Emerson unidrive m200, unidrive m201 User Manual

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Page 1

User Guide

Unidrive M200/201

Model size 1 to 6

Variable Speed AC drive for induction motors

Part Number: 0478-0042-04 Issue: 4

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 firmware version

This product is supplied with the latest firmware version. If this drive is to be connected to an existing system or machine, all drive firmware versions should be verified to confirm the same functionality as drives of the same model already present. This may also apply to drives returned from a Control Techniques Service Centre or Repair Centre. If there is any doubt please contact the supplier of the product.

The firmware version of the drive can be checked by looking at Pr 11.029.

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 must not be discarded but should instead be recycled by a specialist recycler of electronic equipment. Recyclers will find the products easy to dismantle 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 fasteners. 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 prefers 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.

REACH legislation

EC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (REACH) requires the supplier of an article to inform the recipient if it contains more than a specified proportion of any substance which is considered by the European Chemicals Agency (ECHA) to be a Substance of Very High Concern (SVHC) and is therefore listed by them as a candidate for compulsory authorisation.

For current information on how this requirement applies in relation to specific Control Techniques products, please approach your usual contact in the first instance. Control Techniques position statement can be viewed at: http://www.controltechniques.com/REACH

Issue Number: 4 Drive Firmware: 01.03.00 onwards

For patent and intellectual property related information please go to: www.ctpatents.info

Page 3

How to use this guide

NOTE

1 Safety information

2 Product information

3 Mechanical installation

4 Electrical installation

5 Getting started

6 Basic parameters

7 Running the motor

8 Optimization

10 Advanced parameters

9 NV Media card operation

11 Technical data

12 Diagnostics

13 UL listing information

This user guide provides complete information for installing and operating the drive from start to finish.

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

There are specific safety warnings throughout this guide, located in the relevant sections. In addition, Chapter 1 Safety information contains general safety information. It is essential that the warnings are observed and the information considered when working with or designing a system using the drive.

This map of the user guide helps to find the right sections for the task you wish to complete, but for specific information, refer to Contents on page 4:

Page 4

Contents

1 Safety information .................................7

1.1 Warnings, Cautions and Notes .............................7

1.2 Electrical safety - general warning ........................7

1.3 System design and safety of personnel ................7

1.4 Environmental limits ..............................................7

1.5 Access ...................................................................7

1.6 Fire protection .......................................................7

1.7 Compliance with regulations .................................7

1.8 Motor .....................................................................7

1.9 Mechanical brake control ......................................7

1.10 Adjusting parameters ............................................7

1.11 Electrical installation ..............................................8

1.12 Hazard ...................................................................8

2 Product information ..............................9

2.1 Model number .......................................................9

2.2 Ratings ................................................................10

2.3 Operating modes .................................................13

2.4 Drive features ......................................................14

2.5 Keypad and display .............................................15

2.6 Nameplate description ........................................16

2.7 Options ................................................................17

2.8 Items supplied with the drive ...............................18

3 Mechanical installation .......................19

3.1 Safety information ...............................................19

3.2 Planning the installation ......................................19

3.3 Terminal cover removal .......................................20

3.4 Installing / removing options ................................24

3.5 Dimensions and mounting methods ....................28

3.6 Enclosure for standard drives .............................34

3.7 Enclosure design and drive ambient

temperature .........................................................36

3.8 Heatsink fan operation ........................................36

3.9 Enclosing size 5 to 6 drive for high

environmental protection .....................................37

3.10 External EMC filter ..............................................39

3.11 Electrical terminals ..............................................41

3.12 Routine maintenance ..........................................43

5 Getting started .................................... 72

5.1 Understanding the display .................................. 72

5.2 Keypad operation ............................................... 72

5.3 Menu structure ................................................... 74

5.4 Menu 0 ............................................................... 74

5.5 Advanced menus ............................................... 75

5.6 Changing the operating mode ............................ 75

5.7 Saving parameters ............................................. 75

5.8 Restoring parameter defaults ............................. 76

5.9 Parameter access level and security ................. 76

5.10 Displaying parameters with non-default

values only ......................................................... 76

5.11 Displaying destination parameters only ............. 77

5.12 Communications ................................................ 77

6 Basic parameters ................................ 78

6.1 Menu 0: Basic parameters ................................. 78

6.2 Parameter descriptions ...................................... 82

7 Running the motor .............................. 83

7.1 Quick start connections ...................................... 83

7.2 Changing the operating mode ............................ 83

7.3 Quick start commissioning / start-up .................. 87

8 Optimization ........................................ 89

8.1 Motor map parameters ....................................... 89

8.2 Maximum motor rated current ............................ 95

8.3 Current limits ...................................................... 95

8.4 Motor thermal protection .................................... 95

8.5 Switching frequency ........................................... 96

9 NV Media Card .................................... 97

9.1 Introduction ........................................................ 97

9.2 SD card support ................................................. 97

9.3 NV Media Card parameters ............................... 99

9.4 NV Media Card trips ........................................... 99

4 Electrical installation ...........................45

4.1 Power connections ..............................................45

4.2 AC supply requirements ......................................49

4.3 24 Vdc supply ......................................................52

4.4 Ratings ................................................................53

4.5 Output circuit and motor protection .....................56

4.6 Braking ................................................................59

4.7 Ground leakage ...................................................61

4.8 EMC (Electromagnetic compatibility) ..................62

4.9 Communications connections .............................69

4.10 Control connections ............................................69

4 Unidrive M200 / M201 User Guide

Issue Number: 4

Page 5

10 Advanced parameters .......................100

10.1 Menu 1: Frequency reference ...........................110

10.2 Menu 2: Ramps .................................................114

10.3 Menu 3: Frequency control ...............................117

10.4 Menu 4: Torque and current control ..................122

10.5 Menu 5: Motor control .......................................125

10.6 Menu 6: Sequencer and clock ..........................129

10.7 Menu 7: Analog I/O ...........................................131

10.8 Menu 8: Digital I/O ............................................134

10.9 Menu 9: Programmable logic, motorized

pot, binary sum and timers ................................138

10.10 Menu 10: Status and trips .................................142

10.11 Menu 11: General drive set-up .........................144

10.12 Menu 12: Threshold detectors, variable

selectors and brake control function .................145

10.13 Menu 14: User PID controller ............................150

10.14 Menu 15: Option module set-up ........................153

10.15 Menu 18: Application menu 1 ...........................154

10.16 Menu 20: Application menu 2 ...........................155

10.17 Menu 21: Second motor parameters ................156

10.18 Menu 22: Additional Menu 0 set-up ..................157

11 Technical data ...................................159

11.1 Drive technical data ..........................................159

11.2 Optional external EMC filters ............................177

12 Diagnostics ........................................179

12.1 Status modes (Keypad and LED status) ...........179

12.2 Trip indications ..................................................179

12.3 Identifying a trip / trip source .............................179

12.4 Trips, Sub-trip numbers ....................................180

12.5 Internal / Hardware trips ....................................197

12.6 Alarm indications ...............................................197

12.7 Status indications ..............................................198

12.8 Displaying the trip history ..................................198

12.9 Behaviour of the drive when tripped .................198

13 UL Listing ...........................................199

13.1 General .............................................................199

13.2 Mounting ...........................................................199

13.3 Environment ......................................................199

13.4 Electrical installation .........................................199

13.5 UL listed accessories ........................................199

13.6 Motor overload protection .................................199

13.7 Motor overspeed protection ..............................199

13.8 Thermal memory retention ................................199

13.9 Electrical ratings ................................................199

13.10 cUL requirements for frame size 4 ....................199

13.11 Group installation ..............................................199

Unidrive M200 / M201 User Guide 5 Issue Number: 4

Page 6

Declaration of Conformity

Control Techniques Ltd

The Gro

Newtown

Powys

SY16 3BE

This declaration applies to Unidrive M variable speed drive products, comprising models numbers as shown below:

Maaa-bbcddddd Valid characters:

aaa 100, 101, 200, 201, 300, 400

bb 01, 02, 03

c 1,2 or 4

00013, 00017, 00018, 00023, 00024, 00032,

ddddd

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

harmonized standards:

EN 61800-5-1:2007

EN 61800-3:2004

EN 61000-6-2:2005

EN 61000-6-4:2007

00033, 00041, 00042, 00056, 00075

00056, 00073, 00094, 00100

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

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

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

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

Moteurs Leroy-Somer

Usine des Agriers

Boulevard Marcellin Leroy

CS10015

16915 Angoulême Cedex 9

France

These products comply with the Low Voltage Directive 2006/95/EC and the Electromagnetic Compatibility Directive 2004/108/EC.

T. Alexander

Vice President, Technology

Newtown

Date: 18th December 2013

These electronic drive products are intended to be used with appropriate motors, controllers, electrical protection components and other equipment to form complete end products or systems. Compliance with safety and EMC regulations depends upon installing and configuring drives correctly, including using the specified input filters. The drives must be installed only by professional assemblers who are familiar with requirements for safety and EMC. The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used. Refer to the User Guide. An EMC Data Sheet is also available giving detailed EMC information.

Electromagnetic compatibility (EMC), Limits,

EN 61000-3-2:2006

EN 61000-3-3:2008

EN 61000-3-2:2006 Applicable where input current <16 A. No limits apply for professional equipment where input power >1 kW.

Limits for harmonic current emissions (equipment input current <16 A per phase)

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

6 Unidrive M200 / M201 User Guide

Issue Number: 4

Page 7

Safety

WARNING

CAUTION

NOTE

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Basic

parameters

Running the

motor

Optimization

NV Media

Card

Advanced

parameters

Technical data Diagnostics UL Listing

1 Safety information

1.1 Warnings, Cautions and Notes

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

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

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

1.2 Electrical safety - general warning

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

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

1.3 System design and safety of

personnel

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

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

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

The STOP 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 behavior 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.

1.6 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided. For further information, refer to section

3.2.5 Fire protection on page 19.

1.7 Compliance with regulations

The installer is responsible for complying with all relevant regulations, such as national wiring regulations, accident prevention regulations and electromagnetic compatibility (EMC) regulations. Particular attention must be given to the cross-sectional areas of conductors, the selection of fuses or other protection, and protective ground (earth) connections.

This User Guide contains instruction for achieving compliance with specific EMC standards.

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

2006/42/EC Safety of machinery. 2004/108/EC: Electromagnetic Compatibility.

1.8 Motor

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

Standard squirrel cage induction motors are designed for single speed operation. If it is intended to use the capability of the drive to run a motor at speeds above its designed maximum, it is strongly recommended that the manufacturer is consulted first.

Low speeds may cause the motor to overheat because the cooling fan becomes less effective. The motor should be installed with a protection thermistor. If necessary, an electric forced vent fan should be used.

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

It is essential that the correct value is entered in Pr 00.006 motor rated current. This affects the thermal protection of the motor.

1.9 Mechanical brake control

The brake control functions are provided to allow well co-ordinated operation of an external brake with the drive. While both hardware and software are designed to high standards of quality and robustness, they are not intended for use as safety functions, i.e. where a fault or failure would result in a risk of injury. In any application where the incorrect operation of the brake release mechanism could result in injury, independent protection devices of proven integrity must also be incorporated.

1.10 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 User Guide regarding transport, storage, installation and use of the drive must be complied with, including the specified environmental limits. Drives must not be subjected to excessive physical force.

1.5 Access

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

Unidrive M200 / M201 User Guide 7 Issue Number: 4

Page 8

Safety

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Basic

parameters

Running the

motor

1.11 Electrical installation

1.11.1 Electric shock risk

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

AC supply cables and connections

Output cables and connections

Many internal parts of the drive, and external option units

Unless otherwise indicated, control terminals are single insulated and must not be touched.

1.11.2 Stored charge

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

1.12 Hazard

1.12.1 Falling hazard

The drive presents a falling or toppling hazard. This can still cause injury to personnel and therefore should be handled with care.

Maximum weight:

Size 1: 0.75 kg (1.65 Ib). Size 2: 1.3 kg (3 lb). Size 3: 1.5 kg (3.3 lb). Size 4: 3.13 kg (6.9 Ib). Size 5: 7.4 kg (16.3 Ib). Size 6: 14 kg (30.9 Ib).

Optimization

NV Media

Card

Advanced

parameters

Technical data Diagnostics UL Listing

8 Unidrive M200 / M201 User Guide

Issue Number: 4

Page 9

Safety

Optional Build

Identification Label

Derivative Electrical Specifications

M200 - 03 4 00073

Unidrive M200 Product Line

Frame Size

Current Rating:

Heavy Duty current rating x 10

Drive Format:

A - AC in AC out

Customer Code

Conformal Coating

0 = Standard

1 - English

Voltage Rating:

2 - 200 V (200 - 240

- 400 V (380 - 480

- 575 V (500 - 575

- 690 V (500 - 690

10 %)

1 - 100 V (100 - 120 10 %)

10 %) 5 6 10 %)

10 %)

information

Product

information

Mechanical

installation

Electrical

installation

Getting

started

Basic

parameters

Running the

motor

Optimization

NV Media

2 Product information

2.1 Model number

The way in which the model numbers for the Unidrive M range are formed is illustrated below:

Figure 2-1 Model number

Card

Advanced

parameters

Technical data Diagnostics UL Listing

Documentation

A B 1 00

Reserved

Reserved:

Brake Transistor:

B=Brake

Cooling:

A=Air

Customer Code:

00 = 50 Hz 01 = 60 Hz

Documentation:

0 - Supplied separately

Unidrive M200 / M201 User Guide 9 Issue Number: 4

Page 10

Safety

Available output

current

Heavy Duty

Maximum continuous current (above 50% base speed) -

Normal Duty

Maximum continuous current -

Heavy Duty

Motor rated current set in the drive

Heavy Duty

- with high

overload capability

Normal Duty

NOTE

Motor total

current (Pr 04.001)

as a percentage

of motor rated

current

Motor speed as a percentage of base speed

100%

Max. permissible continuous current

100%

I t protection operates in this region

70%

50%15%

Pr = 0 Pr = 1

04.025

Motor total

current (Pr 04.001)

as a percentage

of motor rated

current

Motor speed as a

percentage of base speed

100%

Max. permissible continuous current

100%

I t protection operates in this region

70%

50%

Pr = 0

Pr = 1

04.025

information

Product

information

Mechanical

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Electrical

installation

Getting started

Basic

parameters

Running the

motor

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NV Media

Card

2.2 Ratings

The size 1 to 4 drive is Heavy Duty rated only. The size 5 to 6 drive is dual rated. The setting of the motor rated current determines which rating applies Heavy Duty or Normal Duty. The two ratings are compatible with motors designed to IEC60034. The graph aside illustrates the difference between Normal Duty and Heavy Duty with respect to continuous current rating and short term overload limits.

Normal Duty Heavy Duty (default)

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

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

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

The speed at which the low speed protection takes effect can be changed by the setting of Low Speed Thermal Protection Mode (04.025). The protection starts when the motor speed is below 15 % of base speed when Pr 04.025 = 0 (default) and below 50 % when Pr 04.025 = 1.

Operation of motor I2t protection

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

• Self ventilated (TENV/TEFC) induction motors

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

If the application uses a self ventilated (TENV/TEFC) induction motor and increased thermal protection is required for speeds below 50 % base speed, then this can be enabled by setting Low Speed Thermal Protection Mode (04.025) = 1.

Motor I2t protection defaults to be compatible with:

• Forced ventilation induction motors

Advanced

parameters

Overload limit -

Technical data Diagnostics UL Listing

Overload limit -

Normal Duty

The continuous current ratings given are for maximum 40 °C (104 °F), 1000 m altitude and 3.0 kHz switching. Derating is required for higher switching frequencies, ambient temperature >40 °C (104 °F) and high altitude. For further information, refer to Chapter 11 Technical data on page 159.

10 Unidrive M200 / M201 User Guide

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Page 11

Safety

information

Product

information

Mechanical

installation

Electrical

installation

Getting

started

Table 2-1 100 V drive ratings (100 V to 120 V ±10 %)

Basic

parameters

Running the

motor

Optimization

NV Media

Card

Heavy Duty

Advanced

parameters

Technical data Diagnostics UL Listing

Model

Maximum

continuous

output current

Open loop peak

current

RFC peak current

Nominal power at

100 V

Motor power at

100 V

AAAkWhp

01100017 1.7 2.6 3.1 0.25 0.33

Frame size 1

01100024 2.4 3.6 4.3 0.37 0.5

02100042 4.2 6.3 7.6 0.75 1

Frame size 2

02100056 5.6 8.4 10.1 1.1 1.5

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

Normal Duty Heavy Duty

Model

Maximum

continuous

output

current

Nominal power at

230 V

Motor

power at

230 V

Peak

current

Maximum

continuous

output

current

Open

loop

peak

current

RFC

peak

current

Nominal power at

230 V

Motor

power at

230 V

A kW hp A A A A kW hp

01200017

Frame size 1

01200024

01200033

01200042

02200024

02200033

Frame size 2

02200042

02200056

02200075

Frame size 3 03200100

Frame size 4

04200133

04200176

1.7 2.6 3.1 0.25 0.33

2.4 3.6 4.3 0.37 0.5

3.3 5 5.9 0.55 0.75

4.2 6.3 7.6 0.75 1

2.4 3.6 4.3 0.37 0.5

3.3 5 5.9 0.55 0.75

4.2 6.3 7.6 0.75 1

5.6 8.4 10.1 1.1 1

7.5 11.3 13.5 1.5 2

10 15 18 2.2 3

13.3 20 23.9 3 3

17.6 16.4 31.7 4 5

Frame size 5 05200250 30 7.5 10 33 25 37.5 50 5.5 7.5

Frame size 6

06200330 50 11 15 55 33 49.5 66 7.5 10

06200440 58 15 20 63.8 44 66 88 11 15

Unidrive M200 / M201 User Guide 11 Issue Number: 4

Page 12

Safety

NOTE

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

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

Normal Duty Heavy Duty

Model

Maximum

continuous

output

current

Nominal power at

400 V

AkWhpA A AAkWhp

02400013

02400018

Frame size 2

02400023

02400032

02400041

03400056

Frame size 3

03400073

03400094

Frame size 4

Frame size 5

04400135

04400170

05400270 30 15 20 33 27 40.5 54 11 20

05400300 31 15 20 34.1 30 45 60 15 20

06400350 38 18.5 25 41.8 35 52.5 70 15 25

Frame size 6

06400420 48 22 30 52.8 42 63 84 18.5 30

06400470 63 30 40 69.3 47 70.5 94 22 30

Basic

parameters

Motor

power at

460 V

Running the

motor

Peak

current

Optimization

Maximum

continuous

NV Media

output

current

Card

Advanced

parameters

O p e n

l oo p

peak

current

Technical data Diagnostics UL Listing

R FC

p ea k

current

Nominal

power at

400 V

power at

1.3 2 2.3 0.37 0.5

1.8 2.7 3.2 0.55 0.75

2.3 3.5 4.1 0.75 1

3.2 4.8 5.8 1.1 1.5

4.1 6.2 7.4 1.5 2

5.6 8.4 10.1 2.2 3

7.3 11 13.1 3 3

9.4 14.1 16.9 4 5

13.5 20.3 24.3 5.5 7.5

17 25.5 30.6 7.5 10

Motor

460 V

Table 2-4 575 V drive ratings (500 V to 575 V ±10 %)

Normal Duty Heavy Duty

Model

Maximum

continuous

output

current

Nominal

power at

575 V

Motor

power at

575 V

Peak

current

Maximum

continuous

output

current

O p e n

loop peak

current

R F C

pe ak

current

Nominal

power at

575 V

Motor

power at

575 V

AkWhpAA AAkWhp

05500030 3.9 2.2 3 4.3 3 4.5 6 1.5 2

Frame size 5

05500040 6.1 4 5 6.7 4 6 8 2.2 3

05500069 10 5.5 7.5 11 6.9 10.3 13.8 4 5

06500100 12 7.5 10 13.2 10 15 20 5.5 7.5

06500150 17 11 15 18.7 15 22.5 30 7.5 10

Frame size 6

06500190 22 15 20 24.2 19 28.5 38 11 15

06500230 27 18.5 25 29.7 23 34.5 46 15 20

06500290 34 22 30 37.4 29 43.5 58 18.5 25

06500350 43 30 40 47.3 35 52.5 70 22 30

2.2.1 Typical short term overload limits

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

Typical values are shown in the table below for RFC-A and open loop (OL) modes:

Table 2-5 Typical overload limits

Operating mode RFC From cold RFC From 100 % Open loop from cold Open loop from 100 %

Normal Duty overload with motor rated current = drive rated current

Heavy Duty overload with motor rated current = drive rated current

110 % for 165 s 110 % for 9 s 110 % for 165 s 110 % for 9 s

180 % for 3 s 180 % for 3 s 150 % for 60 s 150 % for 8 s

Generally the drive rated current is higher than the matching motor rated current allowing a higher level of overload than the default setting.

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

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

12 Unidrive M200 / M201 User Guide

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Page 13

Safety

information

Product

information

Mechanical

installation

Electrical

installation

Getting

started

Basic

parameters

Running the

motor

Optimization

NV Media

Card

Advanced

parameters

Technical data Diagnostics UL Listing

2.3 Operating modes

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

1. Open loop mode

Open loop vector mode Fixed V/F mode (V/Hz) Square V/F mode (V/Hz)

2. RFC - A Without position feedback sensor

2.3.1 Open loop mode

The drive applies power to the motor at frequencies varied by the user. The motor speed is a result of the output frequency of the drive and slip due to the mechanical load. The drive can improve the speed control of the motor by applying slip compensation. The performance at low speed depends on whether V/F mode or open loop vector mode is selected.

Open loop vector mode

The voltage applied to the motor is directly proportional to the frequency except at low speed where the drive uses motor parameters to apply the correct voltage to keep the flux constant under varying load conditions.

Typically 100 % torque is available down to 1 Hz for a 50 Hz motor.

Fixed V/F mode

The voltage applied to the motor is directly proportional to the frequency except at low speed where a voltage boost is provided which is set by the user. This mode can be used for multi-motor applications.

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

Square V/F mode

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

2.3.2 RFC-A mode

Rotor Flux Control for Asynchronous (induction) motors (RFC-A) encompasses closed loop vector control without a position feedback device

Without position feedback sensor

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

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2.4 Drive features

Figure 2-2 Features of the drive (size 1 to 4)

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Key

1. Rating label (On side of drive) 5. Control connections 9. DC bus -

2. Identification label 6. Braking terminal 10. Motor connections

3. Option module 7. Internal EMC filter screw 11. AC supply connections

4. Relay connections 8. DC bus + 12. Ground connections

14 Unidrive M200 / M201 User Guide

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5 6

10 11

V A Hz rpm %

information

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installation

Figure 2-3 Features of the drive (size 5 to 6)

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Key

1. Keypad 6. Braking terminal 11. Ground connections

2. Rating label 7. DC bus +

3. Option module slot 1 8. DC bus -

4. Relay connections 9. Motor connections

5. Control connections 10. AC supply connections

2.5 Keypad and display

The keypad and display provide information to the user regarding the operating status of the drive and trip codes, and provide the means for changing parameters, stopping and starting the drive, and the ability to perform a drive reset.

