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Operating Instructions

1. Z 331 5 E e 280 o 7 9 5 H t T d ae 0 IQ a M Al 315 E L HDD LL e W Tee On 000 pil O boo gt L OSO O j ie 349 5 d U UO 200 WU NY NY O Ny Y Illustration 2 3 Cable Entries and Hole Sizes Small Unit o 431 5 3 380 E S es R m 1 d KLOD 00 D S S o S Ue 1 EEN 415 s AM a Q009 M sexe e D Ce eo Be SN L IE 449 5 L S Illustration 2 4 Cable Entries and Hole Sizes Large Unit Motor side 1xM20 1xM25 1 Also used for 4xM12 6xM12 sensor acuator sockets 2 3 3 Cooling The FCD 302 has no forced cooling It relies only on natural convection for cooling using the cooling fins A minimum of 100 mm 4 in top and bottom air cooling clearance must be provided See Illustration 2 5 e Derating starts above 40 C 104 F and 1000 m 3300 ft elevation above sea lev
2. 1 2 ko e Ch B8eniaidiO Illustration 2 13 Location of Terminals Large Unit Digital and analog inputs outputs 8 USB port Safe stop LCP connection B option lo Standard bus RS 485 Relay 1 eee SS i Profibus Na a lW l a Relay 2 Ethernet port SE av DC bauna f MG04F302 VLT is a registered Danfoss trademark 17 Installation For both small and large unit the service switch is optional The switch is shown mounted on the motor side Alternatively the switch can be located on the mains side or omitted For the large unit the circuit breaker is optional The large unit can be configured with either service switch or circuit breaker not both The illustration shown is not config urable in practice but is displayed to show the respective positions of components only 2 4 3 Terminal Types Motor control and mains terminals are spring loaded CAGE CLAMP type 1 Open the contact by inserting a small screwdriver into the slot above the contact as shown in Illustration 2 14 2 Insert the stripped w
3. 6 12 37 7 7 11 8 10 L 9 M Illustration 2 22 Installation to Achieve a Stopping Category O EN 60204 1 with Safety Cat 3 EN 954 1 PL d ISO 13849 1 130BB749 10 1 Safety device Cat 3 circuit interrupt device possibly 7 Inverter module with release input Door contact S Motor Contactor Coast o 5vDc Short circuit protected cable according to ISO 13849 2 table DA Control board f 4 28 MG04F302 VLT is a registered Danfoss trademark Start Up and Functional Tes VLT Decentral Drive FCD 302 Operating Instructions 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 risk for high voltage on these terminals For initial startup 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 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
4. MG04F302 VLT is a registered Danfoss trademark 43 en Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 3 2 Brakes Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 2 00 DC Hold Current All set ups TRUE o Uint8 2 01 DC Brake Current All set ups TRUE o Uint16 2 02 DC Braking Time 10 0 s All set ups TRUE Uint16 2 03 DC Brake Cut In Speed RPM App Dependent All set ups TRUE 6 N Uint16 2 04 DC Brake Cut In Speed HZ iaa 2 1 Brake Energy Funct EE A A 2 12 Brake Power Limit kW App Dependent Allsetups TRUE 0 Tun 2 2 Mechanical Brake E 15000000 2 26 Torque Ref 0 00 All set ups TRUE Int16 2 27 Torque Ramp Time 0 2 s All set ups TRUE w Mich Uint8 N 44 MG04F302 VLT is a registered Danfoss trademark Denpi Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 4 3 Reference Ramps Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 3 00 Reference Range All set ups TRUE e Uint8 3 01 Reference Feedback Unit All set ups TRUE l Uint8 3 02 Minimum Reference App Dependent All set ups TRUE Int32 3 03 Maximum Reference App Dependent All set ups TRUE LA LA Int32
5. e G S Key Function E Hand On Starts 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 on Off Stops the motor but does not remove power to Warn the frequency converter Auto On Puts the system in remote operational mode Alarm e Responds to an external start command by control terminals or serial communication e Speed reference is from an external source Key Function Back Reverts to the previous step or list in the menu Reset Resets the frequency converter manually after a fault has been cleared structure Cancel Cancels the last change or command as long as Mie display Mode has not changed 4 2 Back Up and Copying Parameter Info Press for a definition of the function being Settings displayed Navigation Use the four navigation arrows to move between Programming data is stored internally in the frequency Keys items in the menu converter OK sia access parameter groups Orta e ablea e The data can be uploaded into the LCP memory AS as a storage back up Ss ae Ee e Once stored in the LCP the data can be i ndicator unction E downloaded back into the frequency converter Green The ON light activates when the frequency converter receives e Data can also be downloaded into other power from mains voltage a DC frequency converters by con
6. Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 9 16 PCD Read Configuration App Dependent 2 set ups TRUE Uint16 OctStr 9 80 Defined Parameters 1 0 N A Allsetups FALSE o Uint16 9 81 Defined Parameters 2 0 N A Allset ups FALSE o VUintt 9 82 Defined Parameters 3 0 N A All set ups FALSE Uint16 9 83 Defined Parameters 4 ed Absa fae EE Uint16 9 93 Changed parameters 4 0 N A Allsetups FALSE o Uint16 9 94 Changed parameters 5 0 N A Allsetups FALSE o Uint16 MG04F302 VLT is a registered Danfoss trademark 53 Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 11 13 Smart Logic Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 13 0 SLC Settings a setae E 13 02 Stop Event null 2 set ups TRUE 13 1 Comparators Comparator Operator a me 13 1 RS Flip Flops Uint8 Int32 54 MG04F302 VLT is a registered Danfoss trademark en Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 12 14 Special Functions v ar Parameter description Default value 4 set up Change Conver Type z o during sion index operation 14 0 Inverter Switching i i eS el 14 03 Overmodulation 1 On All set ups
7. Position Description 01 03 Choices options Product group FCD Frequency 04 06 302 converter series Decentral Drive Advanced performance PK37 0 37 kW 0 5 HP PK55 0 55 kW 0 75 HP PK75 0 75 kW 1 0 HP P1K1 1 1 kw 1 5 HP 07 10 ge l P1K5 1 5 kW 2 0 HP wer size P2K2 2 2 kW 3 0 HP 3 0 kW 4 0 HP large unit P3KO only Installation box only PXXX without power section Phases Mains T Three phase voltage 380 480 V AC Standard Black B66 IP66 Type 4X Standard White 13 15 Enclosure W66 eet P ype Hygienic White Wee ygienic Whi IP66K Type 4X 16 17 RFI filter H1 RFI filter class A1 C2 No brale 18 Brake Brake chopper mechanical brake Supply Position Description Hardware configuration i S 22 Switch option X 23 Display C MG04F302 VLT is a registered Danfoss trademark Choices options Complete product small unit stand alone mount Complete product large unit stand alone mount Drive part small unit No installation box Drive part large unit No installation box Installation box small unit stand alone mount No drive part Installation box large unit stand alone mount No drive part No brackets Flat brackets 40 mm brackets No installation box Metric threads No switch option Service switch on mains input Service switch on motor output Circuit breaker amp mains di
8. Resolution of output frequency at 0 1000 Hz 0 003 Hz All control characteristics are based on a 4 pole asynchronous motor Control card performance Scan interval 1 ms Surroundings Enclosure rating IP66 Type 4X indoor Derating for high ambient temperature Minimum ambient temperature during full scale operation 0 C M Derating for high altitude Control card USB serial communication USB standard Connection to PC is carried out via a standard host device USB cable The USB connection is galvanically isolated from the supply voltage PELV and other high voltage terminals The USB 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 80 MG04F302 VLT is a registered Danfoss trademark Index Index A Alarm IR 34 Mess le LT 67 Automatic Motor Adaptation ENEE 64 Motor Adaptation LAMA 38 tee D ET 33 B Brake Control ici idad dasdi 71 BAKING BE 65 C Cable Lengths And Cross Sectons EE 77 AA A n 14 Communication Option 72 ERR UE ee 29 Control A A an nis 24 Cdra aid asias 8 Card Performance 80 Card 10 V DC Output 80 Card 24 V DC Output 79 Card RS 485 Serial Communication 79 Card USB Serial Communication 80 Characteristics 80 Signal 64 TM Mall raices 35 64 WING D 29 Cooling Clearance EENEG 29 Copying
9. A progress bar shows 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 before 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 e Manual initialisation erases all motor programming localization and monitoring data and restores factory default settings eat VLT Decentral Drive FCD 302 Operating Instructions 4 3 1 Recommended Initialisation 1 Press Main Menu twice to access parameters Scroll to 14 22 Operation Mode Press OK Scroll to Initialisation Press OK Kr ON Bs ie eNO Remove power to the unit and wait for the display to turn off T 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
10. TRUE Une 0 23 Display Line 2 Large 1613 All set ups TRUE Uint16 0 25 My Personal Menu SR 1 set up TRUE o Uint16 0 3 LCP Custom Readout sees seg 0 31 Min Value of User defined Readout 0 00 CustomReadoutUnit All set ups Int32 0 32 Max Value of User defined Readout 100 00 CustomReadoutUnit All set ups Int32 0 37 Display Text 1 0 N A 1 setup TRUE 0 Visstri25 0 38 Display Text 2 0 N A 1 set up TRUE VisStr 25 0 39 Display Text 3 0 N A 1 set up me VisStr 25 0 4 LCP Keypad Mee 0 42 Auto on Key on LCP null All set ups TRUE Uint8 0 44 Off Reset Key on LCP null All set ups mwe Uint8 0 45 Drive Bypass Key on LCP null All set ups TRUE Uint8 0 50 LCP Copy 0 No copy All set ups FALSE Uint8 0 51 Set up Copy 0 No copy All set ups FALSE Uint8 0 6 Password Ps 0 60 Main Menu Password 100 N A 1 set up mwe o Int16 0 65 Quick Menu Password 200 N A 1 set up TRUE o Int16 0 66 Access to Quick Menu w o Password 0 Full access 1 set up TRUE ab Uint8 0 67 Bus Password Access 0 N A All set ups TRUE o Uint16 MG04F302 VLT is a registered Danfoss trademark 41 en Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 2 1 Load Motor Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 1 0 General Set
11. The load and speed combination demands a motor voltage higher than the actual DC link voltage WARNING ALARM TRIP 65 Control Card Over Temperature Control card over temperature The cut out temperature of the control card is 80 C WARNING 66 Heatsink Temperature Low The heat sink temperature is measured as 0 C This could indicate that the temperature sensor is defect Thus the fan speed is increased to the maximum in case the power part or control card is very hot ALARM 67 Option Configuration has Changed One or more options has either been added or removed since the last power down ALARM 68 Safe Stop Safe Stop has been activated To resume normal operation apply 24 V DC to T 37 Press Reset WARNING 68 Safe Stop Safe Stop has been activated Normal operation is resumed when Safe Stop is disabled AWARNING Automatic Restart ALARM 69 Power card temperature The temperature sensor on the power card is either too hot or too cold ALARM 70 Illegal FC Configuration Actual combination of control board and power board is illegal WARNING 73 Safe stop auto restart Safe stopped Note that with automatic restart enabled the motor can start when the fault is cleared WARNING 76 Power Unit Setup The required number of power units does not match the detected number of active power units WARNING 77 Reduced power mode This warning indicates that the drive is operating in reduced power mode that is
12. User Interface Darfi VLT Decentral Drive FCD 302 Operating Instructions 4 1 2 Setting LCP Display Values The display area is activated when the frequency converter receives power from mains voltage or an external 24 V supply The information displayed on the LCP can be customized for user application e Each display readout has a parameter associated with it D The frequency converter status at the bottom line of the display is generated automatically and is not selectable See 6 3 Status Message Definitions Table for more information 6 9 Auto Remote Running Display Parameter number Default setting 1 1 0 20 Motor RPMs 1 2 0 21 Motor current 1 3 0 22 Motor power kW 2 0 23 Motor frequency 3 0 24 Reference in percent 2 E mM 799 RPM 0 98 A 0 75 kW a 0 000 E 53 2 Auto Remote Ramping 2 Le 207RPM 0 98 A 0 75 kw 34 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 Shows operational information e In Auto mode press to toggle between status read out displays e Press repeatedly to scroll through each status display e Press Status plus 4 or Y to adjust the
13. disable Undervoltage warning 410 Inverter undervoltage re 398 enable warning reset Overvoltage warning 778 without brake Dynamic brake turn on 778 Inverter overvoltage re 795 enable warning reset Overvoltage warning with 810 brake Overvoltage trip 820 Table 8 3 FCD 302 DC Voltage Level Fuses The unit is suitable for use on a circuit capable of delivering not more than 100 000 RMS symmetrical Amperes 480 V maximum Circuit breaker The unit is suitable for use on a circuit capable of delivering not more than 10 000 RMS symmetrical Amperes 480 V maximum 76 MG04F302 VLT is a registered Danfoss trademark Specifications VLT Decentral Drive FCD 302 Operating Instructions 8 2 General Specifications Mains supply L1 L2 L3 Supply voltage 380 480 V 10 Mains voltage low mains drop out During low mains voltage or a mains drop out the frequency converter continues until the intermediate circuit voltage drops below the minimum stop level which corresponds typically to 15 below the FC s lowest rated supply voltage Power up and full torque cannot be expected at mains voltage lower than 10 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 480 V maximum Motor output U V W Output voltage 0 100 of s
14. 19 27 a1 aa Recommended circuit breaker small unit Power loss at max load W Weight small unit kg Weight large unit kg Output current 130BB799 10 Table 8 1 FCD 302 Shaft Output Output Current and Input Current To meet UL cULrequirements use the following pre fuses Recommended maximum pre fuse size 25 A a te pw se pa Lajas ses es es ia 16 21 HHS Intermittent 3x441 480 V A 19 Continuous kVA 400 V AC Ia 09 13 17 21 28 39 WA 09 l 2 Continuous 3x380 440 V A Intermittent 3x380 440 V A Continuous 3x441 480 V A Continuous kVA 460 V AC kVA Max cable size mains motor brake mm AWG solid cable 6 10 flexible cable 4 12 Brand Fuse Type UL File no UL Category CCN code Bussmann JFHR2 Bussmann KTS R25 E52273 RK1 JDDZ Bussmann J JDDZ Bussmann T JDDZ Bussmann CC JDDZ Bussmann CC JDDZ Bussmann CC JDDZ SIBA RK1 JDDZ LITTLE FUSE RK1 JDDZ FERRAZ ATM R25 E163267 CC JDDZ FERRAZ A6K 25R E163267 RK1 JDDZ FERRAZ HSJ25 E2137 J HSJ Table 8 2 FCD 302 Pre fuses Meeting UL cUL Requirements MG04F302 VLT is a registered Danfoss trademark 75 Specifications VLT Decentral Drive FCD 302 Operating Instructions DC voltage level 380 480 V units V DC Inverter undervoltage 373
