Control Techniques M100, M101, M200, M201, M300 Installation Guide

...

Frame 1 to 4

Power Installation Guide

Unidrive M100 to M400

Part Number: 0478-0336-01 Issue: 1

Original Instructions

General Information

For the purposes of compliance with the EU Machinery Directive 2006/42/EC.

This guide covers the basic information that is required to install the drive, in applications where a drive malfunction does not result in a mechanical hazard. When the drive is used in a safety related application, i.e. where a malfunction might result in a hazard, it is essential to refer to this guide and the Control User Guide. The Control User Guide is available for download from: http://www.emersonindustrial.com/en-EN/controltechniques/downloads/userguidesandsoftware/Pages/downloads.aspx or www.emersonindustrial.com/en-EN/leroy-somer-motors-drives/downloads/Pages/manuals.aspx The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional operating parameters of the equipment or from mismatching the variable speed drive with the motor. The contents of this guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the contents of the guide, without notice. All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by an information storage or retrieval system, without permission in writing from the publisher.

Drive firmware version

This product is supplied with the latest firmware version. If this drive is to be connected to an existing system or machine, all drive firmware versions should be verified to confirm the same functionality as drives of the same model already present. This may also apply to drives returned from a Emerson Industrial Automation Service Centre or Repair Centre. If there is any doubt please contact the supplier of the product. The firmware version of the drive can be checked by looking at Pr 11.029

Environmental statement

Emerson Industrial Automation is committed to minimising the environmental impacts of its manufacturing operations and of its products throughout their life cycle. To this end, we operate an Environmental Management System (EMS) which is certified to the International Standard ISO 14001. Further information on the EMS, our Environmental Policy and other relevant information is available on request, or can be found at: http://www.emersonindustrial.com/en-EN/controltechniques/aboutus/environment/Pages/environment.aspx. The electronic variable-speed drives manufactured by Emerson Industrial Automation have the potential to save energy and (through increased machine/process efficiency) reduce raw material consumption and scrap throughout their long working lifetime. In typical applications, these positive environmental effects far outweigh the negative impacts of product manufacture and end-of-life disposal. Nevertheless, when the products eventually reach the end of their useful life, they must not be discarded but should instead be recycled by a specialist recycler of electronic equipment. Recyclers will find the products easy to dismantle into their major component parts for efficient recycling. Many parts snap together and can be separated without the use of tools, while other parts are secured with conventional fasteners. Virtually all parts of the product are suitable for recycling. Product packaging is of good quality and can be re-used. Large products are packed in wooden crates, while smaller products come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these containers can be recycled. Polythene, used on the protective film and bags for wrapping product, can be recycled in the same way. Emerson Industrial Automation’s packaging strategy prefers easily-recyclable materials of low environmental impact, and regular reviews identify opportunities for improvement. When preparing to recycle or dispose of any product or packaging, please observe local legislation and best practice.

REACH legislation

EC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (REACH) requires the supplier of an article to inform the recipient if it contains more than a specified proportion of any substance which is considered by the European Chemicals Agency (ECHA) to be a Substance of Very High Concern (SVHC) and is therefore listed by them as a candidate for compulsory authorisation. For current information on how this requirement applies in relation to specific Emerson Industrial Automation’s products, please approach your usual contact in the first instance. Emerson Industrial Automation’s position statement can be viewed at: www.emersonindustrial.com/en-EN/controltechniques/aboutus/environment/reachregulation/Pages/reachregulation.aspx. Copyright © May 2016 Emerson Industrial Automation. The information contained in this guide is for guidance only and does not form part of any contract. The accuracy cannot be guaranteed as Emerson have an ongoing process of development and reserve the right to change the specification of their products without notice. Control Techniques Limited. Registered Office: The Gro, Newtown, Powys SY16 3BE. Registered in England and Wales. Company Reg. No. 01236886. Moteurs Leroy-Somer SAS. Headquarters: Bd Marcellin Leroy, CS 10015, 16915 Angoulême Cedex 9, France. Share Capital: 65 800 512 €, RCS Angoulême 338 567 258. Issue Number: 1

Contents

1 Safety information ....................................................................................... 7

1.1 Warnings, Cautions and Notes ................................................................................ 7

1.2 Electrical safety - general warning ........................................................................... 7

1.3 System design and safety of personnel ................................................................... 7

1.4 Environmental limits ................................................................................................ 7

1.5 Access ..................................................................................................................... 8

1.6 Fire protection .......................................................................................................... 8

1.7 Compliance with regulations .................................................................................... 8

1.8 Motor ....................................................................................................................... 8

1.9 Mechanical brake control ......................................................................................... 8

1.10 Adjusting parameters ............................................................................................... 8

1.11 Electrical installation ................................................................................................ 9

1.12 Hazard ..................................................................................................................... 9

2 Product information ..................................................................................10

2.1 Model number ........................................................................................................ 10

2.2 Nameplate description ........................................................................................... 11

2.3 Ratings .................................................................................................................. 11

2.4 Drive features ........................................................................................................ 14

2.5 Items supplied with the drive ................................................................................. 15

3 Mechanical installation ............................................................................. 16

3.1 Safety information .................................................................................................. 16

3.2 Planning the installation ......................................................................................... 16

3.3 Terminal cover removal ......................................................................................... 19

3.4 Drive dimensions and mounting methods .............................................................. 21

3.5 Enclosure layout .................................................................................................... 23

3.6 Heatsink fan operation ........................................................................................... 27

3.7 External EMC filter ................................................................................................. 28

3.8 Electrical terminals ................................................................................................ 33

