Danfoss VLT Decentral Drive FCD 302 Operating Guide

Operating Guide

VLT® Decentral Drive FCD 302

vlt-drives.danfoss.com


Operating Guide

Contents

1

Introduction

1.1

Purpose of this Operating Guide

1.2

Additional Resources

1.3

1.4

1.5

1.6

Manual and Software Version

Product Overview

1.4.1

1.4.2

Intended Use

Exploded Views

1.4.3

Block Diagram of the Drive

Type Approvals and Certifications

CE Declaration

2

Safety

2.1

Safety Precautions

3

Mechanical Installation

3.1

Unpacking

3.1.1

Items Supplied

3.2

3.3

3.1.2

Storage

Installation Environment

Mounting

3.3.1

Cooling

3.3.2

3.3.3

Recommended Tools and Equipment

Mounting

3.3.3.1

3.3.3.2

Mounting the Installation Box

Installing the Inverter Part

4

4.3

4.4

4.5

4.6

4.7

Electrical Installation

4.1

Safety Instructions

4.2

EMC-compliant Installation

4.8

Grounding

Wiring Schematic

Location of Terminals

Terminal Types

Connecting the Motor

4.7.1

Grounding Shielded Cable

4.7.2

Connecting Several Motors

Connecting AC Mains

4.8.1

Connecting the Drive to Mains

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Contents

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Operating Guide

4.9

Motor and Mains Connection with Service Switch

4.10

Control Terminals

4.10.1

Control Wiring

4.10.2

Terminal Functions

4.10.3

Brake Resistor

4.10.4

Mechanical Brake

4.10.5

Connection of Sensors/Actuators on M12 Sockets

4.10.6

DIP Switches

4.10.7

Safe Torque Off (STO)

4.10.8

RS485 Serial Communication

4.10.8.1

Connecting and Setting Up RS485

4.11

Installation Checklist

5

Commissioning

5.1

Safety Instructions

5.1.1

Before Applying Power

5.2

5.3

5.4

5.5

5.6

5.7

5.3.1

5.3.2

5.3.3

5.3.4

Applying Power

Local Control Panel Operation

Local Control Panel

LCP Layout

Parameter Settings

Uploading/Downloading Data to/from the LCP

5.3.5

5.3.6

Changing Parameter Settings

Restoring Default Settings

5.3.6.1

5.3.6.2

Recommended Initialization

Manual Initialization

Basic Operational Programming

Automatic Motor Adaptation (AMA)

5.5.1

Running AMA

Local-control Test

System Start-up

6

Maintenance, Diagnostics and Troubleshooting

6.1

Maintenance and Service

6.2

6.3

6.4

6.5

6.6

Cleaning

Frontal LEDs

Status Display

Status Message Definitions

Warning and Alarm Types

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Operating Guide

6.7

6.8

Warning and Alarm Displays

List of Warnings and Alarms

7

Specifications

7.1

Electrical Data

7.2

Mains Supply (L1, L2, L3)

7.3

7.4

7.5

7.6

7.7

7.8

7.6.6

7.6.7

7.6.8

7.6.9

7.6.2

7.6.3

7.6.4

7.6.5

Motor Output and Motor Data

7.3.1

Motor Output (U, V, W)

7.3.2

Torque Characteristics

Ambient Conditions

7.4.1

Environment

Cable Lengths and Cross-sections

Control Input/Output and Control Data

7.6.1

Digital Inputs

STO Terminal 37 (Terminal 37 is Fixed PNP Logic)

Analog Inputs:

Pulse/Encoder Inputs

Digital Outputs

Analog Output

Control Card, 24 V DC Output

Control Card, +10 V DC Output

Control Card, RS485 Serial Communication

7.6.10

Control Card, USB Serial Communication

7.6.11

Relay Outputs

7.6.12

Control Card Performance

7.6.13

Control Characteristics

Fuses and Circuit Breakers

7.7.1

Recommendations

7.7.2

Recommended Maximum Pre-fuse Size 25 A

Mechanical Dimensions

8

Appendix

8.1

Symbols, Abbreviations and Conventions

8.1.1

Symbols and Abbreviations

8.2

Quick Menu Parameters


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Operating Guide Introduction

1 Introduction

1.1 Purpose of this Operating Guide

This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified personnel.

Read and follow the instructions to use the drive safely and professionally.

Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive.

VLT

®

is a registered trademark for Danfoss A/S.

1.2 Additional Resources

Other resources are available to understand advanced drive functions and programming.

•

•

The VLT® Decentral DriveFCD 302 Design Guide provides detailed information about capabilities and functionality to design motor control systems.

The VLT® AutomationDrive FC 301/302 Programming Guide provides greater detail on working with parameters and many application examples.

• Instructions for operation with optional equipment.

Supplementary publications and manuals are available at www.danfoss.com

.

1.3 Manual and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome.

Table 1: Manual and Software Version

Edition Remarks Software version

AQ267036816112, version 0201 Editorial update 8.5X

1.4 Product Overview

1.4.1 Intended Use

The drive is an electronic motor controller intended for:

• Regulation of motor speed in response to system feedback or to remote commands from external controllers. A power-drive system consists of the drive, the motor, and equipment driven by the motor.

System and motor status surveillance.

•

The drive can also be used for motor protection.

Depending on the configuration, the drive can be used in standalone applications or form part of a larger appliance or installation.

The VLT® Decentral Drive FCD 302 is designed for decentral mounting, for example, in the food and beverage industry, or for other material handling applications. With the FCD 302, it is possible to reduce costs by placing the power electronics decentrally. Central panels are then rendered obsolete, saving cost, space, and effort for installation and wiring. The basic design is service-friendly with a pluggable electronic part and a flexible and spacious wiring box. It is easy to change electronics without the need for rewiring.

Installation environment: The drive is allowed for use in residential, industrial, and commercial environments in accordance with local laws and standards.

N O T I C E

RADIO INTERFERENCE

-

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

Take the necessary precautions.

Foreseeable misuse

Do not use the drive in applications which are non-compliant with specified operating conditions and environments.

Ensure compliance with the conditions specified in

7.4.1 Environment

.

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Operating Guide

1.4.2 Exploded Views

1

2

5

6

9

10

Illustration 1: Exploded View Small Unit


8

Introduction

AQ267036816112en-000201 / 130R0208 | 7

3

4

7


Operating Guide

3

4

1

2

5

Inverter part

Fastening screws (4 x, 1 in each corner)

Sealing gasket

Inverter part plastic cover

Ground connection pin

Introduction

8

9

6

7

10

Installation box

Display connection

Access to USB port

Service switch-motor side (alternatively, switch located on mains side, or not mounted)

Flat mounting brackets

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Operating Guide

1

2

5

6

9

10

Illustration 2: Exploded View Large Unit


8

Introduction

AQ267036816112en-000201 / 130R0208 | 9

3

4

11

7


Operating Guide Introduction

3

4

1

2

5

6

Inverter part

Fastening screws (4 x, 1 in each corner)

Sealing gasket

Inverter part plastic cover

Ground connection pin

Installation box

7

8

9

10

11

Display connection

Access to USB port

Service switch (1) motor side (alternatively, switch located on mains side, or not mounted)

Flat mounting brackets

Circuit breaker (1) (optional)

1 The unit can be configured with either service switch or circuit breaker, not both. The illustration shown is not configurable in practice, but shows the respective positions of components only.

1.4.3 Block Diagram of the Drive

Illustration 3: Block Diagram

1

2

3

4

•

Mains input

3-phase AC mains power supply to the drive.

•

Rectifier

The rectifier bridge converts the AC input to DC current to supply inverter power.

•

DC bus

Intermediate DC-bus circuit handles the DC current.

•

•

•

•

•

DC reactors

Filter the intermediate DC circuit voltage.

Prove line transient protection.

Reduce RMS current.

Raise the power factor reflected back to the line.

Reduce harmonics on the AC input.

5

6

7

8

•

•

Capacitor bank

Stores the DC power.

Proves ride-through protection for short power losses.

•

Inverter

Converts the DC into a controlled PWM AC waveform for a controlled variable output to the motor.

•

Output to motor

Regulated 3-phase output power to the motor.

•

•

•

Control circuitry

Input power, internal processing, output, and motor current are monitored to provide efficient operation and control.

User interface and external commands are monitored and performed.

Status output and control can be provided.

1.5 Type Approvals and Certifications

The following list is a selection of possible type approvals and certifications for Danfoss drives:

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Operating Guide

Table 2: Type Approvals and Certifications

Introduction

089

N O T I C E

The specific approvals and certification for the drive are on the nameplate of the drive. For more information, contact the local

Danfoss office or partner.


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Operating Guide

1.6 CE Declaration

Introduction

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Operating Guide Safety

2 Safety

2.1 Safety Precautions

W A R N I N G

-

HIGH VOLTAGE

AC drives contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation, start-up, and maintenance by qualified personnel can result in death or serious injury.

Only qualified personnel must perform installation, start-up, and maintenance.

W A R N I N G

UNINTENDED START

When the drive is connected to the AC mains, the motor may start at any time, causing risk of death, serious injury, and equipment or property damage. The motor may start by activation of an external switch, a fieldbus command, an input reference signal

-

-

from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condition.

Press [Off] on the LCP before programming parameters.

Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended motor start.

Check that the drive, motor, and any driven equipment are in operational readiness.

W A R N I N G

-

-

-

-

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 indicator lights are off.

Failure to wait the specified time after power has been removed before performing service or repair work could result in death or serious injury.

Stop the motor.

Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and

DC-link connections to other drives.

Wait for the capacitors to discharge fully. The time for full discharge of the capacitors is minimum 4 minutes for VLT® Decentral Drive FCD 302, 400 V AC, 0.37–3.0 kW (0.5–4.0 hp).

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

C A U T I O N

-

INTERNAL FAILURE HAZARD

An internal failure in the drive can result in serious injury when the drive is not properly closed.

Ensure that all safety covers are in place and securely fastened before applying power.


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Operating Guide Mechanical Installation

3 Mechanical Installation

3.1 Unpacking

•

3.1.1 Items Supplied

The packaging contains:

Accessories bag, supplied only with order of installation box. The bag contains:

-

-

-

2 cable clamps.

Bracket for motor/loads cables.

Elevation bracket for cable clamp.

Screw 4 mm, 20 mm.

•

•

•

•

Thread forming 3.5 mm, 8 mm.

Operating Guide.

Drive.

Depending on options fitted, the box contains 1 or 2 bags and 1 or more booklets.

Make sure that the items supplied and the information on the nameplate correspond to the order confirmation.

Check the packaging and the drive visually for damage caused by inappropriate handling during shipment. File any claim for damage with the carrier. Retain damaged parts for clarification.

6

7

4

5

1

2

9

1

2

3

4

5

VLT®

Decentral Drive www.danfoss.com

Enclosure rating:

Type 4X Indoor Use Only

LISTED E134261 76X1 IND. CONT. EQ.

10

T/C: FCD302P1K5T4W66H1X1XMFCFXXXXA0BXXXXXXDX

P/N: 131Z5118 S/N: 000000G000

1.5kW(400V) / 2.0HP(460V) 3

IN: 3x380-480V 50/60Hz, 3.7/3.1A

OUT: 3x0-Vin 0-590Hz, 4.1/3.4A

IP66 Enclosure Tamb. 40 ˚C/104 ˚F

8

Danfoss A/S

6430 Nordborg

Denmark

MADE IN DENMARK

* 1 3 1 Z 5 1 1 8 0 0 0 0 0 0 G 0 0 0 *

Type code

Ordering number

Serial number

Power rating

Input voltage, frequency, and current (at low/high voltages)

6

7

8

9

10

Output voltage, frequency, and current (at low/high voltages)

Enclosure type and IP rating

Maximum ambient temperature

Certifications

Enclosure rating

N O T I C E

LOSS OF WARRANTY

Do not remove the nameplate from the drive.

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3.1.2 Storage

Ensure that the requirements for storage are fulfilled, see

7.4.1 Environment

.

3.2 Installation Environment

N O T I C E

-

REDUCED LIFETIME

In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/Type rating of the equipment matches the installation environment. Failure to meet requirements for ambient conditions can reduce lifetime of the drive.

Ensure that requirements for air humidity, temperature, and altitude are met.

Vibration and shock

The drive complies with requirements for units mounted on the walls and floors of production premises, and in panels bolted to walls or floors. For detailed ambient conditions, refer to

7.4.1 Environment

.

3.3 Mounting

•

•

3.3.1 Cooling

The VLT® Decentral DriveFCD 302 has no forced cooling. It relies only on natural convection for cooling using the cooling fins.

A minimum of 100 mm (4 in) top and bottom air cooling clearance must be provided.

Derating starts above 40 °C (104 °F) and 1000 m (3280 ft) elevation above sea level. See the VLT® Decentral DriveFCD 302 Design

Guide for detailed information.

100 (4)

100 (4)

100 (4)

100 (4)

Illustration 4: Top and Bottom Cooling Clearance


AQ267036816112en-000201 / 130R0208 | 15



3.3.2 Recommended Tools and Equipment

Table 3: Recommended Tools and Equipment

Equipment Size

Screwdrivers

Socket (Hex)

–

8

Slotted

Slotted/Torx

Spanner

LCP, ordering number 130B1078

LCP cable, ordering number 130B5776

0.4x2.5

1.0x5.5/TX20

19, 24, 28

–

–

3.3.3 Mounting

The VLT® Decentral DriveFCD 302 consists of 2 parts:

•

• Installation box

Electronic part

See

1.4.2 Exploded Views .

Description

–

For fastening inverter screws/mounting of brackets

For spring loaded power and control terminals

For cable clamps inside the installation box

For blind-plugs

Local control panel

Connection cable for local control panel

Illustration 5: Allowed Mounting Positions - Standard Applications

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Illustration 6: Allowed Mounting Positions - Hygienic Applications

3.3.3.1 Mounting the Installation Box

W A R N I N G

-

ELECTRICAL HAZARD

Applying power to the unit at this stage could result in death or serious injury.

Do not apply power before the electrical installation is complete.

W A R N I N G

-

-

PERSONAL INJURY OR PROPERTY DAMAGE

Do not switch on the mains before the 4 screws are tightened. Failure to tighten these screws can result in personal injury or material damage when the unit is loaded.

Tighten screws before switching on power.

Ensure that the strength of the mounting location can support the unit weight.

•

•

•

Use the holes on the rear of the installation box to fix mounting brackets.

Use proper mounting screws or bolts.

For hygienic versions, use cable glands designed to meet hygienic application requirements, for example Rittal HD

2410.110/120/130.


AQ267036816112en-000201 / 130R0208 | 17



1.

Example

Mount the VLT® Decentral DriveFCD 302 vertically on a wall or machine frame. For hygienic versions ensure that liquids drain off the enclosure and orient the unit so the cable glands are located at the base.

