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Danfoss VLT DriveMotor FCM 106 Design Manual

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MAKING MODERN LIVING POSSIBLE
Design Guide
®
VLT
DriveMotor FCP 106 and FCM 106
www.danfoss.com/drives

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Summary of Contents for Danfoss VLT DriveMotor FCM 106

  • Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® DriveMotor FCP 106 and FCM 106 www.danfoss.com/drives...

  • Page 3: Table Of Contents

    ® Contents DriveMotor FCP 106 and FCM 106 Design Guide Contents 1 Introduction 1.1 Purpose of the Design Guide 1.2 Additional Resources 1.3 Symbols, Abbreviations and Conventions 1.4 Approvals 1.5 Software Version 1.6 Disposal Instructions 1.7 Safety 2 Product Overview 2.1 Introduction 2.1.1 Gasket 2.1.2 Key Diagram...
  • Page 4 ® Contents DriveMotor FCP 106 and FCM 106 Design Guide 3.3.6 Output shafts 3.3.7 FCM 106 Inertia 3.3.8 FCM 106 - Motor Frame Size 3.3.9 Motor Thermal Protection 3.3.9.1 Electronic Thermal Relay 3.3.9.2 Thermistor (FCP 106 only) 3.4 Frequency Converter/Options Selections 3.4.1 Remote Mounting Kit 3.4.2 Local Operation Pad 3.5 Special Conditions...
  • Page 5 ® Contents DriveMotor FCP 106 and FCM 106 Design Guide 4.3.3 Smart Logic Control Programming 4.3.4 SLC Application Example 4.4 EC+ Concept for Asynchronous and PM Motors 5 Type Code and Selection Guide 5.1 Drive Configurator 5.2 Type Code String 5.3 Ordering Numbers 6 Specifications 6.1 Clearances, Dimensions, and Weights...

  • Page 6: Introduction

    • ® DriveMotor FCP 106 and FCM 106 Design In no event shall Danfoss be liable for direct, indirect, Guide,provides information required for special, incidental, or consequential damages arising out of integration of the frequency converter into a the use, or the inability to use information contained in diversity of applications.

  • Page 7: Symbols, Abbreviations And Conventions

    Technical literature and approvals are available online at Electronic Thermal Relay www.danfoss.com/BusinessAreas/DrivesSolutions/Documen- Nominal Motor Frequency tations/Technical+Documentation. Frequency Converter High overload Danfoss VLT® Energy Box software is available at Ingress Protection www.danfoss.com/BusinessAreas/DrivesSolutions, PC software Current Limit download area. Rated Inverter Output Current 1.3 Symbols, Abbreviations and...

  • Page 8: Approvals

    Danfoss provides measures may be required. information on safety aspects relating to the frequency converter. Danfoss do this by means of a manufacturer's Certification FCP 106 FCM 106 declaration.

  • Page 9: Software Version

    • detailed safety instructions and warnings. Danfoss provides other types of assistance that can help to Strict adherence to safety precautions and notices is obtain the best EMC result. mandatory for safe operation of the frequency converter.

  • Page 10: Product Overview

    ® DriveMotor FCM 106 The frequency converter is mounted onto the motor upon The product overview applies to both FCP 106 and FCM delivery. The combined FCM 106 and motor from Danfoss 106. is known as the DriveMotor. ® DriveMotor FCP 106 The delivery comprises frequency converter only.

  • Page 11: Key Diagram

    Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide 2.1.2 Key Diagram SMPS GATE DRIVE RS485 0/4 - 20mA 0 - 10V Illustration 2.3 Key Diagram Power card Control card RFI filter MCP (Motor control processor) Rectifier ACP (Application control processor) Intermediate circuit / DC filter Control terminals Inverter...

  • Page 12: Electrical Overview

    Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide 2.1.3 Electrical Overview 3 Phase power input Motor Located in motor block Thermistor located in motor UDC- UDC+ 50 (+10V OUT) relay 2 +10Vdc 0-10Vdc- 53 (A IN) 240V AC 3A 0/4-20 mA 0-10Vdc- 54 (A IN)

  • Page 13: Control Terminals

    Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide 2.1.4 Control Terminals Control terminals BUS TER. 61 68 69 18 19 27 29 42 45 50 53 54 0/4-20mA A OUT / DIG OUT 0/4-20mA A OUT / DIG OUT 12 20 55 Illustration 2.7 Control Terminals Terminal...

