VLT® Midi Drive FC 280

1 Introduction

This operating guide provides information for safe installation and commissioning of the VLT® Midi Drive FC 280 frequency converter.

The operating guide is intended for use by qualified personnel. To use the frequency converter safely and professionally, read and follow the operating guide. Pay particular attention to the safety instructions and general warnings. Always keep this operating guide with the frequency converter.

VLT® is a registered trademark.

1.1 Purpose of the Manual

Provides information for safe installation and commissioning of the VLT® Midi Drive FC 280 frequency converter.

1.2 Additional Resources

Resources available to understand advanced frequency converter functions, programming, and maintenance:

• VLT® Midi Drive FC 280 Design Guide: Provides detailed information about the design and applications.
• VLT® Midi Drive FC 280 Programming Guide: Provides information on programming and includes complete parameter descriptions.

Supplementary publications and manuals are available from Danfoss. See drives.danfoss.com/knowledge-center/technical-documentation/ for listings.

1.3 Document and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. The document version and corresponding software version are shown in Table 1.1.

1.4 Product Overview

1.4.1 Intended Use

The frequency converter is an electronic motor controller intended for:

• Regulation of motor speed in response to system feedback or remote commands. A power drive system consists of the frequency converter, the motor, and driven equipment.
• System and motor status surveillance.

The frequency converter can also be used for motor overload protection. It is allowed for use in residential, industrial, and commercial environments in accordance with local laws and standards. In residential environments, it may cause radio interference requiring mitigation measures.

Foreseeable misuse: Do not use the frequency converter in applications non-compliant with specified operating conditions and environments. Ensure compliance with chapter 9 Specifications.

1.4.2 Block Diagram of the Frequency Converter

Illustration 1.1 shows a block diagram of the internal components:

• 1 Mains input: AC mains supply to the frequency converter.
• 2 Rectifier: Converts AC input to DC current.
• 3 DC bus: Intermediate DC-bus circuit.
• 4 DC reactor: Filters the intermediate DC circuit current, reduces harmonics.
• 5 Capacitor bank: Stores DC power, provides ride-through protection.
• 6 Inverter: Converts DC to controlled PWM AC waveform for the motor.
• 7 Output to motor: Regulated 3-phase output power.
• 8 Control circuitry: Monitors input power, motor current, provides control, user interface, and external command handling.

1.4.3 Enclosure Sizes and Power Ratings

Refer to chapter 9.9 Enclosure Sizes, Power Ratings, and Dimensions.

1.4.4 Safe Torque Off (STO)

The VLT® Midi Drive FC 280 supports Safe Torque Off (STO). See chapter 6 Safe Torque Off (STO) for details.

1.5 Approvals and Certifications

Compliance with standards like IEC/EN 61508 SIL2, IEC/EN 61800-5-2 SIL2, IEC/EN 62061 SILCL of SIL2, IEC/EN 61326-3-1, and EN ISO 13849-1 Category 3 PL d for STO function.

For compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), refer to chapter ADN-compliant Installation in the VLT® Midi Drive FC 280 Design Guide.

The frequency converter complies with UL 508C thermal memory retention requirements.

1.6 Disposal

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

2 Safety

2.1 Safety Symbols

• WARNING: Indicates a potentially hazardous situation that could result in death or serious injury.
• CAUTION: Indicates a potentially hazardous situation that could result in minor or moderate injury, or alert against unsafe practices.
• NOTICE: Indicates important information, including situations that can result in damage to equipment or property.

2.2 Qualified Personnel

Correct and reliable operation requires qualified personnel for transport, storage, installation, operation, and maintenance. Qualified personnel are trained staff authorized to install, commission, and maintain equipment in accordance with pertinent laws and regulations, and are familiar with the instructions and safety measures in this guide.

