Control Techniques Unidrive 1201, UNI1204, Unidrive 1202, Unidrive 1203, Unidrive 1204 User Manual
...
EF
www.controltechniques.com
User Guide
Unidrive
Model sizes 1 to 5
Universal Variable Speed AC Drive
for induction and servo motors
Part Number: 0460-0083-09
Issue Number: 9
General Information
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 software version
This product is supplied with the latest version of user-interface and machine control software. If this product is to be
used in a new or existing system with other drives, there may be some differences between their software and the
software in this product. These differences may cause this product to function differently. This may also apply to drives
returned from a Control Techniques Service Centre.
If there is any doubt, contact a Control Techniques Drive Centre.
Environmental statement
Control Techniques 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 www.greendrives.com.
The electronic variable-speed drives manufactured by Control Techniques 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 can very easily be dismantled into their
major component parts for efficient recycling. Many parts snap together and can be separated without the use of tools,
whilst other parts are secured with conventional screws. 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, whilst smaller
products come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these
containers can be recycled. Polyethylene, used on the protective film and bags for wrapping product, can be recycled in
the same way. Control Techniques' packaging strategy favours 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.
Copyright © August 2003 Control Techniques Drives Limited
Issue Number: 9
Software: V03.02.12 onwards
How to use this User Guide
This User Guide provides complete information for installing and operating a Unidrive from start to finish.
The information is in logical order, taking the reader from receiving the drive through to fine tuning the performance.
NOTE
There are specific safety warnings throughout this guide, located in the relevant sections. In addition, Chapter 1 Safety
Information on page 7 contains general safety information. It is essential that the warnings are observed and the
information considered when working with or designing a system using the drive.
This map of the user guide helps to find the right sections for the task you wish to complete:
1 Safety information
2 Product information
3 Mechanical installation
4 Electrical installation
5 Getting started
6 Menu 0
7 Running the motor
8 Optimisation
9 Macros
10 Advanced parameters
11 Technical data
12 Diagnostics
13 UL listing information
Contents
Declaration of Conformity ................... 6
1 Safety Information .................................7
1.1 Warnings, Cautions and Notes .............................7
1.2 Electrical safety - general warning ........................7
1.3 System design and safety of personnel ................7
1.4 Environmental limits ..............................................7
1.5 Compliance with regulations .................................7
1.6 Motor .....................................................................7
1.7 Adjusting parameters ............................................7
2 Product Information ..............................8
2.1 Ratings ..................................................................8
2.2 Model number .......................................................8
2.3 Nameplate description - drive identification ..........9
2.4 Model variants .......................................................9
2.5 Operating modes .................................................10
2.6 Drive features ......................................................11
2.7 Option Modules ...................................................12
2.8 More information .................................................12
2.9 Items supplied with the drive ...............................13
3 Mechanical Installation .......................14
3.1 Safety information ...............................................14
3.2 Planning the installation ......................................14
3.3 Terminal cover removal .......................................14
3.4 Ingress protection ................................................15
3.5 Option module fitting / removal ...........................15
3.6 Mounting methods ...............................................16
3.7 Enclosure ............................................................24
3.8 Ventilation ...........................................................26
3.9 Baffle plates ........................................................28
3.10 Ambient temperature ...........................................28
3.11 RFI filters .............................................................29
3.12 Power terminals ..................................................35
3.13 Routine maintenance ..........................................36
4 Electrical Installation ...........................37
4.1 Power connections ..............................................37
4.2 AC supply requirements ......................................40
4.3 Supplying the drive with DC / DC bus paralleling 40
4.4 Ratings ................................................................40
4.5 Output circuit and motor protection .....................41
4.6 Braking ................................................................43
4.7 Ground leakage ...................................................44
4.8 EMC (Electromagnetic compatibility) ..................44
4.9 Control connections ............................................49
4.10 Encoder connections ...........................................54
4.11 Configuring a Unidrive size 5 system ..................56
5 Getting Started .................................... 58
5.1 Understanding the display .................................. 58
5.2 Keypad operation ............................................... 58
5.3 Menu structure ................................................... 59
5.4 Advanced keypad functions ............................... 60
5.5 Menu 0 ............................................................... 60
5.6 Advanced menus ............................................... 60
5.7 Changing the operating mode ............................ 61
5.8 Saving parameters ............................................. 61
5.9 Defaulting the drive ............................................ 61
5.10 Parameter security ............................................. 62
5.11 Serial Communications ...................................... 63
6 Menu 0 ................................................. 64
6.1 Single line descriptions ...................................... 64
6.2 Menu 0 full descriptions ..................................... 72
7 Running the motor .............................. 81
7.1 Quick start set-up ............................................... 81
7.2 Quick Start commissioning ................................. 84
7.3 Quick start P.C. commissioning (UniSoft /
VTCSoft) ............................................................ 87
8 Optimisation ........................................ 92
8.1 Motor map parameters ....................................... 92
8.2 Current limits ...................................................... 98
8.3 Motor thermal protection .................................... 99
8.4 Switching frequency ........................................... 99
8.5 High speed operation ......................................... 99
9 Macros ............................................... 101
9.1 Introduction ...................................................... 101
9.2 How to load a macro ........................................ 102
9.3 Macro terminal connection changes ................ 102
9.4 Macro logic diagrams and Menu 0 parameter
changes ............................................................ 106
9.5 Unidrive VTC macro differences ...................... 122
4 Unidrive User Guide
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10 Advanced Parameters ......................123
10.1 Menu 1: Speed references and limits ...............124
10.2 Menu 2: Ramps (accel. / decel.) .......................128
10.3 Menu 3: Speed feedback / frequency slaving ...131
10.4 Menu 4: Current control ....................................135
