Danfoss FC 300 Operating Instructions Manual

Frequency converter

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FC 300 Operating Instructions

Contents

How to Read these Operating Instructions

Approvals .............................................................................................

Symbols ...............................................................................................

Abbreviations ........................................................................................

Safety Instructions and General Warning

Software Version ...................................................................................

High Voltage Warning .............................................................................

Safety Instructions .................................................................................

Avoid Unintended Start ...........................................................................

Safe Stop of FC 302 ...............................................................................

IT Mains ...............................................................................................

How to Install

.................................................................................. 11

How to Get Started ................................................................................ 11

Accessory Bag ≤ 7.5 kW ......................................................................... 12

Mechanical Installation ........................................................................... 13

Electrical Installation .............................................................................. 15

Removal of Knockouts for Extra Cables ..................................................... 15

Connection to Mains and Earthing ............................................................ 15

Motor Connection ................................................................................... 17

Motor Cables ......................................................................................... 19

Fuses ................................................................................................... 20

Access to Control Terminals ..................................................................... 22

Electrical Installation, Control Terminals .................................................... 22

Basic Wiring Example ............................................................................. 23

Electrical Installation, Control Cables ........................................................ 24

Switches S201, S202, and S801 .............................................................. 25

Tightening Torque .................................................................................. 25

Final Set-Up and Test ............................................................................. 26

Additional Connections ........................................................................... 28

24 V Back-up Option .............................................................................. 28

Mounting of Option Modules in Slot B (MCB 101 and MCB 102) ..................... 29

General Purpose Input Output Module MCB 101 ......................................... 29

Encoder Option MCB 102 ........................................................................ 31

Load Sharing ......................................................................................... 32

Relay Option MCB 105 ............................................................................ 33

Brake Connection Option ........................................................................ 36

Relay Connection ................................................................................... 36

Control of Mechanical Brake .................................................................... 37

Motor Thermal Protection ........................................................................ 37

How to Programme

The Local Control Panel .......................................................................... 39

How to Programme on the Graphical Local Control Panel ............................. 39

Quick Transfer of Parameter Settings ........................................................ 42

Reset to Default Setting

Adjust Display Contrast .......................................................................... 43

Connection Examples ............................................................................. 44

Start/Stop ............................................................................................ 44

Pulse Start/Stop .................................................................................... 44

MG.33.A5.02 - VLT is a registered Danfoss trademark

........................................................................ 39

......................................................................... 43

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Summary of Contents for Danfoss FC 300

