MAKING MODERN LIVING POSSIBLE
Design Guide
VLT® Brook Crompton Motor FCM 300
www.danfoss.com/drives
Contents
Contents
VLT® DriveMotor FCM Series
1 Introduction
1.1.1 Software Version 4
1.1.5 Safety Regulations 5
1.1.6 Warning against Unintended Start 5
1.3.1 Integration of Frequency Converter and Motor 6
1.4.1 Ordering Form 7
1.4.2 Product Range 8
1.4.3 Ordering 9
1.4.4 PC Software Tools 9
1.4.5 Ordering info for Frames and Flanges 10
1.4.6 Ordering Info for Inverter Box Position and Drain Hole Position 10
2 Installation
2.1.1 FCM 305-375 for 3 Phases, 380-480 V 11
2.1.2 General Technical Data 12
2.1.3 Tightening Torques 15
2.1.4 Maximum Cable Cross Section 15
2.1.5 Screw Sizes 16
4
11
2.1.6 Protection 16
2.2 Description of the Motor
2.2.1 Handling the FC Motor 18
2.2.2 Bearings 18
2.2.3 Output shafts 19
2.2.4 Dimensions 19
2.2.5 Installation of the FC Motor 21
2.2.6 Alignment 22
2.2.7 Bolt Torques 22
2.2.8 Maintenance 22
2.2.9 FCM 300 Thermal Protection 23
2.3.1 Service Plug Kit (175N2546) 23
2.3.2 Plug Kit (175N2545) 25
2.3.3 Remote Mounting Kit (175N0160) 25
2.3.5 Potentiometer Option (177N0011) 26
2.3.6 Local Operation Pad (LOP) (175N0128) IP65 26
3 Programming
17
28
3.1.1 Control Panel (175NO131) 28
3.1.2 LCP Installation 28
3.1.3 LCP Functions 28
3.1.4 Display 28
MG03BA02 - VLT® is a registered Danfoss trademark 1
Contents
VLT® DriveMotor FCM Series
3.1.5 LEDs 29
3.1.6 Control Keys 29
3.1.7 Control Key Functions 29
3.1.8 Display Read-out State 30
3.1.9 Display Mode 30
3.1.10 Display Mode - Selection of Read-out State 30
3.1.11 Quick Menu Mode Versus Menu Mode 31
3.1.12 Quick Setup via Quick Menu 32
3.1.13 Parameter Selection 32
3.1.14 Menu Mode 32
3.1.15 Parameter Groups 32
3.1.16 Changing Data 33
3.1.17 Changing a Text Value 33
3.1.18 Infinitely Variable Change of Numeric Data Value 33
3.1.19 Menu Structure 34
3.1.20 Parameter Group 0-** Operation/Display 36
3.2.1 Parameter Group 1-** Load/Motor 40
3.6.1 Serial Bus 60
3.6.2 Telegram Communication 60
3.6.3 Telegram Build-up 61
3.6.4 Databytes 61
3.6.5 Control Word According to Fieldbus Profile Standard 63
3.7.1 Parameter Group 5-** Serial Communication 69
3.8.1 Parameter Group 6-** Technical Functions 74
4 All about FCM 300
4.1.1 Galvanic Isolation (PELV) 77
4.1.2 Earth Leakage Current 77
4.1.3 Extreme Running Conditions 78
4.1.4 Acoustic Noise 78
4.1.5 Balance 78
4.1.6 Thermal Protection and Derating 78
4.1.7 Derating for Ambient Temperature 79
77
4.1.8 Derating for Air Pressure 79
4.1.9 Derating for Running at Low Speed 79
4.1.10 Derating for High Switching Frequency 79
4.1.11 Vibration and Shock 80
4.1.12 Air Humidity 80
4.1.13 UL Standard 80
4.1.14 Efficiency 80
4.1.15 Mains Supply Interference/Harmonics 81
2 MG03BA02 - VLT® is a registered Danfoss trademark
Contents
VLT® DriveMotor FCM Series
4.1.16 Power Factor 82
4.1.17 What is CE Labelling? 82
4.1.18 The Machinery Directive (98/37/EEC) 82
4.1.19 The Low-voltage Directive (73/23/EEC) 82
4.1.20 The EMC Directive (89/336/EEC) 82
4.1.21 What is Covered? 82
4.1.22 Danfoss FCM 300 Series Motor and CE Labelling 83
4.1.23 Compliance with EMC Directive 89/336/EEC 83
4.1.24 EMC Standards 83
4.1.25 Aggressive Environments 84
4.2.1 List of Warnings and Alarms 84
4.2.2 What if the Motor does not Start? 85
4.2.3 Warnings 86
4.2.4 Warning Word, Extended Status Word and Alarm Word 88
4.3 List of Parameters
Index
89
95
MG03BA02 - VLT® is a registered Danfoss trademark 3
Introduction
VLT® DriveMotor FCM Series
1
1 Introduction
1.1 Safety
1.1.1 Software Version
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.
