Beijer Electronics BFI-H2 User Manual

User Guide Revision 1.12

Keypad Operation can be found in

section 5.5

Run / Stop 10K Pot

HVAC Display

(Status, Diagnostics, and Programming)

Motor Cable

For correct cable size, see Technical Data in section 13.4. Observe the maximum permissible motor cable length. For Motor cable lengths > 50 metres, an output filter is recommended. Use a screened (shielded cable). The shield should be bonded to earth at

Motor Connection

Check for Star or Delta connection according to the motor voltage rating in section 4.5.

Motor Nameplate Details

Motor Rated Voltage: P1-07 Motor Rated Current: P1-08 Motor Rated Frequency: P1-09 Motor Rated Speed (Optional): P1-10

Fuses or MCB

Check Drive Rating info in section 13.4

AC Supply Connection

200 – 240 Volts + / - 10% 380 – 380 Volts + / - 10% Check Drive Input Voltage information in section 13.2

PE L1 L2 L3

Control Terminal Configuration based on factory settings

Mechanical Mounting

Information can be found in section 3.6.

Hardware Enable

Link the terminals as shown, optionally through switch contacts to enable drive operation

Close the switch to run (enable) Open the switch to stop

RJ45 Connector

IP55 Quick Start Up Guide

Supply Voltage

HVAC Display

(Status, Diagnostics, and Programming)

Motor Cable Sizes

Check the rating information in section 13.4.

Motor Connections

Check for Star or Delta connection according to the motor voltage rating in section 4.5.

Motor Nameplate Details

Motor Rated Voltage: P1-07 Motor Rated Current: P1-08 Motor Rated Frequency: P1-09 Motor Rated Speed (Optional): P1-10

Mechanical Mounting Information can be found in section 3.5.

Control Terminal

Configuration based on factory settings

Hardware

Link the terminals as shown, optionally through switch contacts to enable drive operation

Close the switch to run (enable) Open the switch to stop

Keypad Operation can be found in section 5.5

Applies to Switched version only In-built Isolator:

Mains Power On / Off

Fuses or MCB

Check Drive Rating info in section 13.4.

AC Supply Connection

200 – 240 Volts + / - 10%: 1 / 3 Phase 380 – 380 Volts + / - 10%: 3 Phase

Check Drive Input Voltage information in section 13.2

PE L1 L2 L3

Run / Stop 10K Pot

RJ45 Connector

User Guide Revision 1.12

IP66 Quick Start Up Guide

User Guide Revision 1.12

Fuses or MCB

RJ45 Connector

IP20 Quick Start Up Guide

AC Supply Connection Supply Voltage

3 Phase Units : Connect L1 L2 L3, PE 200 – 240 Volts + / - 10% 1 Phase Units : Connect L1, L2, PE 380 – 380 Volts + / - 10%

Fuses or MCB

o Check the Drive Rating Information in section 13.4

Help Card

Display Information can be found in section 5.1

Keypad Operation can be found in section 5.1

IMPORTANT!

Hardware Enable

Run – Stop 10K Speed Pot

Link the terminals as shown, optionally through switch contacts to enable drive operation

Control Terminals

Based on the factory default parameter settings

Close the switch to run (enable), open to stop

Motor Cable

o For correct cable size in section 13.4 o Observe the maximum permissible motor cable length o For Motor cable lengths > 50 metres, an output filter is

recommended

o Use a screened (shielded cable)

Motor Connection

o Check for Star or Delta connection according to the motor

voltage rating in section 4.5.

o Motor Nameplate Details o Motor Rated Voltage : P1-07 o Motor Rated Current : P1-08 o Motor Rated Frequency : P1-09 o Motor Rated Speed (Optional) : P1-10

User Guide Revision 1.12

EN 61800-5-1: 2003

Adjustable speed electrical power drive systems. Safety requirements. Electrical, thermal and energy.

EN 61800-3 2nd Ed: 2004

Adjustable speed electrical power drive systems. EMC requirements and specific test methods

EN 55011: 2007

Limits and Methods of measurement of radio disturbance characteristics of industrial, scientific and medical (ISM) radio-frequency equipment (EMC)

EN60529 : 1992

Specifications for degrees of protection provided by enclosures

Standard

Classification

Approval Status

IEC61608

SIL 2

Pending Certification

IEC 61800-5-2

Type 2

Pending Certification

IEC 62061

SIL 2

Pending Certification

ISO 13849

PL “d”

Pending Certification

Drive Type / Rating

EMC Category

Cat C1

Cat C2

Cat C3

1 Phase, 230 Volt Input BFI-H2

No additional filtering required Use shielded motor cable

3 Phase, 230/400 Volt Input BFI-H2

Use External Filter

No additional filtering required

Use screened motor cable

Note

For motor cable lengths greater than 100m, an output dv / dt filter must be used, please refer to your local supplier for further details

Declaration of Conformity:

The Manufacturer hereby states that the HVAC Inverter H2 product range conforms to the relevant safety provisions of the Low Voltage Directive 2006/95/EC and the EMC Directive 2004/108/EC and has been designed and manufactured in accordance with the following harmonised European standards:

STO Function

HVAC Inverter H2 incorporates a hardware STO (Safe Torque Off) Function, designed in accordance with the standards listed below.

