Danfoss FCM 300 Series Design Manual

FCM 300 Series

1

MG.03.B6.02 - VL T is a register ed Danfoss trademark

Contents

Chapter 1Chapter 1

Chapter 1 ■

SafetySafety

Safety

....................................................................................................................

..........................................................

pagepage

page

3 3

3

Chapter 2Chapter 2

Chapter 2 ■

IntroductionIntroduction

Introduction

..................................................................................................

.................................................

pagepage

page

5 5

5

Chapter 3Chapter 3

Chapter 3 ■

Product conceptProduct concept

Product concept

..................................................................................

.........................................

pagepage

page

7 7

7

Chapter 4Chapter 4

Chapter 4 ■

Selection of FC motorSelection of FC motor

Selection of FC motor

..............................................................

...............................

pagepage

page

9 9

9

Chapter 5Chapter 5

Chapter 5 ■

TT

T

echnical dataechnical data

echnical data

........................................................................................

............................................

pagepage

page

13 13

13

Chapter 6Chapter 6

Chapter 6 ■

Mechanical specificationsMechanical specifications

Mechanical specifications

................................................

........................

page 17page 17

page 17

Chapter 7Chapter 7

Chapter 7 ■

Local contLocal cont

Local cont

rolrol

rol

..............................................................................................

...............................................

page 27page 27

page 27

Chapter 8Chapter 8

Chapter 8 ■

ParametersParameters

Parameters

....................................................................................................

..................................................

page 37page 37

page 37

Chapter 9Chapter 9

Chapter 9 ■

Serial communicationSerial communication

Serial communication

..................................................................

.................................

page 73page 73

page 73

Chapter 10Chapter 10

Chapter 10 ■

Special conditionsSpecial conditions

Special conditions

..........................................................................

.....................................

page 83page 83

page 83

Chapter 11Chapter 11

Chapter 11 ■

List of warList of war

List of war

nings and alarmsnings and alarms

nings and alarms

............................................

......................

page 93page 93

page 93

Chapter 12Chapter 12

Chapter 12 ■

List of parametersList of parameters

List of parameters

............................................................................

......................................

page 99page 99

page 99

Chapter 13Chapter 13

Chapter 13 ■

IndexIndex

Index

..................................................................................................................

.........................................................

page 103page 103

page 103

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark2

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

The symbols used are the following:

Indicates a general warning.

Indicates something to be noted by the reader.

Indicates a high-voltage warning.

Symbols

FCM 300 Series

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MG.03.B6.02 - VL T is a register ed Danfoss trademark

Chapter 1Chapter 1

Chapter 1 ■ Safety .............................................................. page 4

Safety

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark4

Safety

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.

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.

FCM 300 Series

5

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Chapter 2Chapter 2

Chapter 2 ■ Introduction.....................................................page 6

Introduction

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark6

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, programming, 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.

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

All

users

X = version number YY = language

Misc.

Quick Setup

MG.03.FX.YY

Design

Guide

MG.03.BX.YY

PROFIBUS

Manual

MG.03.EX.YY

Promotion

Brochure

MB.03.CX.YY

Articles

MZ.03.AX.YY

VLT Software

Dialog

MG.50.EX.YY

Data sheet

MD.03.AX.YY

FCM 300 Series

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Chapter 3Chapter 3

Chapter 3 ■ Product concept ............................................. page 8

Product concept

FCM 300 Series

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Product concept

■ 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.

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.

Control structures

■ Key diagram for FCM 300 Series

FCM 300 Series

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Chapter 4Chapter 4

Chapter 4 ■ Product range ............................................... page 10

■ Ordering........................................................ page 10

Selection of FC motor

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark10

■ Product range

VLT® DriveMotor FCM 300 Series, 2/4 poled motors Type

Motor

Mains supply

output

FCM 305FCM 305

FCM 305 0.55 kW FCM 307FCM 307

FCM 307FCM 307

FCM 307 0.75 kW FCM 311FCM 311

FCM 311FCM 311

FCM 311 1.1 kW FCM 315FCM 315

FCM 315FCM 315

FCM 315 1.5 kW FCM 322FCM 322

FCM 322FCM 322

FCM 322 2.2kW

3 phase 380-480 V

FCFC

FC

M 330M 330

M 330 3.0 kW

FCM 340FCM 340

FCM 340 4.0 kW FCM 35FCM 35

FCM 35FCM 35

FCM 35

55

5 5.5 kW

FCM 37FCM 37

FCM 37

55

5 7.5 kW

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

Inverter versions

Drive control:

-ST: Standard version

- SP: Version for PROFIBUS RFI filter:

Inverter with integrated RFI filter, class A1 (industrial) or class B1 (domestic).