10.5 Menu 5: Machine control ...................................139
10.6 Menu 6: Sequencing logic .................................143
10.7 Menu 7: Analog I/O ...........................................145
10.8 Menu 8: Digital I/O ............................................148
10.9 Menu 9: Programmable logic ............................152
10.10 Menu 10: Status flags / trip log .........................155
10.11 Menu 11: Menu 0 customisation / drive specific
ratings ...............................................................156
10.12 Menu 12: Programmable thresholds .................157
10.13 Menu 13: Digital lock / orientation .....................160
10.14 Menu 14: Programmable PID function ..............166
10.15 Menu 15: Regen ...............................................169
10.16 Menu 16 Small option module set-up ...............171
10.17 Menu 17: Large option module set-up ..............179
10.18 Menu 18: Application menu 1 ...........................179
10.19 Menu 19: Application menu 2 ...........................180
10.20 Menu 20: Large option module .........................180
10.21 Unidrive VTC parameter range and default
differences ........................................................181
10.22 Advanced Features ...........................................182
11 Technical Data ...................................190
11.1 Drive ..................................................................190
11.2 Optional RFI filters ............................................197
12 Diagnostics ........................................198
12.1 Trip indications ..................................................198
12.2 Alarm indications ...............................................204
12.3 Status indications ..............................................204
12.4 Displaying the trip history ..................................204
13 UL Listing Information ......................205
13.1 AC supply specification .....................................205
13.2 Maximum continuous output current .................205
13.3 Safety label .......................................................205
Index ...................................................206
Unidrive User Guide 5
Issue Number: 9 www.controltechniques.com
Declaration of Conformity
Control Techniques Ltd
The Gro
Newtown
Powys
UK
SY16 3BE
UNI1201 UNI1202 UNI1203 UNI1204 UNI1205
UNI2201 UNI2202 UNI2203
UNI3201 UNI3202 UNI3203 UNI3204
UNI1401 UNI1402 UNI1403 UNI1404 UNI1405
UNI2401 UNI2402 UNI2403
UNI3401 UNI3402 UNI3403 UNI3404 UNI3405
UNI4401 UNI4402 UNI4403 UNI4404 UNI4405
UNI5401
The AC variable speed drive products listed above, including the VTC,
LFT (all sizes) and REGEN (UNI3401 to UNI4405 only) variants, have
been designed and manufactured in accordance with the following
European harmonised, national and international standards:
EN 60249 Base materials for printed circuits
IEC326-1
IEC326-5
IEC326-6
IEC664-1
EN 60529
UL94 Flammability rating of plastic materials
UL508C Standard for power conversion equipment
EN 50081-1
EN 50081-2
EN 50082-2
EN 61800-3
Printed boards: general information for the
specification writer
Printed boards: specification for single- and doublesided printed boards with plated-through holes
Printed boards: specification for multilayer printed
boards
Insulation co-ordination for equipment within lowvoltage systems: principles, requirements and tests
Degrees of protection provided by enclosures (IP
code)
Generic emission standard for the residential,
1
commercial and light industrial environment
Generic emission standard for the industrial
environment
Generic immunity standard for the industrial
environment
Adjustable speed electrical power drive systems - Part
3: EMC product standard including specific test
methods
These products comply with the Low Voltage Directive 73/23/EEC, the
Electromagnetic Compatibility (EMC) Directive 89/336/EEC and the CE
Marking Directive 93/68/EEC.
W. Dru ry
Executive Vice President, Technology
Newtown
Date: 26 September 2001
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 assemblers 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. A Unidrive EMC Data Sheet is also
available giving detailed EMC information.
1
Conducted emission sizes 1 to 3, not size 4 or 5. See the relevant EMC
Data Sheet.
6 Unidrive User Guide
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Safety
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Product
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Mechanical
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Electrical
Installation
Getting
Star ted
Menu 0
Running
the motor
Optimisation Macros
Advanced
Parameters
Technical
Data
Diagnostics
UL Listing
Information
1 Safety Information
1.1 Warnings, Cautions and Notes
A Warning contains information which is essential for
avoiding a safety hazard.
WARNING
A Caution contains information which is necessary for
avoiding a risk of damage to the product or other equipment.
CAUTION
NOTE
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 User 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 voltage 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 and
maintenance must be carried out by personnel who have the necessary
training and experience. They must read this safety information and this
User Guide carefully.
The STOP function of the drive does not remove dangerous voltages
from the output of the drive or from any external option unit.
Careful consideration must be given to the functions of the drive which
might result in a hazard, either through their intended functions or
through incorrect operation due to a fault.
In any application where a malfunction of the drive could lead to
damage, loss or injury, a risk analysis must be carried out, and where
necessary, further measures taken to reduce the risk.
The STOP and START controls or electrical inputs of the drive must
not be relied upon to ensure safety of personnel. If a safety hazard
could exist from unexpected starting of the drive, an interlock that
electrically isolates the drive from the AC supply must be installed
to prevent the motor being inadvertently started.
To ensure mechanical safety, additional safety devices such as electromechanical interlocks and overspeed protection devices may be
required. The drive must not be used in a safety critical application
without additional high integrity protection against hazards arising from a
malfunction.
Under certain conditions, the drive can suddenly discontinue control of
the motor. If the load on the motor could cause the motor speed to be
increased (e.g. in hoists and cranes), a separate method of braking and
stopping must be used (e.g. a mechanical brake).
1.4 Environmental limits
Instructions in this User 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.
1.5 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 earth (ground) connections.
This User 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:
98/37/EC: Safety of machinery.
89/336/EEC: Electromagnetic Compatibility.
1.6 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 fitted with a protection
thermistor. If necessary, an electric forced vent fan should be used.
1.7 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 User Guide 7
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2 Product Information
2.1 Ratings
Table 2-1 200V drive ratings (200V to 240V ±10%)
Model
Nominal
rating
kW hp
1201 0.37 0.5 2.1 2.4
1202 0.55 0.75 2.8 3.5
1203 0.75 1 3.8 4.6
1204 1.1 1.5 5.6 6.5
1205 2.2 3 9.5 8.6
2201 3 4 12 10.8
2202 4 5 16 14.3
Output
current*
(A)
Menu 0
the motor
Typical
Input
current (A)
Running
Optimisation Macros
Advanced
Parameters
Technical
Data
Diagnostics
* The output currents are given for maximum 40°C (104°F)
ambient, 1,000m altitude and 3kHz switching. Derating is
required for higher switching frequencies, ambient temperatures
>40°C (104°F) and high altitudes. For further information, refer
to section 11.1.1 Power and current ratings on page 190.
** Multiples of 300A output current with 120% overload or multiples
of 240A with 150% overload
NOTE
N
A Unidrive size 5 consists of a control module with one or more power
modules connected in parallel.
i.e. UNI5401 = 1 x control module and 1 x power module
UNI5402 = 1 x control module and 2 x power modules etc.
2.2 Model number
The way in which the model numbers for the Unidrive range are formed
is illustrated below.
