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1. Installation Instructions 2 5 a ca m 1 R 9 506 Os 000 O 200 a 0000 H pre ESosso ssosoc 3 ooo T T RI 4 sssssssssse ol ei La Dez 5 I A nits ay PA C 6 C 9 10 gt gt L1 L2 it vi 2 3 U PE S PE 8 7 Illustration 2 5 Typical Electrical Connection PLC 6 Min 200mm 7 9in between control cables motor and mains 1 Output contactor Generally not recommended Mains 3 phase and reinforced PE 2 grounding rat PE coo Cable insulation stripped Equalising min 16mm 0 025in MG 33 AJ 02 VLT is a registered Danfoss trademark 11 Installation Instructions 2 4 1 Requirements AWARNING EQUIPMENT HAZARD Rotating shafts and electrical equipment can be hazardous All electrical work must conform to national and local electrical codes It is strongly recommended that installation start up and maintenance be performed only by trained and qualified personnel Failure to follow these guidelines could result in death or serious injury CAUTION WIRING ISOLATION Run input power motor wiring and control wiring in three separate metallic conduits or use separated shielded cable for high frequency noise isolation Failu
2. 67 VLT AutomationDrive Operating Specifications Instructions Mains Supply 3 x 525 600V AC P37K P45K P55K a ee Typical Shaft Output kW Enclosure IP21 55 66 Enclosure IP20 Output current Continuous 3 x 525 550V A Intermittent 3 x 525 550V A Continuous 3 x 525 600V A Intermittent 3 x 525 600V A 150 144 Continuous kVA 550V AO VN 514 619 619 829 829 1000 100 0 130 5 Continuous KVA 575V AO VN 518 617 617 827 996 996 1305 Max input current Additional specifications Max cable size IP20 mains motor 95 4 0 mm AWG Max cable size IP20 load share brake 95 4 0 AWG 2 mm Max cable size IP21 55 66 mains motor load share and brake mm AWG2 137 151 131 150 300mcm 120 4 0 150 300mcm Estimated power loss at rated max load W 68 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Specifications p Instructions Mains Supply 3 x 525 690V AC Ee SEENEN Eege mi High Normal Load Typical Shaft output at 550V kW Typical Shaft output at 575V HP Typical Shaft output at 690V kW Enclosure IP21 55 Output current Continuous 3 x 525 550V A 36 Intermitte
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4. 18 Illustration 1 2 Exploded View B and C Sizes IP55 66 RS 485 serial bus connector Digital 1 0 Digital 1 0 and 24 V power supply 24 V power supply 11 Relay 2 04 05 06 12 Lifting ring Mounting slot Eo E E Grounding clamp PE Analog UO connector Analog switches A53 A54 Relay 1 01 02 ojo o ARP 1 1 Purpose of the Manual This manual is intended to provide detailed information for the installation and start up of the frequency converter Chapter 2 Installation provides requirements for mechanical and electrical installation including input motor control and serial communications wiring and control terminal functions Chapter 3 Start Up and Functional Testing provides detailed procedures for start up basic operational programming and functional testing The remaining chapters provide supplementary details These include user interface detailed programming application examples start up troubleshooting and specifications MG 33 AJ 02 VLT is a registered Danfoss trademark Cable strain relief PE ground Brake terminal 81 82 a Load sharing terminal DC bus 88 89 18 Motor output terminals 96 U 97 V 98 W 19 Mains input terminals 91 L1 92 L2 93 L3 1 2 Additional Resources
5. L r L y b Z Illustration 2 1 Top and Bottom Cooling Clearance Enclosure A1 A5 B1 B4 C1 C3 C2 C4 Ca o mm we xe xe zs gt Table 2 1 Minimum Airflow Clearance Requirements MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Installation A nstructions 2 3 2 Lifting e oo e Check the weight of the unit to determine a safe 5 lifting method A em MEE Ensure that the lifting device is suitable for the task g If necessary plan for a hoist crane or forklift with the appropriate rating to move the unit For lifting use hoist rings on the unit when A provided 2 3 3 Mounting fee deed Mount the unit vertically The frequency converter allows side by side instal lation Ensure that the strength of the mounting location NOTE will support the unit weight Ss Back plate is needed when mounted on railings Mount the unit to a solid flat surface or to the optional back plate to provide cooling airflow see Illustration 2 2 and Illustration 2 3 2 3 4 Tightening Torques Improper mounting can result in over heating and reduced performance See 10 4 1 Connection Tightening Torques for proper tightening specifications Use the slotted mounting holes on the unit for wall mounting when provided 130BA219 10 A Illustration 2 2 Proper Mounting with
6. 41 Approvals tintas 1 Auto A A aq Aa 28 Onu s 29 46 48 Automatic Motor Adaptation 24 46 AUtO TOS inicia 27 B Back iii 9 Braking iet ett seo ded 54 46 Branch Circuit Protection 76 C Cable Lengths And Cross Sections 74 Circuit Breakers eee da ARA l l 22 Clearance Clearance eR u aQ Requirements Closed TE 17 Communication 55 55 CON todas 12 22 Control AAA A o deer ET 16 Card Performance 74 Card 10V DC Output 73 Card 24 V DC Output 73 Card RS 485 Serial Communication 73 Card USB Serial Communication 73 CAC s s Aa 74 Siqnal is ieri TI 31 32 46 O eee tette ete eed rete 5 6 Terminals 10 24 29 46 48 32 16 Wa tate EE 16 OU Le EE 12 16 22 14 VLT AutomationDrive Operating Cooling sa p da 8 Clearance ad 22 Copying Parameter Setting EEN 29 Current Boro 25 53 A eee ee e rere n 8 53 D Danfoss FG av ete ER qe ei 20 DC A cree AN 6 47 link A DM E 52 Der Le usina 53 8 Digital WAP Ub m ici talca 48 53 17 elle 15 48 33 Ui Ile 71
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9. Table 10 1 200 240V Frame Sizes A B and C MG 33 AJ 02 VLT is a registered Danfoss trademark 77 Danfi VLT AutomationDrive Operating Specifications p Instructions Enclosure FC 300 Power Recommended Recommended Recommended circuit Max trip level fuse size Max fuse breaker Size kW A Al 0 37 1 5 gG 10 gG 25 PKZMO 16 16 A2 0 37 4 0 gG 10 0 37 3 gG 25 PKZMO 25 25 gG 16 4 A3 5 5 7 5 gG 16 gG 32 PKZMO 25 25 B3 11 15 gG 40 gG 63 PKZM4 50 50 B4 18 5 30 gG 50 18 5 gG 125 NZMB1 A100 100 gG 63 22 gG 80 30 gG 100 37 gG 150 37 NZMB2 A200 150 gG 160 45 gG 160 45 aR 200 55 aR 250 NZMB2 A250 250 aR 250 75 A4 0 37 4 gG 10 0 37 3 gG 32 PKZMO 25 25 gG 16 4 AS 0 37 7 5 gG 10 0 37 3 gG 32 PKZMO 25 25 gG 16 4 7 5 B1 11 15 gG 40 gG 80 PKZM4 63 63 B2 18 5 22 gG 50 18 5 gG 100 NZMB1 A100 100 gG 63 22 Ci 30 45 gG 80 30 gG 160 NZMB2 A200 160 gG 100 37 gG 160 45 C2 55 75 aR 200 55 aR 250 NZMB2 A250 250 aR 250 75 C3 37 45 CA 55 75 gG 300 90 gG 300 90 gG 350 110 gG 350 110 D 90 200 gG 400 132 gG 400 132 gG 500 160 gG 500 160 gG 630 200 gG 630 200 aR 700 250 aR 700 250 E 250 400 aR 900 315 400 aR 900 315 400 aR 1600 450 500 aR 1600 450 500 F 450 800 aR 2000 560 630 aR 2000 560 630 aR 2500 710 800 aR 2500 710 800 Table 10 2 380 500V Frame Sizes A B C D E and F 78 MG 33 AJ 02 VLT
10. lt S 26 Brake resistor power limit X X 27 Brake chopper short circuited 28 Brake check X X gt 30 Motor phase U missing X X X 4 58 Missing Motor 31 Motor phase V missing X X X 4 58 Missing Motor 32 Motor phase W missing X X X 4 58 Missing Motor 33 Inrush Fault PEGH VI SI I I 34 Fieldbus communication fault 35 Option Fault p Parameter group 2 2 2 13 Brake Povver Monitoring 2 15 Brake Check s 37 Phase imbalance 38 Internal Fault 39 Heatsink sensor 40 Overload of Digital Output Terminal 27 X 5 00 Digital I O Mode 5 01 Terminal 27 Mode 50 MG 33 AJ 02 VLT is a registered Danfoss trademark Danfi VLT AutomationDrive Operating Warnings and Alarms Instructions No Description Warning Alarm Trip Alarm Trip Lock Parameter Reference 41 Overload of Digital Output Terminal 29 X 5 00 Digital I O Mode a los 0 x l T ss en Supply n T m s easy H m J x x s sim O Xx s AMA calbraionfaled x bm check Un and x T sz m beer _ x x s ama parameter ander se AMA interupted by wer O x s ama mese 9 s AMA intema
11. Instructions 5 rectifier module ALARM 246 Power card supply This alarm is only for F Frame frequency converter It is equivalent to Alarm 46 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 frequency converter 2 right inverter module in F1 or F3 frequency converter 3 right inverter module in F2 or F4 frequency converter 5 rectifier module ALARM 69 Power card temperaturePower card temperature This alarm is only for F Frame frequency converter It is equivalent to Alarm 69 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 frequency converter 2 right inverter module in F1 or F3 frequency converter 3 right inverter module in F2 or F4 frequency converter 5 rectifier module ALARM 248 Illegal power section configuration This alarm is only for F Frame frequency converters It is equivalent to Alarm 79 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 frequency converter 2 right inverter module in F1 or F3 frequency converter 3 right inverter module in F2 or F4 frequency converter 5 rectifier module WARNING 249 Rect low temperature IGBT sensor fault highpo
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13. Coast Ctrl Ramp down AMA process is in progress The brake chopper is in operation Generative energy is absorbed by the brake resistor The brake chopper is in operation The power limit for the brake resistor defined in 2 12 Brake Power Limit kW is reached e Coast inverse was selected as a function for a digital input parameter group 5 1 The corresponding terminal is not connected e Coast activated by serial communication Control Ramp down was selected in 14 10 Mains Failure e The mains voltage is below the value set in 14 11 Mains Voltage at Mains Fault at mains fault e The frequency converter ramps down the motor using a controlled ramp down 46 MG 33 AJ 02 VLT is a registered Danfoss trademark Status Messages VLT AutomationDrive Operating Instructions Danfi Current High Current Low Operation status The frequency converter output current is above the limit set in 4 51 Warning Current High The frequency converter output current is below the limit set in 4 52 Warning Speed Low Feedback high DC Hold DC hold is selected in 1 80 Function at Stop and a stop command is active The motor is held by a DC current set in 2 00 DC Hold Preheat Current DC Stop The motor is held with a DC current 2 01 DC Brake Current for a specified time 2 02 DC Braking Time e DC Brake is activated in 2 03 DC Brake Cut In Speed RPM and a Sto
14. VLT is a registered Danfoss trademark VLT AutomationDrive Operating Specifications P Instructions 3 Derating for high ambient temperature see special conditions in the Design Guide Minimum ambient temperature during full scale operation 0 C Derating for high altitude see special conditions in the Design Guide EMC standards Emission OA EBEN 61000 6 3 4 EN 53011 EN 61800 3 EN 61000 6 1 2 EMC standards Immunity EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 See section on special conditions in the Design Guide Protection and Features Electronic thermal motor protection against overload Temperature monitoring of the heatsink ensures that the frequency converter trips if the temperature reaches a predefined level An overload temperature cannot be reset until the temperature of the heatsink is below the values stated in the tables on the following pages Guideline these temperatures may vary for different power sizes frame sizes enclosure ratings etc The frequency converter is protected against short circuits on motor terminals U V W If a mains phase is missing the frequency converter trips or issues a warning depending on the load Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high The frequency converter constantly checks for critical levels of internal
15. control User interface and external commands are monitored and performed Status output and control can be provided Table 1 1 Frequency Converter Internal Components 6 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Introduction Instructions 1 5 Frame Sizes and Power Ratings Frame size kW 525 690 N A N A N A N A N A N A 11 22 N A N A N A 30 75 N A Table 1 2 Frames Sizes and Power Ratings MG 33 AJ 02 VLT is a registered Danfoss trademark 2 Installation nstructions 2 Installation 2 1 Installation Site Check List The frequency converter relies on the ambient air for cooling Observe the limitations on ambient air temperature for optimal operation Ensure that the installation location has sufficient support strength to mount the frequency converter Keep the frequency converter interior free from dust and dirt Ensure that the components stay as clean as possible In construction areas provide a protective covering Optional IP55 NEMA 12 or IP66 NEMA 4 enclosures may be necessary Keep the manual drawings and diagrams accessible for detailed installation and operation instructions It is important that the manual is available for equipment operators Locate equipment as near to the motor as possible Keep motor cables as short as possible Check the motor characteristics fo
16. frequency converter reference to OHz This sets the minimum frequency converter speed at OHz MG 33 AJ 02 VLT is a registered Danfoss trademark 31 About Frequency Converter P Danfi VLT AutomationDrive Operating Instructions 6 6 14 Terminal 53 Low Ref Feedb Value Set minimum speed reference on Terminal 53 at 6Hz This tells the frequency converter that the 5 3 Control Terminal Programming minimum voltage received on Terminal 53 0V Examples equals 6Hz output Control terminals can be programmed 147 0 00 A n 2 N Q3 21 E Each terminal has specified functions it is capable o R 6 14 Terminal 53 Low 2 of performing Ref Feedb Value e Parameters associated with the terminal enable the function 000020 000 AC For proper frequency converter functioning the control terminals must be Wired properly 7 6 15 Terminal 53 High Ref Feedb Value Set maximum speed reference on Terminal 53 at 60Hz Programmed for the intended function This tells the frequency converter that the Receiving a signal maximum voltage received on Terminal 53 10V equals 60Hz output See Table 2 3 for control terminal parameter number and default setting Default setting can change based on the 14 7 0 00 A 10 selection in 0 03 Regional Settings Analog Reference Q3 21 6 15 Terminal 53 High Ref Feedb Value 50 000 130BT774 11 With an external d
17. ld EE 73 Disconnect ME 23 SIIC 21 E External Comniands eiie da ned pe HALA 6 46 Controllers 6 Interlock 17 33 Mero iii ra 31 F Fault fero 28 30 MOSS AJO nico 52 Feedback eessen 17 22 55 47 58 Floating Delta 5 s s s s cc 14 Full Load Current 8 21 G Ground Connections ee otio tae RR a al 12 22 LOOPS DE 16 lili 12 13 22 Grounded Delta aan 14 Grounding GOUNdINO EE 12 13 14 21 22 Using Shielded s o 13 MG 33 AJ 02 VLT is a registered Danfoss trademark 85 Index de Instructions H H nd RO nOD 25 29 46 eoe 6 zer diii E a a ua a a Sq P 14 Induced Voltage EE 12 A sas asan 30 nput C rrento unu qan iaa 14 Disconneete a y s O n 14 POWOT s iecit iim Y 12 14 22 49 60 6 21 siqnala n ODE 31 le LEI 16 17 AAA A 10 14 17 21 52 Mere e annie 23 49 53 nstallation 5 8 9 12 16 20 22 54 23 Isolated Mains 14 L Leakage CUM a dA 21 12 Gurrentis53 5mAl as 13 LIfti0ga au s Zay 9 Local M Main 2 28 31 28
18. mm AWG 2 0 3 0 150 MCM 300 Estimated power loss 1140 1143 1353 1400 at rated max load W SES EE T l e Weight enclosure IP21 IP 55 66 kg ur I Rs a ag 154 120 4 0 120 4 0 1636 Mains Supply 3 x 380 500V AC FC 302 3 x 380 480V AC FC 301 P7K5 FC 301 FC 302 Enclosure IP20 1P21 Ta et t A3 Enclosure IP20 FC 301 only a oo 05 S 5 Enclosure IP55 66 asas asas asas asas asas asas asas asas As As Output current High overload 160 for 1 min Shaft output KW 35 11 T 1 EE T s 75 Continuous 16 3 x 380 440V A Intermittent 3 x 380 440V A 25 6 Continuous 3 x 441 500V A 145 Intermittent 3 x 441 500V A 292 orem e o e m o E n E ums ele A ZO gt gt Max input current Additional specifications Mart cable size 24 10 AWG 24 10 AWG mains motor brake AWG 2 mm 0 2 4mm 0 2 4mm Estimated power loss at rated max load W 2 Weight 47 48 4 8 4 9 49 49 enclosure IP20 Fefciency 093 oss 096 oss o os v r v r 09 0 37 7 5 kW only available as 16096 high overload 6 6 MG 33 AJ 02 VLT is a registered Danfoss trademark 63 VLT AutomationDrive Operating Specifications P Instructions Mains Suppl
19. 2 General Technical Data Mains supply L1 L2 L3 Supply voltage 200 240 V 10 Mains voltage low mains drop out During low mains voltage or a mains drop out the FC continues until the intermediate circuit voltage drops below the minimum stop level which corresponds typically to 1596 below the frequency converter s lowest rated supply voltage Power up and full torque cannot be expected at mains voltage lower than 1096 below the frequency converter s lowest rated supply voltage Supply frequency 50 60 Hz 5 The unit is suitable for use on a circuit capable of delivering not more than 100 000 RMS symmetrical Amperes 240 500 600 690 V maximum Motor output U V W Output voltage 0 100 of supply voltage Voltage and power dependent Torque characteristics Starting torque Constant torque maximum 160 for 60 sec 1 Percentage relates to the nominal torque 2 The torque response time depends on application and load but as a general rule the torque step from 0 to reference is 4 5 x torque rise time Digital inputs Programmable digital inputs FC 301 4 5 FC 302 4 6 MG 33 AJ 02 VLT is a registered Danfoss trademark 71 Danfi VLT AutomationDrive Operating Specifications p Instructions Safe stop Terminal 37 Terminal 37 is fixed PNP logic Voltage level 0 24V DC All digital inputs are galvanically isolated from the supply voltage PELV and oth
20. 33 AJ 02 VLT is a registered Danfoss trademark Danfi VLT AutomationDrive Operating Specifications P Instructions Recommended max fuse 1 5 2 2 KTS R 10 KTK R 10 LP CC 10 5 5 KTS R 25 JKS 25 JJS 25 FNQ R 25 KTK R 25 LP CC 25 22 KTS R 60 30 KTS R 80 Table 10 11 525 600V Frame Sizes A B and C Table 10 12 525 600V Frame Sizes A B and C Recommended max fuse Shawmut Shawmut mm 4 KLS R 020 A6K 20 R HSJ 20 5 5 KLS R 025 A6K 25 R HSJ 25 75 KLS R 030 A6K 30 R HSJ 30 11 KLS R 035 A6K 35 R HSJ 35 45 KLS R 125 A6K 125 R HSJ 125 55 2028220 150 KLS R 150 A6K 150 R HSJ 150 75 KLS R 175 A6K 175 R HSJ 175 D 170M fuses shown from Bussmann use the 80 visual indicator TN 80 Type T 110 or TN 110 Type T indicator fuses of the same size and amperage may be substituted MG 33 AJ 02 VLT is a registered Danfoss trademark 83 Specifications VLT AutomationDrive Operating Instructions Recommended max fuse UL compliance only 525 600 V Table 10 13 525 690V Frame Sizes B and C 10 4 Connection Tightening Torques Ferraz Ferraz Bussmann Bussmann Bussmann SIBA LittelFuse FC 302 Max Shawmut Shawmut 52273 E4273 E4273 E180276 E81895 kW prefuse E163267 E2137 E2137 RK1 JDDZ J JDDZ T JDDZ RK1 JDDZ RK1 JDDZ RK1 JDDZ si 11 KTS R 30 JKS 30 JKJS 30 5017906 0
21. 50 Remove some of the load from terminal 50 as the 10V supply is overloaded Max 15mA or minimum 590 Q This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer Troubleshooting Remove the wiring from terminal 50 If the warning clears the problem is with the customer wiring If the warning does not clear replace the control card WARNING ALARM 2 Live zero error This warning or alarm will only appear if programmed by the user in 6 01 Live Zero Timeout Function The signal on one of the analog inputs is less than 50 of the minimum value programmed for that input This condition can be caused by broken wiring or faulty device sending the signal Warning Parameter Reference 17 61 Feedback Signal Monitoring 202 Alarm Trip Alarm Trip Lock X Troubleshooting Check connections on all the analog input terminals Control card terminals 53 and 54 for signals terminal 55 common MCB 101 terminals 11 and 12 for signals terminal 10 common MCB 109 terminals 1 3 5 for signals terminals 2 4 6 common Check that the frequency converter programming and switch settings match the analog signal type Perform Input Terminal Signal Test WARNING ALARM 3 No motor No motor has been connected to the output of the frequency converter WARNING ALARM 4 Mains phase loss A phase is missing on the supply side or the mains vo
22. 6 11 RS 485 Network Connection CAUTION Thermistors must use reinforced or double insulation to meet PELV insulation requirements 44 MG 33 AJ 02 VLT is a registered Danfoss trademark Danfi VLT AutomationDrive Operating Application Set Up Examples instructions Parameters Parameters ci 24 V 12 ool 00 S 4 30 Motor amp 5 40 Function 32 Mech H24V 13 2 o DIN Feedback Loss Relay brake ctrl B N AECH 1 Warning 5 10 Terminal 18 8 Start Com 200 4 31 Motor 100RPM Digital Input DIN 270 Feedback Speed 5 11 Terminal 19 11 Start DIN 29 Digital Input reversing DIN 32 4 32 Motor 5 sec 1 71 Start Delay DIN 330 Feedback Loss 1 72 Start 5 VVC DIN 37 Timeout Function FLUX Clockwise 1 76 Start Current Im n 7 00 Speed PID 2 MCB 102 2 20 Release App dependent 2 21 Activate AIN 53 17 11 Resolution 1024 AIN 54 PPR COM 55 13 00 SL 1 On Half of A OUT 42 Controller Mode Brake Speed nominal slip COM 39 13 01 Start Event 19 Warning RPM of the motor 13 02 Stop Event 44 Reset key Default Value H u gt 21 Warning Notes comments 03 gt Operand no 13 11 Comparato 1 s 050 13 12 Comparato 90 06 r Value 13 51 SL 22 Controller Event Comparator 0 Table 6 14 Mechanical Brake Control 13 52 SL 32 Set Controller Action digital out A 130BB84
