Page 1 ENGINEERING TOMORROW Design Guide VLT® AutomationDrive FC 302 90–710 kW, Enclosure Sizes D and E vlt-drives.danfoss.com...
Page 3: Table Of Contents
6 Options and Accessories Overview 6.1 Fieldbus Devices 6.2 Functional Extensions 6.3 Motion Control and Relay Cards 6.4 Brake Resistors 6.5 Sine-wave Filters 6.6 dU/dt Filters 6.7 Common-mode Filters 6.8 Harmonic Filters 6.9 High-power Kits MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 4 10.1 Safety Instructions 10.2 Wiring Schematic 10.3 Connections 10.4 Control Wiring and Terminals 10.5 Fuses and Circuit Breakers 10.6 Motor 10.7 Braking 10.8 Residual Current Devices (RCD) and Insulation Resistance Monitor (IRM) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 5 13 How to Order a Drive 13.1 Drive Configurator 13.2 Ordering Numbers for Options and Accessories 13.3 Ordering Numbers for Filters and Brake Resistors 13.4 Spare Parts 14 Appendix 14.1 Abbreviations and Symbols 14.2 Definitions Index MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 6: Introduction
• ® The VLT FC Series - Safe Torque Off Operating name, parameter option. Guide describes how to use Danfoss drives in • All dimensions in drawings are in mm (in). functional safety applications. This manual is • supplied with the drive when the Safe Torque Off An asterisk (*) indicates a default setting of a option is present.
Page 7: Safety
IP21/IP54 (Type 1/Type 12). The mains shield is a cover installed inside the enclosure to protect against the accidental touch of the power terminals, according to BGV A2, VBG 4. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 8 • Check which relay options are installed, if any. ® The only allowed relay option is VLT Extended Relay Card MCB 113. 1, 2 Relay plugs Illustration 2.1 Location of Relay Plugs Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 9: Approvals And Certifications
This section provides a brief description of the various The aim of the directive is to ensure personal safety and approvals and certifications that are found on Danfoss avoid property damage when operating electrical drives. Not all approvals are found on all drives.
Page 10 The EAC logo must be both on the product label and on regulations. the packaging label. All products used within the EAC area, must be bought at Danfoss inside the EAC area. 3.1.1.6 UKrSEPRO UKrSEPRO certificate ensures quality and safety of both products and services, in addition to manufacturing stability according to Ukrainian regulatory standards.
Page 11: Enclosure Protection Ratings
The drives meet the requirements of both. NEMA and UL Chassis IP00 Protected chassis IP20 Type 1 IP21 Type 12 IP54 Table 3.2 NEMA and IP Number Cross-reference MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 12 Protected from water at 60° angle. – Protected from splashing water. – Protected from water jets. – Protected from strong water jets. – Protected from temporary immersion. – Protected from permanent immersion. Table 3.3 IP Number Breakdown Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 13: Product Overview
• Lower power consumption for control room cooling equipment. • Reduced ownership costs. • Consistent user interface across the entire range of Danfoss drives. • Application-oriented start-up wizards. • Multi-language user interface. 4.2 Enclosure Size by Power Rating...
Page 14: Overview Of Enclosures, 380-500
2) S = standard, O = optional, and a dash indicates that the option is unavailable. 3) Heat sink access is not available with stainless steel back-channel option. 4) With optional load share and regen terminals. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 15 2) If the enclosure is configured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20. 3) S = standard, O = optional, and a dash indicates that the option is unavailable. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 16: Overview Of Enclosures, 525-690
2) S = standard, O = optional, and a dash indicates that the option is unavailable. 3) Heat sink access is not available with stainless steel back-channel option. 4) With optional load share and regen terminals. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 17 2) If the enclosure is configured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20. 3) S = standard, O = optional, and a dash indicates that the option is unavailable. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 18: Kit Availability
13.2.6 Ordering Numbers for D1h–D8h Kits and chapter 13.2.7 Ordering Numbers for E1h–E4h Kits. 2) The graphical LCP comes standard with enclosures D1h–D8h and E1h–E4h. If more than 1 graphical LCP is required, the kit is available for purchase. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 19: Product Features
During deceleration (ramp-down) if the inertia moment is high, the friction is low, and the ramp- down time is too short for the energy to be dissipated as a loss throughout the drive system. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 20 For high internal temperatures and Danfoss does not recommend using this feature for 525– low motor speed, the drive can also force the PWM pattern 690 V drives connected to an IT mains network.
Page 21: Custom Application Features
Electromagnetic interference (EMI) and radio frequency devices, allowing the system to be regulated with different interference (RFI) are disturbances that can affect an feedback requirements. The drive makes control decisions electrical circuit due to electromagnetic induction or MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 22 At lower speed, the ETR cuts off at lower heat due to less cooling of the motor. In that way, the motor is protected from being overheated even at low speed. The ETR feature calculates the motor temperature based on actual current Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 23 Illustration 5.2 shows where the requirements are indicated Minimum motor frequency on the motor nameplate. Maximum motor frequency When matching drive and motor, Danfoss specifies the Illustration 5.2 Motor Nameplate showing Drive Requirements following extra requirements to ensure adequate motor thermal protection: •...
Page 25: Dynamic Braking Overview
The Safe Torque Off (STO) function is used to stop the protecting the drive from overheating if the brake resistor drive in emergency stop situations. is overloaded. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 26: Mechanical Holding Brake Overview