3.9 Routine maintenance ............................................................................................. 35

4 Electrical installation .................................................................................37

4.1 Power connections ................................................................................................ 38

4.2 AC supply requirements ........................................................................................ 43

4.3 Ratings .................................................................................................................. 47

4.4 Output circuit and motor protection ....................................................................... 51

4.5 Braking .................................................................................................................. 56

4.6 Ground leakage ..................................................................................................... 60

4.7 EMC (Electromagnetic compatibility) ..................................................................... 61

5 Technical data ............................................................................................75

5.1 Drive technical data ............................................................................................... 75

5.2 Optional external EMC filters ................................................................................. 96

6 UL listing information ............................................................................... 99

6.1 UL file reference .................................................................................................... 99

6.2 Option modules, kits and accessories ................................................................... 99

6.3 Enclosure ratings ................................................................................................... 99

6.4 Mounting ................................................................................................................ 99

6.5 Environment .......................................................................................................... 99

6.6 Electrical Installation ............................................................................................ 100

6.7 Motor overload protection and thermal memory retention ................................... 100

6.8 Electrical supply ................................................................................................... 101

6.9 External Class 2 supply ....................................................................................... 101

6.10 Group Installation and Modular Drive Systems ................................................... 101

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

EU Declaration of Conformity

G Williams Vice President, Technology Date: 17th March 2016

Control Techniques Ltd The Gro Newtown Powys UK SY16 3BE

This declaration is issued under the sole responsibility of the manufacturer. The object of the declaration is in conformity with the relevant Union harmonization legislation. The declaration applies to the variable speed drive products shown below:

Model

number

aaaa Basic series

bb Frame size 01, 02, 03, 04, 05, 06, 07, 08, 09, 10, 11

c Voltage rating 1 = 100 V, 2 = 200 V, 4 = 400 V, 5 = 575 V, 6 = 690 V

ddddd Current rating Example 01000 = 100 A

e Drive format

The model number may be followed by additional characters that do not affect the ratings. The variable speed drive products listed above have been designed and manufactured in accordance with the

following European harmonized standards:

EN 61800-5-1:2007

EN 61800-3: 2004+A1:2012

EN 61000-6-2:2005

EN 61000-6-4: 2007+A1:2011

EN 61000-3-2:2014

EN 61000-3-3:2013

EN 61000-3-2:2014 Applicable where input current < 16 A. No limits apply for professional equipment where input power ≥1 kW.

These products comply with the Restriction of Hazardous Substances Directive (2011/65/EU), the Low Voltage Directive (2014/35/EU) and the Electromagnetic Compatibility Directive (2014/30/EU).

Interpretation Nomenclature aaaa - bbc ddddde

M100, M101, M200, M201, M300, M400, M600, M700, M701, M702, F300, H300, E200, E300, HS30, HS70, HS71, HS72, M000, RECT

A = 6P Rectifier + Inverter (internal choke), D = Inverter, E = 6P Rectifier + Inverter (external choke), T = 12P Rectifier + Inverter (external choke)

Adjustable speed electrical power drive systems - Part 5-1: Safety requirements Electrical, thermal and energy

Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods

Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments

Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial environments

Electromagnetic compatibility (EMC) - Part 3-2: Limits for harmonic current emissions (equipment input current ≤16 A per phase)

Electromagnetic compatibility (EMC) - Part 3-3: Limitation of voltage changes, voltage fluctuations and flicker in public, low voltage supply systems, for equipment with rated current ≤16 A per phase and not subject to conditional connection

Moteurs Leroy-Somer Usine des Agriers Boulevard Marcellin Leroy CS10015 16915 Angoulême Cedex 9 France

These electronic drive products are intended to be used with appropriate motors, controllers, electrical protection components and other equipment to form complete end products or systems. Compliance with safety and EMC regulations depends upon installing and configuring drives correctly, including using the specified input filters.

The drives must be installed only by professional installers who are familiar with requirements for safety and EMC. Refer to the Product Documentation. An EMC data sheet is available giving detailed information. The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

EU Declaration of Conformity

(including 2006 Machinery Directive)

Control Techniques Ltd The Gro Newtown Powys UK SY16 3BE

Model

number

aaaa Basic series

bb Frame size 01, 02, 03, 04, 05, 06, 07, 08, 09, 10, 11

c Voltage rating 1 = 100 V, 2 = 200 V, 4 = 400 V, 5 = 575 V, 6 = 690 V

ddddd Current rating Example 01000 = 100 A

e Drive format

The model number may be followed by additional characters that do not affect the ratings.

This declaration relates to these products when used as a safety component of a machine. Only the Safe Torque Off function may be used for a safety function of a machine. None of the other functions of the drive may be used to carry out a safety function.

These products fulfil all the relevant provisions of the Machinery Directive 2006/42/EC and the Electromagnetic Compatibility Directive (2014/30/EU).

