The design guide provides technical information to understand the capabilities of the drive for integration into motor control and monitoring systems.

VLT ® is a registered trademark.

1.2 Additional Resources

Other resources are available to understand advanced drive operation, programming, and directives compliance.

•

The Operating Guide provides detailed information for the installation and start up of the drive.

•

The Programming Guide provides greater detail on how to work with parameters and includes many application examples.

•

The VLT ® Safe Torque Off Operating Guide describes how to use Danfoss drives in functional safety applications. This manual is supplied with the drive when the safe torque off option is present.

•

The VLT ® Brake Resistor Design Guide describes how to select the optimal brake resistor.

•

Optional equipment is available that can change some of the information described in these publications. Be sure to see the instructions supplied with the options, for specific requirements.

Supplementary publications and manuals are available from Danfoss. See drives.danfoss.com/knowledge-center/ technical-documentation/ for listings.

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

MG38C1xx

Remarks

Initial release

Table 1.1 Document and Software Version

Software version

7.51

1.4 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).

•

An asterisk (*) indicates a default setting of a parameter.

MG38C102

Safety Design Guide

2 Safety

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 Qualified Personnel

Only qualified personnel are allowed to install or operate this equipment.

Qualified personnel are defined as trained staff, who are authorized to install, commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Also, the personnel must be familiar with the instructions and safety measures described in this manual.

2.3 Safety Precautions

WARNING

HIGH VOLTAGE

Drives contain high voltage when connected to AC mains input, DC supply, load sharing, or permanent motors.

Failure to use qualified personnel to install, start up, and maintain the drive can result in death or serious injury.

•

Only qualified personnel must install, start up, and maintain the drive.

WARNING

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be present even when the warning LED indicator lights are off. Failure to wait 40 minutes 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 supplies, including battery back-ups, UPS, and

DC-link connections to other drives.

Disconnect or lock motor.

Wait 40 minutes for the capacitors to discharge fully.

Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors are fully discharged.

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.

• Ensure the correct grounding of the equipment by a certified electrical installer.

NOTICE

MAINS SHIELD SAFETY OPTION

A mains shield option is available for enclosures with a protection rating of IP21/IP 54 (Type 1/Type 12). The mains shield is a cover installed inside the enclosure to protect against the accidental touch of the power terminals, according to BGV A2, VBG 4.

2 2

Safety VLT® AutomationDrive FC 302

2 2

2.3.1 ADN-compliant Installation

To prevent spark formation in accordance with the

European Agreement concerning International Carriage of

Dangerous Goods by Inland Waterways (ADN), precautions must be taken for drives with protection rating of IP00

(Chassis), IP20 (Chassis), IP21 (Type 1) or IP54 (Type 12).

•

Do not install a mains switch.

•

Ensure that parameter 14-50 RFI Filter is set to

[1] On .

•

Remove all relay plugs marked RELAY . See

Illustration 2.1

•

Check which relay options are installed, if any.

The only allowed relay option is VLT ® Extended

Relay Card MCB 113.

1, 2 Relay plugs

Illustration 2.1 Location of Relay Plugs

MG38C102

Approvals and Certification...

Design Guide

3 Approvals and Certifications

This section provides a brief description of the various approvals and certifications that are found on Danfoss drives. Not all approvals are found on all drives.

3.1 Regulatory/Compliance Approvals

NOTICE

IMPOSED LIMITATIONS ON THE OUTPUT

FREQUENCY

From software version 6.72 onwards, the output frequency of the drive is limited to 590 Hz due to export control regulations. Software versions 6.xx also limit the maximum output frequency to 590 Hz, but these versions cannot be flashed, that is, neither downgraded nor upgraded.

3.1.1.1 CE Mark

The CE mark (Communauté Européenne) indicates that the product manufacturer conforms to all applicable EU directives. The EU directives applicable to the design and manufacture of drives are listed in

Table 3.1

NOTICE

The CE mark does not regulate the quality of the product. Technical specifications cannot be deduced from the CE mark.

EU Directive

Low Voltage Directive

EMC Directive

Machinery Directive 1)

ErP Directive

ATEX Directive

RoHS Directive

Version

2014/35/EU

2014/30/EU

2014/32/EU

2009/125/EC

2014/34/EU

2002/95/EC

Table 3.1 EU Directives Applicable to Drives

1) Machinery Directive conformance is only required for drives with an integrated safety function.

NOTICE

Drives with an integrated safety function, such as Safe

Torque Off (STO), must comply with the machinery directive.

Declarations of conformity are available on request.

Low Voltage Directive

Drives must be CE-labeled in accordance with the Low

Voltage Directive of January 1, 2014. The Low Voltage

Directive applies to all electrical equipment in the 50–

1000 V AC and the 75–1500 V DC voltage ranges.

The aim of the directive is to ensure personal safety and avoid property damage when operating electrical equipment that is installed, maintained, and used as intended.

EMC Directive

The purpose of the EMC (electromagnetic compatibility)

Directive is to reduce electromagnetic interference and enhance immunity of electrical equipment and installations. The basic protection requirement of the EMC

Directive is that devices that generate electromagnetic interference (EMI), or whose operation can be affected by

EMI, must be designed to limit the generation of electromagnetic interference. The devices must have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

Electrical equipment devices used alone or as part of a system must bear the CE mark. Systems do not require the

CE mark, but must comply with the basic protection requirements of the EMC Directive.

Machinery Directive

The aim of the Machinery Directive is to ensure personal safety and avoid property damage to mechanical equipment used in its intended application. The Machinery

Directive applies to a machine consisting of an aggregate of interconnected components or devices of which at least

1 is capable of mechanical movement.

Drives with an integrated safety function must comply with the Machinery Directive. Drives without a safety function do not fall under the Machinery Directive. If a drive is integrated into a machinery system, Danfoss can provide information on safety aspects relating to the drive.

When drives are used in machines with at least 1 moving part, the machine manufacturer must provide a declaration stating compliance with all relevant statutes and safety measures.

3.1.1.2 ErP Directive

The ErP Directive is the European Ecodesign Directive for energy-related products, including drives. The aim of the directive is to increase energy efficiency and the level of protection of the environment, while increasing the security of the energy supply. Environmental impact of energy-related products includes energy consumption throughout the entire product life cycle.

3 3

Approvals and Certification...

VLT® AutomationDrive FC 302

3 3

3.1.1.3 UL Listing

The Underwriters Laboratory (UL) mark certifies the safety of products and their environmental claims based on standardized testing. Drives of voltage T7 (525–690 V) are

UL-certified for only 525–600 V. The drive complies with UL

61800-5-1 thermal memory retention requirements. For more information, refer to

chapter 10.6.2 Motor Thermal

Protection .

3.1.1.4 CSA/cUL

The CSA/cUL approval is for AC drives of voltage rated at

600 V or lower. The standard ensures that, when the drive is installed according to the provided operating/installation guide, the equipment meets the UL standards for electrical and thermal safety. This mark certifies that the product performs to all required engineering specifications and testing. A certificate of compliance is provided on request.

3.1.1.5 EAC

The EurAsian Conformity (EAC) mark indicates that the product conforms to all requirements and technical regulations applicable to the product per the EurAsian

Customs Union, which is composed of the member states of the EurAsian Economic Union.

The EAC logo must be both on the product label and on the packaging label. All products used within the EAC area, must be bought at Danfoss inside the EAC area.

3.1.1.6 UKrSEPRO

UKrSEPRO certificate ensures quality and safety of both products and services, in addition to manufacturing stability according to Ukrainian regulatory standards. The

UkrSepro certificate is a required document to clear customs for any products coming into and out of the territory of Ukraine.

3.1.1.7 TUV

TUV SUD is a European safety organization which certifies the functional safety of the drive in accordance to EN/IEC

61800-5-2. The TUV SUD both tests products and monitors their production to ensure that companies stay compliant with their regulations.

3.1.1.8 RCM

The Regulatory Compliance Mark (RCM) indicates compliance with telecommunications and EMC/radiocommunications equipment per the Australian

Communications and Media Authorities EMC labeling notice. RCM is now a single compliance mark covering both the A-Tick and the C-Tick compliance marks. RCM compliance is required for placing electrical and electronic devices on the market in Australia and New Zealand.

3.1.1.9 Marine

Marine applications - ships and oil/gas platforms - must be certified by 1 of more marine certification societies in order to receive a regulatory license and insurance. Danfoss VLT ®

AutomationDrive series drives are certified by up to 12 different marine classification societies.

To view or print marine approvals and certificates, go to the download area at http://drives.danfoss.com/industries/ marine-and-offshore/marine-type-approvals/#/ .

3.1.2 Export Control Regulations

Drives can be subject to regional and/or national export control regulations.

An ECCN number is used to classify all drives that are subject to export control regulations.

The ECCN number is provided in the documents accompanying the drive.

In case of re-export, it is the responsibility of the exporter to ensure compliance with the relevant export control regulations.

MG38C102

Approvals and Certification...

Design Guide

3.2 Enclosure Protection Ratings

The VLT ® drive series are available in various enclosure protection to accommodate the needs of the application. Enclosure protection ratings are provided based on 2 international standards:

•

UL type validates that the enclosures meet NEMA (National Electrical Manufacturers Association) standards. The construction and testing requirements for enclosures are provided in NEMA Standards Publication 250-2003 and UL

50, Eleventh Edition.

•

IP (Ingress Protection) ratings outlined by IEC (International Electrotechnical Commission) in the rest of the world.

Standard Danfoss VLT ® drive series are available in various enclosure protections to meet the requirements of IP00 (Chassis),

IP20 (Protected chassis) or IP21 (UL Type 1), or IP54 (UL Type 12). In this manual, UL Type is written as Type. For example,

IP21/Type 1.

UL type standard

Type 1 – Enclosures constructed for indoor use to provide a degree of protection to personnel against incidental contact with the enclosed units and to provide a degree of protection against falling dirt.

Type 12 – General-purpose enclosures are intended for use indoors to protect the enclosed units against the following:

•

Fibers

•

Lint

•

Dust and dirt

•

Light splashing

•

Seepage

•

Dripping and external condensation of noncorrosive liquids

There can be no holes through the enclosure and no conduit knockouts or conduit openings, except when used with oilresistant gaskets to mount oil-tight or dust-tight mechanisms. Doors are also provided with oil-resistant gaskets. In addition, enclosures for combination controllers have hinged doors, which swing horizontally and require a tool to open.

IP Standard

Table 3.2

provides a cross-reference between the 2 standards.

Table 3.3

demonstrates how to read the IP number and then defines the levels of protection. The drives meet the requirements of both.

NEMA and UL

Chassis

Protected chassis

Type 1

Type 12

IP00

IP20

IP21

IP54

Table 3.2 NEMA and IP Number Cross-reference

3 3

Approvals and Certification...

VLT® AutomationDrive FC 302

3 3

–

1 st digit

Table 3.3 IP Number Breakdown

–

2 nd digit

–

Level of protection

No protection.

Protected to 50 mm (2.0 in). No hands would be able to get into the enclosure.

Protected to 12.5 mm (0.5 in). No fingers would be able to get into the enclosure.

Protected to 2.5 mm (0.1 in). No tools would be able to get into the enclosure.

Protected to 1.0 mm (0.04 in). No wires would be able to get into the enclosure.

Protected against dust – limited entry

Protected totally against dust

No protection

Protected from vertical dripping water

Protected from dripping water at 15° angle

Protected from water at 60° angle

Protected from splashing water

Protected from water jets

Protected from strong water jets

Protected from temporary immersion

Protected from permanent immersion

MG38C102

Product Overview Design Guide

4 Product Overview

4.1 Enclosure Size by Power Rating

kW 1)

315

355

400

450

500

Hp 1)

450

500

550

600

650

Available enclosures

E1h/E3h

E2h/E4h

Table 4.1 Enclosure Power Ratings, 380–500 V

1) All power ratings are taken at high overload (150% current for

60 s). Output is measured at 400 V (kW) and 460 V (hp).

kW 1)

355

400

500

560

630

710

Hp 1)

400

500

600

650

750

Available enclosures

E1h/E3h

E2h/E4h

Table 4.2 Enclosure Power Ratings, 525–690 V

1) All power ratings are taken at high overload (150% current for

60 s). Output is measured at 690 V (kW) and 575 V (hp).

4.2 Overview of Enclosures, 380–500 V

E1h Enclosure size

Power rating 1)

Output at 400 V (kW)

Output at 460 V (hp)

Protection rating

UL type

Hardware options 3)

Stainless steel back channel

Mains shielding

Space heater

RFI filter (Class A1)

Safe torque off

No LCP

Graphical LCP

Fuses

Heat sink access

Brake chopper

Regen terminals

Load share terminals

Fuses + load share

Disconnect

Circuit breakers

Contactors

24 V DC supply (SMPS, 5 A)

Dimensions

Height, mm (in)

Width, mm (in)

Depth, mm (in)

Weight, kg (lb)

315–400

450–550

IP21/54

Type 1/12

2043 (80.4)

602 (23.7)

513 (20.2)

295 (650)

–

E2h

450–500

600–650

IP21/54

Type 1/12

–

E3h

315–400

450–550

IP20 2)

Chassis

–

E4h

450–500

600–650

IP20 2)

Chassis

2043 (80.4)

698 (27.5)

513 (20.2)

318 (700)

1578 (62.1)

506 (19.9)

482 (19.0)

272 (600)

1578 (62.1)

604 (23.9)

482 (19.0)

295 (650)

Table 4.3 E1h–E4h Drives, 380–500 V

1) All power ratings are taken at high overload (150% current for 60 s).

2) If the enclosure is configured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20.

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

–

4 4

Product Overview VLT® AutomationDrive FC 302

4 4

4.3 Overview of Enclosures, 525–690 V

E1h Enclosure size

Power rating 1)

Output at 690 V (kW)

Output at 575 V (hp)

Protection rating

UL type

Hardware options 3)

Stainless steel back channel

Mains shielding

Space heater

RFI filter (Class A1)

Safe torque off

No LCP

Graphical LCP

Fuses

Heat sink access

Brake chopper

Regen terminals

Load share terminals

Fuses + load share

Disconnect

Circuit breakers

Contactors

24 V DC supply (SMPS, 5 A)

Dimensions

Height, mm (in)

Width, mm (in)

Depth, mm (in)

Weight, kg (lb)

355–560

400–600

IP21/54

Type 1/12

2043 (80.4)

602 (23.7)

513 (20.2)

295 (650)

–

E2h

630–710

650–950

IP21/54

Type 1/12

–

E3h

355–560

400–600

IP20 2)

Chassis

–

E4h

630–710

650–950

IP20 2)

Chassis

2043 (80.4)

698 (27.5)

513 (20.2)

318 (700)

1578 (62.1)

506 (19.9)

482 (19.0)

272 (600)

1578 (62.1)

604 (23.9)

482 (19.0)

295 (650)

Table 4.4 E1h–E4h Drives, 525–690 V

1) All power ratings are taken at high overload (150% current for 60 s).

2) If the enclosure is configured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20.

3) S = standard, O = optional, and a dash indicates that the option is unavailable.

–

MG38C102

Product Features Design Guide

5 Product Features

5.1 Automated Operational Features

Automated operational features are active when the drive is operating. Most of them require no programming or setup. The drive has a range of built-in protection functions to protect itself and the motor when it runs.

For details of any set-up required, in particular motor parameters, refer to the programming guide .

5.1.1 Short-circuit Protection

Motor (phase-to-phase)

The drive is protected against short circuits on the motor side by current measurement in each of the 3 motor phases. A short circuit between 2 output phases causes an overcurrent in the inverter. The inverter is turned off when the short circuit current exceeds the permitted value

( Alarm 16, Trip Lock ).

Mains side

A drive that works correctly limits the current it can draw from the supply. Still, it is recommended to use fuses and/or circuit breakers on the supply side as protection if there is component break-down inside the drive (first fault). Mains side fuses are mandatory for UL compliance.

NOTICE

To ensure compliance with IEC 60364 for CE or NEC 2009 for UL, it is mandatory to use fuses and/or circuit breakers.

Brake resistor

The drive is protected from a short circuit in the brake resistor.

Load sharing

To protect the DC bus against short circuits and the drives from overload, install DC fuses in series with the load sharing terminals of all connected units.

5.1.2 Overvoltage Protection

Motor-generated overvoltage

The voltage in the DC link is increased when the motor acts as a generator. This situation occurs in following cases:

•

The load rotates the motor at constant output frequency from the drive, that is, the load generates energy.

•

During deceleration (ramp-down) if the inertia moment is high, the friction is low, and the rampdown time is too short for the energy to be dissipated as a loss throughout the drive system.

•

Incorrect slip compensation setting causing higher DC-link voltage.

•

Back EMF from PM motor operation. If coasted at high RPM, the PM motor back EMF can potentially exceed the maximum voltage tolerance of the drive and cause damage. To help prevent this situation, the value of parameter 4-19 Max Output Frequency is automatically limited based on an internal calculation based on the value of parameter 1-40 Back EMF at

1000 RPM , parameter 1-25 Motor Nominal Speed and parameter 1-39 Motor Poles .

NOTICE

To avoid motor overspeeds (for example, due to excessive windmilling effects), equip the drive with a brake resistor.

The overvoltage can be handled either using a brake function ( parameter 2-10 Brake Function ) and/or using overvoltage control ( parameter 2-17 Over-voltage Control ).

Brake functions

Connect a brake resistor for dissipation of surplus brake energy. Connecting a brake resistor allows a higher DC-link voltage during braking.

AC brake is an alternative to improving braking without using a brake resistor. This function controls an overmagnetization of the motor when the motor is acting as a generator. Increasing the electrical losses in the motor allows the OVC function to increase the braking torque without exceeding the overvoltage limit.

NOTICE

AC brake is not as effective as dynamic braking with a resistor.

Overvoltage control (OVC)

By automatically extending the ramp-down time, OVC reduces the risk of the drive tripping due to an overvoltage on the DC-link.

NOTICE

OVC can be activated for a PM motor with all control core, PM VVC + , Flux OL, and Flux CL for PM Motors.

NOTICE

Do not enable OVC in hoisting applications.

5 5

Product Features VLT® AutomationDrive FC 302

5 5

5.1.3 Missing Motor Phase Detection

The missing motor phase function ( parameter 4-58 Missing

Motor Phase Function ) is enabled by default to avoid motor damage if a motor phase is missing. The default setting is

1000 ms, but it can be adjusted for faster detection.

5.1.4 Supply Voltage Imbalance Detection

Operation under severe supply voltage imbalance reduces the lifetime of the motor and drive. If the motor is operated continuously near nominal load, conditions are considered severe. The default setting trips the drive if there is supply voltage imbalance

( parameter 14-12 Response to Mains Imbalance ).

5.1.5 Switching on the Output

Adding a switch to the output between the motor and the drive is allowed, however fault messages can appear.

Danfoss does not recommend using this feature for 525–

690 V drives connected to an IT mains network.

5.1.6 Overload Protection

Torque limit

The torque limit feature protects the motor against overload, independent of the speed. Torque limit is controlled in parameter 4-16 Torque Limit Motor Mode and parameter 4-17 Torque Limit Generator Mode . The time before the torque limit warning trips is controlled in parameter 14-25 Trip Delay at Torque Limit .

Current limit

The current limit is controlled in parameter 4-18 Current

Limit , and the time before the drive trips is controlled in parameter 14-24 Trip Delay at Current Limit .

Speed limit

Mininum speed limit: Parameter 4-11 Motor Speed Low Limit

[RPM] or parameter 4-12 Motor Speed Low Limit [Hz] limit the minimum operating speed range of the drive.

Maximum speed limit: Parameter 4-13 Motor Speed High

Limit [RPM] or parameter 4-19 Max Output Frequency limit the maximum output speed the drive can provide.

Electronic thermal relay (ETR)

ETR is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in

Illustration 5.1

Voltage limit

The inverter turns off to protect the transistors and the DC link capacitors when a certain hard-coded voltage level is reached.

Overtemperature

The drive has built-in temperature sensors and reacts immediately to critical values via hard-coded limits.

5.1.7 Locked Rotor Protection

There can be situations when the rotor is locked due to excessive load or other factors. The locked rotor cannot produce enough cooling, which in turn can overheat the motor winding. The drive is able to detect the locked rotor situation with open-loop PM flux control and PM VVC + control ( parameter 30-22 Locked Rotor Protection ).

5.1.8 Automatic Derating

The drive constantly checks for the following critical levels:

•

High temperature on the control card or heat sink.

•

High motor load.

•

High DC-link voltage.

•

Low motor speed.

As a response to a critical level, the drive adjusts the switching frequency. For high internal temperatures and low motor speed, the drives can also force the PWM pattern to SFAVM.

NOTICE

The automatic derating is different when parameter 14-55 Output Filter is set to [2] Sine-Wave Filter

Fixed .

5.1.9 Automatic Energy Optimization

Automatic energy optimization (AEO) directs the drive to monitor the load on the motor continuously and adjust the output voltage to maximize efficiency. Under light load, the voltage is reduced and the motor current is minimized. The motor benefits from:

•

Increased efficiency.

•

Reduced heating.

•

Quieter operation.

There is no need to select a V/Hz curve because the drive automatically adjusts motor voltage.

5.1.10 Automatic Switching Frequency

Modulation

The drive generates short electrical pulses to form an AC wave pattern. The switching frequency is the rate of these pulses. A low switching frequency (slow pulsing rate) causes audible noise in the motor, making a higher switching frequency preferable. A high switching frequency, however, generates heat in the drive that can limit the amount of current available to the motor.

MG38C102

Product Features Design Guide

Automatic switching frequency modulation regulates these conditions automatically to provide the highest switching frequency without overheating the drive. By providing a regulated high switching frequency, it quiets motor operating noise at slow speeds, when audible noise control is critical, and produces full output power to the motor when required.

5.1.11 Automatic Derating for High

Switching Frequency

The drive is designed for continuous, full-load operation at switching frequencies between 1.5 kHz–2 kHz for 380–500

V, and 1 kHz–1.5 kHz for 525–690V. The frequency range depends on power size and voltage rating. A switching frequency exceeding the maximum allowed range generates increased heat in the drive and requires the output current to be derated.

An automatic feature of the drive is load-dependent switching frequency control. This feature allows the motor to benefit from as high a switching frequency as the load allows.

5.1.12 Power Fluctuation Performance

The drive withstands mains fluctuations such as:

•

Transients.

•

Momentary drop-outs.

•

Short voltage drops.

•

Surges.

The drive automatically compensates for input voltages

± 10% from the nominal to provide full rated motor voltage and torque. With auto restart selected, the drive automatically powers up after a voltage trip. With flying start, the drive synchronizes to motor rotation before start.

5.1.13 Resonance Damping

Resonance damping eliminates the high-frequency motor resonance noise. Automatic or manually selected frequency damping is available.

5.1.14 Temperature-controlled Fans

Sensors in the drive regulate the operation of the internal cooling fans. Often, the cooling fans do not run during low load operation, or when in sleep mode or standby. These sensors reduce noise, increase efficiency, and extend the operating life of the fan.

5.1.15 EMC Compliance

Electromagnetic interference (EMI) and radio frequency interference (RFI) are disturbances that can affect an electrical circuit due to electromagnetic induction or radiation from an external source. The drive is designed to comply with the EMC product standard for drives IEC

61800-3 and the European standard EN 55011. Motor cables must be shielded and properly terminated to comply with the emission levels in EN 55011. For more information regarding EMC performance, see

chapter 10.14.1 EMC Test Results .

5.1.16 Galvanic Isolation of Control

Terminals

All control terminals and output relay terminals are galvanically isolated from mains power, which completely protects the controller circuitry from the input current. The output relay terminals require their own grounding. This isolation meets the stringent protective extra-low voltage

(PELV) requirements for isolation.

The components that make up the galvanic isolation are:

•

Supply, including signal isolation.

•

Gatedrive for the IGBTs, trigger transformers, and optocouplers.

•

The output current Hall effect transducers.

5.2 Custom Application Features

Custom application functions are the most common features programmed in the drive for enhanced system performance. They require minimum programming or setup. See the programming guide for instructions on activating these functions.

5.2.1 Automatic Motor Adaptation

Automatic motor adaptation (AMA) is an automated test procedure used to measure the electrical characteristics of the motor. AMA provides an accurate electronic model of the motor, allowing the drive to calculate optimal performance and efficiency. Running the AMA procedure also maximizes the automatic energy optimization feature of the drive. AMA is performed without the motor rotating and without uncoupling the load from the motor.

5 5

Product Features VLT® AutomationDrive FC 302

5 5

5.2.2 Built-in PID Controller

The built-in proportional, integral, derivative (PID) controller eliminates the need for auxiliary control devices.

The PID controller maintains constant control of closed loop systems where regulated pressure, flow, temperature, or other system requirements must be maintained.

The drive can use 2 feedback signals from 2 different devices, allowing the system to be regulated with different feedback requirements. The drive makes control decisions by comparing the 2 signals to optimize system performance.

5.2.3 Motor Thermal Protection

Motor thermal protection can be provided via:

•

Direct temperature sensing using a

PTC- or KTY sensor in the motor windings and connected on a standard

AI or DI.

PT100 or PT1000 in the motor windings and motor bearings, connected on VLT ®

Sensor Input Card MCB 114.

PTC Thermistor input on VLT ® PTC

Thermistor Card MCB 112 (ATEX approved).

•

Mechanical thermal switch (Klixon type) on a DI.

•

Built-in electronic thermal relay (ETR).

ETR calculates motor temperature by measuring current, frequency, and operating time. The drive shows the thermal load on the motor in percentage and can issue a warning at a programmable overload setpoint.

Programmable options at the overload allow the drive to stop the motor, reduce output, or ignore the condition.

Even at low speeds, the drive meets I2t Class 20 electronic motor overload standards.

16 t [s]

2000

1000

600

500

400

300

200

100

1.0

1.2

1.4

1.6

1.8

Illustration 5.1 ETR Characteristics

2.0

fOUT = 1 x f M,N(par. 1-23) fOUT = 2 x f M,N fOUT = 0.2 x f M,N

(par. 1-24)

The X-axis shows the ratio between I motor

and I motor nominal. The Y-axis shows the time in seconds before the

ETR cuts off and trips the drive. The curves show the characteristic nominal speed, at twice the nominal speed and at 0.2 x the nominal speed.

At lower speed, the ETR cuts off at lower heat due to less cooling of the motor. In that way, the motor is protected from being overheated even at low speed. The ETR feature calculates the motor temperature based on actual current and speed. The calculated temperature is visible as a readout parameter in parameter 16-18 Motor Thermal .

A special version of the ETR is also available for EX-e motors in ATEX areas. This function makes it possible to enter a specific curve to protect the Ex-e motor. See the pogramming guide for set-up instructions.

5.2.4 Motor Thermal Protection for Ex-e

Motors

The drive is equipped with an ATEX ETR thermal monitoring function for operation of Ex-e motors according to EN-60079-7. When combined with an ATEX approved

PTC monitoring device such as the VLT ® MCB 112 PTC option or an external device, the installation does not require an individual approval from an approbated organization.

The ATEX ETR thermal monitoring function enables use of an Ex-e motor instead of a more expensive, larger, and heavier Ex-d motor. The function ensures that the drive limits motor current to prevent overheating.

Requirements related to the Ex-e motor

•

Ensure that the Ex-e motor is approved for operation in hazardous zones (ATEX zone 1/21,

ATEX zone 2/22) with drives. The motor must be certified for the specific hazardous zone.

•

Install the Ex-e motor in zone 1/21 or 2/22 of the hazardous zone, according to motor approval.

MG38C102

Product Features Design Guide

NOTICE

Install the drive outside the hazardous zone.

•

Ensure that the Ex-e motor is equipped with an

ATEX-approved motor overload protection device.

This device monitors the temperature in the motor windings. If there is a critical temperature level or a malfunction, the device switches off the motor.

The VLT ® PTC Thermistor MCB 112 option provides ATEX-approved monitoring of motor temperature. It is a prerequisite that the drive is equipped with 3–6 PTC thermistors in series according to DIN 44081 or 44082.

Alternatively, an external ATEX-approved

PTC protection device can be used.

