Danfoss FC 300 User manual

FC 300 Instruction Manual
Contents
!How to Read this Instruction Manual .................................... 3
"Approvals ............................................................................................. 5
"Symbols ............................................................................................... 5
"Abbreviations ........................................................................................ 6
!Safety Instructions and General Warning ........................... 7
"High voltage warning .............................................................................. 7
"Safety Instructions ................................................................................. 7
"High start torque ................................................................................... 7
"IT Mains ............................................................................................... 8
!How to Install .................................................................................. 9
"How to Get Started ................................................................................ 9
"Accessory Bag ....................................................................................... 10
"Mechanical Installation ........................................................................... 11
"Electrical Installation .............................................................................. 12
"Connection to Mains and Grounding .......................................................... 12
"Motor Connection ................................................................................... 13
"Motor cables ......................................................................................... 14
"Fuses ................................................................................................... 15
"Access to Control Terminals ..................................................................... 17
"Electrical Installation, Control Terminals .................................................... 17
"Control Terminals ................................................................................... 18
"Electrical Installation, Control Cables ........................................................ 19
"Switches S201, S202, and S801 .............................................................. 20
"Tightening Torque .................................................................................. 21
"Final Set-Up and Test ............................................................................. 21
"Additional Connections ........................................................................... 23
"24 V Backup Option ............................................................................... 23
"Load Sharing ......................................................................................... 23
"Brake Connection Option ........................................................................ 24
"Relay connection ................................................................................... 25
"Control of Mechanical Brake .................................................................... 25
"Thermal motor protection ....................................................................... 26
!How to Program .............................................................................. 27
"The Local Control Panel .......................................................................... 27
"How to Program on the Local Control Panel ................................................ 27
"Quick Transfer of Parameter Settings ........................................................ 29
"Reset to Default Setting ......................................................................... 29
"Adjust Display Contrast .......................................................................... 30
"How to Connect a PC to the FC 300 .......................................................... 30
"The FC 300 Software Dialog .................................................................... 30
"Connection Examples ............................................................................. 31
"Start/stop ............................................................................................. 31
"Pulse start/stop ..................................................................................... 31
"Speed up/slow down .............................................................................. 31
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FC 300 Instruction Manual
"Potentiometer reference ......................................................................... 31
"Basic Parameters ................................................................................... 32
"Parameter lists ...................................................................................... 35
!General Specifications .................................................................. 49
!Troubleshooting .............................................................................. 55
"Warnings/Alarm Messages ...................................................................... 55
!Index ................................................................................................... 63
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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, entails instructions on how to
handle the FC 300 correctly.
Page divider for Safety Instructions and General Warnings.
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FC 300 Instruction Manual
How to Read this Instruction Manual
Chapter 3, How to Install , guides you through
mechanical and technical installation.
Page divider for How to Install
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.
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FC 300 Instruction Manual
How to Read this Instruction Manual
"Approvals
"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
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FC 300 Instruction Manual
How to Read this Instruction Manual
"Abbreviations
Alternating current AC
American Wire Gauge. AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit ILIM
Degrees celcius °C
Direct current DC
Electronic Thermistor Relay ETR
Adjustable Frequency Drive AFD
Gram G
Hertz Hz
Kilohertz kHz
Local Control Panel LCP
Meter m
Milliampere mA
Millisecond ms
Minute min
Motion Control Tool MCT
Nanofarad nF
Newton Meters Nm
Nominal motor current IM,N
Nominal motor frequency fM,N
Nominal motor power PM,N
Nominal motor voltage UM,N
Parameter par.
Rated Inverter Output Current IINV
Revolutions Per Minute rpm
Second S
SLC Smart Logic Control
Torque limit TLIM
Volts V
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FC 300 Instruction Manual
Safety Instructions and General Warning
"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 4 minutes
4. Remove motor plugs
"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.
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FC 300 Instruction Manual
Safety Instructions and General Warning
•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.
General warning
130BA024.10
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 back-up.
Using VLT AutomationDrive FC 300 (at and below 7.5 kW):
wait at least 4 minutes
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 0.4 in2(10 mm2) or 2 rated ground wires terminated separately.
Residual Current Device
This product can cause a D.C. current in the protective conductor. Where a residual current device
(RCD) is used for extra protection, only an RCD of Type B (time delayed) shall 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 RCD’s must always follow national and local regulations.
"IT Mains
Do not connect 400-V units with RFI-filters to electrical supplies with a voltage between
phase and ground of more than 440 V. For IT AC line and delta ground (grounded leg),
AC line voltage may exceed 440 V between phase and ground.