UL Listing
Information
2203 5.5 10 25 19.8
3201 7.5 15 34 26
3202 11 20 46 39
3203 15 25 60 53
3204 22 30 74 78
Table 2-2 400V drive ratings (380V to 480V ±10%)
Model
Nominal rating
@380V @460V
kW hp
1401 0.75 1 2.1 3.0
1402 1.1 1.5 2.8 4.3
1403 1.5 2 3.8 5.8
1404 2.2 3 5.6 8.2
1405 4 5 9.5 10.0
2401 5.5 7.5 12 13.0
2402 7.5 10 16 17.0
2403 11 15 25 21.0
3401 15 25 34 27
3402 18.5 30 40 32
3403 22 30 46 40
3404 30 40 60 52
3405 37 50 70 66
4401 45 75 96 76
4402 55 100 124 91
4403 75 125 156 123
4404 90 150 180 145
Output
current*
(A)
Typical
Input
current
(A)
UNI
Model:
UNI - Unidrive
Model
size:
1 - Size 1
2 - Size 2
3 - Size 3
4 - Size 4
5 - Size 5
12
Voltage
rating:
2 - 200V
4 - 400V
Power rating:
Depends on
model size.
See section 2.1
Ratings
05
LFT LV
Model variant:
- Standard
variant
LFT - LFT variant
VTC - VTC variant
REGEN - Regen
variant
See section 2.4
Model variants
more details
Voltage rating:
LV - Low voltage (200V)
- Medium voltage (400V)
for
4405 110 150 202 181
5401 160 200 300** 280
5402 320 400 600** 560
5403 480 600 900** 840
5404 640 800 1200** 1120
5
5405 800 1000 1500** 1400
5406 960 1200 1800** 1680
5407 1120 1400 2100** 1960
5408 1280 1600 2400** 2240
8 Unidrive User Guide
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2.3 Nameplate description - drive
identification
The drive label is found on the top surface of the control pod (right
angles to the display) on Unidrive sizes 1 to 3 and size 5 control module,
and on the side of the Unidrive size 4 and size 5 power module.
Figure 2-1 Typical drive rating labels
Optimisation Macros
Advanced
Parameters
Technical
Data
Diagnostics
UL Listing
Information
Unidrive size 1 to 4 rating label
ve type
(STD,LV,
VTC, LFT)
Power rating
Model
UNI3401 VTC 15kW
Drive
ratings
VOLTAGE 50/60 Hz 3Ph
CURRENT (A)
OVERLOAD: 40.8A FOR 60 SECS
SOFTWARE VERSION: 03.02.11
Unidrive size 5 control module rating label
UNIDRIVE SIZE 5
CONTROL MODULE HW2
IT IS ESSENTIAL TO READ
THE MANUAL BEFORE
CONNECTING THE DRIVE.
SOFTWARE VERSION: 03.02.11
3000005001
INPUT OUTPUT
380/480V 380/480V
27A 34.0A
TO BE USED IN CONJUNCTION
WITH UNIDRIVE SIZE 5 HW2
POWER MODULES (S)
STDL01
IND.
R
CONT..
EQ.
MADE IN THE U.K.
STDJ41
IT IS ESSENTIAL TO READ
THE MANUAL BEFORE
CONNECTING THE DRIVE.
IND.
CONT..
EQ.
MADE IN THE U.K.
Customer and
date code
R
Hardware
revision
Customer and
date code
Approvals
Approval
Key to Approvals
CE approval Europe
C Tick approval Australia
UL / cUL approval
R
USA &
Canada
Unidrive size 5 power module rating label
Drive
ratings
UNI5401 POWER MODULE HW2 110V FAN FITTED
VOLTAGE 50/60 Hz 3Ph
CURRENT (A)
Dual current
ratin
OVERLOAD: 150 FOR 60 SECS
OVERLOAD: 120 FOR 60 SECS
IT IS ESSENTIAL TO READ
THE MANUAL BEFORE
CONNECTING THE DRIVE.
INPUT OUTPUT
380/480V 380/480V
220.0A 240.0A
280.0A 300.0A
2.4 Model variants
2.4.1 Unidrive standard industrial (STD)
...for constant torque loads (All frame sizes)
Operating modes:
Open Loop
Closed Loop vector
Servo
Regen
Overload:
Open loop 150% for 60s
Closed loop vector 175% for 60s (sizes 1 to 4), 150%* for 60s (size
5)
Servo 175% for 4s (sizes 1 to 4), 150%* for 4s (size 5)
Regen 150% for 60s
* Multiples of 300A output current with 120% overload or multiples of
240A with 150% overload
Customer and
STDL01
HEATSINK FAN
110V/120V 50/60HZ
IND.
CONT..
R
EQ.
MADE IN
THE U.K.
date code
Heatsink fan
ratings
Approvals
Figure 2-2 Constant torque load
Percent kW
and torque
100
80
60
40
20
0
Torque
50 10
Percent s
kW
eed
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Technical
Data
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UL Listing
Information
2.4.2 Unidrive LFT
...for lift applications
Overloads and operating modes as Unidrive standard industrial, in
addition:
low acoustic noise
9kHz default switching frequency
S4/S5 duty cycle only
Figure 2-3 Standard S4/S5 duty cycle (Unidrive LFT)
150%
100%
Frequency / speed
0
Current
0
2
50Hz
RPM
1500
2
2.4.3 Unidrive VTC
...for quadratic load (variable torque) applications (fans and pumps)
Open loop fixed boost mode only
120% overload for 60s
Figure 2-4 Variable torque mode
ercent kW
and torque
100
80
60
40
20
0
Torque
50 10
Percent s
kW
eed
2.4.4 Unidrive REGEN
All sizes of Unidrive can be used in regen mode. However, Unidrive
sizes 3 and 4 require an internal modification before being used in a
regen system.
This modification is already completed if the drive has been ordered as a
Unidrive REGEN.
2.5 Operating modes
All variants of Unidrive (except VTC) are designed to operate in any of
the following modes:
1. Open loop mode
V/f mode (V/ Hz)
Open loop vector
2. Closed loop vector
3. Servo
4. Regen
Unidrive VTC can only operate in open loop quadratic V/f mode.
2.5.1 Open Loop mode (OL)
For use with standard AC induction motors.
The drive applies power to the motor at frequencies varied by the user.
The motor speed is a result of the output frequency of the drive and slip
due to the mechanical load. The drive can improve the performance of
the motor by applying slip compensation. The performance at low speed
depends on whether V/f mode or open loop vector mode is selected.
V/f mode
The voltage applied to the motor is directly proportional to the frequency
except at low speed where a voltage boost is provided which is set by
the user. This mode should used for multi-motor applications.
