Danfoss Fc 360 Vlt Automationdrive Frequency Converter User Guide

Danfoss FC 360 VLT AutomationDrive Frequency Converter User Guide

Introduction

This operating guide provides necessary information for qualified personnel to install and commission the AC drive. Read and follow the instructions to use the drive safely and professionally.

Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with local and currently valid legislation.

Safety

Pay particular attention to the safety instructions and general warnings to avoid the risk of death, serious injury, and equipment or property damage.

WARNING

HIGH VOLTAGE
AC drives contain high voltage when connected to AC mains input, DC supply, or load sharing.

UNINTENDED START
The motor may start from control panel, I/O inputs, or fieldbus at any time, when the drive is connected to the AC mains, DC supply, or load sharing.

DISCHARGE TIME
The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be present even when the warning indicator lights are off.

• Stop the motor, and disconnect AC mains, permanent magnet type motors, and remove DC-link supplies, including battery backups, UPS, and DC-link connections to other drives.
• Wait for the capacitors to discharge fully and measure it before performing any service or repair work.
• The minimum waiting time is 4 minutes for 0.37–7.5 kW (0.5–10 hp) drives and 15 minutes for 11–90 kW (15–125 hp) drives.

LEAKAGE CURRENT
Leakage currents of the drive exceed 3.5 mA. Make sure that the minimum size of the ground conductor complies with the local safety regulations for high-touch-current equipment.

Installation

Mechanical Dimensions

Illustration 1: Mechanical Dimensions, Enclosure Sizes J1–J7

Enclosure size 380–480 V	J1	J2	J3	J4	J5	J6	J7
Power size [kW (hp)]	0.37–2.2(0.5–3)	3.0–5.5(4.0–7.5)	7.5(10)	11–15(15–20)	18.5–22(25–30)	30–45(40–60)	55–90(75–125)
Height A	210 (8.3)	272.5 (10.7)	272.5 (10.7)	317.5 (12.5)	410 (16.1)	515 (20.3)	550 (21.7)
Width B	75 (3.0)	90 (3.5)	115 (4.5)	133 (5.2)	150 (5.9)	233 (9.2)	308 (12.1)
Depth C	168 (6.6)	168 (6.6)	168 (6.6)	245 (9.6)	245 (9.6)	241 (9.5)	323 (12.7)
Depth C(1)	173 (6.8)	173 (6.8)	173 (6.8)	250 (9.8)	250 (9.8)	241 (9.5)	323 (12.7)
D	180 (7.1)	240 (9.4)	240 (9.4)	270 (10.6)	364.7 (14.4)	452 (17.8)	484.5 (19.0)
Mounting holes
a	198 (7.8)	260 (10.2)	260 (10.2)	297.5 (11.5)	390 (15.4)	495 (19.5)	521 (20.5)
b	60 (2.4)	70 (2.8)	90 (3.5)	105 (4.1)	120 (4.7)	200 (7.9)	270 (10.6)
Mounting screw	M4	M5	M5	M6	M6	M8	M8

Removing the Front Cover

Procedure:
Remove the front cover with a screwdriver.

Illustration 2: Removing the Front Cover

Illustration 5: Mains, Motor, and Ground Connections (Enclosure Sizes J1–J5)

Connecting to Mains, Motor, Control Terminals, and Relays

Illustration 3: Control Terminals and Relays Connections (Enclosure Sizes J1–J5)

Illustration 4: Control Terminals and Relays Connections (Enclosure Sizes J6–J7)

Illustration 6: Mains, Motor, and Ground Connections (Enclosure Sizes J6–J7)

Control Terminals

Illustration 7: Control Terminals

Specifcations

Table 2: Electrical Data for High Overload, Mains Supply 3×380–480 V AC, Enclosure Size J1–J3

