Control Techniques Unidrive Regen Installation Manual

www.controltechniques.com

Installation Guide

Unidrive

Regen

Part Number: 0460-0026-02
Issue Number: 2

General Information

The manufacturer accepts no liability for any con se quenc es resulting from inappropriate, negligent or incorrect
installation oradjustment 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 interes ts of a co mm itment to a policy
of continuous development and improv ement, the manufacturer reserves the righ t to change t he 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
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Drive software version

This product is s upplied with the latest version of software. If this product is to be used in a n ew or existing system with
other drives, there may be some differences between their software and the software in this product. These differences
may ca use 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.

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Control Techniques is committed to minimising the environmental impacts of its manu facturing operations and of its
products throughout their life cycle. To this end, we operate an Environmental Management System (EMS ) whi ch is
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Nevertheless, when theproducts eventually reach the end of theiruseful life, they can very easily be dismantled into their
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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 © October 2002 Control Techniques Drives Limited
Issue Number: 2

Contents

1 Introduction....................................................................................................................1

1.1 Principles of operation ...........................................................................................................................1

1.2 Power flow .............................................................................................................................................2

1.3 Advantages of Unidrive operating in Regen mode ................................................................................2

2 Sizing of a Regen system .............................................................................................3

3 Power connections........................................................................................................4

3.1 Overall system layout ............................................................................................................................4

3.2 Non standard configurations ..................................................................................................................7

4 Control circuit connections..........................................................................................8

4.1 Digital/ Analog I/O set-up in Regen mode ............................................................................................8

4.2 Regen inductor thermistors ....................................................................................................................9

5 Components.................................................................................................................10

5.1 Motoring drive ......................................................................................................................................10

5.2 Regen drive .........................................................................................................................................10

5.3 Regen inductor ....................................................................................................................................10

5.4 Softstart resistor ...................................................................................................................................11

5.5 Contactors, MCBs and overload ..........................................................................................................11

5.6 Switching frequency filter .....................................................................................................................12

5.7 RFI filter ...............................................................................................................................................13

5.8 Varistors ...............................................................................................................................................13

5.9 Fusing ..................................................................................................................................................14

6 Important considerations............................................................................................16

6.1 Fundamentals ......................................................................................................................................16

6.2 Unidrive size 3 and 4 ...........................................................................................................................16

6.3 Ventilation ............................................................................................................................................16

6.4 Cable length restrictions ......................................................................................................................17

7 Unidrive Regen EMC information...............................................................................19

7.1 Immunity ..............................................................................................................................................19

7.2 Emission ..............................................................................................................................................19

7.3 Dedicated supplies ..............................................................................................................................19

7.4 Other supplies ......................................................................................................................................19

7.5 Supply voltage notching .......................................................................................................................19

7.6 Supply harmonics ................................................................................................................................19

7.7 Switching frequency emission .............................................................................................................19

7.8 Conducted RF emission ......................................................................................................................19

7.9 Radiatedemission ...............................................................................................................................21

7.10 Wiring guidelines .................................................................................................................................21

7.11 Multi-drive systems ..............................................................................................................................21

8 Parameter descriptions...............................................................................................22

8.1 Menu 15: Sinusoidal rectifier ...............................................................................................................22

9 Commissioning and operation...................................................................................28

9.1 Regen parameter settings ...................................................................................................................28

9.2 Regen drive sequencing ......................................................................................................................28

9.3 Regen drive commissioning .................................................................................................................29

9.4 Motoring drive commissioning .............................................................................................................29

9.5 Trip codes ............................................................................................................................................29

Unidrive Regen Installation
Issue Number: 2

Appendix A Unidrive Regen as a Brake Resistor Replacement ............................................. 30

A.1 Introduction .........................................................................................................................................30

A.2 Drive configurations ............................................................................................................................30

A.3 When to use a Regen drive as a brake resistor replacement .............................................................30

A.4 Regen and motoring drive ratings ....................................................................................................... 31

A.5 Power circuit conne ctions and components ....................................................................................... 31

A.6 Control circuit connections .................................................................................................................. 34

A.7 Regen brake drives in operat ion ......................................................................................................... 35

Appendix B Component sizing calculations ............................................................................ 36

B.1 Sizing of MCB for switching frequenc y filter .......................................................................................36

B.2 Resistor sizing for multiple motoring systems .....................................................................................37

