Danfoss VLT AutomationDrive FC 302 User manual

MAKING MODERN LIVING POSSIBLE
Instruction Manual
VLT®AutomationDrive FC 302 Low Harmonic Drive
132–630 kW
www.danfoss.com/drives

Contents
1 Safety 5
1.1 Safety 5
2 Introduction 6
2.1 Exploded View Drawings 6
2.2 Purpose of the Manual 14
2.3 Approvals 14
2.4 Additional Resources 14
2.5 Product Overview 14
2.6 Internal Equipment Functions 15
2.6.1 Working Principle 15
2.6.2 IEEE519 Compliance 15
3 Installation 16
3.1 Installation Site Checklist 16
3.1.1 Planning the Installation Site 16
3.2 Equipment Pre-Installation Checklist 16
3.3 Mechanical Installation 16
3.3.1 Cooling and Airflow 16
3.3.2 Lifting 18
3.3.3 Terminal Locations - Frame Size D13 20
3.3.4 Terminal Locations - Frame Size E9 21
3.3.5 Terminal Locations - Frame Size F18 22
3.3.6 Torque 25
3.4 Electrical Installation 25
3.4.1 Power Connections 25
3.4.2 Grounding 26
3.4.3 Extra Protection (RCD) 26
3.4.4 RFI Switch 27
3.4.5 Shielded Cables 27
3.4.6 Motor Cable 27
3.4.7 Brake Cable 28
3.4.8 Brake Resistor Temperature Switch 28
3.4.9 AC line input connections 28
3.4.10 External Fan Supply 28
3.4.11 Power and Control Wiring for Non-shielded Cables 29
3.4.12 Line Power Disconnects 30
3.4.13 F-Frame Circuit Breakers 30
Contents Instruction Manual
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved.

3.4.14 F-Frame Line Power Contactors 30
3.4.15 Motor Insulation 30
3.4.16 Motor Bearing Currents 31
3.4.17 Control Cable Routing 31
3.4.18 Access to Control Terminals 32
3.4.19 Electrical Installation, Control Terminals 33
3.4.20 Electrical Installation, Control Cables 34
3.4.21 Safe Torque Off (STO) 35
3.4.22 Switches S201, S202, and S801 36
3.4.23 Serial Communication 36
3.5 Final Set-up and Test 36
3.6 Additional Connections 38
3.6.1 Mechanical Brake Control 38
3.6.2 Parallel Connection of Motors 38
3.6.3 Motor Thermal Protection 39
4 Start-up and Functional Testing 40
4.1 Pre-start 40
4.2 Applying Power to the Equipment 41
4.3 Basic Operational Programming 41
4.4 Local Control Test 42
4.5 System Start-up 43
5 User Interface 44
5.1 How to Operate 44
5.1.1 Modes of Operation 44
5.1.2 How to Operate the Graphical LCP (GLCP) 44
5.1.3 Changing Data 48
5.1.4 Changing a Text Value 48
5.1.5 Changing a Group of Numeric Data Values 48
5.1.6 Changing Data Values, Step-by-Step 49
5.1.7 Readout and Programming of Indexed Parameters 49
5.1.8 Quick Transfer of Parameter Settings when Using GLCP 49
5.1.9 Initialization to Default Settings 49
5.1.10 RS-485 Bus Connection 50
5.1.11 How to Connect a PC to the Adjustable Frequency Drive 50
5.1.12 PC Software Tools 51
6 Programming 52
Contents Instruction Manual
Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222

6.1 How to Program the Adjustable Frequency Drive 52
6.1.1 Quick Set-up Parameters 52
6.1.2 Basic Set-up Parameters 55
6.2 How to Program the Active Filter 77
6.2.1 Using the Low Harmonic Drive in NPN Mode 77
6.3 Parameter Lists - Adjustable Frequency Drive 78
6.3.1 Parameter Selection 78
6.4 Parameter Lists - Active Filter 110
7 Application Examples 119
7.1 Introduction 119
7.2 Application Examples 119
7.3 Connection Examples for Control of Motor with External Signal Provider 124
7.3.1 Start/Stop 124
7.3.2 Pulse Start/Stop 124
7.3.3 Speed Up/Down 125
7.3.4 Potentiometer Reference 125
8 Status Messages 126
8.1 Status Display 126
8.2 Status Message Definitions 126
9 Warnings and Alarms 129
9.1 System Monitoring 129
9.2 Warning and Alarm Types 129
9.2.1 Warnings 129
9.2.2 Alarm Trip 129
9.2.3 Alarm Trip Lock 129
9.3 Warning and Alarm Displays 129
9.4 Warnings and Alarm Definitions - Adjustable Frequency Drive 130
9.5 Warning and Alarm Definitions - Filter (Left LCP) 139
10 Basic Start-up Troubleshooting 146
11 Specifications 149
11.1 Power-Dependent Specifications 149
11.1.1 Line Power Supply 3x380–480 V AC 149
11.1.2 Derating for Temperature 152
11.2 Mechanical Dimensions 153
11.3 General Technical Data - Adjustable Frequency Drive 156
Contents Instruction Manual
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved.

