Control Techniques UNI1203, UNI1204, UNI1205, UNI2201, UNI2202 Installation Manual

...

Installation Guide

Universal Variable Speed Drive

for induction and servo motors

0.37kW to 22kW (0.5HP to 30HP)

Part Number: 0460–0037

Issue Number: 1

Unidrive

Unidrive VTC

Unidrive LFT

model sizes 1 to 3

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 (Drive) with the motor.

The contents of this User 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 User Guide, without notice.

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

Important...

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 with other Control Techniques variable speed drives in an existing system, there may be some differences between their software and the software in this product. These differences will cause a difference in functions. This may also apply to variable speed drives returned from a Control Techniques Service Centre.

If there is any doubt, contact a Control Techniques Drive Centre.

Author: RFD

Issue Code: uliu1

Issue Date: September 1999

S/W Version: 03.XX.XX

Contents

Chapter 1 Safety Information 1-1

1.1 Warnings, Cautions and Notes 1-1

1.2 Electrical safety – general warning 1-1

1.3 System design 1-1

1.4 Environmental limits 1-1

1.5 Compliance with regulations 1-1

1.6 Safety of personnel 1-1

1.7 Risk analysis 1-2

1.8 Motor 1-2

1.9 Adjusting parameters 1-2

2 Installing the Drive 2-1

2.1 Environmental requirements 2-1

2.2 EMC considerations 2-2

2.3 Planning the installation 2-3

2.4 Calculating the enclosure size 2-14

Appendix A Motor Connections A-1

A.1 Cable length A-1 A.2 Multiple motors A-1

B UL Listing Information B-1 C Data C-1

C.1 Drive C-1 C.2 Optional RFI filters C-6

2.5 Installing the Drive and RFI filter 2-16

2.6 Power connections 2.27

2.7 Wiring recommendations 2-30

2.8 Variations in the EMC wiring recommendations 2-36

2.9 Signal connections 2-37

Unidrive LV model sizes 1 to 3 Installation Guide Issue code: uliu1

Declaration of Conformity

Control Techniques plc The Gro Newtown Powys UK SY16 3BE

UNI1201 UNI1202 UNI1203 UNI1204 UNI1205 UNI2201 UNI2202 UNI2203 UNI3201 UNI3202 UNI3203 UNI3204

The AC variable speed drive products listed above, including the VTC and LFT variants, have been designed and manufactured in accordance with the following European harmonised, national and international standards:

EN60249 Base materials for printed circuits IEC326-1 Printed boards: general information for the

IEC326-5 Printed boards: specification for single- and

IEC326-6 Printed boards: specification for multilayer

IEC664-1 Insulation co-ordination for equipment

EN60529 Degrees of protection provided by

UL94 Flammability rating of plastic materials UL508C Standard for power conversion equipment EN50081-11Generic emission standard for the

EN50081-2 Generic emission standard for the industrial

EN50082-2 Generic immunity standard for the

EN61800-3 Adjustable speed electrical power drive

Conducted emission. See the relevant EMC Data

Sheet.

specification writer

double-sided printed boards with plated-through holes

printed boards

within low-voltage systems: principles, requirements and tests

enclosures (IP code)

residential, commercial and light industrial environment

environment

industrial environment

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. Drury Executive Vice President, Technology Newtown

Date: 20th September 1999

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. Refer to the Installation Guide. A Unidrive EMC Data Sheet is also available giving detailed EMC information.

Unidrive LV model sizes 1 to 3 Installation Guide

Issue code: uliu1

1 Safety Information

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

1.4 Environmental limits

Instructions in this Installation Guide regarding transport, storage, installation and use of Drives 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 Installation Guide contains instructions for achieving compliance with specific EMC standards.

The voltages used in the Drive can cause severe electric 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 Installation Guide and the accompanying User Guide.

The installation must comply with all relevant safety legislation in the country of use.