Illustration 7: FCD 302 Standalone Mounted with Mounting Brackets

3.3.3.2 Installing the Inverter Part

Procedure for compressing the gasket between the 2 parts.

Procedure

1.

2.

Tighten the 4 connection screws to torque 2.8–3.0 Nm (24–26 in-lb).

Tighten the 4 screws in diagonally opposite order.

3.

Tighten the 2 grounding spears to torque 3.0 (26 in-lb).

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Operating Guide Electrical Installation

4 Electrical Installation

4.1 Safety Instructions

See 2.1 Safety Precautions for general safety instructions.

W A R N I N G

-

-

INDUCED VOLTAGE

Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned off and locked out. Failure to run output motor cables separately or to 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.

W A R N I N G

SHOCK HAZARD

The unit can cause a DC current in the PE conductor. Failure to use a Type B residual current-operated protective device (RCD)

may lead to the RCD not providing the intended protection and therefore may result in death or serious injury.

When an RCD is used for protection against electrical shock, only a Type B device is allowed on the supply side.

•

•

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 not factory-supplied, the installer must provide fuses. See maximum fuse ratings in

7.7.2 Recommended Maximum Pre-fuse Size 25 A .

•

•

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 wire sizes and types.

7.1 Electrical Data for recommended

4.2 EMC-compliant Installation

To obtain an EMC-compliant installation, follow the instructions provided in 4.3 Grounding

,

4.4 Wiring Schematic ,

4.7 Connecting the Motor

, and

4.10.1 Control Wiring .

N O T I C E

POTENTIAL EQUALIZATION

Risk of burst transient when the ground potential between the drive and the control system is different. Install equalizing cables between the system components. Recommended cable cross-section: 16 mm 2 (6 AWG).

•

•

•

•

•

•

4.3 Grounding

For electrical safety

Ground the drive in accordance with applicable standards and directives.

Use a dedicated ground wire for input power, motor power, and control wiring.

Do not ground 1 drive to another in a daisy chain fashion.

Keep the ground wire connections as short as possible.

Follow motor manufacturer's wiring requirements.

Minimum cable cross-section: 10 mm 2 (7 AWG) (or 2 rated ground wires terminated separately).

For EMC-compliant installation


AQ267036816112en-000201 / 130R0208 | 19



•

•

•

Establish electrical contact between the cable shield and the drive enclosure by using metal cable glands or by using the clamps provided on the equipment.

Use high-strand wire to reduce electrical interference.

Do not use pigtails.

N O T I C E

POTENTIAL EQUALIZATION

Risk of burst transient when the ground potential between the drive and the control system is different. Install equalizing cables between the system components. Recommended cable cross-section: 16 mm 2 (6 AWG).

C A U T I O N

PE CONNECTION

The metal pins in the corners of the electronic part and the holes on the corner of the installation box are essential for the protective earth connection. Make sure that they are not loosened, removed, or violated in any way. Tightening torque requirement is

3 Nm (26.6 in-lb).

Illustration 8: PE Connection Between the Installation Box and the Electronic Part

N O T I C E

The external grounding terminal is available as an accessory (ordering number 130B5833).

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Operating Guide

4.4 Wiring Schematic


3-phase power input

Mechanical brake

+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)

122(MBR+)

123(MBR-)

50 (+10 V OUT)

S201

53 (A IN)

S202

54 (A IN)

ON/I=0-20mA

OFF/U=0-10V

Switch mode power supply

10 V DC

15 mA

24 V DC

600 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)

P 5-00

24 V (NPN)

0 V (PNP)

24 V (NPN)

0 V (PNP)

24 V (NPN)

0 V (PNP)

S801

ON=Terminated

OFF=Open

(U) 96

(U) 97

(W) 98

(PE) 99

(R+) 82

(R-) 81

Relay1

03

02

Relay2

01

06

05

04

0 V

(COM A OUT) 39

(A OT) 42

5V

29 (D IN/OUT)

24V

24 V (NPN)

0 V (PNP)

32 (D IN)

33 (D IN)

37 (D IN)

OV

24 V (NPN)

0 V (PNP)

24 V (NPN)

0 V (PNP)

Brake resistor

240 V AC, 2A

240 V AC, 2A

400 V AC, 2A

Analog output

0/4–20 mA

RS485

Interface

S801

GX

(N RS485) 69

(P RS485) 68

(COM RS485) 61

GX

RS485

(PNP) = Source

(NPN) = Sink

Motor

VCXA

PROFIBUS interface

67

GND1

62

63

66

RS485

GND1

Illustration 9: Basic Wiring Schematic


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Operating Guide

2

1

L1

L2

L3

PE

1 L1

3 L2

5 L3

33 NO

41 NC

T1 2

T2 4

T3 6

NO 34

NC 42

L1

91

L2

92

L3

93

12

27

U

96

V

97

W

98

Illustration 10: Large Unit only: Circuit Breaker and Mains Disconnect

1

2

Looping terminals

Circuit breaker

1

L1

L2

L3

PE

1

3

5

7

2

4

6

8

L1

91

L2

92

L3

93

12

27

U

96

V

97

W

98

U

V

W

Illustration 11: Large Unit only: Service Switch at Mains with Looping Terminals

1 Looping terminals


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Operating Guide

4.5 Location of Terminals

4 2 1 3 11 12


5

13

6

13

7 8

Illustration 12: Location of Terminals (Small Unit)

1

4

5

2

3

6

7

Digital and analog inputs/outputs

Safe Torque Off (STO), LCP connection, B-option

Relay 1

Relay 12

Motor, mechanical brake, brake resistor

Mains

24 V DC back-up input

13 9

10

8

9

10

11

12

13

USB port

Standard bus/RS485

PROFIBUS

Ethernet port

Ethernet port

Protective Earth (PE)


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Operating Guide

4 2 1 3 11 12 13

5

13


6

7 8

Illustration 13: Location of Terminals (Large Unit)

13 9 10

1

4

5

2

3

6

7

Digital and analog inputs/outputs

Safe Torque Off (STO), LCP connection, B-option

Relay 1

Relay 12

Motor, mechanical brake, brake resistor

Mains

24 V DC back-up input

8

9

10

11

12

13

USB port

Standard bus/RS485

PROFIBUS

Ethernet port

Ethernet port

Protective Earth (PE)

For both small and large units, the service switch is optional. The switch is shown mounted on the motor side. Alternatively, the switch can be on the mains side or omitted.

For the large unit, the circuit breaker is optional. The large unit can be configured with either service switch or circuit breaker, not both. The illustration shown is not configurable in practice, but shows the respective positions of components only.

4.6 Terminal Types

Motor, control, and mains terminals are spring loaded (CAGE-CLAMP) type.

1.

Open the contact by inserting a small screwdriver into the slot above the contact, as shown in

Illustration 14 .

2.

3.

Insert the stripped wire into the contact.

Remove the screwdriver to fasten the wire into the contact.

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4.

Example

Ensure that the contact is firmly established and not loose. Loose wiring can result in equipment faults or injury.

Illustration 14: Opening the Terminals

4.7 Connecting the Motor

W A R N I N G

INDUCED VOLTAGE

Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned

-

off and locked out. Failure to run output motor cables separately or to 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.

U

U1

W2

U1

N O T I C E

MOTOR PROTECTION

Protection against motor overload is not included in the factory setting. If this function is desired, set parameter 1-90 Motor Ther-

mal Protection to trip or warning. Refer to the VLT® AutomationDrive FC 301/FC 302 Programming Guide for further information.

For correct dimensioning of cable cross-section, see 7.1 Electrical Data .

Table 4: Terminals 96, 97, 98

Terminal

96 97 98

V

V1

U2

V1

W

W1

V2

W1

Motor voltage 0–100% of mains voltage

3 wires out of motor



6 wires out of motor, star connected. Connect U2, V2, W2


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Terminal

PE separately (optional terminal block)

Ground connection

N O T I C E

Do not install power factor correction capacitors between the drive and the motor. Do not wire a starting or pole-changing device between the drive and the motor.

1.

2.

3.

Connect the motor to terminals 96, 97, 98.

Connect ground to PE terminal.

Make sure that the shield of the motor cable is properly grounded at both ends (motor and drive).

4.7.1 Grounding Shielded Cable

Grounding clamps are provided for motor and control wiring.

Illustration 15: Grounding Clamp for Motor and Control Wiring (Small Unit)

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Illustration 16: Grounding Clamp for Motor and Control Wiring (Large Unit)

Procedure

1.

Use a wire stripper to remove the insulation for proper grounding.

2.

3.

Secure the grounding clamp to the stripped portion of the wire with the screws provided.

Secure the grounding wire to the grounding clamp provided.

4.7.2 Connecting Several Motors

The drive can control several parallel-connected motors. The total current consumption of the motors must not exceed the rated output current I

M,N

for the drive.

N O T I C E

Installations with cables connected in a common joint are only recommended for short cable lengths (maximum 10 m (38.2 ft)).

When motors are connected in parallel, parameter 1-29 Automatic Motor Adaptation (AMA) cannot be used.

N O T I C E

The electronic thermal relay (ETR) of the drive cannot be used as motor protection for the individual motor in systems with parallel-connected motors. Provide further motor protection by thermistors in each motor or individual thermal relays. Circuit breakers are not suitable as protection.


AQ267036816112en-000201 / 130R0208 | 27



Illustration 17: Parallel Connection of Motors

•

•

Problems can arise at start-up and at low RPM values when motor sizes differ widely. Motors of low rated motor power have a relatively high ohmic resistance in the stator. This high resistance calls for a higher voltage at start and at low RPM values. To resolve such a problem:

Reduce the load during start-up on the motor of lowest rated motor power.

Configure parallel connections only between motors of comparable rated motor power.

•

•

4.8 Connecting AC Mains

Size the wiring based on the input current of the drive. For maximum wire sizes, see

7.1 Electrical Data

.

Comply with local and national electrical codes for cable sizes.

91

L1

PE

4.8.1 Connecting the Drive to Mains

Table 5: Terminals 91, 92, and 93

Terminals

92

L2

93

L3

Mains voltage 3x380–480 V

Ground connection

Procedure

1.

2.

Connect the 3-phase AC input power wiring to terminals L1, L2, and L3.

Depending on the configuration of the equipment, connect the input power to the mains input terminals or the input disconnect.

3.

4.

Ground the cable in accordance with the grounding instructions, see

4.3 Grounding and

4.7.1 Grounding Shielded Cable

.

When supplied from an isolated mains source (IT mains or floating delta) or TT/TN-S mains with a grounded leg (grounded delta), ensure that parameter 14-50 RFI Filter is set to [0] Off . This setting prevents damage to the DC link and reduces ground capacity currents in accordance with IEC 61800-3.

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Operating Guide

4.9 Motor and Mains Connection with Service Switch


Illustration 18: Motor and Mains Connection with Service Switch

4.10 Control Terminals

4.10.1 Control Wiring

W A R N I N G

-

-

-


When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death, serious injury, and equipment or property damage. The motor may start by activation of an external switch, a fieldbus command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condition.




•

•

•

It is recommended that control wiring is rated for 600 V.

Isolate control wiring from high-power components in the drive.

If the drive is connected to a thermistor, for PELV isolation, ensure that control wiring is reinforced/double insulated.

4.10.2 Terminal Functions

Table 6: Terminal Functions

Terminal

Number

Functions

01, 02, 03

04, 05, 06

Relay 1 output. Usable for AC or DC voltage and resistive or inductive loads.

Relay 2 output. Usable for AC or DC voltage and resistive or inductive loads.

12, 13 24 V DC digital supply voltage. Useable for digital inputs and external transducers. To use the 24 V DC for digital input common, programme parameter 5-00 Digital I/O Mode for PNP operation.

18, 19, 32, 33 Digital inputs. Selectable for NPN or PNP function in parameter 5-00 Digital I/O Mode . Default is PNP.


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35

36

37

20

Terminal

Number

27, 29

Functions

55

61

39

42

50

53, 54

68 (+), 69 (-)

62

63

66

67

B01-B12

G, R, V, N, P

Digital inputs or outputs. Program parameter 5-01 Terminal 27 Mode for terminal 27 and parameter 5-02 Terminal

29 Mode for terminal 29 for selecting the input/output functions. Default setting is input.

Common (-) for external 24 V control back-up supply. Optional.

External + 24 V control back up supply. Optional.

Safe Stop.

Common for digital inputs. To use for digital input common, programme parameter 5-00 Digital I/O Mode for

NPN operation.

Common for analog output.

Analog output. Programmable for various functions in parameter group 6-5* Analog Output 1 . The analog signal is 0–20 mA or 4–20 mA at a maximum of 500 Ω.

10 V DC analog supply voltage. 15 mA maximum commonly used for a potentiometer or thermistor.

Analog input. Selectable for voltage (0 to ±10 V) or current (0 or 4 to ± 20 mA). Closed is for current and open is for voltage. Switches are located on the drive control card.

See

4.10.6 DIP Switches

.

Common for analog inputs.

Common for serial communication (RS485 interface).

See

4.3 Grounding .

RS485 interface. When the drive is connected to an RS485 serial communication bus, a switch on the control card is provided for termination resistance. Set the switch to ON for termination and OFF for no termination.

RxD/TxD –P (red cable) for PROFIBUS. See dedicated literature for VLT® PROFIBUS DP V1 MCA 101) for details.

RxD/TxD –N (green cable) for PROFIBUS.

0 V for PROFIBUS.

+5 V for PROFIBUS.

B-option. See dedicated literature for details.

Connection of LCP.

4.10.3 Brake Resistor

Table 7: Brake Resistor Terminals

Terminal

81 (optional function)


Function

R-

R+

Brake resistor terminals

•

•

The connection cable to the brake resistor must be shielded/armored. Connect the shield to the metal cabinet of the drive and to the metal cabinet of the brake resistor with cable clamps.

Dimension the cross-section of the brake cable to match the brake torque.

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4.10.4 Mechanical Brake

Table 8: Terminals 122 and 123

Number Function



MBR+

MBR-

•

•

In hoisting/lowering applications, control of electro-mechanical brake is required:

The brake is controlled using the special mechanical brake control/supply terminals 122 and 123.

Select brake.

[32] Mechanical brake control in parameter group 5-4* Relays , [1] Array, Relay 2 for applications with an electro-mechanical

•

• 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] . The brake engages only when the drive performs a stop command.

When the drive enters alarm mode or is exposed to an overvoltage situation, the mechanical brake immediately cuts in. For more detailed information, refer to the VLT® AutomationDrive FC 301/FC 302 Programming Guide.

N O T I C E

When the mechanical brake control/supply terminals 122 and 123 are set through parameter group 5–4* Relays , [1] Array , Relay 2 , only 1 relay output (Relay 1) is available for free programming.

