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Danfoss VLT DriveMotor FCP 106 Design Manual

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ENGINEERING TOMORROW
Design Guide
®
VLT
DriveMotor FCP 106
vlt-drives.danfoss.com

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Summary of Contents for Danfoss VLT DriveMotor FCP 106

  • Page 1 ENGINEERING TOMORROW Design Guide ® DriveMotor FCP 106 vlt-drives.danfoss.com...

  • Page 3: Table Of Contents

    2.3.2 Control Structure Closed Loop (PI) 2.4 Local [Hand On] and Remote [Auto On] Control 2.5 Feedback and Reference Handling 2.6 General Aspects of EMC 2.7 Leakage Current 2.8 Galvanic Isolation (PELV) MG03M302 Danfoss A/S © 12/2018 All rights reserved.
  • Page 4 3.7.5 Losses and Efficiency of a Power Drive System 4 Application Examples 4.1 HVAC Application Examples 4.1.1 Star/Delta Starter or Soft Starter not Required 4.1.2 Start/Stop 4.1.3 Pulse Start/Stop 4.1.4 Potentiometer Reference Danfoss A/S © 12/2018 All rights reserved. MG03M302...
  • Page 5 6.5 Ambient Conditions 6.6 Cable Specifications 6.7 Control Input/Output and Control Data 6.8 Fuse and Circuit Breaker Specifications 6.9 Derating According to Ambient Temperature and Switching Frequency 6.10 dU/dt 6.11 Efficiency Index MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 6: Introduction

    60364-4-41 or IEC 60204-1. shooting the PROFIBUS option. Programmable logic controller. • ® The VLT PROFIBUS DP MCA 101 Programming Table 1.2 Abbreviations Guide provides information about configuring the Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 7: Approvals

    EMC Directive. The finished plant does not More information on approvals and certificates, are require CE marking. However, the installation available at www.danfoss.com. Search for approval or must comply with the essential requirements of certificate. the directive. This is assumed by the use of appliances and systems that are CE-labeled under the EMC Directive.

  • Page 8: Ce Mark

    Machinery Directive. Drives without a safety function do not fall under the Machinery Directive. If a drive is Drives with an integrated safety function must comply integrated into a machinery system, Danfoss can provide with the machinery directive. information on safety aspects relating to the drive.

  • Page 9: Ul Compliance

    Only qualified personnel are allowed to install and operate the equipment. Do not attempt repair work without first removing power from the drive and waiting the MG03M302 Danfoss A/S © 12/2018 All rights reserved.
  • Page 10 • Ensure that only trained and qualified personnel perform installation, start-up, and maintenance. • Ensure that electrical work conforms to national and local electrical codes. • Follow the procedures in this guide. Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 11: Product Overview

    Illustration 2.1 VLT DriveMotor FCP 106 connector must be avoided by suitable measures. The drive is designed for both motor- and wall-mounting. The motor is not included in delivery. Illustration 2.2 FCP 106 Motor-mounted MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 12: Key Diagram

    SMPS (switched mode power supply) Reset Rectifier Galvanic isolation DC link/DC filter Control card Start Inverter MCP (motor control processor) Analog/digital output Motor ACP (application control processor) – – Illustration 2.3 Key Diagram Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 13: Electrical Overview

    24 V (NPN) RS485 RS485 (N RS485) 69 0 V (PNP) Interface 29 (DIGI IN) 24 V (NPN) (P RS485) 68 0 V (PNP) (Com RS485) 61 (PNP)-Source PROFIBUS (NPN)-Sink Illustration 2.4 Electrical Overview MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 14: Control Terminals And Relays

    Illustration 2.6 Location of Terminals and Relays, MH2–MH3 Illustration 2.5 Location of Terminals and Relays, MH1 Control terminals BUS TER. 12 18 19 61 68 69 20 27 29 42 45 50 53 54 Illustration 2.7 Control Terminals Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 15: Serial Communication (Fieldbus) Networks

    Memory Module MCM 101 is a small memory plug containing data such as: • Firmware • SIVP file • Pump table • Motor database • Parameter lists The drive comes with the module installed from the factory. MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 16: Configuring With The Vlt ® Memory Module Mcm 101

    Transfer the configuration data from the PC to the drive. This data is NOT encoded. Insert an empty memory module into the MMP. Select which data to copy from the PC to the memory module. Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 17: Copying A Configuration To Several Drives