Typically 100% torque at 4Hz.
Open loop vector mode
The voltage applied to the motor is directly proportional to the frequency
except at low speed where the drive uses motor parameters to apply the
correct voltage to keep the flux constant under varying load conditions.
Typically 100% torque at 1Hz.
2.5.2 Closed loop vector mode (VT)
For use with induction motors with a speed feedback device fitted.
The drive directly controls the speed of the motor using the feedback
device to ensure the rotor speed is exactly as demanded. Motor flux is
accurately controlled at all times to provide full torque all the way down
to zero speed.
Typically 175% torque at 0rpm.
2.5.3 Servo (SV)
For use with permanent magnet brushless motors with a speed and
position feedback device fitted.
The drive directly controls the speed of the motor using the feedback
device to ensure the rotor speed is exactly as demanded. Flux control is
not required because the motor is self excited by the permanent
magnets which form part of the rotor.
Absolute position information is required from the feedback device to
ensure the output voltage is accurately matched to the back EMF of the
motor.
Typically 175% torque at 0rpm
2.5.4 Regen
For use as a regenerative front end for four quadrant operation.
Regen operation allows bi-directional power flow to and from the AC
supply. This provides far greater efficiency levels in applications which
would otherwise dissipate large amounts of energy in the form of heat in
a braking resistor.
The harmonic content of the input current is negligible due to the
sinusoidal nature of the waveform when compared to a conventional
bridge rectifier or thyristor front end.
See the Regen Installation Guide for more information on this operating
mode.
2.5.5 Key to operating mode abbreviations
Abbreviations are throughout this User Guide to define the operating
mode for which the information applies as follows:
OL> Open loop
CL> Closed loop (which incorporates closed loop vector and
servo mode)
VT> Closed loop vector mode
SV> Servo
10 Unidrive User Guide
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2.6 Drive features
Figure 2-5 Features of the drive (Size 1 to 5)
Menu 0
Running
the motor
Upper display
Lower display
Optimisation Macros
Advanced
Parameters
Technical
Data
Diagnostics
UL Listing
Information
Programming keys
Large option
module connection
Encoder connection
{
Control keys
Forward / Reverse
Stop / Reset
Run
Small option
module connection
Control connectors
AC
In
AC
In
5
NOTE
CInAC
Out
ACInAC
Out
N
ACInAC
Out
ACInAC
Out
Sharing
choke
AC
Out
Sharing
choke
AC
Out
Unidrive size 5 consists of a control module and one or more power
modules.
For power ratings greater than 160kW / 200hp, multiple power modules
(up to a maximum of 8) can be connected in parallel.
When multiple power modules are used, an output sharing choke is
required before the drive outputs are connected together.
Unidrive User Guide 11
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2.7 Option Modules
The following option modules are available for use with Unidrive.
Figure 2-6 Unidrive options available for all sizes
Running
the motor
Optimisation Macros
Advanced
Parameters
Technical
Data
Diagnostics
UL Listing
Information
Applications
Applications
F3
UD70
module
module
UD73 UD74 UD75
Profibus-DP Interbus CT Net Modbus
UD78 UD71
Servo RS232
RS485
9901 11
destination addr
F1
F2
M
Universal
Keypad
Unidrive sizes 1 to 4 have built in braking transistors; for Unidrive size 5
a braking option can be fitted if required as shown below:
Figure 2-7 Braking option available for Size 5
UD55 UD53 UD52 UD51 UD50
Cloning
module
Resolver Sin Cos
Encoder
UD76
Pl
Second
Encoder
UD77 UD77
Device
N
CAN CANopen
Extra I/O
The drive must be powered down for a minimum duration of
10 minutes before an option module is fitted or removed.
WARNING
UD77
2.8 More information
The following manuals are also available providing full information on the
various option modules, regen mode and advanced product use:
• Unidrive Advanced User Guide
• Regen Installation Guide
Size 5 Braking
option
• UD50 User Guide (Additional I/O small option module)
• UD51 User Guide (Second encoder small option module)
• UD52 User Guide (SINCOS encoder interface small option module)
• UD53 User Guide (Resolver interface small option module)
• UD55 User Guide (Cloning interface small option module)
• UD70 User Guide (Large option module and software)
• UD71 User Guide (Serial communications large option module)
• UD73 User Guide (Profibus-DP large option module)
• UD74 User Guide (Interbus large option module)
• UD75 CT Net User Guide (Large option module)
• UD76 User Guide (Modbus Plus large option module)
• UD77 User Guide (Device Net large option module)
• UD78 User Guide (Servo large option module)
• CAN User Guide (Large option module)
• CANopen User Guide (Large option module)
• Universal Keypad User Guide
• Universal Keypad Advanced User Guide
Please also see the Unisoft drive commissioning software which
contains a help file detailing full advanced parameter descriptions and
other useful information.
12 Unidrive User Guide
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2.9 Items supplied with the drive
Size 1 Size 2 Size 3 Size 4 Size 5 control Size 5 power
Certificate of quality Certificate of quality Certificate of quality Certificate of quality Certificate of quality Certificate of quality
Safety Booklet Safety Booklet Safety Booklet Safety Booklet Safety Booklet
Mounting brackets Mounting brackets Mounting brackets Mounting brackets Mounting brackets
Interface leads
UL Listing
Control connectors Control connectors Control connectors Control connectors Control connectors
345678910
12
21 22 23 24 25 26 27 28 29 30 3121 22 23 24 25 26 27 28 29 30 31
11
345678910
12
21 22 23 24 25 26 27 28 29 30 3121 22 23 24 25 26 27 28 29 30 31
11
345678910
12
21 22 23 24 25 26 27 28 29 30 3121 22 23 24 25 26 27 28 29 30 31
11
345678910
12
21 22 23 24 25 26 27 28 29 30 3121 22 23 24 25 26 27 28 29 30 31
11
345678910
12
21 22 23 24 25 26 27 28 29 30 3121 22 23 24 25 26 27 28 29 30 31
Gasket foam Gasket foam Gasket foam Gasket foam UL Warning label
CAUTION
Risk of Electric Shock
Power down unit 10minutes
before removing cover
-
.