Table 1.1
Disposal Instruction
1.1.2
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.
Table 1.2
1.1.4 General warnings
NOTICE
All operations must be carried out by appropriately
trained personnel.
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 4.1 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
-
Symbols
1.1.3
The following symbols are used in this Design Guide and
require special attention.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
NOTICE
Indicates highlighted information that should be
regarded with attention to avoid mistakes or operate
equipment at less than optimal performance.
WARNING
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.
WARNING
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
4 MG03BA02 - VLT® is a registered Danfoss trademark
By altitudes above 2 km, please contact
Danfoss Drives regarding PELV.
175NA161.10
Promotion
All
users
X = version number
YY = language
Misc.
Quick Setup
MG.03.FX.YY
Design
Guide
MG03BXYY
PROFIBUS-
Manual
MG.03.EX.YY
Brochure
MB.03.CX.YY
Articles
MZ.03.AX.YY
MCT 10 Setup
Software Manual
MG10RXYY
Data sheet
MD.03.AX.YY
Introduction
VLT® DriveMotor FCM Series
NOTICE
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.
1.1.5 Safety Regulations
The VLT DriveMotor (FC motor) must be discon-
•
nected 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).
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 4.1.2
Earth Leakage Current .
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.
If personal safety considerations make it
necessary to ensure that no unintended start
occurs, these stop functions are not sufficient.
While parameters are being changed, the motor
•
may start.
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.
1.2 Introduction
Specific technical publications on the FCM 300 series:
Design Guide:
Quick Setup:
Table 1.3
Gives all required information for design
purposes, and gives a good insight into
the product concept, product range,
technical data, control, programming, etc.
Helps the users to quickly get their FCM
300 Series motor unit installed and
running.
The Quick Setup is always delivered with
the unit.
1
1
Warning against Unintended Start
1.1.6
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.
Illustration 1.1 Available literature for FCM 300 Series
For further information on the FCM 300 Series, contact the
local Danfoss supplier.
MG03BA02 - VLT® is a registered Danfoss trademark 5
Proc.
Fieldbus
Danfoss
MCT 10 setup
Software
PLC
Proc.
175NA009.13
1
Introduction
1.3 Product Concept
VLT® DriveMotor FCM Series
1.3.1 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 2.2.4 Dimensions ).
Installation is 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.
