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

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Frame 3 to 4

Power Installation Guide

Unidrive M600 to M702 and HS70 to HS72

Part Number: 0478-0254-03 Issue: 3

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 an 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 © February 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: 3 Drive Firmware: 01.14.00.00

Contents

1 Safety information ....................................................................................... 8

1.1 Warnings, Cautions and Notes ................................................................................ 8

1.2 Electrical safety - general warning ........................................................................... 8

1.3 System design and safety of personnel ................................................................... 8

1.4 Environmental limits ................................................................................................ 8

1.5 Access ..................................................................................................................... 9

1.6 Fire protection .......................................................................................................... 9

1.7 Compliance with regulations .................................................................................... 9

1.8 Motor ....................................................................................................................... 9

1.9 Mechanical brake control ......................................................................................... 9

1.10 Adjusting parameters ............................................................................................... 9

1.11 Electrical installation .............................................................................................. 10

2 Product information ..................................................................................11

2.1 Introduction ............................................................................................................ 11

2.2 Model number ........................................................................................................ 11

2.3 Nameplate description ........................................................................................... 12

2.4 Ratings .................................................................................................................. 13

2.5 Drive features ........................................................................................................ 15

2.6 Items supplied with the drive ................................................................................. 16

3 Mechanical installation ............................................................................. 17

3.1 Safety information .................................................................................................. 17

3.2 Planning the installation ......................................................................................... 18

3.3 Terminal cover removal ......................................................................................... 20

3.4 Dimensions and mounting methods ...................................................................... 23

3.5 Enclosure for standard drives ................................................................................ 27

3.6 Enclosure design and drive ambient temperature ................................................. 32

3.7 Heatsink fan operation ........................................................................................... 32

3.8 Enclosing standard drive for high environmental protection .................................. 32

3.9 Installation of high IP insert for size 3 and 4 .......................................................... 34

3.10 Size 3 and 4 internal braking resistor .................................................................... 37

3.11 External EMC filter ................................................................................................. 41

3.12 Terminal size and torque settings .......................................................................... 43

3.13 Routine maintenance ............................................................................................. 44

4 Electrical installation .................................................................................45

4.1 Power and ground connections ............................................................................. 46

4.2 AC Supply requirements ........................................................................................ 48

4.3 Supplying the drive with DC .................................................................................. 50

4.4 DC bus paralleling ................................................................................................. 51

4.5 24 Vdc supply ........................................................................................................ 52

4.6 Low voltage operation ........................................................................................... 53

4.7 Fan power supply .................................................................................................. 53

4.8 Ratings .................................................................................................................. 53

4.9 Output circuit and motor protection ....................................................................... 54

4.10 Braking .................................................................................................................. 57

4.11 Ground leakage ..................................................................................................... 62

4.12 EMC (Electromagnetic compatibility) ..................................................................... 63

5 Technical data ............................................................................................76

5.1 Drive technical data ............................................................................................... 76

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

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

6 UL listing information ................................................................................98

6.1 General ..................................................................................................................98

6.2 Overload, overcurrent and overspeed protection ...................................................98

6.3 Short-circuit protection for branch circuits ..............................................................99

6.4 Control circuit protection ........................................................................................99

6.5 Wiring terminal markings ......................................................................................100

6.6 Environment .........................................................................................................100

6.7 Mounting ..............................................................................................................100

6.8 Listed accessories ................................................................................................101

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Declaration of Conformity

G Williams Vice President, Technology

Date: 30th November 2015

Control Techniques Ltd The Gro Newtown Powys UK SY16 3BE

This declaration applies to the Unidrive M/HS product range comprising model numbers listed below:

Model

number

X Application

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

EN 61000-6-2:2005

EN 61000-6-4:2007

EN 61000-3-2:2006

EN 61000-3-3:2008

EN 61000-3-2: 2006 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 - RoHS 2011/65/EU, the Low Voltage Directive - LVD 2006/95/EC and the Electromagnetic Compatibility Directive - EMC 2004/108/EC.

Interpretation Nomenclature aaaa - bbc ddddde

M = Manufacturing Automation, E = Elevator, F = Flow, H = HVAC, CSD = Compressor, EVC = Emerson Variable Scroll, HS = High Speed

M100, M101, M200, M201, M300, M400, M600, M700, M701, M702, F300, H300, E200, E300, CSD1, HS30, HS70, HS71, HS72, M000, RECT

A = 6P Rectifier + Inverter (internal choke), D = Inverter, E = 6P Rectifier + Inverter (external choke), N = 18P Rectifier + Inverter, T = 12P Rectifier + Inverter

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. 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. Refer to the Product Documentation. An EMC data sheet is also available giving detailed EMC information.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Declaration of Conformity

(including 2006 Machinery Directive)

Control Techniques Ltd The Gro Newtown Powys UK SY16 3BE

This declaration applies to the Unidrive M/HS product range comprising model numbers listed below:

Model

number

X Application

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 EMC Directive 2014/ 108/EC.

EC type examination has been carried out by the following notified body: TUV Rheinland Industrie Service GmbH Am Grauen Stein D-51105 Köln Germany

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

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

EN 62061:2005

Interpretation Nomenclature aaaa - bbc ddddde

M = Manufacturing Automation, E = Elevator, F = Flow, H = HVAC, CSD = Compressor, EVC = Emerson Variable Scroll, HS = High Speed

M300, M400, M600, M700, M701, M702, F300, H300, E200, E300, CSD1, HS30, HS70, HS71, HS72, M000, RECT

A = 6P Rectifier + Inverter (internal choke), D = Inverter, E = 6P Rectifier + Inverter (external choke), N = 18P Rectifier + Inverter, T = 12P Rectifier + Inverter

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 M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Person authorised to complete the technical file:

G Williams Vice President, Technology

Date: 30th November 2015

C Hargis Chief 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. It is the responsibility of the installer to ensure that the design of the complete machine, including its safety-related control system, is carried out in accordance with the requirements of the Machinery Directive and any other relevant legislation. The use of a safety-related drive in itself does not ensure the safety of the machine.

Compliance with safety and EMC regulations depends upon installing and configuring drives correctly, including using the specified input filters. The drive must be installed only by professional installers who are familiar with requirements for safety and EMC. The assembler is responsible for ensuring that the end product or system complies with all relevant laws in the country where it is to be used. For more information regarding Safe Torque Off, refer to the Control User Guide.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

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.

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 M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

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 18.

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. 2004/108/EC: Electromagnetic Compatibility.

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 00.046 motor rated current. This affects the thermal protection of the motor.

Safety information

Product information Mechanical installation Electrical installation Technical data UL listing information

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 M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

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.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

2 Product information

IdentificationLabel

ElectricalSpecifications

Derivative

UnidriveM600 UnidriveM700 UnidriveM701 UnidriveM702 UnidriveHS70 UnidriveHS71 UnidriveHS72

ProductLine

FrameSize

VoltageRating:

CurrentRating:

HeavyDutycurrentratingx 10

PowerFormat:

Reserved

OptionalBuild

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

Documentation

Documentation:

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

2-200V(200-240

-400V(380-480

-575V(500-575

-690V(500-690

± 10%)

4 ±

± ±

10%) 5 10%) 6 10%)

Power Format

M600 - 03 4 00078 A

A - ACinACout(withinternalchoke) D-DCin ACout(Inverter) C- ACinDCout(Rectifier) E- ACin ACout(withoutinternalchoke)

T - ACinACout(12P rectifier plus inverter)

2.1 Introduction

This guide provides the information necessary to install the following drive models:

Unidrive M600 to M702 frame 3 to 4

Unidrive HS70 to HS72 frame 3 to 4

This guide focuses on the drive power section, for example: electrical installation of the supply / motor cables and mechanical installation of the drive.

For information about the drive control section, for example: parameter set up information, control and encoder connections please refer to the Control User Guide.

2.2 Model number

The model numbers for the Unidrive M/HS product range are formed as illustrated below:

Figure 2-1 Model number

Safety information

Product information

Mechanical installation Electrical installation Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

2.3 Nameplate description

Approvals

Inputvoltage

Output

voltage

HeavyDuty/ NormalDuty powerrating

Customerand datecode

Serial number

Input

frequency

No.ofphases& Typicalinputcurrentfor NormalDutyrating

HeavyDuty/ NormalDutyrating outputcurrent

Referto

UserGuide

Model

Frame

size

Voltage

HeavyDuty

currentrating

Driveformat

M600-03200050 A

Key to approvals

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 1990 (B in 1991, C in 1992 etc). Example: A date code of Y28 would correspond to week 28 of year 2015.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

2.4 Ratings

WARNING

NOTE

Fuses

The AC supply to the drive must be installed with suitable protection against overload and short-circuits. The following section shows recommended fuse ratings. Failure to observe this requirement will cause risk of fire.

Nominal cables sizes below are based on the cable installation method B2 (ref: IEC603645-52:2001) unless otherwise specified, and are provided as a guide only. Ensure cables used suit local wiring regulations.

The continuous output current ratings given below 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 76.

Table 2-1 200 V drive ratings, cable sizes and fuse ratings

Max. cont. input

current

Model

3ph Nom

03200050 10.7 16 03200066 13 20 20 1.5 1.5 14 14 8 1.5 2 6.6 1.1 1.5 03200080 17.8 25 25 4 4 12 12 11 2.2 3 8 1.5 2 03200106 20.6 25 25 4 4 12 12 12.7 3 3 10.6 2.2 3 04200137 20.1 25 04200185 26.8 32 30 8 8 8 8 25 5.5 7.5 18.5 4 5

A A A

Fuse

IEC UL

Nom

Class

CC, J

CC,

J or T*

Nominal cable size

European USA

Input Output Input Output

mm2mm

1.5 1.5 14 14 6.6 1.1 1.5 5 0.75 1

6 6 10 10 18 4 5 13.7 3 3

AWG AWG A kW hp A kW hp

Normal Duty Heavy Duty

Max.

Nom

Motor

cont.

output

current

power

230 V

power

230 V

Max. cont.

output

current

Nom

power

230 V

Motor power

230 V

Safety information

Product information

Mechanical installation Electrical installation Technical data UL listing information

Table 2-2 400 V drive ratings, cable sizes and fuse ratings

Max. cont. input

current

Model

3ph Nom

03400025 5 6 03400031 6.6 10 10 1.5 1.5 16 16 4.5 1.5 2 3.1 1.1 1.5 03400045 9.1 10 10 1.5 1.5 14 14 6.2 2.2 3 4.5 1.5 2.0 03400062 13.1 20 20 2.5 2.5 14 14 7.7 3 5 6.2 2.2 3.0 03400078 13.4 20 20 2.5 2.5 14 14 10.4 4 5 7.8 3 5.0 03400100 15.8 20 20 2.5 2.5 12 12 12.3 5.5 7.5 10 4 5.0 04400150 18.7 25 04400172 24.3 32 30 6 6 8 8 24 11 15 17.2 7.5 10.0

A A A

Fuse

IEC UL

Nom

Class

CC, J

CC,

J or T*

Nominal cable size

European USA

Input Output Input Output

mm2mm

1.5 1.5 18 18 3.4 1.1 1.5 2.5 0.75 1.0

or T*

4 4 10 10 18.5 7.5 10 15 5.5 10.0

AWG AWG A kW hp A kW hp

Normal Duty Heavy Duty

Max.

Nom

power

400 V

Motor power

460 V

cont.

output

current

* These fuses are fast acting.

Refer to Chapter 5 Technical data on page 76 for maximum fuse rating, maximum cable size and peak currents.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Max.

cont.

output

current

Nom

power

400 V

Motor power

460 V

Table 2-3 Protective ground cable ratings

NOTE

Input phase

conductor size

≤ 10 mm

> 10 mm2 and ≤ 16 mm

Either 10 mm2 or two conductors of the same cross-sectional area as the input phase conductor

The same cross-sectional area as the input phase conductor

> 16 mm2 and ≤ 35 mm216 mm

> 35 mm

Half of the cross-sectional area of the input phase conductor

Minimum ground conductor size

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. Typical values are shown in the table below:

Table 2-4 Typical overload limits

Operating mode RFC from cold RFC from 100 %

Normal Duty overload with motor rated current = drive rated current

Heavy Duty overload with motor rated current = drive rated current

Open loop

from cold

110 % for 165 s 110 % for 9 s 110 % for 165 s 110 % for 9 s

200 % for 28 s 200 % for 3 s 150 % for 60 s 150 % for 7 s

Open loop

from 100 %

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.

Output current

The continuous output current ratings given on the rating label are for maximum 40 °C (104 °F), 1000 m altitude and 3 kHz switching frequency. Derating is required for higher switching frequencies, ambient temperatures >40 °C (104 °F) and higher altitude. For derating information, refer to the Chapter 5 Technical data on page 76.

Input current

The input current is affected by the supply voltage and impedance. The input current given on the rating label is the typical input current and is stated for a balanced supply.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

2.5 Drive features

Figure 2-3 Features of the drive power section

Key

1. Braking terminal 2. Internal EMC filter 3. DC bus + 4. DC bus -

5. Motor connections 6. AC supply connections 7. Ground connections

Safety information

Product information

Mechanical installation Electrical installation Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

2.6 Items supplied with the drive

The drive is supplied with a copy of the Power Installation Guide and a copy of the Control Getting Started Guide, a safety information booklet, the Certificate of Quality and an accessory kit box

including the items shown in Table 2-5.

Table 2-5 Parts supplied with the drive

Description Size 3 Size 4

Control connectors (1 to 11 way and 21 to 31 way)

x 1* x 1*

Control connectors (1 to 13)

x 1**

Relay connector

x 1

Grounding bracket

x 1

Surface mounting brackets

x 2 x 2

Grounding clamp

x 1

DC terminal cover grommets

x 2

Supply and motor connector

x 1

* Supplied with Unidrive M600 / M700 / M701and HS70 / 71 only.

** Supplied with Unidrive M702 and HS72 only.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

3 Mechanical installation

WARNING

3.1 Safety information

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.

Safety information Product information

Mechanical installation

Electrical installation Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

3.2 Planning the installation

NOTE

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. For further information, refer to section 3.8

3.2.2 Environmental protection

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

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

3.2.4 Electrical safety

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

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.

Enclosing standard drive for high environmental protection

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.

Enclosure for standard drives

Electrical installation on page 45

on page 32.

on page 27.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

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

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Mechanical installation

Electrical installation Technical data UL listing information

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 4.12

(Electromagnetic compatibility) on page 63

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 M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

3.3 Terminal cover removal

WARNING

DC/Braking

terminalcover

Control/ AC/

Motorterminalcover

Control/ AC/

Motorterminalcover

DC/Braking

terminalcover

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 (size 3 to 4)

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Figure 3-4 Removing the size 3 terminal covers

1. Control / AC / Motor terminal cover

2. DC / Braking terminal cover The Control / AC / Motor terminal cover must be removed before removal of the DC / Braking terminal cover. When replacing the terminal covers, the screws should be tightened to a maximum torque of 1 N m (0.7 lb ft).

Figure 3-5 Removing the size 4 terminal covers

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Mechanical installation

Electrical installation Technical data UL listing information

1. Control / AC / Motor terminal cover

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

3.3.2 Removing the finger-guard and DC terminal cover break-outs

Figure 3-6 Removing the finger-guard break-outs

Place finger-guard on a flat solid surface and hit relevant break-outs with hammer as shown (1). Continue until all required break-outs are removed (2). Remove any flash / sharp edges once the break-outs are removed.

Figure 3-7 Removing the size 3 and 4 DC terminal cover break-outs

Grasp the DC terminal cover break-outs with pliers as shown (1) and pull down in the direction shown to remove. Continue until all required break-outs are removed (2). Remove any flash / sharp edges once the break-outs are removed. Use the DC terminal cover grommets supplied in the accessory box (Table 2-5

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Parts supplied with the drive

on page 16) to maintain the seal at the top of the drive.

Issue Number: 3

3.4 Dimensions and mounting methods

WARNING

Drive sizes 3 and 4 can be surface, through-panel or tile mounted using the appropriate brackets.

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.

