Danfoss VLT AutomationDrive FC 300 User manual

VLT®AutomationDrive FC 300
Instruction Manual

Contents
1. How to Read this Instruction Manual
3
Approvals 4
Symbols 4
Abbreviations 5
2. Safety Instructions and General Warning 7
High Voltage 8
Avoid Unintended Start 9
Safe Stop of the FC 300 9
Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) 11
IT Line 12
3. How to Install 13
Mechanical Installation 16
Electrical Installation 21
Connection to Line Power and Grounding 22
Motor Connection 24
Fuses 27
Electrical Installation, Control Terminals 34
Connection Examples 36
Start/Stop 36
Pulse Start/Stop 36
Speed Up/Slow 37
Potentiometer Reference 37
Electrical Installation, Control Cables 38
Switches S201, S202, and S801 39
Additional Connections 43
Mechanical Brake Control 43
Motor Thermal Protection 44
4. How to Program 45
The Graphical and Numerical LCP 45
How to Program on the Graphical LCP 45
How to Program on the Numerical Local Control Panel 46
Quick Setup 48
Parameter Lists 53
VLT
®
AutomationDrive FC 300 Instruction
Manual Contents
MG.33.A9.22 - VLT is a registered Danfoss trademark 1

5. General Specifications 81
6. Troubleshooting 87
Warnings/Alarm Messages 87
Index
96
Contents
VLT
®
AutomationDrive FC 300 Instruction
Manual
2 MG.33.A9.22 - VLT is a registered Danfoss trademark

1. How to Read this Instruction Manual
1.1.1. How to Read this Instruction Manual
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 adjustable frequency
drive may cause improper operation of the adjustable frequency drive or related equipment,
shorten lifetime or cause other problems.
This Instruction Manual will help you get started and 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. The FC 302 is a high performance adjustable frequency
drive 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.
This Instruction Manual covers both the FC 301 and the FC 302. Where information covers both
series, we refer to the FC 300. Otherwise, we refer specifically to either the FC 301 or the 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.
Chapter 2, Safety Instructions and General Warnings, contains 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 Program, shows you how to operate and program the FC 300 via the Local
Control Panel.
Chapter 5, General Specifications, contains technical data about the FC 300.
Chapter 6, Troubleshooting, assists you in solving problems that may occur when using the FC
300.
VLT
®
AutomationDrive FC 300 Instruction
Manual 1. How to Read this Instruction Manual
MG.33.A9.22 - VLT is a registered Danfoss trademark 3
1

Available Literature for the FC 300
-The VLT
®
AutomationDrive FC 300 Instruction Manual provides the information needed
to get the drive up and running.
-The VLT
®
AutomationDrive FC 300 Design Guide contains all the technical information
about the drive design and applications including encoder, resolver and relay options.
-The VLT
®
AutomationDrive FC 300 Profibus Instruction Manual provides the information
required for controlling, monitoring and programming the drive via aProfibus serial com-
munication bus.
-The VLT
®
AutomationDrive FC 300 DeviceNet Instruction Manual provides the informa-
tion required for controlling, monitoring and programming the drive via a DeviceNet serial
communication bus.
-The VLT
®
AutomationDrive FC 300MCT 10Instruction Manual provides information for
installation and use of the software on a PC.
-The VLT
®
AutomationDrive FC 300 IP 21/ Type 1 Instruction provides information for
installing the IP 21/ Type 1 option.
-The VLT
®
AutomationDrive FC 300 24 V DC Backup Instructions provide 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 this Instruction Manual.
NOTE
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
1. How to Read this Instruction Manual
VLT
®
AutomationDrive FC 300 Instruction
Manual
4 MG.33.A9.22 - VLT is a registered Danfoss trademark
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෪Indicates a default setting
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
Volt V
VLT
®
AutomationDrive FC 300 Instruction
Manual 1. How to Read this Instruction Manual
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1

