Danfoss D9h User manual

Operating Guide

VLT® AutomationDrive FC 302

90-710 kW, D9h-D10h and E5h-E6h Enclosed Drives

drives.danfoss.com

1.1

1.2

1.3

1.4

1.5

1.6

2.1

2.2

2.3

3.1

3.2

3.3

3.4

3.4.1

3.4.2

3.4.3

3.5

3.6

3.6.1

3.6.2

3.6.3

3.6.4

4.1

4.2

4.3

4.4

4.5

4.5.1

4.5.2

4.5.3

4.5.4

Contents

Introduction 8

Purpose of this Operating Guide 8

Additional Resources 8

Manual Version 8

Approvals and Certifications 8

Finding the Declaration of Conformity Certificate 9

Declaration of Conformity Certificate 10

Safety 14

Safety Symbols 14

Qualified Personnel 14

Safety Precautions 15

Product Overview 17

Intended Use 17

What is an Enclosed Drive? 17

Location of Options within an Enclosed Drive 20

Drive Identification 22

Identifying the Drive and Its Options 22

Enclosure Size Identification 23

Type Code Identification 24

Power Ratings, Weight, and Dimensions 31

Control Compartment and Local Control Panel (LCP) 33

Control Compartment Overview 33

Control Compartment Door 34

Local Control Panel (LCP) 35

LCP Menu 37

Mechanical Installation 39

Items Supplied 39

Split Shipment 39

Tools Needed 39

Storing the Drive 40

Operating Environment 40

Overview 40

Gases 40

Dust 40

Potentially Explosive Atmospheres 41

Contents

VLT® AutomationDrive FC 302

Operating Guide

4.6

4.7

4.8

4.9

4.10

4.11

4.11.1

4.11.2

4.11.3

5.1

5.2

5.3

5.4

5.5

5.6

5.6.1

5.6.2

5.6.3

5.6.4

5.6.5

5.7

5.7.1

5.7.2

5.7.3

5.7.4

5.7.5

5.7.6

5.8

5.8.1

5.8.2

5.8.3

5.8.4

5.8.5

5.8.6

5.9

5.9.1

Installation Requirements 41

Cooling Requirements 42

Airflow Rates 42

Lifting the Drive 44

Combining Multiple Cabinets from a Split Shipment 44

Installing the Enclosed Drive 46

Creating an Entry for Cables 46

Installing the Drive with Back-channel Cooling Option 46

Securing the Cabinet(s) to the Floor 47

Electrical Installation 49

Safety Instructions 49

EMC-compliant Installation 50

Wiring Overview for D9h and D10h Enclosed Drives 53

Wiring Overview for E5h and E6h Enclosed Drives 54

Control Terminal Wiring Diagram Cross-reference 55

Split Shipment Wiring Harnesses 56

Connecting Wiring Harnesses 56

Cable Routing 57

D10h Wiring Harness 65

E5h Wiring Harness 69

E6h Wiring Harness 75

Control Compartment Wiring 81

Safety Precautions 81

Control Compartment Interior View 82

Control Terminals 83

Relay Terminals 84

Option Card Terminals 84

Control Compartment Options 91

Connecting Motor, Mains, and Ground Cables 99

Power Cabling and Grounding Considerations 99

Connecting to the Mains 100

Connecting the Drive Module to the Motor 102

Connecting the Sine-wave Filter to the Motor 104

Connecting the dU/dt Filter to the Motor 105

Connecting to Ground 107

Installing Upstream Fuses 108

Upstream Fuse Considerations 108

Contents

VLT® AutomationDrive FC 302

Operating Guide

5.9.2

5.9.3

5.10

5.11

5.12

5.13

5.14

5.15

5.16

5.17

7.1

7.2

7.2.1

7.2.2

7.2.3

7.2.4

7.2.5

7.2.6

7.3

7.3.1

7.3.2

7.4

7.5

7.5.1

7.5.2

7.5.3

7.5.4

8.1

8.1.1

8.1.2

8.1.3

8.1.4

8.1.5

Recommended Fuse Ratings for IEC Installation 108

Recommended Fuse Ratings for UL Installation 109

Enabling Motor Operation 110

Selecting the Voltage/Current Input Signal 110

Setting Up RS485 Serial Communication 111

Configuring the Passive Harmonic Filter (PHF) 112

Configuring the dU/dt Filter 112

Configuring the Sine-wave Filter 112

MCCB Configuration 112

Safe Torque Off (STO) Wiring 113

Pre-start Check 114

Commissioning 116

Applying Power to the Drive 116

Programming the Drive 116

Parameter Overview 116

Parameter Navigation 117