Figure 2-4 Unidrive M200 keypad detail Figure 2-5 Unidrive M201 keypad detail

(1) The Enter button is used to enter parameter view or edit mode, or to accept a parameter edit.

(2 / 5) The Navigation buttons can be used to select individual parameters or to edit parameter values.

(3) The Stop / Reset button is used to stop and reset the drive in keypad mode. It can also be used to reset the drive in terminal mode.

(4) The Start button is used to start the drive in keypad mode.

(6) The Escape button is used to exit from the parameter edit / view mode.

(7) The Speed Reference Potentiometer is used to control the speed reference in keypad mode (only available on Unidrive M201).

Unidrive M200 / M201 User Guide 15 Issue Number: 4

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Safety

Model number

Refer to User Guide

Date code

Input

voltage

Power rating

M200-022 00042 A

200-240V 0.75kW

V40

Model

number

Input voltage

Output

voltage

Serial

number

Input

frequency

Power rating

Date code

No. of phases & Typical input current

Heavy duty output current

Approvals

M200-022 00042 A

0.75kW

10.4A / 5.4A

Manuals: www.ctmanuals.info

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2.6 Nameplate description

See Figure 2-2 for location of rating labels.

Figure 2-6 Typical drive rating labels for size 2

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Key to approvals

CE approval Europe

C Tick approval Australia

Technical data Diagnostics UL Listing

Refer to Figure 2-1 Model number on page 9 for further information relating to the labels.

UL / cUL approval

USA &

Canada

RoHS compliant Europe

16 Unidrive M200 / M201 User Guide

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Figure 2-7 Options available with the drive

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1. AI-485 adaptor

2. SI module

3. CT comms cable

4. Remote mountable LCD keypad

5. AI-Backup adaptor module

Table 2-6 System Integration Option module identification

Type Option module Color Name Further details

Purple SI-PROFIBUS

Fieldbus

Medium

Light Grey SI-CANopen

Automation

(I/O expansion)

Orange SI-I/O

Grey

SI-DeviceNet

Profibus option

PROFIBUS adaptor for communications with the drive

DeviceNet option

DeviceNet adaptor for communications with the drive

CANopen option

CANopen adaptor for communications with the drive

Extended I/O

Increases the I/O capability by adding the following combinations:

• Digital I/O

• Digital Inputs

• Analog Inputs (differential or single ended)

• Analog Output

• Relays

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Table 2-7 Adaptor Interface (AI) option module identification

Type Option module Name Further Details

485 serial communications option

Communications AI-485 adaptor

Provides a 485 serial communications interface via an RJ45 connector or alternative screw terminals

Backup AI-Backup adaptor + 24 V Backup and SD Card Interface

2.8 Items supplied with the drive

The drive is supplied with a copy of the Quick Start Guide, a safety information booklet, the Certificate of Quality and an accessory kit box (size 5 to 6 only), including the items shown in Table 2-8.

Table 2-8 Parts supplied with the drive

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

Grounding bracket

x 1

M4 x 8 Double Sem Torx screw

x 2

Grounding bracket

Surface mounting brackets

Grounding clamp

Terminal nuts

Supply and motor connector

Finger guard grommets

x 1

x 2 x 2

x 1 x 1

M6 x 11

x 1 x 1

x 3 x 2

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WARNING

NOTE

Drive

Notless tha n 2X

Ba ffle plate s (m a y be aboveor below bottom ofenclosure)

Bo ttom o f fire

enclosure

Not less than 2 times ‘X’

Baffle plates (may be above or

below bottom of enclosure)

Bottom of fire enclosure

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3 Mechanical installation

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

• Through hole mounting

• High IP as standard or Through-panel mounting

• Enclosure sizing and layout

• Option module installing

• Terminal location and torque settings

3.1 Safety information

Follow the instructions

The mechanical and electrical installation instructions must be adhered to. Any questions or doubt should be referred to the supplier of the equipment. It is the responsibility of the owner or user to ensure that the installation of the drive and any external option unit, and the way in which they are operated and maintained, comply with the requirements of the Health and Safety at Work Act in the United Kingdom or applicable legislation and regulations and codes of practice in the country in which the equipment is used.

Competence of the installer

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

3.2.3 Cooling

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

For further information, refer to section 3.6 Enclosure for standard drives on page 34.

3.2.4 Electrical safety

The installation must be safe under normal and fault conditions. Electrical installation instructions are given in Chapter 4 Electrical installation on page 45.

3.2.5 Fire protection

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

For installation in the USA, a NEMA 12 enclosure is suitable.

For installation outside the USA, the following (based on IEC 62109-1, standard for PV inverters) is recommended.

Enclosure can be metal and/or polymeric, polymer must meet requirements which can be summarized for larger enclosures as using materials meeting at least UL 94 class 5VB at the point of minimum thickness.

Air filter assemblies to be at least class V-2.

The location and size of the bottom shall cover the area shown in Figure 3-1. Any part of the side which is within the area traced out by the 5° angle is also considered to be part of the bottom of the fire enclosure.

Figure 3-1 Fire enclosure bottom layout

Enclosure

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

3.2 Planning the installation

The following considerations must be made when planning the installation:

3.2.1 Access

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

The IP (Ingress Protection) rating of the drive is installation dependent. For further information, refer to section 3.9 Enclosing size 5 to 6 drive for high environmental protection on page 37

3.2.2 Environmental protection

The drive must be protected from:

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

• Contamination with electrically conductive material

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

• Temperature beyond the specified operating and storage ranges

• Corrosive gasses

The bottom, including the part of the side considered to be part of the bottom, must be designed to prevent escape of burning material - either by having no openings or by having a baffle construction. This means that openings for cables etc. must be sealed with materials meeting the 5VB requirement, or else have a baffle above. See Figure 3-2 for acceptable baffle construction. This does not apply for mounting in an enclosed electrical operating area (restricted access) with concrete floor.

Figure 3-2 Fire enclosure baffle construction

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

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WARNING

Control / AC /

Motor Terminal Cover

Control / AC /

Motor Terminal Cover

Control / AC /

Motor Terminal Cover

Control / AC /

Motor Terminal Cover

NOTE

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3.2.6 Electromagnetic compatibility

Variable speed drives are powerful electronic circuits which can cause electromagnetic interference if not installed correctly with careful attention to the layout of the wiring.

Some simple routine precautions can prevent disturbance to typical industrial control equipment.

If it is necessary to meet strict emission limits, or if it is known that electromagnetically sensitive equipment is located nearby, then full precautions must be observed. In-built into the drive, is an internal EMC filter, which reduces emissions under certain conditions. If these conditions are exceeded, then the use of an external EMC filter may be required at the drive inputs, which must be located very close to the drives. Space must be made available for the filters and allowance made for carefully segregated wiring. Both levels of precautions are covered in section 4.8 EMC (Electromagnetic compatibility) on page 62.

3.2.7 Hazardous areas

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

3.3 Terminal cover removal

Isolation device

The AC and / or DC power 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 and / or DC power supply has been disconnected. If the drive has been energized, the power supply must be isolated at least ten minutes before work may continue.

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

3.3.1 Removing the terminal covers

Figure 3-3 Location and identification of terminal covers (size 1 to 4)

The drives shown in Figure 3-3 have a single removable terminal cover which provides access to all electrical connections, i.e. Control, AC, Motor and Brake functions. Figure 3-5 on page 21 illustrates the three steps required to remove the drive terminal covers.

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DC / Braking

terminal cover

left

AC motor

terminal cover

Control

terminal

cover

Control

terminal cover

AC motor

terminal cover

DC / Braking

terminal cover

left

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Figure 3-4 Location and identification of terminal covers (size 5 to 6)

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Figure 3-5 Removing the terminal cover (size 1 to 4)

1. Using a flat bladed screwdriver, turn the terminal cover locking clip anti-clockwise by approximately 30°

2. Slide the terminal cover down

3. Remove terminal cover

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Pozi Pz 2

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Figure 3-6 Removing the size 5 terminal covers

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

Figure 3-7 Removing the size 6 terminal covers

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

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3.3.2 Removing the finger-guard and DC terminal

cover break-outs

Figure 3-8 Removing the finger-guard break-outs

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A: All sizes

B: Size 5 only

C: Size 6 only

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

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CAUTION

NOTE

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3.4 Installing / removing options

Power down the drive before installing / removing the SI option module. Failure to do so may result in damage to the product.

Figure 3-9 Installation of an SI option module (size 2 to 4)

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Installing the option module

• With the option module tilted slightly backwards, align and locate the two holes in the rear of the option module onto the two tabs (1) on the drive.

• Press the option module onto the drive as shown in (2) until the connector mates with the drive, ensuring that the tab (3) retains the option module in place.

Check that the option module is securely located on the drive. Always ensure that the terminal cover is always replaced before use as this ensures that the option module is firmly secured.

Figure 3-10 Removing the SI-Option module (size 2 to 4)

• Press down on the tab (1) to release the option module from the drive housing as shown.

• Tilt the option module slightly towards you and pull away from the drive housing (2).

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Figure 3-11 Installation of an SI option module (size 5 to 6)

• Move the option module in the direction shown (1).

• Align and insert the option module tab into the slot provided (2), This is shown in the detailed view (A).

• Press down on the option module until it clicks in place.

Figure 3-12 Removal of an SI option module (size 5 to 6)

Technical data Diagnostics UL Listing

2 3

• To release the option module from the drive housing, press down on the tab (1) as shown in detailed view (A).

• Tilt the option module towards you as shown in (2).

• Remove the option module by lifting away from the drive as shown in (3).

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Figure 3-13 Installing the AI-485 adaptor to the drive

• Identify the two plastic fingers on the underside of the AI-485 Adaptor (1) - then insert the two fingers into the corresponding slots in the springloaded sliding cover on the top of the drive.

• Hold the adaptor firmly and push the spring loaded protective cover towards the back of the drive to expose the connector block (2) below.

• Press the adaptor downwards (3) until the adaptor connector locates into the drive connection below.

Figure 3-14 Removal of the AI-485 adaptor

• To remove the AI-Adaptor, pull it up away from the drive in the direction shown (1)

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Figure 3-15 Installing the AI-Backup adaptor

• Identify the two plastic fingers on the underside of the AI-Backup adaptor (1) - then insert the two fingers into the corresponding slots in the

spring-loaded sliding cover on the top of the drive.

• Hold the adaptor firmly and push the spring loaded protective cover towards the back of the drive to expose the connector block (2) below.

• Press the adaptor downwards (3) until the adaptor connector locates into the drive connection as shown.

Figure 3-16 Removal of the AI-Backup adaptor

• To remove the AI-Backup adaptor, pull it up away from the drive in the direction shown (1)

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WARNING

160 mm (6.3 in)

137 mm (5.4 in)

130 mm (5.12 in)

75 mm (3.0 in)

9.0 mm

(0.35 in)

8.0 mm

(0.31 in)

143 mm (5.63 in)

53 mm (2.1 in)

11 m m

(0.43 in)

Æ5.0 mm (0.2 in) x 4 holes

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3.5 Dimensions and mounting methods

The drive can be either surface or through-panel mounted using the appropriate brackets. The following drawings show the dimensions of the drive and mounting holes for each method to allow a back plate to be prepared.

The Through-panel mounting kit is not supplied with the drive and can be purchased separately, below are the relevant part numbers:

Table 3-1 Through-panel mounting kit part numbers for size 5 to 6

Size CT part number

5 3470-0067

6 3470-0055

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

Many of the drives in this product range weigh in excess of 15 kg (33 lb). Use appropriate safeguards when lifting these models. A full list of drive weights can be found in section 11.1.19 Weights on page 169.

3.5.1 Surface mounting

Figure 3-17 Surface mounting the size 1 drive

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75 mm (3.0 in)

150 mm (6.0 in)

205 mm (8.07 in)

180 mm (7.1 in)

55 mm (2.20 in)

194 mm (7.63 in)

5.5 mm

(0.22 in)

5.5 mm

(0.22 in)

11 m m

(0.43 in)

Æ5.0 mm (0.2 in) x 4 holes

226 mm (8.9 in)

90 mm (3.54 in)

200 mm (7.9 in)

(0.21 in)

6.0 mm

(0.24 in)

160 mm (6.3 in)

215 mm

(8.5 in)

9.5 mm

(0.2 in) x 4 holes

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Figure 3-18 Surface mounting the size 2 drive

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Figure 3-19 Surface mounting the size 3 drive

5.5 mm

(0.37 in)

70.7 mm (2.80 in)

∅

5.0 mm

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86.0 mm (3.40 in)

175 mm (6.90 in)

115 mm (4.53 in)

245 mm (9.65 in)

277 mm (10.90 in)

265 mm

(10.43 in)

6.0 mm

(0.24 in)

6.0 mm

(0.24 in)

14.5 mm (0.57 in)

Æ6.0 mm (0.24 in) x 4 holes

375 mm (14.78 in)

106 mm (4.17 in)

9.0 mm

(0.35 in)

8.0 mm

(0.32 in)

6.5 mm (0.30 in) x 4 holes

192.0 mm (7.60 in)

143.0 mm (5.63 in)

365.0 mm (14.37 in)

391.0 mm (15.39.0 in)

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Figure 3-20 Surface mounting the size 4 drive

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Figure 3-21 Surface mounting the size 5 drive

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376 mm

(14.80 in)

196.0 mm (7.72 in)

7.0 mm

(0.28 in)

6.0 mm

(0.24 in)

221.0 mm (8.70 in)210.0 mm (8.27 in)

365.0 mm (14.37 in)

389.0 mm (15.32 in)

Æ7.0 mm (0.27 in) x 4 holes

67.0 mm (2.64 in)

125.0 mm (4.92 in)

143.0 mm (5.63 in)

365.0 mm (14.37 in)

409.0 mm (16.10 in)

106 mm (4.17 in)

157 mm (6.18 in)

359 mm (14.13 in)

169 mm (6.65 in)

26 mm

(1.02 in)

167 mm (6.58 in)

26 mm

(1.02 in)

393 mm (15.47 in)

137 mm (5.47 in)

Æ6.5 mm (0.3 in)

(x 4 holes)

Æ5

.0 mm (0.20 in)

(x 4 holes)

17 mm

(0.66 in)

53 mm (2.1 in)

78.5 mm (3.09 in)

68 mm

(2.67 in)

68 mm

(2.67 in)

Radius 1.0 mm

(0.04 in)

78.5 mm (3.09 in)

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Figure 3-22 Surface mounting the size 6 drive

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3.5.2 Through-panel mounting

Figure 3-23 Through-panel mounting the size 5 drive

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98.0 mm (3.86 in)

101.0 mm (3.98 in)

202.0 mm (7.95 in)

101.0 mm (3.98 in)

26.0 mm (1.02 in)

167.0 mm (6.58 in)

21.0 mm (0.83 in)

Radius 1.0 mm

(0.04 in)

196.0 mm (7.72 in)

210.0 mm (8.27 in)

365.0 mm (14.37 in)

412.0 mm (16.22 in)

221.0 mm (8.70 in)

125.0 mm (4.92 in)

96.0 mm (3.78 in)

399.0 mm (15.71 in)

356.0 mm (14.02 in)

264.0 mm (10.39 in)

26.0 mm

(1.02 in)

120.0 mm (4.73 in)

26.0 mm (1.02 in)

98.0 mm (3.86 in)

7.0 mm (0.276 in)

5.0 mm (0.20 in)

NOTE

150 mm (5.91 in)

11 m m

(0.43 in)

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Figure 3-24 Through-panel mounting the size 6 drive

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The outer holes plus the hole located in the center of the bracket are to be used for through panel mounting.

Figure 3-25 Size 2 M201 Variant with front panel potentiometer control

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3.5.3 Mounting brackets

Table 3-2 Mounting brackets (size 5 to 6)

Frame size Surface Qty Through-panel Qty

x 2

5 x 2

Hole size: 6.5 mm (0.26 in) Hole size: 6.5 mm (0.26 in)

6 x 2

Hole size: 6.5 mm (0.26 in) Hole size: 6.5 mm (0.26 in)

3.5.4 Recommended spacing between the drives

Figure 3-26 Recommended spacing between the drives

Hole size: 5.2 mm (0.21 in)

x 2

x 3

Hole size: 5.2 mm (0.21 in)

x 2

Table 3-3 Spacing required between the drives (without high IP bung)

Drive size

40 °C

Spacing (A)

0 mm (0.00)

5 0 mm (0.00) 30 mm (1.18 in)

6 0 mm (0.00 in)

* 50 °C derating applies, refer to Table 11-5 Maximum permissible continuous output current @ 50 °C (122 °F) (size 5 to 6) on page 162.

When through-panel mounted, ideally drives should be spaced 30 mm (1.18 in) to maximize panel stiffness.

Unidrive M200 / M201 User Guide 33 Issue Number: 4

50 °C*

Page 34

Safety

³100 mm

(4 in)

Enclosure

AC supply contactor and fuses or MCB

Locate as required

External controller

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

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

³100 mm

(4 in)

Optional braking resistor and overload

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

device as required

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

Note For EMC compliance:

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

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

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3.6 Enclosure for standard drives

3.6.1 Enclosure layout

Please observe the clearances in the diagram below taking into account any appropriate notes for other devices / auxiliary equipment when planning the installation.

Figure 3-27 Enclosure layout

Table 3-4 Spacing required between drive / enclosure and drive /

EMC filter

Drive Size Spacing (B)

0 mm (0.00 in)

30 mm (1.18 in)

34 Unidrive M200 / M201 User Guide

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Page 35

Safety

intText

–()

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

NOTE

392.4

5.5 40 30–()

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

2HD–

HD+

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

7.135 2 2× 0.6×()–

2 0.6+

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

3kP

intText

–

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

------ -

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3.6.2 Enclosure sizing

1. Add the dissipation figures from section 11.1.2 Power dissipation on page 163 for each drive that is to be installed in the enclosure.

2. If an external EMC filter is to be used with each drive, add the dissipation figures from section 11.2.1 EMC filter ratings on page 178 for each external EMC filter that is to be installed in the enclosure.

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

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

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

Calculating the size of a sealed enclosure

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

Calculate the minimum required unobstructed surface area A enclosure from:

for the

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Figure 3-28 Enclosure having front, sides and top panels free to

dissipate heat

Insert the following values:

40 °C

int

30 °C

ext

k 5.5 P 392.4 W

The minimum required heat conducting area is then:

Where:

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

Maximum expected temperature inoC outside the

ext

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

Example

To calculate the size of an enclosure for the following:

• Two drives operating at the Normal Duty rating

• External EMC filter for each drive

• Braking resistors are to be mounted outside the enclosure

• Maximum ambient temperature inside the enclosure: 40°C

• Maximum ambient temperature outside the enclosure: 30°C

For example, if the power dissipation from each drive is 187 W and the power dissipation from each external EMC filter is 9.2 W.

Total dissipation: 2 x (187 + 9.2) =392.4 W

Power dissipation for the drives and the external EMC filters can be obtained from Chapter 11 Technical data on page 159.

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

2/o

having a heat transmission coefficient of 5.5 W/m

C. Only the top,

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

The value of 5.5 W/m

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

= 7.135 m

(77.8 ft2) (1 m2 = 10.9 ft2)

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

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

=1.821 m (71.7 in)

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

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

• Reducing the ambient temperature outside the enclosure, and/or applying forced-air cooling to the outside of the enclosure

• Reducing the number of drives in the enclosure

• Removing other heat-generating equipment

Calculating the air-flow in a ventilated enclosure

The dimensions of the enclosure are required only for accommodating the equipment. The equipment is cooled by the forced air flow.

Calculate the minimum required volume of ventilating air from:

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

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

Unidrive M200 / M201 User Guide 35

Issue Number: 4

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.

Page 36

Safety

3 1.3× 323.7×

40 30–

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

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Example

To calculate the size of an enclosure for the following:

• Three drives operating at the Normal Duty rating

• External EMC filter for each drive

• Braking resistors are to be mounted outside the enclosure

• Maximum ambient temperature inside the enclosure: 40 °C

• Maximum ambient temperature outside the enclosure: 30 °C

For example, dissipation of each drive: 101 W and dissipation of each external EMC filter: 6.9 W (max).

Total dissipation: 3 x (101 + 6.9) = 323.7 W

Insert the following values:

40 °C

int

30 °C

ext

k 1.3 P 323.7 W

Then:

= 126.2 m

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

3.7 Enclosure design and drive ambient temperature

Drive derating is required for operation in high ambient temperatures

Totally enclosing or through panel mounting the drive in either a sealed cabinet (no airflow) or in a well ventilated cabinet makes a significant difference on drive cooling.

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

for the whole of the drive.

The ambient temperature for the four different combinations is defined below:

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

= T

rate

+ 5 °C

int

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

= T

rate

int

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

= the greater of T

rate

+5 °C, or T

ext

int

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

= the greater of T

rate

ext

or T

int

Where:

= Temperature outside the cabinet

ext

= Temperature inside the cabinet

int

= Temperature used to select current rating from tables in

rate

Chapter 11 Technical data on page 159.

rate

) which

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3.8 Heatsink fan operation

The drive is ventilated by an internal heatsink fan. The fan channels air through the heatsink chamber.

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

The heatsink fan on all drive sizes is a variable speed fan. The drive controls the speed at which the fan runs based on the temperature of the heatsink and the drive's thermal model system. The maximum speed at which the fan operates can be limited in Pr 06.045. This could incur an output current derating. Refer to section 3.12.1 Fan removal procedure on page 44 for information on fan removal. The size 6 is also installed with a variable speed fan to ventilate the capacitor bank. The heatsink fan on the size 5 to 6 is supplied internally by the drive.

36 Unidrive M200 / M201 User Guide

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Page 37

Safety

IP65 enclosure

IP20

Gasket seal

Drive with high IP insert installed

Drive Gasket

Enclosure

rear wall

Through panel securing bracket

Enclosure rear wall

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3.9 Enclosing size 5 to 6 drive for high environmental protection

An explanation of the environmental protection rating is provided in section 11.1.9 IP / UL Rating on page 167.

The standard drive is rated to IP20 pollution degree 2 (dry, nonconductive contamination only). However, it is possible to configure the size 5 to 6 drive to achieve IP65 rating at the rear of the heatsink for through-panel mounting (some current derating is required).

Refer to Table 11-3 on page 160.

This allows the front of the size 5 to 6 drive, along with the various switchgear, to be housed in an IP65 enclosure with the heatsink protruding through the panel to the external environment. The majority of the heat generated by the drive is dissipated outside the enclosure, thereby maintaining a reduced temperature inside the enclosure.

This relies on a good seal being made between the heatsink and the rear of the enclosure using the gaskets provided.

Figure 3-29 Example of IP65 through-panel layout

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Figure 3-30 Installing the gasket

Technical data Diagnostics UL Listing

The main gasket should be installed as shown in Figure 3-30

In order to achieve the high IP rating on the size 5 drive, it is necessary to seal a heatsink vent by installing the high IP insert as shown in

Figure 3-32.

Table 3-5 Through-panel mounting kit part numbers

Size CT part number

5 3470-0067

6 3470-0055

To seal the space between the drive and the backplate, use the two securing brackets as shown in Figure 3-30. The securing brackets, gasket and high IP inserts are included in the through-panel mounting kit. The part numbers are shown in Table 3-5.