15. 64 69 70 75 75 76 Introduction 1 Introduction 1 1 Introduction 1 1 1 Approvals l v 1 1 2 Symbols The following symbols are used in this manual AWARNING Indicates a potentially hazardous situation which could result in death or serious injury ACAUTION Indicates a potentially hazardous situation which could result in minor or moderate injury or unsafe practice CAUTION Indicates a situation with potential for equipment or property damage only accidents NOTE Indicates highlighted information useful to avoid mistakes or sub optimal equipment performance Indicates default setting of parameter 1 2 Safety AWARNING HIGH VOLTAGE Frequency converters contain high voltage when connected to AC mains input power Installation start up and maintenance to be performed by qualified personnel only Failure to perform installation start up and maintenance by qualified personnel could result in death or serious injury VLT Decentral Drive FCD 302 Operating Instructions AWARNING UNINTENDED START When the frequency converter is connected to the AC mains start the motor using an external switch a serial bus command an input reference signal or a cleared fault condition Use appropriate precautions to guard against an unintended start AWARNING DISCHARGE TIME Frequency converters contain DC link capacitors that can remain charged even when AC mains input power is disconnec
16. Induced voltage from output motor cables run together can charge 130BC286 10 gt ata equipment capacitors even with the equipment NS leii Ta turned off and locked out oto Haret AR y 92 l 3 L2 gin A 24 E vo Overload and equipment protection oB sB Ti E m6 oB Wo e An electronically activated function within the HE 33 NO A NO 34 R ge frequency converter provides overload protection oe eee f 41 NC 1 MA 27 for the motor Set 1 90 Motor Thermal Protection ii G to warning or trip as required Refer to the FCD 302 Programming Guide MG04GXYY for further information 1 90 Motor Thermal Protection measures motor current and is internally set based on the value in 7 24 Motor Current A 1 2 x FLA full load amps service factor is built in and maintained Should the motor current increase Illustration 2 10 Large Unit only Circuit Breaker and Mains Disconnect 1 Looping terminal ping ennas above that value 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 7 Troubleshooting for details on the trip function 130BC287 10 x Es A Ce e Because the motor wiring carries high frequency iu current it is important that wiring for mains input ly power motor pow
17. PES 4 rar S EBRES TTT T L AAA Motor 3 122 MBR Switch Mode Mechanical Power Supply 4 brake sea 10Vdc 24Vdc R4 82 Brake o voun 15mA 600mA resistor 50 10 D 10Vdc E He r Sp R 81 S201 10Vdc oe es D 10Vde TP 53AIN g 4 9 ON I 0 20mA IS e E 0 4 20 mA 5 S202 OFF U 0 10V 10Vdc 954 A IN ES g 240Vac 2A 410Vde J 02 0 4 20 mA A 55 COMA IN 01 gt A 7A relay2 eet 7 12 24 V OUT 06 Py f L 240Vac 2A T T 13 24 V OUT P 5 00 Oo 400Vac 2A 24V NPN l l 04 l l 1 184DAN OV PNP l I rf 1 5 19 D IN GEN COM A OUT 39 Y Y Analog Output i If 0 4 20 mA i 1 ov AQT 42 gt 20 COMDIN l DI 24V NPN 27 DNOU S aay zau T l g ON Terminated N OFF Open d e 5V A l 1529 DIN OUT CC T l r 2a y 3 f s801 GX l Do l d oV Ze l md l RS 485 N RS 485 69 i T RS 485 24V NPN Interface a 1 T J T A l SCHT OV PNP P RS 485 68 on l E TP 33 DIN a Z COM RS 485 61 I l A PNP Source vo 1 1 T NPN Sink k y 37 DIN ITT 1777 VCXA A 67 GND1 62 l Profibus 1 interface 63 a RS485 5 66 GND1 i T Illustration 2 9 Electrical Installation MG04F302 VLT is a registered Danfoss trademark 15 Darfi Installation VLT Decentral Drive FCD 302 Operating Instructions e Run motor cables from multiple frequency converters separately
18. Ensure the cable glands and blind and blind plugs guarantee the right enclosure plugs are properly tightened to protection degree is achieved Liquids and or excessive dust ingress in the drive can cause sub optimal performance or damage Vibration Ensure the equipment is not exposed to a high level of vibration Mount the panel solidly or use shock mounts as necessary Table 3 1 Start Up Check List 3 2 Applying Power to the Frequency Converter AWARNING HIGH VOLTAGE Frequency converters contain high voltage when connected to AC mains input power Only qualified personnel must perform installation start up and maintenance Failure to perform installation start up and maintenance by qualified personnel could result in death or serious injury 1 Perform pre start up procedure described in 3 1 Pre start 2 Confirm input line voltage is balanced within 3 If not correct input voltage imbalance before proceeding Repeat procedure after voltage correction 3 Ensure optional equipment wiring if present matches installation application 4 Ensure that all operator devices are in OFF position VLT Decentral Drive FCD 302 Operating Instructions AWARNING UNINTENDED START When frequency converter is connected to AC mains input power the motor may start at any time The frequency converter motor and any driven equipment must be in operational readiness Failure to be in
19. FALSE Uint8 14 3 Current Limit Ctrl SS EE EES 14 31 Current Lim Ctrl Integration Time 0 020 s All set ups FALSE Uint16 14 32 Current Lim Ctrl Filter Time 1 0 ms All set ups TRUE 1 LA A Vint16 14 4 Energy Optimising SSES DS ee N 14 56 Capacitance Output Filter App Dependent All set ups FALSE Uint16 14 57 Inductance Output Filter App Dependent All set ups FALSE a Uint16 14 59 Actual Number of Inverter Units App Dependent FALSE 0 Uint8 MG04F302 VLT is a registered Danfoss trademark 55 Programming VLT Decentral Drive FCD 302 Operating Instructions en 56 MG04F302 VLT is a registered Danfoss trademark Par Parameter description Default value 4 set up Change Conver Type No during sion index operation EE EE 14 72 Legacy Alarm Word 0 N A All set ups FALSE Uint32 14 8 Options HE AA 14 9 Fault Settings Sa DEER KS Programming eat VLT Decentral Drive FCD 302 Operating Instructions 5 3 13 15 Drive Information Par Parameter description Default value 4 set up Change during Conver Type No operation sion index 15 02 kWh Counter 0 kWh All set ups FALSE 75 Uint32 15 1 Data Log Settings MA EI EN 15 4 Drive Identification A eege a 15 40 FC Type 0 N A All set ups FALSE VisStr 6 MG04F302 VLT is a registered Dan
20. Instructions 4 User Interface 4 1 Local Control Panel The LCP is the combined display and keypad The LCP can be attached to the display connector outside the unit without opening the enclosure via the LCP cable plug The LCP is the user interface to the frequency converter The LCP has several user functions Start stop and control speed when in local control Display operational data status warnings and cautions Programming frequency converter functions Manually reset the frequency converter after a fault when auto reset is inactive An optional numeric LCP NLCP is also available The NLCP operates in a manner similar to the LCP See the FCD 302 Programming Guide MGO4GXYY for details on use of the NLCP 4 1 1 LCP Layout The LCP is divided into four functional groups see Illustration 4 1 Status La 1234rpm 1 0A 43 5Hz g 43 5Hz Run OK Quick Main Alarm b Status Menu Menu Log on on 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 MG04F302 VLT is a registered Danfoss trademark 130BC362 10 33
21. 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 trips and stop by coasting lf coasting is not acceptable for Denpi VLT Decentral Drive FCD 302 Operating Instructions example if it causes danger then the frequency converter and machinery must be stopped using the appropriate stopping mode before using this function Depending on the application a mechanical brake is required e Concerning synchronous and permanent magnet motor frequency converters in 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 e 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 Do not use this function as a control for startin
22. NPN 18 U DE Voltage level logic 1 NPN lt 14 V DC Input resistance D Ge DEET 4 KQ All digital inputs are Baran isolated ae the BO Veltada PELV E aer lal Ee rindo 1 Terminals 27 and 29 can also be programmed as output Safe stop Terminal 37 Terminal 37 is fixed PNP logic Voltage level 0 24 V DC Analog inputs Number of analog inputs 2 Max voltage Current mode eee Switch S201 switch S202 ON I Current level 0 4 to 20 mA scaleable The analog inputs are galvanically isolated from the supply voltage PELV and other high voltage terminals PELV isolation 2 ES 24V aaa ee Ja l wene Mains S g High 37 voltage Motor Functional i bam isolation Rs4g5 C DC Bus Pulse encoder inputs Programmable pulse encoder inputs 2 1 Terminal number pulse encoder 29 331 322 332 Max frequency at terminal 29 32 35 M0 kHz Push pull driven 78 MG04F302 VLT is a registered Danfoss trademark Denpi Specifications VLT Decentral Drive FCD 302 Operating Instructions Max frequency at terminal 29 32 33 5 kHz open collector The pulse and encoder inputs terminals 29 32 33 are galvanically isolated from the supply voltage PELV and other high voltage terminals 1 Pulse inputs are 29 and 33 2 Encoder inputs 32 A and 33 B Analog output Number of programmable analog outputs 1 The analogue output is galvani
23. Parameter Setting EEN 35 D DC A siii isenta eiiiai 64 BIV 71 Default Setting EE A0 Digital VLT Decentral Drive FCD 302 Operating Instructions EM LT 29 External Commanden 64 F Fault LOG HT 34 Feedback TTT 29 64 H Hand Hdi 35 DD 35 65 initialisation a e aia 36 Input POW O 29 TE eT 29 Intermediate Circuit ccceccecsessessessessecssssessessscsssstssscssssesssesceseeseeses 71 IT dE 20 K KITY Te T TTT 71 L Language Package 1 37 Package 2 37 Package iran di inicia 37 le E dead ecssniestueversusconsasetea nsanvcee EERE 37 ET EE 64 Local Eent unninn nnen Control Panel eh A aA NR T E n a M Main Men Bee ene eT REO AN Reactance Mains Supply ALT LDE T 77 Vol ias 34 35 64 Manual Initialisation o onconconononommmmmm 36 Menu ewe 33 34 AAA A O 35 MG04F302 VLT is a registered Danfoss trademark 81 Index Motor GUO INE TT 34 Frequency N Navigation Keys sese 64 33 35 Noise Isolation TTT 29 O Operation Keys 35 Output e IEN 64 Performance U V WI 77 leu Tah T T 64 OVEIVOLLAQE Assens EEGENEN 64 P Pwer FACTO TTT 29 Programming siinne 34 33 35 Protection And Features 77 Pulse Encoder Inputs EENEG 78 Q QUICK Men T 34 R ROPER EIN CE anidaci n 64 34 Relay OUtpUuts sis ssssssccoassccstssssantsssiascossacacsuseesesuscaseoisstcsnsisssconsdisioassasions 79 Remote Reference 64 RESO ETT 33 36 64 35 Run aa VE
24. Reset to return to operation mode 4 3 2 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 the following frequency converter information e 15 00 Operating Hours e 15 03 Power Up s o 15 04 Over Temp s e 15 05 Over Volt s 36 MG04F302 VLT is a registered Danfoss trademark Programming 5 Programming 5 1 Introduction 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 See 4 User Interface for details on using the LCP function keys Parameters may also be accessed through a PC using the MCT 10 Set up Software see 5 4 7 Remote Programming with v The quick menu is intended for initial start up Data entered in a parameter can change the options available in the parameters following that entry The quick menu presents easy guidelines for getting most systems up and running The main menu accesses all parameters and allows for advanced frequency converter applications 5 2 Quick Setup 0 01 Language Option Function Defines the language to be used in the display The frequency converter can be delivered with 4 different lan
25. active when 8 04 Control Word Timeout Function is NOT set to Off MG04F302 VLT is a registered Danfoss trademark 71 Troubleshooting If 8 04 Control Word Timeout Function is set to Stop and Trip a warning appears and the frequency converter ramps down until it trips while giving an alarm 8 03 Control Word Timeout Time could possibly be increased WARNING ALARM 22 Hoist Mechanical Brake The report value shows 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 is an extra protection function that checks if the fan is running mounted The fan warning can be disabled in 14 53 Fan Monitor set to 0 Disabled WARNING 25 Brake resistor short circuited The brake resistor is monitored during operation If it short circuits the brake function is disconnected and the warning appears The frequency converter still works but without the brake function Turn off 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 percentage as a mean value over the last 120 s based on the resistance value of the brake resistor 2 11 Brake Resistor ohm and the intermediate circuit voltage The warning is active when the dissipated braking power is higher than 90 If 2 Trip
26. avoid damage to the intermediate circuit and to reduce earth capacity currents in accordance with IEC 61800 3 Mains voltage 3x380 480 V C E IN lemoman SSS Denpi VLT Decentral Drive FCD 302 Operating Instructions 2 4 7 Motor and Mains Connection with Service Switch 195NA288 10 2 4 8 Brake Resistor No 81 optional 82 optional Brake resistor function terminals e The connection cable to the brake resistor must be screened armoured Connect the screen to the metal cabinet of the frequency converter and to the metal cabinet of the brake resistor with cable clamps e Dimension the cross section of the brake cable to match the brake torque 2 4 9 Mechanical Brake No 122 optional function 123 optional function Mechanical brake UDC 0 45 x RMS mains voltage max current 0 8 A 20 MG04F302 VLT is a registered Danfoss trademark Installation In hoisting lowering applications control of electro mechanical brake is required The brake is controlled using the special mechanical brake control supply terminals 122 and 123 Select 32 Mechanical brake control in parameter group 5 4 1 Array Relay 2 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 e The brake is engaged when the output frequency is less than the frequency set i
27. 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 is not required use the regular stop function of the frequency converter 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 e 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 FCD 302 Design Guide MGO4HXYY e Have a good knowledge of the generic and safety standards applicable to the specific application User is defined as integrator operator servicing maintenance staff Protective Measures e Safety engineering systems may only be installed and commissioned by qualified and skilled personnel D 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
