Danfoss VLT AutomationDrive FC 301 Design Manual Download

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MAKING MODERN LIVING POSSIBLE

Design Guide

VLT

AutomationDrive FC 301/302

0.25-75 kW

www.danfoss.com/drives

Summary of Contents for VLT AutomationDrive FC 301

Page 1: ...MAKING MODERN LIVING POSSIBLE Design Guide VLT AutomationDrive FC 301 302 0 25 75 kW www danfoss com drives...

Page 2: ......

Page 3: ...2 Qualified Personnel 12 2 3 Safety Precautions 12 3 Basic Operating Principles 14 3 1 General 14 3 2 Description of Operation 14 3 3 Sequence of Operation 14 3 3 1 Rectifier Section 14 3 3 2 Interme...

Page 4: ...Imbalance Detection 37 4 1 5 Switching on the Output 37 4 1 6 Overload Protection 37 4 1 7 Locked Rotor Protection 37 4 1 8 Automatic Derating 37 4 1 9 Automatic Energy Optimisation 37 4 1 10 Automati...

Page 5: ...5 1 7 Aggressive Atmospheres 47 5 1 7 1 Gases 47 5 1 7 2 Dust Exposure 47 5 1 7 3 Potentially Explosive Atmospheres 48 5 1 8 Maintenance 48 5 1 9 Storage 48 5 2 General Aspects of EMC 49 5 2 1 EMC Te...

Page 6: ...pes B 73 6 2 6 3 Derating for Ambient Temperature Enclosure Types C 76 6 2 7 Measured Values for dU dt Testing 78 6 2 8 Efficiency 81 6 2 9 Acoustic Noise 81 7 How to Order 82 7 1 Drive Configurator 8...

Page 7: ...138 9 6 3 Load Sharing 138 9 6 4 Brake Resistor 138 9 6 5 PC Software 139 9 6 5 1 MCT 10 139 9 6 5 2 MCT 31 139 9 6 5 3 Harmonic Calculation Software HCS 139 9 7 Additional Motor Information 140 9 7...

Page 8: ...Harmonic Filters 170 11 4 6 IP21 Type 1 Enclosure Kit 170 11 4 7 Remote Mounting Kit for LCP 173 11 4 8 Mounting Bracket for Enclosure Types A5 B1 B2 C1 and C2 174 12 RS 485 Installation and Set up 17...

Page 9: ...1 7 CRC Check Field 184 12 11 8 Coil Register Addressing 184 12 11 9 How to Control the Frequency Converter 186 12 11 10 Function Codes Supported by Modbus RTU 186 12 11 11 Modbus Exception Codes 186...

Page 10: ...on and description of illustrations Italicised text indicates cross reference link footnote parameter name parameter group name parameter option 60 AVM 60 Asynchronous Vector Modulation A Ampere AMP A...

Page 11: ...alert against unsafe practices NOTICE Indicates important information including situations that may result in damage to equipment or property 1 4 Definitions Coast The motor shaft is in free mode No t...

Page 12: ...6 72 Table 1 2 Document and Software Version 1 6 Regulatory Compliance Frequency converters are designed in compliance with the directives described in this section 1 6 1 CE Mark The CE mark Communaut...

Page 13: ...request 1 6 2 UL Compliance UL Listed Illustration 1 1 UL NOTICE Frequency converters of enclosure type T7 525 690 V are not certified for UL The frequency converter complies with UL508C thermal memo...

Page 14: ...cted to AC mains the motor may start at any time causing risk of death serious injury equipment or property damage The motor can start by means of an external switch a serial bus command an input refe...

Page 15: ...intenance Ensure that electrical work conforms to national and local electrical codes Follow the procedures in this manual CAUTION WINDMILLING Unintended rotation of permanent magnet motors causes ris...

Page 16: ...wave filter circuit consisting of the DC bus inductor and the DC bus capacitor bank The DC bus inductor provides series impedance to changing current This aids the filtering process while reducing har...

Page 17: ...specific considerations and should not be attempted without first consulting Danfoss application engineering In the second method the frequency converter is powered exclusively from a DC source This i...

Page 18: ...9 D IN 24 V NPN 0 V PNP 27 24 V 0 V D IN OUT 0 V PNP 24 V NPN D IN OUT 0 V 24 V 29 24 V NPN 0 V PNP 0 V PNP 24 V NPN 33 D IN 32 D IN 1 2 ON S201 ON 2 1 S202 ON 0 4 20 mA OFF 0 10 V DC 10 V DC 95 P 5 0...

Page 19: ...4 Cable clamp 10 Potential equalisation min 16 mm2 0 025 in 5 Cable insulation stripped 11 Clearance between control cable motor cable and mains cable Min 200 mm 6 Cable gland Illustration 3 3 EMC com...

Page 20: ...speed PID feedback in 7 00 Speed PID Feedback Source Torque control The torque control function is used in applications where the torque on motor output shaft is controlling the application as tension...

Page 21: ...ration protection Load sharing Brake Resistor Drive Control Board Illustration 3 4 Control Principle FC 301 FC 302 is a high performance frequency converter for demanding applications The frequency co...

Page 22: ...o 1 VVC and 1 00 Configuration Mode is set to 0 Speed open loop The resulting reference from the reference handling system is received and fed through the ramp limitation and speed limitation before b...

Page 23: ...M Non salient motor In the shown configuration 1 01 Motor Control Principle is set to 2 Flux sensorless and 1 00 Configuration Mode is set to 0 Speed open loop The resulting reference from the referen...

Page 24: ...peed closed loop The motor control in this configuration relies on a feedback signal from an encoder or resolver mounted directly on the motor set in 1 02 Flux Motor Feedback Source Select 1 Speed clo...

Page 25: ...nded PID Speed CL N A Not Active N A Not Active Table 3 1 Control Configurations with Active Speed Control N A means that the specific mode is not available at all Not Active means that the specific m...

Page 26: ...This feature increases the dynamic performance of the speed control loop 7 09 Speed PID Error Correction w Ramp The speed error between ramp and actual speed is held up against the setting in this pa...

Page 27: ...for safe keeping 0 50 LCP Copy 1 All to LCP Table 3 3 Programming Order 3 6 6 2 Tuning PID Speed Control The following tuning guidelines are relevant when using one of the Flux motor control principl...