2.3 Safety Precautions

• WARNING: HIGH VOLTAGE Frequency converters contain high voltage. Failure to perform installation, start-up, and maintenance by qualified personnel can result in death or serious injury. Only qualified personnel must perform these tasks.
• WARNING: UNINTENDED START The motor may start at any time when connected to AC mains, DC supply, or load sharing. Unintended start during programming, service, or repair can result in death, serious injury, or property damage. To prevent this: disconnect from mains, press [Off/Reset] on LCP before programming, and ensure all equipment is wired and assembled before connecting to AC mains.
• WARNING: DISCHARGE TIME DC-link capacitors remain charged even when power is removed. High voltage can be present. Failure to wait the specified time after power removal before service can result in death or serious injury. Disconnect AC mains and remote DC-link supplies. Wait for capacitors to discharge fully (minimum waiting times in Table 2.1). Use a voltage measuring device to confirm discharge.
• WARNING: LEAKAGE CURRENT HAZARD Leakage currents exceed 3.5 mA. Failure to ground properly can result in death or serious injury. Ensure correct grounding by a certified electrical installer.
• WARNING: EQUIPMENT HAZARD Contact with rotating shafts and electrical equipment can result in death or serious injury. Ensure only trained and qualified personnel perform installation, start-up, and maintenance. Ensure electrical work conforms to codes. Follow guide procedures.
• CAUTION: INTERNAL FAILURE HAZARD An internal failure can result in serious injury if the frequency converter is not properly closed. Ensure all safety covers are in place and securely fastened before applying power.

3 Mechanical Installation

3.1 Unpacking

3.1.1 Items Supplied

Verify that supplied items and nameplate information correspond to the order confirmation. Check packaging and unit visually for damage. File claims with the carrier and retain damaged parts.

Product Nameplate (Example): Illustration 3.1 shows a typical product nameplate with details like product logo, name, ordering number, type code, power rating, input/output voltage/current/frequency, IP rating, country of origin, serial number, EAC logo, CE mark, TÜV logo, UL logo, and disposal information.

NOTICE: Do not remove the nameplate (loss of warranty).

3.1.2 Storage

Ensure storage requirements are fulfilled. Refer to chapter 9.4 Ambient Conditions.

3.2 Installation Environment

NOTICE: In environments with airborne liquids, particles, or corrosive gases, ensure the IP/Type rating matches the environment. Failure to meet ambient condition requirements can reduce lifetime. Ensure air humidity, temperature, and altitude requirements are met.

Vibration and shock: The frequency converter complies with requirements for units mounted on walls and floors, and in panels bolted to walls or floors.

For detailed ambient conditions specifications, refer to chapter 9.4 Ambient Conditions.

3.3 Mounting

NOTICE: Improper mounting can result in overheating and reduced performance.

• Cooling: Ensure 100 mm (3.9 in) of top and bottom clearance for air cooling.
• Lifting: Check unit weight (chapter 9.9). Ensure lifting device suitability. Use hoist rings when provided.
• Mounting: The unit allows side-by-side installation. Mount vertically to a solid flat surface or optional backplate for cooling airflow. Use slotted mounting holes for wall mounting. For dimensions, see chapter 9.9.

3.3.1 Side-by-side Installation

All VLT® Midi Drive FC 280 units can be installed side by side. Units do not require extra side ventilation.

NOTICE: If an IP21 conversion kit is used, mounting units side by side could lead to overheating. Avoid this if the IP21 kit is used.

3.3.2 Bus Decoupling Kit

This kit ensures mechanical fixation and electrical shielding for control cassette variants (PROFIBUS, PROFINET, CANopen, Ethernet). It includes horizontal and optional vertical decoupling plates.

Mounting the bus decoupling kit:

1. Place the horizontal decoupling plate on the control cassette and fasten with 2 screws (torque 0.7–1.0 Nm).
2. Optional: Mount the vertical decoupling plate by removing springs/clamps from the horizontal plate, mounting them on the vertical plate, and fastening with 2 screws (torque 0.7–1.0 Nm).
3. Push cable connectors into sockets.
4. Place PROFIBUS/CANopen/PROFINET/Ethernet cables between spring-loaded metal clamps for fixation and shielding.

NOTICE: If the IP21 top cover is used, do not mount the vertical decoupling plate as its height affects proper installation.

4 Electrical Installation

4.1 Safety Instructions

See chapter 2 Safety for general instructions.