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24. Back Plate Item A is a back plate properly installed for required airflow to cool the unit MG 33 AJ 02 VLT is a registered Danfoss trademark 9 Danfi VLT AutomationDrive Operating Installation Instructions 2 4 Electrical Installation This section contains detailed instructions for wiring the frequency converter The following tasks are described Wiring the motor to the frequency converter output terminals Wiring the AC mains to the frequency converter input terminals Connecting control and serial communication wiring After power has been applied checking input and motor power programming control terminals for their intended functions o J 7 A AAA 4 AK 4 S 9110 ml S 0 96 2 S E 212 ws T i 93 L3 als W 98 input KA 4 P L 95 PES A A E d L I PE 99 LT i wid Motor 777 DC bus I 380 Svvitch Mode J Power Supp ao 4K 10Vdc 24Vdc SR R 82 Brake 15mA 130 200mA A resistor m 50
25. Danfi VLT AutomationDrive Operating Terminal Programming e ete 17 Programming Examples 32 Thermistor TOM Ot iia 14 53 44 Control Wiring cerit s 14 Tightening Of 84 Torque Characteristics e S ida 71 Limit E 25 Transient Protection 6 Trip yj M 49 A E 12 Triples 49 Troubleshooting entente 5 52 60 V 71 W Warning And 8 5 7 5 50 And Alarm Displays 49 And Alarm Ty Pesa 49 VER 49 UE 12 13 MG 33 AJ 02 VLT is a registered Danfoss trademark 87
26. Illustration 2 11 and shows the removable frequency converter connectors Terminal functions and default settings are summarized in Table 2 3 130BB921 10 Illustration 2 11 Control Terminal Locations 1 2 12 13 18 19 27 29 32 33 20 37 5 Q Q Q Q Q Q Q 2 3 5 58 69 39 42 20 a4 23 Illustration 2 12 Terminal Numbers Connector 1 provides four programmable digital inputs terminals two additional digital terminals programmable as either input or output a 24V DC terminal supply voltage and a common for optional customer supplied 24V DC voltage FC 302 and FC 301 optional in A1 enclosure also provide a digital input for STO Safe Torque Off function Connector 2 terminals 68 and 69 are for an RS 485 serial communications connection Connector 3 provides two analog inputs one analog output 10V DC supply voltage and commons for the inputs and output Connector 4 is a USB port available for use with the MCT 10 Set up Software Danfi VLT AutomationDrive Operating e Also provided are two Form C relay outputs that are in various locations depending upon the frequency converter configuration and size Some options available for ordering with the unit may provide additional terminals See the manual provided with the equipment option See 10 2 General Technical Data for term
27. Instructions Danfi 130BB927 10 Parameters 6 12 Terminal 53 4mA Low Current 6 13 Terminal 53 20mA 6 14 Terminal 53 ORPM Low Ref Feedb Value 6 15 Terminal 53 High Ref Feedb Value 1500RPM Default Value Notes comments COM 20 DIN 27 DIN 29 DIN 32 DIN 33 DIN 37 10 50 AIN 53 Table 6 5 Start Stop Comman Speed Parameters 5 10 Terminal 18 Digital Input 5 12 Terminal 27 8 Start 130BB802 10 0 No Digital Input operation 5 19 Terminal 37 1 Safe Stop Safe Stop Alarm Default Value Notes comments If 5 12 Terminal 27 Digital Input is set to 0 No operation a jumper wire to terminal 27 is not needed d with Safe Stop 130BB805 10 Start 18 42 Table 6 6 Pulse Start Stop Speed 30BB803 10 Parameters 5 10 Terminal 18 Setting 9 Latched Start 6 Stop Inverse 5 12 Terminal 27 Digital Input Default Value Notes comments If 5 12 Terminal 27 Digital Input is set to 0 No operation a jumper wire to terminal 27 is not needed 130BB806 10 Latched Start 18 Stop Inverse 27 MG 33 AJ 02 VLT is a registered Danfoss trademark Application Set Up Examples instr etions Danfoss
28. Mains DIETS pU RR 12 TT DEE 62 66 67 68 Supply ET DC 71 ee 28 29 46 52 56 Manual lnitialisation 30 Mechanical Brake Control 20 Menu Keys E 27 28 SUCIA UD 29 35 Modb s REU ainia EN 20 Danfi VLT AutomationDrive Operating Motor A A dier 8 12 13 SI o aaa aN ua A A 6 24 53 56 28 Data A 24 25 30 54 53 56 24 PEOtGCtIOD a erret rob iii 12 75 Rotation Kl D 23 Status 6 VViring 12 13 Wiring Adici n 22 e ll EE 9 22 Multiple Frequency 5 2226 12 13 e tos 21 Navigation 2 23 31 46 27 29 Noise lsolation 12 22 Open 17 31 Operation Keys 29 Optional Equipment 14 17 23 6 Output A e 47 53 Overcurrent VOR PR Hte US 47 Overload Protection 8 12 Ov rVoltage miccional sib 26 47 P VIE 14 44 Power Conneetions c dE 12 Id aros sr 6 13 22 62 Pre starte i 21 Programming Progr
29. Manual Initialisation 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 and apply power to the unit Factory default parameter settings are restored during start up This may take slightly longer than normal Manual initialisation does not reset the following frequency converter information 15 00 Operating Hours 15 03 Power Up s 15 04 Over Temp s 15 05 Over Volt s 30 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating About Frequency Converter P q y nstructions 5 About Frequency Converter Programming KS 2 14 7 0 00A mu d 5 1 Introduction Analog Reference Reference Q3 21 5 m 1 3 02 Minimum Reference The frequency converter is programmed for its application functions using parameters Parameters are accessed by pressing either Quick Menu or Main Menu on the LCP 0 000142 See 4 User Interface for details on using the LCP function x keys Parameters may also be accessed through a PC using the MCT 10 Set up Software see 5 6 1 Remote Programming with 3 3 03 Maximum Reference Set maximum internal frequency converter reference to 60Hz This sets The quick menu is intended for initial start up Q2 Quick the maximum frequency 2577 speed at 60Hz 5 Set Up Data entered in a parameter can change the options Note that
30. U missing Motor phase U between the frequency converter and the motor is missing Remove power from the frequency converter and check motor phase U ALARM 31 Motor phase V missing Motor phase V between the frequency converter and the motor is missing Remove power from the frequency converter and check motor phase V ALARM 32 Motor phase W missing Motor phase W between the frequency converter and the motor is missing Remove power from the frequency converter and check motor phase W ALARM 33 Inrush fault Too many power ups have occurred within a short time period Let the unit cool to operating temperature WARNING ALARM 34 communication fault Communication between the and the communication option card is not operating WARNING ALARM 35 Option fault An option alarm is received The alarm is option specific The most likely cause is a power up or a communication fault WARNING ALARM 36 Mains failure This warning alarm is only active if the supply voltage to the frequency converter is lost and 14 10 Mains Failure is NOT set to 0 No Function Check the fuses to the frequency converter and mains power supply to the unit ALARM 37 Phase imbalance There is a current imbalance between the power units Danfi VLT AutomationDrive Operating ALARM 38 Internal fault When an internal fault occurs a code number defined in the table below is displayed Troubleshooting Cycle power to the frequency converter Ch
31. VLT AutomationDrive Operating Parameters 5 10 Terminal 18 Digital Input 5 11 Terminal 19 10 Digital Input 5 12 Terminal 27 Digital Input Setting 8 Start 130BB934 10 DIN 18 DIN 19 COM 20 DIN 27 DIN 29 DIN 32 Reversing 0 No DIN 330 operation PIN 370 s 14 Terminal 32 16 Preset 7 17 Preset AIN Digital Input ref bit 1 COM 55 3 10 Preset AOUT 42 Reference COM 39 Preset ref 0 Preset ref 1 Preset ref 2 Preset ref 3 Default Value Notes comments Table 6 7 Start Stop with Reversing and 4 Preset Speeds Parameters Finan _ 001 m 01 424V 13 001 5 11 Terminal 19 1 Reset m DIN 18 Digital Input DIN 19 E Default Value Notes comments Table 6 8 External Alarm Reset Parameters 481 24 V 13 tal 6 70 Terminal 53 em D IN 18 Low Voltage DIN 19 6 11 Terminal 53 COM 20 High Voltage DIN 27 6 14 Terminal 53 ORPM DIN 29 Low Ref Feedb DIN 32 Value DIN 33 6 15 Terminal 53 1500RPM DIN 37 High Ref Feedb 10V 500 Value AIN 530 5k Default Value Notes comments Table 6 9 Speed Reference using a manual potentiometer Parameters 5 10 Terminal 18 Digital Input Setting 8 Start 130BB804 10 5 12 T
32. WARNING ALARM 22 Hoist mechanical brake Report value will show what kind it is O The torque ref was not reached before timeout 1 There was no brake feedback before timeout WARNING 23 Internal fan fault The fan warning function checks if the fan is running The fan warning can be disabled in 14 53 Fan Monitor Troubleshooting Check for proper fan operation Cycle power to the frequency converter and check that the fan operates briefly at start up Check the sensors on the heatsink and control card WARNING 24 External fan fault The fan warning function checks if the fan is running The fan warning can be disabled in 14 53 Fan Monitor Troubleshooting Check for proper fan operation Cycle power to the frequency converter and check that the fan operates briefly at start up Check the sensors on the heatsink and control card WARNING 25 Brake resistor short circuit The brake resistor is monitored during operation If a short circuit occurs the brake function is disabled and the warning appears The frequency converter is still operational but without the brake function Remove power to the frequency converter and replace the brake resistor see 2 15 Brake Check WARNING ALARM 26 Brake resistor power limit The power transmitted to the brake resistor is calculated as a mean value over the last 120 seconds of run time The calculation is based on the intermediate circuit voltage and the brake resistance value set
33. complying with the dimensioning rules See EN 60364 5 54 8 543 7 for further information Using RCDs Where residual current devices RCDs also known as earth leakage circuit breakers ELCBs are used comply with the following Use RCDs of type B only which are capable of detecting AC and DC currents Use RCDs with an inrush delay to prevent faults due to transient earth currents Dimension RCDs according to the system configu ration and environmental considerations Danfi VLT AutomationDrive Operating 2 4 2 2 Grounding Using Shielded Cable Earthing grounding clamps are provided for motor wiring see Illustration 2 7 130BA266 10 Illustration 2 7 Grounding with Shielded Cable 2 4 3 Motor Connection AWARNING INDUCED VOLTAGE Run output motor cables from multiple frequency converters separately Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out Failure to run output motor cables separately could result in death or serious injury For maximum wire sizes see 10 1 Power dependent Specifications Comply with local and national electrical codes for cable sizes Motor wiring knockouts or access panels are provided at the base of IP21 and higher NEMA1 12 units Do not install power factor correction capacitors between the frequency converter and the motor Do not wire a starting or pole c
34. doing any service or repair and wait the amount of time specified in Table 1 1 Failure to wait the specified time after power has been removed prior to doing service or repair on the unit could result in death or serious injury Voltage V Minimum waiting time minutes uc uo ME 200 240 5 5 37 kW 380 480 0 25 7 5 kW 11 75 kW 525 600 0 75 7 5 kW 11 75 kW 525 690 n a 11 75 kW High voltage may be present even when the warning LEDs are off Table 1 1 Discharge Time VLT AutomationDrive Operating Symbols The follovving symbols are used in this manual AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices CAUTION Indicates a situation that may result in equipment or property damage only accidents NOTE Indicates highlighted information that should be regarded with attention to avoid mistakes or operate equipment at less than optimal performance Approvals EQ C MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Safet y Instructions MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Contents Instructions Contents 1 Introduction 4 M
35. grounding 130BB489 10 Illustration 2 18 Serial Communication Wiring Diagram For basic serial communication set up select the following 1 Protocol type in 8 30 Protocol 2 Frequency converter address in 8 31 Address 3 Baud rate in 8 32 Baud Rate Two communication protocols are internal to the frequency converter Follow motor manufacturer wiring requirements Danfoss FC Modbus RTU Functions can be programmed remotely using the protocol software and RS 485 connection or in parameter group 8 Communications and Options Selecting a specific communication protocol changes various default parameter settings to match that protocol s specifications along with making additional protocol specific parameters available Option cards which install into the frequency converter are available to provide additional communication protocols See the option card documentation for installation and operation instructions 20 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Start Up and Functional Tes nstructions 3 Start Up and Functional Testing 3 1 Pre start 3 1 1 Safety Inspection AWARNING HIGH VOLTAGE If input and output connections have been connected improperly there is potential for high voltage on these terminals If power leads for multiple motors are improperly run in same conduit there is potential for leakage current to charge capacitors within t
36. is not required use the frequency converter s regular stop function instead When automatic restart is used the requirements according to ISO 12100 2 paragraph 5 3 2 5 must be fulfilled Liability Conditions It is the responsibility of the user to ensure personnel installing and operating the Safe Stop function Read and understand the safety regulations concerning health and safety accident prevention Understand the generic and safety guidelines given in this description and the extended description in the Design Guide Have a good knowledge of the generic and safety standards applicable to the specific application MG 33 AJ 02 VLT is a registered Danfoss trademark 17 Installation nstructions User is defined as integrator operator servicing maintenance staff Standards Use of safe stop on terminal 37 requires that the user satisfies all provisions for safety including relevant lavvs regulations and guidelines The optional safe stop function complies vvith the follovving standards EN 954 1 1996 Category 3 IEC 60204 1 2005 category 0 uncontrolled stop EC 61508 1998 SIL2 IEC 61800 5 2 2007 safe torque off STO function EC 62061 2005 SIL CL2 ISO 13849 1 2006 Category 3 PL d SO 14118 2000 EN 1037 prevention of unexpected start up The information and instructions of the instruction manual are not sufficient for a proper and safe use of the safe stop functionality The
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39. press OK Fas 13 796 13 0A 1 1 Q1 My Personal Menu r q 22 Quick Setup Q5 Changes Made 130BB847 10 Q6 Loggings v Select language and press OK Then enter the motor data in parameters 1 20 1 21 through 1 25 The information can be found on the motor nameplate 1 20 Motor Power kW or 1 21 Motor Power HP 1 22 Motor Voltage 1 23 Motor Frequency 1 24 Motor Current 1 25 Motor Nominal Speed z 0 0 Hz 0 00kVV 1 1 ai 1 21 Motor Power kW 130BT772 10 30 Walt l v A jumper wire should be in place between control terminals 12 and 27 If this is the case leave 5 12 Terminal 27 Digital Input at factory default Otherwise select No Operation For frequency converters with an optional Danfoss bypass no jumper wire is required 3 02 Minimum Reference 3 03 Maximum Reference 3 41 Ramp 1 Ramp Up Time 3 42 Ramp 1 Ramp Down Time 3 13 Reference Site Linked to Hand Auto Local Remote This concludes the quick set up procedure Press Status to return to the operational display 24 Danfi VLT AutomationDrive Operating 3 4 Automatic Motor Adaptation Automatic motor adaptation AMA is a test procedure that measures the electrical characteristics of the motor to optimize compatibility between the frequency converter and the motor The frequency converter builds a mathematical model of the motor for regulating output mot
40. temperature load current high voltage on the intermediate circuit and low motor speeds As a response to a critical level the frequency converter can adjust the switching frequency and or change the switching pattern in order to ensure the performance of the frequency converter MG 33 AJ 02 VLT is a registered Danfoss trademark 75 Specifications P Instructions 10 3 Fuse Tables It is recommended to use fuses and or Circuit Breakers on the supply side as protection in case of component break down inside the frequency converter first fault NOTE This is mandatory in order to ensure compliance with IEC 60364 for CE or NEC 2009 for UL AWARNING Personnel and property must be protected against the consequence of component break down internally in the frequency converter Branch Circuit Protection In order to protect the installation against electrical and fire hazard all branch circuits in an installation switch gear machines etc must be protected against short circuit and over current according to national international regulations NOTE The recommendations given do not cover Branch circuit protection for UL Short circuit protection Danfoss recommends using the fuses Circuit Breakers mentioned below to protect service personnel and property in case of component break down in the frequency converter Over current protection The frequency converter provides overload protection to limit th
41. time expires Start fwd rev Start forward and start reverse were selected as functions for two different digital inputs parameter group 5 1 The motor will start in forward or reverse depending on which corresponding terminal is activated Stop The frequency converter has received a stop command from the LCP digital input or serial communication Trip An alarm occurred and the motor is stopped Once the cause of the alarm is cleared the frequency converter can be reset manually by pressing Reset or remotely by control terminals or serial communication Trip lock An alarm occurred and the motor is stopped Once the cause of the alarm is cleared power must be cycled to the frequency converter The frequency converter can then be reset manually by pressing Reset or remotely by control terminals or serial communication 48 MG 33 AJ 02 VLT is a registered Danfoss trademark Warnings and Alarms Instructions 8 Warnings and Alarms 8 1 System Monitoring The frequency converter monitors the condition of its input power output and motor factors as well as other system performance indicators A warning or alarm may not necessarily indicate a problem internal to the frequency converter itself In many cases it indicates failure conditions from input voltage motor load or temperature external signals or other areas monitored by the frequency converter s internal logic Be sure to
42. voltage a DC bus terminal or an external 24V supply The information displayed on the LCP can be customized for user application Each display readout has a parameter associated with it Options are selected in main menu 0 2 The frequency converter status at the bottom line of the display is generated automatically and is not selectable See 7 Status Messages for definitions and details 28 Display Default setting Speed RPM Motor Current Power kW Frequency Parameter number Reference ml E 799 RPM 7 83 A 364kw 5 0 000 53 2 Ey Auto Remote Rang Ge 207RPM 5 25A xs 10 24 4 kW 6 9 Q o 1308 062 10 Auto Remote Running G VLT AutomationDrive Operating Danfi 4 1 3 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 Status Quick Main Alarm Menu Menu Log 130BP045 10 Key Status Quick Menu Main Menu Alarm Log Function Press to show operational information In Auto mode press and hold to toggle between status read out displays Press repeatedly to scroll through each status display Press and hold Status plus 4 or Y to adjust the display brightness The symbol in the upper right corner of the display shows the direction of motor rotation