  • Page 14: Control Structures

    Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide 2.2 Control Structures In parameter 1-00 Configuration Mode select whether open or closed loop control applies. 2.2.1 Control Structure Open Loop In the configuration shown in Illustration 2.8, 1-00 Configuration Mode is set to [0] Open loop. The resulting reference from the reference handling system or the local reference is received and fed through the ramp limitation and speed limitation before being sent to the motor control.

  • Page 15: Control Structure Closed Loop (Pi)

    Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide 2.2.2 Control Structure Closed Loop (PI) The internal controller allows the frequency converter to become an integral part of the controlled system. The frequency converter receives a feedback signal from a sensor in the system. It then compares this feedback to a set-point reference value and determines the difference, if any, between these 2 signals.

  • Page 16: Feedback And Reference Handling

    Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide 2.4 Feedback and Reference Handling 2.4.1 Reference Handling Details for Open Loop and Closed Loop operation. Intern resource P 4 - 12 Motor Relative scalling reference P 3-14 Preset relative Speed low reference limit (Hz)
  • Page 17 Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide Where X is the external reference, the preset reference or the sum of these and Y is 3-14 Preset Relative Reference in [%]. If Y, 3-14 Preset Relative Reference is set to 0%, the reference is not affected by the scaling.

  • Page 18: General Aspects Of Emc

    Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide 2.5 General Aspects of EMC Electrical interference is conducted at frequencies in the range 150 kHz to 30 MHz. Airborne interference from the frequency converter system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor. Capacitance in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents.

  • Page 19: Emc-Compliant Electrical Installation

    Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide 2.5.1 EMC-compliant Electrical Installation Control cables Motor Mains, 3-phase, and reinforced PE Frequency converter Cable insulation (stripped) Min. 200 mm clearance between control cable, mains cable, and mains motor cable. Illustration 2.14 EMC-compliant Electrical Installation, FCP 106 MG03M102 - 08/2015...
  • Page 20 Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide Control cables DriveMotor Mains, 3-phase, and reinforced PE Min. 200 mm clearance between control cable, mains Cable insulation (stripped) cable, and mains motor cable. Illustration 2.15 EMC-compliant Electrical Installation, FCM 106 MG03M102 - 08/2015...
  • Page 21 Product Overview ® DriveMotor FCP 106 and FCM 106 Design Guide To ensure EMC-compliant electrical installation, observe frequencies. Use the cable clamps provided these general points: instead. • Ensure the same potential between frequency • Use only screened motor cables and screened converter and ground potential of PLC.

  • Page 22: Leakage Current

    Relay 42kV/42 N.A. N.A. environment. All Danfoss frequency converters comply wires Ω with the requirements for the industrial environment and Enclosure N.A. N.A. 8 kV AD 10V/m N.A.

  • Page 23: Residual Current Device (Rcd) Protection

    PELV For installation at altitudes above 2000 m, contact supplies. Danfoss hotline regarding PELV. 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 400 V).

  • Page 24: System Integration

    Converter and Motor This chapter describes the considerations necessary to integrate the frequency converter into a system design. The Danfoss VLT frequency converter integrated onto the The chapter is divided into 4 sections: asynchronous or permanent magnet motor enables speed control in a single unit.

  • Page 25: Mains Input

    System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide Danfoss MCT 10 Start/stop Closed loop process control 2 Speed reference Combined fieldbus and traditional control signals Illustration 3.1 Example of Control Structures 3.2 Mains Input 3.2.1 Mains Supply Interference/Harmonics 3.2.1.1 General Aspects of Harmonics...

  • Page 26: Harmonics Emission Requirements

    PWHC current up to and including 16 A per phase. Four emission 5.5-7.5 kW, classes are defined: Class A through D. The Danfoss 380-480 V 35.9 39.2 frequency converters are in Class A. However, there are no...

  • Page 27: Motors

    System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide 3.3 Motors 3.3.1 Exploded Views The FCM 106 consists of the following parts: Illustration 3.3 FCM 106 with Asynchronous Motor, B3 Exploded View Item Description Item Description Frequency converter cover Foot fixing bolt Frequency converter enclosure Stator frame...
  • Page 28 System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide Illustration 3.4 FCM 106 with PM Motor, B5 Exploded View Item Description Item Description Frequency converter cover Fixing bolt endshield drive end Frequency converter enclosure Shaft key Motor connector Rotor Motor connector gasket Snap ring...