1

3

4

4.10.5 Connection of Sensors/Actuators on M12 Sockets

Table 9: 4 x M12 Connection Input

Pin Wire color Terminal

Brown

Blue

Black

12

20

18, 19, 32, 33

Table 10: 2 x M12 Connection Output

Pin Wire color

1

3

4

Brown

Blue

Black

Terminal

Reserved (1)

20

02, 05

Function

+24 V

0 V

Digital input

Function

Reserved

0 V

N.O. (24 V)

1 When reserved wires for option are used. If not utilized, they can be cut off.

•

•

Mechanical brake

UDC = 0.45 x RMS mains voltage

Maximum current = 0.8 A


AQ267036816112en-000201 / 130R0208 | 31



LCP RL2 RL1 33

FB2 FB1

USB

18 19 32

Illustration 19: Connection of Sensors/Actuators on M12 Sockets

•

•

•

•

4.10.6 DIP Switches

Analog input terminals 53 and 54 can select either voltage (0-10 V) or current (0-20 mA) input signals.

Set switches S201 (terminal 53) and S202 (terminal 54) to select the signal type. ON is for current, OFF for voltage.

Terminal 53 default is for a speed reference in open loop.

Terminal 54 default is for a feedback signal in closed loop.

1 2

3

4

Illustration 20: Location of DIP Switches

5

1

2

3

S201 - terminal 53

S202 - terminal 54

S801 - standard bus termination

4

5

PROFIBUS termination

Fieldbus address

N O T I C E

Switches 4 and 5 are only valid for units fitted with fieldbus options.

Refer to VLT® PROFIBUS DP V1 MCA 101 Programming Guide for further information.

4.10.7 Safe Torque Off (STO)

To run STO, additional wiring for the drive is required.

Refer to the VLT® Frequency Converters Safe Torque Off Operating Guide for further information.

•

•

4.10.8 RS485 Serial Communication

Use shielded serial communication cable.

See 4.3 Grounding

for proper grounding.

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•

•

•

•

-

-

2 communication protocols are internal to the drive:

Danfoss FC.

Modbus RTU.

Functions can be programmed remotely using the protocol software and RS485 connection or in parameter group 8-** Communications and Options .

Selecting a specific communication protocol changes various default parameter settings to match the specifications of that protocol and makes more protocol-specific parameters available.

Option cards for the drive are available to provide extra communication protocols. See the option card documentation for installation and operating guides.

4.10.8.1 Connecting and Setting Up RS485

Procedure

1.

Connect RS485 serial communication wiring to terminals (+)68 and (-)69.

61

68

69

+

RS485

2.

3.

4.

Illustration 21: Serial Communication Wiring Diagram

Select the protocol type in parameter 8-30 Protocol .

Set the drive address in parameter 8-31 Address .

Set the baud rate in parameter 8-32 Baud Rate .

4.11 Installation Checklist

Before completing installation of the unit, inspect the entire installation as detailed in

Table 11

. Check and mark the items when completed.

Table 11: Start-up Checklist

Inspect for Description ☑

Auxiliary equipment

•

•

•

Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers located on the input power side of the drive, or the output side to the motor. Examine their operational readiness and ensure that they are ready in all respects for operation at full speed.

Check function and installation of any sensors used for feedback to the drive.

Remove power factor correction caps on motor(s), if present.

Cable routing

Control wiring

Ensure that input power, motor wiring and control wiring are separated or in 3 separate metallic conduits for high-frequency noise isolation.

•

•

•

Check for broken or damaged wires and connections.

Check the voltage source of the signals, if necessary.

The use of shielded cable or twisted pair is recommended. Ensure that the shield is terminated correctly at both ends.


AQ267036816112en-000201 / 130R0208 | 33



Inspect for

EMC considerations

Environmental considerations

Description

Check for proper installation regarding electromagnetic compatibility.

See the equipment label for the maximum ambient operating temperature limits. Temperature is not to exceed 40°C (104°F). Humidity levels must be 5-95% non-condensing.

Cooling clearance Units require top and bottom clearance adequate to ensure proper air flow for cooling.

Fusing and circuit breakers

Check that all fuses are inserted firmly and in operational condition and that all circuit breakers are in the open position. Check for proper fusing or circuit breakers.

Input and output power wiring

•

• Check for loose connections.

Check for proper fusing or circuit breakers.

☑

Switches

Grounding

Installation box and electronics part

Cable glands and blind plugs

Vibration

Ensure that all switch and disconnect settings are in the proper position.

The equipment requires a dedicated ground wire from its chassis to the plant ground. Check for good ground connections that are tight and free of oxidation.

Ensure the installation box and the electronics part is properly closed. Check that all 4 fastening screws are tightened with the right torque.

Ensure the cable glands and blind plugs are properly tightened to guarantee that the right enclosure protection degree is achieved. Liquids and/or excessive dust ingress in the drive can cause sub-optimal performance or damage.

Ensure the equipment is not exposed to a high level of vibration. Mount the panel solidly or use shock mounts as necessary.

C A U T I O N

-

INTERNAL FAILURE HAZARD

An internal failure in the drive can result in serious injury when the drive is not properly closed.

Ensure that all safety covers are in place and securely fastened before applying power.

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Operating Guide Commissioning

5 Commissioning

5.1 Safety Instructions

See 2.1 Safety Precautions for general safety instuctions.

W A R N I N G

-

HIGH VOLTAGE



7.

8.

9.

4.

5.

6.

5.1.1 Before Applying Power

Procedure

1.

2.

3.

Close the safety cover properly.

Check that all cable glands are firmly tightened.

Ensure that input power to the unit is off and locked out. Do no rely on the drive disconnect switches for input power isolation.

Verify that there is no voltage on input terminals L1 (91), L2 (92), and L3 (93), phase-to-phase, and phase-to-ground.

Verify that there is no voltage on output terminals 96 (U), 97 (V), and 98 (W), phase-to-phase, and phase-to-ground.

Confirm continuity of the motor by measuring Ω values on U–V (96–97), V–W (97–98), and W–U (98–96).

Check for proper grounding of the drive and the motor.

Inspect the drive for loose connections on the terminals.

Confirm that the supply voltage matches the voltage of the drive and the motor.

5.2 Applying Power

W A R N I N G


When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death, serious injury, and equipment or property damage. The motor may start by activation of an external switch, a fieldbus command,

-

-

an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condition.




Procedure

1.

Confirm that the input voltage is balanced within 3%. If not, correct the input voltage imbalance before proceeding. Repeat this procedure after the voltage correction.

2.

3.

Ensure that any optional equipment wiring matches the installation application.

Ensure that all operator devices are in the OFF position. Panel doors must be closed and covers securely fastened.

4.

Apply power to the unit. Do not start the drive now. For units with a disconnect switch, turn it to the ON position to apply power to the drive.


AQ267036816112en-000201 / 130R0208 | 35



5.3 Local Control Panel Operation

•

5.3.1 Local Control Panel

The local control panel (LCP) is the combined display and keypad on the front of the unit.

LCP functions

Control drive speed in hand-on mode.

•

•

•

• Start, stop, and control speed when in local control.

Show operational data, status, warnings, and cautions.

Program drive functions.

Manually reset the drive after a fault when auto reset is inactive.

An optional numeric LCP (NLCP) is also available. The NLCP operates in a manner similar to the LCP. See the product-relevant Programming Guide for details on use of the NLCP.

N O T I C E

For commissioning via PC, install the MCT 10 Set-up Software. The software is available for download (basic version) or for ordering (advanced version, code number 130B1000). For more information and downloads, see www.danfoss.com

.

•

•

•

•

5.3.2 LCP Layout

The LCP is divided into 4 functional groups:

A: Display area

B: Display menus and keys

C: Navigation keys and indicator lights (LEDs)

D: Operation keys and reset

1

2

A

Status

799 RPM 7.83 A

0.000

53.2 %

1(1)

36.4 kW

Auto Remote Ramping 4

6

B Status

Quick

Menu

Main

Menu

Alarm

Log

7

B ack

C an ce l

10

15

16

17

C

On

Warn.

Alarm

OK

D Hand

On

Off

Auto

On

18 19

Illustration 22: Local Control Panel (LCP)

20

Reset

21

3

5

9

8

11

12

13

14

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3

4

1

2

5

Area A: Display area

The display area is activated when the drive receives power from mains voltage, a DC bus terminal, or an external 24 V DC supply.

The information shown on the LCP can be customized for user application. Select options in the Quick Menu Q3-13 Display Settings .

Table 12: Legend to Area A, Display Area

Callout Parameter Default setting

Parameter 0-20 Display Line 1.1 Small



Parameter 0-23 Display Line 2 Large

Parameter 0-24 Display Line 3 Large

[1617] Speed [RPM]

[1614] Motor Current

[1610] Power [kW]

[1613] Frequency

[1602] Reference %

Area B: Display menu keys

Menu keys are used for menu access for parameter set-up, toggling through status display modes during normal operation, and viewing fault log data.

Table 13: Legend to Area B, Display Menu Keys

Callout Key Function

6

7

Status Shows operational information.

Quick Menu Allows access to programming parameters for initial setup instructions and many detailed application instructions.

8

9

Main Menu Allows access to all programming parameters.

Alarm Log Shows a list of current warnings, the last 10 alarms, and the maintenance log.

12

13

10

11

14

Area C: Navigation keys and indicator lights (LEDs)

Navigation keys are used for programming functions and moving the display cursor. The navigation keys also provide speed control in local (hand) operation. There are also 3 drive status indicator lights in this area.

Table 14: Legend to Area C, Navigation Keys


Back

Cancel

Info

Navigation keys

OK

Reverts to the previous step or list in the menu structure.

Cancels the last change or command as long as the display mode has not changed.

Press for a definition of the function being shown.

Press to move between items in the menu.

Press to access parameter groups or to enable a choice.

Table 15: Legend to Area C, Indicator Lights (LEDs)

Callout Indicator Light Function

15 ON

16

17

WARN

ALARM

Green The ON light activates when the drive receives power from mains voltage, a DC bus terminal, or an external 24 V DC supply.

Yellow When warning conditions are met, the yellow WARN light comes on and text appears in the display area identifying the problem.

Red A fault condition causes the red alarm light to flash and an alarm text is shown.


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Area D: Operation keys and reset

Operation keys are a the bottom of the LCP.

Table 16: Legend to Area D, Operation Keys and Reset


18 Hand On Starts the drive in local control.

• An external stop signal by control input or serial communication overrides the local control.

19

20

Off Stops the motor but does not remove power to the drive.

Auto On Puts the system in remote control.

• Responds to an exteral start command by control terminals or serial communication.

21 Reset Resets the drive manually after a fault has been cleared.

N O T I C E

The display contrast can be adjusted by pressing [Status] and[ ▵ ]/[ ▿ ] keys.

•

•

•

5.3.3 Parameter Settings

Establishing the correct programming for applications often requires setting functions in several related parameters.

Programming data are stored internally in the drive.

For back-up, upload data into the LCP memory.

To download data to another drive, connect the LCP to that unit and download the stored settings.

Restoring factory default settings does not change data stored in the LCP memory.

5.3.4 Uploading/Downloading Data to/from the LCP

Procedure

1.

Press [Off] to stop the motor before uploading or downloading data.

4.

5.

2.

3.

Press [Main Menu].

Go to parameter 0-50 LCP Copy and press [OK].

Select [1] All to LCP to upload data to the LCP, or select [2] All from LCP to download data from the LCP.

Press [OK].

6.

 A progress bar shows the uploading or downloading process.

Press [Hand On] or [Auto On] to return to normal operation.

5.3.5 Changing Parameter Settings

Parameter settings can be accessed and changed via the [Quick Menu] or [Main Menu] keys. The Quick Menu only gives access to a limited number of parameters.

Procedure

1.

2.

3.

4.

5.

6.

7.

Press [Quick Menu] or [Main Menu] on the LCP.

Press [ ▵ ]/[ ▿ ] to browse through the parameter groups, press [OK] to select a parameter group.

Press [ ▵ ]/[ ▿ ] to browse through the parameters, press [OK] to select a parameter.

Press [ ▵ ]/[ ▿ ] to change the value of a parameter setting.

Press [ ◃ ]/[ ▹ ] to shift digit when a decimal parameter is in the editing state.

Press [OK] to accept the change.

Press either [Back] twice to enter Status , or press [Main Menu] once to enter Main Menu .

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5.3.6 Restoring Default Settings

N O T I C E

-

RISK OF LOSING DATA

When restoring default settings, there is a risk of losing programming, motor data, localization, and monitoring records.

Provide a back-up by uploading data to the LCP before initialization.

•

•

Restoring the default parameter settings is done by initialization of the drive. Initialization is carried out via parameter 14-22 Operation Mode (recommended) or manually.

Initialization via parameter 14-22 Operation Mode does not reset the drive settings such as hours run, serial communication selections, personal menu settings, fault log, alarm log, and other monitoring functions.

Manual initialization erases all motor programming, localization, and monitoring data, and restores factory default settings.

5.3.6.1 Recommended Initialization

Procedure

1.

Press [Main Menu] twice to access parameter.

4.

5.

2.

3.

Scroll to parameter 14-22 Operation Mode and press [OK].

Scroll to [2] Initialisation and press [OK].

Remove power to the unit and wait for the display to turn off.

Apply power to the unit.

6.

7.

 Default parameter settings are restored during start-up. This may take slightly longer than normal.

Alarm 80, Drive initialised is shown.

Press [Reset] to return to operating mode.

5.3.6.2 Manual Initialization

Procedure

1.

Remove power to the unit and wait for the display to turn off.

2.

Press and hold [Status], [Main Menu], and [OK] at the same time while applying power to the unit (approximately 5 s or until a click is heard and the fan starts).

 Factory default parameter settings are restored during start-up. This might take slightly longer than normal.

•

•

•

•

Manual initialization resets parameter settings except for the settings in:

Parameter 15-00 Operating Hours .

Parameter 15-03 Power Up's .

Parameter 15-04 Over Temp's

Parameter 15-05 Over Volt's .

.

5.4 Basic Operational Programming

Drives require basic operational programming before running for best performance. Basic operational programming requires entering motor nameplate data for the motor being operated and the minimum and maximum motor speeds. Enter the data in accordance with the following procedure. See

5.3.2 LCP Layout for detailed instructions on entering data through the LCP. Enter the data

with power ON, but before operating the drive.

1.

Press [Quick Menu] on the LCP.


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Operating Guide

2.

Use the navigation keys to scroll to parameter group Q2 Quick Setup and press [OK].

Commissioning

13.7% 0.75A 1 (1)

Quick Menus

Q1 My Personal Menu

Q2 Quick Setup

Q3 Function Setups

Q5 Changes Made

3.

4.

Illustration 23: Quick Menus

-

-

-

-

-

-

Select language and press [OK].

