Emerson SP3201, SP2203, SP2202, SP3202, SP4202 Installation Manual

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Page 1

Installation Guide

Regen

200V, 400V, 575V, 690V

Part Number: 0471-0029-02 Issue: 2

www.controltechniques.com

Page 2

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.

Issue Number: 2

Software: 01.07.01 onwards

Page 3

How to use this guide

System design

Programming

and

commissioning

This user guide provides complete information for installing and operating a Unidrive SP from start to finish.

The information is in logical order, taking the reader from receiving the drive through to fine tuning the performance.

NOTE

There are specific safety warnings throughout this guide, located in the relevant sections. In addition, Chapter 1 Safety Information 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 guide should be read in-line with the relevant User Guide also, which contains additional information which may be required whilst designing and commissioning a regen system.

This map of the user guide helps to find the right sections for the task you wish to complete:

1 Safety information

2 Introduction

3 Product information

4 System design

5 Mechanical Installation

6 Electrical installation

7 Getting started

8 Optimisation

9 Parameters

Familiarisation System design

commissioning

Programming

and

Troubleshooting

10 Technical data

11 Component sizing calculations

12 Diagnostics

Page 4

Contents

1 Safety Information .................................6

1.1 Warnings, Cautions and Notes .............................6

1.2 Electrical safety - general warning ........................6

1.3 System design and safety of personnel ................6

1.4 Environmental limits ..............................................6

1.5 Compliance with regulations .................................6

1.6 Special note on SECURE DISABLE/ENABLE

function in regen operation ....................................6

1.7 Adjusting parameters ............................................6

2 Introduction ............................................7

2.1 Regen operation ....................................................7

2.2 Advantages of Unidrive SP operating in regen

mode .....................................................................7

2.3 Principles of operation ...........................................7

2.4 Power flow .............................................................8

2.5 Synchronisation .....................................................8

2.6 Current trimming ...................................................8

2.7 Regen system configurations ................................8

2.8 Regen drive system types .....................................9

3 Product Information ............................12

3.1 Model number .....................................................12

3.2 Nameplate description ........................................12

3.3 Ratings ................................................................13

3.4 Drive features ......................................................17

3.5 Unidrive SPMC half controlled thyristor rectifier ..19

3.6 Unidrive SPMC/U technical data .........................20

3.7 Output Sharing Chokes (for motoring drives

only) ....................................................................22

3.8 Options ................................................................23

3.9 Items supplied with the drive ...............................25

3.10 Regen components .............................................25

4 System design .....................................30

4.1 Introduction .........................................................30

4.2 Power connections ..............................................30

4.3 Non standard applications ...................................40

4.4 Cable length restrictions ......................................40

4.5 Cable types and lengths ......................................42

4.6 Exceeding maximum cable length ......................42

5 Mechanical Installation .......................45

5.1 Safety information ...............................................45

5.2 Planning the installation ......................................45

5.3 Regen component dimensions ............................46

5.4 External EMC filter .............................................55

5.5 Enclosure ............................................................62

5.6 Cubicle design and drive ambient temperature ...64

6 Electrical Installation .......................... 65

6.1 Power connections ............................................. 66

6.2 AC supplies ........................................................ 74

6.3 Cable and fuse ratings ....................................... 75

6.4 EMC (Electromagnetic compatibility) ................. 77

6.5 External EMC filter ............................................. 78

6.6 Control connections ........................................... 83

7 Getting started .................................... 86

7.1 Regen parameter settings .................................. 86

7.2 Regen drive sequencing .................................... 86

7.3 Regen drive commissioning ............................... 87

7.4 Motoring drive commissioning ............................ 88

8 Optimisation ........................................ 89

8.1 Power feed-forward compensation (Pr 3.10) ..... 89

8.2 Current loop gains .............................................. 89

8.3 Voltage controller gain (Pr 3.06) ........................ 90

8.4 Power factor correction (Pr 4.08) ....................... 91

8.5 Current trimming ................................................ 91

9 Parameters .......................................... 92

9.1 Parameter ranges and variable maximums: ...... 92

9.2 Menu 0: Basic parameters ................................. 93

9.3 Menu 3: Regen sequencer ................................. 94

9.4 Menu 4: Current control ................................... 100

9.5 Menu 5: Regen control ..................................... 107

9.6 Menu 6: Clock .................................................. 111

9.7 Menu 7: Analogue I/O ...................................... 119

9.8 Menu 8: Digital I/O ........................................... 132

9.9 Menu 9: Programmable logic, motorised pot

and binary sum ................................................. 138

9.10 Menu 10: Status and trips ................................ 146

9.11 Menu 11: General drive set-up ......................... 154

9.12 Menu 12: Threshold detectors and variable

selectors ........................................................... 165

9.13 Menu 14: User PID controller ........................... 172

9.14 Menus 15, 16 and 17: Solutions Module set-up 178

9.15 Menu 18: Application menu 1 ........................... 179

9.16 Menu 19: Application menu 2 ........................... 180

9.17 Menu 20: Application menu 3 ........................... 181

9.18 Menu 22: Additional menu 0 set-up ................. 182

10 Technical data ................................... 183

10.1 Drive ................................................................. 183

10.2 Supply requirements ........................................ 191

10.3 Protection ......................................................... 192

10.4 Component data ............................................... 196

10.5 Optional external EMC filters ........................... 199

11 Component sizing ............................. 203

11.1 Sizing of MCB for switching frequency filter ..... 203

11.2 Resistor sizing for multiple drive systems ........ 204

11.3 Thermal / magnetic overload protection for soft

start circuit ........................................................ 204

4 Unidrive SP Regen Installation Guide

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12 Diagnostics ........................................206

12.1 Trip indications ..................................................206

12.2 Alarm indications ...............................................215

12.3 Status indications ..............................................215

12.4 Displaying the trip history ..................................215

Unid rive SP Regen Insta llation G uide 5 Issue Number: 2 www.controltechniques.com

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Safety

Information

Introduction

Product

information

System

design

Mechanical

installation

Electrical

installation

1 Safety Information

1.1 Warnings, Cautions and Notes

A Warning contains information which is essential for avoiding a safety hazard.

WARNING

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

CAUTION

NOTE

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

1.2 Electrical safety - general warning

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

Specific warnings are given at the relevant places in this 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 and maintenance must be carried out by personnel who have the necessary training and experience. They must read this safety information and this guide carefully.

The STOP and SECURE DISABLE 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.

None of the drive functions must be used to ensure safety of personnel, i.e. they must not be used for safety-related functions.

Careful consideration must be given to the functions of the drive which might result in a hazard, either through their intended 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.

personnel

Getting started

of fuses or other protection, and protective earth (ground) connections.

This guide contains instruction for achieving compliance with specific EMC standards.

Within the European Union, all machinery in which this product is used must comply with the following directives:

Optimisation Parameters

98/37/EC: Safety of machinery. 89/336/EEC: Electromagnetic Compatibility.

Technical

data

Component

sizing

Diagnostics

1.6 Special note on SECURE DISABLE/

ENABLE function in regen operation

In regen operation the enable input of the Regen drive stage has no safety functions. It only enables the active rectifier operation. It does not disable any operation of the motoring drive(s) and it does not prevent the regen stage from producing DC power.

The enable input of the motoring drive stage can be used for safety functions if required. Consult the Unidrive SP User Guide for information on SECURE DISABLE.

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.

1.4 Environmental limits

Instructions in this guide regarding transport, storage, installation and use of the drive must be complied with, including the specified environmental limits. Drives must not be subjected to excessive physical force.

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

6 Unidrive SP Regen Installation Guide

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Page 7

Safety

Information

Introduction

Product

information

System

design

Mechanical

installation

Electrical

installation

2 Introduction

The following installation guide should be read in conjunction with the Unidrive SP User Guide.

Any Unidrive SP drive can be configured as an AC Regenerative Unit (hereafter referred to as a Regen drive).

This guide covers the following:

• Principles and advantages of operation in regen mode

• Safety information

• EMC information

• Detailed information on additional components required

• System design

• Special considerations

• Installation

• Commissioning and optimisation of the completed system

At least two Unidrive SP drives are required to form a complete regenerative system - one connected to the supply and the second one connected to the motor. A Unidrive SP in regen mode converts the AC mains supply to a controlled DC voltage, which is then fed into another drive(s) to control a motor(s).

NOTE

The motoring drive(s) in a regen configuration could be another drive other than a Unidrive SP, e.g. Unidrive classic or Commander SK etc.

NOTE

The following regen components are also required in addition to the Unidrive SP drives.

1. Regen inductor

2. Switching frequency filter inductor

3. Switching frequency filter capacitor

4. Softstart resistor

5. Varistors

6. MCBs

7. Overload relays

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

• Transient operation is possible between 40 and 72Hz down to the above supply voltage levels for approximately 1 second.

• The Regen and motoring drives are identical (when using Unidrive SP).

• Power feed-forward term available, using analogue I/O set-up

• A fast transient response is possible using the power feed forward term.

2.3 Principles of operation

The input stage of a non-regenerative AC drive is usually an uncontrolled diode rectifier, therefore power cannot be fed back onto the AC mains supply. By replacing the diode input rectifier with a voltage source PWM input converter (Unidrive SP), AC supply power flow can be bi-directional with full control over the input current waveform and power factor. Currents can now be controlled to give near unity power factor and a low level of line frequency harmonics.

In the case of a Unidrive SP operating in regenerative mode, the IGBT stage is used as a sinusoidal rectifier converting the AC supply to a controlled DC voltage.

Furthermore, by maintaining the DC bus voltage above the peak supply voltage the load motor can be operated at a higher speed without field weakening. Alternatively, the higher output voltage available can be exploited by using a motor with a rated voltage higher than the AC mains supply, thus reducing the current for a given power.

Regen inductors must be used to ensure a minimum source impedance, these being selected and specified later in the guide.

The difference between the PWM line voltage and the supply voltage occurs across the regen inductors at the Regen drive. This voltage has a high frequency component, which is blocked by the regen inductor, and a sinusoidal component at line frequency. As a result currents flowing in these inductors are sinusoidal with a small high frequency ripple component.

2.1 Regen operation

For use as a regenerative front end for four quadrant operation.

Regen operation allows bi-directional power flow to and from the AC supply. This provides far greater efficiency levels in applications which would otherwise dissipate large amounts of energy in the form of heat in a braking resistor.

The harmonic content of the input current is negligible due to the sinusoidal nature of the waveform when compared to a conventional bridge rectifier or thyristor front end.

2.2 Advantages of Unidrive SP operating in regen mode

The main advantages of an AC Regen system are:

• Energy saving

• The input current waveform is sinusoidal

• The input current has a near unity power factor

• Power factor correction can be implemented using Pr 4.08

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

mains supply.

• The Regen drive will synchronise to any frequency between 30 and

100Hz, provided the supply voltage is within the supply requirements (operating frequency range of 48Hz to 65Hz)

• Under conditions of AC mains instability, a Unidrive SP Regen

system can continue to operate down to approximately 75Vac (200V product) 150Vac (400V product) 225Vac (575V and 690V product) supply voltage without any effect on the DC bus voltage and hence on the operation of the motoring drives (increased current will be taken from the AC supply during this condition to compensate up to the current limit of the Regen drive)

Unid rive SP Regen Insta llation G uide 7 Issue Number: 2 www.controltechniques.com

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Safety

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Introduction

Product

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System

design

Mechanical

installation

Electrical

installation

2.4 Power flow

The following phasor diagram illustrates the relationship between the supply voltage and the Regen drive voltage. The angle between the two voltage vectors is approximately 5° at full load, this results in a near unity power factor of 0.996.

Figure 2-1

U V W

+DC

-DC

VAC

JLIrω

Supply

jLIrω

Power flow from supply

Supply voltage

V Voltage at line terminals of Regen drive

j LI Voltage across Regen inductor

I Current at line terminals of Regen drive

jLIrω

Power flow back to supply

The direction of the power flow can be changed relative to the supply voltage, by making small changes to the Regen drives output voltage and phase.

2.5 Synchronisation

The synchronisation of the Regen drive to the supply does not require additional hardware. The space vector modulator within the Regen drive represents the angle and magnitude of the AC supply at all times. This however is not the case when the AC supply is first connected or when the Regen drive is disabled.

Unless some form of synchronisation is carried out the current controllers will start with values of zero resulting in zero volts being applied to the inverter output terminals. The phase locked loop (PLL) would also start with zero and so would not lock onto the supply.

To overcome these problems the following information must be obtained before the Regen drive attempts to start:

1. The mains supply voltage vector magnitude

2. The angle of the supply voltage vector

3. The frequency of the supply

These values are obtained by carrying out a synchronisation on enable

• The first stage of the pre-start tests is to measure the initial DC Bus voltage, which is assumed to be equal to the peak line-to-line voltage of the supply.

• The second stage of the pre-start test is to apply two short pulses of zero volts at the converter input. These pulses must be short enough so that the peak current is less than the over current trip level of the converter. The time between the pulses must also be long enough so that the current built up in the input inductors during the first pulse has decayed to a low level before the second pulse is applied. These are used to calculate the instantaneous angle of the supply voltage vector during the first test pulse. The second test pulse is

Getting started

Optimisation Parameters

Te ch n ic al

data

Component

sizing

Diagnostics

then applied at time Td later to allow the supply frequency to be calculated. At this stage the supply inductance is also calculated

• Once the synchronization is complete the phase locked loop (PLL) is set-up. At this point the whole control system could be started and should operate without any large transients.

• To improve the robustness of the start-up phase a further short test pulse voltage vector, with the same magnitude and phase as the estimated supply voltage vector is applied. This is to detect measurement errors that could have occurred because of supply distortion present during the pre-start tests.

2.6 Current trimming

A current feedback trimming routine runs before the drive is enabled to minimise offsets in the current feedback. This feature can be user configured, for more details refer to section 8.5 Current trimming on page 91.

2.7 Regen system configurations

The Regen drive has been designed to provide a regulated DC supply to other motoring drives. The Regen drive gives bi-directional power flow with sinusoidal currents and a near unity power factor.

Following are the possible configurations for Unidrive SP Regen:

• Single Regen, single or multiple motoring (Figure 4-1 on page 32)

• Single Regen, multiple motoring using a Unidrive SPMC (Figure 42 on page 34)

• Single Regen, multiple motoring using an external charging resistor (Figure 4-3 on page 36)

• Multiple Regen, multiple motoring using a Unidrive SPMC (Figure 44 on page 38)

Refer to Table 3-2 on page 14, for the Regen drive ratings.

The sizing of a regen system must take into account the following factors:

• Line voltage

• Motor rated current, rated voltage and power factor

• Maximum load power and overload conditions

In general, when designing a regen system, equal Regen and motoring drive rated currents will work correctly. However, care must be taken to ensure that under worst case supply conditions the Regen drive is able to supply or absorb all the required power. In multi-drive configurations, the Regen drive must be of a sufficient size to supply the net peak power demanded by the combined load of all the motoring drives and total system losses.

If the Regen drive is unable to supply the full power required by the motoring drive, the DC bus voltage will drop and in severe cases may lose synchronisation with the mains and trip. If the Regen drive is unable to regenerate the full power from the motoring drive on the DC bus, then the Regen and motoring drive(s) will trip on over-voltage.

8 Unidrive SP Regen Installation Guide

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Safety

Information

Introduction

Product

information

System

design

Mechanical

installation

Electrical

installation

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

2.8 Regen drive system types

2.8.1 Single Regen, single motoring system

Figure 2-2 shows a typical layout for a standard regen system consisting of a single Regen drive and single motoring drive. In this configuration the Regen drive is supplying the motoring drive and passing the regenerative energy back to the mains supply.

NOTE

The power up connections to L1, L2, L3 of the Regen drive are only made during power-up. Once both drives are powered up, this is switched out and the main regen supply switched in. The auxiliary on the charging circuit to the Regen drive’s L1, L2, L3 connections for power up must be closed (charging supply removed) before the Regen drive can be enabled.

Figure 2-2 Single Regen, single motoring system

Regen

inductor

Additional

circuitry

Regen drive

AC supply

connection

+DC

-DC

L2 L3

Common

DC bus

connections

Motoring drive

+DC

-DC

Motor

Connection

Power up only

NOTE

For the above single Regen, single motoring configuration; the Regen drive must be of the same frame size or larger.

2.8.2 Single Regen, multiple motoring system

Figure 2-4 shows the layout for a regen system consisting of a single Regen drive with multiple motoring drives. In this configuration the Regen drive is sized to the total power of all motoring drives.

Figure 2-3 Single Regen, multiple motoring system

Regen

Inductor

Additional

Circuitry

Regen Drive

AC Supply

Connection

+DC

-DC

L2 L3

DC Bus

Connections

Motoring Drive

+DC

-DC

Connection

Motor

Power up only

Motoring Drive

+DC

Connection

-DC

Motor

It is also possible to have a single Regen drive powering multiple motoring drives as shown with the power up connections also being provided via the Regen drives L1, L2, L3 inputs and using the Regen drives own internal softstart. In this arrangement the total capacitance of the motoring drives must not exceed the capacitance of the Regen drive, in cases where this does please contact Technical Support.

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Safety

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Mechanical

installation

Figure 2-4 Single Regen, multiple motoring system

Electrical

installation

Getting started

Optimisation Parameters

Te ch n ic al

data

Component

sizing

Diagnostics

Regen

Additional

circuitry

External

charging

circuit

inductor

Regen drive

AC supply

connection

+DC

-DC

Motoring drive 1

+DC

-DC

connection

Motor

Motoring drive 2

Charging circuit can consist of either Unidrive SPMC solution or external charging circuit as detailed in Chapter 4

System Design

L1 L2 L3

Unidrive

SPMC

+DC -DC

Common DC Bus

+DC

connection

-DC

connections

Motor

Motoring drive 3

+DC

connection

-DC

Motor

NOTE

For a single Regen and multiple motoring drive arrangement optional charging circuits can be used for the increased inrush current generated by the additional capacitance of the multiple motoring drives. The charging circuit can consist of either a Unidrive SPMC rectifier module or an external charging resistor as detailed in Chapter 4 System design

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Safety

Information

Introduction

Product

information

System

design

Mechanical

installation

Electrical

installation

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

2.8.3 Multiple Regen, multiple motoring system

Figure 2-5 shows a multiple regen drive system with multiple motoring drives. For this configuration the regen drives are sized to the total power requirement of all motoring drives.

NOTE

For the multiple regen and multiple motoring drives arrangement there are two possible options for the required start-up circuit. This can either consist of a Unidrive SPMC rectifier module (for example an SPMC 1402 is capable of charging a maximum DC Bus capacitance of 66mF) or an external charging resistor as detailed in Chapter 4 System design on page 30.

Special care should be taken when designing a multiple regen and multiple motoring drive system ensuring that all the required fusing is in place on both the common DC Bus connections and the AC supply to all regen drives.

Figure 2-5 Multiple Regen, multiple motoring system

DC Bus

Additional

Circuitry

Regen Drive

U V W

+DC

-DC

Connections

Motoring Drive

Motor

Connection

U V W

+DC

-DC

Regen Drive

Additional

Circuitry

Additional

Circuitry

Additional

Circuitry

External charging

circuit

Charging circuit can consist of either Unidrive SPMC solution or external charging circuit (Unidrive SPMC recommended)

U V W

Regen Drive

U V W

Regen Drive

U V W

SPMC

+DC

-DC

+DC

-DC

+DC

-DC

+DC

-DC

Motoring DriveMotoring Drive

+DC

-DC

Motor

Connection

U V W

Motoring DriveMotoring DriveMotoring DriveMotoring Drive

Motor

Connection

U V W

+DC

-DC

Motoring Drive

Motor

Connection

U V W

+DC

-DC

NOTE

All drives paralleled must be of the same frame size, and a derating also applies as specified in Chapter 3 Product Information on page 12

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Information

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Product

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Mechanical

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Electrical

installation

Getting started

Optimisation Parameters

3 Product Information

3.1 Model number

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

Technical

data

Component

sizing

Diagnostics

Unidrive SP product line

SP:

Solutions platform complete inverter drive

Power module power stages

SPMA:

for custom drive systems AC input

SPMD:

Power module power stages for custom drive systems DC input

SP frame size

Voltage rating

Voltage independent

200V to 240V

380V to 480V

500V to 575V

500V to 690V

Configuration

Wall mount

Wall mount, no dynamic brake control

Stand alone, no dynamic brake control

Current rating step

SPX

1 4 0 1

3.2 Nameplate description

See Figure 3-2 on page 17 for location of rating labels.

Figure 3-1 Typical drive rating labels

Rating label

Input voltage rating

Model

Output voltage range

Approvals label

I/P 200-240V 50-60Hz 3ph 6.6A

SP1201

O/P 0-240V 4.3 / 5.2A

Model

Please read manual before connecting.

Input frequency

S.No:

3000005001

SP 1,5 TL

Heavy Duty / Normal Duty rating output current

SP1201 0.75 / 1.1kW

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

SP 1,5 TL

IND. CONT. EQ.

No. of phases

Typical input current for Normal Duty rating

Serial number

Heavy Duty Normal Duty power rating

Approvals

Key to approvals

CE approval Europe

C Tick approval Australia

UL / cUL approval

USA &

Canada

Serial number

3000005001

STDL25

Made In U.K

Ser No:

Customer and

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Mechanical installation

3.3 Ratings

Table 3-1 200V Drive ratings (200V to 240V ±10%)

Normal Duty Heavy Duty

Model

1201 5.2 1.1 1.5 4.3 0.75 1.0

1202 6.8 1.5 2.0 5.8 1.1 1.5 1203 9.6 2.2 3.0 7.5 1.5 2.0 1204 11 3.0 3.0 10.6 2.2 3.0

2201 15.5 4.0 5.0 12.6 3.0 3.0

2202 22 5.5 7.5 17 4.0 5.0

2203 28 7.5 10 25 5.5 7.5

3201 42 11 15 31 7.5 10

3202 54 15 20 42 11 15

4201 68 18.5 25 56 15 20

4202 80 22 30 68 18.5 25

4203 104 30 40 80 22 30

5201 130 37 50 105 30 40

Maximum

continuous

output current

AkWhpAkWhp

Nominal

power

at 220V

Electrical

installation

Motor power

at 230V

Getting

started

Maximum

continuous

output current

Optimisation Parameters

Nominal

power

at 220V

Motor power

at 230V

Technical

data

Component

sizing

Diagnostics

5202 154 45 60 130 37 50

1201 192 55 175 156 45 60

1202 248 75 100 192 55 75

1203 312 90 125 250 75 100

SPMD

1204 350 110 150 290 90 125

NOTE

The above current ratings are given for max 40°C (104°F), 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 both the Unidrive SP and SPM User Guides.

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Table 3-2 400V drive ratings (380V to 480V ±10%)

Model

1405 8.8 4.0 5.0 7.6 3.0 5.0

1406 11 5.5 7.5 9.5 4.0 5.0

2401 15.3 7.5 10 13 5.5 10 2402 21 11 15 16.5 7.5 10 2403 29 15 20 25 11 20 2404

3401 35 18.5 25 32 15 25

3402 43 22 30 40 18.5 30

3403 56 30 40 46 22 30

4401 68 37 50 60 30 50

Maximum

continuous

input current

AkWhpAkWhp

Electrical

installation

Normal Duty Heavy Duty

Typical motor

power

at 400V

Getting started

Typ i cal m o to r

power

at 460V

Optimisation Parameters

Maximum

continuous

input current

29 15 20

Technical

data

Typical motor

power

at 400V

Component

sizing

Diagnostics

Typical motor

power

at 460V

4402 83 45 60 74 37 60

4403 104 55 75 96 45 75

5401 138 75 100 124 55 100

5402 168 90 125 156 75 125

6401 202 110 150 180 90 150

6402 236 132 200 210 110 150

1401 205 110 150 180 90 150

SPMA

1402 236 132 200 210 110 150

1401 205 110 150 180 90 150

1402 246 132 200 210 110 150

1403 290 160 250 246 132 200

SPMD

1404 350 200 300 290 160 250

NOTE

The SPMD1404 can deliver 350A continuously only if the ambient is 35°C or lower and it is docked to the SPMC. Under all other circumstances the current rating is 335A. The above current ratings are given for max 40°C (104°F), 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 both the Unidrive SP and SPM User Guides.