Drive		HK37		HK55		HK75		H1K1		H1K5		H2K2		H3K0		H4K0		H5K5		H7K5
Enclosure size		J1		J1		J1		J1		J1		J1		J2		J2		J2		J3
High overload=150–160 % current during 60 s
Typical shaft output [kW]		0.37		0.55		0.75		1.1		1.5		2.2		3		4		5.5		7.5
Typical shaft output [hp]		0.5		0.75		1		1.5		2		3		4		5.5		7.5		10
Output current (3-phase)
Continuous (3×380–440 V) [A]		1.2		1.7		2.2		3		3.7		5.3		7.2		9		12		15.5
Continuous (3×441–480 V) [A]		1.1		1.6		2.1		2.8		3.4		4.8		6.3		8.2		11		14
Intermittent (60 s overload) [A]		1.9		2.7		3.5		4.8		5.9		8.5		11.5		14.4		19.2		24.8
Continuous kVA (400 V AC) [kVA]		0.84		1.18		1.53		2.08		2.57		3.68		4.99		6.24		8.32		10.74
Continuous kVA (480 V AC) [kVA]		0.9		1.3		1.7		2.5		2.8		4.0		5.2		6.8		9.1		11.6
Enclosure size		J1		J1		J1		J1		J1		J1		J2		J2		J2		J3
Maximum input current
Continuous (3×380–440 V) [A]	1.2		1.6		2.1		2.6		3.5		4.7		6.3		8.3		11.2		15.1
Continuous (3×441–480 V) [A]	1.0		1.2		1.8		2.0		2.9		3.9		4.3		6.8		9.4		12.6
Intermittent (60 s overload)	1.9		2.6		3.4		4.2		5.6		7.5		10.1		13.3		17.9		24.2
Maximum cable size (mains, motor, brake, and load sharing) [mm2 (AWG)]	4 (12)
Estimated power loss at rated maximum load [W]	20.88		25.16		30.01		40.01		52.91		73.97		94.81		115.5		157.54		192.83
Weight [kg (lb)](Enclosure protection rating IP20)	2.3(5.1)		2.3(5.1)		2.3(5.1)		2.3(5.1)		2.3(5.1)		2.5(5.5)		3.6(7.9)		3.6(7.9)		3.6(7.9)		4.1(9.0)
Efficiency [%]	96.2		97.0		97.2		97.4		97.4		97.6		97.5		97.6		97.7		98.0

Table 3: Electrical Data for High Overload, Mains Supply 3×380–480 V AC, Enclosure Size J4–J7

Drive	H11K	H15K	H18K	H22K	H30K	H37K	H45K	H55K	H75K
Enclosure size	J4	J4	J5	J5	J6	J6	J6	J7	J7
High overload=150–160% current during 60 s
Typical shaft output [kW]	11	15	18.5	22	30	37	45	55	75
Typical shaft output [hp]	15	20	25	30	40	50	60	75	100
Output current (3-phase)
Continuous (3×380–440 V) [A]	23	31	37	42.5	61	73	90	106	147
Continuous (3×441–480 V) [A]	21	27	34	40	52	65	77	96	124
Intermittent (60 s overload) [A]	34.5	46.5	55.5	63.8	91.5	109.5	135	159	220.5
Continuous kVA (400 V AC) [kVA]	15.94	21.48	25.64	29.45	42.3	50.6	62.4	73.4	101.8
Continuous kVA (480 V AC) [kVA]	17.5	22.4	28.3	33.3	43.2	54.0	64.0	79.8	103.1
Maximum input current
Continuous (3×380–440 V) [A]	22.1	29.9	35.2	41.5	57	70.3	84.2	102.9	140.3
Continuous (3×441–480 V) [A]	18.4	24.7	29.3	34.6	49.3	60.8	72.7	88.8	121.1
Intermittent (60 s overload)	33.2	44.9	52.8	62.3	85.5	105.5	126.3	154.4	210.5
Maximum cable size (mains, motor, brake, and load sharing) [mm2 (AWG)]	16 (6)				50 (1/0)				95 (3/0)
Estimated power loss at rated maximum load [W]	289.53	393.36	402.83	467.52	630	848	1175	1250	1507
Weight [kg (lb)](Enclosure protection rating IP20)	9.4(20.7)	9.5(20.9)	12.3(27.1)	12.5(27.6)	22.4(49.4)	22.5(49.6)	22.6(49.8)	37.3(82.2)	38.7(85.3)
Efficiency [%]	97.8	97.8	98.1	97.9	98.1	98.0	97.7	98.0	98.2

