Page 1: Table Of Contents
Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) Safe Stop Commissioning Test FC 300 Selection Electrical Data General Specifications Efficiency Acoustic Noise Peak Voltage on Motor Purpose of derating Automatic adaptations to ensure performance MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 2 Smart Logic Control Programming Options and Accessories Options and Accessories Mounting of Option Modules in Slot B General Purpose Input Output Module MCB 101 Encoder Option MCB 102 Resolver Option MCB 103 MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 3 RS-485 Installation and Set-up FC Protocol Overview Network Configuration FC Protocol Message Framing Structure - FC 300 Examples Danfoss FC Control Profile Troubleshooting Status messages - FC 300 DG Warnings/Alarm Messages Index MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 4 FC 300 Design Guide MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 5: How To Read This Design Guide
AutomationDrive FC 300 DeviceNet Operating Instructions MG.33.DX.YY provide the information required for controlling, monitoring and programming the drive via a DeviceNet field- bus. X = Revision number YY = Language code Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/Drives- Solutions/Documentations/Technical+Documentation. Approvals ® MG.33.B8.02 - VLT...
Page 6: Symbols
Nominal motor current Nominal motor frequency Nominal motor power Nominal motor voltage Parameter par. Protective Extra Low Voltage PELV Printed Circuit Board Rated Inverter Output Current Revolutions Per Minute Second Torque limit Volts MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 7: Definitions
The rated motor current (nameplate data). M-TYPE Size and type of the connected motor (dependencies). The rated motor speed (nameplate data). The rated motor power (nameplate data). The rated torque (motor). The instantaneous motor voltage. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 8 Voltage input, 0-10 V DC (FC 301) Voltage input, -10 - +10 V DC (FC 302). Analog Outputs The analog outputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 9 [OK] on the LCP. Process PID The PID regulator maintains the desired speed, pressure, temperature, etc. by adjusting the output fre- quency to match the varying load. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 10 ϕ Power Factor Power factor x U x I The power factor is the relation between I The power factor for 3-phase control: x cos ϕ1 since cos ϕ1 = 1 MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 11 In addition, a high power factor indicates that the different harmonic currents are low. The FC 300 frequency converters' built-in DC coils produce a high power factor, which minimizes the imposed load on the mains supply. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 12 FC 300 Design Guide MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 13: Introduction To Fc 300
(linking of DC intermediate circuit) and external 24 V DC have been installed. Check that all voltage inputs have been disconnected and that the necessary time has passed before com- mencing repair work. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 14: Disposal Instruction
Before doing service on the frequency converter wait at least the amount of time indicated below: FC 300: 0.25 – 7.5 kW 4 minutes FC 300: 11 – 22 kW 15 minutes FC 300: 30 - 75 kW 15 minutes MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 15: Software Version
Design Guide Software version: 4.0x This Design Guide can be used for all FC 300 frequency converters with software version 4.0x. The software version number can be seen from parameter 15-43. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 16 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 decla- ration of conformity upon request.
Page 17 Danfoss CE labels the frequency converters in accordance with the low-voltage directive. This means that if the frequency converter is installed correctly, we guarantee compliance with the low-voltage directive. Danfoss issues a declaration of conformity that confirms our CE labelling in accordance with the low- voltage directive.
Page 18 The frequency converter 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. IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970 IEC/EN 60068-2-64: Vibration, broad-band random MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 19: Control Principle
Short circuit behaviour on FC 301 depends on the current transducer in the positive DC link and the desaturation protection with feedback from the 3 lower IGBT's and the brake. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 20: Control Structure In Vvc
PID control. The Speed PID control parameters are located in the par. group 7-0*. The resulting reference from the Speed PID control is sent to the motor control limited by the frequency limit. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 21: Control Structure In Flux Sensorless (Fc 302 Only)
