Danfoss VLT series User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT®AutomationDrive FC 302
12-pulse
vlt-drives.danfoss.com

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 Approvals and Certications 4
1.5 Disposal 5
1.6 Abbreviations and Conventions 5
2 Safety Instructions 7
2.1 Safety Symbols 7
2.2 Qualied Personnel 7
2.3 Safety Regulations 7
3 How to Install 9
3.1 Pre-installation 9
3.1.1 Planning the Installation Site 9
3.1.1.1 Inspection on Receipt 9
3.1.2 Transportation and Unpacking 9
3.1.3 Lifting Unit 9
3.1.4 Mechanical Dimensions 12
3.2 Mechanical Installation 18
3.2.1 Preparation for Installation 18
3.2.2 Tools Required 18
3.2.3 General Considerations 18
3.2.4 Terminal Locations, F8–F15 20
3.2.4.1 Inverter and Rectier, Enclosure Sizes F8, and F9 20
3.2.4.2 Inverter, Enclosure Sizes F10 and F11 21
3.2.4.3 Inverter, Enclosure Sizes F12 and F13 22
3.2.4.4 Inverter, Enclosure Sizes F14 and F15 23
3.2.4.5 Rectier, Enclosure Sizes F10, F11, F12, and F13 24
3.2.4.6 Rectier, Enclosure Sizes F14 and F15 25
3.2.4.7 Options Cabinet, Enclosure Size F9 26
3.2.4.8 Options Cabinet, Enclosure Sizes F11 and F13 27
3.2.4.9 Options Cabinet, Enclosure Size F15 28
3.2.5 Cooling and Airow 28
3.3 Installing the Panel Options 34
3.3.1 Panel Options 34
3.4 Electrical Installation 35
3.4.1 Transformer Selection 36
3.4.2 Power Connections 36
Contents Operating Instructions
MG34Q402 Danfoss A/S © 04/2016 All rights reserved. 1

3.4.3 Grounding 45
3.4.4 Extra Protection (RCD) 45
3.4.5 RFI Switch 45
3.4.6 Torque 46
3.4.7 Shielded Cables 46
3.4.8 Motor Cable 46
3.4.9 Brake Cable for Frequency Converters with Factory-installed Brake Chopper Op-
tion 47
3.4.10 Shielding against Electrical Noise 47
3.4.11 Connection of Mains 48
3.4.12 External Fan Supply 48
3.4.13 Fuses 48
3.4.14 Supplementary Fuses 50
3.4.15 Motor Insulation 51
3.4.16 Motor Bearing Currents 51
3.4.17 Brake Resistor Temperature Switch 51
3.4.18 Control Cable Routing 52
3.4.19 Access to Control Terminals 52
3.4.20 Wiring to Control Terminals 52
3.4.21 Electrical Installation, Control Cables 53
3.4.22 Switches S201, S202, and S801 55
3.5 Connection Examples 56
3.5.1 Start/Stop 56
3.5.2 Pulse Start/Stop 56
3.6 Final Set-up and Test 57
3.7 Additional Connections 58
3.7.1 Mechanical Brake Control 58
3.7.2 Parallel Connection of Motors 59
3.7.3 Motor Thermal Protection 59
4 How to Programme 60
4.1 The Graphical LCP 60
4.1.1 Initial Commissioning 61
4.2 Quick Set-up 62
4.3 Parameter Menu Structure 65
5 General Specications 71
5.1 Mains Supply 71
5.2 Motor Output and Motor Data 71
5.3 Ambient Conditions 71
5.4 Cable Specications 72
Contents VLT®AutomationDrive FC 302
2 Danfoss A/S © 04/2016 All rights reserved. MG34Q402

5.5 Control Input/output and Control Data 72
5.6 Electrical Data 76
6 Warnings and Alarms 83
6.1 Warning and Alarm Types 83
6.2 Warning and Alarm Denitions 83
Index 93
Contents Operating Instructions
MG34Q402 Danfoss A/S © 04/2016 All rights reserved. 3

1 Introduction
1.1 Purpose of the Manual
The frequency converter is designed to provide high shaft
performance on electrical motors. Read these operating
instructions carefully for proper use. Incorrect handling of
the frequency converter may cause improper operation of
the frequency converter or related equipment, shorten
lifetime, or cause other troubles.
These operating instructions provide information on:
•Start-up.
•Installation.
•Programming.
