Control Techniques Unidrive SP Users Manual

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User Guide

Model sizes 0 to 6

Universal Variable Speed AC Drive for induction and servo motors

Part Number: 0471-0000-12 Issue: 12

www.controltechniques.com

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 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.

The software version of the drive can be checked by looking at Pr 11.29 (or Pr 0.50) and Pr 11.34. The software version takes the form of zz.yy.xx, where Pr 11.29 displays zz.yy and Pr 11.34 displays xx, i.e. for software version 01.01.00, Pr 11.29 would display 1.01 and Pr 11.34 would display 0.

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, while 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, while smaller products come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these containers can be recycled. Polythene, used on the protective film and bags for wrapping product, can be recycled in the same way. 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.

How to use this guide

NOTE

1 Safety information

2 Product information

3 Mechanical installation

4 Electrical installation

5 Getting started

6 Basic parameters

7 Running the motor

8 Optimization

9 SMARTCARD operation

11 Advanced parameters

12 Technical data

13 Diagnostics

14 UL listing information

10 Onboard PLC

This user guide provides complete information for installing and operating the drive from start to finish. The information is in logical order, taking the reader from receiving the drive through to fine tuning the performance.

There are specific safety warnings throughout this guide, located in the relevant sections. In addition, Chapter 1 Safety Information 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, but for specific information, refer to Contents on page 4:

Contents

Declaration of Conformity (size 0) .......... 6

Declaration of Conformity (Size 1 to 3) .. 7

Declaration of Conformity (Size 4 and 5) 8

Declaration of Conformity (Size 6) .......... 9

1 Safety Information ...............................10

1.1 Warnings, Cautions and Notes ...........................10

1.2 Electrical safety - general warning ......................10

1.3 System design and safety of personnel ..............10

1.4 Environmental limits ............................................10

1.5 Compliance with regulations ...............................10

1.6 Motor ...................................................................10

1.7 Adjusting parameters ..........................................10

2 Product Information ............................11

2.1 Ratings ................................................................11

2.2 Model number .....................................................15

2.3 Operating modes .................................................15

2.4 Compatible encoders ..........................................16

2.5 Drive features ......................................................17

2.6 Nameplate description ........................................19

2.7 Options ................................................................21

2.8 Items supplied with the drive ...............................24

3 Mechanical Installation .......................25

3.1 Safety information ...............................................25

3.2 Planning the installation ......................................25

3.3 Terminal cover removal .......................................25

3.4 Solutions Module / keypad installation / removal 29

3.5 Mounting methods ...............................................32

3.6 Enclosure for standard drives .............................42

3.7 Enclosure design and drive ambient

temperature .........................................................43

3.8 Heatsink fan operation ........................................44

3.9 Enclosing standard drive for high environmental

protection ............................................................44

3.10 External EMC filter .............................................48

3.11 Internal/heatsink mounted braking resistor .........54

3.12 Electrical terminals ..............................................58

3.13 Routine maintenance ..........................................60

4 Electrical Installation .......................... 61

4.1 Power connections ............................................. 61

4.2 AC supply requirements ..................................... 65

4.3 Supplying the drive with DC / DC bus paralleling 66

4.4 Heatsink fan supply ............................................ 66

4.5 Control 24Vdc supply ......................................... 66

4.6 Low voltage DC power supply ............................ 67

4.7 Ratings ............................................................... 67

4.8 Output circuit and motor protection .................... 70

4.9 Braking ............................................................... 72

4.10 Ground leakage .................................................. 75

4.11 EMC (Electromagnetic compatibility) ................. 75

4.12 Serial communications connections ................... 84

4.13 Control connections ........................................... 85

4.14 Encoder connections .......................................... 89

4.15 Low voltage DC mode enable and heatsink fan

supply connections (size 4 to 6) ......................... 92

4.16 SAFE TORQUE OFF (SECURE DISABLE) ....... 93

5 Getting Started.................................... 96

5.1 Understanding the display .................................. 96

5.2 Keypad operation ............................................... 96

5.3 Menu structure ................................................... 97

5.4 Menu 0 ............................................................... 98

5.5 Advanced menus ............................................... 99

5.6 Changing the operating mode .......................... 100

5.7 Saving parameters ........................................... 100

5.8 Restoring parameter defaults ........................... 100

5.9 Parameter access level and security ............... 101

5.10 Displaying parameters with non-default values

only ................................................................... 102

5.11 Displaying destination parameters only ........... 102

5.12 Serial communications ..................................... 102

6 Basic parameters .............................. 104

6.1 Single line descriptions .................................... 104

6.2 Full descriptions ............................................... 108

7 Running the motor ............................ 118

7.1 Quick start Connections ................................... 118

7.2 Changing the operating mode .......................... 118

7.3 Quick Start commissioning/start-up ................. 122

7.4 Quick start commissioning/start-up (CTSoft) ... 126

7.5 Setting up a feedback device ........................... 126

8 Optimization ...................................... 130

8.1 Motor map parameters ..................................... 130

8.2 Maximum motor rated current .......................... 140

8.3 Current limits .................................................... 140

8.4 Motor thermal protection .................................. 140

8.5 Switching frequency ......................................... 141

8.6 High speed operation ....................................... 141

4 Unidrive SP User Guide

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9 SMARTCARD operation .................... 143

9.1 Introduction .......................................................143

9.2 Transferring data ...............................................144

9.3 Data block header information ..........................146

9.4 SMARTCARD parameters ................................146

9.5 SMARTCARD trips ...........................................148

10 Onboard PLC .....................................150

10.1 Onboard PLC and SYPTLite .............................150

10.2 Benefits .............................................................150

10.3 Limitations .........................................................150

10.4 Getting started ..................................................151

10.5 Onboard PLC parameters .................................151

10.6 Onboard PLC trips ............................................152

10.7 Onboard PLC and the SMARTCARD ...............152

11 Advanced parameters .......................153

11.1 Menu 1: Frequency / speed reference ..............160

11.2 Menu 2: Ramps .................................................164

11.3 Menu 3: Frequency slaving, speed feedback

and speed control .............................................167

11.4 Menu 4: Torque and current control ..................172

11.5 Menu 5: Motor control .......................................176

11.6 Menu 6: Sequencer and clock ..........................181

11.7 Menu 7: Analog I/O ...........................................184

11.8 Menu 8: Digital I/O ............................................186

11.9 Menu 9: Programmable logic, motorized pot,

binary sum and timers .......................................189

11.10 Menu 10: Status and trips .................................192

11.11 Menu 11: General drive set-up .........................193

11.12 Menu 12: Threshold detectors, variable

selectors and brake control function .................194

11.13 Menu 13: Position control .................................200

11.14 Menu 14: User PID controller ............................206

11.15 Menus 15, 16 and 17: Solutions Module set-up 209

11.16 Menu 18: Application menu 1 ...........................245

11.17 Menu 19: Application menu 2 ...........................245

11.18 Menu 20: Application menu 3 ...........................245

11.19 Menu 21: Second motor parameters ................246

11.20 Menu 22: Additional Menu 0 set-up ..................248

11.21 Advanced features ............................................249

14 UL Listing Information ......................294

14.1 Common UL information ...................................294

14.2 Power dependant UL information .....................294

14.3 AC supply specification .....................................294

14.4 Maximum continuous output current .................294

14.5 Safety label .......................................................295

14.6 UL listed accessories ........................................295

List of figures .................................... 296

List of tables ..................................... 298

Index .................................................. 300

12 Technical Data ...................................258

12.1 Drive technical data ..........................................258

12.2 Optional external EMC filters ............................272

13 Diagnostics ........................................276

13.1 Trip indications ..................................................276

13.2 Alarm indications ...............................................292

13.3 Status indications ..............................................292

13.4 Displaying the trip history ..................................293

13.5 Behaviour of the drive when tripped .................293

Unidrive SP User Guide 5 Issue Number: 12 www.controltechniques.com

Control Techniques Ltd

The Gro

Newtown

Powys

SY16 3BE

Declaration of Conformity (size 0)

SP0201 SP0202 SP0203 SP0204 SP0205

SP0401 SP0402 SP0403 SP0404 SP0405

The AC variable speed drive products listed above have been designed and manufactured in accordance with the following European

harmonised standards:

EN 61800-5-1

EN 61800-3

EN 61000-6-2

EN 61000-6-4

EN 61000-3-2

EN 61000-3-3

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

Adjustable speed electrical power drive systems safety requirements - electrical, thermal and energy

Adjustable speed electrical power drive systems. EMC product standard including specific test methods

Electromagnetic compatibility (EMC). Generic standards. Immunity standard for industrial environments

Electromagnetic compatibility (EMC). Generic standards. Emission standard for industrial environments

Electromagnetic compatibility (EMC), Limits, Limits for harmonic current emissions (equipment input current <16A per phase)

Electromagnetic compatibility (EMC), Limits, Limitation of voltage fluctuations and flicker in lowvoltage supply systems for equipment with rated current <16A

These products comply with the Low Voltage Directive 2006/95/EC, the Electromagnetic Compatibility (EMC) Directive 2004/108/EC and the CE Marking Directive 93/68/EEC.

W. Dru ry

Executive Vice President, Technology

Newtown

Date: 8th August 2007

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 User Guide. An EMC Data Sheet is also available giving detailed EMC information.

6 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Declaration of Conformity (Size 1 to 3)

Control Techniques Ltd

The Gro

Newtown

Powys

SY16 3BE

SP1201 SP1202 SP1203 SP1204

SP2201 SP2202 SP2203

SP3201 SP3202

SP1401 SP1402 SP1403 SP1404 SP1405 SP1406

SP2401 SP2402 SP2403 SP2404

SP3401 SP3402 SP3403

SP3501 SP3502 SP3503 SP3504 SP3505 SP3506 SP3507

The AC variable speed drive products listed above have been designed and manufactured in accordance with the following European

harmonised standards:

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. D ru ry

Executive Vice President, Technology

Newtown

EN 50178 Electronic equipment for use in power installations

Adjustable speed electrical power drive systems.

EN 61800-3

EN 61000-6-2

EN 61000-6-4

EN 50081-2

EN 50082-2

EN 61000-3-2

EN 61000-3-3

These products are for professional use, and power input exceeds

1kW for all models, so no limits apply.

EMC product standard including specific test methods

Electromagnetic compatibility (EMC). Generic standards. Immunity standard for industrial environments

Electromagnetic compatibility (EMC). Generic standards. Emission standard for industrial environments

Electromagnetic compatibility. Generic emission standard. Industrial environment

Electromagnetic compatibility. Generic immunity standard. Industrial environment

Electromagnetic compatibility (EMC). Limits. Limits

for harmonic current emissions (equipment input current up to and including 16 A per phase)

Electromagnetic compatibility (EMC). Limits. Limitation of voltage fluctuations and flicker in lowvoltage supply systems for equipment with rated current <= 16 A

Date: 22nd July 2004

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 this User Guide. An EMC Data Sheet is also available giving detailed EMC information.

Unidrive SP User Guide 7 Issue Number: 12 www.controltechniques.com

Control Techniques Ltd

The Gro

Newtown

Powys

SY16 3BE

Declaration of Conformity (Size 4 and 5)

SP4201 SP4202 SP4203

SP5201 SP5202

SP4401 SP4402 SP4403

SP5401 SP5402

SP4601 SP4602 SP4603 SP4604 SP4605 SP4606

SP5601 SP5602

The AC variable speed drive products listed above have been designed and manufactured in accordance with the following European

harmonised standards:

EN 61800-5-1

EN 61800-3

EN 61000-6-2

EN 61000-6-4

Adjustable speed electrical power drive systems safety requirements - electrical, thermal and energy

Adjustable speed electrical power drive systems. EMC product standard including specific test methods

Electromagnetic compatibility (EMC). Generic standards. Immunity standard for industrial environments

Electromagnetic compatibility (EMC). Generic standards. Emission standard for industrial environments

These products comply with the Low Voltage Directive 2006/95/EC, the Electromagnetic Compatibility (EMC) Directive 2004/108/EC and the CE Marking Directive 93/68/EEC.

Executive Vice President, Technology

Newtown

Date: 21st July 2006

8 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Control Techniques Ltd

The Gro

Newtown

Powys

SY16 3BE

Declaration of Conformity (Size 6)

SP6401 SP6402

SP6601 SP6602

The AC variable speed drive products listed above have been designed and manufactured in accordance with the following European

harmonised standards:

EN 61800-5-1

EN 61800-3

EN 61000-6-2

Adjustable speed electrical power drive systems safety requirements - electrical, thermal and energy

Adjustable speed electrical power drive systems. EMC product standard including specific test methods

Electromagnetic compatibility (EMC). Generic standards. Immunity standard for industrial environments

These products comply with the Low Voltage Directive 2006/95/EC, the Electromagnetic Compatibility (EMC) Directive 89/336/EEC and the CE Marking Directive 93/68/EEC.

Executive Vice President, Technology

Newtown

Date: 17th January 2005

Unidrive SP User Guide 9 Issue Number: 12 www.controltechniques.com

Safety

WARNING

CAUTION

NOTE

Information

Product

Information

Mechanical

Installation

Electrical

Installation

Getting Started

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

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.

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

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

1.2 Electrical safety - general warning

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

Specific warnings are given at the relevant places in this User Guide.

1.3 System design and safety of

The drive is intended as a component for professional incorporation into complete equipment or a system. If installed incorrectly, the drive may present a safety hazard.

The drive uses high voltages and currents, carries a high level of stored electrical energy, and is used to control equipment which can cause injury.

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

The STOP and SAFE TORQUE OFF (SECURE DISABLE) function functions of the drive do not isolate dangerous voltages from the output of the drive or from any external option unit. The supply must be disconnected by an approved electrical isolation device before gaining access to the electrical connections.

With the sole exception of the SAFE TORQUE OFF (SECURE DISABLE) function, none of the drive functions must be used to ensure safety of personnel, i.e. they must not be used for safetyrelated functions.

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

The SAFE TORQUE OFF (SECURE DISABLE) function has been approved

prevention of unexpected starting of the drive. It may be used in a safety-related application. The system designer is responsible for

ensuring that the complete system is safe and designed correctly according to the relevant safety standards.

personnel

as meeting the requirements of EN954-1 category 3 for the

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 installed with a protection thermistor. If necessary, an electric forced vent fan should be used.

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

It is essential that the correct value is entered in parameter 0.46 motor rated current. This affects the thermal protection of the motor.

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.

Independent approval by BGIA has been given.

10 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

Available output

current

Overload limit -

Heavy Duty

Maximum continuous current (above 50% base speed) -

Normal Duty

Maximum continuous current -

Heavy Duty

Motor rated current set in the drive

Heavy Duty

- with high

overload capability

Normal Duty

Overload limit -

Normal Duty

NOTE

Motor total

current (Pr 4.01)

as a percentage

of motor rated

current

Motor speed as a percentage of base speed

100%

Max. permissible continuous current

100%

I t protection operates in this region

70%

50%15%

Pr = 0 Pr = 1

4.25

Motor total

current (Pr 4.01)

as a percentage

of motor rated

current

Motor speed as a percentage of base speed

100%

Max. permissible

continuous current

100%

I t protection operates in this region

70%

50%

Pr = 0

Pr = 1

4.25

Information

Product

Information

Mechanical

Installation

Electrical

Installation

Getting Started

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

2 Product Information

2.1 Ratings

The Unidrive SP is dual rated. The setting of the motor rated current determines which rating applies Heavy Duty or Normal Duty. The two ratings are compatible with motors designed to IEC60034. The graph aside illustrates the difference between Normal Duty and Heavy Duty with respect to continuous current rating and short term overload limits.

Normal Duty Heavy Duty (default)

For applications which use Self ventilated (TENV/TEFC) induction motors and require a low overload capability, and full torque at low speeds is not required (e.g. fans, pumps). Self ventilated (TENV/TEFC) induction motors require increased protection against overload due to the reduced cooling effect of the fan

at low speed. To provide the correct level of protection the I

t software operates at a level which is speed dependent. This is illustrated in the graph below.

The speed at which the low speed protection takes effect can be changed by the setting of Pr 4.25. The protection starts when the motor speed is below 15% of base speed when Pr 4.25 = 0 (default) and below 50% when Pr 4.25 = 1.

Operation of motor I2t protection (It.AC trip)

Motor I2t protection is fixed as shown below and is compatible with:

• Self ventilated (TENV/TEFC) induction motors

For constant torque applications or applications which require a high overload capability, or full torque is required at low speeds (e.g. winders, hoists). The thermal protection is set to protect force ventilated induction motors and permanent magnet servo motors by default.

If the application uses a self ventilated (TENV/TEFC) induction motor and increased thermal protection is required for speeds below 50% base speed, then this can be enabled by setting Pr 4.25 = 1.

Motor I2t protection defaults to be compatible with:

• Forced ventilation induction motors

• Permanent magnet servo motors

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

Unidrive SP User Guide 11 Issue Number: 12 www.controltechniques.com

Safety

Information

Product

Information

Mechanical

Installation

Electrical

Installation

Getting Started

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

The continuous current ratings given are for maximum 40°C (104°F), 1000m altitude and 3.0 kHz switching. Derating is required for higher switching frequencies, ambient temperature >40°C (104°F) and high altitude. For further information, refer to section 12.1.1 Power and current ratings (Derating for switching frequency and temperature) on page 258.

Table 2-1 200V drive ratings (200V to 240V ±10%)

Normal Duty Heavy Duty

Model

Maximum

continuous

output current

AkWhpAAAAkWhp

0201 0202 0203 0204 0205 1201 5.2 1.1 1.5 5.7 4.3 6.4 7.5 0.75 1.0 1202 6.8 1.5 2.0 7.4 5.8 8.7 10.1 1.1 1.5 1203 9.6 2.2 3.0 10.5 7.5 11.2 13.1 1.5 2.0 1204 11 3.0 3.0 12.1 10.6 15.9 18.5 2.2 3.0

2201 15.5 4.0 5.0 17.0 12.6 18.9 22 3.0 3.0

2202 22 5.5 7.5 24.2 17 25.5 29.7 4.0 5.0

2203 28 7.5 10 30.8 25 37.5 43.7 5.5 7.5

3201 42 11 15 46 31 46.5 54.2 7.5 10

3202 54 15 20 59 42 63 73.5 11 15

Nominal

power

at 220V

Motor power

at 230V

Peak

current

Maximum

continuous

output current

2.2 3.3 3.8 (3.3)* 0.37 0.5

3.1 4.6 5.4 (4.6)* 0.55 0.75

4.0 6.0 7.0 (6.0)* 0.75 1.0

5.7 8.5 9.9 (8.5)* 1.1 1.5

7.5 11.2

Open

loop peak

current

Closed

loop peak

current

13.1 (11.2)*

Nominal

power

at 220V

1.5 2.0

Motor power

at 230V

4201 68 18.5 25 74 56 84 98 15 20

4202 80 22 30 88 68 102 119 18.5 25

4203 104 30 40 114 80 120 140 22 30

5201 130 37 50 143 105 157 183 30 40

5202 154 45 60 169 130 195 227 37 50

*The closed loop peak current is based on 175% of the maximum continuous output current when the drive is used on a 3 phase supply. The value in brackets is the peak current based on 150% of the maximum continuous output current when the drive is used on a 1 phase supply.

12 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

Information

Product

Information

Mechanical

Installation

Electrical

Installation

Getting Started

parameters

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

Normal Duty Heavy Duty

Model

Maximum

continuous

output current

AkWhpA AAAkWhp

0401 0402 0403 0404 0405 1401 2.8 1.1 1.5 3.0 2.1 3.1 3.6 0.75 1.0 1402 3.8 1.5 2.0 4.1 3.0 4.5 5.2 1.1 2.0 1403 5.0 2.2 3.0 5.5 4.2 6.3 7.3 1.5 3.0 1404 6.9 3.0 5.0 7.5 5.8 8.7 10.1 2.2 3.0 1405 8.8 4.0 5.0 9.6 7.6 11.4 13.3 3.0 5.0 1406 11 5.5 7.5 12.1 9.5 14.2 16.6 4.0 5.0 2401 15.3 7.5 10 16.8 13 19.5 22.7 5.5 10 2402 21 11 15 23 16.5 24.7 28.8 7.5 10 2403 29 15 20 31 25 34.5 40.2 11 20 2404

3401 35 18.5 25 38 32 48 56 15 25

3402 43 22 30 47 40 60 70 18.5 30

3403 56 30 40 61 46 69 80.5 22 30

4401 68 37 50 74 60 90 105 30 50

Nominal

power

at 400V

Basic

Running

the motor

Motor power

at 460V

Optimization

Peak

current

SMARTCARD

operation

Maximum

continuous

output current

Onboard

1.3 1.9 2.2 0.37 0.5

1.7 2.5 2.9 0.55 0.75

2.1 3.1 3.6 0.75 1.0

3.0 4.5 5.2 1.1 1.5

4.2 6.3

29 43.5 50.7 15 20

PLC

Open

loop peak

current

Advanced

parameters

Closed

loop peak

current

7.3

Technical

Data

Diagnostics

Nominal

power

at 400V

1.5 2.0

UL Listing

Information

Motor power

at 460V

4402 83 45 60 91 74 111 129.5 37 60

4403 104 55 75 114 96 144 168 45 75

5401 138 75 100 151 124 186 217 55 100

5402 168 90 125 184 156 234 273 75 125

6401 205 110 150 225 180 231 269 90 150

6402 236 132 200 259 210 270 315 110 150

Unidrive SP User Guide 13 Issue Number: 12 www.controltechniques.com

Safety

56 4

Information

Product

Information

Mechanical

Installation

Electrical

Installation

Getting Started

Table 2-3 575V drive ratings (500V to 575V ±10%)

Normal Duty Heavy Duty

Model

Maximum

continuous

output current

AkWhpA AAAkWhp

3501 5.4 3.0 3.0 5.9 4.1 6.1 7.1 2.2 2.0 3502 6.1 4.0 5.0 6.7 5.4 8.1 9.4 3.0 3.0 3503 8.4 5.5 7.5 9.2 6.1 9.1 10.6 4.0 5.0 3504 11 7.5 10 12.1 9.5 14.2 16.6 5.5 7.5 3505 16 11 15 17.6 12 18 21 7.5 10 3506 22 15 20 24.2 18 27 31.5 11 15 3507 27 18.5 25 29.7 22 33 38.5 15 20

4603 36 22 30 39.6 27 40.5 47.2 18.5 25

4604 43 30 40 47.3 36 54 63 22 30

4605 52 37 50 57.2 43 64.5 75.2 30 40

4606 62 45 60 68 52 78 91 37 50

5601 84 55 75 92 63 93 108.5 45 60

5602 99 75 100 108 85 126 147 55 75

Nominal

power

at 575V

Basic

parameters

Running

the motor

Motor power

at 575V

Optimization

Peak

current

SMARTCARD

operation

Maximum

continuous

output current

Onboard

PLC

Open

loop peak

current

Advanced

parameters

Closed

loop peak

current

Technical

Data

Diagnostics

Nominal

power

at 575V

UL Listing

Information

Motor power

at 575V

6601 125 90 125 137 100 128 149 75 100

6602 144 110 150 158 125 160 187 90 125

The power ratings above for model size 4 and larger are for the 690V drives when used on a 500V to 575V supply.

Table 2-4 690V drive ratings (500V to 690V ±10%)

Normal Duty Heavy Duty

Model

Maximum

continuous

output current

AkWhpA AAAkWhp

4601 22 18.5 25 24.2 19 27 31.5 15 20 4602 27 22 30 29.7 22 33 38.5 18.5 25 4603 36 30 40 39.6 27 40.5 47.2 22 30 4604 43 37 50 47.3 36 54 63 30 40 4605 52 45 60 57.2 43 64.5 75.2 37 50 4606 62 55 75 68.2 52 78 91 45 60

5601 84 75 100 92 63 93 108.5 55 75

5602 99 90 125 108 85 126 147 75 100

Nominal

power

at 690V

Motor power

at 690V

Peak

current

Maximum

continuous

output current

Open

loop peak

current

loop peak

Closed

current

Nominal

power

at 690V

Motor power

at 690V

6601 125 110 150 137 100 128 149 90 125

6602 144 132 175 158 125 160 187 110 150

14 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

NOTE

Unidrive product line

SP frame size

Voltage rating

2: 4: 5: 6:

200V to 240V 380V to 480V 500V to 575V 500V to 690V

Configuration

0: Wall mount drive

Current rating step

Solutions Platform Complete inverter drive

SP 6 4 0 1

Information

Product

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Electrical

Installation

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Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

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Advanced

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Technical

Data

Diagnostics

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2.1.1 Typical short term overload limits

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

Typical values are shown in the table below for closed loop vector (VT) and open loop (OL) modes:

Table 2-5 Typical overload limits for size 0 to 5

Operating mode Closed loop from cold Closed loop from 100% Open loop from cold Open loop from 100%

Normal Duty overload with motor rated current = drive rated current 110% for 165s 110% for 9s 110% for 165s 110% for 9s Heavy Duty overload with motor rated current = drive rated current 175% for 40s 175% for 5s 150% for 60s 150% for 8s Heavy Duty overload with a typical 4 pole motor 200% for 28s 200% for 3s 175% for 40s 175% for 5s

Table 2-6 Typical overload limits for size 6

Operating mode Closed loop from cold Closed loop from 100% Open loop from cold Open loop from 100%

Generally the drive rated current is higher than the matching motor rated current allowing a higher level of overload than the default setting as illustrated by the example of a typical 4 pole motor.

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

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

2.2 Model number

The way in which the model numbers for the Unidrive SP range are formed is illustrated below.

2.3 Operating modes

The Unidrive SP is designed to operate in any of the following modes:

1. Open loop mode Open loop vector mode Fixed V/F mode (V/Hz) Quadratic V/F mode (V/Hz)

2. RFC mode

3. Closed loop vector

4. Servo

5. Regen

2.3.1 Open loop mode

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 speed control 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.

For further details refer to section 8.1.1 Open loop motor control on page 130.

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 is available down to 1Hz for a 50Hz motor.

Fixed 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 can be used for multi-motor applications.

Typically 100% torque is available down to 4Hz for a 50Hz motor.

Quadratic V/F mode

The voltage applied to the motor is directly proportional to the square of the frequency except at low speed where a voltage boost is provided which is set by the user. This mode can be used for running fan or pump applications with quadratic load characteristics or for multi-motor applications. This mode is not suitable for applications requiring a high starting torque.

2.3.2 RFC mode

Rotor flux control provides closed loop control without the need for position feedback by using current, voltages and key motor parameters to estimate the motor speed. It can eliminate instability traditionally associated with open loop control such as operating large motors with light loads at low frequencies.

For further details, refer to section 8.1.2 RFC mode on page 132.

2.3.3 Closed loop vector mode

For use with induction motors with a feedback device installed. 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.

2.3.4 Servo

For use with permanent magnet brushless motors with a feedback device installed.

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. Full torque is available all the way down to zero speed.

Unidrive SP User Guide 15 Issue Number: 12 www.controltechniques.com

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2.3.5 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 SCR/thyristor front end.

See the Unidrive SP Regen Installation Guide for more information about operation in this mode.

2.4 Compatible encoders

Table 2-7 Encoders compatible with Unidrive SP

Encoder type

Quadrature incremental encoders with or without marker pulse

Quadrature incremental encoders with UVW commutation signals for absolute position for permanent magnet motors with or without marker pulse

Forward / reverse incremental encoders with or without marker pulse

Forward / reverse incremental encoders with UVW commutation signals for absolute position for permanent magnet motors with or without marker pulse

Frequency and direction incremental encoders with or without marker pulse

Frequency and direction incremental encoders with UVW commutation signals for absolute position for permanent magnet motors with or without marker pulse

Sincos incremental encoders SC (6) Heidenhain sincos encoders with Endat comms for

absolute position Stegmann sincos encoders with Hiperface comms

for absolute position Sincos encoders with SSI comms for absolute

position SSI encoders (Gray code or binary) SSI (10) Endat comms only encoders EndAt (8) UVW commutation only encoders* Ab.SErvo (3)

* This feedback device provides very low resolution feedback and should not be used for applications requiring a high level of performance

Pr 3.38 setting

Ab (0)

Ab.SErvo (3)

Fr (2)

Fr.SErvo (5)

Fd (1)

Fd.SErvo (4)

SC.EndAt (9)

SC.HiPEr (7)

SC.SSI (11)

Optimization

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16 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

Motor

connections

Marker tag

location

Relay terminal

Line to ground varistor screw

AC supply

48V connection (for low voltage DC operation)

Braking resistor connections

SMARTCARD slot

Serial port connector

Control terminals

Keypad connection

EMC bracket

Ground screw

Internal EMC filter screw

Control cable strain relief

Solutions Module slot 2 cover

Solutions Module slot 1 cover

Encoder In connection

EMC bracket

Ground screw

Status LED

Rating label

Approvals label

Brake

resistor slot

Fan

Information

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Mechanical

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Electrical

Installation

2.5 Drive features

Figure 2-1 Features of the size 0 drive

Getting Started

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

Unidrive SP User Guide 17 Issue Number: 12 www.controltechniques.com

Safety

Solutions Module slot 2

SMARTCARD slot

Keypad connection

Serial port connector

Encoder connection

Control terminals

Solutions Module slot 1

Solutions Module slot 3

Rating label

Status LED

Approvals label

Relay terminals

AC supply /

motor

connections

AC supply /

motor

connections

±DC Bus / Braking / 48V connection (for low voltage operation)

±DC Bus (High

current)

/ Braking

48V connection / ±DC Bus (Low current)

Internal EMC filter

AC supply /

motor

connections

48V connection / ±DC Bus (Low current)

Internal EMC filter

±DC Bus (High

current)

/ Braking

Motor

connections

supply

Internal

EMCfilter

Low voltage DC mode enable

supply

Brake

resistor

supply

Internal

EMC filter

supply

Motor

connections

Low voltage DC mode enable

Brake

resistor

supply

Internal

EMC filter

supply

Motor

connections

Low voltage DC mode enable / heatsink fan supply connections

Brake

resistor

Power stage label

NOTE

Information

Product

Information

Mechanical

Installation

Electrical

Installation

Getting Started

Figure 2-2 Features of the size 1 to 6 drive

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

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Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

The size 6 drive requires a 24V supply for the heatsink fan.

18 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

Model

SP0204 1.1kW

S/N: 3000005001 SPZ 2 M/TL

Serial number

Rating

Please read the manual before connecting

Electric Shock Risk: Wait 10 mins

between disconnecting supply

and accessing terminals

E171230

Date code

Approvals

Approvals label

I/P 200-240V 50-60Hz 1/3ph 13.5/7.9A O/P 0-240V 5.7/5.7A

Input voltage

Model Serial

number

Single/three phase peak output current

Output voltage range

SPZ 2 M/TL 3ph

Rating label

S/N: 3000005001

Single/three phase input current

Frequency

Motor

output

Q26

Designed in the U.K. Made in China

IND. CONTROL EQUIPMENT

RoHS

Compliant

Information

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Basic

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2.6 Nameplate description

See Figure 2-1 and Figure 2-2 for location of rating labels.

Figure 2-3 Typical drive rating labels for size 0

Running

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Unidrive SP User Guide 19 Issue Number: 12 www.controltechniques.com

Safety

SP1201

I/P 200-240V 50-60Hz 3ph 7.1A

O/P 0-240V 4.3 / 5.2A

Model

Input voltage rating

Input frequency

No. of phases

Typical input current for Normal Duty rating

Heavy Duty / Normal Duty rating output current

Output voltage range

SP 1,5 TL

Rating label (size 1 to 6)

S.No:

3000005001

Serial number

Model

Heavy Duty / Normal Duty power rating

Customer and date code

Approvals

IND. CONT. EQ.

Please read manual before connecting.

SP1201 0.75 / 1.1kW

STDL25

Electric Shock Risk: Wait 10 min between disconnecting supply & removing covers

Ser No:

3000005001

Made In U.K

Serial number

SP 1,5 TL

Approvals label (Size 1 to 6)

Model

Heavy Duty / Normal Duty power rating

Customer and

date code

Approvals

Please read manual before connecting.

SP5402 75 / 90kW

STDN39

Electric Shock Risk: Wait 10 min between disconnecting supply & removing covers

Ser No: 3000005001

Made In U.K

Serial number

SP 100 T

Power stage label (Size 5 and 6 only)

I/P 380-480V 50-60Hz 3ph 152.0A O/P 0-480V

156 / 168A

Input voltage

Output voltage

Input

frequency

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

Heavy Duty /

Normal Duty

rating output current

E171230

CE approval Europe

C Tick approval Australia

UL / cUL approval

USA &

Canada

Key to approvals

Information

Product

Information

Mechanical

Installation

Electrical

Installation

Getting Started

Basic

parameters

Figure 2-4 Typical drive rating labels for size 1 to 6 drives

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

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20 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

Keypad

Automation Fieldbus

Feedback

SMARTCARD*

CT Comms cable

Internal braking resistor (size 0 to 2 only)

External footprint / bookcase EMC filter

Inputs Outputs

• Incremental encoders • Quadrature

• SinCos encoders • Frequency and direction

• SSI encoders • SSI simulated outputs

• EnDat encoders

Information

Product

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Mechanical

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Electrical

Installation

Getting Started

2.7 Options

Figure 2-5 Options available with Unidrive SP

Basic

parameters

Running

the motor

Optimization

SMARTCARD

operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL Listing

Information

* A SMARTCARD is provided as standard. For further information, refer to Chapter 9 SMARTCARD operation on page 143.

All Solutions Modules are color-coded in order to make identification easy. The following table shows the color-code key and gives further details on their function.

Table 2-8 Solutions Module identification

Type Solutions Module Color Name Further Details

Feedback

Unidrive SP User Guide 21 Issue Number: 12 www.controltechniques.com

Light Green

SM-Universal Encoder Plus

Light Blue SM-Resolver

Brown SM-Encoder Plus

Dark Brown

N/A

SM-Encoder Output Plus

15-way D-type converter

Single ended

N/A

encoder interface (15V or 24V)

Universal Feedback interface

Feedback interface for the following devices:

Resolver interface

Feedback interface for resolvers. Simulated quadrature encoder outputs

Incremental encoder interface

Feedback interface for incremental encoders without commutation signals. No simulated encoder outputs available

Incremental encoder interface

Feedback interface for incremental encoders without commutation signals. Simulated encoder output for quadrature, frequency and direction signals

Drive encoder input converter

Provides screw terminal interface for encoder wiring and spade terminal for shield

Single ended encoder interface

Provides an interface for single ended ABZ or UVW encoder signals, such as those from hall effect sensors. 15V and 24V versions are available.

Safety

• Digital inputs x 3

• Analog output (voltage) x 1

• Digital I/O x 3 • Relay x 2

• Analog inputs (voltage) x 2

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Table 2-8 Solutions Module identification

Type Solutions Module Color Name Further Details

Extended I/O interface

Increases the I/O capability by adding the following to the

Yellow SM-I/O Plus

existing I/O in the drive:

Extended I/O interface

Increase the I/O capability by adding the following to the

Yellow SM-I/O 32

existing I/O in the drive:

• High speed digital I/O x 32

• +24V output

Additional I/O

1 x Analog input (± 10V bi-polar or current modes) 1 x Analog output (0-10V or current modes) 3 x Digital input and 1 x Relay

Additional I/O with real time clock

As per SM-I/O Lite but with the addition of a Real Time Clock

Automation

(I/O

Expansion)

Dark Yellow SM-I/O Lite

Dark Red SM-I/O Timer

for scheduling drive running

Isolated I/O to NAMUR NE37 specifications

For chemical industry applications

Turquoise SM-I/O PELV

1 x Analog input (current modes) 2 x Analog outputs (current modes) 4 x Digital input / outputs, 1 x Digital input, 2 x Relay outputs

Technical

Data

Diagnostics

UL Listing

Information

Automation

(Applications)

Olive SM-I/O 120V

Cobalt Blue

SM-I/O 24V Protected

Dark Green SM-Applications

White SM-Applications Lite

Dark Blue SM-EZMotion

Moss Green

White

SM-Applications Plus

SM-Applications Lite V2

Additional I/O conforming to IEC 61131-2 120Vac

6 digital inputs and 2 relay outputs rated for 120Vac operation

Additional I/O with overvoltage protection up to 48V

2 x Analog outputs (current modes) 4 x Digital input / outputs, 3 x Digital inputs, 2 x Relay outputs

Applications Processor (with CTNet)

processor for running pre-defined and /or customer created

application software with CTNet support

Applications Processor

processor for running pre-defined and /or customer created

application software

Motion Controller

/2 axis motion controller with processor for running customer

created application specific software

Applications Processor (with CTNet)

processor for running pre-defined and /or customer created application software with CTNet support. Enhanced performance over SM-Applications

Applications Processor

processor for running pre-defined and /or customer created application software. Enhanced performance over SMApplications Lite

22 Unidrive SP User Guide

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Getting Started

Basic

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Running

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Optimization

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Onboard

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Advanced

parameters

Table 2-8 Solutions Module identification

Type Solutions Module Color Name Further Details

Technical

Data

Diagnostics

UL Listing

Information

Fieldbus

Purple SM-PROFIBUS-DP

Medium Grey SM-DeviceNet

Dark Grey SM-INTERBUS

Pink SM-CAN

Light Grey SM-CANopen

Red SM-SERCOS

Beige SM-Ethernet

Profibus option

PROFIBUS DP adapter for communications with the drive

DeviceNet option

Devicenet adapter for communications with the drive

Interbus option

Interbus adapter for communications with the drive

CAN option

CAN adapter for communications with the drive

CANopen option

CANopen adapter for communications with the drive

SERCOS option

Class B compliant. Torque velocity and position control modes supported with data rates (bit/s): 2MB, 4MB, 8MB and 16MB. Minimum 250μs network cycle time. Two digital high speed probe inputs 1μs for position capture

Ethernet option

10 base-T / 100 base-T; Supports web pages, SMTP mail and multiple protocols: DHCP IP addressing; Standard RJ45 connection

Brown Red SM-EtherCAT

Pale Green SM-LON

EtherCAT option

EtherCAT adapter for communications with the drive

LonWorks option

LonWorks adapter for communications with the drive

SLM interface

The SM-SLM allows SLM feedback to be connected directly to

SLM Orange SM-SLM

the Unidrive SP drive and allows operation in either of the following modes:

• Encoder only mode

• Host mode

Table 2-9 Keypad identification

Type Keypad Name Further Details

LED keypad option

Keypad with a LED display for size 0

LED keypad option

Keypad with a LED display for size 1 to 9

LCD keypad option

Keypad with an alpha-numeric LCD display with Help function

Keypad

SP0 Keypad

SM-Keypad

SM-Keypad Plus

Unidrive SP User Guide 23 Issue Number: 12 www.controltechniques.com

Safety

CAUTION

Risk of Electric Shock

Power down unit 10minutes

before removing cover

M8x20

M6x12

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2.8 Items supplied with the drive

The drive is supplied with a printed manual, a SMARTCARD, a safety information booklet, the Certificate of Quality, an accessory kit box including the items shown in Table 2-10, and a CD ROM containing all related product documentation and software tools.

Table 2-10 Parts supplied with the drive

Description Size 0 Size 1 Size 2 Size 3 Size 4 Size 5 Size 6

Control connectors

Relay connector

UL warning label

Grounding bracket

Through panel mounting gasket

Through panel mounting bracket

Surface mounting brackets

Top surface mounting brackets

Nylon washers

Sealing clips

Mounting screws

Grounding clamp

Ground cable bridge and M5 nuts

DC terminal cover grommets

Ferrite ring

Supply and motor connector

Ground mounting screws

Fan supply connector

IP54 gasket

IP54 insert

24 Unidrive SP User Guide

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NOTE

WARNING

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3 Mechanical Installation

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

• Through-hole mounting

• IP54 as standard or through-panel mounting

• Enclosure sizing and layout

• Solutions Module fitting

• 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 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.

Many of the drives in this product range weigh in excess of 15kg (33lb). Use appropriate safeguards when lifting these models. A full list of drive weights can be found in section

12.1.19 Weights on page 266

Enclosure The drive is intended to be mounted in an enclosure which

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

3.2 Planning the installation

The following considerations must be made when planning the installation:

3.2.1 Access

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

The IP (Ingress Protection) rating of the drive is installation dependent. For further information, please refer to section 3.9 Enclosing standard drive for high environmental protection on page 44.

3.2.2 Environmental protection

The drive must be protected from:

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

• contamination with electrically conductive material

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

• temperature beyond the specified operating and storage ranges

• corrosive gasses

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

3.2.3 Cooling

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

For further information, refer to section 3.6.2 Enclosure sizing on page 42.

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 61.

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.

If it is necessary to meet strict emission limits, or if it is known that electromagnetically sensitive equipment is located nearby, then full precautions must be observed. In-built into the drive, is an internal EMC filter, which reduces emissions under certain conditions. If these conditions are exceeded, then the use of an external EMC filter may be required at the drive inputs, which must be located very close to the drives. Space must be made available for the filters and allowance made for carefully segregated wiring. Both levels of precautions are covered in section 4.11 EMC (Electromagnetic compatibility) on page 75.

3.2.7 Hazardous areas

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

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 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 energized, 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 authorized distributor.

3.3.1 Removing the terminal covers

Size 0 is not fitted with any terminal covers. Size 1 is fitted with two terminal covers: Size 2 is fitted with three terminal covers: Control, High current DC /

Braking and low voltage DC terminal covers. Size 3 is fitted with four terminal covers: Control, High current DC /

Braking, low voltage DC and AC terminal covers. Size 4, 5 and 6 are fitted with three terminal covers: Control, input and

output terminal covers.

Control

and DC terminal covers.

Unidrive SP User Guide 25 Issue Number: 12 www.controltechniques.com

Safety

Control

Low voltage DC

Control ControlAC

High current

DC / Braking

Input

ControlOutput ControlOutput

Control

Output

Input

21 3

4 5

Low voltage DC

High current

DC / Braking

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In order to provide access to the mounting holes when a size 1, 2 or 3 drive is through-panel mounted, the control terminal cover must be removed. For size 3 the high current DC / Braking and AC terminal covers must also be removed. Once the drive has been mounted, the terminal covers can be replaced.

Figure 3-1 Location and identification of terminal covers

Optimization

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26 Unidrive SP User Guide

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Safety

Pozi Pz2

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To remove a terminal cover, undo the screw and lift the terminal cover off as shown. The control terminal cover must be removed first before the DC (size 1) / low voltage DC (sizes 2 and 3) terminal cover can be removed.

When replacing the terminal covers the screws should be tightened with a maximum torque of 1 N m (0.7 lb ft).

Figure 3-2 Removing the size 1 terminal covers

Figure 3-3 Removing the size 2 terminal covers

Figure 3-4 Removing the size 3 terminal covers

Unidrive SP User Guide 27 Issue Number: 12 www.controltechniques.com

Safety

Pozi Pz2

All sizes

Size 3 only

Sizes 4 to 6 only

Size 2 only

Sizes 1 to 3 only

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Figure 3-5 Removing the size 4, 5 and 6 terminal covers (size 4 illustrated)

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

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

Figure 3-7 Removing the DC terminal cover break-outs

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Grasp the DC terminal cover break-outs with pliers as shown (1) and twist to remove. Continue until all required break-outs are removed (2).

Remove any flash / sharp edges once the break-outs are removed. Use the DC terminal cover grommets supplied in the accessory box (Table 2-

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

28 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

10 on page 24) to maintain the seal at the top of the drive. Grommets are available for the size 4 to 6 finger-guards. Two versions

are available allowing for either single or double cable entries. These are not required if the optional conduit box is installed.

Safety

Single cable entry grommet

Single cable

CAUTION

NOTE

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Figure 3-8 Size 4 to 6 finger-guard grommets

The grommets are available as a kit of four grommets under the following part numbers:

9500-0074 Kit of four single entry grommets 9500-0075 Kit of four double entry grommets

3.4 Solutions Module / keypad installation / removal

Power down the drive before installing / removing the Solutions Module. Failure to do so may result in damage to the product.

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Figure 3-9 Installation of a Solutions Module on size 0

On size 0 the protective tab from the Solutions Module slot must be removed before attempting to fit a Solutions Module.

Unidrive SP User Guide 29 Issue Number: 12 www.controltechniques.com

Safety

Fitting Solutions Module

Removing Solutions Module

Three Solutions Modules fitted

Solutions Module in slot 1

Solutions Module in slot 2

Solutions Module in slot 3

NOTE

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Figure 3-10 Installation and removal of a Solutions Module on size 1 to 6

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To install the Solutions Module, press down in the direction shown above until it clicks into place.

To remove the Solutions Module, press inwards at the points shown (A) and pull in the direction shown (B).

Figure 3-11 Installation of a keypad on size 0

The drive has the facility for all three Solutions Module slots to be used at the same time, as illustrated.

It is recommended that the Solutions Module slots are used in the following order: slot 3, slot 2 and slot 1.

30 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

AAB

Fitting keypad

Removing keypad

NOTE

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Figure 3-12 Installation and removal of a keypad on size 1 to 6

To install, align the keypad and press gently in the direction shown until it clicks into position.

To remove, while pressing the tabs inwards (A), gently lift the keypad in the direction indicated (B).

The keypad can be installed / removed while the drive is powered up and running a motor, providing that the drive is not operating in keypad mode.

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Unidrive SP User Guide 31 Issue Number: 12 www.controltechniques.com

Safety

47mm (1.85in)

312.7mm (12.31in)

WARNING

62mm

(2.44in)

249.7mm (9.83in)

220mm (8.66in)

47mm

(1.85in)

7.5mm

(0.3in)

304mm

(11.96in)

292mm

(11.49in)

6mm

(0.24in)

∅

5.4mm (0.21in)

322mm

(12.68in)

226mm (8.9in)

229mm (9.02in)

Information

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3.5 Mounting methods

Size 0 can be mounted using a DIN rail, either fixed at the top or the bottom of the drive (as illustrated in Figure 3-13). Two screws are required to fix the drive to the backplate at the opposite end to the DIN rail.

Figure 3-13 Mounting the size 0 using a DIN rail

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Unidrive SP size 1 to 6 units can be either surface or through-panel mounted using the appropriate brackets. Size 0 can only be surface mounted.

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

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

Many of the drives in this product range weigh in excess of 15kg (33lb). Use appropriate safeguards when lifting these models. A full list of drive weights can be found in section

12.1.19 Weights on page 266

3.5.1 Surface mounting

Figure 3-14 Surface mounting the size 0 drive

32 Unidrive SP User Guide

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Safety

100mm (3.937in)

219mm

(8.622in)

40.0 5.0mm

(1.575 0.197in)

∅

6.5mm

(0.256in)

386mm

(15.197in)

368mm

(14.488in)

370.0 1.0mm

(14.567 0.039in)

∅

6.5mm

(0.256in)

30.0mm

(1.181in)

155mm

(6.102in)

368mm (14.488in)

219mm

(8.622in)

371.6mm (14.630in)

∅

6.5mm

(0.256in)

∅

6.5mm

(0.256in)

21mm (0.827in)

337.5 1.0mm

(13.287 0.039in)

106 1.0mm

4.173 0.039in

24.5mm

(0.965in)

Information

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Figure 3-15 Surface mounting the size 1 drive

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Figure 3-16 Surface mounting the size 2 drive

Unidrive SP User Guide 33 Issue Number: 12 www.controltechniques.com

Safety

250mm (9.843in)

368mm (14.488in)

260mm (10.236in)

361mm

(14.213in)

∅

6.5mm

(0.256in)

21mm (0.827in)

327 1.0mm

(12.874 0.039in)

∅

6.5mm

(0.256in)

106 1.0mm

(4.173 0.039in)

97mm

(3.819in)

47mm

(1.850in)

310mm (12.205in)

510mm (20.079in)

298mm (11.732in)

258.6 0.5mm

(10.181 0.020in)

528.8

0.5mm

(20.819

0.020in)

546.8mm

(21.528in)

18.4mm (0.724in)

25.7 0.5mm

(1.012 0.020in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

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Figure 3-17 Surface mounting the size 3 drive

Figure 3-18 Surface mounting the size 4 drive

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34 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

258.6 0.5mm

(10.181 0.020in)

25.7 0.5mm

(1.012 0.020in)

839.3

0.5mm

(33.043

0.020in)

310mm (12.205in)

298mm (11.732in)

857.3mm (33.752in)

820mm (32.283in)

18.4mm (0.72in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

Information

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Figure 3-19 Surface mounting the size 5 drive

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Unidrive SP User Guide 35 Issue Number: 12 www.controltechniques.com

Safety

310mm (12.205in)

18.9mm (0.744in)

1131mm

(44.528in)

298mm (11.732in)

1168.8mm (46.016in)

25.7 0.5mm

(1.012 0.020in)

258.6 0.5mm

(10.181 0.020in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

1150.8 ±0.5mm

(45.307 0.020in)

Information

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Figure 3-20 Surface mounting the size 6 drive

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36 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

100mm

(3.973in)

368mm

(14.488in)

391mm

(15.394in)

219mm (8.622in)

80mm

(3.150in)

342mm

(13.465in)

343.0 0.5mm

(13.504 0.020in)

368.0 1.0mm

(14.488 0.039in)

9.4 0.75mm

(0.370 0.030in)

70.0 0.3mm

(2.756 0.012in)

93.0 0.5mm

(3.661 0.020in)

35.0 .15mm

(1.378 0.006in)

±0 ±

139mm (5.472in)

∅

6.5mm

(0.256in)

∅

6.5mm

(0.256in)

15.6 0.5mm

(0.614 0.020in)

368mm (14.488in)

391mm (15.394in)

155mm (6.102in)

219mm (8.622in)

139mm (5.472in)

293mm (11.535in)

9.3 0.5mm

(0.366 0.020in)

101.5 0.5mm

(3.996 0.020in)

64.6 0.5mm

(2.543 0.020in)

70 0.3mm

(2.756 0.012in)

148 0.5mm

(5.827 0.020in)

294 0.5mm

(11.575 0.020in)

368.0 1.0mm

(14.488 0.039in)

∅

6.5mm

(0.256in)

∅

6.5mm

(0.256in)

35.0 0.15mm

(1.378 0.006in)

± ±

80mm

(3.150in)

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3.5.2 Through-panel mounting

When the drive is through-panel mounted, the main terminal cover(s) must be removed in order to provide access to the mounting holes. Once the drive has been mounted, the terminal cover(s) can be replaced.

Figure 3-21 Through-panel mounting the size 1 drive

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Figure 3-22 Through-panel mounting the size 2 drive

Unidrive SP User Guide 37 Issue Number: 12 www.controltechniques.com

Safety

250mm(9.843in)

368mm (14.488in)

140mm (5.512in) 120mm (4.724in)

260mm (10.236in)

283mm

(11.142in)

236 0.5mm

(9.291 0.020in)

287 0.5mm (11.299 0.020in)

80.3mm

(0.315 0.012in)

56 0.5mm

(2.205 0.020in)

∅

6.5mm

(0.256in)

∅

6.5mm

(0.256in)

310mm (12.205in)

510mm (20.079in)

298mm (11.732in)

200mm (7.874in)

98mm

(3.858in)

540.3

0.5mm

(21.272

0.020in)

258.6 0.5mm

(10.181 0.020in)

286.0 0.5mm

(11.260 0.020in)

± ±

487.0 0.5mm (19.173 0.020in)

484mm (19.055in)

258.6 0.5mm

(10.181 0.020in)

14.2

0.5mm

0.559 0.020in)

± ±

26.65

0.5mm

1.049 0.020in)

558mm (21.969in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

R6.5mm

(0.256in)

R6.5mm

(0.256in)

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Figure 3-23 Through-panel mounting the size 3 drive

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Figure 3-24 Through-panel mounting the size 4 drive

When a size 4 is through-panel mounted, the grounding link bracket must be folded upwards. This is required to provide a grounding point for the grounding bracket. See section 4.11.1 Grounding hardware on page 75 for more information.

38 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

310mm (12.205in)

258.6 0.5mm

(10.181 0.020inm)

14.2 0.5mm

(0.559 0.020in)

286.0 0.5mm

(11.260 0.020in)

852.6

0.5mm

(33.567

0.020in)

258.6 0.5mm

(10.181 0.020in)

26.7 0.5mm

(1.051 0.020in)

797.5 0.5mm (31.398 0.020in)

794.5mm (31.280in)

298mm (11.732in)

200mm (7.874in)

98mm

(3.858in)

820mm (32.283in)

868mm (34.173in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

R6.5mm

(0.256in)

R6.5mm

(0.256in)

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Figure 3-25 Through-panel mounting the size 5 drive

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When a size 5 is through-panel mounted, the grounding link bracket must be folded upwards. This is required to provide a grounding point for the grounding bracket. See section 4.11.1 Grounding hardware on page 75 for more information.

Unidrive SP User Guide 39 Issue Number: 12 www.controltechniques.com

Safety

310mm (12.205in) 200mm (7.874in)

1105.6mm (43.528in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

1131mm

(44.528in)

1179.3mm (46.429in)

98mm

(3.858in)

298mm (11.732in)

258.6 0.5mm

(10.181 0.020in)

286.0 0.5mm

(11.260 0.020in)

± ±

1107.8 0.5mm

(43.614 0.020in)

27.1 0.5mm

(1.067 0.020in)

13.7±±0.5mm

(0.539 0.020in)

258.6 0.5mm

(10.181 0.020in)

1161.2

0.5mm

(45.717

0.020in)

R6.5mm

(0.256in)

R6.5mm

(0.256in)

NOTE

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Figure 3-26 Through-panel mounting the size 6 drive

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In order to achieve IP54 rating (NEMA 12) for through-panel mounting, an IP54 insert must be installed (size 1 and 2) and the heatsink fan should be replaced with an IP54 rated fan (sizes 1 to 4). Additionally, the gasket provided should be installed between the drive and the backplate to ensure a good seal for the enclosure. If the heatsink mounted braking resistor is to be used with the drive through-panel mounted, refer to section 3.11 Internal/heatsink mounted braking resistor on page 54 prior to mounting the drive. For further information refer to section

3.9 Enclosing standard drive for high environmental protection on page 44.

40 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

Short section

Long section

Short section

Long section

Information

Table 3-1 Mounting brackets

Model

size

Product

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Hole

size

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Figure 3-29 Location of top surface mounting brackets for size 5 and 6

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2x2x1

6.5mm

(0.256in)

3x2

8.5mm

(0.335in)

5 & 6

To avoid damaging the through-panel mounting bracket when throughpanel mounting a size 1 or size 2, the through-panel mounting bracket should be used to mount the top of the drive to the back plate before the bottom of the drive is mounted to the back plate. The tightening torque should be 4 N m (2.9 lb ft).

3.5.3 Installation of the mounting bracket on size 4, 5 and 6

Size 4, 5 and 6 use the same mounting brackets for surface and through-panel mounting.

The mounting bracket has a long section and a short section.

Figure 3-27 Size 4, 5 and 6 mounting bracket

The mounting bracket must be installed in the correct orientation with the long section inserted into or attached to the drive and the short section is attached to the back plate. Figure 3-28 shows the orientation of the mounting bracket when the drive is surface and through-panel mounted.

Figure 3-28 Orientation of the size 4, 5 and 6 mounting bracket

When through-panel mounted, the mounting brackets on the left hand side of the drive can be secured using the screws already located there. On the right hand side, the mounting brackets are just inserted into the slots in the chasis of the drive; no fixing screws are present here.

Size 5 and 6 also require two top mounting brackets when the drive is surface mounted. The two brackets should be installed to the top of the drive as shown in Figure 3-29.

The maximum torque setting for the screws into the drive chassis is 10 N m (7.4 lb. ft).

Unidrive SP User Guide 41 Issue Number: 12 www.controltechniques.com

Safety

≥

100mm

(4in)

Enclosure

AC supply contactor and fuses or MCB

Locate as required

External controller

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

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

≥

100mm

(4in)

Optional braking resistor and overload

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

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

Note For EMC compliance:

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

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

Size 0 and 1: 0mm (0in)

Sizes 2 to 6: 30mm (1.181in)

≥

intText

–()

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

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3.6 Enclosure for standard drives

3.6.1 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 3-30 Enclosure layout

3.6.2 Enclosure sizing

1. Add the dissipation figures from section 12.1.2 Power dissipation on page 261 for each drive that is to be installed in the enclosure.

2. If an external EMC filter is to be used with each drive, add the dissipation figures from section 12.2.1 EMC filter ratings on page 273 for each external EMC filter that is to be installed in the enclosure.

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

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

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

Calculating the size of a sealed enclosure

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

Calculate the minimum required unobstructed surface area A enclosure from:

42 Unidrive SP User Guide

for the

www.controltechniques.com Issue Number: 12

Where:

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

Maximum expected temperature in

ext

C outside the enclosure Maximum permissible temperature in oC inside the

int

Example

To calculate the size of an enclosure for the following:

enclosure

P Power in Watts dissipated by all heat sources in the

enclosure

k Heat transmission coefficient of the enclosure material

2/o

in W/m

• Two SP1406 models operating at the Normal Duty rating

• Each drive to operate at 6kHz PWM switching frequency

• Schaffner 16 A (4200-6119) external EMC filter for each drive

• Braking resistors are to be mounted outside the enclosure

• Maximum ambient temperature inside the enclosure: 40°C

• Maximum ambient temperature outside the enclosure: 30°C

Safety

392.4

5.5 40 30–()

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

2HD–

HD+

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

7.135 2 2× 0.6×()–

20.6+

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

3kP

intText

–

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

-------

31.3× 323.7×

40 30–

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

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Dissipation of each drive: 187 W (see section 12-4 Losses @ 40°C (104°F) ambient on page 261)

Dissipation of each external EMC filter: 9.2 W (max) (see section

12.2.1 EMC filter ratings on page 273) Total dissipation: 2 x (187 + 9.2) =392.4 W The enclosure is to be made from painted 2 mm (0.079 in) sheet steel

2/o

having a heat transmission coefficient of 5.5 W/m

C. Only the top,

front, and two sides of the enclosure are free to dissipate heat.

The value of 5.5 W/m

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

Figure 3-31 Enclosure having front, sides and top panels free to

dissipate heat

Insert the following values:

40°C

int

30°C

ext

k 5.5 P 392.4 W

The minimum required heat conducting area is then:

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Where:

V Air-flow in m T

Maximum expected temperature in °C outside the

ext

per hour (1 m3/hr = 0.59 ft3/min)

enclosure

Maximum permissible temperature in °C inside the

int

enclosure

P Power in Watts dissipated by all heat sources in the

enclosure

k Ratio of

Where:

is the air pressure at sea level

is the air pressure at the installation

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

Example

To calculate the size of an enclosure for the following:

• Three SP1403 models operating at the Normal Duty rating

• Each drive to operate at 6kHz PWM switching frequency

• Schaffner 10A (4200-6118) external EMC filter for each drive

• Braking resistors are to be mounted outside the enclosure

• Maximum ambient temperature inside the enclosure: 40°C

• Maximum ambient temperature outside the enclosure: 30°C

Dissipation of each drive: 101 W Dissipation of each external EMC filter: 6.9 W (max) Total dissipation: 3 x (101 + 6.9) = 323.7 W Insert the following values:

40°C

int

30°C

ext

k 1.3 P 323.7 W

Then:

UL Listing

Information

= 7.135 m

(77.8 ft2) (1 m2 = 10.9 ft2)

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

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

=1.821 m (71.7 in)

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

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

the drives

• Reducing the ambient temperature outside the enclosure, and/or

applying forced-air cooling to the outside of the enclosure

• Reducing the number of drives in the enclosure

• Removing other heat-generating equipment

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:

= 126.2 m

/hr (74.5 ft3 /min) (1 m3/ hr = 0.59 ft3/min)

3.7 Enclosure design and drive ambient temperature

Drive derating is required for operation in high ambient temperatures Totally enclosing or through panel mounting the drive in either a sealed

cabinet (no airflow) or in a well ventilated cabinet makes a significant difference on drive cooling.

The chosen method affects the ambient temperature value (T should be used for any necessary derating to ensure sufficient cooling

for the whole of the drive. The ambient temperature for the four different combinations is defined

below:

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

= T

rate

+ 5°C

int

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

= T

rate

int

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

= the greater of T

rate

+5°C, or T

ext

int

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

= the greater of T

rate

ext

or T

int

Where:

= Temperature outside the cabinet

ext

= Temperature inside the cabinet

int

= Temperature used to select current rating from tables in

rate

Chapter 12 Technical Data .

rate

) which

Unidrive SP User Guide 43 Issue Number: 12 www.controltechniques.com

Safety

IP20

(NEMA1)

IP54 (UL Type 12 / NEMA 12)

enclosure

Drive with IP54 insert and IP54 fan installed

Gasket seal

Drive

Gasket

Enclosure

rear wall

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3.8 Heatsink fan operation

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

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

The heatsink fan on size 0 to 2 is a dual speed fan and on size 3 to 6 it is a variable speed fan. The drive controls the speed at which the fan runs based on the temperature of the heatsink and the drive's thermal model system. The size 3 to 6 is also fitted with a variable speed fan to ventilate the capacitor bank.

The heatsink fan on size 0 to 5 is supplied internally by the drive. The heatsink fan on size 6 requires an external 24Vdc supply. See section

4.4 Heatsink fan supply on page 66 for more information.

3.9 Enclosing standard drive for high environmental protection

An explanation of environmental protection rating is provided in section

12.1.9 IP / UL Rating on page 264.

The standard drive is rated to IP20 pollution degree 2 (dry, nonconductive contamination only) (NEMA 1). However, it is possible to configure the drive to achieve IP54 rating (UL Type 12 / NEMA 12) at the rear of the heatsink for through-panel mounting (some current derating is required for size 1 and 2). Refer to Table 2-43 .

This allows the front of the drive, along with various switchgear, to be housed in an IP54 (UL Type 12 / NEMA 12) enclosure with the heatsink protruding through the panel to the external environment. Thus, the majority of the heat generated by the drive is dissipated outside the enclosure maintaining a reduced temperature inside the enclosure. This also relies on a good seal being made between the heatsink and the rear of the enclosure using the gaskets provided.

For Type 12 the drive must be mounted on a flat surface of a Type 12 enclosure.

Figure 3-32 Example of IP54 (UL Type 12 / NEMA 12) through-

panel layout

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The main gasket should be installed as shown in Figure 3-33. Any screws / bolts that are used for mounting should be installed with the nylon washers provided in the kit box to maintain a seal around the screw hole. See Figure 3-36.

In order to achieve the high IP rating at the rear of the heatsink with size 1 and 2, it is necessary to seal a heatsink vent by installing the IP54 insert as shown in Figure 3-34 and Figure 3-35.

Figure 3-33 Installing the gasket

44 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

Remove metal clip (1). Push tab in the direction shown (2) and lift hinged baffle as shown (3)

Remove IP54 insert from hinged baffle by releasing clip (4). Rotate the IP54 insert through 180 so that the flat side faces away from the fan (5).

Lower IP54 insert into position as shown (7).

Remove the backing from the IP54 insert gasket and stick it into the recess of the IP54 insert (6). (The gasket can be found in the accessories box.)

IP54 insert

Close hinged baffle (8) and click into position. Replace metal clip (9).

IP54 insert gasket

Push plastic tabs in the

direction shown (1).

Push tab in the direction

shown (2), and lift hinged

baffle as shown (3).

Take IP54 insert from the accessories box (4).

Lower the IP54 insert into

the ventilation hole in the

heatsink (5).

Close hinged baffle (6) and click into position, ensuring tabs locate correctly.

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Figure 3-34 Installation of IP54 insert for size 1

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Figure 3-35 Installation of IP54 insert for size 2

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In order to remove the IP54 insert, repeat steps (1), (2) and (3), reverse steps (7), (6), (5) and (4) and repeat steps (8) and (9).

Unidrive SP User Guide 45 Issue Number: 12 www.controltechniques.com

In order to remove the IP54 insert, repeat steps (1) (2) and (3), reverse steps (5) and (4) and repeat step (6).

Safety

Holes equispaced along length of drive

Backplate

Enclosure

rear wall

12345

BM8M6

Information

For sizes 4 to 6 it may be necessary to improve the rigidity of the through panel mounting surface due to the larger distance between the top and bottom mounting brackets and the need to maintain compression on the gasket.

When the drive is mounted, if the gap between the drive flange (which the gasket rests on) and the rear wall of the enclosure is ≥6mm at any point around the drive then the following methods can be used to compress the gasket further:

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1. Use a thicker panel for the mounting wall of the enclosure through which the drive is mounted.

2. Use an internal backplate to pull the rear wall of the enclosure up to the drive gasket. See Figure 3-36 for details. (Nylon washers are supplied in the standard drive kit for sealing off any nut and bolt fixings that exit through the rear wall of the panel).

3. If an internal backplate is not available a separate clamp can be used to simulate option 2. See Figure 3-37. 4 off sealing clamps are supplied in the drive kit box.

Figure 3-36 Option 2 for achieving IP54 (UL type 12 / NEMA 12) through-panel mounting

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Table 3-2 Description of fixings Table 3-3 Quantity of nylon washers supplied with the drive

Item Description Size Quantity of M8 (A) Quantity of M6 (B)

1Bolt 1 0 3 2 Flat washer 2 0 3 3 Nylon washer (from kitbox) 3 0 4 4 Flat washer 4 4 4 5 Spring washer 5 4 4 6Nut 6 4 4

46 Unidrive SP User Guide

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Safety

Sealing bracket (4 places)

Enclosure rear wall

NOTE

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Figure 3-37 Option 3 for achieving IP54 (UL Type 12 / NEMA 12) through panel mounting

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For increased fan lifetime in a dirty environment the heatsink fan must be replaced with an IP54 rated fan. Contact the supplier of the drive for details. If the standard fan is used in a dirty/dusty environment, reduced fan lifetime will result. Regular cleaning of the fan and heatsink is recommended in this environment. The heatsink fan installed in sizes 5 and 6 are IP54 rated as standard.

The guidelines in Table 3-4 should be followed.

Table 3-4 Environment considerations

Environment

Clean

Dry, dusty (nonconductive)

Dry, dusty (conductive)

IP54

Insert

Not

installed

Installed Standard

Installed

IP54 compliance Installed IP54

Fan Comments

Standard

Regular cleaning recommended. Fan lifetime may be reduced.

Standard /

IP54

Regular cleaning recommended. Fan lifetime may be reduced.

Regular cleaning recommended.

A current derating must be applied to the size 1 and 2 if the IP54 insert and/or IP54 rated fan are installed. Derating information is provided in section 12.1.1 Power and current ratings (Derating for switching frequency and temperature) on page 258.

Failure to do so may result in nuisance tripping.

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

panel mounted

Frame size Power loss

1 ≤50W 2 ≤75W 3 ≤100W 4 ≤204W 5 ≤347W 6 ≤480W

When designing an IP54 (NEMA 12) enclosure (Figure 3-32), consideration should be made to the dissipation from the front of the drive.

Unidrive SP User Guide 47 Issue Number: 12 www.controltechniques.com

Safety

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3.10 External EMC filter

In order to provide our customers with a degree of flexibility, external EMC filters have been sourced from two manufacturers: Schaffner & Epcos. Filter details for each drive rating are provided in the tables below. Both the Schaffner and Epcos filters meet the same specifications.

Table 3-6 Drive EMC filter details (size 0 to 6)

Drive

CT part no. Weight CT part no. Weight

1 phase

SP0201 to SP0205 4200-6000 1.2 kg (2.64 lb)

3 phase

SP0201 to SP0205 4200-6001 1.2 kg (2.64 lb)

SP0401 to SP0405 4200-6002 1.2 kg (2.64 lb)

SP1201 to SP1202 4200-6118

SP1203 to SP1204 4200-6119 4200-6120

SP1401 to SP1404 4200-6118

SP1405 to SP1406 4200-6119 4200-6120

SP2201 to SP2203 4200-6210 2.0 kg (4.4 lb) 4200-6211 3.3 kg (7.3 lb)

SP2401 to SP2404 4200-6210 2.0 kg (4.4 lb) 4200-6211 3.3 kg (7.3 lb)

SP3201 to SP3202 4200-6307 3.5 kg (7.7 lb) 4200-6306 5.1 kg (11.2 lb)

SP4201 to SP4203 4200-6406 4.0 kg (8.8 lb) 4200-6405 7.8 kg (17.2 lb)

SP5201 to SP5202 4200-6503 6.8 kg (15.0 lb) 4200-6501 12.0 kg (26.5 lb)

SP3401 to SP3403 4200-6305

SP3501 to SP3507 4200-6309 4200-6308

SP4401 to SP4403 4200-6406 4.0 kg (8.8 lb) 4200-6405 7.8 kg (17.2 lb)

SP4601 to SP4606 4200-6408 3.8 kg (8.4 lb) 4200-6407 8.0 kg (17.6 lb)

SP5401 to SP5402 4200-6503 6.8 kg (15.0 lb) 4200-6501 12.0 kg (26.5 lb)

SP5601 to SP5602 4200-6504 4.4 kg (9.7 lb) 4200-6502 10.0 kg (22.0 lb)

SP6401 to SP6402 4200-6603

SP6601 to SP6602 4200-6604 4200-6602

Schaffner Epcos

1.4 kg (3.1 lb)

3.5 kg (7.7 lb)

5.25 kg (11.6 lb)

4200-6121

4200-6306

4200-6601

2.1 kg (4.6 lb)

5.1 kg (11.2 lb)

8.6 kg (19.0 lb)

The external EMC filters for sizes 0 to 3 can be footprint or bookcase mounted, see Figure 3-38 and Figure 3-39. The external EMC filters for sizes 4 to 6 are designed to be mounted above the drive, as shown in Figure 3-40.

Mount the external EMC filter following the guidelines in section 4.11.5 Compliance with generic emission standards on page 81.

Figure 3-38 Footprint mounting the EMC

filter

Figure 3-39 Bookcase mounting the EMC

filter

Figure 3-40 Size 4 to 6 mounting of EMC

filter

48 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

29mm (1.14in)

359mm (14.13in)

339mm (13.35in)

304mm (11.97in)

38mm (1.50in)

61mm (2.40in)

M5 M5

Torque settings of connector = 0.8 N m

∅

5.3mm (M5) (0.21in)

∅

5.3mm (M5) (0.21in)

V: Ground stud: M5 X: M6 threaded holes for footprint mounting of the drive Y: Footprint mounting holes 6.5mm (0.256in) Z: Bookcase mounting holes 6.5mm (0.256in)

∅

L3L1 L2

HBA

Cable size:

2.5mm 14AWG

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Installation

Figure 3-41 Size 0 external EMC filter

Figure 3-42 Size 1 external EMC filter

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All filter mounting holes are suitable for M6 fasteners.

Unidrive SP User Guide 49 Issue Number: 12 www.controltechniques.com

CT part no.ManufacturerABCDHW

4200-6118

4200-6119 4200-6121 4200-6120

Schaffner

Epcos

390 mm

(15.354 in)

423 mm

(16.654 in)

74 mm

(2.913 in)

45 mm

(1.772 in)

440 mm

(17.323 in)

450 mm

(17.717 in)

100 mm

(3.937 in)

Safety

V: Ground stud: M5

X: M6 threaded holes for footprint mounting of the drive

Y: Footprint mounting holes 6.5mm (0.256in) Z: Bookcase mounting slots 6.5mm (0.256in) wide

∅

L1'

L2'

L3'

Cable size:

4mm 10AWG

Information

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Installation

Figure 3-43 Size 2 external EMC filter

Getting Started

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All filter mounting holes are suitable for M6 fasteners.

CT part no. Manufacturer A B C D E H W

4200-6210 Schaffner

4200-6211 Epcos

371.5 mm

(14.626 in)

404.5 mm

(15.925 in)

125 mm

(4.921 in)

55 mm

(2.165 in)

30 mm

(1.181 in)

428.5 mm

(16.870 in)

431.5 mm

(16.988 in)

155 mm

(6.102 in)

50 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

V: Ground stud: M6

X: M6 threaded holes for footprint mounting of the drive

Y: Footprint mounting holes 6.5mm (0.256in) Z: Bookcase mounting slots 6.5mm (0.256in) wide

∅

Cable size: 16mm 6AWG

ZZX

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Figure 3-44 Size 3 external EMC filter

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CT part no. Manufacturer A B C D E H W

4200-6305 4200-6307 4200-6309 4200-6306 4200-6308

Schaffner

Epcos

361 mm

(14.213 in)

365 mm

(14.370 in)

396 mm

(15.591 in)

210 mm

(8.268 in)

60 mm

(2.362 in)

30 mm

(1.181 in)

414 mm

(16.299 in)

425 mm

(16.732 in)

250 mm

(9.843 in)

Unidrive SP User Guide 51 Issue Number: 12 www.controltechniques.com

Safety

Schaffner

Epcos

V: Ground stud: M10 Z: Bookcase mounting slots 6.5mm (0.256in wide)

Information

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Figure 3-45 Size 4 and 5 external EMC filter

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CT part no. Manufacturer A B C D E F H W

4200-6406

4200-6408

4200-6503

4200-6504

4200-6405

4200-6407

4200-6501 4200-6502

Schaffner

Epcos

260 mm

(10.236 in)

275 mm

(10.827 in)

170 mm

(6.693 in)

150 mm

(5.906 in)

170 mm

(6.693 in)

100 mm

(3.937 in)

120 mm

(4.724 in)

100 mm

(3.937 in)

90 mm

(3.543in)

120 mm

(4.724 in)

65 mm

(2.559 in)

85 mm

(3.346 in)

65 mm

(2.559 in)

65 mm

(2.559 in)

85 mm

(3.346 in)

1.5 mm

(0.059in)

300 mm

(11.811 in)

2 mm

(0.079 in)

1 mm

(0.039 in)

225 mm

(8.858 in)

208 mm

(8.189 in)

249 mm

(9.803 in)

225 mm

(8.858 in)

207 mm

(8.150 in)

205 mm

(8.071 in)

249 mm

(9.803 in)

52 Unidrive SP User Guide

www.controltechniques.com Issue Number: 12

Safety

V: Ground stud: M10 Z: Hole size: 10.5mm

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Figure 3-46 Size 6 external EMC filter

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CT part no.

4200-6603

4200-6604

4200-6601 4200-6602

Manufacturer

Schaffner

Epcos

ABCDE FGH I JW

191 mm

(7.717 in)

200 mm

(7.874 in)

140 mm

(5.512 in)

110 mm

(4.331 in)

108 mm

(4.252 in)

136 mm

(5.354 in)

147 mm

(5.787 in)

210 mm

(8.268 in)

2 mm

(0.079in)

38 mm

(1.496 in)

36.5 mm

(1.437 in)

295 mm

(11.614 in)

357 mm

(14.055 in)

364 mm

(14.331 in)

66 mm

(2.958 in)

128 mm

(5.039 in)

127 mm

(5.000 in)

53.5 mm

(2.106 in)

230 mm

(9.055 in)

Unidrive SP User Guide 53 Issue Number: 12 www.controltechniques.com

Safety

Brake

connections

Thermistor connector

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3.11 Internal/heatsink mounted braking resistor

3.11.1 Size 0 internal braking resistor

The size 0 has been designed to accommodate an optional internal resistor. When the internal resistor is used, an external thermal protection device is not required as the resistor is designed such that it will fail safely under fault conditions. The in-built software overload protection is set up at default to protect the resistor.

Figure 3-47 Fitting an optional internal braking resistor (top view of drive)

1. Remove screws

2. Remove grill

3. Fit the optional internal braking resistor in the slot provided and electrically connect the braking resistor (connections shown in Figure 4-1 on page 61). Ensure that the braking resistor thermistor is connected to the drive

4. Locate the braking resistor onto the drive tab

5. Refit the grill and mounting screws by reversing the procedure in points 1 and 2

54 Unidrive SP User Guide

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Safety

The size 1and 2 have been designed with an optional space-saving heatsink mounted resistor. The resistor can be installed within the heatsink fins of the drive. When the heatsink mounted resistor is used, an external thermal protection device is not required as the resistor is designed such that it will fail safely under fault conditions. The in-built software overload protection is set up at default to protect the resistor. The resistor is rated to IP54 (NEMA12).

If the drive is to be through-panel mounted with the heatsink mounted brake resistor installed, then the aperture in the panel through which the drive is mounted must be modified as shown in Figure 3-48 and Figure 3-49. This is in order to allow for the braking resistor cables and grommets.

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

To avoid the risk of fire when the drive is surface mounted with the braking resistor installed, the back plate should be a non-flammable material.

WARNING

93mm

(3.661in)

∅

6.5mm

(0.256in)

60mm

(2.362in)

15.6mm

(0.614in)

∅

15.0mm

(0.591in)

66mm

(2.598in)

148mm

(5.827in)

115 mm

(4.528in)

∅

15.0mm

(0.591in)

∅

6.5mm

(0.256in)

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3.11.2 Size 1 and 2 heatsink mounted braking resistor

Figure 3-48 Through-panel mounting cut-out details for size 1 Figure 3-49 Through-panel mounting cut-out details for size 2

The part numbers for the resistor kits are as follows:

Size 1: 1220-2756-01 Size 2: 1220-2758-01

Each kit contains the following:

• A braking resistor assembly

• A through-panel grommet

• An installation sheet

• A wire clip (Size 2 only)

3.11.3 Size 1 braking resistor fitting instructions

Figure 3-50 Fitting the heatsink mounted braking resistor on size 1

• Remove both terminal covers as detailed in section

3.3.1 Removing the terminal covers on page 25.

• Remove the two break-outs that line-up with the BR and +DC terminal connections as detailed in section 3.3.2 Removing the finger-guard and DC terminal cover break-outs on page 28.

• Install the braking resistor to the heatsink as shown in Figure 3-50. The resistor is installed with captive screws.

• The screws should be tightened to a maximum torque of 2 N m (1.5 lb ft).

• Ensure the cables are routed between the fins of the heatsink, and that the cables are not trapped between heatsink fins and the resistor.

Figure 3-51 Connecting the brake resistor on a surface mounted size 1

• Install the DC terminal cover grommets supplied in the accessory

Unidrive SP User Guide 55 Issue Number: 12 www.controltechniques.com

box with the drive, to the cables. To ensure a good seal, the grommets are a tight fit. Lubrication may be required to help install the grommets to the cables.

• Terminate the cables with suitable crimps and connect to the BR and +DC terminals. Tighten the screw terminals to a maximum torque of 1.5 Nm (1.1 lb ft).

• Replace both terminal covers.

Safety

Remove 5mm (0.197in) from the length of this clip

Route the cables between these two heatsink fins

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Figure 3-52 Connecting the brake resistor on a through-panel mounted size 1

• See Figure 3-48 for through-panel mounting cut-out details.

• Pass the cables through the hole in the panel and install the through-panel grommet.

• Install the through-panel mounting bracket.

• Install the DC terminal cover grommets supplied in the accessory box with the drive, to the cables. To ensure a good seal, the grommets are a tight fit. Lubrication may be required to help install the grommets to the cables.

• Terminate the cables with suitable crimps and connect to the BR and +DC terminals. Tighten the screw terminals to a maximum torque of 1.5 Nm (1.1 lb ft).

• Replace both terminal covers.

3.11.4 Size 2 braking resistor fitting instructions

Figure 3-53 Removing the baffle plate on a size 2

• Remove the DC cover as detailed in section 3.3.1 Removing the terminal covers on page 25.

• Remove the two break-outs that line-up with the BR and +DC terminal connections as detailed in section 3.3.2 Removing the finger-guard and DC terminal cover break-outs on page 28.

• Lift the hinged fan baffle by pushing plastic tabs in the direction shown (1). Push tab in the direction shown (2), and lift the baffle as shown (3).

• Remove the metal heatsink baffle plate by removing the two screws. These two screws are no longer required.

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Figure 3-54 Modifying the fan baffle on a size 2

Figure 3-55 Fitting the heatsink mounted braking resistor on a size 2

• Remove 5mm (0.197in) from the length of the clip on the plastic fan baffle.

• Install clip to heatsink in the position shown in diagram opposite. Route the long cables of the resistor assembly between the fins of the heatsink as shown in Figure 3-55.

• Install the heatsink baffle plate in place with the cables routed underneath. Ensure the cables are not trapped between a heatsink fin and the baffle plate.

• Install the braking resistors to the heatsink. The resistors are installed with captive screws.

• The screws should be tightened to a maximum torque of 2.0 N m (1.5 lb ft).

• Close the hinged fan baffle.

• Install cables to heatsink clip.

56 Unidrive SP User Guide

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Safety

CAUTION

Parameter

Size 0 Size 1 and 2

200V drive 400V drive 200V drive 400V drive

Full power braking time Pr 10.30 0.06 0.01 0.04 0.02 Full power braking period Pr 10.31 2.6 1.7 3.3

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Figure 3-56 Connecting the brake resistor on a surface mounted size 2

• Install the DC terminal cover grommets supplied in the accessory

box with the drive, to the cables. To ensure a good seal, the grommets are a tight fit. Lubrication may be required to help install the grommets to the cables.

• Terminate the cables with suitable crimps and connect to the BR

and DC2 terminals.

• Replace the terminal cover.

Figure 3-57 Connecting the brake resistor on a through-panel mounted size 2

• See Figure 3-49 for through-panel mounting cut-out details.

• Pass the cables through the hole in the panel and install the hole

grommet.

• Install the mounting bracket.

• Install the DC terminal cover grommets supplied in the accessory

box with the drive, to the cables. To ensure a good seal, the grommets are a tight fit. Lubrication may be required to help install the grommets to the cables.

• Terminate the cables with suitable crimps and connect to the BR

and DC2 terminals.

• Replace the terminal cover.

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3.11.5 Braking resistor overload protection parameter settings

Failure to observe the following information may damage the resistor.

The drive’s software contains an overload protection function for a braking resistor. On size 1 and 2 this function is enabled at default to protect the heatsink mounted resistor. Below are the parameter settings.

For more information on the braking resistor software overload protection, see the Advanced User Guide. If the heatsink mounted braking resistor is to be used at more than half of its average power rating then the drive's cooling fan must be

set to full speed by setting Pr 6.45 to On (1).

See section 4.9.1 Heatsink mounted braking resistor on page 72 for the resistor specifications.

Unidrive SP User Guide 57 Issue Number: 12 www.controltechniques.com

Safety

M10 nut 17mm AF

2.5mm

M10 nut 17mm AF

2.5mm6M10 nut

17mm AF

2.5mm

M10 nut

17mm AF

T20 Torx

Pozi Pz 2

T20 Torx

Pozi Pz 2

Pozi Pz 3

T20 Torx

Pozi Pz 2

Pozi Pz 3

Control terminals

2.5mm

Relay terminals

3mm

8mm AF

Ground

connections

Ground

connections

Low voltage DC/

DC supply/Brake

Internal EMC filter ground connection

AC power

terminals

AC power

terminals

AC power

terminals

Pozi Pz 2

DC high

current

Internal EMC

filter ground

connection

DC high

current

Internal EMC

filter ground

connection

AC input / DC input

AC output/

Brake

Low voltage

DC enable

AC output/

Brake

Low voltage

DC enable

AC output/

Brake

Low voltage DC

enable / Heatsink

fan supply

Low

current DC

Low

current DC

1 - 6

T30 Torx

Pozi Pz 2

AC input /

Low voltage DC /

Brake

Ground connection

Control terminals

2.5mm

Relay terminals

2.5mm

T30 Torx

Pozi Pz 2

AC output/

DC input

Ground connections

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3.12 Electrical terminals

3.12.1 Location of the power and ground terminals

Figure 3-58 Locations of the power and ground terminals

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3.12.2 Terminal sizes and torque settings

To avoid a fire hazard and maintain validity of the UL listing, adhere to the specified tightening torques for the power and ground terminals. Refer to the following tables.

Table 3-7 Drive control and relay terminal data

Model Connection type Torque setting

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

Table 3-8 Drive power terminal data

Model

size

AC terminals

Plug-in

terminal block

1.5 N m

(1.1 lb ft)

High current

DC and braking

Terminal block

1.0 N m (0.73 lb ft)

Terminal block (M4 screws)

1.5 N m (1.1 lb ft)

Terminal

block

(M5 screws)

1.5 N m

(1.1 lb ft)

Terminal block (M6 screws)

4 5 6

2.5 N m (1.8 lb ft)

M10 stud

15 N m

(11.1 lb ft)

Torque tolerance ±10%

Table 3-9 Plug-in terminal block maximum cable sizes

Model size Terminal block description Max cable size

All 11 way control connectors

All 2 way relay connector

1 and 2 6 way AC power connector

4, 5 and 6 Low Voltage DC Enable connector

6 Heatsink fan supply connector

The maximum cable size for the power terminals on Unidrive SP size 0

is 4mm

(10 AWG).

Table 3-10 Schaffner external EMC filter terminal data (size 0)

CT part

number

4200-6000 4200-6001 4200-6002

Power and ground connections

Max cable size Max torque

4mm

12AWG

Low voltage DCGround

terminal

Screw (M6)

4.0 N m

(2.9 lb ft)

Stud (M5)

Te rm i n al

block

4.0 N m

(2.9 lb ft)

(M4 screws)

1.5 N m

(1.1 lb ft)

6.0 N m

(4.4 lb ft)

M10 stud

12 N m

(8.8 lb ft)

8 mm

(16 AWG)

(12 AWG)

(8 AWG)

(16 AWG)

1.5 mm

2.5 mm

1.5 mm

0.8 N m

(0.6 lb ft)

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Table 3-11 Schaffner external EMC filter terminal data (size 1 to 6)

CT part

number

4200-6118 4200-6119

4200-6210

4200-6305 4200-6307 4200-6309

4200-6406

4200-6408

4200-6503

4200-6504

4200-6603 4200-6604

Power

connections

Max cable

size

4mm

12AWG

10mm

8AWG

16mm

6AWG

50mm

0AWG

25mm

4AWG

95mm

4/0AWG

50mm

0AWG

Max torque

0.8 N m

(0.6 lb ft)

2 N m

(1.5 lb ft)

2.2 N m

(1.6 lb ft)

8 N m

(5.9 lb ft)

2.3 N m

(1.7 lb ft)

20 N m

(14.7 lb ft)

8 N m

(5.9 lb ft)

connections

Ground

stud size

M10

Ground

Max torque

3.5 N m

(2.6 lb ft)

3.5 N m

(2.6 lb ft)

3.9 N m

(2.9 lb ft)

25 N m

(18.4 lb ft)

3.9 N m

(2.9 lb ft)

25 N m

(18.4 lb ft)

25 N m

(18.4 lb ft)

25 N m

(18.4 lb ft)

Table 3-12 Epcos external EMC Filter terminal data

CT part

number

4200-6120 4200-6121

4200-6211

4200-6306

4200-6308

4200-6405 4200-6407 4200-6501 4200-6502

connections

Max cable

size

4mm

12AWG

10mm

8AWG

16mm

6AWG

10mm

8AWG

50mm

0AWG

95mm

4/0AWG

Power

Max torque

0.6 N m

(0.4 lb ft)

1.35 N m (1.0 lb ft)

2.2 N m

(1.6 lb ft)

1.35 N m (1.0 lb ft)

6.8 N m

(5.0 lb ft)

20 N m

(14.7 lb ft)

connections

Ground

stud size

M10

Ground

Max torque

3.0 N m

(2.2 lb ft)

3.0 N m

(2.2 lb ft)

5.1 N m

(3.8 lb ft)

10 N m

(7.4 lb ft)

4200-6601 4200-6602

Unidrive SP User Guide 59 Issue Number: 12 www.controltechniques.com

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3.13 Routine maintenance

The drive should be installed in a cool, clean, well ventilated location. Contact of moisture and dust with the drive should be prevented.

Regular checks of the following should be carried out to ensure drive / installation reliability are maximised:

Environment

Ambient temperature

Dust

Moisture

Enclosure

Enclosure door filters

Electrical

Screw connections Ensure all screw terminals remain tight

Crimp terminals

Cables Check all cables for signs of damage

Ensure the enclosure temperature remains at or below maximum specified

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

Ensure the drive enclosure shows no signs of condensation

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

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

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60 Unidrive SP User Guide

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WARNING

L2L1L3

UVW

Optional EMC

filter

Optional

line reactor

Fuses

Mains supply

Supply ground

connections

High current

-DC connections

Low voltage

DC (48V)

*This is not required if the optional internal braking resistor is used

SP020X = 200 to 240V 10%

SP040X = 380 to 480V 10%

± ±

Connectors specification:

Maximum size of power cable = 4.0mm (10AWG) Torque setting = 1 N m

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4 Electrical Installation

Many cable management features have been incorporated into the product and accessories, this chapter shows how to optimize them. Key features include:

• SAFE TORQUE OFF (SECURE DISABLE) function

• Internal EMC filter

• EMC compliance with shielding / grounding accessories

• Product rating, fusing and cabling information

• Brake resistor details (selection / ratings)

Electric shock risk

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

• AC supply cables and connections

• DC and brake cables, and connections

• Output cables and connections

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

Isolation device

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

STOP function

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

4.1 Power connections

4.1.1 AC and DC connections

Figure 4-1 Size 0 power connections

SAFE TORQUE OFF (SECURE DISABLE) function The SAFE TORQUE OFF (SECURE DISABLE) function does not remove dangerous voltages from the drive, the motor or any external option units.

Stored charge

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

Equipment supplied by plug and socket

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

Permanent magnet motors

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

When using a 200V Unidrive SP size 0 on a single-phase supply, the live and neutral conductors can be connected to any of the AC input connections on the drive.

Unidrive SP User Guide 61 Issue Number: 12 www.controltechniques.com

Safety

L1 L2

L2L1 L3 U V W

Optional EMC

filter

Optional

line reactor

Fuses

Mains Supply

Motor

Optional ground

connection

Supply

Ground

AC Connections

BR48V -DC +DC

DC Connections

Internal

EMC filter

L2L1L3

UVW

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Motor

Optional ground

connection

Supply

Ground

AC Connections

Thermal

overload

protection

device

DC1 DC2

DC Connections

(High current DC and braking)

48V

-DC

+DC

DC Connections

(Low current DC and 48V)

Internal

EMC filter

DC1 = DC2 = +

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Figure 4-2 Size 1 power connections Figure 4-3 Size 2 power connections

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If the heatsink mounted resistor is used (size 1 and 2 only), an overload protection device is not required. The resistor is designed to fail safely under fault conditions.

See Figure 4-6 for further information on ground connections.

62 Unidrive SP User Guide

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L1 L2

L2L1 L3 U V W

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Motor

Optional ground

connection

Supply

Ground

AC Connections

Thermal

overload

protection

device

DC1 DC2

DC Connections

(High current DC and braking)

48V -DC +DC

DC Connections

(Low current DC and 48V)

Internal

EMC filter

DC1 = DC2 = +

UVW

Motor

Optional ground connection

+DC

Thermal

overload

protection

device

Output connections

Input connections

Mains

Supply

L1 L2

Optional

line reactor

Optional

EMC filter

Fuses

L1L2L3

+DC

-DC

Internal

EMC filter

Supply ground

4 5 6

Size 6 only:

Heatsink fan supply connections

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Figure 4-4 Size 3 power connections

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Figure 4-5 Size 4, 5 and 6 power connections

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On size 2 and 3, the high current DC connections must always be used when using a braking resistor, supplying the drive from DC (low voltage DC or high voltage DC) or using the drive in a parallel DC bus system. The low current DC connection is used to connect low voltage DC to the drive internal power supply and to connect the internal EMC filter.

See Figure 4-7 for further information on ground connections.

Unidrive SP User Guide 63 Issue Number: 12 www.controltechniques.com

* See section 4.1.2 Ground connections . ** See section 4.4 Heatsink fan supply on page 66 for more information.

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Plain washers

Spring washer

M6 bolt

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4.1.2 Ground connections

Size 0

On a size 0, the supply and motor ground connections are made using an M6 screw at the top (supply) and bottom (motor) of the drive. See Figure 4-1 on page 61.

Size 1

On a size 1, the supply and motor ground connections are made using the studs located either side of the drive near the plug-in power connector. Refer to Figure 4-2 on page 62.

Size 2

On a size 2, the supply and motor ground connections are made using the grounding bridge that locates at the bottom of the drive. See Figure 4-6 for details.

Size 3

On a size 3, the supply and motor ground connections are made using an M6 nut and bolt that locates in the fork protruding from the heatsink between the AC supply and motor output terminals. See Figure 4-7 for details.

Size 4, 5 and 6

On a size 4, 5 and 6, the supply and motor ground connections are made using an M10 bolt at the top (supply) and bottom (motor) of the drive. See Figure 4-8 on page 65.

The supply ground and motor ground connections to the drive are connected internally by a copper conductor with a cross-sectional area given below:

Size 4: 19.2mm Size 5: 60mm Size 6: 75mm

This connection is sufficient to provide the ground (equipotential bonding) connection for the motor circuit under the following conditions:

(0.03in2, or slightly bigger than 6 AWG)

(0.09in2, or slightly bigger than 1 AWG)

(0.12in2, or slightly bigger than 2/0 AWG)

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Figure 4-6 Size 2 ground connections

Figure 4-7 Size 3 ground connections

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To standard Conditions

Supply phase conductors having cross-sectional area not exceeding:

IEC 60204-1 & EN 60204-1

Size 4: 38.4mm Size 5: 120mm Size 6: 150mm

Supply protection device rating not exceeding:

NFPA 79

Size 4: 200A Size 5: 600A Size 6: 1000A

If the necessary conditions are not met, an additional ground connection must be provided to link the motor circuit ground and the supply ground.

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Supply ground

Motor ground

WARNING

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Figure 4-8 Size 4, 5 and 6 ground connections

The ground loop impedance must conform to the requirements of local safety regulations.

The drive must be grounded by a connection capable of carrying the prospective fault current until the protective device (fuse, etc.) disconnects the AC supply.

The ground connections must be inspected and tested at appropriate intervals.

4.2 AC supply requirements

Voltage:

SPx2xx 200V to 240V ±10% SPx4xx 380V to 480V ±10% SPx5xx 500V to 575V ±10%

SPx6xx 500V to 690V ±10% Number of phases: 3* *200V size 0 drives can also be used on a single phase supply. Maximum supply imbalance: 2% negative phase sequence (equivalent

to 3% voltage imbalance between phases). Frequency range: 48 to 65 Hz For UL compliance only, the maximum supply symmetrical fault current

must be limited to 100kA

4.2.1 Supply types

All drives are suitable for use on any supply type i.e TN-S, TN-C-S, TT and IT.

• Supplies with voltage up to 600V may have grounding at any

potential, i.e. neutral, centre or corner (“grounded delta”)

• Supplies with voltage above 600V may not have corner grounding Drives are suitable for use on supplies of installation category III and

lower, according to IEC60664-1. This means they may be connected permanently to the supply at its origin in a building, but for outdoor installation additional over-voltage suppression (transient voltage surge suppression) must be provided to reduce category IV to category III.

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Operation with IT (ungrounded) supplies:

Special attention is required when using internal or external EMC filters with ungrounded supplies, because in the event of a ground (earth) fault in the motor circuit the drive may not trip and the filter could be over-stressed. In this case, either the filter must not be used (removed) or additional independent motor ground fault protection must be provided. Refer to Table 4-1. For instructions on removal, refer to Figure 4-22 Removal of internal EMC filter and line to ground varistors (size 0) , Figure 4-23 Removal of internal EMC filter (size 1 to 3) and Figure 4-24 Removal of internal EMC filter (sizes 4 to 6) on page 78. For details of ground fault protection contact the supplier of the drive.

A ground fault in the supply has no effect in any case. If the motor must continue to run with a ground fault in its own circuit then an input isolating transformer must be provided and if an EMC filter is required it must be located in the primary circuit.

Unusual hazards can occur on ungrounded supplies with more than one source, for example on ships. Contact the supplier of the drive for more information.

Table 4-1 Behaviour of the drive in the event of a motor circuit

ground (earth) fault with an IT supply

Drive size Internal filter only External filter (with internal)

0 (200V)

May not trip – precautions

required

Drive trips on fault

0 (400V) Drive trips on fault Drive trips on fault

1 and 2 Drive trips on fault Drive trips on fault

4 to 6

May not trip – precautions

required

May not trip – precautions

required

Drive trips on fault

May not trip – precautions

required

4.2.2 Supplies requiring line reactors

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

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

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

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

• Power factor correction equipment connected close to the drive.

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

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

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

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

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

SP0201 SP0202 SP0203 SP0204 SP0205 SP0401 SP0402 SP0403 SP0404 SP0405 SP1201 SP1202 SP1203 SP1204 SP1401 SP1402 SP1403 SP1404

Model sizes SP1405 to SP4606 have an internal DC choke and SP5201

Unidrive SP User Guide 65 Issue Number: 12 www.controltechniques.com

Safety

100

----------

-------

2π f I

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

×=

55 54 53 52 51 50

65 64 63 62 61 60

To the heatsink fan

Pre-wired internally

24V low voltage DC mode enable

Not used

24V heatsink fan supply

Upper terminal connector

Lower terminal connector

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to SP6602 have internal AC line chokes, so they do not require AC line reactors except for cases of excessive phase unbalance or extreme supply conditions.

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

Reactor current ratings

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

Not less than the continuous input current rating of the drive

Repetitive peak current rating:

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

4.2.3 Input inductor calculation

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

Where:

I = drive rated input current (A)

L = inductance (H) f = supply frequency (Hz) V = voltage between lines

4.3 Supplying the drive with DC / DC bus paralleling

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

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

a second motoring drive.

2. Allow the use of one braking resistor to dissipate regenerative

energy from several drives.

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

For application data, contact the supplier of the drive.

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4.4 Heatsink fan supply

The heatsink fan on size 0 to 5 is supplied internally by the drive. The heatsink fan on size 6 requires an external 24Vdc supply. The

connections for the heatsink fan supply must be made to the upper terminal connector near to the W phase output on the drive. Figure 4-9 shows the position of the heatsink fan supply connections.

Figure 4-9 Location of the size 6 heatsink fan supply connections

Figure 4-10 Size 6 heatsink fan supply connections

The heatsink fan supply requirements are as follows:

Nominal voltage: 24Vdc Minimum voltage: 23.5Vdc Maximum voltage: 27Vdc Current drawn: 3.3A Recommended power supply: 24V, 100W, 4.5A

Recommended fuse: 4A fast blow (I

t less than 20A2s)

4.5 Control 24Vdc supply

The 24Vdc input has three main functions.

• It can be used to supplement the drive's own internal 24V when multiple SM-Universal Encoder Plus, SM-Encoder Output Plus, SM-

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66 Unidrive SP User Guide

I/O Plus, or SM-I/O 32 modules are being used and the current drawn by these modules is greater than the drive can supply. (If too much current is drawn from the drive, the drive will initiate a 'PS.24V' trip)

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

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

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

Maximum continuous operating voltage: 30.0 V Minimum continuous operating voltage: 19.2 V Nominal operating voltage: 24.0 V Minimum start up voltage: 21.6 V Maximum power supply requirement at 24V: 60 W Recommended fuse: 3 A, 50 Vdc

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

4.6 Low voltage DC power supply

The drive can be operated from low voltage DC supplies, nominally 24Vdc (control) and 48Vdc (power). The low voltage DC power operating mode is designed either, to allow for motor operation in an emergency back-up situation following failure of the AC supply, for example in elevators; or to limit the speed of a servo motor during commissioning / start-up of equipment, for example a robot cell.

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

Size 0

Minimum continuous operating voltage: 36V Minimum start up voltage: 40V Nominal continuous operating voltage: 48 to 72V Maximum braking IGBT turn on voltage: 95.4V Maximum over voltage trip threshold: 104.4V

Size 1

Minimum continuous operating voltage: 36V Minimum start up voltage: 40V Nominal continuous operating voltage: 48V Maximum braking IGBT turn on voltage: 63.6V Maximum over voltage trip threshold: 69.6V

Size 2 and 3

Size 4 (200V drives)

Minimum continuous operating voltage: 36V Nominal continuous operating voltage: 48 to 72V Maximum braking IGBT turn on voltage: 95.4V Maximum over voltage trip threshold: 104.4V

Size 4, 5 and 6 (400V and 690V drives)

Minimum continuous operating voltage: 36V Nominal continuous operating voltage: 48 to 96V Maximum braking IGBT turn on voltage: 127.2V Maximum over voltage trip threshold: 139.2V

See section 4.5 Control 24Vdc supply on page 66 for 24V back-up to control.

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4.7 Ratings

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

Typical input current

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

The values of typical input current are stated for a balanced supply.

Maximum continuous input current

The values of maximum continuous input current are given to aid the selection of cables and fuses. These values are stated for the worst case condition with the unusual combination of stiff supply with bad balance. The value stated for the maximum continuous input current would only be seen in one of the input phases. The current in the other two phases would be significantly lower.

The values of maximum input current are stated for a supply with a 2% negative phase-sequence imbalance and rated at the supply fault current given in Table 4-2.

Table 4-2 Supply fault current used to calculate maximum input currents

Model Symmetrical fault level (kA)

All 100

The nominal low voltage supply level is set by the user in Pr 6.46. The default setting is 48V for all drive sizes. The over voltage trip threshold and braking IGBT turn on voltage are scaled from this value as follows:

Brake IGBT turn on = 1.325 x Pr 6.46 (V) Over voltage trip = 1.45 x Pr 6.46 (V)

For application data, refer to the Unidrive SP Low Voltage DC Operation Installation Guide.

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Table 4-3 Size 0 to 3 input current, fuse and cable size ratings (European)

Model

Typical

input

current

Maximum

continuous

input current

Fuse

rating

IEC gG

Cable size

EN60204

Input

Output

SP0201 3.2 (5.0)* 3.6 (5.0)* 6 0.75 0.75 SP0202 4.8 (7.6)* 5.6 (7.6)* 10 1 0.75 SP0203 6.0 (9.6)* 6.9 (9.6)* 12 1.5 0.75 SP0204 7.9 (13.5)* 8.9 (13.5)* 16 2.5 0.75 SP0205

10.6 (17.4)*

12.3 (17.4)* 20 4 0.75 SP1201 7.1 9.5 10 1.5 1.0 SP1202 9.2 11.3 12 1.5 1.0 SP1203 12.5 16.4 20 4.0 1.0 SP1204 15.4 19.1 20 4.0 1.5 SP2201 13.4 18.1 20 4.0 2.5 SP2202 18.2 22.6 25 4.0 4.0 SP2203 24.2 28.3 32 6.0 6.0 SP3201 35.4 43.1 50 16 16 SP3202 46.8 54.3 63 25 25 SP0401 2.0 2.3 4 0.75 0.75 SP0402 2.6 2.8 4 0.75 0.75 SP0403 3.2 3.3 6 0.75 0.75 SP0404 4.3 4.4 6 0.75 0.75 SP0405 5.6 5.7 8 0.75 0.75 SP1401 4.1 4.8 8 1.0 1.0 SP1402 5.1 5.8 8 1.0 1.0 SP1403 6.8 7.4 8 1.0 1.0 SP1404 9.3 10.6 12 1.5 1.0 SP1405 10 11 12 1.5 1.0 SP1406 12.6 13.4 16 2.5 1.5 SP2401 15.7 17 20 4.0 2.5 SP2402 20.2 21.4 25 4.0 4.0 SP2403 26.6 27.6 32 6.0 6.0 SP2404 26.6 27.6 32 6.0 6.0 SP3401 34.2 36.2 40 10 10 SP3402 40.2 42.7 50 16 16 SP3403 51.3 53.5 63 25 25 SP3501 5.0 6.7 8 1.0 1.0 SP3502 6.0 8.2 10 1.0 1.0 SP3503 7.8 11.1 12 1.5 1.0 SP3504 9.9 14.4 16 2.5 1.5 SP3505 13.8 18.1 20 4.0 2.5 SP3506 18.2 22.2 25 4.0 4.0 SP3507 22.2 26.0 32 6.0 6.0

*The value in the bracket is when the drive is used on a 1 phase supply.

Table 4-4 Size 0 to 3 input current, fuse and cable size ratings (USA)

Model

Typical

input

current

Maximum

continuous

input current

Fuse rating

Class CC or

J** <30A

Class J** >30A

Cable size

UL508C

Input

Output

AWG

SP0201 3.2 (5.0)* 3.6 (5.0)* 10 16 24 SP0202 4.8 (7.6)* 5.6 (7.6)* 10 16 22 SP0203 6.0 (9.6)* 6.9 (9.6)* 16 14 20 SP0204 7.9 (13.5)* 8.9 (13.5)* 20 12 18 SP0205

10.6 (17.4)*

12.3 (17.4)* 20 12 18 SP1201 7.1 9.5 10 14 18 SP1202 9.2 11.3 15 14 16 SP1203 12.5 16.4 20 12 14 SP1204 15.4 19.1 20 12 14 SP2201 13.4 18.1 20 12 14 SP2202 18.2 22.6 25 10 10 SP2203 24.2 28.3 30 8 8 SP3201 35.4 43.1 45 6 6 SP3202 46.8 54.3 60 4 4 SP0401 2.0 2.3 10 16 24 SP0402 2.6 2.8 10 16 24 SP0403 3.2 3.3 10 16 24 SP0404 4.3 4.4 10 16 22 SP0405 5.6 5.7 10 16 20 SP1401 4.1 4.8 8 16 22 SP1402 5.1 5.8 8 16 20 SP1403 6.8 7.4 10 16 18 SP1404 9.3 10.6 15 14 16 SP1405 10 11 15 14 14 SP1406 12.6 13.4 15 14 14 SP2401 15.7 17 20 12 14 SP2402 20.2 21.4 25 10 10 SP2403 26.6 27.6 30 8 8 SP2404 26.6 27.6 30 8 8 SP3401 34.2 36.2 40 6 6 SP3402 40.2 42.7 45 6 6 SP3403 51.3 53.5 60 4 4 SP3501 5.0 6.7 10 16 18 SP3502 6.0 8.2 10 16 16 SP3503 7.8 11.1 15 14 14 SP3504 9.9 14.4 15 14 14 SP3505 13.8 18.1 20 12 14 SP3506 18.2 22.2 25 10 10 SP3507 22.2 26.0 30 8 8

*The value in the bracket is when the drive is used on a 1 phase supply. ** Fast acting or high speed class J fuses only.

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Table 4-5 Size 4 and larger input current, fuse and cable size ratings

Fuse option 1

Typical input

current

Model

Maximum

input current

IEC class

North

America:

Ferraz HSJ

AAAA A A

4201 62.1 4202 72.1

4203 94.5

5201 116

5202 137 4401 61.2

4402 76.3

4403 94.1

5401 126

5402 152

6401 224

6402 247

4601 23

4602 26.1

4603 32.9

4604 39

4605 46.2

4606 55.2

5601 75.5

5602 89.1

6601 128

6602 144

68.9 100 90 90 160 25 25 3 3

78.1 100 100 100 160 35 35 3 3

99.9 125 125 125 200 70 70 1 1 142 200 175 160 200 95 95 2/0 2/0 165 250 225 200 250 120 120 4/0 4/0

62.3 80 80 80 160 25 25 3 3

79.6 110 110 100 200 35 35 2 2

97.2 125 125 125 200 70 70 1 1 131 200 175 160 200 95 95 2/0 2/0 156 250 225 200 250 120 120 4/0 4/0 241 315 300 250 315 2 x 70 2 x 70 2 x 2/0 2 x 2/0 266 315 300 300 350 2 x 120 2 x 120 2 x 4/0 2 x 4/0

26.5 63 60 32 125 4 4 10 10

28.8 63 60 40 125 6 6 8 8

35.1 63 60 50 125 10 10 8 8

41 63 60 50 125 16 16 6 6

47.9 63 60 63 125 16 16 6 6

56.9 80 60 63 125 25 25 4 4

82.6 125 100 90 160 35 35 2 2

94.8 125 100 125 160 50 50 1 1 138 200 200 200 200 2 x 50 2 x 50 2 x 1 2 x 1 156 200 200 200 200 2 x 50 2 x 50 2 x 1 2 x 1

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Fuse option 2

semiconductor fuse in series

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HRC

IEC class gG

UL class J

Semi-

conductor

IEC class aR

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Cable size

EN60204 UL508C

Input

Output

Input

AWG

UL Listing

Information

Output

AWG

Installation class (ref: IEC60364-5-52:2001)

B1 - Separate cables in conduit. B2 - Multicore cable in conduit C - Multicore cable in free air.

Cable sizes are from IEC60364-5-52:2001 table A.52.C with correction factor for 40°C ambient of 0.87 (from table A52.14) for cable installation method B2 (multicore cable in conduit).

Cable size may be reduced if a different installation method is used, or if the ambient temperature is lower.

The recommended cable sizes above are only a guide. The mounting and grouping of cables affects their current-carrying capacity, in some cases smaller cables may be acceptable but in other cases a larger cable is required to avoid excessive temperature or voltage drop. Refer to local wiring regulations for the correct size of cables.

The recommended output cable sizes assume that the motor maximum current matches that of the drive. Where a motor of reduced rating is used the cable rating may be chosen to match that of the motor. To ensure that the motor and cable are protected against overload, the drive must be programmed with the correct motor rated current.

UL listing is dependent on the use of the correct type of UL-listed fuse, and applies when symmetrical short-circuit current does not exceed 100kA. See Chapter 14 UL Listing Information on page 294 for sizing information.

Fuses The AC supply to the drive must be installed with suitable protection against overload and short-circuits. Table 4-3, Table 4-4 and Table 4-5 show recommended fuse ratings. Failure to observe this requirement will cause risk of fire.

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

An MCB (miniature circuit breaker) or MCCB (moulded-case circuitbreaker) with type C may be used in place of fuses on sizes 1 to 3 under the following conditions:

• The fault-clearing capacity must be sufficient for the installation

• For frame sizes 2 and 3, the drive must be mounted in an enclosure which meets the requirements for a fire enclosure

See Chapter 14 UL Listing Information for UL listing requirements.

Fuse types

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

Ground connections

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

4.7.1 Main AC supply contactor

The recommended AC supply contactor type for sizes 0 to 6 is AC1.

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4.8 Output circuit and motor protection

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

The drive provides overload protection for the motor and its cable. For this to be effective, Pr 0.46 Motor rated current must be set to suit the motor.

Pr 0.46 Motor rated current must be set correctly to avoid a risk of fire in the event of motor overload.

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

4.8.1 Cable types and lengths

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 4-6, Table 4-7 and Table 4-8.

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

• AC supply to external EMC filter (when used)

• AC supply (or external EMC filter) to drive

• Drive to motor

• Drive to braking resistor

Table 4-6 Maximum motor cable lengths (200V drives)

200V Nominal AC supply voltage

Maximum permissible motor cable length for each of

Model

3kHz 4kHz 6kHz 8kHz 12kHz 16kHz

SP0201 SP0202 SP0203 SP0204 SP0205 SP1201 65m (210ft) SP1202 100m (330ft) SP1203 130m (425ft) SP1204 SP2201 SP2202 SP2203

200m

(660ft) SP3201 SP3202 SP4201 SP4202 SP4203 SP5201 SP5202

250m

(820ft)

250m

(820ft)

the following frequencies

50m

(165ft)

75m

(245ft)

90m

(295ft)

90m

(295ft)

150m

(490ft)

185m

(607ft)

185m

(607ft)

100m

(330ft)

125m

(410ft)

125m

(410ft)

5 0 m

(165ft)

37m

(120ft)

Table 4-7 Maximum motor cable lengths (400V drives)

400V Nominal AC supply voltage

Maximum permissible motor cable length for each of

Model

the following frequencies

3kHz 4kHz 6kHz 8kHz 12kHz 16kHz

SP0401 SP0402 SP0403 SP0404

50m

(165ft)

SP0405 SP1401 65m (210ft) SP1402 100m (330ft) SP1403 130m (425ft) SP1404 SP1405 SP1406 SP2401 SP2402 SP2403

200m

(660ft)

150m

(490ft)

100m

(330ft)

75m

(245ft)

5 0 m

(165ft)

SP2404 SP3401 SP3402 SP3403 SP4401 SP4402 SP4403 SP5401 SP5402

250m

(820ft)

185m

(607ft)

125m

(410ft)

90m

(295ft)

SP6401 SP6402

Table 4-8 Maximum motor cable lengths (575V drives)

575V Nominal AC supply voltage

Maximum permissible motor cable length for each of

Model

the following frequencies

3kHz 4kHz 6kHz 8kHz 12kHz 16kHz

SP3501 SP3502 SP3503 SP3504 SP3505

200m

(660ft)

150m

(490ft)

100m

(330ft)

75m

(245ft)

SP3506 SP3507

37m

(120ft)

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Normal capacitance

Shield or armour separated from the cores

High capacitance

Shield or armour close to the cores

Motor

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relay

Chain connection (preferred)

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Table 4-9 Maximum motor cable lengths (690V drives)

690V Nominal AC supply voltage

Maximum permissible motor cable length for each of

Model

the following frequencies

3kHz 4kHz 6kHz 8kHz 12kHz 16kHz

SP4601 SP4602 SP4603 SP4604 SP4605 SP4606

250m

(820ft)

185m

(607ft)

125m

(410ft)

90m

(295ft)

SP5601 SP5602 SP6601 SP6602

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

• The default switching frequency is 3kHz for open-loop and closedloop vector and 6kHz for servo.

High-capacitance cables

The maximum cable length is reduced from that shown in Table 4-6, Table 4-7, Table 4-8 and Table 4-9 if high capacitance motor cables are used.

Most cables have an insulating jacket between the cores and the armor or shield; these cables have a low capacitance and are recommended. Cables that do not have an insulating jacket tend to have high capacitance; if a cable of this type is used, the maximum cable length is half that quoted in the tables. (Figure 4-11 shows how to identify the two types.)

Figure 4-11 Cable construction influencing the capacitance

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For multiple motors, the precautions given in section 4.8.3 Multiple motors should be followed.

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

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

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

4.8.3 Multiple motors

Open-loop only

If the drive is to control more than one motor, one of the fixed V/F modes should be selected (Pr 5.14 = Fd or SrE). Make the motor connections as shown in Figure 4-12 and Figure 4-13. The maximum cable lengths in Table 4-6, Table 4-7, Table 4-8 and Table 4-9 apply to the sum of the total cable lengths from the drive to each motor. It is recommended that each motor is connected through a protection relay

since the drive cannot protect each motor individually. For sinusoidal filter or an output inductor must be connected as shown in Figure 4-13, even when the cable lengths are less than the maximum permissible. For details of inductor sizes refer to the supplier of the drive.

Figure 4-12 Preferred chain connection for multiple motors

connection, a

The cable used for Table 4-6, Table 4-7, Table 4-8 and Table 4-9 is shielded and contains four cores. Typical capacitance for this type of cable is 130pF/m (i.e. from one core to all others and the shield connected together).

4.8.2 Motor winding voltage

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

For normal operation with AC supplies up to 500Vac and a standard motor with a good quality insulation system, there is no need for any special precautions. In case of doubt the motor supplier should be consulted.

Special precautions are recommended under the following conditions, but only if the motor cable length exceeds 10m:

• AC supply voltage exceeds 500V

• DC supply voltage exceeds 670V

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

• Multiple motors connected to a single drive

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Safety

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Inductor

Motor protection relay

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Figure 4-13 Alternative connection for multiple motors

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4.9 Braking

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

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

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

Table 4-10 shows the DC voltage level at which the drive turns on the braking transistor.

Table 4-10 Braking transistor turn on voltage

Drive voltage rating DC bus voltage level

200V 390V 400V 780V 575V 930V 690V 1120V

4.8.4 A / Δ motor operation

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

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

400V drive 400V rated voltage 200V drive 200V rated voltage

A typical 3 phase motor would be connected in for 200V operation, however, variations on this are common e.g.

A for 400V operation or Δ

A 690V Δ 400V

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

4.8.5 Output contactor

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

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

The recommended motor contactor is the AC3 type. Switching of an output contactor should only occur when the output of

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

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

2. High levels of radio frequency noise emission

3. Increased contactor wear and tear The Drive Enable terminal (T31) when opened provides a SAFE

TORQUE OFF (SECURE DISABLE) function. This can in many cases replace output contactors.

For further information see section 4.16 SAFE TORQUE OFF (SECURE

DISABLE) on page 93.

When a braking resistor is used, Pr 0.15 should be set to FASt ramp mode.

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

4.9.1 Heatsink mounted braking resistor

A resistor has been especially designed to be mounted internal to the drive (size 0) or within the heatsink of the drive (sizes 1 and 2). See section 3.11 Internal/heatsink mounted braking resistor on page 54 for mounting details. The design of the resistor is such that no thermal protection circuit is required, as the device will fail safely under fault conditions. On sizes 0, 1 and 2, the in built software overload protection is set up at default for the designated heatsink mounted resistor. Table 411 provides the resistor data for each drive rating.

The internal braking resistor for size 0 is fitted with a thermistor which must be connected to the drive whenever the internal braking resistor in installed.

The internal/heatsink mounted resistor is suitable for applications with a low level of regen energy only. See Table 4-11.

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Parameter

Size 0 Size 1 and 2

200V drive

400V drive

200V drive

400V drive

Full power braking time

Pr 10.30 0.06 0.01 0.04 0.02

Full power braking period

Pr 10.31 2.6 1.7 3.3

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Braking resistor overload protection parameter settings

Failure to observe the following information may damage the resistor.

The drive’s software contains an overload protection function for a braking resistor. On size 0 to 2 this function is enabled at default to protect the heatsink mounted resistor. Below are the parameter settings.

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connection requires the cable to be armored or shielded, since it is not fully contained in a metal enclosure. See section 4.11.5 Compliance with generic emission standards on page 81 for further details.

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

Minimum resistances and power ratings

Table 4-12 Minimum resistance values and peak power rating for

the braking resistor at 40°C (104°F)

Average power

for 60s

0.74

Model

SP0201

Minimum

resistance*

Instantaneous

power rating

SP0202 1.1 SP0203 1.5

35 4.35 SP0204 2.2 SP0205 3.0

For more information on the braking resistor software overload protection, see Pr 10.30 and Pr 10.31 full descriptions in the Advanced User Guide.

If the heatsink mounted braking resistor is to be used at more than half of its average power rating then the drive's cooling fan must be at full speed controlled by setting Pr 6.45 to On (1).

Table 4-11 Heatsink mounted braking resistor data

Parameter Size 0 Size 1 Size 2

Part number 1299-0001-00 1220-2756-01 1220-2758-01 DC resistance at 25°C70Ω 75Ω 37.5Ω Peak instantaneous power

over 1ms at nominal

8.7kW 8kW 16kW

resistance Average power over 60s * 50W 50W 100W Ingress Protection (IP)

rating

N/A IP54

Maximum altitude 2000m

* To keep the temperature of the resistor below 70°C (158°F) in a 30°C (86°F) ambient, the average power rating is 50W for size 1 and 100W for size 2. The above parameter settings ensure this is the case.

Size 3 and larger do not have heatsink mounted braking resistors, hence the default values of Pr 10.30 and Pr 10.31 are 0 (i.e. software braking resistor overload protection disabled).

The internal braking resistor for size 0 can be used with the drive even though its resistance is lower than the minimum resistance values given in Table 4-12, because of the following reasons.

• The braking resistor overload protection function in the drive is set up to limit the power dissipated in the resistor

• The braking resistor is fitted with a thermistor which will trip the drive if the resistor is too hot

• The power rating of the resistor is only 50W

If an external resistor is used with the drive, its resistance must be equal to or greater than the value given in Table 4-12.

4.9.2 External braking resistor

Overload protection When an external braking resistor is used, it is essential that an overload protection device is incorporated in the braking resistor circuit; this is described in Figure 4-14 on page 74.

SP1201 SP1202 2.2

43 3.5

1.5

SP1203 3.0 SP1204 29 5.3 4.4 SP2201 SP2202 8.0

18 8.9

6.0

SP2203 8.9 SP3201 SP3202 19.3

5.0 30.3

SP4201** SP4202** 27.8

5.0 30.3

13.1

22.5

SP4203** 30.3 SP5201** SP5202**

SP0401

3.5 53 43.5

0.74 SP0402 1.1 SP0403 1.5

105 5.79 SP0404 2.2 SP0405 3.0 SP1401 SP1402 2.2 SP1403 3.0

74 8.3

1.5

SP1404 4.4 SP1405 SP1406 8.0

58 10.6

SP2401 SP2402 13.1 SP2403 19.3

19 33.1

6.0

9.6

SP2404 22.5 SP3401 SP3402 27.8

18 35.5

22.5

SP3403 33.0

SP4401** SP4402** 53.0

11 55.3

45.0

SP4403** 9 67.6 67.5 SP5401** SP5402** 86.9 SP6401** SP6402**

7 86.9

5 122 122

82.5

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

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Instantaneous

power rating

Average power

for 60s

4.4

Model

SP3501

Minimum

resistance*

SP3502 6.0 SP3503 8.0 SP3504 9.6

18 50.7 SP3505 13.1 SP3506 19.3 SP3507 22.5

SP4601**

19.3 SP4602** 22.5 SP4603** 27.8 SP4604** 33.0

13 95.0

SP4605** 45.0 SP4606** 55.5 SP5601** SP5602** 82.5 SP6601** SP6602** 125

10 125

67.5

113

* Resistor tolerance: ±10% ** The power ratings specified are for a stand-alone drive only. If the

drive is part of a common DC bus system different ratings must be used. Contact the supplier of the drive for more information.

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.

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

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

Thermal protection circuit for the braking resistor

The thermal protection circuit must disconnect the AC supply from the drive if the resistor becomes overloaded due to a fault. Figure 4-14 shows a typical circuit arrangement.

Figure 4-14 Typical protection circuit for a braking resistor

See Figure 4-2 on page 62, Figure 4-3 and Figure 4-4 on page 63, and Figure 4-5 on page 63 for the location of the +DC and braking resistor connections.

4.9.3 Braking resistor software overload protection

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

• Resistor short-time overload time (Pr 10.30)

• Resistor minimum time between repeated short-time overloads (Pr 10.31)

This data should be obtained from the manufacturer of the braking resistors.

Pr 10.39 gives an indication of braking resistor temperature based on a simple thermal model. Zero indicates the resistor is close to ambient and 100% is the maximum temperature the resistor can withstand. A br.rS alarm is given if this parameter is above 75% and the braking IGBT is active. An It.br trip will occur if Pr 10.39 reaches 100%, when Pr 10.37 is set to 0 (default value) or 1.

If Pr 10.37 is equal to 2 or 3 an It.br trip will not occur when Pr 10.39 reaches 100%, but instead the braking IGBT will be disabled until Pr 10.39 falls below 95%. This option is intended for applications with parallel connected DC buses where there are several braking resistors, each of which cannot withstand full DC bus voltage continuously. With this type of application it is unlikely the braking energy will be shared equally between the resistors because of voltage measurement tolerances within the individual drives. Therefore with Pr 10.37 set to 2 or 3, then as soon as a resistor has reached its maximum temperature the drive will disable the braking IGBT, and another resistor on another drive will take up the braking energy. Once Pr 10.39 has fallen below 95% the drive will allow the braking IGBT to operate again.

See the Advanced User Guide for more information on Pr 10.30, Pr

10.31, Pr 10.37 and Pr 10.39.

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

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4.10 Ground leakage

The ground leakage current depends upon whether the internal EMC filter is installed. The drive is supplied with the filter installed. Instructions for removing the internal filter are given in Figure 4-23 Removal of

internal EMC filter (size 1 to 3) and Figure 4-24 Removal of internal EMC filter (sizes 4 to 6) on page 78.

With internal filter installed: Size 0: 12mA* AC at 400V 50Hz

30µA DC with a 600V DC bus (10MΩ)

Size 1 to 3: 28mA* AC at 400V 50Hz

30µA DC with a 600V DC bus (10MΩ)

Size 4 to 6: 56mA* AC at 400V 50Hz

18µA DC with a 600V DC bus (33MΩ)

* Proportional to the supply voltage and frequency.

With internal filter removed:

<1mA Note that in both cases there is an internal voltage surge protection device connected to ground. Under normal circumstances this carries negligible current.

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

4.10.1 Use of residual current device (RCD)

There are three common types of ELCB / RCD:

1. AC - detects AC fault currents

2. A - detects AC and pulsating DC fault currents (provided the DC

current reaches zero at least once every half cycle)

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

• Type AC should never be used with drives.

• Type A can only be used with single phase drives

• Type B must be used with three phase drives

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section 4.11.5 should be followed to give reduced radio-frequency emission.

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

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

• The Declaration of Conformity at the front of this manual

• Chapter 12 Technical Data on page 258 ...the correct external EMC filter must be used and all of the guidelines in

section 4.11.3 General requirements for EMC and section

4.11.5 Compliance with generic emission standards must be followed.

Table 4-13 Unidrive SP and EMC filter cross reference

Drive

Schaffner Epcos

CT part no. CT part no.

SP0201 to SP0205 (1 phase) 4200-6000 SP0201 to SP0205 (3 phase) 4200-6001

SP1201 to SP1202 4200-6118 4200-6121 SP1203 to SP1204 4200-6119 4200-6120 SP2201 to SP2203 4200-6210 4200-6211 SP3201 to SP3202 4200-6307 4200-6306 SP4201 to SP4203 4200-6406 4200-6405 SP5201 to SP5202 4200-6503 4200-6501 SP0401 to SP0405 4200-6002 SP1401 to SP1404 4200-6118 4200-6121 SP1405 to SP1406 4200-6119 4200-6120 SP2401 to SP2404 4200-6210 4200-6211 SP3401 to SP3403 4200-6305 4200-6306 SP4401 to SP4403 4200-6406 4200-6405 SP5401 to SP5402 4200-6503 4200-6501 SP6401 to SP6402 4200-6603 4200-6601 SP3501 to SP3507 4200-6309 4200-6308 SP4601 to SP4606 4200-6408 4200-6407 SP5601 to SP5602 4200-6504 4200-6502 SP6601 to SP6602 4200-6604 4200-6602

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

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

4.11 EMC (Electromagnetic compatibility)

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

Section 4.11.3, General requirements for all applications, to ensure reliable operation of the drive and minimise the risk of disturbing nearby equipment. The immunity standards specified in section 11 will be met, but no specific emission standards. Note also the special requirements given in Surge immunity of control circuits - long cables and connections outside a building on page 83 for increased surge immunity of control circuits where control wiring is extended.

Section 4.11.4, Requirements for meeting the EMC standard for power drive systems, IEC61800-3 (EN61800-3).

Section 4.11.5, Requirements for meeting the generic emission standards for the industrial environment, IEC61000-6-4, EN61000-6-4,

EN50081-2. The recommendations of section 4.11.3 will usually be sufficient to avoid

causing disturbance to adjacent equipment of industrial quality. If particularly sensitive equipment is to be used nearby, or in a nonindustrial environment, then the recommendations of section 4.11.4 or

High ground leakage current

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

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

4.11.1 Grounding hardware

The drive is supplied with a grounding bracket, and sizes 1 to 3 with a grounding clamp, to facilitate EMC compliance. They provide a convenient method for direct grounding of cable shields without the use of "pig-tails". Cable shields can be bared and clamped to the grounding

bracket using metal clips or clamps that the shield must in all cases be continued through the clamp to the intended terminal on the drive, in accordance with the connection details for the specific signal.

A suitable clamp is the Phoenix DIN rail mounted SK14 cable clamp

(for cables with a maximum outer diameter of 14mm). See Figure 4-15 for details of using the grounded metal panel on size 0. See Figure 4-16 and Figure 4-17 for details on installing the grounding

clamp. See Figure 4-18 and Figure 4-19 for details on installing the grounding

bracket.

(not supplied) or cable ties. Note

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Figure 4-15 Use of the EMC bracket on size 0

Figure 4-16 Installation of grounding clamp (size 1 and 2)

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Figure 4-18 Installation of grounding bracket (size 0)

Figure 4-19 Installation of grounding bracket (sizes 1 to 6)

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Figure 4-17 Installation of grounding clamp (size 3)

Loosen the ground connection nuts and slide the grounding bracket in the direction shown. Once in place, re-tighten the ground connection nuts.

On size 1 and 2, the grounding bracket is secured using the power ground terminal of the drive. Ensure that the supply ground connection is secure after installing / removing the grounding bracket. Failure to do so will result in the drive not being grounded.

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

When a size 4 or 5 is through-panel mounted, the grounding link bracket must be folded upwards. A screw can be used to secure the bracket or it can be located under the mounting bracket to ensure that a ground connection is made. This is required to provide a grounding point for the grounding bracket as shown in Figure 4-20.

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Mounting bracket

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Figure 4-20 Size 4 and 5 grounding link bracket in its surface

mount position (as supplied)

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For 200V size 0 and frame sizes 3 and above, when the drive is used with ungrounded (IT) supplies the internal EMC filter must be removed unless additional motor ground fault protection is installed or, in the case of 200V size 0 and size 3 only, the external filter is also used. For instructions on removal, refer to Figure 4-22, Figure 4-23 and Figure 4-24. For details of ground fault protection contact the supplier of the drive.

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

The internal EMC filter reduces radio-frequency emission into the line power supply. Where the motor cable is short, it permits the requirements of EN61800-3 to be met for the second environment - see section 4.11.4 Compliance with EN 61800-3 (standard for Power Drive

Systems) on page 80 and section 12.1.24 Electromagnetic compatibility (EMC) on page 270. For longer motor cables the filter continues to

provide a useful reduction in emission level, and when used with any length of shielded motor cable up to the limit for the drive, it is unlikely that nearby industrial equipment will be disturbed. It is recommended that the filter be used in all applications unless the instructions given above require it to be removed or the ground leakage current of 12mA for size 0, 28mA for size 1 to 3 or 56mA for size 4 to 6 is unacceptable. See Figure 4-22, Figure 4-23 and Figure 4-24 for details of removing and installing the internal EMC filter.

Figure 4-22 Removal of internal EMC filter and line to ground

varistors (size 0)

Figure 4-21 Size 4 and 5 grounding link bracket folded up into its

through- panel mount position

The supply must be disconnected before removing the internal EMC filter or line to ground varistor screws.

1. Internal EMC filter. Remove the bottom screw as shown.

2. Line to ground varistors. Remove the top screw as shown.

The line to ground varistors should only be removed in special circumstances.

Figure 4-23 Removal of internal EMC filter (size 1 to 3)

4.11.2 Internal EMC filter

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

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Optional

ground

connection

External controller

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

Metal backplate

Grounding bar

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

Use four core cable to

connect the motor to the drive.

The ground conductor in the motor cable must be connected

directly to the earth terminal of

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

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

3 phase AC supply

Optional EMC filter

Metal backplate safety bonded to power ground busbar

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Loosen / remove screws as shown (1) and (2). Remove filter (3), and ensure the screws are replaced and re-tightened (4).

Figure 4-24 Removal of internal EMC filter (sizes 4 to 6)

Loosen screws (1). Remove EMC filter in the direction shown (2).

Figure 4-25 General EMC enclosure layout showing ground connections

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4.11.3 General requirements for EMC

Ground (earth) connections

The grounding arrangements should be in accordance with Figure 4-25, which shows a single drive on a back-plate with or without an additional enclosure.

Figure 4-25 shows how to manage EMC when using an unshielded motor cable. However a shielded cable is preferable, in which case it should be installed as shown in section 4.11.5 Compliance with generic emission standards on page 81.

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Optional braking resistor and overload

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

300mm

(12in)

NOTE

Twisted

pair

cable

Twisted pair shield

Cable

Cable overall shield

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Cable layout

Figure 4-26 indicates the clearances which should be observed around the drive and related ‘noisy’ power cables by all sensitive control signals / equipment.

Figure 4-26 Drive cable clearances

Any signal cables which are carried inside the motor cable (i.e. motor thermistor, motor brake) will pick up large pulse currents via the cable capacitance. The shield of these signal cables must be connected to ground close to the motor cable, to avoid this noise current spreading through the control system.

Feedback device cable shielding

Shielding considerations are important for PWM drive installations due to the high voltages and currents present in the output (motor) circuit with a very wide frequency spectrum, typically from 0 to 20 MHz.

The following guidance is divided into two parts:

1. Ensuring correct transfer of data without disturbance from electrical

noise originating either within the drive or from outside.

2. Additional measures to prevent unwanted emission of radio

frequency noise. These are optional and only required where the

installation is subject to specific requirements for radio frequency

emission control.

To ensure correct transfer of data, observe the following:

Resolver connections:

• Use a cable with an overall shield and twisted pairs for the resolver signals

• Connect the cable shield to the drive 0V connection by the shortest possible link ("pigtail")

• It is generally preferable not to connect the cable shield to the resolver. However in cases where there is an exceptional level of common-mode noise voltage present on the resolver body, it may be helpful to connect the shield there. If this is done then it becomes essential to ensure the absolute minimum length of "pigtails" at both shield connections, and possibly to clamp the cable shield directly to the resolver body and to the drive grounding bracket.

• The cable should preferably not be interrupted. If interruptions are unavoidable, ensure the absolute minimum length of "pigtail" in the shield connections at each interruption.

Encoder connections:

• Use a cable with the correct impedance

• Use a cable with individually shielded twisted pairs

• Connect the cable shields to 0V at both the drive and the encoder, using the shortest possible links ("pigtails")

• The cable should preferably not be interrupted. If interruptions are unavoidable, ensure the absolute minimum length of "pigtail" in the shield connections at each interruption. Preferably, use a connection method which provides substantial metallic clamps for the cable shield terminations.

The above applies where the encoder body is isolated from the motor and where the encoder circuit is isolated from the encoder body. Where there is no isolation between the encoder circuits and the motor body, and in case of doubt, the following additional requirement must be observed. This gives the best possible noise immunity.

• The shields must be directly clamped to the encoder body (no pigtail) and to the drive grounding bracket. This may be achieved by clamping of the individual shields or by providing an additional overall shield which is clamped.

The recommendations of the encoder manufacturer must also be adhered to for the encoder connections.

In order to guarantee maximum noise immunity for any application double shielded cable as shown should be used.

In some cases single shielding of each pair of differential signals cables, or a single overall shield with individual shield on the thermistor connections is sufficient. In these cases all the shields should be connected to ground and 0V at both ends.

If the 0V is required to be left floating a cable with individual shields and an overall shield must be used.

Figure 4-27 and Figure 4-28 illustrate the preferred construction of cable and the method of clamping. The outer sheath of the cable should be stripped back enough to allow the clamp to be installed. The shield must not be broken or opened at this point. The clamps should be installed close to the drive or feedback device, with the ground connections made to a ground plate or similar metallic ground surface.

Figure 4-27 Feedback cable, twisted pair

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Cable shield

Twisted

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shield

Cable shield

Twisted

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shield

Connection

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Connection

at drive

Ground clamp on shield

Shield

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to 0V

Shield

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Figure 4-28 Feedback cable connections

To ensure suppression of radio frequency emission, observe the following:

• Use a cable with an overall shield

• Clamp the overall shield to grounded metallic surfaces at both the

4.11.4 Compliance with EN 61800-3 (standard for

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

Operation in the first environment

Observe the guidelines given in section 4.11.5 Compliance with generic emission standards on page 81. An external EMC filter will always be

required.

Operation in the second environment

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

The drive contains an in-built filter for basic emission control. In some cases feeding the motor cables (U, V and W) once through a ferrite ring can maintain compliance for longer cable lengths. The requirements of operating in the second environment are met, depending on the motor cable length for 3kHz switching frequency as stated in Table 4-14 and Table 4-15.

encoder and the drive, as illustrated in Figure 4-28

Power Drive Systems)

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

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

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Table 4-14 Second environment emission compliance (size 0)

Drive

size

0 In-built

Filter Voltage

200 Unrestricted Restricted 400 Unrestricted Restricted

Motor cable length (m)

0 to 12 12 to 14 >14

Table 4-15 Second environment emission compliance (size 1 to 6)

Drive

size

Filter Voltage

Motor cable length (m)

0 to 4 4 to 10 10 to 100

In-built Any Unrestricted Restricted

In-built and

ferrite ring

Any Unrestricted Restricted

In-built Any Restricted

In-built and

ferrite ring

Any Unrestricted Restricted

3 In-built Any Restricted 4 In-built Any Restricted

5 In-built

200 & 400 Unrestricted

690 Restricted

6 In-built Any Unrestricted

Key:

Restricted:EN 61800-3 second environment, restricted distribution

(Additional measures may be required to prevent interference)

Unrestricted:EN 61800-3 second environment, unrestricted distribution For longer motor cables, an external filter is required. Where a filter is

required, follow the guidelines in section 4.11.5 Compliance with generic emission standards .

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

4.11.3 General requirements for EMC on page 78.

The second environment typically includes an industrial lowvoltage power supply network which does not supply buildings used for residential purposes. Operating the drive in this environment without an external EMC filter may cause interference to nearby electronic equipment whose sensitivity has not been appreciated. The user must take remedial measures if this situation arises. If the consequences of unexpected disturbances are severe, it is recommended that the guidelines in section 4.11.5 Compliance with generic emission standards be adhered to.

Refer to section 12.1.24 Electromagnetic compatibility (EMC) on page 270 for further information on compliance with EMC standards and definitions of environments.

Detailed instructions and EMC information are given in the EMC Data Sheet which is available from the supplier of the drive.

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≥

100mm

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≥

100mm

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Do not modify the filter wires

100mm (4in)

100mm

(4in)

100mm (4in)

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4.11.5 Compliance with generic emission standards

The following information applies to frame sizes 0 to 5. Size 6 upwards does not comply with the requirements of the generic

standards for radiated emission. Size 6 complies with the requirements for conducted emission. Use the recommended filter and shielded motor cable. Observe the

layout rules given in Figure 4-29. Ensure the AC supply and ground cables are at least 100mm from the power module and motor cable.

Figure 4-29 Supply and ground cable clearance (size 0 to 3)

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Figure 4-30 Supply and ground cable clearance (size 4 to 6)

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Sensitive signal cable

≥

300mm

(12in)

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

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

+DC BR

Optional external braking resistor

Enclosure

+DC BR

Optional external braking resistor

Enclosure

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Avoid placing sensitive signal circuits in a zone 300mm (12in) all around the power module.

Figure 4-31 Sensitive signal circuit clearance

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Connect the shield of the motor cable to the ground terminal of the motor frame using a link that is as short as possible and not exceeding 50mm

(2in) long. A full 360

termination of the shield to the terminal housing of

the motor is beneficial. It is unimportant for EMC purposes whether the motor cable contains an

internal (safety) ground core, or there is a separate external ground conductor, or grounding is through the shield alone. An internal ground core will carry a high noise current and therefore it must be terminated as close as possible to the shield termination.

Figure 4-33 Grounding the motor cable shield

Ensure good EMC grounding.

Figure 4-32 Grounding the drive, motor cable shield and filter

Unshielded wiring to the optional braking resistor(s) may be used, provided the wiring does not run external to the enclosure. Ensure a minimum spacing of 300mm (12in) from signal wiring and the AC supply wiring to the external EMC filter. Otherwise this wiring must be shielded.

Figure 4-34 Shielding requirements of optional external braking

resistor

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From

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To the

motor

Back-plate

Enclosure

Isolator

Coupling bar

From the Drive

To the motor

(If

required)

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If the control wiring is to leave the enclosure, it must be shielded and the shield(s) clamped to the drive using the grounding bracket as shown in Figure 4-35. Remove the outer insulating cover of the cable to ensure the shield(s) make contact with the bracket, but keep the shield(s) intact until as close as possible to the terminals

Alternatively, wiring may be passed through a ferrite ring, part no. 3225-

1004.

Figure 4-35 Grounding of signal cable shields using the

grounding bracket

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Figure 4-36 Connecting the motor cable to a terminal block in the

enclosure

Using a motor isolator / disconnect-switch

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

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

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

Figure 4-37 Connecting the motor cable to an isolator / disconnect switch

4.11.6 Variations in the EMC wiring

Interruptions to the motor cable

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

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

• Installing a motor isolator / disconnect switch for safety when work is done on the motor

In these cases the following guidelines should be followed.

Terminal block in the enclosure

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

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

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

These circuits meet the requirements of EN61000-6-2 (1kV surge) provided the 0V connection is not grounded.

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

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

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

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

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Signal from plant Signal to drive

0V 0V

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

Signal from plant Signal to drive

0V 0V

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

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

3. Additional over-voltage suppression - for the analog and digital inputs and outputs, a zener diode network or a commercially available surge suppressor may be connected in parallel with the input circuit as shown in Figure 4-38 and Figure 4-39.

If a digital port experiences a severe surge its protective trip may operate (O.Ld1 trip code 26). For continued operation after such an event, the trip can be reset automatically by setting Pr 10.34 to 5.

Figure 4-38 Surge suppression for digital and unipolar inputs and

outputs

Figure 4-39 Surge suppression for analog and bipolar inputs and

outputs

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

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

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

4.12 Serial communications connections

The drive has a serial communications port (serial port) as standard supporting 2 wire EIA485 communications. Please see Table 4-16 for

the connection details for the RJ45 connector.

Figure 4-40 Location of the RJ45 serial comms connector

Table 4-16 Connection details for RJ45 connector

Pin Function

1120Ω Termination resistor 2RX TX 3 Isolated 0V 4 +24V (100mA) 5 Isolated 0V 6 TX enable 7RX\ TX\

RX\ TX\ (if termination resistors are required, link to pin 1)

Shell Isolated 0V

The communications port applies a 2 unit load to the communications network.

Minimum number of connections are 2, 3, 7 and shield. Shielded cable must be used at all times.

4.12.1 Isolation of the serial communications port

The serial PC communications port is double insulated and meets the requirements for SELV in EN50178.

In order to meet the requirements for SELV in IEC60950 (IT equipment) it is necessary for the control computer to be grounded. Alternatively, when a lap-top or similar device is used which has no provision for grounding, an isolation device must be incorporated in the communications lead.

An isolated serial communications lead has been designed to connect the drive to IT equipment (such as lap-top computers), and is available from the supplier of the drive. See below for details:

Table 4-17 Isolated serial comms lead details

Part number Description

4500-0087 CT EIA232 Comms cable 4500-0096 CT USB Comms cable

The “isolated serial communications” lead has reinforced insulation as defined in IEC60950 for altitudes up to 3,000m.

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When using the CT EIA232 Comms cable the available baud rate is limited to 19.2k baud.

4.12.2 Multi-drop network

The drive can be used on a 2 wire EIA485 multi-drop network using the drive's serial communications port when the following guidelines are adhered to.

Connections

The network should be a daisy chain arrangement and not a star, although short stubs to the drive are allowed.

The minimum connections are pins 2 (RX TX), 3 (isolated 0V), 7 (RX\ TX\) and the shield.

Pin 4 (+24V) on each drive can be connected together but there is no power sharing mechanism between drives and therefore the maximum power available is the same as a single drive. (If pin 4 is not linked to the other drives on the network and has an individual load then the maximum power can be taken from pin 4 of each drive.)

Termination resistors

If a drive is on the end of the network chain then pins 1 and 8 should be linked together. This will connect an internal 120Ω termination resistor between RXTX and RX\TX\. (If the end unit is not a drive or the user wishes to use their own termination resistor, a 120Ω termination resistor should be connected between RXTX and RX\TX\ at the end unit.)

If the host is connected to a single drive then termination resistors should not be used unless the baud rate is high.

CT Comms Cable

The CT Comms Cable can be used on a multi-drop network but should only be used occasionally for diagnostic and set up purposes. The network must also be made up entirely of Unidrive SPs.

If the CT Comms Cable is to be used, then pin 6 (TX enable) should be connected on all drives and pin 4 (+24V) should be linked to at least 1 drive to supply power to the converter in the cable.

Only one CT Comms Cable can be used on a network.

4.12.3 Multi-drop network

The drive can be used on a 2 wire EIA485 multi-drop network using the drive's serial communications port when the following guidelines are adhered to.

Connections

The network should be a daisy chain arrangement and not a star, although short stubs to the drive are allowed.

The minimum connections are pins 2 (RX TX), 3 (isolated 0V), 7 (RX\ TX\) and the shield.

Termination resistors

If the host is connected to a single drive then termination resistors should not be used unless the baud rate is high.

CT Comms Cable

The CT Comms Cable can be used on a multi-drop network but should only be used occasionally for diagnostic and set up purposes. The network must also be made up entirely of Unidrive SPs.

If the CT Comms Cable is to be used, then pin 6 (TX enable) should be connected on all drives and pin 4 (+24V) should be linked to at least 1 drive to supply power to the converter in the cable.

Only one CT Comms Cable can be used on a network.

4.13 Control connections

4.13.1 General

Table 4-18 The control connections consist of:

Function Qty Control parameters available

Differential analog input 1

Single ended analog input

Analog output 2 Source, mode, scaling, 9,10 Digital input 3 Destination, invert, logic select 27, 28, 29

Digital input / output 3

Relay 1 Source, invert 41,42 Drive enable (SAFE

TORQUE OFF (SECURE DISABLE))

+10V User output 1 4 +24V User output 1 Source, invert 22

0V common 6

+24V External input 1 2

Destination, offset, offset trim, invert, scaling

Mode, offset, scaling, invert,

destination

Input / output mode select, destination / source, invert, logic select

131

Key:

Destination parameter:

Source parameter:

Mode parameter:

indicates the parameter which is being controlled by the terminal / function

indicates the parameter being output by the terminal

analog - indicates the mode of operation of the terminal, i.e. voltage 0-10V, current 4-20mA etc.

digital - indicates the mode of operation of the terminal, i.e. positive / negative logic (the Drive Enable terminal is fixed in positive logic), open collector.

All analog terminal functions can be programmed in menu 7. All digital terminal functions (including the relay) can be programmed in

menu 8. The setting of Pr 1.14 and Pr 6.04 can cause the function of digital inputs

T25 to T29 to change. For more information, please refer to section

11.21.1 Reference modes on page 249and section 11.21.7 Start / stop logic modes on page 254.

The control circuits are isolated from the power circuits in the drive by basic insulation (single insulation) only. The installer must ensure that the external control circuits are insulated from human contact by at least one layer of insulation (supplementary insulation) rated for use at the AC supply voltage.

If the control circuits are to be connected to other circuits classified as Safety Extra Low Voltage (SELV) (e.g. to a personal computer), an additional isolating barrier must be included in order to maintain the SELV classification.

If any of the digital inputs or outputs (including the drive enable input) are connected in parallel with an inductive load (i.e. contactor or motor brake) then suitable suppression (i.e. diode or varistor) should be used on the coil of the load. If no suppression is used then over voltage spikes can cause damage to the digital inputs and outputs on the drive.

Ensure the logic sense is correct for the control circuit to be used. Incorrect logic sense could cause the motor to be started unexpectedly. Positive logic is the default state for Unidrive SP.

Ter mi nal

number

5,6

7,8

24, 25, 26

1, 3, 11, 21,

23, 30

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21 31

0V common External 24V supply

common

Analog frequency/speed reference 1

Connections for

single-ended

input

signal

Connections for

differential

input signal

0V common

Analog input 2

Analog input 1

common

125

321222324

27282930314142

At zero speed

Reset

Run forward

Run reverse

Analog input 1/

input 2 select

Jog forward select

SAFE TORQUE OFF

(SECURE DISABLE) /

Drive enable**

Status relay

Drive OK

Speed / frequency

0V common

Analog

frequency/speed

reference 2

7119108

Torque (active

current)

Analog input 3

Motor thermistor*

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Any signal cables which are carried inside the motor cable (i.e. motor thermistor, motor brake) will pick up large pulse currents via the cable capacitance. The shield of these signal cables must be connected to ground close to the point of exit of the motor cable, to avoid this noise current spreading through the control system.

The SAFE TORQUE OFF (SECURE DISABLE) / drive enable terminal is a positive logic input only. It is not affected by the setting of Pr 8.29

Positive logic select.

The common 0V from analog signals should, wherever possible, not be connected to the same 0V terminal as the common 0V from digital signals. Terminals 3 and 11 should be used for connecting the 0V common of analog signals and terminals 21, 23 and 30 for digital signals. This is to prevent small voltage drops in the terminal connections causing inaccuracies in the analog signals.

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Figure 4-41 Default terminal functions

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* With software V01.07.00 and later, Analog input 3 is configured as a motor thermistor input. With software V01.06.02 and earlier, Analog input 3 has no default function. Refer to Analog input 3 on page 87.

**The SAFE TORQUE OFF (SECURE DISABLE) / Drive enable terminal

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4.13.2 Control terminal specification

1 0V common

Function

2 +24V external input

Function

Nominal voltage +24.0Vdc Minimum continuous operating

voltage Maximum continuous operating

voltage Minimum start-up voltage 21.6Vdc Recommended power supply 60W 24Vdc nominal Recommended fuse 3A, 50Vdc

3 0V common

Function

4 +10V user output

Function Supply for external analog devices

Voltage tolerance ±1% Nominal output current 10mA Protection Current limit and trip @ 30mA

Precision reference Analog input 1

5 Non-inverting input

6 Inverting input

Default function Frequency/speed reference

Type of input

Full scale voltage range ±9.8V ±1% Absolute maximum

voltage range Working common mode voltage

range Input resistance Resolution 16-bit plus sign (as speed reference) Monotonic Yes (including 0V) Dead band None (including 0V) Jumps None (including 0V) Maximum offset Maximum non linearity 0.3% of input Maximum gain asymmetry 0.5% Input filter bandwidth single pole ~1kHz

Sampling period

Common connection for all external devices

To supply the control circuit without providing a supply to the power stage

+19.2Vdc

+30.0Vdc

Common connection for all external devices

Bipolar differential analog (For single-ended use, connect terminal 6 to terminal 3)

±36V relative to 0V

±13V relative to 0V

Ω ±1%

100k

700

μV

250

μs with destinations as Pr 1.36, Pr 1.37

3.22 in closed loop vector or servo

or Pr mode. 4ms for open loop mode and all other destinations in closed loop vector or servo mode.

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7 Analog input 2

Default function Frequency/speed reference

Type of input

Mode controlled by... Pr

Operating in Voltage mode

Full scale voltage range ±9.8V ±3% Maximum offset ±30mV Absolute maximum voltage range ±36V relative to 0V Input resistance

Operating in current mode

Current ranges

Maximum offset Absolute maximum voltage

(reverse bias) Absolute maximum current +70mA Equivalent input resistance

Common to all modes

Resolution 10 bit + sign

Sample period

Bipolar single-ended analog voltage or unipolar current

7.11

>100k

0 to 20mA ±5%, 20 to 0mA ±5%, 4 to 20mA ±5%, 20 to 4mA ±5%

250

μA

−36V max

Ω at 20mA

≤200

250

μs when configured as voltage input

with destinations as Pr Pr

3.22 or Pr 4.08 in closed loop vector or

servo mode. 4ms for open loop mode, all other destinations in closed loop vector or servo mode, or any destination when configured as a current input.

1.36, Pr 1.37,

8 Analog input 3

Default function

Type of input

Mode controlled by... Pr

Operating in Voltage mode (default)

Voltage range ±9.8V ±3% Maximum offset ±30mV Absolute maximum voltage range ±36V relative to 0V Input resistance

Operating in current mode

Current ranges

Maximum offset Absolute maximum voltage

(reverse bias) Absolute maximum current +70mA Equivalent input resistance

Operating in thermistor input mode

Internal pull-up voltage <5V Trip threshold resistance

Reset resistance

Short-circuit detection resistance

Common to all modes

Resolution 10 bit + sign

Sample period

V01.07.00 and later: Motor thermistor input (PTC) V01.06.02 and earlier: Not configured

Bipolar single-ended analog voltage, unipolar current or motor thermistor input

7.15

>100k

0 to 20mA ±5%, 20 to 0mA ±5%, 4 to 20mA ±5%, 20 to 4mA ±5%

μA

250

−36V max

Ω at 20mA

≤200

Ω ±10%

3.3k

Ω ±10%

1.8k

Ω ±40%

250

μs when configured as voltage input

with destinations as Pr

3.22 or Pr 4.08 in closed loop vector or

Pr servo mode. 4ms for open loop mode, all other destinations in closed loop vector or servo mode, or any destination when configured as a current input.

1.36, Pr 1.37,

T8 analog input 3 has a parallel connection to terminal 15 of the drive encoder connector.

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9 Analog output 1

10 Analog output 2

Terminal 9 default function

Terminal 10 default function Motor active current

Type of output

Mode controlled by... Pr

Operating in Voltage mode (default)

Voltage range ±10V ±3% Maximum offset ±200mV Maximum output current ±35mA Load resistance Protection 35mA max. Short circuit protection

Operating in current mode

Current ranges

Maximum offset Maximum open circuit voltage +15V Maximum load resistance

Common to all modes

Resolution 10-bit (plus sign in voltage mode)

Update period

OL> Motor FREQUENCY output signal CL> SPEED output signal

Bipolar single-ended analog voltage or unipolar single ended current

7.21 and Pr 7.24

Ω min

0 to 20mA ±5% 4 to 20mA ±5%

μA

600

μs when configured as a high speed

250 output with sources as Pr all modes or Pr vector or servo mode. 4ms when configured as any other type of output or with all other sources.

3.02, Pr 5.03 in closed loop

4.02, Pr 4.17 in

24 Digital I/O 1

25 Digital I/O 2

26 Digital I/O 3

Terminal 24 default function AT ZERO SPEED output

Terminal 25 default function DRIVE RESET input

Terminal 26 default function RUN FORWARD input

Type

Input / output mode controlled by... Pr

Operating as an input

Logic mode controlled by... Pr 8.29 Absolute maximum applied voltage

range Impedance Input thresholds 10.0V ±0.8V

Operating as an output

Open collector outputs selected Pr 8.30 Nominal maximum output current 200mA (total including terminal 22) Maximum output current 240mA (total including terminal 22)

Common to all modes

Voltage range 0V to +24V

Sample / Update period

Positive or negative logic digital inputs, positive or negative logic push-pull outputs or open collector outputs

8.31, Pr 8.32 and Pr 8.33

±30V

μs when configured as an input with

250 destinations as Pr when configured as an input with

destination as Pr cases.

6.35 or Pr 6.36. 600μs

6.29. 4ms in all other

11 0V common

Function

Common connection for all external devices

21 0V common

Function

Common connection for all external devices

22 +24V user output (selectable)

Terminal 22 default function +24V user output

Can be switched on or off to act as a fourth

Programmability

Nominal output current 200mA (including all digital I/O) Maximum output current 240mA (including all digital I/O) Protection Current limit and trip

digital output (positive logic only) by setting the source Pr

8.18

8.28 and source invert Pr

23 0V common

Function

Common connection for all external devices

27 Digital Input 4

28 Digital Input 5

29 Digital Input 6

Terminal 27 default function RUN REVERSE input

Terminal 28 default function Analog INPUT 1 / INPUT 2 select

Terminal 29 default function JOG SELECT input

Type Negative or positive logic digital inputs Logic mode controlled by... Pr Voltage range 0V to +24V Absolute maximum applied voltage

range Impedance Input thresholds 10.0V ±0.8V

Sample / Update period

8.29

±30V

250

μs with destinations as Pr 6.35 or

6.36. 600μs with destination as Pr 6.29.

4ms in all other cases.

30 0V common

Function

Common connection for all external devices

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Drive encoder connector

Female 15-way D-type

Encoder

input

NOTE

5 10

Drive encoder connector

Female 15-way D-type

Information

Type Positive logic only digital input Voltage range 0V to +24V Absolute maximum applied voltage ±30V Thresholds 15.5V ±2.5V

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Drive enable (SAFE TORQUE OFF (SECURE DISABLE) function)

Nominal: 8ms Maximum: 20ms

The drive enable terminal (T31) provides a SAFE TORQUE OFF (SECURE DISABLE) function. The SAFE TORQUE OFF (SECURE DISABLE) function meets the requirements of EN954-1 category 3 for the prevention of unexpected starting of the drive. It may be used in a safety-related application in preventing the drive from generating torque in the motor to a high level of integrity.

Refer to section 4.16 SAFE TORQUE OFF (SECURE DISABLE) on page 93 for further information.

Relay contacts

Default function

Contact voltage rating 240Vac, Installation over-voltage category II

Contact maximum current rating

Contact minimum recommended rating

Contact type Normally open Default contact condition Closed when power applied and drive OK Update period 4ms

Drive OK indicator

2A AC 240V 4A DC 30V resistive load

0.5A DC 30V inductive load (L/R = 40ms)

12V 100mA

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Figure 4-43 Location of encoder connector (size 0)

Figure 4-44 Connecting the encoder ground tab to the EMC

bracket

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A fuse or other over-current protection should be installed to the relay circuit.

4.14 Encoder connections

4.14.1 Location of encoder connector (size 0)

Before using the encoder connector on size 0 for the first time, the break-out need removing as shown in Figure 4-42.

Figure 4-42 Access to encoder connections

After removing the break-out, ensure that the ground tab is connected to ground. This will connect 0V of the drive to ground. This is required to enable the drive to meet IP20 when the break-out is removed.

Do not remove the break-out if the encoder connection is not required.

The size of the connecting cable between the encoder ground tab and the EMC bracket should be equal to the input cable.

4.14.2 Location of encoder connector (size 1 to 6)

Figure 4-45 Location of encoder connector

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4.14.3 Encoder types

Table 4-19 Encoder types

Setting of

Pr 3.38

(0)

(1)

(2)

Quadrature incremental encoder with or without marker pulse

Incremental encoder with frequency pulses and direction, with or without marker pulse Incremental encoder with forward pulses and reverse pulses, with or without marker pulse

Description

Quadrature incremental encoder with UVW commutation

Ab.SErVO

signals, with or without marker pulse Encoder with UVW commutation signals only (Pr 3.34 set

(3)

to zero)*

Fd.SErVO

Fr.SErVO

SC.HiPEr

EndAt

SC.EndAt

SSI

(10)

SC.SSI

(11)

Incremental encoder with frequency pulses and direction

(4)

with commutation signals**, with or without marker pulse Incremental encoder with forward pulses and reverse pulses

(5)

with commutation signals**, with or without marker pulse

SinCos encoder without serial communications

(6)

Absolute SinCos encoder with HiperFace serial

(7)

communications protocol (Stegmann) Absolute EndAt serial communications encoder

(8)

(Heidenhain) Absolute SinCos encoder with EnDat serial

(9)

communications protocol (Heidenhain)

Absolute SSI only encoder

Absolute SinCos encoder with SSI

* This feedback device provides very low resolution feedback and should not be used for applications requiring a high level of performance ** The U, V & W commutation signals are required with an incremental type encoder when used with a servo motor. The UVW commutation signals are

used to define the motor position during the first 120

electrical rotation after the drive is powered-up or the encoder is initialized.

4.14.4 Encoder connection details

Table 4-20 Drive encoder connector details

Setting of Pr 3.38

Ter min al

1AFF A F F Cos 2 A\ F\ F\ A\ F\ F\ Cosref Cosref Cosref 3BDR B D R Sin Sin Sin 4 B\ D\ R\ B\ D\ R\ Sinref Sinref Sinref 5Z* 6 Z\* Encoder input - Data\ (input/output)

11 12 W\ Encoder input - Clock\ (output) 13 +V*** 14 0V common 15 th****

(0)

(1)

Simulated encoder

Aout, Fout**

Simulated encoder

Aout\, Fout\**

Simulated encoder

Bout, Dout**

Simulated encoder

Bout\, Dout\**

(2)

Ab.SErVO

(3)

Fd.SErVO

(4)

Fr.SErVO

(5)

(6)

SC.HiPEr

(7)

EndAt

(8)

SC.EndAt

(9)

(10)

Cos Cos

Encoder input - Data (input/output)

Simulated encoder

Aout, Fout**

Simulated encoder

Aout\, Fout\**

Simulated encoder

Bout, Dout**

Simulated encoder

Bout\, Dout\**

W Encoder input - Clock (output)

SSI

SC.SSI

(11)

* Marker pulse is optional ** Simulated encoder output only available in open-loop *** The encoder supply is selectable through parameter configuration to

5Vdc, 8Vdc and 15Vdc

**** Terminal 15 is a parallel connection to T8 analog input 3. If this is to

be used as a thermistor input, ensure that Pr 7.15 is set to ‘th.sc’ (7), ‘th’ (8) or ‘th.diSP’ (9).

SSI encoders typically have maximum baud rate of 500kBaud. When a SSI only encoder is used for speed feedback with a closed loop vector or

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servo motor, a large speed feedback filter (Pr 3.42) is required due to the time taken for the position information to be transferred from the encoder into the drive. The addition of this filter means that SSI only encoders are not suitable for speed feedback in dynamic or high-speed applications.

4.14.5 Specifications

Feedback device connections

Ab, Fd, Fr, Ab.SErVO, Fd.SErVO and Fr.SErVO encoders

1 Channel A, Frequency or Forward inputs

2 Channel A\, Frequency\ or Forward\ inputs

3 Channel B, Direction or Reverse inputs

4 Channel B\, Direction\ or Reverse\ inputs

Type EIA 485 differential receivers

Maximum input frequency

Line loading <2 unit loads

Line termination components

Working common mode range +12V to –7V

Absolute maximum applied voltage relative to 0V

Absolute maximum applied differential voltage

5 Marker pulse channel Z

6 Marker pulse channel Z\

7 Phase channel U

8 Phase channel U\

9 Phase channel V

10 Phase channel V\

11 Phase channel W

12 Phase channel W\

Type EIA 485 differential receivers

Maximum input frequency 512kHz

Line loading

Line termination components

Working common mode range +12V to –7V

Absolute maximum applied voltage relative to 0V

Absolute maximum applied differential voltage

V01.06.01 and later: 500kHz V01.06.00 and earlier: 410kHz

120

Ω (switchable)

±25V

32 unit loads (for terminals 5 and 6) 1 unit load (for terminals 7 to 12)

Ω (switchable for terminals 5 and 6,

120 always in circuit for terminals 7 to 12)

+14V to -9V

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SC, SC.HiPEr, EndAt, SC.EndAt, SSI and SC.SSI encoders

1 Channel Cos*

2 Channel Cosref*

3 Channel Sin*

4 Channel Sinref*

Type Differential voltage

Maximum Signal level

Maximum input frequency See Table 4-21

Maximum applied differential voltage and common mode voltage range

1.25V peak to peak (sin with regard to sinref and cos with regard to cosref)

±4V

For the SinCos encoder to be compatible with Unidrive SP, the output signals from the encoder must be a 1V peak to peak differential voltage (across Sin to Sinref and Cos to Cosref).

The majority of encoders have a DC offset on all signals. Stegmann encoders typically have a 2.5Vdc offset. The Sinref and Cosref are a flat DC level at 2.5Vdc and the Cos and Sin signals have a 1V peak to peak waveform biased at 2.5Vdc.

Encoders are available which have a 1V peak to peak voltage on Sin, Sinref, Cos and Cosref. This results in a 2V peak to peak voltage seen at the drive's encoder terminals. It is not recommended that encoders of this type are used with Unidrive SP, and that the encoder feedback signals should meet the above parameters (1V peak to peak).

Resolution: The sinewave frequency can be up to 500kHz but the resolution is reduced at high frequency. Table 4-21 shows the number of bits of interpolated information at different frequencies and with different voltage levels at the drive encoder port. The total resolution in bits per revolution is the ELPR plus the number of bits of interpolated information. Although it is possible to obtain 11 bits of interpolation information, the nominal design value is 10 bits.

* Not used with EndAt and SSI communications only encoders.

Table 4-21 Feedback resolution based on frequency and voltage level

Volt/Freq 1kHz 5kHz 50kHz 100kHz 200kHz 500kHz

1.2 11 11 10 10 9 8

1.0 11 11 10 9 9 7

0.8 10 10 10 9 8 7

0.6 10 10 9 9 8 7

0.4999876

5 Data**

6 Data\**

11 Clock***

12 Clock\***

Type EIA 485 differential transceivers

Maximum frequency 2MHz

Line loading

Working common mode range +12V to –7V

Absolute maximum applied voltage relative to 0V

Absolute maximum applied differential voltage

32 unit loads (for terminals 5 and 6) 1 unit load (for terminals 11 and 12)

±14V

** Not used with SC encoders. *** Not used with SC and SC.HiPEr encoders.

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55 54 53 52 51 50

To the heatsink fan

Pre-wired internally

24V low voltage DC mode enable

55 54 53 52 51 50

65 64 63 62 61 60

To the heatsink fan

Pre-wired internally

24V low voltage DC mode enable

Not used

24V heatsink fan supply

Upper terminal connector

Lower terminal connector

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Frequency slaving outputs (open loop only)

Ab, Fd, Fr, SC, SC.HiPEr, EndAt, SC.EndAt, SSI and SC.SSI encoders

7 Frequency slaving out channel A

8 Frequency slaving out channel A\

9 Frequency slaving out channel B

10 Frequency slaving out channel B\

Type EIA 485 differential transceivers

Maximum output frequency 512kHz

Absolute maximum applied voltage relative to 0V

Absolute maximum applied differential voltage

Common to all Encoder types

13 Encoder supply voltage

Supply voltage

Maximum output current 300mA for 5V and 8V

The voltage on terminal 13 is controlled by Pr 3.36. The default for this parameter is 5V (0) but this can be set to 8V (1) or 15V (2). Setting the encoder voltage supply too high for the encoder could result in damage to the feedback device.

The termination resistors should be disabled if the outputs from the encoder are higher than 5V.

±14V

5.15V ±

2%, 8V ±5% or 15V ±5%

200mA for 15V

4.15 Low voltage DC mode enable and heatsink fan supply connections (size 4 to 6)

Sizes 4 to 6 require a 24V enable signal to terminal 50 and 51 of the lower terminal connector near the W phase output, to allow the drive to be used from a low voltage DC supply.

For more information regarding low voltage DC operation, see the Low Voltage DC Mode Installation Guide.

Figure 4-46 Location of the size 4 to 6 low voltage DC mode

enable connections

14 0V common

15 Motor thermistor input

This terminal is connected internally to terminal 8 of the signal connector. Connect only one of these terminals to a motor thermistor. Analog input 3 must be in thermistor mode, Pr 7.15 = th.SC (7), th (8) or th.diSP (9).

Figure 4-47 Size 4 and 5 low voltage DC mode enable connections

Figure 4-48 Size 6 low voltage DC mode enable connections

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4.15.1 Low voltage DC mode enable connections (sizes 4 to 6)

50 0V

51 24V low voltage DC mode enable

Function

To allow the drive it be used from low voltage DC supply

Nominal voltage 24.0Vdc

Minimum continuous operating voltage

Maximum continuous operating voltage

19.2Vdc

30.0Vdc

Nominal current consumption 500mA

Recommended fuse

8A 600V AC fast acting class CC type fuse

Heatsink fan connections

No user connections

4.15.2 Heatsink fan supply connections (size 6 only)

No connection

No user connections

64 0V

65 24V heatsink fan supply

Function

To provide the power supply to the heatsink mounted fan

Nominal voltage 24Vdc

Minimum continuous operating voltage

Maximum continuous operating voltage

23.5V

27V

Current consumption 3.3A

Recommended power supply 24V, 100W, 4.5A

Recommended fuse

4A fast blow (I

t less than 20A2s)

4.16 SAFE TORQUE OFF (SECURE

DISABLE)

The SAFE TORQUE OFF (SECURE DISABLE) function provides a means for preventing the drive from generating torque in the motor, with a very high level of integrity. It is suitable for incorporation into a safety system for a machine. It is also suitable for use as a conventional drive enable input.

The SAFE TORQUE OFF (SECURE DISABLE) function makes use of the special property of an inverter drive with an induction motor, which is that torque cannot be generated without the continuous correct active behaviour of the inverter circuit. All credible faults in the inverter power circuit cause a loss of torque generation.

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The SAFE TORQUE OFF (SECURE DISABLE) function is fail-safe, so when the SAFE TORQUE OFF (SECURE DISABLE) input is disconnected the drive will not operate the motor, even if a combination of components within the drive has failed. Most component failures are revealed by the drive failing to operate. SAFE TORQUE OFF (SECURE DISABLE) is also independent of the drive firmware. This meets the requirements of EN954-1 category 3 for the prevention of operation of

the motor.

On drives with date code P04 and later the SAFE TORQUE OFF (SECURE DISABLE) input also meets the requirements of EN 81-1 clause 12.7.3 b) as part of a system for preventing unwanted operation

of the motor in a lift (elevator).

Independent approval has been given by BGIA.

Independent approval of concept has been given by TÜV. Please

consult the separate guide for lift applications for further information. SAFE TORQUE OFF (SECURE DISABLE) can be used to eliminate

electro-mechanical contactors, including special safety contactors, which would otherwise be required for safety applications.

Note on response time of SAFE TORQUE OFF (SECURE DISABLE), and use with safety controllers with self-testing outputs (drives with date code P04 and later).

SAFE TORQUE OFF (SECURE DISABLE) has been designed to have a response time of greater than 1ms, so that it is compatible with safety controllers whose outputs are subject to a dynamic test with a pulse width not exceeding 1ms.

For applications where a fast-acting disable function is required, please see section 11.21.10 Fast Disable on page 257

Note on the use of servo motors, other permanent-magnet motors, reluctance motors and salient-pole induction motors

When the drive is disabled through SAFE TORQUE OFF (SECURE DISABLE), a possible (although highly unlikely) failure mode is for two power devices in the inverter circuit to conduct incorrectly.

This fault cannot produce a steady rotating torque in any AC motor. It produces no torque in a conventional induction motor with a cage rotor. If the rotor has permanent magnets and/or saliency, then a transient alignment torque may occur. The motor may briefly try to rotate by up to 180° electrical, for a permanent magnet motor, or 90° electrical, for a salient pole induction motor or reluctance motor. This possible failure mode must be allowed for in the machine design.

The design of safety-related control systems must only be done by personnel with the required training and experience.

The SAFE TORQUE OFF (SECURE DISABLE) function will only ensure the safety of a machine if it is correctly incorporated into a complete safety system. The system must be subject to a risk assessment to confirm that the residual risk of an unsafe event is at an acceptable level for the application.

To maintain category 3 according to EN954-1 the environment limits given in section 12.1 Drive technical data on page 258 must be adhered to.

SAFE TORQUE OFF (SECURE DISABLE) inhibits the operation of the drive, this includes inhibiting braking. If the drive is required to provide both braking and SAFE TORQUE OFF (SECURE DISABLE) in the same operation (e.g. for emergency stop) then a safety timer relay or similar device must be used to ensure that the drive is disabled a suitable time after braking. The braking function in the drive is provided by an electronic circuit which is not fail-safe. If braking is a safety requirement, it must be supplemented by an independent fail-safe braking mechanism.

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Stop

Star t

Drive

Enable

K1 (or at drive output)

+24V

Drive

Using contactor

Using SECURE DISABLE

T31

3 ~

Stop

Star t

+24V

Stop

Star t

Drive

Enable

+24V

Safety relay

Two-channel interlocks

Reset

K1 K2

3 ~

Stop

Star t

Drive

+24V

Safety relay

Interlocks

Reset

Drive run

(Pr )

10.02

Protected wiring (screened or segregated)

3 ~

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SAFE TORQUE OFF (SECURE DISABLE) does not provide electrical isolation. The supply to the drive must be disconnected by an approved isolation device before gaining access to power connections.

The following diagrams illustrate how the SAFE TORQUE OFF (SECURE DISABLE) input can be used to eliminate contactors and safety contactors from control systems. Please note these are provided for illustration only, every specific arrangement must be verified for suitability in the proposed application.

In the first example, illustrated in Figure 4-49, the SAFE TORQUE OFF (SECURE DISABLE) function is used to replace a simple power contactor in applications where the risk of injury from unexpected starting is small, but it is not acceptable to rely on the complex hardware and firmware/software used by the stop/start function within the drive.

Figure 4-49 Start / stop control EN954-1 category B - replacement

of contactor

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Figure 4-50 Category 3 interlock using electromechanical safety

contactors

The safety function of the example circuit is to ensure that the motor does not operate when the interlocks are not signalling a safe state. The safety relay is used to check the two interlock channels and detect faults in those channels. The stop/start buttons are shown for completeness as part of a typical arrangement, they do not carry out a safety function and are not necessary for the safe operation of the circuit.

Figure 4-51 Category 3 interlock using SAFE TORQUE OFF

(SECURE DISABLE) with protected wiring

In the conventional system, a contactor failure in the unsafe direction is detected the next time the safety relay is reset. Since the drive is not part of the safety system it has to be assumed that AC power is always

In the second example, illustrated in Figure 4-50 and Figure 4-51, a conventional high-integrity system which uses two safety contactors with auxiliary contacts with connected movement is replaced by a single SAFE TORQUE OFF (SECURE DISABLE) system. This arrangement meets EN954-1 category 3.

available to drive the motor, so two contactors in series are required in order to prevent the first failure from causing an unsafe event (i.e. the motor driven).

With SAFE TORQUE OFF (SECURE DISABLE) there are no single faults in the drive which can permit the motor to be driven. Therefore it is not necessary to have a second channel to interrupt the power connection, nor a fault detection circuit.

It is important to note that a single short-circuit from the Enable input (SAFE TORQUE OFF (SECURE DISABLE)) to a DC supply of approximately +24V would cause the drive to be enabled. For this reason, Figure 4-51 shows the wire from the Enable input to the safety relay as "protected wiring" so that the possibility of a short circuit from this wire to the DC supply can be excluded, as specified in ISO 13849-2. The wiring can be protected by placing it in a segregated cable duct or other enclosure, or by providing it with a grounded shield. The shield is

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provided to avoid a hazard from an electrical fault. It may be grounded by any convenient method, no special EMC precautions are required.

If the use of protected wiring is not acceptable, so that the possibility of this short circuit must be allowed for, then a relay must be used to monitor the state of the Enable input, together with a single safety contactor to prevent operation of the motor after a fault. This is illustrated in Figure 4-52.

Safety

NOTE

Stop

Star t

Drive

+24V

Safety relay

Two-channel interlocks

Reset

K1 K2

3 ~

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The auxiliary relay K2 must be located in the same enclosure and close to the drive, with its coil connected as closely as possible to the drive enable / SAFE TORQUE OFF (SECURE DISABLE) input.

Figure 4-52 Use of contactor and relay to avoid the need for

protected wiring

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Upper display

Lower display

Mode (black) button

Joypad

Fwd / Rev (blue) button Stop/reset (red) button Start (green) button

Control buttons

Mode (black) button

Joypad

Fwd / Rev (blue) button Stop/reset (red) button Start (green) button

Control buttons

Help button

Mode (black) button

Stop/reset (red) button

Upper display

Lower display

Start (green) button

Fwd / Rev (blue) button

Navigation keys

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5 Getting Started

This chapter introduces the user interfaces, menu structure and security level of the drive.

5.1 Understanding the display

There are two types of keypad available for the Unidrive SP, LED and LCD. The SM-Keypad and SP0 Keypad have an LED display, and the SMKeypad Plus has an LCD display. The SP0 Keypad can only be fitted to size 0, and the SM-Keypad can only be fitted to size 1 to 6. The SM-Keypad Plus can either be fitted to the size 1 to 6, or it can be remotely mounted on an enclosure door.

5.1.1 SM-Keypad/SP0 Keypad (LED)

The display consists of two horizontal rows of 7 segment LED displays. The upper display shows the drive status or the current menu and

parameter number being viewed. The lower display shows the parameter value or the specific trip type.

Figure 5-1 SM-Keypad Figure 5-2 SM-Keypad Plus

5.1.2 SM-Keypad Plus (LCD)

The display consists of three lines of text. The top line shows the drive status or the current menu and parameter

number being viewed on the left, and the parameter value or the specific trip type on the right.

The lower two lines show the parameter name or the help text.

Figure 5-3 SP0 Keypad

The red stop button is also used to reset the drive.

The SM-Keypad/SP0 Keypad and the SM-Keypad Plus can indicate when a SMARTCARD access is taking place or when the second motor map is active (menu 21). These are indicated on the displays as follows.

SM-Keypad / SP0 Keypad SM-Keypad Plus

SMARTCARD access taking place

Second motor map active

The decimal point after the fourth digit in the upper display will flash.

The decimal point after the third digit in the upper display will flash.

The symbol ‘CC’ will appear in the lower left hand corner of the display

The symbol ‘Mot2’ will appear in the lower left hand corner of the display

5.2 Keypad operation

5.2.1 Control buttons

The keypad consists of:

1. Joypad - used to navigate the parameter structure and change parameter values.

2. Mode button - used to change between the display modes – parameter view, parameter edit, status.

3. Three control buttons - used to control the drive if keypad mode is selected.

4. Help button (SM-Keypad Plus only) - displays text briefly describing the selected parameter. The Help button toggles between other display modes and parameter help mode. The up and down functions on the joypad scroll the help text to

allow the whole string to be viewed. The right and left functions on the joypad have no function when help text is being viewed. The display examples in this section show the SM-Keypad 7 segment LED display. The examples are the same for the SM-Keypad Plus except that

the information displayed on the lower row on the SM-Keypad is displayed on the right hand side of the top row on the SM-Keypad Plus.

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Use

* keys

to select parameter for editing

To enter Edit Mode, press key

Status Mode

(Display not flashing)

Parameter Mode

(Upper display flashing)

Edit Mode

(Character to be edited in lower line of display flashing) Change parameter values

using keys.

When returning to Parameter Mode use the

keys to select another parameter to change, if required

To exit Edit Mode, press key

To enter Parameter Mode, press key or

Temporary Parameter Mode

(Upper display flashing)

Timeout**

To return to Status Mode, press

key

parameter

R/W parameter

Pr value

5.05

Menu 5. Parameter 5

Trip type (UU = undervolts)

Drive status = tripped

Trip StatusAlarm Status

Parameter

View Mode

Healthy Status

Status Mode

WARNING

NOTE

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Figure 5-4 Display modes

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* can only be used to move between menus if L2 access has been enabled (Pr 0.49). Refer to section 5.9 on page 101. **Timeout defined by Pr 11.4 1 (default value = 240s).

Figure 5-5 Mode examples

When changing the values of parameters, make a note of the new values in case they need to be entered again.

For new parameter-values to apply after the AC supply to the drive is interrupted, new values must be saved. Refer to section 5.7 Saving parameters on page 100.

Do not change parameter values without careful consideration; incorrect values may cause damage or a safety hazard.

5.3 Menu structure

The drive parameter structure consists of menus and parameters. The drive initially powers up so that only menu 0 can be viewed. The up

and down arrow buttons are used to navigate between parameters and once level 2 access (L2) has been enabled (see Pr 0.49) the left and right buttons are used to navigate between menus. For further information, refer to section 5.9 Parameter access level and security on page 101.

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Menu 0

....XX.00....

0.50

0.49

0.48

0.47

0.46

0.01

0.02

0.03

0.04

0.05

Moves between parameters

Moves between Menus

Menu 0

0.04

0.05

0.06

Menu 2

2.21

Menu 1

1.14

Menu 4

4.07

5 0

150

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Figure 5-6 Parameter navigation

* can only be used to move between menus if L2 access has been enabled (Pr 0.49). Refer to section 5.9 Parameter access level and security on page 101.

The menus and parameters roll over in both directions. i.e. if the last parameter is displayed, a further press will cause the

display to rollover and show the first parameter. When changing between menus the drive remembers which parameter

was last viewed in a particular menu and thus displays that parameter.

Figure 5-7 Menu structure

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Figure 5-8 Menu 0 copying

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5.4 Menu 0

Menu 0 is used to bring together various commonly used parameters for basic easy set up of the drive.

Appropriate parameters are copied from the advanced menus into menu 0 and thus exist in both locations.

For further information, refer to Chapter 6 Basic parameters on page 104.

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5.5 Advanced menus

The advanced menus consist of groups or parameters appropriate to a specific function or feature of the drive. Menus 0 to 22 can be viewed on all keypads. Menus 40 and 41 are specific to the SM-Keypad Plus (LCD). Menus 70 to 91 can be viewed with an SM-Keypad Plus (LCD) only when an SM-Applications is installed.

Table 5-1 Advanced menu descriptions

Menu Description LED LCD

Commonly used basic set up parameters for quick

/ easy programming 1 Frequency / speed reference 99 2Ramps 99

Slave frequency, speed feedback and speed 3

control 4 Torque and current control 99 5 Motor control 99 6 Sequencer and clock 99 7 Analog I/O 99 8 Digital I/O 99

Programmable logic, motorized pot and binary 9

sum

10 Status and trips 99 11 General drive set-up 99 12 Threshold detectors and variable selectors 99 13 Position control 99 14 User PID controller 99

15,

Solutions Module set-up 99

16, 17

18 Application menu 1 99 19 Application menu 2 99 20 Application menu 3 99 21 Second motor parameters 99 22 Additional Menu 0 set-up 99 40 Keypad configuration menu X 9 41 User filter menu X 9 70 PLC registers X 9 71 PLC registers X 9 72 PLC registers X 9 73 PLC registers X 9 74 PLC registers X 9 75 PLC registers X 9 85 Timer function parameters X 9 86 Digital I/O parameters X 9 88 Status parameters X 9 90 General parameters X 9 91 Fast access parameters X 9

5.5.1 SM-Keypad Plus set-up menus

Table 5-2 Menu 40 parameter descriptions

Parameter

40.00 Parameter 0 0 to 32767 English (0), Custom (1),

40.01 Language selection

French (2), German (3),

Spanish (4), Italian (5)

40.02 Software version

40.03 Save to flash

Idle (0), Save (1),

Restore (2), Default (3)

40.04 LCD contrast

Drive and attribute database

40.05

upload was bypassed

40.06 Browsing favourites control

Updated (0), Bypass (1)

Normal (0), Filter (1)

40.07 Keypad security code

Communication channel

40.08

selection

Disable (0), Slot1 (1), Slot2

(2), Slot3 (3), Slave (4),

40.09 Hardware key code

40.10 Drive node ID (Address)

40.11 Flash ROM memory size

4Mbit (0), 8Mbit (1)

40.19 String database version number

40.20 Screen saver strings and enable

None (0), Default (1),

40.21 Screen saver interval

40.22 Turbo browse time interval

Table 5-3 Menu 41 parameter descriptions

Parameter

41.00 Parameter 0 0 to 32767

41.01

Browsing filter source F01 to F50 Pr 0.00 to Pr 391.51

41.50

41.51 Browsing favourites control Normal (0), Filter (1)

Ú)

Range(

999999

0 to 31

0 to 999

Direct (5)

0 to 999 0 to 255

0 to 999999

User (2) 0 to 600

0 to 200ms

Ú)

Range(

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5.5.2 Display messages

The following tables indicate the various possible mnemonics which can be displayed by the drive and their meaning.

Trip types are not listed here but can be found in Chapter 6 Basic parameters on page 104 if required.

Table 5-4 Alarm indications

Lower

display

br.rS Braking resistor overload

Braking resistor I

t accumulator (Pr 10.39) in the drive has reached

75.0% of the value at which the drive will trip and the braking IGBT is active.

Hot

Heatsink or control board or inverter IGBT over temperature alarms are active

• The drive heatsink temperature has reached a threshold and the drive will trip ‘Oh2’ if the temperature continues to rise (see the ‘Oh2’ trip).

• The ambient temperature around the control PCB is approaching the over temperature threshold (see the ‘O.CtL’ trip).

OVLd Motor overload

The motor I

t accumulator in the drive has reached 75% of the value at

which the drive will be tripped and the load on the drive is >100%

Auto tune Autotune in progress

The autotune procedure has been initialised. 'Auto' and 'tunE' will flash alternatively on the display.

Lt Limit switch is active

Indicates that a limit switch is active and that it is causing the motor to be stopped (i.e. forward limit switch with forward reference etc.)

PLC Onboard PLC program is running

An Onboard PLC program is installed and running. The lower display will flash 'PLC' once every 10s.

Table 5-5 Solutions Module and SMARTCARD status indications

on power-up

Lower

display

boot

A parameter set is being transferred from the SMARTCARD to the drive during power-up. For further information, please refer to section

9.2.4 Booting up from the SMARTCARD on every power up (Pr 11.42 =

boot (4)) on page 145.

cArd

The drive is writing a parameter set to the SMARTCARD during powerup. For further information, please refer to section 9.2.3 Auto saving parameter changes (Pr 11.42 = Auto (3)) on page 145.

The drive is writing information to a Solutions Module.

Description

5.6 Changing the operating mode

Changing the operating mode returns all parameters to their default value, including the motor parameters. (Pr 0.49 Security status and Pr 0.34 User security code are not affected by this procedure.)

Procedure

Use the following procedure only if a different operating mode is required:

1. Ensure the drive is not enabled, i.e. terminal 31 is open or Pr 6.15 is Off (0)

2. Enter either of the following values in Pr xx.00, as appropriate: 1253 (EUR, 50Hz AC supply frequency) 1254 (USA, 60Hz AC supply frequency)

3. Change the setting of Pr 0.48 as follows:

Pr 0.48 setting Operating mode

1 Open-loop

2 Closed-loop vector

3 Closed-loop Servo

Regen (See the Unidrive SP Regen

Installation Guide for more information

about operating in this mode)

The figures in the second column apply when serial communications are used.

4. Either:

• Press the red reset button

• Toggle the reset digital input

• Carry out a drive reset through serial communications by setting Pr 10.38 to 100 (ensure that Pr. xx.00 returns to 0).

Entering 1253 or 1254 in Pr xx.00 will only load defaults if the setting of Pr 0.48 has been changed.

5.7 Saving parameters

When changing a parameter in Menu 0, the new value is saved when pressing the Mode button to return to parameter view mode from

parameter edit mode. If parameters have been changed in the advanced menus, then the

change will not be saved automatically. A save function must be carried out.

Procedure

Enter 1000* in Pr. xx.00 Either:

• Press the red reset button

• Toggle the reset digital input

• Carry out a drive reset through serial communications by setting Pr 10.38 to 100 (ensure that Pr. xx.00 returns to 0).

*If the drive is in the under voltage trip state or is being supplied from a low voltage DC supply, a value of 1001 must be entered into Pr xx.00 to perform a save function.

5.8 Restoring parameter defaults

Restoring parameter defaults by this method saves the default values in the drive’s memory. (Pr 0.49 and Pr 0.34 are not affected by this procedure.)

Procedure

1. Ensure the drive is not enabled, i.e. terminal 31 is open or Pr 6.15 is Off (0)

2. Enter 1233 (EUR 50Hz settings) or 1244 (USA 60Hz settings) in Pr xx.00.

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Control Techniques Unidrive SP Users Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Declaration of Conformity (size 0)

Declaration of Conformity (Size 1 to 3)

Declaration of Conformity (Size 4 and 5)

Declaration of Conformity (Size 6)

1 Safety Information

1.1 Warnings, Cautions and Notes

1.2 Electrical safety - general warning

1.4 Environmental limits

1.5 Compliance with regulations

1.6 Motor

1.7 Adjusting parameters

2 Product Information

2.1 Ratings

2.1.1 Typical short term overload limits

2.2 Model number

2.3 Operating modes

2.3.1 Open loop mode

2.3.2 RFC mode

2.3.3 Closed loop vector mode

2.3.4 Servo

2.3.5 Regen

2.4 Compatible encoders

2.5 Drive features

2.6 Nameplate description

2.7 Options

2.8 Items supplied with the drive

3 Mechanical Installation

3.1 Safety information

3.2 Planning the installation

3.2.1 Access

3.2.2 Environmental protection

3.2.3 Cooling

3.2.4 Electrical safety

3.2.5 Fire protection

3.2.6 Electromagnetic compatibility

3.2.7 Hazardous areas

3.3 Terminal cover removal

3.3.1 Removing the terminal covers

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

3.4 Solutions Module / keypad installation / removal

3.5 Mounting methods

3.5.1 Surface mounting

3.5.2 Through-panel mounting

3.5.3 Installation of the mounting bracket on size 4, 5 and 6

3.6 Enclosure for standard drives

3.6.1 Enclosure layout

3.6.2 Enclosure sizing

3.7 Enclosure design and drive ambient temperature

3.8 Heatsink fan operation

3.9 Enclosing standard drive for high environmental protection

3.10 External EMC filter

3.11 Internal/heatsink mounted braking resistor

3.11.1 Size 0 internal braking resistor

3.11.2 Size 1 and 2 heatsink mounted braking resistor

3.11.3 Size 1 braking resistor fitting instructions

3.11.4 Size 2 braking resistor fitting instructions

3.11.5 Braking resistor overload protection parameter settings

3.12 Electrical terminals

3.12.1 Location of the power and ground terminals

3.12.2 Terminal sizes and torque settings

3.13 Routine maintenance

4 Electrical Installation

4.1 Power connections

4.1.1 AC and DC connections

4.1.2 Ground connections

4.2 AC supply requirements

4.2.1 Supply types

4.2.2 Supplies requiring line reactors

4.2.3 Input inductor calculation

4.3 Supplying the drive with DC / DC bus paralleling

4.4 Heatsink fan supply

4.5 Control 24Vdc supply

4.6 Low voltage DC power supply

4.7 Ratings

4.7.1 Main AC supply contactor

4.8 Output circuit and motor protection