Danfoss VLT DriveMotor FCP 106 User Manual Download

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ENGINEERING TOMORROW

Design Guide

VLT

DriveMotor FCP 106/FCM 106

vlt-drives.danfoss.com

Summary of Contents for VLT DriveMotor FCP 106

Page 1: ...ENGINEERING TOMORROW Design Guide VLT DriveMotor FCP 106 FCM 106 vlt drives danfoss com...

Page 2: ......

Page 3: ...2 1 2 Key Diagram 11 2 1 3 Electrical Overview 12 2 1 4 Control Terminals and Relays 3 13 2 1 5 Serial Communication Fieldbus Networks 14 2 2 VLT Memory Module MCM 101 14 2 2 1 Configuring with the V...

Page 4: ...cy Converter Options Selections 39 3 4 1 Remote Mounting Kit 39 3 4 2 Local Operation Pad 39 3 5 Special Conditions 40 3 5 1 Purpose of Derating 40 3 5 2 Derating for Ambient Temperature and Switching...

Page 5: ...Year 51 4 3 Control Examples 52 4 3 1 Improved Control 52 4 3 2 Smart Logic Control 52 4 3 3 Smart Logic Control Programming 52 4 3 4 SLC Application Example 53 4 4 EC Concept for Asynchronous and PM...

Page 6: ...Overload Data VLT DriveMotor FCM 106 71 6 9 Fuse and Circuit Breaker Specifications 72 6 10 Derating According to Ambient Temperature and Switching Frequency 74 6 11 dU dt 74 6 12 Efficiency 75 Index...

Page 7: ...nstallation Guide provides information about installing the PROFIBUS and troubleshooting The VLT PROFIBUS DP MCA 101 Programming Guide provides information about configuring the system controlling the...

Page 8: ...on of conformity is based on the following directives Low Voltage Directive 2006 95 EC based on EN 61800 5 1 2007 EMC Directive 2004 108 EC based on EN 61800 3 2004 UL listed Product evaluation is com...

Page 9: ...irective is that devices that generate electromagnetic interference EMI or whose operation could be affected by EMI must be designed to limit the generation of electromagnetic interference The devices...

Page 10: ...be separately collected with electrical and electronic waste according to local and currently valid legislation 1 7 Safety 1 7 1 General Safety Principles If handled improperly frequency converters ha...

Page 11: ...duration of waiting time is specified in Table 1 3 Before performing any service or repair work use an appropriate voltage measuring device to make sure that the capacitors are fully discharged Volta...

Page 12: ...106 2 1 1 Gasket Mounting of the FCP 106 onto a motor requires fitting a customised gasket The gasket fits between the motor adapter plate and the motor No gasket is supplied with the FCP 106 frequenc...

Page 13: ...Gate drive 13 Control terminals 2 RFI filter 8 SMPS 14 Reset 3 Rectifier 9 Galvanic isolation 15 Jog 4 Intermediate circuit DC filter 10 Control card 16 Start 5 Inverter 11 MCP motor control processo...

Page 14: ...S MCM 24 V NPN 0 V PNP 24 V NPN 0 V PNP 24 V NPN 0 V PNP 24 V NPN 0 V PNP Bus ter RS485 Interface N RS485 69 P RS485 68 Com RS485 61 RS485 PNP Source NPN Sink Bus ter 1 2 ON ON Terminated OFF Untermin...

Page 15: ...1 Illustration 2 5 Location of Terminals and Relays MH1 195NA409 12 1 2 3 4 8 5 6 7 1 Control terminals 2 Relay terminals 3 UDC UDC Line L3 L2 L1 4 PE 5 LCP connector 6 VLT PROFIBUS DP MCA 101 7 VLT M...

Page 16: ...terminals 18 19 27 and 29 2 1 5 Serial Communication Fieldbus Networks These protocols are embedded in the frequency converter BACnet MSTP Modbus RTU FC Protocol 2 2 VLT Memory Module MCM 101 The VLT...

Page 17: ...ter NOTICE The first power up takes approximately 3 minutes During this time all data is transferred to the new frequency converter 2 2 2 Copying Data via PC and Memory Module Programmer MMP By using...

Page 18: ...is possible to transfer the configuration of 1 VLT DriveMotor FCP 106 or VLT DriveMotor FCM 106 to several others It only requires a frequency converter that already has the wanted configuration 1 Re...

Page 19: ...imitation After that it is 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 refe...

Page 20: ...re 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 20 81 PI Normal Inverse control 195NA450 11 Illustration 2 14 Clo...

Page 21: ...rence 1 100 Preset reference 2 100 Preset reference 3 100 Preset reference 4 100 Preset reference 5 100 Preset reference 6 100 Preset reference 7 100 No function Analog reference 200 Local bus referen...

