Danfoss VLT DriveMotor FCP 106, VLT DriveMotor FCM 106 Operating Instructions Manual

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MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® DriveMotor FCP 106 and FCM 106

www.danfoss.com/drives

Contents Operating Instructions

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Product Overview

1.3.1 Intended Use 4

1.3.2 Electrical Overview 5

1.4 Approvals

1.5 Disposal Instruction

2 Safety

2.1 Qualified Personnel

2.2 Safety Precautions

3 Mechanical Installation

3.1 Unpacking

3.1.1 Items Supplied, FCP 106 9

3.1.2 Additional Items Required, FCP 106 9

3.1.3 Items Supplied, FCM 106 9

3 3 4 4

6 6

7 7 7

9 9

3.1.4 Identification of Unit 9

3.1.5 Nameplates 9

3.1.6 Lifting 10

3.2 Installation Environment

3.3 Mounting

3.3.1 Introduction 11

3.3.2 Prepare Gasket 11

3.3.3 Prepare Adapter Plate 11

3.3.4 Mount the DriveMotor 12

3.3.5 Shaft Alignment 12

3.3.6 Bearing Life and Lubrication 13

4 Electrical Installation

4.1 Safety Instructions

4.2 IT Mains

4.3 EMC-Compliant Installation

4.4 Cable Requirements

4.5 Grounding

10 11

14 14 14 15 17 17

4.6 Motor Connection

4.6.1 Connect FCP 106 to Motor 17

4.6.2 Thermistor Input from Motor 19

4.7 AC Mains Connection

Contents Operating Instructions

4.8 Control Wiring

4.8.1 Control Terminals 20

4.8.2 Load Sharing 21

4.8.3 Brake 21

4.9 Installation Checklist

5 Commissioning

5.1 Applying Power

5.2 Local Control Panel Operation

5.3 Basic Programming

5.3.1 Start-up Wizardfor Open Loop Applications 24

5.3.2 Set-up Wizard for Closed Loop Applications 26

5.3.3 Quick Menu: Motor Set-up 27

5.3.4 Changing Parameter Settings 28

5.3.5 Thermistor Set-up 28

6 Maintenance, Diagnostics and Troubleshooting

6.1 Maintenance

23 23 23 24

29 29

6.1.1 Before Starting Repair Work 29

6.2 List of Warnings and Alarms

7 Specifications

7.1 Clearances, Dimensions and Weights

7.1.1 Clearances 31

7.1.2 FCP 106 Dimensions 32

7.1.3 FCM 106 Dimensions 33

7.1.4 Weight 36

7.2 Electrical Data

7.3 Mains Supply

7.4 Protection and Features

7.5 Ambient Conditions

7.6 Cable Specifications

7.7 Control Input/Output and Control Data

7.8 Connection Tightening Torques

7.9 FCM 106 Motor Specifications

7.10 Fuse and Circuit Breaker Specifications

31 31

37 39 39 39 40 40 42 42 43

8 Appendix

8.1 Abbreviations and Conventions

8.2 Parameter Menu Structure

Index

45 45 45

195NA447.10

195NA419.10

Introduction Operating Instructions

1 Introduction

1.1 Purpose of the Manual

This manual provides information required to install and commission the frequency converter.

VLT® DriveMotor FCP 106

The delivery comprises frequency converter only. A wall adapter plate or motor adapter plate is also required for installation. Order the adapter plate separately.

DriveMotor FCM 106

VLT

The frequency converter is mounted onto the motor upon delivery. The combined FCM 106 and motor from Danfoss is known as the DriveMotor.

Illustration 1.1 FCP 106

Illustration 1.2 FCM 106

Introduction Operating Instructions

1.2 Additional Resources

Literature available:

VLT® DriveMotor FCP 106 and FCM 106 Operating

•

Instructions, for information required to install and commission the frequency converter.

VLT

•

Technical literature and approvals are available online at

www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.

DriveMotor FCP 106 and FCM 106 Design

Guide,provides information required for

integration of the frequency converter into a diversity of applications.

VLT® DriveMotor FCP 106 and FCM 106 Programming Guide, for how to program the unit,

including complete parameter descriptions.

VLT® LCP Instruction, for operation of the local control panel (LCP).

VLT

LOP Instruction, for operation of the local

operation pad (LOP).

Modbus RTU Operating Instructions, Operating Instructions VLT® DriveMotor FCP 106 and FCM 106 BACnet, and Operating Instructions VLT® DriveMotor FCP 106 and FCM 106 Metasys, for information required for

controlling, monitoring, and programming the frequency converter.

PC-based Configuration Tool MCT 10, enables configuration of the frequency converter from a Windows™ based PC environment.

Danfoss VLT® Energy Box software, for energy calculation in HVAC applications.

1.3

Product Overview

1.3.1 Intended Use

The frequency converter is an electronic motor controller intended for

regulation of motor speed in response to system

•

feedback or to remote commands from external controllers. A power drive system consists of the frequency converter, the motor, and equipment driven by the motor.

system and motor status surveillance.

•

The frequency converter can also be used for motor protection.

Depending on configuration, the frequency converter can be used in standalone applications or form part of a larger appliance or installation.

The frequency converter is allowed for use in residential, industrial, and commercial environments in accordance with local laws and standards.

NOTICE

In a residential environment, this product can cause radio interference, in which case supplementary mitigation measures can be required.

Foreseeable Misuse

Do not use the frequency converter in applications which are non-compliant with specified operating conditions and environments. Ensure compliance with the conditions specified in chapter 7 Specifications.

Danfoss VLT® Energy Box software is available at www.danfoss.com/BusinessAreas/DrivesSolutions, PC software download area.

195NA410.11

L1 L2 L3

3 Phase power input

+10Vdc

0-10Vdc0/4-20 mA

0/4-20 mA

0-10Vdc-

50 (+10V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN/OUT)

42 0/4-20mA A OUT / DIG OUT

45 0/4-20mA A OUT / DIG OUT

12 (+24V OUT)

18 (DIGI IN)

19 (DIGI IN)

20 (COM D IN)

27 (DIGI IN)

29 (DIGI IN)

24V (NPN) 0V (PNP)

Bus ter.

RS-485 Interface

(N PS-485) 69

(P RS-485) 68

(Com RS-485) 61

RS-485

(PNP)-Source (NPN)-Sink

Bus ter.

1 2

ON=Terminated OFF=Unterminated

relay 1

240V AC 3A

relay 2

240V AC 3A

UDC+

UDC-

Motor

U V W

Thermistor

located in

motor

Group 5-*

Located in

motor block

Introduction Operating Instructions

1.3.2 Electrical Overview

Illustration 1.3 Electrical Overview

Introduction Operating Instructions

1.4 Approvals

NOTICE

In a domestic environment, this product may cause radio interference, in which case supplementary mitigation measures may be required.

Certification FCP 106 FCM 106

EC Declaration of Conformity

UL Listed -

UL Recognised

C-tick

Table 1.1 Approvals

✓ ✓

✓

✓ ✓

✓

The EC declaration of conformity is based on the following directives:

Low Voltage Directive 2006/95/EC, based on

•

EN61800-5-1 (2007) EMC Directive 2004/108/EC based on EN61800-3

•

(2004)

UL Listed

Product evaluation is complete and the product can be installed in a system. The system must also be UL listed by the appropriate party.

UL Recognised

Additional evaluation is required before the combined frequency converter and motor can be operated. The system in which the product is installed must also be UL listed by the appropriate party.

The frequency converter complies with UL508C thermal memory retention requirements. For more information, refer to the section Motor Thermal Protection in the Design Guide.

1.5

Disposal Instruction

Equipment containing electrical components must 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.

Safety

2 Safety

Operating Instructions

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation which could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which could result in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTICE

Indicates important information, including situations that may result in damage to equipment or property.

2.1 Qualified Personnel

Correct and reliable transport, storage, installation, operation and maintenance are required for the troublefree and safe operation of the frequency converter. Only qualified personnel is allowed to install or operate this equipment.

Qualified personnel is defined as trained staff, who are authorised to install, commission, and maintain equipment, systems and circuits in accordance with pertinent laws and regulations. Additionally, the personnel must be familiar with the instructions and safety measures described in this document.

2.2

Safety Precautions

WARNING

HIGH VOLTAGE

Frequency converters contain high voltage when connected to AC mains input power. Failure to perform installation, start up, and maintenance by qualified personnel could result in death or serious injury.

Only qualified personnel are permitted to

•

perform installation, start up, and maintenance.

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains, the motor may start at any time, causing risk of death, serious injury, equipment, or property damage. The motor can start by means of an external switch, a serial bus command, an input reference signal from the LCP or LOP, or after a cleared fault condition.

1. Disconnect the frequency converter from mains whenever personal safety considerations make it necessary to avoid unintended motor start.

2. Press [Off/Reset] on the LCP, before programming parameters.

3. The frequency converter, motor, and any driven equipment must be in operational readiness when the frequency converter is connected to AC mains.

WARNING

DISCHARGE TIME

The frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not powered. Failure to wait the specified time after power has been removed before performing service or repair work, could result in death or serious injury.

1. Stop motor.

2. Disconnect AC mains, permanent magnet type motors, and remote DC-link power supplies, including battery back-ups, UPS, and DC-link connections to other frequency converters.

3. Wait for the capacitors to discharge fully, before performing any service or repair work. The duration of waiting time is specified in Table 2.1.

Minimum waiting

[kW]

time

(min)

Voltage

[V]

3x400 0.55–7.5 4

High voltage can be present even when the warning LED

Power Range

indicator lights are off.

2 2

Table 2.1 Discharge Time

1) Power ratings relate to NO, see chapter 7.2 Electrical Data.

Safety Operating Instructions

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

Ensure only trained and qualified personnel

•

perform installation, start up, and maintenance. Ensure that electrical work conforms to national

•

and local electrical codes. Follow the procedures in this manual.

•

CAUTION

WINDMILLING

Unintended rotation of permanent magnet motors causes risk of personal injury and equipment damage.

Ensure that permanent magnet motors are

•

blocked to prevent unintended rotation.

WARNING

LEAKAGE CURRENT HAZARD

Follow national and local codes regarding protective earthing of equipment with a leakage current exceeding

3.5 mA. Frequency converter technology implies high frequency switching at high power. This switching generates a leakage current in the ground connection. A fault current in the frequency converter at the output power terminals can contain a DC component which can charge the filter capacitors and cause a transient ground current. The ground leakage current depends on various system configurations including RFI filtering, screened motor cables, and frequency converter power. EN/ IEC61800-5-1 (Power Drive System Product Standard) requires special care because the leakage current exceeds 3.5 mA. See EN60364-5-54 paragraph 543.7 for further information.

Ensure correct grounding of the equipment by

•

a certified electrical installer. Grounding must be reinforced in one of the

•

following ways:

- Ensure ground wire with cross-section of at least 10 mm2, or

- Ensure 2 separate ground wires, both complying with the dimensioning rules.

WARNING

DC CURRENT RISK

This product can cause a DC current in the protective conductor. Take the following precautions:

Where a residual current device (RCD) is used

•

for extra protection, use only an RCD of Type B (time delayed) on the supply side of this product.

Protective earthing of the frequency converter

•

and the use of RCDs must always follow national and local regulations.

Failure to follow the precautions can lead to personal injury or property damage.

WARNING

GROUNDING HAZARD

For operator safety, it is important to ground the frequency converter properly in accordance with national and local electrical codes, as well as the instructions in this manual. Ground currents are higher than 3.5 mA. Failure to ground the frequency converter properly could result in death or serious injury. It is the responsibility of the user or certified electrical installer, to ensure correct grounding of the equipment in accordance with national and local electrical codes and standards.

