Danfoss FC 300 User manual

FC 300 Instruction Manual
Contents
!How to Read this Instruction Manual .................................... 3
"Approvals ............................................................................................. 4
"Symbols ............................................................................................... 5
"Abbreviations ........................................................................................ 5
!Safety Instructions and General Warning ........................... 7
"Disposal Instructions .............................................................................. 7
"Software Version ................................................................................... 7
"High voltage warning .............................................................................. 8
"Safety Instructions ................................................................................. 8
"High start torque ................................................................................... 8
"Safe Stop of FC 302 ............................................................................... 9
"IT Line ................................................................................................. 9
!How to Install .................................................................................. 11
"How to Get Started ................................................................................ 11
"Accessory Bag ≤10 HP [7.5 kW] ............................................................. 12
"Mechanical Installation ........................................................................... 14
"Electrical Installation .............................................................................. 15
"Removal of Knockouts for Extra Cables ..................................................... 15
"Connection to Line Supply and Grounding ................................................. 15
"Motor Connection ................................................................................... 18
"Motor cables ......................................................................................... 20
"Fuses ................................................................................................... 21
"Access to Control Terminals ..................................................................... 23
"Electrical Installation, Control Terminals .................................................... 23
"Basic Wiring Example ............................................................................. 24
"Connection Examples ............................................................................. 25
"Start/Stop ............................................................................................ 25
"Pulse start/stop ..................................................................................... 25
"Speed up/slow down .............................................................................. 26
"Potentiometer Reference ......................................................................... 26
"Electrical Installation, Control Cables ........................................................ 27
"Switches S201, S202, and S801 .............................................................. 28
"Tightening Torque .................................................................................. 28
"Final Set-Up and Test ............................................................................. 29
"Additional Connections ........................................................................... 31
"Control of Mechanical Brake .................................................................... 31
"Motor Thermal Protection ........................................................................ 31
!How to Program .............................................................................. 33
"Quick Setup .......................................................................................... 34
"Parameter lists ...................................................................................... 37
"Parameter Selection ............................................................................... 38
!General Specifications .................................................................. 53
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FC 300 Instruction Manual
!Warnings and Alarms ................................................................... 59
"Warnings/Alarm Messages ...................................................................... 59
!Index ................................................................................................... 67
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FC 300 Instruction Manual
How to Read this Instruction Manual
"How to Read this Instruction Manual
This Instruction Manual will help you get started, install, program, and troubleshoot
your VLT®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.
ThisInstructionManualcoversbothFC301andFC302. Whereinformationcoversbothseries,we
refer to FC 300. Otherwise, we refer specifically to either FC 301 or FC 302.
Chapter 1, How to Read this Instruction
Manual, introduces the manual and informs you
about the approvals, symbols, and abbreviations
used in this literature.
Page divider for How to Read this Instruction Manual.
Chapter 2, Safety Instructions and General
Warnings,entail
s instructions on how to
handle the FC 300 correctly.
Page divider for Safety Instructions and General Warnings.
Chapter 3, How to Install , guides you through
mechanical and technical installation.
Page divider for How to Install
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FC 300 Instruction Manual
How to Read this Instruction Manual
Chapter 4, How to Program,showsyou
how to operate and program the FC 300 via
the Local Control Panel.
Page divider for How to Program.
Chapter 5, General Specifications, entails
technical data about FC 300.
Page divider for General Specifications.
Chapter 6, Troubleshooting, assists you in solving
problems that may occur when using FC 300.
Page divider for Troubleshooting.
Available literature for FC 300
-The VLT®AutomationDrive FC 300 Instruction Manual provides the necessary infor-
mation 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 (Instruction Manual) provide the
information required for controlling, monitoring, and programming the drive via a Profibus fieldbus.
-The VLT®AutomationDrive FC 300 DeviceNet Operating Instructions (Instruction Manual) provide the
information required for controlling, monitoring, and programming the drive via a DeviceNet fieldbus.
-The VLT®AutomationDrive FC 300 MCT 10 Operating Instructions (Instruction Manual) provide
information for installation and use of the software on a PC.