EC type examination has been carried out by the following notified body: TUV Rheinland Industrie Service GmbH Am Grauen Stein D-51105 Köln Germany EC type-examination certificate numbers: 01/205/5270.01/14 dated 2014-11-11 01/205/5387.01/15 dated 2015-01-29 01/205/5383.02/15 dated 2015-04-21

Notified body identification number: 0035 The harmonized standards used are shown below:

EN 61800-5-1:2007

EN 61800-5-2:2007

EN ISO 13849-1:2008

EN ISO 13849-2:2008 Safety of machinery, Safety-related parts of control systems. Validation

EN 61800-3: 2004+A1:2012

EN 62061:2005

Person authorised to complete the technical file:

Interpretation Nomenclature aaaa - bbc ddddde

M300, M400, M600, M700, M701, M702, F300, H300, E200, E300, HS30, HS70, HS71, HS72, M000, RECT

A = 6P Rectifier + Inverter (internal choke), D = Inverter, E = 6P Rectifier + Inverter (external choke), T = 12P Rectifier + Inverter (external choke)

Adjustable speed electrical power drive systems - Part 5-1: Safety requirements

- Electrical, thermal and energy

Adjustable speed electrical power drive systems - Part 5-2: Safety requirements

- Functional

Safety of Machinery, Safety-related parts of control systems, General principles for design

Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods

Safety of machinery, Functional safety of safety related electrical, electronic and programmable electronic control systems

Moteurs Leroy-Somer Usine des Agriers Boulevard Marcellin Leroy CS10015 16915 Angoulême Cedex 9 France

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

P Knight

G. Williams Vice President, Technology Date: 17th March 2016 Place: Newtown, Powys, UK

Conformity Engineer Newtown, Powys, UK

IMPORTANT NOTICE These electronic drive products are intended to be used with appropriate motors, controllers, electrical

protection components and other equipment to form complete end products or systems. Compliance with safety and EMC regulations depends upon installing and configuring drives correctly, including using the specified input filters.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

1 Safety information

WARNING

CAUTION

NOTE

1.1 Warnings, Cautions and Notes

A Warning contains information which is essential for avoiding a safety hazard.

A Caution contains information which is necessary for avoiding a risk of damage to the product or other equipment.

A Note contains information, which helps to ensure correct operation of the product.

1.2 Electrical safety - general warning

The voltages used in the drive can cause severe electrical shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or adjacent to the drive. Specific warnings are given at the relevant places in this guide.

1.3 System design and safety of personnel

The drive is intended as a component for professional incorporation into complete equipment or a system. If installed incorrectly, the drive 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 equipment which can cause injury.

Close attention is required to the electrical installation and the system design to avoid hazards either in normal operation or in the event of equipment malfunction. System design, installation, commissioning/start-up and maintenance must be carried out by personnel who have the necessary training and experience. They must read this safety information and this Guide carefully.

The STOP and Safe Torque Off functions of the drive do not isolate dangerous voltages from the output of the drive or from any external option unit. The supply must be disconnected by an approved electrical isolation device before gaining access to the electrical connections.

With the sole exception of the Safe Torque Off function, none of the drive functions must be used to ensure safety of personnel, i.e. they must not be used for safety-related functions.

Careful consideration must be given to the functions of the drive which might result in a hazard, either through their intended behavior or through incorrect operation due to a fault. In any application where a malfunction of the drive or its control system could lead to or allow damage, loss or injury, a risk analysis must be carried out, and where necessary, further measures taken to reduce the risk for example, an over-speed protection device in case of failure of the speed control, or a fail-safe mechanical brake in case of loss of motor braking.

The Safe Torque Off function may be used in a safety-related application. The system designer is responsible for ensuring that the complete system is safe and designed correctly according to the relevant safety standards.

Safety information

Product information Mechanical installation Electrical installation Technical data UL listing information

1.4 Environmental limits

Instructions in this guide regarding transport, storage, installation and use of the drive must be complied with, including the specified environmental limits. Drives must not be subjected to excessive physical force.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

1.5 Access

Drive access must be restricted to authorized personnel only. Safety regulations which apply at the place of use must be complied with.

1.6 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided. For further information, refer to section 3.2.5 Fire protection on page 17.

1.7 Compliance with regulations

The installer is responsible for complying with all relevant regulations, such as national wiring regulations, accident prevention regulations and electromagnetic compatibility (EMC) regulations. Particular attention must be given to the cross-sectional areas of conductors, the selection of fuses or other protection, and protective ground (earth) connections.

This guide contains instruction for achieving compliance with specific EMC standards.

Within the European Union, all machinery in which this product is used must comply with the following directives:

2006/42/EC: Safety of machinery. 2014/30/EU: Electromagnetic Compatibility Directive.

1.8 Motor

Ensure the motor is installed in accordance with the manufacturer’s recommendations. Ensure the motor shaft is not exposed.

Standard squirrel cage induction motors are designed for single speed operation. If it is intended to use the capability of the drive to run a motor at speeds above its designed maximum, it is strongly recommended that the manufacturer is consulted first.

Low speeds may cause the motor to overheat because the cooling fan becomes less effective. The motor should be installed with a protection thermistor. If necessary, an electric forced vent fan should be used.

The values of the motor parameters set in the drive affect the protection of the motor. The default values in the drive should not be relied upon.

It is essential that the correct value is entered in Pr 00.006 motor rated current. This affects the thermal protection of the motor.

1.9 Mechanical brake control

The brake control functions are provided to allow well co-ordinated operation of an external brake with the drive. While both hardware and software are designed to high standards of quality and robustness, they are not intended for use as safety functions, i.e. where a fault or failure would result in a risk of injury. In any application where the incorrect operation of the brake release mechanism could result in injury, independent protection devices of proven integrity must also be incorporated.

1.10 Adjusting parameters

Some parameters have a profound effect on the operation of the drive. They must not be altered without careful consideration of the impact on the controlled system. Measures must be taken to prevent unwanted changes due to error or tampering.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

1.11 Electrical installation

1.11.1 Electric shock risk

The voltages present in the following locations can cause severe electric shock and may be lethal:

• AC supply cables and connections

• Output cables and connections

• Many internal parts of the drive, and external option units Unless otherwise indicated, control terminals are single insulated and must not be touched.