3.4.1 Drive dimensions

Figure 3-8 Drive dimensions (size 3 illustrated)

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Mechanical installation

Electrical installation Technical data UL listing information

Size

H1 H2 W D

mm in mm in mm in mm in

3 382 15.04 4 391 15.39 124 4.88

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

365 14.37

83 3.27

200 7.87

3.4.2 Surface mounting

6.0mm

(0.24in)

73.0mm(2.87in)

5.5mm

(0.22in)

370mm

(14.57in)

375mm

(14.76in)

8mm

(0.32in)

6.5mm

(0.26in) x4holes

9mm

(0.35in)

53mm

(2.09in)

53mm

(2.09in)

106mm (4.17in)

40mm

(1.58in)

Figure 3-9 Surface mounting dimensions

Surface mounting size 3

Each mounting bracket contains 5 mounting slots / holes, the outer holes (5.2 mm) x 2 should be used for mounting the drive to the backplate as this allows the heatsink fan to be replaced without removing the drive from the backplate. The inner slots / holes (6.2 mm) x 3 are used for Unidrive SP size 1 retrofit applications.

Surface mounting size 4

The outer holes in the mounting bracket (6.5 mm) x 2 are to be used for surface mounting.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

3.4.3 Through-panel mounting

WARNING

17mm

(0.67in)

68.5mm (2.70in)

117mm(4.61in)

168mm(6.61in)

58.5mm (2.30in)

106mm(4.17in)

97mm(3.82in)

36.5mm (1.44in)

Æ5.20mm(0.21in) x8holes

73mm(2.87in)

36.5mm (1.44in)

15mm (0.59in)

129mm(5.08in)

26mm(1.02in)

168mm(6.61in)

360mm(14.17in)

389mm(15.32in)

26mm(1.02in)

Radius1.0mm(0.04in)

38mm

(1.50in)

38mm

(1.50in)

76mm(2.99in)

48.5mm (1.91in)

Radius1.0mm (0.04in)

The drive can be through-panel mounted using the appropriate brackets, see section 3.8

standard drive for high environmental protection

on page 32 for further details.

The through-panel mounting kit is not supplied with the drive and can be purchased separately, below are the relevant part numbers:

Size CT part number

3 3470-0053

4 3470-0056

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.

Figure 3-10 Through-panel mounting dimensions

Enclosing

Safety information Product information

Mechanical installation

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Electrical installation Technical data UL listing information

3.4.4 Mounting brackets

NOTE

Table 3-1 Mounting brackets

Frame

size

Surface Qty Through-panel* Qty

x 2

Outer hole size: 5.2 mm (0.20 in)

Centre hole / slot size: 6.2 mm (0.24 in)

Hole size: 6.5 mm (0.26 in)

x 2

Hole size: 5.2 mm (0.21 in)

* A gasket is supplied in the through-panel mounting kit, see section 3.8

high environmental protection

on page 32 for further details.

A retrofit kit is available for Unidrive M/HS size 4 that allows mounting of the drive in applications previously using Unidrive SP size 2, the part number of this kit is 3470-0062. A similar kit is not necessary for Unidrive M/HS size 3 because it has the same mounting hole positions as Unidrive SP size 1.

x 1

x 2

x 1

Enclosing standard drive for

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

3.4.5 Tile mounting

Enclosure

Drive sizes 3 to 4 can be tile mounted where limited mounting space is available. The drive is mounted sideways with the side panel against the mounting surface as shown in Figure 3-11. The tile mounting kit is not supplied with the drive, it can be purchased separately using the following part numbers:

Size CT part number

3 3470-0049

4 3470-0060

Figure 3-11 Tile mounting

Safety information Product information

Mechanical installation

3.5 Enclosure for standard drives

Figure 3-12 Recommended spacing between the drives

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Electrical installation Technical data UL listing information

Table 3-2

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

³100mm

(4in)

Optionalbrakingresistorandoverload

Locateas

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).

* 50 °C derating applies, refer to Table 5-5

(122 °F)

Spacing required between the drives (without high IP insert)

Drive Size

40°C 50°C*

Spacing (A)

0 mm (0.00 in)

Maximum permissible continuous output current @ 50 °C

on page 79.

When through-panel mounted, ideally drives should be spaced 30 mm (1.18 in) to maximize panel stiffness.

3.5.1 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 3-13 Enclosure layout

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

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

NOTE

k T

in tTex t

–( )

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

Drive Size Spacing (B)

3 0 mm (0.00 in)

4 30 mm (1.18 in)

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

3.5.2 Enclosure sizing

1. Add the dissipation figures from section 5.1.3 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 96 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 from 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

Power dissipation

Ae for the enclosure from:

on page 80 for each drive that is

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Mechanical installation

Electrical installation Technical data UL listing information

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

outside

all

heat sources in the enclosure

the enclosure

inside

the enclosure

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

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

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

NOTE

392.4

5.5 40 30–( )

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

Ae2H D–

H D+

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

7.135 2 2× 0.6×( )– 2 0.6+

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

Chapter 5

Technical data

on page 76.

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 by the supplier of the material). If in any doubt, allow for a greater margin in the temperature rise.

Figure 3-14 Enclosure having front, sides and top panels free to dissipate heat

Insert the following values:

40 °C

int

30 °C

ext

5.5

392.4 W

The minimum required heat conducting area is then:

= 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 M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

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:

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Mechanical installation

Electrical installation Technical data UL listing information

126.2 m3/hr (74.5 ft3 /min)

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

(1 m3/ hr = 0.59 ft3/min)

3.6 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

= T

rate

+ 5 °C

int

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

= T

rate

int

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

= the greater of T

rate

+5 °C, or T

ext

int

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

= the greater of T

rate

ext

or T

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 76.

3.7 Heatsink fan operation

The drive is ventilated by an internal heatsink mounted fan. The fan housing forms a baffle plate, channelling the air through the heatsink chamber. Thus, regardless of mounting method (surface mounting or through-panel mounting), the installing of additional baffle plates is not required.

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

The heatsink fan on all sizes is a variable 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 derating. Refer to section 3.13.1

Fan removal procedure

06.045

. This could incur an output current

on page 44 for information on fan removal.

3.8 Enclosing standard drive for high environmental protection

An explanation of environmental protection rating is provided in section 5.1.10 page 85.

The standard drive is rated to IP20 pollution degree 2 (dry, non-conductive contamination only) (NEMA 1). However, it is possible to configure the drive to achieve IP65 rating (sizes 3 to 4) (NEMA

12) at the rear of the heatsink for through-panel mounting (some current derating is required). Refer

to Chapter 5

Technical data

on page 76.

This allows the front of the drive, along with various switchgear, to be housed in a high IP enclosure with the heatsink protruding through the panel to the external environment. Thus, the majority of the heat generated by the drive is dissipated outside the enclosure maintaining a reduced temperature inside the enclosure. This also relies on a good seal being made between the heatsink and the rear of the enclosure using the gaskets provided.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

IP / UL Rating

Issue Number: 3

Figure 3-15 Example of IP65 (sizes 3 to 4) (NEMA 12) through-panel layout

IP20

(NEMA1)

IP65(sizes3to4)(NEMA 12)enclosure

Drivewith highIP insert installed

Gasket

seal

NOTE

Drive

Gasket

Enclosure rearwall

Safety information Product information

The main gasket should be installed as shown in Figure 3-16.

On drive sizes 3 and 4, in order to achieve the high IP rating at the rear of the heatsink it is necessary to seal a heatsink vent by installing the high IP insert as shown in Figure 3-18 and Figure 3-19 on

page 36.

The heatsink fans have conformal coated PCBs and have sealant at cable entry points. This means that the electronics of the fan are rated to IP54. Dripping, splashing or sprayed water can impede the operation of the fan, therefore if the environment is such that the fan may be subjected to more than occasional dripping or sprayed water while operational, then suitable drip protection covers should be employed.

Figure 3-16 Installing the gasket

To seal the space between the drive and the backplate, use two sealing brackets as shown in Figure 3-17.

Mechanical installation

Electrical installation Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Figure 3-17 Through panel mounting

Throughpanel

securingbracket

Enclosure rearwall

Throughpanel securingbracket

3.9 Installation of high IP insert for size 3 and 4

The standard drive is rated to IP20 pollution degree 2 (dry, non-conductive contamination only) (NEMA 1). However, it is possible to configure the drive to achieve IP65 rating sizes 3 to 4 (NEMA

12) at the rear of the heatsink for through-panel mounting (some current derating is required).

On drive sizes 3 and 4, in order to achieve the high IP rating at the rear of the heatsink it is necessary to seal a heatsink vent by installing the high IP insert as shown in Figure 3-18.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Figure 3-18 Installation of high IP insert for size 3

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Mechanical installation

Electrical installation Technical data UL listing information

1. To install the high IP insert, firstly place a flat head screwdriver into the slots highlighted (1).

2. Pull the hinged baffle down to expose the ventilation hole, install the high IP insert into the ventilation hole in the heatsink (2).

3. Ensure the high IP insert is securely installed by firmly pressing it into place (3).

4. Close the hinged baffle as shown (1).

5. To remove the high IP insert, reverse the above instructions.

The guidelines in Table 3-4 should be followed.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Figure 3-19 Installation of high IP insert for size 4

1. To install the high IP insert, firstly place a flat head screwdriver into the slots highlighted (1).

2. Pull the hinged baffle up to expose the ventilation hole, install the high IP insert into the ventilation hole in the heatsink (2).

3. Ensure the high IP insert is securely installed by firmly pressing it into place (3).

4. Close the hinged baffle as shown (1).

5. To remove the high IP insert, reverse the above instructions.

The guidelines in Table 3-4 should be followed.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Table 3-4 Environmental considerations

NOTE

WARNING

Environment High IP insert Comments

Clean Not installed

Dry, dusty (non-conductive) Installed

IP65 compliance Installed

A current derating must be applied to the drive if the high IP insert is installed. Derating information is provided in Chapter 5

Technical data

Failure to do so may result in nuisance tripping.

Safety information Product information

Regular cleaning recommendedDry, dusty (conductive) Installed

on page 76

When designing an IP65 (NEMA 12) enclosure (Figure 3-15

4) (NEMA 12) through-panel layout

on page 33), consideration should be made to the

Example of IP65 (sizes 3 to

dissipation from the front of the drive.

Table 3-5 Power losses from the front of the drive when through-panel mounted

Frame size Power loss

≤

50 W

75 W

3.10 Size 3 and 4 internal braking resistor

Size 3 and 4 have been designed with an optional space-saving heatsink mounted resistor. The resistor can be installed within the heatsink fins of the drive. When the heatsink resistor is used, an external thermal protection device is not required as the resistor is designed such that it will fail safely under any fault conditions. The in-built software overload protection is set-up at default to protect the resistor. The resistor is rated to IP54 (NEMA 12).

Table 3-6 Size 3 and 4 internal braking resistor part numbers

Frame size Part number

3 1220-2752

4 1299-0003

The internal / heatsink mounted braking resistors must only be used with the following drives. Brake resistor 1220-2752 must only be used with size 3 drives. Brake resistor 1299-0003 must only be used with size 4 drives.

Mechanical installation

Electrical installation Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

3.10.1 Internal braking resistor installation instructions

Brake resistor bung

Figure 3-20 Brake resistor installation on size 3

• Remove the terminal covers.

• Remove the internal EMC filter as shown in Figure 4-11

filter

• Remove the brake resistor bung (1) from the hole in the chassis, the closed end of the bung will

• Feed brake resistor bung onto outer insulation of brake resistor cable. The wider end of the bung

• Install the braking resistor to the heatsink using the captive screws. The screws should be tighten

• Route the cables through the provided hole at the rear of the heatsink as shown in Figure 3-20

• Crimp the cable ends and make appropriate connections. The brake terminals must be tightened

• Replace the terminal covers on the drive, tighten to a maximum torque of 1 N m (0.7 lb ft).

on page 66.

need to be pierced so that the cable has access to be routed through.

should be inserted first. The Narrow end should align with end of insulation.

to a maximum torque of 2 N m (1.5 lb ft).

and take the cable out from the front side of the drive. Ensure the cables are routed between the fins of the heatsink, and the cables are not trapped between the heatsink fins and the resistor.

to a maximum torque of 2 N m (1.5 Ib ft).

Removal of the size 3 internal EMC

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Figure 3-21 Brake resistor installation on size 4

Brake resistor bung

• Remove the terminal covers.

• Remove the brake resistor bung from the hole (1) in the chassis, the closed end of the bung will need to be pierced so that the cable has access to be routed through.

• Feed brake resistor bung onto outer insulation of brake resistor cable. The wider end of the bung should be inserted first. The Narrow end should align with end of insulation.

• Install the braking resistor to the heatsink using the captive screws. The screws should be tighten to a maximum torque of 2 N m (1.5 lb ft).

• Route the cables through the provided hole at the rear of the heatsink as shown in Figure 3-21 and take the cable out from the front side of the drive. Ensure the cables are routed between the fins of the heatsink, and the cables are not trapped between the heatsink fins and the resistor.

• Crimp the cable ends and make appropriate connections. The brake terminals must be tightened to a maximum torque of 2 N m (1.5 Ib ft).

• Replace the terminal covers on the drive, tighten to a maximum torque of 1 N m (0.7 lb ft).

Safety information Product information

Mechanical installation

Electrical installation Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

3.10.2 External brake resistor

118mm(4.65in)

15.5mm (0.61in)

Æ 4.5mm(0.18in) x2holes

1.5mm (0.06in)

30.5mm (1.20in)

80mm(3.15in)

130mm(5.12in)

Æ 4.5x6mm(0.18in) x2holes

R=1.5mm (0.06)

External brake resistors are available from Emerson Industrial Automation for drive sizes 3 to 4. They can be mounted in the enclosure as per mounting recommendation in Figure 3-13

layout

on page 28 using mounting bracket part number 6541-0187 (shown in Figure 3-23). Figure 322 below shows the brake resistor mounted on the mounting bracket. Two M4 screws and nuts (2) can be used to fix the brake resistor to the mounting bracket. One M4 nut with washer (1) is provided to use for the ground connection. The brake resistor is equipped with a thermal switch, the thermal switch should be integrated in the control circuit by the user.

Figure 3-22 Brake resistor with the mounting bracket

1. Ground connection (1 x M4 nut and washer).

2. Attaching the brake resistor to the mounting bracket (using 2 x M4 screws and nuts).

Figure 3-23 Mounting bracket dimensions

Enclosure

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Figure 3-24 Brake resistor dimensions

60mm(2.36in)

68mm(2.68in)

118mm(4.65in)

130mm(5.12in)

Æ 4.5mm(0.18in)

x4holes

15mm (0.59in)

3.11 External EMC filter

The external EMC filter for size 3 and 4 drives can be footprint mounted or bookcase mounted as shown in Figure 3-25 and Figure 3-26.

Figure 3-25 Footprint mounting the EMC

filter

Figure 3-26 Bookcase mounting the EMC

filter

Safety information Product information

Mechanical installation

Electrical installation Technical data UL listing information

3.11.1 Optional external EMC filters

Table 3-7 EMC filter cross reference

Model CT part number

200 V

03200050 to 03200106 4200-3230 04200137 to 04200185 4200-0272

400 V

03400025 to 03400100 4200-3480 04400150 to 04400172 4200-0252

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

3.11.2 EMC filter ratings

V1 W1

Netz / Line

Last / Load

V2 W2

Table 3-8 Optional external EMC filter details

CT part

number

Maximum

continuous

current

(104 °F)

@ 50 °C (122 °F)

Voltage

rating

IEC UL

rating

Power dissipation

at rated current

@ 40 °C (104 °F)

@ 50 °C (122 °F)

A A V V W W mA mA MΩ

4200-3230 20 18.5 250 300

4200-3480 16 15 528 600 13 11 10.7 151

4200-0272 27 24.8 250 300 33 28 6.8 137

20 17 2.4 60

4200-0252 25 23 528 600 28 24 11.1 182

Figure 3-27 External EMC filter

Ground leakage

Balanced

supply

phase-to-

phase and

phase-to-

ground

Worst

case@ 40 °C

Discharge

resistors

1.68

V: Ground stud

Z: Bookcase mounting slot diameter.