Table 4: Electrical Data for Normal Overload, Mains Supply 3×380–480 V AC, Enclosure Size J4–J7

Drive	Q11K	Q15K	Q18K	Q22K	Q30K	Q37K	Q45K	Q55K	Q75K	Q90K
Enclosure size	J4	J4	J5	J5	J6	J6	J6	J7	J7	J7
Normal overload=110% current during 60 s
Typical shaft output [kW]	11	15	18.5	22	30	37	45	55	75	90
Typical shaft output [hp]	15	20	25	30	40	50	60	75	100	125
Output current (3-phase)
Continuous (3×380–440 V) [A]	23	31	37	42.5	61	73	90	106	147	177
Continuous (3×441–480 V) [A]	21	27	34	40	52	65	77	96	124	160
Intermittent (60 s overload) [A]	25.3	34.1	40.7	46.8	67.1	80.3	99	116.6	161.7	194.7
Continuous kVA (400 V AC) [kVA]	15.94	21.48	25.64	29.45	42.3	50.6	62.4	73.4	101.8	122.6
Continuous kVA (480 V AC) [kVA]	17.5	22.4	28.3	33.3	43.2	54.0	64.0	79.8	103.1	133
Maximum input current
Continuous (3×380–440 V) [A]	22.1	29.9	35.2	41.5	57	70.3	84.2	102.9	140.3	165.6
Continuous (3×441–480 V) [A]	18.4	24.7	29.3	34.6	49.3	60.8	72.7	88.8	121.1	142.7
Intermittent (60 s overload)	24.3	32.9	38.7	45.7	62.7	77.3	92.6	113.2	154.3	182.2
Maximum cable size (mains, motor, brake, and load sharing) [mm2 (AWG)]	16 (6)				50 (1/0)				95 (3/0)	120 (4/0)
Estimated power loss at rated maximum load [W]	289.53	393.36	402.83	467.52	630	848	1175	1250	1507	1781
Weight [kg (lb)] (Enclosure protection rating IP20)	9.4 (20.7)	9.5 (20.9)	12.3 (27.1)	12.5 (27.6)	22.4 (49.4)	22.5 (49.6)	22.6 (49.8)	37.3 (82.2)	38.7 (85.3)	40.7 (89.7)
Efficiency [%]	97.8	97.8	98.1	97.9	98.1	98.0	97.7	98.0	98.2	98.3

Table 4: Electrical Data for Normal Overload, Mains Supply 3×380–480 V AC, Enclosure Size J4–J7

