, 4 (10, 12, 12) ([AWG]) Estimated power loss at rated maximum load (W) Efficiency 0.96 0.96 0.96 0.96 0.96 0.96 0.96 Table 8.10 A3 Enclosure, Mains Supply 525–690 V IP20/Protected Chassis, P1K1–P7K5 Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 43 ] ([AWG]) Estimated power loss at rated maximum load (W) 0.98 0.98 0.98 0.98 Efficiency Table 8.11 B2/B4 Enclosure, Mains Supply 525–690 V IP20/IP21/IP55 - Chassis/NEMA 1/NEMA 12 (FC 302 only), P11K–P22K MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 44 LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy-efficiency-directive/#/ 4) Efficiency measured at nominal current. For energy efficiency class, see chapter 8.4 Ambient Conditions. For part load losses, see drives.danfoss.com/knowledge-center/energy-efficiency-directive/#/. 5) Cable cross-section is regarded for copper cables. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 45: Mains Supply
L1, L2, L3 Supply terminals (12-pulse) L1-1, L2-1, L3-1, L1-2, L2-2, L3-2 200–240 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 46: Ambient Conditions
8.5 Cable Specifications Cable lengths and cross-sections for control cables Maximum motor cable length, shielded FC 301: 50 m (164 ft)/FC 302: 150 m (492 ft) Maximum motor cable length, unshielded FC 301: 75 m (246 ft)/FC 302: 300 m (984 ft) Maximum cross-section to control terminals, flexible/rigid wire without cable end sleeves 1.5 mm...
Page 47 See parameter group 5-1* Digital Inputs in the programming guide. Maximum voltage on input 28 V DC Input resistance, R Approximately 4 kΩ Pulse input accuracy (0.1–1 kHz) Maximum error: 0.1% of full scale MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 48 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 protective earth. Use only an isolated laptop as PC connection to the USB connector on the frequency converter. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 49 Specifications Operating 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) Maximum terminal load (AC-1) on 1–3 (NC), 1–2 (NO) (resistive load) 240 V AC, 2 A Maximum terminal load (AC-15) (inductive load @ cosφ...
Page 50: Fuses And Circuit Breakers
37.0 (50.0) aR-200 aR-250 18.5 (25.0) gG-80 gG-150 NZMB2-A200 22.0 (30.0) aR-125 aR-160 30.0 (40.0) aR-160 aR-200 NZMB2-A250 37.0 (50.0) aR-200 aR-250 Table 8.13 200–240 V, Enclosure Sizes A, B, and C Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 51 NZMB2-A250 75.0 (100.0) aR-250 37.0 (50.0) gG-100 gG-150 NZMB2-A200 45.0 (60.0) gG-160 gG-160 55.0 (75.0) aR-200 aR-250 NZMB2-A250 75.0 (100.0) aR-250 Table 8.14 380–500 V, Enclosure Sizes A, B, and C MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 52 – – C2/C3 37.0 (50.0) gG-63 gG-100 – – 45.0 (60.0) gG-80 gG-125 55.0 (75.0) gG-100 gG-160 – – 75.0 (100.0) gG-125 Table 8.16 525–690 V, Enclosure Sizes A, B, and C Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 53 4) A50X fuses from Ferraz Shawmut may substitute A25X for 240 V converters. frequency converters. 2) FWH fuses from Bussmann may substitute FWX for 240 V frequency converters. 3) A6KR fuses from Ferraz Shawmut may substitute A2KR for 240 V frequency converters. MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 54 A50-P-225 L50-S-225 75.0 (100.0) 2028220-250 KLS-R-250 – A6K-250-R FWH-250 HSJ-250 A50-P-250 L50-S-250 Table 8.20 380–500 V, Enclosure Sizes A, B, and C 1) Ferraz Shawmut A50QS fuses may substitute for A50P fuses. Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 55 JKS-150 JJS-150 – – – 2028220-150 KLS-R-150 A6K-150-R HSJ-150 (75.0) 75.0 KTS-R-175 JKS-175 JJS-175 – – – 2028220-200 KLS-R-175 A6K-175-R HSJ-175 (100.0) Table 8.21 525–600 V, Enclosure Sizes A, B, and C MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 56 HST-100 55.0 (75.0) 125 A KTS-R-125 JKS-125 JJS-125 2028220-125 KLS-150 A6K-125-R HST-125 75.0 (100.0) 150 A KTS-R-150 JKS-150 JJS-150 2028220-150 KLS-175 A6K-150-R HST-150 Table 8.23 525–690 V, Enclosure Sizes B, and C Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 57: Connection Tightening Torques
24 (212) (over 95 mm 37–45 (50– 55–75 (75– 11–22 (15– (3 AWG)) 100) Load sharing, brake cables. 14 (124) Relay. 0.5–0.6 (4.4–5.3) Ground. 2–3 (17.7–26.6) Table 8.24 Tightening Torque for Cables MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 62 2.2 (19.5) 2 (17.7) 2 (17.7) – 1) See Illustration 8.2 and Illustration 8.3 for top and bottom mounting holes. Table 8.27 Power Ratings, Weight, and Dimensions, Enclosure Sizes C1–C4 and D3h Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 63 Specifications Operating Guide Illustration 8.2 Top and Bottom Mounting Holes (See chapter 8.9 Power Ratings, Weight, and Dimensions) Illustration 8.3 Top and Bottom Mounting Holes (B4, C3, and MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 64: Appendix
Numbered lists indicate procedures. Bullet lists indicate other information. Italicized text indicates: • Cross-reference. • Link. • Parameter name. • Parameter group name. • Parameter option. • Footnote. All dimensions in drawings are in [mm] (in). 9.2 Parameter Menu Structure Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 74: Index
Control card................. 23, 46, 47 DC Output, 10 V................46 RS485....................46 Serial communication..............46 Heat sink USB serial communication............46 Warning..................28, 30 Warning....................29 High voltage..................6, 17 Convention..................... 62 Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 75 RS485....................46 Serial communication..............46 USB serial communication............46 Nameplate....................8 Service...................... 22 Shielded cable................14, 16 Shock......................8 Optional equipment................14 Short circuit.................... 25 STO......................15 see also Safe Torque Off MG33AT02 Danfoss A/S © 05/2018 All rights reserved.
Page 76 Voltage imbalance................23 Voltage level................... 44 Warnings List of....................23 Warnings..................... 22 Weight...................... 56 Windmilling....................7 Wire size.................... 10, 14 Wiring Control wiring................... 14 Motor wiring..................14 Thermistor control wiring............. 15 schematic.................... 13 Danfoss A/S © 05/2018 All rights reserved. MG33AT02...
Page 78 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.

This manual is also suitable for:

Fc 302

Danfoss FC 301 Operating Manual

1 Introduction

2 Safety

3 Mechanical Installation

4 Electrical Installation

5 Commissioning

6 Basic I/O Configuration

7 Maintenance, Diagnostics, and Troubleshooting

8 Specifications

9 Appendix

Index

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