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Danfoss VLT FCD 302 Operating Manual
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Danfoss VLT FCD 302 Operating Manual

Danfoss VLT FCD 302 Operating Manual

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Operating Guide
VLT® Decentral Drive FCD 302
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Summary of Contents for Danfoss VLT FCD 302

  • Page 1 Operating Guide VLT® Decentral Drive FCD 302 drives.danfoss.com |...
  • Page 3 3.4.3 Mounting the Installation Box 4 Electrical Installation 4.1 Wiring Diagram 4.2 Block Diagram of the Drive 4.3 EMC-compliant Installation 4.4 Grounding 4.5 Terminals Overview 4.5.1 Terminal Locations 4.6 Electrical Connections for Motors Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 4 6.3 Front Indicator Lights 6.4 Local Control Panel Operation 6.4.1 Overview of the LCP 6.4.2 Uploading and Downloading Data with the LCP 6.4.3 Changing Parameter Settings 6.4.4 Restoring Default Settings 6.4.5 Initialization 6.4.5.1 Recommended Initialization | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 5 7.7.8 Control Card +10 V DC Output 7.7.9 Control Card RS485 Serial Communication 7.7.10 Control Card USB Serial Communication 7.7.11 Relay Outputs 7.7.12 Control Card Performance 7.7.13 Control Characteristics 8 Maintenance 8.1 Preventive Maintenance Recommendations Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 6 Operating Guide | VLT® Decentral Drive FCD 302 Contents 8.2 Cleaning 9 Appendix 9.1 Abbreviations | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 7 Remarks Software version AQ267036816112, version 0301 New document structure. 9.X.X Editorial update. 1.5 Approvals 1.5.1 Type Approvals and Certifications Table 2 shows examples of possible type approvals and certifications for Danfoss drives. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 8 Table 2: Type Approvals and Certifications   NOTICE Information of approvals and certification for the specific drive are located on the drives nameplate. For more information, contact the local Danfoss office or partner. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 9 Operating Guide | VLT® Decentral Drive FCD 302 Introduction and Safety 1.5.2 Declaration of Conformity Figure 1: EU Declaration of Conformity for VLT® Decentral Drive FCD 302 page 1 Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 10 Operating Guide | VLT® Decentral Drive FCD 302 Introduction and Safety Figure 2: EU Declaration of Conformity for VLT® Decentral Drive FCD 302 page 2 | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 11 Operating Guide | VLT® Decentral Drive FCD 302 Introduction and Safety Figure 3: UK Declaration of Conformity for VLT® Decentral Drive FCD 302 page 3 Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 12 Operating Guide | VLT® Decentral Drive FCD 302 Introduction and Safety Figure 4: UK Declaration of Conformity for VLT® Decentral Drive FCD 302 page 4 | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 13 Operating Guide | VLT® Decentral Drive FCD 302 Introduction and Safety 1.6 Safety Symbols The following symbols are used in Danfoss documentation.   DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury.   WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
  • Page 14 Decentral Drive FCD 302, 400 V AC, 0.37–3.0 kW (0.5–4.0 hp). Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors are fully discharged. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 15 7.1 Electrical Data for recommended wire sizes and types. 1.9 Disposal Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with local and currently valid legislation. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 16 Retain damaged parts for verification. The drive is shipped with a selection of loose components packed in plastic bags. The amount of these components depend on the enclosure size and product configuration. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 17 (0.25 in) Ø13 mm (0,51 in) 41 mm (1.61 in) 315 mm (12.4 in) 349.5 mm (13.75 in) WARNING ALARM Bus MS Figure 6: Dimensions VLT® Decentral Drive FCD 302 Small Unit Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 18 Figure 7: Dimensions VLT® Decentral Drive FCD 302 Large Unit 2.3 Storage Ensure that the requirements for storage are fulfilled. See 7.4 Ambient Conditions for further information of temperature during storage/ transport. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 19 Provide a minimum of 100 mm (4 in) top and bottom air cooling clearance during installation, as shown in Figure Derating starts above 40 °C (104 °F) and 1000 m (3280 ft) elevation above sea level. See the VLT® Decentral Drive FCD 302 Design Guide for detailed information. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 20 Figure 9: VLT® Decentral Drive FCD 302 Small/Large Unit Inverter part Installation box Install the installation box and inverter part according to the allowed mounting positions: For standard applications, see Figure For hygienic applications, see Figure | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 21 3.4.2 Installing the Inverter Part Procedure for compressing the gasket between the 2 parts. Tighten the 4 connection screws to torque 2.8–3.0 Nm (24–26 in-lb). Tighten the 4 screws in diagonally opposite order. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 22 Mount the VLT® Decentral Drive FCD 302 vertically on a wall or machine frame. For hygienic applications, ensure that liquids drain off the enclosure and orient the unit so the cable glands are located at the base. Figure 12: FCD 302 Standalone Mounted with Mounting Brackets (Example) | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 23 Operating Guide | VLT® Decentral Drive FCD 302 Mechanical Installation Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 24 24 V (NPN) (COM RS485) 61 33 (D IN) 0 V (PNP) (PNP) = Source (NPN) = Sink 37 (D IN) VCXA GND1 PROFIBUS RS485 interface GND1 Figure 13: Basic Wiring Diagram | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 25 Capacitor bank Inverter Output to motor Control circuitry Mains input: 3-phase AC mains supply to the drive. Rectifier: The rectifier bridge converts the AC input to DC current to supply inverter power. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 26 The metal pins in the corners of the electronic part and the holes on the corner of the installation box are essential for the protective ground connection. Make sure that they are not loosened, removed, or violated in any way. Tightening torque is 3 Nm (26.6 in-lb). | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 27 Figure 17: PE Connection PE connection between installation box/inverter part The external grounding terminal is available as an accessory (code number 130B5833). 4.5 Terminals Overview 4.5.1 Terminal Locations Figure 18: Terminal Location (Small Unit) Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 28 Motor, control, and mains terminals are spring loaded (type, cage clamp). Open the contact by inserting a small screwdriver into the slot above the contact, see Figure Insert the stripped wire into the contact. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 29 Table 5: Terminals 96, 97, 98 Terminal Description Motor voltage 0–100% of mains voltage 3 wires out of the motor 6 wires out of the motor 6 wires out of the motor Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 30 Ensure proper grounding of the motor cable shield at both the motor and drive ends. 4.6.2 Grounding Shielded Cable Grounding clamps are provided for motor and control wiring. Figure 21: Grounding Clamp for Motor and Control Wiring (Small Unit) | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 31 The electronic thermal relay (ETR) of the drive cannot be used as motor protection for the individual motor in systems with parallel-connected motors. Provide further motor protection by thermistors in each motor or individual thermal relays. Circuit breakers are not suitable as protection. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 32 When supplied from an isolated mains source (IT mains or floating delta) or TT/TN-S mains with a grounded leg (grounded delta), ensure that parameter 14–50 RFI Filter is set to [0] Off. This setting prevents damage to the DC link and reduces ground capacity currents in accordance with IEC 61800-3. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 33 JKS- E4273 J/JDDZ Bussmann JJS- E4273 T/JDDZ Bussmann FNQ-R- E4273 CC/JDDZ Bussmann KTK-R- E4273 CC/JDDZ Bussmann LP-CC- E4273 CC/JDDZ SIBA 5017906- E180276 RK1/JDDZ Littelfuse KLS-R E81895 RK1/JDDZ Ferraz Shawmut ATM-R E2137 CC/JDDZ Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 34 380–480 V units (V DC) Inverter undervoltage disable Undervoltage warning Inverter undervoltage re-enables (warning reset) Overvoltage warning (without brake) Dynamic brake turn-on Inverter overvoltage re-enables (warning reset) Overvoltage warning (with brake) Overvoltage trip | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 35 Analog input. Selectable for voltage (0 to ±10 V) or current (0 or 4 to ± 20 mA). Closed is for current and open is for voltage. Switches are located on the drive control card. See 5.6 DIP Switches. Common for analog inputs. Common for serial communication (RS485 interface). See Grounding. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 36   NOTICE When the mechanical brake control/supply terminals 122 and 123 are set through parameter group 5–4* Relays, [1] Array, Relay 2, only 1 relay output (Relay 1) is available for free programming. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 37 Set switch S202 terminal 54 to select the signal type: ON=current, OFF=voltage. Terminal 53 (default) is for a speed reference in an open loop. Terminal 54 (default) is for a feedback signal in a closed loop. Figure 26: Location of DIP Switches Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 38 Protocol type in parameter 8–30 Protocol. Drive address in parameter 8–31 Address. Baud rate in parameter 8–32 Baud Rate. 5.8 Safe Torque Off (STO) Additional wiring for the drive is required to run safe torque off (STO). | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 39 Operating Guide | VLT® Decentral Drive FCD 302 Controls and Options Installation Refer to the VLT® Frequency Converters Safe Torque Off Operating Guide for further information. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 40 Ensure that the cable glands and blind plugs are properly tightened to guarantee that the right plugs enclosure protection degree is achieved. Liquids and/or excessive dust ingress in the drive can cause suboptimal performance or damage. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 41 Description Green The drive receives power from mains voltage or 24 V external supply. – – No power from mains voltage or 24 V external supply. Warning Yellow Warning situation is present. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 42 6.4.1 Overview of the LCP Easily program the drive via the local control panel (LCP). Status 1(0) 1234rpm 10.4A 43.5Hz 43.5Hz Run OK Quick Main Alarm Status Menu Menu Warn. Alarm Reset Figure 29: The LCP | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 43 Mode (recommended) or manually. Initialization via parameter 14-22 Operation Mode does not reset the drive settings such as hours run, serial communication selections, personal menu settings, fault log, alarm log, and other monitoring functions. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 44 Use the navigation keys to scroll to Q2 Quick Setup and press [OK]. 13.7% 0.75A 1 (1) Quick Menus Q1 My Personal Menu Q2 Quick Setup Q3 Function Setups Q5 Changes Made Figure 30: Quick Menus Select language and press [OK]. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 45 The motor shaft does not turn and no harm is done to the motor while running AMA. Some motors may be unable to run the complete version of the test. In that case, select [2] Enable reduced AMA. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 46 A comprehensive list of all warnings and alarms for the VLT® Decentral Drive FCD 302 is found in the VLT® AutomationDrive FC 301/302 Programming Guide. The following list highlights a selection of the most frequently occurring alarms and warnings encountered during drive operation. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 47 Warning 6, DC Link Voltage Low Cause The DC-link voltage (DC) is lower than the low-voltage warning limit. The limit depends on the drive voltage rating. The unit is still active. WARNING/ALARM 9, Inverter Overload Cause Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 48 Mode. Parameter 14-25 Trip Delay at Torque Limit can change this warning from a warning-only condition to a warning followed by an alarm. Troubleshooting If the motor torque limit is exceeded during ramp-up, extend the ramp-up time. If the generator torque limit is exceeded during ramp-down, extend the ramp-down time. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 49 Alarm 15, Hardware Mismatch Cause A fitted option is not operational with the present control card hardware or software. Troubleshooting Record the values of the following parameters and contact Danfoss. Parameter 15-40 FC Type Parameter 15-41 Power Section Parameter 15-42 Voltage...
  • Page 50 For drives with AC fans, the voltage to the fan is monitored. Troubleshooting Cycle for proper fan operation. Cycle power to the drive and check that the fan operates briefly at start-up. Check the sensors on the control card. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 51 The ambient temperature is too high. The motor cables are too long. Incorrect airflow clearance above and below the drive. Blocked airflow around the drive. Damaged heat sink fan. Dirty heat sink. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 52 Motor phase W between the drive and the motor is missing. Troubleshooting Disconnect power from the drive and check motor phase W. ALARM 33, Inrush Fault Cause Too many power-ups have occurred within a short time period. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 53 The software version of the option or the fieldbus variant is not ported/allowed. compatible with the drive software. 1379–2819 Internal fault. Contact the supplier or service department. 1792 Hardware reset of digital signal processor. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 54 Internal fault. Contact the supplier or service department. Troubleshooting See the above table for the causes and solutions for different internal faults. If the fault persists, contact the Danfoss supplier or service department for assistance. WARNING 40, Overload T27 Troubleshooting Check the load connected to terminal 27 or remove the short-circuit connection.
  • Page 55 If 24 V DC is used, verify proper supply power. Check for a defective heat sink fan. WARNING/ALARM 47, 24 V Supply Low Cause The 24 V DC is measured on the control card. Troubleshooting Check for a defective control card. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 56 ALARM 50, AMA Calibration Cause A calibration error has occurred. Troubleshooting Contact a Danfoss supplier or the Danfoss service department. ALARM 51, AMA check U and I Cause The settings for motor voltage, motor current, and motor power are wrong.
  • Page 57 Try to restart the AMA. Repeated restarts can overheat the motor. ALARM 58, AMA Internal Fault Cause An AMA internal fault occurs. Troubleshooting Contact a local Danfoss supplier. WARNING/ALARM 59, Current Limit Cause The current is higher than the value in parameter4-18 Current Limit. Troubleshooting Ensure that the motor data in parameter 1-20 to parameter 1-25 is set correctly.
  • Page 58 WARNING/ALARM 65, Control Card Over Temperature Cause The cutout temperature of the control card has exceeded the upper limit. Troubleshooting Check that the ambient operating temperature is within the limits. Check the fan operation. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 59 Cause The control card and power card are incompatible. Troubleshooting To check compatibility, contact the Danfoss supplier with the type code from the unit nameplate and the part numbers on the cards. ALARM 71, PTC 1 Safe Stop Cause Because the motor is too warm, the VLT® PTC Thermistor Card MCB 112 activated Safe Torque Off (STO).
  • Page 60 The scaling card has an incorrect code number or is not installed. The MK102 connector on the power card could not be installed. ALARM 80, Drive Initialized to Default Value Cause Parameter settings are initialized to default settings after a manual reset. Troubleshooting To clear the alarm, reset the unit. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 61 ALARM 91, Analog Input 54 Wrong Settings Troubleshooting Set switch S202 in position OFF (voltage input) when a KTY sensor is connected to analog input terminal 54. ALARM 99, Locked Rotor Cause Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 62 The drive has run for more than 60 s in a period of 600 s below the allowed minimum frequency as set in parameter 1-98 ATEX ETR Interpol. Points. Freq.). WARNING 251, New Typecode Cause The power card or other components have been replaced, and the type code has changed. Troubleshooting Reset the drive for normal operation. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 63 2) Applies to the dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses may increase. LCP and typical control card power consumption are included. For power loss data according to EN 50598-2, refer to ecosmart.mydrive.danfoss.com.
  • Page 64 Minimum ambient temperature during full-scale operation 0 °C (32 °F) Minimum ambient temperature at reduced speed performance -10 °C (14 °F) Temperature during storage/transport -25...65/70 °C (-13...149/158 °F) Maximum altitude above sea level 1000 m (3280 ft) | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 65 2xM25 1) Also used for 4xM12/6xM12 sensor/actuator sockets. 7.7 Control Input/Output and Control Data 7.7.1 Digital Inputs Programmable digital inputs 4 (6) Terminal number 18, 19, 27 , 29 , 32, 33 Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 66 0 V to +10 V (scalable) Input resistance, R Approximately 10 kΩ Maximum voltage ±20 V Current mode Switch S201/S202 = ON (I) Current level 0/4 mA to 20 mA (scaleable) Approximately 200 Ω Input resistance, R | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 67 2) Encoder inputs: 32=A, 33=B. The pulse and encoder inputs (terminals 29, 32, 33) are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. 7.7.5 Digital Outputs Programmable digital/pulse outputs Terminal number 27, 29 Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 68 Terminal number 68 (P, TX+, RX+), 69 (N, TX-, RX-) Terminal number 61 Common for terminals 68 and 69 The RS485 serial communication circuit is galvanically isolated from the supply voltage (PELV). | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 69 3) UL applications 300 V AC 2 A. 7.7.12 Control Card Performance Scan interval 1 ms 7.7.13 Control Characteristics Resolution of output frequency at 0–590 Hz ±0.003 Hz Repeat accuracy of precise start/stop (terminals 18, 19) ≤±0.1 ms Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 70 Speed accuracy (closed loop), depending on resolution of feed- 0–6000 RPM: Error ±0.15 RPM back device Torque control accuracy (speed feedback) Maximum error ±5% of rated torque All control characteristics are based on a 4-pole asynchronous motor. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 71 8.1 Preventive Maintenance Recommendations Generally, all technical equipment, including Danfoss AC drives, need a minimum level of preventive maintenance. To ensure trouble-free operation and long life of the drive, regular maintenance is recommended. It is also recommended as a good service practice to record a maintenance log with counter values, date, and time describing the maintenance and service actions.
  • Page 72 1) Defined as the time after the commissioning/startup or the time from the previous inspection. 2) Defined as the time after the commissioning/startup or the time from the previous service schedule actions. | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
  • Page 73 Use the solvent concentration recommended by the manufacturer. Avoid high- pressure hot water cleaning at close proximity or of long duration, because this method of cleaning can damage gaskets and labels. Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208 |...
  • Page 74 Protective extra low voltage Printed circuit board PM motor Permanent magnet motor Pulse width motor Root mean square Revolutions per minute Regen Regenerative terminals Safe torque off Torque limit Nominal motor voltage | Danfoss A/S © 2025.04 AQ267036816112en-000301 / 130R0208...
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  • Page 76 Danfoss reserves the right to alter its products without notice. This also applies to products ordered but not delivered provided that such alterations can be made without changes to form, fit or function of the product. All trademarks in this material are property of Danfoss A/S or Danfoss group companies.