The Process PID parameters are found in par. group 7-2* and 7-3*. Control Structure in Flux with Motor Feedback Control structure in Flux with motor feedback configuration (only available in FC 302): ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 22: Internal Current Control In Vvc Plus Mode
To permanently select the remote reference select Remote [1]. By selecting Linked to Hand/Auto [0] (default) the reference site will depend on which mode is active. (Hand Mode or Auto Mode). MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 23 Par. 1-05 Local Mode Configuration determines the kind of application control principle that is used when the Local reference is made active. Reference Handling Local Reference Remote Reference The reference handling system for calculating the Remote reference is shown in the illustration below. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 24: Reference Handling
When par. 3-00 Reference Range: [0] Min - Max 0% reference equals 0 [unit] where unit can be any unit e.g. rpm, m/s, bar etc. 100% reference equals the Max (abs (par. 3-03 Maximum Ref- erence), abs (par. 3-02 Minimum Reference)). MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 25: Scaling Of 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” (P1 and P2 in the graph below) are clamped whereas a feedback above or below is not. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 26 Par. 6-15 Par. 6-25 Par. 6-25 Par. 5-53 Par. 5-58 Maximum input value Par. 6-11 [V] Par. 6-13 [mA] Par. 6-21 [V] Par. 6-23 [mA] Par. 5-51 [Hz] Par. 5-56 [Hz] MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 27: Dead Band Around Zero
P1 = (1V, 0 RPM) will result in a -1V to +1V dead band in this case provided that the end point P2 is placed in either Quadrant 1 or Quadrant 4. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 28 FC 300 Design Guide Introduction to FC 300 Case 1: Positive Reference with Dead band, Digital input to trigger reverse This Case shows how Reference input with limits inside Min – Max limits clamps. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 29 This Case shows how Reference input with limits outside -Max – +Max limits clamps to the inputs low and high limits before addition to External reference. And how the External reference is clamped to -Max – +Max by the Reference algorithm. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 30 FC 300 Design Guide Introduction to FC 300 Case 3: Negative to positive reference with dead band, Sign determines the direction, -Max – +Max MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 31: Speed Pid Control
The Speed PID monitors the actual RPM of the motor by using a 24V (HTL) incremental encoder In the parameter list below it is assumed that all other parameters and switches remain at their default setting. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 32 Typically a Max Torque Ripple of 3 % is acceptable. For incremental encoders the Encoder Resolution is found in either par. 5-70 (24V HTL on standard drive) or par. 17-11 (5V TTL on MCB102 Option). MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 33: Process Pid Control
The two Flux motor control prin- ciples are specially dependant on proper Speed Control PID tuning (prior to tuning the Process Control PID) to yield their full potential. Process PID Control diagram ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 34 (speed) of less than 1.6 Hz. The low-pass filter improves steady state performance but selecting a too large filter time will deteriorate the dynamic performance of the Process PID Control. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 35 Temperature reference via potentiometer (-5-35°C, 0-10 VDC) connected to terminal 53. Temperature feedback via transmitter (-10-40°C, 4-20 mA) connected to terminal 54. Switch S202 set to ON (current input). Example of Process PID Control set-up ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 36 6) Basic PID settings Process PID Normal/Inverse 7-30 [0] Normal Process PID Anti Wind-up 7-31 [1] On Process PID start speed 7-37 300 rpm Save parameters to LCP 0-50 [1] All to LCP MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 37: Ziegler Nichols Tuning Method
Experience has shown that the control setting according to Ziegler Nichols rule provides a good closed loop response for many systems. The process operator can do the final tuning of the control iteratively to yield satisfactory control. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 38 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. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 39: Motor Cables To Comply With Emc Regulations
HX - No EMC filters build in the frequency converter (600 V units only) H1 - Integrated EMC filter. Fulfil Class A1/B H2 - No additional EMC filter. Fulfil Class A2 H3 - Integrated EMC filter. Fulfil class A1/B (Enclosure type A1 only) ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 40: Emc Immunity
