Danfoss VLT FC 300 User manual

Contents
1. How to Read the Instruction Manual
3
How to Read the Instruction Manual 3
Approvals 4
Symbols 4
Abbreviations 5
2. Safety Instructions and General Warning 7
Disposal Instructions 7
High Voltage 8
Safety Instructions 8
Avoid Unintended Start 9
Safe Stop 10
Safe Stop Installation 11
IT Line 11
3. How to Install 13
How to Get Started 13
Pre-installation 14
Planning the Installation Site 14
Receiving the Adjustable Frequency Drive 14
Transportation and Unpacking 14
Lifting 15
Rated Power 21
Mechanical Installation 22
Tools Needed 22
General Considerations 22
Installation in Enclosures - IP 00 / Chassis units 32
Installation on the Wall - IP 21 (NEMA 1) and IP 54 (NEMA 12) Units 32
Floor Mounting - Pedestal Installation IP 21 (NEMA1) and IP 54 (NEMA12) 33
Gland/Conduit Entry - IP 21 (NEMA 1) and IP 54 (NEMA12) 35
IP 21 Drip shield installation (D1 and D2 enclosure) 36
Field Installation of Options 36
Installation on pedestal 46
Electrical Installation 49
Control Wires 49
Power Connections 50
VLT
®
Automation Drive FC 300
Instruction Manual High Power Contents
MG.33.U1.22 - VLT®is a registered Danfoss trademark. 1

Line connection 59
Fuses 60
Electrical Installation, Control Terminals 63
Connection Examples 65
Start/Stop 65
Pulse Start/Stop 65
Speed Up/Slow 66
Potentiometer Reference 66
Electrical Installation, Control Cables 67
Switches S201, S202, and S801 69
Final Set-Up and Test 70
Additional Connections 72
Mechanical Brake Control 72
Motor Thermal Protection 73
4. How to Program 75
The Graphical and Numerical LCP 75
How to Program on the Graphical LCP 75
How to Program on the Numerical Local Control Panel 76
Quick Setup 78
Parameter Lists 83
5. General Specifications 111
Product Specification: 117
6. Warnings and Alarms 127
Status Messages 127
Warnings/Alarm Messages 127
Index
136
Contents
VLT
®
Automation Drive FC 300
Instruction Manual High Power
2 MG.33.U1.22 - VLT®is a registered Danfoss trademark.

1. How to Read the Instruction Manual
1.1. How to Read the Instruction Manual
1.1.1. How to Read this Instruction Manual
The adjustable frequency drive 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 as well as install, program, and troubleshoot your
adjustable frequency drive.
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 adjustable frequency drive 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 adjustable frequency
drive via the Local Control Panel.
Chapter 5, General Specifications, contains technical data about the adjustable frequency
drive.
Chapter 6, Warnings and Alarms, assists you in solving problems that may occur when using
the adjustable frequency drive.
Available Literature for the FC 300
-The VLT
®
Automation Drive FC 300 Instruction Manual provides the neccessary infor-
mation for getting the drive up and running.
-The VLT
®
Automation Drive FC 300 Design Guide contains all technical information about
the drive design and applications including encoder, resolver and relay options.
-The VLT
®
Automation Drive FC 300 Profibus Instruction Manual provide the information
required for controlling, monitoring and programming the drive via a Profibus serial com-
munication bus.
-The VLT
®
Automation Drive FC 300 DeviceNet Instruction Manual provides the infor-
mation required for controlling, monitoring and programming the drive via a DeviceNet
serial communication bus.
-The VLT
®
Automation Drive FC 300 MCT 10 Instruction Manual provides information for
installing and using the software on a PC.
-The VLT
®
Automation Drive FC 300 24 V DC Backup instructions provide information for
installing the 24 V DC backup option.
VLT
®
Automation Drive FC 300
Instruction Manual High Power 1. How to Read the Instruction Manual
MG.33.U1.22 - VLT®is a registered Danfoss trademark. 3
1

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.
∗Indicates a default setting
1. How to Read the Instruction Manual
VLT
®
Automation Drive FC 300
Instruction Manual High Power
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1

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
®
Automation Drive FC 300
Instruction Manual High Power 1. How to Read the Instruction Manual
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1

2. Safety Instructions and General Warning
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®
Automation Drive FC 300
Instruction Manual High Power
6 MG.33.U1.22 - VLT®is a registered Danfoss trademark.
2