    Place and tighten the lid. Power cycle the drive. Repeat steps 3–7 for each drive that is to receive the configuration. Place the memory module in the original drive. Place and tighten the lid. MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 18: Control Structures

    Motor speed Local low limit [Hz] reference scaled to 100% P 4-10 P 4-19 -100% LCP Hand on, Motor speed Max output o and auto direction frequency on keys Illustration 2.13 Open-loop Structure Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 19: Control Structure Closed Loop (Pi)

    Reset. Hand Auto Off Reset Illustration 2.15 LCP Control Keys Local reference forces the configuration mode to open loop, independent of the setting in parameter 1-00 Configu- ration Mode. MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 20: Feedback And Reference Handling

    The scaled reference is calculated as follows: supplied externally, most commonly from an analog input. Select this external source via the 3 reference source Reference  =  X  +  X  ×   parameters: Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 21: General Aspects Of Emc

    Flow • Flow Relay • Control cable signal • Signal interface • Brake In some situations, however, it is necessary to break the Illustration 2.17 Feedback Conversion shield to avoid current loops. MG03M302 Danfoss A/S © 12/2018 All rights reserved.
  • Page 22 50 MHz (airborne). See enclosure. chapter 2.6.1 EMC-compliant Electrical Installation for more information on EMC. When unshielded cables are used, some emission requirements are not complied with, although most immunity requirements are observed. Danfoss A/S © 12/2018 All rights reserved. MG03M302...
  • Page 23 Mains, 3-phase, and reinforced PE Drive Cable insulation (stripped) Minimum 200 mm (7.87 in) clearance between control cable, mains cable, and mains motor cable. Illustration 2.19 EMC-compliant Electrical Installation, FCP 106 Wall-mounted MG03M302 Danfoss A/S © 12/2018 All rights reserved.
  • Page 24 Use the cable control cables. clamps provided instead. • • Connect the shield to ground at both ends. Ensure the same potential between drive and ground potential of the PLC. Danfoss A/S © 12/2018 All rights reserved. MG03M302...
  • Page 25 Simulation of interference brought about by requirements for the home and office environment. All switching a contactor, relay, or similar devices. Danfoss drives comply with the requirements for the MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 26: Leakage Current

    The ground leakage current is made up of several contri- butions and depends on various system configurations, The leakage current also depends on the line distortion. including: • RFI filtering. • Motor cable length. • Motor cable screening. • Drive power. Danfoss A/S © 12/2018 All rights reserved. MG03M302...
  • Page 27 RCD of Type B is detected depends on the type of RCD used. allowed on the supply side. Failure to follow the recommendation means that the RCD cannot provide the intended protection. MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 28: Galvanic Isolation (Pelv)

    Relay input output High-voltage circuit I/O control card Custom relays Illustration 2.25 Galvanic Isolation NOTICE HIGH ALTITUDE For installation at altitudes above 2000 m (6562 ft), contact Danfoss hotline regarding clearance (PELV). Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 29: System Integration

    Other considerations (chapter 3.4 Drive/ Options Selections) Combined fieldbus and traditional control signals with closed-loop PI control is possible. • Ambient operating conditions for the drive including: Environment Enclosures MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 30: Mains Supply Interference/Harmonics

    • Using drives with internal harmonic filters. THD % = 5   +  U 7   +  ...  +  U • Using advanced external filters (active or passive). % of U) Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 31: Harmonics Emission Requirements

    Individual harmonic current I public low voltage distribution system having an input current of ≤16 A per phase. Four emission classes are 2.2–4 kW (3.0–5.0 defined: Class A through D. The Danfoss drives are in Class 35.29 35.29 7.11 5.14 hp), 380–480 V...

  • Page 32: Drive/Options Selections

    Panel cutout. Panel thickness 1–3 mm (0.04– 0.12 in) 3.4.1 Remote Mounting Kit Panel Gasket Illustration 3.4 Remote Mounting Kit Connector 42 mm Illustration 3.3 Remote Mounting Kit Connections Control panel Panel door Illustration 3.5 LCP Remote Mounting Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 33: Local Operation Pad

    • At low speeds. White • Blue With long motor cables. • Cables with a large cross-section. Table 3.7 Electrical Connections • At high ambient temperature. This section describes the actions required. MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 34: Derating For Ambient Temperature And Switching Frequency

    (656 ft) altitude. measurement in each of the 3 motor phases or in the DC • Above 2000 m (6561 ft) altitude, contact Danfoss link. A short circuit between 2 output phases causes an regarding PELV. overcurrent in the inverter. The inverter turns off when the...