+
Power connector
UL Warning label UL Warning label
CAUTION
Risk of Electric Shock
Power down unit 10minutes
before removing cover
CAUTION
Risk of Electric Shock
Power down unit 10minutes
before removing cover
Power connector
L3
L1 L2
U
VW
UL Warning label UL Warning label
CAUTION
Risk of Electric Shock
Power down unit 10minutes
before removing cover
CAUTION
Risk of Electric Shock
Power down unit 10minutes
before removing cover
11
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3 Mechanical Installation
This chapter describes how to use all mechanical features to install the
drive. Key features of this chapter include:
• Option module fitting
• Mounting methods
• Enclosure sizing and layout
• Terminal location and torque settings
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
WARNING
WARNING
3.2 Planning the installation
The following considerations must be made when planning the
installation:
3.2.1 Access
Access must be restricted to authorised personnel only. Safety
regulations which apply at the place of use must be complied with.
3.2.2 Environmental protection
The drive must be protected from:
• moisture, including dripping water or spraying water and
• contamination with electrically conductive material
• contamination with any form of dust which may restrict the fan, or
• temperature beyond the specified operating and storage ranges
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, please refer to section 3.7.2 Enclosure sizing on
page 24.
3.2.4 Electrical safety
The installation must be safe under normal and fault conditions.
Electrical installation instructions are given in Chapter 4 Electrical
Installation on page 37.
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.
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.
condensation. An anti-condensation heater may be required, which
must be switched off when the drive is running.
impair airflow over various components
Optimisation Macros
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. These will include the use of RFI filters 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
4.8 EMC (Electromagnetic compatibility) on page 44.
Advanced
Parameters
Technical
Data
Diagnostics
UL Listing
Information
3.2.7 Hazardous areas
The drive must not be located in a classified hazardous areas unless it is
installed in an approved enclosure and the installation is certified.
3.3 Terminal cover removal
Isolation device
The AC supply must be disconnected from the drive using an
approved isolation device before any cover is removed from
WARNING
WARNING
3.3.1 Removing the terminal covers
Unidrive sizes 1 to 4 and the size 5 control module are fitted with one or
two terminal covers depending on the model size. When model sizes 1,
3 and 4 are through-panel mounted, the terminal cover(s) must first be
removed in order for access to be gained to the lower mounting holes.
Figure 3-1 Removing the terminal covers
The terminal cover(s) of all models must be removed for access to the
electrical connectors.
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 supply has been
disconnected. If the drive has been energised, the AC
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 Control
Techniques or their authorised distributor.
3.2.5 Fire protection
The drive enclosure is not classified as a fire enclosure. A separate fire
enclosure must be provided.
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.
14 Unidrive User Guide
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Figure 3-2 View from the underside showing how a terminal cover
is removed from the drive
Remove terminal covers, as follows:
1. Working on either side of the terminal cover, push the inner edge of
the cover firmly outward until it becomes unclipped.
2. Swing the side of the cover outward and upward until the remaining
clips become released.
3. Remove the gland plate
Figure 3-3 Removing the three terminal covers on the Size 5
power module
Optimisation Macros
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Parameters
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Data
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Information
3.4 Ingress protection
Size 1 to 4:
Gland plate(s) not fitted: IP00
Gland plate(s) fitted; cable glands not fitted: IP10
Gland plate(s) fitted; cable-glands fitted: IP40, NEMA 1
Size 5 power and control modules: IP00
3.5 Option module fitting / removal
Power down the drive before fitting / removing an option
module. Failure to do so may result in damage to the product.
CAUTION
The small option module should be placed under the two green securing
clips in the main housing beneath the drive display and pushed firmly
into place. Ensure the two connectors mate securely.
Figure 3-4 Fitting of a Unidrive small option module
The large option module slides into the space directly beneath the drive
display so that only the front face of the module can be seen. Ensure the
module clicks into place indicating that the two connectors have mated
successfully.
Figure 3-5 Fitting of a Unidrive large option module
M5 pozidriv
screw
Remove the three terminal covers on the power module, as follows:
1. Remove the two pozidriv screws.
2. Remove the upper cover.
3. Remove the two pozidriv screws.
4. Remove the lower cover until it is released from the middle cover.
5. Remove the four screws that are now revealed.
6. Remove the middle cover.
All the power terminals and ribbon-cable connectors are now accessible.
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3.6 Mounting methods
Unidrive sizes 1 to 4 can be either through hole or surface mounted
using the appropriate brackets.
The Unidrive size 5 consists of two modules:
• the control module should be surface mounted
• the power module must be through hole mounted.
The following drawings show the dimensions of the drive and mounting
holes for each method to allow a back plate to be prepared.
Figure 3-6 Surface mounting of model sizes 1 and 2
Model
size 1
13.189in 14.409in
WARNING
WARNING
Lifting the drive
The weights of model sizes 3 and 4 are 22kg (49lbs) and
70kg (154lbs) respectively; the size 5 power module exceeds
100kg (220lbs). Use appropriate safeguards when lifting
these models.
If the drive has been used at high load levels for a period of
time, the heatsink may be hot. Human contact with the
heatsink should be restricted.
0.787in
Back-plate
13.524in
0.787in
13.031i
Model
size 2
3.740in
3.740in
1.870in
13.189in 14.409in
7.874in
Back-plate
0.650in
13.524in
0.650in
7.480in
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Figure 3-7 Surface mounting of model sizes 3 and 4
Model
size 3
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Back-plate
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Data
1.772in
Diagnostics
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Model
size 4
14.764in
7.382in
9.843in
13.189in 14.488in
27.559in30.118
in
10.236in
Back-plate
0.650in
0.669in
13.622i
6.890in
0.650in
0.669in
28.071in
19.685in
2.559in 2.559in5.650in 5.650in
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Figure 3-8 Through-panel mounting of model sizes 1 and 2
Model
size 1
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Parameters
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Model
size 2
7.480in
3.740in
13.189in
13.189in
14.331in
14.331in
7.874in
4.724in
3.150
in
11.614in 13.583in
0.512in
3.406in
0.650in
Back-plate
11.614in 13.583i
0.512in
0.650in
7.165in
NOTE
N
When drives are through-panel mounted, a baffle plate is required to
ensure the correct level of air-flow is maintained through the heatsink.
For further information, please refer to section 3.9 Baffle plates on
page 28.
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Figure 3-9 Through-panel mounting of model sizes 3 and 4
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Parameters
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Data
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Information
Model
size 3
Model
size 4
14.764in
13.189in 14.331in
10.236in
4.724in 5.512in
Back-plate
11. 299 in
0.276in0.630
0.138in 2.559in
0.650in
in
5.177in 7.362in
0.650in
13.583in
2.717in2.717in
14.094in
27.559in 29.252in
19.685in
NOTE
N
When drives are through-panel mounted, a baffle plate is required to
ensure the correct level of air-flow is maintained through the heatsink.
