Danfoss VLT AutomationDrive FC 301 User manual

MAKING MODERN LIVING POSSIBLE
Instruction Manual
VLT®AutomationDrive FC 301/302
0.25–75 kW
www.danfoss.com/drives

Contents
1 Introduction 4
1.1 Purpose of the Manual 4
1.2 Additional Resources 4
1.3 Document and Software Version 4
1.4 Product Overview 4
1.5 Approvals and Certifications 7
1.6 Disposal 7
2 Safety 8
2.1 Safety Symbols 8
2.2 Qualified Personnel 8
2.3 Safety Precautions 8
3 Mechanical Installation 10
3.1 Unpacking 10
3.1.1 Items Supplied 10
3.2 Installation Environments 10
3.3 Mounting 11
4 Electrical Installation 13
4.1 Safety Instructions 13
4.2 EMC-compliant Installation 13
4.3 Grounding 13
4.4 Wiring Schematic 14
4.5 Access 16
4.6 Motor Connection 16
4.7 AC Line Input Connection 17
4.8 Control Wiring 17
4.8.1 Control Terminal Types 18
4.8.2 Wiring to Control Terminals 19
4.8.3 Enabling Motor Operation (Terminal 27) 19
4.8.4 Voltage/Current Input Selection (Switches) 20
4.8.5 Mechanical Brake Control 20
4.8.6 RS-485 Serial Communication 21
4.9 Installation Check List 22
5 Commissioning 23
5.1 Safety Instructions 23
5.2 Applying Power 23
Contents Instruction Manual
MG33AP22 Danfoss A/S © Rev. 09/2014 All rights reserved.

5.3 Local Control Panel Operation 23
5.3.1 Local Control Panel 23
5.3.2 LCP Layout 24
5.3.3 Parameter Settings 25
5.3.4 Uploading/Downloading Data to/from the LCP 25
5.3.5 Changing Parameter Settings 25
5.3.6 Restoring Default Settings 26
5.4 Basic Programming 26
5.4.1 Commissioning with SmartStart 26
5.4.2 Commissioning via [Main Menu] 27
5.4.3 Asynchronous Motor Set-up 27
5.4.4 PM Motor Set-up 28
5.4.5 SynRM Motor Set-up with VVC+29
5.4.6 Automatic Motor Adaptation (AMA) 30
5.5 Checking Motor Rotation 31
5.6 Checking Encoder Rotation 31
5.7 Local Control Test 31
5.8 System Start-up 31
6 Application Set-up Examples 32
7 Maintenance, Diagnostics and Troubleshooting 38
7.1 Maintenance and Service 38
7.2 Status Messages 38
7.3 Warning and Alarm Types 40
7.4 List of Warnings and Alarms 41
7.5 Troubleshooting 50
8 Specifications 52
8.1 Electrical Data 52
8.1.1 Line Power Supply 200–240 V 52
8.1.2 Line Power Supply 380–500 V 55
8.1.3 Line Power Supply 525–600 V (FC 302 only) 58
8.1.4 Line Power Supply 525–690 V (FC 302 only) 61
8.2 Line Power Supply 64
8.3 Motor Output and Motor Data 64
8.4 Ambient Conditions 65
8.5 Cable Specifications 65
8.6 Control Input/Output and Control Data 66
Contents Instruction Manual
Danfoss A/S © Rev. 09/2014 All rights reserved. MG33AP22

8.7 Fuses and Circuit Breakers 69
8.8 Connection Tightening Torques 76
8.9 Power Ratings, Weight and Dimensions 77
9 Appendix 79
9.1 Symbols, Abbreviations and Conventions 79
9.2 Parameter Menu Structure 79
Index 85
Contents Instruction Manual
MG33AP22 Danfoss A/S © Rev. 09/2014 All rights reserved.

1 Introduction
1.1 Purpose of the Manual
This instruction manual provides information for safe
installation and commissioning of the adjustable frequency
drive.
This instruction manual is intended for use by qualified
personnel.
Read and follow the instruction manual to use the
adjustable frequency drive safely and professionally, and
pay particular attention to the safety instructions and
general warnings. Keep this instruction manual available
with the adjustable frequency drive at all times.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced
adjustable frequency drive functions and programming.
•The VLT
®
AutomationDrive FC 302 Programming
Guide provides greater detail on working with
parameters and many application examples.
•The VLT
®
AutomationDrive FC 302 Design Guide
provides detailed information about capabilities
and functionality to design motor control
systems.
•Instructions for operation with optional
equipment.
Supplementary publications and manuals are available
from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical+Documentation.htm
for listings.
1.3 Document and Software Version
This manual is regularly reviewed and updated. All
suggestions for improvement are welcome. Table 1.1 shows
the document version and the corresponding software
version.
Edition Remarks Software version
MG33APxx Replaces MG33AOxx 7.XX
Table 1.1 Document and Software Version
1.4 Product Overview
1.4.1 Intended Use
The adjustable frequency drive is an electronic motor
controller intended for:
•Regulation of motor speed in response to system
feedback or to remote commands from external
controllers. A power drive system consists of the
adjustable frequency drive, the motor and
equipment driven by the motor.
•System and motor status surveillance.
The adjustable frequency drive can also be used for motor
protection.
Depending on the configuration, the adjustable frequency
drive can be used in standalone applications or form part
of a larger appliance or installation.
The adjustable frequency drive is allowed for use in
residential, industrial and commercial environments in
accordance with local laws and standards.
NOTICE!
In a residential environment, this product can cause
radio interference, in which case supplementary
mitigation measures can be required.
Foreseeable misuse
Do not use the adjustable frequency drive in applications
which are non-compliant with specified operating
conditions and environments. Ensure compliance with the
conditions specified in chapter 8 Specifications.
Introduction Instruction Manual
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1