Table 3-9 Size 3 external EMC filter dimensions

CT part

number

4200-3230

4200-3480

Table 3-10 Size 4 external EMC filter dimensions

CT part number

4200-0272

4200-0252

Unidrive M/HS Frame 3 and 4 Power Installation Guide

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

384 mm

(15.12 in)

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

395 mm

(15.55 in)

X: Threaded holes for footprint mounting of the drive

CS: Cable size

414 mm

(16.30 in)

425 mm

(16.73 in)

56 mm

(2.21 in)

100 mm (3.94 in)

41 mm

(1.61 in)

60 mm

(2.36 in)

33 mm

(1.30 in)

426 mm

(16.77 in)

437 mm (17.2 in)

Y: Footprint mounting hole diameter

5.5 mm

(0.22 in)

83 mm

(3.27 in)

123 mm (4.84 in)

6.5 mm

(0.26 in)

Issue Number: 3

2.5 mm

(14 AWG)

6 mm

(10 AWG)

3.11.3 EMC filter torque settings

Table 3-11 Optional external EMC Filter terminal data

CT part number

4200-3230

4200-3480

4200-0252

4200-0272

connections

Max cable

size

4 mm

(12 AWG)

6 mm

(10 AWG)

Power

Max torque

0.8 N m

(0.59 lb ft)

1.8 N m

(0.88 lb ft)

Ground stud

Ground

connections

size

Table 3-12 Fastener details for drive footprint mounting on external EMC filter

Type Size 3 Size 4

Screw specification Property class 8.8. standard metric, coarse thread

Thread size M5 M6

Length (mm) 12 12

Washer Helical spring, split spring or conical spring

Torque (N m) 6.0 10.0

3.12 Terminal size and torque settings

Table 3-13 Drive control and relay terminal data

Model Connection type Torque setting

All Plug-in terminal block 0.5 N m (0.4 lb ft)

Safety information Product information

Max torque

2.5 N m

(1.8 lb ft)

5.0 N m

(3.7 lb ft)

Mechanical installation

Electrical installation Technical data UL listing information

Table 3-14 Drive power terminal data

Frame

size

3 and 4

AC and motor terminals DC and braking Ground terminal

Recommended Maximum Recommended Maximum Recommended Maximum

Plug-in terminal block T20 Torx (M4)

0.7 N m

(0.5 lb ft)

0.8 N m

(0.6 lb ft)

2.0 N m

(1.4 Ib ft)

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

2.5 N m

(1.8 Ib ft)

T20 Torx (M4) / M4 Nut

(7 mm AF)

2.0 N m

(1.4 Ib ft)

2.5 N m

(1.8 Ib ft)

3.13 Routine maintenance

NOTE

The drive should be installed in a cool, clean, well ventilated location. Contact of moisture and dust with the drive should be prevented. Regular checks of the following should be carried out to ensure

drive / installation reliability are maximized:

Environment

Ambient temperature Ensure the enclosure temperature remains at or below maximum specified

Dust

Moisture Ensure the drive enclosure shows no signs of condensation

Enclosure

Enclosure door filters Ensure filters are not blocked and that air is free to flow

Electrical

Screw connections Ensure all screw terminals remain tight

Crimp terminals

Cables Check all cables for signs of damage

3.13.1 Fan removal procedure

Figure 3-28 Removal of the size 3 and 4 heatsink fan (size 3 shown)

Ensure the drive remains dust free – check that the heatsink and drive fan are not gathering dust. The lifetime of the fan is reduced in dusty environments.

Ensure all crimp terminals remains tight – check for any discoloration which could indicate overheating

Ensure the fan cable is disconnected from the drive prior to attempting fan removal.

1. Press the two tabs inwards to release the fan from the drive frame.

2. Using the central fan tab, withdraw the fan assembly from the drive housing.

Replace the fan by reversing the above instructions.

If the drive is surface mounted using the outer holes on the mounting bracket, then the heatsink fan can be replaced without removing the drive from the backplate.

Table 3-15 Heatsink fan part numbers

Model Fan part number

Size 3 3251-0029

Size 4 3251-0245

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

4 Electrical installation

WARNING

Electric shock risk

The voltages present in the following locations can cause severe electric shock and may be lethal: AC supply cables and connections DC and brake 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.

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.

STOP function

The STOP function does not remove dangerous voltages from the drive, the motor or any external option units.

Safe Torque Off function

The Safe Torque Off function does not remove dangerous voltages from the drive, the motor or any external option units.

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 AC and / or DC power supply must be isolated at least ten minutes before work may continue. 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.

Safety information Product information Mechanical installation

Electrical installation

Technical data UL listing information

Equipment supplied by plug and socket

Special attention must be given if the drive is installed in equipment which is connected to the AC supply by a plug and socket. The AC supply terminals of the drive are connected to the internal capacitors through rectifier diodes which are not intended to give safety isolation. If the plug terminals can be touched when the plug is disconnected from the socket, a means of automatically isolating the plug from the drive must be used (e.g. a latching relay).

Permanent magnet motors

Permanent magnet motors generate electrical power if they are rotated, even when the supply to the drive is disconnected. If that happens then the drive will become energized through its motor terminals. If the motor load is capable of rotating the motor when the supply is disconnected, then the motor must be isolated from the drive before gaining access to any live parts.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

4.1 Power and ground connections

L2L1L3

U V W

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Motor

Optional ground

connection

Supply

AC Connections

DC Connections

+DC

-DC

Internal

EMC filter

Ground connection

studs

Additional ground

connection

Figure 4-1 Size 3 power and ground connections

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Figure 4-2 Size 4 power and ground connections

L1 L2

L2L1 L3 U V W

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Motor

Optional ground

connection

Supply

AC Connections

+DC

-DC

DC / Brake connections

Ground connection

studs

Additional ground

connection

Safety information Product information Mechanical installation

Electrical installation

Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

4.1.1 Ground connections

WARNING

NOTE

WARNING

Electrochemical corrosion of grounding terminals

Ensure that grounding terminals are protected against corrosion i.e. as could be caused by condensation.

The drive must be connected to the system ground of the AC supply. The ground wiring must conform to local regulations and codes of practice.

For further information on ground cable sizes, refer to Table 2-3

ratings

on page 14.

Protective ground cable

On size 3 and 4, the supply and motor ground connections are made using the M4 studs located either side of the drive near the plug-in power connectors. See Figure 4-1 and Figure 4-2 for details.

The ground loop impedance must conform to the requirements of local safety regulations. The drive must be grounded by a connection capable of carrying the prospective fault current until the protective device (fuse, etc.) disconnects the AC supply. The ground connections must be inspected and tested at appropriate intervals.

4.2 AC Supply requirements

AC supply voltage:

200 V drive: 200 V to 240 V ±10 % 400 V drive: 380 V to 480 V ±10 %

Number of phases: 3

Maximum supply imbalance: 2 % negative phase sequence (equivalent to 3 % voltage imbalance between phases).

Frequency range: 45 to 66 Hz

For UL compliance only, the maximum supply symmetrical fault current must be limited to 100 kA

Table 4-1 Supply fault current used to calculate maximum input currents

Model Symmetrical fault level (kA)

All 100

4.2.1 Supply types

All drives are suitable for use on any supply type i.e TN-S, TN-C-S, TT and IT. Drives are suitable for use on supplies of installation category III and lower, according to IEC60664-1. This means they may be connected permanently to the supply at its origin in a building, but for outdoor installation additional over-voltage suppression (transient voltage surge suppression) must be provided to reduce category IV to category III.

Operation with IT (ungrounded) supplies:

Special attention is required when using internal or external EMC filters with ungrounded supplies, because in the event of a ground (earth) fault in the motor circuit the drive may not trip and the filter could be over-stressed. In this case, either the filter must not be used (removed) or additional independent motor ground fault protection must be provided. For instructions on removal, refer to Figure 4-11 and Figure 4-12 on page 66. For details of ground fault protection contact the supplier of the drive.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

A ground fault in the supply has no effect in any case. If the motor must continue to run with a ground

WARNING

fault in its own circuit then an input isolating transformer must be provided and if an EMC filter is required it must be located in the primary circuit. Unusual hazards can occur on ungrounded supplies with more than one source, for example on ships. Contact the supplier of the drive for more

information.

If an SI-Applications Plus module is installed in the drive, then the drive must not be used on a corner-grounded or centre-grounded delta supply if the supply voltage is above 300 V. If this is required, please contact the supplier of the drive for more information.

4.2.2 Supplies requiring line reactors

Input line reactors reduce the risk of damage to the drive resulting from poor phase balance or severe disturbances on the supply network.

Where line reactors are to be used, reactance values of approximately 2 % are recommended. Higher values may be used if necessary, but may result in a loss of drive output (reduced torque at high speed) because of the voltage drop.

For all drive ratings, 2 % line reactors permit drives to be used with a supply unbalance of up to 3.5 % negative phase sequence (equivalent to 5% voltage imbalance between phases).

Severe disturbances may be caused by the following factors, for example:

• Power factor correction equipment connected close to the drive.

• Large DC drives having no or inadequate line reactors connected to the supply.

• Across the line (DOL) started motor(s) connected to the supply such that when any of these motors are started, the voltage dip exceeds 20 %.

Such disturbances may cause excessive peak currents to flow in the input power circuit of the drive. This may cause nuisance tripping, or in extreme cases, failure of the drive.

Drives of low power rating may also be susceptible to disturbance when connected to supplies with a high rated capacity.

Line reactors are particularly recommended for use with the following drive models when one of the above factors exists, or when the supply capacity exceeds 175 kVA:

03200050, 03200066, 03200080, 03200106,

03400025, 03400031, 03400045, 03400062

Model sizes 03400078 to 04400172 have an internal DC choke so they do not require AC line reactors except for cases of excessive phase unbalance or extreme supply conditions.

When required, each drive must have its own reactor(s). Three individual reactors or a single threephase reactor should be used.

Reactor current ratings

The current rating of the line reactors should be as follows:

Continuous current rating:

Not less than the continuous input current rating of the drive

Repetitive peak current rating:

Not less than twice the continuous input current rating of the drive

Safety information Product information Mechanical installation

Electrical installation

Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Table 4-2 2 % line reactors

100

----------

-------

2π fI

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

×=

Drive

model

number

03200050 200 INL2001 4401-0143 13.5 0.79 1.8 156 70 125

03200066 200 INL2001 4401-0143 13.5 0.79 1.8 156 70 125

03200080 200 INL2002 4401-0144 20.6 0.48 2.4 156 80 125

03200106 200 INL2002 4401-0144 20.6 0.48 2.4 156 80 125

04200137 200 INL2002 4401-0144 20.6 0.48 2.4 156 80 125

04200185 200 INL2003 4401-0145 26.8 0.32 2.5 156 80 125

03400025 400 INL4001 4401-0148 6.6 2.94 1.3 80 75 130

03400031 400 INL4001 4401-0148 6.6 2.94 1.3 80 75 130

03400045 400 INL4002 4401-0149 9.1 1.62 1.8 156 70 125

03400062 400 INL4011 4401-0234 13 1.12 2.5 156 80 125

03400078 400 INL4011 4401-0234 13 1.12 2.5 156 80 125

03400100 400 INL4003 4401-0151 15.8 1.05 2.6 156 80 125

04400150 400 INL4004 4401-0152 18.7 0.79 3.5 156 60 145

04400172 400 INL4005 4401-0153 24.3 0.61 4.9 156 75 145

Voltage

Line reactor

rating

designation

V A mH kg mm mm mm

CT Part number

Line reactor current

rating

Inductance Weight Length Width Height

4.2.3 Input inductor calculation

To calculate the inductance required (at Y %), use the following equation:

Where:

= drive rated input current (A)

= inductance (H)

= supply frequency (Hz)

= voltage between lines

4.3 Supplying the drive with DC

All drive sizes have the option to be powered from an external DC power supply. Refer to section

4.1

Power and ground connections

The DC supply connections for size 3 and 4 are located under the DC / Braking terminal cover. Figure 4-3 shows DC supply connections and cable routing.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

on page 46 to identify the location of DC supply connections.

Issue Number: 3

Figure 4-3 DC supply connections (size 3 shown)

NOTE

The Internal EMC filter and plastics have been removed from the above image to demonstrate the routing of the DC cables.

4.4 DC bus paralleling

DC bus paralleling using standard cable / busbars is supported by all frame sizes.

On frame sizes 3 and 4, terminal and enclosure design enables the DC bus of a number of drives to be connected together using pre-made busbars. The diagram below shows how the busbar links connect the DC bus of several drives together.

The connecting of the DC bus between several drives is typically used to:

1. Return energy from a drive which is being overhauled by the load to a second motoring drive.

2. Allow the use of one braking resistor to dissipate regenerative energy from several drives.

Figure 4-4 DC bus paralleling (size 3 shown)

Safety information Product information Mechanical installation

Electrical installation

There are limitations to the combinations of drives which can be used in this configuration.

For application data, contact the supplier of the drive.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data UL listing information

The DC bus paralleling kit is not supplied with the drive but available to order from the

NOTE

supplier of the drive.

Table 4-3 DC bus paralleling kit part numbers

Size CT part number

3 3470-0048

4 3470-0061

4.5 24 Vdc supply

The 24 Vdc supply connected to control terminals 1 & 2* provides the following functions:

• It can be used to supplement the drive's own internal 24 V supply when multiple option modules are being used and the current drawn by these module is greater than the drive can supply.

• It can be used as a back-up power supply to keep the control circuits of the drive powered up when the line power supply is removed. This allows any fieldbus modules, application modules, encoders or serial communications to continue to operate.

• It can be used to commission the drive when the line power supply is not available, as the display operates correctly. However, the drive will be in the Under voltage trip state unless either line power supply or low voltage DC operation is enabled, therefore diagnostics may not be possible. (Power down save parameters are not saved when using the 24 V back-up power supply input).

• If the DC bus voltage is too low to run the main SMPS in the drive, then the 24 V supply can be used to supply all the low voltage power requirements of the drive.

Select

(06.067) must also be enabled for this to happen.

Table 4-4 24 Vdc Supply connections

Function Sizes 3 and 4

Supplement the drive’s internal supply

and back-up supply for the control circuit

Low Under Voltage Threshold

Terminal

1, 2*

* Terminal 9 on

The working voltage range of the control 24 V power supply is as follows:

1 0 V

2 +24 Vdc

Nominal operating voltage 24.0 Vdc

Minimum continuous operating voltage 19.2 V

Maximum continuous operating voltage 28.0 V

Minimum start up voltage 21.6 V

Maximum power supply requirement at 24 V 40 W

Recommended fuse 3 A, 50 Vdc

Minimum and maximum voltage values include ripple and noise. Ripple and noise values must not exceed 5 %.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Unidrive M702

and

Unidrive HS72.

Issue Number: 3

4.6 Low voltage operation

NOTE

WARNING

With the addition of a 24 Vdc power supply to supply the control circuits, the drive is able to operate from a low voltage DC supply with a range from 24 Vdc to the maximum DC volts. It is possible for the drive to go from operating on a normal line power supply voltage to operating on a much lower supply voltage without interruption.

Going from low voltage operation to normal mains operation requires the inrush current to be controlled. This may be provided externally. If not, the drive supply can be interrupted to utilise the normal soft starting method in the drive.

To fully exploit the new low voltage mode of operation, the under voltage trip level is now user programmable. For application data, contact the supplier of the drive.

The working voltage range of the low voltage DC power supply is as follows:

Size 3 to 4

Minimum continuous operating voltage: 26 V

Minimum start up voltage: 32 V

Maximum over voltage trip threshold: 230 V drives: 415 V

400 V drives: 830 V

4.7 Fan power supply

The fans installed on all drive sizes are supplied internally by the drive.

4.8 Ratings

See section 2.4

Maximum continuous input current

The values of maximum continuous input current are given to aid the selection of cables and fuses. These values are stated for the worst case condition with the unusual combination of stiff supply with high imbalance. The value stated for the maximum continuous input current would only be seen in one of the input phases. The current in the other two phases would be significantly lower. The values of maximum input current are stated for a supply with a 2 % negative phase-sequence imbalance and rated at the maximum supply fault current given in section 4.2

requirements

The nominal cable sizes given in section 2.4 wiring regulations for the correct size of cables. In some cases a larger cable is required to avoid excessive voltage drop.

