Danfoss VLT AutomationDrive FC 300 User manual

Contents
1. How to Read these Operating Instructions
3
Approvals 4
Symbols 4
Abbreviations 5
2. Safety Instructions and General Warning 7
Disposal Instruction 7
High Voltage 7
Avoid Unintended Start 9
Safe Stop of FC 300 9
Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) 11
IT Mains 11
3. How to Install 13
Accessory Bag 15
Mechanical Installation 16
Electrical Installation 21
Removal of Knockouts for Extra Cables 22
Connection to Mains and Earthing 22
Motor Connection 23
Fuses 26
Electrical Installation, Control Terminals 29
Connection Examples 30
Start/Stop 30
Pulse Start/Stop 30
Speed Up/Down 31
Potentiometer Reference 31
Electrical Installation, Control Cables 32
Switches S201, S202, and S801 33
Additional Connections 37
Mechanical Brake Control 37
Motor Thermal Protection 38
4. How to Programme 39
The Graphical and Numerical LCP 39
How to Programme on the Graphical LCP 39
How to Programme on the Numerical Local Control Panel 40
Quick Setup 42
Parameter Lists 46
VLT
®
AutomationDrive FC 300 Operating
Instructions Contents
MG.33.A9.02 - VLT is a registered Danfoss trademark 1

5. General Specifications 75
6. Troubleshooting 81
Warnings/Alarm Messages 81
Index
90
Contents
VLT
®
AutomationDrive FC 300 Operating
Instructions
2 MG.33.A9.02 - VLT is a registered Danfoss trademark

1. How to Read these Operating Instructions
1.1.1. How to Read these Operating Instructions
VLT
®
AutomationDrive FC 300 is designed to provide high shaft performance on electrical motors.
Please read this manual carefully for proper use. Incorrect handling of the frequency converter
may cause improper operation of the frequency converter or related equipment, shorten lifetime
or cause other troubles.
These Operating Instructions will help you get started, install, program, and troubleshoot your
VLT
®
AutomationDrive FC 300.
The VLT
®
AutomationDrive FC 300 comes in twoshaft performance levels. The VLT
®
Automa-
tionDrive FC 300 comes in two shaft performance levels. FC 301 ranges from scalar (U/f) to VVC
+ and handles asynchronous motors only. FC 302 is a high performance frequency converter for
asynchronous as well as permanent motors and handles various kinds of motor control principles
such as scalar (U/f), VVC+ and Flux vector motor control.
These Operating Instructions cover both FC 301 and FC 302. Where information covers both ser-
ies, we refer to FC 300. Otherwise, we refer specifically to either FC 301 or FC 302.
Chapter 1, How to Read these Operating Instructions, introduces the manual and informs
you about the approvals, symbols, and abbreviations used in this literature.
Chapter 2, Safety Instructions and General Warnings, entails instructions on how to handle
the FC 300 correctly.
Chapter 3, How to Install, guides you through mechanical and technical installation.
Chapter 4, How to Programme, shows you how to operate and programme the FC 300 via the
Local Control Panel.
Chapter 5, General Specifications, contains technical data about FC 300.
Chapter 6, Troubleshooting, assists you in solving problems that may occur when using FC 300.
VLT
®
AutomationDrive FC 300 Operating
Instructions 1. How to Read these Operating Instructions
MG.33.A9.02 - VLT is a registered Danfoss trademark 3
1

Available Literature for FC 300
-The VLT
®
AutomationDrive FC 300 Operating Instructions provide the neccessary infor-
mation for getting the drive up and running.
-The VLT
®
AutomationDrive FC 300 Design Guide entails all technical information about
the drive design and applications including encoder, resolver and relay options.
-The VLT
®
AutomationDrive FC 300 Profibus Operating Instructions provide the informa-
tion required for controlling, monitoring and programming the drive via aProfibus field-
bus.
-The VLT
®
AutomationDrive FC 300 DeviceNet Operating Instructions provide the infor-
mation required for controlling, monitoring and programming the drive via aDeviceNet
fieldbus.
-The VLT
®
AutomationDrive FC 300MCT 10 Operating Instructions 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.
1.1.2. Approvals
1.1.3. Symbols
Symbols used in these Operating Instructions.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
∗Indicates default setting
1. How to Read these Operating Instructions
VLT
®
AutomationDrive FC 300 Operating
Instructions
4 MG.33.A9.02 - VLT is a registered Danfoss trademark
1