43. when the output frequency is less than the frequency set in 2 21 Activate Brake Speed RPMlor 2 22 Activate Brake Speed Hz and only if the frequency converter carries out a stop command If the frequency converter is in alarm mode or in an over voltage situation the mechanical brake immediately cuts in In the vertical movement the key point is that the load must be held stopped controlled raised lowered in a perfectly safe mode during the entire operation Because the frequency converter is not a safety device the crane lift designer OEM must decide on the type and number of safety devices e g speed switch emergency brakes etc to be used in order to be able to stop the load in case of emergency or malfunction of the system according to relevant national crane lift regulations o a e o lt cea L1 L2 L3 Dri NS Output U v w relay 02 01 Command Circuit 220Vac Mechanical Brake Output ATI Frewheeling eL A Contactor diode Shaft nput A2 Y Brake Power Circuit 380Vac Illustration 2 17 Connecting the Mechanical Brake to the Frequency Converter Danfi VLT AutomationDrive Operating 2 4 6 Serial Communication Connect RS 485 serial communication wiring to terminals 68 and 69 Screened serial communication cable is recommended See 2 4 2 Earth Grounding Requirements for proper
44. yDeqQpaa4 JOJOW xn 4 e di uud 03402 1010 uoneianbiuo sBunjas fes u n Jo OW pue peo SS9 Y puomssed sng pJOMssed O M HIND 01 ss oy pJomssed nue pino pJOMSSed O M NU W UIW O1 ss 23V piomsseg nue ulelW paomssed Ado gt dn 3 s Ado q51 aaes Ado gt d21 uo Kay fssed4g d21 uo Aen D s u uo 401 uo Aen Dose d21 uo Kay uo oiny d21 uo Aen JO d21 uo Aen uo pueH ped y 421 al Ke dsiq z al eldsiq e dsig inopeey p uy p sN JO INJEA xeyy jnopeay pauljap 1asf Jo enjeA UNA inopeey pauljap sas 104 Hun ynopeay wono 421 Dua leuosi q W aur Kejdsiq 3618 z eur Kejdsiq yews CL eur ejdsig yews CL eur edsig pews LL eur Aejdsig fe dsig 421 dnjas enpe nope y JauueyD sdn 3 s anopeey sdn s paxur 3nopeay o payur dn 195 511 dn 3as dn 3 suones do dn s JOWUOW e ueuuojiad pueH dn Jamod 1e age 6uneiedo s5um s jeuoibay n n peeds 1010 oben6ue sBuinjas oiseg CUATE anyon nua ule 195 MG 33 AJ 02 VLT is a registered Danfoss trademark 36 VLT AutomationDrive Operating Instructions About Frequency Converter P DIS 1 s u g0 1 dois 20 61 10942 Wels 10 131101140 1S 00 sbumes 51S 0 1 2001 MEWS EL SI9JUNO PIPE 66 c SJ9JUNOD o ey21U 86 21 BIJUuO uod 96 21 193 14 WIOIS 1se peoJg S6 Z uon
45. 00 630 900 aR 1600 630 900 F 630 1200 aR 2000 1000 aR 2000 1000 aR 2500 1200 aR 2500 1200 Table 10 4 525 690V Frame Sizes E and F MG 33 AJ 02 VLT is a registered Danfoss trademark 79 Danfi VLT AutomationDrive Operating Specifications P Instructions UL Compliance Fuses or Circuit Breakers are mandatory to comply with NEC 2009 We recommend using a selection of the following The fuses below are suitable for use on a circuit capable of delivering 100 000 Arms symmetrical 240V or 480V or 500V or 600V depending on the frequency converter voltage rating With the proper fusing the drive Short Circuit Current Rating SCCR is 100 000 Arms Recommended max fuse FC 300 Bussmann Bussmann Power kw Type CC 0 25 0 37 LP CC 5 0 55 1 1 KTN R 10 FNQ R 10 KTK R 10 LP CC 10 1 5 KTN R 15 FNQ R 15 KTK R 15 LP CC 15 22 KTN R 20 FNQ R 20 KTK R 20 LP CC 20 Table 10 5 200 240V Frame Sizes A B and C Recommended max fuse FC 300 Ferraz Ferraz y Type RP 3 0 5017906 025 KLN R 25 ATM R 25 A2K 25 R Table 10 6 200 240V Frame Sizes A B and C 80 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Danfi Specifications Instructions Recommended max fuse Littel fuse Shawmut Shawmut 00 Table 10 7
46. 06 Clockwise Direction is set to 1 Inverse counter clockwise Ab Verify that the motor turns counter clockwise 5b Verify that the LCP direction arrow is counter clockwise 3 6 Check Encoder Rotation Check encoder rotation only if encoder feedback is used Check encoder rotation in default open loop control 1 Verify that the encoder connection is according to the wiring diagram a z 130BA090 11 12 13 18 19 27 29 32 33 20 37 Et Ste E adela WAIAIOIODI AIODIAIDIA 7 M 7 TOTO FOO FO FO FC QO O OO Ol O O O pe AA SZ IA OS SS AQUI A NA L Ill L II il 1 2511 N HJ V 24V or 10 30V encoder NOTE When using an encoder option refer to the option manual 2 Enter the Speed PID feed back source in 7 00 Speed PID Feedback Source 3 Press Hand On 4 Press gt for positive speed reference 1 06 Clockwise Direction at O Normal Danfi VLT AutomationDrive Operating 5 Check in 16 57 Feedback RPM that the feed back is positive NOTE If the feedback is negative the encoder connection is wrong 3 7 Local control Test ACAUTION MOTOR START Ensure that the motor system and any attached equipment is ready for start It is the responsibility of the user to ensure safe operation under any operational condition Failure to ensure that the motor system and any attached equipment is ready for start could result in perso
47. 0V Intermittent 60 sec overload 3 x 441 500V A Continuous kVA 400V AC kVA 42 3 50 6 50 6 62 4 62 4 73 4 73 4 102 EE 147 221 130 195 102 177 195 160 176 123 Continuous kVA 460V AC kVA 51 8 63 7 83 7 104 128 Max input current Continuous 3 x 380 440V Intermittent 60 sec overload 3 x 380 440V A Continuous 3 x 441 500V Intermittent 60 sec overload 3 x 441 500V A Additional specifications Max cable size IP20 mains and motor mm AWG Max cable size IP20 load share and brake mm AVVG Max cable size IP21 55 66 mm AWG Max cable size vvith mains disconnect AWG E pe e 70 3 0 Weight enclosure IP21 IP55 66 kg Eficiency MG 33 AJ 02 VLT is a registered Danfoss trademark 133 200 118 177 150 300mcm 120 4 0 150 300mcm Estimated power loss 1083 1022 1384 1232 at rated max load W Tete pepe pe pepa 161 177 145 160 65 VLT AutomationDrive Operating Specifications P Instructions Mains Supply 3 x 525 600V AC FC 302 only Typical Shaft Output kw oz 11 15 22 3 4 55 GEES Enclosure 1p55 45 As as as 45 as A Output current Continuous 3 x 525 550V A ntermittent 3 x 525 5
48. 10 V OUT JST m S201 0 10Vdc 2 Wi t amp 53 A IN 19Vde 2 ON 0 4 20mA relay d 0 4 20 mA 5202 OFF 0 10Vdc 03 0 10Vdc 54 A IN Il 9 10Vdc 117 12 240Vac 2A 0 4 20 mA m 55 COM A IN oT relay2 KE m PA 12 24V OUT oe m ac T y 13 24V OUT P300 is 400Vac 2A i 24V NPN 1 1 1 1 18 D IN OV PNP 04 24V NPN T 19 D IN OV PNP COMA OUT 39 111 Analog Output 0 4 20 mA A OUT 42 20 COMDIN 2 127 DIN OUT 20 S801 F 24V OV PNP m O ON Terminated 1 zi OFF Open ov sv E 24V NPN Ae 5729 D IN OUT ni F 24V y S801 L ov EV RS 485 N RS 485 69 RS 485 24V NPN Interface T v I 32 D IN y OV PNP P RS 485 68 j 24V NPN IF an i 33 DIN OV PNP COM RS 485 61 x 37 DIN LI 1777 ITTI Illustration 2 4 Basic Wiring Schematic Drawing A Analog D Digital Terminal 37 is used for Safe Stop For Safe Stop installation instructions refer to the Design Guide Terminal 37 is not included in AutomationDrive FC 301 except frame size A1 Relay 2 and terminal 29 have no function in AutomationDrive FC 301 10 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating
49. 2 ODW OU peasy 024 22 ODW UJ0JJ pesy c 024 cc ve ODW Woy peag 024 12 ed D a 424 c ve ODW 0 3HIM OL 024 OL vE ODW 01 M 6 024 60 ODW 01 PIM 8 024 80 vE ODW 01 3HIM 024 Z0 v ODW 01 31M 9 024 90 vE ODW 01 au S 024 SO VE ODW 01 au t Q2d vO vE ODIN 01 au 004 60 ODW 01 au 024 ZO vE ODW 01 WM L 004 LO vE ed 934M Q2d 0 v synopesy ered ODW bt 3181 pneq elas S8ySy ODW 09X 56 66 uoneuluH BLES S8ySH ODW 09X y6 ayer pneq NV ODN Z9X 16 qI pou NV ODW Z9X 06 sbum s 3104 ODW 6 Wueje Je pJOM 5 181 88 UJJe e ye 9 875 201 8 UJeje 3e fEuluL 98 62 2QAvc jeuiayx3 Aq p rddns ODW 58 66 95J19Y8 INOIALUog v8 40113198 INOIAeYSY E8 EE BuiiolluoW sn1e1S ALQ 28 22 ayes dn lamod 18 4equunN ue160Jd pa1eAn y 08 SJojouJeJed eqo 5 8 E indino jeubid g 6sx jeune 0 66 indino 2 1610 65 2 41 1 69 6 1ndino esi5iq 9 65 2 89 6 indino jeubid 5 65 241 9 indino 2 1610 p 6sx 241 1 99 E 1ndino jeubiq 6 65 jeutuue s9 e indino esi5iq 2 65 2411 79 66 indino ef 1 65 241 69 66 indy 2610 z 69X 2411 29 66 ndul 2 1610 1 65 2414 19 66 epow Z 6SX pue 1 6SX 1 09 66 indy 2610 01 5 Ieu uu l 65 66 indu jeubid 6 5 2414 85 66 indu e4161 g sx euw 29 6 i
50. 2 10 low 330 benre 0 5 40 Function 1801 SL digital Current Relay output A a Speed 1 I L Default Value v I 1 I I Notes comments I If the limit in the feedback Start 18 1 monitor is exceeded VVarning 90 Start will be issued The SLC monitors eg 19 Warning 90 and in the case that Warning 90 becomes TRUE then Relay output Relay 1 is triggered Open d a Closed J NES External equipment may then indicate that service may be required If the feedback error goes below the limit again within 5 sec then the drive continues and the warning disappears But Relay 1 will still be triggered until Reset on the LCP Table 6 13 Using SLC to Set a Relay MG 33 AJ 02 VLT is a registered Danfoss trademark 45 Status Messages g nstructions 7 Status Messages 7 1 Status Display VVhen the frequency converter is in status mode status messages are generated automatically from vvithin the frequency converter and appear in the bottom line of the display see Illustration 7 1 m 799RPM 7 83A 36 4kW E 0 000 S 53 2 Auto Remote Ramping Hand Local Stop Off Running Jogging Stand by a b c Illustration 7 1 Status Display a The first word on the status line indicates where the stop start command originates b The second word on the status line indicates where th
51. 200 240V Frame Sizes A and KTS fuses from Bussmann may substitute KTN for 240V frequency converters FWH fuses from Bussmann may substitute FWX for 240V frequency converters A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240V frequency converters A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240V frequency converters Recommended max fuse FC 300 Bussmann Bussmann Bussmann Bussmann Bussmann m Type CC Table 10 8 380 500V Frame Sizes A B and C MG 33 AJ 02 VLT is a registered Danfoss trademark 81 Danfi VLT AutomationDrive Operating Specifications P Instructions Recommended max fuse Ferraz Ferraz FC 302 SIBA Littel fuse Shawmut Shawmut Type CC Type RK1 ATM R 6 A6K 6 R ATM R 10 A6K 10 R ATM R 15 A6K 15 R kW Type RK1 0 37 1 1 5017906 006 1 5 2 2 5017906 010 3 5017906 016 Type RK1 KLS R 6 LS R 10 LS R 15 4 5017906 020 LS R 20 ATM R 20 A6K 20 R 5 5 5017906 025 K ATM R 25 A6K 25 R 75 5012406 032 K ATM R 30 A6K 30 R 11 5014006 040 K A6K 40 R Table 10 9 380 500V Frame Sizes A B and C Recommended max fuse FC 302 Bussmann Ferraz Shawmut Ferraz Shavvmut Littel fuse kin E zm 5 5 FWH 25 HSJ 25 Table 10 10 380 500V Frame Sizes A B and C 1 Ferraz Shawmut A50QS fuses may substitute for A50P fuses 82 MG
52. 24 nlEA jenpy 1uiodiag 9AUp JOHd p ds z bor sng paads Bor sng Bor sng JUNO 40414 e e S pay sabessayy e e s qUNOD 10113 sng juno abessay sng s nsoubeiq 1104 24 Dojas 44O Dojos 244 Lage aualajay 1 s 1d payas dn 195 pajas Bulssanay pajas HAS Dojos lg 20 pajas dois Ino Dojos Bunseo sng jeubiq uoneinbyuoo peal 424 UONRINBIJUO 424 sjeubis 40 5 uon l s uieJ6a a 195 02010ud JW 24 Aejag 1eu5 1a1u SEW Aejaq asuodsay Xen Aejaq asuodsay uunululyy awn pe1eumns3 sug dois Aed ley pneg od D4 SseJppy 090 01d s um s 3104 53 MLD P410M 101402 ajqesnByuoD MIS PIOM Sn383S a qRINSIJUO IJO1d pJoM OMJUO sbunjes p1oM 115 inopeey 196611 sisoubeiq p40M 0J1UO 1959 uonounj 1no uuil Jo pu3 uon un4 1no uu l pJoM 101002 SUI 1no uul l pJOA 101002 92JhOS pJOM 104002 AUS OMJUO sBunjas e19uan suondo pue wwo gt 49114 00 did Sse oJd 49114 JOY did sse oJd umop duu DW did SS 201d dn dwey pmy Old 590 14 uiec Cid Sse oJg 014 p pu 1x3 did ss xold II did 5593014 APY H2 AUl EUHON 1ndinO did 559204 424 122 AU RULON DA Daa did 55920 4 xinos q PMY did ss oold Jou XEW 18 ayers 122 did sse oJq JOY UII 18 9 e s UID Old sse oJg duet SOY INAINO did ss old due
53. 30 KLS R 030 A6K 30 R HST 30 15 18 5 KTS R 45 JKS 45 JJS 45 5014006 050 KLS R 045 A6K 45 R HST 45 22 KTS R 60 JKS 60 JJS 60 5014006 063 KLS R 060 A6K 60 R HST 60 30 KTS R 80 JKS 80 JJS 80 5014006 080 KLS R 075 A6K 80 R HST 80 37 KTS R 90 JKS 90 JJS 90 5014006 100 KLS R 090 A6K 90 R HST 90 45 100 A KTS R 100 5 100 JJS 100 5014006 100 KLS R 100 A6K 100 R HST 100 55 125A KTS R 125 JKS 125 JJS 125 2028220 125 KLS 150 A6K 125 R HST 125 75 150A KTS R 150 JKS 150 JJS 150 2028220 150 KLS 175 A6K 150 R HST 150 Table 10 14 Tightening of Terminals D For different cable dimensions x y where x lt 95mm and y 2 95mm 84 MG 33 AJ 02 VLT is a registered Danfoss trademark Power kW Torque Nm 200 240V 380 480 500V 525 600V 525 690V Motor Brake Earth Relay sure connection 22 22 22 4 5 4 5 3 7 3 7 3 0 6 C1 15 22 30 45 30 45 10 10 10 10 3 0 6 l DES Instructions Index A O PME 17 s s 17 A A 6 14 AAA A w M a s 6 10 14 MENSIS MER 6 Alarm LOG uer 30 28 A e chu Inl Mua M ulu 49 AMA With T27 Connectedq 41 Without T27 Connecteq 41 Analog tele 15 52 72 Gutp t SAR 15 73 Application Examples
54. 50 60Hz is a regional variation available in the parameters following that entry EX 14 7 0 00A 10 o The main menu accesses all parameters and allows for S 3 03 Maximum Reference advanced frequency converter applications 5 2 Programming Example 50 000 Hz Here is an example for programming the frequency converter for a common application in open loop using the quick menu 4 6 10 Terminal 53 Low Voltage Set minimum external voltage reference on Terminal 53 at OV Thi ts th ini i t si at OV This procedure programs the frequency converter Tos sets the minimum input signal a to receive a 0 10V DC analog control signal on EE 27 He input terminal 53 The frequency converter will respond by providing H Gal z 2 6 60Hz output to the motor proportional to the Voltage input signal 0 10V DC 6 60Hz Select the following parameters using the navigation keys to 0 00 V scroll to the titles and press OK after each action 1 3 15 Reference Resource 1 5 6 11 Terminal 53 High Voltage Set maximum 2 external voltage reference on Terminal 53 at 10V Ve 9908 1 3 This sets the maximum input signal at 10V 3 15 Reference Resource m 14 7 0 00A 10 5 6 11 Terminal 53 High HW Analog input 53 Voltage z 10 00 V 2 3 02 Minimum Reference Set minimum internal
55. 50V A 18 4 Continuous us 3 x 551 600V A i ntermittent Continuous kVA 525 V AC kVA 5625051 110 Continuous kVA 575V AC kVA 12 24 27 49 l 90 110 Max input current Continuous 3 x 525 600V A 105 Intermittent 166 3 x 525 600V A Additional specifications Max cable size mains motor brake AWG mm Estimated power loss at rated max load W 2 24 10 AWG 0 2 4 mm 145 195 Weight enclosure IP55 kg Efficiency 2 66 MG 33 AJ 02 VLT is a registered Danfoss trademark Danfi VLT AutomationDrive Operating Specifications p Instructions Mains Supply 3 x 525 600V AC FC 302 High Normal Load Typical Shaft Output KW Output current P30K NO 37 C1 B4 Additional specifications Max cable size IP20 mains motor load share and brake mm AWG Continuous Intermittent Continuous Intermittent Continuous kVA 550V AC kVA 514 Continuous kVA 575V AC IKVA 17 9 219 21 9 26 9 26 9 33 9 339 40 8 40 8 51 8 Max input current Continuous ntermittent 54 at 550V A Continuous Intermittent Max cable size IP21 55 66 mains motor load share and brake mm AVVG Max cable size with mains disconnect mm AWG Estimated power loss Weight Weight MG 33 AJ 02 VLT is a registered Danfoss trademark 23 5
56. 92 1 Sum s epooed ez v apow uonejedo zc p Sul 1181594 2neujoiny Lz pL poN 19594 07 7 Jose 011 Z pL ino au dmpeg UN Y L pL Jop deis aime sure L p auejequu suleyy 3e uonp und ZL t Un sure 18 abeyon sutew LL vL Sing SuIew OL 7 HO UO SUIBN 21 71 uonesu duuo awl pe d 90 pL wopuey WMd 0 uone npouleAQ 0 r KouenbaJ4 BuIu31IAS LO vL uJeneg BUIYIIMS 00 7 DulupiMS Jean pl suon un4 ends pL UONIY s llonuo 1S ZS 1lu A3 s llonuo IS LS SOJeJS xS EL ue oog an 21601 vr c 1o1eJedQ 21601 Ep E z uesjoog 1601 22 61 L any 21601 Lp ue oog ajny 21507 0t s jny 91507 EL J9 OJ300 1S OZ E SJ WIL 22 61 y puesado 43 94 91 21 S 44 SH SL Sdo dili SY L EL nlEA J01eJeduJO 21 21 JOJe19dO Joyesedwo L puesado 4o eseduuo 01 S103e1eduJo 21 21 MG 33 AJ 02 VLT is a registered Danfoss trademark 38 VLT AutomationDrive Operating Instructions About Frequency Converter P 1uejsuo 2 8 WAL 9p SE enjeA YBIH Z 8bX uu l ANJA qpee jeu MOT 2 8 WIL 14 1 2 YBIH Z 8bX WAL 1uaun MOT Z 8PX WAL Zir S 7 8vX 1ndul Bojeuy b SE yw duet ubIH 01 8 uu l 26 S quur duet MOT 01 8 UJ 9E SE JOWUOW d l l 01 87X WAL SE SE juejsuo SUI OL 8bX
57. 93 Dry pump A no flow condition in the system with the frequency converter operating at high speed may indicate a dry pump 22 26 Dry Pump Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM 94 End of curve Feedback is lower than the set point This may indicate leakage in the system 22 50 End of Curve Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared Danfi VLT AutomationDrive Operating ALARM 95 Broken belt Torque is below the torque level set for no load indicating a broken belt 22 60 Broken Belt Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM 96 Start delayed Motor start has been delayed due to short cycle protection 22 76 Interval between Starts is enabled Troubleshoot the system and reset the frequency converter after the fault has been cleared WARNING 97 Stop delayed Stopping the motor has been delayed due to short cycle protection 22 76 Interval between Starts is enabled Troubleshoot the system and reset the frequency converter after the fault has been cleared WARNING 98 Clock fault Time is not set or the RTC clock has failed Reset the clock in 0 70 Date and Time WARNING 163 ATEX ETR cur lim warning The warning limit of ATEX ETR rated current curve has been reached The warning is
58. 9IJUNO dois asidaid uonounj dois s d ZH dois ye uon un4 104 p ds ui Wd dois ye uoun 104 p ds UW dois 16 uon unj syueunsn py dois quand PLIS zH p ds ues Wdy p ds uge eis Bulka uon un4 ne ey q ueis syu unsnfpv uexs Eau LUN WIXe IN enjeu uunullUIW ad peo1 paads o7 18 Juan UN jue3suo au Buluadueg adueuosay B6uiu duueq e ueuosay 1uejsuo awl uonesueduJo dils uonesuadwo dils uonesuedujo peo peeds uBiH uonesuedujo peo p ds mo7 u d q peo Aduanbas4 s sind 3591 14e1sA 4 JU9JIND s sind 1591 1181SA 4 3 aasuapeseyd Y N N hsH eseu yn Buluayeampjay u n np i ebeyoA KouanbaJ4 YIYS 9PON ZH 5ulsn uSeyy euon p ds uy Wdy Suisnaubeyy jeuuoN pasds ul p ds 0 97 1e uonesn ubeyy 1070W Bum s d pul peo1 195HO ajbuy 1o1oW Wdy 0001 18 554 S lod 402011 p1 s xe p y e uei1sisay sso 0 4X 3DUEPeay uleyy ZX 5eye 10104 LX e uei eay bexe97 101815 M e ueisisag 103104 Sy 9 ueisisey 101815 ejeqg 1010W APY VINV uonedepy Jojoy 21euoiny enbio peiey 1002 1030W p ds jeulwon 1O1OW jUaUND 1030W fouenbaJ4 1070W 1010N dH 18 0d 1030W MJ 490g 102011 ejeq 1030W uon nu3suo JOJOW uon2e as 1070W uon liq ISIMADO uoneanfiuo epo 16207 PEOH AQ sonsuejeJeu INDIO 95Jnos
59. G 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Contents Instructions 3 4 Automatic Motor Adaptation 24 2 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Instructions 8 4 1 Fault Messages MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Instructions Introduction 1 Introduction 130BB492 10 Illustration 1 1 Exploded View A1 A3 IP20 10 Motor output terminals 96 U 97 V 98 W LCP RS 485 serial bus connector 68 69 Relay 1 01 02 03 Analog UO connector 12 Relay 2 04 05 06 Brake 81 82 and load sharing 88 89 terminals Mains input terminals 91 L1 92 L2 93 L3 Decoupling pite rs Sena bus terminal swich win 4 MG 33 AJ 02 VLT is a registered Danfoss trademark Introduction i Instructions VLT AutomationDrive Operating 130BB493 10 Wo 8g Eur Z m Q 3 lo pm 9 Q o o el o 4 I Se D L e ol lol lo ei lol lo 10 ol e H Wer e e o el o o o llo o
60. Operating Instructions Inspect for Auxiliary equipment Cable routing Control wiring Cooling clearance EMC considerations Environmental considerations Fusing and circuit breakers Grounding Input and output power wiring Panel interior Switches Vibration Table 3 1 Start Up Check List 22 Description Look for auxiliary equipment switches disconnects or input fuses circuit breakers that may reside on input power side of frequency converter or output side to 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 frequency converter Remove power factor correction caps on motor s if present Ensure that input power motor wiring and control wiring are separated or in three separate metallic conduits for high frequency noise isolation Check for broken or damaged wires and loose connections Check that control wiring is isolated from power and motor wiring for noise immunity 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 Measure that top and bottom clearance is adequate to ensure proper air flow for cooling Check for proper installation regarding electromagnetic compatibility See equipment label for the maximum ambient operating temperature limits Humi