  • Page 29: Lifting

    System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide • 3.3.2 Lifting when using an eyebolt, that the shoulder of the eyebolt is tightened firmly against the face of the NOTICE stator frame, before lifting. LIFTING - EQUIPMENT DAMAGE RISK Eyebolts or lifting trunnions supplied with the unit are Incorrect lifting can result in equipment damage.

  • Page 30: Balance

    System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide 3.3.5 Balance 3.3.9 Motor Thermal Protection The FCM 106 is balanced to class R according to ISO8821 Motor protection can be implemented using a range of (reduced balance). For critical applications especially at techniques: Electronic Thermal Relay (ETR);...

  • Page 31: Thermistor (Fcp 106 Only)

    System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide NOTICE 3.3.9.2 Thermistor (FCP 106 only) If the thermistor is not galvanically isolated, then The thermistor is positioned between motor windings. The interchanging the thermistor wires with the motor wires connection for the thermistor is placed in the motor plug: may permanently damage the frequency converter.

  • Page 32: Local Operation Pad

    System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide 3.4.2 Local Operation Pad 62.5 + _ 0.2 Status Quick Main Menu Menu Menu Com. Warn. Alarm Hand Auto Reset Illustration 3.11 LOP Connections Illustration 3.9 Remote Mounting Kit Connector Dual speed Dual mode Dual direction...

  • Page 33: Special Conditions

    Reduce the max. ambient temperature * indicates factory setting by 1 °C per 200m altitude. • Above 2000 m altitude, contact Danfoss Alarms are reset at every start. To avoid this reset, either regarding PELV. • leave the brown wire unconnected, or An alternative is to lower the ambient temperature at high •...

  • Page 34: Extreme Running Conditions

    System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide • 3.5.5 Extreme Running Conditions 2-10 Brake Function and • 2-17 Over-voltage Control Short Circuit (Motor Phase – Phase) The frequency converter is protected against short circuits NOTICE by current measurement in each of the 3 motor phases or OVC cannot be activated when running a PM motor (that in the DC link.

  • Page 35: Cooling

    System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide 3.6.4 Aggressive Environments and maximizes overall system reliability. Follow the recommendations listed for maximum performance and equipment longevity. A frequency converter contains many mechanical and electronic components. All are to some extent vulnerable •...

  • Page 36: Acoustic Noise

    System Integration ® DriveMotor FCP 106 and FCM 106 Design Guide 3.6.6 Acoustic Noise 3.6.7 Vibration and Shock FCP 106 The frequency converter complies with requirements that Acoustic noise originates from the sources: exist for units mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors.

  • Page 37: Application Examples

    Application Examples ® DriveMotor FCP 106 and FCM 106 Design Guide 4 Application Examples 4.1.2 Start/Stop 4.1 HVAC Application Examples 4.1.1 Star/Delta Starter or Soft-starter not Terminal 18 = start/stop 5-10 Terminal 18 Digital Input [8] Required Start Terminal 27 = No operation 5-12 Terminal 27 Digital Input When larger motors are started, it is necessary in many [0] No operation (Default coast inverse) countries to use equipment that limits the start-up current.

  • Page 38: Pulse Start/Stop

    Application Examples ® DriveMotor FCP 106 and FCM 106 Design Guide 4.1.3 Pulse Start/Stop 4.1.4 Potentiometer Reference Terminal 18 = start/stop 5-10 Terminal 18 Digital Input [9] Voltage reference via a potentiometer. Latched start Terminal 27= Stop 5-12 Terminal 27 Digital Input [6] Stop 3-15 Reference 1 Source [1] = Analog Input 53 inverse 6-10 Terminal 53 Low Voltage = 0 V...

  • Page 39: Automatic Motor Adaptation (Ama)

    Application Examples ® DriveMotor FCP 106 and FCM 106 Design Guide 4.1.5 Automatic Motor Adaptation (AMA) 4.1.6 Fan Application with Resonance Vibrations AMA is an algorithm to measure the electrical motor parameters on a motor at standstill. This means that AMA In the following applications resonant vibrations can arise, itself does not supply any torque.