Electromagnetic Compatibility

All drives are designed with high standards of EMC in mind. All versions suitable for operation on Single Phase 230 volt and Three Phase 400 volt supplies and intended for use within the European Union are fitted with an internal EMC filter. This EMC filter is designed to reduce the conducted emissions back into the supply via the power cables for compliance with harmonised European standards. It is the responsibility of the installer to ensure that the equipment or system into which the product is incorporated complies with the EMC legislation of the country of use. Within the European Union, equipment into which this product is incorporated must comply with the EMC Directive 2004/108/EC. When using a drive with an internal or optional external filter, compliance with the following EMC Categories, as defined by EN61800-3:2004 can be achieved:

All rights reserved. No part of this User Guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by any information storage or retrieval system without permission in writing from the publisher.

All HVAC units carry a 2 year warranty against manufacturing defects from the date of manufacture. The manufacturer accepts no liability for any damage caused during or resulting from transport, receipt of delivery, installation or commissioning. The manufacturer also accepts no liability for damage or consequences resulting from inappropriate, negligent or incorrect installation, incorrect adjustment of the operating parameters of the drive, incorrect matching of the drive to the motor, incorrect installation, unacceptable dust, moisture, corrosive substances, excessive vibration or ambient temperatures outside of the design specification.

The local distributor may offer different terms and conditions at their discretion, and in all cases concerning warranty, the local distributor should be contacted first.

The contents of this User Guide are believed to be correct at the time of printing. In the interest of a commitment to a policy of continuous improvement, the manufacturer reserves the right to change the specification of the product or its performance or the contents of the User Guide without notice.

This User Guide is for use with version 1.10 Firmware.

User Guide Revision 1.12

The Manufacturer adopts a policy of continuous improvement and whilst every effort has been made to provide accurate and up to date information, the information contained in this User Guide should be used for guidance purposes only and does not form the part of any contract.

User Guide Revision 1.12

1. Introduction ................................................................................................................................ 8

1.1. Important safety information ............................................................................................................................................. 8

2. General Information and Ratings ................................................................................................. 9

2.1. Drive model numbers.......................................................................................................................................................... 9

2.2. Identifying the Drive by Model Number ........................................................................................................................... 10

3. Mechanical Installation ............................................................................................................. 11

3.1. General .............................................................................................................................................................................. 11

3.2. Before Installation ............................................................................................................................................................. 11

3.3. UL Compliant Installation .................................................................................................................................................. 11

3.4. Mechanical dimensions and Mounting – IP20 Units ......................................................................................................... 11

3.5. Mechanical dimensions and mounting – IP66 Units ......................................................................................................... 12

3.6. Mechanical dimensions and mounting – IP55 .................................................................................................................. 12

3.7. Mechanical dimensions and mounting – IP40 Units ......................................................................................................... 13

3.8. Guidelines for Enclosure mounting (IP20 Units) ............................................................................................................... 14

3.9. Guidelines for mounting IP55, and IP66 Units .................................................................................................................. 14

3.10. Guidelines for mounting IP40 Units .................................................................................................................................. 15

3.11. Removing the Terminal Cover ........................................................................................................................................... 16

3.12. Gland Plate and Lock Off ................................................................................................................................................... 19

4. Electrical Installation ................................................................................................................. 20

4.1. Grounding the Drive .......................................................................................................................................................... 20

4.2. Wiring Precautions ............................................................................................................................................................ 21

4.3. Incoming Power Connection ............................................................................................................................................. 21

4.4. Drive and Motor Connection ............................................................................................................................................ 21

4.5. Motor Terminal Box Connections ..................................................................................................................................... 22

4.6. Motor Thermistor Connection .......................................................................................................................................... 22

4.7. Control Terminal Wiring .................................................................................................................................................... 23

4.8. Connection Diagram ......................................................................................................................................................... 23

5. Managing the Keypad ................................................................................................................ 24

5.1. Keypad Layout and Function – Standard LED Keypad (IP20 Drives) ................................................................................. 24

5.2. Changing Parameters – Standard LED Keypad (IP20 Drives)............................................................................................. 24

5.3. Advanced Keypad Operation Short Cuts – Standard LED Keypad (IP20 Drives) ............................................................... 25

5.4. Drive Operating Displays – Standard LED Keypad (IP20 Drives) ....................................................................................... 25

5.5. Keypad Layout and Function – Standard OLED Keypad (IP55 and IP66 Drives) ................................................................ 25

5.6. Drive Operating Displays – Standard OLED Keypad (IP55 and IP66 Drives) ...................................................................... 26

5.7. Accessing and Changing Parameter Values – Standard OLED Keypad (IP55 and IP66 Drives) ......................................... 26