28. control adjusts the V Hz ratio to run the motor in controlled mode and to prevent the frequency converter from tripping For frequency converters with an external 24 V power supply installed only Mains supply to the frequency converter is removed but the control card is supplied by the external 24 V Protection mode is active The unit has detected a critical status an overcurrent or overvoltage e To avoid tripping switching frequency is reduced to 4 kHz s If possible protection mode ends after approximately 10 s e Protection mode can be restricted in 14 26 Trip Delay at Inverter Fault The motor is decelerating using 3 87 Quick Stop Ramp Time 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 Ref high The sum of all active references is above the reference limit set in 4 55 Warning Reference High Ref low The sum of all active references is below the reference limit set in 4 54 Warning Reference Low Run on ref Run request Running Sleep Mode 66 The frequency converter is running in the reference range The feedback value matches the setpoint value A start command has been given but the moto
29. display brightness e The symbol in the upper right corner of the display shows the direction of motor rotation 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 e Press to access Q2 Quick Setup for sequenced instructions to program the basic frequency controller set up e Follow the sequence of parameters as presented for the function set up Allows access to all programming parameters e Press twice to access top level index e Press once to return to the last location accessed e Press 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 e For details about the frequency converter before it entered the alarm mode select the alarm number using the navigation keys and press OK MG04F302 VLT is a registered Danfoss trademark Darfi User Interface VLT Decentral Drive FCD 302 Operating Instructions 4 1 4 Navigation Keys 4 1 5 Operation Keys Navigation keys are used for programming functions and Operation keys are found at the bottom of the LCP 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 130BP046 10
30. includes DigiPot function 4 Limits Warnings setting of limits and warning parameters 5 Digital inputs and outputs includes relay controls 6 Analog inputs and outputs 7 Controls setting parameters for speed and process controls 8 Communication and option parameters setting of FC RS 485 485 and FC USB port parameters 9 Profibus 13 Smart Logic Control parameters 14 Special function parameters 15 Drive information parameters 16 Read out parameters 17 Motor Feedback Option parameters 30 Special Features 40 MG04F302 VLT is a registered Danfoss trademark Programming 5 3 1 0 Operation Display VLT Decentral Drive FCD 302 Operating Instructions Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 0 0 Basic Settings A A 0 02 Motor Speed Unit 0 RPM 2 set ups FALSE TI Uint8 0 03 Regional Settings 0 International 2 set ups FALSE Uint8 0 04 Operating State at Power up Hand 1 Forced stop ref old All set ups E Uint8 0 09 Performance Monitor 0 0 All set ups Uint16 0 1 Set up Operations TI 0 10 Active Set up 1 Set up 1 1 set up mwe Uint8 0 14 Readout Edit Set ups Channel 0 N A All set ups TRUE o Int32 0 20 Display Line 1 1 Small 1617 All set ups TRUE 1 Uintl6 0 21 Display Line 1 2 Small 1614 All set ups TRUE Uintl6 0 22 Display Line 1 3 Small 1610 All set ups
31. less than the allowed number of inverter sections This warning generates on power cycle when the frequency converter is set to run with fewer inverters and remains on eat VLT Decentral Drive FCD 302 Operating Instructions 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 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 setting after a manual three finger reset ALARM 81 CSIV corrupt CSIV file has syntax errors ALARM 82 CSIV parameter error CSIV failed to initialise a parameter ALARM 85 Dang fail PB Profibus Profisafe Error ALARM 86 Dang fail DI Sensor Error 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 configuration and
32. the option layout for some reason has changed Enable an option layout change 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 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 202 has to be set in position OFF voltage input when a KTY sensor is connected to analogue input terminal 54 ALARM 250 New Spare Part The power or Switch Mode Power Supply has been exchanged The frequency converter type code must be restored in the EEPROM Select the correct type code in 14 23 Typecode Setting according to the label on unit Remember to select Save to EEPROM to complete ALARM 251 New Type Code The frequency converter has got a new type code 74 MG04F302 VLT is a registered Danfoss trademark Specifications 8 Specifications 8 1 VLT Decentral Drive FCD 302 Operating Instructions Electrical Data and Wire Sizes Mains Supply 3x380 480 V AC Frequency Converter Rated Shaft Output kW Rated Shaft Output hp Max input current 130BB800 10 e Ps eos Pwi Pie Pe car oss ozs an a Ps ors o pas 20 30 DEIER 26 35 a3 so a0 Continuous anan Vial RER 14
33. 3 48 Ramp 1 S ramp Ratio at Decel End 50 All set ups TRUE Uint8 3 5 Ramp 2 3 75 Ramp 4 S ramp Ratio at Accel Start 50 All set ups TRUE Uint8 N n N MG04F302 VLT is a registered Danfoss trademark 45 Denpi Programming VLT Decentral Drive FCD 302 Operating Instructions Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 3 80 Jog Ramp Time App Dependent All set ups TRUE 2 Uint32 3 9 Digital Pot Meter a a oa N NIN 1 46 MG04F302 VLT is a registered Danfoss trademark Denpi Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 5 4 Limits Warnings Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 4 12 Motor Speed Low Limit Hz App Dependent All set ups TRUE 1 Uint16 4 3 Motor Speed Mon ane a aa 15 Adj Warnings eee o 4 50 Warning Current Low 0 00 A All set ups TRUE 2 Uint32 999999 999 ReferenceFeed 999999 999 ReferenceFeed MG04F302 VLT is a registered Danfoss trademark 47 Denpi Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 6 5 Digital In Out v ar Parameter description Default value 4 set up Ch
34. 9 On Reference Bandwidth tee NEE Uint8 74 Adv Process PID a aa pea 7 5 Adv Process PID II Po ALA N 1 i ik 7 51 Process PID Feed Fwd Gain 1 00 N A All set ups TRUE Uint16 7 52 Process PID Feed Fwd Ramp up All set ups TRUE Uint32 N 7 53 Process PID Feed Fwd Ramp down All set ups TRUE Uint32 7 56 Process PID Ref Filter Time 0 001 s All set ups TRUE Uint16 7 57 Process PID Fb Filter Time 0 001 s All set ups TRUE Uint16 LA LA MG04F302 VLT is a registered Danfoss trademark 51 en Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 9 8 Comm and Options Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 8 0 General Settings ae a el 8 03 Control Word Timeout Time 1 0 s 1 set up TRUE Uint32 8 1 Ctrl Word Settings pe RS 8 3 FC Port Settings mn a aa 8 4 FC MC protocol set NI ee ee 8 41 Parameters for signals 0 All set ups FALSE Uint16 8 5 Digital Bus AAA 8 8 FC Port Diagnostics ae GES eae oa LA 1 LA v N 52 MG04F302 VLT is a registered Danfoss trademark Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 10 9 Profibus Denpi
35. Decentral Drive FCD 302 Operating Instructions Grounding shielded cable Earthing grounding clamps are provided for motor and control wiring see Illustration 2 17 2 c S n S L dp 72 ASS cc TITO LU oo Illustration 2 17 Earthing Grounding Clamp for Motor and Control Wiring Small Unit 2 S S S A o ge nie l J ke ae E Ge LA LI LI LA p Illustration 2 18 Earthing Grounding Clamp for Motor and Control Wiring Large Unit MG04F302 VLT is a registered Danfoss trademark 23 Installation 1 Use a wire stripper to remove the insulation for proper grounding 2 Secure the grounding clamp to the stripped portion of the wire with the screws p
36. F302 VLT is a registered Danfoss trademark Start Up and Functional Tes 1 22 Motor Voltage 1 23 Motor Frequency 1 24 Motor Current 1 25 Motor Nominal Speed D 0 0 Hr atej Wy Motor Setup og 1 21 Motor Power ky 130839510 4 Continue set up of Quick Menu parameters 5 12 Terminal 27 Digital Input lf terminal default is Coast inverse it is possible to change this setting to No function 1 29 Automatic Motor Adaptation AMA Set desired AMA function Enable complete AMA is recommended See detailed 3 4 Automatic Motor Adaptation 3 02 Minimum Reference Set the minimum speed of the motor shaft 3 03 Maximum Reference Set the maximum speed of the motor shaft 3 41 Ramp 1 Ramp up Time Set the ramping up time regarding synchronous motor speed ns 3 42 Ramp 1 Ramp Down Time Set the ramping down time regarding synchronous motor speed ns 3 13 Reference Site Set the site from where the reference must work See Quick Menu Parameters for further details 3 4 Automatic Motor Adaptation Automatic motor adaptation AMA is a test procedure which measures the electrical characteristics of the motor The AMA procedure optimizes compatibility between the frequency converter and the motor The frequency converter builds a mathematical model of the motor for regulating output motor current The procedure also tests the input phase balance of electrical power and compares the motor characteristics with the dat
37. Frequent causes of unsuccessful AMA e incorrectly registered motor name plate data e too great a difference between the motor power size and the frequency converter power size MG04F302 VLT is a registered Danfoss trademark 31 Start Up and Functional Tes 3 5 Local control Test AWARNING MOTOR START Ensure that the motor system and any attached equipment are ready for start Failure to ensure that the motor system and any attached equipment are ready for start could result in personal 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 4 and v on the LCP increase and decrease the speed output of the frequency converter 4 and gt move the display cursor in the numeric display Moving the cursor left of the decimal point provides quicker input changes 1 Press Hand Onl 2 Accelerate the frequency converter by pressing 4 to full speed 3 Note any acceleration problems 4 Press Off 5 Note any deceleration problems In the event of acceleration problems If warnings or alarms occur see 7 Troubleshooting Check that motor data is entered correctly Increase the ramp up time in 3 47 Ramp 1 Ramp up Time Increase current limit in 4 18 Current Limit Increase torque limit in 4 16 Torque Limit Motor Mode In the event of decelera
38. MAKING MODERN LIVING POSSIBLE ON Warning Alarm Bus MS NS1 NS2 Pafi NU Decentral Drive Operating Instructions VLT Decentral Drive FCD 302 THE REAL DRIVE Contents VLT Decentral Drive FCD 302 Operating Instructions Contents 1 Introduction Ln Ln MG04F302 VLT is a registered Danfoss trademark Contents VLT Decentral Drive FCD 302 Operating Instructions 3 1 1 Safety Inspection 29 2 MG04F302 VLT is a registered Danfoss trademark Contents VLT Decentral Drive FCD 302 Operating Instructions Contents Illustration Illustration 1 1 Frequency Converter Block Diagram Illustration 2 1 Exploded View Small Unit Illustration 2 2 Exploded View Large Unit Illustration 2 3 Cable Entries and Hole Sizes Small Unit Illustration 2 4 Cable Entries and Hole Sizes Large Unit Illustration 2 5 Top and Bottom Cooling Clearance Illustration 2 6 FCD 302 Stand Alone Mounted with Mounting Brackets Illustration 2 7 Permitted Mounting Positions Standard Applications Illustration 2 8 Permitted Mounting Positions Hygienic Applications Illustration 2 9 Electrical Installation Illustration 2 10 Large Unit only Circuit Breaker and Mains Disconnect Illustration 2 11 Large Unit only Service Switch at Mains with Looping Terminals Illustration 2 12 Location of Terminals Small Unit Illustration 2 13 Location of Terminals Large Unit Illustration 2 14 Opening the Terminals Illustr
39. T Decentral Drive FCD 302 Operating Instructions 5 3 16 30 Special Features Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 30 0 Wobble a E 30 02 Wobble Delta Frequency 25 All set ups TRUE Uint8 30 03 Wobble Delta Freq Scaling Resource 0 No function PEE Uint8 30 04 Wobble Jump Frequency Hz Uints 30 05 Wobble Jump Frequency o Allsetups TRUE o Uint8 30 2 Adv Start Adjust SET Ve VA 30 8 Compatibility 1 aaa a 30 80 d axis Inductance Ld App Dependent Allsetups FALSE 6 Int32 30 84 Process PID Proportional Gain 0 100 N A All set ups TRUE Uint16 1 E D LA 1 H kel e 1 H wil RIN 62 MG04F302 VLT is a registered Danfoss trademark Programming VLT Decentral Drive FCD 302 Operating Instructions 5 4 Remote Programming with MCT 10 Set up Software Danfoss offers 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
40. TION The electronic thermal relay ETR of the frequency Terminal Function converter cannot be used as motor protection for the No individual motor in systems with parallel connected 01 02 03 Relay 1 output Useable for AC or DC voltage and motors Provide further motor protection by thermistors in resistive or inductive loads each motor or individual thermal relays Circuit breakers 04 05 06 Relay 2 output Useable for AC or DC voltage and are not suitable as protection resistive or inductive loads 12 13 24 V DC digital supply voltage Useable for digital 2 inputs and external transducers To use the 24 V S l H S DC for digital input common programme S 5 00 Digital I O Mode for PNP operation 18 19 32 33 Digital inputs Selectable for NPN or PNP function in 5 00 Digital I O Mode Default is PNP l TITE MELIN lu rol 7 27 29 Digital inputs or outputs Programmable for either 5 01 Terminal 27 Mode for terminal 27 and 5 02 Terminal 29 Mode for 29 selects input output gt function Default setting is input 35 Common for external 24 V control back up Illustration 2 15 Parallel Connection of Motors supply Optional 36 External 24 V control back up supply Optional 37 Safe Stop See Safe Stop installation for details Problems can arise at start up and at low RPM values 20 Common for digital
