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Danfoss FC 300, Design Manual

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Efficiency of the adjustable frequency drive (

η

 VLT

)

The load on the adjustable frequency drive has little effect on its efficiency. In general, the efficiency is the same at the rated motor frequency f

M,N

, even

if the motor supplies 100% of the rated shaft torque or only 75%, i.e., in the case of part loads.

This also means that the efficiency of the adjustable frequency drive does not change even if other U/f characteristics are chosen.
However, the U/f characteristics influence the efficiency of the motor.

The efficiency declines a little when the switching frequency is set to a value greater than 5 kHz. The efficiency will also be slightly reduced if the AC line
voltage is 480 V, or if the motor cable is longer than 98.43 ft [30 m].

Efficiency of the motor (

η

MOTOR 

)

The efficiency of a motor connected to the adjustable frequency drive depends on magnetizing level. In general, the efficiency is just as good as with
line operation. The efficiency of the motor depends on the type of motor.

In the range of 75–100% of the rated torque, the efficiency of the motor is practically constant, both when it is controlled by the adjustable frequency
drive, and when it runs directly on line power.

In small motors, the influence from the U/f characteristic on efficiency is marginal. However, in motors from 15 hp [11 kW] and up, the advantages are
significant.

In general, the switching frequency does not affect the efficiency of small motors. The efficiency of motors from 15 hp [11 kW] and up improves by 1–
2%. This is because the sine shape of the motor current is almost perfect at high switching frequency.

Efficiency of the system (

η

SYSTEM

)

To calculate the system efficiency, the efficiency of the adjustable frequency drive (

η

VLT

) is multiplied by the efficiency of the motor (

η

MOTOR

):

η

SYSTEM

) = 

η

 VLT

 x 

η

MOTOR

Example showing typical trends in the range 0–125 hp [0–90 kW]

Calculate the efficiency of the system at different loads based on the graph below. The factor in this graph must be multiplied with the specific efficiency
factor listed in the specification tables:

Figure 4.1: The above example shows the efficiency of a 75 hp [55 kW], 380–480 V AC adjustable frequency drive at 25% load at 25 Hz.
The graph is showing 0.97 - rated efficiency for a 75 hp [55 kW] adjustable frequency drive is 0.98. The actual efficiency is then:
0.97x0.98=0.95.

FC 300 Design Guide

4 AutomationDrive FC 300 Selection

MG.33.BC.22 - VLT

®

 is a registered Danfoss trademark

4-25

  4

Summary of Contents for FC 300

Page 1: ...h Motor Feedback 3 8 Internal Current Control in VVCplus Mode 3 8 Local Hand On and Remote Auto On Control 3 8 Reference Limits 3 11 Scaling of Preset References and Bus References 3 11 Scaling of Analog and Pulse References and Feedback 3 12 Dead Band Around Zero 3 12 Speed PID Control 3 15 Process PID Control 3 18 Ziegler Nichols Tuning Method 3 22 EMC Test Results 3 24 PELV Protective Extra Low...

Page 2: ...tallation 7 1 Planning the Installation Site 7 1 Receiving the Adjustable Frequency Drive 7 1 Transportation and Unpacking 7 1 Lifting 7 2 Mechanical Dimensions 7 4 Mechanical Installation 7 11 Terminal Locations Frame size D 7 13 Terminal Locations Frame size E 7 15 Terminal Locations Frame size F 7 19 Cooling and Airflow 7 22 8 Electrical Installation 8 1 Connections Frame Sizes A B and C 8 1 Co...

Page 3: ... Application Examples 9 1 Encoder Connection 9 2 Encoder Direction 9 2 Closed loop Drive System 9 3 Programming of Torque Limit and Stop 9 3 Advanced Mechanical Brake Control for Hoisting Applications 9 4 Automatic Motor Adaptation AMA 9 5 Smart Logic Control Programming 9 5 SLC Application Example 9 6 MCB 112 PTC Thermistor Card 9 7 Torque Control Open loop 9 9 10 Options and Accessories 10 1 Mou...

Page 4: ... Power Options 10 24 Frame Size F Panel Options 10 24 11 RS 485 Installation and Set up 11 1 RS 485 Installation and Set up 11 1 Network Configuration 11 3 Adjustable frequency drive Protocol Message Framing Structure AutomationDrive FC 300 11 4 Examples 11 10 Modbus RTU Overview 11 11 Modbus RTU Message Framing Structure 11 13 How to Access Parameters 11 18 Danfoss FC Control Profile 11 19 12 Ind...

Page 5: ...ons The VLT AutomationDrive Profibus Instruction Manual MG 33 CX YY provides the information required for controlling monitoring and program ming the drive via a Profibus serial communication bus The VLT AutomationDrive DeviceNet Instruction Manual MG 33 DX YY provides the information required for controlling monitoring and pro gramming the drive via a DeviceNet serial communication bus X Revision...

Page 6: ...ive terminals Regen Second s Synchronous Motor Speed ns Torque limit TLIM Volt V The maximum output current IVLT MAX The rated output current supplied by the adjustable frequency drive IVLT N 1 1 4 Definitions Adjustable frequency drive Coast The motor shaft is in free mode No torque on motor IVLT MAX The maximum output current IVLT N The rated output current supplied by the adjustable frequency d...

Page 7: ...arameters 4 12 4 13 and 4 19 fMIN The minimum motor frequency from adjustable frequency drive Default 0 Hz fM N The rated motor frequency nameplate data IM The motor current IM N The rated motor current nameplate data nM N The rated motor speed nameplate data ns Synchronous motor speed ns 2 par 1 23 60 s par 1 39 PM N The rated motor power nameplate data TM N The rated torque motor UM The instanta...

Page 8: ...neous Analog Inputs The analog inputs are used for controlling various functions of the adjustable frequency drive There are two types of analog inputs Current input 0 20 mA and 4 20 mA Voltage input 0 10 V DC AutomationDrive FC 301 Voltage input 10 10 V DC AutomationDrive FC 302 Analog Outputs The analog outputs can supply a signal of 0 20 mA 4 20 mA Automatic Motor Adaptation AMA AMA algorithm d...

Page 9: ...ameters are not activated until you enter OK on the LCP Process PID The PID regulator maintains the desired speed pressure temperature etc by adjusting the output frequency to match the varying load PCD Process Data Pulse Input Incremental Encoder An external digital sensor used for feedback information of motor speed and direction Encoders are used for high speed accuracy feedback and in high dyn...

Page 10: ...ing reset or in some cases by being programmed to reset automatically Trip may not be used for personal safety VT Characteristics Variable torque characteristics used for pumps and fans VVCplus If compared with standard voltage frequency ratio control Voltage Vector Control VVCplus improves the dynamics and the stability both when the speed reference is changed and in relation to the load torque 6...

Page 11: ...disconnected and that the necessary time has elapsed before commencing repair work Warning against unintended start 1 The motor can be brought to a stop by means of digital commands bus commands references or a local stop while the adjustable frequency drive is connected to line power If personal safety considerations e g risk of personal injury caused by contact with moving machine parts followin...

Page 12: ...s Protection mode is not usable because the drive will usually not be able to leave this mode again and therefore it will extend the time before activating the brake which is not recommended Protection mode can be disabled by setting par 14 26 Trip Delay at Inverter Fault to zero which means that the drive will trip immediately if one of the hardware limits is exceeded NOTE It is recommended to di...

Page 13: ...beled in accordance with the Low voltage Directive of January 1 1997 The directive applies to all electrical equipment and appliances used in the 50 1000 V AC and the 75 1500 V DC voltage ranges Danfoss CE labels in accordance with the directive and issues a declaration of conformity upon request The EMC directive 89 336 EEC EMC is short for electromagnetic compatibility The presence of electromag...

Page 14: ...by using CE labeled components or by testing the EMC of the system If he chooses to use only CE labeled components he does not have to test the entire system 2 4 3 Danfoss Adjustable Frequency Drive and CE Labeling CE labeling is a positive feature when used for its original purpose i e to facilitate trade within the EU and EFTA However CE labeling may cover many different specifications Thus you ...

Page 15: ...chanical electrical or thermal failure in the adjustable frequency drive A typical indicator of excessive levels of airborne particles is the presence of dust particles around the adjustable frequency drive fan In very dusty environments use equipment with enclosure rating IP 54 55 or a cabinet for IP 00 IP 20 TYPE 1 equipment In environments with high temperatures and humidity corrosive gases suc...

Page 16: ... bolted to walls or floors IEC EN 60068 2 6 Vibration sinusoidal 1970 IEC EN 60068 2 64 Vibration broad band random NOTE D and E frames have a stainless steel backchannel option to provide additional protection in aggressive environments Proper ventilation is still required for the internal components of the drive Contact factory for additional information 2 Safety and Conformity FC 300 Design Gui...

Page 17: ...0 25 3 7 kW 200 240 V 0 5 10 hp 0 37 7 5 kW 380 480 500 V 1 10 hp 0 75 7 5 kW 525 600 V Frame size B1 B2 B3 B4 Enclosure protection IP 21 55 66 21 55 66 20 20 NEMA Type 1 Type 12 Type 1 Type 12 Chassis Chassis High overload rated power 160 over load torque 7 5 10 hp 5 5 7 5 kW 200 240 V 15 20 hp 11 15 kW 380 480 500 V 15 20 hp 11 15 kW 525 600 V 15 hp 11 kW 200 250 V 25 30 hp 18 5 22 kW 380 480 50...

Page 18: ...hp 30 45 kW 525 600 V 40 50 hp 30 37 kW 200 240 V 75 100 hp 55 75 kW 380 480 500 V 75 125 hp 55 90 kW 525 600 V 40 100 hp 30 75 kW 525 690 V 25 30 hp 18 5 22 kW 200 240 V 50 60 hp 37 45 kW 380 480 500 V 50 60 hp 37 45 kW 525 600 V 40 50 hp 30 37 kW 200 240 V 75 100 hp 55 75 kW 380 480 500 V 75 125 hp 55 90 kW 525 600 V 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3 2 MG 33 BC 22 VL...

Page 19: ...overload rated power 160 over load torque 350 550 hp 250 400 kW at 400 V 380 500 V 500 750 hp 355 560 kW at 690 V 525 690 V 350 550 hp 250 400 kW at 400 V 380 500 V 500 750 hp 355 560 kW at 690 V 525 690 V 600 850 hp 450 630 kW at 400 V 380 500 V 850 1075 hp 630 800 kW at 690 V 525 690 V 950 1075 hp 710 800 kW at 400 V 380 500 V 1200 1350 hp 900 1000 kW at 690 V 525 690 V NOTE The F frames have fo...

Page 20: ...ications where the torque on motor output shaft is controlling the application as tension control Torque control can be selected in par 1 00 either in VVC open loop 4 or flux control closed loop with motor speed feedback 2 Torque setting is done by setting an analog digital or bus controlled reference The max speed limit factor is set in par 4 21 When running torque control it is recommended to ma...

Page 21: ...DC link and the desaturation protection with feedback from the 3 lower IGBTs and the brake Figure 3 1 AutomationDrive FC 301 AutomationDrive FC 302 is a high performance adjustable frequency drive for demanding applications The adjustable frequency drive can handle various kinds of motor control principles such as U f special motor mode VVCplus or Flux Vector motor control AutomationDrive FC 302 i...

Page 22: ... maximum frequency limit If par 1 00 Configuration Mode is set to Speed closed loop 1 the resulting reference will be passed from the ramp limitation and speed limitation into a speed PID control The Speed PID control parameters are located in the par group 7 0 The resulting reference from the speed PID control is sent to the motor control limited by the frequency limit Select Process 3 in par 1 0...

Page 23: ...e ramp and speed limitations as determined by the parameter settings indicated An estimated speed feedback is generated to the speed PID to control the output frequency The Speed PID must be set with its P I and D parameters par group 7 0 Select Process 3 in par 1 00 Configuration Mode to use the process PID control for closed loop control of e g speed or pressure in the controlled application The...

Page 24: ...control of e g speed or a process variable in the controlled application 3 2 7 Internal Current Control in VVCplus Mode The adjustable frequency drive features an integral current limit control which is activated when the motor current and thus the torque is higher than the torque limits set in par 4 16 Torque Limit Motor Mode par 4 17 Torque Limit Generator Mode and par 4 18 Current Limit When th...

Page 25: ...Auto 0 default the reference site will depend on which mode is active Hand Mode or Auto Mode Hand On Auto LCP Keys par 3 13 Reference Site Active Reference Hand Linked to Hand Auto Local Hand Off Linked to Hand Auto Local Auto Linked to Hand Auto Remote Auto Off Linked to Hand Auto Remote All keys Local Local All keys Remote Remote The table shows under which conditions either the local reference ...

Page 26: ...ternally selected references comprising any combination determined by the setting of par 3 15 Reference Resource 1 par 3 16 Reference Resource 2 and par 3 17 Reference Resource 3 of a fixed preset reference par 3 10 Preset Reference variable analog references variable digital pulse references and various serial bus references in whatever unit the adjustable frequency drive is controlled Hz RPM Nm ...

Page 27: ...ference cannot be set to less than 0 unless the par 1 00 Configuration Mode is set to 3 Process In this case the subsequent relations between the resulting reference after clamp ing and the sum of all references are as shown to the right 3 3 2 Scaling of Preset References and Bus References Preset references are scaled according to the following rules When par 3 00 Reference Range 0 Min Max 0 refe...

Page 28: ... 5 55 Term 33 Low Frequency Hz P2 Maximum input value Maximum reference value Maximum reference value par 6 15 Ter minal 53 High Ref Feedb Value par 6 15 Termi nal 53 High Ref Feedb Value par 6 25 Ter minal 54 High Ref Feedb Value par 6 25 Termi nal 54 High Ref Feedb Value par 5 53 Term 29 High Ref Feedb Value par 5 58 Term 33 High Ref Feedb Val ue Maximum input value par 6 11 Ter minal 53 High Vo...

Page 29: ...example will result in a 1 V to 1 V dead band in this case provided that the end point P2 is placed in either quadrant 1 or quadrant 4 Case 1 Positive Reference with Dead band Digital input to trigger reverse This case shows how a reference input with limits inside Min Max limits clamps FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 MG 33 BC 22 VLT is a registered Danfoss trademark 3...

Page 30: ...e input with limits outside Max Max limits clamps to the input s low and high limits before addition to external reference And how the External reference is clamped to Max Max by the Reference algorithm 3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3 14 MG 33 BC 22 VLT is a registered Danfoss trademark 3 ...

Page 31: ...CTIVE 2 Torque N A N A N A Not Active 3 Process Not Active ACTIVE ACTIVE Note N A means that the specific mode is not available at all Not Active means that the specific mode is available but the Speed Control is not active in that mode Note The Speed Control PID will work under the default parameter setting but tuning the parameters is highly recommended to optimize the motor control performance ...

Page 32: ...rentiation time for slow changes and a suitably quick gain for quick changes Par 7 06 Speed PID Lowpass Filter Time A low pass filter that dampens oscillations on the feedback signal and improves steady state performance However a filter time that is too long will deteriorate the dynamic performance of the speed PID control Practical settings of 7 06 taken from the number of pulses per revolution ...