Par. 14-50 RFI 1 can be used to disconnect the internal RFI capacities from the intermediate circuit.
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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 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.
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
Find the following parts included in the FC
300 Accessory Bag.
1 + 2 only available in units with brake chopper.
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FC 300 Instruction Manual
How to Install
"Mechanical Installation
Mechanical dimensions
FramesizeB
0.34-3.0 HP
(0.25-2.2 kW)
(200-240 V)
0.5-5.4 HP
(0.37-4.0 kW)
(380-500 V)
FramesizeC
4.0-5.0 HP
(3.0-3.7 kW)
(200-240 V)
7.4-10 HP
(5.5-7.5 kW)
(380-500 V)
1.0-10 HP
(0.75-7.5 kW)
(550-600 V)
Height
Height of back plate A10.6 in (268
mm)
10.6 in (268
mm)
Distance between
mounting holes a10.1 in (257 mm)
10.1 in (257
mm)
Width
Width of back plate B3.54 in (90
mm)
5.12 in (130
mm)
Distance between
mounting holes b2.76 in (70 mm)
4.33 in (110
mm)
Depth
From back plate to
front C8.66 in (220 mm)
8.66 in (220
mm)
With option A/B 8.66 in (220
mm)
8.66 in (220
mm)
Without options 8.07 in (205
mm)
8.07 in (205
mm)
Screw holes
c0.315 in (8.0
mm)
0.315 in (8.0
mm)
dø 0.433 in (ø
11 mm)
ø 0.433 in (ø
11 mm)
eø 0.217 in (ø
5.5 mm)
ø 0.217 in (ø
5.5 mm)
f0.256 in (6.5
mm)
0.256 in (6.5
mm)
Max weight 10.2 lb (4.9
kg) 14.6 lb (6.6 kg)
FC 300 IP20 - see accompanying table for
mechanical dimensions.
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.
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FC 300 Instruction Manual
How to Install
For installation of IP21/TYPE 1/IP4X top and bottom - see the Option Guide enclosed with the FC 300.
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.
"Electrical Installation
"Connection to Mains 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 FC 300.
3. Connect mains wires to the mains
plug connector.
The ground connection cable cross-section
must be at least 0.015 in.2(10 mm2)or2
rated mains wires terminated separately.
How to connect to mains and grounding.
NOTE
Check that mains voltage corresponds
to the mains voltage of the FC
300 nameplate.
Do not connect 400-V units with
RFI-filters to electrical supplies with a
voltage between phase and ground of
more than 440 V. For IT AC line and delta ground
(grounded leg), AC line voltage may exceed
440 V between phase and ground.
Terminals for mains and grounding.
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FC 300 Instruction Manual
How to Install
"Motor Connection
NOTE
Motor cable must be shielded/armored. If
an non-shielded/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 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 to 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
No. 96 97 98 Motor voltage 0-100%
U V W of mains 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 an 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 high frequency impedance.
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FC 300 Instruction Manual
How to Install
"Fuses
Branch circuit protection:
In order to protect the installation against electrical and fire hazard, all branch circuits
in an installation, switch gear, machines etc., must be short circuit- and overcurrent-
protected according to the national/international regulations.
Short circuit protection:
Theadjustablefrequencydrivemustbeprotectedagainst short circuit to avoid electrical or fire
hazard. Danfoss recommends using the fuses mentioned below to protect service personnel and
other equipment in case of an internal failure in the drive. The adjustable frequency drive provides
full short circuit protection in case of a short circuit on the motor output.
Overcurrent protection:
Provide overload protection to avoid fire hazard due to overheating of the cables in the installation.
The adjustable frequency drive is equipped with an internal overcurrent protection that can be used
for upstream overload protection (UL-applications excluded). See par. 4-18. Moreover, fuses or
circuit breakers can be used to provide the overcurrent protection in the installation. Overcurrent
protection must always be carried out according to national regulations.
To comply with UL/cUL approvals, use pre-fuses according to the tables below.