Ratings

on page 13.

AC supply

on page 65.

Ratings

on page 13 are only a guide. Refer to local

The nominal output cable sizes in section 2.4 maximum current matches that of the drive. Where a motor of reduced rating is used the cable rating may be chosen to match that of the motor. To ensure that the motor and cable are protected against over-load, the drive must be programmed with the correct motor rated current.

Ratings

on page 13 assume that the motor

Safety information Product information Mechanical installation

Electrical installation

Technical data UL listing information

Fuses

The AC supply to the drive must be installed with suitable protection against overload and short-circuits. Nominal fuse ratings are shown in section 2.4 to observe this requirement will cause risk of fire.

A fuse or other protection must be included in all live connections to the AC supply.

Fuse types

The fuse voltage rating must be suitable for the drive supply voltage.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Ratings

on page 13. Failure

4.8.1 Main AC supply contactor

WARNING

Normal capacitance

Shield or armour separated from the cores

High capacitance

Shield or armour close to the cores

The recommended AC supply contactor type for size 3 to 4 is AC1.

4.9 Output circuit and motor protection

The output circuit has fast-acting electronic short-circuit protection which limits the fault current to typically no more than five times the rated output current, and interrupts the current in approximately 20 µs. No additional short-circuit protection devices are required.

The drive provides overload protection for the motor and its cable. For this to be effective,

Current (00.046

) must be set to suit the motor.

Rated

Rated Current (00.046

overload.

There is also provision for the use of a motor thermistor to prevent over-heating of the motor, e.g. due to loss of cooling.

) must be set correctly to avoid a risk of fire in the event of motor

4.9.1 Motor cable types

Since capacitance in the motor cable causes loading on the output of the drive, ensure the cable length does not exceed the values given in Table 5-21 and Table 5-22.

Use 105 °C (221 °F) (UL 60/75 °C temp rise) PVC-insulated cable with copper conductors having a suitable voltage rating, for the following power connections:

• AC supply to external EMC filter (when used)

• AC supply (or external EMC filter) to drive

• Drive to motor

• Drive to braking resistor

4.9.2 High-capacitance / reduced diameter cables

The maximum cable length is reduced from that shown in Table 5-21 and Table 5-22 if high capacitance or reduced diameter motor cables are used.

Most cables have an insulating jacket between the cores and the armor or shield; these cables have a low capacitance and are recommended. Cables that do not have an insulating jacket tend to have high capacitance; if a cable of this type is used, the maximum cable length is half that quoted in the tables, (Figure 4-5 shows how to identify the two types).

Figure 4-5 Cable construction influencing the capacitance

The maximum motor cable lengths specified in section 5.1.22

types

is shielded and contains four cores. Typical capacitance for this type of cable is 130 pF/m (i.e.

from one core to all others and the shield connected together).

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Maximum motor cable lengths and

Issue Number: 3

4.9.3 Motor winding voltage

The PWM output voltage can adversely affect the inter-turn insulation in the motor. This is because of the high rate of change of voltage, in conjunction with the impedance of the motor cable and the distributed nature of the motor winding.

For normal operation with AC supplies up to 500 Vac and a standard motor with a good quality insulation system, there is no need for any special precautions. In case of doubt the motor supplier should be consulted. Special precautions are recommended under the following conditions, but only if the motor cable length exceeds 10 m:

• AC supply voltage exceeds 500 V

• DC supply voltage exceeds 670 V, i.e regenerative / AFE supply.

• Operation of 400 V drive with continuous or very frequent sustained braking

• Multiple motors connected to a single drive

For multiple motors, the precautions given in section 4.9.4

For the other cases listed, it is recommended that an inverter-rated motor be used taking into account the voltage rating of the inverter. This has a reinforced insulation system intended by the manufacturer for repetitive fast-rising pulsed voltage operation.

Users of 575 V NEMA rated motors should note that the specification for inverter-rated motors given in NEMA MG1 section 31 is sufficient for motoring operation but not where the motor spends significant periods braking. In that case an insulation peak voltage rating of 2.2 kV is recommended.

If it is not practical to use an inverter-rated motor, an output choke (inductor) should be used. The recommended type is a simple iron-cored component with a reactance of about 2 %. The exact value is not critical. This operates in conjunction with the capacitance of the motor cable to increase the rise-time of the motor terminal voltage and prevent excessive electrical stress.

Multiple motors

should be followed.

4.9.4 Multiple motors

Open-loop only

If the drive is to control more than one motor, one of the fixed V/F modes should be selected (Pr

05.014

The maximum motor cable lengths specified in section 5.1.22

types

It is recommended that each motor is connected through a protection relay since the drive cannot protect each motor individually. For connection, a sinusoidal filter or an output inductor must be

connected as shown in Figure 4-7, even when the cable lengths are less than the maximum permissible. For high DC voltages or when supplied by a regen system, a sinusoidal filter is recommended. For details of filter or inductor sizes refer to the supplier of the drive.

= Fixed or Squared). Make the motor connections as shown in Figure 4-6 and Figure 4-7.

Maximum motor cable lengths and

on page 90 apply to the sum of the total cable lengths from the drive to each motor.

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Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Figure 4-6 Preferred chain connection for multiple motors

Motor protection relay

Chain connection (preferred)

connection

Inductor

Motor protection relay

Figure 4-7 Alternative connection for multiple motors

4.9.5 / ∆ motor operation

The voltage rating for and ∆ connections of the motor should always be checked before attempting to run the motor.

The default setting of the motor rated voltage parameter is the same as the drive rated voltage, i.e.

400 V drive 400 V rated voltage 230 V drive 230 V rated voltage

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

A typical 3 phase motor would be connected in for 400 V operation or ∆ for 230 V operation,

WARNING

NOTE

however, variations on this are common e.g. 690 V ∆ 400 V.

Incorrect connection of the windings will cause severe under or over fluxing of the motor, leading to a very poor output torque or motor saturation and overheating respectively.

4.9.6 Output contactor

If the cable between the drive and the motor is to be interrupted by a contactor or circuit breaker, ensure that the drive is disabled before the contactor or circuit breaker is opened or closed. Severe arcing may occur if this circuit is interrupted with the motor running at high current and low speed.

A contactor is sometimes required to be installed between the drive and motor for safety purposes.

The recommended motor contactor is the AC3 type.

Switching of an output contactor should only occur when the output of the drive is disabled.

Opening or closing of the contactor with the drive enabled will lead to:

1. OI ac trips (which cannot be reset for 10 seconds)

2. High levels of radio frequency noise emission

3. Increased contactor wear and tear

The Drive Enable terminal when opened provides a Safe Torque Off function. This can in many cases replace output contactors.

For further information see the

Control User Guide

4.10 Braking

Braking occurs when the drive is decelerating the motor, or is preventing the motor from gaining speed due to mechanical influences. During braking, energy is returned to the drive from the motor.

When motor braking is applied by the drive, the maximum regenerated power that the drive can absorb is equal to the power dissipation (losses) of the drive.

When the regenerated power is likely to exceed these losses, the DC bus voltage of the drive increases. Under default conditions, the drive brakes the motor under PI control, which extends the deceleration time as necessary in order to prevent the DC bus voltage from rising above a user defined set-point.

If the drive is expected to rapidly decelerate a load, or to hold back an overhauling load, a braking resistor must be installed.

Table 4-5 shows the default DC voltage level at which the drive turns on the braking transistor. However the braking resistor turn on and the turn off voltages are programmable with

Lower Threshold

(06.073) and

Braking IGBT Upper Threshold

(06.074).

Braking IGBT

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Technical data UL listing information

Table 4-5 Default braking transistor turn on voltage

Drive voltage rating DC bus voltage level

200 V 390 V

400 V 780 V

When a braking resistor is used, Pr

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

00.015

should be set to Fast ramp mode.

High temperatures

WARNING

NOTE

CAUTION

Parameter

Size 3 Size 4

200 V

drive

400 V

drive

200 V

drive

400 V

drive

Braking resistor rated power Pr 10.030 50 W 100 W

Braking resistor thermal time constant Pr 10.031 3.3 s 2.0 s

Braking resistor resistance Pr 10.061 75 Ω 38 Ω

Braking resistors can reach high temperatures. Locate braking resistors so that damage cannot result. Use cable having insulation capable of withstanding high temperatures.

4.10.1 Heatsink mounted braking resistor

A resistor has been especially designed to be mounted within the heatsink of the drive (size 3 and 4). See section 3.10 resistor is such that no thermal protection circuit is required, as the device will fail safely under fault conditions. On size 3 and 4 the in built software overload protection is set-up at default for the designated heatsink mounted resistor. The heatsink mounted resistor is not supplied with the drive and can be purchased separately.

Table 4-6 provides the resistor data for each drive rating.

Size 3 and 4 internal braking resistor

for mounting details. The design of the

The internal / heatsink mounted resistor is suitable for applications with a low level of regen energy only. See Table 4-6.

Braking resistor overload protection parameter settings Failure to observe the following information may damage the resistor.

The drive software contains an overload protection function for a braking resistor. On size 3 and 4 this function is enabled at default to protect the heatsink mounted resistor. Below are the parameter settings.

For more information on the braking resistor software overload protection, see Pr

10.030,

10.031

and Pr

10.061

software overload protection

full descriptions in

on page 62

section 4.10.3 Braking resistor

If the resistor is to be used at more than half of its average power rating, the drive cooling fan must be set to full speed by setting Pr

06.045

to 11.

Table 4-6 Heatsink mounted braking resistor data

Parameter Size 3 Size 4

Part number 1220-2752 1299-0003

DC resistance at 25 °C 75

Ω

Peak instantaneous power over 1 ms at nominal resistance 8 kW 16 kW

Average power over 60 s * 50 W 100 W

Ingress Protection (IP) rating IP54

Maximum altitude 2000 m

* To keep the temperature of the resistor below 70 °C (158 °F) in a 30 °C (86 °F) ambient, the average power rating is 50 W for size 3, 100 W for size 4. The above parameter settings ensure this is the case.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

37.5

Ω

4.10.2 External braking resistor

WARNING

Overload protection

When an external braking resistor is used, it is essential that an overload protection device is incorporated in the braking resistor circuit; this is described in

When a braking resistor is to be mounted outside the enclosure, ensure that it is mounted in a ventilated metal housing that will perform the following functions:

• Prevent inadvertent contact with the resistor

• Allow adequate ventilation for the resistor

When compliance with EMC emission standards is required, external connection requires the cable to be armored or shielded, since it is not fully contained in a metal enclosure. See section

4.12.5

Compliance with generic emission standards

on page 70 for further details.

Internal connection does not require the cable to be armored or shielded.

Table 4-7 Minimum resistance values and peak power rating for the braking resistor at 40 °C (104 °F)

Model

Minimum resistance

Instantaneous power

rating

Ω kW kW

200 V

03200050

03200066 1.9

03200080 2.8

22 7.7

03200106 3.6

04200137

04200185 6.3

18 9.4

400 V

03400025

03400031 2.0

03400045 2.8

74 9.2

03400062 4.6

03400078

03400100 6.6

04400150

04400172 12.6

50 13.6

37 18.3

* Resistor tolerance: ±10 %. The minimum resistance specified are for stand-alone drive systems only. If the drive is to be used as part of a common DC bus system different values may be required. See

Braking resistor software overload protection

on page 62.

Figure 4-8 on page 61.

Continuous power

rating

1.5

4.6

1.5

5.0

9.0

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Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

For high-inertia loads or under continuous braking, the continuous power dissipated in the braking resistor may be as high as the power rating of the drive. The total energy dissipated in the braking resistor is dependent on the amount of energy to be extracted from the load.

The instantaneous power rating refers to the short-term maximum power dissipated during the on intervals of the pulse width modulated braking control cycle. The braking resistor must be able to withstand this dissipation for short intervals (milliseconds). Higher resistance values require proportionately lower instantaneous power ratings.

In most applications, braking occurs only occasionally. This allows the continuous power rating of the braking resistor to be much lower than the power rating of the drive. It is therefore essential that the instantaneous power rating and energy rating of the braking resistor are sufficient for the most extreme braking duty that is likely to be encountered.

Optimization of the braking resistor requires careful consideration of the braking duty.

Select a value of resistance for the braking resistor that is not less than the specified minimum resistance. Larger resistance values may give a cost saving, as well as a safety benefit in the event of a fault in the braking system. Braking capability will then be reduced, which could cause the drive to trip during braking if the value chosen is too large.

The following external brake resistors are available from the supplier of the drive for sizes 3 and 4.

Table 4-8 External brake resistors (40° C ambient) for drive sizes 3 and 4

Part

number

1220-

2201

1220-

2401

1220-

2801

Part desc

DBR, 100 W, 20R, 130 x 68, TS

DBR, 100 W, 40R, 130 x 68, TS

DBR, 100 W, 80R, 130 x 68, TS

Ohmic

value

Pr10.061

20 Ω 100 W 2.0 MW 2300 W 1000 W 650 W 250 W 20

40 Ω 100 W 1.6 MW 1900 W 900 W 610 W 240 W 16

80 Ω 100 W 1.25 MW 1500 W 775 W 570 W 230 W 12.5

Cont power rating

Pr10.030

Max inst

power rating

ton = 1 ms

Pulse

power

1/120 s

(ED 0.8 %)

Pulse

power

5/120 s

(ED 4.2 %)

Pulse

power

10/120 s

(ED 8.3 %)

Pulse

power

40/120 s

(ED 33 %)

Time constant Pr10.031

The brake resistors can be used in a series or parallel to get the required resistance and power depending on the size of the drive as per Table 4-7. The brake resistor is equipped with a thermal switch. The thermal switch should be integrated in the control circuit by the user.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

The resistor combinations shown in Table 4-9 below can be made using one or more brake resistor/s

Optional EMC filter

Stop

Start / Reset

Thermal protection device

Braking resistor

Drive

Main contactor power supply

+DC

from Table 4-8 above. Pr in Table 4-8 above. Refer to description of Pr

4.10.3 Braking resistor software overload protection

10.030

, Pr

10.031

and Pr

10.030

10.061

should be set as per information provided

, Pr

10.031

and Pr

10.061

section

on page 62 for more information.

Table 4-9 Resistor combinations

Heavy

Model

03200050 0.7 135 101

03200066 1.1 92 69

03200080 1.5 68 51

03200106 2.2 46 34

03400025 0.7 540 405

03400031 1.1 370 277

03400045 1.5 271 203

03400062 2.2 184 138

03400078 3.0 135 101

03400100 4.0 101 76

04200137 3.0 34 25

04200185 4.0 26 19

04400150 5.5 74 56

04400172 7.5 54 40

duty

kW Ω Ω Vdc Ω Ω

150 %

Peak

power

200 %

Peak

power

Braking voltage

390 22

780

390 18

780 37

Resistor

Min. value

Resistor

combinations

1 x 40 = 40

2 x 80 = 40 (when

connected in parallel)

1 x 80 = 80

2 x 40 = 80 (when

connected in series)

1 x 20 = 20

2 x 40 = 20 (when

connected in parallel)

1 x 40 = 40

2 x 80 = 40 (when

connected in parallel)

Thermal protection circuit for the braking resistor

The thermal protection circuit must disconnect the AC supply from the drive if the resistor becomes overloaded due to a fault. Figure 4-8 shows a typical circuit arrangement.

Figure 4-8 Typical protection circuit for a braking resistor

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Electrical installation

See Figure 4-1 on page 46 and Figure 4-2 on page 47 for the location of the +DC and braking resistor connections.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data UL listing information

4.10.3 Braking resistor software overload protection

Pr 10.031

Resistor pulse power rating x Braking time

Resistor continuous power rating

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

WARNING

The drive software contains an overload protection function for a braking resistor. In order to enable and set-up this function, it is necessary to enter three values into the drive:

•

Braking Resistor Rated Power

•

Braking Resistor Thermal Time Constant

•

Braking Resistor Resistance

This data should be obtained from the manufacturer of the braking resistor. The braking resistor thermal time constant can be calculated from resistor data sheet values using the following equation:

10.039

gives an indication of braking resistor temperature based on a simple thermal model. Zero indicates the resistor is close to ambient and 100 % is the maximum temperature the resistor can withstand. A ‘Brake Resistor’ alarm is given if this parameter is above 75 % and the braking IGBT is active. A Brake R Too Hot trip will occur if Pr (default value) or 1.