Follow all local and national electrical codes to

•

ground electrical equipment properly. Establish proper protective grounding for

•

equipment with current higher than 3.5 mA. A dedicated ground wire is required for input

•

power, motor power, and control wiring. Use the clamps provided with on the

•

equipment for proper ground connections. Do not ground one frequency converter to

•

another in a "daisy chain" fashion. Keep the ground wire connections as short as

•

possible. Use of high-strand wire to reduce electrical

•

noise is recommended. Follow motor manufacturer wiring

•

requirements.

NOTICE

HIGH ALTITUDES

For installation at altitudes above 2000 m, contact Danfoss regarding PELV.

2 3

456

Enclosure: IP66 , Tamb. 40

C / 104 F

V LT

MADE IN DENMARK

P/N: 134G2844 S/N: 010400G253

4.0kW(400V) / 5.0HP(460V) IN: 3x380-480V 50/60Hz , 8.3/6.8A OUT: 3x0-Vin 0-400Hz , 9.0/8.2A

*1 3 1U3 9 3 0 0 1 0 1 0 2 G 2 9 0 *

Drive Motor www.danfoss.com

T/C: FCP106P4K0T4C66H1FSXXAXX

Enclosure rating: Type 4X E134261 Ind. Contr. Eq.

195NA484.10

Mechanical Installation

3 Mechanical Installation

3.1 Unpacking

Operating Instructions

3.1.3

Items Supplied, FCM 106

NOTICE

INSTALLATION - EQUIPMENT DAMAGE RISK Incorrect installation can result in equipment damage.

Before installation check for fan cover damage,

•

shaft damage, foot or mounting damage, and loose fasteners.

Check nameplate details.

•

Ensure level mounting surface, balanced

•

mounting. Avoid misalignment. Ensure gaskets, sealants, and guards are

•

correctly fitted. Ensure correct belt tension.

•

Items Supplied, FCP 106

3.1.1

Check all items are present:

1 FCP 106 frequency converter

•

1 accessory bag

•

Operating Instructions

•

Check all items are present:

1 FCM 106 frequency converter with motor

•

1 accessory bag

•

Operating Instructions

•

3.1.4 Identification of Unit

Items supplied may vary according to product configuration.

Make sure the items supplied and the

•

information on the nameplate correspond to the order confirmation.

Check the packaging and the frequency converter

•

visually for damage caused by inappropriate handling during shipment. File any claim for damage with the carrier. Retain damaged parts for clarification.

Nameplates

3.1.5

3 3

Additional Items Required, FCP 106

3.1.2

1 adapter plate (wall adapter plate or motor

•

adapter plate) 1 gasket, used between motor adapter plate and

•

frequency converter 1 motor connector

•

4 screws for fastening frequency converter to

•

adapter plate 4 screws for fastening motor adapter plate to

•

motor Crimp terminals:

•

AMP standard power timer contacts female, see chapter 4.6.1 Connect FCP 106 to Motor for ordering numbers

3 pcs for motor terminals, UVW

2 pcs for thermistor (optional)

2 guiding pins (optional)

•

1 Type code 2 Certifications 3 Enclosure rating 4 Bar code for manufacturer use 5 Certifications 6

Serial number

7 Enclosure type and IP rating, max. ambient temperature

Output voltage, frequency, and current (at low/high

voltages)

9 Input voltage, frequency, and current (at low/high voltages) 10 Power rating 11 Ordering number

Illustration 3.1 FCP 106 Nameplate (Example)

1): Example of format: Serial number ‘xxxxx253’ indicates manufacture in week 25, year 2013

195NA483.10

V LT

MOTOR REF: HPS112 1500 159

Drive Motor www.danfoss.com

T/C: FCM106P7K5T4C55H1FSXXAXXE4N7K5150B03000

Listed E347257 EP Motors for Ind. Use Enclosure rating Type 12

Tamb. 40

C/104 F

MADE IN DENMARK

P/N: 134L4306 S/N: 000000G000

IN: 3X380-480V, 50-60Hz, 15/13A

Out: 7.5kW(400V) / 10HP(460V)

Cos /PF: 0.98 / 0.96

MSV: &OEM4&

DUTY Class S1IP55

0-1500 min /50Hz

-1

Wt 14.5 kg

789

DBV: &OEM3&

Mechanical Installation

Operating Instructions

3.1.6 Lifting

NOTICE

LIFTING - EQUIPMENT DAMAGE RISK Incorrect lifting can result in equipment damage.

Handling and lifting of the unit must only be undertaken by qualified personnel. Ensure

Type code

2 Certifications 3 Enclosure rating 4

Serial number 5 Motor duty class 6 Certifications 7 Weight 8 Motor power factor 9 Enclosure rating - Ingress protection (IP) class

10 Frequency range 11 Motor reference 12 Maximum ambient temperature 13 Power rating 14 Input voltage, current, and frequency (at low/high voltages) 15 Ordering number

Illustration 3.2 FCM 106 Nameplate (Example)

Eyebolts or lifting trunnions supplied with the unit are rated to bear the weight of the unit only, not the additional weight of ancillary equipment attached.

3.1.7

Ensure that requirements for storage are fulfilled. Refer to chapter 7.5 Ambient Conditions for further details.

Use both lifting lugs when provided.

•

For vertical lift, prevent uncontrolled rotation.

•

For lift machine, do not lift other equipment

•

with motor lifting points only.

availability of full product documentation,

•

together with tools and equipment necessary for safe working practice.

cranes, jacks, slings, and lifting beams are rated

•

to bear the weight of equipment to be lifted. For weight of unit, see chapter 7.1.4 Weight.

when using an eyebolt, that the shoulder of the

•

eyebolt is tightened firmly against the face of the stator frame, before lifting.

Storage

1): Example of format: Serial number ‘xxxxx253’ indicates manufacture in week 25, year 2013

NOTICE

Do not remove the nameplate from the frequency converter (loss of warranty).

3.2

Installation Environment

NOTICE

In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/Type rating of the equipment matches the installation environment. Failure to meet requirements for ambient conditions can reduce lifetime of the frequency converter. Ensure that requirements for air humidity, temperature and altitude are met.

Vibration and Shock

The frequency converter complies with requirements for units mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors.

For detailed ambient conditions specifications, refer to chapter 7.5 Ambient Conditions.

195NA414.10

Mechanical Installation

3.3 Mounting

Operating Instructions

3.3.1 Introduction

There are different mounting alternatives.

FCM 106

The frequency converter is mounted onto the motor upon delivery. The combined unit is known as the DriveMotor. Installation procedure:

Mount the DriveMotor, see chapter 3.3.4 Mount the DriveMotor.

2. Perform the electrical installation, starting with

chapter 4.7.1 Connecting to Mains.

FCP 106

Mount the frequency converter onto the adapter plate, which is

fastened to a flat surface beside the motor, or

•

mounted directly onto the motor. When

•

assembled, the combined frequency converter and motor is known as the DriveMotor.

Installation procedure:

1. Prepare the gasket and adapter plate, see

chapter 3.3.2 Prepare Gasket and chapter 3.3.3 Prepare Adapter Plate.

2. Connect frequency converter to motor. See

chapter 4.6.1 Connect FCP 106 to Motor. The combined unit is then known as the DriveMotor.

Mount the DriveMotor, see chapter 3.3.4 Mount the DriveMotor.

4. Perform the remaining electrical installation, from

the section chapter 4.7.1 Connecting to Mains.

frequency converter, or ensure metallic contact between the motor adapter plate and motor.

Use a UL approved material for the gasket, when

•

UL listing or recognition is required for the assembled product.

3.3.3 Prepare Adapter Plate

The adapter plate is available with or without pre-drilled holes.

For adapter plate with pre-drilled holes, no extra

•

holes are required. Pre-drilled holes are specific for FCM 106 motors only

For adapter plate with no pre-drilled holes, refer

•

to Illustration 3.3.

3 3

Prepare Gasket

3.3.2

Preparation of a gasket applies only when mounting FCP 106 onto a motor.

Mounting of FCP 106 onto a motor requires fitting a customised gasket. The gasket fits between the motor adapter plate and the motor.

No gasket is supplied with the FCP 106. Therefore, before installation, design and test a gasket to fulfil the ingress protection requirement (for example IP55, IP54, Type 3R).

Requirements for gasket:

Maintain the ground connection between

•

frequency converter and motor. The frequency converter is grounded to the motor adapter plate. Use a wire connection between motor and

Area 1 Area 2

Illustration 3.3 Adapter Plate, Guide for Drilling Holes

When the adapter plate has no holes, drill them as follows:

4 holes within area 1, for fastening adapter plate

•

to motor (required). 1 hole within area 2, for a lifting lug (optional).

•

Make allowance for countersunk screws.

•

195NA411.11

Mechanical Installation Operating Instructions

3.3.4 Mount the DriveMotor

Illustration 3.4 Installation Orientation

Mount the DriveMotor with adequate access for routine maintenance. Observe the recommended clearances, see chapter 7 Specifications. A minimum of 0.75 m clearance around the motor is recommended, both for working access and adequate airflow at the motor fan inlet. See also chapter 7.1 Clearances, Dimensions and Weights. Where more than one DriveMotor is mounted in close proximity, 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.

Fitting pinions, pulleys and couplings.

Drill pinions, pulleys and couplings to standard limits and fit on the shaft with a screwing motion. Ensure correct guarding of all moving parts.

3.3.5 Shaft Alignment

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

Make allowance for shaft endfloat and thermal expansion in both axial and vertical planes. Flexible drive couplings are preferred.

NOTICE

Tapping of fittings onto the 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 Installation Operating Instructions

3.3.6 Bearing Life and Lubrication

The life expectancy of the ball bearings is standard, when the following conditions are fulfilled:

temperature of 80 °C

•

radial forces in load point corresponding to half shaft extension do not exceed the values specified by motor

•

manufacturer

Motor type Frame size Lubrication type Temperature

range

Asynchronous80-180 Lithium basis

PM 71-160

Table 3.1 Lubrication

-40 to 140°C

3 3

Frame

size

71 1500/3000 N.A. N.A. 6203 2ZC3 6203 2ZC3 80 1500/3000 6204 2ZC3 6204 2ZC3 N.A. N.A.

90 1500/3000 6205 2ZC3 6205 2ZC3 6206 2ZC3 6205 2ZC3 100 1500/3000 6206 2ZC3 6206 2ZC3 N.A. N.A. 112 1500/3000 6306 2ZC3 6306 2ZC3 6208 2ZC3 6306 2ZC3 132 1500/3000 6208 2ZC3 6208 2ZC3 6309 2ZC3 6208 2ZC3 160 1500/3000 180 1500/3000

Table 3.2 Standard Bearing References and Oil Seals for Motors

Speed [RPM]

Bearing type, asynchronous motors Bearing type, PM motors

Drive end Non-drive end Drive end Non-drive end

a) a) a) a)

N.A. N.A. N.A. N.A.

a) Data available upon future release.

195NA403.10

Electrical Installation Operating Instructions

4 Electrical Installation

4.1 Safety Instructions

See chapter 2 Safety for general safety instructions.

4.2

IT Mains

CAUTION

IT MAINS

WARNING

INDUCED VOLTAGE

Induced voltage from output motor cables that run together can charge equipment capacitors even with the equipment turned off and locked out. Failure to run output motor cables separately or use screened cables could result in death or serious injury.

run output motor cables separately, or

•

use screened cables

•

CAUTION

SHOCK HAZARD

The frequency converter can cause a DC current in the PE conductor. Failure to follow the recommendation below means the RCD may not provide the intended protection.

When a residual current-operated protective

•

device (RCD) is used for protection against electrical shock, only an RCD of Type B is permitted on the supply side.

Installation on isolated mains source, that is, IT mains. Max. supply voltage allowed when connected to mains: 440 V (3x380-480 V units).

For IT mains operation only,

disconnect power and wait until discharged. See

•

discharge time in Table 2.1. remove cover, see Illustration 4.6.

•

disable the RFI filter by removing the RFI switch/

•

screw. For location, see Illustration 4.1.

In this mode, the internal RFI filter capacitors between housing and the mains RFI filter circuit are disabled, to reduce the ground capacity currents.