41. a entered in parameters 1 20 to 1 25 Run this procedure at startup It does not cause the motor to run or harm to the motor For best result run the procedure on a cold motor Darfi VLT Decentral Drive FCD 302 Operating Instructions To run AMA 1 Enter the motor name plate data in the frequency converter as described in 3 3 1 Basic Operational Programming 2 Connect terminal 37 to terminal 13 3 Connect terminal 27 to terminal 12 or set 5 12 Terminal 27 Digital Input to No function 4 Activate the AMA 1 29 Automatic Motor Adaptation AMA 5 Choose between complete or reduced AMA 6 Press OK The display shows Press Hand on to start 7 Press Hand On A progress bar indicates that the AMA is in progress Stop the AMA during operation Press Off the frequency converter enters into alarm mode and the display shows that the user terminated the AMA procedure Successful AMA l The display shows Press OK to finish AMA 2 Press OK exit the AMA state Unsuccessful AMA 1 The frequency converter enters alarm mode A description of the alarm can be found in 7 Troubleshooting 2 Report Value in the Alarm Log shows that the last measuring sequence carried out by the AMA before the frequency converter entered alarm mode This number along with the description of the alarm assists in troubleshooting If contacting Danfoss for service make sure to mention number and alarm description NOTE
42. according to the EHEDG guidelines suitable for installation in environments with high focus on cleanability Mount the FCD 302 vertically on a wall or machine frame to ensure liquids drain off the enclosure Orient the unit so the cable glands are located at the base Use cable glands designed to meet hygienic application requirements for example Rittal HD 2410 110 120 130 Hygienic purpose cable glands ensure optimal cleanability in the installation NOTE Only frequency converters configured as hygienic enclosure designation FCD 302 P XXX T4 W69 have the EHEDG certification 130BC383 10 Illustration 2 8 Permitted Mounting Positions Hygienic Applications Darfi VLT Decentral Drive FCD 302 Operating Instructions 2 3 4 2 Cleaning The enclosure IP66 NEMA type 4x indoor provides protection against dirt and water ingress The enclosure is suitable for cleaning methods and solvents used in food and beverage plants Use the solvent concentration recommended by the manufacturer Avoid high pressure hot water cleaning at close proximity or of long duration because this method of cleaning can damage gaskets and labels 2 3 5 Tightening Torques To compress the gasket between the two parts e Tighten the four connection screws to torque 2 8 3 0 Nm e Tighten these screws in
43. al Drive FCD 302 Operating Instructions 18 V When powered with 24 V DC with the MCB 107 option only the 24 V and 5 V supplies are monitored When powered with three phase mains voltage all three phases supplied are monitored WARNING 47 24 V supply low The external 24 V DC backup power supply may be overloaded otherwise Contact your Danfoss supplier WARNING 48 1 8 V supply low Contact your Danfoss supplier WARNING 49 Speed limit The speed is not within the specified range in 4 11 Motor Speed Low Limit RPM and 4 13 Motor Speed High Limit RPM ALARM 50 AMA calibration failed The motor is not suitable for the particular size of drive Start the AMA procedure once again by 1 29 Automatic Motor Adaptation AMA eventually with a reduced AMA function If still failing check the motor data ALARM 51 AMA check Unom and Inom The setting of motor voltage motor current and motor power is presumably wrong Check the settings ALARM 52 AMA low Inom The motor current is too low Check the settings ALARM 53 AMA motor too big The motor is too large for the AMA to be carried out ALARM 54 AMA motor too small The motor is too small for the AMA to be carried out ALARM 55 AMA par out of range The motor parameter values found from the motor are outside acceptable range ALARM 56 AMA interrupted by user The AMA has been interrupted by the user ALARM 57 AMA timeout Try to start the AMA again a nu
44. alog voltage input and terminal 50 10 V supply or between terminal 18 or 19 digital input PNP only and terminal 50 If a KTY sensor is used check for correct connection between terminal 54 and 55 WARNING ALARM 12 Torque limit The torque is higher than the value in 4 76 Torque Limit Motor Mode in motor operation or the torque is higher than the value in 4 17 Torque Limit Generator Mode in regenerative operation WARNING ALARM 13 Over Current The inverter peak current limit approx 200 of the rated current is exceeded The warning lasts approx 8 12 s then the frequency converter trips and issues an alarm Turn off the frequency converter and check if the motor shaft can be turned and if the motor size matches the frequency converter If extended mechanical brake control is selected trip can be reset externally ALARM 14 Earth fault There is a discharge from the output phases to earth either in the cable between the frequency converter and the motor or in the motor itself Turn off the frequency converter and remove the earth fault ALARM 15 Incomplete hardware The control board hardware or software does not support a fitted option ALARM 16 Short circuit There is short circuiting in the motor or on the motor terminals Turn off the frequency converter and remove the short circuit WARNING ALARM 17 Control word timeout There is no communication to the frequency converter The warning is only
45. and frequency converter e For correct dimensioning of cable cross section see 8 1 1 Electrical Data and Wire Sizes 6 wires out of motor V1 W1 6 wires out of motor Star connected Connect U2 V2 W2 separately optional terminal block PE fP Earth connection NOTE Do not install power factor correction capacitors between the frequency converter and the motor Do not wire a starting or pole changing device between the frequency converter and the motor U1 Parallel connection of motors The frequency converter can control several parallel connected motors The total current consumption of the motors must not exceed the rated output current Imn for the frequency converter 18 MG04F302 VLT is a registered Danfoss trademark Darfi Installation VLT Decentral Drive FCD 302 Operating Instructions NOTE e Itis recommended that control wiring is rated for e Installations with cables connected in a common 600 y joint as in Illustration 2 15 is only recommended e Isolate control wiring from high power for short cable lengths max 10 m components in the frequency converter When motors are connected in parallel D If the frequency converter is connected to a 1 29 Automatic Motor Adaptation AMA cannot be thermistor for PELV isolation ensure control used wiring is reinforced double insulated e See 8 2 General Specifications for control terminal iring sizes and maximum loads CAU
46. ange Conver Type z o during sion index operation 5 Digital WO mode 5 00 Digital VO Mode sto PNP Al set ups FALSE Ums 5 01 Terminal 27 Mode 0 Input All set ups TRUE P Uints 5 02 Terminal 29 Mode 0 Input All set ups TRUE a Uints 5 1 Digital Inputs 5 10 Terminal 18 Digital Input null All set ups TRUE Uint8 5 3 Digital Outputs ae eel 23 5 55 Term 33 Low Frequency 100 Hz All set ups TRUE Uint32 NIN w w 1 www 48 MG04F302 VLT is a registered Danfoss trademark Programming VLT Decentral Drive FCD 302 Operating Instructions Par No 5 6 Pulse Output Parameter description Default value 4 set up Change Conver during sion index a Type 5 80 5 90 5 93 5 94 5 95 5 96 5 7 24V Encoder Input 5 9 Bus Controlled Terminal 27 Pulse Output Variable null SE set ups TRUE Se a a ee e Sa AN Term 32 33 Pulses per Revolution 1024 N A All set ups FALSE SS Term 32 33 Encoder Direction 0 Clockwise All set ups FALSE P 5 8 I O Options Digital amp Relay Bus Control 0 N A All set ups TRUE SS Pulse Out 27 Bus Control 0 00 All set ups TRUE Pulse Out 27 Timeout Preset 0 00 TRUE Pulse Out 29 Bus Control 0 00 All set ups TRUE Pulse Out 29 Timeout Preset 0 00 TRUE MG04F302 VLT is a registered Danfoss trademark Uint32 Uint16 Ui
47. as for frequency converters 8 MG04F302 VLT is a registered Danfoss trademark Installation VLT Decentral Drive FCD 302 Operating Instructions 2 Installation 2 1 Check List The packaging contains Accessories bag supplied only with order of installation box Contents 2 cable clamps bracket for motor loads cables elevation bracket for cable clamp screw 4 mm 20 mm thread forming 3 5 mm 8 mm Documentation Frequency converter Depending on options fitted the box will contain one or two bags and one or more booklets When unpacking the frequency converter ensure that the unit is undamaged and complete Compare model number of unit on the name plate to what was ordered to verify the proper equipment Ensure the mains power supply frequency converter and motor are rated for same voltage MG04F302 VLT is a registered Danfoss trademark VLT Decentral Drive FCD 302 Operating Instructions Installation 2 2 Exploded View of the FCD 302 OL 6ZEDAOEL Service switch motor side alternatively switch located on Installation box Display connection s Access to USB port OU Le fo v lt WI Di E GU E O z Nn v v U Vi D E v g un LL Sealing gasket Inverter part plastic cover Illustration 2 1 Exploded View Small Unit Inverter part mains side or not mounted Flat mounting brackets Ground conn
48. ation 2 15 Parallel Connection of Motors Illustration 2 16 PE Connection between the Installation Box and the Electronic Part Illustration 2 17 Earthing Grounding Clamp for Motor and Control Wiring Small Unit Illustration 2 18 Earthing Grounding Clamp for Motor and Control Wiring Large Unit Illustration 2 19 Location of DIP Switches Illustration 2 20 Electronic Part Illustration 2 21 Jumper between Terminal 13 and 37 Denpi 6 10 11 12 12 13 13 13 14 15 16 16 17 17 18 19 22 23 23 25 25 27 Illustration 2 22 Installation to Achieve a Stopping Category 0 EN 60204 1 with Safety Cat 3 EN 954 1 PL d ISO 13849 1 Illustration 4 1 LCP Illustration 6 1 Frontal LEDs Illustration 6 2 Status Display MG04F302 VLT is a registered Danfoss trademark 28 33 64 64 Contents VLT Decentral Drive FCD 302 Operating Instructions Contents Table Table 1 1 Frequency Converter Internal Components Table 1 2 Type Code Description Table 2 1 4xM12 Connection Input Table 2 2 2xM12 Connection Output Table 3 1 Start Up Check List Table 6 1 LED Status Table 7 1 Alarm Warning Code List Table 7 2 Description of Alarm Word Warning Word and Extended Status Word Table 8 1 FCD 302 Shaft Output Output Current and Input Current Table 8 2 FCD 302 Pre fuses Meeting UL cUL Requirements Table 8 3 FCD 302 DC Voltage Level 4 MG04F302 VLT is a registered Danfoss trademark 21 21 30
49. atus 6 2 Status Display When the frequency converter is in status mode status messages are generated automatically from within the frequency converter and appear in the bottom line of the display see Illustration 6 2 2 S Y a SA 799RPM 0 98A 0 75kW 0 000 53 2 Auto Remote Ramping Hand Local Stop Off Running Jogging Stand by a b c Illustration 6 2 Status Display a The first word in the status line indicates where the stop start command originates b The second word in the status line indicates where the speed control originates C 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 6 3 Status Message Definitions Table The next three tables define the meaning of the status message display words Operation Mode Off The frequency converter does not react to any control signal until Auto On or Hand On is pressed Auto On The frequency converter is controlled from the control terminals and or the serial communi cation 64 MG04F302 VLT is a registered Danfoss trademark Status Indication Dafoe VLT Decentral Drive FCD 302 Operating Instructions Operation Mode Hand On The navigation keys on the LCP control
50. btract the code from 3072 Ex Error code 3238 3238 3072 166 is outside the limit 5123 Option in slot A Hardware incompatible with Control board hardware 5124 Option in slot B Hardware incompatible with Control board hardware 5376 Out of memory 6231 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 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 ALARM 45 Earth fault 2 There is a discharge from the output phases to earth either in the cable between the frequency converter and the motor or in the motor itself Turn off the frequency converter and remove the earth fault This alarm is detected under the start up test sequence 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 24 V 5 V Dafoe VLT Decentr
51. cally isolated from the supply voltage PELV and other high voltage terminals Control card RS 485 serial communication Terminal number 68 P TX RX 69 N TX RX The RS 485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage PELV Digital output Programmable digital pulse outputs 2 1 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 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 ground potential as the analog and digital inputs and outputs Relay outputs Programmable relay outputs 2 Relay 01 Terminal do 3 break 1 2 make MG04F302 VLT is a registered Danfoss trademark 79 Denpi Specifications VLT Decentral Drive FCD 302 Operating Instructions Max terminal load DC 1 on 4 5 NO Resistive load 80VDC 2A M 1 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 300 V AC 2A Control card 10 V DC output Terminal number 50 The 10 V DC supply is galvanically isolated from the supply voltage PELV and other high voltage terminals Control characteristics
52. ce of the signals if necessary e The use of shielded cable or twisted pair is recommended Ensure that the shield is terminated correctly at both ends EMC Check for proper installation regarding considerations electromagnetic compatibility Environmental See equipment label for the maximum considerations ambient operating temperature limits Temperature is not to exceed 40 C 104 F Humidity levels must be 5 95 non condensing Cooling Units require top and bottom clearance clearance adequate to ensure proper air flow for cooling Fusing and Check that all fuses are inserted firmly circuit and in operational condition and that breakers all circuit breakers are in the open position Check for proper fusing or circuit breakers MG04F302 VLT is a registered Danfoss trademark 29 Start Up and Functional Tes Inspect for Description 74l Input and e Check for loose connections output power Check for proper fusing or circuit wiring breakers Switches Ensure that all switch and disconnect Grounding The equipment requires a dedicated ground wire from its chassis to the plant ground Check for good ground connections that are tight and free of oxidation Installation Ensure the installation box and the box and electronics part is properly closed electronics Check that all four fastening screws are part tightened with the right torque Cable glands
53. d the motor remains stopped 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 until a run permissive signal is received via a digital input the motor is stopped The motor is running as programmed in 3 19 Jog Speed RPM e Jog was selected as function for a digital input parameter group 5 1 The corresponding terminal for example 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 for example No signal The monitoring function is active MG04F302 VLT is a registered Danfoss trademark 65 Status Indication Dafoe VLT Decentral Drive FCD 302 Operating Instructions Motor check OVC control PowerUnit Off Protection md QStop Ramping Operation Status 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
