Danfoss VLT AutomationDrive FC 302 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT®AutomationDrive FC 302 Low Harmonic Drive
132-630 kW
www.danfoss.com/drives

Contents
1 Safety 4
1.1 Safety 4
2 Introduction 5
2.1 Exploded View Drawings 5
2.2 Purpose of the Manual 13
2.3 Approvals 13
2.3.1 Approvals 13
2.4 Additional Resources 13
2.5 Product Overview 13
2.6 Internal Equipment Functions 14
2.6.1 Working Principle 14
2.6.2 IEEE519 Compliance 14
3 Installation 15
3.1 Installation Site Checklist 15
3.2 Equipment Pre-Installation Checklist 15
3.3 Mechanical Installation 15
3.3.1 Cooling and Airflow 15
3.3.2 Lifting 17
3.3.3 Terminal Locations for Frame Size D13 18
3.3.4 Terminal Locations for Frame Size E9 19
3.3.5 Terminal Locations - Frame Size F18 20
3.3.6 Torque 23
3.4 Electrical Installation 23
3.4.1 EMC Interference 25
3.4.2 Extra Protection (RCD) 26
3.4.3 RFI Switch 26
3.4.4 Shielded Cables 26
3.4.5 Motor Cable 26
3.4.6 Brake Cable 27
3.4.7 Brake Resistor Temperature Switch 27
3.4.8 Mains Connection 27
3.4.9 External Fan Supply 27
3.4.10 Power and Control Wiring for Unscreened Cables 28
3.4.11 Mains Disconnects 29
3.4.12 F-Frame Circuit Breakers 29
3.4.13 F-Frame Mains Contactors 29
3.4.14 Motor Insulation 29
3.4.15 Motor Bearing Currents 29
Contents Operating Instructions
MG37A202 Danfoss A/S © Rev. 2014-07-29 All rights reserved. 1

3.4.16 Motor Thermal Protection 30
3.4.17 Control Cable Routing 30
3.4.18 Access to Control Terminals 31
3.4.19 Electrical Installation, Control Terminals 31
3.4.20 Electrical Installation, Control Cables 33
3.4.21 Switches S201, S202, and S801 34
3.4.22 Serial Communication 34
3.5 Final Set-up and Test 34
3.6 Additional Connections 35
3.6.1 Mechanical Brake Control 35
3.6.2 Parallel Connection of Motors 35
3.6.3 F-frame Options 36
4 Start Up and Functional Testing 38
4.1 Pre-start 38
4.2 Applying Power to the Equipment 39
4.3 Basic Operational Programming 39
4.4 Local Control Test 40
4.5 System Start Up 41
5 User Interface 42
5.1 How to Operate 42
5.1.1 Modes of Operation 42
5.1.2 How to Operate Graphical LCP (GLCP) 42
5.1.3 Changing Data 45
5.1.4 Changing a Text Value 46
5.1.5 Changing a Group of Numeric Data Values 46
5.1.6 Changing of Data Value, Step-by-Step 46
5.1.7 Read-out and Programming of Indexed Parameters 46
5.1.8 Quick Transfer of Parameter Settings with the LCP 46
5.1.9 Initialisation to Default Settings 47
5.1.10 RS-485 Bus Connection 47
5.1.11 Connection to a PC 47
5.1.12 PC Software Tools 48
6 Programming 49
6.1 How to Programme the Frequency Converter 49
6.1.1 Quick Setup Parameters 49
6.1.2 Basic Setup Parameters 51
6.2 How to Programme the Active Filter 71
6.2.1 Using the Low Harmonic Drive in NPN Mode 72
Contents Operating Instructions
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6.3 Parameter Lists - Frequency Converter 72
6.3.1 Parameter Selection 73
6.4 Parameter Lists - Active Filter 106
7 Application Examples 112
7.1 Introduction 112
7.2 Application Examples 112
7.3 Connection Examples for Control of Motor with External Signal Provider 117
7.3.1 Start/Stop 117
7.3.2 Pulse Start/Stop 117
7.3.3 Speed Up/Down 117
7.3.4 Potentiometer Reference 118
8 Status Messages 119
8.1 Status Display 119
8.2 Status Message Definitions 119
9 Warnings and Alarms 122
9.1 System Monitoring 122
9.2 Warning and Alarm Types 122
9.2.1 Warnings 122
9.2.2 Alarm Trip 122
9.2.3 Alarm Trip-lock 122
9.3 Warning and Alarm Displays 122
9.4 Warnings and Alarm Definitions - Frequency Converter 123
9.5 Active Filter Warning and Alarm Definitions 131
10 Basic Start-up Troubleshooting 136
11 Specifications 139
11.1 Power-Dependent Specifications 139
11.1.1 Mains Supply 3x380-480 V AC 139
11.1.2 Derating for Temperature 142
11.2 Mechanical Dimensions 143
11.3 General Technical Data - Frequency Converter 145
11.4 General Technical Data - Filter 149
11.5 Fuses 153
11.5.1 Non UL compliance 153
11.5.2 Fuse Tables 154
11.5.3 Supplementary Fuses - High Power 154
11.6 General Torque Tightening Values 155
Index 157
Contents Operating Instructions
MG37A202 Danfoss A/S © Rev. 2014-07-29 All rights reserved. 3

