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Danfoss FC 300 Design Manual

Danfoss FC 300 Design Manual

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Download this manual See also: Programming Manual, Design Manual
FC 300 Design Guide
Contents
How to Read this Design Guide
Control Structure in VVC
Internal Current Control in VVC
Mechanical Holding Brake
Dynamic Braking
Selection of Brake Resistor
Mechanical Brake Control
plus
Advanced Vector Control
plus
Mode
MG.33.BC.22 - VLT
®
is a registered Danfoss trademark
Contents
1-1
1-1
1-1
1-2
1-2
2-1
2-1
2-5
3-1
3-1
3-4
3-4
3-5
3-6
3-7
3-8
3-8
3-8
3-11
3-11
3-12
3-12
3-15
3-18
3-22
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3-26
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3-37

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Summary of Contents for Danfoss FC 300

  • Page 1: Table Of Contents

    How to Read this Design Guide Symbols Abbreviations Definitions 2 Safety and Conformity Safety Precautions Aggressive Environments 3 Introduction to AutomationDrive FC 300 Product Overview Control Principle AutomationDrive FC 300 Controls AutomationDrive FC 301 vs. AutomationDrive FC 302 Control Principle plus Control Structure in VVC...
  • Page 2 Contents FC 300 Design Guide 4 AutomationDrive FC 300 Selection Electrical Data - 200–240 V Electrical Data - 380–500 V Electrical Data - 525–600 V Electrical Data - 525–690 V 4-12 General Specifications 4-20 Acoustic Noise 4-26 du/dt Conditions 4-26...
  • Page 3 Electrical Installation, Control Cables 8-39 Relay Output 8-41 Additional Connections 8-42 How to Connect a PC to the Adjustable Frequency Drive 8-43 The AutomationDrive FC 300 PC software 8-44 Residual Current Device 8-50 Final Set-up and Test 8-51 9 Application Examples Encoder Connection...
  • Page 4 Contents FC 300 Design Guide MCB 112 PTC Thermistor Card 10-13 MCB 113 Extended Relay Card 10-15 MCF 106 A/ B in C Option Adaptor 10-16 Brake Resistors 10-18 Remote Mounting Kit for LCP 10-19 IP21/IP 4X/ TYPE 1 Enclosure Kit...

  • Page 5: How To Read This Design Guide

    1 How to Read this Design Guide 1.1.1 How to Read this Design Guide This Design Guide will introduce all aspects of your AutomationDrive FC 300. Available literature for AutomationDrive FC 300 The VLT AutomationDrive Instruction Manual MG.33.AX.YY provides the neccessary information for getting the drive up and running.

  • Page 6: Abbreviations

    1 How to Read this Design Guide FC 300 Design Guide 1.1.3 Abbreviations Alternating current American wire gauge Ampere/AMP Automatic Motor Adaptation Current limit °C Degrees Celsius Direct current Drive Dependent D-TYPE Electro Magnetic Compatibility Electronic Thermal Relay Adjustable Frequency Drive...
  • Page 7 FC 300 Design Guide 1 How to Read this Design Guide Motor: The motor frequency when the jog function is activated (via digital terminals). Motor frequency. Output from the adjustable frequency drive. Output frequency is related to the shaft speed on motor depending on number of poles and slip frequency.
  • Page 8 1 How to Read this Design Guide FC 300 Design Guide η The efficiency of the adjustable frequency drive is defined as the ratio between the power output and the power input. Start-disable command A stop command belonging to the group 1 control commands - see this group.
  • Page 9 FC 300 Design Guide 1 How to Read this Design Guide Hiperface ® Hiperface ® is a registered trademark by Stegmann. Initializing Operation Mode If initialization is carried out (par. 14-22 ), the adjustable frequency drive returns to the default setting.
  • Page 10 In addition, a high power factor indicates that the different harmonic currents are low. All Danfoss adjustable frequency drives have built-in DC coils in the DC link to increase the power factor and to reduce the THD on the line power supply.

  • Page 11: Safety And Conformity

    FC 300 Design Guide 2 Safety and Conformity 2 Safety and Conformity 2.1 Safety Precautions 2.1.1 Safety Precautions The voltage of the adjustable frequency drive is dangerous whenever connected to line power. Incorrect installation of the motor, adjustable frequency drive or serial communication bus may cause damage to the equipment, serious personal injury or death. Con- sequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.
  • Page 12 2 Safety and Conformity FC 300 Design Guide Touching the electrical parts may be fatal - even after the equipment has been disconnected from line power. Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic backup.
  • Page 13 Adjustable frequency drives must be CE-labeled in accordance with the Low-voltage Directive of January 1, 1997. The directive applies to all electrical equipment and appliances used in the 50–1000 V AC and the 75–1500 V DC voltage ranges. Danfoss CE-labels in accordance with the directive and issues a declaration of conformity upon request.
  • Page 14 Danfoss CE labels the adjustable frequency drives in accordance with the low-voltage directive. This means that if the adjustable frequency drive is installed correctly, we guarantee compliance with the low-voltage directive. Danfoss issuesWe issue a declaration of conformity that confirms our CE labeling in accordance with the low-voltage directive.

  • Page 15: Aggressive Environments

    It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer. As an aid to the installer, Danfoss has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for power EMC Immunity drive systems are complied with, provided that the EMC-correct instructions for installation are followed;...
  • Page 16 2 Safety and Conformity FC 300 Design Guide The adjustable frequency drive has been tested according to the procedure based on the shown standards: The adjustable frequency drive complies with requirements that exist for units mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors.

  • Page 17: Introduction To Automationdrive Fc

    FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 3 Introduction to AutomationDrive FC 300 3.1 Product Overview Frame size depends on enclosure type, power range and AC line voltage Frame size Enclosure 20/21 20/21 20/21 55/66 protection NEMA...
  • Page 18 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide Frame size Enclosure 21/55/66 21/55/66 protection NEMA Type 1/Type 12 Type 1/Type 12 Chassis Chassis High overload rated 25–30 hp [15–22 kW] (200–240 40–50 hp [30–37 kW] (200– 25–30 hp [18.5–22 kW] 40–50 hp [30–37 kW] (200–...
  • Page 19 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 Frame size Enclosure 21/54 21/54 protection NEMA Type 1/ Type 12 Type 1/ Type 12 Chassis Chassis High overload rated 125–150 hp [90–110 kW] at 175–300 hp [132–200 kW] 125–150 hp [90–110 kW] at 175–300 hp [132–200 kW] at...

  • Page 20: Control Principle

    3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.2.1 Control Principle An adjustable frequency drive rectifies AC voltage from line into DC voltage, after which this DC voltage is converted into an AC current with a variable amplitude and frequency.

  • Page 21: Automationdrive Fc 301 Vs. Automationdrive Fc 302 Control Principle

    FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 3.2.3 AutomationDrive FC 301 vs. AutomationDrive FC 302 Control Principle AutomationDrive FC 301 is a general purpose adjustable frequency drive for variable speed applications. The control principle is based on Voltage Vector...
  • Page 22 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.2.4 Control Structure in VVC plus Advanced Vector Control Control structure in VVC plus open-loop and closed-loop configurations: In the configuration shown in the figure above, par. 1-01 Motor Control Principle is set to “VVC...

  • Page 23: Control Structure In Flux Sensorless (Automationdrive Fc 302 Only)

    FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 3.2.5 Control Structure in Flux Sensorless (AutomationDrive FC 302 only) Control structure in flux sensorless open-loop and closed-loop configurations. Motor Control Principle Configuration Mode In the shown configuration, par. 1-01 is set to “Flux sensorless [2]”...

  • Page 24: Control Structure In Flux With Motor Feedback

    3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.2.6 Control Structure in Flux with Motor Feedback Control structure in Flux with motor feedback configuration (only available in AutomationDrive FC 302): In the shown configuration, par. 1-01 Motor Control Principle is set to “Flux w motor feedb [3]”...
  • Page 25 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 After pressing the [Auto On] key, the adjustable frequency drive goes into auto mode and follows (as default) the remote reference. In this mode, it is possible to control the adjustable frequency drive via the digital inputs and various serial interfaces (RS-485, USB, or an optional serial commu- nication bus).
  • Page 26 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.3 Reference Handling Local Reference The local reference is active when the drive is operated with ‘Hand On’ bottom active. Adjust the reference by up/down and left/right arrows respectively. Remote Reference The reference handling system for calculating the Remote reference is shown in the figure below.

  • Page 27: Reference Limits

    FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 The two types of reference inputs are combined in the following formula: Remote reference = X + X * Y / 100%. If relative reference is not used par. No function...

  • Page 28: Scaling Of Analog And Pulse References And Feedback

    3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.3.3 Scaling of Analog and Pulse References and Feedback References and feedback are scaled from analog and pulse inputs in the same way. The only difference is that a reference above or below the specified minimum and maximum “endpoints”...
  • Page 29 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 The size of the Dead Band is defined by either P1 or P2 as shown in the graph below. Thus, a reference endpoint of P1 = (0 V, 0 RPM) will not result in any dead band, but a reference endpoint of P1 = (1 V, 0 RPM), for example, will result in a -1 V to +1 V dead band in this case, provided that the end point P2 is placed in either quadrant 1 or quadrant 4.
  • Page 30 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide Case 2: Positive reference with dead band, digital input to trigger reverse. Clamping rules. This case shows how a reference input with limits outside -Max – +Max limits clamps to the input's low and high limits before addition to external reference, And how the External reference is clamped to -Max –...

  • Page 31: Speed Pid Control

    FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 Case 3: Negative to positive reference with dead band, sign determines the direction, -Max – +Max 3.4 PID Control 3.4.1 Speed PID Control The table shows the control configurations where the Speed Control is active.
  • Page 32 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide The following parameters are relevant for the Speed Control: Parameter Description of function Speed PID Feedback Par. 7-00 Select from which input the speed PID should get its feedback. Source Speed PID Proportional Par.
  • Page 33 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 In the parameter list below, it is assumed that all other parameters and switches remain at their default setting. The following must be programmed in the order shown - see an explanation of the settings in the Programming Guide.

