Danfoss VLT AutomationDrive FC 303 Instruction Manual Download

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MAKING MODERN LIVING POSSIBLE

Instruction Manual

VLT

AutomationDrive FC 300

Summary of Contents for VLT AutomationDrive FC 303

Page 1: ...MAKING MODERN LIVING POSSIBLE Instruction Manual VLT AutomationDrive FC 300...

Page 2: ...NG DISCHARGE TIME Adjustable frequency drives contain DC link capacitors that can remain charged even when AC line power is discon nected To avoid electrical hazards remove AC line power from the adju...

Page 3: ...Safety VLT AutomationDrive Instruction Manual MG 33 AI 22 VLT is a registered Danfoss trademark...

Page 4: ...ents 3 5 2 4 2 1 Leakage Current 3 5mA 3 6 2 4 2 2 Grounding Using Shielded Cable 3 6 2 4 3 Motor Connection 3 6 2 4 4 AC Line Power Connection 3 7 2 4 5 Control Wiring 3 7 2 4 5 1 Access 3 7 2 4 5 2...

Page 5: ...the LCP 5 4 4 3 Restoring Default Settings 5 4 4 3 1 Recommended Initialization 5 4 4 3 2 Manual Initialization 5 4 5 About Adjustable Frequency Drive Programming 6 1 5 1 Introduction 6 1 5 2 Programm...

Page 6: ...asic Troubleshooting 10 1 9 1 Start Up and Operation 10 1 10 Specifications 11 1 10 1 Power dependent Specifications 11 1 10 2 General Technical Data 11 11 10 3 Fuse Tables 11 16 10 3 2 CE Compliance...

Page 7: ...Contents VLT AutomationDrive Instruction Manual MG 33 AI 22 VLT is a registered Danfoss trademark...

Page 8: ...ug 13 Brake 81 82 and load sharing 88 89 terminals 5 Analog switches A53 A54 14 Line power input terminals 91 L1 92 L2 93 L3 6 Cable strain relief PE ground 15 USB connector 7 Decoupling plate 16 Seri...

Page 9: ...93 L3 10 Relay 1 01 02 03 1 1 Purpose of the Manual This manual is intended to provide detailed information for the installation and start up of the adjustable frequency drive Chapter 2 Installation...

Page 10: ...ency and voltage of the output are regulated to control the motor speed or torque The adjustable frequency drive can vary the speed of the motor in response to system feedback such as position sensors...

Page 11: ...input 5 Capacitor bank Stores the DC power Provides ride through protection for short power losses 6 Inverter Converts the DC into a controlled PWM AC waveform for a controlled variable output to the...

Page 12: ...10 5 5 7 5 5 0 37 4 0 5 10 0 37 7 5 15 20 11 15 25 30 18 5 22 15 20 11 15 25 40 18 5 30 40 60 30 45 75 100 55 75 50 60 37 45 75 100 55 75 525 600 N A N A 1 10 0 75 7 5 N A 1 10 0 75 7 5 15 20 11 15 25...

Page 13: ...Introduction VLT AutomationDrive Instruction Manual 1 6 MG 33 AI 22 VLT is a registered Danfoss trademark 1 1...

Page 14: ...r of unit on the nameplate to what was ordered to verify the proper equipment Ensure each of the following are rated for the same voltage Line power Adjustable frequency drive Motor Ensure that Adjust...

Page 15: ...ocation will support the unit weight Mount the unit to a solid flat surface or to the optional backplate to provide cooling airflow see Figure 2 2 and Figure 2 3 Improper mounting can result in overhe...

Page 16: ...ring After power has been applied checking input and motor power programming control terminals for their intended functions Figure 2 4 Basic Wiring Schematic Drawing A Analog D Digital Terminal 37 is...

Page 17: ...ine power 2 Adjustable frequency drive 7 Motor 3 phase and PE 3 Output contactor Generally not recommended 8 Line power 3 phase and reinforced PE 4 Grounding rail PE 9 Control wiring 5 Cable insulatio...

