Danfoss VLT AutomationDrive FC 301 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
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 10
4 Electrical Installation 12
4.1 Safety Instructions 12
4.2 EMC-compliant Installation 12
4.3 Grounding 12
4.4 Wiring Schematic 13
4.5 Access 15
4.6 Motor Connection 15
4.7 AC Mains Connection 16
4.8 Control Wiring 16
4.8.1 Control Terminal Types 16
4.8.2 Wiring to Control Terminals 18
4.8.3 Enabling Motor Operation (Terminal 27) 18
4.8.4 Voltage/Current Input Selection (Switches) 19
4.8.5 Mechanical Brake Control 19
4.8.6 RS-485 Serial Communication 20
4.9 Installation Check List 21
5 Commissioning 22
5.1 Safety Instructions 22
5.2 Applying Power 22
5.3 Local Control Panel Operation 22
Contents Operating Instructions
MG33AP02 Danfoss A/S © Rev. 07/2014 All rights reserved. 1

5.3.1 Local Control Panel 22
5.3.2 LCP Layout 23
5.3.3 Parameter Settings 24
5.3.4 Uploading/Downloading Data to/from the LCP 24
5.3.5 Changing Parameter Settings 24
5.3.6 Restoring Default Settings 24
5.4 Basic Programming 25
5.4.1 Commissioning with SmartStart 25
5.4.2 Commissioning via [Main Menu] 25
5.4.3 Asynchronous Motor Set-up 26
5.4.4 PM Motor Set-up 26
5.4.5 SynRM Motor Set-up with VVC+28
5.4.6 Automatic Motor Adaptation (AMA) 28
5.5 Checking Motor Rotation 29
5.6 Checking Encoder Rotation 29
5.7 Local-control Test 29
5.8 System Start-up 30
6 Application Set-up Examples 31
7 Maintenance, Diagnostics and Troubleshooting 37
7.1 Maintenance and Service 37
7.2 Status Messages 37
7.3 Warning and Alarm Types 39
7.4 List of Warnings and Alarms 40
7.5 Troubleshooting 47
8 Specifications 50
8.1 Electrical Data 50
8.1.1 Mains Supply 200-240 V 50
8.1.2 Mains Supply 380-500 V 52
8.1.3 Mains Supply 525-600 V (FC 302 only) 55
8.1.4 Mains Supply 525-690 V (FC 302 only) 58
8.2 Mains Supply 60
8.3 Motor Output and Motor Data 60
8.4 Ambient Conditions 61
8.5 Cable Specifications 61
8.6 Control Input/Output and Control Data 61
8.7 Fuses and Circuit Breakers 65
8.8 Connection Tightening Torques 71
8.9 Power Ratings, Weight and Dimensions 72
Contents Operating Instructions
2 Danfoss A/S © Rev. 07/2014 All rights reserved. MG33AP02

9 Appendix 73
9.1 Symbols, Abbreviations and Conventions 73
9.2 Parameter Menu Structure 73
Index 79
Contents Operating Instructions
MG33AP02 Danfoss A/S © Rev. 07/2014 All rights reserved. 3

1 Introduction
1.1 Purpose of the Manual
These operating instructions provide information for safe
installation and commissioning of the frequency converter.
The operating instructions are intended for use by
qualified personnel.
Read and follow the operating instructions to use the
frequency converter safely and professionally, and pay
particular attention to the safety instructions and general
warnings. Keep these operating instructions available with
the frequency converter at all times.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced
frequency converter 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 frequency converter 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
frequency converter, the motor and equipment
driven by the motor.
•System and motor status surveillance.
The frequency converter can also be used for motor
protection.
Depending on the configuration, the frequency converter
can be used in standalone applications or form part of a
larger appliance or installation.
The frequency converter 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 frequency converter in applications which
are non-compliant with specified operating conditions and
environments. Ensure compliance with the conditions
specified in chapter 8 Specifications.
Introduction Operating Instructions
4 Danfoss A/S © Rev. 07/2014 All rights reserved. MG33AP02
1
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 screen connector
6 Cable screen 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 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
Illustration 1.1 Exploded View Enclosure Types B and C, IP55 and IP66
Introduction Operating Instructions
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11

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 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable screen 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 Screened cable grounding clamp and strain relief 18 Cover
Illustration 1.2 Exploded View Enclosure Type A, IP20
Introduction Operating Instructions
6 Danfoss A/S © Rev. 07/2014 All rights reserved. MG33AP02
1
1