Page 33: ...ault 1500 RPM default Check that the ramp settings are within drive capabilities and allowed application operating specifications par 3 41 Ramp 1 Ramp up Time par 3 42 Ramp 1 Ramp down Time default setting default setting Set acceptable limits for the motor speed and frequency par 4 11 Motor Speed Low Limit RPM par 4 13 Motor Speed High Limit RPM par 4 19 Max Out put Frequency 0 RPM default 1500 R...

Page 34: ... resolution and the feedback filter time but other factors in the application might limit the par 7 02 Speed PID Proportional Gain to a lower value To minimize the overshoot par 7 03 Speed PID Integral Time could be set to approx 2 5 s varies with the application Par 7 04 Speed PID Differentiation Time should be set to 0 until everything else is tuned If necessary finish the tuning by experimentin...

Page 35: ...value that is too small may lead to oscillations Par 7 35 Process PID Differentiation Time Provides a gain proportional to the rate of change of the feedback A setting of zero disables the differentiator Par 7 36 Process PID Differentiation Gain Limit If there are quick changes in reference or feedback in a given application which means that the error changes swiftly the differentiator may soon be...

Page 36: ...increased as well so as to gen erate more air When the temperature drops the speed is reduced The transmitter used is a temperature sensor with a working range of 14 104 F 10 40 C 4 20 mA Max speed 300 1 500 RPM NOTE The example shows a two wire transmitter 1 Start Stop via switch connected to terminal 18 2 Temperature reference via potentiometer 23 95 F 5 35 C 0 10 VDC connected to terminal 53 3 ...

Page 37: ...Voltage V or milli Amps I NOTE Switches are sensitive Make a power cycling keeping default setting of V 5 Scale analog inputs used for reference and feedback Set terminal 53 low voltage Set terminal 53 high voltage Set terminal 54 low feedback value Set terminal 54 high feedback value Set feedback source 6 10 6 11 6 24 6 25 7 20 0 V 10 V 23 F 5 C 95 F 35 C 2 Analog input 54 6 Basic PID settings Pr...

Page 38: ...ultimate gain The period of the oscillation Pu called the ultimate period is determined as shown in Figure 1 Figure 3 4 Figure 1 Marginally stable system Pu should be measured when the amplitude of oscillation is quite small Then we back off from this gain again as shown in Table 1 Ku is the gain at which the oscillation is obtained Type of Control Proportional Gain Integral Time Differentiation T...

Page 39: ...magnetic field I4 from the shielded motor cable according to the below figure The shield reduces the radiated interference but increases the low frequency interference in the line power supply The motor cable shield must be connected to the adjustable frequency drive enclosure as well as on the motor enclosure This is best done by using integrated shield clamps so as to avoid twisted shield ends p...

Page 40: ...ive FC 302 0 50 hp 0 37 kW 200 240 V 164 ft 50 m 492 ft 150 m 492 ft 150 m No Yes 0 100 hp 0 75 kW 380 480 V 164 ft 50 m 492 ft 150 m 492 ft 150 m No Yes H2 AutomationDrive FC 301 0 5 hp 0 3 7 kW 200 240 V No No 5 m No No AutomationDrive FC 302 7 5 50 hp 5 5 37 kW 200 240 V No No 82 in 25 m No No 0 10 hp 0 7 5 kW 380 480 V No No 5 m No No 15 100 hp 11 75 kW 380 480 V No No 82 in 25 m No No 125 107...

Page 41: ... An EMC plan should be made When the generic emission standards are used the adjustable frequency drives are required to comply with the following limits Environment Generic standard Conducted emission requirement ac cording to the limits given in EN55011 First environment home and office EN IEC61000 6 3 Emission standard for residential commercial and light industrial environments Class B Second ...

Page 42: ...mmunity 3 6 1 PELV Protective Extra Low Voltage PELV offers protection by way of extra low voltage Protection against electric shock is ensured when the electrical supply is of the PELV type and the installation is made as described in local national regulations on PELV supplies All control terminals and relay terminals 01 03 04 06 comply with PELV Protective Extra Low Voltage Does not apply to gr...

Page 43: ... allowed only if indicated on the nameplate for the specific unit Leakage Current The ground leakage current from the adjustable frequency drive exceeds 3 5 mA To ensure that the ground cable has a good me chanical connection to the ground connection terminal 95 the cable cross section must be at least 3 9 in2 10 mm2 or two rated ground wires terminated separately Residual Current Device This prod...

Page 44: ...ns in the motor The AC brake function cannot be used in applications with high cycling frequency since this will overheat the motor 2 10 2 DC brake An over modulated DC current added to the AC current works as an eddy current brake 2 02 0 s 3 8 3 Selection of Brake Resistor To handle higher demands by generatoric braking a brake resistor is necessary Using a brake resistor ensures that the energy ...

Page 45: ...vel 1 675 hp 500 kW at 86 braking torque 750 hp 560 kW at 76 braking torque 2 675 hp 500 kW at 130 braking torque 750 hp 560 kW at 115 braking torque Danfoss offers brake resistors with duty cycle of 5 10 and 40 If a 10 duty cycle is applied the brake resistors are able to absorb braking energy for 10 of the cycle time The remaining 90 of the cycle time will be used on dissipating excess heat NOTE...

Page 46: ...Danfoss brake resistors are used Danfoss recommends the brake resistance Rrec i e one that guarantees that the adjustable frequency drive is able to brake at the highest braking torque Mbr of 160 The formula can be written as Rrec Ω Udc 2 x 100 Pmotor x Mbr x VLT x motor ηmotor is typically at 0 90 ηVLT is typically at 0 98 For 200 V 480 V 500 V and 600 V adjustable frequency drives Rrec at 160 br...

Page 47: ...d as an alternative brake function in par 2 17 Over voltage Control This function is active for all units The function ensures that a trip can be avoided if the DC link voltage increases This is done by increasing the output frequency to limit the voltage from the DC link It is a very useful function e g if the ramp down time is too short since tripping of the adjustable frequency drive is avoided...

Page 48: ...lications make sure that the torque limits in par 4 16 Torque Limit Motor Mode and par 4 17 Torque Limit Generator Mode are set lower than the current limit in par 4 18 Current Limit Also it is recommendable to set par 14 25 Trip Delay at Torque Limit to 0 par 14 26 Trip Delay at Inverter Fault to 0 and par 14 10 Line Failure to 3 Coasting 3 9 2 Hoist Mechanical Brake The VLT AutomationDrive featu...

Page 49: ...ad is released In order to react as quickly as possible on the load step that follows upon brake release the speed PID control can be boosted by increasing the proportional gain Figure 3 6 Brake release sequence for hoist mechanical brake control I Activate brake delay The adjustable frequency drive starts again from the mechanical brake engaged position II Stop delay When the time between success...

Page 50: ... in each of the three motor phases or in the DC link A short circuit between two output phases will cause an overcurrent in the inverter The inverter will be turned off individually when the short circuit current exceeds the permitted value Alarm 16 Trip Lock To protect the adjustable frequency drive against a short circuit at the load sharing and brake outputs please see the design guidelines Swi...

Page 51: ...oad determine how long it takes for the inverter to coast Static Overload in VVCplus Mode When the adjustable frequency drive is overloaded the torque limit in par 4 16 Torque Limit Motor Mode par 4 17 Torque Limit Generator Mode is reached the controls reduces the output frequency to reduce the load If the overload is excessive a current may occur that makes the adjustable frequency drive cut out...

Page 52: ...R Electronic Thermal relay The adjustable frequency drive ETR function measures actual current speed and time to calculate motor temperature and protect the motor from being overheated Warning or trip An external thermistor input is also available ETR is an electronic feature that simulates a bimetal relay based on internal measurements The characteristic is shown in the following figure Figure 3 ...

Page 53: ...y is called Safe Stop Prior to integration and use of 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 levels are appropriate and sufficient After installing safe stop a commissioning test as specified in section Safe Stop Commissioning Test of the Design Guide must be performed A pass...

Page 54: ...ands for operation made on a safety related system is greater than one per year or greater than twice the frequency of testing This value shall be considered if the safety device is operated in high demand more often than once per year or continuous mode of operation where the frequency of demands for operation made on a safety related system is greater than one per year or greater than twice the ...

Page 55: ...FC 300 Design Guide 3 Introduction to AutomationDrive FC 300 MG 33 BC 22 VLT is a registered Danfoss trademark 3 39 3 ...

Page 56: ...3 Introduction to AutomationDrive FC 300 FC 300 Design Guide 3 40 MG 33 BC 22 VLT is a registered Danfoss trademark 3 ...

Page 57: ...ctive contamination is provided Such a protection is ach ieved by using AutomationDrive FC 302 with protection class IP54 or higher If AutomationDrive FC 302 with lower protection or AutomationDrive FC 301 A1 which is only delivered with an IP21 enclosure are used then an operating environment cor responding to the inside of an IP54 encapsulation must be en sured If there is a risk of conductive c...

Page 58: ...havior This means that in order to terminate the safe stop and resume normal operation the 24 V DC must first be reapplied to Terminal 37 Subsequently a reset signal must be given via Bus Digital I O or Reset key The Safe Stop function can be set to automatic restart behavior by setting the value of par 5 19 Terminal 37 Safe Stop from default value 1 to value 3 If an MCB112 option is connected to ...

Page 59: ...ctions are for when only the MCB 112 uses the safe stop If selections 4 or 5 are chosen by mistake and the external safety device triggers safe stop the adjustable frequency drive will react with an alarm Dangerous Failure A72 and coast the drive safely without automatic restart Selections 6 9 must be chosen for the combination of external safety device and MCB 112 NOTE Note that selection 7 and 8...

Page 60: ...Safe Stop and MCB112 where par 5 19 Terminal 37 Safe Stop is set to 7 or 8 1 Remove the 24 V DC voltage supply to terminal 37 by the interrupt device while the motor is driven by the AutomationDrive FC 302 i e line power supply is not interrupted The test step is passed if the motor reacts with a coast and the mechanical brake if connected is activated and if an LCP is mounted the warning Safe Sto...

Page 61: ...A1 IP20 2 7 2 7 2 7 2 7 2 7 2 7 A5 IP55 66 13 5 13 5 13 5 13 5 13 5 13 5 13 5 13 5 13 5 Efficiency 4 0 94 0 94 0 95 0 95 0 96 0 96 0 96 0 96 0 96 0 34 5 hp 0 25 3 7 kW only available as 160 high overload Line Power Supply 3 x 200 240 V AC AutomationDrive FC 301 AutomationDrive FC 302 P5K5 P7K5 P11K High Normal Load HO NO HO NO HO NO Typical Shaft Output kW 5 5 7 5 7 5 11 11 15 Enclosure IP20 B3 B3...

Page 62: ... current Continuous 3 x 200 240 V A 54 68 68 80 80 104 104 130 130 154 Intermittent 60 sec overload 3 x 200 240 V A 81 74 8 102 88 120 114 156 143 195 169 Max cable size IP20 mm2 AWG 2 35 2 90 3 0 90 3 0 120 4 0 120 4 0 Max cable size IP 21 55 66 mm2 AWG 2 90 3 0 90 3 0 90 3 0 120 4 0 120 4 0 Max cable size with line power disconnect 35 2 70 3 0 150 MCM 300 Max electrical fuses A 1 125 125 160 200...

Page 63: ...kVA 0 9 1 3 1 7 2 1 2 8 3 9 5 0 6 9 9 0 11 0 Continuous kVA 460 V AC kVA 0 9 1 3 1 7 2 4 2 7 3 8 5 0 6 5 8 8 11 6 Max cable size line power motor brake AWG 2 mm2 24 10 AWG 0 00031 0 0062 in2 0 2 4 mm2 24 10 AWG 0 00031 0 0062 in2 0 2 4 mm2 Max input current Continuous 3 x 380 440 V A 1 2 1 6 2 2 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermittent 3 x 380 440 V A 1 9 2 6 3 5 4 3 5 9 8 0 10 4 14 4 18 7 23 0 ...

Page 64: ...2 2 22 2 26 26 30 5 30 5 42 3 Continuous kVA 460 V AC kVA 21 5 27 1 31 9 41 4 Max input current Continuous 3 x 380 440 V A 22 29 29 34 34 40 40 55 Intermittent 60 sec over load 3 x 380 440 V A 35 2 31 9 46 4 37 4 54 4 44 64 60 5 Continuous 3 x 441 500 V A 19 25 25 31 31 36 36 47 Intermittent 60 sec over load 3 x 441 500 V A 30 4 27 5 40 34 1 49 6 39 6 57 6 51 7 Max cable size mm2 AWG 2 16 6 16 6 3...

Page 65: ...current Continuous 3 x 380 440 V A 55 66 66 82 82 96 96 133 133 161 Intermittent 60 sec overload 3 x 380 440 V A 82 5 72 6 99 90 2 123 106 144 146 200 177 Continuous 3 x 441 500 V A 47 59 59 73 73 95 95 118 118 145 Intermittent 60 sec overload 3 x 441 500 V A 70 5 64 9 88 5 80 3 110 105 143 130 177 160 Max cable size IP20 line power and motor mm2 AWG2 35 2 50 1 50 1 95 4 0 150 300 mcm Max cable si...

Page 66: ...191 191 241 241 288 288 353 Continuous KVA at 500 V KVA 139 165 165 208 208 262 262 313 313 384 Max input current Continuous at 400 V A 171 204 204 251 251 304 304 381 381 463 Continuous at 460 500 V A 154 183 183 231 231 291 291 348 348 427 Max cable size line power motor brake and load share mm2 AWG2 2 x 70 2 x 2 0 2 x 70 2 x 2 0 2 x 150 2 x 300 mcm 2 x 150 2 x 300 mcm 2 x 150 2 x 300 mcm Max ex...

Page 67: ...tinuous KVA at 500 V KVA 384 468 468 511 511 587 587 632 Max input current Continuous at 400 V A 472 590 590 647 647 733 684 787 Continuous at 460 500 V A 436 531 531 580 580 667 667 718 Max cable size line power motor and load share mm2 AWG2 4x240 4x500 mcm 4x240 4x500 mcm 4x240 4x500 mcm 4x240 4x500 mcm Max cable size brake mm2 AWG2 2 x 185 2 x 350 mcm 2 x 185 2 x 350 mcm 2 x 185 2 x 350 mcm 2 x...

Page 68: ...A 779 857 857 964 964 1090 1090 1227 1227 1422 1422 1675 Continuous at 460 500 V A 711 759 759 867 867 1022 1022 1129 1129 1344 1344 1490 Max cable size mo tor mm2 AWG2 8x150 8x300 mcm 12x150 12x300 mcm Max cable size line power F1 F2 mm2 AWG2 8x240 8x500 mcm Max cable size line power F3 F4 mm2 AWG2 8x456 8x900 mcm Max cable size load sharing mm2 AWG2 4x120 4x250 mcm Max cable size brake mm2 AWG2 ...

Page 69: ...A 1 7 2 5 2 8 3 9 5 0 6 1 9 0 11 0 Continuous kVA 575 V AC kVA 1 7 2 4 2 7 3 9 4 9 6 1 9 0 11 0 Max cable size line power motor brake AWG 2 mm2 24 10 AWG 0 00031 0 0062 in2 0 2 4 mm2 24 10 AWG 0 00031 0 0062 in2 0 2 4 mm2 Max input current Continuous 3 x 525 600 V A 1 7 2 4 2 7 4 1 5 2 5 8 8 6 10 4 Intermittent 3 x 525 600 V A 2 7 3 8 4 3 6 6 8 3 9 3 13 8 16 6 Max electrical fuses1 A 10 10 10 20 2...