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.
Caution
The adjustable frequency drive DC link capacitors remain charged after power has been dis-
connected. To avoid the electrical shock hazard, disconnect the adjustable frequency drive
from the power supply before carrying out maintenance. Before servicing the adjustable fre-
quency drive, wait the minimum amount of time indicated below:
380-500 V 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
®
Automation Drive FC 300
Instruction Manual High Power 2. Safety Instructions and General Warning
MG.33.U1.22 - VLT®is a registered Danfoss trademark. 7
2

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.
2.1.3. Safety Instructions
• Make sure the adjustable frequency drive is properly grounded.
• Protect users against supply voltage.
• Protect the motor against overloading in accordance with national and local regulations.
• Motor overload protection is not included in the default settings. To add this function,
set parameter 1-90
Motor thermal protection to value ETR trip or ETR warning . For the
North American market: ETR functions provide class 20 motor overload protection, in
accordance with NEC.
• The ground leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switch. It does not disconnect the adjustable frequency
drive from line power.
2.1.4. 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.
When using the adjustable frequency drive: wait at least 40 minutes.
A shorter time is allowed only if indicated on the nameplate for the specific unit.
2. Safety Instructions and General Warning
VLT
®
Automation Drive FC 300
Instruction Manual High Power
8 MG.33.U1.22 - VLT®is a registered Danfoss trademark.
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Leakage Current
The ground leakage current from the adjustable frequency drive 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 have 2 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 (x=version number).
Protective grounding of the adjustable frequency drive and the use of RCDs must
always follow national and local regulations.
2.1.5. 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.
2.1.6. Avoid Unintended Start
While the adjustable frequency drive is connected to line power, the motor can be
started/stopped using digital commands, bus commands, references or via the Local
Control Panel.
• Disconnect the adjustable frequency drive from line power whenever personal safety
considerations make it necessary to avoid an unintended start.
• To avoid an unintended start, always activate the [OFF] key before changing parameters.
• An electronic fault, temporary overload, a fault in the line supply, or lost motor connection
may cause a stopped motor to start. The adjustable frequency drive with safe stop pro-
vides protection against unintended start, if Safe Stop Terminal 37 is deactivated or
disconnected.
VLT
®
Automation Drive FC 300
Instruction Manual High Power 2. Safety Instructions and General Warning
MG.33.U1.22 - VLT®is a registered Danfoss trademark. 9
2

2.1.7. Safe Stop
The FC 302 can perform the safety function Safe Torque Off (As defined by draft CD IEC
61800-5-2) or
Stop Category 0 (as defined in EN 60204-1).
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
®
Automation Drive FC 300
Instruction Manual High Power
10 MG.33.U1.22 - VLT®is a registered Danfoss trademark.
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2.1.8. Safe Stop Installation
To carry out an installation of a Catego-
ry 0 Stop (EN60204) in conformity 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 an un-
shielded cable instead of a shielded
one.
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).
2.1.9. 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.
VLT
®
Automation Drive FC 300
Instruction Manual High Power 2. Safety Instructions and General Warning
MG.33.U1.22 - VLT®is a registered Danfoss trademark. 11
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3. How to Install
VLT
®
Automation Drive FC 300
Instruction Manual High Power
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3. How to Install
3.1. How to Get Started
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 adjustable frequency drive 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
®
Automation Drive FC 300
Instruction Manual High Power 3. How to Install
MG.33.U1.22 - VLT®is a registered Danfoss trademark. 13
3

3.2. Pre-installation
3.2.1. Planning the Installation Site
NOTE
Before performing the installation, it is important to plan the installation of the ad-
justable frequency drive. Neglecting this may result in extra work during and after
installation.
Select the best possible operation site by considering the following (see details on
the following pages and in the respective Design Guides):
• Ambient operating temperature
• Installation method
• How to cool the unit
• Position of the adjustable frequency drive.
•Cablerouting
• Ensure the power source supplies the correct voltage and necessary current.
• Ensure that the motor current rating is within the maximum current from the adjustable
frequency drive.
• If the adjustable frequency drive is without built-in fuses, ensure that the external fuses
are rated correctly.
3.2.2. Receiving the Adjustable Frequency Drive
When receiving the adjustable frequency drive, make sure that the packaging is intact, and look
for any damage that might have occurred to the unit during transport. If damage has occurred,
immediately contact the shipping company to make a damage claim.
3.2.3. Transportation and Unpacking
Before unpacking the adjustable frequency drive, it is recommended to unload it as close as pos-
sible to the final installation site.
Remove the cardboard box and keep the adjustable frequency drive on the pallet as long as pos-
sible. Remark: The cardboard box cover contains a drilling master for the mounting holes.
3. How to Install
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®
Automation Drive FC 300
Instruction Manual High Power
14 MG.33.U1.22 - VLT®is a registered Danfoss trademark.
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3.2: Mounting Template
3.2.4. Lifting
Always lift the adjustable frequency drive using the dedicated lifting holes. Use a bar to avoid
bending the lifting holes of the adjustable frequency drive.
3.3: Recommended lifting method
VLT
®
Automation Drive FC 300
Instruction Manual High Power 3. How to Install
MG.33.U1.22 - VLT®is a registered Danfoss trademark. 15
3