1.11.2 Stored charge

The drive contains capacitors that remain charged to a potentially lethal voltage after the AC supply has been disconnected. If the drive has been energized, the AC supply must be isolated at least ten minutes before work may continue.

1.12 Hazard

1.12.1 Falling hazard

The drive presents a falling or toppling hazard. This can still cause injury to personnel and therefore should be handled with care.

Maximum weight:

Size 1: 0.75 kg (1.65 Ib) Size 2: 1.3 kg (3.0 lb) Size 3: 1.5 kg (3.3 lb) Size 4: 3.13 kg (6.9 Ib)

Safety information

Product information Mechanical installation Electrical installation Technical data UL listing information

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

2 Product information

OptionalBuild

IdentificationLabel

Derivative ElectricalSpecifications

M400 - 03 4 00073

ProductLine UnidriveM400 UnidriveM300 UnidriveM200 UnidriveM201 UnidriveM101 UnidriveM100

FrameSize

CustomerCode

A B 1 00

CustomerCode:

00 = 50 Hz 01 = 60 Hz

Reserved:

ConformalCoating:

0=Standard

IP / NEMA Rating:

1 = IP20 / NEMA 1

BrakeTransistor:

B = Brake

Cooling:

A = Air

Reserved

Documentation

Documentation:

VoltageRating:

CurrentRating:

HeavyDutycurrentratingx 10

DriveFormat:

A - ACin ACout

2-200V(200-240

-400V(380-480

-575V(500-575

-690V(500-690

± 10%)

1-100V(100-120 10%)±

±±10%)

5 6 10%)

± 10%)

0-Suppliedseparately 1-English 2-French 3-Italian 4-German 5-Spanish

2.1 Model number

The way in which the model numbers for the Unidrive M product range is formed is illustrated below:

Figure 2-1 Model number

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

2.2 Nameplate description

Model

number

Input voltage

Output

voltage

Serial

number

Input

frequency

Power rating

Date code

No. of phases & Typical input current

Heavy duty output current

Approvals

M400-022 00042 A

0.75kW

10.4A / 5.4A

Patents: www.ctpatents.info Manuals: www.ctmanuals.info

0-550Hz

Output

frequency

Key to approvals

Modelnumber

Referto UserGuide

Datecode

Input

voltage

Powerrating

M400-02200042 A

200-240V0.75kW

V40

CE approval Europe

RCM -Regulatory Compliance Mark

Australia

UL / cUL approval USA & Canada

RoHS compliant Europe

Functional safety USA & Canada

EurAsian Conformity

EurAsia

NOTE

Figure 2-2 Typical drive rating labels

Date code format

The date code is split into two sections: a letter followed by a number. The letter indicates the year, and the number indicates the week number (within the year) in which the drive was built.The letters go in alphabetical order, starting with A in 1991 (B in 1992, C in 1993 etc). Example: A date code of Y28 would correspond to week 28 of year 2015.

2.3 Ratings

The continuous current ratings given are for maximum 40 °C (104 °F), 1000 m altitude and 3 kHz switching frequency. Derating is required for higher switching frequencies, ambient temperature >40 °C (104 °F) and high altitude. For further information, refer to Chapter 5 Technical data on page 75.

Safety information

Product information

Mechanical installation Electrical installation Technical data UL listing information

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

Table 2-1 100 V drive ratings (100 V to 120 V ±10 %)

Heavy Duty

Model

Input

phases

Maximum

continuous

output current

Open loop

peak current

RFC peak

current

Nominal power

100 V

Motor power

ph A A A kW hp

01100017

01100024 2.4 3.6 4.3 0.37 0.5

02100042 4.2 6.3 7.6 0.75 1

1.7 2.6 3.1 0.25 0.33

02100056 5.6 8.4 10.1 1.1 1.5

Table 2-2 200 V drive ratings (200 V to 240 V ±10 %)

Heavy Duty

Model

01200017 1 1.7 2.6 3.1 0.25 0.33

01200024 1 2.4 3.6 4.3 0.37 0.5

01200033 1 3.3 5 5.9 0.55 0.75

01200042 1 4.2 6.3 7.6 0.75 1

02200024 1/3 2.4 3.6 4.3 0.37 0.5

02200033 1/3 3.3 5 5.9 0.55 0.75

02200042 1/3 4.2 6.3 7.6 0.75 1

02200056 1/3 5.6 8.4 10.1 1.1 1

02200075 1/3 7.5 11.3 13.5 1.5 2

03200100 1/3 10 15 18 2.2 3

04200133 1/3 13.3 20 23.9 3 3

04200176 3 17.6 26.4 31.7 4 5

Input phases

ph A A A kW hp

Maximum

continuous

output current

Open loop

peak current

RFC peak

current

Nominal power

at 230 V

at 100 V

Motor power

at 230 V

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

Table 2-3 400 V drive ratings (380 V to 480 V ±10 %)

NOTE

Heavy Duty

Model

02400013

02400018 1.8 2.7 3.2 0.55 0.75

02400023 2.3 3.5 4.1 0.75 1

02400032 3.2 4.8 5.8 1.1 1.5

02400041 4.1 6.2 7.4 1.5 2

03400056

03400073 7.3 11 13.1 3 3

03400094 9.4 14.1 16.9 4 5

04400135

04400170 17 25.5 30.6 7.5 10

Input phases

ph A A A kW hp

Maximum

continuous

output current

1.3 2 2.3 0.37 0.5

5.6 8.4 10.1 2.2 3

13.5 20.3 24.3 5.5 7.5

Open loop

peak current

RFC peak

current

Nominal

power at 400 V

Motor power

at 460 V

2.3.1 Typical short term overload limits

The maximum percentage overload limit changes depending on the selected motor. Variations in motor rated current, motor power factor and motor leakage inductance all result in changes in the maximum possible overload. The exact value for a specific motor can be calculated using the equations detailed in Menu 4 in the Parameter Reference Guide.

