Danfoss FCM 300 Design guide

MAKING MODERN LIVING POSSIBLE

Design Guide

FCM 300

ATB Motors

VLT® FCM Series

Contents

Introduction	4
Software version	4
Safety regulations	5
Warning against unintended start	5
Introduction	6
Integration of frequency converter and motor	7
Ordering form	8
Product range	9
Ordering	10
PC Software tools	10
Ordering info for Frames and Flanges	11
Ordering info for inverter box position and drain hole position	11
Installation	12
FCM 305-375 for 3 phases, 380-480 V	12
General technical data	12
Tightening Torques	16
Maximum Cable Cross Section	16
Screw Sizes	16
Protection:	16
Description of the motor	17
Handling the FC motor	18
Bearings	18
Output shafts	19
Dimensions	19
Installation of the FC motor	22
Alignment	22
Bolt torques	23
Maintenance	23
Forced ventilation (FV) units	23
Voltage range for forced ventilation (FV) unit	24
FCM 300 Thermal Protection	24
Service plug kit (175N2546)	25
Plug kit (175N2545)	25
Remote mounting kit (175N0160)	25
Potentiometer option (177N0011)	26
Local Operation Pad (LOP) (175N0128) IP65	26
Programming	28
Control panel (175NO131)	28
LCP installation	28
LCP functions	28
Display	28
LEDs	29
Control keys	29
Control key functions	29
Display read-out state	30

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1

VLT® FCM Series
Display mode	30
Display mode - selection of read-out state	30
Quick menu mode versus Menu mode	31
Quick Setup via Quick menu	31
Parameter selection	31
Menu mode	32
Parameter groups	32
Changing data	32
Changing a text value	32
Infinitely variable change of numeric data value	32
Menu structure	33
Parameter Group 0-** Operation/Display	34
Parameter Group 1-** Load/Motor	40
Serial bus	68
Telegram communication	68
Telegram build-up	68
Databytes	69
Control word according to Fieldbus Profile Standard	71
Parameter Group 5-** Serial Communication	77
Parameter Group 6-** Technical Functions	84
All about FCM 300	88
Galvanic isolation (PELV)	88
Earth leakage current	88
Extreme running conditions	88
Acoustic noise	89
Balance	89
Thermal Protection and Derating	89
Derating for ambient temperature	89
Derating for air pressure	90
Derating for running at low speed	90
Derating for high switching frequency	90
Vibration and shock	91
Air humidity	91
UL standard	91
Efficiency	91
Mains supply interference/harmonics	91
Power factor	92
What is CE labelling?	92
The machinery directive(98/37/EEC)	92
The low-voltage directive (73/23/EEC)	92
The EMC directive(89/336/EEC)	92
What is covered?	92
Danfoss FCM 300 Series motor and CE labelling	92
Compliance with EMC directive 89/336/EEC	93
EMC standards	93
Aggressive environments	94
List of warnings and alarms	95
What if the motor does not start?	95

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VLT® FCM Series
Warnings	96
Warning word, extended Status word and Alarm word	97
List of parameters	99
Index	104

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3

VLT® FCM Series

FCM 300 Series

Design Guide

Software version: 3.1x

This Design Guide can be used for all FCM 300 Series frequency converters with software version 3.1x. The software version number can be seen from parameter 624 Software version no.

Disposal Instruction

Equipment containing electrical components may not be disposed of together with domestic waste. It must be separately collected with electrical and electronic waste according to local and currently valid legislation.

When reading through this Design Guide, you will come across various symbols that require special attention.

The symbols used are the following:

This symbol indicates a general warning.

NB!

This symbol indicates something to be noted by the reader.

This symbol indicates a high-voltage warning.

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VLT® FCM Series

All operations must be carried out by appropriately trained personel.

Use all lifting facilities provided e.g. both lifting points if fitted or single lifting point if fitted*.

Vertical lifting - Prevent uncontrolled rotation.

Lift machine - Do not lift other equipment with motor lifting points only.

Before installation check for fan cover damage, shaft damage, foot/mounting damage, and loose fasteners. Check nameplate details.

Ensure level mounting surface, balanced mounting, not misaligned.

Gaskets, and/or sealants, and guards must be correctly fitted.

Correct belt tension.

Please observe derating rules, see "Special conditions".

*Note: maximum hand lift is 20 kg below shoulder, but above ground level. Max. gross weights:

-Frame size 80: 15 kg

-Frame size 90 & 100: 30 kg

-Frame size 112: 45 kg

-Frame size 132: 80 kg

The voltage on the FC motor is dangerous when the motor is connected to mains. Incorrect installation of the FC motor may lead to material damage or serious injury, or it may be fatal.

Consequently, the instructions in this manual as well as national and local rules and safety regulations must be complied with.

Touching the electrical parts may be fatal, even after the mains supply has been disconnected. Wait at least 4 minutes.

-Installation must be fused and isolated correctly.

-Covers and cable entries must be fitted.

By altitudes above 2 km, please contact Danfoss Drives regarding PELV.

NB!

It is the user's or certified electrician's responsibility to ensure correct earthing and protection in accordance with applicable national and local requirements and standards.

Safety regulations

1.The VLT DriveMotor (FC motor) must be disconnected from mains if repair work is to be carried out.

Check that the mains supply has been disconnected and that the necessary time has passed (4 minutes).

2.Correct protective earthing of the equipment must be established, the user must be protected against supply voltage, and the motor must be protected against overload in accordance with applicable national and local regulations.

Use of RCD's (ELCB relays) is described in chapter 10.