Page 28: ..._ 0 100 100 0 100 100 Illustration 3 9 Process PID Control Diagram Table 3 5 sums up the characteristics that can be set up for the process control Parameter Description of function 7 20 Process CL F...

Page 29: ...n 1 6 oscillations per second is damped by the filter The control is only carried out on a feedback signal that varies by a frequency speed of less than 1 6 Hz The low pass filter improves steady stat...

Page 30: ...Process Control is used when the remote reference is active 1 05 Local Mode Configuration determines the kind of application control principle that is used when the local reference is active One of th...

Page 31: ...utput Speed up speed down ref Remote Ref in max ref max ref Scale to RPM or Hz Scale to Nm Scale to process unit Relative X X Y 100 DigiPot DigiPot DigiPot max ref min ref DigiPot D1 P 5 1x 15 Preset...

Page 32: ...the Programming Guide The scaling of analog references are described in parameter groups 6 1 Analog Input 1 and 6 2 Analog Input 2 and the scaling of digital pulse references are described in paramete...

Page 33: ...and pulse inputs in the same way The only difference is that a reference above or below the specified minimum and maximum endpoints P1 and P2 in Illustration 3 17 are clamped whereas a feedback above...

Page 34: ...ant 2 Quadrant 3 Quadrant 1 Quadrant 4 Terminal X low Terminal X high Low reference feedback value High reference feedback value 1 1 130BA180 10 1500 6 6 V 1500 10 10 P1 P2 0 Illustration 3 20 Reverse...

Page 35: ...to min max reference giving a speed Scale to speed 500 RPM 500 RPM Range Speed setpoint Motor control Range 200 RPM 200 RPM Motor Digital input 19 Low No reversing High Reversing Limits Speed Setpoin...

Page 36: ...100 100 500 RPM 500 RPM Limited to 200 200 1000 RPM 1000 RPM Reference is scaled according to max reference giving a speed Scale to speed 500 RPM 500 RPM Range Speed setpoint Motor control Range 200...

Page 37: ...tor Limits speed to min max motor speed Motor PID RPM Dead band General Reference parameters Reference Range Max Max Minimum Reference Don t care Maximum Reference 1000 RPM 100 0 General Motor paramet...

Page 38: ...converter ie the load generates energy During deceleration ramp down if the moment of inertia is high the friction is low and the ramp down time is too short for the energy to be dissipated as a loss...

Page 39: ...uilt in temperature sensors and reacts immediately to critical values via hard coded limits 4 1 7 Locked Rotor Protection There may be situations when the rotor is locked due to excessive load or some...

Page 40: ...erference RFI in case of radio frequency is disturbance which can affect an electrical circuit due to electro magnetic induction or radiation from an external source The frequency converter is designe...

Page 41: ...pecific curve to protect the Ex e motor The Programming Guide takes the user through the set up 4 2 3 Mains Drop out During a mains drop out the frequency converter keeps running until the intermediat...

Page 42: ...between independently programmed functions activated by digital inputs or a serial command Independent set ups are used for example to change references or for day night or summer winter operation or...

Page 43: ...tection against unintended behaviour resulting from broken cable Monitoring of mechanical brake feedback throughout the complete cycle This helps protect the mechanical brake especially if more freque...

Page 44: ...n salient PM motors 2 26 Torque Ref to 2 33 Speed PID Start Lowpass Filter Time are only available for the hoist mechanical brake control FLUX with motor feedback 2 30 Position P Start Propor tional G...

Page 45: ...nly when event 0 is evaluated TRUE the SLC executes action 0 and starts evaluating event 1 It is possible to programme from 1 to 20 events and actions When the last event action has been executed the...

Page 46: ...an be driven by VLT AutomationDrive FC 302 and VLT Decentral Drive FCD 302 in the folllowing power sizes dependent on demands of the actual application 0 75 kW 1 1 kW 1 5 kW 2 2 kW 3 0 kW When 1 PM no...

Page 47: ...zes have a small secundary fan close to the control card ensuring that the internal air is circulated to avoid hot spots The main fan is controlled by the internal temperature in the frequency convert...

Page 48: ...d for additional cooling or derating of the motor 5 1 4 2 Derating for Low Air Pressure The cooling capability of air is decreased at lower air pressure Below 1000 m altitude no derating is necessary...

Page 49: ...sulphide mg m3 0 01 0 1 0 5 3 0 10 Chlorine mg m3 0 01 0 1 0 03 0 3 1 0 Hydrogen chloride mg m3 0 01 0 1 0 5 1 0 5 0 Hydrogen fluoride mg m3 0 003 0 01 0 03 0 1 3 0 Ammonia mg m3 0 3 1 0 3 0 10 35 Ozo...

Page 50: ...ent is in compliance with the e classification The restriction on the e connection space consists of the maximum voltage allowed in this space The output voltage of a frequency converter is usually li...

Page 51: ...s increase the screen impedance at higher frequencies which reduces the screen effect and increases the leakage current I4 If a screened cable is used for relay control cable signal interface and brak...

Page 52: ...V 50 150 150 No Yes Yes H2 H5 FC 301 0 3 7 kW 200 240 V No No 5 No No Yes FC 302 5 5 37 kW 200 240 V2 No No 25 No No Yes 0 7 5 kW 380 500 V No No 5 No No Yes 11 75 kW 380 500 V2 No No 25 No No Yes 11...

Page 53: ...cond environment industrial environment EN IEC 61000 6 4 Emission standard for industrial environments Class A Group 1 Table 5 4 Correlation between Generic Emission Standards and EN 55011 5 2 3 Immun...

Page 54: ...necessary a sine wave filter dU dt For motor cable lengths the maximum cable length listed in chapter 6 2 General Specifications the motor insulation ratings listed in Table 5 6 are recommended If a m...

Page 55: ...stration 5 4 Intermediate Circuit Coils NOTICE Some of the harmonic currents might disturb communi cation equipment connected to the same transformer or cause resonance in connection with power factor...

Page 56: ...rs There are various harmonic mitigation standards regulations and recommendations Different standards apply in different geographical areas and industries The following standards are the most common...