Figure 3-31 Through-panel mounting detail

Unidrive M200 / M201 User Guide 37 Issue Number: 4

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NOTE

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Figure 3-32 Installation of high IP insert for size 5

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Table 3-7 Power losses from the front of the drive when through-

panel mounted

Frame size Power loss

• To install the high IP insert, firstly place a flat head screwdriver into the slot highlighted (1).

• Pull the hinged baffle up to expose the ventilation holes, install the high IP inserts into the ventilation holes in the heatsink (2).

• Ensure the high IP inserts are securely installed by firmly pressing them into place (3).

• Close the hinged baffle as shown (1).

To remove the high IP inserts, reverse the above instructions.

The guidelines in Table 3-7 should be followed.

Table 3-6 Environmental considerations

Environment High IP insert Comments

Clean Not installed

Dry, dusty (non-conductive) Installed

Dry, dusty (conductive) Installed

IP65 compliance Installed

Regular cleaning

recommended

A current derating must be applied to the drive if the high IP insert is installed. Derating information is provided in section 11.1.1 Power and current ratings (Derating for switching frequency and temperature) on page 159.

Failure to do so may result in nuisance tripping.

When designing an IP65 enclosure, refer to Figure 3-29 on page 37 for an example of an IP65 through-panel layout. Consideration should be made with regard to the heat dissipation from the front of the drive.

38 Unidrive M200 / M201 User Guide

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U1 V1 W1

Netz / Line

Last / Load

V2 W2

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3.10 External EMC filter

The external EMC filter details for each drive rating are provided in the table below.

Table 3-8 Drive and EMC filter cross reference

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Model CT part number

kg lb

200 V

05200250 4200-0312 5.5 12.13

06200330 to 06200440 4200-2300 6.5 14.3

400 V

05400270 to 05400300 4200-0402 5.5 12.13

06400350 to 06400470 4200-4800 6.7 14.8

575 V

05500030 to 05500069 4200-0122

06500100 to 06500350 4200-3690 7.0 15.4

Mount the external EMC filter following the guidelines in section 4.8.5 Compliance with generic emission standards on page 66.

Figure 3-33 Footprint mounting the EMC filter Figure 3-34 Bookcase mounting the EMC filter

Weight

Figure 3-35 Size 1 to 6 external EMC filter

V: Ground stud X: Threaded holes for footprint mounting of the drive Y: Footprint mounting hole diameter

Z: Bookcase mounting slot diameter. CS: Cable size

Unidrive M200 / M201 User Guide 39 Issue Number: 4

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Table 3-9 Size 1 external EMC filter dimensions

CT part

number

ABCDEHWVXYZCS

Table 3-10 Size 2 external EMC filter dimensions

CT part

number

ABCDEHWVXYZCS

Table 3-11 Size 3 external EMC filter dimensions

CT part

number

ABCDEHWVXYZCS

Table 3-12 Size 4 external EMC filter dimensions

CT part

number

ABCDEHWVXYZCS

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Table 3-13 Size 5 external EMC filter dimensions

CT part

number

ABCDEFHWVXYZCS

4200-0312

4200-0402

4200-0122

395 mm

(15.55 in)

425 mm

(16.73 in)

106 mm (4.17 in)

60 mm

(2.36 in)

Table 3-14 Size 6 external EMC filter dimensions

CT part

number

4200-2300

4200-4800

4200-3690

ABCDEFHWVXYZCS

392 mm

(15.43 in)

420 mm

(16.54 in)

180 mm (7.09 in)

60 mm

(2.36 in)

33 mm

(1.30 in)

33 mm

(1.30 in)

11.5 mm (0.45 in)

437 mm (17.2 in)

434 mm

(17.09 in)

143 mm (5.63 in)

210 mm (8.27 in)

M6 M6

6.5 mm

(0.26 in)

6.5 mm

(0.26 in)

6.5 mm

(0.26 in)

6.5 mm

(0.26 in)

10 mm

(8 AWG)

2.5 mm

(14 AWG)

16 mm

(6 AWG)

40 Unidrive M200 / M201 User Guide

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3.11 Electrical terminals

3.11.1 Location of the power and ground terminals

Figure 3-36 Locations of the power and ground terminals (size 1 to 4)

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8 3

Key:

1. Control terminals 4. AC power terminals 7. DC bus +

2. Relay terminals 5. Motor terminals 8. Brake terminal

3. Ground connections 6. DC bus -

Unidrive M200 / M201 User Guide 41

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Figure 3-37 Locations of the power and ground terminals (size 5 to 6)

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Key

1. Control terminals 4. Ground connections 7. DC bus -

2. Relay terminals 5. AC power terminals 8. DC bus +

3. Additional ground connection 6. Motor terminals 9. Brake terminal

3.11.2 Terminal sizes and torque settings

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

Table 3-15 Drive control terminal data

Model Connection type Torque setting

All Screw terminals 0.2 N m (0.15 lb ft)

Table 3-16 Drive relay terminal data

Model Connection type Torque setting

All Screw terminals 0.5 N m (0.4 lb ft)

42 Unidrive M200 / M201 User Guide

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Table 3-17 Drive power terminal data

Model

size

1 0.5 N m (0.4 lb ft)

AC and motor terminals DC and braking Ground terminal

Recommended Maximum Recommended Maximum Recommended Maximum

0.5 N m (0.4 lb ft)

1.4 N m (1 lb ft)

1.4 N m (1 lb ft)3

1.5 N m (1.1 lb ft)

Plug-in terminal block M4 Nut (7 mm AF) M5 Nut (8 mm AF)

1.5 N m (1.1 lb ft) 1.8 N m (1.3 lb ft) 1.5 N m (1.1 lb ft) 2.5 N m (1.8 lb ft) 2.0 N m (1.4 lb ft) 5.0 N m (3.7 lb ft)

M6 Nut (10 mm AF) M6 Nut (10 mm AF) M6 Nut (10 mm AF)

6.0 N m (4.4 lb ft) 8.0 N m (6.0 lb ft) 6.0 N m (4.4 lb ft) 8.0 N m (6.0 lb ft) 6.0 N m (4.4 lb ft) 8.0 N m (6.0 lb ft)

Table 3-18 Terminal block maximum cable sizes Table 3-19 External EMC filter terminal data

Model size

Terminal block

description

All Control connector

All 2-way relay connector

AC input power connector

1 to 4

AC output power

connector

3-way AC power

connector

Max cable size

6 mm

8 mm

(16 AWG)

(12 AWG)

(10 AWG)

(12 AWG)

(8 AWG)

1.5 mm

2.5 mm

CT part

number

4200-2300

4200-4800

4200-3690

Max cable

connections

size

16 mm

Power

Max torque

2.3 N m

(1.70 Ib ft)

stud size

3-way motor connector

connections

Ground

Max torque

4.8 N m

(2.8 Ib ft)

3.12 Routine maintenance

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

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

Environment

Ambient temperature Ensure the enclosure temperature remains at or below maximum specified

Dust

Moisture Ensure the drive enclosure shows no signs of condensation

Enclosure

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

Electrical

Screw connections Ensure all screw terminals remain tight

Crimp terminals

Cables Check all cables for signs of damage

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

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

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3.12.1 Fan removal procedure

Figure 3-38 Removal of size 5 heatsink fan

A: Press the tabs (1) inwards to release the fan assembly from the underside of the drive.

B: Use the tabs (1) to withdraw the fan by pulling it away from the drive.

C: Depress and hold the locking release on the fan cable lead as shown (2).

D: With the locking release depressed (2), take hold of the fan supply cable and carefully pull to separate the connectors.

Figure 3-39 Removal of the size 6 heatsink fan

A: Press the tabs (1) inwards to release the fan assembly from the underside of the drive.

B: Use the tabs (1) to withdraw the fan by pulling it away from the drive.

C: Depress and hold the locking release on the fan cable lead as shown (2).

D: With the locking release depressed (2), take hold of the fan supply cable and carefully pull to separate the connectors.

44 Unidrive M200 / M201 User Guide

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Page 45

Safety

WARNING

WAR NING

WARNING

Fuses

Mains

Supply

Supply Ground

Thermal

L1 L2

L2L1 L3

Optional EMC

Optional

braking resistor

filter

Optional

line reactor

Fuses

Mains

Supply

Supply Ground

PE U

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4 Electrical installation

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

• Internal EMC filter

• EMC compliance with shielding / grounding accessories

• Product rating, fusing and cabling information

• Brake resistor details (selection / ratings)

Electric shock risk

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

• AC supply cables and connections

• DC and brake cables, and connections

• Output cables and connections

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

Isolation device

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

STOP function

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

Stored charge

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

4.1 Power connections

4.1.1 AC and DC connections

Figure 4-1 Size 1 power connections

L2-N

Optional

braking resistor

BR U

overload

protection

device

Motor

Optional ground

connection

L VW

Optional EMC

filter

Optional

line reactor

L1 L2-N

See Figure 4-7 Size 1 to 4 ground connections (size 2 shown) on page 48 for further information on ground connections.

Figure 4-2 Size 2 power connections

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).

Unidrive M200 / M201 User Guide 45 Issue Number: 4

Motor

Optional ground

connection

+BR

Thermal overload

protection

device

See Figure 4-7 Size 1 to 4 ground connections (size 2 shown) on page 48 for further information on ground connections.

Page 46

Safety

NOTE

L1 L2

L2L1 L3

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Supply Ground

PE UV

Motor

Optional ground

connection

+BR

Optional

braking resistor

Thermal overload

protection

device

Internal

EMC

filter

L1 L2

L2L1 L3

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Supply Ground

Internal

EMC

filter

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On the size 2 110 V drives, the supply should be connected L1 and L3. Also the DC bus (-) has no internal connection.

Figure 4-3 Size 3 power connections

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Figure 4-4 Size 4 power connections

See Figure 4-7 Size 1 to 4 ground connections (size 2 shown) on page 48 for further information on ground connections.

Optional

braking resistor

Motor

Optional

connection

round

+BR

Thermal

overload

protection

device

See Figure 4-7 Size 1 to 4 ground connections (size 2 shown) on page 48 for further information on ground connections.

46 Unidrive M200 / M201 User Guide

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Page 47

Safety

DC / Brake connections

Optional braking resistor

Thermal

overload

protection

device

DC -

DC +

L1 L2

L2L1 L3 U V W

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Motor

Optional ground

connection

Supply

Ground

AC Connections Motor Connections

DC / Brake connections

DC +

DC -

L1 L2

L2L1 L3 U V W

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Motor

Optional ground

connection

Supply

Ground

AC Connections Motor Connections

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protection

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Figure 4-5 Size 5 power connections

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Figure 4-6 Size 6 power connections

The upper terminal block (1) is used for AC supply connection.

The lower terminal block (2) is used for Motor connection.

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4.1.2 Ground connections

Electrochemical corrosion of grounding terminals

Ensure that grounding terminals are protected against corrosion i.e. as could be caused by condensation.

Size 1 to 4

On sizes 1 to 4, the supply and motor ground connections are made using the ground connections located at the bottom of the drive as shown in Figure 4-7.

Figure 4-7 Size 1 to 4 ground connections (size 2 shown)

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Size 6

On a size 6, the supply and motor ground connections are made using the M6 studs located above the supply and motor terminals. Refer to Figure 4-9 below.

Figure 4-9 Size 6 ground connections

1: 4 x M4 threaded holes for the ground connection.

Size 5

On size 5 the supply and motor ground connections are made using the M5 studs located near the plug-in power connector.

Figure 4-8 Size 5 ground connections

1. Ground connection studs.

1. Ground connection studs

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

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

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

Table 4-1 Protective ground cable ratings

Input phase

conductor size

 10 mm

Minimum ground conductor size

Either 10 mm2or two conductors of the same cross-sectional area as the input phase conductor.

> 10 mm

> 16 mm

> 35 mm

and  16 mm

and  35 mm216 mm

The same cross-sectional area as the input

phase conductor

Half of the cross-sectional area of the input phase conductor

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4.2 AC supply requirements

Voltage:

100 V drive: 100 V to 120 V ±10 % 200 V drive: 200 V to 240 V ±10 % 400 V drive: 380 V to 480 V ±10 % 575 V drive: 500 V to 575 V ±10 %

Number of phases: 3

Maximum supply imbalance: 2 % negative phase sequence (equivalent to 3 % voltage imbalance between phases).

Frequency range: 48 to 62 Hz

For UL compliance only, the maximum supply symmetrical fault current must be limited to 100 kA

4.2.1 Supply types

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

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

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

• Supplies with voltage above 600 V may not have corner grounding

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

Operation with IT (ungrounded) supplies:

Special attention is required when using internal or external EMC filters with ungrounded supplies, because in the event of a ground (earth) fault in the motor circuit the drive may not trip and the filter could be over-stressed. In this case, either the filter must not be used i.e. removed, or additional independent motor ground fault protection must be provided. For instructions on removal, refer to section 4.8.2 Internal EMC filter on page 63. For details of ground fault protection contact the supplier of the drive.

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Line reactors are particularly recommended for use with the following drive models when one of the above factors exists, or when the supply capacity exceeds 175 kVA. Size 1 to 3.

Model sizes 04200133 to 06500350 have an internal DC choke so they do not require AC line reactors except for cases of excessive phase unbalance or extreme supply conditions.

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

Reactor current ratings

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

Continuous current rating:

Not less than the continuous input current rating of the drive

Repetitive peak current rating:

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

4.2.3 Input inductor calculation

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

Where:

I = drive rated input current (A) L = inductance (H) f = supply frequency (Hz) V = voltage between lines

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

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

4.2.2 Supplies requiring line reactors

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

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

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

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

• Power factor correction equipment connected close to the drive.

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

the supply.

• Across the line (DOL) started motor(s) connected to the supply such

that when any of these motors are started, the voltage dip exceeds 20 %.

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

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

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4.2.4 Input line reactor specification for size 1 to 6

Table 4-2 AC line reactor values

Drives used

with

01200017

01200024

Reactor

part

number

Input

phases

Inductance

mH A A kg L D H

4402-0224 1 2.25 6.5 13 0.8 72 65 90

Continuous rms current

01200033

01200042

02200024

4402-0225 1 1.0 15.1 30.2 1.1 82 75 100

02200033

02200042

02200056

02200075

03200100

4402-0226 1 0.5 26.2 52.4 1.5 82 90 105

04200133

02200024

02200033

02200042

02400013

02400018

4402-0227 3 2.0 7.9 15.8 3.5 150 90 150

02400023

02400032

02400041

02200056

02200075

03200100

03400056

03400073

4402-0228 3 1.0 15.4 47.4 3.8 150 90 150

03400094

04200133

04400135

05200250 4402-0229 3 0.4 24.6 49.2 3.8 150 90 150

04200176

04400170

05400270

4402-0232 3 0.6 27.4 54.8 6 180 100 190

05400300

06200330

4400-0240** 3 0.45 46 92 11 190 150 22506400350

06400420

06200440

06400470

4400-0241** 3 0.3 74 148 15 250 150 275

**These input reactors are not stocked by Control Techniques. Contact your local Drive Centre.

The AC line reactors for the 110 V and other size drives should be sourced locally.

Peak

current

Weight

Dimensions

(mm)

The reactance values will be higher than 2 % with some of these drives, which may result in a loss of drive output (reduced torque at high speed) because of the voltage drop.

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Figure 4-10 Input line reactor 4402-0224, 4402-0225 and 4402-0226

Table 4-3 Dimensions

Part No

A B C D E Mounting hole

Dimensions

4402-0224 90 mm (3.54 in) 72 mm (2.84 in) 44.5 mm (1.75in) 35 mm (1.38 in) 65 mm (2.56 in)

4402-0226 105 mm (4.13 in) 53 mm (2.09 in) 90 mm (3.54 in)

82 mm (3.23 in) 54 mm (2.13in)

40 mm (1.58 in) 75 mm (2.95 in)

Figure 4-11 Input line reactor 4402-0227, 4402-0228, 4402-0229

Technical data Diagnostics UL Listing

Ground

terminal

8 mm x 4 mm

(0.32 in x 0.16 in)

M34402-0225 100 mm (3.94 in)

Table 4-4 Dimensions

Part No

A B C D E Mounting slot

4402-0227

150 mm (5.91in) 150 mm (5.91in) 120 mm (4.72 in) 47 mm (1.85 in) 90 mm (3.54in)

4402-0229

Unidrive M200 / M201 User Guide 51 Issue Number: 4

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Ground

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17 mm x 7 mm

(0.67 in x 0.28 in)

M54402-0228

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4.3 24 Vdc supply

The 24 Vdc supply connected to the +24 V supply terminals on the AIBackup adaptor provides the following functions:

• It can be used as a back-up power supply to keep the control circuits of the drive powered up when the line power supply is removed. This allows any fieldbus modules or serial communications to continue to operate. If the line power supply is re-applied, then the normal operation can carry on after the drive automatically re-initializes the power board parameters.

• It can be used to clone or load parameters in order to pre-configure drives when the line power supply is not available. The keypad can be used to setup parameters if required. However, the drive will be in the Under Voltage state unless the line power supply is enabled, therefore diagnostics may not be possible. (Power down save parameters are not saved when using the 24 V back-up power supply input).

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

0 V 0 V

+ 24 V + 24 V Backup supply input

Nominal operating voltage 24.0 Vdc

Minimum continuous operating voltage 19.2 V

Maximum continuous operating voltage 30.0 V

Minimum start up voltage 12.0 V

Minimum power supply requirement at 24 V 20 W

Recommended fuse 1 A, 50 Vdc

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

Figure 4-12 Location of the 24 Vdc power supply connection on

the AI-Backup adaptor

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4.4 Ratings

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

Typical input current

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

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

Maximum continuous input current

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

The values of maximum input current are stated for a supply with a 2 % negative phase-sequence imbalance and rated at the supply fault current given in Table 4-5.

Table 4-5 Supply fault current used to calculate maximum input currents

Model Symmetrical fault level (kA)

All 100

Fuses

The AC supply to the drive must be installed with suitable protection against overload and short-circuits. Table 4-6, Table 4-7, Table 4-8 and Table 4-9 show the recommended fuse ratings. Failure to observe this requirement will cause risk of fire.

Table 4-6 AC Input current and fuse ratings (100 V)

Fuse rating

Model

Typical input

current

Maximum

continuous

input current

AAA

Maximum

overload input

current

IEC gG Class CC or Class J

Maximum Maximum

01100017 8.7 8.7 10 10

01100024 11.1 11.1 16 16

02100042 18.8 18.8 20 20

02100056 24.0 24.0 25 25

Table 4-7 AC Input current and fuse ratings (200 V)

Fuse rating

Class

Nominal

Maximum

1ph 3ph

Model

Typical

input

current

Maximum

continuous

input

current

AA AA

Maximum

overload

input

current

Nominal

Maximum

1ph 3ph

01200017 4.5 4.5

01200024 5.3 5.3

01200033 8.3 8.3 10

IEC UL / USA

01200042 10.4 10.4 16 16

02200024 5.3/3.2 5.3/4.1 6

10 5

02200033 8.3/4.3 8.3/6.7 10 10

02200042 10.4/5.4 10.4/7.5 16 10 16 10

02200056 14.9/7.4 14.9/11.3

02200075 18.1/9.1 18.1/13.5

20 16 20 16

03200100 23.9/12.8 23.9/17.7 30/25 25 20

04200133 23.7/13.5 23.7/16.9 25 20

04200176 17.0 21.3 25 25

05200250 24 31 52 40

06200330 42 48 64

06200440 49 56 85

25 20

40 40

Class

CC or J

or J

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Table 4-8 AC Input current and fuse ratings (400 V)

Model

Typical

input

current

Maximum

continuous

input

current

Maximum

overload

input

current

Fuse rating

IEC UL / USA

Nominal Maximum

Class

Nominal Maximum

AA AA

02400013 2.1 2.4

02400018 2.6 2.9

02400023 3.1 3.5

02400032 4.7 5.1

02400041 5.8 6.2 10

03400056 8.3 8.7 13 10

03400073 10.2 12.2 18

03400094 13.1 14.8 20.7 20

04400135 14.0 16.3 20

04400170 18.5 20.7 25 25

05400270 26 29 52

05400300 27 30 58

40 40

06400350 32 36 67

35 35

63 63 gG

06400470 54 60 90 60

60 CC or J06400420 41 46 80 50

Class

CC or J

Table 4-9 AC Input current and fuse ratings (575 V)

Maximum

overload

input

current

Model

Typical

input

current

Maximum

continuous

input current

AAA

05500030 4 4 7

IEC UL / USA

Nominal Maximum

AA A A

20 gG

Fuse rating

Class

Nominal Maximum

05500069 9 11 15 20 20 20

06500100 12 13 22 20

06500150 17 19 33 32 25

06500190 22 24 41 40 30

06500230 26 29 50

06500350 41 47 76 63 50

Ensure cables used suit local wiring regulations.

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

Table 4-10 Cable ratings (100 V)

Model

Cable size (IEC 60364-5-52)

Input Output Input Output

Cable size (UL508C)

AWG

Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum

01100017 1

01100024 1.5 1 14

02100042 2.5

02100056 4 1 10

2.5

10 16 12

Class

CC or J05500040 6 7 9 10

CC or J

5006500290 33 37 63 40

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Table 4-11 Cable ratings (200 V)

Model

Cable size (IEC 60364-5-52)

Input Output Input Output

Cable size (UL508C)

AWG

Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum

01200017

01200024

01200033

1 6 1 2.516101612

01200042

02200024

02200033

02200042

6 1 2.5

10 16 12

02200056 2.5/1.5 12/14

02200075 2.5 12

03200100 4 6 1.5 2.5 10/12 10 14 12

04200133 4/2.5

04200176 4

6 2.52.510101212

05200250 10 10 10 10 8888

06200330 16

06200440 25 25 3 3

Table 4-12 Cable ratings (400 V)

Model

Cable size (IEC 60364-5-52)

Input Output Input Output

Cable size (UL508C)

AWG

Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum

02400013

02400018

02400023

1 6 1 2.516101612

02400032

02400041

03400056 1

2.5

1203400073 1.5 1 12 16

03400094 2.5 1.5 12 14

04400135 2.5

04400170 4

05400270

05400300

66668888

06400350 10

6 2.52.510101212

306400420 16 16 4 4

06400470 25 25 3 3

Table 4-13 Cable ratings (575 V)

Cable size (IEC 60364-5-52)

Model

Input Output Input Output

Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum

05500030 0.75

1.5

05500069 1.5 1.5

06500100 2.5

06500150 4 4

06500190 6 6

06500230

06500290

06500350 16

Unidrive M200 / M201 User Guide 55 Issue Number: 4

0.75

1.5

2.5

14 14

Cable size (UL508C)

AWG

1605500040 1 1

10 10

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PVC insulated cable should be used.

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

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

B1 - Separate cables in conduit.

B2 - Multicore cable in conduit.

C - Multicore cable in free air.

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

The nominal output cable sizes assume that the motor maximum current matches that of the drive. Where a motor of reduced rating is used the cable rating may be chosen to match that of the motor. To ensure that the motor and cable are protected against overload, the drive must be programmed with the correct motor rated current. A fuse or other protection must be included in all live connections to the AC supply.

Fuse types

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

MCB

Do not use an MCB instead of the recommended fuses.

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.

