Danfoss VLT series Bedienungsanleitung

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT®AutomationDrive FC 302

12-pulse

vlt-drives.danfoss.com

Contents

1 Introduction 4

1.1 Purpose of the Manual 4

1.2 Additional Resources 4

1.3 Document and Software Version 4

1.4 Approvals and Certications 4

1.5 Disposal 5

1.6 Abbreviations and Conventions 5

2 Safety Instructions 7

2.1 Safety Symbols 7

2.2 Qualied Personnel 7

2.3 Safety Regulations 7

3 How to Install 9

3.1 Pre-installation 9

3.1.1 Planning the Installation Site 9

3.1.1.1 Inspection on Receipt 9

3.1.2 Transportation and Unpacking 9

3.1.3 Lifting Unit 9

3.1.4 Mechanical Dimensions 12

3.2 Mechanical Installation 18

3.2.1 Preparation for Installation 18

3.2.2 Tools Required 18

3.2.3 General Considerations 18

3.2.4 Terminal Locations, F8–F15 20

3.2.4.1 Inverter and Rectier, Enclosure Sizes F8, and F9 20

3.2.4.2 Inverter, Enclosure Sizes F10 and F11 21

3.2.4.3 Inverter, Enclosure Sizes F12 and F13 22

3.2.4.4 Inverter, Enclosure Sizes F14 and F15 23

3.2.4.5 Rectier, Enclosure Sizes F10, F11, F12, and F13 24

3.2.4.6 Rectier, Enclosure Sizes F14 and F15 25

3.2.4.7 Options Cabinet, Enclosure Size F9 26

3.2.4.8 Options Cabinet, Enclosure Sizes F11 and F13 27

3.2.4.9 Options Cabinet, Enclosure Size F15 28

3.2.5 Cooling and Airow 28

3.3 Installing the Panel Options 34

3.3.1 Panel Options 34

3.4 Electrical Installation 35

3.4.1 Transformer Selection 36

3.4.2 Power Connections 36

Contents Operating Instructions

3.4.3 Grounding 45

3.4.4 Extra Protection (RCD) 45

3.4.5 RFI Switch 45

3.4.6 Torque 46

3.4.7 Shielded Cables 46

3.4.8 Motor Cable 46

3.4.9 Brake Cable for Frequency Converters with Factory-installed Brake Chopper Op-

tion 47

3.4.10 Shielding against Electrical Noise 47

3.4.11 Connection of Mains 48

3.4.12 External Fan Supply 48

3.4.13 Fuses 48

3.4.14 Supplementary Fuses 50

3.4.15 Motor Insulation 51

3.4.16 Motor Bearing Currents 51

3.4.17 Brake Resistor Temperature Switch 51

3.4.18 Control Cable Routing 52

3.4.19 Access to Control Terminals 52

3.4.20 Wiring to Control Terminals 52

3.4.21 Electrical Installation, Control Cables 53

3.4.22 Switches S201, S202, and S801 55

3.5 Connection Examples 56

3.5.1 Start/Stop 56

3.5.2 Pulse Start/Stop 56

3.6 Final Set-up and Test 57

3.7 Additional Connections 58

3.7.1 Mechanical Brake Control 58

3.7.2 Parallel Connection of Motors 59

3.7.3 Motor Thermal Protection 59

4 How to Programme 60

4.1 The Graphical LCP 60

4.1.1 Initial Commissioning 61

4.2 Quick Set-up 62

4.3 Parameter Menu Structure 65

5 General Specications 71

5.1 Mains Supply 71

5.2 Motor Output and Motor Data 71

5.3 Ambient Conditions 71

5.4 Cable Specications 72

Contents VLT®AutomationDrive FC 302

5.5 Control Input/output and Control Data 72

5.6 Electrical Data 76

6 Warnings and Alarms 83

6.1 Warning and Alarm Types 83

6.2 Warning and Alarm Denitions 83

Index 93

Contents Operating Instructions

1 Introduction

1.1 Purpose of the Manual

The frequency converter is designed to provide high shaft

performance on electrical motors. Read these operating

instructions carefully for proper use. Incorrect handling of

the frequency converter may cause improper operation of

the frequency converter or related equipment, shorten

lifetime, or cause other troubles.

These operating instructions provide information on:

•Start-up.

•Installation.

•Programming.

•Troubleshooting.

•Chapter 1 Introduction introduces the manual and

informs about approvals, symbols, and abbrevi-

ations used in this manual.

•Chapter 2 Safety Instructions entails instructions on

how to handle the frequency converter in a safe

way.

•Chapter 3 How to Install guides through the

mechanical and electrical installations.

•Chapter 4 How to Programme explains how to

operate and programme the frequency converter

via the LCP.

•Chapter 5 General Specications contains technical

data about the frequency converter.