-The VLT®AutomationDrive FC 300 IP21 / TYPE 1 Instruction provides information
for installing the IP21 / TYPE 1 option.
-The VLT®AutomationDrive FC 300 24 V DC Backup Instruction provides information
for installing the 24 V DC Backup option.
Danfoss Drives technical literature is also available online at www.danfoss.com/drives.
"Approvals
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FC 300 Instruction Manual
How to Read this Instruction Manual
"Symbols
Symbols used in these Operating Instructions.
NOTE
Indicates something to be noted
by the reader
Indicates a general warning.
Indicates a high voltage warning
Indicates default setting
"Abbreviations
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit ILIM
Degrees Celsius °C
Direct current DC
Drive Dependent D-TYPE
Electro Magnetic Compellability EMC
Electronic Thermal Relay ETR
Adjustable Frequency Drive AFD
Gram g
Hertz Hz
Kilohertz kHz
Local Control Panel LCP
Meter m
Milli Henry Inductance mH
Milliampere mA
Millisecond, Second ms, s
Minute min
Motion Control Tool MCT
Motor Type Dependent M-TYPE
Nanofarad nF
Newton meter Nm
Nominal motor current IM,N
Nominal motor frequency fM,N
Nominal motor power PM,N
Nominal motor voltage UM,N
Parameter par.
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Rated Inverter Output Current IINV
Revolutions per minute RPM
Second s
Torq u e l i m i t TLIM
Volt V
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FC 300 Instruction Manual
How to Read this Instruction Manual
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FC 300 Instruction Manual
Safety Instructions and General Warning
Equipment containing electrical components may notbedisposed
together with domestic waste.
It must be collected separately as electrical and electronic waste
according to local and currently valid legislation.
Caution
The FC 300 AutomationDrive DC link capacitors remain charged after power has been
disconnected. To avoid an electrical shock hazard, disconnect the FC 300 from the power
supply before carrying outmaintenance. Waitatleastaslongasfollowsbeforeservicingthe
adjustable frequency drive:
FC 300: 0.34 – 10 HP
[0.25–7.5
kW]
4minutes
FC 300: 14.75 – 29.5
HP [11 – 22
kW]
15 minutes
BeawarethattheremaybehighvoltageontheDClinkevenwhentheLEDsareturnedoff.
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FC 300 Instruction Manual
Safety Instructions and General Warning
FC 300
Instruction Manual
Software version: 3.5x
This instruction manual can be used for all FC 300 Series adjustable frequency drives (AFD)
with software version 3.5x.
Thesoftwareversionnumbercanbeseenfromparameter15-43.
"High voltage warning
The voltage of the FC 300 is dangerous whenever the converter is connected to electrical
power. Incorrectfittingofthemotororadjustablefrequencydrivemaycausedamageto
the equipment, serious injury or death. Consequently, it is essential to comply with the
instructions in this manual as well as local and national rules and safety regulations.
"Safety Instructions
•Make sure the FC 300 is properly connected to ground.
•Do not remove mains plugs or motor plugs while the FC 300 is connected to mains.
•Protect users against supply voltage.
•Protect the motor against overloading according to national and local regulations.
•Motor overload protection is not included in the default settings. To add this function, set parameter
1-90 Motor thermal protection to value ETR trip or ETR warning. For the North American market:
ETR functions provide class 20 motor overload protection, in accordance with NEC.
•The ground 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
1. Disconnect FC 300 from AC line.
2. Disconnect DC bus terminals 88 and 89
3. Wait at least 15 minutes
4. Remove motor cable
"High start torque
While FC 300 is connected to AC line, the motor can be started/stopped using digital
commands, bus commands, references or a local stop.
•Disconnect the FC 300 from AC line whenever personal safety considerations make
it necessary to avoid unintended start.
•To avoid unintended start, always activate the [OFF] key before changing parameters.
•Unless terminal 37 is turned off, an electronic fault, temporary overload, a fault in the AC line
supply, or lost motor connection may cause a stopped motor to start.