Programming Example for an Open-loop Application 117

Entering System Information 118

Configuring Automatic Energy Optimization 119

Configuring Automatic Motor Adaptation 119

Testing Before System Start-up 119

Testing Motor Rotation 119

Testing Encoder Rotation 119

Starting Up the Drive for the First Time 120

Parameter Settings 120

Parameter Setting Overview 120

Uploading and Downloading Parameter Settings 120

Restoring Factory Default Settings Using the Recommended Initialization 121

Restoring Factory Default Settings Using Manual Initialization 121

Wiring Configuration Examples 122

Application Examples 122

Programming a Closed-loop Drive System 122

Wiring Configuration for Automatic Motor Adaptation (AMA) 123

Wiring Configuration for Automatic Motor Adaptation (AMA) without T27 123

Wiring Configuration: Speed 124

Wiring Configuration: Feedback 126

Contents

VLT® AutomationDrive FC 302

Operating Guide

8.1.6

8.1.7

8.1.8

8.1.9

8.1.10

8.1.11

8.1.12

8.1.13

8.1.14

8.1.15

9.1

9.2

9.3

9.4

9.5

10.1

10.1.1

10.1.2

10.2

10.3

10.3.1

10.3.2

10.4

10.5

10.6

10.6.1

10.6.2

10.6.3

10.6.4

10.6.5

10.6.6

10.6.7

10.6.8

10.6.9

10.6.10

Wiring Configuration: Run/Stop 127

Wiring Configuration: Start/Stop 129

Wiring Configuration: External Alarm Reset 131

Wiring Configuration: RS485 131

Wiring Configuration: Motor Thermistor 132

Wiring for Regeneration 132

Wiring Configuration for a Relay Set-up with Smart Logic Control 133

Wiring Configuration: Mechanical Brake Control 134

Wiring Configuration for the Encoder 135

Wiring Configuration for Torque and Stop Limit 135

Maintenance, Diagnostics, and Troubleshooting 137

Maintenance and Service 137

Disposal 137

Status Messages 137

Warnings and Alarms 140

Troubleshooting 158

Specifications 161

Electrical Data 161

Electrical Data, 380–500 V AC 161

Electrical Data, 525–690 V AC 166

Mains Supply 171

Motor Output and Motor Data 171

Motor Output (U, V, W) 171

Torque Characteristics 172

Ambient Conditions 172

Motor and Control Cables 172

Control Input/Output and Control Data 173

Control Card, USB Serial Communication 173

STO Terminal XD2.19 (Terminal XD2.19 is Fixed PNP Logic) 173

Control Card, 24 V DC Output 173

Control Card, 10 V DC Output 173

Digital Outputs 174

Digital Inputs 174

Pulse/Encoder Inputs 174

Control Characteristics 175

Relay Outputs 175

Analog Output 176

Contents

VLT® AutomationDrive FC 302

Operating Guide

10.6.11

10.6.12

10.6.13

10.7

10.7.1

10.7.2

10.7.3

10.7.4

10.8

10.8.1

10.8.2

10.8.3

10.8.4

10.8.5

10.9

10.9.1

10.9.2

10.9.3

10.9.4

10.9.5

10.10

10.11

11.1

11.2

11.3

11.4

11.5

11.6

11.6.1

11.6.2

11.6.3

11.6.4

11.6.5

11.6.6

11.6.7

11.6.8

Analog Inputs 176

Control Card, RS485 Serial Communication 176

Control Card Performance 176

Filter Specifications 177

Passive Harmonic Filter Specifications 177

Line Reactor Specifications 177

dU/dt Filter Specifications 178

Sine-wave Filter Specifications 178

Fuses, Circuit Breakers, and Switches 179

Panel Fuses 180

Contactor Switches 181

Fusible Disconnect Switches 182

Non-fusible Disconnect Switches 183

Molded-case Circuit Breakers 184

Enclosure Dimensions 185

Pedestal Dimensions 185

D9h Enclosed Drive Exterior Dimensions 186

D10h Enclosed Drive Exterior Dimensions 186

E5h Enclosed Drive Exterior Dimensions 187

E6h Enclosed Drive Exterior Dimensions 188

Enclosure Airflow 189

Fastener Torque Ratings 189

Appendix 190

Conventions 190

Abbreviations 190

International/North American Default Parameter Settings 192

Required Parameter Settings for Drive Options 193

Block Diagrams 194

Input Power Option Losses 197