61. Other resources are available to understand advanced frequency converter functions and programming The Programming Guide provides greater detail in how to work with parameters and many application examples The Design Guide is intended to provide detailed capabilities and functionality to design motor control systems Introduction Instructions e Supplemental publications and manuals are available from Danfoss See http www danfoss com Products Literature TechnicaltDocumentation htm for listings Optional equipment is available that may change some of the procedures described Be sure to see the instructions supplied with those options for specific requirements Contact the local Danfoss supplier or go to http www danfoss com Products Literature Technical Documentation htm for downloads or additional information 1 3 Product Overview A frequency converter is an electronic motor controller that converts AC mains input into a variable AC waveform output The frequency and voltage of the output are regulated to control the motor speed or torque The frequency converter can vary the speed of the motor in response to system feedback such as position sensors on a conveyor belt The frequency converter can also regulate the motor by responding to remote commands from external controllers In addition the frequency converter monitors the system and motor status issues warnings or alarms for fault conditions
62. Safet y Instructions Safety AWARNING HIGH VOLTAGE Frequency converters contain high voltage when connected to AC mains input power Installation start up and maintenance should be performed by qualified personnel only Failure to perform installation start up and maintenance by qualified personnel could result in death or serious injury High Voltage Frequency converts are connected to hazardous mains voltages Extreme care should be taken to protect against shock Only trained personnel familiar with electronic equipment should install start or maintain this equipment AWARNING UNINTENDED START When the frequency converter is connected to AC mains the motor may start at any time The frequency converter motor and any driven equipment must be in operational readiness Failure to be in operational readiness when the frequency converter is connected to AC mains could result in death serious injury equipment or property damage Unintended Start When the frequency converter is connected to the AC mains the motor may be started by means of an external switch a serial bus command an input reference signal or a cleared fault condition Use appropriate cautions to guard against an unintended start AWARNING DISCHARGE TIME Frequency converters contain DC link capacitors that can remain charged even when AC mains is disconnected To avoid electrical hazards remove AC mains from the frequency converter before
63. activated at 83 and de activated at 65 of the permitted thermal overload ALARM 164 ATEX ETR cur lim alarm The ATEX ETR permitted thermal overload has been exceeded WARNING 165 ATEX ETR freq lim vvarning The frequency converter is running more than 50 seconds below the permitted minimum frequency 1 98 ATEX ETR interpol points freq 0 ALARM 166 ATEX ETR freq lim alarm The frequency converter has operated more than 60 second in a period of 600 seconds below the permitted minimum frequency 1 98 ATEX ETR interpol points freq 10 ALARM 243 Brake IGBT This alarm is only for F Frame drives It is equivalent to Alarm 27 The report value in the alarm log indicates which power module generated the alarm ALARM 244 Heatsink temperature This alarm is only for F Frame frequency converters It is equivalent to Alarm 29 The report value in the alarm log indicates which power module generated the alarm ALARM 245 Heatsink sensor This alarm is only for F Frame frequency converters It is equivalent to Alarm 39 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 frequency converter 2 right inverter module in F1 or F3 frequency convertere 3 right inverter module in F2 or F4 frequency converter 58 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Warnings and Alarms
64. amming 5 17 26 28 30 33 35 40 52 23 27 29 31 Explica dina 31 Protection And 5 22 75 Pulse Encoder 5 72 Q Quick A O A e E was 31 33 28 m 24 86 MG 33 AJ 02 VLT is a registered Danfoss trademark l nes Instructions R Ramp down 5 2 25 RL u u ane 25 RED 13 Referencia 1 41 46 47 28 Relay Outputs crime aiii 15 74 Remote Commands 6 Programming Se Reference usce A Ee A iege RFI Filter RMS Current dai ias 6 Run Command Permissive S Safety Inspection a aa awa uu a Gas s 21 Screened Control 165 225 16 Serial Communication 6 10 15 16 29 30 46 47 48 54 49 20 73 28 Stunt nace 48 26 28 Shielded Specifications qaa te 5 9 20 62 Speed ees 17 26 32 46 41 Start Up ertet 5 30 31 21 22 60 Status MOSS m 46 Mode toe ot e i RE 46 Stop Mee lu EI EE 47 Supply Voltage 14 15 21 52 53 55 Surtoundirigs u id a 74 Switching Frequency u u 47 53 Symbols eum ibis ma dee E a Phu 1 System F edback eee eese een Ree ay 6 Monitoring 49 26 T Technical Data eiis 71 Temperature Limite 22
65. and which set up is active This is not programmable Allows access to programming parameters for initial set up instructions and many detailed application instructions Press to access Q2 Quick Setup for sequenced instructions to program the basic frequency controller set up Follow the sequence of parameters as presented for the function set up Allows access to all programming parameters Press twice to access top level index Press once to return to the last location accessed Press and hold to enter a parameter number for direct access to that parameter Displays a list of current warnings the last 10 alarms and the maintenance log For details about the frequency converter before it entered the alarm mode select the alarm number using the navigation keys and press OK MG 33 AJ 02 VLT is a registered Danfoss trademark User Interface Instructions 4 1 4 Navigation Keys Navigation keys are used for programming functions and moving the display cursor The navigation keys also provide speed control in local hand operation Three frequency converter status indicator lights are also located in this area 130BT117 10 On Warm Alarm Key Function Back Reverts to the previous step or list in the menu structure Cancel Cancels the last change or command as long as the display mode has not changed Info Press for a definition of the
66. arning and Alarm Displays n l 0 0Hz 0 000psi 0 00A Y 0 0Hz x 1 0 Off a ILive zero error W2 Off Remote Stop An alarm or trip lock alarm will flash on display along with the alarm number 40 0 0Hz 0 000kW 0 00A 0 0Hz 0 e Auto Remote Trip In addition to the text and alarm code on the frequency converter display the status indicator lights operate 130BB467 10 Warn LED Alarm LED Warning OFF Alarm ON Flashing Trip Lock ON ON Flashing MG 33 AJ 02 VLT is a registered Danfoss trademark 49 Danfi VLT AutomationDrive Operating Warnings and Alarms Instructions 8 4 Warning and Alarm Definitions defines whether a warning is issued prior to an alarm and whether the alarm trips the unit or trip locks the unit No Description Warning Alarm Trip Alarm Trip Lock Parameter Reference 2 Live zero error X 6 01 Live Zero Timeout Function Mains phase loss X X 14 12 Function at Mains Imbalance 0 Motor ETR over temperature 11 Motor thermistor over temperature X X X E E EES La INN x ES E E voljo 1 90 Motor Thermal Protection 1 90 Motor Thermal Protection 3 6 17 Control word time out X X 8 04 Control Word Timeout Function 20 Temp Input Error 21 Param Error n m m S m smi
67. ating when the motor temperature reaches an acceptable level and when the Digital Input from the MCB 112 is deactivated When that happens a reset signal must be is be sent via Bus Digital 1 O or by pressing RESET ALARM 72 Dangerous failure Safe Stop with Trip Lock The Dangerous Failure Alarm is issued if the combination of safe stop commands is unexpected This is the case if the MCB 112 VLT PTC Thermistor Card enables X44 10 but safe stop is somehow not enabled Furthermore if the MCB 112 is the only device using safe stop specified through selection 4 or 5 in 5 19 Terminal 37 Safe Stop an unexpected combination is activation of safe stop without the X44 10 being activated The following table summarizes the unexpected combinations that lead to Alarm 72 Note that if X44 10 is activated in selection 2 or 3 this signal is ignored However the MCB 112 will still be able to activate Safe Stop WARNING 73 Safe stop auto restart Safe stopped Note that with automatic restart enabled the motor may start when the fault is cleared ALARM 74 PTC Thermistor Alarm related to the ATEX option The PTC is not working ALARM 75 Illegal profile sel Parameter value must not be written while motor is running Stop motor before writing MCO profile to 8 10 Control Word Profile for instance WARNING 76 Power unit setup The required number of power units does not match the detected number of active power units Troubleshoo
68. ating before using this function Depending on the application a mechanical brake may be required Concerning synchronous and permanent magnet motor frequency converters in case of a multiple IGBT power semiconductor failure In spite of the activation of the Safe torque off function the frequency converter system can produce an alignment torque which maximally rotates the motor shaft by 180 p degrees p denotes the pole pair number This function is suitable for performing mechanical work on the frequency converter system or affected area of a machine only It does not provide electrical safety This function should not be used as a control for starting and or stopping the frequency converter The following requirements have to be meet to perform a safe installation of the frequency converter 1 Remove the jumper wire between control terminals 37 and 12 or 13 Cutting or breaking the jumper is not sufficient to avoid short circuiting See jumper on Illustration 2 15 2 Connect an external Safety monitoring relay via a NO safety function the instruction for the safety device must be followed to terminal 37 safe stop and either terminal 12 or 13 24V DC The Safety monitoring relay must comply with Category 3 EN 954 1 PL d ISO 13849 1 130BA874 10 Illustration 2 15 Jumper between Terminal 12 13 24V and 37 18 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Opera
69. cold to operate This warning is based on the temperature sensor in the IGBT module Increase the ambient temperature of the unit Also a trickle amount of current can be supplied to the frequency converter whenever the motor is stopped by setting 2 00 DC Hold Preheat Current at 5 and 1 80 Function at Stop ALARM 67 Option module configuration has changed One or more options have either been added or removed since the last power down Check that the configuration change is intentional and reset the frequency converter ALARM 68 Safe stop activated Loss of the 24V DC signal on terminal 37 has caused the frequency converter to trip To resume normal operation apply 24V DC to terminal 37 and reset the frequency converter ALARM 69 Power card temperaturePower card temperature The temperature sensor on the power card is either too hot or too cold Troubleshooting Check that the ambient operating temperature is within limits Check for clogged filters Check fan operation Check the power card ALARM 70 Illegal FC configuration The control card and power card are incompatible Contact your supplier with the typecode of the unit from the nameplate and the part numbers of the cards to check compatibility ALARM 71 PTC 1 safe stop Safe Stop has been activated from the MCB 112 PTC Thermistor Card motor too warm Normal operation can be resumed when the MCB 112 applies 24 V DC to T 37 again Danfi VLT AutomationDrive Oper
70. cy Rotate input power leads into the lf imbalance leg stays on same input converter unit frequency converter one position A terminal it is a problem with the toB BtoC Cto A unit Contact supplier Problem with motor or motor Rotate output motor leads one If imbalanced leg follows the wire wiring position U to V V to W W to U the problem is in the motor or motor wiring Check motor and motor wiring Problem with drive unit Rotate output motor leads one If imbalance leg stays on same position U to V V to W W to U output terminal it is a problem with the unit Contact supplier MG 33 AJ 02 VLT is a registered Danfoss trademark 61 VLT AutomationDrive Operating Specifications P Instructions 10 Specifications 10 1 Power dependent Specifications Mains Supply 3 x 200 240V AC FC 301 FC 302 PK25 PK37 PK55 PK75 P1K1 P1K5 P2K2 P3K7 Typical Shaft Output KW 15 2 2 37 Enclosure IP20 IP21 A2 A2 A3 EnclosurelP 20 FC 301 only l a J a a oa xam aa Enclosure IP55 66 A4 A5 A4 A5 A4 A5 A4 A5 A4 A5 A4 A5 A4 A5 A5 Output current sme jJ we j SENE De p a e lt w w oo S f e om oe gt Continuous Max input current sepe Intermittent Additional specifications Max cable size mains motor brake Imm AWG2 0 2 4 24 10 Estimated power loss Wei
71. d with the terminals and their settings are shown next to the drawings Where switch settings for analog terminals A53 or A54 are required these are also shown 6 2 Application Examples Parameters 1 29 Automatic 1 Enable Motor Adaptation complete 130BB929 10 DIN 19 AMA AMA COM 20 5 12 Terminal 27 2 Coast B ar Digital Input inverse DIN 29 Default Value Notes comments Parameter group 1 2 must be set according to motor Table 6 1 AMA with T27 Connected VLT AutomationDrive Operating Parameters 1 29 Automatic Setting 1 Enable Motor Adaptation complete AMA AMA 5 12 Terminal 27 0 No operation Default Value 130BB930 10 Notes comments Parameter group 1 2 must be set according to motor Table 6 2 AMA without T27 Connected Parameters Function Setting N m 40 24V 13 6 10 Terminal 53 DIN 18 Low Voltage DIN 19 6 11 Terminal 53 COM 20 High Voltage DIN 27 6 14 Terminal 53 ORPM DIN 29 Low Ref Feedb DIN 32 Value DIN 33 R 6 15 Terminal 53 1500RPM DIN 37 High Ref Feedb 10V 50 Value AIN 53 E Default Value AIN 54 Notes comments COM 55 AOUT I 10 10V Table 6 3 Analog Speed Reference Voltage MG 33 AJ 02 VLT is a registered Danfoss trademark 41 Application Set Up Examples VLT AutomationDrive Operating
72. dard 1 1 Full speed Connection to PC is carried out via a standard host device USB cable The USB connection is galvanically isolated from the supply voltage PELV and other high voltage terminals MG 33 AJ 02 VLT is a registered Danfoss trademark 73 Danfi Specifications VLT AutomationDrive Operating Instructions The USB ground connection is not galvanically isolated from protection earth Use only an isolated laptop as PC connection to the USB connector on the frequency converter Relay outputs Programmable relay outputs FC 301all kW 1 FC 302 all kW 2 7 IEC 60947 part 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 300V AC2A Cable lengths and cross sections for control cables Max motor cable length screened FC 301 50m FC 301 A1 25m FC 302 150m Power cables see tables in 10 1 Power dependent Specifications Control card performance 7 r FC 301 5 ms FC 302 1 ms Control characteristics Resolution of output frequency at 0 1000Hz 0 003Hz All control characteristics are based on a 4 pole asynchronous motor Environment Enclosure 1P201 Type 1 IP212 Type 1 IP55 Type 12 IP 66 1 Only for lt 3 7kW 200 240V lt 7 5kW 400 480 500V 2 As enclosure kit for lt 3 7kW 200 240V lt 7 5kW 400 480 500V 74 MG 33 AJ 02
73. dd INDA v 0L sKeM V 24015 66 01 UO S A M 3 U lA Q ZE O Senj eA e1eg 2401S 12 01 eliy 06 01 SS 22V 42 01 t SOD 82 01 Ja SOD 22 01 Ia SOD 12 01 L SOD 02 01 5 SOD Z OL 013005 ON SL OL ION 1 01 Jajyaweseg BuiuJeM 21 01 peay BIJuO 6360 sse oJd 21 01 M BIJUO 0360 55920 11 01 uon2e es ad eyeq 5592014 01 01 Joke 21 01 Ja1uno HO sng nope y 20 01 J9JUNO 104113 INOPPIY 90 01 y yuno 40414 lluusue1 1nopeey 90 01 q DYW 20 01 ae y pneg 10 01 10203014 NV 00 01 s5um s UOWWO 0 01 snqpl li NYD OL J3JUNO UOISIADY Snqijold 66 6 S ssajawesed pabuey 6 6 p ssajawesed pabuey 6 6 ssajaweJeg pabueyD 76 6 2 SIdjauweJleg pabuey 16 6 1 Suajaweseg pebueu 06 6 S SI9IBUWRIEd paud 8 6 p Slajaweseg pauyeq 8 6 9 4 paud 78 6 Z sawed paud 18 6 sjejeujejeg peuyeq 08 6 uone ynuep Od SZ 6 leseygeAugsnqyold 2 6 San eA ejeq ALS snqyojd 17 6 L PAOM snieis 89 6 L pP40M 0 3402 79 6 JequinN 9 JOJd S9 6 uone yHuep 39149A v9 6 pneg jenpy 9 6 pJoM buiujeM SNQUOJA ES 6 Jojuno uonenjls INBA 7S 6 q qun yned 75 6 po Ned st 6 L L Jojuno Bess N yne IOIDUOH SS 201d yupa 4 sjeubIS 40 ssajaWeled uon l s uue1B 1 SseJppv PON uonesnbyuo gt peay 424 uoneinbyuod IUM 0
74. dity levels must be 5 95 non condensing Check for proper fusing or circuit breakers Check that all fuses are inserted firmly and in operational condition and that all circuit breakers are in the open position The unit requires a ground wire from its chassis to the building ground Check for good ground connections that are tight and free of oxidation Grounding to conduit or mounting the back panel to a metal surface is not a suitable ground Check for loose connections Check that motor and mains are in separate conduit or separated screened cables Inspect that the unit interior is free of dirt metal chips moisture and corrosion Ensure that all switch and disconnect settings are in the proper position Check that the unit is mounted solidly or that shock mounts are used as necessary Look for any unusual amount of vibration the unit may be subjected to MG 33 AJ 02 VLT is a registered Danfoss trademark Start Up and Functional Tes nstructions 3 2 Applying Power to the Frequency Converter AWARNING HIGH VOLTAGE Frequency converters contain high voltage when connected to AC mains Installation start up and maintenance should be performed by qualified personnel only Failure to perform installation start up and maintenance by qualified personnel could result in death or serious injury AWARNING UNINTENDED START When frequency converter is connected to AC mains the mo
75. e Department ALARM 39 Heatsink sensor No feedback from the heatsink temperature sensor The signal from the IGBT thermal sensor is not available on the power card The problem could be on the power card on the gate drive card or the ribbon cable between the power card and gate drive card WARNING 40 Overload of digital output terminal 27 Check the load connected to terminal 27 or remove short circuit connection Check 5 00 Digital I O Mode and 5 01 Terminal 27 Mode MG 33 AJ 02 VLT is a registered Danfoss trademark 55 Warnings and Alarms Instructions WARNING 41 Overload of digital output terminal 29 Check the load connected to terminal 29 or remove short circuit connection Check 5 00 Digital I O Mode and 5 02 Terminal 29 Mode WARNING 42 Overload of digital output on X30 6 or overload of digital output on X30 7 For X30 6 check the load connected to X30 6 or remove short circuit connection Check 5 32 Term X30 6 Digi Out MCB 101 For X30 7 check the load connected to X30 7 or remove short circuit connection Check 5 33 Term X30 7 Digi Out MCB 101 ALARM 43 Ext supply MCB 113 Ext Relay Option is mounted without ext 24V DC Either connect an ext 24V DC supply or specify that no external supply is used via 14 80 Option Supplied by External 24VDC 0 A change in 14 80 Option Supplied by External 24VDC requires a power cycle ALARM 45 Ear
76. e speed control originates The last part of the status line gives the present frequency converter status These show the operational mode the frequency converter is in NOTE In auto remote mode the frequency converter requires external commands to execute functions VLT AutomationDrive Operating 7 2 Status Message Definitions Table The next three tables define the meaning of the status message display words Operation mode Off Auto On Hand On The frequency converter does not react to any control signal until Auto On or Hand On is pressed The frequency converter is controlled from the control terminals and or the serial communi cation The frequency converter can be controlled by the navigation keys on the LCP Stop commands reset reversing DC brake and other signals applied to the control terminals can override local control Remote Local Reference site The speed reference is given from external signals serial communication or internal preset references The frequency converter uses Hand On control or reference values from the LCP AC Brake AMA finish OK Operation status AC Brake was selected in 2 70 Brake Function The AC brake over magnetizes the motor to achieve a controlled slow down Automatic motor adaptation AMA was carried out successfully AMA ready AMA is ready to start Press Hand On to start AMA running Braking Braking max
77. eck that the option is properly installed Check for loose or missing wiring It may be necessary to contact your Danfoss supplier or service department Note the code number for further troubleshooting directions No Text 0 Serial port cannot be initialised Contact yourDanfoss supplier or DanfossService Department 256 258 Power EEPROM data is defect or too old 512 519 lnternal fault Contact yourDanfoss supplier or Danfoss Service Department 783 Parameter value outside of min max limits 1024 1284 Internal fault Contact your Danfoss supplier or the Danfoss Service Department 1299 Option SW in slot A is too old 1300 Option SW in slot B is too old 1302 Option SW in slot C1 is too old 1315 Option SW in slot A is not supported not allowed 1316 Option SW in slot B is not supported not allowed 1318 Option SW in slot C1 is not supported not allowed 1379 2819 Internal fault Contact yourDanfoss supplier or DanfossService Department 2820 LCP stack overflow 2821 Serial port overflow 2822 USB port overflow 3072 5122 Parameter value is outside its limits 5123 Option in slot A Hardware incompatible with control board hardware 5124 Option in slot B Hardware incompatible with control board hardware 5125 Option in slot CO Hardware incompatible with control board hardware 5126 Option in slot C1 Hardware incompatible with control board hardware 5376 6231 Internal fault Contact yourDanfoss supplier or DanfossServic