•Troubleshooting.
•Chapter 1 Introduction introduces the manual and
informs about approvals, symbols, and abbrevi-
ations used in this manual.
•Chapter 2 Safety Instructions entails instructions on
how to handle the frequency converter in a safe
way.
•Chapter 3 How to Install guides through the
mechanical and electrical installations.
•Chapter 4 How to Programme explains how to
operate and programme the frequency converter
via the LCP.
•Chapter 5 General Specications contains technical
data about the frequency converter.
•Chapter 6 Warnings and Alarms assists in solving
problems that may occur when using the
frequency converter.
VLT®is a registered trademark.
DeviceNet™is a trademark of ODVA, Inc.
1.2 Additional Resources
•The VLT
®
AutomationDrive FC 301/FC 302 Design
Guide details all technical information about the
frequency converter and customer design and
applications.
•The VLT
®
AutomationDrive FC 301/FC 302
Programming Guide provides information on how
to programme and includes complete parameter
descriptions.
•The VLT
®
PROFIBUS DP MCA 101 Installation Guide
provides information about installing and trouble-
shooting of the PROFIBUS eldbus option.
•The VLT
®
PROFIBUS DP MCA 101 Programming
Guide provides the information required for
controlling, monitoring, and programming the
frequency converter via a PROFIBUS eldbus.
•The VLT
®
DeviceNet MCA 104 Installation Guide
provides information about installing and trouble-
shooting of the DeviceNet®eldbus option.
•The VLT
®
DeviceNet MCA 104 Programming Guide
provides the information required for controlling,
monitoring, and programming the frequency
converter via a DeviceNet®eldbus.
Danfoss technical documentation is also available online at
http://drives.danfoss.com/knowledge-center/technical-
documentation/.
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
MG34Q4xx F14 and F15 enclosure sizes added.
Software version update.
7.4x
Table 1.1 Document and Software Version
1.4 Approvals and Certications
1.4.1 Approvals
The frequency converter complies with UL 508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the
product-specic design guide.
NOTICE
Imposed limitations on the output frequency
(due to export control regulations):
From software version 6.72 onwards, the output
frequency of the frequency converter is limited to
590 Hz. Software versions 6.xx also limit the maximum
output frequency to 590 Hz, but these versions cannot
be ashed, that is, neither downgraded nor upgraded.
Introduction VLT®AutomationDrive FC 302
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The 1400–2000 kW (1875–2680 hp) 690 V frequency
converters are approved for CE only.
1.5 Disposal
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
1.6 Abbreviations and Conventions
60°AVM 60°asynchronous vector modulation
A Ampere/AMP
AC Alternating current
AD Air discharge
AEO Automatic energy optimization
AI Analog input
AIC Ampere interrupting current
AMA Automatic motor adaptation
AWG American wire gauge
°CDegrees celsius
CB Circuit breaker
CD Constant discharge
CDM Complete drive module: The frequency converter,
feeding section, and auxiliaries
CE European Conformity (European safety standards)
CM Common mode
CT Constant torque
DC Direct current
DI Digital input
DM Dierential mode
D-TYPE Drive dependent
EMC Electromagnetic compatibility
EMF Electromotive force
ETR Electronic thermal relay
fJOG Motor frequency when jog function is activated
fMMotor frequency
fMAX Maximum output frequency, the frequency
converter applies on its output
fMIN Minimum motor frequency from the frequency
converter
fM,N Nominal motor frequency
FC Frequency converter
Hiperface®Hiperface®is a registered trademark by Stegmann
HO High overload
hp Horse power
HTL HTL encoder (10–30 V) pulses - High-voltage
transistor logic
Hz Hertz
IINV Rated inverter output current
ILIM Current limit
IM,N Nominal motor current
IVLT,MAX Maximum output current
IVLT,N Rated output current supplied by the frequency
converter
kHz Kilohertz
LCP Local control panel
lsb Least signicant bit
m Meter
mA Milliampere
MCM Mille circular mil
MCT Motion control tool
mH Inductance in milli Henry
mm Millimeter
ms Millisecond
msb Most signicant bit
ηVLT Eciency of the frequency converter dened as
ratio between power output and power input
nF Capacitance in nano Farad
NLCP Numerical local control panel
Nm Newton meter
NO Normal overload
nsSynchronous motor speed
Online/
Oine
Parameters
Changes to online parameters are activated
immediately after the data value is changed
Pbr,cont. Rated power of the brake resistor (average power
during continuous braking)
PCB Printed circuit board
PCD Process data
PDS Power drive system: a CDM and a motor
PELV Protective extra low voltage
PmFrequency converter nominal output power as