1.3 System design

The Drive is intended as a component for professional incorporation into complete equipment or systems. 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 mechanical 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 Installation Guide carefully.

To ensure mechanical safety, additional safety devices such as electro-mechanical interlocks may be required. The Drive must not be used in a safetycritical application without additional high-integrity protection against hazards arising from a malfunction.

Unidrive LV model sizes 1 to 3 Installation Guide Issue code: uliu1

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 Safety of personnel

The STOP function of the Drive does not remove dangerous voltages from the output of the Drive or from any external option unit.

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 must be installed to prevent the motor being inadvertently started.

Careful consideration must be given to the functions of the Drive which might result in a hazard, either through their intended functions (eg. Auto-start) or through incorrect operation due to a fault or trip (eg. stop/start, forward/reverse, maximum speed).

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 (eg. hoists and cranes), a separate method of braking and stopping the motor must be used (eg. a mechanical brake).

Safety Information 1-1

AC supply

Before connecting the AC supply to the Drive, it is important that you understand the operating controls and their operation. If in doubt, do not adjust the Drive. Damage may occur, or lives put at risk. Carefully follow the instructions in this Installation Guide.

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.

Before making adjustments to the Drive, ensure all personnel in the area are warned. Make notes of all adjustments that are made.

1.7 Risk analysis

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. This would normally be an appropriate form of independent safety back-up system using simple electromechanical components.

1.8 Motor

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

Low speeds may cause the motor to over-heat because the cooling fan becomes less effective. The motor should then be fitted with a protection thermistor. If necessary, a separate cooling fan should be used.

If a Drive is to be used to control a number of motors, special measures need to be taken to ensure protection of the motors; refer to Motor protection in Appendix A Motor Information.

1.9 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.

1-2 Safety Information

Unidrive LV model sizes 1 to 3 Installation Guide

Issue code: uliu1

2 Installing the Drive

Adhere to the instructions

Warning

Note

Unless otherwise stated, instructions and information in this Installation Guide relate to all versions of the Unidrive.

2.1 Environmental

Warning

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.

Competence of the installer

The Drive must be installed only 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.

requirements

Installation in an enclosure

The Drive must be protected against water, condensation and electrically conductive contamination. When the gland plate and appropriate glands are fitted, the Drive can attain ingress protection to NEMA 1 and IP40 (in accordance with IEC529). UL listing is valid when the Drive is installed in a type 1 enclosure as defined in UL 50.

Authorized access

Warning

The enclosure should prevent access by anyone except for authorized, trained service personnel.

Fire enclosure

Warning

The Drive case is not classified as a fire enclosure. When this protection is required, the Drive should be installed in a fire enclosure.

Hazardous areas

Warning

1. Refer to Appendix C Data for details of the

environmental requirements.

2. If condensation is likely to occur when the Drive

is not in use, an anti-condensation heater must be installed. This heater must be switched off when the Drive is in use; automatic switching is recommended.

3. If the Drive is to be mounted directly above any

heat-generating equipment (such as another Drive), the maximum temperature of the air immediately below the Drive should be taken as the ambient temperature for the Drive.

4. If the Drive is to be mounted beneath other

equipment, such as another Drive, the Drive should not cause the ambient temperature requirements of the equipment to be exceeded.

5. When compliance with EMC emission standards

is required, the enclosure must be made of metal but does not require special EMC features.

UL-listing requirements are given in Appendix B.

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

Before a Drive is used in the fully sinusoidal Regeneration mode, the Drive and the accompanying motoring Drive(s) must be modified. Contact the supplier of the Drive for details.

Unidrive LV model sizes 1 to 3 Installation Guide Issue code: uliu1

Installing the Drive 2-1

2.2 EMC considerations

Depending on the requirements of the installation, one of the following levels of electromagnetic compatibility (EMC) should be adopted:

Routine EMC precautions

These precautions are recommended when strict compliance with emission standards is not required. The risk of disturbing adjacent electronic equipment is minimized by adopting these precautions.

