Danfoss D9h User manual

Operating Guide
VLT® AutomationDrive FC 302
90-710 kW, D9h-D10h and E5h-E6h Enclosed Drives
drives.danfoss.com

1
1.1
1.2
1.3
1.4
1.5
1.6
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
3.5
3.6
3.6.1
3.6.2
3.6.3
3.6.4
4
4.1
4.2
4.3
4.4
4.5
4.5.1
4.5.2
4.5.3
4.5.4
Contents
Introduction 8
Purpose of this Operating Guide 8
Additional Resources 8
Manual Version 8
Approvals and Certifications 8
Finding the Declaration of Conformity Certificate 9
Declaration of Conformity Certificate 10
Safety 14
Safety Symbols 14
Qualified Personnel 14
Safety Precautions 15
Product Overview 17
Intended Use 17
What is an Enclosed Drive? 17
Location of Options within an Enclosed Drive 20
Drive Identification 22
Identifying the Drive and Its Options 22
Enclosure Size Identification 23
Type Code Identification 24
Power Ratings, Weight, and Dimensions 31
Control Compartment and Local Control Panel (LCP) 33
Control Compartment Overview 33
Control Compartment Door 34
Local Control Panel (LCP) 35
LCP Menu 37
Mechanical Installation 39
Items Supplied 39
Split Shipment 39
Tools Needed 39
Storing the Drive 40
Operating Environment 40
Overview 40
Gases 40
Dust 40
Potentially Explosive Atmospheres 41
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Contents
VLT® AutomationDrive FC 302
Operating Guide

4.6
4.7
4.8
4.9
4.10
4.11
4.11.1
4.11.2
4.11.3
5
5.1
5.2
5.3
5.4
5.5
5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.7
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
5.7.6
5.8
5.8.1
5.8.2
5.8.3
5.8.4
5.8.5
5.8.6
5.9
5.9.1
Installation Requirements 41
Cooling Requirements 42
Airflow Rates 42
Lifting the Drive 44
Combining Multiple Cabinets from a Split Shipment 44
Installing the Enclosed Drive 46
Creating an Entry for Cables 46
Installing the Drive with Back-channel Cooling Option 46
Securing the Cabinet(s) to the Floor 47
Electrical Installation 49
Safety Instructions 49
EMC-compliant Installation 50
Wiring Overview for D9h and D10h Enclosed Drives 53
Wiring Overview for E5h and E6h Enclosed Drives 54
Control Terminal Wiring Diagram Cross-reference 55
Split Shipment Wiring Harnesses 56
Connecting Wiring Harnesses 56
Cable Routing 57
D10h Wiring Harness 65
E5h Wiring Harness 69
E6h Wiring Harness 75
Control Compartment Wiring 81
Safety Precautions 81
Control Compartment Interior View 82
Control Terminals 83
Relay Terminals 84
Option Card Terminals 84
Control Compartment Options 91
Connecting Motor, Mains, and Ground Cables 99
Power Cabling and Grounding Considerations 99
Connecting to the Mains 100
Connecting the Drive Module to the Motor 102
Connecting the Sine-wave Filter to the Motor 104
Connecting the dU/dt Filter to the Motor 105
Connecting to Ground 107
Installing Upstream Fuses 108
Upstream Fuse Considerations 108
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Contents
VLT® AutomationDrive FC 302
Operating Guide