If Pr

10.037

but instead the braking IGBT will be disabled until Pr for applications with parallel connected DC buses where there are several braking resistors, each of which cannot withstand full DC bus voltage continuously. With this type of application it is unlikely the braking energy will be shared equally between the resistors because of voltage measurement tolerances within the individual drives. Therefore with Pr resistor has reached its maximum temperature the drive will disable the braking IGBT, and another resistor on another drive will take up the braking energy. Once Pr drive will allow the braking IGBT to operate again.

See the Pr

10.039

This software overload protection should be used in addition to an external overload protection device.

is equal to 2 or 3, a Brake R Too Hot trip will not occur when Pr

Parameter Reference Guide

(10.030)

(10.061)

(10.031)

10.039

reaches 100 %, when Pr

10.039

for more information on Pr

10.037

is set to 0

10.039

10.031

, Pr

reaches 100 %,

10.037

falls below 95 %. This option is intended

10.037

set to 2 or 3, then as soon as a

10.039

has fallen below 95 % the

10.030

, Pr

and

4.11 Ground leakage

The ground leakage current depends upon whether the internal EMC filter is installed or not. The drive is supplied with the filter installed. Instructions for removing the internal filter are given in section 4.12.2

With internal filter installed: Size 3 to 4:

* Proportional to the supply voltage and frequency.

With internal filter removed:

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Internal EMC filter

28 mA* AC at 400 V 50 Hz

30 µA DC with a 600 V DC bus (10 MΩ)

<1 mA

When the internal filter is installed the leakage current is high. In this case a permanent fixed ground connection must be provided, or other suitable measures taken to prevent a safety hazard occurring if the connection is lost.

on page 65.

Issue Number: 3

4.11.1 Use of residual current device (RCD)

WARNING

There are three common types of ELCB / RCD:

1. AC - detects AC fault currents

2. A - detects AC and pulsating DC fault currents (provided the DC current reaches zero at least once every half cycle)

3. B - detects AC, pulsating DC and smooth DC fault currents

• Type AC should never be used with drives.

• Type A can only be used with single phase drives

• Type B must be used with three phase drives

Only type B ELCB / RCD are suitable for use with 3 phase inverter drives.

If an external EMC filter is used, a delay of at least 50 ms should be incorporated to ensure spurious trips are not seen. The leakage current is likely to exceed the trip level if all of the phases are not energized simultaneously.

4.12 EMC (Electromagnetic compatibility)

The requirements for EMC are divided into three levels in the following three sections:

• section 4.12.3, General requirements for EMC, this is for all applications, to ensure reliable operation of the drive and minimise the risk of disturbing nearby equipment. The immunity standards specified in Chapter 5.1.25 met, but no specific emission standards are applied.

• section 4.12.4, Requirements for meeting the EMC standard for power drive systems, IEC618003 (EN 61800-3:2004).

• section 4.12.5, Requirements for meeting the generic emission standards for the industrial environment, IEC61000-6-4, EN 61000-6-4:2007.

The recommendations of section 4.12.3 will usually be sufficient to avoid causing disturbance to adjacent equipment of industrial quality. If particularly sensitive equipment is to be used nearby, or in a non-industrial environment, then the recommendations of section 4.12.4 or section 4.12.5 should be followed to give reduced radio-frequency emission.

In order to ensure the installation meets the various emission standards described in:

• The EMC data sheet available from the supplier of the drive

• The Declaration of Conformity at the front of this manual

• Chapter 5

The correct external EMC filter must be used and all of the guidelines in section 4.12.3

requirements for EMC Ground (earth) connections generic emission standards

Technical data

on page 76

on page 70 must be followed.

Electromagnetic compatibility (EMC)

on page 67 and section 4.12.5

on page 93 will be

General

Compliance with

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Technical data UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Table 4-10 Drive and EMC filter cross reference

WARNING

NOTE

Model CT part number

200 V

03200050 to 03200106 4200-3230 04200137 to 04200185 4200-0272

400 V

03400025 to 03400100 4200-3480 04400150 to 04400172 4200-0252

High ground leakage current

When an EMC filter is used, a permanent fixed ground connection must be provided which does not pass through a connector or flexible power cord. This includes the internal EMC filter.

The installer of the drive is responsible for ensuring compliance with the EMC regulations that apply in the country in which the drive is to be used.

4.12.1 Grounding hardware

The drive is supplied with a grounding bracket and grounding clamp to facilitate EMC compliance. They provide a convenient method for direct grounding of cable shields without the use of "pig-tails”.

Cable shields can be bared and clamped to the grounding bracket using metal clips or clamps1 (not

supplied) or cable ties. Note that the shield must in all cases be continued through the clamp to the intended terminal on the drive, in accordance with the connection details for the specific signal.

A suitable clamp is the Phoenix DIN rail mounted SK14 cable clamp (for cables with a maximum

outer diameter of 14 mm).

• See Figure 4-9 for details on installing the grounding clamp.

• See Figure 4-10 for details on installing the grounding bracket.

Figure 4-9 Installation of grounding clamp (size 3 and 4)

Loosen the ground connection nuts and slide the grounding clamp in the direction shown. Once in place, the ground connection nuts should be tightened with a maximum torque of 2 N m (1.47 lb ft).

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Figure 4-10 Installation of grounding bracket (all sizes -size 3 shown)

WARNING

Loosen the ground connection nuts and slide the grounding bracket in the direction shown. Once in place, the ground connection nuts should be tightened with a maximum torque of 2 N m (1.47 lb ft).

On size 3 and 4 the grounding bracket is secured using the power ground terminal of the drive. Ensure that the supply ground connection is secure after installing / removing the grounding bracket. Failure to do so will result in the drive not being grounded.

A faston tab is located on the grounding bracket for the purpose of connecting the drive 0 V to ground should the user require to do so.

4.12.2 Internal EMC filter

It is recommended that the internal EMC filter be kept in place unless there is a specific reason for

removing it.

If the drive is used with ungrounded (IT) supplies, the internal EMC filter must be removed unless additional motor ground fault protection is installed. For instructions on removal refer to section 4.12.2. For details of ground fault protection contact the supplier of the drive.

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Electrical installation

If the drive is used as a motoring drive as part of a regen system, then the internal EMC filter must be removed.

The internal EMC filter reduces radio-frequency emission into the line power supply. Where the motor cable is short, it permits the requirements of EN 61800-3:2004 to be met for the second environment - see section 4.12.4

Systems)

on page 69 and section 12.1.27

Compliance with EN 61800-3:2004 (standard for Power Drive

Electromagnetic compatibility (EMC)

on page 254. For longer motor cables the filter continues to provide a useful reduction in emission levels, and when used with any length of shielded motor cable up to the limit for the drive, it is unlikely that nearby industrial equipment will be disturbed. It is recommended that the filter be used in all applications unless the instructions given above require it to be removed, or where the ground leakage current of 28 mA for size 3 is unacceptable. See section 4.12.2 for details of removing and installing the internal

EMC filter.

The supply must be disconnected before removing the internal EMC filter.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data UL listing information

Figure 4-11 Removal of the size 3 internal EMC filter

Remove the screw and nut (1) and (2) as shown above. Lift away from the securing points and rotate away from the drive. Ensure the screw and nut are

replaced and re-tightened with a maximum torque of 2 N m (1.47 lb ft).

Figure 4-12 Removal of the size 4 internal EMC filter

To electrically disconnect the Internal EMC filter, remove the screw as highlighted above (1).

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

4.12.3 General requirements for EMC Ground (earth) connections

Optional ground

connection

External controller

If the control circuit 0V is to be grounded, this should be done at the system controller only to avoid injecting noise currents into the 0V circuit

Metal backplate

Grounding bar

If ground connections are made using a separate cable, they should run parallel to the appropriate power cable to minimise emissions

Use four core cable to connect the motor to the drive. The ground conductor in the motor cable must be connected

directly to the earth terminal of

the drive and motor. It must not be connected directly to the power earth busbar.

The incoming supply ground should be connected to a single power ground bus bar or low impedance earth terminal inside the cubicle. This should be used as a common 'clean' ground for all components inside the cubicle.

3 phase AC supply

Optional EMC filter

Metal backplate safety bonded to power ground busbar

The grounding arrangements should be in accordance with Figure 4-13, which shows a single drive on a back-plate with or without an additional enclosure.

Figure 4-13 shows how to configure and minimise EMC when using unshielded motor cable. However shielded cable is a better option, in which case it should be installed as shown in section

4.12.5

Compliance with generic emission standards

Figure 4-13 General EMC enclosure layout showing ground connections

on page 70.

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Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data UL listing information

Cable layout

Optional braking resistor and overload

Do not place sensitive (unscreened) signal circuits in a zone extending 300 mm (12”) all around the Drive, motor cable, input cable from EMC filter and unshielded braking resistor cable (if used)

300 mm

(12 in)

NOTE

Figure 4-14 indicates the clearances which should be observed around the drive and related ‘noisy’ power cables by all sensitive control signals / equipment.

Figure 4-14 Drive cable clearances

Any signal cables which are carried inside the motor cable (i.e. motor thermistor, motor brake) will pick up large pulse currents via the cable capacitance. The shield of these signal cables must be

connected to ground close to the motor cable, to avoid this noise current spreading through the control system.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

4.12.4 Compliance with EN 61800-3:2004 (standard for Power Drive

CAUTION

Systems)

Meeting the requirements of this standard depends on the environment that the drive is intended to operate in, as follows:

Operation in the first environment

Observe the guidelines given in section 4.12.5

page 70. An external EMC filter will always be required.

This is a product of the restricted distribution class according to IEC 61800-3

In a residential environment this product may cause radio interference in which case the user may be required to take adequate measures.

Operation in the second environment

In all cases a shielded motor cable must be used, and an EMC filter is required for all drives with a rated input current of less than 100 A.

The drive contains an in-built filter for basic emission control. In some cases feeding the motor cables (U, V and W) once through a ferrite ring can maintain compliance for longer cable lengths.

For longer motor cables, an external filter is required. Where a filter is required, follow the guidelines in section 4.12.5

Compliance with generic emission standards

Where a filter is not required, follow the guidelines given in section 4.12.3

EMC Ground (earth) connections

on page 67.

The second environment typically includes an industrial low-voltage power supply network which does not supply buildings used for residential purposes. Operating the drive in this environment without an external EMC filter may cause interference to nearby electronic equipment whose sensitivity has not been appreciated. The user must take remedial measures if this situation arises. If the consequences of unexpected disturbances are severe, it is recommended that the guidelines in section 4.12.5

emission standards

be adhered to.

Compliance with generic emission standards

General requirements for

Compliance with generic

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Electrical installation

Refer to section 5.1.25

Electromagnetic compatibility (EMC)

compliance with EMC standards and definitions of environments.

Detailed instructions and EMC information are given in the the supplier of the drive.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

on page 93 for further information on

EMC Data Sheet

which is available from

Technical data UL listing information

4.12.5 Compliance with generic emission standards

≥

100 mm

(4 in)

≥

100 mm

(4 in)

Do not modify the filter wires

Sensitive signal cable

≥

300 mm

(12 in)

Use the recommended filter and shielded motor cable. Observe the layout rules given in Figure 4-15 and Figure 4-17. Ensure the AC supply and ground cables are at least 100 mm from the power module and motor cable.

Figure 4-15 Supply and ground cable clearance (sizes 3 to 4)

Figure 4-16 Sensitive signal circuit clearance

Avoid placing sensitive signal circuits in a zone 300 mm (12 in) in the area immediately surrounding the power module. Ensure good EMC grounding.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Figure 4-17 Grounding the drive, motor cable shield and filter

Ensure direct metal contact at drive and filter mounting points (any paint must be removed).

Motor cable shield (unbroken) electrically connected to and held in place by grounding clamp.

Connect the shield of the motor cable to the ground terminal of the motor frame using a link that is as short as possible and not exceeding 50 mm (2 in) long.

A complete 360° termination of the shield to the terminal housing of the motor is beneficial.

From an EMC consideration it is irrelevant whether the motor cable contains an internal (safety) ground core, or if there is a separate external ground conductor, or where grounding is through the shield alone. An internal ground core will carry a high noise current and therefore it must be terminated as close as possible to the shield termination.

Figure 4-18 Grounding the motor cable shield

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Electrical installation

Unshielded wiring to the optional braking resistor(s) may be used provided the wiring runs internally to the enclosure. Ensure a minimum spacing of 300 mm (12 in) from the signal wiring and the AC supply wiring to the external EMC filter. If this condition cannot be met then the wiring must be shielded.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data UL listing information

Figure 4-19 Shielding requirements of optional external braking resistor

+DC

Optional external braking resistor

Enclosure

+DC

Optional external braking resistor

Enclosure

If the control wiring is to leave the enclosure, it must be shielded and the shield(s) clamped to the drive using the grounding bracket as shown in Figure 4-20. Remove the outer insulating cover of the cable to ensure the shield(s) make direct contact with the bracket, but keep the shield(s) intact until as close as possible to the terminals. Alternatively, wiring may be passed through a ferrite ring, part number 3225-1004.

Figure 4-20 Grounding of signal cable shields using the grounding bracket

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

4.12.6 Variations in the EMC wiring

From the Drive

To the motor

Back-plate

Enclosure

Isolator

Coupling bar

From the Drive

To the motor

(If required)

Interruptions to the motor cable

The motor cable should ideally be a single length of shielded or armored cable having no interruptions. In some situations it may be necessary to interrupt the cable, as in the following examples:

• Connecting the motor cable to a terminal block in the drive enclosure

• Installing a motor isolator / disconnect switch for safety when work is done on the motor In these cases the following guidelines should be followed.

Terminal block in the enclosure

The motor cable shields should be bonded to the back-plate using uninsulated metal cable-clamps which should be positioned as close as possible to the terminal block. Keep the length of power conductors to a minimum and ensure that all sensitive equipment and circuits are at least 0.3 m (12 in) away from the terminal block.

Figure 4-21 Connecting the motor cable to a terminal block in the enclosure

Safety information Product information Mechanical installation

Electrical installation

Using a motor isolator / disconnect-switch

The motor cable shields should be connected by a very short conductor having a low inductance. The use of a flat metal coupling-bar is recommended; conventional wire is not suitable.

The shields should be bonded directly to the coupling-bar using uninsulated metal cable-clamps. Keep the length of the exposed power conductors to a minimum and ensure that all sensitive equipment and circuits are at least 0.3 m (12 in) away.

The coupling-bar may be grounded to a known low-impedance ground nearby, for example a large metallic structure which is connected closely to the drive ground.

Figure 4-22 Connecting the motor cable to an isolator / disconnect switch

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data UL listing information

Surge immunity of control circuits - long cables and connections outside a building

Signal from plant Signal to drive

0V 0V

30V zener diode e.g. 2xBZW50-15

Signal from plant Signal to drive

0V 0V

2 x 15V zener diode e.g. 2xBZW50-15

The input/output ports for the control circuits are designed for general use within machines and small systems without any special precautions.

These circuits meet the requirements of EN 61000-6-2:2005 (1 kV surge) provided the 0 V connection is not grounded.

In applications where they may be exposed to high-energy voltage surges, some special measures may be required to prevent malfunction or damage. Surges may be caused by lightning or severe power faults in association with grounding arrangements which permit high transient voltages between nominally grounded points. This is a particular risk where the circuits extend outside the protection of a building.

As a general rule, if the circuits are to pass outside the building where the drive is located, or if cable runs within a building exceed 30 m, some additional precautions are advisable. One of the following techniques should be used:

1. Galvanic isolation, i.e. do not connect the control 0 V terminal to ground. Avoid loops in the control wiring, i.e. ensure every control wire is accompanied by its return (0 V) wire.