Page 57: ...electrical parts could be fatal even after the equipment has been disconnected from mains Also make sure that other voltage inputs have been disconnected such as load sharing linkage of DC intermediat...

Page 58: ...nds and T cycle is the total cycle time The brake resistance is calculated as shown Rbr Udc 2 Ppeak where Ppeak Pmotor x Mbr x motor x VLT W The brake resistance depends on the intermediate circuit vo...

Page 59: ...on The brake is protected against short circuiting of the brake resistor and the brake transistor is monitored to ensure that short circuiting of the transistor is detected A relay digital output can...

Page 60: ...0 26 7 Continuous kVA 208 V kVA 0 65 0 86 1 26 1 66 2 38 2 70 3 82 4 50 6 00 Max input current Continuous 200 240 V A 1 6 2 2 3 2 4 1 5 9 6 8 9 5 11 3 15 0 Intermittent 200 240 V A 2 6 3 5 5 1 6 6 9 4...

Page 61: ...NO HO NO HO NO HO NO Typical Shaft Output kW 15 18 5 18 5 22 22 30 30 37 37 45 Enclosure IP20 B4 C3 C3 C4 C4 Enclosure IP21 IP55 IP66 C1 C1 C1 C2 C2 Output current Continuous 200 240 V A 59 4 74 8 74...

Page 62: ...uous kVA 460 V kVA 0 9 1 3 1 7 2 4 2 7 3 8 5 0 6 5 8 8 11 6 Max input current Continuous 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 380 440 V A 1 9 2 6 3 5 4 3 5 9 8 0 10 4 14...

Page 63: ...380 440 V A 35 2 31 9 46 4 37 4 54 4 44 64 60 5 Continuous 441 500 V A 19 25 25 31 31 36 36 47 Intermittent 60 s overload 441 500 V A 30 4 27 5 40 34 1 49 6 39 6 57 6 51 7 Additional specifications I...

Page 64: ...200 177 Continuous 441 500 V A 47 59 59 73 73 95 95 118 118 145 Intermittent 60 s overload 441 500 V A 70 5 64 9 88 5 80 3 110 105 143 130 177 160 Additional specifications IP20 max cable cross secti...

Page 65: ...1 7 2 5 2 8 3 9 5 0 6 1 9 0 11 0 Continuous kVA 575 V kVA 1 7 2 4 2 7 3 9 4 9 6 1 9 0 11 0 Max input current Continuous 525 600 V A 1 7 2 4 2 7 4 1 5 2 5 8 8 6 10 4 Intermittent 525 600 V A 2 7 3 8 4...

Page 66: ...nt at 550 V A 28 23 33 28 41 36 52 43 59 54 Continuous at 575 V A 16 20 20 24 24 31 31 37 37 47 Intermittent at 575 V A 26 22 32 27 39 34 50 41 56 52 Additional specifications IP20 max cable cross sec...

Page 67: ...87 118 105 143 137 Continuous at 575 V A 47 56 56 75 75 91 91 119 Intermittent at 575 V A 70 62 85 83 113 100 137 131 Additional specifications IP20 max cable cross section for mains and motor mm2 AWG...

Page 68: ...NO HO NO HO NO HO NO Typical Shaft output at 550 V kW 7 5 11 11 15 15 18 5 18 5 22 Typical Shaft output at 690 V kW 11 15 15 18 5 18 5 22 22 30 Enclosure IP20 B4 B4 B4 B4 Enclosure IP21 IP55 B2 B2 B2...

Page 69: ...0 70 3 0 2 0 2 0 185 150 120 350 MCM 300 MCM 4 0 Estimated power loss at rated max load W 3 600 740 740 900 900 1100 1100 1500 1500 1800 Efficiency 2 0 98 0 98 0 98 0 98 0 98 Table 6 12 B4 C2 C3 Enclo...

Page 70: ...11 75 kW maximum 1 time min Switching on input supply L1 L2 L3 power ups 90 kW maximum 1 time 2 min Environment according to EN60664 1 overvoltage category III pollution degree 2 The unit is suitable...

Page 71: ...00 m Maximum cross section to control terminals flexible rigid wire without cable end sleeves 1 5 mm2 16 AWG Maximum cross section to control terminals flexible wire with cable end sleeves 1 mm2 18 AW...

Page 72: ...sing a freewheel diode or alternatively a 30 or 50 V MOV for quicker response time across the coil Typical contactors can be bought with this diode Analog inputs Number of analog inputs 2 Terminal num...

Page 73: ...m output frequency at frequency output 32 kHz Accuracy of frequency output Max error 0 1 of full scale Resolution of frequency outputs 12 bit 1 Terminal 27 and 29 can also be programmed as input The d...

Page 74: ...4 240 V AC 0 2 A Max terminal load DC 1 1 on 4 5 NO Resistive load 80 V DC 2 A Max terminal load DC 13 1 on 4 5 NO Inductive load 24 V DC 0 1 A Max terminal load AC 1 1 on 4 6 NC Resistive load 240 V...

Page 75: ...ustration 6 4 Derating of Iout for Different TAMB MAX for Enclosures Type A using 60 AVM and maximum 10 m motor cable SFAVM 2 20 4 6 8 10 12 14 16 40 60 80 100 110 Iout A1 A3 45 C A4 A5 40 C A1 A3 50...

Page 76: ...osure Types B1 and B2 using SFAVM in High overload mode 160 over torque 2 20 4 6 8 10 12 14 16 40 60 80 100 110 fsw kHz 45 C 50 C 55 C 0 0 Iout NO 130BA403 11 B1 B2 Illustration 6 11 Derating of Iout...

Page 77: ...utput current derating with switching frequency and ambient temperature for 600 V frequency converters enclosure type B SFAVM NO 1 2 4 6 8 20 10 40 60 80 90 100 o 50 C o 45 C 110 fsw kHz 0 0 lout B1 B...

Page 78: ...C2 Illustration 6 21 Derating of Iout for different TAMB MAX for enclosure types C1 and C2 using 60 AVM in Normal overload mode 110 over torque 130BB831 10 80 90 100 110 lout C3 C4 HO 2 4 6 8 20 10 4...