Drive	Q11K	Q15K	Q18K	Q22K	Q30K	Q37K	Q45K	Q55K	Q75K	Q90K
Enclosure size	J4	J4	J5	J5	J6	J6	J6	J7	J7	J7
Normal overload=110% current during 60 s
Typical shaft output [kW]	11	15	18.5	22	30	37	45	55	75	90
Typical shaft output [hp]	15	20	25	30	40	50	60	75	100	125
Output current (3-phase)
Continuous (3×380–440 V) [A]	23	31	37	42.5	61	73	90	106	147	177
Continuous (3×441–480 V) [A]	21	27	34	40	52	65	77	96	124	160
Intermittent (60 s overload) [A]	25.3	34.1	40.7	46.8	67.1	80.3	99	116.6	161.7	194.7
Continuous kVA (400 V AC) [kVA]	15.94	21.48	25.64	29.45	42.3	50.6	62.4	73.4	101.8	122.6
Continuous kVA (480 V AC) [kVA]	17.5	22.4	28.3	33.3	43.2	54.0	64.0	79.8	103.1	133
Maximum input current
Continuous (3×380–440 V) [A]	22.1	29.9	35.2	41.5	57	70.3	84.2	102.9	140.3	165.6
Continuous (3×441–480 V) [A]	18.4	24.7	29.3	34.6	49.3	60.8	72.7	88.8	121.1	142.7
Intermittent (60 s overload)	24.3	32.9	38.7	45.7	62.7	77.3	92.6	113.2	154.3	182.2
Maximum cable size (mains, motor, brake, and load sharing) [mm2 (AWG)]	16 (6)				50 (1/0)				95 (3/0)	120 (4/0)
Estimated power loss at rated maximum load [W]	289.53	393.36	402.83	467.52	630	848	1175	1250	1507	1781
Weight [kg (lb)](Enclosure protection rating IP20)	9.4(20.7)	9.5(20.9)	12.3(27.1)	12.5(27.6)	22.4(49.4)	22.5(49.6)	22.6(49.8)	37.3(82.2)	38.7(85.3)	40.7(89.7)
Efficiency [%]	97.8	97.8	98.1	97.9	98.1	98.0	97.7	98.0	98.2	98.3

Ambient Conditions

J1–J7 enclosure size	IP20
Vibration test	1.0 g
Relative humidty	5%–95% (IEC 721-3-3; Class 3K3 (non-condensing) during operation)
Aggressive environment (IEC 60068-2-43) H2S test	Class Kd
Test method according to IEC 60068-2-43	H2S (10 days)
Ambient temperature (at 60 AVM switching mode) with derating at full continuous output current	Maximum 55 °C (131 °F)Maximum 45 °C (113 °F)1)
Minimum ambient temperature during full-scale operation	-15 °C (5 °F)
Minimum ambient temperature at reduced performance	-20 °C (-4 °F)
Temperature during storage/transport	-25 to +65/70 °C (-13 to +149/158 °F)
Maximum altitude above sea level without derating	1000 m (3281 ft)
Maximum altitude above sea level with derating	3000 m (9842 ft)

Note: (1) P90K operates at 40 °C (104 °F).

Mounting Clearance

Enclosure size	J1–J5	J6–J7
Clearance above and below the unit [mm (in)])	100 (3.94)	200 (7.87)

EMC Compatibility and Motor Cable Length

EMC standard, Emission/Immunity		Category C3/EN/IEC 61800-3
Maximum motor cable length, shielded		50 m (164 ft)
Maximum motor cable length, unshielded	0.37–22 kW (0.5–30 hp)	75 m (246 ft)
	30–90 kW (40–125 hp)	100 m (328 ft)
Maximum cross-section to control terminals, flexible/rigid wire		2.5 mm2/14 AWG
Minimum cross-section to control terminals		0.55 mm2/30 AWG

Programming

Local Control Panel (LCP)

Illustration 8: Local Control Panel (LCP 21 and LCP 23)

Functional Section A: Display

Table 5: Display Function

Number	Function
1	The setup number shows the active setup and the edit setup. For LCP 21: The setup number shows the active setup and the edit setup. If the same setup acts as both active and edit setup, only that setup number is shown (factory setting). For LCP 23, the setup number shows on the upper right corner in the status mode. For example, “1(2)” means the active setup is “1” and the editing setup is “2”.
2	LCP 21 shows only parameter number. LCP 23 shows both parameter number and name.
3	Parameter value.
4	Motor direction indicated by a small arrow pointing either clockwise or counterclockwise. For LCP 23, it only shows in status menu on the upper right corner of the screen.
5	The triangle indicates if the LCP is in Status, Quick Menu, or Main Menu.

