Danfoss VLT AutomationDrive FC 300 User manual

FC 300 Operating Instructions
Contents
How to Read these Operating Instructions ........................ 3
Approvals ............................................................................................. 4
Symbols ............................................................................................... 5
Abbreviations ........................................................................................ 5
Safety Instructions and General Warning ........................... 7
High Voltage Warning ............................................................................. 7
Safety Instructions ................................................................................ 7
Avoid Unintended Start ........................................................................... 7
IT Mains ............................................................................................... 8
HowtoInstall .................................................................................. 11
How to Get Started ................................................................................ 11
Accessory Bag ....................................................................................... 12
Mechanical Installation ........................................................................... 12
Electrical Installation .............................................................................. 13
Connection to Mains and Earthing ............................................................ 13
Motor Connection .................................................................................. 15
Motor Cables ......................................................................................... 16
Fuses ................................................................................................... 17
Access to Control Terminals ..................................................................... 18
Electrical Installation, Control Terminals .................................................... 18
Control Terminals ................................................................................... 19
Electrical Installation, Control Cables ........................................................ 20
Switches S201, S202, and S801 .............................................................. 21
Tightening Torque .................................................................................. 21
Final Set-Up and Test ............................................................................. 22
Additional Connections ........................................................................... 23
24 V Back-up Option .............................................................................. 23
Load Sharing ......................................................................................... 24
Brake Connection Option ........................................................................ 24
Relay Connection ................................................................................... 25
Control of Mechanical Brake .................................................................... 25
Motor Thermal Protection ........................................................................ 26
HowtoProgramme ....................................................................... 27
The Local Control Panel .......................................................................... 27
How to Programme on the Local Control Panel ........................................... 27
Quick Transfer of Parameter Settings ........................................................ 29
Reset to Default Setting ......................................................................... 29
Adjust Display Contrast .......................................................................... 30
How to Connect a PC to the FC 300 .......................................................... 30
The FC 300 Software Dialogue ................................................................. 30
Connection Examples ............................................................................. 31
Start/Stop ............................................................................................ 31
Pulse Start/Stop .................................................................................... 31
Speed Up/Down .................................................................................... 31
Potentiometer reference ......................................................................... 31
Basic Parameters ................................................................................... 32
Parameter Lists ..................................................................................... 34
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FC 300 Operating Instructions
General Specifications .................................................................. 47
Troubleshooting .............................................................................. 53
Warnings/Alarm Messages ...................................................................... 53
Index ................................................................................................... 59
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FC 300 Operating Instructions
How to Read these Operating Instructions
How to Read these Operating Instructions
These Operating Instructions will help you get started, install, program, and troubleshoot your VLT®
AutomationDrive FC 300.
The FC 300 comes in two shaft performance levels. FC 301 ranges from scalar (U/f) to VVC+, and FC
302 ranges from scalar (U/f) to servo performance.
These Operating Instructions cover both FC 301 and FC 302. Where information covers both series, we refer
to FC 300. Otherwise, we refer specifically to either FC 301 or FC 302.
Chapter 1, How to Read these Operating
Instructions, introduces the manual and
informs you about the approvals, symbols, and
abbreviations used in this literature.
Page divider for How to Read these Operating Instructions.
Chapter 2, Safety Instructions and General
Warnings,entail
s instructions on how to handle
the FC 300 correctly.
Page divider for Safety Instructions and General Warnings.
Chapter 3, How to Install , guides you through
mechanical and technical installation.
Page divider for How to Install
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FC 300 Operating Instructions
How to Read these Operating Instructions
Chapter 4, How to Programme,showsyouhow
to operate and programme the FC 300 via the Local
Control Panel.
Page divider for How to Programme.
Chapter 5, General Specifications, entails
technical data about FC 300.
Page divider for General Specifications.
Chapter 6, Troubleshooting, assists you in solving
problems that may occur when using FC 300.
Page divider for Troubleshooting.
Available literature for FC 300
-The VLT®AutomationDrive FC 300 Operating Instructions provide the neccessary information for getting
the drive up and running.
-The VLT®AutomationDrive FC 300 Design Guide entails all technical information about the drive and
customer design and applications.
-The VLT®AutomationDrive FC 300 Profibus Operating Instructions provide the information required for
controlling, monitoring and programming the drive via a Profibus fieldbus.
-The VLT®AutomationDrive FC 300 DeviceNet Operating Instructions provide the information required for
controlling, monitoring and programming the drive via a DeviceNet fieldbus.
-The VLT®AutomationDrive FC 300 MCT 10 Operating Instructions provide information for installation and
use of the software on a PC.