•

Sine-wave filter is required when

Long cables (voltage peaks) or increased mains voltage produce voltages exceeding the maximum allowable voltage at motor terminals.

Minimum switching frequency of the drive does not meet the requirement stated by the motor manufacturer. The minimum switching frequency of the drive is shown as the default value in parameter 14-01 Switching Frequency .

Compatibility of motor and drive

For motors certified according to EN-60079-7, a data list including limits and rules is supplied by the motor manufacturer as a data sheet, or on the motor nameplate.

During planning, installation, commissioning, operation, and service, follow the limits and rules supplied by the manufacturer for:

•

Minimum switching frequency.

•

Maximum current.

•

Minimum motor frequency.

•

Maximum motor frequency.

Illustration 5.2

shows where the requirements are indicated on the motor nameplate.

СЄ 1180 xЗ

CONVERTER SUPPLY

VALID FOR 380 - 415V FWP 50Hz

3 ~ Motor

MIN. SWITCHING FREQ. FOR PWM CONV. 3kHz l = 1.5XI

M,N

= 10s t

COOL

= 10min

MIN. FREQ. 5Hz MAX. FREQ. 85 Hz

Ex-e ll T3 f [Hz]

PTC

Ix/I

M,N

PWM-CONTROL

5 15

0.4

0.8

°C DIN 44081/-82

1.0

0.95

1 Minimum switching frequency

2 Maximum current

3 Minimum motor frequency

4 Maximum motor frequency

Illustration 5.2 Motor Nameplate showing Drive Requirements

When matching drive and motor, Danfoss specifies the following extra requirements to ensure adequate motor thermal protection:

•

Do not exceed the maximum allowed ratio between drive size and motor size. The typical value is I

VLT, n

≤ 2x I m,n

•

Consider all voltage drops from drive to motor. If the motor runs with lower voltage than listed in the U/f characteristics, current can increase, triggering an alarm.

For further information, see the application example in

chapter 12 Application Examples .

5 5

Product Features VLT® AutomationDrive FC 302

5 5

5.2.5 Mains Drop-out

During a mains drop-out, the drive keeps running until the

DC-link voltage drops below the minimum stop level. The minimum stop level is typically 15% below the lowest rated supply voltage. The mains voltage before the dropout and the motor load determines how long it takes for the drive to coast.

The drive can be configured ( parameter 14-10 Mains Failure ) to different types of behavior during mains drop-out:

•

Trip Lock once the DC link is exhausted.

•

Coast with flying start whenever mains return

( parameter 1-73 Flying Start ).

•

Kinetic back-up.

•

Controlled ramp down.

Flying start

This selection makes it possible to catch a motor that is spinning freely due to a mains drop-out. This option is relevant for centrifuges and fans.

Kinetic back-up

This selection ensures that the drive runs as long as there is energy in the system. For short mains drop-out, the operation is restored after mains return, without bringing the application to a stop or losing control at any time.

Several variants of kinetic back-up can be selected.

Configure the behavior of the drive at mains drop-out, in parameter 14-10 Mains Failure and parameter 1-73 Flying

Start .

5.2.6 Automatic Restart

The drive can be programmed to restart the motor automatically after a minor trip, such as momentary power loss or fluctuation. This feature eliminates the need for manual resetting, and enhances automated operation for remotely controlled systems. The number of restart attempts and the duration between attempts can be limited.

5.2.7 Full Torque at Reduced Speed

The drive follows a variable V/Hz curve to provide full motor torque even at reduced speeds. Full output torque can coincide with the maximum designed operating speed of the motor. This drive differs from variable torque drives and constant torque drives. Variable torque drives provide reduced motor torque at low speed. Constant torque drives provide excess voltage, heat, and motor noise at less than full speed.

5.2.8 Frequency Bypass

In some applications, the system can have operational speeds that create a mechanical resonance. This mechanical resonance can generate excessive noise and possibly damage mechanical components in the system.

The drive has 4 programmable bypass-frequency bandwidths. The bandwidths allow the motor to step over speeds that induce system resonance.

5.2.9 Motor Preheat

To preheat a motor in a cold or damp environment, a small amount of DC current can be trickled continuously into the motor to protect it from condensation and cold starts. This function can eliminate the need for a space heater.

5.2.10 Programmable Set-ups

The drive has 4 set-ups that can be independently programmed. Using multi-setup, it is possible to switch 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 to control multiple motors. The LCP shows the active set-up.

Set-up data can be copied from drive to drive by downloading the information from the removable LCP.

5.2.11 Smart Logic Control (SLC)

Smart logic control (SLC) is a sequence of user-defined actions (see parameter 13-52 SL Controller Action [x]) executed by the SLC when the associated user-defined event (see parameter 13-51 SL Controller Event [x]) is evaluated as TRUE by the SLC.

The condition for an event can be a particular status, or that the output from a logic rule or a comparator operand becomes TRUE. The condition leads to an associated action as shown in

Illustration 5.3

MG38C102

Product Features Design Guide

Par. 13-51

SL Controller Event

Running

Warning

Torque limit

Digital input X 30/2

. . .

Par. 13-43

Logic Rule Operator 2

. . .

Par. 13-11

Comparator Operator

TRUE longer than..

. . .

Illustration 5.3 SLC Event and Action

Par. 13-52

SL Controller Action

Coast

Start timer

Set Do X low

Select set-up 2

. . .

Events and actions are each numbered and linked in pairs

(states), which means that when event [0] is fulfilled

(attains the value TRUE), action [0] is executed. After the 1 st action is executed, the conditions of the next event are evaluated. If this event is evaluated as true, then the corresponding action is executed. Only 1 event is evaluated at any time. If an event is evaluated as false, nothing happens in the SLC during the current scan interval and no other events are evaluated. When the SLC starts, it only evaluates event [0] during each scan interval.

Only when event [0] is evaluated as true, the SLC executes action [0] and starts evaluating the next event. It is possible to program 1–20 events and actions.

When the last event/action has been executed, the sequence starts over again from event [0]/action [0].

Illustration 5.4

shows an example with 4 event/actions:

Start event P13-01

13-51.0

13-52.0

13-51.1

13-52.1

Stop event P13-02

State 4

13-51.3

13-52.3

State 3

13-52.2

Stop event P13-02

Illustration 5.4 Order of Execution when 4 Events/Actions are

Programmed

Comparators

Comparators are used for comparing continuous variables

(output frequency, output current, analog input, and so on) to fixed preset values.

Par. 13-11

Comparator Operator

Par. 13-10

Comparator Operand

Par. 13-12

Comparator Value

TRUE longer than.

. . .

Illustration 5.5 Comparators

Logic rules

Combine up to 3 boolean inputs (TRUE/FALSE inputs) from timers, comparators, digital inputs, status bits, and events using the logical operators AND, OR, and NOT.

Par. 13-43

Logic Rule Operator 2

Par. 13-40

Logic Rule Boolean 1

Par. 13-42

Logic Rule Boolean 2

Par. 13-41

Logic Rule Operator 1

. . .

Par. 13-44

Logic Rule Boolean 3

Illustration 5.6 Logic Rules

5.2.12 Safe Torque Off

The Safe Torque Off (STO) function is used to stop the drive in emergency stop situations. The FC 302 drive can use the STO function with asynchronous, synchronous, and permanent magnet motors.

For more information about Safe Torque Off, including installation and commissioning, refer to the Safe Torque Off

Operating Guide .

Liability conditions

The customer is responsible for ensuring that personnel know how to install and operate the safe torque off function by:

•

Reading and understanding the safety regulations concerning health, safety, and accident prevention.

•

Understanding the generic and safety guidelines provided in the Safe Torque Off Operating Guide .

•

Having a good knowledge of the generic and safety standards for the specific application.

5 5

Product Features VLT® AutomationDrive FC 302

5 5

5.3 Dynamic Braking Overview

Dynamic braking slows the motor using 1 of the following methods:

•

AC brake

The brake energy is distributed in the motor by changing the loss conditions in the motor

( parameter 2-10 Brake Function = [2]). The AC brake function cannot be used in applications with high cycling frequency since this situation overheats the motor.

•

DC brake

An overmodulated DC current added to the AC current works as an eddy current brake

( parameter 2-02 DC Braking Time ≠ 0 s ).

•

Resistor brake

A brake IGBT keeps the overvoltage under a certain threshold by directing the brake energy from the motor to the connected brake resistor

( parameter 2-10 Brake Function = [1]). For more information on selecting a brake resistor, see VLT ®

Brake Resistor MCE 101 Design Guide .

For drives equipped with the brake option, a brake IGBT along with terminals 81(R-) and 82(R+) are included for connecting an external brake resistor.

The function of the brake IGBT is to limit the voltage in the

DC link whenever the maximum voltage limit is exceeded.

It limits the voltage by switching the externally mounted resistor across the DC bus to remove excess DC voltage present on the bus capacitors.

External brake resistor placement has the advantages of selecting the resistor based on application need, dissipating the energy outside of the control panel, and protecting the drive from overheating if the brake resistor is overloaded.

The brake IGBT gate signal originates on the control card and is delivered to the brake IGBT via the power card and gatedrive card. Also, the power and control cards monitor the brake IGBT for a short circuit. The power card also monitors the brake resistor for overloads.

MG38C102

Product Features Design Guide

5.4 Mechanical Holding Brake Overview

A mechanical holding brake is an external piece of equipment mounted directly on the motor shaft that performs static braking. Static braking is when a brake is used to clamp down on the motor after the load has been stopped. A holding brake is either controlled by a PLC or directly by a digital output from the drive.

NOTICE

A drive cannot provide a safe control of a mechanical brake. A redundancy circuitry for the brake control must be included in the installation.

5.4.1 Mechanical Brake Using Open Loop Control

For hoisting applications, typically it is necessary to control an electro-magnetic brake. A relay output (relay 1 or relay 2) or a programmed digital output (terminal 27 or 29) is required. Normally, this output must be closed for as long as the drive is unable to hold the motor. In parameter 5-40 Function Relay (array parameter), parameter 5-30 Terminal 27 Digital Output , or parameter 5-31 Terminal 29 Digital Output , select [32] mechanical brake control for applications with an electro-magnetic brake.

When [32] mechanical brake control is selected, the mechanical brake relay remains closed during start until the output current is above the level selected in parameter 2-20 Release Brake Current . During stop, the mechanical brake closes when the speed is below the level selected in parameter 2-21 Activate Brake Speed [RPM] . If the drive is brought into an alarm condition, such as an overvoltage situation, the mechanical brake immediately cuts in. The mechanical brake also cuts in during safe torque off.

Consider the following when using the electro-magnetic brake:

•

Use any relay output or digital output (terminal 27 or 29). If necessary, use a contactor.

•

Ensure that the output is switched off as long as the drive is unable to rotate the motor. Examples include the load being too heavy or the motor not being mounted.

•

Before connecting the mechanical brake, select [32] Mechanical brake control in parameter group 5-4* Relays (or in parameter group 5-3* Digital Outputs ).

•

The brake is released when the motor current exceeds the preset value in parameter 2-20 Release Brake Current .

•

The brake is engaged when the output frequency is less than the frequency set in parameter 2-21 Activate Brake

Speed [RPM] or parameter 2-22 Activate Brake Speed [Hz] and only if the drive carries out a stop command.

NOTICE

For vertical lifting or hoisting applications, ensure that the load can be stopped if there is an emergency or a malfunction. If the drive is in alarm mode or in an overvoltage situation, the mechanical brake cuts in.

For hoisting applications, make sure that the torque limits in parameter 4-16 Torque Limit Motor Mode and parameter 4-17 Torque Limit Generator Mode are set lower than the current limit in parameter 4-18 Current Limit . It is also recommended to set parameter 14-25 Trip Delay at Torque Limit to 0, parameter 14-26 Trip Delay at Inverter Fault to 0, and parameter 14-10 Mains Failure to [3] Coasting .

5 5

Product Features VLT® AutomationDrive FC 302

5 5

Start term.18

Par 1-71

Start delay time

1=on

0=off

Shaft speed

Par 1-74

Start speed

Output current

Pre-magnetizing current or

DC hold current

Par 2-23

Brake delay time

Par 1-76 Start current/

Par 2-00 DC hold current

Reaction time EMK brake

Relay 01

Mechanical brake locked

Mechanical brake free on off

Illustration 5.7 Mechanical Brake Control in Open Loop

Par 2-20

Release brake current

Par 2-21

Activate brake speed

Time

5.4.2 Mechanical Brake Using Closed Loop Control

The VLT ® AutomationDrive features a mechanical brake control designed for hoisting applications and supports the following functions:

•

2 channels for mechanical brake feedback, offering protection against unintended behavior resulting from a broken cable.

•

Monitoring the mechanical brake feedback throughout the complete cycle. Monitoring helps protect the mechanical brake - especially if more drives are connected to the same shaft.

•

No ramp up until feedback confirms that mechanical brake is open.

•

Improved load control at stop.

•

The transition when motor takes over the load from the brake can be configured.

Parameter 1-72 Start Function [6] Hoist Mech. Brake Rel activates the hoist mechanical brake. The main difference compared to the regular mechanical brake control is that the hoist mechanical brake function has direct control over the brake relay.

Instead of setting a current to release the brake, the torque applied against the closed brake before release is defined.

Because the torque is defined directly, the set-up is more straightforward for hoisting applications.

MG38C102

Product Features Design Guide

The hoist mechanical brake strategy is based on the following 3-step sequence, where motor control and brake release are synchronized to obtain the smoothest possible brake release.

Pre-magnetize the motor.

To ensure that there is a hold on the motor and to verify that it is mounted correctly, the motor is first premagnetized.

Apply torque against the closed brake.

When the load is held by the mechanical brake, its size cannot be determined, only its direction. The moment the brake opens, the motor must take over the load. To facilitate the takeover, a user-defined torque

( parameter 2-26 Torque Ref ) is applied in the hoisting direction. This process is used to initialize the speed controller that finally takes over the load. To reduce wear on the gearbox due to backlash, the torque is ramped up.

Release the brake.

When the torque reaches the value set in parameter 2-26 Torque Ref , the brake is released. The value set in parameter 2-25 Brake Release Time determines the delay before the load is released. To react as quickly as possible on the load-step that follows after brake release, the speed-PID control can be boosted by increasing the proportional gain.

5 5

Motor

Speed Torque Ramp

Up Time p. 2-27

Torque Ref. p. 2-26

Brake Release

Time p. 2-25

Ramp 1 Up

P. 3-41

W22

Active

Torque

Ref.

Brake

Relay

High

Low

Contact no.1

E.g. DI32 [70] Mech. Brake Feedback

Mech Brake

Feedback

High

Low

Contact no.2

OPTIONAL

E.g. DI33 [71] Mech. Brake Feedback

Mech Brake

Position

Open

Closed

Gain Boost. p. 2-28

Gain Boost or

Postion Control

Illustration 5.8 Brake Release Sequence for Hoist Mechanical Brake Control

A22

Active

Ramp 1 Down

P. 3-42

Stop Delay

P. 2-24

Activate Brake

Delay

P. 2-23

Torque Ramp

Down Time

p. 2-29

A22

Active W22

Active

Parameter 2-26 Torque Ref to parameter 2-33 Speed PID Start Lowpass Filter Time are only available for the hoist mechanical brake control (FLUX with motor feedback). Parameter 2-30 Position P Start Proportional Gain to parameter 2-33 Speed PID Start

Lowpass Filter Time can be set up for smooth transition change from speed control to position control during parameter 2-25 Brake Release Time - the time when the load is transferred from the mechanical brake to the drive.

Parameter 2-30 Position P Start Proportional Gain to parameter 2-33 Speed PID Start Lowpass Filter Time are activated when parameter 2-28 Gain Boost Factor is set to 0. See

Illustration 5.8

for more information.

NOTICE

For an example of advanced mechanical brake control for hoisting applications, see

chapter 12 Application Examples .

Product Features VLT® AutomationDrive FC 302

5 5

5.5 Load Share Overview

Load share is a feature that allows the connection of DC circuits of several drives, creating a multiple-drive system to run 1 mechanical load. Load share provides the following benefits:

Energy savings

A motor running in regenerative mode can supply drives that are running in motoring mode.

Reduced need for spare parts

Usually, only 1 brake resistor is needed for the entire drive system instead of 1 brake resistor for per drive.

Power back-up

If there is mains failure, all linked drives can be supplied through the DC link from a back-up. The application can continue running or go though a controlled shutdown process.

Preconditions

The following preconditions must be met before load sharing is considered:

•

The drive must be equipped with load sharing terminals.

•

Product series must be the same. Only VLT ® AutomationDrive drives used with other VLT ® AutomationDrive drives.

•

Drives must be placed physically close to one another to allow the wiring between them to be no longer than 25 m (82 ft).

•

Drives must have the same voltage rating.

•

When adding a brake resistor in a load sharing configuration, all drives must be equipped with a brake chopper.

•

Fuses must be added to load share terminals.

For a diagram of a load share application in which best practices are applied, see

Illustration 5.9

DC connecting point for additional drives in the load sharing application

2x aR-1000 A 2x aR-1500 A

315 kW

FC 302

500 kW

FC 302

3x 1.2%

3x Class L-800 A

82 81

380 V

Common mains disconnect switch

Illustration 5.9 Diagram of a Load Share Application Where Best Practices are Applied

82 81

3x 1.2%

3x Class L-1200 A

Mains connecting point for additional drives in the load sharing application

MG38C102

Product Features Design Guide

Load sharing

Units with the built-in load sharing option contain terminals (+) 89 DC and (–) 88 DC. Within the drive, these terminals connect to the DC bus in front of the DC-link reactor and bus capacitors.

The load sharing terminals can connect in 2 different configurations.

•

Terminals tie the DC-bus circuits of multiple drives together. This configuration allows a unit that is in a regenerative mode to share its excess bus voltage with another unit that is running a motor. Load sharing in this manner can reduce the need for external dynamic brake resistors, while also saving energy. The number of units that can be connected in this way is infinite, as long as each unit has the same voltage rating. In addition, depending on the size and number of units, it may be necessary to install DC reactors and DC fuses in the DC-link connections, and AC reactors on the mains. Attempting such a configuration requires specific considerations.

•

The drive is powered exclusively from a DC source. This configuration requires:

A DC source.

A means to soft charge the DC bus at power-up.

5.6 Regen Overview

Regen typically occurs in applications with continuous braking such as cranes/hoists, downhill conveyors, and centrifuges where energy is pulled out of a decelerated motor.

The excess energy is removed from the drive using 1 of the following options:

•

Brake chopper allows the excess energy to be dissipated in the form of heat within the brake resistor coils.

•

Regen terminals allow a 3 rd party regen unit to be connected to the drive, allowing the excess energy to be returned to the power grid.

Returning excess energy back to the power grid is the most efficient use of regenerated energy in applications using continuous braking.

5 5

Product Features VLT® AutomationDrive FC 302

5 5

5.7 Back-channel Cooling Overview

A unique back-channel duct passes cooling air over the heat sinks with minimal air passing through the electronics area.

There is an IP54/Type 12 seal between the back-channel cooling duct and the electronics area of the VLT ® drive. This backchannel cooling allows 90% of the heat losses to be exhausted directly outside the enclosure. This design improves reliability and prolongs component life by dramatically reducing interior temperatures and contamination of the electronic components.

Illustration 5.10

shows the standard airflow configuration for an E1h–E4h drive.

Different back-channel cooling kits are available to redirect the airflow based on individual needs.

Illustration 5.11

shows 2 optional airflow configurations for an E1h–E4h drive.

225 mm (8.9 in)

Illustration 5.10 Standard Airflow Configuration for E1h/E2h (Left) and E3h/E4h (Right)

225 mm (8.9 in)

Illustration 5.11 Optional Airflow Configuration Through the Back Wall for E1h/E2h (Left) and E3h/E4h (Right)

MG38C102

Options and Accessories Ove...

Design Guide

6 Options and Accessories Overview

6.1 Fieldbus Devices

This section describes the fieldbus devices that are available with the VLT ® AutomationDrive series. Using a fieldbus device reduces system cost, delivers faster and more efficient communication, and provides an easier user interface. For ordering numbers, refer to

chapter 13.2 Ordering Numbers for Options and Accessories

6.1.1 VLT

PROFIBUS DP V1 MCA 101

The MCA 101 provides:

•

Wide compatibility, a high level of availability, support for all major PLC vendors, and compatibility with future versions.

•

Fast, efficient communication, transparent installation, advanced diagnosis, and parameterization and auto-configuration of process data via GSD file.

•

Acyclic parameterization using PROFIBUS DP-V1,

PROFdrive, or Danfoss FC profile state machines.

6.1.2 VLT

DeviceNet MCA 104

The MCA 104 provides:

•

Support of the ODVA AC drive profile supported via I/O instance 20/70 and 21/71 secures compatibility to existing systems.

•

Benefits from ODVA’s strong conformance testing policies that ensure products are interoperable.

6.1.3 VLT

CAN Open MCA 105

The MCA 105 option provides:

•

Standardized handling.

•

Interoperability.

•

Low cost.

This option is fully equipped with both high-priority access to control the drive (PDO communication) and to access all parameters through acyclic data (SDO communication).

For interoperability, the option uses the DSP 402 AC drive profile.

6.1.4 VLT

PROFIBUS Converter MCA 113

The MCA 113 option is a special version of the PROFIBUS options that emulates the VLT ® 3000 commands in the

VLT ® VLT ® AutomationDrive.

The VLT ® 3000 can be replaced by the VLT ®

AutomationDrive, or an existing system can be expanded without costly change of the PLC program. For upgrade to a different fieldbus, the installed converter can be removed and replaced with a new option. The MCA 113 option secures the investment without losing flexibility.

6.1.5 VLT

PROFIBUS Converter MCA 114

The MCA 114 option is a special version of the PROFIBUS options that emulates the VLT ® 5000 commands in the

VLT ® VLT ® AutomationDrive. This option supports DP-V1.

The VLT ® 5000 can be replaced by the VLT ®

AutomationDrive, or an existing system can be expanded without costly change of the PLC program. For upgrade to a different fieldbus, the installed converter can be removed and replaced with a new option. The MCA 114 option secures the investment without losing flexibility.

6.1.6 VLT

PROFINET MCA 120

The MCA 120 option combines the highest performance with the highest degree of openness. The option is designed so that many of the features from the VLT ®

PROFIBUS MCA 101 can be reused, minimizing user effort to migrate PROFINET and securing the investment in a PLC program.

•

Same PPO types as the VLT ® PROFIBUS DP V1

MCA 101 for easy migration to PROFINET.

•

Built-in web server for remote diagnosis and reading out of basic drive parameters.

•

Supports MRP.

•

Supports DP-V1. Diagnostic allows easy, fast, and standardized handling of warning and fault information into the PLC, improving bandwidth in the system.

•

Supports PROFIsafe when combined with VLT ®

Safety Option MCB 152.

•

Implementation in accordance with Conformance

Class B.

6 6

Options and Accessories Ove...

VLT® AutomationDrive FC 302

6 6

6.1.7 VLT

EtherNet/IP MCA 121

Ethernet is the future standard for communication at the factory floor. The VLT ® EtherNet/IP MCA 121 option is based on the newest technology available for industrial use and handles even the most demanding requirements.

EtherNet/IP™ extends standard commercial Ethernet to the

Common Industrial Protocol (CIP™) – the same upper-layer protocol and object model found in DeviceNet.

MCA 121 offers advanced features such as:

•

Built-in, high-performance switch enabling linetopology, which eliminates the need for external switches.

•

DLR Ring (from October 2015).

•

Advanced switch and diagnosis functions.

•

Built-in web server.

•

E-mail client for service notification.

•

Unicast and Multicast communication.

6.1.8 VLT

Modbus TCP MCA 122

The MCA 122 option connects to Modbus TCP-based networks. It handles connection intervals down to 5 ms in both directions, positioning it among the fastest performing Modbus TCP devices in the market. For master redundancy, it features hot swapping between 2 masters.

Other features include:

•

Built-in web-server for remote diagnosis and reading out basic drive parameters.

•

Email notification that can be configured to send an email message to 1 or more recipients when certain alarms or warnings occur, or when they are cleared.

•

Dual master PLC connection for redundancy.

6.1.9 VLT

POWERLINK MCA 123

The MCA 123 option represents the 2 nd generation of fieldbus. The high bit rate of industrial Ethernet can now be used to make the full power of IT technologies used in the automation world available for the factory world.

This fieldbus option provides high performance, real-time, and time synchronization features. Due to its CANopenbased communication models, network management, and device description model, it offers a fast communication network and the following features:

•

Dynamic motion control applications.

•

Material handling.

•

Synchronization and positioning applications.

6.1.10 VLT

EtherCAT MCA 124

The MCA 124 option offers connectivity to EtherCAT® based networks via the EtherCAT Protocol.

The option handles the EtherCAT line communication in full speed, and connection towards the drive with an interval down to 4 ms in both directions, allowing the MCA

124 to participate in networks ranging from low performance up to servo applications.

•

EoE Ethernet over EtherCAT support.

•

HTTP (hypertext transfer protocol) for diagnosis via built-in web server.

•

CoE (CAN over Ethernet) for access to drive parameters.

•

SMTP (simple mail transfer protocol) for e-mail notification.

•

TCP/IP for easy access to drive configuration data from MCT 10.

6.2 Functional Extensions

This section describes the functional extension options that are available with the VLT ® AutomationDrive series. For ordering numbers, refer to

chapter 13.2 Ordering Numbers for Options and Accessories

6.2.1 VLT

General Purpose I/O Module

MCB 101

The MCB 101 option offers an extended number of control inputs and outputs:

•

3 digital inputs 0–24 V: Logic 0 < 5 V; Logic 1 >

10 V.

•

2 analog inputs 0–10 V: Resolution 10 bits plus sign.

•

2 digital outputs NPN/PNP push-pull.

•

1 analog output 0/4–20 mA.

•

Spring-loaded connection.

MG38C102

Options and Accessories Ove...

Design Guide

6.2.2 VLT

Encoder Input MCB 102

The MCB 102 option offers the possibility to connect various types of incremental and absolute encoders. The connected encoder can be used for closed-loop speed control and closed-loop flux motor control. The following encoder types are supported:

•

5 V TTL (RS 422)

•

1VPP SinCos

•

SSI

•

HIPERFACE

•

EnDat

6.2.3 VLT

Resolver Option MCB 103

The MCB 103 option enables connection of a resolver to provide speed feedback from the motor.

•

Primary voltage: 2–8 V rms

•

Primary frequency: 2.0–15 kHz

•

Primary maximum current: 50 mA rms

•

Secondary input voltage: 4 V rms

•

Spring-loaded connection

6.2.4 VLT

Relay Card MCB 105

The MCB 105 option extends relay functions with 3 more relay outputs.

•

Protects control cable connection.

•

Spring-loaded control wire connection.

Maximum switch rate (rated load/minimum load)

6 minutes -1 /20 s -1

Maximum terminal load

AC-1 resistive load: 240 V AC, 2 A

6.2.5 VLT

Safe PLC Interface Option

MCB 108

The MCB 108 option provides a safety input based on a single-pole 24 V DC input. For most applications, this input provides a way to implement safety in a cost-effective way.

For applications that work with more advanced products like Safety PLC and light curtains, the fail-safe PLC interface enables the connection of a 2-wire safety link. The PLC

Interface allows the fail-safe PLC to interrupt on the plus or the minus link without interfering with the sense signal of the fail-safe PLC.

6.2.6 VLT

PTC Thermistor Card MCB 112

The MCB 112 option provides extra motor monitoring compared to the built-in ETR function and thermistor terminal.

•

Protects the motor from overheating.

•

ATEX-approved for use with Ex-d and Ex-e motors

(EX-e only FC 302).

•

Uses Safe Torque Off function, which is approved in accordance with SIL 2 IEC 61508.

6.2.7 VLT

Sensor Input Option MCB 114

The MCB 114 option protects the motor from being overheated by monitoring the temperature of motor bearings and windings.

•

3 self-detecting sensor inputs for 2 or 3-wire

PT100/PT1000 sensors.

•

1 extra analog input 4–20 mA.