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Mechanical installation

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

Normal Duty Heavy Duty

Model

Maximum

continuous

output current

AkWhpAkWhp

3501 5.4 3.0 3.0 4.1 2.2 2.0 3502 6.1 4.0 5.0 5.4 3.0 3.0 3503 8.4 5.5 7.5 6.1 4.0 5.0 3504 11 7.5 10 9.5 5.5 7.5 3505 16 11 15 12 7.5 10 3506 22 15 20 18 11 15 3507 27 18.5 25 22 15 20

4603 36 22 30 27 18.5 25

4604 43 30 40 36 22 30

4605 52 37 50 43 30 40

4606 62 45 60 52 37 50

5601 84 55 75 63 45 60

Nominal

power

at 575V

Electrical

installation

Motor

power

at 575V

Getting

started

Maximum

continuous

output current

Optimisation Parameters

Nominal

power

at 575V

Motor power

at 575V

Technical

data

Component

sizing

Diagnostics

SPMA

5602 99 75 100 85 55 75

6601 125 90 125 100 75 100

6602 144 110 150 125 90 125

1601 125 90 125 100 75 100

1602 144 110 150 125 90 125

1601 125 110 150 100 90 125

1602 144 132 175 125 110 150

1603 168 160 200 144 132 175

SPMD

1604 192 185 250 168 160 200

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

NOTE

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System

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Table 3-4 690V Drive ratings (690V ±10%)

Maximum

continuous

output current

AkWhpAkWhp

Model

4601 22 18.5 25 19 15 20 4602 27 22 30 22 18.5 25 4603 36 30 40 27 22 30 4604 43 37 50 36 30 40 4605 52 45 60 43 37 50 4606 62 55 75 52 45 60

5601 84 75 100 63 55 75

Mechanical

installation

Normal Duty Heavy Duty

Nominal

power

at 690V

Electrical

installation

Motor

power

at 690V

Getting started

Maximum

continuous

output current

Optimisation Parameters

Nominal

power

at 690V

Motor

power

at 690V

Technical

data

Component

sizing

Diagnostics

SPMA

5602 99 90 125 85 75 100

6601 125 110 150 100 90 125

6602 144 132 175 125 110 150

1601 125 110 150 100 90 125

1602 144 132 175 125 110 150

1601 125 110 150 100 90 125

1602 144 132 175 125 110 150

1603 168 160 200 144 132 175

SPMD

1604 192 185 250 168 160 200

NOTE

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3.4 Drive features

Figure 3-2 Features of the drive sizes 1 to 6

SMARTCARD slot

Keypad connection

Serial port connector

Approvals label

Status LED

Rating label

Solutions Module slot 1

Solutions Module slot 2

Solutions Module slot 3

Mechanical installation

Electrical

installation

DC Bus output (High current)

EMC capacitor must be removed

Getting

started

Optimisation Parameters

DC Bus output (High current)

EMC capacitor must be removed

Technical

data

DC Bus output (High current)

Component

sizing

Diagnostics

EMC capacito must be removed

Charging input

(L1, L2, L3)

Control terminals

Relay terminals

EMC capacitor

DC Bus output

(High current)

Charging input

(L1, L2, L3)

must be

removed

AC supply (U, V, W)

Charging input

(L1, L2, L3)

Charging input

(L1, L2, L3)

AC supply (U, V, W)

EMC capacitor

must be

removed

DC Bus output

(High current)

Charging input

(L1, L2, L3)

(U, V, W)

Charging input

(L1, L2, L3)

C supply

EMC capacitor

must be

removed

DC Bus output

(High current)

AC supply

(U, V, W)

AC supply

(U, V, W)

C supply (U, V, W)

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Figure 3-3 Features of the drive sizes SPMA and SPMD

SMARTCARD slot

Keypad connection

Serial port connector

Electrical

installation

Getting started

Optimisation Parameters

Technical

data

Master interface Slave interface

Cover Base

Approvals label B

Status LED

Rating label

Solutions Module slot 1

Solutions Module slot 2

Solutions Module slot 3

Stat us LED

Component

sizing

Diagnostics

EMC capacitor

must be removed

Charging input

(L1, L2, L3)

Encoder connection

EMC capacitor

must be removed

Output connections

to slave

Control terminals

Relay terminals

(high current)

DC Bus output

Input from Master /

Output to slave

SPMA SPMD

AC supply

(U, V, W)

Heatsink fan

supply connections

AC supply

(U, V, W)

Heatsink fan

suppl

connections

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Optimisation Parameters

3.5 Unidrive SPMC half controlled thyristor rectifier

NOTE

For the 200V modules where an external charging circuit is required the SPMU1401, SPMU1402 and SPMU2402 can be used as detailed following:

Figure 3-4 Rectifier (SPMC and SPMU)

SPMC 1 402

Unidrive SPM product line

Controlled rectifier

SPMC:

SPMU:

Uncontrolled rectifier

Number of rectifier stages

Vol tag e rat i ng

4: 380V to 480V 6: 500V to 690V

Current rating step

The Unidrive SPMC is a controlled thyristor rectifier and the SPMU is an uncontrolled rectifier.

SPMC1402 and 1601

Figure 3-5 Single half controlled thyristor

+DC

SPMU1401, 1402 and 1601

Figure 3-7 Single diode rectifier

Technical

data

Component

sizing

+DC

Diagnostics

SPMC2402 and 2601

Figure 3-6 Dual half controlled thyristor

L1A

L2A

L3A

L1B

L2B

L3B

-DC

+DC (A)

-DC (A)

+DC (B)

-DC

SPMU2402 and 2601

Figure 3-8 Dual diode rectifier

+DC (A)

L1A

L2A

L3A

-DC (A)

+DC (B)

L1B

L2B

L3B

-DC(B)

-DC (B)

The Unidrive SPMC is a half controlled thyristor bridge is used as a front end to the SPMD inverter module or as a stand alone rectifier for several smaller drives. Soft-start is built in.

The Unidrive SPMU is used as a front end to the SPMD inverter module or as a stand alone rectifier for several smaller drives. Softstart must be supplied externally using a resistor and contactor or SPMC.

An external 24V, 3A power supply is required in addition to the AC supply to allow the rectifier to operate. Control wiring is required between the rectifier and motoring drive(s) so that if the rectifier indicates a fault the motoring drive(s) will be disabled.

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Component

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Diagnostics

The 24V supply must be protected using a 4A slow-blow fuse, one for each supply pole.

Control connections to the Unidrive SPMC/U should be made with 0.5mm2 cable. The status relay contacts are rated for switching non-inductive loads at 250Vac 6A non-inductive, up to 4Adc if the voltage is limited to 40V or up to

400mA dc if the voltage is limited to 250Vdc. Protection from overcurrent must be provided.

Figure 3-9 SPMC/U rating label

Input voltage, frequency, no. of phases and current

Approvals

Serial number

STDN39

Customer and

date code

Status1 Status0

Status

LEDs

I/P 380-480V 50-60Hz 3ph 204A O/P 513-648V 552A

Output voltage and current

Model:

SPMC = Controlled SPMU = Uncontrolled

SPMC1402

Number of rectifier stages

Ser No: 3000005001

Voltage

rating:

4 - 400V 6 - 690V

Indicates sub-rating within frame size

3.6 Unidrive SPMC/U technical data

Table 3-5 Unidrive SPMC / U input current, fuse and cable ratings

Semi-conductor fuse

in series with HRC fuse

HRC IEC

class gG UL

class J

Semi-

conductor

IEC class aR

Model

Typical input

current

Maximum

input current

Typical DC

current

Adc

SPMC1402 339 344 379 540 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0

SPMC2402 2 x 308 2 x 312 2 x 345 450 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0

SPMU1401 207 210 222 250 315 2 x 70 2 x 2/0 2 x 70 2 x 2/0

SPMU1402 339 344 379 540 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0

SPMU2402 2 x 339 609 2 x 379 450 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0

SPMC1601 192 195 209 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0

SPMC2601 2 x 170 2 x 173 2 x 185 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0

SPMU1601 192 195 209 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0

SPMU2601 2 x 170 2 x 173 2 x 185 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0

Cable sizes

AC input DC output

AWG

The user must provide a means of preventing live parts from being touched. A cover around the electrical connections at the top of the inverter and the bottom of the rectifier where the

WARNING

cables enter is required.

Input fuses as specified must be provided.

WARNING

The Unidrive SPMC/U depends on the drive for protection. Status outputs must be linked to the drive enable regen drive(s) and circuit to ensure that when the rectifier indicates

WARNING

a fault the motoring drive(s) are disabled.

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Diagnostics

Table 3-6 Key to Unidrive SPMC (rectifier) LEDs Table 3-7 Key to Unidrive SPMU (rectifier) LEDs

Status Output

1: Left LED

OFF OFF

0: Right LED

Definition

Mains loss or 24V supply to the rectifier has been lost

Status Output

1: Left LED

0: Right LED

Definition

OFF OFF 24V supply to the rectifier has been lost

Any of the following:

OFF ON Phase loss OFF ON

• Internal fault

• Check that rectifier is an SPMU. This could indicate that unit is an SPMC

Any of the following:

• Rectifier heatsink over temperature

• Rectifier PCB over temperature

• Status input wire break

ON OFF

• Snubber overheating due to excessive cable charging current or supply notching

• Rectifier heatsink over temperature

• Rectifier PCB over temperature

ON OFF

• Status input wire break

ON ON System healthy ON ON System healthy

The half controlled thyristor rectifier can be used as an external charging module for a regen system consisting of multiple drives. The required softstart function is built into the SPMC module as standard. An external 24V, 3A power supply is required in addition to the AC supply for the SPMC to allow the rectifier to operate. Control wiring is required between the rectifier and drive(s) so that if the rectifier indicates a fault all drive(s) will be disabled.

Table 3-8 SPM rectifier charging data

Model

AC line current

(100% Normal Duty Motor Current)

DC link current

(100% Normal Duty Motor Current)

Maximum

DC bus

capacitance on

a supply <25kA

Maximum

DC bus

capacitance on

a supply <25kA

Max capacitance

(mF)

When used with

line reactor

Max capacitance

(mF)

When used with

line reactor

SPMU

1401

207 339 677 339 677 192 385 192 385

222 379 758 379 758 209 418 209 418

44 66 132 66 132 29.3 59 29.3 59

INL401 INL402 2 x INL402 INL402 2 x INL402 INL602 2 x INL602 INL602 2 x INL602

44 66 66 66 66 29.3 29.3 29.3 29.3

INL401 INL402 INL412 INL402 INL412 INL602 INL612 INL602 INL612

SPMU

1402

SPMU

2402

SPMC

1402

SPMC

2402

SPMU

1601

SPMU

2601

SPMC

1601

SPMC

2601

Also refer to the Unidrive SPM User Guide for further detailed information on the Unidrive SPMC mechanical and electrical installation.

• The user must provide a means of preventing live parts from being touched. A cover around the electrical connections at the top of the inverter and the bottom of the rectifier where the cables enter is required.

WARNING

• Fusing as specified must be provided.

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Diagnostics

3.7 Output Sharing Chokes (for motoring drives only)

The following section covers the output sharing chokes which are currently available for Unidrive SP. These being used for the motoring drives in a regen system only (between drive and motor).

Figure 3-10 Output sharing choke identification

OTL:

Output sharing choke

Voltage rating

4: 380V to 480V 6: 500V to 690V

0: Single 1: Dual

Current rating step

NOTE

OTL

4 0 1

For the 200V SPMx modules used in parallel configurations and where output sharing chokes are required the 400V OTL output sharing chokes should be used.

The following tables detail the output chokes required for the various configurations of paralleled SPMA and SPMD power modules.

When connecting either SPMA or SPMD drives in parallel they must be de-rated by 5%

CAUTION

NOTE

In order to achieve the best possible current sharing between paralleled Unidrive SPM modules, sharing chokes must be fitted.

Table 3-9 400 / 600V output sharing choke ratings

Model

CurrentAInductanceµHWidth (W)mmDepth (D)mmHeight (H)mmWeight

Part No.

OTL401 221 40.1 240 220 210 20 4401-0197-00

OTL402 267 34 242 220 205 20 4401-0198-00

OTL403 313 28.5 242 220 205 25 4401-0199-00

OTL404 378 23.9 242 220 205 25 4401-0200-00

OTL601 135 103.9 242 170 203 20 4401-0201-00

OTL602 156 81.8 242 170 203 20 4401-0202-00

OTL603 181 70.1 242 200 203 20 4401-0203-00

OTL604 207 59.2 242 200 203 20 4401-0204-00

Table 3-10 400 / 600V centre tapped output sharing choke ratings

Model

CurrentAInductanceµHWidth (W)mmDepth (D)mmHeight (H)mmWeight

Part No.

OTL411 389.5 42.8 300 150 160 8 4401-0188-00

OTL412 470.3 36.7 300 150 160 8 4401-0189-00

OTL413 551 31.1 300 150 160 8 4401-0192-00

OTL414 665 26.6 300 150 160 9 4401-0186-00

OTL611 237.5 110.4 300 150 160 8 4401-0193-00

OTL612 273.6 88.4 300 150 160 8 4401-0194-00

OTL613 319.2 76.7 300 150 160 8 4401-0195-00

OTL614 364.8 65.7 300 150 160 8 4401-0196-00

The OTLX1X centre tapped output sharing chokes can only be used when two Unidrive SPM drives are paralleled together. For all other combinations the OTLX0X output

CAUTION

sharing choke must be used.

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3.8 Options

Figure 3-11 Options available for Unidrive SP Regen

SMARTCARD*

Electrical

installation

Getting

started

Keypad

Optimisation Parameters

Technical

Automation Fieldbus

data

Component

sizing

Diagnostics

External footprint / bookcase

CT Comms cable

EMC filter

* A SMARTCARD is provided with the Unidrive SP as standard. Only one SMARTCARD can be fitted at any one time.

NOTE

Position feedback modules will still function with a drive configured in regen mode, however, this would only be required where the Regen drive is to be used to provide additional Solutions Module slots for the motoring drive.

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Diagnostics

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

Table 3-11 Solutions Module identification

Type Solutions Module Colour 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:

• digital inputs x 3

• analogue output (voltage) x 1

• digital I/O x 3 • relay x 2

• analogue inputs (voltage) x 2

Automation

Fieldbus

Dark Green SM-Applications

White SM-Applications Lite

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

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

Profibus option

PROFIBUS DP adapter for communications with the Unidrive SP.

DeviceNet option

Devicenet adapter for communications with the Unidrive SP

Interbus option

Interbus adapter for communications with the Unidrive SP

CAN option

CAN adapter for communications with the Unidrive SP

CANopen option

CANopen adapter for communications with the Unidrive SP

SERCOS option

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

N/A SM-Keypad

LED keypad option

Keypad with a LED display

Keypad

N/A SM-Keypad Plus

NOTE

Position feedback modules will still function with a drive configured in

LCD keypad option

Keypad with an alpha-numeric LCD display with Help function

regen mode, however, this would only be required where the Regen drive is to be used to provide additional Solutions Module slots for the motoring drive.

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3.9 Items supplied with the drive

The drive is supplied with a copy of the Unidrive SP Short Form Guide, a SMARTCARD, the safety booklet, the certificate of quality, an accessory kit box (see the Unidrive SP User Guide for details) and a CD ROM containing the following user guides:

• Unidrive SP User Guide (English, French, German, Italian, Spanish)

• Unidrive SP Advanced User Guide

• Unidrive SP Regen Installation Guide

• Solutions Module User Guides

• Unidrive SPM User Guide

3.10 Regen components

3.10.1 Regen inductor

The following regen inductors are special parts being designed for very high levels of harmonic voltage and having a high saturation current with good linearity below saturation.

CAUTION

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

Table 3-12 200V (200V to 240V ± 10%) Regen Inductors

Heavy Duty Normal Duty

SPMD1201 SP5202 4401-0321 0.22 156.0

SPMD1202 SPMD1201 4401-0322 0.18 192.0

SPMD1203 SPMD1202 4401-0323 0.14 250.0

SPMD1204 SPMD1203 4401-0324 0.11 312.0

Under no circumstances must a part be used other than those listed.

Drive

Part number mH Arms

SP1203 SP1203 4401-0310 3.50 9.6

SP1204 SP1204 4401-0311 2.70 11.0

SP2201 SP2201 4401-0312 2.20 15.5

SP2202 SP2202 4401-0313 1.60 22.0

SP2203 SP2203 4401-0314 1.10 31.0

SP3201

4401-0314 1.10 31.0

SP3202 SP3201 4401-0315 0.81 42.0

SP4201 SP3202 4401-0316 0.60 56.0

SP4202 SP4201 4401-0317 0.50 68.0

SP4203 SP4202 4401-0318 0.40 80.0

SP5201 SP4203 4401-0319 0.32 105.0

SP5202 SP5201 4401-0320 0.26 130.0

SPMD1204 4401-0325 0.10 350.0

Table 3-13 400V (380V to 480V ± 10%) Regen Inductor

Drive

Heavy Duty Normal Duty

Part number mH Arms

SP1405 SP1405 4401-0001 6.30 9.5

SP1406

4401-0001 6.30 9.5

SP1406 4401-0002 5.00 12.0

SP2401 SP2401 4401-0003 3.75 16.0

SP2402

4401-0003 3.75 16.0

SP2403 SP2402 4401-0004 2.40 25.0

SP2404 SP2403 4401-0005 1.76 34.0

SP3401 SP2404 4401-0005 1.76 34.0

SP3402 SP3401 4401-0006 1.50 40.0

SP3403 SP3402 4401-0007 1.30 46.0

SP4401 SP3403 4401-0008 1.00 60.0

SP4401 4401-0009 0.78 70.0

SP4402 SP4402 4401-0010 0.63 96.0

SP4403

4401-0010 0.63 96.0

SP5401 SP4403 4401-0011 0.48 124.0

SP5402 SP5401 4401-0012 0.38 156.0

SP6401 SP5402 4401-0013 0.33 180.0

SP6402 SP6401 4401-0014 0.30 200.0

SP6402 4401-0015 0.20 300.0

SPMA1401

4401-0013 0.33 180.0

SPMA1402 SPMA1401 4401-0014 0.30 200.0

SPMA1402 4401-0015 0.20 300.0

SPMD1401

4401-0013 0.33 180.0

SPMD1402 SPMD1401 4401-0014 0.30 200.0

SPMD1402 4401-0015 0.20 300.0

SPMD1403 SPMD1403 4401-0015 0.20 300.0

SPMD1404

4401-0015 0.20 300.0

SPMD1404 4401-0205-00 0.16 350.0

Table 3-14 575V (500V to 575V ± 10%) Regen Inductor

Drive

Heavy Duty Normal Duty

Part number mH Arms

SP3505 SP3505 4401-0210 5.30 19.0

SP3506

4401-0211 4.60 22.0

SP3507 SP3506 4401-0212 3.80 27.0

SP3507 4401-0212 3.80 27.0

SP4601

4401-0211 4.60 22.0

SP4602 SP4601 4401-0212 3.80 27.0

SP4603 SP4602 4401-0212 3.80 27.0

SP4604 SP4603 4401-0213 2.80 36.0

SP4605 SP4604 4401-0214 2.40 43.0

SP4606 SP4605 4401-0215 1.90 52.0

SP5601 SP4606 4401-0216 1.60 63.0

SP5602 SP5601 4401-0217 1.20 85.0

SP6601 SP5602 4401-0218 1.00 100.0

SP6602 SP6601 4401-0219 0.80 125.0

SPMA1601

SPMD1601

4401-0218 1.00 100.0

SPMA1602 SPMA1601 4401-0219 0.80 125.0

SPMD1602 SPMD1601 4401-0219 0.80 125.0

SPMA1602 4401-0220 0.70 144.0

SPMD1602 4401-0220 0.70 144.0

SPMD1603 SP6602 4401-0220 0.70 144.0

SPMD1604 SPMD1603 4401-0221 0.60 168.0

SPMD1604 4401-0222 0.53 192.0

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Table 3-15 690V (690V ± 10%) Regen Inductor

Drive

Heavy Duty Normal Duty

SP4601

Part number mH Arms

4401-0210 5.30 19.0

SP4602 SP4601 4401-0211 4.60 22.0

SP4603 SP4602 4401-0212 3.80 27.0

SP4604 SP4603 4401-0213 2.80 36.0

SP4605 SP4604 4401-0214 2.40 43.0

SP4606 SP4605 4401-0215 1.90 52.0

SP5601 SP4606 4401-0216 1.60 63.0

SP5602 SP5601 4401-0217 1.20 85.0

SP6601 SP5602 4401-0218 1.00 100.0

SP6602 SP6601 4401-0219 0.80 125.0

SPMA1601

SPMD1601

4401-0218 1.00 100.0

SPMA1602 SPMA1601 4401-0219 0.80 125.0

SPMD1602 SPMD1601 4401-0219 0.80 125.0

SPMA1602 4401-0220 0.70 144.0

SPMD1602 4401-0220 0.70 144.0

SPMD1603 SP6602 4401-0220 0.70 144.0

SPMD1604 SPMD1603 4401-0221 0.60 168.0

SPMD1604 4401-0222 0.53 192.0

3.10.2 Switching frequency filter

These components are used to form the filter, preventing switching frequency harmonic currents getting back onto the supply. If the filter is not fitted, the presence of currents in the kHz region could cause supply problems or disturbance to other equipment.

Table 3-16 200V (200V to 240V ± 10%) SFF Inductors

Drive

Heavy Duty Normal Duty

SP1203 SP1203 4401-1310 0.88 9.6

SP1204 SP1204 4401-1311 1.50 11.0

SP2201 SP2201 4401-1312 1.10 15.5

SP2202 SP2202 4401-1313 0.70 22.0

SP2203 SP2203 4401-1314 0.50 31.0

SP3201

SP3202 SP3201 4401-1315 0.40 42.0

SP4201 SP3202 4401-1316 0.30 56.0

SP4202 SP4201 4401-1317 0.25 68.0

SP4203 SP4202 4401-1318 0.20 80.0

SP5201 SP4203 4401-1319 0.16 105.0

SP5202 SP5201 4401-1320 0.13 130.0

SPMD1201 SP5202 4401-1321 0.11 156.0

SPMD1202 SPMD1201 4401-1322 0.088 192.0

SPMD1203 SPMD1202 4401-1323 0.068 250.0

SPMD1204 SPMD1203 4401-1324 0.055 312.0

SPMD1204 4401-1325 0.048 350.0

Part number mH Arms

4401-1314 0.50 31.0

Table 3-17 400V (380V to 480V ± 10%) SFF Inductor

Drive

Heavy Duty Normal Duty

Part number mH Arms

SP1405 SP1405 4401-0162 3.16 9.5

SP1406

4401-0162 3.16 9.5

SP1406 4401-0163 2.50 12.0

SP2401 SP2401 4401-0164 1.875 16.0

SP2402 SP2402 4401-0165 1.20 25.0

SP2403

4401-0165 1.20 25.0

SP2404 SP2403 4401-0166 0.88 34.0

SP3401 SP2404 4401-0166 0.88 34.0

SP3402 SP3401 4401-0167 0.75 40.0

SP3403 SP3402 4401-0168 0.65 46.0

SP4401 SP3403 4401-0169 0.50 60.0

SP4401 4401-0170 0.39 70.0

SP4402 SP4402 4401-0171 0.315 96.0

SP4403

4401-0171 0.315 96.0

SP5401 SP4403 4401-0172 0.24 124.0

SP5402 SP5401 4401-0173 0.19 156.0

SP6401 SP5402 4401-0174 0.165 180.0

SP6402 SP6401 4401-0175 0.135 220.0

SP6402 4401-0176 0.10 300.0

SPMA1401

4401-0174 0.165 180.0

SPMA1402 SPMA1401 4401-0175 0.135 220.0

SPMA1402 4401-0176 0.10 300.0

SPMD1401

4401-0174 0.165 180.0

SPMD1402 SPMD1401 4401-0175 0.135 220.0

SPMD1403 SPMD1402 4401-0176 0.10 300.0

SPMD1404 SPMD1403 4401-0176 0.10 300.0

SPMD1404 4401-1205 0.08 350.0

Table 3-18 575V (500V to 575V ± 10%) SFF Inductor

Drive

Heavy Duty Normal Duty

Part number mH Arms

SP3505 SP3505 4401-1211 1.40 22.0

SP3506

4401-1211 1.40 22.0

SP3506 4401-1213 1.40 36.0

SP3507 SP3507 4401-1213 1.40 36.0

SP4601 SP4601 4401-1211 1.40 22.0

SP4602

4401-1211 1.40 22.0

SP4603 SP4602 4401-1213 1.40 36.0

SP4604 SP4603 4401-1214 1.20 43.0

SP4605 SP4604 4401-1215 1.00 52.0

SP4606 SP4605 4401-1216 0.80 63.0

SP5601 SP4606 4401-1217 0.60 85.0

SP5602 SP5601 4401-1218 0.50 100.0

SP6601 SP5602 4401-1219 0.40 125.0

SP6602 SP6601 4401-1220 0.35 144.0

SPMA1601

SPMD1601

4401-1219 0.40 125.0

SPMA1602 SPMA1601 4401-1220 0.35 144.0

SPMD1602 SPMD1601 4401-1220 0.35 144.0

SPMA1602 4401-1221 0.30 168.0

SPMD1602 4401-1221 0.30 168.0

SPMD1603 SP6602 4401-1221 0.30 168.0

SPMD1604 SPMD1603 4401-1222 0.26 192.0

SPMD1604 4401-1223 0.21 192.0

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Table 3-19 690V (690V ± 10%) SFF Inductor

Drive

Heavy Duty Normal Duty

Part number mH Arms

SP4601 SP4601 4401-1211 1.40 22.0

SP4602

4401-1211 1.40 22.0

SP4603 SP4602 4401-1213 1.40 36.0

SP4604 SP4603 4401-1213 1.40 36.0

SP4605 SP4604 4401-1214 1.20 43.0

SP4606 SP4605 4401-1215 1.00 52.0

SP5601 SP4606 4401-1216 0.80 63.0

SP5602 SP5601 4401-1217 0.60 85.0

SP6601 SP5602 4401-1218 0.50 100.0

SP6602 SP6601 4401-1219 0.40 125.0

SPMA1601

SPMD1601

4401-1218 0.50 100.0

SPMA1602 SPMA1601 4401-1219 0.40 125.0

SPMD1602 SPMD1601 4401-1219 0.40 125.0

SPMA1602 4401-1220 0.35 144.0

SPMD1602 4401-1220 0.35 144.0

SPMD1603 SP6602 4401-1220 0.35 144.0

SPMD1604 SPMD1603 4401-1221 0.30 168.0

SPMD1604 4401-1222 0.26 192.0

The inductors are standard three phase inductors (rated at Unidrive SP Regen drive rated current). They carry only 50/60Hz current with a negligible amount of high frequency current. The above switching frequency filter inductors are calculated at 4% of the regen drives rating using the following formula. A tolerance can be applied to the calculated value in the range of, -10% to +30%.

