Page 1: Table Of Contents
Hoist Mechanical Brake Safe Stop of FC 300 Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) Safe Stop Commissioning Test 4. FC 300 Selection Electrical Data General Specifications Efficiency MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 2 Motor Thermal Protection How to Connect a PC to the FC 300 The FC 300 PC Software Residual Current Device 7. Application Examples Start/Stop Pulse Start/Stop Potentiometer Reference Encoder Connection Encoder Direction MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 3 Sine-wave Filters 9. RS-485 Installation and Set-up RS-485 Installation and Set-up Network Configuration FC Protocol Message Framing Structure - FC 300 Examples Danfoss FC Control Profile 10. Troubleshooting Warnings/Alarm Messages Index MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 4 1. How to Read this Design Guide FC 300 Design Guide MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 5: How To Read This Design Guide
DeviceNet fieldbus. X = Revision number YY = Language code Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/ DrivesSolutions/Documentations/Technical+Documentation. 1.1.2. Approvals 1.1.3. Symbols Symbols used in this guide.
Page 6: Abbreviations
Size and type of the connected drive (dependencies). VLT,MAX The maximum output current. VLT,N The rated output current supplied by the frequency converter. VLT, MAX The maximum output voltage. Input: Control command MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 7 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. The rated motor voltage (nameplate data). Break-away torque MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 8 The analog outputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal. Automatic Motor Adaptation, AMA AMA algorithm determines the electrical parameters for the connected motor at standstill. MG.33.B9.02 - 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 out- put frequency to match the varying load. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 10 ) im- proves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque. 60° AVM Switching pattern called 60°Asynchronous Vector Modulation (par. 14-00). MG.33.B9.02 - 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 12 2. Safety and Conformity FC 300 Design Guide MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 13: Safety And Conformity
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 back up. Refer to FC 300 Operating Instructions (MG.33.A8.xx) for further safety guidelines. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 14: Disposal Instruction
Design Guide Software version: 4.5x 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 15 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 16 The Design Guide offers detailed instructions for installation to ensure EMC-correct installation. Furthermore, Danfoss specifies which our different products comply with. Danfoss gladly provides other types of assistance that can help you obtain the best EMC result. 2.4.4. Compliance with EMC Directive 89/336/EEC As mentioned, the frequency converter is mostly used by professionals of the trade as a complex component forming part of a larger appliance, system, or installation.
Page 17 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 18 3. Introduction to FC 300 FC 300 Design Guide MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 19: Introduction To Fc
FC 300 Design Guide 3. Introduction to FC 300 3. Introduction to FC 300 3.1. Product Overview MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 20 3. Introduction to FC 300 FC 300 Design Guide MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 21: Control Principle
IGBTs connected to the control board. 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 22: Control Structure In Vvcplus
In the configuration shown in the illustration above, par. 1-01 is set to plus “VVC [1]” and par. 1-00 is set to “Speed open loop [0]”. The resulting reference from the MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 23: Control Structure In Flux Sensorless (Fc 302 Only)
The Process PID parameters are found in par. group 7-2* and 7-3*. 3.2.6. Control Structure in Flux with Motor Feedback Control structure in Flux with motor feedback configuration (only available in FC 302): MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 24: Internal Current Control In Vvcplus Mode
5-1* (digital inputs) or par. group mode, it is possible to control the frequency 8-5* (serial communication). converter via the digital inputs and various se- rial interfaces (RS-485, USB, or an optional MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 25 Torque or Process Control) is used when the Remote reference is active (see table above for the conditions). Local Mode Configuration Par. 1-05 determines the kind of application control principle that is used when the Local reference is made active. Reference Handling Local Reference Remote Reference MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 26: Reference Handling
References and feedback can be scaled in physical units (i.e. RPM, Hz, °C) or simply in % relating Minimum Reference Maximum Reference to the values of par. 3-02 and par. 3-03 MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 27: Scaling Of References And Feedback
“endpoints” (P1 and P2 in the graph below) are clamped whereas a feedback above or below is not. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 28: Dead Band Around Zero