-The VLT®AutomationDrive FC 300 IP21 / TYPE 1 Instruction provides information for installing the
IP21 / TYPE 1 option.
-The VLT®AutomationDrive FC 300 24 V DC Backup Instruction provides information for installing the 24
V DC Backup option.
Danfoss Drives technical literature is also available online at www.danfoss.com/drives.
Approvals
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FC 300 Operating Instructions
How to Read these Operating Instructions
Symbols
Symbols used in these Operating Instructions.
NB!:
Indicates something to be noted by the
reader.
Indicates a general warning.
Indicates a high-voltage warning.
Indicates default setting
Abbreviations
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit ILIM
Degrees celcius °C
Direct current DC
Electronic Thermistor Relay ETR
Frequency Converter FC
Gram g
Hertz Hz
Kilohertz kHz
Local Control Panel LCP
Meter m
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.
Rated Inverter Output Current IINV
Revolutions Per Minute RPM
Second s
SLC Smart Logic Control
To r q ue l im i t T LIM
Volts V
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FC 300 Operating Instructions
How to Read these Operating Instructions
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FC 300 Operating Instructions
Safety Instructions and General Warning
High Voltage Warning
The voltage of the FC 300 is dangerous whenever the converter is connected to mains. Incorrect
fitting of the motor or VLT may cause damage to the equipment, serious injury or death.
Consequently, it is essential to comply with the instructions in this manual as well as local and
national rules and safety regulations.
Safety Instructions
•Make sure the FC 300 is properly connected to earth.
•Do not remove mains plugs or motor plugs while the FC 300 is connected to mains.
•Protect users against supply voltage.
•Protect the motor against overloading according to 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 earth leakage current exceeds 3.5 mA.
•The [OFF] key is not a safety switch. It does not disconnect the FC 300 from mains.
Before commencing repair work
1. Disconnect FC 300 from mains
2. Disconnect DC bus terminals 88 and 89
3. Wait at least 4 minutes
4. Remove motor plugs
Avoid Unintended Start
While FC 300 is connected to mains, the motor can be started/stopped using digital commands, bus
commands, references or via the LCP.
•Disconnect the FC 300 from mains whenever personal safety considerations make it necessary to avoid
unintended start.
•To avoid unintended start, always activate the [OFF] key before changing parameters.
•Unless terminal 37 is turned off, an electronic fault, temporary overload, a fault in the mains supply, or
lost motor connection may cause a stopped motor to start.
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FC 300 Operating Instructions
Safety Instructions and General Warning
General warning
130BA024.10
Warning:
Touching the electrical parts may be fatal - even after the
equipment has been disconnected from mains.
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 back-up.
Using VLT AutomationDrive FC 300 (at and below 7.5 kW):
wait at least 4 minutes
Leakage Current
The earth leakage current from the frequency converter
exceeds 3.5 mA. To ensure that the earth cable has a good
mechanical connection to the earth connection (terminal 95),
the cable cross section must be at least 10 mm2/
6 AWG or 2 rated earth wires terminated separately.
Residual current device
This product can cause a D.C. current in the
protective conductor. Where a residual current
device (RCD) is used for extra protection, only
an RCD of Type B (time delayed) shall be used
on the supply side of this product. See also RCD
Application Note MN.90.GX.02.
Protective earthing of the FC 300 and the use
of RCD’s must always follow national and local
regulations.
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FC 300 Operating Instructions
Safety Instructions and General Warning
IT Mains
IT Mains
Do not connect 400 V units with RFI-filters to mains supplies
with a voltage between phase and earth of more than 440 V.
For IT mains and delta earth (grounded leg), mains voltage
may exceed 440 V between phase and earth.
Par. 14-50 RFI 1 can be used to disconnect the internal RFI capacities from the intermediate circuit.
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FC 300 Operating Instructions
Safety Instructions and General Warning
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FC 300 Operating Instructions
How to Install
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 corresponding Instructions.
How to get started
You can carry out a quick and EMC-correct
installation of the FC 300 by following the steps
described below.
Read the safety instructions before
installing the unit.
Diagram showing basic installation including mains, motor,
start/stop key, and potentiometer for speed adjustment.
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FC 300 Operating Instructions
How to Install
Accessory Bag
Find the following parts included in the FC 300
Accessory Bag.
1 + 2 only available in units with brake chopper.
