Danfoss VLT DriveMotor FCM 106, Design Manual

Page 1: ...MAKING MODERN LIVING POSSIBLE Design Guide VLT DriveMotor FCP 106 and FCM 106 www danfoss com drives...

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Page 3: ...al Hand On and Remote Auto Control 13 2 4 Feedback and Reference Handling 14 2 5 General Aspects of EMC 16 2 5 1 EMC compliant Electrical Installation 17 2 6 Leakage Current 20 2 6 1 Residual Current...

Page 4: ...3 3 6 4 Aggressive Environments 33 3 6 5 Ambient Temperature 33 3 6 6 Acoustic Noise 34 3 6 7 Vibration and Shock 34 4 Application Examples 35 4 1 HVAC Application Examples 35 4 1 1 Star Delta Starter...

Page 5: ...ding to FCP 106 Enclosure 48 6 1 3 FCP 106 Dimensions 48 6 1 4 FCM 106 Dimensions 49 6 1 5 Weight 52 6 2 Electrical Data 53 6 3 Mains Supply 55 6 4 Protection and Features 55 6 5 Ambient Conditions 55...

Page 6: ...countries Danfoss does not warrant that a software program produced according to the guidelines provided in this manual functions properly in every physical hardware or software environment Although...

Page 7: ...Gauge AMA Automatic Motor Adaptation C Degrees Celsius DC Direct Current EMC Electromagnetic Compatibility ETR Electronic Thermal Relay fM N Nominal Motor Frequency FC Frequency Converter HO High ove...

Page 8: ...oltage directive of October 5 2nd edition 2007 The directive applies to all electrical equipment and appliances used in the 50 1000 V AC and the 75 1500 V DC voltage ranges Danfoss CE labels in accord...

Page 9: ...s other types of assistance that can help to obtain the best EMC result 1 4 4 Compliance with EMC Directive and CE Labelling The frequency converter is mostly used by professionals of the trade as a c...

Page 10: ...itting a customised gasket The gasket fits between the motor adapter plate and the motor No gasket is supplied with the FCP 106 frequency converter Therefore before installation design and test a gask...

Page 11: ...ontrol card 2 RFI filter 11 MCP Motor control processor 3 Rectifier 12 ACP Application control processor 4 Intermediate circuit DC filter 13 Control terminals 5 Inverter 14 Reset 6 Motor 15 Jog 7 Gate...

Page 12: ...IN 24V NPN 0V PNP 24V NPN 0V PNP 24V NPN 0V PNP 24V NPN 0V PNP Bus ter RS 485 Interface N PS 485 69 P RS 485 68 Com RS 485 61 RS 485 PNP Source NPN Sink Bus ter 1 2 ON ON Terminated OFF Unterminated...

Page 13: ...figuration Factory setting 12 24 V output 18 Digital input PNP NPN Start 19 Digital input PNP NPN No operation 20 Com 27 Digital input PNP NPN Coast inverse 29 Digital input PNP NPN Jog 50 10 V output...

Page 14: ...on before being sent to the motor control The output from the motor control is then limited by the maximum frequency limit Reference handling Remote reference Auto mode Hand mode Local reference scale...

Page 15: ...rease the pressure provided by the pump Reference Feedback S 1 PI 100 0 100 100 Scale to speed To motor control P 4 10 Motor speed direction P 4 19 Max output frequency Hz 7 30 PI Normal Inverse contr...

Page 16: ...Reference Unit P 3 16 Reference 2 resource Local bus reference 200 P 3 17 Reference 3 resource Pulse reference 200 P 20 12 Reference Feedback unit or rpm P 4 14 Motor Speed high limit Hz P 4 12 Motor...

Page 17: ...Feedback 1 source 2 4 3 Feedback Conversion In some applications it may be useful to convert the feedback signal One example of this is using a pressure signal to provide flow feedback Since the squar...