L switching frequency filter mH = VLL / √3 x 1 / Irated x 0.04 x 1 / (2 x pi x f).

Where:

VLL = Supply voltage line-to-line f = Supply frequency Irated = Drive rated current

NOTE

This calculation also gives the correct inductance value for a 480V, 60Hz supply.

Table 3-20 200V (200V to 240V ± 10%) SFF Capacitors

Drive

Heavy Duty Normal Duty

Part number uF Arms

SP1203 SP1203

1664-1074 7 1.7SP1204 SP1204

SP2201 SP2201

SP2202 SP2202

SP2203 SP2203

SP3201 SP3201

1664-2174 16.6 4.3

SP3202

SP4201 SP3202

1665-8324 32 11SP4202 SP4201

SP4203 SP4202

SP5201 SP4203

1664-2644 64 17SP5202 SP5201

SPMD1201 SP5202

SPMD1202 SPMD1201

SPMD1203 SPMD1202

SPMD1204 SPMD1203

2 x 1664-2644 2 x 64 2 x 17

SPMD1204

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Table 3-21 400V (380V to 480V ± 10%) SFF Capacitors

Drive

Heavy Duty Normal Duty

Part number uF Arms

SP1405 SP1405

SP1406 SP1406

SP2401 SP2401

1610-7804 8 4.3

SP2402 SP2402

SP2403

SP2404 SP2403

SP3401 SP2404

SP3402 SP3401

SP3403 SP3402

1665-8324 32 11

SP4401 SP3403

SP4401

SP4402 SP4402

SP4403 SP4403

SP5401 SP5401

SP5402 SP5402

SP6401 SP6401

SP6402

1665-8484 48 17

SPMA1401 SPMA1401

SPMA1402

SPMD1401 SPMD1401

SPMD1402

SP6402

SPMA1402 SPMA1402

SPMD1402

1665-8774 77 26

SPMD1403 SPMD1403

SPMD1404

SPMD1404 2 x 1665-8394 2 x 39 2 x 13

Table 3-22 575V (500V to 575V ± 10%) SFF Capacitors

Drive

Heavy Duty Normal Duty

Part number uF Arms

SP3505 SP3505

SP3506 SP3506

SP3507 SP3507

SP4601 SP4601

SP4602 SP4602

SP4603 SP4603

1666-8113 11.2 5

SP4604 SP4604

SP4605 SP4605

SP4606 SP4606

SP5601 SP5601

SP5602

SP6601 SP5602

SP6602 SP6601

SPMA1601 SP6602

SPMA1602 SPMA1601

1666-8223 22.5 10

SPMD1601 SPMA1602

SPMD1602 SPMD1601

SPMD1603 SPMD1602

SPMD1604 SPMD1603

SPMD1604

2 x 1666-8233

2 x

22.5

Diagnostics

2 x 10

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Table 3-23 690V (690V ± 10%) SFF Capacitors

Drive

Heavy Duty Normal Duty

Part number uF Arms

SP4601 SP4601

SP4602 SP4602

SP4603 SP4603

SP4604 SP4604

1668-7833 8.3 4.3

SP4605 SP4605

SP4606 SP4606

SP5601

SP5602 SP5601

SP6601 SP5602

SP6602 SP6601

SPMA1601 SPMA1601

1668-8163 16.6 8.6

SPMA1602 SPMD1601

SPMD1601

SPMD1602

SP6602

SPMA1602

SPMD1602

2 x 1668-8163 2 x 16.6 2 x 8.6

SPMD1603 SPMD1603

SPMD1604 SPMD1604

3.10.3 Varistors

AC line voltage transients can typically be caused by the switching of large items of plant or by lightning strikes on another part of the supply system. If these transients are not suppressed they can cause damage to the insulation of the regen input inductors, or to the Regen drive electronics.

The following varistors should therefore be fitted as shown in section 4.2 Power connections .

Tab le 3-24 Va ris t or d a ta

Drive rating

200V

(200V to 240V±10%)

400V

(380V to 480V±10%)

575V

(500V to 575V±10%)

690V

(690V±10%)

Varisto r

voltage rating

RMS

Energy

rating

550 620 3 Line to line 2482-3291

680 760 3 Line to ground 2482-3211

550 620 3 Line to line 2482-3291

680 760 3 Line to ground 2482-3211

680 760 3 Line to line 2482-3211

1000 1200 3 Line to ground 2482-3218

385 550 6 2 in series line to line 2482-3262

1000 1200 3 Line to ground 2482-3218

Quantity

per

system

Configuration CT part number

3.10.4 EMC filters

In order to provide customers with a degree of flexibility, external EMC filters have been sourced from two manufacturers, Schaffner and Epcos, as detailed in both the Unidrive SP, and SPM User Guides.

For currents exceeding 300A up to 2500A, suitable filters are also available from both Epcos and Schaffner as detailed.

• Epcos B84143-B250-5xx (range up to 2500A)

• Schaffner FN3359-300-99 (range up to 2400A)

These filters may not give strict conformity with EN6000-6-4 but in conjunction with EMC installation guidelines they will reduce emissions to sufficiently low levels to minimise the risk of disturbance.

When a EMC filter is used, the switching frequency filter detailed must also be used. Failure to observe this may result in the EMC filter becoming ineffective and being damaged.

CAUTION

Refer to section 6.4 EMC (Electromagnetic compatibility) on page 77.

CAUTION

Figure 3-12 Removal of internal EMC filter (size 1 to 3)

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

The internal EMC filter must be removed from the drive.

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Figure 3-13 Removal of internal EMC filter (size 4 to 6 and the

SPMA/SPMD)

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

3.10.5 External charging resistor

The following external charging resistors are available from Control Techniques and can be used with a regen system consisting of multiple regen, multiple motoring or single regen, multiple motoring drives. For correct sizing of the charging resistor required, refer to section

11. 2 Resistor sizing for multiple drive systems on page 204. Also, see section 10.4.2 Softstart resistor - type TG series on page 197 for further technical data and thermal protection information on the following resistors.

Table 3-25 External charging resistors

Drive

All sizes

External charging

resistor part no.

1270-3157 150

1270-2483 48

Ω

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

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4 System design

4.1 Introduction

The sizing of a regen system must take into account the following factors:

1. Line voltage variation

2. Motor rated current, rated voltage and power factor

3. Maximum required power and overload requirements

4. Heavy Duty / Normal Duty Regen drive ratings

If the Regen drive is unable to supply the full power required by the motoring drive(s), the DC bus voltage will drop, and in severe cases may lose synchronisation with the AC supply and trip. If the Regen drive is unable to regenerate the full power from the motoring drive(s) into the DC bus, then the Regen drive and motoring drive(s) will trip on overvoltage.

4.1.1 Single Regen, single motoring drive

The following calculations can be carried out for either a single Regen drive, motoring drive system or single Regen drive, multiple motoring drive system.

Example

In the case of a 23A (Normal Duty), SP2403 operating in regen mode from a 400V supply, and a SP2403 driving a 400V rated, 0.85 pf motor:

The rated power of the Regen drive is:

3 Rated current× Supply voltage×

= 1.73 x 23 x 400 = 15.9kW

The motoring drive can supply power:

3 Rated current× Motor voltage Power factor××

= 1.73 x 23 x 400 x 0.85 = 13.5kW

Drive losses

2 x Unidrive SP 2403 = 626W

When the motoring drive is supplying rated current to the motor, the Regen drive needs to provide 13.5kW, plus drive losses = 14.126kW. The Regen drive can supply 15.9kW at rated current, which is ample, in this case.

Conversely, in some cases, a Regen drive of the same rating as the motoring drive, may not be able to supply enough power, as the following example shows:

Example

In the case of a 96A (Heavy Duty), SP4403 operating in regen mode, and a SP4403 driving a 75kW, 400V, 0.95pf motor:

If the motoring drive is supplying 175% maximum current, and the Regen drive has its 380V supply at the lower limits of -10% (342Vac), then, with a regen current limit of 150%:

Getting started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

requirement to 112.352kW. However, this Regen drive is only capable of supplying approximately 85.1kW and therefore a drive of a larger rating is required.

4.1.2 Multiple motoring drives

In multi-drive configurations, the Regen drive must be of a sufficient size to supply the net peak power demanded by the combined load of all motoring drives plus the combined losses, including its own losses.

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

The previous calculations can be used for the sizing of multiple motoring drives also.

4.2 Power connections

The following section covers the power connections required for Unidrive SP regen systems.

• For single Regen, single motoring systems, AC supply connections are made to L1, L2 and L3 drive terminals and the drive’s internal soft start circuit is used for power-up.

• The single Regen, multiple motoring and multiple regen, multiple motoring systems require an external charging circuit due to the extra capacitance from the additional drives. No AC connections are made to the Regen drive’s L1, L2 and L3 terminals. The external charging circuit can consist of either the SPMC solution or an external charging resistor as shown in the following.

• For the regen brake resistor replacement system, the motoring drive’s internal soft start is used for power-up with no AC connections to L1, L2, L3 on the Regen drive.

For control circuit connections refer to section 6.6 Control connections on page 83.

NOTE

If the regen system is not a standard configuration or changes are required to the following systems and set ups, contact the supplier of the drive.

The Regen drive maximum available power is:

3 150% Rated current×× Supply voltage×

= 1.73 x 1.5 x 96 x 342 = 85.1kW

The motoring drives maximum. power is:

3 175% Rated current× Motor voltage×× Power factor×

= 1.73 x 1.75 x 96 x 400 x 0.95 = 110.4kW

Drive losses

2 x Unidrive SP 4403 = 1.952kW

The Regen drive is also required to supply the Regen and motoring drive losses in this example 1.952kW which brings the total power

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4.2.1 Single Regen, single / multiple motoring system

Figure 4-1 Power connections: Single Regen, single / multiple motoring system

L1 L2 L3

RFI

F1 F2 F3

VDR4

Aux.2a

VDR1

VDR2

VDR5

VDR6

Charging branch circuit

Aux.2b

VDR3

Aux.3

Supply ground

L1 L2 L3 PE

AC Supply

Power-up

Connections

-DC +DC Motoring drive DC

Connections

Regen drive

AC Supply

Connections

UVW

Vsupply

Aux.2b

0V common

2 3 4 5 6 7 8 9 10 11 41 42

Drive healthy

Reset input

Technical

data

Contactor

Optimisation Parameters

Note: Surge suppressors to be fiited to contactor coils.

ux.3

ux.2a

22 23 24 25 26 27 28 29 30 31

+24 output

Contactor clo sed

Enable motor drive

thermistor

Regen inductor

Component

sizing

ux.1

0common

Drive enable

control

-DC

+DC

Rly.1

(optional)

Diagnostics

T.2 4 T.3 0

OPD1

Table 4-1 Key to Figure 4-1

Key Description

L1, L2, L3 Three phase supply

F1, F2, F3 Main regen system supply fuses

VDR1, VDR2, VDR3 Varistor network line-to-line

VDR4, VDR5, VDR6 Varistor network line-to-ground

RFI Optional RFI Filter

C1 Switching frequency filter capacitor

L1 Switching frequency filter inductor

L2 Regen inductor

K1 Main supply switch or contactor

K2 Regen drive main contactor

K3 Charging contactor

OPD1 Overload protection device for C1

Aux.3 K3 NC auxiliary contact

Aux.2a K2 NO auxiliary contact

Aux.2b K2 NC auxiliary contact

Aux.1 OPD1 NO auxiliary contact

Rly.1

Mt.1 Motor thermistor

Tc.1 Regen inductor thermistor

Optional isolation for enable between Regen and motoring drive

Aux.1

Vsupply

Tc. 1

Table 4-1 Key to Figure 4-1

Key Description

Vsupply System control supply

+DC, -DC Motoring drive power connection to Regen drive

S1 Regen drive enable

S2 Motoring drive enable

S3 Motoring drive reset

S4 Motoring drive run forward

S5 Motoring drive run reverse

S6 Regen drive reset input (Pr 8.24 = Pr 10.33)

Figure 4-1 shows both the power and control connections for the standard regen solution this being a single regen and single motoring drive system.

For this solution the Vac supply is temporarily connected to the Regen drive’s L1, L2, L3 inputs for initial power-up only, removing the need for an external charging circuit. The main AC supply to L1, L2, L3 on the Regen drive (K3) is interlocked with the Regen drive’s enable preventing operation when the charging circuit is still connected.

NOTE

The regen inductor duty is very arduous and therefore selection is critical as a result only Regen inductors specified in this guide should be used.

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T.2 4 T.3 0

L1 L2 L3 PE

AC Supply

NOT USED

-DC +DC

Motoring drive DC

Connections

22 23 24 25 26 27 28 29 30 31

+24V output

Motoring drive

Motor

Connections

NOTE

UVW

VDR4, VDR5 and VDR6 when operating with a 690Vac supply should consist of two varistors each in series as detailed in Table 3-24 on page 28.

0V common

2 3 4 5 6 7 8 9 10 11 41 42

Mt.1

S3 S4

Drive reset

Run forwar d

Run revers e

Motor thermistor

0common

Drive enable

Drive healthy

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4.2.2 Single Regen, multiple motoring system using a Unidrive SPMC

Figure 4-2 Power connections: Single Regen, multiple motoring system

-DC

Aux.2c

0V common

F13

F14

F11

+24Vdc external supply

F12

L1 L2 L3

F1 F2 F3

VDR4

Unidrive

SPMC

L1L2L3

VDR3

VDR2

VDR6

VDR5

+DC

Aux.2a

Technical

data

Component

sizing

Vsupply

Aux.2b

Diagnostics

-DC

+DC

T.2 4

T.3 0

control

Rly.1

optional

Drive enable

Vsupply

RFI

Charging

branch

circuit

OPD1

Aux.1

Aux.3

Connections NOT USED

L1 L2 L3 PE

AC Supply

Regen drive

AC Supply

Connections

UVW

2a 2b 2c

Aux

-DC +DC

Motoring drive DC

Connections

22 23 24 25 26 27 28 29 30 31

+24 output

Enable motor drive

0V common

2 3 4 5 6 7 8 9 10 11 41 42

Contactor close d

thermistor

Regen inductor

Tc. 1

Reset input

Drive healthy

0common

Contactor

Table 4-2 Key to Figure 4-3 Figure 4-2 shows both the power and control connections for the

Key Description

L1, L2, L3 Three phase supply

F1, F2, F3 Main regen system supply fuses VDR1, VDR2, VDR3 Varistor network line-to-line VDR4, VDR5, VDR6 Varistor network line-to-ground

F7, F8, F9, F10

F11, F12

F13, F14

RFI Optional RFI filter

C1 Switching frequency filter capacitor L1 Switching frequency filter inductor L2 Regen inductor K1 Main supply contactor K2 Regen drive main contactor

K3 Charging contactor

OPD1 Overload protection device for C1

Aux.1 OPD NO auxiliary contact

Aux.2a K2 NO auxiliary contact

Aux.2b K2 NC auxiliary contact Aux.2c NC auxiliary for SPMC (optional)

Aux.3 K3 NC auxiliary contact Rly.1

Mt.1 Motor thermistor 1 Mt.2 Motor thermistor 2

Tc.1 Regen inductor thermistor

+DC, -DC Motoring drive power connection to Regen drive

S1 Regen drive enable S2 Motoring drive e nable S3 Motoring drive reset S4 Motoring drive run forward S5 Motoring drive run reverse S6 Regen drive reset input (Pr 8.24 = Pr 10.33)

Vsupply System control supply

DC bus fusing to motoring drive DC bus fusing to Regen drive SPMC DC fuse protection

Optional isolation for enable between Regen and motoring drive(s)

multiple motoring regen solution. For the multiple motoring system an external charging circuit is required due to the additional capacitance from the multiple motoring drives. The external charging circuit is interlocked with the Regen drive enable to prevent operation with this circuit still connected.

In this example, the external charging circuit consists of a Unidrive SPMC module. Refer to section 3.5 Unidrive SPMC half controlled thyristor rectifier on page 19 for further details of the Unidrive SPMC.

NOTE

For the multiple motoring drive solution, the Regen drive and associated Unidrive SPMC must be sized to the total power requirements of all motoring drives.

NOTE

The regen inductor duty is very arduous and therefore selection is critical. As a result only regen inductors specified in this guide should be used.

NOTE

Fusing F4, F5, F6 are only required where fusing F1, F2, F3 exceed these. For example in a multiple regen drive system, where F1, F2, F3 equal total system current rating.

NOTE

The SPMC uses the regen inductor as line reactors. The SPMC may be powered from the incoming supply using a standard line reactor if required.

34 Unidrive SP Regen Installation Guide

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Safety

Information

-DC

+DC

T.2 4

T.3 0

Introduction

information

UVW

Connections

Motor

Product

Motoring drive

System

design

Connections

NOT USED

L1 L2 L3 PE

AC Supply

Mechanical installation

Electrical

installation

Getting

started

Optimisation Parameters

UVW

Connections

Motor

Motoring drive

Technical

data

NOT USED

Connections

AC Supply

Component

sizing

L1 L2 L3 PE

Diagnostics

Mt.1

NOTE

DC bus fusing is required for all motoring drives in a single Regen,

2 3 4 5 6 7 8 9 10 11 41 42

0V common

Motor thermistor

Drive healthy

Connections

drive DC

Drive reset

Run forward

Run reverse

0V common

Drive enable

-DC +DC

Motoring

22 23 24 25 26 27 28 29 30 31

S3 S4

multiple drive system in both the +DC and -DC.

NOTE

VDR4, VDR5 and VDR6 when operating with a 690Vac supply should consist of two varistors each in series as detailed in Table 3-24 on page 28.

See Chapter 10 Technical data on page 183 for fuse rating information.

Unidrive SPMC

For a regen system, the SPMC can be used to charge the common DC bus when the power is first applied, however this will once the regen system is powered up no longer be required.

The Unidrive SPMC must be supplied with 24Vdc to feed both the fans and control circuits. This 24Vdc can also be used as a means of starting and stopping the SPMC rectifier as the SPMC will only fire its thyristors when the 24Vdc is present.

Fitting a 5A relay interlocked (or a normally closed auxiliary contact) to the Regen drives main contactor to switch the 24V supply will allow the SPMC to charge the common DC bus then be disabled (optional).

The total amount of capacitance on the common DC bus that the SPMC can drive is limited due to the inrush current (produced during power up and during brownouts).

See the following Table for the capacitance limit.

Unidrive SP drive DC bus capacitance levels are available in Table 111 on page 203.

Mt.2

2 3 4 5 6 7 8 9 10 11 41 42

0V common

Motor thermistor

Drive healthy

Connections

drive DC

+24V output+24V output

Drive reset

Run forward

Run reverse

0V common

Drive enable

-DC +DC

Motoring

22 23 24 25 26 27 28 29 30 31

F10

S3 S4

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Optimisation Parameters

4.2.3 Single Regen, multiple motoring system using an external charging resistor

Figure 4-3 Power connections: Single Regen, multiple motoring system

Technical

data

Vsupply

Aux.2b

Component

sizing

Diagnostics

L1 L2 L3

RFI

F1 F2 F3

VDR4

OPD1

Charging branch circuit

VDR1

VDR2

VDR6

VDR5

Aux.1

Rs.1

Aux.3 OPD2

VDR3

-DC

+DC

L1 L2 L3 PE

AC Supply

Connections

NOT USED

-DC +DC

Motoring drive DC

Connections

Aux.3

Aux.2a

22 23 24 25 26 27 28 29 30 31

+24 output

En ble motor drive

Reset input

Drive healthy

Contactor closed

0 common

Aux.1

Drive enable

Rly.1

optional

T.24

T.30

Regen drive

AC Supply

Connections

UVW

0V common

2 3 4 5 6 7 8 9 10 11 41 42

Tc.1

thermistor

Regen inductor

control

Contactor

Vsupply

Aux.2a

Aux.2b

Table 4-3 Key to Figure 4-3 Figure 4-3 shows both the power and control connections for the

Key Description

L1, L2, L3 Three phase supply

F1, F2, F3 Main regen system supply fuses VDR1, VDR2, VDR3 Varistor network line-to-line VDR4, VDR5, VDR6 Varistor network line-to-ground

F4, F5, F6, F7

F8, F9

RFI Optional RFI filter

C1 Switching frequency filter capacitor

L1 Switching frequency filter inductor

L2 Regen inductor K1 Main supply contactor K2 Regen drive main contactor K3 Charging contactor

OPD1 Overload protection device for C1 OPD2 Overload protection device for Rs.1

Aux.1 OPD1 NO auxiliary contact

Aux.2a K2 NO auxiliary contact

Aux.2b K2 NC auxiliary contact

Aux.3 K3 NC auxiliary contact

Rly.1

Mt.1 Motor thermistor 1 Mt.2 Motor thermistor 2

Tc.1 Regen inductor thermistor

Rs.1 Charging resistor

+DC, -DC Motoring drive power connection to Regen drive

S1 Regen drive enable

S2 Motoring drive enable

S3 Motoring drive reset

S4 Motoring drive run forward

S5 Motoring drive run reverse

S6 Regen drive reset input (Pr 8.24 = Pr 10.33)

Vsupply System control suply

DC bus fusing to motoring drive DC Bus fusing to regen drive

Optional isolation for enable between Regen and motoring drive(s)

multiple motoring regen solution. For this multiple motoring system solution an external charging circuit is required due to the additional capacitance from the multiple motoring drives. The external charging circuit is interlocked with the Regen drive enable to prevent operation with this circuit still connected.

For sizing of the external charging circuit required for the multiple motoring drive system, refer to Chapter 11 Component sizing on page 203. For details on charging resistors and protection refer to section 10.4.2 Softstart resistor - type TG series on page 197.

NOTE

For the multiple motoring drive solution, the Regen drive and associated external components must be sized to the total power requirements of all motoring drives.

NOTE

The regen inductor duty is very arduous and therefore selection is critical. As a result only regen inductors specified in this guide should be used.

36 Unidrive SP Regen Installation Guide

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Information

-DC

+DC

T.2 4

T.3 0

Introduction

information

UVW

Connections

Product

Motor

System

design

Motoring drive

NOT USED

Connections

L1 L2 L3 PE

AC Supply

Mechanical installation

Electrical

installation

Getting

started

Optimisation Parameters

UVW

Connections

Motor

Motoring drive

Technical

data

Connections

NOT USED

AC Supply

Component

L1 L2 L3 PE

sizing

Diagnostics

Mt.1

NOTE

DC bus fusing is required for all motoring drives in a single Regen,

2 3 4 5 6 7 8 9 10 11 41 42

0V common

Motor thermistor

Drive healthy

Connections

drive DC

+24V output

Drive reset

Run forward

Run reverse

0V common

Drive enable

-DC +DC

Motoring

22 23 24 25 2 6 27 28 29 30 31

S3 S4

multiple motoring drive system in both the +DC and -DC.

NOTE

VDR4, VDR5 and VDR6 when operating with a 690Vac supply should consist of two varistors each in series as detailed in Table 3-24 on page 28.

See Chapter 10 Technical data on page 183 for fuse rating information.