6.2.8 VLT

Safety Option MCB 150 and

MCB 151

MCB 150 and MCB 151 options expand the safe torque off functions, which are integrated in a standard VLT ®

AutomationDrive. Use the Safe Stop 1 (SS1) function to perform a controlled stop before removing torque. Use the

Safety-Limited Speed (SLS) function to monitor whether a specified speed is exceeded.

These options can be used up to PL d according to ISO

13849-1 and SIL 2 according to IEC 61508.

•

Extra standards-compliant safety functions.

•

Replacement of external safety equipment.

•

Reduced space requirements.

•

2 safe programmable inputs.

•

1 safe output (for T37).

•

Easier machine certification.

•

Drive can be powered continuously.

•

Safe LCP copy.

•

Dynamic commissioning report.

•

TTL (MCB 150) or HTL (MCB 151) encoder as speed feedback.

6 6

Options and Accessories Ove...

VLT® AutomationDrive FC 302

6 6

6.2.9 VLT

Safety Option MCB 152

The MCB 152 option activates safe torque off via the

PROFIsafe fieldbus with VLT ® PROFINET MCA 120 fieldbus option. It improves flexibility by connecting safety devices within a plant.

The safety functions of the MCB 152 are implemented according to EN IEC 61800-5-2. The MCB 152 supports

PROFIsafe functionality to activate integrated safety functions of the VLT ® AutomationDrive from any PROFIsafe host, up to Safety Integrity Level SIL 2 according to EN IEC

61508 and EN IEC 62061, and Performance Level PL d,

Category 3 according to EN ISO 13849-1.

•

PROFIsafe device (with MCA 120).

•

Replacement of external safety equipment.

•

2 safe programmable inputs.

•

Safe LCP copy.

•

Dynamic commissioning report.

6.3 Motion Control and Relay Cards

This section describes the motion control and relay card options that are available with the VLT ® AutomationDrive series. For ordering numbers, refer to

chapter 13.2 Ordering

Numbers for Options and Accessories .

6.3.1 VLT

Motion Control Option MCO 305

The MCO 305 option is an integrated programmable motion controller that adds extra functionality for VLT ®

VLT ® AutomationDrive.

The MCO 305 option offers easy-to-use motion functions combined with programmability – an ideal solution for positioning and synchronizing applications.

•

Synchronization (electronic shaft), positioning, and electronic cam control.

•

2 separate interfaces supporting both incremental and absolute encoders.

•

1 encoder output (virtual master function).

•

10 digital inputs.

•

8 digital outputs.

•

Supports CANopen motion bus, encoders, and I/O modules.

•

Sends and receives data via fieldbus interface

(requires fieldbus option).

•

PC software tools for debugging and commissioning: program and cam editor.

•

Structured programming language with both cyclic and event-driven execution.

6.3.2 VLT

Synchronizing Controller

MCO 350

The MCO 350 option for VLT ® AutomationDrive expands the functional properties of the AC drive in synchronizing applications, and replaces traditional mechanical solutions.

•

Speed synchronizing.

•

Position (angle) synchronizing with or without marker correction.

•

On-line adjustable gear ratio.

•

On-line adjustable position (angle) offset.

•

Encoder output with virtual master function for synchronization of multiple followers.

•

Control via I/Os or fieldbus.

•

Home function.

•

Configuration and readout of status and data via the LCP.

6.3.3 VLT

Positioning Controller MCO 351

The MCO 351 option offers a host of user-friendly benefits for positioning applications in many industries.

•

Relative positioning.

•

Absolute positioning.

•

Touch-probe positioning.

•

End-limit handling (software and hardware).

•

Control via I/Os or fieldbus.

•

Mechanical brake handling (programmable hold delay).

•

Error handling.

•

Jog speed/manual operation.

•

Marker-related positioning.

•

Home function.

•

Configuration and readout of status and data via the LCP.

MG38C102

Options and Accessories Ove...

Design Guide

6.3.4 VLT

Extended Relay Card MCB 113

The MCB 113 option adds inputs/outputs for increased flexibility.

•

7 digital inputs.

•

2 analog outputs.

•

4 SPDT relays.

•

Meets NAMUR recommendations.

•

Galvanic isolation capability.

6.4 Brake Resistors

In applications where the motor is used as a brake, energy is generated in the motor and sent back into the drive. If the energy cannot be transported back to the motor, it increases the voltage in the drive DC line. In applications with frequent braking and/or high inertia loads, this increase can lead to an overvoltage trip in the drive and, finally, a shutdown. Brake resistors are used to dissipate the excess energy resulting from the regenerative braking.

The resistor is selected based on its ohmic value, its power dissipation rate, and its physical size. Danfoss offers a wide variety of different resistors that are specially designed to

Danfoss drives. For ordering numbers and more information on how to dimension brake resistors, refer to the VLT ® Brake Resistor MCE 101 Design Guide .

6.5 Sine-wave Filters

When a drive controls a motor, resonance noise is heard from the motor. This noise, which is the result of the motor design, occurs every time an inverter switch in the drive is activated. The frequency of the resonance noise thus corresponds to the switching frequency of the drive.

Danfoss supplies a sine-wave filter to dampen the acoustic motor noise. The filter reduces the ramp-up time of the voltage, the peak load voltage (U

PEAK

), and the ripple current ( Δ I) to the motor, which means that current and voltage become almost sinusoidal. The 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 enclosure.

For ordering numbers and more information on sine-wave filters, refer to the Output Filters Design Guide .

6.6 dU/dt Filters

Danfoss supplies dU/dt filters which are differential mode, low-pass filters that reduce motor terminal phase-to-phase peak voltages and reduce the rise time to a level that lowers the stress on the insulation at the motor windings.

This is a typical issue with set-ups using short motor cables.

Compared to sine-wave filters, the dU/dt filters have a cutoff frequency above the switching frequency.

For ordering numbers and more information on dU/dt filters, refer to the Output Filters Design Guide .

6.7 Common-mode Filters

High-frequency common-mode cores (HF-CM cores) reduce electromagnetic interference and eliminate bearing damage by electrical discharge. They are special nanocrystalline magnetic cores that have superior filtering performance compared to regular ferrite cores. The HF-CM core acts like a common-mode inductor between phases and ground.

Installed around the 3 motor phases (U, V, W), the common mode filters reduce high-frequency commonmode currents. As a result, high-frequency electromagnetic interference from the motor cable is reduced.

For ordering numbers refer to the Output Filters Design

Guide .

6.8 Harmonic Filters

The VLT ® Advanced Harmonic Filters AHF 005 & AHF 010 should not be compared with traditional harmonic trap filters. The Danfoss harmonic filters have been specially designed to match the Danfoss drives.

By connecting the AHF 005 or AHF 010 in front of a

Danfoss drive, the total harmonic current distortion generated back to the mains is reduced to 5% and 10%.

For ordering numbers and more information on how to dimension brake resistors, refer to the VLT

®

Advanced

Harmonic Filters AHF 005/AHF 010 Design Guide .

6.9 High-power Kits

High-power kits, such as back-wall cooling, space heater, mains shield, are available for these enclosures. See

chapter 13.2 Ordering Numbers for Options and Accessories

for a brief description and ordering numbers for all available kits.

6 6

Specifications VLT® AutomationDrive FC 302

7 Specifications

7 7

7.1 Electrical Data, 380–500 V

VLT ® AutomationDrive FC 302

High/normal overload

(High overload=150% current during 60 s, normal overload=110% current during 60 s)

Typical shaft output at 400 V [kW]

Typical shaft output at 460 V [hp]

Typical shaft output at 500 V [kW]

Enclosure size

Output current (3-phase)

Continuous (at 400 V) [A]

Intermittent (60 s overload)

(at 400 V) [A]

Continuous (at 460/500 V) [A]

Intermittent (60 s overload)

(at 460/500 V) [A]

Continuous kVA (at 400 V) [kVA]

Continuous kVA (at 460 V) [kVA]

Continuous kVA (at 500 V) [kVA]

Maximum input current

Continuous (at 400 V) [A]

Continuous (at 460/500 V) [A]

Maximum number and size of cables per phase (E1h)

Mains and motor without brake [mm 2 (AWG)] 1)

Mains and motor with brake [mm 2 (AWG)] 1)

Brake or regen [mm 2 (AWG)] 1)

Maximum number and size of cables per phase (E3h)

Mains and motor [mm 2 (AWG)] 1)

Brake [mm 2 (AWG)] 1)

Load share or regen [mm 2 (AWG)] 1)

Maximum external mains fuses [A] 2)

Estimated power loss at 400 V [W] 3), 4)

Estimated power loss at 460 V [W] 3), 4)

Efficiency 4)

Output frequency [Hz]

Heat sink overtemperature trip [ ° C ( ° F)]

Control card overtemperature trip [ ° C ( ° F)]

Power card overtemperature trip [ ° C ( ° F)]

Fan power card overtemperature trip [ ° C ( ° F)]

Active in-rush card overtemperature trip

[ ° C ( ° F)]

600

900

540

810

416

430

468

578

520

N315

315

450

355

E1h/E3h

355

500

400

658

724

590

649

456

470

511

634

569

5x240 (5x500 mcm)

4x240 (4x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

800

6178

5322

6928

5910

0.98

0–590

110 (230)

80 (176)

85 (185)

Table 7.1 Electrical Data for Enclosures E1h/E3h, Mains Supply 3x380–500 V AC

658

987

590

885

456

470

511

355

500

400

E1h/E3h

400

600

500

634

569

N355

718

653

5x240 (5x500 mcm)

4x240 (4x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

800

6851

5846

8036

6933

0.98

0–590

110 (230)

80 (176)

85 (185)

745

820

678

746

516

540

587

N400

695

1043

678

1017

482

540

587

400

550

500

E1h/E3h

450

600

530

800

880

730

803

554

582

632

670

653

771

704

5x240 (5x500 mcm)

4x240 (4x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

800

7297

7240

8783

7969

0.98

0–590

110 (230)

80 (176)

85 (185)

MG38C102

Specifications Design Guide

VLT ® AutomationDrive FC 302

High/normal overload

(High overload=150% current during 60 s, normal overload=110% current during 60 s)

Typical shaft output at 400 V [kW]

Typical shaft output at 460 V [hp]

Typical shaft output at 500 V [kW]

Enclosure size

Output current (3-phase)

Continuous (at 400 V) [A]

Intermittent (60 s overload)

(at 400 V) [A]

Continuous (at 460/500 V) [A]

Intermittent (60 s overload)

(at 460/500 V) [A]

Continuous kVA (at 400 V) [kVA]

Continuous kVA (at 460 V) [kVA]

Continuous kVA

(at 500 V) [kVA]

Maximum input current

Continuous (at 400 V) [A]

Continuous (at 460/500 V) [A]

Maximum number and size of cables per phase (E2h)

Mains and motor without brake [mm 2 (AWG)] 1)

Mains and motor with brake [mm 2 (AWG)] 1)

Brake or regen [mm 2 (AWG)] 1)

Maximum number and size of cables per phase (E4h)

Mains and motor [mm 2 (AWG)] 1)

Brake [mm 2 (AWG)] 1)

Load share or regen [mm 2 (AWG)] 1)

Maximum external mains fuses [A] 2)

Estimated power loss at 400 V [W] 3), 4)

Estimated power loss at 460 V [W] 3), 4)

Efficiency 4)

Output frequency [Hz]

Heat sink overtemperature trip [ ° C ( ° F)]

Control card overtemperature trip [ ° C ( ° F)]

Power card overtemperature trip [ ° C ( ° F)]

Fan power card overtemperature trip [ ° C ( ° F)]

Active in-rush card overtemperature trip [ ° C ( ° F)]

450

600

530

800

1200

730

1095

554

582

632

771

704

N450

E2h/E4h

500

650

560

880

968

780

858

610

621

675

848

752

6x240 (6x500 mcm)

5x240 (5x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

8352

7182

1200

0.98

0–590

110 (230)

80 (176)

85 (185)

9473

7809

500

650

560

880

1320

780

1170

610

621

675

848

752

N500

E2h/E4h

560

750

630

990

1089

890

979

686

709

771

954

858

6x240 (6x500 mcm)

5x240 (5x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

9449

7771

1200

0.98

0–590

100 (212)

80 (176)

85 (185)

11102

9236

Table 7.2 Electrical Data for Enclosures E2h/E4h, Mains Supply 3x380–500 V AC

1) American Wire Gauge.

2) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

3) Typical power loss is at normal conditions and expected to be within ± 15% (tolerance relates to variety in voltage and cable conditions.) These values are based on a typical motor efficiency (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies for dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyefficiency. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.

4) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Efficiency measured at nominal current. For energy

efficiency class, see chapter 7.5 Ambient Conditions. For part load losses, see www.danfoss.com/vltenergyefficiency.

7 7

Specifications VLT® AutomationDrive FC 302

7 7

7.2 Electrical Data, 525–690 V

VLT ® AutomationDrive FC 302

High/normal overload

(High overload=150% current during 60 s, normal overload=110% current during 60 s)

Typical shaft output at 550 V [kW]

Typical shaft output at 575 V [hp]

Typical shaft output at 690 V [kW]

Enclosure size

Output current (3-phase)

Continuous (at 550 V) [A]

Intermittent (60 s overload) (at 550 V) [A]

Continuous (at 575/690 V) [A]

Intermittent (60 s overload)

(at 575/690 V) [A]

Continuous kVA (at 550 V) [kVA]

Continuous kVA (at 575 V) [kVA]

Continuous kVA (at 690 V) [kVA]

Maximum input current

Continuous (at 550 V) [A]

Continuous (at 575 V) [A]

Continuous (at 690 V) [A]

Maximum number and size of cables per phase (E1h)

Mains and motor without brake [mm 2 (AWG)] 1)

Mains and motor with brake [mm 2 (AWG)] 1)

Brake or regen [mm 2 (AWG)] 1)

Maximum number and size of cables per phase (E3h)

Mains and motor [mm 2 (AWG)] 1)

Brake [mm 2 (AWG)] 1)

Load share or regen [mm 2 (AWG)] 1)

Maximum external mains fuses [A] 2)

Estimated power loss at 600 V [W] 3)4)

Estimated power loss at 690 V [W] 3)4)

Efficiency 4)

Output frequency [Hz]

Heat sink overtemperature trip [ ° C ( ° F)]

Control card overtemperature trip [ ° C ( ° F)]

Power card overtemperature trip [ ° C ( ° F)]

Fan power card overtemperature trip [ ° C ( ° F)]

Active in-rush card overtemperature trip

[ ° C ( ° F)]

395

593

380

570

376

378

454

381

366

N355

315

400

355

E1h/E3h

355

450

470

517

450

495

448

538

453

434

5x240 (5x500 mcm)

4x240 (4x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

800

4989 6062

4920 5939

0.98

0–590

110 (230)

80 (176)

85 (185)

Table 7.3 Electrical Data for Enclosures E1h/E3h, Mains Supply 3x525–690 V AC

429

644

410

615

409

408

490

355

400

E1h/E3h

400

500

413

395

N400

504

482

5x240 (5x500 mcm)

4x240 (4x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

800

5419 6879

5332

0.98

0–590

110 (230)

80 (176)

85 (185)

6715

85 (185)

523

575

500

550

498

598

N500

523

785

500

750

498

598

400

500

E1h/E3h

450

600

560

596

656

570

627

568

681

504

482

574

549

5x240 (5x500 mcm)

4x240 (4x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

800

6833 8076

6678

0.98

0–590

110 (230)

80 (176)

85 (185)

7852

85 (185)

MG38C102

Specifications Design Guide

VLT ® AutomationDrive FC 302

High/normal overload

(High overload=150% current during 60 s, normal overload=110% current during 60 s)

Typical shaft output at 550 V [kW]

Typical shaft output at 575 V [hp]

Typical shaft output at 690 V [kW]

Enclosure size

Output current (3-phase)

Continuous (at 550 V) [A]

Intermittent (60 s overload) (at 550 V) [A]

Continuous (at 575/690 V) [A]

Intermittent (60 s overload)

(at 575/690 V) [A]

Continuous kVA (at 550 V) [kVA]

Continuous kVA (at 575 V) [kVA]

Continuous kVA (at 690 V) [kVA]

Maximum input current

Continuous (at 550 V) [A]

Continuous (at 575 V) [A]

Continuous (at 690 V) [A]

Maximum number and size of cables per phase (E2h)

Mains and motor without brake [mm 2 (AWG)] 1)

Mains and motor with brake [mm 2 (AWG)] 1)

Brake or regen [mm 2 (AWG)] 1)

Maximum number and size of cables per phase (E4h)

Mains and motor [mm 2 (AWG)] 1)

Brake [mm 2 (AWG)] 1)

Load share or regen [mm 2 (AWG)] 1)

Maximum external mains fuses [A] 2)

Estimated power loss at 600 V [W] 3)4)

Estimated power loss at 690 V [W] 3)4)

Efficiency 4)

Output frequency [Hz]

Heat sink overtemperature trip [ ° C ( ° F)]

Control card overtemperature trip [ ° C ( ° F)]

Power card overtemperature trip [ ° C ( ° F)]

Fan power card overtemperature trip [ ° C ( ° F)]

Active in-rush card overtemperature trip

[ ° C ( ° F)]

450

600

560

596

894

570

855

568

681

574

549

N560

E1h/E3h

500

650

630

693

630

693

600

627

753

607

6x240 (6x500 mcm)

5x240 (5x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

800

8069

7848

0.98

0–590

110 (230)

80 (176)

85 (185)

9208

8921

500

650

630

659

989

630

945

628

627

753

635

607

6x240 (6x500 mcm)

5x240 (5x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

1200

8543

8363

N630

E2h/E4h

0.98

0–590

110 (230)

80 (176)

85 (185)

560

750

710

763

839

730

803

727

872

735

704

10346

10066

560

750

710

763

1145

730

1095

727

872

735

704

N710

E2h/E4h

670

950

800

857

819

6x240 (6x500 mcm)

5x240 (5x500 mcm)

2x185 (2x350 mcm)

6x240 (6x500 mcm)

2x185 (2x350 mcm)

4x185 (4x350 mcm)

1200

10319

10060

0.98

0–590

110 (230)

80 (176)

85 (185)

12723

12321

Table 7.4 Electrical Data for Enclosures E1h–E4h, Mains Supply 3x525–690 V AC

1) American Wire Gauge.

2) For fuse ratings, see chapter 10.5 Fuses and Circuit Breakers.

4) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Efficiency measured at nominal current. For energy

efficiency class, see chapter 7.5 Ambient Conditions. For part load losses, see www.danfoss.com/vltenergyefficiency.

889

978

850

935

847

1016

7 7

Specifications VLT® AutomationDrive FC 302

7 7

7.3 Mains Supply

Mains supply (L1, L2, L3)

Supply voltage 380–500 V ±10%, 525–690 V ±10%

Mains voltage low/mains voltage drop-out:

During low mains voltage or a mains drop-out, the drive continues until the DC-link voltage drops below the minimum stop level, which corresponds typically to 15% below the lowest rated supply voltage of the drive. Power-up and full torque cannot be expected at mains voltage lower than 10% below the lowest rated supply voltage of the drive.

Supply frequency

Maximum imbalance temporary between mains phases

True power factor (λ)

Displacement power factor (cos Φ) near unity

Switching on input supply L1, L2, L3 (power ups)

Environment according to EN60664-1

50/60 Hz ±5%

3.0% of rated supply voltage 1)

≥0.9 nominal at rated load

(>0.98)

Maximum 1 time/2 minute

Overvoltage category III/pollution degree 2

The drive is suitable for use on a circuit capable of delivering up to 100 kA short circuit current rating (SCCR) at 480/600 V.

1) Calculations based on UL/IEC61800-3.

7.4 Motor Output and Motor Data

Motor output (U, V, W)

Output voltage

Output frequency

Switching on output

Ramp times

1) Dependent on voltage and power.

Torque characteristics

Starting torque (constant torque)

Overload torque (constant torque)

1) Percentage relates to the nominal current of the drive.

2) Once every 10 minutes.

0–100% of supply voltage

0–590 Hz 1)

Unlimited

0.01–3600 s

Maximum 150% for 60 s 1)2)

7.5 Ambient Conditions

Environment

E1h/E2h enclosure

E3h/E4h enclosure

Vibration test (standard/ruggedized)

Relative humidity

Aggressive environment (IEC 60068-2-43) H

S test

Aggressive gases (IEC 60721-3-3)

Test method according to IEC 60068-2-43

Ambient temperature (at SFAVM switching mode)

5%–95% (IEC 721-3-3; Class 3K3 (non-condensing) during operation)

- with derating

- with full output power of typical EFF2 motors (up to 90% output current)

- at full continuous FC output current

Minimum ambient temperature during full-scale operation

Minimum ambient temperature at reduced performance

Temperature during storage/transport

Maximum altitude above sea level without derating

Maximum altitude above sea level with derating

IP21/Type 1, IP54/Type 12

IP20/Chassis

Class Kd

Class 3C3

H2S (10 days)

Maximum 55 °

0.7 g/1.0 g

C (131 ° F) 1)

Maximum 50 ° C (122 ° F) 1)

Maximum 45 ° C (113 ° F) 1)

0 ° C (32 ° F)

10 ° C (50 ° F)

-25 to +65/70 ° C (13 to 149/158 ° F)

1000 m (3281 ft)

3000 m (9842 ft)

1) For more information on derating, see chapter 9.6 Derating.

EMC standards, Emission EN 61800-3

MG38C102

Specifications Design Guide

EMC standards, Immunity

Energy efficiency class 1)

1) Determined according to EN 50598-2 at:

•

Rated load.

•

90% rated frequency.

•

Switching frequency factory setting.

•

Switching pattern factory setting.

7.6 Cable Specifications

Cable lengths and cross-sections for control cables 1)

Maximum motor cable length, shielded/armored

Maximum motor cable length, unshielded/unarmored

Maximum cross-section to motor, mains, load sharing, and brake

Maximum cross-section to control terminals, rigid wire

Maximum cross-section to control terminals, flexible cable

Maximum cross-section to control terminals, cable with enclosed core

Minimum cross-section to control terminals

1) For power cables, see electrical data in chapter 7 Specifications.

EN 61800-3

IE2

150 m (492 ft)

300 m (984 ft)

See

chapter 7 Specifications

1.5 mm 2 /16 AWG (2x0.75 mm 2 )

1 mm 2 /18 AWG

0.5 mm 2 /20 AWG

0.25 mm 2 /23 AWG

7.7 Control Input/Output and Control Data

Digital inputs

Programmable digital inputs

Terminal number

Logic

Voltage level

Voltage level, logic 0 PNP

Voltage level, logic 1 PNP

Voltage level, logic 0 NPN

Voltage level, logic 1 NPN

Maximum voltage on input

Input resistance, R i

All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

1) Terminals 27 and 29 can also be programmed as outputs.

4 (6)

18, 19, 27 1) , 29 1) , 32, 33

PNP or NPN

0–24 V DC

<5 V DC

>10 V DC

>19 V DC

<14 V DC

28 V DC

Approximately 4 k Ω

Analog inputs

Number of analog inputs

Terminal number

Modes

Mode select

Voltage mode

Voltage level

Input resistance, R

Maximum voltage

Current mode

Current level

Input resistance, R

Maximum current i i

Resolution for analog inputs

Accuracy of analog inputs

Bandwidth

53, 54

Voltage or current

Switches A53 and A54

Switch A53/A54=(U)

-10 V to +10 V (scaleable)

Approximately 10 k Ω

± 20 V

Switch A53/A54=(I)

0/4 to 20 mA (scaleable)

Approximately 200 Ω

30 mA

10 bit (+ sign)

Maximum error 0.5% of full scale

100 Hz

The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

7 7

Specifications VLT® AutomationDrive FC 302

PELV isolation

+24 V

Control

Functional isolation

RS485

Illustration 7.1 PELV Isolation

High voltage

Mains

Motor

DC-bus

7 7

Pulse inputs

Programmable pulse inputs

Terminal number pulse

Maximum frequency at terminal 29, 33 (push-pull driven)

Maximum frequency at terminal 29, 33 (open collector)

Minimum frequency at terminal 29, 33

Voltage level

Maximum voltage on input

Input resistance, R i

Pulse input accuracy (0.1–1 kHz)

29, 33

110 kHz

5 kHz

4 Hz

See Digital Inputs in

chapter 7.7 Control Input/Output and Control Data

28 V DC

Approximately 4 k Ω

Maximum error: 0.1% of full scale

Analog output

Number of programmable analog outputs

Terminal number

Current range at analog output

Maximum resistor load to common at analog output

Accuracy on analog output

Resolution on analog output

0/4–20 mA

500 Ω

Maximum error: 0.8% of full scale

8 bit

The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control card, RS485 serial communication

Terminal number

Terminal number 61

68 (P, TX+, RX+), 69 (N, TX-, RX-)

Common for terminals 68 and 69

The RS485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage (PELV).

Digital output

Programmable digital/pulse outputs

Terminal number

Voltage level at digital/frequency output

Maximum output current (sink or source)

Maximum load at frequency output

Maximum capacitive load at frequency output

Minimum output frequency at frequency output

Maximum output frequency at frequency output

Accuracy of frequency output

Resolution of frequency outputs

1) Terminals 27 and 29 can also be programmed as inputs.

The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

27, 29 1)

0–24 V

40 mA

1 k Ω

10 nF

0 Hz

32 kHz

Maximum error: 0.1% of full scale

12 bit

MG38C102

Specifications Design Guide

Control card, 24 V DC output

Terminal number

Maximum load

12, 13

200 mA

The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs.

Relay outputs

Programmable relay outputs

Maximum cross-section to relay terminals

Minimum cross-section to relay terminals

Length of stripped wire

Relay 01 terminal number

Maximum terminal load (AC-1) 1) on 1–2 (NO) (Resistive load) 2)3)

Maximum terminal load (AC-15) 1) on 1–2 (NO) (Inductive load @ cos φ 0.4)

Maximum terminal load (DC-1) 1) on 1–2 (NO) (Resistive load)

Maximum terminal load (DC-13) 1) on 1–2 (NO) (Inductive load)

Maximum terminal load (AC-1) 1) on 1–3 (NC) (Resistive load)

Maximum terminal load (AC-15) 1) on 1–3 (NC) (Inductive load @ cos φ 0.4)

Maximum terminal load (DC-1) 1) on 1–3 (NC) (Resistive load)

Maximum terminal load (DC-13) 1) on 1–3 (NC) (Inductive load)

Minimum terminal load on 1–3 (NC), 1–2 (NO)

Environment according to EN 60664-1

Relay 02 terminal number

Maximum terminal load (AC-1) 1) on 4–5 (NO) (Resistive load) 2)3)

Maximum terminal load (AC-15) 1) on 4–5 (NO) (Inductive load @ cos φ 0.4)

Maximum terminal load (DC-1) 1) on 4–5 (NO) (Resistive load)

Maximum terminal load (DC-13) 1) on 4–5 (NO) (Inductive load)

Maximum terminal load (AC-1) 1) on 4–6 (NC) (Resistive load)

Maximum terminal load (AC-15) 1) on 4–6 (NC) (Inductive load @ cos φ 0.4)

Maximum terminal load (DC-1) 1) on 4–6 (NC) (Resistive load)

Maximum terminal load (DC-13) 1) on 4–6 (NC) (Inductive load)

Minimum terminal load on 4–6 (NC), 4–5 (NO)

Environment according to EN 60664-1

The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).

1) IEC 60947 part 4 and 5.

2) Overvoltage Category II.

3) UL applications 300 V AC 2 A.

2.5 mm 2 (12 AWG)

0.2 mm 2 (30 AWG)

8 mm (0.3 in)

1–3 (break), 1–2 (make)

400 V AC, 2 A

240 V AC, 0.2 A

80 V DC, 2 A

24 V DC, 0.1 A

240 V AC, 2 A

240 V AC, 0.2 A

50 V DC, 2 A

24 V DC, 0.1 A

24 V DC 10 mA, 24 V AC 2 mA

Overvoltage category III/pollution degree 2

4–6 (break), 4–5 (make)

400 V AC, 2 A

240 V AC, 0.2 A

80 V DC, 2 A

24 V DC, 0.1 A

240 V AC, 2 A

240 V AC, 0.2 A

50 V DC, 2 A

24 V DC, 0.1 A

24 V DC 10 mA, 24 V AC 2 mA

Overvoltage category III/pollution degree 2

Control card, +10 V DC output

Terminal number

Output voltage

Maximum load

The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control characteristics

Resolution of output frequency at 0–1000 Hz

System response time (terminals 18, 19, 27, 29, 32, 33)

Speed control range (open loop)

Speed accuracy (open loop)

All control characteristics are based on a 4-pole asynchronous motor.