1.1.4. 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 Compatibility EMC
Electronic Thermal Relay ETR
drive FC
Gram g
Hertz Hz
Kilohertz kHz
Local Control Panel LCP
Meter m
Millihenry Inductance mH
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.
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Rated Inverter Output Current IINV
Revolutions Per Minute RPM
Second s
Torque limit TLIM
Volts V
VLT
®
AutomationDrive FC 300 Operating
Instructions 1. How to Read these Operating Instructions
MG.33.A9.02 - VLT is a registered Danfoss trademark 5
1

2. Safety Instructions and General Warning
VLT
®
AutomationDrive FC 300 Operating
Instructions
6 MG.33.A9.02 - VLT is a registered Danfoss trademark
2

2. Safety Instructions and General Warning
2.1.1. Disposal Instruction
Equipment containing electrical components may not be disposed of
together with domestic waste.
It must be separately collected with Electrical and Electronic waste
according to local and currently valid legislation.
The FC 300 AutomationDrive DC link capacitors remain charged after power has
been disconnected. To avoid electrical shock hazard, disconnect the FC 300 from
the mains before carrying out maintenance. When using a PM-motor, make sure it
is disconnected. Before doing service on the frequency converter wait at least the
amount of time indicated below:
FC 300 380 - 500 V 0.25 - 7.5 kW 4 minutes
11 - 75 kW 15 minutes
90 - 200 kW 20 minutes
250 - 400 kW 40 minutes
525 - 690 V 37 - 250 kW 20 minutes
315 - 560 kW 30 minutes
FC 300
Operating Instructions
Software version: 4.5x
These Operating Instructions can be used for all FC 300 frequency converters with software
version 4.5x.
The software version number can be seen from parameter 15-43.
2.1.2. High Voltage
The voltage of the frequency converter is dangerous whenever the frequency con-
verter is connected to mains. Incorrect installation or operation of the motor or
frequency converter may cause damage to the equipment, serious personal injury
or death. The instructions in this manual must consequently be observed, as well as
applicable local and national rules and safety regulations.
VLT
®
AutomationDrive FC 300 Operating
Instructions 2. Safety Instructions and General Warning
MG.33.A9.02 - VLT is a registered Danfoss trademark 7
2

Installation in high altitudes
At altitudes above 2 km, please contact Danfoss Drives regarding PELV.
The voltage of the frequency converter is dangerous whenever connected to mains.
Incorrect installation of the motor, frequency converter or fieldbus may cause dam-
age to the equipment, serious personal injury or death. Consequently, the instruc-
tions in this manual, as well as national and local rules and safety regulations, must
be complied with.
Safety Regulations
1. The frequency converter must be disconnected from mains if repair work is to be carried
out. Check that the mains supply has been disconnected and that the necessary time has
passed before removing motor and mains plugs.
2. The [STOP/RESET] key on the control panel of the frequency converter does not dis-
connect the equipment from mains and is thus not to be used as a safety switch.
3. Correct protective earthing of the equipment must be established, the user must be pro-
tected against supply voltage, and the motor must be protected against overload in
accordance with applicable national and local regulations.
4. The earth leakage currents are higher than 3.5 mA.
5. Protection against motor overload is not included in the factory setting. If this function
is desired, set par. 1-90 to data value ETR trip or data value ETR warning.
6. Do not remove the plugs for the motor and mains supply while the frequency converter
is connected to mains. Check that the mains supply has been disconnected and that the
necessary time has passed before removing motor and mains plugs.
7. Please note that the frequency converter has more voltage inputs than L1, L2 and L3,
when load sharing (linking of DC intermediate circuit) and external 24 V DC have been
installed. Check that all voltage inputs have been disconnected and that the necessary
time has passed before commencing repair work.
2.1.3. General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been dis-
connected from mains.
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: wait at least 15 minutes.
Shorter time is allowed only if indicated on the nameplate for the specific unit.
2. Safety Instructions and General Warning
VLT
®
AutomationDrive FC 300 Operating
Instructions
8 MG.33.A9.02 - VLT is a registered Danfoss trademark
2