Functional Section B: Menu Key
Press [Menu] to select among Status, Quick Menu, or Main Menu.
Functional Section C: Indicator Lights (LEDs) and Navigation Keys
Table 6: Indicator Lights (LEDs) 

Table 7: Navigation Keys

 NOTICE

[2] Coast inverse is the default option for parameter 5-12 Terminal 27 Digital Input. If there is no 24 V supply to terminal 27, [Hand On] does not start the motor. Connect terminal 12 to terminal 27

Automatic Motor Adaptation (AMA)

• Via running AMA in VVC+ mode, the drive builds a mathematical model of the motor to optimize compati- bility between drive and motor, and thus enhances the motor control performance.
• Some motors may be unable to run the complete version of the test. In that case, select [2] Enable Reduced AMA in parameter 1-29 Automatic Motor Adaptation (AMA).
• For best results, run the following procedure on a cold motor.

Procedure:

1. Set motor data in parameter group 1-** Load and Motor according to the motor nameplate.
2. Connect terminal 27 to terminal 12 (24 V voltage) or choose [0] No operation in parameter 5-12 Terminal 27 Digital Input.
3. Set [1] Enable Complete AMA or [2] Enable Reduced AMA for parameter 1-29 Automatic Motor Adaptation (AMA).
4. Press the [Hand On] key, the test runs automatically and the main display indicates when it is completed