10.5 V ±

0.5 V

25 mA

± 0.003 Hz

≤ 2 ms

1:100 of synchronous speed

30–4000 RPM: Maximum error of ± 8 RPM

7 7

Specifications VLT® AutomationDrive FC 302

Control card performance

Scan interval 5 ms

Control card, USB serial communication

USB standard

USB plug

1.1 (full speed)

USB type B device plug

NOTICE

Connection to PC is carried out via a standard host/device USB cable.

The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

The USB connection is not galvanically isolated from ground. Use only isolated laptop/PC as connection to the USB connector on the drive or an isolated USB cable/converter.

MG38C102

Exterior and Terminal Dimen...

Design Guide

8 Exterior and Terminal Dimensions

8.1 E1h Exterior and Terminal Dimensions

8.1.1 E1h Exterior Dimensions

22 (0.8)

3X 13 (0.5)

2043

(80.4)

2002

(78.8)

1553

(61.1)

1393

(54.9)

912

(35.9)

393 (15.5)

602 (23.7)

Illustration 8.1 Front View of E1h

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

2X 20 (0.8)

2X 101 (4.0)

2X 9 (0.7)

8 8

1 Knockout panel

Illustration 8.2 Side View of E1h

280 (11.0)

513

(20.2)

567

(22.3)

35 (1.4)

190 (7.5)

125 (4.9)

MG38C102

Exterior and Terminal Dimen...

Design Guide

96 (3.8)

206

(8.1)

412 (16.2)

18 (0.7)

168 (6.6)

154 (6.1)

168 (6.6)

1800 (70.9)

1209 (47.6)

601 (23.7)

4X 73 (2.8)

69 (2.7)

1 Heat sink access panel (optional)

Illustration 8.3 Back View of E1h

4X 457 (18.0)

464 (18.3)

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

750 (29.5)

558

(22.0)

22 (0.8)

137

(5.4)

412 (16.2)

560 (22.0)

184

(7.3)

424

(16.7)

17 (0.7)

14 (0.6)

11 (0.4)

293 (11.5)

173 (6.8)

22 (0.8) 560 (22.0)

1 Gland plate

Illustration 8.4 Door Clearance and Gland Plate Dimensions for E1h

MG38C102

Exterior and Terminal Dimen...

8.1.2 E1h Terminal Dimensions

Design Guide

6X 613 (24.1)

515 (20.3)

485 (19.1)

200 (7.9)

0 (0.0)

Mains terminals

Brake or regen terminals

Illustration 8.5 E1h Terminal Dimensions (Front View)

Motor terminals

Ground terminals, M10 nut

721 (28.4)

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

649 (25.5) 649 (25.5)

8 8

0 (0.0) 0 (0.0)

5X 14 (0.5)

44 (1.8)

0 (0.0)

36 (1.4)

Illustration 8.6 E1h Terminal Dimensions (Side Views)

MG38C102

Exterior and Terminal Dimen...

Design Guide

8.2 E2h Exterior and Terminal Dimensions

8.2.1 E2h Exterior Dimensions

(3.8)

3X 13 (0.5)

2043

(80.4)

2002

(78.8)

1553

(61.1)

1393

(54.9)

912

(35.9)

394

(15.5)

698

(27.5)

Illustration 8.7 Front View of E2h

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

2X 20 (0.8)

2X 101 (4.0)

2X 9 (0.7)

8 8

1 Knockout panel

Illustration 8.8 Side View of E2h

280 (11.0)

513

(20.2)

567

(22.3)

125 (4.9)

35 (1.4)

190 (7.5)

MG38C102

Exterior and Terminal Dimen...

Design Guide

96 (3.8) 254

(10.0)

508 (20.0)

18 (0.7)

168 (6.6)

154 (6.1)

1209 (47.6)

168 (6.6)

1800 (70.9)

601 (23.7)

4X 121 (4.8)

69 (2.7)

1 Heat sink access panel (optional)

Illustration 8.9 Back View of E2h

4X 457 (18.0)

560 (22.0)

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

871 (34.3)

653

(25.7)

22 (0.8)

137

(5.4)

508 (20.0)

656 (25.8)

184

(7.3)

424

(16.7)

17 (0.7)

14 (0.6)

11 (0.4)

293 (11.5)

173 (6.8)

22 (0.8) 656 (25.8)

1 Gland plate

Illustration 8.10 Door Clearance and Gland Plate Dimensions for E2h

MG38C102

Exterior and Terminal Dimen...

8.2.2 E2h Terminal Dimensions

Design Guide

6X 613 (24.1)

515 (20.3)

485 (19.1)

200 (7.9)

0 (0.0)

Mains terminals

Brake or regen terminals

Illustration 8.11 E2h Terminal Dimensions (Front View)

Motor terminals

Ground terminals, M10 nut

721 (28.4)

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

649 (25.5) 649 (25.5)

8 8

0 (0.0) 0 (0.0)

5X 14 (0.5)

44 (1.8)

0 (0.0)

36 (1.4)

Illustration 8.12 E2h Terminal Dimensions (Side Views)

MG38C102

Exterior and Terminal Dimen...

Design Guide

8.3 E3h Exterior and Terminal Dimensions

8.3.1 E3h Exterior Dimensions

3X 13 (0.5)

1578

(62.1)

1537

(60.5)

1348

(53.1)

Illustration 8.13 Front View of E3h

(1.2)

506

(19.9)

10 (0.4)

13 (0.5)

15 (0.6)

10 (0.4)

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

2X 20 (0.8)

2X 101 (4.0)

2X 19 (0.7)

8 8

Illustration 8.14 Side View of E3h

2X 21 (0.8)

482 (19.0)

2X 18 (0.7)

MG38C102

Exterior and Terminal Dimen...

Design Guide

48 (1.9)

206

(8.1)

412

(16.2)

18 (0.7)

168 (6.6)

154 (6.1)

744 (29.3)

39 (1.5)

22 (0.9)

1 Heat sink access panel (optional)

Illustration 8.15 Back View of E3h

215 (8.5)

430 (16.9)

4X 457 (18.0)

464 (18.3)

168 (6.6)

136 (5.4)

1335 (52.5)

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

262

(10.3)

8 8

19 (0.7) 2X 219 (8.6)

2X 220

(8.6)

160

(6.3)

RFI shield termination (standard with RFI option)

Cable/EMC clamp

Gland plate

Illustration 8.16 RFI Shield Termination and Gland Plate Dimensions for E3h

294

(11.6)

163

(6.4)

MG38C102

Exterior and Terminal Dimen...

8.3.2 E3h Terminal Dimensions

Design Guide

6X 148 (5.8)

90 (3.5)

50 (2.0)

0 (0.0)

Mains terminals

Brake or regen terminals

Illustration 8.17 E3h Terminal Dimensions (Front View)

Motor terminals

Ground terminals, M8 and M10 nuts

256 (10.1)

33 (1.3)

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

184

(7.2)

184

(7.2)

0 (0.0)

8 8

5X 14 (0.5)

44 (1.8)

0 (0.0)

36 (1.4)

Illustration 8.18 E3h Mains, Motor, and Ground Terminal Dimensions (Side Views)

0 (0.0)

MG38C102

Exterior and Terminal Dimen...

Design Guide

2X 125 (4.9)

0 (0.0)

20 (0.8)

0 (0.0)

35(1.4)

Illustration 8.19 E3h Load Share/Regen Terminal Dimensions

8X 14 (0.5)

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

8.4 E4h Exterior and Terminal Dimensions

8.4.1 E4h Exterior Dimensions

3X 13 (0.5)

8 8

1578

(62.1)

1537

(60.5)

1348

(53.1)

(1.2)

Illustration 8.20 Front View of E4h

604

(23.8)

10 (0.4)

13 (0.5)

15 (0.6)

10 (0.4)

MG38C102

Exterior and Terminal Dimen...

Design Guide

2X 20 (0.8)

2X 101 (4.0)

2X 19 (0.7)

Illustration 8.21 Side View of E4h

2X 21 (0.8)

482 (19.0)

2X 18 (0.7)

8 8

Exterior and Terminal Dimen...

48 (1.9)

VLT® AutomationDrive FC 302

254

(10.0)

508

(20.1)

18 (0.7)

168 (6.6)

154 (6.1)

1335 (52.5)

8 8

744 (29.3)

39 (1.5)

4X 74 (2.9)

22 (0.9)

1 Heat sink access panel (optional)

Illustration 8.22 Back View of E4h

263 (10.4)

4X 457 (18.0)

526 (20.7)

560 (22.0)

168 (6.6)

136 (5.4)

MG38C102

Exterior and Terminal Dimen...

Design Guide

262

(10.3)

19 (0.7) 2X 268 (10.6)

2X 220

(8.6)

160

(6.3)

RFI shield termination (standard with RFI option)

Cable/EMC clamp

Gland plate

Illustration 8.23 RFI Shield Termination and Gland Plate Dimensions for E4h

294

(11.6)

163

(6.4)

8 8

Exterior and Terminal Dimen...

8.4.2 E4h Terminal Dimensions

VLT® AutomationDrive FC 302

8 8

6X 148 (5.8)

90 (3.5)

50 (2.0)

0 (0.0)

Mains terminals

Brake or regen terminals

Illustration 8.24 E4h Terminal Dimensions (Front View)

Motor terminals

Ground terminals, M8 and M10 nuts

256 (10.1)

33 (1.3)

MG38C102

Exterior and Terminal Dimen...

Design Guide

184

(7.2)

184

(7.2)

0 (0.0)

5X 14 (0.5)

44 (1.8)

0 (0.0)

36 (1.4)

Illustration 8.25 E4h Mains, Motor, and Ground Terminal Dimensions (Side Views)

0 (0.0)

8 8

Exterior and Terminal Dimen...

VLT® AutomationDrive FC 302

2X 125 (4.9)

0 (0.0)

8 8

20 (0.8)

0 (0.0)

35(1.4)

Illustration 8.26 E4h Load Share/Regen Terminal Dimensions

8X 14 (0.5)

MG38C102

Mechanical Installation Con...

Design Guide

9 Mechanical Installation Considerations

9.1 Storage

Store the drive in a dry location. Keep the equipment sealed in its packaging until installation. Refer to

chapter 7.5 Ambient Conditions

for recommended ambient temperature.

Periodic forming (capacitor charging) is not necessary during storage unless storage exceeds 12 months.

9.2 Lifting the Unit

Always lift the drive using the dedicated lifting eyes. To avoid bending the lifting holes, use a bar.

WARNING

RISK OF INJURY OR DEATH

Follow local safety regulations for lifting heavy weights.

Failure to follow recommendations and local safety regulations can result in death or serious injury.

• Ensure that the lifting equipment is in proper working condition.

•

See

chapter 4 Product Overview

for the weight of the different enclosure sizes.

•

Maximum diameter for bar: 20 mm (0.8 in).

•

The angle from the top of the drive to the lifting cable: 60 ° or greater.

Illustration 9.1 Recommended Lifting Method

9.3 Operating Environment

In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/Type rating of the equipment matches the installation environment. For specifications regarding ambient conditions, see

chapter 7.5 Ambient Conditions .

NOTICE

CONDENSATION

Moisture can condense on the electronic components and cause short circuits. Avoid installation in areas subject to frost. Install an optional space heater when the drive is colder than the ambient air. Operating in standby mode reduces the risk of condensation as long as the power dissipation keeps the circuitry free of moisture.

NOTICE

EXTREME AMBIENT CONDITIONS

Hot or cold temperatures compromise unit performance and longevity.

•

Do not operate in environments where the ambient temperature exceeds 55 ° C (131 ° F).

•

The drive can operate at temperatures down to

-10 ° C (14 ° F). However, proper operation at rated load is only guaranteed at 0 ° C (32 ° F) or higher.

•

If temperature exceeds ambient temperature limits, extra air conditioning of the cabinet or installation site is required.

9.3.1 Gases

Aggressive gases, such as hydrogen sulphide, chlorine, or ammonia can damage the electrical and mechanical components. The unit uses conformal-coated circuit boards to reduce the effects of aggressive gases. For conformalcoating class specifications and ratings, see

chapter 7.5 Ambient Conditions .

9.3.2 Dust

When installing the drive in dusty environments, pay attention to the following:

Periodic maintenance

When dust accumulates on electronic components, it acts as a layer of insulation. This layer reduces the cooling capacity of the components, and the components become

9 9

Mechanical Installation Con...

VLT® AutomationDrive FC 302

9 9 warmer. The hotter environment decreases the life of the electronic components.

Keep the heat sink and fans free from dust build-up. For more service and maintenance information, refer to the operating guide.

Cooling fans

Fans provide airflow to cool the drive. When fans are exposed to dusty environments, the dust can damage the fan bearings and cause premature fan failure. Also, dust can accumulate on fan blades causing an imbalance which prevents the fans from properly cooling the unit.

9.3.3 Potentially Explosive Atmospheres

WARNING

EXPLOSIVE ATMOSPHERE

Do not install the drive in a potentially explosive atmosphere. Install the unit in a cabinet outside of this area. Failure to follow this guideline increases risk of death or serious injury.

Systems operated in potentially explosive atmospheres must fulfill special conditions. EU Directive 94/9/EC

(ATEX 95) classifies the operation of electronic devices in potentially explosive atmospheres.

•

Class d specifies that if a spark occurs, it is contained in a protected area.

•

Class e prohibits any occurrence of a spark.

Motors with class d protection

Does not require approval. Special wiring and containment are required.

Motors with class e protection

When combined with an ATEX approved PTC monitoring device like the VLT ® PTC Thermistor Card MCB 112, installation does not need an individual approval from an approbated organization.

Motors with class d/e protection

The motor itself has an e ignition protection class, while the motor cabling and connection environment is in compliance with the d classification. To attenuate the high peak voltage, use a sine-wave filter at the drive output.

When using a drive in a potentially explosive atmosphere, use the following:

•

Motors with ignition protection class d or e.

•

PTC temperature sensor to monitor the motor temperature.

•

Short motor cables.

•

Sine-wave output filters when shielded motor cables are not used.

NOTICE

MOTOR THERMISTOR SENSOR MONITORING

VLT ® AutomationDrive units with the VLT ® PTC

Thermistor Card MCB 112 option are PTB-certified for potentially explosive atmospheres.

9.4 Mounting Configurations

Table 9.1

lists the available mounting configurations for each enclosure. For specific wall mount or pedestal mount installation instructions, see the operating guide . See also

chapter 8 Exterior and Terminal Dimensions

NOTICE

Improper mounting can result in overheating and reduced performance.

Mounting

Pedestal

Wall

E1h

–

E2h

–

E3h

–

E4h

–

Table 9.1 Mounting Configurations for Enclosures E1h–E4h

Mounting considerations:

•

Locate the unit as near to the motor as possible.

See

chapter 7.6 Cable Specifications

for the maximum motor cable length.

•

Ensure unit stability by mounting the unit to a solid surface.

•

Enclosures E3h and E4h can be mounted:

Vertically on the backplate of the panel

(typical installation).

Vertically upside down on the backplate of the panel.

Horizontally on its back, mounted on the backplate of the panel.

Horizontally on its side, mounted on floor of the panel.

•

Ensure that the strength of the mounting location supports the unit weight.

•

Ensure that there is enough space around the unit for proper cooling. Refer to

chapter 5.7 Backchannel Cooling Overview .

•

Ensure enough access to open the door.

•

Ensure cable entry from the bottom.

1) For non-typical installation, contact the factory .

MG38C102

Mechanical Installation Con...

Design Guide

9.5 Cooling

NOTICE

Improper mounting can result in overheating and reduced performance. For proper mounting, refer to chapter 9.4.1 Mounting Configurations .

•

Ensure that top and bottom clearance for air cooling is provided. Clearance requirement:

225 mm (9 in).

•

Provide sufficient airflow flow rate. See

Table 9.2

•

Consider derating for temperatures starting between 45 ° C (113 ° F) and 50 ° C (122 ° F) and elevation 1000 m (3300 ft) above sea level. See

chapter 9.6 Derating

for detailed information on derating.

The drive utilizes a back-channel cooling concept that removes heat sink cooling air. The heat sink cooling air carries approximately 90% of the heat out of the back channel of the drive. Redirect the back-channel air from the panel or room by using:

•

Duct cooling

Back-channel cooling kits are available to direct the heat sink cooling air out of the panel when

IP20/Chassis drives are installed in Rittal enclosures. Use of these kits reduce the heat in the panel and smaller door fans can be specified.

•

Back-wall cooling

Installing top and base covers to the unit allows the back-channel cooling air to be ventilated out of the room.

NOTICE

For E3h and E4h enclosures (IP20/Chassis), at least 1 door fan is required on the enclosure to remove the heat not contained in the back-channel of the drive. It also removes any additional losses generated by other components inside the drive. To select the appropriate fan size, calculate the total required airflow.

Secure the necessary airflow over the heat sink.

E1h

E2h

E3h

E4h

Frame Door fan/top fan

[m 3 /hr (cfm)]

510 (300)

552 (325)

595 (350)

629 (370)

Table 9.2 Airflow Rate

Heat sink fan

[m 3 /hr (cfm)]

994 (585)

1053–1206 (620–710)

994 (585)

1053–1206 (620–710)

9.6 Derating

Derating is used to reduce output current in certain situations, which prevents the drive from generating excessive heat within the enclosure. Consider derating when any of the following conditions are present:

•

Low-speed operation.

•

Low air pressure (operating at high altitudes).

•

High ambient temperature.

•

High switching frequency.

•

Long motor cables.

•

Cables with a large cross-section.

If these conditions are present, Danfoss recommends stepping up 1 power size.

9.6.1 Derating for Low-Speed Operation

When a motor is connected to a drive, it is necessary to check that the cooling of the motor is adequate. The level of cooling required depends on the load on the motor, the operating speed, and the length of time.

Constant torque applications

A problem can occur at low RPM values in constant torque applications. In a constant torque application, a motor can overheat at low speeds because less cooling air is being provided by the fan within the motor.

If the motor is run continuously at an RPM value lower than half of the rated value, the motor must be supplied with extra air cooling. If extra air cooling cannot be provided, a motor designed for low RPM/constant torque applications can be used instead.

Variable (quadratic) torque applications

Extra cooling or derating of the motor is not required in variable torque applications where the torque is proportional to the square of the speed, and the power is proportional to the cube of the speed. Centrifugal pumps and fans are common variable torque applications.

9 9

Mechanical Installation Con...

VLT® AutomationDrive FC 302

9.6.2 Derating for Altitude

The cooling capability of air is decreased at lower air pressure.

No derating is necessary at or below 1000 m (3281 ft). Above 1000 m (3281 ft), the ambient temperature (T

AMB

) or maximum output current (I

MAX

) should be derated. Refer to

Illustration 9.2

Max.I

out

(%) at T

AMB, MAX

100%

96%

92%

AMB, MAX at 100% I out

HO NO

0 K -5 K

-3 K

-6 K

-8 K

-11 K

1 km 2 km 3 km Altitude (km)

Illustration 9.2 Derating of Output Current Based on Altitude at T

AMB

MAX

9 9

Illustration 9.2

shows that at 41.7 ° C (107 ° F), 100% of the rated output current is available. At 45 ° C (113 ° F) (T

AMB

, MAX-3

K), 91% of the rated output current is available.

9.6.3 Derating for Ambient Temperature and Switching Frequency

NOTICE

FACTORY DERATING

Danfoss drives are already derated for operational temperature (55 ° C (131 ° F) T

AMB,MAX

and 50 ° C (122 ° F) T

AMB,AVG

Use the graphs in

Table 9.3

Table 9.4

to determine if the output current must be derated based on switching frequency and ambient temperature. When referring to the graphs, I out

indicates the percentage of rated output current, and fsw indicates the switching frequency.

MG38C102

Mechanical Installation Con...

Design Guide

Enclosure Switching pattern

60 AVM E1h–E4h

N315 to N500

380–500 V

110

100

SFAVM

110

100

High overload HO, 150%

2 3 4 fsw [kHz]

2 fsw [kHz]

5 6

50 ˚C (122 ˚F)

55 ˚C (131 ˚F)

45 ˚C (113 ˚F)

50 ˚C (122 ˚F)

55 ˚C (131 ˚F)

110

100

Normal overload NO, 110%

110

100

0 1 2 3 fsw [kHz]

4 5 6

45 ˚C (113 ˚F)

50 ˚C (122 ˚F)

50 ˚C (131 ˚F)

1 2 fsw [kHz]

3 4

40 ˚C (104 ˚F)

45 ˚C (113 ˚F)

50 ˚C (122 ˚F)

55 ˚C (131 ˚F)

Table 9.3 Derating Tables for Drives Rated 380–500 V

Enclosure Switching pattern

60 AVM E1h–E4h

N355 to N710

525–690 V

SFAVM

High overload HO, 150%

110

100

50 ˚C (122 ˚F)

55 ˚C (131 ˚F)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

fsw [kHz]

3.5

4.0

4.5

5.0

5.5

110

100

0.0

0.5

1.0

1.5

2.0

fsw [kHz]

2.5

3.0

45 ˚C (113 ˚F)

50 ˚C (122 ˚F)

55 ˚C (131 ˚F)

3.5

4.0

Normal overload NO, 110%

110

100

45 ˚C (113 ˚F)

50 ˚C (122 ˚F)

55 ˚C (131 ˚F)

0.0

0.5

1.0

1.5

2.0

2.5

3.0 3.5

fsw [kHz]

4.0

4.5

5.0

5.5

110

100

0.0

0.5

1.0

1.5

2.0

fsw [kHz]

2.5

3.0

40 ˚C (104 ˚F)

45 ˚C (113 ˚F)

50 ˚C (122 ˚F)

55 ˚C (131 ˚F)

3.5

4.0

Table 9.4 Derating Tables for Drives Rated 525–690 V

9 9

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 Electrical Installation Considerations

10 10

10.1 Safety Instructions

See

chapter 2 Safety

for general safety instructions.

WARNING

INDUCED VOLTAGE

Induced voltage from output motor cables from different drives that are run together can charge equipment capacitors even with the equipment turned off and locked out. Failure to run output motor cables separately or use shielded cables could result in death or serious injury.

•

Run output motor cables separately or use shielded cables.

•

Simultaneously lock out all the drives.

WARNING

SHOCK HAZARD

The drive can cause a DC current in the ground conductor and thus result in death or serious injury.

•

When a residual current-operated protective device (RCD) is used for protection against electrical shock, only an RCD of Type B is allowed on the supply side.

Failure to follow the recommendation means that the

RCD cannot provide the intended protection.

Overcurrent protection

•

Extra protective equipment such as short-circuit protection or motor thermal protection between drive and motor is required for applications with multiple motors.

•

Input fusing is required to provide short circuit and overcurrent protection. If fuses are not factory-supplied, the installer must provide them.

See maximum fuse ratings in

chapter 10.5 Fuses and Circuit Breakers

Wire type and ratings

•

All wiring must comply with local and national regulations regarding cross-section and ambient temperature requirements.

•

Power connection wire recommendation:

Minimum 75 ° C (167 ° F) rated copper wire.

See

chapter 7.6 Cable Specifications

for recommended wire sizes and types.

CAUTION

PROPERTY DAMAGE!

Protection against motor overload is not included in the default setting. To add this function, set parameter 1-90 Motor Thermal Protection to [ETR trip] or

[ETR warning] . For the North American market, the ETR function provides class 20 motor overload protection in accordance with NEC. Failure to set parameter 1-90 Motor

Thermal Protection to [ETR trip] or [ETR warning] means that motor overload protection is not provided and, if the motor overheats, property damage can occur.

MG38C102

Electrical Installation Con...

10.2 Wiring Schematic

Design Guide

230 V AC

50/60 Hz

TB5

R1 Space heater (optional) power input

Load share

(optional)

+10 V DC

-10 V DC - +10 V DC

0/4-20 mA

-10 V DC - +10 V DC

0/4-20 mA

91 (L1)

92 (L2)

93 (L3)

95 PE

88 (-)

89 (+)

50 (+10 V OUT)

A53 U-I (S201)

53 (A IN)

A54 U-I (S202)

54 (A IN)

ON=0-20 mA

OFF=0-10 V

Switch mode power supply

10 V DC

+ +

24 V DC

200 mA

55 (COM A IN)

12 (+24 V OUT)

13 (+24 V OUT)

18 (D IN)

19 (D IN)

20 (COM D IN)

27 (D IN/OUT)

24V

P 5-00

24 V (NPN)

0 V (PNP)

24 V (NPN)

0 V (PNP)

24 V (NPN)

0 V (PNP)

(U) 96

(V) 97

(W) 98

(PE) 99

Regen +

(R+) 82

(R-) 81

Regen - 83

Relay1

Relay2

(COM A OUT) 39

(A OUT) 42

S801/Bus Term.

OFF-ON

ON=Terminated

OFF=Open

5V 2

29 (D IN/OUT)

24V

24 V (NPN)

0 V (PNP)

32 (D IN)

33 (D IN)

24 V (NPN)

0 V (PNP)

24 V (NPN)

0 V (PNP)

RS485 interface

S801

(P RS485) 68

(N RS485) 69

(COM RS485) 61

37 (D IN) 1)

Brake resistor

(optional)

Regen (optional)

240 V AC, 2A

400 V AC, 2A

240 V AC, 2A

400 V AC, 2A

Analog output

0/4-20 mA

Motor

Brake temperature

(NC)

RS485

(PNP) = Source

(NPN) = Sink

Illustration 10.1 Basic Wiring Schematic

A=Analog, D=Digital

1) Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off

Operating Guide.

10 10

Electrical Installation Con...

VLT® AutomationDrive FC 302

10.3 Connections

10.3.1 Power Connections

NOTICE

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. UL applications require 75 ° C (167 ° F) copper conductors. Non-UL applications can use 75 ° C

(167 ° F) and 90 ° C (194 ° F) copper conductors.

The power cable connections are located as shown in

Illustration 10.2

. See

chapter 7 Specifications

for correct dimensioning of motor cable cross-section and length.

For protection of the drive, use the recommended fuses unless the unit has built-in fuses. Recommended fuses are listed in

chapter 10.5 Fuses and Circuit Breakers

. Ensure that proper fusing complies with local regulations.

The connection of mains is fitted to the mains switch if included.

10 10 3 Phase power input

91 (L1)

92 (L2)

93 (L3)

95 PE

Illustration 10.2 Power Cable Connections

NOTICE

The motor cable must be shielded/armored. If an unshielded/unarmored cable is used, some EMC requirements are not complied with. Use a shielded/ armored motor cable to comply with EMC emission specifications. For more information, see

chapter 10.15 EMC-compliant Installation

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 contactor, continue the shield at the lowest possible HF impedance.

Connect the motor cable shield to both the decoupling plate of the drive and the metal housing of the motor.

Make the shield connections with the largest possible surface area (cable clamp) by using the installation devices within the drive.

Cable length and cross-section

The drive has been EMC tested with a given length of cable. Keep the motor cable as short as possible to reduce the noise level and leakage currents.

Switching frequency

When drives are used together with sine-wave filters to reduce the acoustic noise from a motor, the switching frequency must be set according to the instructions in parameter 14-01 Switching Frequency .

Terminal 96 97 98 99

– U V W PE 1) Motor voltage 0–100% of mains voltage. 3 wires out of motor.

– U1 V1 W1

W2 U2 V2

PE 1)

Delta-connected.

6 wires out of motor.

– U1 V1 W1 PE 1) Star-connected U2, V2, W2

U2, V2, and W2 to be interconnected separately.

Table 10.1 Motor Cable Connection

1) Protected ground connection

NOTICE

In motors without phase insulation, paper, or other insulation reinforcement suitable for operation with voltage supply, use a sine-wave filter on the output of the drive.

Motor

96 97 98

Illustration 10.3 Motor Cable Connection

10.3.2 DC Bus Connection

The DC bus terminal is used for DC back-up, with the DC link being supplied from an external source.