Typical values are shown in the table below for RFC-A and open loop (OL) modes:

Table 2-4 Typical overload limits

Operating mode RFC From cold RFC From 100 %

Heavy Duty overload with motor rated current = drive rated

180 % for 3 s 180 % for 3 s 150 % for 60 s 150 % for 8 s

current

Open loop from

cold

Open loop from

100 %

Safety information

Product information

Mechanical installation Electrical installation Technical data UL listing information

Generally the drive rated current is higher than the matching motor rated current allowing a higher level of overload than the default setting.

The time allowed in the overload region is proportionally reduced at very low output frequency on

some drive ratings.

The maximum overload level which can be attained is independent of the speed.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

2.4 Drive features

Figure 2-3 Features of the drive (Unidrive M400 illustrated)

Key

1. Rating label (On side of drive)

2. Identification label 6. Braking terminal 10. Motor connections 14. Keypad connection

3. Option module connection

4. Relay connections 8. DC bus + 12. Ground connections

5. Control connections 9. DC bus - 13. Safe Torque Off

7. Internal EMC filter screw

11. AC supply connections

connections

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

2.5 Items supplied with the drive

The drive is supplied with a copy of the Control Quick Start Guide, a copy of the Power Installation Guide, a safety information booklet, the Certificate of Quality and the items shown in Table 2-5.

Table 2-5 Parts supplied with the drive

Description Size 1 Size 2 Size 3 Size 4

Safety information

STO connector

Grounding bracket

M4 x 8 Double Sem Torx screw

* Unidrive M300/ M400 only.

Product information

x 1

Mechanical installation Electrical installation Technical data UL listing information

x 4

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

3 Mechanical installation

WARNING

3.1 Safety information

This chapter describes how to use all mechanical details to install the drive. The drive is intended to be installed in an enclosure. Key features of this chapter include:

• High IP as standard

• Enclosure sizing and layout

• Terminal location and torque settings

Follow the instructions

The mechanical and electrical installation instructions must be adhered to. Any questions or doubt should be referred to the supplier of the equipment. It is the responsibility of the owner or user to ensure that the installation of the drive and any external option unit, and the way in which they are operated and maintained, comply with the requirements of the Health and Safety at Work Act in the United Kingdom or applicable legislation and regulations and codes of practice in the country in which the equipment is used.

Stored charge

Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions, it is possible that the capacitors may fail to discharge, or be prevented from being discharged by a voltage applied to the output terminals. If the drive has failed in a manner that causes the display to go blank immediately, it is possible the capacitors will not be discharged. In this case, consult Emerson Industrial Automation or their authorized distributor.

Competence of the installer

The drive must be installed by professional assemblers who are familiar with the requirements for safety and EMC. The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used.

Enclosure

The drive is intended to be mounted in an enclosure which prevents access except by trained and authorized personnel, and which prevents the ingress of contamination. It is designed for use in an environment classified as pollution degree 2 in accordance with IEC 60664-1. This means that only dry, non-conducting contamination is acceptable.

3.2 Planning the installation

The following considerations must be made when planning the installation:

3.2.1 Access

Access must be restricted to authorized personnel only. Safety regulations which apply at the place of use must be complied with.

The IP (Ingress Protection) rating of the drive is installation dependent.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

3.2.2 Environmental protection

NOTE

The drive must be protected from:

• Moisture, including dripping water or spraying water and condensation. An anti-condensation heater may be required, which must be switched off when the drive is running.

• Contamination with electrically conductive material

• Contamination with any form of dust which may restrict the fan, or impair airflow over various components

• Temperature beyond the specified operating and storage ranges

• Corrosive gasses

During installation it is recommended that the vents on the drive are covered to prevent debris (e.g. wire off-cuts) from entering the drive.

3.2.3 Cooling

The heat produced by the drive must be removed without its specified operating temperature being exceeded. Note that a sealed enclosure gives much reduced cooling compared with a ventilated one, and may need to be larger and/or use internal air circulating fans.

For further information, refer to section 3.5.1

Enclosure sizing

on page 24.

3.2.4 Electrical safety

The installation must be safe under normal and fault conditions. Electrical installation instructions are given in Chapter 4

Electrical installation on page 37

3.2.5 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided.

For installation in the USA, a NEMA 12 enclosure is suitable.

For installation outside the USA, the following (based on IEC 62109-1, standard for PV inverters) is recommended.

Enclosure can be metal and/or polymeric, polymer must meet requirements which can be summarized for larger enclosures as using materials meeting at least UL 94 class 5VB at the point of minimum thickness.

Air filter assemblies to be at least class V-2.

The location and size of the bottom shall cover the area shown in Figure 3-1. Any part of the side which is within the area traced out by the 5° angle is also considered to be part of the bottom of the fire enclosure.

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Electrical installation Technical data UL listing information

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

Figure 3-1 Fire enclosure bottom layout

Drive

N o t le s s t ha n 2 X

B a ff le p la te s ( m a y b e a b ov e o r b e lo w b o tt o m o f e n cl o su r e)

B o tt o m o f f ir e

e n cl os u re

Not less than 2 times ‘X’

Baffle plates (may be above or

below bottom of enclosure)

Bottom of fire enclosure

The bottom, including the part of the side considered to be part of the bottom, must be designed to prevent escape of burning material - either by having no openings or by having a baffle construction. This means that openings for cables etc. must be sealed with materials meeting the 5VB requirement, or else have a baffle above. See Figure 3-2 for acceptable baffle construction. This does not apply for mounting in an enclosed electrical operating area (restricted access) with concrete floor.