For information on ground cable sizes, refer to Table 4-1 Protective ground cable ratings on page 48.

4.4.1 Main AC supply contactor

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

4.5 Output circuit and motor protection

The output circuit has fast-acting electronic short-circuit protection which limits the fault current to typically no more than 2.5 times the rated output current, and interrupts the current in approximately 20 µs. No additional short-circuit protection devices are required.

The drive provides overload protection for the motor and its cable. For this to be effective, Rated Current (00.006) must be set to suit the motor.

Motor Rated Current (00.006) must be set correctly to avoid a risk of fire in the event of motor overload.

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

4.5.1 Cable types and lengths

Since capacitance in the motor cable causes loading on the output of the drive, ensure the cable length does not exceed the values given in Table 414, Table 4-15, Table 4-16 and Table 4-17.

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

• AC supply to external EMC filter (when used)

• AC supply (or external EMC filter) to drive

• Drive to motor

• Drive to braking resistor

Table 4-14 Maximum motor cable lengths (100 V drives)

100 V Nominal AC supply voltage

Model

0.667 kHz 1 kHz 2 kHz 3 kHz 4 kHz 6 kHz 8 kHz 12 kHz 16 kHz

01100017

01100024

02100042

02100056

Maximum permissible motor cable length for each of the following switching frequencies

50 m (164 ft)

100 m (328 ft)

37.5 m

(123 ft)

75 m

(246 ft)

25 m

(82 ft)

50 m

(164 ft)

18.75 m (61 ft)

37.5 m (123 ft)

12.5 m (41 ft)

25 m

(82 ft)

9 m

(30 ft)

18 m

(59 ft)

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Table 4-15 Maximum motor cable lengths (200 V drives)

200 V Nominal AC supply voltage

Maximum permissible motor cable length for each of the following switching frequencies

Model

0.667 kHz

kHz

01200017

01200024

01200033

50 m

(165 ft)

01200042

02200024

02200033

02200042

02200056

100 m

(330 ft)

02200075

03200100

04200133

04200176

05200250

06200330

06200440

100 m

(330 ft)

100 m

(330 ft)

200 m

(660 ft)

300 m

(984 ft)

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kHz

200 m

(660 ft)

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37.5 m

(122 ft)

75 m

(245 ft)

75 m

(245 ft)

75 m

(245 ft)

150 m

(490 ft)

150 m

(490 ft)

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25 m

(82.5 ft)

50 m

(165 ft)

50 m

(165 ft)

50 m

(165 ft)

100 m

(330 ft)

100 m

(330 ft)

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18.75 m

Technical data Diagnostics UL Listing

kHz

12.5 m

(61 ft)

37.5 m (122 ft)

75 m

(245 ft)

75 m

245 ft)

(

(41 ft)

25 m

(82.5 ft)

25 m

(82.5 ft)

25 m

(82.5 ft)

50 m

(165 ft)

50 m

(165 ft)

kHz

9 m

(30 ft)

18 m

(60 ft)

18 m

(60 ft)

18 m

(60 ft)

37 m

(120 ft)

Table 4-16 Maximum motor cable lengths (400 V drives)

400 V Nominal AC supply voltage

Maximum permissible motor cable length for each of the following switching frequencies

Model

0.667 kHz

kHz

02400013

02400018

02400023

02400032

100 m

(330 ft)

02400041

03400056

03400073

03400094

04400135

04400170

05400270

05400300

06400350

06400420

06400470

100 m

(330 ft)

100 m

(330 ft)

200 m

(660 ft)

300 m

(984 ft)

kHz

200 m

(660 ft)

kHz

75 m

(245 ft)

75 m

(245 ft)

75 m

(245 ft)

150 m

(490 ft)

150 m

(490 ft)

kHz

50 m

(165 ft)

50 m

(165 ft)

50 m

(165 ft)

100 m

(330 ft)

100 m

(330 ft)

kHz

37.5 m

(122 ft)

37.5 m

(122 ft)

37.5 m

(122 ft)

75 m

(245 ft)

75 m

(245 ft)

kHz

25 m

(82.5 ft)

25 m

(82.5 ft)

25 m

(82.5 ft)

50 m

(165 ft)

50 m

(165 ft)

kHz

18.25 m (60 ft)

37 m

(120 ft)

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Table 4-17 Maximum motor cable lengths (575 V drives)

575 V Nominal AC supply voltage

Maximum permissible motor cable length for each of the following switching frequencies

Model

05500030

05500040

05500069

0.667 kHz

kHz

200 m

(660 ft)

06500100

06500150

06500190

06500230

300 m

(984 ft)

200 m

(660 ft)

06500290

06500350

4.5.2 High-capacitance / reduced diameter cables

The maximum cable length is reduced from that shown in section

4.5.1 Cable types and lengths on page 56 capacitance or reduced diameter motor cables are used.

Most cables have an insulating jacket between the cores and the armor or shield; these cables have a low capacitance and are recommended. Cables that do not have an insulating jacket tend to have high capacitance; if a cable of this type is used, the maximum cable length is half that quoted in the tables, (Figure 4-13 shows how to identify the two types).

Figure 4-13 Cable construction influencing the capacitance

Normal capacitance

Shield or armour separated from the cores

High capacitance

Shield or armour close to the cores

The maximum motor cable lengths specified section 4.5.1 Cable types and lengths on page 56 is shielded and contains four cores. Typical

capacitance for this type of cable is 130 pF/m (i.e. from one core to all others and the shield connected together).

4.5.3 Motor winding voltage

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

For normal operation with AC supplies up to 500 Vac and a standard motor with a good quality insulation system, there is no need for any special precautions. In case of doubt the motor supplier should be consulted. Special precautions are recommended under the following conditions, but only if the motor cable length exceeds 10 m:

• AC supply voltage exceeds 500 V

• DC supply voltage exceeds 670 V

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

• Multiple motors connected to a single drive

For multiple motors, the precautions given in section 4.5.4 Multiple motors on page 58 should be followed.

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

Users of 575 V NEMA rated motors should note that the specification for inverter-rated motors given in NEMA MG1 section 31 is sufficient for

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75 m

(245 ft)

kHz

50 m

(165 ft)

kHz

motoring operation but not where the motor spends significant periods

braking. In that case an insulation peak voltage rating of 2.2 kV is recommended.

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

4.5.4 Multiple motors

Open-loop only

If the drive is to control more than one motor, one of the fixed V/F modes should be selected (Pr 05.014 = Fixed or Squared). Make the motor connections as shown in Figure 4-14 and Figure 4-15. The maximum cable lengths in Table 4-14 to Table 4-17 apply to the sum of the total cable lengths from the drive to each motor.

It is recommended that each motor is connected through a protection

relay since the drive cannot protect each motor individually. For connection, a sinusoidal filter or an output inductor must be connected as shown in Figure 4-15, even when the cable lengths are less than the maximum permissible. For details of inductor sizes refer to the supplier of the drive.

Figure 4-14 Preferred chain connection for multiple motors

Motor protection

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Figure 4-15 Alternative connection for multiple motors

4.5.5 / Δ motor operation

The voltage rating for and Δ connections of the motor should always

be checked before attempting to run the motor.

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

400 V drive 400 V rated voltage 230 V drive 230 V rated voltage

A typical 3 phase motor would be connected in

for 400 V operation or

Δ for 230 V operation, however, variations on this are common e.g.

Δ 400 V.

690 V

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

4.5.6 Output contactor

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

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

The recommended motor contactor is the AC3 type.

Switching of an output contactor should only occur when the output of the drive is disabled.

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

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

2. High levels of radio frequency noise emission

3. Increased contactor wear and tear

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

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

Table 4-18 shows the default DC voltage level at which the drive turns on the braking transistor. However the braking resistor turn on and the turn off voltages are programmable with Braking IGBT Lower Threshold (06.073) and Braking IGBT Upper Threshold (06.074).

Table 4-18 Default braking transistor turn on voltage

Drive voltage rating DC bus voltage level

100 & 200 V 390 V

400 V 780 V

575 V 930 V

When a braking resistor is used, Pr 02.004 should be set to Fast ramp mode.

High temperatures

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

Braking resistor overload protection parameter settings

Failure to observe the following information may damage the resistor. The drive software contains an overload protection function for a braking resistor. For more information on the braking resistor software overload protection, see Pr 10.030, Pr 10.031 and Pr 10.061 full descriptions in the Parameter Reference Guide.

4.6.1 External braking resistor

Overload protection

When an external braking resistor is used, it is essential that an overload protection device is incorporated in the braking resistor circuit; this is described in Figure 4-16 on page 60.

When a braking resistor is to be mounted outside the enclosure, ensure that it is mounted in a ventilated metal housing that will perform the following functions:

• Prevent inadvertent contact with the resistor

• Allow adequate ventilation for the resistor

When compliance with EMC emission standards is required, external connection requires the cable to be armored or shielded, since it is not fully contained in a metal enclosure. See section 4.8.5 Compliance with generic emission standards on page 66 for further details.

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

4.6 Braking

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

When motor braking is applied by the drive, the maximum regenerated power that the drive can absorb is equal to the power dissipation (losses) of the drive.

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Stop

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Braking resistor

Drive

Main contactor power supply

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Minimum resistance values and peak power rating for the braking resistor at 40 °C (104 °F)

Table 4-19 Braking resistor resistance and power rating (100 V)

Minimum

Model

resistance*

01100017

01100024

02100042

02100056

130 1.2

68 2.2

Table 4-20 Braking resistor resistance and power rating (200 V)

Minimum

Model

resistance*

01200017

01200024

01200033

130 1.2

01200042

02200024

02200033

02200042

02200056

68 2.2

02200075

03200100 45 3.4 2.2

04200133

04200176

22 6.9

05200250 16.5 10.3 8.6

06200330

06200440 16.4

8.6 19.7

Table 4-21 Braking resistor resistance and power rating (400 V)

Minimum

Model

resistance*

02400013

02400018

02400023

270 2.3

02400032

02400041

03400056

03400073 3

100 6.1

03400094 4

04400135

04400170

50 12.2

05400270 31.5 21.5 16.2

05400300 18 37.5 19.6

06400350

06400420 25

06400470 32.7

17 39.8

Instantaneous

power rating

Instantaneous

power rating

Instantaneous

power rating

Continuous

power rating

Continuous

power rating

12.6

Continuous

power rating

2.2

21.6

Table 4-22 Braking resistor resistance and power rating (575 V)

Minimum

Model

resistance*

05500030

05500040 4.6

80 12.1

Instantaneous

power rating

Continuous

power rating

2.6

05500069 6.5

06500100

8.7

06500150 12.3

06500190 16.3

06500230 19.9

13 74

06500290 24.2

06500350 31.7

* Resistor tolerance: ±10 %

For high-inertia loads or under continuous braking, the continuous power dissipated in the braking resistor may be as high as the power rating of the drive. The total energy dissipated in the braking resistor is dependent on the amount of energy to be extracted from the load.

The instantaneous power rating refers to the short-term maximum power dissipated during the on intervals of the pulse width modulated braking control cycle. The braking resistor must be able to withstand this dissipation for short intervals (milliseconds). Higher resistance values require proportionately lower instantaneous power ratings.

In most applications, braking occurs only occasionally. This allows the continuous power rating of the braking resistor to be much lower than the power rating of the drive. It is therefore essential that the instantaneous power rating and energy rating of the braking resistor are sufficient for the most extreme braking duty that is likely to be encountered.

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

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

Thermal protection circuit for the braking resistor

The thermal protection circuit must disconnect the AC supply from the drive if the resistor becomes overloaded due to a fault. Figure 4-16 shows a typical circuit arrangement.

Figure 4-16 Typical protection circuit for a braking resistor

60 Unidrive M200 / M201 User Guide

See Figure 4-1 on page 45 to Figure 4-6 on page 47 for the location of the +DC and braking resistor connections.

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4.6.2 Braking resistor software overload protection

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

• Braking Resistor Rated Power (10.030)

• Braking Resistor Thermal Time Constant (10.031)

• Braking Resistor Resistance (10.061) This data should be obtained from the manufacturer of the braking resistors.

Pr 10.039 gives an indication of braking resistor temperature based on a simple thermal model. Zero indicates the resistor is close to ambient and 100 % is the maximum temperature the resistor can withstand. A ‘br.rES’ alarm is given if this parameter is above 75 % and the braking IGBT is active. An It.br trip will occur if Pr 10.039 reaches 100 %, when Pr 10.037 is set to 0 (default value) or 1.

If Pr 10.037 is equal to 2 or 3, an It.br trip will not occur when Pr 10.039 reaches 100 %, but instead the braking IGBT will be disabled until Pr 10.039 falls below 95 %. This option is intended for applications with parallel connected DC buses where there are several braking resistors, each of which cannot withstand full DC bus voltage continuously. With this type of application it is unlikely the braking energy will be shared equally between the resistors because of voltage measurement tolerances within the individual drives. Therefore with Pr 10.037 set to 2 or 3, then as soon as a resistor has reached its maximum temperature the drive will disable the braking IGBT, and another resistor on another drive will take up the braking energy. Once Pr 10.039 has fallen below 95 % the drive will allow the braking IGBT to operate again.

See the Parameter Reference Guide for more information on Pr 10.030, Pr 10.031, Pr 10.037 and Pr 10.039.

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

4.7 Ground leakage

The ground leakage current depends upon whether the internal EMC filter is installed or not. The drive is supplied with the filter installed. Instructions for removing the internal filter are given in section

4.8.2 Internal EMC filter on page 63.

With internal filter installed: Size 1:

2.5 mA* AC at 230 V 50 Hz (line to line supply, star point ground)

9.2 mA* AC at 230 V 50 Hz (line to neutral supply, star point ground)

Size 2:

9.36 mA* AC at 110 V, 50 Hz (2 phase, line to line supply, star point ground)

16.4 mA* AC at 110 V, 50 Hz (1 phase, line to neutral supply, star point ground)

5.3 mA* AC at 230 V, 50 Hz (3 phase supply, star point ground)

15.4 mA* AC at 230 V, 50 Hz (1 phase, line to neutral supply, star point ground)

9.6 mA* AC at 400 V, 50 Hz (3 phase supply, star point ground)

Size 3:

19.7 mA* AC at 400 V 50 Hz (star point ground)

47.4 mA* AC at 400 V 50 Hz (corner ground)

Size 4:

21 mA* AC at 230 V 50 Hz (3 phase, star point ground)

6.8 mA* AC at 230 V 50 Hz (1 phase, line to line supply, star point ground) 30 mA* AC at 230 V 50 Hz (1 phase, line to neutral supply, star point ground) 50 mA* AC at 400 V 50 Hz (3 phase, star point ground)

* Proportional to the supply voltage and frequency.

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With internal filter removed:

Size 1: <1.5 mA (line to line supply, star point ground)

<1 mA (line to neutral supply, star point ground)

Size 2: <1.7 mA (line to line supply, star point ground)

<1.9 mA (line to neutral supply, star point ground)

Size 3: <3.3 mA (star point ground)

<4.9 mA (corner ground)

Size 4: < 3.5 mA (star point ground)

The above leakage currents are just the leakage currents of the drive with the internal EMC filter connected and do not take into account any leakage currents of the motor or motor cable.

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

When the leakage current exceeds 3.5 mA, a permanent fixed ground connection must be provided using two independent conductors each with a cross-section equal to or exceeding that of the supply conductors. The drive is provided with two ground connections to facilitate this. Both ground connections are necessary to meet EN 61800-5-1:

2007.

4.7.1 Use of residual current device (RCD)

There are three common types of ELCB / RCD:

1. AC - detects AC fault currents

2. A - detects AC and pulsating DC fault currents (provided the DC current reaches zero at least once every half cycle)

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

• Type AC should never be used with drives.

• Type A can only be used with single phase drives

• Type B must be used with three phase drives

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

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

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4.8 EMC (Electromagnetic compatibility)

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

Section 4.10.3, General requirements for all applications, to ensure reliable operation of the drive and minimise the risk of disturbing nearby equipment. The immunity standards specified in Chapter 11 Technical data on page 159 will be met, but no specific emission standards are applied. Note also the special requirements given in Surge immunity of control circuits - long cables and connections outside a building on page 68 for increased surge immunity of control circuits where control wiring is extended.

Section 4.8.4, Requirements for meeting the EMC standard for power drive systems, IEC61800-3 (EN 61800-3:2004).

Section 4.8.5, Requirements for meeting the generic emission standards for the industrial environment, IEC61000-6-4, EN 61000-6-

4:2007.

The recommendations of section 4.8.3 General requirements for EMC on page 65 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 non-industrial environment, then the recommendations of section 4.8.4 or section 4.8.5 should be followed to give reduced radio-frequency emission.

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

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

• The Declaration of Conformity at the front of this manual

• Chapter 11 Technical data on page 159

The correct external EMC filter must be used and all of the guidelines in section 4.8.3 General requirements for EMC on page 65 and section

4.8.5 Compliance with generic emission standards on page 66 must be followed.

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See Figure 4-17 for details regarding the installation of the grounding bracket.

Figure 4-17 Installation of grounding bracket (size 1 to 4)

Loosen the ground connection screws and slide the grounding bracket in the direction shown. Once in place, the ground connection screws should be tightened to a maximum torque of 1.5 N m (1.1 lb ft).

Figure 4-18 Installation of grounding bracket (size 5 to 6 - size 5

shown)

Table 4-23 Drive and EMC filter cross reference

Model CT part number

200 V

05200250 4200-0312

06200330 to 06200440 4200-2300

400 V

05400270 to 05400300 4200-0402

06400350 to 06400470 4200-4800

575 V

05500030 to 05500069 4200-0122

06500100 to 06500350 4200-3690

High ground leakage current

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

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

4.8.1 Grounding hardware

The drive is supplied with a grounding bracket / clamp to facilitate EMC compliance. This provides a convenient method for direct grounding of cable shields without the use of "pig-tails”. Cable shields can be bared

and clamped to the grounding bracket using metal clips or clamps supplied) or cable ties. Note that the shield must in all cases be continued through the clamp to the intended terminal on the drive, in accordance with the connection details for the specific signal.

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

(for cables with a maximum outer diameter of 14 mm).

(not

Loosen the ground connection nuts and slide the grounding bracket in the direction shown. Once in place, the ground connection nuts should be tightened to a maximum torque of 2.0 N m (1.47 lb ft).

62 Unidrive M200 / M201 User Guide

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Figure 4-19 Installation of grounding clamp size 5

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Figure 4-20 Installation of grounding clamp size 6

Loosen the ground connection nuts and slide the grounding clamp down onto the pillars in the direction shown. Once in place, the ground connection nuts should be tightened with a maximum torque of 2 N m

(1.47 lb ft).

The grounding clamp is secured using the provided 2 x M4 x 10 mm fasteners. The fasteners should be tightened with the maximum torque of 2 N m (1.47 Ib ft).

4.8.2 Internal EMC filter

It is recommended that the internal EMC filter be kept in place unless there is a specific reason for removing it. If the drive is used as a motoring drive as part of a regen system, then the internal EMC filter must be removed.

The internal EMC filter reduces radio-frequency emission into the line power supply. Where the motor cable is short, it permits the requirements of EN 61800-3:2004 to be met for the second environment

- see section 4.8.4 Compliance with EN 61800-3:2004 (standard for

Power Drive Systems) on page 66 and section on page 176. For longer motor cables the filter continues to provide a useful reduction in emission levels, and when used with any length of shielded motor cable up to the limit for the drive, it is unlikely that nearby industrial equipment will be disturbed. It is recommended that the filter be used in all applications unless the instructions given above require it to be removed, or where the ground leakage current of 9.2 mA for size 1 is unacceptable. As shown in Figure 4-21 the size 1 internal EMC filter is removed by removing the screw (1).

The supply must be disconnected before removing the internal EMC filter.

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Figure 4-21 Removal of the size 1 internal EMC filter

To electrically disconnect the internal EMC filter, remove the screw as shown above (1).

Figure 4-22 Removal of the size 2 internal EMC filter

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Figure 4-24 Removal of the size 4 internal EMC filter

To electrically disconnect the internal EMC filter, remove the screw as shown above (1).

Figure 4-25 Removal of the size 5 internal EMC filter

To electrically disconnect the internal EMC filter, remove the screw as shown above (1).

Figure 4-23 Removal of the size 3 internal EMC filter

To electrically disconnect the internal EMC filter, remove the screw as shown above (1).

64 Unidrive M200 / M201 User Guide

Remove the three M4 terminal nuts (1). Lift away the cover (2) to expose the M4 Torx internal EMC filter removal screw. Finally remove the M4 Torx internal EMC filter removal screw (3) to electrically disconnect the

internal EMC filter.

Figure 4-26 Removal of the size 6 internal EMC filter

To electrically disconnect the internal EMC filter, remove the screw as shown above (1).

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connection

External controller

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

Metal backplate

Grounding bar

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

Use four core cable to

connect the motor to the drive.

The ground conductor in the motor cable must be connected

directly to the earth terminal of

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

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

3 phase AC supply

Optional EMC filter

Metal backplate

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4.8.3 General requirements for EMC

Ground (earth) connections

The grounding arrangements should be in accordance with Figure 4-27, which shows a single drive on a back-plate with or without an additional enclosure.

Figure 4-27 shows how to configure and minimise EMC when using unshielded motor cable. However shielded cable is a better option, in which case it should be installed as shown in section 4.8.5 Compliance with generic emission standards on page 66.

Figure 4-27 General EMC enclosure layout showing ground connections

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Optional ground

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Optional braking resistor and overload

Do not place sensitive (unscreened) signal circuits within a zone extending 300 mm (12 in)

around the Drive, motor cable, or input cable from the EMC filter and unshielded braking resistor cable (if used)

300 mm

(12 in)

NOTE

CAUTION

100 mm

(4 in)

Do not modify

the filter wires

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Cable layout

Figure 4-28 indicates the clearances which should be observed around the drive and related ‘noisy’ power cables by all sensitive control signals / equipment.

Figure 4-28 Drive cable clearances

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Operation in the second environment

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

The drive contains an in-built filter for basic emission control. In some cases feeding the motor cables (U, V and W) once through a ferrite ring can maintain compliance for longer cable lengths.

For longer motor cables, an external filter is required. Where a filter is required, follow the guidelines in Section 4.8.5 Compliance with generic emission standards .

Where a filter is not required, follow the guidelines given in section

4.8.3 General requirements for EMC on page 65.

The second environment typically includes an industrial lowvoltage power supply network which does not supply buildings used for residential purposes. Operating the drive in this environment without an external EMC filter may cause interference to nearby electronic equipment whose sensitivity has not been appreciated. The user must take remedial measures if this situation arises. If the consequences of unexpected disturbances are severe, it is recommended that the guidelines in Section 4.8.5 Compliance with generic emission standards be adhered to.

Refer to section 11.1.25 Electromagnetic compatibility (EMC) on page 176 for further information on compliance with EMC standards and definitions of environments.

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

4.8.5 Compliance with generic emission standards

The following information applies to frame sizes 1 to 6.

Use the recommended filter and shielded motor cable. Observe the layout rules given in Figure 4-29. Ensure the AC supply and ground cables are at least 100 mm from the power module and motor cable.