Illustration 1.2 Control Structures
6 MG03BA02 - VLT® is a registered Danfoss trademark
175NA121.14
B2
BC
Inverter position
Motor drain hole position
D
0
1
2
3
Introduction
VLT® DriveMotor FCM Series
1.4 Selection of FC motor, FCM 300
1.4.1 Ordering Form
1
1
Illustration 1.3
MG03BA02 - VLT® is a registered Danfoss trademark 7
Introduction
VLT® DriveMotor FCM Series
1
1.4.2 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
FCM 330 3.0 kW
FCM 340 4.0 kW
FCM 355 5.5 kW
FCM 375 7.5 kW
Table 1.4 Power Size
Each type in the product range is available in different
versions:
Inverter versions
Power size:
(See Table 1.4)
Application
P: Process
•
S: Sensorless (special pump OEM)
•
Mains voltage:
T4: 380-480 V three phase supply
•
Enclosure
C55: IP55
•
C66: IP66
•
Hardware variant:
ST: Standard
•
RFI filter
R1: Compliance with class 1A
•
R2: Compliance with class 1B
•
Display connector
3 phase 380-480 V
Number of poles
2: 2 pole motor
•
4: 4 pole motor
•
Motor data
B2: IE2 high efficiency motor
•
BC: IE2 high efficiency motor/cast iron
•
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 1.4.5 Ordering info for Frames and Flanges).
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
•
Inverter position
D: Standard on top
•
Motor drain hole position
(see 1.4.6 Ordering Info for Inverter Box Position and Drain
Hole Position)
0: No drain hole
•
1: Opposite inverter box both ends (drive/non
•
drive)
2: 90° inverter box right
•
3: 90° inverter box left
•
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
•
8 MG03BA02 - VLT® is a registered Danfoss trademark
175NA162.10
Introduction
1.4.3 Ordering
VLT® DriveMotor FCM Series
1.4.4
PC Software Tools
1
1
Take a copy of the ordering form, see 1.4.1 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-figure 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 1.4.4 PC Software Tools ).
Ordering numbers, MCT 10
Use code number 130B1000 for ordering the CD
containing MCT 10 Set-up Software.
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.
PC Software - MCT 10
All frequency converters are equipped with a serial
communication port. Danfoss provides 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:
Ordering numbers, accessories
Local Operation Pad incl. cable (LOP)
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
Table 1.5
175N0128
Illustration 1.4
MG03BA02 - VLT® is a registered Danfoss trademark 9
ISA
ISA
2
3
1
ISA ISA
1
ISA
1
175NA125.11
Introduction
VLT® DriveMotor FCM Series
1
1.4.5 Ordering info for Frames and Flanges
Frame sizes and the corresponding flange sizes for
different mounting versions
Type
FCM 305 80
FCM 307 80
FCM 311 90
FCM 315 90
FCM 322 100
FCM 330 100
FCM 340 112
FCM 355 132
FCM 375 132
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
Motor frame size
4 pole
Mounting version
B5/B35 165 115/130
B14/B34 100 75/85/115/130
B5/B35 165 115/130
B14/B34 100 75/85/115/130
B5/B35 165 110/115/130 215
B14/B34 115 85/100/130/165
B5/B35 165 110/115/130 215
B14/B34 115 85/100/130/165
B5/B35 215 165
B14/B34 130 165 85/100/115
B5/B35 215 165
B14/B34 130 165 85/100/115
B5/B35 215 165
B14/B34 130 165 85/100/115
B5/B35 265 215
B14/B34 165 215
B5/B35 265 215
B14/B34 165 215
Flange size, standard
(S) [mm]
alternatives (A) [mm]
Flange size,
Flange size,
alternatives (B) [mm]
Table 1.6
Ordering Info for Inverter Box Position and Drain Hole Position
1.4.6
Inverter box position, always top mounted.
All drain holes are mounted with screw and washer, IP 66
if not opened.
1: Drain holes opposite inverter side, both drive end and
non drive end.
2/3: Drain holes 90° to inverter, both drive end and non
drive end.
