Danfoss VLT Midi Drive FC 280 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT®Midi Drive FC 280
vlt-drives.danfoss.com

Contents
1 Introduction 3
1.1 Purpose of the Manual 3
1.2 Additional Resources 3
1.3 Document and Software Version 3
1.4 Product Overview 3
1.5 Approvals and Certications 4
1.6 Disposal 4
2 Safety 5
2.1 Safety Symbols 5
2.2 Qualied Personnel 5
2.3 Safety Precautions 5
3 Mechanical Installation 7
3.1 Unpacking 7
3.2 Installation Environment 7
3.3 Mounting 7
4 Electrical Installation 10
4.1 Safety Instructions 10
4.2 EMC-compliant Installation 10
4.3 Grounding 10
4.4 Wiring Schematic 12
4.5 Access 14
4.6 Motor Connection 14
4.7 AC Mains Connection 15
4.8 Control Wiring 16
4.9 Installation Checklist 19
5 Commissioning 20
5.1 Safety Instructions 20
5.2 Applying Power 20
5.3 Local Control Panel Operation 20
5.4 Basic Programming 28
5.5 Checking Motor Rotation 30
5.6 Checking Encoder Rotation 30
5.7 Local-control Test 30
5.8 System Start-up 31
5.9 STO Commissioning 31
6 Safe Torque O (STO) 32
Contents Operating Instructions
MG07A102 Danfoss A/S © 11/2015 All rights reserved. 1

6.1 Safety Precautions for STO 33
6.2 Safe Torque O Installation 33
6.3 STO Commissioning 34
6.4 Maintenance and Service for STO 35
6.5 STO Technical Data 37
7 Application Examples 38
8 Maintenance, Diagnostics, and Troubleshooting 41
8.1 Maintenance and Service 41
8.2 Warning and Alarm Types 41
8.3 Warning and Alarm Display 41
8.4 List of Warnings and Alarms 43
8.5 Troubleshooting 45
9 Specications 47
9.1 Electrical Data 47
9.2 Mains Supply (3-phase) 48
9.3 Motor Output and Motor Data 48
9.4 Ambient Conditions 48
9.5 Cable Specications 49
9.6 Control Input/Output and Control Data 49
9.7 Connection Tightening Torques 52
9.8 Fuses and Circuit Breakers 52
9.9 Enclosure Sizes, Power Ratings, and Dimensions 53
10 Appendix 54
10.1 Symbols, Abbreviations, and Conventions 54
10.2 Parameter Menu Structure 54
Index 60
Contents VLT®Midi Drive FC 280
2 Danfoss A/S © 11/2015 All rights reserved. MG07A102

1 Introduction
1.1 Purpose of the Manual
These operating instructions provide information for safe
installation and commissioning of the VLT®Midi Drive FC
280 frequency converter.
The operating instructions are intended for use by
qualied personnel.
To use the frequency converter safely and professionally,
read and follow the operating instructions. Pay particular
attention to the safety instructions and general warnings.
Always keep these operating instructions with the
frequency converter.
VLT®is a registered trademark.
1.2 Additional Resources
Resources available to understand advanced frequency
converter functions and programming:
•VLT® Midi Drive FC 280 Design Guide.
•VLT® Midi Drive FC 280 Programming Guide.
Supplementary publications and manuals are available
from Danfoss. See vlt-drives.danfoss.com/Support/Technical-
Documentation/ 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
MG07A1 The rst edition of this manual 1.0
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 conguration, 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 specied operating conditions and
environments. Ensure compliance with the conditions
specied in chapter 9 Specications.
1.4.2 Block Diagram of the Frequency
Converter
Illustration 1.1 is a block diagram of the internal
components of the frequency converter. See Table 1.2 for
their functions.
M
7
63
4
5
21
8
130BE200.11
Illustration 1.1 Frequency Converter Block Diagram
Area Component Functions
1 Mains input •AC mains power supply to the
frequency converter.
2Rectier
•The rectier bridge converts
the AC input to DC current to
supply inverter power.
3 DC bus •Intermediate DC-bus circuit
handles the DC current.
Introduction Operating Instructions
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11