54. diagonally opposite order e Tighten the two earthing spears to torque 3 0 Nm 2 4 Electrical Installation The frequency converter must be wired for operation in the following manner e Wire the motor to the frequency converter output terminals e Connect control and serial communication wiring e Wire the AC mains to the frequency converter input terminals e After power has been applied input and motor power must be checked and control terminals programmed for intended functions This section provides detailed descriptions of the requirements and procedures to accomplish these tasks Illustration 2 9 shows a basic electrical connection 14 MG04F302 VLT is a registered Danfoss trademark Installation VLT Decentral Drive FCD 302 Operating Instructions 2 a T E i 4 aR 4k de S 5 91 L1 V S us R Lag a o H v 1 3 phase 921 1 WIT Zi 11 1 8 power 93 L3 a maA 7 ME input i T le Wa d E 95
55. e 3 42 Ramp 1 Ramp Down Time Range Function MG04F302 VLT is a registered Danfoss trademark 39 eat Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 Parameter Lists Changes during operation TRUE means that the parameter can be changed while the frequency converter is in operation and FALSE means that it must be stopped before a change can be made 4 Set up All set up the parameters can be set individually in each of the four set ups that is one single parameter can have four different data values In all set ups 1 set up data value is the same Conversion index This number refers to a conversion figure used when writing or reading to and from the frequency converter Conv index Conv factor 100 1 67 1 60 6 1000000 5 100000 4 10000 3 1000 2 100 1 10 0 1 1 0 1 2 0 01 3 0 001 4 0 0001 5 0 00001 6 0 000001 Data Description Type type See the FCD 302 Design Guide MGO4HXYY for further information about data types 33 35 and 54 Parameters for the frequency converter are grouped into various parameter groups for easy selection of the correct parameters for optimized operation of the frequency converter 0 Operation and Display parameters for basic frequency converter settings 1 Load and Motor parameters 2 Brakes 3 References and ramping parameters
56. e control system or serial communi cation network e Stores the DC power e Provides a regulated DC current supply e Provides ride through protection for short power losses 6 Inverter The inverter converts the DC into a controlled PWM AC waveform for a controlled variable output to the motor The FCD 302 is designed for decentral mounting for example in the food and beverage industry or for other material handling applications With the FCD 302 it is 6 MG04F302 VLT is a registered Danfoss trademark Introduction VLT Decentral Drive FCD 302 Operating Instructions Area Title Functions By controlling the voltage and frequency the frequency converter provides regulated motor control from 0 50 60 Hz at 100 supply voltage 1 7 Type Code Description Position 1 Area Title Control circuitry Functions Input power internal processing output and motor current are monitored to provide efficient operation and control User interface and external commands are monitored and performed Status output and control can be provided Table 1 1 Frequency Converter Internal Components 2345678 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 33 3435 36 37 39 39 F C D 3 0 2 PP T 4 H 1 XA B X X X X X D 130BB797 10
57. ection pin MG04F302 VLT is a registered Danfoss trademark 10 Installation VLT Decentral Drive FCD 302 Operating Instructions 130BC380 10 Illustration 2 2 Exploded View Large Unit 1 Inverter part 7 Display connection 2 Fastening screws 4 x one in each corner Is Access to USB port 3 Sealing gasket Service switch motor side alternatively switch located on mains side or not mounted 4 Inverter part plastic cover ho Flat mounting brackets Ground connection pin mm Circuit breaker optional 6 Installation box The unit can be configured with either service switch or circuit breaker not both The illustration shown is not configurable in practice but is displayed to show the respective positions of components only MG04F302 VLT is a registered Danfoss trademark 11 Installation VLT Decentral Drive FCD 302 Operating Instructions 2 3 Mechanical Installation 2 3 1 Recommended Tools and Equipment Equipment Screwdrivers Socket Hex Slotted Slotted Torx Spanner 130B1078 130B5776 LCP part no LCP cable part no 1 0x5 5 TX20 19 24 28 2 3 2 Mechanical Dimensions Description For fastening inverter screws mounting of brackets For spring loaded power and control terminals For cable clamps inside the installation box For blind plugs Local control panel Connection cable for local control panel
58. el See FCD 302 Design Guide MGO4HXYY for detailed information MG04F302 VLT is a registered Danfoss trademark Installation VLT Decentral Drive FCD 302 Operating Instructions m 2 S S 100 4 2 2 y 12 gt 00 4 00 4 Illustration 2 6 FCD 302 Stand Alone Mounted with Mounting Brackets 100 4 Permitted mounting positions Illustration 2 5 Top and Bottom Cooling Clearance 5 S NS 6 3 e ZS 2 3 4 Mounting S O a ETS The FCD 302 consists of two parts The installation box and the electronic part See 2 2 Exploded View of the FCD 302 AWARNING Do not switch on the mains before the 4 screws are tightened Failure to tighten these screws can result in personal injury or material damage when the unit is loaded E O Stand alone mounting The holes on the rear of the installation box are used to fix mounting brackets e Ensure that the strength of the mounting location can support the unit weight HEA e Make sure that the proper mounting screws or bolts are used Illustration 2 7 Permitted Mounting Positions Standard Applications MG04F302 VLT is a registered Danfoss trademark 13 Installation 2 3 4 1 Hygienic Installation The FCD 302 is designed
59. enceFeedbackUnit 3 Int32 MG04F302 VLT is a registered Danfoss trademark 59 Denpi Programming VLT Decentral Drive FCD 302 Operating Instructions Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 16 6 Inputs amp Outputs A a 16 60 Digital Input 0 N A All set ups FALSE Uint16 16 61 0 Current All set ups FALSE Uint8 16 67 Freq Input 29 Hz 0 N A Allset ups FALSE o m2 16 8 Fieldbus amp FC Port SES aaa ae 16 82 Fieldbus REF 1 0 N A All set ups FALSE N2 16 9 Diagnosis Readouts ae ere Kee 60 MG04F302 VLT is a registered Danfoss trademark Denpi Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 15 17 Motor Feedb Option bel ar Parameter description Default value 4 set up Change Conver Type z o during sion index operation 17 10 Signal Type 1 RS422 5V TTL All set ups FALSE Ums 17 11 Resolution PPR 1024 N A All set ups FALSE 0 T Unna 17 2 Abs Enc Interface 17 20 Protocol Selection 0 None A Uints 17 21 Resolution Positions Rev App Dependent Allsetups FALSE o Uint32 17 5 Resolver Interface lt E eee 17 6 Monitoring and App 1 ee ee eee LA N MG04F302 VLT is a registered Danfoss trademark 61 en Programming VL
60. er and control are run w separately Use separated shielded wire or metallic conduit Failure to isolate power motor and control wiring could result in less than optimum equipment performance W Iw o ls IM O 4 e When using cable trays place sensitive cables Illustration 2 11 Large Unit only Service Switch at Mains with such as telephone or data cables in a separate Looping Terminals cable tray to the motor cable If signal cables run across power cables these cables must cross at an angle of 90 1 Looping terminals Wire type and ratings e All wiring must comply with local and national 2 4 1 Requirements regulations regarding cross section and ambient temperature requirements AWARNING e The screen must have low RF impedance which EQUIPMENT HAZARD is achieved by a braided screen of copper e e l aluminium or iron Rotating shafts and electrical equipment can be hazardous All electrical work must conform to national and local e Danfoss recommends that all power connections electrical codes Installation start up and maintenance to are made with a minimum 75 C rated copper be performed only by trained and qualified personnel wire Failure to follow these guidelines could result in death or serious injury e See 8 1 Electrical Data and Wire Sizes for recommended wire sizes Cable glands It must be assured that appropriate cable glands needed for the environment are ch
61. erter trips after a given time depending on the unit To check whether the supply voltage matches the frequency converter see 8 2 General Specifications WARNING ALARM 9 Inverter overloaded 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 warns at 98 and trips at 100 while giving an alarm The frequency converter cannot be reset until the counter is below 90 Dafoe VLT Decentral Drive FCD 302 Operating Instructions The fault is that the frequency converter overloads more than 100 for too long WARNING ALARM 10 Motor ETR electronic overload over temperature According to the electronic thermal protection ETR the motor is too hot Select whether the frequency converter will trigger a warning or an alarm when the counter reaches 100 in 1 90 Motor Thermal Protection The fault is that the motor overloads more than 100 for too long Check that the motor 1 24 Motor Current is set correctly WARNING ALARM 11 Motor thermistor over temp The motor has exceeded the temperature limit Wait until the motor is cooled down The thermistor or the thermistor connection disconnects when the temperature limit is exceeded Set the frequency convertor to give either a warning or an alarm when the counter reaches 100 in 1 90 Motor Thermal Protection Check that the thermistor is connected correctly between terminal 53 or 54 an
62. foss trademark 57 Darfi Programming VLT Decentral Drive FCD 302 Operating Instructions Par Parameter description Default value 4 set up Change during Conver Type No operation sion index 15 60 Option Mounted 0 N A All set ups FALSE VisStr 30 15 9 Parameter Info MA MM A 58 MG04F302 VLT is a registered Danfoss trademark en Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 14 16 Data Readouts Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 16 0 General Status 16 00 Control Word 0 N A All set ups FALSE 0 Vi 16 01 Reference Unit 0 000 ReferenceFeedbackUnit All set ups FALSE 3 Int32 16 02 Reference 0 0 All set ups FALSE 1 Int16 16 03 Status Word 0 N A All set ups FALSE 0 Vi 16 1 Motor Status 16 09 0 00 CustomReadoutUnit All set ups FALSE 2 Int32 5 16 05 Main Actual Value E N2 a A 16 20 Motor Angle 0 N A All set ups TRUE 0 Uint16 16 3 Drive Status ae Gees C o oov VisStr 5 16 41 LCP Bottom Statusline 0 N A All set ups TRUE 0 0 16 49 Current Fault Source 0 N A All set ups TRUE 0 Vint8 16 5 Ref 8 Feedb 16 50 External Reference 0 0 N A All set ups FALSE 7 1 Int16 16 52 0 000 Refer
63. g and or stopping the frequency converter Meet the following requirements to perform a safe instal lation 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 in Illustration 2 21 2 Connect an external Safety monitoring relay to terminal 37 safe stop and either terminal 12 or 13 24 V DC The Safety monitoring relay must comply with Category 3 EN 954 1 PL d ISO 13849 1 The instructions of the manufacturer must be followed 26 MG04F302 VLT is a registered Danfoss trademark Installation VLT Decentral Drive FCD 302 Operating Instructions Sea So 90 0 1 01 02 03 a es E LIT 130BC393 10 i D o D 0 fa q e O o D O D o O CAD CAB H T RI R H O I Ja l zea OH er CO De Illustration 2 21 Jumper between Terminal 13 and 37 MG04F302 VLT is a registered Danfoss trademark 27 Installation VLT Decentral Drive FCD 302 Operating Instructions
64. guage packages English and German are included in all packages English cannot be erased or manipulated English Part of Language packages 1 4 011 Deutsch Part of Language packages 1 4 Part of Language package 1 a Nederlands Part of Language package 1 Part of Language package 2 Bee DEE RE VLT Decentral Drive FCD 302 Operating Instructions 0 01 Language Function Option Slovenian Part of Language package 3 Korean Part of Language package 2 Japanese Part of Language package 2 Turkish Part of Language package 4 Trad Chinese Part of Language package 2 5 Bulgarian Part of Language package 3 rpski Part of Language package 3 Romanian Part of Language package 3 Magyar Part of Language package 3 Czech Part of Language package 3 Polski Part of Language package 4 Russian Part of Language package 3 Thai Part of Language package 2 Bahasa Indonesia Part of Language package 2 52 Hrvatski 1 20 Motor Power kW Range Function Size 0 09 Enter the nominal motor power in kW 3000 00 kw The default value corresponds to the related according to the motor nameplate data nominal rated output of the unit This parameter cannot be adjusted while the motor is running This parameter is visible in LCP if 0 03 Regional Settings is 0 International NOTE Four sizes down one size up from nominal unit rating 1 22 Motor Voltage Size 10 Enter the nominal mot
65. han 50 of the value set in 6 70 Terminal 53 Low Voltage 6 12 Terminal 53 Low Current 6 20 Terminal 54 Low Voltage or 6 22 Terminal 54 Low Current respectively 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 voltage imbalance is too high This message also appears in the event of a fault in the input rectifier on the frequency converter 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 overvoltage limit of the control system The frequency converter is still active WARNING 6 DC link voltage low The intermediate circuit voltage DC is below the undervoltage limit of the control system The frequency converter is still active WARNING ALARM 7 DC over voltage If the intermediate circuit voltage exceeds the limit the frequency converter trips after a time Possible corrections Connect a brake resistor Extend the ramp time 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 voltage warning low limit see Table 7 2 the frequency converter checks if 24 V backup supply is connected If no 24 V backup supply is connected the frequency conv