Enter the motor data in parameter 1-20 Motor Power [kW] / parameter 1-21 Motor Power [HP] through parameter 1-25 Motor

Nominal Speed . The information can be found on the motor nameplate. The entire quick menu is shown in International/

North American default parameter settings.

Parameter 1-20 Motor Power [kW]

Parameter 1-21 Motor Power [HP]

Parameter 1-22 Motor Voltage

Parameter 1-23 Motor Frequency

Parameter 1-24 Motor Current

Parameter 1-25 Motor Nominal Speed

0.0 Hz 0.00kW 1(1)

Motor Setup Q2

1 - 21 Motor Power [kW]

2.2 kW

5.

Illustration 24: Motor Set-up

Continue set-up of Quick Menu parameters: a.

Parameter 5-12 Terminal 27 Digital Input

[0] No operation .

. If terminal default is [2] Coast inverse , it is possible to change this setting to b.

c.

d.

e.

Parameter 1-29 Automatic Motor Adaptation (AMA) . Set desired AMA function. Enable complete AMA is recommended.

Parameter 3-02 Minimum Reference . Set the minimum speed of the motor shaft.

Parameter 3-03 Maximum Reference . Set the maximum speed of the motor shaft.

Parameter 3-41 Ramp 1 Ramp Up Time . Set the ramping up time regarding synchronous motor speed, ns.

f.

g.

Parameter 3-42 Ramp 1 Ramp Down Time

Parameter 3-13 Reference Site

. Set the ramping down time regarding synchronous motor speed, ns.

. Set the site from where the reference must work.

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5.5 Automatic Motor Adaptation (AMA)

AMA is not relevant for permanent magnet motors.

N O T I C E

•

•

•

•

•

•

Automatic motor adaptation (AMA) is a procedure that optimizes compatibility between the drive and the motor.

The drive builds a mathematical model of the motor for regulating output motor current. The procedure also tests the input phase balance of electrical power. It compares the motor characteristics with the data entered in parameters 1-20 to 1-25 .

The motor shaft does not turn and no harm is done to the motor while running AMA.

Some motors may be unable to run the complete version of the test. In that case, select

If an output filter is connected to the motor, select [2] Enable reduced AMA .

[2] Enable reduced AMA .

If warnings or alarms occur, see 6.8 List of Warnings and Alarms .

Run this procedure on a cold motor for best results.

5.5.1 Running AMA

Enter the advanced motor data in parameter group 1-3* Adv. Motor Data .

Procedure

1.

Press [Main Menu] to access parameters.

2.

Scroll to parameter group 1-** Load and Motor and press [OK].

Scroll to parameter group 1-2* Motor Data and press [OK].

3.

4.

5.

6.

Scroll to parameter 1-29 Automatic Motor Adaptation (AMA) and press [OK].

Select [1] Enable complete AMA and press [OK].

Follow on-screen instructions.

 The test runs automatically and indicates when it is complete.

5.6 Local-control Test

To reset the drive after a trip, see 6.6 Warning and Alarm Types

.

Procedure

1.

Press [Hand On] to provide a local start command to the drive.

2.

Accelerate the drive by pressing [ ▵ ] to full speed. Moving the cursor left of the decimal point provides quicker input changes.

3.

4.

Note any acceleration problems.

Press [Off] and note any deceleration problems.

5.7 System Start-up

The procedure in this section requires wiring and application programming to be completed. The following procedure is recommended after application setup is completed.

If warnings or alarms occur, see

6.6 Warning and Alarm Types and

6.8 List of Warnings and Alarms .

1.

Press [Auto on].

2.

Apply an external run command.

3.

4.

5.

Adjust the speed reference throughout the speed range.

Remove the external run command.

Check the sound and vibration levels of the motor to ensure that the system is working as intended.


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Operating Guide

Maintenance, Diagnostics and

Troubleshooting

6 Maintenance, Diagnostics and Troubleshooting

6.1 Maintenance and Service

Under normal operating conditions and load profiles, the drive is maintenance-free throughout its designed lifetime. To prevent breakdown, danger, and damage, examine the drive for loose terminal connections, excessive dust buildup, and so on, at regular intervals. Replace worn or damaged parts with Danfoss authorized parts. For service and support, contact the local Danfoss supplier.

W A R N I N G


When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death, serious injury, and equipment or property damage. The motor may start by activation of an external switch, a fieldbus command,

-

-

an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condition.




6.2 Cleaning

The enclosure (IP66/NEMA type 4x indoor) provides protection against dirt and water ingress. The enclosure is suitable for cleaning methods and solvents used in food and beverage plants. Use the solvent concentration recommended by the manufacturer. Avoid high-pressure hot water cleaning at close proximity or of long duration, because this method of cleaning can damage gaskets and labels.

6.3 Frontal LEDs

The actual status can be read via 6 LEDs, which signal the actual status of the unit.

ON W ar ning A lar m

Bus MS NS1 NS2

Illustration 25: Frontal LEDs

Table 17: Description of Frontal LEDs

Name Color

ON Green

Status

On

Warning Yellow

Alarm Red

Off

On

Off

Flashing

Off

Indication, frontal LEDs

The drive receives power from mains voltage or external 24 V supply.

No power from mains voltage or external 24 V supply.

Warning situation is present.

No warning is present.

Alarm is present.

No alarm is present

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Troubleshooting

Name Color Status

Bus MS Only relevant if optional fieldbus is present. See fieldbus-dedicated manuals for specific information.

Bus NS1 Only relevant if optional fieldbus is present. See fieldbus-dedicated manuals for specific information.

Bus NS2 Only relevant if optional fieldbus is present. See fieldbus-dedicated manuals for specific information.

Indication, frontal LEDs

Bus Module Status

Bus Network Status 1

Bus Network Status 2

6.4 Status Display

When the drive is in Status mode, status messages are generated automatically and appear in the bottom line of the display, see

Illustration 26

.

Status

799RPM 7.83A 36.4kW

0.000

53.2%

1(1)

1

Auto

Hand

Off

Remote

Local

2

3

Illustration 26: Status Display

1

2

Ramping

Stop

Running

Jogging

.

.

.

Standby

Operating mode (see Table 18 )

Reference site (see

Table 19

)

3 Operation status (see

Table 20

)

6.5 Status Message Definitions

See Table 18 to

Table 20

for definitions of the status messages.

Table 18: Operating Mode

Off The drive does not react to any control signal until [Auto On] or [Hand On] is pressed.

Auto On The drive is controlled from the control terminals and/or the serial communication.

Hand On The drive is controlled by the navigation keys on the LCP. Stop commands, reset, reversing, DC brake, and other signals applied to the control terminals override local control.

Table 19: Reference Site

Remote The speed reference is given from external signals, serial communication, or internal preset references.

Local

The drive uses [Hand On] control or reference values from the LCP.


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Operating Guide


Troubleshooting

Table 20: Operation Status

AC Brake [2] AC brake is selected in controlled slow down.

parameter 2-10 Brake Function . The AC brake overmagnetizes the motor to achieve a

AMA finish

OK

AMA was carried out successfully.

AMA ready AMA is ready to start. Press [Hand On] to start.

AMA running

AMA process is in progress.

The brake chopper is in operation. Generative energy is absorbed by the brake resistor.

Braking

Braking max.

Coast

The brake chopper is in operation. The power limit for the brake resistor defined in

Limit (kW) has been reached.

parameter 2-12 Brake Power

•

•

Coast inverse was selected as a function for a digital input ( parameter group 5-1* Digital Inputs ). The corresponding terminal is not connected.

Coast activated by serial communication.

Ctrl. rampdown

•

•

[1] Control Ramp-down was selected in parameter 14-10 Mains Failure .

The mains voltage is below the value set in parameter 14-11 Mains Voltage at Mains Fault .

The drive ramps down the motor using a controlled ramp down.

Current

High

The drive output current is above the limit set in parameter 4-51 Warning Current High

Current Low The drive output current is below the limit set in parameter 4-52 Warning Speed Low .

.

DC Hold

DC Stop

[1] DC hold is selected in parameter 1-80 Function at Stop and a stop command is active. The motor is held by a DC current set in parameter 2-00 DC Hold/Preheat Current .

•

•

•

The motor is held with a DC current ( parameter 2-01 DC Brake Current ) for a specified time ( parameter 2-02 DC

Braking Time ).

The DC brake cut in speed is reached in parameter 2-03 DC Brake Cut In Speed [RPM] and a stop command is active.

[5] DC-brake inverse is selected as a function for a digital input ( sponding terminal is not active.

parameter group 5-1* Digital Inputs ). The corre-

The DC brake is activated via serial communication.

Feedback high

Feedback low

Freeze output

The sum of all active feedbacks is above the feedback limit set in

The sum of all active feedbacks is below the feedback limit set in parameter 4-57 Warning Feedback High parameter 4-56 Warning Feedback Low .

.

•

•

The remote reference is active, which holds the present speed.

[20] Freeze output sponding terminal is active. Speed control is only possible via the terminal options [21] Speed up and [22]

Speed down .

is selected as a function for a digital input ( parameter group 5-1* Digital Inputs ). The corre-

Hold ramp is activated via serial communication.

Freeze output request

A freeze output command was given, but the motor remains stopped until a run permissive signal is received.

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Troubleshooting

Freeze ref.

[19] Freeze reference is selected as a function for a digital input ( parameter group 5-1* Digital Inputs ). The corresponding terminal is active. The drive saves the actual reference. Changing the reference is now only possible via terminal options [21] Speed up and [22] Speed down .

Jog request A jog command was given, but the motor remains stopped until a run permissive signal is received via a digital input.

Jogging

•

•

•

The motor is running as programmed in parameter 3-19 Jog Speed [RPM] .

[14] Jog was selected as a function for a digital input ( terminal (for example, terminal 29) is active.

parameter group 5-1* Digital Inputs ). The corresponding

The jog function is activated via the serial communication.

The jog function is selected as a reaction for a monitoring function (for example, for the no signal function).

The monitoring function is active.

Motor check In parameter 1-80 Function at Stop , [2] Motor Check is selected. A stop command is active. To ensure that a motor is connected to the drive, a permanent test current is applied to the motor.

OVC control Overvoltage control is activated via parameter 2-17 Over-voltage Control , [2] Enabled . The connected motor supplies the drive with generative energy. The overvoltage control adjusts the V/Hz ratio to run the motor in controlled mode and to prevent the drive from tripping.

PowerUnit

Off

Protection md

(Only drives with a 24 V external supply installed). Mains supply to the drive was removed, and the control card is supplied by the external 24 V.

•

•

•

Protection mode is active. The unit detected a critical status (overcurrent or overvoltage).

To avoid tripping, switching frequency is reduced to 4 kHz.

If possible, protection mode ends after approximately 10 s.

Protection mode can be restricted in parameter 14-26 Trip Delay at Inverter Fault .

QStop

•

•

The motor is decelerating using parameter 3-81 Quick Stop Ramp Time .

[4] Quick stop inverse is selected as a function for a digital input ( sponding terminal is not active.

parameter group 5-1* Digital Inputs ). The corre-

The quick stop function is activated via serial communication.

Ramping The motor is accelerating/decelerating using the active ramp up/down. The reference, a limit value, or a standstill is not yet reached.

The sum of all active references is above the reference limit set in parameter 4-55 Warning Reference High .

Ref. high

Ref. low

Run on ref.

The sum of all active references is below the reference limit set in parameter 4-54 Warning Reference Low .

The drive is running in the reference range. The feedback value matches the setpoint value.

Run request A start command was given, but the motor remains stopped until a run permissive signal is received via digital input.

Running The drive drives the motor.

Sleep Mode The energy-saving function is enabled. The motor has stopped, but restarts automatically when required.

Speed high Motor speed is above the value set in parameter 4-53 Warning Speed High .

Speed low Motor speed is below the value set in parameter 4-52 Warning Speed Low .

Standby

In auto-on mode, the drive starts the motor with a start signal from a digital input or serial communication.

Start delay In parameter 1-71 Start Delay , a delay starting time was set. A start command is activated, and the motor starts after the start delay time expires.


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Operating Guide


Troubleshooting

Start fwd/rev

Stop

Trip

Trip lock

[12] Enable start forward and [13] Enable start reverse are selected as options for 2 different digital inputs ( parameter group 5-1* Digital Inputs ). The motor starts in forward or reverse direction depending on which terminal is activated.

The drive received a stop command from the LCP, digital input, or serial communication.

An alarm occurred and the motor is stopped. Once the cause of the alarm is cleared, the drive can be reset manually by pressing [Reset] or remotely by control terminals or serial communication.

An alarm occurred, and the motor is stopped. When the cause of the alarm is cleared, cycle power to the drive.

The drive can then be reset manually by pressing [Reset], or remotely by control terminals or serial communication.

N O T I C E

In auto/remote mode, the drive requires external commands to execute functions.

•

•

•

•

6.6 Warning and Alarm Types

Warnings

A warning is issued when an alarm condition is impending, or when an abnormal operating condition is present and may result in the drive issuing an alarm. A warning clears by itself when the abnormal condition ceases.

Alarms

An alarm indicates a fault that requires immediate attention. The fault always triggers a trip or a trip lock. Reset the system after an alarm.

Trip

An alarm is issued when the drive is tripped, meaning that the drive suspends operation to prevent damage to the drive or system.

The motor coasts to a stop. The drive logic continues to operate and monitor the drive status. After the fault condition is remedied, the drive can be reset. It is then ready to start operation again.

Trip lock

Input power is cycled. The motor coasts to a stop. The drive continues to monitor the drive status. Remove input power to the drive, correct the cause of the fault, and reset the drive.

Resetting the drive after a trip/trip lock

A trip can be reset in any of 4 ways:

Press [Reset] on the LCP.

Digital reset input command.

Serial communication reset input command.

Auto reset.

•

•

6.7 Warning and Alarm Displays

A warning is shown in the LCP along with the warning number.

An alarm flashes along with the alarm number.

Status

1(1)

0.0Hz 0.000kW 0.00A

0.0Hz

0

Earth Fault [A14]

Auto Remote Trip

Illustration 27: Alarm Example

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Operating Guide

In addition to the text and alarm code in the LCP there are 3 status indicator lights.

B ack

Ca nc el


Troubleshooting

On

Warn.

Alarm

OK

Illustration 28: Status Indicator Lights

Warning

Alarm

Trip lock

Warning indicator light

On

Off

On

Alarm indicator light

Off

On (flashing)

On (flashing)

6.8 List of Warnings and Alarms

The following warning and alarm information defines each warning or alarm condition, provides the probable cause for the condition, and entails a remedy or troubleshooting procedure.

•

6.8.1 WARNING/ALARM 4, Mains Phase Loss

Cause

A phase is missing on the supply side, or the mains voltage imbalance is too high. This message also appears for a fault in the input rectifier. Options are programmed in parameter 14-12 Function at Mains Imbalance .