  • Page 34: Process Pid Control

    3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.4.2 Tuning PID speed control The following tuning guidelines are relevant when using one of the Flux motor control principles in applications where the load is mainly inertial (with a low amount of friction).
  • Page 35 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 Figure 3.3: Process PID Control diagram The following parameters are relevant for process control. Parameter Description of function Par. 7-20 Process CL Feedback 1 Resource Select from which source (i.e., analog or pulse input) the process PID should receive its feedback Par.
  • Page 36 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.4.4 Example of Process PID Control The following is an example of process PID control used in a ventilation system: In a ventilation system, the temperature is to be able to be set from 23°–...
  • Page 37 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 Example of Process PID Control set-up Function Par. no. Setting Initialize the adjustable frequency drive 14-22 [2] Initialization - perform power cycling - press reset 1) Set motor parameters: Set the motor parameters according to nameplate data 1-2*...

  • Page 38: Ziegler Nichols Tuning Method

    3 Introduction to AutomationDrive FC 300 FC 300 Design Guide NOTE! If necessary, start/stop can be activated a number of times in order to provoke a variation of the feedback signal. 3.4.5 Ziegler Nichols Tuning Method In order to tune the PID controls of the adjustable frequency drive, several tuning methods can be used. One approach is to use a technique which was developed in the 1950s, but which has stood the test of time and is still used today.
  • Page 39 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 Step 2: Increase the value of the proportional gain until the point of instability is reached (sustained oscillations) and the critical value of gain, , is reached. Step 3: Measure the period of oscillation to obtain the critical time constant, Step 4: Use the table above to calculate the necessary PID control parameters.

  • Page 40: Emc Test Results

    3 Introduction to AutomationDrive FC 300 FC 300 Design Guide In order to reduce the interference level from the entire system (unit + installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50 MHz (airborne) is especially generated by the control electronics.
  • Page 41 The immunity requirements for adjustable frequency drives depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss adjustable frequency drives comply with the requirements for the industrial environment and consequently comply also with the lower requirements for home and office environment with a large safety margin.

  • Page 42: Pelv - Protective Extra Low Voltage

    3 Introduction to AutomationDrive FC 300 FC 300 Design Guide • EN 61000-4-4 (IEC 61000-4-4): Electrical interference: Simulation of interference brought about by switching a contactor, relay or similar devices. • EN 61000-4-5 (IEC 61000-4-5): Surge transients: Simulation of transients brought about, e.g., by lightning that strikes near installations.
  • Page 43 Installation at high altitude: 380–500 V, enclosure A, B and C: At altitudes above 6,500 ft [2 km], please contact Danfoss regarding PELV. 380–500 V, enclosure D, E and F: At altitudes above 10,000 ft [3 km], please contact Danfoss regarding PELV.

  • Page 44: Brake Functions In Automationdrive Fc 300

    3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.8 Brake Functions in AutomationDrive FC 300 The brake function is applied for braking the load on the motor shaft, either as dynamic braking or static braking. 3.8.1 Mechanical Holding Brake A mechanical holding brake mounted directly on the motor shaft normally performs static braking.
  • Page 45 750 hp [560 kW] at 115% braking torque Danfoss offers brake resistors with duty cycle of 5%, 10% and 40%. If a 10% duty cycle is applied, the brake resistors are able to absorb braking energy for 10% of the cycle time. The remaining 90% of the cycle time will be used on dissipating excess heat.
  • Page 46 * Power size dependent NOTE! Check that the brake resistor can cope with a voltage of 410 V, 820 V, 850 V, 975 V or 1130 V - unless Danfoss brake resistors are used. Danfoss recommends the brake resistance R , i.e., one that guarantees...

  • Page 47: Control With Brake Function

    FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 NOTE! If a short circuit in the brake transistor occurs, power dissipation in the brake resistor is only prevented by using a line switch or contactor to disconnect the line power for the adjustable frequency drive. (The contactor can be controlled by the adjustable frequency drive).

  • Page 48: Hoist Mechanical Brake

    3 Introduction to AutomationDrive FC 300 FC 300 Design Guide In hoisting/lowering applications, it must be possible to control an electro-mechanical brake. Step-by-step Description • To control the mechanical brake, any relay output or digital output (terminal 27 or 29) can be used. If necessary, use a suitable contactor.
  • Page 49 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 3-step sequence Pre-magnetize the motor In order to ensure that there is a hold on the motor, and to verify that it is mounted correctly, the motor is first pre-magnetized.
  • Page 50 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.10 Smart Logic Controller - AutomationDrive FC 300 The Smart Logic Control (SLC) is essentially a sequence of user defined actions (see par. 13-52 SL Controller Action ) executed by the SLC when the...
  • Page 51 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 Brake Function Over-voltage Control See par. 2-10 and par. 2-17 to select the method used for controlling the intermediate circuit voltage level. Line Drop-out During a line drop-out, the adjustable frequency drive keeps running until the intermediate circuit voltage drops below the minimum stop level, which is typically 15% below the adjustable frequency drive's lowest rated supply voltage.
  • Page 52 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3.11.1 Motor Thermal Protection To protect the application from serious damage, VLT AutomationDrive offers several dedicated features Torque Limit: The torque limit feature: the motor is protected for being overloaded independent of the speed. Torque limit is controlled in...

  • Page 53: Safe Stop Of Automationdrive Fc 300

    FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 3.12 Safe Stop of AutomationDrive FC 300 The AutomationDrive FC 302, and also the AutomationDrive FC 301 in A1 enclosure, can perform the safety function Safe Torque Off (As defined by IEC...
  • Page 54 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide Abbreviations related to Functional Safety Abbreviation Reference Description Cat. EN 954-1 Safety category, levels 1-4 Failure In Time: 1E-9 hours IEC 61508 Hardware Fault Tolerance: HFT = n means, that n+1 faults could cause a loss of the safety function...
  • Page 55 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 3-39 MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 56 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3-40 MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 57 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 3.12.1 Safe Stop Installation - AutomationDrive FC 302 only (and AutomationDrive FC 301 in Frame Size A1) To carry out an installation of a Category 0 Stop (EN60204) in conformance with Safety Cat. 3 (EN 954-1) / PL “d” (ISO...
  • Page 58 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide Activation and Termination of Safe Stop The safe stop function is activated by removing the voltage at Terminal 37 of the safe inverter. By connecting the safe inverter to external safety devices providing a safe relay, an installation for a safe Stop Category 1 can be obtained.
  • Page 59 FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 Figure 3.10: Figure of the essential aspects for installing a combination of a safe stop application and a MCB112 application. The diagram Terminal 37 Safe Stop shows a Restart input for the external Safety Device. This means that in this installation, par. 5-19 might be set to value [7] or [8].
  • Page 60 After installation and before first operation, perform a commissioning test of an installation or application making use of AutomationDrive FC 300 Safe Stop. Moreover, perform the test after each modification of the installation or application, of which the AutomationDrive FC 300 Safe Stop is a part. NOTE! Passing a commissioning test is mandatory for fulfilling Safety Category 3 by this type of installation or application.

  • Page 61: Automationdrive Fc 300 Selection

    FC 300 Design Guide 4 AutomationDrive FC 300 Selection 4 AutomationDrive FC 300 Selection 4.1 Electrical Data - 200–240 V Line Power Supply 3 x 200–240 V AC AutomationDrive FC 301/AutomationDrive FC 302 PK25 PK37 PK55 PK75 P1K1 P1K5 P2K2...
  • Page 62 4 AutomationDrive FC 300 Selection FC 300 Design Guide Line Power Supply 3 x 200–240 V AC AutomationDrive FC 301/ P15K P18K5 P22K P30K P37K AutomationDrive FC 302 High/ Normal Load* Typical Shaft Output 18.5 18.5 [kW] Enclosure IP20 Enclosure IP21...

  • Page 63: Electrical Data - 380-500

    FC 300 Design Guide 4 AutomationDrive FC 300 Selection 4.2 Electrical Data - 380–500 V Line Power Supply 3 x 380–500 V AC (AutomationDrive FC 302), 3 x 380–480 V AC (AutomationDrive FC 301) PK 37 PK 55 PK75 P1K1...
  • Page 64 4 AutomationDrive FC 300 Selection FC 300 Design Guide Line Power Supply 3 x 380–500 V AC (AutomationDrive FC 302), 3 x 380–480 V AC (AutomationDrive FC 301) AutomationDrive FC 301/ P11K P15K P18K P22K AutomationDrive FC 302 High/ Normal Load* Typical Shaft output [kW] 18.5...
  • Page 65 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Line Power Supply 3 x 380–500 V AC (AutomationDrive FC 302), 3 x 380–480 V AC (AutomationDrive FC 301) AutomationDrive FC 301/AutomationDrive P30K P37K P45K P55K P75K FC 302 High/ Normal Load*...
  • Page 66 4 AutomationDrive FC 300 Selection FC 300 Design Guide Line Power Supply 3 x 380–500 V AC AutomationDrive FC P90K P110 P132 P160 P200 High/ Normal Load* Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [HP]...
  • Page 67 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Line Power Supply 3 x 380–500 V AC AutomationDrive FC 302 P250 P315 P355 P400 High/ Normal Load* Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [HP]...
  • Page 68 4 AutomationDrive FC 300 Selection FC 300 Design Guide Line Power Supply 3 x 380–500 V AC AutomationDrive P450 P500 P560 P630 P710 P800 FC 302 High/ Normal Load* Typical Shaft output 1000 at 400 V [kW] Typical Shaft output...

  • Page 69: Electrical Data - 525-600

    FC 300 Design Guide 4 AutomationDrive FC 300 Selection 4.3 Electrical Data - 525–600 V Line Power Supply 3 x 525–600 V AC (AutomationDrive FC 302 only) AutomationDrive FC 302 PK75 P1K1 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 Typical Shaft Output [kW] 0.75...
  • Page 70 4 AutomationDrive FC 300 Selection FC 300 Design Guide Line Power Supply 3 x 525–600 VAC AutomationDrive FC 302 P11K P15K P18K5 P22K P30K High/ Normal Load* Typical Shaft Output [kW] 18.5 18.5 Enclosure IP 21, 55, 66 Enclosure IP20...
  • Page 71 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Line Power Supply 3 x 525–600 VAC AutomationDrive FC 302 P37K P45K P55K P75K High/ Normal Load* Typical Shaft Output [kW] Enclosure IP21, 55, 66 Enclosure IP20 Output current Continuous (3 x 525–550 V) [A] Intermittent (3 x 525–550 V) [A]...