2. Shielded cable with additional power ground bonding. The cable shield may be connected to ground at both ends, but in addition the ground conductors at both ends of the cable must be bonded together by a power ground cable (equipotential bonding cable) with cross-sectional

area of at least 10 mm2, or 10 times the area of the signal cable shield, or to suit the electrical safety requirements of the plant. This ensures that fault or surge current passes mainly through the ground cable and not in the signal cable shield. If the building or plant has a well-designed common bonded network this precaution is not necessary.

3. Additional over-voltage suppression - for the analog and digital inputs and outputs, a zener diode network or a commercially available surge suppressor may be connected in parallel with the input circuit as shown in Figure 4-23 and Figure 4-24.

If a digital port experiences a severe surge its protective trip may operate (I/O Overload trip). For continued operation after such an event, the trip can be reset automatically by setting Pr

10.034

to 5.

Figure 4-23 Surge suppression for digital and unipolar inputs and outputs

Figure 4-24 Surge suppression for analog and bipolar inputs and outputs

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Surge suppression devices are available as rail-mounting modules, e.g. from Phoenix Contact:

Unipolar TT-UKK5-D/24 DC Bipolar TT-UKK5-D/24 AC

These devices are not suitable for encoder signals or fast digital data networks because the capacitance of the diodes adversely affects the signal. Most encoders have galvanic isolation of the signal circuit from the motor frame, in which case no precautions are required. For data networks, follow the specific recommendations for the particular network.

Safety information Product information Mechanical installation

Electrical installation

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data UL listing information

Technical data

5.1 Drive technical data

5.1.1 Power and current ratings

For a full explanation of ‘Normal Duty’ and ‘Heavy Duty’ refer to the

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 5.1.2

ratings (Derating for switching frequency and temperature)

on page 77.

Table 5-1 200 V drive ratings (200 V to 240 V ±10 %)

Normal Duty Heavy Duty

Max

Nominal

Model

03200050 6.6 1.1 1.5 7.2 5 7.5 10 0.75 1

03200066 8 1.5 2 8.8 6.6 9.9 13.2 1.1 1.5

03200080 11 2.2 3 12.1 8 12 16 1.5 2

03200106 12.7 3 3 13.9 10.6 15.9 21.2 2.2 3

04200137 18 4 5 19.8 13.7 20.5 27.4 3 3

04200185 25 5.5 7.5 27.5 18.5 27.7 37 4 5

cont

output

current

power

at 230 V

A kW hp A A A A kW hp

Motor power

at 230 V

Peak

current

Max

cont

output

current

Table 5-2 400 V drive ratings (380 V to 480 V ±10 %)

Control User Guide

Open

loop

peak

current

RFC

peak

current

Power and current

Nominal

power

at 230 V

Motor

power

Normal Duty Heavy Duty

Max

Nominal

Model

03400025 3.4 1.1 1.5 3.7 2.5 3.7 5.0 0.75 1.0

03400031 4.5 1.5 2.0 4.9 3.1 4.6 6.2 1.1 1.5

03400045 6.2 2.2 3.0 6.8 4.5 6.7 9.0 1.5 2.0

03400062 7.7 3.0 5.0 8.4 6.2 9.3 12.4 2.2 3.0

03400078 10.4 4.0 5.0 11.4 7.8 11.7

03400100 12.3 5.5 7.5 13.5 10.0 15.0

04400150 18.5 7.5 10.0 20.3 15.0 22.5

04400172 24.0 11.0 15.0 26.4 17.2 25.8

Unidrive M/HS Frame 3 and 4 Power Installation Guide

cont

output

current

power

at 400 V

A kW hp A A A A kW hp

Motor

power

at 460 V

Peak

current

Max

cont

output

current

Open

loop peak

current

RFC

peak

current

15.6

20.0

30.0

34.4

Nominal

power

at 400 V

3.0 5.0

4.0 5.0

5.5 10.0

7.5 10.0

at 460 V

Issue Number: 3

Motor

power

5.1.2 Power and current ratings (Derating for switching frequency and temperature)

Table 5-3 Maximum permissible continuous output current @ 40 °C (104 °F) ambient

Normal Duty Heavy Duty

Safety information Product information Mechanical installation Electrical installation

Nominal

Model

kW hp

200 V

03200050 1.1 1.5 6.6 0.75 1.0 5.0

03200066 1.5 2.0 8.0 1.1 1.5 6.6

03200080 2.2 3.0 11 10.2 1.5 2.0 8.0 7.5

03200106 3.0 3.0 12.7 12.1 10.2 2.2 3.0 10.6 8.8 7.5

04200137 4.0 5.0 18 3.0 3.0 13.7

04200185 5.5 7.5 25 24 22 4.0 5.0 18.5 17.6 16

400 V

03400025 1.1 1.5 3.4 0.75 1.0 2.5

03400031 1.5 2.0 4.5 1.1 1.5 3.1

03400045 2.2 3.0 6.2 5.0 1.5 2.0 4.5 3.7

03400062 3.0 5.0 7.7 6.2 5.0 2.2 3.0 6.2 5.8 4.5 3.8

03400078 4.0 5.0 10.4 7.6 5.7 3.0 5.0 7.8 7.6 5.7 4.4

03400100 5.5 7.5 12.3 10.5 7.6 5.8 4.0 5.0 10 9.2 7.7 5.7 4.4

04400150 7.5 10 18.5 14.6 11.1 5.5 10 15.0 14.4 11.5 9.4

04400172 11 15 24 21.8 19.2 14.6 11.2 7.5 10 17.2 16.1 14.4 11.5 9.4

Maximum permissible continuous output

rating

current (A) for the following switching

kHz3kHz4kHz6kHz8kHz12kHz16kHz

frequencies

Nominal

rating

kW hp

Maximum permissible continuous output

current (A) for the following switching

kHz3kHz4kHz6kHz8kHz12kHz16kHz

frequencies

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data

UL listing information

Table 5-4 Maximum permissible continuous output current @ 40 °C (104 °F) ambient with

high IP insert installed

Normal Duty Heavy Duty

Model

200 V

03200050 6.6 5.0

03200066 8.0 6.6

03200080 11.0 9.7 8.0 6.9

03200106 12.3 11.9 11.1 10.0 9.0 6.4 4.7 10.6 10.4 9.3 7.8 6.8

04200137 14.5 13.5 12.2 10.5 9.6 13.7 13.5 12.2 10.5 9.6

04200185 14.5 13.5 12.2 10.5 9.6 14.5 13.5 12.2 10.5 9.6

400 V

03400025 3.4 3.3 2.5

03400031 4.5 4.4 4.1 3.6 3.3 3.1

03400045 5.1 5.0 4.7 4.4 4.1 3.6 3.3 4.5 4.4 4.1 3.6 3.2

03400062 7.7 7.4 6.7 6.2 5.7 5.0 6.2 5.6 4.5 3.8

03400078 8.3 7.6 6.9 6.0 5.2 7.8 7.6 6.9 5.3 4.0

03400100 8.3 7.6 6.9 6.0 5.2 8.3 7.6 6.9 5.3 4.0

04400150 8.6 8.4 6.9 8.6 8.4 6.9

04400172 8.6 8.4 6.9 8.6 8.4 6.9

Maximum permissible continuous output current

for the following switching frequencies

kHz3kHz4kHz6kHz8kHz12kHz16kHz2kHz3kHz4kHz6kHz8kHz12kHz16kHz

(A)

Maximum permissible continuous output current

for the following switching frequencies

(A)

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Table 5-5 Maximum permissible continuous output current @ 50 °C (122 °F)

NOTE

Normal Duty Heavy Duty

Model

200 V

03200050 6.6 5.0

03200066 8.0 6.6

03200080 11 10.5 9.1 8.0 7.0

03200106 12.7 12.6 12.2 11.7 10.5 9.1 10.6 9.6 8.1 7.0

04200137 18 13.7

04200185 22.2 20.2 18.5 17.9 16.2 14.8

400 V

03400025 3.4 2.5

03400031 4.5 3.1

03400045 6.2 5.9 5.4 4.4 4.5 4.2 3.4

03400062 7.6 7.2 6.9 6.4 5.9 5.4 4.4 7.6 5.8 4.5 3.8

03400078 10.4 9.3 8.5 6.9 5.1 7.8 7.0 5.1 3.9

03400100 11.9 11.2 10.5 9.3 8.5 6.9 5.2 10.0 8.3 7.0 5.2 3.9

04400150 18 17.5 17 16.3 15.8 12.2 9.3 15 14.8 13.2 10.6 8.6

04400172 18 17.5 17 16.3 15.8 12.2 9.3 17.2 16.8 14.8 13.2 10.6 8.6

Maximum permissible continuous output current

for the following switching frequencies

kHz3kHz4kHz6kHz8kHz12kHz16kHz2kHz3kHz4kHz6kHz8kHz12kHz16kHz

(A)

Maximum permissible continuous output current

for the following switching frequencies

(A)

Safety information Product information Mechanical installation Electrical installation

55 °C ratings are available on request.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data

UL listing information

5.1.3 Power dissipation

Table 5-6 Losses @ 40° C (104° F) ambient

Normal Duty Heavy Duty

Nominal

Model

200 V

03200050 1.1 1.5 88 93 95 99 104 113 122 0.75 1 74 78 8 0 84 87 94 101

03200066 1.5 2 95 100 102 107 113 122 133 1.1 1.5 8 5 89 91 9 4 99 108 116

03200080 2.2 3 117 123 126 133 139 151 146 1.5 2 92 97 99 105 109 118 111

03200106 3 3 129 136 141 149 158 168 157 2.2 3 109 115 118 126 134 124 116

04200137 4 5 171 180 187 201 216 244 273 3 3 138 145 151 163 174 198 221

04200185 5.5 7.5 227 239 248 266 284 308 314 4 5 176 185 192 207 221 237 241

400 V

03400025 1.1 1.5 76 80 84 94 103 123 141 0.75 1 67 71 7 6 83 92 108 124

03400031 1.5 2 84 88 92 104 115 137 160 1.1 1.5 66 69 73 82 91 107 124

03400045 2.2 3 99 104 112 125 139 167 157 1.5 2 79 83 88 99 109 131 125

03400062 3 5 108 114 122 137 153 149 147 2.2 3 93 98 105 118 123 118 127

03400078 4 5 138 145 158 186 212 201 197 3 5 109 115 125 145 161 166 165

03400100 5 7.5 155 163 179 209 208 201 200 4 5 131 138 151 163 163 166 165

04400150 7.5 10 214 225 244 283 322 325 310 5.5 10 180 189 205 238 262 274 286

04400172 11 15 269 283 307 325 329 325 315 7.5 10 199 210 227 249 262 274 286

rating

kW hp

Drive losses (W) taking into account

any current derating for the given

kHz3 kHz 4 kHz 6 kHz 8 kHz

conditions

kHz

Nominal

rating

kW hp

Drive losses (W) taking into account any current

derating for the given conditions

khz3 kHz 4kHz 6kHz 8 kHz

kHz

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Table 5-7 Losses @ 40°C (104° F) ambient with high IP insert installed

Normal Duty Heavy Duty

Model

200 V

03200050 88 93 95 99 104 113 122 74 78 80 84 87 94 101

03200066 95 100 102 107 113 122 133 85 89 91 94 99 108 116

03200080 117 123 126 133 140 158 157 92 97 99 105 109 118 112

03200106 122 128 124 122 118 98 84 109 115 119 127 122 120 122

04200137 138 145 151 151 146 142 146 145 153 160 161 155 152 155

04200185 204 215 205 194 189 187 199 176 185 192 202 193 191 200

400 V

03400025 76 80 84 94 103 123 137 67 71 76 83 92 108 124

03400031 84 88 92 102 105 110 134 66 69 73 82 91 107 126

03400045 80 84 85 89 92 109 134 79 83 88 96 100 109 130

03400062 108 114 117 122 135 172 203 93 98 105 118 122 136 155

03400078 112 118 134 155 173 221 267 109 115 126 155 173 195 205

03400100 112 118 134 155 173 221 267 106 112 126 155 173 195 205

04400150 100 105 114 132 153 197 207 103 108 118 136 156 202 214

04400172 96 101 111 131 152 197 207 100 105 114 133 157 202 214

Drive losses (W) taking into consideration any

current derating for the given conditions

kHz3 kHz 4 kHz 6 kHz 8 kHz

kHz

Drive losses (W) taking into consideration any

current derating for the given conditions

kHz 2 kHz3 kHz 4 kHz 6 kHz 8 kHz

kHz

Safety information Product information Mechanical installation Electrical installation

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data

UL listing information

Table 5-8 Losses @ 50° C (122° F) ambient

Normal Duty Heavy Duty

Model

200 V

03200050 88 93 95 99 104 113 122 74 78 80 84 87 94 101

03200066 95 100 102 107 113 122 133 85 89 91 94 99 108 116

03200080 117 123 126 133 139 144 139 92 97 99 105 109 118 113

03200106 129 136 140 143 147 151 150 109 115 118 126 121 117 116

04200137 171 180 187 201 216 253 297 138 145 151 163 174 198 228

04200185 203 214 223 244 265 312 334 176 185 192 207 217 230 247

400 V

03400025 76 80 84 118 103 123 141 67 71 76 83 92 108 124

03400031 84 88 92 104 115 137 160 66 69 73 82 91 107 124

03400045 99 104 112 125 132 146 155 79 83 88 99 109 122 121

03400062 106 106 109 114 117 145 155 118 124 132 148 148 140 139

03400078 138 145 158 175 194 225 225 109 115 125 148 160 166 172

03400100 152 152 160 175 194 225 230 131 138 152 158 160 170 172

04400150 213 213 227 262 300 323 325 180 189 205 240 253 276 297

04400172 212 212 227 262 300 318 321 200 211 226 240 253 276 297

Drive losses (W) taking into accou nt any current

derating for the given conditions

kHz3 kHz 4 kHz 6 kHz 8 kHz

kHz

Drive losses (W) taking into account any current

derating for the given conditions

kHz 2 kHz3 kHz 4 kHz 6 kHz 8 kHz

kHz

Table 5-9 Power losses from the front of the drive when through-panel mounted

Frame size Power loss

3 ≤ 50 W

4 ≤ 75 W

5.1.4 Temperature, humidity and cooling method

Ambient temperature operating range:

- 20 °C to 55 °C (- 4 °F to 131 °F). Output current derating must be applied at ambient temperatures >40 °C (104 °F).

Cooling method: Forced convection

Maximum humidity: 95 % non-condensing at 40 °C (104 °F)

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

5.1.5 Supply requirements

AC supply voltage:

200 V drive: 200 V to 240 V ±10 % 400 V drive: 380 V to 480 V ±10 %

Number of phases: 3

Maximum supply imbalance: 2 % negative phase sequence (equivalent to 3 % voltage imbalance between phases).

Frequency range: 45 to 66 Hz

For UL compliance only, the maximum supply symmetrical fault current must be limited to 100 kA

5.1.6 Line reactors

Input line reactors reduce the risk of damage to the drive resulting from poor phase balance or severe disturbances on the supply network.

For all drive ratings, 2 % line reactors permit drives to be used with a supply unbalance of up to 3.5 % negative phase sequence (equivalent to 5% voltage imbalance between phases).

Severe disturbances may be caused by the following factors, for example:

• Power factor correction equipment connected close to the drive.

• Large DC drives having no or inadequate line reactors connected to the supply.

• Across the line (DOL) started motor(s) connected to the supply such that when any of these

motors are started, the voltage dip exceeds 20 %.

Such disturbances may cause excessive peak currents to flow in the input power circuit of the drive. This may cause nuisance tripping, or in extreme cases, failure of the drive.

Drives of low power rating may also be susceptible to disturbance when connected to supplies with a high rated capacity.

Line reactors are particularly recommended for use with the following drive models when one of the above factors exists, or when the supply capacity exceeds 175 kVA:

03200050, 03200066, 03200080, 03200106,

03400025, 03400031, 03400045, 03400062

Model sizes 03400078 to 04400172 have an internal DC choke so they do not require AC line reactors except for cases of excessive phase unbalance or extreme supply conditions.

When required, each drive must have its own reactor(s). Three individual reactors or a single threephase reactor should be used.