66. has been selected in 2 13 Brake Power Monitoring the frequency converter cuts out and issues this alarm when the dissipated braking power is higher than 100 WARNING ALARM 27 Brake chopper fault The brake transistor is monitored during operation and if it short circuits the brake function disconnects and the warning comes up The frequency converter is still able to run However because the brake transistor has short circuited substantial power is transmitted to the brake resistor even when it is inactive Turn off the frequency converter and remove the brake resistor This alarm warning can also arise due to overheating of the brake resistor Terminals 104 to 106 are available as brake resistor with Klixon inputs ACAUTION There is a risk of substantial power being transmitted to the brake resistor if the brake transistor is short circuited WARNING ALARM 28 Brake check failed Brake resistor fault the brake resistor is not connected working ALARM 29 Drive over temperature The cut out temperature of the heat sink is 95 C 5 C The temperature fault cannot be reset until the temperature of the heatsink is below 70 C 5 C VLT Decentral Drive FCD 302 Operating Instructions The fault could be Ambient temperature too high Too long motor cable ALARM 30 Motor phase U missing Motor phase U between the frequency converter and the motor is missing Turn off the frequency converter and check mot
67. he cause of the alarm has been rectified Alarms that are not trip locked can also be reset using the automatic reset function in 14 20 Reset Mode AWARNING Automatic wake up is possible When a warning and alarm are marked against a code in Table 7 1 this means that either a warning occurs before an alarm or else that the user can specify whether a given fault will trigger a warning or an alarm Example 1 90 Motor Thermal Protection After an alarm or trip the motor carries on coasting and the alarm and warning flash Once the problem has been rectified only the alarm continues flashing until the frequency converter is reset i E E 5 6 B S BK No Description Warning Alarm Trip Alarm Trip Lock Poe 2 w TH HH H SSS 3 DEER EC SE 6 pc tnk voltage low aere AA a pc under votage AA o meneror AA Parameter Reference 6 01 Live Zero Timeout Function 1 80 Function at Stop X 14 12 Function at Mains Imbalance 1 90 Motor Thermal Protection 1 90 Motor Thermal Protection NININ G lW lG x x lt Brake resistor power limit gt 17 Control word time out X 8 04 Control Word Timeout Function 22 Hoist Mech Brake X Parameter group 2 2 oc 2 13 Brake Power Monitoring MG04F302 VLT is a registered Danfoss trademark 67 Darfi Troubleshooting VLT Decentral Drive FCD 302 Operating Instructions No Descripti
68. ication Orientated Control cannot recognize the EEPROM data 516 Cannot write to the EEPROM because a write command is on progress 517 The write command is under time out 518 Failure in the EEPROM 519 Missing or invalid BarCode data in EEPROM 1024 1279 CAN telegram cannot be sent 1027 indicate a possible hardware failure 1281 Digital Signal Processor flash time out 1282 Power micro software version mismatch 72 MG04F302 VLT is a registered Danfoss trademark Troubleshooting 1283 Power EEPROM data version mismatch 1284 Cannot read Digital Signal Processor software version 1299 Option SW in slot A is too old 1300 Option SW in slot B 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 1536 An exception in the Application Orientated Control is registered Debug information written in LCP 1792 DSP watchdog is active Debugging of power part data Motor Orientated Control data not transferred correctly 2049 Power data restarted 2315 Missing SW version from power unit 2816 Stack overflow Control board module 2817 Scheduler slow tasks 2818 Fast tasks 28191 Parameter thread 2820 LCP stack overflow 2821 Serial port overflow 2822 USB port overflow 3072 Parameter value is outside its limits Perform an initiali 5122 zation Parameter number causing the alarm Su
69. ing motor torque motor thermal protection etc Mains failure inverse De DigiPot Increase 55 NOTE DigiPot Decrease 56 This parameter cannot be changed while the motor is DigiPot Clear running Reset Counter A Reset Counter B 65 1 25 Motor Nominal Speed 1 29 Automatic Motor Adaptation AMA Size related 100 60000 Enter the nominal motor speed Option Function RPM value from the motor nameplate data This data is used for calculating automatic motor The AMA function optimizes dynamic motor performance by automatically optimizing the advanced motor parameters 1 30 Stator Resistance Rs to 1 35 Main Reactance Xh at NOTE motor standstill Activate the AMA function by pressing Hand This parameter cannot be changed while the motor is running compensations on after selecting 7 or 2 See also 3 4 Automatic Motor Adaptation After a normal sequence the display will read Press 5 12 Terminal 27 Digital Input OK to finish AMA After pressing OK the Option Function frequency converter is ready for operation Select the function from the available digital input This parameter cannot be adjusted while the motor is running range No operation 0 Enable Performs AMA of the stator resistance Rs the Reset D complete rotor resistance Rr the stator leakage Coast inverse D AMA reactance Xi the rotor leakage reactance X2 Coast and reset inverse D and the main reactance Xn Quick
70. inputs To use for digital when motor sizes differ widely Motors of low rated motor input common programme 5 00 Digital LO Mode power have a relatively high ohmic resistance in the stator for NPN operation This high resistance calls for a higher voltage at start and 39 Common for analog output at low RPM values To resolve such a problem 42 Analog output Programmable for various functions in parameter group 6 5 The analog reduce the load during startup on the motor of signal is 0 20 mA or 4 20 mA at a maximum of lowest rated motor power 500 Q configure parallel connections only between a 10 V DCianalog supply voltage 15 mA maximun commonly used for a potentiometer or motors of comparable rated motor power y P thermistor S 53 54 Analog input Selectable for voltage 0 to 10 V 2 4 5 Control Wiring Sc 3 or current 0 or 4 to 20 mA Closed is for current and open is for voltage Switches are AWARN l NG located on the frequency converter control card UNINTENDED START See 2 4 13 DIP Switches When frequency converter is connected to AC mains input gt gt Common foranalog inputs power the motor can 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 61 Common for serial communication RS 485 i
71. ire into the contact 3 Remove the screwdriver to fasten the wire into the contact 4 Ensure that the contact is firmly established and not loose Loose wiring can result in equipment faults or injury 195NA248 10 Illustration 2 14 Opening the Terminals 2 4 4 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 VLT Decentral Drive FCD 302 Operating Instructions CAUTION WIRING ISOLATION Run input power motor wiring and control wiring in three separate metallic conduits Alternatively use separated shielded motor and control cables for high frequency noise isolation Failure to isolate power motor and control wiring can result in sub optimal performance of the frequency converter and associated equipment MOTOR PROTECTION Protection against motor overload is not included in the factory setting If this function is desired set 1 90 Motor Thermal Protection to trip or warning Refer to the FCD 302 Programming Guide MGO4GXYY for further information e Connect the motor to terminals 96 97 98 e Connect earth to PE terminal e Make sure that the screen of the motor cable is properly earthed at both ends motor
72. llers Area Title Functions Danfoss sales representatives are also trained to 1 Mains input Three phase AC mains power supply to the provide customer service and instruction for frequency converter applications 2 Rectifier The rectifier bridge converts the AC input to Contact your Danfoss supplier or go to www Danfoss com for downloads or additional information In technical literature reference numbers X refers to version number 3 and YY refers to language code DC current for use within the frequency converter The intermediate DC bus circuit of the frequency converter handles the DC current for internal routing 1 5 Product Overview 4 DC line e Filter the intermediate DC circuit voltage reactors S e e Prove line transient protection 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 e Reduce RMS current e Raise the power factor reflected back to the line e Reduce harmonics on the AC input In addition the frequency converter monitors the system 5 and motor status issues warnings or alarms for fault conditions starts and stops the motor optimizes energy efficiency provides line harmonics protection and offers many more control monitoring and efficiency functions Operation and monitoring functions are available as status indications to an outsid
73. mber of times until the AMA is carried out Note that repeated runs may heat the motor to a level where the resistance Rs and Rr are increased In most cases however this is not critical ALARM 58 AMA internal fault Contact your Danfoss supplier WARNING 59 Current limit The current is higher than the value in 4 18 Current Limit WARNING 60 External interlock External interlock has been activated To resume normal operation apply 24 V DC to the terminal programmed for external interlock and reset the frequency converter via serial communication digital I O or by pressing Reset 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 MG04F302 VLT is a registered Danfoss trademark 73 Troubleshooting 4 32 Motor Feedback Loss Timeout During a commissioning procedure the function may be effective WARNING 62 Output Frequency at Maximum Limit The output frequency is higher than the value set in 4 19 Max Output Frequency This is a warning in VVCPIus mode and an alarm trip in Flux mode ALARM 63 Mechanical Brake Low The actual motor current has not exceeded the release brake current within the Start delay time window WARNING 64 Voltage Limit
74. n 2 27 Activate Brake Speed RPM or 2 22 Activate Brake Speed Hz The brake engages only when the frequency converter performs a stop command When the frequency converter enters alarm mode or is exposed to an over voltage situation the mechanical brake immediately cuts in For more detailed information refer to the FCD 302 Programming Guide MGO4GXYY NOTE When the Mechanical Brake Control Supply terminals 122 and 123 are set through parameter group 5 4 7 Array Relay 2 only one relay output Relay 1 is available for free programming 2 4 10 Connection of Sensors Actuators on M12 Sockets Pin Wire colour Terminal Function 1 Brown 12 24 V 3 DV 4 Digital input Table 2 1 4xM12 Connection Input Pin Wire colour Terminal Function 1 Brown Reserved Reserved 3 Blue 20 DV A Black 02 05 N O 24 V Table 2 2 2xM12 Connection Output When reserved wires for option are used If not utilised they can be cut off VLT Decentral Drive FCD 302 Operating Instructions 130BC389 10 2 4 11 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 this manual Ground currents are higher than 3 5 mA Failure to ground freque
75. ncy 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 e Proper protective grounding for equipment with ground currents higher than 3 5 mA must be established see Leakage Current 3 5 mA following e A dedicated ground wire is required for input power and motor e Use the clamps provided with on the equipment for proper ground connections e Use of high strand wire to reduce electrical noise is recommended MG04F302 VLT is a registered Danfoss trademark 21 Installation VLT Decentral Drive FCD 302 Operating Instructions ACAUTION PE CONNECTION The metal pins in the corners of the electronic part and the holes on the corner of the installation box are essential for the protective earth connection Make sure that they are not loosened removed or violated in any way Tightening torque requirement is 3 Nm See Illustration 2 16 a BOLOS OO LS 130BC391 10 q Illustration 2 16 PE Connection between the Installation Box and the Electronic Part NOTE The external grounding terminal is available as an accessory part no 130B5833 22 MG04F302 VLT is a registered Danfoss trademark i Installation VLT
76. necting the LCP into bus terminal or an external 24 V those units and downloading the stored settings supply This is a quick way to program multiple units Yellow When warning conditions are met with the same settings the yellow WARN light comes on e Initialisation of the frequency converter to restore and text appears in the display factory default settings does not change data area identifying the problem stored in the LCP memory Red A fault condition causes the red alarm light to flash and an alarm ae AP 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 or equipment or property damage MG04F302 VLT is a registered Danfoss trademark 35 User Interface 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 ST E Y Pi 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 2 Go to 0 50 LCP Copy 3 Press OK 4 Select All from LCP 5 Press OK
77. nerisciuicnncemiiineninnennaiiana inniit 64 S Screened Control Cables sss 24 Speed Reference Start Up Stator Leakage Reactance Status Mode 64 Stop COMMA Gs T 64 VLT Decentral Drive FCD 302 Operating Instructions SUPTFOUMGIA C 80 Switching Freouencn ENEE 64 T Torque Characteristics ENEE 77 V Voltage Level ee ee 78 W UO Tai ls D 67 82 MG04F302 VLT is a registered Danfoss trademark www danfoss com drives Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 130R0208 MG04F302 IN Oe M G A 4 F 3 amp 2
78. nt16 Vint32 N2 Uint16 N2 Uint16 49 en Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 7 6 Analog In Out fo LA 2 Analog Input 2 EA A Hick 6 5 Analog Output 1 EAS AAA Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 6 0 Analog VO Mode le HS 6 1 Analog Input 1 6 10 Terminal 53 Low Voltage 0 07 V Int16 6 16 Terminal 53 Filter Time Constant 0 001 s All set ups TRUE Vint16 6 26 Terminal 54 Filter Time Constant 0 001 s All set ups TRUE Vint16 50 MG04F302 VLT is a registered Danfoss trademark 6 54 Terminal 42 Output Timeout Preset 0 00 1 set up TRUE 2 Uint16 en Programming VLT Decentral Drive FCD 302 Operating Instructions 5 3 8 7 Controllers v ar Parameter description Default value 4 set up Change Conver Type z o during sion index operation 7 00 Speed PID Feedback Source All set ups FALSE o Uint8 7 02 Speed PID Proportional Gain App Dependent All set ups TRUE Uint16 7 03 Speed PID Integral Time App Dependent All set ups TRUE 4 Uint32 7 04 Speed PID Differentiation Time App Dependent All set ups TRUE 4 Uint16 7 1 Torque PI OH bison SAN S 7 2 Process Ctrl Feedb sees aa 7 3 Process PID Ctrl ES aan ae 7 38 Process PID Feed Forward Factor 0 All set ups TRUE Uint16 7 3