5.9.2
5.9.3
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
6
7
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.3
7.3.1
7.3.2
7.4
7.5
7.5.1
7.5.2
7.5.3
7.5.4
8
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
Recommended Fuse Ratings for IEC Installation 108
Recommended Fuse Ratings for UL Installation 109
Enabling Motor Operation 110
Selecting the Voltage/Current Input Signal 110
Setting Up RS485 Serial Communication 111
Configuring the Passive Harmonic Filter (PHF) 112
Configuring the dU/dt Filter 112
Configuring the Sine-wave Filter 112
MCCB Configuration 112
Safe Torque Off (STO) Wiring 113
Pre-start Check 114
Commissioning 116
Applying Power to the Drive 116
Programming the Drive 116
Parameter Overview 116
Parameter Navigation 117
Programming Example for an Open-loop Application 117
Entering System Information 118
Configuring Automatic Energy Optimization 119
Configuring Automatic Motor Adaptation 119
Testing Before System Start-up 119
Testing Motor Rotation 119
Testing Encoder Rotation 119
Starting Up the Drive for the First Time 120
Parameter Settings 120
Parameter Setting Overview 120
Uploading and Downloading Parameter Settings 120
Restoring Factory Default Settings Using the Recommended Initialization 121
Restoring Factory Default Settings Using Manual Initialization 121
Wiring Configuration Examples 122
Application Examples 122
Programming a Closed-loop Drive System 122
Wiring Configuration for Automatic Motor Adaptation (AMA) 123
Wiring Configuration for Automatic Motor Adaptation (AMA) without T27 123
Wiring Configuration: Speed 124
Wiring Configuration: Feedback 126
AQ262139143212en-000301/130R0879 | 5Danfoss A/S © 2021.10
Contents
VLT® AutomationDrive FC 302
Operating Guide

8.1.6
8.1.7
8.1.8
8.1.9
8.1.10
8.1.11
8.1.12
8.1.13
8.1.14
8.1.15
9
9.1
9.2
9.3
9.4
9.5
10
10.1
10.1.1
10.1.2
10.2
10.3
10.3.1
10.3.2
10.4
10.5
10.6
10.6.1
10.6.2
10.6.3
10.6.4
10.6.5
10.6.6
10.6.7
10.6.8
10.6.9
10.6.10
Wiring Configuration: Run/Stop 127
Wiring Configuration: Start/Stop 129
Wiring Configuration: External Alarm Reset 131
Wiring Configuration: RS485 131
Wiring Configuration: Motor Thermistor 132
Wiring for Regeneration 132
Wiring Configuration for a Relay Set-up with Smart Logic Control 133
Wiring Configuration: Mechanical Brake Control 134
Wiring Configuration for the Encoder 135
Wiring Configuration for Torque and Stop Limit 135
Maintenance, Diagnostics, and Troubleshooting 137
Maintenance and Service 137
Disposal 137
Status Messages 137
Warnings and Alarms 140
Troubleshooting 158
Specifications 161
Electrical Data 161
Electrical Data, 380–500 V AC 161
Electrical Data, 525–690 V AC 166
Mains Supply 171
Motor Output and Motor Data 171
Motor Output (U, V, W) 171
Torque Characteristics 172
Ambient Conditions 172
Motor and Control Cables 172
Control Input/Output and Control Data 173
Control Card, USB Serial Communication 173
STO Terminal XD2.19 (Terminal XD2.19 is Fixed PNP Logic) 173
Control Card, 24 V DC Output 173
Control Card, 10 V DC Output 173
Digital Outputs 174
Digital Inputs 174
Pulse/Encoder Inputs 174
Control Characteristics 175
Relay Outputs 175
Analog Output 176
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Contents
VLT® AutomationDrive FC 302
Operating Guide