B.3 Multiple Unidrive size 5 systems ......................................................................................................... 38

B.4 Thermal / magnetic overload protection for soft start circuit ...............................................................38

Appendix C Long cables ............................................................................................................41

C.1 Exceeding the maximum cable length ................................................................................................ 41

Appendix D Regen kits ............................................................................................................... 43

D.1 Single R egen, single motoring systems .............................................................................................. 43

D.2 Single Regen, multiple motoring and multiple Regen, multiple motoring systems .............................43

Appendix E Unidrive Regen specifications ............................................................................. 44

Appendix F Physical dimensions ............................................................................................. 45

F.1 Regen inductor ................................................................................................................................... 45

F.2 Softstart resistor - type TG series ....................................................................................................... 47

F.3 Switching frequency filter capacitors .................................................................................................. 48

F.4 Switching frequency filter inductor ......................................................................................................51

F.5 Varistors ..............................................................................................................................................53

Unidrive Regen Installation Guide

Issue Number: 2

1 Introduction

R

+DC-

Any standard Unidrive canbe configured asanAC Regenerative Unit (hereafterreferredtoas Regen drive).
This Installation guide covers the following:

• Principles andadvantagesofoperation in Regen mode

• Details of additionalcomponentsrequired

• ConfigurationofRegen systems
At least two Unidrives are required to form a complete Regenerative system - one connected to the supply and the second one to the motor. A

Unidrive in Regen mode converts the AC mainssupply to a controlled DC voltage which is fed intoother drive(s)to controla motor.

Figure1-1 Regen drivesystem connection

3Phase

Supply

Regen

Inductor

R

Y

B

Additional

Circuitry

U
V
W

egen Drive

AC

DC

+DC

-DC

Motoring Drive

DC

DC

AC

U
V

W

M

1.1 Principles of operation

The inputstage of a non-regenerative AC drive is usually an uncontrolled dioderectifier, therefore power cannot be fed back intothe AC mains
supply.

In the case of a Unidrive operating in Regenerative mode, the IGBT bridge is used as a sinusoidal rectifier, which converts the AC supply to a
controlled DC voltage.This DC voltage canthen be usedtosupply oneormore Unidrives whichcontrolmotors,commonlyknown as motoring drives.

A Regen drive produces a PWM output voltage which has a sinusoidal fundamentalatanamplitude andphase which are almost the same as those
of the AC supply voltage. The differencebetween thedrive PWM linevoltageandthesupplyvoltage occursacross theRegen drive’sinductors.This
voltage has a high frequency component which is blocked by the Regen inductor and a smallsinusoidal component at linefrequency.Asa result,
currents flowing in these inductors are sinusoidal with a small high frequency ripple component.

NOTE

T erminals L1, L2 and L3 and the associated diode rectifier are not connected and are redundant on drives used in a Regen configuration.

Figure 1-2 Phasor diagram

N

Power flowfrom supply Power flowback to supply

V

s

V

r

jωLI
I

r

Supply Voltage
Voltage at line terminals of Regen drive

Voltage across RegenInductor

r

Current at line terminals of Regen drive

UnidriveRegenInstallation Guide 1
Issue Number: 2 www.controltechniques.com

1.2 Power flow

The phasor diagraminFigure 1-2 illustratesthe relationship between the supply voltage and the Regen drivevoltage. The angle betweenthe two
voltage vectorsis approximately 5° at fullload, givingapowerfactor which is nearunity.

The directionofthe power flow can bechanged relative tothesupply voltage, by makingsmall changes to theRegendrive outputvoltage andphase.
A fast transient response is achievedby means of a space vector modulator.

1.3 Advantages of Unidrive operating in Regen mode

The main advantages for an AC Regen system are:

• Energy saving

• The inputcurrent waveformissinusoidal

• The input current has a near unity power factor

• The output voltage for the motor can be higher than the available AC mains voltage

• The Regen drive willsynchronise to any frequency between30and100Hz, provided the supply voltage is between 380V-10% and 480V +10%

• Underconditionsof AC mains instability,a UnidriveRegen system cancontinuetofunction downtoapproximately150Vac supplyvoltage without
any effect on the DC bus voltage and hence on the operation of the motoring drives (increased current will be taken from the AC supply to
compensate up to the currentlimit of the Regendrive)