Page 79: ...pes C T6 60 AVM Pulse Width Modulation 1 2 4 6 8 20 10 40 60 80 90 100 o 50 C o 45 C 110 fsw kHz 0 0 lout C1 C2 NO 130BB821 10 Illustration 6 28 Output current derating with switching frequency and am...

Page 80: ...C3 6 2 7 Measured Values for dU dt Testing To avoid damage to motors without phase insulation paper or other insulation reinforcement designed for operation of the frequency converter it is strongly...

Page 81: ...150 240 0 776 0 546 0 562 Table 6 19 P30KT2 Cable length m Mains voltage V Rise time s Upeak kV dU dt kV s 30 240 0 300 0 598 1 594 100 240 0 536 0 566 0 844 150 240 0 776 0 546 0 562 Table 6 20 P37K...

Page 82: ...e V Rise time s Upeak kV dU dt kV s 5 480 0 371 1 170 2 523 Table 6 31 P55KT5 Cable length m Mains voltage V Rise time s Upeak kV dU dt kV s 5 480 0 371 1 170 2 523 Table 6 32 P75KT5 600 V T6 Cable le...

Page 83: ...onnected to the frequency converter depends on magnetising level 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 prac...

Page 84: ...with back plate P21 IP21 NEMA Type 1 with back plate P55 IP55 NEMA Type 12 with back plate Z20 IP 201 E66 IP 66 Description Pos Possible choices RFI filter 16 17 Hx No EMC filters built in the frequen...

Page 85: ...BX No option BK MCB 101 General purpose I O option BR MCB 102 Encoder option BU MCB 103 Resolver option BP MCB 105 Relay option BZ MCB 108 Safety PLC Interface B2 MCB 112 PTC Thermistor Card B4 MCB 1...

Page 86: ...lish German German German German French Chinese Slovenian Spanish Danish Korean Bulgarian English US Dutch Japanese Serbian Greek Spanish Thai Romanian Brazilian Portuguese Swedish Traditional Chinese...

Page 87: ...1 130B3910 VLT Back plate IP21 Type 1 IP55 Type 12 enclosure type C2 130B3911 VLT Back plate IP20 Type 1 enclosure type C3 130B4170 VLT Back plate IP20 Type 1 enclosure type C4 130B4171 VLT Back plate...

Page 88: ...tion MCB 141 130B6447 VLT Safe option MCB 150 130B3280 VLT Safe option MCB 151 130B3290 Mounting Kits for C options VLT Mounting Kit for C Option 40 mm enclosure types A2 A3 130B7530 VLT Mounting Kit...

Page 89: ...A1 Accessory bag enclosure type A1 130B1021 Accessory bag A2 A3 Accessory bag enclosure type A2 A3 130B1022 Accessory bag A5 Accessory bag enclosure type A5 130B1023 Accessory bag A1 A5 Accessory bag...

Page 90: ...70 0 200 175u3026 1 5 1 6 T2 2 2 40 2 44 6 48 0 200 175u3031 1 5 1 9 T2 3 29 1 32 3 35 0 300 175u3325 1 5 2 7 T2 3 7 22 5 25 9 27 0 360 175u3326 175u3477 175u3478 1 5 3 5 T2 5 5 17 7 19 7 18 0 570 17...

Page 91: ...570 175u3302 175u3404 175u3403 1 5 2 7 T2 2 2 40 2 44 6 48 0 960 175u3303 175u3406 175u3405 1 5 4 2 T2 3 29 1 32 3 35 1 130 175u3304 175u3408 175u3407 1 5 5 4 T2 3 7 22 5 25 9 27 1 400 175u3305 175u3...

Page 92: ...450 175u3335 175u3450 175u3449 1 5 1 9 T4 5 5 62 5 68 2 80 0 570 175u3336 175u3452 175u3451 1 5 2 5 T4 7 5 45 3 49 6 56 0 680 175u3337 175u3027 175u3028 1 5 3 3 T4 11 34 9 38 0 38 1 130 175u3338 175u...

Page 93: ...20 175u3419 1 5 2 1 T4 3 117 127 9 145 1 130 175u3313 175u3422 175u3421 1 5 2 7 T4 4 86 9 94 6 110 1 700 175u3314 175u3424 175u3423 1 5 3 7 T4 5 5 62 5 68 2 80 2 200 175u3315 175u3138 175u3139 1 5 5 T...

Page 94: ...5 1 6 T2 2 2 45 0 51 0 48 0 200 175u3031 1 5 1 9 T2 3 31 5 37 0 35 0 300 175u3325 1 5 2 7 T2 3 7 22 5 29 7 27 0 360 175u3326 175u3477 175u3478 1 5 3 5 T2 5 5 17 7 19 7 18 0 570 175u3327 175u3442 175u3...

Page 95: ...70 175u3302 175u3404 175u3403 1 5 2 7 T2 2 2 45 0 51 0 48 0 960 175u3303 175u3406 175u3405 1 5 4 2 T2 3 31 5 37 0 35 1 130 175u3304 175u3408 175u3407 1 5 5 4 T2 3 7 22 5 29 7 27 1 400 175u3305 175u341...

Page 96: ...450 175u3335 175u3450 175u3449 1 5 1 9 T5 5 5 72 0 84 4 80 0 570 175u3336 175u3452 175u3451 1 5 2 5 T5 7 5 50 0 61 4 56 0 680 175u3337 175u3027 175u3028 1 5 3 3 T5 11 36 0 41 2 38 1 130 175u3338 175u3...

Page 97: ...0 175u3419 1 5 2 1 T5 3 135 158 5 145 1 130 175u3313 175u3422 175u3421 1 5 2 7 T5 4 99 0 117 2 110 1 700 175u3314 175u3424 175u3423 1 5 3 7 T5 5 5 72 0 84 4 80 2 200 175u3315 175u3138 175u3139 1 5 5 T...

Page 98: ...9 0 114 5 100 0 570 175u3344 175u3136 175u3137 1 5 2 3 T6 7 5 69 0 83 2 72 0 680 175u3345 175u3456 175u3455 1 5 2 9 T6 11 48 6 56 1 52 1 130 175u3346 175u3458 175u3457 1 5 4 4 T6 15 35 1 40 8 38 1 400...