Troubleshooting

Check the supply voltage and supply currents to the drive.

6.8.2 WARNING 5, DC Link Voltage High

Cause

The DC-link voltage (DC) is higher than the high-voltage warning limit. The limit depends on the drive voltage rating. The unit is still active.

6.8.3 WARNING 6, DC Link Voltage Low

Cause

The DC-link voltage (DC) is lower than the low voltage warning limit. The limit depends on the drive voltage rating. The unit is still active.

•

•

•

6.8.4 WARNING/ALARM 8, DC Undervoltage

Cause

If the DC-link voltage drops below the undervoltage limit, the drive checks for 24 V DC back-up supply. If no 24 V DC back-up supply is connected, the drive trips after a fixed time delay. The time delay varies with unit size.

Troubleshooting

Check that the supply voltage matches the drive voltage.

Perform an input voltage test.

Perform a soft-charge circuit test.


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Operating Guide


Troubleshooting

•

•

•

6.8.5 WARNING/ALARM 9, Inverter Overload

Cause

The drive has run with more than 100% overload for too long and is about to cut out. The counter for electronic thermal inverter protection issues a warning at 98% and trips at 100% with an alarm. The drive cannot be reset until the counter is below 90%.

Troubleshooting

Compare the output current shown on the LCP with the drive rated current.

Compare the output current shown on the LCP with the measured motor current.

Show the thermal drive load on the LCP and monitor the value. When running above the drive continuous current rating, the counter increases. When running below the drive continuos current rating, the counter decreases.

6.8.6 WARNING/ALARM 10, Motor Overload Temperature

Cause

According to the electronic thermal protection (ETR), the motor is too hot.

Select 1 of these options:

•

•

•

The drive issues a warning or an alarm when the counter is >90% if parameter 1-90 Motor Thermal Protection is set to warning options.

The drive trips when the counter reaches 100% if parameter 1-90 Motor Thermal Protection is set to trip options.

•

•

•

•

•

The fault occurs when the motor runs with more than 100% overload for too long.

Troubleshooting

Check for motor overheating.

Check if the motor is mechanically overloaded.

Check that the motor current set in parameter 1-24 Motor Current is correct.

Ensure that the motor data in parameters 1-20 to 1-25 is set correctly.

If an external fan is in use, check that it is selected in parameter 1-91 Motor External Fan .

Running AMA in parameter 1-29 Automatic Motor Adaptation (AMA) tunes the drive to the motor more accurately and reduces thermal loading.

•

•

•

•

•

6.8.7 WARNING/ALARM 11, Motor Thermistor Overtemp

The motor thermistor indicates that the motor temperature is too high.

Troubleshooting

Check for motor overheating.

Check that the thermistor is securely connected.

Check if the motor is mechanically overloaded.

When using terminal 53 or 54, check that the thermistor is connected correctly between either terminal 53 or 54 (analog voltage input) and terminal 50 (+10 V supply). Also check that the terminal switch for 53 and 54 is set for voltage. Check that parameter

1-93 Thermistor Resource selects 53 or 54.

When using terminal 18, 19, 31, 32, or 33 (digital inputs), check that the thermistor is connected correctly between the digital input terminal used (digital input PNP only) and terminal 50. Select the terminal to use in parameter 1-93 Thermistor Resource .

•

•

•

•

6.8.8 WARNING/ALARM 12, Torque Limit

Cause

The torque has exceeded the value in parameter 4-16 Torque Limit Motor Mode or the value in parameter 4-17 Torque Limit Generator

Mode . Parameter 14-25 Trip Delay at Torque Limit can change this warning from a warning-only condition to a warning followed by an alarm.

Troubleshooting

If the motor torque limit is exceeded during ramp-up, extend the ramp-up time.

If the generator torque limit is exceeded during ramp-down time, extend the ramp-down time.

If torque limit occurs while running, increase the torque limit. Make sure that the system can operate safely at a higher torque.

Check the application for excessive current draw on the motor.

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Troubleshooting

•

•

•

6.8.9 WARNING/ALARM 13, Overcurrent

Cause

The inverter peak current limit (approximately 200% of the rated current) is exceeded. The warning lasts approximately 1.5 s, then the drive trips and issues an alarm. Shock loading or quick acceleration with high-inertia loads can cause this fault. If the acceleration during ramp-up is quick, the fault can also appear after kinetic back-up. If extended mechanical brake control is selected, a trip can be reset externally.

Troubleshooting

Remove power and check if the motor shaft can be turned.

Check that the motor size matches the drive.

Check that the motor data is correct in parameters 1-20 to 1-25 .

•

•

•

6.8.10 ALARM 14, Earth (Ground) Fault

Cause

There is current from the output phase to ground, either in the cable between the drive and the motor, or in the motor itself. The current transducers detect the ground fault by measuring current going out from the drive and current going into the drive from the motor. Ground fault is issued if the deviation of the 2 currents is too large. The current going out of the drive must be the same as the current going into the drive.

Troubleshooting

Remove power to the drive and repair the ground fault.

Check for ground faults in the motor by measuring the resistance to ground of the motor cables and the motor with a megohmmeter.

Reset any potential individual offset in the 3 current transducers in the drive. Perform a manual initialization or perform a complete AMA. This method is most relevant after changing the power card.

•

•

•

•

•

•

•

•

•

6.8.11 ALARM 15, Hardware Mismatch

Cause

A fitted option is not operational with the present control card hardware or software.

Troubleshooting

Record the value of the following parameters and contact Danfoss.

Parameter 15-40 FC Type .

Parameter 15-41 Power Section .

Parameter 15-42 Voltage .

Parameter 15-43 Software Version .

Parameter 15-45 Actual Typecode String .

Parameter 15-49 SW ID Control Card .

Parameter 15-50 SW ID Power Card .

Parameter 15-60 Option Mounted .

Parameter 15-61 Option SW Version (for each option slot).

6.8.12 ALARM 16, Short Circuit

Cause

There is short-circuiting in the motor or motor wiring.

Troubleshooting

W A R N I N G

-

HIGH VOLTAGE



•

• Disconnect power before proceeding.

Remove the power to the drive and repair the short circuit.


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Operating Guide


Troubleshooting

•

•

•

•

6.8.13 WARNING/ALARM 17, Control Word Timeout

Cause

There is no communication to the drive. The warning is only active when parameter 8-04 Control Word Timeout Function is NOT set to

[0] Off .

If parameter 8-04 Control Word Timeout Function is set to [5] Stop and trip , a warning appears, and the drive ramps down to a stop and shows an alarm.

Troubleshooting

Check the connections on the serial communication cable.

Increase parameter 8-03 Control Word Timeout Time .

Check the operation of the communication equipment.

Verify that proper EMC installation was performed.

6.8.14 WARNING/ALARM 22, Hoist Mechanical Brake

Cause

The value of this warning/alarm shows the type of warning/alarm.

0 = The torque reference was not reached before timeout ( parameter 2-27 Torque Ramp Up Time ).

1 = Expected brake feedback was not received before timeout ( parameter 2-23 Activate Brake Delay , parameter 2-25 Brake Release

Time ).

•

•

•

6.8.15 WARNING 23, Internal Fan Fault

Cause

The fan warning function is a protective function that checks if the fan is running/mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ( [0] Disabled ).

For drives with DC fans, a feedback sensor is mounted in the fan. If the fan is commanded to run and there is no feedback from the sensor, this alarm appears. For drives with AC fans, the voltage to the fan is monitored.

Troubleshooting

Check for proper fan operation.

Cycle power to the drive and check that the fan operates briefly at start-up.

Check the sensors on the control card.

•

6.8.16 WARNING 25, Brake Resistor Short Circuit

Cause

The brake resistor is monitored during operation. If a short circuit occurs, the brake function is disabled and the warning appears.

The drive is still operational, but without the brake function.

Troubleshooting

Remove the power to the drive and replace the brake resistor (refer to parameter 2-15 Brake Check ).

6.8.17 WARNING/ALARM 26, Brake Resistor Power Limit

Cause

The power transmitted to the brake resistor is calculated as a mean value over the last 120 s of run time. The calculation is based on the DC-link voltage and the brake resistor value set in parameter 2-16 AC Brake Max. Current . The warning is active when the dissipated braking power is higher than 90% of the brake resistor power. If option [2] Trip is selected in parameter 2-13 Brake Power Monitoring , the drive trips when the dissipated braking power reaches 100%.

•

6.8.18 WARNING/ALARM 27, Brake Chopper Fault

Cause

The brake transistor is monitored during operation, and if a short circuit occurs, the brake function is disabled, and a warning is issued. The drive is still operational, but since the brake transistor has short-circuited, substantial power is transmitted to the brake resistor, even if it is inactive.

Troubleshooting

Remove the power to the drive and remove the brake resistor.

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Troubleshooting

•

6.8.19 WARNING/ALARM 28, Brake Check Failed

Cause

The brake resistor is not connected or not working.

Troubleshooting

Check parameter 2-15 Brake Check .

•

•

•

•

•

•

6.8.20 ALARM 29, Heat Sink Temp

Cause

The maximum temperature of the heat sink is exceeded. The temperature fault is not reset until the temperature drops below a defined heat sink temperature. The trip and reset points are different based on the drive power size.

Troubleshooting

Check for the following conditions:

The ambient temperature is too high.

The motor cables are too long.

Incorrect airflow clearance above and below the drive.

Blocked airflow around the drive.

Damaged heat sink fan.

Dirty heat sink.

6.8.21 ALARM 30, Motor Phase U Missing

Cause

Motor phase U between the drive and the motor is missing.

Troubleshooting

W A R N I N G

-

HIGH VOLTAGE



•


Remove the power from the drive and check motor phase U.

6.8.22 ALARM 31, Motor Phase V Missing

Cause

Motor phase V between the drive and the motor is missing.

Troubleshooting

W A R N I N G

HIGH VOLTAGE

-



•


Remove the power from the drive and check motor phase V.


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Troubleshooting

6.8.23 ALARM 32, Motor Phase W Missing

Cause

Motor phase W between the drive and the motor is missing.

Troubleshooting

W A R N I N G

HIGH VOLTAGE

AC drives contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation,

start-up, and maintenance by qualified personnel can result in death or serious injury.


•


Remove the power from the drive and check motor phase W.

•

•

6.8.24 ALARM 33, Inrush Fault

Cause

Too many power-ups have occurred within a short time period.

Troubleshooting

Let the unit cool to operating temperature.

Check potential DC-link fault to ground.

6.8.25 WARNING/ALARM 34, Fieldbus Communication Fault

Cause

The fieldbus on the communication option card is not working.

•

6.8.26 WARNING/ALARM 36, Mains Failure

Cause

This warning/alarm is only active if the supply voltage to the drive is lost and parameter 14-10 Mains Failure is not set to [0] No Function .

Troubleshooting

Check the fuses to the drive and mains supply to the unit.

6.8.27 ALARM 37, Phase Imbalance

Cause

There is a current imbalance between the power units.

6.8.28 ALARM 38, Internal Fault

Cause

When an internal fault occurs, a code number defined in Table 21

is shown.

Troubleshooting

•

• Cycle power.

Check that the option is properly installed.

• Check for loose or missing wiring.

It may be necessary to contact the Danfoss supplier or service department. Note the code number for further troubleshooting directions.

Table 21: Internal Fault Codes

Number Text

0

256–258

512–519

The serial port cannot be initialized. Contact the Danfoss supplier or Danfoss service department.

The power EEPROM data is defective or too old. Replace the power card.

Internal fault. Contact the Danfoss supplier or Danfoss service department.

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Number

783

Text

Parameter value outside of minimum/maximum limits.

1024–1284 Internal fault. Contact the Danfoss supplier or Danfoss service department.

1299

1300

1302

1315

The option software in slot A is too old.

The option software in slot B is too old.

The option software in slot C1 is too old.

The option software in slot A is not supported/allowed.

1316

1318

The option software in slot B is not supported/ allowed.

The option software in slot C1 is not supported/ allowed.

1379–2819 Internal fault. Contact the Danfoss supplier or Danfoss service department.

1792 Hardware reset of digital signal processor.

1793

1794

1795

1796

Motor-derived parameters not transferred correctly to the digital signal processor.

Power data not transferred correctly at power-up to the digital signal processor.

The digital signal processor has received too many unknown SPI telegrams. The AC drive also uses this fault code if the MCO does not power up correctly. This situation can occur due to poor EMC protection or improper grounding.

RAM copy error.

2561

2820

2821

2822

Replace the control card.

LCP stack overflow.

Serial port overflow.

USB port overflow.

3072–5122 Parameter value is outside its limits.

5123 Option in slot A: Hardware incompatible with the control board hardware.

5124

5125

Option in slot B: Hardware incompatible with the control board hardware.

Option in slot C0: Hardware incompatible with the control board hardware.

5126 Option in slot C1: Hardware incompatible with the control board hardware.

5376– 6231 Internal fault. Contact the Danfoss supplier or Danfoss service department.

•

•

6.8.29 WARNING 40, Overload of Digital Output Terminal 27

Troubleshooting

Check the load connected to terminal 27 or remove the short-circuit connection.

Check parameter 5-00 Digital I/O Mode and parameter 5-01 Terminal 27 Mode .

•

•

6.8.30 WARNING 41, Overload of Digital Output Terminal 29

Troubleshooting

Check the load connected to terminal 29 or remove the short-circuit connection.

Check parameter 5-00 Digital I/O Mode and parameter 5-02 Terminal 29 Mode .


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Troubleshooting

6.8.31 WARNING 42, Ovrld X30/6-7

Troubleshooting

For terminal X30/6:

•

•

•

• Check the load connected to the terminal, or remove the short-circuit connection.

Check parameter 5-32 Term X30/6 Digi out (MCB 101) (VLT® General Purpose I/O MCB 101).

For terminal X30/7:

Check the load connected to the terminal, or remove the short-circuit connection.

Check parameter 5-33 Term X30/7 Digi Out (MCB 101) (VLT® General Purpose I/O MCB 101).

•

•

6.8.32 ALARM 43, Ext. Supply

Either connect a 24 V DC external supply or specify that no external supply is used via parameter 14-80 Option Supplied by External

24VDC , [0] No . A change in parameter 14-80 Option Supplied by External 24VDC requires a power cycle.

Cause

VLT® Extended Relay Option MCB 113 is mounted without 24 V DC.

Troubleshooting

Choose 1 of the following:

Connect a 24 V DC external supply.

Specify that no external supply is used via parameter 14-80 Option Supplied by External 24VDC , [0] No . A change in parameter

14-80 Option Supplied by External 24VDC requires a power cycle.

•

•

•

6.8.33 ALARM 45, Earth Fault 2

Cause

Ground fault.