• The Regen and motoring drives are identical

2 Unidrive Regen Installation Guide

www.controltechniques.com Issue Number: 2

2 Sizing of a Regen system

Refer to Appendix E Unidrive Regen specifications on page 44, for the specifications of the Unidrive Regen.
The sizing of a Regen system musttake into account the following factors:

•Linevoltage

• Motor rated current, rated voltage and power factor

• Maximum load power and overload conditions
In general, when designing a Regen system, equalRege n and motoring drive rated currents will work correctly. However, care must be taken to
ensurethat under worstcasesupply conditions theRegen drive is able to supply or absorballtherequired power. In multi-drive configurations, the
Regendrive must be of a sufficientsize to supply the netpeakpower demanded by thecombined loadofall the motoring drivesandthe drivelosses.

If the Regendrive is unabletosupply the fullpower required by the motoring drive, theDC busvoltage willdrop and in severe cases may lose
synchronisation with the mains and trip.Ifthe Regen drive is unable to regenerate the full powerfrom the motoring drive intotheDC bus, thenthe
Regen/motoring drive will trip on over-voltage.

The following are twoexamples of how the required ratings of a Regen drive can be calculated.

NOTE

The Regen drive’s current limits are set at 150% and are not adjustable.
In the caseofa 25A,UNI2403 operating in Regen mode from a 400V supply, and a UNI2403driving a 400V rated, 0.85 pf motor:
The rated power of the Regen drive is = √3 x Ratedcurrent x Supply voltage

The motoring drive can supply power = √3 x Rated current x Motor voltage x Powerfactor

When the motoring driveissupplying rated current to themotor, the Regen driveonlyneeds to provide14.7kW, plus drivelosses. The Regen drive
can supply 17.3kW at rated current, which is ample, in this case.

Conversely, in somecases, a Regen driveofthesame rating asthe motoring drive, may not be able to supply enough power, as the following
example shows:

Example

In the caseofa 156A,UNI4403 operatinginRegenmode, and a UNI4403drivinga 75kW, 400V, 0.95pf motor:
If the motoring drive is supplying 175% maximum current and the Regendrive has its380Vsupply at the lowerlimits of -10%(342Vac), then,atthe

Regencurrent limitof150%:
The Regen drive max. available power is = √3 x 150% x Rated current x Supply voltage

The motoring drive max.poweris = √3 x 175% x Rated currentx Motorvoltage x Power factor

The Regendrive is also required to supplytheRegen and motoring drive losses.However, t his Regen drive is onlycapable of supplying
approximately 138.6kW and therefore a drive of a larger current rating is required.

Due to the effects of increased DC bus capacitance, there is a limit to the number of motoring drives that can be supplied from a Regen drive. This is
true irrespective of the balance of power between the motoring drivesandtheRegen drive.

NOTE

If the system consists of one Regen Unidrive and morethanthree motoringdrives, ControlTechniquesTechnical SupportMUSTbeconsulted about
the design of the system.

N

= 1.73 x 25 x 400
= 17.3kW

= 1.73 x 25 x 400 x 0.85
= 14.7kW

=1.73x1.5x156x342
=138.6kW

=1.73x1.75x156x400x0.95
=179.7kW

N

UnidriveRegenInstallation Guide 3
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3 Power connections

The following section covers the power connections required for Unidrive Regen systems. Note that with Unidrive Regen systems there are no AC
supply connectionsmade to L1, L2 or L3 driveterminals.

NOTE

For control circuitconnections refertoChapter 4 Control circuit connectionson page 8.

3.1 Overall system layout

The table below shows the key to the following system layout diagrams.

Table 3-1 KeytoFigure3-1andFigure3-2

V1, V2,V3 Varistor network 550V (linetoline)
V4, V5,V6 Varistor network 680V (linetoground)

N

E Ground connection point

RFI EMC filter

SFFL Switching frequency filter inductor

L regx Regen inductor

Rsx Softstart resistor

R-control Ribboncablestocontrolpod(Unidrivesize5only)

R-parallel Ribboncables between powermodules (Unidrive size5only)

Fsx ACsupply fusing

Fx ACRegenfusing(Unidrivesize5only)

SFF Cx Switching frequency filter capacitor

Rdx Switching frequency filter capacitor discharge resistor

Tcx Thermocouple

K1 Supply contactor
K2 Main contactor
K3 Auxiliary contactor

MCB1x Switching frequency filtercapacitorMCB

aux1x

aux2 Main contactorauxiliaryfor“main contactor closedsignal”
aux3 K3 auxiliary with coil supplyfor K2
Ovld Thermal, Magnetic overload

Switching frequency filter MCB auxiliary through which Regen drive enable is
connected

4 Unidrive Regen Installation Guide

www.controltechniques.com Issue Number: 2

3.1.1 Standard single Regen, single/mul tip le m otoring system

Figure 3-1 Power connections: Single Regen

DC Bus to

Motoring

Drive(s)

Ovld

MCB1

UnidriveRegenInstallation Guide 5
Issue Number: 2 www.controltechniques.com

3.1.2 Standard multiple Regen, multiple motoring system

R - control

If the total power requirement istoogreat for one Unidrive size 5 Regen drivetosupply, more than one drive can be used.
OneRegensystem can consist of multiple Unidrive size5Regen drives,which can supply multiple Unidrive size5motoring drives, providing thatthe

totalload power doesnot exceed the rating of the Regen drives. See figure3-2for a dual size 5 Regen configuration.

NOTE

High power set-upsshould useUnidrivesize 5. This is the onlymodule whichis designedforparallelRegen operation.
For systemswith more thantwoUnidrive size 5 drives in parallel Regenoperation, contactCTTechnical Support.

Figure 3-2 Power connections: Unidrive size 5 multiple Regen

N

DC

Bus

Common

-DC

+DC

E

+DC

Size 5

Regen

Drive 1

Unidrive

U

V

W-DC

Lreg1

F1F2F3

R-parallel

E

Tc1

K2

SFFL

Lreg2

aux 2

aux 1b

MCB 1b

aux 1a

MCB 1a

E

-DC

+DC

Size 5

Regen

Drive 1

Unidrive

U

V

W

F4

F5

F6

aux 3

K3

Ovld

SFF C2

Rd6

Rd4

SFF C1

Rd3

Rd1

E

E

Tc2

Rs1

E

Rd5

E

Rd2

RFI

V3

V1

V2

K1

FS1

FS2

Y

R

Supply

3Phase

E

V6

V5

E

V4

FS3

B

6 Unidrive Regen Installation Guide

www.controltechniques.com Issue Number: 2

3.2 Non standard configurations

There are a number of possible options available when designing a Unidrive Regen system depending on the user requirements and the nature of the
AC supply. Non standard systems can be created where favourable supply conditions exist, allowing cost and space savings to be achieved by
reducing the number of components.

3.2.1 Switching frequenc y filter

If the supply to the Regen driveisshared with other equipment, then it is strongly recommendedthat a switching frequency filter be incorporated in
order to avoid the risk of interference or damage to the other equipment.

3.2.2 Supply assessment

The following guidelines should be used when assessing whether or not a switchingfrequency filterisrequired.
Symbols used are:

Nominal drive 100% current rating.

I

Drive

I

Short circuit current of supply at pointofcoupling with other equipment.

SC

Ratedcurrent of supply.

I

Supply

The switching frequency filter may be omitted if the following relation is true:

I

Drive

I

SC

If the short-circuit currentisnot known,thenareasonableestimatecanbe madeifitisassumed that the fault currentof the supply is 20 times the
ratedcurrent.This is very commonly the case wherethe supplyisderived through a distributiontransformer from a higher voltage supply with a high
fault level.

Then:

I

Drive

I

Supply

This second relation is helpful but must be used with care. It is reliable where the Regen drive is supplied through its own cable run from a point close
to the distribution transformer terminals. If theRegen drive shares a long cablerunwith other equipment, thentheeffect of the cableimpedanceon
the faultlevel must be taken into account if a risk of disturbance to the other equipment is to be avoided.

This procedure will normally be applied when assessing a non-dedicated low-voltage supply. It may also be applied to the medium/high voltage
supplywhere the low-voltagesupply is dedicated to the drive.Inthatcase the currents used mustbe referred to the highvoltage side of the
transformer.

3.2.3 RFI filter

Whether or not an RFI filter is required is dependent upon the user requirements and the AC supply network. For further details refer to Chapter
7 Unidrive Regen EMC information on page 19. An RFI filter must not be fitted without a switching frequency filter present in the system.

1

<

140

1

<

7

UnidriveRegenInstallation Guide 7
Issue Number: 2 www.controltechniques.com

4 Control circuit connections

All power circuit connections should be made as shown in Chapter 3 Power connections on page4.