  • Page 72: Electrical Data - 525-690

    4 AutomationDrive FC 300 Selection FC 300 Design Guide 4.4 Electrical Data - 525–690 V Line Power Supply 3 x 525–690 V AC AutomationDrive FC 302 P11K P15K P18K P22K High/ Normal Load* Typical Shaft output at 550 18.5 18.5...
  • Page 73 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Line Power Supply 3 x 525–690 V AC AutomationDrive FC P75K P30K P37K P45K P55K High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP]...
  • Page 74 4 AutomationDrive FC 300 Selection FC 300 Design Guide Line Power Supply 3 x 525–690 V AC AutomationDrive FC P90K P37K P45K P55K P75K High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP]...
  • Page 75 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Line Power Supply 3 x 525–690 V AC AutomationDrive FC 302 P110 P132 P160 P200 High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP]...
  • Page 76 4 AutomationDrive FC 300 Selection FC 300 Design Guide Line Power Supply 3 x 525–690 V AC AutomationDrive FC 302 P250 P315 P355 High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP]...
  • Page 77 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Line Power Supply 3 x 525–690 V AC AutomationDrive FC 302 P400 P500 P560 High/ Normal Load* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP]...
  • Page 78 4 AutomationDrive FC 300 Selection FC 300 Design Guide Line Power Supply 3 x 525–690 V AC AutomationDrive FC P630 P710 P800 P900 P1M0 High/ Normal Load* Typical Shaft output at 550 V [kW] 1000 Typical Shaft output at 575 V [HP]...
  • Page 79 FC 300 Design Guide 4 AutomationDrive FC 300 Selection 1) For type of fuse, see the section Fuses. 2) American Wire Gauge. 3) Measured using 16.4 ft [5 m] shielded motor cables at rated load and rated frequency. 4) The typical power loss is at nominal load conditions and expected to be within +/-15% (tolerance relates to variety in voltage and cable conditions).

  • Page 80: General Specifications

    4 AutomationDrive FC 300 Selection FC 300 Design Guide 4.5 General Specifications Line power supply (L1, L2, L3): Supply voltage 200–240 V ±10% Supply voltage AutomationDrive FC 301: 380–480 V / AutomationDrive FC 302: 380–500 V ±10% Supply voltage AutomationDrive FC 302: 525–690 V ±10%...
  • Page 81 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Protection and Features: • Electronic thermal motor protection against overload. • Temperature monitoring of the heatsink ensures that the adjustable frequency drive trips if the temperature reaches a predefined level. An overload temperature cannot be reset until the temperature of the heatsink is below the values stated in the tables on the following pages (guideline - these temperatures may vary for different power sizes, frame sizes, enclosure ratings, etc.).
  • Page 82 4 AutomationDrive FC 300 Selection FC 300 Design Guide Analog inputs: Number of analog inputs Terminal number 53, 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201/switch S202 = OFF (U) Voltage level...
  • Page 83 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Control card, RS-485 serial communication: Terminal number 68 (P,TX+, RX+), 69 (N,TX-, RX-) Terminal number 61 Common for terminals 68 and 69 The RS-485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage (PELV).
  • Page 84 4 AutomationDrive FC 300 Selection FC 300 Design Guide Control characteristics: Resolution of output frequency at 0–1000 Hz +/- 0.003 Hz Precise start/stop ≤± 0.1 msec Repeat accuracy of (terminals 18, 19) ≤ 2 ms System response time (terminals 18, 19, 27, 29, 32, 33)
  • Page 85 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Efficiency of the adjustable frequency drive (η The load on the adjustable frequency drive has little effect on its efficiency. In general, the efficiency is the same at the rated motor frequency f , even if the motor supplies 100% of the rated shaft torque or only 75%, i.e., in the case of part loads.

  • Page 86: Acoustic Noise

    If the motor cable is long (328 ft. [100 m]), the rise time and peak voltage are higher. Peak voltage on the motor terminals is caused by the switching of the IGBTs. The AutomationDrive FC 300 complies with the demands of IEC 60034-25 regarding motors designed to be controlled by adjustable frequency drives.
  • Page 87 FC 300 Design Guide 4 AutomationDrive FC 300 Selection AutomationDrive FC 300, P7K5T2 Cable AC line Upeak length [m] voltage [V] Rise time [μsec] [kV] du/dt [kV/μsec] 0.264 0.624 1.890 0.536 0.596 0.889 0.568 0.568 0.800 AutomationDrive FC 300, P11KT2...
  • Page 88 4 AutomationDrive FC 300 Selection FC 300 Design Guide AutomationDrive FC 300, P1K5T4 Cable AC line Rise time Upeak du/dt length [m] voltage [V] [μsec] [kV] [kV/μsec] 0.640 0.690 0.862 0.470 0.985 0.985 0.760 1.045 0.947 AutomationDrive FC 300, P4K0T4...
  • Page 89 FC 300 Design Guide 4 AutomationDrive FC 300 Selection AutomationDrive FC 300, P30KT4 Cable AC line Rise time Upeak du/dt length [m] voltage [μsec] [kV] [kV/μsec] 0.368 1.270 2.853 0.536 1.260 1.978 0.680 1.240 1.426 0.712 1.200 1.334 AutomationDrive FC 300, P37KT4...
  • Page 90 4 AutomationDrive FC 300 Selection FC 300 Design Guide 125–450 hp [90–315 kW] / 525–690 V Cable AC line Peak length voltage Rise time voltage du/dt 115 ft [30 m] 690 V 0.38µsec. 1573 3309 V/µsec. 1.72 µsec. 115 ft [30 m]...

  • Page 91: Special Conditions

    FC 300 Design Guide 4 AutomationDrive FC 300 Selection 4.9 Special Conditions 4.9.1 Purpose of Derating Derating must be taken into account when using the adjustable frequency drive at low air pressure (high elevations), at low speeds, with long motor cables, cables with a large cross-section or at high ambient temperature.
  • Page 92 4 AutomationDrive FC 300 Selection FC 300 Design Guide Frame Size B (except B2 525–690 V) Overload Mode For the B and C frames, the derating also depends on the overload mode selected in par. 1-04 60º AVM - Pulse Width Modulation SFAVM - Stator Frequency Asyncron Vector Modulation Figure 4.6: Derating of I...
  • Page 93 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Frame size C (except C2 525–690 V) SFAVM - Stator Frequency Asyncron Vector Modulation 60º AVM - Pulse Width Modulation Figure 4.13: Derating of I for different T for frame AMB, MAX Figure 4.12: Derating of I...
  • Page 94 4 AutomationDrive FC 300 Selection FC 300 Design Guide Frame size D 60º AVM - Pulse Width Modulation, 380–500 V SFAVM - Stator Frequency Asyncron Vector Modulation, 380– 500 V Figure 4.18: Derating of I for different T for frame AMB, MAX Figure 4.19: Derating of I...
  • Page 95 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Figure 4.25: Derating of I for different T for frame Figure 4.24: Derating of I for different T for frame AMB, MAX AMB, MAX size D at 690 V, using SFAVM in Normal torque mode (110% size D at 690 V, using 60º...
  • Page 96 4 AutomationDrive FC 300 Selection FC 300 Design Guide Frame sizes E and F 60º AVM - Pulse Width Modulation, 380–500 V SFAVM - Stator Frequency Asyncron Vector Modulation, 380– 500 V Figure 4.30: Derating of I for different T...
  • Page 97 FC 300 Design Guide 4 AutomationDrive FC 300 Selection Figure 4.36: Derating of I for different T for frame Figure 4.37: Derating of I for different T for frame AMB, MAX AMB, MAX sizes E and F at 690 V, using 60º AVM in Normal torque sizes E and F at 690 V, using SFAVM in Normal torque mode mode (110% over torque).
  • Page 98 4 AutomationDrive FC 300 Selection FC 300 Design Guide 4.9.3 Derating for low air pressure The cooling capability of air is decreased at a lower air pressure. At an altitude lower than 3,280 ft [1,000 m], no derating is necessary, but above 3,280 ft [1,000 m], the ambient temperature (T ) or max.

  • Page 99: Automatic Adaptations To Ensure Performance

    FC 300 Design Guide 4 AutomationDrive FC 300 Selection 4.9.4 Derating for running at low speed When a motor is connected to an adjustable frequency drive, it is necessary to make sure that the cooling of the motor is adequate.
  • Page 100 4 AutomationDrive FC 300 Selection FC 300 Design Guide 4-40 MG.33.BC.22 - VLT ® is a registered Danfoss trademark...

  • Page 101: How To Order

    It is possible to design an AutomationDrive FC 300 adjustable frequency drive according to the application requirements by using the ordering number system. For the AutomationDrive FC 300 series, you can order standard drives and drives with integral options by sending a type code string describing the product to the local Danfoss sales office, e.g.:...