Reactor current ratings

The current rating of the line reactors should be as follows:

Continuous current rating:

Not less than the continuous input current rating of the drive

Repetitive peak current rating:

Not less than twice the continuous input current rating of the drive

Safety information Product information Mechanical installation Electrical installation

Technical data

UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Table 5-10 2 % line reactors

Drive

model

number

03200050 200 INL2001 4401-0143 13.5 0.79 1.8 156 70 125

03200066 200 INL2001 4401-0143 13.5 0.79 1.8 156 70 125

03200080 200 INL2002 4401-0144 20.6 0.48 2.4 156 80 125

03200106 200 INL2002 4401-0144 20.6 0.48 2.4 156 80 125

04200137 200 INL2002 4401-0144 20.6 0.48 2.4 156 80 125

04200185 200 INL2003 4401-0145 26.8 0.32 2.5 156 80 125

03400025 400 INL4001 4401-0148 6.6 2.94 1.3 80 75 130

03400031 400 INL4001 4401-0148 6.6 2.94 1.3 80 75 130

03400045 400 INL4002 4401-0149 9.1 1.62 1.8 156 70 125

03400062 400 INL4011 4401-0234 13 1.12 2.5 156 80 125

03400078 400 INL4011 4401-0234 13 1.12 2.5 156 80 125

03400100 400 INL4003 4401-0151 15.8 1.05 2.6 156 80 125

04400150 400 INL4004 4401-0152 18.7 0.79 3.5 156 60 145

04400172 400 INL4005 4401-0153 24.3 0.61 4.9 156 75 145

Voltage

Line reactor

rating

designation

V A mH kg mm mm mm

CT Part number

Line reactor current

rating

Inductance Weight Length Width Height

5.1.7 Motor requirements

No. of phases: 3

Maximum voltage:

200 V drive: 240 V 400 V drive: 480 V

5.1.8 Storage

-40 °C (-40 °F) to +55 °C (131 °F) for long term storage, or to +70 °C (158 °F) for short term storage.

Storage time is 2 years.

Electrolytic capacitors in any electronic product have a storage period after which they require reforming or replacing.

The DC bus capacitors have a storage period of 10 years.

The low voltage capacitors on the control supplies typically have a storage period of 2 years and are thus the limiting factor.

Low voltage capacitors cannot be reformed due to their location in the circuit and thus may require replacing if the drive is stored for a period of 2 years or greater without power being applied.

It is therefore recommended that drives are powered up for a minimum of 1 hour after every 2 years of storage. This process allows the drive to be stored for a further 2 years.

5.1.9 Altitude

Altitude range: 0 to 3,000 m (9,900 ft), subject to the following conditions:

1,000 m to 3,000 m (3,300 ft to 9,900 ft) above sea level: de-rate the maximum output current from the specified figure by 1% per 100 m (330 ft) above 1,000 m (3,300 ft)

For example at 3,000 m (9,900 ft) the output current of the drive would have to be de-rated by 20 %.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

5.1.10

The drive is rated to IP20 pollution degree 2 (dry, non-conductive contamination only) (NEMA 1). However, it is possible to configure the drive to achieve IP65 rating (sizes 3 to 4) (NEMA 12) at the rear of the heatsink for through-panel mounting (some current derating is required).

The IP rating of a product is a measure of protection against ingress and contact to foreign bodies and water. It is stated as IP XX, where the two digits (XX) indicate the degree of protection provided as shown in Table 5-11.

Table 5-11 IP Rating degrees of protection

Protection against contact and ingress of foreign bodies

0 No protection 0 No protection

7 - 7 Protection against immersion 8 - 8 Protection against submersion

Table 5-12 UL enclosure ratings

IP / UL Rating

First digit Second digit

Protection against ingress of water

Protection against large foreign bodies φ > 50 mm (large area contact with the hand)

Protection against medium size foreign bodies φ > 12 mm (finger)

Protection against small foreign bodies φ >

2.5 mm (tools, wires) Protection against granular foreign bodies

> 1mm (tools, wires)

Protection against dust deposit, complete protection against accidental contact.

Protection against dust ingress, complete protection against accidental contact.

UL rating Description

Type 1

Type 12

Enclosures are intended for indoor use, primarily to provide a degree of protection against limited amounts of falling dirt.

Enclosures are intended for indoor use, primarily to provide a degree of protection against dust, falling dirt and dripping non-corrosive liquids.

Protection against vertically falling drops of

water Protection against spraywater (up to 15 °

from the vertical) Protection against spraywater (up to 60 °

from the vertical) Protection against splashwater (from all

directions) Protection against heavy splash water (from

all directions, at high pressure) Protection against deckwater (e.g. in heavy

seas)

5.1.11 Corrosive gasses

Concentrations of corrosive gases must not exceed the levels given in:

• Table A2 of EN 50178:1998

• Class 3C2 of IEC 60721-3-3

This corresponds to the levels typical of urban areas with industrial activities and/or heavy traffic, but not in the immediate neighborhood of industrial sources with chemical emissions.

5.1.12 RoHS compliance

The drive meets EU directive 2011/65/EU for RoHS compliance.

Safety information Product information Mechanical installation Electrical installation

Technical data

UL listing information

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

5.1.13 Vibration

NOTE

Maximum recommended continuous vibration level 0.14 g r.m.s. broad-band 5 to 200 Hz.

This is the limit for broad-band (random) vibration. Narrow-band vibration at this level which coincides with a structural resonance could result in premature failure.

Bump Test

Testing in each of three mutually perpendicular axes in turn. Referenced standard:IEC 60068-2-29: Test Eb: Severity: 18 g, 6 ms, half sine No. of Bumps: 600 (100 in each direction of each axis)

Random Vibration Test

Testing in each of three mutually perpendicular axes in turn. Referenced standard:IEC 60068-2-64: Test Fh: Severity: 1.0 m²/s³ (0.01 g²/Hz) ASD from 5 to 20 Hz

-3 dB/octave from 20 to 200 Hz

Duration: 30 minutes in each of 3 mutually perpendicular axes.

Sinusoidal Vibration Test

Testing in each of three mutually perpendicular axes in turn. Referenced standard: IEC 60068-2-6: Test Fc: Frequency range: 5 to 500 Hz Severity: 3.5 mm peak displacement from 5 to 9 Hz

10 m/s² peak acceleration from 9 to 200 Hz

15 m/s² peak acceleration from 200 to 500 Hz Sweep rate: 1 octave/minute Duration: 15 minutes in each of 3 mutually perpendicular axes.

EN 61800-5-1:2007, Section 5.2.6.4. referring to IEC 60068-2-6

Frequency range: 10 to 150 Hz Amplitude: 10 to 57 Hz at 0.075 mm pk

57 to 150 Hz at 1g p Sweep rate: 1 octave/minute Duration: 10 sweep cycles per axis in each of 3 mutually perpendicular axes

5.1.14

By electronic control: unlimited By interrupting the AC supply: ≤20 (equally spaced)

5.1.15 Start up time

This is the time taken from the moment of applying power to the drive, to the drive being ready to run the motor:

For faster start up time a 24V backup supply can be used, see section 4.5 page 52.

Starts per hour

Sizes 3 and 4 = 2.5 s

24 Vdc supply

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

5.1.16

Unidrive Mxxx models:

In all operating modes (Open loop, RFC-A, RFC-S) the maximum output frequency is limited to 550 Hz.

Unidrive HSxx models:

In open loop mode the maximum achievable output frequency is 3,000 Hz.

In RFC-A and RFC-S modes, the maximum achievable output frequency is 1,250Hz.

In RFC-S mode the speed is also limited by the voltage constant (Ke) of the motor unless field weakening operation is enabled. Ke is a specific constant for the servo motor being used. It can normally be found on the motor data sheet in V/k rpm (volts per 1,000 rpm).

It is recommended that a minimum ratio of 12:1 is maintained between the switching frequency and the maximum output frequency to maintain the quality of the output waveform. If this minimum ratio is exceeded, extra motor losses will result due to the increased harmonic content of the output waveform.

5.1.17

Speed:

The absolute frequency and speed accuracy depends on the accuracy of the crystal used with the drive microprocessor. The accuracy of the crystal is 100 ppm, and so the absolute frequency/speed accuracy is 100 ppm (0.01 %) of the reference, when a preset speed is used. If an analog input is used the absolute accuracy is further limited by the absolute accuracy of the analog input.

The following data applies to the drive only; it does not include the performance of the source of the control signals.

Open loop resolution:

Closed loop resolution

Current:

The resolution of the current feedback is 10 bit plus sign.

Accuracy: typical 2 %

Output frequency / speed range

Accuracy and resolution

Preset frequency reference: 0.1 Hz Precision frequency reference: 0.001 Hz

Preset speed reference: 0.1 rpm Precision speed reference: 0.001 rpm Analog input 1: 11 bit plus sign Analog input 2: 11 bit plus sign

worst case 5 %

Safety information Product information Mechanical installation Electrical installation

Technical data

5.1.18

The heatsink fan generates the majority of the sound pressure level at 1 m produced by the drive. The heatsink fan is a variable 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.

Table 5-13 gives the sound pressure level at 1 m produced by the drive when running at maximum normal and heavy duty current and when the heatsink fan is running at minimum speed.

Table 5-13 Acoustic noise data

*At 40 °C ambient and 3 kHz switching frequency.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Acoustic noise

Size

3 62.8 50.9 42.9 4 62.6 56.9 45.8

Max ND operation

dBA

Max HD operation*

dBA

Min fan speed

dBA

UL listing information

5.1.19 Overall dimensions

WARNING

H Height including surface mounting brackets W Width D Projection forward of panel when surface mounted F Projection forward of panel when through-panel mounted R Projection rear of panel when through-panel mounted

Table 5-14 Overall drive dimensions

Size

H W D F R

382 mm

(15.04 in)

391 mm

(15.39 in)

83 mm

(3.27 in) 124 mm

(4.88 in)

Dimension

200 mm (7.87 in)

134 mm (5.28 in)

67 mm

(2.64 in)

67 mm

(2.64 in)

5.1.20

Table 5-15 Overall drive weights

Weights

Size Model kg lb

4 All variants 6.5 14.30

034300078, 034300100 4.5 9.9

All other variants 4.0 8.8

5.1.21 Input current, fuse and cable size ratings

The input current is affected by the supply voltage and impedance.

Typical input current

The values of typical input current are given to aid calculations for power flow and power loss. The values of typical input current are stated for a balanced supply.

Maximum continuous input current

The values of maximum input current are stated for a supply with a 2 % negative phase-sequence imbalance and rated at the maximum supply fault current given in Table 5-16.

Table 5-16 Supply fault current used to calculate maximum input currents

Model Symmetrical fault level (kA)

All 100

Fuses

The AC supply to the drive must be installed with suitable protection against overload and short-circuits. Table 5-17 and Table 5-18 shows the recommended fuse ratings. Failure to observe this requirement will cause risk of fire.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Table 5-17 AC Input current and fuse ratings (200 V)

NOTE

CAUTION

Model

03200050

03200066

03200080

03200106

04200137

04200185

Typical

input

current

Maximum

continuous

input

current

A A A A A A A

8.2

9.9

10.4

12.6

Maximum

overload

input

current

15.8

20.9

20 30 25 25

28 41 32 32 30 30

Nominal Max

* These fuses are fast acting.

Table 5-18 AC Input current and fuse ratings (400 V)

Model

03400025

03400031

03400045

03400062

03400100

04400150

04400172

Typical

input

current

Maximum

continuous

input

current

A A A A A A A

Maximum

overload

input

current

Nominal Max

10 10

20 20 20 2003400078

25 25

32 32 30 30

* These fuses are fast acting.

Fuse rating

IEC UL / USA

Nominal Max

Class

25 gG

IEC UL / USA

Class

25 25

Fuse rating

Nominal Max

10 10

25 25

Class

CC, J or

Class

CC, J or

Safety information Product information Mechanical installation Electrical installation

Ensure cables used suit local wiring regulations.

The nominal cable sizes below are only a guide. The mounting and grouping of cables

affects their current-carrying capacity, in some cases smaller cables may be acceptable

but in other cases a larger cable is required to avoid excessive temperature or voltage

drop. Refer to local wiring regulations for the correct size of cables.

Table 5-19 Cable ratings (200 V)

Cable size (IEC) mm

Model

Nominal Max

03200050

03200066

03200080

03200106

04200137

04200185

Input Output Input Output

Install

method

1.5

4 B2

4 4

8 B2

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Nominal Max

1.5

8 8 8

Install

method

4 B2

8 B2

Cable size (UL) AWG

Nominal Max Nominal Max

12 12

Technical data

UL listing information

Table 5-20 Cable ratings (400 V)

Cable size (IEC)

Model

Nominal Max

03400025

03400031 16 16

03400045

03400078

03400100 12 12

04400150

04400172

Input Output Input Output

method

1.5

4 B2

2.5 2.5

6 6

6 B2

Install

Nominal Max

1.5

Install

method

4 B2

6 B2

Nominal Max Nominal Max

Cable size (UL)

AWG

14 1403400062

8 8

5.1.22

Maximum motor cable lengths and types

Since capacitance in the motor cable causes loading on the output of the drive, ensure the cable length does not exceed the values given in Table 5-21 and Table 5-22.

Use 105 °C (221 °F) (UL 60/75 °C temp rise) PVC-insulated cable with copper conductors having a suitable voltage rating, for the following power connections:

• AC supply to external EMC filter (when used)

• AC supply (or external EMC filter) to drive

• Drive to motor

• Drive to braking resistor

Table 5-21 Maximum motor cable lengths (200 V drives)

200 V Nominal AC supply voltage

Maximum permissible motor cable length for each of the following switching

Model

03200050 65 m (210 ft)

03200066 100 m (330 ft)

03200080 130 m (425 ft)

03200106 200 m (660 ft)

04200137

04200185

kHz

200 m (660 ft)

kHz

150 m

(490 ft)

150 m

(490 ft)

kHz

frequencies

kHz

100 m

(330 ft)

100 m

(330 ft)

kHz

75 m

(245 ft)

75 m

(245 ft)

12 kHz 16 kHz

50 m

(165 ft)

50 m

(165 ft)

37 m

(120 ft)

37 m

(120 ft)

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

Table 5-22 Maximum motor cable lengths (400 V drives)

400 V Nominal AC supply voltage

Maximum permissible motor cable length for each of the following

Model

03400025 65 m (210 ft)

03400031 100 m (330 ft)

03400045 130 m (425 ft)

03400062

03400078

03400100

04400150

04400172

kHz

200 m (660 ft)

kHz

switching frequencies

kHz

150 m

(490 ft)

150 m

(490 ft)

kHz

100 m

(330 ft)

100 m

(330 ft)

kHz

75 m

(245 ft)

75 m

(245 ft)

kHz

50 m

(165 ft)

50 m

(165 ft)

kHz

37 m

(120 ft)

37 m

(120 ft)

• Cable lengths in excess of the specified values may be used only when special techniques are adopted; refer to the supplier of the drive.

• The default switching frequency is 3 kHz for Open-loop and RFC-A and 6 kHz for RFC-S mode.

The maximum cable length is reduced from that shown in Table 5-21 and Table 5-22 if high capacitance or reduced diameter motor cables are used, refer to Chapter 4.9.2

reduced diameter cables

on page 54.

High-capacitance /

5.1.23 Braking resistor values

Table 5-23 Braking resistor resistance and power rating at 40 °C (104 °F) (200 V)

Safety information Product information Mechanical installation Electrical installation

Model

Minimum

resistance *

Ω

Instantaneous power

rating

kW kW

03200050 03200066 2.2 03200080 3.1

22 7.7

03200106 4.2 04200137 04200185 7.4

18 9.4

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Continuous

power rating

1.7

5.1

Technical data

UL listing information

Table 5-24 Braking resistor resistance and power rating at 40 °C (104 °F) (400 V)

Minimum

Model

resistance *

Ω

03400025 03400031 2.3 03400045 3.1

74 9.2

Instantaneous power

rating

kW kW

Continuous

power rating

1.7

03400062 5.1 03400078 03400100 7.3 04400150 04400172 13.9

50 13.6

37 18.3

6.4

12.5

Braking resistor software overload protection

on page 62.