1 kV/12 Ω CM Enclosure 8 kV AD — — 10 V/m — 6 kV CD AD: Air Discharge CD: Contact Discharge CM: Common mode DM: Differential mode 1. Injection on cable shield. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 41 Internal inrush, RFI, and temperature measurement circuits. Galvanic isolation Custom relays. The functional galvanic isolation (a and b on drawing) is for the 24 V back-up option and for the RS 485 standard bus interface. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 42: Earth Leakage Current
(of the cycle time) 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 brake power for 10% of the cycle time. The remaining 90% of the cycle time will be used on dissipating excess heat.
Page 43 The resistor brake circuit resistance selected should not be higher than that recommended by Danfoss. If a brake resistor with a higher ohmic value is selected, the 160% braking torque may not be achieved because there is a risk that the frequency converter cuts out for safety reasons.
Page 44: Mechanical Brakecontrol
2-21 Activate Brake Speed [RPM]. If the frequency converter is brought into an alarm condition, i.e. over-voltage situation, the me- chanical brake immediately cuts in. This is also the case during safe stop. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 45: Hoist Mechanical Brake
By using the Proportional Gain Boost (par. 2-28) a quicker control when releasing the brake can be ob- tained. The hoist mechanical brake strategy is based on a 3-step sequence, where motor control and brake release are synchronized in order to obtain the smoothest possible brake release: ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 46 Only one event will be evaluated at any time. If an event is evaluated as FALSE, nothing happens (in the SLC) during the present scan interval and no other events will be evaluated. This means that when the MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 47 Switching on the output between the motor and the frequency converter is fully permitted. You cannot damage the frequency converter in any way by switching on the output. However, fault messages may appear. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 48: Safe Stop Of Fc 300
FC 301 A1 enclosure: When Safe Stop is included in the drive, position 18 of Type Code must be either T or U. If position 18 is B or X, Safe Stop Terminal 37 is not included! Example: Type Code for FC 301 A1 with Safe Stop: FC-301PK75T4Z20H4TGCXXXSXXXXA0BXCXXXXD0 MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 49: Safe Stop Installation (Fc 302 And Fc 301 - A1 Enclosure Only)
Bridge jumper between terminal 37 and 24 VDC vice. If the interrupt device and the fre- quency converter are placed in the same installation panel, you can use a regular cable instead of a protected one. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 50: Safe Stop Commissioning Test
In order to use the Safe Stop functionality in conformance with the requirements of EN-954-1 Category 3, a number of conditions must be fulfilled by the installation of Safe Stop. Please see section Safe Stop Installation for further information. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 51 37 and subsequent reset. Provide this protection via the interrupt device, at the application level, or organisational level. For more information - see section Safe Stop Installation. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 52 FC 300 Design Guide MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 53: Fc 300 Selection
[W] Weight, enclosure IP20 [kg] A1 (IP 20) Efficiency 0.94 0.94 0.95 0.95 0.96 0.96 0.96 0.96 0.96 0.25 - 3.7 kW only available as 160% high overload. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 54 FC 300 Design Guide FC 300 Selection MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 55 FC 300 Design Guide FC 300 Selection ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 56 FC 300 Design Guide FC 300 Selection MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 57 FC 300 Design Guide FC 300 Selection ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 58 30W to the losses. (Though typical only 4W extra for a fully loaded control card, or options for slot A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccur- acy must be allowed for (+/-5%). MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 59: General Specifications
Maximum cross section to control terminals, flexible wire with cable end sleeves with collar 0.5 mm /20 AWG Minimum cross section to control terminals 0.25 mm / 24 AWG Protection and Features: ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 60 EN 954-1. For correct and safe use of the Safe Stop function follow the related information and instructions in the Design Guide. 4) FC 302 and FC 301/ A1 with safe stop only. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 61 The pulse and encoder inputs (terminals 29, 32, 33) are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. 1) Pulse inputs are 29 and 33 2) Encoder inputs: 32 = A, and 33 = B 3) Terminal 29: Only FC 302 ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 62 (Inductive load) 24 V DC, 0.1A Relay 02 (FC 302 only) Terminal number 4-6 (break), 4-5 (make) Max. terminal load (AC-1) on 4-5 (NO) (Resistive load) 400 V AC, 2 A MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 63 Minimum ambient temperature during full-scale operation 0 °C Minimum ambient temperature at reduced performance - 10 °C Temperature during storage/transport -25 - +65/70 °C Maximum altitude above sea level 1000 m ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 64: Efficiency