high overload (HO)
PM,N Nominal motor power
PM motor Permanent magnet motor
Process PID PID (proportional integrated dierential) regulator
that maintains the speed, pressure, temperature,
and so on
Rbr,nom Nominal resistor value that ensures a brake power
on the motor shaft of 150/160% for 1 minute
RCD Residual current device
Regen Regenerative terminals
Rmin Minimum permissible brake resistor value by
frequency converter
RMS Root mean square
RPM Revolutions per minute
Rrec Recommended brake resistor resistance of
Danfoss brake resistors
s Second
SCCR Short circuit current rating
SFAVM Stator ux-oriented asynchronous vector
modulation
STW Status word
SMPS Switch mode power supply
Introduction Operating Instructions
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THD Total harmonic distortion
TLIM Torque limit
TTL TTL encoder (5 V) pulses - transistor transistor
logic
UM,N Nominal motor voltage
UL Underwriters Laboratories (US organization for the
safety certication)
V Volts
VT Variable torque
VVC+Voltage vector control plus
Table 1.2 Abbreviations
Conventions
Numbered lists indicate procedures.
Bullet lists indicate other information and description of
illustrations.
Italicized text indicates:
•Cross-reference.
•Link.
•Footnote.
•Parameter name, parameter group name,
parameter option.
All dimensions in drawings are in mm (in).
* Indicates a default setting of a parameter.
Introduction VLT®AutomationDrive FC 302
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2 Safety Instructions
2.1 Safety Symbols
The following symbols are used in this guide:
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 and 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 qualied personnel must be familiar
with the instructions and safety measures described in this
manual.
2.3 Safety Regulations
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 or LOP, via remote operation using MCT 10
Set-up Software, or after a cleared fault condition.
To prevent unintended motor start:
•Press [O/Reset] on the LCP before
programming parameters.
•Disconnect the frequency converter from the
mains.
•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 power
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 duration of 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 Instructions Operating Instructions
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Voltage
[V]
Power range
[kW (hp)]
Minimum waiting
time
(minutes)
380–500 250–1000 (350–1350) 30
525–690 355–2000 (475–2700) 40
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.
WARNING
UNINTENDED MOTOR ROTATION
WINDMILLING
Unintended rotation of permanent magnet motors
creates voltage and can charge the unit, resulting in
death, 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.
To run STO, more wiring for the frequency converter is
required. Refer to VLT
®
Frequency Converters Safe Torque O
Operating Instructions for further information.
Safety Instructions VLT®AutomationDrive FC 302
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3 How to Install
3.1 Pre-installation
3.1.1 Planning the Installation Site
NOTICE
Plan the installation of the frequency converter before
commencing. Not planning the installation thoroughly
can 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 the
respective design guides):
•Ambient operating temperature.
•Installation method.
•How to cool the unit.
•Position of the frequency converter.
•Cable routing.
•Ensure that the power source supplies the correct
voltage and necessary current.
•Ensure that the motor current rating is within the
maximum current from the frequency converter.
•If the frequency converter is without built-in
fuses, ensure that the external fuses are rated
correctly.
3.1.1.1 Inspection on Receipt
After receiving the delivery, immediately check whether
the items supplied match the shipping documents. Danfoss
does not honor claims for faults registered later.
Register a complaint immediately:
•With the carrier if there is visible transport
damage.
•With the responsible Danfoss representative if
there are visible defects or incomplete delivery.
3.1.2 Transportation and Unpacking
Locate the frequency converter as close as possible to the
nal installation site before unpacking.
Remove the box and handle the frequency converter on
the pallet, as long as possible.
3.1.3 Lifting Unit
Always lift the frequency converter via the dedicated lifting
eyes.
130BB753.11
Illustration 3.1 Recommended Lifting Method,
Enclosure Size F8.
How to Install Operating Instructions
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130BB688.11
Illustration 3.2 Recommended Lifting Method,
Enclosure Size F9/F10.
130BB689.11
Illustration 3.3 Recommended Lifting Method,
Enclosure Size F11/F12/F13/F14.