3.2.5. Mechanical Dimensions
3. How to Install
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®
Automation Drive FC 300
Instruction Manual High Power
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VLT
®
Automation Drive FC 300
Instruction Manual High Power 3. How to Install
MG.33.U1.22 - VLT®is a registered Danfoss trademark. 17
3

3. How to Install
VLT
®
Automation Drive FC 300
Instruction Manual High Power
18 MG.33.U1.22 - VLT®is a registered Danfoss trademark.
3

VLT
®
Automation Drive FC 300
Instruction Manual High Power 3. How to Install
MG.33.U1.22 - VLT®is a registered Danfoss trademark. 19
3

Mechanical dimensions, D Enclosures
Frame size D1 D2 D3 D4
125-150 hp [90-110
kW]
(380-500 V)
150-175 hp [110-132
kW]
(525-690 V)
175-300 hp [132-200
kW]
(380-500 V)
250-450 hp [160-315
kW]
(525-690 V)
125-150 hp
[90-110 kW]
(380-500 V)
150-175 hp
[110-132
kW]
(525-690 V)
175-300 hp
[132-200
kW]
(380-500 V)
250-450 hp
[160-315
kW]
(525-690 V)
IP
NEMA 21 Type 1
54
Type 12
21
Type 1
54
Type 12
00
Chassis
00
Chassis
Card-
board
box size
Shipping
dimen-
sions
Height
25.6 in
[650 mm]
25.6 in [650
mm]
25.6 in
[650 mm]
25.6 in [650
mm]
25.6 in [650
mm]
25.6 in [650
mm]
Width 68.1 in
[1730 mm]
68.1 in [1730
mm]
68.1 in
[1730 mm]
68.1 in [1730
mm]
48 in [1220
mm]
58.7 in [1490
mm]
Depth 22.4 in
[570 mm]
22.4 in [570
mm]
22.4 in
[570 mm]
22.4 in [570
mm]
22.4 in [570
mm]
22.4 in [570
mm]
Drive di-
men-
sions Height 45.6 in
[1159 mm]
45.6 in [1159
mm]
60.6 in
[1540 mm]
60.6 in [1540
mm]
39.3 in [997
mm]
50.3 in [1277
mm]
Width 16.5 in
[420 mm]
16.5 in [420
mm]
16.5 in
[420 mm]
16.5 in [420
mm]
16.1 in [408
mm]
16.1 in [408
mm]
Depth 14.7 in
[373 mm]
14.7 in [373
mm]
14.7 in
[373 mm]
14.7 in [373
mm]
14.7 in [373
mm]
14.7 in [373
mm]
Max
weight
229.3 lbs
[104 kg]
229.3 lbs
[104 kg]
332. 9 lbs
[151 kg]
332. 9 lbs
[151 kg]
200.6 lbs [91
kg]
304.2 lbs [138
kg]
Mechanical dimensions, E Enclosures
Frame size E1 E2
350-550 hp [250-400 kW]
(380-500 V)
500-750 hp [355-560 kW]
(525-690 V)
350-550 hp
[250-400 kW]
(380-500 V)
500-750 hp
[355-560 kW]
(525-690 V)
IP
NEMA 21 Type 12
54
Type 12
00
Chassis
Cardboard box size
Shipping dimensions Height 33.1 in [840 mm] 33.1 in [840 mm] 32.7 in [831 mm]
Width 86.5 in [2197 mm] 86.5 in [2197 mm] 67.1 in [1705 mm]
Depth 29 in [736 mm] 29 in [736 mm] 29 in [736 mm]
Drive dimensions Height 78.7 in [2000 mm] 78.7 in [2000 mm] 59 in [1499 mm]
Width 23.6 in [600 mm] 23.6 in [600 mm] 23 in [585 mm]
Depth 19.5 in [494 mm] 19.5 in [494 mm] 19.5 in [494 mm]
Max weight 690 lbs [313 kg] 690 lbs [313 kg] 611 lbs [277 kg]
3. How to Install
VLT
®
Automation Drive FC 300
Instruction Manual High Power
20 MG.33.U1.22 - VLT®is a registered Danfoss trademark.
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