78. elow the specified limit in 1 86 Trip Speed Low RPM except when starting or stopping the frequency converter will trip ALARM 50 AMA calibration failed Contact yourDanfoss supplier or DanfossService Department ALARM 51 AMA check Unom and Inom The settings for motor voltage motor current and motor power are wrong Check the settings in parameters 1 20 to 1 25 ALARM 52 AMA low Inom The motor current is too low Check the setting in 4 18 Current Limit ALARM 53 AMA motor too big The motor is too big for the AMA to operate ALARM 54 AMA motor too small The motor is too small for the AMA to operate ALARM 55 AMA Parameter out of range The parameter values of the motor are outside of the acceptable range AMAwill not run ALARM 56 AMA interrupted by user The AMA has been interrupted by the user ALARM 57 AMA timeout Try to restart AMA again Repeated restarts may over heat the motor ALARM 58 AMA internal fault Contact your Danfoss supplier WARNING 59 Current limit The current is higher than the value in 4 78 Current Limit Ensure that Motor data in parameters 1 20 through 1 25 are set correctly Possibly increase the current limit Be sure the system can operate safely at a higher limit ALARM 60 External interlock A digital input signal is indicating a fault condition external to the frequency converter An external interlock has commanded the frequency converter to trip Clear the external fault cond
79. er high voltage terminals 1 Terminals 27 and 29 can also be programmed as output 2 Except safe stop input Terminal 37 3 Terminal 37 is only available in FC 302 and FC 301 A1 with Safe Stop It can only be used as safe stop input Terminal 37 is suitable for PL d ISO13849 1 SIL 2 IEC 61508 and SILCL 2 EN 62061 and implements a Safe Stop function in accordance with Safe Torque Off STO EN 61800 5 2 and Stop Category 0 EN 60204 1 Terminal 37 and the Safe Stop function are designed in conformance with EN 60204 1 EN 61800 5 1 EN 61800 2 EN 61800 3 and EN 954 1 For correct and safe use of the Safe Stop function follow the related information and instructions in the Design Guide 4 When using a contactor with a DC coil inside in combination with Safe Stop it is important to make a return way for the current from the coil when turning it off This can be done by using a freewheel diode or alternatively a 30 or 50 V MOV for quicker response time across the coil Typical contactors can be bought with this diode Analog inputs Number of analog inputs 2 Voltage level Input resistance Ri The analog inputs are galvanically isolated from the supply voltage PELV and other high voltage terminals PELV isolation 2 E 24V 5 18 Control Mains 3 i High 37 voltage Motor Functional isolation RS485 DC Bus Pulse encoder inputs Programmable pulse enc
80. eration 5 40 11 0 No operation Form C relay output Usable for AC or DC voltage and resistive or 01 02 03 04 05 06 inductive loads Table 2 3 Terminal Description 2 4 5 3 Wiring to Control Terminals Control terminal connectors can be unplugged from the frequency converter for ease of installation as shown in Illustration 2 11 1 Open the contact by inserting a small screwdriver into the slot above or below the contact as shown in Illustration 2 13 2 Insert the bared control wire into the contact 3 Remove the screwdriver to fasten the control wire into the contact 4 Ensure the contact is firmly established and not loose Loose control wiring can be the source of equipment faults or less than optimal operation See 10 1 Power dependent Specifications for control terminal wiring sizes See 6 Application Set Up Examples for typical control wiring connections 130BA310 10 Illustration 2 13 Connecting Control Wiring Danfi VLT AutomationDrive Operating 2 4 5 4 Using Screened Control Cables Correct screening The preferred method in most cases is to secure control and serial communication cables with screening clamps provided at both ends to ensure best possible high frequency cable contact If the earth potential between the frequency converter and the PLC is different electric noise may occur that will disturb the entire system Solve this pr
81. erminal 27 19 Freeze Digital Input Reference 5 13 Terminal 29 21 Speed Up 5 14 Terminal 32 Digital Input Default Value 221 Speed Dovvn Notes comments Table 6 10 Speed Up Down MG 33 AJ 02 VLT is a registered Danfoss trademark 43 Danfoss VLT AutomationDrive Operating Instructions Application Set Up Examples e Parameters S Setting m Speed pee 24V 13 2 Thermistor I Reference I DIN 18 trip d gt DIN 19 Protection I MB I I I I b 1 1 I COM 20 1 93 Thermistor 1111 Analog Start 18 HE 1 1 i DIN 27 d I i S Source input 53 1 1 1 Freeze ref 27 i H IN 32 Default Value I I i Speed up 29 1 0 DIN 33 H Notes comments Speed down 32 DIN 37 If only a warning is desired 1 90 Motor Thermal Protection Parameters should be set to 1 Thermistor o Setting warning Vi vm 1 424V 13 8 30 Protocol bal DIN 18 8 31 Address D IN 19 8 32 Baud Rate COM 20 Default Value DIN 27 DIN 29 Notes comments DIN 32 Select protocol address and DIN 33 baud rate in the above Zeb Th able 6 otor Thermistor DIN 37 mentioned parameters 10V 50 AIN 53 AIN 54 COM 55 A OUT 42 COM 39 Bee 01 02 03 04 S 05 L 06 RS 485 61 68 69 Table
82. ess for A2 A3 B3 B4 C3 and C4 Comply with local and national electrical codes for Enclosures cable sizes Connect 3 phase AC input power wiring to terminals L1 L2 and L3 see Illustration 2 8 Depending on the configuration of the equipment input power will be connected to the mains input terminals or the input disconnect 130BT334 10 Ground the cable in accordance with grounding instructions provided in 2 4 2 Earth Grounding Requirements All frequency converters may be used with an isolated input source as well as with ground reference power lines When supplied from an isolated mains source IT mains or floating delta or TT TN S mains with a grounded leg grounded delta set 14 50 RFI Filter to OFF When off the il internal RFI filter capacitors between the chassis M f and the intermediate circuit are isolated to avoid damage to the intermediate circuit and to reduce earth capacity currents in accordance with IEC 61800 3 Illustration 2 10 Control Wiring Access for A4 A5 B1 B2 C1 and C2 Enclosures Please see Table 2 2 before tightening the covers 14 MG 33 AJ 02 VLT is a registered Danfoss trademark Installation A nstructions Frame IP20 IP21 IP55 IP66 A4 A5 2 B1 2 2 B2 2 2 Ci 2 2 C2 2 2 No screws to tighten Does not exist Table 2 2 Tightening Torques for Covers Nm 2 4 5 2 Control Terminal Types
83. et preset reference reference active Terminal active in parameter group3 7 connection correct Scaling of References Check for correct wiring terminals correct Reference signal Check scaling of terminals Check available reference signal 60 MG 33 AJ 02 VLT is a registered Danfoss trademark Basic Troubleshooting Danfi VLT AutomationDrive Operating Instructions Symptom Motor running in wrong direction Motor is not reaching maximum speed Motor speed unstable Motor runs rough Motor will not brake Open power fuses or circuit breaker trip Mains current imbalance greater than 3 Motor current imbalance greater than 3 Possible Cause Test Solution Motor rotation limit Check that 4 10 Motor sped direction Program correct settings is programmed correctly Active reversing signal Check if a reversing command is Deactivate reversing signal programmed for the terminal in parameter group5 1 Digital inputs Wrong motor phase connection See 3 5 Check Motor Rotation in this manual Frequency limits set wrong Check output limits in 4 73 Motor 1 Program correct limits speed high limit RPM 4 14 Motor speed high limit Hz and 4 19 Max output frequency Reference input signal not scaled Check reference input signal scaling Program correct settings in 6 Analog I O mode and parameter group3 1 References Possible incor
84. evice providing a 0 10V control signal connected to frequency converter terminal 53 the system is now ready for operation Note that the scroll bar on the right in the last illustration of the display is at the bottom indicating the procedure is complete Illustration 5 1 shows the wiring connections used to enable this set up A53 130BB482 10 Illustration 5 1 Wiring Example for External Device Providing 0 10V Control Signal frequency converter left external device right 32 MG 33 AJ 02 VLT is a registered Danfoss trademark About Frequency Converter P q y Instructions The following example shows accessing Terminal 18 to see the default setting 1 Press Main Menu twice scroll to parameter group 5 Digital In Out and press OK ES e 14 6 0 00A 1 1 95 2 E 2 Brakes 2 m 3 Reference Ramps 4 Limits Warnings r q p Digital In Out 197 2 Scroll to parameter group 5 1 Digital Inputs and press OK oi 2 14 7 0 00A 1 1 g nm Digital In Out San 5 z 5 0 Digital I O mode SR Digital Inputs i 5 4 Relays 5 5 Pulse Input Y 3 Scroll to 5 10 Terminal 18 Digital Input Press OK to access function choices The default setting Start is shown 2 14 7 0 00A 1 1 e KN Digital Inputs 5 1 6 A o 5 10 Terminal 18 Di
85. face for detailed instructions on entering data through the LCP Enter data with power ON but prior to operating the frequency converter VLT AutomationDrive Operating Press Main Menu twice on the LCP Use the navigation keys to scroll to parameter group 0 Operation Display and press OK 1107 RPM 3 84 A x 1 1 Main menu 0 se Operation Display 1 ex Load Motor 2 xx Brakes 3 xx Reference Ramps 130BP066 10 Use navigation keys to scroll to parameter group 0 0 Basic Settings and press OK 0 2 LCP Display 0 3 LCP Custom Readout 0 0 0 00A 10 En 0 0x Basic Settings J H 0 1 Set up Opperations o Use navigation keys to scroll to 0 03 Regional Settings and press OK 0 International 0 096 0 00A 10 0 0 03 Regional Settings 4 130BP087 10 130BP088 10 Use navigation keys to select International or North America as appropriate and press OK This changes the default settings for a number of basic parameters See 5 4 International North American Default Parameter Settings for a complete list Press Quick Menu on the LCP MG 33 AJ 02 VLT is a registered Danfoss trademark 23 3 Start Up and Functional Tes 7 10 11 12 13 14 Instructions Use the navigation keys to scroll to parameter group Q2 Quick Setup and
86. function being displayed Navigation Use the four navigation arrows to move between Keys items in the menu OK Use to access parameter groups or to enable a choice Light Indicator Function Green The ON light activates when the frequency converter receives power from mains voltage a DC bus terminal or an external 24 V 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 displayed 4 1 5 Operation Keys Operation keys are found at the bottom of the control panel 130BP046 10 VLT AutomationDrive Operating Key Function Hand On Press to start the frequency converter in local control e Use the navigation keys to control frequency converter speed e An external stop signal by control input or serial communication overrides the local hand on off Stops the motor but does not remove power to the frequency converter Auto On Puts the system in remote operational mode e Responds to an external start command by control terminals or serial communication e Speed reference is from an external source Reset Resets the frequency converter manually after a fault has been cleared 4 2 BackUp and Copying Parameter Settings Programming data is stored internally in the frequency converte
87. ght enclosure IP20 kg A1 IP20 A5 IP55 66 fenya oa ss oos 096 o 096 096 096 0 25 3 7kW only available as 16096 high overload Mains Supply 3 x 200 240V AC FC 301 FC 302 High Normal Load Output current Continuous 3 x 200 240V A Intermittent 60 sec overload E 65 3 3 x 200 240V A Continuous kVA 208V AC kVA Max input current Continuous 3 x 200 240V A Intermittent 60 sec overload b 2 59 4 3 x 200 240V A Additional specifications Max cable size mm AWG Max cable size with mains disconnect Estimated power loss at rated max load W SE 310 z i 465 Weight 15 54 602 62 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Specifications p Instructions Mains Supply 3 x 200 240V AC FC 30VFC 302 High Normal Load Output current Continuous ntermittent 60 sec overload 187 1 T T T T T T kVA 208V AC kVA Max input current Continuous 3 x 200 240V A Intermittent 60 sec overload y 169 3 x 200 240V A Additional specifications Max cable size IP20 mm AWG 2 35 2 90 3 0 90 3 0 120 4 0 Max cable size IP21 55 66 mm AWG 2 90 3 0 90 3 0 90 3 0 120 4 0 Max cable size with mains disconnect
88. gital m Input EN Start 5 4 International North American Default Parameter Settings Setting 0 03 Regional Settings to O International or 1 North America changes the default settings for some parameters Table 5 1 lists those parameters that are effected Danfoss VLT AutomationDrive Operating Parameter International North American default parameter default parameter value value 1 23 Motor 50Hz 60Hz 3 03 Maximum 50Hz 60Hz Reference 557 3 04 Reference Sum External Preset Function 4 13 Motor Speed 1500RPM 1800RPM High Limit RPM See Note 3 and 5 Parameter International North American default parameter default parameter value value 0 03 Regional International North America 1 20 Motor Power See Note 1 See Note 1 kw 1 21 Motor Power See Note 2 HP See Note 2 1 22 Motor Voltage 230V 400V 575V 208V 460V 575V 4 14 Motor Speed 50Hz 60Hz High Limit Hz See Note 4 4 19 Max Output 132Hz 120Hz Frequency 4 53 Warning Speed 1500RPM 1800RPM High 5 12 Terminal 27 Coast inverse External interlock Digital Input 5 40 Function Relay No alarm 6 15 Terminal 53 50 60 High Ref Feedb Value 6 50 Terminal 42 No operation Speed 4 20mA 14 20 Reset Mode Infinite auto reset Table 5 1 International North American Default Parameter Settings Note 1 1 20 Motor Power kW is only visible when 0 03 Reg
89. hange this 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 extend the ramp down time If torque limit occurs while running possibly increase the torque limit Be sure the system can operate safely at a higher torque Check the application for excessive current draw on the motor WARNING ALARM 13 Over current The inverter peak current limit approx 20096 of the rated current is exceeded The warning lasts about 1 5 sec then the frequency converter trips and issues an alarm This fault may be caused by shock loading or fast acceleration with MG 33 AJ 02 VLT is a registered Danfoss trademark 53 Warnings and Alarms Instructions high inertia loads If extended mechanical brake control is selected trip can be reset externally Troubleshooting Remove power and check if the motor shaft can be turned Check that the motor size matches the frequency converter Check parameters 1 20 through 1 25 for correct motor data ALARM 14 Earth ground fault There is current from the output phases to earth either in the cable between the frequency converter and the motor or in the motor itself Troubleshooting Remove power to the frequency converter and repair the earth fault Check for earth faults in the motor by measuring the resistance t
90. hanging device between the frequency converter and the motor Connect the 3 phase motor wiring to terminals 96 U 97 V and 98 W Ground the cable in accordance with grounding instructions provided Torque terminals in accordance with the information provided in 10 4 1 Connection Tightening Torques MG 33 AJ 02 VLT is a registered Danfoss trademark 13 Danfi VLT AutomationDrive Operating Installation Instructions Follow motor manufacturer wiring requirements 2 4 5 Control Wiring Illustration 2 8 represents mains input motor and earth grounding for basic frequency converters Actual configu Isolate control wiring from high power rations vary vvith unit types and optional equipment components in the frequency converter If the frequency converter is connected to a thermistor for PELV isolation optional thermistor control wiring must be reinforced double insulated A 24 VDC supply voltage is recommended 2 4 5 1 Access 130BB920 10 E Remove access cover plate with a screw driver See Illustration 2 9 Or remove front cover by loosening attaching screws See Illustration 2 10 130BT248 10 Illustration 2 8 Example of Motor Mains and Earth Wiring 2 4 4 AC Mains Connection Size wiring based upon the input current of the frequency converter For maximum wire sizes see 10 1 Power dependent Specifications Illustration 2 9 Control Wiring Acc
91. he frequency converter even when disconnected from mains input For initial start up make no assumptions about power components Follow pre start procedures Failure to follow pre start procedures could result in personal injury or damage to equipment 1 Input power to the unit must be OFF and locked out Do not rely on the frequency converter disconnect switches for input power isolation 2 Verify that there is no voltage on input terminals L1 91 L2 92 and L3 93 phase to phase and phase to ground 3 Verify that there is no voltage on output terminals 96 U 97 V and 98 W phase to phase and phase to ground 4 Confirm continuity of the motor by measuring ohm values on U V 96 97 V W 97 98 and W U 98 96 5 Check for proper grounding of the frequency converter as well as the motor 6 Inspect the frequency converter for loose connections on terminals 7 Record the following motor nameplate data power voltage frequency full load current and nominal speed These values are needed to program motor nameplate data later 8 Confirm that the supply voltage matches voltage of frequency converter and motor MG 33 AJ 02 VLT is a registered Danfoss trademark 21 Start Up and Functional Tes 3 1 2 Start Up Check List CAUTION Before applying power to the unit inspect the entire installation as detailed in Table 3 1 Check mark those items when completed VLT AutomationDrive
92. in 2 16 AC brake Max Current The warning is active when the dissipated braking is higher than 90 of the brake resistance power If Trip 2 is selected in 2 13 Brake Power Monitoring the frequency converter will trip when the dissipated braking power reaches 100 WARNING ALARM 27 Brake chopper fault The brake transistor is monitored during operation and if a short circuit occurs the brake function is disabled and a warning is issued The frequency converter is still operational but since the brake transistor has short circuited substantial power is transmitted to the brake resistor even if it is inactive 54 MG 33 AJ 02 VLT is a registered Danfoss trademark Warnings and Alarms Instructions Remove power to the frequency converter and remove the brake resistor WARNING ALARM 28 Brake check failed The brake resistor is not connected or not working Check 2 15 Brake Check ALARM 29 Heatsink temp The maximum temperature of the heatsink has been exceeded The temperature fault will not reset until the temperature falls below the reset heatsink temperature The trip and reset points are based on the frequency converter power size Troubleshooting Check for the following conditions Ambient temperature too high Motor cable too long Incorrect airflow clearance above and below the frequency converter Blocked airflow around the frequency converter Damaged heatsink fan Dirty heatsink ALARM 30 Motor phase
93. inal ratings details Terminal description Default Terminal Parameter setting Description Digital inputs outputs 12 13 a DC so jasa 19 O Reversing 24V DC supply voltage Maximum output current is 200mA total 130mA for FC 301 for all 24V loads Useable for digital inputs and external transducers 32 0 No Digital inputs operation 33 operation 27 2 Coast Selectable for either inverse digital input or output 29 Default setting is input 20 Common for digital inputs and OV potential for 24V supply 37 Safe input Used for STO Analog inputs outputs 39 Common for analog output 42 Programmable analog output The analog signal is 0 20mA or 4 20mA at a maximum of 5000 50 10V DC 10V DC analog supply voltage 15mA maximum commonly used for potentiometer or thermistor 53 Analog input 54 Feedback Selectable for voltage or current Switches A53 and A54 select mA or V 55 Common for analog input MG 33 AJ 02 VLT is a registered Danfoss trademark 15 Installation Instructions Terminal description Default setting Serial communication Integrated RC Filter for cable screen ONLY for Terminal Parameter Description 61 connecting the screen when experiencing EMC problems 8 3 RS 485 Interface A 8 3 control card switch is 68 69 provided for termination resistance Relays 0 No op