Page 18: ...he leakage current I4 If a screened cable is used for relay control cable signal interface and brake the screen must be mounted on the enclosure at both ends In some situations however it is necessary...

Page 19: ...Mains 3 phase and reinforced PE 3 Frequency converter 7 Cable insulation stripped 4 Min 200 mm clearance between control cable mains cable and mains motor cable Illustration 2 14 EMC compliant Electr...

Page 20: ...hase and reinforced PE 3 Min 200 mm clearance between control cable mains cable and mains motor cable 6 Cable insulation stripped Illustration 2 15 EMC compliant Electrical Installation FCM 106 Produc...

Page 21: ...Frequency converters installed in the first environment home and office with a supply voltage less than 1000 V which are neither plug in nor movable and are intended to be installed and commissioned b...

Page 22: ...y lightning that strikes near installations EN 61000 4 6 IEC 61000 4 6 RF Common mode Simulation of the effect from radio transmission equipment joined by connection cables Basic standard Burst IEC 61...

Page 23: ...described in local national regulations on PELV supplies All control terminals and relay terminals 01 03 04 06 comply with PELV Protective Extra Low Voltage Does not apply to grounded Delta leg above...

Page 24: ...onverter integrated onto the asynchronous or permanent magnet motor enables speed control in a single unit The FCM 106 is a very compact alternative to a central solution where the frequency converter...

Page 25: ...irectly Increased heat losses can lead to overload of the transformer and high temperature in the cables Therefore keep the harmonics at a low level by using frequency converters with internal harmoni...

Page 26: ...ce 98 86 59 48 Harmonic current distortion factor THC PWHC 0 55 1 5 kW 380 480 V typical 38 30 1 Limit for Rsce 95 63 Table 3 3 MH1 1 Power ratings relate to NO see chapter 6 2 Electrical Data MH21 In...

Page 27: ...rter enclosure 14 Stator frame 3 Motor connector 15 Fixing bolt endshield drive end 4 Motor connector gasket 16 Shaft key 5 Motor adapter plate 17 Rotor 6 Gasket between motor and motor adapter plate...

Page 28: ...osure 13 Shaft key 3 Motor connector 14 Rotor 4 Motor connector gasket 15 Snap ring 5 Motor adapter plate 16 Pre load washer 6 Gasket between motor and motor adapter plate 17 Endshield non drive end 7...

Page 29: ...ked Bearings may be fitted with a shaft locking device which should be kept in place during storage Shafts should be rotated by hand one quarter of a revolution at weekly intervals Bearings are despat...

Page 30: ...rmal switch Klixon type 3 3 9 1 Electronic Thermal Relay ETR is functional for asynchronous motors only The ETR protection comprises simulation of a bimetal relay based on internal frequency converter...

Page 31: ...temperature increases the thermistor value above 2 9 k The frequency converter is reactivated when the thermistor value decreases below 0 8 k 195NA439 10 R OFF ON 800 2 9 k Illustration 3 7 Frequency...

Page 32: ...2 Local Operation Pad 195NA441 10 53 18 19 27 12 50 55 Illustration 3 11 LOP Connections Key Dual speed operation Dual mode operation Dual direction operation Key Set reference Key I Run with referen...

Page 33: ...ls 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 o...

Page 34: ...reached Select the method used for controlling the intermediate circuit voltage level via 2 10 Brake Function and 2 17 Over voltage Control NOTICE OVC cannot be activated when running a PM motor that...

Page 35: ...e life of the frequency converter Liquids can be carried through the air and condense in the frequency converter and may cause corrosion of components and metal parts Steam oil and salt water may caus...

Page 36: ...65 5 71 5 1500 10 off 65 61 5 66 5 1500 16 off 64 60 65 5 1500 16 on 64 5 62 65 5 Table 3 15 FCM 106 Acoustic Noise Levels Measured 1m from the Unit 3 6 7 Vibration and Shock The frequency converter c...

Page 37: ...0 600 700 800 4 3 2 1 175HA227 10 Illustration 4 1 Start up Current 1 VLT DriveMotor FCM 106 2 Star delta starter 3 Soft starter 4 Start directly on mains Table 4 1 Legend for Illustration 4 1 4 1 2 S...

Page 38: ...p inverse 3 Speed 4 Start 18 5 Stop 27 Table 4 3 Legend for Illustration 4 3 4 1 4 Potentiometer Reference Voltage reference via a potentiometer 3 15 Reference 1 Source 1 Analog Input 53 6 10 Terminal...

Page 39: ...the AMA function Only Complete AMA can be activated when running a PM motor when 1 10 Motor Construction is set to 1 PM non salient SPM 4 1 6 Fan Application with Resonance Vibrations In the following...

Page 40: ...th alternative control systems and technologies a frequency converter is the optimum energy control system for controlling fan and pump systems SYSTEM CURVE FAN CURVE PRESSURE 130BA780 10 A B C 0 20 4...

Page 41: ...d the fact that the frequency converter has a built in facility that enables the frequency converter to function as a Building Management System BMS Illustration 4 8 shows typical energy savings obtai...

Page 42: ...ons where a PLC is generates a simple sequence the SLC can take over elementary tasks from the main control SLC is designed to act from events sent to or generated in the frequency converter The frequ...

Page 43: ...Preset reference 0 to first preset speed 3 10 Preset Reference 0 in percentage of Max reference speed 3 03 Maximum Reference For example 60 Set preset reference 1 to second preset speed 3 10 Preset Re...

Page 44: ...version of plug fans with external rotor motors To achieve the compact construction the motor extends into the intake area of the impeller This intrusion impacts the efficiency of the fan negatively a...

Page 45: ...l overload is included in the frequency converter motor Ordering numbers for frequency converter motor standard variants are available later in this chapter To configure the correct frequency converte...

Page 46: ...Reserved Motor range 25 E Standard motor range Efficiency class 26 2 Motor Efficiency IE2 4 Motor Efficiency IE4 Load profile 27 N Normal overload H High overload Shaft power 28 30 0 55 7 5 kW K55 7K...

Page 47: ...ze alternatives B 4 pole mm mm 0 55 kW 80 B5 B35 165 B14 B34 100 75 85 115 130 0 75 kW 80 B5 B35 165 B14 B34 100 75 85 115 130 1 1 kW 90 B5 B35 165 215 B14 B34 115 85 100 130 165 1 5 kW 90 B5 B35 165...

Page 48: ...nfigurator at www danfoss com drives Item Description Ordering No Fan assembly MH1 Fan assembly enclosure type MH1 134B0345 Fan assembly MH2 Fan assembly enclosure type MH2 134B0395 Fan assembly MH3 F...

Page 49: ...0 100 MH2 IP66 Type 4X 2 2 4 0 40 100 MH3 IP66 Type 4X 5 5 7 5 50 100 Table 6 1 Minimum Clearance for Cooling 1 Power ratings relate to NO see chapter 6 2 Electrical Data Enclosure type Maximum depth...

Page 50: ...rresponding to FCP 106 Enclosure 6 1 3 FCP 106 Dimensions 195NA418 10 C C B A a X Y Illustration 6 2 FCP 106 Dimensions Enclosure type Power1 kW Length mm Width mm Height mm Cable gland diameter Mount...

Page 51: ...5 153 170 170 192 192 220 256 256 320 320 348 348 BB mm 108 125 150 150 166 166 176 180 218 270 310 310 348 BC mm 83 89 116 91 110 144 126 134 136 180 180 256 256 L mm 246 272 317 317 366 400 388 445...

Page 52: ...00 200 200 250 250 300 350 350 S mm M8 M10 M10 M10 M12 M12 M12 M16 M16 T mm 3 5 3 5 3 5 3 5 4 4 4 5 5 LA mm 10 10 12 12 14 14 14 15 13 HA mm HA H height of the frequency converter For frequency conver...

Page 53: ...4 Motor frame size 71 80 90S 100L 112M 132S 160M L 180M M mm 115 130 130 165 165 215 265 N mm 95 110 110 130 130 180 230 P mm 140 160 160 200 200 250 300 S mm M8 M8 M8 M10 M10 M12 M16 T mm 2 5 3 5 3 5...

Page 54: ...apter plate kg Combined FCP 106 and motor adapter plate kg MH1 3 9 0 42 4 3 MH2 5 8 0 54 6 3 MH3 8 1 0 78 8 9 Table 6 9 Weight of FCP 106 Shaft power kW PM motor Asynchronous motor 1500 rpm 3000 rpm 1...

Page 55: ...V A 1 3 2 1 2 4 3 5 4 7 6 3 8 3 Intermittent 3x380 440 V A 1 4 2 0 2 3 2 6 2 6 3 7 3 9 4 6 5 2 7 0 6 9 9 6 9 1 12 0 Continuous 3x440 480 V A 1 2 1 8 2 2 2 9 3 9 5 3 6 8 Intermittent 3 x 440 480 V A 1...

Page 56: ...A 9 4 13 Intermittent 3 x 440 480 V A 10 15 14 Max mains fuses See chapter 6 9 Fuse and Circuit Breaker Specifications Table 6 12 Mains Supply 3x380 480 V AC Normal and High Overload MH3 Enclosure 1...

Page 57: ...the temperature of the heatsink is below 70 C 5 C Guideline these temperatures may vary for different power sizes enclosures etc The frequency converter auto derating function ensures that the heatsin...

Page 58: ...30 AWG Max cross section to thermistor input at motor connector 4 0 mm2 6 7 Control Input Output and Control Data Digital inputsA Programmable digital inputs 4 Terminal number 18 19 27 29 Logic PNP or...

Page 59: ...01 02 NO 04 06 NC 04 05 NO Max terminal load AC 1 1 on 01 02 04 05 NO Resistive load 250 V AC 3 A Max terminal load AC 15 1 on 01 02 04 05 NO Inductive load cos 0 4 250 V AC 0 2 A Max terminal load D...

Page 60: ...ses must be designed for protection in a circuit capable of supplying a maximum of 100 000 Arms symmetrical 480 V maximum Circuit breakers must be designed for protection in a circuit capable of suppl...

Page 61: ...TI25 M 047B3 150 6 10 10 10 10 10 10 10 MH2 2 2 CTI25M 047B3149 CTI25M 047B3152 CTI25 M 047B3 149 CTI25 M 047B3 152 6 20 20 20 20 20 16 20 3 0 CTI25M 047B3149 CTI25M 047B3152 CTI25 M 047B3 149 CTI25 M...

Page 62: ...eased fsw kHz 2 0 10 0 10 20 30 40 50 60 70 80 90 100 110 Iout 16 40 45 50 5 o C o C o C 130BC218 10 Illustration 6 3 400 V MH1 0 55 1 5 kW fsw kHz 2 0 10 0 10 20 30 40 50 60 70 80 90 100 110 Iout 16...

Page 63: ...98 0 97 0 96 0 95 0 93 0 92 0 50 100 200 0 94 Relative Efficiency 130BB252 11 1 01 150 Speed 100 load 75 load 50 load 25 load Illustration 6 6 Typical Efficiency Curves Example Assume a 22 kW 380 480V...

Page 64: ...elays 3 11 terminalsControl Terminals 11 Controlling Fans and Pumps 38 Conventions 5 Cooling 33 Copyright Limitation of Liability and Revision Rights 4 D Derating for Low Air Pressure 31 DeviceNet 4 D...

Page 65: ...Pulse Start Stop 36 R Reference Handling 14 Relay output 57 Relays 11 Remote Mounting Kit 29 S Screened cable 19 Short Circuit Motor Phase Phase 32 Smart Logic Control 40 Logic Control Programming 40...

Page 66: ...ts 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 trademark...