  • Page 40: Energy Saving Examples

    Application Examples ® DriveMotor FCP 106 and FCM 106 Design Guide the width of the resonance peak. In most situations, it is possible to hear the resonance. SYSTEM CURVE 4.2 Energy Saving Examples 4.2.1 Why use a Frequency Converter for FAN CURVE Controlling Fans and Pumps? A frequency converter takes advantage of the fact that...

  • Page 41: Example Of Energy Savings

    Discharge dampers reduce power consumption somewhat. Pressure : Inlet Guide Vans offer a 40% reduction but are expensive Power : to install. The Danfoss frequency converter solution reduces energy consumption with more than 50% and is Q=Flow P=Power easy to install.

  • Page 42: Control Examples

    Application Examples ® DriveMotor FCP 106 and FCM 106 Design Guide 4.3 Control Examples Energy savings shaft shaft output 4.3.1 Better Control When a frequency converter is used for controlling the flow or pressure of a system, improved control is obtained. A frequency converter can vary the speed of the fan or pump, obtaining variable control of flow and pressure.

  • Page 43: Slc Application Example

    Application Examples ® DriveMotor FCP 106 and FCM 106 Design Guide Start event P13-01 State 1 13-51.0 13-52.0 State 2 13-51.1 Stop 13-52.1 event P13-02 Stop event P13-02 State 4 13-51.3 13-52.3 State 3 13-51.2 13-52.2 Stop event P13-02 Illustration 4.11 Example with 3 Events/Actions 4.3.4 SLC Application Example Max.

  • Page 44: Ec+ Concept For Asynchronous And Pm Motors

    The flexibility of EC+ ensures that such reduction of system Programming of both FCP 106 and FCM 106 is identical to efficiency is avoided, and provides the system designer programming of all other Danfoss frequency converters. and the end user with the following benefits: MG03M102 - 08/2015...

  • Page 45: Type Code And Selection Guide

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

  • Page 46: Type Code String

    Type Code and Selection Gui... ® DriveMotor FCP 106 and FCM 106 Design Guide 5.2 Type Code String Example of Drive Configurator interface setup: The numbers shown in the boxes refer to the letter/figure number of the Type Code String - read from left to right. Product Name Position...
  • Page 47 Type Code and Selection Gui... ® DriveMotor FCP 106 and FCM 106 Design Guide 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Illustration 5.1 Type Code String Example 5.2.1 Motor Frame Sizes and Flanges...

  • Page 48: Ordering Numbers

    ) [AWG 20-17] For ordering numbers and ordering in general, refer to • 927833 (1.5-2.5 mm ) [AWG 15.5-13.5] • VLT Shop at http://vltshop.danfoss.com. • 927824 (2.5-4 mm ) [AWG 13-11] • Drive Configurator at www.danfoss.com/drives. For full installation information including motor ®...

  • Page 49: Specifications

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide 6 Specifications 6.1 Clearances, Dimensions, and Weights 6.1.1 Clearances Observe the minimum clearances listed in Table 6.1 to ensure sufficient air flow for the frequency converter. When air flow is obstructed close to the frequency converter, ensure adequate inlet of cool air and exhaust of hot air from the unit.

  • Page 50: Motor Frame Size Corresponding To Fcp 106 Enclosure

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide 6.1.2 Motor Frame Size Corresponding to FCP 106 Enclosure PM motor Asynchronous motor FCP 106 Power 1500 RPM 3000 RPM 3000 RPM 1500 RPM Enclosure [kW] N.A. N.A. N.A. 0.55 0.75 Table 6.3 Motor Frame Size Corresponding to FCP 106 Enclosure 6.1.3 FCP 106 Dimensions...

  • Page 51: Fcm 106 Dimensions

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide 6.1.4 FCM 106 Dimensions Motor 100L 100L 112M 132S 132M 160M 160L 180M 180L frame size A [mm] B [mm] C [mm] H [mm] K [mm] 12.5 AA [mm] 34.5 AB [mm] BB [mm] BC [mm]...
  • Page 52 Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide Motor 100L 112M 132S 160M 180M frame size M [mm] N [mm] P [mm] S [mm] T [mm] LA [mm] HA [mm] HA = H + (height of the frequency converter) For frequency converter dimensions, see Table 6.4.
  • Page 53 Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide Small flange B14 Motor 100L 112M 132S 160M/L 180M frame size M [mm] N [mm] P [mm] S [mm] T [mm] LA [MM] Large flange B14 Motor 100L 112M 132S 160M/L 180M frame size...