Compliance with EMC emission

standards

These precautions are recommended when strict compliance with emission standards is required. In addition, it is recommended that these precautions are taken when the Drive is installed in a residential area, or adjacent to sensitive electronic equipment such as radio receivers or similar.

Compliance with EN61800-3 (standard for Power Drive 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 Compliance with EMC emission standards. An RFI filter will always

be required. Some model sizes may require additional filtering techniques to be applied.

Operation in the second environment

An RFI filter may not be required. Follow the guidelines given in Routine EMC precautions or

Compliance with EMC emission standards

depending on the requirements of the end user.

The second environment typically includes an industrial low-voltage power supply

Caution

Instructions are given later in this chapter for these levels of EMC. Refer to Appendix C Data for further information on compliance with EMC standards and definitions of environments.

Detailed instructions and EMC information are given in the Unidrive LV EMC Data Sheet which is available from the Drive Centres and distributors listed at the end of this Installation Guide.

Compliance data is given in Appendix C Data.

network which does not supply buildings used for domestic purposes. Operating the Drive in this environment without an RFI 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 emission limits of EN50081-2 be adhered to.

Note

The installer of the Drive is responsible for ensuring compliance with the EMC regulations that apply where the Drive is to be used.

The Drive will comply with the standards for emission, such as EN50081–2, only when the instructions given in Planning the installation and Wiring recommendations later in this chapter are followed closely.

2-2 Installing the Drive

Unidrive LV model sizes 1 to 3 Installation Guide

Issue code: uliu1

2.3 Planning the installation

Model

UNI 1201

UNI 1202

UNI 1203

UNI 1204

UNI 1205

UNI 2201

UNI 2202

UNI 2203

UNI 3201

UNI 3202

UNI 3203

UNI 3204

Table 2–1 Fuse ratings for all versions of

the Unidrive LV

Instructions in numbered steps

The instructions in this section are contained in numbered steps. In some of these steps you will need to make a note of a value for future reference and, to help with identification, the number of the step.

AC supply protection

The

AC supply to the Drive must

be fitted with suitable

Warning

protection against overload and short-circuits. Table 2–1 shows recommended fuse ratings. Failure to observe this recommendation will cause a risk of fire.

TEP 1 Include a fuse of the specified rating in

each phase of the

AC supply. The use of the

following types of fuse is recommended:

• Europe: Type gG HRC industrial fuses to

IEC 269 (BS88)

• USA: RK1 600V

An MCB or MCCB having the correct thermal

and magnetic trip ratings may be used in place of fuses, on condition the fault-current clearing capacity is sufficient for the installation.

Power cables

Wiring must be in accordance with local regulations and

Warning

Cable type and size

codes of practice. The table below shows typical cable sizes for power input and output wiring. In the event of a conflict, local regulations prevail.

Fuse rating

6 A 10 A 10 A 16 A 16 A

16 A

20 A

35 A

40 A 60 A 70 A 80 A

Note

UL listing is dependent on the use of the correct type of UL-listed fuse, and applies when the symmetrical short-circuit current does not exceed 5kA. Refer to Appendix B UL Listing Information.

STEP 2 For the following power connections...

•

AC supply to RFI filter (when used)

•

AC supply (or RFI filter) to Drive

• Drive to motor

• Drive to braking resistor

... use 105°C (221°F) pvc-insulated cable of

suitable voltage rating and having copper conductors, as shown in Table 2–2.