Mechanical Installation
Mechanical dimensions
FramesizeB
0.25-2.2 kW
(200-240 V)
0.37-4.0 kW
(380-500 V)
FramesizeC
3.0-3.7 kW
(200-240 V)
5.5-7.5 kW
(380-500 V)
0.75-7.5 kW
(550-600 V)
Height
Height of back plate A268 mm 268 mm
Distance between
mounting holes a257 mm 257 mm
Width
Widthofbackplate B90 mm 130 mm
Distance between
mounting holes b70 mm 110 mm
Depth
From back plate to
front C220 mm 220 mm
With option A/B 220 mm 220 mm
Without options 205 mm 205 mm
Screw holes
c8.0 mm 8.0 mm
dø11mm ø11mm
eø 5.5 mm ø5.5mm
f6.5 mm 6.5 mm
Max weight 4.9 kg 6.6 kg
FC 300 IP20 - see accompanying table for
mechanical dimensions.
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FC 300 Operating Instructions
How to Install
1. Drill holes in accordance with the measurements given.
2. You must provide screws suitable for the surface on which you want to mount the FC 300. Retighten
all four screws.
For installation of IP21/TYPE 1/IP4X top and bottom - see the Option Guide enclosed with the FC 300.
FC 300 IP20 allows side-by-side installation. Because of the need for cooling, there must be a minimum of
100 mm free air passage above and below the FC 300.
Electrical Installation
Connection to Mains and Earthing
NB!:
The plug connector for power can be
removed.
1. Make sure the FC 300 is properly earthed.
Connect to earth connection (terminal 95). Use
screw from the accessory bag.
2. Place plug connector 91, 92, 93 from the
accessory bag onto the terminals labelled MAINS
at the bottom of FC 300.
3. Connect mains wires to the mains plug
connector.
The earth connection cable cross section
mustbeatleast10mm
2or 2 rated mains
wires terminated separately.
How to connect to mains and earthing.
NB!:
Check that mains voltage corresponds to
the mains voltage of the FC 300 name
plate.
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FC 300 Operating Instructions
How to Install
IT Mains
Do not connect 400 V units with RFI-filters to mains supplies
with a voltage between phase and earth of more than 440 V.
For IT mains and delta earth (grounded leg), mains voltage
may exceed 440 V between phase and earth.
Terminals for mains and earthing.
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FC 300 Operating Instructions
How to Install
Motor Connection
NB!:
Motor cable must be screened/armoured.
If an unscreened/unarmoured cable is
used, some EMC requirements are not
complied with. For more information, see EMC
specifications in the VLT AutomationDrive FC 300
Design Guide.
1. Fasten decoupling plate to the bottom of FC 300
with screws and washers from the accessory
bag.
2. Attach motor cable to terminals 96(U),97(V),
98 (W).
3. Connect to earth connection (terminal 99) on
decoupling plate with screws from the accessory
bag.
4. Insert plug connectors 96 (U), 97 (V), 98 (W)
and motor cable to terminals labelled MOTOR.
5. Fasten screened cable to decoupling plate with
screws and washers from the accessory bag.
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FC 300 Operating Instructions
How to Install
No. 96 97 98 Motor voltage 0-100%
U V W of mains voltage.
3 wires out of motor
U1 V1 W1
W2 U2 V2 6 wires out of motor, Delta-connected
U1 V1 W1 6 wires out of motor, Star-connected
U2, V2, W2 to be interconnected separately
No. 99 Earth connection
PE
All types of three-phase asynchronous standard
motors can be connected to the FC 300. Normally,
small motors are star-connected (230/400 V,
/Y). Large motors are normally delta-connected
(400/690 V, /Y). Refer to the motor name plate
for correct connection mode and voltage.
NB!:
In motors without phase insulation paper or other insulation reinforcement suitable for operation
with voltage supply (such as a frequency converter), fit an LC filter on the output of the FC 300.
Motor Cables
See chapter General Specifications for correct dimensioning of motor cable cross-section and length. Always
comply with national and local regulations on cable cross-section.
•Use a screened/armoured motor cable to comply with EMC emission specifications unless otherwise
stated for the RFI filter used.
•Keep the motor cable as short as possible to reduce the noise level and leakage currents.
•Connect the motor cable screen to the decoupling plate of the FC 300 and to the metal cabinet of
the motor.
•Make the screen connections with the largest possible surface area (cable clamp). This is done by using
the supplied installation devices in the FC 300.
•Avoid mounting with twisted screen ends (pigtails), which will spoil high frequency screening effects.
•If it is necessary to split the screen to install a motor isolator or motor relay, the screen must be
continued with the lowest possible high frequency impedance.
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FC 300 Operating Instructions
How to Install
Fuses
Branch circuit protection:
In order to protect the installation against electrical and fire hazard, all branch circuits in an
installation, switch gear, machines etc., must be shortcircuit and overcurrent protected according to the
national/international regulations.