And both points defining the scaling graph are in the same quadrant. The size of the Dead Band is defined by either P1 or P2 as shown in the graph below. MG.33.B9.02 - 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 clam- ped to -Max – +Max by the Reference algorithm. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 30 3. Introduction to FC 300 FC 300 Design Guide Case 3: Negative to positive reference with dead band, Sign determines the direction, -Max – +Max MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 31: Speed Pid Control
The two Flux motor control principles are specially dependant on proper tuning to yield their full potential. The following parameters are relevant for the Speed Control: MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 32 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 order shown - see explanation of settings in the Program- ming Guide. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 33 A practical value for the Bandwith is 20 rad/s. Check the result of the par. 7-02 calculation against the following formula (not required if you are using a high resolution feedback such as a SinCos feedback): MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 34: Process Pid Control
Speed Control PID tuning (prior to tuning the Process Control PID) to yield their full potential. Illustration 3.1: Process PID Control diagram The following parameters are relevant for the Process Control MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 35 (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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 36 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 37 ) to 0.3 and increase it until the feedback signal again begins to vary continuously. Then reduce the value until the feedback signal has stabi- lised. Now lower the proportional gain by 40-60%. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 38: 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 39 More- over, ensure good electrical contact from the mounting plate through the mounting screws to the frequency converter chassis. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 40 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 41: Emc Immunity
• EN 61000-4-6 (IEC 61000-4-6): RF Common mode Simulation of the effect from radio-transmitting equipment connected to connection cables. See following EMC immunity form. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 42 Custom relays. Illustration 3.3: Galvanic isolation 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 43: Earth Leakage Current
Also make sure that other voltage inputs have been disconnected, such as load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up. Using VLT AutomationDrive FC 300: wait at least the amount of time indicated in Safety Precautions -section.
Page 44 FC 300 Design Guide 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 45 The resistor brake circuit resistance selected should not be higher than that recom- mended 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 46: Mechanical Brakecontrol
. If the frequency converter is brought into an alarm condition, i.e. over-voltage situation, the mechanical brake immediately cuts in. This is also the case during safe stop. In hoisting/lowering applications, it must be possible to control an electro-mehanical brake. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 47: Hoist Mechanical Brake
In order to react as quickly as possible on the load-step that follows upon brake release, the speed-PID control can be boosted by increasing the proportional gain. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 48 / action . When the last been executed, the sequence starts over event [1] / action [1] again from . The illustra- tion shows an example with three events / actions MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 49 Static Overload in VVCplus mode When the frequency converter is overloaded (the torque limit in par. 4-16/4-17 is reached), the controls reduces the output frequency to reduce the load. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 50: Safe Stop Of Fc
Safe Stop and resume normal operation, first the 24Vdc must be reapplied to Terminal 37. Subsequently, a reset signal must be given (via Bus, Digital I/O, or [Reset] key). MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 51 In particular, the following paragraphs of standards under the EU Machinery Directive must be observed: 5.2.1, 5.2.2, and 5.2.3. of EN954-1:1996 (or ISO 13849-1:2006), 4.11.3 and 4.11.4 of EN292-2 (ISO 12100-2:2003). MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 52: Safe Stop Installation (Fc 302 And Fc 301 - A1 Enclosure Only)
The AND logic itself must conform to EN 954-1, Safety Category 3. The connection from the output of the safe AND logic to Safe Stop terminal 37 must be short-circuit protected. See figure below: MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 53: Safe Stop Commissioning Test
Moreover, perform the test after each modification of the installation or application, which the FC 300 Safe Stop is part of. A passed commissioning test is mandatory for fulfilment of Safety Category 3 by such an installation or application. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 54 37 and subsequent reset. Provide this protection via the interrupt device, at the application level, or organisational level. Safe Stop Installation For more information - see section MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 55: Fc 300 Selection
A5 (IP55, 66) 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 0.94 0.94 0.95 0.95 0.96 0.96 0.96 0.96 0.96 Efficiency 0.25 - 3.7 kW only available as 160% high overload. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 56 [W] Weight, enclosure IP21, IP 55, 66 [kg] Efficiency 0.964 0.959 0.964 * High overload = 160% torque during 60 s, Normal overload = 110% torque during 60 s MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 57 [W] Weight, enclosure IP21, IP 55, 66 [kg] 0.964 0.965 0.965 0.966 0.966 Efficiency * High overload = 160% torque during 60 s, Normal overload = 110% torque during 60 s MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 58 Enclosure IP55, 66 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 14.2 14.2 Efficiency 0.93 0.95 0.96 0.96 0.97 0.97 0.97 0.97 0.97 0.97 0.37 - 7.5 kW only available as 160% high overload. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 59 Weight, enclosure IP21, IP 55, 66 [kg] 0.977 0.978 0.979 0.978 Efficiency * High overload = 160% torque during 60 s, Normal overload = 110% torque during 60 s MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 60 [W] Weight, enclosure IP21, IP 55, 66 [kg] Efficiency 0.983 0.983 0.982 0.983 0.985 * High overload = 160% torque during 60 s, Normal overload = 110% torque during 60 s MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 61 IP 54 [kg] Weight, enclosure IP00 81.9 [kg] 0.971 0.973 0.974 0.976 0.977 Efficiency * High overload = 160% torque during 60 s, Normal overload = 110% torque during 60 s MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 62 IP21, IP 54 [kg] Weight, enclosure IP00 [kg] Efficiency 0.976 0.978 0.978 0.980 * High overload = 160% torque during 60 s, Normal overload = 110% torque during 60 s MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 63 (3 x 525-600 V ) [A] Max. pre-fuses Environment Estimated power loss at rated max. load [W] Enclosure IP 20 Weight, enclosure IP20 [kg] 0.97 0.97 0.97 0.97 0.97 0.97 0.97 0.97 Efficiency MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 64 IP21, IP 54 [kg] Weight, enclosure IP00 [kg] Efficiency 0.98 0.98 0.98 0.98 0.98 * High overload = 160% torque during 60 s, Normal overload = 110% torque during 60 s MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 65 IP21, IP 54 [kg] Weight, enclosure IP00 [kg] Efficiency 0.976 0.978 0.978 0.979 * High overload = 160% torque during 60 s, Normal overload = 110% torque during 60 s MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 66 Weight, enclosure IP21, IP 54 [kg] Weight, enclosure IP00 [kg] Efficiency 0.981 0.984 0.985 * High overload = 160% torque during 60 s, Normal overload = 110% torque during 60 s MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 67 If the switching frequency is increased compared to the default setting, the power losses may rise significantly. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 68 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 inaccuracy must be allowed for (+/-5%). MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 69: General Specifications
Temperature monitoring of the heatsink ensures that the frequency converter 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 MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 70 Switch S201/switch S202 = OFF (U) Voltage level FC 301: 0 to + 10/ FC 302: -10 to +10 V (scaleable) Input resistance, R approx. 10 kΩ Max. voltage ± 20 V MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 71 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). MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 72 Control card, 10 V DC output: Terminal number Output voltage 10.5 V ±0.5 V Max. load 15 mA The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 73: Efficiency
The load on the frequency converter 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 case of part loads. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 74: Acoustic Noise
If the peak voltage is too high, especially motors without PEAK phase coil insulation are affected. If the motor cable is short (a few metres), the rise time and peak voltage are lower. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 75: Du/Dt Conditions
The derating depends on the switching pattern, which can be set to 60 PWM or SFAVM in par. 14-00. A enclosures 60 PWM - Pulse Width Modulation MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 76 Illustration 4.4: Derating of I for different T AMB, AMB, for enclosure A, using 60 PWM and maximum for enclosure A, using SFAVM and maximum 10 m motor cable 10 m motor cable MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 77 C, using 60 PWM in High torque Illustration 4.10: Derating of I for different T AMB, for enclosure C, using SFAVM in High torque mode (160% over torque) mode (160% over torque) MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 78 D at 500 V, using 60 PWM in for enclosure D at 500 V, using SFAVM in Nor- Normal torque mode (110% over torque) mal torque mode (110% over torque) MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 79 D at 690 V, using 60 PWM in High for enclosure D at 690 V, using SFAVM in High torque mode (160% over torque). Note: P315 torque mode (160% over torque). Note: P315 MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 80 E at 500 V, using 60 PWM in for enclosure E at 500 V, using SFAVM in Nor- Normal torque mode (110% over torque) mal torque mode (110% over torque) MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 81 ) should be derated in accordance with the shown diagram. Illustration 4.33: Derating of output current versus altitude at T . By altitudes above 2 km, please AMB, MAX contact Danfoss Drives regarding PELV. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 82: 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 83: 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 representative.
Page 84 C option soft- ware D options DX: No option D0: DC back-up D0: MCB 107 Ext. 24 V back- 1): FC 301/ A1 enclosure only 2): Power sizes ≥ 11 kW only MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 85 MCT 10 set-up software - unlimited users 130B1006 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.B9.02 - VLT ®...
Page 86 Accessory bag A2 Accessory bag, frame size A2/A3 130B1022 Accessory bag B1 Accessory bag, frame size B1 130B2060 Accessory bag B2 Accessory bag, frame size B2 130B2061 Accessory bag MCO 305 130B7535 MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 87 FC 300 Design Guide 5. How to Order MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 88 5. How to Order FC 300 Design Guide MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 89 144A 100, 125 175G6618 175G6640 P75K - P90K Matching the frequency converter and filter is pre-calculated based on 400V/480V and on a typical motor load (4 pole) and 110 % torque. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 90 130B2318 130B2292 1200 A P630 P710 2 kHz 60 Hz 130B2318 130B2292 1200 A When using Sine-wave filters, the switching frequency should comply with filter par. 14-01 Switching Frequency specifications in MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 91 130B2384 130B2340 1320 A P970 P1M2 1.5 kHz 60 Hz 130B2384 130B2340 1320 A When using Sine-wave filters, the switching frequency should comply with filter specifications in par. 14-01 Switching Frequency MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 92 6. How to Install FC 300 Design Guide MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 93: How To Install
FC 300 Design Guide 6. How to Install 6. How to Install 6.1. Mechanical Dimension MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 94 * The front of the frequency converter is slightly convex. C is the shortest distance from back to front (i.e. measured from corner to corner) of the frequency converter. D is the longest distance from back to front (i.e. measured in the middle) of the frequency converter. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 95 * The front of the frequency converter is slightly convex. C is the shortest distance from back to front (i.e. measured from corner to corner) of the frequency converter. D is the longest distance from back to front (i.e. measured in the middle) of the frequency converter. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 96 Drive dimensions Height 2000 mm 2000 mm 1499 mm Width 600 mm 600 mm 585 mm Depth 494 mm 494 mm 494 mm Max weight 313 kg 313 kg 277 kg MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 97: Mechanical Installation
101/301 units. For DC link connection (Load sharing) the connector 1 can be ordered sepa- rately (Code no 130B1064) An eight pole connector is included in accessory bag for FC 101/301 without Safe Stop. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 98 300. Retighten all four screws. Mounting frame sizes A1, A2 and A3: Mounting frame sizes A5, B1, B2, C1 and C2: The back wall must always be solid for opti- mum cooling. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 99 Mounting frame sizes A5, B1, B2, C1 and C2 provided with a back plate A due to insufficient on a non-solid back wall, the drive must be cooling air over the heat sink. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 100: Electrical Installation
Furthermore the terminal screw must be retightened after two days due to softness of the alu- minium. It is crucial to keep the connection a gas tight joint, otherwise the aluminium surface will oxidize again. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 101: Removal Of Knockouts For Extra Cables
6.3.2. Connection to Mains and Earthing The plug connector for power is plugable on FC 300 up to 7.5 kW. Fit the two screws in the de-coupling plate, slide it into place and tighten the screws. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 102 Mains connection for frame sizes A1, A2 and Mains connector A5 (IP 55/66) Enclosure When disconnector is used (A5 enclosure) the PE must be mounted on the left side of the drive. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 103: Motor Connection
FC 300. If it is necessary to split the screen to install a motor isolator or motor relay, the screen must be continued with the lowest possible HF im- pedance. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 104 (400/690 V, Δ). Refer to the motor name plate for correct connection mode and voltage. Illustration 6.4: Motor connection C1 and C2 (IP 21/ NEMA Type 1 and IP 55/66/ NEMA Type 12) enclosure MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 105: 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 equip- MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 106 200A 380-500 type 160A 380-500 type 250A 380-500 type 55K-75 250A 380-500 type 1) Max. fuses - see national/international reg- ulations for selecting an applicable fuse size. UL Compliance 200-240 V MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 107 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 convert- ers. A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V frequency convert- ers. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 108: Access To Control Terminals
Pull out the cable. Insert the cable in the adjacent cir- Max. 0.4 x 2.5 mm cular hole. Remove the screw driver. The cable is now mounted to the terminal. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 109 Assembling of IP55 / NEMA Type 12 (A5 housing) with mains disconnector Mains switch is placed on left side on B1, B2, C1 and C2 enclosures. Mains switch on A5 enclosure is placed on right side MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 110: Basic Wiring Example
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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 111: Electrical Installation, Control Cables
The digital and analogue in- and outputs must be connected separately to the FC 300 common inputs (terminal 20, 55, 39) to avoid ground currents from both groups to affect other groups. For example, switching on the digital input may disturb the analog input signal. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 112: Motor Cables
If it is necessary to split the screen to install a motor isolator or motor relay, the screen must be continued with the lowest possible HF impedance. 6.3.11. Electrical Installation of Motor Cables Screening of cables MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 113: Switches S201, S202, And S801
When changing the function of S201, S202 or S801 be careful not to use force for the switch over. It is recommended to remove the LCP fixture (cradle) when oper- ating the switches. The switches must not be operated with power on the frequency converter. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 114 6. How to Install FC 300 Design Guide MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 115 AMA, or remove the Sine-wave filter during the AMA procedure. Press the [OK] key. The display shows “Press [Hand on] to start”. Press the [Hand on] key. A progress bar indicates if the AMA is in progress. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 116 "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 117: 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. 6.5.2. 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 118: Relay Connection
This is only recommended when U/f is selec- parallel-connected motors. The total current ted in par. 1-01. consumption of the motors must not exceed the rated output current I for the frequency converter. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 119 Terminal 96 connected to U-phase Terminal 97 connected to V-phase Terminal 98 connected to W-phase Thedirection of motor rotation is changed by switching two motor phases. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 120: Motor Thermal Protection
In order to avoid potential equalizing currents in the screen, earth the cable screen via terminal 61, which is connected to the frame via an RC-link. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 121: How To Connect A Pc To The Fc 300
Carry out a high voltage test by short-circuiting terminals U, V, W, L and L . Energize by max. 2.15 kV DC for one second between this short-circuit and the chassis. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 122 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 re- EMC test results quirements are fulfilled. See the paragraph MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 123 Illustration 6.14: EMC-correct electrical installation of a frequency converter in cabinet. 6.8.2. 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 124 Twisted copper wire or armoured steel wire cable. 1 Single-layer braided copper wire with varying percentage screen cov- erage. This is the typical Danfoss reference cable.1 Double-layer braided copper wire.1 Twin layer of braided copper wire with a magnetic, screened/armoured intermediate layer.1...
Page 125 . A non-sinusoidal current is transformed by means of a Fourier analysis and split up into sine-wave currents with dif- ferent frequencies, i.e. different harmonic cur- rents I with 50 Hz as the basic frequency: MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 126: 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 127: Application Examples
Terminal 37 = Safe stop (where available!) 7.1.2. Pulse Start/Stop Latched start Terminal 18 = Par. 5-10 [9] Stop inverse Terminal 27= Par. 5-12 [6] Terminal 37 = Safe stop (where available!) MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 128: Potentiometer Reference
Terminal 53, Low Voltage = 0 Volt Terminal 53, High Voltage = 10 Volt Terminal 53, Low Ref./Feedback = 0 Terminal 53, High Ref./Feedback = 1500 RPM Switch S201 = OFF (U) MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 129: Encoder Connection
In applications with an external electro-mechanical brake, such as hoisting applications, it is pos- sible to stop the frequency converter via a 'standard' stop command and simultaneously activate the external electro-mechanical brake. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 130 Sine-wave filter while running a total AMA. After completion of the AMA, reinsert the Sine-wave filter. • If motors are coupled in parallel, use only reduced AMA if any. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 131: Smart Logic Control Programming
Set Event 4 in par. 13-51 [1] to Select preset 0 Set Action 1 in par. 13-52 [1] to [10] Start Timer 0 Set Action 2 in par. 13-52 [2] to [29] MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 132 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 133: Options And Accessories
8. Options and Accessories 8.1. Options and Accessories Danfoss offers a wide range of options and accessories for VLT AutomationDrive FC 300 Series. 8.1.1. Mounting of Option Modules in Slot A Slot A position is dedicated to Fieldbus options. For further information, see separate operating instructions.
Page 134 If the digital inputs 7, 8 or 9 are to be switched by use of the internal 24 V power supply (terminal 9) the connection between terminal 1 and 5 which is illustrated in the drawing has to be estab- lished. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 135 Voltage level, logic '1' NPN (GND = 24 V) > 19 V DC Maximum voltage on input 28 V continous Pulse frequency range 0 - 110 kHz Duty cycle, min. pulse width 4.5 ms Input impedance > 2 kΩ MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 136: Encoder Option Mcb
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 SSI encoder: Absolute Encoder monitor: MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 137 Z inv in- -Data Clock Clock Z input OR -Data RS485 RS485 inv. inv. Data in Data in Future use Data in inv. Data in inv. Future use Max. 5V on X31.5-12 MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 138: Resolver Option Mcb
Secondary load App. 10 kΩ • Enlarged LCP fixture and enlarged terminal cover Selection of parameters: 17-5x resolver Inter- face. MCB 103 Resolver Option supports a various number of resolver types. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 139 Wiring: The max cable length is 150 m when a twisted pair type of cable is used. Resolver cables must be screened and separated from the motor cables. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 140: Relay Option Mcb
Label for covering access to switches S201, S202 and S801 • Cable strips for fastening cables to relay module The relay option does not support FC 302 frequency converters manufactured before week 50/2004. Min. software version: 2.03 (par. 15-43). MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 141 1. The label MUST be placed on the LCP frame as shown (UL approved). Warning Dual supply How to add the MCB 105 option: • The power to the frequency converter must be disconnected. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 142: Back-Up Option Mcb 107 (Option D)
Max. input current 2.2 A Average input current for FC 302 0.9 A Max cable length 75 m Input capacitance load < 10 uF Power-up delay < 0.6 s The inputs are protected. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 143: Mcb 112 Vlt ® Ptc Thermistor Card
Inputs of the FC302 (or a DI of a mounted option) must be set to PCT Card 1 [80] in order to use the information from X44/ 10. Par. 5-19 Terminal 37 Safe Stop must be configured to the desired Safe Stop functionality (default is Safe Stop Alarm). MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 144 20 W ≤ R ≤ 40 W Power consumption 60 mA Testing conditions: EN 60 947-8 Measurement voltage surge resistance 6000 V Overvoltage category Degree of pollution Measurement isolation voltage Vbis 690 V MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 145 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 8.1.15.
Page 146: Ip 21/Ip 4X/ Type 1 Enclosure Kit
If the enclosure kit is used, an IP 20 unit is upgraded to comply with enclosure IP 21/ 4X top/ TYPE 1. The IP 4X top can be applied to all standard IP 20 FC 30X variants. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 147: Sine-Wave Filters
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 148 9. RS-485 Installation and Set-up FC 300 Design Guide MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 149: Installation And Set-Up
Connect signal wires to terminal 68 (P+) and terminal 69 (N-) on the main control board of the frequency converter. Connect the cable screen to the cable clamps. Screened, twisted-pair cables are recommended in order to reduce noise between conductors. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 150 When crossing is unavoidable, the RS-485 cable must cross motor and brake resistor cables at an angle of 90 degrees. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 151: Network Configuration
FC 300 Design Guide 9. RS-485 Installation and Set-up The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss Drives standard field- bus. It defines an access technique according to the master-slave principle for communications via a serial bus.
Page 152 Bit 7 = 1 (address format 1-126 active) Bit 0-6 = Frequency converter address 1-126 Bit 0-6 = 0 Broadcast The slave returns the address byte unchanged to the master in the response telegram. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 153 The text block is used to read or write texts via the data block. 9.4.7. The PKE Field The PKE field contains two sub-fields: Parameter command and response AK, and Parameter number PNU: MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 154 Command cannot be performed text transferred If the command cannot be performed, the slave sends this response: 0111 Command cannot be performed - and issues the following fault report in the parameter value (PWE): MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 155 To read a text via the PWE block, set the parameter command (AK) to ’F’ Hex. The index character high-byte must be “4”. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 156 The block of process words is divided into two blocks of 16 bits, which always occur in the defined sequence. PCD 1 PCD 2 Control telegram (master⇒slave Control word) Reference-value Control telegram (slave ⇒master) Status word Present outp. frequency MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 157: Examples
If the value in par. 3-41 is 10 s, the response from the slave to the master will be: 3E8 Hex corresponds to 1000 decimal. The conversion index for par. 3-41 is -2, i.e. 0.01. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 158: Danfoss Fc Control Profile
9. RS-485 Installation and Set-up FC 300 Design Guide 9.6. Danfoss FC Control Profile 9.6.1. Control Word According to FC Profile(Par. 8-10 = FC profile) Bit value = 0 Bit value = 1 Reference value external selection lsb Reference value...
Page 159 Thus, you can turn off the control word if you do not want to use it when updating or reading parameters. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 160 No operation In operation Drive OK Stopped, auto start Voltage OK Voltage exceeded Torque OK Torque exceeded Timer OK Timer exceeded Explanation of the Status Bits Bit 00, Control not ready/ready: MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 161 Bit 12 = ’0’: There is no temporary over temperature on the inverter. Bit 12 = ’1’: The inverter stops because of over temperature but the unit does not trip and will resume operation once the over temperature stops. Bit 13, Voltage OK/limit exceeded: MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 162 9.6.4. PROFIdrive Control Profile This section describes the functionality of the control word and status word in the PROFIdrive Control word profile to PROFIdrive profile. Select this profile by setting par. 8-10 MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 163 The selection in par. 8-50 Coasting select determines how bit 03 is linked with the corresponding function of the digital inputs. Bit 04, Quick stop/Ramp MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 164 Is used to reduce the speed reference value by the amount given in par. 3-12 down value. When bit 11 = "0", no modification of the reference value occurs. When bit 11 = "1", the reference value is reduced. Bit 12, No function/Catch up MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 165 Bit 15 causes reversing only when selected. 9.6.6. Status Word according to PROFIdrive Profile (STW) The Status word is used to notify a master (e.g. a PC) about the status of a slave. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 166 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.B9.02 - VLT ® is a registered Danfoss trademark...
Page 167 When bit 15 = "0", the timers for the thermal motor protection and thermal frequency converter protection have not exceeded 100%. When bit 15 = "1", one of the timers has exceeded 100%. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 168 10. Troubleshooting FC 300 Design Guide MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 169: Troubleshooting
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 frequency converter is reset. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 170 54 AMA motor too small 55 AMA parameter out of range 56 AMA interrupted by user 57 AMA time-out 58 AMA internal fault 59 Current limit Table 10.1: Alarm/Warning code list MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 171 Alarm flashing red tions. A trip lock is an action when an alarm Trip locked yellow and red occurs, which may cause damage to drive or MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 172 WARNING/ALARM 3, No motor: tem. The frequency converter is still active. No motor has been connected to the output of the frequency converter. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 173 There is short-circuiting in the motor or on the The fault is that the frequency converter is motor terminals. overloaded by more than 100% for too long. Turn off the frequency converter and remove the short-circuit. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 174 This warning/alarm is only active if the supply Turn off the frequency converter and remove voltage to the frequency converter is lost and the brake resistor. parameter 14-10 is NOT set to OFF. Possible MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 175 2049 Power data restarted ALARM 38, Internal fault: 2315 Missing SW version from power By this alarm it may be necessary to contact unit your Danfoss supplier. Some typical alarm 2816 Stack overflow Control board messages: module 2817 Scheduler slow tasks...
Page 176 Maximum Limit: level) and when the Digital Input from the The output frequency is higher than the value MCB 112 is deactivated. Warning: Automatic set in par. 4-19 Restart. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 177 Select the correct type code in Par 14-23 ac- cording to the label on unit. Remember to select ‘Save to EEPROM’ to complete. ALARM 251, New Type Code: The Frequency Converter has got a new type code. MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 178: Index
Control Card, Rs 485 Serial Communication Control Card, Usb Serial Communication Control Characteristics Control Terminals Control Word Control Word According To Profidrive Profile (ctw) Cooling Cooling Conditions Dc Brake Dc Bus Connection Dc Link MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 179 Fuses Galvanic Isolation (pelv) General Warning Harmonic Filters High Voltage Test Hoist Mechanical Brake Hold Output Frequency Intermediate Circuit 45, 49, 74, 172 Internal Current Control In Vvcplus Mode Kty Sensor MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 180 Process Pid Control Profibus 5, 85 Programming Of Torque Limit And Stop Protection 16, 42, 43, 105 Protection And Features Pulse Start/stop Pulse/encoder Inputs Rated Motor Speed 10, 43 Reference Handling MG.33.B9.02 - VLT ® is a registered Danfoss trademark...
Page 181 Torque Control Usb Connection Use Of Emc-correct Cables Vibration And Shock Voltage Level Voltage Reference Via A Potentiometer Vvcplus 10, 22 Warnings What Is Ce Conformity And Labelling? What Is Covered MG.33.B9.02 - VLT ® is a registered Danfoss trademark...

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