11.4 General Technical Data - Filter 160
11.4.1 Power Rating 161
11.4.2 Derating for Altitude 164
11.5 Fuses 164
11.5.1 Non- UL compliance 164
11.5.2 Fuse Tables 165
11.5.3 Supplementary Fuses - High Power 166
11.6 General Torque Tightening Values 167
Index 168
Contents Instruction Manual
Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222

1 Safety
1.1 Safety
WARNING
HIGH VOLTAGE
Adjustable frequency drives contain high voltage when
connected to AC line input power. Qualified personnel
only should perform installation, start-up, and
maintenance. Failure to have qualified personnel
perform installation, start-up, and maintenance could
result in death or serious injury.
WARNING
UNINTENDED START
When the adjustable frequency drive is connected to AC
line power, the motor may start at any time. The
adjustable frequency drive, motor, and any driven
equipment must be in operational readiness. Failure to
be in operational readiness when the adjustable
frequency drive is connected to AC line power could
result in death, serious injury, equipment, or property
damage.
WARNING
DISCHARGE TIME
Adjustable frequency drives contain DC link capacitors
that can remain charged even when the adjustable
frequency drive is not powered. To avoid electrical
hazards, disconnect AC line power, any permanent
magnet type motors, and any remote DC link power
supplies, including battery backups, UPS and DC link
connections to other adjustable frequency drives. Wait
for the capacitors to fully discharge before performing
any service or repair work. The wait time required is
listed in the Discharge Time table. Failure to wait the
specified time after power has been removed before
doing service or repair could result in death or serious
injury.
Voltage
[V]
Power range
(hp [kW])
Minimum waiting time
(min)
380–500 175–350 [132–250 kW]* 20
425–850 [315–630 kW] 40
Table 1.1 Discharge Times
*Power ranges are for normal overload operation.
Table 1.2 Approvals
Safety Instruction Manual
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 5
11

2 Introduction
2.1 Exploded View Drawings
130BX167.10
1
19 13
12
25
5
4
22
21
20
18
17
3
16
15
14
11
24
2
10
9
8
7
6
23
1 Control card 14 SCR/diode module
2 Control input terminals 15 IGBT output bus bar
3 Local control panel (LCP) 16 Output motor terminals
4 Control card C option 17 Current sensor
5 Mounting bracket 18 Fan assembly
6 Power card mounting plate 19 Fan transformer
7 Power card 20 AC input terminals
8 Capacitor bank assembly 21 AC input bus bar
9 Soft-charge fuses 22 Input terminal mounting plate assembly
10 Soft-charge card 23 Fan fuse
11 DC inductor 24 Capacitor bank cover plate
12 Soft charge module 25 IGBT gate drive card
13 IGBT module
Figure 2.1 Frame Size D13 Drive Enclosure
Introduction Instruction Manual
6 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
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130BD571.11
1
67
89
11
13
15
16
20
21
22
2
3
4
5
10
12
14
18
19
17
1 Local control panel (LCP) 13 Electrical fuses
2 Active filter card (AFC) 14 Line power disconnect
3 Metal oxide varistor (MOV) 15 Line Power Terminals
4 Soft-charge resistors 16 Heatsink fan
5 AC capacitors discharge board 17 DC capacitor bank
6 Line power contactor 18 Current transformer
7 LC inductor 19 RFI differential mode filter
8 AC capacitors 20 RFI common mode filter
9 Line power bus bars to drive input 21 HI inductor
10 IGBT fuses 22 Power card
11 RFI
Figure 2.2 Frame Size D13 Filter Enclosure
Introduction Instruction Manual
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 7
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1
3
2
7
5
4
10
9
8
25
24
6
130BX168.10
20
19 18
17
16
15
14
13
12
11
23
22
21
1 Control card 14 SCR and diode
2 Control input terminals 15 Fan inductor (not on all units)
3 Local control panel (LCP) 16 Soft-charge resistor assembly
4 Control card C option 17 IGBT output bus bar
5 Mounting bracket 18 Fan assembly
6 Power card mounting plate 19 Output motor terminals
7 Power card 20 Current sensor
8 IGBT gate drive card 21 Main AC power input terminals
9 Upper capacitor bank assembly 22 Input terminal mounting plate
10 Soft-charge fuses 23 AC input bus bar
11 DC inductor 24 Soft-charge card
12 Fan transformer 25 Lower capacitor bank assembly
13 IGBT module
Figure 2.3 Frame Size E9 Drive Enclosure
Introduction Instruction Manual
8 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
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