4.1 Digital / Analog I/O set-up in Regen mode

The following table lists the default functions of the analog and digital I/O on a Regen drive. The terminals which are listed as “Fixed” have dedicated
functions for Regen operation. They mustbe connected to perform their allocated functionandcannot be re-programmed.

Table 4-1 Functions of the analog and digital I/O

Terminal No.

1 Drive relay Fixed
2 Drive relay Fixed

5 Analog input1 User-programmable
7 Analog input2 User-programmable
8 Analog input3 User-programmable

9 Analogoutput 1 User-programmable Output- Supply current
10 Analog output 2 User-programmable Output - Supply power
24 Digital output 1 Fixed Not used
25 Digital output 2 Fixed Output - Enable other drive
26 Digital output 3 User-programmable Drivehealthy
27 Digital input 1 User-programmable Input - Reset
28 Digital input 2 Fixed Input - Main contactor closed
29 Digital input 3 User-programmable
30 Enable Fixed Enable

* Pr 8.25 must be setby theuser. See Table 4-2.

Terminal

Description

Fixed or

Programmable

Function in Regen Mode

Output - close auxiliary contactor*
Output - close auxiliary contactor*

Figure 4-1 shows typical control connections for a Regenandmotoring drive. In this example the motoring drive is configured for 4-20mA Speed/
Torque reference and sequencing Mode 4 with Run Forward and Run Reverseinputs.

NOTE

All control connections for theRegen drive mustbe madeas shownin Figure 4-1.
The Regen drive healthy signal can be taken from digital output 3 on terminal 26 (if the Regen drive is disabled, trips, or detects that the mains supply

is lostthis output thenbecomes inactive).

Table 4-2 Configuration of drive relay

Pr8.25 -Relay

NOTE

Unidrive Regenhas beendesignedto operate innegativelogicasdefault.In orderfor thedrive to beconfigured tooperateinpositivelogicalterations
must be madetothecontrol connectionsand parameter settings (contact C.T. TechnicalSupport forthis information).

N

Parameter Description Drive

The Regen drives relay on terminal 1 and 2 has to be

Source

configured toclose theauxiliary contactoronpowerupand
remove the softstart circuit. Set Pr 8.25 to Pr 15.14

Regen drive

N

8 Unidrive Regen Installation Guide

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4.2 Regen inductor thermistors

0

A

A

0

0

D

D

2

D

2

D

2

D

2

D

3

E

3

0

M

0

A

A

A

A

A

1

A

1

0

2

0

2

+

2

0

2

D

2

D

2

D

2

D

2

D

2

D

3

E

3

0

M

Each of the Unidrive 3-phase Regen Inductors has a thermistor fitted; when the system consistsof multipleRegen drivesthethermistorsshould be
connected in series due to there only being a singlethermistorinput on the Regen drive.

Figure 4-1 Control connections - (negative logic configuration)

Externalpower supply

for K2 coil

External power supply

forK3coil

K2

aux3

Tc1

K3

1
2
3

VAnalog

4

10V Out

5

nalog I/P 1+

6

nalog I/P 1-

7

Analog I/P 2

8

Analog I/P 3

9

AnalogO/P 1

10

AnalogO/P 2

11

VAnalog

Relay NO

(Set Pr to

8.25

Pr )

15.14

Regen Drive

21

0V

22

+24V Out

23

V Digital

24

Drive

Healthy

aux2

aux 1x

Output enable

User
enable

25

6
7
8
9
0
1

igitalI/O 1
igitalI/O 2
igitalI/O 3
igitalI/P 1
igitalI/P 2
igitalI/P 3
nable

V Digital

Drive

Healthy

Speed/T orque Ref

4 - 20mA Current

Loop

otor Thermistor

At ZeroSpeed O/P

Reset

Fwd
Rev

User enable

1
2
3

VAnalog

4

10V Out

5

nalog I/P 1+

6

nalog I/P 1-

7

nalog I/P 2

8

nalog I/P 3

9

nalog O/P 1

0

nalog O/P 2

1

VAnalog

1

V

2

24V Out

3

V Digital

4

igitalI/O 1

5

igitalI/O 2

6

igitalI/O 3

7

igitalI/P 1

8

igitalI/P 2

9

igitalI/P 3

0

nable

1

V Digital

Relay NO

otoring Drive

UnidriveRegenInstallation Guide 9
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5 Components