Page 70: ...33 9 40 8 40 8 51 8 Max cable size IP20 line power motor load share and brake AWG 2 mm2 16 6 35 2 Max cable size IP21 55 66 line power motor load share and brake AWG 2 mm2 16 6 35 2 90 3 0 Max cable size with line pow er disconnect 16 6 35 2 Max input current Continuous at 550 V A 17 2 20 9 20 9 25 4 25 4 32 7 32 7 39 39 49 Intermittent at 550 V A 28 23 33 28 41 36 52 43 59 54 Continuous at 575 V ...

Page 71: ...0 line power motor AWG 2 mm2 50 1 95 4 0 150 300 mcm Max cable size IP20 load share brake AWG 2 mm2 50 1 95 4 0 Max cable size IP21 55 66 line power motor load share and brake AWG 2 mm2 90 3 0 120 4 0 Max cable size with line power disconnect 35 2 70 3 0 150 300 mcm Max input current Continuous at 550 V A 49 59 59 78 9 78 9 95 3 95 3 124 3 Intermittent at 550 V A 74 65 89 87 118 105 143 137 Contin...

Page 72: ...28 8 24 2 35 2 29 7 43 2 37 4 Continuous KVA at 550 V KVA 13 3 18 1 18 1 21 9 21 9 26 7 26 7 34 3 Continuous KVA at 575 V KVA 12 9 17 9 17 9 21 9 21 9 26 9 26 9 33 9 Continuous KVA at 690 V KVA 15 5 21 5 21 5 26 3 26 3 32 3 32 3 40 6 Max input current Continuous 3 x 525 690 V A 15 19 5 19 5 24 24 29 29 36 Intermittent 60 sec over load 3 x 525 690 V A 23 2 21 5 31 2 26 4 38 4 31 9 46 4 39 6 Max cab...

Page 73: ... 78 68 2 93 91 3 124 5 110 Continuous KVA at 550 V KVA 34 3 41 0 41 0 51 4 51 4 61 9 61 9 82 9 82 9 100 0 Continuous KVA at 575 V KVA 33 9 40 8 40 8 51 8 51 8 61 7 61 7 82 7 82 7 99 6 Continuous KVA at 690 V KVA 40 6 49 0 49 0 62 1 62 1 74 1 74 1 99 2 99 2 119 5 Max input current Continuous at 550 V A 36 49 49 59 59 71 71 87 87 99 Continuous at 575 V A 54 53 9 72 64 9 87 78 1 105 95 7 129 108 9 Ma...

Page 74: ...VA at 575 V KVA 46 54 54 73 73 86 86 108 108 130 Continuous KVA at 690 V KVA 55 65 65 87 87 103 103 129 129 157 Max input current Continuous at 550 V A 53 60 60 77 77 89 89 110 110 130 Continuous at 575 V A 51 58 58 74 74 85 85 106 106 124 Continuous at 690 V A 50 58 58 77 77 87 87 109 109 128 Max cable size line power motor load share and brake mm2 AWG 2x70 2x2 0 Max external electrical fuses A 1...

Page 75: ...9 Continuous KVA at 690 V KVA 157 185 185 229 229 289 289 347 Max input current Continuous at 550 V A 130 158 158 198 198 245 245 299 Continuous at 575 V A 124 151 151 189 189 234 234 286 Continuous at 690 V A 128 155 155 197 197 240 240 296 Max cable size line power motor load share and brake mm2 AWG 2 x 70 2 x 2 0 2 x 70 2 x 2 0 2 x 150 2 x 300 mcm 2 x 150 2 x 300 mcm Max external electrical fus...

Page 76: ...rent Continuous at 550 V A 299 355 355 408 381 453 Continuous at 575 V A 286 339 339 390 366 434 Continuous at 690 V A 296 352 352 400 366 434 Max cable size line power mo tor and load share mm2 AWG 2 x 150 2 x 300 mcm 2 x 150 2 x 300 mcm 4 x 240 4 x 500 mcm Max cable size brake mm2 AWG 2 x 150 2 x 300 mcm 2 x 150 2 x 300 mcm 2 x 185 2 x 350 mcm Max external electrical fuses A 1 500 550 700 Estima...

Page 77: ... 490 598 598 681 681 753 Max input current Continuous at 550 V A 413 504 504 574 574 607 Continuous at 575 V A 395 482 482 549 549 607 Continuous at 690 V A 395 482 482 549 549 607 Max cable size line power mo tor and load share mm2 AWG 4x240 4x500 mcm 4x240 4x500 mcm 4x240 4x500 mcm Max cable size brake mm2 AWG 2 x 185 2 x 350 mcm 2 x 185 2 x 350 mcm 2 x 185 2 x 350 mcm Max external electrical fu...

Page 78: ...79 1282 Continuous at 575 V A 613 711 711 828 828 920 920 1032 1032 1227 Continuous at 690 V A 613 711 711 828 828 920 920 1032 1032 1227 Max cable size motor mm2 AWG2 8x150 8x300 mcm 12x150 12x300 mcm Max cable size line power F1 F2 mm2 AWG2 8x240 8x500 mcm Max cable size line power F3 F4 mm2 AWG2 8x456 8x900 mcm Max cable size load sharing mm2 AWG2 4x120 4x250 mcm Max cable size brake mm2 AWG2 4...

Page 79: ...r loss in the adjustable frequency drive and opposite If the switching frequency is increased compared to the default setting the power losses may rise significantly LCP and typical control card power consumptions are included Further options and customer load may add up to 30 W to the losses Though typical only 4 W extra for a fully loaded control card or options for slot A or slot B each Althoug...

Page 80: ...tage Output frequency 0 33 10 hp 0 25 75 kW AutomationDrive FC 301 0 2 1000 Hz AutomationDrive FC 302 0 1000 Hz Output frequency 125 1350 hp 90 1000 kW 0 800 Hz Output frequency in flux mode AutomationDrive FC 302 only 0 300 Hz Switching on output Unlimited Ramp times 0 01 3600 sec Voltage and power dependent Torque characteristics Starting torque Constant torque maximum 160 for 60 sec Starting to...

Page 81: ...271 291 32 33 Logic PNP or NPN Voltage level 0 24 V DC Voltage level logic 0 PNP 5 V DC Voltage level logic 1 PNP 10 V DC Voltage level logic 0 NPN2 19 V DC Voltage level logic 1 NPN2 14 V DC Maximum voltage on input 28 V DC Pulse frequency ranges 0 110 kHz Duty cycle Min pulse width 4 5 ms Input resistance Ri approx 4 kΩ Safe stop Terminal 373 Terminal 37 is fixed PNP logic Voltage level 0 24 V D...

Page 82: ...l 29 32 33 110 kHz push pull driven Max frequency at terminal 29 32 33 5 kHz open collector Min frequency at terminal 29 32 33 4 Hz Voltage level see section on Digital input Maximum voltage on input 28 V DC Input resistance Ri approx 4 kΩ Pulse input accuracy 0 1 1 kHz Max error 0 1 of full scale Encoder input accuracy 1 110 kHz Max error 0 05 of full scale The pulse and encoder inputs terminals ...

Page 83: ...erminal load AC 1 1 on 1 3 NC 1 2 NO Resistive load 240 V AC 2 A Max terminal load AC 15 1 Inductive load cosφ 0 4 240 V AC 0 2 A Max terminal load DC 1 1 on 1 2 NO 1 3 NC Resistive load 60 V DC 1A Max terminal load DC 13 1 Inductive load 24 V DC 0 1A Relay 02 AutomationDrive FC 302 only Terminal number 4 6 break 4 5 make Max terminal load AC 1 1 on 4 5 NO Resistive load 2 3 Overvoltage cat II 400...

Page 84: ...d Test method according to IEC 60068 2 43 H2S 10 days Ambient temperature frame size A B and C Max 122 F 50 C 24 hour average maximum 113 F 45 C Ambient temperature frame size D E and F Max 113 F 45 C 24 hour average maximum 122 F 40 C Derating for high ambient temperature see section on special conditions Minimum ambient temperature during full scale operation 32 F 0 C Minimum ambient temperature...

Page 85: ...he adjustable frequency drive and when it runs directly on line power In small motors the influence from the U f characteristic on efficiency is marginal However in motors from 15 hp 11 kW and up the advantages are significant In general the switching frequency does not affect the efficiency of small motors The efficiency of motors from 15 hp 11 kW and up improves by 1 2 This is because the sine s...

Page 86: ...reases by a du dt ratio depending on the motor cable type cross section length shielded or unshielded inductance The natural induction causes an overshoot UPEAK in the motor voltage before it stabilizes itself at a level depending on the voltage in the intermediate circuit The rise time and the peak voltage UPEAK affect the service life of the motor If the peak voltage is too high motors without p...

Page 87: ...m AC line voltage V Rise time μsec Upeak kV du dt kV μsec 36 240 0 244 0 608 1 993 136 240 0 568 0 580 0 816 150 240 0 720 0 574 0 637 AutomationDrive FC 300 P22KT2 Cable length m AC line voltage V Rise time μsec Upeak kV du dt kV μsec 15 240 0 194 0 626 2 581 50 240 0 252 0 574 1 822 150 240 0 488 0 538 0 882 AutomationDrive FC 300 P30KT2 Cable length m AC line voltage V Rise time μsec Upeak kV d...

Page 88: ...AC line voltage V Rise time μsec Upeak kV du dt kV μsec 36 480 0 396 1 210 2 444 100 480 0 844 1 230 1 165 150 480 0 696 1 160 1 333 AutomationDrive FC 300 P15KT4 Cable length m AC line voltage V Rise time μsec Upeak kV du dt kV μsec 36 480 0 396 1 210 2 444 100 480 0 844 1 230 1 165 150 480 0 696 1 160 1 333 AutomationDrive FC 300 P18KT4 Cable length m AC line voltage V Rise time μsec Upeak kV du...

Page 89: ...du dt kV μsec 5 480 0 371 1 170 2 523 High Power range The power sizes below at the appropriate AC line voltages comply with the requirements of IEC 60034 17 regarding normal motors controlled by adjustable frequency drives IEC 60034 25 regarding motors designed to be controlled by adjustable frequency drives and NEMA MG 1 1998 Part 31 4 4 2 for inverter fed motors The power sizes below do not com...

Page 90: ...V 2 0 72 µsec 1061 857 V µsec 1 With Danfoss du dt filter 2 With du dt filter 500 1350 hp 355 1000 kW 525 690 V Cable length AC line voltage Rise time Peak voltage du dt 115 ft 30 m 690 V 0 57 µsec 1611 2261 V µsec 115 ft 30 m 575 V 0 25 µsec 2510 V µsec 115 ft 30 m 690 V1 1 13 µsec 1629 1150 V µsec 1 With Danfoss du dt filter 4 AutomationDrive FC 300 Selection FC 300 Design Guide 4 30 MG 33 BC 22...

Page 91: ...ng pattern which can be set to 60º AVM or SFAVM in par 14 00 Switching Pattern Frame size A 60º AVM Pulse Width Modulation Figure 4 2 Derating of Iout for different TAMB MAX for frame size A using 60º AVM SFAVM Stator Frequency Asyncron Vector Modulation Figure 4 3 Derating of Iout for different TAMB MAX for frame size A using SFAVM When using only 33 ft 10 m motor cable or less in frame size A le...

Page 92: ...0º AVM in Normal torque mode 110 over torque Figure 4 9 Derating of Iout for different TAMB MAX for frame size B using SFAVM in Normal torque mode 110 over torque Frame Size B2 525 690 V Figure 4 10 Output current derating with switching fre quency and ambient temperature for frame size B2 60º AVM Note The graph is drawn with the current as absolute value and is valid for both high and normal over...

Page 93: ...4 15 Derating of Iout for different TAMB MAX for frame size C using SFAVM in Normal torque mode 110 over torque Frame size C2 525 690 V Figure 4 16 Output current derating with switching fre quency and ambient temperature for frame size C2 60º AVM Note The graph is drawn with the current as absolute value and is valid for both high and normal overload Figure 4 17 Output current derating with switc...

Page 94: ... 110 over torque Figure 4 21 Derating of Iout for different TAMB MAX for frame size D at 500 V using SFAVM in Normal torque mode 110 over torque 60º AVM Pulse Width Modulation 525 690 V except P315 Figure 4 22 Derating of Iout for different TAMB MAX for frame size D at 690 V using 60º AVM in High torque mode 160 over torque Note not valid for P315 SFAVM Stator Frequency Asyncron Vector Modulation ...

Page 95: ...gh torque mode 160 over torque Note P315 only SFAVM Stator Frequency Asyncron Vector Modulation 525 690 V P315 Figure 4 27 Derating of Iout for different TAMB MAX for frame size D at 690 V using SFAVM in High torque mode 160 over torque Note P315 only Figure 4 28 Derating of Iout for different TAMB MAX for frame size D at 690 V using 60º AVM in Normal torque mode 110 over torque Note P315 only Fig...

Page 96: ...0 V using 60º AVM in Normal torque mode 110 over torque Figure 4 33 Derating of Iout for different TAMB MAX for frame sizes E and F at 500 V using SFAVM in Normal torque mode 110 over torque 60º AVM Pulse Width Modulation 525 690 V Figure 4 34 Derating of Iout for different TAMB MAX for frame sizes E and F at 690 V using 60º AVM in High torque mode 160 over torque SFAVM Stator Frequency Asyncron V...

Page 97: ...60º AVM in Normal torque mode 110 over torque Figure 4 37 Derating of Iout for different TAMB MAX for frame sizes E and F at 690 V using SFAVM in Normal torque mode 110 over torque FC 300 Design Guide 4 AutomationDrive FC 300 Selection MG 33 BC 22 VLT is a registered Danfoss trademark 4 37 4 ...

Page 98: ...6 600 feet 2 km please contact Danfoss regarding PELV An alternative is to lower the ambient temperature at high altitudes and thereby ensure 100 output current at high altitudes As an example of how to read the graph the situation at 6 600 ft 2 km is elaborated At a temperature of 113 F 45 C TAMB MAX 3 3 K 91 of the rated output current is available At a temperature of 107 F 41 7 C 100 of the rat...

Page 99: ...the square of the speed and the power is proportional to the cube of the speed there is no need for additional cooling or de rating of the motor In the graphs shown below the typical VT curve is below the maximum torque with de rating and maximum torque with forced cooling at all speeds Maximum load for a standard motor at 104 F 40 C driven by an adjustable frequency drive type VLT FCxxx Legend Ty...

Page 100: ...4 AutomationDrive FC 300 Selection FC 300 Design Guide 4 40 MG 33 BC 22 VLT is a registered Danfoss trademark 4 ...

Page 101: ...generate the type code string The drive configurator will automatically generate an eight digit sales number to be delivered to your local sales office Furthermore you can establish a project list with several products and send it to a Danfoss sales representative The drive configurator can be found on the global Internet site www danfoss com drives Drives will automatically be delivered with a la...