  • Page 102: Ordering Form Type Code

    5 How to Order FC 300 Design Guide 5.1.2 Ordering Form Type Code Not all choices/options are available for each AutomationDrive FC 301/ AutomationDrive FC 302 variant. To verify if the appropriate version is Product groups available, please consult the Drive Configurator on the Internet.
  • Page 103 FC 300 Design Guide 5 How to Order Ordering type codemodel number frame sizes A, B and C Ordering type codemodel number frame sizes D and E Description Possible choice Description Possible choice Product group 1-3 AutomationDrive FC 302 Drive series...
  • Page 104 5 How to Order FC 300 Design Guide Ordering type codemodel number frame size F Description Possible choice Description Possible choice Line power op- X: No AC line power option tion Product group AutomationDrive FC 302 : Line power disconnect and fuse...
  • Page 105 FC 300 Design Guide 5 How to Order Ordering type codemodel number, options (all frame sizes) Description Possible choice A options AX: No A option A0: MCA 101 Profibus DP V1 (standard) A1: MCA 101 Profibus DP V1 (with top...
  • Page 106 5 How to Order FC 300 Design Guide 5.2.1 Ordering Numbers: Options and Accessories Type Description Ordering no. Miscellaneous hardware A5 panel through kit Panel through kit for frame size A5 130B1028 B1 panel through kit Panel through kit for frame size B1...
  • Page 107 MCT 10 Set-up software - unlimited users 130B1006 Options can be ordered as factory built-in options, see ordering information. For information on serial communication bus and application option combatibility with older software versions, please contact your Danfoss supplier. Type Description Ordering no.
  • Page 108 5 How to Order FC 300 Design Guide 5.2.3 Ordering Numbers: High Power Option Kits Description Ordering Number Instruction Number NEMA-3R (Rittal Enclosures) D3 Frame 176F4600 175R5922 D4 Frame 176F4601 E2 Frame 176F1852 NEMA-3R (Welded Enclosures) D3 Frame 176F0296 175R1068...
  • Page 109 FC 300 Design Guide 5 How to Order AutomationDrive FC 302 - Line power: 200–240V (T2) - 10% Duty Cycle AutomationDrive FC Order no. Period Cable cross- Therm. relay Max. brake tor- m (HO) br, nom br avg que with Rrec*...
  • Page 110 5 How to Order FC 300 Design Guide AutomationDrive FC 301 - Line power: 380–480 V (T4) - 10% Duty Cycle AutomationDrive FC Order no. Period Cable cross- Therm. re- Max. brake tor- m (HO) br. nom br avg que with R...
  • Page 111 FC 300 Design Guide 5 How to Order AutomationDrive FC 302 - Line power: 380–500 V (T5) - 10% Duty Cycle Automation Order no. Period Cable Therm. Max. brake torque m (HO) br, nom br avg Drive FC 302 cross-sec-...
  • Page 112 5 How to Order FC 300 Design Guide AutomationDrive FC 302 - Line power: 525–600 V (T6) - 10% Duty Cycle Automation Order no. Period Cable cross- Therm. Max. brake torque m (HO) br, nom br avg Drive FC 302...
  • Page 113 FC 300 Design Guide 5 How to Order AutomationDrive FC 302 - Line power: 525–690 V (T7) - 10% Duty Cycle AutomationDriv Order no. Period Cable cross- Max. brake torque m (HO) br, nom br avg e FC 302 section...
  • Page 114 5 How to Order FC 300 Design Guide AutomationDrive FC 301/302 - Line power: 200–240V (T2) - 40% Duty Cycle AutomationDrive FC Order no. Period Cable cross- Therm. Max. brake tor- m (HO) br, nom br avg 301/302 section relay...
  • Page 115 FC 300 Design Guide 5 How to Order AutomationDrive FC 302 - Line power: 380–500 V (T5) - 40% Duty Cycle AutomationDrive Order no. Period Cable Therm. Max. brake torque m (HO) br, nom br avg FC 302 cross-sec- relay...
  • Page 116 5 How to Order FC 300 Design Guide AutomationDrive FC 302 - Line power: 525–600 V (T6) - 40% Duty Cycle AutomationDrive Order no. Period Cable Therm. Max. brake torque m (HO) br, nom br avg FC 302 cross-sec- relay...
  • Page 117 *) Rating for each thermistor relay (using one thermistor relay per resistor). Installation *) Parallel star connection (see the chapter). *) Please contact Danfoss for further info. *) With Klixon Switch : Rated motor size for VLT type : Minimum permissible brake resistor - by drive...
  • Page 118 5 How to Order FC 300 Design Guide 5.2.6 Flat Packs AutomationDrive FC 301 - Line power: 200–240 V (T2) AutomationDrive FC 301 Flatpack IP65 for horizontal conveyors Rrec per item Duty Cycle Order no. m (HO) br, nom [kW] [Ω]...
  • Page 119 FC 300 Design Guide 5 How to Order AutomationDrive FC 302 Line power: 380–500 V (T5) AutomationDrive FC 302 Flatpack IP65 for horizontal conveyors Rrec per item Duty Cycle Order no. m (HO) br. nom [kW] [Ω] [Ω] [Ω / W]...
  • Page 120 5 How to Order FC 300 Design Guide 5.2.7 Ordering Numbers: Harmonic Filters Harmonic filters are used to reduce line harmonics. • AHF 010: 10% current distortion • AHF 005: 5% current distortion Typical Motor Used [kW] Danfoss AHF 005...
  • Page 121 FC 300 Design Guide 5 How to Order Adjustable frequency drive Typical Motor Used [kW] Danfoss AHF 005 Danfoss AHF 010 AHF,N size 130B2538 130B2539 PK37-P7K5 10 - 15 175G6612 175G6634 P11K 175G6613 175G6635 P15K 25 - 30 175G6614 175G6636...
  • Page 122 5 How to Order FC 300 Design Guide 690 V Typical Motor Used Adjustable frequency IAHF Danfoss AHF 005 Danfoss AHF 010 [kW] drive size, 525–690 V 130B2328 130B2293 P37K 45 - 55 130B2330 130B2295 P45K - P55K 75 - 90...
  • Page 123 FC 300 Design Guide 5 How to Order 5.2.9 Ordering Numbers: Sine-wave Filter Modules, 525–690 V AC 3 x 525–600/690 V Adjustable frequency drive size Rated filter Max Output Fre- current at 50 Min Switching quency ([Hz] with Frequency [kHz]...
  • Page 124 5 How to Order FC 300 Design Guide 5.2.11 Ordering Numbers: du/dt Filters, 525–690 V AC Line power supply 3x525–690 V 3 x 525–690 V Adjustable frequency drive size Minimum Maximum output Rated filter cur- switching fre- frequency [Hz] rent at 50 Hz...

  • Page 125: Mechanical Installation - Frame Size A, B And C

    6 Mechanical Installation - Frame Size A, B and FC 300 Design Guide 6 Mechanical Installation - Frame Size A, B and C 6.1.1 Safety Requirements of Mechanical Installation Pay attention to the requirements that apply to integration and the field mounting kit. Follow the information in the list to avoid serious damage or injury, especially when installing large units.
  • Page 126 6 Mechanical Installation - Frame Size A, B and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 127 6 Mechanical Installation - Frame Size A, B and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 128 6 Mechanical Installation - Frame Size A, B and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 129 6 Mechanical Installation - Frame Size A, B and FC 300 Design Guide 6.1.2 Mechanical Mounting IP21/IP4X/ TYPE 1 Enclosure Kit Options and Accessories All Frame Sizes allow side-by-side installation except when a is used (see the section of the Design Guide).
  • Page 130 6 Mechanical Installation - Frame Size A, B and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...

  • Page 131: Mechanical Installation - Frame Size D, E And F

    7 Mechanical Installation - Frame size D, E and FC 300 Design Guide 7 Mechanical Installation - Frame size D, E and F 7.1 Pre-installation 7.1.1 Planning the Installation Site NOTE! Before performing the installation, it is important to plan the installation of the adjustable frequency drive. Neglecting this may result in extra work during and after installation.

  • Page 132: Lifting

    7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Figure 7.1: Mounting Template 7.1.4 Lifting Always lift the adjustable frequency drive using the dedicated lifting holes. For all D and E2 (IP00) enclosures, use a bar to avoid bending the lifting holes of the adjustable frequency drive.
  • Page 133 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Figure 7.3: Recommended lifting method, frame size F1. Figure 7.5: Recommended lifting method, frame size F3. Figure 7.4: Recommended lifting method, frame size F2. Figure 7.6: Recommended lifting method, frame size F4.
  • Page 134 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 135 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 136 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 137 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 138 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 139 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide MG.33.BC.22 - VLT ® is a registered Danfoss trademark...

  • Page 140: Mechanical Dimensions

    7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Mechanical dimensions, frame size D Frame size 175–300 hp [132–200 125–150 hp [90–110 175–300 hp [132–200 125–150 hp [90–110 (380–500 V) (380–500 V) (380–500 V) (380–500 V) 250–450 hp [160–315...

  • Page 141: Mechanical Installation

    7 Mechanical Installation - Frame size D, E and FC 300 Design Guide 7.2 Mechanical Installation Preparation of the mechanical installation of the adjustable frequency drive must be done carefully to ensure proper results and to avoid additional work during installation. Start by taking a close look at the mechanical drawings at the end of this instruction manual to become familiar with the space demands.
  • Page 142 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Figure 7.10: Space in front of IP21/IP54 enclosure type, frame size F3 Figure 7.9: Space in front of IP21/IP54 enclosure type, frame size F1 Figure 7.12: Space in front of IP21/IP54 enclosure type, frame size F4 Figure 7.11: Space in front of IP21/IP54 enclosure type,...

  • Page 143: Terminal Locations - Frame Size D

    7 Mechanical Installation - Frame size D, E and FC 300 Design Guide 7.2.3 Terminal Locations - Frame size D Take the following terminal positions into consideration when you design for cable access. Figure 7.13: Position of power connections, frame size D3 and D4 Figure 7.14: Position of power connections with disconnect switch, frame size D1 and D2...
  • Page 144 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide IP 21 (NEMA 1) / IP 54 (NEMA 12) IP 00 / Chassis Frame size D1 Frame size D2 Frame size D3 Frame size D4 277 (10.9) 379 (14.9)

  • Page 145: Terminal Locations - Frame Size E

    7 Mechanical Installation - Frame size D, E and FC 300 Design Guide 7.2.4 Terminal Locations - Frame size E Terminal Locations - E1 Give thought to the following terminal positions when designing the cable access. Figure 7.15: IP21 (NEMA Type 1) and IP54 (NEMA Type 12) enclosure power connection positions Figure 7.16: IP21 (NEMA type 1) and IP54 (NEMA type 12) enclosure power connection positions (detail B)
  • Page 146 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Figure 7.17: IP21 (NEMA type 1) and IP54 (NEMA type 12) enclosure power connection position of disconnect switch Frame Unit type Dimension for disconnect terminal size IP54/IP21 UL AND NEMA1/NEMA12 350/450 hp [250/315 kW] (400 V) AND 500/600–675/850 hp [355/450–500/630 KW]...
  • Page 147 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Terminal locations - Frame size E2 Give thought to the following terminal positions when designing the cable access. Figure 7.18: IP00 enclosure power connection positions Figure 7.19: IP00 enclosure power connection positions 7-17 MG.33.BC.22 - VLT...
  • Page 148 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Figure 7.20: IP00 enclosure power connections positions of disconnect switch Note that the power cables are heavy and difficult to bend. Give thought to the optimum position of the adjustable frequency drive for ensuring easy installation of the cables.

  • Page 149: Terminal Locations - Frame Size F

    7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Frame Unit type Dimension for disconnect terminal size IPOO/CHASSIS 350/450 hp [250/315 kW] (400 V) AND 500/600–675/850 hp [355/450–500/630 KW] 381 (15.0) 245 (9.6) 334 (13.1) 423 (16.7) 256 (10.1)
  • Page 150 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Terminal locations - Frame size F2 and F4 Figure 7.23: Terminal locations - Inverter cabinet - F2 and F4 (front, left and right side view). The connector plate is 1.65 in [42 mm] below .
  • Page 151 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Terminal locations - Rectifier (F1, F2, F3 and F4) Figure 7.24: Terminal locations - Rectifier (left side, front and right side view). The connector plate is 1.65 in [42 mm] below .0 level.