•Chapter 6 Warnings and Alarms assists in solving

problems that may occur when using the

frequency converter.

VLT®is a registered trademark.

DeviceNet™is a trademark of ODVA, Inc.

1.2 Additional Resources

•The VLT

AutomationDrive FC 301/FC 302 Design

Guide details all technical information about the

frequency converter and customer design and

applications.

•The VLT

AutomationDrive FC 301/FC 302

Programming Guide provides information on how

to programme and includes complete parameter

descriptions.

•The VLT

PROFIBUS DP MCA 101 Installation Guide

provides information about installing and trouble-

shooting of the PROFIBUS eldbus option.

•The VLT

PROFIBUS DP MCA 101 Programming

Guide provides the information required for

controlling, monitoring, and programming the

frequency converter via a PROFIBUS eldbus.

•The VLT

DeviceNet MCA 104 Installation Guide

provides information about installing and trouble-

shooting of the DeviceNet®eldbus option.

•The VLT

DeviceNet MCA 104 Programming Guide

provides the information required for controlling,

monitoring, and programming the frequency

converter via a DeviceNet®eldbus.

Danfoss technical documentation is also available online at

http://drives.danfoss.com/knowledge-center/technical-

documentation/.

1.3 Document and Software Version

This manual is regularly reviewed and updated. All

suggestions for improvement are welcome. Table 1.1 shows

the document version and the corresponding software

version.

Edition Remarks Software

version

MG34Q4xx F14 and F15 enclosure sizes added.

Software version update.

7.4x

Table 1.1 Document and Software Version

1.4 Approvals and Certications

1.4.1 Approvals

The frequency converter complies with UL 508C thermal

memory retention requirements. For more information,

refer to the section Motor Thermal Protection in the

product-specic design guide.

NOTICE

Imposed limitations on the output frequency

(due to export control regulations):

From software version 6.72 onwards, the output

frequency of the frequency converter is limited to

590 Hz. Software versions 6.xx also limit the maximum

output frequency to 590 Hz, but these versions cannot

be ashed, that is, neither downgraded nor upgraded.

Introduction VLT®AutomationDrive FC 302

The 1400–2000 kW (1875–2680 hp) 690 V frequency

converters are approved for CE only.

1.5 Disposal

Do not dispose of equipment containing

electrical components together with

domestic waste.

Collect it separately in accordance with

local and currently valid legislation.

1.6 Abbreviations and Conventions

60°AVM 60°asynchronous vector modulation

A Ampere/AMP

AC Alternating current

AD Air discharge

AEO Automatic energy optimization

AI Analog input

AIC Ampere interrupting current

AMA Automatic motor adaptation

AWG American wire gauge

°CDegrees celsius

CB Circuit breaker

CD Constant discharge

CDM Complete drive module: The frequency converter,

feeding section, and auxiliaries

CE European Conformity (European safety standards)

CM Common mode

CT Constant torque

DC Direct current

DI Digital input

DM Dierential mode

D-TYPE Drive dependent

EMC Electromagnetic compatibility

EMF Electromotive force

ETR Electronic thermal relay

fJOG Motor frequency when jog function is activated

fMMotor frequency

fMAX Maximum output frequency, the frequency

converter applies on its output

fMIN Minimum motor frequency from the frequency

converter

fM,N Nominal motor frequency

FC Frequency converter

Hiperface®Hiperface®is a registered trademark by Stegmann

HO High overload

hp Horse power

HTL HTL encoder (10–30 V) pulses - High-voltage

transistor logic

Hz Hertz

IINV Rated inverter output current

ILIM Current limit

IM,N Nominal motor current

IVLT,MAX Maximum output current

IVLT,N Rated output current supplied by the frequency

converter

kHz Kilohertz

LCP Local control panel

lsb Least signicant bit

m Meter

mA Milliampere

MCM Mille circular mil

MCT Motion control tool

mH Inductance in milli Henry

mm Millimeter

ms Millisecond

msb Most signicant bit

ηVLT Eciency of the frequency converter dened as

ratio between power output and power input

nF Capacitance in nano Farad

NLCP Numerical local control panel

Nm Newton meter

NO Normal overload

nsSynchronous motor speed

Online/

Oine

Parameters

Changes to online parameters are activated

immediately after the data value is changed

Pbr,cont. Rated power of the brake resistor (average power

during continuous braking)

PCB Printed circuit board

PCD Process data

PDS Power drive system: a CDM and a motor

PELV Protective extra low voltage

PmFrequency converter nominal output power as

high overload (HO)