Page 102: ...ower option 21 Adaptation A 22 Adaptation B 23 Software release 24 27 Software language 28 A options 29 30 B options 31 32 C0 options MCO 33 34 C1 options 35 C option software 36 37 D options 38 39 Not all choices options are available for each AutomationDrive FC 301 AutomationDrive FC 302 variant To verify if the appropriate version is available please consult the Drive Configurator on the Intern...

Page 103: ...1 kW only Ordering type codemodel number frame sizes D and E Description Pos Possible choice Product group 1 3 AutomationDrive FC 302 Drive series 4 6 AutomationDrive FC 302 Power rating 8 10 50 750 hp 37 560 kW Phases 11 Three phases T AC line voltage 11 12 T 5 380 500 V AC T 7 525 690 V AC Enclosure 13 15 E00 IP00 Chassis C00 IP00 Chassis w stainless steel back channel E0D IP00 Chassis D3 P37K P...

Page 104: ...h Pilz safety relay 4 N IEC Emergency stop pushbutton with brake IGBT and brake terminals 4 P IEC Emergency stop pushbutton with regeneration terminals4 Display 19 G Graphical Local Control Panel LCP Coating PCB 20 C Coated PCB Description Pos Possible choice Line power op tion 21 X No AC line power option 32 Line power disconnect and fuse 52 Line power disconnect fuse and load sharing 7 Fuse A Fu...

Page 105: ...CB 108 Safety PLC Interface B2 MCB 112 PTC Thermistor Card C0 E0 options 33 34 CX No option C4 MCO 305 Programmable Motion Controller BK MCB 101 General purpose I O in E0 BZ MCB 108 Safety PLC Interface in E0 C1 options A B in C Option Adaptor 35 X No option R MCB 113 Ext Relay Card Z MCA 140 Modbus RTU OEM option E MCF 106 A B in C Option Adaptor C option soft ware E1 options 36 37 XX Standard co...

Page 106: ...ctors 130B1116 USB cable extension for A5 B1 130B1155 USB cable extension for B2 C1 C2 130B1156 Footmount frame for flat pack resistors frame size A2 175U0085 Footmount frame for flat pack resistors frame size A3 175U0088 Footmount frame for 2 flat pack resistors frame size A2 175U0087 Footmount frame for 2 flat pack resistors frame size A3 175U0086 Ordering numbers for duct cooling kits NEMA 3R k...

Page 107: ...0 pieces 6 pole spring loaded connectors 130B1071 Connectors AutomationDrive FC 300 RS485 10 pieces 3 pole spring loaded connectors for RS 485 130B1070 Connectors AutomationDrive FC 300 3 pole 10 pieces 3 pole connectors for relay 01 130B1069 Connectors AutomationDrive FC 302 3 pole 10 pieces 3 pole connectors for relay 02 130B1068 Connectors AutomationDrive FC 300 Line Power 10 pieces line connec...

Page 108: ...al Cover D3 D4 Frame 176F1779 175R1108 line Power Shield D1 D2 Frames 176F0799 175R5923 E1 Frame 176F1851 Input Plates See Instr 175R5795 Loadshare D1 D3 Frame 176F8456 175R5637 D2 D4 Frame 176F8455 Top Entry Sub D or Shield Termination D3 D4 E2 Frames 176F1742 175R5964 5 2 4 Ordering Numbers Brake Resistors 10 AutomationDrive FC 301 Line power 200 240V T2 10 Duty Cycle AutomationDrive FC 301 Pm H...

Page 109: ...160 160 P3K0 3 31 5 37 35 0 43 1824 120 1 5 2 5 160 160 P3K7 3 7 22 5 29 6 25 0 8 1825 120 1 5 5 7 160 160 AutomationDrive FC 301 302 Line power 200 240 V T2 10 Duty Cycle AutomationDrive FC 301 302 Pm HO Rmin Rbr nom Rrec Pbr avg Order no Period Cable cross section2 Therm relay Max brake tor que with Rrec T2 kW Ω Ω Ω kW 175Uxxxx s mm2 A P5K5 5 5 18 20 20 1 1826 120 1 5 7 1 158 160 P7K5 7 5 13 14 ...

Page 110: ...P4K0 4 87 97 110 0 6 1845 120 1 5 2 3 140 160 P5K5 5 5 63 69 80 0 85 1846 120 1 5 3 3 139 160 P7K5 7 5 45 50 65 1 1847 120 1 5 3 9 124 160 P11K 11 34 9 38 8 40 1 8 1848 120 1 5 7 1 155 160 P15K 15 25 3 28 1 30 2 8 1849 120 1 5 9 7 150 160 P18K 18 5 20 3 22 6 25 3 5 1850 120 1 5 12 144 160 P22K 22 16 9 18 8 20 4 1851 120 1 5 14 150 160 P30K 30 13 2 14 7 15 4 8 1852 120 2 5 18 147 150 P37K 37 11 12 ...

Page 111: ...150 150 P90K 90 3 8 5 2 3 8 36 0078 600 35 97 150 150 P110 110 3 2 4 2 3 2 27 1961 300 35 92 150 150 P110 110 3 4 3 2 42 0079 600 50 115 150 150 P132 132 3 3 5 2 6 32 1962 300 50 111 150 150 P160 160 2 2 9 2 1 39 1963 300 70 136 150 150 P200 200 2 3 6 6 2 3 3 28 x 2 56 2 x 1061 3 300 2 x 505 1304 106 150 P200 200 1 6 2 3 6 6 3 2 2 28 x 3 84 3 x 1061 3 300 3 x 50 5 1304 150 150 P250 250 2 6 1 9 5 2...

Page 112: ...20 1 5 9 7 160 160 P22K 22 22 5 27 6 25 3 5 1850 120 1 5 12 150 150 P30K 30 18 21 6 20 4 1851 120 1 5 14 150 150 P37K 37 13 5 17 3 15 4 8 1852 120 2 5 18 150 150 P45K 45 10 8 14 2 12 5 5 1853 120 2 5 21 150 150 P55K 55 8 8 11 6 9 8 15 2008 120 10 39 150 150 P75K 75 6 6 8 4 7 3 13 0069 120 10 42 150 150 P90K 90 4 7 7 4 7 18 1959 300 16 62 150 150 P110 110 4 7 5 8 4 7 18 1959 300 16 62 150 150 P132 ...

Page 113: ... kW 175Uxxxx s mm2 A PK25 0 25 368 408 425 0 43 1941 120 1 5 1 154 160 PK37 0 37 248 276 310 0 80 1942 120 1 5 1 6 142 160 PK55 0 55 166 185 210 1 35 1943 120 1 5 2 5 141 160 PK75 0 75 121 135 145 0 26 1920 120 1 5 1 3 149 160 P1K1 1 1 81 91 4 90 0 43 1921 120 1 5 2 2 160 160 P1K5 1 5 58 5 66 2 65 0 80 1922 120 1 5 3 5 160 160 P2K2 2 2 40 2 44 6 50 1 00 1923 120 1 5 4 5 143 160 P3K0 3 29 1 32 4 35...

Page 114: ... PK75 0 75 485 539 620 0 26 1940 120 1 5 0 6 139 160 P1K1 1 1 329 366 425 0 43 1941 120 1 5 1 138 160 P1K5 1 5 240 267 310 0 80 1942 120 1 5 1 6 138 160 P2K2 2 2 161 179 210 1 35 1943 120 1 5 2 5 137 160 P3K0 3 117 130 150 2 00 1944 120 1 5 3 7 139 160 P4K0 4 87 97 110 2 40 1945 120 1 5 4 7 140 160 P5K5 5 5 63 69 80 3 00 1946 120 1 5 6 1 139 160 P7K5 7 5 45 50 65 4 50 1947 120 1 5 8 3 124 160 P11K...

Page 115: ...160 P30K 30 15 15 9 15 15 6 1952 120 10 32 150 150 P37K 37 12 13 12 19 1953 120 10 40 150 150 P45K 45 10 10 9 8 38 2007 120 16 62 150 150 P55K 55 7 9 7 3 38 0068 120 25 72 150 150 P55K 55 7 3 8 6 150 150 P75K 75 4 7 6 2 4 7 45 0066 120 25 87 150 150 P75K 75 4 7 6 2 150 150 P75K 75 4 7 6 2 150 150 P90K 90 3 8 5 2 7 6 2 3 8 38 x 2 75 2 x 0072 3 600 2 x 705 1404 150 150 P90K 90 3 8 5 2 150 150 P110 1...

Page 116: ...1 5 8 3 160 160 P15K 15 36 41 3 40 11 1948 120 1 5 11 160 160 P18K 18 5 27 33 2 30 18 1949 120 2 5 18 160 160 P22K 22 22 5 27 6 25 23 1950 120 4 23 150 150 P30K 30 18 21 6 20 25 1951 120 4 25 150 150 P37K 37 13 5 17 3 15 32 1952 120 10 32 150 150 P45K 45 10 8 14 2 12 40 1953 120 10 40 150 150 P55K 55 8 8 11 6 9 8 62 2007 120 16 62 150 150 P75K 75 6 6 8 4 7 3 72 0068 120 25 72 150 150 P90K 90 4 7 7...

Page 117: ...rque 2 All cabling must comply with national and local regulations on cable cross sections and ambient temperature Copper 140 167 F 60 75 C conductors are recommended 3 Order the specified amount of Brake Resistors e g 2 x 1062 2 pieces of 175U1062 See table header for the first four characters 175U or 130B 4 Rating for each thermistor relay using one thermistor relay per resistor 5 Parallel star ...

Page 118: ...K55 0 55 189 211 220 100 or 210 200 20 or 37 1004 or 0987 PK75 0 75 130 154 150 100 or 150 200 14 or 27 1005 or 0989 P1K1 1 1 81 0 104 4 100 100 or 100 200 10 or 19 1006 or 0991 P1K5 1 5 58 5 75 7 72 200 14 0992 P2K2 2 2 45 0 51 0 50 200 10 0993 P3K0 3 31 5 37 0 35 200 or 72 200 7 or 14 0994 or 2 x 0992 P3K7 3 7 22 5 29 6 60 200 11 2 x 0996 AutomationDrive FC 301 Line power 380 480 V T4 Automation...

Page 119: ...0 200 14 or 27 1001 or 0982 P1K1 1 1 425 453 430 100 or 430 200 10 or 20 1002 or 0983 P1K5 1 5 310 0 330 4 310 200 14 0984 P2K2 2 2 210 0 222 6 210 200 10 0987 P3K0 3 150 0 161 4 150 200 or 300 200 7 14 0989 or 2 x 0985 P4K0 4 110 120 240 200 10 2 x 0986 P5K5 5 5 80 86 160 200 8 2 x 0988 P7K5 7 5 65 62 130 200 6 2 x 0990 P11K 11 40 0 42 1 80 240 5 2 x 0090 P15K 15 30 0 30 5 72 240 4 2 x 0091 FC 30...

Page 120: ...11 2X 175G6633 P355 694 400 175G6611 175G6688 175G6633 175G6691 P400 740 450 2X 175G6688 2X 175G6691 P450 Table 5 1 380 415 V 50Hz IAHF N Typical Motor Used kW Danfoss AHF 005 Danfoss AHF 010 Adjustable frequency drive size 10 0 37 4 130B2540 130B2541 PK37 P4K0 19 5 5 7 5 130B2460 130B2472 P5K5 P7K5 26 11 130B2461 130B2473 P11K 35 15 18 5 130B2462 130B2474 P15K P18K 43 22 130B2463 130B2475 P22K 72...

Page 121: ...75G6664 P110 217 160 175G6653 175G6665 P132 289 200 175G6654 175G6666 P160 324 250 175G6655 175G6667 P200 434 315 175G6653 175G6653 175G6665 175G6665 P250 506 355 175G6653 175G6654 175G6665 175G6666 P315 578 400 175G6654 175G6654 175G6666 175G6666 P355 648 500 175G6655 175G6655 175G66967 175G6667 P400 Table 5 4 500 V 50 Hz Matching the adjustable frequency drive and filter is pre calculated based ...

Page 122: ... 5 120 130B2441 130B2406 PK55 P1K1 P1K5 P1K1 P1K5 8 5 120 130B2443 130B2408 PK75 P1K5 P2K2 P3K0 P2K2 P3K0 10 5 120 130B2444 130B2409 P4K0 P4K0 17 5 120 130B2446 130B2411 P2K2 P4K0 P5K5 P7K5 P5K5 P7K5 24 4 100 130B2447 130B2412 P5K5 P11K P11K 38 4 100 130B2448 130B2413 P7K5 P15K P18K P15K P18K 48 4 100 130B2307 130B2281 P11K P22K P22K 62 3 100 130B2308 130B2282 P15K P30K P30K 75 3 100 130B2309 130B...

Page 123: ... on 525 V 690 V and on a typical motor load 4 pole and 160 torque NOTE When using sine wave filters the switching frequency should comply with filter specifications in par 14 01 Switching Frequency 5 2 10 Ordering Numbers du dt Filters 380 480 500 V AC Line power supply 3x380 500 V 3 x 380 500 V Adjustable frequency drive size Rated filter cur rent at 50 Hz Minimum switch ing frequency kHz Maximum...

Page 124: ...100 130B2424 130B2415 P22K P30K P37K 75 2 100 130B2425 130B2416 P37K P45K P45K P55K 115 2 100 130B2426 130B2417 P55K P75K P75K P90K 165 2 100 130B2427 130B2418 P110 P132 260 2 100 130B2428 130B2419 P160 P200 310 2 100 130B2429 130B2420 P250 430 1 5 100 130B2238 130B2235 P315 P400 530 1 5 100 130B2239 130B2236 P500 630 1 5 100 130B2274 130B2280 P560 P630 765 1 5 100 130B2430 130B2421 P710 1350 1 5 ...

Page 125: ...not exceed the maximum temperature stated for the adjustable frequency drive and that the 24 hour average temperature is not exceeded Locate the maximum temperature and 24 hour average in the paragraph Derating for Ambient Temperature If the ambient temperature is in the range of 113 131 F 45 55 C derating of the adjustable frequency drive will become relevant see Derating for Ambient Temperature ...

Page 126: ...P20 Accessory bags containing necessary brackets screws and connectors are included with the drives upon delivery Top and bottom mounting holes B4 C3 and C4 only All measurements in mm A5 in IP55 66 only 6 Mechanical Installation Frame Size A B and C FC 300 Design Guide 6 2 MG 33 BC 22 VLT is a registered Danfoss trademark 6 ...

Page 127: ...2 in 257 mm 13 78 in 350 mm 15 79 in 402 mm 17 87 in 454 mm 24 57 in 624 mm 14 96 in 380 mm 19 49 in 495 mm 25 51 in 648 mm 29 09 in 739 mm 20 51 in 521 mm 24 84 in 631 mm Width Width of backplate B 2 95 in 75 mm 3 54 in 90 mm 3 54 in 90 mm 5 12 in 130 mm 5 12 in 130 mm 9 53 in 242 mm 9 53 in 242 mm 9 53 in 242 mm 6 50 in 165 mm 9 06 in 230 mm 12 13 in 308 mm 14 57 in 370 mm 12 13 in 308 mm 14 57 ...