Over-current Protection

Additional protective equipment such as short-

•

circuit protection or motor thermal protection between frequency converter and motor is required for applications with multiple motors.

Input fusing is required to provide short-circuit

•

and over-current protection. If not factorysupplied, fuses must be provided by the installer. See maximum fuse ratings in Table 7.15.

Wire Type and Ratings

All wiring must comply with local and national

•

regulations regarding cross-section and ambient temperature requirements.

Power connection wire recommendation:

•

minimum 75 °C rated copper wire.

See chapter 7.10 Fuse and Circuit Breaker Specifications and chapter 7.6 Cable Specifications for recommended wire sizes and types.

1 RFI switch/screw

Illustration 4.1 Location of RFI Switch/Screw

CAUTION

To reinsert, use an M3x12 screw only.

195NA420.10

Electrical Installation

4.3 EMC-Compliant Installation

Operating Instructions

4 4

1 PLC 5 Control cables 2 Motor 6 Mains, 3-phase, and reinforced PE 3 Frequency converter 7 Cable insulation (stripped) 4 Min. 200 mm clearance between control cable, mains cable, and mains motor cable.

Illustration 4.2 EMC-compliant Electrical Installation, FCP 106

195NA407.10

5 4

Electrical Installation

Operating Instructions

1 PLC 4 Control cables 2 DriveMotor 5 Mains, 3-phase, and reinforced PE 3 Min. 200 mm clearance between control cable, mains

cable, and mains motor cable.

6 Cable insulation (stripped)

Illustration 4.3 EMC-compliant Electrical Installation, FCM 106

Electrical Installation

Operating Instructions

To ensure EMC-compliant electrical installation, observe these general points:

Use only screened motor cables and screened

•

control cables. Connect the screen to earth at both ends.

•

Avoid installation with twisted screen ends

•

(pigtails), since this ruins the screen effect at high frequencies. Use the cable clamps provided instead.

Ensure the same potential between frequency

•

converter and ground potential of PLC. Use star washers and galvanically conductive

•

installation plates.

4.4 Cable Requirements

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper or aluminium conductors required, (75 °C) recommended. For cable specifications refer to chapter 7.6 Cable Specifications.

4.5

Grounding

When connecting the FCP 106 to a third party motor, ensure the frequency converter is grounded at minimum 2 points:

Ensure metal contact between adapter plate and

•

motor. Mount an extra ground wire on the adapter plate.

•

Mount an extra ground wire on the motor.

•

4.6

Motor Connection

4.6.1 Connect FCP 106 to Motor

NOTICE

To avoid damage to equipment, before mounting the FCP 106 on the motor,

observe cooling clearances specified in

•

Table 7.1. observe screw clearances listed in Table 7.2.

•

NOTICE

RISK OF DAMAGE Risk of damage to motor or frequency converter exists if screws extend too far into the enclosure or too far above the adapter plate.

To connect the FCP 106 to the motor, follow the installation steps shown in Table 4.1 and Illustration 4.4.

Step Description

1 Mount motor phases and thermistor wires in crimp

terminals. Note: Crimp order numbers from manufacturer TE (AMP standard power timer contacts):

927827 (0.5-1mm2) [AWG 20-17]

•

927833 (1.5-2.5mm2) [AWG 15.5-13.5]

•

927824 (2.5-4mm2) [AWG 13-11]

•

2 Mount PE clamp to motor connector and connect crimp

PE terminal to wire.

3 Mount the gasket between the motor and adapter plate.

See chapter 3.3.2 Prepare Gasket

4 Pull motor phases and thermistor wires through the neck

of the adapter plate.

5 Mount the adapter plate onto the motor using 4 screws.

Insert guide pins into 2 of the screw holes, before

•

lowering the adapter plate into position. Remove the guide pins when mounting screws.

Ensure metallic contact is established between the

•

adapter plate and the motor, via the screws.

6 Mount motor connector gaskets onto the neck of the

adapter plate.

7 Click the terminals into the motor connector.

Mount the 3 motor phases.

•

Mount the 2 thermistor wires.

•

Mount PE connector

•

For correct installation refer to terminal numbers

•

printed on the motor connector.

NOTICE

The thermistor is not galvanically isolated. Interchanging the thermistor wires with the motor wires may permanently damage the frequency converter.

8 Click motor connector into the neck of the adapter plate. 9 Position FCP 106 on adapter plate. 10 Fasten the FCP 106 to adapter plate using 4 screws.

Table 4.1 Installation steps as shown in Illustration 4.4

The FCP 106 is now mounted onto the motor. The combined unit is known as the DriveMotor.

4 4

195NA415.10

7,8

Electrical Installation

Operating Instructions

MT1, M

Motor thermistor wires

U, V, W Motor phases

Illustration 4.4 Connecting FCP 106 to Motor

195NA413.10

195NA408.10

Electrical Installation Operating Instructions

4.6.2 Thermistor Input from Motor

Connect the motor thermistor to the terminals located in the motor connector, as shown in section chapter 4.6.1 Connect FCP 106 to Motor.

Set 1-90 Motor Thermal Protection according to guidelines in chapter 5.3.5 Thermistor Set-up. For more detailed

information refer to the VLT® DriveMotor FCP 106 and FCM 106 Programming Guide.

NOTICE

The thermistor is not galvanically isolated. Interchanging the thermistor wires with the motor wires may permanently damage the frequency converter.

4 4

4.7 AC Mains Connection

4.7.1 Connecting to Mains

The frequency converter is designed to operate all standard 3-phased asynchronous motors and PM motors. For maximum cross section on wires, see

chapter 7.2.1 Mains Supply 3x380-480 V AC Normal and High Overload.

For wall mount of FCP 106

To comply with EMC emissions requirements,

•

use screened motor cable, maximum

length 0.5 m. connect this cable to both the

decoupling plate and the metal housing of the motor.

See also chapter 4.3 EMC-Compliant Installation.

•

Procedure for connection of mains power

Observe safety precautions, see chapter 2.2 Safety Precautions.

2. Loosen front cover screws.

Remove the front cover, see Illustration 4.6.

4. Mount cable glands.

5. Connect the earth wires to the earth terminals via

the cable glands, see Illustration 4.7.

6. Connect the mains cable to terminals L1, L2, and

L3, and tighten screws. See Illustration 4.7.

7. Reassemble cover and tighten screws.

For tightening torques, see chapter 7.8 Connection Tightening Torques.

1 2, 3 Entries for other cables: control, RS-485, and relay

4 Mains cable entry

Illustration 4.5 Location of Cable Entries, MH1-MH3

Illustration 4.6 Remove Front Cover

LCP extension cable entry

cables

195NA405.10

195NA458.10

195NA409.10

Electrical Installation

Operating Instructions

Illustration 4.8 Location of Terminals and Relays, MH1

1 Control terminals 2 Relays 3 Line (L3, L2, L1) 4 PE 5 RS-485

Illustration 4.7 Cabling, MH1-MH3

4.8

Control Wiring

4.8.1 Control Terminals

Procedure:

1. Connect the terminal and cables at the locations

shown in Illustration 4.8 and Illustration 4.9.

2. For additional terminal details, refer to the following sections.

3. Mount the front cover and tighten the screws.

4. The frequency converter is now ready. For startup, go to section chapter 5.1.2 Start-up

Illustration 4.9 Location of Terminals and Relays, MH2-MH3

1 Control terminals 2 Relays 3 UDC+, UDC-, Line (L3, L2, L1) 4 PE 5 LCP connector

Table 4.2 Legend to Illustration 4.9, Illustration 4.8

12 20 55

27 29 42 45 50 53 54

DIGI IN

61 68 69

COMM. GND

+24V

0/4-20mA A OUT / DIG OUT 0/4-20mA A OUT / DIG OUT

GND

10V/20mA IN

10V OUT

130BB625.10

BUS TER.

OFF ON

Electrical Installation Operating Instructions

Control terminals

Illustration 4.10 Control Terminals

Terminal number

12 +24 V output 18 Digital input *PNP/NPN Start 19 Digital input *PNP/NPN No operation 20 Com 27 Digital input *PNP/NPN Coast inverse 29 Digital input *PNP/NPN Jog 50 +10 V output 53 Analog input *0-10 V/0-20 mA/

54 Analog input *0-10 V/0-20 mA/

55 Com 42 12 bit *0-20 mA/4-20

45 12 bit *0-20 mA/4-20

1, 2, 3 Relay 1 1,2 NO 1,3 NC [9] Alarm 4, 5, 6 Relay 2 4,5 NO 4,6 NC [5] Drive

Function Configuration Factory

setting

Ref1

4-20 mA

Ref2

4-20 mA

Analog

mA/DO

Analog

mA/DO

running

NOTICE

Increasing voltage beyond the limit will decrease lifetime, and may permanently damage the frequency converter.

4 4

Table 4.3 Control Terminal Functions

* indicates default setting

Note: PNP/NPN is common for terminals 18, 19 and 27

Load Sharing

4.8.2

Load sharing is not permissible.

4.8.3

Brake

The frequency converter has no internal brake. An external brake can be connected between the UDC+ and UDCterminals. Limit the voltage between these terminals to maximum 768 V.

Electrical Installation Operating Instructions

4.9 Installation Checklist

Before completing installation of the unit, inspect the entire installation as detailed in Table 4.4. Check and mark the items when completed.

Inspect for Description

Auxiliary equipment•Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on the

input power side of the frequency converter or output side to the motor. Ensure that they are ready for full-speed operation

Cable routing

Control wiring

Cooling clearance

Ambient conditions•Check that requirements for ambient conditions are met

Fusing and circuit breakers

Grounding

Input and output power wiring

Panel interior

Switches

Vibration

Check function and installation of any sensors used for feedback to the frequency converter

•

Remove any power factor correction caps on motor(s)

•

Adjust any power factor correction caps on the mains side and ensure that they are dampened

•

Ensure that motor wiring and control wiring are separated or screened or in 3 separate metallic conduits

•

for high-frequency interference isolation

Check for broken or damaged wires and loose connections

•

Check that control wiring is isolated from power and motor wiring for noise immunity

•

Check the voltage source of the signals, if necessary

•

The use of screened cable or twisted pair is recommended. Ensure that the shield is terminated correctly

•

Measure that top and bottom clearance is adequate to ensure proper air flow for cooling, see

•

chapter 7.1 Clearances, Dimensions and Weights

Check for proper fusing or circuit breakers

•

Check that all fuses are inserted firmly and are in operational condition and that all circuit breakers are in

•

the open position

Check for sufficient ground connections that are tight and free of oxidation

•

Grounding to conduit, or mounting the back panel to a metal surface, is not a suitable grounding

•

Check for loose connections

•

Check that motor and mains are in separate conduit or separated screened cables

•

Inspect that the unit interior is free of dirt, metal chips, moisture, and corrosion

•

Check that the unit is mounted on an unpainted, metal surface

•

Ensure that all switch and disconnect settings are in the proper positions

•

Check that the unit is mounted solidly, or that shock mounts are used, as necessary

•

Check for an unusual amount of vibration

•

☑

Table 4.4 Installation Check List

CAUTION

POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE Risk of personal injury when the frequency converter is not properly closed.

Before applying power, ensure all safety covers are in place and securely fastened.

•

130BB628.10

Select Language [ 0 ] English Setup 1

130BB765.11

Com.

1-20 Motor Power [5] 0.37kW - 0.5HP Setup 1

13 14 15

Status

Main Menu

Quick Menu

Hand

Reset

Auto

Alarm

Warn.

Back

O

Commissioning Operating Instructions

5 Commissioning

5.1 Applying Power

5.1.1 Turn on Mains Power

Turn on mains power to power up the frequency converter.

5.1.2 Start-up

5 5

Start the frequency converter. At the first power-up with LCP connected, select the preferred language. Once selected, this screen does not appear again in the following power-ups. To change language at a later stage, go to 0-01 Language.