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FC 300 Instruction Manual
Safety Instructions and General Warning
"Safe Stop of FC 302
The FC 302 can perform the Designated Safety Function Uncontrolled Stopping by removal of power. (as
defined by draft IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1). It is designed and approved
suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop.
In order to install and use the Safe Stop function in accordance with the requirements of Safety
Category 3 in EN 954-1, the related information and instructions of the FC 300 Design Guide
MG.33.BX.YY must be followed! The information and instructions of the Instruction Manual are
not sufficient for a correct and safe use of the Safe Stop functionality!
General warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been
disconnected from the power supply.
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 backup.
Using VLT AutomationDrive FC 300: wait at least 15 minutes.
A shorter time is allowed only if indicated on the nameplate for the specific unit.
Leakage Current
The ground leakage current from the FC 300 exceeds 3.5 mA. To ensure that the ground cable
has a good mechanical connection to the ground connection (terminal 95), the cable cross-section
must be at least 3.9 in2 [10 mm2] or have 2 rated ground wires terminated separately.
Residual Current Device
This product can cause DC current in the protective conductor. If a residual current device (RCD)
is used for extra protection, only an RCD of Type B (time delayed) may be used on the supply
side of this product. See also RCD Application Note MN.90.GX.02.
Protective grounding of the FC 300 and the use of RCDs must always follow national and local regulations.
IT Line
Do not connect 400 V adjustable frequency drives with RFI filters to line power supplies
with a voltage between phase and ground of more than 440 V.
For IT line and delta ground (grounded leg), line voltage may exceed
440 V between phase and ground.
Par. 14-50 RFI 1 can be used on the FC 302 to disconnect the internal RFI capacitors from the RFI
filter to ground. If this is done, it will reduce the RFI performance to A2 level.
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FC 300 Instruction Manual
Safety Instructions and General Warning
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FC 300 Instruction Manual
How to Install
"About How to Install
This chapter covers mechanical and electrical installations to and from power
terminals and control card terminals.
Electrical installation of options is described in the corresponding "Option Guide".
"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.
Diagram showing basic installation including,
electrical connection, motor, start/stop key, and
potentiometer for speed adjustment.
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FC 300 Instruction Manual
How to Install
"Accessory Bag ≤10 HP [7.5 kW]
The following parts are included in the FC
300 Accessory Bag.
1 + 2 only available in units with brake chopper.
There is only one relay connector for the FC
301. (≤10 HP [7.5 kW])
For the DC link connection (load sharing), connector 1 can
be ordered separately (order number 130B1064).
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FC 300 Instruction Manual
How to Install
Accessory Bag ≤10 HP [7.5 kW], IP 55
1 + 2 only available in units with brake chopper.
There is only one relay connector for the FC 301.
(≤10 HP [7.5 kW], IP55)
Accessory Bag 14.75-29.5 HP [11-22 kW]
There is only one relay connector for the FC 301.
(14.75-29.5 HP [11-22 kW])
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FC 300 Instruction Manual
How to Install
"Mechanical Installation
"Mechanical Mounting
1. Drill holes in accordance with the measurements given.
2. 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 4 in (100 mm) free air passage above and below the FC 300.
The back wall must always be solid.
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FC 300 Instruction Manual
How to Install
"Electrical Installation
NOTE
Cables General
Always comply with national and local regulations on cable cross-sections.
Tightening-up Torque
AFD size Cable for: Tightening-up torque
0.34-10 HP [0.25-7.5
kW]
Line, brake resistor, load sharing motor
cable
0.5-0.6 Nm
1.8 Nm
14.75-10 HP [11-15
kW]
Line, brake resistor, load sharing motor
cable
1.8 Nm
14.75-10 HP [11-15
kW]
Motor cable 1.8 Nm
Relay 0.5-0.6 Nm
Ground 2-3 Nm
"RemovalofKnockoutsforExtraCables
1. Remove the cable entry from the adjustable frequency drive (avoid foreign parts entering
the adjustable frequency drive when removing knockouts).
2. The cable entry must be supported around the knockout you intend to remove.
3. The knockout can now be removed with a strong mandrel and a hammer.
4. Remove burrs from the hole.
5. Mount cable entry on adjustable frequency drive.
"Connection to Line Supply and Grounding
NOTE
The plug connector for power can
be removed.