5.8. Resetting Parameters to Factory Default Settings – Standard OLED Keypad (IP55 and IP66 Drives) ............................... 27

5.9. Resetting Parameters to User Default Settings – Standard OLED Keypad (IP55 and IP66 Drives) ................................... 27

5.10. Changing the Language on the OLED Display – Standard OLED Keypad (IP55 and IP66 Drives) ...................................... 28

5.11. Selecting between Hand and Auto Control – Standard OLED Keypad (IP55 and IP66 Drives) .......................................... 28

6. Commissioning .......................................................................................................................... 29

6.1. General .............................................................................................................................................................................. 29

7. HVAC Specific Feature Setup (Menu 8) ....................................................................................... 30

7.1. Pump Staging – DOL Cascade ............................................................................................................................................ 30

7.2. Pump Staging – Multiple Drive Cascade ........................................................................................................................... 31

7.3. Maintenance Interval Set-up and Reset............................................................................................................................ 32

7.4. Load Profile Monitoring Function ..................................................................................................................................... 33

7.5. Pump Clean Function ........................................................................................................................................................ 34

7.6. Pump Stir Function ............................................................................................................................................................ 35

7.7. Bypass Control Function ................................................................................................................................................... 36

7.8. Fire Mode Function ........................................................................................................................................................... 38

7.9. Motor Pre-Heat Function and DC Injection ...................................................................................................................... 40

8. PID Control Applications ............................................................................................................ 42

8.1. Overview ........................................................................................................................................................................... 42

8.2. PID Function Set-up .......................................................................................................................................................... 42

8.3. Application Example.......................................................................................................................................................... 45

8.4. PID Pipe Prime (Fill) Mode with Pipe Break Detection. .................................................................................................... 46

9. Parameters ............................................................................................................................... 47

9.1. Parameter Set Overview ................................................................................................................................................... 47

9.2. Parameter Group 1 – Basic Parameters ............................................................................................................................ 47

10. Digital Input Functions .............................................................................................................. 49

User Guide Revision 1.12

10.1. Digital Input Configuration Parameter P1-13 ................................................................................................................... 49

11. Extended Parameters ................................................................................................................ 50

11.1. Parameter Group 2 - Extended parameters ...................................................................................................................... 50

11.2. Parameter Group 3 – PID Control ..................................................................................................................................... 54

11.3. Parameter Group 4 – High Performance Motor Control .................................................................................................. 55

11.4. Parameter Group 5 – Communication Parameters .......................................................................................................... 55

11.5. Parameter Group 6 – Advance Feature configuration ...................................................................................................... 56

11.6. Parameter Group 7 – Reserved (not available) ................................................................................................................. 57

11.7. Parameter Group 8 – HVAC Function Specific Parameters ............................................................................................... 57

11.8. Parameter Group 9 – Advance drive control logic configuration ..................................................................................... 59

11.9. Parameter Group 0 – Monitoring Parameters (Read Only) .............................................................................................. 60

12. Serial communications .............................................................................................................. 63

12.1. RS-485 communications.................................................................................................................................................... 63

12.2. Modbus RTU Communications ......................................................................................................................................... 63

13. Technical Data........................................................................................................................... 65

13.1. Environmental ................................................................................................................................................................... 65

13.2. Input voltage ranges ......................................................................................................................................................... 65

13.3. Maximum supply ratings for UL compliance ..................................................................................................................... 65

13.4. Output Power and Current ratings ................................................................................................................................... 65

13.5. Additional Information for UL Approved Installations ...................................................................................................... 67

14. Parameter Change Tables .......................................................................................................... 68

15. Troubleshooting ........................................................................................................................ 70

15.1. Fault messages .................................................................................................................................................................. 70

User Guide Revision 1.12

Danger : Indicates a risk of electric shock, which, if not avoided, could result in damage to the equipment and possible injury or death.

Danger : Indicates a potentially hazardous situation other than electrical, which if not avoided, could result in damage to property.

This variable speed drive product is intended for professional incorporation into complete equipment or systems as part of a fixed installation. If installed incorrectly it may present a safety hazard. The drive uses high voltages and currents, carries a high level of stored electrical energy, and is used to control mechanical plant that may cause injury. Close attention is required to system design and electrical installation to avoid hazards in either normal operation or in the event of equipment malfunction. Only qualified electricians are allowed to install and maintain this product.

System design, installation, commissioning and maintenance must be carried out only by personnel who have the necessary training and experience. They must carefully read this safety information and the instructions in this Guide and follow all information regarding transport, storage, installation and use of the drive, including the specified environmental limitations.

Do not perform any flash test or voltage withstand test on the drive. Any electrical measurements required should be carried out with the drive disconnected.

Electric shock hazard! Disconnect and ISOLATE the drive before attempting any work on it. High voltages are present at the terminals and within the drive for up to 10 minutes after disconnection of the electrical supply. Always ensure by using a suitable multimeter that no voltage is present on any drive power terminals prior to commencing any work.