Cooling:

- TEFV: Motor cooled by a shaft mounted fan (IC 411)

- FV: Motor cooled by an independent fan (IC 416) Mounting versions

- Foot mounting (B3)

- Flange mounting (B5)

- Face mounting (B14)

- Foot + flange mounting (B35)

- Foot + face mounting (B34) See chapter 6.

Inverter box position: Top, right side or left side. Drainhole (+ position): None, between feet, opposite

feet, vertical drive end, vertical non-drive end, 90° right of feet, 90° left of feet. Brake kits: No brake, brake with or without handrelease

Selection of FC motor

■ Ordering

Take a copy of the ordering forms on page 12. 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, which may look as follows:

FCM 330-P-T4-ST-S55-R1-100LT-4-1-B05-215-T-D1

This means that the FC motor ordered is a FCM 330 for three-phase mains voltage of 380-480 V (

T4) and

for process applications (

P). The inverter is a standard

version for remote control (

ST) in an IP55 enclosure

(

S55) with integrated RFI filter, class A1 (R1). The

motor frame size is

100LT. The motor has 4 poles (4)

and is cooled by a shaft mounted fan (

1). The motor

is for flange mounting (

B05) and the flange size is 215 mm. The inverter box is mounted on the top of the motor (

T) and the drainhole is placed between

feet (

D1).

If you wish to place your order by using the type code directly, please use the codes given in parenthesis on the left-hand side of the ordering forms. The code sequence in the type code is stated at the top of each part of the form (character number).

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 (1-30). Together with the order confirmation the customer receives an 8-figure code number to be used when reordering.

Danfoss PC software for serial communication 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 VLT

®

Software

Dialog is available for this purpose (see chapter 9). Ordering numbers, VLT® Software Dialog

VLT

®

Software Dialog 175Z0953

Incl Basic, Logging, Template, Guided tour modules in 6 languages (Danish, English, German, Italian, Spanish and French)

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 66 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 (LOP) 175N0128 Local Control Panel (LCP 2) 175N0131 Remote mounting kit (LCP 2) 175N0160 Plug kit (LCP 2) 175N0161 Cable for plug kit (LCP 2) 175N0162 Cable (direct mounting) (LCP 2) 175N0165 Service plug kit (LCP 2) 175N0166 PG 16 to ½" NPT 176H9207 PG 21 to 3/4" NPT 176H9208

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Selection of FC motor

■ Ordering info for Frames and Flanges

Flange size according to IEC ref. FFxxx (Dimension M in chapter 6) S: Available as standard shaft A: Available as an alternative with specially elongated shaft to provide standard shaft for frame B : Available as an alternative with standard shaft for frame, requiring no modification

Frame sizes and the corresponding flange sizes for different mounting versions

Type Motor frame size Mounting version Flange size, Flange size, Flange size

standard (S) alternatives (A) alternatives (B)

4 pole 2 pole [mm] [mm] [mm]

FCM 305 080MG 080MF

B5/B35 165 85/100/115/130 B14/B34 100 75/85/115/130/165 B5/B35 165 85/100/115/130

FCM 307 080MR 080MF

B14/B34 100 75/85/115/130/165

FCM 311 090LK 090SJ

B5/B35 165 100/115/130 215 B14/B34 115 85/100/130/165 B5/B35 165 100/115/130

FCM 315 090LT 090SJ

B14/B34 115 85/100/130/165

FCM 322 100LR 100LJ

B5/B35 215 165 B14/B34 130 165 85/100/115/215 B5/B35 215 165

FCM 330 100LT 100LM

B14/B34 130 165 85/100/115/215

FCM 340 112MT 112MS

B5/B35 215 115/130/165 B14/B34 130 165 85/100/115/215

FCM 355 132SJ 132SF

B5/B35 265 215 B14/B34 165 215 B5/B35 265 215

FCM 375 132MT 132SJ

B14/B34 165 215

■ Ordering info for inverter box position and drain hole position.