Page 99: ...175u3321 175u3436 175u3435 1 5 2 3 T6 4 135 159 2 145 1 700 175u3322 175u3126 175u3127 1 5 3 3 T6 5 5 99 0 114 5 100 2 200 175u3323 175u3438 175u3437 1 5 4 4 T6 7 5 69 0 83 2 72 3 200 175u3324 175u34...

Page 100: ...ble 7 16 T7 Vertical Braking 40 Duty Cycle Horizontal braking Duty cycle 10 and maximum 120 s repetition rates according the reference brake profile Average power corresponds to 6 Vertical braking Dut...

Page 101: ...100 or 150 200 14 or 27 1005 or 0989 P1K1 1 1 81 0 105 1 100 100 or 100 200 10 or 19 1006 or 0991 P1K5 1 5 58 5 76 0 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...

Page 102: ...200 14 0984 P2K2 2 2 189 0 218 6 210 200 10 0987 P3K0 3 135 0 158 5 150 200 or 300 200 7 or 14 0989 or 2 x 0985 P4K0 4 99 117 240 200 10 2 x 0986 P5K5 5 5 72 84 160 200 8 2 x 0988 P7K5 7 5 50 61 130 2...

Page 103: ...B1176 P37K 66 37 66 130B1399 130B1241 130B1281 130B1180 P45K 82 45 82 130B1442 130B1247 130B1291 130B1201 P55K 96 55 96 130B1443 130B1248 130B1292 130B1204 P75K 133 75 133 130B1444 130B1249 130B1293 1...

Page 104: ...P22K 29 24 29 130B5263 130B5248 130B5231 130B5214 P30K 36 33 36 130B5265 130B5250 130B5233 130B5216 P37K 49 40 50 130B5266 130B5251 130B5234 130B5217 P45K 58 50 58 130B5267 130B5252 130B5235 130B5218...

Page 105: ...2 2 10 6 5 5 13 5 5 11 17 16 13 5 130B2411 130B2446 3 12 5 7 5 16 7 5 14 5 3 7 16 7 5 5 24 2 11 24 11 21 24 23 18 4 130B2412 130B2447 7 5 30 8 15 32 15 27 38 36 28 5 4 130B2413 130B2448 18 5 37 5 18 5...

Page 106: ...B4124 Table 7 27 Sine Wave Filters for Frequency Converters with 525 690 V 1 Ordering numbers marked with are IP23 Parameter Setting 14 00 Switching Pattern 1 SFAVM 14 01 Switching Frequency Set accor...

Page 107: ...2 15 27 11 19 15 18 18 5 37 5 18 5 34 15 23 18 5 22 22 44 22 40 18 5 28 22 27 11 46 2 30 61 30 52 30 43 30 34 90 80 58 54 130B2838 130B2839 130B2840 15 59 4 37 73 37 65 37 54 37 41 18 5 74 8 45 90 55...

Page 108: ...ividual filter is not recommended 14 55 Output Filter 0 No Filter 14 56 Capacitance Output Filter Not used 14 57 Inductance Output Filter Not used Table 7 30 Parameter Settings for dU dt Filter Operat...

Page 109: ...cy converter is cooled by means of air circulation To protect the unit from overheating it must be ensured that the ambient temperature does NOT exceed the maximum temperature stated for the frequency...

Page 110: ...plate B 75 90 90 130 130 200 242 242 242 165 230 Width of back plate with one C option B 130 130 170 170 242 242 242 205 230 Width of back plate with 2 C options B 150 150 190 190 242 242 242 225 230...

Page 111: ...back plate with 2 C options B 308 370 308 370 Distance between mounting holes b 272 334 270 330 Depth mm Depth without option A B C 310 335 333 333 275 With option A B C 310 335 333 333 275 Screw hol...

Page 112: ...l cooling conditions allow a free air passage above and below the frequency converter See Table 8 3 a b 130BA419 10 Illustration 8 2 Clearance Enclosure Type A1 A2 A3 A4 A5 B1 B2 B3 B4 C1 C3 C2 C4 a m...

Page 113: ...h IP66 take extra care to maintain the corrosive resistant surface A fibre washer or a nylon washer may be used to protect the epoxy coating 130BA392 11 2 1 3 4 1 Back plate 2 IP66 frequency converter...

Page 114: ...equipment by a certified electrical installer For electrical safety Ground the frequency converter in accordance with applicable standards and directives Use a dedicated ground wire for input power m...

Page 115: ...A1 0 25 1 5 0 37 1 5 Mains Brake resistor load sharing Motor cables 0 5 0 6 A2 0 25 2 2 0 37 4 A3 3 3 7 5 5 7 5 1 1 7 5 A4 0 25 2 2 0 37 4 A5 3 3 7 5 5 7 5 B1 5 5 7 5 11 15 Mains Brake resistor load s...

Page 116: ...25 2 Motor 3 4 28 4 M25 3 Brake load sharing 3 4 28 4 M25 4 Control cable 1 2 22 5 M20 5 Control cable 1 2 22 5 M20 1 Tolerance 0 2 mm Illustration 9 1 A2 IP21 4 5 6 1 3 2 130BB657 10 Hole number and...

Page 117: ...e 0 2 mm 2 Knock out hole Illustration 9 5 A5 IP55 4 5 3 6 2 1 130BB666 10 Hole number and recommended use Nearest metric 1 Mains M25 2 Motor M25 3 Brake load sharing 28 4 mm1 4 Control cable M25 5 Co...

Page 118: ...lustration 9 9 B1 IP55 Threaded Gland Holes 1 4 5 3 2 130BB660 10 Hole number and recommended use Dimensions1 Nearest metric UL in mm 1 Mains 1 1 4 44 2 M40 2 Motor 1 1 4 44 2 M40 3 Brake load sharing...

Page 119: ...13 B3 IP21 5 3 2 4 1 130BB661 10 Hole number and recommended use Dimensions1 Nearest metric UL in mm 1 Mains 2 63 3 M63 2 Motor 2 63 3 M63 3 Brake load sharing 1 1 2 50 2 M50 4 Control cable 3 4 28 4...

Page 120: ...I FILTER INSTALLED When installed on a delta grounded grid or an IT grid including ground fault condition mains input voltage in the range of 380 500 V T4 T5 must not exceed 480 V RMS between mains an...