5.1.24 Torque settings and maximum cable size

Table 5-25 Drive control and relay terminal data

Model Connection type Torque setting

All Plug-in terminal block 0.5 N m (0.4 lb ft)

Table 5-26 Drive power terminal data

Frame

size

3 and 4

AC and motor terminals DC and braking Ground terminal

Recommended Maximum Recommended Maximum Recommended Maximum

Plug-in terminal block T20 Torx (M4)

0.7 N m

(0.5 lb ft)

0.8 N m

(0.6 lb ft)

2.0 N m

(1.4 Ib ft)

2.5 N m

(1.8 Ib ft)

T20 Torx (M4) / M4 Nut

(7 mm AF)

2.0 N m

(1.4 Ib ft)

2.5 N m

(1.8 Ib ft)

Table 5-27 Plug-in terminal block maximum cable sizes

Frame size Terminal block description Max cable size

All

11 way control connectors

2 way relay connector

6 way AC power connector

1.5 mm2 (16 AWG)

2.5 mm2 (12 AWG)

6 mm2 (10 AWG)

Table 5-28 External EMC filter terminal data

CT part

number

4200-0252

4200-0272

4200-3230

4200-3480

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Max cable size Max torque Ground stud size Max torque

16 mm

(6 AWG)

4 mm

(12 AWG)

Power

connections

1.8 N m

(1.4 lb ft)

0.8 N m

(0.59 lb ft)

Ground

connections

4.8 N m

(2.8 lb ft)

3.0 N m

(2.2 lb ft)

Issue Number: 3

5.1.25 Electromagnetic compatibility (EMC)

This is a summary of the EMC performance of the drive. For full details, refer to the which can be obtained from the supplier of the drive.

Table 5-29 Immunity compliance

Standard Type of immunity Test specification Application Level

IEC61000-4-2 EN61000-4-2

IEC61000-4-3 EN61000-4-3

IEC61000-4-4 EN61000-4-4

IEC61000-4-5 EN61000-4-5

IEC61000-4-6 EN61000-4-6

IEC61000-4-11 EN61000-4-11

IEC61000-6-1 EN61000-6-1:2007

IEC61000-6-2 EN61000-6-2:2005

IEC61800-3 EN61800-3:2004

See section 4.12.6

grounding and external surge protection of the control ports.

Electrostatic discharge

Radio frequency radiated field

Fast transient burst

Surges

Conducted radio frequency

Voltage dips and interruptions

Generic immunity standard for the residential, commercial and light - industrial environment

Generic immunity standard for the industrial environment

Product standard for adjustable speed power drive systems (immunity requirements)

Variations in the EMC wiring

6 kV contact discharge 8 kV air discharge

10 V/m prior to modulation 80 - 1000 MHz 80 % AM (1 kHz) modulation

5/50 ns 2 kV transient at 5 kHz repetition frequency via coupling clamp

5/50 ns 2 kV transient at 5 kHz repetition frequency by direct injection

Common mode 4 kV

1.2/50 µs waveshape

Differential mode 2 kV1.2/50 µs waveshape

Lines to ground

10V prior to modulation

0.15 - 80 MHz 80 % AM (1 kHz) modulation

-30 % 10 ms +60 % 100 ms

-60 % 1 s <-95 % 5 s

on page 73 for possible requirements regarding

Module enclosure

Control lines

Power lines

AC supply lines: line to ground

AC supply lines: line to line

Signal ports to

ground

Control and power lines

AC power ports

Meets immunity requirements for first and second environments

EMC Data Sheet

Level 3 (industrial)

Level 4 (industrial harsh)

Level 3 (industrial)

Level 4

Level 3

Level 2

Level 3 (industrial)

Complies

Safety information Product information Mechanical installation Electrical installation

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data

UL listing information

Emission

The drive contains an in-built filter for basic emission control. An additional optional external filter provides further reduction of emission. The requirements of the following standards are met, depending on the motor cable length and switching frequency.

Table 5-30 Size 3 emission compliance (200 V drives)

Motor cable

length (m)

Using internal filter:

0 – 2 C3 C4

Using internal filter and ferrite ring (2 turns):

0 – 10 C3 C4

10-20 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

2 3 4 6 8 12 16

Switching Frequency (kHz)

Table 5-31 Size 3 emission compliance (400 V drives)

Motor cable

length (m)

Using internal filter:

0 – 5 C3 C4

Using internal filter and ferrite ring (2 turns):

0 – 10 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

2 3 4 6 8 12 16

Switching Frequency (kHz)

Table 5-32 Size 4 emission compliance (200 V drives)

Motor cable

length (m)

Using internal filter:

0 – 2 C3 C4

Using internal filter and ferrite ring (2 turns):

0 – 4 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Unidrive M/HS Frame 3 and 4 Power Installation Guide

2 3 4 6 8 12 16

Switching Frequency (kHz)

Issue Number: 3

Table 5-33 Size 4 emission compliance (400 V drives)

CAUTION

Motor cable

length (m)

Using internal filter:

0 – 4 C3 C4

Using internal filter and ferrite ring (2 turns):

0 – 10 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Key

(shown in decreasing order of permitted emission level):

2 3 4 6 8 12 16

Switching Frequency (kHz)

E2R EN 61800-3:2004 second environment, restricted distribution (Additional measures may be

required to prevent interference)

E2U EN 61800-3:2004 second environment, unrestricted distribution

I Industrial generic standard EN 61000-6-4:2007

EN 61800-3:2004 first environment restricted distribution (The following caution is required

by EN 61800-3:2004)

This is a product of the restricted distribution class according to IEC 61800-3. In a residential environment this product may cause radio interference in which case the user may be required to take adequate measures.

R Residential generic standard EN 61000-6-3:2007

EN 61800-3:2004 first environment unrestricted distribution

EN 61800-3:2004 defines the following:

• The first environment is one that includes residential premises. It also includes establishments directly connected without intermediate transformers to a low-voltage power supply network which supplies buildings used for residential purposes.

• The second environment is one that includes all establishments other than those directly connected to a low-voltage power supply network which supplies buildings used for residential purposes.

• Restricted distribution is defined as a mode of sales distribution in which the manufacturer restricts the supply of equipment to suppliers, customers or users who separately or jointly have technical competence in the EMC requirements of the application of drives.

Safety information Product information Mechanical installation Electrical installation

Technical data

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

UL listing information

IEC 61800-3:2004 and EN 61800-3:2004

The 2004 revision of the standard uses different terminology to align the requirements of the standard better with the EC EMC Directive.

Power drive systems are categorized C1 to C4:

Category Definition

Corresponding code

used above

C1 Intended for use in the first or second environments R

Not a plug-in or movable device, and intended for use in

the first environment only when installed by a

professional, or in the second environment

Intended for use in the second environment, not the first environment

Intended for use in the second environment in a system rated at over 400A, or in a complex system.

E2U

E2R

Note that category 4 is more restrictive than E2R, since the rated current of the PDS must exceed 400 A or the supply voltage exceed 1000 V, for the complete PDS.

5.2 Optional external EMC filters

Table 5-34 EMC filter cross reference

Model CT part number

200 V

03200050 to 03200106 4200-3230 04200137 to 04200185 4200-0272

400 V

03400025 to 03400100 4200-3480 04400150 to 04400172 4200-0252

5.2.1

Table 5-35 Optional external EMC filter details

4200-3230 20 18.5 250 300

4200-0272 27 24.8 250 300 33 28 6.8 137

4200-3480 16 15 528 600 13 11 10.7 151

4200-0252 25 23 528 600 28 24 11.1 182

EMC filter ratings

Part

number

(104 °F)

Maximum

continuous

current

@ 50 °C (122 °F)

A A V V W W mA mA M

Voltage

rating

IEC UL

rating

Power

dissipation at

rated current

@ 40 °C (104 °F)

@ 50 °C

(122 °F)

20 17 2.4 60

Ground leakage

Balanced

supply

phase-to-

phase and

phase-to-

ground

Worst

case@ 40 °C

Discharge

resistors

Ω

1.68

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Issue Number: 3

5.2.2 Overall EMC filter dimensions

Table 5-36 Optional external EMC filter dimensions

Part

number

4200-3230 426 16.77 83 3.27 41 1.61 1.9 4.20

4200-0272 437 17.20 123 4.84 60 2.36 4.0 8.82

4200-3480 426 16.77 83 3.27 41 1.61 2.0 4.40

4200-0252 437 17.20 123 4.84 60 2.36 4.1 9.04

H W D

mm inch mm inch mm inch kg lb

Dimension (mm)

Weight

5.2.3 EMC filter torque settings

Table 5-37 Optional external EMC Filter terminal data

Part

number

4200-0252

4200-0272

4200-3230

4200-3480

Power

connections

Max cable size Max torque Ground stud size Max torque

16 mm

(6 AWG)

4 mm

(12 AWG)

1.8 N m

(1.4 lb ft)

0.8 N m

(0.59 lb ft)

connections

Ground

5.0 N m

(3.7 lb ft)

2.5 N m

(1.8 lb ft)

Safety information Product information Mechanical installation Electrical installation

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

Technical data

UL listing information

6.1 General

6.1.1 Scope of approvals

All models are listed to both US and Canadian safety requirements.

The UL file number is: E171230.

The Manufacturing Location Code is: 8D14.

6.1.2 Manufacturers name

The manufacturer is Emerson Industrial Automation.

6.1.3 Electrical ratings

The electrical ratings are tabulated in

6.1.4 Multiple wiring arrangements

The drives are not intended for use in applications that require different wiring arrangements. The drives are not multiple rated.

6.1.5 Model numbers

The way in which the model numbers for the section 2.1

Introduction

on page 11.

6.1.6 Plenum rating

The drives are suitable for installation in a compartment (duct) handling conditioned air when installed as enclosed types with the intended Type 1 terminal kit.

6.1.7 Operating temperature

The drives are rated for use at 40 °C ambient temperature.

Operation at 50 °C is permitted with derated output. Refer to Table 5-5 on page 79 for further information.

Operation at 55 °C is permitted with derated output, 55 °C ratings are available on request.

6.1.8 Installation warnings, cautions and notes

The appropriate installation warnings, cautions and notes are located in Chapter 1

information

on page 8.

Table 2-1 and Table 2-2 on page 13.

Unidrive M/HS

product range is formed is illustrated in

Safety

6.2 Overload, overcurrent and overspeed protection

6.2.1 Degree of protection level

The devices incorporate solid state overload protection for the motor load. The protection levels are expressed as a percentage of full-load current. Refer to the information.

In order for the motor protection to work properly, the motor rated current must be entered into Pr

00.046

or Pr

05.007

The protection level may be adjusted below 150 % if required. Refer to the further information.

The drive incorporates solid state motor overspeed protection. However, this feature does not provide the level of protection provided by an independent, high-integrity overspeed protection device.

Unidrive M/HS Frame 3 and 4 Power Installation Guide

Control User Guide

for further

for

Issue Number: 3

6.2.2 Thermal memory protection

The drives are provided with motor load and speed sensitive overload protection with thermal memory retention.

The thermal memory protection complies with UL requirements for shutdown, loss of power and speed sensitivity.

For a full explanation of the thermal protection system refer to the

In order to comply with UL requirements for thermal memory retention it is necessary to set the

Thermal Protection Mode

be set to 1.

(Pr

04.016

) to zero; and the

Low Speed Protection Mode

Control User Guide.

(Pr

04.025

) must

6.2.3 Use with motors with thermal protectors

The drive is provided with a means to accept and act upon a signal from a thermal sensor or switch imbedded in the motor or from an external protective relay. Refer to the further information.

Control User Guide

for

6.2.4 Specific overcurrent protective device

The drive is not required to be connected to a supply source with a specific overcurrent protective device other than those specified in section 2.4

Ratings

on page 13.

6.3 Short-circuit protection for branch circuits

6.3.1 Short-circuit rating

The drive is suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 600 Vac maximum, when protected by the overcurrent protective devices as described in section 2.4

Unless otherwise indicated in section 2.4 class CC, J or T rated 600 Vac.

Unless otherwise indicated in section 2.4 type with category control number DIVQ or DIVQ7, rated 600 Vac.

6.3.2 Solid state short-circuit protection

The drive is provided with solid state short-circuit protection. Integral solid state protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the National Electrical Code and any additional local codes.

6.3.3 Common DC bus systems

Frame sizes 3 and 4 are approved for use in modular drive systems using a common DC bus.

For permitted combinations of converter and inverter, along with the required branch circuit protection, contact Emerson Industrial Automation.

Ratings

on page 13

Ratings

on page 13, branch fuses may be any UL listed

on page 13, circuit breakers may be any UL listed

Safety information Product information Mechanical installation Electrical installation Technical data

6.4 Control circuit protection

6.4.1 Control circuit wiring

All control circuits are located in limited voltage, limited current isolated secondary circuits. Additional wiring protection is not required.

Unidrive M/HS Frame 3 and 4 Power Installation Guide Issue Number: 3

UL listing information

6.4.2 Supplemental fuse

When the control circuits are supplied with an external 24 V supply, a supplemental fuse is required as described in section 4.5

24 Vdc supply

on page 52.

6.4.3 Listed accessory kits

All drives are supplied with an accessory kit box, refer to Table 2-5 page 16.

Parts supplied with the drive

6.5 Wiring terminal markings

6.5.1 Marking for proper connection

All main terminals are plainly marked. There are no multiple circuit arrangements.

6.5.2 Terminal connection of ground supply conductor.

The terminals for the connection of the grounded supply circuit conductor are identified by means of an earth symbol (IEC 60417, symbol No. 5019).

Ground connections must use UL listed closed loop (ring) terminals.

6.5.3 User relay contact

An isolated user relay contact is provided that may be wired in the field to become part of a class 1 or class 2 circuit. This is described in the

6.5.4 Type of conductors

Use copper conductors only.

6.5.5 Temperature rating of conductors

Use 75 °C rated conductors only.

6.5.6 Torque values

Torque values for field wiring terminals are provided in

settings

on page 43

Control User Guide.

section 3.12 Terminal size and torque

6.6 Environment

6.6.1 Environment

Drives are intended for operation in pollution degree 2 environments.

Drives are supplied as open type.

Drives are classed as Enclosed Type 1 when installed with the intended Type 1 terminal kit.

Drives are classed as Type 12 when through hole mounted using the Type 12 kit (high IP kit).

6.7 Mounting

6.7.1 Surface mounting

All drives are suitable for Surface mounting. Mounting instructions are given in

3.4 Dimensions and mounting methods

on page 23

6.7.2 Bookcase mounting

In order to minimize the width of the installation, drives may be mounted side by side with or without airspace between them.

6.7.3 Tile mounting

Frame sizes 3 and 4 are suitable for tile mounting. The drive is mounted sideways with the side panel against the mounting surface. Tile mounting kits are available.

100

Unidrive M/HS Frame 3 and 4 Power Installation Guide

section

Issue Number: 3

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

2 Product information

2.1 Introduction

2.2 Model number

2.3 Nameplate description

2.4 Ratings

2.5 Drive features

2.6 Items supplied with the drive

3 Mechanical installation

3.1 Safety information

3.2 Planning the installation

3.3 Terminal cover removal

3.4 Dimensions and mounting methods

3.5 Enclosure for standard drives

3.6 Enclosure design and drive ambient temperature

3.7 Heatsink fan operation

3.8 Enclosing standard drive for high environmental protection

3.9 Installation of high IP insert for size 3 and 4

3.10 Size 3 and 4 internal braking resistor

3.11 External EMC filter

3.12 Terminal size and torque settings

3.13 Routine maintenance

4 Electrical installation

4.1 Power and ground connections

4.2 AC Supply requirements

4.3 Supplying the drive with DC

4.4 DC bus paralleling

4.5 24 Vdc supply

4.6 Low voltage operation

4.7 Fan power supply

4.8 Ratings

4.9 Output circuit and motor protection

4.10 Braking

4.11 Ground leakage

4.12 EMC (Electromagnetic compatibility)

Technical data

5.1 Drive technical data

5.2 Optional external EMC filters

UL listing information

6.1 General

6.2 Overload, overcurrent and overspeed protection

6.3 Short-circuit protection for branch circuits

6.4 Control circuit protection

6.5 Wiring terminal markings

6.6 Environment

6.7 Mounting