Page 1: Table Of Contents
How to Programme on the Graphical Local Control Panel ......39 Quick Transfer of Parameter Settings ............42 Reset to Default Setting ................. 43 Adjust Display Contrast ................43 Connection Examples ................44 Start/Stop .................... 44 Pulse Start/Stop ..................44 MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 2 FC 300 Operating Instructions Speed Up/Down ..................44 Potentiometer Reference ................. 44 Basic Parameters ................... 45 Parameter Lists ..................47 General Specifications ..............63 Troubleshooting ................69 Warnings/Alarm Messages ..............69 Index ....................77 MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 3: How To Read These Operating Instructions
® AutomationDrive FC 300. The FC 300 comes in two shaft performance levels. FC 301 ranges from scalar (U/f) to VVC+, and FC 302 ranges from scalar (U/f) to servo performance. These Operating Instructions cover both FC 301 and FC 302. Where information covers both series, we refer to FC 300.
Page 4: Approvals
AutomationDrive FC 300 Operating Instructions provide the neccessary information for getting the drive up and running. The VLT ® AutomationDrive FC 300 Design Guide entails all technical information about the drive and customer design and applications. The VLT ® AutomationDrive FC 300 Profibus Operating Instructions provide the information required for controlling, monitoring and programming the drive via a Profibus fieldbus.
Page 5: Symbols
Motor Type Dependent M-TYPE Nanofarad Newton Meters Nominal motor current Nominal motor frequency Nominal motor power Nominal motor voltage Parameter par. Rated Inverter Output Current I Revolutions Per Minute Second Torque limit Volts MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 6 FC 300 Operating Instructions How to Read these Operating Instructions MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 7: Safety Instructions And General Warning
Safety Instructions and General Warning FC 300 Operating Instructions Software version: 3.xx These Operating Instructions can be used for all FC 300 frequency converters with software version 3.xx. The software version number can be seen from parameter 15-43. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 8: High Voltage Warning
ETR functions provide class 20 motor overload protection, in accordance with NEC. The earth leakage current exceeds 3.5 mA. • The [OFF] key is not a safety switch. It does not disconnect the FC 300 from mains. • Before Commencing Repair Work...
Page 9: It Mains
Shorter time is allowed only if indicated on the nameplate for the specific unit. Leakage Current The earth leakage current from the FC 300 exceeds 3.5 mA. To ensure that the earth cable has a good mechanical connection to the earth connection (terminal 95), the cable cross section must be at least 10 mm2 or 2 rated earth wires terminated separately.
Page 10 FC 300 Operating Instructions Safety Instructions and General Warning MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 11: How To Install
Electrical installation of options is described in the corresponding Instructions. How to Get Started You can carry out a quick and EMC-correct installation of the FC 300 by following the steps described below. Read the safety instructions before installing the unit.
Page 12: Accessory Bag ≤ 7.5 Kw
There is only one relay connector for FC 301. (≤ 7.5 kW) Accessory Bag ≤ 7.5 kW, IP 55 1 + 2 only available in units with brake chopper. There is only one relay connector for FC 301. (≤ 7.5 kW, IP55) MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 13: Mechanical Installation
Accessory Bag 11-22 kW There is only one relay connector for FC 301. (11-22 kW) Mechanical Installation Basic Enclosures FC 300 IP20 - see table for Mechanical dimensions of the IP Mechanical dimensions of the IP mechanical dimensions 21/IP 4x/ TYPE 1 enclosure kit (≤...
Page 14 You must provide screws suitable for the surface on which you want to mount the FC 300. Retighten all four screws. FC 300 IP20 allows side-by-side installation. Because of the need for cooling, there must be a minimum of 100 mm free air passage above and below the FC 300.
Page 15: Electrical Installation
Connection to Mains and Earthing NB!: The plug connector for power can be removed. Make sure the FC 300 is properly earthed. Connect to earth connection (terminal 95). Use screw from the accessory bag. Place plug connector 91, 92, 93 from the accessory bag onto the terminals labelled MAINS at the bottom of FC 300.
Page 16 440 V. For IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase and earth. How to connect to mains and earthing with disconnector (A5 enclosure). MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 17: Motor Connection
For more information, see EMC specifications in the VLT AutomationDrive FC 300 Design Guide. Fasten decoupling plate to the bottom of FC 300 with screws and washers from the accessory bag. Attach motor cable to terminals 96 (U), 97 (V), 98 (W).
Page 18 In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply (such as a frequency converter), fit an LC filter on the output of the FC 300. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 19: Motor Cables
Keep the motor cable as short as possible to reduce the noise level and leakage currents. • Connect the motor cable screen to the decoupling plate of the FC 300 and to the metal cabinet of the motor. • •...
Page 20: Fuses
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 or other 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 21 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.A5.02 - VLT is a registered Danfoss trademark...
Page 22: Access To Control Terminals
Insert the cable in the adjacent circular hole. Remove the screw driver. The cable is now mounted to the terminal. To remove the cable from the terminal: Insert a screw driver in the square hole. Pull out the cable. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 23: Basic Wiring Example
Assembling of IP55 / NEMA TYPE 12 (A5 housing) with mains disconnector Basic Wiring Example Mount terminals from the accessory bag to the front of the FC 300. Connect terminals 18, 27 and 37 (FC 302 only) to +24 V (terminal 12/13) Default settings:...
Page 24: Electrical Installation, Control Cables