1 Safety
1.1 Safety
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when
connected to AC mains input power. Qualified personnel
only should perform installation, start up, and
maintenance. Failure to perform installation, start up,
and maintenance by qualified personnel could result in
death or serious injury.
WARNING
UNINTENDED START
When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency
converter, motor, and any driven equipment must be in
operational readiness. Failure to be in operational
readiness when the frequency converter is connected to
AC mains could result in death, serious injury,
equipment, or property damage.
WARNING
DISCHARGE TIME
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is
not powered. To avoid electrical hazards, disconnect AC
mains, any permanent magnet type motors, and any
remote DC-link power supplies, including battery back-
ups, UPS, and DC-link connections to other frequency
converters. Wait for the capacitors to fully discharge
before performing any service or repair work. The
amount of wait time is listed in the Discharge Time table.
Failure to wait the specified time after power has been
removed before doing service or repair could result in
death or serious injury.
Voltage [V] Power range [kW] Minimum waiting time
(minutes)
380-500 160-250 kW* 20
315-710 kW 40
Table 1.1 Discharge Times
*Power ranges are for normal overload operation.
Safety Operating Instructions
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1

2 Introduction
2.1 Exploded View Drawings
130BX167.10
1
19 13
12
25
5
4
22
21
20
18
17
3
16
15
14
11
24
2
10
9
8
7
6
23
1 Control card 14 SCR/diode module
2 Control input terminals 15 IGBT output bus bar
3 Local control panel (LCP) 16 Output motor terminals
4 Control card C option 17 Current sensor
5 Mounting bracket 18 Fan assembly
6 Power card mounting plate 19 Fan transformer
7 Power card 20 AC input terminals
8 Capacitor bank assembly 21 AC input bus bar
9 Soft charge fuses 22 Input terminal mounting plate assembly
10 Soft charge card 23 Fan fuse
11 DC inductor 24 Capacitor bank cover plate
12 Soft charge module 25 IGBT gate drive card
13 IGBT module
Illustration 2.1 Frame Size D13 Drive Enclosure
Introduction Operating Instructions
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22