Page 128: ...9 53 in 242 mm 12 21 in 310 mm 13 20 in 335 mm 13 11 in 333 mm 13 11 in 333 mm Screw holes c 0 24 in 6 0 mm 0 32 in 8 0 mm 0 32 in 8 0 mm 0 32 in 8 0 mm 0 32 in 8 0 mm 0 33 in 8 25 mm 0 47 in 12 mm 0 47 in 12 mm 0 32 in 8 mm 0 49 in 12 5 mm 0 49 in 12 5 mm d ø0 35 in 8 mm ø0 43 in 11 mm ø0 43 in 11 mm ø0 43 in 11 mm ø0 43 in 11 mm ø0 47 in 12 mm ø0 75 in 19 mm ø0 75 in 19 mm 0 47 in 12 mm ø0 75 in...

Page 129: ...00 100 100 100 200 100 200 200 225 200 225 b mm 100 100 100 100 100 200 100 200 200 225 200 225 Table 6 1 AutomationDrive FC 301 only 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 adjustable frequency drive Retighten all four screws Table 6 2 Mounting frame sizes A5 B1 B2 B3 B4 C1 C2 C3 and C4 on a non soli...

Page 130: ...6 Mechanical Installation Frame Size A B and C FC 300 Design Guide 6 6 MG 33 BC 22 VLT is a registered Danfoss trademark 6 ...

Page 131: ...stable frequency drive is without built in fuses ensure that the external fuses are rated correctly 7 1 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 7 1...

Page 132: ...ended lifting method frame sizes D and E NOTE The lifting bar must be able to handle the weight of the adjustable frequency drive See Mechanical Dimensions for the weight of the different frame sizes Maximum diameter for bar is 1 in 2 5 cm The angle from the top of the drive to the lifting cable should be 60 degrees or greater 7 Mechanical Installation Frame size D E and F FC 300 Design Guide 7 2 ...

Page 133: ...the adjustable frequency drive but is not attached to frame sizes F1 F4 during shipment The plinth is required to allow airflow to the drive to provide proper cooling The F frames should be positioned on top of the plinth in the final installation location The angle from the top of the drive to the lifting cable should be 60 degrees or greater FC 300 Design Guide 7 Mechanical Installation Frame si...

Page 134: ... Please note airflow directions 7 1 5 Mechanical Dimensions 7 Mechanical Installation Frame size D E and F FC 300 Design Guide 7 4 MG 33 BC 22 VLT is a registered Danfoss trademark 7 ...

Page 135: ... Please note airflow directions FC 300 Design Guide 7 Mechanical Installation Frame size D E and F MG 33 BC 22 VLT is a registered Danfoss trademark 7 5 7 ...

Page 136: ... Please note airflow directions 7 Mechanical Installation Frame size D E and F FC 300 Design Guide 7 6 MG 33 BC 22 VLT is a registered Danfoss trademark 7 ...

Page 137: ... Please note airflow directions FC 300 Design Guide 7 Mechanical Installation Frame size D E and F MG 33 BC 22 VLT is a registered Danfoss trademark 7 7 7 ...

Page 138: ...F1 IP 21 54 NEMA 1 12 F3 IP 21 54 NEMA 1 12 1 Minimum clearance from ceiling 7 Mechanical Installation Frame size D E and F FC 300 Design Guide 7 8 MG 33 BC 22 VLT is a registered Danfoss trademark 7 ...

Page 139: ...F2 IP 21 54 NEMA 1 12 F4 IP 21 54 NEMA 1 12 1 Minimum clearance from ceiling FC 300 Design Guide 7 Mechanical Installation Frame size D E and F MG 33 BC 22 VLT is a registered Danfoss trademark 7 9 7 ...

Page 140: ...b 151 kg 200 62 lb 91 kg 304 23 lb 138 kg Mechanical dimensions frame sizes E and F Frame size E1 E2 F1 F2 F3 F4 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 600 850 hp 450 630 kW 380 500 V 850 1075 hp 630 800 kW 525 690 V 950 1075 hp 710 800 kW 380 500 V 1200 1350 hp 900 1000 kW 525 690 V 600 850 hp 450 630 kW 380 ...

Page 141: ...r cable connectors in IP 21 Nema 1 and IP 54 units Lifting bar to lift the unit rod or tube max Ø1 in 25 mm able to lift minimum 880 lbs 400 kg Crane or other lifting aid to place the adjustable frequency drive in position A Torx T50 tool is needed to install the E1 in IP21 and IP54 enclosure types 7 2 2 General Considerations Space Ensure proper space above and below the adjustable frequency driv...

Page 142: ...4 Wire access Ensure that proper cable access is present including the necessary bending allowance As the IP00 enclosure is open to the bottom cables must be fixed to the back panel of the enclosure where the adjustable frequency drive is mounted i e by using cable clamps NOTE All cable lugs shoes must mount within the width of the terminal bus bar 7 Mechanical Installation Frame size D E and F FC...

Page 143: ... size D1 and D2 Be aware that the power cables are heavy and hard to bend Give thought to the optimum position of the adjustable frequency drive for ensuring easy installation of the cables NOTE All D frames are available with standard input terminals or disconnect switch All terminal dimensions can be found in the table on the next page FC 300 Design Guide 7 Mechanical Installation Frame size D E...

Page 144: ...4 13 9 K 284 11 2 277 10 9 277 10 9 270 10 6 L 334 13 1 334 13 1 326 12 8 326 12 8 M 250 9 8 250 9 8 243 9 6 243 9 6 N 167 6 6 167 6 6 159 6 3 159 6 3 O 261 10 3 260 10 3 261 10 3 261 10 3 P 170 6 7 169 6 7 170 6 7 170 6 7 Q 120 4 7 120 4 7 120 4 7 120 4 7 R 256 10 1 350 13 8 98 3 8 93 3 7 S 308 12 1 332 13 0 301 11 8 324 12 8 T 252 9 9 262 10 3 245 9 6 255 10 0 U 196 7 7 192 7 6 189 7 4 185 7 3 V...

Page 145: ...the cable access Figure 7 15 IP21 NEMA Type 1 and IP54 NEMA Type 12 enclosure power connection positions Figure 7 16 IP21 NEMA type 1 and IP54 NEMA type 12 enclosure power connection positions detail B FC 300 Design Guide 7 Mechanical Installation Frame size D E and F MG 33 BC 22 VLT is a registered Danfoss trademark 7 15 7 ...

Page 146: ...4 IP21 UL AND NEMA1 NEMA12 350 450 hp 250 315 kW 400 V AND 500 600 675 850 hp 355 450 500 630 KW 690 V 381 15 0 253 9 9 253 9 9 431 17 0 562 22 1 N A 450 500 550 600 hp 315 355 400 450 kW 400 V 371 14 6 371 14 6 341 13 4 431 17 0 431 17 0 455 17 9 7 Mechanical Installation Frame size D E and F FC 300 Design Guide 7 16 MG 33 BC 22 VLT is a registered Danfoss trademark 7 ...

Page 147: ...positions when designing the cable access Figure 7 18 IP00 enclosure power connection positions Figure 7 19 IP00 enclosure power connection positions FC 300 Design Guide 7 Mechanical Installation Frame size D E and F MG 33 BC 22 VLT is a registered Danfoss trademark 7 17 7 ...

Page 148: ...ensuring easy installation of the cables Each terminal allows for the use of up to 4 cables with cable lugs or the use of standard box lug Ground is connected to relevant termination point in the drive Figure 7 21 Terminal in details NOTE Power connections can be made to positions A or B 7 Mechanical Installation Frame size D E and F FC 300 Design Guide 7 18 MG 33 BC 22 VLT is a registered Danfoss...

Page 149: ...onsist of an inverter cabinet on the right and rectifier cabinet on the left The F3 and F4 have an additional options cabinet left of the rectifier cabinet The F3 is an F1 with an additional options cabinet The F4 is an F2 with an additional options cabinet Terminal locations Frame size F1 and F3 Figure 7 22 Terminal locations Inverter Cabinet F1 and F3 front left and right side view The connector...

Page 150: ... locations Inverter cabinet F2 and F4 front left and right side view The connector plate is 1 65 in 42 mm below 0 level 1 Earth ground bar 7 Mechanical Installation Frame size D E and F FC 300 Design Guide 7 20 MG 33 BC 22 VLT is a registered Danfoss trademark 7 ...

Page 151: ...d Share Terminal 2 Earth ground bar 3 Load Share Terminal Terminal locations Options cabinet F3 and F4 Figure 7 25 Terminal locations Options cabinet left side front and right side view The connector plate is 1 65 in 42 mm below 0 level 1 Earth ground bar FC 300 Design Guide 7 Mechanical Installation Frame size D E and F MG 33 BC 22 VLT is a registered Danfoss trademark 7 21 7 ...

Page 152: ...been developed to optimize installation of IP00 chassis adjustable frequency drives in Rittal TS8 enclosures utilizing the fan of the adjustable frequency drive for forced air cooling of the backchannel The air out the top of the enclosure could but ducted outside a facility so the heat losses from the backchannel are not dissipated within the control room reducing air conditioning requirements of...

Page 153: ... 340 m3 h 200 cfm 1105 m3 h 650 cfm E1 P315 P400T5 P500 P560T7 340 m3 h 200 cfm 1445 m3 h 850 cfm IP21 NEMA 1 F1 F2 F3 and F4 700 m3 h 412 cfm 985 m3 h 580 cfm IP54 NEMA 12 F1 F2 F3 and F4 525 m3 h 309 cfm 985 m3 h 580 cfm IP00 Chassis D3 and D4 255 m3 h 150 cfm 765 m3 h 450 cfm E2 P250T5 P355T7 P400T7 340 m3 h 200 cfm 1105 m3 h 650 cfm E2 P315 P400T5 P500 P560T7 340 m3 h 200 cfm 1445 m3 h 850 cfm...

Page 154: ...29 E frame Derating vs Pressure Change Large Fan P315T5 P400T5 and P500T7 P560T7 Drive air flow 850 cfm 1445 m3 h Figure 7 30 F1 F2 F3 F4 frame Derating vs Pressure Change Drive air flow 580 cfm 985 m3 h 7 Mechanical Installation Frame size D E and F FC 300 Design Guide 7 24 MG 33 BC 22 VLT is a registered Danfoss trademark 7 ...

Page 155: ...mplate on the wall and drill the holes as indicated Ensure proper distance to the floor and the ceiling for cooling A minimum of 8 9 in 225 mm below the adjustable frequency drive is needed Mount the bolts at the bottom and lift the adjustable frequency drive up on the bolts Tilt the adjustable frequency drive against the wall and mount the upper bolts Tighten all four bolts to secure the adjustab...

Page 156: ... drive to ensure the specified protection degree as well as ensuring proper cooling of the unit If the connector plate is not mounted the adjustable frequency drive may trip on Alarm 69 Pwr Card Temp Figure 7 32 Example of proper installation of the connector plate Frame size D1 D2 Frame size E1 Cable entries viewed from the bottom of the adjustable frequency drive 1 Line power side 2 Motor side 7...

Page 157: ...ame size F4 F1 F4 Cable entries viewed from the bottom of the adjustable frequency drive 1 Place conduits in marked areas FC 300 Design Guide 7 Mechanical Installation Frame size D E and F MG 33 BC 22 VLT is a registered Danfoss trademark 7 27 7 ...

Page 158: ...adjustable frequency drive is placed on the pedestal 7 2 9 IP21 Drip Shield Installation Frame size D1 and D2 To comply with the IP21 rating a separate drip shield is to be installed as explained below Remove the two front screws Insert the drip shield and replace the screws Torque the screws to 5 6 Nm 50 in lbs Figure 7 34 Install the drip shield 7 Mechanical Installation Frame size D E and F FC ...

Page 159: ...stor load sharing motor cables 1 8 Nm Relay 0 5 0 6 Nm Ground 2 3 Nm B2 15 hp 11 kW 25 30 hp 18 5 22 kW 15 30 hp 11 22 kW Line power brake resistor load sharing cables 4 5 Nm Motor cables 4 5 Nm Relay 0 5 0 6 Nm Ground 2 3 Nm B3 7 5 10 hp 5 5 7 5 kW 15 20 hp 11 15 kW Line power brake resistor load sharing motor cables 1 8 Nm Relay 0 5 0 6 Nm Ground 2 3 Nm B4 15 20 hp 11 15 kW 25 40 hp 18 5 30 kW L...

Page 160: ...ounded Connect to ground connection terminal 95 Use screw from the accessory bag 3 Place plug connector 91 L1 92 L2 93 L3 from the accessory bag onto the terminals labeled MAINS at the bottom of the adjustable frequency drive 4 Attach the line wires to the line power plug connector 5 Support the cable with the enclosed supporting brackets NOTE Ensure that AC line voltage corresponds to the AC line...

Page 161: ...AC line input connections for Frame sizes A1 A2 and A3 FC 300 Design Guide 8 Electrical Installation MG 33 BC 22 VLT is a registered Danfoss trademark 8 3 8 ...

Page 162: ...nections frame sizes B1 and B2 IP 21 NEMA Type 1 and IP 55 66 NEMA Type 12 Figure 8 2 AC line input connections size B3 IP20 Figure 8 3 AC line input connections size B4 IP20 Figure 8 4 AC line input connections size C1 and C2 IP 21 NEMA Type 1 and IP 55 66 NEMA Type 12 8 Electrical Installation FC 300 Design Guide 8 4 MG 33 BC 22 VLT is a registered Danfoss trademark 8 ...

Page 163: ...ross section The adjustable frequency drive has been tested with a given length of cable and a given cross section of that cable If the cross section is increased the cable capacitance and thus the leakage current may increase thereby requiring that the cable length is reduced accordingly Keep the motor cable as short as possible to reduce the noise level and leakage currents Switching frequency W...

Page 164: ...ype 12 Figure 8 9 Motor connection for size B1 and B2 IP 21 NEMA Type 1 IP 55 NEMA Type 12 and IP66 NEMA Type 4X Figure 8 10 Motor connection for size B3 Figure 8 11 Motor connection for frame size B4 8 Electrical Installation FC 300 Design Guide 8 6 MG 33 BC 22 VLT is a registered Danfoss trademark 8 ...

Page 165: ... 8 16 Cable entry holes for frame size C1 The sug gested use of the holes are purely recommendations and other solutions are possible Figure 8 17 Cable entry holes for frame size C2 The sug gested use of the holes are purely recommendations and other solutions are possible Term no 96 97 98 99 U V W PE1 Motor voltage 0 100 of AC line voltage 3 wires out of motor U1 V1 W1 PE1 Delta connected W2 U2 V...

Page 166: ...4 Relay Connection To set relay output see par group 5 4 Relays No 01 02 make normally open 01 03 break normally closed 04 05 make normally open 04 06 break normally closed Terminals for relay connection Frame sizes A1 A2 and A3 Terminals for relay connection Frame sizes A5 B1 and B2 Terminals for relay connection Frame sizes C1 and C2 8 Electrical Installation FC 300 Design Guide 8 8 MG 33 BC 22 ...