Illustration 5.1 Select Language

5.2 Local Control Panel Operation

5.2.1 Programming with the Local Control Panel (LCP)

Illustration 5.2 Local Control Panel (LCP)

A. Alphanumeric display

The LCD-display is back-lit with 2 alphanumeric lines. All data is displayed on the LCP.

Information can be read from the display.

NOTICE

The frequency converter can also be programmed from a PC via RS-485 COM port by installing the MCT 10 Set-up Software. Order this software using code number 130B1000, or download from the Danfoss web site:

www.danfoss.com/BusinessAreas/DrivesSolutions/softwaredownload

The LCP is divided into 4 functional sections.

A. Alphanumeric display B. Menu selection C. Navigation keys and indicator lights (LEDs) D. Operation keys and indicator lights (LEDs)

Parameter number and name.

1 2 Parameter value. 3 Set-up number shows the active set-up and the edit set-

up. If the same set-up acts as both active and edit set-up, only that set-up number is shown (factory setting). When active and edit set-up differ, both numbers are shown in the display (Set-up 12). The number flashing, indicates the edit set-up.

4 Motor direction is shown to the bottom left of the display

– indicated by a small arrow pointing either clockwise or counterclockwise.

B. Menu key

Use the [Menu] key to select between status, quick menu or main menu.

The triangle indicates if the LCP is in status, quick menu or main menu.

195NA422.10

38mm

+24V

DIG IN DIG IN

COM DIG IN

A OUT / D OUT A OUT / D OUT

18 19

27 29

50 53 54

01 02 03

04 05 06

0-10V

Start

+10V A IN A IN

COM

130BB674.10

Reference

130BB629.10

Press OK to start Wizard Push Back to skip it Setup 1

Commissioning Operating Instructions

C. Navigation keys and indicator lights (LEDs)

6 Com LED: Flashes when bus communication is communi-

cating. 7 Green LED/On: Control section is working. 8 Yellow LED/Warn.: Indicates a warning. 9 Flashing Red LED/Alarm: Indicates an alarm. 10 [Back]: For moving to the previous step or layer in the

navigation structure 11

[▲] [▼] [►]: For maneuvering between parameter groups,

parameters and within parameters. Can also be used for

setting local reference.

12 [OK]: For selecting a parameter and for accepting changes to

parameter settings

After use, remove the LCP cable from the frequency converter, to maintain the ingress protection class of the enclosure.

5.3 Basic Programming

This manual explains initial set-up only. For full parameter lists refer to the VLT® DriveMotor FCP 106 and FCP 106

Programming Guide.

Upon initial startup the frequency converter will enter the Start-up wizard for Open Loop Applications, see chapter 5.3.1 Start-up Wizardfor Open Loop Applications. Once the start-up wizard is complete, the following additional set-up wizards and instructions are available:

D. Operation keys and indicator lights (LEDs)

13 [Hand On]: Starts the motor and enables control of the

frequency converter via the LCP.

NOTICE

Terminal 27 Digital Input (5-12 Terminal 27 Digital Input) has coast inverse as default setting. This

means that [Hand On] does not start the motor if

For general instructions in changing parameter settings, refer to chapter 5.3.4 Changing Parameter Settings.

chapter 5.3.2 Set-up Wizard for Closed Loop

•

Applications chapter 5.3.3 Quick Menu: Motor Set-up

•

chapter 5.3.5 Thermistor Set-up

•

there is no 24 V to terminal 27. Connect terminal

Start-up Wizardfor Open Loop

12 to terminal 27.

5.3.1 Applications

14 [Off/Reset]: Stops the motor (Off). If in alarm mode the

15 [Auto On]: Frequency converter is controlled either via

5.2.2 Connect LCP Cable

1 Control panel 2 Panel door

To view or change the frequency converter settings, attach the LCP using the LCP cable. See Illustration 5.3.

alarm is reset.

control terminals or serial communication.

Illustration 5.3 LCP Remote Mounting

The start-up wizard guides the installer through the set-up of the frequency converter in a clear and structured manner to set up an open loop application. An open loop application does not utilise a feedback signal from the process.

Illustration 5.4 Principle Wiring for Open Loop Start-up Wizard

Illustration 5.5 Wizard Start View

195NA416.10

International

4-12

Motor Speed low Limit

4-14

Motor Speed high Limit

3-41

Ramp 1 ramp-up time

3-42

Ramp 1 ramp-down Time

1-73 Active

Flying start?

Disable

1-20

Motor Power

1-22

Motor Voltage

1-23

Motor frequency

1-24

Motor current

1-25

Motor nominal speed

0-03

Regional Settings

... the FCP106 /FCM106 Wizard starts

380-440V/50Hz

Grid Type

Asynchronous Motor

Asynchronous

1-10

Motor Type

1-24

Motor current

1-25

Motor nominal speed

1-26

Motor Cont. Rated Torque

1-30

Stator resistance

1-39

Motor poles

1-40

Back EMF at 1000 rpm

1-37

d-axis inductance

4-19

Max Output Frequency

6 - 10 T53 low Voltage

6 - 11 T53 high Voltage

6 - 12 T53 Low Current

6 - 13 T53 High Current

Current

Voltage

Setup 1

AMA Failed

0.0 Hz

0.0 kW

Wizard completed Press OK to accept

1-29

Automatic Motor Adaption

O

Auto Motor Adapt OK Press OK

5 - 40 Function of Relay 2

No function

5 - 40 Function of Relay 1 [0] No function

3-03

Max Reference

3-02

Min Reference

AMA running

-----

AMA failed

Perform AMA

(Do not perform AMA)

AMA OK

6 - 19 T53 Mode

Current

3.8

3000

RPM

5.4

0.65

Ohms

0065

1.50

0050

04.66

1420

RPM

[0]

Motor Type = Asynchronous

Motor Type = PM Motor

0000

0050

0003

04.66

13.30

0050

0220

0000

0050

Status

Main Menu

Quick Menu

Hand

O

Reset

Auto

Alarm

Warn.

Status Screen

The Wizard can always be

reentered via the Quick Menu!

Power Up Screen

At power up, select preferred laguage.

Select language [1] English

0.0 Hz

0.0 kW

Setup 1

Status

Main Menu

Quick Menu

Hand

O

Reset

Auto

Alarm

Warn.

Press OK to start Wizard Press Back to skip it

Setup 1

Status

Main Menu

Quick Menu

Hand

O

Reset

Auto

Alarm

Warn.

The Wizard start screen appears.

Wizard Screen

Com.

Setup 1

[12]

Setup 1

[0]

Setup 1

[0]

Setup 1

[0]

[1]

Setup 1

[0]

Setup 1

0-06

PM motor

Commissioning

Operating Instructions

The wizard start view appears after power up, and remains until a parameter setting is changed. Access to the wizard

Illustration 5.6 Start-up Wizard for Open Loop Applications

is always available later, via the quick menu. Press [OK] to start the wizard. Press [Back] to return to the status screen.

5 5

195NA417.10

6-29 Terminal 54 Mode

[1]

Voltage

6-25 T54 high Feedback

0050

20-94 PI integral time

0020.00

Current

Voltage

This dialog is forced to be set to

[1] Analog input 54

20-00 Feedback1 source

[1]

Analog input 54

3-10 Preset reference [0]

0.00

3-03 Max Reference

50.00

3-02 Min Reference

0.00

Asynchronous Motor

1-73 Flying Start

[0]

1-22 Motor Voltage

0050

1-24 Motor current

04.66

1-25 Motor nominal speed

1420

RPM

3-41 Ramp 1 ramp-up time

0003

3-42 Ramp1 ramp-down time

0003

0-06 Grid Type

4-12 Motor speed low limit

0016

4-14 Motor speed high limit

0050

1-20 Motor Power

1.10

1-23 Motor frequency

0050

6-22 T54 Low Current

6-24 T54 low Feedback

0016

6-23 T54 high Current

13.30

6-25 T54 high Feedback

0050

0.01

20-81 PI Normal/Inverse Control

[0]

Normal

20-83 PI Normal/Inverse Control

0050

20-93 PI Proportional Gain

00.50

1-29 Automatic Motor Adaption

[0]

O

6-20 T54 low Voltage

0050

6-24 T54 low Feedback

0016

6-21 T54 high Voltage

0220

6-26 T54 Filter time const.

1-00 Conguration Mode

[3]

Closed Loop

0-03 Regional Settings

[0]

1-10 Motor Type

[0]

Asynchronous

[12]

380-440V/50Hz

1-30 Stator resistance

0.65

Ohms

1-25 Motor nominal speed

3000

RPM

1-24 Motor Current

3.8

1-26 Motor Cont. Rated Torque

5.4

1-37 d-axis inductance(Ld)

4-19 Max Ouput Frequency

0065

1-40 Back EMF at 1000 rpm

PM motor

1-39 Motor poles

04.66

MotorType = Asynchronous

MotorType = PM Motor

International

Resource

Setup 1

Commissioning

Operating Instructions

5.3.2 Set-up Wizard for Closed Loop Applications

Illustration 5.7 Closed Loop Set-up Wizard

195NA462.10

Asynchronous Motor

1-73 Flying Start

[0]

Disabled

1-22 Motor Voltage

400

1-24 Motor current

3.80

1-25 Motor nominal speed

1420

RPM

3-41 Ramp 1 ramp-up time

3.00

3-42 Ramp1 ramp-down time

3.00

0-06 Grid Type

4-12 Motor speed low limit

4-14 Motor speed high limit

1-20 Motor Power

1.1

1-23 Motor frequency

0-03 Regional Settings

[0]

1-10 Motor Type

[0]

Asynchronous

[12]

380-440V/50Hz

1-30 Stator resistance

0.65

Ohms

1-25 Motor nominal speed

3000

RPM

1-24 Motor Current

3.80

1-26 Motor Cont. Rated Torque

5.4

1-37 d-axis inductance(Ld)

4-19 Max Ouput Frequency

0065

1-40 Back EMF at 1000 rpm

PM motor

1-39 Motor poles

Asynchronous

PM Motor

International

Setup 1

Commissioning Operating Instructions

5.3.3 Quick Menu: Motor Set-up

The Quick Menu Motor Set-up guides the installer through setting of the required motor parameters.

NOTICE

MOTOR OVERLOAD PROTECTION

Thermal protection of the motor is recommended. Especially when running at low speed, the cooling from the integrated motor fan is often not sufficient.

Use PTC or Klixon, see chapter 4.6.2 Thermistor

•

Input from Motor, or Enable motor thermal protection by setting

•

1-90 Motor Thermal Protection to [4] ETR trip 1.

5 5

Illustration 5.8 Quick Menu Motor Set-up

Commissioning Operating Instructions

5.3.4 Changing Parameter Settings

Quick access to change parameter settings

1. To enter the Quick Menu, press [Menu] until the indicator in the display is located at Quick Menu.

Press [▲] [▼] to select wizard, closed loop set-up, motor set-up, or changes made, then press [OK].

Press [▲] [▼] to browse through the parameters in the Quick Menu.

4. Press [OK] to select a parameter.

Press [▲] [▼] to change the value of a parameter setting.

Press [►] to shift digit when a decimal parameter is in the editing state.

7. Press [OK] to accept the change.

8. Press either [Back] twice to enter “Status”, or press [Menu] once to enter “Main Menu”.

The Main Menu accesses all parameters

1. Press [Menu] until the indicator in the display is located at “Main Menu”.

Press [▲] [▼] to browse through the parameter groups.

3. Press [OK] to select a parameter group.

Press [▲] [▼] to browse through the parameters in the specific group.

5. Press [OK] to select the parameter.

Press [▲] [▼] to set/change the parameter value.

Changes Made

1. Press [Menu] until the indicator in the display is located at “Quick Menus”.

Press [▲] [▼] to browse through the quick menus.

Press [OK] to select 05 Changes Made. Changes Made lists all parameters changed from

•

default settings The list shows only parameters which have been

•

changed in the current edit-setup. Parameters which have been reset to default

•

values are not listed. The message 'Empty' indicates that no

•

parameters have been changed.