Unidrive LV model sizes 1 to 3 Installation Guide Issue code: uliu1

Installing the Drive 2-3

Table 2–2 Cable sizes

210

330

430

660

990

660

Table 2–3 Maximum cable lengths

Model Cable size

UNI 1201 1.5 mm UNI 1202 2.5 mm UNI 1203 2.5 mm UNI 1204 2.5 mm UNI 1205 2.5 mm UNI 2201 2.5 mm UNI 2202 4 mm UNI 2203 4 mm UNI 3201 6 mm UNI 3202 10 mm UNI 3203 16 mm UNI 3204 25 mm

16 AWG

14 AWG

14 AWG 10 AWG 10 AWG

8 AWG 6 AWG 4 AWG 4 AWG

When EMC emission requirements are to be

met, shielded cable or steel wire armoured cable may be required for the following:

AC supply to enclosure

•

• Drive to motor

• Drive to braking resistor when part of the

cable is outside the enclosure

For further details, see Wiring guidelines later in this chapter.

Motor cable

STEP 3 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 2–3.

Note

Maximum length of the encoder cable

Model Maximum cable length *

UNI 1201 65 UNI 1202 100 UNI 1203 130 UNI 1204 200 UNI 1205 300

UNI 2201 ~ UNI 2203

UNI 3201 ~ UNI 3204

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

(

PWM switching

frequency at 3kHz)

300

200

The maximum cable length is reduced from that

shown in the table under the following conditions:

PWM switching frequency exceeding

•

3kHz in model size 3 The maximum cable length is reduced in proportion to the increase in 9kHz, the maximum length is

PWM switching frequency, eg. at

/3 of that

shown.

• High-capacitance cables Most cables

have an insulating jacket between the cores and the armour 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 table. (Figure 2–1 shows how to identify the two types.)

When a Unidrive LV or Unidrive LFT LV is to be used in a closed-loop system and with long motor cables, the corresponding length of the encoder cable may cause an excessive supply-voltage drop between the Drive and encoder. In this case, do not use the Drive to supply the encoder; install a separate

DC supply close to the encoder.

2-4 Installing the Drive

Normal capacitance

Shield or armour separated from the cores

High capacitance

Shield or armour close to the cores

Figure 2–1 Cable construction influencing

the capacitance

Multiple motors

Special requirements apply when the Drive is to

control more than one motor. Refer to Appendix A Motor Connections.

Unidrive LV model sizes 1 to 3 Installation Guide

Issue code: uliu1

Isolator switch in the motor cable

An isolator switch may be connected in the motor cable for safety purposes. Refer to the following Warning and Note.

The isolator switch must not be operated when the Drive is

AC-rated switch

Warning

enabled. (If an is used and the Drive is producing a low output frequency when the switch is opened, severe arcing can occur which will prevent the switch from breaking the circuit.)

A suitable interlock arrangement can be used, such as an isolator switch fitted with additional contacts that open before the main contacts. These additional contacts should be used to disable the Drive.

Note

If the isolator switch is closed when the Drive is enabled, the Drive may trip.

When EMC compliance is required, refer to Variations in the EMC wiring recommendations later in this

chapter.

The Drive has two forms of thermal protection for the power output stage (IGBT bridge), as follows:

1. A thermistor mounted on the heatsink monitors

the heatsink temperature. If this exceeds 95°C (203°F), the thermistor will cause the Drive to trip. The display will indicate Oh2.

2. Intelligent thermal modelling estimates (by

calculation) the junction temperature of the IGBTs. There are two temperature thresholds which cause the following to occur:

• If the first threshold is reached, the

PWM

switching frequency is halved in order to reduce dissipation in the IGBTs. (When the frequency is halved, the value of parameter

PWM switching frequency remains at the

0.41 value set by the user; if the frequency is 3kHz or 4.5kHz, no halving occurs). Then at one second intervals, the Drive will attempt to restore the original

PWM switching

frequency. This will be successful if the estimated temperature has reduced sufficiently.

• If the estimated temperature has continued

to rise and reaches a second threshold, the Drive will trip. The display will indicate Oh1.

TEP 4 Note that the Drive can deliver an

overload current, as shown in Table 2–4.

Table 2–4 Overload current

Output current,

PWM switching frequency,

Ambient temperature

Thermal protection

Note

The Drive can supply the rated current up to an ambient temperature of 40 (depending on the

PWM switching frequency

used).