1.4.3 Block Diagram of the Frequency
Converter
Illustration 1.3 is a block diagram of the frequency
converter's internal components. See Table 1.2 for their
functions.
Illustration 1.3 Frequency Converter Block Diagram
Area Title Functions
1 Mains input
•3-phase AC mains power
supply to the frequency
converter.
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 Illustration 1.3
1.4.4 Enclosure Types and Power Ratings
For enclosure types and power ratings of the frequency
converters, 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. Frequency converters of enclosure
type T7 (525-690 V) are not certified for UL.
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the
product specific design guide.
For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation 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 Operating Instructions
MG33AP02 Danfoss A/S © Rev. 07/2014 All rights reserved. 7
11

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 frequency converter. Only
qualified personnel are allowed to install or operate this
equipment.
Qualified personnel are defined as trained staff, who are
authorised 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 these operating instructions.
2.3 Safety Precautions
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when
connected to AC mains 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 frequency converter is connected to AC mains,
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 frequency converter from the
mains.
•Press [Off/Reset] on the LCP before
programming parameters.
•The frequency converter, motor, and any driven
equipment must be fully wired and assembled
when the frequency converter is connected to
AC mains, DC power supply, or load sharing.
WARNING
DISCHARGE TIME
The frequency converter contains DC-link capacitors,
which can remain charged even when the frequency
converter is not powered. Failure to wait the specified
time after power has been removed before performing
service or repair work, could result in death or serious
injury.
1. Stop the motor.
2. Disconnect AC mains, permanent magnet type
motors, and remote DC-link power supplies,
including battery back-ups, UPS, and DC-link
connections to other frequency converters.
3. Wait for the capacitors to discharge fully, before
performing any service or repair work. The
duration of waiting time is specified in
Table 2.1.
Voltage [V] Minimum waiting time (minutes)
4 7 15
200-240 0.25-3.7 kW 5.5-37 kW
380-500 0.25-7.5 kW 11-75 kW
525-600 0.75-7.5 kW 11-75 kW
525-690 1.5-7.5 kW 11-75 kW
High voltage may be present even when the warning LED
indicator lights are off.
Table 2.1 Discharge Time
Safety Operating Instructions
8 Danfoss A/S © Rev. 07/2014 All rights reserved. MG33AP02
22

WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
frequency converter properly can result in death or
serious injury.
•Ensure the correct grounding of the equipment
by a certified electrical installer.
WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment
can result in death or serious injury.
•Ensure that only trained and qualified
personnel perform installation, start up, and
maintenance.
•Ensure that electrical work conforms to national
and local electrical codes.
•Follow the procedures in these document.
WARNING
UNINTENDED MOTOR ROTATION
WINDMILLING
Unintended rotation of permanent magnet motors can
result in serious injury or equipment damage.
•Ensure that permanent magnet motors are
blocked to prevent unintended rotation.
CAUTION
INTERNAL FAILURE HAZARD
An internal failure in the frequency converter can result
in serious injury, when the frequency converter is not
properly closed.
•Ensure that all safety covers are in place and
securely fastened before applying power.
Safety Operating Instructions
MG33AP02 Danfoss A/S © Rev. 07/2014 All rights reserved. 9
22