Area Component Functions
4 DC reactor
•Filters the intermediate DC
circuit current.
•Provides line transient
protection.
•Reduces the root mean square
(RMS) current.
•Raises the power factor
reected back to the line.
•Reduces 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.
8 Control circuitry
•Input power, internal
processing, output, and motor
current are monitored to
provide ecient 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 1.1
1.4.3 Enclosure Sizes and Power Ratings
For enclosure sizes and power ratings of the frequency
converters, refer to chapter 9.9 Enclosure Sizes, Power
Ratings, and Dimensions.
1.4.4 Safe Torque O (STO)
The VLT®Midi Drive FC 280 frequency converter supports
Safe Torque O (STO). See chapter 9.9 Enclosure Sizes, Power
Ratings, and Dimensions for details about the installation,
commissioning, maintenance, and technical data of STO.
1.5 Approvals and Certications
For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation in the
VLT
®
Midi Drive FC 280 Design Guide.
Applied standards and compliance for STO
Use of STO on terminals 37 and 38 requires that the user
satises all provisions for safety including relevant laws,
regulations, and guidelines. The integrated STO function
complies with the following standards:
•IEC/EN 61508: 2010 SIL 2
•IEC/EN 61800-5-2: 2007 SIL2
•IEC/EN 62061: 2012 SILCL of SIL2
•EN ISO 13849-1: 2008 Category 3 PL d
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 VLT®Midi Drive FC 280
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2 Safety
2.1 Safety Symbols
The following symbols are used in this document:
WARNING
Indicates a potentially hazardous situation that could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that 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 Qualied Personnel
Correct and reliable transport, storage, installation,
operation, and maintenance are required for the trouble-
free and safe operation of the frequency converter. Only
qualied personnel are allowed to install or operate this
equipment.
Qualied personnel are dened as trained sta, who are
authorized to install, commission, and maintain equipment,
systems, and circuits in accordance with pertinent laws and
regulations. Also, the personnel must be familiar with the
instructions and safety measures described in this guide.
2.3 Safety Precautions
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when
connected to AC mains input, DC supply, or load sharing.
Failure to perform installation, start-up, and maintenance
by qualied personnel can result in death or serious
injury.
•Only qualied personnel must perform instal-
lation, start-up, and maintenance.
WARNING
UNINTENDED START
When the frequency converter is connected to AC mains,
DC 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 with an external
switch, a eldbus command, an input reference signal
from the LCP, via remote operation using MCT 10 Set-up
Software, or after a cleared fault condition.
To prevent unintended motor start:
•Disconnect the frequency converter from the
mains.
•Press [O/Reset] on the LCP before
programming parameters.
•Completely wire and assemble the frequency
converter, motor, and any driven equipment
before connecting the frequency converter to
AC mains, DC 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. High voltage can be present
even when the warning LED indicator lights are o.
Failure to wait the specied time after power has been
removed before performing service or repair work can
result in death or serious injury.
•Stop the motor.
•Disconnect AC mains and remote DC-link
supplies, including battery back-ups, UPS, and
DC-link connections to other frequency
converters.
•Disconnect or lock PM motor.
•Wait for the capacitors to discharge fully. The
minimum waiting time is specied in Table 2.1.
•Before performing any service or repair work,
use an appropriate voltage measuring device to
make sure that the capacitors are fully
discharged.
Safety Operating Instructions
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Voltage [V] Power range
[kW (hp)]
Minimum waiting time
(minutes)
200–240 0.37–3.7 (0.5–5) 4
380–480 0.37–7.5 (0.5–10) 4
11–22 (15–30) 15
Table 2.1 Discharge Time
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 certied electrical installer.
WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment
can result in death or serious injury.
•Ensure that only trained and qualied personnel
perform installation, start-up, and maintenance.
•Ensure that electrical work conforms to national
and local electrical codes.
•Follow the procedures in this guide.
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 VLT®Midi Drive FC 280
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3 Mechanical Installation
3.1 Unpacking
3.1.1 Items Supplied
Items supplied may vary according to product congu-
ration.
•Make sure the items supplied and the information
on the nameplate correspond to the order conr-
mation.
•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 clarication.
130BE616.11
CAUTION:
WARNING:
SEE MANUAL
STORED CHARGE DO NOT TOUCH UNTILL 4 MIN. AFTER
DISCONNECTION
RISK OF ELECTRIC SHOCK-DUAL SUPPLY DISCONNECT MAINS
AND LOADSHARING BEFORE SERVICE
1
7
10
9
8
2
3
4
6
12
5
11
1 Type code
2 Order number
3 Power rating
4Input voltage, frequency, and current (at low/high
voltages)
5Output voltage, frequency, and current (at low/high
voltages)
6 Enclosure type and IP rating
7 Disposal
8 CE mark
9 Serial number
10 Functional safety
11 Rated ambient temperature
12 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 requirements for storage are fullled. Refer to
chapter 9.4 Ambient Conditions for further details.
3.2 Installation Environment
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
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 oors of production
premises, as well as in panels bolted to walls or oors.
For detailed ambient conditions specications, refer to
chapter 9.4 Ambient Conditions.
3.3 Mounting
NOTICE
Improper mounting can result in overheating and
reduced performance.
Cooling
•Ensure 100 mm of top and bottom clearance for
air cooling.
Lifting
•To determine a safe lifting method, check the
weight of the unit, see chapter 9.9 Enclosure Sizes,
Power Ratings, 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.
Mechanical Installation Operating Instructions
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33

Mounting
To adapt to the mounting holes of FC 280, contact the
local Danfoss supplier to order a separate backplate.
To mount the frequency converter:
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 close to the motor as possible.
Keep the motor cables as short as possible.
3. Mount the unit vertically to a solid at surface or
to the optional backplate to provide cooling
airow.
4. When provided, use the slotted mounting holes
on the unit for wall mounting.
C
a
b
130BA648.12
f
e
B
A
a
d
e
b
c
Illustration 3.2 Top and Bottom Mounting Holes (See
chapter 9.9 Enclosure Sizes, Power Ratings, and Dimensions)
3.3.1 Side-by-side Installation
Side-by-side installation
All FC 280 units can be installed side-by-side in vertical or
horizontal position. The units do not require extra
ventilation on the side.
130BE615.10
Illustration 3.3 Side-by-side Installation
CAUTION
RISK OF OVERHEATING
If IP21 solution is used, mounting the units side-by-side
could lead to overheating and unit damages.
•Avoid mounting the units side-by-side if IP21
solution is used.
3.3.2 Bus Decoupling Kit
The bus decoupling kit ensures mechanical xation and
electrical screening of cables for the following control
cassette variants:
•Control cassette with PROFIBUS.
•Control cassette with PROFINET.
•Control cassette with CANopen.
•Control cassette with Ethernet.
Each bus decoupling kit contains 1 horizontal decoupling
plate and 1 vertical decoupling plate. Mounting the
vertical decoupling plate is optional. The vertical
decoupling plate provides better mechanical support for
PROFINET and Ethernet connectors and cables.
Mechanical Installation VLT®Midi Drive FC 280
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