Page 167: ...ighten the bolts Frame size Terminal Torque Bolt size D1 D2 D3 and D4 Line power Motor 19 Nm 168 in lbs M10 Load sharing Brake 9 5 Nm 84 in lbs M8 E1 and E2 Line power Motor Load sharing 19 NM 168 in lbs M10 Brake 9 5 Nm 84 in lbs M8 F1 F2 F3 and F4 Line power Motor 19 Nm 168 in lbs M10 Load sharing Brake Regen 19 Nm 168 in lbs 9 5 Nm 84 in lbs 19 Nm 168 in lbs M10 M8 M10 Table 8 1 Torque for term...

Page 168: ...sion specifications For more information see EMC specifications in the Design Guide See section General Specifications for correct dimensioning of motor cable cross section and length Shielding of cables Avoid installation with twisted shield ends pigtails They spoil the shielding effect at higher frequencies If it is necessary to break the shield to install a motor isolator or motor contactor the...

Page 169: ... 1 Protected Ground Connection NOTE In motors without phase insulation paper or other in sulation reinforcement suitable for operation with volt age supply such as a adjustable frequency drive fit a sine wave filter on the output of the adjustable fre quency drive Figure 8 19 Compact IP 21 NEMA 1 and IP 54 NEMA 12 frame size D1 FC 300 Design Guide 8 Electrical Installation MG 33 BC 22 VLT is a reg...

Page 170: ...Switch 6 SMPS Fuse see fuse tables for part number 106 104 105 7 AUX Fan 3 Line 100 101 102 103 R S T L1 L2 L1 L2 91 92 93 8 Fan Fuse see fuse tables for part number L1 L2 L3 9 Line power ground 4 Load sharing 10 Motor DC DC U V W 88 89 96 97 98 T1 T2 T3 8 Electrical Installation FC 300 Design Guide 8 12 MG 33 BC 22 VLT is a registered Danfoss trademark 8 ...

Page 171: ...act IP 00 Chassis frame size D3 Figure 8 22 Compact IP 00 Chassis with disconnect fuse and RFI filter frame size D4 FC 300 Design Guide 8 Electrical Installation MG 33 BC 22 VLT is a registered Danfoss trademark 8 13 8 ...

Page 172: ... for part number L1 L2 L3 9 Line power ground 4 Load sharing 10 Motor DC DC U V W 88 89 96 97 98 T1 T2 T3 Figure 8 23 Position of ground terminals IP00 frame sizes D Figure 8 24 Position of ground terminals IP21 NEMA type 1 and IP54 NEMA type 12 NOTE D2 and D4 shown as examples D1 and D3 are equivalent 8 Electrical Installation FC 300 Design Guide 8 14 MG 33 BC 22 VLT is a registered Danfoss trade...

Page 173: ... NEMA 1 and IP 54 NEMA 12 frame size E1 Figure 8 26 Compact IP 00 Chassis with disconnect fuse and RFI filter frame size E2 FC 300 Design Guide 8 Electrical Installation MG 33 BC 22 VLT is a registered Danfoss trademark 8 15 8 ...

Page 174: ...se see fuse tables for part number 3 Line 8 AUX Fan R S T 100 101 102 103 91 92 93 L1 L2 L1 L2 L1 L2 L3 9 Line power ground 4 Brake 10 Motor R R U V W 81 82 96 97 98 T1 T2 T3 Figure 8 27 Position of ground terminals IP00 frame sizes E 8 Electrical Installation FC 300 Design Guide 8 16 MG 33 BC 22 VLT is a registered Danfoss trademark 8 ...

Page 175: ...Manual Motor Starters 7 SMPS Fuse See fuse tables for part numbers 3 30 A Fuse Protected Power Terminals 8 Manual Motor Controller fuses 3 or 6 pieces See fuse tables for part numbers 4 Line 9 Line Fuses F1 and F2 frame 3 pieces See fuse tables for part numbers R S T 10 30 Amp Fuse Protected Power fuses L1 L2 L3 FC 300 Design Guide 8 Electrical Installation MG 33 BC 22 VLT is a registered Danfoss ...

Page 176: ... 98 04 05 06 T1 T2 T3 3 NAMUR 7 NAMUR Fuse See fuse tables for part numbers 4 AUX Fan 8 Fan Fuses See fuse tables for part numbers 100 101 102 103 9 SMPS Fuses See fuse tables for part numbers L1 L2 L1 L2 5 Brake R R 81 82 8 Electrical Installation FC 300 Design Guide 8 18 MG 33 BC 22 VLT is a registered Danfoss trademark 8 ...

Page 177: ... 98 04 05 06 T1 T2 T3 3 NAMUR 7 NAMUR Fuse See fuse tables for part numbers 4 AUX Fan 8 Fan Fuses See fuse tables for part numbers 100 101 102 103 9 SMPS Fuses See fuse tables for part numbers L1 L2 L1 L2 5 Brake R R 81 82 FC 300 Design Guide 8 Electrical Installation MG 33 BC 22 VLT is a registered Danfoss trademark 8 19 8 ...

Page 178: ...es for part numbers 3 Line power 5 Line Fuses F3 and F4 3 pieces R S T See fuse tables for part numbers 91 92 93 6 Contactor Relay Coil 230 V AC N C and N O Aux Contacts L1 L2 L3 7 Circuit Breaker Shunt Trip Control Terminals 230 V AC or 230 V DC 8 Electrical Installation FC 300 Design Guide 8 20 MG 33 BC 22 VLT is a registered Danfoss trademark 8 ...

Page 179: ...nnection is made on the power card Terminal No Function 100 101 102 103 Auxiliary supply S T Internal supply S T The connector located on the power card provides the AC line voltage connection for the cooling fans The fans are factory equipped to be supplied from a common AC line jumpers between 100 102 and 101 103 If an external supply is needed the jumpers are removed and the supply is connected...

Page 180: ... 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 to the adjustable frequency drive Max fuse size1 Min rated voltage Type K25 K75 10A 200 240 V type gG 1K1 2K2 20A 200 240 V type gG 3K0 3K7 32A 200 240 V type gG 5K5 7K5 63A 200 240 V type gG 11K 80...

Page 181: ...ussmann SIBA Littel fuse Ferraz Shawmut kW Type JFHR2 Type RK1 JFHR2 JFHR2 22K FWX 150 2028220 150 L25S 150 A25X 150 30K FWX 200 2028220 200 L25S 200 A25X 200 37K FWX 250 2028220 250 L25S 250 A25X 250 KTS fuses from Bussmann may substitute for KTN for 240 V adjustable frequency drives FWH fuses from Bussmann may substitute for FWX for 240 V adjustable frequency drives KLSR fuses from LITTEL FUSE m...

Page 182: ...substituted for A50P fuses 170M fuses shown from Bussmann use the 80 visual indicator TN 80 Type T 110 or TN 110 Type T indicator fuses of the same size and amperage may be substituted 525 600 V frame sizes A B and C Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann kW Type RK1 Type J Type T Type CC Type CC Type CC K75 1K5 KTS R 5 JKS 5 JJS 6 FNQ R 5 KTK R 5 LP CC 5 2K2 4K0 KTS R10 JKS 10 JJS ...

Page 183: ...RD30D08A 0400 NOS 400 170M4012 170M4016 P160 FWH 500 JJS 500 2061032 5 L50S 500 6 6URD30D08A 0500 NOS 500 170M4014 170M4016 P200 FWH 600 JJS 600 2062032 63 L50S 600 6 6URD32D08A 630 NOS 600 170M4016 170M4016 Table 8 2 Frame size D Line fuses 380 500 V Size Type Bussmann PN Rating Ferraz Siba P250 170M4017 700 A 700 V 6 9URD31D08A0700 20 610 32 700 P315 170M6013 900 A 700 V 6 9URD33D08A0900 20 630 ...

Page 184: ...2 900 Table 8 7 Frame size E 525 690 V Size Type Bussmann PN Rating Siba Internal Bussmann Option P630 170M7081 1600 A 700 V 20 695 32 1600 170M7082 P710 170M7081 1600 A 700 V 20 695 32 1600 170M7082 P800 170M7081 1600 A 700 V 20 695 32 1600 170M7082 P900 170M7081 1600 A 700 V 20 695 32 1600 170M7082 P1M0 170M7082 2000 A 700 V 20 695 32 2000 170M7082 Table 8 8 Frame size F Line fuses 525 690 V Siz...

Page 185: ...30 P1M0 525 690 V LPJ 20 SP or SPI 20 A 600 V Any listed Class J Dual Ele ment Time Delay 20 A 10 16 A Fuse P450 P800 380 500 V LPJ 25 SP or SPI 25 A 600 V Any listed Class J Dual Ele ment Time Delay 25 A P630 P1M0 525 690 V LPJ 20 SP or SPI 20 A 600 V Any listed Class J Dual Ele ment Time Delay 20 A Table 8 12 Manual Motor Controller Fuses Frame size Bussmann PN Rating Alternative Fuses F LPJ 30 ...

Page 186: ...raus Naimer KG160 T303 C2 125 hp 90 kW Kraus Naimer KG250 T303 8 4 2 Line Power Disconnectors Frame Size D E and F Frame size Power Voltage Type D1 D3 P90K P110 380 500 V P90K P132 525 690 V ABB OETL NF200A or OT200U12 91 D2 D4 P132 P200 380 500 V P160 P315 525 690 V ABB OETL NF400A or OT400U12 91 E1 E2 P250 380 500 V P355 P560 525 690 V ABB OETL NF600A E1 E2 P315 P400 380 500 V ABB OETL NF800A F3...

Page 187: ...or Cable The motor must be connected to terminals U T1 96 V T2 97 W T3 98 Ground to terminal 99 All types of three phase asynchronous standard motors can be used with an adjustable frequency drive unit The factory setting is for clockwise rotation with the adjustable frequency drive output connected as follows Terminal No Function 96 97 98 99 Line power U T1 V T2 W T3 Ground Terminal U T1 96 conne...

Page 188: ...ent see motor nameplate For thermal motor protection it is also possible to use the MCB 112 PTC thermistor card option This card provides an ATEX certificate to protect motors in explosion hazard areas Zone 1 21 and Zone 2 22 Please refer to the Design Guide for further information 8 5 3 Parallel Connection of Motors The adjustable frequency drive can control several parallel connected motors When...

Page 189: ... low RPM values if motor sizes are widely different because small motors relatively high ohmic resistance in the stator calls for a higher voltage at start and at low RPM values The electronic thermal relay ETR of the adjustable frequency drive cannot be used as motor protection for the individual motor of systems with parallel connected motors Provide further motor protection with for example the...

Page 190: ... Strictly follow the EMC Installation guideline Reinforce the PE so the high frequency impedance is lower in the PE than the input power leads Provide a good high frequency connection between the motor and the adjustable frequency drive for instance by shielded cable which has a 360 connection in the motor and the adjustable frequency drive Make sure that the impedance from adjustable frequency dr...

Page 191: ...Figure 8 33 Frame sizes A1 A2 A3 B3 B4 C3 and C4 Figure 8 34 Frame sizes A5 B1 B2 C1 and C2 FC 300 Design Guide 8 Electrical Installation MG 33 BC 22 VLT is a registered Danfoss trademark 8 33 8 ...

Page 192: ...ether with other control wires see picture Control card wiring path for the D3 Control card wiring for the D1 D2 D4 E1 and E2 use the same path Control card wiring path for the F1 F3 Control card wiring for the F2 F4 use the same path In the Chassis IP00 and NEMA 1 units it is also possible to connect the serial communication bus from the top of the unit as shown on the picture to the right On the...

Page 193: ...full operation of the LCP including parameter setting without connection to line power Please note that a warning of low voltage will be given when 24 V DC has been connected however there will be no tripping Use 24 V DC supply of type PELV to ensure correct galvanic isolation type PELV on the control terminals of the adjustable frequency drive FC 300 Design Guide 8 Electrical Installation MG 33 B...

Page 194: ...o 10 V configuration for the analog input terminals 53 and 54 respectively Switch S801 BUS TER can be used to enable termination on the RS 485 port terminals 68 and 69 See drawing Diagram showing all electrical terminals in section Electrical Installation Default setting S201 A53 OFF voltage input S202 A54 OFF voltage input S801 Bus termination OFF When changing the function of S201 S202 or S801 b...

Page 195: ... hole 3 Insert the cable in the adjacent circular hole 4 Remove the screwdriver The cable is now mounted to the terminal To remove the cable from the terminal 1 Insert a screwdriver1 in the square hole 2 Pull out the cable 1 Max 0 015 x 0 1 in 0 4 x 2 5 mm 1 2 3 FC 300 Design Guide 8 Electrical Installation MG 33 BC 22 VLT is a registered Danfoss trademark 8 37 8 ...

Page 196: ...onnect terminals 18 27 and 37 AutomationDrive FC 302 only to 24 V terminal 12 13 Default settings 18 Start par 5 10 Terminal 18 Digital Input 9 27 Stop inverse par 5 12 Terminal 27 Digital Input 6 37 safe stop inverse 8 Electrical Installation FC 300 Design Guide 8 38 MG 33 BC 22 VLT is a registered Danfoss trademark 8 ...

Page 197: ...de Terminal 37 is not included in AutomationDrive FC 301 Except AutomationDrive FC 301 A1 which includes Safe Stop Relay 2 and Terminal 29 have no function in AutomationDrive FC 301 In rare cases very long control cables and analog signals may depending on installation result in 50 60 Hz ground loops due to noise from line power supply cables If this occurs it may be necessary to break the shield ...

Page 198: ...roups For example switching on the digital input may disturb the analog input signal Input polarity of control terminals NOTE Control cables must be shielded armored See section entitled Grounding of Shielded Armored Control Cables for the correct termination of control cables 130BA681 10 130BA681 10 8 Electrical Installation FC 300 Design Guide 8 40 MG 33 BC 22 VLT is a registered Danfoss tradema...

Page 199: ...resistor If the input between 104 and 106 is established the adjustable frequency drive will trip on warning alarm 27 Brake IGBT If the connection is closed between 104 and 105 the adjustable frequency drive will trip on warning alarm 27 Brake IGBT Normally closed 104 106 factory installed jumper Normally open 104 105 Terminal No Function 106 104 105 Brake resistor temperature switch If the temper...

Page 200: ... may not isolate the adjustable frequency drive due to DC link connection 8 7 3 Installation of Brake Cable The connection cable to the brake resistor must be shielded and the max length from the adjustable frequency drive to the DC bar is limited to 82 ft 25 m 1 Connect the shield by means of cable clamps to the conductive back plate on the adjustable frequency drive and to the metal cabinet of t...

Page 201: ...nated by a resistor network at both ends For this purpose set switch S801 on the control card to ON For more information see the paragraph Switches S201 S202 and S801 NOTE Communication protocol must be set to par 8 30 Protocol 8 7 5 How to Connect a PC to the Adjustable Frequency Drive To control the adjustable frequency drive from a PC install the MCT 10 Set up Software The PC is connected via a...

Page 202: ...rive has a high leakage current and must be grounded appropriately for safety reasons Always follow local safety regulations High frequency grounding Keep the ground wire connections as short as possible Connect the different ground systems at the lowest possible conductor impedance The lowest possible conductor impedance is obtained by keeping the conductor as short as possible and by using the g...