Where supply to the drive is through a plug and socket connector, do not disconnect until 10 minutes have elapsed after turning off the supply.

Ensure correct earthing connections. The earth cable must be sufficient to carry the maximum supply fault current which normally will be limited by the fuses or MCB. Suitably rated fuses or MCB should be fitted in the mains supply to the drive, according to any local legislation or codes.

Do not carry out any work on the drive control cables whilst power is applied to the drive or to the external control circuits.

Within the European Union, all machinery in which this product is used must comply with Directive 98/37/EC, Safety of Machinery. In particular, the machine manufacturer is responsible for providing a main switch and ensuring the electrical equipment complies with EN60204-1.

The level of integrity offered by the drive control input functions – for example stop/start, forward/reverse and maximum speed, is not sufficient for use in safety-critical applications without independent channels of protection. All applications where malfunction could cause injury or loss of life must be subject to a risk assessment and further protection provided where needed.

The driven motor can start at power up if the enable input signal is present.

The STOP function does not remove potentially lethal high voltages. ISOLATE the drive and wait 10 minutes before starting any work on it. Never carry out any work on the Drive, Motor or Motor cable whilst the input power is still applied.

The drive can be programmed to operate the driven motor at speeds above or below the speed achieved when connecting the motor directly to the mains supply. Obtain confirmation from the manufacturers of the motor and the driven machine about suitability for operation over the intended speed range prior to machine start up.

Do not activate the automatic fault reset function on any systems whereby this may cause a potentially dangerous situation.

The drive has an Ingress Protection rating of IP55, and are intended for indoor use only

When mounting the drive, ensure that sufficient cooling is provided. Do not carry out drilling operations with the drive in place, dust and swarf from drilling may lead to damage.

The entry of conductive or flammable foreign bodies should be prevented. Flammable material should not be placed close to the drive

Relative humidity must be less than 95% (non-condensing).

Ensure that the supply voltage, frequency and no. of phases (1 or 3 phase) correspond to the rating of the drive as delivered.

Never connect the mains power supply to the Output terminals U, V, W.

Do not install any type of automatic switchgear between the drive and the motor

Wherever control cabling is close to power cabling, maintain a minimum separation of 100 mm and arrange crossings at 90 degrees Ensure that all terminals are tightened to the appropriate torque setting

Do not attempt to carry out any repair of the drive. In the case of suspected fault or malfunction, contact your local Sales Partner for further assistance.

1. Introduction

1.1. Important safety information

Please read the IMPORTANT SAFETY INFORMATION below, and all Warning and Caution information elsewhere.

2. General Information and Ratings

200-240V ±10% - 1 Phase Input

kW Model with Filter

Output

Current (A)

Frame

Size

BFI-H2-22-0043-1KF12-xx

0.75

4.3

BFI-H2-22-0070-1KF12-xx

1.5 7 2

BFI-H2-22-0105-1KF12-xx

2.2

10.5

200-240V ±10% - 3 Phase Input

kW Model Number with Filter

Output

Current (A)

Frame

Size

BFI-H2-22-0043-3KF12-xx

0.75

4.3

BFI-H2-22-0070-3KF12-xx

1.5 7 2

BFI-H2-22-0105-3KF12-xx

2.2

10.5

BFI-H2-32-0018-3KF12-xx

4.0

BFI-H2-32-0240-3KF12-xx

5.5

380-480V ±10% - 3 Phase Input

kW Model Number with Filter

Output

Current (A)

Frame

Size

BFI-H2-24-0022-3KF12-xx

0.75

2.2

BFI-H2-24-0041-3KF12-xx

1.5

4.1

BFI-H2-24-0058-3KF12-xx

2.2

5.8

BFI-H2-24-0095-3KF12-xx

9.5

BFI-H2-34-0140-3KF12-xx

5.5

BFI-H2-34-0180-3KF12-xx

7.5

BFI-H2-34-0240-3KF12-xx

200-240V ±10% - 1 Phase Input

kW Model with Filter

Output

Current (A)

Frame

Size

BFI-H2-0043-22-1KF1X-xx / BFI-H2-22-0043-1KF1D-xx

0.75

4.3

BFI-H2-22-0070-1KF1X-xx / BFI-H2-22-0070-1KF1D-xx

1.5 7 2

BFI-H2-22-0105-1KF1X-xx / BFI-H2-22-0105-1KF1D-xx

2.2

10.5

200-240V ±10% - 3 Phase Input

kW Model Number with Filter

Output

Current (A)

Frame

Size

BFI-H2-22-0043-3KF1X-xx / BFI-H2-22-0043-3KF1D-xx

0.75

4.3

BFI-H2-22-0070-3KF1X-xx / BFI-H2-22-0070-3KF1D-xx

1.5 7 2

BFI-H2-22-0105-3KF1X-xx / BFI-H2-22-0105-3KF1D-xx

2.2

10.5

BFI-H2-32-0180-3KF1X-xx / BFI-H2-32-0180-3KF1D-xx

4.0

380-480V ±10% - 3 Phase Input

kW Model Number with Filter

Output

Current (A)

