Danfoss VLT DriveMotor FCP 106 User manual

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

Contents
1 Introduction 3
1.1 Purpose of the Manual 3
1.2 Additional Resources 4
1.3 Product Overview 4
1.3.1 Intended Use 4
1.3.2 Electrical Overview 5
1.4 Approvals 6
1.5 Disposal Instruction 6
2 Safety 7
2.1 Qualified Personnel 7
2.2 Safety Precautions 7
3 Mechanical Installation 9
3.1 Unpacking 9
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
3.1.4 Identification of Unit 9
3.1.5 Nameplates 9
3.1.6 Lifting 10
3.2 Installation Environment 10
3.3 Mounting 11
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 14
4.1 Safety Instructions 14
4.2 IT Mains 14
4.3 EMC-Compliant Installation 15
4.4 Cable Requirements 17
4.5 Grounding 17
4.6 Motor Connection 17
4.6.1 Connect FCP 106 to Motor 17
4.6.2 Thermistor Input from Motor 19
4.7 AC Mains Connection 19
Contents Operating Instructions
MG03L202 Danfoss A/S © Rev. 06/2014 All rights reserved. 1

4.8 Control Wiring 20
4.8.1 Control Terminals 20
4.8.2 Load Sharing 21
4.8.3 Brake 21
4.9 Installation Checklist 22
5 Commissioning 23
5.1 Applying Power 23
5.2 Local Control Panel Operation 23
5.3 Basic Programming 24
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 29
6.1 Maintenance 29
6.1.1 Before Starting Repair Work 29
6.2 List of Warnings and Alarms 29
7 Specifications 31
7.1 Clearances, Dimensions and Weights 31
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 37
7.3 Mains Supply 39
7.4 Protection and Features 39
7.5 Ambient Conditions 39
7.6 Cable Specifications 40
7.7 Control Input/Output and Control Data 40
7.8 Connection Tightening Torques 42
7.9 FCM 106 Motor Specifications 42
7.10 Fuse and Circuit Breaker Specifications 43
8 Appendix 45
8.1 Abbreviations and Conventions 45
8.2 Parameter Menu Structure 45
Index 48
Contents Operating Instructions
2 Danfoss A/S © Rev. 06/2014 All rights reserved. MG03L202

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.
195NA447.10
Illustration 1.1 FCP 106
VLT®DriveMotor FCM 106
The frequency converter is mounted onto the motor upon
delivery. The combined FCM 106 and motor from Danfoss
is known as the DriveMotor.
195NA419.10
Illustration 1.2 FCM 106
Introduction Operating Instructions
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11

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
®
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.
Technical literature and approvals are available online at
www.danfoss.com/BusinessAreas/DrivesSolutions/Documen-
tations/Technical+Documentation.
Danfoss VLT® Energy Box software is available at
www.danfoss.com/BusinessAreas/DrivesSolutions, PC software
download area.
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.
Introduction Operating Instructions
4 Danfoss A/S © Rev. 06/2014 All rights reserved. MG03L202
1
1

1.3.2 Electrical Overview
195NA410.11
L1
L2
L3
PE
3 Phase
power
input
+10Vdc
0-10Vdc-
0/4-20 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)
24V (NPN)
0V (PNP)
24V (NPN)
0V (PNP)
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
ON=Terminated
OFF=Unterminated
03
02
01
relay 1
240V AC 3A
06
05
04
relay 2
240V AC 3A
UDC+
UDC-
PE Motor
U
V
W
T1
T2
Thermistor
located in
motor
Group 5-*
Located in
motor block
Illustration 1.3 Electrical Overview
Introduction Operating Instructions
MG03L202 Danfoss A/S © Rev. 06/2014 All rights reserved. 5
11

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.
Introduction Operating Instructions
6 Danfoss A/S © Rev. 06/2014 All rights reserved. MG03L202
1
1

2 Safety
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 trouble-
free 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.
Voltage
[V]
Power Range1)
[kW]
Minimum waiting
time
(min)
3x400 0.55–7.5 4
High voltage can be present even when the warning LED
indicator lights are off.
Table 2.1 Discharge Time
1) Power ratings relate to NO, see chapter 7.2 Electrical Data.
Safety Operating Instructions
MG03L202 Danfoss A/S © Rev. 06/2014 All rights reserved. 7
22

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.
NOTICE
HIGH ALTITUDES
For installation at altitudes above 2000 m, contact
Danfoss regarding PELV.
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.
Safety Operating Instructions
8 Danfoss A/S © Rev. 06/2014 All rights reserved. MG03L202
22

3 Mechanical Installation
3.1 Unpacking
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.
3.1.1 Items Supplied, FCP 106
Check all items are present:
•1 FCP 106 frequency converter
•1 accessory bag
•Operating Instructions
3.1.2 Additional Items Required, FCP 106
•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)
3.1.3 Items Supplied, FCM 106
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 configu-
ration.
•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.
3.1.5 Nameplates
1
2 3
456
Enclosure: IP66 , Tamb. 40 C / 104 F
V LT
MADE IN
DENMARK
R
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
o*1 3 1
U 3 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.
o
7
8
9
10
11
195NA484.10
1 Type code
2 Certifications
3 Enclosure rating
4 Bar code for manufacturer use
5 Certifications
6Serial number1)
7 Enclosure type and IP rating, max. ambient temperature
8Output 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
Mechanical Installation Operating Instructions
MG03L202 Danfoss A/S © Rev. 06/2014 All rights reserved. 9
33

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
oo
1MADE 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
ϕ
MSV: &OEM4&
DUTY Class S1IP55
0-1500 min /50Hz
-1
Wt 14.5 kg
5
2
3
4
6
789
10
11
12
13
14
15
DBV: &OEM3&
1Type code
2 Certifications
3 Enclosure rating
4Serial number1)
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)
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).
3.1.6 Lifting
NOTICE
LIFTING - EQUIPMENT DAMAGE RISK
Incorrect lifting can result in equipment damage.
•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.
Handling and lifting of the unit must only be undertaken
by qualified personnel. Ensure
•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.
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 Storage
Ensure that requirements for storage are fulfilled. Refer to
chapter 7.5 Ambient Conditions for further details.
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.
Mechanical Installation Operating Instructions
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33

3.3 Mounting
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:
1. 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.
3. 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.
3.3.2 Prepare Gasket
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
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.
195NA414.10
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.
Mechanical Installation Operating Instructions
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33

3.3.4 Mount the DriveMotor
195NA411.11
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.
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.
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.
Mechanical Installation Operating Instructions
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33

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
Asynchrono
us
80-180 Lithium basis -40 to 140°C
PM 71-160
Table 3.1 Lubrication
Frame
size
Speed
[RPM]
Bearing type, asynchronous motors Bearing type, PM motors
Drive end Non-drive end Drive end Non-drive end
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 a) a) N.A. N.A.
180 1500/3000 a) a) N.A. N.A.
Table 3.2 Standard Bearing References and Oil Seals for Motors
a) Data available upon future release.
Mechanical Installation Operating Instructions
MG03L202 Danfoss A/S © Rev. 06/2014 All rights reserved. 13
33

4 Electrical Installation
4.1 Safety Instructions
See chapter 2 Safety for general safety instructions.
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.
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 factory-
supplied, 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.
4.2 IT Mains
CAUTION
IT MAINS
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.
195NA403.10
1
1 RFI switch/screw
Illustration 4.1 Location of RFI Switch/Screw
CAUTION
To reinsert, use an M3x12 screw only.
Electrical Installation Operating Instructions
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4.3 EMC-Compliant Installation
195NA420.10
L1
L2
L3
PE
7
1
2
3
4
56
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
Electrical Installation Operating Instructions
MG03L202 Danfoss A/S © Rev. 06/2014 All rights reserved. 15
44

195NA407.10
L1
L2
L3
PE
1
6
2
5 4
3
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
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44

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 instal-
lation 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.
Electrical Installation Operating Instructions
MG03L202 Danfoss A/S © Rev. 06/2014 All rights reserved. 17
44

195NA415.10
6
9
1
10
7,8
5
4
3
T1
MMT2
UV
W
PE
2
MT1, MT2 Motor thermistor wires
U, V, W Motor phases
Illustration 4.4 Connecting FCP 106 to Motor
Electrical Installation Operating Instructions
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