Illustration 1.5
10 MG03BA02 - VLT® is a registered Danfoss trademark
Installation
VLT® DriveMotor FCM Series
2 Installation
2.1 Technical Data
2.1.1 FCM 305-375 for 3 Phases, 380-480 V
2 2
FCM
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]
4 pole [Nm]
Frame
size [mm] 80 80 90 90 100 100 112 132 132
DriveMotor Weight
[kg]
Drive Weight [kg] 2.2 2.2 2.8 2.8 4.1 4.2 6.4 10.4 10.4
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
380 V 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
480 V 4 p 1.1 1.3 2.0 2.6 3.7 5.1 6.3 8.7 12.3
Efficiency at nom. speed
2 pole 73.4 75.3 77.5 79.0 81.3 82.7 83.8 85.1 86.2
4 pole 75.9 77.5 79.3 80.5 82.4 83.6 84.6 85.8 86.7
Power terminals
[AWG] 10 10 10 10 10 10 10 6 6
[mm2]
Gland sizes 3xM20x1.5 3xM20x1.5 3xM20x1.5 3xM20x1.5 3xM20x1.5 3xM20x1.5 3xM20x1.5 1xM25x1.5/
Max. prefuse
UL4) [A]
IEC4) [A]
1)
At 400 V 3000 r/min
2)
At 400 V 1500 r/min
3)
2 pole motor - B3
4)
Type gG prefuses must be used. To maintain UL/cUL, use prefuses of the type Bussmann KTS-R 500 V or Ferraz Shawmut, ATMR Class C
(max. 30 A). 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.
1)
2)
3)
305 307 311 315 322 330 340 355 375
1.8 2.4 3.5 4.8 7.0 9.5 12.6 17.5 24.0
3.5 4.8 7.0 9.6 14.0 19.1 25.4 35.0 48.0
11 13 17 20 26 28 37 56 61
4 4 4 4 4 4 4 10 10
2xM20x1.5
10 10 10 10 10 15 15 25 25
25 25 25 25 25 25 25 25 25
1xM25x1.5/
2xM20x1.5
Table 2.1
MG03BA02 - VLT® is a registered Danfoss trademark 11
Installation
VLT® DriveMotor FCM Series
2.1.2 General Technical Data
Mains supply, TT, TN and IT* (L1, L2, L3)
22
Supply voltage 380-480 V units 3x380/400/415/440/460/480 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, R
Scanning time 20 mses
i
approx. 2 kΩ
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, R
No. of programmable analogue current inputs 1
Terminal no. X101-1
Current range 0 - 20 mA (scalable)
Input resistance, R
Resolution 9 bit
Accuracy on input Max. error 1% of full scale
Scanning time 20 ms.
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 analogue output 0 - 20 mA
Maximum load to frame (terminal 8) at analogue output
Accuracy of analogue output Max. error: 1.5% of full scale
Resolution on analogue output. 8 bit
i
i
approx. 10 kΩ
approx. 300 Ω
R
500 Ω
LOAD
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
12 MG03BA02 - VLT® is a registered Danfoss trademark
Installation
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)
Frequency range
Resolution on output frequency 0.1%
System response time Max. 40 ms.
Speed accuracy (open loop, CT mode, 4 P motor driven in speed range 150-1500 rPm) ±15 rpm
Externals
Enclosure
Vibration test 1 g
Max. relative humidity 95% for storage/transport/operation
Ambient temperature Max. 40° C (24-hour average max. 35° C)
See 4.1.7 Derating for 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 4.1.8 Derating for Air Pressure
EMC standards applied, Emission EN 61000-6-3/EN 6100-6-4, EN 61800-3, EN 55011, EN 55014
EMC standards applied,
Immunity
Safety standards applied, EN 60146, EN 50178, EN 60204, UL508
VLT® DriveMotor FCM Series
0-132 Hz
See 4.1 Special Conditions for frequency range for IP 66 motors at the end of this section.
IP 55 (IP65, IP66)
See 4.1 Special Conditions for frequency range for IP 66 motors at the end of this section.
EN 61000-6-2, EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6,
ENV 50204
2 2
NOTICE
The normal IP 66 solution is only intended for speed up to maximum 3000 rpm. If higher speed is needed, notify when
ordering.