For further information, please refer to section 3.9 Baffle plates on
page 28.
25.591in 28.248in
Back-plate
0.295in
0.669in
5.118in 5.118in
7.559in 9.902in
1
72in
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Figure 3-10 Unidrive Size 5 overall dimensions
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35.5mm
(1.398in)
Advanced
Parameters
Technical
Data
Diagnostics
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Information
315mm
(12.402in)
1248mm
(49.134in)
35.5mm
(1.398in)
278mm
(10.945in)
1319mm
(51.926in)
355mm
(13.976in
340mm
(13.386in)
484mm
(19.055in)
144mm
(5.669in)
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Figure 3-11 Unidrive Size 5 mounting dimensions
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Rear view of
power module
Heatsink
duct
1248mm
(49.134in)
278mm
(10.945in)
Exhaust port
Heatsink
duct
144mm
(5.669in)
Exhaust
port
Side view of
power module
Inlet port
(internal fan)
154mm
(6.063in)
139mm
(5.472in)
256mm
(10.079in)
Inlet port
(external fan)
Inlet port
(internal fan)
Alternative
inlet port
(external fan)
144mm
5.669in)
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Figure 3-12 Unidrive size 5 backplate mounting holes and aperture
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Parameters
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Outline of
the power
module
Aperture
Location of aperture in relation to
the outline of the power module
16.5mm
33.5mm
0.650in
1.319in
20mm
0.787in
1319mm
51.929in
1252mm
49.291in
315mm
12.402in
282mm
11.102in
16.5mm
0.650in
20mm
0.787in
1286mm
50.630in
Locations and dimensions of the
mounting holes in relation to the aperture
203mm
7.992in
∅
11m m
0.433in
339mm
13.346in
23.5mm
0.925in
28.5mm
1.122in
670mm
26.378in
37.5mm
1.476in
∅
8mm
0.315in
590mm
23.228in
37.5mm
1.476in
28.5m
1.122in
8mm
∅
0.315in
33.5mm
1.319in
Figure 3-13 Unidrive Size 5 control module surface mounting
Back-plate
NOTE
335mm
(13.189in)
47.5mm
(1.870in)
95mm
(3.740in)
N
368mm
(14.488in)
143mm
(5.630in)
The Unidrive size 5 control module should be located within 2m of the
power module to allow the interconnections to be made using the ribbon
cables supplied with the power module.
10mm
0.413in
(0.787in)
345mm
(13.583in)
mm
11m m
in
20mm
(0.787in)
332mm
(13.071in)
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Table 3-1 General views of the mounting brackets
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Parameters
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Model
size
1
2
3
Through-panel Surface Hole size
M6
Upper and lower
M6
Upper and lower
Upper
M6
Lower
M6
(through-
panel)
4
Upper
M8
(surface)
Lower
5
M6
Upper and lower
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3.7 Enclosure
3.7.1 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 3-14 Enclosure layout
AC supply
> 100mm
(3.937in)
contactor and
fuses or MCB
Optional
RFI filter
Ensure minimum clearances
are maintained for the
drive and RFI filter
Forced or convection air-flow
must not be restricted by any
object or cabling
Control
module
(size 5
only)
> 5mm
(0.197in)
Optimisation Macros
Locate
as required
> 100mm
(3.937in)
> 5mm
(0.197in)
> 100mm
(3.937in)
Advanced
Parameters
Locate as close to
the drive as possible
(to keep the cable
as short as possible)
respecting the minimum
clearances
Technical
Data
Diagnostics
Note: for EMC compliance
1) A separate RFI filter is
required for each drive
2) Power cabling must be
at least 100mm (4in) from
the drive in all directions
UL Listing
Information
Drive
> 5mm
Controller
Signal cables
Plan for all signal cables
to be routed at least
300mm (12in) from the drive
and any power cable
(0.197in)
> 100mm
(3.937in)
3.7.2 Enclosure sizing
1. Add the dissipation figures from section 11.1.2 Power dissipation (all
versions) on page 191 for each drive that is to be installed in the
enclosure.
2. If an RFI filter is to be used with each drive, add the dissipation
figures from section 11.2.1 Ratings on page 197 for each RFI filter
that is to be installed in the enclosure.
3. If the braking resistor is to be mounted inside the enclosure, add the
average power figures for each braking resistor that is to be installed
in the enclosure.
4. Calculate the total heat dissipation (in Watts) of any other equipment
to be installed in the enclosure.
5. Add the heat dissipation figures obtained above. This gives a figure
in Watts for the total heat that will be dissipated inside the enclosure.
Note: Footprint RFI filters
are available for Unidrive
> 5mm
(0.197in)
Optional
braking resistor
and overload
Locate resistor
external to cubicle
(preferably near to
or at the top of the
cubicle)
frame sizes 1 and 2
Indicates minimu
clearance required
from device
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 A
enclosure from:
e
–()
kT
intText
P
-----------------------------------
A
=
Where:
A
Unobstructed surface area in m2 (1m2 = 10.8 ft2)
e
T
Maximum expected ambient temperature in
ext
enclosure
Maximum permissible ambient temperature in oC inside the
T
int
enclosure
P Power in Watts dissipated by all heat sources in the
enclosure
k Heat transmission coefficient of the enclosure material
2/o
in Wm
C
for the
e
o
C outside the
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Example
To calculate the size of an enclosure for the following:
• Two UNI1405 models
• Each drive to operate at 4.5kHz PWM switching frequency
• RFI 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
Dissipation of each drive: 190W
Dissipation of each RFI filter: 7.7W (max)
Total dissipation: 2 x (190 + 7.7) = 395.4W
The enclosure is to be made from painted 2mm (0.079 in) sheet steel
having a heat transmission coefficient of 5.5W/m
2/o
C. Only the top, front,
and two sides of the enclosure are to be free to dissipate heat.
Figure 3-15 Enclosure having front, sides and top panels free to
dissipate heat
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Parameters
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Diagnostics
Calculating the air-flow in a ventilated enclosure
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:
3kP
---------------------------
=
V
Where:
V Air-flow in m
T
ext
T
int
P Power in Watts dissipated by all heat sources in the
k Ratio of
Where:
Typically use a factor of 1.2 to 1.3, to allow also for pressure-drops in
dirty air-filters.