1. Make sure the FC 300 is properly grounded.
Connect to ground connection (terminal 95).
Use screw from the accessory bag.
2. Place plug connector 91, 92, 93 from the
accessory bag onto the terminals labeled
MAINS at the bottom of the FC 300.
3. Connect line wires to the line plug connector.
The ground connection cable cross-section
must be at least 3.9 in2[10 mm2]or
have 2 rated line supply wires terminated
separately according to EN 50178.
The line supply connection is fitted to the line
supply switch if this is included.
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FC 300 Instruction Manual
How to Install
How to connect to the line supply and grounding
(A2 and A3 enclosure).
How to connect to the line supply and ground-
ing (A5 enclosure).
Howtoconnecttothelinesupplyandgrounding
(B1 and B2 enclosure).
NOTE
Check that AC line voltage corresponds to
the line voltage of the FC 300 nameplate.
IT Line
Do not connect 400 V adjustable
frequency drives with RFI filters to line
supplies with a voltage between phase
and ground of more than 440 V.
For IT lines and delta ground (grounded leg),
line voltage may exceed 440 V between
phase and ground.
Terminals for line supply and grounding.
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FC 300 Instruction Manual
How to Install
How to connect to the line supply and grounding
with disconnector (A5 enclosure).
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FC 300 Instruction Manual
How to Install
"Motor Connection
NOTE
Motor cable must be shielded/armored. If
an unshielded/unarmored cable is used,
some EMC requirements are not complied
with. For more information, see EMC specifications
in the VLT AutomationDrive FC 300 Design Guide.
1. Fasten decoupling plate to the bottom
of the FC 300 with screws and washers
from the accessory bag.
2. Attach motor cable to terminals 96 (U),
97 (V), 98 (W).
3. Connect to ground connection (terminal
99) on decoupling plate with screws from
the accessory bag.
4. Insert plug connectors 96 (U), 97 (V), 98 (W)
and motor cable into terminals labeled MOTOR.
5. Fasten shielded cable to decoupling plate with
screws and washers from the accessory bag.
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FC 300 Instruction Manual
How to Install
Motor connection ≤10 HP [7.5 kW] IP 20 (A2
and A3 enclosures)
Motor connection ≤10 HP [7.5 kW] IP 55 / NEMA type 12
Motor connection 14.75-29.5 HP [11-22 kW] IP 21
/ NEMA type 1 (B1 and B2 enclosures)
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FC 300 Instruction Manual
How to Install
No. 96 97 98 Motor voltage 0-100%
U V W of AC line voltage.
3 wires out of motor
U1 V1 W1
W2 U2 V2 6 wires out of motor, Delta-connected
U1 V1 W1 6 wires out of motor, Star-connected
U2, V2, W2 to be interconnected separately
No. 99 Ground connection
PE
All types of three-phase asynchronous standard
motors can be connected to the FC 300. Normally,
small motors are star-connected (230/400 V,
/Y). Large motors are normally delta-connected
(400/690 V, /Y). Refer to the motor nameplate
for correct connection mode and voltage.
NOTE
In motors without phase insulation paper or other insulation reinforcement suitable for operation
with voltage supply (such as adjustable frequency drive), fit an LC filter on the output of the FC 300.
"Motor cables
See Technical data for correct sizing of motor cable cross-section and length. Always comply
with national and local regulations on cable cross-section.
•Use a shielded/armoured motor cable to comply with EMC emission specifications
unless otherwise stated for the RFI filter used.
•Keep the motor cable as short as possible to reduce the noise level and leakage currents.
•Connect the motor cable shield to the decoupling plate of the FC 300 and to the metal cabinet of the motor.
•Make the shield connections with the largest possible surface area (cable clamp). This is
done by using the supplied installation devices in the FC 300.
•Avoid mounting with twisted screen ends (pigtails), which will spoil high frequency screening effects.
•If it is necessary to split the shield to install a motor isolator or motor relay, the shield
must be continued with the lowest possible HF impedance.
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