4-17 Torque Limit Generator Mode are set lower than the current limit in parameter 4-18 Current Limit. It is also recommended to set parameter 14-25 Trip Delay at Torque Limit to 0, parameter 14-26 Trip Delay at Inverter Fault to 0, and parameter 14-10 Mains Failure to [3] Coasting. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 27 Pre-magnetize the motor. To ensure that there is a hold on the motor and to verify that it is mounted correctly, the motor is first pre- magnetized. Apply torque against the closed brake. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 28 2-28 Gain Boost Factor is set to 0. See Illustration 5.8 for more information. NOTICE For an example of advanced mechanical brake control for hoisting applications, see chapter 12 Application Examples. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 29: Load Share Overview
3x Class L-1200 A Mains connecting point for additional drives in the 380 V load sharing application Common mains disconnect switch Illustration 5.9 Diagram of a Load Share Application Where Best Practices are Applied MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 30: Regen Overview
Regen terminals allow a third-party regen unit to be connected to the drive, allowing the excess energy to be returned to the power grid. Returning excess energy back to the power grid is the most efficient use of regenerated energy in applications using continuous braking. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 31: Back-Channel Cooling Overview
Illustration 5.11 Optional Airflow Configuration Using Back-channel Cooling Kits for Enclosures D1h–D8h. (Left) In-bottom/out-back cooling kit for enclosures D1h/D2h. (Center) In-bottom/out-top cooling kit for enclosures D3h/D4h. (Right) In-back/out-back cooling kit for enclosures D5–D8h. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 32 225 mm (8.9 in) Illustration 5.12 Standard Airflow Configuration for E1h/E2h (Left) and E3h/E4h (Right) 225 mm (8.9 in) Illustration 5.13 Optional Airflow Configuration Through the Back Wall for E1h/E2h (Left) and E3h/E4h (Right) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 33: Options And Accessories Overview
Acyclic parameterization using PROFIBUS DP-V1, ® ® The VLT 5000 can be replaced by the VLT PROFIdrive, or Danfoss FC profile state machines. AutomationDrive FC 302, or an existing system can be expanded without costly change of the PLC program. For 6.1.2 VLT ®...
Page 34: Functional Extensions
The following encoder types are supported: network and the following features: • 5 V TTL (RS 422) • Dynamic motion control applications. • 1VPP SinCos • Material handling. • • Synchronization and positioning applications. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 35 (EX-e only FC 302). • PROFIsafe device (with MCA 120). • Uses Safe Torque Off function, which is approved • Replacement of external safety equipment. in accordance with SIL 2 IEC 61508. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 36: Motion Control And Relay Cards
The resistor is selected based on its ohmic value, its power • On-line adjustable gear ratio. dissipation rate, and its physical size. Danfoss offers a wide • variety of different resistors that are specially designed to On-line adjustable position (angle) offset.
Page 37: Sine-Wave Filters
By connecting the AHF 005 or AHF 010 in front of a Danfoss supplies a sine-wave filter to dampen the acoustic Danfoss drive, the total harmonic current distortion motor noise. The filter reduces the ramp-up time of the generated back to the mains is reduced to 5% and 10%.
Page 38: Specifications
If the switching frequency is higher than the default setting, the power losses can increase. 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/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 39 If the switching frequency is higher than the default setting, the power losses can increase. 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/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 40 If the switching frequency is higher than the default setting, the power losses can increase. 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/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 41 If the switching frequency is higher than the default setting, the power losses can increase. 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/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 42: Electrical Data, 525-690
If the switching frequency is higher than the default setting, the power losses can increase. 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/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 43 If the switching frequency is higher than the default setting, the power losses can increase. 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/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 44 If the switching frequency is higher than the default setting, the power losses can increase. 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/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 45 If the switching frequency is higher than the default setting, the power losses can increase. 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/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 46: Mains Supply
Maximum altitude above sea level without derating 1000 m (3281 ft) Maximum altitude above sea level with derating 3000 m (9842 ft) 1) For more information on derating, see chapter 9.6 Derating. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 47: Cable Specifications
10 bit (+ sign) Accuracy of analog inputs Maximum error 0.5% of full scale Bandwidth 100 Hz The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 48 Resolution of frequency outputs 12 bit 1) Terminals 27 and 29 can also be programmed as inputs. The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 49 System response time (terminals 18, 19, 27, 29, 32, 33) Speed control range (open loop) 1:100 of synchronous speed 30–4000 RPM: Maximum error of ±8 RPM Speed accuracy (open loop) All control characteristics are based on a 4-pole asynchronous motor. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 50: Enclosure Weights
1) With optional load share and regen terminals. Enclosure 380–480/500 V 525–690 V 295 (650) 295 (650) 318 (700) 318 (700) 272 (600) 272 (600) 295 (650) 295 (650) Table 7.10 Enclosure E1h–E4h Weights, kg (lb) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 51: Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8 Exterior and Terminal Dimensions 8.1 D1h Exterior and Terminal Dimensions 8.1.1 D1h Exterior Dimensions Illustration 8.1 Front View of D1h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 54 VLT® AutomationDrive FC 302 298 (11.7) 404 (15.9) Illustration 8.4 Door Clearance for D1h 27 (1.0) 137 (5.4) 138 (5.4) 205 (8.1) Mains side Motor side Illustration 8.5 Gland Plate Dimensions for D1h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 55 Exterior and Terminal Dimen... Design Guide 8.1.2 D1h Terminal Dimensions 200 (7.9) 94 (3.7) 88 (3.5) Mains terminals Motor terminals Ground terminals – – Illustration 8.6 D1h Terminal Dimensions (Front View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 56 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 (0.5) (0.5) (1.3) (1.3) Mains terminals Motor terminals Illustration 8.7 D1h Terminal Dimensions(Side Views) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 57: D2H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8.2 D2h Exterior and Terminal Dimensions 8.2.1 D2h Exterior Dimensions 96 (3.8) 211 (8.3) 871 (34.3) 602 (23.7) Illustration 8.8 Front View of D2h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 58 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 378 (14.9) 142 (5.6) 18 (0.7) 20 (0.8) 148 (5.8) 1050 (41.3) 718 (28.3) Illustration 8.9 Side View of D2h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 59 130 (5.1) 11 (0.4) (4.2) 213 (8.4) 1099 (43.3) 320 (12.6) 1051 (41.4) 857 (33.7) 75 (2.9) 11 (0.4) 20 (0.8) 24 (0.9) 9 (0.3) 271 (10.7) Illustration 8.10 Back View of D2h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 60 VLT® AutomationDrive FC 302 395 (15.6) 523 (20.6) Illustration 8.11 Door Clearance for D2h 369 (14.5) 27 (1.0) 185 (7.3) 145 (5.7) 196 (7.7) Mains side Motor side Illustration 8.12 Gland Plate Dimensions for D2h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 61 Design Guide 8.2.2 D2h Terminal Dimensions 331 (13.0) 211 (8.3) 168 (6.6) 168 (6.6) 143 (5.6) 143 (5.6) Mains terminals Motor terminals Ground terminals – – Illustration 8.13 D2h Terminal Dimensions (Front View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 62 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 15 (0.6) 15 (0.6) 19 (0.8) 18 (0.7) 35 (1.4) 38 (1.5) Mains terminals Motor terminals Illustration 8.14 D2h Terminal Dimensions (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 63: D3H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8.3 D3h Exterior and Terminal Dimensions 8.3.1 D3h Exterior Dimensions 61 (2.4) 128 (5.0) 660 (26.0) 495 (19.5) Illustration 8.15 Front View of D3h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 64 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 375 (14.8) 82 (3.2) 39 (1.5) 18 (0.7) 20 (0.8) 148 (5.8) 844 (33.2) Illustration 8.16 Side View of D3h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 65 25 (1.0) 909 (35.8) 11 (0.4) 78 (3.1) 200 (7.9) 889 (35.0) 844 (33.2) 656 (25.8) 25 (1.0) 11 (0.4) 20 (0.8) 200 (7.9) (0.9) 9 (0.3) Illustration 8.17 Back View of D3h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 66 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 8.3.2 D3h Terminal Dimensions 292 (11.5) 188 (7.4) 83 (3.3) Mains terminals Motor terminals Brake terminals Ground terminals Illustration 8.18 D3h Terminal Dimensions (Front View) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 67 13 (0.5) 13 (0.5) 32 (1.3) 32 (1.3) 1 and 6 Bottom brake/regen terminals 3 and 5 Mains terminals 2 and 7 Motor terminals Ground terminals Illustration 8.19 D3h Terminal Dimensions (Side Views) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 68: D4H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 8.4 D4h Exterior and Terminal Dimensions 8.4.1 D4h Enclosure Dimensions 59 (2.3) 176 (6.9) 868 (34.2) 611 (24.1) Illustration 8.20 Front View of D4h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 69 Exterior and Terminal Dimen... Design Guide 39 (1.5) 375 (14.8) 18 (0.7) 142 (5.6) 20 (0.8) 148 (5.8) 1050 (41.3) Illustration 8.21 Side Dimensions for D4h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 70 25 (1.0) (4.2) 1122 (44.2) 213 (8.4) 320 (12.6) 1096 (43.1) 1051 (41.4) 857 (33.7) (1.6) 11 (0.4) 24 (0.9) 20 (0.8) 9 (0.3) 271 (10.7) Illustration 8.22 Back Dimensions for D4h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 71 Exterior and Terminal Dimen... Design Guide 8.4.2 D4h Terminal Dimensions 376 (14.8) 319 (12.6) 200 (7.9) Mains terminals Motor terminals Brake terminals Ground terminals Illustration 8.23 D4h Terminal Dimensions (Front View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 72 15 (0.6) 19 (0.8) 18 (0.7) 38 (1.5) 35 (1.4) 1 and 6 Brake/regeneration terminals 3 and 5 Mains terminals 2 and 7 Motor terminals Ground terminals Illustration 8.24 D4h Terminal Dimensions(Side Views) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 73: D5H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8.5 D5h Exterior and Terminal Dimensions 8.5.1 D5h Exterior Dimensions 149 (5.9) 1107 (43.6) 733 (28.9) Illustration 8.25 Front View of D5h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 74 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 381 (15.0) 115 (4.5) 23 (0.9) 161 (6.3) 1277 (50.3) Illustration 8.26 Side View of D5h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 75 (3.1) 11 (0.4) (7.9) 1324 (52.1) 1276 (50.2) 1111 (43.7) (4.8) 130 (5.1) (2.5) 11 (0.4) (3.1 220 (8.7) (7.9) 24 (0.9) (0.3) (0.8) 200 (7.9) Illustration 8.27 Back View of D5h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 76 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 433 (17.0) 218 (8.6) 670 (26.4) Illustration 8.28 Heat Sink Access Dimensions for D5h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 77 Design Guide 298 (11.7) 404 (15.9) Illustration 8.29 Door Clearance for D5h 242 (9.5) 121 (4.8) 43 (1.7) 224 (8.8) 111 (4.4) Mains side Motor side Illustration 8.30 Gland Plate Dimensions for D5h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 78 8.5.2 D5h Terminal Dimensions 227 (9.0) 221 (8.7) 196 (7.7) 148 (5.8) 118 (4.6) 90 (3.6) Mains terminals Brake terminals Ground terminals Motor terminals Illustration 8.31 D5h Terminal Dimensions with Disconnect Option (Front View) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 79 Exterior and Terminal Dimen... Design Guide Mains terminals Motor terminals Brake terminals – – Illustration 8.32 D5h Terminal Dimensions with Disconnect Option (Side Views) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 80 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 727 (28.6) 623 (24.5) 517 (20.4) 511 (20.1) Mains terminals Motor terminals Brake terminals Ground terminals Illustration 8.33 D5h Terminal Dimensions with Brake Option (Front View) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 81 Exterior and Terminal Dimen... Design Guide Mains terminals Motor terminals Brake terminals – – Illustration 8.34 D5h Terminal Dimensionswith Brake Option (Side Views) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 82: D6H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 8.6 D6h Exterior and Terminal Dimensions 8.6.1 D6h Exterior Dimensions 159 (6.3) 1447 (57.0) 909 (35.8) Illustration 8.35 Front View of D6h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 84 (7.9) 1663 (65.5) 1615 (63.6) 1452 (57.2) (4.8) 130 (5.1) (3.1) (7.9) 11 (0.4) 64 (3.0) 559 (22.0) 24 (0.9) 9 (0.1) 20 (0.8) 200 (7.9) Illustration 8.37 Back View of D6h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 86 VLT® AutomationDrive FC 302 298 (11.7) 404 (15.9) Illustration 8.39 Door Clearance for D6h 242 (9.5) 121 (4.8) 43 (1.7) 224 (8.8) 111 (4.4) Mains side Motor side Illustration 8.40 Gland Plate Dimensions for D6h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 87 195 (7.7) 153 (6.0) 123 (4.8) 96 (3.8) Mains terminals Brake terminals Ground terminals Motor terminals TB6 terminal block for contactor – – Illustration 8.41 D6h Terminal Dimensions with Contactor Option (Front View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 88 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 Mains terminals Motor terminals Brake terminals – – Illustration 8.42 D6h Terminal Dimensions with Contactor Option (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 89 Exterior and Terminal Dimen... Design Guide 225 (8.9) Mains terminals Brake terminals Ground terminals Motor terminals TB6 terminal block for contactor – – Illustration 8.43 D6h Terminal Dimensions with Contactor and Disconnect Options (Front View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 90 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 Brake terminals Motor terminals Mains terminals – – Illustration 8.44 D6h Terminal Dimensions with Contactor and Disconnect Options (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 91 Exterior and Terminal Dimen... Design Guide 467 (18.4) Mains terminals Brake terminals Ground terminals Motor terminals Illustration 8.45 D6h Terminal Dimensions with Circuit Breaker Option (Front View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 92 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 Mains terminals Motor terminals Brake terminals – – Illustration 8.46 D6h Terminal Dimensions with Circuit Breaker Option (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 93: D7H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8.7 D7h Exterior and Terminal Dimensions 8.7.1 D7h Exterior Dimensions 209 (8.2) 1754 (69.1) 1282 (50.5) Illustration 8.47 Front View of D7h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 94 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 386 (15.2) 156 (6.2) 23 (0.9) 25 (1.0) 161 (6.3) 193 (76.0) Illustration 8.48 Side View of D7h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 95 11 (0.4) 130 (5.1) (1.0) (4.2) (8.4) (12.6) 1953 (76.9) (77.9) 1760 (69.3) 130 (5.1) 385 (15.2) (2.8) (4.2) (8.4) 25 (1.0) (12.6) (9.3) (26.3) 14 (0.6) Illustration 8.49 Back View of D7h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 96 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 591 (23.3) (12.4) 1168 (46.0) Illustration 8.50 Heat Sink Access Dimensions for D7h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 97 Exterior and Terminal Dimen... Design Guide 1731 (68.1) 1537 (60.5) (18.4) 11 (0.4) (10.7) 23 (0.9) Illustration 8.51 Wall Mount Dimensions for D7h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 98 VLT® AutomationDrive FC 302 395 (15.6) 523 (20.6) Illustration 8.52 Door Clearance for D7h 337 (13.3) 169 (6.6) 43 (1.7) 222 (8.7) 115 (4.5) Mains side Motor side Illustration 8.53 Gland Plate Dimensions for D7h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 99 8.7.2 D7h Terminal Dimensions 545 (21.4) 515 (20.3) 412 (16.2) 395 (15.6) 372 (14.7) Mains terminals Motor terminals Brake terminals Ground terminals Illustration 8.54 D7h Terminal Dimensions with Disconnect Option (Front View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 100 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 Mains terminals Motor terminals Brake terminals – – Illustration 8.55 D7h Terminal Dimensions with Disconnect Option (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 101 Exterior and Terminal Dimen... Design Guide 1260 (49.6) 1202 (47.3) 1082 (42.6) 1034 (40.7) 1009 (39.7) Mains terminals Brake terminals Ground terminals Motor terminals Illustration 8.56 D7h Terminal Dimensions with Brake Option (Front View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 102 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 Brake terminals Motor terminals Mains terminals – – Illustration 8.57 D7h Terminal Dimensions with Brake Option (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 103: D8H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8.8 D8h Exterior and Terminal Dimensions 8.8.1 D8h Exterior Dimensions 215 (8.5) 1699 (66.9) (30.2) 1400 (55.1) (4.4) Illustration 8.58 Front View of D8h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 104 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 406 (16.0) 156 (6.2) 23 (0.9) 25 (1.0) 162 (6.4) 2236 (88.0) Illustration 8.59 Side View of D8h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 105 11 (0.4) (8.4) 25 (1.0) (12.6) 2259 (88.9) 130 (5.1) 2284 (89.9) 2065 (81.3) (4.2) (8.4) 385 (15.2) 72 (2.8) (12.6) (38.3) (9.3) (1.0) 14 (0.6) Illustration 8.60 Back View of D8h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 106 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 591 (23.3) (12.4) 1473 (58.0) Illustration 8.61 Heat Sink Access Dimensions for D8h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 107 Design Guide 395 (15.6) 523 (20.6) Illustration 8.62 Door Clearance for D8h 337 (13.3) 169 (6.6) 43 (1.7) 222 (8.7) 115 (4.5) Mains side Motor side Illustration 8.63 Gland Plate Dimensions for D8h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 108 521 (20.5) 418 (16.5) 401 (15.8) 378 (14.9) Mains terminals TB6 terminal block for contactor Brake terminals Motor terminals Ground terminals – – Illustration 8.64 D8h Terminal Dimensions with Contactor Option (Front View) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 109 Exterior and Terminal Dimen... Design Guide Mains terminals Motor terminals Brake terminals – – Illustration 8.65 D8h Terminal Dimensions with Contactor Option (Side Views) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 110 VLT® AutomationDrive FC 302 567 (22.3) Mains terminals TB6 terminal block for contactor Brake terminals Motor terminals Ground terminals – – Illustration 8.66 D8h Terminal Dimensions with Contactor and Disconnect Options (Front View) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 111 Exterior and Terminal Dimen... Design Guide Mains terminals Motor terminals Brake terminals – – Illustration 8.67 D8h Terminal Dimensions with Contactor and Disconnect Options (Side View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 112 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 (23.8) Mains terminals Ground terminals Brake terminals Motor terminals Illustration 8.68 D8h Terminal Dimensions with Circuit Breaker Option (Front View) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 113 15 (0.6) 32 (1.3) 16 (0.6) (0.8) 14 (0.5) 35 (1.4) 18 (0.7) Mains terminals Motor terminals Brake terminals – – Illustration 8.69 D8h Terminal Dimensions with Circuit Breaker Option (Side View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 114: E1H Exterior And Terminal Dimensions