Terminal

88, 89

Function

DC Bus

Table 10.2 DC Bus Terminals

MG38C102

Electrical Installation Con...

Design Guide

10.3.3 Load Sharing

Load sharing links together the DC intermediate circuits of several drives. For an overview, see

chapter 5.5 Load Share

Overview .

The load sharing feature requires extra equipment and safety considerations. Consult Danfoss for ordering and installation recommendations.

Terminal

88, 89

Function

Load sharing

Table 10.3 Load Sharing Terminals

The connection cable must be shielded and the maximum length from the drive to the DC bar is limited to 25 m

(82 ft).

10.3.4 Brake Cable

The connection cable to the brake resistor must be shielded and the maximum length from the drive to the

DC bar is limited to 25 m (82 ft).

•

Use cable clamps to connect the shield to the conductive backplate on the drive and to the metal cabinet of the brake resistor.

•

Size the brake cable cross-section to match the brake torque.

Terminal

81, 82

Function

Brake resistor terminals

Table 10.4 Brake Resistor Terminals

See the VLT ® Brake Resistor MCE 101 Design Guide for more details.

NOTICE

If a short circuit in the brake IGBT occurs, prevent power dissipation in the brake resistor by using a mains switch or contactor to disconnect the mains from the drive.

Only the drive should control the contactor.

10.4 Control Wiring and Terminals

10.4.1 Control Cable Routing

Tie down and route all control wires as shown in

Illustration 10.4

. Remember to connect the shields in a

proper way to ensure optimum electrical immunity.

•

Isolate control wiring from high-power cables.

•

When the drive is connected to a thermistor, ensure that the thermistor control wiring is shielded and reinforced/double insulated. A 24 V

DC supply voltage is recommended.

Fieldbus connection

Connections are made to the relevant options on the control card. See the relevant fieldbus instruction. The cable must be tied down and routed along with other control wires inside the unit. See

Illustration 10.4

10 10

MG38C102

Illustration 10.4 Control Card Wiring Path

10 10

Electrical Installation Con...

VLT® AutomationDrive FC 302

10.4.2 Control Terminals

Illustration 10.5

shows the removable drive connectors.

Terminal functions and default settings are summarized in

Table 10.5

–

Table 10.7

Illustration 10.5 Control Terminal Locations

61 68 69 39 42 50 53 54 55

Terminal

68 (+)

69 (-)

01, 02, 03

Serial communication terminals

Parameter Default setting

Description

– – Integrated RC-filter for cable shield. ONLY for connecting the shield in case of EMC problems.

Parameter group 8-3* FC

Port Settings

Parameter group 8-3* FC

Port Settings

–

RS485 interface. A switch (BUS TER.) is provided on the control card for bus termination resistance. See the

VLT ® AutomationDrive

FC 300 90–1200 kW

Design Guide .

Parameter 5-40

Function Relay

[0]

04, 05, 06 Parameter 5-40

Function Relay

[1]

Relays

[0] No operation

Form C relay output.

For AC or DC voltage and resistive or inductive loads.

Table 10.5 Serial Communication Terminal Descriptions

12 13 18 19 27 29 32 33 20 37

Serial communication terminals

Digital input/output terminals

Analog input/output terminals

Illustration 10.6 Terminal Numbers Located on the Connectors

MG38C102

Electrical Installation Con...

Design Guide

Terminal

12, 13

Digital input/output terminals

Parameter Default setting

Description

– +24 V DC 24 V DC supply voltage for digital inputs and external transducers.

Maximum output current 200 mA for all

24 V loads.

[8] Start Digital inputs.

Parameter 5-10

Terminal 18

Digital Input

Parameter 5-11

Terminal 19

Digital Input

[10]

Reversing

[0] No operation

Parameter 5-14

Terminal 32

Digital Input

Parameter 5-15

Terminal 33

Digital Input

Parameter 5-12

Terminal 27

Digital Input

Parameter 5-13

Terminal 29

Digital Input

–

[0] No operation

[2] Coast inverse

[14] JOG

–

For digital input or output. Default setting is input.

– STO

Common for digital inputs and 0 V potential for 24 V supply.

When not using the optional STO feature, a jumper wire is required between terminal 12 (or 13) and terminal 37. This set-up allows the drive to operate with factory default programming values.

Table 10.6 Digital Input/Output Terminal Descriptions

Terminal

Analog input/output terminals

Parameter Default setting

Description

– – Common for analog output.

Parameter 6-50

Terminal 42

Output

–

[0] No operation

Programmable analog output. 0–20 mA or

4–20 mA at a maximum of 500 Ω .

+10 V DC 10 V DC analog supply voltage for potentiometer or thermistor. 15 mA maximum.

Parameter group 6-1*

Analog Input 1

Parameter group 6-2*

Analog Input 2

–

Reference Analog input. For voltage or current.

Feedback

Switches A53 and

A54 select mA or V.

– Common for analog input.

Table 10.7 Analog Input/Output Terminal Descriptions

Relay terminals:

RELAY 1 RELAY 2

01 02 03 04 05 06

Illustration 10.7 Relay 1 and Relay 2 Terminals

10 10

•

Relay 1 and relay 2. The location of the outputs depends on the drive configuration. See the operating guide .

•

Terminals on built-in optional equipment. See the instructions provided with the equipment option.

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 10

10.5 Fuses and Circuit Breakers

Fuses ensure that possible damage to the drive is limited to damages inside the unit. To ensure compliance with EN 50178, use identical Bussmann fuses as replacements. Refer to

Table 10.8

NOTICE

Use of fuses on the supply side is mandatory for IEC 60364 (CE) and NEC 2009 (UL) compliant installations.

Input voltage (V)

380–500

525–690

Table 10.8 Fuse Options

Bussmann ordering number

170M7309

170M7342

The fuses listed in

Table 10.8

are suitable for use on a circuit capable of delivering 100000 A rms

(symmetrical), depending on the drive voltage rating. With the proper fusing, the drive short circuit current rating (SCCR) is 100000 A rms

. E1h and E2h drives are supplied with internal drive fusing to meet the 100 kA SCCR and to comply with UL 61800-5-1 enclosed drive requirements. E3h and E4h drives must be fitted with Type aR fuses to meet the 100 kA SCCR.

NOTICE

DISCONNECT SWITCH

All units ordered and supplied with a factory-installed disconnect switch require Class L branch circuit fusing to meet the 100 kA SCCR for the drive. If a circuit breaker is used, the SCCR rating is 42 kA. The input voltage and power rating of the drive determines the specific Class L fuse. The input voltage and power rating is found on the product nameplate. For more information regarding the nameplate, see the operating guide .

Input voltage (V)

380–500

525–690

Power rating (kW)

315–400

450–500

355–560

630–710

Short circuit rating (A)

42000

100000

42000

100000

40000

100000

42000

100000

Required protection

Circuit breaker

Class L fuse, 800 A

Circuit breaker

Class L fuse, 1200 A

Circuit breaker

Class L fuse, 800 A

Circuit breaker

Class L fuse, 1200 A

10.6 Motor

10.6.1 Motor Cable

All types of 3-phase asynchronous standard motors can be used with a drive unit. The motor must be connected to the following terminals:

•

U/T1/96

•

V/T2/97

•

W/T3/98

•

Ground to terminal 99

Factory setting is for clockwise rotation with the drive output connected as follows:

MG38C102

Electrical Installation Con...

Terminal

Function

Mains U/T1

V/T2

W/T3

Ground

Table 10.9 Motor Cable Terminals

Motor

96 97 98

Motor

Design Guide

96 97 98

Illustration 10.8 Changing Motor Rotation

•

Terminal U/T1/96 connected to U-phase

•

Terminal V/T2/97 connected to V-phase

•

Terminal W/T3/98 connected to W-phase

The direction of rotation can be changed by switching 2 phases in the motor cable, or by changing the setting of parameter 4-10 Motor Speed Direction .

Motor rotation check can be performed using parameter 1-28 Motor Rotation Check and following the configuration shown in

Illustration 10.8

10.6.2 Motor Thermal Protection

The electronic thermal relay in the drive has received ULapproval for single motor overload protection, when parameter 1-90 Motor Thermal Protection is set for ETR Trip and parameter 1-24 Motor Current is set to the rated motor current (see the motor nameplate).

For motor thermal protection, it is also possible to use the

VLT ® PTC Thermistor Card MCB 112 option. This card provides ATEX certification to protect motors in explosion hazardous areas Zone 1/21 and Zone 2/22. When parameter 1-90 Motor Thermal Protection , set to [20] ATEX

ETR , is combined with the use of MCB 112, it is possible to control an Ex-e motor in explosion hazardous areas.

Consult the programming guide for details on how to set up the drive for safe operation of Ex-e motors.

10.6.3 Parallel Connection of Motors

The drive can control several parallel-connected motors.

For different configurations of parallel-connected motors, see

Illustration 10.9

When using parallel motor connection, observe the following points:

•

Run applications with parallel motors in U/F mode (volts per hertz).

•

VVC + mode can be used in some applications.

•

Total current consumption of motors must not exceed the rated output current I

INV

for the drive.

•

Problems can occur at start and at low RPM if motor sizes are widely different because the relatively high ohmic resistance in the stator of a small motor demands a higher voltage at start and at low RPM.

•

The electronic thermal relay (ETR) of the drive cannot be used as motor overload protection.

Provide further motor overload protection by including thermistors in each motor winding or individual thermal relays.

•

When motors are connected in parallel, parameter 1-02 Flux Motor Feedback Source cannot be used, and parameter 1-01 Motor Control

Principle must be set to [0] U/f .

10 10

Electrical Installation Con...

VLT® AutomationDrive FC 302 a d

10 10 b e c f

A Installations with cables connected in a common joint as shown in A and B are only recommended for short cable lengths.

B Be aware of the maximum motor cable length specified in

chapter 7.6 Cable Specifications

C The total motor cable length specified in

chapter 7.6 Cable Specifications

is valid as long as the parallel cables are kept short less than 10 m (32 ft) each.

D Consider voltage drop across the motor cables.

E Consider voltage drop across the motor cables.

The total motor cable length specified in chapter 7.6 Cable Specifications

is valid as long as the parallel cables are kept less than 10 m

(32 ft) each.

Illustration 10.9 Different Parallel Connections of Motors

MG38C102

Electrical Installation Con...

Design Guide

10.6.4 Motor Insulation

For motor cable lengths that are less than or equal to the maximum cable length listed in

chapter 7.6 Cable Specifications

, use the motor insulation ratings shown in

Table 10.10

. If a motor has lower insulation rating, Danfoss recommends using a dU/dt or sine-wave filter.

Nominal mains voltage

≤ 420 V

420 V<U

500 V<U

600 V<U

≤ 500 V

≤ 600 V

≤ 690 V

Motor insulation

Standard U

=1300 V

Reinforced U

=1600 V

Reinforced U

=1800 V

Reinforced U

=2000 V

Table 10.10 Motor Insulation Ratings

10.6.5 Motor Bearing Currents

To eliminate circulating bearing currents in all motors installed with VLT ® AutomationDrive, install NDE (non-drive end) insulated bearings. To minimize DE (drive end) bearing and shaft currents, ensure proper grounding of the drive, motor, driven machine, and motor to the driven machine.

Standard mitigation strategies:

•

Use an insulated bearing.

•

Follow proper installation procedures.

Ensure that the motor and load motor are aligned.

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 drive. Use a shielded cable that has a

360 ° connection in the motor and the drive.

Ensure that the impedance from the drive to building ground is lower than the grounding impedance of the machine. This procedure can be difficult for pumps.

Make a direct ground connection between the motor and load motor.

•

Lower the IGBT switching frequency.

•

Modify the inverter waveform, 60 ° AVM vs.

SFAVM.

•

Install a shaft grounding system or use an isolating coupling.

•

Apply conductive lubrication.

•

Use minimum speed settings if possible.

•

Try to ensure that the mains voltage is balanced to ground. This procedure can be difficult for IT,

TT, TN-CS, or grounded leg systems.

•

Use a dU/dt or sine-wave filter.

10.7 Braking

10.7.1 Brake Resistor Selection

To handle the higher demands of resistor braking, a brake resistor is necessary. The brake resistor absorbs the energy instead of the drive. For more information, see the VLT ®

Brake Resistor MCE 101 Design Guide .

If the amount of kinetic energy transferred to the resistor in each braking period is not known, the average power can be calculated based on the cycle time and braking time (intermittent duty cycle). The resistor intermittent duty cycle indicates the duty cycle at which the resistor is active.

Illustration 10.10

shows a typical braking cycle.

Motor suppliers often use S5 when stating the allowed load, which is an expression of intermittent duty cycle. The intermittent duty cycle for the resistor is calculated as follows:

Duty cycle=t b

T=cycle time in s t b

is the braking time in s (of the cycle time)

10 10

Load

Speed ta tc

T tb to ta tc tb to ta

Time

Illustration 10.10 Typical Braking Cycle

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 10

Nominal braking

[45 ° C

(113 ° F)]

Overload braking

[45 ° C

(113 ° F)]

Nominal braking

[25 ° C

(77 ° F)]

Overload braking

[25 ° C

(77 ° F)]

Power size (high overload)

N315 N355 N400 N450 N500

600 600 600 600 600 Cycle time

(s)

Current (%) 100

Braking time (s)

240 240

240

Cycle time

(s)

300

Current (%) 136

300

107

30 30 30 Braking time (s)

Cycle time

(s)

600

Current (%) 100

Braking time (s)

240 240

Cycle time

(s)

300 300

Current (%) 136 113

Braking time (s)

30 10

600

240

300

100

600

240

300

600

240

300

107

Table 10.11 Braking Capability, 380–500 V

Nominal braking

[45 ° C

(113 ° F)]

Overload braking

[45 ° C

(113 ° F)]

Nominal braking

[25 ° C

(77 ° F)]

Overload braking

[25 ° C

(77 ° F)]

Cycle time (s)

Current

(%)

Braking time (s)

Cycle time (s)

Current

(%)

Braking time (s)

Cycle time (s)

Current

(%)

Braking time (s)

Cycle time (s)

Current

(%)

Braking time (s)

Power size (high overload)

N355 N400 N500 N560 N630 N710

600 600 600 600 600 600

240

300

113

600

240

300

113

240

300

100

600

240

300

100

240

300

600

240

300

240

300

600

240

300

240

300

600

240

300

240

300

240

300

Table 10.12 Braking Capability, 525–690 V

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 brake power for 10% of the cycle time.

The remaining 90% of the cycle time is used to dissipate excess heat.

NOTICE

Make sure that the resistor is designed to handle the required braking time.

The maximum allowed load on the brake resistor is stated as a peak power at a given intermittent duty cycle. The brake resistance is calculated as shown:

R br

Ω =

U 2 dc

P peak where

P peak

=P motor xM br

[%]xη motor xη

VLT

[W]

As can be seen, the brake resistance depends on the DClink voltage (U dc

Size

380–500 V 1)

525–690 V

Brake active

810 V

1084 V

Warning before cut out

828 V

1109 V

Cut out

(trip)

855 V

1130 V

Table 10.13 FC 302 Brake Limits

1) Power size dependent

NOTICE

Check that the brake resistor can handle a voltage of

410 V, 820 V, 850 V, 975 V, or 1130 V. Danfossbrake resistors are rated for use on all Danfoss drives.

Danfoss recommends the brake resistance R rec

. This calculation guarantees that the drive is able to brake at the highest braking torque (M br(%)

) of 150%. The formula can be written as:

R rec

Ω =

P motor

x M

2 dc

x 100 br ( % )

xη

VLT

x η motor

η motor

is typically at 0.90

VLT

is typically at 0.98

For 200 V, 480 V, 500 V, and 600 V drives, R rec

at 160% braking torque is written as:

200V : R rec

= 107780 motor

500V : R rec P motor

600V : R rec P motor

690V : R rec P motor

MG38C102

Electrical Installation Con...

Design Guide

NOTICE

The resistor brake circuit resistance selected should not be higher than what is recommended by Danfoss. Enclosure sizes E1h–E4h contain 1 brake chopper.

NOTICE

If a short circuit occurs in the brake transistor, power dissipation in the brake resistor is prevented only by using a mains switch or contactor to disconnect the mains from the drive, or a contact in the brake circuit. Uninterrupted power dissipation in the brake resistor can cause overheating, damage, or a fire.

WARNING

FIRE HAZARD

Brake resistors get hot while/after braking, and must be placed in a secure environment to avoid fire risk.

10.7.2 Control with Brake Function

A relay/digital can be used to protect the brake resistor against overloading or overheating by generating a fault in the drive. If the brake IGBT is overloaded or overheated, the relay/digital signal from the brake to the drive turns off the brake

IGBT. This relay/digital signal does not protect against a short circuit in the brake IGBT. Danfoss recommends a means to disconnect the brake if a short circuit occurs in the brake IGBT.

In addition, the brake makes it possible to read out the momentary power and the average power for the latest 120 s. The brake can monitor the power energizing and make sure that it does not exceed the limit selected in parameter 2-12 Brake

Power Limit (kW) . Parameter 2-13 Brake Power Monitoring selects what function occurs when the power transmitted to the brake resistor exceeds the limit set in parameter 2-12 Brake Power Limit (kW) .

NOTICE

Monitoring the brake power is not a safety function; a thermal switch connected to an external contactor is required for that purpose. The brake resistor circuit is not ground leakage protected.

Overvoltage control (OVC) can be selected as an alternative brake function in parameter 2-17 Over-voltage Control . This function is active for all units and ensures that if the DC-link voltage increases, the output frequency also increases to limit the voltage from the DC link, which avoids a trip.

NOTICE

OVC cannot be activated when running a PM motor, while parameter 1-10 Motor Construction is set to [1] PM nonsalient SPM .

10.8 Residual Current Devices (RCD) and Insulation Resistance Monitor (IRM)

Use RCD relays, multiple protective grounding, or grounding as extra protection, provided they comply with local safety regulations.

If a ground fault appears, a DC current can develop in the faulty current. If RCD relays are used, local regulations must be observed. Relays must be suitable for protection of 3-phase equipment with a bridge rectifier and for a brief discharge on power-up. See

chapter 10.9 Leakage Current

for more details.

10 10

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 10

10.9 Leakage Current

Follow national and local codes regarding protective grounding of equipment where leakage current exceeds

3.5 mA.

Drive technology implies high-frequency switching at high power. This high-frequency switching generates a leakage current in the ground connection.

The ground leakage current is made up of several contributions and depends on various system configurations, including:

•

RFI filtering.

•

Motor cable length.

•

Motor cable screening.

•

Drive power.

Leakage current a

Leakage current

THDv=0%

THDv=5%

Illustration 10.12 Line Distortion Influences Leakage Current b

Motor cable length

Illustration 10.11 Motor cable length and power size influence on leakage current. Power size a > power size b.

The leakage current also depends on the line distortion.

If the leakage current exceeds 3.5 mA, compliance with

EN/IEC61800-5-1 (power drive system product standard) requires special care.

Reinforce grounding with the following protective earth connection requirements:

•

Ground wire (terminal 95) of at least 10 mm 2 (8

AWG) cross-section.

•

2 separate ground wires both complying with the dimensioning rules.

See EN/IEC61800-5-1 and EN 50178 for further information.

Using RCDs

Where residual current devices (RCDs), also known as ground leakage circuit breakers, are used, comply with the following:

•

Use RCDs of type B only as they can detect AC and DC currents.

•

Use RCDs with a delay to prevent faults due to transient ground currents.

•

Dimension RCDs according to the system configuration and environmental considerations.

The leakage current includes several frequencies originating from both the mains frequency and the switching frequency. Whether the switching frequency is detected depends on the type of RCD used.

MG38C102

Electrical Installation Con...

Design Guide

Leakage current

RCD with low f cut-

RCD with high f cut-

Mains

50 Hz 150 Hz

3rd harmonics f sw

Cable

Frequency

Illustration 10.13 Main Contributions to Leakage Current

The amount of leakage current detected by the RCD depends on the cut-off frequency of the RCD.

Leakage current [mA]

100 Hz

2 kHz

100 kHz

Illustration 10.14 Influence of the RCD Cut-off Frequency on

Leakage Current

Filter to [ON]. Refer also to the Application Note, VLT on IT

Mains, MN50P . It is important to use isolation monitors that are rated for use together with power electronics (IEC

61557-8).

Danfoss does not recommend using an output contactor for 525–690 V drives connected to an IT mains network.

10.11 Efficiency

Efficiency of the drive (η

VLT

)

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

M,N

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

The efficiency of the drive does not change even if other

U/f characteristics are selected. However, the U/f characteristics influence the efficiency of the motor.

The efficiency declines slightly when the switching frequency is set to a value of above 5 kHz. The efficiency is slightly reduced when the mains voltage is 480 V, or if the motor cable is longer than 30 m (98 ft.).

Drive efficiency calculation

Calculate the efficiency of the drive at different speeds and loads based on

Illustration 10.15

. The factor in this graph must be multiplied with the specific efficiency factor listed in the specification tables in

chapter 7.1 Electrical Data,

380–500 V

and

chapter 7.2 Electrical Data, 525–690 V .

1.01

1.0

0.99

0.98

0.97

0.96

0.95

0.94

0.93

0.92

0% 50% 100%

% Speed

150% 200%

100% load 75% load 50% load 25% load

Illustration 10.15 Typical Efficiency Curves

10 10

10.10 IT Mains

Mains Supply Isolated from Ground

If the drive is supplied from an isolated mains source (IT mains, floating delta, or grounded delta) or TT/TN-S mains with grounded leg, the RFI switch is recommended to be turned off via parameter 14-50 RFI Filter on the drive and parameter 14-50 RFI Filter on the filter. For more detail, see

IEC 364-3. In the off position, the filter capacitors between the chassis and the DC link are cut off to avoid damage to the DC link and to reduce the ground capacity currents, according to IEC 61800-3.

If optimum EMC performance is needed, or parallel motors are connected, or the motor cable length is above 25 m

(82 ft), Danfoss recommends setting parameter 14-50 RFI

Example: Assume a 160 kW, 380–480 V AC drive at 25% load at 50% speed.

Illustration 10.15

shows 0.97 - rated efficiency for a 160 kW drive is 0.98. The actual efficiency is then: 0.97x 0.98=0.95.

Efficiency of the motor (η

MOTOR)

The efficiency of a motor connected to the drive depends on magnetizing level. In general, the efficiency is as good as with mains 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 the drive controls it and when it runs directly on the mains.

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 10

In small motors, the influence from the U/f characteristic on efficiency is marginal. However, in motors from 11 kW

(14.75 hp) and up, the advantages are significant.

Typically the switching frequency does not affect the efficiency of small motors. Motors from 11 kW (14.75 hp) and up have their efficiency improved (1–2%) because the shape of the motor current sine-wave is almost perfect at high switching frequency.

Efficiency of the System ( η

SYSTEM

)

To calculate system efficiency, the efficiency of the drive

(η

VLT

) is multiplied by the efficiency of the motor ( η

MOTOR

SYSTEM

= η

VLT

x η

MOTOR

10.12 Acoustic Noise

The acoustic noise from the drive comes from 3 sources:

•

DC intermediate circuit coils.

•

Internal fans.

•

RFI filter choke.

Table 10.14

lists the typical acoustic noise values measured at a distance of 1 m (9 ft) from the unit.

E1h–E4h

Enclosure size

Table 10.14 Acoustic Noise dBA at full fan speed

Test results performed according to ISO 3744 for audible noise magnitude in a controlled environment. Noise tone has been quantified for engineering data record of hardware performance per ISO 1996-2 Annex D.

A new fan control algorithm for E1h-E4h enlosure sizes helps improve audible noise performance by allowing the operator to select different fan operation modes based on specific conditions. For more information, see parameter 30-50 Heat Sink Fan Mode .

10.13 dU/dt Conditions

NOTICE

To avoid the premature aging of motors that are not designed to be used with drives, such as those motors without phase insulation paper or other insulation reinforcement, Danfoss strongly recommends a dU/dt filter or a sine-wave filter fitted on the output of the drive. For further information about dU/dt and sine-wave filters, see the Output Filters Design Guide .

When a transistor in the inverter bridge switches, the voltage across the motor increases by a dU/dt ratio depending on:

•

The motor cable (type, cross-section, length shielded or unshielded).

•

Inductance.

The natural induction causes an overshoot U

PEAK

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 U

PEAK affect the service life of the motor. In particular, motors without phase coil insulation are affected if the peak voltage is too high.

Motor cable length affects the rise time and peak voltage.

For example, if the motor cable is short (a few meters), the rise time and peak voltage are lower. If the motor cable is long (100 m (328 ft)), the rise time and peak voltage are higher.

Peak voltage on the motor terminals is caused by the switching of the IGBTs. The drive complies with the demands of IEC 60034-25 regarding motors designed to be controlled by drives. The drive also complies with IEC

60034-17 regarding Norm motors controlled by drives.

High-power range

The power sizes in the following tables at the appropriate mains voltages comply with the requirements of IEC

60034-17 regarding normal motors controlled by drives,

IEC 60034-25 regarding motors designed to be controlled by drives, and NEMA MG 1-1998 Part 31.4.4.2 for inverter fed motors. The power sizes in the following tables do not comply with NEMA MG 1-1998 Part 30.2.2.8 for general purpose motors.

MG38C102

Electrical Installation Con...

Design Guide

380–500 V

Power size [kW (hp)]

315–400 (450–550)

450–500 (600–650)

Cable [m (ft)]

5 (16)

30 (98)

150 (492)

300 (984)

5 (16)

30 (98)

150 (492)

300 (984)

Mains voltage

[V]

460

Rise time [

0.23

0.72

0.46

1.84

0.42

0.57

0.63

2.21

µ s] Peak voltage [V]

1038

1061

1142

1244

1042

1200

1110

1175

Table 10.15 NEMA dU/dt Test Results for E1h–E4h with Unshielded Cables and No Output Filter, 380–500 V

Power size [kW (hp)]

315–400 (450–550)

450–500 (600–650)

Cable [m (ft)]

5 (16)

30 (98)

150 (492)

300 (984)

5 (16)

30 (98)

150 (492)

300 (984)

Mains voltage

[V]

460

Rise time [

0.33

1.27

0.84

2.25

0.53

1.22

0.90

2.29

µ s] Peak voltage [V]

1038

1061

1142

1244

1042

1200

1110

1175

Table 10.16 IEC dU/dt Test Results for E1h–E4h with Unshielded Cables and No Output Filter, 380–500 V

Power size [kW (hp)]

315–400 (450–550)

450–500 (600–650)

Cable [m (ft)]

5 (16)

30 (98)

150 (492)

5 (16)

30 (98)

150 (492)

Mains voltage

[V]

460

Rise time [

0.17

–

0.41

0.17

–

0.22

µ s] Peak voltage [V]

1017

–

1268

1042

–

1233

Table 10.17 NEMA dU/dt Test Results for E1h–E4h with Shielded Cables and No Output Filter, 380–500 V

Power size [kW (hp)]

315–400 (450–550)

450–500 (600–650)

Cable [m (ft)]

5 (16)

30 (98)

150 (492)

5 (16)

30 (98)

150 (492)

Mains voltage

[V]

460

Rise time [

0.26

–

0.70

0.27

–

0.52

µ s] Peak voltage [V]

1017

–

1268

1042

–

1233

Table 10.18 IEC dU/dt Test Results for E1h–E4h with Shielded Cables and No Output Filter, 380–500 V dU/dt [V/ µ s]

2372

644

1160

283

1295

820

844

239 dU/dt [V/ µ s]

2556

668

1094

443

1569

1436

993

411 dU/dt [V/ µ s]

3176

–

1311

3126

–

2356 dU/dt [V/ µ s]

3128

–

1448

3132

–

1897

10 10

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 10

525–690 V

Power size [kW (hp)]

355–560 (400–600)

630–710 (650–750)

Cable [m (ft)]

30 (98)

50 (164)

5 (16)

20 (65)

50 (164)

Mains voltage

[V]

690

Rise time [

0.37

0.86

0.25

0.33

0.82

µ s] Peak voltage [V]

1625

2030

1212

1525

2040

Table 10.19 IEC dU/dt Test Results for E1h–E4h with Unshielded Cables and No Output Filter, 525–690 V

Power size [kW (hp)]

355–560 (400–600)

630–710 (650–750)

Cable [m (ft)]

5 (16)

48 (157)

150 (492)

5 (16)

48 (157)

150 (492)

Mains voltage

[V]

690

Rise time [ µ s]

0.23

0.38

0.94

0.26

0.46

0.94

Peak voltage [V]

1450

1637

1762

1262

1625

1710

Table 10.20 IEC dU/dt Test Results for E1h–E4h with Shielded Cables and No Output Filter, 525–690 V

NOTICE

TEST RESULTS

NEMA does not provide dU/dt results for 690 V.

dU/dt [V/ µ s]

3494

1895

3850

3712

1996 dU/dt [V/ µ s]

5217

3400

1502

3894

2826

1455

10.14 Electromagnetic Compatibility (EMC) Overview

Electrical devices both generate interference and are affected by interference from other generated sources. The electromagnetic compatibility (EMC) of these effects depends on the power and the harmonic characteristics of the devices.