10.6.11
10.6.12
10.6.13
10.7
10.7.1
10.7.2
10.7.3
10.7.4
10.8
10.8.1
10.8.2
10.8.3
10.8.4
10.8.5
10.9
10.9.1
10.9.2
10.9.3
10.9.4
10.9.5
10.10
10.11
11
11.1
11.2
11.3
11.4
11.5
11.6
11.6.1
11.6.2
11.6.3
11.6.4
11.6.5
11.6.6
11.6.7
11.6.8
Analog Inputs 176
Control Card, RS485 Serial Communication 176
Control Card Performance 176
Filter Specifications 177
Passive Harmonic Filter Specifications 177
Line Reactor Specifications 177
dU/dt Filter Specifications 178
Sine-wave Filter Specifications 178
Fuses, Circuit Breakers, and Switches 179
Panel Fuses 180
Contactor Switches 181
Fusible Disconnect Switches 182
Non-fusible Disconnect Switches 183
Molded-case Circuit Breakers 184
Enclosure Dimensions 185
Pedestal Dimensions 185
D9h Enclosed Drive Exterior Dimensions 186
D10h Enclosed Drive Exterior Dimensions 186
E5h Enclosed Drive Exterior Dimensions 187
E6h Enclosed Drive Exterior Dimensions 188
Enclosure Airflow 189
Fastener Torque Ratings 189
Appendix 190
Conventions 190
Abbreviations 190
International/North American Default Parameter Settings 192
Required Parameter Settings for Drive Options 193
Block Diagrams 194
Input Power Option Losses 197
Contactor Losses 197
Fusible Disconnect Losses 198
Non-fusible Disconnect Losses 199
Molded-case Circuit Breaker (MCCB) Losses 200
Passive Harmonic Filter (PHF) Losses 201
Line Reactor Losses 202
dU/dt Filter Losses 203
Sine-wave Filter Losses 204
AQ262139143212en-000301/130R0879 | 7Danfoss A/S © 2021.10
Contents
VLT® AutomationDrive FC 302
Operating Guide

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1 Introduction
1.1 Purpose of this Operating Guide
This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified
personnel.
Read and follow the instructions to use the drive safely and professionally.
Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive.
VLT®is a registered trademark for Danfoss A/S.
1.2 Additional Resources
Other resources are available to understand advanced drive functions and programming.
The Programming Guide provides detailed information on the LCP, menu system, parameters, and troubleshooting with alarms
and warnings.
The Design Guide provides detailed information about capabilities and functionality to design motor control systems.
The Safe Torque Off Operating Guide provides detailed specifications, requirements, and installation instructions for the Safe
Torque Off function.
Supplementary publications and manuals are available from Danfoss, see www.danfoss.com.
1.3 Manual Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
The original language of this manual is English.
Table 1: Manual and Software Version
Version
Remarks
Software version
AQ262139143212 - 0301
Updated split shipment content, added CE certification, added addl sine wave
and line reactor power loss tables.
8.43
MG80F1xx
First version
8.23
1.4 Approvals and Certifications
The following list is a selection of possible type approvals and certifications for Danfoss drives:
089
The specific approvals and certification for the enclosed drive or drive module are on the nameplate of the drive. For more informa-
tion, contact the local Danfoss office or partner.
AQ262139143212en-000301 / 130R08798 | Danfoss A/S © 2021.10
Introduction
VLT® AutomationDrive FC 302
Operating Guide

1.
2.
3.
4.
a.
b.
5.
Thermal memory retention requirement
The enclosed drive is UL listed per UL508A and CSA 14 standards. The drive module in the enclosed drive system complies with UL
508C or UL 61800-5-1 thermal memory retention requirements. For more information on UL 508C thermal memory retention re-
quirements, refer to the Motor Thermal Protection section in the product-specific Design Guide.
NOTICE
OUTPUT FREQUENCY LIMIT
Due to export control regulations, the output frequency of the enclosed drive (with no output filters) is limited to 590 Hz. For
demands exceeding 590 Hz, contact Danfoss. For enclosed drives with output filters, the maximum output frequency is limited to
60 Hz without derating and to 100/120 Hz with derating.
ADN-compliance
For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by In-
land Waterways (ADN), refer to section ADN-compliant Installation in the product-specific Design Guide.
1.5 Finding the Declaration of Conformity Certificate
Open a web browser and enter https://www.danfoss.com/en/service-and-support/documentation/.
Click Certificates & declarations.
Use the Search field to search for PLV*.
The system provides a list of the search results.
Filter the search results be entering the following criteria.
Business unit = Drives
Documents/Document types = Certificate
Scroll down until you find the PLV XXX titled certificate for the specific product segment, such as PLV 302 EU Declaration.
Double click the link to the open the certificate. For an example, see 1.6 Declaration of Conformity Certificate.
AQ262139143212en-000301 / 130R0879 | 9Danfoss A/S © 2021.10
Introduction
VLT® AutomationDrive FC 302
Operating Guide