8.9 E1h Exterior and Terminal Dimensions 8.9.1 E1h Exterior Dimensions 22 (0.8) 13 (0.5) 2043 (80.4) 2002 (78.8) 1553 (61.1) 1393 (54.9) (35.9) 393 (15.5) 602 (23.7) Illustration 8.70 Front View of E1h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 115 Exterior and Terminal Dimen... Design Guide 2X 101 (4.0) 2X 9 (0.7) 20 (0.8) 125 (4.9) 280 (11.0) 35 (1.4) 190 (7.5) (20.2) (22.3) Knockout panel Illustration 8.71 Side View of E1h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 116 168 (6.6) 154 (6.1) 1800 (70.9) 168 (6.6) 1209 (47.6) 601 (23.7) 4X 73 (2.8) 4X 457 (18.0) 69 (2.7) 464 (18.3) Heat sink access panel (optional) Illustration 8.72 Back View of E1h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 117 11 (0.4) (16.7) (7.3) 22 (0.8) 17 (0.7) (5.4) 412 (16.2) 560 (22.0) 293 (11.5) 173 (6.8) 560 (22.0) 22 (0.8) Gland plate Illustration 8.73 Door Clearance and Gland Plate Dimensions for E1h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 118 8.9.2 E1h Terminal Dimensions 721 (28.4) 613 (24.1) 515 (20.3) 485 (19.1) 200 (7.9) 0 (0.0) Mains terminals Motor terminals Brake or regen terminals Ground terminals, M10 nut Illustration 8.74 E1h Terminal Dimensions (Front View) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 119 Exterior and Terminal Dimen... Design Guide 649 (25.5) 649 (25.5) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Illustration 8.75 E1h Terminal Dimensions (Side Views) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 120: E2H Exterior And Terminal Dimensions
VLT® AutomationDrive FC 302 8.10 E2h Exterior and Terminal Dimensions 8.10.1 E2h Exterior Dimensions 13 (0.5) (3.8) 2043 (80.4) 2002 (78.8) 1553 (61.1) 1393 (54.9) (35.9) (15.5) (27.5) Illustration 8.76 Front View of E2h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 121 Exterior and Terminal Dimen... Design Guide 2X 101 (4.0) 2X 9 (0.7) 20 (0.8) 125 (4.9) 280 (11.0) 35 (1.4) (20.2) 190 (7.5) (22.3) Knockout panel Illustration 8.77 Side View of E2h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 122 168 (6.6) 154 (6.1) 1800 (70.9) 168 (6.6) 1209 (47.6) 601 (23.7) 4X 121 (4.8) 4X 457 (18.0) 560 (22.0) 69 (2.7) Heat sink access panel (optional) Illustration 8.78 Back View of E2h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 123 11 (0.4) (16.7) (7.3) 22 (0.8) 17 (0.7) (5.4) 508 (20.0) 656 (25.8) 293 (11.5) 173 (6.8) 22 (0.8) 656 (25.8) Gland plate Illustration 8.79 Door Clearance and Gland Plate Dimensions for E2h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 124 8.10.2 E2h Terminal Dimensions 721 (28.4) 613 (24.1) 515 (20.3) 485 (19.1) 200 (7.9) 0 (0.0) Mains terminals Motor terminals Brake or regen terminals Ground terminals, M10 nut Illustration 8.80 E2h Terminal Dimensions (Front View) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 125 Exterior and Terminal Dimen... Design Guide 649 (25.5) 649 (25.5) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Illustration 8.81 E2h Terminal Dimensions (Side Views) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 126: E3H Exterior And Terminal Dimensions
8.11 E3h Exterior and Terminal Dimensions 8.11.1 E3h Exterior Dimensions 13 (0.5) 1537 (60.5) 1578 (62.1) 1348 (53.1) 13 (0.5) 15 (0.6) 10 (0.4) (1.2) 10 (0.4) (19.9) Illustration 8.82 Front View of E3h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 127 Exterior and Terminal Dimen... Design Guide 20 (0.8) 2X 101 (4.0) 2X 19 (0.7) 2X 18 (0.7) 2X 21 (0.8) 482 (19.0) Illustration 8.83 Side View of E3h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 128 1335 (52.5) 744 (29.3) 168 (6.6) 136 (5.4) 39 (1.5) 215 (8.5) 430 (16.9) 4X 457 (18.0) 22 (0.9) 464 (18.3) Heat sink access panel (optional) Illustration 8.84 Back View of E3h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 129 (11.6) 19 (0.7) 2X 219 (8.6) 2X 220 (8.6) (6.3) RFI shield termination (standard with RFI option) Cable/EMC clamp Gland plate Illustration 8.85 RFI Shield Termination and Gland Plate Dimensions for E3h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 130 6X 148 (5.8) 90 (3.5) 50 (2.0) 33 (1.3) 0 (0.0) Mains terminals Motor terminals Brake or regen terminals Ground terminals, M8 and M10 nuts Illustration 8.86 E3h Terminal Dimensions (Front View) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 131 Exterior and Terminal Dimen... Design Guide (7.2) (7.2) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Illustration 8.87 E3h Mains, Motor, and Ground Terminal Dimensions (Side Views) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 132 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 2X 125 (4.9) 0 (0.0) 20 (0.8) 0 (0.0) 14 (0.5) 35(1.4) Illustration 8.88 E3h Load Share/Regen Terminal Dimensions Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 133: E4H Exterior And Terminal Dimensions
8.12 E4h Exterior and Terminal Dimensions 8.12.1 E4h Exterior Dimensions 13 (0.5) 1578 1537 (62.1) (60.5) 1348 (53.1) 13 (0.5) 15 (0.6) 10 (0.4) 10 (0.4) (1.2) (23.8) Illustration 8.89 Front View of E4h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 134 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 20 (0.8) 2X 101 (4.0) 2X 19 (0.7) 2X 18 (0.7) 2X 21 (0.8) 482 (19.0) Illustration 8.90 Side View of E4h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 135 744 (29.3) 168 (6.6) 136 (5.4) 39 (1.5) 263 (10.4) 4X 74 (2.9) 4X 457 (18.0) 526 (20.7) 22 (0.9) 560 (22.0) Heat sink access panel (optional) Illustration 8.91 Back View of E4h MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 136 (11.6) 19 (0.7) 2X 268 (10.6) 2X 220 (8.6) (6.3) RFI shield termination (standard with RFI option) Cable/EMC clamp Gland plate Illustration 8.92 RFI Shield Termination and Gland Plate Dimensions for E4h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 137 6X 148 (5.8) 90 (3.5) 50 (2.0) 33 (1.3) 0 (0.0) Mains terminals Motor terminals Brake or regen terminals Ground terminals, M8 and M10 nuts Illustration 8.93 E4h Terminal Dimensions (Front View) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 138 Exterior and Terminal Dimen... VLT® AutomationDrive FC 302 (7.2) (7.2) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Illustration 8.94 E4h Mains, Motor, and Ground Terminal Dimensions (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 139 Exterior and Terminal Dimen... Design Guide 2X 125 (4.9) 0 (0.0) 20 (0.8) 0 (0.0) 14 (0.5) 35(1.4) Illustration 8.95 E4h Load Share/Regen Terminal Dimensions MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 140: Mechanical Installation Considerations
The unit uses conformal-coated circuit boards to reduce the effects of aggressive gases. For conformal- coating class specifications and ratings, see chapter 7.5 Ambient Conditions. Illustration 9.1 Recommended Lifting Method Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 141: Mounting Configurations