130BD571.11
1
67
89
11
13
15
16
20
21
22
2
3
4
5
10
12
14
18
19
17
1 Local control panel (LCP) 13 Mains fuses
2 Active filter card (AFC) 14 Mains disconnect
3 Metal oxide varistor (MOV) 15 Mains terminals
4 Soft charge resistors 16 Heat sink fan
5 AC capacitors discharge board 17 DC capacitor bank
6 Mains contactor 18 Current transformer
7 LC inductor 19 RFI differential mode filter
8 AC capacitors 20 RFI common mode filter
9 Mains bus bars to drive input 21 HI inductor
10 IGBT fuses 22 Power card
11 RFI
Illustration 2.2 Frame Size D13 Filter Enclosure
Introduction Operating Instructions
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1
3
2
7
5
4
10
9
8
25
24
6
130BX168.10
20
19 18
17
16
15
14
13
12
11
23
22
21
1 Control card 14 SCR and diode
2 Control input terminals 15 Fan inductor (not on all units)
3 Local control panel (LCP) 16 Soft charge resistor assembly
4 Control card C option 17 IGBT output bus bar
5 Mounting bracket 18 Fan assembly
6 Power card mounting plate 19 Output motor terminals
7 Power card 20 Current sensor
8 IGBT gate drive card 21 Mains AC power input terminals
9 Upper capacitor bank assembly 22 Input terminal mounting plate
10 Soft charge fuses 23 AC input bus bar
11 DC inductor 24 Soft charge card
12 Fan transformer 25 Lower capacitor bank assembly
13 IGBT module
Illustration 2.3 Frame Size E9 Drive Enclosure
Introduction Operating Instructions
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22

130BD572.11
1
5
6
7
9
10
11
12
14
16
17
18
19
20
21
2
3
4
8
13
15
1 Local control panel (LCP) 12 AC capacitor current transducers
2 Active filter card (AFC) 13 Heat sink fan
3 Mains contactors 14 Mains terminals
4 Soft charge resistors 15 Mains disconnect
5 RFI differential mode filter 16 Mains fuses
6 RFI common mode filter 17 LC inductor
7 Current transformer (CT) 18 HI inductor
8 Mains bus bars to drive output 19 Power card
9 AC capacitors 20 Control card
10 RFI 21 LCP cradle
11 Lower DC capacitor bank
Illustration 2.4 Frame Size E9 Filter Enclosure
Introduction Operating Instructions
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130BX334.11
2
3
4
5
6
1
1 Contactor 4 Circuit breaker or disconnect (if purchased)
2 RFI filter 5 AC mains/line fuses (if purchased)
3 Mains AC power input terminals
Illustration 2.5 Frame Size F18 Input Options Cabinet
Introduction Operating Instructions
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22

130BD573.10
1
2
5
6
7
10
11
15
17
3
4
8
9
13
14
16
18
12
1 Local control panel (LCP) 10 Mains bus bars to drive input
2 Active filter card (AFC) 11 Heat sink fans
3 Soft charge resistors 12 Mains terminals (R/L1, S/L2, T/L3) from options cabinet
4 Metal oxide varistor (MOV) 13 RFI differential mode filter
5 AC capacitors discharge board 14 RFI common mode filter
6 LC inductor 15 Mains contactor
7 HI inductor 16 Power card
8 Mixing fan 17 Control card
9 IGBT fuses 18 LCP cradle
Illustration 2.6 Frame Size F18 Filter Cabinet
Introduction Operating Instructions
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1
2
5
6
7
8
9
10
11
12
4
3
130BX331.11
13
1 Rectifier module 7 Module lifting eye bolts (mounted on a vertical strut)
2 DC bus bar 8 Module heat sink fan
3 SMPS fuse 9 Fan door cover
4 (Optional) back AC fuse mounting bracket 10 SMPS fuse
5 (Optional) middle AC fuse mounting bracket 11 Power card
6 (Optional) front AC fuse mounting bracket 12 Panel connectors
Illustration 2.7 Frame Size F18 Rectifier Cabinet
Introduction Operating Instructions
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22