  • Page 54: Weight

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide M6 DIN 332-DH FCM 106 with Asynchronous or PM motor Motor 100L 112M 132S 160M/L 180M frame size D [mm] F [mm] G [mm] 15.5 42.5 Table 6.8 FCM 106 Dimensions: Shaft Drive End - Asynchronous or PM Motor 6.1.5 Weight Weight FCP 106...

  • Page 55: Electrical Data

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide 6.2 Electrical Data Enclosure PK55 PK75 P1K1 P1K5 P2K2 P3K0 P4K0 P5K5 Overload Typical shaft 0.55 0.75 output [kW] Typical shaft 0.75 output [hp] Max. cable cross- section in terminals 4/10 4/10 4/10...
  • Page 56 Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide Enclosure P5K5 P7K5 Overload Typical shaft output [kW] Typical shaft output [hp] Max. cable cross-section in terminals 4/10 4/10 (mains, motor) /AWG] Output current 40 °C ambient temperature Continuous 15.5 (3x380-440 V) [A] Intermittent 13.2...

  • Page 57: Mains Supply

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide 6.3 Mains Supply Mains supply (L1, L2, L3) 380-480 V ±10% Supply voltage Mains voltage low/mains drop-out: • During low mains voltage or a mains drop-out, the frequency converter continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the lowest rated supply voltage of the frequency converter.

  • Page 58: Cable Specifications

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide Maximum altitude above sea level without derating 1000 m Maximum altitude above sea level with derating 3000 m Safety standards EN/IEC 60204-1, EN/IEC 61800-5-1, UL 508C EMC standards, Emission EN61000-3-2, EN61000-3-12, EN55011, EN61000-6-4 EMC standards, Immunity EN61800-3, EN61000-6-1/2 6.6 Cable Specifications...
  • Page 59 Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide Analog output Number of programmable analog outputs Terminal number 42, 45 Current range at analog output 0/4-20 mA 500 Ω Max. load to common at analog output Max. voltage at analog output 17 V Accuracy on analog output Max.

  • Page 60: Fcm Motor Specifications

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide 6.8 FCM Motor Specifications Motor output (U, V, W) Output voltage 0-100% of supply voltage plus Output frequency, asynchronous motor 0-200 Hz (VVC ), 0-400 Hz (u/f) Output frequency, PM motor 0-390 Hz (VVC plus Switching on output...
  • Page 61 Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide Circuit Breaker Fuse Rec. Rec. Max. Maximum UL Power non-UL non-UL [kW] Enclosure Rec. Max. Type type Rec. UL Max. UL non- non- RK5, 380-480 RK1, J, T, CTI25 CTI25 CTI25M - CTI25M - 0.55...

  • Page 62: Derating According To Ambient Temperature And Switching Frequency

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide 6.10 Derating According to Ambient Temperature and Switching Frequency The ambient temperature measured over 24 hours should be at least 5 C lower than the max. ambient temperature. If the frequency converter is operated at high ambient temperature, the continuous output current should be decreased.

  • Page 63: Du/Dt

    Specifications ® DriveMotor FCP 106 and FCM 106 Design Guide 6.11 dU/dt Shaft output power Cable length AC line voltage Rise time dU/dt peak [kW] [µs] [kV] [kV/µs] 0.55 0.57 0.75 0.57 0.57 0.57 <0.5 <0.5 <0.5 <0.5 <0.5 Table 6.14 dU/dt, MH1-MH3 Example: Assume a 22 kW, 380-480V AC frequency a) Data available upon future release converter runs at 25% load at 50% speed.

  • Page 64: Index

    ® Index DriveMotor FCP 106 and FCM 106 Design Guide Index Derating for Low Air Pressure............31 DeviceNet....................4 Abbreviations..................5 Digital Acoustic inputs....................56 Noise..................... 34 output....................57 noise levels..................34 Dimensions Aggressive Environments..............33 Dimensions..............49, 50, 51, 52 Air Humidity..................
  • Page 65 ® Index DriveMotor FCP 106 and FCM 106 Design Guide LCP......................13 Smart Logic Control..................40 Leakage Current.................. 20 Logic Control Programming............40 Lifting....................... 27 Soft-starter..................... 35 Local (Hand On) and Remote (Auto On) Control....13 Software Version..................7 Lubrication..................... 27 Star/Delta Starter................
  • 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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