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
2 Danfoss A/S © Rev. 2014-07-29 All rights reserved. MG37A202

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
MG37A202 Danfoss A/S © Rev. 2014-07-29 All rights reserved. 5
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
MG37A202 Danfoss A/S © Rev. 2014-07-29 All rights reserved. 7
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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