Frame

Size

BFI-H2-24-0022-3KF1X-xx / BFI-H2-24-0022-3KF1D-xx

0.75

2.2

BFI-H2-24-0041-3KF1X-xx / BFI-H2-24-0041-3KF1D-xx

1.5

4.1

BFI-H2-24-0058-3KF1X-xx / BFI-H2-24-0058-3KF1D-xx

2.2

5.8

BFI-H2-24-0095-3KF1X-xx / BFI-H2-24-0095-3KF1D-xx

9.5

BFI-H2-34-0140-3KF1X-xx / BFI-H2-34-0140-3KF1D-xx

5.5

BFI-H2-34-0180-3KF1X-xx / BFI-H2-34-0180-3KF1D-xx

7.5

2.1. Drive model numbers

2.1.1. IP20 Enclosed Units

User Guide Revision 1.12

2.1.2. IP66 Enclosed Units

2.1.3. IP55 Enclosed Units

BFI

2 - 0023

Product Family

IP Rating

2 = IP20 X = IP66 Non Switched Y = IP66 Switched

Generation

Dynamic Brake Transistor

1 = Not Fitted 4 = Internal Transistor

Frame Size

1-8

Filter Type

0 = No Filter A = Internal 400V EMC Filter B = Internal 230V EMC Filter

Input Voltage

1 = 110 – 115 2 = 200 – 240 4 = 380 - 480

No. Of Input Phases Current Rating

200-240V ±10% - 3 Phase Input

kW Model Number with Filter

Output

Current (A)

Frame

Size

BFI-H2-44-0240-3KF1N-xx

5.5

BFI-H2-44-0300-3KF1N-xx

7.5

BFI-H2-44-0460-3KF1N-xx

BFI-H2-54-0610-3KF1N-xx

BFI-H2-54-0720-3KF1N-xx

18.5

BFI-H2-64-0900-3KF1N-xx

BFI-H2-64-1100-3KF1N-xx

110

BFI-H2-64-1500-3KF1N-xx

150

BFI-H2-64-1800-3KF1N-xx

180

BFI-H2-74-2020-3KF1N-xx

202

BFI-H2-74-2480-3KF1N-xx

248

380-480V ±10% - 3 Phase Input

kW Model Number with Filter

Output

Current (A)

Frame

Size

BFI-H2-44-0240-3KF1N-xx

24 4 BFI-H2-44-0300-3KF1N-xx

30 4 BFI-H2-44-0390-3KF1N-xx

18.5

39 4 BFI-H2-44-0460-3KF1N-xx

BFI-H2-54-0610-3KF1N-xx

BFI-H2-54-0720-3KF1N-xx

BFI-H2-54-0900-3KF1N-xx

BFI-H2-64-1100-3KF1N-xx

110

BFI-H2-64-1500-3KF1N-xx

150

BFI-H2-64-1800-3KF1N-xx

180

BFI-H2-64-2020-3KF1N-xx

110

202

BFI-H2-74-2400-3KF1N-xx

132

240

BFI-H2-74-3020-3KF1N-xx

160

302

380-480V ±10% - 3 Phase Input

kW Model Number with filter

Output

Current (A)

Frame

Size

BFI-H2-84-3700-3KF14-xx

200

370

BFI-H2-84-4500-3KF14-xx

250

450

User Guide Revision 1.12

2.1.4. IP40 Enclosed Units

2.2. Identifying the Drive by Model Number

Each drive can be identified by its model number, shown below. The model number is on the shipping label and the drive nameplate. The model number includes the drive and factory fitted options.

User Guide Revision 1.12

Drive

Size

A B C D E F G H I

in mm

221

8.70

207

8.15

137

5.39

209

8.23

5.3

0.21 2 221

8.70

207

8.15

137

5.39

209

8.23

5.3

261

10.28

246

9.69 - -

247

9.72 6 0.24 3 261

10.28

246

9.69 - -

247

9.72

3. Mechanical Installation

3.1. General

 The drive should be mounted in a vertical position only on a flat, flame resistant vibration free mounting using the integral holes.  The drive must be installed in a pollution degree 1 or 2 environment only.  Do not mount flammable material close to the drive  Ensure that the minimum cooling air gaps, as detailed in section 3.8 thru 3.10 are left clear  Ensure that the ambient temperature range does not exceed the permissible limits for the drive given in section 13.1  Provide suitable clean, moisture and contaminant free cooling air sufficient to fulfil the cooling requirements of the drive according

to section 13.1

3.2. Before Installation

 Carefully Unpack the drive and check for any signs of damage. Notify the shipper immediately if any exist.  Check the drive rating label to ensure it is of the correct type and power requirements for the application.  Store the drive in its box until required. Storage should be clean and dry and within the temperature range –40°C to +60°C

3.3. UL Compliant Installation

Note the following for UL-compliant installation:

 The drive can be operated within an ambient temperature range as stated in section 13.1  For IP20 units, installation is required in a pollution degree 1 environment  For IP55 AND IP66 units, installation in a pollution degree 2 environment is permissible  UL Listed ring terminals / lugs must be used for all bus bar and grounding connections

3.4. Mechanical dimensions and Mounting – IP20 Units

Control Terminal Torque Settings : All Sizes : 0.8 Nm (7 lb-in) Power Terminal Torque Settings : All Sizes : 1 Nm (8.85 lb-in)

 IP20 Units are intended for installation within a control cabinet.  When mounting with screws

o Using the drive as a template, or the dimensions shown above, mark the locations for drilling o Ensure that when mounting locations are drilled, the dust from drilling does not enter the drive o Mount the drive to the cabinet back-plate using suitable M5 mounting screws o Position the drive, and tighten the mounting screws securely

 When Din Rail Mounting (Frame Size 2 Only)

o Locate the DIN rail mounting slot on the rear of the drive onto the top of the DIN rail first o Press the bottom of the drive onto the DIN rail until the lower clip attaches to the DIN rail o If necessary, use a suitable flat blade screw driver to pull the DIN rail clip down to allow the drive to mount securely on the

rail

o To remove the drive from the DIN rail, use a suitable flat blade screwdriver to pull the release tab downwards, and lift the

bottom of the drive away from the rail first

User Guide Revision 1.12

Drive

Size

A B C D E F G H I

in mm

257

10.12

220

8.66 - -

200

7.87

28.5

1.12 2 257

10.12

220

8.66 - -

200

310

12.20

277

10.89 - -

252

9.90

33.4

1.31 3 310

12.20

277

10.89 - -

252

Drive Size

A B C D E F G H I

mm mm

440

17.32

418

16.46

423

16.65

0.31

240 4 440

17.32

418

16.46

423

16.65

0.31

540

21.26

515

20.28

520

20.47

0.31

270 5 540

21.26

515

20.28

520

20.47

0.31

865

34.06

830

32.68

840

33.07

0.39

330 6 865

34.06

830

32.68

840

33.07

0.39

1280

50.39

1245

49.02

1255

49.41

0.39

360 7 1280

50.39

1245

49.02

1255

49.41

0.39

G F A B C

A F G H D B E E ØH

ØI

ØH

ØI

3.5. Mechanical dimensions and mounting – IP66 Units

Control Terminal Torque Settings: All Sizes: 0.8 Nm (7 lb-in) Power Terminal Torque Settings: All Sizes: 1 Nm (8.85 lb-in)

3.6. Mechanical dimensions and mounting – IP55

User Guide Revision 1.12

Drive Size

A B C D E F G H I J mm

2000

78.74

1925

75.79

1950

76.77

733

28.86

516

20.31

500

19.69

350

13.78

406

15.98

1.38

0.75

ØI

ØH

G F A C D

Control Terminal Torque Settings: All Sizes: 0.8 Nm (7 lb-in) Power Terminal Torque Settings: Frame Size 4: 1.2 – 1.5 Nm Frame Size 5: 2.5 – 4.5 Nm Frame Size 6: 8 Nm Frame Size 7: 8 Nm

3.7. Mechanical dimensions and mounting – IP40 Units

Control Terminal Torque Settings: All Sizes: 0.8Nm (7lb-in) Power Terminal Torque Settings: All Sizes: 50Nm (37 lb-ft)

User Guide Revision 1.12

Drive

Size X Above &

Below

Either

Side

Between

Recommended airflow

CFM (m3/min)

2.95

1.97

1.81

100

3.94

1.97

2.05

Note :

Dimension Z assumes that the drives are mounted side-byside with no clearance.

Typical drive heat losses are 3% of operating load conditions.

Above are guidelines only and the operating ambient temperature of the drive MUST be maintained at all times.

Drive

Size X Above &

Below

Either

Side

2 (IP66)

150

5.9

0.394

3 (IP66)

150

5.9

0.394

4 (IP55)

200

7.9

0.394

5 (IP55)

200

7.9

0.394

6 (IP55)

200

7.9

0.394

7 (IP55)

200

7.9

0.394

Note :

Typical drive heat losses are 3% of operating load conditions.

Above are guidelines only and the operating ambient temperature of the drive MUST be maintained at all times.

3.8. Guidelines for Enclosure mounting (IP20 Units)

 Installation should be in a suitable enclosure, according to EN60529 or other relevant local codes or standards.  Enclosures should be made from a thermally conductive material.  Where vented enclosures are used, there should be venting above the drive and below the drive to ensure good air circulation – see

the diagram below. Air should be drawn in below the drive and expelled above the drive.

 In any environments where the conditions require it, the enclosure must be designed to protect the drive against ingress of airborne

dust, corrosive gases or liquids, conductive contaminants (such as condensation, carbon dust, and metallic particles) and sprays or splashing water from all directions.

 High moisture, salt or chemical content environments should use a suitably sealed (non-vented) enclosure.