Page 121: ...the Ground Cable 130BA263 10 95 M A I N S DC BR BR U V W 91 92 93 L1 L2 L3 RELAY 1 RELAY 2 Illustration 9 19 Mounting Mains Plug and Tightening Wires DC BR BR U V W M A I N S L1 L2 L3 91 92 93 RELAY 1...

Page 122: ...Mains and Grounding with Disconnector When disconnector is used enclosures A4 A5 mount the PE on the left side of the frequency converter 130BT332 10 Illustration 9 23 Mains Connection Enclosures B1 a...

Page 123: ...llustration 9 25 Mains Connection Enclosure B4 130BA389 10 95 91 L1 92 L2 93 L3 Illustration 9 26 Mains Connection Enclosures C1 and C2 IP21 NEMA Type 1 and IP55 66 NEMA Type 12 Electrical Installatio...

Page 124: ...ide is mandatory to ensure compliance with IEC 60364 for CE or NEC 2009 for UL Branch Circuit Protection To protect the installation against electrical and fire hazard all branch circuits in an instal...

Page 125: ...ter short circuit current rating SCCR is 100 000 Arms The following UL listed fuses are suitable UL248 4 class CC fuses UL248 8 class J fuses UL248 12 class R fuses RK1 UL248 15 class T fuses The foll...

Page 126: ...0 gG 80 PKZM4 63 63 B2 18 5 22 gG 50 18 5 gG 63 22 gG 100 NZMB1 A100 100 B3 11 15 gG 40 gG 63 PKZM4 50 50 B4 18 5 30 gG 50 18 5 gG 63 22 gG 80 30 gG 125 NZMB1 A100 100 C1 30 45 gG 80 30 gG 100 37 gG 1...

Page 127: ...200 75 aR 250 NZMB2 A250 250 C3 37 45 gG 63 37 gG 100 45 gG 150 NZMB2 A200 150 C4 55 75 aR 160 55 aR 200 75 aR 250 NZMB2 A250 250 Table 9 5 525 600 V Enclosure Types A B and C Enclosure Power kW Reco...

Page 128: ...30 KTK R 30 LP CC 30 5 5 KTN R 50 KS 50 JJN 50 7 5 KTN R 60 JKS 60 JJN 60 11 KTN R 80 JKS 80 JJN 80 15 18 5 KTN R 125 JKS 125 JJN 125 22 KTN R 150 JKS 150 JJN 150 30 KTN R 200 JKS 200 JJN 200 37 KTN R...

Page 129: ...HAWMUT may substitute A25X for 240 V frequency converters Recommended max fuse Power kW Bussmann Type RK1 Bussmann Type J Bussmann Type T Bussmann Type CC Bussmann Type CC Bussmann Type CC 0 37 1 1 KT...

Page 130: ...A6K 25 R 7 5 5012406 032 KLS R 30 ATM R 30 A6K 30 R 11 5014006 040 KLS R 40 A6K 40 R 15 5014006 050 KLS R 50 A6K 50 R 18 5014006 063 KLS R 60 A6K 60 R 22 2028220 100 KLS R 80 A6K 80 R 30 2028220 125 K...

Page 131: ...mann Type T Bussmann Type CC Bussmann Type CC Bussmann Type CC 0 75 1 1 KTS R 5 JKS 5 JJS 6 FNQ R 5 KTK R 5 LP CC 5 1 5 2 2 KTS R 10 JKS 10 JJS 10 FNQ R 10 KTK R 10 LP CC 10 3 KTS R15 JKS 15 JJS 15 FN...

Page 132: ...6K 175 R HSJ 175 Table 9 14 525 600 V Enclosure Types A B and C Recommended max fuse Power kW Bussmann Type RK1 Bussmann Type J Bussmann Type T Bussmann Type CC Bussmann Type CC Bussmann Type CC kW 1...

Page 133: ...TS R 60 JKS 60 JJS 60 5014006 063 KLS R 060 A6K 60 R HST 60 30 80 A KTS R 80 JKS 80 JJS 80 5014006 080 KLS R 075 A6K 80 R HST 80 37 90 A KTS R 90 JKS 90 JJS 90 5014006 100 KLS R 090 A6K 90 R HST 90 45...

Page 134: ...pedance NOTICE Strip a piece of the motor cable to expose the screen behind the cable clamp AND connect the ground connection to terminal 99 Connect the motor cable screen to both the decoupling plate...

Page 135: ...name plate for correct connection mode and voltage MOTOR MOTOR U V W 99 130BT302 12 Illustration 9 30 Motor Connection for Enclosures A1 A2 and A3 U V W 96 97 98 130BT337 10 Illustration 9 31 Motor C...

Page 136: ...2 L3 93 97 U V W 96 98 Illustration 9 36 Motor Connection for Enclosures C3 and C4 9 5 Earth Leakage Current Protection Follow national and local codes regarding protective earthing of equipment with...

Page 137: ...es both complying with the dimensioning rules See EN IEC61800 5 1 and EN50178 for further information Using RCDs Where residual current devices RCDs also known as earth leakage circuit breakers ELCBs...

Page 138: ...l open 400 V Terminal 06 normal closed 240 V Relay 1 and relay 2 are programmed in 5 40 Function Relay 5 41 On Delay Relay and 5 42 Off Delay Relay Additional relay outputs by using Relay Option Modul...

Page 139: ...4 03 02 01 DC Illustration 9 43 Terminals for Relay Connection Enclosure Types C1 and C2 3 1 1 130BA215 10 RELAY 1 RELAY 2 9 9 6 0 3 0 2 0 1 9 0 0 5 0 4 Illustration 9 44 Terminals for Relay Connectio...

Page 140: ...external source It uses terminals 88 and 89 The connection cable must be screened and the max length from the frequency converter to the DC bar is limited to 25 m 82 ft Load sharing enables linking o...

Page 141: ...nd shield connected in the PC USB port 130BT308 10 Illustration 9 48 USB Connection 9 6 5 1 MCT 10 To control the frequency converter from a PC install the MCT 10 Set up Software Data storage in PC vi...