How to Install VLT®AutomationDrive FC 302
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130BE141.10
Illustration 3.4 Recommended lifting method, Enclosure Size F15
NOTICE
The plinth is provided in the same packaging as the frequency converter, but is not attached during shipment. The
plinth is required to allow airow cooling to the frequency converter. Position the frequency converter on top of the
plinth in the nal installation location. The angle from the top of the frequency converter to the lifting cable must be
>60°.
In addition to Illustration 3.1 to Illustration 3.3, a spreader bar can be used to lift the frequency converter.
How to Install Operating Instructions
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3.1.4 Mechanical Dimensions
F8 IP21/54 – NEMA 1/12 F9 IP21/54 – NEMA 1/12
130BB754.11
800 (31.50) 607 (23.90)
IP/21 NEMA 1
IP/54
NEMA 12
1400 m3/h
(824 cfm)
1050 m3/h
(618 cfm)
1970 m3/h
(1160 cfm)
2280 (89.76)
2205 (86.81)
1497 (58.94)
130BB568.11
1400 (55.12)
607 (23.90)
IP/21 NEMA 1
IP/54
NEMA 12
2100 m3/h
(1236 cfm)
1575 m3/h
(927 cfm)
1970 m3/h
(1160 cfm)
2280 (89.76)
2205 (86.81)
1497 (58.94)
All dimensions in mm (in)
Table 3.1 Mechanical Dimensions, Enclosure Sizes F8 and F9
How to Install VLT®AutomationDrive FC 302
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F10 IP21/54 – NEMA 1/12 F11 IP21/54 – NEMA 1/12
130BB569.11
1600 (62.99)
607 (23.90)
IP/21 NEMA 1
IP/54
NEMA 12
2800 m3/h
(1648 cfm)
2100 m3/h
(1236 cfm)
3940 m3/h
(2320 cfm)
2280 (89.76)
2205 (86.81)
1497 (58.94)
130BB570.11
2400 (94.49)
607 (23.90)
IP/21 NEMA 1
IP/54
NEMA 12
4200 m3/h
(2472 cfm)
3150 m3/h
(1854 cfm)
3940 m3/h
(2320 cfm)
2280 (89.76)
2205 (86.81)
1497 (58.94)
All dimensions in mm (in)
Table 3.2 Mechanical Dimensions, Enclosure Sizes F10 and F 11
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F12 IP21/54 – NEMA 1/12 F13 IP21/54 – NEMA 1/12
130BB571.11
2000 (78.74)
607 (23.90)
IP/21 NEMA 1
IP/54
NEMA 12
2800 m3/h
(2472 cfm)
3150 m3/h
(1854 cfm)
4925 m3/h
(2900 cfm)
2280 (89.76)
2205 (86.81)
1497 (58.94)
130BB572.11
2800 (110,24)
607 (23.90)
IP/21 NEMA 1
IP/54
NEMA 12
4200 m3/h
(2472cfm)
3150 m3/h
(1854 cfm)
4925 m3/h
(2900 cfm)
2280 (89.76)
2205 (86.81)
1497 (58.94)
All dimensions in mm (in)
Table 3.3 Mechanical Dimensions, Enclosure Sizes F12 and F13
How to Install VLT®AutomationDrive FC 302
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F14 IP21/54 – NEMA 1/12
130BC150.12
800 [31.5]
800 [31.5]
2400 [94.5]
2280 [89.8]
2205 [86.8]
1497 [58.9]
7883 m3/h
(4680 cfm)
IP/21 NEMA 1 2800 m3/h
(2472 cfm) IP/54 NEMA 12 3150 m3/h (1854 cfm)
All dimensions in mm (in)
Table 3.4 Mechanical Dimensions, Enclosure Size F14
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F15 IP21/54 – NEMA 1/12
800 (31.5)
IP21/NEMA1 2800 m3/Hr 2472 CFM IP21/NEMA12 3150 m3/Hr 1854 CFM
7883 m3/Hr 4640 CFM
800 (31.5)
800 (31.5)
3600 (141.7)
600 (23.6)
600 (23.6)
130BE181.10
2280 (89.9)
2205 (86.8)
1497 (58.9)
All dimensions in mm (in)
Table 3.5 Mechanical Dimensions, Enclosure Size F15
How to Install VLT®AutomationDrive FC 302
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Enclosure size F8 F9 F10 F11
130BE142.10
130BE144.10
130BE145.10
130BE146.10
High overload
rated power –
150% overload
torque
250–400 kW (380–500 V)
355–560 kW (525–690 V)
250–400 kW (380–500 V)
355–56 kW (525–690 V)
450–630 kW (380–500 V)