1.4.2 Exploded Views
1
2
3
4
5
6
7
8
9
10
11
12 13
16
17
18
19
14
15
FAN MOUNTING
QDF-30
DC- DC+
Removejumper to activate Safe Stop
Max.24 Volt !
12 13 18 19 27 29 32 33 20
61 68 39 42 50 53 54
06 05 04 03 02 01
130BB493.10
1 Local control panel (LCP) 11 Relay 2 (04, 05, 06)
2 Cover 12 Lifting ring
3 RS-485 serial bus connector 13 Mounting slot
4 Digital I/O and 24 V power supply 14 Grounding clamp (PE)
5 Analog I/O connector 15 Cable shield connector
6 Cable shield connector 16 Brake terminal (-81, +82)
7 USB connector 17 Load sharing terminal (DC bus) (-88, +89)
8 Serial bus terminal switch 18 Motor output terminals 96 (U), 97 (V), 98 (W)
9 Analog switches (A53), (A54) 19 Line power input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
Figure 1.1 Exploded View Enclosure Types B and C, IP55 and IP66
Introduction Instruction Manual
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1
23
4
5
6
7
8
9
10
11
12
13
14
8
15
16
17
18
130BB492.10
1 Local control panel (LCP) 10 Motor output terminals 96 (U), 97 (V), 98 (W)
2 RS-485 serial bus connector (+68, -69) 11 Relay 2 (01, 02, 03)
3 Analog I/O connector 12 Relay 1 (04, 05, 06)
4 LCP input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals
5 Analog switches (A53), (A54) 14 Line power input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable shield connector 15 USB connector
7 Decoupling plate 16 Serial bus terminal switch
8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply
9 Shielded cable grounding clamp and strain relief 18 Cover
Figure 1.2 Exploded View Enclosure Type A, IP20
Introduction Instruction Manual
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1.4.3 Block Diagram of the Adjustable
Frequency Drive
Figure 1.3 is a block diagram of the adjustable frequency
drive's internal components. See Table 1.2 for their
functions.
Figure 1.3 Adjustable Frequency Drive Block Diagram
Area Title Functions
1 Line power input
•3-phase AC line power supply
to the adjustable frequency
drive.
2 Rectifier
•The rectifier bridge converts
the AC input to DC current to
supply inverter power.
3 DC bus •Intermediate DC bus circuit
handles the DC current.
4 DC reactors
•Filter the intermediate DC
circuit voltage.
•Prove line transient
protection.
•Reduce RMS current.
•Raise the power factor
reflected back to the line.
•Reduce harmonics on the AC
input.
5 Capacitor bank
•Stores the DC power.
•Provides ride-through
protection for short power
losses.
6 Inverter
•Converts the DC into a
controlled PWM AC waveform
for a controlled variable
output to the motor.
7 Output to motor •Regulated 3-phase output
power to the motor.
Area Title Functions
8 Control circuitry
•Input power, internal
processing, output, and motor
current are monitored to
provide efficient operation
and control.
•User interface and external
commands are monitored and
performed.
•Status output and control can
be provided.
Table 1.2 Legend to Figure 1.3
1.4.4 Enclosure Types and Power Ratings
For enclosure types and power ratings of the adjustable
frequency drives, refer to chapter 8.9 Power Ratings, Weight
and Dimensions.
1.5 Approvals and Certifications
More approvals and certifications are available. Contact the
local Danfoss partner. Adjustable frequency drives of
enclosure type T7 (525–690 V) are not certified for UL.
The adjustable frequency drive complies with UL508C
thermal memory retention requirements. For more
information, refer to the section Motor Thermal Protection
in the product specific design guide.
1.6 Disposal
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Introduction Instruction Manual
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2 Safety
2.1 Safety Symbols
The following symbols are used in this document:
WARNING
Indicates a potentially hazardous situation which could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.
NOTICE!
Indicates important information, including situations that
can result in damage to equipment or property.
2.2 Qualified Personnel
Correct and reliable transport, storage, installation,
operation, and maintenance are required for the trouble-
free and safe operation of the adjustable frequency drive.
Only qualified personnel are allowed to install or operate
this equipment.
Qualified personnel are defined as trained staff, who are
authorized to install, commission, and maintain equipment,
systems, and circuits in accordance with pertinent laws and
regulations. Additionally, the qualified personnel must be
familiar with the instructions and safety measures
described in this instruction manual.
2.3 Safety Precautions
WARNING
HIGH VOLTAGE
Adjustable frequency drives contain high voltage when
connected to AC line power input, DC power supply, or
load sharing. Failure to perform installation, start-up, and
maintenance by qualified personnel can result in death
or serious injury.
•Installation, start-up, and maintenance must be
performed by qualified personnel only.
WARNING
UNINTENDED START
When the adjustable frequency drive is connected to AC
line power, DC power supply, or load sharing, the motor
may start at any time. Unintended start during
programming, service, or repair work can result in death,
serious injury, or property damage. The motor can start
via an external switch, a serial bus command, an input
reference signal from the LCP, or after a cleared fault
condition.
To prevent unintended motor start:
•Disconnect the adjustable frequency drive from
line power.
•Press [Off/Reset] on the LCP before
programming parameters.
•The adjustable frequency drive, motor, and any
driven equipment must be fully wired and
assembled when the adjustable frequency drive
is connected to AC line power, DC power
supply, or load sharing.
Safety Instruction Manual
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