Figure 4-29 Supply and ground cable clearance (sizes 1 to 6)

Any signal cables which are carried inside the motor cable (i.e. motor thermistor, motor brake) will pick up large pulse currents via the cable capacitance. The shield of these signal cables must be connected to ground close to the motor cable, to avoid this noise current spreading through the control system.

4.8.4 Compliance with EN 61800-3:2004 (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 4.8.5 Compliance with generic emission standards on page 66. An external EMC filter will always be

required.

This is a product of the restricted distribution class according to IEC 61800-3

In a residential environment this product may cause radio interference in which case the user may be required to take adequate measures.

66 Unidrive M200 / M201 User Guide

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Optional external braking resistor

Enclosure

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Avoid placing sensitive signal circuits in a zone 300 mm (12 in) in the area immediately surrounding the power module.

Figure 4-30 Sensitive signal circuit clearance

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The unbroken motor cable shield (unbroken) electrically connected to and held in place by means of the grounding bracket.

Connect the shield of the motor cable to the ground terminal of the motor frame using a link that is as short as possible and not exceeding 50 mm (2 in) long.

A complete 360

termination of the shield to the terminal housing of the

motor is beneficial.

From an EMC consideration it is irrelevant whether the motor cable contains an internal (safety) ground core, or if there is a separate external ground conductor, or where grounding is through the shield alone. An internal ground core will carry a high noise current and therefore it must be terminated as close as possible to the shield termination.

Figure 4-32 Grounding the motor cable shield

Ensure good EMC grounding.

Figure 4-31 Grounding the drive, motor cable shield and filter

Unshielded wiring to the optional braking resistor(s) may be used provided the wiring runs internally to the enclosure. Ensure a minimum spacing of 300 mm (12 in) from the signal wiring and the AC supply wiring to the external EMC filter. If this condition cannot be met then the wiring must be shielded.

Figure 4-33 Shielding requirements of optional external braking

resistor

+DC

1: Ensure direct metal contact at the drive and filter mounting points. Any paint must be removed beforehand.

Unidrive M200 / M201 User Guide 67 Issue Number: 4

If the control wiring is to leave the enclosure, it must be shielded and the shield(s) clamped to the drive using the grounding bracket as shown in Figure 4-34.

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Coupling bar

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Signal from plant Signal to drive

0V 0V

30V zener diode e.g. 2xBZW50-15

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Remove the outer insulating cover of the cable to ensure the shield(s) make direct contact with the bracket, but keep the shield(s) intact until as close as possible to the terminals

Alternatively, wiring may be passed through a ferrite ring, part number 3225-1004.

Figure 4-34 Grounding of signal cable shields using the

grounding bracket

4.8.6 Variations in the EMC wiring

Interruptions to the motor cable

The motor cable should ideally be a single length of shielded or armored cable having no interruptions. In some situations it may be necessary to interrupt the cable, as in the following examples:

• Connecting the motor cable to a terminal block in the drive enclosure

• Installing a motor isolator / disconnect switch for safety when work is

done on the motor

In these cases the following guidelines should be followed.

Terminal block in the enclosure

The motor cable shields should be bonded to the back-plate using uninsulated metal cable-clamps which should be positioned as close as possible to the terminal block. Keep the length of power conductors to a minimum and ensure that all sensitive equipment and circuits are at least 0.3 m (12 in) away from the terminal block.

Figure 4-35 Connecting the motor cable to a terminal block in the

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The coupling-bar may be grounded to a known low-impedance ground nearby, for example a large metallic structure which is connected closely to the drive ground.

Figure 4-36 Connecting the motor cable to an isolator /

disconnect switch

Surge immunity of control circuits - long cables and connections outside a building

The input/output ports for the control circuits are designed for general use within machines and small systems without any special precautions.

These circuits meet the requirements of EN 61000-6-2:2005 (1 kV surge) provided the 0 V connection is not grounded.

In applications where they may be exposed to high-energy voltage surges, some special measures may be required to prevent malfunction or damage. Surges may be caused by lightning or severe power faults in association with grounding arrangements which permit high transient voltages between nominally grounded points. This is a particular risk where the circuits extend outside the protection of a building.

As a general rule, if the circuits are to pass outside the building where the drive is located, or if cable runs within a building exceed 30 m, some additional precautions are advisable. One of the following techniques should be used:

1. Galvanic isolation, i.e. do not connect the control 0 V terminal to ground. Avoid loops in the control wiring, i.e. ensure every control wire is accompanied by its return (0 V) wire.

2. Shielded cable with additional power ground bonding. The cable shield may be connected to ground at both ends, but in addition the ground conductors at both ends of the cable must be bonded together by a power ground cable (equipotential bonding cable) with

cross-sectional area of at least 10 mm signal cable shield, or to suit the electrical safety requirements of the plant. This ensures that fault or surge current passes mainly through the ground cable and not in the signal cable shield. If the building or plant has a well-designed common bonded network this precaution is not necessary.

3. Additional over-voltage suppression - for the analog and digital inputs and outputs, a zener diode network or a commercially available surge suppressor may be connected in parallel with the input circuit as shown in Figure 4-37 and Figure 4-38.

If a digital port experiences a severe surge its protective trip may operate (O.Ld1 trip). For continued operation after such an event, the trip can be reset automatically by setting Pr 10.034 to 5.

Figure 4-37 Surge suppression for digital and unipolar inputs and

outputs

, or 10 times the area of the

Using a motor isolator / disconnect-switch

The motor cable shields should be connected by a very short conductor having a low inductance. The use of a flat metal coupling-bar is recommended; conventional wire is not suitable.

The shields should be bonded directly to the coupling-bar using uninsulated metal cable-clamps. Keep the length of the exposed power conductors to a minimum and ensure that all sensitive equipment and circuits are at least 0.3 m (12 in) away.

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Signal from plant Signal to drive

0V 0V

2 x 15V zener diode e.g. 2xBZW50-15

123456

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Figure 4-38 Surge suppression for analog and bipolar inputs and

outputs

Surge suppression devices are available as rail-mounting modules, e.g. from Phoenix Contact:

Unipolar TT-UKK5-D/24 DC Bipolar TT-UKK5-D/24 AC

These devices are not suitable for encoder signals or fast digital data networks because the capacitance of the diodes adversely affects the signal. Most encoders have galvanic isolation of the signal circuit from the motor frame, in which case no precautions are required. For data networks, follow the specific recommendations for the particular network.

4.9 Communications connections

Installing an AI-485 Adaptor provides the drive with a 2 wire 485 serial communications interface. This enables the drive set-up, operation and monitoring to be carried out with a PC or controller as required.

Figure 4-39 Location of the AI-485 Adaptor option

4.9.1 485 serial communications

The drive only supports Modbus RTU protocol. See Table 4-24 for the connection details.

Standard Ethernet cables are not recommended for use when connecting drives on a 485 network as they do not have the correct twisted pairs for the pinout of the serial comms port.

Table 4-24 Serial communication port pin-outs (RJ45)

Pin Function

1 120 Ω Termination resistor

2RX TX

30 V

4 +24 V (100 mA)

5 Not connected

6 TX enable

7RX\ TX\

8 RX\ TX\ (if termination resistors are required, link to pin 1)

Minimum number of connections are 2, 3, 7 and shield.

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Table 4-25 Serial communication port pin-outs (screw terminal

block)

Pin Function

10 V

2RX\ TX\

3RX TX 4 120 Ω Termination resistor

5 TX Enable

6 +24 V (100 mA)

4.9.2 Isolation of the 485 serial communications

port

The serial PC communications port is single insulated and meets the requirements for ELV.

When using the communications port with a personal computer or centralised controller e.g. PLC, an isolation device must be included with a rated voltage at least equal to the drive supply voltage. Ensure that the correct fuses are installed at the drive input, and that the drive is connected to the correct supply voltage. If a serial communications converter other than the CT Comms cable is used to connect to other circuits classified as Safety Extra Low Voltage (SELV) (e.g. to a personal computer), then a safety isolating barrier must be included to maintain the SELV classification.

An isolated serial communications lead has been designed to connect the drive to IT equipment (such as laptop computers), and is available from the supplier of the drive. See below for details:

Table 4-26 Isolated serial comms lead details

Part number Description

4500-0096 CT USB Comms cable

The “isolated serial communications” lead has reinforced insulation as defined in IEC60950 for altitudes up to 3,000 m.

4.10 Control connections

4.10.1 General

Table 4-27 The control connections consist of:

Function Qty

Single ended analog input

Analog output 1 Source, mode, scaling, 7

Digital input 4 Destination, invert

Digital input / output 1

Relay 1 Source, invert 41, 42

Drive enable 1

+10 V User output 1

+24 V User output 1

0V common 1

Control parameters

available

Mode, offset, invert, scaling,

destination

Input / output mode select, destination / source, invert

Key:

Destination parameter:

Source parameter:

Mode parameter:

Indicates the parameter which is being controlled by the terminal / function

Indicates the parameter being output by the terminal

Analog - indicates the mode of operation of the terminal, i.e. voltage 0-10 V, current 4-20 mA etc. Digital - indicates the mode of operation of the terminal, (the Drive Enable terminal is fixed in positive logic).

All analog terminal functions can be programmed in menu 7.

Ter mina l

number

2, 5

11, 12, 13,

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Frequency

Run forward

Run reverse

Analog input 1/

input 2 select

Relay (over-voltage category II)

Drive OK

Analog

frequency

reference 1

Analog

frequency

reference 2

0V common

Drive enable

+10 V

+24 V

Analog input 1 select

Analog input 2 select

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All digital terminal functions (including the relay) can be programmed in menu 8.

The control circuits are isolated from the power circuits in the drive by basic insulation (single insulation) only. The installer must ensure that the external control circuits are insulated from human contact by at least one layer of insulation (supplementary insulation) rated for use at the AC supply voltage.

If the control circuits are to be connected to other circuits classified as Safety Extra Low Voltage (SELV) (e.g. to a personal computer), an additional isolating barrier must be included in order to maintain the SELV classification.

If any of the digital inputs (including the drive enable input) are connected in parallel with an inductive load (i.e. contactor or motor brake) then suitable suppression (i.e. diode or varistor) should be used on the coil of the load. If no suppression is used then over voltage spikes can cause damage to the digital inputs and outputs on the drive.

Any signal cables which are carried inside the motor cable (i.e. motor thermistor, motor brake) will pick up large pulse currents via the cable capacitance. The shield of these signal cables must be connected to ground close to the point of exit of the motor cable, to avoid this noise current spreading through the control system.

Figure 4-40 Default terminal functions

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4.10.2 Control terminal specification

1 0V common

Function Common connection for all external devices

2 Analog input 1

Default function Frequency reference

Type of input

Mode controlled by… Pr 07.007

Operating in voltage mode (default)

Full scale voltage range 0 V to +10 V ±3 %

Maximum offset ±30 mV

Absolute maximum voltage range -18 V to +30 V relative to 0 V

Input resistance 100 k

Operating in current mode

Current ranges

Maximum offset 250 µA

Absolute maximum voltage (reverse bias)

Absolute maximum current 25 mA

Equivalent input resistance 165 

Common to all modes

Resolution 11 bits

Sample / update 5 ms

4 +10 V user output

Default function Supply for external analog devices

Nominal voltage 10.2 V

Voltage tolerance ±3 %

Maximum output current 5 mA

Unipolar single-ended analog voltage or unipolar current

0 to 20 mA ±5 %, 20 to 0 mA ±5 %, 4 to 20 mA ±5 %, 20 to 4 mA ±5 %

-18 V to +30 V relative to 0 V

5 Analog input 2

Default function Frequency reference

Type of input

Mode controlled by.... Pr 07.011

Operating in voltage mode (default)

Full scale voltage range 0 V to +10 V ±3 %

Maximum offset ±30 mV

Absolute maximum voltage range -18 V to +30 V relative to 0 V

Input resistance 100 k

Resolution 11 bits

Sample / update period 5 ms

Operating in digital mode

Absolute maximum applied voltage range

Impedance 6.8 k

Input threshold 10 V ±0.8 V from IEC 61131-2

Sample / update period

Unipolar single-ended analog voltage or positive logic only digital input

-18 V to +30 V relative to 0 V

2 ms when routed to destinations Pr 06.035 or Pr 06.036, otherwise 6 ms.

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7 Analog output 1

Default function Frequency output

Type of output Unipolar single-ended analog voltage

Voltage range +10 V

Maximum offset 15 mV

Load resistance  2 kȍ

Protection Short circuit relative to 0 V

Resolution 0.1 %

Sample / update period 5 ms

9 +24 V user output

Default function Supply for external digital devices

Voltage tolerance ±20 %

Maximum output current 100 mA

Protection Current limit and trip

10 Digital I/O 1

Default function AT ZERO FREQUENCY output

Positive logic digital input, positive logic

Type

Input / output mode controlled by … Pr 08.031

Operating as in input

Absolute maximum applied voltage range

Impedance 6.8 kȍ

Input threshold 10 V ±0.8 V from IEC 61131-2

Operating as an output

Nominal maximum output current 50 mA

Maximum output current 100 mA (total including +24 Vout)

Common to all modes

Voltage range 0 V to +24 V

Sample / update period

voltage source output. PWM or frequency output modes can be selected.

-8 V to +30 V relative to 0 V

2 ms when routed to destinations Pr 06.035 or Pr 06.036, otherwise 6 ms

14 Digital Input 5

Terminal 14 default function Analog INPUT 1 / INPUT 2 select

Positive logic only digital input. Frequency

Type

Voltage range 0 V to +24 V

Absolute maximum applied voltage range

Impedance 6.8 kȍ

Input threshold 10 V ±0.8 V from IEC 61131-2

Sample / update period

Relay contacts

Default function Drive OK indicator

Contact voltage rating 240 Vac, Installation over-voltage category II

Contact maximum current rating

Contact minimum recommended rating

Contact type Normally open

Default contact condition Closed when power applied and drive OK

Update period 4 ms

input or motor thermistor input (bias for DIN44081 ptc, KTY84, PT1000, PT2000 and other types) mode can be selected.

-18 V to +30 V relative to 0 V

2 ms when routed to destinations Pr 06.035 or Pr 06.036, otherwise 6 ms.

2 A AC 240 V 4 A DC 30 V resistive load

0.5 A DC 30 V inductive load (L/R = 40 ms)

12 V 100 mA

To prevent the risk of a fire hazard in the event of a fault, a fuse or other over-current protection must be installed in the relay circuit.

11 Digital Input 2

12 Digital Input 3

13 Digital Input 4

Terminal 11 default function DRIVE ENABLE input

Terminal 12 default function RUN FORWARD input

Terminal 13 default function RUN REVERSE input

Type Positive logic only digital inputs

Voltage range 0 V to +24 V

Absolute maximum applied voltage range

Impedance 6.8 kȍ

Input threshold 10 V ±0.8 V from IEC 61131-2

Sample / update period

-18 V to +30 V relative to 0 V

2 ms when routed to destinations Pr 06.035 or Pr 06.036, otherwise 6 ms.

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5 Getting started

This chapter introduces the user interfaces, menu structure and security levels of the drive.

5.1 Understanding the display

5.1.1 Keypad

The keypad display consists of a 6 digit LED display. The display shows the drive status or the menu and parameter number currently being edited.

The option module Unidrive menu (S.mm.ppp) is only displayed if the option module is installed. Where S signifies the option module slot number and the mm.ppp signifies the menu and parameter number of the option module’s internal menus and parameter.

The display also includes LED indicators showing units and status as shown in Figure 5-1. When the drive is powered up, the display will show the power up parameter defined by Parameter Displayed At Power-Up (11.022).

Figure 5-1 Unidrive M200 keypad detail

1. Escape button

2. Down button

3. Start button

4. Stop / Reset button (red)

5. Up button

6. Enter button

7. Run forward indicator

8. Run reverse indicator

9. Keypad reference indicator

10. Unit indicators

Figure 5-2 Unidrive M201 keypad detail

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The red stop button is also used to reset the drive.

The parameter value is correctly displayed on the keypad display as shown in Table 5-1.

On the Unidrive M201, the speed reference potentiometer is used to adjust the keypad reference.

Table 5-1 Keypad display formats

Display formats Value

Standard 100.99

Date 31.12.11 or 12.31.11

Time 12.34.56

Character ABCDEF

Binary 5

IP Address 192.168 88.1*

MAC Address 01.02.03 04.05.06*

Version number 01.23.45

*Alternate display

5.2 Keypad operation

5.2.1 Control buttons

The keypad consists of:

• Up and down button - Used to navigate the parameter structure and change parameter values.

• Enter button - Used to toggle between parameter edit and view mode. This button can also be used to select between slot menu and parameter display.

• Escape button - Used to exit from parameter edit or view mode. In parameter edit mode, if parameter values are edited and the escape button pressed, the parameter value will be restored to the value it had on entry to edit mode.

• Start button - Used to provide a 'Run' command if keypad mode is selected.

• Stop / Reset button - Used to reset the drive. In keypad mode can be used for 'Stop'.

1. Run forward indicator

2. Unit indicators

3. Speed reference potentiometer

4. Keypad reference indicator

5. Run reverse indicator

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Show previous or next

parameter

- Press and release to go to next or previous parameter. Parameter flashes briefly then goes back to View.

- Holding or scrolls through each parameter within the menu.

Press and release.

Show last slot / menu / param

selected

Press and release to

edit Parameter

Menu select

Press or to select menu

Edited digits flash

Press and

release to view

Parameter select

Press or to select parameter.

Edited digits flash

Press and release

to edit

- Press and release to accept new value to be set.

- Reset drive if required.

- Execute action if required.

Press and release to

discard new

value and return

to original value

Press and release to

edit Menu

Press and release to

edit Parameter

View

Edit

Press or to select value

- Edited digit flashes

- Holding or increases or decreases value.

- Modified value has a direct effect on the drive except routing parameters and special parameters.

- New value can be validated or discarded.

- Holding + or edit the next or previous

digit.

Press and release to

go back to status

Timeout

240 s or hold

Press and release to

edit Menu

Slot select

(Only if option installed)

Press or to select _ or 1

Edited digit flashes

Press and release to

edit Slot

Parameter format s.mm.ppp

s: _ or 0: for drive. If drive is selected then hide first digit and show only menu and parameter.

1: for option mm: menu number (0 to 99) ppp: parameter number (0 to 999)

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Figure 5-3 Display modes

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Go to Status if no

option installed

If Drive Status (Pr 10.101) = 4 (Run) Show value only If Drive Status (Pr 10.101) <> 4 Show status only

Status

The up and down buttons can only be used to move between menus if Pr 00.010 has been set to show 'ALL'. Refer to section 5.9 Parameter access level and security on page 76.

Unidrive M200 / M201 User Guide 73 Issue Number: 4

Holding

or timeout will discard

new value and return

to original value.

- Holding and together sets value to zero.

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6â UG\

(Uâ8 Gâ28â/G

3 4

1 2

WARNING

NOTE

Menu 0

00.004

00.005

00.006

Menu 2

02.021

Menu 1

11.034

Menu 4

05.007

0.00 AV

0.00

10.0

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Figure 5-4 Mode examples

1 Parameter view mode: Read write or Read only

2 Status mode: Drive OK status

If the drive is ok and the parameters are not being edited or viewed, the display will show one of the following:

inh', 'rdy' or status mode parameter value.

3 Status mode: Trip status When the drive is in trip condition, the display will indicate that the drive has tripped and the display will show the trip code. For further information regarding trip codes, refer to section 12.4 Trips, Sub-trip numbers on page 180.

4 Status mode: Alarm status During an 'alarm' condition the display flashes between the drive status parameter value and the alarm.

5.3 Menu structure

The drive parameter structure consists of menus and parameters.

The drive initially powers up so that only Menu 0 can be viewed. The up and down arrow buttons are used to navigate between parameters and once Pr 00.010 has been set to 'All' the up and down buttons are used to navigate between menus.

For further information refer to section 5.9 Parameter access level and security on page 76.

The menus and parameters rollover in both directions i.e. if the last parameter is displayed, a further press will cause the display to rollover and show the first parameter.

When changing between menus, the drive remembers which parameter was last viewed in a particular menu and thus displays that parameter.

5.4 Menu 0

Menu 0 is used to bring together various commonly used parameters for basic easy set up of the drive. The parameters displayed in Menu 0 can be configured in Menu 22. Appropriate parameters are copied from the advanced menus into Menu 0 and thus exist in both locations.

For further information, refer to Chapter 6 Basic parameters on page 78.

Figure 5-5 Menu 0 copying

Do not change parameter values without careful consideration; incorrect values may cause damage or a safety hazard.

When changing the values of parameters, make a note of the new values in case they need to be entered again.

For new parameter values to apply after the line power supply to the drive is interrupted, new values must be saved. Refer to section

5.7 Saving parameters on page 75.

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5.5 Advanced menus

The advanced menus consist of groups or parameters appropriate to a specific function or feature of the drive. Menus 0 to 22 can be viewed on the Keypad.

The option module menu (S.mm.ppp) is only displayed if the option module is installed. Where S signifies the option module slot number and the mm.ppp signifies the menu and parameter number of the option module’s internal menus and parameter.

Table 5-2 Advanced menu descriptions

Menu Description

Commonly used basic set up parameters for quick / easy

programming 1 Frequency reference

2Ramps 3 Frequency control 4 Torque and current control

5 Motor control 6 Sequencer and clock 7 Analog I/O

8 Digital I/O 9 Programmable logic, motorized pot, binary sum, timers

10 Status and trips

11 Drive set-up and identification, serial communications 12 Threshold detectors and variable selectors 14 User PID controller

15 Option module slot 1 set-up menu 18 General option module application menu 1 20 General option module application menu 2

21 Second motor parameters 22 Menu 0 set-up

Slot 1 Slot 1 option menus*

* Only displayed when the option module is installed.

5.5.1 Display messages

The following tables indicate the various possible mnemonics which can be displayed by the drive and their meaning.

Table 5-3 Status indications

5.5.2 Alarm indications

An alarm is an indication given on the display by alternating the alarm string with the drive status string on the display. Alarms strings are not displayed when a parameter is being edited.

Table 5-4 Alarm indications

Alarm string Description

Brake resistor overload. Braking Resistor Thermal

br.res

Accumulator (10.039) in the drive has reached 75.0 % of the value at which the drive will trip.

Motor Protection Accumulator (04.019) in the drive

OV.Ld

has reached 75.0 % of the value at which the drive will trip and the load on the drive is >100 %.

Drive over temperature. Percentage Of Drive

d.OV.Ld

Thermal Trip Level (07.036) in the drive is greater than 90 %.

tuning

The autotune procedure has been initialized and an autotune in progress.

Limit switch active. Indicates that a limit switch is active and that is causing the motor to be stopped.

Opt.AI Option slot alarm.

Lo.AC Low voltage mode. See Low AC Alarm (10.107).

I.AC.Lt

Current limit active. See Current Limit Active (10.009).

5.6 Changing the operating mode

Procedure

Use the following procedure only if a different operating mode is required:

1. Ensure the drive is not enabled, i.e. terminal 11 is open or Pr 06.015

is OFF (0)

2. Change the setting of Pr 00.079 as follows:

Pr 00.079 setting Operating mode

23(Qâ/3

5)&$

The figures in the second column apply when serial communications are used.