(η MOTOR η = η x η SYSTEM MOTOR Acoustic Noise The acoustic noise from the frequency converter comes from three sources: DC intermediate circuit coils. Integral fan. RFI filter choke. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 65: Peak Voltage On Motor
In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply (such as a frequency converter), fit a sine-wave filter on the output of the FC 300. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 66: Purpose Of Derating
A, Derating of I for different T for enclosure A, AMB, MAX AMB, MAX using 60 PWM and maximum 10 m motor cable using SFAVM and maximum 10 m motor cable MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 67 60 PWM in Normal torque mode (110% over tor- Derating of I for different T for enclosure C, AMB, MAX que) using SFAVM in Normal torque mode (110% over tor- que) ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 68 (I ) should be derated in accordance with the shown diagram. Derating of output current versus altitude at T . By altitudes above 2 km, please contact Danfoss Drives re- AMB, MAX garding PELV. An alternative is to lower the ambient temperature at high altitudes and thereby ensure 100% output current at high altitudes.
Page 69: Automatic Adaptations To Ensure Performance
As a response to a critical level, the frequency converter can adjust the switching frequency and/ or change the switching pattern in order to ensure the performance of the drive. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 70 FC 300 Design Guide MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 71: How To Order
The Drive Configurator will automatically generate an eight-digit sales number to be delivered to your local sales office. Furthermore, you can establish a project list with several products and send it to a Danfoss sales repre- sentative.
Page 72 2): Power sizes ≥ 11 kW only Not all choices/options are available for each FC 301/FC 302 variant. To verify if the appropriate version is available, please consult the Drive Con- figurator on the Internet. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 73: Ordering Numbers
Accessory bag MCO 305 130B7535 Options can be ordered as factory built-in options, see ordering information. For information on fieldbus and application option combatibility with older software versions, please contact your Danfoss supplier. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 74 FC 300 Design Guide How to Order MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 75 FC 300 Design Guide How to Order ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 76 80 W 130B2408 130B2443 P2K2 - P3K7 17 A 160% 120 Hz 125 W 130B2411 130B2446 When using Sine-wave filters, the switching frequency must be minimum 4.5 kHz (see par. 14-01). MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 77 IP00 IP20 PK75 - P7K5 13 A 160% 60 Hz 170 W 130B2321 130B2341 When using Sine-wave filters, the switching frequency must be minimum 4.5 kHz (see par. 14-01). ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 78 FC 300 Design Guide MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 79: How To Install
FC 300 Design Guide How to Install Mechanical Dimension See the following table for enclosure dimensions ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 80 FC 300 Design Guide How to Install MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 81: Mechanical Installation
For DC link connection (Load sharing) the connector 1 can be ordered separately (Code no 130B1064) An eight pole connector is included in accessory bag for FC 101/301 without Safe Stop. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 82 Drill holes in accordance with the measurements given. You must provide screws suitable for the surface on which you want to mount the FC 300. Re- tighten all four screws. Mounting frame sizes A1, A2 and A3: MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 83 The service life of the frequency converter is reduced if derating for ambient temperature is not taken into account. Field Mounting For field mounting the IP 21/IP 4X top/TYPE 1 kits or IP 54/55 units are recommended. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 84: Electrical Installation
Cable entry has to be supported around the knockout you intend to remove. The knockout can now be removed with a strong mandrel and a hammer. Remove burrs from the hole. Mount Cable entry on frequency converter. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 85: Connection To Mains And Earthing