3.The earth leakage currents are higher than 3.5 mA. This means that the FC motor requires a fixed, permanent installation as well as reinforced protective earthing.

Warning against unintended start

1.The motor can be brought to a stop by means of digital commands, bus commands, or references, while the frequency converter is connected to mains.

If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not sufficient .

2.While parameters are being changed, the motor may start.

3.A motor that has been stopped may start if faults occur in the electronics of the FC motor, or if a temporary overload or a fault in the mains supply ceases.

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5

	VLT® FCM Series
Introduction	Specific technical publications on the FCM 300 series:
Design Guide:	Gives all required information for design purposes, and gives a good insight
	into the product concept, product range, technical data, control, program-
	ming, etc.
Quick Setup:	Helps the users to quickly get their FCM 300 Series motor unit installed and
	running.
	The Quick Setup is always delivered with the unit.

If you have any questions concerning FCM 300 Series, please call us. We have drive specialists all over the world ready to advise you on applications, programming, training and service.

							All
	Promotion										Misc.
							users

Available literature

The chart below gives an overview of the literature available for the FCM 300 Series.

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Design

Brochure

Quick Setup

MCT 10 Setup

PROFIBUS-

Data sheet

MB.03.CX.YY

MG.03.FX.YY

Guide

Software Manual

Manual

MD.03.AX.YY

MG.03.HX.YY

MG.10.RX.YY

MG.03.EX.YY

	Articles									X =	version number
	MZ.03.AX.YY									YY =	language

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VLT® FCM Series

Integration of frequency converter and motor

The Danfoss VLT frequency converter integrated onto the asynchronous motor gives infinite speed control in one unit.

The VLT DriveMotor FCM 300 Series is a very compact alternative to the ordinary solution with VLT frequency converter and motor as separate units. The frequency converter is attached instead of the motor terminal box, and it is no higher than the standard terminal box, nor wider or longer than the motor (see chapter 6).

Installation is made extremely easy. Panel space is not a problem. There is no need for special details on wiring to meet the EMC directive, since motor cables are not necessary. The only connections are mains and control connections.

Control structures

Factory-set adaption between frequency converter and motor gives precise and energy efficient control in addition to eliminating pre-setting on site.

The FC motor can be used in stand alone SYSTEMs with traditional control signals, such as start/stop signals, speed references and closed loop process control or in multiple drive SYSTEMs with control signals distributed by a field bus.

Combination of fieldbus and traditional control signals and closed loop PID control is possible.

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VLT® FCM Series

Ordering form

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VLT® FCM Series

Product range

VLT DriveMotor FCM 300 Series, 2/4 poled motors

Type	Motor output	Mains supply
FCM 305	0.55 kW
FCM 307	0.75 kW
FCM 311	1.1 kW
FCM 315	1.5 kW
FCM 322	2.2 kW	3 phase 380-480 V
FCM 330	3.0 kW
FCM 340	4.0 kW
FCM 355	5.5 kW
FCM 375	7.5 kW

Each type in the product range is available in different versions:

Inverter versions

Power size:

(See power size table) Application

•P: Process

•S: Sensorless (special pump OEM) Mains voltage:

•T4: 380-480 V three phase supply Enclosure

•C55: IP55

•C65: IP65

•C66: IP66

Hardware variant:

•ST: Standard

RFI filter

•R1: Compliance with class 1A

•R2: Compliance with class 1B Display connector

•D0: No display plug able connector

Fieldbus

•F00: No fieldbus

•F10: Profibus DPV1 3 MB

•F12: Profibus DPV1 12 MB

Motor thermistor

•X: No motor thermistor Number of poles

•2: 2 pole motor

•4: 4 pole motor

Motor data

•00: ATB motor Motor mounting option

•B03: Foot mounting

•B05: B5 flange

•B14: B14 face

•B34: Foot and B14 face

•B35: Foot and B5 flange

Motor flange code

(Regarding standard flange size and available flange sizes, see table, IEC-FFxxx, Dimension M).

•000: Foot mounting only

•085: 85 mm

•100: 100 mm

•115: 115 mm

•130: 130 mm

•165: 165 mm

•215: 215 mm

•265: 265 mm

•300: 300 mm

Motor cooling method

•1: Shaft mounted fan

•2: Forced ventilation

Motor drain hole position (see drawing)

•D0: No drain hole

•D1: Opposite inverter box both ends (drive/ non drive)

•D2: 90 (deg) inverter box right

•D3: 90 (deg) inverter box left

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VLT® FCM Series

Ordering

Take a copy of the ordering form, see section Ordering form. Fill in and post or fax your order to the nearest branch office of the Danfoss sales organisation. On the basis of your order, the FCM 300 Series motor is given a type code.

The ordering form for the basic unit must always be completed. When the type code is written, always state the characters of the basic string (1-34). Together with the order confirmation the customer receives an 8-fig- ure code number to be used when reordering.

Danfoss PC software for serial communication, MCT 10

All FCM 300 Series units have an RS 485 port as standard, which enables them to communicate e.g. with a PC. A programme entitled MCT 10 is available for this purpose (see section PC Software tools).

Ordering numbers, MCT 10

Please order your CD containing MCT 10 Set-up Software using code number 130B1000.

Accessories for the FC motor

A Local Operation Pad (LOP) for local set point and start/stop is available for the FC motor. The LOP is IP 65 enclosed. A Local Control Panel (LCP 2) which makes up a complete interface for operation, programming and monitoring of the FC motor is also available.