The Drive can be operated in an ambient temperature up to 50

C (122oF) at de-rated output current. In this case, ensure the value of parameter 0.46 Motor rated current does not exceed the value given in Table 2-5.

C (104°°F)

Unidrive LV

Open-loop

Up to 150% of the rated current for 60 seconds

Closed-loop Vector

Up to 175% of the rated current for 60 seconds

Closed-loop Servo

Up to 175% of the rated current for 4 seconds

Unidrive VTC LV

For a variable-torque load

Up to 120% of the rated current for 60 seconds

Unidrive LFT LV operating on

standard S4/S5 duty cycle

Open-loop

Up to 150% of the rated current

Closed-loop Vector

Up to 175% of the rated current

Closed-loop Servo

Up to 175% of the rated current

Unidrive LV model sizes 1 to 3 Installation Guide Issue code: uliu1

Installing the Drive 2-5

150% 100%

Frequency / speed

Current

50Hz 1500

RPM

20 60

Figure 2–2 Standard S4/S5 duty cycle

(Unidrive LFT LV)

Unidrive LV and Unidrive VTC LV Refer

to Table 2–5 to find the maximum continuous output current that can be obtained for the required ambient temperature and

PWM switching frequency. The maximum

ambient temperature can be 40°C or 50°C (104°F or 122°F). Note that the nominal power rating of the Drive may not be achieved above 40°C.

Unidrive LFT LV Refer to Table 2–6 to find

the maximum continuous output current that can be obtained for the ambient temperature for a standard S4/S5 duty-cycle or for continuous operation. Refer to a Drive Centre or distributor for information on other duty ratios.

Make a note of this step number and the

following:

• Unidrive LV and Unidrive VTC LV

Chosen maximum ambient temperature.

• Unidrive LV and Unidrive VTC LV

Chosen

PWM switching frequency for

each Drive.

• All Unidrive LV versions From Table 2–

7, the maximum power dissipation (heat) figure (PP

) at the chosen PWM switching

DISSDISS

frequency for each Drive (this figure is the total power dissipation at the maximum continuous output current available at the chosen

PWM switching frequency, and

includes power dissipated in option modules when fitted). Power dissipation in the Unidrive LFT is the same as that for the standard Unidrive when operating at 9kHz

PWM switching frequency.

Caution

Operation in a maximum ambient temperature of 50°°C (122°°F)

Unless the precaution described here is taken, the Drive will limit the maximum continuous output current only to the value for 40°°C, and not to the value stated in Table 2–5 for 50°°C.

Make a note of the value for 50°°C; you will need to refer to it when you reach Configuring the Drive for the motor in Chapter 2 of the User Guide.

At that point, ensure that the value to be entered in parameter 0.46 Motor – rated current does not exceed the noted value.

• Unidrive LV and Unidrive VTC LV If

the maximum ambient temperature will be 50°C (122°F), note the value of the maximum permissible output current obtained from Table 2–5. This will be the maximum value that parameter 0.46 Motor – rated current should be set at.

2-6 Installing the Drive

Unidrive LV model sizes 1 to 3 Installation Guide

Issue code: uliu1

Table 2–5 Maximum permissible continuous output current for Unidrive LV and Unidrive VTC LV

40°°C (104°F)

ambient

Model kW HP 3kHz 4.5kHz 6kHz 9kHz 12kHz

UNI 1201 0.37 kW 0.5 2.1 A 2.1 A 2.1 A 2.1 A 2.1 A UNI 1202 0.55 kW 0.75 2.8 A 2.8 A 2.8 A 2.8 A 2.8 A UNI 1203 0.75 kW 1.0 3.8 A 3.8 A 3.8 A 3.8 A 3.8 A UNI 1204 1.1 kW 1.5 5.6 A 5.6 A 5.6 A 5.6 A 4.5 A UNI 1205 2.2 kW 3.0 9.5 A 9.5 A 8.5 A 7.0 A 5.5 A