Page 18: ...Alarms for details on the trip function Because the motor wiring carries high frequency current it is important that wiring for line power motor power and control is run separately Use metallic condu...

Page 19: ...parate ground wires both complying with the dimensioning rules See EN 60364 5 54 543 7 for further information Using RCDs Where residual current devices RCDs also known as ground leakage circuit break...

Page 20: ...rdance with grounding instructions provided in 2 4 2 Grounding Requirements All adjustable frequency drives may be used with an isolated input source as well as with ground reference power lines When...

Page 21: ...digital input for STO Safe Torque Off function Connector 2 terminals 68 and 69 are for an RS 485 serial communications connection Connector 3 provides two analog inputs one analog output 10V DC suppl...

Page 22: ...5 40 1 0 No operation Table 2 3 Terminal Description 2 4 5 3 Wiring to Control Terminals Control terminal connectors can be unplugged from the Adjustable frequency drive for ease of installation as s...

Page 23: ...required between terminal 12 or 13 and terminal 27 for the Adjustable frequency drive to operate when using factory default programming values Digital input terminal 27 is designed to receive an 24V D...

Page 24: ...ded description in the Design Guide Have a good knowledge of the generic and safety standards applicable to the specific application User is defined as integrator operator servicing maintenance staff...

Page 25: ...ower semiconductor failure In spite of the activation of the Safe torque off function the Adjustable frequency drive system can produce an alignment torque which maximally rotates the motor shaft by 1...

Page 26: ...st 9 5V DC 4 Adjustable frequency drive 10 Safe channel 5 Line power 11 Short circuit protected cable if not inside installation cabinet 6 Control board Safe Stop Commissioning Test After installation...

Page 27: ...vement the key point is that the load must be held stopped controlled raised lowered in a perfectly safe mode during the entire operation Because the Adjustable frequency drive is not a safety device...

Page 28: ...e and RS 485 connection or in parameter group 8 Communications and Options Selecting a specific communication protocol changes various default parameter settings to match that protocol s specification...

Page 29: ...Installation VLT AutomationDrive Instruction Manual 2 16 MG 33 AI 22 VLT is a registered Danfoss trademark 2 2...

Page 30: ...ncy drive disconnect switches for input power isolation 2 Verify that there is no voltage on input terminals L1 91 L2 92 and L3 93 phase to phase and phase to ground 3 Verify that there is no voltage...

Page 31: ...nce is adequate to ensure proper airflow for cooling EMC considerations Check for proper installation regarding electromagnetic compatibility Environmental considerations See equipment label for the m...

Page 32: ...l 27 See Figure 2 15 for details 3 3 Basic Operational Programming Adjustable frequency drives require basic operational programming prior to running for best performance Basic operational programming...

Page 33: ...edure that measures the electrical characteristics of the motor to optimize compatibility between the Adjustable frequency drive and the motor The Adjustable frequency drive builds a mathematical mode...

Page 34: ...the motor system and any attached equipment is ready for start It is the responsibility of the user to ensure safe operation under any operational condition Failure to ensure that the motor system an...

Page 35: ...e listed in 1 2 Additional Resources The following procedure is recommended after application set up by the user is completed CAUTION MOTOR START Ensure that the motor system and any attached equipmen...

Page 36: ...for details on use of the NLCP NOTE The display contrast can be adjusted by pressing STATUS and the up down key 4 1 1 LCP Layout The LCP is divided into four functional groups see Figure 4 1 Auto on...

Page 37: ...nction Status Press to show operational information In Auto mode press and hold to toggle between status readout displays Press repeatedly to scroll through each status display Press and hold Status p...

Page 38: ...trol panel 130BP046 10 Hand on Off Auto on Reset Key Function Hand On Press to start the adjustable frequency drive in local control Use the navigation keys to control adjustable frequency drive speed...