The earth connection cable cross section must be at least 10 mm or 2 x rated mains wires terminated separately according to EN 50178. The mains connection is fitted to the mains switch if this is included. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 86 Mains connection C1 and C2 (IP 21/ NEMA Type 1 and IP 55/66/ NEMA Type 12) enclosures and IP 55/66/ NEMA Type 12) enclosures Usually the power cables for mains are unshielded cables. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 87: Motor Connection
When frequency convert- ers are used together with Sine-wave filters to reduce the acoustic noise from a motor, the switching frequency must be set according to the Sine-wave filter instruction in Par. 14-01. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 88 Motor voltage 0-100% of mains 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. Protected Earth Connection MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 89: Fuses
Short-circuit protection: The frequency converter 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 frequency converter provides full short-circuit protection in case of a short-circuit on the motor output.
Page 90 L50S fuses from LITTEL FUSE may substitute L50S fuses for 240 V frequency converters. A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V frequency converters. A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V frequency converters. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 91: Access To Control Terminals
6 pole analog I/O. USB Connection. Control Terminals, FC 302 Drawing reference numbers: 10 pole plug digital I/O. 3 pole plug RS485 Bus. 6 pole analog I/O. USB Connection. Control terminals (all enclosures) ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 92: Electrical Installation, Control Terminals
Connect terminals 18, 27 and 37 (FC 302 only) to +24 V (terminal 12/13) Default settings: 18 = Start, Par 5-10 [9] 27 = Stop inverse, Par 5-12 [6] 37 = safe stop inverse MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 93: Electrical Installation, Control Cables
Safe Stop Installation in the FC 300 Design Guide. * Terminal 37 is not included in FC 301 (Except FC 301 A1, which includes Safe Stop). Terminal 29 and Relay 2, are not included in FC 301. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 94 Input polarity of control terminals Control cables must be screened/arm- oured. See section entitled Earthing of Screened/Arm- oured Control Cables for the correct termination of control cables. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 95: Motor Cables
Furthermore, the terminal screw must be retightened after two days due to the softness of the aluminium. It is crucial to keep the connection a gas tight joint, otherwise the aluminium surface will oxidize again. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 96: Switches S201, S202, And S801
It is recom- mended to remove the LCP fixture (cradle) when operating the switches. The switches must not be operated with power on the frequency convert- MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 97: Final Set-Up And Test
Press the [Hand on] key. A progress bar indicates if the AMA is in progress. Stop the AMA during operation Press the [OFF] key - the frequency converter enters into alarm mode and the display shows that the AMA was terminated by the user. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 98 "Report Value” in the [Alarm Log] shows the last measuring sequence carried out by the AMA, before the frequency converter 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 number and alarm description.
Page 99: Additional Connections
The DC bus terminal is used for DC back-up, with the intermediate circuit being supplied from an external source. Terminal numbers: 88, 89 Please contact Danfoss if you require further information. Installation of Load sharing The connection cable must be screened and the max. length from the frequency converter to the DC bar is 25 metres.
Page 100: Relay Connection
04 - 05 make (normally open) 04 - 06 break (normally closed) Terminals for relay connection Terminals for relay connection (Frame sizes A1, A2 and A3). (Frame sizes A5, B1, B2, C1 and C2). MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 101: Relay Output
The electronic thermal relay (ETR) of the frequency converter cannot be used as motor protection for the individual motor of systems with parallel-connected motors. Provide further motor protection by e.g. thermistors in each motor or individual thermal relays. (Circuit breakers are not suitable as protection). ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 102: Motor Thermal Protection
P signal (TX+, RX+), while terminal 69 is connected to the N signal (TX-,RX-). If more than one frequency converter is connec- ted to a master, use parallel connections. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 103: How To Connect A Pc To The Fc 300