UNI 2201 3.0 kW 4.0 12.0 A 12.0 A 12.0 A 12.0 A 11.7 A UNI 2202 4.0 kW 5.0 16.0 A 16.0 A 16.0 A 14.2 A 11.7 A UNI 2203 5.5 kW 10.0 25.0 A 21.7 A 18.2 A 14.2 A 11.7 A

UNI 3201 7.5 kW 15.0 34.0 A 34.0 A 34.0 A 28.0 A 23.0 A UNI 3202 11 kW 20.0 46.0 A 46.0 A 40.0 A 32.0 A 26.6 A UNI 3203 15 kW 25.0 60.0 A 47.0 A 40.0 A 32.0 A 26.7 A UNI 3204 22 kW 30.0 74.0 A 56.0 A 46.0 A 35.0 A 28.0 A

50°°C (122°F)

ambient

Model kW HP 3kHz 4.5kHz 6kHz 9kHz 12kHz

UNI 1201 0.37 kW 0.5 2.1 A 2.1 A 2.1 A 2.1 A 2.1 A UNI 1202 0.55 kW 0.75 2.8 A 2.8 A 2.8 A 2.8 A 2.8 A UNI 1203 0.75 kW 1.0 3.8 A 3.8 A 3.8 A 3.8 A 3.3 A UNI 1204 1.1 kW 1.5 5.6 A 5.6 A 5.1 A 4.0 A 3.3 A UNI 1205 2.2 kW 3.0 6.9 A 5.9 A 5.1 A 4.0 A 3.3 A

UNI 2201 3.0 kW 4.0 12.0 A 12.0 A 12.0 A 11.6 A 9.7 A UNI 2202 4.0 kW 5.0 16.0 A 16.0 A 14.7 A 11.6 A 9.7 A UNI 2203 5.5 kW 10.0 20.0 A 17.3 A 14.7 A 11.6 A 9.7 A

UNI 3201 7.5 kW 15.0 34.0 A 34.0 A 28.0 A 21.0 A 17.9 A UNI 3202 11 kW 20.0 44.0 A 36.0 A 31.0 A 24.0 A 20.6 A UNI 3203 15 kW 25.0 44.0 A 36.0 A 31.0 A 24.0 A 20.9 A UNI 3204 22 kW 30.0 50.0 A 41.0 A 34.0 A 26.0 A 23.0 A

Nominal

rating

Nominal

rating

Maximum permissible

continuous output current

Maximum permissible

continuous output current

Unidrive LV model sizes 1 to 3 Installation Guide Issue code: uliu1

Installing the Drive 2-7

Table 2–6 Maximum permissible output current for Unidrive LFT LV

Continuous

operation at 40°C

2.1 A

2.8 A

3.8 A

4.0 A

4.3 A

12.0 A

14.2 A

28.0 A

32.0 A

33.0 A

35.0 A

Model

UNI 1201

UNI 1202

UNI 1203

UNI 1204

UNI 1205

UNI 2201

UNI 2202

UNI 2203

UNI 3201

UNI 3202

UNI 3203

UNI 3204

(at 9kHz

PWM switching frequency)

Model Nominal

rating

kW HP Standard duty cycle

at 40°°C

UNI 1201 LFT 0.37 kW 0.5 2.1 A UNI 1202 LFT 0.55 kW 0.75 2.8 A UNI 1203 LFT 0.75 kW 1.0 3.8 A UNI 1204 LFT 1.1 kW 1.5 5.6 A UNI 1205 LFT 2.2 kW 3.0 9.5 A

UNI 2201 LFT 3.0 kW 4.0 12.0 A UNI 2202 LFT 4.0 kW 5.0 16.0 A UNI 2203 LFT 5.5 kW 10.0 25.0 A

UNI 3201 LFT 7.5 kW 15.0 34.0 A UNI 3202 LFT 11 kW 20.0 46.0 A UNI 3203 LFT 15 kW 25.0 60.0 A UNI 3204 LFT 22 kW 30.0 74.0 A