Ordering numbers, accessories

Local Operation Pad incl. cable(LOP)	175N0128
Local Control Panel (LCP 2)	175N0131
Remote mounting kit (LCP 2)	175N0160
Plug kit (LCP 2)	175N2545
Cable for plug kit (LCP 2)	175N0162
Cable (direct mounting) (LCP 2)	175N0165
Service plug kit (LCP 2)	175N2546
Potentiometer option	177N0011

PC Software tools

PC Software - MCT 10

All drives are equipped with a serial communication port. We provide a PC tool for communication between PC and frequency converter, VLT Motion Control Tool MCT 10 Set-up Software.

MCT 10 Set-up Software

MCT 10 has been designed as an easy to use interactive tool for setting parameters in our frequency converters.

The MCT 10 Set-up Software will be useful for:

•Planning a communication network off-line. MCT 10 contains a complete frequency converter database

•Commissioning frequency converters on line

•Saving settings for all frequency converters

•Replacing a drive in a network

•Expanding an existing network

•Future developed drives will be supported

The MCT 10 Set-up Software Modules

The following modules are included in the software package:

MCT 10 Set-up Software

Setting parameters

Copy to and from frequency converters Documentation and print out of parameter settings incl. diagrams

SyncPos

Creating SyncPos programme

Ordering number:

Please order your CD containing MCT 10 Set-up Software using code number 130B1000.

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VLT® FCM Series

Ordering info for Frames and Flanges

Frame sizes and the corresponding flange sizes for different mounting versions

	Type	Motor frame size	Mounting version	Flange code, standard Flange code, alterna-
				(S) [mm]	tives*[mm]
	FCM 305	80	B5/B35	165	100/115/130/215
			B14/B34	100	85/115/130
	FCM 307	80	B5/B35	165	100/115/130/215
			B14/B34	100	85/115/130
	FCM 311	90	B5/B35	165	130/215
			B14/B34	115	100/130
	FCM 315	90	B5/B35	165	130/215
			B14/B34	115	100/130
	FCM 322	100	B5/B35	215	165/265
			B14/B34	130	115/165
	FCM 330	100	B5/B35	215	165/265
			B14/B34	130	115/165
	FCM 340	112	B5/B35	215	165/265
			B14/B34	130	165
	FCM 355	132	B5/B35	265	215/300
			B14/B34	165	130
	FCM 375	132	B5/B35	265	215/300
			B14/B34	165	130

Flange size according to IEC ref. FFxxx (Dimension M), see section Dimensions S: Available as standard shaft

* No changes regarding shaft dimensions

Ordering info for inverter box position and drain hole position

Inverter box position, always top mounted.

All drain holes are mounted with screw and washer, IP 66 if not opened.

D1: Drain holes opposite inverter side, both drive end and non drive end.

D2/D3: Drain holes 90° to inverter, both drive end and non drive end.

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							VLT® FCM Series
FCM 305-375 for 3 phases, 380-480 V
FCM		305	307	311	315	322	330	340	355	375
Motor output
[HP]		0.75	1.0	1.5	2.0	3.0	4.0	5.0	7.5	10.0
[kW]		0.55	0.75	1.1	1.5	2.2	3.0	4.0	5.5	7.5
Motor torque
2 pole [Nm]1)		1.8	2.4	3.5	4.8	7.0	9.5	12.6	17.5	24.0
4 pole [Nm]2)		3.5	4.8	7.0	9.6	14.0	19.1	25.4	35.0	48.0
Frame
size [mm]		80	80	90	90	100	100	112	132	132
Weight [kg]		11	13	17	20	26	28	37	56	61
Input	current
[A]
380 V
2 p		1.5	1.8	2.3	3.4	4.5	5.0	8.0	12.0	15.0
4 p		1.4	1.7	2.5	3.3	4.7	6.4	8.0	11.0	15.5
480 V
2 p		1.2	1.4	1.8	2.7	3.6	4.0	6.3	9.5	11.9
4 p		1.1	1.3	2.0	2.6	3.7	5.1	6.3	8.7	12.3
Efficiency at
nom. speed
(4 pole) %		66	71	74	80	80	81	80	84	84
Efficiency at
nom. speed
(2 pole) %		61	64	76	75	76	85	82	83	91
Power	termi-
nals
[AWG]		10	10	10	10	10	10	10	6	6
[mm2]		4	4	4	4	4	4	4	10	10
Gland sizes		3xM20x1.5	3xM20x1.5	3xM20x1.5	3xM20x1.5	3xM20x1.5	3xM20x1.5	3xM20x1.5	1xM25x1.5	1xM25x1.5/
									/	2xM20x1.5
									2xM20x1.5
Max. prefuse
UL3) [A]		10	10	10	10	10	15	15	25	25
IEC3) [A]		25	25	25	25	25	25	25	25	25

1)At 400 V 3000 r/min

2)At 400 V 1500 r/min

3)Type gG prefuses must be used. If you want to maintain UL/cUL you must use prefuses of the type Bussmann KTS-R 500 V or Ferraz Shawmut, ATMR Class C (max. 30A). The fuses must be placed for protection in a circuit that is capable of supplying a maximum of 100,000 amps RMS (symmetrical), 500 V maximum.