94. investigate those areas exterior to the frequency converter as indicated in the alarm or warning 8 2 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 frequency converter issuing an alarm A warning clears by itself when the abnormal condition is removed Alarms Trip An alarm is issued when the frequency converter is tripped that is the frequency converter suspends operation to prevent frequency converter or system damage The motor will coast to a stop The frequency converter logic will continue to operate and monitor the frequency converter status After the fault condition is remedied the frequency converter can be reset It will then be ready to start operation again A trip can be reset in any of 4 ways e Press RESET on the LCP Digital reset input command Serial communication reset input command Auto reset Trip lock An alarm that causes the frequency converter to trip lock requires that input power be cycled The motor will coast to a stop The frequency converter logic will continue to operate and monitor the frequency converter status Remove input power to the frequency converter and correct the cause of the fault then restore power This action puts the frequency converter into a trip condition as described above and may be reset in any of those 4 ways VLT AutomationDrive Operating 8 3 W
95. ional Settings is set to 0 International Note 2 1 21 Motor Power HP is only visible when 0 03 Regional Settings is set to 1 North America Note 3 This parameter is only visible when 0 02 Motor Speed Unit is set to 0 RPM Note 4 This parameter is only visible when 0 02 Motor Speed Unit is set to 1 Hz Note 5 The default value depends on the number of motor poles For a 4 poled motor the international default value is 1500RPM and for a 2 poled motor 3000RPM The corresponding values for North America is 1800 and 3600RPM respectively Changes made to default settings are stored and available for viewing in the quick menu along with any programming entered into parameters 1 Press Quick Menul 2 Scroll to Q5 Changes Made and press OK MG 33 AJ 02 VLT is a registered Danfoss trademark 33 VLT AutomationDrive Operating About Frequency Converter P q y nstructions 25 996 0 00A 1 1 Ka A Q1 My Personal Menu E s Q2 Quick Setup 05 Changes Made Q6 Loggings v 3 Select Q5 2 Since Factory Setting to view all programming changes or Q5 1 Last 10 Changes for the most recent bei e 25 9 0 00A 1 1 co Changes Made Q5 m 5 al Q5 1 Last 10 Changes m 052 Since Factory Setti 34 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating About Freq
96. ional specifications Max cable size mains motor load share and brake mm AWG Estimated power loss at rated max load W Weight enclosure IP21 IP55 kg Efficiency 480 592 720 880 1200 For fuse ratings see 10 3 1 Fuses 1 High overload 160 torque during 60 sec Normal overload 110 torque during 60 sec 2 American Wire Gauge 3 Measured using 5 m screened motor cables at rated load and rated frequency 4 The typical power loss is at nominal load conditions and expected to be within 15 tolerence relates to variety in voltage and cable conditions Values are based on a typical motor efficiency eff2 eff3 border line Motors with lower efficiency will also add to the power loss in the frequency converter and opposite If the switching frequency is increased compared to the default setting the power losses may rise significantly LCP and typical control card power consumptions are included Further options and customer load may add up to 30W to the losses Though typical only 4W extra for a fully loaded control card or options for slot A or slot B each Although measurements are made with state of the art equipment some measurement inaccuracy must be allowed for 5 70 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Specifications P Instructions 10
97. is a registered Danfoss trademark Danfi VLT AutomationDrive Operating Specifications P Instructions Enclosure FC 300 Power Recommended Recommended Recommended circuit Max trip level fuse size Max fuse breaker size i 1517 Mer 2 2 0 75 4 0 gG 10 gG 25 PKZMO 25 25 A3 5 5 7 5 5 2 gG 32 PKZMO 25 25 B3 11 15 m gG 63 PKZM4 50 50 B4 18 5 30 gG 40 18 5 gG 125 NZMB1 A100 100 gG 50 22 gG 63 30 C3 37 45 gG 63 37 gG 150 NZMB2 A200 150 C4 aR 160 55 E NZMB2 A250 250 aR 200 75 A5 75 7 gG 10 0 75 5 5 I PKZM0 25 25 gG 16 7 5 B1 gG 25 11 PKZM4 63 63 gG 32 15 gG 40 18 5 B2 22 30 gG 50 22 gG 100 NZMB1 A100 100 gG 63 30 C1 37 55 gG 63 37 gG 160 37 45 NZMB2 A200 160 gG 100 45 aR 250 55 aR 160 55 o gt aR 200 75 aR 250 NZMB2 A250 250 Table 10 3 525 600V Frame Sizes A B and C Enclosure FC 300 Power Recommended Recommended Recommended circuit Max trip level fuse size Max fuse breaker Size A B2 E C2 gG 80 30 I gG 100 37 gG 125 45 gG 160 55 7 gG 125 37 gG 160 45 gG 160 45 gG 200 55 75 gG 200 55 75 aR 250 90 aR 250 90 D aR 315 110 aR 315 110 2 aR 350 132 160 aR 350 132 160 aR 400 200 aR 400 200 aR 500 250 aR 500 250 aR 550 315 aR 550 315 E 355 560 aR 900 500 560 aR 900 500 560 aR 16
98. ition To resume normal operation apply 24V DC to the terminal programmed for external interlock Reset the frequency converter WARNING ALARM 61 Feedback error An error between calculated speed and speed measurement from feedback device The function Warning Alarm Disabling setting is in 4 30 Motor Feedback Loss Function Accepted error setting in 4 31 Motor Feedback Speed Error and the allowed time the error occur setting in 4 32 Motor Feedback Loss Timeout During a commissioning procedure the function may be effective 56 MG 33 AJ 02 VLT is a registered Danfoss trademark Warnings and Alarms Instructions WARNING 62 Output frequency at maximum limit The output frequency has reached the value set in 4 19 Max Output Frequency Check the application to determine the cause Possibly increase the output frequency limit Be sure the system can operate safely at a higher output frequency The warning will clear when the output drops below the maximum limit ALARM 63 Mechanical brake low The actual motor current has not exceeded the release brake current within the Start delay time window WARNING ALARM 65 Control card over temperature The cutout temperature of the control card is 80 C Troubleshooting Check that the ambient operating temperature is within limits Check for clogged filters Check fan operation Check the control card WARNING 66 Heatsink temperature low The frequency converter is too
99. ive Operating Specifications P Instructions 10 3 2 CE Compliance Fuses or Circuit Breakers are mandatory to comply with IEC 60364 Danfoss recommend using a selection of the following The fuses below are suitable for use on a circuit capable of delivering 100 000 Arms symmetrical 240V or 480V or 500V or 600V depending on the frequency converter voltage rating With the proper fusing the frequency converter short circuit current rating SCCR is 100 000 Arms Enclosure FC 300 Power Recommended Recommended Recommended circuit Max trip level fuse size Max fuse breaker Size A MEA EE D Al 0 25 1 5 gG 10 gG 25 PKZMO 16 16 A2 0 25 2 2 gG 10 0 25 1 5 gG 25 PKZMO 25 25 gG 16 2 2 A3 3 0 3 7 gG 16 3 gG 32 PKZMO 25 25 gG 20 3 7 B3 5 5 gG 25 gG 63 PKZM4 50 50 B4 7 5 15 gG 32 7 5 gG 125 NZMB1 A100 100 gG 50 11 gG 63 15 C3 18 5 22 gG 80 18 5 gG 150 18 5 NZMB2 A200 150 aR 125 22 aR 160 22 R CA 30 37 aR 160 30 aR 200 30 NZMB2 A250 250 aR 200 37 aR 250 37 A4 0 25 22 gG 10 0 25 1 5 gG 32 PKZMO 25 25 A5 0 25 3 7 gG 10 0 25 1 5 gG 32 PKZMO 25 25 gG 16 2 2 3 gG 20 3 7 B1 5 5 7 5 gG 25 5 5 gG 80 PKZM4 63 63 s l B2 11 gG 50 gG 100 NZMB1 A100 100 C1 15 22 gG 63 15 gG 160 15 18 5 NZMB2 A200 160 gG 80 18 5 aR 160 22 gG 100 22 C2 30 37 aR 160 30 aR 200 30 NZMB2 A250 250 aR 200 37 aR 250 37
100. k that the supply voltage matches the frequency converter voltage Perform Input voltage test Perform soft charge and rectifier circuit test WARNING ALARM 9 Inverter overload The frequency converter is about to cut out because of an overload too high current for too long The counter for electronic thermal inverter protection gives a warning at 9896 and trips at 10096 while giving an alarm The frequency converter cannot be reset until the counter is below 9096 The fault is that the frequency converter is overloaded by more than 10096 for too long Troubleshooting Compare the output current shown on the LCP with the frequency converter rated current Compare the output current shown on the LCP with measured motor current Display the Thermal Drive Load on the LCP and monitor the value When running above the frequency converter continuous current rating the counter should increase When running below the frequency converter continuous current rating the counter should decrease See the derating section in the Design Guide for more details if a high switching frequency is required WARNING ALARM 10 Motor overload temperature According to the electronic thermal protection ETR the motor is too hot Select whether the frequency converter gives a warning or an alarm when the counter reaches 10096 in 1 90 Motor Thermal Protection The fault occurs when the motor is overloaded by more than 10096 for too long VLT Automati
101. l 174 b l xew indino sind 9 qe1eA indino asing ZZ euro ndino sind JUeJSUOD SWI 14 5 4 anjeA uf E wL 37 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Instructions About Frequency Converter P uones u n yoo Jepoo2u3 aynjosqy ZE ZE Aduanbas4 190 Japoduq einjosqy DE ZE u16ue1 ejeq Japoduq einjosqy SE ZE uonnjosag aynjosqy E ZE 030 01g einjosqy ZE ZE uonnjosey 1094 LE ZE ed eubis ejuauaJDul 06 26 4 po u2 c NYD 2243 SL ZE q pou 2243 y L ZE 1onuo ZUJ 21 26 HUN JASN 21 22 Jojeunuouag HUN ISN 11 26 uon liq jeuonei1og OL ZE BULOYUON Jepoou3 60 ZE u16ue lqe 1epoou3 ainjosqy 80 ZE UOIneJauas yoo 4 po u2 einjosqy ZO ZE x20 1epo2u3 einjosqy 90 26 e eq jepo u3 ainjosqy S0 ZE SSX e1eJpneg einjosqy 70 22 uonnjos y ainjosqy 60 26 0203014 einjosqy 20 22 uonn osag je1usulaJ2U LO ZE ed jeubis jezyu w u 00 22 7 1opoou3 0 22 Sbuinas lseg ODW 22 UONRAIIY ssedAg 61 12 sinoy Bujuuny ssed g LL 1 prom snieis ssed g 01 16 uoneAnoy epo 1591 60 12 Aejaq au dill ssed g 20 16 Aejaq au 4819 ssed g 10 18 apow ssed g 00 1 uleg jeuonjodoJd did ss old Y8 0 uled jeuonjodoJd did p ds 68 06 WYO 103515 exelg 18 0 2ue1onpul s xe p 08 06 I amp uji
102. l 9 e s UNA NANO Zy 6 4 indino Zp jeuruue nding 5oyeuy 1uejsuo SUL d lili Z1 0 X 4 YBIH ZL OEX WAL MOT ZL OEX WAL abeyon Z1 0 X jeuru ebeyoA MOT ZL O X euro L y indu Bojeuy 1uejsuo SUI d lili LL OEX uu l YBIH LL OEX uu l ANJLA qp 4 M MOT LL OEX WEL abeyon YBIH L1 0 X IBEYOA MOT LL O X euro 1ndul 6ojeuy 1uejsuo SWI Ja S Jeuruue nleA qpea4 jeg ubiH ys jeuruua qpea4 jeg MOT tS Ieuluu quand YBIH tS euro L quaUND MOT tS Jeuruue abeyon ubiH tS Jeur 9beyoA wo ps eura L z mduj 6ojeuy 1 815402 AMI au ES euw anjeA qpea4 jeg ES jeuruua ANJLA qpees jed MOT ES JeuruJe 1 quand YBIH ES jeuruJa p JU3JIN MOT ES Jeuiuue abeyon ubiH S 6 9beyoA MOT ES jeuruJa L L indu 6ojeuy UONDUNY 1noaui OJ9Z BAIT SUL INOSUWI 0J9Z SAI 1 Bojeuy 1no u bojeuy y s ld INOSWI 9 0EX MO sind 104300 sng 9 0 X INO sind 1eseJd NO3WIL 6Z MO sind 10100 sng 628 INO sind 1eseJd INO3WIL Z INO sind 10nuo2 sng ZZH MO sind 031402 sng Aejay 79 jeubiq p llonuo sng uonpeJig Jepoou3 ee ze WAL uonnjoA ey Jad ses ng EE ZE uer yndu 1epo2u3 Ac 9 0 X bai xeyy indino sind lqeHEA mado sind 9 0 X euro L 674 ba14 Xew indino sind 3 qeneA indino as nd 62 jeuiuua
103. l fuk x T s tin SCS x 61 Feedback Error X X 4 30 Motor Feedback rr 63 Mechanical Brake Low X 2 20 Release Brake ers e X 67 Option Configuration has changed x 68 Safe Stop X 009 5 19 Terminal 37 Safe T 70 T x j n rrersese 0 2 eeschter FP 73 Safe Stop Auto Restart X X 5 19 Terminal 37 Safe 74 PTC thermistor j j gt 75 megal Profle se j x li O 76 jPowerUntSetup XT 77 Reduced power mode X 14 59 Actual Number of 78 Tracking Error X X 4 34 Tracking Error m Meat og AA m O T m csv same T m legal Option comina OO T m no say option 7 T m option Detection 7 x m mechanical ake mg TR MG 33 AJ 02 VLT is a registered Danfoss trademark 51 Warnings and Alarms Instructions Danfi VLT AutomationDrive Operating N Description 251 New Type Code Table 8 1 Alarm Warning Code List X Dependent on parameter 1 Can not be Auto reset via 74 20 Reset Mode 8 4 1 Fault Messages The warning alarm information below defines the warning alarm condition provides the probable cause for the condition and details a remedy or troubleshooting procedure WARNING 1 10 Volts low The control card voltage is below 10V from terminal
104. ltage imbalance is too high This message also appears for a fault in the input rectifier on the frequency converter Options are programmed at 14 12 Function at Mains Imbalance Troubleshooting Check the supply voltage and supply currents to the frequency converter WARNING 5 DC link voltage high The intermediate circuit voltage DC is higher than the high voltage warning limit The limit is dependent on the frequency converter voltage rating The frequency converter is still active 52 MG 33 AJ 02 VLT is a registered Danfoss trademark Warnings and Alarms Instructions WARNING 6 DC link voltage low The intermediate circuit voltage DC is lower than the low voltage warning limit The limit is dependent on the frequency converter voltage rating The frequency converter is still active WARNING ALARM 7 DC overvoltage If the intermediate circuit voltage exceeds the limit the frequency converter trips after a time Troubleshooting Connect a brake resistor Extend the ramp time Change the ramp type Activate functions in 2 10 Brake Function Increase 14 26 Trip Delay at Inverter Fault WARNING ALARM 8 DC under voltage If the intermediate circuit voltage DC drops below the under voltage limit the frequency converter checks if a 24V DC backup supply is connected If no 24V DC backup supply is connected the frequency converter trips after a fixed time delay The time delay varies with unit size Troubleshooting Chec
105. lustration 2 6 If not factory supplied fuses must be provided by the installer as part of installation See maximum fuse ratings in 10 3 Fuse Tables VLT AutomationDrive Operating 130BB460 10 L1 L2 L3 91 92 93 Fuses L1 12 1 3 GND Illustration 2 6 Frequency Converter Fuses Wire Type and Ratings All wiring must comply with local and national regulations regarding cross section and ambient temperature requirements Danfoss recommends that all power connections be made with a minimum 75 C rated copper wire See 10 1 Power dependent Specifications for recommended wire sizes 2 4 2 Earth Grounding Requirements AWARNING GROUNDING HAZARD For operator safety it is important to ground frequency converter properly in accordance with national and local electrical codes as well as instructions contained within these instructions Ground currents are higher than 3 5mA Failure to ground frequency converter properly could result in death or serious injury NOTE It is the responsibility of the user or certified electrical installer to ensure correct grounding earthing of the equipment in accordance with national and local electrical codes and standards Follow all local and national electrical codes to ground electrical equipment properly Proper protective grounding for equipment with ground curre
106. me e Quick stop inverse was chosen as a function for a digital input parameter group 5 1 The corresponding terminal is not active e The quick stop function was activated via serial communication 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 4 55 Warning Reference High The sum of all active references is below the reference limit set in 4 54 Warning Reference Low MG 33 AJ 02 VLT is a registered Danfoss trademark 47 VLT AutomationDrive Operating Status Messages 9 Instructions Operation status Run on ref The frequency converter is running in the reference range The feedback value matches the setpoint value Run request A start command has been given but the motor is stopped until a run permissive signal is received via digital input Running The motor is driven by the frequency converter Speed high Motor speed is above the value set in 4 53 Warning Speed High Speed low Motor speed is below the value set in 4 52 Warning Speed Low Standby In Auto On mode the frequency converter will start the motor with a start signal from a digital input or serial communication Start delay In 1 71 Start Delay a delay starting time was set A start command is activated and the motor will start after the start delay
107. nal injury or equipment damage NOTE The hand on key on the LCP provides a local start command to the frequency converter The OFF key provides the stop function When operating in local mode the up and down arrows on the LCP increase and decrease the speed output of the frequency converter The left and right arrow keys move the display cursor in the numeric display 1 Press Hand Onl 2 Accelerate the frequency converter by pressing 4 to full speed Moving the cursor left of the decimal point provides quicker input changes 3 Note any acceleration problems 4 Press OFF 5 Note any deceleration problems If acceleration problems were encountered If warnings or alarms occur see 8 Warnings and Alarms Check that motor data is entered correctly Increase the ramp up time in 3 41 Ramp 1 Ramp Up Time Increase current limit in 4 18 Current Limit Increase torque limit in 4 16 Torque Limit Motor Mode If deceleration problems were encountered If warnings or alarms occur see 8 Warnings and Alarms Check that motor data is entered correctly Increase the ramp down time in 3 42 Ramp 1 Ramp Down Time MG 33 AJ 02 VLT is a registered Danfoss trademark 25 VLT AutomationDrive Operating Start Up and Functional Tes nstructions Enable overvoltage control in 2 17 Over voltage Control See 8 4 Warning and Alarm Definitions for resetting the frequency converter after a tri
108. ncy Converter P q y Instructions 5 6 Remote Programming with MCT 10 Set up Software Danfoss has a software program available for developing storing and transferring frequency converter programming The MCT 10 Set up Software allows the user to connect a PC to the frequency converter and perform live programming rather than using the LCP Also all frequency converter programming can be done off line and simply downloaded into frequency converter Or the entire frequency converter profile can be loaded onto the PC for back up storage or analysis The USB connector or RS 485 terminal are available for connecting to the frequency converter MCT 10 Set up Software is available for free download at www VLT software com A CD is also available by requesting part number 130B1000 A user s manual provides detailed operation instructions 40 MG 33 AJ 02 VLT is a registered Danfoss trademark Application Set Up Examples instr etions 6 Application Set Up Examples 6 1 Introduction NOTE A jumper wire may be required between terminal 12 or 13 and terminal 27 for the frequency converter to operate when using factory default programming values See 2 4 1 7 Jumper Terminals 12 and 27 for details The examples in this section are intended as a quick reference for common applications Parameter settings are the regional default values unless otherwise indicated selected in 0 03 Regional Settings Parameters associate
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110. nt 60 sec overload 396 3 x 525 550V A Continuous 34 3 x 551 690V A Intermittent 60 sec overload 374 3 x 551 690V A I Continuous KVA at 550V KVA 34 3 Continuous KVA at 575V KVA Continuous KVA at 690V KVA 15 5 21 5 21 5 26 3 26 3 323 323 40 6 Max input current Continuous 36 3 x 525 690V A ntermittent 60 sec overload 39 6 3 x 525 690V A Additional specifications Max cable size mains motor load share and brake mm AWG Estimated power loss at rated max load W Weight enclosure IP21 IP55 kg Efficiency 35 1 0 375 27 MG 33 AJ 02 VLT is a registered Danfoss trademark 69 VLT AutomationDrive Operating Specifications P Instructions Mains Supply 3 x 525 690V AC High Normal Load ur Re EH Typical Shaft output at 550V kW Typical Shaft output at 575V HP Typical Shaft output at 690V kW Enclosure IP21 55 IP21 Enclosure IP21 55 Output current Continuous 3 x 525 550V A 36 43 43 54 54 65 65 87 87 105 Intermittent 60 sec overload P S 115 5 3 x 525 550V A Continuous 3 x 551 690V 100 Intermittent 60 sec overload S J E E 110 3 x 551 690V A Continuous KVA at 550V KVA S d j E S d 100 0 Continuous KVA at 575V KVA 228 Continuous KVA Max input current Continuous Continuous Addit