Troubleshooting

Check for proper grounding and loose connections.

Check for proper wire size.

Check the motor cables for short circuits or leakage currents.

•

6.8.34 ALARM 46, Power Card Supply

Cause

The supply on the power card is out of range. Another reason can be a defective heat sink fan.

There are 3 supplies generated by the switch mode supply (SMPS) on the power card:

24 V.

•

•

•

•

•

•

• 5 V.

±18 V.

When powered with VLT

®

24 V DC Supply MCB 107, only 24 V and 5 V supplies are monitored. When powered with 3-phase mains voltage, all 3 supplies are monitored.

Troubleshooting

Check for a defective power card.

Check for a defective control card.

Check for a defective option card.

If a 24 V DC supply is used, verify proper supply power.

Check for a defective heat sink fan.

6.8.35 WARNING 47, 24 V Supply Low

Cause

The supply on the power card is out of range.

There are 3 supplies generated by the switch mode supply (SMPS) on the power card:

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Operating Guide


Troubleshooting

•

•

•

24 V

5 V

±18 V

•

Troubleshooting

Check for a defective power card.

•

•

6.8.36 WARNING 48, 1.8 V Supply Low

Cause

The 1.8 V DC supply used on the control card is outside of the allowed limits. The supply is measured on the control card.

Troubleshooting

Check for a defective control card.

If an option card is present, check for overvoltage.

6.8.37 WARNING 49, Speed Limit

Cause

The warning is shown when the speed is outside of the specified range in parameter 4-11 Motor Speed Low Limit [RPM] and parameter 4-13 Motor Speed High Limit [RPM] . When the speed is below the specified limit in parameter 1-86 Trip Speed Low [RPM] (except when starting or stopping), the drive trips.

•

6.8.38 ALARM 50, AMA Calibration Failed

Troubleshooting

Contact the Danfoss supplier or service department.

•

6.8.39 ALARM 51, AMA Check Unom and Inom

Cause

The settings for motor voltage, motor current, and motor power are wrong.

Troubleshooting

Check settings in parameters 1-20 to 1-25 .

•

6.8.40 ALARM 52, AMA Low Inom

Cause

The motor current is too low.

Troubleshooting

Check the settings in parameter 1-24 Motor Current .

6.8.41 ALARM 53, AMA Motor Too Big

Cause

The motor is too big for the AMA to operate.

6.8.42 ALARM 54, AMA Motor Too Small

Cause

The motor is too small for the AMA to operate.

6.8.43 ALARM 55, AMA Parameter Out of Range

Cause

The AMA cannot run because the paramenter values of the motor are out of the acceptable range.

6.8.44 ALARM 56, AMA Interrupted by User

Cause

The AMA is manually interrupted.

6.8.45 ALARM 57, AMA Internal Fault

Cause

Try to restart the AMA. Repeated restarts can overheat the motor.


AQ267036816112en-000201 / 130R0208 | 55


Operating Guide


Troubleshooting

6.8.46 ALARM 58, AMA Internal Fault

Troubleshooting

Contact the Danfoss supplier.

•

•

6.8.47 WARNING 59, Current Limit

Cause

The current is higher than the value in parameter 4-18 Current Limit .

Troubleshooting

Ensure that the motor data in parameters 1-20 to 1-25 is set correctly.

Increase the current limit if necessary. Ensure that the system can operate safely at a higher limit.

•

•

•

6.8.48 WARNING 60, External Interlock

Cause

A digital input signal indicates a fault condition external to the drive. An external interlock has commanded the drive to trip.

Troubleshooting

Clear the external fault condition.

To resume normal operation, apply 24 V DC to the terminal programmed for external interlock.

Reset the drive.

•

•

•

6.8.49 WARNING/ALARM 61, Feedback Error

Cause

An error between calculated speed and speed measurement from feedback device.

Troubleshooting

Check the settings for warning/alarm/disabling in parameter 4-30 Motor Feedback Loss Function .

Set the tolerable error in parameter 4-31 Motor Feedback Speed Error .

Set the tolerable feedback loss time in parameter 4-32 Motor Feedback Loss Timeout.

•

6.8.50 WARNING 62, Output Frequency at Maximum Limit

Cause

The output frequency has reached the value set in parameter 4-19 Max Output Frequency .

Troubleshooting

Check the application for possible causes.

• Increase the output frequency limit. Be sure that the system can operate safely at a higher output frequency.

The warning clears when the output drops below the maximum limit.

6.8.51 ALARM 63, Mechanical Brake Low

Cause

The actual motor current has not exceeded the release brake current within the start delay time window.

6.8.52 WARNING 64, Voltage Limit

Cause

The load and speed combination demands a motor voltage higher than the actual DC-link voltage.

•

•

•

•

6.8.53 WARNING/ALARM 65, Control Card Overtemperature

Cause

The cutout temperature of the control card has exceeded the upper limit.

Troubleshooting

Check that the ambient operating temperature is within the limits.

Check for clogged filters.

Check fan operation.

Check the control card.

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Operating Guide


Troubleshooting

•

•

6.8.54 WARNING 66, Heat Sink Temperature Low

Cause

The drive is too cold to operate. This warning is based on the temperature sensor in the IGBT module.

Troubleshooting

Increase the ambient temperature of the unit.

Supply a trickle amount of current to the drive whenever the motor is stopped by setting parameter 2-00 DC Hold/Preheat Current to 5% and parameter 1-80 Function at Stop .

•

6.8.55 ALARM 67, Option Module Configuration has Changed

Cause

One or more options have either been added or removed since the last power-down.

Troubleshooting

Check that the configuration change is intentional and reset the unit.

•

6.8.56 ALARM 68, Safe Stop Activated

Cause

Safe Torque Off (STO) has been activated.

Troubleshooting

To resume normal operation, apply 24 V DC to terminal 37, then send a reset signal (via bus, digital, or by pressing [Reset]).

•

6.8.57 ALARM 70, Illegal FC Configuration

Cause

The control card and power card are incompatible.

Troubleshooting

To check compatibility, contact the Danfoss supplier with the type code from the unit nameplate and the part numbers on the cards.

•

6.8.58 ALARM 71, PTC 1 Safe Stop

Cause

Because the motor is too warm, the VLT

®

PTC Thermistor Card MCB 112 activated the Safe Torque Off (STO).

Troubleshooting

-

Once the motor temperature reaches an acceptable level and the digital input from MCB 112 is deactivated, perform 1 of the following:

Send a reset signal via bus or digital I/O.

Press [Reset].

•

•

6.8.59 ALARM 72, Dangerous Failure

Cause

Safe Torque Off (STO) with trip lock.

Troubleshooting

An unexpected combination of STO commands has occurred:

VLT

®

PTC Thermistor Card MCB 112 enables X44/10, but STO is not enabled.

MCB 112 is the only device using STO (specified through selection [4] PTC 1 alarm or [5] PTC 12 warning in parameter 5-19 Terminal 37 Safe Stop ). STO is activated, but X44/10 is not activated.

•

6.8.60 WARNING 73, Safe Stop Auto Restart

Cause

STO activated.

Troubleshooting

With automatic restart enabled, the motor can start when the fault is cleared.


AQ267036816112en-000201 / 130R0208 | 57


Operating Guide


Troubleshooting

6.8.61 ALARM 74, PTC Thermistor

Cause

The PTC is not working. Alarm is related to VLT

®

PTC Thermistor Card MCB 112.

•

6.8.62 ALARM 75, Illegal Profile Sel.

Cause

Do not write the parameter value while the motor is running.

Troubleshooting

Stop the motor before writing the MCO profile to parameter 8-10 Control Word Profile .

6.8.63 WARNING 77, Reduced Power Mode

Cause

The drive is operating in reduced power mode (less than allowed number of inverter sections). The warning is generated on power cycle when the drive is set to run with fewer inverters and remains on.

•

•

•

•

6.8.64 ALARM 78, Tracking Error

Cause

The difference between setpoint value and actual value exceeds the value in parameter 4-35 Tracking Error .

Troubleshooting

Disable the function or select an alarm/warning in parameter 4-34 Tracking Error Function .

Investigate the mechanics around the load and motor. Check feedback connections from motor encoder to drive.

Select motor feedback function in parameter 4-30 Motor Feedback Loss Function .

Adjust the tracking error band in parameter 4-35 Tracking Error and parameter 4-37 Tracking Error Ramping .

6.8.65 ALARM 79, Illegal Power Section Configuration

Cause

The scaling card has an incorrect part number or is not installed. The MK102 connector on the power card could not be installed.

6.8.66 ALARM 80, Drive Initialized to Default Value

Cause

Parameter settings are initialized to default settings after a manual reset. To clear the alarm, reset the unit.

6.8.67 ALARM 81, CSIV Corrupt

Cause

The CSIV file has syntax errors.

6.8.68 ALARM 82, CSIV Parameter Error

Cause

CSIV failed to initialize a parameter.

6.8.69 ALARM 83, Illegal Option Combination

Cause

The mounted options are incompatible.

6.8.70 ALARM 84, No Safety Option

Cause

The safety option was removed without applying a general reset.

Troubleshooting

Reconnect the safety option.

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Operating Guide


Troubleshooting

•

•

6.8.71 ALARM 88, Option Detection

Cause

A change in the option layout is detected. Parameter 14-89 Option Detection is set to [0] Frozen configuration and the option layout has been changed.

Troubleshooting

To apply the change, enable option layout changes in parameter 14-89 Option Detection .

Alternatively, restore the correct option configuration.

6.8.72 WARNING 89, Mechanical Brake Sliding

Cause

The hoist brake monitor detects a motor speed exceeding 10 RPM.

•

6.8.73 ALARM 90, Feedback Monitor

Troubleshooting

Check the connection to the encoder/resolver option and, if necessary, replace the VLT

®

Encoder Input MCB 102 or VLT

®

Resolver Input MCB 103.

•

6.8.74 ALARM 91, Analog Input 54 Wrong Settings

Troubleshooting

Set switch S202 in position OFF (voltage input) when a KTY sensor is connected to analog input terminal 54.

•

•

•

6.8.75 ALARM 99, Locked Rotor

Cause

The rotor is blocked.

Troubleshooting

Check if the motor shaft is locked.

Check if the start current triggers the current limit set in parameter 4-18 Current Limit .

Check if it increases the value in parameter 30-23 Locked Rotor Detection Time [s] .

•

6.8.76 WARNING/ALARM 104, Mixing Fan Fault

Cause

The fan is not operating. The fan monitor checks that the fan is spinning at power-up or whenever the mixing fan is turned on. The mixing fan fault can be configured as a warning or an alarm in parameter 14-53 Fan Monitor .

Troubleshooting

Cycle power to the drive to determine if the warning/alarm returns.

6.8.77 WARNING/ALARM 122, Mot. Rotat. Unexp.

Cause

The drive performs a function that requires the motor to be at standstill, for example DC hold for PM motors.

6.8.78 WARNING 163, ATEX ETR Cur.Lim.Warning

Cause

The drive has run above the characteristic curve for more than 50 s. The warning is activated at 83% and deactivated at 85% of the allowed thermal overload.

6.8.79 ALARM 164, ATEX ETR Cur.Lim.Alarm

Cause

Running above the characteristic curve for more than 60 s within a period of 600 s activates the alarm, and the drive trips.

6.8.80 WARNING 165, ATEX ETR Freq.Lim.Warning

Cause

The drive has run for more than 50 s below the allowed minimum frequency ( parameter 1-98 ATEX ETR Interpol. Points Freq.

).


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Operating Guide


Troubleshooting

6.8.81 ALARM 166, ATEX ETR Freq.Lim.Alarm

The drive has run for more than 60 s (in a period of 600 s) below the allowed minimum frequency ( parameter 1-98 ATEX ETR Interpol.

Points. Freq.

).

6.8.82 WARNING 251, New Typecode

Cause

The power card or other components have been replaced, and the typecode has changed.

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Operating Guide Specifications

7 Specifications

7.1 Electrical Data

Table 22: Shaft Output, Output Current, and Input Current

Mains Supply 3x380–480 V AC

Drive

Rated shaft output [kW]

Rated shaft output [hp]

Maximum input current

Continuous (3x380–440 V) [A]

Intermittent (3x380–440 V) [A]



Recommended maximum fuse size (non UL)

Built-in circuit breaker (large unit)

Recommended circuit breaker Danfoss CTI-25M (small and large unit) part number:

0.37, 0.55 kW

0.75, 1.1 kW

1.5, 2.2, and 3 kW

Recommended circuit breaker Danfoss CTI-45MB (small unit) part number: (1)

0.55, 0.75 kW

1.1 kW

1.5 kW

2.2 kW

Power loss at maximum load [W] (2)

Efficiency (3)

Weight, small unit [kg (lb)]

Weight, large unit [kg (lb)]

Output current



PK37 PK55 PK75 P1K1 P1K5 P2K2 P3K0

0.37

0.55

0.75

1.1

1.5

2.2

3.0

0.5

0.75

1.0

1.5

2.0

3.0

4.0

1.2

1.9

1.0

1.6

gG-25

1.6

2.6

1.4

2.2

2.2

3.5

1.9

3.0

2.7

4.3

2.7

4.3

CTI-25M ordering number: 047B3151

3.7

5.9

3.1

5.0

5.0

8.0

4.3

6.9

6.5

10.4

5.7

9.1

Ordering number: 047B3148







35 42 46 58 62 88 116

0.93

0.95

0.96

0.96

0.97

0.97

0.97

9.8 (21.6)

13.9 (30.6)

1.3

2.1

1.8

2.9

2.4

3.8

3.0

4.8

4.1

6.6

5.2

8.3

7.2

11.5


AQ267036816112en-000201 / 130R0208 | 61



Mains Supply 3x380–480 V AC



Continuous kVA (400 V AC) [kVA]

Continuous kVA (460 V AC) [kVA]

Maximum cable size: (mains, motor, brake) [mm 2 /AWG]

1.2

1.9

0.9

0.9

1.6

2.6

1.3

1.3

solid cable 6/10 flexible cable 4/12

2.1

3.4

1.7

1.7

3.0

4.8

2.1

2.4

3.4

5.4

2.8

2.7

4.8

7.7

3.9

3.8

6.3

10.1

5.0

5.0

1 Type CTI-45MB circuit breakers are not available for 3 kW (4 hp) units.

2 Applies to the dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses may increase. LCP and typical control card power consumption are included. For power loss data according to EN 50598-2, refer to www.danfoss.com

.

3

Efficiency measured at nominal current. For energy efficiency class, see 7.4.1 Environment

. For part load losses see www.danfoss.com

.