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark12

Ordering form FCM 300 Series

Mounting vs. and flange size (char. nos. 24-29) (B03) B3 Foot 0 0 0 (B05) B5 Flange flange size (B35) Foot & flange flange size (B14) Face flange size (B34) Foot & face flange size

Tick off as appropriate and select flange size from the table on page 11.

Inverter box position (char. no. 30) (T) Top (R) Right side (L) Left side

Tick off as appropriate. Inverter box position is seen from drive end. (See drawing on page 11).

Drain hole position (char. nos. 31-32) (00) None (D1) Between feet (D2) Opposite feet (D3) Vertical drive end (D4) Vertical non-drive end (D5) 90

° °

° right of feet

(D6) 90

° °

° left of feet

Tick off as appropriate. (See drawing on page 11).

Other options (contact Danfoss for code)

Number of FCM 300 Series ordered

Ordering form FCM 300 Series

FCM type (character nos. 1-6) FCM

Select the required FCM type from the product range on the previous page and fill in the squares.

Application range (char. no. 7) (P) Process

Mains voltage (char. nos. 8-9) (T4) 3-phase 380-480 V AC

Tick off as appropriate.

Inverter vs. (char. nos. 10-11) (ST) Standard (SP) PROFIBUS

Tick off as appropriate.

Enclosure (char. no. 12-14) (S55) IP55 (S56) IP56 (S66) IP66

RFI filter (char. nos. 15-16) (R1) W/ integrated filter, class A1 (R2) W/integrated filter, class B1

Tick off as appropriate.

Frame size (char. nos. 17-21)

Fill in the squares with the appropriate value from column 2 and 3 in the table on page 11.

Polarity (char. no. 22) (4) 4 poles (2) 2 poles

Tick off as appropriate.

Cooling (char. no. 23) (1) (IC 411) Shaft mounted fan (6) (IC 416) Forced ventilation unit

Tick off as appropriate.

Selection of FC motor

Ordered by:

Date:

FCM 300 Series

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Chapter 5Chapter 5

Chapter 5 ■ FCM 305-375 for 3 phases, 380-480 V ........ page 14

■ General technical data .................................page 14

Technical data

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark14

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 ϕ ....................................................................................................... max. 0.9/1.0 at rated load

- No. of switching operations on supply input L1, L2, L3 ................................................. approx. 1 time/2 min

See chapter 10, "Special conditions". *) Not valid for RFI class 1B units

Torque characteristics:

- Starting torque/overload torque .............................................................................................. 160 % for 1 min

- Continuous torque ........................................................................................................................see page 84

■ FCM 305-375 for 3 phases, 380-480V

■ General technical data

FCMFCM

FCM

305305

305

307307

307

311311

311

315 315

315

322322

322

330330

330

340340

340

355355

355

375375

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] 1.8 2.4 3.5 4.8 7.0 9.5 12.6 17.5 24.0 4 pole [Nm] 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]111317202628375661 Input current [A] 380 V 2 p 1.4 1.6 2.2 2.8 4.1 5.3 7.0 9.3 13.0 4 p 1.4 1.7 2.5 3.3 4.7 6.4 7.9 11.1 15.3 480 V 2 p 1.2 1.3 1.8 2.3 3.3 4.2 5.6 7.4 10.2 4 p 1.1 1.4 2.0 2.6 3.7 5.1 6.4 8.8 11.9 Power terminals [AWG] 10 10 10 10 10 10 10 6 6 [mm2] 44444441010 Gland sizes 3XPG16 3XPG16 3XPG16 3XPG16 3XPG16 3XPG16 3XPG16 1XPG21/ 1XPG21/

3XPG16 3XPG16 Max. prefuse UL

1)

[A] 10 10 10 10 10 15 15 25 25

IEC1) [A] 25 25 25 25 25 25 25 25 25

1)

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, type ATMR (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.