111. nts higher than 3 5mA must be established see Leakage Current gt 3 5mA e A dedicatedground wire is required for input power motor power and control wiring Use the clamps provided with on the equipment for proper ground connections 12 MG 33 AJ 02 VLT is a registered Danfoss trademark Installation Instructions Do not ground one frequency converter to another in a daisy chain fashion Keep the ground wire connections as short as possible Use of high strand wire to reduce electrical noise is recommended Follow motor manufacturer wiring requirements 2 4 2 1 Leakage Current gt 3 5mA Follow national and local codes regarding protective earthing of equipment with a leakage current gt 3 5mA Frequency converter technology implies high frequency switching at high power This will generate a leakage current in the earth connection A fault current in the frequency converter at the output power terminals might contain a DC component which can charge the filter capacitors and cause a transient earth current The earth leakage current depends on various system configurations including RFI filtering screened motor cables and frequency converter power EN IEC61800 5 1 Power Drive System Product Standard requires special care if the leakage current exceeds 3 5mA Earth grounding must be reinforced in one of the following ways Earth ground wire of at least 10mm Two separate earth ground wires both
112. o ground of the motor leads and the motor with a megohmmeter ALARM 15 Hardware mismatch A fitted option is not operational with the present control board hardware or software Record the value of the following parameters and contact your Danfoss supplier 15 40 FC Type 15 41 Power Section 15 42 Voltage 15 43 Software Version 15 45 Actual Typecode String 15 49 SW ID Control Card 15 50 SW ID Power Card 15 60 Option Mounted 15 61 Option SW Version ALARM 16 Short circuit There is a short circuit in the motor or motor wiring Remove power to the frequency converter and repair the short circuit WARNING ALARM 17 Control word timeout There is no communication to the frequency converter The warning will only be active when 8 04 Control Timeout Function is NOT set to 0 OFF If 8 04 Control Timeout Function is set to Stop and Trip a warning appears and the frequency converter ramps down until it stops then displays an alarm Troubleshooting Check connections on the serial communication cable Increase 8 03 Control Timeout Time Danfi VLT AutomationDrive Operating Check operation of the communication equipment Verify proper installation based on EMC requirements WARNING ALARM 20 Temp input error The temperature sensor is not connected WARNING ALARM 21 Parameter error The parameter is out of range The parameter number is reported in the LCP The affected parameter must be set to a valid value
113. oaded power supply SMPS To rule out a problem in the control If the display stays lit then the due to improper control wiring or a wiring disconnect all control wiring problem is in the control wiring fault within the frequency by removing the terminal blocks Check the wiring for shorts or Intermittent display R converter incorrect connections If the display continues to cut out follow the procedure for display dark Service switch open or missing Check if the motor is connected and Connect the motor and check the motor connection the connection is not interrupted service switch by a service switch or other devise No mains power with 24V DC If the display is functioning but no Apply mains power to run the unit option card output check that mains power is applied to the frequency converter LCP Stop Check if Off has been pressed Press Auto On or Hand On depending on your operation mode to run the motor EE Missing start signal Standby Check 5 10 Start for correct setting Apply a valid start signal to start the for terminal 18 use default setting motor Motor coast signal active Coasting Check 5 12 Coast inv for correct Apply 24V on terminal 27 or setting for terminal 27 use default programm this terminal to No setting operation Wrong reference signal source Check reference signal Local Program correct settings Check 3 13 remote or bus reference Preset Reference site S
114. oblem by fitting an equalizing cable next to the control cable Minimum cable cross section 16 mm PLC FC 2 0 0 N P POBE 2 el 6 m PE PE PE vi PE L Min 16 mm Equalizing cable 50 60Hz ground loops With very long control cables ground loops may occur To eliminate ground loops connect one end of the screen to ground with a 100nF capacitor keeping leads short PLC Wess SS 130BB609 11 lt RISA SS NS RS PE onF PE Avoid EMC noise on serial communication This terminal is connected to earth via an internal RC link Use twisted pair cables to reduce interference between conductors The recommended method is shown below o m P 8 ca m o el 0 m PE PE PET H PE L Min 16 mm Equalizing cable Alternatively the connection to terminal 61 can be omitted FC FC F 9 v 69 m 68 o e PE PE PEH 27 PE L Min 16 mm Equalizing cable 130BB924 10 2 4 5 5 Control Terminal Functions Frequency converter functions are commanded by receiving control input signals Each terminal must be programmed for the function it will be supporting in the parameters 16 MG 33 AJ 02 VLT is a registered Danfoss trademark Installation Instructions associated with tha
115. oder inputs 2 1 Voltage level 72 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Specifications P Instructions Maximum voltage on input The pulse and encoder inputs terminals 29 32 33 are galvanically isolated from the supply voltage PELV and other high voltage terminals 7 FC 302 only 2 Pulse inputs are 29 and 33 3 Encoder inputs 32 A and 33 B Digital output Programmable digital pulse outputs 2 Terminal 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 Analog output Number of programmable analog outputs 1 The analogue output is galvanically isolated from the supply voltage PELV and other high voltage terminals Control card 24 V DC output Terminal number 12 13 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 Control card 10V DC output Terminal number 50 The 10V DC supply is galvanically isolated from the supply voltage PELV and other high voltage terminals Control card RS 485 serial communication i number The RS 485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage PELV Control card USB serial communication USB stan
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117. onDrive Operating Troubleshooting Check for motor overheating Check if the motor is mechanically overloaded Check that the motor current set in 1 24 Motor Current is correct Ensure that Motor data in parameters 1 20 through 1 25 are set correctly If an external fan is in use check in 1 91 Motor External Fan that it is selected Running AMA in 1 29 Automatic Motor Adaptation AMA may tune the frequency converter to the motor more accurately and reduce thermal loading WARNING ALARM 11 Motor thermistor over temp The thermistor might be disconnected Select whether the frequency converter gives a warning or an alarm in 1 90 Motor Thermal Protection Troubleshooting Check for motor overheating 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 10V supply and that the terminal switch for 53 or 54 is set for voltage Check 1 93 Thermistor Source selects terminal 53 or 54 When using digital inputs 18 or 19 check that the thermistor is connected correctly between either terminal 18 or 19 digital input PNP only and terminal 50 Check 1 93 Thermistor Source selects terminal 18 or 19 WARNING ALARM 12 Torque limit The torque has exceeded the value in 4 16 Torque Limit Motor Mode or the value in 4 17 Torque Limit Generator Mode 14 25 Trip Delay at Torque Limit can c
118. or 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 It does not cause the motor to run or harm to the motor Some motors may be unable to run the complete version of the test In that case select Enable reduced AMA If an output filter is connected to the motor select Enable reduced AMA If warnings or alarms occur see 8 Warnings and Alarms Run this procedure on a cold motor for best results To run AMA 1 1006 OV Di E bD Press Main Menu to access parameters Scroll to parameter group 1 Load and Motor Press OK Scroll to parameter group 1 2 Motor Data Press OK Scroll to 1 29 Automatic Motor Adaptation AMA Press OK Select Enable complete AMA Press OK Follow on screen instructions The test will run automatically and indicate when it is complete MG 33 AJ 02 VLT is a registered Danfoss trademark Start Up and Functional Tes nstructions 3 5 Check Motor Rotation Prior to running the frequency converter check the motor rotation 1 Press Hands on 2 Press gt for positive speed reference 3 Check that the speed displayed is positive When 1 06 Clockwise Direction is set to 0 Normal default clockwise 4a Verify that the motor turns clockwise 5a Verify that the LCP direction arrow is clockwise When 1
119. ows the downloading process 6 Press Hand On or Auto On to return to normal operation 4 3 Restoring Default Settings CAUTION Initialisation restores the unit to factory default settings Any programming motor data localization and monitoring records will be lost Uploading data to the LCP provides a backup prior to initialisation Restoring the frequency converter parameter settings back to default values is done by initialisation of the frequency converter Initialisation can be through 14 22 Operation Mode or manually Initialisation using 14 22 Operation Mode does not change frequency converter data such as operating hours serial communication selections personal menu settings fault log alarm log and other monitoring functions Using 14 22 Operation Mode is generally recommended Manual initialisation erases all motor programming localization and monitoring data and restores factory default settings Danfi VLT AutomationDrive Operating 4 3 1 Recommended Initialisation 1 Press Main Menu twice to access parameters 2 Scroll to 14 22 Operation Mode 3 Press OK 4 Scroll to Initialisation 5 Press OK 6 Remove power to the unit and wait for the display to turn off 7 Apply power to the unit Default parameter settings are restored during start up This may take slightly longer than normal 8 Alarm 80 is displayed 9 Press Reset to return to operation mode 4 3 2
120. p NOTE 3 1 Pre start through 3 7 Local control Test in this chapter conclude the procedures for applying power to the frequency converter basic programming set up and functional testing 3 8 System Start Up The procedure in this section requires user wiring and application programming to be completed 6 Application Set Up Examples is intended to help with this task Other aids to application set up are listed in 1 2 Additional Resources The following procedure is recommended after application set up by the user is completed ACAUTION MOTOR START Ensure that the motor system and any attached equipment is ready for start It is the responsibility of the user to ensure safe operation under any operational condition Failure to ensure that the motor system and any attached equipment is ready for start could result in personal injury or equipment damage 1 Press Auto On 2 Ensure that external control functions are properly wired to the frequency converter and all programming completed 3 Apply an external run command 4 Adjust the speed reference throughout the speed range 5 Remove the external run command 6 Note any problems If warnings or alarms occur see 8 Warnings and Alarms 26 MG 33 AJ 02 VLT is a registered Danfoss trademark User Interface 4 User Interface 4 1 Local Control Panel VLT AutomationDrive Operating Instructions 4 1 1 LCP Layout The LCP is divided into fo
121. p command is active e DC Brake inverse is selected as a function for a digital input parameter group 5 1 The corresponding terminal is not active e The DC Brake is activated via serial communication The sum of all active feedbacks is above the feedback limit set in 4 57 Warning Feedback High Feedback low Freeze output Freeze output request Freeze ref Jog request The sum of all active feedbacks is below the feedback limit set in 4 56 Warning Feedback Low The remote reference is active which holds the present speed e Freeze output was selected as a function for a digital input Group 5 1 The corresponding terminal is active Speed control is only possible via the terminal functions speed up and speed down e Hold ramp is activated via serial communi cation A freeze output command has been given but the motor will remain stopped until a run permissive signal is received Freeze Reference was chosen as a function for a digital input parameter group 5 1 The corresponding terminal is active The frequency converter saves the actual reference Changing the reference is now only possible via terminal functions speed up and speed down A jog command has been given but the motor will be stopped until a run permissive signal is received via a digital input Jogging Motor check OVC control Operation status The motor is running as programmed in 3 19 Jog Speed RPM e Jog
122. p snoiAeuag r0 UOHOW Jo 3120 A EO EE UONO A 9UJOH 40 dwey ZO E SOd WO 3 SHO 1UIOd OJ9Z 10 6 AWOH 93104 00 UOHOW SWOH 0 SDUIN S APY ODW x EE aainos nq q 06 26 1yu uido A dq x6 ZE dal Douu 40 UMOP eq 68 29 Dau 104 dn eg 88 26 l 40 UMOP 23 8 26 ef pai 104 dn dy 98 26 uone l y 3ne q S8 ZE AMOOl A 1Inej q v8 7 uolnjosay 20 9A 68 26 ad L dwey 28 26 duuey 15911045 18 29 19p03U3 1NOJ9A uinuiixew 08 ZE 1922 Sg 3DOJ A 8 7 Sau d lil 40449 uollisod Y L ZE eun s y Mu e36e3u 6 26 An e q MOPUIM 101402 au JO zis ZL ZE uoneAn2v MOPUIM 1044402 AY JO 3ZIS L ZE JOJLIBUDH D IJOJH JO BWI ue s O ZE 0105 Old 104 au Burdues 69 26 9 e S JO JO NLYIY SH A M 89 26 1043 UONISOJ pa esajO XeW 9 c psemsoj paaj4 UoleJajaddy 99 26 psemsoj paa4 NDOJIA S9 C yipimpueg did v9 c ung 216934 104 INJEA HUIT 69 26 40326 Je16e1U 29 22 10326 L9 ZE 10198 feuonuodold 09 26 d llonuo did 9 ZE Jase 22JnOS 25 29 INM 1587 ZOE ODW 15 26 APIS BDINOS DEE DINOS p eqpeeJ G ZE psen5 NYD LUJ St c QI pou U 0 1402 LUJ t C uoneuluue Jopo2u3 Ot c BuuolluoNW Jopo2u3 66 26 y16U97 lqe einjosqy 82 29 39 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating About Freque
123. qneduio 8 0 s aur uon eieg 10104 p y o7 62 06 uon olq 10104 pe 201 ZZ 0 96 3u8 un anbsoy Bunes ubiH Lz 0 s anbsoy Bues uf 02 06 3snfpy Hes APY 22 06 2 bai exea lqqoAA 61 02 UNA ones wopuey 440 21 02 xew oney wopuey qqoAA LL 0 oney lqqoM 01 02 uono unj wopuey ajqqoM 60 06 Sau UMOQ dn lqqoAA 80 0 euin e uenbes qqo A 0 06 eui duin e qqoM 90 06 96 dunf qqoAA S0 0 ZH ADuanbas4 duunr ejqqoM 70 02 inos q Buije s baJ4 e1l q lqqoAA 0 0 96 ADuanbas4 2199 lqqoAA 20 06 ZH ear lqqoA 10 06 POW 9 Iqq9M 00 02 131990M 0 0 s91m3894 2 wei indino p le3S 4122 Cid sse oJd 66 81 padulel did 55920 26 81 indino 14 5592014 16 8 10113 Old SS 201d 06 81 synopesy did 06 81 c indy jeubiq 09 8 z s nd no syndu 9 81 OL 8bX 1nduj dwe 66 81 1 8vX 1ndu d l l g 8 v 8vx 1ndul duet 26 81 vu z 8px indu Bojeuy 96 8 sinopeay Bojeuy 8L z synopeay 2320 yx 81 Bulnoyuoy eubis x eqpeeJ 19 21 Uuol12 41Iq eqpeeJ 09 ddy pue Bulloyuoy 9 21 Spa J9A OS9H 6S L uonnjosag WIS J9po2u3 96 Z oney uoneuuojsuelJ ES ZL mdul zs ebeyoA 1ndul Lc s lod OS ZL e eyie1u 5 amp S ZL 91e1pneg 30 vE Z jeuuoj 2q ISS 97 71 yol Sc Z u16ue1 eA ISS 92 eu suonis
124. r indino did ss old yasay ued Old sse oJg ld 55920Jq APY upiMpueg adUaJaJay UO J032e4 did SS 201d NUL 4122 HO Aid ss 5oid eui uonenuasJaylq Ald ss old eui e165 l1u did SS 201d uleg jeuonjodoJd did 55920 4 p ds 11815 did SS 201d dnpuim nuy did Sse oJq J011u05 3SISAU JELWJON Old 559204 HD did sse ouq 92Jnosay z yDeQpae4 72 sse oJg 92Jnosay y eqp 4 1 ss oold qpaa UO ss oold awit uoneibau d anbio uleg euonuodoJg Id nbio 1 UO Id J012e4 did p ds oney 1830 yoeqp z Cid peeds Sul d lili ssedmo7 did p ds yw 4122 Ig did peeds eui uonenueJeyiq did peeds eui e16a1u1 did peeds uleg jeuonjdodoJd did p ds yDeqpae4 Cid p ds H did p ds s ld MOWIL INAINO 6 jeuruJe 0402 sng 6 ural XEVV SEX euw 3129S um SEX 41 indino E SPX 2 v 1ndino Bojeuy 38saJd 1noeuu indino L SpX e 0402 sng L SpX e 9 e2s XEVV L SyX 2 9 e s UNA 1 SEX e indino 1 SEX jeuruue 1ndino Bojeuy s ld MOWIL indino 8 0 X jeuruue 0 1407 sng 8 0 X 2014 XEVV 8 0 X 2014 9 amp 2S UI 8 0 X feulun T indino 8 0 X jeuruue z ndino 5oyeuy 13414 indino Bojeuy 19591 ino uull indino Zy jeuruJe l HD sng indino Zy uus ayes xew NANO zr jeuruJa
125. r The data can be up loaded into the LCP memory as a storage back up Once stored in the LCP the data can be downloaded back into the frequency converter Or downloaded into other frequency converters by connecting the LCP into those units and downloading the stored settings This is a quick way to program multiple units with the same settings Initialisation of the frequency converter to restore factory default settings does not change data stored in the LCP memory AWARNING UNINTENDED START When frequency converter is connected to AC mains the motor may start at any time The frequency converter motor and any driven equipment must be in operational readiness Failure to be in operational readiness when the frequency converter is connected to AC mains could result in death serious injury equipment or property damage MG 33 AJ 02 VLT is a registered Danfoss trademark 29 User Interface Instructions 4 2 1 Uploading Data to the LCP 1 Press OFF to stop the motor before uploading or downloading data Go to 0 50 LCP Copy Press OK Select All to LCP Kr cogo ay Press OK A progress bar shows the uploading process 6 Press Hand On or Auto On to return to normal operation 4 2 2 Downloading Data from the LCP 1 Press OFF to stop the motor before uploading or downloading data Go to 0 50 LCP Copy Press OK Select All from LCP Pi ply Press OK A progress bar sh
126. r actual tolerances Do not exceed 300m 1000ft for unshielded motor leads e 150m 500ft for shielded cable 2 2 Frequency Converter and Motor Pre installation Check List Compare the model number of unit on the nameplate to what was ordered to verify the proper equipment Ensure each of the following are rated for same voltage Mains power Frequency converter Motor Ensure that frequency converter output current rating is equal to or greater than motor full load current for peak motor performance Motor size and frequency converter power must match for proper overload protection If frequency converter rating is less than motor full motor output cannot be achieved VLT AutomationDrive Operating 2 3 Mechanical Installation 2 3 1 Cooling To provide cooling airflow mount the unit to a solid flat surface or to the optional back plate see 2 3 3 Mounting Top and bottom clearance for air cooling must be provided Generally 100 225mm 4 10in is required See Illustration 2 1 for clearance requirements e Improper mounting can result in over heating and reduced performance Derating for temperatures starting between 40 C 104 F and 50 C 122 F and elevation 1000m 3300ft above sea level must be considered See the equipment Design Guide for detailed information 2 S 7 o lt m o a m
127. re to isolate power motor and control wiring could result in less than optimum frequency converter and associated equipment performance For your safety comply with the following requirements Electronic controls equipment is connected to hazardous mains voltage Extreme care should be taken to protect against electrical hazards when applying power to the unit Run motor cables from multiple frequency converters separately Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out Overload and Equipment Protection An electronically activated function within the frequency converter provides overload protection for the motor The overload calculates the level of increase to activate timing for the trip controller output stop function The higher the current draw the quicker the trip response The overload provides Class 20 motor protection See 8 Warnings and Alarms for details on the trip function Because the motor wiring carries high frequency current it is important that wiring for mains motor power and control are run separately Use metallic conduit or separated shielded wire Failure to isolate power motor and control wiring could result in less than optimum equipment performance All frequency converters must be provided with short circuit and over current protection Input fusing is required to provide this protection see Il