–
T
intText
3
per hour
Maximum expected ambient temperature in
enclosure
Maximum permissible ambient temperature in oC inside the
enclosure
enclosure
P
o
-------
P
l
P
is the air pressure at sea level
0
is the air pressure at the installation
P
I
UL Listing
Information
o
C outside the
H
D
W
Insert the following values:
T
40°C
int
30°C
T
ext
k 5.5
P 395.4W
The minimum required heat conducting area is then:
395.4
---------------------------------
A
=
e
5.5 40 30–()
2
=7.2m
(78ft2) (1m = 3.3 ft)
Estimate two of the enclosure dimensions - the height (H) and depth (D),
for instance. Calculate the width (W) from:
2HD–
A
e
--------------------------
=
W
HD+
Inserting H = 2m and D = 0.6m, obtain the minimum width:
7.2 2 2× 0.6×()–
----------------------------------------------
W
=
20.6+
= 1.8m (6ft)
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
Example
To calculate the size of an enclosure for the following:
• Three UNI3401 models
• Each drive to operate at 6kHz PWM switching frequency
• RFI filter for each drive
• Braking resistors are to be mounted outside the enclosure
• Maximum ambient temperature inside the enclosure: 40
• Maximum ambient temperature outside the enclosure: 30
Dissipation of each drive: 670W
Dissipation of each RFI filter: 12.8W (max)
Total dissipation: 3 x (670 + 60) = 2048.4W
Insert the following values:
T
40°C
int
30°C
T
ext
k 1.3
P 2048.4W
Then:
31.3× 2048.4×
------------------------------------------
V
=
40 30–
3
/ hr (471ft3 / min)
3
/min)
(1m
= 799m
3
/ hr = 0.59ft
o
C
o
C
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3.8 Ventilation
Unidrive sizes 1-4 are ventilated by internally supplied heatsink fans.
Ensure the minimum clearances around the drive are maintained to
allow air to flow freely.
The Unidrive size 5 requires ventilation at the front (control) and rear
(heatsink) of the module.
Two parallel independent paths must be provided as shown to ensure
the heat produced is dispersed.
A heatsink fan is fitted as standard on request however this requires
either a 110Vac or 240Vac external single phase power supply to be
connected at the bottom left hand corner of the power module.
The choice of fan power supply must be made when ordering the power
module.
3.8.1 Ventilation requirements for the Size 5 power
Figure 3-16 Typical ventilation arrangement using the internal
module
≥
300mm
(12 in)
Wall
heatsink fan
3
≥
1000m /hr
3
(588ft /min)
≥
7 m/s (23 ft/s)
Back-plate
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If a fan is not fitted internally, the air flow must be obtained by an external
fan and ducting. The blanking plate at the lower end of the duct must be
removed in order to expose the inlet port (see Figure 3-17).
The air supply must be obtained from outside the enclosure and the
exhaust air must exit the enclosure. The maximum permissible heatsink
temperature is 95°C (203°F). Take the following precautions to help
ensure this is not exceeded:
1. Ensure the temperature of the air at the inlet port of the heatsink
does not exceed 40°C (104°F).
2. Ensure that the upward flow of the exhaust air from the top of the
heatsink will be unobstructed. Fit additional ducting having the same
cross-sectional area as the heatsink to extract all the exhaust air
from the enclosure.
3. Ensure the volume of the exhaust air is not less than 1,000m
3
/min), equivalent airspeed 7m/s (23 ft/s). Measure the air-flow
(588ft
3
/hr
to ensure it is adequate.
4. If the power module has a ventilation fan fitted in the heatsink, to
ensure that a sufficient amount of air is available to supply the fan,
locate the enclosure at least 300mm (12 in) from a wall or large
object that will be behind the enclosure. Fit a duct between the rear
panel of the enclosure and the inlet port at the rear of the heatsink.
If the power module does not have an internal fan, a forced air-flow
must be ducted into the inlet port at the bottom of the heatsink.
5. Ensure that the exhaust air is not recycled into the inlet port of the
heatsink or into the enclosure.
Exhaust
duct
Heatsink
Inlet duct
3
400m /hr
≥
3
(235 ft /min)
1 m/s
≥
(3.3 ft/s)
≥
150mm (6 in)
≥
150mm
(6 in)
Vent
Enclosure
Power
module
Fan for
cooling the
control
section
NOTE
N
The solutions shown for Unidrive size 5 ventilation are to illustrate the
important points which must be considered. Many variations of this are
possible to suit the specific site conditions.
Sharing choke
(for parallel
operation only)
Cooling the heatsink
When designing the cooling system, allow for the rear of the power
module to produce 4kW of heat. This heat is dissipated in a heatsink that
is inside a vertical duct at the rear of the power module. Forced air-flow
is required through the duct in order to cool the heatsink.
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Figure 3-17 Typical ventilation arrangement using an external
heatsink fan
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≥
1000m /hr
3
(588ft /min)
≥
7 m/s
(23 ft/s)
Heatsink
aust duct
aust duct
Back-plate
3
≥
3
400m /hr
≥
3
(235 ft /min)
1 m/s
≥
(3.3 ft/s)
150mm
(6 in)
Vent
Enclosure
module
Power
≥
1000m /hr
3
(588ft /min)
≥
7 m/s
(23 ft/s)
3
3
≥
1000m /hr
3
(588ft /min)
≥
7 m/s
(23 ft/s)
≥
1000m /hr
(588ft /min)
≥
7 m/s
(23 ft/s)
3
3
Inlet duct
≥
150mm (6 in)
Fan for
cooling the
control
section
Sharing choke
(for parallel
operation only)
Cooling the control components in the Size 5 power module
The circuit boards, DC-bus capacitors, etc., in the front part of the power
module generate about 700W of heat when the power module is
operating at full load. Since the heatsink fan does not ventilate these
components, a separate air-flow must be used to remove the heat. The
following precautions must be taken:
1. It is recommended that a fan is installed in the lower part of the
enclosure door to drive air into the enclosure. An air vent should be
added to the upper part of the door to remove the exhaust air.
2. It is recommended that the airflow is ducted into the front of the
drive. This airflow must be at least 400m
air speed of 1m/s (3.3ft/s) through the front control section of the
size 5 power module.
If the airflow is not ducted into the front of the drive, the airflow into
the enclosure must be at least 1000m
speed of 7m/s (23ft/s) for a enclosure of 800mm x 800mm
x 2200mm.
3. The maximum temperature of the air in the enclosure must not
exceed 40°C (104°F).