Figure 3-2 Fire enclosure baffle construction

3.2.6 Electromagnetic compatibility

Variable speed drives are powerful electronic circuits which can cause electromagnetic interference if not installed correctly with careful attention to the layout of the wiring.

Some simple routine precautions can prevent disturbance to typical industrial control equipment.

If it is necessary to meet strict emission limits, or if it is known that electromagnetically sensitive equipment is located nearby, then full precautions must be observed. In-built into the drive, is an internal EMC filter, which reduces emissions under certain conditions. If these conditions are exceeded, then the use of an external EMC filter may be required at the drive inputs, which must be located very close to the drives. Space must be made available for the filters and allowance made for carefully segregated wiring. Both levels of precautions are covered in section 4.7

(Electromagnetic compatibility) on page 61

EMC

3.2.7 Hazardous areas

The drive must not be located in a classified hazardous area unless it is installed in an approved enclosure and the installation is certified.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

3.3 Terminal cover removal

WARNING

Control/ AC/

Motorterminalcover

Control/ AC/

Motorterminalcover

Control/ AC/

Motorterminalcover

Control/ AC/

Motorterminalcover

NOTE

Isolation device

The AC and / or DC power supply must be disconnected from the drive using an approved isolation device before any cover is removed from the drive or before any servicing work is performed.

Stored charge

The drive contains capacitors that remain charged to a potentially lethal voltage after the AC and / or DC power supply has been disconnected. If the drive has been energized, the power supply must be isolated at least ten minutes before work may continue.

3.3.1 Removing the terminal covers

Figure 3-3 Location and identification of terminal covers (Unidrive M400 size 1 to 4 shown)

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Mechanical installation

Electrical installation Technical data UL listing information

The drives shown in Figure 3-3 above, have a single removable terminal cover which provides access to all electrical connections, i.e. Control, AC, Motor and Brake functions. Figure 3-4 illustrates the three steps required to remove the drive terminal covers.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

Figure 3-4 Removing the terminal cover (Unidrive M400 size 1 to 4 shown)

1. Using a flat bladed screwdriver, turn the terminal cover locking clip anti-clockwise by approximately 30°

2. Slide the terminal cover down

3. Remove terminal cover in direction shown.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

3.3.2 Removal of the STO (Safe Torque Off) connector

WARNING

Figure 3-5 Removing the STO connector

Safety information Product information

Mechanical installation

To remove the STO terminal block:

1. Using tab on STO terminal block, pull upwards.

2. Pull away from the control module as shown on the tab as shown in Figure 3-5 above.

3.4 Drive dimensions and mounting methods

The following drawings show the dimensions of the drive and mounting holes to allow a back-plate to be prepared.

If the drive has been used at high load levels for a period of time, the heatsink can reach temperatures in excess of 70 °C (158 °F). Human contact with the heatsink should be prevented.

The drives can be panel mounted with 0 mm space between the drives.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

Electrical installation Technical data UL listing information

Figure 3-6 Dimensions (Unidrive M200 / M201 shown)

H M1

11 mm

(0.43 in)

Cover release

NOTE

To remove the terminal cover, use a flat bladed screwdriver to rotate the terminal cover locating clip

by approximately 30° in a counter clockwise direction, and then slide the cover down.

Drive

Size

1 160 6.30 75 2.95 130 5.12 143 5.70 53 2.08 5 0.2 2 205 8.07 78 3.07 150 5.91 194 7.63 55 2.17 5 0.2 3 226 8.90 90 3.54 160 6.30 215 8.46 70.7 2.80 5 0.2 4 277 10.91 115 4.53 175 6.89 265 10.43 86 3.40 6 0.23

H W D M1 M2 ∅∅∅∅ A B*

mm in mm in mm in mm in mm in mm in mm in mm in

0 0.00 100 3.93

A minimum clearance of 100 mm above and below Frame 01 to 04 products is required for applications where the product is subjected to rated load and rated ambient temperature.

* A minimum clearance of 50 mm above and below Frame 01 to 04 products is permissible in applications where either the ambient operating temperature is 35 °C or less or the average output current is derated by 20 %.

Derating for reduced clearances is to be applied in addition to the derating for increased switching frequency if operating above 3 kHz.

We recommend that cables are routed carefully to ensure that the airflow in and out of the product is not impeded, when using the reduced clearances.

If DIN rail mounting is used in an installation where the drive is to be subjected to shock or vibration, it is recommended that the bottom mounting screws are used to secure the drive to the back-plate. If the installation is going to be subjected to heavy shock or vibration, then it is recommended that the drive is surface mounted rather than DIN rail mounted.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

The DIN rail mounting mechanism has been designed so no tools are required to install

NOTE

³100mm

(4in)

Enclosure ACsupply contactorand fusesorMCB

Locateas required

External controller

Signalcables Planforallsignalcables toberoutedatleast 300mm(12in)fromthe driveandanypowercable

Ensureminimumclearances aremaintainedforthedrive andexternalEMCfilter.Forced orconvectionair-flowmustnot berestrictedbyanyobjector cabling

³100mm

(4in)

Optionalbrakingresistorandoverload

Locateoptionalbraking resistorexternalto cubicle(preferablyneartoor ontopofthecubicle). Locatetheoverloadprotection

deviceasrequired

TheexternalEMCfiltercanbe bookcasemounted(nexttothe drive)orfootprintmounted(with thedrivemountedontothefilter).

