Danfoss VLT AutomationDrive FC 300 User manual

Contents
How to Read these Operating Instructions
3
Approvals 6
Symbols 6
Abbreviations 6
Safety Instructions and General Warning
7
Disposal Instruction 7
Software Version 8
High Voltage Warning 8
Safety Instructions 8
Avoid Unintended Start 9
Safe Stop of FC 300 9
Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) 10
IT Mains 11
How to Install
13
How to Get Started 13
Accessory Bag 15
Mechanical Installation 16
Electrical Installation 19
Removal of Knockouts for Extra Cables 19
Connection to Mains and Earthing 20
Motor Connection 22
Fuses 25
Electrical Installation , Control Terminals 27
Connection Examples 28
Start/Stop 28
Pulse Start/Stop 28
Speed Up/Down 29
Potentiometer Reference 29
Electrical Installation , Control Cables 30
Switches S201, S202, and S801 31
Final Set-Up and Test 32
Additional Connections 34
Mechanical Brake Control 34
Motor Thermal Protection 35
How to Programme
37
The FC 300 Graphical and Numerical LCP 37
How to Programme on the Graphical LCP 37
How to Programme on the Numerical Local Control Panel 38
Quick Setup 40
Parameter Lists 44
Parameter Selection 45
General Specifications
69
MG.33.A8.02 - VLT is a registered Danfoss trademark 1

Warnings and Alarms
75
Warnings / Alarm Messages 75
Index
83
2MG.33.A8.02 - VLT is a registered Danfoss trademark

How to Read these Operating Instructions
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 im-
proper 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®Au-
tomationDrive FC 300.
The VLT®AutomationDrive FC 300 comes in two shaft performance levels . The VLT®AutomationDrive
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 series, we
refer to FC 300. Otherwise, we refer specifically to either FC 301 or FC 302.
Chapter 1, How to Read these Operating In-
structions, introduces the manual and informs
you about the approvals, symbols, and abbrevia-
tions used in this literature.
Page divider for How to Read these Operating Instruc-
tions.
Chapter 2, Safety Instructions and General
Warnings, entails instructions on how to handle
the FC 300 correctly.
Page divider for Safety Instructions and General Warn-
ings.
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Chapter 3, How to Install, guides you through
mechanical and technical installation.
Page divider for How to Install
Chapter 4, How to Programme, shows you how
to operate and programme the FC 300 via the Lo-
cal Control Panel.
Page divider for How to Programme.
Chapter 5, General Specifications, contains
technical data about FC 300.
Page divider for General Specifications.
Chapter 6, Troubleshooting, assists you in solv-
ing problems that may occur when using FC 300.
Page divider for Troubleshooting.
Available literature for FC 300
-The VLT®AutomationDrive FC 300 Operating Instructions provide the neccessary information 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 information re-
quired for controlling, monitoring and programming the drive via a Profibus fieldbus.
-The VLT®AutomationDrive FC 300 DeviceNet Operating Instructions provide the information re-
quired for controlling, monitoring and programming the drive via a DeviceNet fieldbus.
-The VLT®AutomationDrive FC 300 MCT 10 Operating Instructions provide information for instal-
lation and use of the software on a PC.
How to Read these Operating Instructions
4MG.33.A8.02 - VLT is a registered Danfoss trademark

-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.
How to Read these Operating Instructions
MG.33.A8.02 - VLT is a registered Danfoss trademark 5