79. nterface See 2 4 13 DIP Switches 68 69 RS 485 interface When the frequency converter is connected to an RS 485 serial communication bus a switch on thecontrol card is provided for termination resistance Set the switch to ON for termination and OFF for no termination MG04F302 VLT is a registered Danfoss trademark 19 Installation Terminal Function No 62 RxD TxD P red cable for Profibus See dedicated literature MCA 101 for details S S S 2 4 6 AC Mains Input Connection e Size wiring based upon the input current of the frequency converter See the maximum wire size in the Input Current and Wire tables in 8 Specifi cations Comply with local and national electrical codes for cable sizes Connect 3 phase AC input power wiring to terminals L1 L2 and L3 Depending on the configuration of the equipment connect the input power to the mains input terminals or the input disconnect e Ground the cable in accordance with grounding instructions provided in General Earth Ground Requirements All frequency converters can 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 set to OFF the internal RFI filter capacitors between the chassis and the intermediate circuit are isolated to
80. on Warning Alarm Trip Alarm Trip Lock Parameter Reference 27 Brake chopper Zender x x Y 25 e AA as communione RA pelen AA r frese A REES a Heatsink sensor ll A0 Overload of Digital Output Terminal 27 X 5 00 Digital I O Mode 5 01 Terminal 27 41 Overload of Digital Output Terminal 29 X 5 00 Digital I O Mode 5 02 Terminal 29 45 46 Jor ard supply XTX 47 48 18Vsupplylow x x 49 Speed limit X sf tee 51 AWA check Wro and fon H HT Suel 53 busmt ll 54 motortoosmal ll 55 AMA parameter out otan Too ooo so AMA interupted by wer H CS E H T HS sa fama merae RA 59 caen o fenem me gt a S 82 Output Frequency at mexmon Eme a Jegen RO Ci OCS S 66 heat sink Temperature ow OR 87 Configuration has changed __ x o e H AA 70_ Megal FC configuration A 76 Power unit sep AR 77 Reduced power mode lx 14 59 Actual Number of Inverter Units REES 80 Drive Initialized to Default Value AE A eme A e2 ES paramerer nar OA e prorrata eg OA 91 Analogue input 54 wrong settings HU A ee OS 202 68 MG04F302 VLT is a registered Danfoss trademark Troubleshooting Dafoe VLT Decentral Drive FCD 302 Operating Instructions No Description Warning Alarm Trip Alarm Trip Lock Parameter Reference 251 ll Table 7 1 Alarm Warning Code List X Dependent on parame
81. operational readiness when the frequency converter is connected to AC mains could result in death serious injury equipment or property damage 5 Apply power to the unit DO NOT start the frequency converter at this time For units with a disconnect switch on the mains side turn to the ON position to apply power to the frequency converter 3 3 Quick Setup Frequency converters require basic operational programming before running for best performance Basic operational programming requires entering motor nameplate data for the motor being operated and the minimum and maximum motor speeds Enter this data in accordance with the following procedure See 4 User Interface for detailed instructions on entering data through the LCP Enter this data with power ON but before operating the frequency converter 1 Press Quick Menu on the LCP 2 Use the navigation keys to scroll to parameter group Q2 Quick Setup and press OK gt 13 7 0 75A Q1 My Personal Menu 130BC394 10 Q2 Quick Setup Q3 Function Setups Q5 Changes Made TZ 3 Select language and press OK Then enter the motor data in 1 20 Motor Power kW 1 21 Motor Power HP through 1 25 Motor Nominal Speed The information can be found on the motor nameplate The entire quick menu is shown in International North American Default Parameter Settings 1 20 Motor Power kW 1 21 Motor Power HP 30 MG04
82. or phase U ALARM 31 Motor phase V missing Motor phase V between the frequency converter and the motor is missing Turn off 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 Turn off the frequency converter and check motor phase W ALARM 33 Inrush fault Too many power ups have occurred within a short time period See 8 2 General Specifications for the allowed number of power ups within 1 minute WARNING ALARM 34 Fieldbus communication fault The fieldbus on the communication option card is not working correctly Check parameters associated with the module and check the wiring for fieldbus 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 Off Possible correction check the fuses to the frequency converter ALARM 37 Phase imbalance There is a current imbalance between the power units ALARM 38 Internal fault When this alarm arises it can be necessary to contact the Danfoss supplier Some typical alarm messages 0 The serial port cannot be initialized Serious hardware failure 256 The power EEPROM data is defect or too old 512 The control board EEPROM data is defect or too old 513 Communication time out Reading EEPROM data 514 Communication time out Reading EEPROM data 515 The Appl
83. or voltage related 1000 V according to the motor nameplate data The default value corresponds to the nominal rated output of the unit This parameter cannot be adjusted while the motor is running MG04F302 VLT is a registered Danfoss trademark 37 eat Programming VLT Decentral Drive FCD 302 Operating Instructions 1 23 Motor Frequency 5 12 Terminal 27 Digital Input Range Function Option Function Size 20 Min Max motor frequency 20 1000 Hz Start reversing related 1000 Select the motor frequency value from the Enable start forward 12 Hz motor nameplate data If a value different Enable start reverse 13 from 50 Hz or 60 Hz is selected it is Jog 14 necessary to adapt the load independent Preset ref bit 0 settings in 1 50 Motor Magnetisation at Zero Speed to 1 53 Model Shift Frequency For 87 Hz operation with 230 400 V motors set the nameplate data for 230 V 50 Hz Adapt 4 13 Motor Speed High Limit RPM and 3 03 Maximum Reference to the 87 Hz application Preset ref bit 1 7 Preset ref bit 2 a Freeze reference Freeze output 20 21 22 23 Speed up Speed down Set up select bit 0 1 24 Motor Current Set up select bit 1 24 S Catch u 28 Range Function l l Si 0 10 E h inal Slow down 29 ize 10 nter the nominal motor current Pulse input related 10000 00 A value from the motor nameplate E aro data This data is used for SE k Ramp bit 1 35 calculat
84. osen and carefully mounted For your safety comply with the following requirements D Electronic controls equipment is connected to hazardous mains voltage Take extreme precautions against electrical hazards when AWARNING applying power to the unit eee Do not plug unplug the electronic part with mains voltage e Wear safety glasses whenever working on electric switched on control or rotating equipment 16 MG04F302 VLT is a registered Danfoss trademark Installation VLT Decentral Drive FCD 302 Operating Instructions 2 4 2 Location of Terminals 130BC385 10 SS 12 123 o a 2 8 815 Sit a SE E M a 8 EI E a er U LU ie H Illustration 2 12 Location of Terminals Small Unit 130BC386 10 KEE teu ea 5 S E
85. r is stopped until a run permissive signal is received via digital input The frequency converter runs the motor The energy saving function is enabled The motor has stopped but will restart automat ically when required Speed high Speed low Standby Start delay Start fwd rev Stop Trip Trip lock Operation Status Motor speed is above the value set in 4 53 Warning Speed High Motor speed is below the value set in 4 52 Warning Speed Low In Auto On mode the frequency converter starts the motor with a start signal from a digital input or serial communication 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 time expires Start forward and start reverse were selected as functions for two different digital inputs parameter group 5 1 The motor starts in forward or reverse depending on which corresponding terminal is activated The frequency converter has received a stop command from the LCP digital input or serial communication An alarm occurred and the motor is stopped Once the cause of the alarm is cleared the frequency converter can be reset manually by pressing Reset or remotely by control terminals or serial communication 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 re
86. rovided 3 Secure the grounding wire to the grounding clamp provided Leakage current 3 5 mA NOTE Follow national and local codes regarding protective earthing of equipment with a leakage current gt 3 5 mA The frequency converter technology implies high frequency switching at high power This generates a leakage current in the earth connection RFI filtering and screened motor cables contribute to this phenomenon According to EN IEC61800 5 1 Power Drive System Product Standard which implies special means if the leakage current exceeds 3 5 mA earth grounding must be reinforced in one of the following ways Earth ground wire 10 mm optional accessory required for mounting part no 130B5974 Two separate earth ground wires both complying with the dimensioning rules RCD use A fault current in the frequency converter or at the output power terminals can contain a DC component and charging of the filter capacitors can cause a transient earth current Where Residual Current Devices RCDs also known as Earth Leakage Circuit Breakers ELCBs are used the following must be taken into account Use RCDs of type B only e Use RCDs with an inrush delay Use RCDs of 300 mA if possible 2 4 12 Earthing of 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 freq
87. rrent OFF for voltage e Terminal 53 default is for a speed reference in open loop e Terminal 54 default is for a feedback signal in closed loop 24 MG04F302 VLT is a registered Danfoss trademark Installation 130BB708 10 4 5 Illustration 2 19 Location of DIP Switches 1 S201 terminal 53 202 terminal 54 S801 standard bus termination Fieldbus address NOTE Switches 4 and 5 are only valid for units fitted with fieldbus options 2 4 14 Serial Communication Connect RS 485 serial communication wiring to terminals 68 and 69 Switch S801 BUS TER can be used to enable termination on the RS 485 port terminals 68 and 69 See Illustration 2 19 Shielded serial communication cable is recommended e See 2 4 11 Earth Grounding Requirements for proper grounding e Two communication protocols are internal to the frequency converter Danfoss FC Modbus RTU For basic serial communication setup select the following Protocol type in 8 30 Protocol e Frequency converter address in 8 31 Address Baud rate in 8 32 FC Port Baud Rate Functions can be programmed remotely using the protocol software and RS 485 connection or in parameter group 8 Communications and Options Darfi VLT Decentral Drive FCD 302 Operating Instructions e Selecting a specific communication protocol changes various default parameter settings to match
88. s Fault W34 8388608 24V Supply Low reserved Unused A47 24 01000000 16777216 Mains Failure A36 reserved Mains Failure w36 reserved Unused 25 02000000 33554432 1 8V Supply Low Current Limit W59 Unused A48 26 04000000 67108864 Brake Resistor A25 reserved Low Temp w66 Unused 27 o8000000 134217728 Brake IGBT A27 Voltage Limit W64 Unused 28 10000000 268435456 Option Change A67 Encoder loss W90 Unused 29 20000000 536870912 Drive Initialized A80 Feedback Fault Feedback Fault W61 Unused pees D A anno 30 40000000 1073741824 Safe Stop A68 PTC 1 Safe Stop Safe Stop W68 PTC 1 Safe Unused pe A A A e 31 80000000 2147483648 Mech brake low Dangerous Failure Extended Status Word Unused ed T A Table 7 2 Description of Alarm Word Warning Word and Extended Status Word 24V Supply Low W47 70 MG04F302 VLT is a registered Danfoss trademark Troubleshooting The alarm words warning words and extended status words can be read out via serial bus or optional fieldbus for diagnosis See also 16 94 Ext Status Word WARNING 1 10 Volts low The 10 V voltage from terminal 50 on the control card is below 10 V Remove some of the load from terminal 50 as the 10 V supply is overloaded Max 15 mA or minimum 590 Q WARNING ALARM 2 Live zero error The signal on terminal 53 or 54 is less t
89. sconnect looping terminals large unit only Service switch on mains input with additional looping terminals large unit only No display connector No installation box With Display Connector Introduction VLT Decentral Drive FCD 302 Operating Instructions Position Description Choices options 24 Sensor plugs 25 Motor plug 26 Mains plug M12 Ethernet 27 Fieldbus plug M12 Profibus 28 X For future use AX No A option AO Profibus DP 29 30 A option AN Ethernet IP AL ProfiNet X No B option Encoder option 31 32 B option BU Resolver option B Safety PLC Interface 33 37 Reserved XXXXX For future use DX No D option 24 V DC back up input x No sensor plugs Direct mount 4xM12 4 digital inputs Direct mount 6xM12 4 digital inputs 2 relay outputs No motor plug No mains plug No fieldbus plug w N 38 39 D option Table 1 2 Type Code Description Not all choices options are available for each FCD 302 variant To verify if the appropriate version is available consult the Drive Configurator on the Internet http driveconfig danfoss com NOTE A and D options for FCD 302 are integrated into the control card Therefore pluggable options for frequency converters cannot be used here Future retrofit will require exchange of the entire control card B options are pluggable using the same concept
90. set manually by pressing Reset or remotely by control terminals or serial communication MG04F302 VLT is a registered Danfoss trademark Troubleshooting 7 Troubleshooting 7 1 1 Warnings Alarm Messages A warning or an alarm appears as an LED signal on the front of the frequency converter and is indicated by a code on the display A warning remains active until its cause is no longer present Under certain circumstances the motor can still continue to operate Warning messages can be critical but are not necessarily so If there is an alarm the frequency converter trips Alarms must be reset to restart operation once their cause has been rectified Perform the reset in one of three ways 1 By pressing Reset on the LCP 2 Via a digital input with the Reset function 3 Via serial communication optional fieldbus NOTE After a manual reset pressing Reset on the LCP Auto On must be pressed to restart the motor If an alarm cannot be reset the reason may be that its cause has not been rectified or the alarm is trip locked see also Table 7 1 VLT Decentral Drive FCD 302 Operating Instructions Alarms that are trip locked offer additional protection meaning that the mains supply must be switched off before the alarm can be reset After being switched back on the frequency converter is no longer blocked Reset the frequency converter as described above once t