• WARNING: INDUCED VOLTAGE Induced voltage from output motor cables can charge capacitors. Failure to run cables separately or use shielded cables can result in death or serious injury. Run output motor cables separately, use shielded cables, and lock out all frequency converters simultaneously.
• WARNING: SHOCK HAZARD The frequency converter can cause DC current in the PE conductor. Failure to ground properly can result in death or serious injury. Use only an RCD of Type B on the supply side.
• Overcurrent protection: Extra protective equipment is required for multiple motors. Input fusing is required for short-circuit and overcurrent protection. Provide fuses if not factory-supplied (see chapter 9.8).
• Wire type and ratings: All wiring must comply with local/national regulations. Use minimum 75 °C (167 °F) rated copper wire. See chapter 9.5 for recommended sizes.

4.2 EMC-compliant Installation

Follow instructions in chapters 4.3 Grounding, 4.4 Wiring Schematic, 4.6 Motor Connection, and 4.8 Control Wiring.

4.3 Grounding

WARNING: LEAKAGE CURRENT HAZARD Leakage currents exceed 3.5 mA. Failure to ground properly can result in death or serious injury. Ensure correct grounding by a certified electrical installer.

• For electrical safety: Ground in accordance with standards. Use dedicated ground wires. Do not ground converters in a daisy-chain fashion (Illustration 4.1). Keep ground wire connections short. Follow motor manufacturer requirements. Minimum cross-section: 10 mm² (7 AWG). Separately terminate 2 ground wires.
• For EMC-compliant installation: Establish electrical contact between cable shield and enclosure using metal glands or provided clamps (chapter 4.6). Use high-strand wire. Do not use pigtails.

NOTICE: POTENTIAL EQUALIZATION Risk of burst transient due to ground potential differences. Install equalizing cables between system components. Recommended cross-section: 16 mm² (6 AWG).

4.4 Wiring Schematic

Illustration 4.2 shows the basic wiring schematic for power input (terminals 91-99), motor connection (terminals 96-98), DC bus connection (terminals 88, 89), brake resistor connection (terminal 81), and control wiring (terminals 12, 13, 18, 19, 27, 29, 32, 33, 37, 38, 42, 50, 53, 54, 55, 61, 68, 69). Terminal functions and default settings are in Tables 4.1 and 4.2.

Illustration 4.3 shows a typical electrical connection layout, highlighting separation of motor, mains, and control cables, and the grounding rail.

4.5 Access

Remove the cover plate with a screwdriver to access terminals. Tighten terminals according to chapter 9.7.

4.6 Motor Connection

WARNING: INDUCED VOLTAGE Run output motor cables separately and use shielded cables. Comply with codes for cable sizes. Follow motor manufacturer requirements. Do not wire starting or pole-changing devices between the converter and motor.

Procedure:

1. Strip outer cable insulation.
2. Position cable under clamp for mechanical fixation and electrical contact of the shield.
3. Connect ground cable to the nearest grounding terminal (chapter 4.3).
4. Connect 3-phase motor wiring to terminals 96 (U), 97 (V), and 98 (W) (Illustration 4.5).

Illustrations 4.6, 4.7, and 4.8 show mains, motor, and grounding connections for single-phase and 3-phase units.

4.7 AC Mains Connection

Size wiring based on input current (chapter 9.1). Comply with codes.

Procedure:

1. Connect AC input power cables to terminals N/L (single-phase) or L1/L2/L3 (3-phase) (Illustrations 4.6, 4.7).
2. Connect input power to mains input terminals or disconnect switch.
3. Ground cable per chapter 4.3.
4. For isolated mains sources (IT mains, floating delta) or TT/TN-S mains with grounded leg, remove the RFI filter screw to prevent damage and reduce ground capacity currents per IEC 61800-3.

4.8 Control Wiring

4.8.1 Control Terminal Types

Illustration 4.9 shows removable connectors. Terminal functions and default settings are in Tables 4.1 and 4.2. See chapter 9.6 for terminal ratings.

• Terminals 12, 13: +24 V DC supply (100 mA max).
• Terminals 18, 19: Digital inputs. Default: Terminal 18 [8] Start Input, Terminal 19 [10] Reversing.
• Terminal 27: Selectable digital input, digital output, or pulse output. Default: [2] Coast inverse (Digital Input).
• Terminals 29, 32, 33: Digital inputs. Terminal 33 can be used for pulse input.
• Terminals 37, 38: Functional safety inputs (STO).
• Terminal 42: Programmable analog output (0–20 mA or 4–20 mA). Can also be digital output.
• Terminal 50: +10 V DC analog supply (15 mA max).
• Terminals 53, 54: Analog inputs. Terminal 53 supports voltage mode only. Terminal 54 supports voltage or current mode. Common for digital/analog inputs.
• Terminal 55: Common for analog inputs.
• Terminals 61, 68, 69: RS485 interface. Terminal 61 is for cable shield.
• Relays 01, 02, 03: Form C relay output.