FCM 300 Series

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Control card, analogue inputs:

- No. of programmable analogue voltage inputs .............................................................................................. 1

- Terminal nos. ......................................................................................................................................... X101-2

- Voltage level.................................................................................................................... 0 - 10 V DC (scalable)

- Input resistance, R

i

..................................................................................................................... approx. 10 kΩ

- No. of programmable analogue current inputs.................................................................................................1

- Terminal no. ........................................................................................................................................... X101-1

- Current range ................................................................................................................. ... 0 - 20 mA (scalable)

- Input resistance, R

i

.....................................................................................................................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 ........................................................... R

LOAD

≤ 500 Ω

- Accuracy of analogue output ............................................................................ Max. error: 1.5% of full scale

- Resolution on analogue output. .................................................................................................................8 bit

Control card, RS 485 serial communication:

- Terminal nos. ....................................................................................................................................X100-1, -2

Control characteristics (frequency converter):

- Frequency range...............................................................................................................................0 - 132 Hz

- Resolution on output frequency ............................................................................................................. 0.1 %

- System response time .............................................................................................................. Max. 40 msec.

Technical data

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, R

i

..................................................................................................................... approx. 2 kΩ

- Scanning time ................................................................................................................................... 20 msec

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

FCM 300 Series

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Terminal arrangement (for installation see quick setup, MG.03.Fx.xx)

T echnical data

Screen

Externals:

- Enclosure ............................................................................................................................. IP 55 (IP56, IP66)

- Vibration test ........................................................................................................... (IEC 68 see page 85) 1 g

- Max. relative humidity ................................................... 93 % +2 %, -3 % (IEC 68-2-3) for storage/transport

- Ambient temperature .......................................................................Max. 40°C (24-hour average max. 35°C)

Derating for high ambient temperature, see chapter 10.

- 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

Derating for air pressure, see chapter 10.

- EMC standards applied, Emission................................... EN 50081-1/2, EN 61800-3, EN 55011, EN 55014

Immunity ................... EN 50082-2, EN 61000-4-2, IEC 1000-4-3, EN 61000-4-4

EN 61000-4-5, ENV 50140, ENV 50141

- Safety standards applied, ............................................................................ EN 60146, EN 50178, EN 60204

UL508

Protection:

••

• Thermal overload protection of motor and electronics.

••

• Monitoring of the intermediate circuit voltage ensures that the inverter cuts out if the intermediate circuit

voltage gets too high or too low.

••

• If a mains phase is missing, the inverter will cut out when a load is placed on the motor.

FCM 300 Series

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Reset (pushbutton) Start Jog

Speed reference

- 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

Connection diagram - factory setting

X100: Terminal block for data communication

Terminal No. Function

1 P RS 485 for connection to 2 N RS 485 bus or PC 3 5 V DC

Supply for RS 485 bus

4 0 V DC

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 MG90AXYY.

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

T echnical data

FCM 300 Series

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Tightening Torques

Cover (lid) screws: 19.5 - 21.2 lb-in (2.2 - 2.4 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. Earth ground and cable clamp screws all require T-20 Torx or flat-blade screwdriver. Lid screws require Philips screwdriver.

Maximum Cable Cross Section

Note:

Use

o

60 C copper wire or better

AWG mm

2

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

■

FCM 300 Series

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Chapter 6 ■ Description of the FC motor ......................... page 20

■ Handling the FC motor .................................page 21

■ Dimensions................................................... page 22

■ Installation of the FC motor .......................... page 24

■ Maintenance ................................................ page 25

■ Forced ventilation units .................................page 26

Mechanical specifications

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark20

ItemItem

Item

DescriptionDescription

Description 1 Flinger (when fitted) 2 Drive end oilseal 3 Endshield fixing bolt 4 Drive end endshield 5 Preload washer 6 Bearing 7 Shaft key 8 Rotor assembly 9 Stator assembly with or without fee 10 Connector block 11 Gasket 12 Detachable feet 13 Foot fixing bolt and washer 14 Bearing retention circlip 15 Non-drive endshield 16 Bearing circlip 17 Fan 18 Fan cover

ItemItem

Item

DescriptionDescription

Description 19 Fan cover screw and washer 20 Screwed bung 21 O‘ ring 22 ISM box 23 Cable strap 24 Cable strap screws 25 ISM box lid 26 Torx screw 27 Washer 28 Face endshield 29 Flange endshield 30 Brake hub 31 Brake hub retention circlip 32 Brake and adaptor plate 33 Stub shaft 34 Brake fan cover 35 Force vent fan cover 36 Terminal box

■ Description of the motor

The FC motor consists of the following parts:

Mechanical specifications

FCM 300 Series

21

MG.03.B6.02 - VL T is a register ed Danfoss trademark

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.