  • Page 152: Cooling And Airflow

    7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Terminal locations - Options Cabinet with circuit breaker/ molded case switch (F3 and F4) Figure 7.26: Terminal locations - Options cabinet with circuit breaker/ molded case switch (left side, front and right side view). The connector plate is 1.65 in [42 mm] below .0 level.
  • Page 153 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide NOTE! A door fan is required on the enclosure to remove the heat losses not contained in the backchannel of the drive and any additional losses generated from other components installed inside the enclosure. The total required air flow must be calculated so that the appropriate fans can be selected.
  • Page 154 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Figure 7.28: E frame Derating vs. Pressure Change (Small Fan), P250T5 and P355T7-P400T7 Drive air flow: 650 cfm (1105 m3/h) Figure 7.29: E frame Derating vs. Pressure Change (Large Fan), P315T5-P400T5 and P500T7-P560T7 Drive air flow: 850 cfm (1445 m3/h) Figure 7.30: F1, F2, F3, F4 frame Derating vs.
  • Page 155 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide 7.2.7 Installation on the wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units This only applies to frame sizes D1 and D2 . Thought must be given to where the unit should be installed.
  • Page 156 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide 7.2.8 Connector/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) Cables are connected through the connector plate from the bottom. Remove the plate and plan where to place the entry for the connectors or conduits.
  • Page 157 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Frame size F1 Frame size F2 Frame size F3 Frame size F4 F1-F4: Cable entries viewed from the bottom of the adjustable frequency drive - 1) Place conduits in marked areas 7-27 MG.33.BC.22 - VLT...
  • Page 158 7 Mechanical Installation - Frame size D, E and FC 300 Design Guide Figure 7.33: Mounting of bottom plate,frame size E1. The bottom plate of the E1 can be mounted from either inside or outside of the enclosure, allowing flexibility in the installation process, i.e., if mounted from the bottom the connectors and cables can be mounted before the adjustable frequency drive is placed on the pedestal.

  • Page 159: Electrical Installation

    FC 300 Design Guide 8 Electrical Installation 8 Electrical Installation 8.1 Connections Frame Sizes A, B and C NOTE! Cables General All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper (167°F [75°C]) conductors are recommended.

  • Page 160: Connection To Line Power And Grounding

    8 Electrical Installation FC 300 Design Guide 8.1.1 Removal of Knockouts for Extra Cables Remove the cable entry from the adjustable frequency drive (this prevents foreign parts from falling into the adjustable frequency drive when removing knockouts) The cable entry must be supported around the knockout you intend to remove.
  • Page 161 FC 300 Design Guide 8 Electrical Installation AC line input connections for Frame sizes A1, A2 and A3: MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 162 8 Electrical Installation FC 300 Design Guide AC line power connector frame size A5 (IP 55/66) When a disconnector is used (frame size A5) the PE must be mounted on the left side of the drive. Figure 8.1: AC line input connections frame sizes B1 and B2 (IP 21/NEMA Type 1 and IP 55/66/ NEMA Type 12).

  • Page 163: Motor Connection

    FC 300 Design Guide 8 Electrical Installation Figure 8.5: AC line input connections size C3 (IP20). Figure 8.6: AC line input connections size C4 (IP20). The power cables for line power are usually unshielded cables. 8.1.3 Motor Connection NOTE! Motor cable must be shielded/armored. If an unshielded/unarmored cable is used, some EMC requirements are not complied with. Use a shielded/armored motor cable to comply with EMC emission specifications.
  • Page 164 8 Electrical Installation FC 300 Design Guide Figure 8.8: Motor connection for size A5 (IP 55/66/NEMA Type 12) Figure 8.7: Motor connection for A1, A2 and A3 Figure 8.9: Motor connection for size B1 and B2 (IP 21/ NEMA Type 1, IP 55/ NEMA Type 12 and IP66/ NEMA Type Figure 8.10: Motor connection for size B3.
  • Page 165 FC 300 Design Guide 8 Electrical Installation Figure 8.13: Motor connection for frame size C3 and C4. Figure 8.12: Motor connection frame size C1 and C2 (IP 21/ NEMA Type 1 and IP 55/66/ NEMA Type 12) Figure 8.16: Cable entry holes for frame size C1. The sug- Figure 8.14: Cable entry holes for frame size B1.

  • Page 166: Relay Connection

    8 Electrical Installation FC 300 Design Guide NOTE! In motors without phase insulation paper or other in- sulation reinforcement suitable for operation with volt- age supply (such as a adjustable frequency drive), fit a sine-wave filter on the output of the adjustable fre- quency drive.

  • Page 167: Connections - Frame Sizes D, E And F

    FC 300 Design Guide 8 Electrical Installation 8.2 Connections - Frame Sizes D, E and F 8.2.1 Torque When tightening all electrical connections, it is very important to tighten with the correct torque. Too low or too high torque results in a bad elec- trical connection.

  • Page 168: Power Connections

    8 Electrical Installation FC 300 Design Guide 8.2.2 Power Connections Cabling and Fusing NOTE! Cables General All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. UL applications require 167°F [75°C] copper conductors. 167°F [75°C] and 194°F [90°C] copper conductors are thermally acceptable for the adjustable fre- quency drive to use in non-UL applications.
  • Page 169 FC 300 Design Guide 8 Electrical Installation Term. no. Motor voltage 0–100% of AC line voltage. 3 wires out of motor Delta-connected 6 wires out of motor Star-connected U2, V2, W2 U2, V2 and W2 to be interconnected separately. 1)Protected Ground Connection...
  • Page 170 8 Electrical Installation FC 300 Design Guide Figure 8.20: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) with disconnect, fuse and RFI filter, frame size D2 AUX Relay Brake Temp Switch SMPS Fuse (see fuse tables for part number)
  • Page 171 FC 300 Design Guide 8 Electrical Installation Figure 8.21: Compact IP 00 (Chassis), frame size D3 Figure 8.22: Compact IP 00 (Chassis) with disconnect, fuse and RFI filter, frame size D4 8-13 MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 172 8 Electrical Installation FC 300 Design Guide AUX Relay Brake Temp Switch SMPS Fuse (see fuse tables for part number) AUX Fan Line Fan Fuse (see fuse tables for part number) Line power ground Load sharing Motor Figure 8.23: Position of ground terminals IP00, frame sizes Figure 8.24: Position of ground terminals IP21 (NEMA type...
  • Page 173 FC 300 Design Guide 8 Electrical Installation Figure 8.25: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) frame size E1 Figure 8.26: Compact IP 00 (Chassis) with disconnect, fuse and RFI filter, frame size E2 8-15 MG.33.BC.22 - VLT ®...
  • Page 174 8 Electrical Installation FC 300 Design Guide AUX Relay Load sharing Temp Switch SMPS Fuse (see fuse tables for part number) Fan Fuse (see fuse tables for part number) Line AUX Fan Line power ground Brake Motor Figure 8.27: Position of ground terminals IP00, frame sizes E 8-16 MG.33.BC.22 - VLT...
  • Page 175 FC 300 Design Guide 8 Electrical Installation Figure 8.28: Rectifier Cabinet, frame size F1, F2, F3 and F4 24 V DC, 5 A Load sharing T1 Output Taps Temp Switch 104 105 Control Transformer Fuses (2 or 4 pieces). See fuse tables for part numbers Manual Motor Starters SMPS Fuse.
  • Page 176 8 Electrical Installation FC 300 Design Guide Figure 8.29: Inverter Cabinet, frame size F1 and F3 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 177 FC 300 Design Guide 8 Electrical Installation Figure 8.30: Inverter Cabinet, frame size F2 and F4 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 178 8 Electrical Installation FC 300 Design Guide Figure 8.31: Options Cabinet, frame size F3 and F4 Pilz Relay Terminal Safety Relay Coil Fuse with PILS Relay RCD or IRM Terminal See fuse tables for part numbers Line power Line Fuses, F3 and F4 (3 pieces) See fuse tables for part numbers Contactor Relay Coil (230 V AC).
  • Page 179 FC 300 Design Guide 8 Electrical Installation 8.2.3 Shielding against Electrical Noise Before mounting the line power cable, mount the EMC metal cover to ensure best EMC performance. NOTE: The EMC metal cover is only included in units with an RFI filter.

  • Page 180: Fuses

    Short-circuit protection: The adjustable frequency drive must be protected against short-circuit to avoid electrical or fire hazard. Danfoss recommends using the fuses mentioned below to protect service personnel and equipment in case of an internal failure in the drive. The adjustable frequency drive provides full short-circuit protection in case of a short-circuit on the motor output.
  • Page 181 FC 300 Design Guide 8 Electrical Installation UL Compliance - max. fuse size The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240 V, or 480 V, or 500 V, or 600 V depending on the drive voltage rating.
  • Page 182 8 Electrical Installation FC 300 Design Guide Ferraz- Ferraz- SIBA Littel fuse Shawmut Shawmut Type RK1 Type RK1 Type CC Type RK1 K37-1K1 5017906-006 KLS-R6 ATM-R6 A6K-6R 1K5-2K2 5017906-010 KLS-R10 ATM-R10 A6K-10R 5017906-016 KLS-R15 ATM-R15 A6K-15R 5017906-020 KLS-R20 ATM-R20 A6K-20R...
  • Page 183 FC 300 Design Guide 8 Electrical Installation 525–690 V*, frame sizes B and C Ferraz- Ferraz- Bussmann Bussmann Bussmann SIBA LittelFuse Shawmut Shawmut Max. prefuse E52273 E4273 E4273 E180276 E81895 E163267/ E2137 RK1/JDDZ J/JDDZ T/JDDZ RK1/JDDZ RK1/JDDZ E2137 J/HSJ RK1/JDDZ...
  • Page 184 8 Electrical Installation FC 300 Design Guide 525–690 V, frame sizes D, E and F Bussmann SIBA Ferraz-Shawmut Internal Size/Type E125085 Amps E180276 E76491 Option JFHR2 JFHR2 JFHR2 Bussmann P37K 170M3013 2061032.125 6.6URD30D08A0125 170M3015 P45K 170M3014 2061032.16 6.6URD30D08A0160 170M3015 P55K 170M3015 2061032.2...
  • Page 185 FC 300 Design Guide 8 Electrical Installation Size/Type Bussmann PN* LittelFuse Rating P90K-P250, 380–500 V KTK-4 4 A, 600 V P37K-P400, 525–690 V KTK-4 4 A, 600 V P315-P800, 380–500 V KLK-15 15A, 600 V P500-P1M0, 525–690 V KLK-15 15A, 600 V Table 8.11: Fan Fuses...