1 Open-loop

2RFC-A

String Description

The drive is inhibited and cannot be run. The Drive Enable signal is not applied to

inh

the drive enable terminal or Pr 06.015 is set to 0. The other conditions that can prevent the drive from enabling are shown as bits in Enable Conditions (06.010)

The drive is ready to run. The drive enable

rdy

is active, but the drive inverter is not active because the final drive run is not active

Stop The drive is stopped / holding zero speed. Enabled

S.Loss Supply loss condition has been detected Enabled

dc inj The drive is applying dc injection braking Enabled

The drive has tripped and no longer

controlling the motor. The trip code appears on the display.

The drive is in the under voltage state either in low voltage or high voltage mode.

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When the operating mode is changed, a parameter save is carried out.

5.7 Saving parameters

When changing a parameter in Menu 0, the new value is saved when

pressing the Enter button to return to parameter view mode

from parameter edit mode.

If parameters have been changed in the advanced menus, then the change will not be saved automatically. A save function must be carried out.

Procedure

1. Select ‘Save'* in Pr mm.000 (alternatively enter a value of 1000* in Pr mm.000)

2. Either:

• Press the red reset button

• Carry out a drive reset through serial communications by setting Pr 10.038 to 100

* If the drive is in the under voltage state (i.e. when the AI-Backup adaptor terminals are being supplied from a +24 Vdc supply) a value of 1001 must be entered into Pr mm.000 to perform a save function.

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5.8 Restoring parameter defaults

Restoring parameter defaults by this method saves the default values in the drives memory. User security status (00.010) and User security code (00.025) are not affected by this procedure).

Procedure

1. Ensure the drive is not enabled, i.e. terminal 11 is open or Pr 06.015

is OFF (0)

2. Select 'Def.50’ or 'Def.60' in Pr mm.000. (alternatively, enter 1233 (50 Hz settings) or 1244 (60 Hz settings) in Pr mm.000).

3. Either:

• Press the red reset button

• Carry out a drive reset through serial communications by setting Pr 10.038 to 100

5.9 Parameter access level and security

The parameter access level determines whether the user has access to Menu 0 only or to all the advanced menus (Menus 1 to 22) in addition to Menu 0.

The User Security determines whether the access to the user is read only or read write.

Both the User Security and Parameter Access Level can operate independently of each other as shown in table Table 5-5.

Table 5-5 Parameter access level and security

User

security

status

(11.044)

0 Menu 0

1 All Menus

3 Read-only

4 Status only

5 No access

The default settings of the drive are Parameter Access Level Menu 0 and user Security Open i.e. read / write access to Menu 0 with the advanced menus not visible.

Access level

Read-only Menu 0

User

security

Open RW Not visible

Closed RO Not visible

Open RW RW

Closed RO RO

Open RO Not visible

Closed RO Not visible

Open RO RO

Closed RO RO

Open Not visible Not visible

Closed Not visible Not visible

Open Not visible Not visible

Closed Not visible Not visible

Menu 0

status

Advanced

menu status

5.9.1 User Security Level / Access Level

The drive provides a number of different levels of security that can be set by the user via User Security Status (11.044); these are shown in the table below.

User Security

Status

(Pr 11.044)

LEVEL.0 (0)

ALL (1)

r.only.0 (2)

r.only.A (3)

Status (4)

no.acc (5)

All writable parameters are available to be edited but only parameters in Menu 0 are visible

All parameters are visible and all writable parameters are available to be edited

Access is limited to Menu 0 parameters only. All parameters are read-only

All parameters are read-only however all menus and parameters are visible

The keypad remains in status mode and no parameters can be viewed or edited

The keypad remains in status mode and no parameters can be viewed or edited. Drive parameters cannot be accessed via a comms/fieldbus interface in the drive or any option module

Description

5.9.2 Changing the User Security Level /Access Level

The security level is determined by the setting of Pr 00.010 or Pr 11.044.

The Security Level can be changed through the keypad even if the User Security Code has been set.

5.9.3 User Security Code

The User Security Code, when set, prevents write access to any of the parameters in any menu.

Setting User Security Code

Enter a value between 1 and 9999 in Pr 00.025 and press the

button; the security code has now been set to this value. In order to activate the security, the Security level must be set to desired level in Pr 00.010. When the drive is reset, the security code will have been activated and the drive returns to Menu 0. The value of Pr 00.025 will return to 0 in order to hide the security code.

Unlocking User Security Code

Select a parameter that need to be edited and press the button, the display will now show ‘Co’. Use the arrow buttons to set the security

code and press the button. With the correct security code entered, the display will revert to the parameter selected in edit mode.

If an incorrect security code is entered, the following message ‘Co.Err’ is displayed, and the display will revert to parameter view mode.

Disabling User Security

Unlock the previously set security code as detailed above. Set Pr 00.025

to 0 and press the button. The User Security has now been disabled, and will not have to be unlocked each time the drive is

powered up to allow read / write access to the parameters.

76 Unidrive M200 / M201 User Guide

5.10 Displaying parameters with non-

default values only

By selecting 'diff.d' in Pr mm.000 (Alternatively, enter 12000 in Pr mm.000), the only parameters that will be visible to the user will be those containing a non-default value. This function does not require a drive reset to become active. In order to deactivate this function, return to Pr mm.000 and select 'none' (alternatively enter a value of 0). Please note that this function can be affected by the access level enabled, refer to section 5.9 Parameter access level and security on page 76 for further information regarding access level.

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5.11 Displaying destination parameters only

By selecting 'dest' in Pr mm.000 (Alternatively enter 12001 in Pr mm.000), the only parameters that will be visible to the user will be destination parameters. This function does not require a drive reset to become active. In order to deactivate this function, return to Pr mm.000 and select 'none' (alternatively enter a value of 0).

Please note that this function can be affected by the access level enabled, refer to section 5.9 Parameter access level and security on page 76 for further information regarding access level.

5.12 Communications

5.12.1 485 Serial communications

Communication is via the RJ45 connector or screw terminals (parallel connection). The drive only supports Modbus RTU protocol.

The communications port applies a network.

USB to EIA485 Communications

An external USB hardware interface such as a PC cannot be used directly with the 2-wire EIA485 interface of the drive. Therefore a suitable converter is required.

A suitable USB to EIA485 isolated converter is available from Control Techniques as follows:

• CT USB Comms cable (CT Part No. 4500-0096)

When using one of the above converters or any other suitable converter with the drive, it is recommended that no terminating resistors be connected on the network. It may be necessary to 'link out' the terminating resistor within the converter depending on which type is used. The information on how to link out the terminating resistor will normally be contained in the user information supplied with the converter.

Serial communications set-up parameters

The following parameters need to be set according to the system

requirements.

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Serial communications set-up parameters

Serial Mode

(11.024)

Serial Baud Rate

(11.025)

Serial Address

(11.023)

8 2 NP (0), 8 1 NP (1), 8 1 EP (2), 8 1 OP (3), 8 2 NP M (4), 8 1 NP M (5), 8 1 EP M (6), 8 1 OP M (7), 7 1 EP (8), 7 1 OP (9), 7 1 EP M (10), 7 1 OP M (11)

300 (0), 600 (1), 1200 (2), 2400 (3), 4800 (4), 9600 (5), 19200 (6), 38400 (7), 57600(8), 76800(9), 115200 (10)

1 to 247

The drive only supports the Modbus RTU protocol and is always a slave. This parameter defines the supported data formats used by the 485 comms port (if installed) on the drive. This parameter can be changed via the drive keypad, via a option module or via the comms interface itself.

This parameter can be changed via the drive keypad, via a option module or via the comms interface itself. If it is changed via the comms interface, the response to the command uses the original baud rate. The master should wait at least 20 ms before sending a new message using the new baud rate.

This parameter defines the serial address and an addresses between 1 and 247 are permitted.

Unidrive M200 / M201 User Guide 77 Issue Number: 4

Page 78

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Menu 0 is used to bring together various commonly used parameters for basic easy set up of the drive. All the parameters in Menu 0 appear in other menus in the drive (denoted by {…}). Menus 22 can be used to configure the parameters in Menu 0.

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Technical data Diagnostics UL Listing

6 Basic parameters

6.1 Menu 0: Basic parameters

Range

Parameter

00.001 Minimum Reference Clamp ±VM_NEGATIVE_REF_CLAMP1 Hz 0.00 Hz RW Num US

00.002 Maximum Reference Clamp ±VM_POSITIVE_REF_CLAMP Hz

00.003 Acceleration Rate 1 ±VM_ACCEL_RATE s 5.0 s RW Num US

00.004 Deceleration Rate 1 ±VM_ACCEL_RATE s 10.0 s RW Num US

00.005 Drive Configuration

00.006 Motor Rated Current ±VM_RATED_CURRENT A

00.007 Motor Rated Speed 0.0 to 80000.0 rpm

00.008 Motor Rated Voltage ±VM_AC_VOLTAGE_SET V

00.009 Motor Rated Power Factor 0.00 to 1.00 0.85 RW Num RA US

00.010 User Security Status

00.015 Jog Reference 0.00 to 300.00 Hz 1.50 Hz RW Num US

00.016 Analog Input 1 Mode

00.017 Bipolar Reference Enable Off (0) or On (1) Off (0) RW Bit US

00.018 Preset Reference 1 ±VM_SPEED_FREQ_REF Hz 0.00 Hz RW Num US

00.025 User Security Code 0 to 9999 0 RW Num ND NC PT US

Power-up Keypad Control Mode

00.027

Reference

00.028 Ramp Mode Select Fast (0), Std (1), Std.bst (2), Fst.bst (3) Std (1) RW Txt US

00.029 Ramp Enable

00.030 Parameter Cloning None (0), rEAd (1), Prog (2), Auto (3), boot (4) None (0) RW Txt NC US

00.031 Stop Mode

Dynamic V to F Select / Flux

00.032

Optimization Select

00.033 Catch A Spinning Motor dis (0), Enable (1), Fr.Only (2), Rv.Only (3) dis (0) RW Txt US

00.034 Digital Input 5 Select Input (0), th.Sct (1), th (2), th.Notr (3), Fr (4) Input (0) RW Txt US

00.035 Digital Output 1 Control 0 to 21 0 RW US

00.036 Analog Output 1 Control 0 to 15 0 RW US

00.037 Maximum Switching Frequency

00.038 Autotune 0 to 2 0 to 3 0 RW Num NC US

00.039 Motor Rated Frequency 0.0 to VM_SPEED_FREQ_REF_UNIPOLAR Hz

00.040 Number of Motor Poles* Auto (0) to 32 (16) Auto 0 RW Num US

00.041 Control Mode

00.042 Low Frequency Voltage Boost 0.0 to 25.0 % 3.0 % RW Num US

00.043 Serial Baud Rate

00.044 Serial Address 1 to 247 1 RW Num US

00.045 Reset Serial Communications Off (0) or On (1) Off (0) RW ND NC

00.046 Brake Release Current Threshold 0 to 200 % 50 % RW Num US

AV (0), AI (1), AV.Pr (2), AI.Pr (3), Preset (4), Pad

20-4.L (-3), 4-20.H (-2), 20-4.H (-1), 0-20 (0), 20-0

(1), 4-20.tr (2), 20-4.tr (3), 4-20 (4), 20-4 (5), Volt (6)

8 (6), 12 (7), 16 (8) kHz

Ur.S (0), Ur (1), Fd (2),

300 (0), 600 (1), 1200 (2), 2400 (3), 4800 (4), 9600

OL RFC-A OL RFC-A

(5), Pad.Ref (6), E.Pot (7), torque (8), Pid (9)

LEVEL.0 (0), ALL (1), r.only.0 (2), r.only.A (3),

Status (4), no.acc(5)

4-20.S (-6), 20-4.S (-5), 4-20.L (-4),

Reset (0), Last (1), Preset (2) Reset (0) RW Txt US

Coast (0), rp (1), rp.dc I (2), dc I (3), td.dc I (4),

dis (5), No.rp (6)

0.667 (0), 1 (1), 2 (2), 3 (3), 4 (4), 6 (5),

Ur.Auto (3), Ur.I (4),

SrE (5)

(5), 19200 (6), 38400 (7), 57600 (8), 76800 (9),

(Ú) Default (Ö)

50Hz default: 50.00 Hz 60Hz default: 60.00 Hz

AV ( 0 ) RW T x t P T U S

Maximum Heavy Duty Rating

(11.032) A

50Hz default:

1500.0 rpm

60Hz default:

1800.0 rpm

110V drive: 230 V

200V drive: 230 V 400V drive 50 Hz: 400 V 400V drive 60 Hz: 460 V

575V drive: 575 V

690V drive: 690 V

Off (0) or On (1) On (1) RW Bit US

0 to 1 0 RW Num US

2 (2), 3 (3), 4 (4),

6 (5), 8 (6), 12 (7),

16 (8) kHz

50Hz: 50.00 Hz 60Hz: 60.00 Hz

Ur.I (4) RW Txt US

115200 (10)

50Hz default:

1450.0 rpm

60Hz default:

1750.0 rpm

LEVEL.0 (0) RW Num ND NC PT

Volt ( 6) RW Tx t US

rp (1) RW Txt US

3 (3) kHz RW Txt US

19200 (6) RW Txt US

RW Num US

RW Num RA US

RW Num US

RW Num RA US

Typ e

78 Unidrive M200 / M201 User Guide

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Range

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(Ú) Default (Ö)

OL RFC-A OL RFC-A

Advanced

parameters

Technical data Diagnostics UL Listing

Type

00.047 Brake Apply Current Threshold 0 to 200 % 10 % RW US

00.048 BC Brake Release Frequency 0.00 to 20.00 Hz 1.00 Hz RW Num US

00.049 BC Brake Apply Frequency 0.00 to 20.00 Hz 2.00 Hz RW Num US

00.050 BC Brake Delay 0.0 to 25.0 s 1.0 s RW Num US

00.051 BC Post-brake Release Delay 0.0 to 25.0 s 1.0 s RW Num US

00.053 BC Initial Direction Ref (0), For (1), Rev (2) Ref (0) RW Txt US

BC Brake Apply Through Zero

00.054

Threshold

0.00 to 25.00 Hz 0.00 Hz RW Num US

00.055 BC Enable dis (0), Relay (1), dig IO (2), User (3) dis (0) RW Txt US

Frequency Controller Proportional

00.065

Gain Kp1

Frequency Controller Integral Gain

00.066

Ki1

00.067 Sensorless Mode Filter

0.000 to

200.000 s/rad

0.00 to

/rad

655.35 s

4 (0), 5 (1), 6 (2), 8 (3),

12 (4), 20 (5) ms

0.100 s/rad RW Num US

0.10 s2/rad

RW Num US

4 (0) ms RW Txt US

00.069 Spin Start Boost 0.0 to 10.0 1.0 RW US

00.076 Action on Trip Detection 0 to 31 0 RW US

Maximum Heavy Duty Current

00.077

Rating

00.078 Software Version 0 to 999999

0.00 to 9999.99 A

RO Num ND NC PT

RO ND NC PT

00.079 User Drive Mode OPEn.LP (1), RFC-A (2) OPEn.LP (1) RW Txt ND NC PT US

00.080 User Security Status

LEVEL.0 (0), ALL (1), r.only.0 (2), r.only.A (3),

Status (4), no.acc(5)

LEVEL.O. (0) RW Txt ND PT

RW Read / Write RO Read only Num Number parameter Bit Bit parameter Txt Text string Bin Binary parameter FI Filtered

ND No default value NC Not copied PT Protected parameter RA Rating dependent US User save PS Power-down save DE Destination

* If this parameter is read via serial communications, it will show pole pairs.

Unidrive M200 / M201 User Guide 79 Issue Number: 4

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Pad

Pad.Ref

E. Pot

tor

Pid

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Figure 6-1 Menu 0 logic diagram

Analog reference

Analog input 1

Analog input 2

01.015

01.050

Preset frequency reference

Preset

00.018

Reference 1

Keypad reference

Electrical

installation

Analog input

00.016

1 mode

set

Getting

started

01.050

Basic

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Running the

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Card

Analog input 1/ input 2 select

AV.P r

AI.Pr

Advanced

parameters

Configuration

1 2 3

4 5 6

Technical data Diagnostics UL Listing

Bipolar

Drive

00.005

Reference

Enable

00.017

Key

Input

terminals

Output

terminals

00.XXX

Read-write parameter

Read-only parameter

(RW)

(RO)

The parameters are all shown in their default settings

80 Unidrive M200 / M201 User Guide

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Resistor

optional

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RUN

12 13

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RUN REVERSE

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OL,

RFC-A>

NV Media

Card

FREQUENCY

Advanced

parameters

AT ZERO FREQUENCY

Technical data Diagnostics UL Listing

Minimum

Reference

Clamp

00.001

Maximum

Reference

Clamp

00.002

RFC-A mode only

00.003

Acceleration Rate 1

00.004

Deceleration Rate 1

00.028

Ramp Mode

Select

Ramps

Ramp Enable

00.029

RFC-A Frequency-loop

PID

03.012

gains

00.065

00.066

Frequency Controller Differential Feedback Gain Kd 1

Motor

05.004

Frequency

Controller Proportional Gain Kp 1

Frequency

Controller

Integral

Gain Ki 1

Rpm

Analog output

Motor-voltage control

OL>

05.004

Estimated Motor Speed

Torque Mode

04.011

Selector

00.033

Motor

00.006 ~ 00.009

Power Factor

Rated Voltage

Rated Speed

Rated Current

00.041

Control mode

00.042

Low Frequency Voltage Boost

00.032

Dynamic

Select

Digital output

parameters

V/f

RFC-A>

Drive

L3L2L1

Unidrive M200 / M201 User Guide 81 Issue Number: 4

RFC-A Torque

Producing

Current

Power stage

Maximum Switching

00.037

Frequency

05.001

Output Frequency

04.002

04.001

Magnetising Current

Current Magnitude

U V W

+ BR

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6.2 Parameter descriptions

6.2.1 Pr mm.000

Pr mm.000 is available in all menus, commonly used functions are provided as text strings in Pr mm.000 shown in Table 6-1. The functions in Table 6-1 can also be selected by entering the appropriate numeric values (as shown in Table 6-2) in Pr mm.000. For example, enter 7001 in Pr mm.000 to store drive parameters on an NV media card.

Table 6-1 Commonly used functions in xx.000

Value Equivalent value String Action

1000 1

6001 2

4001 3

6002 4

4002 5

6003 6

4003 7

12000 8

12001 9

1233 10

1244 11

1070 12

None No action

SAVE Save drive parameters to non-volatile memory

Load the data from file 1 on a non-volatile media card into the drive provided it is a parameter file

SAVE1 Store the drive parameters in file 1 on a non-volatile media card

Load the data from file 2 on a non-volatile media card into the drive provided it is a parameter file

SAVE2 Store the drive parameters in file 2 on a non-volatile media card

Load the data from file 3 on a non-volatile media card into the drive provided it is a parameter file

SAVE3 Store the drive parameters in file 3 on a non-volatile media card

diff.d Only display parameters that are different from their default value

dest Only display parameters that are used to set-up destinations

def.50 Load 50 Hz defaults

def.60 Load 60 Hz defaults

rst.opt Reset all option modules

Table 6-2 Functions in Pr mm.000

Value Action

1000 Save parameters when Under Voltage Active (Pr 10.016) is not active.

1001 Save parameter under all conditions

1070 Reset option module

1233 Load standard (50 Hz) defaults

1234 Load standard (50 Hz) defaults to all menus except option module menu 15

1244 Load US (60 Hz) defaults

1245 Load US (60 Hz) defaults to all menus except option module menu 15

1299 Reset {St.HF} trip.

2001* Create a boot file on a non-volatile media card based on the present drive parameters including all Menu 20 parameters

4yyy* NV media card: Transfer the drive parameters to parameter file yyy

6yyy* NV media card: Load the drive parameters from parameter file yyy

7yyy* NV media card: Erase file yyy

8yyy* NV Media card: Compare the data in the drive with file yyy

9555* NV media card: Clear the warning suppression flag

9666* NV media card: Set the warning suppression flag

9777* NV media card: Clear the read-only flag

9888* NV media card: Set the read-only flag

12000** Only display parameters that are different from their default value. This action does not require a drive reset.

12001** Only display parameters that are used to set-up destinations (i.e. DE format bit is 1). This action does not require a drive reset.

Backup all drive data (parameter differences from defaults and miscellaneous option data), including the drive name; the store will

40yyy

occur to the </fs/MCDF/driveyyy/> folder; if it does not exist, it will be created. Since the name is stored, this is a backup, rather than a clone. The command code will be cleared when all drive and option data have been saved.

60yyy

Load all drive data (parameter differences from defaults and miscellaneous option data); the load will come from the </fs/MCDF/ driveyyy/> folder. The command code will not be cleared until the drive and all option data have been loaded.

* See Chapter 9 NV Media Card on page 97 for more information on these functions. ** These functions do not require a drive reset to become active. All other functions require a drive reset to initiate the function. Equivalent values and strings are also provided in the table above.

82 Unidrive M200 / M201 User Guide

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WAR NING

CAUTION

WAR NING

NOTE

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7 Running the motor

This chapter takes the new user through all the essential steps to running a motor for the first time, in each of the possible operating modes.

For information on tuning the drive for the best performance, see Chapter 8 Optimization on page 89.

Ensure that no damage or safety hazard could arise from the motor starting unexpectedly.

The values of the motor parameters affect the protection of the motor. The default values in the drive should not be relied upon. It is essential that the correct value is entered in Pr 00.006 Motor Rated Current. This affects the thermal protection of the motor.

If the drive is started using the keypad it will run to the speed defined by the keypad reference (Pr 01.017). This may not be acceptable depending on the application. The user must check in Pr 01.017 and ensure that the keypad reference has been set to 0.

If the intended maximum speed affects the safety of the machinery, additional independent over-speed protection must be used.

7.2 Changing the operating mode

Procedure

Use the following procedure only if a different operating mode is required:

1. Ensure that the drive is not enabled, i.e. terminal 11 is open or

Pr 06.015 is OFF(0).

2. Change the setting of Pr 00.079 as follows:

Pr 00.079 setting Operating mode

23(Qâ/3

U)&$

The figures in the second column apply when serial communications are used.

3. Either:

• Press the red reset button

• Carry out a drive reset through serial communications by setting

Pr 10.038 to 100 (ensure that Pr. mm.000 returns to 0).

When the operating mode is changed, a parameter save is carried out.

1 Open-loop

2RFC-A

7.1 Quick start connections

7.1.1 Basic requirements

This section shows the basic connections which must be made for the drive to run in the required mode. For minimal parameter settings to run in each mode please see the relevant part of section 7.3 Quick start commissioning / start-up on page 87.

Table 7-1 Minimum control connection requirements for each

control mode

Drive control method Requirements

Drive enable

Terminal mode

Keypad mode Drive enable

Serial communications

Table 7-2 Minimum control connection requirements for each

mode of operation

Operating mode Requirements

Open loop mode Induction motor

RFC – A mode (without speed feedback)

Speed / Torque reference Run forward / Run reverse

Drive enable Serial communications link

Induction motor without speed feedback

Unidrive M200 / M201 User Guide 83 Issue Number: 4

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L1 L2 L3

Fuses

L1 L2 L3UVW

UVW

10 11 12 13 14

+10 V

24 V

Run FWD

Drive enable

Run REV

Braking resistor (optional)

Induction motor

Frequency Reference input

T e

i n a

o d e

e y

p a d

o d e

Thermal overload for braking resistor to protect against fire risk. This must be wired to interrupt the AC supply in the event of a fault.

information

Figure 7-1 Minimum connections to get the motor running in any operating mode (size 1 to 4)

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84 Unidrive M200 / M201 User Guide

Issue Number: 4

Page 85

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Thermal overload for braking resistor to protect against fire risk. This must be wired to interrupt the AC supply in the event of a fault.