4.8.2 Wiring to Control Terminals

Control terminal connectors are unplugged for ease of installation. Keep control cables short and separate from high-power cables. Wire terminals by inserting sleeved cables and fastening screws. Ensure firm contact.

4.8.3 Enabling Motor Operation (Terminal 27)

A jumper wire is required between terminal 12 (or 13) and terminal 27 for operation with factory default settings. Terminal 27 is a 24 V DC external interlock command input. If no interlock device is used, wire a jumper from terminal 12 (recommended) or 13 to terminal 27.

NOTICE: UNABLE TO START The frequency converter cannot operate without a signal on terminal 27 unless reprogrammed.

4.8.4 Mechanical Brake Control

In hoisting/lowering applications, control an electro-mechanical brake using a relay or digital output (terminal 27). Keep the output closed (voltage-free) while the converter cannot hold the motor at standstill. Select [32] Mechanical brake control in parameter group 5-4*. The brake releases when motor current exceeds parameter 2-20 Release Brake Current and engages when output frequency is below parameter 2-22 Activate Brake Speed [Hz] during a stop command. The brake closes immediately in alarm or overvoltage situations. The converter is not a safety device; system designer must integrate safety devices per regulations.

Illustration 4.11 shows connecting the mechanical brake.

4.8.5 USB Data Communication

NOTICE: USB bus has no address-setting capacity. Connecting multiple converters via USB can cause issues. It is advised to connect only 1 converter via USB to a PC.

4.8.6 RS485 Serial Communication

Connect RS485 serial communication wiring to terminals (+)68 and (-)69. Shielded cable is recommended. See chapter 4.3 for grounding. Set protocol type (8-30), address (8-31), and baud rate (8-32) in parameter group 8-3*.

4.9 Installation Checklist

Inspect the installation as detailed in Table 4.3:

• Auxiliary equipment: Check switches, disconnects, fuses/breakers. Check sensor function. Remove power factor correction capacitors on motors. Adjust mains-side capacitors.
• Cable routing: Separate motor and control wiring, shielded or in separate metallic conduits.
• Control wiring: Check for broken wires, loose connections. Isolate from power/motor wiring. Check voltage source. Use shielded or twisted pair cables. Terminate shields correctly.
• Cooling clearance: Ensure adequate top/bottom clearance (chapter 3.3).
• Ambient conditions: Check requirements are met.
• Fusing and circuit breakers: Check proper fusing/breakers. Ensure fuses are firm, breakers are open.
• Grounding: Check sufficient, tight, oxidation-free ground connections. Do not ground to conduit.
• Input and output power wiring: Check connections. Ensure motor and mains cables are in separate conduit or shielded.
• Panel interior: Inspect for dirt, metal chips, moisture, corrosion. Unit should be mounted on an unpainted metal surface.
• Switches: Ensure all switch and disconnect settings are proper.
• Vibration: Check solid mounting or use shock mounts. Check for unusual vibration.

CAUTION: POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE Before applying power, ensure all safety covers are in place and securely fastened.

5 Commissioning

5.1 Safety Instructions

See chapter 2 Safety. WARNING: HIGH VOLTAGE Qualified personnel only. Before applying power:

1. Close cover properly.
2. Tighten cable glands.
3. Ensure input power is off and locked out.
4. Verify no voltage on input/output terminals.
5. Confirm motor continuity.
6. Check proper grounding.
7. Inspect for loose connections.
8. Confirm supply voltage matches unit and motor voltage.

5.2 Applying Power

1. Confirm input voltage balance is within 3%.
2. Ensure optional equipment wiring is correct.
3. Ensure operator devices are OFF. Close panel doors and fasten covers.
4. Apply power. Do not start yet. Turn disconnect switch ON if equipped.

5.3 Local Control Panel Operation

The converter supports Numeric Local Control Panel (NLCP), Graphic Local Control Panel (GLCP), and blind cover. Programming is also possible via MCT 10 Set-up Software (downloadable from Danfoss website).