2
1
16
15
14
13
12
11
10
8
7
6
54
9
3
130BX330.11
1 Fan transformer 9 Fan door cover
2 DC link inductor 10 Module heat sink fan
3 Top cover plate 11 Inverter module
4 MDCIC board 12 Panel connectors
5 Control card 13 DC fuse
6 SMPS fuse and fan fuse 14 Mounting bracket
7 Motor output bus bar 15 (+) DC bus bar
8 Brake output bus bar 16 (-) DC bus bar
Illustration 2.8 Frame Size F18 Inverter Cabinet
Introduction Operating Instructions
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2.2 Purpose of the Manual
The purpose of this manual is to provide information for
the installation and operation of a VLT®Low Harmonic
Drive. The manual includes relevant safety information for
installation and operation. Chapter 1 Safety,
chapter 2 Introduction, and chapter 3 Installation introduce
the unit function and cover proper mechanical and
electrical installation procedures. There are chapters on
start-up and commissioning, applications and basic
troubleshooting. Chapter 11 Specifications provides a quick
reference for ratings and dimensions, as well as other
operating specifications. This manual provides a basic
knowledge of the unit and explains setup and basic
operation.
VLT®is a registered trademark.
2.3 Approvals
2.3.1 Approvals
Table 2.1 Compliance Marks: CE, UL, and C-Tick
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to .
2.4 Additional Resources
Other resources are available to understand advanced
functions and programming.
•The VLT
®
AutomationDrive FC 302Operating
Instructions provide details on installation and
operation of the frequency converter.
•The VLT
®
AutomationDrive FC 302 Programming
Guide provides greater detail on working with
parameters and many application examples.
•The VLT
®
AutomationDrive FC 302 Design Guide
provides detailed capabilities and functionality to
design motor control systems.
•Supplemental publications and manuals are
available from Danfoss.
See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/Technical
+Documentation.htm for listings.
•Optional equipment may change some of the
procedures described. Reference the instructions
supplied with those options for specific
requirements. Contact the local Danfoss supplier
or visit the Danfoss website: www.danfoss.com/
BusinessAreas/DrivesSolutions/Documentations/
Technical+Documentation.htm, for downloads or
additional information.
•The VLT
®
Active Filter AAF00x Operating
Instructions provide additional information about
the filter portion of the Low Harmonic Drive.
2.5 Product Overview
A frequency converter (also called a drive) is an electronic
motor controller that converts DC into a variable AC
waveform output. The frequency and voltage of the output
are regulated to control the motor speed or torque. The
frequency converter can vary the speed of the motor in
response to system feedback, such as with position sensors
on a conveyor belt. The frequency converter can also
regulate the motor by responding to remote commands
from external controllers.
The frequency converter
•monitors the system and motor status
•issues warnings or alarms for fault conditions
•starts and stops the motor
•optimises energy efficiency
Operation and monitoring functions are available as status
indications to an outside control system or serial communi-
cation network.
A Low Harmonic Drive (LHD) is a single unit that combines
the frequency converter with an advanced active filter
(AAF) for harmonic mitigation. The frequency converter
and filter are 2 separate pieces packaged together in an
integrated system, but each functions independently. In
this manual, there are separate specifications for the
frequency converter and the filter. Since the frequency
converter and filter are together in the same enclosure, the
unit is transported, installed, and operated as a single
entity.
Introduction Operating Instructions
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22