Mt.2

2 3 4 5 6 7 8 9 10 11 41 42

0V common

Motor thermistor

Drive healthy

Connections

drive DC

+24V output

Drive reset

Run forward

Run reverse

0V common

Drive enable

-DC +DC

Motoring

22 23 24 25 2 6 27 28 29 30 31

S3 S4

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Electrical

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Getting started

4.2.4 Multiple Regen, multiple motoring using Unidrive SPMC

Figure 4-4 Power connections: Multiple Regen, multiple motoring system

VDR3

VDR1

VDR2

VDR6

L1 L2 L3

F1 F2 F3

VDR4

VDR5

L1 L2 L3

RFI

Aux.3

OPD1

F10 F11 F12

L1 L2 L3

Unidrive

SPMC

+DC

-DC

L1 L2 L3 PE

AC Supply

Connections not used

Regen drive 1 master

AC Supply

Connections

UVW

OPD2

Aux.1

Aux.2c

0V common

F13

F14

2a 2b 2c Aux

Aux.4c

+24Vdc external supply

F16

F15

-DC +DC

Motoring drive DC

Connections

2 3 4 5 6 7 8 9 10 11 41 42

Optimisation Parameters

Aux.3

Aux.2a

Aux.4a

22 23 24 25 26 27 28 29 30 31

0V common

+24 output

Enable motor drive

+10V user output

Contactor closed

Regen inductor

Drive healthy

thermistor

Reset input

Vsupply

Technical

data

0 common

control

Contactor

Component

Aux.2

Aux.1

Drive enable

sizing

Rly.1

optional

Diagnostics

-DC

+DC

T.24 T.30

Vsupply

Aux.2b

Aux.4b

Aux.2

Tc.1

L1 L2 L3 PE

AC Supply

Connections not used

Regen drive 2 Slave

AC Supply

Connections

UVW

4a 4b 4c Aux

F18

F17

-DC +DC

Motoring drive DC

Connections

22 23 24 25 26 27 28 29 30 31

2 3 4 5 6 7 8 9 10 11 41 42

Control cable to regen master

Control cable to additional regen slave

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-DC

+DC

T.24

T.30

Introduction

Product

information

System

design

Mechanical installation

Electrical

installation

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

Connections

NOT USED

Connections

drive DC

+24V output

Drive reset

Run forward

Run reverse

0V common

Drive enable

AC Supply

Motoring

L1 L2 L3 PE

-DC +DC

22 23 24 25 26 27 28 29 30 31

UVW

Connections

Motor

Motoring drive

UVW

Mt.2

2 3 4 5 6 7 8 9 10 11 41 42

0V common

Motor thermistor

Drive healthy

F19

F20

S3 S4

Connections

NOT USED

Connections

drive DC

+24V output

Drive reset

Run forward

Run reverse

0V common

Drive enable

AC Supply

Motoring

UVW

Mt.1

UVW

Connections

Motor

Motoring drive

2 3 4 5 6 7 8 9 10 11 41 42

0V common

Motor thermistor

Drive healthy

Table 4-4 Key to Figure 4-4

Key Description Key Description

L1, L2, L3 Three phase supply Aux.1 OPD1 NO auxiliary contact

F1, F2, F3 Main regen system supply AC fuses Aux.2 OPD2 NO auxiliary contact

F4, F5, F6 Regen drive 1 AC fuses Aux.2a K2 NO auxiliary contact regen 1

F7, F8, F9 Regen drive 2 AC fuses Aux.2b K2 NC auxiliary contact regen 1

F10, F11, F12 SPMC AC fusing Aux.2c K2 NC auxiliary contact regen 1

F13, F14 DC Bus fusing to SPMC Aux.3 K3 NC auxiliary contact

F15, F16, F17, F18 DC Bus fusing to regen drives Aux.4a K4 NO auxiliary contact regen 2

F19, F20, F21, F22 DC Bus fusing to motoring drive Aux.4b K4 NC auxiliary contact regen 2

VDR1, 2, 3 Varistor network line-to-line Aux.4c K4 NC auxiliary contact regen 2

VDR4, 5, 6 Varistor network line-to-ground

RFI Optional RFI filter

Rly.1

Optional isolation for enable between Regen and motoring drive(s)

L1 Switching frequency filter inductor Mt.1 Motor thermistor 1

L2 Regen inductor (regen 1) Mt.2 Motor thermistor 2

L3 Regen inductor (regen 2) Tc.1 Regen inductor thermistor

C1 Switching frequency filter capacitor (regen 1) Tc.2 Regen inductor thermistor

C2 Switching frequency filter capacitor (regen 2) +DC, -DC Motoring drive power connection to Regen drive

K1 Main supply contactor S1 Regen drive enable

K2 Regen drive 1 main contactor S2 Motoring drive enable

K3 Charging contactor S3 Motoring drive reset

K4 Regen drive 2 main contactor S4 Motoring drive run forward

OPD1 Overload protection device for C1 S5 Motoring drive run reverse

OPD2 Overload protection device for C2 S6 Regen drive reset (user programmed)

Vsupply System control supply

L1 L2 L3 PE

-DC +DC

22 23 24 25 26 27 28 29 30 31

F21

F22

S3 S4

Unidr ive SP Re gen Inst allatio n Guide 39 Issue Number: 2 www.controltechniques.com

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Safety

Information

NOTE

For the multiple motoring drive solution, the Regen drive and associated

Introduction

Product

information

System

design

Mechanical

installation

Electrical

installation

external components must be sized to the total power requirements of all motoring drives.

NOTE

The regen inductor duty is very arduous and therefore selection is critical. As a result only regen inductors specified in this guide should be used.

NOTE

VDR4, VDR5 and VDR6 when operating with a 690Vac supply should consist of two varistors each in series as detailed in Table 3-24 on page 28.

4.2.5 Regen and motoring drive ratings

NOTE

The Regen drive’s current limits are detailed in section 3.3 Ratings on page 13.

In general the Regen drive must be rated at a power greater than, or equal to, the maximum braking power.

Example:

• Two 30kW motoring drives are each driving 30kW motors. The load

If each motor supplies between 20 and 30kW motoring, and the braking power varies from 0 to 30kW, the maximum total braking power is 30 20 = 10kW, which is what the Regen drive should be rated for.

In drive configurations where the motoring drive power rating is several times the expected braking power, it is necessary to consider the peak braking power returned from the load.

Example:

• The motoring drive is a 75kW Unidrive SP. Motoring power is 75kW.

From these figures, it may appear that a 22kW Regen drive will provide sufficient braking power. However, dynamically the peak braking power could be much greater. If the 75kW drive current limits are set at 150% for motoring and braking (default settings), the peak brake power could be:

This is much greater than the 22kW Regen drive is able to return to the supply, hence a larger drive is required.

NOTE

If the Regen drive is not rated for the required braking power, then the drives will trip on DC bus over-voltage.

is such that only one drive is braking at a time.

Steady state braking power is 20kW.

√3 × 156A × 400V × 150% = 162kW

4.3 Non standard applications

4.3.1 Omitting the switching frequency filter

If the supply to the Regen drive is shared with other equipment, then it is generally recommended that a switching frequency filter should be incorporated in order to avoid the risk of interference or damage to the other equipment. However some saving in cost and space is possible by omitting the filter if the supply impedance is very low compared to that of the drive, i.e. if the drive current rating is much less than that of the supply where it is shared with other equipment.

4.3.2 Supply assessment

The following guidelines should be used when assessing whether or not a switching frequency filter is required.

Symbols used are:

Nominal drive 100% current rating.

Drive

Short circuit current of supply at point of coupling with other

equipment.

Rated current of supply.

Supply

Getting started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

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

Drive

140

If the short-circuit current is not known, then a reasonable estimate can be made if it is assumed that the fault current of the supply is 20 times the rated current. This is very commonly the case where the supply is derived through a distribution transformer from a higher voltage supply with a high fault level.

Then:

Drive

Supply

Note that the short-circuit current data used must be realistic, it must not be the maximum likely value which is sometimes used when selecting the interrupting capacity of switchgear and protection devices.

This second relation is helpful if the short-circuit current of the supply is not known, but must be used with care. It is reliable where the Regen drive is supplied through its own cable run from a point close to the distribution transformer terminals. If the Regen drive shares a long cable run with other equipment, then the effect of the cable impedance on the fault level must be taken into account if a risk of disturbance to the other equipment is to be avoided.

This procedure will normally be applied when assessing a non-dedicated low-voltage supply. It may also be applied to the medium/high voltage supply where the low-voltage supply is dedicated to the drive. In that case the currents used must be referred to the high voltage side of the transformer. If the supply to the regen system has an unusually high impedance, for example because it derives from a generator whose rating is not much greater than that of the drive, then a more complex filter might be required to ensure stability of the current control loops. Please contact the supplier of the drive if it is to be used with a generator whose rating is less than twice that of the drive.

4.4 Cable length restrictions

There are 3 significant cable lengths which must be taken into account when designing a regen system. Refer to Figure 4-5 on page 41.

4.4.1 AC supply connection

A is the AC cable length between the regen inductor and the Regen drives terminals.

In general, no special precautions are necessary for the AC supply wiring in respect to the Regen drive. Ideally, the regen inductors should be mounted close to the drive terminals.

If it is necessary to use a cable longer than 5m, a screened cable should be used with the screen grounded.

4.4.2 DC bus connection

B is the length of the DC bus connection between the Regen and motoring drive, the + DC bus connections between the drives should be treated as a single two core cable and not two individual cable / bus bar lengths.

The DC power output from the Unidrive SP which is used as the input stage to the motoring drive(s) carries a common-mode high frequency voltage comparable with the output voltage from a standard drive. All precautions recommended for motor cables must also be applied to all cables connected to this DC circuit.

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Component

sizing

Diagnostics

4.4.3 Motor connection

C is the AC cable length between the motoring drive and the motor.

Figure 4-5 Calculating the cable length of the regen system

Cable length B

4.4.4 Cable length

The sum total length of the DC bus and motor cables (B and C in Figure 4-5) must not exceed the values shown in the table below:

Table 4-5 200V Regen system maximum cable lengths

200V Nominal AC supply voltage

DC bus connections

Model

Maximum permissible cable length

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

R e

e n

d r

v e

M o

t o

r i

n g

d r

v e

SP1201 65m (210ft)

SP1202 100m (330ft)

SP1203 130m (425ft)

SP1204

SP2201

SP2202

SP2203

200m

(660ft)

150m

(490ft)

100m

(330ft)

75m

(245ft)

50m

(165ft)

37m

(120ft)

SP3201

SP3202

SP4201

SP4202

SP4203

SP5201

C a

b l

e l

e n g t

h A

Regen inductor Motor

C a

b l

e l

e n g t

h C

SP5202

SPMD1201

SPMD1202

SPMD1203

SPMD1204

Table 4-6 400V Regen system maximum cable lengths

65m

(210ft)

250m

(820ft)

250m

(820ft)

65m

(210ft)

185m

(607ft)

185m

(607ft)

65m

(210ft)

125m

(410ft)

125m

(410ft)

65m

(210ft)

90m

(295ft)

400V Nominal AC supply voltage

Model

Maximum permissible cable length

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

SP1405

SP1406

SP2401

SP2402

SP2403

SP2404

200m

(660ft)

150m

(490ft)

100m

(330ft)

75m

(245ft)

50m

(165ft)

37m

(120ft)

SP3401

SP3402

SP3403

SP4401

SP4402

SP4403

SP5401

90m

(295ft)

SP5402

SP6401

SP6402

SPMA1401

250m

(820ft)

185m

(607ft)

125m

(410ft)

SPMA1402

SPMD1401

SPMD1402

SPMD1403

SPMD1404

Unidr ive SP Re gen Inst allatio n Guide 41 Issue Number: 2 www.controltechniques.com

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Table 4-7 575V Regen system maximum cable length

575V Nominal AC supply voltage

Model

Maximum permissible cable length

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

SP3501

SP3502

SP3503

SP3504

SP3505

200m

(660ft)

150m

(490ft)

100m

(330ft)

75m

(245ft)

SP3506

SP3507

Table 4-8 690V Regen system maximum cable length

690V Nominal AC supply voltage

Model

Maximum permissible cable length

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

SP4601

SP4602

SP4603

SP4604

SP4605

90m

(295ft)

SP4606

SP5601

SP5602

SP6601

200m

(660ft)

185m

(607ft)

125m

(410ft)

SP6602

SPMA1601

SPMA1602

SPMD1601

SPMD1602

SPMD1603

SPMD1604

If the cable length in the above table is exceeded, additional components are required. Refer to section 4.6 Exceeding maximum cable length .

4.5 Cable types and lengths

Since capacitance in the cabling causes loading, ensure the cable length does not exceed the values given.

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 Regen drive

• Regen drive to motoring drive (or busbar arrangement could be used)

• Motoring drive to motor

Getting started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

Figure 4-6 Location of forced cooling

Table 4-9 200V Regen system exceeding maximum cable lengths

200V Nominal AC supply voltage

Maximum permissible cable length with forced cooling

Model

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

Forced

cooling

required

SP1201 65m (210ft)

SP1202 100m (330ft)

SP1203 130m (425ft)

SP1204

SP2201

SP2202

SP2203

200m

(660ft)

150m

(490ft)

100m

(330ft)

75m

(245ft)

(165ft)

50m

37m

(120ft)

SP3201

SP3202

SP4201

SP4202

SP4203

SP5201

SP5202

65m

(210ft)

250m

(820ft)

65m

(210ft)

185m

(607ft)

65m

(210ft)

125m

(410ft)

65m

(210ft)

90m

(295ft)

Air flow >

160m3 / hr

SPMD1201

SPMD1202

SPMD1203

250m

(820ft)

185m

(607ft)

125m

(410ft)

SPMD1204

4.6 Exceeding maximum cable length

If the total maximum length specified is exceeded, the increased circulating currents caused by the extra cable capacitance will have an effect on the other parts of the system. This will necessitate additional components to be added to the standard arrangement.

4.6.1 Regen inductor

If the maximum cable length specified is exceeded this will introduce increased heating of the regen inductor. To overcome the additional heating forced cooling should be introduced into the system as specified in the following table.

The forced cooling should be positioned as shown below to provide the specified airflow directly onto the regen inductor windings.

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Table 4-10 400V Regen system maximum cable lengths

400V Nominal AC supply voltage

Maximum permissible cable length with forced cooling

Model

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

requirements

SP1405

SP1406

SP2401

SP2402

SP2403

SP2404

200m

(660ft)

150m

(490ft)

100m

(330ft)

75m

(245ft)

(165ft)

50m

37m

(120ft)

SP3401

SP3402

SP3403

SP4401

SP4402

SP4403

SP5401

90m

(295ft)

SP5402

250m

185m

SP6401

SP6402

(820ft)

(607ft)

125m

(410ft)

SPMA1401

SPMA1402

SPMD1401

SPMD1402

SPMD1403

SPMD1404

Table 4-11 575V Regen system maximum cable length

575V Nominal AC supply voltage

Maximum permissible cable length with forced cooling

Model

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

requirements

SP3501

SP3502

SP3503

SP3504

SP3505

200m

(660ft)

150m

(490ft)

100m

(330ft)

75m

(245ft)

SP3506

SP3507

Electrical

installation

Forced cooling

Air flow

160m3 / hr

Forced cooling

Air flow

160m3 / hr

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

Table 4-12 690V Regen system maximum cable length

690V Nominal AC supply voltage

Maximum permissible cable length with forced cooling

Model

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

Forced

cooling

requirements

SP4601

SP4602

SP4603

SP4604

SP4605

90m

(295ft)

SP4606

SP5601

SP5602

SP6601

200m

(660ft)

185m

(607ft)

125m

(410ft)

Air flow

160m3 / hr

SP6602

SPMA1601

SPMA1602

SPMD1601

SPMD1602

SPMD1603

SPMD1604

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

4.6.2 High-capacitance cables

The maximum cable length is reduced from that shown if high capacitance cables are used.

Most cables have an insulating jacket between the cores and the armour or shield; these cables have a low capacitance and are recommended. Cables that do not have an insulating jacket tend to have high capacitance; if a cable of this type is used, the maximum cable length is half that quoted in the tables. (Figure 4-7 shows how to identify the two types.)

Figure 4-7 Cable construction influencing the capacitance

Normal capacitance

Shield or armour separated from the cores

High capacitance

Shield or armour close to the cores

The cable used 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).

4.6.3 EMC filter

When an EMC filter is used the capacitors to ground carry common mode current.

When the maximum cable length without additional ventilation specified is exceeded, extra circulating currents can result in heating and saturation of the EMC filter. To prevent this, some capacitance line to ground should be provided as an additional path for this current, as shown in Figure 4-8. See also section 4.4.3 Motor connection on page 41.

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Safety

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Introduction

Figure 4-8 EMC filter

EMC

filter

Product

information

witching

frequency

filter inductor

System

design

Mechanical

installation

Regen

inductor

Electrical

installation

Getting started

The I

Optimisation Parameters

is the total current line to ground, therefore each capacitor will

RMS

have to carry 4.5A.

Ground leakage current

The value of capacitance required means that the ground leakage current exceeds the usual safety limit of 3.5mA. The

WARNING

user should be aware of the high leakage current. A permanent fixed ground connection must be provided to the system.

Technical

data

Component

sizing

Diagnostics

Line to ground capacitance

NOTE

If the cable length exceeds the maximum cable length with additional

Switching frequency

filter ca

acitor

cooling, Control Techniques Technical Support must be consulted.

Whether or not an EMC filter is required is dependent upon the user requirements and the AC supply network. For further details refer to section 6.4 EMC (Electromagnetic compatibility) on page 77.

When using an EMC filter, a switching frequency filter must also be used to protect the EMC filter from overload.

CAUTION

4.6.4 Line to ground capacitors for multi-drive

systems

Selection of line to ground capacitors for regen systems with long cables.

In order to select the appropriate capacitors, the rms value of the current line to ground, the AC supply voltage and minimum capacitance values are required.

A minimum capacitance value of 1µF per phase should be used with the final capacitance value being determined by the level of current line to ground. In practice, to carry the required level of current the capacitor will generally have a higher capacitive value. The current rating of the capacitors should be at a high frequency such as 100kHz at the relevant supply voltage. Polypropylene type capacitors (x type) are the most suitable because of their low loss at high frequency.

The rms value of the current can be estimated from the following formula:

WARNING

Discharge time

Resistors must be fitted in parallel with the capacitors to ensure that they discharge when the supply is removed. The resistor values should be chosen so that the discharge time is no longer than for the drive itself. Typically values of about 5MΩ are suitable, and are high enough not to cause the system to fail a simple insulation test.

2.8 104–KV

RMS

×=

×× Σlf

Where:

k is 1 for simple rectifier-input systems, √2 for regen systems

is DC bus voltage

∑lf

is the sum of the products of motor cable lengths and switching

frequencies of all drives in the system, including in the case of regenerative systems the Regen drive with the total DC cable length

l is total cable length in m

is switching frequency in kHz

If all drives operate at 3kHz, the expression can be simplified to:

= 4.85 x 10

RMS

Example

A regen system operating with a supply of 400Vac giving a DC bus

-4

x K x V

x √l

voltage of 620V at 3kHz switching frequency and a cable length of 1km (motors + DC) has an I

= 4.85 x 10

RMS

= 4.85 x 10

RMS

= 13.4A

RMS

of:

RMS

-4

x K x V

-4

x √2 x 620 x √1.000

x √l

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Electrical

installation

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Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

5 Mechanical Installation

This chapter describes the installation of the Regen drive components. Key features of this chapter include:

• Regen component dimensions

• Enclosure sizing and layout

• Enclosure ventilation

• Cubicle design with high ambient temperatures

Refer to the Mechanical Installation sections in both the Unidrive SP and Unidrive SPM User Guides for drive mechanical information.

5.1 Safety information

Follow the instructions The mechanical and electrical installation instructions must be adhered to. Any questions or doubt should be referred to

WARNING

5.2 Planning the installation

The following considerations must be made when planning the installation:

5.2.1 Access

Access must be restricted to authorised 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 the Unidrive SP and Unidrive SPM User Guides.

5.2.2 Environmental protection

The drive must be protected from:

• moisture, including dripping water or spraying water and

• contamination with electrically conductive material

• contamination with any form of dust which may restrict the fan, or

• temperature beyond the specified operating and storage ranges

5.2.3 Cooling

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

For further information, please refer to section 5.5.2 Enclosure sizing on page 62.

NOTE

Through hole mounting is possible for all Unidrive SP modules and the Unidrive SPMC which can reduce cubicle heating and cooling requirements. Refer to Unidrive SP User Guide and Unidrive SPM User Guide.

the supplier of the equipment. It is the responsibility of the owner or user to ensure that the installation of the drive and any external option unit, and the way in which they are operated and maintained, comply with the requirements of the Health and Safety at Work Act in the United Kingdom or applicable legislation and regulations and codes of practice in the country in which the equipment is used.

Competence of the installer The drive must be installed by professional assemblers who are familiar with the requirements for safety and EMC. The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used.

condensation. An anti-condensation heater may be required, which must be switched off when the drive is running.

impair airflow over various components

5.2.4 Electrical safety

The installation must be safe under normal and fault conditions. Electrical installation instructions are given in Chapter 6 Electrical Installation on page 65.

5.2.5 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided.

5.2.6 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. Refer to section 6.4 EMC (Electromagnetic compatibility) on page 77.

5.2.7 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.

Isolation device The AC supply must be disconnected from the drive using an approved isolation device before any cover is removed from

WARNING

the drive or before any servicing work is performed.

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

Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions, it is possible that the capacitors may fail to discharge, or be prevented from being discharged by a voltage applied to the output terminals. If the drive has failed in a manner that causes the display to go blank immediately, it is possible the capacitors will not be discharged. In this case, consult Control Techniques or their authorised distributor.

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Safety

Information

Introduction

5.3 Regen component dimensions

The dimensions listed are for the following items:

• Regen inductor

• Switching frequency filter inductor

• Switching frequency filter capacitor

•Varistors

• External charging resistor (used in multiple motoring configurations)

Product

information

System

design

Mechanical installation

Electrical

installation

Getting started

Figure 5-1 Top view of fixing type A

Optimisation Parameters

5.3.1 Regen inductor

The following regen inductors can produce significant losses with a normal operating temperature in the region of 170°C dependant upon the ambient temperature. Location of the

CAUTION

Table 5-1 200V Regen inductor specifications

Inductor part

Table 5-2 400V Regen inductor specifications

Inductor part

4401-0205-00 350 0.16 2169.0 500 320 570 165 320 x 260 11

regen inductor should be considered to avoid damage to heat sensitive components or create a fire risk.

number

4401-0310 9.6 3.5 71 215 180 200 10 120 x 140 9 4401-0311 11.0 2.7 72 215 180 200 11 120 x 140 9 4401-0312 15.5 2.2 116 215 180 200 12 120 x 140 9 4401-0313 22 1.6 157 215 180 200 15 120 x 140 9 4401-0314 31 1.10 193 270 180 240 17 160 x 140 9 4401-0315 42 0.81 200 270 200 240 24 160 x 160 9 4401-0316 56 0.6 264 325 220 320 32 200 x 180 11 4401-0317 68 0.5 299 325 220 320 33 200 x 180 11 4401-0318 80 0.4 298 325 220 320 39 200 x 180 11 4401-0319 105 0.32 338 370 260 360 55 240 x 220 11 4401-0320 130 0.26 394 375 280 360 65 240 x 240 11 4401-0321 156 0.22 475 395 280 360 77 240 x 240 11 4401-0322 192 0.18 526 395 280 360 97 240 x 240 11 4401-0323 250 0.14 610 430 300 410 110 280 x 260 11 4401-0324 312 0.11 776 430 300 410 120 280 x 260 11 4401-0325 350 0.10 863 490 320 480 130 320 x 260 11

number

4401-0001 9.5 6.32 125.0 200 180 215 12 120 x 140 9

4401-0002 12 5.00 146.0 200 180 215 14 120 x 140 9

4401-0003 16 3.75 175.0 240 180 270 17 160 x 140 9

4401-0004 25 2.40 210.0 240 180 270 24 160 x 160 9

4401-0005 34 1.76 285.0 320 220 325 32 200 x 180 11

4401-0006 40 1.50 310.0 320 220 325 33 200 x 180 11

4401-0007 46 1.30 320.0 320 220 325 39 200 x 180 11

4401-0008 60 1.00 345.0 360 260 370 55 240 x 220 11

4401-0009 70 0.78 415.0 360 260 370 65 240 x 240 11

4401-0010 96 0.63 515.0 360 260 370 75 240 x 240 11

4401-0011 124 0.48 585.0 360 260 370 95 240 x 240 11

4401-0012 156 0.38 645.0 410 300 430 110 280 x 260 11

4401-0013 180 0.33 775.0 410 300 430 120 280 x 260 11

4401-0014 200 0.30 845.0 480 320 490 130 320 x 260 11

4401-0015 300 0.20 1760.0 480 320 490 140 320 x 240 11

Amps mH

LossesWL

mmDmmHmm

LossesWL

mmDmmHmm

WeightkgFixing centres (x * y)