■ Handling the FC motor

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 311 17 FCM 315 20 FCM 322 26 FCM 330 28 FCM 340 37 FCM 355 56 FCM 375 61

Mechanical specifications

■■

■

Bearings.

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 Lubrication Temperatur size type range

80-132 Esso unirex N3 -10 to + 1400C

Bearing life

Maximum hours bearing life (Lna) expected at 80

o

C bearing temp. x 103 hours.

FCM 3000 min

-1

1500 min

-1

Horiz. Vert. Horiz. Vert.

305-315 22 22 32 32 322-340 26 26 35 35 355-375 26 26 35 35

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 Drive end Non-drive end

305-307 All All 6204 2Z 6202 2Z 20 x 30 x 7 15 x 24 x 5 311-315 All All 6205 2Z 6203 2Z 25 x 35 x 7 17 x 28 x 6 322-330 All All 6206 2Z 6205 2Z 30 x 42 x 7 25 x 37 x 7 340 All All 6206 2Z 6205 2Z 30 x 42 x 7 25 x 37 x 7 355-375 All All 6208 2Z 6305 2Z 40 x 52 x 7 25 x 37 x 7

■■

■

Output shafts.

Output shafts are produced from 35/40 Ton (460/540 MN/m

2

) tensile steel. Drive end shafts are provided with a tapped hole to DIN 332 Form D and a closed profile keyway as standard.

Balance

All motors are dynamically balanced, to ISO 2373 with key convention to IEC 34-14.

InertiaInertia

Inertia

FCM J [kgm2]

2 pole 4 pole

305 0.0015 0.0019 307 0.0015 0.0027 311 0.0024 0.0035 315 0.0024 0.0047 322 0.006 0.009 330 0.007 0.010 340 0.008 0.016 355 0.017 0.027 375 0.020 0.032

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark22

FCMFCM

FCM

305305

305

307307

307

311311

311

315315

315

322322

322

330330

330

340340

340

355355

355

375375

375

Frame sizeFrame size

Frame size

8080

80

8080

80

9090

90

9090

90

100100

100

100100

100

112112

112

132132

132

132132

132 D [mm] 1 9 19 24 24 28 28 28 3 8 38 E [mm] 40 40 50 50 6 0 60 60 80 80 ED [mm] 32 32 40 40 50 50 50 70 70 ED1 [mm] 445555555 DH M6x16 M6x16 M8x19 M8x19 M10x22 M10x22 M10x22 M12x28 M12x28 F [mm] 66888881010 G [mm] 15.5 15.5 20 2 0 24 24 24 33 33

Foot mounting - B3Foot mounting - B3

Foot mounting - B3

GeneralGeneral

General

FCMFCM

FCM

305305

305

307307

307

311311

311

315315

315

322322

322

330330

330

340340

340

355355

355

375375

375

Frame sizeFrame size

Frame size

8080

80

8080

80

9090

90

9090

90

100100

100

100100

100

112112

112

132132

132

132132

132 A [mm] 125 125 140 140 160 160 190 216 216 B [mm] 100 100 125 125 140 140 140 140 178 C [mm] 50 50 56 56 63 63 70 89 89 H [mm] 80 80 90 90 100 100 112 132 132 K [mm] 10 10 10 10 12 12 12 12 12 AA [mm] 27 27 28 28 28 28 35 38 38 AB [mm] 157 157 165 165 184 184 218 24 2 242 BB [mm] 127 127 152 152 170 170 17 0 208 208 BC [mm] 13.5 13.5 38.5 13.5 1 5 15 15 53 15 L [mm] 298 298 3 42 342 397 397 410 490 490 AC [mm] 158 158 178 178 199 199 21 5 255 255 HD [mm] 219.5 219.5 234 234 2 6 4 26 4 29 1 3 3 5 3 3 5 EB [mm] 1.5 1. 5 1.5 1.5 66666 FCL [mm] 206 206 230 230 256 256 286 358 35 8 FCW[mm] 141 141 158 158 176 176 197 245 245