1.6 Declaration of Conformity Certificate
AQ262139143212en-000301 / 130R087910 | Danfoss A/S © 2021.10
Introduction
VLT® AutomationDrive FC 302
Operating Guide

AQ262139143212en-000301 / 130R0879 | 11Danfoss A/S © 2021.10
Introduction
VLT® AutomationDrive FC 302
Operating Guide

AQ262139143212en-000301 / 130R087912 | Danfoss A/S © 2021.10
Introduction
VLT® AutomationDrive FC 302
Operating Guide

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Introduction
VLT® AutomationDrive FC 302
Operating Guide

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2 Safety
2.1 Safety Symbols
The following symbols are used in this manual:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
2.2 Qualified Personnel
To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, as-
semble, install, program, commission, maintain, and decommission this equipment.
Persons with proven skills:
Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably
experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.
Are familiar with the basic regulations concerning health and safety/accident prevention.
Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in
the Operating Guide.
Have good knowledge of the generic and specialist standards applicable to the specific application.
AQ262139143212en-000301 / 130R087914 | Danfoss A/S © 2021.10
Safety
VLT® AutomationDrive FC 302
Operating Guide

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2.3 Safety Precautions
WARNING
LACK OF SAFETY AWARENESS
This document gives important information on how to prevent injury and damage to the equipment or the system. Ignoring
them can lead to death, serious injury, or severe damage to the equipment.
Make sure to fully understand the dangers and safety measures incurred in the application.
WARNING
DISCHARGE TIME
The drive contains DC-link capacitors and, if input filter options are present, extra capacitors and inductors. These components
can remain charged even when the drive is not powered. High voltage can be present even when the warning indicator lights are
off.
Failure to wait the specified time after power has been removed before performing service or repair work could result in death or
serious injury.
Stop the motor.
Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and
DC-link connections to other drives.
Wait for the capacitors to discharge fully. The minimum waiting time is specified both in the Discharge Time table and on the
nameplate on top of the drive.
Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors
are fully discharged.
Table 2: Discharge Time
Drive model
Minimum waiting time
D9h/D10h
20 minutes
E5h/E6h
40 minutes
WARNING
HIGH VOLTAGE
AC drives contain high voltage when connected to AC mains input. Failure to perform installation , start-up, and maintenance by
qualified personnel can result in death or serious injury.
Only qualified personnel must perform installation, start-up, and maintenance.
WARNING
UNINTENDED START
When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death,
serious injury, and equipment or property damage. The motor may start by activation of an external switch, a fieldbus command,
an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condi-
tion.
Press [Off] on the LCP before programming parameters.
Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended motor
start.
Check that the drive, motor, and any driven equipment are in operational readiness.
AQ262139143212en-000301 / 130R0879 | 15Danfoss A/S © 2021.10
Safety
VLT® AutomationDrive FC 302
Operating Guide

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WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.
Ensure the correct grounding of the equipment by a certified electrical installer.
WARNING
ROTATING SHAFTS
Contact with rotating shafts and electrical equipment can result in death or serious injury.
Ensure that only trained and qualified 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 drive can result in serious injury when the drive is not properly closed.
Ensure that all safety covers are in place and securely fastened before applying power.
AQ262139143212en-000301 / 130R087916 | Danfoss A/S © 2021.10
Safety
VLT® AutomationDrive FC 302
Operating Guide