Uncontrolled interaction between electrical devices in a system can degrade compatibility and impair reliable operation.

Interference takes the form of the following:

•

Electrostatic discharges

•

Rapid voltage fluctuations

•

High-frequency interference

Electrical interference is most commonly found at frequencies in the range 150 kHz to 30 MHz. Airborne interference from the drive system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor.

Capacitive currents in the motor cable, coupled with a high dU/dt from the motor voltage, generate leakage currents. See

Illustration 10.16

. Shielded motor cables have higher capacitance between the phase wires and the shield, and again

between the shield and ground. This added cable capacitance, along with other parasitic capacitance and motor inductance, changes the electromagnetic emission signature produced by the unit. The change in electromagnetic emission signature occurs mainly in emissions less than 5 MHz. Most of the leakage current (I1) is carried back to the unit through the PE (I3), leaving only a small electromagnetic field (I4) from the shielded motor cable. The shield reduces the radiated interference but increases the low-frequency interference on the mains.

MG38C102

Electrical Installation Con...

z z z z

Design Guide

S U

3 4 5 6

1 Ground wire

2 Shield

3 AC mains supply

4 Drive

5 Shielded motor cable

6 Motor

Illustration 10.16 Electric Model Showing Possible Leakage Currents

Cs Possible shunt parasitic capacitance paths (varies with different installations)

I1 Common-mode leakage current

I2 Shielded motor cable

I3 Safety ground (fourth conductor in motor cables

I4 Unintended common-mode current

– –

10.14.1 EMC Test Results

The following test results have been obtained using a drive (with options if relevant), a shielded control cable, a control box with potentiometer, a motor, and motor shielded cable.

RFI filter type

Standards and requirements

EN 55011

EN/IEC 61800-3

FC 302 90–800 kW 380–500 V

90–1200 kW 525–

690 V

FC 302 90–800 kW 380–500 V No

90–315 kW 525–690 V No

Table 10.21 EMC Test Results (Emission and Immunity) and light industries

Conducted emission

Class B

Housing, trades

Class A group 1

Industrial environment

Class A group

Industrial environment

Category C1

First environment

Home and office

Category C2

First environment

Home and office

Category C3

Second environment

Industrial

Radiated emission

Class B

Housing, trades

Class A group 1

Industrial and light industries environment

Category C1

First environment

Home and office

Category C2

First environment

Home and office

150 m (492 ft)

30 m (98 ft) 150 m (492 ft)

Yes

10 10

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 10

WARNING

This type of power drive system is not intended to be used on a low-voltage public network that supplies domestic premises. Radio frequency interference is expected if used on such a network, and supplementary mitigation measures may be required.

10.14.2 Emission Requirements

According to the EMC product standard for adjustable speed drives EN/IEC 61800-3:2004, the EMC requirements depend on the environment in which the drive is installed. These environments along with the mains voltage supply requirements are defined in

Table 10.22

The drives comply with EMC requirements described in IEC/EN 61800-3 (2004)+AM1 (2011), category C3, for equipment having greater than 100 A per-phase current draw, installed in the second environment. Compliance testing is performed with a 150 m (492 ft) shielded motor cable.

Category

(EN 61800-3)

Definition Conducted emission (EN 55011)

First environment (home and office) with a supply voltage less than 1000 V

First environment (home and office) with a supply voltage less than 1000 V, which is not plug-in or movable and where a professional is intended to be used to install or commission the system.

Second environment (industrial) with a supply voltage lower than 1000 V

Second environment with the following:

•

Supply voltage equal to or above 1000 V

•

Rated current equal to or above 400 A

•

Intended for use in complex systems

Class B

Class A Group 1

Class A Group 2

No limit line.

An EMC plan must be made.

Table 10.22 Emission Requirements

When the generic emission standards are used, the drives are required to comply with

Table 10.23

Environment Generic Standard

First environment

(home and office)

Second environment

(industrial environment)

EN/IEC 61000-6-3 Emission standard for residential, commercial, and light industrial environments.

EN/IEC 61000-6-4 Emission standard for industrial environments.

Table 10.23 Generic Emission Standard Limits

Conducted emission requirement according to EN 55011 limits

Class B

Class A Group 1

MG38C102

Electrical Installation Con...

Design Guide

10.14.3 Immunity Requirements

The immunity requirements for drives depend on the installation environment. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss drives comply with the requirements for both the industrial and the home/office environment.

To document immunity against burst transient, the following immunity tests have been performed on a drive (with options if relevant), a shielded control cable, and a control box with potentiometer, motor cable, and motor. The tests were performed in accordance with the following basic standards. For more details, see

Table 10.24

•

EN 61000-4-2 (IEC 61000-4-2): Electrostatic discharges (ESD): Simulation of electrostatic discharges from human beings.

•

EN 61000-4-3 (IEC 61000-4-3): Incoming electromagnetic field radiation, amplitude modulated simulation of the effects of radar, radio communication equipment, and mobile communications equipment.

•

EN 61000-4-4 (IEC 61000-4-4): Burst transients: Simulation of interference brought about by switching a contactor, relay, or similar devices.

•

EN 61000-4-5 (IEC 61000-4-5): Surge transients: Simulation of transients brought about by lightning strikes near installations.

•

EN 61000-4-6 (IEC 61000-4-6): RF common mode: Simulation of the effect from radio-transmission equipment joined by connection cables.

Basic standard

Acceptance criterion

Line

Motor

Brake

Load sharing

Control wires

Standard bus

Relay wires

Application and Fieldbus options

LCP cable

External 24 V DC

Burst

IEC 61000-4-4

4 kV CM

2 kV CM

Surge

IEC 61000-4-5

2 kV/2 Ω DM

4 kV/12 Ω CM

4 kV/2

4 kV/2 Ω 1)

2 kV/2 Ω

2 kV/2

2 kV/2 Ω

ESD

IEC

61000-4-2

–

2 kV CM

2 V CM

2 kV/2 Ω 1)

0.5 kV/2 Ω DM

1 kV/12 Ω CM

–

Enclosure – 8 kV AD

6 kV CD

Table 10.24 EMC Immunity Form, Voltage Range: 380–500 V, 525–600 V, 525–690 V

1) Injection on cable shield

AD: air discharge; CD: contact discharge; CM: common mode; DM: differential mode

Radiated electromagnetic Field

IEC 61000-4-3

–

10 V/m

RF common mode voltage

IEC 61000-4-6

10 V

RMS

10 V

RMS

10 V

RMS

10 V

RMS

10 V

RMS

10 V

RMS

10 V

RMS

10 V

RMS

10 V

RMS

10 V

RMS

–

10 10

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 10

10.14.4 EMC Compatibility

NOTICE

OPERATOR RESPONSIBILITY

According to the EN 61800–3 standard for variable-speed drive systems, the operator is responsible for ensuring

EMC compliance. Manufacturers can offer solutions for operation conforming to the standard. Operators are responsible for applying these solutions, and for paying the associated costs.

There are 2 options for ensuring electromagnetic compatibility.

•

Eliminate or minimize interference at the source of emitted interference.

•

Increase the immunity to interference in devices affected by its reception.

RFI filters

The goal is to obtain systems that operate stably without radio frequency interference between components. To achieve a high level of immunity, use drives with highquality RFI filters.

NOTICE

RADIO INTERFERENCE

In a domestic environment, this product can cause radio interference in which case supplementary mitigation measures are required.

PELV and galvanic isolation compliance

All E1h–E4h drives control and relay terminals comply with

PELV (excluding grounded Delta leg above 400 V).

Galvanic (ensured) isolation is obtained by fulfilling requirements for higher isolation and by providing the relevant creepage/clearance distances. These requirements are described in the EN 61800–5–1 standard.

Electrical isolation is provided as shown (see

Illustration 10.17

). The components described comply with

both PELV and the galvanic isolation requirements.

7 6 4 3

5 2

1 Current transducers

2 Galvanic isolation for the RS485 standard bus interface

3 Gatedrive for the IGBTs

4 Supply (SMPS) including signal isolation of V DC, indicating the intermediate current voltage

5 Galvanic isolation for the 24 V back-up option

6 Opto-coupler, brake module (optional)

7 Internal inrush, RFI, and temperature measurement circuits

8 Customer relays

Illustration 10.17 Galvanic Isolation

10.15 EMC-compliant Installation

To obtain an EMC-compliant installation, follow the instructions provided in the operating guide . For an example of proper EMC installation, see

Illustration 10.18

NOTICE

TWISTED SHIELD ENDS (PIGTAILS)

Twisted shield ends increase the shield impedance at higher frequencies, which reduces the shield effect and increases the leakage current. Avoid twisted shield ends by using integrated shield clamps.

•

For use with relays, control cables, a signal interface, fieldbus, or brake, connect the shield to the enclosure at both ends. If the ground path has high impedance, is noisy, or is carrying current, break the shield connection on 1 end to avoid ground current loops.

•

Convey the currents back to the unit using a metal mounting plate. Ensure good electrical contact from the mounting plate through the mounting screws to the drive chassis.

•

Use shielded cables for motor output cables. An alternative is unshielded motor cables within metal conduit.

MG38C102

Electrical Installation Con...

Design Guide

NOTICE

SHIELDED CABLES

If shielded cables or metal conduits are not used, the unit and the installation do not meet regulatory limits on radio frequency (RF) emission levels.

•

Ensure that motor and brake cables are as short as possible to reduce the interference level from the entire system.

•

Avoid placing cables with a sensitive signal level alongside motor and brake cables.

•

For communication and command/control lines, follow the particular communication protocol standards. For example, USB must use shielded cables, but RS485/ethernet can use shielded UTP or unshielded UTP cables.

•

Ensure that all control terminal connections are

PELV.

NOTICE

EMC INTERFERENCE

Use shielded cables for motor and control wiring, and separate cables for mains input, motor wiring, and control wiring. Failure to isolate power, motor, and control cables can result in unintended behavior or reduced performance. Minimum 200 mm (7.9 in) clearance between mains input, motor, and control cables are required.

NOTICE

INSTALLATION AT HIGH ALTITUDE

There is a risk for overvoltage. Isolation between components and critical parts could be insufficient, and not comply with PELV requirements. Reduce the risk for overvoltage by using external protective devices or galvanic isolation.

For installations above 2000 m (6500 ft) altitude, contact

Danfoss regarding PELV compliance.

NOTICE

PELV COMPLIANCE

Prevent electric shock by using protective extra low voltage (PELV) electrical supply and complying with local and national PELV regulations.

10 10

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 10

PE u v w

PLC

Minimum 16 mm 2 (6 AWG) equalizing cable

Control cables

Minimum 200 mm (7.9 in) between control cables, motor cables, and mains cables.

Mains supply

Bare (unpainted) surface

Star washers

Brake cable (shielded)

Motor cable (shielded)

Illustration 10.18 Example of Proper EMC Installation

10 Mains cable (unshielded)

11 Output contactor, and so on

12 Cable insulation stripped

13 Common ground busbar. Follow local and national requirements for cabinet grounding.

14 Brake resistor

15 Metal box

16 Connection to motor

17 Motor

18 EMC cable gland

MG38C102

Electrical Installation Con...

Design Guide

10.16 Harmonics Overview

Non-linear loads such as found with drives do not draw current uniformly from the power line. This non-sinusoidal current has components which are multiples of the basic current frequency. These components are referred to as harmonics. It is important to control the total harmonic distortion on the mains supply. Although the harmonic currents do not directly affect electrical energy consumption, they generate heat in wiring and transformers that can affect other devices on the same power line.

10.16.1 Harmonic Analysis

Since harmonics increase heat losses, it is important to design systems with harmonics in mind to prevent overloading the transformer, inductors, and wiring. When necessary, perform an analysis of the system harmonics to determine equipment effects.

A non-sinusoidal current is transformed with a Fourier series analysis into sine-wave currents at different frequencies, that is, different harmonic currents I

with

50 Hz or 60 Hz as the basic frequency.

Abbreviation f

I n

U n n

Description

Basic frequency (50 Hz or 60 Hz)

Current at the basic frequency

Voltage at the basic frequency

Current at the n th harmonic frequency

Voltage at the n th harmonic frequency

Harmonic order

Table 10.25 Harmonics-related Abbreviations

Current

Frequency

Basic current (I

)

50 Hz

Harmonic current (I

250 Hz

350 Hz

Table 10.26 Basic Currents and Harmonic Currents n

)

550 Hz

Current

Input current

Harmonic current

RMS

1.0

0.9

0.5

0.2

11-49

<0.1

Table 10.27 Harmonic Currents Compared to the RMS Input

Current

The voltage distortion on the mains supply voltage depends on the size of the harmonic currents multiplied by the mains impedance for the frequency in question. The total voltage distortion (THDi) is calculated based on the individual voltage harmonics using this formula:

10.16.2 Effect of Harmonics in a Power

Distribution System

Illustration 10.19

, a transformer is connected on the primary side to a point of common coupling PCC1, on the medium voltage supply. The transformer has an impedance

Z xfr

and feeds several loads. The point of common coupling where all loads are connected is PCC2. Each load connects through cables that have an impedance Z

, Z

PCC

Z xfr

Point of common coupling

Medium voltage

Low voltage

Transformer impedance

Modeling resistance and inductance in the wiring

Illustration 10.19 Small Distribution System

Harmonic currents drawn by non-linear loads cause distortion of the voltage because of the voltage drop on the impedances of the distribution system. Higher impedances result in higher levels of voltage distortion.

Current distortion relates to apparatus performance and it relates to the individual load. Voltage distortion relates to system performance. It is not possible to determine the voltage distortion in the PCC knowing only the harmonic performance of the load. To predict the distortion in the

PCC, the configuration of the distribution system and relevant impedances must be known.

10 10

Electrical Installation Con...

VLT® AutomationDrive FC 302

10 10

A commonly used term for describing the impedance of a grid is the short circuit ratio R sce

, where R sce

is defined as the ratio between the short circuit apparent power of the supply at the PCC (S sc

) and the rated apparent power of the load.

(S equ

R sce

S sc equ where S sc

= U supply

and S equ

= U × I equ

Negative effects of harmonics

•

Harmonic currents contribute to system losses (in cabling and transformer).

•

Harmonic voltage distortion causes disturbance to other loads and increases losses in other loads.

10.16.3 IEC Harmonic Standards

In most of Europe, the basis for the objective assessment of the quality of mains power is the Electromagnetic Compatibility of Devices Act (EMVG). Compliance with these regulations ensures that all devices and networks connected to electrical distribution systems fulfill their intended purpose without generating problems.

Standard

EN 61000-2-2, EN 61000-2-4, EN 50160

EN 61000-3-2, 61000-3-12

EN 50178

Definition

Define the mains voltage limits required for public and industrial power grids.

Regulate mains interference generated by connected devices in lower current products.

Monitors electronic equipment for use in power installations.

Table 10.28 EN Design Standards for Mains Power Quality

There are 2 European standards that address harmonics in the frequency range from 0 Hz to 9 kHz:

EN 61000–2–2 (Compatibility Levels for Low-Frequency Conducted Disturbances and Signaling in Public Low-Voltage

Power Supply Systems

The EN 61000–2–2 standard states the requirements for compatibility levels for PCC (point of common coupling) of lowvoltage AC systems on a public supply network. Limits are specified only for harmonic voltage and total harmonic distortion of the voltage. EN 61000–2–2 does not define limits for harmonic currents. In situations where the total harmonic distortion

THD(V)=8%, PCC limits are identical to those limits specified in the EN 61000–2–4 Class 2.

EN 61000–2–4 (Compatibility Levels for Low-Frequency Conducted Disturbances and Signaling in Industrial Plants)

The EN 61000–2–4 standard states the requirements for compatibility levels in industrial and private networks. The standard further defines the following 3 classes of electromagnetic environments:

•

Class 1 relates to compatibility levels that are less than the public supply network, which affects equipment sensitive to disturbances (lab equipment, some automation equipment, and certain protection devices).

•

Class 2 relates to compatibility levels that are equal to the public supply network. The class applies to PCCs on the public supply network and to IPCs (internal points of coupling) on industrial or other private supply networks. Any equipment designed for operation on a public supply network is allowed in this class.

•

Class 3 relates to compatibility levels greater than the public supply network. This class applies only to IPCs in industrial environments. Use this class where the following equipment is found:

Large drives.

Welding machines.

Large motors starting frequently.

Loads that change quickly.

Typically, a class cannot be defined ahead of time without considering the intended equipment and processes to be used in the environment. VLT ® high-power drives observe the limits of Class 3 under typical supply system conditions (R

>10 or

Line

<10%).

MG38C102

Electrical Installation Con...

Design Guide

Harmonic order (h)

17 ˂ h≤49

Table 10.29 Compatibility Levels for Harmonics

Class 1 (V h

2.27 x (17/h) – 0.27

Class 2 (V

3.5

2 h

2.27 x (17/h) – 0.27

THDv

Class 1

Class 2

Table 10.30 Compatibility Levels for the Total Harmonic Voltage Distortion THDv

10.16.4 Harmonic Compliance

Danfoss drives comply with the following standards:

•

IEC61000-2-4

•

IEC61000-3-4

•

G5/4

10.16.5 Harmonic Mitigation

In cases where extra harmonic suppression is required, Danfoss offers the following mitigation equipment:

•

VLT ® 12-pulse drives

•

VLT ® AHF filters

•

VLT ® Low Harmonic Drives

•

VLT ® Active Filters

Class 3 (V h

4.5

4.5 x (17/h) – 0.5

Class 3

10%

Selecting the right solution depends on several factors:

•

The grid (background distortion, mains unbalance, resonance, and type of supply (transformer/generator).

•

Application (load profile, number of loads, and load size).

•

Local/national requirements/regulations (such as IEEE 519, IEC, and G5/4).

•

Total cost of ownership (initial cost, efficiency, and maintenance).

10.16.6 Harmonic Calculation

Use the free Danfoss MCT 31 calculation software to determine the degree of voltage pollution on the grid and needed precaution. The VLT ® Harmonic Calculation MCT 31 is available at www.danfoss.com

10 10

Basic Operating Principles ...

VLT® AutomationDrive FC 302

11 Basic Operating Principles of a Drive

11 11

This chapter provides an overview of the primary assemblies and circuitry of a Danfoss drive. It describes the internal electrical and signal processing functions. A description of the internal control structure is also included.

11.1 Description of Operation

A drive is an electronic controller that supplies a regulated amount of AC power to a 3-phase inductive motor. By supplying variable frequency and voltage to the motor, the drive varies the motor speed or maintains a constant speed as the load on the motor changes. Also, the drive can stop and start a motor without the mechanical stress associated with a line start.

In its basic form, the drive can be divided into the following 4 main areas:

Rectifier

The rectifier consists of SCRs or diodes that convert 3phase AC voltage to pulsating DC voltage.

DC link (DC bus)

The DC-link consists of inductors and capacitor banks that stabilize the pulsating DC voltage.

Inverter

The inverter uses IGBTs to convert the DC voltage to variable voltage and variable frequency AC.

Control

The control area consists of software that runs the hardware to produce the variable voltage that controls and regulates the AC motor.

1 2 3

11.2 Drive Controls

The following processes are used to control and regulate the motor:

•

User input/reference.

•

Feedback handling.

•

User-defined control structure.

Open loop/closed-loop mode.

Motor control (speed, torque, or process).

•

Control algorithms (VVC + , flux sensorless, flux with motor feedback, and internal current control

VVC + ).

11.2.1 User Inputs/References

The drive uses an input source (also called reference) to control and regulate the motor. The drive receives this input either

•

Manually via the LCP. This method is referred to as local [Hand On].

•

Remotely via analog/digital inputs and various serial interfaces (RS485, USB, or an optional fieldbus). This method is referred to as remote

[Auto On] and is the default input setting.

Active reference

The term active reference refers to the active input source.

The active reference is configured in parameter 3-13 Reference Site . See

Illustration 11.2

and

Table 11.1

For more information, see the programming guide .

Rectifier (SCR/diodes)

DC link (DC bus)

Inverter (IGBTs)

Illustration 11.1 Internal Processing

MG38C102

Basic Operating Principles ...

Design Guide

Remote reference

Local reference

(Auto On)

(Hand On)

Remote

Linked to hand/auto

Local

Reference

LCP keys:

(Hand On), (Off), and (Auto On)

P 3-13 Reference Site

Illustration 11.2 Selecting Active Reference

LCP Keys

[Hand On]

[Hand On] ⇒ (Off)

[Auto On]

[Auto On] ⇒ (Off)

All keys

Parameter 3-13 Reference

Site

Linked to hand/auto

Local

Remote

Active

Reference

Local

Remote

Local

Remote

Table 11.1 Local and Remote Reference Configurations

11.2.2 Remote Handling of References

Remote handling of reference applies to both open-loop and closed-loop operation. See

Illustration 11.3

Up to 8 internal preset references can be programmed into the drive. The active internal preset reference can be selected externally through digital control inputs or through the serial communications bus.

External references can also be supplied to the drive, most commonly through an analog control input. All reference sources and the bus reference are added to produce the total external reference. The active reference can be selected from the following:

•

External reference

•

Preset reference

•

Setpoint

•

Sum of the external reference, preset reference, and setpoint

The active reference can be scaled. The scaled reference is calculated as follows:

Where X is the external reference, the preset reference, or the sum of these references, and Y is parameter 3-14 Preset

Relative Reference in [%].

If Y, parameter 3-14 Preset Relative Reference , is set to 0%, the scaling does not affect the reference.

11 11

Basic Operating Principles ...

VLT® AutomationDrive FC 302

P 3-14

Preset relative ref.

Input command:

Preset ref. bit0, bit1, bit2

[4]

[5]

[6]

[7]

[0]

[1]

[2]

[3]

No function

Analog inputs

Frequency inputs

Ext. closed loop outputs

DigiPot

Input command:

Freeze ref.



P 3-04

Ref. function

Relative

X+X*Y

/100

±200%



±200% on

±200% off

Input command:

Ref. Preset

±100%

& increase/ decrease ref.

max ref.

% min ref.

P 1-00

Configuration mode

Open loop

Scale to

RPM,Hz or %

Scale to

Closed loop unit

Closed loop

Remote ref.

11 11

No function

Analog inputs

Frequency inputs

Ext. closed loop outputs

DigiPot



No function

Analog inputs

Frequency inputs

Ext. closed loop outputs

DigiPot

Bus reference

Illustration 11.3 Remote Handling of Reference

External reference in %

Setpoint

Closed loop

±200%

From Feedback Handling

Ref. in %

Increase

0/1

DigiPot

Digipot ref.

±200%

Clear

0/1

MG38C102

Basic Operating Principles ...

Design Guide

11.2.3 Feedback Handling

Feedback handling can be configured to work with applications requiring advanced control, such as multiple setpoints and multiple types of feedback. See

Illustration 11.4

. Three types of control are common:

Single zone (single setpoint)

This control type is a basic feedback configuration. Setpoint 1 is added to any other reference (if any) and the feedback signal is selected.

Multi-zone (single setpoint)

This control type uses 2 or 3 feedback sensors but only 1 setpoint. The feedback can be added, subtracted, or averaged. In addition, the maximum or minimum value can be used. Setpoint 1 is used exclusively in this configuration.

Multi-zone (setpoint/feedback)

The setpoint/feedback pair with the largest difference controls the speed of the drive. The maximum value attempts to keep all zones at or below their respective setpoints, while the minimum value attempts to keep all zones at or above their respective setpoints.

Example

A 2-zone, 2-setpoint application. Zone 1 setpoint is 15 bar, and the feedback is 5.5 bar. Zone 2 setpoint is 4.4 bar, and the feedback is 4.6 bar. If maximum is selected, the zone 2 setpoint and feedback are sent to the PID controller, since it has the smaller difference (feedback is higher than setpoint, resulting in a negative difference). If minimum is selected, the zone 1 setpoint and feedback is sent to the PID controller, since it has the larger difference (feedback is lower than setpoint, resulting in a positive difference).

Setpoint to

Reference

Handling

Setpoint 1

P 20-21

Setpoint 2

P 20-22

Setpoint 3

P 20-23

Multi setpoint min.

Multi setpoint max.

11 11

Feedback

Feedback 1 Source

P 20-00

Feedback 2 Source

P 20-03

Feedback 3 Source

P 20-06

Feedback conv.

P 20-01

Feedback conv.

P 20-04

Feedback conv.

P 20-07

Feedback 1

Feedback 2

Feedback 3

Feedback 1 only

Feedback 2 only

Feedback 3 only

Sum (1+2+3)

Difference (1-2)

Average (1+2+3)

Minimum (1|2|3)

Maximum (1|2|3)

Feedback Function

P 20-20

Illustration 11.4 Block Diagram of Feedback Signal Processing

101

Basic Operating Principles ...

VLT® AutomationDrive FC 302

Feedback conversion

In some applications, it is useful to convert the feedback signal. One example is using a pressure signal to provide flow feedback. Since the square root of pressure is proportional to flow, the square root of the pressure signal yields a value proportional to the flow, see

Illustration 11.5

Reference signal

Reference

PID

Desired flow

FB conversion

FB P

Flow

FB signal

Illustration 11.5 Feedback Conversion

11 11

11.2.4 Control Structure Overview

The control structure is a software process that controls the motor based on user-defined references (for example, RPM) and whether feedback is used/not used (closed loop/open loop). The operator defines the control in parameter 1-00 Configuration Mode .

The control structures are as follows:

Open-loop control structure

•

Speed (RPM)

•

Torque (Nm)

Closed-loop control structure

•

Speed (RPM)

•

Torque (Nm)

•

Process (user-defined units, for example, feet, lpm, psi, %, bar)

MG38C102

Basic Operating Principles ...

Design Guide

11.2.5 Open-loop Control Structure

In open-loop mode, the drive uses 1 or more references (local or remote) to control the speed or torque of the motor. There are 2 types of open-loop control:

•

Speed control. No feedback from the motor.

•

Torque control. Used in VVC + mode. The function is used in mechanically robust applications, but its accuracy is limited. Open loop torque function works only in 1 speed direction. The torque is calculated based on current measurement within the drive. See

chapter 12 Application Examples

In the configuration shown in

Illustration 11.6

, the drive operates in open-loop mode. It receives input from either the LCP

(hand-on mode) or via a remote signal (auto-on mode). The signal (speed reference) is received and conditioned with the following:

•

Programmed minimum and maximum motor speed limits (in RPM and Hz).

•

Ramp-up and ramp-down times.

•

Motor rotation direction.

The reference is then passed on to control the motor.

Reference handling

Remote reference

P 4-13

Motor speed high limit [RPM]

P 4-14

Motor speed high limit [Hz]

Auto mode

Hand mode

Remote

Linked to hand/auto

Local

Reference

Local reference scaled to

RPM or Hz

P 4-11

Motor speed low limit [RPM]

LCP Hand on, off and auto on keys

P 3-13

Reference site

P 4-12

Motor speed low limit [Hz]

Illustration 11.6 Block Diagram of an Open-loop Control Structure

P 3-4* Ramp 1

P 3-5* Ramp 2

Ramp

100%

-100%

To motor control

P 4-10

Motor speed direction

11 11

103

Basic Operating Principles ...