General technical data

Mains supply, TT, TN and IT* (L1, L2, L3):

- Supply voltage 380-480 V units	3 x 380/400/415/440/460/480 V ±10%
- Supply frequency	50/60 Hz
- Max. imbalance of supply voltage	±2% of rated supply voltage
- Power factor / cos	max. 0.9/1.0 at rated load
- No. of switching operations on supply input L1, L2, L3	approx. 1 time/2 min
*) Not valid for RFI class 1B units
Torque characteristics:
- Starting torque/overload torque	160 % for 1 min
- Continuous torque	see above
Control card, digital/pulse inputs:
- Number of programmable digital inputs	4
- Terminal nos.	X101-2, -3, -4, -5
- Voltage level	0-24 V DC (PNP positive logics)
- Voltage level, logic 0	< 5 V DC
- Voltage level, logic 1	> 10 V DC
- Maximum voltage on input	28 V DC
- Input resistance, Ri	approx. 2 kΩ
- Scanning time	20 msec

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	VLT® FCM Series
Control card, pulse input:
- No. of programmable pulse inputs	1
- Terminal nos.	X101-3
- Max. frequency on terminal 3, open collector/push pull 24 V	8 kHz/70 kHz
- Resolution	10 bit
- Accuracy (0.1-1 kHz), terminal 3	Max. error: 0.5% of full scale
- Accuracy (1-12 kHz), terminal 3	Max. error: 0.1% of full scale
Control card, analogue inputs:
- No. of programmable analogue voltage inputs	1
- Terminal nos.	X101-2
- Voltage level	0 - 10 V DC (scalable)
- Input resistance, Ri	approx. 10 kΩ
- No. of programmable analogue current inputs	1
- Terminal no.	X101-1
- Current range	0 - 20 mA (scalable)
- Input resistance, Ri	approx. 300 Ω
- Resolution	9 bit
- Accuracy on input	Max. error 1% of full scale
- Scanning time	20 msec.
Control card, digital/pulse and analogue outputs:
- No. of programmable digital and analogue outputs	1
- Terminal nos.	X101-9
- Voltage level at digital output/load	0 - 24 V DC/25 mA
- Current at analoque output	0 - 20 mA
- Maximum load to frame (terminal 8) at analogue output	RLOAD 500 Ω
- Accuracy of analogue output	Max. error: 1.5% of full scale
- Resolution on analogue output.	8 bit
Relay output:
- No. of programmable relay outputs	1
- Terminal number (resistive and inductive load)	1-3 (break), 1-2 (make)
- Max. terminal load (AC1) on 1-3, 1-2	250 V AC, 2A, 500 VA
- Max. terminal load (DC1) (IEC 947) on 1-3, 1-2	25 V DC, 3A / 50 V DC, 1.5 A , 75 W
- Min. terminal load (AC/DC) on 1-3, 1-2 control card	24 V DC, 10 mA/ 24 V AC, 100 mA

Rated values for up to 300,000 operations (at inductive loads the number of operations is reduced by 50%)

Control card, RS 485 serial communication:

- Terminal nos.			X100-1, -2
Control characteristics (frequency converter):
			0 - 132 Hz
- Frequency range	Please see special conditions for frequency range for IP 66 motors at the end of this section.
- Resolution on output frequency			0.1 %
- System response time			Max. 40 msec.
- Speed accuracy (open loop, CT mode, 4 P motor driven in speed range 150-1500 rPm)			+/- 15 rpm
Externals:
			IP 55 (IP65, IP66)
- Enclosure	Please see special conditions for frequency range for IP 66 motors at the end of this section.
- Vibration test			1 g
- Max. relative humidity		95 % for storage/transport/operation
- Ambient temperature		Max. 40°C (24-hour average max. 35°C)

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13

		VLT® FCM Series
see Derating for high ambient temperature
- Min. ambient temperature in full operation		0°C
- Min. ambient temperature at reduced performance		-10°C
- Temperature during storage/transport		-25 - +65/70°C
- Max. altitude above sea level		1000 m
see Derating for air pressure
- EMC standards applied, Emission	EN 61000-6-3/EN 6100-6-4, EN 61800-3, EN 55011, EN 55014
EN 61000-6-2, EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5,
- EMC standards applied, Immunity		EN 61000-4-6, ENV 50204
- Safety standards applied,		EN 60146, EN 50178, EN 60204, UL508

NB!

Please note that the normal IP 66 solution is only intended for speed up to maximum 3000 rpm. If higher speed is needed, please give notification when ordering.

Key diagram for FCM 300 Series

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		VLT® FCM Series
X101: Terminal block for analogue/digital control signals
Terminal No.	Function	Example
1	Analogue input (0-20 mA)	Feedback signal
2	Analogue (0-10 V)/digital input 2	Speed reference
3	Digital input (or pulse) 3	Reset
4	Digital input (or precise stop) 4	Start
5	Digital input (other) 5	Jog (fixed speed)
6	24 V DC supply for digital inputs (max. 150 mA)
7	10 V DC supply for potentiometer (max. 15 mA)
8	0 V for terminals 1-7 and 9
9	Analogue (0-20 mA)/digital output	Fault indication
Connection diagram - factory setting
		- Reset to be closed short time for resetting fault trips
		- Start to be closed for changing to run mode
		- Jog will run at fixed speed while closed (10 Hz)
		- Speed reference (0-10 V) determines speed while in
		run mode

X102: Terminal block for relay output

Terminal No.	Function
1-2	Make (normally open)
1-3	Brake (normally closed)

See parameter 323 (relay output) for programming of relay output.

X100: Terminal block for data communication

Terminal No.	Function
1	P RS 485	for connection to
		bus or PC
2	N RS 485
3	5 V DC	Supply for RS
4	0 V DC	485 bus

LED 300-304

LED 300 (red): Fault trip

LED 301 (yellow): Warning

LED 302 (green): Power on

LED 303-304: Communication

For PROFIBUS versions please refer to the manual MG.90.AX.YY.