The following parts are required to assemble a Unidrive Regen system:

•Motoringdrive

• Regendrive

• Regeninductor

• Softstart resistor

• Contactors,MCBs and overload

• Switching frequency filter (optional)

• RFIfilter (optional)

•Varistors

• Fuses

NOTE

The Regen inductor and softstart resistor duty cycle is very arduous. Therefore, correct component selection is critical. The most sensitive aspects
are line-inductorlinearity, saturation currentand resistor-energypulse rating.Only inductorsandsoftstart resistors as specified in this Installation
Guide should be used.

5.1 Motoring drive

Unidrive in Open Loop,Closed Loop or Servomode. Any software version.
This controlsthemotor by convertingthe DC bus voltagetoa variable voltage, variable frequency supply. Power flowis betweenthe DC bus and the

motor. TherearenoACsupply connections.

5.2 Regen drive

Unidrive in Regen mode. (Must be software version 2.10.04 or higher).
The Regen drive converts the AC supply to a regulated DC voltage. It also provides bi-directional power flow and sinusoidal input currents.

5.3 Regen inductor

The Regen inductor supports the difference between the PWM voltage from the Regen drive and sinusoidal voltage from the supply.

NOTE

Regen inductors are special parts. Under no circumstances must a part be used other than those listed in Table 5-1.

Table 5-1 3-phase Regen inductors

Drive Model

N

N

Rated

power

kW A rms mH

UNI 1405 4 9.5 6.3 1 4401-0001
UNI 2401 5.5 12 5.0 1 4401-0002
UNI 2402 7.5 16 3.75 1 4401-0003
UNI 2403 11 25 2.4 1 4401-0004
UNI 3401 15 34 1.76 1 4401-0005
UNI 3402 18.5 40 1.5 1 4401-0006
UNI 3403 22 46 1.3 1 4401-0007
UNI 3404 30 60 1.0 1 4401-0008
UNI 3405 37 70 0.78 1 4401-0009
UNI 4401 45 96 0.63 1 4401-0010
UNI 4402 55 124 0.48 1 4401-0011
UNI 4403 75 156 0.38 1 4401-0012
UNI 4404 90 180 0.33 1 4401-0013
UNI 4405 110 202 0.30 1 4401-0014
UNI 5401 160 300 0.24 1 4401-0015

Rated

current

Inductance

Number
requiredper
Regen drive

CT

part number

10 Unidrive Regen Installation Guide

www.controltechniques.com Issue Number: 2

5.4 Softstart resistor

The start-up circuit limits the amountofcurrent flowing intothe DCbusoftheRegen driveandinto the motoring drives.

5.4.1 Single systems

The softstart resistor for singleRegen applications mustbeasspecifiedin the following table. Energyrating andoverload are non-standard and both
are important.

Table 5-2 Single Regen, single motoring, Unidrive size 1 to 5

Drive

size

1 1 150 1270-3157 150
2 1 150 1270-3157 150
3 1 48 1270-2483 48
4 2 24 1270-2483 48
5 2 24 1270-2483 48

Table 5-3 Softstart resistor data

Drive size Resistors Rms current

1 1270-3157 0.4 5
2 1270-3157 0.4 5
3 1270-2483 0.5 15
4 1270-2483 x 2 0.6 32
5 1270-2483 x 2 1.2 32

The above figures havebeencalculatedassumingapeak supply voltage of480Vac +10%.Refer alsoto AppendixBComponent Sizing Calculations.

Number of

parallel resistors

5.4.2 Multiple systems

In nonstandardcases,e.g. multiple motoring, multipleRegen systems, thesoft-start resistor sizeand ratingmust be recalculated due to thecharging
characteristics changing. For the method of calculating the new resistor size and rating, refer to Appendix B Component sizing calculations on
page 36.

5.4.3 Protection

Protection for the softstart circuit is provided using a thermal overload to protect against a high impedance short circuit, and a separate magnetic
overload to protectagainst a directshort circuit.For multiplesystems the softstartresistorsizemustberecalculated resulting in resizing of the
thermalmagnetic overload required. Refer to Appendix B Component sizing calculations on page 36.