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3 Product Overview
3.1 Intended Use
NOTICE
OUTPUT FREQUENCY LIMIT
Due to export control regulations, the output frequency of the drive is limited to 590 Hz. For demands exceeding 590 Hz, contact
Danfoss.
The enclosed drive is an electronic motor controller that converts AC mains input into a variable AC waveform output. The frequen-
cy and voltage of the output are regulated to control the motor speed or torque. Depending on the configuration, the drive can be
used in standalone applications or form part of a larger system or installation. The enclosed drive is designed to:
Regulate motor speed in response to system feedback or remote commands from external controllers.
Provide motor overload protection.
Monitor system and motor status.
Reduce harmonics and increase the power factor using the optional passive harmonic filter or line reactor.
Reduce motor acoustic noise and protect motor insulation with the optional output filters.
Reduce bearing current and shaft voltage with the optional common-mode filter.
Reduce high-frequency, electromagnetic noise in the motor cables with the optional dU/dt filter.
Provide sinusoidal output with optional sine-wave filter.
The enclosed drive is designed for residential, industrial, and commercial environments in accordance with local laws and stand-
ards. Do not use this drive in applications that are non-compliant with specified operating conditions and environments.
NOTICE
RADIO INTERFERENCE
In a residential environment, this product can cause radio interference.
Take supplementary mitigation measures.
3.2 What is an Enclosed Drive?
The enclosed drive is an IP21/54 (NEMA 1/12) enclosure surrounding an IP20 (Protected Chassis) drive to form the basis of the sys-
tem. There are 4 enclosed drive models with varying power ratings.
D9h model: 90–132 kW (100–200 hp).
D10h model: 160–315 kW (200–350 hp).
E5h model: 315–560 kW (400–600 hp).
E6h model: 450–710 kW (600–750 hp).
The enclosed drive is available with various power options and input and output filters to create a factory-built, custom drive. Some
options and filters result in extra cabinets attached to the left or right side of the drive cabinet. These optional cabinets are shown
with dotted lines, while the drive cabinet is shaded.
AQ262139143212en-000301 / 130R0879 | 17Danfoss A/S © 2021.10
Product Overview
VLT® AutomationDrive FC 302
Operating Guide

e30bu152.10
13
2
4
5
Illustration 1: Possible Configurations for a D9h Enclosed Drive
1
Input filter cabinet (passive harmonic filter or line re-
actor)
2
Drive cabinet
3
Sine-wave filter cabinet
4
Control compartment
5
Input power options(1)
1The D9h enclosure does not require an input power options cabinet – the input power options are placed in the drive cabinet.
e30bu067.10
1
24
5
3
Illustration 2: Possible Configurations for a D10h Enclosed Drive
1
Input filter cabinet (passive harmonic filter or line re-
actor)
2
Input power options cabinet(1)
3
Drive cabinet
4
Sine-wave filter cabinet
5
Control compartment
1If more than 1 input power option is ordered, the D10h enclosed drive requires an input power options cabinet. Otherwise, the single input power
option is placed below the control compartment in the drive cabinet.
AQ262139143212en-000301 / 130R087918 | Danfoss A/S © 2021.10
Product Overview
VLT® AutomationDrive FC 302
Operating Guide

e30bu068.10
1
2
4
3
6
5
3
Illustration 3: Possible Configurations for an E5h or E6h Enclosed Drive
1
Input filter cabinet (passive harmonic filter or line re-
actor)
2
Input power options cabinet
3
Drive cabinet
4
Sine-wave filter cabinet
5
Control compartment
6
dU/dt filter cabinet
AQ262139143212en-000301 / 130R0879 | 19Danfoss A/S © 2021.10
Product Overview
VLT® AutomationDrive FC 302
Operating Guide

3.3 Location of Options within an Enclosed Drive
e30bu177.11
1
2
3
4
5
6
7
8
9
10
Illustration 4: Visual Representation of a D9h Enclosure and the Locations of Available Options
1
Passive harmonic filter (PHF)
2
Line reactor
3
Non-fusible disconnect
4
Fusible disconnect
5
Molded-case circuit breaker (MCCB)
6
Mains contactor
7
dU/dt filter
8
Common-mode filter
9
Sine-wave filter
10
Drive module (varies in power rating)
AQ262139143212en-000301 / 130R087920 | Danfoss A/S © 2021.10
Product Overview
VLT® AutomationDrive FC 302
Operating Guide