Page 22: ...30BB895 10 PI P P P Ref signal Desired flow FB conversion Ref FB Flow FB signal Flow P 20 01 Illustration 2 17 Feedback Conversion 2 6 General Aspects of EMC Burst transient is conducted at frequencie...

Page 23: ...electrical contact from the mounting plate through the mounting screws to the frequency converter enclosure When unscreened cables are used some emission requirements are not complied with although m...

Page 24: ...and reinforced PE 3 Frequency converter 7 Cable insulation stripped 4 Minimum 200 mm 7 87 in clearance between control cable mains cable and mains motor cable Illustration 2 19 EMC compliant Electric...

Page 25: ...s 3 phase and reinforced PE 3 Minimum 200 mm 7 87 in clearance between control cable and mains cable 6 Cable insulation stripped Illustration 2 20 EMC compliant Electrical Installation FCM 106 Product...

Page 26: ...stallation and commissioning Class A Group 1 C3 Frequency converters installed in the second environment industrial with a supply voltage lower than 1000 V Class A Group 2 C4 Frequency converters inst...

Page 27: ...on equipment as well as mobile communications equipment EN 61000 4 4 IEC 61000 4 4 Burst transients Simulation of interference brought about by switching a contactor relay or similar devices EN 61000...

Page 28: ...current exceeds 3 5 mA compliance with EN IEC61800 5 1 power drive system product standard requires special care Reinforce grounding with the following protective ground connection requirements Ground...

Page 29: ...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 30: ...r integrated onto the asynchronous or permanent magnet motor enables speed control in a single unit The FCM 106 is a compact alternative to a central solution where the frequency converter and motor a...

Page 31: ...n directly 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 harm...

Page 32: ...that apply to frequency converters are given in Table 4 in the standard There are requirements for individual harmonics 5th 7th 11th and 13th and for THDi and PWHD 3 2 1 3 Harmonics Test Results Emiss...

Page 33: ...el guidelines The harmonic current data in Table 3 3 to Table 3 5 are listed in accordance with IEC EN 61000 3 12 regarding the power drive systems product standard These data may be used As the basis...

Page 34: ...t key 5 Motor adapter plate 17 Rotor 6 Gasket between motor and motor adapter plate 18 Pre load washer 7 Dust seal drive end 19 End shield non drive end 8 End shield drive end 20 Fixing bolt end shiel...

Page 35: ...nap ring 5 Motor adapter plate 16 Pre load washer 6 Gasket between motor and motor adapter plate 17 End shield non drive end 7 Dust seal drive end 18 Fixing bolt end shield non drive end 8 Flange end...

Page 36: ...shoulder of the eyebolt is tightened firmly against the face of the stator frame before lifting Eyebolts or lifting trunnions supplied with the unit are rated to bear the weight of the unit only not t...

Page 37: ...20 4 830 665 440 350 470 380 410 310 90 2 670 535 340 260 380 315 310 235 4 940 750 480 365 470 385 440 330 100 2 920 735 480 360 540 460 430 325 4 1290 1030 680 530 740 620 620 465 112 2 930 745 480...

Page 38: ...0 390 132 XXL 1500 1970 1575 1090 850 1300 1080 890 670 1800 1770 1415 980 765 1170 970 800 600 3000 1400 1120 780 610 990 835 580 435 3600 1260 1010 700 550 890 750 520 390 Table 3 7 Permissible Forc...

Page 39: ...een motor windings Mechanical thermal switch 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 interna...

Page 40: ...nal nominal 5 C nominal 5 C C Illustration 3 6 Typical Thermistor Behaviour When the motor temperature increases the thermistor value above 2 9 k the frequency converter trips When the thermistor valu...

Page 41: ...nel cutout Panel thickness 1 3 mm 0 04 0 12 in 2 Panel 3 Gasket 4 LCP Illustration 3 9 Remote Mounting Kit Connector 195NA422 12 1 2 42 mm 1 Control panel 2 Panel door Illustration 3 10 LCP Remote Mou...

Page 42: ...wire to terminal 18 3 5 Special Conditions 3 5 1 Purpose of Derating Consider derating when using the frequency converter At low air pressure high altitudes At low speeds With long motor cables Cable...

Page 43: ...a moment is high the friction is low and the ramp down time is too short for the energy to be dissipated as a loss in the frequency converter the motor and the installation Incorrect slip compensation...

Page 44: ...net or instal lation site may be required 3 6 3 Cooling Frequency converters dissipate power in the form of heat Adhere to the following recommendations for effective cooling of the units Maximum air...

Page 45: ...5 FCP 106 Acoustic Noise Levels Fan on Measured 1 m from the Unit FCM 106 Acoustic noise originates from the sources Motor fan External fan Motor stator and rotor DC intermediate circuit coils RFI fil...