5.3.5

Thermistor Set-up

Set 1-90 Motor Thermal Protection to [1] Thermistor warning or [2] Thermistor trip. For details refer to VLT

FCP 106 and FCM 106 Programming Guide.

DriveMotor

Maintenance, Diagnostics an... Operating Instructions

6 Maintenance, Diagnostics and Troubleshooting

6.1 Maintenance

Under normal operating conditions and load profiles, the frequency converter is maintenance-free throughout its designed lifetime. To prevent breakdown, danger, and damage, examine the frequency converter at regular intervals depending on the operating conditions. Replace worn or damaged parts with original spare parts or standard parts. For service and support, refer to www.danfoss.com/contact/sales_and_services/.

6.1.1 Before Starting Repair Work

Before starting repair work:

Read the safety warnings in

2. Disconnect the frequency converter from mains.

3. Disconnect the frequency converter from external DC supply, if present.

4. Disconnect the frequency converter from motor as it can generate voltage when turned, for example by windmilling.

5. Wait for discharge of the DC link. For discharge time, see Table 2.1.

6. Remove the frequency converter from the motor adapter plate or wall mounting plate.

6.2 List of Warnings and Alarms

Alarm/ warning number

2 Live zero error X X

4 Mains ph. loss X X X

7 DC over volt X X Intermediate circuit voltage exceeds limit. 8 DC under volt X X Intermediate circuit voltage is lower than “voltage warning low” limit.

10 Motor ETR over X X

11 Motor th over X X

13 Over Current X X X Inverter peak current limit is exceeded. 14 Earth Fault X X Discharge from output phases to ground. 16 Short Circuit X X Short-circuit in motor or on motor terminals.

25 Brake resistor

27 Short circuited X X 28 Brake check X X

30 U phase loss X X

31 V phase loss X X

32 W phase loss X X

38 Internal fault X X Contact the local Danfoss supplier.

Fault text Warning Alarm Trip lock Cause of problem

Signal on terminal 53 or 54 is less than 50% of value set in 6-10 Terminal 53 Low Voltage, 6-12 Terminal 53 Low Current, 6-20 Terminal 54 Low Voltageor 6-22 Terminal 54 Low Current. See also parameter group 6–0* Analog In/Out Missing phase on supply side or excess voltage imbalance. Check supply voltage. See 14-12 Function at Mains Imbalance

Inverter overload

Control word timeout

short

X X More than 100% load for too long.

Motor is overheated due to more than 100% load for too long. See 1-90 Motor Thermal Protection. Thermistor or thermistor connection is disconnected. See 1-90 Motor Thermal Protection.

X X

No communication to frequency converter. See parameter group 8-0*

Comm. and Options.

Motor phase U is missing. Check the phase. See 4-58 Missing Motor Phase Function. Motor phase V is missing. Check the phase. See 4-58 Missing Motor Phase Function. Motor phase W is missing. Check the phase. See 4-58 Missing Motor Phase Function.

6 6

Maintenance, Diagnostics an...

Alarm/ warning number

40 Overload T27 X The terminal 27 is overloaded or short circuited to earth. 41 Overload T29 X The terminal 29 is overloaded or short circuited to earth.

Fault text Warning Alarm Trip lock Cause of problem

Earth Fault DESAT Gate drive voltage fault 24 V supply low

AMA U

AMA low I AMA motor too big AMA motor too small AMA parameter out of range AMA interrupted by user

nom

, I

nom

X X

X X X 24 V DC is possibly overloaded.

X The motor current is too low. Check the settings.

X The motor is too large to perform AMA.

X The motor is too small to perform AMA.

X The user has interrrupted the AMA.

Operating Instructions

Discharge from output phases to ground, using the value of 15–31 Alarm Log Value if possible.

The supply on the power card is out of range. Contact the local Danfoss supplier.

The setting of motor voltage, motor current, and motor power is presumably wrong. Check the settings.

The parameter values found from the motor are outside acceptable range

Try to start the AMA again a number of times, until the AMA is complete.

NOTICE

57 AMA time-out X

Repeated runs can heat the motor to a level where the resistance Rs and Rr are increased. In most cases, however, this is not critical

58 AMA internal X X Contact the local Danfoss supplier. 59 Current limit X

63 Mechanical

69 Pwr. Card Temp X X X

80 Drive initialised X All parameter settings are initialised to default settings.

95 Broken Belt X X

99 Locked rotor X

101

126 Motor Rotating X High back-emf voltage. Stop the rotor of the PM motor. 127 Back EMF too

201 Fire Mode X Fire mode has been activated

202

External Interlock

brake low

Auto DC Braking

Flow/pressure info missing

high

Fire Mode Limits Exceeded

X The frequency converter is auto DC braking

X Flow/pressure information is missing

X Fire Mode has suppressed one or more warranty voiding alarms

The current is higher than the value in 4-18 Current Limit External interlock has been activated. To resume normal operation, apply 24 V DC to the terminal programmed for external interlock and reset the frequency converter. Reset via serial communication, digital I/O, or [Reset] on the LCP). The minimum required current for opening the mechanical brake has not been reached. The temperature sensor on the power card is either too hot or too cold.

Torque is below the torque level set for no load, indicating a broken belt. See parameter group 22-6* Broken Belt Detection. The drive detected a locked rotor situation. See 30-22 Locked Rotor Protection and 30-23 Locked Rotor Detection Time [s].

Table 6.1 Warnings and Alarms

1 2

195NA494.10

Specifications Operating Instructions

7 Specifications

7.1 Clearances, Dimensions and Weights

7.1.1 Clearances

Observe the minimum clearances listed in Table 7.1 to ensure sufficient air flow for the frequency converter. When air flow is obstructed close to the frequency converter, ensure adequate inlet of cool air and exhaust of hot air from the unit.

Enclosure

type

MH1 IP54/Type 3R 0.55-1.5 30 100 MH2 IP54/Type 3R 2.2-4.0 40 100 MH3 IP54/Type 3R 5.5-7.5 50 100

Table 7.1 Minimum Clearance for Cooling

1) Power ratings relate to NO, see chapter 7.2 Electrical Data.

Enclosure

type

MH1 3 0.5 MH2 4 0.5 MH3 3.5 0.5

Table 7.2 Information for Screws to Fasten Motor Adapter Plate

Maximum depth of hole

into adapter plate (A)

IP class

[mm]

3x380-480 V Motor flange end Cooling fan end

Maximum height of

screw above adapter

plate (B)

[mm]

Power

[kW]

1 Adapter plate 2 Screw A Maximum depth of hole into adapter plate B Maximum height of screw above adapter plate

Clearance at ends

[mm]

7 7

Illustration 7.1 Screws to Fasten Motor Adapter Plate

195NA418.10

Specifications Operating Instructions

7.1.2 FCP 106 Dimensions

Illustration 7.2 FCP 106 Dimensions

Power

Enclosure type

MH1 0.55-1.5 231.4 130 162.1 106.8 M20 M20 M6 MH2 2.2-4.0 276.8 166 187.1 113.2 M20 M20 M6 MH3 5.5-7.5 321.7 211 221.1 123.4 M20 M25 M6

Table 7.3 FCP 106 Dimensions

1) Power ratings relate to NO, see chapter 7.2 Electrical Data.

[kW]

3x380-480 V A a B C X Y

Length

[mm]

Width

[mm]

Height

[mm]

Cable gland diameter Mounting

hole

195NA454.10

AC1

ED1

Specifications

7.1.3 FCM 106 Dimensions

Operating Instructions

7 7

Motor

71 80 90S 90L 100L 100L 112M 132S 132M 160M 160L 180M 180L frame size

A [mm] 112 125 140 140 160 160 190 216 216 254 254 279 279 B [mm] 90 100 100 125 140 140 140 140 178 210 254 241 279 C [mm] 45 50 56 56 63 63 70 89 89 108 108 121 121 H [mm] 71 80 90 90 100 100 112 132 132 160 160 180 180 K [mm] 8 10 10 10 11 11 12.5 12 12 14 14 15 15 AA [mm] 31 34.5 37 37 44 44 48 59 59 76 76 75 75 AB [mm] 135 153 170 170 192 192 220 256 256 320 320 348 348 BB [mm] 108 125 150 150 166 166 176 180 218 270 310 310 348 BC [mm] 83 89 116 91 110 144 126 134 136 180 180 256 256 L [mm] 246 272 317 317 366 400 388 445 485 608 652 687 725 AC [mm] 139 160 180 180 196 194 225 248 248 317 317 360 360 E [mm] 30 40 50 50 60 60 60 80 80 110 110 110 110 ED [mm] 20 30 30 40 40 50 50 70 70 100 100 100 100 EB [mm] 4 4 4 4 4 4 4 4 4 4 4 5 5 FCL [mm] FCW [mm] HA [mm] HA = H + (height of the frequency converter)

For frequency converter dimensions, see Table 7.3.

Table 7.4 FCM 106 Dimensions: Foot Mounting - B3 Asynchronous or PM Motor

195NA455.10

Specifications Operating Instructions

Motor

71 80 90S 90L 100L 112M 132S 160M 180M

frame size

M [mm] 130 165 165 165 215 215 265 300 300 N [mm] 110 130 130 130 180 180 230 250 250 P [mm] 160 200 200 200 250 250 300 350 350 S [mm] M8 M10 M10 M10 M12 M12 M12 M16 M16 T [mm] 3.5 3.5 3.5 3.5 4 4 4 5 5 LA [mm] 10 10 12 12 14 14 14 15 13 HA [mm] HA = H + (height of the frequency converter)

For frequency converter dimensions, see Table 7.3.

Table 7.5 FCM 106 Dimensions: Flange Mounting - B5, B35 for Asynchronous or PM Motor

195NA456.10

Specifications

Operating Instructions

7 7

Small flange B14 Motor frame size

M [mm] 85 100 115 130 130 165 215 N [mm] 70 80 95 110 110 130 180 P [mm] 105 120 140 160 160 200 250 S [mm] M6 M6 M8 M8 M8 M10 M12 T [mm] 2.5 3 3 3.5 3.5 3.5 4 LA [MM] 11 9 9 10 10 30 12 -

Motor frame size

M [mm] 115 130 130 165 165 215 265 N [mm] 95 110 110 130 130 180 230 P [mm] 140 160 160 200 200 250 300 S [mm] M8 M8 M8 M10 M10 M12 M16 T [mm] 2.5 3.5 3.5 3.5 3.5 4 5 LA [MM] 8 8.5 9 12 12 12 12 HA [mm] HA = H + (height of the frequency converter)

Table 7.6 FCM 106 Dimensions: Face Mounting - B14, B34 for Asynchronous or PM motor

71 80 90S 100L 112M 132S 160M/L 180M

Large flange B14

71 80 90S 100L 112M 132S 160M/L 180M

For frequency converter dimensions, see Table 7.3.

195NA457.10

M6 DIN 332-DH

Specifications Operating Instructions

FCM 106 with Asynchronous or PM motor Motor frame size

D [mm] 14 19 24 28 28 38 42 48 F [mm] 5 6 8 8 8 10 12 14 G [mm] 11 15.5 20 24 24 33 37 42.5 DH M5 M6 M8 M10 M10 M12 M16 M16

Table 7.7 FCM 106 Dimensions: Shaft Drive End - Asynchronous or PM Motor

71 80 90S 100L 112M 132S 160M/L 180M

plate

[kg]

Weight

Combined FCP 106 and motor adapter

Frame

size

plate

[kg]

Weight

[kg]

Weight

7.1.4

FCP 106

Weight

[kg]

Enclosure type

MH1 3.9 0.42 4.3 MH2 5.8 0.54 6.3 MH3 8.1 0.78 8.9

Table 7.8 Weight of FCP 106

Frame

size

To calculate the total weight of the unit, add

weight of combined frequency converter and

•

adapter plate, see Table 7.8, and weight of motor, see Table 7.9.