  • Page 186: Disconnectors, Circuit Breakers And Contactors

    8 Electrical Installation FC 300 Design Guide 8.4 Disconnectors, Circuit Breakers and Contactors 8.4.1 Line Power Disconnectors Assembling of IP55 / NEMA Type 12 (A5 housing) with line power disconnector The line power switch is placed on left side on frame sizes B1, B2, C1 and C2 . The line power switch on A5 frames is placed on right side...
  • Page 187 FC 300 Design Guide 8 Electrical Installation 8.4.3 F Frame Circuit Breakers Frame size Power & Voltage Type P450 380–500 V & P630-P710 525–690 V Merlin Gerin NPJF36120U31AABSCYP P500-P630 380–500 V & P800 525–690 V Merlin Gerin NRJF36200U31AABSCYP P710 380–500 V & P900-P1M0 525–690 V Merlin Gerin NRJF36200U31AABSCYP P800 380–500 V...

  • Page 188: Motor Thermal Protection

    8 Electrical Installation FC 300 Design Guide F frame Requirements F1/F3 requirements: Motor phase cable quantities must be multiples of 2, resulting in 2, 4, 6, or 8 (1 cable is not allowed) to obtain equal amount of wires attached to both inverter module terminals. The cables are required to be equal length within 10% between the inverter module terminals and the first common point of a phase.
  • Page 189 FC 300 Design Guide 8 Electrical Installation Frame Size Power Size Voltage [V] 1 cable [m] 2 cables [m] 3 cables [m] 4 cables [m] A1, A2, A5 0.5-1 hp [0.37–0.75 A2, A5 1.5–2 hp [1.1–1.5 A2, A5 3–5 hp [2.2–4 kW] A3, A5 7.5–10 hp [5.5–7.5...

  • Page 190: Motor Insulation

    8 Electrical Installation FC 300 Design Guide 8.5.4 Motor Insulation For motor cable lengths ≤, the maximum cable length listed in the General Nominal AC Line Voltage Motor Insulation Specifications tables the following motor insulation ratings are recom- ≤ 420 V...
  • Page 191 FC 300 Design Guide 8 Electrical Installation Figure 8.34: Frame sizes A5, B1, B2, C1 and C2 Figure 8.33: Frame sizes A1, A2, A3, B3, B4, C3 and C4 8-33 MG.33.BC.22 - VLT ® is a registered Danfoss trademark...

  • Page 192: Control Cable Routing

    8 Electrical Installation FC 300 Design Guide 8.6.2 Control Cable Routing Tie down all control wires to the designated control cable routing as shown in the picture. Remember to connect the shields in a proper way to ensure optimum electrical immunity.
  • Page 193 FC 300 Design Guide 8 Electrical Installation Installation of 24 Volt external DC Supply Torque: 0.5–0.6 Nm (5 in-lbs) Screw size: M3 Function 35 (-), 36 (+) 24 V external DC supply 24 VDC external supply can be used as low-voltage supply to the control card and any option cards installed. This enables full operation of the LCP (including parameter setting) without connection to line power.

  • Page 194: Control Terminals

    8 Electrical Installation FC 300 Design Guide 8.6.3 Control Terminals Control Terminals, AutomationDrive FC 301 Drawing reference numbers: 8-pole plug, digital I/O. 3-pole plug, RS-485 bus. 6-pole, analog I/O. USB Connection. Control Terminals, AutomationDrive FC 302 Drawing reference numbers: 10-pole plug, digital I/O.

  • Page 195: Electrical Installation, Control Terminals

    FC 300 Design Guide 8 Electrical Installation 8.6.5 Electrical Installation, Control Terminals To mount the cable to the terminal: Strip insulation of 0.34–0.39 in [9–10 mm] Insert a screwdriver in the square hole. Insert the cable in the adjacent circular hole.

  • Page 196: Basic Wiring Example

    8 Electrical Installation FC 300 Design Guide 8.6.6 Basic Wiring Example Mount terminals from the accessory bag to the front of the ad- justable frequency drive. Connect terminals 18, 27 and 37 (AutomationDrive FC 302 only) to +24 V (terminal 12/13) Default settings: 18 = Start, par.

  • Page 197: Electrical Installation, Control Cables

    FC 300 Design Guide 8 Electrical Installation 8.6.7 Electrical Installation, Control Cables Figure 8.37: Diagram showing all electrical terminals without options. A = analog, D = digital Terminal 37 is used for Safe Stop. For instructions on Safe Stop installation, please refer to the section...
  • Page 198 8 Electrical Installation FC 300 Design Guide The digital and analog inputs and outputs must be connected separately to the common inputs (terminal 20, 55, 39) of the adjustable frequency drive to avoid ground currents from both groups to affect other groups. For example, switching on the digital input may disturb the analog input signal.

  • Page 199: Relay Output

    FC 300 Design Guide 8 Electrical Installation 8.6.8 Relay Output Relay 1 • Terminal 01: common • Terminal 02: normal open 240 V AC • Terminal 03: normal closed 240 V AC Relay 2 (Not AutomationDrive FC 301) • Terminal 04: common •...

  • Page 200: Additional Connections

    8.7.1 DC Bus Connection The DC bus terminal is used for DC back-up, with the intermediate circuit being supplied from an external source. Terminal numbers used: 88, 89 Please contact Danfoss if you require further information. 8.7.2 Load Sharing Terminal No.

  • Page 201: How To Connect A Pc To The Adjustable Frequency Drive

    FC 300 Design Guide 8 Electrical Installation Please note that voltages up to 1099 V DC, depending on the supply voltage, may occur on the terminals. Frame size F Requirements The brake resistor(s) must be connected to the brake terminals in each inverter module.

  • Page 202: The Automationdrive Fc 300 Pc Software

    8 Electrical Installation FC 300 Design Guide 8.7.6 The AutomationDrive FC 300 PC software Data storage in PC via MCT 10 Set-up Software: Data transfer from PC to drive via MCT 10 Set-up Software: Connect a PC to the unit via the USB com port.
  • Page 203 FC 300 Design Guide 8 Electrical Installation 8.9 EMC-correct Installation 8.9.1 Electrical Installation - EMC Precautions The following is a guideline for good engineering practice when installing adjustable frequency drives. Follow these guidelines to comply with EN 61800-3 First environment Second environment, .
  • Page 204 8 Electrical Installation FC 300 Design Guide Figure 8.39: EMC-compliant electrical installation of an adjustable frequency drive in a cabinet. Figure 8.40: Electrical connection diagram. 8-46 MG.33.BC.22 - VLT ® is a registered Danfoss trademark...
  • Page 205 8.9.2 Use of EMC-correct Cables Danfoss recommends braided shielded/armored cables to optimize EMC immunity of the control cables and the EMC emission from the motor cables. The ability of a cable to reduce the in and outgoing radiation of electric noise depends on the transfer impedance (Z ).
  • Page 206 8 Electrical Installation FC 300 Design Guide 8.9.3 Grounding of Shielded/Armored Control Cables Generally speaking, control cables must be braided and shielded/armored, and the shield must be connected by means of a cable clamp at both ends to the metal cabinet of the unit.
  • Page 207 FC 300 Design Guide 8 Electrical Installation 8.9.4 RFI Switch Line power supply isolated from ground If the adjustable frequency drive is supplied from an isolated line power source ( IT line power, floating delta and grounded delta) or TT/TN-S line power with grounded leg, the RFI switch is recommended to be turned off (OFF) via par.

  • Page 208: Residual Current Device

    8 Electrical Installation FC 300 Design Guide 8.11.1 Residual Current Device You can use RCD relays, multiple protective grounding or grounding as extra protection, provided that local safety regulations are complied with. If a ground fault appears, a DC content may develop in the faulty current.

  • Page 209: Final Set-Up And Test

    FC 300 Design Guide 8 Electrical Installation 8.12 Final Set-up and Test To test the set-up and ensure that the adjustable frequency drive is running, follow these steps. Step 1. Locate the motor nameplate NOTE! The motor is either star- (Y) or delta-connected (Δ). This information is located on the motor nameplate data.
  • Page 210 "Report Value” in the [Alarm Log] shows the last measuring sequence carried out by the AMA before the adjustable frequency drive entered alarm mode. This number along with the description of the alarm will assist you in troubleshooting. If you contact Danfoss for service, make sure to mention the number and alarm description.

  • Page 211: Application Examples

    FC 300 Design Guide 9 Application Examples 9 Application Examples 9.1.1 Start/Stop Terminal 18 Digital Input Start Terminal 18 = par. 5-10 Terminal 27 Digital Input No operation Terminal 27 = par. 5-12 (De- coast inverse fault Terminal 37 = Safe stop (where available!) 9.1.2 Pulse Start/Stop...

  • Page 212: Encoder Connection

    9 Application Examples FC 300 Design Guide 9.1.3 Potentiometer Reference Voltage reference via a potentiometer: Analog input 53 Reference Source 1 = [1] (default) Terminal 53, Low Voltage = 0 Volt Terminal 53, High Voltage = 10 Volt Terminal 53, Low Ref./Feedback = 0 RPM Terminal 53, High Ref./Feedback = 1,500 RPM...

  • Page 213: Closed-Loop Drive System

    FC 300 Design Guide 9 Application Examples 9.1.6 Closed-loop Drive System A drive system consist usually of more elements such as: • Motor • (Gearbox) (Mechanical Brake) • AutomationDrive FC 302 AutomationDrive • Encoder as feedback system • Brake resistor for dynamic braking •...

  • Page 214: Advanced Mechanical Brake Control For Hoisting Applications

    9 Application Examples FC 300 Design Guide 9.1.8 Advanced Mechanical Brake Control for Hoisting Applications 1. The vertical movement In the vertical movement, the key point is that the load must be held, stopped, controlled (raised, lowered) in a perfectly safe mode during the entire operation.

  • Page 215: Automatic Motor Adaptation (Ama)

    9.1.10 Smart Logic Control Programming A new useful facility in AutomationDrive FC 300 is the Smart Logic Control (SLC). In applications where a PLC is generating a simple sequence, the SLC may take over elementary tasks from the main control.