Motors with class e protection Table 9.1 Mounting Configurations When combined with an ATEX approved PTC monitoring 1) Can be wall mounted, but Danfoss recommends that the drive is ® device like the VLT PTC Thermistor Card MCB 112, instal- panel mounted inside an enclosure due to its protection rating.
Page 142: Cooling
The heat sink cooling air Manual derating carries approximately 90% of the heat out of the back When the following conditions are present, Danfoss channel of the drive. Redirect the back-channel air from recommends selecting a drive 1 power size higher (for the panel or room by using: •...
Page 143 Illustration 9.2 shows that at 41.7 °C (107 °F), 100% of the rated output current is available. At 45 °C (113 °F) (T , MAX-3 K), 91% of the rated output current is available. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 144 VLT® AutomationDrive FC 302 9.6.3 Derating for Ambient Temperature and Switching Frequency NOTICE FACTORY DERATING Danfoss drives are already derated for operational temperature (55 °C (131 °F) T and 50 °C (122 °F) T AMB,MAX AMB,AVG Use the graphs in Table 9.4 to Table 9.5 to determine if the output current must be derated based on switching frequency and ambient temperature.
Page 145 40 ˚C (104 ˚F) 50 ˚C (122 ˚F) 45 ˚C (113 ˚F) 55 ˚C (131 ˚F) 50 ˚C (122 ˚F) 55 ˚C (131 ˚F) Table 9.5 Derating Tables for Drives Rated 525–690 V MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 146: Electrical Installation Considerations
NEC. Failure to set parameter 1-90 Motor RCD cannot provide the intended protection. Thermal Protection to [ETR trip] or [ETR warning] means that motor overload protection is not provided and, if the motor overheats, property damage can occur. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 147: Wiring Schematic
Illustration 10.1 Basic Wiring Schematic A=Analog, D=Digital ® 1) Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the VLT FC Series - Safe Torque Off Operating Guide. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 148: Connections
Connect the motor cable shield to both the decoupling plate of the drive and the metal housing of the motor. Make the shield connections with the largest possible surface area (cable clamp) by using the installation devices within the drive. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 149 When connecting the PC to the drive through a USB cable, The load sharing feature requires extra equipment and Danfoss recommends using a USB isolator with galvanic safety considerations. Consult Danfoss for ordering and isolation to protect the PC USB host controller from installation recommendations.
Page 150: Control Wiring And Terminals
Minimum 16 mm cable must be tied down and routed along with other Equalizing cable control wires inside the unit. See Illustration 10.5. PLC etc. Drive Ground Ground 100 nF Drive Drive Ground Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 151 8-3* FC switch (BUS TER.) is Port Settings provided on the control card for bus 69 (-) Parameter – termination group 8-3* FC resistance. Port Settings Table 10.5 Serial Communication Terminal Descriptions MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 152 Parameter Default Description setting – – Common for analog output. Parameter 6-50 [0] No Programmable analog Terminal 42 operation output. 0–20 mA or Output 4–20 mA at a maximum of 500 Ω. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 153: Fuses And Circuit Breakers
If the drive is supplied with a mains disconnect, the SCCR of the drive is 100000 amps at all voltages (380–690 V). If the drive is supplied with a circuit breaker, the SCCR depends on the voltage. See Table 10.13. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 154 Circuit breaker 100000 Class L fuse, 1200 A 525–690 355–560 (400–600) 40000 Circuit breaker 100000 Class L fuse, 800 A 525–690 630–710 (650–750) 42000 Circuit breaker 100000 Class L fuse, 1200 A Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 155: Motor
When motors are connected in parallel, parameter 1-02 Flux Motor Feedback Source cannot be used, and parameter 1-01 Motor Control Principle must be set to [0] U/f. Illustration 10.9 Changing Motor Rotation MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 156 The total motor cable length specified in chapter 7.6 Cable Specifications is valid as long as the parallel cables are kept less than 10 m (32 ft) each. Illustration 10.10 Different Parallel Connections of Motors Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 157: Braking
• Try to ensure that the mains voltage is balanced Table 10.18. If a motor has lower insulation rating, Danfoss to ground. This procedure can be difficult for IT, recommends using a dU/dt or sine-wave filter.
Page 158 Cycle time (s) [25 °C (77 °F)] Current (%) Braking time (s) Overload braking Cycle time (s) [25 °C (77 °F)] Current (%) Braking time (s) Table 10.22 E1h–E4h Braking Capability, 525–690 V Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 159 Check that the brake resistor can handle a voltage of fault in the drive. If the brake IGBT is overloaded or 410 V, 820 V, 850 V, 975 V, or 1130 V. Danfoss brake overheated, the relay/digital signal from the brake to the resistors are rated for use on all Danfoss drives.
Page 160: Residual Current Devices (Rcd) And Insulation Resistance Monitor (Irm)
• Ground wire (terminal 95) of at least 10 mm (8 AWG) cross-section. • 2 separate ground wires both complying with the dimensioning rules. See EN/IEC61800-5-1 and EN 50178 for further information. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 161: It Mains
25 m switching frequency. Whether the switching frequency is (82 ft), Danfoss recommends setting parameter 14-50 RFI detected depends on the type of RCD used. Filter to [ON]. Refer also to the Application Note, VLT on IT Mains.
Page 162: Acoustic Noise
ISO 1996-2 Annex D. A new fan control algorithm for E1h-E4h enlosure sizes helps improve audible noise performance by allowing the Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 163 160–315 (200–350) 30 (98) – – – 150 (492) 0.42 1885 300 (984) 1.38 2163 1253 Table 10.29 IEC dU/dt Test Results for D1h–D8h with Unshielded Cables and No Output Filter, 525–690 V MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 164 5 (16) 0.27 1042 3132 30 (98) – – – 150 (492) 0.52 1233 1897 Table 10.34 IEC dU/dt Test Results for E1h–E4h with Shielded Cables and No Output Filter, 380–500 V Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 165 Unshielded cable with no filter Shielded cable with dU/dt filter Illustration 10.18 Peak Voltages at Motor Terminals for Illustration 10.17 dU/dt at Motor Terminals for Enclosures E1h/ Enclosures E1h/E3h, 380–500 V E3h, 380–500 V MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 166 DC-link voltage increases by 20%. This effect is similar to increasing the mains voltage by 20%. Consider this voltage increase when performing motor insulation analysis for braking applications. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 167 Unshielded cable with no filter Unshielded cable with no filter Illustration 10.22 Peak Voltages at Motor Terminals for Illustration 10.24 Peak Voltages at Motor Terminals for Enclosures E2h/E4h, 525–690 V Enclosures E2h/E4h, 525–690 V MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 168: Electromagnetic Compatibility (Emc) Overview