2.6 Internal Equipment Functions
2.6.1 Working Principle
The VLT Low Harmonic Drive is a high-power frequency converter with an integrated active filter. An active filter is a device
that actively monitors harmonic distortion levels and injects compensative harmonic current onto the line to cancel the
harmonics.
Mains
380 to
500 VAC
Optional
RFI
Optional
Fuses
Optional
Manual
Disconnect
HI Reactor
Lm
Lm
Lm
Lac
Lac
Lac
AC
Contactor
Relay 12
Control & AUX
Feedback
Relay 12
Control & AUX
Feedback
Soft-Charge
Converter
Side Filter Power Stage
AF Current
Sensors
Capacitor
Current Sensors
Frequency converter
Main’s
3
3
3
CTs
NC
Relay
Lc
Lc
Lc
Cef Cef Cef
Ref Ref Ref
Ir
Is
It
130bb406.10
Illustration 2.9 Basic Layout for the Low Harmonic Drive
Low Harmonic Drives are designed to draw an ideal sinusoidal current waveform from the supply grid with a power factor
of 1. Where traditional non-linear load draws pulse-shaped currents, the Low Harmonic Drive compensates that via the
parallel filter path, lowering the stress on the supply grid. The Low Harmonic Drive meets the highest harmonic standards
with a THiD less than 5% at full load for <3% pre-distortion on a 3% unbalanced 3-phase grid.
2.6.2 IEEE519 Compliance
The Low Harmonic Drive is designed to meet IEEE519 recommendation for Isc/Il >20 for even individual harmonic levels.
The filter has a progressive switching frequency that creates a wide frequency spread, giving lower individual harmonic
levels above the 50th.
Introduction Operating Instructions
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3 Installation
3.1 Installation Site Checklist
3.1.1 Planning the Installation Site
Select the best possible operation site by considering the
following (see details on the following pages, and in the
Design Guide):
•Ambient operating temperature
•Installation method
•Cooling
•Position of the unit
•Cable routing
•Voltage and current supply from power source
•Current rating within range
•Fuse ratings if not using built-in fuses
3.2 Equipment Pre-Installation Checklist
•Before unpacking the frequency converter,
examine the packaging for signs of damage. If
the unit is damaged, refuse delivery and
immediately contact the shipping company to
claim the damage.
•Before unpacking the frequency converter, locate
it as close as possible to the final installation site
•Compare the model number on the nameplate to
what was ordered to verify the proper equipment
•Ensure each of the following are rated for the
same voltage:
-Mains (power)
-Frequency converter
-Motor
•Ensure the output current rating is equal to or
greater than the motor full load current for peak
motor performance.
-Motor size and frequency converter
power must match for proper overload
protection.
-If frequency converter rating is less than
that of the motor, full motor output is
impossible.
3.3 Mechanical Installation
3.3.1 Cooling and Airflow
Cooling
Cooling can be obtained in different ways, by using the
cooling ducts in the bottom and the top of the unit, by
taking air in and out the back of the unit or by combining
the cooling possibilities.
Back cooling
The backchannel air can also be ventilated in and out the
back of a Rittal TS8 enclosure for frame size F18 LHD. This
offers a solution where the backchannel could take air
from outside the facility and return the heat losses outside
the facility thus reducing air-conditioning requirements.
NOTICE
A door fan(s) is required on the enclosure to remove the
heat losses not contained in the backchannel of the
drive and any additional losses generated from other
components installed inside the enclosure. The total
required air flow must be calculated so that the
appropriate fans can be selected. Some enclosure
manufacturers offer software for performing the
calculations (i.e. Rittal Therm software).
Airflow
The necessary airflow over the heat sink must be secured.
The flow rate is shown in Table 3.1.
Enclosure protection Frame size Door fan/top fan airflow
Total airflow of multiple fans
Heat sink fan
Total airflow for multiple fans
IP21/NEMA 1
IP54/NEMA 12
D13 P160–P250
(LHD120)
3 door fans, 510 m3/h (300 cfm)
(2+1, 3x170=510)
2 heat sink fans, 1530 m3/h (900
cfm)
(1+1, 2x765=1530)
E9 P315–P400
(LHD210)
4 door fans, 680 m3/h (400 cfm)
(2+2, 4x170=680)
2 heat sink fans, 2675 m3/h
(1574 cfm)
(1+1, 1230+1445=2675)
F18 P500–P710
(LHD330)
6 door fans, 3150 m3/h (1854
cfm)
(6x525=3150)
5 heat sink fans, 4485 m3/h
(2639 cfm)
2+1+2, ((2x765)+(3x985)=4485)
Table 3.1 Heat Sink Air Flow
Installation Operating Instructions
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33

