Danfoss VLT AutomationDrive FC 302 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT® AutomationDrive FC 302
90–315 kW
www.danfoss.com/drives

Contents
1 Introduction 4
1.1 Product Overview 4
1.1.1 Interior Views 4
1.1.2 Extended Options Cabinets 5
1.2 Purpose of the Manual 5
1.3 Additional Resources 6
1.4 Product Overview 6
1.5 Internal Controller Functions 6
1.6 Frame Sizes and Power Ratings 7
2 Safety 8
2.1 Safety 8
3 Installation 9
3.1 Planning the Installation Site 9
3.2 Pre-Installation Check List 9
3.3 Mechanical Installation 9
3.3.1 Cooling 9
3.3.2 Lifting 10
3.3.3 Wall Mounting - IP21 (NEMA 1) and IP54 (NEMA 12) Units 10
3.4 Electrical Installation 11
3.4.1 General Requirements 11
3.4.2 Grounding Requirements 14
3.4.2.1 Leakage Current (>3.5 mA) 14
3.4.2.2 Grounding IP20 Enclosures 15
3.4.2.3 Grounding IP21/54 Enclosures 15
3.4.3 Motor Connection 16
3.4.3.1 Terminal Locations: D1h-D4h 17
3.4.3.2 Terminal Locations: D5h-D8h 20
3.4.4 Motor Cable 30
3.4.5 Motor Rotation Check 30
3.4.6 AC Mains Connection 30
3.5 Control Wiring Connection 30
3.5.1 Access 31
3.5.2 Using Screened Control Cables 31
3.5.3 Grounding of Screened Control Cables 31
3.5.4 Control Terminal Types 32
3.5.5 Wiring to Control Terminals 33
3.5.6 Control Terminal Functions 33
3.5.7 Safe Torque Off (STO) 34
Contents Operating Instructions
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3.6 Serial Communication 34
3.7 Optional Equipment 34
3.7.1 Load Share Terminals 34
3.7.2 Regeneration Terminals 34
3.7.3 Anti-condensation Heater 35
3.7.4 Brake Chopper 35
3.7.5 Mains Shield 35
3.7.6 Mains Disconnect 35
3.7.7 Contactor 35
3.7.8 Circuit Breaker 35
4 Start Up and Commissioning 36
4.1 Pre-start 36
4.2 Applying Power 37
4.3 Basic Operational Programming 37
4.4 Local-control Test 38
4.5 System Start Up 39
5 User Interface 40
5.1 Local Control Panel 40
5.1.1 LCP Layout 40
5.1.2 Setting LCP Display Values 41
5.1.3 Display Menu Keys 41
5.1.4 Navigation Keys 41
5.1.5 Operation Keys 42
5.2 Back Up and Copying Parameter Settings 42
5.2.1 Uploading Data to the LCP 43
5.2.2 Downloading Data from the LCP 43
5.3 Restoring Default Settings 43
5.3.1 Recommended Initialisation 43
5.3.2 Manual Initialisation 43
6 Programming 44
6.1 Introduction 44
6.2 Programming Example 44
6.3 Control Terminal Programming Examples 46
6.4 International/North American Default Parameter Settings 46
6.5 Parameter Menu Structure 47
6.6 Remote Programming with MCT 10 Set-up Software 52
7 Application Examples 53
7.1 Introduction 53
Contents Operating Instructions
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7.2 Application Examples 53
7.3 Connection Examples for Control of Motor with External Signal Provider 57
7.3.1 Start/Stop 58
7.3.2 Pulse Start/Stop 58
7.3.3 Speed Up/Down 58
7.3.4 Potentiometer Reference 59
8 Status Messages 60
8.1 Status Display 60
8.2 Status Message Definitions Table 60
9 Warnings and Alarms 63
9.1 System Monitoring 63
9.2 Warning and Alarm Types 63
9.2.1 Warnings 63
9.2.2 Alarm Trip 63
9.2.3 Alarm Trip-lock 63
9.3 Warning and Alarm Displays 63
9.4 Warning and Alarm Definitions 64
9.5 Fault Messages 66
10 Basic Troubleshooting 73
11 Specifications 76
11.1 Power-dependent Specifications 76
11.2 General Technical Data 79
11.3 Fuse Tables 83
11.3.1 Protection 83
11.3.2 Fuse Selection 83
11.3.3 Short Circuit Current Rating (SCCR) 84
11.3.4 Connection Tightening Torques 84
Index 85
Contents Operating Instructions
MG34U302 Danfoss A/S © Rev. 2014-02-20 All rights reserved. 3

1 Introduction