Common-mode leakage current AC mains supply Shielded motor cable Drive Safety ground (4 conductor in motor cables) Shielded motor cable Unintended common-mode current Motor – – Illustration 10.25 Electric Model Showing Possible Leakage Currents Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 169 Rated current equal to or above 400 A. • Intended for use in complex systems. Table 10.38 Emission Requirements When the generic emission standards are used, the drives are required to comply with Table 10.39. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 170 The immunity requirements for drives depend on the installation environment. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss drives comply with the requirements for both the industrial and the home/office environment.
Page 171: Emc-Compliant Installation
Ensure good electrical contact from the mounting plate through the mounting screws to the drive chassis. • Use shielded cables for motor output cables. An alternative is unshielded motor cables within metal conduit. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 172 For installations above 2000 m (6500 ft) altitude, contact Danfoss regarding PELV compliance. NOTICE PELV COMPLIANCE Prevent electric shock by using protective extra low voltage (PELV) electrical supply and complying with local and national PELV regulations. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 173 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 10.27 Example of Proper EMC Installation MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 174: Harmonics Overview
The PCC, the configuration of the distribution system and total voltage distortion (THDi) is calculated based on the relevant impedances must be known. individual voltage harmonics using this formula: Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 175 Typically, a class cannot be defined ahead of time without considering the intended equipment and processes to be used in ® the environment. VLT high-power drives observe the limits of Class 3 under typical supply system conditions (R >10 or <10%). Line MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 176 • Total cost of ownership (initial cost, efficiency, and maintenance). 10.16.6 Harmonic Calculation Use the free Danfoss MCT 31 calculation software to determine the degree of voltage pollution on the grid and needed ® precaution. The VLT Harmonic Calculation MCT 31 is available at www.danfoss.com.
Page 177: Basic Operating Principles Of A Drive
11 Basic Operating Principles of a Drive 11.2 Drive Controls This chapter provides an overview of the primary assemblies and circuitry of a Danfoss drive. It describes the The following processes are used to control and regulate internal electrical and signal processing functions. A...
Page 178 Y is parameter 3-14 Preset Relative Reference in [%]. If Y, parameter 3-14 Preset Relative Reference, is set to 0%, the scaling does not affect the reference. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 179 No function Digipot ref. DigiPot Decrease ±200% Analog inputs Closed loop Setpoint ±200% Frequency inputs From Feedback Handling Ext. closed loop outputs Clear DigiPot Open loop reference Illustration 11.3 Remote Handling of Reference MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 180 P 20-04 Average (1+2+3) P 20-03 Minimum (1|2|3) Maximum (1|2|3) Feedback conv. Feedback 3 Feedback 3 Source P 20-07 P 20-06 Feedback Function P 20-20 Illustration 11.4 Block Diagram of Feedback Signal Processing Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 181 See chapter 12 Application Examples. In the configuration shown in Illustration 11.6, the drive operates in open-loop mode. It receives input from either the LCP (hand-on mode) or via a remote signal (auto-on mode). MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 182 • Process control. Used to control application parameters that are measured by different sensors (pressure, temperature, and flow) and are affected by the connected motor through a pump or fan. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 183 In Illustration 11.8, the resulting reference from the reference handling system is received and fed through the ramp limitation and speed limitation before being sent to the motor control. The output of the motor control is then limited by the maximum frequency limit. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 184 Select [3] Process in parameter 1-00 Configuration Mode to use the process PID control for closed-loop control of the controlled application. The process PID parameters are found in parameter groups 7-2* Process Ctrl. Feedb and 7-3* Process PID Ctrl. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 185 When the drive is at the current limit during motor operation or regenerative operation, it tries to get below the preset torque limits as quickly as possible without losing control of the motor. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 186: Application Examples
D IN Notes/comments: Set D IN parameter group 1-2* Motor Data according to motor +10 V nameplate. A IN A IN A OUT Table 12.1 Wiring Configuration for AMA with T27 Connected Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 187: Wiring Configurations For Analog Speed Reference
27 is not needed. A OUT erminal 53 High Ref./Feedb. Value *=Default value Notes/comments: Table 12.5 Wiring Configuration for Start/Stop Command with Safe Torque Off Table 12.3 Wiring Configuration for Analog Speed Reference (Voltage) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 188 A OUT Table 12.7 Wiring Configuration for Start/Stop with Reversing and 4 Preset Speeds Table 12.6 Wiring Configuration for Pulse Start/Stop Speed Latched Start (18) Stop Inverse (27) Illustration 12.3 Latched Start/Stop Inverse Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 189: Wiring Configuration For An External Alarm Reset
53 Low Ref./Feedb. Value Parameter 6-15 T 1500 RPM U - I erminal 53 High Ref./Feedb. Value *=Default value Notes/comments: Table 12.9 Wiring Configuration for Speed Reference (Using a Manual Potentiometer) MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 190: Wiring Configuration For Rs485 Network Connection
Protection to [1] Thermistor +10 V warning. A IN A IN A OUT U - I RS-485 Table 12.12 Wiring Configuration for a Motor Thermistor Table 12.11 Wiring Configuration for RS485 Network Connection Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 191: Wiring Configuration For A Relay Set-Up With Smart Logic Control