Page 142: ...art and at low RPM values The frequency converter can control several parallel connected motors When using parallel motor connection observe the following VCC mode may be used in some applications The...

Page 143: ...ables without Load 130BD777 10 Illustration 9 53 Parallel Cables with Load 130BD778 10 Illustration 9 54 LC Filter for Long Parallel Cables 130BD779 10 Illustration 9 55 Long Cables in Series Connecti...

Page 144: ...mance Wires with greater square have a lower impedance and better EMC grounding In case where more devices with metal cabinets are used mount them on common metal mounting plate to improve EMC perform...

Page 145: ...9 10 11 Illustration 9 56 Location of Relay Plugs Pos 8 and 9 Manufacturer declaration is available upon request Electrical Installation VLT AutomationDrive FC 301 FC 302 Design Guide 0 25 75 kW MG33...

Page 146: ...ents Parameter group 1 2 Motor Data must be set according to motor Table 10 1 AMA with T27 Connected Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 1...

Page 147: ...Stop Alarm Default Value Notes comments If 5 12 Terminal 27 Digital Input is set to 0 No operation a jumper wire to terminal 27 is not needed Table 10 5 Start Stop Command with Safe Torque Off 130BB8...

Page 148: ...ue Notes comments Table 10 8 External Alarm Reset Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 A53 U I 5k...

Page 149: ...ddress and Baud rate in the above mentioned parameters Table 10 11 RS 485 Network Connection Parameters 130BB686 12 VLT 24 V 24 V D IN D IN D IN COM D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 1...

Page 150: ...ed If the feedback error goes below the limit again within 5 s the frequency converter continues and the warning disappears But relay 1 is still triggered until Reset on the LCP Table 10 13 Using SLC...

Page 151: ...ast inverse or 3 Coast and Reset inverse and program terminal 29 to 1 Terminal mode 29 Output and 27 Torque limit stop Description If a stop command is active via terminal 18 and the frequency convert...

Page 152: ...ing to 0 to 10 V over the potentiometer Starting and stopping is controlled by a switch connected to terminal 18 The Speed PID monitors the actual RPM of the motor by using a 24 V HTL incremental enco...

Page 153: ...r Operator 1 13 12 Comparat or Value 90 13 51 SL Controller Event 22 Comparator 0 13 52 SL Controller Action 32 Set digital out A low 5 40 Function Relay 80 SL digital output A Default Value Notes com...

Page 154: ...Galvanic Isolation in MCB 101 Digital analog inputs are galvanically isolated from other inputs outputs on the MCB 101 and in the control card of the frequency converter Digital analog outputs in the...

Page 155: ...on for analog inputs 10 bit sign Accuracy of analog inputs Max error 0 5 of full scale Bandwidth FC 301 20 Hz FC 302 100 Hz Digital outputs terminal X30 6 7 Number of digital outputs 2 Terminal number...

Page 156: ...visible when removing the LCP Reaction in case of an encoder error can be selected in 17 61 Feedback Signal Monitoring 0 Disabled 1 Warning or 2 Trip When the encoder option kit is ordered separately...

Page 157: ...tor feedback device for Permanent Magnet brushless synchronous motors When the Resolver option is ordered separately the kit includes Resolver Option MCB 103 Enlarged LCP fixture and enlarged terminal...

Page 158: ...g is set to 1 Warning or 2 Trip 130BT102 10 Illustration 11 7 Permanent Magnet PM Motor with Resolver as Speed Feedback Set up example In this example a Permanent Magnet PM Motor is used with resolver...

Page 159: ...e 1 Enabled Table 11 3 Parameters to Adjust 11 2 4 VLT Relay Card MCB 105 The Relay Option MCB 105 includes 3 pieces of SPDT contacts and must be fitted into option slot B Electrical Data Max terminal...

Page 160: ...C2 C3 C4 WARNING Warning Dual supply How to add the Relay Card MCB 105 Option 1 Disconnect power to the frequency converter 2 Disconnect power to the live part connections on relay terminals 3 Remove...

Page 161: ...10 2 3 4 5 6 7 8 9 12 11 2 2 2 130BA176 11 1 NC 2 Live part 3 PELV Illustration 11 12 Correct Relay Wiring NOTICE Do not combine 24 48 V systems with high voltage systems Options and Accessories VLT A...

Page 162: ...e the following precautions The FC 302 with MCB 108 including the connections between X31 9 and Terminal 37 must be placed inside an IP54 enclosure Safe Stop activation i e removal of 24 V DC voltage...

Page 163: ...m ZIEHL X44 12 13 18 19 27 29 32 33 20 37 3 NC 4 NC 5 NC 6 NC 7 NC 8 NC 9 NC 10 11 NC 12 1 T1 2 T2 TP TP PTC M3 130BA638 10 DO Motor protection MCB 112 PTC Thermistor Card Option B Reference for 10 12...

Page 164: ...for the VLT AutomationDrive and is automatically detected after mounting 130BA965 10 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 2 1 13 14 A03 A03 Ext 24 VDC DI1 DI2 DI3 DI4 DI5 DI6...

Page 165: ...set point transmitter sensor inputs Typical motors designed with temperature sensors to protect bearings from being overloaded are fitted with 3 PT100 1000 temperature sensors one in front one in the...

Page 166: ...nected are expected to be galvanically isolated from the mains voltage level IEC 61800 5 1 and UL508C Cabling Maximum signal cable length 500 m 11 2 8 2 Electrical Wiring MCB 114 Sensor Input Option B...

Page 167: ...tomatically detected after mounting The MCB 15x can be used to monitor the stopping starting or speed of a rotating or laterally moving device As speed monitor the option is often used in combination...

Page 168: ...V DC Input current min 6 mA Vin 24 V inrush current 12 mA peak Input resistance approx 4 k Galvanic isolation No Short circuit proof Yes Input pulse recognition time min 3 ms Discrepancy time min 9 ms...

Page 169: ...ply voltage 24 V DC Voltage tolerance 0 5 V DC to 4 5 V DC Maximum output current 150 mA Short circuit proof Yes Cable length 30 m screened or unscreened cable 30 m screened cable Ground I O section C...