Contactor Losses 197

Fusible Disconnect Losses 198

Non-fusible Disconnect Losses 199

Molded-case Circuit Breaker (MCCB) Losses 200

Passive Harmonic Filter (PHF) Losses 201

Line Reactor Losses 202

dU/dt Filter Losses 203

Sine-wave Filter Losses 204

Contents

VLT® AutomationDrive FC 302

Operating Guide

•

1 Introduction

1.1 Purpose of this Operating Guide

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

personnel.

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

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

VLT®is a registered trademark for Danfoss A/S.

1.2 Additional Resources

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

The Programming Guide provides detailed information on the LCP, menu system, parameters, and troubleshooting with alarms

and warnings.

The Design Guide provides detailed information about capabilities and functionality to design motor control systems.

The Safe Torque Off Operating Guide provides detailed specifications, requirements, and installation instructions for the Safe

Torque Off function.

Supplementary publications and manuals are available from Danfoss, see www.danfoss.com.

1.3 Manual Version

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

The original language of this manual is English.

Table 1: Manual and Software Version

Version

Remarks

Software version

AQ262139143212 - 0301

Updated split shipment content, added CE certification, added addl sine wave

and line reactor power loss tables.

8.43

MG80F1xx

First version

8.23

1.4 Approvals and Certifications

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

089

The specific approvals and certification for the enclosed drive or drive module are on the nameplate of the drive. For more informa-

tion, contact the local Danfoss office or partner.

Introduction

VLT® AutomationDrive FC 302

Operating Guide

Thermal memory retention requirement

The enclosed drive is UL listed per UL508A and CSA 14 standards. The drive module in the enclosed drive system complies with UL

508C or UL 61800-5-1 thermal memory retention requirements. For more information on UL 508C thermal memory retention re-

quirements, refer to the Motor Thermal Protection section in the product-specific Design Guide.

NOTICE

OUTPUT FREQUENCY LIMIT

Due to export control regulations, the output frequency of the enclosed drive (with no output filters) is limited to 590 Hz. For

demands exceeding 590 Hz, contact Danfoss. For enclosed drives with output filters, the maximum output frequency is limited to

60 Hz without derating and to 100/120 Hz with derating.

ADN-compliance

For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by In-

land Waterways (ADN), refer to section ADN-compliant Installation in the product-specific Design Guide.

1.5 Finding the Declaration of Conformity Certificate

Open a web browser and enter https://www.danfoss.com/en/service-and-support/documentation/.

Click Certificates & declarations.

Use the Search field to search for PLV*.

The system provides a list of the search results.

Filter the search results be entering the following criteria.

Business unit = Drives

Documents/Document types = Certificate

Scroll down until you find the PLV XXX titled certificate for the specific product segment, such as PLV 302 EU Declaration.

Double click the link to the open the certificate. For an example, see 1.6 Declaration of Conformity Certificate.

Introduction

VLT® AutomationDrive FC 302

Operating Guide

1.6 Declaration of Conformity Certificate

Introduction

VLT® AutomationDrive FC 302

Operating Guide

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