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15

				VLT® FCM Series
Tightening Torques
Cover (lid) screws:			25.6 - 31lb-in (3 - 3.5 Nm)
Plastic cable entrance plugs:			19.5 lb-in (2.2 Nm)
L1, L2, L3 (AC Line) screws (FCM 305-340):			5 - 7 lb-in (0.5 - 0.6 Nm)
L1, L2, L3 (AC Line) screws (FCM 355-375):			15 lb-in (1.2 - 1.5 Nm)
Earth Ground:			30.1 lb-in (3.4 Nm)
Terminal screws require a max 2.5 mm flat-blade
screwdriver.
AC Line screws require a 8mm flat-blade screwdriver.
Lid screws , earth ground and cable clamp screws all
require T-20 Torx or flat-blade screwdriver (max. tight-
ening speed 300 RPM).
Maximum Cable Cross Section
Note:
Use °60 C copper wire or better
		AWG		mm2
Max size AC Line cable (FCM 305-340):		10		4.0
Max size AC Line cable (FCM 355-375):		6		10
Max size control cable:		16		1.5
Max size serial communication cable:		16		1.5
Earth Ground:		6		10
Screw Sizes
Cover (lid) screws:				M5
Earth Ground and Cable Clamp screws (FCM 305-340):				M4
Earth Ground and Cable Clamp screws (FCM 355-375):				M5
Protection:				mediate circuit voltage gets too high or too
•	Thermal overload protection of motor and			low.
	electronics.		•	If a mains phase is missing, the inverter will
•	Monitoring of the intermediate circuit voltage			cut out when a load is placed on the motor.

ensures that the inverter cuts out if the inter-

Terminal arrangement (for installation see quick setup, MG.03.AX.62)

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VLT® FCM Series

Description of the motor	The FC motor consists of the following parts:

Item	Description
1	Gasket
2	Name plate
3	Shim ring
4	Ball bearing
5	Circlip for drive-end bearing
6	Key
7	Rotor
8	Shim ring for bearing
9	Tension screws
10	Tolerance ring for air blower
11	Air blower
12	Endshield drive end
13	Stator
14	Endshield non drive end
15	Connector block
16	Gasket
17	Screws for connector block
18	Metric blind plugs

Item Description

19Gaskets for cable glands

20Cable Clamps

21Screws for cable clamps

22Frequency inverter

23Lid for frequency inverter

24Gasket

25Torx-screws for inverter monting

26Screws for lid

27Mounting screws for flange ring

28Flange ring

29Stator

30Mounting screws for air blower hood

31Air blower hood

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17

VLT® FCM Series

Handling the FC motor

Handling and lifting of VLT DriveMotors (FC motors) must only be undertaken by qualified personnel. Full product documentation and operating instructions must be available together with tools and equipment necessary for safe working practice. Eyebolts and/or lifting trunnions supplied with the FC motor are designed to support only the weight of the FC motor, not the weight of the FC motor and any auxcillary equipment attached to it. Be absolutely sure that cranes, jacks, slings and lifting beams are capable of carrying the weight of equipment to be lifted. Where an eyebolt is provided with the motor, this should be screwed

down until its shoulder is firmly against the face of the stator frame to be lifted.

FCM type	approx. weight (kg.)
FCM 305	11
FCM 307	13
FCM 307	17
FCM 315	20
FCM 322	26
FCM 330	28
FCM 340	37
FCM 355	56
FCM 375	61

Bearings

The standard solution is fixed bearing in the drive side of the motor (shaft output side).

To avoid static indention, the storage area should be vibration free. Where exposure to some vibration is unavoidable, the shaft should be locked. 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 despatched from the works fully charged with lithium based grease.

Lubrication
Frame size	Lubrication type	Temperatur range
80-132	Esso unirex N3	-10 to + 1400°C

Bearing life
Maximum hours bearing life (Lna) expected at 80° C bearing temp. x 103 hours.
FCM		3000 min-1		1500 min-1
	Horiz.	Vert.	Horiz.	Vert.
305-315	22	22	30	30
322-340	26	26	30	30
355-375	26	26	30	30

Lna bearing life is the adjusted, L10 life rating, taking account of: -Reliability -Material improvement -Lubrication conditions.

Standard Bearing references and oil seals

FCM	Mounting	Poles (2/4)	Bearings		Oil seals - Bore x O/D x width in mm
			Drive end	Non-drive end
305-307	All	All	6204 2Z-C3	6204 2RS-C3	20 x 30 x 7
311-315	All	All	6205 2Z-C3	6205 2RS-C3	25 x 35 x 7
322-330	All	All	6206 2Z-C3	6206 2RS-C3	30 x 42 x 7
340	All	All	6206 2Z-C3	6206 2RS-C3	30 x 42 x 7
355-375	All	All	6208 2Z-C3	6208 2RS-C3	40 x 52 x 7

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				VLT® FCM Series
	Output shafts	Inertia J [kgm2]
	Balance		FCM	2 pole	4 pole
	All motors are dynamically balanced, to ISO 8821with
			305	0.00082	0.0019
	key convention to IEC 60034-14.
		307		0.00082	0.0027
			311	0.00090	0.0022
		315		0.0011	0.0030
			322	0.0024	0.0042
			330	0.0028	0.0050
			340	0.0053	0.0091
			355	0.0072	0.0143
		375		0.0097	0.0190

Dimensions

Foot mounting - B3

General
FCM	305	307	311	315	322	330	340	355	375

Frame size	80	80	90	90	100	100	112	132	132
A [mm]	125	125	140	140	160	160	190	216	216
B [mm]	100	100	125	125	140	140	140	178	178
C [mm]	50	50	56	56	63	63	70	89	89
H [mm]	80	80	90	90	100	100	112	132	132
K [mm]	9	9	9	9	12	12	12	12	12
EB [mm]	4	4	5	5	5	5	5	5	5
AA [mm]	33.5	33.5	35	35	38	38	44	55	55
AB [mm]	153	153	170	170	195	195	225	256	256
BB [mm]	125	125	155	155	176	176	176	218	218
L [mm]	293	293	319	319	363	363	380	485	485
AC [mm]	159	159	176	176	196	196	220	246	246
HD [mm]	228.5	228.5	241	241	267	267	296	344	344
FCL [mm]	206	206	230	230	256	256	286	340	340
FCW [mm]	142	142	158	158	176	176	197	235	235

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VLT® FCM Series

Flange mounting - B5, B35 (B3+B5)

B5
FCM	305	307	311	315	322	330	340	355	375
Frame size	80	80	90	90	100	100	112	132	132
IEC Ref.	FF165	FF165	FF165	FF165	FF215	FF215	FF215	FF265	FF265
DIN Ref.	A200	A200	A200	A200	A250	A250	A250	A300	A300
M [mm]	165	165	165	165	215	215	215	265	265
N [mm]	130	130	130	130	180	180	180	250	230
P [mm]	200	200	200	200	250	250	250	300	300
S [mm]	12	12	11.5	11.5	14	14	14	14	14
T [mm]	3.5	3.5	3.5	3.5	4	4	4	4	4
LA [mm]	10	10	10	10	11	11	11	12	12

Face mounting - B14, B34 (B3+B14)

B14
FCM	305	307	311	315	322	330	340	355	375
Frame size	80	80	90	90	100	100	112	132	132
IEC Ref.	FT100	FT100	FT115	FT115	FT130	FT130	FT130	FT165	FT165
DIN Ref.	C120	C120	C140	C140	C160	C160	C160	C200	C200
M [mm]	100	100	115	115	130	130	130	165	165
N [mm]	80	80	95	95	110	110	110	130	130
P [mm]	120	120	140	140	160	160	160	200	200
S [mm]	M6	M6	M8	M8	M8	M8	M8	M10	M10
T [mm]	3	3	3	3	3.5	3.5	3.5	3.5	3.5
LA [mm]	12	12	10	10	10	10	10	12	12

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VLT® FCM Series

Shaft Drive End

Shaft tapped

DH x deep to

DIN 332 Form DR

Closed profile keyway

FCM	305	307	311	315	322	330	340	355	375
Frame size	80	80	90	90	100	100	112	132	132
D [mm]	19	19	24	24	28	28	28	38	38
E [mm]	40	40	50	50	60	60	60	80	80
ED [mm]	32	32	40	40	50	50	50	70	70
DH [mm]	M6x16	M6x16	M8x19	M8x19	M10x22	M10x22	M10x22	M12x28	M12x28
F [mm]	6	6	8	8	8	8	8	10	10

GA [mm]

21.5

21.5

27

27

31

31

31

41

41

Forced ventilation

FCM	305	307	311	315	322	330	340	355	375
Frame size	80	80	90	90	100	100	112	132	132
AD [mm]	132	132	160	160	170	170	182	195	195
L [mm]	386	386	427,5	427,5	440	440	482	616	616

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VLT® FCM Series

Installation of the FC motor

FC motors must be installed with adequate access for routine maintenance. A minimum of 0.75m of working space around the motor is recommended. Adequate space around the motor, particularly at the fan inlet (50 mm), is also necessary to facilitate airflow.

Where several FC motors are installed in close proximity, care must be taken to ensure that there is no recirculation of exhausted warm air. Foundations must be solid, rigid and level.

NB!

Electrical installation

Do not remove the top foil inside the inverter part, as this is a part of the protective arrangements.

Fitting pinions, pulleys and couplings.

These should be bored to our standard limits and fitted on the shaft with a screwing motion. Attention must be paid to correct guarding of all moving parts.

Tapping of fitments onto the FC motor shaft, with a hammer or mallet, causes bearing damage. This results in an increase in bearing noise and a significant reduction in bearing life.

NB!

Max. length of mounting bolts penetrating the B14 flange, see section Dimensions in this chapter.

Alignment

When the application calls for direct coupling, the shafts must be correctly aligned in all three planes. Bad alignment can be a major source of noise and vibration.

Maximum permissible axial and radial loads in N

Allowance must be made for shaft endfloat and thermal expansion in both axial and vertical planes. It is preferable to use flexible drive couplings.

Frame size	Poles	Axial load in [N]	Radial load in [N] at 0.5 X shaft
		Horizontal shaft	length
80	2	570	610
80	4	760	770
90	2	600	650
90	4	810	820
100	2	830	890
100	4	1120	1160
112	2	820	890
112	4	1100	1110
132	2	1300	1440
132	4	1710	1780

All figures are based on L10 bearing life of 20,000 hours, standrad bearings.

Reinforced bearings available.

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VLT® FCM Series

Bolt torques

Endshields and lid should be secured with the bolt sizes and torque's detailed in the table below.

Endshield fixing bolt torques
FCM	Frame size	Bolt diameter	Torque
Type
		Nm.
305-307	80	M5	5
311-315	90	M5	5
322-330	100	M6 (taptite)	8-10
340	112	M6 (taptite)	8-10
355-375	132	M8 (taptite)	29

LID screws torque: 2.2 - 2.4 Nm

Maintenance

Routine cleaning of the FC motor

Remove the fan cover and ensure that all air inlet holes are completely free. Clean any dirt and obstructions from behind the fan and along the ribs of the frame, and between the motor and inverter part.

Periodic maintenance of motor part.

a.Remove the inverter part, the fan cover and the fan which is keyed to the shaft extension. Loosen and remove bearing cover screws and endshield bolts/studs.The endshields should then be eased off their spigots.

b.The rotor can now be carefully withdrawn from the stator, taking care not to damage the stator bore and both stator and rotor windings.

c.Having dismantled the motor, maintenance can be carried out to remove all dirt. For this purpose, the use of an air line supplying dry compressed air under comparatively low pressure is best, as a high velocity air-stream can force dirt into the spaces between the windings and insulation, etc. Grease-remov- ing solvents can cause damage to impregnating varnish or insulation

d.The FC-motor should be re-assembled in the reverse order from dismantling, remembering to ease endshields onto bearings and spigots. DO NOT USE FORCE.

e.Before starting, check that the rotor revolves freely. Ensure that the electrical connections are correct.

f.Refit any pulley, coupling, sprocket etc. which has been removed, being particularly careful to ensure correct alignment with the

driven part, as misalignment will lead to ultimate bearing trouble and shaft breakage.

g.When replacing screws and bolts, care should be taken to use only those with the requisite quality and tensile strength recommended by the manufacturer. These must also be of identical thread form and screw/ bolt length (see the table above).

Forced ventilation (FV) units

In some applications the fan built on to the motor shaft do not give sufficient cooling for operation at low speed. That problem is solved by mounting a FV unit.

Typical applications are for example conveyors, spindles and other constant torque (CT) applications where the customer wants a wide control range without reduction in torque down to low speed.

The VLT Drive Motor yields full continuous torque down to low speed with FV built on. The forced vent enclosure is IP 66. Approved according to UL.

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23

VLT® FCM Series

Voltage range for forced ventilation (FV) unit

The FVU can be supplied with a wide range of voltages depending on the way the terminals are connected. Standard is three phase 380-500 V (50 Hz), 380-575

V (60 Hz) with the possibility to connect three phase 220-290 V (50 Hz), 220-332 V (60 Hz) or single phase 230-277 V (50/60 Hz). The capacitor for single phase is mounted inside the terminal box.

FCM 300 Thermal Protection

The thermal protection of FC and motor is covered in the following way:

1.Overload situations are handled by the calculated electrical load (I 2X t).

2.Missing ventillation and high ambient temperature is handled by the temperature measurement. The derating for low speed (due to missing ventillation) is not incoporated in the electrical load calculaton but taken care of by the temperature measurement. Forced ventillation is thus automaticly covered.

Electrical load

The current is measured in the DC link and the estimated load is calculated. The level of the electrical load is set at an output torque of 105%. Above that level a counter is increased, below the level it is decreased. The counter starts at zero. When the counter reaches 100, the unit trips. At 98 the warning indication goes on (LED and status word).

Load	Time from 0 to 100	Time from 100 to 0
0%	-	60 sec
20%	-	100 sec
40%	-	150 sec
60%	-	200 sec
80%	-	250 sec
105%	900 sec (if over 105%)	300 sec (if under 105%)
120%	550 sec	-
140%	210 sec	-
160%	60 sec	-
>165%	20 sec	-

At full AC brake (parameter 400) a load > 165% is simulated => 20 sec to trip.

The value can be read in parameter 527. (LCP:FC thermal)..

Temperature measurement

The temperature measurement is sensing the temperature within the electronics box.'

At warning level => Warning indication goes on (LED and status word) and the unit might trip if the temperature doesn't sink back below warning level within 15 minutes. If the function TEMP.DEP.SW is activated in parameter 412, the switching frequency is decreased gradually down to 2 kHz attempting to decrease the temperature.

Trip level => Immediate trip and alarm indication (LED and status word).

The value can be read in parameter 537 (LCP: Heat sink temp.).

The temperature levels seem to be high, but due to a local heating of the sensor the practical levels of the inside air temperature are approx. 10 deg C lower.

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VLT® FCM Series

Service plug kit (175N2546)

Purpose:

To run LCP2 and PROFIBUS at the same time. The service plug can be used with FCM 300 of serial number 03Gxxx and software version as from 2.03. Used together with cable for plug kit 175N0162.

Plug kit (175N2545)

Purpose

To make a plugable connection between LCP 2 and

FCM 300.

Used together with cable for plug kit 175N0162.

Remote mounting kit (175N0160)

Connections

																																																	Colour of wire/	Terminal X100/	D-sub pin
																																																	yellow	1	8
																																																	green	2	9
																																																	red	3	2
																																																	blue	4	3

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25

VLT® FCM Series

Remote mounting kit cont.

Potentiometer option (177N0011)

Option to control the reference by means of a potentiometer. The option is mounted instead of a cable bracket. The potentiometer is operated by removing the blind plug to set the desired reference, and then mount the blind plug again.