VLT® AutomationDrive FC 302

11 11

11.2.6 Closed-loop Control Structure

In closed-loop mode, the drive uses 1 or more references (local or remote) and feedback sensors to control the motor. The drive receives a feedback signal from a sensor in the system. It then compares this feedback to a setpoint reference value and determines if there is any discrepancy between these 2 signals. The drive then adjusts the speed of the motor to correct the discrepancy.

For example, consider a pump application in which the speed of the pump is controlled so that the static pressure in a pipe is constant (see

Illustration 11.7

). The drive receives a feedback signal from a sensor in the system. It compares this feedback

to a setpoint reference value and determines the discrepancy if any, between these 2 signals. It then adjusts the speed of the motor to compensate for the discrepancy.

The static pressure setpoint is the reference signal to the drive. A static pressure sensor measures the actual static pressure in the pipe and provides this information to the drive as a feedback signal. If the feedback signal exceeds the setpoint reference, the drive ramps down to reduce the pressure. Similarly, if the pipe pressure is lower than the setpoint reference, the drive ramps up to increase the pump pressure.

There are 3 types of closed-loop control:

•

Speed control. This type of control requires a speed PID feedback for an input. A properly optimized speed closedloop control has higher accuracy than a speed open-loop control. The speed control selects which input to use as speed PID feedback in parameter 7-00 Speed PID Feedback Source .

•

Torque control. Used in flux mode with encoder feedback, this control offers superior performance in all 4 quadrants and at all motor speeds.

The torque control function is used in applications where the torque on the motor output shaft is controlling the application as tension control. Torque control is selected in parameter 1-00 Configuration Mode , either in [4] VVC+ open loop or [2] Flux control closed loop with motor speed feedback . Torque setting is done by setting an analog, digital, or bus-controlled reference. The maximum speed limit factor is set in parameter 4-21 Speed Limit Factor

Source . When running torque control, it is recommended to make a full AMA procedure since the correct motor data is essential for optimal performance.

•

Process control. Used to control application parameters that can be measured by different sensors (pressure, temperature, and flow) and be affected by the connected motor through a pump or fan.

100%

Ref.

Handling

(Illustration)



Feedback

Handling

(Illustration)

*[-1]

P 20-81

PID Normal/Inverse

Control

Illustration 11.7 Block Diagram of Closed-loop Controller

PID

100%

-100%

P 4-10

Motor speed direction

Scale to speed

To motor control

Programmable features

While the default values for the drive in closed loop often provide satisfactory performance, system control can often be optimized by tuning the PID parameters. Auto tuning is provided for this optimization.

•

Inverse regulation - motor speed increases when a feedback signal is high.

•

Start-up frequency - lets the system quickly reach an operating status before the PID controller takes over.

•

Built-in lowpass filter - reduces feedback signal noise.

MG38C102

Basic Operating Principles ...

Design Guide

11.2.7 Control Processing

See Active/Inactive Parameters in Different Drive Control Modes in the programming guide for an overview of which control configuration is available for your application, depending on selection of AC motor or PM non-salient motor.

11.2.7.1 Control Structure in VVC

Ref.

P 1-00

Config. mode

P 4-13

Motor speed high limit (RPM)

P 4-14

Motor speed high limit (Hz)

High P 3-**

P 1-00

Config. mode

Ramp

Motor controller

P 4-19

Max. output freq.

+f max.

-f max.



Process

P 7-20 Process feedback

1 source

P 7-22 Process feedback

2 source

Low

P 4-11

Motor speed low limit (RPM)

P 4-12

Motor speed low limit (Hz)



P 7-0*

Speed

PID

P 7-00 Speed PID feedback source

Illustration 11.8 Control Structure in VVC + Open Loop and Closed-loop Configurations

Motor controller

P 4-19

Max. output freq.

+f max.

-f max.

Illustration 11.8

, the resulting reference from the reference handling system is received and fed through the ramp limitation and speed limitation before being sent to the motor control. The output of the motor control is then limited by the maximum frequency limit.

Parameter 1-01 Motor Control Principle is set to [1] VVC + and parameter 1-00 Configuration Mode is set to [0] Speed open loop .

If parameter 1-00 Configuration Mode is set to [1] Speed closed loop , the resulting reference is passed from the ramp limitation and speed limitation into a speed PID control. The speed PID control parameters are located in parameter group

7-0* Speed PID Ctrl . The resulting reference from the speed PID control is sent to the motor control limited by the frequency limit.

Select [3] Process in parameter 1-00 Configuration Mode to use the process PID control for closed-loop control of, for example, speed or pressure in the controlled application. The process PID parameters are in parameter groups 7-2* Process Ctrl. Feedb and 7-3* Process PID Ctrl .

11 11

105

Basic Operating Principles ...

VLT® AutomationDrive FC 302

11.2.7.2 Control Structure in Flux Sensorless

P 1-00

Config. mode

Ref.



Process

PID

P 4-13 Motor speed high limit [RPM]

P 4-14 Motor speed high limit [Hz]

High P 3-**

Ramp



Low

P 4-11 Motor speed low limit [RPM]

P 4-12 Motor speed low limit [Hz]

P 7-0*

Speed

PID

Motor controller

P 4-19

Max. output freq.

+f max.

-f max.

P 7-20 Process feedback

1 source

P 7-22 Process feedback

2 source

Illustration 11.9 Control Structure in Flux Sensorless Open Loop and Closed-loop Configurations

11 11

Illustration 11.9

, the resulting reference from the reference handling system is fed through the ramp and speed limitations as determined by the parameter settings indicated.

Parameter 1-01 Motor Control Principle is set to [2] Flux Sensorless and parameter 1-00 Configuration Mode is set to [0] Speed open loop . 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 ( parameter group 7-0* Speed PID control ).

Select [3] Process in parameter 1-00 Configuration Mode to use the process PID control for closed-loop control of that is, speed or pressure in the controlled application. The process PID parameters are found in parameter groups 7-2* Process Ctrl.

Feedb and 7-3* Process PID Ctrl .

MG38C102

Basic Operating Principles ...

Design Guide

11.2.7.3 Control Structure in Flux with Motor Feedback

P 1-00

Config. mode

Torque

P 4-13 Motor speed high limit (RPM)

P 4-14 Motor speed high limit (Hz)

High P 3-**

Ref.

P 7-2*

Process

PID

Ramp

_ _

P 7-20 Process feedback

1 source

P 7-22 Process feedback

2 source

Low

P 4-11 Motor speed low limit (RPM)

P 4-12 Motor speed low limit (Hz)

P 7-00

PID source

Illustration 11.10 Control Structure in Flux with Motor Feedback Configuration

P 7-0*

Speed

PID

P 1-00

Config. mode

Motor controller

P 4-19

Max. output freq.

+f max.

-f max.

Illustration 11.10

, the motor control in this configuration relies on a feedback signal from an encoder or resolver mounted directly on the motor (set in parameter 1-02 Flux Motor Feedback Source ). The resulting reference can be used as input for the speed PID control, or directly as a torque reference.

Parameter 1-01 Motor Control Principle is set to [3] Flux w motor feedb and parameter 1-00 Configuration Mode is set to [1]

Speed closed loop . The speed PID control parameters are in parameter group 7-0* Speed PID Control

Torque control can only be selected in the Flux with motor feedback ( parameter 1-01 Motor Control Principle ) configuration.

When this mode has been selected, the reference uses the Nm unit. It requires no torque feedback, since the actual torque is calculated based on the current measurement of the drive.

Process PID control can be used for closed-loop control of speed or pressure in the controlled application. The process PID parameters are located in parameter groups 7-2* Process Ctrl. Feedb and 7-3* Process PID Ctrl .

11.2.7.4 Internal Current Control in VVC

Mode

When the motor current/torque exceed the torque limits set in parameter 4-16 Torque Limit Motor Mode , parameter 4-17 Torque Limit Generator Mode , and parameter 4-18 Current Limit , the integral current limit control is activated.

When the drive is at the current limit during motor operation or regenerative operation, it tries to get below the preset torque limits as quickly as possible without losing control of the motor.

11 11

107

Application Examples VLT® AutomationDrive FC 302

12 Application Examples

12 12

The examples in this section are intended as a quick reference for common applications.

•

Parameter settings are the regional default values unless otherwise indicated (selected in parameter 0-03 Regional Settings ).

•

Parameters associated with the terminals and their settings are shown next to the drawings.

•

Where switch settings for analog terminals A53 or

A54 are required, these settings are also shown.

•

For STO, a jumper wire may be required between terminal 12 and terminal 37 when using factory default programming values.

12.1 Programming a Closed-loop Drive

System

A closed-loop drive system usually consists of the following:

•

Motor

•

Drive

•

Encoder as feedback system

•

Mechanical brake

•

Brake resistor for dynamic braking

•

Transmission

•

Gear box

•

Load

Applications demanding mechanical brake control typically need a brake resistor.

Brake resistor

Transmission

Encoder

Motor

Mechanical brake

Gearbox

Load

Illustration 12.1 Basic Set-up for FC 302 Closed-loop Speed

Control

MG38C102

Application Examples Design Guide

+24 V

D IN

COM

D IN

12.2 Wiring Configurations for Automatic

Motor Adaptation (AMA)

Parameters

Function Setting

Parameter 1-29

Automatic Motor

[1] Enable complete AMA

Adaptation

(AMA)

Parameter 5-12 T erminal 27

Digital Input

*=Default value

[2]* Coast inverse

Notes/comments: Set parameter group 1-2* Motor

Data according to motor nameplate.

+10 V

A IN

COM

A OUT

COM

Table 12.1 Wiring Configuration for AMA with T27 Connected

+10 V

A IN

COM

A OUT

COM

D IN

+24 V

D IN

COM

Parameters

Function Setting

Parameter 1-29

Automatic Motor

[1] Enable complete AMA

Adaptation

(AMA)

Parameter 5-12 T erminal 27

Digital Input

*=Default value

[0] No operation

Notes/comments: Set parameter group 1-2* Motor

Data according to motor nameplate.

Table 12.2 Wiring Configuration for AMA without

T27 Connected

+10 V

A IN

COM

A OUT

COM

U - I

+24 V

D IN

COM

D IN

12.3 Wiring Configurations for Analog

Speed Reference

-10 - +10V

Parameters

Function Setting

Parameter 6-10 T erminal 53 Low

0.07 V*

Voltage

10 V* Parameter 6-11 T erminal 53 High

Voltage

Parameter 6-14 T erminal 53 Low

Ref./Feedb. Value

0 RPM

Parameter 6-15 T erminal 53 High

Ref./Feedb. Value

*=Default value

Notes/comments:

1500 RPM

A53

+10 V

A IN

COM

A OUT

COM

+24 V

D IN

COM

D IN

Table 12.3 Wiring Configuration for Analog Speed Reference

(Voltage)

4 - 20mA

Parameters

Function Setting

Parameter 6-12 T erminal 53 Low

4 mA*

Current

20 mA* Parameter 6-13 T erminal 53 High

Current

Parameter 6-14 T erminal 53 Low

Ref./Feedb. Value

0 RPM

Parameter 6-15 T erminal 53 High

Ref./Feedb. Value

*=Default value

Notes/comments:

1500 RPM

U - I

A53

Table 12.4 Wiring Configuration for Analog Speed Reference

(Current)

12 12

109

Application Examples VLT® AutomationDrive FC 302

+24 V

D IN

COM

D IN

12.4 Wiring Configurations for Start/Stop

+10

A IN

COM

A OUT

COM

Parameters

Function Setting

Parameter 5-10 T erminal 18

[8] Start*

Digital Input

Parameter 5-12 T erminal 27

Digital Input

Parameter 5-19 T erminal 37 Safe

Stop

[0] No operation

[1] Safe

Torque Off

Alarm

*=Default value

Notes/comments:

If parameter 5-12 Terminal 27

Digital Input is set to [0] No operation , a jumper wire to terminal 27 is not needed.

+10 V

A IN

COM

A OUT

COM

D IN

+24 V

D IN

COM

Parameters

Function Setting

Parameter 5-10 T erminal 18

Digital Input

[9] Latched

Start

Parameter 5-12 T erminal 27

Digital Input

[6] Stop

Inverse

*=Default value

Notes/comments:

If parameter 5-12 Terminal 27

Digital Input is set to [0] No operation , a jumper wire to terminal 27 is not needed.

Table 12.5 Wiring Configuration for Start/Stop Command with

Safe Torque Off

Speed

Table 12.6 Wiring Configuration for Pulse Start/Stop

Speed

12 12

Start/Stop (18)

Illustration 12.2 Start/Stop with Safe Torque Off

Latched Start (18)

Stop Inverse (27)

Illustration 12.3 Latched Start/Stop Inverse

MG38C102

Application Examples

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

Design Guide

Parameters

Function Setting

Parameter 5-10 T erminal 18

[8] Start

Digital Input

Parameter 5-11 T erminal 19

Digital Input

[10]

Reversing*

Parameter 5-12 T erminal 27

Digital Input

Parameter 5-14 T erminal 32

Digital Input

Parameter 5-15 T erminal 33

Digital Input

Parameter 3-10 P reset Reference

[0] No operation

[16] Preset ref bit 0

[17] Preset ref bit 1

Preset ref. 0

Preset ref. 1

Preset ref. 2

Preset ref. 3

*=Default value

Notes/comments:

25%

50%

75%

100%

12.5 Wiring Configuration for an External

Alarm Reset

+24 V

D IN

COM

D IN

Parameters

Function Setting

Parameter 5-11 T erminal 19

[1] Reset

Digital Input

*=Default value

Notes/comments:

+10 V

A IN

COM

A OUT

COM

Table 12.7 Wiring Configuration for Start/Stop with Reversing and 4 Preset Speeds

Table 12.8 Wiring Configuration for an External Alarm Reset

12 12

111

12 12

Application Examples

12.6 Wiring Configuration for Speed

Reference Using a Manual

Potentiometer

+10 V

A IN

COM

A OUT

COM

+24 V

D IN

COM

D IN

Parameters

Function Setting

0.07 V* Parameter 6-10 T erminal 53 Low

Voltage

10 V* Parameter 6-11 T erminal 53 High

Voltage

Parameter 6-14 T erminal 53 Low

Ref./Feedb. Value

0 RPM

Parameter 6-15 T erminal 53 High

≈ 5kΩ

Ref./Feedb. Value

*=Default value

Notes/comments:

1500 RPM

U - I

A53

Table 12.9 Wiring Configuration for Speed Reference

(Using a Manual Potentiometer)

VLT® AutomationDrive FC 302

12.7 Wiring Configuration for Speed Up/

Speed Down

+10 V

A IN

COM

A OUT

COM

+24 V

D IN

COM

D IN

Parameters

Function Setting

Parameter 5-10 T erminal 18

[8] Start*

Digital Input

Parameter 5-12 T erminal 27

Digital Input

Parameter 5-13 T erminal 29

Digital Input

[19] Freeze

Reference

[21] Speed Up

Parameter 5-14 T erminal 32

Digital Input

*=Default value

Notes/comments:

[22] Speed

Down

Table 12.10 Wiring Configuration for Speed Up/Speed Down

Speed

Reference

Start (18)

Freeze ref (27)

Speed up (29)

Speed down (32)

Illustration 12.4 Speed Up/Speed Down

MG38C102

Application Examples Design Guide

+24 V

D IN

COM

D IN

12.8 Wiring Configuration for RS485

Network Connection

Parameters

Function Setting

Parameter 8-30

Protocol

FC*

1* Parameter 8-31

Address

Parameter 8-32

Baud Rate

*=Default value

9600*

Notes/comments:

Select protocol, address, and baud rate in the parameters.

+10 V

A IN

COM

A OUT

COM

RS-485

Table 12.11 Wiring Configuration for RS485 Network Connection

12 12

113

Application Examples VLT® AutomationDrive FC 302

12 12

+10 V

A IN

COM

A OUT

COM

+24 V

D IN

COM

D IN

VLT

U - I

A53

12.9 Wiring Configuration for a Motor

Thermistor

NOTICE

Thermistors must use reinforced or double insulation to meet PELV insulation requirements.

Parameters

Function Setting

Parameter 1-90

Motor Thermal

Protection

[2] Thermistor trip

Parameter 1-93 T hermistor Source

*=Default value

[1] analog input 53

Notes/comments:

If only a warning is wanted, set parameter 1-90 Motor Thermal

Protection to [1] Thermistor warning .

Table 12.12 Wiring Configuration for a Motor Thermistor

12.10 Wiring Configuration for a Relay Setup with Smart Logic Control

+10 V

A IN

COM

A OUT

COM

+24 V

D IN

COM

D IN

Parameters

Function Setting

Parameter 4-30

Motor Feedback

[1] Warning

Loss Function

100 RPM Parameter 4-31

Motor Feedback

Speed Error

Parameter 4-32

Motor Feedback

Loss Timeout

5 s

Parameter 7-00 S peed PID

Feedback Source

Parameter 17-11

Resolution (PPR)

[2] MCB 102

1024*

[1] On Parameter 13-00

SL Controller

Mode

Parameter 13-01

Start Event

Parameter 13-02

Stop Event

Parameter 13-10

Comparator

Operand

Parameter 13-11

Comparator

Operator

[19] Warning

[44] Reset key

[21] Warning no.

[1] ≈ (equal)*

Parameter 13-12

Comparator

Value

Parameter 13-51

SL Controller

Event

[22]

Comparator 0

Parameter 13-52

SL Controller

Action

Parameter 5-40 F unction Relay

*=Default value

[32] Set digital out A low

[80] SL digital output A

Notes/comments:

If the limit in the feedback monitor is exceeded, warning 90,

Feedback Mon.

is issued. The SLC monitors warning 90, Feedback

Mon.

and if the warning becomes true, relay 1 is triggered.

External equipment may require service. If the feedback error goes below the limit again within 5 s, the drive continues and the warning disappears. Reset relay 1 by pressing [Reset] on the

LCP.

Table 12.13 Wiring Configuration for a Relay Set-up with

Smart Logic Control

MG38C102

Application Examples Design Guide

+24 V

D IN

COM

D IN

12.11 Wiring Configuration for Mechanical

Brake Control

+10 V

A IN

COM

A OUT

COM

Parameters

Function Setting

Parameter 5-40 F unction Relay

[32] Mech.

brake ctrl.

[8] Start* Parameter 5-10 T erminal 18

Digital Input

[11] Start reversing

Parameter 5-11 T erminal 19

Digital Input

Parameter 1-71 S tart Delay

Parameter 1-72 S tart Function

0.2

[5] VVC+/

FLUX

Clockwise

Parameter 1-76 S tart Current

Parameter 2-20

Release Brake

Current

Im,n

App.

dependent

Parameter 2-21

Activate Brake

Speed [RPM]

*=Default value

Notes/comments:

Half of nominal slip of the motor

Table 12.14 Wiring Configuration for Mechanical Brake Control

1-76

Current

Speed

1-71

Start (18)

Start reversing (19)

2-21 1-71

Relay output

Open

Closed

Illustration 12.5 Mechanical Brake Control

2-21

Time

115

12 12

Application Examples VLT® AutomationDrive FC 302

12 12

12.12 Configuring the Encoder

Before setting up the encoder, the basic wire configuration for a closed-loop speed control system is shown in

Illustration 12.7

12 13 18 19 27 29 32 33 20 37

24 V or 10–30 V encoder

Illustration 12.6 Encoder Connection to the Drive

The direction of the encoder, identified by looking into the shaft end, is determined by which order the pulses enter the drive.

•

Clockwise (CW) direction means channel A is 90 electrical degrees before channel B.

•

Counterclockwise (CCW) direction means channel

B is 90 electrical degrees before A.

12.13 Wire Configuration for Torque and

Stop Limit

In applications with an external electro-mechanical brake, such as hoisting applications, it is possible to stop the drive via a standard stop command and simultaneously activate the external electro-mechanical brake.

Illustration 12.8

shows the programming of these drive connections.

If a stop command is active via terminal 18 and the drive is not at the torque limit, the motor ramps down to 0 Hz.

If the drive is at the torque limit and a stop command is activated, the system activates terminal 29 output

(programmed to [27] Torque limit & stop ). The signal to terminal 27 changes from logic 1 to logic 0 and the motor starts to coast. This process ensures that the hoist stops even if the drive itself cannot handle the required torque, for example due to excessive overload.

To program the stop and torque limit, connect to the following terminals:

Start/stop via terminal 18

( Parameter 5-10 Terminal 18 Digital Input [8] Start ).

Quick stop via terminal 27

( Parameter 5-12 Terminal 27 Digital Input [2] Coasting Stop,

Inverse ).

Terminal 29 output

( Parameter 5-02 Terminal 29 Mode [1] Terminal 29 Mode

Output parameter 5-31 Terminal 29 Digital Output [27] Torque limit & stop ).

Relay output [0] (Relay 1)

( Parameter 5-40 Function Relay [32] Mechanical Brake

Control ).

CCW

Illustration 12.7 24 V incremental encoder. Maximum cable length 5 m (16 ft).

MG38C102

Application Examples Design Guide

12 13 18 19 27 29 32 33 20 37

External

24 V DC

Start

I max

0.1 Amp

P 5-40 [0] [32]

Mechanical brake connection

Illustration 12.8 Wire Configuration for Torque and Stop Limit

117

12 12

How to Order a Drive VLT® AutomationDrive FC 302

13 How to Order a Drive

13.1 Drive Configurator

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

F C T

21 22

25 26 27

X X X

28 29

X A

30 31

32 33

34 35 36 37 38 39

13 13

Table 13.1 Type Code String

Product groups 1–3

Drive series

Generation code

Power rating

Phases

Mains Voltage

Enclosure

Enclosure type

Enclosure class

Control supply voltage

Hardware configuration

RFI filter/Low Harmonic Drive/12pulse

Brake

Display (LCP)

Coating PCB

Mains option

Adaptation A

Adaptation B

Software release

Software language

A option

B options

C0 options, MCO

C1 options

C option software

D options

24–27

29–30

31–32

33–34

36–37

38–39

13–15

16–23

16–17

4–6

8–10

Table 13.2 Type Code Example for Ordering a Drive

Configure the correct drive for the proper application by using the internet-based drive configurator. The drive configurator is found on the global internet site: www.danfoss.com/drives . The configurator creates a type code string and an 8-digit sales number, which can be delivered to the local sales office. It is also possible to build a project list with several products and send it to a

Danfoss sales representative.

An example of a type code string is:

FC-302N355T5E20H4BGCXXXSXXXXA0BXCXXXXD0

The meaning of the characters in the string is defined in

Table 13.3

. In the example above, a PROFIBUS DP-V1 and a

24 V back-up option is built-in.

Drives are delivered automatically with a language package relevant to the region from which they are ordered. Four regional language packages cover the following languages:

Language package 1

English, German, French, Danish, Dutch, Spanish, Swedish,

Italian, and Finnish.

Language package 2

English, German, Chinese, Korean, Japanese, Thai,

Traditional Chinese, and Bahasa Indonesian.

Language package 3

English, German, Slovenian, Bulgarian, Serbian, Romanian,

Hungarian, Czech, and Russian.

Language package 4

English, German, Spanish, English US, Greek, Brazilian

Portuguese, Turkish, and Polish.

To order drives with a different language package, contact the local Danfoss sales office.

MG38C102

How to Order a Drive Design Guide

Description

Product group

Drive series

Power rating

Phases

Mains voltage

Enclosure

RFI filter

Brake

Display

Coating PCB

Mains option

Hardware, adaptation A

Hardware, adaptation B

Software release

Position

1–3

4–6

8–10

11–12

13–15

16–17

24–28

Possible option

FC-

302: FC 302

N315: 315 kW (450 hp)

N355: 355 kW (500 hp)

N400: 400 kW (550 hp)

N450: 450 kW (600 hp)

N500: 500 kW (650 hp)

N560: 560 kW (750 hp)

N630: 630 kW (900 hp)

N710: 710 kW (1000 hp)

Three phases (T)

T5: 380–500 V AC

T7: 525–690 V AC

E00: IP00/Chassis (only enclosures E3h/E4h with top regen/loadshare)

E20: IP20/Chassis

E21: IP21/Type 1

E54: IP54/Type 12

E2M: IP21/Type 1 + mains shield

E5M: IP54/Type 12 + mains shield

H21: IP21/Type 1 + space heater

H54: IP54/Type 12 + space heater

C20: IP20/Type 1 + stainless steel back channel

C21: IP21/Type 1 + stainless steel back channel

C54: IP54/Type 12 + stainless steel back channel

C2M: IP21/Type 1 + mains shield + stainless steel back channel

C5M: IP54/Type 12 + mains shield + stainless steel back channel

C2H: IP21/Type 1 + space heater + stainless steel back channel

C5H: IP54/Type 12 + space heater + stainless steel back channel

H2: RFI filter, class A2 (C3)

H4: RFI filter, class A1 (C2)

X: No brake chopper

B: Brake chopper mounted

T: Safe torque off (STO)

U: Brake chopper + safe torque off

R: Regen terminals

S: Brake chopper + regen terminals (only enclosures E3h/E4h)

X: No LCP

G: Graphical LCP (LCP-102)

J: No LCP + USB through the door

L: Graphical LCP + USB through the door

C: Coated PCB

R: Coated PCB 3C3 + ruggedized

X: No mains option

3: Mains disconnect + fuses

7: Fuses

A: Fuses + load share terminals (only enclosures E3h/E4h)

D: Load share terminals (only enclosures E3h/E4h)

X: No option

Q: Heat sink access

SXXX: Latest release - standard software

S067: Integrated motion control software

X: Standard language pack Software language 28

Table 13.3 Ordering Type Code for Enclosures E1h–E4h

119

13 13

How to Order a Drive VLT® AutomationDrive FC 302

13 13

Description

A option

B options

C0/ E0 options

C1 options/ A/B in C option adapter

C option software/E1 options

D options

Position Possible option

29–30 AX: No A option

A0: VLT ® PROFIBUS DP V1 MCA 101

A4: VLT ® DeviceNet MCA 104

A6: VLT ® CANopen MCA 105

A8: VLT ® EtherCAT MCA 124

AT: VLT ® PROFIBUS Converter MCA 113

AU: VLT ® PROFIBUS Converter MCA 114

AL: VLT ® PROFINET MCA 120

AN: VLT ® EtherNet/IP MCA 121

AQ: VLT ® POWERLINK MCA 122

AY: VLT ® Modbus TCP MCA 123

31–32 BX: No option

B2: VLT ® PTC Thermistor Card MCB 112

B4: VLT ® Sensor Input Option MCB 114

B6: VLT ® Safety Option MCB 150

B7: VLT ® Safety Option MCB 151

B8: VLT ® Safety Option MCB 152

BK: VLT ® General Purpose I/O Module MCB 101

BP: VLT ® Relay Card MCB 105

BR: VLT ® Encoder Input MCB 102

BU: VLT ® Resolver Option MCB 103

BY: VLT ® Extended Cascade Controller MCO101

BZ: MCB 108 Safe PLC I/O MCB 108

33–34

36–37

CX: No option

C4: VLT ® Motion Control Option MCO 305

X: No option

R: VLT ® Extended Relay Card MCB 113

XX: No software option

10: VLT ® Synchronizing Controller MCO-350

11: VLT ® Position Controller MCO-351

38–39 DX: No option

D0: VLT ® 24 V DC Supply MCB-107

Table 13.4 Type Code Ordering Options for Enclosures E1h–E4h

MG38C102

How to Order a Drive Design Guide

13.2 Ordering Numbers for Options and Accessories

Type

Miscellaneous hardware

PROFIBUS top entry

USB in the door

Ground bar

Description

Top entry for enclosure protection rating IP54.

USB extension cord kit to allow access to the drive controls via laptop computer without opening the drive.

More grounding points for E1h and E2h drives.

Mains shield, E1h

Mains shield, E2h

Terminal blocks

Shielding (cover) mounted in front of the power terminals to protect from accidental contact.

Screw terminal blocks for replacing spring loaded terminals.

(1 pc 10 pin 1 pc 6 pin and 1 pc 3-pin connectors)

Back-channel cooling kits

In bottom/out top, E3h

In bottom/out top, E4h

In back/out back, E1h

In back/out back, E2h

In back/out back, E3h

In back/out back, E4h

In bottom/out back, E3h

Allows the cooling air to be directed in through the bottom and out through the top of the drive. This kit used only for enclosure E3h with

600 mm (21.6 in) base plate.