Page 170: ...style A2 and A3 40 mm for one C option 130B7530 A2 and A3 60 mm for C0 C1 option 130B7531 B3 40 mm for one C option 130B1413 B3 60 mm for C0 C1 option 130B1414 Compact A5 130B7532 B C D E and F except...

Page 171: ...tputs 1 Digital Output Input 2 Digital Output Input 3 Digital Output 4 Digital Output 5 Digital Output 6 Digital Output 7 Digital Output 8 Digital Output Table 11 9 Terminal Block X59 Terminal number...

Page 172: ...acoustic motor noise is reduced to a minimum The ripple current in the Sine wave filter coils also causes some noise Solve the problem by integrating the filter in a cabinet or similar 11 4 3 dU dt F...

Page 173: ...24 Place the top cover as shown If an A or B option is used the brim must be fitted to cover the top inlet Place the base part C at the bottom of the frequency converter and use the clamps from the a...

Page 174: ...1 Mechanical Dimensions for details E F D C B A 130BT620 12 Illustration 11 25 Enclosure Type B3 130BT621 12 D C A G Illustration 11 26 Enclosure Types B4 C3 C4 A Top cover B Brim C Base part D Base...

Page 175: ...m The LCP enclosure is rated IP66 Enclosure IP66 front Max cable length between and unit 3 m Communication std RS 485 Table 11 15 Technical Data 130BA138 10 Illustration 11 27 LCP Kit with Graphical L...

Page 176: ...ration 11 31 Upper Bracket Measure distance A or B and position the upper bracket but do not tighten it See dimensions in Table 11 16 Enclosure IP A mm B mm Ordering number A5 55 66 480 495 130B1080 B...

Page 177: ...rter is in place lower the upper bracket Step 4 130BA847 10 Illustration 11 33 Tightening of Screws Now tighten the screws For extra security drill and mount screws in all holes Options and Accessorie...

Page 178: ...ys use screened twisted pair STP cable for bus cabling and follow good common installation practice Low impedance ground connection of the screen at every node is important including at high frequenci...

Page 179: ...t national and local regulations for example regarding protective earth connection Keep the RS 485 communication cable away from motor and brake resistor cables to avoid coupling of high frequency noi...

Page 180: ...art character STX 02 hex 2 A byte denoting the telegram length LGE 3 A byte denoting the frequency converter address ADR A number of data bytes variable depending on the type of telegram follows A dat...

Page 181: ...r to master ADR LGE STX PCD1 PCD2 BCC 130BA269 10 Illustration 12 7 Process Block Parameter block The parameter block is used to transfer parameters between master and follower The data block is made...

Page 182: ...11 Data change in the defined parameter is not possible in the frequency converter s present mode Certain parameters can only be changed when the motor is turned off 82 There is no bus access to the...

Page 183: ...attributes of each parameter are displayed in factory setting Parameter values are transferred as whole numbers only Conversion factors are therefore used to transfer decimals 4 12 Motor Speed Low Li...

Page 184: ...of the capabilities and limitations of the controller 12 9 3 Modbus RTU Overview Regardless of the type of physical communication networks the Modbus RTU Overview describes the process a controller u...

Page 185: ...h byte in a message containing 2 4 bit hexadecimal characters The format for each byte is shown in Table 12 11 Start bit Data byte Stop parity Stop Table 12 11 Format for Each Byte Coding System 8 bit...

Page 186: ...wer places a unique code into the data field of the response message This tells the master what kind of error occurred or the reason for the exception Also refer to chapter 12 11 10 Function Codes Sup...

Page 187: ...sting stop Safety closed 36 No alarm Alarm 37 Not used Not used 38 Not used Not used 39 Not used Not used 40 No warning Warning 41 Not at reference At reference 42 Hand mode Auto mode 43 Out of freq r...

Page 188: ...server or follower More 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 reque...

Page 189: ...ter for 1 register 16 bits and the function 10 hex Preset Multiple Registers for 2 registers 32 bits Readable sizes range from 1 register 16 bits up to 10 registers 20 characters Non standard data typ...

Page 190: ...on on a digital input Bit 07 Reset Bit 07 0 No reset Bit 07 1 Resets a trip Reset is activated on the signal s leading edge i e when changing from logic 0 to logic 1 Bit 08 Jog Bit 08 1 The output fre...

Page 191: ...converter is tripped and locked Bit 07 No warning warning Bit 07 0 There are no warnings Bit 07 1 A warning has occurred Bit 08 Speed reference speed reference Bit 08 0 The motor is running but the p...

Page 192: ...cy output Use ramp 06 Ramp stop Start 07 No function Reset 08 Jog 1 OFF Jog 1 ON 09 Jog 2 OFF Jog 2 ON 10 Data invalid Data valid 11 No function Slow down 12 No function Catch up 13 Parameter set up S...

Page 193: ...d to tell the frequency converter whether the control word is to be used or ignored Bit 10 0 causes the control word to be ignored Bit 10 1 causes the control word to be used This function is relevant...

Page 194: ...n 8 10 Control Word Profile bit 06 is 1 after a switch off acknowledgment after activation of OFF2 or OFF3 and after switching on the mains voltage Start not possible is reset with bit 00 of the contr...

Page 195: ...5 Timer OK Timer exceeded When bit 15 0 the timers for the thermal motor protection and thermal frequency converter protection have not exceeded 100 When bit 15 1 one of the timers has exceeded 100 RS...

Page 196: ...word 187 190 Conventions 8 Cooling Cooling 46 47 conditions 110 D DC brake 188 bus connection 138 DC link 19 55 Dead band 31 Decoupling plate 132 Definitions 9 Derating automatic 37 Derating low air...

Page 197: ...tia 36 Motor cable 112 132 140 connection 132 feedback 22 output 68 phases 36 power 112 thermal protection 189 thermistor 147 voltage 78 wiring 18 Motor generated overvoltage 36 N Network connection 1...

Page 198: ...ne wave filter 103 132 170 Software versions 87 Speed PID 18 20 23 reference 144 146 Start stop command 145 Status word 189 192 Switching on the output 37 T Telegram length LGE 178 Temperature Tempera...

Page 199: ...Index VLT AutomationDrive FC 301 FC 302 Design Guide 0 25 75 kW MG33BF02 Rev 2013 12 20 197...

Page 200: ...ithout notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in...

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