10 11 12 13 14

+10 V

24 V

Run FWD Run REV

Frequency Reference input

i n a

o d e

K e

y p a

o d e

Braking resistor

(optional)

L1 L2 L3

Fuses

L1 L2 L3

UVW

Open loop

RFC-A

Sensorless

Drive enable

information

Figure 7-2 Minimum connections to get the motor running in any operating mode (size 5)

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Thermal overload for braking resistor to protect against fire risk. This must be wired to interrupt the AC supply in the event of a fault.

10 11 12 13 14

+10 V

24 V

Run FWD Run REV

Frequency Reference input

T e

i n a

o d e

K e

y p a

o d e

Braking resistor

(optional)

L1 L2 L3

L1 L2 L3UVW

UVW

Open loop

RFC-A

Sensorless

Fuses

Drive enable

information

Figure 7-3 Minimum connections to get the motor running in any operating mode (size 6)

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86 Unidrive M200 / M201 User Guide

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Mot X XXXXXXXXX No XXXXXXXXXX kg

IP55 I.cl F C 40 s S1

VHzmin-1kW cosφA 230 400

50 1445 2.20 0.80 8.50

4.90

CN = 14.5Nm 240 415

50 1445 2. 20 0.76 8.50

4.90

CN = 14.4Nm

CTP- VEN 1PHASE 1=0,46A P=110W R.F 32MN

I.E.C 34 1(87)

0.02

100Hz

0.03

0.04

A rotating autotune will cause the motor to accelerate up to 2/3 base speed in the direction selected regardless of the reference provided. Once complete the motor will coast to a

stop. The enable signal must be removed before the drive can be made to run at the required reference. The drive can be stopped at any time by removing the run signal or removing the drive enable.

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7.3 Quick start commissioning / start-up

7.3.1 Open loop

Action Detail

Ensure:

Before power-up

Power-up the drive

Enter motor nameplate details

• The drive enable signal is not given (terminal 11)

• Run signal is not given

• Motor is connected

Verify that open loop mode is displayed as the drive powers up. If the mode is incorrect see section 5.6 Changing the operating mode on page 75. Ensure:

• Drive displays ‘inh’ If the drive trips, see section 12 Diagnostics on page 179.

Enter:

• Motor rated frequency in Pr 00.039 (Hz)

• Motor rated current in Pr 00.006 (A)

• Motor rated speed in Pr 00.007 (rpm)

• Motor rated voltage in Pr 00.008 (V) - check if or connection

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Technical data Diagnostics UL Listing

Set maximum frequency

Set acceleration / deceleration rates

Autotune

Save parameters

Enter:

• Maximum frequency in Pr 00.002 (Hz)

Enter:

• Acceleration rate in Pr 00.003 (s/100 Hz)

• Deceleration rate in Pr 00.004 (s/100 Hz) (If braking resistor installed, set Pr 00.028 = FAST. Also ensure Pr 10.030 and Pr 10.031 and Pr 10.061 are set correctly, otherwise premature ‘It.br’ trips may be seen).

The drive is able to perform either a stationary or a rotating autotune. The motor must be at a standstill before an autotune is enabled. A rotating autotune should be used whenever possible so the measured value of power factor of the motor is used by the drive.

• A stationary autotune can be used when the motor is loaded and it is not possible to uncouple the load from the motor shaft. A stationary autotune measures the stator resistance of the motor and the dead time compensation for the drive. These are required for good performance in vector control modes. A stationary autotune does not measure the power factor of the motor so the value on the motor nameplate must be entered into Pr 00.009.

• A rotating autotune should only be used if the motor is uncoupled. A rotating autotune first performs a stationary autotune before rotating the motor at

/3 base speed in the direction selected. The

rotating autotune measures the power factor of the motor.

To perform an autotune:

•Set Pr 00.038 = 1 for a stationary autotune or set Pr 00.038 = 2 for a rotating autotune

• Close the Drive Enable signal (apply +24 V to terminal 11). The drive will display ’rdy’.

• Close the run signal (apply +24 V to terminal 12 or 13). The display will flash ’tuning’ while the drive is performing the autotune.

• Wait for the drive to display ‘inh’ and for the motor to come to a standstill.

If the drive trips, see Chapter 12 Diagnostics on page 179.

• Remove the drive enable and run signal from the drive.

Select 'Save' in Pr mm.000 (alternatively enter a value of 1000 in Pr mm.000) and press the red

reset button.

cos

∅

Run Drive is now ready to run

Unidrive M200 / M201 User Guide 87 Issue Number: 4

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Mot X XXXXXXXXX No XXXXXXXXXX kg

IP55 I.cl F C 40 s S1

VHzmin-1kW cosφA 230 400

50 1445 2.20 0.80 8.50

4.90

CN = 14.5Nm 240 415

50 1445 2.20 0. 76 8.50

4.90

CN = 14.4Nm

CTP- VEN 1PHASE 1=0,46A P=110W R.F 32MN

I.E.C 34 1(87)

0.02

1000rpm

0.03

0.04

A rotating autotune will cause the motor to accelerate up to 2/3 base speed in the direction selected regardless of the reference provided. Once complete the motor will coast to a stop. The enable signal

must be removed before the drive can be made to run at the required reference. The drive can be stopped at any time by removing the run signal or removing the drive enable.

WARNING

cos

∅

N rpm

saturation

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7.3.2 RFC - A mode (without position feedback)

Induction motor without position feedback

Action Detail

Before power-up

Power-up the drive

Enter motor nameplate details

Ensure:

• The drive enable signal is not given (terminal 11)

• Run signal is not given

Verify that RFC-A mode is displayed as the drive powers up.

If the mode is incorrect see section 5.6 Changing the operating mode on page 75. Ensure:

• Drive displays ‘inh’ If the drive trips, see Chapter 12 Diagnostics on page 179.

Enter:

• Motor rated frequency in Pr 00.039 (Hz)

• Motor rated current in Pr 00.006 (A)

• Motor rated speed in Pr 00.007 (rpm)

• Motor rated voltage in Pr 00.008 (V) - check if or connection

Optimization

NV Media

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Advanced

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Technical data Diagnostics UL Listing

Set maximum frequency

Enter:

• Maximum frequency in Pr 00.002 (Hz)

Enter: Set acceleration / deceleration rates

• Acceleration rate in Pr 00.003 (s/100 Hz)

• Deceleration rate in Pr 00.004 (s/100 Hz) (If the braking resistor is installed, set Pr 00.028 = FAST. Also ensure Pr 10.030, Pr 10.031 and Pr 10.061 are set correctly, otherwise premature ‘It.br’ trips may be seen).

The drive is able to perform either a stationary or a rotating autotune. The motor must be at a standstill before an autotune is enabled. A stationary autotune will give moderate performance whereas a rotating autotune will give improved performance as it measures the actual values of the motor parameters required by the drive.

• A stationary autotune can be used when the motor is loaded and it is not possible to uncouple the load from the motor shaft. The stationary autotune measures the stator resistance and transient inductance of the motor. These are used to calculate the current loop gains, and at the end of the test the values in

Autotune

Pr 04.013 and Pr 04.014 are updated. A stationary autotune does not measure the power factor of the motor so the value on the motor nameplate must be entered into Pr 00.009.

• A rotating autotune should only be used if the motor is uncoupled. A rotating autotune first performs a stationary autotune before rotating the motor at autotune measures the stator inductance of the motor and calculates the power factor.

To perform an autotune:

•Set Pr 00.038 = 1 for a stationary autotune or set Pr 00.038 = 2 for a rotating autotune

• Close the drive enable signal (apply +24 V to terminal 11). The drive will display ’rdy’.

• Close the run signal (apply +24 V to terminal 12 or 13). The display will flash ‘tuning’ while the drive is performing the autotune.

• Wait for the drive to display ’inh’ and for the motor to come to a standstill

If the drive trips, see Chapter 12 Diagnostics on page 179.

• Remove the drive enable and run signal from the drive.

Save parameters

Select 'Save' in Pr

mm.000

(alternatively enter a value of 1000 in Pr

Run The drive is now ready to run

/3 base speed in the direction selected. The rotating

mm.000

) and press red reset button.

breakpoints

88 Unidrive M200 / M201 User Guide

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Output voltage

Pr / 2

00.008

Pr / 2

00.039

Output frequency

Output voltage characteristic

00.039

00.040 2

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

00.007 60

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

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8 Optimization

This chapter takes the user through methods of optimizing the drive set-up and maximize the performance. The auto-tuning features of the drive simplify the optimization tasks.

8.1 Motor map parameters

8.1.1 Open loop motor control

Pr 00.006 {05.007} Motor Rated Current Defines the maximum continuous motor current

• The rated current parameter must be set to the maximum continuous current of the motor. The motor rated current is used in the following:

• Current limits (see section section 8.3 Current limits on page 95, for more information)

• Motor thermal overload protection (see section section 8.4 Motor thermal protection on page 95, for more information)

• Vector mode voltage control (see Control Mode later in this table)

• Slip compensation (see Enable Slip Compensation (05.027), later in this table)

• Dynamic V/F control

Pr 00.008 {05.009} Motor Rated Voltage Defines the voltage applied to the motor at rated frequency

Pr 00.039 {05.006} Motor Rated Frequency Defines the frequency at which rated voltage is applied

The Motor Rated Voltage (00.008) and the Motor Rated Frequency (00.039) are used to define the voltage to frequency characteristic applied to the motor (see Control Mode, later in this table). The Motor Rated Frequency is also used in conjunction with the motor rated speed to calculate the rated slip for slip compensation (see Motor Rated Speed, later in this table).

Pr 00.007 {05.008} Motor Rated Speed Defines the full load rated speed of the motor

Pr 00.040 {05.011} Number of Motor Poles Defines the number of motor poles

The motor rated speed and the number of poles are used with the motor rated frequency to calculate the rated slip of induction machines in Hz.

Rated slip (Hz) = Motor rated frequency - (Number of pole pairs x [Motor rated speed / 60]) =

If Pr 00.007 is set to 0 or to synchronous speed, slip compensation is disabled. If slip compensation is required this parameter should be set to the nameplate value, which should give the correct rpm for a hot machine. Sometimes it will be necessary to adjust this when the drive is commissioned because the nameplate value may be inaccurate. Slip compensation will operate correctly both below base speed and within the field-weakening region. Slip compensation is normally used to correct for the motor speed to prevent speed variation with load. The rated load rpm can be set higher than synchronous speed to deliberately introduce speed droop. This can be useful to aid load sharing with mechanically coupled motors.

Pr 00.040 is also used in the calculation of the motor speed display by the drive for a given output frequency. When Pr 00.040 is set to ‘Auto’, the number of motor poles is automatically calculated from the rated frequency Pr 00.039, and the motor rated speed Pr 00.007.

Number of poles = 120 x (Rated Frequency (00.039) / Rated Speed (00.007)) rounded to the nearest even number.

Pr 00.043 {05.010} Motor Rated Power Factor Defines the angle between the motor voltage and current

The power factor is the true power factor of the motor, i.e. the angle between the motor voltage and current. The power factor is used in conjunction with the Motor Rated Current (00.006), to calculate the rated active current and magnetising current of the motor. The rated active current is used extensively to control the drive, and the magnetising current is used in vector mode stator resistance compensation. It is important that this parameter is set up correctly. The drive can measure the motor rated power factor by performing a rotating autotune (see Autotune (Pr 00.038), below).

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Pr 00.038 {05.012} Autotune

There are two autotune tests available in open loop mode, a stationary and a rotating test. A rotating autotune should be used whenever possible so the measured value of power factor of the motor is used by the drive.

• A stationary autotune can be used when the motor is loaded and it is not possible to remove the load from the motor shaft. The stationary test measures the Stator Resistance (05.017), Transient Inductance (05.024), Maximum Deadtime Compensation (05.059) and Current At Maximum Deadtime Compensation (05.060) which are required for good performance in vector control modes (see Control Mode later in this table). The stationary autotune does not measure the power factor of the motor so the value on the motor nameplate must be entered into Pr 00.009. To perform a Stationary autotune, set Pr 00.038 to 1, and provide the drive with both an enable signal (on terminal 11) and a run signal (on terminals 12 or 13).

• A rotating autotune should only be used if the motor is unloaded. A rotating autotune first performs a stationary autotune, as above, then a rotating test is performed in which the motor is accelerated with currently selected ramps up to a frequency of Motor Rated Frequency (05.006) x 2/3, and the frequency is maintained at that level for 4 seconds. Stator Inductance (05.025) is measured and this value is used in conjunction with other motor parameters to calculate Motor Rated Power Factor (05.010). To perform a Rotating autotune, set Pr 00.038 to 2, and provide the drive with both an enable signal (on terminal 11) and a run signal (on terminals 12 or 13).

Following the completion of an autotune test the drive will go into the inhibit state. The drive must be placed into a controlled disable condition before the drive can be made to run at the required reference. The drive can be put in to a controlled disable condition by removing the signal from terminal 11, setting the Drive Enable (06.015) to OFF (0) or disabling the drive via the Control Word (06.042) and Control Word Enable (06.043).

Pr 00.041 {05.014} Control Mode

There are several voltage modes available which fall into two categories, vector control and fixed boost.

Vector control

Vector control mode provides the motor with a linear voltage characteristic from 0 Hz to Motor Rated Frequency, and then a constant voltage above motor rated frequency. When the drive operates between motor rated frequency/50 and motor rated frequency/4, full vector based stator resistance compensation is applied. When the drive operates between motor rated frequency/4 and motor rated frequency/2 the stator resistance compensation is gradually reduced to zero as the frequency increases. For the vector modes to operate correctly the Motor Rated Power Factor, Stator Resistance (05.017), Maximum Deadtime Compensation (05.059) and current at Maximum Deadtime Compensation (05.060) are all required to be set up accurately. The drive can be made to measure these by performing an autotune (see Pr 00.038 Autotune). The drive can also be made to measure the stator resistance automatically every time the drive is enabled or the first time the drive is enabled after it is powered up, by selecting one of the vector control voltage modes.

(0) Ur S = The stator resistance is measured and the parameters for the selected motor map are over-written each time the drive is made to run. This test can only be done with a stationary motor where the flux has decayed to zero. Therefore this mode should only be used if the motor is guaranteed to be stationary each time the drive is made to run. To prevent the test from being done before the flux has decayed there is a period of 1 second after the drive has been in the ready state during which the test is not done if the drive is made to run again. In this case, previously measured values are used. Ur S mode ensures that the drive compensates for any change in motor parameters due to changes in temperature. The new value of stator resistance is not automatically saved to the drive's EEPROM.

(4) Ur I = The stator resistance is measured when the drive is first made to run after each power-up. This test can only be done with a stationary motor. Therefore this mode should only be used if the motor is guaranteed to be stationary the first time the drive is made to run after each power-up. The new value of stator resistance is not automatically saved to the drive's EEPROM.

(1) Ur = The stator resistance and voltage offset are not measured. The user can enter the motor and cabling resistance into the Stator Resistance (05.017). However this will not include resistance effects within the drive inverter. Therefore if this mode is to be used, it is best to use an autotune test initially to measure the stator resistance.

(3) Ur_Auto= The stator resistance is measured once, the first time the drive is made to run. After the test has been completed successfully the Control Mode (00.041) is changed to Ur mode. The Stator Resistance (05.017) parameter is written to, and along with the Control Mode (00.041), are saved in the drive's EEPROM. If the test fails, the voltage mode will stay set to Ur Auto and the test will be repeated next time the drive is made to run.

Fixed boost

The stator resistance is not used in the control of the motor, instead a fixed characteristic with low frequency voltage boost as defined by Pr 00.042, is used. Fixed boost mode should be used when the drive is controlling multiple motors. There are two settings of fixed boost available:

ixed = This mode provides the motor with a linear voltage characteristic from 0 Hz to Motor Rated Frequency (00.039), and then a constant

(2) F voltage above rated frequency. (5) Square = This mode provides the motor with a square law voltage characteristic from 0 Hz to Motor Rated Frequency (00.039), and then a constant voltage above rated frequency. This mode is suitable for variable torque applications like fans and pumps where the load is proportional to the square of the speed of the motor shaft. This mode should not be used if a high starting torque is required.

90 Unidrive M200 / M201 User Guide

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Output voltage

Pr / 2

00.008

Pr / 2

00.039

Output frequency

Output voltage characteristic

(Fd)

Voltage boost

00.042

00.008

00.042

00.039

Shaft speed

Demanded speed

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Pr 00.041 {05.014} Control Mode (cont)

For both these modes, at low frequencies (from 0 Hz to ½ x Pr 00.039) a voltage boost is applied as defined by Pr 00.042 as shown below:

Pr 05.027 Enable Slip Compensation

When a motor, being controlled in open loop mode, has load applied a characteristic of the motor is that the output speed droops in proportion to the load applied as shown:

In order to prevent the speed droop shown above slip compensation should be enabled. To enable slip compensation Pr 05.027 must be set to a 1 (this is the default setting), and the motor rated speed must be entered in Pr 00.007 (Pr 05.008).

The motor rated speed parameter should be set to the synchronous speed of the motor minus the slip speed. This is normally displayed on the motor nameplate, i.e. for a typical 18.5 kW, 50 Hz, 4 pole motor, the motor rated speed would be approximately 1465 rpm. The synchronous speed for a 50 Hz, 4 pole motor is 1500 rpm, so therefore the slip speed would be 35 rpm. If the synchronous speed is entered in Pr 00.007, slip compensation will be disabled. If too small a value is entered in Pr 00.007, the motor will run faster than the demanded frequency. The synchronous speeds for 50 Hz motors with different numbers of poles are as follows:

2 pole = 3000 rpm, 4 pole = 1500 rpm, 6pole =1000 rpm, 8 pole = 750 rpm

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Pr / 2

00.008

Pr / 2

00.039

Output frequency

Output voltage characteristic

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8.1.2 RFC-A mode

Induction motor without Position feedback

Pr 00.006 {05.007} Motor Rated Current Defines the maximum motor continuous current

The motor rated current parameter must be set to the maximum continuous current of the motor. The motor rated current is used in the following:

• Current limits (see section 8.3 Current limits on page 95, for more information).

• Motor thermal overload protection (see section 8.4 Motor thermal protection on page 95, for more information)

• Vector control algorithm

Pr 00.008 {05.009} Motor Rated Voltage Defines the voltage applied to the motor at rated frequency

Pr 00.039 {05.006} Motor Rated Frequency Defines the frequency at which rated voltage is applied

The Motor Rated Voltage (00.008) and the Motor Rated Frequency (Pr 00.039) are used to define the voltage to frequency characteristic applied to the motor. The motor rated frequency is also used in conjunction with the motor rated speed to calculate the rated slip for slip compensation (see Motor Rated Speed (00.007), later in this table).

Pr 00.007 {05.008} Motor Rated Speed Defines the full load rated speed of the motor

Pr 00.040 {05.011} Number of Motor Poles Defines the number of motor poles

The motor rated speed and motor rated frequency are used to determine the full load slip of the motor which is used by the vector control algorithm.

Incorrect setting of this parameter has the following effects:

• Reduced efficiency of motor operation

• Reduction of maximum torque available from the motor

• Reduced transient performance

• Inaccurate control of absolute torque in torque control modes

The nameplate value is normally the value for a hot motor; however, some adjustment may be required when the drive is commissioned if the nameplate value is inaccurate. A fixed value can be entered in this parameter.

When Pr 00.040 is set to 'Auto', the number of motor poles is automatically calculated from the Motor Rated Frequency (00.039), and the Motor Rated Speed (00.007).

Number of poles = 120 x (Motor Rated Frequency (00.039 / Motor Rated Speed (00.007) rounded to the nearest even number.

Pr 00.009 {5.10} Motor Rated Power Factor Defines the angle between the motor voltage and current

The power factor is the true power factor of the motor, i.e. the angle between the motor voltage and current. If the Stator Inductance (05.025) is set to zero then the power factor is used in conjunction with the Motor Rated Current (00.006) and other motor parameters to calculate the rated active and magnetising currents of the motor, which are used in the vector control algorithm. If the stator inductance has a non-zero value this parameter is not used by the drive, but is continuously written with a calculated value of power factor. The stator inductance can be measured by the drive by performing a rotating autotune (see Autotune (Pr 00.038), later in this table).

92 Unidrive M200 / M201 User Guide

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Pr 00.038 {05.012} Autotune

There are three autotune tests available in RFC-A mode, a stationary test, a rotating test and an inertia measurement test. A stationary autotune will give moderate performance whereas a rotating autotune will give improved performance as it measures the actual values of the motor parameters required by the drive. An inertia measurement test should be performed separately to a stationary or rotating autotune.

It is highly recommended that a rotating autotune is performed (Pr 00.038 set to 2).

• A stationary autotune can be used when the motor is loaded and it is not possible to remove the load from the motor shaft. The stationary

autotune measures the Stator Resistance (05.017) and Transient Inductance (05.024) of the motor. These are used to calculate the current loop gains, and at the end of the test the values in Pr 04.013 and Pr 04.014 are updated. A stationary autotune does not measure the power factor of the motor so the value on the motor nameplate must be entered into Pr 00.009. To perform a Stationary autotune, set Pr 00.038 to 1, and provide the drive with both an enable signal (on terminal 11) and a run signal (on terminal 12 or 13).

• A rotating autotune should only be used if the motor is unloaded. A rotating autotune first performs a stationary autotune, a rotating test is then

performed which the motor is accelerated with currently selected ramps up to a frequency of Motor Rated Frequency (05.006) x 2/3, and the frequency is maintained at the level for up to 40 s. During the rotating autotune the Stator Inductance (05.025), and the motor saturation breakpoints (Pr 05.029, Pr 05.030, Pr 05.062 and Pr 05.063) are modified by the drive. The power factor is also modified for user information only, but is not used after this point as the stator inductance is used in the vector control algorithm instead. To perform a Rotating autotune, set Pr 00.038 to 2, and provide the drive with both an enable signal (on terminal 11) and a run signal (on terminal 12 or 13).

• The inertia measurement test can measure the total inertia of the load and the motor. This is used to set the speed loop gains (see Frequency

loop gains) and to provide torque feed-forwards when required during acceleration. During the inertia measurement test motor is accelerated with the currently selected ramps up to a speed of Motor Rated Speed (05.008) / 4, and this speed is maintained at this level for 60 seconds. The Motor And Load Inertia (03.018) is measured. If the required speed is not achieved on the final attempt the test is aborted and an Autotune trip is initiated. To perform an Inertia measurement autotune, set Pr 00.038 to 3, and provide the drive with both an enable signal (on terminal

11) and a run signal (on terminal 12 or 13). Following the completion of an autotune test the drive will go into the inhibit state. The drive must be placed into a controlled disable condition before the drive can be made to run at the required reference. The drive can be put in to a controlled disable condition by removing the drive enable signal from terminal 11, setting the Drive Enable (06.015) to OFF (0) or disabling the drive via the control word (Pr 06.042 & Pr 06.043).