3 Mechanical Installation
3.1 Unpacking
3.1.1 Items Supplied
Items supplied may vary according to product configu-
ration.
•Make sure the items supplied and the
information on the nameplate correspond to the
order confirmation.
•Check the packaging and the frequency converter
visually for damage caused by inappropriate
handling during shipment. File any claim for
damage with the carrier. Retain damaged parts
for clarification.
130BD600.10
CHASSIS/ IP20 Tamb.50 C/122 F
V LT
MADE IN DENMARK
R
P/N: 131X3537 S/N: 010122G430
0.37kW/ 0.50HP
IN: 3x200-240V 50/60Hz 2.2A
OUT: 3x0-Vin 0-1000Hz 2.4A
o
CAUTION:
See manual for special condition/mains fuse
voir manual de conditions speclales/fusibles
WARNING:
Stored charge, wait 4 min.
Charge residuelle, attendez 4 min.
* 1 3 1
X
3 5 3 7 0 1 0 1 2 2 G 4 3 0 *
`
Automation Drive
www.danfoss.com
T/C: FC-302PK37T2E20H1BGXXXXSXXXXA6BKC4XXXD0
Listed 76X1 E134261 Ind. Contr. Eq.
o
`
1
2
4
5
6
78
9
10
3
1 Type code
2 Order number
3 Serial number
4 Power rating
5Input voltage, frequency and current (at low/high
voltages)
6Output voltage, frequency and current (at low/high
voltages)
7 Enclosure type and IP rating
8 Maximum ambient temperature
9 Certifications
10 Discharge time (Warning)
Illustration 3.1 Product Nameplate (Example)
NOTICE
Do not remove the nameplate from the frequency
converter (loss of warranty).
3.1.2 Storage
Ensure that the requirements for storage are fulfilled. Refer
to chapter 8.4 Ambient Conditions for further details.
3.2 Installation Environments
NOTICE
In environments with airborne liquids, particles, or
corrosive gases, ensure that the IP/type rating of the
equipment matches the installation environment. Failure
to meet requirements for ambient conditions can reduce
the lifetime of the frequency converter. Ensure that
requirements for air humidity, temperature, and altitude
are met.
Vibration and shock
The frequency converter complies with requirements for
units mounted on the walls and floors of production
premises, as well as in panels bolted to walls or floors.
For detailed ambient conditions specifications, refer to
chapter 8.4 Ambient Conditions.
3.3 Mounting
NOTICE
Improper mounting can result in overheating and
reduced performance.
Cooling
•Ensure that top and bottom clearance for air
cooling is provided. See Illustration 3.2 for
clearance requirements.
Mechanical Installation Operating Instructions
10 Danfoss A/S © Rev. 07/2014 All rights reserved. MG33AP02
33

a
a
130BD528.10
Illustration 3.2 Top and Bottom Cooling Clearance
Enclosure A1-A5 B1-B4 C1, C3 C2, C4
a [mm] 100 200 200 225
Table 3.1 Minimum Airflow Clearance Requirements
Lifting
•To determine a safe lifting method, check the
weight of the unit, see chapter 8.9 Power Ratings,
Weight and Dimensions.
•Ensure that the lifting device is suitable for the
task.
•If necessary, plan for a hoist, crane, or forklift with
the appropriate rating to move the unit.
•For lifting, use hoist rings on the unit, when
provided.
Mounting
1. Ensure that the strength of the mounting location
supports the unit weight. The frequency
converter allows side-by-side installation.
2. Locate the unit as near to the motor as possible.
Keep the motor cables as short as possible.
3. Mount the unit vertically to a solid flat surface or
to the optional back plate to provide cooling
airflow.
4. Use the slotted mounting holes on the unit for
wall mounting, when provided.
Mounting with back plate and railings
130BD504.10
Illustration 3.3 Proper Mounting with Back Plate
NOTICE
Back plate is required when mounted on railings.
C
a
b
130BA648.12
f
e
B
A
a
d
e
b
c
Illustration 3.4 Top and Bottom Mounting Holes (See
chapter 8.9 Power Ratings, Weight and Dimensions)
a
e
f
130BA715.12
Illustration 3.5 Top and Bottom Mounting Holes (B4, C3, C4)
Mechanical Installation Operating Instructions
MG33AP02 Danfoss A/S © Rev. 07/2014 All rights reserved. 11
33