•

PM motor Asynchronous motor

Shaft power

[kW]

0.55 71 4.8 N.A. N.A. N.A.

0.75 71 5.4 71 4.8 80S 11 71 9.5

1.1 71 7.0 71 4.8 90S 16.4 80 11

1.5 71 10 71 6.0 90L 16.4 80 14

2.2 90 12 71 6.6 100L 22.4 90L 16 3 90 14 90S 12 100L 26.5 100L 23 4 90 17 90S 14 112M 30.4 100L 28

5.5 112 30 90S 16 132S 55 112M 53

7.5 112 33 112M 26 132M 65 112M 53

1500 rpm 3000 rpm 1500 rpm 3000 rpm

Frame

size

Weight

[kg]

Frame

size

Motor adapter

[kg]

Weight

[kg]

Table 7.9 Approximate Weight of Motor

Specifications Operating Instructions

7.2 Electrical Data

Enclosure

Overload Typical shaft output [kW] Typical shaft output [hp] Max. cable crosssection in terminals (mains, motor) [mm2/AWG]

Output current 40 °C ambient temperature

Continuous (3x380-440 V) [A] Intermittent (3x380-440 V) [A] Continuous (3x440-480 V) [A] Intermittent (3x440-480 V) [A]

Max. input current

Continuous (3x380-440 V )[A] Intermittent (3x380-440 V) [A] Continuous (3x440-480 V) [A] Intermittent (3 x 440-480 V) [A] Max. mains fuses

PK55 PK75 P1K1 P1K5 P2K2 P3K0 P4K0 P5K5

NO HO NO HO NO HO NO HO NO HO NO HO NO HO

0.55 0.75 1.1 1.5 2.2 3.0 4.0

0.75 1.0 1.5 2.0 3.0 4.0 5.0

4/10 4/10 4/10 4/10 4/10 4/10 4/10

1.7 2.2 3.0 3.7 5.3 7.2 9.0

1.9 2.7 2.4 3.5 3.3 4.8 4.1 5.9 5.8 8.5 7.9 11.5 9.9 14.4

1.6 2.1 2.8 3.4 4.8 6.3 8.2

1.8 2.6 2.3 3.4 3.1 4.5 3.7 5.4 5.3 7.7 6.9 10.1 9.0 13.2

1.3 2.1 2.4 3.5 4.7 6.3 8.3

1.4 2.0 2.3 2.6 2.6 3.7 3.9 4.6 5.2 7.0 6.9 9.6 9.1 12.0

1.2 1.8 2.2 2.9 3.9 5.3 6.8

1.3 1.9 2.0 2.5 2.4 3.5 3.2 4.2 4.3 6.3 5.8 8.4 7.5 11.0

MH1 MH2 MH3

7 7

See chapter 7.10 Fuse and Circuit Breaker Specifications

Table 7.10 Mains Supply 3x380-480 V AC Normal and High Overload: MH1, MH2, and MH3 Enclosure

1) NO: Normal overload, 110% for 1 minute. HO: High overload, 160% for 1 minute A frequency converter intended for HO requires a corresponding motor rating. For example, Table 7.10 shows that a 1.5 kW motor for HO requires a P2K2 frequency converter.

2) Max. cable cross-section is the largest cable cross-section that can be attached to the terminals. Always observe national and local regulations.

Specifications Operating Instructions

Enclosure

Overload Typical shaft output [kW] 5.5 7.5 Typical shaft output [hp] 7.5 10 Max. cable cross-section in terminals (mains, motor) [mm2/AWG]

Output current 40 °C ambient temperature

Continuous (3x380-440 V) [A] Intermittent (3x380-440 V) [A] Continuous (3x440-480 V) [A]

Intermittent (3x440-480 V) [A]

Max. input current

Continuous (3x380-440 V )[A] Intermittent (3x380-440 V) [A] Continuous (3x440-480 V) [A] Intermittent (3 x 440-480 V) [A]

Max. mains fuses

P5K5 P7K5

NO HO NO

13.2 14.4 17.1

12.1 13.2 15.4

12 17 17

10 15 14

See chapter 7.10 Fuse and Circuit

MH3

4/10 4/10

12 15.5

11 14

11 15

9.4 13

Breaker Specifications

Table 7.11 Mains Supply 3x380-480 V AC Normal and High Overload: MH3 Enclosure

1) NO: Normal overload, 110% for 1 minute. HO: High overload, 160% for 1 minute A frequency converter intended for HO requires a corresponding motor rating. For example, Table 7.11 shows that a 5.5 kW motor for HO requires a P7K5 frequency converter.

2) Max. cable cross-section is the largest cable cross-section that can be attached to the terminals. Always observe national and local regulations.

Specifications Operating Instructions

7.3 Mains Supply

Mains supply (L1, L2, L3) Supply voltage 380-480 V ±10%

Mains voltage low/mains drop-out:

During low mains voltage or a mains drop-out, the frequency converter continues until the intermediate circuit

•

voltage drops below the minimum stop level, which corresponds typically to 15% below the lowest rated supply voltage of the frequency converter. Power-up and full torque cannot be expected at mains voltage lower than 10% below the lowest rated supply voltage of the frequency converter.

Supply frequency 50/60 Hz Max. imbalance temporary between mains phases 3.0% of rated supply voltage True Power Factor (λ) ≥ 0.9 nominal at rated load Displacement Power Factor (cosφ) near unity (>0.98) Switching on the input supply L1, L2, L3 (power-ups) Max. 2 times/min. Environment according to EN 60664-1 overvoltage category III/pollution degree 2 The unit is suitable for use on a circuit capable of delivering not more than

100,000 RMS symmetrical Amperes, 480 V maximum, with fuses used as branch circuit protection

•

10,000 RMS symmetrical Amperes, 480 V maximum, with circuit breakers used as branch circuit protection

•

7 7

7.4 Protection and Features

Protection and features

Electronic thermal motor protection against overload.

•

Temperature monitoring of the heat sink ensures that the frequency converter trips when the temperature reaches

•

90 °C ±5°C. An overload temperature cannot be reset until the temperature of the heatsink is below 70 °C ±5 °C (Guideline - these temperatures may vary for different power sizes, enclosures etc.). The frequency converter auto derating function ensures that the heatsink temperature does not reach 90 °C.

The frequency converter is protected against short-circuits between motor terminals U, V, W.

•

When a motor phase is missing, the frequency converter trips and issues an alarm.

•

When a mains phase is missing, the frequency converter trips or issues a warning (depending on the load).

•

Monitoring of the intermediate circuit voltage ensures that the frequency converter trips, when the intermediate

•

circuit voltage is too low or too high. The frequency converter is protected against earth faults on motor terminals U, V, W.

•

All control terminals and relay terminals 01-03/04-06 comply with PELV (Protective Extra Low Voltage). However

•

this does not apply to grounded Delta leg above 400 V.

7.5 Ambient Conditions

Environment Enclosure IP54/Type 3R Stationary vibration (IEC 60721-3-3 Class 3M6) 2.0 g Non-stationary vibration (IEC 60721-3-3 Class 3M6) 25.0 g Relative humidity (IEC 60721-3-3; Class 3K4 (non-condensing)) 5%-95% during operation Aggressive environment (IEC 60721-3-3) Class 3C3 Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature 40 °C (24-hour average)

Minimum ambient temperature during full-scale operation -10 °C Minimum ambient temperature at reduced performance -20 °C Temperature during storage -25 to +65 °C Temperature during transport -25 to +70 °C

Specifications Operating Instructions

Maximum altitude above sea level without derating 1000 m Maximum altitude above sea level with derating 3000 m Safety standards EN/IEC 60204-1, EN/IEC 61800-5-1, UL 508C EMC standards, Emission EN61000-3-2, EN61000-3-12, EN55011, EN61000-6-4 EMC standards, Immunity EN61800-3, EN61000-6-1/2

7.6 Cable Specifications

Cable lengths and cross sections Max. motor cable length, screened/armoured 0.5 m Max. cross section to motor, mains for MH1-MH3 4 mm2/10 AWG Max. cross section DC terminals on enclosure type MH1-MH3 4 mm2/10 AWG Maximum cross section to control terminals, rigid wire 2.5 mm2/14 AWG Maximum cross section to control terminals, flexible cable 2.5 mm2/14 AWG Minimum cross section to control terminals 0.05 mm2/30 AWG Max. cross section to thermistor input (at motor connector) 4.0 mm

7.7 Control Input/Output and Control Data

Digital inputs

Programmable digital inputs 4 Terminal number 18, 19, 27, 29 Logic PNP or NPN Voltage level 0-24 V DC Voltage level, logic '0' PNP <5 V DC Voltage level, logic '1' PNP >10 V DC Voltage level, logic '0' NPN >19 V DC Voltage level, logic '1' NPN <14 V DC Maximum voltage on input 28 V DC Input resistance, R

Approx. 4 kΩ

Digital input 29 as Pulse input Max frequency 32 kHz Push-Pull-Driven & 5 kHz (O.C.)

Analog inputs

Number of analog inputs 2 Terminal number 53, 54 Terminal 53 mode Parameter 6-19: 1=voltage, 0=current Terminal 54 mode Parameter 6-29: 1=voltage, 0=current Voltage level 0-10 V Input resistance, R

approx. 10 kΩ Max. voltage 20 V Current level 0/4 to 20 mA (scalable) Input resistance, R

<500 Ω

Max. current 29 mA

Analog output

Number of programmable analog outputs 2 Terminal number 42, 45 Current range at analog output 0/4-20 mA Max. load to common at analog output 500 Ω Max. voltage at analog output 17 V Accuracy on analog output Max. error: 0.4% of full scale Resolution on analog output 10 bit

Terminal 42 and 45 can also be programmed as digital outputs.

Specifications Operating Instructions

Digital output Number of digital outputs 2 Terminal number 42, 45 Voltage level at digital output 17 V Max. output current at digital output 20 mA Max. load at digital output 1 kΩ

1) Terminals 42 and 45 can also be programmed as analog output.

Control card, RS-485 serial communication Terminal number 68 (P, TX+, RX+), 69 (N, TX-, RX-) Terminal number 61 Common for terminals 68 and 69

Control card, 24 V DC output

Terminal number 12 Maximum load 80 mA

Relay output

Programmable relay output 2 Relay 01 and 02 01-03 (NC), 01-02 (NO), 04-06 (NC), 04-05 (NO) Max. terminal load (AC-1)1) on 01-02/04-05 (NO) (Resistive load) 250 V AC, 3 A Max. terminal load (AC-15)1) on 01-02/04-05 (NO) (Inductive load @ cosφ 0.4) 250 V AC, 0.2 A Max. terminal load (DC-1)1) on 01-02/04-05 (NO) (Resistive load) 30 V DC, 2 A Max. terminal load (DC-13)1) on 01-02/04-05 (NO) (Inductive load) 24 V DC, 0.1 A Max. terminal load (AC-1)1) on 01-03/04-06 (NC) (Resistive load) 250 V AC, 3 A Max. terminal load (AC-15)1) on 01-03/04-06 (NC) (Inductive load @ cosφ 0.4) 250 V AC, 0.2 A Max. terminal load (DC-1)1) on 01-03/04-06 (NC) (Resistive load)

Min. terminal load on 01-03 (NC), 01-02 (NO) 24 V DC 10 mA, 24 V AC 20 mA

30 V DC, 2 A

Environment according to EN 60664-1 Overvoltage category III/pollution degree 2

IEC 60947 parts 4 and 5.

Control card, 10 V DC output

Terminal number 50 Output voltage 10.5 V ±0.5 V Max. load 25 mA

All inputs, outputs, circuits, DC supplies and relay contacts are galvanically isolated from the supply voltage (PELV) and

other high-voltage terminals.