5.3.1 Numeric Local Control Panel (NLCP)

The NLCP has 4 sections:

• A. Numeric display: Backlit LCD showing data, parameter numbers, values, and motor direction.
• B. Menu key: Switches between Status, Quick Menu, and Main Menu.
• C. Navigation keys and indicator lights (LEDs): Navigation keys ([Back], Arrows, [OK]) for menu traversal and value adjustment. Indicator lights: [On] (Green), [Warn] (Yellow), [Alarm] (Red).
• D. Operation keys and indicator lights (LEDs): [Hand On] (start local), [Off/Reset] (stop/reset), [Auto On] (start remote).

Illustration 5.1 shows the NLCP view. Illustration 5.2 details display information. Table 5.2 lists indicator lights, Table 5.3 navigation keys, and Table 5.4 operation keys.

Right-key Function: Pressing [] allows editing individual digits of a parameter value.

NOTICE: LCP shows INITIALISING during start-up. Converter is ready when this message disappears.

5.3.3 Quick Menu on NLCP

Provides access to frequently used parameters. Navigate via [Menu] key, select QM1 or QM2, browse parameters with arrows, press [OK] to select, change values, press [OK] to accept. Exit via [Back] or [Menu].

Illustration 5.4 shows the Quick Menu structure.

5.3.4 Main Menu on NLCP

Provides access to all parameters. Navigate through parameter groups and parameters using arrow keys and [OK]. Change values using arrows, press [OK] to accept. Exit via [Back] or [Menu]. Illustrations 5.5, 5.6, 5.7 and Tables 5.5, 5.6, 5.7 describe parameter value changes for continuous, enumerated, and array parameters.

5.3.5 GLCP Layout

The GLCP has 4 functional groups:

• A. Display area: Shows operational information (parameter numbers, current, power, frequency, etc.). Customizable via Quick Menu Q3-13. Table 5.8 lists default display parameters.
• B. Display menu keys: [Status], [Quick Menu], [Main Menu], [Alarm Log] for navigation and information access. Table 5.9 lists key functions.
• C. Navigation keys and indicator lights (LEDs): [Back], [Cancel], [Info], Navigation keys, [OK]. Indicator lights: [On] (Green), [Warn] (Yellow), [Alarm] (Red). Table 5.10 lists navigation keys, Table 5.11 indicator lights.
• D. Operation keys and reset: [Hand on], [Off], [Auto on], [Reset]. Table 5.12 lists key functions.

Illustration 5.8 shows the GLCP layout.

NOTICE: Adjust display contrast using [Status] and arrow keys.

5.3.6 Parameter Settings

Correct programming requires setting related parameters. Details are in chapter 10.2 Parameter Menu Structure. Data is stored internally; upload to LCP memory for backup.

5.3.7 Changing Parameter Settings with GLCP

Access and change settings via Quick Menu or Main Menu. Navigate using arrow keys and [OK]. Change values with arrows, shift digits with [], press [OK] to accept. Exit via [Back] or [Main Menu]. Quick Menu Q5 - Changes Made lists modified parameters.

5.3.8 Uploading/Downloading Data to/from the GLCP

1. Press [Off] to stop the motor.
2. Go to Main Menu, parameter 0-50 LCP Copy, press [OK].
3. Select [1] All to LCP (upload) or [2] All from LCP (download).
4. Press [OK]. A progress bar shows status.
5. Press [Hand On] or [Auto On] to return to operation.

5.3.9 Restoring Default Settings with LCP

NOTICE: Restoring defaults may erase programming and data. Upload data to LCP before initialization for backup.

Initialization is done via parameter 14-22 Operation Mode (recommended) or manually. Initialization does not reset parameter 1-06 Clockwise Direction.

• Recommended initialization (via 14-22): Select [2] Initialisation, press [OK]. Remove power, then reapply power. Default settings are restored. Alarm 80, Drive initialized to default value is shown. Press [Reset].
• Manual initialization: Remove power. Press and hold [Status], [Main Menu], and [OK] (GLCP) or [Menu] and [OK] (NLCP) while applying power. Factory defaults are restored. This method does not reset operating hours, power ups, etc.