MG03BA02 - VLT® is a registered Danfoss trademark 13
Installation
VLT® DriveMotor FCM Series
22
Illustration 2.1 Key Diagram for FCM 300 Series
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
Table 2.2 X101: Terminal Block for Analogue/Digital Control Signals
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
-
Table 2.3 Connection Diagram - Factory Setting
14 MG03BA02 - VLT® is a registered Danfoss trademark
Installation
Terminal No. Function
1-2 Make (normally open)
1-3 Brake (normally closed)
Table 2.4 X102: Terminal Block for Relay Output
VLT® DriveMotor FCM Series
2 2
NOTICE
See parameter 323 (relay output) for
programming of relay output.
LED 300-304
LED 300 (red): Fault trip
LED 301 (yellow): Warning
LED 302 (green): Power on
Terminal No. Function
1 P RS 485 For connection to
2 N RS 485
3 5 V DC Supply for RS 485
4 0 V DC
Table 2.5 X100: Terminal Block for Data Communication
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)
Table 2.6
bus or PC
bus
LED 303-304: Communication
For PROFIBUS versions, refer to the manual MG90AXYY.
2.1.3 Tightening Torques
Terminal screws require a max 2.5 mm flat-blade screwdriver.
AC Line screws require an 8 mm flat-blade screwdriver.
Lid screws, earth ground and cable clamp screws all require T-20 Torx or flat-blade screwdriver (max. tightening speed 300
RPM).
Maximum Cable Cross Section
2.1.4
Note
Use °60 C copper wire or better
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
Table 2.7
MG03BA02 - VLT® is a registered Danfoss trademark 15
AWG
mm
2
Installation
VLT® DriveMotor FCM Series
2.1.5 Screw Sizes
Cover (lid) screws M5
22
Earth Ground and Cable Clamp screws (FCM 305-340): M4
Earth Ground and Cable Clamp screws (FCM 355-375) M5
Table 2.8
2.1.6 Protection
If a mains phase is missing, the inverter will cut
•
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.
out when a load is placed on the motor.
Illustration 2.2 Terminal Arrangement (for Installation see Quick Setup, MG03AXYY)
16 MG03BA02 - VLT® is a registered Danfoss trademark
175NA163.10
Installation
2.2 Description of the Motor
The FC motor consists of the following parts:
VLT® DriveMotor FCM Series
2 2
Illustration 2.3
Item Description Item Description
1 Flinger (when fitted) 16 Bearing circlip
2 Drive and oilseal 17 Fan
3 Endshield fixing bolt 18 Fan cover
4 Drive and end endshield 19 Fan cover screw and washer
5 Preload washer 20 Screwed bung
6 Bearing 21 O-ring
7 Shaft key 22 ISM box
8 Rotor assembly 23 Cable strap
9 Stator assembly with or without fee 24 Cable strap screws
10 Connector block 25 ISM box lid
11 Gasket 26 Torx screw
12 Detachable feet 27 Washer
13 Foot fixing bolt and washer 28 Face endshield
14 Bearing retention circlip 29 Flange endshield
15 Non-drive endshield
Table 2.9
MG03BA02 - VLT® is a registered Danfoss trademark 17
Installation
VLT® DriveMotor FCM Series
2.2.1 Handling the FC Motor
Handling and lifting of VLT DriveMotors (FC motors) must
22
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 aucillary equipment attached to it. Be
absolutely sure that cranes, jacks, slings and lifting beams
are capable of carrying the weight of equipment to be
Bearings
2.2.2
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.
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
Frame size Lubrication type Temperature range
80-132 Esso unirex N3 -30°C to + 140°C
Table 2.11 Lubrication
Table 2.10 Weight
Maximum hours bearing life (Lna) expected at 80° C bearing temp. x 103 hours.
FCM
305-315
355-375
Lna bearing life is the adjusted, L10 life rating, taking account of: -Reliability -Material improvement -Lubrication conditions.
Table 2.12 Bearing Life
FCM Bearings Oil seals - Bore x O/D x width in mm
Drive end Non-drive end Drive end Non-drive end
305-307 6204ZZ 6003ZZ 20x30x7 17x28x6
311-315 6205ZZ 6003ZZ 25x35x7 17x28x6
322-330 6206ZZ 6005ZZ 30x42x7 25x37x7
340 6206ZZ 6005ZZ 30x42x7 25x37x7
355-375 6208ZZ 6005ZZ 40x52x7 25x37x7
Table 2.13 Standard Bearing References and Oil Seals
Horiz. Vert. Horiz. Vert.