Leakage Current
The earth leakage current from the FC 300 exceeds 3.5 mA. To ensure that the earth
cable has a good mechanical connection to the earth connection (terminal 95), the
cable cross section must be at least 10 mm
2
or 2 times rated earth 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 de-
layed) shall be used on the supply side of this product. See also RCD Application
Note MN.90.GX.02.
Protective earthing of the FC 300 and the use of RCD's must always follow national
and local regulations.
2.1.4. Before Commencing Repair Work
1. Disconnect the frequency converter from mains
2. Wait for discharge of the DC-link. See period of time on the warning label.
3. Disconnect DC bus terminals 88 and 89
4. Remove motor cable
2.1.5. Avoid Unintended Start
While FC 300 is connected to mains, the motor can be started/stopped using digital commands,
bus commands, references or via the Local Control Panel (LCP).
• Disconnect the FC 300 from mains whenever personal safety considerations make it
necessary to avoid unintended start.
• To avoid unintended start, always activate the [OFF] key before changing parameters.
• An electronic fault, temporary overload, a fault in the mains supply, or lost motor con-
nection may cause a stopped motor to start. FC 300 with Safe Stop (i.e. FC 301 in A1
enclosure and FC 302) provides protection against unintended start, if the Safe Stop
Terminal 37 is on low voltage level or disconnected.
2.1.6. Safe Stop of FC 300
The FC 302, and also the FC301 in A1 enclosure, can perform the safety function Safe Torque
Off
(As defined by IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).
FC 301 A1 enclosure: When Safe Stop is included in the drive, position 18 of Type Code must be
either T or U. If position 18 is B or X, Safe Stop Terminal 37 is not included!
Example:
Type Code for FC 301 A1 with Safe Stop: FC-301PK75T4Z20H4TGCXXXSXXXXA0BXCXXXXD0
It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This
functionality is called Safe Stop. Prior to integration and use of Safe Stop in an installation, a
thorough risk analysis on the installation must be carried out in order to determine whether the
Safe Stop functionality and safety category are appropriate and sufficient. 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 fol-
lowed! The information and instructions of the Operating Instructions are not sufficient for a
correct and safe use of the Safe Stop functionality!
VLT
®
AutomationDrive FC 300 Operating
Instructions 2. Safety Instructions and General Warning
MG.33.A9.02 - VLT is a registered Danfoss trademark 9
2

2. Safety Instructions and General Warning
VLT
®
AutomationDrive FC 300 Operating
Instructions
10 MG.33.A9.02 - VLT is a registered Danfoss trademark
2

2.1.7. Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only)
To carry out an installation of a Catego-
ry 0 Stop (EN60204) in conformance
with Safety Category 3 (EN954-1), fol-
low these instructions:
1. The bridge (jumper) between Termi-
nal 37 and 24 V DC must be re-
moved. Cutting or breaking the
jumper is not sufficient. Remove it
entirely to avoid short-circuiting. See
jumper on illustration.
2. Connect terminal 37 to 24 V DC by a
short-circuit protected cable. The 24
V DC voltage supply must be inter-
ruptible by an EN954-1 Category 3
circuit interrupt device. If the inter-
rupt device and the frequency con-
verter are placed in the same instal-
lation panel, you can use a regular
cable instead of a protected one.
3. Unless the FC302 itself has protec-
tion class IP54 and higher, it must be
placed in an IP 54 enclosure. Conse-
quently, FC301 A1 must always be
placed in an IP 54 enclosure.
Illustration 2.1: Bridge jumper between terminal
37 and 24 VDC
The illustration below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN
954-1). The circuit interrupt is caused by an opening door contact. The illustration also shows how
to connect a non-safety related hardware coast.
Illustration 2.2: Illustration of the essential aspects of an installation to achieve a Stopping Category 0 (EN
60204-1) with safety Category 3 (EN 954-1).
2.1.8. IT Mains
Par. 14-50 RFI 1 can on FC 102/202/302 be used 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.
VLT
®
AutomationDrive FC 300 Operating
Instructions 2. Safety Instructions and General Warning
MG.33.A9.02 - VLT is a registered Danfoss trademark 11
2

3. How to Install
VLT
®
AutomationDrive FC 300 Operating
Instructions
12 MG.33.A9.02 - VLT is a registered Danfoss trademark
3

3. How to Install
3.1.1. 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 relevant Operating Instructions and Design
Guide.
3.1.2. How to Get Started
FC 300 AutomationDrive is designed to ach-
ieve a quick and EMC-correct installation by
following the steps described below.
Read the safety instructions before installing the unit.
Mechanical Installation
• Mechanical mounting
Electrical Installation
• Connection to Mains and Protecting
Earth
• Motor connection and cables
• Fuses and circuit breakers
• Control terminals - cables
Quick setup
• Local Control Panel, LCP
• Automatic Motor Adaptation, AMA
• Programming
Frame size is depending on enclosure type,
power range and mains voltage
Illustration 3.1: Diagram showing basic installa-
tion including mains, motor, start/stop key, and
potentiometer for speed adjustment.
VLT
®
AutomationDrive FC 300 Operating
Instructions 3. How to Install
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3