Note ForEMCcompliance:

1)WhenusinganexternalEMC filter,onefilterisrequiredfor eachdrive

2)Powercablingmustbeat least100mm(4in)fromthe driveinalldirections

and remove the drive from a DIN rail. Please ensure the top mounting lugs are located correctly on the DIN rail before installation is initiated. The DIN rail used should conform to DIN46277-3.

3.5 Enclosure layout

Please observe the clearances in the diagram below taking into account any appropriate notes for other devices / auxiliary equipment when planning the installation.

Figure 3-7 Enclosure layout (Unidrive M400 illustrated)

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Mechanical installation

Table 3-1 Spacing required between drive / enclosure and drive / EMC filter

Drive size Spacing (B)

All 0 mm (0.00 in)

Electrical installation Technical data UL listing information

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

3.5.1 Enclosure sizing

k T

in tTex t

–( )

-----------------------------------

NOTE

1. Add the dissipation figures from section 5.1.2 to be installed in the enclosure.

2. If an external EMC filter is to be used with each drive, add the dissipation figures from section

5.2.1

EMC filter ratings

on page 97 for each external EMC filter that is to be installed in the

enclosure.

3. If the braking resistor is to be mounted inside the enclosure, add the average power figures for each braking resistor that is to be installed in the enclosure.

4. Calculate the total heat dissipation (in Watts) of any other equipment to be installed in the enclosure.

5. Add the heat dissipation figures obtained above. This gives a figure in Watts for the total heat that will be dissipated inside the enclosure.

Calculating the size of a sealed enclosure

The enclosure transfers internally generated heat into the surrounding air by natural convection (or external forced air flow); the greater the surface area of the enclosure walls, the better is the dissipation capability. Only the surfaces of the enclosure that are unobstructed (not in contact with a wall or floor) can dissipate heat.

Calculate the minimum required unobstructed surface area

Where:

Unobstructed surface area in m2 (1 m2 = 10.9 ft2)

Maximum expected temperature in

ext

Maximum permissible temperature in oC

int

Power in Watts dissipated by

Heat transmission coefficient of the enclosure material in W/m2/oC

Example

To calculate the size of an enclosure for the following:

• Two drives operating at the Normal Duty rating

• External EMC filter for each drive

• Braking resistors are to be mounted outside the enclosure

• Maximum ambient temperature inside the enclosure: 40 °C

• Maximum ambient temperature outside the enclosure: 30 °C

For example, if the power dissipation from each drive is 187 W and the power dissipation from each external EMC filter is 9.2 W.

Total dissipation: 2 x (187 + 9.2) =392.4 W

Power dissipation

Ae for the enclosure from:

outside

all

heat sources in the enclosure

the enclosure

inside

the enclosure

on page 77 for each drive that is

Power dissipation for the drives and the external EMC filters can be obtained from Chapter 5

Technical data

on page 75.

The enclosure is to be made from painted 2 mm (0.079 in) sheet steel having a heat transmission

coefficient of 5.5 W/m2/oC. Only the top, front, and two sides of the enclosure are free to dissipate heat.

The value of 5.5 W/m2/ºC can generally be used with a sheet steel enclosure (exact values can be obtained from the supplier of the material). If in any doubt, allow for a greater margin in the temperature rise.

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

Figure 3-8 Enclosure having front, sides and top panels free to dissipate heat

392.4

5.5 40 30–( )

---------------------------------

Ae2H D–

H D+

--------------------------

7.135 2 2× 0.6×( )– 2 0.6+

-----------------------------------------------------

Insert the following values:

40 °C

int

30 °C

ext

5.5

392.4 W

The minimum required heat conducting area is then:

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Mechanical installation

= 7.135 m2 (77.8 ft2)

(1 m2 = 10.9 ft2)

Estimate two of the enclosure dimensions - the height (H) and depth (D), for instance. Calculate the width (W) from:

Inserting H = 2m and D = 0.6 m, obtain the minimum width:

=1.821 m (71.7 in)

If the enclosure is too large for the space available, it can be made smaller only by attending to one or all of the following:

• Using a lower PWM switching frequency to reduce the dissipation in the drives

• Reducing the ambient temperature outside the enclosure, and/or applying forced-air cooling to the outside of the enclosure

• Reducing the number of drives in the enclosure

• Removing other heat-generating equipment

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

Electrical installation Technical data UL listing information

Calculating the air-flow in a ventilated enclosure

3k P

in tTex t

–

---------------------------

-------

3 1.3× 323.7×

40 30–

---------------------------------------

The dimensions of the enclosure are required only for accommodating the equipment. The equipment is cooled by the forced air flow.

Calculate the minimum required volume of ventilating air from:

Where:

Air-flow in m3 per hour (1 m3/hr = 0.59 ft3/min)

Maximum expected temperature in °C outside

ext

Maximum permissible temperature in °C

int

Power in Watts dissipated by

Ratio of

all

heat sources in the enclosure

the enclosure

inside

the enclosure

Where:

P0 is the air pressure at sea level PI is the air pressure at the installation

Typically use a factor of 1.2 to 1.3, to allow also for pressure-drops in dirty air-filters.

Example

To calculate the size of an enclosure for the following:

• Three drives operating at the Normal Duty rating

• External EMC filter for each drive

• Braking resistors are to be mounted outside the enclosure

• Maximum ambient temperature inside the enclosure: 40 °C

• Maximum ambient temperature outside the enclosure: 30 °C

For example, dissipation of each drive: 101 W and dissipation of each external EMC filter: 6.9 W (max).