30 30 30 30322-340
3000 min
-1
1500 min
-1
18 MG03BA02 - VLT® is a registered Danfoss trademark
Installation
VLT® DriveMotor FCM Series
2.2.3 Output shafts
Output shafts are produced from 35/40 Ton (460/540
MN/m2) tensile steel. Drive end shafts are provided with a
tapped hole to DIN332 Form D and a closed profile
keyway as standard.
Balance
All motors are dynamically balanced, to ISO 8821with key
convention to IEC 60034-14.
2.2.4
Dimensions
2 2
FCM 2 pole 4 pole
305 0.00082 0.0019
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
Table 2.14 Inertia
J [kgm2]
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] 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] 157 157 164 164 184 184 218 242 242
BB [mm] 127 127 150 150 170 170 170 208 208
BC [mm] 13.5 13.5
L [mm] 278 278 322 322 368 368 382 484.5
AC [mm] 160 160 178 178 199 199 215 255 255
HD [mm] 219.5 219.5 238 238 264 264 292 334 334
EB [mm] 1.5 1.5 2.5 2.5 6 6 6 6 6
FCL [mm] 206 206 230 230 256 256 286 357.5 357.5
FCW [mm] 141 141 158 158 176 176 196 242.5 242.5
Table 2.15 Foot Mounting - B3
1)
2 pole motor = 37.5. 2)2 pole motor = 53
1)
12.5
MG03BA02 - VLT® is a registered Danfoss trademark 19
12.5
1)
15 15 15 53 15
484.5
2)
Installation
VLT® DriveMotor FCM Series
22
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
ED1 [mm] 4 4 5 5 5 5 5 5 5
DH M6x16 M6x16 M8x19 M8x19 M10x22 M10x22 M10x22 M12x28 M12x28
F [mm] 6 6 8 8 8 8 8 10 10
G [mm] 15.5 15.5 20 20 24 24 24 33 33
Table 2.16 Shaft Drive End
B5 FCM
Frame size 48 56 63 71 80 90 100 112 132
IEC Ref. FF85 FF100 FF115 FF130 FF165 FF165 FF215 FF215 FF265
DIN Ref. A105 A120 A140 A160 A200 A200 A250 A250 A300
C [mm] 50 56 63 70 89
M [mm] 85 100 115 130 165 165 215 215 265
N [mm] 70 80 95 110 130 130 180 180 230
P [mm] 105 120 140 160 200 200 250 250 300
S [mm] 10 10 12 12 14.5 14.5 14.5
T [mm] 3 3.5 3.5 3.5 4 4 4
LA [MM] 7 7 12 10 12 12 12
305/307 311/315 322/330 340 355/375
Table 2.17 Flange Mounting - B5, B35, (B3+B5)
20 MG03BA02 - VLT® is a registered Danfoss trademark
Installation
B14 FCM 305/307 311/315 322/330 340 355/375
Frame size 56 63 71 80 90 100 112 132
IEC Ref. FT65 FT75 FT85 FT100 FT115 FT130 FT130 FT165
DIN Ref. C80 C90 C105 C120 C140 C160 C160 C2OO
C [mm] 50 56 63 70 89
M [mm] 65 75 85 100 115 130 130 165
N [mm] 50 60 70 80 95 110 110 130
P [mm] 80 90 105 120 140 160 164 200
S [mm] M5 M6 M6 M8 M8 M8 M10
T [mm] 2.5 2.5 3 3 3.5 3.5 3.5
LA [MM] 9 9 9 9 8.5 13 13
Max. the B14
flange
8.5 11 11 11.5 15 15.5 17
VLT® DriveMotor FCM Series
2 2
Table 2.18 Face Mounting - B14, B34 (B3+B14)
Installation of the FC Motor
2.2.5
Illustration 2.4
FC motors must be installed with adequate access for
routine maintenance. A minimum of 0.75 m 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.