Enclosure type A1 A2 A3 A5 B1 B2 C1 C2 Enclosure protection
IP 20/21 20/21 20/21 55/66 21/55/66 21/55/66 21/55/66 21/55/66 NEMA Chassis/Type 1 Chassis/
Type 1
Chassis/
Type 1
Type 12/Type 4X Type 1/Type 12 Type 1/Type 12
Rated power
0.25 – 1.5 kW (200-240 V) 0.37 – 1.5 kW (380-480 V)
0.25-3 kW (200– 240 V) 0.37-4.0 kW (380-480/ 500V) 0.75-4 kW (525-600 V)
3.7 kW (200-240 V) 5.5-7.5 kW (380-480/ 500 V) 5.5-7.5 kW (525-600V )
0.25-3.7 kW (200-240 V) 0.37-7.5 kW (380-480/ 500 V) 0.75 -7.5 kW (525-600 V)
5.5-7.5 kW (200-240 V) 11-15 kW (380-480/ 500V)
11 kW (200-250 V) 18.5-22 kW (380-480/ 500V)
15-22 kW (200-240 V) 30-45kW (380-480/ 500V)
30-37 kW (200-240 V) 55-75 kW (380-480/ 500V)
3. How to Install
VLT
®
AutomationDrive FC 300 Operating
Instructions
14 MG.33.A9.02 - VLT is a registered Danfoss trademark
3

3.1.3. Accessory Bag
Find the following parts included in the FC
100/ 300 Accessory Bag.
Frame sizes A1, A2 and A3
IP20/Chassis
Frame size A5
IP55/Type 12
Frame sizes B1 and B2
IP21/IP55/Type 1/Type 12
Frame sizes C1 and C2
IP55/66/Type 1/Type 12
1 + 2 only available in units with brake chopper. Only one relay connector is included for FC
101/301 units. For DC link connection (Load sharing) the connector 1 can be ordered sepa-
rately (Code no 130B1064)
An eight pole connector is included in accessory bag for FC 101/301 without Safe Stop.
VLT
®
AutomationDrive FC 300 Operating
Instructions 3. How to Install
MG.33.A9.02 - VLT is a registered Danfoss trademark 15
3

3.2. Mechanical Installation
3.2.1. Mechanical mounting
FC 300 IP20 Frame sizes A1, A2 and A3 as well as IP21/ IP55 Frame sizes A5, B1, B2, C1 and C2
allow side-by-side installation.
If the IP 21 Enclosure kit (130B1122 or 130B1123) is used there must be a clearance between
the drives of min 50 mm.
For optimal cooling conditions allow a free air passage above and below the frequency converter.
See table below.
Air passage for different enclosures
Enclosure: A1 A2 A3 A5 B1 B2 C1 C2
a (mm): 100 100 100 100 100 100 200 225
b (mm): 100 100 100 100 100 100 200 225
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.
Mounting frame sizes A1, A2 and A3:
3. How to Install
VLT
®
AutomationDrive FC 300 Operating
Instructions
16 MG.33.A9.02 - VLT is a registered Danfoss trademark
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Mounting frame sizes A5, B1, B2, C1 and C2: The back wall must always be solid for opti-
mum cooling.
Mounting frame sizes A5, B1, B2, C1 and C2
on a non-solid back wall, the drive must be
provided with a back plate A due to insufficient
cooling air over the heat sink.
VLT
®
AutomationDrive FC 300 Operating
Instructions 3. How to Install
MG.33.A9.02 - VLT is a registered Danfoss trademark 17
3

See the following tables for enclosure dimen-
sions
3. How to Install
VLT
®
AutomationDrive FC 300 Operating
Instructions
18 MG.33.A9.02 - VLT is a registered Danfoss trademark
3