7 7

Specifications Operating Instructions

7.8 Connection Tightening Torques

Location Type Torque

[Nm]

Front cover screws T20 or slot 3-3.5

Plastic cable blind

plugs

Control card T10 1.3

Relay card T10 1.3

Control plate T20 or slot 1.5

Connection to

adapter plate

Table 7.12 Tightening Torques for Frequency Converter External Screws

Enclosure type

MH1 0.55-1.5

MH3 5.5-7.5

24 mm or 28 mm

socket

T20 or slot

Power

[kW]

380-480 V

2.2

7.0

Line Motor DC

connection

crimp,

1.4

no applied

torque

1.4 0.5 3.0 0.5 0.9MH2 2.2-4

Torque

[Nm]

Control

terminals

Earth Relay RFI switch

Table 7.13 Tightening Torques for Frequency Converter Internal Screws

Power

Enclosure type

MH1 0.55-1.5 MH2 2.2-4 MH3 5.5-7.5

Table 7.14 Screw Types for Frequency Converter Internal Screws

1) Power ratings relate to NO, see chapter 7.2 Electrical Data.

[kW]

380-480 V

Line Motor DC

slot or Phillips

crimp

connection

slot or

Phillips

Type

Control

terminals

slot or

Phillips

Earth Relay RFI switch

T20,

slot, or

10 mm socket

slot

T20 or

slot

7.9 FCM 106 Motor Specifications

Motor output (U, V, W) Output voltage 0-100% of supply voltage Output frequency, asynchronous motor 0-200 Hz (VVC Output frequency, PM motor 0-390 Hz (VVC Switching on output Unlimited Ramp times 0.05-3600 s

Thermistor input (at motor connector) Input conditions Fault: >2.9 kΩ, no fault: <800 Ω

plus

), 0-400 Hz (u/f)

plus

PM)

Specifications Operating Instructions

7.10 Fuse and Circuit Breaker Specifications

Overcurrent protection

Provide overload protection to avoid overheating of the cables in the installation. Overcurrent protection must always be carried out according to local and national regulations. Fuses must be designed for protection in a circuit capable of supplying a maximum of 100,000 A circuit capable of supplying a maximum of 10,000 A circuit breaker.

UL/Non UL Compliance

Use the circuit breakers or fuses listed in Table 7.15, to ensure compliance with UL or IEC 61800-5-1. Circuit breakers must be designed for protection in a circuit capable of supplying a maximum of 10,000 A 480 V maximum. In the event of malfunction, failure to follow the protection recommendation can result in damage to the frequency converter.

Power

Enclosure

type

MH1

MH2

[kW]

380-480 V

0.55

0.75

1.1

1.5

2.2

3.0

4.0

Rec. UL Max. UL

CTI25M -

047B3146

CTI25M -

047B3147

CTI25M -

047B3147

CTI25M -

047B3148

CTI25M -

047B3149

CTI25M -

047B3149

CTI25M -

047B3150

(symmetrical), 480 V maximum. Circuit breakers must be designed for protection in a

rms

(symmetrical), 480 V maximum; or the value rated on the individual

rms

(symmetrical),

rms

Circuit Breaker Fuse

CTI25M -

047B3149

CTI25M -

047B3149

CTI25M -

047B3150

CTI25M -

047B3150

CTI25M -

047B3152

CTI25M -

047B3152

CTI25M -

047B3102

Rec. non-

CTI25

M -

047B3

146

CTI25

M -

047B3

147

CTI25

M -

047B3

147

CTI25

M -

047B3

148

CTI25

M -

047B3

149

CTI25

M -

047B3

149

CTI25

M -

047B3

150

Max. non-

CTI25

M -

047B3

149

CTI25

M -

047B3

149

CTI25

M -

047B3

150

CTI25

M -

047B3

150

CTI25

M -

047B3

152

CTI25

M -

047B3

152

CTI25

M -

047B3

102

Rec.

RK5, RK1,

RK5 RK1 J T CC gG gG

J, T,

6 6 6 6 6 6 10 10

6 10 10 10 10 10 10 10

6 20 20 20 20 20 16 20

15 25 25 25 25 25 16 25

15 30 30 30 30 30 16 32

Maximum UL

Type

Rec.

non-UL

Max.

non-UL

7 7

Specifications Operating Instructions

Circuit Breaker Fuse

Max. non-

CTI25

M -

047B3

102

CTI25

M -

047B3

102

Rec.

RK5, RK1,

RK5 RK1 J T CC gG gG

J, T,

20 30 30 30 30 30 25 32

25 30 30 30 30 30 25 32

Power

Enclosure

type

MH3

Table 7.15 Fuses and Circuit Breakers

1) Power ratings relate to NO, see chapter 7.2 Electrical Data.

[kW]

380-480 V

5.5

7.5

Rec. UL Max. UL

CTI25M -

047B3150

CTI25M -

047B3151

CTI25M -

047B3102

CTI25M -

047B3102

Rec. non-

CTI25

M -

047B3

150

CTI25

M -

047B3

151

Maximum UL

Type

Rec.

non-UL

Max.

non-UL

Appendix Operating Instructions

8 Appendix

8.1 Abbreviations and Conventions

AC Alternating Current AEO Automatic Energy Optimization AWG American Wire Gauge AMA Automatic Motor Adaptation °C DC Direct Current EMC Electromagnetic Compatibility ETR Electronic Thermal Relay f

M,N

FC Frequency Converter HO High overload IP Ingress Protection I

LIM

INV

M,N

VLT,MAX

VLT,N

LCP Local Control Panel N.A. Not applicable NO Normal overload P

M,N

PCB Printed Circuit Board PE Protective earth PELV Protective Extra Low Voltage Regen Regenerative Terminals RPM Revolutions Per Minute T

LIM

M,N

Degrees Celsius

Nominal Motor Frequency

Current Limit Rated Inverter Output Current Nominal Motor Current The Maximum Output Current The Rated Output Current Supplied by the Frequency Converter

Nominal Motor Power

Torque Limit Nominal Motor Voltage

8 8

Table 8.1 Abbreviations

Conventions

Numbered lists indicate procedures. Bullet lists indicate other information and description of illustrations. Italicised text indicates

cross reference

•

link

•

footnote

•

parameter name, parameter group name, parameter option

•

8.2 Parameter Menu Structure

Appendix Operating Instructions

13-44 Logic Rule Boolean 3

13-12 Comparator Value

13-1* Comparators

13-10 Comparator Operand

13-11 Comparator Operator

13-2* Timers

13-20 SL Controller Timer

13-4* Logic Rules

13-40 Logic Rule Boolean 1

13-43 Logic Rule Operator 2

13-42 Logic Rule Boolean 2

13-41 Logic Rule Operator 1

13-5* States

13-51 SL Controller Event

13-52 SL Controller Action

14-** Special Functions

14-0* Inverter Switching

14-01 Switching Frequency

14-03 Overmodulation

14-07 Dead Time Compensation

14-08 Damping Gain Factor

14-1* Mains On/Off

14-10 Mains Failure

14-12 Function at Mains Imbalance

14-11 Mains Voltage at Mains Fault

14-21 Automatic Restart Time

14-2* Reset Functions

14-20 Reset Mode

14-23 Typecode Setting

14-22 Operation Mode

14-27 Action At Inverter Fault

14-29 Service Code

14-28 Production Settings

14-4* Energy Optimising

14-40 VT Level

14-41 AEO Minimum Magnetisation

14-5* Environment

14-50 RFI Filter

14-55 Output Filter

14-51 DC Link Voltage Compensation

14-52 Fan Control

14-53 Fan Monitor

14-6* Auto Derate

Level

14-63 Min Switch Frequency

14-64 Dead Time Compensation Zero Current

sation

14-65 Speed Derate Dead Time Compen-

14-9* Fault Settings

14-90 Fault Level

15-** Drive Information

15-0* Operating Data

15-01 Running Hours

15-00 Operating hours

15-03 Power Up's

15-02 kWh Counter

15-04 Over Temp's

15-05 Over Volt's

15-06 Reset kWh Counter

6-76 Terminal 45 Output Bus Control

6-74 Terminal 45 Output Max Scale

6-73 Terminal 45 Output Min Scale

6-72 Terminal 45 Digital Output

4-54 Warning Reference Low

4-55 Warning Reference High

4-50 Warning Current Low

4-51 Warning Current High

1-63 Slip Compensation Time Constant

1-64 Resonance Dampening

1-6* Load Depen. Setting

1-62 Slip Compensation

6-9* Analog/Digital Output 42

6-90 Terminal 42 Mode

6-91 Terminal 42 Analog Output

4-56 Warning Feedback Low

4-57 Warning Feedback High

4-58 Missing Motor Phase Function

1-66 Min. Current at Low Speed

1-65 Resonance Dampening Time Constant

1-7* Start Adjustments

6-92 Terminal 42 Digital Output

4-6* Speed Bypass

1-71 Start Delay

6-96 Terminal 42 Output Bus Control

6-94 Terminal 42 Output Max Scale

6-93 Terminal 42 Output Min Scale

4-64 Semi-Auto Bypass Set-up

4-63 Bypass Speed To [Hz]

4-61 Bypass Speed From [Hz]

1-72 Start Function

1-73 Flying Start

1-8* Stop Adjustments

6-98 Drive Type

8-** Comm. and Options

5-** Digital In/Out

5-0* Digital I/O mode

1-80 Function at Stop

1-82 Min Speed for Function at Stop [Hz]

8-0* General Settings

8-01 Control Site

8-02 Control Source

8-03 Control Timeout Time

5-03 Digital Input 29 Mode

5-00 Digital Input Mode

5-1* Digital Inputs

5-10 Terminal 18 Digital Input

1-9* Motor Temperature

1-90 Motor Thermal Protection

1-93 Thermistor Source

2-** Brakes

8-04 Control Timeout Function

8-3* FC Port Settings

8-30 Protocol

5-13 Terminal 29 Digital Input

5-12 Terminal 27 Digital Input

5-11 Terminal 19 Digital Input

2-01 DC Brake Current

2-0* DC-Brake

2-00 DC Hold/Preheat Current

8-31 Address

8-32 Baud Rate

8-33 Parity / Stop Bits

5-3* Digital Outputs

5-34 On Delay, Digital Output

5-35 Off Delay, Digital Output

2-06 Parking Current

2-04 DC Brake Cut In Speed [Hz]

2-02 DC Braking Time

8-35 Minimum Response Delay

8-36 Maximum Response Delay

5-4* Relays

5-40 Function Relay

2-07 Parking Time

2-1* Brake Energy Funct.