7.2 Mains Supply (L1, L2, L3)

Supply voltage (1)(2)

Supply frequency

Maximum imbalance temporary between mains phases

True power factor (λ)

Displacement power factor (cos Φ)

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

380–480 V/500–600 V ±10%

50/60 Hz ±5%

3.0% of rated supply voltage

≥0.9 nominal at rated load

Near unity (>0.98)

Maximum 2 times per minute

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

2 The unit is suitable for use on a circuit capable of delivering not more than 100000 RMS symmetrical Amperes, 240/500/600/690 V maximum.

7.3 Motor Output and Motor Data

7.3.1 Motor Output (U, V, W)

Output voltage

Output frequency

Output frequency in flux mode

Switching on output

Ramp times

0–100% of supply voltage

0–590 Hz (1)

0–300 Hz

Unlimited

0.01–3600 s

1 Dependent on voltage and power.

7.3.2 Torque Characteristics

Starting torque (constant torque)

Starting torque

Overload torque (constant torque)

Starting torque (variable torque)

Overload torque (variable torque)

1 Percentage relates to the nominal torque of the drive, dependent on power size.

Maximum 160% for 60 s (1)

Maximum 180% up to 0.5 s (1)

Maximum 160% for 60 s (1)

Maximum 110% for 60 s (1)

Maximum 110% for 60 s (1)

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7.4 Ambient Conditions

7.4.1 Environment

Enclosure rating

Vibration test for units without circuit breaker

Mount unit with integrated circuit breaker on a level, vibrationproof, and torsionally rigid support structure.

Maximum relative humidity

Ambient temperature (1)

Minimum ambient temperature during full-scale operation

Minimum ambient temperature at reduced speed performance

Temperature during storage/transport

Maximum altitude above sea level

Energy efficiency class (2)

IP66/Type 4X

1.7 g RMS

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

Maximum 40 °C (75 °F) (24-hour average maximum 35 °C (95 °F))

0 °C (32 °F)

-10 °C (14 °F)

-25 to +65/70 °C (-13 to +149/158 °F)

1000 m (3280 ft)

IE2

•

•

•

•

•

1 See Special Conditions in the design guide for:

Derating for high ambient temperature.

• Derating for high altitude.

2 Determined according to EN 50598-2 at:

Rated load.

90% rated frequency.

Switching frequency factory setting.

Switching pattern factory setting.

7.5 Cable Lengths and Cross-sections

Maximum motor cable length, shielded

Maximum motor cable length, unshielded, without fulfilling emission specification

Maximum cross-section to control terminals, flexible/rigid wire without cable end sleeves

Maximum cross-section to control terminals, flexible wire with cable end sleeves

Maximum cross-section to control terminals, flexible wire with cable end sleeves with collar

Minimum cross-section to control terminals

Maximum cross-section to mains and motor, stranded/rigid wire

Maximum cross-section to mains and motor, flexible wire

Maximum cross-section to mains and motor, flexible with/without plastic sleeve

Maximum cross-section to mains and motor, flexible with TWIN ferrule

Minimum cross-section to mains and motor, flexible/rigid/stranded

Nominal/rated current

10 m (32.8 ft)

10 m (32.8 ft)

1.5 mm 2 /16 AWG

1.5 mm 2 /16 AWG

1.5 mm 2 /16 AWG

0.25 mm 2 /24 AWG

6 mm 2 /10 AWG

4 mm 2 /12 AWG

4 mm 2 /12 AWG

1 mm 2 /17 AWG

0.5 mm 2 /20 AWG

25 A (up to 50 A with optional looping terminals)

See electrical data tables in 7.1 Electrical Data

for more information.

It is mandatory to ground the mains connection properly using T95 (PE) of the drive. The ground connection cable cross-section must be at least 10 mm 2 (8 AWG) or 2 rated mains wires terminated separately according to EN 50178. Use unshielded cable.

See also

4.3 Grounding

.


AQ267036816112en-000201 / 130R0208 | 63



7.6 Control Input/Output and Control Data

7.6.1 Digital Inputs

Programmable digital inputs

Terminal number

Logic

Voltage level

Voltage level, logic 0 PNP


Voltage level, logic 0 NPN

Voltage level, logic 1 NPN

Maximum voltage on input

Pulse frequency range

(Duty cycle) Minimum pulse width

Input resistance, R i

4 (6) (1)

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

PNP or NPN

0–24 V

<5 V DC

>10 V DC

>19 V DC

<14 V DC

28 V DC

0–110 kHz

4.5 ms

Approximately 4 kΩ

1 Terminals 27 and 29 can also be programmed as output.

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

7.6.2 STO Terminal 37 (Terminal 37 is Fixed PNP Logic)

Voltage level



Typical input current at 24 V

Typical input current at 20 V

Input capacitance

0–24 V DC

<4 V DC

>20 V DC

50 mA rms

60 mA rms

400 nF

7.6.3 Analog Inputs:

Number of analog inputs

Terminal number

Modes

Mode select

Voltage mode

Voltage level


Maximum voltage

Current mode

Current level


Maximum current

Resolution for analog inputs

Accuracy of analog inputs

Bandwidth

2

53, 54

Voltage or current

Switch S201 and switch S202

Switch S201/switch S202 = OFF (U)

0–10 V (scaleable)


±20 V

Switch S201/S202 = ON (I)

0/4–20 mA (scaleable)

Approximately 200 Ω

30 mA

10 bit (+ sign)

Maximum error 0.5% of full scale

200 Hz

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

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2 3

+24V

18

4

5

6

37

1

RS485

Illustration 29: Analog Inputs

1

2

3

Functional isolation

Control

PELV isolation

4

5

6

Mains

High voltage

Motor

7.6.4 Pulse/Encoder Inputs

Programmable pulse/encoder inputs

Terminal number pulse/encoder

Maximum frequency at terminals 29, 32, 33



Voltage level

Maximum voltage on input


Pulse input accuracy (0.1–1 kHz)

Encoder input accuracy (1–11 kHz)

2/1

29 (1) , 33 (2) /32 (3) , 33 (3)

110 kHz (Push-pull driven)

5 kHz (Open collector)

4 Hz

See

7.6.1 Digital Inputs

.

28 V DC


Maximum error: 0.1% of full scale


1 FC 302 only.

2 Pulse inputs are 29 and 33.

3 Encoder inputs: 32=A, 33=B.

The pulse and encoder inputs (terminals 29, 32, 33) are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

7.6.5 Digital Outputs

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

2

27, 29 (1)

0–24 V

40 mA

1 kΩ

10 nF

0 Hz

32 kHz



AQ267036816112en-000201 / 130R0208 | 65



Resolution of frequency outputs 12 bit

1 Terminals 27 and 29 can also be programmed as input.

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

7.6.6 Analog Output

Number of programmable outputs

Terminal number

Current range at analog output

Maximum load GND - analog output less than

Accuracy on analog output

Resolution of analog output

1

42

0/4 to 20 mA

500 Ω


12 bit

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

7.6.7 Control Card, 24 V DC Output

Terminal number

Output voltage

Maximum load

12, 13

24 V +1, -3 V

600 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.

7.6.8 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.

50

10.5 V ±0.5 V

15 mA

7.6.9 Control Card, RS485 Serial Communication

Terminal number

Terminal number 61

The RS485 serial communication circuit is galvanically isolated from the supply voltage (PELV).

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

Common for terminals 68 and 69

7.6.10 Control Card, USB Serial Communication

USB standard

USB plug

1.1 (full speed)

USB type B plug

Connection to the 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 ground connection is not galvanically isolated from protective earth. Use only an isolated laptop as PC connection to the

USB connector on the drive.

7.6.11 Relay Outputs

Programmable relay outputs

Relay 01 terminal number

Maximum terminal load (AC-1) (1) on 1–3 (NC), 1–2 (NO) (resistive load)

Maximum terminal load (AC-15) (1) (inductive load @ cosφ 0.4)

2

1–3 (break), 1–2 (make)

240 V AC, 2 A

240 V AC, 0.2 A

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Maximum terminal load (DC-1) (1) load)

on 1–2 (NO), 1–3 (NC) (resistive

Maximum terminal load (DC-13) (1) (inductive load)

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 @ cosφ 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 @ cosφ 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 1–3 (NC), 1–2 (NO), 4–6 (NC), 4–5 (NO)

Environment according to EN 60664-1

48 V DC, 1 A

24 V DC, 0.1 A

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

48 V DC, 1 A

24 V DC, 0.1 A

24 V DC 10 mA, 24 V AC 20 mA

Overvoltage category III/pollution degree 2

1 IEC 60947 parts 4 and 5. The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).

2 Overvoltage Category II.

3 UL applications 300 V AC 2 A.

7.6.12 Control Card Performance

Scan interval 1 ms

7.6.13 Control Characteristics

Resolution of output frequency at 0–590 Hz

Repeat accuracy of precise start/stop (terminals 18, 19)

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

Speed control range (open loop)

Speed control range (closed loop)

Speed accuracy (open loop)

Speed accuracy (closed loop), depending on resolution of feedback device

Torque control accuracy (speed feedback)

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

±0.003 Hz

≤±0.1 ms

≤2 ms

1:100 of synchronous speed

1:1000 of synchronous speed

30–4000 RPM: Error ±8 RPM

0–6000 RPM: Error ±0.15 RPM

Maximum error ±5% of rated torque

7.7 Fuses and Circuit Breakers

•

•

•

7.7.1 Recommendations

American Wire Gauge. Maximum cable cross-section is the largest cable cross-section that can be attached to the terminals.

Always observe national and local regulations.

Type gG pre-fuses must be used. To maintain UL/cUL, use pre-fuses of these types (see Table 23 ).

Measured using a 10 m (32.8 ft) shielded/armored motor cable with a rated load and rated frequency.

Fuses

The unit is suitable for use on a circuit capable of delivering not more than 100000 RMS symmetrical Amperes, 500 V maximum.

Circuit breaker

The unit is suitable for use on a circuit capable of delivering not more than 10000 RMS symmetrical Amperes, 500 V maximum.


AQ267036816112en-000201 / 130R0208 | 67



7.7.2 Recommended Maximum Pre-fuse Size 25 A

Table 23: FCD 302 Pre-fuses Meeting UL/cUL Requirements

Brand Fuse type (1) UL file number

Bussmann

Bussmann

FWH-

KTS-R

E91958

E4273

Bussmann

Bussmann

Bussmann

Bussmann

Bussmann

SIBA

Little Fuse

Ferraz-Shawmut

Ferraz-Shawmut

Ferraz-Shawmut

JKS-

JJS-

FNQ-R-

KTK-R-

LP-CC-

5017906-

KLS-R

ATM-R

A6K-R

HSJ

E4273

E4273

E4273

E4273

E4273

E180276

E81895

E2137

E2137

E2137

UL category (CCN code)

JFHR2

RK1/JDDZ

J/JDDZ

T/JDDZ

CC/JDDZ

CC/JDDZ

CC/JDDZ

RK1/JDDZ

RK1/JDDZ

CC/JDDZ

RK1/JDDZ

J/HSJ

1 5 A (0.37 kW (0.5 hp)), 7 A (0.55 kW (0.75 hp)), 9 A (0.75 kW (1.0 hp)), 12 A (1.1 kW (1.5 hp)), 15 A (1.5 kW (2.0 hp)), 20 A (2.2 kW (3.0 hp)), 25 A (3 kW

(4.0 hp))

Table 24: FCD 302 DC Voltage Level

DC voltage level 380–480 V units (V DC)

Inverter undervoltage disable

Undervoltage warning

Inverter undervoltage re-enable (warning reset)

Overvoltage warning (without brake)

Dynamic brake turn on

Inverter overvoltage re-enable (warning reset)

Overvoltage warning (with brake)

Overvoltage trip

373

410

398

778

778

795

810

820

7.8 Mechanical Dimensions

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Operating Guide

331.5 mm (13.05 in)

280 mm (11.02 in)

6.5 mm

(0.25 in)

Ø13 mm

(0,51 in)

41 mm

(1.61 in) 315 mm (12.4 in)

349.5 mm (13.75 in)

ON

WARNING ALARM

Bus MS NS1 NS2

Illustration 30: Cable Entries and Hole Sizes (Small Unit)

Specifications


AQ267036816112en-000201 / 130R0208 | 69


Operating Guide

431.5 mm (16.98 in)

380 mm (14.96 in)

6.5 mm

(0.25 in)

Ø13 mm

(0,51 in)

32 mm

(1.25 in) 415 mm (16.33 in)

449.5 mm (17.69 in)

Illustration 31: Cable Entries and Hole Sizes (Large Unit)

Table 25: Mechanical Dimensions

Motor side

Control side

Mains side

1 Also used for 4xM12/6xM12 sensor/actuator sockets.

1xM20, 1xM25

2xM20, 9xM16 (1)

2xM25

Specifications

70 | Danfoss A/S © 2021.09

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Operating Guide

8 Appendix

8.1 Symbols, Abbreviations and Conventions

8.1.1 Symbols and Abbreviations

°C Degrees Celsius

°F

AC

AEO

AWG

Degrees Fahrenheit

Alternating current

Automatic energy optimization

American wire gauge

LCP

MCT n s

P

M,N

PELV

AMA

DC

EMC

ETR f

M,N

I

INV

I

LIM

I

M,N

I

VLT,MAX

I

VLT,N

IP

PCB

PM motor

PWM

RPM

Automatic motor adaptation

Direct current

Electro-magnetic compatibility

Electronic thermal relay

Nominal motor frequency

Rated inverter output current

Current limit

Nominal motor current

Maximum output current

Rated output current supplied by the drive

Ingress protection

Local control panel

Motion control tool

Synchronous motor speed

Nominal motor power

Protective extra low voltage

Printed circuit board

Permanent magnet motor

Pulse width motor

Revolutions per minute


Appendix

AQ267036816112en-000201 / 130R0208 | 71


Operating Guide Appendix

Regen

T

LIM

U

M,N

Regenerative terminals

Torque limit

Nominal motor voltage

8.2 Quick Menu Parameters

Table 26: Parameter 0-01 Language

Option Function

Defines the language. The drive is delivered with 4 different language packages. English and German are included in all packages. English cannot be erased or manipulated.

[0]* English

[1] Deutsch

[2] Français

[3] Dansk

[4] Spanish

[5] Italiano

[6] Svenska

[7] Nederlands

[10] Chinese

[20] Suomi

[22] English US

[27] Greek

[28] Bras.Port

[36] Slovenian

[39] Korean

[40] Japanese

[41] Turkish

[42] Trad. Chinese

[43] Bulgarian

[44] Srpski

[45] Romanian

[46] Magyar

[47] Czech

[48] Polski

[49] Russian

Part of language packages 1–4

Part of language packages 1–4

Part of language package 1























72 | Danfoss A/S © 2021.09

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Option

[50] Thai

Function


[51] Bahasa Indonesia Part of language package 2

[52] Hrvatski Part of language package 3

Table 27: Parameter 1-20 Motor Power [kW]

Range Function

Size related*

[0.09 -

3000.00 kW] N O T I C E

This parameter cannot be adjusted while the motor is running.

Enter the nominal motor power in kW according to the motor nameplate data. The default value corresponds to the nominal rated output of the drive. This parameter is visible in the LCP if parameter 0-03 Regional Settings is set to [0] International .

Table 28: Parameter 1-22 Motor Voltage

Range Function

Size related* [10 - 1000 V] Enter the nominal motor voltage according to the motor nameplate data. The default value corresponds to the nominal rated output of the drive.

Table 29: Parameter 1-23 Motor Frequency

Range Function

Size related*

[20 -

1000 Hz] N O T I C E

From software version 6.72 onwards, the output frequency of the drive is limited to 590 Hz.

Select the motor frequency value form the motor nameplate data. If a value other than 50 Hz or 60 Hz is selected, adapt the load-independent settings in parameter 1-50 Motor Magnetization at Zero Speed to parameter 1-53 Model Shift Frequency . For 87 Hz, adapt parameter 4-13 Motor Speed High Limit [RPM] and parameter 3-03 Maximum Reference .

Table 30: Parameter 1-24 Motor Current

Range Function

Size related*

[0.10 -

10000.00 A] N O T I C E


Enter the nominal motor current value from the motor nameplate data. The data is used for calculating motor torque, motor thermal protection, and so on.

Table 31: Parameter 1-25 Motor Nominal Speed

Range Function

Size related*

[100 -

60000 RPM] N O T I C E



AQ267036816112en-000201 / 130R0208 | 73



Range Function

Enter the nominal motor speed value from the motor nameplate data. The data is used for calculating automatic motor compensations.

Latched start

Reversing

Start reversing

Enable start forward

Enable start reverse

Jog

Preset ref bit 0

Preset ref bit 1

Preset ref bit 2

Freeze reference

Freeze output

Speed up

Speed down

Setup select bit 0

Setup select bit 1

Catch up

Slow down

Pulse input

Ramp bit 0

Ramp bit 1

[22]

[23]

[24]

[28]

[18]

[19]

[20]

[21]

[29]

[32]

[34]

[35]

[13]

[14]

[16]

[17]

[9]

[10]

[11]

[12]

Table 32: Parameter 5-12 Terminal 27 Digital Input

Option Function

Select the function from the available digital input range.

[4]

[5]

[6]

[8]

[0]

[1]

[2]

[3]

No operation

Reset

Coast inverse

Coast and reset inverse

Quick stop inverse

DC-brake inverse

Stop inverse

Start

74 | Danfoss A/S © 2021.09

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[56]

[57]

[62]

[65]

Option

[36] Mains failure inverse

[55] DigiPot increase

DigiPot decrease

DigiPot clear

Reset Counter A

Reset Counter B

Function

Table 33: Parameter 1-29 Automatic Motor Adaptation (AMA)

Option Function

N O T I C E


The AMA function optimizes dynamic motor performance by automatically optimizing the advanced motor parameters ( parameter 1-30 Stator Resistance (Rs) to parameter 1-35 Main Reactance (Xh) ) at motor standstill.

Activate the AMA function by pressing [Hand On] after selecting [1] Enable complete AMA or [2] Enable reduced AMA . After a normal sequence, the display reads Press [OK] to finish AMA . After pressing [OK], the drive is ready for operation.

[0]* OFF

[1] Enable complete

AMA

[2] Enable reduced

AMA

Performs AMA of the stator resistance R s

, the rotor resistance R r leakage reactance X

2

, and the main reactance X h

.

, the stator leakage reactance X

1

, the rotor

Performs a reduced AMA of the stator resistance R between the drive and the motor.

s

in the system only. Select this option if an LC filter is used

N O T I C E

For the best adaptation of the drive, run AMA on a cold motor.

AMA cannot be performed while the motor is running.

N O T I C E

N O T I C E

AMA cannot be performed on permanent magnet motors.

N O T I C E

It is important to set parameter group 1-* Motor Data correctly since these parameters form part of the AMA algorithm. An AMA must be performed to achieve optimum dynamic motor performance. Depending on the power rating of the motor, it takes up to 10 minutes.

N O T I C E

To avoid generating external torque during AMA, disconnect the motor shaft from the application.


AQ267036816112en-000201 / 130R0208 | 75



N O T I C E

If 1 of the settings in parameter group 1-2* Motor Data is changed, parameter 1-30 Stator Resistance (Rs) to parameter 1-39 Motor

Poles , the Advanced Motor parameters return to their default settings.

Table 34: Parameter 3-02 Minimum Reference

Range Function

Size related*

[-999999.999 - parameter 3-03 ReferenceFeedbackUnit ]

•

Enter the minimum reference. The minimum reference is the lowest value obtainable by summing all references. Minimum reference is active only when parameter 3-00 Reference Range is set to [0] Min.–Max .The minimum reference unit matches:

The configuration of parameter 1-00 Configuration Mode and for [2] Torque set to Nm.

for [1] Speed closed loop set to RPM

• The unit selected in parameter 3-01 Reference/Feedback Unit .

If option [10] Synchronization is selected in parameter 1-00 Configuration Mode , this parameter defines the maximum speed deviation when performing the position offset defined in parameter

3-26 Master Offset .

Table 35: Parameter 3-03 Maximum Reference

Range Function

Size related*

[parameter 3-02 -

999999.999 ReferenceFeedbackUnit]

•

•

Enter the maximum reference. The maximum reference is the highest value obtainable by summing all references. The maximum reference unit matches:

The configuration of parameter 1-00 Configuration Mode and for [2] Torque set to Nm.

for [1] Speed closed loop set to RPM

The unit selected in parameter 3-00 Reference Range .

If option [9] Positioning is selected in parameter 1-00 Configuration Mode , this parameter defines the default speed for positioning.

Table 36: Parameter 3-41 Ramp 1 Ramp Up Time

Range Function

Size related*

[0.01 -

3600 s]

Enter the ramp-up time, that is, the acceleration time from 0 RPM to the synchronous motor speed n s

.

Select a ramp-up time which prevents the output current from exceeding the current limit in parameter

4-18 Current Limit during ramping. The value 0.00 corresponds to 0.01 s in speed mode. See ramp-down time in parameter 3-42 Ramp 1 Ramp Down Time .

Table 37: Parameter 3-42 Ramp 1 Ramp Down Time

Range Function

Size related*

[0.01 -

3600 s]

Enter the ramp-down time, that is, the deceleration time from the synchronous motor speed n s

to 0 RPM.

Select a ramp-down time such that no overvoltage occurs in the inverter due to regenerative operation of the motor, and such that the generated current does not exceed the current limit in parameter 4-18

Current Limit . The value 0.00 corresponds to 0.01 s in speed mode. See ramp-up time in parameter 3-41

Ramp 1 Ramp Up Time .

76 | Danfoss A/S © 2021.09

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Operating Guide Index

Index

+

+10 V DC output........................................................................................... 66

2

24 V DC output..............................................................................................66

Encoder input................................................................................................ 65

Environment.................................................................................................. 63

Equipment...................................................................................................... 16

External command.........................................................................10, 10, 46

External controller.......................................................................................... 6

External interlock..........................................................................................56

A

Abbreviations................................................................................................ 71

AC input....................................................................................................10, 28

AC mains...................................................................................................10, 28

AC waveform..................................................................................................10

Additional resources......................................................................................6

Alarm.................................................................................................................46

Alarm log......................................................................................................... 37

AMA............................................................................................................41, 44

Ambient conditions.....................................................................................63

Analog input.................................................................................................. 64

Analog output............................................................................................... 66

Approvals and certifications.....................................................................10

Auto on....................................................................................... 38, 41, 43, 45

Auto-reset....................................................................................................... 36

Automatic motor adaptation.....................................................41, 48, 55

F

Fans

Internal fault..........................................................................................50

Mixing fan fault.................................................................................... 59

Fault log...........................................................................................................37

Feedback.................................................................................................. 33, 44

Fieldbus

Warning.................................................................................................. 52

Floating delta.................................................................................................28

Fuse................................................................................................................... 19

Fuses................................................................................................... 33, 52, 67

Fusing............................................................................................................... 33

G

Grounded delta.............................................................................................28

Grounding.........................................................................................28, 33, 35

B

Brake resistor....................................................................................30, 50, 50

Braking............................................................................................................. 44

H

Hand on.................................................................................................... 38, 43

Harmonics.......................................................................................................10

Heat sink.......................................................................................................... 51

C

Cable length, control cables.....................................................................63

Cable specifications.....................................................................................63

Circuit breaker............................................................................................... 67

Cleaning...........................................................................................................42

Conduit............................................................................................................ 33

Control card...............................................................................66, 66, 66, 66

Control card performance.........................................................................67

Control characteristics................................................................................67

Control signal.................................................................................................43

Control terminal..............................................................................38, 43, 46

Control wiring...........................................................................19, 22, 29, 33

Cooling.............................................................................................................15

Cooling clearance.........................................................................................33

Cross-section, control cable..................................................................... 63

I

IEC 61800-3.....................................................................................................28

IEC 721-3-3......................................................................................................63

Initialization, manual...................................................................................39

Initialization, recommended....................................................................39

Input current..................................................................................................28

Input disconnect...........................................................................................28

Input power..........................................................10, 19, 22, 28, 33, 35, 46

Input terminal.........................................................................................28, 35

Input voltage..................................................................................................35

Installation...................................................................................................... 33

Installation environment...........................................................................15

Intended use.....................................................................................................6

Isolated mains................................................................................................28

D

DC current................................................................................................10, 44

Digital input.............................................................................................45, 64

Digital output................................................................................................ 65

DIP switch........................................................................................................32

Disconnect switch.................................................................................35, 35

Downloading data from the LCP............................................................38

L

LED.....................................................................................................................42

List of warnings and alarms......................................................................47

Local control.....................................................................................36, 38, 43

Location of terminals.................................................................................. 23

E

Efficiency......................................................................................................... 61

Electrical interference.................................................................................19

EMC....................................................................................................................33

EMC interference..........................................................................................22

EMC-compliant installation...................................................................... 19

EN 60664-1......................................................................................................67

M

Main menu......................................................................................................37

Mains

Mains connection................................................................................28

Mains voltage................................................................................. 37,44

Warning............................................................................................ 47,52

Maintenance.................................................................................................. 42

Manual initialization....................................................................................39

Mechanical brake......................................................................................... 31


AQ267036816112en-000201/130R0208 | 77



Mechanical brake control..........................................................................49

Mechanical dimensions............................................................................. 68

Menu key..................................................................................................36, 37

Menu structure..............................................................................................37

Motor

Motor current......................................................................10,10,37,41

Thermal protection.............................................................................19

Motor power......................................................................................... 37

Motor data............................................................................................. 41

Warning.......................................................................... 48,48,51,51,52

Motor output................................................................................................. 62

Motor power........................................................................................... 19, 19

Motor protection............................................................................................ 6

Motor status......................................................................................................6

Motor wiring........................................................................................... 22, 33

Mounting position....................................................................................... 16

N

Navigation key.................................................................................36, 37, 43

Noise isolation............................................................................................... 33

P

Parameter setting..................................................................................38, 38

Phase imbalance...........................................................................................52

Potential equalization.................................................................................20

Power factor............................................................................................ 10, 33

Power wire connection.............................................................................. 19

Programming..........................................................................................36, 38

Pulse input...................................................................................................... 65

S

Safe Torque Off............................................................................................. 32

See STO

Serial communication.....................................................38, 43, 44, 45, 46

Service.............................................................................................................. 42

Setpoint........................................................................................................... 45

Setup..........................................................................................................37, 41

Shielded cable........................................................................................ 22, 33

Shielded twisted pair (STP)....................................................................... 32

Shock................................................................................................................ 15

Short circuit

Alarm....................................................................................................... 49

Sleep mode.....................................................................................................45

Speed reference.....................................................................................41, 43

Status display.................................................................................................43

Status mode................................................................................................... 43

STO..................................................................................32, 57, 57, 57, 57, 64

Storage.............................................................................................................15

Supply voltage........................................................................................35, 62

Switches

Disconnect...........................................................................13,29,35,42

Switching frequency................................................................................... 45

Symbols........................................................................................................... 71

System feedback.............................................................................................6

O

Operation key......................................................................................... 36, 36

Optional equipment....................................................................................35

Output current.............................................................................................. 44

Output terminal............................................................................................ 35

Overcurrent protection..............................................................................19

Overvoltage....................................................................................................45

T

Terminal types...............................................................................................25

Thermistor

Warning.................................................................................................. 58

Tools..................................................................................................................16

Torque

Warning.................................................................................................. 48

Torque characteristics................................................................................ 62

Transient..........................................................................................................10

Transient protection....................................................................................10

Trip.....................................................................................................................46

Trip lock............................................................................................................46

Troubleshooting...........................................................................................47

Q

Qualified personnel........................................................................................6

Quick menu............................................................................................. 37, 37

U

UL certification.............................................................................................. 10

Unintended start..................................................................... 13, 29, 35, 42

Uploading data to the LCP........................................................................38

USB serial communication........................................................................66

R

Recommended initialization....................................................................39

Reference....................................................................................37, 43, 45, 45

Relay output...................................................................................................66

Remote command..........................................................................................6

Remote reference.........................................................................................44

Reset.................................................................36, 36, 38, 39, 46, 46, 46, 57

RFI filter............................................................................................................ 28

RMS current....................................................................................................10

RS485................................................................................................................ 32

RS485 serial communication....................................................................66

Run command...............................................................................................41

Run permissive..............................................................................................44

V

Vibration.......................................................................................................... 15

Voltage

Safety warning........................................................13,35,49,51,51,52

W

Warning........................................................................................................... 46

Wire size...........................................................................................................19

Wire type and ratings..................................................................................19

Wiring schematic..........................................................................................21

78 | Danfoss A/S © 2021.09

AQ267036816112en-000201/130R0208




AQ267036816112en-000201/130R0208 | 79

Danfoss A/S

Ulsnaes 1

DK-6300 Graasten vlt-drives.danfoss.com

Danfoss can accept no responsibility for possible errors in catalogs, brochures, and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

*130R0208*


*M0012401* AQ267036816112en-000201 / 130R0208

Danfoss VLT Decentral Drive FCD 302 Operating Guide

Operating Guide

VLT® Decentral Drive FCD 302

vlt-drives.danfoss.com

Contents

1 Introduction

2 Safety

3 Mechanical Installation

VLT®

4 Electrical Installation

5 Commissioning

6 Maintenance, Diagnostics and Troubleshooting

Status

Earth Fault [A14]

7 Specifications

8 Appendix

Index

Danfoss A/S

Ulsnaes 1

DK-6300 Graasten vlt-drives.danfoss.com

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