1.1 Product Overview
1.1.1 Interior Views
130BC252.11
1
15 14
8
9
12
13 (IP 20/Chassis)
13
(IP 21/54
NEMA 1/12)
11
10
16
Illustration 1.1 D1 Interior Components
130BC301.11
1
2
3
4
5
6
7
8
9
10
11
Illustration 1.2 Close-up View: LCP and Control Functions
1LCP (Local Control Panel) 9 Relay 2 (04, 05, 06)
2 RS-485 serial bus connector 10 Lifting ring
3 Digital I/O and 24 V power supply 11 Mounting slot
4 Analog I/O connector 12 Cable clamp (PE)
5 USB connector 13 Earth (ground)
6 Serial bus terminal switch 14 Motor output terminals 96 (U), 97 (V), 98 (W)
7 Analog switches (A53), (A54) 15 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
8 Relay 1 (01, 02, 03) 16 TB5 (IP21/54 only). Terminal block for anti-condensation heater
Table 1.1 Legend to Illustration 1.1 and Illustration 1.2
NOTICE
For location of TB6 (terminal block for contactor), see chapter 3.4.3.2 Terminal Locations: D5h-D8h.
Introduction Operating Instructions
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1.1.2 Extended Options Cabinets
If a frequency converter is ordered with one of the
following options, it is supplied with an options cabinet
that makes it taller.
•Brake chopper
•Mains disconnect
•Contactor
•Mains disconnect with contactor
•Circuit breaker
Illustration 1.3 shows an example of a frequency converter
with an options cabinet. Table 1.2 lists the variants for the
frequency converters that include input options.
Options unit
designations
Extension cabinets Possible options
D5h D1h enclosure with
short extension
Brake, Disconnect
D6h D1h enclosure with tall
extension
Contactor, Contactor
with Disconnect,
Circuit Breaker
D7h D2h enclosure with
short extension
Brake, Disconnect
D8h D2h enclosure with tall
extension
Contactor, Contactor
with Disconnect,
Circuit Breaker
Table 1.2 Overview of Extended Options
The D7h and D8h frequency converters (D2h plus options
cabinet), include a 200 mm pedestal for floor mounting.
There is a safety latch on the front cover of the options
cabinet. If the frequency converter is supplied with a mains
disconnect or circuit breaker, the safety latch prevents the
cabinet door from being opened while the frequency
converter is energized. Before opening the door of the
frequency converter, the disconnect or circuit breaker must
be opened (to de-energize the frequency converter) and
the cover of the options cabinet must be removed.
For frequency converters purchased with a disconnect,
contactor or circuit breaker, the name plate label includes
a type code for a replacement that does not include the
option. If there is a problem with the frequency converter,
it is replaced independent of the options.
Refer to chapter 3.7 Optional Equipment for more detailed
descriptions of the input options and other options that
may be added to the frequency converter.
130BC539.10
1754
[69.1]
Illustration 1.3 D7h Enclosure
1.2 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and start up of the frequency converter.
provides requirements for mechanical and electrical instal-
lation, including input, motor, control and serial
communications wiring and control terminal functions.
chapter 4 Start Up and Commissioning provides detailed
Introduction Operating Instructions
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procedures for start up, basic operational programming,
and functional testing. The remaining chapters provide
supplementary details. These details include user interface,
detailed programming, application examples, start-up
troubleshooting, and specifications.