2. Safety Instructions and General Warning
VLT
®
AutomationDrive FC 300 Instruction
Manual
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2. Safety Instructions and General Warning
2.1.1. Disposal Instructions
Equipment containing electrical components may not be disposed of
together with domestic waste.
It must be collected separately as electrical and electronic waste in
accordance with local and currently valid legislation.
The FC 300 AutomationDrive DC link capacitors remain charged after power has
been disconnected. To avoid electrical shock, disconnect the FC 300 from the line
supply before carrying out maintenance procedures. When using a PM motor, make
sure it is disconnected. Before servicing the adjustable frequency drive, wait the
minimum amount of time indicated below:
FC 300 380-500 V 0.33-10 hp
[0.25-7.5 kW]
4 minutes
15-100 hp [11-75
kW]
15 minutes
125-300 hp
[90-200 kW]
20 minutes
350-550 hp
[250-400 kW]
40 minutes
525-690 V 50-350 hp
[37-250 kW]
20 minutes
450-750 hp
[315-560 kW]
30 minutes
FC 300
Instruction Manual
Software version: 4.5x
This Instruction Manual can be used for all FC 300 adjustable frequency drives with software
version 4.5x.
The software version number can be found in parameter 15-43.
VLT
®
AutomationDrive FC 300 Instruction
Manual 2. Safety Instructions and General Warning
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2.1.2. High Voltage
The voltage of the adjustable frequency drive is dangerous whenever the adjustable
frequency drive is connected to line power. Incorrect installation or operation of the
motor or adjustable frequency drive may cause damage to the equipment, serious
personal injury or death. The instructions in this manual must therefore be observed,
in addition to applicable local and national rules and safety regulations.
Installation at high altitudes
At altitudes higher than 6,500 ft [2 km], please contact Danfoss Drives regarding
PELV.
The voltage of the adjustable frequency drive is dangerous whenever connected to
line power. Incorrect installation of the motor, adjustable frequency drive or serial
communication bus may cause damage to the equipment, serious personal injury or
death. Consequently, the instructions in this manual, as well as national and local
rules and safety regulations, must be followed.
Safety Regulations
1. The adjustable frequency drive must be disconnected from line power if repair work is
to be carried out. Make sure that the line supply has been disconnected and that the
necessary time has passed before removing motor and line plugs.
2. The [STOP/RESET] key on the control panel of the adjustable frequency drive does not
disconnect the equipment from line power and is thus not to be used as a safety switch.
3. Correct protective grounding of the equipment must be established, the user must be
protected against supply voltage, and the motor must be protected against overload in
accordance with applicable national and local regulations.
4. The ground 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 line supply while the adjustable frequency
drive is connected to line power. Make sure that the line supply has been disconnected
and that the necessary time has passed before removing motor and line plugs.
7. Please note that the adjustable frequency drive 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. Make sure that all voltage inputs have been disconnected and that the neces-
sary time has passed before commencing repair work.
2. Safety Instructions and General Warning
VLT
®
AutomationDrive FC 300 Instruction
Manual
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2.1.3. General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been dis-
connected from line power.
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 0.016 in.
2
[10 mm
2
] or 2 times 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 meet national
and local regulations.
2.1.4. Before Commencing Repair Work
1. Disconnect the adjustable frequency drive from the line power.
2. Wait for the discharge of the DC link. See the 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 the FC 300 is connected to line power, the motor can be started/stopped using digital com-
mands, bus commands, references or via the Local Control Panel (LCP).
• Disconnect the FC 300 from line power whenever personal safety considerations make
it necessary to avoid an unintended start.
• To avoid an unintended starts, always activate the [OFF] key before changing parame-
ters.
• An electronic fault, temporary overload, a fault in the line supply, or lost motor connection
may cause a stopped motor to start. The FC 300 with Safe Stop (i.e., FC 301 in A1
enclosure and FC 302) provides protection against unintended starts if the Safe Stop
Terminal 37 is on low voltage level or disconnected.
2.1.6. Safe Stop of the 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).
VLT
®
AutomationDrive FC 300 Instruction
Manual 2. Safety Instructions and General Warning
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2