Technical

data

Fixing

Component

sizing

Fixing

Diagnostics

type

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Electrical

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Getting

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Optimisation Parameters

Technical

Table 5-3 575V / 690V Regen inductor specifications

Inductor part

number

Amps mH

LossesWL

mmDmmHmm

WeightkgFixing centres (x * y)mmFixingmmFixing

4401-0210 19 5.3 268 325 220 320 32 200 x 180 11

4401-0211 22 4.6 288 325 220 320 33 200 x 180 11

4401-0212 27 3.8 322 325 220 320 39 200 x 180 11

4401-0213 36 2.8 348 370 260 360 55 240 x 220 11

4401-0214 43 2.4 398 375 280 360 65 240 x 240 11

4401-0215 52 1.9 456 395 280 360 77 240 x 240 11

4401-0216 63 1.6 503 395 280 360 97 240 x 240 11

4401-0217 85 1.20 605 430 300 410 110 280 x 260 11

4401-0218 100 1.00 950 500 350 480 170 320 x 260 11

4401-0219 125 0.80 880 490 320 480 130 320 x 260 11

4401-0220 144 0.70 1022 500 320 480 140 320 x 260 11

4401-0221 168 0.60 1656 555 300 480 165 320 x 240 11

4401-0222 192 0.53 1350 600 350 480 180 320 x 260 11

Figure 5-2 Regen inductor type 1 dimensions

data

Component

sizing

type

Diagnostics

Figure 5-3 Regen inductor type 2 dimensions

A1 B1 C1

A2 B2 C2

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Technical

Figure 5-4 Regen inductor type 3 dimensions

A1 B1 C1

A2 B2 C2

5.3.2 Switching frequency filter inductor

Table 5-4 200V SFF inductor specifications

Inductor part

number

Amps mH

LossesWL

mmDmmHmm

4401-1310 9.6 0.88 10 150 90 150 4 120 x 47 8 x 18

4401-1311 11.0 1.50 18 150 90 150 4 120 x 47 8 x 18

4401-1312 15.5 1.10 26 150 90 150 4 120 x 47 8 x 18

4401-1313 22 0.70 33 150 90 150 4 120 x 47 8 x 18

4401-1314 31 0.50 37 190 100 180 6 130 x 54 8 x 20

4401-1315 42 0.40 38 190 120 180 10 130 x 74 8 x 20

4401-1316 56 0.30 48 190 160 180 12 130 x 184 8 x 20

4401-1317 68 0.25 58 190 160 180 12 130 x 184 8 x 20

4401-1318 80 0.20 60 190 160 180 13 130 x 184 8 x 20

4401-1319 105 0.16 78 255 160 240 16 200 x 180 10 x 20

4401-1320 130 0.13 86 255 170 240 20 200 x 90 10 x 20

4401-1321 156 0.11 92 255 180 240 22 200 x 100 10 x 20

4401-1322 192 0.088 97 255 190 240 25 200 x 100 10 x 20

4401-1323 250 0.068 119 300 180 300 37 204 x 113 10 x 20

4401-1324 312 0.055 170 300 180 300 37 204 x 113 10 x 20

4401-1325 350 0.048 162 300 190 300 49 204 x 123 10 x 20

WeightkgFixing centres (x * y)mmFixing

data

Component

sizing

Fixing

type

Diagnostics

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Safety

Information

Table 5-5 400V SFF inductor specifications

Inductor part

number

4401-0162 9.5 3.160 28 150 90 150 4 120 x 47 8 x 18

4401-0163 12 2.500 35 150 90 150 4 120 x 47 8 x 18

4401-0164 16 1.875 37 180 100 190 6 120 x 54 8 x 20

4401-0165 25 1.200 40 180 150 190 10 120 x 74 8 x 20

4401-0166 34 0.880 52 180 160 190 12 120 x 84 8 x 20

4401-0167 40 0.750 60 180 160 190 12 120 x 84 8 x 20

4401-0168 46 0.650 60 180 160 190 13 120 x 84 8 x 20

4401-0169 60 0.500 80 240 160 255 16 200 x 80 10 x 20

4401-0170 70 0.390 90 240 170 255 20 200 x 90 10 x 20

4401-0171 96 0.315 100 240 180 255 22 200 x 100 10 x 20

4401-0172 124 0.240 110 240 190 255 25 200 x 100 10 x 20

4401-0173 156 0.190 130 300 180 300 37 204 x 113 10 x 20

4401-0174 180 0.165 170 300 180 300 37 204 x 113 10 x 20

4401-0175 220 0.135 180 300 190 300 49 204 x 123 10 x 20

4401-0176 300 0.100 220 300 200 300 50 204 x 130 10 x 20

4401-1205 350 0.08 300 325 220 325 55 204 x 160 4 x 10

4401-0176 600 0.050 400 410 300 430 110 280 x 260 11

4401-0176 1200 0.025 700 480 320 560 170 320 x 240 11

Introduction

Product

information

Amps mH

System

design

LossesWL

Mechanical installation

mmDmmHmm

Electrical

installation

Getting

started

WeightkgFixing centres (x * y)mmFixing

Optimisation Parameters

Technical

data

Component

sizing

Fixing

type

A4401-0176 900 0.034 530 480 320 500 140 320 x 240 11

Diagnostics

Table 5-6 575V / 690V SFF inductor specifications

LossesWL

mmDmmHmm

Inductor part

number

4401-1211 22 1.40 36 190 120 180 10 130 x 74 8 x 20

4401-1213 36 1.40 81 255 160 240 16 200 x 80 10 x 20

4401-1214 43 1.20 86 255 170 240 20 200 x 90 10 x 20

4401-1215 52 1.00 93 255 180 240 22 200 x 100 10 x 20

4401-1216

4401-1217 85 0.60 122 300 180 300 37 204 x 113 10 x 20

4401-1218 100 0.50 190 300 180 300 37 204 x 120 4 x 10

4401-1219 125 0.40 172 300 190 300 49 204 x 123 10 x 20

4401-1220 144 0.35 177 300 200 300 50 204 x 130 10 x 20

4401-1221 168 0.30 207 300 200 300 50 204 x 130 10 x 20

4401-1222 192 0.26 220 325 220 325 55 204 x 160 4 x 10

4401-1223 192 0.21 189 300 200 300 50 204 x 130 10 x 20

Figure 5-5 Top view of fixing type A Figure 5-6 Top view of fixing type B

Amps mH

63 0.80 95 255 190 240 25 200 x 100 10 x 20

WeightkgFixing centres (x * y)mmFixing

Fixing

type

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Electrical

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Figure 5-7 Switching frequency filter inductor type 1 dimensions

A1 A2 B1 B2 C1 C2

Getting started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

Figure 5-8 Switching frequency filter inductor type 2 dimensions

Figure 5-9 Switching frequency filter inductor type 3 dimensions

A1 B1

A2 B2 C2

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Electrical

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Figure 5-10 Switching frequency filter inductor type 4 dimensions

560(REF)

5.3.3 Output sharing choke (for motoring drives only)

Table 5-7 400 / 600V output sharing choke ratings

Model

CurrentAInductanceµHWidth (W)mmDepth (D)mmHeight (H)mmCable length

(CLa) mm

OTL401 221 40.1 240 220 210

OTL402 267 34 242 220 205 20 4401-0198-00

OTL403 313 28.5 242 220 205 25 4401-0199-00

OTL404 378 23.9 242 220 205 25 4401-0200-00

OTL601 135 103.9 242 170 203 20 4401-0201-00

71.5

OTL602 156 81.8 242 170 203 20 4401-0202-00

OTL603 181 70.1 242 200 203 20 4401-0203-00

OTL604 207 59.2 242 200 203 20 4401-0204-00

Weight

Part No.

20 4401-0197-00

Technical

data

Component

sizing

Diagnostics

Figure 5-11 OTLx0x output sharing choke

Centre tapped output sharing chokes

The OTLX1X centre tapped output sharing chokes can only be used when two Unidrive SPM drives are paralleled together. For all other combinations the OTLX0X output

CAUTION

sharing choke must be used.

CL(a)

M10

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Technical

data

Component

sizing

Table 5-8 400 / 600V centre tapped output sharing choke ratings

Model

CurrentAInductanceµHWidth (W)mmDepth (D)mmHeight (H)

OTL411 389.5 42.8 300 150 160

Cable length mm

CLa CLb CLc

Weight

Part No.

8 4401-0188-00

OTL412 470.3 36.7 300 150 160 8 4401-0189-00

OTL413 551 31.1 300 150 160 8 4401-0192-00

OTL414 665 26.6 300 150 160 9 4401-0186-00

OTL611 237.5 110.4 300 150 160 8 4401-0193-00

335 335 265

OTL612 273.6 88.4 300 150 160 8 4401-0194-00

OTL613 319.2 76.7 300 150 160 8 4401-0195-00

OTL614 364.8 65.7 300 150 160 8 4401-0196-00

Figure 5-12 OTLx1x centre tapped dual output sharing choke

M10

U, V, W (b)

Diagnostics

Ua Va

U motor V motor

W motor

CL(b)

CL(a)

U, V, W motor

CL(c)

M10

U, V, W (a)

M10

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odule

Information

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Product

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System

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Mechanical installation

Electrical

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Optimisation Parameters

Technical

5.3.4 Switching frequency filter capacitors

Table 5-9 Switching frequency filter capacitors

3-phase capacitor

Pt No.

(uF)

∅ x L (mm)

Discharge resistor

(kΩ)

Weight

(kg)

Mounting

1664-1074 3 x 7.0 53 x 114 390 0.3 M8 Stud 4 PHIcap

1664-2174 3 x 16.6 63.5 x 129 390 0.4 M12 Stud 10 PHIcap

1610-7804 3 x 8.0 75 x 210 390 0.5 M12 Stud 15 Polecap

1668-7833 3 x 8.3 116.2 x 204 390 1.2 M12 Stud 10 Windcap

1666-8113 3 x 11.2 116.2 x 204 390 1.3 M12 Stud 10 Windcap

1668-8163 3 x 16.6 116.2 x 204 390 1.2 M12 Stud 10 Windcap

1666-8223 3 x 22.5 116.2 x 204 390 1.4 M12 Stud 10 Windcap

1665-8324 3 x 32 116.2 x 204 390 1.1 M12 Stud 10 Phasecap

1665-8394 3 x 39 116.2 x 204 390 1.2 M12 Stud 10 Phasecap

1665-8484 3 x 48 116.2 x 204 390 1.3 M12 Stud 10 Phasecap

1664-2644 3 x 64 116.2 x 204 390 1.2 M12 Stud 10 Phasecap

1665-8774 3 x 77 116.2 x 204 390 1.8 M12 Stud 10 Phasecap

Max torque

(Nm)

data

Component

Typ e N o

sizing

Diagnostics

Discharge resistors

PoleCap capacitors have a pre-mounted ceramic discharge module, all other capacitor types (Windcap, Phasecap or PHI capacitors) can have either three preformed discharge resistors or a pre-mounted ceramic discharge module supplied with capacitors.

Figure 5-13 Discharge resistor arrangement

Discharge Resistor

Arrangements

Three preformed

resistors

Ceramic discharge

Cautions and warnings

In case of dents of more than 2 mm depth or any other mechanical damage, capacitors must not be used at all.

To ensure the full functionality of the overpressure disconnector, elastic elements must not be hindered and a minimum space of 5 cm has to be kept above each capacitor.

Protection should be provided to prevent over current and short circuit.

Discharging

Capacitors must be discharged to a maximum of 10% of rated voltage before they are switched in again.

The capacitor must be discharged to 75 V or less within 3 minutes.

There must be not any switch, fuse or any other disconnecting device in the circuit between the power capacitor and the discharging device.

Over current and short circuit protection

Use HRC fuses or MCCBs for short circuit protection. Short circuit protection and connecting cables should be selected so that 1.5 times the rated capacitor current can be permanently handled.

HRC fuses do not protect a capacitor against overload - they are only for short circuit protection.

The HRC fuse rating should be 1.6 to 1.8 times rated capacitor current.

Figure 5-14 3-phase PHIcap dimensions

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Figure 5-15 3-phase Polecap dimensions Figure 5-16 3-phase Windcap / Phasecap dimensions

Terminal cover (uv resistant)

Label

Torqu e = N m

81.2 0.3mm

Cable gland

210mm max.

16 +1mm

Mxx

∅

16.0 0.1mm

Mxx

19.6 0.5mm

∅

Marking

Tor q ue T=Nm

Impregnating Hole

To rq ue T=1.2Nm

Diagnostics

18mm

16.8 0.5mm

Ø22mm

SW 17mm

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Diagnostics

5.4 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 5-10 Drive EMC filter details (size 1 to 6)

Drive

CT part no. Weight CT part no. Weight

SP1201 to SP1204

4200-6118

4200-6119 4200-6120

SP2201 to SP2203 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)

SP1401 to SP1404 4200-6118

SP1405 to SP1406 4200-6119 4200-6120

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

SP3401 to SP3403 4200-6305 3.5 kg (7.7 lb) 4200-6306 5.1 kg (11.2 lb)

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

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

SP6401 to SP6402 4200-6603 5.25 kg (11.6 lb) 4200-6601 10.0 kg (22.0 lb)

SP3501 to SP3507 4200-6309 3.5 kg (7.7 lb) 4200-6308 5.1 kg (11.2 lb)

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

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

SP6601 to SP6602 4200-6604 5.25 kg (11.6 lb) 4200-6602 8.6 kg (18.9 Ib)

Schaffner Epcos

1.4 kg (3.1 lb)

4200-6121

2.1 kg (4.6 lb)

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 5-11 Drive EMC filter details

Drive

SPMD1201 to

SPMD1204

SPMA1401 to

SPMA1402

SPMD1401 to

SPMD1404

SPMD1601 to

SPMD1602

SPMD1601 to

SPMD1604

Schaffner Epcos

CT part no. Weight CT part no. Weight

4200-6315

4200-6603

4200-6315

4200-6604

4200-6316

5.5 kg

(12.1 Ib)

5.25 kg

(11.6 lb)

5.5 kg

(12.1 Ib)

5.25 kg

(11.6 lb)

5.5 kg

(12.1 Ib)

4200-6313

4200-6601

4200-6313

4200-6602

4200-6314

8.6 kg

(18.9 Ib)

10.0 kg

(22.0 Ib)

8.6 kg

(18.9 Ib)

8.6 kg

(18.9 Ib)

8.5 kg

(18.7 Ib)

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data

Component

sizing

Diagnostics

The external EMC filters for sizes 1 to 3 can be footprint or bookcase mounted, see Figure 5-17 and Figure 5-18. The external EMC filters for sizes 4 to 6 are designed to be mounted above the drive, as shown in Figure 5-19.

Mount the external EMC filter following the guidelines in section 4.11.5 Compliance with generic emission standards on page 88.

Figure 5-17 Footprint mounting the EMC filter Figure 5-18 Bookcase mounting the EMC filter

Figure 5-19 Size 4 to 6 mounting of EMC filter Figure 5-20

Mounting the external EMC filter

Mount the external EMC filter following the guidelines in section 6.12.5 Compliance with generic emission standards on page 62

Figure 5-21 Size 1 external EMC filter

L3L1 L2

Cable size:

2.5mm 14AWG

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)

∅

All filter mounting holes are suitable for M6 fasteners.

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)

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Figure 5-22 Size 2 external EMC filter

System

design

Mechanical installation

Electrical

installation

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

Cable size:

4mm 10AWG

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

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)

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Figure 5-23 Size 3 external EMC filter

System

design

Mechanical installation

Electrical

installation

Getting started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

Cable size

16mm 6AWG

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

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)

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Figure 5-24 Size 4 and 5 external EMC filter

Schaffner

Epcos

Mechanical installation

Electrical

installation

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

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

CT part no.ManufacturerABCDEFHW

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)

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Figure 5-25 Size 6 external EMC filter

System

design

Mechanical installation

Electrical

installation

Getting started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

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

CT part no.

4200-6601

4200-6602

4200-6603

4200-6604

4200-6313

4200-6314

4200-6315

4200-6316

Manufacturer

Schaffner

ABCDEFGH I JW

196 mm

(7.717 in)

139.9 mm (5.508 in)

108 mm

(4.252 in)

230 mm

(9.055 in)

In order to provide our customers with a degree of flexibility, external EMC filters have been sourced from two manufacturers: Schaffner and Epcos. The external EMC Filter ratings and dimensions information are available in the Unidrive SP User Guide.

For currents exceeding 300A up to 2500A, suitable filters are also available from both Epcos and Schaffner as detailed.

• Epcos B84143-B250-5xx (range up to 2500A)

• Schaffner FN3359-300-99 (range up to 2400A)

210 mm

(8.268 in)

2 mm

(0.079in)

38 mm

(1.496 in)

136 mm

(5.354 in)

128 mm

(5.039 in)

53.5 mm

(2.106 in)

These filters may not give strict conformity with EN6000-6-4 but in conjunction with EMC installation guidelines they will reduce emissions

to sufficiently low levels to minimise the risk of disturbance.

When a EMC filter is used, the switching frequency filter detailed must also be used. Failure to observe this may result in the EMC filter becoming ineffective and being damaged.

CAUTION

Refer to section 6.4 EMC (Electromagnetic compatibility) on page 77.

364 mm

(14.331 in)

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Component

sizing

Diagnostics

5.4.1 External charging resistor - type TG series

Figure 5-26 External charging resistor dimensions

Table 5-12 External charging resistor specifications

External charging

resistor part no.

Resistance

Diameter (A) mmLength (B)

1270-3157 150Ω 19.1 73 1270-2483 48Ω x 1 22.2 165.1

5.4.2 Varistors

Figure 5-28 Varistor dimensions

1Nom

Figure 5-27 Resistor mounting bracket dimensions

Table 5-13 Resistor mounting bracket dimensions

ABCD

24.0mm 33.5mm 21.45mm±0.2 ∅5.0

NOTE

For component selection refer to either Chapter 10 Technical data on page 183 or section 3.10 Regen components on page 25.

60 max

Coat line

max

Table 5-14 Varistor specifications

Varisto r

Drive rating

200V

(200V to 240V±10%)

400V

(380V to 480V±10%)

575V

(500V to 575V±10%)

690V

(690V±10%)

voltage rating

RMS

550 620 3 Line to line 2482-3291

680 760 3 Line to ground 2482-3211

550 620 3 Line to line 2482-3291

680 760 3 Line to ground 2482-3211

680 760 3 Line to line 2482-3211

1000 1200 3 Line to ground 2482-3218

385 550 6 2 in series line to line 2482-3262

1000 1200 3 Line to ground 2482-3218

21 max

8dia.hole

25°

Energy

rating

1.613

Quantity

per

system

Configuration CT part number

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5.5 Enclosure

5.5.1 Enclosure layout

Please observe the clearances in the diagram below for the Unidrive SP plus also take into account any clearances required for other devices / auxiliary equipment when planning the installation.

Figure 5-29 Enclosure layout

Getting started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

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

External

controller

3 phase

AC supply,

PE, contactor

isolator

B B

Regen drive

components

Regen

DC bus connections

Motoring drive

Size 1: 0mm (0in) Sizes 2 to 6: 30mm (1.181in

≥

100mm (4in)

Standard wiring practices apply

≥

Cubicle layout must take into account the addition regen components required ensuring suitable clearances are allowed. Sensitive components should not be placed above heat producing components such as the regen inductor.

5.5.2 Enclosure sizing

1. Add the dissipation figures from Chapter 10 Technical data for each drive that is to be installed in the enclosure.

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

• EMC filter

• Switching frequency filter

• Regen choke

3. 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:

-----------------------------------=

–()

intText

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

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

for the

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Example

To calculate the size of a non-ventilated enclosure for the following:

• Two SP 1405 (1 x Regen and 1 x motoring drive) 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

• Maximum ambient temperature inside the enclosure: 40°C

• Maximum ambient temperature outside the enclosure: 30°C

Dissipation of each drive: 147 W (see Chapter 12 Technical Data in the Unidrive SP User Guide)

Dissipation of external EMC filter: 9.2 W (max) (see Chapter 12 Tech n i c a l D a ta in the Unidrive SP User Guide)

Dissipation of each external regen inductor: 125 W x 1 (see section

10.4.1 Regen inductors on page 196)

Dissipation of external switching frequency filter: 28 W x 1 (see Chapter 10 Technical data on page 183)

Total dissipation: ((147 x 2) + 9.2 + 125 + 28) = 456.2 W

The enclosure is to be made from painted 2 mm (0.079 in) sheet steel

having a heat transmission coefficient of 5.5 W/m

2/o

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 cubicle (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 5-30 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 456.2 W

The minimum required heat conducting area is then:

= 8.294 m

456.2

---------------------------------=

5.5 40 30–()

(90.36 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:

2HD–

--------------------------=

HD+

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

10.72 2 2× 0.6×()–

-----------------------------------------------------=

20.6+

=3.2 m (126.02 in)

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

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:

3kP

---------------------------=

–

intText

Where:

V Air-flow in m T

Maximum expected temperature in °C outside the

ext

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:

• Two SP1406 (1 x Regen and 1 x motoring drive) models

operating at the Normal Duty rating

• Each drive to operate at 6kHz PWM switching frequency

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

• Maximum ambient temperature inside the enclosure: 40°C

• Maximum ambient temperature outside the enclosure: 30°C

Dissipation of each drive: 147 W (see Chapter 12 Technic a l D a t a in the Unidrive SP User Guide) Dissipation of external EMC filter: 9.2 W (max) (see Chapter 12 Technical Data in the Unidrive SP User Guide)

Dissipation of external regen inductor: 125 W x 1 (see section

10.4.1 Regen inductors on page 196)

Dissipation of external switching frequency filter: 28 W x 1 (see Chapter 10 Technical data on page 183)

Total dissipation: ((147 x 2) + (9.2 + 125 + 28) = 456.2 W

Insert the following values:

40°C

int

30°C

ext

k 1.3 P 456.2 W

Then:

21.3× 456.2×

---------------------------------------=

= 118.6 m

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

-------

40 30–

/hr (70.05 ft3 /min) (1 m3/ hr = 0.59 ft3/min)

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5.6 Cubicle design and drive ambient temperature

Drive derating is required for operation in high ambient temperatures (derating information is provided in the Unidrive SP User Guide).

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 10 Technical data on page 183.

rate

) which

Getting started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

CAUTION

Regen inductors can produce significant losses with a normal operating temperature in the region of 150°C dependant upon the ambient temperature. Location of the regen inductors should be considered to prevent damage to heat sensitive components or create a fire risk.

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6 Electrical Installation

Electric shock risk

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

WARNING

• AC supply cables and connections

• DC 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.

Stored charge

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

Electrical

installation

Getting started

Optimisation Parameters

Te ch n ic a l

data

Component

sizing

Diagnostics

WARNING

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).

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Electrical

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6.1 Power connections

6.1.1 AC and DC regen connections

Figure 6-1 Unidrive SP size 1 Regen drive power connections

DC connections

(High current DC to motoring drive[s])

Getting

started

Optimisation Parameters

Te ch ni ca l

data

Component

sizing

Diagnostics

BR48V -DC +DC

Internal

EMC filter

To b e removed

Regen drive

AC supply connections

L2L1 L3 U V W

BR48V -DC +DC

Internal

EMC filter

To b e removed

Motoring drive

Motor connections

L2L1 L3 U V W

L1, L2, L3

(Refer to Chapter 4

System design)

Motor

Vac supply

Optional ground

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Figure 6-2 Unidrive SP size 2 power connections

Electrical

installation

DC connections

(High current DC to motoring drive[s])

Getting started

Optimisation Parameters

Te ch n ic a l

data

Component

sizing

Diagnostics

DC1 = DC2 = +

BRDC1 DC2 48V -DC +DC

Internal

EMC filter

To b e removed

DC1 = DC2 = +

Regen drive

AC supply connections

L2L1 L3 U V W PE

BRDC1 DC2

48V -DC +DC

Motoring drive

Motor connections

L2L1 L3 U V W PE

Internal

EMC filter

To b e removed

L1, L2, L3

(Refer to Chapter 4

)System design

Motor

Vac supply

Optional ground

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 6-8 for further information on ground connections.

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Figure 6-3 Unidrive SP size 3 power connections

Electrical

installation

DC connections

(High current DC to motoring drive[s])

Getting

started

Optimisation Parameters

Te ch ni ca l

data

Component

sizing

Diagnostics

DC1 = DC2 = +

BRDC1 DC2

Regen drive

L2L1 L3 U V WPE

48V -DC +DC

AC supply connections

Internal

EMC filter

To b e removed

DC1 = DC2 = +

BRDC1 DC2 48V -DC +DC

Internal

EMC filter

To b e removed

Motoring drive

Motor connections

L2L1 L3 U V WPE

L1, L2, L3

(Refer to Chapter 4

)System design

Motor

Vac su pp ly

Optional ground

On Unidrive SP 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 48V or high voltage) or using the drive in a parallel DC bus system. The low current DC connection is used only to connect the internal EMC filter.

See Figure 6-9 for further information on ground connections.

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Figure 6-4 Unidrive SP size 4, 5 and 6 power connections

(Refer to Chapter 4

System design

L1, L2, L3

)

Electrical

installation

Getting started

Optimisation Parameters

Te ch n ic a l

data

Component

sizing

Diagnostics

L1 L2 L3

To be removed

+DC -DC

Internal

EMC filter

DC Connections

(High current DC

to motoring drive[s])

Regen drive

5 6

L1 L2 L3

Internal

EMC filter

+DC -DC

Motoring drive

AC supply connections

UVW

Vac supply

UVW

Motor

Optional ground

connection

* See section 6.1.2 Ground connections .

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Figure 6-5 Unidrive SPMA power connections

Mechanical

installation

Electrical

installation

Getting

started

Optimisation Parameters

Te ch ni ca l

data

Component

sizing

Diagnostics

(Refer to Chapter 4

System design

L1, L2, L3

L1 L2 L3

To be removed

Internal

EMC filter

)

+DC -DC

DC Connections

(High current DC

to motoring drive[s])

L1 L2 L3

To be removed

+DC -DC

Internal

EMC filter

Motoring drive

Regen drive

SPMA

AC supply connections

UVW

Vac supply

SPMA

Motor connections

UVW

Motor

Optional ground

connection

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Figure 6-6 Unidrive SPMD power connections

Introduction

Product

information

System

design

Mechanical

installation

Electrical

installation

Getting started

Optimisation Parameters

Te ch n ic a l

data

Component

sizing

Diagnostics

To b e removed

+DC -DC

Internal

EMC filter

DC Connections

(High current DC

to motoring drive[s])

To b e removed

Internal

EMC filter

+DC -DC

Motoring drive

Regen drive

SPMD

SPMA

AC supply connections

UVW

Vac supply

Motor connections

UVW

Motor

Optional ground

connection

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Figure 6-7 Unidrive SPMC power connections

Mechanical

installation

Electrical

installation

Getting

started

Optimisation Parameters

Te ch ni ca l

data

Component

sizing

Diagnostics

L1 L2 L3

SPMC

Used as only

softstart

+DC -DCPE

To be removed

+DC -DC

Internal

EMC filter

DC Connections

(High current DC

to motoring drive[s])

To be removed

Internal

EMC filter

+DC -DC

SPMD SPMD

AC supply connections

UVW

Vac supply

* See section 6.1.2 Ground connections .