Page 39: ...tion of the adjustable frequency drive Initialization can be through 14 22 Operation Mode or manually Initialization using 14 22 Operation Mode does not change adjustable frequency drive data such as...

Page 40: ...lowing parameters using the navigation keys to scroll to the titles and press OK after each action 1 3 15 Reference Resource 1 5 1 130BB848 10 3 15 Reference Resource 1 Analog input 53 14 7 0 00A 1 1...

Page 41: ...he wiring connections used to enable this set up 53 55 6 1 A53 U I 130BB482 10 0 10V Figure 5 1 Wiring Example for External Device Providing 0 10V Control Signal adjustable frequency drive left extern...

Page 42: ...Frequency 132Hz 120Hz 4 53 Warning Speed High 1500 RPM 1800 RPM 5 12 Terminal 27 Digital Input Coast inverse External interlock 5 40 Function Relay No operation No alarm 6 15 Terminal 53 High Ref Feed...

Page 43: ...include such things as input and output signal types programming terminals minimum and maximum signal ranges custom displays automatic restart and other features See the LCP display to view detailed p...

Page 44: ...s 3 0 Reference Limits 3 00 Reference Range 3 01 Reference Feedback Unit 3 02 Minimum Reference 3 03 Maximum Reference 3 04 Reference Function 3 1 References 3 10 Preset Reference 3 11 Jog Speed Hz 3...

Page 45: ...Control Word Source 8 03 Control Word Timeout Time 8 04 Control Word Timeout Function 8 05 End of Timeout Function 8 06 Reset Control Word Timeout 8 07 Diagnosis Trigger 8 08 Readout Filtering 8 1 Ct...

Page 46: ...ue Nm High 16 3 Drive Status 16 30 DC Link Voltage 16 32 Brake Energy s 16 33 Brake Energy 2 min 16 34 Heatsink Temp 16 35 Inverter Thermal 16 36 Inv Nom Current 16 37 Inv Max Current 16 38 SL Control...

Page 47: ...X57 10 Digital Input 33 60 Terminal X59 1 and X59 2 Mode 33 61 Terminal X59 1 Digital Input 33 62 Terminal X59 2 Digital Input 33 63 Terminal X59 1 Digital Output 33 64 Terminal X59 2 Digital Output...

Page 48: ...e off line and simply downloaded into Adjustable frequency drive Or the entire Adjustable frequency drive profile can be loaded onto the PC for backup storage or analysis The USB connector or RS 485 t...

Page 49: ...About Adjustable Frequency VLT AutomationDrive Instruction Manual 5 10 MG 33 AI 22 VLT is a registered Danfoss trademark 5 5...

Page 50: ...e AMA 5 12 Terminal 27 Digital Input 2 Coast inverse Default Value Notes comments Parameter group 1 2 must be set according to motor Table 6 1 AMA with T27 Connected Parameters FC 24 V 24 V D IN D IN...

Page 51: ...operation 5 19 Terminal 37 Safe Stop 1 Safe 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 6 5 Sta...

Page 52: ...Notes comments Table 6 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 13...

Page 53: ...twork Connection CAUTION Thermistors must use reinforced or double insulation to meet PELV insulation requirements 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 O...

Page 54: ...red External equipment may then indicate that service may be required If the feedback error goes below the limit again within 5 sec then the drive continues and the warning disappears But Relay 1 will...

Page 55: ...Application Set Up Examples VLT AutomationDrive Instruction Manual 6 6 MG 33 AI 22 VLT is a registered Danfoss trademark 6 6...

Page 56: ...d from the control terminals and or the serial communication Hand On The adjustable frequency drive can be controlled by the navigation keys on the LCP Stop commands reset reversing DC brake and other...

Page 57: ...Freeze Reference was chosen as a function for a digital input parameter group 5 1 The corresponding terminal is active The adjustable frequency drive saves the actual reference Changing the reference...

Page 58: ...Speed Low Standby In Auto On mode the adjustable frequency drive will start the motor with a start signal from a digital input or serial communication Start delay In 1 71 Start Delay a delay starting...