Page 203: ... armor conduit to ground at both ends for motor cables as well as for control cables In some cases it is not possible to connect the shield at both ends If so connect the shield at the adjustable frequency drive See also Grounding of Braided Shielded Armored Control Cables Avoid terminating the shield armor with twisted ends pigtails It increases the high frequency impedance of the shield which re...

Page 204: ...pliant electrical installation of an adjustable frequency drive in a cabinet Figure 8 40 Electrical connection diagram 8 Electrical Installation FC 300 Design Guide 8 46 MG 33 BC 22 VLT is a registered Danfoss trademark 8 ...

Page 205: ...able Transfer impedance ZT can be assessed on the basis of the following factors The conductibility of the shield material The contact resistance between the individual shield conductors The shield coverage i e the physical area of the cable covered by the shield often stated as a percentage value Shield type i e braided or twisted pattern a Aluminum clad with copper wire b Twisted copper wire or ...

Page 206: ...otential between the adjustable frequency drive and the PLC etc is different electric noise may occur that will disturb the entire system Solve this problem by fitting an equal izing cable next to the control cable Minimum cable cross sec tion 0 025 in2 16 mm2 d For 50 60 Hz ground loops If very long control cables are used 50 60 Hz ground loops may occur Solve this problem by connecting one end o...

Page 207: ...transformed by means of a Fourier analysis and split up into sine wave currents with different frequencies i e different harmonic currents I N with 50 Hz as the basic frequency Harmonic currents I1 I5 I7 Hz 50 Hz 250 Hz 350 Hz The harmonics do not affect the power consumption directly but increase the heat losses in the installation transformer cables Consequently in plants with a high percentage ...

Page 208: ...ppears a DC content may develop in the faulty current If RCD relays are used you must observe local regulations Relays must be suitable for protection of 3 phase equipment with a bridge rectifier and for a brief discharge on power up see section Ground Leakage Current for further information 8 Electrical Installation FC 300 Design Guide 8 50 MG 33 BC 22 VLT is a registered Danfoss trademark 8 ...

Page 209: ...Activate the Automatic Motor Adaptation AMA Performing an AMA will ensure optimum performance The AMA measures the values from the motor model equivalent diagram 1 Connect terminal 37 to terminal 12 if terminal 37 is available 2 Connect terminal 27 to terminal 12 or set par 5 12 Terminal 27 Digital Input to No function 3 Activate the AMA par 1 29 Automatic Motor Adaptation AMA 4 Choose between com...

Page 210: ...n of the alarm will assist you in troubleshooting If you contact Danfoss for service make sure to mention the number and alarm description NOTE An unsuccessful AMA is often caused by incorrectly registered motor nameplate data or a difference between the motor power size and the adjustable frequency drive power size that is too large Step 4 Set speed limit and ramp times par 3 02 Minimum Reference...

Page 211: ...eration De fault coast inverse Terminal 37 Safe stop where available 9 1 2 Pulse Start Stop Terminal 18 par 5 10 Terminal 18 Digital InputLatched start 9 Terminal 27 par 5 12 Terminal 27 Digital InputStop inverse 6 Terminal 37 Safe stop where available FC 300 Design Guide 9 Application Examples MG 33 BC 22 VLT is a registered Danfoss trademark 9 1 9 ...

Page 212: ...p the encoder the basic settings for a closed loop speed control system will be shown Encoder connection to the adjustable frequency drive 24 V incremental encoder Max cable length 16 ft 5 m 9 1 5 Encoder Direction The direction of the encoder is determined by which order the pulses are entering the drive A clockwise direction means channel A is 90 electrical degrees before channel B Counter Clock...

Page 213: ... or Coast and Reset inverse 3 and program terminal 29 to Terminal mode 29 Output 1 and Torque limit stop 27 Description If a stop command is active via terminal 18 and the adjustable frequency drive is not at the torque limit the motor ramps down to 0 Hz If the adjustable frequency drive is at the torque limit and a stop command is activated terminal 29 Output programmed to Torque limit and stop 2...

Page 214: ...ted on the contactor s coil for protection of the adjustable frequency drive The contact 01 02 in the adjustable frequency drive stays normally open so the output is not energized When the START condition comes from the command circuit the drive closes the 01 02 contact according to the programmed brake logic The output is now energized until STOP condition occurs If the adjustable frequency drive...

Page 215: ...m a few minutes on small motors to more than 15 minutes on large motors Limitations and preconditions For the AMA to determine the motor parameters optimally enter the correct motor nameplate data in par 1 20 Motor Power kW to par 1 28 Motor Rotation Check For the best adjustment of the adjustable frequency drive carry out AMA on a cold motor Repeated AMA runs may lead to a heating of the motor wh...

Page 216: ...reset Reference 1 Ex 0 zero Set the timer 0 for constant running speed in par 13 20 SL Controller Timer 0 Ex 2 sec Set Event 1 in par 13 51 SL Controller Event 1 to True 1 Set Event 2 in par 13 51 SL Controller Event 2 to On Reference 4 Set Event 3 in par 13 51 SL Controller Event 3 to Time Out 0 30 Set Event 4 in par 13 51 SL Controller Event 1 to False 0 Set Action 1 in par 13 52 SL Controller A...

Page 217: ...e PTCs from the motor with the option card X44 12 is connected with Safe Stop terminal 37 on the FC 302 Terminal X44 10 is connected to a digital input of the FC 302 This digital input can be terminal 33 but this is only an example any other digital input could be used instead The use of this signal allows the drive to determine which source has activated the Safe Stop as other components can be c...

Page 218: ...ication bus when the conditions of the PTC are acceptable again the temperature of the motor has dropped Par 5 15 Terminal 33 Digital Input 80 PTC Card 1 Connects the digital Input of terminal 33 in the FC 302 to the MCB 112 which makes it possible for the MCB 112 to indicate when Safe Stop has been activated from here Alternatively par 5 19 could be set to option 5 PTC 1 Warning which means an au...

Page 219: ...er 5 19 could be 8 PTC 1 Relay A W or 9 PTC 1 Relay W A which are combinations of alarm and warning The choice depends on the needs of the customer NOTE Selection 4 9 in par 5 19 will only be visible in case the MCB 112 is plugged into the B option slot Take care that the DI that is set to 80 is not also configured as Thermistor Resource motor protection in par 1 93 Please refer to Parameter setti...

Page 220: ... range 3 00 Min max 0 Terminal 53 Low Voltage 6 10 0 V Default 0 07 V Terminal 53 High Voltage 6 11 10V Terminal 53 Low Ref 6 14 0 Nm Terminal 53 High Ref 6 15 Max torque on motor shaft Speed Limit Factor Adjustable on input 54 Speed Limit Factor Source Operation 4 21 Analog Input 54 6 Terminal 54 Low Voltage 6 20 0 V default 0 07 V Terminal 54 High Voltage 6 21 10 V Terminal 54 Low Ref 6 24 0V Te...

Page 221: ...ontrol Panel the terminal cover and the LCP frame from the adjustable frequency drive Insert the MCB10x option card into slot B Connect the control cables and relieve the cable by the enclosed cable strips Remove the knock out in the extended LCP frame so that the option will fit under the extended LCP frame Fit the extended LCP frame and terminal cover Fit the LCP or blind cover in the extended L...

Page 222: ...e How to Order section for a list of ordering numbers The installation is illustrated using MCB 112 as an example For more information on installation of the MCO305 see the separate instruction manual Frame sizes A2 A3 and B3 Frame sizes A5 B1 B2 B4 C1 C2 C3 and C4 If both C0 and C1 options are to be installed the installation is carried out as shown below Note that this is only possible for frame...

Page 223: ...tal and analog inputs and outputs of AutomationDrive FC 301 and AutomationDrive FC 302 Contents MCB 101 must be fitted into slot B in the VLT AutomationDrive MCB 101 option module Extended fixture for LCP Terminal cover FC 300 Design Guide 10 Options and Accessories MG 33 BC 22 VLT is a registered Danfoss trademark 10 3 10 ...

Page 224: ...alvanically isolated from other inputs outputs on the MCB101 but not from these on the control card of the drive If digital inputs 7 8 or 9 are to be switched using the internal 24 V power supply terminal 9 the connection between terminal 1 and 5 illustrated in the drawing has to be established Figure 10 2 Principle Diagram 10 Options and Accessories FC 300 Design Guide 10 4 MG 33 BC 22 VLT is a r...

Page 225: ...log inputs 10 bit sign Accuracy of analog inputs Max error 0 5 of full scale Bandwidth AutomationDrive FC 301 20 Hz AutomationDrive FC 302 100 Hz 10 2 4 Digital Outputs Terminal X30 6 7 Digital output Number of digital outputs 2 Terminal number X30 6 X30 7 Voltage level at digital frequency output 0 24 V Max output current 40 mA Max load 600 Ω Max capacitive load 10 nF Minimum output frequency 0 H...

Page 226: ...nitoring None Warning or Trip When the encoder option kit is ordered separately it includes Encoder Option MCB 102 Enlarged LCP fixture and enlarged terminal cover The encoder option does not support AutomationDrive FC 302 adjustable frequency drives manufactured before week 50 2004 Min software version 2 03 par 15 43 Software Version Connector Designa tion X31 Incremental Encoder please refer to ...

Page 227: ...Max cable length 492 ft 150 m FC 300 Design Guide 10 Options and Accessories MG 33 BC 22 VLT is a registered Danfoss trademark 10 7 10 ...

Page 228: ...er Input Volt age par 17 51 Input Voltage 2 0 8 0 Vrms 7 0Vrms Resolver Input Fre quency par 17 52 Input Frequency 2 15 kHz 10 0 kHz Transformation ratio par 17 53 Transformation Ratio 0 1 1 1 0 5 Secondary input volt age Max 4 Vrms Secondary load App 10 kΩ NOTE The Resolver Option MCB 103 can only be used with rotor supplied resolver types Stator supplied resolv ers cannot be used LED indicators ...

Page 229: ...Control Principle Flux with feedback 3 par 1 10 Motor Construction PM non salient SPM 1 par 1 24 Motor Current Nameplate par 1 25 Motor Nominal Speed Nameplate par 1 26 Motor Cont Rated Torque Nameplate AMA is not possible on PM motors par 1 30 Stator Resistance Rs Motor data sheet par 1 37 d axis Inductance Ld Motor data sheet mH par 1 39 Motor Poles Motor data sheet par 1 40 Back EMF at 1000 RPM...

Page 230: ...Label for covering access to switches S201 S202 and S801 Cable strips for fastening cables to relay module The relay option does not support AutomationDrive FC 302 adjustable frequency drives manufactured before week 50 2004 Min software version 2 03 par 15 43 Software Version A2 A3 B3 A5 B1 B2 B4 C1 C2 C3 C4 1 IMPORTANT The label MUST be placed on the LCP frame as shown UL approved Warning Dual s...

Page 231: ...xture and enlarged terminal cover Replace the LCP Connect power to the adjustable frequency drive Select the relay functions in par 5 40 Function Relay 6 8 par 5 41 On Delay Relay 6 8 and par 5 42 Off Delay Relay 6 8 NOTE Array 6 is relay 7 array 7 is relay 8 and array 8 is relay 9 Do not combine 24 48 V systems with high voltage systems FC 300 Design Guide 10 Options and Accessories MG 33 BC 22 V...

Page 232: ...ers Terminal 35 external 24 V DC supply Terminal 36 external 24 V DC supply Follow these steps 1 Remove the LCP or blind cover 2 Remove the Terminal Cover 3 Remove the Cable Decoupling Plate and the plastic cover un derneath 4 Insert the 24 V DC Backup External Supply Option in the Option Slot 5 Mount the Cable Decoupling Plate 6 Attach the terminal cover and the LCP or blind cover When MCB 107 24...

Page 233: ...ve FC 302 that a request for safe stop came from the MCB 112 in order to ensure a suitable alarm handling One of the digital Inputs of the AutomationDrive FC 302 or a DI of a mounted option must be set to PCT Card 1 80 in order to use the information from X44 10 par 5 19 Terminal 37 Safe Stop Terminal 37 Safe Stop must be configured to the desired safe stop functionality default is Safe Stop Alarm...

Page 234: ...ution 2 Measurement isolation voltage Vbis 690 V Reliable galvanic isolation until Vi 500 V Perm ambient temperature 4 F 20 C 140 F 60 C EN 60068 2 1 Dry heat Moisture 5 95 no condensation permissible EMC resistance EN61000 6 2 EMC emissions EN61000 6 4 Vibration resistance 10 1000 Hz 1 14g Shock resistance 50 g Safety system values EN 61508 ISO 13849 for Tu 167 F 75 C ongoing Category 2 SIL 2 for...

Page 235: ...e galvanic isolation between the VLT AutomationDrive and the option card If galvanic isolation is not needed the option card can be supplied through internal 24 V from the drive NOTE It is OK to combine 24 V signals with high voltage signals in the relays as long as there is one unused relay in between To set up the MCB 113 use Par groups 5 1 Digital input 6 7 Analog output 3 6 8 Analog output 4 1...

Page 236: ...C option adaptor is a C option that makes it possible to combine a number of different options 130BB093 10 Figure 10 6 Drawing of MCF 106 A B in C option adaptor Two options can be installed in the MCF 106 at the same time The upper slot is called E0 and the lower is called E1 One A and one B option can be installed in the standard A and B slots of the control card behind the LCP blind cover With ...

Page 237: ... 101 General Purpose I O A 2B1 D A2 C D Yes MCB 103 Resolver option A 2B1 D A2 C D Yes MCB 108 PLC Safe Interface A 2B1 D A2 C D No MCB 112 PTC Thermistor Card 3 A 2B1 D A2 C D C0 No MCO 305 Programmable Motion Control None A B4 C 5 D No MCO 350 Synchronizing Control None A B4 D No MCO 351 Positioning Control None A B4 D No MCO 352 Center Winder None A B4 D C1 No MCA 103 ProfiSafe Safe Stop None A...

Page 238: ... near future MCA 121 EthernetIP will be the first one to be available for MCF 106 For installations in bookstyle enclosures A2 A3 and B3 the 2 36 in 60 mm mounting kit is used and must be ordered when buying the adaptor as a separate option Please see the MCF 106 Instruction Manual MI38Fxyy for installation instructions 10 10 Brake Resistors In applications where the motor is used as a brake energ...

Page 239: ...ngth between and unit 9 8 ft 3 m Communication std RS 485 Ordering no 130B1113 Ordering no 130B1114 Figure 10 7 LCP kit with graphical LCP fasteners 9 8 ft 3 m cable and gasket Figure 10 8 LCP kit with numerical LCP fasteners and gasket LCP kit without an LCP is also available Ordering number 130B1117 For IP55 units the ordering number is 130B1129 FC 300 Design Guide 10 Options and Accessories MG ...

Page 240: ...e fitted to cover the top inlet Place the base part C at the bottom of the drive and use the clamps from the acces sory bag to correctly fasten the cables Holes for cable connectors Size A2 2x M25 and 3xM32 Size A3 3xM25 and 3xM32 A2 Enclosure A3 Enclosure Dimensions Enclosure type Height mm A Width mm B Depth mm C A2 372 90 205 A3 372 130 205 B3 475 165 249 B4 670 255 246 C3 755 329 337 C4 950 39...