3
/hr (235ft3/min), equivalent
3
/hr (588ft3/min), equivalent air
0
40 C
0
(104 F)
Inlet duct
Inlet duct
Figure 3-18 Alternative location of the exhaust duct in order to
minimize overall height
Exhaust duct
Back-plate
≥
150mm
(6 in)
Vent
Enclosure
Power
module
Heatsink
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3.9 Baffle plates
When a Unidrive size 1 to 4 is through-panel mounted, the fitting of a
baffle plate causes the heatsink to act as a chimney; this enhances the
air flow along the heatsink fins to aid cooling (this naturally occurs when
the drive is surface mounted).
You may make a baffle plate from any suitable conducting or nonconducting material and attach it to the heatsink by the method
described as follows.
Figure 3-19 Dimensions for the fabrication of baffle plates for
model sizes 1 and 2
3.228in 6.929in
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Figure 3-20 Dimensions for the fabrication of baffle plates for
model sizes 3 and 4
4.016in 7.697in
9.606in
1.614in
0.512in
1.535in
13.563in 14.449in
2.146in
1.969
in
0.276in
3.583in 5.118in
13.780in
189.5mm
3.780in
4.724in
7.461in
6.949in
22.047in
23.150in
3.425in
in
7.154in
Attaching a fabricated baffle plate to the heatsink
Table 3-2 Methods of attaching the baffle plate
Model size Method of attachment
1
2
3
4
Use M6 x 12mm max (or equivalent) thread-forming screws to
screw into the holes in the heatsink, or tap the holes to a suitable
Use the surface mounting brackets.
thread size.
17.236in
18.622in
0.693in
76mm
2.992in
3.10 Ambient temperature
The maximum ambient temperature under which the drive can operate
without derating is 40°C.
Derating can be applied to allow operation up to 50°C ambient
temperature.
Please see section 11.1.1 Power and current ratings on page 190 if
derating is required.
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3.11 RFI filters
RFI filters are available for all sizes of Unidrive as follows:
Table 3-3 RFI filters
Drive Filter type Schaffner part no. CT part no. Max cable size Weight
UNI1201 to 1205 Bookcase FS5111-10-29 4200-6105
UNI1201 to 1205
Footprint or
Bookcase
FS5101-10-07 4200-6104
UNI2201 to 2202 Bookcase FS5112-16-07 4200-6109
UNI2201 to 2202
Footprint or
Bookcase
FS5106-16-07 4200-6108
UNI2203 Bookcase FS5113-25-29 4200-6114
UNI2203
Footprint or
Bookcase
FS5106-25-07 4200-6113
UNI3201 to 3202 Bookcase FS5113-50-53 4200-6116
UNI3203 Bookcase FS5113-63-34 4200-6117
UNI3204 Bookcase FS5113-100-35 4200-6106
UNI1401 to 1405 Bookcase FS5111-10-29 4200-6105
UNI1401 - 1405
Footprint or
Bookcase
FS5101-10-07 4200-6104
UNI2401 Bookcase FS5112-16-07 4200-6109
UNI2401
Footprint or
Bookcase
FS5106-16-07 4200-6108
UNI2402 to 2403 Bookcase FS5113-25-29 4200-6114
UNI2402 to 2403
Footprint or
Bookcase
FS5106-25-07 4200-6113
UNI3401 to 3403 Bookcase FS5113-50-53 4200-6116
UNI3404 Bookcase FS5113-63-34 4200-6117
UNI3405 Bookcase FS5113-100-35 4200-6106
UNI4401 to 4402 Bookcase FS5113-150-40 4200-6107
UNI4403 to 4404 Bookcase FS5113-180-40 4200-6111
UNI4405 Bookcase FS5113-220-37 4200-6112
4 mm
4 mm
4 mm
4 mm
4 mm
4 mm
10 mm
10 mm
50 mm
4 mm
4 mm
4 mm
4 mm
4 mm
4 mm
10 mm
10 mm
50 mm
95 mm
95 mm
150 mm
2
10 AWG
2
10 AWG
2
10 AWG
2
10 AWG
2
10 AWG
2
10 AWG
2
6 AWG
2
6 AWG
2
1/0 AWG
2
10 AWG
2
10 AWG
2
10 AWG
2
10 AWG
2
10 AWG
2
10 AWG
2
6 AWG
2
6 AWG
2
1/0 AWG
2
4/0 AWG
2
4/0 AWG
2
6/0 AWG
UNI5401 Bookcase FS113-300-99 4200-6115 M12 stud 16kg (35lb)
The RFI filters can be surface-mounted only.
Mount the RFI filter following the guidelines in Figure 4-12 EMC
compliance on page 48.
1.4kg (3lb)
2.1kg (5lb)
2.7kg (6lb)
2.1kg (5lb)
2.7kg (6lb)
2.1kg (5lb)
3.8kg (9lb)
3.8kg (9lb)
7.8kg (17lb)
1.4kg (3lb)
2.1kg (5lb)
2.7kg (6lb)
2.1kg (5lb)
2.7kg (6lb)
2.1kg (5lb)
3.8kg (9lb)
3.8kg (9lb)
7.8kg (17lb)
7.8kg (17lb)
15kg (33lb)
15kg (33lb)
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3.11.1 Unidrive size 1 filters
Figure 3-21 Unidrive size 1 bookcase mounted filter
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Ground Terminal M5
Technical
Data
Dimension
Model
A 230mm (9.055in)
B 25mm (0.984in)
C 218mm (8.583in)
D 47.5mm (1.870in)
H 95mm (3.740in)
L 240mm (9.449in)
W 45mm (1.772in)
Z 4.5mm (0.177in)
Diagnostics
UNI1201 to UNI1205
UNI1401 to UNI1405
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RFI Filter
4200-6105
FS5111-10-29
Figure 3-22 Unidrive size 1 footprint or bookcase mounted filter
RFI Filter
Dimension
Model
A 380mm (14.961in)
B 35mm (1.378in)
C 60mm (2.362in)
F 364mm (14.331in)
G 16.5mm (0.650in)
H 68mm (2.677in)
L 390mm (15.354in)
S
U
W 85mm (3.346in)
XM6 (4x)
Z 5.5mm (0.217in)
Ground
Terminal
4200-6104
FS5101-10-07
UNI1201 to UNI1205
UNI1401 to UNI1405
300mm ±5mm
(11.811in ±0.197in)
3x 2.5mm
2
(AWG14)
M5
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