The enclosure design and layout should ensure that the adequate ventilation paths and clearances are left to allow air to circulate through the drive heatsink. The Manufacturer recommends the following minimum sizes for drives mounted in non-ventilated metallic enclosures:-

3.9. Guidelines for mounting IP55, and IP66 Units

 Before mounting the drive, ensure that the chosen location meets the environmental condition requirements for the drive shown in

section 13.1

 The drive must be mounted vertically, on a suitable flat surface  The minimum mounting clearances as shown in the table below must be observed  The mounting site and chosen mountings should be sufficient to support the weight of the drives

User Guide Revision 1.12

Note :

Typical drive heat losses are 3% of operating load conditions.

Above are guidelines only and the operating ambient temperature of the drive MUST be maintained at all times.

Level Ground

3.10. Guidelines for mounting IP40 Units

 Before mounting the drive, ensure that the chosen location meets the environmental condition requirements for the drive shown in

section 13.1

 The drive must be floor standing, placed on a Horizontal and suitably flat surface  The Enclosure must be anchored to an adjacent wall using the mounting points provided  All Enclosure vents must remain clear with airflow unobstructed  The mounting site and chosen mountings should be sufficient to support the weight of the drives

3.11. Removing the Terminal Cover

3.11.1. Frame Size 2

3.11.2. Frame Size 3

3.11.3. Frame Size 4

3.11.4. Frame Size 5

Using a suitable flat blade screwdriver, rotate the two retaining screws indicated until the screw slot is vertical.

Using a suitable flat blade screwdriver, rotate the four retaining screws indicated until the screw slot is vertical.

Terminal Cover Release Screws

Using a suitable flat blade screwdriver, rotate the two retaining screws indicated until the screw slot is vertical

User Guide Revision 1.12

3.11.5. Frame Size 6

3.11.6. Frame Size 7

Using a suitable flat blade screwdriver, rotate the two retaining screws indicated until the screw slot is vertical

Using a suitable flat blade screwdriver, rotate the four retaining screws indicated until the screw slot is vertical

User Guide Revision 1.12

3.11.7. Frame Size 8

Open

Access to Control Terminal Wiring

and Options Module Slot

Access to Power and Motor Wiring

The use of a suitable gland system is required to maintain the appropriate IP / Nema rating. Cable entry holes will need to be drilled to suit this system. Some guidelines sizes are defined below: Please take care when drilling to avoid leaving any particles within the product.

Cable Gland recommended Hole Sizes & types:

Min Gland Rating

Hole Size

Imperial

Metric

Size 2

IP66

3 x 22mm

3 PG13.5

3 x M20

Size 3

IP66

1 x 22mm and 2 x 28mm

1 PG13.5 and 2 PG16

1 x M20 and 2 x M25

 UL rated ingress protection ("Type " ) is only met when cables are installed using a UL recognized bushing or fitting for a flexible-

conduit system which meets the required level of protection ("Type")

 For conduit installations the conduit entry holes require standard opening to the required sizes specified per the NEC  Not intended for rigid conduit system

Power Isolator Lock Off – IP66 with Built in Isolator Option

On the switched models the main power isolator switch can be locked in the ‘Off’ position using a 20mm standard shackle padlock (not supplied).

IP66 / Nema 12 Unit Lock Off

IP66 / Nema 4X Unit Lock Off

3.12. Gland Plate and Lock Off

User Guide Revision 1.12

This manual is intended as a guide for proper installation. The Manufacturer cannot assume responsibility for the compliance or the non-compliance to any code, national, local or otherwise, for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

This drive contains high voltage capacitors that take time to discharge after removal of the main supply. Before working on the drive, ensure isolation of the main supply from line inputs. Wait ten (10) minutes for the capacitors to discharge to safe voltage levels. Failure to observe this precaution could result in severe bodily injury or loss of life.

Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

Remove the screws as indicated below

Internal

EMC

Filter

Internal

Surge

Protection

Earth

4. Electrical Installation

4.1. Grounding the Drive

4.1.1. Grounding Guidelines

The ground terminal of each drive should be individually connected DIRECTLY to the site ground bus bar (through the filter if installed). Drive ground connections should not loop from one drive to another, or to, or from any other equipment. Ground loop impedance must confirm to local industrial safety regulations. To meet UL regulations, UL approved ring crimp terminals should be used for all ground wiring connections. The drive Safety Ground must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be checked periodically.

4.1.2. Protective Earth Conductor

The Cross sectional area of the PE Conductor must be at least equal to that of the incoming supply conductor.

4.1.3. Safety Ground

This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod, or bus bar. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.

4.1.4. Motor Ground

The motor ground must be connected to one of the ground terminals on the drive.

4.1.5. Ground Fault Monitoring

As with all inverters, a leakage current to earth can exist. The drive is designed to produce the minimum possible leakage current whilst complying with worldwide standards. The level of current is affected by motor cable length and type, the effective switching frequency, the earth connections used and the type of RFI filter installed. If an ELCB (Earth Leakage Circuit Breaker) is to be used, the following conditions apply: -

 A Type B Device must be used  The device must be suitable for protecting equipment with a DC component in the leakage current  Individual ELCBs should be used for each drive

Drives with an EMC filter have an inherently higher leakage current to Ground (Earth). For applications where tripping occurs the EMC filter can be disconnected (on IP20 units only) by removing the EMC screw on the side of the product.