Common for the digital and analog in- and outputs must be connected separately to avoid common mode currents from one group (i.e. the digital inputs) to affect other groups (i.e. the analog inputs). MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 25: Switches S201, S202, And S801
Use a clamp from the accessory bag to connect the screen to the decoupling plate for control cables. See section entitled Earthing of screened/armoured control cables in the VLT AutomationDrive FC 300 Design Guide for the correct termination of control cables. Switches S201, S202, and S801...
Page 26: Final Set-Up And Test
AMA, or remove the LC 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.A5.02 - VLT is a registered Danfoss trademark...
Page 27 "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 Service, make sure to mention number and alarm description.
Page 28: Additional Connections
Attach 24 V DC cable to the 24 V plug connector. Insert plug connector into terminals labellled 35, 36. Connection to 24 V back-up supply (≤ 7.5 kW). Connection to 24 V back-up supply (11-22 kW). MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 29: Mounting Of Option Modules In Slot B (Mcb 101 And Mcb 102)
MCB 101 is used for extension of digital and analog inputs and outputs of FC 301 and FC 302 AutomationDrive. Contents: MCB 101 must be fitted into slot B in the AutomationDrive. • MCB 101 option module Extended fixture for LCP • Terminal cover • MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 30 Logic “0”: Input < 5 V DC Logic “0”: Input > 10 V DC NPN type: Common = 24 V Logic “0”: Input > 19 V DC Logic “0”: Input < 14 V DC MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 31: Encoder Option Mcb 102
B inv input REFSIN B inv input Z input +Data RS485 Z input OR +Data RS485 Z inv input -Data RS485 Z input OR -Data RS485 Future use Future use Max. 5V on X31.5-12 MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 32: Load Sharing
FC 300 Operating Instructions How to Install Load Sharing With load sharing you can connect several FC 300’s DC intermediate circuits if you extend the installation using extra fuses and AC coils (see illustration). NB!: Load sharing cables must be screened/armoured. If an unscreened/unarmoured cable is used, some EMC requirements are not complied with.
Page 33: 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). ≤ 7.5 kW IMPORTANT 1. The label MUST be placed on the LCP frame as shown (UL approved). MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 34 FC 300 Operating Instructions How to Install 11-22 kW IMPORTANT 1. The label MUST be placed on the LCP frame as shown (UL approved). Warning Dual supply MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 35 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) Do not combine low voltage parts and PELV systems. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 36: Brake Connection Option
(normally open) 01 - 03 break (normally closed) 04 - 05 make (normally open) 04 - 06 break (normally closed) Terminals for relay connection (≤ 7.5 kW). Terminals for relay connection (11-22 kW). MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 37: Control Of Mechanical Brake
RPM values. The electronic thermal relay (ETR) of the FC 300 cannot be used as motor protection for the individual motor in systems with motors connected in parallel. Further motor protection must be provided, e.g. thermistors in each motor or individual thermal relays.
Page 38 FC 300 Operating Instructions How to Install MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 39: How To Programme
The LCD-display has back light and a total of 6 alpha-numeric lines. The display lines show the direction of rotation (arrow), the chosen Set-up as well as the programming Set-up. The display is divided into 3 sections: MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 40 Press [status] and [ ] for brighter display Most FC 300 parameter set-ups can be changed immediately via the control panel, unless a password has been created via par. 0-60 Main Menu Password or via par. 0-65 Quick Menu Password.
Page 41 Enable [1] or Disable [0] via par. 0-40 [Hand on] key on LCP. External stop signals activated by means of control signals or a serial bus will over- ride a “start” command via the LCP. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 42: Quick Transfer Of Parameter Settings
Press the [OK] key All parameter settings are now stored in the LCP indicated by the progress bar. When 100% is reached, press [OK]. NB!: Stop the motor before performing this operation. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 43: Reset To Default Setting
Initialisation. Power down the frequency converter. The frequency converter will automatically restore to default settings during the next power up. Adjust Display Contrast Hold down [STATUS] and use the up or down navigation arrow to adjust the display contrast MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 44: Connection Examples
Par. 6-11 Terminal 53, High Voltage = 10 Volt Par. 6-14 Terminal 53, Low Ref./Feedb. Value = 0 RPM Par. 6-15 Terminal 53, High Ref./Feedb. Value = 1.500 RPM Switch S201 = OFF (U) MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 45: Basic Parameters
AMA on a cold motor. Select Enable complete AMA, if the frequency converter is to carry out AMA of the stator default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 46 Minimum reference is only active if Min - Max [0] is set in par. 3-00. Speed control, closed loop: RPM Torque control, speed feedback: Nm default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 47: Parameter Lists
Bit sequence of 16 boolean variables Time difference w/o date TimD See the FC 300 Design Guide for further information about data types 33, 35 and 54. default setting display text value for use in communication via serial communication port...
Page 48 200 N/A 1 set-up TRUE Uint16 0-66 Access to Quick Menu w/o Password [0] Full access 1 set-up TRUE Uint8 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 49 1-91 Motor External Fan [0] No All set-ups TRUE Uint16 1-93 Thermistor Resource [0] None All set-ups FALSE Uint8 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 50 Activate Brake Speed [Hz] ExpressionLimit All set-ups TRUE Uint16 2-23 Activate Brake Delay 0.0 s All set-ups TRUE Uint8 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 51 Int16 3-94 Minimum Limit -100 % All set-ups TRUE Int16 3-95 Ramp Delay 1.000 N/A All set-ups TRUE TimD default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 52 Bypass Speed To [RPM] ExpressionLimit All set-ups TRUE Uint16 4-63 Bypass Speed To [Hz] ExpressionLimit All set-ups TRUE Uint16 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 53 Pulse Out #29 Bus Control 0.00 % All set-ups TRUE 5-96 Pulse Out #29 Timeout Preset 0.00 % 1 set-up TRUE Uint16 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 54 Terminal X30/8 Min. Scale 0.00 % All set-ups TRUE Int16 6-62 Terminal X30/8 Max. Scale 100.00 % All set-ups TRUE Int16 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 55 Bus Jog 1 Speed 100 RPM All set-ups TRUE Uint16 8-91 Bus Jog 2 Speed 200 RPM All set-ups TRUE Uint16 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 56 Changed Parameters (3) 0 N/A All set-ups FALSE Uint16 9-93 Changed parameters (4) 0 N/A All set-ups FALSE Uint16 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 57 10-50 Process Data Config Write. ExpressionLimit 2 set-ups TRUE Uint16 10-51 Process Data Config Read. ExpressionLimit 2 set-ups TRUE Uint16 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 58 14-5* Environment 14-50 RFI Filter [1] On 1 set-up FALSE Uint8 14-52 Fan Control [0] Auto All set-ups TRUE Uint8 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 59 Uint16 15-93 Modified Parameters 0 N/A All set-ups FALSE Uint16 15-99 Parameter Metadata 0 N/A All set-ups FALSE Uint16 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 60 16-92 Warning Word 0 N/A All set-ups FALSE Uint32 16-94 Ext. Status Word 0 N/A All set-ups FALSE Uint32 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 61 [4] 9600 All set-ups FALSE Uint8 17-6* Monitoring and App. 17-60 Encoder Positive Direction [0] Clockwise All set-ups FALSE Uint8 default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 62 FC 300 Operating Instructions How to Programme default setting display text value for use in communication via serial communication port MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 63: General Specifications
Starting torque ................. maximum 180% up to 0.5 sec. Overload torque (Constant torque) ............. maximum 160% for 1 min. *Percentage relates to FC 300’s nominal current. Digital inputs: Programmable digital inputs ..............FC 301: 4 (5) / FC 302: 4 (6) Terminal number ..................
Page 64 Accuracy of analog inputs ................. Max. error 0.5% of full scale Bandwidth ..................FC 301: 20 Hz / FC 302: 100 Hz The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 65 Terminal number ......................... 50 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.A5.02 - VLT is a registered Danfoss trademark...
Page 66 Max. motor cable length, unscreened/unarmoured ........FC 301: 75 m / FC 302: 300 m Max. cross section to motor, mains, load sharing and brake (see section Electrical Data in the FC 300 Design Guide MG.33.BX.YY for more information), (0.25 kW - 7.5 kW) ........4 mm / 10 AWG Max.
Page 67 EN 61800-3, EN 61000-6-3/4, EN 55011 EMC standards, Immunity ..............EN 61800-3, EN 61000-6-1/2, EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6 See section on special conditions in the Design Guide MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 68 Monitoring of the intermediate circuit voltage ensures that the frequency converter trips • if the intermediate circuit voltage is too low or too high. • The frequency converter is protected against earth faults on motor terminals U, V, W. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 69: Troubleshooting
[RESET] key. The table (next page) shows the various warnings and alarms, and whether the fault locks the FC 300. After an Alarm/Trip locked, cut off the mains supply and correct the fault. Reconnect mains supply. The FC 300 is now unlocked. The Alarm/Trip can be reset manually in three ways: Via the operating key [RESET] on the LCP.
Page 70 Control Card Overtemperature Heatsink Temperature Low Option Configuration has Changed Safe Stop Activated Drive Initialised to Default Value (X) Dependent on parameter LED indication Warning yellow Alarm flashing red Trip locked yellow and red MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 71 This message also appears in case of a fault in the 50% of the value set in par. 6-10, 6-12, input rectifier on the frequency converter. 6-20, or 6-22 respectively. Check the supply voltage and supply currents to the frequency converter. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 72 4-17 (in regenerative operation). The voltages stated are the intermediate circuit voltage of the FC 300 with a tolerance of ± 5 %. The WARNING/ALARM 13 corresponding mains voltage is the intermediate Over Current: circuit voltage (DC-link) divided by 1.35...
Page 73 See the chapter General Specifications for the allowed number of powerups within one minute. WARNING 27 Brake chopper fault: The brake transistor is monitored during operation and if it short-circuits, the brake function disconnects MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 74 The motor is too big for the AMA to be carried out. and thus the fan speed is increased to the maximum in case the power part or control card is very hot. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 75 Illegal Frequency Configuration: Actual combination of control board and power board is illegal. ALARM 80 Drive Initialised to Default Value: Parameter settings are initialised to default setting after a manual (three-finger) reset. MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 76 FC 300 Operating Instructions Troubleshooting MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 77: Index
..........Main Menu mode ..........Digital inputs: ..........Main reactance ........... Digital output .......... Mains plug connector ..........Display Contrast ........Mains supply (L1, L2, L3) ........... Maximum Reference ............MCT 10 MG.33.A5.02 - VLT is a registered Danfoss trademark...
Page 78 Ramp 1 Ramp Down Time ........Ramp 1 Ramp up Time ..........Relay Connection ........... Relay outputs ....Removal of Knockouts for Extra Cables ............. Repair Work ............. Reset ........Residual Current Device ........... screened/armoured MG.33.A5.02 - VLT is a registered Danfoss trademark...

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