Total dissipation: 3 x (101 + 6.9) = 323.7 W

Insert the following values:

40 °C

int

30 °C

ext

1.3

323.7 W

Then:

126.2 m3/hr (74.5 ft3 /min)

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

(1 m3/ hr = 0.59 ft3/min)

Issue Number: 1

3.5.2 Enclosure design and drive ambient temperature

Drive derating is required for operation in high ambient temperatures

Totally enclosing or through panel mounting the drive in either a sealed cabinet (no airflow) or in a well ventilated cabinet makes a significant difference on drive cooling.

The chosen method affects the ambient temperature value (T

) which should be used for any

rate

necessary derating to ensure sufficient cooling for the whole of the drive.

The ambient temperature for the four different combinations is defined below:

1. Totally enclosed with no air flow (<2 m/s) over the drive T

2. Totally enclosed with air flow (>2 m/s) over the drive T

3. Through panel mounted with no airflow (<2 m/s) over the drive T T

int

4. Through panel mounted with air flow (>2 m/s) over the drive T

rate

= T

int

rate

+ 5 °C

int

= the greater of T

+5 °C, or

ext

or T

ext

int

Where:

= Temperature outside the cabinet

ext

= Temperature inside the cabinet

int

= Temperature used to select current rating from tables in Chapter 5

rate

Technical data

page 75.

3.6 Heatsink fan operation

The drive is ventilated by an internal heatsink fan. The fan channels air through the heatsink chamber.

Ensure the minimum clearances around the drive are maintained to allow air to flow freely.

The heatsink fan on all drive sizes is a variable speed fan (except for size 1 which has a single speed fan). The drive controls the speed at which the fan runs based on the temperature of the heatsink and the drive's thermal model system. The maximum speed at which the fan operates can be limited in Pr

06.045

. This could incur an output current derating.

Table 3-2 Environmental considerations

Environment Comments

Clean

Dry, dusty (non-conductive)

Dry, dusty (conductive)

Regular cleaning recommended

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Electrical installation Technical data UL listing information

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

3.7 External EMC filter

The external EMC filter details for each drive rating are provided in the table below.

Model CT part number

100 V

01100017 to 01100024

02100042 to 02100056 4200-2000 0.90 1.98

200 V

01200017 to 01200042

02200024 to 02200075

03200100

04200133 to 04200176

400 V

02400013 to 02400041

03400056 to 03400094

04400135 to 04400170

Mount the external EMC filter following the guidelines in section 4.7.5

emission standards

on page 69

4200-1000

4200-1001 (low leakage)

4200-1000

4200-1001 (low leakage)

4200-2001

4200-2002 (low leakage)

4200-2003

4200-2004 (low leakage)

4200-3000

4200-3001 (low leakage)

4200-3004

4200-3005 (low leakage)

4200-4000

4200-4001 (low leakage)

4200-4002

4200-4003 (low leakage)

4200-2005

4200-2006 (low leakage)

4200-3008

4200-3009 (low leakage)

4200-4004

4200-4005 (low leakage)

Compliance with generic

Weight

kg lb

0.49 1.08

0.86 1.89

0.88 1.94

0.92 2.02

0.95 2.09

1.3 2.86

1.4 3.08

0.82 1.80

1 2.20

1.4 3.08

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

Figure 3-9 Footprint mounting the EMC filter

Figure 3-10 Bookcase mounting the EMC filter

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Mechanical installation

Electrical installation Technical data UL listing information

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide Issue Number: 1

Figure 3-11 Size 1 to 4 external EMC filter

V: Ground stud

Z: Bookcase mounting slot diameter CS: Cable size

Table 3-3 Size 1 external EMC filter dimensions

CT part

number

4200-1000

4200-1001

A B C D H W V/X Y Z CS

160 mm (6.30 in)

198.8 mm (7.83 in)

52.4 mm (2.06 in)

Table 3-4 Size 2 external EMC filter dimensions

CT part

number

4200-2000

4200-2001

4200-2002

4200-2003

4200-2004

4200-2005

4200-2006

A B C D H W V/X Y Z CS

206 mm (8.11 in)

244.8 mm (9.64 in)

53.4 mm (2.10 in)

X: Threaded holes for footprint

mounting of the drive

41 mm

(1.61 in)

41 mm

(1.61 in)

215 mm

(8.46 in)

261 mm (10.2 in)

75 mm

(2.95 in)

78 mm

(3.07 in)

Y: Footprint mounting hole diameter

4.5 mm

(0.18 in)

4.5 mm

(0.18 in)

4.5 mm

(0.18 in)

4.5 mm

(0.18 in)

1.5 mm

(16 AWG)

4.0 mm

(12 AWG)

1.5 mm

(16 AWG)

Unidrive M100 to M400 Frame 1 to 4 Power Installation Guide

Issue Number: 1

+ 72 hidden pages

Control Techniques M100, M101, M200, M201, M300 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Safety information

1.1 Warnings, Cautions and Notes

1.2 Electrical safety - general warning

1.3 System design and safety of personnel

1.4 Environmental limits

1.5 Access

1.6 Fire protection

1.7 Compliance with regulations

1.8 Motor

1.9 Mechanical brake control

1.10 Adjusting parameters

1.11 Electrical installation

1.12 Hazard

2 Product information

2.1 Model number

2.2 Nameplate description

2.3 Ratings

2.4 Drive features

2.5 Items supplied with the drive

3 Mechanical installation

3.1 Safety information

3.2 Planning the installation

3.3 Terminal cover removal

3.4 Drive dimensions and mounting methods

3.5 Enclosure layout

3.6 Heatsink fan operation

3.7 External EMC filter