91. stop inverse 4 Enable Performs a reduced AMA of the stator DC brake inverse 5 reduced resistance Rs in the system only Select this Stop inverse 16 AMA option if an LC filter is used between the Start 8 frequency converter and the motor Latched start 9 Reversing 10 38 MG04F302 VLT is a registered Danfoss trademark Programming VLT Decentral Drive FCD 302 Operating Instructions Note e For the best adaptation of the frequency converter run AMA on a cold motor e AMA cannot be performed while the motor is running e AMA cannot be performed on permanent magnet motors NOTE It is important to set motor parameter group 1 2 correctly since these parameters form part of the AMA algorithm An AMA must be performed to achieve optimum dynamic motor performance Depending on the power rating of the motor It takes up to 10 min NOTE Avoid generating external torque during AMA by discon necting the motor shaft from the application NOTE If one of the settings in parameter group 1 2 is changed 1 30 Stator Resistance Rs to 1 39 Motor Poles the Advanced Motor Parameters return to default setting 3 02 Minimum Reference Range Function Size related 999999 999 par 3 03 Reference FeedbackUnit 3 03 Maximum Reference Range Function Size related par 3 02 999999 999 Reference FeedbackUnit 3 41 Ramp 1 Ramp up Time Range Function 0 01 3600 00 s e
92. t set in 4 57 Warning Current High The frequency converter output current is below the limit set in 4 52 Warning Speed Low 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 Feedback high Feedback low Freeze output Freeze output request Freeze ref Jog request Jogging Operation Status 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 Stop 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 feedback is above the feedback limit set in 4 57 Warning Feedback High The sum of all active feedback 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 parameter group 5 1 The corresponding terminal is active Speed control is only possible via the terminal functions Speed Up and Speed Down s Hold ramp is activated via serial communi cation A freeze output command has been given but until a run permissive signal is receive
93. ted To avoid electrical hazards remove AC mains input power from the frequency converter before doing any service or repair and wait at least 4 minutes AWARNING REPAIR WORK In the event of an error alarm or warning refer to 7 Troubleshooting Before commencing repair work refer to the FCD 302 Service Manual MG93AXYY NOTE PELV COMPLIANCE All control terminals and relay terminals 01 03 04 06 comply with PELV Protective Extra Low Voltage However in grounded delta configuration above 400 V the frequency converter is not PELV compliant 1 3 Purpose of the Manual This manual is intended to provide detailed information for the installation and start up of the frequency converter 2 Installation provides details of mechanical and electrical installation 3 Start Up and Functional Testing provides detailed procedures for startup and functional testing The remaining chapters provide supplementary details These include user interface basic operational concepts programming and application examples start up trouble shooting and equipment specifications Optional equipment is available that can change some of the procedures described Be sure to see the instructions supplied with those options for specific requirements MG04F302 VLT is a registered Danfoss trademark 5 Dafoe Introduction VLT Decentral Drive FCD 302 Operating Instructions possible to reduce costs by placing the power electronics decentrally Cen
94. ter 1 Can not be Auto reset via 14 20 Reset Mode A trip is the action performed when an alarm arises The trip causes the motor to coast Reset the trip by pressing Reset or perform a reset via a digital input parameter group 5 1 1 Trip is used when the original event causing the alarm cannot damage the frequency converter or cause dangerous conditions A trip lock is the action performed when an alarm occurs which can cause damage to the frequency converter or connected parts A trip lock situation can only be reset by a power cycling LED Indication Trip locked yellow and red MG04F302 VLT is a registered Danfoss trademark 69 Denpi Troubleshooting VLT Decentral Drive FCD 302 Operating Instructions Alarm Word Extended Status Word Alarm Word Alarm Word 2 Warning Word Warning Extended Word 2 Status Word 0 00000001 Brake Check A28 ServiceTrip Read Brake Check W28 Ramping Write 1 00000002 2 Heatsink temp A29 ServiceTrip Heatsink temp W29 reserved 2 00000004 4 Earth Fault A14 ServiceTrip Earth Fault W14 reserved Start CW CCW Typecode Sparepart 3 00000008 Ctrl Card Temp A65 ServiceTrip Ctrl Card Temp W65 reserved Slow Down reserved 00000010 16 Ctrl Word TO A17 ServiceTrip Ctrl Word TO W17 Catch Up reserved i 20 z 22 00400000 23 00800000 AMA Running A CONTAIN wo 4194304 Unused Fieldbus Fault A34 reserved Fieldbu
95. terminal are available for connecting to the frequency converter MCT 10 Set up Software with limited functionality is available for free download athttp www Danfoss com Enter MCT 10 download in the search window MCT 10 Setup software with full functionality is available on CD part no 130B1000 For more information refer to the MCT 10 Set up Software Operating Instructions MG10RXYY MG04F302 VLT is a registered Danfoss trademark 63 Status Indication VLT Decentral Drive FCD 302 Operating Instructions 6 Status Indication 6 1 Frontal LEDs The actual status can be read on the outside of the FCD products Six LEDs signal the actual status of the unit with the meaning described in Table 6 1 ON Warning Alarm o o O O CO O Bus MS Mai Mai 130BB710 10 Illustration 6 1 Frontal LEDs Name Status Indication The frequency converter receives power from mains voltage or external 24 V supply No power from mains voltage or external 24 V supply Warning situation is present Warning No warning is present Alarm is present Only relevant if No alarm is present Bus Module Status Bus Network Status 1 Bus Network Status 2 Bus NS1 optional fieldbus is present See Profibus manual MG34NXYY Ethernet manual MG90JXYY and ProfiNet manual MG90UXYY for specific information Table 6 1 LED St
96. that specifications of the protocol along with making additional protocol specific parameters available e Control card options are available to provide additional communication protocols See the option card documentation for installation and operation instructions e Profibus e Ethernet IP e ProfiNet 2 4 15 Connection to PC To control the frequency converter from a PC install the MCT 10 Set up Software The PC is connected via a standard host device USB cable or via the RS 485 interface STs sH d L Sy 010000 O OB 000 O gt gt vi ES Illustration 2 20 Electronic Part ACAUTION The USB connection is galvanically isolated from the supply voltage PELV and other high voltage terminals The USB connection is not galvanically isolated from protection earth Use only isolated laptop PC as connection to the USB connector on frequency converter or an isolated USB cable converter 2 4 16 Safe Stop The FCD 302 provides safe stop functionality via control terminal 37 Safe stop disables the control voltage of the power semiconductors of the frequency controller output stage This in turn prevents generating the voltage required to rotate the motor When the Safe Stop T37 is MG04F302 VLT is a registered Danfoss trademark 25 Installation activated the frequency converter issues an alarm trips the unit and
97. the frequency converter Stop commands reset reversing DC brake and other signals applied to the control terminals can override local control Reference Site Remote The speed reference is given from external signals serial communication or internal preset references Local The frequency converter uses Hand On control or reference values from the LCP Operation Status AC Brake AC Brake was selected in 2 70 Brake Function The AC brake over magnetizes the motor to achieve a controlled slow down finish OK Automatic motor adaptation AMA was carried out successfully ready AMA is ready to start Press Hand On to start running AMA process is in progress Braking The brake chopper is in operation Generative energy is absorbed by the brake resistor Braking max The brake chopper is in operation The power limit for the brake resistor defined in 2 12 Brake Power Limit kW has been reached Coast e Coast inverse was selected as a function Ctrl Ramp down Current High Current Low DC Hold 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 The frequency converter output current is above the limi
98. the motor by measuring ohm values on U V 96 97 V W 97 98 and W U 98 96 5 Inspect the frequency converter for loose connections on terminals 6 Close the box mounting the electronic part onto the installation box 7 Check for proper grounding of the frequency converter as well as the motor 8 Record the following motor nameplate data power voltage frequency full load current and nominal speed These values are required to program motor nameplate data later on 9 Confirm that the supply voltage matches voltage of frequency converter and motor 3 1 2 Start Up Check List CAUTION Before applying power to the unit inspect the entire installation as detailed in Table 3 1 Inspect for Description Auxiliary e Look for auxiliary equipment equipment switches disconnects or input fuses circuit breakers located 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 e Check function and installation of any sensors used for feedback to frequency converter e Remove power factor correction caps on motor s if present Cable routing Ensure that input power motor wiring and control wiring are separated or in three separate metallic conduits for high frequency noise isolation Control wiring e Check for broken or damaged wires and connections e Check the voltage sour
99. tings ae ee el 1 02 Flux Motor Feedback Source 1 24 V encoder All set ups FALSE Uint8 1 03 Torque Characteristics 0 Constant torque e E Uint8 1 1 Motor Selection a he Ee 1 2 Motor Data KE 1 3 Adv Motor Data a en eee 1 35 Main Reactance Xh App Dependent All set ups FALSE 4 Uint32 1 36 Iron Loss Resistance Rfe Uint32 1 5 Load Indep Setting ae e e 42 MG04F302 VLT is a registered Danfoss trademark Denpi Programming VLT Decentral Drive FCD 302 Operating Instructions Par Parameter description Default value 4 set up Change Conver Type No during sion index operation 1 6 Load Depen Setting SEE ae 1 60 Low Speed Load Compensation 100 All set ups TRUE 1 64 Resonance Dampening 100 All set ups TRUE Uint16 1 65 Resonance Dampening Time Constant All set ups TRUE 3 Uint8 Int16 Int16 Int16 1 69 Maximum Inertia 4 Uint32 1 7 Start Adjustments aaa EE Uint8 Uint8 EZ o E o aes a Ee L E 1 84 Precise Stop Counter Value 100000 N A All set ups TRUE 0 1 9 Motor Temperature e Feed ee aa ss pee Uint8 Uint16 Uint16 Uint8 Uint32 Uint8 Uint8 Vint16 1 91 Motor External Fan 0 No All set ups TRUE 193 0 None Ml setups TRUE 1 94 ATEX ETR cur lim speed reduction TRUE Vint8 Vint16 1 99 ATEX ETR interpol points current App Dependent 2setups TRUE o Int16
100. tion problems If warnings or alarms occur see 7 Troubleshooting Check that motor data is entered correctly Increase the ramp down time in 3 42 Ramp 1 Ramp Down Time Enable overvoltage control in 2 17 Over voltage Control See 7 1 Warnings Alarm Messages for resetting the frequency converter after a trip VLT Decentral Drive FCD 302 Operating Instructions 3 6 System Start Up The first three sections in this chapter conclude the procedures for applying power to the frequency converter basic programming set up and functional testing Perform the following procedures after completion of user wiring and application programming The following procedure is recommended after application setup by the user is completed ACAUTION MOTOR START Ensure that the motor system and any attached equipment are ready for start Failure to ensure that the motor system and any attached equipment are 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 7 Troubleshooting 32 MG04F302 VLT is a registered Danfoss trademark User Interface VLT Decentral Drive FCD 302 Operating
101. tral panels are then rendered obsolete saving cost space and effort for installation and wiring The basic design is service friendly with a pluggable electronic part and a flexible and spacious wiring box It is easy to change electronics without the need for re 1 4 Additional Resources Other resources are available to understand advanced frequency controller functions and programming e The FCD 302 Programming Guide MGO4GXYY pares provides greater detail in how to work with parameters and many application examples 1 6 Internal Frequency Converter Controller e The FCD 302 Design Guide MGO4HXYY is intended Functions to provide detailed capabilities and functionality to design motor control systems MCB 102 manual Below is a block diagram of the internal components of the frequency converter See Table 1 1 for their functions MCB 103 manual o e Safe PLC Interface Option MCB 108 instruction S MI33JXYY 1 2 3 6 3 4 ko s Fieldbus manuals Profibus manual MG34NXYY a T Ethernet manual MG90JXYY and ProfiNet manual Y Ge 5 MG90UXYY e Brake Resistor Design Guide MG90OXYY l 8 l e Training courses both on line and in person d f e Hotline telephone and on line help E Illustration 1 1 Frequency Converter Block Diagram Installation set up and commissioning is also available by Danfoss trained and approved insta
102. uency 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 problem by fitting an equalizing cable next to the control cable Minimum cable cross section 16 mm VLT Decentral Drive FCD 302 Operating Instructions PLC 2 9 N N T E a a o el el D PE PE PE TA PE L Min 16 mm Equalizing cable 50 60 Hz 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 FC Ba Te 100nF PE 130BB609 11 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 130BB923 10 Equalizing cable Alternatively the connection to terminal 61 can be omitted FC E S os 68 E o al ba PE PE PES py PE L Min 16 mm Equalizing cable 2 4 13 DIP Switches e Analog input terminals 53 and 54 can select for either voltage 0 10 V or current 0 20 mA input signals e Set switches 201 terminal 53 and S202 terminal 54 to select the signal type ON is for cu
103. upply voltage Torque Characteristics Starting torque Constant torque maximum 160 for 60 s 1 Percentage relates to the nominal torque Cable lengths and cross sections for control cables Max motor cable length screened 10m Power cables see tables in Electrical Data of the FCD 302 Design Guide MGO4HXYY 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 The frequency converter is protected against short circuits on motor terminals U V W e 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 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 drive MG04F302 VLT is a registered Danfoss trademark 77 Specifications VLT Decentral Drive FCD 302 Operating Instructions Digital inputs Programmable digital inputs 4 6 Voltage level logic 0

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