NOTICE
Electrical installation
Do not remove the top foil inside the inverter part, as
this is a part of the protective arrangements.
MG03BA02 - VLT® is a registered Danfoss trademark 21
Installation
VLT® DriveMotor FCM Series
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
22
to correct guarding of all moving parts.
2.2.6 Alignment
When the application calls for direct coupling, the shafts
NOTICE
Tapping of fittings onto the FC motor shaft, with a
must be correctly aligned in all three planes. Bad
alignment can be a major source of noise and vibration.
hammer or mallet, causes bearing damage. This results
in an increase in bearing noise and a significant
reduction in bearing life.
Allowance must be made for shaft endfloat and thermal
expansion in both axial and vertical planes. It is preferable
to use flexible drive couplings.
NOTICE
Max. the B14 flange, see 2.2.4 Dimensions .
Horizontal shaft Vertical shaft
Shaft up Shaft down
Type Poles Load towards
motor
W-DA80
W-DA90
W-DA100
W-DA112
W-DA132
2 339 539 321 565 362 521 774
4 303 503 283 530 330 583 729
2 444 684 421 716 476 661 915
4 398 638 366 682 442 606 854
2 781 1101 743 1159 839 1063 1295
4 710 1030 655 1107 787 975 1215
2 768 1088 715 1170 850 1035 1295
4 690 1010 612 1131 811 932 1202
2 1355 1707 1266 1838 1486 1618 2114
4 1253 1605 1130 1779 1427 1482 2068
Load away
from motor
Load towards
motor
Load away
from motor
Load up Load
down
Maximum
permissible radial
load at the end of
shaft (horizontal
mounting)
Table 2.19 Maximum Permissible External Axial and Radial Loads in Newtons
Bolt Torques
2.2.7
Remove the fan cover and ensure that all air inlet holes
are completely free. Clean any dirt and obstructions from
Endshields and lid should be secured with the bolt sizes
and torques detailed in Table 2.20.
FCM Type Frame size Bolt diameter Nm. Torque
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
Table 2.20 Endshield Fixing Bolt Torques
Maintenance
2.2.8
behind the fan and along the ribs of the frame, and
between the motor and inverter part.
Periodic maintenance of motor part
Routine cleaning of the FC motor
1. 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.
2. The rotor can now be carefully withdrawn from
the stator, taking care not to damage the stator
bore and both stator and rotor windings.
3. 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
22 MG03BA02 - VLT® is a registered Danfoss trademark
Installation
VLT® DriveMotor FCM Series
into the spaces between the windings and
insulation, etc. Grease-removing solvents can
cause damage to impregnating varnish or
insulation
4. 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.
5. Before starting, check that the rotor revolves
freely. Ensure that the electrical connections are
correct.
6. 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.
7. 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
Table 2.24).
FCM 300 Thermal Protection
2.2.9
The thermal protection of FC and motor is covered in the
following way:
Overload situations are handled by the calculated
•
electrical load (I 2X t).
Missing ventilation and high ambient
•
temperature is handled by the temperature
measurement. The derating for low speed (due to
missing ventilation) is not incorporated in the
electrical load calculation but taken care of by
the temperature measurement. Forced ventilation
is thus automatically 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
0% - 60 s
20% - 100 s
40% - 150 s
60% - 200 s
80% - 250 s
105% 900 s (if over 105%) 300 s (if under 105%)
120% 550 s 140% 210 s 160% 60 s >165% 20 s -
At full AC brake (parameter 400) a load > 165% is
simulated => 20 s to trip.
The value can be read in parameter 527. (LCP:FC thermal).
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° C lower.
2.3
Time from 0 to 100 Time from 100 to 0
Table 2.21
Local Control
2.3.1 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.