4 Electrical Installation
4.1 Safety Instructions
See chapter 2 Safety for general safety instructions.
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run
together can charge equipment capacitors, even with the
equipment turned off and locked out. Failure to run
output motor cables separately or use screened cables
could result in death or serious injury.
•Run output motor cables separately, or
•Use screened cables.
CAUTION
SHOCK HAZARD
The frequency converter can cause a DC current in the
PE conductor. Failure to follow the recommendation
below means the RCD may not provide the intended
protection.
•When a residual current-operated protective
device (RCD) is used for protection against
electrical shock, only an RCD of Type B is
permitted on the supply side.
Overcurrent protection
•Additional protective equipment, such as short-
circuit protection or motor thermal protection
between frequency converter and motor, is
required for applications with multiple motors.
•Input fusing is required to provide short-circuit
and overcurrent protection. If not factory-
supplied, fuses must be provided by the installer.
See maximum fuse ratings in chapter 8.7 Fuses
and Circuit Breakers.
Wire type and ratings
•All wiring must comply with local and national
regulations regarding cross-section and ambient
temperature requirements.
•Power connection wire recommendation:
Minimum 75 °C rated copper wire.
See chapter 8.1 Electrical Data and chapter 8.5 Cable Specifi-
cations for recommended wire sizes and types.
4.2 EMC-compliant Installation
To obtain an EMC-compliant installation, follow the
instructions provided in chapter 4.3 Grounding,
chapter 4.4 Wiring Schematic, chapter 4.6 Motor Connection,
and chapter 4.8 Control Wiring.
4.3 Grounding
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
frequency converter properly could result in death or
serious injury.
•Ensure the correct grounding of the equipment
by a certified electrical installer.
For electrical safety
•Ground the frequency converter in accordance
with applicable standards and directives.
•Use a dedicated ground wire for input power,
motor power, and control wiring.
•Do not ground one frequency converter to
another in a daisy chain fashion.
•Keep the ground wire connections as short as
possible.
•Follow motor manufacturer wiring requirements.
•Minimum cable cross-section: 10 mm2(or 2 rated
ground wires terminated separately).
For EMC-compliant installation
•Establish electrical contact between the cable
screen and the frequency converter enclosure by
using metal cable glands or by using the clamps
provided on the equipment (see
chapter 4.6 Motor Connection).
•Use high-strand wire to reduce electrical
interference.
•Do not use pigtails.
NOTICE
POTENTIAL EQUALISATION
Risk of electrical interference, when the ground potential
between the frequency converter and the control system
is different. Install equalising cables between the system
components. Recommended cable cross-section: 16 mm2.
Electrical Installation Operating Instructions
12 Danfoss A/S © Rev. 07/2014 All rights reserved. MG33AP02
44

4.4 Wiring Schematic
130BD599.11
3-phase
power
input
DC bus Switch Mode
Power Supply
Motor
Analog Output
Interface
relay1
relay2
ON=Terminated
OFF=Open
Brake
resistor
91 (L1)
92 (L2)
93 (L3)
PE
88 (-)
89 (+)
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24 V OUT)
13 (+24 V OUT)
37 (D IN)
18 (D IN)
20 (COM D IN)
10 V DC
15 mA 130/200 mA
+ - + -
(U) 96
(V) 97
(W) 98
(PE) 99
(COM A OUT) 39
(A OUT) 42
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0 V
5V
S801
0/4-20 mA
RS-485
RS-485
03
+10 V DC
0/-10 V DC -
+10 V DC
+10 V DC
0/4-20 mA
0/-10 V DC-
240 V AC, 2 A
24 V DC
02
01
05
04
06
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
19 (D IN)
24 V (NPN)
0 V (PNP)
27
24 V
0 V
(D IN/OUT)
0 V (PNP)
24 V (NPN)
(D IN/OUT)
0 V
24 V
29
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
S201
ON
21
S202
ON=0/4-20 mA
OFF=0/-10 V DC -
+10 V DC
95
P 5-00
21
ON
S801
(R+) 82
(R-) 81
: Chassis
**
240 V AC, 2 A
400 V AC, 2 A
*
*
*
: Ground
: Ground 1
: Ground 2
: PE
Illustration 4.1 Basic Wiring Schematic
A=Analog, D=Digital
*Terminal 37 (optional) is used for Safe Torque Off (STO). For installation instructions, refer to the VLT
®
Safe Torque Off
Operating Instructions. Terminal 37 is not included in FC 301 (except enclosure type A1). Relay 2 and terminal 29 have no
function in FC 301.
**Do not connect cable screen.
Electrical Installation Operating Instructions
MG33AP02 Danfoss A/S © Rev. 07/2014 All rights reserved. 13
44

130BD529.11
1
2
3
4
5
6
7
8
PE
U
V
W
9
L1
L2
L3
PE
10
11
1 PLC 7 Motor, 3-phase and PE (screened)
2 Frequency converter 8 Mains, 3-phase and reinforced PE (not screened)
3 Output contactor 9 Control wiring (screened)
4 Cable clamp 10 Potential equalisation min. 16 mm2(0.025 in)
5 Cable insulation (stripped) 11 Clearance between control cable, motor cable and mains cable:
Min. 200 mm
6 Cable gland
Illustration 4.2 EMC-compliant Electrical Connection
For more information about EMC, see chapter 4.2 EMC-compliant Installation
Electrical Installation Operating Instructions
14 Danfoss A/S © Rev. 07/2014 All rights reserved. MG33AP02
44