Short circuit protection:
The frequency converter must be protected against short-circuit to avoid electrical or fire hazard. Danfoss
recommends using the fuses mentioned below to protect service personnel or other equipment in case of
an internal failure in the drive. The frequency converter provides full short circuit protection in case of a
short-circuit on the motor output.
Over current protection:
Provide overload protection to avoid fire hazard due to overheating of the cables in the installation. The
frequency converter is equipped with an internal over current protection that can be used for upstream
overload protection (UL-applications excluded). See par. 4-18. Moreover, fuses or circuit breakers can
be used to provide the over current protection in the installation. Over current protection must always
be carried out according to national regulations.
To comply with UL/cUL approvals, use pre-fuses according to the tables below.
200-240 V
VLT Bussmann Bussmann Bussmann SIBA Littel fuse Ferraz-
Shawmut
Ferraz-
Shawmut
Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1
K2-K75 KTN-R10 JKS-10 JJN-10 5017906-010 KLN-R10 ATM-R10 A2K-10R
1K1-2K2 KTN-R20 JKS-20 JJN-20 5017906-020 KLN-R20 ATM-R20 A2K-20R
3K0-3K7 KTN-R30 JKS-30 JJN-30 5012406-032 KLN-R30 ATM-R30 A2K-30R
380-500 V, 525-600 V
VLT Bussmann Bussmann Bussmann SIBA Littel fuse Ferraz-
Shawmut
Ferraz-
Shawmut
Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1
K37-1K5 KTS-R10 JKS-10 JJS-10 5017906-010 KLS-R10 ATM-R10 A6K-10R
2K2-4K0 KTS-R20 JKS-20 JJS-20 5017906-020 KLS-R20 ATM-R20 A6K-20R
5K5-7K5 KTS-R30 JKS-30 JJS-30 5012406-032 KLS-R30 ATM-R30 A6K-30R
KTS-fuses from Bussmann may substitute KTN for 240 V frequency converters.
FWH-fuses from Bussmann may substitute FWX for 240 V frequency converters.
KLSR fuses from LITTEL FUSE may substitute KLNR fuses for 240 V frequency converters.
L50S fuses from LITTEL FUSE may substitute L50S fuses for 240 V frequency converters.
A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V frequency converters.
A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V frequency converters.
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FC 300 Operating Instructions
How to Install
Non UL compliance
If UL/cUL is not to be complied with, we recommend
using the following fuses, which will ensure
compliance with EN50178:
In case of malfunction, not following the
recommendation may result in unnecessary damage
of the frequency converter. Fuses must be designed
for protection in a circuit capable of supplying a
maximum of 100,000 Arms (symmetrical), 500 V
maximum.
VLT Max. fuse size Voltage Type
K25-K75 10A1) 200-240 V type gG
1K1-2K2 20A1) 200-240 V type gG
3K0-3K7 32A1) 200-240 V type gG
K37-1K5 10A1) 380-500V type gG
2K2-4K0 20A1) 380-500V type gG
5K5-7K5 32A1) 380-500V type gG
1) Max. fuses - see national/international
regulations for selecting an applicable fuse size.
Access to Control Terminals
All terminals to the control cables are located
underneath the terminal cover on the front of the
frequency converter. Remove the terminal cover by
means of a screwdriver (see illustration).
Electrical Installation, Control Terminals
1. Mount terminals from the accessory bag to the
front of the FC 300.
2. Connect terminals 18, 27, and 37 to +24 V
(terminal 12/13) with the control cable.
Default settings:
18=start
27=coastinverse
37 = safe stop inverse
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FC 300 Operating Instructions
How to Install
NB!:
To mount the cable to the terminal:
1. Strip isolation of 1-10 mm
2. Insert a screw driver in the square hole.
3. Insert the cable in the adjacent circular hole.
4. Remove the screw driver. The cable is now
mounted to the terminal.
NB!:
To remove the cable from the terminal:
1. Insert a screw driver in the square hole.
2. Pull out the cable.
Control Terminals
Drawing reference numbers:
1. 10 pole plug digital I/O.
2. 3 pole plug RS485 Bus.
3. 6 pole analog I/O.
4. USB Connection.
Control terminals
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FC 300 Operating Instructions
How to Install
Electrical Installation, Control Cables
Diagram showing all electrical terminals. Terminal 37 is not included in FC 301.
Very long control cables and analogue signals may in rare cases and depending on installation result in 50/60
Hz earth loops due to noise from mains supply cables.
If this occurs, you may have to break the screen or insert a 100 nF capacitor between screen and chassis.
Common for the digital and analog in- and outputs must be connected separately to avoid common mode
currents from one group (i.e. the digital inputs) to affect other groups (i.e. the analog inputs).
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