Page 46: ...asses Complete drive modules According to the standard EN 50598 2 the complete drive module CDM comprises the frequency converter its feeding section and its auxiliaries Energy efficiency classes for...

Page 47: ...r 67 8 kVA Rated output power PCDM 59 2 kW Rated efficiency r 98 3 Illustration 3 16 and Illustration 3 17 show the power loss and efficiency curves The speed is proportional to the frequency 130BD930...

Page 48: ...rsus Switching Frequency kHz NOTICE A frequency converter produces extra harmonic losses in the motor These losses decrease when switching frequency increases 3 7 4 Losses and Efficiency of a Power Dr...

Page 49: ...5 50Hz 200 300 400 600 700 800 4 3 2 1 175HA227 10 1 VLT DriveMotor 2 Star delta starter 3 Soft starter 4 Start directly on mains Illustration 4 1 Start up Current 4 1 2 Start Stop Terminal 18 Start...

Page 50: ...iometer Reference 4 1 5 Automatic Motor Adaptation AMA AMA is an algorithm to measure the electrical motor parameters on a motor at standstill The AMA itself does not supply any torque AMA is useful w...

Page 51: ...low the correct motor voltage for example at 43 Hz overmodulation can compensate up to the required motor voltage level Disadvantage of overmodulation The non sinusoidal voltages increase the harmonic...

Page 52: ...80 of the rated flow for the remainder of the year the amount of energy saved is even more than 50 Illustration 4 7 describes the dependence of flow pressure and power consumption on RPM n 100 50 25 1...

Page 53: ...d on pump characteristics obtained from a pump datasheet The result obtained shows energy savings in excess of 50 at the given flow distribution over a year The payback period depends on the price per...

Page 54: ...ing The smart logic control SLC comprises a sequence of user defined actions see parameter 13 52 SL Controller Action executed by the SLC when the SLC evaluates the associated user defined event see p...

Page 55: ...ence 1 For example 0 zero 5 Set the timer 0 for constant running speed in parameter 13 20 SL Controller Timer 0 For example 2 s 6 Set event 1 in parameter 13 51 SL Controller Event to 1 True 7 Set eve...

Page 56: ...nto the intake area of the impeller This intrusion impacts the efficiency of the fan negatively and therefore reduces the efficiency of the entire ventilation unit In this case high motor efficiency d...

Page 57: ...le is included in the frequency converter Ordering numbers for frequency converter motor standard variants are available in chapter 5 3 Ordering Numbers To configure the correct frequency converter or...

Page 58: ...MCM 101 VLT PROFIBUS DP MCA 101 Not assigned 24 X Reserved Motor range 25 E Standard motor range Efficiency class 26 2 Motor efficiency IE2 4 Motor efficiency IE4 Load profile motor 27 N Normal overlo...

Page 59: ...dard S Flange size alternatives B 4 pole mm mm 0 55 80 B5 B35 165 B14 B34 100 75 85 115 130 0 75 80 B5 B35 165 B14 B34 100 75 85 115 130 1 1 90 B5 B35 165 215 B14 B34 115 85 100 130 165 1 5 90 B5 B35...

Page 60: ...foss com drives Item Description Ordering number Fan assembly MH1 Fan assembly Enclosure size MH1 134B0345 Fan assembly MH2 Fan assembly Enclosure size MH2 134B0395 Fan assembly MH3 Fan assembly Enclo...

Page 61: ...NO see chapter 6 2 Electrical Data 2 The stated IP and Type rating only apply when the FCP 106 is mounted on a wall mount plate or a motor with the adapter plate Ensure that the gasket between the ada...

Page 62: ...lustration 6 2 FCP 106 Dimensions Enclosure type Power1 kW hp Length mm in Width mm in Height mm in Cable gland diameter Mounting hole Normal lid High lid for VLT PROFIBUS DP MCA 101 option 3x380 480...

Page 63: ...0 4 3 144 5 7 126 5 0 134 5 3 136 5 4 L mm in 246 9 7 272 10 7 317 12 5 317 12 5 366 14 4 400 15 7 388 15 3 445 17 5 485 19 1 AC mm in 139 5 5 160 6 3 180 7 1 180 7 1 196 7 7 194 7 6 225 8 9 248 9 8 2...

Page 64: ...6 HA mm in HA AC1 height of the frequency converter For frequency converter dimensions see Table 6 4 HD mm in without VLT PROFIBUS DP MCA 101 MH1 247 9 7 267 10 5 286 11 3 286 11 3 MH2 248 9 8 268 10...