Approvals
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
Abbreviations
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit ILIM
Degrees Celcius °C
Direct current DC
Drive Dependent D-TYPE
Electro Magnetic Compatibility EMC
Electronic ThermAL Relay ETR
Frequency Converter FC
Gram g
Hertz Hz
Kilohertz kHz
Local Control Panel LCP
Meter m
Milli Henry 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
How to Read these Operating Instructions
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Safety Instructions and General Warning
Disposal Instruction
Equipment containing electrical components may not be disposed of togeth-
er with domestic waste.
It must be separately collected with Electrical and Electronic waste accord-
ing to local and currently valid legislation.
Caution
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 mainte-
nance. Before doing service on the frequency converter wait at least the amount of time indicated
below:
FC 300: 0.25 – 7.5 kW 4 minutes
FC 300: 11 – 22 kW 15 minutes
FC 300: 30 - 75 kW 15 minutes
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FC 300
Operating Instructions
Software version: 4.0x
These Operating Instructions can be used for all FC 300 frequency converters with software version
4.0x.
The software version number can be seen from parameter 15-43.
High Voltage Warning
The voltage of the FC 300 is dangerous whenever the converter is connected to mains. In-
correct fitting of the motor or frequency converter may cause damage to 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 earth.
• 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 pa-
rameter 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 earth leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switch. It does not disconnect the FC 300 from mains.
General warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been disconnected
from mains.
Also make sure that other voltage inputs have been disconnected, such as load-sharing (link-
age 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.
Safety Instructions and General Warning
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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 sec-
tion must be at least 10 mm2or 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 delayed) 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.
Before Commencing Repair Work
1. Disconnect FC 300 from mains
2. Disconnect DC bus terminals 88 and 89
3. Wait for discharge of the DC-link. See period of time on the warning label.
4. Remove motor cable
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 connection 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.
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 draft CD 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 func-
tionality 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 instruc-
tions of the FC 300 Design Guide MG.33.BX.YY must be followed! The information and instructions of the
Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality!
Safety Instructions and General Warning
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Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only)
To carry out an installation of a Category 0 Stop
(EN60204) in conformance with Safety Category
3 (EN954-1), follow these instructions:
1. The bridge (jumper) between Terminal 37
and 24 V DC must be removed. Cutting or
breaking the jumper is not sufficient. Re-
move 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 interruptible by an
EN954-1 Category 3 circuit interrupt de-
vice. If the interrupt device and the fre-
quency converter are placed in the same
installation panel, you can use a regular
cable instead of a protected one.
Bridge jumper between terminal 37 and 24 VDC
Safety Instructions and General Warning
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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 of the essential aspects of an installation to achieve a Stopping Category 0 (EN 60204-1) with safety Cat-
egory 3 (EN 954-1).
IT Mains
Do not connect 400 V frequency converters with RFI-filters to mains with a voltage between
phase and earth of more than 440 V.
For IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase
and earth.
Par. 14-50 RFI 1 can on FC 302 be used to disconnect the internal RFI capacitiors from the RFI filter to
ground. If this is done it will reduce the RFI performance to A2 level.
Safety Instructions and General Warning
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12 MG.33.A8.02 - VLT is a registered Danfoss trademark

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 and Design Guide
MG33.BX.YY.
How to Get Started
FC 300 AutomationDrive is designed to achieve a
quick and EMC-correct installation by following
the steps described below.
Read the safety instructions before in-
stalling 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
Diagram showing basic installation including mains, mo-
tor, start/stop key, and potentiometer for speed adjust-
ment.
How to Install
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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)
How to Install
14 MG.33.A8.02 - VLT is a registered Danfoss trademark

Accessory Bag
Find the following parts included in the FC 300 Ac-
cessory Bag.
FC 301/FC 302
Frame sizes A1, A2 and A3
IP20/Chassis
FC 301/FC 302
Frame size A5
IP55/Type 12
FC 301/FC 302
Frame sizes B1 and B2
IP21/IP55/Type 1/Type 12
1 + 2 only available in units with brake chopper. Only one relay connector is included for FC 301 units.
For DC link connection (Load sharing) the connector 1 can be ordered separately (Code no 130B1064)
An eight pole connector included in accessory bag for FC 301 without Safe Stop.
How to Install
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Mechanical Installation
Mechanical mounting
FC 300 IP20 Frame sizes A1, A2 and A3 allow side-by-side installation . Due to cooling conditions , there
must be a minimum of 100 mm free air passage above and below the FC 300.
If the IP 21 Enclosure kit (130B1122 or 130B1123) is used there must be a clearance between the drives
of min 50 mm.
B1, B2, C1 and C2 enclosures allow side-by-side installation.
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. Re-
tighten all four screws.
Mounting frame sizes A1, A2 and A3:
How to Install
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Mounting frame sizes A5, B1, B2, C1 and C2: The back wall must always be solid for optimum
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.
See the following table for enclosure dimensions
How to Install
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Mechanical dimensions
Frame size A1 A2 A3 A5 B1 B2 C1 C2
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)
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
20 Chassis
21 Type 1
20 Chassis
21 Type 1
20 Chassis
21 Type 1
55/66 Type 12
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 A200 mm 268 mm 375 mm 268 mm 375 mm 420 mm 480 mm 650 mm 680 mm 770 mm Height with de-cou- pling plate A315.95 -373.79 -373.79 - - - - Distance between mounting holes a190 mm 257 mm 350 mm 257 mm 350 mm 402 mm 454 mm 624 mm 648 mm 739 mm Width Width of back plate B75 mm 90 mm 90 mm 130 mm 130 mm 242 mm 242 mm 242 mm 308 mm 370 mm Width of back plate with one C option B130 mm 130 mm 170 mm 170 mm 242 mm 242 mm 242 mm 308 mm 370 mm Width of back plate with two C options B150 mm 150 mm 190 mm 190 mm 242 mm 242 mm 242 mm 308 mm 370 mm Distance between mounting holes b60 mm 70 mm 70 mm 110 mm 110 mm 215 mm 210 mm 210 mm 272 mm 334 mm Depth Depth without op- tion A/B C205 mm 205 mm 205 mm 205 mm 205 mm 195 mm 260 mm 260 mm 310 mm 335 mm With option A/B C220 mm 220 mm 220 mm 220 mm 220 mm 195 mm 260 mm 260 mm 310 mm 335 mm Without option A/B D207 mm 207 mm 207 mm - - - - - With option A/B D222 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 12 mm 12 mm 12 mm 12 mm
dø8 mm ø11 mm ø11 mm ø11 mm ø11 mm ø12 mm ø19 mm ø19 mm ø19 mm ø19 mm
eø5 mm ø5.5 mm ø5.5 mm ø5.5 mm ø5.5 mm ø6.5 mm ø9 mm ø9 mm ø9.8 mm ø9.8 mm
f5 mm 9 mm 9 mm 9 mm 9 mm 9 mm 9 mm 9 mm 17.6 mm 18 mm
Max weight 2.7 kg 4.9 kg 5.3 kg 6.6 kg 7.0 kg 13.5/14.2 kg 23 kg 27 kg 43 kg 61 kg
How to Install
18 MG.33.A8.02 - VLT is a registered Danfoss trademark