Maximum permissible output current

Continuous

operation at 50°°C

2.1 A

2.8 A

3.3 A

11.0 A

21.0 A

24.0 A

26.0 A

Table 2–7 Maximum total power dissipation (Unidrive LV, Unidrive VTC LV and Unidrive LFT LV)

Nominal

rating

kW HP 3kHz 4.5kHz 6kHz 9kHz 12kHz

0.37kW 0.5 80 W 80 W 90 W 90 W 90 W

0.55kW 0.75 90 W 90 W 100 W 100 W 110 W

0.75kW 1.0 100 W 110 W 110 W 120 W 130 W

1.1kW 1.5 130 W 130 W 140 W 150 W 150 W

2.2kW 3.0 180 W 190 W 190 W 190 W 170 W

3.0kW 4.0 210 W 230 W 250 W 280 W 310 W

4.0kW 5.0 270 W 290 W 310 W 320 W 310 W

5.5kW 10.0 400 W 380 W 360 W 330 W 310 W

7.5kW 15.0 570 W 620 W 670 W 660 W 630 W

11kW 20.0 730 W 800 W 770 W 730 W 700 W

15kW 25.0 950 W 830 W 790 W 740 W 710 W

22kW 30.0 1090 W 990 W 920 W 850 W 800 W

Maximum total power dissipation

The default PWM switching frequency is a follows...

2-8 Installing the Drive

Unidrive LV and Unidrive VTC LV: 3kHz Unidrive LFT LV: 9kHz

Unidrive LV model sizes 1 to 3 Installation Guide

Issue code: uliu1

Using an RFI filter

Using a braking resistor

STEP 5 For compliance with the emission

standards such as EN 50081-1 or EN 50081-2, use the recommended RFI filter as shown in Table 2–8. Use one RFI filter for each Drive. (Standards that are met are specified in Appendix C Data)

Make a note of this step number and the

following for each filter to be used:

• Size code or part number

• Maximum power dissipation figure

• IP rating

Table 2–8 RFI filter data

Model RFI filter

rating

UNI 1201 UNI 1202 UNI 1203 UNI 1204 UNI 1205

UNI 2201 UNI 2202 UNI 2203

UNI 3201 UNI 3202 UNI 3203 UNI 3204

Size Part

number

4200–0010 25 IP20

4200–0027 40 IP20

4200–1051 60 IP00

4200–1071 100 IP00

Maximum

power

dissipation

(W)

Model size 1

When the motor cable is to exceed 50m (165 feet), use RFI filter size B (4200–0027).

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 by the motor.

When the motor is being braked 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, a braking resistor must be connected.

By default, the Drive brakes the motor under PI control which extends the deceleration time as necessary in order to keep the

DC bus at a constant

voltage. The method of braking can be changed; if required, refer to Appendix D Menu 0 Parameters in the User Guide.

Note

When a braking resistor is used, the Drive should be operated in FASt ramp mode. If this is not done, instability may arise. See Braking resistor in Chapter 2 of the User Guide.

Housing the resistor, and routing the connecting cable

High temperatures

Braking resistors can reach

Warning

high temperatures. Locate braking resistors so that damage cannot result.

Use cable having insulation capable of withstanding high temperatures.

Overload protection

Unidrive LV model sizes 1 to 3 Installation Guide Issue code: uliu1

Warning

It is essential that an overload protection device is incorporated in the braking resistor circuit; this is described in Protection circuit for an optional braking resistor in

TEP 8.

Installing the Drive 2-9

STEP 6 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 armoured or shielded, since it is not fully contained in a metal enclosure.

Internal connection does not require the cable

to be armoured or shielded.