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 deemed suitable for the requirements of Safety Category 3 in EN 954-1. This
function is called safe stop. Prior to integrating and using safe stop in an installation, a thorough
risk analysis must be carried out on the installation 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 followed!
The information and instructions contained in the Instruction Manual are not sufficient for a correct
and safe use of the safe stop functionality!
2. Safety Instructions and General Warning
VLT
®
AutomationDrive FC 300 Instruction
Manual
10 MG.33.A9.22 - 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 accordance with
Safety Category 3 (EN954-1), follow
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 adjustable fre-
quency drive are placed in the same
installation panel, you can use a reg-
ular cable instead of a protected one.
3. Unless the FC302 itself has protec-
tion class IP 54 and higher, it must
be placed in an IP 54 enclosure. Con-
sequently, FC301 A1 must always be
placed in an IP 54 enclosure.
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 interruption is caused by an opening door contact. The illustration also shows
how to connect a non-safety-related hardware coast.
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).
VLT
®
AutomationDrive FC 300 Instruction
Manual 2. Safety Instructions and General Warning
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2.1.8. IT Line
Par. 14-50 RFI 1 can be used on the FC 102/202/302 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.
2. Safety Instructions and General Warning
VLT
®
AutomationDrive FC 300 Instruction
Manual
12 MG.33.A9.22 - VLT is a registered Danfoss trademark
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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 Instruction Manual and Design Guide.
3.1.2. How to Get Started
The FC 300 AutomationDrive is designed for quick installation and is EMC compliant. Just follow
the steps described below.
Read the safety instructions before installing the unit.
Mechanical Installation
• Mechanical mounting
Electrical Installation
• Connection to Line and Protecting
Ground
• Motor connection and cables
• Fuses and circuit breakers
• Control terminals - cables
Quick set-up
• Local Control Panel, LCP
• Automatic Motor Adaptation, AMA
• Programming
Frame size is dependent on enclosure type,
power range and line voltage.
3.1: Diagram showing basic installation including
line power, motor, start/stop key, and potentiom-
eter for speed adjustment.
VLT
®
AutomationDrive FC 300 Instruction
Manual 3. 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
0.34-2 hp [0.25-1.5 kW] (200-240 V) 0.5-2 hp [0.37-1.5 kW] (380-480 V)
0.34-4 hp [0.25-3 kW] (200-240 V) 0.5-5 hp [0.37-4 kW] (380-480/ 500 V) 1-5 hp [0.75-4 kW] (525-600 V)
5 hp [3.7 kW] (200-240 V) 5.5-7.5 kW (380-480/ 500 V) 7.5-10 hp [5.5-7.5 kW ] (525-600V)
0.34-5 hp [0.25-3.7 kW ] (200-240 V) 0.5-10 hp [0.37-7.5 kW] (380-480/ 500 V) 1-10 hp [0.75 -7.5 kW] (525-600 V)
7.5-10 hp [5.5-7.5 kW] (200-240 V) 15-20 hp [11-15 kW] (380-480/ 500 V)
15 hp [11 kW] (200-250 V) 25-30 hp [18.5-22 kW] (380-480/ 500 V)
20-30 hp [15-22 kW] (200-240 V) 40-60 hp [30-45 kW] (380-480/ 500 V)
40-50 hp [30-37 kW] (200-240 V) 75-100 hp [55-75 kW] (380-480/ 500 V)
3. How to Install
VLT
®
AutomationDrive FC 300 Instruction
Manual
14 MG.33.A9.22 - VLT is a registered Danfoss trademark
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3.1.3. Accessory Bag
Find the following parts included in the FC 100/300 Accessory Bag.
Frame sizes A1, A2 and A3
IP 20/Chassis
Frame size A5
IP 55/Type 12
Frame sizes B1 and B2
IP 21/IP 55/Type 1/Type 12
Frame sizes C1 and C2
IP 55/66/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), connector 1 can be ordered separately
(code no. 130B1064).
An eight-pole connector is included in the accessory bag for the FC 101/301 without Safe Stop.
VLT
®
AutomationDrive FC 300 Instruction
Manual 3. How to Install
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3.2. Mechanical Installation
3.2.1. Mechanical mounting
FC 300 IP 20 Frame sizes A1, A2 and A3, as well as IP 21/ IP 55 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 min. clearance of 2
in. [50 mm] between the drives.
For optimal cooling conditions, allow a free air passage above and below the adjustable frequency
drive. 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 use screws that are suitable for the surface on which you want to mount the
FC 300. Retighten all four screws.
3. How to Install
VLT
®
AutomationDrive FC 300 Instruction
Manual
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Mounting frame sizes A1, A2 and A3:
Mounting frame sizes A5, B1, B2, C1 and C2:
The back wall must always be solid for optimum cooling.
When 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 heatsink.
VLT
®
AutomationDrive FC 300 Instruction
Manual 3. How to Install
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See the following tables for enclosure dimensions
3. How to Install
VLT
®
AutomationDrive FC 300 Instruction
Manual
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