5 s, the drive continues and the warning disappears. Reset relay 1 by pressing [Reset] on the LCP. Table 12.13 Wiring Configuration for a Relay Set-up with Smart Logic Control MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 192: Wiring Configuration For The Encoder
To program the stop and torque limit, connect to the following terminals: • Start/stop via terminal 18 (Parameter 5-10 Terminal 18 Digital Input [8] Start). • Quick stop via terminal 27 Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 193 Relay output [0] (Relay 1) (Parameter 5-40 Function Relay [32] Mechanical Brake Control). Start 0.1 Amp External 24 V DC P 5-40 [0] [32] Mechanical brake connection Illustration 12.8 Wire Configuration for Torque and Stop Limit MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 194: How To Order A Drive
Hungarian, Czech, and Russian. Language package 4 English, German, Spanish, English US, Greek, Brazilian Portuguese, Turkish, and Polish. To order drives with a different language package, contact the local Danfoss sales office. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 195 X: No adaptation Q: Heat sink access panel Software release 24-27 Actual software Software language X: Standard language pack Table 13.3 Ordering Type Code for Enclosures D1h–D8h 1) Available for all D-frames. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 196 Q: Heat sink access Software release 24–28 SXXX: Latest release - standard software S067: Integrated motion control software Software language X: Standard language pack Table 13.4 Ordering Type Code for Enclosures E1h–E4h Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 197 11: VLT Position Controller MCO 351 (requires C4 option) D options 38– DX: No option ® D0: VLT 24 V DC Supply MCB 107 Table 13.5 Ordering Type Codes for FC 302 Options MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 198: Ordering Numbers For Options And Accessories
130B5546 130B5646 EtherCAT MCA 124 Table 13.6 Ordering Numbers for A Options For information on fieldbus and application option compatibility with older software versions, contact the Danfoss supplier. 13.2.2 Ordering Numbers for B Options: Functional Extensions Description Ordering number Uncoated Coated ®...
Page 199 Enclosure size: 2000 mm (78.7 in). Back-channel duct kit, D4h Duct kit that converts enclosure to either in-bottom/out-top venting 176F3628 or top only venting. Enclosure size: 1800 mm (70.9 in). MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 200 This kit is used only for enclosures D7h/D8h. LCP 101 Numerical local control panel (NLCP). 130B1124 LCP 102 Graphical Local control panel (GLCP). 130B1107 LCP cable Separate LCP cable, 3 m (9 ft). 175Z0929 Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 201 In back/out top, E4h Allows the cooling air to be directed in through the back and out 176F6616 – through the top of the drive. This kit is used only for enclosure E4h. MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 202: Ordering Numbers For Filters And Brake Resistors
Advanced Harmonic Filters AHF 005/AHF 010 Design Guide. • Output Filters Design Guide. 13.4 Spare Parts ® Consult the VLT Shop or the Drive Configurator (www.danfoss.com/drives) for the spare parts that are available for your application. Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 203: Appendix
TTL encoder (5 V) pulses - transistor logic Rated output current supplied by the drive VLT,N Nominal motor voltage Kilohertz Underwriters Laboratories (US organization for the Local control panel safety certification) Least significant bit Volts MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 204: Definitions
14.2 Definitions currents are low. Brake resistor All Danfoss drives have built-in DC coils in the DC link to have a high-power factor and reduce the THD on the main The brake resistor is a module capable of absorbing the brake power generated in regenerative braking.
Page 205: Index
Overview of back-channel cooling..........29 Mechanical holding brake............24 Requirements.................. 140 Static braking..................24 Use as an alternative brake function........158 CSA/cUL approval................... 8 Wiring configuration for mechanical brake......189 Break-away torque................202 Cable clamp..................148 MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 206 E4h exterior..................131 E4h terminal..................135 Export control regulations..............8 Product series overview..............13 Extended relay card................34 Discharge time..................5 Disconnect.................... 152 Door clearance........49, 55, 71, 80, 91, 101, 112 Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 207 Galvanic isolation..............19, 46, 169 Leakage current................5, 158 Gases....................... 138 Lifting....................24, 138 General purpose I/O module............32 see also Hoisting Gland plate..........49, 55, 71, 80, 91, 101, 112 Grounding................19, 148, 158 MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 208 Thermistor wiring configuration..........188 Preheat..................... 22 Wiring schematic................145 Process control..................180 Mounting configurations..............140 PROFIBUS..................31, 196 PROFINET....................31 Programming guide................4 NEMA protection rating................ 9 Open loop..................... 179 Operating guide..................4 Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 209 Switch Location of E3h shield termination......... 127 A53 and A54................45, 150 Location of E4h shield termination......... 134 Using switch with IT grid............159 Switches Disconnect..................152 Rise time....................160 Rotor......................18 MG38C202 Danfoss A/S © 01/2018 All rights reserved.
Page 210 Points for 380–500 V drives........... 36, 38 Points for 525–690 V drives........... 40, 42 TÜV certificate..................8 Type code....................192 UKrSEPRO certificate................8 Enclosure protection rating............9 Listing mark..................8 USB specifications................48 Danfoss A/S © 01/2018 All rights reserved. MG38C202...
Page 212 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.

Danfoss VLT AutomationDrive FC 302 Design Manual

1 Introduction

2 Safety

3 Approvals and Certifications

4 Product Overview

5 Product Features

6 Options and Accessories Overview

7 Specifications

8 Exterior and Terminal Dimensions

9 Mechanical Installation Considerations

10 Electrical Installation Considerations

11 Basic Operating Principles of a Drive

12 Application Examples

13 How to Order a Drive

14 Appendix

Index

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