Page 59: ...Status Messages VLT AutomationDrive Instruction Manual 7 4 MG 33 AI 22 VLT is a registered Danfoss trademark 7 7...

Page 60: ...ndition is remedied the Adjustable frequency drive can be reset It will then be ready to start operation again A trip can be reset in any of 4 ways Press RESET on the LCP Digital reset input command S...

Page 61: ...4 Ground Fault X X X 15 Hardware mismatch X X 16 Short Circuit X X 17 Control word time out X X 8 04 Control Word Timeout Function 20 Temp Input Error 21 Param Error 22 Hoist Mech Brake X X Parameter...

Page 62: ...cking error X X 4 30 Motor Feedback Loss Function 62 Output Frequency at Maximum Limit X 63 Mechanical Brake Low X 2 20 Release Brake Current 64 Voltage Limit X 65 Control Board Over temperature X X X...

Page 63: ...ove some of the load from terminal 50 as the 10V supply is overloaded Max 15mA or minimum 590 This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiomet...

Page 64: ...on gives a warning at 98 and trips at 100 while giving an alarm The Adjustable frequency drive cannot be reset until the counter is below 90 The fault is that the Adjustable frequency drive is overloa...

Page 65: ...to the Adjustable frequency drive and repair the ground fault Check for ground faults in the motor by measuring the resistance to ground of the motor leads and the motor with a megohmmeter ALARM 15 Ha...

Page 66: ...r is not connected or not working Check 2 15 Brake Check ALARM 29 Heatsink temp The maximum temperature of the heatsink has been exceeded The temperature fault will not reset until the temperature fal...

Page 67: ...eck 5 00 Digital I O Mode and 5 01 Terminal 27 Mode WARNING 41 Overload of digital output terminal 29 Check the load connected to terminal 29 or remove short circuit connection Check 5 00 Digital I O...

Page 68: ...r Feedback Loss Function Accepted error setting in 4 31 Motor Feedback Speed Error and the allowed time the error occur setting in 4 32 Motor Feedback Loss Timeout During a commissioning procedure the...

Page 69: ...l be generated on power cycle when the Adjustable frequency drive is set to run with fewer inverters and will remain on ALARM 78 Tracking error The difference between setpoint value and actual value h...

Page 70: ...he permitted minimum frequency 1 98 ATEX ETR interpol points freq 0 ALARM 243 Brake IGBT This alarm is only for F Frame drives It is equivalent to Alarm 27 The report value in the alarm log indicates...

Page 71: ...sensor fault highpower units only WARNING 250 New spare part A component in the Adjustable frequency drive has been replaced Reset the Adjustable frequency drive for normal operation WARNING 251 New...

Page 72: ...LCP from VLT 2800 or 5000 6000 8000 FCD or FCM Use only LCP 101 P N 130B1124 or LCP 102 P N 130B1107 Wrong contrast setting Press Status Up Down arrows to adjust the contrast Display LCP is defective...

Page 73: ...at 4 10 Motor speed direction is programmed correctly Program correct settings Active reversing signal Check if a reversing command is programmed for the terminal in parameter group5 1 Digital inputs...

Page 74: ...ads into the drive one position A to B B to C C to A If imbalanced leg follows the wire it is a power problem Check line power supply Problem with the Adjustable frequency drive unit Rotate input powe...

Page 75: ...Basic Troubleshooting VLT AutomationDrive Instruction Manual 9 4 MG 33 AI 22 VLT is a registered Danfoss trademark 9 9...

Page 76: ...4 9 4 9 4 9 6 6 6 6 A1 IP20 2 7 2 7 2 7 2 7 2 7 2 7 A5 IP 55 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 25 3 7 kW only available as 16...

Page 77: ...1 5 51 5 61 2 Max input current Continuous 3 x 200 240V A 54 68 68 80 80 104 104 130 130 154 Intermittent 60 sec overload 3 x 200 240V A 81 74 8 102 88 120 114 156 143 195 169 Additional specification...