Shaft Drive EndShaft Drive End

Shaft Drive End

Mechanical specifications

■ Dimensions

FCM 300 Series

23

MG.03.B6.02 - VL T is a register ed Danfoss trademark

B14B14

B14

FCMFCM

FCM

305/ 305/

305/

311/ 311/

311/

322/ 322/

322/

355/ 355/

355/

307307

307

315315

315

330330

330

340340

340

375375

375

Frame sizeFrame size

Frame size

5656

56

6363

63

7171

71

8080

80

9090

90

100100

100

112112

112

132132

132 IEC Ref. FT65 FT75 FT85 FT100 FT115 FT130 FT130 FT215 DIN Ref. C80 C90 C105 C120 C140 C160 C160 C200 M [mm] 65 75 85 100 115 130 130 165 N [mm] 50 60 70 80 95 110 110 130 P [mm] 80 90 105 120 140 160 160 200 S M5M6M6M8M8M8M10 T [mm] 2.5 2.5 3 3 3.5 3.5 3.5 LA [mm] 9 9 9 9 12.5 13 14

Flange mounting - B5, B35 (B3+B5)Flange mounting - B5, B35 (B3+B5)

Flange mounting - B5, B35 (B3+B5)

B5B5

B5

FCMFCM

FCM

305/ 305/

305/

311/ 311/

311/

322/ 322/

322/

355/ 355/

355/

307307

307

315315

315

330330

330

340340

340

375375

375

Frame sizeFrame size

Frame size

4848

48

5656

56

6363

63

7171

71

8080

80

9090

90

100100

100

112112

112

132132

132 IEC Ref. FF85 FF100 FF115 FF130 FF165 FF165 FF215 FF215 FF265 DIN Ref. A105 A120 A140 A160 A200 A200 A250 A250 A300 M [mm] 85 100 115 130 165 1 65 215 215 265 N [mm] 70 80 95 110 130 130 180 180 2 30 P [mm] 105 120 140 160 200 200 250 250 300 S [mm] 10 10 1 2 12 15 15 15 T [mm] 3 3.5 3.5 3.5 4 4 4 LA [mm] 7 7 12 12 1 2 12 12

Face mounting - B14, B34 (B3+B14)Face mounting - B14, B34 (B3+B14)

Face mounting - B14, B34 (B3+B14)

Mechanical specifications

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark24

■ 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.

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.

Mechanical specifications

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.

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

■ Alignment

Maximum permissible external axial and radial loads in N

1

- standard ball bearings

Horizontal shaft Vertical shaft

Load towards Load away Shaft up Shaft down Frame motor from motor lo ad load l oad l oa d size Poles Up Down Up Down Max. radial

2

80 2 275 441 481 245 294 432 638

4 373 549 569 343 392 520 785

90 2 412 638 598 294 373 520 824

4 540 765 716 402 471 628 903

100 2 8 53 853 932 932 814 814 1207

4 1010 1010 1118 1118 961 961 1393

112 2 8 53 853 932 932 814 814 1207

4 1010 1010 1118 1118 961 961 1393

132S 2 1059 1403 1570 952 1216 1305 1785

4 1265 1609 1825 1138 1472 1481 1972

132M 4 1256 1609 1854 1109 1501 1462 2040

1

All figures are based on Lna bearing life of 20,000 hours.

Lna = adjusted L10 life rating taking account of:-Reliability -Material improvements -Lubrication conditions

2

Max. permissible radial load at end of shaft (horizontal mounting).