Minimum resistances and power ratings

Table 2–9 Minimum resistance values and

peak power rating for the braking resistor at 40°°C (104°°F)

Model Minimum

resistance

UNI 1201 ~ UNI 1205 20Ω 15kW UNI 2201 20Ω 15kW UNI 2202, UNI 2203 15Ω 20kW UNI 3201 ~ UNI 3204 5Ω 60kW

The minimum resistance allows the braking resistor to dissipate up to approximately 300% of the power rating of the Drive for up to 60 seconds.

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 essential, though, 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.

Instantaneous

power rating

Optimization of the braking resistor requires a careful consideration of the braking duty. This is described more fully in Optimizing an optional braking resistor in the Unidrive Advanced User Guide.

TEP 7 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 may cause the Drive to trip during braking. If this occurs, refer to Deceleration rate in Chapter 2 of the User Guide.

TEP 8 Estimate the average power that will be

dissipated in the resistor. A method of estimating this power is described in Optimizing

an optional braking resistor in the Unidrive Advanced User Guide. Make a note of this step

number and the average power to be dissipated in the resistor.

Thermal protection circuit for the braking resistor

The thermal protection circuit must disconnect the

AC supply from the Drive if the resistor becomes

overloaded. Figure 2–3 shows a typical circuit arrangement.

Optional RFI filter

Stop

Start / Reset

Thermal protection device

Braking resistor

Figure 2–3 Typical protection circuit for a

braking resistor

Drive

2-10 Installing the Drive

Unidrive LV model sizes 1 to 3 Installation Guide

Issue code: uliu1

Enclosure layout

STEP 9 Use one of the following enclosure

layouts, depending on the requirements of the installation:

Routine EMC precautions Refer to

Figure 2–4 which shows the recommended layout for two Drives, and the signal and power cables.

Compliance with EMC emission

standards Refer to Figure 2–5 which shows the recommended layout for two Drives, two RFI filters, and the signal and power cables.

TEP 10 Decide whether the enclosure is to be

sealed or ventilated, as follows:

A sealed enclosure can give a high ingress-

protection rating, but with reduced heat removal capabilities. If possible, locate heatgenerating equipment (other than braking resistors) in the lower part of the enclosure to encourage internal convection. If necessary, a taller enclosure, and/or air-circulation fans inside the enclosure, can be used. For calculating the minimum size of sealed enclosure that will adequately cool the Drive(s), refer later in this chapter to Calculating the size

of a sealed enclosure.

If a high ingress-protection rating is not

required, a ventilated enclosure can be used with a fan to supply forced air cooling; this can give a lower ambient temperature than a sealed enclosure. For calculating the minimum required volume of cooling air, refer later in this chapter to Calculating the air-flow in a ventilated enclosure.

TEP 11 For compliance with EMC emission

standards, ensure the enclosure is fitted with an unpainted metal back-plate for mounting the Drive and RFI filter. For example, a zinc plated steel back-plate is suitable (see Figure 2–5).

TEP 12 Ensure the Drive is installed vertically for

best flow of cooling air through the Drive and heatsink.

TEP 13 Ensure the clearances around the Drive are

as follows:

Above and below: ≥100mm (4 in)

Both sides: ≥5mm (

/4 in)

Note

When surface mounting a model size 3, allow a clearance of 150mm (6in) above the Drive; this is required for dismounting. A minimum clearance of 100mm (4in) is required for ventilation.

For overall dimensions and weights of the Drive

and RFI filter, see Appendix C Data.

TEP 14 When compliance with EMC emission

standards is required, the RFI filter must be installed at the specified position for each Drive (see Figure 2–5).

TEP 15 When a braking resistor is to be used, it

can be installed outside or inside the enclosure. When installed inside, it must be mounted in the upper part of the enclosure to prevent it heating the other equipment by convection.

Unidrive LV model sizes 1 to 3 Installation Guide Issue code: uliu1

Installing the Drive 2-11

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Specifications and Main Features

Frequently Asked Questions

User Manual