  • Page 35: Motor Thermal Protection

    In this case, ETR does not activate and therefore a different method of thermal protection is required. Activate ETR in parameter 1-90 Motor Thermal Protection. ETR is controlled in parameter 4-18 Current Limit. MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 36: Thermistor

    NOTICE • Extra air conditioning of the cabinet or instal- Select the thermistor according to the specification in lation site may be required. Illustration 3.10 and Illustration 3.11. Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 37: Cooling

    Curve D (1–3) Long-term test 2.52 g components. 60068-2-35, 60068-2-36 Such chemical reactions rapidly affect and damage the Table 3.10 Vibration and Shock Test Procedure Compliance electronic components. In such environments, mount the MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 38: Energy Efficiency

    • ® Advanced Harmonic Filter AHF 005 • ® Advanced Harmonic Filter AHF 010 • ® Line Reactor MCC 103 • ® Sine-wave Filter MCC 101 • ® dU/dt Filter MCC 102 Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 39: Ie And Ies Classes

    IE1 = state of the art. • IE2 = above state of the art. Danfoss drives fulfill energy efficiency class IE2. The energy efficiency class is defined at the nominal point of the CDM. Power drive systems (PDS) Torque-producing current [%]...

  • Page 40: Losses And Efficiency Of A Motor

    The efficiency depends on the type of motor and the level of magnetization. For more information about motor types, refer to the motor technology brochure at www.danfoss.com. Search for motor technology. Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 41: Application Examples

    Full load & speed 1 VLT ® DriveMotor Start/stop 2 Star/delta starter Speed 3 Soft starter 4 Start directly on mains Start/stop [18] Illustration 4.2 Start/Stop and Running Speed Illustration 4.1 Start-up Current MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 42: Pulse Start/Stop

    For the AMA to determine the motor parameters optimally, enter the correct motor nameplate data in parameter 1-20 Motor Power to parameter 1-28 Motor Rotation Check. For induction motor, enter the correct motor Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 43: Fan Application With Resonance Vibrations

    The drive can give nominal grid voltage at nominal grid frequency. When the mains voltage occasionally drops below the correct motor voltage, for example at 43 Hz, overmodulation MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 44: Example Of Energy Savings

    4.2.4 Comparison of Energy Savings Volume % Illustration 4.6 Energy Savings at Reduced Fan Capacity The Danfoss drive solution offers major savings compared with traditional energy-saving solutions. This is because the drive is able to control fan speed according to thermal 4.2.3 Example of Energy Savings...

  • Page 45: Example With Varying Flow Over 1 Year

    Discharge dampers reduce power consumption somewhat. 1650rpm Inlet guide vans offer a 40% reduction but are expensive to install. The Danfoss drive solution reduces energy consumption with more than 50% and is easy to install. 1350rpm 4.2.5 Example with Varying Flow over 1...

  • Page 46: Control Examples

    SLC is designed to act from events sent to or generated in 13-52.3 State 3 the drive. The drive then performs the pre-programmed 13-51.2 13-52.2 action. Stop event P13-02 Illustration 4.11 Example with 3 Events/Actions Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 47: Slc Application Example

    2 s. mode. Set event 1 in parameter 13-51 SL Controller Event to [1] True. Set event 2 in parameter 13-51 SL Controller Event to [4] On Reference. MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 48: Ec+ Concept For Asynchronous And Pm Motors

    Advantages The flexibility of EC+ ensures that such reduction of system efficiency is avoided, and provides the system designer and the end user with the following benefits: Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 49: Type Code And Selection Guide

    The Drive Configurator automatically generates an 8-digit sales number to be delivered to the local sales office. Furthermore, it can produce a project list with several products and send it to a Danfoss sales representative. To access the Drive Configurator, go to: www.danfoss.com, and search for drive configurator.