5.4 Basic Programming

5.4.1 Asynchronous Motor Set-up

Enter motor data from the nameplate into parameters 1-20 to 1-26. For optimum VVC+ performance, enter advanced data (1-30 to 1-35) from the motor datasheet. Run Automatic Motor Adaptation (AMA) via parameter 1-29.

5.4.2 PM Motor Set-up in VVC+

Set parameter 1-10 Motor Construction to a PM motor option ([1] PM, non salient SPM, [2] PM, salient IPM, non Sat, or [3] PM, salient IPM, Sat). Select [0] Open Loop in parameter 1-00 Configuration Mode. NOTICE: Encoder feedback is not supported for PM motors.

Program PM motor data (1-24, 1-26, 1-25, 1-39, 1-30, 1-37, 1-40) from motor nameplate and datasheet. Measure or calculate values as described.

Test motor operation: Start at low speed. Check installation, programming, and data. Table 5.13 provides recommendations for different inertia applications.

5.4.3 Automatic Motor Adaptation (AMA)

Run AMA to optimize converter-motor compatibility in VVC+ mode. It builds a mathematical model of the motor. Select [2] Enable reduced AMA if the complete test fails. For best results, run on a cold motor.

To run AMA using LCP:

1. Connect terminals 13 and 27 (if not already connected).
2. Enter Main Menu, go to parameter group 1-** Load and Motor.
3. Set motor parameters (1-2*).
4. Set motor cable length (1-42).
5. Go to parameter 1-29 Automatic Motor Adaption (AMA).
6. Select [1] Enable complete AMA, press [OK].
7. The test runs automatically (3–10 minutes).

NOTICE: AMA function does not cause motor to run and does not harm the motor.

5.5 Checking Motor Rotation

Press [Hand On], set positive speed reference, and check speed display. Verify wiring and motor direction matches parameter 1-06 Clockwise Direction.

5.6 Checking Encoder Rotation

If encoder feedback is used: Set parameter 1-00 to [0] Open Loop, 7-00 to [1] 24 V encoder. Press [Hand On], set positive speed reference. Check parameter 16-57 Feedback [RPM] for positive feedback. NOTICE: NEGATIVE FEEDBACK If feedback is negative, reverse encoder connection or use parameter 5-71 Term 32/33 Encoder Direction.

5.7 Local-control Test

Press [Hand On], accelerate to full speed using [], note acceleration issues. Press [Off], note deceleration issues. See chapter 8.5 Troubleshooting. Reset after trip per chapter 8.2.

5.8 System Start-up

After application setup: Press [Auto On], apply external run command, adjust speed reference, remove command. Check sound and vibration. Reset after warnings/alarms.

5.9 STO Commissioning

Refer to chapter 6 Safe Torque Off (STO) for installation and commissioning.

6 Safe Torque Off (STO)

The STO function is part of a safety control system, preventing motor rotation in emergency situations. It complies with IEC/EN 61508 SIL2, IEC/EN 61800-5-2 SIL2, IEC/EN 62061 SILCL of SIL2, and EN ISO 13849-1 Category 3 PL d.

A thorough risk analysis is required to determine if STO and safety levels are sufficient. STO is controlled via terminals 37 and 38, cutting off power to IGBT gate driving circuits (Illustration 6.1).

Table 6.1 shows STO status based on terminal energization.

Test pulse filtering: Test pulses on STO lines below 1.8 V for max 5 ms are ignored (Illustration 6.2).

Asynchronous input tolerance: Discrepancy longer than 12 ms between signals at terminals 37/38 causes STO fault alarm (188). Valid signals require both terminals low for 80 ms to activate STO, and both high for 20 ms to deactivate.

6.1 Safety Precautions for STO

• Qualified personnel: Only qualified personnel are allowed to install or operate.
• NOTICE: Perform commissioning test after installation and changes.
• WARNING: RISK OF ELECTRICAL SHOCK STO does NOT isolate mains voltage. Perform work only after isolating mains voltage and waiting discharge time (chapter 2.3.1).
• NOTICE: Consider timing and distance for coast-to-stop (STO) in machine design (EN 60204-1).

6.2 Safe Torque Off Installation

Follow chapter 4 Electrical Installation for power connections. Enable STO by removing the jumper between terminals 12, 37, and 38 (Illustration 6.3).

Connect a dual-channel safety device (safety PLC, light curtain, etc.) to terminals 37 and 38. The device must comply with required safety levels. Illustrations 6.4 and 6.5 show wiring schematics for STO applications.

NOTICE: STO signal must be PELV supplied.

• Eliminate short circuit risks.
• Shield STO cables if longer than 20 m (65.6 ft) or outside the cabinet.
• Connect safety device directly to terminals 37 and 38.

6.3 STO Commissioning

6.3.1 Activation of Safe Torque Off

Activate STO by removing 24 V DC supply from terminals 37 and 38. This issues alarm 68 (Safe Torque Off), trips the unit, and coasts the motor. Use STO for emergency stops; use standard stop for normal operation.

NOTICE: If STO is activated during DC undervoltage, alarm 68 is skipped, but STO operation is unaffected.

6.3.2 Deactivation of Safe Torque Off

Follow Table 6.2 to deactivate STO and resume operation based on restart mode.

• Manual restart (default): Reapply 24 V DC to terminals 37/38, then send a reset signal.
• Automatic restart: Reapply 24 V DC to terminals 37/38.

WARNING: RISK OF INJURY OR DEATH Reapplying 24 V DC can start the motor. Ensure all safety measures are taken before reapplying supply.

6.3.3 STO Commissioning Test

Perform a commissioning test after installation and before first operation, and after any modification. Follow instructions in 6.3.4 or 6.3.5 based on restart mode.

NOTICE: Successful commissioning test is mandatory.

6.3.4 Test for STO Applications in Manual Restart Mode

For parameter 5-19 set to [1] Safe Torque Off Alarm:

1. Set parameter 5-40 Function Relay to [190] Safe Function active.
2. Remove 24 V DC from terminals 37/38 while motor is driving.
3. Verify: motor coasts, alarm 68 shows on LCP.
4. Reapply 24 V DC to 37/38. Motor remains coasted.
5. Send reset signal. Motor becomes operational.

Test is successful if all steps pass.

6.3.5 Test for STO Applications in Automatic Restart Mode

For parameter 5-19 set to [3] Safe Torque Off Warning:

1. Remove 24 V DC from terminals 37/38 while motor is driving.
2. Verify: motor coasts, Warning 68 shows on LCP.
3. Reapply 24 V DC to 37/38. Motor becomes operational.

Test is successful if all steps pass.

NOTICE: See warning on restart behavior in 6.1.

6.4 Maintenance and Service for STO

• User is responsible for security measures. Parameters can be password protected.
• Functional test: Basic and diagnostic tests.
• Basic functional test (if STO not used for 1 year): Set 5-19 to [1]. Remove 24 V DC from 37/38. Check alarm 68. Verify trip and coasting. Attempt start; motor should not start. Reconnect 24 V DC. Motor restarts only after reset signal.
• Diagnostic functional test: Verify no warnings/alarms when 24 V DC is connected. Remove 24 V DC from terminal 37, verify alarm 188 (STO Function Fault). Reapply 24 V DC, reset alarm. Repeat for terminal 38.

6.5 STO Technical Data

Table 6.3 lists technical data for STO, including safety standards, safety function, performance, reaction time, and proof test interval.

7 Application Examples

7.1 Introduction

Examples provide quick reference for common applications. Parameter settings are regional defaults unless specified. Terminal settings are shown next to drawings. NOTICE: If STO is not used, a jumper is required between terminals 12, 37, and 38.

7.2 Application Examples

• 7.2.1 AMA: Connect terminals 13 and 27. Set parameter 1-29 to [1] Enable complete AMA. Set 1-2* Motor Data per motor specs. If terminals 13 and 27 are not connected, set 5-12 to [0] No operation.
• 7.2.2 Speed: Analog speed reference via voltage (Table 7.2) or current (Table 7.3). Using a manual potentiometer (Table 7.4). Speed Up/Speed Down control via digital inputs (Table 7.5).
• 7.2.3 Start/Stop: Table 7.6 shows Start/Stop with Reversing and 4 Preset Speeds using digital inputs.
• 7.2.4 External Alarm Reset: Use digital input (Terminal 19) for reset (Table 7.7).
• 7.2.5 Motor Thermistor: Use parameter 1-90 [2] Thermistor Motor Thermal Protection and 1-93 Thermistor Source (Table 7.8). For warning only, set 1-90 to [1] Thermistor warning.
• 7.2.6 SLC (Smart Logic Controller): Example for using SLC to set a relay output based on feedback monitoring (Table 7.9). If feedback limit is exceeded, warning 61 is issued, triggering relay 1. Relay persists until [Off/Reset] is pressed.