  • Page 216: Slc Application Example

    9 Application Examples FC 300 Design Guide 9.1.11 SLC Application Example One sequence 1: Start – ramp up – run at reference speed 2 sec – ramp down and hold shaft until stop. Ramp 1 Ramp-up Time Ramp 1 Ramp-down Time Set the ramping times in par.

  • Page 217: Mcb 112 Ptc Thermistor Card

    FC 300 Design Guide 9 Application Examples SL Controller Mode Set the Smart Logic Control in par. 13-00 to ON. Start / stop command is applied on terminal 18. If stop signal is applied the adjustable frequency drive will ramp down and go into free mode.
  • Page 218 9 Application Examples FC 300 Design Guide Programming example 1 Par. 5-19 Terminal 37 Safe Stop PTC 1 Alarm In case the motor temperature is too high, or in the event of a PTC failure, the MCB 112 activates the Safe Stop of the FC 302 (Safe Stop terminal 37 goes LOW (active) and digital input 33 goes HIGH (active)).

  • Page 219: Torque Control Open-Loop

    FC 300 Design Guide 9 Application Examples Programming example 2 Par. 5-19 Terminal 37 Safe Stop PTC 1 & Relay Alarm In case the motor temperature is too high, or in the event of a PTC failure, the MCB 112 activates the Safe Stop of the FC 302 (Safe Stop terminal 37 goes LOW (active) and digital input 33 goes HIGH (active)).
  • Page 220 9 Application Examples FC 300 Design Guide Parameter set-up Torque open-loop in VVC+ mode Function Parameter Setting Data Value Basic Settings Configuration Mode 1-00 Torque Open-loop Motor Control Principle 1-01 VVC+ Torque PI control settings Torque PI Proportional Gain 7-12...

  • Page 221: Options And Accessories

    10 Options and Accessories 10 Options and Accessories Danfoss offers a wide range of options and accessories for VLT AutomationDrive. 10.1.1 Mounting of Option Modules in Slot A Slot A position is dedicated to serial communication bus options. For further information, see the Instruction Manual.

  • Page 222: Mounting Of Options In Slot C

    10 Options and Accessories FC 300 Design Guide 10.1.3 Mounting of Options in Slot C The power to the adjustable frequency drive must be disconnected. It is strongly recommended to make sure the parameter data is saved (e.g., by MCT10 software) before option modules are inserted/removed from the drive.

  • Page 223: General Purpose Input Output Module Mcb

    FC 300 Design Guide 10 Options and Accessories Figure 10.1: Frame sizes A2, A3 and B3 10.2 General Purpose Input Output Module MCB 101 MCB 101 is used for extension of digital and analog inputs and outputs of AutomationDrive FC 301 and AutomationDrive FC 302.
  • Page 224 10 Options and Accessories FC 300 Design Guide 10.2.1 Galvanic Isolation in the MCB101 Digital/analog inputs are galvanically isolated from other inputs/outputs on the MCB101 and in the control card of the adjustable frequency drive. Digital/ analog outputs in the MCB101 are galvanically isolated from other inputs/outputs on the MCB101, but not from these on the control card of the drive.
  • Page 225 FC 300 Design Guide 10 Options and Accessories 10.2.2 Digital Inputs - Terminal X30/1-4: Digital input: Number of digital inputs Terminal number X30.2, X30.3, X30.4 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic'0' PNP (GND = 0 V) <...

  • Page 226: Encoder Option Mcb

    10 Options and Accessories FC 300 Design Guide 10.3 Encoder Option MCB 102 The encoder module can be used as feedback source for closed-loop flux control (par. 1-02 Flux Motor Feedback Source ) as well as closed-loop speed control (par. 7-00 Speed PID Feedback Source ).
  • Page 227 FC 300 Design Guide 10 Options and Accessories Max. cable length 492 ft [150 m]. 10-7 MG.33.BC.22 - VLT ® is a registered Danfoss trademark...

  • Page 228: Resolver Option Mcb

    10 Options and Accessories FC 300 Design Guide 10.4 Resolver Option MCB 103 MCB 103 Resolver option is used for interfacing resolver motor feedback to VLT AutomationDrive. Resolvers are used basically as motor feedback device for permanent magnet brushless synchronous motors.
  • Page 229 FC 300 Design Guide 10 Options and Accessories Set-up example In this example, a permanent magnet (PM) motor is used with resolver as speed feedback. A PM motor must usually operate in flux mode. Wiring: The max cable length is 490 ft [150 m] when a twisted-pair cable is used.

  • Page 230: Relay Option Mcb

    10 Options and Accessories FC 300 Design Guide 10.5 Relay Option MCB 105 The MCB 105 option includes 3 pieces of SPDT contacts and must be fitted into option slot B. Electrical Data: Max terminal load (AC-1) (Resistive load) 240 V AC 2A Max terminal load (AC-15) (Inductive load @ cosφ...
  • Page 231 FC 300 Design Guide 10 Options and Accessories • Connect the control cables and fasten the cables with the enclosed cable strips. • Make sure the length of the stripped wire is correct (see the following drawing). • Do not mix live parts (high voltage) with control signals (PELV).

  • Page 232: Backup Option Mcb

    10 Options and Accessories FC 300 Design Guide 10.6 24 V Backup Option MCB 107 External 24 V DC Supply An external 24 V DC supply can be installed for low-voltage supply to the control card and any option card installed. This enables full operation of the LCP (including the parameter setting) without connection to line power.

  • Page 233: Mcb 112 Ptc Thermistor Card

    FC 300 Design Guide 10 Options and Accessories 10.7 MCB 112 PTC Thermistor Card The MCB 112 option makes it possible to monitor the temperature of an electrical motor through a PTC thermistor input. It is a B option for AutomationDrive FC 302 with safe stop.
  • Page 234 10 Options and Accessories FC 300 Design Guide Electrical Data Resistor connection: PTC compliant with DIN 44081 and DIN 44082. Number 1..6 resistors in series 3.3 Ω..3.65 Ω ... 3.85 Ω Shut-off value 1.7 Ω ..1.8 Ω ... 1.95 Ω...

  • Page 235: Mcb 113 Extended Relay Card

    The MCB 113 adds seven digital inputs, two analog outputs and four SPDT relays to the standard I/O of the drive for increased flexibility and to comply with the German NAMUR NE37 recommendations. The MCB 113 is a standard C1 option for the Danfoss VLT® AutomationDrive and is automatically detected after mounting. Mounting of Option Modules in Slot C1 For information on mounting and installation of the option, please see earlier in this chapter.

  • Page 236: Mcf 106 A/ B In C Option Adaptor

    10 Options and Accessories FC 300 Design Guide Digital Inputs: Numbers Range 0/24V Mode PNP/NPN Input impedance 5 hp [4 kW] Low trigger level 6.4 V High trigger level 17 V Maximum thru-put delay 10 ms Analog Outputs: Numbers Range 0/4–20 mA...
  • Page 237 FC 300 Design Guide 10 Options and Accessories • One serial communication bus (A option) at any time – in the standard A slot or in the E0 slot of the adaptor. • The MCB 121 Ethernet takes up both slot A and slot B when installed in the standard slot A of the control card. The only way to install a B option at the same time: Use the standard B slot of the control card and move the MCA 121 in the E1 slot of the adapter.

  • Page 238: Brake Resistors

    Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected in respect to its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide Control with brake function variety of different resistors that are specially designed to our adjustable frequency drives.

  • Page 239: Remote Mounting Kit For Lcp

    FC 300 Design Guide 10 Options and Accessories 10.11 Remote Mounting Kit for LCP The LCP can be moved to the front of a cabinet by using the remote built- Technical data in kit. The enclosure is the IP65. The fastening screws must be tightened...

  • Page 240: Ip21/Ip 4X/ Type 1 Enclosure Kit

    10 Options and Accessories FC 300 Design Guide 10.12 IP21/IP 4X/ TYPE 1 Enclosure Kit IP 20/IP 4X top/ TYPE 1 is an optional enclosure element available for IP 20 Compact units. If the enclosure kit is used, an IP 20 unit is upgraded to comply with enclosure IP 21/ 4X top/TYPE 1.
  • Page 241 FC 300 Design Guide 10 Options and Accessories A – Top cover B – Brim C – Base part D – Base cover E – Screw(s) F - Fan cover G - Top clip When option module A and/ or option module B is/are used, the brim (B) must be fitted to the top cover (A).

  • Page 242: Mounting Bracket For Frame Size A5, B1, B2, C1 And C2

    10 Options and Accessories FC 300 Design Guide 10.13 Mounting Bracket for Frame Size A5, B1, B2, C1 and C2 Mounting Bracket for Frame Size A5, B1, B2, C1 and C2 Step 1 Step 2 Position the lower bracket and mount it with screws. Do not tighten the...
  • Page 243 FC 300 Design Guide 10 Options and Accessories Step 3 Step 4 Place the adjustable frequency drive in the lower bracket, and lift the Now tighten the screws. For extra security, drill and mount screws in all upper one. When the adjustable frequency drive is in place, lower the holes.

  • Page 244: Sine-Wave Filters

    The frequency of the resonance noise thus corresponds to the switching frequency of the adjustable frequency drive. For the AutomationDrive FC 300, Danfoss can supply a sine-wave filter to dampen the acoustic motor noise. and the ripple current ΔI to the motor, which means that current and...
  • Page 245 FC 300 Design Guide 10 Options and Accessories RCD (Residual Current Device) Uses the core balance method to monitor ground fault currents in grounded and high-resistance grounded systems (TN and TT systems in IEC termi- nology). There is a pre-warning (50% of main alarm setpoint) and a main alarm setpoint. Associated with each setpoint is an SPDT alarm relay for external use.
  • Page 246 10 Options and Accessories FC 300 Design Guide External Temperature Monitoring Designed for monitoring temperatures of external system components, such as the motor windings and/or bearings. Includes eight universal input modules plus two dedicated thermistor input modules. All ten modules are integrated into the drive’s safe stop circuit and can be monitored via a serial commu- nication bus network (requires the purchase of a separate module/bus coupler).