Regen drive

Motor connections

UVW

Motor

Optional ground

Motoring drive

connection

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6.1.2 Ground connections

Size 1

On a Unidrive SP 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 6-1 on page 66.

Size 2

On a Unidrive SP size 2, the supply and motor ground connections are made using the grounding bridge that locates at the bottom of the drive. See Figure 6-8 for details.

Size 3

On a Unidrive SP 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 6-9 for details.

Size 4, 5, 6, SPMA and SPMD

On a Unidrive SP size 4, 5, 6, SPMA and SPMD the supply and motor ground connections are made using an M10 bolt at the top (supply) and bottom (motor) of the drive. See Figure 6-10.

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

SPMA: 75mm

SPMD: 120mm

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

Table 6-1 Cables and standards

Standard Conditions

IEC 60204-1 & EN 60204-1

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

(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)

(0.18in2, or slightly bigger than 2 AWG)

Supply phase conductors having cross-sectional area not exceeding:

Size 4: 38.4mm

Size 5: 120mm

Size 6: 150mm

SPMA: 150mm

SPMD: 240mm

Getting started

Optimisation Parameters

Te ch n ic a l

data

Component

sizing

Figure 6-8 Unidrive SP size 2 ground connections

Figure 6-9 Unidrive SP size 3 ground connections

Diagnostics

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

The drive must be grounded by a connection capable of

WARNING

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.

Plain washers

Spring washer

M6 bolt

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Figure 6-10 Unidrive SP size 4, 5, 6, SPMA and SPMD ground

Introduction

connections

Product

information

System

design

Mechanical

installation

Electrical

installation

Supply ground

Motor ground

Figure 6-11 Unidrive SPMC/U ground connections

Supply ground

Getting

started

Optimisation Parameters

Te ch ni ca l

data

Component

sizing

Diagnostics

6.2 AC supplies

NOTE

Drives rated for supply voltages up to 690V are suitable for use with supply types with neutral or centre grounding i.e. TN-S, TN-C-S, TT

The following supplies are not permitted with Unidrive SP Regen

1. Corner grounded supplies (grounded Delta)

2. Ungrounded supplies (IT) > 575V

6.2.1 Supply types

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.

6.2.2 Dedicated supplies

The nature of the mains supply has an important effect on the EMC arrangements. For a dedicated supply, i.e. one which has no other electrical equipment fed from the secondary of its distribution transformer, normally neither an EMC filter or a switching frequency filter are required. Refer to section 4.3.1 Omitting the switching frequency filter on page 40.

6.2.3 Other supplies

Wherever other equipment shares the same low voltage supply, i.e. 400Vac, careful consideration must be given to the likely need for both switching frequency and EMC filters, as explained in section

6.5.11 Switching frequency emission and section 6.5.12 Conducted RF emission .

6.2.4 Supply voltage notching

Because of the use of input inductors and an active rectifier the drive causes no notching - but see section 6.5.11 Switching frequency emission for advice on switching frequency emission.

6.2.5 Supply harmonics

When operated from a balanced sinusoidal three-phase supply, the regenerative Unidrive SP generates minimal harmonic current.

Imbalance between phase voltages will cause the drive to generate some harmonic current. Existing voltage harmonics on the power system will cause some harmonic current to flow from the supply into the drive. Note that this latter effect is not an emission, but it may be difficult to distinguish between incoming and outgoing harmonic current in a site measurement unless accurate phase angle data is available for the harmonics. No general rule can be given for these effects, but the generated harmonic current levels will always be small compared with those caused by a conventional drive with rectifier input.

Motor ground

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6.3 Cable and fuse 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 maximum supply fault current given in Table 6-2 to Table 6-2.

Tab le 6-2

Model

SP1201 5.2 10 1.0 10 18

SP1202 6.8 10 1.0 10 16

SP1203 9.6 12 1.0 12 14

SP1204 11 12 1.0 12 14

SP2201 15.5 20 2.5 20 14

SP2202 22 25 4.0 25 10

SP2203 28 32 6.0 32 8

SP3201 42 50 16 50 16

SP3202 54 63 25 63 25

SP1405 8.8 12 1.0 15 14

SP1406 11 16 1.5 15 14

SP2401 15.3 20 2.5 20 14

SP2402 21 25 4.0 25 10

SP2403 29 32 6.0 30 8

SP2404 29 32 6.0 30 8

SP3401 35 40 10 40 6

SP3402 43 50 16 45 6

SP3403 56 63 25 60 4

SP3501 5.4 8 1.0 8 18

SP3502 6.1 8 1.0 8 16

SP3503 8.4 12 1.0 12 14

SP3504 11 12 1.0 12 14

SP3505 16 20 2.5 20 14

SP3506 22 25 4.0 25 10

SP3507 27 32 6.0 32 8

Size 1 to 3 input current, fuse and cable size ratings

European USA

Maximum

Cable size

EN60204

Input

Fuse

rating

IEC gG

UL508C

continuous

input

current

Fuse

rating

IEC gG

Cable

size

Input AWG

Getting started

Optimisation Parameters

Te ch n ic a l

data

Component

sizing

Diagnostics

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Safety

Information

Tab le 6-3

Model

Introduction

Size 4, 5, 6 and the SPM input current, fuse and cable size ratings (universal)

Maximum

continuous

input

current

Product

information

System

design

Mechanical

installation

IEC class gR OR

American Ferraz HSJ

IEC classgRNorth American

Ferraz HSJ

North

Electrical

installation

HRC AND

HRC IEC class gG

UL class J

Getting

started

Optimisation Parameters

Semi-conductor Cable size

Semi- Conductor

IEC class aR

Te ch ni ca l

data

AWG

SP4201 68 100 90 90 160 25 3

SP4202 80 100 100 100 160 35 3

SP4203 104 125 125 125 200 70 1

SP5201 130 200 175 160 200 95 210

SP5202 154 250 225 200 250 120 410

SP4401 68 80 80 80 160 25 3

SP4402 83 110 110 100 200 35 2

SP4403 104 125 125 125 200 70 1

SP5401 138 200 175 160 200 95 2/0

SP5402 168 250 225 200 250 120 4/0

SP6401 205 250 250 250 315 2 x 70 2 x 2/0

SP6402 236 315 300 300 350 2 x 120 2 x 4/0

SPMA1401 205 315 300 250 315 2 x 70 2 x 2/0

SPMA1402 246 315 300 300 350 2 x 120 2 x 4/0

SPMD1201 192

SPMD1202 248

SPMD1203 312

Refer to SPMC

SPMD1204 350

SPMD1401 205

SPMD1402 246

SPMD1403 290

Refer to SPMC

SPMD1404 350

SP4601 22 63 60 32 125 4 10

SP4602 27 63 60 40 125 6 8

SP4603 36 63 60 50 125 10 8

SP4604 43 63 60 50 125 16 6

SP4605 52 63 60 63 125 16 6

SP4606 62 80 60 63 125 25 4

SP5601 84 125 100 90 160 35 2

SP5602 99 125 100 125 160 50 1

SP6601 125 160 175 150 315 2 x 50 2 x 1

SP6602 144 160 175 160 315 2 x 50 2 x 1

SPMA1601 125 200 200 200 200 2 x 50 2 x 1

SPMA1602 144 200 200 200 200 2 x 50 2 x 1

SPMD1601 125

SPMD1602 144

SPMD1603 168

Refer to SPMC

SPMD1604 192

Component

sizing

Diagnostics

Table 6-4 Unidrive SPMD input current, fuse and cabling ratings

Model

Typical DC

Input current

Maximum DC

Input current

Maximum DC

Input voltage

Vdc

DC fuse

IEC class aR

DC Cable size

AWG

SPMD1401 222 343 800 400 2 x 70 2 x 2/0

SPMD1402 268 400 800 560 2 x 95 2 x 4/0

SPMD1403 314 457 800 560 2 x 120 2 x 4/0

SPMD1404 379 552 800 560 2 x 120 2 x 4/0

SPMD1601 135 191 1150 250 2 x 95 2 x 4/0

SPMD1602 157 240 1150 315 2 x 120 2 x 4/0

SPMD1603 184 275 1150 350 2 x 120 2 x 4/0

SPMD1604 209 323 1150 400 2 x 120 2 x 4/0

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Optimisation Parameters

Te ch n ic a l

data

Table 6-5 SPMC / U input current, fuse and cable ratings

Cable sizes

AWG

Model

Typical

input

current

Maximum

input

current

Typical

current

Adc

Semi-conductor fuse

in series with HRC fuse

HRC IEC

class gG UL

class J

Semi-

conductor

IEC class aR

AC input DC output

SPMC1402 339 344 379 540 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0

SPMC2402 2 x 308 2 x 312 2 x 345 450 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0

SPMU1401 207 210 222 250 315 2 x 70 2 x 2/0 2 x 70 2 x 2/0

SPMU1402 339 344 379 540 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0

SPMU2402 2 x 339 609 2 x 379 450 400 2 x 120 2 x 4/0 2 x 120 2 x 4/0

SPMC1601 192 195 209 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0

SPMC2601 2 x 170 2 x 173 2 x 185 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0

SPMU1601 192 195 209 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0

SPMU2601 2 x 170 2 x 173 2 x 185 250 250 2 x 70 2 x 2/0 2 x 120 2 x 4/0

The recommended cable sizes above are only a guide. Refer to local wiring regulations for the correct size of cables. In some cases a larger cable is required to avoid excessive voltage drop.

NOTE

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

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

• Type AC should never be used with drives.

• Type A can only be used with single phase drives

• Type B must be used with three phase drives

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

WARNING

to local wiring regulations for the correct size of cables.

6.4 EMC (Electromagnetic compatibility)

Fuses

The AC supply to the drive must be fitted with suitable protection against overload and short-circuits. Failure to

WARNING

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 Unidrive SP 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.

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.

6.3.1 Main AC supply contactor

The recommended AC supply contactor type for sizes 1 to 6 is AC1.

6.3.2 Motor winding voltage

Refer to the guidelines given in section 4.7.2 of the Unidrive SP User Guide. The DC bus voltage in a regen system with a 400V supply is

usually 700V, which corresponds to an AC supply voltage of 519V. Unless the motor cable is less than 10m long it is recommended that either an inverter-grade motor should be used or else output chokes should be fitted to protect the motor from the effect of the fast-rising output voltage pulses.

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

Section 6.5.2, 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 in the EMC section of the Unidrive SP User Guide for increased surge immunity of control circuits where control wiring is extended.

Section 6.5.3, Requirements for meeting the EMC standard for power drive systems, IEC61800-3 (EN61800-3).

Section 6.5.4, Requirements for meeting the generic emission standards for the industrial environment, IEC61000-6-4, EN61000-6-4,

EN50081-2.

The recommendations of section 6.5.2 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 6.5.3 or section 6.5.4 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 10 Technical data

...the correct external EMC filter must be used and all of the guidelines in section 6.5.2 General requirements for EMC and section

6.5.4 Compliance with generic emission standards must be followed.

Component

sizing

Diagnostics

6.3.3 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)

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Optimisation Parameters

Te ch ni ca l

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Component

sizing

Diagnostics

Table 6-6 Unidrive SP / EMC filter cross reference

Drive

Schaffner Epcos

CT part no. CT part no.

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

SPMD1201 to SPMD1204 4200-6315 4200-6313

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

SPMA1401 to SPMA1402 4200-6603 4200-6601

SPMD1401 to SPMD1404 4200-6315 4200-6313

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

SPMA1601 to SPMA1602 4200-6604 4200-6602

SPMD1601 to SPMD1604 4200-6316 4200-6314

6.5.1 Removal of internal EMC filter

The internal EMC filter must be removed from the drive.

CAUTION

Figure 6-12 Removal of internal EMC filter (size 1 to 3)

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

Figure 6-13 Removal of internal EMC filter (size 4 to 6)

6.5 External EMC filter

For currents exceeding 300A up to 2500A, suitable filters are also available from both Epcos and Schaffner as detailed.

• Epcos B84143-B250-5xx (range up to 2500A)

• Schaffner FN3359-300-99 (range up to 2400A)

These filters may not give strict conformity with EN6000-6-4 but in conjunction with EMC installation guidelines they will reduce emissions

to sufficiently low levels to minimise the risk of disturbance.

When a EMC filter is used, the switching frequency filter detailed must also be used. Failure to observe this may result in the EMC filter becoming ineffective and being damaged.

CAUTION

WARNING

CAUTION

Refer to section 6.4 EMC (Electromagnetic compatibility) on page 77.

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.

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

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6.5.2 General requirements for EMC

Ground (earth) connections

The grounding arrangements should be in accordance with Figure 6-14, which shows both drives mounted on a back-plate with or without an additional enclosure.

Figure 6-14 shows how to manage EMC when using a shielded motor cable, and indicates the clearances which should be observed around the drive and related ‘noisy’ power cables by all sensitive control signals / equipment.

Figure 6-14 General EMC enclosure layout showing earth / ground connections

DC bus connections

Do not place sensitive (unscreened) signal circuits in a zone extending 300mm (12”) all around the drive, motor cable, input cable from EMC filter

Regen drive

Optimisation Parameters

Motoring drive

Te ch n ic a l

data

The DC connection between the Regen and motoring drive carries common mode high frequency voltage comparable with the output voltage from a standard drive. Screened cable should be used with the screen connection connected to a single power ground busbar or low impedance ground terminal inside the cubicle.

Component

sizing

Diagnostics

The voltage present in the wiring between the Regen drive and regen inductor is a source of radio emission. These cables should be kept as short as possible. (I.e. The regen inductor mounted as close as possible to the Regen drive.)

Metal backplate safety bonded to power ground busbar

EMC filter

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

Grounding bar

Regen

components

Screen and ground connections should be followed as shown in

.Electrical Installation

Signal cables

External controller

Use four core cable to connect the motor to the drive. The ground conductor in the motor cable must be connected directly to the ground terminal of the drive and motor. It must not be connected directly to the power ground busbar.

If the control circuit 0V is to be grounded, this

300mm

(12in)

should be done at the system controller only to avoid injecting noise currents into the 0V circuit

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6.5.3 Compliance with EN61800-3 (standard for Power Drive Systems)

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

Operation in the first environment

Observe the guidelines given in section 6.5.4 Compliance with generic emission standards on page 80. An external EMC filter will always be

required.

This is a product of the restricted distribution class according to IEC61800-3

In a domestic environment this product may cause radio

CAUTION

interference in which case the user may be required to take adequate measures.

Operation in the second environment

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

Size 1

Where a filter is required, follow the guidelines in section 6.5.2 General requirements for EMC on page 79.

For cable lengths up to 10m compliance can be maintained by fitting a ferrite ring, part no. 4200-0000, 4200-0001 or 4200-3608, to the drive output. Feed the motor cables (U,V,W) through the ring once.

Size 2 and 3

Where a filter is required, follow the guidelines in section 6.5.2 General requirements for EMC on page 79.

The second environment typically includes an industrial lowvoltage power supply network which does not supply buildings used for domestic purposes. Operating the drive in this environment without an external EMC filter may cause

CAUTION

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 6.5.4 Compliance with generic emission standards be adhered to.

Refer to section 6.4 EMC (Electromagnetic compatibility) on page 77 for further information on compliance with EMC standards and definitions of environments.

Detailed instructions and EMC information are given in the Unidrive SP EMC Data Sheet which is available from the supplier of the drive.

6.5.4 Compliance with generic emission standards

Use the recommended filter and shielded motor cable. Observe the layout rules given in the current Unidrive SP User Guide.

6.5.5 Immunity

The immunity of the individual drive modules is not affected by operation in the regenerative mode. See drive EMC data sheets for further information.

This guide recommends the use of varistors between the incoming AC supply lines. These are strongly recommended to protect the drive from surges caused by lightning activity and/or mains supply switching operations.

Since the regenerative input stage must remain synchronised to the supply, there is a limit to the permitted rate of change of supply frequency. If rates of change exceeding 100Hz/s are expected then C.T. Technical Support should be consulted. This would only arise under exceptional circumstances e.g. where the power system is supplied from an individual generator.

6.5.6 Emission

Emission occurs over a wide range of frequencies. The effects are divided into three main categories:

• Low frequency effects, such as supply harmonics and notching

• High frequency emission below 30MHz where emission is predominantly by conduction

• High frequency emission above 30MHz where emission is predominantly by radiation

6.5.7 Dedicated supplies

6.5.8 Other supplies

Wherever other equipment shares the same low voltage supply, i.e. 400Vac, careful consideration must be given to the likely need for both switching frequency and EMC filters, as explained in section

6.5.11 Switching frequency emission and section 6.5.12 Conducted RF

emission .

6.5.9 Supply voltage notching

Because of the use of input inductors and an active rectifier the drive causes no notching - but see section 6.5.11 Switching frequency emission for advice on switching frequency emission.

6.5.10 Supply harmonics

When operated from a balanced sinusoidal three-phase supply, the regenerative Unidrive SP generates minimal harmonic current.

6.5.11 Switching frequency emission

The Regen drive uses a PWM technique to generate a sinusoidal input voltage phase-locked to the mains supply. The input current therefore contains no harmonics of the supply unless the supply itself contains harmonics or is unbalanced. It does however contain current at the switching frequency and its harmonics, modulated by the supply frequency. For example, with a 3kHz switching frequency and 50Hz supply frequency there is current at 2.90, 3.10, 5.95, 6.05kHz etc. The switching frequency is not related to that of the supply, so the emission will not be a true harmonic - it is sometimes referred to as an “interharmonic”. The possible effect of this current is similar to that of a high-order harmonic, and it spreads through the power system in a manner depending on the associated impedances. The internal impedance of the Regen drive is dominated by the series inductors at the input. The voltage produced at switching frequency at the supply point is therefore determined by the potential divider action of the series inductors and the supply impedance; Supply assessment on page 40 gives guidelines to help in assessing whether a switching-frequency filter is required. In case of doubt, unless the drive operates from a dedicated supply not shared with other loads, it is strongly recommended that the filter be fitted.

Failure to fit a switching frequency filter may result in damage to other equipment, e.g. fluorescent light fittings, power factor correction capacitors and EMC filters.

CAUTION

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6.5.12 Conducted RF emission

Radio frequency emission in the frequency range from 150kHz to 30MHz is mainly conducted out of the equipment through electrical wiring. It is essential for compliance with all emission standards, except for IEC61800-3 second environment, that the recommended EMC filter and a shielded (screened) motor cable are used. Most types of cable can be used provided it has an overall screen. For example, the screen formed by the armouring of steel wired armoured cable is acceptable. The capacitance of the cable forms a load on the drive and should be kept to a minimum. The same considerations apply to any cables connecting the DC bus between drives, except that short direct wiring within the same enclosure need not be screened.

When an EMC filter is used the switching frequency filter discussed above must also be used. Failure to observe this may result in the EMC filter becoming ineffective and being

CAUTION

When used with the recommended filters, the Regen drive system complies with the requirements for conducted emission in the following standards:

Table 6-7 Requirements for conducted emission

damaged.

Motor cable length (m)

0 to 100 I

Switching frequency (kHz)

Getting started

Optimisation Parameters

Te ch n ic a l

data

Component

sizing

Diagnostics

Key to

table

Standard Description

EN50081-2

Generic emission standard for the industrial environment

EN61800-3

IEC1800-3

Product standard for adjustable speed power drive systems

The first environment is one where the low voltage supply network also supplies domestic premises

Restricted distribution means that drives are available only to installers with EMC competence

Frequency

range

0.15 to 0.5MHz

0.5 to 30MHz

Requirements for the first environment Requirements for the second environment: unrestricted distribution

For installation in the “second environment”, i.e. where the low voltage supply network does not supply domestic premises, no filter is required in order to meet IEC61800-3 (EN61800-3):1996.

Operation without a filter is a practical cost-effective possibility in an industrial installation where existing levels of electrical noise are likely to be high, and any electronic

CAUTION

equipment in operation has been designed for such an environment. There is some risk of disturbance to other equipment, and in this case the user and supplier of the drive system must jointly take responsibility for correcting any problem which occurs.

Limits Application

79dBµV quasi peak

66dBµV average

73dBµV quasi peak

60dBµV average

: restricted distribution2

AC supply lines

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Recommended EMC filters

These are the same filters as recommended for standard (nonregenerative) operation:

Table 6-8 Recommended filters

Drive

Motor cable

length m

SP1201 to SP1202

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

SPMD1201 to SPMD1204 4200-6315 4200-6313

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

100

SP5401 to SP5402 4200-6503 4200-6501

SP6401 to SP6402 4200-6603 4200-6601

SPMA1401 to SPMA1402 4200-6603 4200-6601

SPMD1401 to SPMD1404 4200-6315 4200-6313

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

SPMA1601 to SPMA1602 4200-6604 4200-6602

SPMD1601 to SPMD1604 4200-6316 4200-6314

Schaffner Epcos

CT part no. CT part no.

4200-6118 4200-6121

Getting

started

Optimisation Parameters

Te ch ni ca l

data

Figure 6-15 Power cable considerations

The DC connection between the Regen and motoring drive carries common mode high frequency voltage comparable with the output voltage from a standard drive. Clearances and recommendations for standard power cables must be applied here.

Cable length B

DC bus connections

Regen drive

Cable length A

Standard wiring practices apply.

Regen inductor Moto

Component

sizing

Motoring drive

Cable length C

Diagnostics

6.5.13 Radiated emission

Radio frequency emission in the frequency range from 30MHz to 1GHz is mainly radiated directly from the equipment and from the wiring in its immediate vicinity. Operation in regenerative mode does not alter the radiated emission behaviour, and the EMC data sheet for the individual Unidrive SPs used should be consulted for further information.

NOTE

Theoretically the use of two drives physically close together can cause an increase in emission level of 3dB compared with a single drive, although this is usually not observed in practice. All Unidrive SPs have sufficient margin in respect of the generic standard for the industrial environment EN61000-6-4 to allow for this increase.

6.5.14 Wiring guidelines

The wiring guidelines provided for the individual drives also apply to regenerative operation, except that the switching frequency filter must be interposed between the input drive and the EMC filter. The same principles apply, the most important aspect being that the input connections to the EMC filter should be carefully segregated from the power wiring of the drives which carries a relatively high “noise” voltage.

6.5.15 Main contactors K2 with SPMC

When using an SPMC for the charging of a regen system the main contactor K2 should be positioned as close as possible to the Regen drives power terminals.

6.5.16 Multi-drive systems

It is common for regenerative drive systems to be constructed using numbers of drives with a single input stage, or other more complex arrangements. It is generally not possible to lay down specific EMC requirements for such systems, since they are too large for standardised tests to be carried out. In many cases the environment corresponds to the “second environment” as described in IEC61800-3, in which case no specific limit to conducted emission is required. National legislation such as the European Union EMC Directive does not usually require that complex installations meet specific standards, but only that they meet the essential protection requirements, i.e. not to cause or suffer from electromagnetic interference.

Where the environment is known to include equipment which is sensitive to electromagnetic disturbance, or the low voltage supply network is shared with domestic dwellings, then precautions should be taken to minimise conducted radio frequency emission by the use of a filter at the system power input.

For currents exceeding 300A up to 2500A suitable filters are available from the following manufacturers:

Epcos B84143-B250-5xx (range up to 2500A) Schaffner FN3359-300-99 (range up to 2400A)

These filters may not give strict conformity with EN61000-6-4, but in conjunction with the relevant EMC installation guidelines they will reduce emission to sufficiently low levels to minimise the risk of disturbance.

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6.6 Control connections

6.6.1 Unidrive SPMC control terminals

The following diagram shows the required connections for the SPMC to T.84 and T.85. Also shown is the status relay which can be utilised if required.

Figure 6-16 Single rectifier control terminals and descriptions

Single Rectifier

Status relay

Getting started

Optimisation Parameters

Te ch n ic a l

data

Component

sizing

Diagnostics

Inverter (master)

Fan control 0V common Status input 0 0V common Status input 1 0V common

External 24V supply 0V common Status output 0 0V common Status output 1 0V common

SPMA / SPMD

0V common Status 1 input

0V common Status 0 input

Figure 6-17 Parallel rectifier control terminals and descriptions

Rectifier 1

Status relay

Fan control 0V common Status input 0 0V common Status input 1 0V common

Rectifier 2

Status relay

Fan control 0V common Status input 0 0V common Status input 1 0V common

External 24V supply

0V common Status output 0 0V common Status output 1 0V common

Inverter (master)

SPMA / SPMD

External 24V supply 0V common Status output 0 0V common Status output 1 0V common

0V common Status 1 input

0V common Status 0 input

Unidrive SPMC/U external 24V supply requirements

Nominal voltage: 24V Minimum voltage: 23V Maximum voltage: 28V Current drawn: 3A Minimum start-up voltage: 18V Recommended power supply: 24V, 100W, 4.5A

Recommended fuse:

4A fast blow (I2t <20A2s)

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6.6.2 Unidrive SP control terminals

Table 6-10 The Unidrive SP control connections consist of:

Function Qty Control parameters Terminal No.