PM,N Nominal motor power

PM motor Permanent magnet motor

Process PID PID (proportional integrated dierential) regulator

that maintains the speed, pressure, temperature,

and so on

Rbr,nom Nominal resistor value that ensures a brake power

on the motor shaft of 150/160% for 1 minute

RCD Residual current device

Regen Regenerative terminals

Rmin Minimum permissible brake resistor value by

frequency converter

RMS Root mean square

RPM Revolutions per minute

Rrec Recommended brake resistor resistance of

Danfoss brake resistors

s Second

SCCR Short circuit current rating

SFAVM Stator ux-oriented asynchronous vector

modulation

STW Status word

SMPS Switch mode power supply

Introduction Operating Instructions

THD Total harmonic distortion

TLIM Torque limit

TTL TTL encoder (5 V) pulses - transistor transistor

logic

UM,N Nominal motor voltage

UL Underwriters Laboratories (US organization for the

safety certication)

V Volts

VT Variable torque

VVC+Voltage vector control plus

Table 1.2 Abbreviations

Conventions

Numbered lists indicate procedures.

Bullet lists indicate other information and description of

illustrations.

Italicized text indicates:

•Cross-reference.

•Link.

•Footnote.

•Parameter name, parameter group name,

parameter option.

All dimensions in drawings are in mm (in).

* Indicates a default setting of a parameter.

Introduction VLT®AutomationDrive FC 302

2 Safety Instructions

2.1 Safety Symbols

The following symbols are used in this guide:

WARNING

Indicates a potentially hazardous situation that could

result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could

result in minor or moderate injury. It can also be used to

alert against unsafe practices.

NOTICE

Indicates important information, including situations that

can result in damage to equipment or property.

2.2 Qualied Personnel

Correct and reliable transport, storage, installation,

operation, and maintenance are required for the trouble-

free and safe operation of the frequency converter. Only

qualied personnel are allowed to install and operate this

equipment.

Qualied personnel are dened as trained sta, who are

authorized to install, commission, and maintain equipment,

systems, and circuits in accordance with pertinent laws and

regulations. Also, the qualied personnel must be familiar

with the instructions and safety measures described in this

manual.

2.3 Safety Regulations

WARNING

HIGH VOLTAGE

Frequency converters contain high voltage when

connected to AC mains input, DC supply, or load sharing.

Failure to perform installation, start-up, and maintenance

by qualied personnel can result in death or serious

injury.

•Only qualied personnel must perform instal-

lation, start-up, and maintenance.

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains,

DC supply, or load sharing, the motor may start at any

time. Unintended start during programming, service, or

repair work can result in death, serious injury, or

property damage. The motor can start with an external

switch, a eldbus command, an input reference signal

from the LCP or LOP, via remote operation using MCT 10

Set-up Software, or after a cleared fault condition.

To prevent unintended motor start:

•Press [O/Reset] on the LCP before

programming parameters.

•Disconnect the frequency converter from the

mains.

•Completely wire and assemble the frequency

converter, motor, and any driven equipment

before connecting the frequency converter to

AC mains, DC supply, or load sharing.

WARNING

DISCHARGE TIME

The frequency converter contains DC-link capacitors,

which can remain charged even when the frequency

converter is not powered. High voltage can be present

even when the warning LED indicator lights are o.

Failure to wait the specied time after power has been

removed before performing service or repair work can

result in death or serious injury.

•Stop the motor.

•Disconnect AC mains and remote DC-link power

supplies, including battery back-ups, UPS, and

DC-link connections to other frequency

converters.

•Disconnect or lock PM motor.

•Wait for the capacitors to discharge fully. The

minimum duration of waiting time is specied

in Table 2.1.

•Before performing any service or repair work,

use an appropriate voltage measuring device to

make sure that the capacitors are fully

discharged.

Safety Instructions Operating Instructions

Voltage

[V]

Power range

[kW (hp)]

Minimum waiting

time

(minutes)

380–500 250–1000 (350–1350) 30

525–690 355–2000 (475–2700) 40

Table 2.1 Discharge Time

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the

frequency converter properly can result in death or

serious injury.

•Ensure the correct grounding of the equipment

by a certied electrical installer.

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment

can result in death or serious injury.

•Ensure that only trained and qualied personnel

perform installation, start-up, and maintenance.

•Ensure that electrical work conforms to national

and local electrical codes.

•Follow the procedures in this guide.

WARNING

UNINTENDED MOTOR ROTATION

WINDMILLING

Unintended rotation of permanent magnet motors

creates voltage and can charge the unit, resulting in

death, serious injury, or equipment damage.

•Ensure that permanent magnet motors are

blocked to prevent unintended rotation.

CAUTION

INTERNAL FAILURE HAZARD

An internal failure in the frequency converter can result

in serious injury when the frequency converter is not

properly closed.

•Ensure that all safety covers are in place and

securely fastened before applying power.

To run STO, more wiring for the frequency converter is

required. Refer to VLT

Frequency Converters Safe Torque O

Operating Instructions for further information.

Safety Instructions VLT®AutomationDrive FC 302

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