Allows the cooling air to be directed in through the bottom and out through the top of the drive. This kit used only for enclosure E3h with

800 mm (31.5 in) base plate.

Allows the cooling air to be directed in through the bottom and out through the top of the drive. This kit used only for enclosure E4h with

800 mm (31.5 in) base plate.

Allows the cooling air to be directed in and out through the back of the drive. This kit used only for enclosures E1h.

Allows the cooling air to be directed in and out through the back of the drive. This kit used only for enclosures E2h.

Allows the cooling air to be directed in and out through the back of the drive. This kit used only for enclosures E3h.

Allows the cooling air to be directed in and out through the back of the drive. This kit used only for enclosures E4h.

Allows the cooling air to be directed in through the bottom and out through the back of the drive. This kit used only for enclosure E3h with 600 mm (21.6 in) base plate.

Allows the cooling air to be directed in through the bottom and out through the back of the drive. This kit used only for enclosure E3h with 800 mm (31.5 in) base plate.

In bottom/out back, E4h

In back/out top, E3h

In back/out top, E4h

Allows the cooling air to be directed in through the bottom and out through the back of the drive. This kit used only for enclosure E4h with 800 mm (31.5 in) base plate.

Allows the cooling air to be directed in through the back and out through the top of the drive. This kit used only for enclosures E3h.

Allows the cooling air to be directed in through the back and out through the top of the drive. This kit used only for enclosures E4h.

LCP

LCP 101

LCP 102

LCP cable

LCP kit, IP21

Numerical local control panel (NLCP).

Graphical Local control panel (GLCP).

Separate LCP cable, 3 m (9 feet).

Panel mounting kit including graphical LCP, fasteners, 3 m (9 feet) cable and gasket.

Panel mounting kit including numerical LCP, fasteners and gasket.

LCP kit, IP21

LCP kit, IP21 Panel mounting kit for all LCPs including fasteners, 3 m (9 feet) cable and gasket.

Options for slot A (Fieldbus Devices)

Ordering number

176F1742

130B1156

176F6609

176F6619

176F6620

130B1116

176F6606

176F6607

176F6608

176F6617

176F6618

176F6610

176F6611

176F6612

176F6613

176F6614

176F6615

176F6616

130B1124

130B1107

175Z0929

130B1113

130B1114

130B1117

Uncoated Coated

13 13

121

How to Order a Drive VLT® AutomationDrive FC 302

13 13

MCA 101

MCA 104

MCA 105

MCA 113

MCA 114

MCA 120

MCA 121

PROFIBUS option DP V0/V1.

DeviceNet option.

CANopen.

PROFIBUS VLT 3000 protocol converter.

PROFIBUS VLT 5000 protocol converter.

PROFINET option.

EtherNet/IP option.

MCA 122

MCA 123

Modbus TCP option.

Powerlink option.

MCA 124 EtherCAT option.

Options for slot B (Functional Extensions)

MCB 101 General-purpose input output option.

MCB 102

MCB 103

MCB 105

MCB 108

MCB 112

MCB 114

MCB 150

MCB 151

Encoder option.

Resolver option.

Relay option.

Safety PLC interface (DC/DC converter).

ATEX PTC thermistor card.

PT100 sensor input.

Safety option (TTL encoder).

Safety option (HTL encoder).

MCB 152 Safety option (PROFIsafe functionality).

Options for slot C (motion control and relay cards)

MCO 305

MCO 350

Programmable motion controller.

Synchronizing controller.

MCO 351

MCB 113

Option for slot D

MCB 107

External options

EtherNet/IP

Positioning controller.

Extended relay card.

24 V DC backup.

Ethernet master.

130B1100

130B1102

130B1103

–

130B1135

130B1119

130B1196

130B1489

130B5546

130B1125

130B1115

130B1127

130B1110

130B1120

–

130B1172

–

130B1134

130B1152

130B1153

130B1164

Uncoated

130B1108

130B1200

130B1202

130B1205

130B1245

130B1246

130B1235

130B1219

130B1296

130B1490

130B5646

130B1212

130B1203

130B1227

130B1210

130B1220

130B1137

130B1272

130B3280

130B3290

130B9860

130B1234

130B1252

120B1253

130B1264

Coated

130B1208

175N2584

Table 13.5 Options and Accessories

Type

PC software

MCT 10

Description

MCT 10 Set-up Software - 1 user.

MCT 10 Set-up Software - 5 users.

MCT 10 Set-up Software - 10 users.

MCT 10 Set-up Software - 25 users.

MCT 10 Set-up Software - 50 users.

MCT 10 Set-up Software - 100 users.

MCT 10 Set-up Software - unlimited users.

Ordering number

130B1000

130B1001

130B1002

130B1003

130B1004

130B1005

130B1006

Table 13.6 Software Options

Options can be ordered as factory built-in options. For information on fieldbus and application option compatibility with older software versions, contact the Danfoss supplier.

MG38C102

How to Order a Drive Design Guide

13.3 Ordering Numbers for Filters and Brake Resistors

Refer to the following design guides for dimensioning specifications and ordering numbers for filters and brake resistors:

•

VLT ® Brake Resistor MCE 101 Design Guide .

•

VLT ® Advanced Harmonic Filters AHF 005/AHF 010 Design Guide .

•

Output Filters Design Guide .

13.4 Spare Parts

Consult the VLT shop or the Drive Configurator ( www.danfoss.com/drives ) for the spare parts that are available for your application.

123

13 13

Appendix VLT® AutomationDrive FC 302

14 Appendix

14 14 kHz

LCP lsb m mA

INV

LIM

M,N

VLT,MAX

VLT,N

D-TYPE

EMC

EMF

ETR

° F f

JOG f

M f

MAX

14.1 Abbreviations and Symbols

60 ° AVM

AEO

AIC

AMA

AWG

° C

CDM f

MIN f

M,N

Hiperface ®

HO hp

HTL

60 ° asynchronous vector modulation

Ampere/AMP

Alternating current

Air discharge

Automatic energy optimization

Analog input

Ampere interrupting current

Automatic motor adaptation

American wire gauge

Degrees Celsius

Circuit breaker

Constant discharge

Complete drive module: The drive, feeding section, and auxiliaries

European conformity (European safety standards)

Common mode

Constant torque

Direct current

Digital input

Differential mode

Drive dependent

Electromagnetic compatibility

Electromotive force

Electronic thermal relay

Degrees Fahrenheit

Motor frequency when jog function is activated

Motor frequency

Maximum output frequency that the drive applies on its output

Minimum motor frequency from the drive

Nominal motor frequency

Frequency converter (drive)

Hiperface ® is a registered trademark by Stegmann

High overload

Horse power

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

Hertz

Rated inverter output current

Current limit

Nominal motor current

Maximum output current

Rated output current supplied by the drive

Kilohertz

Local control panel

Least significant bit

Meter

Milliampere

MCM

MCT mH mm ms msb

VLT

PCB

PCD

PDS

PELV

P m nF

NLCP

NO n s

Online/

Offline

Parameters

P br,cont.

Mille circular mil

Motion control tool

Inductance in milli Henry

Millimeter

Millisecond

Most significant bit

Efficiency of the drive defined as ratio between power output and power input

Capacitance in nano Farad

Numerical local control panel

Newton meter

Normal overload

Synchronous motor speed

Changes to online parameters are activated immediately after the data value is changed

M,N

PM motor

Rated power of the brake resistor (average power during continuous braking)

Printed circuit board

Process data

Power drive system: CDM and a motor

Protective extra low voltage

Drive nominal output power as high overload

(HO)

Nominal motor power

Permanent magnet motor

Process PID PID (proportional integrated differential) regulator that maintains the speed, pressure, temperature, and so on

R br,nom

Nominal resistor value that ensures a brake power on the motor shaft of 150/160% for 1 minute

RCD

Regen

R min

Residual current device

Regenerative terminals

Minimum allowed brake resistor value by the drive

RMS

RPM

R rec s

SCCR

SFAVM

Root average square

Revolutions per minute

Recommended brake resistor resistance of

Danfoss brake resistors

Second

Short-circuit current rating

Stator flux-oriented asynchronous vector modulation

STW

SMPS

THD

LIM

TTL

Status word

Switch mode power supply

Total harmonic distortion

Torque limit

TTL encoder (5 V) pulses - transistor logic

M,N

Nominal motor voltage

Underwriters Laboratories (US organization for the safety certification)

MG38C102

Appendix Design Guide

VVC +

Volts

Variable torque

Voltage vector control plus

Table 14.1 Abbreviations and Symbols

14.2 Definitions

Brake resistor

The brake resistor is a module capable of absorbing the brake power generated in regenerative braking. This regenerative brake power increases the DC-link voltage and a brake chopper ensures that the power is transmitted to the brake resistor.

Break-away torque n s

Torque

Pull-out

Illustration 14.1 Break-away Torque Chart

RPM

Coast

The motor shaft is in free mode. No torque on the motor.

CT characteristics

Constant torque characteristics used for all applications such as conveyor belts, displacement pumps, and cranes.

Initializing

If initializing is carried out ( parameter 14-22 Operation

Mode ), the drive returns to the default setting.

Intermittent duty cycle

An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an off-load period. The operation can be either periodic duty or nonperiodic duty.

Power factor

The true power factor (lambda) takes all the harmonics into consideration and is always smaller than the power factor (cos phi) that only considers the 1 st harmonics of current and voltage.

Uλ x Iλ x cosϕ

Uλ x Iλ

Cos phi is also known as displacement power factor.

Both lambda and cos phi are stated for Danfoss VLT ® drives in

chapter 7.3 Mains Supply .

The power factor indicates to which extent the drive imposes a load on the mains supply.

The lower the power factor, the higher the I

RMS

for the same kW performance.

In addition, a high-power factor indicates that the harmonic currents are low.

All Danfoss drives have built-in DC coils in the DC link to have a high-power factor and reduce the THD on the main supply.

Pulse input/incremental encoder

An external digital sensor used for feedback information of motor speed and direction. Encoders are used for highspeed accuracy feedback and in high dynamic applications.

Set-up

Save parameter settings in 4 set-ups. Change between the

4 parameter set-ups and edit 1 set-up while another set-up is active.

Slip compensation

The drive compensates for the motor slip by giving the frequency a supplement that follows the measured motor load, keeping the motor speed almost constant.

Smart logic Control (SLC)

The SLC is a sequence of user-defined actions executed when the associated user-defined events are evaluated as true by the SLC. ( Parameter group 13-** Smart Logic ).

FC Standard bus

Includes RS485 bus with FC protocol or MC protocol. See parameter 8-30 Protocol .

Thermistor

A temperature-dependent resistor placed where the temperature is to be monitored (drive or motor).

Trip

A state entered in fault situations, such as when the drive is subject to an overtemperature or when it protects the motor, process, or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is canceled. Cancel the trip state by either:

•

Activating reset.

•

Programming the drive to reset automatically.

Do not use trip for personal safety.

Trip lock

A state entered in fault situations when the drive is protecting itself and requires physical intervention. A locked trip can only be canceled by cutting off mains, removing the cause of the fault, and reconnecting the drive. Restart is prevented until the trip state is canceled by activating reset.

VT characteristics

Variable torque characteristics for pumps and fans.

14 14

125

Index VLT® AutomationDrive FC 302

Index

A

Abbreviations...................................................................................... 125

AC brake................................................................................................... 20

Acoustic noise........................................................................................ 86

Active reference.................................................................................... 98

Airflow

Configurations.................................................................................. 26

Rates..................................................................................................... 69

Alarm reset........................................................................................... 111

Altitude..................................................................................................... 70

AMA

Wiring configuration.................................................................... 109

Ambient conditions

Overview............................................................................................. 67

Specifications.................................................................................... 36

Analog

Input specifications......................................................................... 37

Input/output descriptions and default settings................... 77

Output specifications..................................................................... 38

Wiring configuration for speed reference............................ 109

Analog speed reference wiring configuration........................ 109

ATEX monitoring............................................................................ 16, 68

Auto on..................................................................................................... 98

Automatic energy optimization...................................................... 14

Automatic motor adaptation........................................................... 15

Automatic switching frequency modulation............................. 14

B

Back-channel cooling................................................................... 26, 69

Brake resistor

Definition.......................................................................................... 125

Design guide........................................................................................ 4

Formula for rated power............................................................. 124

Ordering............................................................................................ 123

Overview............................................................................................. 31

Selecting............................................................................................. 81

Terminals............................................................................................. 75

Wiring schematic............................................................................. 73

Braking

Capability chart................................................................................ 82

Control with brake function......................................................... 83

Dynamic braking.............................................................................. 20

Electro-magnetic brake................................................................. 21

Electro-mechanical brake........................................................... 116

Limits.................................................................................................... 82

Mechanical holding brake............................................................ 21

Static braking.................................................................................... 21

Use as an alternative brake function......................................... 83

Wiring configuration for mechanical brake......................... 115

Break-away torque............................................................................. 125

C

Cables

Brake..................................................................................................... 75

Cable type and ratings................................................................... 72

Motor cables...................................................................................... 78

Opening............................................................................................... 41

Power connections.......................................................................... 74

Routing................................................................................................ 75

Shielded............................................................................................... 93

Shielding............................................................................................. 74

Specifications............................................................................. 32, 37

Calculations

Brake resistance................................................................................ 82

Braking torque.................................................................................. 83

Harmonic software.......................................................................... 97

Resistor duty cycle........................................................................... 81

Scaled reference............................................................................... 99

Short-circuit ratio............................................................................. 96

THDi...................................................................................................... 95

CANOpen................................................................................................. 27

Capacitor storage................................................................................. 67

CE mark....................................................................................................... 7

Circuit breaker......................................................................... 13, 78, 84

Closed loop....................................................................... 102, 104, 108

Commercial environment................................................................. 90

Common-mode filter.......................................................................... 31

Compliance

Directives............................................................................................... 7

With ADN............................................................................................... 6

Condensation......................................................................................... 67

Conducted emission........................................................................... 89

Control

Characteristics................................................................................... 39

Description of operation............................................................... 98

Structures......................................................................................... 102

Types of............................................................................................. 104

Control card

RS485 specifications....................................................................... 38

Specifications.................................................................................... 40

Control terminals.................................................................................. 76

Controller................................................................................................. 30

Conventions.............................................................................................. 4

Cooling

Dust warning..................................................................................... 67

Overview of back-channel cooling............................................ 26

Requirements.................................................................................... 69

CSA/cUL approval................................................................................... 8

MG38C102

Index Design Guide

Current

Distortion............................................................................................ 95

Formula for current limit............................................................. 124

Fundamental current...................................................................... 95

Harmonic current............................................................................. 95

Internal current control............................................................... 107

Leakage current................................................................................ 84

Mitigating motor.............................................................................. 81

Rated output current................................................................... 124

Transient ground.............................................................................. 84

D

DC brake.................................................................................................. 20

DC bus

Description of operation............................................................... 98

Terminals............................................................................................. 74

Derating.............................................................................. 14, 15, 36, 69

DeviceNet...................................................................................... 27, 122

Digital

Input specifications......................................................................... 37

Input/output descriptions and default settings................... 77

Output specifications..................................................................... 38

Dimensions

E1h exterior........................................................................................ 41

E1h terminal....................................................................................... 45

E2h exterior........................................................................................ 47

E2h terminal....................................................................................... 51

E3h exterior........................................................................................ 53

E3h terminal....................................................................................... 57

E4h exterior........................................................................................ 60

E4h terminal....................................................................................... 64

Product series overview................................................................ 11

Discharge time......................................................................................... 5

Disconnect.............................................................................................. 78

Door clearance...................................................................................... 41

Drive

Clearance requirements................................................................ 69

Configurator.................................................................................... 118

Dimensions of product series...................................................... 11

Power ratings..................................................................................... 11

DU/dt........................................................................................................ 86

Duct cooling........................................................................................... 69

Duty cycle

Calculation.......................................................................................... 81

Definition.......................................................................................... 125

E

EAC mark.................................................................................................... 8

Efficiency

Calculation.......................................................................................... 85

Formula for drive efficiency....................................................... 124

Specifications.................................................................................... 32

Using AMA.......................................................................................... 15

Electromagnetic interference.......................................................... 15

Electro-mechanical brake............................................................... 116

Electronic thermal overload............................................................. 16

Electronic thermal relay (ETR).......................................................... 72

EMC

Compatibility..................................................................................... 92

Directive................................................................................................. 7

General aspects................................................................................ 88

Installation.......................................................................................... 94

Interference........................................................................................ 93

Test results.......................................................................................... 89

Emission requirements....................................................................... 90

Enclosure protection............................................................................. 9

Encoder

Configuration.................................................................................. 116

Definition.......................................................................................... 125

Determining encoder direction............................................... 116

VLT® Encoder Input MCB 102....................................................... 29

Energy efficiency class........................................................................ 36

Environment.................................................................................... 36, 67

ErP directive.............................................................................................. 7

EtherCAT.................................................................................................. 28

EtherNet/IP.............................................................................................. 28

Explosive atmosphere......................................................................... 68

Export control regulations................................................................... 8

Extended relay card............................................................................. 31

Exterior dimensions

E1h......................................................................................................... 41

E2h......................................................................................................... 47

E3h......................................................................................................... 53

E4h......................................................................................................... 60

External alarm reset wiring configuration................................ 111

F

Fans

Required airflow............................................................................... 69

Temperature-controlled fans....................................................... 15

Feedback

Conversion....................................................................................... 102

Handling........................................................................................... 101

Signal................................................................................................. 104

Fieldbus............................................................................................. 27, 75

Filters

Common-mode filter...................................................................... 31

DU/dt filter.......................................................................................... 31

Harmonic filter.................................................................................. 31

Ordering............................................................................................ 123

RFI filter................................................................................................ 92

Sine-wave filter.......................................................................... 31, 74

Flux

Control structure in flux sensorless......................................... 106

Control structure in flux with motor feedback................... 107

Flying start................................................................................ 14, 15, 18

127

Index VLT® AutomationDrive FC 302

Formula

Current limit.................................................................................... 124

Drive efficiency............................................................................... 124

Output current............................................................................... 124

Rated power of the brake resistor........................................... 124

Fourier series analysis......................................................................... 95

Frequency bypass................................................................................. 18

Fuses

For use with power connections................................................ 74

Overcurrent protection.................................................................. 72

Recommendation for mains supply.......................................... 13

Specifications.................................................................................... 78

G

Galvanic isolation................................................................... 15, 38, 92

Gases......................................................................................................... 67

General purpose I/O module........................................................... 28

Gland plate.............................................................................................. 41

Grounding........................................................................................ 15, 84

H

Hand on.................................................................................................... 98

Harmonics

Definition of power factor.......................................................... 125

EN standards...................................................................................... 96

Filter...................................................................................................... 31

IEC standards..................................................................................... 96

Mitigation........................................................................................... 97

Overview............................................................................................. 95

Heat sink

Access panel...................................................................................... 43

Cleaning.............................................................................................. 68

Required airflow............................................................................... 69

Heater

Usage.................................................................................................... 67

Wiring schematic............................................................................. 73

High voltage............................................................................................. 5

High-altitude installation................................................................... 93

Hoisting............................................................................................. 21, 22

Humidity.................................................................................................. 67

I

Immunity requirements..................................................................... 91

Input specifications............................................................................. 37

Installation

Electrical.............................................................................................. 72

Qualified personnel........................................................................... 5

Requirements.................................................................................... 68

Insulation................................................................................................. 81

Inverter..................................................................................................... 98

IP rating...................................................................................................... 9

IT mains.................................................................................................... 85

K

Kinetic back-up...................................................................................... 18

Kits............................................................................................................. 31

Knockout panel..................................................................................... 42

L

Language packages.......................................................................... 118

Leakage current................................................................................ 5, 84

Lifting................................................................................................. 21, 67 see also Hoisting

Load share

Overview............................................................................................. 24

Short-circuit protection................................................................. 13

Terminals...................................................................................... 25, 75

Warning.................................................................................................. 5

Wiring schematic............................................................................. 73

Low voltage

Directive................................................................................................. 7

Public network.................................................................................. 90

Low-speed operation.......................................................................... 69

M

Machinery directive............................................................................... 7

Mains

Drop-out............................................................................................. 18

Fluctuations....................................................................................... 15

Shield...................................................................................................... 5

Specifications.................................................................................... 36

Supply specifications...................................................................... 36

Maintenance.......................................................................................... 68

Marine certification................................................................................ 8

Mechanical brake

Using closed-loop control............................................................. 22

Using open-loop control............................................................... 21

Wiring configuration.................................................................... 115

Modbus.................................................................................................... 28

Modulation.................................................................................... 14, 124

Motion control option........................................................................ 30

MG38C102

Index Design Guide

Motor

Break-away torque definition.................................................... 125

Cables..................................................................................... 74, 78, 84

Class protection................................................................................ 68

Ex-e................................................................................................. 16, 29

Feedback.......................................................................................... 107

Full torque.......................................................................................... 18

Insulation............................................................................................ 81

Leakage current................................................................................ 84

Missing phase detection............................................................... 14

Mitigating bearing currents......................................................... 81

Nameplate.......................................................................................... 17

Output specifications..................................................................... 36

Parallel connection.......................................................................... 79

Rotation............................................................................................... 79

Thermal protection.................................................................. 16, 79

Thermistor wiring configuration.............................................. 114

Wiring schematic............................................................................. 73

Mounting configurations.................................................................. 68

N

NEMA protection rating........................................................................ 9

O

Open loop................................................................................... 102, 103

Operating guide...................................................................................... 4

Options

Enclosure availability...................................................................... 11

Fieldbus............................................................................................... 27

Functional extensions.................................................................... 28

Motion control.................................................................................. 30

Ordering......................................................................... 119, 120, 122

Relay cards.......................................................................................... 30

Ordering................................................................................................ 118

Output

Contactor..................................................................................... 85, 94

Specifications.................................................................................... 38

Switch................................................................................................... 14

Overcurrent protection...................................................................... 72

Overload

Electronic thermal overload......................................................... 16

Issue with harmonics...................................................................... 95

Limits.................................................................................................... 14

Overtemperature............................................................................... 125

Overvoltage

Alternative brake function............................................................ 83

Braking................................................................................................. 31

Protection........................................................................................... 13

P

PELV............................................................................................. 15, 38, 92

Periodic forming................................................................................... 67

PID controller...................................................................... 16, 101, 105

Pigtails...................................................................................................... 92

Point of common coupling............................................................... 95

Positioning controller.......................................................................... 30

Potentiometer.............................................................................. 77, 112

Power

Connections....................................................................................... 74

Factor................................................................................................. 125

Losses................................................................................................... 32

Ratings.......................................................................................... 11, 32

POWERLINK............................................................................................. 28

Preheat..................................................................................................... 18

Process control.................................................................................... 104

PROFIBUS....................................................................................... 27, 122

PROFINET................................................................................................. 27

Programming guide............................................................................... 4

Protection

Brake function................................................................................... 13

Enclosure rating................................................................................ 11

Motor thermal................................................................................... 16

Overcurrent........................................................................................ 72

Overload.............................................................................................. 14

Overvoltage....................................................................................... 13

Short circuit........................................................................................ 13

Supply voltage imbalance............................................................ 14

PTC thermistor card............................................................................. 29

Pulse

Input specifications......................................................................... 38

Wiring configuration for start/stop......................................... 110

Q

Qualified personnel................................................................................ 5

R

Radiated emission................................................................................ 89

Radio frequency interference.......................................................... 15

RCM mark................................................................................................... 8

Rectifier.................................................................................................... 98

Reference

Active reference................................................................................ 98

Remote handling of........................................................................ 99

Remote reference............................................................................. 99

Speed input..................................................................................... 109

Regen

Availability.......................................................................................... 11

Overview............................................................................................. 25

Terminals............................................................................................. 45

Relay

ADN-compliant installation............................................................ 6

Card....................................................................................................... 30

Extended relay card option.......................................................... 31

Option.................................................................................................. 29

Specifications.................................................................................... 39

Terminals............................................................................................. 77

Remote reference................................................................................. 99

Residential environment.................................................................... 90

Residual current device............................................................... 83, 84

129

Index VLT® AutomationDrive FC 302

Resistor brake......................................................................................... 20

Resolver option..................................................................................... 29

Resonance damping............................................................................ 15

Restart....................................................................................................... 18

RFI

Filter...................................................................................................... 92

Location of E3h shield termination........................................... 56

Location of E4h shield termination........................................... 63

Using switch with IT mains........................................................... 85

Rise time.................................................................................................. 86

Rotor.......................................................................................................... 14

RS485

FC standard bus............................................................................. 125

Terminals............................................................................................. 76

Wiring configuration.................................................................... 113

Wiring schematic............................................................................. 73

S

Safe PLC interface option.................................................................. 29

Safe Torque Off

Design guide........................................................................................ 4

Machinery directive compliance.................................................. 7

Overview............................................................................................. 19

Terminal location............................................................................. 77

Wiring configuration.................................................................... 110

Wiring schematic............................................................................. 73

Safety

Instructions.................................................................................... 5, 72

Options................................................................................................ 29

Scaled reference.................................................................................... 99

Sensor input option............................................................................. 29

Serial communication......................................................................... 76

Shielding

Cables................................................................................................... 74

Mains....................................................................................................... 5

RFI termination................................................................................. 56

Twisted ends...................................................................................... 92

Short circuit

Braking.......................................................................................... 20, 83

Definition.......................................................................................... 125

Ratio calculation............................................................................... 96

SCCR rating......................................................................................... 78

Short-circuit protection................................................................. 13

Sine-wave filter............................................................................... 31, 74

Slip compensation............................................................................. 125

Smart logic control

Overview............................................................................................. 18

Wiring configuration.................................................................... 114

Software versions............................................................................... 122

Spare parts............................................................................................ 123

Speed

Control............................................................................................... 104

PID feedback................................................................................... 104

Wiring configuration for speed reference............................ 112

Wiring configuration for speed up/down............................. 112

Start/stop wiring configuration.......................................... 110, 111

STO............................................................................................................... 4 see also Safe Torque Off

Storage..................................................................................................... 67

Switches

A53 and A54................................................................................ 37, 77

Disconnect.......................................................................................... 78

Switching frequency

Derating........................................................................................ 14, 70

Power connections.......................................................................... 74

Sine-wave filter.......................................................................... 31, 74

Use with RCDs................................................................................... 84

Synchronizing controller.................................................................... 30

T

Temperature.................................................................................... 67, 70

Terminal dimensions

E1h......................................................................................................... 45

E2h......................................................................................................... 51

E3h......................................................................................................... 57

E4h......................................................................................................... 64

Terminals

Analog input/output...................................................................... 77

Brake resistor..................................................................................... 75

Control descriptions and default settings.............................. 76

Digital input/output........................................................................ 77

Load share.......................................................................................... 75

Relay terminals.................................................................................. 77

RS485.................................................................................................... 76

Serial communication.................................................................... 76

Terminal 37......................................................................................... 77

Thermistor

Cable routing..................................................................................... 75

Definition.......................................................................................... 125

Terminal location............................................................................. 77

Wiring configuration.................................................................... 114

Torque

Characteristic..................................................................................... 36

Control............................................................................................... 104

Wiring configuration for torque and stop limit.................. 116

Transducer............................................................................................... 77

Transformer............................................................................................ 95

Trip

Definition.......................................................................................... 125

Points for 380–500 V drives.......................................................... 32

Points for 525–690 V drives.......................................................... 34

TUV certificate.......................................................................................... 8

Type code.............................................................................................. 118

U

UKrSEPRO certificate.............................................................................. 8

Enclosure protection rating............................................................ 9

Listing mark.......................................................................................... 8

USB specifications................................................................................ 40

MG38C102

Index Design Guide

User input................................................................................................ 98

V

Voltage imbalance............................................................................... 14

VVC+.............................................................................................. 105, 107

W

Warnings............................................................................................. 5, 72

Wires.......................................................................................................... 72 see also Cables

Wiring schematic.................................................................................. 73

131

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130R0797 MG38C102 *MG38C102* 05/2017

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