Differential analogue input

Single ended analogue input

Analogue output 2 Source, mode, scaling, 9,10

Digital input 3 Destination, invert, logic select 27,28,29

Digital input / output 3

Relay 1

Drive enable (Secure Disable)

+10V User output 1

+24V User output 1 Source, invert 22

0V common 6

+24V External input 1

All analogue terminal functions can be programmed in menu 7.

Available digital terminal functions can be programmed in menu 8.

NOTE

The digital I/O at default has been configured to accept external signals from main and auxiliary contactors to allow the regen mode to function correctly. Before changing any routing, refer to Menu 8 descriptions.

Destination, offset, offset trim,

invert, scaling

Mode, offset, scaling, invert,

destination

Not user available, used for regen configuration

Relay configured for contactor coil power supply

5,6

7,8

24,25,26

41,42

1, 3, 11, 21,

23, 30

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Te ch ni ca l

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Component

sizing

Diagnostics

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

WARNING

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

WARNING

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.

CAUTION

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.

CAUTION

NOTE

Positive logic is the default state for Unidrive SP.

The 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.

NOTE

The common 0V from analogue 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 analogue 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 analogue signals.

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Figure 6-18 Default terminal functions

design

Mechanical

installation

Electrical

installation

Getting started

Optimisation Parameters

Te ch n ic a l

data

Component

sizing

Diagnostics

0V common

External +24V input

0V common

Non inverting

Inverting

Analogue input 1

+10V output

Analogue input 2

Analogue input 3

Analogue output 1

Analogue output 2

0V common

Regen drive

Polarised signal connectors

21 31

User definable

Regen inductor thermistor

Analogue frequency/speed reference 1

Connections for

single-ended input

differential input signal

frequency/speed

signal

Connections for

nalogue

reference 2

Motoring drive

Polarised signal connectors

21 31

0V common

External +24V input

0V common

Non inverting

Inverting

Analogue input

0V common

Non inverting

Inverting

+10V output

Analogue input 2

0V common

+24V output

0V common

Enable motor drive

Contactor closed

Drive healthy

Reset input

0V common

Secure Disable/

Drive enable**

Status relay

Enable relay

Input from regen circuit

User definable

Used for control of external regen system contactors

Optional

Enable connected through Regen system auxiliaries

nalogue input 3

(Motor thermistor*)

Speed /

frequency

Torque (active

current)

Analogue input 3

Analogue output 1

Analogue output 2

0V common

+24V output

0V common

At zero speed

Reset

Run forward

Run reverse

Analogue input 1 / input 2 select

Jog forward

0V common

Secure Disable/ Drive enable**

Status r elay drive healthy

* Analogue input 3 can be configured as a motor thermistor input, refer to the Unidrive SP User Guide.

**The Secure Disable / Drive enable terminal is a positive logic input only.

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7 Getting started

7.1 Regen parameter settings

7.1.1 Switching frequency Pr 5.18 (Pr 0.41)

Set the switching frequency on the Regen drive to the required value (3kHz default value).

A higher switching frequency setting has the following advantages:

• Line current ripple at the switching frequency is reduced, giving improved waveform quality.

• Acoustic noise produced by the line inductors is reduced.

• Dynamic DC bus voltage response is improved.

NOTE

In some cases, setting the switching frequency to a value greater than the default 3kHz results in current derating. Refer to Chapter 12 Technical Data in the Unidrive SP User Guide.

7.1.2 DC bus voltage set point

The table below defines the DC Bus voltage set point levels, assuming a tolerance of ±10% on the given supply voltage. The minimum value is defined as the peak input voltage plus some headroom. Headroom is required by the drive to allow correct control of the current. It is advisable to set the voltage below the maximum value to give more allowance for transient voltage overshoots.

Table 7-1 DC bus voltage set point - Pr 3.05 (Pr 0.01)

The DC bus voltage set point, see Pr 3.05 (Pr 0.01), should be set to a level that is suitable for the AC supply voltage being used. It is very important that the Regen drive DC bus voltage set point Pr 3.05 (Pr 0.01) is set above the peak AC supply voltage by at least 50Vac.

7.2 Regen drive sequencing

When a Regen drive is enabled, it goes through a line synchronisation sequence. During this procedure, test pulses are applied to the incoming line to determine the voltage and phase. When it has been successfully synchronised to the line, the DC bus voltage controller is enabled and the DC bus voltage rises to the target voltage.

Only when all of these stages have been completed successfully is the motoring drive enabled. If at any time there is a fault, or the Regen drive is disabled, the motoring drive will also be disabled.

This sequence of events is important to prevent damage to the Regen drive, motoring drive or external power circuit components.

The sequence of events is as follows:

Voltage levels DC Bus voltage set-point

Supply voltage

Vac

200 350 350

400 700 700

575 835 835

690 1005 1005

Default

Vdc

Recommended

Vdc

Getting

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Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

Power applied and power removed 400V system

Single Regen: Single Motoring

Vdc

Drive Health

Aux.2

Aux.1

Aux.3

1234

1. K1 (main supply contactor / isolator) is closed with charging circuit active (K3 closed).

2. DC bus charges through the Regen drives Vac inputs L1, L2, L3 (charging circuit)

3. If the DC Bus > 430Vdc then K2 Regen drive main contactor and Aux.2 are closed via Regen drives relay, control terminals 41, 42.

4. K3 charging contactor is opened via K2 (Regen drive main contactor) and Aux.1 closes. The Regen drive enable, S1 can now be applied

5. The Regen drive and motoring drives can be enabled (enable signal from Regen drive to motoring drives active, control terminal 24)

6. K1 (main supply contactor / isolator) is opened removing power from the regen system.

7. DC bus discharges to 410Vdc at which point drive the healthy relay becomes in-active. The Regen drives enable is removed. The motoring drives enable signal from Regen drive becomes in-active

8. Regen drive main contactor, K2 is opened via the drive healthy relay, control terminals 41, 42. Aux.2 opens informing the drive that the Regen drives main contactor K2 is open.

9. K3 charging contactor is closed and Aux.1 opens

Power applied and power removed 400V system

Single Regen: Multiple Motoring (Unidrive SPMC)

Vdc

Drive Healthy

Aux.2

Aux.2A

Aux.1

Aux.3

1234 5 678

1. K1 (main supply contactor / isolator) is closed with charging circuit active (K3 closed).

2. DC bus charges through Unidrive SPMC (charging circuit).

3. If the DC Bus > 430Vdc then K2 Regen drive main contactor and Aux.2 are closed via Regen drives relay, control terminals 41, 42.

4. K3 charging contactor is opened via K2 (Regen drive main contactor), SPMC 24Vdc is removed Aux.2A and Aux.1 closes. The Regen drive enable, S1 can now be applied.

5. The Regen drive and motoring drives can be enabled (enable signal from Regen drive to motoring drives active, control terminal 24).

6. K1 (main supply contactor / isolator) is opened removing power from the regen system.

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7. DC bus discharges to 410Vdc at which point drive the healthy relay becomes in-active. The Regen drives enable is removed. The motoring drives enable signal from Regen drive becomes in-active.

8. Regen drive main contactor, K2 is opened via the drive healthy relay, control terminals 41, 42.

9. Aux.2 opens informing the drive that the Regen drives main contactor K2 is open. K3 charging contactor is closed and Aux.1 opens.

Power applied and power removed 400V system

Single Regen: Multiple Motoring - external charging resistor

Vdc

Drive Healthy

Aux.2

Aux.1

Aux.3

1234

1. K1 (main supply contactor / isolator) is closed with charging circuit active (K3 closed).

2. DC bus charges through the external charging resistors (charging circuit).

3. If the DC Bus > 430Vdc then K2 Regen drive main contactor and Aux.2 are closed via Regen drives relay, control terminals 41, 42.

4. K3 charging contactor is opened via K2 (Regen drive main contactor) and Aux.1 closes. The Regen drive enable, S1 can now be applied.

5. The Regen drive and motoring drives can be enabled (enable signal from Regen drive to motoring drives active, control terminal 24).

6. K1 (main supply contactor / isolator) is opened removing power from the regen system.

7. DC bus discharges to 410Vdc at which point drive the healthy relay becomes in-active. The Regen drives enable is removed. The motoring drives enable signal from Regen drive becomes in-active.

8. Regen drive main contactor, K2 is opened via the drive healthy relay, control terminals 41, 42. Aux.2 opens informing the drive that the Regen drives main contactor K2 is open.

9. K3 charging contactor is closed and Aux.1 opens

Power applied and power removed 400V system

Regen brake resistor replacement

Vdc

Drive Healthy

Aux.2

Aux.1

12345678

1. K1 (main supply contactor / isolator) is closed.

2. DC bus charges through motoring drives L1, L2, L3 Vac inputs.

3. If the DC Bus > 430Vdc then K2 Regen drive main contactor and Aux.2 are closed via Regen drives relay, control terminals 41, 42.

4. Regen drive enable, S1 can now be applied.

5. The Regen drive and motoring drives can be enabled (enable signal from Regen drive to motoring drives active, control terminal 24).

Getting

started

Optimisation Parameters

Te ch ni ca l

data

Component

sizing

Diagnostics

6. K1 (main supply contactor / isolator) is opened removing power from the regen system.

7. DC bus discharges to 410Vdc at which point drive the healthy relay becomes in-active. The Regen drives enable is removed. The motoring drives enable signal from Regen drive becomes in-active.

8. Regen drive main contactor, K2 is opened via the drive healthy relay, control terminals 41, 42. Aux.2 opens informing the drive that the Regen drives main contactor K2 is open.

NOTE

When the Regen drive has powered-up and the DC bus voltage has exceeded 430Vdc, Pr 3.07 changes from 0 to 1 activating the drives relay which in turn closes the Regen drive main contactor. If either the DC bus voltage falls below the contactor open voltage (410Vdc) or the system is synchronised and the AC voltage falls below contactor open voltage (150Vac), Pr 3.07 will change from a 1 to 0 opening the Regen drive main contactor.

Synchronisation:

• Apply test pulses to line to determine magnitude and phase.

• Attempt to synchronise to the line.

• If synchronisation is successful then enable the DC bus voltage controller.

DC bus voltage controller active:

• DC bus voltage rises to reference level.

• Motoring drive enabled by digital output from Regen drive.

Motoring drive active:

• The motor may now be energised and rotated.

• Power flows to and from the line as necessary via the Regen drive.

• DC bus voltage remains stable.

Whilst running if:

• The line voltage dips too low

The Regen drive synchronises to the Vac supply and therefore knows the supply voltage (Pr 5.02)

• OR the DC bus voltage goes out of regulation

DC bus drops below the contactor open voltage level (410 Vdc)

• OR there is any trip on the Regen drive

Drive healthy no longer active. Regen and motoring drive(s) enable removed

• OR the supply contactor is de-energised

Aux.2 connected to control terminal 25 of Regen drive

• OR the Regen drive is disabled

• OR the MCB trips

Switching frequency filter or external charging resistor

Then:

• the Regen drive will inhibit

• the motoring drive will be disabled by the Regen drive

• the Regen drive main contactor will be opened

7.2.1 Sequence

The motoring drive must only be enabled when the Regen drive is enabled, healthy, and synchronised to the AC supply. This will prevent any damage to the regen drive start-up circuit and prevent OV trips.

7.3 Regen drive commissioning

• Ensure power and control connections are made as specified in this Installation Guide.

• Ensure the Regen and motoring drives are not enabled.

• Switch on the AC supply.

• Both the Regen and motoring drives should now power up through the relevant start-up circuits in standard open loop mode.

• On the Regen drive, configure the drive type Pr 11. 31 (Pr 0.48) to REGEN.

• The main contactors should now close; the relevant start-up circuit is disabled at this point.

• On the Regen drive, set up the switching frequency and DC bus set point voltage to the required values in either Menu 0 or Menu 3, refer to section 7.1.2 DC bus voltage set point . Save the parameters.

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• The Regen drive can now be enabled, the Regen drive should display ACT.

• The commissioning of the motoring drive(s) can now be carried out.

7.4 Motoring drive commissioning

7.4.1 Motoring drive enable

When the Regen drive has been successfully synchronised, Pr 3.09 on the Regen drive will become active and digital output F1 on terminal 24 also becomes active allowing the motoring drive(s) to be enabled. If the Regen drive trips or attempts to re-synchronise to the supply, Pr 3.09 becomes zero and the enable signal for the motoring drive(s) is removed.

The setting of certain parameters in the motoring drive must be given special consideration when used in a regen system.

7.4.2 Ramp Mode - Pr 2.04 (Pr 0.15)

When a motoring drive is used in a regen system, the ramp mode should be set to FAST. The default setting of standard control will result in incorrect operation.

7.4.3 Voltage Control Mode - Open loop only Pr 5.14

(Pr 0.07)

The default setting of UR_I does not function correctly in the motoring drive when used in a regen system. When the system is powered up, the motoring drive is disabled while the Regen drive synchronises to the AC supply. The resultant delay before the motoring drive is enabled means that the stator resistance test cannot be completed. When open loop vector operation is required the voltage mode should be set to UR_S.

7.4.4 AC Supply Loss Mode - Pr 6.03

The motoring drive will not operate correctly if the AC supply loss mode is set to STOP. If the AC supply is lost, the Regen drive disables the motoring drive and prevents a controlled stop from being completed.

Getting

started

Optimisation Parameters

Technical

data

Component

sizing

Diagnostics

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8 Optimisation

The following section covers optimisation of the regen system which can be carried out by the user.

Feature Detail

Power feed-forward

Voltage controller gain

Current loop gains

Power factor correction

The Regen drive uses a DC bus voltage controller with inner current controllers as shown in Figure 8-1 Regen controllers :

Figure 8-1 Regen controllers

3.05

Pr DC bus voltage set point

DC bus

voltage

The gains of the voltage and current controllers affect the stability of the Regen system, with incorrect settings resulting in over-voltage or overcurrent trips.

8.1 Power feed-forward compensation

(Pr 3.10)

Power feed-forward compensation can be used to reduce the transient DC bus voltages produced when a fast load transient occurs on the motoring drives connected to the Regen drive.

100.0% power feed-forward is equivalent to an active current of:

Drive rated current / 0.45 (i.e. over current trip level)

and a Vac terminal peak phase voltage equal to:

DC_VOLTAGE_MAX / 2

This scaling is the same as the power output from Pr 5.03 when highspeed output mode is used (Refer to section 9.7 Menu 7: Analogue I/O ). Therefore an analogue output from the drive supplying the load, and analogue input 2 or 3 of the drive acting as the supply Regen drive can be connected together to give power feed-forward compensation without further scaling if the two drives are of equal rating.

If the ratings are different the analogue input scaling must be used to give the correct power feed-forward, where the scaling is given by (load drive) drive rated current / (Regen drive) drive rated current.

Figure 8-2 shows the Regen drives analogue inputs and motoring drives analogue outputs which can be used to pass Pr 5.03 (motoring drive output power) to the Regen drive which is then used for the power feedforward.

Power feed-forward can be used to reduce fast transient DC Bus voltage effects produced by transient load conditions on motoring drives mainly in Dynamic applications where spurious over-voltage and/or over-current trips are experienced.

The voltage controller gain can be implemented to overcome instability in the DC voltage on the common DC Bus in the following conditions,

• A brake resistor replacement system where the ratio between regen brake drive and motoring drive(s) DC Bus capacitance is large

• With multiple motoring drive(s) where the ratio between the regen drive(s) and motor drive(s) DC Bus capacitance is large.

Ensure the voltage controller gain is not increased to high as this can also introduce excessive ripple and instability on the DC Bus.

The current loop gains can be optimised to overcome spurious over-current trips during either synchronisation to the power supply, or during operation. The default gain settings are sufficient for most applications however these can be modified with the proportional (Kp) being the most critical for stability.

This does not optimize the regen system but improves the power factor of the supply that is connected to the regen system.

• Will introduce cost saving (electricity bill), compensate for inductive loads on the same supply, and overcome voltage drops due to “soft supplies”.

• A separate power factor correction unit may not be required.

• The symmetrical current limit must be below its maximum in order for power factor correction to work (therefore may be limited due to regen drive size).

Voltage

controller

Current

controllers

Current

feedback

Getting

started

Optimisation

Parameters

Technical

data

Component

sizing

Diagnostics

Only one analogue output from the motoring drive and one analogue input to the Regen drive is required to configure the power feedforward term.

Figure 8-2 Power Feedforward configurations

Pr set-up

Analogue input 2

Destination Pr = 3.10

7.12

Scaling Pr

Analogue input 3

Destination Pr = 3.10 Scaling Pr

7.16

7.14

7.18

Regen drive

Analogue I/P 2

Analogue I/P 3

0V common

Motoring drive

Analogue O/P 1

Analogue O/P 2

0V common

Pr set-up

nalogue output 1

7.19

Source Pr =

5.03

Mode Pr =

7.21

H.SPd

nalogue output 2

7.22

Source Pr = 5.03

7.24

Mode Pr =

H.SPd

8.2 Current loop gains

The defaults current loop gains (Kp, Pr 4.13 and Ki, Pr 4.14) are suitable for most standard regen systems. However if the input inductance is significantly higher the proportional gain may need to be adjusted as described following.

The most critical parameter for stability is the current controller proportional gain, Pr 4.13. The required value for this is dependent upon the Regen drives input inductance. If the inductance of the supply is a significant proportion of the recommended regen inductor

i.e. 60/I

Where:

then the proportional gain may need to be increased.

The supply inductance is likely to be negligible compared to the regen inductor value with small drives, but is likely to be significant with larger drives. The proportional gain, Pr 4.13 should be adjusted as described following using the total inductance per phase.

The proportional gain, Pr 4.13 can be set by the user so that

Pr 4.13 = Kp = (L / T) x (I

Where:

T is the sample time of the current controllers. The drive compensates for any change of sample time, and so it should be assumed that the sample time is equivalent to the lowest sample rate of 167µs.

mH per phase,

is the drive rated current

/ Vfs) x (256 / 5)

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L is the total input inductance. This is the inductance value in Pr 3.02 (at power-up this parameter is zero). Each time the Regen drive is enabled the total input inductance is measured and displayed in Pr 3.02. The value given is only approximate, and will give an indication as whether the input inductance is correct for the sinusoidal rectifier unit size. The measured value should include the supply inductance as well as the Regen drives input inductors, however, the supply filter capacitance, masks the effect of the supply inductance. Therefore the value measured is usually the Regen drive regen inductor value.

is the peak full-scale current feedback

= Drive rated current x √2 / 0.45 (Drive rated current [Pr 11. 32])

Vfs is the maximum DC bus voltage.

Therefore:

4.13

= Kp = (L / 167µs) x (Drive rated current x √2 / 0.45 / Vfs) x (256 / 5)

= K x L x Rated drive current

Where:

K = √2 / (0.45 x Vfs x 167µs) x (256 / 5)

Drive voltage rating Vfs K

200V 415V 2322

400V 830V 1161

575V 990V 973

690V 1190V 809

This set-up will give a step response with minimum overshoot after a step change of current reference. The approximate performance of the current controllers will be as given below. The proportional gain can be increased by a factor of 1.5 giving a similar increase in bandwidth, however, this gives a step response with approximately 12.5% overshoot.

Table 8-1 Current loop sample times

Switching frequency

kHz

Current control sample time (T)

µs

3 167

4 125

683

8 125

12 83

16 125

As previously detailed the current controller integral gain, Pr 4.14 is not so critical with the recommended value being the default setting.

8.3 Voltage controller gain (Pr 3.06)

Even when the voltage controller gain is set correctly there will be a transient change of DC bus voltage when there is a change in the load on any motoring drive connected to the Regen drive. This can be reduced substantially by using an analogue input for power feed forward compensation.

The following discussion relates to a system without power feed-forward compensation.

If the power flow from the supply is increased (i.e. more power is taken from the supply or less power is fed back into the supply) the DC bus voltage will fall, but the minimum level will be limited to just below the peak rectified level of the supply provided the maximum rating of the unit is not exceeded.

If the power flow from the supply is reduced (i.e. less power is taken from the supply or more power is fed back into the supply) the DC bus voltage will rise. During a rapid transient the DC bus will rise and then fall as shown in Figure 8-3 DC Bus transient .

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Figure 8-3 DC Bus transient

ch3: dT= 194ms dV=2.24 V

Active regen

unit current

Regen unit

DC bus voltage

50ms/div

The example shown is for a very rapid load change where the torque reference of the motor drive has been changed instantly from one value to another.

The proportional gain of the voltage controller, Kp, Pr 3.06, defines the voltage transient because the integral term is too slow to have an effect. (In applications where the motor drive is operating under speed control, the speed controller may only require a limited rate of change of torque demand, and so the transient voltage may be less than covered in the discussion below.)

If the DC Bus voltage set point voltage Pr 3.05, plus the transient rise exceed the over-voltage trip level the Regen drive will trip.

When a 400V motor is operated above base speed from a drive in closed loop vector mode, fed from the Regen drive with the same rating, supplying a DC voltage of 700V, and an instantaneous change of torque is demanded (i.e. -100% to +100%) the peak of the voltage transient (∆V) is approximately 80V if the current controllers are set up correctly and the voltage controller uses the default gain. (Operating with maximum voltage on the motor, i.e. above base speed, gives the biggest transient of power and hence the biggest value of (∆V. )

If the load change, drive voltage rating, motor voltage or DC Bus voltage set point are different then ∆V is calculated from:

∆V = 80V x K

x K

x KMV x K

RAT

Where:

= Load change / 200%

= Drive voltage rating / 400

RAT

= Motor voltage / 400

= 700 / DC bus voltage set point

In some applications, particularly with a high DC bus voltage set point and low switching frequency it may be necessary to limit the rate of change of power flow to prevent over voltage trips. A first order filter on the torque reference of the motor drive (Pr 4.12) is the most effective method to reduce the transient further. (A fixed limit of the rate of change of torque demand is less effective.) Table 8-2 Rate of change gives an approximate indication of the reduction in ∆V for different time constants. (As already mentioned the value of ∆V given is for an instantaneous change of torque representing the worst case. In applications where a speed controller is used in the motor drive the transient will already include an inherent filter).

Table 8-2 Rate of change

Time constant Change in ∆V

20ms x 0.75

40ms x 0.5

The transient produced is approximately proportional to the voltage controller gain Pr 3.06. The default voltage controller gain is set to give a value that is suitable for most applications. The gain may need to be increased if the DC bus capacitance is high compared to two drives of

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similar rating coupled together. However, care must be taken to ensure that the gain is not too high as this can cause excessive ripple in the DC bus voltage.

8.4 Power factor correction (Pr 4.08)

In regen mode it is possible to produce some current in the x axis of the reference frame so that the Regen drive can be made to produce or consume reactive power. Pr 4.08 defines the level of reactive current as a percentage of the regen drives rated current (Pr 5.07). Positive reactive current produces a component of current flowing from the supply to the drive at the Regen drive terminals that lags the respective phase voltage, and negative reactive current produces a component of current that leads the respective voltage. It should be noted that the maximum current in regen mode is limited to DRIVE_CURRENT_MAX, and so the drive applies a limit to this parameter (REGEN_REACTIVE_MAX) to limit the current magnitude. Therefore the symmetrical current limit (Pr 4.07) must be reduced below its maximum value before Pr 4.08 can be increased from zero.

Figure 8-4 Power flow from supply to regen drive

Voltage across

regen inductor

JwLIr

Power

factor

Vs Supply voltage

Vr Voltage at regen drive terminals

Ir Total current at regen drive terminals

JwLIr Voltage across regen inductor ϕ Power factor

Modifying Ir directly

affects power factor

X axis component of

Isx

current

Getting

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Diagnostics

Mode 2 (Pr 3.11 = 1) is available to allow the current trimming to be optimised, and overcome any inaccuracies due to noise / harmonics from the AC Supply connected to the regen system.

If operating in Mode 2 (Pr 3.11 = 1) the auxiliary contact on the "Regen drive main contactor" as shown in this installation guide needs to be moved from T.31 to T.25 to allow the current trimming to be carried out during each enable. The current trimming only occurs when the main contactor is open, therefore when the regen drive enable signal is given with Mode 2 (Pr 3.11 = 1) the main contactor will open and close before the regen drive becomes active.

Both strategies are shown in the following state machine

Figure 8-5 Current trimming state diagram

Mains loss or contactor open

when it should be closed

Mains Loss

Supply o.k

Current Trim

Disabled

Enabled Pr

Close Main Contactor

Waiting for Ena ble

3.11

Open Contactor

Current Trim

Close Main Contactor

Active

(not synchronised)

Synchronied

Trim co mplete

Contactor closed + 100ms delay

Enabled (Pr3.11=1)

Contactor open + 100ms delay

Trim co mplete

Contactor closed + 100ms delay

Synchronised

8.5 Current trimming

From software V1.10 for Unidrive SP the current trimming can be user configurable. The default setting for the current trimming in software V1.10 is as with previous software versions.

The current trimming mode parameter (Pr 3.11) defines the strategy used for trimming the current feedback when operating in regen mode with Unidrive SP.

The two modes that can be selected are as detailed following

Mode 1 - At power up only [Pr 3.11 = 0] Current trimming is only carried out once after power-up, as previously available (pre software V1.10) with Unidrive SP Regen.