Electrical Installation
NB!
Cables General
All cabling must comply with national and local regulations on cable cross-sections and am-
bient temperature. Copper (60/75°C) conductors are recommended.
Aluminium Conductors
Terminals can accept aluminium conductors but
the conductor surface has to be clean and the ox-
idation must be removed and sealed by neutal
acid free Vaseline grease before the conductor is
connected.
Furthermore the terminal screw must be retight-
ened after two days due to softness of the alumi-
nium. It is crucial to keep the connection a gas
tight joint, otherwise the aluminium surface will
oxidize again.
Tightening-up Torque
FC size 200 - 240 V 380 - 500 V 525 - 600 V Cable for: Tightening up torque
A1 0.25-1.5 kW 0.37-1.5 kW -Line, Brake resistor, load
sharing, Motor cables
0.5-0.6 Nm
A2 0.25-2.2 kW 0.37-4 kW 0.75-4 kW
A3 3-3.7 kW 5.5-7.5 kW 5.5-7.5 kW
A5 3-3.7 kW 5.5-7.5 kW 0.75-7.5 kW
B1 5.5-7.5 kW 11-15 kW -Line, Brake resistor, load
sharing, Motor cables
1.8 Nm
Relay 0.5-0.6 Nm
Earth 2-3 Nm
B2 11 kW 18.5-22 kW -Line, Brake resistor, load
sharing cables
4.5 Nm
Motor cables 4.5 Nm
Relay 0.5-0.6 Nm
Earth 2-3 Nm
C1 15-22 kW 30-45 kW -Line, Brake resistor, load
sharing cables
10 Nm
Motor cables 10 Nm
Relay 0.5-0.6 Nm
Earth 2-3 Nm
C2 30-37 kW 55-75 kW -Line, Brake resistor, load
sharing cables
14 Nm
Motor cables 10 Nm
Relay 0.5-0.6 Nm
Earth 2-3 Nm
Removal of Knockouts for Extra Cables
1. Remove cable entry from the frequency converter (Avoiding foreign parts falling into the fre-
quency converter when removing knockouts)
2. Cable entry has to 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 frequency converter.
How to Install
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Connection to Mains and Earthing
NB!
The plug connector for power is pluga-
ble on FC 302 up to 7.5 kW.
1. Fit the two screws in the de-coupling
plate, slide it into place and tighten the
screws.
2. Make sure the FC 300 is properly earthed.
Connect to earth connection (terminal
95). Use screw from the accessory bag.
3. Place plug connector 91(L1), 92(L2), 93
(L3) from the accessory bag onto the ter-
minals labelled MAINS at the bottom of FC
300.
4. Attach mains wires to the mains plug con-
nector.
5. Support the cable with the supporting en-
closed brackets.
NB!
Check that mains voltage corresponds
to the mains voltage of the FC 300
name plate.
IT Mains
Do not connect 400 V frequency con-
verters with RFI-filters to mains sup-
plies with a voltage between phase
and earth of more than 440 V.
The earth connection cable cross sec-
tion must be at least 10 mm2or 2 x
rated mains wires terminated sepa-
rately according to EN 50178.
The mains connection is fitted to the mains switch
if this is included.
How to Install
20 MG.33.A8.02 - VLT is a registered Danfoss trademark