200-240 V
VLT Bussmann Bussmann Bussmann SIBA Littel fuse Ferraz-
Shawmut
Ferraz-
Shawmut
Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1
K2-K75 KTN-R10 JKS-10 JJN-10 5017906-010 KLN-R10 ATM-R10 A2K-10R
1K1-2K2 KTN-R20 JKS-20 JJN-20 5017906-020 KLN-R20 ATM-R20 A2K-20R
3K0-3K7 KTN-R30 JKS-30 JJN-30 5012406-032 KLN-R30 ATM-R30 A2K-30R
380-500 V, 525-600 V
VLT BussmannBussmannBussmannSIBA Littel fuse Ferraz-
Shawmut
Ferraz-
Shawmut
Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1
K37-1K5 KTS-R10 JKS-10 JJS-10 5017906-010 KLS-R10 ATM-R10 A6K-10R
2K2-4K0 KTS-R20 JKS-20 JJS-20 5017906-020 KLS-R20 ATM-R20 A6K-20R
5K5-7K5 KTS-R30 JKS-30 JJS-30 5012406-032 KLS-R30 ATM-R30 A6K-30R
KTS fuses from Bussmann may substitute KTN for 240 V adjustable frequency drives.
FWH fuses from Bussmann may substitute FWX for 240 V adjustable frequency drives.
KLSR fuses from LITTEL FUSE may substitute KLNR fuses for 240 V adjustable frequency drives.
L50S fuses from LITTEL FUSE may substitute L50S fuses for 240 V adjustable frequency drives.
A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V adjustable frequency drives.
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FC 300 Instruction Manual
How to Install
A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V adjustable frequency drives.
Non-UL compliance
If UL/cUL is not to be complied with, we
recommend using the following fuses, which will
ensure compliance with EN50178:
In case of malfunction, not following the
recommendation may result in unnecessary
damage of the adjustable frequency drive. Fuses
must be designed for protection in a circuit
capable of supplying a maximum of 100,000
Arms (symmetrical), 500 V maximum.
VLT Max. fuse size Voltage Type
K25-K75 10A1) 200-240 V type gG
1K1-2K2 20A1) 200-240 V type gG
3K0-3K7 32A1) 200-240 V type gG
K37-1K5 10A1) 380-500V type gG
2K2-4K0 20A1) 380-500V type gG
5K5-7K5 32A1) 380-500V type gG
1) Max. fuses - see national/international
regulations for selecting an applicable fuse size.
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FC 300 Instruction Manual
How to Install
"Access to Control Terminals
All terminals to the control cables are located
underneath the terminal cover on the front of the
adjustable frequency drive. Remove the terminal
cover by means of a screwdriver (see illustration).
"Electrical Installation, Control Terminals
1. Mount terminals from the accessory bag
to the front of the FC 300.
2. Connect terminals 18, 27, and 37 to +24 V
(terminal 12/13) with the control cable.
Default settings:
18 = start
27 = coast inverse
37 = safe stop inverse
NOTE
To mount the cable to the terminal:
1. Strip isolation of 0.35 - 0.4 in. (9-10 mm)
2. Insert a screwdriver in the square hole.
3. Insert the cable in the adjacent circular hole.
4. Remove the screwdriver. The cable is now
mounted to the terminal.
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FC 300 Instruction Manual
How to Install
NOTE
To remove the cable from the terminal:
1. Insert a screwdriver in the square hole.
2. Pull out the cable.
"Control Terminals
Drawing reference numbers:
1. 10 pole plug digital I/O.
2. 3poleplugRS485Bus.
3. 6poleanalogI/O.
4. USB Connection.
Control terminals
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FC 300 Instruction Manual
How to Install
"Electrical Installation, Control Cables
Diagram showing all electrical terminals. Terminal 37 is not included in FC 301.
Very long control cables and analog signals may in rare cases, depending on installation, result
in 50/60 Hz ground loops due to noise from mains supply cables.
If this occurs, you may have to break the shield or insert a 100 nF capacitor between shield and chassis.
Common for the digital and analog inputs 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).
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FC 300 Instruction Manual
How to Install
NOTE
Control cables must be shielded/armored.
1. Use a clamp from the accessory bag
to connect the shield to the decoupling
plate for control cables.
See section entitled Grounding of shielded/armored
control cables in the VLT AutomationDrive FC 300
Design Guide for the correct termination
of control cables.
"Switches S201, S202, and S801
Switches S201 (A53) and S202 (A54) are used
to select a current (0-20 mA) or a voltage
(-10 to 10 V) configuration of the analog input
terminals 53 and 54 respectively.
Switch S801 (BUS TER.) can be used to
enable termination on the RS-485 port
(terminals 68 and 69).
See drawing Diagram showing all electrical
terminals in section Electrical Installation.
Default setting:
S201 (A53) = OFF (voltage input)
S202 (A54) = OFF (voltage input)
S801 (Bus termination) = OFF
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