Page 78: ...3 1 7 2 1 2 8 3 9 5 0 6 9 9 0 11 0 Continuous kVA 460V AC 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 3 x 380 440V A 1 2 1 6 2 2 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermitten...

Page 79: ...16 6 22 2 22 2 26 26 30 5 30 5 42 3 Continuous kVA 460V AC kVA 21 5 27 1 31 9 41 4 Max input current Continuous 3 x 380 440V A 22 29 29 34 34 40 40 55 Intermittent 60 sec overload 3 x 380 440V A 35 2...

Page 80: ...x input current Continuous 3 x 380 440V A 55 66 66 82 82 96 96 133 133 161 Intermittent 60 sec overload 3 x 380 440V A 82 5 72 6 99 90 2 123 106 144 146 200 177 Continuous 3 x 441 500V A 47 59 59 73 7...

Page 81: ...VA 1 7 2 5 2 8 3 9 5 0 6 1 9 0 11 0 Continuous kVA 575V AC kVA 1 7 2 4 2 7 3 9 4 9 6 1 9 0 11 0 Max input current Continuous 3 x 525 600V A 1 7 2 4 2 7 4 1 5 2 5 8 8 6 10 4 Intermittent 3 x 525 600V A...

Page 82: ...3 9 40 8 40 8 51 8 Max input current Continuous at 550V A 17 2 20 9 20 9 25 4 25 4 32 7 32 7 39 39 49 Intermittent at 550V A 28 23 33 28 41 36 52 43 59 54 Continuous at 575V A 16 20 20 24 24 31 31 37...

Page 83: ...nt Continuous at 550V A 49 59 59 78 9 78 9 95 3 95 3 124 3 Intermittent at 550V A 74 65 89 87 118 105 143 137 Continuous at 575V A 47 56 56 75 75 91 91 119 Intermittent at 575V A 70 62 85 83 113 100 1...

Page 84: ...551 690V A 20 8 19 8 28 8 24 2 35 2 29 7 43 2 37 4 Continuous KVA at 550V KVA 13 3 18 1 18 1 21 9 21 9 26 7 26 7 34 3 Continuous KVA at 575V KVA 12 9 17 9 17 9 21 9 21 9 26 9 26 9 33 9 Continuous KVA...

Page 85: ...re and brake mm2 AWG 95 4 0 Estimated power loss at rated max load W 4 480 592 720 880 1200 Weight enclosure IP21 IP55 kg 65 Efficiency4 0 98 0 98 0 98 0 98 0 98 For fuse ratings see 10 3 1 Fuses 1 Hi...

Page 86: ...ot more than 100 000 RMS symmetrical Amperes 240 500 600 690 V maximum Motor output U V W Output voltage 0 100 of supply voltage Output frequency 0 33 10 hp 0 25 75 kW FC 301 0 2 1000Hz FC 302 0 1000H...

Page 87: ...follow the related information and instructions in the Design Guide 4 When using a contactor with a DC coil inside and in combination with safe stop it is important to provide a return path for the cu...

Page 88: ...ut frequency at frequency output 32kHz 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 digital...

Page 89: ...AC 15 1 on 4 6 NC Inductive load cos 0 4 240V AC 0 2A Max terminal load DC 1 1 on 4 6 NC Resistive load 50V DC 2A Max terminal load DC 13 1 on 4 6 NC Inductive load 24 V DC 0 1A Min terminal load on...

Page 90: ...EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 See section on special conditions in the Design Guide Protection and Features Electronic thermal motor protection against overload Tem...

Page 91: ...es in the installation The adjustable frequency drive is equipped with an internal overcurrent protection 4 18 Current Limit that can be used for upstream overload protection UL applications excluded...