  • Page 247: Installation And Set-Up

    FC 300 Design Guide 11 RS-485 Installation and Set-up 11 RS-485 Installation and Set-up 11.1 RS-485 Installation and Set-up 11.1.1 Overview RS-485 is a two-wire bus interface compatible with multi-drop network topology, i.e., nodes can be connected as a bus, or via drop cables from a common trunk line.
  • Page 248 11 RS-485 Installation and Set-up FC 300 Design Guide 11.1.2 Network Connection Connect the adjustable frequency drive to the RS-485 network as follows (see also diagram): Connect signal wires to terminal 68 (P+) and terminal 69 (N-) on the main control board of the adjustable frequency drive.

  • Page 249: Network Configuration

    90 degrees. The adjustable frequency drive protocol, also referred to as adjustable frequency drive bus or standard bus, is the Danfoss standard serial communication bus. It defines an access technique according to the master-slave principle for communications via a serial bus.

  • Page 250: Adjustable Frequency Drive Protocol Message Framing Structure - Automationdrive Fc

    11 RS-485 Installation and Set-up FC 300 Design Guide 11.4 Adjustable frequency drive Protocol Message Framing Structure - AutomationDrive FC 300 11.4.1 Content of a Character (byte) Each character transferred begins with a start bit. Then 8 data bits are transferred, corresponding to a byte. Each character is secured via a parity bit, which is set at "1"...
  • Page 251 FC 300 Design Guide 11 RS-485 Installation and Set-up 11.4.4 Adjustable Frequency Drive Address (ADR) Two different address formats are used. The address range of the adjustable frequency drive is either 1-31 or 1-126. 1. Address format 1-31: Bit 7 = 0 (address format 1-31 active)
  • Page 252 11 RS-485 Installation and Set-up FC 300 Design Guide 11.4.6 The Data Field The structure of data blocks depends on the type of message. There are three message types, and the type applies for both control messages (mas- ter=>slave) and response messages (slave=>master).
  • Page 253 FC 300 Design Guide 11 RS-485 Installation and Set-up 11.4.7 The PKE Field The PKE field contains two sub-fields: Parameter command and response AK, and Parameter number PNU: Bits no. 12-15 transfer parameter commands from master to slave and return processed slave responses to the master.
  • Page 254 11 RS-485 Installation and Set-up FC 300 Design Guide PWE low (Hex) Fault Report The parameter number used does not exit. There is no write access to the defined parameter. Data value exceeds the parameter's limits. The sub index used does not exit.
  • Page 255 FC 300 Design Guide 11 RS-485 Installation and Set-up 11.4.11 Data Types Supported by AutomationDrive FC 300 Unsigned means that there is no operational sign in the message. Data types Description Integer 16 Integer 32 Unsigned 8 Unsigned 16 Unsigned 32...

  • Page 256: Examples

    11 RS-485 Installation and Set-up FC 300 Design Guide 11.5 Examples 11.5.1 Writing a Parameter Value Motor Speed High Limit [Hz] Change par. 4-14 to 100 Hz. Write the data in EEPROM. Motor Speed High Limit PKE = E19E Hex - Write single word in par. 4-14...

  • Page 257: Modbus Rtu Overview

    FC 300 Design Guide 11 RS-485 Installation and Set-up 11.6 Modbus RTU Overview 11.6.1 Assumptions This instruction manual assumes that the installed controller supports the interfaces in this document and that all the requirements stipulated in the controller, as well as the adjustable frequency drive, are strictly observed, along with all limitations therein.
  • Page 258 11 RS-485 Installation and Set-up FC 300 Design Guide 11.6.4 Adjustable Frequency Drive with Modbus RTU The adjustable frequency drive communicates in Modbus RTU format over the built-in RS-485 interface. Modbus RTU provides access to the control word and bus reference of the adjustable frequency drive.

  • Page 259: Modbus Rtu Message Framing Structure

    FC 300 Design Guide 11 RS-485 Installation and Set-up 11.7 Network Configuration To enable Modbus RTU on the adjustable frequency drive, set the following parameters: Parameter Number Parameter name Setting 8-30 Protocol Modbus RTU 8-31 Address 1 - 247 8-32...
  • Page 260 11 RS-485 Installation and Set-up FC 300 Design Guide 11.8.3 Start / Stop Field Messages start with a silent period of at least 3.5 character intervals. This is implemented as a multiple of character intervals at the selected network baud rate (shown as Start T1-T2-T3-T4). The first field to be transmitted is the device address. Following the last transmitted character, a similar period of at least 3.5 character intervals marks the end of the message.
  • Page 261 FC 300 Design Guide 11 RS-485 Installation and Set-up 11.8.8 Coil Register Addressing In Modbus, all data are organized in coils and holding registers. Coils hold a single bit, whereas holding registers hold a 2-byte word (i.e., 16 bits). All data addresses in Modbus messages are referenced to zero.
  • Page 262 11 RS-485 Installation and Set-up FC 300 Design Guide Holding registers Register Number Description 00001-00006 Reserved 00007 Last error code from an adjustable frequency drive data object interface 00008 Reserved 00009 Parameter index* 00010-00990 000 parameter group (parameters 001 through 099)
  • Page 263 FC 300 Design Guide 11 RS-485 Installation and Set-up 11.8.11 Modbus Exception Codes For a full explanation of the structure of an exception code response, please refer to the section Modbus RTU Message Framing Structure, Function Field. Modbus Exception Codes...

  • Page 264: How To Access Parameters

    11 RS-485 Installation and Set-up FC 300 Design Guide 11.9 How to Access Parameters 11.9.1 Parameter Handling The PNU (Parameter Number) is translated from the register address contained in the Modbus read or write message. The parameter number is translated to Modbus as (10 x parameter number) DECIMAL.

  • Page 265: Danfoss Fc Control Profile

    FC 300 Design Guide 11 RS-485 Installation and Set-up 11.10 Danfoss FC Control Profile Control Profile 11.10.1 Control Word According to FC Profile(par. 8-10 = FC profile) Bit value = 0 Bit value = 1 Reference value external selection lsb...
  • Page 266 11 RS-485 Installation and Set-up FC 300 Design Guide Bit 03, Coasting: Bit 03 = ’0’: The adjustable frequency drive immediately "lets go" of the motor, (the output transistors are "shut off") and it coasts to a standstill. Bit 03 = ’1’: The adjustable frequency drive starts the motor if the other starting conditions are met.
  • Page 267 FC 300 Design Guide 11 RS-485 Installation and Set-up Bit 11, Relay 01: Control word bit 11 Function Relay Bit 11 = "0": Relay not activated. Bit 11 = "1": Relay 01 activated provided that is chosen in par. 5-40...
  • Page 268 11 RS-485 Installation and Set-up FC 300 Design Guide Bit 01, Drive ready: Bit 01 = ’1’: The adjustable frequency drive is ready for operation but the coasting command is active via the digital inputs or via serial communication. Bit 02, Coasting stop: Bit 02 = ’0’: The adjustable frequency drive releases the motor.
  • Page 269 FC 300 Design Guide 11 RS-485 Installation and Set-up Bit 14, Torque OK/limit exceeded: Current Limit Current Bit 14 = ’0’: The motor current is lower than the torque limit selected in par. 4-18 . Bit 14 = ’1’: The torque limit in par. 4-18 Limit is exceeded.
  • Page 270 11 RS-485 Installation and Set-up FC 300 Design Guide 11.10.4 PROFIdrive Control Profile This section describes the functionality of the control word and status word in the PROFIdrive profile. Select this profile by setting par. 8-10 Control Word Profile 11.10.5 Control Word according to PROFIdrive Profile (CTW)
  • Page 271 FC 300 Design Guide 11 RS-485 Installation and Set-up Bit 03, Coasting/No coasting Coasting stop bit 03 = "0" leads to a stop. When bit 03 = "1", the adjustable frequency drive can start if the other start conditions are satisfied.
  • Page 272 11 RS-485 Installation and Set-up FC 300 Design Guide Bit 10, Data invalid/valid Is used to tell the adjustable frequency drive whether the control word is to be used or ignored. Bit 10 = “0” causes the control word to be ignored, Bit 10 = “1”...
  • Page 273 FC 300 Design Guide 11 RS-485 Installation and Set-up 11.10.6 Status Word according to PROFIdrive Profile (STW) The status word is used to notify a master (e.g., a PC) about the status Bit = 0 Bit = 1 of a slave.
  • Page 274 11 RS-485 Installation and Set-up FC 300 Design Guide Bit 05, ON 3/OFF 3 When bit 02 of the control word is "0", then bit 05 = "0". When bit 02 of the control word is "1", then bit 05 = "1".

  • Page 275: Index

    FC 300 Design Guide Index Index 24 Vdc Power Supply 10-25 30 Ampere, Fuse-protected Terminals 10-25 Abbreviations Access To Control Terminals 8-32 Accessory Bags Acoustic Noise 4-26 Adjustable Frequency Drive With Modbus Rtu 11-12 Aggressive Environments Air Humidity Airflow 7-23...
  • Page 276 Index FC 300 Design Guide Control Card, +10 V Dc Output 4-23 Control Card, 24 V Dc Output 4-23 Control Card, Rs-485 Serial Communication 4-22 Control Card, Usb Serial Communication 4-24 Control Characteristics 4-24 Control Terminals 8-36, 8-37 Control Word...
  • Page 277 FC 300 Design Guide Index General Aspects Of Emc Emissions 3-23 General Considerations 7-11 General Warning Ground Leakage Current 8-44 Ground Leakage Current 3-27 Grounding 8-48 Grounding 8-44 Grounding Of Shielded/armored Control Cables 8-48 Harmonic Filters 5-20 High Power Fuse Tables...
  • Page 278 Index FC 300 Design Guide Motor Cable 8-29 Motor Cables 8-45 Motor Connection Motor Feedback Motor Nameplate 8-51 Motor Output 4-20 Motor Parameters Motor Phases 3-34 Motor Protection 4-21, 8-31 Motor Thermal Protection 11-23 Motor Thermal Protection 3-36, 8-30 Motor Voltage...
  • Page 279 FC 300 Design Guide Index Rfi Switch 8-49 Rise Time 4-26 Rs 485 Bus Connection 8-43 Rs-485 11-1 Safe Stop 3-37 Safety Ground Connection 8-44 Safety Precautions Safety Requirements Of Mechanical Installation Scaling Of Analog And Pulse References And Feedback...
  • Page 280 Index FC 300 Design Guide What Is Ce Conformity And Labeling? What Is Covered Wire Access 7-12 12-6 ® MG.33.BC.22 - VLT is a registered Danfoss trademark...

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