8-43 PCD Read Configuration

8-4* FC MC protocol set

8-42 PCD Write Configuration

8-5* Digital/Bus

5-41 On Delay, Relay

5-42 Off Delay, Relay

5-5* Pulse Input

5-50 Term. 29 Low Frequency

2-16 AC brake Max. Current

2-17 Over-voltage Control

2-10 Brake Function

3-** Reference / Ramps

8-50 Coasting Select

8-51 Quick Stop Select

8-52 DC Brake Select

5-51 Term. 29 High Frequency

5-52 Term. 29 Low Ref./Feedb. Value

5-53 Term. 29 High Ref./Feedb. Value

3-0* Reference Limits

3-02 Minimum Reference

3-03 Maximum Reference

8-56 Preset Reference Select

8-53 Start Select

8-54 Reversing Select

8-55 Set-up Select

5-9* Bus Controlled

5-90 Digital & Relay Bus Control

6-** Analog In/Out

6-0* Analog I/O Mode

3-14 Preset Relative Reference

3-1* References

3-10 Preset Reference

3-11 Jog Speed [Hz]

8-7* BACnet

8-70 BACnet Device Instance

6-01 Live Zero Timeout Function

6-00 Live Zero Timeout Time

3-16 Reference 2 Source

3-15 Reference 1 Source

8-72 MS/TP Max Masters

8-73 MS/TP Max Info Frames

6-1* Analog Input 53

6-10 Terminal 53 Low Voltage

3-17 Reference 3 Source

3-4* Ramp 1

8-75 Initialisation Password

8-74 "I-Am" Service

6-12 Terminal 53 Low Current

6-11 Terminal 53 High Voltage

3-41 Ramp 1 Ramp Up Time

3-42 Ramp 1 Ramp Down Time

8-79 Protocol Firmware Version

8-8* FC Port Diagnostics

8-80 Bus Message Count

6-15 Terminal 53 High Ref./Feedb. Value

6-14 Terminal 53 Low Ref./Feedb. Value

6-13 Terminal 53 High Current

3-5* Ramp 2

3-51 Ramp 2 Ramp Up Time

3-52 Ramp 2 Ramp Down Time

8-83 Slave Error Count

8-81 Bus Error Count

8-82 Slave Messages Rcvd

6-19 Terminal 53 Mode

6-16 Terminal 53 Filter Time Constant

6-2* Analog Input 54

3-8* Other Ramps

3-80 Jog Ramp Time

3-81 Quick Stop Ramp Time

8-88 Reset FC port Diagnostics

8-85 Slave Timeout Errors

8-84 Slave Messages Sent

6-22 Terminal 54 Low Current

6-21 Terminal 54 High Voltage

6-20 Terminal 54 Low Voltage

4-** Limits / Warnings

4-1* Motor Limits

4-10 Motor Speed Direction

8-9* Bus Jog / Feedback

8-94 Bus Feedback 1

13-** Smart Logic

6-25 Terminal 54 High Ref./Feedb. Value

6-24 Terminal 54 Low Ref./Feedb. Value

6-23 Terminal 54 High Current

4-18 Current Limit

4-14 Motor Speed High Limit [Hz]

4-12 Motor Speed Low Limit [Hz]

13-01 Start Event

13-0* SLC Settings

13-00 SL Controller Mode

6-29 Terminal 54 Mode

6-26 Terminal 54 Filter Time Constant

6-7* Analog/Digital Output 45

4-19 Max Output Frequency

4-4* Adj. Warnings 2

4-40 Warning Freq. Low

13-02 Stop Event

13-03 Reset SLC

6-70 Terminal 45 Mode

6-71 Terminal 45 Analog Output

4-41 Warning Freq. High

4-5* Adj. Warnings

0-** Operation / Display

0-0* Basic Settings

0-01 Language

0-03 Regional Settings

0-04 Operating State at Power-up

0-06 GridType

0-07 Auto DC Braking

0-1* Set-up Operations

0-10 Active Set-up

0-11 Programming Set-up

0-12 Link Setups

0-3* LCP Custom Readout

0-30 Custom Readout Unit

0-31 Custom Readout Min Value

0-32 Custom Readout Max Value

1-37 d-axis Inductance (Ld)

0-4* LCP Keypad

0-40 [Hand on] Key on LCP

0-42 [Auto on] Key on LCP

0-44 [Off/Reset] Key on LCP

0-5* Copy/Save

0-50 LCP Copy

0-51 Set-up Copy

0-6* Password

0-60 Main Menu Password

1-** Load and Motor

0-37 Display Text 1

0-38 Display Text 2

0-39 Display Text 3

1-0* General Settings

1-00 Configuration Mode

1-01 Motor Control Principle

1-03 Torque Characteristics

1-06 Clockwise Direction

1-1* Motor Selection

1-10 Motor Construction

1-15 Low Speed Filter Time Const.

1-16 High Speed Filter Time Const.

1-2* Motor Data

1-20 Motor Power [kW]

1-22 Motor Voltage

1-23 Motor Frequency

1-24 Motor Current

1-25 Motor Nominal Speed

1-29 Automatic Motor Adaptation (AMA)

1-26 Motor Cont. Rated Torque

1-3* Adv. Motor Data

1-30 Stator Resistance (Rs)

1-17 Voltage filter time const.

1-33 Stator Leakage Reactance (X1)

1-35 Main Reactance (Xh)

1-39 Motor Poles

1-4* Adv. Motor Data II

1-40 Back EMF at 1000 RPM

1-5* Load Indep. Setting

1-52 Min Speed Normal Magnetising [Hz]

1-50 Motor Magnetisation at Zero Speed

1-56 U/f Characteristic - F

1-55 U/f Characteristic - U

Appendix Operating Instructions

24-05 FM Preset Reference

24-09 FM Alarm Handling

24-1* Drive Bypass

16-65 Analog Output 42 [mA]

16-64 Analog Input 54

16-63 Terminal 54 Setting

24-11 Drive Bypass Delay Time

24-10 Drive Bypass Function

30-** Special Features

16-67 Pulse Input [Hz]

16-71 Relay Output [bin]

16-66 Digital Output

30-2* Adv. Start Adjust

30-22 Locked Rotor Detection

16-72 Counter A

16-73 Counter B

30-23 Locked Rotor Detection Time [s]

16-79 Analog Output AO45 [mA]

16-8* Fieldbus & FC Port

16-86 FC Port REF 1

16-9* Diagnosis Readouts

16-90 Alarm Word

16-91 Alarm Word 2

16-92 Warning Word

16-93 Warning Word 2

16-94 Ext. Status Word

16-95 Ext. Status Word 2

18-** Info & Readouts

18-1* Fire Mode Log

18-10 FireMode Log:Event

18-5* Ref. & Feedb.

18-50 Sensorless Readout [unit]

20-** Drive Closed Loop

20-0* Feedback

20-01 Feedback 1 Conversion

20-00 Feedback 1 Source

20-1*

20-12 Reference/Feedback Unit

20-6* Sensorless

20-60 Sensorless Unit

20-69 Sensorless Information

20-83 PI Start Speed [Hz]

20-8* PI Basic Settings

20-81 PI Normal/ Inverse Control

20-84 On Reference Bandwidth

20-9* PI Controller

20-91 PI Anti Windup

20-93 PI Proportional Gain

20-94 PI Integral Time

20-97 PI Feed Forward Factor

22-** Appl. Functions

22-0* Miscellaneous

22-01 Power Filter Time

22-4* Sleep Mode

22-40 Minimum Run Time

22-41 Minimum Sleep Time

22-44 Wake-up Ref./FB Difference

22-43 Wake-up Speed [Hz]

22-46 Maximum Boost Time

22-45 Setpoint Boost

22-47 Sleep Speed [Hz]

22-6* Broken Belt Detection

22-62 Broken Belt Delay

22-61 Broken Belt Torque

22-60 Broken Belt Function

24-** Appl. Functions 2

24-0* Fire Mode

24-00 FM Function

8 8

15-07 Reset Running Hours Counter

15-3* Alarm Log

15-31 Alarm Log: Value

15-30 Alarm Log: Error Code

15-4* Drive Identification

15-40 FC Type

15-41 Power Section

15-42 Voltage

15-43 Software Version

15-44 Ordered TypeCode

15-46 Drive Ordering No

15-47 Power Card Ordering No

15-45 Actual TypeCode

15-50 SW ID Power Card

15-9* Parameter Info

15-92 Defined Parameters

15-98 Drive Identification

15-97 Application Type

16-** Data Readouts

16-0* General Status

16-00 Control Word

16-01 Reference [Unit]

16-02 Reference [%]

16-03 Status Word

16-05 Main Actual Value [%]

16-09 Custom Readout

16-1* Motor Status

16-10 Power [kW]

16-11 Power [hp]

16-13 Frequency

16-12 Motor Voltage

16-14 Motor Current

16-15 Frequency [%]

16-16 Torque [Nm]

16-18 Motor Thermal

16-2*

16-22 Torque [%]

16-26 Power Filtered [kW]

16-27 Power Filtered [hp]

16-3* Drive Status

16-30 DC Link Voltage

16-34 Heatsink Temp.

16-35 Inverter Thermal

16-37 Inv. Max. Current

16-36 Inv. Nom. Current

16-38 SL Controller State

16-5* Ref. & Feedb.

16-50 External Reference

16-52 Feedback[Unit]

16-6* Inputs & Outputs

16-60 Digital Input

16-62 Analog Input 53

16-61 Terminal 53 Switch Setting

15-57 File version

15-52 OEM Information

15-53 Power Card Serial Number

15-51 Drive Serial Number

15-48 LCP Id No

15-49 SW ID Control Card

Index Operating Instructions

Index

Abbreviations......................................................................................... 45

Adapter plate........................................................................... 11, 17, 18

Additional Items Required................................................................... 9

AMA........................................................................................................... 30

Analog inputs......................................................................................... 40

Analog output....................................................................................... 40

Approvals................................................................................................... 6

Automatic Motor Adaptation.......................................................... 30

Auxiliary equipment............................................................................ 22

Bearing..................................................................................................... 13

Broken belt.............................................................................................. 30

Cable lengths and cross sections.................................................... 40

Cable Requirements............................................................................ 17

Cable routing......................................................................................... 22

Certification............................................................................................... 6

Changing Parameter Settings.......................................................... 28

Circuit breaker....................................................................................... 44

Circuit breakers..................................................................................... 22

Clearances............................................................................................... 31

Closed Loop Applications.................................................................. 26

Closed Loop Set-up Wizard.............................................................. 26

Conduit..................................................................................................... 22

Connecting to Mains........................................................................... 19

Control card, 10 V DC output........................................................... 41

Control card, 24 V DC output........................................................... 41

Control card, RS-485 serial communication............................... 41

Control terminals.................................................................................. 21

Control terminalsControl Terminals.............................................. 20

Control Terminals and Relays 2....................................................... 20

Control Terminals and Relays 3....................................................... 20

Control wiring........................................................................................ 22

Conventions........................................................................................... 45

Cooling clearance................................................................................. 22

DC current............................................................................................... 14

DC over volt............................................................................................ 29

DC under volt......................................................................................... 29

DeviceNet.................................................................................................. 4

Digital inputs.......................................................................................... 40

Digital output......................................................................................... 41

Dimensions........................................................................ 33, 34, 35, 36

Dimensions with Asynchronous and PM motor....................... 33

Discharge time......................................................................................... 7

Display...................................................................................................... 23

DriveMotor....................................................................................... 11, 12

Earth fault................................................................................................ 29

Electrical installation........................................................................... 17

Electrical Overview................................................................................. 5

Electronic waste...................................................................................... 6

EMC-Compliant Electrical Installation........................................... 15

EMC-Compliant Installation.............................................................. 15

Environment........................................................................................... 39

ETR............................................................................................................. 29

External controllers................................................................................ 4

External interlock.................................................................................. 30

Feedback................................................................................................. 22

Fire mode................................................................................................ 30

Foreseeable misuse................................................................................ 4

Fuse........................................................................................................... 44

Fuses................................................................................................... 14, 22

Gasket....................................................................................................... 11

Ground connections............................................................................ 22

Ground fault........................................................................................... 29

Grounding............................................................................................... 22

High altitude............................................................................................. 8

High voltage............................................................................................. 7

Identification............................................................................................ 9

Input power............................................................................................ 22

Input power wiring.............................................................................. 22

Installation.............................................................................................. 22

Installation Environments................................................................. 10

Installation of the DriveMotor.......................................................... 12

Intended Use............................................................................................ 4

Interference isolation.......................................................................... 22

Index Operating Instructions

Internal brake......................................................................................... 21

Inverter overload.................................................................................. 29

IT mains.................................................................................................... 14

Items supplied.......................................................................................... 9

Items Supplied......................................................................................... 9

LCP cable................................................................................................. 24

LCP Remote Mounting....................................................................... 24

Leakage current....................................................................................... 8

Lifting........................................................................................................ 10

List of Warnings and Alarms............................................................. 29

Load sharing........................................................................................... 21

Local Control Panel (LCP).................................................................. 23

Lubrication.............................................................................................. 13

Mains imbalance................................................................................... 29

Mains phase loss................................................................................... 29

Mains power........................................................................................... 23

Mains supply (L1, L2, L3).................................................................... 39

Mains Supply 3x380-480 V AC Normal and High Overload........

Maintenance.......................................................................................... 29

Manual........................................................................................................ 3

Danfoss VLT DriveMotor FCP 106, VLT DriveMotor FCM 106 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual