Quick guide Plug-in fans GPPM with FC101_106 August 2014
Fläkt Woods permanent magnet motors and speed controllers for plug fans GPPM 1. General Fläkt Woods offers a wide range of permanent magnet motors (PM) and speed controllers for plug fans. PM motor has high efficiency (IE4) due to the permanent magnets in rotor. Also part load efficiency is better compared to asynchronous motors. When rotor has no losses and stator needs less current, temperature inside the motor is lower and it gives longer running time for bearings. Direct on-line connection is not possible for permanent magnet motors. Speed controller is always needed. This controller has special algorithm for PM motors. Speed controller is programmed with fan and motor specific parameters. 2. Speed controller alternatives Speed controllers can be delivered as an integrated version or separately. Controller integrated to motor is available up to 7.5 kw and separate controllers up to 11 kw. 2
IP54 speed controller mounted at AHU casing. Separate speed controller should be mounted near the fan. Motor cable shall not be no longer than 10 m. With longer cables some motor parameters should be changed. Speed controller is delivered with 3.5 m motor cable for fan sizes up to 050. For bigger fans motor cable length is 4.5 m. 3
3. Fan and motor data Fan code Motor code including drive Power [kw] Motor Current [A] Frame Size Max speed [rpm] Max freq. [Hz] Nominal speed [min -1 ] Motor weight [kg] GPPM-1-00-025-06-0 APPM-30-0080-30-0e 0,8 1,6 71 3700 185 3000 4,8 GPPM-1-00-025-06-0 APPM-45-0150-30-0e 1,5 3,1 71 4500 225 4500 5,4 GPPM-1-00-028-06-0 APPM-30-0080-30-0e 0,8 1,6 71 3150 157 3000 4,8 GPPM-1-00-028-06-0 APPM-36-0150-30-0e 1,5 3,1 71 3600 180 3600 6,2 GPPM-1-00-028-06-0 APPM-45-0220-30-0e 2,2 4,5 71 4500 225 4500 6 GPPM-1-00-031-06-0 APPM-30-0110-30-0e 1,1 2,4 71 3000 150 3000 5,4 GPPM-1-00-031-06-0 APPM-36-0180-30-0e 1,8 3,7 71 3340 167 3600 6 GPPM-1-00-031-06-0 APPM-45-0300-30-0e 3 6,2 71 4000 200 4500 6,6 GPPM-1-00-035-06-0 APPM-30-0110-30-0e 1,1 2,4 71 2200 110 3000 5,4 GPPM-1-00-035-06-0 APPM-25-0150-30-0e 1,5 3,2 71 2500 125 2500 7,1 GPPM-1-00-035-06-0 APPM-30-0220-30-0e 2,2 4,4 71 2970 148 3000 6,6 GPPM-1-00-035-09-0 APPM-36-0360-30-0e 3,6 8 90 3570 238 3600 12 GPPM-1-00-040-06-0 APPM-20-0110-30-0e 1,1 2,3 71 2050 102,5 1800 7,1 GPPM-1-00-040-06-0 APPM-18-0180-30-0e 1,8 3,6 71 1950 97,5 1800 6,6 GPPM-1-00-040-09-0 APPM-36-0360-30-0e 3,6 8 90 2750 183 3600 12 GPPM-1-00-040-09-0 APPM-30-0400-30-0e 4 9,1 90 3100 206 3000 14 GPPM-1-00-045-06-0 APPM-15-0110-30-0e 1,1 2,3 71 1500 75 1800 7,1 GPPM-1-00-045-06-0 APPM-18-0180-30-0e 1,8 3,6 71 1950 97,5 1800 6,6 GPPM-1-00-045-09-0 APPM-30-0400-30-0e 4 9,1 90 2300 153 3000 14 GPPM-1-00-045-09-0 APPM-30-0550-30-0e 5,5 13 90 2600 173 3000 16 GPPM-1-00-050-09-0 APPM-17-0220-30-0e 2,2 5 90 1700 113 1700 12 GPPM-1-00-050-09-0 APPM-18-0360-30-0e 3,6 7,5 90 2000 133 1800 16 GPPM-1-00-050-09-0 APPM-18-0480-30-0e 4,8 10,2 90 2200 146 1800 20,5 GPPM-1-00-050-11-0 APPM-26-0750-30-0e 7,5 14,9 112 2500 125 2600 27 GPPM-1-00-056-09-0 APPM-14-0220-30-0e 2,2 5,2 90 1390 92 1440 12 GPPM-1-00-056-09-0 APPM-17-0400-30-0e 4 9,7 90 1700 113 1700 17 GPPM-1-00-056-09-0 APPM-20-0550-30-0e 5,5 10,7 90 1900 126,7 2000 17 GPPM-1-00-056-11-0 APPM-21-0750-30-0e 7,5 14,6 112 2050 102,5 2100 30 GPPM-1-00-063-09-0 APPM-11-0220-30-0e 2,2 6 90 1100 73 1100 14 GPPM-1-00-063-11-0 APPM-16-0550-30-0e 5,5 11,2 112 1550 77,5 1600 27 GPPM-1-00-063-11-0 APPM-18-0750-30-0e 7,5 15,6 112 1750 87,5 1800 27,5 GPPM-1-00-063-11-0 APPM-20-1100-30-0e 11 20,2 112 2000 100 2000 30 GPPM-1-00-071-09-0 APPM-10-0300-30-0e 3 8,7 90 1050 70 1050 15 GPPM-1-00-071-11-0 APPM-13-0550-30-0e 5,5 11 112 1300 65 1300 30 GPPM-1-00-071-11-0 APPM-15-0750-30-0e 7,5 15,7 112 1430 71,5 1500 30,5 4
Fan code Motor code including drive Power [kw] Motor Current [A] Frame Size Max speed [rpm] Max freq. [Hz] Nominal speed [min -1 ] GPPM-1-00-071-11-0 APPM-16-1100-30-0e 11 22 112 1660 83 1650 33 GPPM-1-00-080-11-0 APPM-11-0550-30-0e 5,5 11,3 112 1050 52,5 1100 30 GPPM-1-00-080-11-0 APPM-12-0750-30-0e 7,5 15,4 112 1200 60 1230 33 GPPM-1-00-080-13-0 APPM-13-1100-30-0e 11 24,1 132 1350 67,5 1350 46 GPPM-1-00-090-13-0 APPM-10-0750-30-0e 7,5 16,4 132 950 47,5 1000 50 GPPM-1-00-090-13-0 APPM-11-1100-30-0e 11 22,9 132 1140 57 1140 58 GPPM-1-00-100-13-0 APPM-08-0750-30-0e 7,5 15,7 132 840 42 850 50 GPPM-1-00-100-13-0 APPM-09-1100-30-0e 11 22,9 132 950 47,5 950 65 11 kw motors only with separate speed controller Motor weight [kg] 4. Speed controller data for separate and integrated versions Mains supply (L1, L2, L3) Supply voltage 380-480 V ±10% 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 input supply L1, L2, L3 (power-ups) maximum 2 times/min. Environment according to EN60664-1 overvoltage category III/pollution degree 2 Motor output (U, V, W) Output voltage Output frequency for PM motors 0-100% of supply voltage 0-390 Hz Digital inputs: Programmable digital inputs 4 Logic PNP or NPN Voltage level 0-24 V DC Analog inputs: Number of analog inputs 2 Modes Voltage or current Voltage level 0 to + 10 (scalable) Current level 0/4 to 20 ma (scalable) Analog output: Number of programmable analog outputs 2 Current range at analog output 0/4-20 ma Digital output: Programmable digital 2 Voltage level at digital 17 V 5
Max. current at digital output: 20 ma Relay outputs: Programmable relay outputs 2 Max. terminal load (AC-1 Resistive load) 250 V AC, 3 A Control card, 10 V DC output: Output voltage Max. load Control card, 24 V DC output: Max. load 10.5 V ±0.5 V 25 ma 80 ma Surroundings: Enclosure separate unit IP 54 Enclosure integrated unit IP 55 Vibration test separate unit 1.0 g Vibration test integrated unit 2.0 g Max. relative humidity, during operation 5% - 95%(non-condensing) Maximum ambient temperature 40 C Minimum ambient temperature during full-scale operation 0 C separate unit, -10 C integrated unit Fieldbus communication: Modbus RTU BACnet MSTP N2 Metasys FC Protocol Physical layer Built-in Built-in Built-in Built-in RS-485 5. Separate speed controller dimensions Power Dimensions (mm) Weight (kw) Height Width Depth Hole diam. (kg) A a B b C D IP 54 0,75 4 332 318,5 115 74 225 5,5 5,3 5,5...7,5 369 354 135 89 237 6,5 7,2 11 18,5 476 460 180 133 290 6,5 13,8 6
6. Specification for motor Admissible environmental temperature: from -15 C up to +40 C, with altitudes 1000 m above sea level Mounting: IM B3 Drive operating voltage: 400 VAC Insulation class: "F"; temperature rise to class B (TEFC execution) IP55 degree of protection for the whole range Reduced dimensions 7. Installation Warning: Risk of electric shock. Motor terminals may still be Live if the impeller is rotating, even when the main incoming supplied has been isolated. Ensure the impeller is kept stationary before opening and whilst the terminal box is open. 7
Speed controller and motor shall be installed by a qualified electrician with adequate knowledge how to install speed-controlled drive systems (frequency inverters) and EMC safety. All cabling must comply with national and local regulations on cable cross-sections and ambient temperature 8. Connection diagram 9. Cabling 9.1 Supply cable Mount mains supply to terminals L1, L2 and L3 and ground wires to earth terminal and tighten. Short circuit protection: The speed controller must be protected against short-circuit to avoid electrical or fire hazard. The fuses mentioned below are recommended to use to protect service personnel 8
and equipment in case of an internal failure in the speed controller. Speed controller provides full short circuit protection in case of a short circuit on the motor output. Over current protection: Provide overload protection to avoid fire hazard due to overheating of the cables in the installation. The speed controller is equipped with an internal over-current protection that can be used for upstream overload protection (UL-applications excluded). See par. 4-18 Current Limit. Moreover, fuses or circuit breakers can be used to provide the over-current protection in the installation. Over-current protection must always be carried out according to national regulations. Leakage Current (>3,5mA) EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3,5mA. Earth grounding must be reinforced in one of the following ways: Earth ground wire of at least 10mm2 Two separate earth ground wires both complying with the dimensioning rules Isolation switch All speed controllers may be used with an isolated input source as well as with ground reference power lines. 9.2 Recommended fuses on the supply side Power (kw) 0.55 0.75 1.1 1.5 2.2 3 4 5.5 7.5 11 15 3x380-480VAC Rec. non UL type gg 10 10 10 10 16 16 16 25 25 50 50 See national/international regulations for selecting an applicable fuse size. 9.3 Motor cable with separate drive Speed controller is delivered with 3.5 m motor cable for fan sizes up to 050. For bigger fans motor cable length is 4.5 m. If it should be shortened or replaced with longer one few rules should be followed. Motor cable should be shielded type. Shield should be grounded 360 at both ends of cable. Motor cable should be no longer than 10 meters to achieve EMC-level EN 55011 Class B. Motor is connected to star inside the motor. Phase wires are connected to terminals U1, V1, W1. Terminal connectors are not needed. 9.4 Control cable 9
Control cable should be shielded. Keep control cable distance min 200 mm from mains and motor cable. 10 Control signals Start/Stop Fan is started with potential free switch connected between terminals 12 and 18. There is +24 VDC in this circuit. AUTO-mode should be selected from operation panel. Interlock By opening interlock signal between terminals 12-27 fan can be stopped and then it s not possible to start from operating panel manually or via bus. With this signal fan running can be interlocked to circulating pump alarm or ventilation emergency stop. Speed reference Speed can be controlled with 0 10V signal connected in terminals 53(+) and 55(-). Relay outputs Alarm signal is available in relay1 (terminals 01, 02 and 03). Running indication is available in relay 2 (terminals 04, 05 and 06). Single speed operation: Set constant speed reference (Hz) in parameter 412. Only external start signal is needed. Two speed operation: Lower speed reference (Hz) is set in parameter 412 and higher speed reference (Hz) in parameter 311. Lower speed is activated with start signal (terminals 12-18). Higher speed is activated by closing terminals 12-29. Modbus RTU Speed controller can be controlled via Modbus RTU. RS-485 cable is connected to the terminals 68 (P), 69 (N) and 61 (COM). If speed controller is last unit in line, it should be terminated by setting switch S801 in ON position. Modbus operation is described in speed controller operation instructions. 11. Start up and functional testing After power up test check motor rotation if separate speed controller is delivered: Set speed controller to Hand on mode from operation panel. Motor will start to rotate. For changing the direction of rotation, disconnect supply voltage and wait for power to discharge. Make sure that motor impeller is not rotating during making connections. Reverse the connection of any two of the three motor cables on the motor or frequency converter side of the connection. 10
When direction of rotation is right set speed controller to Auto on mode. Then speed controller will follow control signals. 12. Parameters Speed controller parameters are set at the factory providing for optimal performance of fan and motor. This includes motor parameters, ramp times, starting and stopping methods and speed limitations. Changing of these parameters may result unstable operation or motor won t start. Original parameter values can be downloaded from operation panel in case of losing them: Go to parameter 0-50 LPC Copy Set parameter value to 2 (All from LCP) Wait that copy is completed Parameters are password protected. Changing of motor parameters may cause motor failure. Password for main menu is 100 and for quick menu 200. 13. Operating panel Operating panel is standard in separate speed controller but accessory with integrated motor. 11
14. Alarms and warnings If alarm or warning messages appear, consult speed controller operating manual in place fault messages and troubleshooting. Warning! Speed controller tries to restart the motor after alarm so the fan may start automatically Protection and Features: Electronic thermal motor protection against overload. Temperature monitoring of the heatsink ensures that the speed controller trips if the temperature is too high. The speed controller is protected against short-circuits on motor terminals U, V, W. If a mains phase is missing, the speed controller trips or issues a warning (depending on the load). Monitoring of the intermediate circuit voltage ensures that the speed controller trips if the intermediate circuit voltage is too low or too high. The speed controller is protected against earth faults on motor terminals U, V, W. If the speed controller can t find rotor position, Locked Rotor alarm is generated Motor is stopped if motor back voltage is too high. Motor is stopped if 24V supply is too low 12
Motor is stopped if motor phase is missing Motor is stopped if inverter overloaded too long 13