630–800 kW (525–690 V)
710–800 kW (380–500 V)
900–1200 kW (525–690 V)
IP
NEMA
21, 54
12
21, 54
12
21, 54
12
21, 54
12
Shipping dimensions [mm (in)]
Height 2324 (91.5) 2324 (91.5) 2324 (91.5) 2324 (91.5)
Width 970 (38.2) 1568 (61.7) 1760 (69.3) 2559 (100.7)
Depth 1130 (44.5) 1130 (44.5) 1130 (44.5) 1130 (44.5)
Frequency converter dimensions [mm (in)]
Height 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8)
Width 800 (31.5) 1400 (55.1) 1600 (63.0) 2400 (94.5)
Depth 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9)
Max weight
[kg (lb)] 440 (970) 656 (1446) 880 (1940) 1096 (2416)
Table 3.6 Mechanical Dimensions, Enclosure Sizes F8–F11
Enclosure size F12 F13 F14 F15
130BE147.10
130BE148.10
130BE149.11
130BE150.10
High overload
rated power –
150% overload
torque
450–630 kW (380–500 V)
630–800 kW (525–690 V)
710–800 kW (380–500 V)
900–1200 kW (525–690 V) 1400–1800 kW (525–690 V) 1400–1800 kW (525–690 V)
IP
NEMA
21, 54
12
21, 54
12
21, 54
12
21, 54
12
Shipping dimensions [mm (in)]
Height 2324 (91.5) 2324 (91.5) 2324 (91.5) 2324 (91.5)
Width 2160 (85.0) 2960 (116.5) 2578 (101.5) 3778 (148.7)
Depth 1130 (44.5) 1130 (44.5) 1130 (44.5) 1130 (44.5)
Frequency converter dimensions [mm]
Height 2204 (86.8) 2204 (86.8) 2204 (86.8) 2204 (86.8)
Width 2000 (78.7) 2800 (110.2) 2400 (94.5) 3600 (141.7)
Depth 606 (23.9) 606 (23.9) 606 (23.9) 606 (23.9)
Max weight
[kg (lb)] 1022 (2253) 1238 (2729) 1410 (3108) 1626 (3585)
Table 3.7 Mechanical Dimensions, Enclosure Sizes F12–F15
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3.2 Mechanical Installation
3.2.1 Preparation for Installation
To ensure reliable and eective installation of the
frequency converter, make the following preparations:
•Provide a suitable mounting arrangement. The
mounting arrangement depends on the design,
weight, and torque of the frequency converter.
•To ensure that the space requirements are met,
examine the mechanical drawings.
•Ensure that all wiring is done in accordance with
national regulations.
3.2.2 Tools Required
•Drill with 10 mm or 12 mm bit.
•Tape measure.
•Wrench with relevant metric sockets (7–17 mm).
•Extensions to wrench.
•Sheet metal punch for conduits or cable glands in
IP21/NEMA 1 and IP54 units
•Lifting bar to lift the unit (rod or tube maximum
Ø 25 mm (1 in), able to lift minimum 400 kg (880
lb).
•Crane or other lifting aid to place the frequency
converter in position.
3.2.3 General Considerations
Space
To allow airow and cable access, ensure sucient space
above and below the frequency converter. In addition,
allow for enough space in front of the unit to open the
panel door, see Illustration 3.5 to Illustration 3.12.
776
(30.6)
130BB531.10
Illustration 3.5 Space in Front of Enclosure Size F8
130BB003.13
776
(30.6)
578
(22.8)
Illustration 3.6 Space in Front of Enclosure Size F9
776
(30.6)
776
(30.6)
130BB574.10
Illustration 3.7 Space in Front of Enclosure Size F10
130BB575.10
776 (30.6)
(2x)
Illustration 3.8 Space in Front of Enclosure Size F11
130BB576.10
776
(30.6) 624
(24.6)
579
(22.8)
Illustration 3.9 Space in Front of Enclosure Size F12
130BB577.10
776
(30.6)
776
(30.6) 624
(24.6)
579
(22.8)
Illustration 3.10 Space in Front of Enclosure Size F13
130BB575.10
776 (30.6)
(2x)
Illustration 3.11 Space in Front of Enclosure Size F14
How to Install VLT®AutomationDrive FC 302
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