NOTICE
EMC INTERFERENCE
Use screened cables for motor and control wiring, and
separate cables for input power, motor wiring and
control wiring. Failure to isolate power, motor and
control cables can result in unintended behaviour or
reduced performance. Minimum 200 mm (7.9 in)
clearance between power, motor and control cables is
required.
4.5 Access
•Remove cover with a screw driver (See
Illustration 4.3) or by loosening attaching screws
(See Illustration 4.4).
130BT248.10
Illustration 4.3 Access to Wiring for IP20 and IP21 Enclosures
130BT334.10
Illustration 4.4 Access to Wiring for IP55 and IP66 Enclosures
See Table 4.1 before tightening covers.
Enclosure IP55 IP66
A4/A5 2 2
B1/B2 2.2 2.2
C1/C2 2.2 2.2
No screws to tighten for A1/A2/A3/B3/B4/C3/C4.
Table 4.1 Tightening Torques for Covers [Nm]
4.6 Motor Connection
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run
together can charge equipment capacitors, even with the
equipment turned off and locked out. Failure to run
output motor cables separately or use screened cables
could result in death or serious injury.
•Run output motor cables separately, or
•Use screened cables.
•Comply with local and national electrical codes
for cable sizes. For maximum wire sizes see
chapter 8.1 Electrical Data.
•Follow motor manufacturer wiring requirements.
•Motor wiring knockouts or access panels are
provided at the base of IP21 (NEMA1/12) and
higher units.
•Do not wire a starting or pole-changing device
(e.g. Dahlander motor or slip ring induction
motor) between the frequency converter and the
motor.
Procedure
1. Strip a section of the outer cable insulation.
2. Position the stripped wire under the cable clamp
to establish mechanical fixation and electrical
contact between the cable screen and ground.
3. Connect the ground wire to the nearest
grounding terminal in accordance with the
grounding instructions provided in
chapter 4.3 Grounding, see Illustration 4.5.
4. Connect the 3-phase motor wiring to terminals
96 (U), 97 (V), and 98 (W), see Illustration 4.5.
5. Tighten the terminals in accordance with the
information provided in chapter 8.8 Connection
Tightening Torques.
Electrical Installation Operating Instructions
MG33AP02 Danfoss A/S © Rev. 07/2014 All rights reserved. 15
44

130BD531.10
U
VW
96
97
98
Illustration 4.5 Motor Connection
Illustration 4.6 represents mains input, motor and
grounding for basic frequency converters. Actual configu-
rations vary with unit types and optional equipment.
95
130BB920.10
+DC
BR- B
MAINS
L1 L2 L3
91 92 93
RELAY 1 RELAY 2
99
- LC -
U V W
MOTOR
99
Illustration 4.6 Example of Motor, Mains and Ground Wiring
4.7 AC Mains Connection
•Size the wiring based upon the input current of
the frequency converter. For maximum wire sizes,
see chapter 8.1 Electrical Data.
•Comply with local and national electrical codes
for cable sizes.
Procedure
1. Connect the 3-phase AC input power wiring to
terminals L1, L2, and L3 (see Illustration 4.6).
2. Depending on the configuration of the
equipment, connect the input power to the
mains input terminals or the input disconnect.
3. Ground the cable in accordance with the
grounding instructions provided in
chapter 4.3 Grounding.
4. When supplied from an isolated mains source (IT
mains or floating delta) or TT/TN-S mains with a
grounded leg (grounded delta), ensure that
14-50 RFI Filter is set to [0] Off to avoid damage to
the intermediate circuit and to reduce ground
capacity currents in accordance with IEC 61800-3.
4.8 Control Wiring
•Isolate the control wiring from the high power
components in the frequency converter.
•When the frequency converter is connected to a
thermistor, ensure that the thermistor control
wiring is screened and reinforced/double
insulated. A 24 V DC supply voltage is
recommended.
4.8.1 Control Terminal Types
Illustration 4.7 and Illustration 4.8 show the removable
frequency converter connectors. Terminal functions and
default settings are summarised in Table 4.2 and Table 4.3.
2
3
4
1
130BB921.11
Illustration 4.7 Control Terminal Locations
Electrical Installation Operating Instructions
16 Danfoss A/S © Rev. 07/2014 All rights reserved. MG33AP02
44