Mode 2 - At power up and on each enable [Pr 3.11 = 1] Current trimming is carried out as previously available, once after power-up, and now in addition it is also carried out before the drive runs each time it is enabled (software V1.10 onwards) with Unidrive SP Regen.

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9 Parameters

9.1 Parameter ranges and variable maximums:

The two values provided define the minimum and maximum values for the given parameter. In some cases the parameter range is variable and dependant on either:

• other parameters

• the drive rating

• drive mode

• or a combination of these

The values given in Table 9-1 are the variable maximums used in the drive.

Table 9-1 Definition of parameter ranges & variable maximums

Maximum Definition

Maximum motor rated current

RATED_CURRENT_MAX [9999.99A]

DRIVE_CURRENT_MAX [9999.99A]

RATED_CURRENT_MAX = 1.36 x Rated drive current. The rated current can be increased above the Regen drive rated current up to a level not exceeding 1.36 x Regen drive rated current. (Maximum rated current is the maximum Normal Duty current rating.) The actual level varies from one drive size to another, refer to Table 3-2 on page 14. Maximum drive current The maximum drive current is the current at the over current trip level and is given by: DRIVE_CURRENT_MAX = Regen drive rated current / 0.45 Unidrive SP in regen mode operates in a reference frame that is aligned to the voltage at the drive terminals. As the phase shift across the input inductors is small, the reference frame is approximately aligned with the supply voltage. The maximum normal operating current is controlled by the current limits.

DRIVE_CURRENT_MAX is used in calculating the maximum of some parameters and is fixed at 1.75 x rated drive current. The drive can operate up to this level under normal conditions.

CURRENT_LIMIT_MAX is used as the maximum for some parameters such as the user current limits. The maximum current limit is defined as follows (with a maximum of 1000%):

Maximum current

⎛⎞

CURRENT_LIMIT_MAX

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

⎝⎠

Regen drive rated current

100%×=

CURRENT_LIMIT_MAX [1000.0%]

TORQUE_PROD_CURRENT_MAX [1000.0%]

USER_CURRENT_MAX [1000.0%]

DC_VOLTAGE_SET_MAX [1150V]

DC_VOLTAGE_MAX [1190V]

POWER_MAX [9999.99kW]

Where:

The Regen drive rated current is give by Pr 5.07

The maximum current is either 1.75 x rated drive current when the rated current set by Pr 5.07 is ≤maximum Heavy Duty current rating, otherwise it is 1.1 x maximum rated current.

The rated active and rated magnetising currents are calculated from regen mode rated current (Pr 5.07) as:

Rated active current = Regen mode rated current Rated magnetising current = 0

In this mode, the drive only requires the regen mode rated current to set the maximum current limit correctly and scale the current limits, and so no user autotuning is required to set these accurately.

It is possible to set a level of reactive current with Pr 4.08 in regen mode. This parameter has a limit defined as REGEN_REACTIVE_MAX that is provided to limit the total current to DRIVE_CURRENT_MAX.

REGEN_REACTIVE_MAX

Reactive drive current 1.75×

⎛⎞

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

⎝⎠

Regen drive rated current

–

Pr 4.07

100%×=

Motor rated current is given by Pr 5.07

Maximum torque producing current

This is used as a maximum for the real current (active current) in a Regen drive.

Current parameter limit selected by the user

The user can select a maximum for Pr 4.08 (reactive current reference) and Pr 4.20 (active current reference) to give suitable scaling for analogue I/O with Pr 4.24. This maximum is subject to a limit of MOTOR1_CURRENT_LIMIT_MAX. USER_CURRENT_MAX = Pr 4.24

Maximum DC voltage set-point

400V rating drive: 0 to 800V

Maximum DC bus voltage

The maximum measurable DC bus voltage 400V drives: 830V

Maximum power in kW

The maximum power has been chosen to allow for the maximum power that can be output by the drive with maximum AC output voltage, maximum controlled current and unity power factor. Therefore:

Software V01.07.01 and earlier: POWER_MAX = √3 x AC_VOLTAGE_MAX x RATED_CURRENT x 1.75 Software V01.08.00 and later: POWER_MAX = √3 x AC_VOLTAGE_MAX x DRIVE_CURRENT_MAX

The values given in square brackets indicate the absolute maximum value allowed for the variable maximum.

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9.2 Menu 0: Basic parameters

Table 9-2 Unidrive SP Regen menu 0 parameter descriptions

Parameter

0.00 xx.00 0 to 32,767 0 RW Uni

0.01 Voltage setpoint {3.05} 0 to DC_VOLTAGE_SET_MAX V 700 Vdc RW Uni US

0.02 Voltage controller Kp gain {3.06} 0 to 65535 4000 RW Bi US

0.03 Enable motor drive {3.09} OFF (0) or On (1) RO Uni NC

0.04 DC bus voltage {5.05} 0 to +DC_VOLTAGE_MAX V RO Uni FI NC PT

0.05 Output / supply voltage {5.02} 0 to AC_VOLTAGE_MAX V RO Uni FI NC PT

0.06 Regen drive status {3.03} 0 to 15 RO Uni NC PT

0.07 Regen restart mode {3.04}0 to 2 1RWUniUS

0.08 Close soft start contactor {3.07} OFF (0) or On (1) RO Uni NC

0.09 Soft start contactor closed {3.08} OFF (0) or On (1) RO Uni NC

0.10 Power feed forward compensation {3.10} ±100.0 % 0.0 RW Bi NC

0.11 Output / supply frequency {5.01} ±100.0 Hz RO Bi FI NC PT

0.12 Current magnitude {4.01} 0 to DRIVE_CURRENT_MAX A RO Uni FI NC PT

0.13 Active current {4.02} ±DRIVE_CURRENT_MAX A RO Bi FI NC PT

0.14 Output / supply power {5.03}±POWER_MAX kW RO Bi FI NC PT

0.15 Reactive power {3.01} ±POWER_MAX kVAR’s RO Bi FI NC PT

0.16 Input inductance {3.02} 0.000 to 500.000 mH RO Uni NC PT

0.17 Reactive current reference {4.08} ±REGEN_REACTIVE_MAX % 0.0 RW Bi US

0.18 Positive logic select {8.29} OFF (0) or On (1) On (1) RW Bit PT US

0.19 T7 analogue input 2 mode {7.11}

0.20 T7 analogue input 2 destination {7.14}Pr 0.00 to 21.51 Pr 3.10 RW Uni DE PT US

0.21 T8 analogue input 3 mode {7.15}

0.22 Not used

0.23 Not used

0.24 Not used

0.25 Not used

0.26 Not used

0.27 Not used

0.28 Not used

SMARTCARD parameter data

0.29

previously loaded

0.30 Parameter cloning {11. 42 }

0.31 Drive voltage rating {11.33 } 200 (0), 400 (1), 575 (2), 690 (3) RO Txt NC PT

0.32 Maximum Heavy Duty current rating {11. 32} 0.00 to 9999.99A RO Uni NC PT

0.33 Not used

0.34 User security code {11.30}0 to 999 0RWUniNCPTPS

0.35 Serial mode {11.2 4} AnSI (0), rtU (1) rtU (1) RW Txt US

0.36 Baud rate {11.25}

0.37 Serial address {11.23}0 to 247 1RWUniUS

0.38 Current controller Kp gain {4.13} 0 to 30,000 45 RW Uni US

0.39 Current controller Ki gain {4.14} 0 to 30,000 1,000 RW Uni US

0.40 Not used

0.41 Maximum switching frequency {5.18} 0 to 5 (3, 4, 6, 8, 12, 16 kHz) 0 (3kHz) RW Uni US

0.42 Not used

0.43 Not used

0.44 Not used

0.45 Thermal time constant {4.15} 0.0 to 400.0 89.0 RW Uni US

0.46 Regen drive rated current {5.07} 0 to RATED_CURRENT_MAX A RW Uni US

0.47 Not used

0.48 User drive mode {11. 31 }

0.49 Security status {11 .44} L1 (0), L2 (1), Loc (2) L2 (1) RW Txt PT US

0.50 Software version {11. 29} 1.00 to 99.99 RO Uni NC PT

0.51 to

Not used

0.59

11.36} 0 to 999 0 RO Uni NC PT US

{

0-20 (0), 20-0 (1), 4-20.tr (2), 20-4.tr (3),

4-20 (4), 20-4 (5), VOLt (6)

0-20 (0), 20-0 (1), 4-20.tr (2), 20-4.tr (3),

4-20 (4), 20-4 (5), VOLt (6), th.SC (7),

nonE (0), rEAd (1), Prog (2), AutO (3),

300 (0), 600 (1), 1200 (2), 2400 (3), 4800 (4),

57600 (8)*, 115200 (9)* *Modbus RTU only

th (8), th.diSP (9)

9600 (5), 19200 (6), 38400 (7),

OPEn LP (1), CL VECt (2),

SErVO (3), rEGEn (4)

Ú) Default(Ö)

Range(

boot (4)

VOLt (6) RW Txt US

nonE (0) RW Txt NC *

19200 (6) RW Txt US

rEGEn (4) RW Txt NC PT

Typ e

RW Read / Write RO Read only Uni Unipolar Bi Bi-polar Bit Bit parameter Txt Text string

FI Filtered DE Destination NC Not cloned RA Rating dependent PT Protected US User save PS Power down save

* Modes 1 and 2 are not user saved, Modes 0, 3 and 4 are user saved

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9.3 Menu 3: Regen sequencer

In regen mode the drive assumes the mains is lost, it does not close the input, and does not attempt synchronisation if the DC bus voltage is below the levels given in the table below.

If the unit is synchronised and the DC bus voltage falls below this level the unit is disabled and the Regen drive main contactor is opened.

The Regen drive also monitors the voltage at it's AC terminals (U, V and W) for mains loss and if this falls below the levels given in the table the unit is disabled and the Regen drive main contactor is opened.

Vol tag e

rating

DC voltage mains loss

detection level

AC voltage mains loss

detection level

200 V 205 Vdc 75 Vac 215 Vdc

400 V 410 Vdc 150 Vac 430 Vdc

575 V 540 Vdc 225 Vac 565 Vdc

690 V 540 Vdc 225 Vac 565 Vdc

Figure 9-1 Menu 3 Regen logic diagram

Main

contactor

Enable input

Power feed-forward compensation

Voltage set-point

DC bus voltage

closed

3.10

3.05

2.01

5.05

3.08

Power to current conversion

Kp gain

Regen

sequencer

3.04

3.06

Ki gain No user access

Regen restart mode

DC voltage for supply

healthy

2.013.03

Voltage

controller

kp gain

Current

control

(Menu 4)

Close start up

contactor

3.07

Enable

motor drive

3.09

Regen status

Modulator and power circuit

Mains supply

Key

Input

The parameters are all shown at their default settings

terminals

Output terminals

0.XX

Read-write (RW) parameter

Read-only (RO) parameter

Output voltage

Output power

Reactive power

Output frequency

Input inductance

2.01

5.02

2.01

5.03

2.01

3.01

2.01

5.01

2.01

3.02

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Table 9-3 Menu 3 Regen parameter descriptions

Parameter

Ú) Default(Ö)

Range(

3.01 Reactive power ±POWER_MAX kVAR’s RO Bi FI NC PT

3.02 Input inductance 0.000 to 500.000 mH RO Uni NC PT

3.03 Regen drive status 0 to 15 RO Uni NC PT

3.04 Regen restart mode 0 to 2 1 RW Uni US

3.05 Voltage setpoint 0 to DC_VOLTAGE_SET_MAX V 700 Vdc RW Uni US

3.06 Voltage controller Kp gain 0 to 65535 4000 RW Bi US

3.07 Close start up contactor OFF (0) or On (1) RO Uni NC

3.08 Main contactor closed OFF (0) or On (1) 0 RO Uni NC

3.09 Enable motor drive OFF (0) or On (1) RO Uni NC

3.10 Power feed forward compensation ±100.0 % 0.0 RW Bi NC

3.11 Current trimming mode 0 to 1 0 RW Uni US

RW Read / Write RO Read only Uni Unipolar Bi Bi-polar Bit Bit parameter Txt Text string

FI Filtered DE Destination NC Not cloned RA Rating dependent PT Protected US User save PS Power down save

Typ e

Figure 9-2 Current trimming state diagram

Mains loss or contactor open

when it should be closed

Mains Loss

Supply o.k

Current Trim

Disabled

Enabled Pr

Close Main Contactor

Waiting for Ena ble

3.11

Open Contactor

Current Trim

Close Main Contactor

Active

(not synchronised)

Synchronied

Trim co mplete

Contactor closed + 100ms delay

Enabled (Pr3.11=1)

Contactor open + 100ms delay

Trim co mplete

Contactor closed + 100ms delay

Synchronised

3.01

Reactive power

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

1 12111

Range Regen ±POWER_MAX kVAR’s

Update rate Background

The power (Pr 5.03) and the reactive power are the power or VAR's respectively that flow from the supply to the drive. Therefore when this parameter is positive the phase current flowing from the supply to the drive contains a component that lags the respective phase voltage, and when this parameter is negative the phase current contains a component which leads the respective phase voltage at the drive terminals.

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3.02

Input inductance

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

3111 1

Range Regen 0.000 to 500.000mH

Update rate Background

At power-up this parameter is zero. Each time the Regen drive is enabled the supply inductance is measured and displayed by this parameter. The value given is only approximate, but will give an indication as whether the input inductance is correct for the sinusoidal rectifier unit size. The measured value should include the supply inductance as well as the Regen drive input inductance, however, the supply filter capacitance, masks the effect of the supply inductance. Therefore the value measured is usually the Regen drive input inductor value.

3.03

Regen status

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

111 1

Range Regen 0 to 15

Update rate 4ms

If an L.Sync trip occurs Pr 3.03 indicates the reason. At power-up and on trip reset this parameter is set to zero. Once an L.Sync trip has occurred this parameter shows when the trip occurred and the reason for the last L.Sync trip as indicated by the bits in the table below. The reasons for the trip are either because the supply frequency is out of range or the PLL (phase lock loop) within the drive cannot synchronise to the supply waveforms.

Bit Status

0 Tripped during synchronisation

1 Tripped while running

2 Reason for trip was supply frequency <30.0Hz

3 Reason for trip was supply frequency >100.0Hz

4 Reason for trip was PLL could not be synchronised

3.04

Regen restart mode

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

1 1111

Range Regen 0 to 2

Default Regen 1

Update rate Background

Pr 3.04 defines the action taken after enable and when a synchronisation failure occurs.

0, rESYnC: Continuously attempt to re-synchronise

1, del.triP: delayed trip

Attempt to synchronise for 30s. If unsuccessful after this time then give a LI.SYnC trip. After a failure during running attempt to re-synchronise for 30s before tripping.

2, triP: immediate trip

Attempt to synchronise for 30s. If unsuccessful after this time then give a LI.SYnC trip. After a failure during running, trip immediately.

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3.05

Voltage set-point

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

1 1 111

Range Regen 0 to DC_VOLTAGE_SET_MAX V

200V rating drive: 350

Default Regen

400V rating drive: 700 575V rating drive: 835 690V rating drive: 1005

Update rate Background

The Regen drive will attempt to hold the DC bus at the level specified by this parameter. The DC bus voltage must always be higher than the peak of the line to line supply voltage if the unit is to operate correctly. The default values can be used with most supplies giving a reasonable level of control headroom. However, with higher voltage supplies the set-point must be raised.

3.06

Voltage controller Kp gain

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

111

Range Regen 0 to 65,535

Default Regen 4,000

Update rate Background

When the drive is operated as a Regen drive it uses a DC bus voltage controller with inner current controllers as shown below.

Pr DC

3.05

bus voltage set point

DC bus

voltage

Voltage

controller

Current

controllers

Current

feedback

The gains of the voltage and current controllers affect the stability of the regen unit control system and incorrect gain settings can result in overvoltage or over-current trips. In many applications the default gains given for the current controllers (Pr 4.13 and Pr 4.14) will be suitable, however, it may be necessary for the user to change these if the inductance or resistance of the supply plus the regen inductors varies significantly from the expected values.

Setting the current controller gains

The most critical parameter for stability is the current controller proportional gain (Pr 4.13). The required value for this is dependent on the Regen unit input inductance. If the inductance of the supply is a significant proportion of the recommended regen inductor (i.e. 60/IDR mH per phase, where IDR is equivalent to Kc), then the proportional gain may need to be increased. The supply inductance is likely to be negligible compared to the regen inductor value with small drives, but is likely to be significant with larger drives.

The proportional gain Pr 4.13 should be adjusted as described below using the total inductance per phase. The current controller integral gain Pr 4.14 is not so critical, and in a majority of cases the default value is suitable. However, if it is necessary to adjust this parameter it should be set up as described below using the supply resistance for one phase.

The proportional gain Kp (Pr 4.13) is the most critical value in controlling the performance of the current controllers. The value can be set by the user so that

Kp = (L / T) x (I

/ Vfs) x (256 / 5)

Where:

L is the total inductance per phase

is the peak full scale current feedback = Kc x √2 / 0.45. Where Kc is the current scaling for each size of drive.

is the maximum DC link voltage.

Therefore:

Kp = (L / 167µs) x (Kc x √2 / 0.45 / V

) x (256 / 5) = K x L x Kc

Where:

K = [√2 / (0.45 x V

x 167µs)] x (256 / 5)

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There is one value of the scaling factor K for each drive voltage rating as shown in the table below.

Drive voltage rating Vfs K

200V 415V 2322

400V 830V 1161

575V 990V 973

690V 1190V 809

The integral gain Ki (Pr 4.14) is less critical and should be set so that

Ki = Kp x 256 x T / τ

where

is the time constant (L / R).

R is the resistance of the supply for one phase.

Therefore

Ki = (K x L x Kc) x 256 x 167µs x R / L = 0.0427 x K x R x Kc

The above equations give the gain values that should give the best response at all switching frequencies with minimal overshoot. If required the gains can be adjusted to improve performance as follows:

1. The integral gain (Ki) can be used to improve the performance of the current controllers by reducing the effects of inverter non-linearity. These effects become more significant with higher switching frequency. These effects will more significant for drives with higher current ratings and higher voltage ratings. If Ki is increased by a factor of 4 it is possible to get up to 10% overshoot in response to a step change of current reference. For high performance applications, it is recommended that Ki is increased by a factor of 4 from the auto-tuned values. As the inverter non-linearity is worse with higher switching frequencies it is may be necessary to increase Ki by a factor of 8 for operation with 16kHz switching frequency.

2. It is possible to increase the proportional gain (Kp) to reduce the response time of the current controllers. If Kp is increased by a factor of 1.5 then the response to a step change of reference will give 12.5% overshoot. It is recommended that Ki is increased in preference to Kp.

Setting the voltage controller gain

Even when the gains are set correctly there will be a transient change of DC Bus voltage when there is a change in the load on any drive connected to the Regen unit. This can be reduced substantially by using an analogue input for power feed forward compensation (see Pr 3.10). The following discussion relates to a system without power feed-forward compensation.

If the power flow from the supply is increased (i.e. more power is taken from the supply or less power is fed back into the supply) the DC Bus voltage will fall, but the minimum level will be limited to just below the peak rectified level of the supply provided the maximum rating of the unit is not exceeded. If the power flow from the supply is reduced (i.e. less power is taken from the supply or more power is fed back into the supply) the DC Bus voltage will rise. During a rapid transient the bus will rise and then fall as shown below.

ch3: dT= 194ms dV=2.24 V

ctive regen

unit current

Regen unit DC Bus voltage

50mS/div

The example shown is for a very rapid load change where the torque reference of the motor drive has been changed instantly from one value to another. The proportional gain of the voltage controller defines the voltage transient because the integral term is too slow to have an effect. (In applications where the motor drive is operating under speed control, the speed controller may only require a limited rate of change of torque demand, and so the transient voltage may be less than covered in the discussion below.) If the set point voltage (Pr 3.05) plus the transient rise exceed the over-voltage trip level the Regen unit will trip.

When a 400V motor is operated above base speed from a drive in vector mode, fed from the Regen unit with the same rating supplying a DC voltage of 700V, and an instantaneous change of torque is demanded (i.e. -100% to +100%) the peak of the voltage transient (∆V) is approximately 80V if the current controllers are set up correctly and the voltage controller uses the default gain. (Operating with maximum voltage on the motor, i.e. above base speed, gives the biggest transient of power and hence the biggest value of ∆V. )

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If the load change, drive voltage rating, motor voltage or DC Bus set-point are different then ∆V is calculated from:

X K

∆V = 80V x K

x KMV X KSP

RAT

Where:

= load change / 200%

= Drive voltage rating / 400

RAT

= motor voltage / 400

= 700 / DC Bus voltage set point

In some applications, particularly with a high d.c. bus voltage set point and low switching frequency it may be necessary to limit the rate of change of power flow to prevent over voltage trips. A first order filter on the torque reference of the motor drive (i.e. using Pr 4.12) is the most effective method to reduce the transient further. (A fixed limit of the rate of change of torque demand is less effective.) The following table gives an approximate indication of the reduction in ∆V for different time constants. (As already mentioned the value of ∆V given if for an instantaneous change of torque representing the worst case. In applications where a speed controller is used in the motor drive the transient will already include an inherent filter).

Time constant Change in ∆V

20mS x 0.75

40mS x 0.5

The transient produced is approximately proportional to the voltage controller gain. The default voltage controller gain is set to give a value that is suitable for most applications. The gain may need to be increased if the DC Bus capacitance is high compared to two drives of similar rating coupled together. However, care must be taken to ensure that the gain is not too high as this can cause excessive ripple in the DC Bus voltage.

3.07

Close start up contactor

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

111

Update rate 4ms

When the Regen drive has powered-up through the soft-start and the DC Bus voltage has stopped rising and is higher than the contactor close voltage this bit changes from 0 to 1. If the DC Bus voltage falls below the contactor open voltage DC or the system is synchronised and the AC voltage falls below contactor open voltage AC this bit changes to zero. When regen mode is selected this bit is routed to the drive relay output (Terminals 41/42) as default.

This output, or an alternative output, can be used to control the soft-start contactor.

Drive Rating

Vac

Contactor Close

Vdc

Contactor Open

Vdc

Contactor Open

Vac

200V 215 205 75

400V 430 410 150

575V 565 540 225

690V 565 540 225

3.08

Main contactor closed

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

111

Default Regen 0

Update rate 4ms

When regen mode is selected Pr 3.08 is the destination for the digital input on terminal 25 (T25) as default. This input, or an alternative input, should be connected to an auxiliary contact on the soft-start contactor so that it follows the state of the contactor. The Regen drive will only attempt to synchronise to the supply when this parameter is one. This parameter is also used to monitor the contactor when the Regen drive is running. If at any time this parameter is zero the Regen drive is immediately disabled.

3.09

Enable motor drive

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

111

Update rate 4ms

When the unit has been enabled and successfully synchronised this bit will become active. If the Regen drive attempts to re-synchronise or trips, this bit becomes inactive. When regen mode is selected this bit is routed to a the digital output on terminal 24 (T24) as default. The output, or an alternative output, should be used to enable the motor drive(s) connected to the DC bus of the Regen drive.

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3.10

Power feed-forward compensation

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

12 1 1

Range Regen ±100 %

Default Regen 0.00

Update rate 4ms

Power feed-forward compensation can be used to reduce the transient DC bus voltage produced when a fast load transient occurs on drives connected to the Regen drive. 100.0% power feed-forward is equivalent to an active current of Rated drive current / 0.45 (i.e. over current trip level) and an AC terminal peak phase voltage equal to DC_VOLTAGE_MAX / 2. This scaling is the same as the power output from Pr 5.03 when high speed output mode is used (see section 9.7 Menu 7: Analogue I/O ). Therefore an analogue output of the drive supplying the load and analogue input 2 or 3 of the drive acting as the supply Regen drive can be connected together to give power feed-forward compensation without further scaling if the two drives are of equal rating. If the ratings are different the analogue input scaling must be used to give the correct power feed-forwards, where the scaling is given by:

Load drive Rated drive current / Regen drive rated drive current

3.11

Current trimming mode

Drive mode Regen

Coding

Bit SP FI DE Txt VM DP ND RA NC NV PT US RW BU PS

111

Range Regen 0 to 1

Default Regen 0

Update rate 4ms read

This parameter defines the strategy used for current trimming in regen mode. If Pr 3.11=0 then current trimming is only carried out once after powerup. If Pr 3.11=1 current trimming is carried out after power-up and then before the drive runs each time it is enabled.

9.4 Menu 4: Current control

In Regen mode the drive operates in a reference frame that is aligned to the voltage at the drive terminals. Because the phase shift across the input inductors is small, the reference frame is approximately aligned with the supply voltage. The maximum normal operating current is controlled by the current limits.

DRIVE_CURRENT_MAX is used in calculating the maximum of some parameters and is fixed at 1.75 x rated drive current. The drive can operate up to this level under normal conditions.

The relationship between the voltage and current for Regen mode operation is shown in the following vector diagram.

Regen mod

wLi

= Regen unit

terminal voltage

Supply voltage

Definitions:

is = Regen drive terminal voltage vector

vs = Regen drive current vector

CURRENT_LIMIT_MAX is used as the maximum for some parameters such as the user current limits. The maximum current limit is defined as follows (with a maximum of 1000%):

CURRENT_LIMIT_MAX

Maximum current

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

Motor rated current

100%×=

Where:

Regen drive rated current is given by Pr 5.07

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