VLT®is a registered trademark.
1.3 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
•The VLT
®
Programming Guide provides greater
detail on working with parameters and many
application examples.
•The VLT
®
Design Guide is intended to provide
detailed capabilities and functionality to design
motor control systems.
•Supplemental publications and manuals are
available from Danfoss.
See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical
+Documentation.htm for listings.
•Optional equipment is available that may change
some of the procedures described. Reference the
instructions supplied with those options for
specific requirements. Contact the local Danfoss
supplier or visit the Danfoss website:
www.danfoss.com/BusinessAreas/DrivesSolutions/
Documentations/VLT+Technical+Documen-
tation.htm, for downloads or additional
information.
1.4 Product Overview
A frequency converter is an electronic motor controller
that converts DC into a variable AC waveform output. The
frequency and voltage of the output are regulated to
control the motor speed or torque. The frequency
converter can vary the speed of the motor in response to
system feedback, such as position sensors on a conveyor
belt. The frequency converter can also regulate the motor
by responding to remote commands from external
controllers.
In addition, the frequency converter monitors the system
and motor status, issues warnings or alarms for fault
conditions, starts and stops the motor, optimizes energy
efficiency, and offers many more control, monitoring, and
efficiency functions. Operation and monitoring functions
are available as status indications to an outside control
system or serial communication network.
1.5 Internal Controller Functions
Illustration 1.4 is a block diagram of the frequency
converter's internal components. See Table 1.3 for their
functions.
Illustration 1.4 Frequency Converter Block Diagram
Area Title Functions
1 Mains input
•Three-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 three-phase output
power to the motor
Introduction Operating Instructions
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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 1.3 Legend to Illustration 1.4
1.6 Frame Sizes and Power Ratings
kW High Overload 75 90 110 132 160 200 250 315 315
kW Normal Overload 90 110 132 160 200 250 315 355 400
400 V D3h D3h D3h D4h D4h D4h
500 V D3h D3h D3h D4h D4h D4h
525 V D3h D3h D3h D4h D4h D4h D4h
690 V D3h D3h D3h D4h D4h D4h D4h
Table 1.4 kW Rated Frequency Converters
HP High Overload 100 125 150 200 250 300 350 350
HP Normal Overload 125 150 200 250 300 350 400 450
460 V D3h D3h D3h D4h D4h D4h
575 V D3h D3h D3h D4h D4h D4h D4h
Table 1.5 HP Rated Frequency Converters
Introduction Operating Instructions
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2 Safety
2.1 Safety
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when
connected to AC mains input power. Qualified personnel
only should perform installation, start up, and
maintenance. Failure to perform installation, start up,
and maintenance by qualified personnel could result in
death or serious injury.
WARNING
UNINTENDED START
When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency
converter, motor, and any driven equipment must be in
operational readiness. Failure to be in operational
readiness when the frequency converter is connected to
AC mains could result in death, serious injury,
equipment, or property damage.
WARNING
DISCHARGE TIME
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is
not powered. To avoid electrical hazards, disconnect AC
mains, any permanent magnet type motors, and any
remote DC-link power supplies, including battery back-
ups, UPS, and DC-link connections to other frequency
converters. Wait for the capacitors to fully discharge
before performing any service or repair work. The
amount of wait time 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 [kW] Minimum waiting time
[min]
3x400 90-250 20
3x400 110-315 20
3x500 110-315 20
3x500 132-355 20
3x525 75-250 20
3x525 90-315 20
3x690 90-250 20
3x690 110-315 20
Table 2.1 Discharge Time
Table 2.2 Approvals
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the Design
Guide.
NOTICE
Imposed limitations on the output frequency
(due to export control regulations):
From software version 6.72 the output frequency of the
frequency converter is limited to 590 Hz. Software
versions 6x.xx also limit the maximum output frequency
to 590 Hz, but these versions cannot be flashed, i.e.
neither downgraded nor upgraded.
Safety Operating Instructions
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