12 13 18 19 27 29 32 33 20 37
39 42 50 53 54 55
61 68 69
130BB931.10
1
2 3
Illustration 4.8 Terminal Numbers
•Connector 1 provides 4 programmable digital
inputs terminals, 2 additional digital terminals
programmable as either input or output, a 24 V
DC terminal supply voltage, and a common for
optional customer supplied 24 V DC voltage. FC
302 and FC 301 (optional in A1 enclosure) also
provide a digital input for STO function.
•Connector 2 terminals (+)68 and (-)69 for RS-485
serial communication connection
•Connector 3 provides 2 analog inputs, 1 analog
output, 10 V DC supply voltage, and commons
for the inputs and output
•Connector 4 is a USB port available for use with
the MCT 10 Set-up Software
Terminal description
Terminal Parameter
Default
setting Description
Digital inputs/outputs
12, 13 - +24 V DC 24 V DC supply
voltage for digital
inputs and external
transducers. Maximum
output current 200
mA (130 mA for FC
301) for all 24 V loads.
18 5-10 [8] Start
Digital inputs.
19 5-11 [10] Reversing
32 5-14 [0] No
operation
33 5-15 [0] No
operation
27 5-12 [2] Coast
inverse
For digital input or
output. Default setting
is input.
29 5-13 [14] JOG
20 - Common for digital
inputs and 0 V
potential for 24 V
supply.
37 - STO Safe input.
Analog inputs/outputs
39 - Common for analog
output
42 6-50 [0] No
operation
Programmable analog
output. 0-20 mA or
4-20 mA at a
maximum of 500 Ω
50 - +10 V DC 10 V DC analog
supply voltage for
potentiometer or
thermistor. 15 mA
maximum
53 6-1* Reference Analog input. For
voltage or current.
Switches A53 and A54
select mA or V.
54 6-2* Feedback
55 - Common for analog
input
Table 4.2 Terminal Description Digital Inputs/Outputs,
Analog Inputs/Outputs
Electrical Installation Operating Instructions
MG33AP02 Danfoss A/S © Rev. 07/2014 All rights reserved. 17
44

Terminal description
Terminal Parameter
Default
setting Description
Serial communication
61 - Integrated RC-filter for
cable screen. ONLY for
connecting the screen
in the event of EMC
problems.
68 (+) 8-3* RS-485 interface. A
control card switch is
provided for
termination resistance.
69 (-) 8-3*
Relays
01, 02, 03 5-40 [0]
[0] No
operation
Form C relay output.
For AC or DC voltage
and resistive or
inductive loads.
04, 05, 06 5-40 [1] [0] No
operation
Table 4.3 Terminal Description Serial Communication
Additional terminal:
•2 form C relay outputs. The location of the
outputs depends on the frequency converter
configuration.
•Terminals located on built-in optional equipment.
See the manual provided with the equipment
option.
4.8.2 Wiring to Control Terminals
Control terminal connectors can be unplugged from the
frequency converter for ease of installation, as shown in
Illustration 4.7.
NOTICE
Keep control wires as short as possible and separate
from high power cables to minimise interference.
1. Open the contact by inserting a small screwdriver
into the slot above the contact and push the
screwdriver slightly upwards.
130BD546.10
2
1
10 mm
29
27 32
19
18
13
12 33
Illustration 4.9 Connecting Control Wires
2. Insert the bared control wire into the contact.
3. Remove the screwdriver to fasten the control wire
into the contact.
4. Ensure that the contact is firmly established and
not loose. Loose control wiring can be the source
of equipment faults or less than optimal
operation.
See chapter 8.5 Cable Specifications for control terminal
wiring sizes and chapter 6 Application Set-up Examples for
typical control wiring connections.
4.8.3 Enabling Motor Operation (Terminal
27)
A jumper wire may be required between terminal 12 (or
13) and terminal 27 for the frequency converter to operate
when using factory default programming values.
•Digital input terminal 27 is designed to receive 24
V DC external interlock command.
•When no interlock device is used, wire a jumper
between control terminal 12 (recommended) or
13 to terminal 27. This provides an internal 24 V
signal on terminal 27.
•When the status line at the bottom of the LCP
reads AUTO REMOTE COAST, this indicates that the
unit is ready to operate but is missing an input
signal on terminal 27.
•When factory installed optional equipment is
wired to terminal 27, do not remove that wiring.
NOTICE
The frequency converter cannot operate without a signal
on terminal 27, unless terminal 27 is re-programmed.
Electrical Installation Operating Instructions
18 Danfoss A/S © Rev. 07/2014 All rights reserved. MG33AP02
44