Colour of wire	Terminal on X101
White	2 (analog input)
Red	8 (0 V)
Black	7 (+10 V)
Local Operation Pad (LOP) (175N0128) IP65		Wiring
		Colour of wire	Terminal	Function
		White	2	Reference
		Brown	3	Reset
		Purple * or Grey	4	See table under button
		Green	5	See table under button
		Red	6	+24V
		Yellow	7	+10V
		Blue	8	Ground
		* Can be orange in some cables

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VLT® FCM Series

Local Operation Panel (LOP) 175N0128 IP 65			Fixture for LOP 175N2717 (included in 175N0128)

Functions/settings	Key I (Start)	Key II (Start)	Key (Stop)
Default - Dual speed operation (connect	Run on set refer-	Run on 10 Hz** jog	Stop (and reset* - if trip)
purple wire):	ence (+/-)	speed
No changes to factory setting.
Function 2 - Dual mode operation (con-	Run with Setup 1	Run with Setup 2	Stop (and reset* - if trip)
nect purple wire)
Select desired modes of operation in Set-
ups 1 and 2 (use para. 4-6) Parameter
335 = 18 (select Setup)
Function 3 - Dual direction operation	Run forward	Run reverse	Stop (and reset* - if trip)
(connect grey wire)
Parameter 335 = 10 (start reversing) Pa-
rameter 200 = 1 (both directions)
*If no reset is required, do not connect the brown
wire**or set parameter 213		NB!
Use the +/- keys to set reference		After fitting, cut off or isolate excess wire.

At power up the unit will always be in stop mode. Set reference will be stored during power down. If permanent start mode is desired, connect terminal 6 to terminal 4 and do not connect purple/grey wire to terminal 4. This means the stop function on LOP is disabled.

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27

VLT® FCM Series

Control panel (175NO131)

The FC motor optionally features a Local Control Panel- LCP 2 which makes up a complete interface for operation and monitoring of the FC motor.

IP 65 on front.

NB!

The LCP from the VLT 5000 Series (code number 175Z0401) cannot be used for the FC motor. However, the general LCP 2 (code number 175N0131) can be used for both the FCM 300, VLT 2800 and the VLT 5000 Series.

LCP installation

The LCP 2 is connected to the terminal X100, 1-4 (see separate instruction MI.03.AX.YY).

1.Service Plug Kit (175N2546) (see section Service plug kit) and cabel 175N0162

2.Plug kit (175N2545) (see section Plug kit) and cabel 175N0162

3.Remote mounting kit (175N0160) (see section Remote mounting kit)

LCP functions

The functions of the control panel can be divided into three groups:

•display

•keys for changing program parameters

•keys for local operation

All data are indicated by means of a 4-line alphanumeric display, which in normal operation is able show

4 measurements and 3 operating conditions continuously. During programming, all the information required for quick, effective parameter Setup of the FC motor will be displayed. As a supplement to the display, there are three LEDs for voltage, warning and alarm. All program parameters of the FC motor can be changed immediately from the control panel, unless this function has been blocked via parameter 018.

Display

The LCD-displayhas rear lighting and a total of 4 al- pha-numeric lines together with a box that shows the direction of rotation (arrow) and the chosen Setup as well as the Setup in which programming is taking place if that is the case.

1st line shows up to 3 measurements continuously in normal operating status or a text which explains the 2nd line.

2nd line shows a measurement with related unit continuously, regardless of status (except in the case of alarm/warning).

2nd line	12345678	1	<![if ! IE]> <![endif]>10.175ZA443
1st line	12345678901234567890
		SETUP
3rd line	12345678901234567890
4th line	12345678901234567890

3rd line is normally blank and is used in the menu mode to show the selected parameter number or parameter group number and name.

4th line is used in operating status for showing a status text or in data change mode for showing the value of the selected parameter.

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VLT® FCM Series

An arrow indicates the direction of rotation of the motor. Furthermore, the Setup which has been selected as the Active Setup in parameter 004 is shown. When programming another Setup than the Active Setup, the number of the Setup which is being programmed will appear to the right. This second Setup number will flash.

LEDs

At the bottom of the control panel is a red alarm LEDand a yellow warning LED, as well as a green voltage LED.

If certain threshold values are exceeded, the alarm and/or warning lamp lights up together with a status and alarm text on the control panel.

The voltage LED is activated when the FC motor receives voltage; at the same time the rear lighting of the display will be on.

Control keys

The control keys are divided into functions. This means that the keys between display and indicator LEDs are used for parameter Setup, including choice of display indication during normal operation.

Keys for local control are found under the indicator LEDs.

Control key functions

[DISPLAY / STATUS] is used for selecting the mode of display or for changing back to Display mode from either the Quick menu mode or the Menu mode.

[QUICK MENU] is used for programming the parameters that belong under the Quick menu mode. It is possible to switch directly between Quick menu mode and Menu mode.

[MENU] is used for programming all parameters. It is possible to switch directly between Menu mode and Quick menu mode.

[CHANGE DATA] is used for changing the parameter selected either in the Menu mode or the Quick menu mode.

[CANCEL] is used if a change of the selected parameter is not to be carried out.

[OK] is used for confirming a change of the parameter selected.

[+/-] is used for selecting parameter and for changing the chosen parameter or for changing the read out in line 2.

[<>] is used for selecting group and to move the cursor when changing numerical parameters.

[STOP / RESET] is used for stopping or for resetting the FC motor after a drop-out (trip). Can be selected via parameter 014 to be active or inactive. If stop is activated, line 2 will flash, and [START] must be activated.

NB!

Pressing [STOP/RESET] will prevent motor from running also with disconnected LCP 2. Restarting is only possible via the LCP 2 [START] key.

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