Page 241: ... option module B is are used the brim B must be fitted to the top cover A B3 Enclosure B4 C3 C4 Enclosure NOTE Side by side installation is not possible when using the IP 21 IP 4X TYPE 1 Enclosure Kit FC 300 Design Guide 10 Options and Accessories MG 33 BC 22 VLT is a registered Danfoss trademark 10 21 10 ...

Page 242: ... difficult to mount the adjustable frequency drive Measure distance A or B and position the upper bracket but do not tighten it See dimensions below Frame size A5 B1 B2 B3 B4 IP 55 66 21 55 66 21 55 66 21 55 66 21 55 66 A mm 480 535 705 730 820 B mm 495 550 720 745 835 Ordering number 130B1080 130B1081 130B1082 130B1083 130B1084 10 Options and Accessories FC 300 Design Guide 10 22 MG 33 BC 22 VLT ...

Page 243: ...d lift the upper one When the adjustable frequency drive is in place lower the upper bracket Now tighten the screws For extra security drill and mount screws in all holes FC 300 Design Guide 10 Options and Accessories MG 33 BC 22 VLT is a registered Danfoss trademark 10 23 10 ...

Page 244: ...he heaters at 10 C 50 F and turn them off at 15 6 C 60 F Cabinet Light with Power Outlet A light mounted on the cabinet interior of frame size F adjustable frequency drives increase visibility during servicing and maintenance The housing light includes a power outlet for temporarily powering tools or other devices available in two voltages 230 V 50 Hz 2 5 A CE ENEC 120 V 60 Hz 5 A UL cUL Transform...

Page 245: ...sure and a Pilz relay that monitors it in conjunction with the drive s safe stop circuit and the line power contactor located in the options cabinet Manual Motor Starters Provide 3 phase power for electric blowers often required for larger motors Power for the starters is provided from the load side of any supplied contactor circuit breaker or disconnect switch Power is fused before each motor sta...

Page 246: ...ple Analog current or analog voltage Additional features One universal output configurable for analog voltage or analog current Two output relays N O Dual line LC display and LED diagnostics Sensor lead wire break short circuit and incorrect polarity detection Interface set up software Dedicated thermistor inputs 2 Features Each module is capable of monitoring up to six thermistors in a series Fau...

Page 247: ... for bus cabling and always follow good common installation practice Low impedance ground connection of the shield at every node is very important also at high frequencies This can be achieved by connecting a large surface of the shield to ground by means of a cable clamp or a conductive cable gland for example It may be necessary to apply potential equalizing cables to maintain the same ground po...

Page 248: ...isted pair cables are recommended in or der to reduce noise between conductors Figure 11 1 Network Terminal Connection Figure 11 2 Control card terminals 11 1 3 RS 485 Bus Termination Use the terminator dip switch on the main control board of the adjustable frequency drive to terminate the RS 485 bus NOTE The factory setting for the dip switch is OFF Terminator Switch Factory Setting 11 RS 485 Ins...

Page 249: ...um of 126 slaves can be connected to the bus The individual slaves are selected by the master via an address character in the message A slave itself can never transmit without first being requested to do so and direct message transfer between the individual slaves is not possible Communications occur in the half duplex mode The master function cannot be transferred to another node single master sy...

Page 250: ...llowed by a byte denoting the message length LGE and a byte denoting the adjustable frequency drive address ADR A number of data bytes variable depending on the type of message follows The message is completed by a data control byte BCC 11 4 3 Message Length LGE The message length is the number of data bytes plus the address byte ADR and the data control byte BCC The length of messages with 4 data...

Page 251: ...djustable frequency drive address 1 31 2 Address format 1 126 Bit 7 1 address format 1 126 active Bit 0 6 Adjustable frequency drive address 1 126 Bit 0 6 0 Broadcast The slave returns the address byte unchanged to the master in the response telegram 11 4 5 Data Control Byte BCC The checksum is calculated as an XOR function Before the first byte in the telegram is received the calculated checksum ...

Page 252: ...ytes 2 words and contains Control word and reference value from master to slave Status word and present output frequency from slave to master Parameter block The parameter block is used to transfer parameters between master and slave The data block is made up of 12 bytes 6 words and also contains the process block Text block The text block is used to read or write texts via the data block 11 RS 48...

Page 253: ...word 1 1 0 1 Write parameter value in RAM and EEPROM double word 1 1 1 0 Write parameter value in RAM and EEPROM word 1 1 1 1 Read write text Response slave master Bit no Response 15 14 13 12 0 0 0 0 No response 0 0 0 1 Parameter value transferred word 0 0 1 0 Parameter value transferred double word 0 1 1 1 Command cannot be performed 1 1 1 1 text transferred If the command cannot be performed the...

Page 254: ...a parameter value write write the new value in the PWE block and send from the master to the slave When a slave responds to a parameter request read command the present parameter value in the PWE block is transferred and returned to the master If a parameter contains not a numerical value but several data options e g par 0 01 Language where 0 corresponds to English and 4 corresponds to Danish sele...

Page 255: ...d Low Limit Hz has a conversion factor of 0 1 To preset the minimum frequency to 10 Hz transfer the value 100 A conversion factor of 0 1 means that the value transferred is multiplied by 0 1 The value 100 is thus perceived as 10 0 Conversion table Conversion index Conversion factor 74 0 1 2 100 1 10 0 1 1 0 1 2 0 01 3 0 001 4 0 0001 5 0 00001 11 4 13 Process Words PCD The block of process words is...

Page 256: ...r 4 14 is 19E in hexadecimal The response from the slave to the master will be 11 5 2 Reading a Parameter Value Read the value in par 3 41 Ramp 1 Ramp up Time PKE 1155 Hex Read parameter value in par 3 41 Ramp 1 Ramp up Time IND 0000 Hex PWEHIGH 0000 Hex PWELOW 0000 Hex If the value in par 3 41 Ramp 1 Ramp up Time is 10 s the response from the slave to the master will be NOTE 3E8 Hex corresponds t...

Page 257: ...f action to be taken and extract any data or other information contained in the message If a reply is required the controller will construct the reply message and send it Controllers communicate using a master slave technique in which only one device the master can initiate transactions called queries The other devices slaves respond by supplying the requested data to the master or taking the acti...

Page 258: ... Coast stop Quick stop DC Brake stop Normal ramp stop Reset after a fault trip Run at a variety of preset speeds Run in reverse Change the active set up Control the adjustable frequency drive s built in relay The bus reference is commonly used for speed control It is also possible to access the parameters read their values and where possible write values to them This permits a range of control opt...

Page 259: ...CRC 11 8 2 Modbus RTU Message Structure The transmitting device places a Modbus RTU message into a frame with a known beginning and ending point This allows receiving devices to begin at the start of the message read the address portion determine which device is addressed or all devices if the message is broadcast and to recognize when the message is completed Partial messages are detected and err...

Page 260: ... master it uses the function code field to indicate either a normal error free response or that some kind of error occurred called an exception response For a normal response the slave simply echoes the original function code For an exception response the slave returns a code that is equivalent to the original function code with its most significant bit set to logic 1 In addition the slave places ...

Page 261: ...equency drive feedback signal Slave to master 65 Parameter write control master to slave Master to slave 0 Parameter changes are written to the RAM of the adjustable frequency drive 1 Parameter changes are written to the RAM and EEPROM of the adjust able frequency drive 66 65536 Reserved Coil 0 1 01 Preset reference LSB 02 Preset reference MSB 03 DC brake No DC brake 04 Coast stop No coast stop 05...

Page 262: ...exed parameter 11 8 9 How to Control the Adjustable Frequency Drive This section describes codes that can be used in the function and data fields of a Modbus RTU message For a complete description of all the message fields please refer to the section Modbus RTU Message Framing Structure 11 8 10 Function Codes Supported by Modbus RTU Modbus RTU supports use of the following function codes in the fu...

Page 263: ... specifically the combination of reference number and transfer length is invalid For a controller with 100 registers a request with offset 96 and length 4 would succeed a request with offset 96 and length 5 will generate exception 02 3 Illegal data value A value contained in the query data field is not an allowable value for server or slave This indicates a fault in the structure of the remainder ...

Page 264: ...ent attributes for each parameter can be seen in the section on factory settings Since a parameter value can only be transferred as a whole number a conversion factor must be used to transfer decimals Please refer to the Parameters section 11 9 6 Parameter Values Standard Data Types Standard data types are int16 int32 uint8 uint16 and uint32 They are stored as 4x registers 40001 4FFFF The paramete...

Page 265: ...n of the Control Bits Bits 00 01 Bits 00 and 01 are used to choose between the four reference values which are pre programmed in par 3 10 Preset Reference according to the following table Programmed ref value Par Bit 01 Bit 00 1 par 3 10 Preset Reference 0 0 0 2 par 3 10 Preset Reference 1 0 1 3 par 3 10 Preset Reference 2 1 0 4 par 3 10 Preset Reference 3 1 1 NOTE Make a selection in par 8 56 Pre...

Page 266: ... stop and makes the motor speed ramp down to stop via the selected ramp down parameter Bit 06 1 Permits the adjustable frequency drive to start the motor if the other starting conditions are met NOTE Make a selection in par 8 53 Start Select to define how Bit 06 Ramp stop start gates with the corresponding function on a digital input Bit 07 Reset Bit 07 0 No reset Bit 07 1 Resets a trip Reset is a...

Page 267: ...15 causes reversing only when Ser communication Logic or or Logic and is selected 11 10 2 Status Word According to FC Profile STW par 8 10 Control Profile FC profile Bit Bit 0 Bit 1 00 Control not ready Control ready 01 Drive not ready Drive ready 02 Coasting Enable 03 No error Trip 04 No error Error no trip 05 Reserved 06 No error Triplock 07 No warning Warning 08 Speed reference Speed reference ...

Page 268: ...up down during start stop Bit 08 1 The motor speed matches the preset speed reference Bit 09 Local operation bus control Bit 09 0 STOP RESET is activate on the control unit or Local control in par 3 13 Reference Site is selected You cannot control the adjustable frequency drive via serial communication Bit 09 1 It is possible to control the adjustable frequency drive via the serial communication b...

Page 269: ...he adjustable frequency drive is lost or if an internal communication problem has occurred 11 10 3 Bus Speed Reference Value Speed reference value is transmitted to the adjustable frequency drive in a relative value expressed as The value is transmitted in the form of a 16 bit word in integers 0 32767 the value 16384 4000 Hex corre sponds to 100 Negative figures are formatted by means of 2 s com p...

Page 270: ... is 0 Hz and if Relay 123 has been selected in par 5 40 Function Relay When bit 00 1 the adjustable frequency drive is in State 1 Switching on inhibited Please refer to the PROFIdrive State Transition Diagram at the end of this section Bit 01 OFF 2 ON 2 Coasting stop When bit 01 0 a coasting stop and activation of the output relay 1 or 2 occurs if the output frequency is 0 Hz and if Relay 123 has ...

Page 271: ...cording to the respective reference value Bit 06 Ramp stop Start Normal ramp stop using the ramp times of the actual ramp as selected In addition activation of the output relay 01 or 04 if the output frequency is 0 Hz if Relay 123 has been selected in par 5 40 Function Relay Bit 06 0 leads to a stop When bit 06 1 the adjustable frequency drive can start if the other start conditions are satisfied ...

Page 272: ...rence value occurs When bit 12 1 the reference value is increased If both slowing down and accelerating are activated bit 11 and 12 1 slowing down has priority i e the speed reference value will be reduced Bits 13 14 Set up selection Bits 13 and 14 are used to choose between the four parameter set ups according to the following table The function is only possible if Multi Set up has been chosen in...

Page 273: ...y drive control is ready but there is not necessarily power supply to the unit present in the event of external 24 V supply of the control system Bit 01 VLT not ready ready Same significance as bit 00 however there is a supply of the power unit The adjustable frequency drive is ready when it receives the necessary start signals Bit 02 Coasting Enable When bit 02 0 bit 00 01 or 02 of the control wo...

Page 274: ... the output frequency is outside the limits set in par 4 52 Warning Speed Low and par 4 53 Warning Speed High When bit 10 1 the output frequency is within the indicated limits Bit 11 No operation Operation When bit 11 0 the motor does not turn When bit 11 1 the adjustable frequency drive has a start signal or the output frequency is higher than 0 Hz Bit 12 Drive OK Stopped autostart When bit 12 0 ...

Page 275: ...7 Brake Function 3 31 Brake Resistor 3 28 Brake Resistor Cabling 3 33 Brake Resistor Temperature Switch 8 41 Brake Resistors 10 18 Brake Resistors 10 18 Braking Energy 1 4 3 31 Break away Torque 1 3 C Cable Clamp 8 48 Cable Clamps 8 45 Cable Cross section 5 17 Cable Lengths And Cross sections 4 20 Cable Positions 7 14 Cable length And Cross section 8 10 Cabling 8 10 Catch Up Slow down 3 11 Ce Conf...

Page 276: ...Digital Inputs 4 21 Digital Output 4 23 Digital Outputs Terminal X30 6 7 10 5 Disposal Instructions 2 2 Drip Shield Installation 7 28 Drive Configurator 5 1 Duct Cooling 7 22 E Efficiency 4 25 Electrical Installation 8 37 8 39 Electrical Installation Emc Precautions 8 45 Electrical Terminals 8 39 Electro mechanical Brake 9 3 Emc Directive 89 336 eec 2 5 Emc Precautions 11 3 Emc Test Results 3 24 E...

Page 277: ...5 Insulation Resistance Monitor irm 10 25 Intermediate Circuit 3 34 4 26 Internal Current Control In Vvcplus Mode 3 8 Ip 21 type 1 Enclosure Kit 10 20 It Line Power 8 49 J Jog 1 3 Jog 11 20 L Leakage Current 3 27 Lifting 7 2 Line Drop out 3 35 Line Power Disconnectors 8 28 Line Power Supply 1 6 Line Power Supply 4 1 4 9 4 10 4 11 Line Power Supply l1 L2 L3 4 20 Line Power Supply Interference 8 49 ...

Page 278: ...ine Wave Filter Modules 200 500 V Ac 5 22 Ordering Numbers Sine wave Filter Modules 525 690 V Ac 5 23 Output Performance u V W 4 20 P Parameter Values 11 18 Pelv Protective Extra Low Voltage 3 26 Planning The Installation Site 7 1 Plc 8 48 Potentiometer Reference 9 2 Power Connections 8 10 Process Pid Control 3 18 Profibus 1 1 5 6 Programming Of Torque Limit And Stop 9 3 Protection 2 5 3 26 3 27 8...

Page 279: ...eed Pid 3 4 3 6 Speed Pid Control 3 15 Start stop 9 1 Static Overload In Vvcplus Mode 3 35 Status Word 11 21 Status Word According To Profidrive Profile stw 11 27 Surroundings 4 24 Switches S201 S202 And S801 8 36 Switching Frequency 8 10 Switching On The Output 3 34 Synchronous Motor Speed 1 3 T Terminal Locations 7 15 Terminal Locations Frame Size D 7 2 The Emc Directive 89 336 eec 2 3 The Low v...

Page 280: ...W What Is Ce Conformity And Labeling 2 3 What Is Covered 2 4 Wire Access 7 12 Index FC 300 Design Guide 12 6 MG 33 BC 22 VLT is a registered Danfoss trademark ...

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