128. reats to human life property damage and to avoid fire hazard due to overheating of the cables in the instal lation The frequency converter is equipped with an internal over current protection 4 78 Current Limit that can be used for upstream overload protection UL applications excluded Moreover fuses or Circuit Breakers can be used to provide the over current protection in the installation Over current protection must always be carried out according to national regulations 10 3 1 Recommendations AWARNING In case of malfunction not following the recommendation may result in personnel risk and damage to the frequency converter and other equipment The following tables list the recommended rated current Recommended fuses are of the type gG for small to medium power sizes For larger powers aR fuses are recommended For Circuit Breakers Moeller types have been tested to have Danfi VLT AutomationDrive Operating a recommendation Other types of circuit breakers may be used provide they limit the energy into the frequency converter to a level equal to or lower than the Moeller types If fuses Circuit Breakers according to recommendations are chosen possible damages on the frequency converter will mainly be limited to damages inside the unit For further information please see Application Note Fuses and Circuit Breakers MN 90 TX YY 76 MG 33 AJ 02 VLT is a registered Danfoss trademark Danfi VLT AutomationDr
129. rect parameter Check the settings of all motor Check settings in parameter settings parameters including all motor group1 6 Analog I O mode For compensation settings For closed closed loop operation check loop operation check PID settings settings in parameter group 20 0 Feedback Possible over magnetization Check for incorrect motor settings in Check motor settings in parameter all motor parameters groups 1 2 Motor data 1 3 Adv motor data and 1 5 Load indep setting Possible incorrect settings in the Check brake parameters Check Check parameter group2 0 DC brake parameters Possible too ramp time settings brake and 3 0 Reference limits short ramp down times Phase to phase short Motor or panel has a short phase to Eliminate any shorts detected phase Check motor and panel phase to for shorts Motor overload Motor is overloaded for the Perform startup test and verify application motor current is within specifi cations If motor current is exceeding nameplate full load current motor may run only with reduced load Review the specifi cations for the application Loose connections Perform pre startup check for loose Tighten loose connections connections Problem with mains power See Rotate input power leads into the lf imbalanced leg follows the wire it Alarm 4 Mains phase loss drive one position A to B B to C C is a power problem Check mains description to A power supply Problem with the frequen
130. related information and instructions of the relevant Design Guide must be follovved Protective Measures Safety engineering systems may only be installed and commissioned by qualified and skilled personnel The unit must be installed in an IP54 cabinet or in an equivalent environment The cable between terminal 37 and the external safety device must be short circuit protected according to ISO 13849 2 table D 4 If any external forces influence the motor axis e g suspended loads additional measures e g a safety holding brake are required in order to eliminate hazards Safe Stop Installation and Set Up AWARNING SAFE STOP FUNCTION The safe stop function does NOT isolate mains voltage to the frequency converter or auxiliary circuits Perform work on electrical parts of the frequency converter or the motor only after isolating the mains voltage supply and waiting the length of time specified under Safety in this manual Failure to isolate the mains voltage supply from the unit and waiting the time specified could result in death or serious injury It is not recommended to stop the frequency converter by using the Safe Torque Off function If a running frequency converter is stopped by using the function the unit will trip and stop by coasting If this is not acceptable e g causes danger the frequency converter and machinery must be stopped using the appropriate stopping mode Danfi VLT AutomationDrive Oper
131. rter before changing switch positions Set switches A53 and A54 to select the signal type U selects voltage selects current The switches are accessible when the LCP has been removed see Illustration 2 14 Note that some option cards available for the unit may cover these switches and must be removed to change switch settings Always remove power to the unit before removing option cards Terminal 53 default is for a speed reference signal in open loop set in 16 61 Terminal 53 Switch Setting Terminal 54 default is for a feedback signal in closed loop set in 16 63 Terminal 54 Switch Setting VLT AutomationDrive Operating 130BT310 10 VLT Illustration 2 14 Location of Terminals 53 and 54 Switches and Bus Termination Switch 2 4 5 8 Terminal 37 Terminal 37 Safe Stop Function The FC 302 and FC 301 optional for A1 enclosure is available with safe stop functionality via control terminal 37 Safe stop disables the control voltage of the power semicon ductors of the frequency converter output stage which in turn prevents generating the voltage required to rotate the motor When the Safe Stop T37 is activated the frequency converter issues an alarm trips the unit and coasts the motor to a stop Manual restart is required The safe stop function can be used for stopping the frequency converter in emergency stop situations In the normal operating mode when safe stop
132. starts and stops the motor optimizes energy efficiency and offers many more control monitoring and efficiency functions Operation and monitoring functions are available as status indications to an outside control system or serial communication network 1 4 Internal Frequency Converter Controller Functions Below is a block diagram of the frequency converter s internal components See Table 1 1 for their functions e TLOLOWZSZL Illustration 1 3 Frequency Converter Block Diagram VLT AutomationDrive Operating Danfi Area Title Mains input Rectifier DC bus DC reactors Capacitor bank Inverter Output to motor Control circuitry Functions Three phase AC mains power supply to the frequency converter The rectifier bridge converts the AC input to DC current to supply inverter power The frequency converter s intermediate DC bus circuit handles the DC current 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 Stores the DC power Provides ride through protection for short power losses Converts the DC into a controlled PWM AC waveform for a controlled variable output to the motor Regulated three phase output power to the motor Input power internal processing output and motor current are monitored to provide efficient operation and
133. t terminal SeeTable 2 3 for terminals and associated parameters It is important to confirm that the control terminal is programmed for the correct function See 4 User Interface for details on accessing parameters and 5 About Frequency Converter Programming for details on programming The default terminal programming is intended to initiate frequency converter functioning in a typical operational mode 2 4 5 6 Jumper Terminals 12 and 27 A jumper wire may be required between terminal 12 or 13 and terminal 27 for the frequency converter to operate when using factory default programming values Digital input terminal 27 is designed to receive an 24V DC external interlock command In many applications the user wires an external interlock device to terminal 27 When no interlock device is used wire a jumper between control terminal 12 recommended or 13 to terminal 27 This provides in internal 24V signal on terminal 27 No signal present prevents the unit from operating When the status line at the bottom of the LCP reads AUTO REMOTE COAST this indicates that the unit is ready to operate but is missing an input signal on terminal 27 When factory installed optional equipment is wired to terminal 27 do not remove that wiring 2 4 5 7 Terminal 53 and 54 Switches Analog input terminals 53 and 54 can select either voltage 10 to 10V or current 0 4 20mA input signals Remove power to the frequency conve
134. th fault 2 Earth ground fault on start up Troubleshooting Check for proper earthing grounding and loose connections Check for proper wire size Check motor cables for short circuits or leakage currents ALARM 46 Power card supply The supply on the power card is out of range There are three power supplies generated by the switch mode power supply SMPS on the power card 24V 5V 18V When powered with 24V DC with the MCB 107 option only the 24V and 5V supplies are monitored When powered with three phase mains voltage all three supplied are monitored Troubleshooting Check for a defective power card Check for a defective control card Check for a defective option card If a 24V DC power supply is used verify proper supply power WARNING 47 24V supply low The 24 V DC is measured on the control card The external 24V DC backup power supply may be overloaded otherwise contact your Danfoss supplier WARNING 48 1 8V supply low The 1 8V DC supply used on the control card is outside of allowable limits The power supply is measured on the control card Check for a defective control card If an option card is present check for an overvoltage condition Danfi VLT AutomationDrive Operating WARNING 49 Speed limit When the speed is not within the specified range in 4 11 Motor Speed Low Limit RPM and 4 13 Motor Speed High Limit RPM the frequency converter will show a warning When the speed is b
135. ting Installation Instructions N w 130BB749 10 N Illustration 2 16 Installation to Achieve a Stopping Category 0 EN 60204 1 with Safety Cat 3 EN 954 1 PL d ISO 13849 1 1 Safety device Cat 3 circuit interrupt device possibly with 7 Inverter release input Door contact lg Motor Contactor Coast a 5V DC Short circuit protected cable if not inside installation cabinet CT A Safe Stop Commissioning Test After installation and before first operation perform a commissioning test of the installation making use of safe stop Moreover perform the test after each modification of the installation MG 33 AJ 02 VLT is a registered Danfoss trademark 19 Installation nstructions 2 4 5 9 Mechanical Brake Control n hoisting lovvering applications it is necessary to be able to control an electro mechanical brake Control the brake using any relay output or digital output terminal 27 or 29 Keep the output closed voltage free as long as the frequency converter is unable to support the motor for example due to the load being too heavy Select Mechanical brake control 32 in par 5 4 for applications with an electro mechanical brake The brake is released when the motor current exceeds the preset value in 2 20 Release Brake Current The brake is engaged
136. ting When replacing an F frame module this will occur if the power specific data in the module power card does not match the rest of the frequency converter Please confirm the spare part and its power card are the correct part number 77 WARNING Reduced power mode This warning indicates that the frequency converter is operating in reduced power mode i e less than the allowed number of inverter sections This warning will be generated on power cycle when the frequency converter is set to run with fewer inverters and will remain on ALARM 78 Tracking error The difference between set point value and actual value has exceeded the value in 4 35 Tracking Error Disable the function by 4 34 Tracking Error Function or select an alarm warning also in 4 34 Tracking Error Function Investigate the mechanics around the load and motor Check feedback connections from motor encoder to frequency converter Select motor feedback function in 4 30 Motor Feedback Loss Function Adjust tracking error band in 4 35 Tracking Error and 4 37 Tracking Error Ramping MG 33 AJ 02 VLT is a registered Danfoss trademark 57 Warnings and Alarms Instructions ALARM 79 Illegal power section configuration The scaling card is the incorrect part number or not installed Also MK102 connector on the power card could not be installed ALARM 80 Drive initialised to default value Parameter settings are initialised to default settings after a man
137. tor may start at any time The frequency converter motor and any driven equipment must be in operational readiness Failure to be in operational readiness when the frequency converter is connected to AC mains could result in death serious injury equipment or property damage 1 Confirm input voltage is balanced within 3 If not correct input voltage imbalance before proceeding Repeat procedure after voltage correction 2 Ensure optional equipment wiring if present matches installation application 3 Ensure that all operator devices are in the OFF position Panel doors closed or cover mounted 4 Apply power to the unit DO NOT start the frequency converter at this time For units with a disconnect switch turn to the ON position to apply power to the frequency converter NOTE If the status line at the bottom of the LCP reads AUTO REMOTE COAST this indicates that the unit is ready to operate but is missing an input signal on terminal 27 See Illustration 2 15 for details 3 3 Basic Operational Programming Frequency converters require basic operational programming prior to 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 data in accordance with the following procedure Parameter settings recommended are intended for start up and checkout purposes Application settings may vary See 4 User Inter
138. ual reset Reset the unit to clear the alarm ALARM 81 CSIV corrupt CSIV file has syntax errors ALARM 82 CSIV parameter error CSIV failed to init a parameter ALARM 83 Illegal option combination The mounted options are not supported to work together ALARM 84 No safety option The safety option was removed without applying a general reset Reconnect the safety option ALARM 88 Option detection A change in the option layout has been detected This alarm occurs when 14 89 Option Detection is set to 0 Frozen config uration and the option layout for some reason has changed An option layout change has to be enabled in 14 89 Option Detection before the change is accepted If the change of configuration is not accepted it is only possible to reset Alarm 88 Trip lock when the option configuration has been re established corrected WARNING 89 Mechanical brake sliding The hoist brake monitor has detected a motor speed gt 10rpm ALARM 90 Feedback monitor Check the connection to encoder resolver option and eventually replace the MCB 102 or MCB 103 ALARM 91 Analogue input 54 wrong settings Switch S202 has to be set in position OFF voltage input when a KTY sensor is connected to analogue input terminal 54 ALARM 92 No flow A no flow condition has been detected in the system 22 23 No Flow Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM
139. uency Converter P q y Instructions 5 5 Parameter Menu Structure Establishing the correct programming for applications often requires setting functions in several related parameters These parameter settings provide the frequency converter with system details for the frequency converter to operate properly System details may include such things as input and output signal types programming terminals minimum and maximum signal ranges custom displays automatic restart and other features See the LCP display to view detailed parameter programming and setting options Press Info in any menu location to view additional details for that function 5 Press and hold Main Menu to enter a parameter number for direct access to that parameter Details for common application set ups are provided in 6 Application Set Up Examples MG 33 AJ 02 VLT is a registered Danfoss trademark 35 VLT AutomationDrive Operating Instructions About Frequency Converter P MO EE Wel Aduanbas4 YBIH gg WAL fouenbaJ4 MOT ES WAL 628 JUBISUO SWI 13114 esind anjeA qp z x ubiH 62 WHEL AP394 J98 MOT 67 WL Aduanbas4 YBIH 62 WAL ADuanbas4 MOT 6Z WAL indu sind Aejay Aejaq HO Aejay Aejaq uo Aejay uon unJ skejay LOL GW MO 6iq 06 wL LOL 9DW MO IBIA 9 0 X uu l indino 2110 62 24 jeubig ZZ s
140. ur functional groups see The local control panel LCP is the combined display and Illustration 4 1 keypad on the front of the unit The LCP is the user interface to the frequency converter e o a The LCP has several user functions Q Start stop and control speed when in local Status 10 control 1234rpm 10 4A 43 5Hz Display operational data status warnings and cautions a 43 5Hz Programming frequency converter functions Manually reset the frequency converter after a fault when auto reset is inactive Run OK An optional numeric LCP NLCP is also available The NLCP operates in a manner similar to the LCP See the b Seis Quick Main Alarm Programming Guide for details on use of the NLCP Menu m Log The display contrast can be adjusted by pressing STATUS and the up down key E Warn Alarm Illustration 4 1 LCP a Display area b Display menu keys for changing the display to show status options programming or error message history c Navigation keys for programming functions moving the display cursor and speed control in local operation Also included are the status indicator lights d Operational mode keys and reset MG 33 AJ 02 VLT is a registered Danfoss trademark 27 User Interface Instructions 4 1 2 Setting LCP Display Values The display area is activated when the frequency converter receives power from mains
141. was selected as function for a digital input parameter group 5 1 The corresponding terminal e g Terminal 29 is active e The Jog function is activated via the serial communication e The Jog function was selected as a reaction for a monitoring function e g No signal The monitoring function is active In 1 80 Function at Stop Motor Check was selected A stop command is active To ensure that a motor is connected to the frequency converter a permanent test current is applied to the motor Overvoltage control was activated in 2 17 Over voltage Control The connected motor is supplying the frequency converter with generative energy The overvoltage control adjusts the V Hz ratio to run the motor in controlled mode and to prevent the frequency converter from tripping PowerUnit Off For frequency converters with an external 24V power supply installed only Mains supply to the frequency converter is removed but the control card is supplied by the external 24V Protection md QStop Ramping Ref high Ref low Protection mode is active The unit has detected a critical status an overcurrent or overvoltage e To avoid tripping switching frequency is reduced to 4kHz If possible protection mode ends after approximately 10sec e Protection mode can be restricted in 14 26 Trip Delay at Inverter Fault The motor is decelerating using 3 87 Quick Stop Ramp Ti
142. wer units only WARNING 250 New spare part A component in the frequency converter has been replaced Reset the frequency converter for normal operation WARNING 251 New typecode A component in the frequency converter has been replaced and the typecode changed Reset the frequency converter for normal operation MG 33 AJ 02 VLT is a registered Danfoss trademark 59 VLT AutomationDrive Operating Basic Troubleshooting instructions 9 Basic Troubleshooting 9 1 Start Up and Operation See Alarm Log in Table 4 1 Symptom Possible Cause Test Solution Missing input power See Table 3 1 Check the input power source Missing or open fuses or circuit See open fuses and tripped circuit Follow the recommendations breaker tripped breaker in this table for possible provided causes No power to the LCP Check the LCP cable for proper Replace the faulty LCP or connection or damage connection cable Shortcut on control voltage Check the 24V control voltage Wire the terminals properly terminal 12 or 50 or at control supply for terminal 12 13 to 20 39 or Display dark No function terminals 10V supply for terminal 50 to 55 Wrong LCP LCP from VLT 2800 or Use only LCP 101 P N 130B1124 or Wrong contrast setting Press Status Up Down arrows to Display LCP is defective Test using a different LCP Replace the faulty LCP or A connection cable Internal voltage supply fault or Contact supplier sss Overl
143. y 3 x 380 500V AC FC 302 3 x 380 480V AC FC 301 FC 301 FC 302 High Normal Load Enclosure IP20 Enclosure IP21 Bs Ba Enclosure IP55 66 Output current a 3 x 380 440V A i i Intermittent 60 sec overload 3 x 380 440V A Continuous 52 3 x 441 500V A 30 0 Intermittent 60 sec overload 3 x 441 500V A 57 2 Continuous kVA 400V AC kVA 42 3 Continuous kVA 414 460V AC kVA Max input current Continuous 55 3 x 380 440V A Intermittent 60 sec overload 3 x 380 440V A 60 5 Continuous 47 3 x 441 5001 A Intermittent 60 sec overload 517 3 x 441 500V A Additional specifications Max cable size mm AWG 2 Max cable size with mains disconnect Estimated power loss 291 392 379 465 444 525 547 at rated max load W 2 Weight enclosure IP20 kg 235 5 Weight 23 enclosure IP21 IP55 66 kg Efficiency 739 64 MG 33 AJ 02 VLT is a registered Danfoss trademark VLT AutomationDrive Operating Specifications p Instructions Mains Supply 3 x 380 500 V AC FC 302 3 x 380 480V AC FC 301 FC 301 FC 302 P37K P45K P55K High Normal Load Enclosure IP20 Enclosure IP21 Enclosure IP55 66 Output current Continuous 3 x 380 440V Intermittent 60 sec overload 3 x 380 440V A Continuous 3 x 441 50

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