Page 92: ...5 1 5 gG 16 2 2 gG 25 PKZM0 25 25 A3 3 0 3 7 gG 16 3 gG 20 3 7 gG 32 PKZM0 25 25 B3 5 5 gG 25 gG 63 PKZM4 50 50 B4 7 5 1 5 gG 32 7 5 gG 50 11 gG 63 15 gG 125 NZMB1 A100 100 C3 18 5 22 gG 80 18 5 aR 12...

Page 93: ...25 A5 0 37 7 5 gG 10 0 37 3 gG 16 4 7 5 gG 32 PKZM0 25 25 B1 11 15 gG 40 gG 80 PKZM4 63 63 B2 18 5 22 gG 50 18 5 gG 63 22 gG 100 NZMB1 A100 100 C1 30 45 gG 80 30 gG 100 37 gG 160 45 gG 160 NZMB2 A200...

Page 94: ...5 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 A5 0 75 7 5 gG 10 0 75 5 5 gG 16 7 5 gG 32 PKZM0 25 25 B1 11 18 gG 25 11 gG 32 15 gG 40 18 5 gG 80 PKZM4 6...

Page 95: ...0 45 gG 200 55 75 aR 250 90 aR 315 110 aR 350 132 160 aR 400 200 aR 500 250 aR 550 315 gG 125 37 gG 160 45 gG 200 55 75 aR 250 90 aR 315 110 aR 350 132 160 aR 400 200 aR 500 250 aR 550 315 E 355 560 a...

Page 96: ...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 30 22 KTN R 150 JKS 150 JJN 150 40 30 KTN R 200 JKS 200 JJN 200 37 KTN R 2...

Page 97: ...RAZ SHAWMUT may substitute A25X for 240V adjustable frequency drives Recommended max fuse FC 300 Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann kW Type RK1 Type J Type T Type CC Type CC Type CC...

Page 98: ...2028220 160 KLS R 150 A6K 150 R 55 2028220 200 KLS R 200 A6K 200 R 75 2028220 250 KLS R 250 A6K 250 R Table 10 9 380 500V Frame Sizes A B and C Recommended max fuse FC 302 Bussmann Ferraz Shawmut Ferr...

Page 99: ...t Ferraz Shawmut kW Type RK1 Type RK1 Type RK1 J 0 75 1 1 5017906 005 KLS R 005 A6K 5 R HSJ 6 1 5 2 2 5017906 010 KLS R 010 A6K 10 R HSJ 10 3 5017906 016 KLS R 015 A6K 15 R HSJ 15 4 5017906 020 KLS R...

Page 100: ...only 525 600 V Table 10 13 525 690V Frame Sizes B and C 10 4 Connection Tightening Torques Power kW Torque Nm Enclo sure 200 240V 380 480 500V 525 600V 525 690V Line power Motor DC connection Brake Gr...

Page 101: ...Specifications VLT AutomationDrive Instruction Manual 10 26 MG 33 AI 22 VLT is a registered Danfoss trademark 10 10...

Page 102: ...C Output 10 13 Card 24 V DC Output 10 13 Card RS 485 Serial Communication 10 14 Card USB Serial Communication 10 14 Characteristics 10 14 Signal 5 1 5 2 7 1 System 1 3 Terminals 2 3 3 4 4 3 7 1 7 3 5...

Page 103: ...ol Test 3 5 Mode 3 5 Operation 4 1 Start 3 5 M Main Menu 4 2 5 1 4 2 Manual Initialization 4 4 Mechanical Brake Control 2 14 Menu Keys 4 1 4 2 Structure 4 3 5 4 Modbus RTU 2 15 Motor Cables 2 1 2 5 2...

Page 104: ...10 1 Speed Reference 2 10 3 6 5 2 7 1 Start Up 5 1 Start up 1 2 4 4 3 1 3 2 Status Messages 7 1 Mode 7 1 Stop Command 7 2 Supply Voltage 2 7 2 8 3 1 8 5 8 7 Surroundings 10 15 Switching Frequency 7 2...

Page 105: ...www danfoss com drives MG33AI22 130R0300 MG33AI22 Rev 2011 05 13...

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