Open the appropriate file Choose “Save as” Choose “Write to drive” All parameters are now stored. All parameters are now transferred to the drive. A separate manual for MCT 10 Set-up Software is available. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 104 If the installation is not carried out according to the guideline and if unscreened cables and control wires are used, some emission requirements are not complied with, although the immunity requirements are fulfilled. See the paragraph EMC test results. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 105 FC 300 Design Guide How to Install EMC-correct electrical installation of an IP20 frequency converter. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 106 How to Install Use of EMC-Correct Cables Danfoss recommends braided screened/armoured cables to optimise 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 107 61. This terminal is connected to earth via an internal RC link. Use twisted- pair cables to reduce the differential mode interference between the conductors. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 108: Residual Current Device
If RCD relays are used, you must observe local regulations. Relays must be suitable for protection of 3- phase equipment with a bridge rectifier and for a brief discharge on power-up see section Earth Leakage Current for further information. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 109: Application Examples
Terminal 37 = Safe stop (FC 302 and FC 301 A1 only) Pulse Start/Stop Terminal 18 = Par. 5-10 [9] Latched start Terminal 27= Par. 5-12 [6] Stop inverse Terminal 37 = Safe stop (FC 302 and FC 301 A1 only) ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 110: Potentiometer Reference
Clockwise direction means channel A is 90 electrical degrees before channel B. Counter Clockwise direction means channel B is 90 electrical degrees before A. The direction determined by looking into the shaft end. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 111: Closed Loop Drive System
Par. 5-12 Coasting Stop, Inverse [2] Terminal 29 Output Par. 5-02 Terminal 29 Mode Output [1] Par. 5-31 Torque Limit & Stop [27] Relay output [0] (Relay 1) Par. 5-40 Mechanical Brake Control [32] ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 112: Smart Logic Control Programming
In applications where a PLC is generating a simple sequence the SLC may take over elementary tasks from the main control. SLC is designed to act from event sent to or generated in the FC 302. The frequency converter will then perform the pre-programmed action. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 113 Set Action 2 in par. 13-52 [2] to Start Timer 0 [29] Set Action 3 in par. 13-52 [3] to Select preset 1 [11] Set Action 4 in par. 13-52 [4] to No Action [1] ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 114 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 frequency converter will ramp down and go into free mode. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 115: Options And Accessories
FC 300 Design Guide Options and Accessories Danfoss offers a wide range of options and accessories for VLT AutomationDrive FC 300 Series. Mounting of Option Modules in Slot B The power to the frequency converter must be disconnected. It is strongly recommended to make sure the parameter data is saved (i.e. by MCT10 software ) before option modules are inserted/removed from the drive.
Page 116 Voltage level, logic'0' PNP (GND = 0 V) < 5 V DC Voltage level, logic'1' PNP (GND = 0 V) > 10 V DC Voltage level, logic '0' NPN (GND = 24V) < 14 V DC MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 117: Encoder Option Mcb 102
Supported encoder types: Incremental encoder: 5 V TTL type, RS422, max. frequency: 410 kHz Incremental encoder: 1Vpp, sine-cosine Hiperface® Encoder: Absolute and Sine-Cosine (Stegmann/SICK) EnDat encoder: Absolute and Sine-Cosine (Heidenhain) Supports version 2.1 MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 118 Z inv input -Data RS485 Clock out inv. Clock out inv. input OR -Data RS485 Data in Data in Future use Data in inv. Data in inv. Future use Max. 5V on X31.5-12 MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 119: Resolver Option Mcb
LED 2 is on when Cosinus signal is OK from re- solver LED 3 is on when Sinus signal is OK from resolver The LEDs are active when par. 17-61 is set to Warning or Trip. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 120 Poles Resolver data sheet Par. 17-51 Input Voltage Resolver data sheet Par. 17-52 Input Frequency Resolver data sheet Par. 17-53 Transformation Ratio Resolver data sheet Par. 17-59 Resolver Interface Enabled [1] MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 121: Relay Option Mcb 105
The relay option does not support FC 302 frequency converters manufactured before week 50/2004. Min. software version: 2.03 (par. 15-43). Frame sizes A1, A2 and A3 IMPORTANT 1. The label MUST be placed on the LCP frame as shown (UL approved). MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 122 • Select the relay functions in par. 5-40 [6-8], 5-41 [6-8] and 5-42 [6-8]. NB (Array [6] is relay 7, array [7] is relay 8, and array [8] is relay 9) MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 123 FC 300 Design Guide Options and Accessories Do not combine 24/ 48 V systems with high voltage systems. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 124: Back-Up Option Mcb 107 (Option D)