NOTICE
For the drive section, the fan runs for the following
reasons:
•AMA
•DC Hold
•Pre-Mag
•DC Brake
•60% of nominal current is exceeded
•Specific heat sink temperature exceeded (power
size dependent)
•Specific power card ambient temperature
exceeded (power size dependent)
•Specific control card ambient temperature
exceeded
Once the fan is started, it runs for minimum 10 minutes.
NOTICE
For the active filter, the fan runs for the following
reasons:
•Active filter running
•Active filter not running, but mains current
exceeding limit (power size dependent)
•Specific heat sink temperature exceeded (power
size dependent)
•Specific power card ambient temperature
exceeded (power size dependent)
•Specific control card ambient temperature
exceeded
Once the fan is started, it runs for minimum 10 minutes.
External ducts
If additional duct work is added externally to the Rittal
cabinet, the pressure drop in the ducting must be
calculated. Use the charts below to derate the frequency
converter according to the pressure drop.
90
80
70
60
50
40
30
20
10
0
0 0.5 4.9 13 27.3 45.9 66 89.3 115.7 147
(%)
(Pa)
Pressure Increase
Drive Derating
130BB007.10
Illustration 3.1 D-Frame Derating vs. Pressure Change
Drive Air Flow: 450 cfm (765 m3/h)
90
80
70
60
50
40
30
20
10
0
(%)
Drive Derating
0 0 0.1 3.6 9.8 21.5 43.4 76 237.5 278.9
(Pa)
Pressure Change
130BB010.10
147.1
Illustration 3.2 E-Frame Derating vs. Pressure Change (Small
Fan), P315
Drive Air Flow: 650 cfm (1105 m3/h)
90
80
70
60
50
40
30
20
10
0
(%)
Drive Derating
0 0.2 0.6 2.2 5.8 11.4 18.1 30.8 152.8 210.8
(Pa)
Pressure Change
130BB011.10
69.5
Illustration 3.3 E-Frame Derating vs. Pressure Change (Large
Fan) P355-P450
Drive Air Flow: 850 cfm (1445 m3/h)
Installation Operating Instructions
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90
80
70
60
50
40
30
20
10
0
(%)
Drive Derating
0 25 50 75 100 125 150 175 225
130BB190.10
200
Pressure Change
Illustration 3.4 F-Frame Derating vs. Pressure Change
Drive Air Flow: 580 cfm (985 m3/h)
3.3.2 Lifting
Lift the frequency converter using the dedicated lifting
eyes. For all D-frames, use a bar to avoid bending the
lifting holes of the frequency converter.
Lifting Holes
130BC166.10
Illustration 3.5 Recommended Lifting Method, Frame Size D13
130BC170.10
Lifting Holes
Illustration 3.6 Recommended Lifting Method, Frame Size E9
WARNING
The lifting bar must be able to handle the weight of the
frequency converter. See chapter 11.2 Mechanical
Dimensions for the weight of the different frame sizes.
Maximum diameter for bar is 2.5 cm (1 inch). The angle
from the top of the frequency converter to the lifting
cable should be 60° or greater.
1
2
130BD574.10
1 Lifting holes for the filter
2 Lifting holes for the frequency converter
Illustration 3.7 Recommended Lifting Method, Frame Size F18
NOTICE
A spreader bar is also an acceptable way to lift the F-
frame.
NOTICE
The F18 pedestal is packaged separately and included in
the shipment. Mount the frequency converter on the
pedestal in its final location. The pedestal allows proper
airflow and cooling.
Installation Operating Instructions
MG37A202 Danfoss A/S © Rev. 2014-07-29 All rights reserved. 17
33

3.3.3 Terminal Locations for Frame Size D13
267.4
[10.5]
476.0
[18.7]
29.0
[1.1]
MAINS INPUT TERMINALS
268.1
[10.6]
88.0
[3.5] 204.0
[8.0]
259.7
[10.2]
796.3
[31.3]
83.5
[3.3]
167.0
[6.6]
.8
[.0]
120.2
[4.7]
MOTOR
OUTPUT TERMINALS
130BC603.10
Illustration 3.8 Frame Size D13 Terminal Locations
Allow for bend radius of heavy power cables.
NOTICE
All D-frames are available with standard input terminals, fuse, or disconnect switch.
Installation Operating Instructions
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