Table 5-4 Thermal magnetic overload

Drivesize Rated CurrentARated Voltage

1 & 2 0.3 480 1 4133-0117

3 1 480 1 4133-0217

4 & 5 2 480 1 4133-0277

Totalvalue Resistors

Ω CT part number Value Ω

Charging current

Vac

A

Number of

Poles

A

CT part number

5.5 Contactors, MCBs and overload

Contactors and MCBs are required as follows:

Table 5-5 Contactors and MCBs

Function Ref Description Specification

3 pole NO + auxiliary NO

Main contactor K2

Auxiliary

contactor

Switching

frequency filter

MCB

Thermal

magnetic

overload

MCB 1x is fitted between the switching frequency filter capacitors and the AC supply. The MCB should have an auxiliary which the enable for the
Regen and motoring drive is connected through. This will act as a safe guard and prevent the system running with a fault on the switching frequency
filter. Also refertoAppendix B Component sizing calculations on page36.

contact. Coil voltage selected
to suit available supply.

K3 2 pole NC + auxiliary NO

MCB

3 pole + auxiliary NC

1x

Ovld Single pole

UnidriveRegenInstallationGuide 11
Issue Number: 2 www.controltechniques.com

Current ratingequal to totalcurrentrequirement.
Voltage rating equaltoAC mains supplyvoltage.

Coil mustnotexceed 240Vac5A resistiveload.
Installation category 1.

Currentrating sized to rms currentof switchingfrequency filter
capacitors andchargingcurrent at powerup.
(Refer to Table 5-6).

Sized to thesoftstart resistortoprotect thermally and
magnetically.(Refer to Appendix B Componentsizing
calculations on page 36).

5.6 Switching frequency filter

The AC input terminals of a Regen drive produce a PWM output voltage, which has a sinusoidal component at line frequency, plus significant
harmonics at the switching frequency and its multiples.

This filter prevents switching frequency harmonic currents gettingbackinto the supply. If the filter is notfitted, the presence of currents in the kHz
regioncould cause supply problemsordisturbance to otherequipment.

NOTE

The switching frequencyfilter inductors needtobe rated to the totalcurrent requirement.
The followinginductorsarestandard 3-phase inductors(ratedatdrive ratedcurrentfora singleRegensystem or rated at total currentrequirementfor

multiple Regensystem), they carry only 50/60Hzcurrentwith a negligible amountof highfrequency current.
The capacitors specified below are suitable for operation at any switching frequency. These capacitors are sized for operation at 3kHz however

operation above 3kHz is possible with the capacitors being more effective.

Table 5-6 Switching frequency filter

N

Drive 3-phase inductor 3-phase capacitor MCB rating

Rated

Model

UNI 1405 9.5 3.160 4401-0162
UNI 2401 12 2.500 4401-0163 31
UNI 2402 16 1.875 4401-0164 36
UNI 2403 25 1.200 4401-0165 45
UNI 3401 34 0.880 4401-0166
UNI 3402 40 0.750 4401-0167 115
UNI 3403 46 0.650 4401-0168 124
UNI 3404 60 0.500 4401-0169 142
UNI 3405 70 0.390 4401-0170 160
UNI 4401 96 0.315 4401-0171
UNI 4402 124 0.240 4401-0172 262
UNI 4403 156 0.190 4401-0173 325
UNI 4404 180 0.165 4401-0174 348
UNI 4405 202 0.135 4401-0175 385
UNI 5401 300 0.100 4401-0176 80 (x1)
UNI 5402 600 0.050 4401-0177 80 (x2) 580
UNI 5403 900 0.034 4401-0178 80 (x3) 580
UNI 5404 1200 0.025 4401-0179 80 (x4) 580

UNI 540

current

AmH µFAA

X

300 x

Lfilt

X

0.100 /

CT part

number

X

Cfilt

5.7 1610 - 5752 2.1

24 1665 - 2244 15

48 1665 - 2484 25

80 (xX)580

CT part

number

1665 - 2804

rms

current

35 per

capacitor

Peak

current

28

106

252

580

X

= number of size 5 drives

5.6.1 Protection

An MCB shouldbefitted between the AC supplyand the capacitor.This is to protect thewiring betweenthecapacitorandthemainbus bar.

NOTE

For multiple Regen systems, refertoAppendix B Component sizing calculations on page 36 for sizing of the MCB.