2 2
MG03BA02 - VLT® is a registered Danfoss trademark 23
Installation
VLT® DriveMotor FCM Series
22
Illustration 2.5
24 MG03BA02 - VLT® is a registered Danfoss trademark
Installation
VLT® DriveMotor FCM Series
2.3.2 Plug Kit (175N2545)
Purpose
To make a plugable connection between LCP 2 and FCM
300.
Used together with cable for plug kit 175N0162.
Illustration 2.6
2.3.4
Remote Mounting Kit Cont.
Illustration 2.8
2 2
Remote Mounting Kit (175N0160)
2.3.3
Illustration 2.7 Connections
Colour of wire/ Terminal X100/ D-sub pin
yellow 1 8
green 2 9
red 3 2
blue 4 3
Illustration 2.9
Table 2.22
MG03BA02 - VLT® is a registered Danfoss trademark 25
Installation
VLT® DriveMotor FCM Series
2.3.5 Potentiometer Option (177N0011)
Option to control the reference by means of a potenti-
22
ometer. 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.
Illustration 2.10
Illustration 2.12 Local Operation Panel (LOP) 175N0128 IP 65
Colour of wire Terminal on X101
White 2 (analog input)
Red 8 (0 V)
Black 7 (+10 V)
Table 2.23
Local Operation Pad (LOP)
2.3.6
(175N0128) IP65
Illustration 2.11
Colour of wire Terminal Function
White 2 Reference
Brown 3 Reset
Purple* or Grey 4
Green 5
Red 6 +24 V
Yellow 7 +10 V
Blue 8 Ground
* Can be orange in some cables
See Illustration 2.11
Illustration 2.13 Fixture for LOP 175N2717 (included in
175N0128)
Table 2.24 Wiring
26 MG03BA02 - VLT® is a registered Danfoss trademark
Installation
Functions/settings Key I (Start) Key II (Start)
Default - Dual speed operation (connect purple
wire):
No changes to factory setting.
Function 2 - Dual mode operation (connect
purple wire):
Select desired modes of operation in Setups 1
and 2 (use para. 4-6) Parameter 335 = 18 (select
Setup)
Function 3 - Dual direction operation (connect
grey wire):
Parameter 335 = 10 (start reversing) Parameter
200 = 1 (both directions)
Table 2.25
*If no reset is required, do not connect the brown wire
**or set parameter 213
VLT® DriveMotor FCM Series
Run on set reference
(+/-)
Run with Setup 1 Run with Setup 2 Stop (and reset* - if trip)
Run forward Run reverse Stop (and reset* - if trip)
Run on 10 Hz** jog
speed
NOTICE
After fitting, cut off or isolate excess wire.
Use the [+[/[-] keys to set reference
Key (Stop)
Stop (and reset* - if trip)
2 2
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.
MG03BA02 - VLT® is a registered Danfoss trademark 27
Programming
3 Programming
VLT® DriveMotor FCM Series
33
3.1 Parameters
3.1.1 Control Panel (175NO131)
The FC motor optionally features a Local Control PanelLCP 2 which makes up a complete interface for operation
and monitoring of the FC motor.
IP 65 on front.
3.1.2 LCP Installation
The LCP 2 is connected to the terminal X100, 1-4 (see
separate instruction MI03AXYY).
1.
Service Plug Kit (175N2546) (see 2.3.1 Service Plug
Kit (175N2546)) and cable 175N0162
2.
Plug kit (175N2545) (see 2.3.2 Plug Kit
(175N2545)) and cable 175N0162
3.
Remote mounting kit (175N0160) (see 2.3.4
Remote Mounting Kit Cont.)
LCP Functions
3.1.3
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 Set-up 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.
Illustration 3.1
Display
3.1.4
The LCD display is back lit and has a total of 4 alphanumeric lines together with a box that shows the direction
of rotation (arrow) and the chosen Set-up as well as the
Set-up in which programming is taking place if that is the
case.
Illustration 3.2
28 MG03BA02 - VLT® is a registered Danfoss trademark
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