Troubleshooting

Table 9: Warning and Alarm Code List

Number	Description	Warning	Alarm	Trip lock	Cause
2	Live zero error	X	X	–	Signal on terminal 53 or 54 is less than 50% of the values set in parameter 6-10 Terminal 53 Low Voltage, parameter 6-12 Terminal 53 Low Current, parameter 6-20 Terminal 54 Low Voltage, and parameter 6-22 Terminal 54 Low Current.
3	No motor	X	–	–	No motor has been connected to the output of the drive, or 1 motor phase is missing.
4	Mains phase loss(1)	X	X	X	Missing phase on the supply side, or the voltage imbalance is too high. Check the supply voltage.
7	DC overvoltage(1)	X	X	–	DC-link voltage exceeds the limit.
8	DC undervoltage(1)	X	X	–	DC-link voltage drops below the voltage warning low limit.
9	Inverter overloaded	X	X	–	More than 100% load for too long.
10	Motor ETR overtemp- erature	X	X	–	Motor is too hot due to more than 100% load for too long.
11	Motor thermistor overtemperature	X	X	–	Thermistor or thermistor connection is disconnected, or the motor is too hot.
12	Torque limit	X	X	–	Torque exceeds value set in either parameter 4-16 Torque Limit Motor Mode or parameter 4-17 Torque Limit Generator Mode.
13	Overcurrent	X	X	X	Inverter peak current limit is exceeded. For J1–J6 units, if this alarm occurs on power-up, check whether power cables are mistakenly connected to the motor terminals.
14	Ground fault	–	X	X	Discharge from output phases to ground.
16	Short circuit	–	X	X	Short circuit in motor or on motor terminals. For J7 units, if this alarm occurs on power-up, check whether power cables are mistakenly connected to the motor terminals.
17	Control word timeout	X	X	–	No communication to the drive.
18	Start failed	–	X	–	–
25	Brake resistor short- circuited	–	X	X	Brake resistor is short-circuited, thus the brake function is discon- nected.
26	Brake overload	X	X	–	The power transmitted to the brake resistor over the last 120 s exceeds the limit. Possible corrections: Decrease brake energy via lower speed or longer ramp time.
27	Brake IGBT/Brake chopper short-circuited	–	X	X	Brake transistor is short-circuited, thus brake function is disconn- ected.
28	Brake check	–	X	–	Brake resistor is not connected/working.
30	U phase loss	–	X	X	Motor phase U is missing. Check the phase.
31	V phase loss	–	X	X	Motor phase V is missing. Check the phase.
32	W phase loss	–	X	X	Motor phase W is missing. Check the phase.
34	Fieldbus fault	X	X	–	PROFIBUS communication issues have occurred.
35	Option fault	–	X	–	Fieldbus or option B detects internal faults.
36	Mains failure	X	X	–	This warning/alarm is only active if the supply voltage to the driveis lost and parameter 14-10 Mains Failure is NOT set to [0] No Fun- ction.
38	Internal fault	–	X	X	Contact the local supplier.
40	Overload T27	X	–	–	Check the load connected to terminal 27 or remove short-circuit connection.
41	Overload T29	X	–	–	Check the load connected to terminal 29 or remove short-circuit connection.
46	Gate drive voltage fault	–	X	X	–
47	24 V supply low	X	X	X	24 V DC may be overloaded.
50	AMA calibration	–	X	–	–
51	AMA check Unom and Inom	–	X	–	Wrong setting for motor voltage and/or motor current.
52	AMA low Inom	–	X	–	Motor current is too low. Check the settings.
53	AMA big motor	–	X	–	The power size of the motor is too large for the AMA to operate.
54	AMA small motor	–	X	–	The power size of the motor is too small for the AMA to operate.
55	AMA parameter range	–	X	–	The parameter values of the motor are outside of the acceptable range. AMA does not run.
56	AMA interrupt	–	X	–	The AMA is interrupted.
57	AMA timeout	–	X	–	–
58	AMA internal	–	X	–	Contact the local supplier.
59	Current limit	X	X	–	The drive is overloaded.
60	External Interlock	–	X	–	–
61	Encoder loss	X	X	–	–
63	Mechanical brake low	–	X	–	Actual motor current has not exceeded release brake currentwithin start delay time window.
65	Control card temp	X	X	X	The cutout temperature of the control card is 80 °C (176 °F).
67	Option module config- uration has changed	–	X	–	One or more options have either been added or removed since the last power-down.
69	Power card temp	X	X	X	–
70	Illegal FC config	–	X	X	–
80	Drive initialized todefault value	–	X	–	All parameter settings are initialized to default settings.
87	Auto DC brake	X	–	–	Occurs in IT mains when the drive coasts and the DC voltage is higher than 830 V. Energy on DC-link is consumed by the motor. This function can be enabled/disabled in parameter 0-07 Auto DC Braking.
88	Option detection	–	X	–	A change in the option layout is detected. Parameter 14-89 Option Detection is set to [0] Frozen configuration and the option layout has been changed.•  To apply the change, enable option layout changes in parameter 14-89 Option Detection.•   Alternatively, restore the correct option configuration.
90	Feedback monitor	X	X	–	A feedback fault is detected by option B.
95	Broken belt	X	X	–	–
99	Locked rotor	–	X	–	–
101	Flow/pressure inform-ation missing	–	X	X	–
120	Position control fault	–	X	–	–
124	Tension limit	–	X	–	–
126	Motor rotating	–	X	–	–
127	Back EMF too high(2)	X	–	–	Try to start PM motor which is rotating in an abnormal high speed.
250	New spare part	–	X	X	–
251	New type code	–	X	X	–

Note:

1. These faults may be caused by mains distortions. Installing a Sanford line filter may rectify this problem.
2. For enclosure size J7, the warning can also be caused by high UDC voltage.
3. An (X) marked in the above table indicates that the warning or alarm has occurred. A warning precedes an alarm

Accessories and Spare Parts

Accessories and spare parts		Code number	Accessories and spare parts		Code number
(1)	VLT® encoder input MCB 102	132B0282	(6)	Remote mounting kit for LCP with cable, 3 m	132B0102
(2)	VLT® resolver input MCB 103	132B0283	(7)	LCP remote mounting cable, 3 m	132B0132
(3)	VLT® 24 V DC supply MCB 107	130B1208	(8)	Standard control cassette	132B0255
(4)	VLT® graphical control panel LCP 23	132B0801	(9)	Control cassette (with Profibus)	132B0256
(5)	VLT® numeric control panel LCP 21	132B0254	(10)	Control cassette (with ProfiNet)	132B0257

Technical Documentation

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References

• Global AC drive manufacturer - Danfoss Drives | Danfoss