FCM 300 Series

25

MG.03.B6.02 - VL T is a register ed Danfoss trademark

Maximum permissible external axial and radial loads in N1 - angular contact bearings

Horizontal shaft Vertical shaft

Load towards Load away Shaft up Shaft down Frame motor from motor lo ad load l oad l oa d size Poles Up Down Up Down Max. radial

2

80 2 1375 2205 2405 1225 1470 2160 3190

4 1865 2745 2845 1715 1960 2600 3925

90 2 2060 3190 2990 1470 1865 2600 4120

4 2700 3825 3580 2010 2355 3140 4515

100 2 4265 4265 4660 4660 4070 4070 6035

4 5050 5050 5590 5590 4805 4805 6965

112 2 4265 4265 4660 4660 4070 4070 6035

4 5050 5050 5590 5590 4805 4805 6965

132S 2 5295 7015 7850 4760 6080 6525 8925

4 6325 8045 9125 5690 7360 7405 9860

132M 4 6280 8045 9270 5545 7505 7310 10200

1

All figures are based on Lna bearing life of 20,000 hours.

Lna = adjusted L10 life rating taking account of:-Reliability -Material improvements -Lubrication conditions

2

Max. permissible radial load at end of shaft (horizontal mounting).

Mechanical specifications

■ Bolt torques

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

Foot fixing bolt torques

FCM Type Frame size Bolt diameter Torque

Nm.

305-307 80 M8 (taptite) 24-25 311-315 90 M8 (taptite) 24-25 322-330 100 M8 (taptite) 32-35 340 112 M8 (taptite) 32-35 355-375 132 M8 (taptite) 32-35

Endshield fixing bolt torques

FCM Type Frame size Bolt diameter Torque

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 M6 (taptite) 8-10

LID screws torque: 2.2 - 2.4 Nm

■■

■

Maintenance

Routine cleaning of the FC motorRoutine cleaning of the FC motor

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.Periodic maintenance of motor 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-removing 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 . Ensur e that the electrical connections ar e correct.

(f) Refit any pulley , coupling, spr ocket 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).

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark26

Mechanical specifications

■ 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 (see drawing on page 84). That problem is solved by mounting a FV unit.

Typical applications are for example conveyors, spindles and other contant torque (CT) applications where the customer wants a wide control range down to low speed.

The FV unit is available in 2 versions. The characteristics of the two versions are the same. The variable factors are the length and the placing of the terminal box.

The VLT Drive Motor yields full continuous torque down to low speed with FV built on.

Short version - only forced ventilation units:Short version - only forced ventilation units:

Short version - only forced ventilation units: The terminal box is mounted on the side of the motor.

8080

80

9090

90

100100

100

112112

112

132132

132 L: 384 456 480 496 553 X: 138 149 161 172 192 W: 160 178 199 215 255

Standard version - brake and forced ventilation units:Standard version - brake and forced ventilation units:

Standard version - brake and forced ventilation units: The terminal box is mounted in line with the inverter box.

8080

80

9090

90

100100

100

112112

112

132132

132

L: 434 510 557 573 653 W: 160 178 199 215 255

Voltage range for forced ventilation (FV) units:

Frame size: Prefuse [A]

80 0.55 and 0.75 kW 1 phase 1 x 230V +/-6% 0.2 90-132 1.1 to 7.5 kW 3 phase 3 x 230/400V +/-6% 0.25

NB!NB!

NB! Restricted voltage range applies when FCM 300 series is fitted with forced ventilation unit.

Brake data: FCM type Frame Size Torque Nm Thermal capacity kJ/h Brake inertia kgcm2 305-307 80 10 250 1.22 311-315 90 20 350 2.10 322-330 100 40 550 5 340 112 40 550 14 355-375 132 80 800 70

The VLT Drive Motor can be delivered with an electo mechanical brake, which is controlled by the frequency converter. See parameter 138 and 139 for adjustment.

■ Brake Motors

Forced ventilation units can be ordered with different supply voltages.

FCM 300 Series

27

MG.03.B6.02 - VL T is a register ed Danfoss trademark

Chapter 7Chapter 7

Chapter 7 ■ Control panel ................................................. page 28

■ Display...........................................................page 28

■ Control key functions .................................... page 29

■ Display read-out state .................................. page 30

■ Display mode ................................................ page 30

■ Display mode - selection of read-out state .. page 30

■ Quick menu mode vs.

the menu mode ............................................ page 31

■ Quick Setup via Quick menu ....................... page 31

■ Parameter selection ...................................... page 31

■ Menu mode .................................................. page 32

■ Parameter groups ......................................... page 32

■ Changing data .............................................. page 32

■ Changing a text value ................................... page 32

■ Infinitely variable change of numeric

data value ..................................................... page 33

■ Menu structure ............................................. page 34

■ Service plug kit ............................................. page 35

■ Plug kit .......................................................... page 35

■ Remote mounting kit .................................... page 35

■ Local Operation Pad (LOP) ........................... page 36

Local Control

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark28

■■

■ Control panel

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.