The drive product range has input supply voltage surge suppression components fitted to protect the drive from line voltage transients, typically originating from lightening strikes or switching of high power equipment on the same supply.

4.1.6. Shield Termination (Cable Screen)

The safety ground terminal provides a grounding point for the motor cable shield. The motor cable shield connected to this terminal (drive end) should also be connected to the motor frame (motor end). Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal.

User Guide Revision 1.12

4.2. Wiring Precautions

Connect the drive according to section 4.3 and 4.4, ensuring that motor terminal box connections are correct. There are two connections in general: Star and Delta. It is essential to ensure that the motor is connected in accordance with the voltage at which it will be operated. For more information, refer to section 4.5 Motor Terminal Box Connection.

It is recommended that the power cabling should be 4-core PVC-insulated screened cable, laid in accordance with local industrial regulations and codes of practice.

4.3. Incoming Power Connection

 For a single phase supply, power should be connected to L1/L, L2/N.  For 3 phase supplies power should be connected to L1, L2, and L3. Phase sequence is not important.  For compliance with CE and C Tick EMC requirements, a symmetrical shielded cable is recommended.  A fixed installation is required according to IEC61800-5-1 with a suitable disconnecting device installed between the drive and the AC

Power Source. The disconnecting device must conform to the local safety code / regulations (e.g. within Europe, EN60204-1, Safety of machinery).

 The cables should be dimensions according to any local codes or regulations. Guideline dimensions are given in section13.4.  Suitable fuses to provide wiring protection of the input power cable should be installed in the incoming supply line, according to the

data in section 13.4. The fuses must comply with any local codes or regulations in place. In general, type gG (IEC 60269) or UL type T fuses are suitable; however in some cases type aR fuses may be required. The operating time of the fuses must be below 0.5 seconds.

 Where allowed by local regulations, suitably dimensioned type B MCB circuit breakers of equivalent rating may be utilised in place of

fuses, providing that the clearing capacity is sufficient for the installation.

 When the power supply is removed from the drive, a minimum of 30 seconds should be allowed before re-applying the power. A

minimum of 10 minutes should be allowed before removing the terminal covers or connection.

 The maximum permissible short circuit current at the drive Power terminals as defined in IEC60439-1 is 100kA.  An optional Input Choke is recommended to be installed in the supply line for drives where any of the following conditions occur:-

o The incoming supply impedance is low or the fault level / short circuit current is high o The supply is prone to dips or brown outs o An imbalance exists on the supply (3 phase drives) o The power supply to the drive is via a busbar and brush gear system (typically overhead Cranes).

 In all other installations, an input choke is recommended to ensure protection of the drive against power supply faults. Refer to your

local Invertek sales partner for available options

 Optidrive HVAC models in frame sizes 4 to 8 are factory fitted with an Input choke as standard.

4.4. Drive and Motor Connection

 The motor should be connected to the drive U, V, and W terminals using a suitable 3 or 4 core cable. Where a 3 core cable is utilised,

with the shield operating as an earth conductor, the shield must have a cross sectional area at least equal to the phase conductors when they are made from the same material. Where a 4 core cable is utilised, the earth conductor must be of at least equal cross sectional area and manufactured from the same material as the phase conductors.

 The motor earth must be connected to one of the drive earth terminals.  For compliance with the European EMC directive, a suitable screened (shielded) cable should be used. Braided or twisted type

screened cable where the screen covers at least 85% of the cable surface area, designed with low impedance to HF signals are recommended as a minimum. Installation within a suitable steel or copper tube is generally also acceptable.

 The cable screen should be terminated at the motor end using an EMC type gland allowing connection to the motor body through

the largest possible surface area

 Where drives are mounted in a steel control panel enclosure, the cable screen may be terminated directly to the control panel using

a suitable EMC clamp or gland, as close to the drive as possible.

 For IP55 drives, connect the motor cable screen to the internal ground clamp

User Guide Revision 1.12

Incoming Supply Voltage

Motor Nameplate Voltages

Connection

230

230 / 400

Delta

400

400 / 690

400

230 / 400

Star

Additional Information

 Compatible Thermistor : PTC Type, 2.5kΩ trip level  Use a setting of P1-13 that have Input 5 function as External Trip, e.g. P1-

13 = 6. Refer to section Error! Reference source not found. for further etails.

4.5. Motor Terminal Box Connections

Most general purpose motors are wound for operation on dual voltage supplies. This is indicated on the nameplate of the motor

This operational voltage is normally selected when installing the motor by selecting either STAR or DELTA connection. STAR always gives the higher of the two voltage ratings.

4.6. Motor Thermistor Connection

Where a motor thermistor is to be used, it should be connected as follows :-

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