  • Page 50: Ordering Numbers

    For full installation information including motor Enclosure size MH2 ® connection, refer to the VLT DriveMotor FCP 106 Operating Accessory bag, Accessory bag, 134B0446 Guide. Enclosure size MH3 Table 5.3 Ordering Numbers, Spare Parts Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 51: Specifications

    Table 6.2 Details for Motor Adapter Plate Screws Adapter plate Screw Maximum depth of hole into adapter plate Maximum height of screw above adapter plate Illustration 6.1 Screws to Fasten Motor Adapter Plate MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 52: Dimensions

    [kg (lb)] and motor adapter plate [kg (lb)] 3.9 (8.6) 0.7 (1.5) 4.6 (10.1) 5.8 (12.8) 1.12 (2.5) 6.92 (15.3) 8.1 (17.9) 1.48 (3.3) 9.58 (21.2) Table 6.4 Weight of FCP 106 Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 53: Electrical Data

    3) Applies to dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses may increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com and search for ecoSmart.
  • Page 54 3) Applies to dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses may increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com and search for ecoSmart.

  • Page 55: Mains Supply

    Minimum ambient temperature during full-scale operation -20 °C (-4 °F) Minimum ambient temperature at reduced performance 50 °C (122 °F) Maximum ambient temperature at reduced performance -25 to +65 °C (-13 to +149 °F) Temperature during storage MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 56: Cable Specifications

    Parameter 6-29 Terminal 54 mode: 1=voltage, 0=current Voltage level 0–10 V Input resistance, R Approximately 10 kΩ Maximum voltage 20 V Current level 0/4 to 20 mA (scalable) <500 Ω Input resistance, R Maximum current 29 mA Danfoss A/S © 12/2018 All rights reserved. MG03M302...
  • Page 57 Environment according to EN 60664-1 Overvoltage category III/pollution degree 2 1) IEC 60947 sections 4 and 5. Control Card, 10 V DC Output Terminal number 10.5 V ±0.5 V Output voltage Maximum load 25 mA MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 58: Fuse And Circuit Breaker Specifications

    Design fuses for protection in a circuit capable of supplying a maximum of 100000 A (symmetrical), 480 V maximum. See Table 6.7 and Table 6.8 for circuit breaker capacity for Danfoss CTI25M circuit breaker at 480 V maximum.

  • Page 59: Derating According To Ambient Temperature And Switching Frequency

    Illustration 6.4 400 V MH2 2.2–4.0 kW (3.0–5.0 hp) 110 % 100% [kHz] Illustration 6.3 400 V MH1 0.55–1.5 kW (0.75–2.0 hp) [kHz] Illustration 6.5 400 V MH3 5.5–7.5 kW (7.5–10 hp) MG03M302 Danfoss A/S © 12/2018 All rights reserved.

  • Page 60: Du/Dt

    25% load at 50% speed. The graph shows 0.97, whereas rated efficiency for a 22 kW (30 hp) drive is 0.98. The actual efficiency is then: 0.97 x 0.98 = 0.95. Danfoss A/S © 12/2018 All rights reserved. MG03M302...

  • Page 61: Index

    ETR......................33 Control card Example of energy savings............... 42 Control card 10 V DC output............55 Control card, 24 V DC output............55 Export control regulations..............7 Control card, RS485 serial communication......55 MG03M302 Danfoss A/S © 12/2018 All rights reserved.
  • Page 62 Relay terminal................... 53 supply 3x380–480 V AC normal and high overload.... 51 Reset..................... 5, 31 Memory module..................4 Reset alarm..................... 17 Memory module programmer............4 Modbus....................... 4 filter....................... 24 Modbus RTU................... 13 Danfoss A/S © 12/2018 All rights reserved. MG03M302...
  • Page 63 Low Voltage Directive (2014/35/EU)........... 5 UL 508C....................54 Star/delta starter................... 39 Static overload in VVC+ mode............33 Switching frequency..................25, 38 loss......................38 Switching on the input supply............53 Switching on the output..............32 Symbols...................... 4 MG03M302 Danfoss A/S © 12/2018 All rights reserved.
  • Page 64 Type code and selection guide............47 UL compliance..................56 Unintended start..................7 Variable control of flow and pressure........... 44 Varying flow over 1 year..............43 Vibration and shock................35 What is covered..................5 Windmilling....................8 Danfoss A/S © 12/2018 All rights reserved. MG03M302...
  • Page 65 Index Design Guide MG03M302 Danfoss A/S © 12/2018 All rights reserved.
  • Page 66 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products 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 trademarks in this material are property of the respective companies.

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