When MCB 107, 24 V back-up option is supplying the control circuit, the internal 24 V supply is au- tomatically disconnected. Connection to 24 V back-up supply on frame sizes A5, B1, B2, C1 and C2. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 125: Ip 21/Ip 4X/ Type 1 Enclosure Kit
The resistor is selected in respect to its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide verity of different resistors that are specially designed to our drive code numbers can be found in section How to order.
Page 126: Sine-Wave Filters
The frequency of the resonance noise thus corresponds to the switching frequency of the frequency converter. For the FC 300 Series, Danfoss can supply a Sine-wave filter to dampen the acoustic motor noise. The filter reduces the ramp-up time of the voltage, the peak load voltage U...
Page 127: Rs-485 Installation And Set-Up
Cable: Screened twisted pair (STP) Impedance: 120 Ohm Cable length: Max. 1200 m (including drop lines) Max. 500 m station-to-station ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 128 Use the terminator dip switch on the main control board of the frequency converter to terminate the RS-485 bus. The factory setting for the dip switch is OFF. Terminator Switch Factory Setting MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 129 When crossing is unavoidable, the RS-485 cable must cross motor and brake resistor cables at an angle of 90 degrees. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 130: Fc Protocol Overview
FC 300 Design Guide RS-485 Installation and Set-up The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss Drives standard fieldbus. It defines an access technique according to the master-slave principle for communications via a serial bus.
Page 131: Fc Protocol Message Framing Structure - Fc 300
The slave returns the address byte unchanged to the master in the response telegram. Data Control Byte (BCC) The checksum is calculated as an XOR-function. Before the first byte in the telegram is received, the Calculated Checksum is 0. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 132 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. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 133 The index is used together with the parameter number to read/write-access parameters with an index, e.g. par. 15-30 Error Code. The index consists of 2 bytes, a low byte and a high byte. Only the low byte is used as an index. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 134 Conversion factors are therefore used to transfer fer the value 100. A conversion factor of 0.1 decimals. means that the value transferred is multiplied by 0.1. The value 100 is thus perceived as 10.0. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 135 The block of process words is divided into two blocks of 16 bits, which always occur in the defined se- quence. PCD 1 PCD 2 Control telegram (master⇒ Control word slave) Reference-value Control telegram (slave ⇒master) Status word Present outp. frequency ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 136: Examples
3E8 Hex corresponds to 1000 decimal. The conversion index for par. 3-41 is -2, i.e. 0.01. Danfoss FC Control Profile Control Word According to FC Profile(Par. 8-10 = FC profile) MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 137 Bit 02 = ’0’ leads to DC braking and stop. Set braking current and duration in par. 2-01 DC Brake Cur- rent and 2-02 DC Braking Time . Bit 02 = ’1’ leads to ramping. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 138 Bit 10 = ’1’: The control word is used. This function is relevant because the telegram always contains the control word, regardless of the telegram type. Thus, you can turn off the control word if you do not want to use it when updating or reading parameters. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 139 Bit 15 = ’0’: No reversing. Bit 15 = ’1’: Reversing. In the default setting, reversing is set to digital in par. 8-54 Reversing Select. Bit 15 causes reversing only when Ser. communication, Logic or or Logic and is selected. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 140 Bit 06 = ’0’: The frequency converter is not in fault mode. Bit 06 = “1”: The frequency converter is tripped and locked. Bit 07, No warning/warning: Bit 07 = ’0’: There are no warnings. Bit 07 = ’1’: A warning has occurred. Bit 08, Speed≠ reference/speed = reference: MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 141 Bit 15 = ’1’: One of the timers exceeds 100%. All bits in the STW are set to ’0’ if the connection between the Interbus option and the fre- quency converter is lost, or an internal communication problem has occurred. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 142 100%. Negative figures are for- matted by means of 2’s complement. The Actual Output frequency (MAV) is scaled in the same way as the bus reference. The reference and MAV are scaled as follows: MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 143 Coasting stop Bit 03 = "0" leads to a stop. When bit 03 = "1", the frequency converter can start if the other start conditions are satisfied. The selection in par. 8-50 Coasting select determines how bit 03 is linked with the corre- sponding function of the digital inputs. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 144 When bit 12 = "1", the reference value is increased. If both - slowing down and accelerating - are activated (bit 11 and 12 = "1"), slowing down has priority, i.e. the speed reference value will be reduced. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 145 Bit 15 = “1” causes reversing. Note: In the factory setting reversing is set to digital in par. 8-54 Reversing select. Bit 15 causes reversing only when Ser. communication, Logic or or Logic and is selected. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 146 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". MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 147 When bit 15 = "0", the timers for the thermal motor protection and thermal frequency converter protec- tion have not exceeded 100%. When bit 15 = "1", one of the timers has exceeded 100%. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 148 FC 300 Design Guide MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 149: Troubleshooting
This is possible, for instance, in parameters 1-90 Motor Thermal Protection. After an alarm or trip, the motor carries on coasting, and the alarm and warning flash. Once the problem has been rectified, only the alarm continues flashing until the FC 300 is reset. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 150 AMA check U and I AMA low I AMA motor too big AMA motor too small AMA parameter out of range AMA interrupted by user AMA timeout AMA internal fault Current limit MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 151 Alarm flashing red cause dangerous conditions. A trip lock is an ac- Trip locked yellow and red tion when an alarm occurs, which may cause dam- ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 152 Extended Status Word The alarm words, warning words and extended status words can be read out via serial bus or optional fieldbus for diagnose. See also par. 16-90, 16-92 and 16-94. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 153: Dc Link Voltage High
The thermistor or the thermistor connection is dis- connected. You can choose if you want the fre- quency converter to give a warning or an alarm when the counter reaches 100% in par. 1-90. ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 154: Torque Limit
If par. 8-04 is set to Stop and Trip, a warning ap- circuited. pears and the frequency converter ramps down until it trips, while giving an alarm. par. 8-03 Control word Timeout Time could pos- sibly be increased. MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 155: Brake Check (X) (X)
Internal fault: Brake resistor fault: the brake resistor is not con- By this alarm it may be necessary to contact your nected/working. Danfoss supplier. Some typical alarm messages: ALARM 29 0 The serial port cannot be initialized. Se- Drive over temperature:...
Page 156 WARNING 61 24 V supply low: Encoder loss: The external 24 V DC backup power supply may Contact your Danfoss supplier. be overloaded, otherwise Contact your Danfoss supplier. WARNING 62 Output Frequency at Maximum Limit: WARNING 48 The output frequency is higher than the value set 1.8 V supply low:...
Page 157 KTY sensor is connected to ana- logue input terminal 54. ALARM 250 New Spare Part: The power or Switch Mode Power Supply has been exchanged. The frequency converter type code ® MG.33.B8.02 - VLT is a registered Danfoss trademark...
Page 158: Index
Cable Length And Cross-section Digital Output Cable Lengths And Cross Sections Digital Outputs - Terminal X30/6, 7 Catch Up / Slow Down Direction Of Motor Rotation Clockwise Rotation Disposal Instruction Coasting MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 159 High Voltage Test Motor Name Plate Hoist Mechanical Brake Motor Output Hold Output Frequency Motor Parameters Motor Phases Motor Protection Intermediate Circuit Motor Protection Intermediate Circuit Motor Rotation Intermediate Circuit Motor Thermal Protection MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 160 Use Of Emc-correct Cables Reference Handling Vibration And Shock Relay Connection Voltage Level Relay Outputs Vvcplus Removal Of Knockouts For Extra Cables Vvcplus Residual Current Device Residual Current Device Rise Time MG.33.B8.02 - VLT ® is a registered Danfoss trademark...
Page 161 FC 300 Design Guide Index Warnings MG.33.B8.02 - VLT ® is a registered Danfoss trademark...

Danfoss VLT AutomationDrive FC 300 Design Manual

Table of Contents

How to Read this Design Guide

Introduction to FC 300

FC 300 Selection

How to Order

How to Install

Application Examples

Options and Accessories

RS-485 Installation and Set-Up

Troubleshooting

Troubleshooting Alarm/Warning Code List

Quick Links

Chapters

Need help?

Questions and answers

Related Manuals for Danfoss VLT AutomationDrive FC 300

Summary of Contents for Danfoss VLT AutomationDrive FC 300

Table of Contents