Mechanical dimensions
Frame size A1 A2 A3 A5
0.25–1.5 kW
(200-240 V)
0.37-1.5 kW
(380-480 V)
0.25-3 kW (200-240
V)
0.37-4.0 kW
(380-480/
500 V)
0.75-4 kW
(525-600 V)
3.7 kW
(200-240 V)
5.5-7.5 kW
(380-480/
500 V)
5.5-7.5 kW
(525-600 V)
0.25-3.7 kW
(200-240 V)
0.37-7.5 kW
(380-480/
500 V)
0.75-7.5 kW
(525-600 V)
IP
NEMA
20
Chassis
21
Type 1
20
Chassis
21
Type 1
20
Chassis
21
Type 1
55/66
Type 12
Height
Height of
back plate A200 mm 268 mm 375 mm 268 mm 375 mm 420 mm
Height with
de-coupling
plate
A316 mm -374 mm 374 mm - -
Distance be-
tween
mounting
holes
a190 mm 257 mm 350 mm 257 mm 350 mm 402 mm
Width
Width of
back plate B75 mm 90 mm 90 mm 130 mm 130 mm 242 mm
Width of
back plate
with one C
option
B130 mm 130 mm 170 mm 170 mm 242 mm
Width of
back plate
with two C
options
B150 mm 150 mm 190 mm 190 mm 242 mm
Distance be-
tween
mounting
holes
b60 mm 70 mm 70 mm 110 mm 110 mm 215 mm
Depth
Depth with-
out option A/
B
C205 mm 205 mm 205 mm 205 mm 205 mm 195 mm
With option
A/B C220 mm 220 mm 220 mm 220 mm 220 mm 195 mm
Without op-
tion A/B D* 207 mm 207 mm 207 mm -
With option
A/B D* 222 mm 222 mm 222 mm -
Screw
holes
c6.0 mm 8.0 mm 8.0 mm 8.0 mm 8.0 mm 8.25 mm
dø8 mm ø11 mm ø11 mm ø11 mm ø11 mm ø12 mm
eø5 mm ø5.5 mm ø5.5 mm ø5.5 mm ø5.5 mm ø6.5 mm
f5 mm 9 mm 9 mm 9 mm 9 mm 9 mm
Max weight 2.7 kg 4.9 kg 5.3 kg 6.6 kg 7.0 kg 13.5/14.2 kg
* The front of the frequency converter is slightly convex. C is the shortest distance from back to front (i.e. measured
from corner to corner) of the frequency converter. D is the longest distance from back to front (i.e. measured in the
middle) of the frequency converter.
VLT
®
AutomationDrive FC 300 Operating
Instructions 3. How to Install
MG.33.A9.02 - VLT is a registered Danfoss trademark 19
3

Mechanical dimensions
Frame size B1 B2 C1 C2
5.5-7.5 kW
(200-240 V)
11-15 kW
(380-480/500 V)
11 kW
(200-240 V)
18.5-22 kW
(380-480/
500 V)
15-22 kW
(200-240 V)
30-45 kW
(380-480/
500 V)
30-37 kW
(200-240 V)
55-75 kW
(380-480/
500 V)
IP
NEMA
21/ 55/66
Type 1/Type 12
21/55/66
Type 1/Type 12
21/55/66
Type 1/Type 12
21/55/66
Type 1/Type 12
Height
Height of back
plate A480 mm 650 mm 680 mm 770 mm
Height with de-
coupling plate A - -
Distance be-
tween mount-
ing holes
a454 mm 624 mm 648 mm 739 mm
Width
Width of back
plate B242 mm 242 mm 308 mm 370 mm
Width of back
plate with one C
option
B242 mm 242 mm 308 mm 370 mm
Width of back
plate with two C
options
B242 mm 242 mm 308 mm 370 mm
Distance be-
tween mount-
ing holes
b210 mm 210 mm 272 mm 334 mm
Depth
Depth without
option A/B C260 mm 260 mm 310 mm 335 mm
With option A/B C260 mm 260 mm 310 mm 335 mm
Without option
A/B D* - - - -
With option A/B D* - - - -
Screw holes
c12 mm 12 mm 12 mm 12 mm
dø19 mm ø19 mm ø19 mm ø19 mm
eø9 mm ø9 mm ø9.8 mm ø9.8 mm
f9 mm 9 mm 17.6 mm 18 mm
Max weight 23 kg 27 kg 43 kg 61 kg
* The front of the frequency converter is slightly convex. C is the shortest distance from back to front (i.e. measured
from corner to corner) of the frequency converter. D is the longest distance from back to front (i.e. measured in the
middle) of the frequency converter.
3. How to Install
VLT
®
AutomationDrive FC 300 Operating
Instructions
20 MG.33.A9.02 - VLT is a registered Danfoss trademark
3