NB!NB!

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).

■■

■ 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 to show 4 measurements and 3 operating conditions continuously. During programming, all the information required for quick, effective parameter

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.

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 LED and a yellow warning LED, as well as a green voltage LED.

red yellow green

Local Control

■■

■ Display

The LCD-display has rear lighting and a total of 4 alpha-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

2nd line

3rd line

4th line

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).

12345678901234567890

12345678

12345678901234567890

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.

FCM 300 Series

29

MG.03.B6.02 - VL T is a register ed Danfoss trademark

■■

■ 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.

[JOG] overrides the output frequency to a preset frequency while the key is kept down. Can be selected via parameter 015 to be active or inactive.

[FWD / REV] changes the direction of rotation of the motor, which is indicated by means of the arrow on the display although only in Local. Can be selected via parameter 016 to be active or inactive (parameter 013 must be set to [1] or [3] and parameter 200 set to [1].

[START] is used for starting the FC motor a fter stop vi a the [Stop] key. Is always active, but cannot override a stop command given via the terminal strip.

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.

Local Control

FCM 300 Series

MG.03.B6.02 - VL T is a register ed Danfoss trademark30

■ Display read-out state

The display read-out state can be varied - see the list on page 32 - depending on whether the FC motor is in normal operation or is being programmed.

■ Display mode

In normal operation, up to 4 different operating variables can be indicated continuously: 1,1 and 1,2 and 1,3 and 2, and in line 4 the present operating status or alarms and warnings that have arisen.

■ Display mode - selection of read-out state

There are three options in connection with the choice of read-out state in the Display mode - I, II and III. The choice of read-out state determines the number of operating variables read out.

STATUS

VAR 2

VAR 1.1 VAR 1.2 VAR 1.3

Operating variables 1,1 and 1,2 and 1,3 in the first line, and operating variable 2 in the second line are selected via parameter 009, 010, 011 and 012.

• Read-out state I: This read-out state is standard after starting up or after initialisation.

Line 2 gives the data value of an operating variable with related unit, and line 1 provides a text which explains line 2, cf. table. In the example, Frequency has been selected as variable via parameter 009. During normal operation another variable can immediately be read out by using the [+/-] keys.

50.0 HZ

FREQUENCY

MOTOR IS RUNNING

Local Control

Read-out I: II: III: state:

Line 1 Description Data value Description

for operating for 3 operating for 3 operating variable in line 2 variables in line 1variables in line 1

The table below gives the units linked to the variables in the first and second line of the display (see parameter 009).

Operating variable:Operating variable:

Operating variable:

Unit:Unit:

Unit:

Reference [%] Reference [unit]* Feedback [unit]* Frequency [Hz] Frequency x scaling [- ] Motor current [A] Torque [% ] Power [kW] Power [HP] Motor voltage [V ] DC-link voltage [V] FC thermal [% ] Hours run [Hours] Input status, dig. Input [Binary code] External reference [%] Status word [Hex] Heat sink temp. [ºC] Alarm word [Hex] Control word [Hex] Warning word 1 [Hex] Warning word 2 [Hex] Analog input 1 [mA] Analog input 2 [V ]

*) Select in parameter 416.

The unit is shown in readout state 1 line 1 otherwise 'U' is shown.

NB!

If the keys for local control have been selected as active, they will remain active

both when the frequency has been set for Local Control and for Remote Control via parameter 002, although with the exception of [FWD/REV], which is only active in Local operation.

NB!

If no external stop function has been selected

and the [STOP] key has been selected as inactive via parameter 014, the FC motor can be started and can only be stopped by disconnecting the voltage to the motor.

Danfoss FCM 300 Series Design Manual

Specifications and Main Features

Frequently Asked Questions

User Manual