{04.013} / {04.014} Current Loop Gains

The current loop gains proportional (Kp) and integral (Ki) gains control the response of the current loop to a change in current (torque) demand. The default values give satisfactory operation with most motors. However, for optimal performance in dynamic applications it may be necessary to change the gains to improve the performance. The Current Controller Kp Gain (04.013) is the most critical value in controlling the performance. The values for the current loop gains can be calculated by performing a stationary or rotating autotune (see Autotune Pr 00.038 earlier in this table) the drive measures the Stator Resistance (05.017) and Transient Inductance (05.024) of the motor and calculates the current loop gains.

This will give a step response with minimum overshoot after a step change of current reference. 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. The equation for the integral gain gives a conservative value. In some applications where it is necessary for the reference frame used by the drive to dynamically follow the flux very closely (i.e. high speed Sensorless RFC-A induction motor applications) the integral gain may need to have a significantly higher value.

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Frequency Loop Gains

(00.065 {03.010}, Pr 00.066 {03.011}

The frequency loop gains control the response of the frequency controller to a change in frequency demand. The frequency controller includes proportional (Kp) and integral (Ki) feed forward terms, and a differential (Kd) feedback term. The drive holds two sets of these gains and either set may be selected for use by the frequency controller with Pr 03.016. If Pr 03.016 = 0, gains Kp1, Ki1 and Kd1 (Pr 03.010 to Pr 03.012) are used, and if Pr 03.016 = 1, gains Kp2, Ki2 and Kd2 (Pr 03.013 to Pr 03.015) are used. Pr 03.016 may be changed when the drive is enabled or disabled.

Frequency Controller Proportional Gain (Kp), Pr 00.007 {03.010} and Pr 03.013

If the proportional gain has a value and the integral gain is set to zero the controller will only have a proportional term, and there must be a frequency error to produce a torque reference. Therefore as the motor load increases there will be a difference between the reference and actual frequencies. This effect, called regulation, depends on the level of the proportional gain, the higher the gain the smaller the frequency error for a given load. If the proportional gain is too high either the acoustic noise produced by numerical quantization becomes unacceptable, or the stability limit is reached.

Frequency Controller Integral Gain (Ki), Pr 00.008 {03.011} and Pr 03.014

The integral gain is provided to prevent frequency regulation. The error is accumulated over a period of time and used to produce the necessary torque demand without any frequency error. Increasing the integral gain reduces the time taken for the frequency to reach the correct level and increases the stiffness of the system, i.e. it reduces the positional displacement produced by applying a load torque to the motor. Unfortunately increasing the integral gain also reduces the system damping giving overshoot after a transient. For a given integral gain the damping can be improved by increasing the proportional gain. A compromise must be reached where the system response, stiffness and damping are all adequate for the application. For RFC-A Sensorless mode, it is unlikely that the integral gain can be increased much above 0.50.

Differential Gain (Kd), Pr 03.012 and Pr 03.015

The differential gain is provided in the feedback of the frequency controller to give additional damping. The differential term is implemented in a way that does not introduce excessive noise normally associated with this type of function. Increasing the differential term reduces the overshoot produced by under-damping, however, for most applications the proportional and integral gains alone are sufficient.

Gain Change Threshold, Pr 03.017

If the Frequency Controller Gain Select (03.016) = 2, gains Kp1, Ki1 and Kd1 (Pr 03.010 to Pr 03.012) are used while the modulus of the frequency demand is less than the value held by Gain Change Threshold (03.017), else gains Kp2, Ki2 and Kd2 (Pr 03.013 to Pr 03.015) will be used.

Tuning the frequency loop gains:

This involves the connecting of an oscilloscope to analog output 1 to

Frequency demand

monitor the frequency feedback. Give the drive a step change in frequency reference and monitor the

esponse of the drive on the oscilloscope.

r The proportional gain (Kp) should be set up initially. The value should be increased up to the point where the frequency overshoots and then reduced slightly.

Insufficient proportional gain

[]

00.065

The integral gain (Ki) should then be increased up to the point where the frequency becomes unstable and then reduced slightly. It may now be possible to increase the proportional gain to a higher value and the process should be repeated until the system response approaches the ideal response as shown. The diagram shows the effect of incorrect P and I gain settings as

Excessive proportional gain [

00.065]

well as the ideal response.

Excessive integral gain [

00.066

]

94 Unidrive M200 / M201 User Guide

Ideal response

Issue Number: 4

Page 95

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0.00

0.70

1.00

Pr = 0 Pr = 1

04.025

1.00

1.05

Base speed/ frequency

50% of base

speed/frequency

0.00

0.70

1.00

Pr = 0 Pr = 1

04.025

1.00

1.01

Base speed/ frequency

50% of base speed/ frequency

15% of

base speed/

frequency

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8.2 Maximum motor rated current

Size 1 to 4:

The maximum motor rated current is the Maximum Heavy Duty Current Rating (11.032).

The values for the Heavy Duty rating can be found in section

2.2 Ratings on page 10.

Size 5 onwards:

The maximum motor rated current allowed by the drive is greater than the Maximum Heavy Duty Current Rating (11.032). The ratio between the Normal Duty rating and the Maximum Heavy Duty Current Rating (11.032) varies between drive sizes. The values for the Normal and Heavy Duty rating can be found in section 2.2 Ratings on page 10. If the

Motor Rated Current (00.006) is set above the Maximum Heavy Duty Current Rating (11.032), the current limits and the motor thermal

protection scheme are modified (see section 8.3 Current limits on page 95 and section 8.4 Motor thermal protection below for further information).

8.3 Current limits

The default setting for the current limit parameters is:

• 165 % x motor rated current for open loop mode.

• 175 % x motor rated current for RFC-A mode.

There are three parameters which control the current limits:

• Motoring current limit: power flowing from the drive to the motor

• Regen current limit: power flowing from the motor to the drive

• Symmetrical current limit: current limit for both motoring and regen operation

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Figure 8-1 Motor thermal protection (Heavy Duty)

If Pr 04.025 is 0 the characteristic is for a motor which can operate at rated current over the whole speed range. Induction motors with this type of characteristic normally have forced cooling. If Pr 04.025 is 1 the characteristic is intended for motors where the cooling effect of motor fan reduces with reduced motor speed below 50 % of base speed/ frequency. The maximum value for K1 is 1.05, so that above the knee of the characteristics the motor can operate continuously up to 105 % current.

Figure 8-2 Motor thermal protection (Normal Duty)

The lowest of either the motoring and regen current limit, or the symmetrical current limit applies.

The maximum setting of these parameters depends on the values of motor rated current, drive rated current and the power factor.

With size 5 upwards, increasing the motor rated current (Pr 00.006 / Pr 05.007) above the Heavy Duty rating (default value), will automatically reduce the current limits in Pr 04.005 to Pr 04.007. If the motor rated current is then set to or below the Heavy Duty rating, the current limits will be left at their reduced values.

The drive can be oversized to permit a higher current limit setting to provide higher accelerating torque as required up to a maximum of 1000 %.

Both settings of Pr 04.025 are intended for motors where the cooling effect of the motor fan reduces with reduced motor speed, but with different speeds below which the cooling effect is reduced. If Pr 04.025 is 0 the characteristic is intended for motors where the cooling effect reduces with motor speed below 15 % of base speed/frequency. If Pr 04.025 is 1 the characteristic is intended for motors where the cooling effect reduces with motor speed below 50 % of base speed/frequency.

8.4 Motor thermal protection

A time constant thermal model is provided to estimate the motor temperature as a percentage of its maximum allowed temperature.

The motor thermal protection is modelled using losses in the motor. The losses in the motor are calculated as a percentage value, so that under these conditions the Motor Protection Accumulator (04.019) would eventually reach 100 %.

Percentage losses = 100 % x [Load related losses]

Where:

Rated

)

Load related losses = I / (K

x I

Where:

I = Current Magnitude (04.001)

= Motor Rated Current (05.007)

Rated

If Motor Rated Current (05.007) ≤ Maximum Heavy Duty Current (11.032)

The maximum value for K1 is 1.01, so that above the knee of the characteristics the motor can operate continuously up to 101 % current

When the estimated temperature in Pr 04.019 reaches 100 % the drive takes some action depending on the setting of Pr 04.016. If Pr 04.016 is 0, the drive trips when Pr 04.019 reaches 100 %. If Pr 04.016 is 1, the current limit is reduced to (K - 0.05) x 100 % when Pr 04.019 reaches 100 %.

The current limit is set back to the user defined level when Pr 04.019 falls below 95 %. The thermal model temperature accumulator is reset to zero at power-up and accumulates the temperature of the motor while the drive remains powered-up. If the rated current defined by Pr 05.007 is altered, the accumulator is reset to zero.

The default setting of the thermal time constant (Pr 04.015) is 179 s which is equivalent to an overload of 150 % for 120 s from cold.

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To rq ue

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Rated speed

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8.5 Switching frequency

The default switching frequency is 3 kHz, however this can be increased up to a maximum of 16 kHz by Pr 05.018 (dependent on drive size). The available switching frequencies are shown below.

Table 8-1 Available switching frequencies

Drive

size

1 to 6 All 9 9 9999 9 9 9

If switching frequency is increased from 3 kHz the following apply:

1. Increased heat loss in the drive, which means that derating to the output current must be applied. See the derating tables for switching frequency and ambient temperature in section 11.1.1 Power and current ratings (Derating for switching frequency and temperature) on page 159.

2. Reduced heating of the motor - due to improved output waveform quality.

3. Reduced acoustic noise generated by the motor.

4. Increased sample rate on the speed and current controllers. A trade off must be made between motor heating, drive heating and the demands of the application with respect to the sample time required.

Table 8-2 Sample rates for various control tasks at each

Level 1 250 μs 167 μs

Level 2 250 μs

Level 3 1 ms Voltage controller

Level 4 4 ms

Background

0.667

Model

kHz1kHz2kHz3kHz4kHz6kHz8kHz

switching frequency

0.667, 1 kHz

3, 6, 12

kHz

2, 4, 8, 16

kHz

2 kHz = 250 μs 4 kHz = 125 μs 8 kHz = 125 μs

16 kHz = 125 μs

kHz

Open

loop

Peak limit

Current

limit and

ramps

Time critical user

Non-time critical user

RFC-A

Current

controllers

Speed

controller

and ramps

interface

kHz

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The saturation breakpoint parameters (Pr 05.029, Pr 05. 030, Pr 05.062 and Pr 05.063) found during the autotune in RFC-A mode ensure the magnetizing current is reduced in the correct proportion for the specific motor. (In open loop mode the magnetizing current is not actively controlled).

8.5.2 Maximum frequency

In all operating modes the maximum output frequency is limited to 550 Hz.

8.5.3 Over-modulation (open-loop only)

The maximum output voltage level of the drive is normally limited to an equivalent of the drive input voltage minus voltage drops within the drive (the drive will also retain a few percent of the voltage in order to maintain current control). If the motor rated voltage is set at the same level as the supply voltage, some pulse deletion will occur as the drive output voltage approaches the rated voltage level. If Pr 05.020 (Over-modulation enable) is set to 1 the modulator will allow over modulation, so that as the output frequency increases beyond the rated frequency the voltage continues to increase above the rated voltage. The modulation depth will increase beyond unity; first producing trapezoidal and then quasi-square waveforms.

This can be used for example:

• To obtain high output frequencies with a low switching frequency which would not be possible with space vector modulation limited to unity modulation depth,

• In order to maintain a higher output voltage with a low supply voltage.

The disadvantage is that the machine current will be distorted as the modulation depth increases above unity, and will contain a significant amount of low order odd harmonics of the fundamental output frequency. The additional low order harmonics cause increased losses and heating in the motor.

8.5.1 Field weakening (constant power) operation

The drive can be used to run an induction machine above synchronous speed into the constant power region. The speed continues to increase and the available shaft torque reduces. The characteristics below show the torque and output voltage characteristics as the speed is increased above the rated value.

Figure 8-3 Torque and rated voltage against speed

Care must be taken to ensure the torque available above base speed is sufficient for the application to run satisfactorily.

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9 NV Media Card

9.1 Introduction

The Non-Volatile Media Card feature enables simple configuration of parameters, parameter back-up and drive cloning using an SD card.

The SD card can be used for:

• Parameter copying between drives

• Saving drive parameter sets

The NV Media Card (SD card) is located in the AI-Backup adaptor.

The drive only communicates with the NV Media Card when commanded to read or write, meaning the card may be "hot swapped".

Figure 9-1 Installation of the SD card

1. Installing the SD card

A flat bladed screwdriver or similar tool is required in order to insert / remove the SD card fully into the AI-Backup adaptor.

Before inserting / removing the SD card into / from the AI-Backup adaptor, the AI-Backup adaptor must be removed from the drive.

9.2 SD card support

An SD memory card can be inserted in the AI-Backup Adaptor in order to transfer data to the drive, however the following limitations should be noted:

If a parameter from the source drive does not exist in the target drive then no data is transferred for that parameter.

If the data for the parameter in the target drive is out of range then the data is limited to the range of the target parameter.

If the target drive has a different rating to the source drive then the normal rules for this type of transfer apply as described later.

No checking is possible to determine if the source and target product types are the same, and so no warning is given if they are different.

If an SD card is used then the drive will recognise the following file types through the drive parameter interface.

File Type Description

A file that contains all clonable user save

Parameter file

Macro file

parameters from the drive menus (1 to 30) in difference from default format

The same as a parameter file, but defaults are not loaded before the data is transferred from the card

9.2.1 Changing the drive mode

If the source drive mode is different from the target drive mode then the mode will be changed to the source drive mode before the parameters are transferred. If the required drive mode is outside the allowed range for the target then a {C.typ} trip is initiated and no data is transferred.

9.2.2 Different voltage ratings

If the voltage rating of the source and target drives is different then all parameters except those that are rating dependent (i.e. attribute RA=1) are transferred to the target drive. The rating dependent parameters are left at their default values. After the parameters have been transferred and saved to non-volatile memory a {C.rtg} trip is given as a warning. The table below gives a list of the rating dependent parameters.

Parameters

Standard Ramp Voltage (02.008)

Motoring Current Limit (04.005)

M2 Motoring Current Limit (21.027)

Regenerating Current Limit (04.006)

M2 Regenerating Current Limit (21.028)

Symmetrical Current Limit (04.007)

M2 Symmetrical Current Limit (21.029)

User Current Maximum Scaling (04.024)

Motor Rated Current (05.007)

M2 Motor Rated Current (21.007)

Motor Rated Voltage (05.009)

M2 Motor Rated Voltage (21.009)

Motor Rated Power Factor (05.010)

M2 Motor Rated Power Factor (21.010)

Stator Resistance (05.017)

M2 Stator Resistance (21.012)

Maximum Switching Frequency (05.018)

Transient Inductance /Ld (05.024)

M2 Transient Inductance /Ld (21.014)

Stator Inductance (05.025)

M2 Stator Inductance (21.024)

Injection Braking Level (06.006)

Supply Loss Detection Level (06.048)

9.2.3 Different option modules installed

If the option module ID code (15.001) is different for any option module installed to the source drive compared to the destination drive, then the parameters for the set-up for that option module are not transferred, but and are instead set to their default values. After the parameters have been transferred and saved to non-volatile memory, a {C.OPt} trip is given as a warning.

These files can be created on a card by the drive and then transferred to any other drive including derivatives. If the Drive Derivative (11.028) is different between the source and target drives then the data is transferred but a {C.Pr} trip is initiated.

It is possible for other data to be stored on the card, but this should not be stored in the <MCDF> folder and it will not be visible via the drive parameter interface.

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9.2.4 Different current ratings

If any of the current rating parameters (Maximum Heavy Duty Rating (11.032), Maximum Rated Current (11.060) or Full Scale Current Kc (11.061)) are different between the source and target then all parameters are still written to the target drive, but some may be limited by their allowed range. To give similar performance in the target compared to the source drive the frequency and current controller gains are modified as shown below. Note that this does not apply if the file identification number is larger than 500.

Gains Multiplier

Frequency Controller Proportional Gain Kp1 (03.010)

Frequency Controller Integral Gain Ki1 (03.011)

[Source Full Scale Current Kc (11.061)] /

[Target Full Scale Current Kc (11.061)]

Frequency Controller Proportional Gain Kp2 (03.013)

Frequency Controller Integral Gain Ki2 (03.014)

M2 Frequency Controller Proportional Gain Kp (21.017)

M2 Frequency Controller Integral Gain Ki (21.018)

Current Controller Kp Gain (04.013)

Current Controller Ki Gain (04.014)

M2 Current Controller Kp Gain (21.022)

[Source Full Scale Current Kc (11.061)] /

[Target Full Scale Current Kc (11.061)]

M2 Current Controller Ki Gain (21.023)

9.2.5 Different variable maximums

It should be noted that if ratings of the source and target drives are different, it is possible that some parameters with variable maximums may be limited and not have the same values as in the source drive.

9.2.6 Macro files

Macro files are created in the same way as parameter files except that NV Media Card Create Special File (11.072) must be set to 1 before the file is created on the NV media card. NV Media Card Create Special File (11.072) is set to zero after the file has been created or the transfer fails. When a macro file is transferred to a drive the drive mode is not changed even if the actual mode is different to that in the file and defaults are not loaded before the parameters are copied from the file to the drive.

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The table below gives a summary of the values used in Pr mm.000 for NV media card operations. The yyy represents the file identification number.

Table 9-1 Functions in Pr mm.000

Value Action

Transfer the drive parameters to parameter file 001 and sets

2001

the block as bootable. This will include the parameters from the attached option module.

4yyy

5yyy

6yyy

Transfer the drive parameters to parameter file yyy. This will include the parameters from attached option module.

Transfer the onboard user program to onboard user program file yyy.

Load the drive parameters from parameter file yyy or the onboard user program from onboard user program file yyy.

7yyy Erase file yyy.

Compare the data in the drive with the file yyy. The data in the drive is compared to the data in the file yyy. If the files are

8yyy

the same then Pr mm.000 is simply reset to 0 when the compare is complete. If the files are different a {Card Compare} trip is initiated. All other NV media card trips also apply.

9555 Clear the warning suppression flag.

9666 Set the warning suppression flag.

9777 Clear the read-only flag.

9888 Set the read-only flag.

Backup all drive data (parameter differences from defaults, an onboard user program and miscellaneous option data), including the drive name; the store will occur to the </fs/

40yyy

MCDF/driveyyy/> folder; if it does not exist, it will be created. Since the name is stored, this is a backup, rather than a clone. The command value will be cleared when all drive and option data has been saved.

Load all drive data (parameter differences from defaults, an onboard user program and miscellaneous option data); the

60yyy

load will come from the <fs/MCDF/driveyyy/> folder. The command value will not be cleared until the drive and all option data have been loaded.

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9.3 NV Media Card parameters

Table 9-2 Key to parameter table coding

RW Read / Write ND No default value

RO Read only NC Not copied

Num Number parameter PT Protected parameter

Bit Bit parameter RA Rating dependant

Txt Text string US User save

Bin Binary parameter PS Power-down save

FI Filtered DE Destination

11.036 NV Media Card File Previously Loaded

RO Num NC PT

0 to 999

This parameter shows the number of the data block last transferred from an SD card to the drive. If defaults are subsequently reloaded this parameter is set to 0.

11.037 NV Media Card File Number

RW Num

0 to 999

This parameter should have the data block number which the user would like the information displayed in Pr 11.038, Pr 11.039.

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11.038 NV Media Card File Type

RO Txt ND NC PT

0 to 2

Displays the type of data block selected with Pr 11.037.

Pr 11.038 String Type / mode

0 None No file selected

1 Open-loop Open loop mode parameter file

2 RFC-A RFC-A mode parameter file

11.039 NV Media Card File Version

RO Num ND NC PT

0 to 9999

Displays the version number of the file selected in Pr 11.037.

11.042 Parameter Cloning

RW Txt NC US*

None (0), Read (1), Prog

(2), Auto (3),

Boot (4)

9.4 NV Media Card trips

After an attempt to read, write or erase data from a NV Media Card a trip is initiated if there has been a problem with the command.

See Chapter 12 Diagnostics on page 179 for more information on NV Media Card trips.

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10 Advanced parameters

This is a quick reference to all parameters in the drive showing units, ranges limits etc, with block diagrams to illustrate their function. Full descriptions of the parameters can be found in the Parameter Reference Guide.

These advanced parameters are listed for reference purposes only. The lists in this chapter do not include sufficient information for adjusting these parameters. Incorrect adjustment can affect the safety of the system, and damage the drive and or external equipment. Before attempting to adjust any of these parameters, refer to the Parameter reference guide.

Table 10-1 Menu descriptions

Menu Description

Commonly used basic set up parameters for quick / easy

programming 1 Frequency reference 2 Ramps

3 Frequency control 4 Torque and current control 5 Motor control

6 Sequencer and clock 7 Analog I/O 8 Digital I/O

9 Programmable logic, motorized pot, binary sum, timers

10 Status and trips 11 Drive set-up and identification, serial communications

12 Threshold detectors and variable selectors 14 User PID controller 15 Option module slot 1 set-up menu

18 General option module application menu 1 20 General option module application menu 2

21 Second motor parameters 22 Menu 0 set-up

Slot 1 Slot 1 option menus**

** Only displayed when the option module is installed.

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Operation mode abbreviations:

Open-loop: Sensorless control for induction motors

RFC-A: Asynchronous Rotor Flux Control for induction motors

Default abbreviations:

Standard default value (50 Hz AC supply frequency)

USA default value (60 Hz AC supply frequency)

Parameter numbers shown in brackets {...} are the equivalent Menu 0 parameters. Some Menu 0 parameters appear twice since their function depends on the operating mode.

In some cases, the function or range of a parameter is affected by the setting of another parameter. The information in the lists relates to the default condition of any parameters affected in this way.

Table 10-2 Key to parameter table coding

Coding Attribute

RW Read/Write: can be written by the user

RO Read only: can only be read by the user

Bit 1 bit parameter. ‘On’ or ‘Off’ on the display

Num Number: can be uni-polar or bi-polar

Txt Text: the parameter uses text strings instead of numbers.

Bin Binary parameter

IP IP Address parameter

Mac Mac Address parameter

Date Date parameter

Time Time parameter

Chr Character parameter

Filtered: some parameters which can have rapidly changing

values are filtered when displayed on the drive keypad for easy viewing.

Destination: This parameter selects the destination of an

input or logic function.

Rating dependent: this parameter is likely to have different values and ranges with drives of different voltage and current ratings. Parameters with this attribute will be transferred to the destination drive by non-volatile storage

media when the rating of the destination drive is different from the source drive and the file is a parameter file. However, the values will be transferred if only the current rating is different and the file is a difference from default type file.

No default: The parameter is not modified when defaults are

loaded

Not copied: not transferred to or from non-volatile media

during copying.

PT Protected: cannot be used as a destination.

User save: parameter saved in drive EEPROM when the

user initiates a parameter save.

Power-down save: parameter automatically saved in drive

EEPROM when the under volts (UV) state occurs.

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