8 Maintenance, Diagnostics, and Troubleshooting

8.1 Maintenance and Service

Under normal conditions, the frequency converter is maintenance-free. Examine at regular intervals. Replace worn parts with original spares. Contact local Danfoss supplier for service.

WARNING: UNINTENDED START Prevent unintended motor start during service by disconnecting from mains, pressing [Off/Reset], and ensuring all equipment is wired/assembled before connecting to mains.

8.2 Warning and Alarm Types

• Warning: Indicates an abnormal condition that stops when removed.
• Alarm: Indicates a fault requiring immediate attention, triggering a trip or trip lock. Reset after alarm.
• Trip: Suspends operation to prevent damage; motor coasts to stop. Logic continues to operate. Ready for reset after fault is remedied.
• Trip lock: Suspends operation for serious faults. Motor coasts to stop. Cycle input power before resetting after faults are fixed.

8.3 Warning and Alarm Display

Alarms/trips show text and code on the display. Indicator lights: Yellow [Warn] for warnings, Red flashing [Alarm] for alarms (Illustration 8.3).

8.4 List of Warnings and Alarms

Table 8.1 lists warnings and alarms with their descriptions, types (Warning, Alarm, Trip lock), and causes. Table 8.2 describes Alarm Word, Warning Word, and Extended Status Word bits.

8.5 Troubleshooting

Table 8.3 provides troubleshooting guidance for common symptoms like 'Motor not running', 'Motor wrong direction', 'Max speed not reached', 'Unstable speed', 'Rough running', 'No brake', 'Open fuses/breaker', 'Current imbalance', and 'Noise/vibration'. It includes possible causes, tests, and solutions.

9 Specifications

9.1 Electrical Data

Tables 9.1, 9.2, 9.3, and 9.4 provide detailed electrical data for different mains supplies (3x380-480 V AC, 3x200-240 V AC, 1x200-240 V AC), including output current, kVA, input current, cable sizes, power loss, weight, and efficiency.

9.2 Mains Supply

Details supply voltage tolerances, frequency, phase imbalance, power factor, and switching on input supply.

9.3 Motor Output and Motor Data

Specifies output voltage, frequency, torque characteristics, and starting current.

9.4 Ambient Conditions

Lists requirements for enclosure protection, vibration, humidity, ambient temperature (with and without derating), altitude, and EMC standards.

9.5 Cable Specifications

Provides maximum motor cable lengths (shielded/unshielded), control terminal cable sizes, and STO input cable length.

9.6 Control Input/Output and Control Data

Details digital inputs (PNP/NPN), STO inputs, analog inputs (voltage/current), pulse inputs, digital/pulse outputs, analog outputs, control card outputs (+24V DC, +10V DC), RS485/USB communication, and relay outputs, including their specifications and isolation.

9.7 Connection Tightening Torques

Table 9.5 lists recommended tightening torques for mains, motor, DC connection, brake, ground, and control terminals for different enclosure sizes.

9.8 Fuses and Circuit Breakers

Recommends fuses and circuit breakers for branch circuit protection according to national/international regulations and UL 508C / IEC 61800-5-1 compliance. Table 9.6 lists specific fuse/breaker types for different power ratings and enclosure sizes.

9.9 Enclosure Sizes, Power Ratings, and Dimensions

Table 9.7 and Illustrations 9.2, 9.3, 9.4, 9.5 detail enclosure sizes (K1-K5), power ratings, dimensions (Height A, Width B, Depth C), weight, and mounting hole specifications for IP20, IP21, and NEMA Type 1 configurations.

10 Appendix

10.1 Symbols, Abbreviations, and Conventions

Table 10.1 lists symbols and abbreviations used in the manual. Conventions for illustrations, parameters, and text formatting are also provided.

10.2 Parameter Menu Structure

Provides a comprehensive list of all parameters organized by group, detailing their function and typical settings.