Page 65: ...1 P mm in 140 5 5 160 6 3 160 6 3 200 7 9 200 7 9 250 9 8 S mm in M8 M8 M8 M10 M10 M12 T mm in 2 5 0 1 3 5 0 14 3 5 0 14 3 5 0 14 3 5 0 14 4 0 16 LA mm in 8 0 31 8 5 0 33 9 0 35 12 0 5 12 0 5 12 0 5 H...

Page 66: ...6 92 15 3 MH3 8 1 17 9 1 48 3 3 9 58 21 2 Table 6 9 Weight of FCP 106 Shaft power kW hp PM motor Asynchronous motor 1500 RPM 3000 RPM 1500 RPM 3000 RPM Motor frame size Weight kg lb Motor frame size W...

Page 67: ...Breaker Specifications Estimated power loss W best case typical3 38 44 57 73 91 129 143 Efficiency best case typical4 5 0 96 0 97 0 97 0 97 0 97 0 97 0 97 Table 6 11 Mains Supply 3x380 480 V AC Norma...

Page 68: ...inute HO High overload 160 for 1 minute A frequency converter intended for HO requires a corresponding motor rating For example Table 6 11 shows that a 1 5 kW motor for HO requires a P2K2 frequency co...

Page 69: ...heat sink is below 70 C 158 F 5 C 41 F However these temperatures may vary for different power sizes enclosures and so on The frequency converter autoderating function ensures that the heat sink temp...

Page 70: ...ing pattern factory setting 6 6 Cable Specifications Cable lengths and cross sections Maximum motor cable length for wall mount kit screened armored 2 m 6 56 ft Maximum cross section to motor mains fo...

Page 71: ...m the supply voltage PELV and other high voltage terminals Control card RS485 serial communication Terminal number 68 P TX RX 69 N TX RX Terminal number 61 Common for terminals 68 and 69 Control card...

Page 72: ...0 100 of supply voltage Output frequency asynchronous motor 0 200 Hz VVC 0 400 Hz u f Output frequency PM motor 0 390 Hz VVC PM Switching on output Unlimited Ramp times 0 05 3600 s Thermistor input at...

Page 73: ...9 24 27 214 8 9 9 33 88 299 9 14 4 HPS 90 3000 2 20 2 95 7 25 64 2 5 3 7 81 69 1 5 8 10 99 97 3 8 5 HPS 90 3000 3 00 4 02 9 90 87 6 7 2 10 73 95 7 9 14 99 132 7 11 5 HPS 90 3000 4 00 5 36 13 29 117 6...

Page 74: ...ity for Danfoss CTI25M circuit breaker at 480 V maximum UL non UL compliance To ensure compliance with UL 508C or IEC 61800 5 1 use the circuit breakers or fuses listed in Table 6 14 Table 6 15 and Ta...

Page 75: ...TI25M 047B31021 15000 7 5 10 CTI25M 47B3151 15000 CTI25M 047B31021 15000 Table 6 15 Circuit Breakers Non UL 1 Trip level maximum set to 32 A Enclosure size Power1 kW 3x380 480 V Fuse Recommended UL Ma...

Page 76: ...F 113o F 122o F Illustration 6 4 400 V MH2 2 2 4 0 kW 3 0 5 0 hp fsw kHz 2 0 10 0 10 20 30 40 50 60 70 80 90 100 110 Iout 16 5 130BC222 11 40 45 50 o C o C o C 104o F 113o F 122o F Illustration 6 5 40...

Page 77: ...C frequency converter runs at 25 load at 50 speed The graph shows 0 97 whereas rated efficiency for a 22 kW 30 hp frequency converter is 0 98 The actual efficiency is then 0 97 x 0 98 0 95 Efficiency...

Page 78: ...output 70 Control card 24 V DC output 69 Control card RS485 serial communication 69 Control structures Closed loop 19 Closed loop PI 18 28 Control structure example 28 Open loop 17 18 19 Controlling...

Page 79: ...onnector 13 LCP control keys 18 Leakage current 9 20 Lifting 34 Load sharing 8 9 Lubrication 36 M Magnetization loss 46 Mains dropout 67 drop out 41 supply L1 L2 L3 67 supply 3x380 480 V AC normal and...

Page 80: ...2 25 EN IEC 61000 4 3 25 EN IEC 61000 4 4 25 EN IEC 61000 4 5 25 EN IEC 61000 4 6 25 EN IEC 61000 6 3 24 EN IEC 61000 6 4 24 EN IEC 61800 3 2004 24 EN IEC 61800 5 1 27 68 IEC 60068 2 34 43 IEC 60068 2...

Page 81: ...8 Terminal 42 69 Terminal 45 69 Terminal 50 70 Terminal 53 68 Terminal 54 68 Terminal 68 P TX RX 69 Terminal 69 N TX RX 69 Thermistor 38 Thermistor input at motor connector 70 Transient 26 Type code a...

Page 82: ...ucts 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 resp...

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