N

12 Unidrive Regen Installation Guide

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5.7 RFI filter

E

In common withconventional drives, significantground currentsaregeneratedby the capacitance of the motorto ground, themotor cablesto ground,
and the drivepower circuits to t heir heatsinks.The RFIfilter willprovide a relatively shortr eturn path for ground currents back to the drivespower
circuit.

Table 5-7 RFI filter data

CT Model

Number

UNI1405 480 4 10

UNI2401 to 2402 480 7.5 16

UNI2403 480 11 25

UNI3401 to 3403 480 22 50 Book End 100 4200-6116

UNI3404 480 30 63 B ook End 100 4200-6117

UNI3405 480 37 100 Book End 100 4200-6106
UNI4401 to 4402 480 55 150 Book End 100 4200-6107
UNI4403 to 4404 480 90 180 Book End 100 4200-6111

UNI4405 480 110 220 BookEnd 100 4200-6112

UNI5401 480 160 300 BookEnd 100 4200-6115

Volts

Vac kW A m

Maximum

power

Filter

current

rating

Mounting style

Book End 100 4200-6105

Footprint or Book End 100 4200-6104

Book End 100 4200-6109

Footprint or Book End 100 4200-6108

Book End 100 4200-6114

Footprint or Book End 100 4200-6113

Motor

cable

length

CT part

number

Do not use an RFI filter without the specified switching frequency filter, as failure of the RFI filter will occur, due to the switching currents.

CAUTION

5.8 Varistors

AC line voltage transients can typically be caused by the switching of large items of plant, or by lightning strikes on another part of the supply system.
If thesetransientsare not suppressed, they cancause damagetotheinsulation of the Regen inputinductors,orto the Unidrive Regen drive
electronics.

Table 5-8 Varistors

Configuration

Line to line 1 to 5 550 400 Z500NS 3 2482-1501

Line to ground 1 to 5 680 450 Z680LNS 3 2482-0680

NOTE

Seven varistors are requiredwhen operating with an IT supplyas shown in Figure3-1 on page 5, Figure 3-2 on page 6 and Figure A-2 on page 32.

N

Drive

size

Varistor

voltage

Vac J

5.8.1 Configuration

Varistors should be fitted after the supply fuses, as shown in Figure 5-1:

Figure 5-1 Fitting of Varistors

Fuses Varistors

R

Y

B

550Vac

varistors

680Vac
varistors

RFI

Filter

Varistor

energy

Type number Quantity CT part number

Switching

Frequency

Filter

UnidriveRegenInstallationGuide 13
Issue Number: 2 www.controltechniques.com

5.9 Fusing

RegenInductor

+DC-DC+DC-DCUVW

RegenDriveMotoringDrive

DCBusFusing

RegenInductor+DC-DC

+DC-D

C

+DC-DCUVW

RegenDriveM

o

D

M

o

D

Fusing for the Regen systemis requiredinorder to protectthefollowing:

• Supply transformer

• Supply cables

• Regeninductor

• Regendrive

•Motoringdrive
In the event of failure, the fusing will prevent fire by limiting the amount of energy allowed into the Regen and motoring drive units. The AC supply

fusingshouldberatedtotheRegensystem’scontinuousratedcurrent.TheRegenACfusingwhenusedwitheachmultiplesize5Regendrive
should be ratedtothe 450Acontinuousrated currentof the drive. The +
motoring driveratedcurrent and >

750Vdc.

5.9.1 Standard systems

FusingforastandardRegen system,single Regen plussingle motoring drive (both drives of the same rating)should consistofACsupply fusingas
shown below:

Figure 5-2 Fusing: Standard systems

DCbusfusingwhenusedwithmultiplemotoringdrivesshouldberatedto2x

3 Phase

Supply

AC
Supply
Fusing

R

Y

B

Main

Contactor

Additional

Circuitry

U
V
W

M

5.9.2 Multiple size 1 to 4 motoring drives

When a Regensystem consists of multiplesize 1 to 4 motoringdrives, AC supplyfusing and +DCbusfusingshouldbefittedasshownbelow:

Figure 5-3 Fusing: Multiple size 1 to 4 motoringdrives Regen system

toring
rive

U

3Phase

Supply

V

AC

Supply

R

Fusing

Y

Main

Contactor

Additional

Circuitry

W

B

toring
rive

U
V

W

M

M

14 Unidrive Regen Installation Guide

www.controltechniques.com Issue Number: 2